Service Manual Signature, ISX, and QSX15

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

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX, and QSX15
Registered Office
Cummins Ltd.
Volume 1
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2011
Cummins Inc.
Volume 1
Bulletin 3666239
Printed in U.S.A. 02-MAY-2011 p41
312382_Cummins_Vol1.indd 1 5/10/11 7:10 PM

Service Manual
Signature, ISX, and QSX15
Volume 1
Copyright© 2011 Bulletin 3666239

Cummins Inc. Printed 02-MAY-2011
All rights reserved
Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office
listing is located in Service Literature (Section L).
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.
Table of Contents
Section
Introduction .............................................................................................................................................. i
Engine and System Identification ............................................................................................................ E
Familiarization .......................................................................................................................................... F
Troubleshooting Symptoms ..................................................................................................................... TS
Troubleshooting Symptoms (New Format) .............................................................................................. TT
Complete Engine - Group 00 .................................................................................................................... 0
Engine Disassembly Group 00 ................................................................................................................. DS
Engine Assembly - Group 00 ................................................................................................................... AS
Cylinder Block - Group 01 ........................................................................................................................ 1
Cylinder Head - Group 02 ......................................................................................................................... 2
Rocker Levers - Group 03 ........................................................................................................................ 3
Back .......................................................................................................................................................... back

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

Signature™, ISX, and QSX15 About the Manual
Section i - Introduction Page i-1
About the Manual

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

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

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

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

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

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

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

CAUTION
Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the
vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not
connect the ground clamp of the welder to any of the sensors, wiring harness, the ECM or the engine. Direct
welding of any electronic engine component or engine mounted component must not be attempted. Sensors,
wiring harness, and ECM should be removed if nearby welding will expose these components to temperatures
beyond normal operation. Additionally, all ECM connectors must be disconnected..
General Cleaning Instructions Signature™, ISX, and QSX15
General Cleaning Instructions

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

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

General Information
The following list contains some of the acronyms and abbreviations used in this manual.
API American Petroleum Institute
ASTM American Society of Testing and Materials
BTU British Thermal Unit
BTDC Before Top Dead Center
°C Celsius
CO Carbon Monoxide
CCA Cold Cranking Amperes
CARB California Air Resources Board
C.I.B. Customer Interface Box
C.I.D. Cubic Inch Displacement
CNG Compressed Natural Gas
CPL Control Parts List
cSt Centistokes
DEF Diesel Exhaust Fluid
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency
°F Fahrenheit
ft-lb Foot-Pound Force
FMI Failure Mode Indentifier
GVW Gross Vehicle Weight
Hg Mercury
hp Horsepower
H2O Water
inHg Inches of Mercury
in H20 Inches of Water
ICM Ignition Control Module
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling
MIL Malfunction Indicator Lamp
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
N•m Newton-meter
NOx Mono-Nitrogen Oxides
NG Natural Gas
O2 Oxygen
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer
PID Parameter Identification Descriptions
Acronyms and Abbreviations Signature™, ISX, and QSX15
ppm Parts Per Million

psi Pounds Per Square Inch
PTO Power Takeoff
REPTO Rear Power Take Off
RGT Rear Gear Train
rpm Revolutions Per Minute
SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
SCR Selective Catalytic Reduction
STC Step Timing Control
SID Subsystem Identification Descriptions
VDC Volts of Direct Current
VS Variable Speed
VSS Vehicle Speed Sensor
Section E - Engine and System Identification Page E-a
Section E - Engine and System Identification

Section Contents
Page
Engine Diagrams ...............................................................................................................................................E-3
Engine Views....................................................................................................................................................E-3
Automotive with CM870.................................................................................................................................E-4
Automotive With CM871.................................................................................................................................E-7
Industrial CM570 and Power Generation without CM570..............................................................................E-11
Engine Identification .........................................................................................................................................E-1
ECM Dataplate.................................................................................................................................................E-1
Automotive with CM870 and CM871...............................................................................................................E-1
Automotive, Industrial with CM570 and Power Generation without CM570......................................................E-1
Power Generation..........................................................................................................................................E-2
Engine Dataplate..............................................................................................................................................E-1
Page E-b Section E - Engine and System Identification

Signature™, ISX, and QSX15 Engine Identification
Section E - Engine and System Identification Page E-1
Engine Identification
Engine Dataplate
The engine dataplate, located on top of the rocker lever cover, provides the model identification and other important
data about the engine.
Have the following engine data available when communicating with a Cummins® Authorized Repair Location. The
data on the dataplate are mandatory when sourcing service parts:
1. Engine serial number (ESN)
2. Control parts list
3. Model
4. Advertised horsepower and rpm.
ECM Dataplate
Automotive with CM870 and CM871
The electronic control module (ECM) dataplate is located
on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:
• P/N = part number
• S/N = serial number
• D/C = date code.
Automotive, Industrial with CM570 and Power

Generation without CM570
follows:
Engine Identification Signature™, ISX, and QSX15
Page E-2 Section E - Engine and System Identification
Power Generation
follows:
Signature™, ISX, and QSX15 Engine Diagrams
Engine Diagrams
Engine Views
The following illustrations show the location of the major external engine components, filters, and other service and
maintenance points. Some external components will be at different locations for different engine models.
Engine Diagrams Signature™, ISX, and QSX15
Automotive with CM870
ISX Automotive with CM870 - Left Side View

1. ECM cooling plate
2. ECM
3. EGR mixer
4. Intake manifold air temperature sensor
5. Fuel pump
6. Intake manifold pressure sensor
7. EGR differential pressure sensor mounting location
8. Fuel lift pump
9. EGR connection tube
10. Recirculated exhaust gas temperature sensor ( not shown)
11. Starter
12. Fuel filter
13. Lubricating oil dipstick
14. Centinel™ oil control valve
15. Turbocharger control shutoff valve filter
16. Engine speed sensor
17. Air compressor
18. Fan hub
19. Crankcase breather tube.
ISX Automotive with CM870 - Right Side View

1. Variable geometry turbocharger
2. Variable geometry actuator
3. Turbocharger speed sensor ( not shown)
4. EGR valve
5. Exhaust gas pressure sensor mounting location
6. Thermostat housing
7. Turbocharger control valve
8. Refrigerant compressor
9. Alternator
10. Turbocharger oil supply
11. Water pump
12. Coolant filter
13. Turbocharger oil drain
14. Optional dipstick locations
15. Lubricating oil drain
16. Combination full-flow/bypass lubricating oil filter
17. Flywheel housing
18. Lubricating oil cooler assembly
19. EGR cooler
20. Exhaust manifold.
ISX Automotive with CM870 - Front View

1. Refrigerant drive belt
2. EGR mixer
3. Crankcase breather tube
4. Oil fill
5. Water pump drive belt
6. Vibration damper
7. Water pump
8. Belt tensioner, water pump
9. Alternator
11. Belt tensioner, refrigerant compressor
12. Refrigerant compressor.
Automotive With CM871
ISX Automotive with CM871 - Front View

1. Crankcase breather pressure sensor
2. Intake manifold connection
3. Oil fill tube
4. Water pump drive belt
5. Oil pan
6. Vibration damper
7. Dual outlet water pump
8. Belt tensioner, water pump
9. Alternator
11. Belt tensioner, refrigerant compressor
12. Refrigerant compressor
13. Refrigerant compressor drive belt.
ISX Automotive with CM871 - Left Side View

1. ECM
2. Air intake connection
3. Front EGR connection tube
4. EGR differential pressure sensor
5. EGR differential pressure sensor tubes
6. Fuel pump
7. EGR valve mounting bracket
8. EGR valve
9. Starter
10. Fuel filter
12. Crankcase breather vent tube
13. Air compressor
14. Lubricating oil fill tube
15. Open crankcase ventilation filter housing
16. Fan hub.
ISX Automotive with CM871 — Rear View

1. Aftertreatment Injector fuel supply line
2. Aftertreatment injector coolant supply line
3. Aftertreatment injector adapter tube
4. Aftertreatment injector assembly
5. Aftertreatment injector coolant return line
6. Flywheel
7. Rear EGR connection tube.
ISX Automotive with CM871 - Right Side View

2. Turbocharger speed sensor
3. Variable geometry actuator
4. EGR cooler coolant inlet tube
5. Dual outlet water pump
6. Coolant filter
7. Turbocharger oil drain tube
8. Lubricating oil filter
9. Lubricating oil drain plug
11. EGR cooler coolant return tube
12. Lubricating oil cooler
13. EGR cooler
14. Exhaust manifold.
Industrial CM570 and Power Generation without CM570
QSX15 Industrial with CM570 - Front View

1. Accessory drive belt
2. Water pump/fan drive belt
3. Lubricating oil fill
4. Water pump/fan drive belt tensioner
5. Accessory drive belt tensioner.
QSX15 Industrial with CM570 - Left Side View

1. Gear housing
2. ECM
3. Air intake
4. Engine dataplate
5. Fuel pump
6. Starter
7. Fuel filter
9. Crankshaft timing pin port
10. Vibration dampers
11. Barring device/air compressor
12. Fan hub.
QSX15 Industrial with CM570 - Right Side View

1. Exhaust manifold
2. Turbocharger
3. Oil inlet to turbocharger
4. Wastegate actuator
5. Thermostat housing vent
7. Engine coolant outlet (to radiator)
8. Freon compressor
9. Coolant temperature sensor
10. Alternator
11. Water pump
12. Coolant filter
13. Lubricating oil drain
14. Turbocharger oil drain
18. Engine serial number.
QSX15 Power Generation without CM570 - Front View

1. Accessory drive belt
2. Water pump/fan drive belt
3. Oil fill/crankcase breather
4. Water pump/fan drive belt tensioner
5. Accessory drive belt tensioner.
QSX15 Power Generation without CM570 - Left Side View

1. Gear cover
2. Engine dataplate
3. Air intake
4. Fuel pump
5. Fuel filter
6. Starter
7. Lubricating oil pan
8. Lubricating oil drains
9. Crankshaft timing pin port
11. Vibration dampers
12. Lubricating oil fill/barring device
13. Fan hub.
QSX15 Power Generation without CM570 - Right Side View

1. Exhaust manifold
2. Lubricating oil Inlet to turbocharger
3. Turbocharger
4. Thermostat housing vent
6. Engine coolant outlet (to radiator)
7. Coolant temperature sensor
8. Water pump
9. Coolant filter
10. Lubricating oil drains
14. Engine serial number
15. Turbocharger lubricating oil drain.
Fuel System - Left Side View

1. Intake manifold pressure/temperature sensor 6. ECM/engine harness port (OEM)
2. Fuel outlet 7. ECM
3. Fuel inlet 8. ECM/engine harness port (actuator)
4. Fuel shutoff valve 9. ECM/sensor port
5. Oil pressure/temperature sensor 10. Cooling plate (behind ECM).
Fuel System - Left Side View (continued)

11. Camshaft position sensor
12. Crankshaft position sensor
13. Ambient air pressure sensor
14. Water-in-Fuel sensor
15. Fuel pressure sensor
16. Front and rear rail sensors*
17. Timing actuators
18. Fueling actuators.
* Eliminated on most engines
Fuel Delivery Housing - Front View

1. Priming bypass valve (internal)
2. 320 psi pressure regulator
3. 36-micron filter screen
4. Fuel inlet
5. Quick disconnect pressure tap - suction side
6. Water-In-Fuel sensor
7. 250 psi pressure regulator
8. Fuel shutoff valve
9. Quick disconnect pressure tap - pressure side
10. Fuel pressure sensor
11. Front rail actuator
12. Front timing actuator
13. Rear timing actuator
14. Rear rail actuator.
QSX15 with CM570 Fuel Delivery Housing - Rear View

1. Fuel pump assembly
2. Front rail pressure sensor*
3. Fuel filter
4. Rear rail pressure sensor*.
* Eliminated on most engines.
Section F - Familiarization Page F-a
Section F - Familiarization
Section Contents
Page
Air Intake System - Overview .........................................................................................................................F-34
General Information........................................................................................................................................F-34
Variable Geometry.......................................................................................................................................F-34
Automotive with CM870................................................................................................................................F-34
Automotive With CM871...............................................................................................................................F-35
All Applications............................................................................................................................................ F-36
Complete Engine - Overview ............................................................................................................................F-1
General Information..........................................................................................................................................F-1
Compressed Air System - Overview ...............................................................................................................F-51
Single Cylinder.............................................................................................................................................F-51
Cooling System - Overview ............................................................................................................................ F-24
Cylinder Block - Overview ................................................................................................................................F-3
Cylinder Head - Overview .................................................................................................................................F-4
Electrical Equipment - Overview .................................................................................................................... F-54
Engine Testing - Overview ..............................................................................................................................F-56
Fuel Flow Measurement on Engine or Chassis Dynamometer..........................................................................F-57
Exhaust System - Overview ............................................................................................................................F-40
Flow Diagram, Air Intake System ...................................................................................................................F-37
Flow Diagram..................................................................................................................................................F-37
Automotive, Industrial with CM570 and Power Generation without CM570....................................................F-37
With CM870.................................................................................................................................................F-38
Flow Diagram, Compressed Air System .........................................................................................................F-52
Flow Diagram..................................................................................................................................................F-52
Flow Diagram, Cooling System ...................................................................................................................... F-26
Flow Diagram..................................................................................................................................................F-26
Single Thermostat........................................................................................................................................F-33
Flow Diagram, Exhaust System ......................................................................................................................F-44
Flow Diagram..................................................................................................................................................F-44
With CM870.................................................................................................................................................F-46
Flow Diagram, Fuel System ..............................................................................................................................F-9
Flow Diagram....................................................................................................................................................F-9
Automotive with CM570..................................................................................................................................F-9
Industrial CM570 and Power Generation without CM570.............................................................................. F-13
Flow Diagram, Lubricating Oil System ...........................................................................................................F-18
Flow Diagram..................................................................................................................................................F-18
Page F-b Section F - Familiarization
All Applications............................................................................................................................................ F-21

Fuel System - Overview ....................................................................................................................................F-5
Automotive with CM870..................................................................................................................................F-6
Automotive With CM871.................................................................................................................................F-7
Installation Recommendations..........................................................................................................................F-7
Injectors and Fuel Lines - Overview ...............................................................................................................F-15
Lubricating Oil System - Overview .................................................................................................................F-15
Lubricating Oil..............................................................................................................................................F-15
Lubricating Oil Filters...................................................................................................................................F-16
Lubricating Oil System....................................................................................................................................F-16
New Engine Break-in Oils................................................................................................................................F-17
Oil Drain Intervals...........................................................................................................................................F-17
Rocker Levers - Overview .................................................................................................................................F-5
General Information.......................................................................................................................................F-5
Vehicle Braking - Overview .............................................................................................................................F-59
Signature™, ISX, and QSX15 Complete Engine - Overview
Section F - Familiarization Page F-1
Complete Engine - Overview (000-999)

General Information
Engine Nomenclature
To assist the reader of this manual in accurately identifying the appropriate engine version to repair, the manual is
using the engine's ECM model number as the identifier in the task title of each procedure. The engine(s) for the
corresponding ECM model number nomenclature are as follows:
All Applications
Includes all ISX automotive engines, Signature engines, QSX industrial engines, and all power generation engines,
regardless of ECM model.
Includes ISX automotive EGR engines built with CM870 model ECM, introduced in 2002.
Automotive, Industrial with CM570 and Power Generation without CM570
Includes ISX automotive engines, Signature engines, QSX industrial engines built with CM570 model ECM, and all
power generation engines supplied with their unique control module
ISX automotive and Signature engines built with CM570 model ECM, built 1998 through 2002.
QSX industrial engines built with CM570 model ECM and power generation engines supplied with their unique control
module.
If the user of this manual is not sure of the ECM model number, the ECM model number can be identified by reviewing
the electronic data plate using INSITE™ electronic service tool.
Repair
Concern has been generated at both the factory and in the field about engine failures that occur a short time after an
in-frame repair. Analyses of the returned parts indicate many of the failures are the result of dirt entering the engine
during repair. In particular, investigation of the failure of ISX engine connecting rod and main bearings very soon after
field repairs of the oil cooler, front cover, or cylinder head has shown that 30 percent of the failures are the result of
contamination of some main oil drillings. Investigation into the type and source of the contamination indicates it is
appropriate to restate, review and revise parts cleaning instructions for all engines.
The statement “A person can spend too much time cleaning parts, but a person can not get them too clean” is even
more relevant as customer expectations and regulatory requirements increase. These demands, coupled with
increased diesel engine product complexity, place more pressure on the field technician in terms of time required to
perform a quality repair. In an effort to reduce customer down time, many different labor saving devices, techniques,
and shortcuts are being used to meet customer expectations. However, some of the shortcuts and labor saving efforts
are the very things that can cause contamination of internal engine components that lead to additional failures.
Review the General Cleaning Instructions in this manual. Field shops are strongly encouraged to review these
instructions with all technicians and to include general cleaning instructions in technician training programs and new
technician orientation programs.
Magnetism
If the engine is found to be magnetized, the engine will need to be disassembled and examined for:
• Engine inspection for electrical pass-through damage
• Magnetism of ferrous components
• Debris through the lubrication system
• Damage to bearings and bushings, including: crankshaft thrust bearings, main bearings, connecting rod
bearings, and camshaft bushings
• Component or wear damage.
The Disassembly and Assembly sections of this manual can be used to disassemble and assemble the engine.
Complete Engine - Overview Signature™, ISX, and QSX15
Page F-2 Section F - Familiarization
Acceptable Magnetism Levels

Injectors and Ferrous Injector Components All Other Ferrous Components
5 or less gauss units 15 or less gauss units
Measure each ferrous component with a gauss meter and record the results. If the magnetism is out of specification,
the engine must be treated in general as if:
• Debris (fine particles) have been traveling throughout the lubrication system, resulting in wear and damage to
components.
Components with measured gauss units greater than specification must be demagnetized or replaced. A facility
capable of magnetic testing (Magnaflux) of the engine components is capable of demagnetizing (degaussing)
components.
Check components in the lubrication system closely and thoroughly clean the oil galleries.
Replace all main bearings, thrust bearings, connecting rod bearings, and camshaft bushings.
NOTE: Do not attempt to demagnetize sensors, engine control modules, or actuators.
There are two methods for demagnetizing components:
• Passing the part through an alternating current coil (50 or 60 cycles per second)
• Passing a reversing, 30 point step-down current through the part.
The alternating current coil is suggested for smaller parts.
For larger mass parts, the reversing 30 point step-down is suggested.
Parts with acceptable levels of magnetization must be cleaned and inspected for reuse.
It is recommended to have the alternating current coil just large enough for the parts to pass through. A small part
passed through a large coil will not be demagnetized as well as if it were passed through a smaller coil.
The coil must be located so the longest part axis of the part is perpendicular to the coil when passing through. Parts
must pass through a minimum of 457.2 to 609.6 mm [18 to 24 in] beyond the coil for the most effective
demagnetization.
Do not attempt to demagnetize small parts by loading them into a basket and passing the basket through a coil. Do
not attempt to demagnetize a whole engine assembly.
Direct current demagnetization can be accomplished by using the magnetizing unit. Clamp the part between the head
and tail stock. Activate the demagnetization controls, and the reversing, step-down current passes through the part.
Check all parts with the gauss meter.
When tiny pits occur in clearly defined patterns, or surfaces are fluted, electric current can be the problem. The
patterns will vary with metals, sources, and movement.
For insert bearings, pitting is a chief indication. In anti-friction bearings, such as ball bearings, fluted surfaces, or wavy
lines of pitting in patterns differing with rotation, vibration, and current are the chief indications.
Sources of electrical damage are:
• Electrically actuated components (such as a clutch).
• Static current from belts or other moving parts.
• Grounding of electrical system through the crankshaft when some component such as the generator or engine
block has not been grounded properly.
• An improperly grounded six volt system.
Contaminated Intake Air
For engines that have experienced dust outs because of an intake air system component failure that resulted in
cylinder liner and piston ring wear; these engines must be treated as if the lubricating oil system has been
contaminated with debris. The engine must be disassembled and cleaned appropriately to remove debris from the
oil galleries, block cavities, cylinder head, and air intake system. Do not forget the camshafts and rocker lever pins
and rollers; these must be thoroughly cleaned and examined for wear.
Signature™, ISX, and QSX15 Cylinder Block - Overview
The procedures required to replace an engine will vary

with different engine models, the type of equipment,
optional equipment, and the shop facilities. Use the
following procedures as a guide.
All replacement steps will not apply to all types of
equipment. Complete only the steps that apply to the
equipment involved. Use the equipment manufacturer's
recommendations and precautions for removal of chassis
parts to gain access to the engine.
Cylinder Block - Overview (001-999)

General Information
Some Signature, ISX, and QSX15 engines are equipped
with articulated pistons.
The articulated piston is a two-piece piston consisting of
a forged steel crown and an aluminum skirt.
An open chamber oil gallery is located on the underside
crown of the piston to provide more oil contact with the
piston and give better piston cooling.
Piston cooling nozzle targeting is critical because the oil
is captured in shaker trays.
Some engines are equipped with single-piece pistons.

The single-piece piston is a one-piece piston, that does
not have a bushing and is forged from a high-strength,
alloy steel.
A cover plate, that is not removable, is located on the
underside of the piston to capture oil and cool the piston.
Do not remove this cover plate under any circumstances.
CAUTION
All pistons within a given engine must be of the same
design. All are to be either the articulated design or
the single piece design. Do not mix piston designs in
the same engine. Single piece pistons must have
drilled connecting rods and connecting rod bearings.
Articulated pistons can use either drilled or non-
drilled connecting rods and connecting rod bearings.
Cylinder Head - Overview Signature™, ISX, and QSX15
Connecting Rod
The ISX connecting rods big bore is straight-cut with a four capscrew design. With the introduction of the single-piece
piston the connecting rod I-beam is drilled to provide oil to the piston pin. Single piece pistons must use drilled
connecting rods.
Cylinder Liner
The cylinder liners are of a mid-stop cylinder liner design. The EGR engine cylinder liners are induction hardened.
There are two different designs of cylinder liners used in the Signature, ISX and QSX15 engines. The design used in
a particular engine is dependent on the engine's production vintage.
Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized
by a groove machined into the top surface of the cylinder liner flange.
Engines assembled with engine serial number 14022615 and after have flat-top cylinder liners. They are characterized
by a cylinder liner flange that is flat, except for the fire dam.
Cylinder Head - Overview (002-999)

General Information
The cylinder head is a single slab head design with dual overhead camshafts.
The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve seat inserts,
crossheads, and injector sleeves. The exhaust valves are manufactured from a material capable of operating at a
higher temperature than the intake valves. In addition to being made from different materials, the intake and exhaust
valves are different sizes.
Mark, label, or tag the cylinder head parts such as crossheads, valves, and valve springs with the cylinder number
and location from which they were removed. It is also recommended that the intake and exhaust valve positions be
marked on the combustion face of the cylinder head using a paint pen to facilitate installing the correct parts in the
correct locations.
There are two different designs of cylinder liners used in the Signature, ISX and QSX15 engines. The design used in
a particular engine is dependent on the engine's production vintage.
Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized
by a groove machined into the top surface of the cylinder liner flange.
Engines assembled with engine serial number 14022615 and after have flat-top cylinder liners. They are characterized
by a cylinder liner flange that is flat, except for the fire dam.
CAUTION
Cylinder head gaskets are different depending on the cylinder liner design. The cylinder head gasket designed
to be used with groove-top cylinder liners can not be used with flat-top liners, and the cylinder head gasket
designed to be used with the flat-top cylinder liners can not be used with groove-top cylinder liners.
Engines built with groove-top cylinder liners must use a cylinder head gasket and fire rings.
Engines built with flat-top liners must use a one-piece cylinder head gasket without fire rings.
Two different valve guides and valve guide seals are used
on Signature, ISX, and QSX15 engines.
Engines built prior to engine serial number 14010274 use
non-grooved valve guides and small valve guide seals.
These engines require the valve stem seal installer, Part
Number 3163294, to be used when installing the valve
guide seals.
Signature™, ISX, and QSX15 Fuel System - Overview
Engines with serial number 14010274 and all engines built

after use a larger valve guide seal.
These seals are designed to be installed by hand without
the seal driver.
The new seals snap into a groove machined on the valve
guide. The new style seals are not compatible with the old
style non-grooved valve guides.
Rocker Levers - Overview (003-999)

General Information
General Information
Valves, injectors, and engine brakes (if equipped) must be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be performed using the values listed in this section.
Adjust the valves, injectors, and engine brakes every 800,000 km [500,000 mi], 10,000 hours, or 5 years (whichever
occurs first). Adjustment must be made after any major repair, and the adjustment interval again becomes every
800,000 km [500,000 mi], 10,000 hours, or 5 years (whichever occurs first).
Refer to Procedure 003-004 for valve, engine brake, and injector adjustment values.
Fuel System - Overview (005-999)

General Information
WARNING
Depending on the circumstance, diesel fuel is
flammable. When inspecting or performing service or
repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death or
property damage, never smoke or allow sparks or
flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
CAUTION
Tampering with the fuel system can void the engine
warranty and lower the performance of the engine.
NOTE: Warranty repairs are not to be made to the
Signature, ISX, or QSX fuel system unless the work is
performed in a shop that meets all requirements
established by Cummins Inc. to accurately calibrate, test,
and repair the fuel systems on Cummins® engines.
The performance of the engine is defined by the control
parts list and the fuel system code. The fuel system
calibration must be within published specifications. Fuel
system calibration is certified by several emissions
agencies.
Fuel System - Overview Signature™, ISX, and QSX15
NOTE: There is no mechanical throttle on the Signature,

ISX, or QSX15 fuel system.
The Signature, ISX, and QSX15 fuel system is an
integrated, multi-part system.
It is comprised of the following:
• Supply pump
• Regulators
• Filters
• Timing and fueling actuators
• Camshaft-driven injectors 1 through 6
• ECM, sensors (fuel system control).
The fuel system is split into two banks:

• Front bank (cylinders 1-2-3)
• Rear bank (cylinders 4-5-6).

System Operation
• Fuel is drawn from the tank through a fuel filter by a gear pump (supply pump)
• The supply pump pressure is regulated at 1689 to 2206 kPa [245 to 320 psi] at 2100 rpm
• Fuel passes through a pressure side filter (36 microns)
• Fuel then passes through a rapid restart-style fuel shutoff valve
• Fuel enters a passage feeding the front and rear banks, which connects directly to the fuel actuators
• Within a given bank, the fuel and timing actuators are commanded by the ECM to open
• The opening of each actuator sends a pressure pulse to each injector within the bank
• The timing of these events is tied to engine position
• Due to the firing order (1-5-3-6-2-4) and cam position, only one injector within the bank receives fuel.
The Signature, ISX, and QSX fuel system assembly, integrated fuel system module, or fuel delivery housing is located
on the intake side of the engine.
Fuel for the Engine
• Fuel passes through a rapid restart-style fuel shutoff valve
• Fuel enters a passage feeding the front and rear banks, which connects directly to the fuel actuators
Signature™, ISX, and QSX15 Fuel System - Overview
Aftertreatment Injector Fuel Flow.

System Operation
• Fuel is drawn from the tank through a fuel filter by a gear pump (supply pump)
• The supply pump pressure is regulated at 1689 to 2220 kPa [245 to 322 psi] at 2100 RPM
• Fuel passes through a pressure side filter (10 microns).
• Fuel goes to the engine and the aftertreatment system.
Fuel For the Engine
• Fuel passes through a rapid restart-style fuel shutoff valve
• Fuel enters a passage feeding the front and rear banks, connecting directly to the fuel actuator.
Fuel For the Aftertreatment System
• Fuel flows down to the aftertreatment shutoff valve
• When the valve opens, the fuel passes the aftertreatment fuel pressure sensor
• Fuel then flows around the back of the engine to the aftertreatment fuel injector
• When the aftertreatment fuel injector opens, fuel is sprayed into the exhaust stream
• When the fuel is not flowing to the aftertreatment fuel injector, remaining fuel in the line between the first
aftertreatment shutoff valve and aftertreatment fuel injector is sent through the second aftertreatment shutoff
valve to drain.
Installation Recommendations
Overhead Tank Installation Requirements:
WARNING
If a fuel line shutoff valve is not installed, the
overhead tank can drain when the fuel filter is
changed, causing an extreme fire hazard.
Cummins Inc. recommends a ball-type valve and not a
gate-type valve.
Install a fuel shutoff valve between the filter and the fuel
tank.
Fuel System - Overview Signature™, ISX, and QSX15
Install a check valve in the fuel drain line when the

maximum fuel level in the fuel tank is even or above the
fuel drain that is in the cylinder head. Install the valve with
the fuel flow arrow toward the fuel tank.
Signature™, ISX, and QSX15 Flow Diagram, Fuel System
Flow Diagram, Fuel System (200-001)

Flow Diagram
9 9
11 11
10 8
© Cummins Inc. © Cummins
3 Inc.
© Cummins Inc.
11
8 2
5
© Cummins Inc. 6
©7 Cummins Inc.
1
4
05c00127
With Lift Pump

1. Fuel supply from tank 7. Timing actuator
2. Fuel lift pump 8. Fueling supply to injector
3. Fuel pump 9. Timing fuel supply to injector
4. Pressure fuel filter 10. Injector
5. Fuel shutoff valve 11. Fuel drain to tank.
6. Fueling actuator
Flow Diagram, Fuel System Signature™, ISX, and QSX15
Flow Diagram, Fuel System (200-001)

Flow Diagram 3 10
Automotive with CM570 7 8 8 7
5 6 6
3 5
8 10
9 8 10
© Cummins Inc. 10
© Cummins Inc.
7 4 1
2
7 © Cummins Inc.
5 1
6 4
© Cummins Inc. 2 © Cummins Inc. 00c00001
Without Lift Pump

2. Fuel filter 7. Rail metering supply to injector
3. Gear pump 8. Timing fuel supply to injector
4. Fuel shutoff valve 9. Injector
5. Rail metering actuator 10. Fuel drain to tank.

14
4
© Cummins Inc. 13 © Cummins Inc.

3
10 7 6 15 1
12 © Cummins Inc.
15
1 12
11
© Cummins
89
Inc. © Cummins
5 Inc.
2 2
5
05c00225
With Lift Pump and ECM Cooling Plate

1. Fuel supply from tank 9. Engine fuel temperature sensor
2. Fuel lift pump 10. Compuchek™ fitting (rail fuel pressure)
3. Compuchek™ fitting (fuel inlet restriction) 11. Hot start and stall orifice
4. Fuel pump 12. Fuel inlet to ECM cooling plate
5. Pressure fuel filter 13. ECM cooling plate
6. Fuel shutoff valve 14. Fuel from ECM ccoling plate to fuel pump
7. 250-psi regulator 15. Fuel drain to tank.
8. Rail fuel pressure sensor

14 4
13 3 19
© Cummins
12 Inc. © Cummins Inc.
18
15
21
1
10 7 6 © Cummins Inc.
20
12
19
17
11
© Cummins1 Inc. 16
9 8 © Cummins Inc.
5 2 5 2 20
00c00099
ISX With Lift Pump and Aftertreatment

1. Fuel supply from tank 12. Fuel flow to ECM cooler
2. Fuel lift pump 13. ECM cooler
3. Compuchek™ fitting (fuel inlet restriction) 14. Fuel flow to fuel pump
4. Fuel pump 15. Fuel flow to aftertreatment fuel shutoff valve
5. Pressure fuel filter 16. Aftertreatment fuel shutoff valve
6. Fuel shutoff valve 17. Fuel pressure sensor
7. 250-psi regulator 18. Fuel drain line
8. Rail fuel pressure sensor 19. Fuel return to fuel tank
9. Engine fuel temperature sensor 20. Fuel flow to aftertreatment injector
10. Compuchek™ fitting (rail fuel pressure) 21. Aftertreatment injector.
11. Hot start and stall orifice
9 9
11 11
10 8
© Cummins Inc. © Cummins3 Inc.
© Cummins Inc.
11
8 2

5
7
Inc. 1
6 4
05c00222
QSX15 With Lift Pump

2. Fuel lift pump 8. Fueling supply to injector
3. Fuel pump 9. Timing fuel supply to injector
4. Pressure fuel filter 10. Injector
5. Fuel shutoff valve 11. Fuel drain to tank.
6. Fueling actuator
3 10
7 8 8 7
5 6 6
3 5
8 10
9 8 10
© Cummins Inc. 10
© Cummins Inc.
7 4 1
2
7 © Cummins Inc.
5 1
6 4
© Cummins Inc. 2 © Cummins Inc. 00c00001
QSX15 Without Lift Pump

2. Fuel filter 7. Rail metering supply to injector
3. Gear pump 8. Timing fuel supply to injector
4. Fuel shutoff valve 9. Injector
5. Rail metering actuator 10. Fuel drain to tank.
Signature™, ISX, and QSX15 Lubricating Oil System - Overview
Injectors and Fuel Lines - Overview (006-999)

General Information
The 2002 ISX engine uses a 15-micron pressure side fuel filter. The pressure side fuel filter is mounted to the integrated
fuel system module in the same location as the previous integrated fuel system module-mounted suction side fuel
filter. Pressure side filtration allows for improved diagnostics and improved filtration. The fuel filter has a 40,234 km
[25,000 mi] change interval.
For fuel filter pressure and vacuum information, refer to Procedure 006-015.
For fuel inlet restriction, refer to Procedure 006-020.
ECM Cooling Plate
A fuel-cooled ECM was introduced with the 2002 ISX engine.
The ECM cooling plate is located on the intake side of the cylinder head, directly between the ECM and cylinder head.
The ECM cooling plate receives fuel from the 1724 kPa [250 psi] regulator and returns it to the suction side of the fuel
pump. The 2002 ISX engine uses a different gasket between the cooling plate and the cylinder head than the air-
cooled ECM cooling plate found on the previous ISX engines. To isolate the cooling plate from the heat of the cylinder
head, a new ECM cooling plate gasket is used. Unlike the air-cooled ECM cooling plate gasket, the fuel-cooled ECM
cooling plate gasket does not have a cutout in the lower section. This gasket is not reversible and uses an interference
tab that will not allow the gasket to be installed backward.
Lubricating Oil System - Overview (007-999)

General Information
Lubricating Oil
ISX engines built after February 2004, (ESN first 79035023) have the lubricating oil filter head adapter (spud) staked
to the lubricating oil filter housing to reduce the possibility of the adapter backing out.
The use of quality engine lubricating oils, combined with appropriate lubricating oil drain and filter change intervals,
is a critical factor in maintaining engine performance and durability.
Cummins Inc. recommends the use of a high quality 15W-40 multiviscosity heavy-duty engine lubricating oil that meets
the requirements of Cummins Engineering Specification CES 20071 or CES 20076 (such as Valvoline® Premium Blue®
or Premium Blue® 2000). American Petroleum Institute (API) specification CH-4 can be used as an alternative to CES
20071. Oils that meet API specification CG-4 can be used, but at a reduced drain interval. Refer to Procedure 102-002
in the Operation and Maintenance Manual Industrial and Power Generation QSX15 Engines, Bulletin 3666423 or
Procedure 102-002 in the Operation and Maintenance Manual Signature and ISX Engines, Bulletin 3666251. The oil
grades CC, CD, CE, and CF have been obsoleted by API and must not be used.
Shortened drain intervals can be required with monograde oils as determined by close monitoring of the oil condition
with scheduled oil sampling. Use of single-grade oils can affect engine oil control.
Synthetic engine oils, API category III, are recommended for use in Cummins® engines operating in ambient
temperature conditions consistently below -25°C [-13°F]. Above this temperature, it is recommended the petroleum
based multigrade lubricants be used. Synthetic 0W-30 oils that meet API category III can be used in operations where
the ambient temperature never exceeds 0°C [32°F]. 0W-30 oils do not offer the same level of protection against fuel
dilution as do higher multigrade oils. Higher cylinder wear can be experienced when using 0W-30 oils in high-load
situations.
For further details and an explanation of engine lubricating oils for Cummins® engines, refer to Cummins Engine Oil
Recommendations, Bulletin 3810340.
Additional information regarding lubricating oil availability throughout the world is available in the Engine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy-Duty Automotive and Industrial Engines. The
data book can be ordered from: Engine Manufacturers Association, Two North LaSalle Street, Suite 2200, Chicago,
IL, 60602; Phone: (312) 644-6610, Fax: (312) 827-8737.
The integrated Centinel™ system is a continuous lubricating oil replacement system of electromechanical design. The
Centinel™ system extends lubricating oil and lubricating oil filter change intervals through continuous lubricating oil
exchange. This is accomplished by injecting engine lubricating oil at a controlled rate, proportional to fuel consumed,
into the fuel system for consumption. Makeup lubricating oil (fresh) is introduced into the engine at a rate equal to the
lubricating oil consumed. The Centinel™ system will also monitor the lubricating oil level in the make up tank.
Lubricating Oil System - Overview Signature™, ISX, and QSX15
Lubricating Oil Filters

A combination lubricating oil filter is used on the engine. The upper portion of the combination lubricating oil filter
contains the full-flow filter element while the lower portion contains the bypass filter element.
Lubricating oil circulates through the full-flow portion of the lubricating oil filter, into the lubricating oil cooler housing
and is directed to the engine lubricating oil rifles.
A smaller portion of the lubricating oil circulates through the lower bypass portion of the lubricating oil filter and is
directed to the engine lubricating oil rifles.
Lubricating Oil System
The demand flow and cooling lubricating system
incorporates a lubricating oil pump (1) with a pressure-
sensitive regulator circuit (2) and a high-pressure relief
valve (3).
The API service symbol locations are shown in the

accompanying illustration.
1. The upper half of the symbols displays the
appropriate oil categories.
2. The lower half contains words to describe oil energy-
conserving features.
3. The center section identifies the SAE oil viscosity
grade.
Lubricating oil viscosity must be chosen according to the

typical climate conditions experienced by the user. Use of
15W-40 is recommended for the best engine durability at
higher ambient temperature. For cold temperature
conditions, 10W-30 or 5W-30 viscosity can be used for
easier starting, improved lubricating oil flow, and
improved fuel economy.
Signature™, ISX, and QSX15 Lubricating Oil System - Overview
New Engine Break-in Oils

Special “break-in” engine lubricating oils are not
recommended for new or rebuilt Cummins engines. In
general, use the same lubricating oil during break-in as
that used in normal operation. Synthetic or partially
synthetic engine lubricating oils, however, can not be
used during break-in of a new or rebuilt engine. To make
sure the piston rings seat properly, use a high quality
petroleum-based engine lubricating oil during the first
engine lubricating oil drain period.
Oil Drain Intervals

As the engine lubricating oil becomes contaminated,
essential lubricating oil additives are depleted. Lubricating
oils protect the engine as long as these additives are
functioning properly. Progressive contamination of the
lubricating oil between lubricating oil and filter change
intervals is normal. The amount of contamination will vary
depending on the operation of the engine, kilometers or
miles on the lubricating oil, fuel consumed, and new
lubricating oil added.
Extending lubricating oil and filter change intervals
beyond the recommendations will decrease engine life
because of factors such as corrosion, deposits, and wear.
Use the lubricating oil drain chart in this section to
determine which lubricating oil drain interval to use for an
application.
Flow Diagram, Lubricating Oil System Signature™, ISX, and QSX15
Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
4 1
© Cummins Inc. © Cummins Inc.
8 1 10 11
9 4
4
© Cummins Inc. 3
1
2
3
5 12
3
13
7
00c00003
Vertical Bypass
1. Lubricating oil flow from oil pump 8. Flow to turbocharger
2. Thermostat 9. Flow to main oil rifle
3. Oil cooler bypass flow 10. Oil drain from turbocharger
4. Flow through oil cooler 11. Thermostat open - oil flows through oil cooler
5. Flow return to filter head 12. Thermostat closed - oil flows directly to oil filter
6. Filter bypass valve 13. Flow to oil filter.
7. Oil filter
Signature™, ISX, and QSX15 Flow Diagram, Lubricating Oil System
Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
4
4
5 1
10
9
© 3Cummins Inc. © Cummins
3 Inc.
14 8
11
6 3
4
9 © Cummins Inc. 1
1
15 13
12
© Cummins
7 Inc. 2
© Cummins Inc.
9
07c00248
Horizontal Bypass
1. Lubricating oil flow from oil pump 9. Flow to main oil rifle
2. Thermostat 10. Oil drain from turbocharger
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve open - oil flows to oil filter
7. Oil filter 15. Bypass valve closed - oil flows directly to main oil rifle
8. Flow to turbocharger
4
14 © Cummins Inc. 4
© Cummins Inc. 1
5 10 3
9
9 3 11
8
© Cummins Inc.
3
4 1
15
6 1
13
9 © Cummins Inc.
7 2 © Cummins
12 Inc.
07c00217
Lubricating Oil Filter, Cooler and Bypass

3. Oil transfer to rear oil cooler 11. Thermostat open - oil flows through oil cooler
4. Flow through oil coolers 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil filter 15. Bypass valve open - oil flows directly to main oil rifle.
All Applications
© Cummins Inc.
Lubricating Oil Pump and Power Components

1. Lubricating oil flow from oil pan through suction tube 9. Flow from main bearing to crankshaft
2. Flow from suction tube to oil pump 10. Flow to cylinder head
3. Pressure regulator 11. Flow to piston cooling nozzle
4. High-pressure relief valve 12. Flow to idler gears
5. Flow from oil pump to oil cooler/filter head housing 13. Oil transfer from main oil rifle
6. Oil return from oil cooler/filter head housing to main 14. Flow to air compressor
oil rifle 15. Rifle sensing regulator dump to inlet.
7. Main oil rifle
8. Flow to main bearing
All Applications
2 6
3 13
5
4

3
2
10 1
© Cummins Inc.
9
14
8
© Cummins12Inc. © Cummins Inc.
11 1
1 7
00c00049
Overhead Components
1. Lubricating oil flow from cylinder block to cylinder 8. Flow to valve rocker levers
head 9. Flow to valve camshaft journal bearings
2. Flow around grooved head to drilled camshaft and 10. Intake valve rocker lever
rocker lever shafts 11. Engine brake lever
3. Flow to injector rocker lever shafts 12. Exhaust valve rocker lever
4. Flow to injector rocker levers 13. Injector rocker lever
5. Flow to injector camshaft journal bearings 14. Oil drain from overhead (front and rear).
6. Flow to fuel pump
7. Flow to valve rocker lever shaft
4
1
14 © Cummins Inc.
4 © Cummins Inc.
3
5 10
9 11
9
3
© Cummins 8Inc.3 1
4
15
6 1
13
12 Inc.
9 7 2
07c00302
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil Filter 15. Bypass valve open - oil flows directly to main oil rifle.
Cooling System - Overview Signature™, ISX, and QSX15
Cooling System - Overview (008-999)

General Information
A single thermostat design was implemented with the introduction of the 2002 ISX engine. The thermostat opens at
82°C [180°F] and is the same thermostat used in previous ISX engines, which were designed with two thermostats.
The ISX 2002 engine with EGR implemented an impeller that is similar to the impeller on the QSX15 engine to
maximize the cooling capacity of the water pump. The water pump pulley drive ratio was increased to provide faster
water pump speeds to increase cooling capacity. Increased cooling capacity is required because of the flow and heat
associated with the EGR.
The functions of the cooling system are to:
• Absorb heat from the engine components
• Circulate the coolant in the engine
• Dissipate the heat through the radiator
• Control coolant temperature by the thermostat.
The coolant must be made up of the correct proportions
of water, antifreeze, and supplemental coolant additives
(SCA) to perform these functions properly.
The accompanying chart illustrates the coolant flow

through the engine. For more detail, refer to the Cooling
System Flow Diagram.
Conventionally cooled engines with automatic

transmissions typically use a oil-to-water transmission
torque converter cooler plumbed between the radiator and
the engine water pump.
A torque converter cooling system with a remote bypass
allows the torque converter to receive coolant flow when
the thermostat is closed (engine cold).
Signature™, ISX, and QSX15 Cooling System - Overview
The following publications, available through a Cummins®

Authorized Repair Location, provide cooling system
installation recommendations and specifications
approved by Cummins Inc.:
• Data Sheets for specific engine models
• Operation of Diesel Engines in Cold Climates, Bulletin
3379009
• Heavy-Duty Coolant/SCA Maintenance Requirements,
Bulletin 3387910.
Flow Diagram, Cooling System Signature™, ISX, and QSX15
Flow Diagram, Cooling System (200-003)

Flow Diagram
© Cummins Inc. 6
© Cummins
6
Inc. © Cummins Inc.
1
2 3 4 00c00041
1. Coolant inlet 5. Coolant flow from water pump

2. Coolant flow from coolant filter 6. Coolant flow past oil cooler
3. Coolant bypass flow from thermostat 7. Coolant flow to cylinder head.
4. Coolant flow to water pump
Signature™, ISX, and QSX15 Flow Diagram, Cooling System

Flow Diagram
3 10 3
1 1
© Cummins
4 Inc. 9
© Cummins Inc.
2 2
5
6
© Cummins Inc.
7 11
© Cummins Inc.8 © Cummins

8 Inc.
08c00125
Single Thermostat
1. Coolant flow through cylinder head 7. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 8. Coolant flow to water pump
housing 9. Bypass closed
3. Thermostat 10. Coolant flow to radiator
4. Bypass open 11. Coolant flow from radiator.
5. Coolant flow through thermostat housing to bypass
passage
6. Coolant bypass passage

Flow Diagram
2 3 2
3
4 ©
2 Cummins Inc. © Cummins
4 Inc.
7
5
© Cummins6 Inc.
1

00c00042
Dual Thermostat
1. Coolant flow from cylinder block to cylinder head 5. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 6. Coolant bypass flow to water pump
housing 7. Thermostats.
3. Coolant flow to radiator

7
13
17
16
© Cummins Inc. © Cummins Inc. 3
15
14 6
©
12 Cummins
11 Inc. 5
10
6
9
© Cummins Inc. 8 1
© Cummins Inc.
16
2 3 4 08c00124
1. Coolant inlet 10. Coolant flow around EGR valve

2. Coolant flow from coolant filter 11. EGR valve coolant return to thermostat housing
3. Coolant bypass flow from thermostat 12. EGR cooler coolant supply from cylinder block
4. Coolant flow to water pump 13. Coolant flow through EGR cooler
5. Coolant flow from water pump 14. EGR cooler coolant return to thermostat housing
6. Coolant flow past lubricating oil cooler 15. Thermostat housing
7. Coolant flow to cylinder head. 16. Coolant supply to turbocharger
8. Lubricating oil cooler housing 17. Coolant return from turbocharger.
9. Coolant supply to EGR valve body
3 10 3
1 1
© Cummins
4 Inc. 9
© Cummins Inc.
2 2
5
6
© Cummins Inc.
7 11

8 Inc.
08c00125
Single Thermostat
passage

2
8
10

8 3
9 11
7
© Cummins Inc. 1
6

5 4
08c00251
1. Coolant supply to EGR cooler 7. Coolant flow to actuator valve

2. Coolant flow through EGR cooler 8. Coolant flow from actuator valve to thermostat
3. Coolant return to block housing
4. Lubricating oil cooler housing 9. Coolant flow from turbocharger bearing housing to
5. Coolant flow to turbocharger thermostat housing
6. Coolant flow to turbocharger bearing housing 10. Thermostat housing
11. EGR cooler coolant vent line

7
© Cummins Inc.
6
© Cummins Inc.
1 © Cummins
5 Inc.
2 3 4 08c00259
1. Coolant inlet 5. Coolant flow from water pump

2. Coolant flow from coolant filter 6. Coolant flow past oil cooler
3. Coolant flow to water pump 7. Coolant flow around cylinder liners
4. Coolant bypass flow to water pump 8. Coolant flow to cylinder head.
Single Thermostat
3 10 3
1 1
© Cummins
4 Inc. 9
© Cummins Inc.
2 2
5
6
© Cummins Inc.
7 11

8 Inc.
08c00125
passage
Air Intake System - Overview Signature™, ISX, and QSX15
Air Intake System - Overview (010-999)

General Information
Variable Geometry
To maximize the performance of the engine and also to help decrease emissions levels, a variable geometry
turbocharger is used on the ISX engine, referred to as automotive with CM870 and automotive with CM871
The variable geometry turbochargers have quicker response time, and quicker engine deceleration for quicker shifting
than fixed geometry turbochargers.
Because of the active control of the variable geometry turbocharger, intake manifold pressure and turbocharger noise
can often change. There is not a loss of power associated with the change in intake manifold pressure or turbocharger
noise; however, customer perception of engine power can be affected. Typically, when the intake manifold pressure
and turbocharger noise are changing during steady state operation, the ECM is adjusting the flow of EGR into the
engine and the engine power is not affected.
When the throttle is released, perhaps for a gear change, the variable geometry actuator closes. This prepares the
turbocharger to be ready to build intake manifold pressure quickly to provide improved turbocharger response when
the throttle is depressed after the gear change. Because of this design for improved turbocharger response, after
releasing the throttle, the engine speed of the ISX engine with a variable geometry turbocharger can decrease more
quickly than an engine without a variable geometry turbocharger. Fast deceleration in engine speed can cause drivers
to adjust their shifting styles until they become accustomed to the different deceleration speeds.
Similar to all of Cummins Inc. electronically controlled heavy duty engines, the ISX engine with a variable geometry
turbocharger incorporates a power derate to protect the turbocharger from damage while operating in high altitudes.
The ISX engine with a variable geometry turbocharger meets or exceeds the power output of the ISX engine with a
fixed geometry turbocharger at most altitudes. At and around 2.438 km [8000 ft] elevation, however, a slight power
decrease can be noticeable when operating the ISX engine with a variable geometry turbocharger, when comparing
its performance to the ISX engine with a fixed geometry turbocharger.
The ISX with CM870 variable geometry turbocharger is
pneumatically actuated with air from the OEM air tanks.
High air pressure from the turbocharger control valve
closes the variable geometry mechanism, which
increases the exhaust gas pressure and facilitates EGR
flow through the engine. A closing variable geometry
mechanism also increases turbocharger speed and intake
manifold pressure under certain engine operating
conditions. Lower air pressure from the turbocharger
control valve opens the variable geometry mechanism,
which decreases exhaust gas pressure, turbocharger
speed, and manifold pressure under certain engine
operating conditions.
Depending on the build date, the ISX with CM870 uses
either a low mount turbocharger control valve or a high
mount turbocharger control valve.
The early ISX with CM870 use the high mount

turbocharger control valve, which is located on top of the
front gear housing.
Signature™, ISX, and QSX15 Air Intake System - Overview
The air filter is located on the air shut-off valve.
The later ISX with CM870 engines, engine serial number

first (ESN) 79031440 uses the low mount turbocharger
control valve. The low mount turbocharger control valve
does not require an air filter.
However, the vehicle must be equipped with an air dryer
to meet engine installation requirements. The vehicle air
supply will be plumbed directly to the control valve inlet
port (1). The outlet air supply port (2) to the variable
geometry turbocharger .

The ISX with CM871 variable geometry turbocharger is
electronically actuated. The electronic control module
(ECM) sends a command directly to the variable geometry
actuator mounted on the turbocharger.
Closing the variable geometry mechanism increases the
exhaust gas pressure, facilitating EGR flow through the
engine. Turbocharger speed and intake manifold pressure
will also increase when the variable geometry mechanism
closes under certain engine operating conditions. Closing
the variable geometry turbocharger will also increase
exhaust gas temperature under certain normal engine
operating conditions and during aftertreatment
regeneration events. This is used to improve
aftertreatment component efficiency. Refer to Procedure
011-999 for further information regarding variable
geometry turbocharger and aftertreatment system
interactions.
Opening the variable geometry mechanism decreases
exhaust gas pressure, turbocharger speed and intake
manifold pressure under certain engine operating
conditions.
Air Intake System - Overview Signature™, ISX, and QSX15
All Applications
The combustion air system consists of intake air piping,
turbocharger, charge-air cooler piping, charge air cooler,
and exhaust piping.
The turbocharger uses exhaust gas energy to turn the

turbine wheel. The turbine wheel drives the compressor
impeller that provides pressurized air to the engine for
combustion. The additional air provided by the
turbocharger allows more fuel to be injected to increase
the power output from the engine.
The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures
and shorten the life of the engine.
The turbine and compressor wheels and the shaft are

supported by two rotating bearings in the bearing housing.
Passages in the bearing housing direct filtered,
pressurized engine oil to the shaft bearings and thrust
bearings. The oil is used to lubricate and cool the rotating
components to provide for smooth operation. The oil then
drains from the bearing housing to the engine sump
through the oil drain line.
An adequate supply of good, filtered oil is very important
to the life of the turbocharger.
As the intake air is compressed by the turbocharger, the

air temperature increases. This heated air is then passed
through the charge-air cooler, which cools the air. Cool air
is more dense, which allows more air to be compressed
into the cylinder, yielding a much greater combustion
efficiency.
Signature™, ISX, and QSX15 Flow Diagram, Air Intake System
Flow Diagram, Air Intake System (200-004)

Flow Diagram
6 5
2
4
© Cummins
4
Inc.

1
3
00c00005
1. Intake air inlet to turbocharger 4. From charge air cooler to intake manifold
2. Turbocharger air to charge air cooler 5. Intake valve port
3. Charge air cooler 6. Intake valves.
Flow Diagram, Air Intake System Signature™, ISX, and QSX15
With CM870
7 6
8
5
© Cummins Inc. 9
5 © Cummins
4
Inc.
© Cummins Inc. 3
1
10c00126
1. Intake air inlet to turbocharger 6. EGR mixer

2. Turbocharger air to charge air cooler 7. Air intake connection
3. Charge air cooler 8. Intake valve port
4. From charge air cooler to intake manifold 9. Intake valves.
5. Exhaust gas to EGR mixer
Signature™, ISX, and QSX15 Flow Diagram, Air Intake System
11
10
4
5
6 7
© Cummins Inc.
9
8
© Cummins Inc.
3
© Cummins Inc.
© Cummins Inc. 1 2 © Cummins Inc.

10c00168
1. Intake air inlet to turbocharger 7. Exhaust to exhaust manifold

2. Turbocharger air to charge air cooler 8. Exhaust gas to EGR cooler
3. Charge air cooler 9. Exhaust cooler
4. From charge air cooler to air inlet connector 10. Exhaust gas to EGR valve
5. Intake valve port 11. Exhaust gas to mixer.
6. Intake valves
Exhaust System - Overview Signature™, ISX, and QSX15
Exhaust System - Overview (011-999)

General Information
Exhaust gas recirculates through the engine to reduce the amount of oxides of nitrogen (NO x) emitted from the engine.
The exhaust gas is cooled as if flows through an EGR cooler, and then is mixed with the compressed fresh air from
the turbocharger before entering the intake manifold. EGR was introduced to reduce the amount of in-cylinder oxygen
available for combustion while maintaining the same amount of flow through the engine. Exhaust gases present during
the start of combustion are very stable and have a very slow reaction rate. They absorb heat during combustion,
resulting in lower in-cylinder peak flame temperatures, and therefore, lower NO x emissions.
The EGR mixer was designed to completely mix the EGR gas with the turbocharged air from the charge air cooler.
Complete mixing is necessary to provide smooth operation and decreased emissions.
The variable geometry turbocharger is required for several important engine operating conditions. It is used to facilitate
EGR flow through the engine. Refer to Procedure 010-999 (Air Intake System - Overview) for variable geometry
turbocharger and EGR flow interactions.
The variable geometry turbocharger is also used for engine braking. The variable geometry mechanism closes in
order to increase exhaust manifold pressure. The increased exhaust pressure works against the pistons on the
exhaust stroke, retarding engine speed.
The aftertreatment system is used to reduce particulate
emissions and is composed of six main components:
1. Aftertreatment inlet
2. Aftertreatment diesel particulate filter differential
pressure sensor
3. Aftertreatment diesel oxidation catalyst
4. Aftertreatment diesel particulate filter
5. Aftertreatment outlet
6. Aftertreatment exhaust gas temperature sensors.
NOTE: In some applications, the aftertreatment diesel
oxidation catalyst can be contained within the inlet section
of the aftertreatment system.
Passive regeneration occurs when the exhaust

temperatures are naturally high enough to oxidize the soot
collected in the aftertreatment diesel particulate filter
faster than the soot is collected.
Passive regeneration typically occurs when the
temperature of the aftertreatment diesel particulate filter
is above 316°C [600°F]. This occurs during highway
driving or driving with heavy loads.
Since passive regeneration occurs naturally, it is
considered to be normal engine operation. No fuel is
added to the exhaust stream during passive regeneration.
Signature™, ISX, and QSX15 Exhaust System - Overview
Active regeneration occurs when the exhaust

temperatures are not naturally high enough to oxidize the
soot collected in the aftertreatment diesel particulate filter
faster than it is collected.
Active regeneration requires assistance from the engine
in order to increase the exhaust temperature. This is
typically done by injecting a small amount of diesel fuel
into the exhaust stream (called aftertreatment injection)
which is then oxidized by the aftertreatment diesel
oxidation catalyst. The oxidation of this additional fuel
creates the heat needed to regenerate the aftertreatment
diesel particulate filter.
For active regeneration to occur, the ECM must detect
that the aftertreatment diesel particulate filter restriction
has reached a specified limit. Once this limit is reached,
the engine will alter its operation in order to create exhaust
temperatures high enough to actively regenerate the
aftertreatment diesel particulate filter.
An active regeneration event typically consists of two
parts: a warming up phase and a regenerating phase.
The purpose of the warm up phase is to increase the
exhaust temperatures to the point that aftertreatment
injection can occur.
Exhaust System - Overview Signature™, ISX, and QSX15
Aftertreatment injection requires that temperatures in the aftertreatment system reach approximately 288°C [550°F].
At this temperature and above, the small quantities of fuel injected into the exhaust will properly oxidize across the
aftertreatment diesel oxidation catalyst creating the additional heat required to actively regenerate the aftertreatment
Once the warm up phase is complete and the aftertreatment injection has begun, the active regeneration phase
begins.
During active regeneration, the engine ECM monitors the exhaust temperatures before and after the aftertreatment
diesel particulate filter and maintains the temperatures in a range of approximately 427 to 649°C [800 to 1200°F].
The quantity of fuel used for aftertreatment injection will vary as the temperature is controlled within these limits.
The temperatures achieved during active regeneration are typically higher than those achieved during passive
regeneration. The conversion of soot to carbon dioxide occurs much faster as temperatures increase.
A typical active regeneration event will take approximately 20 to 40 minutes to complete while the vehicle is operating.
The vehicle operator may notice additional turbocharger noise during this time, along with an illuminated high exhaust
temperature lamp, if equipped.
The frequency at which an engine will require an active regeneration varies greatly from application to application. In
general, vehicles with a low vehicle speed, such as urban vehicles, or a low-load duty cycle, will require more active
regeneration events than a heavily loaded vehicle or a vehicle with a high speed duty cycle.
The engine ECM also contains a time-based feature for active regenerations which is used to verify correct
aftertreatment operation when the vehicle duty cycle is typically high enough that active regeneration events are
not necessary.
Under some operating conditions, such as low speed, low load, or stop and go duty cycles, the engine may not have
enough opportunity to regenerate the aftertreatment diesel particulate filter during normal vehicle operation. When
this occurs, the engine illuminates the aftertreatment diesel particulate filter lamp to inform the vehicle operator that
assistance is required, typically in the form of a stationary (parked) regeneration.
Stationary (parked) regeneration is a form of active regeneration that is initiated by the vehicle operator when the
vehicle is not moving.
Refer to Procedure 014-013 (Aftertreatment Testing) in Section 14, for more information on Stationary (Parked)
Regeneration.
The vehicle manufacturer has the that option of installing two switches that control aftertreatment functions: the start
switch and the permit switch.
The start switch (known as the Diesel Particulate Filter Regeneration Start Switch in INSITE™ electronic service tool)
is used to start a stationary (parked) regeneration. The vehicle manufacturer may also reference this switch as a
stationary regeneration switch, start switch, or parked regeneration switch.
The permit switch (known as the Diesel Particulate Filter Permit Switch in INSITE™ electronic service tool) is used to
allow the vehicle operator to disable active regeneration, if necessary. The vehicle manufacturer may also reference
this switch as an inhibit switch, stop switch, or disable switch.
Refer to Procedure 011-056 (Exhaust System Diagnostics) in Section 11, for switch operation and troubleshooting.
Signature™, ISX, and QSX15 Exhaust System - Overview

The Signature™, ISX, and QSX15 engines utilize either a
wastegated, Holset® HX55 or HX60 turbocharger. Some
lower horsepower automotive ratings and most industrial
applications utilize a non-wastegated, fixed geometry
Holset® HX55 turbocharger.
The wastegated turbocharger is comprised of a
turbocharger, wastegate actuator, and wastegate valve in
the turbine housing. A wastegated turbocharger provides
improved response at low engine speeds without
sacrificing turbocharger durability at high speeds. This is
accomplished by allowing exhaust gases to bypass the
turbine wheel during certain modes of engine operation.
During low rpm operation, the turbocharger operates as a
closed-system turbocharger where the gases' energy is
transferred to the compressor wheel and use to compress
intake air. During high rpm operation, however, the
turbocharger becomes an open-system turbocharger and
allows exhaust gases to bypass the turbine wheel. Since
exhaust gas is gated around the turbine wheel, less
energy is absorbed through the turbine and transferred to
the compressor, reducing intake manifold pressures and
turbine speeds.
The wastegate controller is mounted on the air intake

connection and is controlled by the ECM. The wastegate
controller regulates the percentage of the intake manifold
pressures sent to the wastegate actuator. Two solenoids,
similar to the fuel pump shutoff valve of the CELECT™
product, are used in conjunction with four orifices to
regulate this percentage.
The wastegate actuator is mounted on the turbocharger

and consists of a pressure canister, diaphragm, and rod.
As pressure changes in the canister, as dictated by the
wastegate controller, the actuator rod adjusts the
wastegate valve accordingly.
The wastegate valve is mounted inside the turbocharger
in the turbine housing. As the valve opens, exhaust gas is
allowed to bypass the turbine wheel, lowering turbine
speed to adjust intake manifold pressure.
Flow Diagram, Exhaust System Signature™, ISX, and QSX15
Flow Diagram, Exhaust System (200-005)

Flow Diagram
2
© Cummins Inc.
3
00c00006
1. Exhaust valve ports 3. Turbocharger turbine.

2. Exhaust manifold
Signature™, ISX, and QSX15 Flow Diagram, Exhaust System
Flow Diagram, Exhaust System (200-005)

Flow Diagram
© Cummins Inc.

12200016
Wastegate OPEN; Wastegate CLOSED

With CM870
2
1
3 8
4 © Cummins Inc.
5 7

6 11c00066
1. Exhaust gas to manifold 5. EGR valve

2. Exhaust manifold 6. Exhaust gas to EGR cooler connection
3. Exhaust gas to turbocharger 7. EGR cooler
4. Exhaust gas to EGR valve 8. Cooled exhaust gas to EGR connection tube and
EGR mixer.
With CM870
1 1
2 4
© Cummins Inc.
© Cummins Inc. 2
© Cummins Inc.
4
3
5
11c00067
Variable Geometry
1. Exhaust in 4. Sliding nozzle closed
2. Sliding nozzle Open 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow
1 1
2 4
© Cummins Inc.
© Cummins Inc. 2
© Cummins Inc.
4
3
5
11c00067
1. Exhaust gas in 4. Sliding nozzle - closed position

2. Sliding nozzle - open position 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow

9 10
6
4
5 7
3
8
© Cummins Inc.
© Cummins2 Inc. ©1 Cummins Inc.

11c00191
1. Exhaust gas to EGR cooler 6. Front EGR connection tube

2. EGR cooler 7. EGR measurement venturi
3. Cooled exhaust gas to rear EGR connection tube 8. Cooled exhaust gas to the EGR mixer
4. EGR valve mounting bracket 9. EGR differential pressure sensing tubes
5. EGR valve 10. EGR differential pressure sensor.
1 3
5
4
7
8
© Cummins Inc.
10
13
14
© Cummins Inc. 9
11
© Cummins
15
Inc.
12 11c00095
Cummins® Particulate Filter

1. Exhaust from turbocharger 9. Aftertreatment particulate trap differential pressure
2. Aftertreatment fuel injector sensor tubes (High)
3. Exhaust pipe with exhaust mixture 10. Installation alignment tab
4. Exhaust gas temperature sensor (number 1) 11. Aftertreatment particulate trap
5. Aftertreatment inlet 12. Aftertreatment particulate filter differential pressure
6. Aftertreatment particulate trap differential pressure sensor tube (Low)
sensor 13. Aftertreatment outlet
7. Aftertreatment catalyst 14. Exhaust gas temperature sensor (number 3)
8. Exhaust gas temperature sensor (number 2) 15. Exhaust flow exiting aftertreatment system.
Signature™, ISX, and QSX15 Compressed Air System - Overview
Compressed Air System - Overview

(012-999)
General Information
The compressed air system normally consists of a gear-
driven air compressor, air governor, air tanks, and all
necessary plumbing.
Complete installation recommendations are found in
Cummins Inc. publication, Automotive and Bus
Installation Recommendations, Air Compressor Systems,
Bulletin 3884946.
Single Cylinder
The components listed below are commonly used in a
single cylinder air system.
(1) Air Governor
(2) Discharge line
(3) Air dryer
(4) Supply tank
(5) Check valve
(6) Primary tank
(7) Secondary tank
(8) Check valve
(9) Air compressor.
Flow Diagram, Compressed Air System Signature™, ISX, and QSX15
Flow Diagram, Compressed Air System (200-006)

Flow Diagram

1
2
© Cummins Inc.
3
00c00007
1. Coolant 3. Lubricant.
2. Air
Signature™, ISX, and QSX15 Flow Diagram, Compressed Air System
Flow Diagram, Compressed Air System (200-006)

Flow Diagram
1
2 3
© Cummins Inc. 5

6
4
00c00008
WABCO - Type System with Air Dryer

1. Governor 4. Reservoir (wet tank)
2. Discharge 5. Air compressor
3. Intake 6. Air dryer.
Electrical Equipment - Overview Signature™, ISX, and QSX15
Electrical Equipment - Overview (013-999)

General Information
All Delco Remy America alternators are rated for inlet air temperatures of -35 to 93°C [-31 to 200°F], measured 25.4
mm [1 in] from the rear of the unit, except for the 26SI. The 26SI has a maximum rating of 85°C [185°F] because of
the sealed electronics. Avoid mounting the alternator near any heat sources, such as manifolds, turbochargers, and
so forth. Adequate clearance must also be provided at the rear of the alternator for cooling air to enter (the alternator
fan pulls air through toward the front of the unit).
The second most common cause of failure of Cummins® alternators is contamination by dirt, chemicals, water, or
unknown substances. While the alternator is laboratory tested to withstand salt spray, dust, and high humidity, it is
necessary to mount the alternator to minimize environmental and application contamination. Exposure to salt spray
over an extended period of time will shorten the alternator life, as well as increase circuit resistance by causing
corrosion to terminal connections for all electrical components. Exposure to engine oil or oil mist from the engine
breather tubes can cause brush problems in brush alternators, as well as attract other debris. Any contamination of
the rear of the alternator can reduce airflow, which will eventually overheat the diodes.
If operating in extreme environments, especially off-road, the 21SI can be installed with a dust shield, which has shown
to reduce the effects of extreme environments and improve alternator life. Debris shields have been developed for
the 19SI, 22SI, and 23SI alternators. New debris shields have provisions for mounting an air duct in order to route
clean air where necessary.
Establish proper cable routing, and determine cable lengths. Avoid routing taut cables between connections. The
maximum voltage drop in the charging system at rated alternator output is 0.5 VDC for a 12 VDC system, 1.0 VDC
for a 24 VDC system, and 1.5 VDC for a 32 VDC system. The voltage drop in the charging system must be kept to a
minimum in order to make sure enough voltage exists to charge the batteries.
While all Delco Remy America alternators are negative grounds, it is suggested that a full copper return be provided
to the negative (-) terminal of the batteries. This will also make sure that as the vehicle ages, corrosion of the frame
and ground strap do not cause excessive voltage drops. Also, painted mounting brackets can prevent a complete
electrical circuit.
Be sure all electrical connections, including ground connections, are metal-to-metal connections.
CAUTION
Never use any type of toothed lock washer, internal or external tooth (also called star washers), on wiring
connections. The points of the star washer cause current to be conducted only through the points of the star
washer, rather than the larger flat surface of a standard flat washer, and lead to corrosion and a high-
resistance electrical connection.
Mounting Hardware
• All capscrews must be a minimum diameter of 12.7 mm [0.5 in].
• Always use a hardened steel washer under mounting capscrew heads, or use flanged-head hardware. The
washer must match the capscrew diameter.
• Never use any type of lock washer, including toothed or split lock washers, on any mounting connection. Lock
washers are not recommended for mounting capscrews because their trapezoidal cross section provides less
clamping surface and higher clamping stress.
The operating range of the cranking motor and solenoid is -25 to 121°C [-13 to 250°F]. Military application starters
have an operating range from -54 to 121°C [-65 to 250°F]. Locating the motor close to the exhaust manifold or other
heat source can result in reduced motor performance with deterioration of insulation and rubber components. A
minimum 50.8 mm [2 in] clearance is recommended. Where relocation or rotation is not possible, metal shielding can
effectively be used to protect the starter from engagement in hot conditions.
Establish proper cable routing. Avoid routing a taut cable between connections. When routing battery cables from the
frame rails to the cranking motor, anchor the cables to the engine, transmission, or cranking motor, and allow for
relative movement between the engine and the frame. It is highly recommended that a copper ground return be used
and the frame not be relied upon for ground return in the starting circuit, which will prevent corrosion from creating
excessive voltage drops. Using a copper ground cable is especially critical in applications using a wet flywheel
housing, where reliance on frame grounding can create a current path through the crankshaft and main bearings.
Limit the number of cables attached to the battery terminal of the solenoid to not more than two.
When positioning the motor at the mounting location, it is desirable to place the solenoid above the centerline of the
motor (preferably a minimum of 15 degrees above the horizontal). This will prevent potential accumulation of foreign
material or moisture that can restrict operation in the tower portion of the shift lever housing. It also reduces the
possibility of road debris being thrown up and breaking the solenoid cap.
Mounting Specifications
Signature™, ISX, and QSX15 Electrical Equipment - Overview
• The flange-to-flywheel distance is the distance on the engine from the cranking motor mounting surface to the
ring gear face. This distance is 50.8 ± 1.52 mm [2.0 ± 0.060 in]. This dimension must include spacers or
gaskets used on the engine. The cranking motor is designed to function within this dimension. If it is altered,
pinion or ring gear damage can occur.
• Delco Remy America recommends the use of 12-point, flanged head capscrews.
• No lock washers, star washers, or soft washers, including copper electrical connections can be used. Lock
washers and star washers do not have a rectangular cross section and can result in a loss of clamp force on
the mounting capscrews. The yield strength of soft washers or copper connections can be exceeded with
mounting capscrews tightened. In each case, a loose starter mounting will result.
CAUTION
If the engine does not start and must be cranked again, always wait two to three seconds to allow the pinion
and ring gear to stop. If the starter is reengaged immediately, the pinion can be milled or the armature twisted.
The starter is intended only for cranking the engine and must not be used to “bump” the engine.
If the engine does not start within five seconds of cranking, follow the Cold Weather Starting Using Starting Fluid -
With Mechanical or Electrical Metering Equipment (Ether) in Section 1 of the Operation and Maintenance Manual
Signature and ISX Engines, Bulletin 3666311, or Procedure 101-004 (Cold Weather Starting) in Section 1 of the
Operation and Maintenance Manual Signature and ISX Engines, Bulletin 3666251, or Operation and Maintenance
Manual Industrial and Power Generation QSX15 Engines, Bulletin 3666243. Operating the cranking motor for more
than 30 seconds at a time causes stress and/or severe internal heat buildup. A minimum two minute cooling period
is necessary between extended cranking cycles.
When mounting a magnetic switch on a vehicle, the axis of the plunger must be horizontal to the ground and
perpendicular to the axis of travel of the vehicle. This is to make sure the switch is not activated by the movement of
the vehicle. Do not mount the switch on the engine or any metal that can possibly resonate as a result of road or
engine vibration. For engines with separate fuel shutoff solenoids, Cummins Inc. requires the use of two magnetic
switches: one for the fuel shutoff circuit and one for the starting circuit. The fuel shutoff solenoid must not be wired
to the “S” terminal of the starting motor. Wiring to the “S” terminal will cause the shutoff solenoid to fail.
The basic heavy-duty electrical system consists of:
(1) Batteries
(2) Starter
(3) Alternator (generator)
(4) Magnetic switch
(5) Push-button switch
(6) Keyswitch
(7) Control (or relay) circuit wiring
(8) Battery cables or cranking circuit.
Refer to the OEM service repair manual for specific

service information about the charging and starting
circuits.
Refer to the OEM service repair manual or the component
manufacturer's service bulletins for specific service
information about the starting motor and the alternator.
Engine Testing - Overview Signature™, ISX, and QSX15
Engine Testing - Overview (014-999)

General Information
This section outlines engine testing and engine run-in
recommendations for Signature engines. All engines
must be run in after a rebuild or a repair involving the
replacement of one or more piston ring sets, cylinder
liners, or pistons.
NOTE: Incorrect or insufficient break-in of the piston rings
will lead to early oil consumption or high-blowby
complaints. Adherence to these run-in guidelines will
allow the full durability of new pistons, liners, and rings to
be realized.
Before running the engine, make sure the engine is filled
with the proper coolant. Also, make sure the lubricating oil
system is filled and primed.
Signature™, ISX, and QSX15 Engine Testing - Overview
In-Service Run-In:
The following in-service run-in guidelines are recommended for Signature engines after a repair involving replacement
of one or more of the piston ring sets, cylinder liners, or pistons where engine or an engine dynamometer and/or
chassis dynamometer run-in can not be performed.
The majority of heavy-duty diesel applications will provide sufficient run-in under normal loaded operations. However,
light-load/high-rpm operation must be avoided during the run-in period.
Engine Dynamometer Run-In:
This is the preferred method of run-in for engines that have been rebuilt out of chassis. It is neither practical nor
recommended that an engine be removed from the application to conduct the run in after a rebuild or cylinder repair
has been performed in-chassis. There is no requirement, nor is it recommended, for an engine that has been run-in
and tested on an engine dynamometer to be run in again after it has been reinstalled in the vehicle or equipment.
Chassis Dynamometer, Portable Dynamometer, or Load Bank Run-In:
When it is not possible to load an engine immediately after rebuild or repair (example: On-highway tractor that
must be "bobtailed" for delivery, a standby generator or fire pump that can not be operated because of customer
restrictions, a fire truck that can not be loaded with the water pump, etc.), the engine must be run in on a chassis
dynamometer, portable dynamometer, or load bank following the recommendations outlined in the attached
procedures.
Fuel Flow Measurement on Engine or
Chassis Dynamometer
Accurate fuel flow measurement is important for
evaluation of engine performance and troubleshooting on
an engine or chassis dynamometer. The only way an
accurate fuel flow measurement can be obtained is
through proper use of available equipment. Below is a
description of the fuel measuring device, available from
Cummins Engine Company, along with installation and
operation recommendations. The fuel measuring device,
Part No. 3376375, can be used with either a chassis or
engine dynamometer.
Installation:
When installing the fuel measuring device, it is important
to reduce the amount of air that can be introduced into the
system when the device is not in use. Therefore, the
plumbing used must include nonrestrictive shutoff valves,
such as ballcock valves, to contain fuel in the device after
each use. Additional installation considerations are:
• The fuel measuring device, Part No. 3376375,
must be mounted vertically to maintain accuracy
and proper operation.
• A separate fuel supply for use on the dynamometer
is recommended. All fuel used in the measuring
device must be clean for consistent operation.
• Care must be taken to reduce fuel line restriction to
and from the engine. Minimum recommended hose
size is No. 10 for the engine fuel inlet and No. 8 for
the engine fuel drain. The length of either hose must
not exceed 15 feet.
• For accurate fuel consumption or flow measurement
while testing on a chassis dynamometer, it is
recommended to use a fuel cooler to maintain inlet
temperature to the fuel gear at 49°C [120°F] or
below.
Engine Testing - Overview Signature™, ISX, and QSX15
Operation:
This is a schematic of the fuel measuring device, Part No. 3376375. The device consists of the following components:
• Fuel Filter
• Flowmeter
• Float Tank
• Fuel Rail Pressure Gauge
• Fuel cooler is not a part of fuel measuring device, Part No. 3376375; however, it must be used when conducting
a test with the flowmeter.
The fuel measuring device recirculates return fuel to the engine fuel inlet by routing the return fuel to the topside of
the float tank. The fuel is deaerated as it passes through the baffling in the float tank. A ball float valve at the bottom
of the float tank maintains an adequate volume in the tank for deaeration. The fuel is then returned to the engine fuel
inlet. Refer to the sketch for fuel line connection points on the fuel measuring device.
1. Fuel supply from tank
2. Fuel flow to fuel meter
Signature™, ISX, and QSX15 Vehicle Braking - Overview
3. Fuel flow from fuel meter

4. Fuel flow to fuel cooler
5. Injector return fuel
6. Fuel rail pressure.
NOTE: The fuel supply tank must be below the level of the fuel measuring device to prevent overflow of the float tank.
If an overhead fuel supply tank is used, a float-controlled reservoir must be installed between the fuel supply tank
and the fuel measuring device, and below the level of the device.
The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity
of fuel being drawn through the flowmeter is known as makeup fuel or the amount of fuel being burned by the engine.
The flowmeter is graduated to read fuel flow in pounds per hour. The flowmeter contains two floats with respective
scales on either side of the flowmeter. The small float is used to measure lower flows and must be read on the left
scale, as shown. The larger float is for measuring higher flows and must be read on the right scale.
To obtain an accurate fuel rate measurement, the flowmeter reading must be corrected based on the fuel temperature.
There is a fuel temperature gauge on the front panel of the fuel measuring device. The gauge is graduated in percent
of error by which the reading requires correction. By way of illustration, the fuel of an engine reads 125 lb/hr on the
flowmeter, and the temperature gauge reads +2 percent; the corrected fuel flow rate will be 125 plus 2 percent, or
127.5 lb/hr.
Vehicle Braking - Overview (020-999)

General Information
CAUTION
Do not exceed governed engine speed when
operating engine brakes. Engine damage can occur.
The engine brakes are designed to assist the vehicle's
service brakes in slowing down the vehicle. Never use
only the engine brakes to stop the vehicle. If other
engine brakes are used, refer to the component
manufacturer's manual.
Vehicle Braking - Overview Signature™, ISX, and QSX15
Signature and ISX engines are equipped with the

Intebrake™ system (engine brakes). The Intebrake™
system is optional on QSX engines.
Engine brakes use the energy of engine compression to
provide vehicle retardation by converting the engine to an
energy-absorbing device to reduce vehicle speed. This is
accomplished by a hydraulic circuit that opens the
exhaust valves near the end of the compression stroke.
Engine brakes provide the maximum retarding power at
rated speed; therefore, gear selection is important.
The amount of braking power available on Signature, ISX,

or QSX engines is up to 600 hp. Braking power is
managed by the Intebrake™ system (engine brakes).
Engine brake controls consist of the following:

• A six-position selector switch or a three-position
selector switch
• An on/off switch
• A clutch switch
• A throttle sensor
• A service brake pressure switch.
Other switches for cruise control that affect engine brake

operations are:
• Cruise control ON/OFF and SET/RESUME switches
(if the engine brakes in cruise control feature is
turned off)
• Service brake air pressure switch.
Engine brakes can operate while cruise control is turned
on. Refer to Programmable Features in this section.
The six-position selector switch is located next to the on/

off switch in the cab, and allows you to select the retarding
power from brake positions 1 to 6.
The engine brake level specifications (six-position selector

switch):
Position 1 = 17-percent engine braking power
Position 6 = 100-percent engine braking power.
NOTE: For OEMs that use a three-position selector
switch, the engine brake level specifications are:
Position 3 = 100 percent engine braking power.
Signals from the on/off switch, the clutch switch, the

throttle sensor, and the cruise/PTO switches are fed into
the electronic control module (ECM).
NOTE: Any one of these switches can deactivate the
engine brakes. If the engine brakes in cruise control
feature is turned on, the cruise control/PTO switches will
not deactivate the engine brakes.
The ECM then electronically enables or disables the

engine brakes.
NOTE: Engine brakes can not be enabled:
1. When cruise control is active and if the engine
brakes in cruise control feature is turned off
2. When engine speed drops below 850 rpm, or 30 mph
3. When an electronic fault code is active.
The “throttle sensor” is part of the accelerator pedal

assembly located in the cab and will deactivate the engine
brakes when depressed.
The “clutch switch” uses the motion of the clutch linkage

to deactivate the engine brakes when the clutch pedal is
depressed. Depressing the clutch while in cruise control
will disengage the cruise control.
The “service brake pressure switch” is attached to the

service brake air supply line.
Applying the service brakes while in cruise control will
disengage the cruise control and enable the engine
brakes.
If the pedal activated engine brake feature is enabled, the
service brake pedal must be tapped before the engine
brakes will be activated.
Idle the engine 3 to 5 minutes at approximately 1000 rpm

to warm the engine before activating the engine brakes.
Do not operate the engine brakes until the engine oil
temperature is above 30°C [86°F].
To activate the engine brakes, switch the on/off switch to

the ON position. Once activated, the operation of the
engine brakes is fully automatic.
NOTE: Refer to the appropriate pages in this section for
specific information about engine brake operation under
certain road conditions.
WARNING
Do not use the engine brakes while bobtailing or
pulling an empty trailer. With the engine brakes in
operation, wheel lockup can occur more quickly when
the service brakes are applied, especially on vehicles
with single-drive axles.
Make sure the engine brakes are switched to the OFF
position when bobtailing or pulling an empty trailer.
CAUTION
The engine brakes are designed to assist the vehicle's
service brakes in slowing the vehicle to a stop.
Remember, service brakes will be required to bring the
vehicle to a stop.
CAUTION
Do not use the engine brakes to aid clutchless
gearshifting. This can cause the engine to stall or lead
to engine damage.
The ECM will disable the engine brakes when engine rpm
is below 850 rpm or when an electronic fault code is active.
CAUTION
Do not operate the engine if the engine brakes will not
deactivate. To do so will cause severe engine
damage.
If the engine brakes will not shut off, shut off the engine
immediately.
Section TS - Troubleshooting Symptoms Page TS-a
Section TS - Troubleshooting Symptoms

Section Contents
Page
Troubleshooting Procedures and Techniques ...............................................................................................TS-1
General Information........................................................................................................................................TS-1
Troubleshooting Symptoms Charts ...............................................................................................................TS-2
General Information........................................................................................................................................TS-2
Aftertreatment Diesel Particulate Filter — Excessive Ash Cleaning................................................................TS-12
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary Regeneration......................TS-94
Aftertreatment Diesel Particulate Filter — Excessive Soot Loading................................................................TS-11
Air Compressor Air Pressure Rises Slowly .....................................................................................................TS-3
Air Compressor Cycles Frequently..................................................................................................................TS-4
Air Compressor Noise is Excessive.................................................................................................................TS-5
Air Compressor Pumping Excess Lubricating Oil into the Air System .............................................................TS-6
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)....................................TS-8
Air Compressor Will Not Pump Air..................................................................................................................TS-9
Air Compressor Will Not Stop Pumping.........................................................................................................TS-10
Alternator Not Charging or Insufficient Charging...........................................................................................TS-13
Coolant in the Lubricating Oil........................................................................................................................TS-27
Coolant Loss - External.................................................................................................................................TS-15
Coolant Loss - Internal..................................................................................................................................TS-17
Coolant Temperature Above Normal - Gradual Overheat...............................................................................TS-20
Coolant Temperature Above Normal - Sudden Overheat...............................................................................TS-23
Coolant Temperature Below Normal..............................................................................................................TS-25
Crankcase Coalescing Filter - Frequent Replacement...................................................................................TS-30
Crankcase Gases (Blowby) Excessive...........................................................................................................TS-29
Engine Brake - Low Retarding Power or Slow to Activate..............................................................................TS-34
Engine Brake — One or More Cylinders Braking with Power Switch Off........................................................TS-37
Engine Brake Does Not Operate...................................................................................................................TS-31
Engine Cranks Slowly - (Electric Starter).......................................................................................................TS-58
Engine Decelerates Slowly............................................................................................................................TS-39
Engine Noise Excessive................................................................................................................................TS-40
Engine Noise Excessive — Combustion Knocks............................................................................................TS-43
Engine Noise Excessive — Connecting Rod..................................................................................................TS-44
Engine Noise Excessive — Main Bearing......................................................................................................TS-45
Engine Noise Excessive — Piston.................................................................................................................TS-47
Engine Noise Excessive — Turbocharger......................................................................................................TS-48
Engine Shuts Off Unexpectedly or Dies During Deceleration.........................................................................TS-49
Engine Speed Surges in PTO or Cruise Control............................................................................................TS-51
Engine Starts But Will Not Keep Running......................................................................................................TS-53
Engine Will Not Crank - (Electric Starter).......................................................................................................TS-56
Engine Will Not Crank or Cranks Slowly (Air Starter).....................................................................................TS-60
Engine Will Not Shut Off...............................................................................................................................TS-61
Fuel Consumption Excessive........................................................................................................................TS-62
Fuel in Coolant.............................................................................................................................................TS-67
Fuel in the Lubricating Oil.............................................................................................................................TS-68
Intake Manifold Air Temperature Above Specification....................................................................................TS-70
Intake Manifold Pressure (Boost) is Below Normal.........................................................................................TS-72
Lubricating Oil Consumption Excessive........................................................................................................ TS-75
Lubricating Oil Contaminated........................................................................................................................TS-78
Lubricating Oil Filter Plugged........................................................................................................................TS-79
Lubricating Oil in the Fuel.............................................................................................................................TS-74
Lubricating Oil Pressure High.......................................................................................................................TS-82
Lubricating Oil Pressure Low........................................................................................................................TS-83
Lubricating Oil Sludge in the Crankcase Excessive.......................................................................................TS-85
Lubricating Oil Temperature Above Specification..........................................................................................TS-87
Lubricating or Transmission Oil in the Coolant..............................................................................................TS-89
Stationary Regeneration — Will Not Activate.................................................................................................TS-91
Stationary Regeneration - Will Not Complete.................................................................................................TS-95
Turbocharger Leaks Engine Oil or Fuel.........................................................................................................TS-90
Page TS-b Section TS - Troubleshooting Symptoms
Troubleshooting Overview ...........................................................................................................................TS-97

Connecting Rod Bearing Noise.....................................................................................................................TS-97
Coolant Loss Pre-Troubleshooting Guide....................................................................................................TS-106
Driver Interview Questions.......................................................................................................................TS-107
Service History Review.............................................................................................................................TS-108
ECM Data Review:...................................................................................................................................TS-108
Driveability - General Information..................................................................................................................TS-97
Driveability/Low Power - Customer Complaint Form......................................................................................TS-99
Driveability/Low Power/Excessive Fuel Consumption - Checklist.................................................................TS-100
Engine Noise Diagnostic Procedures - General Information...........................................................................TS-97
Fuel Consumption - Customer Complaint Form...........................................................................................TS-103
Fuel Consumption - General Information.....................................................................................................TS-102
Main Bearing Noise...................................................................................................................................... TS-97
Oil Consumption.........................................................................................................................................TS-105
Piston Noise.................................................................................................................................................TS-97
Signature™, ISX, and QSX15 Troubleshooting Procedures and Techniques
Section TS - Troubleshooting Symptoms Page TS-1
Troubleshooting Procedures and Techniques

General Information
A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known
about a complaint, the faster and easier the problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the
easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts are designed to
stimulate a thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint
• Analyze the problem thoroughly
• Relate the symptoms to the basic engine systems and components
• Consider any recent maintenance or repair action that can relate to the complaint
• Double-check before beginning any disassembly
• Solve the problem by using the symptom charts and doing the easiest things first
• Determine the cause of the problem and make a thorough repair
• After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected
Troubleshooting Symptoms Charts Signature™, ISX, and QSX15
Page TS-2 Section TS - Troubleshooting Symptoms
Troubleshooting Symptoms Charts

General Information
Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row
of blocks from top to bottom. Follow through the chart to identify the corrective action.
WARNING
Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be
performed by trained, experienced technicians.
Signature™, ISX, and QSX15 Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly

This is symptom tree t004
Cause Correction
Block the vehicle wheels and check the air system
for leaks with spring brakes applied and released.
STEP 1 Check for leaks from the air compressor gaskets
............ and the air system hoses, fittings, tanks, and
Air system leaks
valves. Refer to Procedure 012-019 and the OEM
service manuals. Turn the keyswitch ON. Walk
around the engine and listen for air leaks.
OK
Go To Next Step
STEP 2 Check for carbon buildup. Replace the air

compressor discharge line and cylinder head
Carbon buildup is excessive in the air discharge ............
assembly if necessary. Refer to Procedure
line, downstream air valves, or cylinder head
012-003.
OK
Go To Next Step
STEP 3 Check the operation of air system valves, air

............ dryers, and other OEM-installed air system
Air system component is malfunctioning
components. Refer to the OEM service manual.
OK
Go To Next Step
Replace the air compressor air cleaner (if
STEP 4 installed). Check the air intake piping. Check
Air intake system restriction to air compressor is ............ engine air intake restriction if the air compressor
excessive inlet is plumbed to the vehicle or equipment intake
system. Refer to Procedure 010-031.
OK
Go To Next Step
STEP 5 Inspect the air compressor head assembly and
............
Air compressor intake or exhaust system leaks air replace if required. Refer to Procedure 012-003.
Air Compressor Cycles Frequently

Cause Correction
Air system leaks
OK
Go To Next Step
STEP 2 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly to the OEM service manual.
OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 3 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to the OEM service
manual.
OK
Go To Next Step
Check for carbon buildup. Replace the air
STEP 4 compressor discharge line and cylinder head
012-003. Check the turbocharger for oil leaks.
Check the intake tube for oil. Refer to Procedure
010-033.
OK
Go To Next Step
STEP 5 Lubricate or replace the air dryer outlet check valve
............
Air dryer outlet check valve is sticking assembly. Refer to the OEM service manual.
Air Compressor Noise is Excessive

Cause Correction
STEP 1
............ Check for ice in low spots of the air discharge line.
Ice buildup in the air system components
OK
Go To Next Step
STEP 2 Check for carbon buildup. Replace the air

compressor discharge line and cylinder head
012-003.
OK
Go To Next Step
STEP 3 Install a ping tank between the air dryer and the
Air compressor is sending air pulses into the air ............ wet tank and check discharge line size for the
tanks application. Refer to the OEM service manual.
OK
Go To Next Step
STEP 4 Check the air compressor timing. Refer to
............
Air compressor timing is not correct Procedure 012-014.
OK
Go To Next Step
STEP 5
Check air compressor mounting hardware. Refer
Air compressor mounting hardware is loose, worn, ............
to Procedure 012-014.
or broken
OK
Go To Next Step
STEP 6 Replace the air compressor. Replace the desiccant
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to
damaged Procedure 012-014 and the OEM service manual.
OK
Go To Next Step
STEP 7
Inspect the drive gears and gear train and repair
Air compressor drive gear or engine gear train is ............
as necessary. Refer to Procedure 012-014.
worn or damaged
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
Verify the correct lubricating oil drain interval.
Refer to Procedure 102-002 in Section 2 of the
STEP 1 Operation and Maintenance Manual Signature and
............
Lubricating oil drain interval is excessive ISX Engines, Bulletin 3666251, or the Operation
and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step
OK
Go To Next Step
STEP 3 Check the air compressor duty cycle. Install larger

............ air compressor if available. Check for and repair all
Air compressor pumping time is excessive
air system leaks. Refer to the OEM service manual.
OK
Go To Next Step
Check for carbon buildup. Replace the air
STEP 4 compressor discharge line, if necessary. Check
Carbon buildup is excessive in the air discharge ............ the turbocharger for oil leaks. Check the intake
line, check valve, or cylinder head tube for oil. Refer to Procedures 012-003 and
010-033.
OK
Go To Next Step
STEP 5
Engine angularity during operation exceeds ............ Refer to the Engine Specification data sheet.
specification
OK
Go To Next Step
STEP 6 Check for excessive blowby. Refer to the

............ Crankcase Gases (Blowby) Excessive symptom
Crankcase pressure is excessive
tree.
OK
Go To Next Step
STEP 7 If coolant temperature is above normal, refer to the

Air compressor runs hot
tree.
OK
Go To Next Step
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to the
damaged OEM service manual.
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Cause Correction
Air system leaks
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3
Inspect the air compressor head assembly and
Air compressor intake or exhaust valve system ............
replace if required. Refer to Procedure 012-019.
leaks air
Air Compressor Will Not Pump Air

Cause Correction
OK
Go To Next Step
STEP 2 Check the unloader system and head assembly

............ system. Replace the head assembly if required.
Unloader system is malfunctioning
Refer to Procedure 012-013.
OK
Go To Next Step
STEP 3
Inspect the air compressor cylinder head and
Air compressor cylinder head is cracked or porous, ............
gasket. Refer to Procedure 012-013.
or has a leaking gasket
OK
Go To Next Step
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to
damaged Procedure 012-014 and the OEM service manual.
Air Compressor Will Not Stop Pumping

Cause Correction
Air system leaks
OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 2 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 3 Inspect the air compressor head assembly and
............
Air compressor intake or exhaust system leaks air replace if required. Refer to Procedure 012-003.
OK
Go To Next Step
............
Aftertreatment Diesel Particulate Filter — Excessive Soot Loading

Cause Correction
STEP 1 Refer to Section TF in the ISX CM871 and ISM

CM876 Electronic Control Systems,
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual, Bulletin
inactive fault codes
4021560.
OK
Go To Next Step
STEP 2 Review the repair history of the engine to

determine aftertreatment diesel particulate filter
Progressive damage from excessive black smoke ............
was replaced or needs replacement. Refer to
caused from an earlier or current failure event.
Procedure 014-013 for test procedure.
OK
Go To Next Step
STEP 3 Perform stationary regeneration with the INSITE
Extended operation of engine in low duty cycle, ............ electronic service tool. Refer to Procedure
extended idling and/or low ambient temperatures 014-013.
OK
Go To Next Step
STEP 4
............ Use lower gear.
Engine is being lugged down
OK
Go To Next Step
STEP 5 Check the air intake system for restriction. Refer to
............
Intake air restriction is high Procedure 010-031.
OK
Go To Next Step
STEP 6 Refer to the Oil Consumption - Excessive
............
Excessive internal oil consumption Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 7 Refer to the Black Smoke - Excessive
............
Excessive black smoke is observed. Troubleshooting Symptom Tree.
Aftertreatment Diesel Particulate Filter — Excessive Ash Cleaning

Cause Correction
STEP 1 Refer to Section TF in the ISX CM871 and ISM
Electronic fault codes active or high counts of ............ CM876 Electronic Control System Troubleshooting
inactive fault codes and Repair Manual, Bulletin 4021560.
OK
Go To Next Step
STEP 2 Perform stationary regeneration with the INSITE
Extended operation of engine in low duty cycle, ............ electronic service tool. Refer to Procedure
extended idling and/or low ambient temperatures 014-013.
OK
Go To Next Step
STEP 3 Use an engine lubricating oil that meets CES

............ 20081. Refer to the appropriate Operation and
Lubricating oil being used has high ash content.
Maintenance.
OK
Go To Next Step
Confirm oil blending into fuel. Drain fuel and
STEP 4 replace with clean fuel. Discontinue practice of
............
Blending of engine lubricating oil into fuel. blending oil with fuel. Refer to the appropriate
Operation and Maintenance Manual.
OK
Go To Next Step
STEP 5 Discontinue use of the fuel supplement/additive
Fuel supplement/additive used has high ash ............ being used. Refer to Cummins Fuel
content. Recommendation Bulletin 3379001.
OK
Go To Next Step
STEP 6
Review the air intake filtration system for
Intake air filtration system malfunctioned allowing ............
malfunction. Refer to Procedure 010-024.
dust contamination.
OK
Go To Next Step
Measure the engine blowby. If blowby is above
specification, refer to the Crankcase Gases
STEP 7 (Blowby). Excessive symptom tree. Replace the
............
Crankcase pressure is excessive blowby sensor if there were not any sensor fault
codes. Refer to Crankcase Gases (Blowby)
Excessive Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 8 Refer to the Oil Consumption - Excessive
............
Excessive internal oil consumption Troubleshooting Symptom Tree.
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 1
Check the battery cables and connections. Refer
Battery cables or connections are loose, broken, or ............
corroded (excessive resistance)
OK
Go To Next Step
STEP 2 Check the condition of the batteries, replace if

............ necessary. Refer to Procedure 013-007 and the
Batteries have failed
OEM service manual.
OK
Go To Next Step
STEP 3 Check the battery heater. Refer to the OEM service
............
Batteries are cold manual.
OK
Go To Next Step
STEP 4 Check the fuses, wires, and connections. Refer to
Electrical system is "open" (blown fuses, broken ............ the OEM service manual and the manufacturer's
wires, or loose connections) wiring diagrams.
OK
Go To Next Step
STEP 5 Check the alternator belt tension. Refer to
............
Alternator belt is loose Procedure 008-080 or 013-021.
OK
Go To Next Step
STEP 6 Check the vehicle gauge. Refer to the OEM service
............
Vehicle gauge is malfunctioning manual.
OK
Go To Next Step
STEP 7 Tighten the pulley. Refer to the manufacturer's
............
Alternator pulley is loose on the shaft instructions.
OK
Go To Next Step
STEP 8 Test the alternator output. Replace the alternator

............ or voltage regulator if necessary. Refer to
Alternator or voltage regulator is malfunctioning
Procedure 013-001 and the OEM service manual.
OK
Go To Next Step
STEP 9
Install an alternator with a higher capacity. Refer to
Alternator is overloaded, or alternator capacity is ............
Procedure 013-001 and the OEM service manual.
below specification
OK
Go To Next Step
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 10 Position the batteries away from heat sources.
............
Battery temperature is above specification Refer to the OEM service manual.
Coolant Loss - External

Cause Correction
Before troubleshooting, it is important to determine
the exact complaint by interviewing the driver,
looking at the service history, and looking at the
STEP 1 ECM information. Refer to located in the
............
Excessive internal or external engine coolant loss Troubleshooting Overview Section. Refer to
procedure t00-004. NOTE: If the truck is eqipped
with an Auxiliary Power Unit, make sure the unit is
not leaking.
OK
Go To Next Step
STEP 2 Check the coolant level. Refer to Refer to OEM
............
Coolant level is above specification service manual.
OK
Go To Next Step
STEP 3
Check the radiator pressure cap. Refer to
Radiator cap is not correct, is malfunctioning, or ............
Procedure 008-047 in Section 8.
has low-pressure rating
OK
Go To Next Step
Refer to the Coolant Temperature Above Normal -
STEP 4 Gradual Overheat and Coolant Temperature
............
Engine is overheating Above Normal - Sudden Overheat symptom trees,
if applicable.
OK
Go To Next Step
Inspect the engine for coolant leaking externally
from items such as coolant hoses, drain valves,
coolant manifolds, expansion and pipe plugs,
fittings, air compressor coolant lines, EGR cooler
coolant lines, turbocharger coolant lines,
transmission oil cooler or torque converter oil
cooler, water pump seal, radiator core, heat
STEP 5 exchanger, lubricating oil cooler housing,
............
External coolant leak aftertreatment diesel exhaust fluid tank heater and
hoses, aftertreatment diesel exhaust fluid dosing
valve coolant lines and OEM mounted components
that have coolant flow. If necessary, pressure test
the cooling system. Refer to Procedure 008-018 in
Section 8. If necessary, pressure test OEM
mounted components. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 6 Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............ routing and for restrictions. Refer to the OEM
not routed correctly service manual.
OK
Go To Next Step
Coolant Loss - External

Cause Correction
STEP 7
Inspect the hoses. Refer to Procedure 008-045 in
Cooling system hose is collapsed, restricted, or ............
Section 8.
leaking
OK
Go To Next Step
STEP 8
Check for air or combustion gases in the cooling
Air or combustion gases are entering the cooling ............
system. Refer to Procedure 008-019 in Section 8.
system
OK
Go To Next Step
STEP 9 Check the EGR valve assembly. Refer to

............ Procedure 011-022 in Section 11 (ISX CM870
EGR valve leaking coolant
only).
OK
Go To Next Step
STEP 10 Check the aftertreatment fuel injector for coolant
............
Aftertreatment fuel injector is leaking coolant leaks. Refer to Procedure 011-061 in Section 11.
OK
Go To Next Step
STEP 11 Check the turbocharger bearing housing. Refer to
............
Turbocharger leaking coolant Procedure 010-033 in Section 10.
OK
Go To Next Step
STEP 12 Check the EGR cooler for leaks. Refer to
............
EGR cooler leaking coolant (external) Procedure 011-019 in Section 11.
OK
Go To Next Step
STEP 13 Check the cylinder head gasket. Refer to
............
Cylinder head gasket is leaking (external) Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 14 Check the cylinder block. Refer to Procedure
............
Cylinder block is leaking (external) 001-026 in Section 1.
Coolant Loss - Internal

Cause Correction
STEP 1 the exact complaint by interviewing the driver,
............ looking at the service history, and looking at the
Excessive internal or external engine coolant loss
ECM information. Refer to the Coolant Loss Pre-
Troubleshooting Overview in Section TS.
OK
Go To Next Step
STEP 2
OK
Go To Next Step
Pressure test the cooling system. Inspect for
coolant leaking externally from items such as
coolant hoses, drain valves, coolant manifolds,
expansion and pipe plugs, fittings, air compressor
coolant lines, EGR cooler coolant lines,
turbocharger coolant lines, transmission oil cooler
or torque converter oil cooler, water pump seal,
STEP 3 radiator core, heat exchanger, lubricating oil cooler
............ housing, aftertreatment diesel exhaust fluid tank
Misdiagnosed coolant leak (external)
heater and hoses, aftertreatment diesel exhaust
fluid dosing valve coolant lines, and OEM mounted
components that have coolant flow. If necessary,
pressure test the OEM-mounted components.
NOTE: If the truck is equipped with an Auxiliary
Power Unit, make sure the unit is not leaking.
Refer to Procedure 008-018 in Section 8 or the
OEM service manual.
OK
Go To Next Step
STEP 4 If applicable, check the fuel heater for coolant
............
Fuel heater is leaking coolant leaks. Refer to the OEM service manual.
OK
Go To Next Step
STEP 5 If applicable, check the transmission oil cooler and
Transmission oil cooler or torque converter cooler ............ torque converter cooler for coolant leaks. Refer to
is leaking the OEM service manual.
OK
Go To Next Step
STEP 6 Inspect the air compressor air inlet and outlet tubes
Air compressor cylinder head is cracked or porous, ............ for signs of coolant. Refer to Procedure 012-007 in
or has a leaking gasket Section 12.
OK
Go To Next Step

Cause Correction
STEP 7 Check the EGR cooler core for leaks. Refer to
............
EGR cooler core is leaking Procedure 011-019 in Section 11.
OK
Go To Next Step
STEP 8 Check the aftertreatment fuel injector for coolant
............
Aftertreatment fuel injector is leaking coolant leaks. Refer to Procedure 011-061 in Section 11.
OK
Go To Next Step
............
Turbocharger bearing housing leaking coolant Procedure 010-033 in Section 10.
OK
Go To Next Step
STEP 10 Replace the injector o-rings and install and tighten

the injectors again to reseat the injector cups.
Injector sleeve is leaking - even with no noticeable ............
Return the engine to operation. Refer to Procedure
defect to the injector o-rings
006-026 in Section 6.
OK
Go To Next Step
For the first investigated instance of internal
coolant loss, perform the corrections in the steps
STEP 11 above and then stop here. Return the engine to
............
First investigated instance of internal coolant loss operation and check for continuing leaks. If the
leaks continue, complete the remaining steps of
this tree.
OK
Go To Next Step
STEP 12 Remove the oil pan. Pressure test the cooling
Cylinder liner is corroded or cracked, or the ............ system to check for leaks. Refer to Procedure
cylinder block is cracked or porous 001-027 in Section 1.
OK
Go To Next Step
STEP 13 Check the lubricating oil cooler for coolant leaks.
............
Lubricating oil cooler is leaking Refer to Procedure 007-003 in Section 7.
OK
Go To Next Step
............
Cylinder head gasket is leaking Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 15 Pressure test the cylinder head. Refer to
............
Cylinder head is cracked or porous Procedure 002-004 in Section 2.
OK
Go To Next Step

Cause Correction
STEP 16 Inspect the cylinder block. Refer to Procedure
............
Cylinder block is cracked or porous 001-026 in Section 1.
Coolant Temperature Above Normal - Gradual Overheat

Cause Correction
Refer to Section TF in the Troubleshooting and
Repair Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334, or
the Troubleshooting and Repair Manual,
STEP 1 Electronic Control System, Signature, ISX and
Electronic fault codes active or high counts of ............ QSX Engines, Bulletin 3666259, or the
inactive fault codes Troubleshooting and Repair Manual, Power
Generation Control Systems QSX15, QSK23,
QSK45, QSK60, QSK78, and QST30 Series
Engines, Bulletin 4021419 for fault code
troubleshooting.
OK
Go To Next Step
STEP 2 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
Open the cold weather radiator cover or the
winterfront. Maintain a minimum of 784 cm2 [122
in2] or approximately 28 x 28 cm [11 x 11 in] of
opening at all times. Refer to the Cold Weather
STEP 3
............ Starting Aids, Procedure 101-005 in Section 7 of
Cold weather radiator cover or winterfront is closed the Operation and Maintenance Manual Signature
and ISX Engines, Bulletin 3666257 or Winterfronts
in Section 1 of the Operation and Maintenance
Manual Signature and ISX Engines, Bulletin
3666311.
OK
Go To Next Step
STEP 4 Check the automatic belt tensioner. Refer to
............
Fan drive belt is loose Procedure 008-002 and 008-080.
OK
Go To Next Step
STEP 5 Inspect the charge air cooler, air conditioner
Charge air cooler fins, radiator fins, or air condenser, and radiator fins. Clean, if necessary.
............
conditioner condenser fins are damaged or Refer to Procedures 010-027, 008-042 and the
obstructed with debris OEM service manual.
OK
Go To Next Step
STEP 6 Check the fan drive and controls. Refer to
............
Fan drive or fan controls are malfunctioning Procedure 008-027.
OK
Go To Next Step

Cause Correction
STEP 7
Procedure 008-047.
OK
Go To Next Step
STEP 8 Inspect the radiator shutters. Repair or replace if
Radiator shutters are not opening completely, or ............ necessary. Check the shutterstat setting. Refer to
the shutterstat setting is wrong the OEM service manual.
OK
Go To Next Step
STEP 9 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to Procedure 008-049
Coolant temperature gauge is malfunctioning
and the OEM service manual.
OK
Go To Next Step
STEP 10
Cooling system hose is collapsed, restricted, or ............ Inspect the hoses. Refer to Procedure 008-045.
leaking
OK
Go To Next Step
STEP 11 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedure 008-038 and the OEM service manual.
OK
Go To Next Step
STEP 12 Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............ routing and for restriction. Refer to Procedure
not routed correctly 008-017 and the OEM service manual.
OK
Go To Next Step
STEP 13 Check the thermostat for the correct part number

............ and for correct operation. Refer to Procedure
Thermostat is not correct or is malfunctioning
008-013.
OK
Go To Next Step
STEP 14
Refer to the Intake Manifold Air Temperature
Intake manifold air temperature is above ............
Above Specification symptom tree.
specification
OK
Go To Next Step

Cause Correction
STEP 15 Check the oil level. Add or drain oil, if necessary.

............ Refer to Procedure 007-037. Check the dipstick
Lubricating oil level is above or below specification
calibration. Refer to Procedure 007-009.
OK
Go To Next Step
STEP 16
Check the swing check valve for correct operation.
Radiator swing check valve is malfunctioning (if ............
Refer to the OEM service manual.
equipped)
OK
Go To Next Step
STEP 17 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
OK
Go To Next Step
STEP 18
Inspect the radiator and clean if necessary. Refer
Radiator core is internally obstructed or damaged, ............
or the check valve or J-tube is malfunctioning
OK
Go To Next Step
STEP 19
Inspect the check valve. Replace if necessary.
Check valve is damaged (with remote-mounted ............
engine coolant heater)
OK
Go To Next Step
STEP 20
system
OK
Go To Next Step
STEP 21 Check the torque converter. Refer to the OEM
............
Torque converter is malfunctioning service manual.
OK
Go To Next Step
STEP 22 Verify that the engine and vehicle cooling systems

............ are using the correct components. Refer to the
Vehicle cooling system is not adequate
OEM service manual.
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 1 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
STEP 2 Troubleshooting and Repair Manual, Electronic
Control System, Signature, ISX and QSX15
Engines, Bulletin 3666259, or the Troubleshooting
and Repair Manual, Power Generation Control
Systems QSX15, QSK23, QSK45, QSK60, QSK78,
and QST30 Series Engines, Bulletin 4021419 for
fault code troubleshooting.
OK
Go To Next Step
STEP 3 Check the fan drive belt. Replace the belt, if
............
Fan drive belt is broken necessary. Refer to Procedure 008-002 or 008-003.
OK
Go To Next Step
............
OK
Go To Next Step
the shutterstat setting is wrong Procedure 008-049.
OK
Go To Next Step
STEP 6
Cooling system hose is collapsed, restricted, or ............ Inspect the hoses. Refer to Procedure 008-045.
leaking
OK
Go To Next Step
STEP 7
Procedure 008-047.
OK
Go To Next Step

008-013.
OK
Go To Next Step
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 9 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
OK
Go To Next Step
STEP 10
equipped)
OK
Go To Next Step
STEP 11
system
OK
Go To Next Step
STEP 12
Check the disc for correct installation. Refer to
Torque converter cooler disc is not installed ............
Procedure 008-062.
correctly
Coolant Temperature Below Normal

Cause Correction
STEP 1 Electronic Control System, Signature, ISX and
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259, or the
troubleshooting.
OK
Go To Next Step
Use an electronic service tool to check the coolant
temperature sensor circuit. Refer to Procedure
019-019 in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Procedure 019-019 in the Troubleshooting and
Repair Manual, Electronic Control System,
STEP 2 Signature, ISX and QSX15 Engines, Bulletin
............ 3666259, or Procedure 019-019 in the
Coolant temperature sensor is malfunctioning
Troubleshooting and Repair Manual,
PowerCommand Control Version 3200 QSX15,
QSK45 and QSK60 Generator Sets, Bulletin
3666394, or Procedure 019-019 in the
Troubleshooting and Repair Manual, Power
Engines, Bulletin 4021419.
OK
Go To Next Step
STEP 3 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to in the OEM service
Coolant temperature gauge is malfunctioning
manual.
OK
Go To Next Step
Check the winterfront, shutters, and under-the-
STEP 4 hood air. Use under-the-hood intake air in cold
............ weather. Refer to Cold Weather Operation, Bulletin
Engine is operating at low ambient temperature
3387266 and the correct Operation and
Maintenance manual.
OK
Go To Next Step
............
OK
Go To Next Step
Coolant Temperature Below Normal

Cause Correction
STEP 6 Check the routing of the coolant fill line. Refer to
............
Coolant fill line is not routed correctly the OEM service manual.
OK
Go To Next Step
STEP 7 Check the shutter operation. Repair or replace the

............ shutters if necessary. Refer to the OEM service
Radiator shutters are stuck open or opening early
manual and Procedure 008-049.
OK
Go To Next Step
STEP 8
equipped)
OK
Go To Next Step
STEP 9 Check the thermostat seal. Check the thermostat
Thermostat seal is damaged, missing, or not ............ for correct seating. Refer to Procedure 008-013 or
installed correctly 008-016.
OK
Go To Next Step

008-013.
OK
Go To Next Step
STEP 11 Check for correct coolant flow through the radiator.
............
Coolant flow through the radiator is not correct Refer to Procedure 008-042.
Coolant in the Lubricating Oil

Cause Correction
the exact complaint by interviewing the driver,
STEP 1 looking at the service history, and reviewing
............
Excessive internal coolant loss lubricating oil analysis information. Refer to Refer
to the Coolant Loss Pre-Troubleshooting Guide
Overview in Section TS.
OK
Go To Next Step
STEP 2 Inspect the air compressor air inlet and outlet tubes
Air compressor cylinder head is cracked or porous, ............ for signs of coolant. Refer to Procedure 012-007 in
or has a leaking gasket Section 12.
OK
Go To Next Step
STEP 3 Check the EGR cooler for leaks. Refer to
............
EGR cooler leaking coolant Procedure 011-019 in Section 11.
OK
Go To Next Step
............
Turbocharger bearing housing leaking coolant Procedure 010-033 in Section 10.
OK
Go To Next Step
STEP 5 Replace the injector o-rings and install and tighten

the injectors again to reseat the injector cups.
Injector sleeve is leaking - even with no noticeable ............
Return the engine to operation. Refer to Procedure
defect to the injector o-rings
OK
Go To Next Step
For the first investigated instance of internal
coolant loss, perform the corrections in the steps
STEP 6 above and then stop here. Return the engine to
............
First investigated instance of internal coolant loss operation and check for continuing leaks. If the
leaks continue, complete the remaining steps of
this tree.
OK
Go To Next Step
STEP 7 Remove the oil pan. Pressure test the cooling
Cylinder liner is corroded or cracked, or the ............ system to check for leaks. Refer to Procedure
cylinder block is cracked or porous 001-027 in Section 1.
OK
Go To Next Step
STEP 8 Check the lubricating oil cooler for coolant leaks

............ and cracks. Refer to Procedure 007-003 in Section
Lubricating oil cooler is leaking
7.
OK
Go To Next Step
Coolant in the Lubricating Oil

Cause Correction
............
Cylinder head gasket is leaking Procedure 002-004 in Section 2.
OK
Go To Next Step
............
OK
Go To Next Step
............
Crankcase Gases (Blowby) Excessive

Cause Correction
STEP 1 Isolate the turbocharger to determine if the

............ turbocharger seals are leaking. Refer to Procedure
Turbocharger oil seal is leaking
OK
Go To Next Step
STEP 2 Isolate the air compressor by disconnecting the air

............ inlet and outlet lines. Refer to the OEM service
Air compressor is malfunctioning
manual.
OK
Go To Next Step
STEP 3 Check the valve guides for wear. Replace the

............ cylinder head, if necessary. Refer to Procedure
Cylinder head valve guides are excessively worn
OK
Go To Next Step
STEP 4 Check the rocker lever housing gasket. Refer to
............
Rocker lever housing gasket is leaking Procedure 003-011.
OK
Go To Next Step
Check for air intake system leaks. Refer to
STEP 5 Procedure 010-024 in Section 10. Check the
pistons, piston rings, and liners for wear or
Piston, cylinder liner, or piston rings are worn or ............
damage. Procedure 001-043 in Section 1,
damaged
Procedure 001-047, or Procedure 001-028 in
Section 1.
Crankcase Coalescing Filter - Frequent Replacement

Cause Correction
Review the engine's maintenance records to
STEP 1 determine if the crankcase breather filter
Filter miles or hours is at expected maintenance ............ replacement is at expected interval, based on
interval for replacement crankcase blowby. Replace the filter if it is
acceptable per the records.
OK
Go To Next Step
STEP 2 Check the oil level. Verify the dipstick calibration

............ and oil pan capacity. Fill the system to the specified
Lubricating oil level is above specification
level. Refer to Procedure 007-009 in Section 7.
OK
Go To Next Step
STEP 3 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-001 in Section 3.
OK
Go To Next Step
STEP 4 Analyze an oil sample for fuel dilution percentage,

............ coolant in oil, and foreign contamination. Repair
Lubricating oil is contaminated
the source of contamination.
OK
Go To Next Step
STEP 5 Refer to Crankcase Gases (Blowby) Excessive
............
Engine Crankcase Gases (Blowby) excessive. Troubleshooting Symptom Tree.
Engine Brake Does Not Operate

Cause Correction
STEP 1
............ Turn on the switch.
Engine brake on/off switch is off
OK
Go To Next Step
Check the programmable parameters and the
STEP 2 selected features with an electronic service tool.
Programmable parameters or selected features ............ Set the parameters and features again, if
are not correct necessary. Refer to the electronic service tool
manual.
OK
Go To Next Step
Signature™ and ISX Engines, Bulletin 4021334.
Refer to the Troubleshooting and Repair Manual
STEP 3 Electronic Control System Signature™, ISX and
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259, for fault code
inactive fault codes troubleshooting. Refer to the Troubleshooting and
Repair Manual, Power Generation Control
and QST30 Series Engines, Bulletin 4021419, for
OK
Go To Next Step
Check the engine brake on/off switch and circuit.
Refer to Procedures 019-034 and 019-035 in
Section 19 in the Troubleshooting and Repair
STEP 4 Signature™ and ISX Engines, Bulletin 4021334.
Engine brake on/off switch or circuit is ............ Refer to Procedures 019-034 and 019-035 in
malfunctioning Section 19 in the Troubleshooting and Repair
Manual Electronic Control System Signature™, ISX
and QSX15 Engines, Bulletin 3666259. Refer to
Procedure 020-012 in Section 20. Refer to
OK
Go To Next Step
Check the engine brake circuit, solenoid, and
harness connectors. Check the engine brake
harness, solenoids, and grounding for continuity.
STEP 5 Refer to Procedure 019-136 in Section 19 in the
Engine brake solenoid, harness or connectors are ............ ISX and ISM CM871 and CM876 Electronic Control
loose, broken or have an open circuit Systems Troubleshooting and Repair Manual,
Bulletin 4021560. Refer to Procedure 020-004 in
Section 20. Refer to Procedure 020-012 in Section
20. Refer to Procedure 020-015 in Section 20..
OK
Go To Next Step

Cause Correction
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedures 019-009 or 019-010 in
STEP 6 Manual, CM870 Electronic Control System,
............ Signature™ and ISX Engines, Bulletin 4021334.
Clutch switch or circuit is malfunctioning
Refer to Procedures 019-009 or 019-010 in Section
19 in the Troubleshooting and Repair Manual
Electronic Control System Signature™, ISX and
QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step
Check for foot pedal restriction. Check the
accelerator pedal or lever position sensor and
circuit. Refer to Procedures 019-085 and 019-086
STEP 7 in Section 19 in the Troubleshooting and Repair
Accelerator pedal or lever position sensor or circuit ............ Manual, CM870 Electronic Control System,
is malfunctioning Signature™ and ISX Engines, Bulletin 4021334.
Refer to Procedures 019-085 and 019-086 in
Section 19 in the ISX Fuel System Troubleshooting
and Repair Manual, Bulletin 3666259.
OK
Go To Next Step
STEP 8
Check the service brake pressure switch and
Service brake pressure switch or circuit is ............
circuit. Refer to the OEM service manual.
malfunctioning
OK
Go To Next Step
Check for poor battery and chassis grounds.
Check ground wires or cables for loose
connections. Check the following grounds, make
STEP 9 sure they are secure, clean, and on a non-painted
............
Engine electrical ground is malfunctioning surface: engine block ground, chassis (or frame
rail) grounds, ECM grounds, alternator and starter
negative posts. Disconnect and clean battery cable
connections.
OK
Go To Next Step
Check the engine brake control valve and the
STEP 10 engine brake piston. Refer to Procedure 020-017
............
Lubricating oil leak (internal) in Section 20. Refer to Procedure 020-019 in
Section 20.
OK
Go To Next Step
STEP 11 Check the engine brake assembly for restriction.
............
Engine brake lubricating oil passage is restricted Refer to Procedure 020-004 in Section 20.
OK
Go To Next Step

Cause Correction
STEP 12 Adjust the engine brakes. Refer to Procedure
............
Engine brake adjustment is not correct 020-004 in Section 20.
Engine Brake - Low Retarding Power or Slow to Activate

Cause Correction
Refer to Driveability-General Information, the
STEP 1 Driveability/Low-Power Customer Complaint Form,
............ and the Driveability Checklist at the end of Section
Interview the operator to verify the complaint
TS. Follow the instructions on the forms before
continuing with this tree.
OK
Go To Next Step
Refer to Section TF in the Signature™ and ISX
CM870 Electronic Control System Troubleshooting
and Repair Manual, Bulletin 4021334, or
STEP 2 Signature™ ISX and QSX15 Electronic Control
Electronic fault codes active or high counts of ............ System T and R Manual, Bulletin 3666259, or
inactive fault codes QSX15, QSK23, QSK45, QSK60, QSK78, and
QST30 Power Generation Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 4021419, for fault code troubleshooting.
OK
Go To Next Step
Programmable parameters or selected features ............ Set the parameters and features again, if
manual.
OK
Go To Next Step
Allow the engine to warm to operating temperature.
STEP 4 If the engine will not reach operating temperature,
............
Engine is cold refer to the Coolant Temperature Below Normal
symptom tree in Section TS.
OK
Go To Next Step
............
Engine brake adjustment is not correct 020-004 in Section 20.
OK
Go To Next Step

Cause Correction
Refer to Procedure 019-034 in Section 19.
Procedure 019-035 in Section 19. These
procedures are found in the Signature™ and ISX
CM870 Electronic Control System,
STEP 6 Troubleshooting and Repair Manual, Bulletin
Engine brake on/off switch or circuit is ............ 4021334. Reference Procedure 019-034 and
malfunctioning Procedure 019-035 in Section 19. These
procedures are found in the Signature™, ISX and
QSX15 Electronic Control System,
3666259. Reference Procedure 020-012, and
OK
Go To Next Step
Check the engine brake circuit, solenoid, and
harness connectors. Check the engine brake
harness, solenoids, and grounding for continuity.
STEP 7 Refer to Procedure 019-136 in Section 19. This
procedure is found in the ISX and ISM CM871 and
Engine brake solenoid, harness or connectors are ............
CM876 Electronic Control Systems
loose, broken or have an open circuit
Troubleshooting and Repair Manual Bulletin
4021560. Reference Procedure 020-004,
Procedure 020-012, and Procedure 020-015 in
Section 20.
OK
Go To Next Step
Check for poor battery and chassis grounds.
Check ground wires or cables for loose
connections. Check the following grounds, make
STEP 8 sure they are secure, clean, and on a non-painted
............
Engine electrical ground is malfunctioning surface: engine block ground, chassis (or frame
rail) grounds, ECM grounds, alternator and starter
negative posts. Disconnect and clean battery cable
connections.
OK
Go To Next Step
STEP 9 Check the oil level. If the level is high, contact a
............
Air in the lubricating oil system Cummins® Authorized Repair Location.
OK
Go To Next Step
STEP 10 Check the engine brake control valve and the

............ engine brake piston. Refer to Procedure 020-017
Lubricating oil leak (internal)
and Procedure 020-019 in Section 20.
OK
Go To Next Step

Cause Correction
STEP 11
............ Refer to Procedure 020-012 in Section 20.
Engine brake solenoid(s) is malfunctioning
OK
Go To Next Step
STEP 12 Check the engine brake control valve(s). Replace

............ the engine brake control valve(s) if necessary.
Engine brake control valve(s) is malfunctioning
OK
Go To Next Step
STEP 13 Check the engine brake assembly for restriction.
............
Engine brake lubricating oil passage is restricted Refer to Procedure 020-004 in Section 20.
OK
Go To Next Step
Perform diagnostics to determine if the
turbocharger has failed. Replace the turbocharger
STEP 14 as necessary. Refer to Bulletin 4021334, for ISX
............
Turbocharger is malfunctioning CM870, Section TT, 70-t02-1001, Guided Step 6.
For ISX CM871 reference Bulletin 4021560,
Section TT, 16-t02-1001a, Guided Step 6.
Engine Brake — One or More Cylinders Braking with Power Switch Off
Cause Correction
Troubleshooting and Repair Manual, Electronic
STEP 1 Control System, Signature, ISX and QSX15
Electronic fault codes active or high counts of ............ Engines, Bulletin 3666259, or Section TF in the
troubleshooting.
OK
Go To Next Step
Check the engine brake enable circuit. Refer to
STEP 2 Signature and ISX Engines, Bulletin 4021334, or
............
Engine brake enable circuit is malfunctioning Procedure 019-034 in the Troubleshooting and
Signature, ISX and QSX15 Engines, Bulletin
3666259.
OK
Go To Next Step
Refer to Procedures 019-034 and 019-035 in the
STEP 3 Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engine brake on/off switch or circuit is ............
Engines, Bulletin 4021334, or Procedures 019-034
malfunctioning
and 019-035 in the Troubleshooting and Repair
Manual, Electronic Control System, Signature, ISX
and QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step
............
Engine brake adjustment is not correct 020-004.
OK
Go To Next Step
STEP 5 Remove the solenoid valve and inspect the top and
............ bottom o-rings. Replace the o-rings if necessary.
Solenoid valve o-ring seals are leaking
Procedure 020-004
OK
Go To Next Step
STEP 6 Check for voltage at the solenoid valve. Refer to
............
Solenoid valve is malfunctioning Procedure 020-012.
OK
Go To Next Step
Engine Brake — One or More Cylinders Braking with Power Switch Off
Cause Correction
STEP 7 Replace the solenoid valve. Refer to Procedure
............
Solenoid valve is stuck in the on position 020-012.
Engine Decelerates Slowly

Cause Correction
Bulletin 4021334, or Troubleshooting and Repair
STEP 1 Manual, Electronic Control System, Signature, ISX
and QSX15 Engines, Bulletin 3666259, or Section
TF in the Troubleshooting and Repair Manual,
Power Generation Control Systems QSX15,
QSK23, QSK45, QSK60, QSK78, and QST30
Series Engines, Bulletin 4021419 for fault code
troubleshooting.
OK
Go To Next Step
Check the percent accelerator pedal or lever
reading on an electronic service tool. Verify that it
STEP 2 reads 100 percent with the accelerator pedal
Accelerator pedal or lever is restricted or ............ depressed and 0 percent when released. Calibrate
malfunctioning the accelerator if possible. Replace the accelerator
pedal if necessary. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 3 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003.
OK
Go To Next Step
STEP 4 Remove and check the injectors. Replace the
............
Injector o-rings are damaged or missing injector o-rings. Refer to Procedure 006-026.
OK
Go To Next Step
STEP 5 Perform the automated cylinder performance test.

............ Replace injectors as necessary. Refer to
Injector is malfunctioning
Procedure 006-026 or 014-008.
OK
Go To Next Step
STEP 6 Check the turbocharger compressor and turbine
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033.
Engine Noise Excessive

When troubleshooting engine noise complaints, make sure the engine accessories (air compressor, fan clutch,
refrigerant compressor, or hydraulic pump) are not the cause of the noise. Refer to Engine Noise Diagnostic
Procedures - General Information at the end of Section TS before using this symptom tree.
Cause Correction
OK
Go To Next Step
STEP 2 Inspect the air intake and exhaust systems for air
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024 in Section 10.
OK
Go To Next Step
Signature™ and ISX Engines, Bulletin 4021334,or
STEP 3 Electronic Control System, Signature™, ISX and
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259,or
Generation Control Systems, QSX15, QSK23,
QSK45, QSK60, QSK78 and QST30 Series
troubleshooting.
OK
Go To Next Step
Check the oil level. Verify the dipstick calibration
STEP 4 and the oil pan capacity. Fill the system to the
............
Lubricating oil level is below specification specified level. Refer to Procedures 007-009 and
OK
Go To Next Step
STEP 5
Isolate each component and check for noise. Refer
Fan clutch, hydraulic pump, or refrigerant ............
to the OEM service manual.
compressor noise is excessive
OK
Go To Next Step
STEP 6 Check the fan. Refer to Procedure 008-040 in
............
Fan is loose, damaged, or not balanced Section 8.
OK
Go To Next Step
STEP 7 Inspect the air piping, chassis, and cab for contact
Air intake or exhaust piping is contacting the ............ points. Refer to Procedure 010-031 in Section 10
chassis or cab or Procedure 010-080 in Section 10.
OK
Go To Next Step

Cause Correction
STEP 8 Verify the condition of the mounts. Refer to
Engine mounts are worn, damaged, loose, or not ............ Procedure 016-010 in Section 16. Refer to the OEM
correct service manual.
OK
Go To Next Step
STEP 9 Refer to the Engine Noise Excessive -
............
Turbocharger noise Turbocharger symptom tree.
OK
Go To Next Step
Remove the vibration damper and operate the
STEP 10 engine at the rpm where the noise normally occurs.
............ If the noise is still present, proceed to the next step.
Vibration damper has failed
If the noise is eliminated, replace the vibration
damper. Refer to Procedure 001-052 in Section 1.
OK
Go To Next Step
STEP 11 Disconnect the drivetrain. Check for engine noise.
............
Drivetrain noise is excessive Refer to the OEM service manual.
OK
Go To Next Step
STEP 12 Refer to the Air Compressor Noise Is Excessive
............
Air compressor noise is excessive symptom tree.
OK
Go To Next Step
STEP 13 Measure and adjust the overhead settings. Refer
............
Overhead adjustments are not correct to Procedure 003-004 in Section 3.
OK
Go To Next Step
STEP 14 Inspect the rocker levers, rocker shafts, and valves

............ for damage or excessive wear. Refer to Procedure
Overhead components are damaged
OK
Go To Next Step
STEP 15 Perform the single-cylinder cutout test. Replace

............ the injectors as necessary. Refer to Procedure
OK
Go To Next Step

Cause Correction
STEP 16 Check the flywheel. Refer to Procedure 016-005 in
............
Flywheel is loose or damaged Section 16.
OK
Go To Next Step
STEP 17 Check the gear backlash and the gear teeth for
Gear train backlash is excessive or the gear teeth ............ excessive wear. Refer to Procedure 001-088 in
are damaged Section 1 and Procedure 007-031 in Section 7.
OK
Go To Next Step
STEP 18 Refer to the Engine Noise Excessive - Main

............ Bearing or Engine Noise Excessive - Connecting
Main bearing or connecting rod bearing noise
Rod symptom trees.
OK
Go To Next Step
STEP 19
Refer to the Engine Noise Excessive - Piston
Piston, piston rings, or cylinder liner is worn or ............
symptom tree.
damaged
OK
Go To Next Step
STEP 20
Disassemble and repair the REPTO as necessary.
Rear engine power take-off (REPTO) noise is ............
excessive
OK
Go To Next Step
STEP 21 Refer to the Engine Noise Excessive - Combustion
............
Combustion knocks Knocks symptom tree.
OK
Go To Next Step
STEP 22 Analyze the oil and inspect the filters to locate an

............ area of probable damage. Refer to Procedure
Internal engine damage
Engine Noise Excessive — Combustion Knocks

Cause Correction
Check the winterfront, shutters, and under-the-
STEP 1 hood air. Use under-the-hood intake air in cold
............
Engine is operating at low ambient temperature weather. Refer to Cold Weather Operation, Bulletin
3387266.
OK
Go To Next Step
STEP 2 Repair or replace the ether starting aids. Refer to
............
Ether starting aid is malfunctioning the OEM service manual.
OK
Go To Next Step
Operate the engine from a tank of high-quality fuel.
Refer to Procedure 018-002 (Fuel
STEP 3 Recommendations and Specifications) in Section
V of the Operation and Maintenance Manual,
Fuel grade is not correct for the application or the ............
Signature and ISX, Bulletin 3666251 or the
fuel quality is poor
Operation and Maintenance Manual, Industrial and
Power Generation, QSX15 Engines, Bulletin
3666423.
OK
Go To Next Step
STEP 4 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003 (Air in Fuel) in Section 6.
OK
Go To Next Step
Remove the vibration damper and operate the
engine at the rpm where the noise normally occurs.
STEP 5 If noise is still present, proceed to the next step. If
............
Vibration damper has failed the noise is eliminated, replace the vibration
damper. Refer to Procedure 001-052 (Vibration
Damper, Viscous) in Section 1.
OK
Go To Next Step
STEP 6 Refer to the Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.
OK
Go To Next Step

006-026 (Injector) in Section 6.
OK
Go To Next Step
............
Overhead adjustments are not correct to Procedure 003-004 (Overhead Set) in Section 3.
Engine Noise Excessive — Connecting Rod

Refer to Engine Noise Diagnostic Procedures — General Information at the end of this section before using this
symptom tree.
Cause Correction
OK
Go To Next Step
Control System, Signature, ISX and QSX Engines,
Bulletin 3666259, or Troubleshooting and Repair
Manual, Power Generation Control Systems
QSX15, QSK23, QSK45, QSK60, QSK78, and
QST30 Series Engines, Bulletin 4021419 for fault
code troubleshooting.
OK
Go To Next Step
............
Lubricating oil level is below specification specified level. Refer to Procedures 007-009 and
007-037.
OK
Go To Next Step
STEP 4 Check the oil pressure. If the pressure is low, refer
............
Lubricating oil pressure is below specification toProcedure 007-028.
OK
Go To Next Step

007-083.
OK
Go To Next Step
STEP 6
Check the torque on the connecting rod
Connecting rod capscrews are loose or not ............
capscrews. Refer to Procedure 001-014.
tightened correctly
OK
Go To Next Step
STEP 7
Inspect the connecting rod bearings. Refer to
Connecting rod bearings are damaged or worn, are ............
Procedure 001-005.
not assembled correctly, or are the wrong bearings
Engine Noise Excessive — Main Bearing

symptom tree.
Cause Correction
OK
Go To Next Step
Refer to Section TF Section TF in the
Troubleshooting and Repair Manual, CM870
STEP 2 and Repair Manual Electronic Control System
Electronic fault codes active or high counts of ............ Signature ISX and QSX15 Engines, Bulletin
inactive fault codes 3666259, or the Troubleshooting and Repair
QST30 Series Engines, Bulletin 4021419 for fault
OK
Go To Next Step
............
Lubricating oil level is below specification specified level. Refer to Procedure 007-009 and
007-037.
OK
Go To Next Step
STEP 4 Check the oil pressure. If the pressure is low, refer
............
Lubricating oil pressure is below specification to Procedure 007-028.
OK
Go To Next Step
STEP 5
............ Check the flywheel. Refer to Procedure 016-005.
Flywheel is loose or damaged
OK
Go To Next Step
STEP 6 Check the torque converter. Refer to the OEM
............
Torque converter is loose service manual.
OK
Go To Next Step
STEP 7 Check the torque on the main bearing capscrews.
Main bearing capscrews are loose, worn or not ............ Inspect the capscrews for wear. Refer to
tightened correctly Procedure 001-006.
OK
Go To Next Step
Engine Noise Excessive — Main Bearing

symptom tree.
Cause Correction
STEP 8 Inspect the main bearings for damage, excessive
Main bearings are damaged or worn, or the wrong ............ wear, and the correct part number. Refer to
bearings are installed Procedure 001-006.
OK
Go To Next Step
STEP 9 Inspect the thrust bearing for damage. Refer to
............
Thrust bearings are damaged Procedure 001-007.
OK
Go To Next Step

007-013.
Engine Noise Excessive — Piston

symptom tree.
Cause Correction
STEP 1 Refer to Procedure 018-002 in the Operation and
Maintenance Manual, Signature and ISX Engines,
Bulletin 3666251, and the Operation and
Maintenance Manual, Industrial and Power
Generation, QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step

006-026.
OK
Go To Next Step
STEP 3 Remove the pistons and inspect the piston pin and
Piston pin or bushing is loose, worn, or not ............ bushing for damage, wear, and correct installation.
installed correctly Refer to Procedure 001-043.
OK
Go To Next Step
STEP 4 Check the pistons, piston rings, and cylinder liner.
Cylinder liner, pistons, or piston rings are worn or ............ Refer to Procedures 001-043, 001-047, and
damaged 001-028.
Engine Noise Excessive — Turbocharger

symptom tree.
Cause Correction
Inspect the air piping, chassis, and cab for contact
points. Refer to Procedure 010-058 in the
STEP 1 Operation and Maintenance Manual, Signature
Air intake or exhaust piping is contacting the ............ and ISX Engines, Bulletin 3666251 and the
chassis or cab Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.
OK
Go To Next Step
STEP 3 Inspect the air intake system for restriction. Clean

............ or replace filter and inlet piping as necessary.
Air intake system restriction is above specification
OK
Go To Next Step
STEP 4 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.
OK
Go To Next Step
Check the turbocharger for damage. Measure the
STEP 5 turbine and compressor wheel clearances. Refer
............ to Procedure 010-033. Perform the EGR/VGT
Turbocharger is worn or damaged
Operation Test. Perform the Turbocharger
Actuator Test.
OK
Go To Next Step
Check the turbocharger part number and compare
STEP 6 it to the Control Parts List (CPL), Bulletin 3379133
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
necessary. Refer to Procedure 010-033.
Engine Shuts Off Unexpectedly or Dies During Deceleration

Cause Correction
STEP 1 the Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or the Troubleshooting
and QST30 Series Engines, Bulletin 4021419.
OK
Go To Next Step
STEP 2 Check the time limit on idle and PTO shutdowns
Idle shutdown or PTO shutdown features are ............ with an electronic service tool. Refer to the
activated electronic service tool manual.
OK
Go To Next Step
STEP 3 Refer to the Engine Performance TT tree in this
............
Engine will not restart manual.
OK
Go To Next Step
View the fault codes and the engine protection data
with an electronic service tool. Refer to the
appropriate electronic service tool manual. Refer
to the corresponding fault code in Section TF
Section TF in the Troubleshooting and Repair
............ Signature and ISX Engines, Bulletin 4021334, or
Engine protection fault code(s) inactive
the Troubleshooting and Repair Manual Electronic
Control System Signature, ISX and QSX15
OK
Go To Next Step
Check the vehicle keyswitch circuit. Refer to
............
Keyswitch circuit is malfunctioning Procedure 019-064in the Troubleshooting and
Repair Manual Electronic Control System,
3666259.
OK
Go To Next Step
STEP 6 Check for fuel inlet restriction. Refer to Procedure
............
Fuel inlet restriction 006-020.
OK
Go To Next Step
Engine Shuts Off Unexpectedly or Dies During Deceleration

Cause Correction
STEP 7 Bleed the fuel system and correct source of the
............
Air in fuel system leak. Refer to Procedure 006-003.
OK
Go To Next Step
STEP 8 Check the engine brake operation, adjustment,

............ and solenoid resistance. Repair or adjust as
Engine brakes are malfunctioning
OK
Go To Next Step
............
Injector o-rings are damaged or missing injector o-rings. Refer to Procedure 006-026.
Engine Speed Surges in PTO or Cruise Control

Cause Correction
Signature™ and ISX Engines, Bulletin 4021334, or
STEP 1 the Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the cruise control/PTO on/off switch and the
circuit. Refer to Procedures 019-021 and 019-022
in Section 19 in the Troubleshooting and Repair
Cruise control/PTO on/off switch or circuit is ............ Signature™ and ISX Engines, Bulletin 4021334, or
malfunctioning Procedures 019-021 and 019-022 in Section 19 in
the Troubleshooting and Repair Manual Electronic
Control System Signature™, ISX and QSX15
OK
Go To Next Step
Verify the ECM calibration is correct. Check the
calibration revision history for applicable fixes to
the calibration stored in the ECM. Refer to the
calibration history spreadsheet
ecm_calibration_rev_history.xlson QuickServe™
Online or the INCAL™ CD-ROM. Compare the
calibration stored in the ECM with the engine rating
and Control Parts List (CPL), Bulletin 4021326 or
STEP 3 4021327. If necessary, calibrate the ECM. Refer to
Electronic control module (ECM) calibration is ............ Procedure 019-032 in Section 19 in the
malfunctioning Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature™ and ISX
Engines, Bulletin 4021334, or ISX Fuel System
3666259, or Procedure 019-032 in Section 19 in
OK
Go To Next Step
Engine Speed Surges in PTO or Cruise Control

Cause Correction
Check the Performance Options of the calibration
stored in the electronic control module (ECM). Use
INSITE™ electronic service tool and INCAL™
STEP 4 Calibration DVD_ROM to check the Performance
Options section for the specific calibration under
Engine is operating in a unique application with a ............
Calibration Selection. If the Performance Option
specific calibration
reads “Vacuum Truck”, the condition may be
normal. A slight oscillation/surging of the engine
speed during unloaded PTO is a normal
consequence of these unique calibrations.
OK
Go To Next Step
Check the engine position sensor and circuit. Refer
to Procedure 019-363 in Section 19 in the
Engines, Bulletin 4021334, or Procedure 019-038
Engine position sensor (EPS) or circuit is ............ Manual Electronic Control System Signature™, ISX
malfunctioning and QSX15 Engines Bulletin 3666259, or
Procedure 019-038 in Section 19 in the
OK
Go To Next Step
STEP 6
Refer to the Engine Performance Troubleshooting
Engine speed surges while in the normal operating ............
Tree in Section TT.
range and not in PTO or cruise control
OK
Go To Next Step
STEP 7 Dry the connectors with Cummins® electronic
............
Moisture in the wiring harness connectors cleaner, Part Number 3824510.
OK
Go To Next Step
STEP 8 Refer to the Engine Performance Troubleshooting
............
Engine speed also surges at idle Tree in Section TT.
Engine Starts But Will Not Keep Running

Cause Correction
Signature and ISX Engines, Bulletin 4021334.
Also, refer to Section TF in the Troubleshooting
STEP 1 and Repair Manual, Electronic Control System,
Signature, ISX and QSX Engines, Bulletin
3666259. Also, refer to Section TF in the
Engines, Bulletin 4021419, for fault code
troubleshooting.
OK
Go To Next Step
STEP 2 Turn OFF the keyswitch for 5 seconds. Turn ON

the keyswitch and check fault lamp operation. Use
Idle shutdown or PTO shutdown features are ............
INSITE™ electronic service tool to check Idle
activated
Shutdown and PTO parameters.
OK
Go To Next Step
STEP 3 Fill the supply tank. Refer to the OEM service
............
Fuel level is low in the tank manual.
OK
Go To Next Step
Check the batteries and the unswitched battery
supply circuit. Refer to Procedure 019-087
(Unswitched Battery Supply Circuit) in Section 19
in the Troubleshooting and Repair Manual, CM870
Engines, Bulletin 4021334. Also, refer to
Procedure 019-087 (Unswitched Battery Supply
STEP 4 Circuit) in Section 19 in the Troubleshooting and
............
Battery voltage is low Repair Manual, Electronic Control System,
Signature, ISX and QSX Engines, Bulletin
3666259. Also, refer to Procedure 019-087
(Unswitched Battery Supply Circuit) in Section 19
in the Troubleshooting and Repair Manual, Power
OK
Go To Next Step
STEP 5 Check for fuel inlet restriction. Refer to Procedure
............
Fuel inlet restriction 006-020 (Fuel Inlet Restriction) in Section 6.
OK
Go To Next Step

Cause Correction
STEP 6 Bleed the fuel system and correct source of the

............ leak. Refer to Procedure 006-003 (Air in Fuel) in
Air in fuel system
Section 6.
OK
Go To Next Step
Check the vehicle keyswitch circuit. Refer to
Procedure 019-064 (Key Switch Battery Supply
Circuit) in Section 19 in the Troubleshooting and
STEP 7 Signature and ISX Engines, Bulletin 4021334.
............
Keyswitch circuit is malfunctioning Also, refer to Procedure 019-064 (Key Switch
Battery Supply Circuit) in Section 19 in the
Control System, Signature, ISX and QSX Engines,
Bulletin 3666259, for fault code troubleshooting.
OK
Go To Next Step
Check the fuel shutoff valve and circuit. Refer to
Procedures 019-049 (Fuel Shutoff Valve Circuit) in
Section 19 and 019-050 (Fuel Shutoff Valve
Solenoid) in Section 19 in the Troubleshooting and
Also, refer to Procedure 019-049 (Fuel Shutoff
Valve Circuit) in Section 19. Also, refer to
Procedure 019-050 (Fuel Shutoff Valve Solenoid)
Fuel shutoff valve(s) closed (electronically ............
and QSX Engines, Bulletin 3666259. Also, refer to
controlled injection)
and QST30 Series Engines, Bulletin 4021419, for
fault code troubleshooting. Also, refer to Procedure
QST30 Series Engines, Bulletin 4021419, for fault
OK
Go To Next Step
Refer to Fuel Recommendations and
STEP 9 Specifications in the Operation and Maintenance
Manual, Signature and ISX Engines, Bulletin
3666251. Also, refer to Fuel Recommendations
and Specifications in the Operation and
OK
Go To Next Step

Cause Correction
STEP 10 Check for transmission malfunctioning, cooling fan

............ operation cycle time, and engine-driven units.
Vehicle parasitics are excessive
Engine Will Not Crank - (Electric Starter)

This is symptom tree t074-005
Cause Correction
STEP 1 Check the batteries and the unswitched battery

............ supply circuit. Refer to Procedure 013-007 in
Battery voltage is low
Section 13.
OK
Go To Next Step
STEP 2 Refer to Procedure 013-007 in Section 13. Replace
............
Battery capacity is below specification the batteries if necessary.
OK
Go To Next Step
STEP 3 Inspect, clean, and tighten both the positive and

negative connections between the starting motor
Broken, loose, or corroded starting circuit ............
and battery, including the magnetic switch. Refer
connections
to Procedure 013-009 in Section 13.
OK
Go To Next Step
STEP 4 Check the starter interlock devices. Refer to the
............
OEM starter interlock devices engaged OEM service manual.
OK
Go To Next Step
STEP 5
............ Disengage engine-driven units.
Engine-driven units are engaged
OK
Go To Next Step
Check the the starting circuit components. Refer to
STEP 6 the OEM service manual and the following
............
Starting circuit component is malfunctioning procedures in Section 13: Procedure 013-017,
Procedure 013-018, and Procedure 013-019.
OK
Go To Next Step
STEP 7 Check the voltage drop at the starting motor. Refer
............
Starter motor malfunction to Procedure 013-020 in Section 13.
OK
Go To Next Step
Remove the starting motor and inspect the gear.
STEP 8 Refer to Procedure 013-020 in Section 13,
............
Starting motor pinion or ring gear is damaged Procedure 016-005 in Section 16, and the OEM
service manual.
OK
Go To Next Step
Engine Will Not Crank - (Electric Starter)

Cause Correction
Change the oil and filters. Refer to Procedure
018-003 in the Operation and Maintenance
STEP 9 Manual, Industrial and Power Generation, QSX15
Engines, Bulletin 3666423 or Procedure 018-003 in
Lubricating oil does not meet specifications for ............
the Operation and Maintenance Manual,
operating conditions
Use the oil type recommended in Section V of the
operation and maintenance manual.
OK
Go To Next Step
STEP 10 Check the crankshaft for ease of rotation. Refer to
............
Crankshaft rotation is impaired Procedure 001-016 in Section 1.
OK
Go To Next Step
Remove the injectors and rotate the crankshaft.
STEP 11 Look for the source of fluid in the cylinder. Refer to
............
Hydraulic lock in a cylinder Procedure 006-026 in Section 6 and Procedure
OK
Go To Next Step
Analyze the oil and inspect the filters to locate an
area of probable damage. Refer to Procedure
Manual, Industrial and Power Generation, QSX15
STEP 12 Engines, Bulletin 3666423 or Procedure 018-003 in
............
Internal engine damage the Operation and Maintenance Manual,
Remove the oil pan and inspect for damaged
camshaft, cam followers, push rods, pistons, and
liners. Refer to Procedure 007-025 in Section 7.
Engine Cranks Slowly - (Electric Starter)

Cause Correction
STEP 1 Check the batteries and the unswitched battery

............ supply circuit. Refer to Procedure 013-007 in
Battery voltage is low
Section 13.
OK
Go To Next Step
STEP 2 Refer to Procedure 013-007 in Section 13. Replace
............
Battery capacity is below specification the batteries if necessary.
OK
Go To Next Step
STEP 3 Inspect, clean, and tighten both the positive and

negative connections between the starting motor
Broken, loose, or corroded starting circuit ............
and battery, including the magnetic switch. Refer
connections
OK
Go To Next Step
STEP 4
OK
Go To Next Step
STEP 5 Check the battery heater. Refer to the OEM service
............
Batteries are cold manual.
OK
Go To Next Step
Check the the starting circuit components. Refer to
STEP 6 the OEM service manual and the following
............
Starting circuit component is malfunctioning procedures in Section 13: Procedure 013-017,
Procedure 013-018, and Procedure 013-019.
OK
Go To Next Step
STEP 7 Check the voltage drop at the starting motor. Refer
............
Starter motor malfunction to Procedure 013-020 in Section 13.
OK
Go To Next Step
Remove the starting motor and inspect the gear.
STEP 8 Refer to Procedure 013-020 in Section 13,
............
Starting motor pinion or ring gear is damaged Procedure 016-005 in Section 16, and the OEM
service manual.
OK
Go To Next Step
Engine Cranks Slowly - (Electric Starter)

Cause Correction
STEP 9 Manual, Industrial and Power Generation, QSX15
Engines, Bulletin 3666423 or Procedure 018-003 in
the Operation and Maintenance Manual,
OK
Go To Next Step
............
Crankshaft rotation is impaired Procedure 001-016 in Section 1.
OK
Go To Next Step
STEP 11 Engines, Bulletin 3666423 or Procedure 018-003 in
............
Internal engine damage the Operation and Maintenance Manual,
Remove the oil pan and inspect for damaged
camshaft, cam followers, push rods, pistons, and
liners. Procedure 007-025 in Section 7.
Engine Will Not Crank or Cranks Slowly (Air Starter)

Cause Correction
STEP 1 Increase air pressure with an external air source.
............
Air pressure is low in the air tanks Refer to the OEM service manual.
OK
Go To Next Step
STEP 2
OK
Go To Next Step
STEP 3 Manual, Signature and ISX Engines, Bulletin
3666251 and 018-003 in the Operation and
engine operation and maintenance manual.
OK
Go To Next Step
STEP 4 Check the starting motor operation. Compare the
Starting motor is malfunctioning or starting motor ............ starting motor with the engine and vehicle
is not correct specifications. Refer to the OEM service manual.
OK
Go To Next Step
STEP 5 Remove the starting motor, and inspect the gear.

............ Refer to Procedure 013-020, 016-005, and the
Starting motor pinion or ring gear is damaged
OEM service manual.
OK
Go To Next Step
............
Crankshaft rotation is impaired Procedure 001-016.
OK
Go To Next Step
STEP 7 Remove the injectors and rotate the crankshaft.

............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
Procedures 006-026 and Procedure 001-016.
OK
Go To Next Step
STEP 8 018-003 in the in the Operation and Maintenance
............ Manual, Signature and ISX Engines, Bulletin
3666251 and 018-003 in the Operation and
Engine Will Not Shut Off

Cause Correction
STEP 1 Signature™, ISX and QSX15 Engines, Bulletin
Electronic fault codes active or high counts of ............ 3666259, or the Troubleshooting and Repair
inactive fault codes Manual, Power Generation Control Systems,
QSX15, QSK23, QSK45, QSK60, QSK78 and
QST30 Series Engines, Bulletin 4021419.
OK
Go To Next Step
Check the vehicle, equipment, or vessel keyswitch
circuit. Refer to Procedure 019-064 in Section 19
in the Troubleshooting and Repair Manual, CM870
STEP 2 Electronic Control System, Signature™ and ISX
............
Keyswitch circuit is malfunctioning Engines, Bulletin 4021334, or the Troubleshooting
and Repair Manual, Electronic Control System,
Signature™, ISX and QSX15 Engines, Bulletin
3666259.
OK
Go To Next Step
STEP 3
Fuel shutoff valve (FSOV) solenoid or circuit is
............ Check the fuel shutoff valve solenoid and circuit.
malfunctioning (electronically controlled fuel
systems)
OK
Go To Next Step
STEP 4 Perform the injector leak test to find the damaged

............ injector(s). Replace the injector(s) as necessary.
OK
Go To Next Step
STEP 5 Check the air intake ducts. Locate and isolate the
Engine is running on fumes drawn into the air ............ source of the fumes. Repair as necessary. Refer to
intake the OEM service manual.
OK
Go To Next Step
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033 in Section 10.
Fuel Consumption Excessive

Cause Correction
Refer to Fuel Consumption General Information
STEP 1 and Customer Complaint Form in Procedure
............ t00-004 (Troubleshooting Overview) at the end of
this section. Follow the instructions on the form
before continuing with this tree.
OK
Go To Next Step
Explain correct engine operation to the operator.
Refer to Procedure 101-015 the Operation and
STEP 2 Maintenance Manual, Signature and ISX Engines,
............
Operator technique is not correct Bulletin 3666251 or 101-015 Operation and
OK
Go To Next Step
Review the VE/VMS® data and compare to the
STEP 3 vehicle and engine specifications. Do not use
............
VE/VMS® analysis uses incorrect data more than 20 percent for the Aero value. Refer to
the VE/VMS® User's Manual.
OK
Go To Next Step
STEP 4 Consider ambient temperatures, wind, tire size,
Equipment and environmental factors are affecting ............ axle alignment, routes, and use of aerodynamic
fuel consumption aids when evaluating fuel consumption.
OK
Go To Next Step
STEP 5 Check for correct gearing and drivetrain
............
Drivetrain is not correctly matched to the engine components. Refer to the OEM service manual.
OK
Go To Next Step
Refer to Section TF or the Troubleshooting and
STEP 6 Signature, ISX and QSX Engines, Bulletin
Electronic fault codes active or high counts of ............ 3666259, or the Troubleshooting and Repair
inactive fault codes Manual, Power Generation Control Systems
OK
Go To Next Step
Programmable parameters or selected features ............ Set the parameters and features again if
manual.
OK
Go To Next Step

Cause Correction
............ or 4021327. Replace the turbocharger if
Turbocharger is not correct
necessary. Refer to Procedure 010-033
(Turbocharger) in Section 10.
OK
Go To Next Step
STEP 9 Check the fuel lines, fuel connections, and fuel

............ filters for leaks. Check the fuel lines to the supply
Fuel leak
tanks. Refer to the OEM service manual.
OK
Go To Next Step
Check the hubometer and odometer calibrations.
STEP 10 Calibrate or replace the hubometer or odometer, if
............
Hubometer or odometer is miscalibrated necessary. Calculate fuel consumption with new
mileage figures.
OK
Go To Next Step
STEP 11 Refer to Procedures 018-002 in the Operation and
Bulletin 3666251 or 018-002 Operation and
OK
Go To Next Step
STEP 12 and oil pan capacity. Fill the system to the specified
............ level. Refer to Procedures 007-009 (Lubricating Oil
Lubricating oil level is above specification
Dipstick) in Section 7 and 007-037 (Lubricating Oil
System) in Section 7.
OK
Go To Next Step

Cause Correction
Verify the electronic control module (ECM)
calibration is correct. Check the calibration
revision history for applicable fixes to the
calibration stored in the ECM. Refer to the
ecm_calibration_rev_history.xlson QuickServe®
Online Internet Website or the INCAL™ calibration
CD. Compare the calibration stored in the ECM
with the engine rating and the Control Parts List
STEP 13 (CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to the appropriate
Electronic control module (ECM) calibration is ............
electronic service tool manual and Procedure
malfunctioning
Signature and ISX Engines, Bulletin 4021334, and
Engines, Bulletin 3666259, or 019-032 in the
OK
Go To Next Step
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
Refer to the appropriate electronic service tool
manual. If necessary, install the correct VSS. Refer
STEP 14 to Procedure 019-091 in the Troubleshooting and
............ Repair Manual, CM870 Electronic Control System,
Vehicle speed sensor (VSS) is not correct
3666259.
OK
Go To Next Step
Check the vehicle speed sensor and circuit. Refer
to Procedures 019-090 and 019-091 in the
STEP 15 Troubleshooting and Repair Manual, CM870
Vehicle speed sensor (VSS) or circuit is ............
malfunctioning
and QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step

Cause Correction
Check the vehicle speed sensor and circuit for
tampering. Check for Fault Code 242. Repair the
circuit as necessary. Refer to Procedures 019-090
Vehicle speed sensor (VSS) tampering has ............ Procedure 019-090 and 019-091 in the
occurred Troubleshooting and Repair Manual, Electronic
OK
Go To Next Step
STEP 17 Check the air intake system for restriction. Clean

............ or replace the air filter and inlet piping as
OK
Go To Next Step
STEP 18
Check the exhaust system for restrictions. Refer to
Exhaust system restriction is not within ............
Procedure 011-009.
specification
OK
Go To Next Step

006-026 or 014-008.
OK
Go To Next Step
STEP 20
Check the wastegate for correct operation. Refer
Turbocharger wastegate is malfunctioning (if ............
equipped)
OK
Go To Next Step
Monitor the turbocharger boost pressure with an
STEP 21 electronic service tool. Refer to Engine
............ Performance Troubleshooting in Section TT.
Turbocharger is malfunctioning
Check the turbocharger variable geometry
operation (if applicable).
OK
Go To Next Step
............
Overhead adjustments are not correct to Procedure 003-004.
OK
Go To Next Step

Cause Correction

007-083.
Fuel in Coolant
Cause Correction
Check the bulk coolant supply. Drain the coolant
and replace with noncontaminated coolant.
Replace the coolant filters. Refer to Procedure
STEP 1 018-003 in the Operation and Maintenance
............
Bulk coolant supply is contaminated Manual, Signature and ISX Engines, Bulletin
3666251 or 018-003 in the Operation and
OK
Go To Next Step
STEP 2 Check the fuel heater and replace, if necessary.
............
Fuel heater is malfunctioning (if equipped) Refer to the manufacturer's instructions.
OK
Go To Next Step
STEP 3
Remove and check the injectors. Check o-rings
Injector o-rings and sleeves are damaged. Injector ............
and injector sleeves. Refer to Procedure 006-026.
o-rings are missing
OK
Go To Next Step
Remove intake and exhaust manifolds. Check for
STEP 4 evidence of coolant leak. If necessary, operate
............
Cylinder head is cracked or porous engine at low idle. Pressure-test the cylinder head.
Fuel in the Lubricating Oil

Cause Correction
Check the bulk oil supply. Drain the oil and replace
STEP 1 with non-contaminated oil. Change the oil filters.
............
Bulk oil supply is contaminated Refer to Procedure 007-083 in Section 7 and
OK
Go To Next Step
Low oil and coolant temperatures can be caused
by long idle times (greater than 10 minutes). Shut
STEP 2 off the engine rather than idle for long periods. If
............
Engine idle time is excessive idle time is necessary, raise the idle speed. Refer
to Bulletin 4021334 for ISX CM870 engines and
Bulletin 4021560 for ISX CM871 engines.
OK
Go To Next Step
Check the fuel tank location. If the fuel tank is
located so the maximum fuel level is higher than
STEP 3 the cylinder head gasket check valves are required
............
Overhead fuel tank in the supply and return lines to keep fuel from
leaking into the engine, contaminating the engine
lubricating oil, or hydraulically locking the engine.
OK
Go To Next Step
STEP 4 Inspect the fuel drain lines for restrictions. Remove

............ any restrictions found. Refer to Procedure 006-012
Fuel drain line is restricted
in Section 6.
OK
Go To Next Step
Perform the fluorescent dye tracer test to confirm
STEP 5 the fuel leak. Add dye to the fuel and inspect the
............ oil for the presence of dye. Replace the fuel pump
Fuel pump seal is leaking
if necessary. Refer to Procedure 005-016 in
Section 5 and Procedure 007-024 in Section 7.
OK
Go To Next Step
Perform diagnostics to find the damaged injector
(s). Replace the injector(s) as necessary. Refer to
STEP 6 Bulletin 4021334, Section TT, 70-t02-1001, Guided
............ Step 5, for ISX CM870 engines. Procedure 014-008
Injector(s) are malfunctioning
for ISX CM870 and ISX CM871 engines. Refer to
Bulletin 4021560, Section TT, 16-t02-1001a,
Guided Step 5, for ISX CM871 engines.
OK
Go To Next Step
Fuel in the Lubricating Oil

Cause Correction
STEP 7 Perform the fluorescent dye tracer test to find the
Top injector o-ring or injector timing plunger is ............ damaged injector. Replace the injector or o-ring.
damaged Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
STEP 8 Inspect the injectors for blown or missing plug
............
Injector has blown or missing plug ball balls. Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
STEP 9 Perform the fuel passage leak test in the cylinder
............
Cylinder head is cracked or porous head. Refer to Procedure 002-004 in Section 2.
OK
Go To Next Step
Check the engine for high crankcase pressure, low
STEP 10 compression, static injection timing, damaged
............
Base engine problem pistons, camshaft, and other parts. Refer to
Intake Manifold Air Temperature Above Specification

Cause Correction
Electronic fault codes active or high counts of ............ Control System, Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the intake manifold temperature sensor.
Refer to Procedure 019-159 in the Troubleshooting
and Repair Manual, Electronic Control System,
STEP 2 3666259, or Procedure 019-059 in Troubleshooting
Intake manifold temperature sensor is ............ and Repair Manual, Power Generation Control
malfunctioning Systems QSX15, QSK23, QSK45, QSK60, QSK78,
and QST30 Series Engines, Bulletin 4021419 or
Procedure 019-059 in Troubleshooting and Repair
OK
Go To Next Step
Open the cold weather radiator cover or the
winterfront. Maintain a minimum of 784 cm2 [122
in2] or approximately 28 x 28 cm [11 x 11 in] of
STEP 3 opening at all times. Refer to Procedure 101-015 in
............ the Operation and Maintenance Manual, Signature
Cold weather radiator cover or winterfront is closed
and ISX Engines, Bulletin 3666251 or Procedure
101-015 Operation and Maintenance Manual,
Industrial and Power Generation, QSX15 Engines,
Bulletin 3666423.
OK
Go To Next Step
STEP 4 Inspect the charge air cooler, air conditioner
Charge air cooler fins, radiator fins, or air condenser, and radiator fins. Clean, if necessary.
............
conditioner condenser fins are damaged or Refer to Procedures 010-027, 008-042 and the
obstructed with debris OEM service manual.
OK
Go To Next Step
STEP 5 Check the belt tension and tighten if necessary.
............
Fan drive belt is loose Refer to Procedure 008-003.
OK
Go To Next Step
............
OK
Go To Next Step
Intake Manifold Air Temperature Above Specification

Cause Correction
STEP 7 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedure 008-038 and the OEM service manual.
OK
Go To Next Step
the shutterstat setting is wrong Procedure 008-049.
OK
Go To Next Step
STEP 9 Verify that the fan is the correct size. Refer to the
............
Fan is not an adequate size for the application OEM service manual.
OK
Go To Next Step
STEP 10 Check the EGR cooler. Refer to Procedure
............
EGR cooler malfunctioning 011-019.
OK
Go To Next Step
STEP 11 Refer to Procedures 010-024, 010-057, or the

............ Engine Performance Troubleshooting in Section
Intake air or exhaust leaks
TT.
OK
Go To Next Step
Check the EGR differential pressure sensor
mounting for leaks. Refer to Procedure 011-028,
STEP 12 Engine Performance Troubleshooting in Section
............
EGR differential pressure sensor leaking TT, and Procedure 019-370 in Troubleshooting and
OK
Go To Next Step
STEP 13 Check the tubes for leaks. Refer to Procedure

............ 011-026 and Engine Performance Troubleshooting
EGR differential pressure sensor tubes leaking
in Section TT.
Intake Manifold Pressure (Boost) is Below Normal

Cause Correction
Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the intake manifold pressure sensor. Refer
to Procedure 019-061 in the Troubleshooting and
............
Intake manifold pressure sensor is malfunctioning Procedure 019-061 in Troubleshooting and Repair
OK
Go To Next Step
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.
OK
Go To Next Step
STEP 4 Inspect the charge air cooler for air restrictions or
............
Charge air cooler is restricted or leaking leaks. Refer to Procedure 010-027.
OK
Go To Next Step
STEP 5 Check the air intake system for restriction. Clean

............ or replace the air filter and inlet piping as
OK
Go To Next Step
STEP 6 Check the wastegate for freedom of movement.
Turbocharger wastegate is damaged or is stuck ............ Inspect the wastegate for damage. Refer to
open Procedure 010-050.
OK
Go To Next Step
STEP 7 Check the turbocharger for damage. Measure the

............ turbine and compressor wheel clearances. Refer
Turbocharger is worn or damaged
OK
Go To Next Step
Intake Manifold Pressure (Boost) is Below Normal

Cause Correction
STEP 8 Check the connection between the manifold and
............
Air compressor connection is loose or damaged the air compressor. Repair or replace if necessary.
OK
Go To Next Step
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
OK
Go To Next Step
STEP 10 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.
OK
Go To Next Step
STEP 11 Refer to Engine Performance Troubleshooting in
............
Engine power output is low Section TT.
Lubricating Oil in the Fuel

Cause Correction
STEP 1 Refer to the Centinel™ Master Repair Manual,
............
Engine equipped with Centinel™ Bulletin 3666231.
OK
Go To Next Step
Perform oil dye test. Refer to Procedure 007-024 in
Section 7. Add dye to oil. Inspect for dye in fuel
STEP 2 tank with black light. If no dye was found in the fuel
............
Check for lubricating oil in fuel Asphaltines are the likely cause of the dark fuel. To
verify, take a fuel sample and perform an analysis
to check for Asphaltines.
OK
Go To Next Step

............ injector o-rings. Refer to Procedure 006-026 in
Injector o-rings are damaged or missing
Section 6.
OK
Go To Next Step
STEP 4 Inspect the cylinder head for Injector bore damage.
............
Cylinder head has damaged injector bore Refer to Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 5 Replace the upper plunger seal in the fuel injector.
............
Damaged injector upper plunger seal Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
STEP 6
Inspect the IFSM mounting gasket and sealing
Integrated Fuel System Module (IFSM) mounting ............
surfaces. Refer to Procedure 005-073 in Section 5.
gasket leaking
OK
Go To Next Step
Inspect the cylinder head for cracked or porous fuel
passages per the Fuel Passage Leak Test. Refer
STEP 7 to Procedure 002-004 in Section 2. Note: It is not
............
Cylinder head is cracked or porous necessary to remove the cylinder head to perform
this procedure unless the tools will not fit on the
cylinder head in chassis.
OK
Go To Next Step
STEP 8 Replace the malfunctioning injector. Refer to
............
Injector is malfunctioning Procedure 006-026 in Section 6.
Lubricating Oil Consumption Excessive

Cause Correction
Check the amount of oil added versus the mileage.
STEP 1 Refer to Procedure 502-016 in Section 2. This
............
Verify the oil consumption rate procedure is in the Warranty Administration
Manual, Bulletin 4021290.
OK
Go To Next Step
Inspect the engine for external oil leaks. Tighten
STEP 2 the capscrews, pipe plugs, and fittings. Replace
............
Lubricating oil leak (external) gaskets, if necessary. Refer to Procedure 007-024
in Section 7.
OK
Go To Next Step
STEP 3 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-001 in Section 3.
OK
Go To Next Step
STEP 4 Check the air lines for carbon buildup and

lubricating oil. Refer to the Air Compressor is
Air compressor is pumping lubricating oil into the ............
Pumping Excessive Lubricating Oil into the Air
air system
System symptom tree.
OK
Go To Next Step
STEP 5 Check the dipstick calibration. Refer to Procedure
............
Lubricating oil dipstick calibration is not correct 007-009 in Section 7.
OK
Go To Next Step
Refer to Procedure 102-002 in Section 2 in the
STEP 6 Operation and Maintenance Manual, Signature™
............ and ISX Engines, Bulletin 3666251. Refer to
Lubricating oil drain interval is excessive
Procedure 102-002 in Section 2 in the Operation
and Maintenance Manual, Industrial and Power
OK
Go To Next Step

Cause Correction
Change the oil and filters. Refer to Service Bulletin
3810340. Use the following procedure in the
Operation and Maintenance Manual, Signature™
and ISX Engines, Bulletin 3666251. Refer to
Procedure 018-003 in Section V. Use the following
STEP 7 procedure in the Operation and Maintenance
Engines, Bulletin 3666423. Refer to Procedure
018-003 in Section V. Use the following procedure
in the Operation and Maintenance Manual,
Industrial and Power Generation, QSX15 Engines,
Section 4. Use the oil type recommended in
Section V.
OK
Go To Next Step
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033 in Section 10.
OK
Go To Next Step
STEP 9 Refer to the Centinel™ Master Repair Manual,
............
Engine equipped with Centinel™ Bulletin 3666231.
OK
Go To Next Step
STEP 10 Check for lubricating oil in the coolant. Refer to the

............ Lubricating or Transmission Oil in the Coolant
Lubricating oil cooler is leaking
symptom tree.
OK
Go To Next Step
STEP 11 Refer to the Lubricating Oil Contaminated
............
Lubricating oil is contaminated with coolant or fuel symptom tree.
OK
Go To Next Step
Perform oil dye test. Refer to Procedure 007-024 in
Section 7. Add dye to oil. Inspect for dye in fuel
STEP 12 tank with black light. If no dye was found in the fuel
............
Check for lubricating oil in fuel Asphaltines are the likely cause of the dark fuel. To
verify, take a fuel sample and perform an analysis
to check for Asphaltines.
OK
Go To Next Step
STEP 13 Check blowby. Refer to Section 14. If blowby is

excessive, check the piston rings for correct
Piston rings are not seated correctly (after an ............
seating. Refer to Procedure 001-043 and
engine rebuild or piston installation)
OK
Go To Next Step

Cause Correction
STEP 14 Check for air intake system leaks. Refer to
Piston, cylinder liner, or piston rings are worn or ............ Procedure 001-043, Procedure 001-047, and
damaged Procedure 001-028 in Section 1.
Lubricating Oil Contaminated

Cause Correction
STEP 1 Perform an oil analysis to determine the
............
Identify lubricating oil contamination contaminants.
OK
Go To Next Step
STEP 2 Check the bulk oil supply. Drain the oil and replace
............ with non-contaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
OK
Go To Next Step
STEP 3
............ Refer to the Coolant Loss - Internal symptom tree.
Internal coolant leaks
OK
Go To Next Step
STEP 4 Change the oil and filters. Refer to the Lubricating

............ Oil Sludge in the Crankcase is Excessive symptom
Lubricating oil sludge is excessive
tree.
OK
Go To Next Step
STEP 5 Refer to the Fuel in the Lubricating Oil symptom
............
Fuel in the lubricating oil tree.
OK
Go To Next Step
STEP 6
Transmission or hydraulic fluid is in the lubricating ............ Refer to the OEM service manual.
oil
Lubricating Oil Filter Plugged

Cause Correction
STEP 1 Measure the differential pressure drop across the

............ lubricating oil filter. Refer to Procedure 007-013 in
Verify the plugged lubricating oil filter complaint
Section 7 .
OK
Go To Next Step
007-037 and Procedure 007-013 in Section 7. For
STEP 2 oil type recommendations, refer to Procedure
018-003 in Section V, in the Signature™ and ISX
Operation and Maintenance Manual, Bulletin
3666251, or Procedure 018-003 in Section V, in the
QSX15 Operation and Maintenance Manual,
Bulletin 3666423.
OK
Go To Next Step
007-037 and Procedure 007-013 in Section 7. Use
INSITE™ electronic service tool to verify the
STEP 3 average kilometers per liter (km/liter) [miles per
The present lubricating oil drain interval was gallon (mpg)]. For the correct oil drain intervals,
............
missed or is exceeded based on duty cycle, or oil refer to Procedure 102-002 in Section 2 of the
and filter combination Signature™ and ISX Operation and Maintenance
Manual, Bulletin 3666251, or Procedure 102-002 in
Section 2 in the QSX15 Operation and
Maintenance Manual, Bulletin 3666423.
OK
Go To Next Step
Change the oil and filter. Refer to Procedure
007-037 and Procedure 007-013 in Section 7. For
oil type recommendations, refer to Procedure
018-003 in Section V, in the Signature™ and ISX
STEP 4 Operation and Maintenance Manual, Bulletin
Engine has history of missed or excessive oil drain ............ 3666251, or Procedure 018-003 in Section V, in the
intervals QSX15 Operation and Maintenance Manual,
Bulletin 3666423. Clean any contaminated
residual engine oil from the oil pan and cylinder
head. Return the engine to operation. Repeat, if
necessary, to reach a full oil drain interval.
OK
Go To Next Step
Lubricating oil is visually contaminated with ............ symptom tree, if a visual inspection reveals
coolant or fuel contamination.
OK
Go To Next Step

Cause Correction
Review the customer oil analysis records if
available. If recent customer oil analysis results are
not available and the results of an oil analysis can
be obtained within a reasonable time frame,
STEP 6 perform an oil analysis. If the results of an oil
analysis can not be obtained within a reasonable
The filter plugging interval is less than 16,093 ............
time frame, proceed with the next step in this
kilometers [10,000 miles]
troubleshooting procedure. Refer to Cummins®
Engine Oil and Oil Analysis Recommendations,
Bulletin 3810340. Refer to the appropriate
troubleshooting symptom tree if lubricating oil
contamination is identified.
OK
Go To Next Step
For the correct fuel recommendations, refer to
STEP 7 Procedure 018-002 in Section V in the Operation
An inspection or customer interview reveals that and Maintenance Manual, Signature™ and ISX
............
the fuel grade may not be correct for the Engines, Bulletin 3666251, or Procedure 018-002
application or the fuel quality is poor in Section V of the Operation and Maintenance
Manual, QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step
Check for excessive engine blowby. Refer to
STEP 8 Procedure 014-002 in Section 14 . If crankcase
............
Combustion gas contamination gases are excessive, refer to the Crankcase Gases
(Blowby) Excessive symptom tree.
OK
Go To Next Step
STEP 9 Check or replace the fuel lines, check valves, or

............ tank vents as needed. Refer to Procedure 006-012
Fuel drain line restriction
in Section 6.
OK
Go To Next Step
Perform diagnostics to find the damaged injector
(s). Replace the injector(s) as necessary. Refer to
Guided Step 5 in Troubleshooting Tree t02-1001 in
STEP 10 Section TT of the Signature™, ISX, and QSX15
............ Service Manual, Bulletin 4021334, or Guided Step
Injector(s) are malfunctioning
5 in Troubleshooting Tree t02-1001a in Section TT
of the CM871 and CM876 Electronic Control
Systems, ISX and ISM Engines, Bulletin 4021560.
Return the engine to operation.
OK
Go To Next Step

Cause Correction
If no documentation of repeat occurrences of
premature oil and filter changes is available in
engine warranty history, or from the customer,
STEP 11 perform the appropriate corrections in the steps
First investigated instance of premature filter ............ above and STOP. Return the engine to operation.
plugging For repeat instances without improvement,
measure and record the pressure drop across the
filter. Verify the completion of the steps above and
continue to the next steps.
OK
Go To Next Step
Review the customer oil analysis records, if
available. If recent customer oil analysis records
STEP 12 are not available, perform an oil analysis to identify
Lubricating oil is contaminated with coolant or fuel ............ potential contamination. For used oil
with no clear visual indication contamination guidelines refer to Cummins®
Engine Oil and Oil Analysis Recommendations,
Bulletin 3810340.
OK
Go To Next Step
STEP 13 Inspect the injectors for missing or damaged o-

rings and plug balls. Replace the o-rings or
Injector has a blown plug ball or a cut o-ring not ............
injector, as necessary. Refer to Procedure 006-026
detected by diagnostics
in Section 6 .
OK
Go To Next Step
Check the engine base timing and adjust the
overhead. Refer to Procedure 001-088 in Section
STEP 14 1 and Procedure 003-004 in Section 3. Return the
............
Engine timing incorrect engine to operation. If no improvement, request
additional Cummins Inc. technical assistance
before continuing to the next step.
OK
Go To Next Step
Check the engine for damaged pistons, rings,
STEP 15 liners, and other parts. Refer to Procedure 002-004
............
Base engine problem in Section 2. Request additional Cummins Inc.
technical assistance.
Lubricating Oil Pressure High

Cause Correction
Electronic fault codes active or high counts of ............ Control System, Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, Troubleshooting and
OK
Go To Next Step
STEP 2 Check the oil pressure switch, gauge, or sensor for
Lubricating oil pressure switch, gauge, or sensor is ............ correct operation and location. Refer to Procedure
malfunctioning or is not in the correct location 007-028 or the OEM service manual.
OK
Go To Next Step
STEP 3 Change the oil and filters. Refer to Service Bulletin
Lubricating oil does not meet specifications for ............ 3810340. Use the oil type recommended in Section
operating conditions V of the operation and maintenance manual.
OK
Go To Next Step
STEP 4 Remove and inspect the high• pressure relief
Lubricating oil high• pressure relief valve or ............ valve or lubricating oil pump. Refer to Procedures
lubricating oil pump is malfunctioning 007-021 and 007-031.
Lubricating Oil Pressure Low

Cause Correction
Check the lubricating oil pressure sensor and
circuit. Refer to Procedures 019-155 or 019-066 in
STEP 1 QST30 Series Engines, Bulletin 4021419, or
Lubricating oil pressure sensor or circuit is ............ Procedure 019-155 in Section 19 in
malfunctioning (electronic controlled fuel system) Troubleshooting and Repair Manual, Electronic
Control System, Signature™, ISX and QSX
in Section 19 in Troubleshooting and Repair
OK
Go To Next Step
Change the oil and filters. Refer to Service Bulletin
3810340 or Procedure 018-003 in Section V in the
Operation and Maintenance Manual, Signature™
STEP 2 and ISX Engines, Bulletin 3666251 or Procedure
Lubricating oil does not meet specifications for ............ 018-003 in Section V in the Operation and
operating conditions Maintenance Manual, Industrial and Power
OK
Go To Next Step
............
Lubricating oil level is above or below specification Refer to Procedure 007-037 in Section 7.
OK
Go To Next Step
STEP 4
Engine angularity during operation exceeds ............ Refer to the Engine Specification data sheet.
specification
OK
Go To Next Step
Measure the differential pressure drop across the
lubricating oil filter. Refer to Procedure 007-013 in
STEP 5 Section 7 or the Lubricating Oil Pressure Low
............
Lubricating oil filter is plugged symptom tree. If lubricating oil filter is plugged,
refer to the Lubricating Oil Filter Plugged symptom
tree.
OK
Go To Next Step
............
OK
Go To Next Step
Lubricating Oil Pressure Low

Cause Correction
STEP 7
Inspect the lubricating oil pump and o-rings. Refer
Lubricating oil pump is malfunctioning or the o- ............
rings are damaged
OK
Go To Next Step
STEP 8 Remove and inspect the high-pressure relief valve
Lubricating oil high-pressure relief valve or ............ or lubricating oil pump. Refer to Procedures
lubricating oil pump is malfunctioning 007-021 and 007-031 in Section 7.
OK
Go To Next Step
STEP 9 Refer to the Lubricating Oil Temperature Above
............
Lubricating oil temperature is above specification Specification symptom tree.
OK
Go To Next Step
STEP 10
Remove and inspect the oil pan or suction tube.
Lubricating oil suction or transfer tube is loose or ............
broken, or the gasket or o-rings are leaking
OK
Go To Next Step
STEP 11 Check the piston cooling nozzles for damage and
Piston cooling nozzles are damaged or are not ............ correct installation. Refer to Procedure 001-046 in
installed correctly Section 1.
OK
Go To Next Step
STEP 12 Check the oil cooler. Refer to Procedure 007-003
............
Lubricating oil cooler is plugged in Section 7.
OK
Go To Next Step
STEP 13 Analyze the oil and inspect the filters, pistons,

............ camshaft, and other parts to locate an area of
probable damage.
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
STEP 1 Check the bulk oil supply. Drain the oil and replace
............ with noncontaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
OK
Go To Next Step
Change the oil and filters. Refer to 007-083. Use
the oil type recommended in 018-003 of the
STEP 2 Operation and Maintenance Manual, Signature
Lubricating oil does not meet specifications for ............ and ISX Engines, Bulletin 3666251 or 018-003
operating conditions Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
Refer to Section 2 in 102-002 of the Operation and
STEP 3 Maintenance Manual, Signature and ISX Engines,
............
Lubricating oil drain interval is excessive Bulletin 3666251 or 102-002 Operation and
OK
Go To Next Step
STEP 4 Refer to Procedure 018-002 in the Operation and
Bulletin 3666251 or 018-002 Operation and
OK
Go To Next Step
STEP 5 Refer to the Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 7 Check for excessive blowby. Refer to the

Crankcase pressure is excessive
tree.
OK
Go To Next Step
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
STEP 8 Check the injector cups for damage and for correct
............
Injector cup is damaged or is not correct part numbers. Refer to Procedure 006-026.
OK
Go To Next Step
STEP 9 Replace the malfunctioning injector. Refer to
............
Injector is malfunctioning Procedure 006-026.
OK
Go To Next Step
Replace the timing or fueling actuator Procedure
019-110 and 019-111 in the Troubleshooting and
STEP 10 019-110 and 019-111 Troubleshooting and Repair
............ Manual, Electronic Control System, Signature, ISX
Timing or fueling actuator malfunctioning
and QSX Engines, Bulletin 3666259, 019-110 and
019-111 Troubleshooting and Repair Manual,
Series Engines, Bulletin 4021419.
OK
Go To Next Step
Check the engine position sensor or circuit. Refer
to Section TF and or Procedure 019-038 in the
STEP 11 Electronic Control System, Signature and ISX
Engines, Bulletin 4021334, or ISX Fuel System
Engine position sensor (EPS) or circuit is ............
malfunctioning or wiring is not correct
3666259, or Troubleshooting and Repair Manual,
Series Engines, Bulletin 4021419 .
OK
Go To Next Step
STEP 12 Check base engine timing. Refer to Procedure
............
Engine is out of time 001-088.
Lubricating Oil Temperature Above Specification

Cause Correction
STEP 1 ISX Fuel System Troubleshooting and Repair
Electronic fault codes active or high counts of ............ Manual, Bulletin 3666259, or Troubleshooting and
inactive fault codes Repair Manual, Power Generation Control
OK
Go To Next Step
Check the oil temperature switch, gauge, or sensor
for correct operation and location. Refer to
Lubricating oil temperature switch, gauge, or ............ 019-155 ISX Fuel System Troubleshooting and
sensor malfunctioning or not in the correct location Repair Manual, Bulletin 3666259, or 019-155
OK
Go To Next Step
Check the lubricating oil temperature sensor and
circuit. Refer to Procedure 019-067 in the
STEP 3 Engines, Bulletin 4021334, or 019-155
Lubricating oil temperature sensor or circuit is ............ Troubleshooting and Repair Manual, Power
malfunctioning (electronic controlled fuel system) Generation Control Systems QSX15, QSK23,
Engines, Bulletin 4021419 or 019-155 ISX Fuel
System Troubleshooting and Repair Manual,
Bulletin 3666259.
OK
Go To Next Step
............
Lubricating oil level is above or below specification Refer to Procedure 007-037.
OK
Go To Next Step
STEP 5 Refer to the Coolant Temperature is Above Normal

............ - Sudden Overheat or the Coolant Temperature is
Coolant temperature is above specification
Above Normal - Gradual Overheat symptom tree.
OK
Go To Next Step
Lubricating Oil Temperature Above Specification

Cause Correction
STEP 6 Check the oil thermostat. Refer to Procedure
............
Lubricating oil thermostat is malfunctioning 007-039.
OK
Go To Next Step
STEP 7
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning
Lubricating or Transmission Oil in the Coolant

Cause Correction
Check the bulk coolant supply. Drain the coolant
STEP 1 and replace with non-contaminated coolant.
............
Bulk coolant supply is contaminated Replace the coolant filters. Refer to Procedure
OK
Go To Next Step
STEP 2 Check the oil cooler. Refer to Procedure 007-003
............
Lubricating oil cooler is malfunctioning in Section 7.
OK
Go To Next Step
STEP 3
Remove and inspect the cooler cores and o-rings.
Torque converter cooler or hydraulic oil cooler is ............
malfunctioning (if applicable)
OK
Go To Next Step

............ Procedure 002-004 or Procedure 002-021 in
Cylinder head gasket is leaking
Section 2.
OK
Go To Next Step
............
OK
Go To Next Step
............
Turbocharger Leaks Engine Oil or Fuel

Cause Correction
Review the engine operating instructions in
Section 1 Procedure 101-015 (Operating the
Engine) in Section 1 in the Operation and
STEP 1 Maintenance Manual, Signature™ and ISX
Engine is operating for extended periods under ............ Engines, Bulletin 3666251 or Procedure 101-015
light- or no-load conditions (slobbering) (Operating the Engine) in Section 1 in the
Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
STEP 2 Remove the intake and exhaust piping, and check
............
Lubricating oil or fuel is entering the turbocharger for oil or fuel.
OK
Go To Next Step
Remove the turbocharger oil drain line and check
STEP 3 for restriction. Clean or replace the oil drain line.
............
Turbocharger oil drain line is restricted Refer to Procedure 010-033 (Turbocharger) in
Section 10.
OK
Go To Next Step
Check for excessive blowby. Refer to Procedures
014-001 (Dynamometer Worksheet) in Section 14,
014-002 (Engine Testing (Chassis Dynamometer))
in Section 14, 014-003 (Engine Run-In (Chassis
Dynamometer)) in Section 14, 014-004 (Engine
STEP 4 Run-In (Without Dynamometer)) in Section 14,
............
Crankcase pressure is excessive 014-005 (Engine Testing (Engine Dynamometer))
in Section 14, 014-006 (Engine Run-In (Engine
Dynamometer)) in Section 14, 014-008 (Engine
Testing (In Chassis) in Section 14, and 014-009
(Engine Testing (Portable Dynamometer or Load
Bank)) in Section 14.
OK
Go To Next Step
Check the turbocharger compressor and turbine
STEP 5 seals. Refer to Procedure 010-033 (Turbocharger)
............
Turbocharger oil seal is leaking in Section 10 and 010-040 (Turbocharger
Compressor Seal Leaks) in Section 10.
OK
Go To Next Step
STEP 6 Check the actuator cross shaft oil seal for leakage.
Turbocharger actuator cross shaft oil seal is ............ Refer to Procedure 010-137 (Variable Geometry
leaking Turbocharger Cross Shaft) in Section 10.
Stationary Regeneration — Will Not Activate

The steps in this tree are intended to cover vehicles equipped with an on vehicle method of activating a stationary
regeneration. This troubleshooting tree can also be used if INSITE™ electronic service tool Aftertreatment Diesel
Particulate Filter Regeneration Test will not operate.
Cause Correction
View and troubleshoot the fault codes with
INSITE™ electronic service tool. Refer to Section
STEP 1 TF for active fault code troubleshooting or
Electronic fault codes active or high counts of ............ Procedure 019-362 for inactive fault code
inactive fault codes troubleshooting in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control
OK
Go To Next Step
STEP 2 A stationary regeneration can not be performed

while the soot load is in the normal range. Refer to
Soot load of the Aftertreatment Diesel Particulate ............
the Aftertreatment Diesel Particulate Filter
Filter is too low
Regeneration Test section of Procedure 014-013.
OK
Go To Next Step
Refer to the OEM instructions on how to perform a
STEP 3 stationary regeneration via the drive/vehicle
interface or refer to the Aftertreatment Diesel
The correct Stationary Regeneration procedure is ............
Particulate Filter Regeneration Test in Procedure
not being followed
014-013 for the INSITE™ electronic service tool
procedure
OK
Go To Next Step
STEP 4
Refer to the OEM instructions on Regeneration
OEM or customer-selected inhibit feature is ............
inhibit features.
preventing a stationary regeneration
OK
Go To Next Step
selected features with an electronic service tool.
Set the parameters and features again if
STEP 5 necessary. Refer to Procedure 019-078 in the
Programmable parameters or selected features ............ Troubleshooting and Repair Manual, CM871 and
are not correct CM876 Electronic Control System, ISX and ISM
Engines, Bulletin 4021560 and to Multiplexing
Troubleshooting, Service Manual, Bulletin
4021378.
OK
Go To Next Step
Check the vehicle brake switch and circuit. Refer
STEP 6 to Refer to Procedures 019-088 and 019-089 in the
............ Troubleshooting and Repair Manual, CM871 and
Vehicle brake switch or circuit is malfunctioning
CM876 Electronic Control Systems, ISX and ISM
OK
Go To Next Step

Cause Correction
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
STEP 7 Refer to the appropriate electronic service tool
manual. If the monitor shows speed, check the
Vehicle speed sensor (VSS) or circuit is ............
sensor and circuit. Refer to Procedures, 019-091,
malfunctioning
and 019-093 the Troubleshooting and Repair
OK
Go To Next Step
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedure 019-009 or 019-010 the
STEP 8 Troubleshooting and Repair Manual, CM871 and
............ CM876 Electronic Control Systems, ISX and ISM
Clutch switch or circuit is malfunctioning
Engines, Bulletin 4021560. If available, use an
electronic service tool to monitor the clutch switch
status.
OK
Go To Next Step
Check for foot pedal restriction. Check the
STEP 9 accelerator pedal or lever position sensor and
circuit. Refer to Procedure 019-085 the
Accelerator pedal or lever position sensor or circuit ............
Troubleshooting and Repair Manual, CM871 and
is malfunctioning
CM876 Electronic Control Systems, ISX and ISM
OK
Go To Next Step
Check the cruise control/PTO selector switch and
STEP 10 circuit. Refer to Procedures 019-021 and 019-022
Cruise control/PTO selector switch or circuit is ............ the Troubleshooting and Repair Manual, CM871
malfunctioning and CM876 Electronic Control Systems, ISX and
ISM Engines, Bulletin 4021560.
OK
Go To Next Step
STEP 11 Verify the parking brake is set. Refer to the OEM
............
Vehicle parking brake is not set instructions.
OK
Go To Next Step
STEP 12 Verify the transmission is in Park, if provided,
Transmission is not in Park, if provided, otherwise ............ otherwise in Neutral. Refer to the OEM
in Neutral instructions.
OK
Go To Next Step

Cause Correction
Verify the electronic control module (ECM)
ecm_calibration_rev_history.xlson QuickServe®
STEP 13 Online Internet Website or the INCAL™ calibration
Electronic control module (ECM) calibration is ............ CD. Compare the calibration stored in the ECM
malfunctioning with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to the appropriate
electronic service tool manual and Procedure
019-032 the Troubleshooting and Repair Manual,
CM871 and CM876 Electronic Control Systems,
ISX and ISM Engines, Bulletin 4021560.
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary

Regeneration
For vehicles that have the diesel particulate lamp illuminating frequently, high exhaust temperature lamp (if equipped)
illuminating frequently, and/or requires frequent stationary regenerations.
Cause Correction
STEP 1 INSITE™ electronic service tool. Refer to the
Electronic fault codes active or high counts of ............ Troubleshooting and Repair Manual, CM871 and
inactive fault codes CM876 Electronic Control System, ISX and ISM
OK
Go To Next Step
Check the aftertreatment system inhibit feature
STEP 2 with INSITE™ electronic service tool. Change the
OEM or customer selected inhibit feature is vehicle route and/or duty cycle so the inhibit
............
preventing active regeneration during vehicle feature does not prevent active regeneration or
operation contact OEM/customer about changing inhibit
features.
OK
Go To Next Step
Check the aftertreatment system trip information
with INSITE™ electronic service tool. Low duty
STEP 3 cycle applications can possibly require more active
regeneration time to keep the aftertreatment
Extended operation of engine in low duty cycle, ............
system functioning correctly. Change the vehicle
extended idling and/or low ambient temperatures
route and/or duty cycle to increase the load on the
engine in order to decrease the amount of active
regeneration time.
OK
Go To Next Step
Maintenance interval for ash cleaning has been
reached. See the corresponding Owners or
STEP 4 Operation and Maintenance manual for the engine
............
Aftertreatment Diesel Particulate Filter is full of ash being serviced. Refer to the Aftertreatment Diesel
Particulate Filter - Excessive Ash Cleaning
Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 5 Refer to the Troubleshooting Performance
............
Engine produces excessive black smoke Symptom Tree.
Stationary Regeneration - Will Not Complete

This tree is to be used when the engine speed changes after the stationary (parked) regeneration has been started
and either stops after a short period of time, or continues for an excessive period of time. If the engine speed does
not increase when the stationary (parked) regeneration is started, refer to the Stationary Regeneration - Will Not
Activate TS tree (t146).
Cause Correction
INSITE™ electronic service tool. Refer to Section
STEP 1 TF for active and inactive fault code
Electronic fault codes active or high counts of ............ troubleshooting, Procedure 019-362 in Section 19
inactive fault codes of the ISX and ISM CM871 and CM876 Electronic
Control System, Troubleshooting and Repair
Manual, Bulletin 4021560.
OK
Go To Next Step
STEP 2 Verify that all of the conditions that allow a

stationary (parked) regeneration to activate are still
Stationary (Parked) Regeneration stops after a ............
valid. Refer to Stationary Regeneration - Will Not
short period of time
Activate symptom tree.
OK
Go To Next Step
Allow the stationary (parked) regeneration to run
until completion, which can take up to 2.5 hours.
Refer to Procedure 014-013 in Section 14. NOTE:
STEP 3 The 2.5 hours is the maximum time that a
Stationary (Parked) Regeneration not allowed to ............ regeneration will take to complete. If the Diesel
run to completion Oxidation Catalyst temperature is not at or above
316°C [600°F] and the aftertreatment injector has
not turned on within 1 hour, abort the regeneration
and continue through this tree.
OK
Go To Next Step
STEP 4
Inspect the OEM exhaust piping and the
Exhaust leaks in the OEM exhaust piping leading
............ aftertreatment system for exhaust leaks. Refer to
to the aftertreatment system or leaks in the
aftertreatment system
OK
Go To Next Step
STEP 5 Monitor the aftertreatment gas temperature sensor

values with INSITE™ electronic service tool during
Aftertreatment Gas Temperature Sensors are not ............
the stationary (parked) regeneration. Refer to
functioning properly
OK
Go To Next Step
Stationary Regeneration - Will Not Complete

This tree is to be used when the engine speed changes after the stationary (parked) regeneration has been started
and either stops after a short period of time, or continues for an excessive period of time. If the engine speed does
not increase when the stationary (parked) regeneration is started, refer to the Stationary Regeneration - Will Not
Activate TS tree (t146).
Cause Correction
Monitor the engine percent load value with
INSITE™ electronic service tool during the
stationary (parked) regeneration. If this value stays
STEP 6 consistently above 8% the metering actuators are
Fuel metering actuators are not functioning ............ over fueling and need to be replaced. Refer to
properly Procedure 019-110 in Section 19 of the ISX and
ISM CM871 and CM876 Electronic Control
System, Troubleshooting and Repair Manual,
Bulletin 4021560.
OK
Go To Next Step
STEP 7 Verify that the EGR valve is closed during the

............ stationary (parked) regeneration. Refer to
EGR valve is not functioning properly
OK
Go To Next Step
Use INSITE™ electronic service tool to verify that
the turbocharger actuator position is maintained at
89 percent closed or higher during the stationary
STEP 8 (parked) regeneration. If the turbocharger actuator
............
Turbocharger is not functioning properly position does not maintain 89 percent closed or
higher, verify that the turbocharger sector gear has
full travel. Refer to Procedure 010-134 in Section
10.
OK
Go To Next Step
STEP 9 Check for progressive damage to the

............ aftertreatment system. Refer to Procedure 014-013
Aftertreatment System is damaged
in Section 14.
OK
Go To Next Step
Verify that the electronic control module (ECM)
STEP 10 ecm_calibration_rev_history.xlson QuickServe™
Online Internet Website or the INCAL™ calibration
Electronic control module (ECM) calibration is ............
CD. Compare the calibration stored in the ECM
malfunctioning
with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
calibrate the ECM. Refer to Procedure 019-032 in
Section 19 of the ISX and ISM CM871 and CM876
Electronic Control System, Troubleshooting and
Repair Manual, Bulletin 4021560.
Signature™, ISX, and QSX15 Troubleshooting Overview
Troubleshooting Overview
Engine Noise Diagnostic Procedures - General Information
NOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air
compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate
noise caused by these units. Noise will also travel to other metal parts not related to the problem. The use of a
stethoscope can help locate an engine noise.
Engine noises heard at the crankshaft speed, engine rpm, are noises related to the crankshaft, rods, pistons, and
piston pins. Noises heard at the camshaft speed, one-half of the engine rpm, are related to the valve train. A handheld
digital tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft
speed.
Engine noise can sometimes be isolated by performing a cylinder cutout test. Refer to the Electronic Service Tool
Manual. If the volume of the noise decreases or the noise disappears, it is related to that particular engine cylinder.
There is not a definite rule or test that will positively determine the source of a noise complaint.
Engine driven components and accessories, such as gear-driven fan clutches, hydraulic pumps, belt-driven
alternators, air-conditioning compressors, and turbochargers can contribute to engine noise. Use the following
information as a guide to diagnosing engine noise.
Main Bearing Noise
(Refer to Engine Noise Excessive - Main Bearing symptom tree)
The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main
bearings are loose, a loud clatter will be heard. The knock is heard regularly every other revolution. The noise is the
loudest when the engine is lugging or under heavy load. The knock is duller than a connecting rod noise. Low oil
pressure can also accompany this condition.
If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there
is no oil at the bearing.
An irregular noise can indicate worn crankshaft thrust bearings.
An intermittent sharp knock indicates excessive crankshaft end clearance. Repeated clutch disengagements can
cause a change in the noise.
Connecting Rod Bearing Noise
(Refer to Engine Noise Excessive - Connecting Rod symptom tree)
Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When
the bearings begin to become loose, the noise can be confused with piston slap or loose piston pins. The noise
increases in volume with engine speed. Low oil pressure can also accompany this condition.
Piston Noise
(Refer to Engine Noise Excessive - Piston symptom tree)
It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a
loud double knock which is usually heard when the engine is idling. When the injector to this cylinder is cut out, a
noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes
more noticeable when the vehicle is operated on the road at steady speed condition.
Driveability - General Information
Driveability is a term which in general describes vehicle performance on the road. Driveability problems for an engine
can be caused by several different factors. Some of the factors are engine related and some are not.
Before troubleshooting, it is important to determine the exact complaint and whether the engine has a real driveability
problem or if it simply does not meet driver expectations. The Driveability-Low Power Customer Complaint Form is a
valuable list of questions that must be used to assist the service technician in determining what type of driveability
problem the vehicle is experiencing. Complete the checklist before troubleshooting the problem. The form can be
found at the end of this section. If an engine is performing to factory specifications but does not meet the customer's
expectations, it must be explained to the customer that nothing is wrong with the vehicle and why.
The troubleshooting symptom charts have been set up to divide driveability problems into two different symptoms:
Engine Power Output Low and Engine Acceleration or Response Poor.
Troubleshooting Overview Signature™, ISX, and QSX15
Low power is a term that is used in the field to describe many different performance problems. However, in this manual
low power is defined as the inability of the engine to produce the power necessary to move the vehicle at a speed that
can be reasonably expected under the given conditions of load, grade, wind, and so on. Low power is usually caused
by the lack of fuel flow which can be caused by any of the following factors:
- Lack of full travel of the throttle pedal
- Failed boost sensor
- Excessive fuel inlet, intake, exhaust, or drainline restriction
- Loose fuel pump suction lines
Low power is not the inability of the vehicle to accelerate satisfactorily from a stop or the bottom of a grade. Refer to
the symptom tree Engine Power Output Low for the proper procedures to locate and correct a low power problem.
The chart starts off with basic items which can cause lower power. It then breaks off into application specific items
that can cause lower power. All of the application specific trees end with a step called “Fuel or air delivery problem”.
This step leads to an engine performance check which requires engine measurements. The last section of this chart
is titled Performance Measurement. This leads the mechanic through the causes and corrections based on the
outcome of the performance check.
Poor acceleration or response is described in this manual as the inability of the vehicle to accelerate satisfactorily
from a stop or from the bottom of a grade. It can also be the lag in acceleration during an attempt to pass or overtake
another vehicle at conditions less than rated speed and load. Poor acceleration or response is difficult to troubleshoot
since it can be caused by factors such as:
- Engine or pump related factors
- Driver technique
- Improper gearing
- Improper engine application
- Worn clutch or clutch linkage
Engine related poor acceleration or response can be caused by several different factors such as:
- Failed boost sensor
- Excessive drainline restriction
- Throttle deadband
Refer to the symptom tree Engine Acceleration or Response Poor for the proper procedures to locate and correct a
poor acceleration or response complaint. For additional information, see Troubleshooting Driveability Complaints,
Bulletin 3387245.
Driveability/Low Power - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
1. How did the problem occur? .... Suddenly ________ Gradually ________
2. Does the vehicle also experience poor fuel economy? .... Yes ____ No ____
3. At what hour/mileage did the problem begin? .... Hours ________ Miles ________ Since New ________
i. After engine repair? .... Yes ____ No ____
ii. After equipment repair? .... Yes _____ No ____
iii. After change in equipment use? .... Yes ____ No ____
iv. After change in selectable programmable parameters? .... Yes ____ No ____
v. If so, what was repaired and when? ........................................................................................
Answer questions 4 through 8 using selections (A through F) listed below. Circle the letter or letters that best describes
the complaint.
A. Compared to fleet D. Personal expectation
B. Compared to competition E. Won't pull on hill
C. Compared to previous engine F. Won't pull on flat
4. A B C D E F Can the vehicle obtain the expected road speed? .... Yes ____ No ____ What is desired speed? ....
rpm/mph ________ What is achieved speed? .... rpm/mph ________ GVW ________________
5. A B C D Is the vehicle able to pull the load? .... Yes ____ No ____ When? In the hills ________ With a loaded
trailer ________ On the flat ________ Other_______
IF QUESTION 4 OR 5 WAS ANSWERED NO, FILL OUT THE DRIVEABILITY/LOW POWER/EXCESSIVE
FUEL CONSUMPTION CHECKLIST AND GO TO THE LOW POWER SYMPTOM TREE.
6. A B C D E F Is the vehicle slow to accelerate or respond? .... Yes ____ No ____ From a stop? .... Yes ____ No
____ After a shift? .... Yes ____ No ____ rpm ________ Before a shift? .... Yes ____ No ____ rpm ________ No
shift? .... Yes ____ No ____ rpm ________
7. A B C D Does the vehicle hesitate after periods of long deceleration or coasting? .... Yes ____ No ____ rpm
________
IF QUESTION 6 OR 7 WAS ANSWERED YES, FILL OUT THE DRIVEABILITY/LOW POWER/EXCESSIVE
FUEL CONSUMPTION CHECKLIST AND GO TO THE POOR ACCELERATION/RESPONSE SYMPTOM
TREE.
8. A B C D E F Additional Comments: .... ....
This Page Can Be Copied For Your Convenience.
Driveability/Low Power/Excessive Fuel Consumption - Checklist

Vehicle/Equipment Specifications
Year/Type/Model: _____________________________________________________________________________________
Wheel Base: ____________________ Vehicle Configuration (ex. 6 X 4 - 2S):___________________________
Transmission Mfg: ________________________ Transmission Model: ___________________
Rear Axle Model: ________________ Rear Axle Ratio: _______________________
Application: On Highway _______ Off Highway _______ Genset _______ Marine _______
Typical GVW: _________________________lbs/kg
Trailer Type (Van, round smooth, etc.): ____________________ Height __________ Width __________
Gap between Tractor and Trailer: _________________
Description of Vehicle aerodynamic aids: ________________________________________________________________
______________________________________________________________________________________________________
General Engine Information
ESN: ___________ CPL: ___________ EPA Certification Year: ___________
ECM Code: ___________ Engine Model: ___________
Engine Rating: ___________ Rated Speed: ___________
Date in Service: ___________ Mpg (average if multiple units): ___________
Engine Brake: Yes ___________ No ___________
Throttle Type: Variable Speed ___________ Automotive ___________
Tires
Steer: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Drive: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Trailer: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Fan Type: Direct Drive _____ Viscous ________ Clutch ________ Est. HP ________
Auxiliary Devices
Power Steering: Yes ___________ No ___________
Air Conditioner: None _____ Standard _____ Bus _____ High Capacity _____
Alternator: Amps@Volts ___________
Road Speeds
Maximum Cruise Control Speed: ___________
Maximum Accelerator Vehicle Speed: ___________
Shift Technique: Progressive Shift _________ Governed Speed Shift ___________
Electronic Features
Gear Down Protection - Heavy Load: ___________mph
Gear Down Protection - Light Load: ___________mph
Cruise Control Upper Droop: ___________mph
Cruise Control Lower Droop: ___________mph
Road Speed Governor Upper Droop: ___________mph
Road Speed Governor Lower Droop: ___________mph
Typical Routes
Route:
Interstate ____ Dump ____ Rural ____ Urban ____ Bus ____
Grades:
Level 1-2% _______ Short 1-5% _______ Long 1-5% _______
Additional Comments:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
Vehicle/Equipment Specifications
Recommended Literature:
Troubleshooting Driveability Complaints, Bulletin 3387137
Fuel Consumption - General Information

The cause of excessive fuel consumption is hard to diagnose and correct because of the potential number of factors
involved. Actual fuel consumption problems can be caused by any of the following factors:
- Engine factors
- Vehicle factors and specifications
- Environmental factors
- Driver technique and operating practices
- Fuel system factors
- Low power/driveability problems
Before troubleshooting, it is important to determine the exact complaint. Is the complaint based on whether the
problem is real or perceived, or does not meet driver expectations? The Fuel Consumption - Customer Complaint
Form (on the next page) is a valuable list of questions that can be used to assist the service technician in determining
the cause of the problem. Complete the form before troubleshooting the complaint. The following are some of the
factors that must be considered when troubleshooting fuel consumption complaints.
1. Result of a Low Power/Driveability Problem: An operator will change his driving style to compensate for a
low power/driveability problem. Some things the driver is likely to do are, (a) shift to a higher engine rpm or (b)
run on the droop curve in a lower gear instead of upshifting to drive at part throttle conditions. These changes
in driving style will increase the amount of fuel used.
2. Driver Technique and Operating Practices: As a general rule, a 1 mph increase in road speed equals a 0.1
mpg increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss
of fuel mileage of 1 mpg.
3. Environmental and Seasonal Weather Changes: As a general rule, there can be as much as a 1 to 1.5 mpg
difference in fuel consumption depending on the season and the weather conditions.
4. Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
5. Truck Route and Terrain: East/west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north/south routes where parts of the trip are not only warmer, but see less wind resistance.
6. Vehicle Aerodynamics: The largest single power requirement for a truce is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mpg.
7. Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
tread design have a sizeable effect on fuel economy and performance. Changing from a bias ply to a low profile
radial tire can reduce rolling resistance by about 36 percent.
Additional vehicle factors, vehicle specifications, and axle alignment can also affect fuel consumption. For additional
information on troubleshooting fuel consumption complaints, refer to Troubleshooting Excessive Fuel Consumption,
Bulletin 3387245.
Fuel Consumption - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
Customer Contact _________________________________________________Customer Phone Number ________________
Describe the issue/complaint in detail, including current fuel economy being achieved:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
Answer the following questions. Some questions require making an X next to the appropriate answer.
1. What is the expected fuel mileage? _______________
2. What is the average GVW? _______________
3. What are the expectations based on?
Original mileage ________ Other units in fleet ________ Competitive engines ________
Previous engine ________ Expectations only ________ VE/VMS report ________
NOTE: If the answer to number 3 is based on comparison (i.e. Other units in fleet, Competitive engines, Previous
engine), the Customer Complaint Form and the Driveability/Low Power/Excessive Fuel Consumption - Checklist
must be filled out for the comparison unit(s) in order to properly troubleshoot the complaint.
4. When did the problem occur?
Since New ________ Suddenly ________ Gradually ________
5. Did the problem start after a repair? Yes ________ No ________
If so, what was repaired and why? ____________________________________________________________
6. Is the vehicle also experiencing a Driveability problem (Low Power or
Poor Acceleration/Response)? Yes ________ No ________
If number 6 is answered Yes, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist.
7. Is the problem seasonal? Yes ________ No ________
8. Weather conditions during fuel consumption check?
Rain _____ Snow _____ Windy _____ Hot Temperatures _____ Cold Temperatures _____
9. How is the fuel usage measured?
Tank _____ Trip _____ Month _____ Year _____
Road Relay _____ ECM _____ Inspec _____
10. If number 9 is answered Road Relay, ECM, or Inspec, how do these fuel numbers compare to actual?
Percent Difference ________
11. If tractor pulls a refrigerated trailer, are fuel tickets kept separate for tractor and trailer fuel?
Yes ________ No ________
12. How is the distance measured?
Hub _____ Odometer _____ Road Relay _____ ECM _____ Inspec _____ Map Miles _____ Dispatch/Paid Miles
_____
13. If number 12 is answered Road Relay, ECM, Inspec, Map, or Dispatch/Paid, how do these distance numbers
compare to actual?
Percent Difference ___________
14. Are accurate records kept of fuel added on the road? Yes ________ No ________
15. Do routes vary between compared vehicles? Yes ________ No ________
16. Have routes changed for the engine being checked? Yes ________ No ________
17. Has driver changed for the engine being checked? Yes ________ No ________
18. Has typical load changed for the engine being checked? Yes ________ No ________
19. Has the fuel source changed? Yes ________ No ________
20. What are the loads hauled, compared to comparison unit? GVW _______________
Heavier ________ Lighter ________
21. At what altitude is the truck operating?
Below 10,000 feet ________ Above 10,000 feet ________
22. According to the driver, how many hours per day is the truck idling? Hours/day __________
The Service Location should fill out the remaining section
Distributor Name __________________________________________ Date __________________
Distributor Contact _________________________________________ Distributor Phone Number
__________________
23. Record the following parameters from Trip Information in INSITE™:
Version of INSITE™ used ______________
Percent Time in Top Gear ______________%
Percent Time One Gear Down ______________%
Percent Time in Cruise Control ______________%
Percent Time at Idle ______________%
PTO Time ______________hrs
Trip Distance ______________mi/km

Trip Fuel Used ______________gal/L
Trip Gear Down Distance ______________mi/km
Trip Top Gear Distance ______________mi/km
Cruise Control Distance ______________mi/km
Vehicle Overspeed 1 Distance ______________mi/km
Vehicle Overspeed 1 Threshold ______________mph/kph
Vehicle Overspeed 1 Time ______________hrs
Vehicle Overspeed 2 Distance ______________mi/km
Vehicle Overspeed 2 Threshold ______________mph/kph
Vehicle Overspeed 2 Time ______________hrs
24. Is the driver technique or operating practices affecting fuel economy?
Incorrect shift rpm? Yes ________ No ________
Rpm at cruise control speed? Yes ________ No ________
Is customer compensating for low power? Yes ________ No ________
25. Have fuel tank vents been verified to be working properly? Yes ________ No ________
26. Has vehicle been checked for brake drag? Yes ________ No ________
27. Has vehicle been checked for tractor and trailer alignment? Yes ________ No ________
28. Has vehicle been checked for fuel leaks? Yes ________ No ________
29. Does vehicle have either a fuel heater or cooler? Yes ________ No ________
30. Is customer using proper fuel for ambient conditions? Yes ________ No ________
31. Are all charge air cooler clamps present and tight? Yes ________ No ________
IF AFTER FILLING OUT THIS FORM IT APPEARS THAT THE PROBLEM IS NOT CAUSED BY VEHICLE
FACTORS, ENVIRONMENTAL FACTORS, OR DRIVER TECHNIQUE, FILL OUT THE DRIVEABILITY/LOW
POWER/EXCESSIVE FUEL CONSUMPTION CHECKLIST.
Oil Consumption
In addition to the information that follows, a service publication is available titled Technical Overview of Oil
Consumption, Bulletin 3379214.
Engine Lubricating Oil Consumption Report

Owner's Name Date of Delivery Engine Serial Number
Month Day Year Engine Model and Horsepower
Address Equipment Manufacturer
City State/Province Equipment Serial Number Fuel Pump Serial Number
Engine Application (describe) Oil and Filter Change Interval Complaint Originally Registered
Oil Filters Date Miles/Hours/Kilometers
Lubricating Oil Added
Date Added Oil Engine Operation Miles/ Quarts/Liters Oil Brand and Viscosity of Oil Used
Hours/Kilometers Added
Start Test
Last Mileage/Hours/Kilometers _________________________ Minus Start Mileage/Hours/Kilometers

___________________________________
Equals Test Mileage/Hours/Kilometers ____________________________ Divided by Oil Added
__________________________________________
Equals ___________________________________________ Usage
Rate________________________________________________________________
Customer Signature Cummins Dealer Cummins Distributor
Cummins Inc. Form 4755
Coolant Loss Pre-Troubleshooting Guide

Before troubleshooting, it is critical to know where the coolant is being lost. It is not always obvious where the missing
coolant has gone.
Before troubleshooting, it is important to determine the exact complaint by interviewing the driver, looking at the
service history and looking at the ECM information.
Driver Interview Questions

Driver's Name:....
ESN:....
What is your complaint?....
How is this engine used?....
What sort of load factors?....
Where is the vehicle driven?....
1. How often do you add coolant?....
2. How do you fill the radiator?....
3. Do you fill to the High or Low mark when the engine is cold (less than 60°C [140°F])?....
4. What type of coolant do you add?....
5. Have you seen any coolant on the ground under your truck?....
6. Have you seen green or white streaks on the engine or near the coolant overflow hose?....
7. Is there any specific condition when you get indications of coolant loss (weather, altitude or load)?....
8. Does the engine ever overheat?....
9. Does the warning light flash?....
10. Under what condition?....
11. What temperature does the coolant run at normally?....
12. Does the cooling fan operate correctly (fan on at 99°C [210°F])?....
13. Have you seen any white smoke at operating temperature, or has anyone told you that white smoke is coming
out of the exhaust?....
14. Do you have oil analysis performed as part of your maintenance?....
15. Are there elevated levels of sodium or potassium?....
16. Have you noticed any increase in moisture condensation on the dipstick or oil fill cap, or moisture in the blowby?
....
17. Have you noticed a milky appearance in your lube oil that might indicate coolant is present?....
18. What other comments do you have that might help us make the right repair?....
Service History Review

Repeat cylinder head or cylinder head gasket repairs can indicate the problem is likely not the cylinder head or cylinder
head gasket. Repeat problems can indicate a deeper problem in the engine. Keep this information in mind while going
through the troubleshooting procedure.
Look at this engine's warranty claims history: who worked on the engine last and what did they do? How many miles/
kilometers are on this engine? Has a cylinder head or cylinder head gasket been replaced before? At how many miles
were the repairs made?
ECM Data Review:
Print out an INSITE™ Image Report from the ECM. Look for high temperature alarms or low coolant level alarms. Either
indication confirms a complaint of loosing coolant.
Are any fault codes logged in the Engine Protection Fault History?
ECM Fault Code 235 - Low Coolant (how many times)?
ECM Fault Code 151 - High Coolant Temperature (how many times)?
At this point, do you know where the coolant is going? If not and the coolant loss is not severe, suggest mounting a
catch bottle on the radiator overflow tube to catch any overflow that can possibly be blowing out and becoming lost
while at speed. Send the vehicle out to collect more data about where the coolant is or is not going. If the catch bottle
has some coolant in it, refer back to the Coolant Loss External (out the overflow) interview questions.
Section TT - Troubleshooting Symptoms (New Format) Page TT-a
Section TT - Troubleshooting Symptoms (New Format)

Section Contents
Page
Engine Performance Troubleshooting Tree - ISX with CM871 ....................................................................TT-64
Engine Performance Troubleshooting Tree - Signature™ and ISX CM870 ....................................................TT-1
Fuel Economy Troubleshooting Tree .........................................................................................................TT-112
Fuel Economy Troubleshooting Tree .........................................................................................................TT-143
Vibration Excessive .....................................................................................................................................TT-148
Page TT-b Section TT - Troubleshooting Symptoms (New Format)

Signature™, ISX, and QSX15 Engine Performance Troubleshooting Tree - Signature™ an [...]
Section TT - Troubleshooting Symptoms (New Format) Page TT-1
Engine Performance Troubleshooting Tree - Signature™ and ISX CM870

This troubleshooting procedure should be followed for the following symptoms:
• Engine Acceleration or Response Poor
• Cranking Fuel Pressure is Low
• Engine Operating Fuel Pressure is Low
• Engine Difficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
• Engine Run On
• Engine Power Output Low
• Engine Runs Rough at Idle
• Engine Runs Rough or Misfires
• Engine Speed Surges at Low or High Idle
• Engine Speed Surges Under Load or in Operating Range
• Smoke, Black - Excessive
• Smoke, White - Excessive
• Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
• Engine Starts But Will Not Keep operating
• Engine Will Not Reach Rated Speed (rpm).
How to Use This Troubleshooting Procedure:

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing
Step 1 troubleshooting. Step 2 asks a series of questions and will provide a list of troubleshooting steps to perform
depending on the symptom. Perform the list of troubleshooting in the sequence shown in the Specifications/Repair
section of the tree.
Shop Talk:
Prior to operating INSITE™ electronic service tool EGR Valve and EGR Valve/Turbocharger Operational Test, the ECM
Calibration Software Phase can possibly need to be updated to the latest Software Phase. The ECM Calibration Phase
Software can be checked in INSITE™ electronic service tool, under 'Features and Parameters'. Expand the selection
for 'System ID and Dataplate'and go to 'Calibration Information'. If the Software Phase is earlier than shown below,
calibrate the ECM, use the January 2006 INCAL™ CD-ROM, or later. Engines with the Software Phase listed below
or later do not require a calibration.
ISX engines with CM870 (engines built after January 2004) require Software Phase 06050302.
ISX engines with CM870 (engines built before January 2004) require no changes at this time.
This is a warrantable calibration change.
Engine Performance Troubleshooting Tree - Signature™ an [...] Signature™, ISX, and QSX15
Page TT-2 Section TT - Troubleshooting Symptoms (New Format)
TROUBLESHOOTING SUMMARY
CAUTION
To reduce the possibility of pin and harness damage, use the following test leads when taking a measurement:
Part Number 3822758 - 20 AWG male Deutsch™/AMP™/Metri-Pack™ test lead and Part Number 3824811 - 12
AWG male Deutsch™/AMP™/Metri-Pack™ test lead.
STEPS SPECIFICATIONS SRT CODE

STEP 1: Perform basic troubleshooting procedures.
STEP 1A: Check for active fault codes or Active fault codes or high counts
high counts of inactive fault of inactive fault codes?
codes.
STEP 1B: Perform basic troubleshooting All steps have been verified to
checks. be correct?
STEP 2: Determination of engine symptom.
STEP 2A: Low power, poor acceleration, Is the engine symptom low
or poor response. power, poor acceleration, or
poor response?
STEP 2B: Engine misfire. Is the engine symptom Engine
Runs Rough or Misfires?
STEP 2C: Excessive black smoke. Is the engine symptom
Excessive Black Smoke?
STEP 2D: Excessive white smoke. Is the engine symptom
Excessive White Smoke and the
engine is using coolant?
STEP 2D-1: Excessive white smoke. Is the engine symptom
Excessive White Smoke and the
engine is not using coolant?
STEP 2E: Engine speed surge or engine Is the engine symptom Engine
speed unstable. Speed Surge or Engine Speed
Unstable?
STEP 2F: Engine will not start or difficult Is the symptom Engine Difficult
to start. to Start or Will Not Start?
STEP 2G: Engine stalls or shuts off Is the symptom Engine Stalls or
unexpectedly. Shuts Off Unexpectedly?
STEP 2H: Engine run on or will not shut Is the engine symptom Engine
down. Run On or Slow to Shut Down
after operated at high idle for 1
minute then keyed OFF?
STEP 3: No-start troubleshooting procedures.
STEP 3A: Verify the fuel system has been Has the fuel system properly
primed. primed?
STEP 3B: Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage
greater than 11-VDC?
STEP 3B-1: Check ECM keyswitch Is the keyswitch voltage equal to
voltage. battery voltage?
STEP 3B-2: Check the fuel shutoff valve Less than 10 ohms?
wire.
STEP 3B-3: Check the ECM power and Is the ECM battery supply
ground. voltage equal to the battery
voltage?
STEP 3C: Check fuel shutoff valve Is the fuel shutoff solenoid
resistance. resistance 1 to 5 ohms for 6-VDC
solenoids, 6 to 15 ohms for 12-
VDC solenoids, 24 to 50 ohms
for 24-VDC solenoids, 42 to 80
ohms for 32-VDC solenoids, 46
to 87 ohms for 36-VDC
solenoids, 92 to 145 ohms for 48-
VDC solenoids, 315 to 375 ohms
for 74-VDC solenoids, 645 to 735
ohms for 115-VAC solenoids?
STEP 3D: Check fuel shutoff valve Debris or damage found on the
actuator. valve disc, valve seat, or
actuator disc?
STEP 3E: Check for correct priming pump Does the lift pump operate after
operation, if equipped. turning the keyswitch ON?
STEP 3E-1: Check priming pump Does pump pressure meet the 69
pressure. kPa [10 psi] specification?
STEP 3F: Check for coolant in the EGR Is coolant present in the
transfer tube. crossover tube?
STEP 4: Fuel system checks.
STEP 4A: Verify the fuel system has been Has the fuel system been
primed. properly primed?
STEP 4B: Check for air in the fuel. Are air bubbles visible in the coil
of clear tubing?
STEP 4C: Check fuel inlet restriction. Is fuel inlet restriction less than
the specifications?
STEP 4D: Check drain line restriction. Is fuel drain line restriction less
than 229 mm-Hg [9 in-Hg]?
STEP 4E: Check rail fuel pressure. Does the rail fuel pressure meet
the specification?
STEP 4E-1: Check the pressure side fuel Is the pressure side fuel filter
filter restriction. pressure drop less than 517 kPa
[75 psi]?
STEP 4E-2: Check 1724 kPa [250 psi] Is the 1724 kPa [250 psi]
pressure regulator. pressure regulator free of debris
or damage?
STEP 4E-3: Check 2206 kPa [320 psi] or Is the pressure regulator free of
2620 kPa [380 psi] pressure debris or damage?
regulator.
STEP 5: Injector and Actuator Diagnostics.
STEP 5A: Perform the injector check valve Did the injector leak test detect
leak test. a leaking injector?
STEP 5B: Perform INSITE™ electronic Does performing INSITE™
service tool Cylinder electronic service tool Cylinder
Performance Test. Performance Test isolate to a
single malfunctioning injector?
STEP 5B-1: Perform INSITE™ electronic Does performing INSITE™
Performance Test at 600 Performance Test isolate to a
rpm. single malfunctioning injector?

STEP 5C: Perform INSITE™ electronic Do all cylinders pass the cylinder
service tool Cylinder Cutout cutout test?
Test.
STEP 5C-1: Perform INSITE™ electronic Can a malfunctioning bank of
service tool Cylinder Cutout injectors be isolated by
Test on both injector banks. operating the engine on either
bank of injectors?
STEP 5C-2: Perform INSITE™ electronic Can a malfunctioning injector be
service tool Cylinder Cutout isolated by operating the engine
Test. on a single injector?
STEP 5C-3: Verify overhead Are the overhead settings within
adjustments are correct for the reset limits outlines in
the suspected Procedure 003-004 in Section 3?
malfunctioning injector.
STEP 5D: Swap the front and rear Does the malfunctioning bank
metering actuators. follow the metering actuator?
STEP 5E: Swap the front and rear timing Does the malfunctioning bank
actuators. follow the timing actuator?
STEP 6: Air handling diagnostic checks.
STEP 6A: Start the engine and read the Active fault codes?
fault codes.
STEP 6B: Check the air intake system for Leaks found?
leaks.
STEP 6C: Check air intake restriction. Restriction greater than 635 mm-
H2O [25 in-H2O] for a used air
filter or 254 mm-H2O [10 in-H2O]
for a new filter?
STEP 6D: Inspect the charge-air cooler. Problems found with the charge-
air cooler?
STEP 6E: Check exhaust restriction. Restriction between 518 mm-
H2O [20.4 in-H2O] or 38 mm-Hg
[1.5 in-Hg] and 1036 mm-H2O
[40.8 in-H2O] or 76 mm-Hg [3.0
in-Hg]?
STEP 6F: Inspect the turbocharger blades Damage found on turbocharger
for damage. blades?
STEP 6G: Determine turbocharger type. Is the turbocharger a variable
geometry turbocharger?
STEP 6H: Check the variable geometry Does the turbocharger actuator
actuator rod for correct travel. rod extend between 10 and 12
mm [0.394 and 0.472 in]?
STEP 6H-1: Check for air leaks and Air leaks found in the system?
inspect air lines.
STEP 6D-2: Check the engine and Connections tight and corrosion-
vehicle grounds. free?
STEP 6D-3: Check for air pressure at the Is vehicle air tank pressure
turbocharger control valve present at the turbocharger
outlet. control valve outlet?
STEP 6H-4: Check for air pressure at the Does the pressure gauge read
turbocharger control valve more than 103 kPa [15 psi] after
outlet. 5 minutes?
STEP 6H-5: Check for correct Does the turbocharger actuator
turbocharger actuator rod travel at least 12 mm [0.472
travel. in]?
STEP 6H-6: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve outlet. valve outlet?
STEP 6H-7: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve inlet. valve inlet?
STEP 6H-8: Check for plugged Is an air leak present at the
turbocharger control shutoff turbocharger control shutoff
valve filter. valve filter head?
STEP 6I: Perform INSITE™ electronic Does the Turbocharger
service tool EGR Valve/ Operational Test pass?
Turbocharger Operational Test.
STEP 6E-1: Check the engine and Connections tight and corrosion-
vehicle grounds. free?
STEP 6J: Inspect the wastegate actuator Holes or cracks found in the
hose. wastegate actuator hose?
STEP 6K: Inspect the wastegate actuator Does the wastegate actuator rod
rod for travel. move?
STEP 6G-1: Inspect wastegate actuator Does the wastegate actuator rod
rod for travel. move?
STEP 6L: Measure resistance of the four- Are the wastegate controller
stage wastegate controllers, if solenoid resistances between
equipped. 7.0 and 8.0 ohms?
STEP 6M: Inspect four-stage wastegate Damage or debris found on the
controller, if equipped. valve disc, valve seat, or
actuator disc?
STEP 7: Check EGR valve for proper operation.
STEP 7A: Check for air leaks in the EGR Air leaks found in the EGR
system. connection tubing?
STEP 7B: Check the repair history. Is there a record of the poppet
head missing?
STEP 7C: Perform EGR Valve Test. Does the EGR Valve Test pass?
STEP 8: Verify electronic features are operating correctly.
STEP 8A: Verify accelerator pedal travel. Does the Accelerator Pedal read
0 when the accelerator is
released and 100 percent when
the accelerator is depressed?
STEP 8B: Monitor vehicle speed. Does the vehicle speed read 0
when the vehicle is not moving?
STEP 8C: Verify electronic feature settings Are the electronic features set
are correct. correctly?
STEP 8D: Check the barometric pressure Is the barometric pressure

sensor reading. sensor reading in INSITE™
electronic service tool within 5
percent of the present local
barometric pressure reading?
STEP 9: Perform base engine mechanical checks.
STEP 9A: Verify overhead adjustments are Overhead settings within the
correct. reuse limits?
STEP 9B: Verify engine brake adjustment. Engine brake settings within the
reuse limits?
STEP 9C: Measure turbocharger axial and Axial and radial clearances
radial clearance. within specification?
STEP 9D: Verify engine blowby is within Engine blowby measurements
specification. within specification?
STEP 9E: Verify base engine timing is Base engine timing within
correct. specification?
STEP 9F: Check for a damaged vibration Vibration damper damaged or
damper. out of specification?
STEP 10: Check the EGR differential pressure sensor and exhaust gas pressure sensor
tubes.
STEP 10A: Check the EGR differential Cracks, restrictions, or leaks
pressure tubes for cracks, present?
restrictions, or leaks.
STEP 10B: Check the exhaust gas pressure Cracks, restrictions, or leaks
sensor tubes for cracks, present?
restrictions, or leaks.
TROUBLESHOOTING STEP

STEP 1A: Check for active fault codes or high counts of inactive fault codes.
Condition:
• Connect INSITE™ electronic service tool.
• Turn keyswitch ON.
Action Specification/Repair Next Step
Check for active fault codes or high counts of Active fault codes or high counts of inactive Go to
inactive fault codes. fault codes? appropriate
• Use INSITE™ electronic service tool to read the YES fault code
fault codes. troubleshooti
ng tree
Active fault codes or high counts of inactive 1B

fault codes?
NO
STEP 1B: Perform basic troubleshooting checks.

Condition:
n/a
The following items must be checked or verified All steps have been verified to be correct? 2A
before continuing: YES
• Verify the fuel level in the tanks.
• Verify there have not been any changes to
CPL components on the engine. All steps have been verified to be correct? Repair
• Verify ECM calibration is correct. NO complete
• Verify fuel grade is correct for the application.
Repair:
• Verify the engine is operating within the
recommended altitude. Correct the condition and verify complaint is
• Verify engine oil is at the correct level. no longer present after repair.
• Verify engine parasitics have not changed.
• Verify engine duty cycle has not changed.
• Verify engine cranking speed is greater than
150 rpm.

STEP 2A: Low power, poor acceleration, or poor response.
Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom low power, poor Perform the
n/a acceleration, or poor response? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure
recommended order listed below:
• Step 4 - Fuel System Checks
• Step 6 - Air Handling Checks
• With EGR - Step 7 - EGR Checks
• Step 8 - Electronic Checks
• Step 5 - Injector Checks
• Step 9 - Base Engine Checks
• With EGR - Step 10 - EGR Differential
Pressure and Exhaust Gas Pressure
Checks.
Is the engine symptom low power, poor 2B

acceleration, or poor response?
NO
STEP 2B: Engine misfire.

Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom Engine Runs Rough Perform the
n/a or Misfires? troubleshooti
YES ng steps
suggested in
Repair: the repair
Checks.
Is the engine symptom Engine Runs Rough 2C

or Misfires?
NO
STEP 2C: Excessive black smoke.

Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom Excessive Black Perform the
Smoke? troubleshooti
n/a
YES ng steps
suggested in
Repair: the repair
• With EGR - Step 7 - EGR Checks
Checks
• Step 9 - Base Engine Checks.
Is the engine symptom Excessive Black 2D

Smoke?
NO
STEP 2D: Excessive white smoke.

Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom Excessive White Perform the
n/a Smoke and the engine is using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
• See the Coolant Loss - Internal symptom
tree.
Is the engine symptom Excessive White 2D-1

Smoke and the engine is using coolant?
NO
STEP 2D-1: Excessive white smoke.

Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom Excessive White Perform the
n/a Smoke and the engine is not using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
Is the engine symptom Excessive White 2E

Smoke and the engine is not using coolant?
NO
STEP 2E: Engine speed surge or engine speed unstable.

Condition:
n/a
Interview the driver and verify the complaint. Is the engine symptom Engine Speed Surge Perform the
n/a or Engine Speed Unstable? troubleshooti
YES ng steps
suggested in
Repair: the repair
Checks
• Step 8 - Electronics Checks
Is the engine symptom Engine Speed Surge 2F

or Engine Speed Unstable?
NO
STEP 2F: Engine will not start or difficult to start.

Condition:
None
Interview the driver to verify the complaint. Is the symptom Engine Difficult to Start or Perform the
n/a Will Not Start? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the steps that pertain to difficult to procedure
start or will not start concerns per the
troubleshooting steps in the recommended
order listed below:
• Step 3 - No Start Checks
• Check the engine base timing. Use the
following procedure in the Signature™,
ISX, and QSX15 Service Manual, Bulletin
3666239. Refer to Procedure 001-088 in
Section 1.
Is the symptom Engine Difficult to Start or 2G

Will Not Start?
NO
STEP 2G: Engine stalls or shuts off unexpectedly.

Condition:
None
Interview the driver to verify the complaint. Is the symptom Engine Stalls or Shuts Off Perform the
n/a Unexpectedly? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the steps that pertain to stalls or procedure
shuts off unexpectedly per the
troubleshooting steps in the recommended
order listed below:
Is the symptom Engine Stalls or Shuts Off 2H

Unexpectedly?
NO
STEP 2H: Engine run on, or will not shut down

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Engine Run On or Perform the
Slow to Shut Down after operated at high idle troubleshooti
n/a
for 1 minute then keyed OFF? ng steps
YES suggested in
the repair
Repair: procedure
Perform the troubleshooting steps in the
Is the engine symptom Engine Run On or Return to the

Slow to Shut Down after operated at high idle appropriate
for 1 minute then keyed OFF? symptom
NO tree

STEP 3A: Verify the fuel system has been primed.
Condition:
• Turn keyswitch OFF.
If entering this tree after a component has been Has the fuel system been properly primed? 3B
replaced in the fuel system, or after the engine YES
was run out of fuel, verify the fuel system has
been properly primed before proceeding.
• Verify the fuel system has been properly Has the fuel system been properly primed? Repair
primed. NO complete
• Use the following procedure for fuel system
Repair:
priming information found in the Signature™,
ISX, and QSX15, Service Manual, Bulletin Prime the fuel system.
3666239. Refer to Procedure 006-015 in • Use the following procedure for fuel
Section 6. system priming information found in the
Signature™, ISX, and QSX15, Service
Manual, Bulletin 3666239. Refer to
STEP 3B: Check fuel shutoff valve voltage.

Condition:
Measure the voltage from the fuel shutoff valve Is the fuel shutoff valve voltage greater than 3C
post to engine block ground. 11-VDC?
n/a YES
Is the fuel shutoff valve voltage greater than 3B-1

11-VDC?
NO
STEP 3B-1: Check ECM keyswitch voltage.

Condition:
• Disconnect the OEM harness from the ECM.
Measure the voltage from the keyswitch input Is the keyswitch voltage equal to battery 3B-2
SIGNAL wire of the OEM harness to engine block voltage?
ground. YES
n/a
Is the keyswitch voltage equal to battery Repair
voltage? complete
NO
Repair:
Repair or replace the OEM power harness,
keyswitch, or check the battery connections.
Use the following procedure in the
Electronic Control System Signature™ and
ISX Engines, Bulletin 4021334. Refer to
STEP 3B-2: Check the fuel shutoff valve wire.

Condition:
• Disconnect the engine harness from the ECM.
• Disconnect the fuel shutoff valve wire from the valve terminal post.
Measure the resistance from the fuel shutoff Less than 10 ohms? 3B-3
valve SIGNAL pin in the ECM connector to the YES
fuel shutoff valve eyelet.
Use the circuit diagram or wiring diagram for Less than 10 ohms? Repair
connector pin identification. complete
NO
Use the following procedure for general
resistance measurement techniques. Use the Repair:
following procedure in the Troubleshooting and Repair or replace the engine harness.
Repair Manual, CM870 Electronic Control
System Signature™ and ISX Engines, Bulletin Use the following procedure in the
4021334.Refer to Procedure 019-360 in Section Troubleshooting and Repair Manual, CM870
19.
ISX Engines, Bulletin 4021334.Refer to
STEP 3B-3: Check the ECM power and ground.

Condition:
• Disconnect the ECM power supply connector from the ECM.
Measure the voltage from the ECM battery Is the ECM battery supply voltage equal to Repair
SUPPLY (-) to the ECM battery SUPPLY (+) pins the battery voltage? complete
in the ECM power harness connector. YES
n/a Repair:
Call for authorization to replace the ECM.
Upon receipt of authorization, replace the
ECM. Use the following procedure in the
ISX Engines, Bulletin 4021334.Refer to
Is the ECM battery supply voltage equal to Repair

the battery voltage? complete
NO
Repair:
Repair or replace the ECM power harness.
STEP 3C: Check fuel shutoff valve resistance.

Condition:
• Disconnect fuel shutoff valve SIGNAL wire from the fuel shutoff solenoid.
• Fuel shutoff valve temperature between 20°C [68°F] and 25°C [78°F].
Measure the resistance from the fuel shutoff Is the fuel shutoff solenoid resistance: 3D
solenoid post to engine block ground. • 1 to 5 ohms for 6-VDC solenoids
The fuel shutoff solenoid must be between 20°C • 6 to 15 ohms for 12-VDC solenoids
[68°F] and 25°C [78°F] before using the • 24 to 50 ohms for 24-VDC solenoids
resistance specifications listed. • 42 to 80 ohms for 32-VDC solenoids
• 46 to 87 ohms for 36-VDC solenoids
• 645 to 735 ohms for 115-VAC solenoids?
YES
Is the fuel shutoff solenoid resistance: Repair

• 1 to 5 ohms for 6-VDC solenoids complete
NO
Repair:
Replace the fuel shutoff solenoid. Use the
following procedure in the Troubleshooting
and Repair Manual, CM870 Electronic
Control System Signature™ and ISX Engines,
Bulletin 4021334.Refer to Procedure 019-050
in Section 19.
STEP 3D: Check fuel shutoff valve actuator.

Condition:
• Remove the fuel shutoff valve solenoid, valve disc, valve seat, and actuator.
Check the valve disc, valve seat, and actuator Debris or damage found on the valve disc, Repair
disc for dirt, metal debris, bonding separation, valve seat, or actuator disc? complete
corrosion, cracks, or wear. YES
n/a Repair:
Replace the damaged fuel shutoff valve
component. Use the following procedure in
CM870 Electronic Control System
Signature™ and ISX Engines, Bulletin
Section 19.
Debris or damage found on the valve disc, 3E

valve seat, or actuator disc?
NO
STEP 3E: Check for correct priming pump operation, if equipped.

Condition:
• Assemble fuel shutoff valve components.
Listen for lift pump operation after the keyswitch Does the lift pump operate after turning the 3E-1
is turned to the ON position. keyswitch ON?
Not all ISX engines use a priming pump and YES
not all priming pumps actuate at keyswitch ON.
Understand which system is present on this Does the lift pump operate after turning the Repair
engine before beginning this step. keyswitch ON? complete
NO
Repair:
Check or replace the lift pump. Use the
following procedure in the Signature™, ISX,
and QSX15 Service Manual, Bulletin
Section 5.
STEP 3E-1: Check priming pump pressure.

Condition:
Measure the priming pressure at the quick Does pump pressure meet the 69 kPa [10 psi] 3F
connect fitting located on the top of the specification?
integrated fuel system module (IFSM). YES
Use the following procedure in the Signature™,
ISX, and QSX15 Service Manual, Bulletin Does pump pressure meet the 69 kPa [10 psi] Repair
3666239. Refer to Procedure 005-045 in Section specification? complete
5.
NO
Repair:
Replace the lift pump.
Signature™ ISX, and QSX15 Service Manual,
Bulletin 3666239. Refer to Procedure
STEP 3F: Check for coolant in the EGR transfer tube.

Condition:
Remove the EGR transfer hose from the EGR Is coolant present in the crossover tube? Repair
cooler outlet. YES complete
n/a Repair:
See the Coolant Loss - Internal symptom
tree.
Is coolant present in the crossover tube? 2A

NO
Repair:
Perform the next troubleshooting procedure
as outlined in Step 2

Condition:
If entering this tree after a component has been Has the fuel system been properly primed? 4B
replaced in the fuel system, or after the engine YES
has been run out of fuel, verify the fuel system
has been properly primed before proceeding.
• Verify the fuel system has been properly Has the fuel system been properly primed? repair
primed. NO complete
Repair:
priming information found in the Signature™,
ISX, and QSX15, Service Manual, Bulletin Prime the fuel system.
3666239. Refer to Procedure 006-015 in • Use the following procedure for fuel
Section 6. system priming information found in the
Signature™, ISX, and QSX15, Service
STEP 4B: Check for air in the fuel.

Condition:
• Operate engine at low idle (engine cranking if troubleshooting No-Start).
Connect the equipment to the quick-connect Are air bubbles visible in the coil of clear Repair
fitting at the fuel module as shown. tubing? complete
• Put a coil in the clear hose. YES
• Put the end of the clear hose in a clean
container. Repair:
• Operate the engine at low idle with no load. Locate and correct the cause of air ingestion
• Slightly open the valve until a steady stream of in the OEM fuel supply system or damaged
fuel is visible. suction-side fuel filter sealing ring.
With EGR:
Check the ECM cooling plate, associated
plumbing, and o-ring seals for failures that
can cause air ingestion. Repair or replace the
malfunctioning component. Use the following
procedure in the Signature™, ISX, and
QSX15 Service Manual, Bulletin 3666239.
Air bubbles visible in the coil of clear tubing? 4C

NO
STEP 4C: Check fuel inlet restriction.

Condition:
• Connect vacuum gauge to the suction side Compuchek™ fitting.
• Operate engine at high idle (engine cranking if troubleshooting No-Start).
If the engine uses a priming pump, wait until after Is fuel inlet restriction less than the 4D
the priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. Dirty - 305 mm-Hg [12 in-Hg]; New - 203 mm-
Check the fuel inlet restriction. Hg [8 in-Hg]
Use the following procedure in the Signature™, YES
3666239. Refer to Procedure 006-020 n Section Is fuel inlet restriction less than the Repair
6. specifications listed below? complete
Dirty - 305 mm-Hg [12 in-Hg]; New - 203 mm-
Hg [8 in-Hg]
NO
Repair:
Locate the cause of high fuel inlet restriction.
Check the suction-side fuel filter and fuel
supply lines.
For QSX15 only, check the 300 micron inlet
filter screen for debris. Use the following
STEP 4D: Check drain line restriction.

Condition:
• Connect pressure gauge, Part Number 3375278.
• Operate engine at high idle (engine cranking if troubleshooting No-Start).
Observe reading on the pressure gauge. Is fuel drain line restriction less than 229 mm- 4E
Hg [9 in-Hg]?
n/a
YES
Is fuel drain line restriction less than 229 mm- Repair

Hg [9 in-Hg]? complete
NO
Repair:
Locate cause of high fuel drain line restriction
in OEM fuel return line.
STEP 4E: Check rail fuel pressure.

Condition:
• Connect pressure gauge, Part Number 3375932, on the Compuchek™ fitting (as shown)
• Operate engine at low idle (engine cranking if troubleshooting No-Start).
Read the rail fuel pressure at low idle and high Does the rail fuel pressure meet the Perform the
idle. specification? next
Read the rail fuel pressure while cranking if the YES troubleshooti
ng procedure
engine will not start.
as outlined in
• Cranking: greater than 689 kPa [100 psi] at Step 2
130 rpm for at least 10 seconds.
• Low idle: 1689 to 1889 kPa [245 to 274 psi] at
Does the rail fuel pressure meet the 4E-2
600 rpm.
specification?
• High idle: 1896 to 2068 kPa [275 to 325 psi] at With EGR
1800 rpm. NO 4E-1
With EGR Repair:
• Cranking: greater than 689 kPa [100 psi] at When cranking, make sure the fuel system is
130 rpm for at least 10 seconds. primed for at least 30 seconds.
600 rpm.
• High idle: 1896 to 2068 kPa [275 to 325 psi] at
1800 rpm.
STEP 4E-1: Check the pressure side fuel filter restriction.

Condition:
• Connect pressure gauge, Part Number 3375932, on the rail fuel pressure Compuchek™ fitting.
• Connect pressure gauge, Part Number 3375932, on the gear pump output pressure Compuchek™ fitting.
• Operate engine at high idle (engine cranking if troubleshooting no-start).
Read the fuel pressure drop across the pressure Is the pressure side fuel filter pressure drop 4E-2
side fuel filter at high idle or while cranking if the less than 517 kPa [75 psi]?
engine will not start. YES
n/a
Is the pressure side fuel filter pressure drop Repair
less than 517 kPa [75 psi]? complete
NO
Repair:
Replace the pressure side fuel filter. Use the
Section 6.
STEP 4E-2: Check 1724 kPa [250 psi] pressure regulator.

Condition:
Turn keyswitch OFF.
Remove the 1724-kPa [250-psi] fuel pressure Is the 1724 kPa [250 psi] pressure regulator 4E-3
regulator. free of debris or damage?
• Inspect for debris or damage or incomplete YES
sealing of the regulator.
Is the 1724 kPa [250 psi] pressure regulator Repair
free of debris or damage? complete
NO
Repair:
Replace 1724 kPa [250 psi] regulator.
Signature™, ISX, and QSX15 Service
STEP 4E-3: Check 2206 kPa [320 psi] or 2620 kPa [380 psi] pressure regulator.
Condition:
Turn keyswitch OFF.
Remove the 2206 kPa [320 psi] fuel pressure Is the pressure regulator free of debris or Repair
regulator. damage? complete
Inspect for debris, damage, or incomplete YES
sealing of the regulator. Repair:
With EGR Replace the fuel pump.
Remove the 2620 kPa [380 psi] fuel pressure Use the following procedure in the
regulator. Signature™, ISX, and QSX15 Service
Inspect for debris, damage, or incomplete Manual, Bulletin 3666239. Refer to
sealing of the regulator. Procedure 005-016 in Section 5.
Is the pressure regulator free of debris or Repair

damage? complete
NO
Repair:
Replace the 2206 kPa [320 psi] regulator.
With EGR
Replace the 2620 kPa [380 psi] regulator.

STEP 5A: Perform the injector check valve leak test.
Condition:
• None
Perform the injector check valve leak test to Did the injector leak test detect a leaking Repair
check for internal injector check valve damage. injector? complete
ISX, and QSX15 Service Manual, Bulletin Repair:
3666239. Refer to Procedure 006-026 in Section
6. Replace the leaking injector. Use the
INSITE™ electronic service tool Injector Check and QSX15 Service Manual, Bulletin
Valve Diagnostics Test can be used as an initial 3666239. Refer to Procedure 006-026 in
test before performing the mechanical check Section 6.
outlined in Procedure 006-026 in Section 6. If
INSITE™ electronic service tool does not detect
a failed injector, perform the injector leak test. Did the injector leak test detect a leaking 5B
Use the following procedure in the Signature™, injector?
ISX, and QSX15 Service Manual, Bulletin NO
6.
STEP 5B: Perform INSITE™ electronic service tool Cylinder Performance Test.
Condition:
• Troubleshoot any active fault codes before performing the test.
• Engine coolant temperature must be greater than 83°C [180°F].
• Operate engine at idle.
Perform INSITE™ electronic service tool Cylinder Does performing INSITE™ electronic service 5C-3
Performance Test. tool Cylinder Performance Test identify a
ISX Signature™:
YES
• There is a horizontal bar graph for each
cylinder that is color coded based on current
contribution state. The bar will be Blue for Does performing INSITE™ electronic service 5B-1
acceptable/pass contribution. The bar will be tool Cylinder Performance Test identify a
Red for unacceptable/fail contribution, either single malfunctioning injector?
Low or High. Monitor the display to see if NO
cylinders or banks drop out during a 2 minute
window. A cylinder can switch from pass to fail
and back to pass quickly, so monitor the
screen closely.
ISX CM870:
• During the initial 30 seconds of the Cylinder
Performance Test, INSITE™ electronic service
tool is checking to make sure all parameters
have been met to enter the test.
• Once the initial Pass or Fail reading is
displayed, the test is live for the next 2
minutes. Monitor the display to see if cylinders
or banks drop out during this 2 minute window.
A cylinder can switch from pass to fail and
back to pass quickly, so monitor the screen
closely.
STEP 5B-1: Perform INSITE™ electronic service tool Cylinder Performance Test at 600 rpm.
Condition:
• Operate engine at 600 rpm idle.
Skip this step and move on to step 5B-2 if the rpm Does performing INSITE™ electronic service 5C-3
value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Adjust the low speed to 600 rpm and perform the
INSITE™ electronic service tool Cylinder YES
Performance Test.
ISX Signature™: Does performing INSITE™ electronic service 5B-2
tool Cylinder Performance Test identify a
• There is a horizontal bar graph for each single malfunctioning injector?
contribution state. The bar will be Blue for NO
acceptable/pass contribution. The bar will be
Red for unacceptable/fail contribution, either
Low or High. Monitor the display to see if
screen closely.
ISX CM870:
closely.
Condition:
The idle speed may need to be adjusted to perform this test. Toggle the cruise control increment/decrement switch
to see if the idle speed can be adjusted. If not, use INSITE™ electronic service tool to either enable the Adjustable
Low Idle Speed feature or adjust the Low Idle Speed.
Skip this step and move on to step 5B-3 if the Does performing INSITE™ electronic service 5C-3
RPM value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Performance Test.
ISX Signature™: Does performing INSITE™ electronic service 5B-3
• There is a horizontal bar graph for each
screen closely.
ISX CM870:
closely.
Condition:
to see if the idle speed can be adjusted. If not, use INSITE™ electronic service tool to either enable the "Adjustable
Low Idle Speed" feature or adjust the Low Idle Speed.
Skip this step and move on to step 5C if the rpm Does performing INSITE™ electronic service 5C-3
value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Performance Test.
ISX Signature™: Does performing INSITE™ electronic service 5C
• There is a horizontal bar graph for each single malfunctioning injector?
screen closely.
ISX CM870:
closely.
STEP 5C: Perform INSITE™ electronic service tool Cylinder Cutout Test
Condition:
• Turn air conditioning OFF.
• Turn fan OFF.
• Disable any electrical loads.
• Operate the engine at the idle speed at which the misfire is present.
Perform INSITE™ electronic service tool cylinder Do all cylinders pass the cylinder cutout test? 5C-1
cutout test. YES
A failing cylinder will have no effect on engine
sound and operation when cut out using this test. Do all cylinders pass the cylinder cutout test? 5C-3
NO
STEP 5C-1: Perform INSITE™ electronic service tool cylinder cutout test on individual injector banks.
Condition:
• Turn fan OFF.
Perform the INSITE™ electronic service tool Can a malfunctioning bank of injectors be 5D
cylinder cutout test. isolated by operating the engine on either
• Operate the engine on the front bank of bank of injectors?
injectors identified by the cylinder cutout test YES
by disabling the rear three cylinders 4, 5, 6
cylinders with INSITE™ electronic service tool.
• Operate the engine on the rear bank of Can a malfunctioning bank of injectors be 5C-2
injectors identified by the Cylinder isolated by operating the engine on either
Performance Test by disabling the front three bank of injectors?
cylinders (1,2,3) with INSITE™ electronic NO
service tool.
• To disable one bank of cylinders with INSITE™
electronic service tool, click on the cylinder
numbers associated with that bank. The front
bank consists of cylinders 1, 2, and 3 and the
rear bank is cylinders 4, 5, and 6.
• A malfunctioning bank of injectors will cause
the engine to run poorly when the opposite
bank is cut out using this test.
STEP 5C-2: Perform INSITE™ electronic service tool Cylinder Cutout Test single cylinder operation.
Condition:
• Turn fan OFF.
Perform the INSITE™ electronic service tool Can a malfunctioning injector be isolated by 5C-3
cylinder cutout test. operating the engine on a single injector?
Operate the engine on the cylinder identified by YES
the Cylinder Performance Test by disabling 5
cylinders with INSITE™ electronic service tool Can a malfunctioning injector be isolated by 5D
and only operating on the suspect cylinder. operating the engine on a single injector?
To disable 5 cylinders with INSITE™ electronic NO
service tool, click on the cylinder numbers until
only 1 cylinder is enabled.
The engine should roughly maintain idle speed
when operating on a single cylinder. A weak or
misfiring cylinder will be detected if the engine
dies or can not maintain idle speed when
operating on a single cylinder.
Continue testing all 6 cylinders by operating the
engine on each individual injector.
If the engine will not run on 1 cylinder regardless
of the cylinder selected, increase the idle RPM
and retest.
Do not run the engine on 1 cylinder for an
extended period of time.
STEP 5C-3: Verify overhead adjustments are correct for the suspected malfunctioning injector.
Condition:
• Remove the rocker lever cover. Use the following procedure in the Signature™, ISX, and QSX15 Service Manual,
Bulletin 3666239. Refer to Procedure 003-011 in Section 3.
Measure the overhead settings for the suspected Are the overhead settings within the reset Repair
malfunctioning injector. limits outlined in Procedure 003-004 in complete
• Check the valve lash and injector pre-load Section 3?
torque before replacing the injector. YES
• Use the following procedure in the Signature™,
3666239. Refer to Procedure 003-004 in Replace the malfunctioning injector.
Section 3.
Are the overhead settings within the reset 5B

limits outlined in Procedure 003-004 in
Section 3?
NO
Repair:
Adjust the overhead settings.
Perform the Cylinder Performance Test to
determine if a misfire still exists after
adjusting the overhead settings.
STEP 5D: Swap the front and rear metering actuators.

Condition:
• Disconnect the engine harness from the timing and metering actuators.
Swap the front and rear metering actuator to Did the cylinder performance test find a Repair
determine if the failed bank of cylinders follows a malfunctioning bank? complete
specific metering actuator. YES
• Use the following procedure in the
Troubleshooting and Repair Manual, CM870 Repair:
Electronic Control System Signature™ and ISX Replace the malfunctioning metering
Engines, Bulletin 4021334.Refer to Procedure actuator. Use the following procedure in the
019-110 in Section 19. Troubleshooting and Repair Manual, CM870
• Perform INSITE™ electronic service tool Electronic Control System Signature™ and
Cylinder Performance Test. ISX Engines, Bulletin 4021334.
• Refer to Procedure 019-110 in Section 19.
Did the cylinder performance test find a 5E

malfunctioning bank?
NO
STEP 5E: Swap the front and rear timing actuators.

Condition:
Swap the front and rear timing actuator to Does the malfunctioning bank follow the Repair
determine if the failed bank of cylinders follows a timing actuator? Complete
specific timing actuator. YES
Troubleshooting and Repair Manual, CM870 Repair:
Electronic Control System Signature™ and ISX Replace the timing actuator. Use the
Engines, Bulletin 4021334. Refer to Procedure following procedure in the Troubleshooting
019-111 in Section 19. and Repair Manual, CM870 Electronic
• Perform INSITE™ electronic service tool Control System Signature™ and ISX Engines,
Cylinder Performance Test. Bulletin 4021334. Refer to Procedure
Does the malfunctioning bank follow the Perform the

timing actuator? next
NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 6A: Start the engine and read the fault codes.
Condition:
• Connect INSITE™ electronic service tool electronic service tool.
• Operate the engine at low idle.
Check the fault codes with the engine running. Active fault codes? Go to
• Use INSITE™ electronic service tool to read the YES appropriate
fault codes. fault code
troubleshooti
ng tree
Active fault codes? 6B

NO
STEP 6B: Check the air intake system for leaks.

Condition:
n/a
Check the air intake system for leaks. Leaks found? Repair
YES complete
10. Replace the damaged component.
On engines equipped with a turbocharged air
compressor, one often overlooked item as a Leaks found? 6C
source of air leaks is the air compressor intake NO
line. The intake line supplies intake air from the
intake of the engine to the air compressor.
STEP 6C: Check air intake restriction.

Condition:
• Operate the engine at advertised horsepower and rpm.
Check the intake system restriction by installing Restriction greater than 635 mm-H2O [25 in- Repair
a vacuum gauge or water manometer into the air H2O] for a used air filter or 254 mm-H2O [10 complete
intake system. in-H2O] for a new filter?
3666239. Refer to Procedure 010-031 in Section Repair:
10. Correct the cause of high intake air
restriction.
Check for plugged air filter or restricted air
intake piping.
Restriction greater than 635 mm-H2O [25 in- 6D

H2O] for a used air filter or 254 mm-H2O [10
in-H2O] for a new filter?
NO
STEP 6D: Inspect the charge-air cooler.

Condition:
• Engine OFF.
Inspect the charge-air cooler for cleanliness, Problems found with the charge-air cooler? Repair
cracks, holes, or other damage. YES complete
• If the initial inspection does not identify a
problem, pressure test the charge air cooler. Repair:
Use the following procedure in the Signature™, Repair or replace the charger-air cooler.
ISX, and QSX15 Service Manual, Bulletin Refer to the OEM service manual.
Section 10.
Problems found with the charge-air cooler? 6E
The pressure test can be used to verify charge-
NO
air cooler problems.
STEP 6E: Check the exhaust restriction.

Condition:
• Install a pressure gauge into the exhaust system.
• Operate the engine at advertised horsepower and rpm.
Check exhaust restriction by installing a pressure Restriction between 518 mm-H2O [20.4 in- 6F
gauge into the exhaust system just past the H2O] or 38 mm-Hg [1.5 in-Hg] and 1036 mm-
turbocharger outlet. H2O [40.8 in-H2O] or 76 mm-Hg [3.0 in-Hg]?
11. Restriction between 518 mm-H2O [20.4 in- Repair
H2O] or 38 mm-Hg [1.5 in-Hg] and 1036 mm- complete
H2O [40.8 in-H2O] or 76 mm-Hg [3.0 in-Hg]?
NO
Repair:
Repair the exhaust system for the source of
the high restriction.
STEP 6F: Inspect the turbocharger blades for damage.

Condition:
• Engine OFF.
• Remove intake and exhaust connections for turbocharger.
Inspect the compressor and turbine blades for Damage found on turbocharger blades? Repair
damage or wear. YES complete
n/a Repair:
Replace the turbocharger.
Damage found on turbocharger blades? 6G

NO
STEP 6G: Determination of turbocharger type.

Condition:
n/a
Determine if the turbocharger is a wastegated or Is the turbocharger a variable geometry 6H

variable geometry turbocharger. turbocharger?
n/a YES
Is the turbocharger a variable geometry 6J

turbocharger?
NO
STEP 6H: Check the variable geometry actuator rod for correct travel.
Condition:
• Engine OFF.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
• Use a straight edge steel ruler.
• Retract and extend the turbocharger actuator at least 10 times.
Use INSITE™ electronic service tool to start the Does the turbocharger actuator rod extend 6I
Turbocharger Actuator Test. between 10 and 12 mm [0.394 and 0.472 in]?
• Adjust the delay timer in the Turbocharger YES
Actuator Test so that the rod movement can be
observed.
• Select the Retract Actuator position with Does the turbocharger actuator rod extend 6H-1
INSITE™ electronic service tool. between 10 and 12 mm [0.394 and 0.472 in]?
• Mark or scribe the VG actuator rod at the base NO
of the actuator.
• Select the Extend Actuator position with
INSITE™ electronic service tool.
• Measure the rod travel by measuring the
distance from the base of the turbocharger
actuator to the scribe mark.
• Use a straight edge steel ruler.
• Retract and extend the turbocharger actuator
at least 10 times.
The turbocharger actuator will move quickly and
crisply. If the actuator rod movement is slow,
there could be a problem with the air supply, a
faulty ground connection on the engine or
chassis, or mechanical problems with the
variable geometry turbocharger assembly.
STEP 6H-1: Check for air leaks and inspect air lines.
Condition:
• Engine OFF.
Use INSITE™ electronic service tool to perform Air leaks found in the system? Repair
the Turbocharger Actuator Test. YES complete
Select the Extend Actuator position. Listen for air Repair:
leaks at the following components:
Repair air leaks.
• Turbocharger control valve
• Turbocharger control shutoff valve inlet
connection Air leaks found in the system? 6H-2
• Turbocharger control shutoff valve outlet NO
connection
• Turbocharger control valve inlet connection
• Turbocharger control valve outlet connection
• Turbocharger actuator inlet connection
• Turbocharger actuator.
• All air lines including the OEM supply line to
the turbocharger control shutoff valve,
turbocharger control shutoff valve to
turbocharger control valve, and turbocharger
control valve to turbocharger actuator
A small amount of air could possibly be heard
escaping from the turbocharger control valve
during the turbocharger actuator test. This is a
normal condition for the valve to achieve output
regulation pressure. Do not replace the
turbocharger control valve for this condition.
STEP 6H-2: Check the engine and vehicle grounds.

Condition:
Check for a loose or corroded engine, chassis, or Connections tight and corrosion-free? 6H-3
battery ground connection. YES
• Check the engine ground connection.
• Check the chassis ground connections.
• Check the battery terminal connections. Connections tight and corrosion-free? Repair
NO complete
Repair:
Tighten the connections.
• Tighten the loose connections and clean
the terminals. Refer to the OEM service
manual.
STEP 6H-3: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
Use INSITE™ electronic service tool to perform Is vehicle air tank pressure present at the 6H-4
the Turbocharger Actutator Test. Select the turbocharger control valve outlet?
Retract Actuator position. YES
Remove the air line connection at the outlet of the
turbocharger control valve. Is vehicle air tank pressure present at the 6H-6
Install an M12 Compuchek™ fitting at the outlet turbocharger control valve outlet?
of the turbocharger control valve. NO
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi].
Use INSITE™ electronic service tool to perform
the Turbocharger Actuator Test. Select the
Extend Actuator position.
STEP 6H-4: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
Use INSITE™ electronic service tool to perform Does the pressure gauge read more than 103 Repair
the Turbocharger Actuator Test. Select the kPa [15 psi] after 5 minutes? complete
Retract Actuator position. YES
• Remove the air line connection at the outlet of
the turbocharger control valve. Repair:
• Install an M12 Compuchek™ fitting at the outlet Replace the turbocharger control valve.
of the turbocharger control valve.
• Install an air pressure gauge that is capable of Use the following procedure in the
reading at least 1034 kPa [150 psi]. Troubleshooting and Repair Manual, CM870
ISX Engines, Bulletin 4021334 or reference
the OEM service manual. Refer to Procedure
Does the pressure gauge read more than 103 6H-5

kPa [15 psi] after 5 minutes?
NO
STEP 6H-5: Check for correct turbocharger actuator travel.

Condition:
• Engine OFF.
Damage to the turbocharger can result if the Does the turbocharger actuator rod travel at Repair
proper removal procedure is not followed. least 12 mm [0.472 in]? complete
Remove the variable geometry actuator from the YES
turbocharger. Use the following procedure in the Repair:
Signature™, ISX, and QSX15 Service Manual,
Bulletin 3666239. Refer to Procedure 010-113 in Replace the turbocharger assembly.
Section 10. Use the following procedure in the
Use INSITE™ electronic service tool to perform Signature™, ISX, and QSX15 Service
the Turbocharger Actuator Test. Manual, Bulletin 3666239. Refer to
• Select the Extend Actuator position.
Does the turbocharger actuator rod travel at Repair
least 12 mm [0.472 in]? complete
NO
Repair:
Replace the turbocharger actuator.
STEP 6H-6: Check for air pressure at the turbocharger control shutoff valve outlet.
Condition:
• Engine OFF.
Use INSITE™ electronic service tool to perform Can air be heard escaping from the Repair
the Turbocharger Actuator Test. turbocharger control shutoff valve outlet? complete
• Select the Extend Actuator position. YES
• Loosen the air line connection at the
turbocharger control shutoff valve outlet. Repair:
Replace the turbocharger control valve.
Can air be heard escaping from the 6H-7

turbocharger control shutoff valve outlet?
NO
STEP 6H-7: Check for air pressure at the turbocharger control shutoff valve inlet.
Condition:
• Engine OFF.
Verify the OEM air supply line is connected to the Can air be heard escaping from the 6H-8
correct port on the turbocharger control shutoff turbocharger control shutoff valve inlet?
valve. YES
• Loosen the air line connection at the
turbocharger control shutoff valve inlet.
Can air be heard escaping from the Repair
turbocharger control shutoff valve inlet? complete
NO
Repair:
Repair the air supply from the OEM air tanks.
STEP 6H-8: Check for plugged turbocharger control shutoff valve filter.
Condition:
• Remove the turbocharger control shutoff valve filter.
Use INSITE™ electronic service tool to perform Is an air leak present at the turbocharger Repair
the Turbocharger Actuator Test. control shutoff valve filter head? complete
• Select the Extend Actuator position. YES
• Listen for an air leak at the turbocharger
control shutoff valve filter head. Repair:
Replace the turbocharger control shutoff
valve filter.
Is an air leak present at the turbocharger Repair

control shutoff valve filter head? complete
NO
Repair:
valve.
STEP 6I: Perform INSITE™ Electronic Service Tool EGR Valve/Turbocharger Operational Test.
Condition:
• Start the engine and run at low idle.
Use INSITE™ electronic service tool to select the Does the Turbocharger Operational Test Perform the
EGR/VGT Operational Test . pass? next
YES troubleshooti
Prior to operating INSITE™ electronic service tool
ng procedure
EGR Valve and EGR Valve/Turbocharger
Operational Test, the ECM Calibration Software as outlined in
Phase can possibly need to be updated to the Step 2
latest Software Phase. The ECM Calibration
Phase Software can be checked in INSITE™ Does the Turbocharger Operational Test 6I-1
electronic service tool, under 'Features and pass?
Parameters'. Expand the selection for 'System NO
ID and Dataplate' and go to 'Calibration
Information'. If the Software Phase is earlier than
shown below, calibrate the ECM, use the January
2006 INCAL™ CD-ROM, or later. Engines with the
Software Phase listed below or later do not
require a calibration.
ISX engines with CM870 (engines built after
January 2004) require Software Phase
06050302.
ISX engines with CM870 (engines built before
January 2004) require no changes at this time.
• Choose the Turbocharger actuator option
under Test Choices.
STEP 6I-1: Check the engine and vehicle grounds.

Condition:
Check for a loose or corroded engine, chassis, or Connections tight and corrosion-free? Repair
battery ground connection. YES complete
• Check the engine ground connection.
• Check the chassis ground connections. Repair:
• Check the battery terminal connections. Replace the variable geometry turbocharger.
Connections tight and corrosion-free? Repair

NO complete
Repair:
Tighten the connections.
• Tighten the loose connections and clean
the terminals. Refer to the OEM service
manual.
STEP 6J: Inspect the wastegate actuator hose.

Condition:
• Engine OFF.
• Remove turbocharger if wastegate actuator is inaccessible.
Inspect the integral wastegate actuator hose for Holes or cracks found in the wastegate Repair
cracks or holes. actuator hose? complete
n/a YES
Repair:
Replace wastegate actuator hose.
Holes or cracks found in the wastegate 6K

actuator hose?
NO
STEP 6K: Inspect the wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the wastegate actuator hose from the wastegate actuator.
Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? 6L
to the actuator and check for actuator movement. YES
n/a
Does the wastegate actuator rod move? 6K-1
NO
STEP 6K-1: Inspect wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the e-clip from the wastegate pin and disconnect the actuator rod.
Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? Repair
to the actuator and check for actuator movement. YES complete
n/a Repair:
Move the wastegate lever on the
turbocharger back and forth and check for
smooth operation. Replace turbocharger
assembly if the wastegate is seized.
Does the wastegate actuator rod move? Repair

NO complete
Repair:
Replace the wastegate actuator.
STEP 6L: Measure resistance of the four-stage wastegate controllers, if equipped.

Condition:
• Engine OFF.
• Disconnect the ring terminals from the four-stage wastegate controllers, if equipped.
Measure the resistance from the wastegate Are the wastegate controller solenoid 6M
controller post to engine block ground. resistances between 7.0 and 8.0 ohms?
The wastegate controller solenoids must be YES
between 20°C and 26°C [68°F and 79°F] before
using the resistance specifications listed. Are the wastegate controller solenoid Repair
resistances between 7.0 and 8.0 ohms? complete
NO
Repair:
Replace the damaged wastegate controller.
STEP 6M: Inspect four-stage wastegate controller, if equipped.

Condition:
• Engine OFF.
• Remove the four-stage wastegate controllers.
Check the valve disc, valve seat, and actuator Damage or debris found on the valve disc, Repair
n/a Repair:
Replace or clean damaged components.
Damage or debris found on the valve disc, Perform the

valve seat, or actuator disc? next
NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 7A: Check for air leaks in the EGR system.
Condition:
n/a
Check for leaks in the EGR connection tubing Air leaks found in the EGR connection Repair
and connections. tubing? complete
Soot streaks can be noticeable where leaks are YES
present. Repair:
Repair any leaks in the EGR system.
Air leaks found in the EGR connection 7B

tubing?
NO
STEP 7B: Check repair history.

Condition:
n/a
Check with the customer for a recent EGR valve Is there any record of the poppet head 7C
replacement. missing?
n/a YES
Repair:
Remove the exhaust manifold and run a wire
through every port to check for the missing
poppet head.
Is there any record of the poppet head 7C

missing?
NO
STEP 7C: Perform EGR Valve Test.

Condition:
Perform INSITE™ electronic service tool EGR Does the EGR Valve Test pass? Perform the
Valve Test. YES next
troubleshooti
Prior to operating INSITE™ electronic service tool
EGR Valve and EGR Valve/Turbocharger ng procedure
as outlined in
Operational Test, the ECM Calibration Software
Step 2
Phase can possibly need to be updated to the
latest Software Phase. The ECM Calibration
Phase Software can be checked in INSITE™ Does the EGR Valve Test pass? Repair
electronic service tool, under 'Features and NO complete
Parameters'. Expand the selection for 'System
ID and Dataplate' and go to 'Calibration Repair:
Information'. If the Software Phase is earlier than Replace the EGR valve.
shown below, calibrate the ECM, use the January
2006 INCAL™ CD-ROM, or later. Engines with the Use the following procedure in the
Software Phase listed below or later do not Signature™, ISX, and QSX15 Service
require a calibration. Manual, Bulletin 3666239. Refer to
ISX engines with CM870 (engines built after
January 2004) require Software Phase
06050302.
ISX engines with CM870 (engines built before
January 2004) require no changes at this time.
• Check for complete travel of the EGR valve by
selecting Open Valve and verifying the EGR
Valve opens 100 percent.

STEP 8A: Verify accelerator pedal travel.
Condition:
Use INSITE™ electronic service tool to monitor Does the Accelerator Pedal read 0 percent 8B
Accelerator Pedal while fully depressing and when the accelerator is released and 100
releasing the accelerator pedal. percent when the accelerator is depressed?
n/a YES
Does the Accelerator Pedal read 0 percent Repair

when the accelerator is released and 100 complete
percent when the accelerator is depressed?
NO
Repair:
Determine and correct the cause of
accelerator pedal restriction.
STEP 8B: Monitor vehicle speed.

Condition:
• Start the engine.
Use INSITE™ electronic service tool to monitor Does the vehicle speed read 0 when the 8C
Vehicle Speed while the vehicle is not moving. vehicle is not moving?
n/a YES
Does the vehicle speed read 0 when the Repair

vehicle is not moving? complete
NO
Repair:
Check the vehicle speed sensor and circuit
or locate the cause of the vehicle speed
interference.
STEP 8C: Verify electronic feature settings are correct.

Condition:
Use INSITE™ electronic service tool to verify the Are the electronic features set correctly? Step 8D
following adjustable parameters are correctly YES
set:
• Maximum vehicle speed
• Powertrain protection Are the electronic features set correctly? Repair
• Rear axle ratio NO complete
• Number of transmission tailshaft gear teeth
Repair:
• Tire revolutions per mile
• Gear-down protection Correct programmable features.
• Cruise control droop settings
• Cruise control maximum vehicle speed.
STEP 8D: Check the barometric pressure sensor reading.

Condition:
• Connect all components.
Check for correct barometric pressure sensor Is the barometric pressure sensor reading in Perform the
reading. INSITE™ electronic service tool within 5 next
• Compare the barometric pressure sensor percent of the present local barometric troubleshooti
reading in INSITE™ electronic service tool data pressure reading? ng procedure
monitor/logger to the present local barometric YES as outlined in
pressure. Step 2
Is the barometric pressure sensor reading in Repair

INSITE™ electronic service tool within 5 complete
percent of the present local barometric
pressure reading?
NO
Repair:
Replace the barometric pressure sensor. Use
the following procedure in the

STEP 9A: Verify overhead adjustments are correct.
Condition:
• Remove valve cover.
Measure the overhead settings. Overhead settings within the reuse limits? 9B
Valve Lash Reuse Limits: YES
• Intake valve lash: 0.102 mm [0.004 in] to 0.483
mm [0.019 in] Overhead settings within the reuse limits? Repair
• Exhaust valve lash: 0.508 mm [0.020 in] to NO complete
0.813 mm [0.032 in].
Repair:
STEP 9B: Verify engine brake adjustment.

Condition:
Verify the engine brakes are operating correctly. Engine brake settings within the reuse limits? 9C
• Measure the engine brake settings. Use the YES
and QSX15 Service Manual, Bulletin 3666239.
Refer to Procedure 020-004 in Section 20. Engine brake settings within the reuse limits? Repair
NO complete
Repair:
Adjust the engine brake settings.
STEP 9C: Measure turbocharger axial and radial clearance.

Condition:
• Engine OFF.
• Disconnect exhaust and intake connections from the turbocharger.
Measure the axial and radial clearance of the Axial and radial clearances within 9D
turbocharger. specification?
3666239. Refer to Procedure 010-033 in Section Axial and radial clearances within Repair
10. specification? complete
NO
Repair:
Replace the turbocharger assembly.
STEP 9D: Verify engine blowby is within specification.

Condition:
• Connect the appropriate orifice to the end of the blowby draft tube.
• Start engine.
Load engine to rated rpm on a chassis Engine blowby measurements within 9E

dynamometer. specification?
Measure the engine blowby. YES
ISX, and QSX15 Service Manual, Bulletin Engine blowby measurements within Repair
3666239. Refer to Procedure 014-010 in Section specification? complete
14. NO
Repair:
Engine may need to be rebuilt. See engine
rebuild specifications.
STEP 9E: Verify base engine timing is correct.

Condition:
Verify the base engine timing is correct. Base engine timing within specification? 9F
3666239. Refer to Procedure 001-088 in Section Base engine timing within specification? Repair
1. complete
NO
Repair:
Correct the base engine timing.
STEP 9F: Check for a damaged vibration damper.

Condition:
• Engine not operating.
• Turn engine OFF.
Remove and visually inspect the vibration Vibration damper damaged or out of Repair
damper. specification? complete
• Use Procedure 001-052 in the appropriate YES
service manual for vibration damper
inspection specifications. Repair:
Replace the vibration damper. Use
Procedure 001-052 in the appropriate service
manual for replacement instructions.
Vibration damper damaged or out of Perform the

specification? next
NO troubleshooti
ng procedure
as outlined in
Step 2
STEP 10: Check the EGR differential pressure sensor and exhaust gas pressure sensor
tubes.
STEP 10A: Check the EGR differential pressure tubes for cracks, restrictions, or leaks.
Condition:
Inspect the EGR differential pressure tubes for Cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the EGR differential
pressure tubes.
Cracks, restrictions, or leaks present? 10B

NO
STEP 10B: Check the exhaust gas pressure tubes for cracks, restrictions, or leaks.
Condition:
Inspect the exhaust gas pressure tubes for Cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the exhaust gas pressure
tubes.
Cracks, restrictions, or leaks present? Perform the

NO next
troubleshooti
ng procedure
as outlined in
Step 2
Engine Performance Troubleshooting Tree - ISX with CM87 [...] Signature™, ISX, and QSX15
Engine Performance Troubleshooting Tree - ISX with CM871

• Engine Acceleration or Response Poor
• Cranking Fuel Pressure is Low
• Engine Operating Fuel Pressure is Low
• Engine Difficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
• Engine Power Output Low
• Engine Runs Rough at Idle
• Engine Runs Rough or Misfires
• Engine Speed Surges at Low or High Idle
• Engine Speed Surges Under Load or in Operating Range
• Smoke, Black - Excessive
• Smoke, White - Excessive
• Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
• Engine Starts But Will Not Keep Operating
• Engine Will Not Reach Rated Speed (rpm)
• Engine Run-on or Will Not Shut Down.

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing
Step 1 troubleshooting. Step 2 asks a series of questions and will provide a list of troubleshooting steps to perform,
depending on the symptom. Perform the list of troubleshooting in the sequence shown in the Specifications/Repair
section of the tree.
Shop Talk:
Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on
QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Refer
Signature™, ISX, and QSX15 Engine Performance Troubleshooting Tree - ISX with CM87 [...]

STEP 1A: Check for active fault codes or Active fault codes or high counts
codes.
STEP 1B: Perform basic troubleshooting All steps have been verified to
checks. be correct?
STEP 1C: Perform INSITE™ electronic 'Engine Operating State' reading
service tool monitor test. a value that can cause an engine
derate?
STEP 2A: Low power, poor acceleration, Engine symptom low power,
or poor response. poor acceleration, or poor
response?
STEP 2B: Engine misfire. Engine symptom Engine
Misfires?
STEP 2C: Excessive black smoke. Engine symptom Excessive
Black Smoke?
STEP 2D: Excessive white smoke. Engine symptom Excessive
White Smoke and the engine is
using coolant?
STEP 2D-1: Excessive white smoke. Engine symptom Excessive
White Smoke and the engine is
using coolant?
STEP 2E: Engine speed surge or engine Engine symptom Engine Speed
speed unstable. Surge or Engine Speed
Unstable?
STEP 2F: Engine will not start or difficult Symptom Engine Difficult to
to start. Start or Will Not Start?
STEP 2G: Engine stalls or shuts off Symptom Engine Stalls or Shuts
unexpectedly. Off Unexpectedly?
STEP 2H: Engine run-on or will not shut Engine symptom Engine Run On
down. or Slow to Shut Down after
operated at high idle for 1 minute
then keyed off?
STEP 3A: Verify the fuel system has been Fuel system been properly
primed. primed?
STEP 3B: Check fuel shutoff valve voltage. Fuel shutoff valve voltage
greater than 11-VDC?
STEP 3B-1: Check the keyswitch Keyswitch voltage equal to
voltage. battery voltage?
STEP 3B-2: Check the fuel shutoff valve Less than 10 ohms?
wire.
STEP 3B-3: Check the ECM power and ECM battery supply voltage
ground. equal to the battery voltage?
STEP 3C: Check fuel shutoff valve Fuel shutoff solenoid resistance:
resistance. 1 to 5 ohms for 6-VDC solenoids;
6 to 15 ohms for 12-VDC

solenoids; 24 to 50 ohms for 24-
VDC solenoids; 42 to 80 ohms
for 32-VDC solenoids; 46 to 87
ohms for 36-VDC solenoids; 92
to 145 ohms for 48-VDC
solenoids; 315 to 375 ohms for
74-VDC solenoids; or 645 to 735
ohms for 115-VAC solenoids?
STEP 3D: Check the fuel shutoff valve Debris or damage found on the
actuator. valve disc, valve seat, or
actuator disc?
STEP 3E: Check for correct priming pump Lift pump operate after turning
operation, if equipped. the keyswitch ON?
STEP 3E-1: Check priming pump Pump pressure meet the 69 kPa
pressure. [10 psi] specification?
STEP 3F: Check for coolant in the EGR Coolant present in the crossover
transfer tube. tube?
STEP 4A: Verify the fuel system has been Fuel system been properly
primed. primed?
STEP 4B: Check for air in the fuel. Air bubbles visible in the coil of
clear tubing?
STEP 4C: Check the fuel inlet restriction. Fuel inlet restriction less than
the specifications listed? Dirty -
305 mm-Hg [12 in-Hg]; New - 203
mm-Hg [8 in-Hg]
STEP 4D: Check drain line restriction. Fuel drain line restriction less
than 229 mm-Hg [9 in-Hg]?
STEP 4E: Check rail fuel pressure. Rail fuel pressure meets the
specification?
STEP 4E-1: Check the pressure side fuel Pressure side fuel filter pressure
filter restriction drop less than 517 kPa [75 psi]?
STEP 4E-2: Check 1724 kPa [250 psi] 1724 kPa [250 psi] pressure
pressure regulator. regulator free of debris or
damage?
STEP 4E-3: Check 2206 kPa [320 psi] or Pressure regulator free of debris
2620 kPa [380 psi] pressure or damage?
regulator.
STEP 5A: Perform the injector check valve Injector leak test detect a leaking
leak test. injector?
STEP 5B: Perform INSITE™ electronic Performing INSITE™ electronic
service tool Cylinder service tool Cylinder
Performance Test. Performance Test isolate to a
STEP 5B-1: Perform INSITE™ electronic Performing INSITE™ electronic

STEP 5C: Perform INSITE™ electronic Cylinders pass the cylinder
service tool Cylinder Cutout cutout test?
Test.
STEP 5C-1: Perform INSITE™ electronic Malfunctioning bank of injectors
service tool Cylinder Cutout isolated by operating the engine
Test on both injector banks. on either bank of injectors?
STEP 5C-2: Perform INSITE™ electronic Malfunctioning injector isolated
service tool Cylinder Cutout by operating the engine on a
Test. single injector?
STEP 5C-3: Verify overhead Overhead settings within the
adjustments are correct for reset limits outlines in Procedure
the suspected 003-004?
STEP 5C-4: Verify overhead Overhead settings within the
adjustments are correct for reset limits outlined in
the suspected Procedure 003-004?
STEP 5D: Swap the front and rear Malfunctioning bank follow the
metering actuators. metering actuator?
STEP 5E: Swap the front and rear timing Malfunctioning bank follow the
actuators. timing actuator?
STEP 6A: Start the engine and read the Active fault codes?
fault codes.
STEP 6B: Check air intake restriction. Air intake restriction greater
than 635 mm-H2O [25 in-H2O] for
a used air filter or 254 mm-H2O
[10 in-H2O] for a new filter?
STEP 6C: Inspect charge-air cooler. Pressure drop is 34 kPa [5 psi] or
less in 15 seconds?
STEP 6D: Inspect the turbocharger blades Damage found on turbocharger
for damage. blades?
STEP 6E: Inspect the turbocharger shaft Nozzle slide evenly from stop to
movement. stop and are the gear teeth
undamaged?
STEP 7A: Check for EGR related fault EGR related fault codes present?
codes.
STEP 7B: Check for inactive EGR Fault Code 1866, 2273, or 2274
differential pressure sensor fault active?
codes.
STEP 7C: Check the EGR differential Leaks detected at either the low
pressure tubes for leaks. or high EGR differential pressure
tubes?
STEP 7D: Check the EGR differential Leaks detected at the EGR
pressure sensor adapter for differential pressure sensor
leaks. adapter?
STEP 7E: Check the EGR differential Debris or soot found in either
pressure tubes for plugging. EGR differential pressure tube?
STEP 7F: Check for air leaks in the EGR Air leaks found in the EGR
system. connection tubing?
STEP 8A: Verify accelerator pedal travel. Accelerator Pedal reads 0 when
the accelerator is released and
100 percent when the
accelerator is depressed?
STEP 8B: Monitor vehicle speed. Vehicle speed reads 0 when the
vehicle is not moving?
STEP 8C: Verify electronic feature settings Electronic features set
are correct. correctly?
STEP 8D: Check the ambient air pressure Barometric pressure sensor
sensor accuracy. reading in INSITE™ electronic
service tool within 5 percent of
the present local barometric
pressure reading?
STEP 8E: Check the intake manifold INSITE™ electronic service tool
pressure sensor accuracy. reading within 17 kPa [2.5 psi] of
mechanical gauge reading?
STEP 9A: Verify static timing adjustment Static timing adjustment
is correct. correct?
STEP 9B: Verify overhead adjustments are Overhead settings within the
correct. reset limits?
STEP 9C: Verify engine brake adjustment. Engine brake settings within the
reset limits?
STEP 9D: Verify crankshaft tone wheel is Crankshaft tone wheel loose?
not loose.
STEP 9E: Check exhaust restriction. Exhaust restriction greater than
305 mm-Hg [12.0 in-Hg]?
STEP 9F: Verify engine blowby is within Engine blowby measurements
specification. within specification?
STEP 10: Aftertreatment checks.
STEP 10A: Check for aftertreatment related Fault codes related to the
fault codes. aftertreatment system found to
be active?
STEP 10B: Perform basic aftertreatment All parts inspected and appear to
troubleshooting checks. be functioning properly?
STEP 10C: Check for signs of internal Any visible smoke (black or
damage to the aftertreatment white) present during the snap
system. throttle acceleration?
STEP 10D: Check exhaust restriction. Exhaust restriction greater than
305 mm-Hg [12.0 in-Hg]?

STEP 1A: Check for active fault codes or high counts of inactive fault codes.
Condition:
Check for active fault codes or high counts of Active fault codes or high counts of inactive Go to
inactive fault codes. fault codes? appropriate
ng tree
Active fault codes or high counts of inactive 1B

fault codes?
NO
STEP 1B: Perform basic troubleshooting checks.

Condition:
n/a
The following items must be checked or verified All steps have been verified to be correct? 1C
before continuing: YES
• Verify the fuel level in the tanks.
• Verify there have not been any changes to
CPL components on the engine. All steps have been verified to be correct? Repair
• Verify fuel grade is correct for the application. NO complete
• Verify the engine is operating within the
Repair:
recommended altitude.
• Verify engine oil is at the correct level. Correct the out-of-specification item and
• Verify engine parasitics have not changed. verify complaint is no longer present after
• Verify engine duty cycle has not changed. repair.
• Verify engine cranking speed is greater than
150 rpm.
• Verify battery voltage is within specification.
STEP 1C: Perform INSITE™ electronic service tool monitor test.

Condition:
• Connect INSITE™ electronic service tool
• Operate engine at the speed and load where the symptom occurs.
Use INSITE™ electronic service tool to monitor 'Engine Operating State' reading a value that 2A
the parameter 'Engine Operating State' at the can cause an engine derate?
same engine operating conditions where the YES
symptom occurs.
Repair:
Refer to Advanced Engine Performance
Troubleshooting Techniques, Bulletin 4021686, Determine if the engine derate is being
for a description of what "User Fueling States" or caused by normal engine operation or by an
"Engine Operating State" can cause engine actual engine failure.
derates. Continue following troubleshooting steps as
outlined in Step 2 if an engine failure is
suspected.
'Engine Operating State' reading a value that 2A

can cause an engine derate?
NO

STEP 2A: Low power, poor acceleration, or poor response.
Condition:
None
Interview the driver and verify the complaint. Engine symptom low power, poor Perform the
acceleration, or poor response? troubleshooti
n/a
YES ng steps
suggested in
Repair: the repair
• Step 7 - EGR Checks
• Step 10 - Aftertreatment Checks
• Step 8 - Electronic Checks
Engine symptom low power, poor 2B

acceleration, or poor response?
NO
STEP 2B: Engine misfire.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Engine Misfires? Perform the
n/a YES troubleshooti
ng steps
Repair: suggested in
Perform the troubleshooting steps in the the repair
recommended order listed below: procedure
• Step 7 - EGR Checks.
Engine symptom Engine Misfires? 2C

NO
STEP 2C: Excessive black smoke.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Excessive Black Smoke? Perform the
Progressive damage to the aftertreatment YES troubleshooti
ng steps
system has occurred if black smoke is visible. Repair: suggested in
Remove the exhaust aftertreatment system from
the vehicle and inspect for reuse. Use the Perform the troubleshooting steps in the the repair
recommended order listed below: procedure
following procedure in the Signature™, ISX, and
QSX15 Service Manual, Bulletin 3666239. • Step 6 - Air Handling Checks
Inspect the aftertreatment system for potential • Step 7 - EGR Checks
damage. Refer to Procedure 011-049 in Section • Step 4 - Fuel System Checks
11. • Step 5 - Injector and Actuator Diagnostics
Engine symptom Excessive Black Smoke? 2D

NO
STEP 2D: Excessive white smoke.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Excessive White Smoke Perform the
n/a and the engine is using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
• See the Coolant Loss - Internal symptom
tree.
Engine symptom Excessive White Smoke 2D-1

and the engine is using coolant?
NO
STEP 2D-1: Excessive white smoke.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Excessive White Smoke Perform the
n/a and the engine is not using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
• Step 10 - Aftertreatment Checks
Engine symptom Excessive White Smoke 2E

and the engine is not using coolant?
NO
STEP 2E: Engine speed surge or engine speed unstable.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Engine Speed Surge or Perform the
n/a Engine Speed Unstable? troubleshooti
YES ng steps
suggested in
Repair: the repair
• Step 7 - EGR Checks
Engine symptom Engine Speed Surge or 2F

Engine Speed Unstable?
NO
STEP 2F: Engine will not start or difficult to start.

Condition:
None
Interview the driver and verify the complaint. Symptom Engine Difficult to Start or Will Perform the
Not Start? troubleshooti
n/a
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps that procedure
pertain to difficult to start or will not start
concerns per the troubleshooting steps in the
• Check the engine base timing. Use the
following procedure in the Signature™,
Section 1.
Symptom Engine Difficult to Start or Will 2G

Not Start?
NO
STEP 2G: Engine stalls or shuts off unexpectedly.

Condition:
None
Interview the driver and verify the complaint. Symptom Engine Stalls or Shuts Off Perform the
n/a Unexpectedly? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps that procedure
pertain to stalls or shuts off unexpectedly per
the troubleshooting steps in the
Symptom Engine Stalls or Shuts Off 2H

Unexpectedly?
NO
STEP 2H: Engine run-on, or will not shut down.

Condition:
None
Interview the driver and verify the complaint. Engine symptom Engine Run On or Slow to Perform the
Shut Down after operated at high idle for 1 troubleshooti
n/a
minute then keyed OFF? ng steps
YES suggested in
the repair
Repair: procedure
Perform the troubleshooting steps in the
Engine symptom Engine Run On or Slow to Return to

Shut Down after operated at high idle for 1 appropriate
minute then keyed OFF? symptom
NO tree

Condition:
Verify the fuel system has been primed. Fuel system been properly primed? 3B
If entering this tree after a component has been YES
replaced in the fuel system, or after the engine
has been run out of fuel, verify the fuel system Fuel system been properly primed? Repair
has been properly primed before proceeding. complete.
NO
priming found in the Signature™, ISX, and QSX Repair:
Service Manual, Bulletin 3666239. Refer to Prime the fuel system.
• Use the following procedure for fuel
system priming found in the Signature™,
ISX, and QSX Service Manual, Bulletin
Section 6.
STEP 3B: Check fuel shutoff valve voltage.

Condition:
Measure the voltage from the fuel shutoff valve Fuel shutoff valve voltage greater than 11- 3C
post to engine block ground. VDC?
n/a YES
Fuel shutoff valve voltage greater than 11- 3B-1

VDC?
NO
STEP 3B-1: Check ECM keyswitch voltage.

Condition:
• Disconnect the OEM harness from the ECM.
Measure the voltage from the keyswitch input Keyswitch voltage equal to battery voltage? 3B-2
SIGNAL wire of the OEM harness to engine block YES
ground.
n/a Keyswitch voltage equal to battery voltage? Repair
NO complete
Repair:
Repair or replace the OEM power harness, or
keyswitch, or check the battery connections.
Use the following procedure found in the ISX
CM871 and ISM CM876 Electronic Control
System, Bulletin 4021560. Refer to
STEP 3B-2: Check the fuel shutoff valve wire.

Condition:
• Disconnect the engine harness from the ECM.
• Disconnect the fuel shutoff valve wire from the valve terminal post.
Measure the resistance from the fuel shutoff Less than 10 ohms? 3B-3
valve SIGNAL pin in the ECM connector to the YES
fuel shutoff valve eyelet.
Repair:
Use the following procedure for general
resistance measurement techniques. Use the Call for authorization to replace the ECM.
following procedure found in the ISX CM871 and Upon receipt of authorization, replace the
ISM CM876 Electronic Control System, Bulletin ECM. Use the following procedure found in
4021560. Refer to Procedure 019-360 in Section the ISX CM871 and ISM CM876 Electronic
19. Control System, Bulletin 4021560. Refer to
Less than 10 ohms? Repair

NO complete
Repair:
Repair or replace the engine harness.
STEP 3B-3: Check the ECM power and ground.

Condition:
• Disconnect the ECM power supply connector from the ECM.
Measure the voltage from the ECM battery ECM battery supply voltage equal to the Repair
SUPPLY (-) to the ECM battery SUPPLY (+) pins battery voltage? complete
in the ECM power harness connector. YES
n/a Repair:
Call for authorization to replace the ECM.
Upon receipt of authorization, replace the
ECM. Use the following procedure found in
the ISX CM871 and ISM CM876 Electronic
Control System, Bulletin 4021560. Refer to
ECM battery supply voltage equal to the Repair

battery voltage? complete
NO
STEP 3C: Check fuel shutoff valve resistance.

Condition:
• Disconnect fuel shutoff valve SIGNAL wire from the fuel shutoff solenoid.
• Be sure fuel shutoff valve temperature is between 20°C [68°F] and 25°C [78°F].
Measure the resistance from the fuel shutoff Fuel shutoff solenoid resistance: 3D
solenoid post to engine block ground. • 1 to 5 ohms for 6-VDC solenoids
The fuel shutoff solenoid must be between 20°C • 6 to 15 ohms for 12-VDC solenoids
[68°F] and 25°C [78°F] before using the • 24 to 50 ohms for 24-VDC solenoids
resistance specifications listed. • 42 to 80 ohms for 32-VDC solenoids
Use the following procedure for general • 92 to 145 ohms for 48-VDC solenoids
resistance measurement techniques. Use the • 315 to 375 ohms for 74-VDC solenoids
following procedure found in the ISX CM871 and
ISM CM876 Electronic Control System, Bulletin YES
19.
Fuel shutoff solenoid resistance: Repair
• 1 to 5 ohms for 6-VDC solenoids complete
NO
Repair:
Replace the fuel shutoff solenoid. Use the
following procedure found in the ISX CM871
and ISM CM876 Electronic Control System,
Bulletin 4021560. Refer to Procedure
STEP 3D: Check fuel shutoff valve actuator.

Condition:
• Remove the fuel shutoff valve solenoid, valve disc, valve seat, and actuator.
Check the valve disc, valve seat, and actuator Debris or damage found on the valve disc, Repair
n/a Repair:
Replace the damaged fuel shutoff valve
component. Use the following procedure
found in the ISX CM871 and ISM CM876
Electronic Control System, Bulletin 4021560.
Debris or damage found on the valve disc, 3E

NO
STEP 3E: Check for correct priming pump operation, if equipped.

Condition:
• Assemble fuel shutoff valve components.
Listen for lift pump operation after the keyswitch Lift pump operate after turning the keyswitch 3E-1
is turned to the ON position. ON or does the engine not use a priming
Not all ISX engines use a priming pump and pump?
not all priming pumps actuate at keyswitch ON. YES
Verify the type of pump system on the engine
before beginning this step. Lift pump operate after turning the keyswitch Repair
ON or does the engine not use a priming complete
pump?
NO
Repair:
Check or replace lift pump. Use the following
STEP 3E-1: Check priming pump pressure.

Condition:
Measure the priming pressure at the quick Pump pressure meet the 69 kPa [10 psi] 3F
connect fitting located on the top of the specification?
integrated fuel system module (IFSM). YES
ISX, and QSX15 Service Manual, Bulletin Pump pressure meet the 69 kPa [10 psi] Replace the
3666239. Refer to Procedure 005-045 in Section specification? lift pump.
5. Use the
NO
following
procedure in
the
Signature™,
ISX, and
QSX15
Service
Manual,
Bulletin
3666239.
Refer to
Procedure
005-045 in
Section 5.
STEP 3F: Check for coolant in the EGR transfer tube.

Condition:
Remove the EGR transfer hose from the EGR Coolant present in the crossover tube? Repair
cooler outlet. YES complete
n/a Repair:
See the Coolant Loss - Internal symptom
tree.
Coolant present in the crossover tube? 2A

NO
Repair:
Perform the next troubleshooting procedure
as outlined in Step 2

Condition:
Verify the fuel system has been primed. Fuel system been properly primed? 4B
If entering this tree after a component has been YES
replaced in the fuel system, or after the engine
has been emptied of fuel, verify the fuel system Fuel system been properly primed? Repair
has been properly primed before proceeding. complete.
NO
priming found in the Signature™, ISX, and QSX Repair:
Service Manual, Bulletin 3666239. Refer to Prime the fuel system.
• Use the following procedure for fuel
system priming found in the Signature™,
ISX, and QSX Service Manual, Bulletin
Section 6.
STEP 4B: Check for air in the fuel.

Condition:
• Operate the engine at low idle (engine cranking if troubleshooting No-Start).
Connect the equipment to the quick-connect Air bubbles visible in the coil of clear tubing? Repair
fitting at the fuel module as shown. YES complete
• Put a coil in the clear hose.
• Put the end of the clear hose in a clean Repair:
container. Locate and correct the cause of air ingestion
• Operate the engine at low idle with no load. in the OEM fuel supply system or damaged
• Slightly open the valve until a steady stream of fuel filter sealing ring.
fuel is visible.
With EGR
Check the ECM cooling plate, associated
plumbing, and o-ring seals for failures that
can cause air ingestion. Repair or replace the
malfunctioning component.
Air bubbles visible in the coil of clear tubing? 4C

NO
STEP 4C: Check fuel inlet restriction.

Condition:
• Connect a vacuum gauge to the suction side Compuchek™ fitting.
• Operate the engine at high idle (engine cranking if troubleshooting No-Start).
If the engine uses a priming pump, wait until after Fuel inlet restriction less than the 4D
the priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. Dirty - 305 mm-Hg [12 in-Hg]; - New - 203 mm-
Check the fuel inlet restriction. Hg [8 in-Hg]
3666239. Refer to Procedure 006-020 in Section Fuel inlet restriction less than the Repair
6. specifications listed below? complete
Dirty - 305 mm-Hg [12 in-Hg]; - New - 203 mm-
Hg [8 in-Hg]
NO
Repair:
supply lines.
STEP 4D: Check drain line restriction.

Condition:
• Operate the engine at high idle (engine cranking if troubleshooting No-Start).
Observe reading on the pressure gauge. Fuel drain line restriction less than 229 mm- 4E
Hg [9 in-Hg]?
n/a
YES
Fuel drain line restriction less than 229 mm- Repair

Hg [9 in-Hg]? complete
NO
Repair:
Locate the cause of high fuel drain line
restriction in the OEM fuel return line.
STEP 4E: Check rail fuel pressure.

Condition:
• Connect pressure gauge, Part Number 3375932, on the Compuchek™ fitting (as shown)
• Operate the engine at low idle (engine cranking if troubleshooting No-Start).
Read the rail fuel pressure at low idle and high Rail fuel pressure meet the specification? Perform the
idle. YES next
Read the rail fuel pressure while cranking if the troubleshooti
ng procedure
engine will not start.
as outlined in
• Cranking: greater than 689 kPa [100 psi] at Step 2
130 rpm for at least 10 seconds.
Rail fuel pressure meet the specification? 4E-1
600 rpm.
• High idle: 1896 to 2068 kPa [275 to 325 psi] at NO with EGR
1800 rpm. 4E-2
STEP 4E-1: Check the pressure side fuel filter restriction.

Condition:
• Connect pressure gauge, Part Number 3375932, on the rail fuel pressure Compuchek™ fitting.
• Connect pressure gauge, Part Number 3375932, on the gear pump output pressure Compuchek™ fitting.
• Operate the engine at high idle (engine cranking if troubleshooting no-start).
Read the fuel pressure drop across the pressure Ppressure side fuel filter pressure drop less 4E-2
side fuel filter at high idle or while cranking if the than 517 kPa [75 psi]?
engine will not start. YES
n/a
Pressure side fuel filter pressure drop less Repair
than 517 kPa [75 psi]? complete
NO
Repair:
Replace the pressure side fuel filter. Use the
Section 6.
STEP 4E-2: Check 1724 kPa [250 psi] pressure regulator.

Condition:
Remove the 1724 kPa [250 psi] fuel pressure 1724 kPa [250 psi] pressure regulator free of 4E-3
regulator. debris or damage?
• Inspect for debris or damage or incomplete YES
sealing of the regulator.
1724 kPa [250 psi] pressure regulator free of Repair
debris or damage? complete
NO
Repair:
STEP 4E-3: Check 2206 kPa [320 psi] or 2620 kPa [380 psi] pressure regulator.
Condition:
Remove the 2206 kPa [320 psi] fuel pressure Pressure regulator free of debris or damage? Repair
regulator. YES complete
• Inspect for debris, damage, or incomplete
sealing of the regulator. Repair:
Replace the gear pump module.
Pressure regulator free of debris or damage? Repair

NO complete
Repair:

STEP 5A: Perform the injector check valve leak test.
Condition:
• None
Perform the injector check valve leak test to Injector leak test detect a leaking injector? Repair
check for internal injector check valve damage. YES complete
Use the following procedure in the Signature™, Repair:
3666239. Refer to Procedure 006-026 in Section Replace the leaking injector. Use the
6. following procedure in the Signature™, ISX,
Section 6.
Injector leak test detect a leaking injector? 5B

NO
STEP 5B: Perform INSITE™ electronic service tool Cylinder Performance Test.
Condition:
• Idle engine.
Perform the INSITE™ electronic service tool Performing INSITE™ electronic service tool 5C-3
Cylinder Performance Test. Cylinder Performance Test identify a single
malfunctioning injector?
During the initial 30 seconds of the Cylinder
Performance Test, INSITE™ electronic service YES
tool is checking to make sure all parameters have
been met to enter the test. Performing INSITE™ electronic service tool 5B-1
Once the initial Pass or Fail reading is displayed, Cylinder Performance Test identify a single
the test is live for the next 2 minutes. Monitor the malfunctioning injector?
display to see if cylinders or banks drop out NO
during this 2 minute window. A cylinder can
switch from pass to fail and back to pass quickly,
so monitor the screen closely.
Condition:
• Idle engine at 600 rpm.
Skip this step and move on to step 5B-2 if the rpm Performing INSITE™ electronic service tool 5C-3
value is the same as that used in step 5B. Cylinder Performance Test identify a single
Adjust the low speed to 600 rpm and perform
Performance Test.
During the initial 30 seconds of the Cylinder Performing INSITE™ electronic service tool 5B-2
Performance Test, INSITE™ electronic service Cylinder Performance Test identify a single
tool is checking to make sure all parameters have malfunctioning injector?
been met to enter the test. NO
Once the initial Pass or Fail reading is displayed,
the test is live for the next 2 minutes. Monitor the
display to see if cylinders or banks drop out
Condition:
• Idle engine at 700 rpm.
to see if the idle speed can be adjusted. If not, use INSITE™ electronic service tool to either enable the Adjustable
Low Idle Speed feature or adjust the Low Idle Speed.
Skip this step and move on to step 5B-3 if the Performing INSITE™ electronic service tool 5C-3
RPM value is the same as that used in step 5B. Cylinder Performance Test identify a single
Adjust the low speed to 700 rpm and perform malfunctioning injector?
Performance Test.
During the initial 30 seconds of the Cylinder Performing INSITE™ electronic service tool 5B-3
Condition:
• Engine idling at 800 rpm.
to see if the idle speed can be adjusted. If not, use INSITE™ electronic service tool to either enable the "Adjustable
Low Idle Speed" feature or adjust the Low Idle Speed.
Skip this step and move on to step 5C if the rpm Performing INSITE™ electronic service tool 5C-3
value is the same as that used in step 5B. Cylinder Performance Test identify a single
Adjust the low speed to 800 rpm and perform
Performance Test.
During the initial 30 seconds of the Cylinder Performing INSITE™ electronic service tool 5C
STEP 5C: Perform INSITE™ electronic service tool Cylinder Cutout Test
Condition:
• Air conditioning is turned off.
• Fan is turned off.
• Any electrical loads are disabled.
• Idle engine at the engine speed at which the misfire is present.
Perform INSITE™ electronic service tool cylinder All cylinders pass the cylinder cutout test? 5C-1
cutout test. YES
A failing cylinder will have no effect on engine
sound and operation when cut out using this test. All cylinders pass the cylinder cutout test? 5C-3
NO
STEP 5C-1: Perform INSITE™ electronic service tool cylinder cutout test on individual injector banks.
Condition:
• Turn OFF air conditioning.
• Turn OFF fan.
• Engine idling at the engine speed at which the misfire is present.
Perform the INSITE™ electronic service tool Malfunctioning bank of injectors isolated by 5D
cylinder cutout test. operating the engine on either bank of
• Operate the engine on the front bank of injectors?
injectors identified by the cylinder cutout test YES
by disabling the rear three cylinders 4, 5, 6
cylinders with INSITE™ electronic service tool.
• Operate the engine on the rear bank of Malfunctioning bank of injectors isolated by 5C-2
injectors identified by the Cylinder operating the engine on either bank of
Performance Test by disabling the front three injectors?
cylinders (1,2,3) with INSITE™ electronic NO
service tool.
• To disable one bank of cylinders with INSITE™
electronic service tool, click on the cylinder
numbers associated with that bank. The front
bank consists of cylinders 1, 2, and 3 and the
rear bank is cylinders 4, 5, and 6.
• A malfunctioning bank of injectors will cause
the engine to run poorly when the opposite
bank is cut out using this test.
STEP 5C-2: Perform INSITE™ electronic service tool Cylinder Cutout Test single cylinder operation.
Condition:
• Air conditioning is turned off.
• Fan is turned off.
• Any electrical loads are disabled.
• Engine idling at the engine speed at which the misfire is present.
Perform the INSITE™ electronic service tool Malfunctioning injector isolated by operating 5C-3
cylinder cut out test. the engine on a single injector?
Operate the engine on the cylinder identified by YES
the Cylinder Performance Test by disabling 5
cylinders with INSITE™ electronic service tool Malfunctioning injector isolated by operating 5D
and only operating on the suspect cylinder. the engine on a single injector?
To disable 5 cylinders with INSITE™ electronic NO
service tool, click on the cylinder numbers until
only 1 cylinder is enabled.
The engine should roughly maintain idle speed
when operating on a single cylinder. A weak or
misfiring cylinder will be detected if the engine
dies or can not maintain idle speed when
operating on a single cylinder.
Continue testing all 6 cylinders by operating the
engine on each individual injector.
If the engine will not run on 1 cylinder regardless
of the cylinder selected, increase the idle RPM
and retest.
Do not run the engine on 1 cylinder for an
extended period of time.
Condition:
Measure the overhead settings for the suspected Overhead settings within the reset limits Repair
malfunctioning injector. outlined in Procedure 003-004? complete
• Check the valve lash and injector pre-load YES
torque before replacing the injector.
• Use the following procedure in the Signature™, Repair:
ISX, and QSX15 Service Manual, Bulletin Replace the malfunctioning injector.
Section 3. Use the following procedure in the
Overhead settings within the reset limits 5B

outlined in Procedure 003-004?
NO
Repair:
Condition:
Measure the overhead settings for the suspected Overhead settings within the reset limits Repair
malfunctioning injector. outlined in Procedure 003-004? complete
• Check the valve lash and injector pre-load YES
torque before replacing the injector.
• Use the following procedure in the Signature™, Repair:
ISX, and QSX15 Service Manual, Bulletin Replace the malfunctioning injector.
Section 3. • Use the following procedure in the
Overhead settings within the reset limits 5B

outlined in Procedure 003-004?
NO
Repair:
Adjust the overhead settings
STEP 5D: Swap the front and rear metering actuators.

Condition:
Swap the front and rear metering actuators to Cylinder performance test find a Repair
determine if the malfunctioning bank of cylinders malfunctioning bank? complete
follows a specific metering actuator. YES
• Use the following procedure found in the ISX
CM871 and ISM CM876 Electronic Control Repair:
System, Bulletin 4021560. Refer to Procedure Replace the malfunctioning metering
019-110 in Section 19. actuator.
• Perform INSITE™ electronic service tool
Cylinder Performance Test. • Use the following procedure found in the
ISX CM871 and ISM CM876 Electronic
Control System, Bulletin 4021560. Refer to
Cylinder performance test find a 5E

malfunctioning bank?
NO
STEP 5E: Swap the front and rear timing actuators

Condition:
Swap the front and rear timing actuators to Malfunctioning bank follow the timing Repair
determine if the malfunctioning bank of cylinders actuator? Complete
follows a specific timing actuator. YES
• Use the following procedure found in the ISX
CM871 and ISM CM876 Electronic Control Repair:
System, Bulletin 4021560. Refer to Procedure Replace the timing actuator.
• Perform INSITE™ electronic service tool Use the following procedure found in the ISX
Cylinder Performance Test. CM871 and ISM CM876 Electronic Control
Malfunctioning bank follow the timing Perform the

actuator? next
NO troubleshooti
ng procedure
as outlined in
Step 2

Condition:
• Operate engine at low idle.
Check the fault codes with the engine running. Active fault codes? Go to
• Use INSITE™ electronic service tool to read the YES appropriate
fault codes. fault code
troubleshooti
ng tree
Active fault codes? 6B

NO
STEP 6B: Check air intake restriction.

Condition:
• Run engine at advertised horsepower and rpm.
Check the intake system restriction by installing Air intake restriction greater than 635 mm- Repair
a vacuum gauge or water manometer into the air H2O [25 in-H2O] for a used air filter or 254 complete
intake system. mm-H2O [10 in-H2O] for a new filter?
3666239. Refer to Procedure 010-031 in Section Repair:
10. Correct the cause of high intake air
restriction.
Check for a plugged air filter or restricted air
intake piping.
Air intake restriction greater than 635 mm- 6C

H2O [25 in-H2O] for a used air filter or 254
mm-H2O [10 in-H2O] for a new filter?
NO
STEP 6C: Inspect charge-air cooler

Condition:
Pressure test the charge-air cooler. Pressure drop 34 kPa [5 psi] or less in 15 6D
• Use the following procedure in the Signature™, seconds?
ISX, and QSX15 Service Manual, Bulletin YES
Section 10.
Pressure drop 34 kPa [5 psi] or less in 15 Repair
seconds? complete
NO
Repair:
Repair the charge-air cooler assembly. Refer
STEP 6D: Inspect the turbocharger blades for damage.

Condition:
• Turn engine OFF.
• Remove intake and exhaust connections from turbocharger.
Inspect the compressor and turbine fins for Damage found on turbocharger blades? Repair
damage or wear. YES complete
Use the following procedure in the Signature™, Repair:
3666239. Refer to Procedure 010-033 in Section Replace the turbocharger.
10. Use the following procedure in the
Damage found on turbocharger blades? 6E

NO
STEP 6E: Inspect the turbocharger shaft movement.

Condition:
• Remove VGT actuator from the turbocharger.
Inspect the sector gear on the turbocharger for Nozzle slide evenly from stop to stop and are Perform new
damaged or broken gear teeth. the gear teeth undamaged? troubleshooti
YES ng procedure
Move the sector gear lever on the turbocharger
bearing housing up and down from stop to stop. as outlined in
Repair: Step 2.
Check for smooth movement between the stops.
Install the turbocharger actuator.
There will be an initial friction force that must be
overcome before the actuator lever will move. Use the following procedure in the
Once movement is started, the actuator lever Signature™, ISX and QSX15 Service Manual,
should move to the other stop position by hand. Bulletin 3666239. Refer to Procedure
ISX and QSX15 Service Manual, Bulletin
3666239. Refer to Procedure 010-134 in Section Nozzle slide evenly from stop to stop and are Repair
10. the gear teeth undamaged? complete.
NO
Repair:
A turbocharger mechanical malfunction has
been detected.
This malfunction may have been caused by
debris exiting the engine, causing the
turbocharger nozzle to stop moving. Inspect
the base engine components for damage.
Inspect the turbocharger for repair and
reuse, if possible. Use the following
procedure in the Signature™, ISX and QSX15
Service Manual, Bulletin 3666239. Refer to

STEP 7A: Check for EGR-related fault codes
Condition:
• Turn keyswitch OFF
• Wait 30 seconds
• Turn keyswitch ON
Check for any EGR-related fault codes. EGR-related fault codes present? Appropriate
YES fault code
n/a
troubleshooti
Repair: ng trees
Troubleshoot electronic fault codes.
EGR-related fault codes present? 7B

NO
STEP 7B: Check for inactive EGR differential pressure sensor fault codes.
Condition:
Check for active fault codes. Fault Code 1866, 2273, or 2274 active? Appropriate
ng tree
Fault Code 1866, 2273, or 2274 active? 7C

NO
STEP 7C: Check the EGR differential pressure tubes for leaks.
Condition:
• Note leaks by traces of soot.
Check the lines for leaks. Leaks detected at either the low or high EGR Repair
n/a differential pressure tubes? complete
YES
Repair:
Tighten the fittings or replace the EGR
differential pressure tube.
Leaks detected at either the low or high EGR 7D

differential pressure tubes?
NO
STEP 7D: Check the EGR differential pressure sensor adapter for leaks.
Condition:
Inspect the EGR differential pressure sensor Leaks detected at the EGR differential Repair
adapter for leaks. pressure sensor adapter? complete
• Leaks will be easily noted by traces of soot. If YES
necessary remove the sensor to inspect the o-
rings between the EGR differential pressure Repair:
sensor and the adapter for proper sealing. Use Replace the EGR differential pressure sensor
the following procedure in the Signature™, ISX, adapter.
Refer to Procedure 011-028 in Section 11. Use the following procedure in the
Leaks detected at the EGR differential 7E

pressure sensor adapter?
NO
STEP 7E: Check the EGR differential pressure tubes for plugging.
Condition:
• Remove the EGR differential pressure tubes.
Inspect the EGR differential pressure tubes for Debris or soot found in either EGR differential Repair
restrictions, soot plugging, and plugging. pressure tube? complete
n/a YES
Repair:
Clear the debris or replace the EGR
differential pressure tube.
Remove the exhaust aftertreatment system
from the vehicle and inspect for reuse.
Debris or soot found in either EGR differential 7F

pressure tube?
NO
STEP 7F: Check for air leaks in the EGR system.

Condition:
None
Check for leaks in the EGR connection tubing Air leaks found in the EGR connection Repair
and connections. tubing? complete
Soot streaks are noticeable where leaks are YES
present. Repair:
Repair any leaks in the EGR system.
Air leaks found in the EGR connection Perform the

tubing? next
NO troubleshooti
ng procedure
as outlined in
Step 2
STEP 8: Verify electronic features operating correctly.

STEP 8A: Verify accelerator pedal travel.
Condition:
With INSITE™ electronic service tool, monitor Accelerator pedal reads 0 percent when the 8B
Accelerator Pedal while fully depressing and accelerator is released and 100 percent when
releasing the accelerator pedal. the accelerator is depressed?
n/a YES
Accelerator pedal reads 0 percent when the Repair

accelerator is released and 100 percent when complete
the accelerator is depressed?
NO
Repair:
Determine and correct the cause of
accelerator pedal restriction.
STEP 8B: Monitor vehicle speed.

Condition:
With INSITE™ electronic service tool, monitor Vehicle speed reads 0 when the vehicle is 8C
Vehicle Speed while the vehicle is not moving. not moving?
n/a YES
Vehicle speed reads 0 when the vehicle is Repair

not moving? complete
NO
Repair:
Check the vehicle speed sensor and circuit
or locate the cause of the vehicle speed
interference.
STEP 8C: Verify electronic feature settings are correct.

Condition:
With INSITE™ electronic service tool, verify the Electronic features set correctly? 8D
following adjustable parameters are correctly YES
set:
• Maximum vehicle speed
• Powertrain protection Electronic features set correctly? Repair
• Rear axle ratio NO complete
• Number of transmission tailshaft gear teeth
Repair:
• Tire revolutions per mile
• Gear-down protection Correct programmable features.
• Cruise control droop settings
• Cruise control maximum vehicle speed.
STEP 8D: Check the ambient air pressure sensor accuracy

Condition:
Check for correct barometric pressure sensor Barometric pressure sensor reading in 8E
reading. INSITE™ electronic service tool within 5
• Compare the barometric pressure sensor percent of the present local barometric
reading in INSITE™ electronic service tool data pressure reading?
monitor/logger to the present local barometric YES
pressure.
Barometric pressure sensor reading in Repair
INSITE™ electronic service tool within 5 complete
percent of the present local barometric
pressure reading?
NO
Repair:
Replace the barometric pressure sensor. Use
the following procedure found in the ISX
STEP 8E: Check the intake manifold pressure sensor accuracy.

Condition:
• Start and operate the engine at high idle after connecting the mechanical intake manifold pressure gauge.
Connect a mechanical intake manifold pressure INSITE™ electronic service tool reading Perform the
gauge to the engine, as close to the intake within 17 kPa [2.5 psi] of mechanical gauge next
manifold pressure sensor as possible. reading? troubleshooti
• Start INSITE™ electronic service tool Data YES ng procedure
Monitor/Logger and compare INSITE™ as outlined in
electronic service tool reading for intake Step 2
manifold pressure to the mechanical gauge.
INSITE™ electronic service tool reading Repair
within 17 kPa [2.5 psi] of mechanical gauge complete
reading?
NO
Repair:
Remove and clean the intake manifold
pressure sensor.

STEP 9A: Verify static timing adjustment is correct.
Condition:
Verify static timing adjustment is correct. Static timing adjustment correct? 9B

Bar the engine to "insert pin" and install the YES
crankshaft pin. Install the appropriate cam
wedges for the engine timing indicated on the Static timing adjustment correct? Repair
engine dataplate. complete
NO
3666239. Refer to Procedure 001-088 in Section Adjust the static timing.
1.
STEP 9B: Verify overhead adjustments are correct.

Condition:
Measure the overhead settings. Overhead settings within the reset limits? 9C
3666239. Refer to Procedure 003-004 in Section Overhead settings within the reset limits? Repair
3. complete
NO
Repair:
STEP 9C: Verify engine brake adjustment.

Condition:
Verify the engine brakes are operating correctly. Engine brake settings within the reset limits? 9D
• Measure the engine brake settings. Use the YES
Refer to Procedure 020-004 in Section 20. Engine brake settings within the reset limits? Repair
NO complete
Repair:
Adjust the engine brake settings.
STEP 9D: Verify crankshaft tone wheel is not loose.

Condition:
• Unplug the crankshaft position sensor.
• Operate the engine at idle.
Operate the engine with the crankshaft position Crankshaft tone wheel loose? Repair
sensor unplugged and identify if idle quality YES complete
improves.
• If idle quality improves, remove the oil pan and Repair:
inspect the crankshaft tone wheel to see if it is Repair the tone wheel.
loose.
Crankshaft tone wheel loose? 9E

NO
STEP 9E: Check exhaust restriction.

Condition:
• Install a pressure gauge into the exhaust system.
Check exhaust restriction by installing a pressure Exhaust restriction greater than 305 mm-Hg Repair
gauge into the exhaust system just past the [12.0 in-Hg]? complete
turbocharger outlet. YES
If a port is not found in the exhaust system, Repair:
remove the exhaust gas temperature 1 sensor
and install the pressure gauge in the temperature Remove the exhaust aftertreatment system
sensor port. from the vehicle and inspect for reuse. Use
the following procedure in the Signature™,
Use the following procedure in the Signature™, ISX, and QSX15 Service Manual, Bulletin
ISX, and QSX15 Service Manual, Bulletin 3666239. Refer to Procedure 011-050 in
3666239. Refer to Procedure 011-009 in Section Section 11.
11.
Exhaust restriction greater than 305 mm-Hg 9F
[12.0 in-Hg]?
NO
STEP 9F: Verify engine blowby is within specification.

Condition:
• Connect the appropriate orifice to the end of the blowby draft tube.
• Start engine.
Load engine to rated rpm on a chassis Engine blowby measurements within Perform the
dynamometer. specification? next
Measure the engine blowby. YES troubleshooti
ng procedure
Use the following procedure in the Signature™, as outlined in
ISX, and QSX15 Service Manual, Bulletin Step 2
14. Engine blowby measurements within Repair
specification? complete
NO
Repair:
Engine may need to be rebuilt. See the
engine specifications.
STEP 10: Aftertreatment checks.

STEP 10A: Check for aftertreatment related fault codes.
Condition:
• Turn keyswitch OFF
Use INSITE™ electronic service tool to read the Fault codes related to the aftertreatment Appropriate
fault codes. system found to be active? fault code
YES troubleshooti
Check for any aftertreatment fault codes,
specifically fault codes related to high soot in the ng tree
aftertreatment particulate trap, face plugging of
the aftertreatment catalyst, and aftertreatment Fault codes related to the aftertreatment 10B
catalyst efficiency. system found to be active?
NO
STEP 10B: Perform basic aftertreatment troubleshooting checks.

Condition:
• None
The following items must be checked or verified All parts inspected and appear to be 10C
before continuing: functioning properly?
• Check to make sure that Ultra Low Sulfur YES
Diesel fuel is being used in the vehicle.
• Check for any fuel leaks around the
aftertreatment fuel shutoff valve or All parts inspected and appear to be Repair
aftertreatment injector components. functioning properly? complete
• Check for any noticeable exhaust leaks NO
around any aftertreatment components.
• Check the exhaust pipes for restrictions that Repair:
can create high exhaust back pressure. Correct the damage and verify the complaint
• Check the aftertreatment sensors, wires, is no longer present after repair.
connectors, and harnesses for proper
connections.
• Check the exhaust gas filter differential
pressure sensor tubes for proper connections.
STEP 10C: Check for signs of an internal damage to the aftertreatment system.
Condition:
• Operate engine to normal operating temperature
• Be sure the vehicle is stationary.
Quickly snap the throttle pedal accelerating the Visible smoke (black or white) present during Repair
engine from low idle to high idle while checking the snap throttle acceleration? complete.
for smoke at the exhaust outlet. YES Troubleshoot
the smoke
Inspect for the following during the snap throttle Repair:
acceleration. complaint,
Damage in the aftertreatment system. use the
• Smoke (any color) coming out of the vehicle proper TT
tailpipe. Remove the exhaust gas aftertreatment tree steps
• Soot or signs of fuel, coolant, or oil inside the system from the vehicle and inspect for
tailpipe. reuse.
If the aftertreatment system is operating Use the following procedure in the
correctly, no visible smoke will be present during Signature™, ISX, and QSX15 Service
the snap throttle acceleration. Any visible smoke Manual, Bulletin 3666239. Refer to
is an indication of a possible malfunction in the Procedure 011-050 in Section 11.
aftertreatment system.
Visible smoke (black or white) present during 10D
the snap throttle acceleration?
NO
STEP 10D: Check exhaust restriction.

Condition:
• Install a pressure gauge into the exhaust system
• Turn keyswitch ON
• Operate engine at advertised horsepower and rpm.
Check exhaust restriction by installing a pressure Exhaust restriction greater than 305 mm-Hg Repair
gauge into the exhaust system just past the [12.0 in-Hg]? complete
turbocharger outlet. YES
If a port is not found in the exhaust system, Repair:
remove the exhaust gas temperature 1 sensor
and install the pressure gauge in the temperature Remove the exhaust aftertreatment system
sensor port. from the vehicle and inspect for reuse.
Use the following procedure in the Signature™, Use the following procedure in the
ISX, and QSX15 Service Manual, Bulletin Signature™, ISX, and QSX15 Service
3666239. Refer to Procedure 011-009 in Section Manual, Bulletin 3666239. Refer to
11. Procedure 011-049 in Section 11.
Exhaust restriction greater than 305 mm-Hg Perform the

[12.0 in-Hg]? next
NO troubleshooti
ng procedure
as outlined in
Step 2
Fuel Economy Troubleshooting Tree Signature™, ISX, and QSX15
Fuel Economy Troubleshooting Tree

• Fuel Consumption Excessive.

This symptom tree is to be used to troubleshoot fuel economy complaints. This tree is used along with the Fuel
Consumption - Customer Complaint Form and the Driveability Low Power/Excessive Fuel - Consumption Checklist to
help isolate engine, chassis, or driver issues associated with excessive fuel consumption.
Shop Talk:
The Fuel Consumption - General Information section of this manual and Troubleshooting Excessive Fuel
Consumption, Bulletin 3666094, should be referenced prior to any troubleshooting being performed on a customer's
engine.
The cause of excessive fuel consumption is difficult to diagnose and correct because of the potential number of factors
• Engine factors
• Vehicle factors and specifications
• Environmental factors
• Driver technique and operating practices
• Fuel system factors
• Low power or driveability problems.
Form is a valuable list of questions that can be used to assist the service technician in determining the cause of the
problem. Complete the form before troubleshooting the complaint. The following are some of the factors that must
be considered when troubleshooting fuel consumption complaints.
• Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
• Vehicle Aerodynamics: The largest single power requirement for a truck is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mile per
gallon.
• Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
• Environmental and Seasonal Weather Changes: There can be as much as 1 to 1.5 mile per gallon difference in fuel
consumption, depending on the season and the weather conditions.
• Truck Route and Terrain: East and west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north and south routes where parts of the trip are not only warmer, but have less wind resistance.
• Driver Technique and Operating Practices: A 1 mile per hour increase in road speed equals a 0.1 mile per gallon
increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss of fuel
mileage of 1 mpg.
• Result of a Low Power or Driveability Problem: An operator will change driving style to compensate for a low power
or driveability problem. Some things the driver is likely to do are (a) shift to a higher engine rpm or (b) run on the
droop curve in a lower gear instead of upshifting to drive at part-throttle conditions. These changes in driving style
will increase the amount of fuel used.
Additional vehicle factors, vehicle specifications, and axle alignment can also affect fuel consumption. For additional
Bulletin 3387245.
Signature™, ISX, and QSX15 Fuel Economy Troubleshooting Tree

STEP 1: Verify the complaint.
STEP 1A: Fill out the Fuel Consumption -
Customer Complaint Form.
STEP 1B: Run VE/VMS™.
STEP 2: Electronic checks using INSITE™.
STEP 2A: Check for fault codes.
STEP 2B: Confirm Features and
Parameters.
STEP 2C: Check the ECM calibration.
STEP 2D: Monitor vehicle speed.
STEP 2D-1: Inspect the engine and
chassis grounds.
STEP 3: Fuel system inspection.
STEP 3A: Inspect the vehicle for fuel
leaks.
STEP 3B: Check the fuel inlet restriction.
STEP 3C: Check the drain line restriction.
STEP 3D: Check the fuel grade.
STEP 3E: Perform the INSITE™ Cylinder
Performance Test.
STEP 3E-1: Interpret the results of the
Cylinder Performance Test.
STEP 3E-2: Interpret the results of the
Cylinder Performance Test.
STEP 3E-3: Measure the resistance
between the actuator and
the actuator base.
STEP 3E-4: Swap the front and rear
metering actuator.
STEP 3E-5: Swap the front and rear
timing actuator.
STEP 4: Check the air handling system.
STEP 4A: Check the air intake restriction.
STEP 4B: Pressure test the charge air
cooler.
STEP 4C: Inspect the charge air cooler.
STEP 4D: Check the exhaust restriction.
STEP 5A: Start the engine and read the
fault codes.
STEP 5B: Inspect the turbocharger blades.
STEP 5C: Determination of turbocharger

type.
STEP 5D: Check the variable geometry
actuator rod for correct travel.
STEP 5D-1: Check for air leaks and
inspect air lines.
STEP 5D-2: Check the engine and
vehicle grounds.
STEP 5D-3: Check for air pressure at the
turbocharger control valve
outlet.
turbocharger control valve
outlet.
STEP 5D-5: Check for correct
turbocharger actuator
travel.
turbocharger control shutoff
valve outlet.
valve inlet.
STEP 5D-8: Check for plugged
valve filter.
STEP 5E: Perform the INSITE™ EGR Valve/
Turbocharger Operational Test.
STEP 5E-1: Check the engine and
vehicle grounds.
STEP 5F: Inspect the wastegate actuator
hose.
STEP 5G: Inspect the wastegate actuator
rod for travel.
STEP 5G-1: Inspect the wastegate
actuator rod for travel.
STEP 5H: Measure the resistance of the
four-stage wastegate
controllers, if equipped.
STEP 5I: Inspect the four-stage
wastegate controller, if
equipped.
STEP 6: Base engine checks.
STEP 6A: Verify the overhead adjustments
are correct.
STEP 6B: Verify the dipstick calibration.
STEP 6C: Analyze the engine oil.
STEP 6D: Check for internal engine
damage.

STEP 1A: Fill out the Fuel Consumption - Customer Complaint Form.
Condition:
fill out the fuel consumption - customer complaint Is the problem caused by vehicle factors, Repair
form in the troubleshooting and repair manual, environmental factors, or driver technique? complete
signature, isx, and qsx15 engines, bulletin YES
3666239.
Is the problem caused by vehicle factors, 1B
environmental factors, or driver technique?
NO
STEP 1B: Run VE/VMS™.

Condition:
fill out the driveability/low power/excessive fuel Taking into consideration the adverse effect 2A
consumption - checklist in the troubleshooting of ambient conditions, does the VE/VMS™
and repair manual, signature, isx, and qsx15 fuel economy conflict with the customer's
engines, bulletin 3666239. current fuel economy?
Use the data gathered to run VE/VMS™ or YES
provide the data to the appropriate support
personnel to run VE/VMS™. Taking into consideration the adverse effect Repair
NOTE: VE/VMS™ does not account for adverse of ambient conditions, does the VE/VMS™ complete
ambient conditions. fuel economy conflict with the customer's
current fuel economy?
NO
Repair:
Explain to the customer the effects of driving
habits and vehicle set up on fuel
consumption.
See Shop Talk for specific examples of how
fuel economy can be effected based on
driving habits and vehicles set up.

Condition:
use insite™ to read the fault codes. Are there any active or high counts of inactive Troubleshoot
fault codes? fault codes.
YES
Are there any active or high counts of inactive 2B

fault codes?
NO
STEP 2B: Confirm features and parameters.

Condition:
confirm the programmable features and Are the features and parameters set 2C
parameters are set correctly. correctly?
Verify the following features and parameters: YES
• Maximum Cruise Control Speed
• Cruise Control Upper Droop Are the features and parameters set Repair
• Cruise Control Lower Droop correctly? complete
• Gear-Down Maximum Vehicle Speed (Heavy NO
Engine Load) = (peak horsepower rpm x 60
min/hr) / (Gear Down Transmission Gear Ratio Repair:
x Rear Axle Ratio x Tire Size) Reset the Features and Parameters to the
• Gear-Down Maximum Vehicle Speed (Light appropriate values.
Engine Load ) = (peak torque rpm x 60 min/
hr) / (Top Gear Transmission Gear Ratio x
Rear Axle Ratio x Tire Size)
• Maximum Accelerator Vehicle Speed
• Road Speed Governor Upper Droop
• Road Speed Governor Lower Droop.
NOTE: Refer to the Feature Help Description in
INSITE™ for additional information.

Condition:
compare the ecm code with the engine rating and Is the calibration correct? 2D
cpl. verify the calibration is correct. YES
Use the calibration notes field in INSITE™ to
confirm the calibration is correct for the Is the calibration correct? Repair
application and CPL. complete
NO
Verify the calibration is not set up for STx, LBSC,
or Multiplexing if the application does not require Repair:
it. Recalibrate the ECM with the correct ECM
Code.

Condition:
with insite™, monitor vehicle speed while the Does vehicle speed read zero when the 3A
vehicle is not moving. vehicle is not moving and the engine is
running?
YES
Does vehicle speed read zero when the 2D-1

vehicle is not moving and the engine is
running?
NO
STEP 2D-1: Inspect the engine and chassis grounds.

Condition:
check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connections. free of corrosion, and tight? complete
• Check the engine ground connection. YES
• Check the battery terminal connections. Repair:
Check the VSS and the VSS circuit.
Refer to Procedure 019-090, 019-091 and
019-092 in the Troubleshooting Manual,
Signature Fuel System, Signature Engines,
Bulletin 3666259.
Are all grounds present, properly grounded, Repair

free of corrosion, and tight? complete
NO
Repair:
Replace, clean, or tighten the grounds.
STEP 3: Fuel system inspection.

STEP 3A: Inspect the vehicle for fuel leaks.
Condition:
check the suction fuel lines, oem fuel Are any leaks present? Repair
connections, suction-side fuel filter, fuel pump, YES complete
ifsm, and actuators for leaks.
Repair:
With EGR
Repair or replace the failed component.
Check for pressure-side fuel filter, fittings and
hoses to and from the ECM, cooling plate, fuel
pump, IFSM, and actuators for leaks. Are any leaks present? 3B
NOTE: Dye can be placed in the fuel to assist in NO
finding fuel system leaks.
STEP 3B: Check the fuel inlet restriction.

Condition:
• Connect vacuum gauge to the suction-side Compucheck® fitting.
• Engine running at high idle.
if the engine uses a fuel lift pump, wait until after Is fuel inlet restriction less than the 3C
priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. • Dirty: 305 mm Hg [12 in Hg]
• New: 203 mm Hg [8 in Hg].
YES
Is fuel inlet restriction less than the Repair

specifications listed below? complete
• Dirty: 305 mm Hg [12 in Hg]
• New: 203 mm Hg [8 in Hg].
NO
Repair:
supply lines.
STEP 3C: Check the drain line restriction.

Condition:
• Engine running at high idle.
observe the reading on the pressure gauge. Is fuel drain line restriction less than 229 mm 3D
Hg [9 in Hg]?
YES
Is fuel drain line restriction less than 229 mm Repair

Hg [9 in Hg]? complete
NO
Repair:
Locate the cause of the high fuel drain line
restriction in the OEM fuel return line.
STEP 3D: Check the fuel grade.

Condition:
verify the fuel grade used is appropriate for the Is the fuel grade used and the quality 3E
application and ambient conditions and fuel acceptable?
quality is acceptable. YES
Run the engine on an alternate, known good fuel
source and verify engine performance if the fuel Is the fuel grade used and the quality Repair
can not be tested appropriately. acceptable? complete
NOTE: Refer to Fuel for Cummins Engines, NO
Bulletin 3379001.
Repair:
Instruct the driver or owner to refuel with
acceptable fuel.
STEP 3E: Perform the INSITE™ Cylinder Performance Test.

Condition:
• Engine running at low idle.
perform the insite™ cylinder performance test. Do all injectors and both banks pass the 4A
NOTE: Do not run the engine above 900 rpm Cylinder Performance Test?
when performing the Cylinder Performance Test. YES
Do all injectors and both banks pass the 3E-1

Cylinder Performance Test?
NO
STEP 3E-1: Interpret the results of the Cylinder Performance Test.

Condition:
interpret the results of the insite™ cylinder Did the Cylinder Performance Test find an Repair
performance test. individual failed cylinder? complete
• If the Cylinder Performance Test displays bar YES
graphs for each cylinder's contribution, use
the INSITE™ help file to interpret the results. Repair:
• If the Cylinder Performance Test displays pass Replace the failed injector.
or fail for each cylinder, run the test at least 3
times to verify the results. Read the Test Refer to Procedure 006-026.
Results under the Results section of the test.
Did the Cylinder Performance Test find an 3E-2
individual failed cylinder?
NO
STEP 3E-2: Interpret the results of the Cylinder Performance Test.

Condition:
interpret the results of the insite™ cylinder Did the Cylinder Performance Test find an 3E-3
performance test. individual failed bank?
• If the Cylinder Performance Test displays bar YES
graphs for each bank's contribution, use the
INSITE™ help file to interpret the results.
• If the Cylinder Performance Test displays pass Did the Cylinder Performance Test find an 4A
or fail for each bank, run the test at least 3 individual failed bank?
times to verify the results. Read the Test NO
Results under the Results section of the test.
STEP 3E-3: Measure the resistance between the actuator and the actuator base.
Condition:
• Disconnect the engine harness from the timing and fueling actuators.
measure the resistance between the actuator Greater than 100k ohms? 3E-4
and the actuator mounting base. YES
Greater than 100k ohms? Repair

NO complete
Repair:
Replace the failed fueling or timing actuator.
Refer to Procedure 019-110 or 019-111 in the
Troubleshooting Manual, Signature Fuel
System, Signature Engines, Bulletin
4021334.
STEP 3E-4: Swap the front and rear fueling actuator.

Condition:
swap the front and rear fueling actuator to Does the failed bank follow the metering Repair
determine if the failed bank of cylinders follows actuator? complete
the actuator. YES
• Refer to Procedure 019-110 in the
Troubleshooting Manual, Signature Fuel Repair:
System, Signature Engines, Bulletin 4021334 Replace the failed fueling actuator. Refer to
for removal and installation. Procedure 019-110 in the Troubleshooting
• Perform the INSITE™ Cylinder Performance Manual, Signature Fuel System, Signature
Test. Engines, Bulletin 4021334.
Does the failed bank follow the metering 3E-5

actuator?
NO
STEP 3E-5: Swap the front and rear timing actuator.

Condition:
swap the front and rear timing actuators to Does the failed bank follow the timing Repair
determine if the failed bank of cylinders follows actuator? complete
the timing actuator. YES
• Refer to Procedure 019-111 in the
Troubleshooting Manual, Signature Fuel Repair:
System, Signature Engines, Bulletin 4021334 Replace the failed timing actuator.
for removal and installation.
• Perform the INSITE™ Cylinder Performance Refer to Procedure 019-111 in the
Test. Troubleshooting Manual, Signature Fuel
4021334.
Does the failed bank follow the timing 3A

actuator?
NO
Repair:
Troubleshooting procedures need to be
repeated from the beginning. A failed injector
or actuator should have been detected.
STEP 4: Check the air handling system.

STEP 4A: Check the air intake restriction.
Condition:
• Run the engine at advertised horsepower and rpm.
check the intake system restriction by installing Is air intake restriction greater than 635 mm Repair
a vacuum gauge or water manometer into the air H2O [25 in H2O] for a used filter or 254 in complete
intake system. H2O [10 in H2O] for a new filter?
Refer to Procedure 010-031. YES
Repair:
Correct the cause of high intake air
restriction.
Check for plugged air filter or restricted air
intake piping.
Is air intake restriction greater than 635 mm 4B

H2O [25 in H2O] for a used filter or 254 in
H2O [10 in H2O] for a new filter?
NO
STEP 4B: Pressure test the charge air cooler.

Condition:
pressure test the charge air cooler. Is the pressure drop 5 psi or less in 15 4C
seconds?
YES
Is the pressure drop 5 psi or less in 15 Repair

seconds? complete
NO
Repair:
Repair the charge air cooler.
STEP 4C: Inspect the charge air cooler.

Condition:
inspect the charge air cooler for bent or plugged Is the charge air cooler free from bent or 4D
fins. plugged fins?
Bent or plugged fins will force the temperature of YES
the air exiting the cooler to raise and force the
engine to work harder to obtain the desired Is the charge air cooler free from bent or Repair
charge flow. A harder working engine will use plugged fins? complete
more fuel.
NO
Repair:
Clean the charge air cooler.
STEP 4D: Check the exhaust restriction.

Condition:
check the exhaust restriction by installing a Is exhaust restriction less than 76 mm Hg [3 5A

pressure gauge into the exhaust system just past in Hg]?
the turbocharger. YES
Is exhaust restriction less than 76 mm Hg [3 Repair
in Hg]? complete
NO
Repair:
Repair the exhaust for source of high
restriction.

Condition:
check the fault codes with the engine running. Are Fault Codes 2355 or 2356 active? Go to
YES appropriate
Use INSITE™ to read the fault codes.
Fault Code
troubleshooti
ng tree.
Are Fault Codes 2355 or 2356 active? 5B

NO
STEP 5B: Inspect the turbocharger blades.

Condition:
• Engine OFF.
• Remove intake and exhaust connections for turbocharger.
inspect the compressor and turbine fins for Was damage found on turbocharger fins or Repair
damage or wear. was axial or radial movement out of complete
specification?
Measure the turbocharger wheel axial
movement. YES
Check the radial movement of the turbocharger Repair:
wheel. Replace the turbocharger.
Refer to Procedure 010-033. Refer to Procedure 010-033.
Was damage found on turbocharger fins or 5C

was axial or radial movement out of
specification?
NO
STEP 5C: Determination of turbocharger type.

Condition:
determine if the turbocharger is a wastegated or Is the turbocharger a variable geometry 5D

variable geometry turbocharger. turbocharger?
YES
Is the turbocharger a variable geometry 5F

turbocharger?
NO
STEP 5D: Check the variable geometry actuator rod for correct travel.
Condition:
• Engine OFF.
• Verify air tanks are fully charged.
perform the turbocharger actuator test using the Does the turbocharger actuator rod extend 5E
insite™ electronic service tool. between 10.2 and 11.8 mm [0.402 and 0.465
• Adjust the delay timer in the Turbocharger in]?
Actuator Test so rod movement can be YES
observed.
• Select the Retract Actuator position with
INSITE™. Does the turbocharger actuator rod extend 5D-1
• Mark or scribe the VG™ actuator rod at the between 10.2 and 11.8 mm [0.402 and 0.465
base of the actuator. in]?
• Select the Extend Actuator position with NO
INSITE™.
• Measure the rod travel by measuring the
distance from the base of the turbocharger
actuator to the scribe mark.
NOTE: The turbocharger actuator should move
quickly and crisply. If the actuator rod movement
is slow, there could be a problem with the air
supply, a faulty ground connection on the engine
or chassis, or mechanical problems with the
variable geometry turbocharger assembly.
STEP 5D-1: Check for air leaks and inspect air lines.
Condition:
• Engine OFF.
• Verify vehicle air tanks are fully charged.
perform the turbocharger actuator test using the Air leaks found in the system? Repair
insite™ electronic service tool. select the extend YES complete
actuator position.
Repair:
Listen for air leaks at the following components:
Repair air leaks.
• Turbocharger control valve
• Turbocharger control shutoff valve inlet
connection Air leaks found in the system? 5D-2
• Turbocharger control shutoff valve outlet NO
connection
• Turbocharger control valve inlet connection
• Turbocharger control valve outlet connection
• Turbocharger actuator
• All air lines, including the OEM supply line to
the turbocharger control shutoff valve,
turbocharger control shutoff valve to the
turbocharger control valve, and turbocharger
control valve to the turbocharger actuator.
STEP 5D-2: Check the engine and vehicle grounds.

Condition:
check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, 5D-3
battery ground connections. free of corrosion, and tight?
• Check the battery terminal connections.
NO
Repair:
Replace, clean, or tighten the ground.
STEP 5D-3: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
perform the turbocharger actuator test using the Is vehicle air tank pressure present at the 5D-4
insite™ electronic service tool. select the retract turbocharger control valve outlet?
actuator position. YES
Remove the air line connection at the outlet of the
turbocharger control valve. Is vehicle air tank pressure present at the 5D-6
Install an M12 Compucheck® fitting, Part Number turbocharger control valve outlet?
3824843, at the outlet of the turbocharger control NO
valve.
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi]
Perform the Turbocharger Actuator Test using
the INSITE™ electronic service tool. Select the
STEP 5D-4: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
perform the turbocharger actuator test using the Does the pressure gauge read more than 15 Repair
insite™ electronic service tool. select the retract psi after 5 minutes? complete
actuator position. YES
Remove the air line connection at the outlet of the Repair:
turbocharger control valve.
Install an M12 Compucheck® fitting at the outlet
of the turbocharger control valve. Refer to Procedure 019-388 in the
Install an air pressure gauge that is capable of System, Signature Engines, Bulletin
reading at least 1034 kPa [150 psi]. 4021334.
Does the pressure gauge read more than 15 5D-5

psi after 5 minutes?
NO
STEP 5D-5: Check for correct turbocharger actuator travel.

Condition:
• Engine OFF.
remove the variable geometry actuator from the Does the turbocharger actuator rod travel at Repair
turbocharger. least 12 mm [0.472 in]? complete
Refer to Procedure 010-113. YES
NOTE: Damage to the turbocharger may result if Repair:
the proper removal procedure is not followed. Replace the turbocharger assembly.
Perform the Turbocharger Actuator Test using Refer to Procedure 010-033.
the INSITE™ electronic service tool. Select the
Does the turbocharger actuator rod travel at Repair
least 12 mm [0.472 in]? complete
NO
Repair:
Replace the turbocharger actuator.
STEP 5D-6: Check for air pressure at the turbocharger control shutoff valve outlet.
Condition:
• Engine OFF.
use insite™ to start the turbocharger actuator test. Can air be heard escaping from the Repair
Loosen the air line connection at the turbocharger control shutoff valve outlet? complete
turbocharger control shutoff valve outlet. YES
Repair:
Refer to Procedure 019-388 in the
4021334.
Can air be heard escaping from the 5D-7

turbocharger control shutoff valve outlet?
NO
STEP 5D-7: Check for air pressure at the turbocharger control shutoff valve inlet.
Condition:
• Engine OFF.
verify the oem air supply line is connected to the Can air be heard escaping from the 5D-8
correct port on the turbocharger control shutoff turbocharger control shutoff valve inlet?
valve. YES
Loosen the air line connection at the
turbocharger control shutoff inlet. Can air be heard escaping from the Repair
turbocharger control shutoff valve inlet? complete
NO
Repair:
Repair the air supply from the OEM air tanks.
STEP 5D-8: Check for plugged turbocharger control shutoff valve filter.
Condition:
• Connect the INSITE™ electronic service tool.
use insite™ to start the turbocharger actuator test. Is an air leak present at the turbocharger Repair
Listen for an air leak at the turbocharger control
shutoff valve filter head. YES
Repair:
valve filter.
Is an air leak present at the turbocharger Repair

NO
Repair:
valve.
Refer to Procedure 019-386 in the
4021334.
STEP 5E: Perform the INSITE™ EGR Valve/Turbocharger Operational Test.

Condition:
select the egr/vgt™ operational test using the Does the Turbocharger Operational Test 6A
insite™ electronic service tool. pass?
Choose the Turbocharger Actuator option under YES
Test Choices.
Does the Turbocharger Operational Test 5E-1
pass?
NO
STEP 5E-1: Check the engine and vehicle grounds.

Condition:
check for a loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connection. free of corrosion, and tight? complete
Replace the variable geometry turbocharger.

NO
Repair:
Replace, clean, or tighten the ground.
STEP 5F: Inspect the wastegate actuator hose.

Condition:
• Engine OFF.
• Remove the turbocharger if wastegate actuator is inaccessible.
inspect the integral wastegate actuator hose for Are holes or cracks found in the wastegate Repair
cracks or holes. actuator hose? complete
YES
Repair:
Replace the wastegate actuator hose.
Are holes or cracks found in the wastegate 5G

actuator hose?
NO
STEP 5G: Inspect the wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the wastegate actuator hose from the wastegate actuator.
apply a regulated air supply of 310 kpa [45 psi] Does the wastegate actuator rod move? 5H
to the actuator and check for actuator movement. YES
Does the wastegate actuator rod move? 5G-1

NO
STEP 5G-1: Inspect the wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the e-clip from the wastegate pin and disconnect the actuator rod.
apply a regulated air supply of 310 kpa [45 psi] Does the wastegate actuator rod move? Repair
to the actuator and check for actuator movement. YES complete
Repair:
Move the wastegate lever on the
turbocharger back and forth and check for
smooth operation. Replace the turbocharger
assembly if the wastegate is seized.
Does the wastegate actuator rod move? Repair

NO complete
Repair:
Replace the wastegate actuator.
STEP 5H: Measure the resistance of the four-stage wastegate controllers, if equipped.
Condition:
• Engine OFF.
• Disconnect the ring terminals from the four-stage wastegate controllers, if equipped.
measure the resistance from the wastegate Are the wastegate controller solenoid 5I
controller post to engine block ground. resistances between 7.0 and 8.0 ohms?
NOTE: The wastegate controller solenoids YES
must be between 20°C and 26°C [68°F and 78°
F] before using the resistance specifications Are the wastegate controller solenoid Repair
listed. resistances between 7.0 and 8.0 ohms? complete
NO
Repair:
Replace the failed wastegate controller.
STEP 5I: Inspect the four-stage wastegate controller, if equipped.

Condition:
• Engine OFF.
• Remove the four-stage wastegate controllers.
check the valve disc, valve seat, and actuator Damage or debris found on the valve disc, Repair
disc for dirt, metal, debris, bonding separation, valve seat, or actuator disc? complete
Repair:
Replace or clean failed components.
Damage or debris found on the valve disc, 6A

NO
STEP 6: Base engine checks.

STEP 6A: Verify the overhead adjustments are correct.
Condition:
measure the overhead settings. Are the overhead settings within the reuse 6B
limits?
Valve Lash Reuse Limits:
YES
• Intake valve lash: 0.102 mm [0.004 in] to 0.483
mm [0.019 in]
• Exhaust valve lash: 0.508 mm [0.020 in] to Are the overhead settings within the reuse Repair
0.813 mm [0.032 in]. limits? complete
NO
Repair:
STEP 6B: Verify the dipstick calibration.

Condition:
verify the dipstick calibration. Is the dipstick calibrated properly? 6C

Drain, remove, clean, and install the lubricating YES
oil pan. Refer to Procedure 007-025.
Check the calibration of the lubricating oil Is the dipstick calibrated properly? Repair
dipstick. Refer to Procedure 007-009. NO complete
Repair:
Calibrate the lubricating oil dipstick.
STEP 6C: Analyze the engine oil.

Condition:
take an engine oil sample. Does the engine oil analysis show any signs Repair
of wear metals or contaminates? complete
YES
Does the engine oil analysis show any signs 6D

of wear metals or contaminates?
NO
Repair:
Locate and replace the worn component or
remove the source of contaminate and repair
the engine as necessary.
STEP 6D: Check for internal engine damage.

Condition:
remove the oil filter. Is any foreign material found in the oil filter? Repair
YES complete
Inspect the oil filter for foreign material. Refer to Repair:
Procedure 007-002. Locate the source of foreign material and
repair the engine as necessary.
Is any foreign material found in the oil filter? Return to the

NO troubleshooti
ng steps or
contact a
local
Cummins
Authorized
Repair
Location, if
all steps
have been
completed
and checked
again.
Fuel Economy Troubleshooting Tree

• Fuel Consumption Excessive

This symptom tree is to be used to troubleshoot fuel economy complaints. This tree is used along with the Fuel
Consumption - Customer Complaint Form and the Driveability Low Power/Excessive Fuel - Consumption Checklist to
help isolate engine, chassis, or driver issues associated with excessive fuel consumption.
Shop Talk:
The Fuel Consumption - General Information section of this manual and Troubleshooting Excessive Fuel
Consumption, Bulletin 3666094, should be referenced prior to any troubleshooting being performed on a customer's
engine.
The cause of excessive fuel consumption is difficult to diagnose and correct because of the potential number of factors
• Engine factors
• Vehicle factors and specifications
• Environmental factors
• Driver technique and operating practices
• Fuel system factors
• Low power or driveability problems.
Form is a valuable list of questions that can be used to assist the service technician in determining the cause of the
problem. Complete the form before troubleshooting the complaint. The following are some of the factors that must
be considered when troubleshooting fuel consumption complaints.
• Excessive idling time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
• Vehicle Aerodynamics: The largest single power requirement for a truck is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mile per
gallon.
• Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
• Environmental and Seasonal Weather Changes: There can be as much as 1 to 1.5 mile per gallon difference in fuel
consumption, depending on the season and the weather conditions.
• Truck Route and Terrain: East and west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north and south routes where parts of the trip are not only warmer, but have less wind resistance.
• Driver Technique and Operating Practices: A 1 mile per hour increase in road speed equals a 0.1 mile per gallon
increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss of fuel
mileage of 1 mpg.
• Result of a Low Power or Driveability Problem: An operator will change driving style to compensate for a low power
or driveability problem. Some things the driver is likely to do are (a) shift to a high engine rpm or (b) run on the
droop curve in a lower gear instead of upshifting to drive at part-throttle conditions. These changes in driving style
will increase the amount of fuel used.
Additional vehicle factors, vehicle specifications and axle alignment, can also affect fuel consumption. For additional
Bulletin 3387245.

STEP 1A: Fill out the Fuel Consumption -
Customer Complaint Form.
STEP 1B: Run VE/VMS.
STEP 2B: Confirm Features and
Parameters.
STEP 2C: Check the ECM calibrations.
STEP 2D-1: Inspect the engine and
chassis grounds.
STEP 3: Engine performance.
STEP 3A: Engine performance
troubleshooting.

STEP 1A: Fill the Fuel Consumption - Customer Complaint Form.
Condition:
Fill out the Fuel Consumption - Customer Is the problem caused by vehicle factors, Repair
Complaint Form in the Troubleshooting and environmental factors, or driver technique? complete
Repair Manual, ISC, QSC8.3, ISL and QSL9 YES
Is the problem caused by vehicle factors, 1B
environmental factors, or driver technique?
NO
STEP 1B: Run VE/VMS.

Condition:
Fill out the Driveability/Low Power/Excessive Taking into consideration the adverse effect 2A
Fuel Consumption - Checklist in Troubleshooting of ambient conditions, does the VE/VMS fuel
and Repair Manual. economy conflict with the customer's current
fuel economy?
Use the data gathered to run VE/VMS or provide
the data to the appropriate support personnel to YES
run VE/VMS.
NOTE: VE/VMS does not account for adverse Taking into consideration the adverse effect Repair
ambient conditions. of ambient conditions, does the VE/VMS fuel complete
economy conflict with the customer's current
fuel economy?
NO
Repair:
Explain to the customer the effects of driving
habits on fuel consumption.

Condition:
Using INSITE™, read the fault codes. Are there any active or high counts of inactive Troubleshoot
fault codes? fault codes
YES
Are there any active or high counts of inactive 2B

fault codes?
NO
STEP 2B: Confirm Features and Parameters.

Condition:
Confirm the Programmable Features and Are the Features and Parameters set 2C
Parameters are set correctly. correctly?
YES
Are the Features and Parameters set Repair

correctly? complete
NO
Repair:
Reset the Features and Parameters to their
appropriate values.

Condition:
Compare the ECM code with the engine rating Is the calibration correct? 2D
and CPL. Verify the calibration is correct. YES
Is the calibration correct? Repair

NO complete
Repair:
Recalibrate the ECM with the correct ECM
code.

Condition:
With INSITE™, monitor Vehicle Speed while the Does vehicle speed read 0 when the vehicle 3A
vehicle is not moving. is not moving?
YES
Does vehicle speed read 0 when the vehicle 2D-1

is not moving?
NO
STEP 2D-1: Inspect the engine and chassis grounds.

Condition:
Check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connection. free of corrosion, and tight? complete
• Check the engine ground connection YES
• Check the chassis ground connections
Check the VSS and the VSS circuit.

NO
Repair:
Replace, clean, or tighten the grounds.
STEP 3: Engine performance.

STEP 3A: Engine performance troubleshooting.
Condition:
Perform the Fuel System Checks, Air Handling Poor fuel economy complaint still exists? Repair
Checks, and Base Engine Checks in the Engine YES complete
Performance Troubleshooting Tree.
Repair:
Perform the Fuel System Checks, Air
Handling Checks, and Base Engine Checks
in the Engine Performance Troubleshooting
Tree.
Poor fuel economy complaint still exists? Repair

NO complete
Vibration Excessive Signature™, ISX, and QSX15
Vibration Excessive
• Vibration excessive
• Cab noise due to vibration

This symptom tree can be used to troubleshoot all vibration-based symptoms listed above. Start by performing Step
1 troubleshooting. Step 2 will ask a series of questions and will provide a list of troubleshooting steps to perform,
depending on the symptoms. Perform the list of troubleshooting steps in the sequence shown in the Specifications/
Repair section of the tree.
Shop Talk:
Vibration Troubleshooting Documentation Information Questions
1) What is the OEM make/model?
2) What are the mileage/hours?
3) Has there been any recent repair and/or maintenance history?
• Any engine/clutch/transmission rebuild, removal, and installation?
• History of repeatedly broken brackets and/or capscrews (alternator, fan, exhaust, etc.)?
• Structural modifications to the vehicle from OEM built?
4) Description of vibration?
• What is shaking (mirror, seat, steering wheel, cab/dash, etc.)?
• Is there excessive noise in the cab during the vibration?
5) What are the conditions when the complaint occurs?
• Power take-off (PTO)?
• Power output (hard pull, during lug down, etc.)?
• During acceleration and/or deceleration?
• At idle?
• With or without a trailer?
• Does vibration increase with engine speed?
• Does vibration increase with road speed?
• Is the vibration at a certain engine RPM?
6) Has the vibration been present since new? (From new, recent repair, modification to equipment)
7) Can the vibration be easily duplicated?
8) Do you have another piece of equipment with the same specification which exhibits the same complaint? (If yes,
get the engine serial number (ESN) and possibly test the vehicle)
9) Are you the only operator of the equipment? (If no, are the symptoms noticed by other operators)?
General Information
Vibration complaints can be very difficult to troubleshoot and understand the root cause. This troubleshooting
document was designed to help guide you through the logical steps of identifying the source. Vibration acceptance
is very subjective; what is objectionable to one person can possibly be acceptable to another.
Vibration complaints can be caused by many parts in the system (system includes the engine, driven component,
mounts, and equipment). The cause can be transmitted or generated from a remote point that is not readily apparent.
Cummins Inc. experience has shown that the engine is rarely the cause of an operator complaint. The majority of the
time, it is the engine mounts or design of the various components on the equipment. The engine is only at fault if
there is a misfire or an engine component that is out of balance.
Vibration complaints that occur only at idle speed are most likely caused by the engine mounts. If the engine mount
natural frequency is close to the engine firing frequency, the engine will cause the mounts to amplify the normal
vibration on an engine idling and cause the adjacent components to vibrate excessively.
Natural Frequency
• Natural frequency, as the name implies, is the frequency at which an object wants to naturally vibrate. The frequency
is primarily dependent on mass and elasticity.
Types of Vibration
Signature™, ISX, and QSX15 Vibration Excessive
1) Linear
a) Rotating components
b) Torque reaction
• Caused by unbalanced rotating components and cylinder firing impulses.
• Can be felt and observed visibly.
• When excessive, can cause operator discomfort and destruction of components.
2) Torsional - twisting stresses
• Cyclic speeding and slowing of rotating components.
• Controlled by flywheel mass and vibration damper.
• Can NOT be felt by the operator.
• Can damage gears and splines.
3) Resonant - component excited at natural frequency
• Is actually linear vibration.
• Resonant vibration occurs when a system or component is excited by linear vibration at its natural frequency.
• Vibration will increase in amplitude as the system's natural frequency is approached. Amplitude will decrease as
the exciting forces (engine firing frequency) increase in frequency beyond the system's natural frequency.
• Resonant vibration can be many times larger in amplitude than the exciting force.
• Vibration must be controlled by design of mounts (engine and cab) and components.
Engine and Cab Mounts
• The mounts must be designed to isolate or reduce the transmission of engine and equipment component vibrations.
• For maximum isolation, it is desired that the natural frequency of the mount be as low as possible.
• Good engine mounts will reduce the amount of engine vibration transmitted to the chassis frame by at least 50
percent at idle.
• Hard engine mounts will give little or no isolation, and can actually magnify the vibration transmitted to the chassis.
• Stiffness (durometer) and size of the isolator, along with the weight of the engine or component applied are the
determining factors when designing a mounting system. An isolator that is correct for one engine, can possibly
not be right for another. Likewise, because of weight differential, a particular isolator designed for the rear of an
engine, probably will not be ideal for the front.

STEP 1: Perform the basic troubleshooting procedures.
STEP 1A: Document the information Documentation completed?
questions in the Shop Talk
section of this tree.
STEP 1B: Duplicate the complaint based Can the customer's complaint be
on the customer description. duplicated?
STEP 1C: Check for active fault codes or Active fault codes or high counts
codes.
STEP 1D: Perform the basic Are all steps verified to be
troubleshooting checks. correct?
STEP 1E: Determine if the engine is Is the engine running rough?
running rough.
STEP 1F: Perform a visual inspection of Is there visible engine mount
the engine mounts (without damage?
removal).
STEP 1G: Check for an engine mounted Engine mounted components
component contacting the frame touching the frame or body?
or body.
STEP 1H: Marine application. Is the engine installed in a
marine application?
STEP 1I: Do an engine RPM sweep. Is the vibration present
stationary below 1050 RPM?
STEP 1J: Do an engine RPM sweep. Is the vibration present
stationary above 1050 RPM?
STEP 1K: Check the vibration engine Is the vibration speed range
speed range. greater than 300 to 400 RPM?
STEP 2: Perform low RPM checks.
STEP 2A: Check that the accessory load is Are all steps verified to be
not excessive for the idle speed correct?
setting.
STEP 2B: Check that the Fast Idle Warm- Is the Fast Idle Warm-Up feature
Up feature is activating (if inactive?
applicable).
STEP 2C: Check that the Alternator Failure Is the Alternator Failure Warning
Warning feature is activating (if feature inactive?
applicable).
STEP 2D: Check for malfunctioning belt Did the vibration go away with
driven accessories. the drive belts removed?
STEP 2E: Check for equipment structural Are any structural modifications
modifications. to the equipment present?
STEP 2F: Check the engine mount Does the vibration go away
transmissibility for the rear during the test condition?
mount.
STEP 2F-1: Check the engine mount Does the vibration go away
transmissibility for all during the test condition?
mounts.
STEP 2G: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 2H: Complaint since new. Has the problem been occurring
since the equipment was new?
STEP 3: Perform higher RPM checks.
STEP 3A: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 3B: Check for malfunctioning belt Did the vibration go away with
driven accessories. the drive belts removed?
STEP 3C: Check for a damaged vibration Is the vibration damper damaged
damper. or out of specification?
STEP 3D: Check the air compressor Is the air compressor timing
timing. correct?
STEP 3E: Check the overhead Are the overhead adjustments
adjustments. correct?
STEP 3F: Check for malfunctioning gear Did the vibration go away?
driven components.
STEP 3G: Check for a damaged PTO. Did the vibration go away?
STEP 3H: Check for a malfunctioning Does the internal balancer meet
engine internal balancer specification?
assembly (4 cylinder B-Series
only).
STEP 3I: Check the clutch or torque Did engaging and disengaging
converter for vibration. the clutch affect the vibration?
STEP 3J: Check for a loose or damaged Does the flywheel meet
flywheel or flex plate. specifications?
STEP 3K: Check the flywheel housing for Does the flywheel housing meet
correct alignment. specifications?
STEP 3L: Check to see if the crankshaft Is the crankshaft balanced?
has been balanced.
STEP 3M: Check for internal engine Is there internal engine damage?
damage.
STEP 4: Operate the mobile equipment.
STEP 4A: Perform a diagnostic road test. Is the vibration present during a
diagnostic road test?
STEP 4A-1: Perform a diagnostic road Is the vibration present with the
test. transmission in neutral, under
the road speed conditions,
where the vibration was
duplicated driving?
STEP 4B: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 4C: Check for drive train Are all steps verified to be
components that are worn, correct?
unbalanced, malfunctioning, or
are not correct.
STEP 5: Marine applications.
STEP 5A: Check the gear ratio and Are the gear ratio and the
propeller configuration. propeller incorrectly matched to
the engine power?
STEP 5B: Check for the correct engine Are the engine mount isolators
mounting isolators and for correct and installed correctly?
proper installation
requirements.
STEP 5C: Check for damaged engine Are the engine mounts and
mounts and isolators. isolators in good condition?
STEP 5D: Check the exhaust system. Is the exhaust system deficient?
STEP 5E: Check the engine driven Is an engine driven accessory
accessories. malfunctioning?
STEP 5F: Check the shaft coupling to gear Is the shaft coupling to gear
coupling alignment. coupling misaligned?
STEP 5G: Check the propeller shaft for Is the propeller shaft installed
proper installation. correctly?
STEP 5H: Check the propeller shaft for Is the propeller shaft
straightness. straightness within the OEM
specification?
STEP 5I: Isolate the engine. Does the engine vibration
persist?
STEP 5J: Check for strut/cutlass bearing Is the strut/cutlass bearing
misalignment. misaligned or strut mounting not
secure?
STEP 5K: Check the propeller. Is the propeller out of balance or
not fitted properly to the shaft?
STEP 5L: Check the V-angle on the V- Does the V-angle on the V-strut
strut. match the angle of the blade on
the prop?
STEP 5M: Check the propeller tunnels. Does the entry and exit of the
propeller tunnel match with the
propeller blades?
STEP 5N: Check the engine to Is the torsional coupling
transmission torsional coupling. incorrect or worn?
STEP 5O: Check the rudder. Does the rudder have excessive
play in the rudder post?
STEP 5P: Check the engine flywheel Is the flywheel housing
housing to cylinder block alignment incorrect?
alignment.
STEP 1: Perform the basic troubleshooting procedures.

STEP 1A: Document the information questions in the Shop Talk section of this tree.
Condition:
• None
Perform the basic troubleshooting questionnaire. Documentation completed? 1B

Complete the vibration troubleshooting YES
documentation information questions contained
in the Shop Talk section of this procedure. Documentation completed? 1A
NO
Repair:
Complete the documentation.
STEP 1B: Duplicate the complaint based on the customer description.

Condition:
• None.
Operate the equipment based on the description Can the customer's complaint be duplicated? 1C
from the customer to duplicate the complaint. YES
Can the customer's complaint be duplicated? Repair

NO complete
STEP 1C: Check for active fault codes or high counts of inactive fault codes.
Condition:
Check the fault codes. Active fault codes or high counts of inactive Repair
• Use INSITE™ electronic service tool to read the fault codes? complete
fault codes. YES
Repair:
See the corresponding Electronic Control
System Troubleshooting and Repair manual
for the engine being serviced.
Active fault codes or high counts of inactive 1D

fault codes?
NO
STEP 1D: Perform the basic troubleshooting checks.

Condition:
• As required.
Check or verify the following items before Are all steps verified to be correct? 1E
continuing. YES
• Battery voltage is low (engine running)
• Lubricating oil level is above specification
• External fuel leak Are all steps verified to be correct? Repair
• Engine idle speed is set too low NO complete
• Engine idle speed is set too high
• Throttle lever or pedal, return spring, or air
throttle damaged or improperly adjusted (use
INSITE™ electronic service tool for electronic
engines)
• Air in the fuel
• Fuel pressure
• Inlet restriction.
STEP 1E: Determine if the engine is running rough.

Condition:
• Engine running at idle speed (less than 900 RPM).
• Accessories off (air conditioning, fan, PTO).
• Engine at operating temperature (greater than 338°C [170°F]).
Determine if the engine is running rough at Is the engine running rough? Complete
engine idle. YES Engine Runs
Refer to the Engine Runs Rough symptom tree Rough
Repair: troubleshooti
in Section TS or the Engine Performance
Refer to the Engine Runs Rough symptom ng tree
Troubleshooting Tree in Section TT.
tree.
Is the engine running rough? 1F

NO
STEP 1F: Perform a visual inspection of the engine mounts (without removal).
Condition:
• Engine not running.
• Engine mounts installed.
Perform a visual inspection of the engine Is there visible engine mount damage? Repair
mounts. YES complete
Look for obvious damage or something shorting Repair:
against the mounts, preventing isolation.
Repair or replace the engine mounts. Refer
Note: A more detail inspection will be carried out to Procedure 016-010 in Section 16 in the
later in the procedure. appropriate service manual.
Is there visible engine mount damage? 1G

NO
STEP 1G: Check for an engine mounted component contacting the frame or body.
Condition:
• Engine mounts installed.
Check for an engine mounted component Engine mounted components touching the Repair
touching the frame or body. frame or body? complete
Inspect the engine and engine mounted YES
components to make sure none of them are Repair:
touching the frame and/or body.
Correct the mounting of the engine mounted
Including but not limited to the following: component.
• Clamps
• Mounting hardware Engine mounted components touching the 1H
• Exhaust system frame or body?
• Air intake piping
• Cooling package support NO
• Etc.
STEP 1H: Marine application.

Condition:
None
Is this engine in a marine application? Is the engine installed in a marine 5A

application?
YES
Is the engine installed in a marine 1I

application?
NO
STEP 1I: Do an engine RPM sweep.

Condition:
• Engine running.
• INSITE™ electronic service tool connected.
• 0 vehicle speed.
Perform a slow (at 100 RPM per second) RPM Is the vibration present stationary below 1050 2A
sweep and note where the vibration occurs. RPM?
Note the engine speed at which any usual YES
vibration or vibration related noise occurs
(mirrors, panels, doors, seat, etc.). Note any Is the vibration present stationary below 1050 1J
speed points or ranges with excessive vibration. RPM?
If a resonance is passed through quickly in NO
getting up to the operating speed range and
doesn't exist in the idle speed or peak operating
range, it represents no major problem.
STEP 1J: Do an engine RPM sweep.

Condition:
• Engine running.
Perform a slow (at 100 RPM per second) RPM Is the vibration present stationary above 1050 1K
sweep and note where the vibration occurs. RPM?
Does the vibration increase progressively from YES
idle to maximum speed? If so, rotating or
reciprocating unbalance is the source. This can Is the vibration present stationary above 1050 4A
be caused by any rotating components or engine RPM?
mount isolation.
NO
STEP 1K: Check the vibration engine speed range.

Condition:
• Engine running.
Perform a slow (at 100 RPM per second) RPM Is the vibration speed range greater than 300 3A
sweep and note where the vibration occurs. to 400 RPM?
This step is to identify if the vibration YES
progressively increases with engine speed or if it
starts and stops within a slow engine RPM band. Is the vibration speed range greater than 300 2A
If the vibration progressively increases with to 400 RPM?
engine speed and has a peak band greater than
300 RPM, this can indicate a rotating component NO
that is out of balance.
If the vibration peak is in a tight band of
approximately 300 to 400 RPM or less, this
indicates that a structural component of the
engine or equipment is going into resonance
because its natural frequency is close to or the
same as the engine firing frequency.
STEP 2: Perform low RPM checks.

STEP 2A: Check that the accessory load is not excessive for the idle speed setting.
Condition:
• Engine running at idle speed (less than 900 RPM).
• Accessories off (air conditioning, fan, and PTO).
• Engine at operating temperature (greater than 77°C [170°F]).
Disable all engine driven accessories and PTOs Are all steps verified to be correct? 2B
to make sure they are not applying excessive YES
load to the engine.
Are all steps verified to be correct? Repair
NO complete
Repair:
Repair as required.
STEP 2B: Check that the Fast Idle Warm-Up feature is activating (if applicable).
Condition:
Check the Fast Idle Warm-Up status. Is the Fast Idle Warm-Up feature inactive? 2C
Use INSITE™ electronic service tool Data YES
Monitor/Logger to check the status of the Fast
Idle Warm-Up feature. Is the Fast Idle Warm-Up feature inactive? Repair
NO complete
Repair:
Disable the Fast Idle Warm-Up feature and
retest for the customer's complaint.
STEP 2C: Check that the Alternator Failure Warning feature is activating (if applicable).
Condition:
Check to see if the Alternator Failure Warning Is the Alternator Failure Warning feature 2D
feature is active. inactive?
Use INSITE™ electronic service tool Data YES
Monitor/Logger to check that the Alternator
Failure Warning feature is active. Is the Alternator Failure Warning feature Repair
inactive? complete
NO
Repair:
Disable the Alternator Failure Warning
feature and retest for the customer's
complaint.
STEP 2D: Check for malfunctioning belt driven accessories.

Condition:
• Drive belt(s) removed.
Remove the drive belt(s) and operate the engine Did the vibration go away with the drive belts Repair
under the conditions where the vibration occurs. removed? complete
Caution: For engines with a belt driven water YES
pump, do not allow the engine to overheat Repair:
during the test. Engine damage will occur.
Repair or replace the malfunctioning belt
driven component.
Did the vibration go away with the drive belts 2E

removed?
NO
STEP 2E: Check for equipment structural modifications.

Condition:
• Visual inspection.
Check for any structural modifications to the Are any structural modifications to the Repair
equipment. equipment present? complete
Check for any structural modifications to the YES
equipment in the engine area that were Repair:
completed by the OEM after equipment
manufacture. Contact the equipment manufacturer. If
possible, remove or isolate the structural
• Snow plows, frame rail extensions, front modification.
bumpers, etc.
Structural modifications can change the natural Are any structural modifications to the 2F
frequency of the frame and engine mounting equipment present?
system, which can result in a vibration complaint.
NO
STEP 2F: Check the engine mount transmissibility of the rear mount.
Condition:
• Loosen the front engine mount capscrews.
• Engine running at the documented RPM where the complaint occurs.
Check the engine mounts. Does the vibration go away during the test 2G
This step is checking to see if the engine mounts condition?
are amplifying the firing frequency of the engine, YES
since the vibration only occurs in a low engine
RPM range. Does the vibration go away during the test 2F-1
• Loosen only the isolator capscrews for the condition?
front engine mount(s) and run the engine at NO
idle.
STEP 2F-1: Check the engine mount transmissibility for all mounts.
Condition:
• Loosen ALL engine mount capscrews.
• Engine running at the documented RPM where the complaint occurs.
Check the engine mounts. Does the vibration go away during the test 2G
condition?
This step is checking to see if the engine mounts
are amplifying the firing frequency of the engine, YES
since the vibration only occurs in a low engine
RPM range. Does the vibration go away during the test 2G
• Loosen the isolator capscrews for ALL of the condition?
engine mounts and run the engine at idle. NO
STEP 2G: Inspect the engine mounts.

Condition:
• Remove engine mount isolators.
This step is a detailed inspection of the engine Are all steps verified to be correct? 2H
mount brackets, isolators, and mounting YES
hardware.
• Check the engine mount isolators for
installation damage. Are all steps verified to be correct? Repair
• Check the alignment of the engine mount NO complete
brackets.
Repair:
• Check for premature wear on the engine
mount isolators and mounting hardware. Repair or replace the damaged components.
STEP 2H: Complaint since new.

Condition:
• Record the odometer/hour meter.
• Review the troubleshooting documentation information questions.
Check the equipment. Has the problem been occurring since the Contact a
equipment was new? Cummins®
Check the equipment mileage/hours and
compare to the vibration customer interview form YES Technical
Support
completed in Step 1A. Repair: Specialist or
• Low mileage is an indication that the complaint The engine mounts are not the right the OEM
has been present since the equipment was specification for the application, or a
new.
structural resonance exists.
• Complaints on new equipment are typically
due to a manufacturing defect in the system or
an inadequate engine mounting design. Has the problem been occurring since the Contact a
equipment was new? Cummins®
NO Technical
Support
Repair: Specialist or
Recheck for shorts, a rough running engine, the OEM
or malfunctioning engine mounts.
STEP 3: Perform higher RPM checks.

STEP 3A: Inspect the engine mounts.
Condition:
• Remove the engine mount isolators.
Inspect the engine mount brackets, isolators, and Are all steps verified to be correct? 3B
mounting hardware. YES
installation damage.
• Check the alignment of the engine mount Are all steps verified to be correct? Repair
brackets. NO complete
Repair:
mount isolators and mounting hardware.
Repair or replace the malfunctioning
components. Refer to Procedure 016-010 in
Section 16 in the appropriate service manual.
STEP 3B: Check for malfunctioning belt driven accessories.

Condition:
• Remove the drive belts.
Check the belt driven accessories. Did the vibration go away with the drive belts Repair
removed? complete
Remove the drive belts and operate the engine
under the conditions where the vibration occurs. YES
Caution: For engines with a belt driven water Repair:
pump, do not allow the engine to overheat Repair or replace the malfunctioning belt
during the test. Engine damage will occur. driven accessory.
Did the vibration go away with the drive belts 3C

removed?
NO
STEP 3C: Check for a damaged vibration damper.

Condition:
Remove and visually inspect the vibration Is the vibration damper damaged or out of Repair
damper. specification? complete
Use Procedure 001-052 in the appropriate YES
service manual for vibration damper inspection Repair:
specifications.
Replace the vibration damper. Reference the
appropriate service manual.
Is the vibration damper damaged or out of 3D

specification?
NO
STEP 3D: Check the air compressor timing.

Condition:
• Air compressor removed.
Check the air compressor timing. Is the air compressor timing correct? 3E
Reference Procedure 012-014 in the appropriate YES
service manual.
Is the air compressor timing correct? Repair
NO complete
Repair:
Correct the air compressor timing and retest
for the vibration complaint. Reference
manual.
STEP 3E: Check the overhead adjustments.

Condition:
• Rocker lever cover removed.
Measure and adjust the overhead settings. Are the overhead adjustments correct? 3F
• Check the overhead components for damage. YES
Reference Procedure 003-004 in the appropriate
service manual. Are the overhead adjustments correct? Repair
NO complete
Repair:
Repair or adjust the overhead. Reference
manual.
STEP 3F: Check for malfunctioning gear driven components.

Condition:
None.
Check the hydraulic pump and air compressor. Did the vibration go away? Repair
If possible, isolate any gear-driven accessories YES complete
and check for vibration. Repair:
Repair or replace the gear driven
components.
Did the vibration go away? 3G

NO
STEP 3G: Check for a damaged PTO.

Condition:
• Disconnect the PTO.
Check the PTO for damage and correct Did the vibration go away? Repair
installation. YES complete
Refer to the OEM service manual. Repair:
Repair the PTO. Refer to the OEM service
manual.
Did the vibration go away? 3H

NO
STEP 3H: Check for a malfunctioning engine internal balancer assembly (4 cylinder B-Series only).
Condition:
• None.
Inspect the engine internal balancer assembly. Does the internal balancer meet 3I
Reference Procedure 001-004 in the appropriate specification?
service manual. YES
Note: This applies to 4 cylinder B-Series engines
only. Does the internal balancer meet Repair
specification? complete
NO
Repair:
Repair the internal balancer. Reference
manual.
STEP 3I: Check the clutch or torque converter for vibration.

Condition:
• Engine running.
With engine running in the operating condition of Did engaging and disengaging the clutch Repair
the vibration, disengage and engage the clutch affect the vibration? complete
serval times. YES
If there is a significant vibration reduction, clutch Repair:
plate(s) balance is the source.
Repair or replace the clutch. Refer to the
OEM service manual.
Did engaging and disengaging the clutch 3J

affect the vibration?
NO
STEP 3J: Check for a loose or damaged flywheel or flex plate.

Condition:
• Transmission removed.
Check the flywheel. Does the flywheel meet specifications? 3K

• Check the flywheel bore and face run out. YES
• Check the flywheel for damage.
Reference Procedure 016-005 in the appropriate Does the flywheel meet specifications? Repair
service manual. complete
NO
Repair:
Repair or replace the flywheel or flexplate.
Reference Procedure 016-005 in the
STEP 3K: Check the flywheel housing for correct alignment.

Condition:
• Transmission removed.
• Flywheel/flexplate removed.
Check the flywheel housing bore and face Does the flywheel housing meet 3L
alignment. specifications?
service manual.
Does the flywheel housing meet Repair
specifications? complete
NO
Repair:
Repair or replace the flywheel housing.
STEP 3L: Check to see if the crankshaft has been balanced.

Condition:
• Lubricating oil pan removed.
Remove the lubricating oil pan. Is the crankshaft balanced? 3M

service manual.
Check the crankshaft to see if it has been Is the crankshaft balanced? Repair
balanced. Reference Procedure 001-016 in the NO complete
Repair:
Note: This step only applies if the complaint has
been present since the engine was new or after Replace the crankshaft. Contact a Cummins®
a crankshaft replacement. Technical Support/Warranty specialist
before proceeding with the repair.
ISX engines built after 01-November-2008 have
a marking on the crankshaft to indicate if it
passed the balancing step in the manufacturing
process. Refer to Procedure 001-016 in Section
1 of the ISX service manual.
STEP 3M: Check for internal engine damage.

Condition:
• None.
Contact a support specialist. Is there internal engine damage? Contact

YES Technical
At this point, a significant amount of labor has
been invested in the repair. Before Support
disassembling the engine, seek troubleshooting
assistance. Contact the appropriate Technical Is there internal engine damage? Contact
Support Channel for your facility. They will NO Technical
provide the necessary guidance and schedule Support
on-site support, if deemed necessary.
• Camshaft journals and number 1 camshaft
bushing are severely damaged
• Gear train backlash is excessive or the gear
teeth are damaged
• Idler gear bushing damaged or worn
• Main or connecting rod bearing damage
• Gears out of balance or gear bushing damage
• Connecting rod damage.
STEP 4: Operate the mobile equipment.

STEP 4A: Perform a diagnostic road test.
Condition:
• Diagnostic road test.
Perform a diagnostic road test, observing where Is the vibration present during a diagnostic 4A-1
the vibration occurs. road test?
If the vibration can be duplicated on the road, YES
place the transmission in neutral and allow the
engine speed to drop to idle under the road Is the vibration present during a diagnostic No repair
speed conditions of the vibration. road test?
NO
STEP 4A-1: Perform a diagnostic road test.

Condition:
• Diagnostic road test.
Perform a diagnostic road test, observing where Is the vibration present with the transmission 4C
the vibration occurs. in neutral, under the road speed conditions,
where the vibration was duplicated driving?
If the vibration can be duplicated on the road,
place the transmission in neutral and allow the YES
engine speed to drop to idle under the conditions
of the vibration. Is the vibration present with the transmission 4B
in neutral, under the road speed conditions,
where the vibration was duplicated driving?
NO
STEP 4B: Inspect the engine mounts.

Condition:
• Remove the engine mount isolators.
This step is a detailed inspection of the engine Are all steps verified to be correct? 4C
mount brackets, isolators, and mounting YES
hardware.
installation damage. Are all steps verified to be correct? Repair
• Check the alignment of the engine mount NO complete
brackets.
Repair:
mount isolators and mounting hardware. Repair or replace damaged components.
• If the equipment is new, check for the proper
mount specification.
Reference Procedure 016-010 in the appropriate
service manual.
STEP 4C: Check for drive train components that are worn, unbalanced, malfunctioning, or are not
correct.
Condition:
• None.
Compare the drive train components to the Are all steps verified to be correct? Contact
engine and equipment specifications. YES Cummins®
Isolate the drive train components and check for Technical
Support and
vibrations. Refer to the OEM service manual.
the OEM
Are all steps verified to be correct? Contact

NO Cummins®
Technical
Support and
the OEM
STEP 5: Marine applications.

STEP 5A: Check the gear ratio and propeller configuration.
Condition:
Check for an incorrect matching of the gear ratio Are the gear ratio and the propeller Repair
and propeller to the engine power. incorrectly matched to the engine power? complete
YES
Repair:
Contact a Cummins® Distributor or a Marine
District Field Service Manager.
Are the gear ratio and the propeller 5B

incorrectly matched to the engine power?
NO
STEP 5B: Check for the correct engine mounting isolators and for proper installation requirements.
Condition:
• None.
Check for the correct engine mount isolators and Are the engine mount isolators correct and 5C
for propeller installation requirements. installed correctly?
YES
Are the engine mount isolators correct and Repair

installed correctly? complete
NO
Repair:
Check for proper isolator installation
requirements. Replace and repair vibration
isolators as needed. Reference Procedure
016-026 in the appropriate service manual
and Engine Mounting/Drive Systems section
in the Marine Recreational Installation
Directions, Bulletin 3884649. If the isolators
are not manufactured by Cummins Inc., refer
STEP 5C: Check for damaged engine mounts and isolators.

Condition:
• None.
Inspect the engine mount and isolators for Are the engine mounts and isolators in good 5D
damage. condition?
YES
Are the engine mounts and isolators in good Repair

condition? complete
NO
Repair:
Remove and replace the engine mount
isolators. Reference Procedure 016-026 in
the appropriate service manual and Engine
Mounting/Drive Systems section in the
Marine Recreational Installation Directions,
Bulletin 3884649. If the isolators are not
manufactured by Cummins Inc., refer to the
OEM service manual.
STEP 5D: Check the exhaust system.

Condition:
• None.
Check for exhaust system deficiencies. Is the exhaust system deficient? Repair
YES complete
Repair:
Repair or replace as needed. See the
Exhaust System section in the Marine
Recreational Installation Directions, Bulletin
3884649, and the OEM service manual.
Is the exhaust system deficient? 5E

NO
STEP 5E: Check the engine driven accessories.

Condition:
Check for engine driven accessory malfunctions. Is an engine driven accessory Repair
• Isolate or disconnect the accessories and malfunctioning? complete
check for vibration. YES
• Do not operate the engine if the sea water
pump is disconnected. Repair:
Determine the cause of the malfunctioning
accessories and correct the problem. See the
Exhaust System section in the Marine
Recreational Installation Directions, Bulletin
3884649, and the OEM service manual.
Is an engine driven accessory 5F

malfunctioning?
NO
STEP 5F: Check the shaft coupling to gear coupling alignment.

Condition:
Check the shaft coupling to gear coupling Is the shaft coupling to gear coupling Repair
alignment. misaligned? complete
YES
Repair:
Repair or replace as needed. Reference
manual and the Engine Mounting/Drive
Systems section in the Marine Recreational
Installation Directions, Bulletin 3884649, and
the gear manufacturer's recommendations.
Is the shaft coupling to gear coupling 5G

misaligned?
NO
STEP 5G: Check the propeller shaft for proper installation.

Condition:
• None.
Check the propeller shaft for proper installation. Is the propeller shaft installed correctly? 5H
YES
Is the propeller shaft installed correctly? Repair

NO complete
Repair:
Repair or replace as needed. Reference
manual and the Engine Mounting/Drive
Systems section in the Marine Recreational
Installation Directions, Bulletin 3884649, and
the gear manufacturer's recommendations.
STEP 5H: Check the propeller shaft for straightness.

Condition:
• None.
Check the propeller shaft for straightness. Is the propeller shaft straightness within the 5I
OEM specification?
YES
Is the propeller shaft straightness within the Repair

OEM specification? complete
NO
Repair:
Repair or replace the propeller shaft as
needed. Refer to an Authorized OEM Service
Location.
STEP 5I: Isolate the engine.

Condition:
• Disconnect the drive shaft.
Run the engine without the drive shaft attached Does the engine vibration persist? Repair
at the coupler. YES complete
Repair:
Check the engine vibration damper for
damage. Repair or replace as needed.
Does the engine vibration persist? 5J

NO
STEP 5J: Check for strut/cutlass bearing misalignment.

Condition:
Check for strut/cutlass bearing misalignment or Is the strut/cutlass bearing misaligned or Repair
strut mounting is not secure. strut mounting not secure? complete
YES
Repair:
Check the strut for mounting stiffness. Repair
or replace as necessary. Refer to an
Authorized OEM Service Location.
Is the strut/cutlass bearing misaligned or 5K

strut mounting not secure?
NO
STEP 5K: Is the propeller out of balance or not fitted properly to the shaft?
Condition:
• None.
Check for propeller out-of-balance or propeller Is the propeller out of balance or not fitted Repair
not fitted properly to shaft. properly to the shaft? complete
YES
Repair:
Check the propeller for accuracy. Repair or
replace as needed. Refer to an Authorized
OEM Service Location.
Is the propeller out of balance or not fitted 5L

properly to the shaft?
NO
STEP 5L: Check the V-angle on the V-strut.

Condition:
• None.
Check to see if the V-angle on the V-strut does Does the V-angle on the V-strut match the 5M
not match the angle of the blade on the propeller. angle of the blade on the prop?
YES
Repair or replace as needed. Refer to an Repair

Authorized OEM Service Location. complete
NO
Repair:
Does the V-angle on the V-strut match the
angle of the blade on the prop?
STEP 5M: Check the propeller tunnels.

Condition:
• None.
Check if the propeller tunnels are properly Does the entry and exit of the propeller tunnel 5N
matched with the propellers. match with the propeller blades?
YES
Does the entry and exit of the propeller tunnel Repair

match with the propeller blades? complete
NO
Repair:
Repair or replace as needed. Refer to an
STEP 5N: Check the engine to transmission torsional coupling.

Condition:
• None.
Check the engine to transmission torsional Is the torsional coupling incorrect or worn? Repair
coupling. YES complete
Repair:
Replace the coupling. Refer to an Authorized
Is the torsional coupling incorrect or worn? 5O

NO
STEP 5O: Check the rudder.

Condition:
None.
Check the rudder for excessive play in the rudder Does the rudder have excessive play in the Repair
post. rudder post? complete
YES
Repair:
Repair or replace as needed. Refer to an
Does the rudder have excessive play in the 5P

rudder post?
NO
STEP 5P: Check the engine flywheel housing to cylinder block alignment.
Condition:
• None.
Check the engine flywheel housing to cylinder Is the flywheel housing alignment incorrect? Repair
block alignment. YES complete
Repair:
Align the flywheel housing to cylinder block.
Is the flywheel housing alignment incorrect? Repair

NO complete
Repair:
The engine can possibly have internal
damage that has not been detected. Analyze
the oil and inspect the filters to locate an area
of probable damage. Reference Procedure
007-083 in the appropriate service manual.
The engine can possibly need to be rebuilt.
Reference Procedure 000-001 and the
engine rebuild specifications in the
appropriate service manual. If the engine is
not damaged, the problem can possibly be
the vessel design. Refer to an Authorized
Section 0 - Complete Engine - Group 00 Page 0-a
Section 0 - Complete Engine - Group 00

Section Contents
Page
Engine Installation ............................................................................................................................................0-7
Finishing Steps.................................................................................................................................................0-9
All Applications..............................................................................................................................................0-9
Install................................................................................................................................................................0-7
Automotive and Industrial...............................................................................................................................0-7
Power Generation..........................................................................................................................................0-8
Engine Removal ................................................................................................................................................0-2
Preparatory Steps.............................................................................................................................................0-2
Remove............................................................................................................................................................0-3
Automotive and Industrial...............................................................................................................................0-3
Power Generation..........................................................................................................................................0-5
Engine Storage - Long Term ...........................................................................................................................0-11
General Information.........................................................................................................................................0-11
Service Tools ....................................................................................................................................................0-1
Engine Removal and Installation.......................................................................................................................0-1
Page 0-b Section 0 - Complete Engine - Group 00

Signature™, ISX, and QSX15 Service Tools
Section 0 - Complete Engine - Group 00 Page 0-1
Service Tools
Engine Removal and Installation
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized
Repair Location.
Tool No. Tool Description Tool Illustration

Engine Lifting Fixture
Used with a hoist to lift the engine.
3162871
Engine Removal Signature™, ISX, and QSX15
Page 0-2 Section 0 - Complete Engine - Group 00
Engine Removal (000-001)

Preparatory Steps
All Applications
Place a tag on all hoses, lines, linkages, and electrical
connections as they are removed to identify their locations
on the engine.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Disconnect the battery cables.
Drain the engine coolant. Refer to Procedure 008-018.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
Drain the lubricating oil. Refer to Procedure 007-037.
Disconnect the starting motor cable, the engine ground
straps, the cab- or chassis-to-engine hoses, the tubing, the
electrical wires, and the hydraulic lines.
Signature™, ISX, and QSX15 Engine Removal
Remove
Automotive and Industrial
Disconnect the intake and the exhaust air pipes.
Disconnect all chassis-mounted, engine-driven
accessories.
Disconnect the drive units from the flywheel.
Disconnect the OEM wiring harness from the electronic

control module (ECM). Refer to Procedure 019-071 in the
Troubleshooting and Repair Manual CM870 Electronic
Control Systems Signature and ISX Engines, Bulletin
4021334.
NOTE: If the rear engine mounts are attached to the

transmission, it will possibly be necessary to remove the
engine and the transmission as an assembly.
Most cab-over configuration vehicles will have the
Cummins® factory-installed rear engine lifting bracket still
installed.
WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection, and wrap a cloth around
the fittings before removing. Liquid refrigerant can
cause serious eye and skin injury.
WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.
Remove all chassis components necessary to remove the

engine.
WARNING
The engine lifting equipment must be designed to lift
the engine and the transmission as an assembly
without causing personal injury.
WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Use a correctly rated hoist, and attach the engine lifting
fixture, Part Number 3162871, to the engine-mounted
lifting brackets to remove the engine.
If the transmission is not removed, place a support under
the transmission to prevent it from falling.
Remove the engine.
Cover all engine openings to prevent dirt and debris from

entering the engine.
Place the engine on suitable engine support stands.
Remove and use all remaining accessories and brackets

with the replacement engine.
Power Generation
accessories.

Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines, Bulletin
3666259.

engine.
WARNING
WARNING
Remove the engine.


Signature™, ISX, and QSX15 Engine Installation
Engine Installation (000-002)

Install
Install all accessories and brackets that were removed
from the previous engine.
If the rear engine mounts are attached to the transmission,

it will possibly be necessary to install the engine and the
transmission as an assembly.
WARNING
WARNING
Use a correctly rated hoist, and attach engine lifting
lifting brackets to install the engine.
CAUTION
Make sure all lines, hoses, and tubes are correctly
routed and fastened to prevent damage.
Align the engine in the chassis, and tighten the engine
mounting capscrews. Refer to the equipment
manufacturer's torque specifications.
Connect all engine and chassis-mounted accessories that
were removed.
Engine Installation Signature™, ISX, and QSX15
Connect the OEM wiring harness to the ECM. Refer to

Procedure 019-071 in the Troubleshooting and Repair
Manual CM870 Electronic Control Systems Signature and
ISX Engines, Bulletin 4021334.
Power Generation

WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer

Manual Electronic Control System Signature, ISX and
Finishing Steps
All Applications
Fill and prime the engine with clean 15W-40 lubricating oil.
Refer to the equipment manufacturer's specifications for

radiator and system capacity.
Fill the cooling system. Refer to Procedure 008-018.
Make a final inspection to make sure all hoses, wires,

linkages, and components have been correctly installed
and tightened.
WARNING
Operate the engine at low idle for 2 to 3 minutes.
Stop the engine and wait 15 minutes for the oil to drain to
the oil pan.
Check the oil and the coolant levels again.
Fill the engine to the correct coolant level, if necessary.

Fill the engine to the correct oil level, if necessary. Refer
Operate the engine for 8 to 10 minutes to check for correct

engine operation, unusual noises, and coolant, fuel, or
lubricating oil leaks.
Repair all leaks and component problems. Refer to the
appropriate sections.
Signature™, ISX, and QSX15 Engine Storage - Long Term
Engine Storage - Long Term (000-005)

General Information
CAUTION
After 24 months in storage, the engine cooling system must be drained and flushed with a suitable solvent
or a hot, lightweight mineral oil. Repeat flushing procedure a second time before being put back into service.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°
F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
This procedure describes the proper method for the long-term (more than 6 months) storage of an engine that is
currently in running condition. This procedure applies to this engine either remaining in chassis - or being removed
out of chassis upon completion of the steps below.
• Operate the engine at high idle until the coolant temperature is 70°C [160°F].
• For engines with aftertreatment devices, perform an active regen to ensure that the aftertreatment is clean before
putting the engine in storage.
• Turn the engine off.
• Drain the oil.
• Install the drain plugs.
• Fill the engine to the high mark using Tectyl™ 910 or equivalent engine preservative oil. This will provide long term
engine rust protection. The oil must meet military specification MIL-PRF-21260, Type P-10, Grade 2, SAE 30.
• Let the engine run for approximately 25 minutes in order to ensure that the engine preservative oil (Tectyl 910 E
or equivalent) is distributed around the engine and its internal components.
CAUTION
DO NOT use fuel system preservative oil on Natural Gas, Propane or Diesel Engines with High Pressure
Common Rail Fuel System or Modular Common Rail Fuel System (MCRS).
Skip the following five steps for Natural Gas, Propane or Diesel Engines with High Pressure Common Rail
Fuel System or Modular Common Rail Fuel System (MCRS).
• Disconnect the engine fuel supply and fuel injector return lines.
• Fill one container with diesel fuel, and the second container with Nox-Rust™ No.518, or equivalent fuel system
preservative oil. The preservative oil must meet Military Specification VV-L-800.
• Put the engine fuel supply and fuel injector return lines in the container that is filled with Diesel fuel and start
the engine.
• After ensuring that the engine is running smoothly, quickly transfer the engine fuel supply line to the container
containing the fuel system preservative oil (Nox-Rust™ No.518, or equivalent) while leaving the fuel injector
return line in the diesel container.
• Operate the engine until the fuel system preservative oil visibly flows out of the fuel injector return line.
• Turn the engine "OFF"
• If you have removed the engine fuel supply and the fuel injector return lines, remove them.
• Drain all the preservative oil from the engine oil pan sump, the air compressor (if applicable), and all the fuel filters
and oil filters.
• If the engine is being stored as a loose engine, drain the engine coolant and cover all cooling system openings
with plastic and tape.
• If the engine is not being removed from chassis and the engine has an extended life coolant with rust inhibitor,
then coolant does NOT need to be drained.
• If the engine will remain in storage for over 24 months, the engine cooling system must be drained and flushed
with a suitable solvent or a hot, lightweight mineral oil. Repeat after each 24 month period.
Engine Storage - Long Term Signature™, ISX, and QSX15
• Remove the intake and exhaust manifolds.

• Spray preservative oil into the intake and exhaust ports in the cylinder heads and in the manifolds.
• Spray preservative oil in the inlet port on the air compressor (if applicable)
• Remove the rocker lever covers.
• Spray the rocker levers, the valve stems, the springs, the valve guides, the crossheads, and the push rods with
preservative oil.
• Install the rocker lever covers, intake and exhaust manifolds.
• Brush or spray the preverative oil on all the exposed surfaces that are not painted. Make sure to coat the flywheel,
flywheel housing and all other unpainted machined surfaces with this preservative oil. Use a rust preservative oil
compound that meets military specification MIL-C-16173C, type P-2, Grade 1 or 2.
• Remove the exhaust aftertreatment components (if applicable).
• Cover all the openings (engine and components) with heavy paper and tape to prevent dirt and moisture from
entering the engine. Cover the entire engine with plastic.
• Put a warning tag on the engine. The tag must indicate:
• Do not operate the engine.
• Do not bar the crankshaft.
• The engine has been treated with preservatives.
• The coolant has been removed.
• The date of treatment.
CAUTION
The engine must be stored in an area that is dry and has uniform temperature.
• The engine must be stored in an area that is dry and has a uniform temperature
NOTE:
To remove the engine from long term storage, follow the following steps:
CAUTION
To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.
• Flush the engine preservative oil out of the engine by removing the plug from the main engine oil rifle and pumping
a hot, lightweight mineral oil through it. Make sure that the engine crankshaft is barred at least three to four
revolutions during this flushing procedure.
• Drain all the mineral oil that was used to flush the engine clean aof the engine preservative oil.
• Install new oil, fuel and coolant filters.
• Fill the engine to the high mark with engine oil.
• If the engine has been in storage for less than 24 months and if the cooling system was drained, fill the cooling
system with coolant. Refer to Procedure 018-004(Coolant Recommendations/Specifications) in Section V for
antifreeze, water, and SCA specifications.
• If the engine has been in storage for 24 months, every 24 months the engine cooling system must be drained
and flushed with a suitable solvent or a hot, lightweight mineral oil. Fill the cooling system with coolant. Refer
to Procedure 018-004(Coolant Recommendations/Specifications) in Section V for antifreeze, water, and SCA
specifications.
• If the engine has been in storage for less than 24 months and the engine has an extended life coolant with a
rust inhibitor, drain the cooling system. Fill the cooling system with coolant. Refer to Procedure 018-004(Coolant
Recommendations/Specifications) in Section V for antifreeze, water, and SCA specifications.
• Adjust the injector (if applicable) and valve clearances. Refer to the Overhead Set procedure in the corresponding
Base Troubleshooting and Repair Manual or Service Manual for the engine being serviced.
• Tighten the intake and exhaust manifold mounting capscrews.
• Prime the lubricating system.
NOTE: Skip this step for if the fuel system has been treated with fuel system preservative oil.
Signature™, ISX, and QSX15 Engine Storage - Long Term
NOTE: Using fuel system preservative oil on Natural Gas, Propane or Diesel Engines with High Pressure Common
Rail Fuel System or Modular Common Rail Fuel System (MCRS) is prohibited.
• If the fuel system has been treated with fuel system preservative oil, as much of the preservative oil as possible
needs to be flushed out of the fuel system prior to attempting to start the engine. Depending on the engines's
fuel system, this can be done by using an external pump to pump clean diesel fuel into the fuel system and
removing various fuel lines to flush the fuel system preservative oil out. Upon flushing the fuel system, make
sure all fuel lines are securely tightened prior to attempting to start the engine.
NOTE: For engines with exhaust aftertreatment components, do not install those components yet. Run the engine
for 15 minutes at operating temperature without the exhaust aftertreatment components. This will prevent any of
the preservatives from damaging the Diesel Particulate Filter (DPF). There will be active faults during this time,
but these fault codes will clear when the aftertreatment is reinstalled.
• Note that if might take multiple cranking attempts to start the engine. Do not crank the engine more than 30
seconds at a time as this might cause the starter to overheat and fail.
• Note that the engine might run rough until the fuel system is completely primed or until all residual fuel system
preservative oil is completely flushed out of the fuel system (if the fuel has been treated with fuel system
preservative oil).
• Install the exhaust aftertreatment components (if applicable).
• Force an active regeneration (if applicable).
Engine Storage - Long Term Signature™, ISX, and QSX15
Notes
Section DS - Engine Disassembly Group 00 Page DS-a
Section DS - Engine Disassembly Group 00

Section Contents
Page
Aftertreatment Adapter Pipe ........................................................................................................................DS-27
Remove........................................................................................................................................................DS-27
Aftertreatment Fuel Injector .........................................................................................................................DS-28
Remove........................................................................................................................................................DS-28
Aftertreatment Fuel Shutoff Manifold ..........................................................................................................DS-24
Remove........................................................................................................................................................DS-24
Aftertreatment Injector Lines .......................................................................................................................DS-20
Remove........................................................................................................................................................DS-20
Air Compressor .............................................................................................................................................DS-63
Remove........................................................................................................................................................DS-63
Air Compressor Coolant Lines .....................................................................................................................DS-63
Finishing Steps.............................................................................................................................................DS-63
Remove........................................................................................................................................................DS-63
Air Intake Connection ...................................................................................................................................DS-19
Remove........................................................................................................................................................DS-19
Automotive with CM870.............................................................................................................................DS-19
Automotive With CM871............................................................................................................................DS-19
Automotive, Industrial with CM570 and Power Generation without CM570................................................. DS-19
Alternator ......................................................................................................................................................DS-53
Remove........................................................................................................................................................DS-53
Driven by Cooling Fan Drive Belt...............................................................................................................DS-53
Alternator/Refrigerant Compressor Mounting Bracket ................................................................................DS-54
Remove........................................................................................................................................................DS-54
Bearings, Connecting Rod ...........................................................................................................................DS-75
Remove........................................................................................................................................................DS-75
Bearings, Main ..............................................................................................................................................DS-84
Remove........................................................................................................................................................DS-84
Bearings, Thrust ...........................................................................................................................................DS-83
Remove........................................................................................................................................................DS-83
Belt Tensioner, Automatic (Water Pump) ....................................................................................................DS-10
Remove........................................................................................................................................................DS-10
Drives Alternator........................................................................................................................................DS-10
Automotive Applications............................................................................................................................ DS-11
Industrial and Power Generation................................................................................................................DS-11
Belt Tensioner, Refrigerant Compressor, Automatic ..................................................................................DS-14
Remove........................................................................................................................................................DS-14
With Water Pump and Refrigerant Compressor Belt Routing......................................................................DS-14
Block Stiffener Plate .....................................................................................................................................DS-72
Remove........................................................................................................................................................DS-72
Coolant Filter ..................................................................................................................................................DS-8
Remove.........................................................................................................................................................DS-8
Coolant Thermostat ......................................................................................................................................DS-52
Remove........................................................................................................................................................DS-52
Coolant Thermostat Housing .......................................................................................................................DS-50
Remove........................................................................................................................................................DS-50
Single Thermostat.....................................................................................................................................DS-50
Dual Thermostat........................................................................................................................................DS-50
Cooling System ..............................................................................................................................................DS-1
Drain..............................................................................................................................................................DS-1
Crankcase Breather (External) .....................................................................................................................DS-15
Remove........................................................................................................................................................DS-15
Crankshaft .................................................................................................................................................... DS-83
Page DS-b Section DS - Engine Disassembly Group 00
Remove........................................................................................................................................................DS-83
Crankshaft Seal, Front ................................................................................................................................. DS-62
Remove........................................................................................................................................................DS-62
Crankshaft Seal, Rear ...................................................................................................................................DS-77
Measure.......................................................................................................................................................DS-78
Remove........................................................................................................................................................DS-77
Cylinder Head ...............................................................................................................................................DS-70
Remove........................................................................................................................................................DS-70
Cylinder Liner ...............................................................................................................................................DS-85
Remove........................................................................................................................................................DS-85
Drive Belt, Cooling Fan ................................................................................................................................DS-10
Remove........................................................................................................................................................DS-10
Drives Alternator........................................................................................................................................DS-10
Drive Belt, Refrigerant Compressor .............................................................................................................DS-14
Remove........................................................................................................................................................DS-14
ECM Cooling Plate, Fuel Cooled ..................................................................................................................DS-20
Remove........................................................................................................................................................DS-20
EGR Connection Tubes ................................................................................................................................DS-44
Remove........................................................................................................................................................DS-44
EGR Cooler ...................................................................................................................................................DS-46
Remove........................................................................................................................................................DS-46
EGR Cooler Coolant Lines ............................................................................................................................DS-39
Remove........................................................................................................................................................DS-39
EGR Mixer .....................................................................................................................................................DS-18
Remove........................................................................................................................................................DS-18
EGR Valve .....................................................................................................................................................DS-41
Remove........................................................................................................................................................DS-41
EGR Valve Coolant Lines .............................................................................................................................DS-41
Remove........................................................................................................................................................DS-41
EGR Valve Mounting Bracket .......................................................................................................................DS-42
Remove........................................................................................................................................................DS-42
Engine Base Timing ..................................................................................................................................... DS-64
Remove........................................................................................................................................................DS-64
Engine Lifting Brackets ................................................................................................................................DS-49
Remove........................................................................................................................................................DS-49
Engine Removal ..............................................................................................................................................DS-4
Remove.........................................................................................................................................................DS-4
Automotive and Industrial............................................................................................................................DS-4
Power Generation........................................................................................................................................DS-6
Engine Support Bracket, Front ....................................................................................................................DS-71
Remove........................................................................................................................................................DS-71
Exhaust Gas Pressure Sensor Adapter ....................................................................................................... DS-43
Remove........................................................................................................................................................DS-43
All Applications..........................................................................................................................................DS-43
Exhaust Gas Pressure Sensor Tube ............................................................................................................DS-43
Remove........................................................................................................................................................DS-43
Exhaust Manifold, Dry ..................................................................................................................................DS-44
Remove........................................................................................................................................................DS-44
Fan Hub, Belt Driven ....................................................................................................................................DS-12
Remove........................................................................................................................................................DS-12
Industrial CM570 and Power Generation without CM570............................................................................DS-13
Fan Support ..................................................................................................................................................DS-13
Remove........................................................................................................................................................DS-13
Flywheel ........................................................................................................................................................DS-77
Remove........................................................................................................................................................DS-77
Flywheel Housing .........................................................................................................................................DS-79
Remove........................................................................................................................................................DS-79
Flywheel Housing, REPTO ...........................................................................................................................DS-80
Remove........................................................................................................................................................DS-80
Section DS - Engine Disassembly Group 00 Page DS-c
Fuel Filter (Spin-On Type) ..............................................................................................................................DS-9

Remove.........................................................................................................................................................DS-9
Gear Cover, Lower .......................................................................................................................................DS-63
Remove........................................................................................................................................................DS-63
Gear Cover, Upper ........................................................................................................................................DS-61
Remove........................................................................................................................................................DS-61
Automotive Applications............................................................................................................................DS-61
Gear Housing, Front .....................................................................................................................................DS-82
Remove........................................................................................................................................................DS-82
Heat Shield ...................................................................................................................................................DS-38
Remove........................................................................................................................................................DS-38
Idler Gear, Lower Scissor .............................................................................................................................DS-71
General Information......................................................................................................................................DS-71
Idler Pulley, Refrigerant Compressor ..........................................................................................................DS-14
Remove........................................................................................................................................................DS-14
Injector ..........................................................................................................................................................DS-58
Remove........................................................................................................................................................DS-58
Integrated Fuel System Module (IFSM) ........................................................................................................DS-25
Remove........................................................................................................................................................DS-25
Lubricating Oil Cooler ..................................................................................................................................DS-48
Remove........................................................................................................................................................DS-48
All Applications..........................................................................................................................................DS-48
Lubricating Oil Dipstick Tube ......................................................................................................................DS-18
Remove........................................................................................................................................................DS-18
Lubricating Oil Fill Tube ...............................................................................................................................DS-16
Remove........................................................................................................................................................DS-16
Lubricating Oil Filter (Spin-On) ......................................................................................................................DS-8
Remove.........................................................................................................................................................DS-8
Lubricating Oil Pan .......................................................................................................................................DS-71
Remove........................................................................................................................................................DS-71
Lubricating Oil Pump ....................................................................................................................................DS-83
Remove........................................................................................................................................................DS-83
Lubricating Oil Suction Tube (Block-Mounted) ...........................................................................................DS-72
Remove........................................................................................................................................................DS-72
Lubricating Oil System ...................................................................................................................................DS-3
Drain..............................................................................................................................................................DS-3
Overhead Camshaft, Injector .......................................................................................................................DS-69
Remove........................................................................................................................................................DS-69
Overhead Camshaft, Valve ...........................................................................................................................DS-68
Remove........................................................................................................................................................DS-68
Piston and Connecting Rod Assembly ........................................................................................................DS-73
Remove........................................................................................................................................................DS-73
Piston Cooling Nozzle ..................................................................................................................................DS-72
Remove........................................................................................................................................................DS-72
Piston Rings .................................................................................................................................................DS-76
Remove........................................................................................................................................................DS-76
Refrigerant Compressor ...............................................................................................................................DS-14
Remove........................................................................................................................................................DS-14
Sanden......................................................................................................................................................DS-14
Climate Control Incorporated.....................................................................................................................DS-15
Refrigerant Compressor Mounting Bracket .................................................................................................DS-54
Remove........................................................................................................................................................DS-54
Sanden......................................................................................................................................................DS-54
Climate Control Incorporated.....................................................................................................................DS-55
Automotive, Industrial with CM570 and Power Generation without CM570.................................................DS-55
Page DS-d Section DS - Engine Disassembly Group 00
Rocker Lever Assembly ...............................................................................................................................DS-57

Remove........................................................................................................................................................DS-57
Rocker Lever Cover ........................................................................................................................................DS-9
Remove.........................................................................................................................................................DS-9
Starting Motor ...............................................................................................................................................DS-10
Remove........................................................................................................................................................DS-10
All Except 50MT With Aluminum Flywheel Housing....................................................................................DS-10
50MT With Aluminum Flywheel Housing....................................................................................................DS-10
Turbocharger ................................................................................................................................................DS-30
Clean...........................................................................................................................................................DS-31
Inspect for Reuse.........................................................................................................................................DS-32
Remove........................................................................................................................................................DS-30
Turbocharger Air Shutoff Valve Filter .........................................................................................................DS-25
Remove........................................................................................................................................................DS-25
Variable Geometry.....................................................................................................................................DS-25
Turbocharger Control Shutoff Valve Filter Head .........................................................................................DS-26
Remove........................................................................................................................................................DS-26
Turbocharger Coolant Hoses .......................................................................................................................DS-29
Remove........................................................................................................................................................DS-29
Turbocharger, Variable Geometry Actuator ................................................................................................DS-28
Remove........................................................................................................................................................DS-28
Turbocharger, Variable Geometry Actuator Air Supply Line ......................................................................DS-27
Remove........................................................................................................................................................DS-27
Turbocharger, Variable Geometry Control Valve Air Supply Line ..............................................................DS-26
Remove........................................................................................................................................................DS-26
Vibration Damper, Viscous ..........................................................................................................................DS-59
Remove........................................................................................................................................................DS-59
Automotive Applications............................................................................................................................DS-59
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................DS-59
Industrial and Power Generation without Crank-Driven Fan or PTO............................................................DS-60
Water Inlet Connection .................................................................................................................................DS-55
Remove........................................................................................................................................................DS-55
Water Pump ..................................................................................................................................................DS-55
Remove........................................................................................................................................................DS-55
Industrial CM570 and Power Generation without CM570............................................................................DS-56
Signature™, ISX, and QSX15 Cooling System
Section DS - Engine Disassembly Group 00 Page DS-1
Cooling System (008-018)

Drain
Position the equipment on level ground.
WARNING
NOTE: If the coolant is being changed, or if the cooling
system is being flushed, leave the coolant flow valves to
the equipment heating systems open, in order to
completely drain the system.
NOTE: Refer to the OEM service manual for special
coolant drain requirements. Special instructions may also
be located near the cooling system access point or fill door
on the vehicle.
Isolate the engine from the vehicle cooling system by
closing coolant flow valves to the equipment heating
systems before starting the repair. This will prevent the
heater circuit from draining, minimizing the chance for air
pockets to be present during the fill process.
This air can be very difficult to purge in some applications
that have several feet of plumbing and multiple heater
cores.
Remove the radiator cap or expansion tank fill cap to allow
the coolant to drain completely.
Cooling System Signature™, ISX, and QSX15
Page DS-2 Section DS - Engine Disassembly Group 00
WARNING
Do not allow the cooling system to dry out.
If the coolant is to be reused, the holding container must
be free of oil and dirt.
A drain pan with a capacity of 57 liters [51 gal] is adequate
for most applications.
Before adding coolant back into the engine, it must be
tested for SCA (Supplemental Coolant Additive)
concentration.
For automotive applications, use the Signature™ and ISX
Operation and Maintenance Manual, Bulletin 3666251.
Refer to Procedure 018-004 in Section V.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.
Open the radiator drain valve(s).
Remove the lower radiator hose(s).
Do not remove the coolant filter.
Check for damaged hoses and loose or damaged hose

clamps. Replace as required.
Check the radiator for leaks, damage, and buildup of dirt.
Clean and replace, as needed.
Close the drain valve(s).
Install the lower radiator hose(s). Refer to the OEM service
manual.
Signature™, ISX, and QSX15 Lubricating Oil System
Lubricating Oil System (007-037)

Drain
WARNING
WARNING
Operate the engine until the water temperature reaches
60°C [140°F].
Shut off the engine.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.
If lubricating oil element failure occurs resulting in
contamination of the lubricating oil, the following is
recommended:
• Inspect the lubricating oil filter by cutting it open and
inspecting for debris. Refer to Procedure 007-083.
• If debris is not found, drain the lubricating oil and
remove the lubricating oil pan. Clean and reinstall the
lubricating oil pan. Refer to Procedure 007-025.
• Remove the valve cover and clean the contaminated
lubricating oil from the cylinder head cavities. This can
be done using a siphoning device. Refer to Procedure
003-011.
• If debris is found, refer to the Cummins Warranty
Administration Manual, Bulletin 4021290.
Install the oil pan drain plug(s) before adding engine oil to
the system.
Torque Value: 47 N•m [ 35 ft-lb ]
Engine Removal (000-001)

Remove
accessories.

Troubleshooting and Repair Manual CM870 Electronic
Control Systems Signature and ISX Engines, Bulletin
4021334.
NOTE: If the rear engine mounts are attached to the

transmission, it will possibly be necessary to remove the
engine and the transmission as an assembly.
Most cab-over configuration vehicles will have the
Cummins® factory-installed rear engine lifting bracket still
installed.
WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection, and wrap a cloth around
the fittings before removing. Liquid refrigerant can
cause serious eye and skin injury.
WARNING

engine.
WARNING
WARNING
If the transmission is not removed, place a support under
the transmission to prevent it from falling.
Remove the engine.


Power Generation
accessories.

Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines, Bulletin
3666259.

engine.
WARNING
WARNING
Remove the engine.


Coolant Filter Signature™, ISX, and QSX15
Lubricating Oil Filter (Spin-On)

(007-013)
Remove
WARNING
WARNING
NOTE: If the lubricating oil filter head adapter comes off
during the removal of the lubricating oil filter, then reinstall
the oil filter head adapter. Use a small amount of Loctite™
on the threads of the oil filter head adapter and tighten.
Refer to Procedure 007-018 (Lubricating Oil Filter Head
Adaptor) in Section 7.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to remove the oil filter.
Coolant Filter (008-006)

Remove
WARNING
Remove the cooling system pressure cap.
WARNING
Turn the coolant on/off valve to the OFF position.
Do not use force to open or close the on/off valve. If the
valve does not turn freely, refer to Procedure 008-082.
Remove and discard the coolant filter. Clean the gasket
surface on the filter head.
Signature™, ISX, and QSX15 Rocker Lever Cover
Fuel Filter (Spin-On Type) (006-015)

Remove
With Pressurized Fuel Filtering
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
Clean the area around the fuel filter head and filter.
Remove the fuel filter with filter wrench, Part Number
3400157.
With Vacuum Fuel Filtering
WARNING
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
3400158.
Rocker Lever Cover (003-011)

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

that have the cover gasket embedded in the rocker lever
cover.
Completely loosen the eight capscrews and isolator
assemblies.
Remove the rocker lever cover, the cover gasket and the
isolators all together as an assembly.
The cover gasket is reusable. Do not damage the cover
gasket when removing the cover or when setting the
assembly aside during repair.
Belt Tensioner, Automatic (Water Pump) Signature™, ISX, and QSX15
Starting Motor (013-020)

Remove
All Except 50MT With Aluminum Flywheel Housing
Remove the three capscrews, starting motor, and starting
motor spacer (if used).
50MT With Aluminum Flywheel Housing

Remove the three mounting capscrews, starting motor,
and starting motor spacer (if used), as well as the
necessary starting motor brackets.
Drive Belt, Cooling Fan (008-002)

Remove
Drives Alternator
CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or cause personal injury.
Pivot the automatic tensioner down to relieve tension on
the belt.
Remove the belt.
Belt Tensioner, Automatic (Water

Pump) (008-080)
Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.
Signature™, ISX, and QSX15 Belt Tensioner, Automatic (Water Pump)
Automotive Applications
NOTE: Different engine configurations utilize different belt
tensioner bracket and belt tensioner arrangements.
For the low-mount belt tensioner:
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Remove the belt tensioner bracket from the water pump.
For the mid-mount belt tensioner:

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

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

support.
Fan Hub, Belt Driven Signature™, ISX, and QSX15
For the low-mount (large version) belt tensioner:


support.
Fan Hub, Belt Driven (008-036)

Remove
WARNING
Remove the mounting capscrews and the fan hub
assembly.
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
Remove alternator belt tensioner and bracket.
Remove the capscrews and the fan hub assembly.
Signature™, ISX, and QSX15 Fan Support
Industrial CM570 and Power Generation without

CM570
Remove the fan hub mounting capscrews.
Remove the fan hub from the fan support.
Fan Support (008-088)

Remove
Remove the belt tensioner support bracket from the fan
support.
Remove two capscrews and install two guide studs.

Remove the remaining six capscrews.
Remove the fan support and guide studs.

Refrigerant Compressor Signature™, ISX, and QSX15
Drive Belt, Refrigerant Compressor

(009-052)
Remove
With Water Pump and Refrigerant Compressor Belt
Routing
CAUTION
Pivot the automatic tensioner counterclockwise to
relieve tension on the belt.
Remove the belt.
Idler Pulley, Refrigerant Compressor

(009-054)
Remove
Routing
Remove the pulley mounting capscrew.
Remove the refrigerant compressor idler pulley.
Belt Tensioner, Refrigerant

Compressor, Automatic (009-053)
Remove
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.
Refrigerant Compressor (009-051)

Remove
Sanden
Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor.
Signature™, ISX, and QSX15 Crankcase Breather (External)
Climate Control Incorporated

capscrews.
Remove the refrigerant compressor and bracket
assembly.
Crankcase Breather (External)

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

cover and block.
Disassemble the breather tube.

Lubricating Oil Fill Tube Signature™, ISX, and QSX15

Disconnect the wiring connector from the breather
pressure sensor.
Loosen the two hose clamps on the inlet hose.
Disconnect hose from breather. Loosen outlet hose
clamp.
Disconnect the outlet hose.
Disconnect the breather oil drain line.
Remove the drain line inline with the connection nipple,
do not bend.
Remove the four mounting capscrews from the crankcase
breather element housing to the breather housing bracket
and remove the housing assembly.
Lubricating Oil Fill Tube (007-065)

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

rotate the oil fill tube connection.
Rotate the oil fill tube connection counterclockwise to
remove.
Signature™, ISX, and QSX15 Lubricating Oil Fill Tube
Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube ring seal
3. Oil fill cap ring seal.
CAUTION
breakage
Remove the tube brace capscrews from the gear cover.
Remove the oil fill tube from the oil fill tube connection.

remove. A smooth, rounded end, bar can be used for
leverage to rotate the oil fill tube connection.
EGR Mixer Signature™, ISX, and QSX15
Ring seals:
2. Oil fill tube o-rings
Lubricating Oil Dipstick Tube

(007-011)
Remove
Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.

clamp.
EGR Mixer (011-021)

Remove
Do not remove the EGR inlet pipe into the EGR mixer.
This is a precision interface and performance will be
affected if disturbed. There is no service procedure for this
and none is required.
Remove the capscrews at the four-bolt flange between the
EGR mixer and the air intake horn.
Signature™, ISX, and QSX15 Air Intake Connection
Air Intake Connection (010-080)

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

Remove the four capscrews that hold the air intake
Cover all open points on the air intake connection and

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

Remove the four mounting capscrews, air inlet
connection, and gasket.
Aftertreatment Injector Lines Signature™, ISX, and QSX15
ECM Cooling Plate, Fuel Cooled

(006-006)
Remove
Disconnect the ECM cooling plate fuel supply line (bottom)
from the integrated fuel system module and the ECM
cooling plate.
Disconnect the ECM cooling plate fuel return line (top)
from the fuel pump and the ECM cooling plate.
Remove the five ECM mounting capscrews and the ECM.

Remove the six cooling plate mounting capscrews and
washers.
Remove the cooling plate and gasket.
Remove five insulating washers and the one ground

washer from the cooling plate mounting holes.
Aftertreatment Injector Lines

(011-051)
Remove
Disconnect the aftertreatment injector coolant supply line
at the inlet to the aftertreatment injector.
at the EGR cooler.
Remove the aftertreatment injector coolant supply line.
Signature™, ISX, and QSX15 Aftertreatment Injector Lines
Disconnect the aftertreatment injector coolant return line

at the aftertreatment injector.
at the oil cooler.
Remove the aftertreatment injector coolant return line.
WARNING
repairs in the fuel system, to reduce the impossibility
of fire and resulting severe personal injury, death or
3375249.
Disconnect the wiring harness from the shut off valve, fuel
drain valve, and pressure sensor.
Disconnect the aftertreatment injector fuel supply line

from the supply outlet of the fuel rifle.
Disconnect the aftertreatment injector fuel supply line at
the inlet to the fuel shutoff manifold.
Remove the aftertreatment injector fuel supply line.
For access lower the fuel shutoff manifold by removing the

two mounting capscrews.
Disconnect the fuel return line from the fuel shutoff

manifold and the fuel control module.

the outlet of the fuel shutoff manifold.
Disconnect the fuel lines from the union fitting, located just
above the EGR valve.
the inlet to the aftertreatment injector, use a 9/16 inch
wrench. In some applications, access to the
aftertreatment injector is difficult and requires removal of
the exhaust adapter pipe. Refer to Procedure 011-043 in
Section 11.

at the coolant heater housing.

at the coolant return manifold.


manifold and the fuel return tee fitting, located in front of
the engine control module.
Remove the P-clips.

the inlet to the aftertreatment injector. In some
applications, access to the aftertreatment injector is
difficult and requires removal of the exhaust adapter pipe.
Aftertreatment Fuel Shutoff Manifold Signature™, ISX, and QSX15
Aftertreatment Fuel Shutoff Manifold

(011-052)
Remove
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Fuel Shutoff Manifold - Make sure the area around the fuel
shutoff manifold is clear of debris.
Use compressed air to clean the area and remove any
loose dirt particles.
Remove the two mounting capscrews.

Remove the fuel shutoff manifold.
Remove the aftertreatment fuel shutoff valve (1),

aftertreatment fuel drain valve (2), and aftertreatment
pressure sensor (3) with a 1-1/8 inch open end wrench.
WARNING
personal injury.
Signature™, ISX, and QSX15 Turbocharger Air Shutoff Valve Filter


Integrated Fuel System Module (IFSM)

(005-073)
Remove
WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Remove two mounting capscrews from the IFSM.
Install two guide studs.
Remove the remaining capscrews, IFSM, and gasket.
Discard the gasket, if damaged.
Turbocharger Air Shutoff Valve Filter

(010-114)
Remove
Variable Geometry
Use filter wrench and remove the air filter from the
turbocharger control shutoff valve.
Turbocharger Control Shutoff Valve Filter Head Signature™, ISX, and QSX15
Turbocharger, Variable Geometry

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

Mask the end of the air line and turbocharger control
shutoff valve to prevent contamination.
Turbocharger Control Shutoff Valve

Filter Head (010-115)
Remove
Variable Geometry
Remove the turbocharger control shutoff valve filter head.
Signature™, ISX, and QSX15 Aftertreatment Adapter Pipe

Actuator Air Supply Line (010-120)
Remove
CAUTION
Disconnect the air line at the turbocharger actuator.
Mask the end of the air line and turbocharger actuator to
prevent contamination.
Remove the p-clip at the thermostat housing.

valve.
Remove the turbocharger control valve air line.
Aftertreatment Adapter Pipe (011-043)

Remove
Remove the V-band clamp between the exhaust adapter
pipe and the turbocharger.
pipe and the OEM exhaust down-pipe.
Remove the adapter pipe assembly from engine.
Remove the gasket from each end and discard. Do not
use a screwdriver or other sharp tool to remove the
gaskets. This will damage the gasket seating area.
Remove the aftertreatment injector from the adapter pipe.
Turbocharger, Variable Geometry Actuator Signature™, ISX, and QSX15
Aftertreatment Fuel Injector (011-042)

Remove
Remove the adaptor tube gasket.
Remove the capscrews holding the injector.

Remove the injector assembly.
Cut the EZ tie holding the injector harness to the heat
shield.
Discard the metal gasket.
Discard the fibrous insulator.
Remove the capscrew spacers.

Actuator (010-113)
Remove
Variable Geometry
CAUTION
The keyswitch must be in the OFF position to make
sure no air pressure is present at the actuator.
Remove the capscrew holding the actuator rod to the
turbocharger cross-shaft.
Remove the snap ring from the cross-shaft.
WARNING
Keep fingers and hands away from the actuator link to
reduce the possibility of personal injury as a result of
sudden movement when air is supplied.
Loosen the two capscrews holding the actuator to the
turbocharger bearing housing.
Use coupling, Part Number 3824843, to apply 414 kPa [60
psi] regulated air pressure to the actuator air inlet, to
reduce the spring load at the linkage.
Remove the two loosened capscrews and actuator.
Signature™, ISX, and QSX15 Turbocharger Coolant Hoses
Turbocharger Coolant Hoses (010-041)

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

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

Remove the turbocharger coolant supply hose from the
lubricating oil filter head (1).
Remove the smaller banjo bolt from the turbocharger
electric actuator coolant inlet port (2) and the large banjo
bolt from the turbocharger bearing housing coolant inlet
port (3).

Remove the turbocharger bearing housing coolant return
hose from the top of the turbocharger and the thermostat
housing (1).
Remove the turbocharger actuator coolant return hose
from the top of the turbocharger and the thermostat
housing (2).
Turbocharger Signature™, ISX, and QSX15
Turbocharger (010-033)
Remove
WARNING
Automotive, Industrial, and Power Generation with
CM570
• Remove the oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.
Remove the intake and exhaust pipes from the

turbocharger.
Remove the charge-air cooler piping from the discharge
elbow.
Remove the clamp, o-ring, and discharge elbow from the

turbocharger.
Discard the o-ring.
NOTE: In some applications, the turbocharger will not

clear the lubricating oil cooler assembly during removal
and installation. It will, perhaps, be necessary to remove
the exhaust manifold and turbocharger together, and then
separate the two components. If the two components
must be removed together for the removal and installation
of the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
If the turbocharger mounting nuts do not loosen freely,
split the nuts to avoid breaking a mounting stud.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and discard the gasket.
Signature™, ISX, and QSX15 Turbocharger
Clean
Turbine Housing Cleaning for ISX Automotive with
CM570, QSX15 with CM570, and Power Generation
with CM570
• The turbocharger turbine housing surface adjacent to
the turbine compressor wheels must be clean,
smooth, and free from deposits.
• Inspect the components to detect signs of burning and
other conditions, in order to obtain as much
information as possible before washing.
NOTE: This procedure applies ONLY to Automotive with
CM570, QSX15 with CM570, and Power Generation with
CM570. Do NOT disassemble variable geometry
turbochargers (VGT).
CAUTION
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.
CAUTION
personal injury.
Scale-like deposits, if any, must be removed by using a
non-metallic bristle brush. After removing the deposits,
wash and dry the components.
Dry the components with compressed air.
CAUTION
personal injury.
NOTE: Do not bead blast aluminum and cast iron
components together.
NOTE: To prevent bead spray impinging directly on the
clamp plate and turbine flange threads, mask and plug off
all items.
NOTE: Prevent the bead spray impinging directly on the
wastegate valve spindle, as beads can penetrate the
spindle bore, and lead to spindle seizure.
It is permissible to bead blast the turbocharger turbine
housing if chemical and brush cleaning is not effective.
After removing the deposits, wash and dry the

components.
Inspect for Reuse

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

Inspect the turbocharger casings.
Replace the housing if through cracks are found in the
outer walls.
Cracking in the turbine housing inlet flange and the inlet

duct generally requires replacement of the turbine
housing. Acceptance and rejection guidelines are shown
in these illustrations. If an exhaust gasket is available,
always make certain that cracks do not exist within the
sealing area.
Check the turbine housing inlet flange flatness. It must be
within 0.1 mm [0.004 in] to be acceptable for reuse.
Flange Fasteners - Clearance Holes

Check the fastener hole diameter. It must not be more
than 1.5 mm [0.006 in] larger than the maximum thread
diameter of the fastener.
CAUTION
If external cracks are found on the turbine housing,
the turbine housing must be replaced.
CAUTION
Turbine blades can be easily damaged and care is
required for the turbine housing installation process.
Cracking of the internal wall at the entry to the turbine
wheel (tongue) is acceptable as a service condition, and
the turbine housing can be re-used.
Inspect the turbocharger compressor v-band outlet and

the discharge elbow v-band connection for dents or
fretting.
Replace the turbocharger or discharge elbow, if damaged,
to prevent compressed air leaks.
Use dial depth gauge, Part Number ST-537.

Push the rotor assembly away from the gauge.
Set the gauge to zero (0).
Push the rotor assembly toward the gauge and record the
reading.
Turbocharger Axial Clearance

mm in
0.025 MIN 0.001
0.127 MAX 0.005
If the turbocharger axial clearance is not within
specifications, the turbocharger must be replaced.
Use a dial indicator to check radial movement at the

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

mm in
0.406 MIN 0.016
0.610 MAX 0.024
If the turbocharger radial clearance is not within
If the engine experiences a turbocharger malfunction or

any other occasion where oil or debris is put into the
charge-air system, the charge-air system must be
inspected and cleaned. Refer to Procedure 010-027 in
Section 10.

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

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

fretting.
Inspect the compressor wheel for signs of rubbing against
the compressor cover. Replace the turbocharger if
rubbing evidence is seen.
Use light finger pressure to push the compressor wheel.
If the compressor wheel contacts the cover, replace the
turbocharger.
Section 10.
Check the axial movement of the turbocharger wheels and

shaft.

mm in
0.025 MIN 0.001
0.127 MAX 0.005
Check the radial movement of the turbocharger wheels

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

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

casings.
walls are found.
are found.
NOTE: All openings on the turbocharger, including the

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

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

fretting.
turbocharger.
Section 10.
Heat Shield Signature™, ISX, and QSX15

shaft.

mm in
0.051 MIN 0.002
0.152 MAX 0.006

and shaft.
housing.
Heat Shield (011-032)

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

Remove the four EGR valve heat shield mounting
capscrews from the EGR valve.
Signature™, ISX, and QSX15 EGR Cooler Coolant Lines
EGR Cooler Coolant Lines (011-031)

Remove
Disconnect the EGR cooler coolant vent line from the EGR
cooler coolant return line and the EGR cooler.
Remove the two mounting capscrews from the EGR cooler

coolant return line.
Disconnect the EGR cooler coolant return line from the
EGR cooler and the elbow connection on the thermostat
housing.
CAUTION
Be sure all the components are clean and free of
debris that can cause damage to o-ring seals.
Disconnect the EGR cooler coolant vent line from the
thermostat housing and the EGR cooler.
Remove the two EGR cooler coolant return tube mounting

capscrews.
EGR Cooler Coolant Lines Signature™, ISX, and QSX15
Remove the EGR cooler coolant return jumper tube from

the EGR cooler.
Remove the EGR cooler coolant supply tube mounting

capscrew.
Slide the EGR cooler coolant supply jumper tube all the
way rearward inside the EGR cooler coolant supply tube.
Remove the EGR cooler coolant supply tube retaining
clamp capscrew from the water pump housing.
Slide the EGR cooler coolant supply tube rearward until

the EGR cooler coolant supply tube is disengaged from
the water pump outlet.
Remove the EGR cooler coolant supply tube from the
engine.
Remove and discard all three o-rings.
Signature™, ISX, and QSX15 EGR Valve
Remove the nuts from the EGR cooler coolant supply tube
mounting bracket.
EGR Valve Coolant Lines (011-030)

Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.
EGR Valve (011-022)

Remove
Loosen the v-band clamp connecting the EGR valve to the
exhaust manifold.
EGR cooler connection.
Remove the EGR valve and v-band clamps.

Remove and discard the gaskets.
EGR Valve Mounting Bracket Signature™, ISX, and QSX15

Disconnect the EGR valve electrical connector.
Make sure to support the EGR valve by hand before

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

capscrews.
Remove the EGR valve from the EGR valve support
bracket.
The EGR valve will need to be moved at an angle forward
and downward in order to disengage it from the EGR valve
support bracket.
Use protective caps from the Air Handling Clear Care Kit
to cover open points on the EGR valve and bracket.
EGR Valve Mounting Bracket (011-044)

Remove
Remove one of the EGR valve bracket rear support
mounting capscrews (2) from the EGR valve mounting
bracket and cylinder head.
Remove the remaining two EGR valve mounting bracket
capscrews (1).
Signature™, ISX, and QSX15 Exhaust Gas Pressure Sensor Adapter
Use protective caps from the Air Handling Clean Care Kit
to cover open points.
Exhaust Gas Pressure Sensor Tube

(011-027)
Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.
Exhaust Gas Pressure Sensor Adapter

(011-033)
Remove
All Applications
Remove the p-clamp mounting capscrew and remove the
adapter.
EGR Connection Tubes Signature™, ISX, and QSX15
Exhaust Manifold, Dry (011-007)

Remove
WARNING
Remove two mounting capscrews and install two guide
studs.
Remove the remaining mounting capscrews, the spacers,
the exhaust manifold assembly and the gaskets.
Discard the gaskets.
Cover open points on the exhaust manifold and cylinder
head using heavy tape.
EGR Connection Tubes (011-025)

Remove
WARNING
The EGR connection tubes can be hot. To reduce the
possibility of personal injury, allow the engine to cool
before removing.
Loosen all hose clamps on the EGR connection tubes and
remove the two p-clip mounting capscrews or nuts
(depending on the vintage of the engine) on the front EGR
connection tube.
If the M10 stud comes out upon removal of the nut, install
the M10 stud into the block until the stud bottoms out.
Remove the one capscrew and one nut or the two nuts
that attach the rear section of the connection tube to the
cylinder block.
Remove the front EGR connection tube.
Remove the one capscrew and one nut that attach the rear
section of the connection tube to the cylinder block.
Remove the rear EGR connection tube from the EGR
cooler.
Signature™, ISX, and QSX15 EGR Connection Tubes
WARNING
before removing.
Loosen the hose clamps on the front EGR connection tube
and remove the hose.
Remove the two retaining capscrews on the lower portion
of the tube at the EGR valve housing outlet.
Remove the front EGR connection tube and hose.
Discard the hose.
Use protective caps from the Air Handling Clean Care Kit,
Part Number 4919403 and Part Number 4919425, to cover
the open points on all components.
Remove the three EGR venturi mounting capscrews.

Remove the EGR venturi.
Cover the irregular openings on the venturi and air intake

connections with protective caps from the Air Handling
Clean Care Kit, Part Number 4919403 and Part Number
4919425.
EGR Cooler Signature™, ISX, and QSX15
Remove the two rear EGR connection capscrews from the

EGR cooler.
Loosen the hose clamp on the rear EGR connection tube.
Pull the EGR cooler outlet connection tube from the EGR
cooler.
EGR Cooler (011-019)

Remove
Loosen the v-band clamp between the EGR cooler and the
Loosen the hose clamps at the rear EGR connection tube.

Remove and discard the EGR hose.
Signature™, ISX, and QSX15 EGR Cooler
CAUTION
The straps on the EGR cooler are not serviceable.
Adjusting or removing the straps can damage the EGR
cooler.
Remove the four capscrews that attach the EGR cooler to
the block.
Remove the four nuts that attach the EGR cooler to the
lubricating oil cooler assembly.
Remove the EGR cooler assembly from the engine.
Remove the coolant supply and vent jumper tubes if they
remain in the block after the cooler is removed.

exhaust manifold. To prevent damage to the EGR cooler
bellows, place the v-band clamp over the exhaust
manifold flange.
Loosen the rear EGR connection tube retaining

capscrews at the EGR cooler gas outlet.
Part Number 4919403, to cover the open points on both
the EGR cooler and EGR plumbing.

the block.
Remove the EGR cooler bracket clamping plates from the
EGR cooler.
Lubricating Oil Cooler Signature™, ISX, and QSX15
Part Number 4919403, to cover the open ports on the EGR
cooler and exhaust manifold.
Lubricating Oil Cooler (007-003)

Remove
All Applications
Remove two oil cooler mounting capscrews and install the
guide pins.
Clean the area above the oil cooler to prevent debris entry
into the oil passages.
WARNING
Remove the remaining 18 capscrews, oil cooler, and
gasket. Discard the gasket.
Signature™, ISX, and QSX15 Engine Lifting Brackets
CAUTION
Immediately upon removal of the lubricating oil cooler
assembly, a plug must be inserted into the housing
and cylinder block oil passage drillings. Failure to
insert the oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plugs, Part Numbers 4918322, 4918324,
and 4918340, are included in protective plug kit, Part
Number 4918319. These plugs are necessary to prevent
debris from entering the lubrication system during the
repair.
Plug the oil cooler housing filtered oil passage with plug,
Part Number 4918323, the block filtered oil passage with
plug, Part Number 4918340, and the block oil pump
passage with plug, Part Number 4918322.
Firmly push the plugs into the oil passages to prevent all
debris from entering the lubrication system when cleaning
the gasket surface.
Engine Lifting Brackets (016-001)

Remove
NOTE: Newer models use three mounting capscrews.
Remove the four capscrews and the rear lifting bracket.
Remove the four capscrews and the front lifting bracket.

Coolant Thermostat Housing Signature™, ISX, and QSX15
Coolant Thermostat Housing (008-014)

Remove
Single Thermostat
Remove the four thermostat housing cover capscrews.
Remove the thermostat cover and gasket.
Discard the gasket.
Remove the thermostat from the thermostat housing

cover.
Remove the three thermostat housing capscrews.

Remove the thermostat housing and gasket.
Discard the gasket.
Dual Thermostat
Remove the upper radiator hose from the thermostat
housing cover.
Signature™, ISX, and QSX15 Coolant Thermostat Housing
Disconnect vent line, if required.

Disconnect the coolant sensor connector.
Remove the four capscrews that attach the thermostat

housing cover to the thermostat housing.
Remove the thermostat housing cover and gasket from
the thermostat housing.
Discard the gasket.
Remove the thermostats from the thermostat housing

cover.
Remove the two capscrews that attach the thermostat

housing to the cylinder head.
Remove the thermostat housing and gasket from the
cylinder head.
Discard the gasket.
Coolant Thermostat Signature™, ISX, and QSX15
Coolant Thermostat (008-013)

Remove
housing cover.
Disconnect vent line.


the thermostat housing. Discard the gasket.

cover.
Signature™, ISX, and QSX15 Alternator
Alternator (013-001)
Remove
Driven by Cooling Fan Drive Belt
Remove the four alternator mounting capscrews.
Remove the alternator from the alternator spacers.

Loosen the alternator support link capscrews.
Remove the support link capscrew from the alternator.
Remove alternator to alternator support capscrews, nut,

washer, and alternator.
Refrigerant Compressor Mounting Bracket Signature™, ISX, and QSX15
Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Remove
Disconnect the wire harness jumper from the EGR valve
motor, EGR valve position sensor and the main engine
wire harness.
Remove the five mounting capscrews from the alternator/
refrigerant compressor mounting bracket.
Gently pry out the bracket from the gear housing.
The split washers will create a slight friction fit between
the bracket and the gear housing.
Remove the wire harness jumper from the alternator/

Remove the six mounting capscrews from the alternator/
The split washers will create a slight friction between the
bracket and the gear housing.
Refrigerant Compressor Mounting

Bracket (009-055)
Remove
Sanden
Remove the mounting capscrew from each refrigerant
compressor bracket.
Remove the refrigerant compressor brackets.
Signature™, ISX, and QSX15 Water Pump

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

Remove the two bracket mounting capscrews and the
bracket.
Remove the support links from the bracket.
Water Inlet Connection (008-082)

Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet connection,
gasket, and o-ring.
Water Pump (008-062)

Remove
Remove two water pump mounting capscrews and install
two guide studs.
Water Pump Signature™, ISX, and QSX15
Remove the remaining three capscrews, the water pump,

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

Remove two water pump capscrews and install guide
studs.
Remove remaining three capscrews, water pump, and
water inlet o-ring seal.

CM570
Remove the pulley (1), pilot adapter (2), and belt tensioner
bracket (3).
Remove the remaining water pump capscrews, and water

inlet o-rings.
Discard the o-ring seals.
Signature™, ISX, and QSX15 Rocker Lever Assembly
Rocker Lever Assembly (003-009)

Remove
There are four rocker lever shafts:
• Front - valve and brake rocker lever shaft
• Rear - valve and brake rocker lever shaft
• Front - injector rocker lever shaft
• Rear - injector rocker lever shaft.
CAUTION
Some valves will not be loose. Do not tighten or
bottom adjusting screw against lever. Engine damage
can occur.
Loosen the valve and injector adjusting screw locknuts on
each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
CAUTION
Use care when handling shafts. Rocker levers can fall
off the shaft during removal and damage the levers.
Remove the valve and brake, rocker lever shaft
capscrews, and the rocker lever shaft assemblies.
Remove the injector, rocker lever shaft capscrews, and
the rocker lever shaft assemblies.
Remove the valve crossheads.
To prevent increased wear, mark each crosshead and
rocker lever shaft assembly as it is removed so it can be
installed back in its original location.
Remove the rocker levers and brake levers from the

shafts.
Remove the rocker lever spacers from the shaft.
Remove the locknuts and the adjusting screws from the
rocker levers.
To prevent increased wear, mark each adjusting screw as
it is removed so it can be installed back in its original
rocker lever.
Injector Signature™, ISX, and QSX15
Injector (006-026)
Remove
CAUTION
Do not bottom out adjusting screws. Engine damage
can occur if adjusting screws are bottomed out.
Remove only the valve and injector shaft for the injector
(s) being removed.
Loosen the injector rocker lever adjusting screws.
Remove the six capscrews and injector rocker lever shaft.
Do not let the rocker levers come off of the shaft during
removal.
Rotate the engine to the valve set mark for the injector
being removed. Refer to Procedure 003-004 in Section 3.
Loosen and turn the valve lash adjusting screws

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

side of the engine to allow the injector to be removed.
Signature™, ISX, and QSX15 Vibration Damper, Viscous
Loosen the injector clamp capscrew.

Use a small magnet to remove the injector clamp
capscrew and washer.
Remove the injector clamp capscrew and washer.
CAUTION
Do not use a heel bar to pry the injector loose from
the cylinder head. Damage to the injector can occur.
Use injector puller, Part Number 3823579, to remove the
injectors.
If the injector spring does come loose from the spring
retainer, it can be reassembled by using a screwdriver to
compress the spring back under the retainer.
Vibration Damper, Viscous (001-052)

Remove
CAUTION
Do not use a hammer or a screwdriver to remove the
vibration damper(s). These tools can damage the
vibration damper(s).
Remove two of the vibration damper(s) and crankshaft
pulley retaining capscrews.
Install two guide studs into the holes.
Remove the remaining 10 capscrews.
Remove the pulley and vibration damper(s).
Industrial and Power Generation with Crank-Driven

Fan or PTO
Remove the crankshaft adapter (1) from the pulley (2).
Vibration Damper, Viscous Signature™, ISX, and QSX15
Remove two pulley capscrews.

CAUTION
vibration damper. These tools can damage the
vibration damper.
Remove the remaining four capscrews.
Remove the pulley (4), vibration damper (3), mounting
spacer (2) and second vibration damper (1).
Remove the guide studs from the crankshaft nose.
Industrial and Power Generation without Crank-Driven

Fan or PTO
Remove two of the pulley capscrews.
Signature™, ISX, and QSX15 Gear Cover, Upper
CAUTION
vibration damper.
spacer (2), and second vibration damper (1).
Gear Cover, Upper (001-079)

Remove
WARNING
The component weighs 23 kg [50 lb] or more. To
reduce the possibility of injury, use a hoist or get
assistance to lift the component.
Remove 16 capscrews and the upper gear cover.
Discard the strip seal.

Some industrial applications use a stamped steel cover
with a clamping plate.
Remove two capscrews and install two guide pins.
Remove the 14 vibration isolator capscrew assemblies.
Crankshaft Seal, Front Signature™, ISX, and QSX15
WARNING
or get assistance to lift the component.
Remove the clamping plate and upper gear cover.
Crankshaft Seal, Front (001-023)

Remove
Remove the eight mounting nuts from the gear cover
studs.
Position the replacer plate (1) over the crankshaft end and
against the crankshaft seal. The large notch between the
teeth needs to bridge the raised gear cover surface.
Make certain that the alignment of the three welded nuts
on the crankshaft seal are positioned into the counterbore
slots of the replacer plate (1).
Install a capscrew (4) with a flat washer (5) in the upper
slot of the replacer plate to hold it in position
CAUTION
Tighten the capscrews by hand until a slight
resistance is felt. Do not overtighten the capscrews or
the seal nuts can break off causing damage to the seal
and leading to front cover damage.
Use a small allen wrench to thread the removal tool
capscrews (2) through the replacer plate and into the seal
nuts.
Tighten the socket head capscrews (2) clockwise into the
three seal removal nuts that are welded on the crankshaft
seal until a slight resistance is felt.
Remove the capscrew in the upper slot of the replacer
plate (1).
Signature™, ISX, and QSX15 Air Compressor
Install the replacer screw (3) into the replacer plate (1).
Turn the screw (3) clockwise until the crankshaft seal is
removed from the crankshaft.
Gear Cover, Lower (001-080)

Remove
NOTE: If the gear cover contains an o-ring seal groove for
the crankshaft seal and the seal needs to be replaced, the
lower gear cover must also be replaced. The new
crankshaft seal has the o-ring incorporated into the seal.
Remove the 15 capscrews and the lower gear cover.
Air Compressor Coolant Lines

(012-004)
Remove
Remove the coolant lines from the air compressor.
Air Compressor (012-014)

Remove
Remove the air connections from the air compressor.
Remove or disconnect the air governor. Refer to the OEM
service manual.
Engine Base Timing Signature™, ISX, and QSX15
Remove the air compressor support bracket and

capscrews.
Remove the four mounting capscrews and the air
compressor.
Discard the gasket.
Engine Base Timing (001-088)

Remove
Valve Camshaft Gear
The injector camshaft scissor gear must be unloaded
during removal of the valve camshaft gear. To unload the
gear, two of the gear screws must be backed out far
enough to allow the teeth on the scissor gear to be aligned.
Unload the injector camshaft scissor gear.
Remove the valve camshaft gear mounting capscrew and
washer.
Early production engines were not equipped with puller

holes in the valve camshaft gear. A 3-jaw gear puller
must be used for gears that do not have puller holes. The
injector and valve gear puller, Part Number 3163069, can
be used for gears that have puller holes.
Install the gear puller, Part Number 3163069.
Install the valve camshaft gear mounting capscrew
completely.
Loosen the capscrew two turns.
Use the gear puller to remove the valve camshaft gear
from the camshaft nose.
Remove the puller.

Do not completely remove the camshaft gear mounting
capscrew when the 3-jaw puller is used. The capscrew
serves as a safety catch by preventing the gear from
shooting off of the camshaft nose.
Remove the valve camshaft gear mounting capscrew,
spacer, and valve camshaft gear.
Signature™, ISX, and QSX15 Engine Base Timing
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Use a lint free cloth and solvent to clean the Loctite™
residue from the nose of the camshaft.
Injector Camshaft Scissor Gear
CAUTION
Remove the rear injector camshaft cover plate before
removal of the injector camshaft gear or camshaft.
The force required to remove the camshaft gear
creates sufficient backwards movement of the
camshaft to crack the rear cover plate.
Remove the injector camshaft rear cover plate.
Remove the injector camshaft scissor gear mounting

Install gear puller, Part Number 3163069.
Install the injector camshaft scissor gear mounting
capscrew. Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft scissor

gear off the camshaft taper.
Remove the gear puller.
Remove the capscrew.
Remove the injector camshaft scissor gear.
WARNING
WARNING
Injector Camshaft Non-Scissor Gear
CAUTION
Remove the injector camshaft gear mounting capscrew

and washer.
Install the injector camshaft gear mounting capscrew.
Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft gear off
the camshaft taper.
Remove the injector camshaft gear.
WARNING
WARNING
Adjustable Idler Gear

The adjustable idler gear shaft can fall out when the
adjustable idler gear is removed.
Remove the retainer capscrews, retainer, gear, and
adjustable idler gear shaft.
Remove the mounting spacer.
Lower Idler Scissor Gear

The lower idler scissor gear must be unloaded during
removal. To unload the gear, two of the gear screws
must be backed out far enough to allow the teeth on the
scissor gear to be aligned.
Unload the lower idler scissor gear.
Remove the idler scissor gear capscrews.
Overhead Camshaft, Valve Signature™, ISX, and QSX15
Remove the retainer, gear, shaft, and thrust bearing.
Lower Idler Non-Scissor Gear

Remove the idler non-scissor gear capscrews and
retainer.
Remove the gear, shaft, and thrust bearing.
Overhead Camshaft, Valve (002-024)

Remove
Remove the retainer capscrews, retainer, seal, and o-ring.
Discard the seal and o-ring.
Signature™, ISX, and QSX15 Overhead Camshaft, Injector
CAUTION
Use caution when removing the camshaft to avoid
damaging the camshaft bushings.
Remove the valve camshaft.
Overhead Camshaft, Injector (002-025)

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

retainer plate and o-rings.
Discard the o-rings.
CAUTION
Remove the injector camshaft.
Cylinder Head Signature™, ISX, and QSX15
Cylinder Head (002-004)

Remove
WARNING
Use a chip vacuum to remove the excess oil from the top
of the cylinder head.
Remove the cylinder head capscrews.
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Remove the cylinder head. Remove and discard the
gasket.
Remove the fire rings from the cylinder liners, if equipped.
NOTE: This step is not applicable if the engine has flat-

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

Make sure the cylinder liner recession or protrusion
(based on liner style) is within specification.
Signature™, ISX, and QSX15 Lubricating Oil Pan
Engine Support Bracket, Front

(016-002)
Remove
WARNING
Remove the two capscrews that attach the support to the
equipment frame.
Use the hoist to lift the weight of the engine off the front
support.
Remove the six mounting capscrews and the front engine

support.
Remove the rubber engine mounts.
Idler Gear, Lower Scissor (001-076)

General Information
Before installation or removal of any gears, read Engine
Base Timing. Refer to Procedure 001-088 in Section 1.
Lubricating Oil Pan (007-025)

Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.
Piston Cooling Nozzle Signature™, ISX, and QSX15
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Remove
Remove the lubricating oil suction tube capscrews,
suction tube, and o-ring. Discard o-ring.
Block Stiffener Plate (001-089)

Remove
Remove the 10 capscrews and the block stiffener plate.
Piston Cooling Nozzle (001-046)

Remove
The crankshaft must be rotated to allow access to remove
all the nozzles.
Remove the piston cooling nozzle capscrews and nozzles.
Signature™, ISX, and QSX15 Piston and Connecting Rod Assembly
Piston and Connecting Rod Assembly

(001-054)
Remove
WARNING
cleaning, following the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.
WARNING
CAUTION
Do not use emery cloth or sandpaper to remove
carbon from the cylinder liners. Aluminum oxide or
silicon particles from emery cloth or sandpaper can
cause serious engine damage. Do not use any
abrasives in the ring travel area. The cylinder liner can
be damaged.
Use a fine fibrous, abrasive pad such as Scotch-Brite™
7448, Part Number 3823258, or equivalent, and solvent to
remove the carbon.
Install two connecting rod guide pins, Part Number

3376038.
Use a T-handle piston pusher to push the connecting rod
away from the crankshaft.
Push the connecting rod until the piston rings are outside
of the top of the cylinder liner.
Remove the upper connecting rod bearing.

Mark the cylinder number and the letter U (upper) on the
flat surface of the bearing tang.
Piston and Connecting Rod Assembly Signature™, ISX, and QSX15
Use both hands to remove the piston and connecting rod

assembly.
The piston and connecting rod assemblies must be
installed in the same cylinder they were removed from to
provide for proper fit of worn mating surfaces if parts are
reused.
Use a tag to mark the cylinder number from which each
piston and connecting rod assembly was removed.
CAUTION
To reduce the possibility of engine damage all pistons
within a given engine must be of the same design - all
are to be either the articulated design or the single-
piece design. Do not mix piston designs in the same
engine. Single-piece pistons must have drilled rods
and connecting rod bearings. Articulated pistons can
use either drilled or non-drilled rods and bearings.
Place the connecting rod and piston assemblies in a

container to protect them from damage.
A unique number (not cylinder number) is stamped on the

connecting rod and matching connecting rod cap. When
the connecting rods and connecting rod cap are installed
in the engine, the numbers on the connecting rod and cap
must match and be installed on the same side (the
exhaust side) of the engine.
Signature™, ISX, and QSX15 Bearings, Connecting Rod
Bearings, Connecting Rod (001-005)

Remove
Rotate the crankshaft so that two of the connecting rods
are at bottom dead center.
Do not remove the capscrews at this time.

Loosen the connecting rod capscrews.
Hit the connecting rod capscrews with a rubber hammer
to loosen the rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap and mark the
cylinder number and the letter "L” on the flat surface of
the bearing tangs.
Install two guide pins, Part Number 3163097, in the

connecting rod.
Push the rod up far enough to allow the upper bearing
shell to be removed. Use a T-handle piston pusher.
Remove the bearing shell and mark the cylinder number
and the letter "U" on the flat surface of the bearing tangs.
Piston Rings Signature™, ISX, and QSX15
Piston Rings (001-047)

Remove
Articulated Piston
Remove the piston rings.
Place a tag on the rings, and record the cylinder number

of the piston on the tag for future reference, if required.
Single-Piece Piston
CAUTION
Do not over-expand the second piston ring on single-
piece pistons.
Use a universal ring expander to remove the second
piston ring on single-piece pistons.

Signature™, ISX, and QSX15 Crankshaft Seal, Rear
Flywheel (016-005)
Remove
WARNING
Use two M6 x 1.5 guide studs to prevent the flywheel from
rotating. Use flywheel capscrew socket, Part Number
2892191, to remove two capscrews and install the guide
studs.
Use a hoist, two t-handles, and a lifting sling. Install the
tee-handles. Use flywheel capscrew socket, Part Number
2892191, to remove the remaining ten capscrews.
Remove the flywheel.
Use a soft-faced mallet to tap the flywheel from the
crankshaft, if necessary. Damage to the clutch surface
can occur if a hard-faced hammer is used.
Remove the pilot bearing spacer from the rear of the

crankshaft.
Use a mandrel and hammer to remove the pilot bearing
from the flywheel.
Crankshaft Seal, Rear (001-024)

Remove
The rear crankshaft seal requires the rear crankshaft seal
replacer kit, Part Number 3164780, for the seal removal
and installation.
1 Replacer plate
2 Pilot drill
3 Replacer screw
4 Self-tapping screw x 10
5 Stud x 3
6 Hex nut x 3.
Crankshaft Seal, Rear Signature™, ISX, and QSX15
Use three flywheel mounting capscrews to secure the

replacer plate (1) to the crankshaft.
Install a pilot drill (2) into one of the holes in the rear
crankshaft seal tool and drill a hole through the seal
casing.
Remove the pilot drill (2) and repeat the procedure for at
least two more evenly spaced holes of the rear crankshaft
seal tool. As many as six holes may be drilled to assist in
removing the rear crankshaft seal.
NOTE: Three stud screws (3) and three hex nuts (4) are
required for some engines with flywheel mounting
capscrews that are too short to mount the replacer plate
(1) to the crankshaft.
NOTE: Three guide pins, Part Number 3164765, are
required on REPTO applications to support the REPTO
crankshaft gear and the replacer plate.
Install at least three self-tapping screws (1) into the

replacer plate (2).
Remove the flywheel capscrews from the rear crankshaft
seal tool.
Install the replacer screw (3) into the center hole of the
replacer plate and turn clockwise to remove the seal.
Measure
Measure the protrusion of the outer rubber portion (A) of
the seal relative to the inner metal portion of the seal (B).
Set the dial indicator to zero on the inner metal portion of
the seal.
Measure and record the protrusion of the outer rubber
portion of the seal. Repeat the measurement in four
locations equally spaced around the crankshaft seal.
The protrusion measurement at each location must be
within +/- 1 mm [+/- 0.04 in]. The difference between any
of the four protrusion measurements must be within +/-
0.5 mm [0.02 in].
If either of these conditions are not met, the rear
crankshaft seal must be removed and a new seal
installed.
Signature™, ISX, and QSX15 Flywheel Housing
Flywheel Housing (016-006)

Remove
Remove the two top exterior capscrews from the flywheel
housing.
WARNING
avoid personal injury, use a hoist or get assistance.
Use a hoist and lifting sling. Install the lifting sling around
both sides of the upper housing. Adjust the hoist until
there is tension in the lifting sling. Remove the remaining
capscrews.
Use a mallet to tap the flywheel housing off the two

locating dowels.
Remove two capscrews, cover plate, and gasket. Discard

the gasket.
Flywheel Housing, REPTO Signature™, ISX, and QSX15
CAUTION
Immediately upon removal of the flywheel housing
assembly, a plug must be inserted into the cylinder
block oil passage drillings. Failure to insert the oil
passage plug can result in a bearing failure,
crankshaft failure, or both.
The reusable plug, Part Number 4918321, is included in
Protective Plug Kit, Part Number 4918319. This plug is
necessary to prevent debris from entering the lubrication
system during the repair.
Plug the block oil passage with plug Part Number
4918321.
Firmly push plug into oil passage to prevent all debris from
entering the lubricating system when cleaning the gasket
surface.
Flywheel Housing, REPTO (016-007)

Remove
Remove the three capscrews from the rear of the oil pan.
WARNING
Remove the 10 10-mm capscrews from the hydraulic
housing.
Remove the hydraulic housing from the REPTO flywheel
housing.
Remove the spray nozzle from the oil supply line hole.
Remove the 12 capscrews (1) from the seal carrier.

Remove the seal carrier (2) from the REPTO flywheel
housing.
Remove oil seal (4) and discard. Refer Procedure 001-024
(Crankshaft Seal, Rear) in Section 1.
Remove the o-ring (3) from the groove on the REPTO
flywheel housing.
Signature™, ISX, and QSX15 Flywheel Housing, REPTO
Remove the four plugs (1) and o-rings (2) from the REPTO
flywheel housing.
Remove the crankshaft gear.

Remove the idler gear shaft capscrew and washer.
Remove the three guide pins.
If the idler gear shaft can not be removed with the handle,
a slide hammer similar to Snap-On, Part Number CJ114,
can be used.
Position the replacer idler plate, Part Number 3164762, on
the idler gear shaft. Install and tighten the two idler gear
capscrews. Install the handle, Part Number 3163089.
Torque Value: 14 N•m [ 124 in-lb ]
Remove the idler shaft, idler gear, and bearing from the
REPTO flywheel housing.
Remove two capscrews from the REPTO flywheel

housing.
Install the two guide pins, Part Number 3164764.
Gear Housing, Front Signature™, ISX, and QSX15
Install the two eye bolts, Part Number 3164767, on the top
of the REPTO flywheel housing. Install the lifting slings to
the eye hooks. Adjust the hoist until there is tension in the
lifting sling.
Remove the remaining capscrews.
WARNING
Use a mallet to tap the REPTO flywheel housing off the
two locating dowels. Remove and discard the gasket.
CAUTION
4918321.
Firmly push the plug into the oil passage to prevent all
debris from entering the lubricating system when cleaning
the gasket surface.
Gear Housing, Front (001-033)

Remove
WARNING
Remove two capscrews and install two guides.
Signature™, ISX, and QSX15 Bearings, Thrust

Remove the housing and gasket.
Discard the gasket.
Remove the guide studs.
Lubricating Oil Pump (007-031)

Remove
CAUTION
Do not discard shims, if equipped. They must be
installed in the original location. Failure to do so can
result in engine damage.
Remove four capscrews, oil pump, and shims if equipped.
When installing a new oil pump, new shims will possibly
be needed to acquire acceptable lash.
Crankshaft (001-016)
Remove
WARNING
Use a lifting strap that will not damage the crankshaft.
Use a hoist and a sling that to remove the crankshaft.
Bearings, Thrust (001-007)

Remove
Remove the thrust bearings from the number four main
bearing cap.
Mark the thrust bearings as being lower, and front or rear
bearings.
Bearings, Main Signature™, ISX, and QSX15
CAUTION
To reduce the possibility of damage to the crankshaft,
use care when removing the upper thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark these bearings as being upper, and front or rear
bearings.
Bearings, Main (001-006)

Remove
CAUTION
Mark any unmarked bearing caps before removing
them from the cylinder block. Do not remove main
bearing capscrews until the main bearing cap is
pulled, or the cap could fall out, causing personal
injury and parts damage.
If the crankshaft is not going to be removed, replace the
main bearings one at a time.
Loosen the main bearing cap capscrews.
Use the main bearing cap puller, Part Number ST-1178,
to remove the cap. The tool must be centered on the cap.
Remove the main bearing capscrews and cap.
Mark the bearing shells with the journal number from

which they were removed.
Remove the lower main bearing shell from the cap.
Signature™, ISX, and QSX15 Cylinder Liner
Rotate the crankshaft with the air compressor drive or a

barring device to remove the main bearing shell.
Mark each main bearing for location if they are to be
installed again in the engine.
Cylinder Liner (001-028)

Remove
The cylinder liners can be removed by using either:
• Cylinder liner puller (universal), Part Number 3163745,
and puller plate (S600), Part Number 3162462.
• Cylinder liner puller (universal), Part Number 3376015.
CAUTION
The cylinder puller must be installed and used as
described to reduce the possibility of damage to the
cylinder block. The puller plate must be parallel to the
main bearing saddles and must not overlap the
cylinder liner outside diameter.
Insert the cylinder liner puller onto the top of the cylinder
block.
The cylinder liner puller must be centered on the top of

the cylinder block.
Turn the puller jackscrew clockwise to loosen the cylinder
liner from the cylinder block.
Use both hands to remove the cylinder liner.
Remove and discard the o-ring seals.
Cylinder Liner Signature™, ISX, and QSX15
Use Dykem™, or equivalent, to place a mark on the intake

air side of the cylinder liner to show cylinder liner
orientation.
Use Dykem™, or equivalent, to mark the cylinder number

on each cylinder liner.
Section AS - Engine Assembly - Group 00 Page AS-a
Section AS - Engine Assembly - Group 00

Section Contents
Page
Aftertreatment Adapter Pipe ......................................................................................................................AS-122
Install.........................................................................................................................................................AS-122
Aftertreatment Fuel Injector .......................................................................................................................AS-122
Install.........................................................................................................................................................AS-122
Aftertreatment Fuel Shutoff Manifold ........................................................................................................AS-126
Install.........................................................................................................................................................AS-126
Aftertreatment Injector Lines .....................................................................................................................AS-127
Install.........................................................................................................................................................AS-127
Air Compressor .............................................................................................................................................AS-57
Install...........................................................................................................................................................AS-57
Air Compressor Coolant Lines .....................................................................................................................AS-58
Finishing Steps.............................................................................................................................................AS-60
Install...........................................................................................................................................................AS-58
Air Intake Connection .................................................................................................................................AS-131
Install.........................................................................................................................................................AS-131
Automotive, Industrial with CM570 and Power Generation without CM570................................................AS-131
Automotive with CM870...........................................................................................................................AS-131
Automotive With CM871...........................................................................................................................AS-131
Alternator ......................................................................................................................................................AS-92
Install...........................................................................................................................................................AS-92
Driven by Cooling Fan Drive Belt...............................................................................................................AS-92
Automotive with CM870.............................................................................................................................AS-92
Alternator/Refrigerant Compressor Mounting Bracket ................................................................................AS-91
Install...........................................................................................................................................................AS-91
Bearings, Thrust .............................................................................................................................................AS-9
Install.............................................................................................................................................................AS-9
Bearings, Connecting Rod ........................................................................................................................... AS-36
Install...........................................................................................................................................................AS-36
Bearings, Main ................................................................................................................................................AS-4
Install.............................................................................................................................................................AS-4
Belt Tensioner, Automatic (Water Pump) ..................................................................................................AS-140
Install.........................................................................................................................................................AS-140
Drives Alternator......................................................................................................................................AS-140
Automotive Applications...........................................................................................................................AS-140
Industrial and Power Generation..............................................................................................................AS-141
Belt Tensioner, Refrigerant Compressor, Automatic ................................................................................AS-137
Install.........................................................................................................................................................AS-137
With Water Pump and Refrigerant Compressor Belt Routing....................................................................AS-137
Block Stiffener Plate .....................................................................................................................................AS-42
Install...........................................................................................................................................................AS-42
Coolant Filter ..............................................................................................................................................AS-146
Install.........................................................................................................................................................AS-146
Coolant Thermostat ......................................................................................................................................AS-92
Install...........................................................................................................................................................AS-92
Coolant Thermostat Housing ....................................................................................................................... AS-94
Install...........................................................................................................................................................AS-94
Single Thermostat......................................................................................................................................AS-94
Dual Thermostat........................................................................................................................................AS-95
Cooling System ...........................................................................................................................................AS-152
Fill..............................................................................................................................................................AS-152
Crankcase Breather (External) ...................................................................................................................AS-135
Install.........................................................................................................................................................AS-135
Crankshaft .....................................................................................................................................................AS-10
Page AS-b Section AS - Engine Assembly - Group 00
Install...........................................................................................................................................................AS-10
Crankshaft Seal, Front ..................................................................................................................................AS-61
Install...........................................................................................................................................................AS-61
Crankshaft Seal, Rear ...................................................................................................................................AS-31
Install...........................................................................................................................................................AS-31
Measure.......................................................................................................................................................AS-32
Cylinder Head ...............................................................................................................................................AS-44
Install...........................................................................................................................................................AS-44
Cylinder Liner .................................................................................................................................................AS-1
Install.............................................................................................................................................................AS-1
Measure.........................................................................................................................................................AS-2
Drive Belt, Cooling Fan ..............................................................................................................................AS-142
Install.........................................................................................................................................................AS-142
Drives Alternator......................................................................................................................................AS-142
Drive Belt, Refrigerant Compressor ...........................................................................................................AS-137
Install.........................................................................................................................................................AS-137
ECM Cooling Plate, Fuel Cooled ................................................................................................................AS-130
Install.........................................................................................................................................................AS-130
EGR Connection Tubes ..............................................................................................................................AS-101
Install.........................................................................................................................................................AS-101
EGR Cooler ...................................................................................................................................................AS-97
Install...........................................................................................................................................................AS-97
EGR Cooler Coolant Lines ..........................................................................................................................AS-109
Install.........................................................................................................................................................AS-109
EGR Mixer ...................................................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
EGR Valve ...................................................................................................................................................AS-107
Install.........................................................................................................................................................AS-107
EGR Valve Coolant Lines ............................................................................................................................AS-108
Install.........................................................................................................................................................AS-108
EGR Valve Mounting Bracket .....................................................................................................................AS-106
Install.........................................................................................................................................................AS-106
Engine Base Timing ......................................................................................................................................AS-46
Adjust...........................................................................................................................................................AS-53
Install...........................................................................................................................................................AS-46
Engine Installation ......................................................................................................................................AS-148
Install.........................................................................................................................................................AS-148
Automotive and Industrial.........................................................................................................................AS-148
Power Generation....................................................................................................................................AS-149
Engine Lifting Brackets ................................................................................................................................AS-96
Install...........................................................................................................................................................AS-96
Engine Support Bracket, Front .................................................................................................................... AS-43
Install...........................................................................................................................................................AS-43
Exhaust Gas Pressure Sensor Adapter ......................................................................................................AS-106
Install.........................................................................................................................................................AS-106
All Applications........................................................................................................................................AS-106
Exhaust Gas Pressure Sensor Tube ..........................................................................................................AS-107
Install.........................................................................................................................................................AS-107
Exhaust Manifold, Dry ................................................................................................................................AS-103
Install.........................................................................................................................................................AS-103
Automotive with CM870 and CM871.........................................................................................................AS-103
Automotive, Industrial with CM570 and Power Generation without CM570................................................AS-104
Fan Hub, Belt Driven ..................................................................................................................................AS-139
Install.........................................................................................................................................................AS-139
Industrial CM570 and Power Generation without CM570..........................................................................AS-139
Fan Support ................................................................................................................................................AS-137
Install.........................................................................................................................................................AS-137
Industrial and Power Generation..............................................................................................................AS-137
Flywheel ........................................................................................................................................................AS-32
Install...........................................................................................................................................................AS-32
Section AS - Engine Assembly - Group 00 Page AS-c
Flywheel Housing .........................................................................................................................................AS-14

Install...........................................................................................................................................................AS-14
Measure.......................................................................................................................................................AS-15
Bore Alignment..........................................................................................................................................AS-15
Face Alignment..........................................................................................................................................AS-17
Flywheel Housing, REPTO ...........................................................................................................................AS-19
Install...........................................................................................................................................................AS-19
Measure.......................................................................................................................................................AS-27
Bore Alignment..........................................................................................................................................AS-27
Face Alignment..........................................................................................................................................AS-29
Fuel Filter (Spin-On Type) ..........................................................................................................................AS-144
Install.........................................................................................................................................................AS-144
Gear Cover, Lower ........................................................................................................................................AS-60
Install...........................................................................................................................................................AS-60
Gear Cover, Upper ........................................................................................................................................AS-64
Install...........................................................................................................................................................AS-64
Automotive Applications.............................................................................................................................AS-64
Industrial and Power Generation................................................................................................................AS-64
Gear Housing, Front .....................................................................................................................................AS-12
Install...........................................................................................................................................................AS-12
Heat Shield ..................................................................................................................................................AS-111
Install.........................................................................................................................................................AS-111
Idler Gear, Lower Scissor .............................................................................................................................AS-43
General Information......................................................................................................................................AS-43
Idler Pulley, Refrigerant Compressor .........................................................................................................AS-137
Install.........................................................................................................................................................AS-137
Injector ..........................................................................................................................................................AS-68
Install...........................................................................................................................................................AS-68
Integrated Fuel System Module (IFSM) ......................................................................................................AS-125
Install.........................................................................................................................................................AS-125
Lubricating Oil Cooler ..................................................................................................................................AS-97
Install...........................................................................................................................................................AS-97
All Applications..........................................................................................................................................AS-97
Lubricating Oil Dipstick Tube .....................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
Lubricating Oil Fill Tube .............................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
Lubricating Oil Filter (Spin-On) ..................................................................................................................AS-147
Install.........................................................................................................................................................AS-147
Lubricating Oil Pan .......................................................................................................................................AS-42
Install...........................................................................................................................................................AS-42
Lubricating Oil Pump ....................................................................................................................................AS-10
Install...........................................................................................................................................................AS-10
Lubricating Oil Suction Tube (Block-Mounted) ...........................................................................................AS-42
Install...........................................................................................................................................................AS-42
Lubricating Oil System ...............................................................................................................................AS-150
Fill..............................................................................................................................................................AS-152
Prime..........................................................................................................................................................AS-150
Overhead Camshaft, Injector .......................................................................................................................AS-45
Install...........................................................................................................................................................AS-45
Overhead Camshaft, Valve ...........................................................................................................................AS-46
Install...........................................................................................................................................................AS-46
Overhead Set ................................................................................................................................................AS-73
Adjust...........................................................................................................................................................AS-77
Measure.......................................................................................................................................................AS-73
General Information...................................................................................................................................AS-73
Page AS-d Section AS - Engine Assembly - Group 00
Piston and Connecting Rod Assembly ........................................................................................................AS-39

Install...........................................................................................................................................................AS-39
Piston Cooling Nozzle ..................................................................................................................................AS-41
Install...........................................................................................................................................................AS-41
Piston Rings ..................................................................................................................................................AS-34
Install...........................................................................................................................................................AS-34
Refrigerant Compressor .............................................................................................................................AS-136
Install.........................................................................................................................................................AS-136
Sanden....................................................................................................................................................AS-136
Climate Control Incorporated...................................................................................................................AS-136
Refrigerant Compressor Mounting Bracket .................................................................................................AS-89
Install...........................................................................................................................................................AS-89
Sanden......................................................................................................................................................AS-89
Climate Control Incorporated.....................................................................................................................AS-90
Automotive, Industrial with CM570 and Power Generation without CM570..................................................AS-90
Rocker Lever Assembly ................................................................................................................................AS-69
Install...........................................................................................................................................................AS-69
Rocker Lever Cover ....................................................................................................................................AS-143
Install.........................................................................................................................................................AS-143
Starting Motor .............................................................................................................................................AS-142
Install.........................................................................................................................................................AS-142
All Except 50MT With Aluminum Flywheel Housing..................................................................................AS-142
50MT With Aluminum Flywheel Housing..................................................................................................AS-142
Turbocharger ..............................................................................................................................................AS-112
Assemble....................................................................................................................................................AS-112
Install.........................................................................................................................................................AS-113
Turbocharger Air Shutoff Valve Filter ........................................................................................................AS-124
Install.........................................................................................................................................................AS-124
Variable Geometry...................................................................................................................................AS-124
Turbocharger Coolant Hoses .....................................................................................................................AS-119
Install.........................................................................................................................................................AS-119
Turbocharger Control Shutoff Valve Filter Head .......................................................................................AS-123
Install.........................................................................................................................................................AS-123
Turbocharger, Variable Geometry Actuator ...............................................................................................AS-121
Install.........................................................................................................................................................AS-121
Turbocharger, Variable Geometry Actuator Air Supply Line ....................................................................AS-123
Install.........................................................................................................................................................AS-123
Turbocharger, Variable Geometry Control Valve Air Supply Line ............................................................AS-124
Install.........................................................................................................................................................AS-124
Vibration Damper, Viscous ...........................................................................................................................AS-65
Eccentricity Check........................................................................................................................................AS-68
Install...........................................................................................................................................................AS-65
Automotive Applications.............................................................................................................................AS-65
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................AS-66
Industrial and Power Generation without Crank-Driven Fan or PTO............................................................AS-67
Wobble Check..............................................................................................................................................AS-68
Water Inlet Connection .................................................................................................................................AS-89
Install...........................................................................................................................................................AS-89
Water Pump ..................................................................................................................................................AS-85
Install...........................................................................................................................................................AS-85
Industrial CM570 and Power Generation without CM570............................................................................AS-87
Automotive With CM871............................................................................................................................AS-89
Section AS - Engine Assembly - Group 00 Page AS-1

Install
CAUTION
Cylinder liners of different design can not be mixed
within an engine. All six cylinder liners must be of the
same design.
There are two different designs of cylinder liners used.
The design used in a particular engine is dependent on
the engine's production vintage.
Engines assembled prior to engine serial number
14022615 have groove-top cylinder liners. They are
characterized by a groove machined into the top surface
of the cylinder liner flange.
Engines with serial number 14022615, and after, are
assembled with flat-top cylinder liners. They are
characterized by a cylinder liner flange that is flat, except
for the fire dam.
Make sure the cylinder block and all parts are clean before
assembly.
Lubricate the two cylinder liner o-ring seals with vegetable
oil prior to assembly.
Install the two o-ring seals onto the cylinder liner.
CAUTION
same design.
Install the cylinder liner into the cylinder block.
When acceptable and used cylinder liners are installed,
rotate the cylinder liner 90 degrees from its original
position in the engine. The thrust and anti-thrust surfaces
must face the front and back of the cylinder block.
Use cylinder liner installation kit, Part Number 3162461,
to seat the liner.
If the cylinder liner does not seat properly, remove it and
inspect the cylinder liner bore seat and cylinder liner for
nicks, burrs, or dirt.
Install the cylinder liner again.
Page AS-2 Section AS - Engine Assembly - Group 00
Measure
Liner Protrusion
Because of design differences, the cylinder liner's position
(relative to the cylinder top deck) will be different.
For groove-top cylinder liners, a recession measurement
is taken. This measures the depth of the groove relative
to the cylinder block deck regardless of the flange or fire
dam height.
For flat-top cylinder liners, a cylinder liner protrusion

measurement is taken which is the height of the cylinder
liner flange above the cylinder block surface regardless of
the flange or fire dam height.
Regardless of the cylinder liner design, the measurement
technique will be the same.
The cylinder liner measurement must be checked before

installing the pistons and connecting rods.
The cylinder liner measurement must be made with the
cylinder liners in the clamped state.
Install and tighten the cylinder liner installation tool.
Use depth gauge, Part Number 3823495, to measure the

clamped state at the intake side three times and average
the readings.
Measure the clamped state of the exhaust side three times
and average the readings.
Cylinder Liner Recession (Groove-Top Cylinder

Liners)
mm in
0.36 MIN 0.014
0.51 MAX 0.019
Cylinder Liner Protrusion (Flat-Top Cylinder Liners)

mm in
0.18 MIN 0.007
0.33 MAX 0.014
If the cylinder liner measurement on either the intake or
exhaust side is not within specifications, the cylinder liner
must be replaced.
For flat-top cylinder liners only:

• The difference between the lowest cylinder liner and
the highest cylinder liner can not be greater than 0.102
mm [0.004 in].
• The maximum allowable difference between adjacent
cylinders is 0.051 mm [0.002 in].
• The protrusion must be within 0.0381 mm [0.0015 in]
around any cylinder.
Before installing the piston and connecting rod

assemblies, wipe the inside of the cylinder liners.Use a
clean cloth with 15W-40 oil.

Install
CAUTION
The cylinder block saddle and the cap mating surfaces
must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their
original location or engine damage can occur.
CAUTION
The bearing tang must fit into the slot in the bearing
saddle or engine damage can occur.
CAUTION
Do not use a capscrew or any hard metal object to
install bearings, as this can damage the crankshaft
and cause an engine failure.
Use clean Lubriplate™ 105 multi-purpose lubricant, or its
equivalent, to lubricate the upper main bearing shell to
crankshaft journal mating surface.
Start the bearing into the upper saddle by hand. Slide the
bearing into position. Take care to not damage the
crankshaft journal while installing the bearing.

equivalent, to lubricate the inside diameter of the bearing
shells and the liner side of the upper thrust bearings.
Align the lower main bearing shell and push it into place.
Signature™, ISX, and QSX15 Bearings, Main
CAUTION
Make sure the bevel side is toward the crankshaft
journal. Incorrect thrust bearing installation will result
in engine damage.
equivalent, to lubricate the liner side of the lower thrust
bearings.
Install the lower thrust bearings in the number four main
bearing cap as shown.
CAUTION
in engine damage.
Install the upper thrust bearings in the number four main
bearing saddle.
Push the crankshaft toward the rear of the engine to install
the front thrust bearing and toward the front of the engine
to install the rear thrust bearing.
CAUTION
Only use Loctite™ 518 thread sealant on the main cap
joint mating surface. Other sealants can become hard,
brittle, and allow oil and debris into the main bearing/
block joint, causing engine damage.
CAUTION
The bead must be 3 to 5 mm [0.12 to 0.20 in] wide and
must not enter the main bearing shell inside the main
bearing shell inside diameter. Sealant in the main
bearing can cause engine damage.
Apply a bead of Loctite™ 518 thread sealant to the two
main bearing cap surfaces on each main bearing cap as
shown.
Use clean 15W-40 engine oil to lubricate the capscrew

threads and flat washers (or the underside of the capscrew
heads if washers are not used).
Drain the excess oil from the capscrews before installing
them.
CAUTION
The main bearing caps are marked with a `V.' Position
the `V' mark so that it points to the front of the engine.
Incorrect positioning will result in severe engine
damage.
Align the capscrew holes in the cap with the holes in the
cylinder block. Make sure the lower bearing shell is in
position.
Install the capscrews through the cap and into the cylinder
block.
To reduce the possibility of bore size issues, clearance

issues, or both, the main bearing capscrews must be
tightened within 15 minutes of the Loctite™ 518 thread
sealant application.
Make sure the bearing shell does not move.

Tighten the capscrews in far enough to use a heel bar to
pry the caps into place.
Tighten both of the capscrews on a main bearing cap to

203 N•m [150 ft-lb].
Loosen both capscrews completely.
The remaining main bearings do not have thrust bearings.

It is recommended to use an air impact wrench and

socket, Tool Numbers 3163059 and 3163060, to rotate the
capscrews an additional 180 degrees.
Use the torque plus angle method to tighten the main
bearing capscrews in the sequence shown.
Torque Value: Step1 149 N•m [ 110 ft-lb ]
Step2 Rotate 180 degrees.
To measure the end clearance of the crankshaft, install a

dial indicator onto the oil pan flange.
Place the tip of the gauge against the crankshaft
counterweight.
Push the crankshaft toward the rear of the cylinder block.
Set the dial indicator at "0" (zero).

Push the crankshaft toward the front of the cylinder block.
If the end clearance is less than 0.10 mm [0.004 in], loosen

all main bearing capscrews one turn.
Push the crankshaft toward the front and then toward the
rear of the cylinder block.
Tighten the main bearing capscrews in sequence.

Torque Value:
Block Main Step1 149 N•m [ 110 ft-lb ]
Bearing
Capscrews
Measure the crankshaft end clearance.
Crankshaft End Clearance - New or Reground

mm in
0.10 MIN 0.004
0.50 MAX 0.020
Crankshafts that have been reground on the thrust

bearing surfaces are marked for oversize thrust bearings
on the rear crankshaft counterweight. If the crankshaft
counterweight is marked, check the thrust ring part
number to make sure the correct thrust ring size is used.
Example: F0.010 = front 0.25 mm [0.010 in]
Example: R0.020 = rear 0.51 mm [0.020 in]
If the crankshaft end play is more than 0.50 mm [0.020 in],

the engine must be removed to allow for replacement of
the crankshaft. Refer to Procedure 000-001 (Engine
Removal) in Section 0.

Install
Use Lubriplate™ 105, or equivalent, to coat the upper
thrust bearings.

the rear thrust bearing, and to the front of the engine to
install the front thrust bearing.
bearing saddle.
The bevel must be toward the crankshaft.
Use Lubriplate™ 105, or equivalent, to coat the lower thrust

bearings.
The bevel of the thrust bearing must be toward the
crankshaft.
Lubricating Oil Pump Signature™, ISX, and QSX15
Install
WARNING
CAUTION
Do not drop the crankshaft on the bearings.
Install the main bearings. Refer to Procedure 001-006 in
Section 1.
The end of the crankshaft with the smallest diameter
must point toward the front of the cylinder block.
Install the crankshaft.

Install
Align dowels on oil pump with mounting holes in the
cylinder block.
Install the oil pump, shims (if they were removed), and the
four capscrews.
Tighten the capscrews.
Use a dial indicator, check the oil pump idler gear back
lash.
Oil Pump Idler Gear Backlash

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

Install
Remove the protective plug from the cylinder block oil
passage. Make sure no debris enters the lubrication
system. Use a clean shop towel, carefully wipe out the oil
passage and inspect to make sure no debris is left in the
passages.

Install a new gear housing mounting gasket.
Signature™, ISX, and QSX15 Gear Housing, Front
The gear housing has the words “Special Capscrew” cast

into the housing at the number 1 mounting location (see
illustration). This capscrew must be the short head
capscrew to prevent contact between the capscrew and
the idler gear.
WARNING
Install the gear housing.
Install the 18 mounting capscrews.

Four different length capscrews are utilized on the front
gear housing. Use the table below to identify the
capscrews and their mounting locations.
Capscrew Mounting Location
Location Size Quantity
14 M10 x 1.5 x 93 1
18, 19, 20 M10 x 1.5 x 70 3
1 M10 x 1.5 x 21.8 (Special 1
Short Head)
All remaining M10 x 1.5 x 2.5 15
Remove the guide studs and install two capscrews.

Tighten the capscrews in the sequence shown.
Torque Value:
All Capscrews Step1 20 N•m [ 15 ft-lb ]
Except (1)
Step2 72 N•m [ 53 ft-lb ]
Torque Value:
Capscrew (1) Step1 20 N•m [ 15 ft-lb ]
Flywheel Housing Signature™, ISX, and QSX15

Install
Remove the protective plug from the block oil passages.
Make sure debris does not enter the lubrication system.
Use a clean shop towel to carefully wipe out the oil
passage.
Install the cover plate and two capscrews. Tighten the

capscrews.
Install two guide studs into the cylinder block to help

support and align the housing during installation.
Position the flywheel housing gasket to the rear of the
engine block using the guide pins.
Install the flywheel housing over the guide studs.

Lubricate the threads and underneath the heads of the
capscrews with clean 15W-40 lubricating oil.
Install capscrews 1, 2, 3, and 4, and tighten in the
sequence shown.
The flywheel housing is located on the block by two ring

dowels from the factory. If a flywheel housing is removed,
it can be reinstalled with the ring dowels in place, but
alignment must be checked with the following alignment
procedure.
If the alignment does not meet specification, the ring
dowels must be removed and the housing must be
realigned without the ring dowels.
CAUTION
The flywheel housing bore and surface must be in
alignment with the crankshaft to prevent possible
damage to the engine, the clutch, or the transmission.
Measure the flywheel housing alignment.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting tool
Part Number ST-1325 and indicator Part Number
3376050.
The dial indicator can be mounted by any method that
holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings
obtained will be inaccurate.
Position the indicator in the 6:00 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00
o'clock positions as (a), (b), and (c) in the concentricity
work sheet. Recheck zero at the 6:00 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
Refer to the accompanying figure to determine the correct
sign when recording these values.
CAUTION
Do not force the crankshaft beyond the point where
the bearing clearance has been removed. Do not pry
against the flywheel housing. These actions can
cause false bearing clearance reading.
Rotate the crankshaft until the dial indicator is at the 12-
o'clock position and zero the gauge.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as (d) in the concentricity work
sheet. This is the vertical bearing clearance adjustment
and will always be positive.
Use the concentricity work sheet (see the accompanying

illustration) to determine the total vertical and horizontal
values.
The total horizontal is equal to the 9:00 o'clock reading (1)
minus the 3 :00 o'clock reading (c).
The total vertical is equal to the 12:00 o'clock reading (b)
plus the bearing clearance (d).
Example:
6:00 o'clock = reference = 0
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Using the work sheet and the numbers from the example,
the total horizontal value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the horizontal side of the

chart and the total vertical on the vertical side of the chart.
Use a straightedge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Using the total horizontal and total vertical values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for SAE 1, 2, and 3 flywheel
housings.
Use the accompanying chart for SAE 0 and ½ flywheel

housings.
Use the accompanying chart for SAE 00 flywheel

housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
The ring dowels are not required to maintain concentricity
of the housing; the clamping force of the capscrews holds
the housing in place.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Recheck the concentricity. When concentricity is within
specification, tighten the capscrews to the specified value.
Face Alignment
CAUTION
The dial indicator tip must not enter the capscrew
holes, or the gauge will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator must be rigid for an
accurate reading. It must not sag. Position the indicator
at the 12:00 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the

3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions.
The crankshaft must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a position is measured.
Continue to rotate the crankshaft until the indicator is at

the 12:00 o'clock position. Check the indicator to make
sure that the needle points to zero. If it does not, the
readings will be incorrect.
Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]
The maximum allowable total indicator reading is

determined by the diameter of the housing bore. If out of
specifications, replace the housing.
SAE Bore Diameter Total Indicator
Number Runout Maximum
00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
½ 584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]
Install the remaining capscrews. Tighten all capscrews in

two steps using the sequence shown.
Step2 197 N•m [ 145 ft-lb ]

Install
Make sure no debris enters the lubrication system.
passage.
Install the two guide pins (3), Part Number 3164764, into
the cylinder block.
cylinder block using guide pins.
WARNING
Install the two eye hooks (4) in the top of the REPTO
flywheel housing. Install the lifting slings to the eye hooks
and push the REPTO flywheel housing onto the two
guides pins (3).
Install the six short capscrews (2) and four long capscrews
(1) in the locations shown.
Remove the two guide pins and install the two other long
capscrews.
Tighten capscrews (1), (2), (9) and (10).

Tighten the remaining capscrews in the sequence shown.
CAUTION
The REPTO flywheel housing bore and face must be
in alignment with the crankshaft to prevent possible
Use the measure step in this procedure to align the
housing.

Step2 197 N•m [ 145 ft-lb ]
Install the three oil pan capscrews.
Install the large o-ring seal (1) and the small o-ring seal (2)
onto the idler shaft.
Assemble the replacer idler shaft plate and handle.

Install the two capscrews in the idler shaft holes and
tighten.
Use clean 15W-40 oil to lubricate the idler shaft.
The two cones (2) are loose and will fall out if not
contained.
Make sure the gear (4), two bearing snap rings (1), and the
two cups (3) are pressed in place before inserting the
assemblies through the center or sides of the REPTO
flywheel housing openings.
Use clean 15W-40 oil to lubricate the bearing snap rings,
cones, cups, idler shaft, and gear.
Make sure the idler shaft plug (1) is facing upward when
installing it into the bore.
Install the gear and bearing assembly through the center
or sides of the REPTO flywheel housing holes. Position
the bearing races together and insert the idler shaft with
the tool through the first bear bore. The running clearance
is 0 to 0.025 mm [0.000 to 0.001 in].
Make sure the idler shaft is properly aligned and seated
against the shoulder of the internal bore.
Repeat the procedure if installing a second gear.

Remove the two capscrews, replacer idler plate, and
handle from the idler shaft.
Lubricate the threads and under the capscrew head with
clean 15W-40 oil.
Install the washer and capscrew and tighten capscrew.
A second idler gear can be installed or an insert shaft can

be used without the idler gear and roller.
Install the o-rings onto the insert shaft. Lubricate the o-
rings with clean 15W-40 oil.
Install the insert shaft into the flywheel housing hole where
the cover plate will be installed (opposite pump location).
Align the hole with the tapped hole in the block.
clean 15W-40 oil.
Install the three guide pins, Part Number 3164765, equally

spaced through the crankshaft gear and into the
crankshaft.
Rotate the idler gears, as necessary, to mesh the
crankshaft gear with the idler gear(s).
Install the crankshaft gear.
Make sure the o-rings are properly seated into the groove
before installation.
Use clean 15W40 oil to lubricate the o-rings.
Install four plugs (1) with o-rings (2) into the REPTO
flywheel housing holes.
Install the o-ring in the REPTO flywheel housing groove.

Install the seal carrier over the two dowels pins on the
Install the 12 capscrews.

Tighten the capscrews in the sequence shown to secure
the seal carrier.
Install the three flywheel mounting capscrews and

spacers. Tighten the flywheel mounting capscrews.
Remove the three flywheel mounting capscrews and
spacers.
CAUTION
The rear crankshaft seal must be pressed evenly into
the bore. If the crankshaft and crankshaft seal is not
pressed evenly into the bore, the oil seal can cause
equipment damage.
Install the rear crankshaft oil seal over the rear crankshaft
seal replacer, Part Number 3164780, and onto the three
guide pins.
Install three flywheel mounting capscrews (without the
washers) through the three holes in the rear crankshaft
seal replacer.
CAUTION
To reduce the possibility of damage to the oil seal and
crankshaft, never use a hammer or mallet to install the
rear crankshaft oil seal.
Do not use lubricants during the installation process.
Apply a 10 percent soap solution to the outer ribbed
surface of the rear crankshaft oil seal.
Tighten the flywheel mounting capscrews no more than ½
revolution at a time, alternating capscrews in a
clockwise pattern, until the rear crankshaft seal replacer,
Part Number 3164780, seats against the REPTO flywheel
housing.
Remove the rear crankshaft seal replacer and the three

flywheel mounting capscrews.
Install the flywheel. Refer to Procedure 016-005 (Flywheel)
in Section 16.
If one side of the REPTO flywheel housing cover access

hole does not use a hydraulic housing, the opening
must be covered in conjunction with the oil supply line
hole and plugging the straight thread plug hole.
Install the 1/8-inch pipe plug (1) into the oil supply line
hole. Make sure the pipe plug is flush with the mounting
surface.
Install the straight thread plug (2) into the flywheel housing
hole. Make sure pipe plug is flush with the mounting
surface.
Install the diamond seal (1) on the REPTO flywheel

housing cover access hole.
Apply a small amount of RTV on the two ends (2) where
the diamond seal comes together and a small amount of
15W-40 oil on the diamond seal.
Install the cover plate to the REPTO flywheel housing
cover access hole. Install the 10 capscrews and tighten.
Make sure the idler gear is locked in position. Use a dial

gauge to check the backlash.
Idler Gear to Crankshaft Gear Backlash

mm in
0.15 MIN 0.006
0.28 MAX 0.011
If the backlash is not within specifications, replace the
idler gear, REPTO hub gear, or both.
NOTE: The spray nozzle and diamond seal are only

installed if a hydraulic housing is used.
Install the spray nozzle (1) into the oil supply line hole.
Tighten the spray nozzle.
clean 15W-40 oil on the diamond seal.
Apply clean 15W-40 oil on the gear teeth and bearings.

Install the hydraulic housing over the dowel pins. The gear
inside the hydraulic housing is free to rotate and will locate
the position of the idler gear as the hydraulic housing is
being installed over the dowel pins.
Install the 10 capscrews and tighten in the sequence

shown.
Verify that backlash exists between the Hydrive housing

gear and idler gear by inserting a tool into the spline to
help rotate the gear.
A small amount of backlash must be present, although
obtaining a measurement is not required.
If no backlash is present, disassemble the Hydrive
housing from the flywheel housing, and assemble the
Hydrive housing to the opposite flywheel housing
mounting pad and check for backlash.
If no backlash is present when assembled on either
flywheel housing mounting pad, the Hydrive housing
must be replaced.
If backlash is present on only one side, the flywheel
housing must be replaced.
Install the threaded plug (1) in the bottom hole of the

hydraulic housing. Tighten the threaded plug.
Install the oil line hose on the straight connectors. Tighten
the hose and check for leaks.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting
tool, Part Number ST-1325, and indicator Part Number
3376050.
obtained will not be accurate.
gauge at zero.

CAUTION

values.
Example:
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Use the work sheet and the numbers from the example.
The total horizontal value equals 0.006, and the total

housings.

housings.

housings.

repositioned.
Face Alignment
CAUTION



Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]

00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
½ 584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]

Step2 197 N•m [ 145 ft-lb ]

Install
The rear crankshaft seal must be oriented with the engine
as shown in the illustration.
CAUTION
Never use a hammer or mallet to install the seal.
Damage to the seal can occur.
Do not use lubricants to install the seal. Apply a 10-
percent soap solution to the outer-ribbed surface of the
seal.
Guide the rear crankshaft seal (1), spacer (2), and replacer
plate (3) over the crankshaft.
NOTE: Spacer, Part Number 4918688, is used to make
sure of the correct installation depth of the crankshaft seal.
The flat side of the spacer should contact the crankshaft
seal during installation.
Flywheel Signature™, ISX, and QSX15
CAUTION
the bore. Misalignment of the seal can cause damage.
Install three flywheel mounting capscrews or replacer
screws and hex nuts, through the replacer plate and into
the end of the crankshaft.
Finger-tighten the three installation capscrews against the
replacer plate.
Tighten the screws not more than ½ of a turn at a time,
in a clockwise pattern, until the installation tool seats
against the flywheel housing.
Tighten the screws.
Remove the replacer plate.
Measure
the seal.
0.5 mm [0.02 in].
installed.
Flywheel (016-005)
Install
Install the pilot bearing spacer into the rear of the
crankshaft with the spacer lip oriented outward.
NOTE: A small amount of clean Lubriplate™ 105 multi-
purpose lubricant, or its equivalent, can be used to help
keep the pilot bearing spacer in position until the flywheel
is assembled.
Signature™, ISX, and QSX15 Flywheel
CAUTION
The flywheel mounting capscrews must be a minimum
of SAE Grade 8 with rolled threads. Use identical
replacements to avoid possible flywheel failure
resulting in personal injury or property damage.
capscrews with clean 15W-40 oil. Allow the excess oil to
drip off the parts. Do not lubricate the threads of the
crankshaft.
WARNING
avoid personal injury, use a hoist or get assistance to
lift the component.
Use two M6 x 1.5 guide studs during assembly.
Install the flywheel. The flywheel must be firmly against
the crankshaft.
Install the ten capscrews.

Remove the t-handles and the guide studs.
Install the remaining two capscrews into the holes from
which the guide studs were removed.
Use flywheel capscrew socket, Part Number 2892191, to
tighten the capscrews in two steps. Use the sequence
shown.
Torque Value:
Step 1 125 N•m [ 92 ft-lb ]
Step 2 250 N•m [ 184 ft-lb ]
Use a mandrel and hammer to install the pilot bearing.

The pilot bearing must be installed even with the pilot bore
surface.

Install
Articulated Piston
CAUTION
Use a copper or aluminum vise protector when
installing the connecting rod in a vise to protect the
connecting rod from damage.
The ring gap of each ring must not be aligned with the
piston pin or with any other ring. If the ring gaps are not
aligned correctly, the rings will not seal properly.
Place the connecting rod in a vise to hold the assembly in
a horizontal position while installing the rings.
A cross-sectioned view of an oil control ring is shown.

The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring.
Do not overlap the ends of the expander ring.
Install the piston rings with TOP toward the top of the
piston.
The rings have the top marked for correct installation.
The oil control ring is symmetrical and can be installed in
either orientation.
The piston must be held in a horizontal position to install

the rings in order to keep the rings in the groove while
installing the ring compressor.
For articulated pistons, the top piston ring (1) is a keystone
ring with no twist or cutback notch.
The intermediate ring (2) is a positive twist design with a
cutback notch (3) on the topside and a two-degree taper
face.
The oil control ring (4) is the bottom piston ring.
Signature™, ISX, and QSX15 Piston Rings
Rotate the rings to position the ring gaps as shown.

piston pin, or with any other ring gap. If the ring gaps are
not aligned correctly, the rings will not seal properly.
Single-Piece Piston
CAUTION
Install the connecting rod in a vise to hold the assembly in

piston.
either orientation.
For single-piece pistons, use a universal piston ring
expander to install the second ring into the piston.
Bearings, Connecting Rod Signature™, ISX, and QSX15
The single-piece ring set is similar to the articulated ring

set, with the exception of the second ring. The second ring
has a rectangular cross-section (2) with an angled cut (3)
on the upper side of the inner diameter to induce a positive
twist. This design improves the slobber-resistance of the
ring pack.

If failure resulted in coolant, oil, excessive fuel or

excessive black smoke entering the exhaust system, the
aftertreatment system must be inspected. Refer to

Install
CAUTION
Connecting rod bearings must match the connecting
rod design. Drilled rods must use drilled rod bearings.
Non-drilled rods must use non-drilled bearings.
Mismatches will cause engine damage.
Connecting rod design must be matched with the proper
connecting rod bearing.
Drilled connecting rods must be fitted with drilled
connecting rod bearings.
Non-drilled connecting rods must be fitted with non-drilled
Drilled and non-drilled connecting rods can be mixed in

the same engine as long as the two piece piston is used.
Engines using single piece pistons can not use non-drilled
connecting rods.
CAUTION
The connecting rod and bearing shell mating surfaces
equivalent to lubricate the crankshaft journal mating
surface of the upper bearing shell.
Install the upper bearing shell into the connecting rod with
the tang of the bearing in the slot of the rod.
Install the bearing shell into the connecting rod cap with
the tang (2) of the bearing in the slot (1) of the cap.
equivalent to lubricate the bearing shell to crankshaft
journal mating surface and the connecting rod capscrews.
CAUTION
The rod cap alpha characters must match the alpha
characters on the connecting rod and must be
installed with the characters aligned to prevent
damage to the connecting rods and crankshaft. The
locking tang of the connecting rod cap must face
toward the intake side of the cylinder block. Rod and
cap mating surfaces must be clean or engine damage
can occur.
Install the cap onto the connecting rod.
Lubricate the threads of the capscrews with clean engine

oil.
Thread the capscrews into the connecting rod and hand
tighten.
The procedure for tightening used capscrews is different
than the procedure for tightening new capscrews.
For used connecting rod capscrews:
Torque Value:
Tighten Step1 70 ± 6 N•m[ 52 ± 4 ft-
Capscrews in lb ]
Numerical
Sequence
Step2 Rotate capscrews in
numerical sequence 60
± 5 degrees
For new connecting rod capscrews:
Torque Value:
Capscrews in lb ]
Numerical
Sequence
Step2 Loosen capscrews in
numerical sequence
Step3 70 ± 6 N•m[ 52 ± 4 ft-
lb ]
± 5 degrees
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
NOTE: The connecting rod must move freely from side to

side on the crankshaft journal. If the rod does not move
freely, remove the rod cap and make sure the bearing
shells are the correct size. Check for dirt or damage on
the crankshaft and the bearing shells.
Repeat the above steps to install the remaining bearing
shells and connecting rod caps.

(001-054)
Install
Immerse the piston in a container of clean 15W-40 oil.
Remove the piston from the container. Let the excess oil
drain from the piston.
Use piston ring compressor, Part Number 3164846, to

compress the rings.
The cylinder block and all parts must be clean before
assembly.
Inspect the cylinder liners for reuse. Refer to Procedure
001-028.
Use a clean, lint-free cloth to clean the connecting rods

and bearing shells.
Do not lubricate the backside of the bearing shells. The
operating clearance of the bearing will be reduced and the
bearing can be damaged during engine operation.
If new bearings are not used, the used bearings must be

installed on the same connecting rod from which they
were removed.
Install the upper bearing shell into the connecting rod.
The tang of the bearing shell (2) must be in the slot of the
cap (1). The end of the bearing shell must be even with
the cap mounting surface.
Use Lubriplate™ 105, Part Number 3163086, or

equivalent, to coat the entire inside circumference of the
bearing shell.
Apply a film of clean 15W-40 oil to the cylinder liner.
Install connecting rod guide pins, Part Number 3163097.
Use the compressor drive or barring device to rotate the

crankshaft so the connecting rod journal of the connecting
rod being installed is at bottom dead center.
CAUTION
Failure to align the deep valve pocket and the piston
skirt cooling nozzle notch correctly will result in
extensive engine damage.
Align the piston crown deep valve pocket on the exhaust
side of the engine, and the piston skirt cooling nozzle
notch to the intake side of the engine.
If the deep valve pocket and the piston skirt cooling nozzle
notch are not on opposite sides, the piston and
connecting rod assembly are not assembled correctly.
Disassemble the piston and connecting rod and assemble
correctly.
Insert the connecting rod through the cylinder liner until
the ring compressor contacts the top of the liner.
Signature™, ISX, and QSX15 Piston Cooling Nozzle
Both articulated pistons and single-piece pistons have an

arrow on the top of the piston crown, which will point to
the front of the engine, when the piston is installed
properly.
CAUTION
Do not use a metal drift to push the piston into the
cylinder liner. The piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the
cylinder liner. Push the piston until the top ring is
completely in the cylinder liner.
If the piston does not move freely, remove the piston and
inspect for broken or damaged rings.
Use the nylon guide pins to align the connecting rod with
the crankshaft while pushing the piston and connecting
rod assembly into place.
Remove the nylon guide pins.

Install
CAUTION
Properly align the nozzles in the locator notch before
tightening the capscrews. Damage to the engine can
occur.
The crankshaft must be rotated to allow access to install
all the nozzles.
Install the nozzle, washers, and capscrews.
Lubricating Oil Pan Signature™, ISX, and QSX15

Install
Install the block stiffener plate and the 10 capscrews.

Mounted) (007-035)
Install
Lubricate the o-ring with clean 15W-40 engine oil.
Install the new o-ring on the oil suction tube.
Install the oil suction tube into the lubricating oil pump.
Install the lubricating oil suction tube capscrews. Tighten
capscrews.

Install
Apply a 1.97 mm [1/8 in] bead of silicon sealant, Part
Number 3164067, to each of the four T-joints where the
front gear housing and flywheel housing gaskets intersect
the oil pan gasket.
Signature™, ISX, and QSX15 Engine Support Bracket, Front
Install a new oil pan gasket.

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

shown.
At the end of the sequence, loosen and tighten capscrew
number 1again.
Install the oil drain plug.

General Information

(016-002)
Install
Install the engine support bracket and the six mounting
capscrews.
Torque: 97 N•m + 60 deg [72 ft-lb + 60 deg]
Install the rubber engine mounts into the crossmember.
WARNING
Lower the front of the engine to the rubber engine mounts.
The capscrew holes in the support bracket must be
aligned with the capscrew holes in the engine mounts.
Install the two capscrews in the support bracket and
engine mount. Tighten to the manufacturer's
specifications.
Remove the lifting fixture or the hoist from the engine.

Install
Two different styles of head gaskets are used on
Signature™, ISX, and QSX15 engines, based on the style
of liner used in the engine. Correctly identify which style
of liner is used before installing the head gasket. Refer to
Install the cylinder head gasket.
WARNING
Two long cylinder head capscrews placed toward each
end of the cylinder head serve as convenient guides when
lowering the cylinder head into place.
Align the cylinder head over the dowel pins and lower into
position.
Use clean 15W-40 oil to lubricate the cylinder head

capscrews.
Allow the excess oil to drain from the threads.
Install the 26 capscrews into the cylinder head.
CAUTION
Make sure the four longer capscrews placed in the
correct location. Engine damage can occur if these
capscrews are not placed in the correct locations.
Tighten capscrews in sequence.
socket, Tool Number 3163059 and 3163484, to rotate the
capscrew 90 degrees.
Torque Value:
Step 1 203 N•m [ 150 ft-lb ]
Step 2 407 N•m [ 300 ft-lb ]
Step 3 Rotate 90 degrees.

Install
CAUTION
Use caution when installing the camshaft to avoid
Coat the inside of the injector camshaft bearings with
Lubriplate™ prior to installing camshaft.
Install the injector camshaft.
Install new o-rings on the retainer plate.

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

Install the capscrews.

Install
CAUTION
Coat the inside of the valve camshaft bushings with
Install the valve camshaft.
Install new o-rings onto the retainer plate.


Install
Timing Wedges:
The timing code is located on the engine dataplate.
• First number - injector wedge
• Second number - valve wedge.
Make sure the wedges with the proper angles are used
and that the wedges are properly seated in their installed
position.
Insert the correct timing wedge to lock the injector
camshaft. Lightly tap the top of the timing wedge with a
mallet to be sure it is properly seated.
WARNING
Do not drive the wedges into place. Engine damage
can occur.
position.
Insert the correct timing wedge to lock the valve camshaft.
Lightly tap the top of the timing wedge with a mallet to be
sure it is properly seated.

The lower scissor idler gear must be unloaded during
installation. To unload the gear, two of the gear screws
Apply Lubriplate™ to the thrust bearing, shaft, and lower
scissor idler gear.
Install the thrust bearing, shaft, and lower scissor idler
gear. The shaft must be installed with the word
“TOP” (stamped on the end of the shaft) toward the top of
the engine.
The lower idler scissor gear front retainer plate is larger in

diameter than the adjustable idler retainer plate. The slots
in the plate go toward the scissor gear
Install the retainer and capscrews.
Tighten all capscrews in a star pattern.
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
Step 2 Rotate each capscrew an additional 60
degrees in the same sequence as
above.
CAUTION
Make sure all the scissor gear screws are tightened to
the proper torque so that they do not back out during
engine operation. Severe engine damage can occur.
Load the lower idler scissor gear by tightening all of the
gear screws.

non-scissor idler gear.
Install the thrust bearing, shaft, and lower non-scissor idler
the engine.
The lower idler non-scissor gear front retainer plate is

larger in diameter than the adjustable idler retainer plate.
The slots in the plate go toward the scissor gear
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
above.

The spacer plate is doweled to the block with two standard
dowels.
Install the mounting spacer plate.
Apply Lubriplate™ to the spacer, shaft, and adjustable idler

gear.
It is possible to install the shaft in an incorrect orientation;
however, it will not be possible to set the gear backlash
correctly.
Install the spacer, shaft and adjustable idler gear. The
shaft must be installed with the word “TOP” (stamped on
the front face of the shaft) oriented toward the top of the
engine.
The adjustable idler front retainer plate is smaller in

diameter than the lower idler scissor gear retainer plate.
The slots on the retainer plate go toward the gear.
The adjustable idler gear is installed loosely, because it is
moved into its final position later in the timing process.
Install the retainer and capscrews. Finger-tighten the
capscrews and then loosen by one “flat,” which is 60
degrees.

Install the injector camshaft rear cover plate.
CAUTION
The injector camshaft nose and injector camshaft
scissor gear must be clean and dry prior to assembly.
Wipe off the taper surface with a clean lint-free cloth
and apply a thin coat of Loctite™ 609, Part Number
3823718, to the inside diameter of the camshaft gear.
Use care not to contaminate the joint with oil prior to
assembly or engine damage may occur.
during installation. To unload the gear, two of the gear
screws must be backed out far enough to allow the teeth
on the scissor gear to be aligned.
Apply a thin coat of Loctite™ 609, Part Number 3823718,

to the inside diameter of the camshaft gear.
The injector camshaft scissor gear needs to be fully

engaged on the camshaft nose taper, yet loose enough so
it can rotate on the camshaft nose.
Install the injector camshaft scissor gear loosely on the
camshaft nose taper.
The injector camshaft scissor gear mounting washer is
larger in diameter than the valve camshaft mounting
washer.
Install the mounting washer and capscrew.
Finger-tighten the capscrew and then loosen by one “flat,”

which is 60 degrees.
The injector camshaft scissor gear is still loose at this
point, to allow the adjustable idler gear to be properly
positioned.
Do not seat the gear.

CAUTION
non-scissor gear must be clean and dry prior to
assembly. Wipe off the taper surface with clean a lint-
free cloth and apply a thin coat of Loctite™ 609, Part
Number 3823718, to the inside diameter of the
camshaft gear. Use care not to contaminate the joint
with oil prior to assembly or engine damage may
occur.

The injector camshaft non-scissor gear needs to be fully

Install the injector camshaft non-scissor gear loosely on
The injector camshaft non-scissor gear mounting washer
is larger in diameter than the valve camshaft mounting
washer.

The injector camshaft non-scissor gear is still loose at this
point to allow the adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
CAUTION
The valve camshaft nose and valve camshaft gear
must be clean and dry prior to assembly. Wipe off the
taper surface with a clean lint-free cloth and apply a
thin coat of Loctite™ 609, Part Number 3823718, to the
inside diameter of the camshaft gear. Use care not to
contaminate the joint with oil prior to assembly or
engine damage may occur.

The valve camshaft gear needs to be fully engaged on the

camshaft nose taper, yet loose enough so it can rotate on
the camshaft nose.
Install the valve camshaft gear loosely on the camshaft
nose taper.
The valve camshaft mounting washer is smaller in
diameter than the injector camshaft scissor gear mounting
washer.

The valve camshaft gear is still loose at this point to allow
the adjustable idler gear to be properly positioned.
Adjust
Backlash (Scissor Gear Combinations)
CAUTION
Do not set backlash between the adjustable idler gear
and the lower scissor idler gear. Severe engine
damage can occur.
This backlash step works with the scissor type injector
camshaft gear and lower idler gear, and the non-scissor
injector camshaft gear with a scissor type lower idler gear.
The injector camshaft scissor gear must still be unloaded
during this step. To unload the gear, two of the gear
Insert, as shown, a narrow shim (0.25 mm [0.010 in]) into
the gear teeth mesh between the adjustable idler gear and
the wide (rear side) gear of the injector camshaft scissor
gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The gear backlash set procedure for engines that

have a non-scissor injector camshaft gear and a scissor
type lower idler gear is the same as that of engines that
utilize two scissor type gears.
Use hand pressure, only, to move the adjustable idler
gear toward the center of the engine (into mesh), so there
is no gap on either side of the shim.
Both of the camshaft gears will rotate slightly on the
camshafts during this step.
Slight drag will be felt on the shim while pulling the shim
in and out.
Backlash (Non-Scissor Gear Combinations)

Removal of the lower front cover is not required when
setting the gear backlash on engines that utilize all non-
scissor gears. An access hole is provided to insert a shim
between the lower non-scissor idler gear and the
adjustable idler gear. The access hole is sealed with a
plug. The plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown with the lower gear
cover removed.
Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear

teeth mesh between the adjustable idler gear and the
injector camshaft gear. The shim is inserted on the load
side of the gear teeth.
teeth mesh between the adjustable idler and the lower
non-scissor idler gear. The shim is inserted on the load
gear so there is no gap between the teeth and either side
of the shims.
in and out.

While holding the adjustable idler gear in position, tighten
the adjustable idler gear mounting capscrews.
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
above.
Remove the feeler gauge.
CAUTION
Load the injector camshaft scissor gear by tightening all
of the gear screws.
The valve camshaft gear will rotate slightly on the valve
camshaft during this step.
Tighten the injector camshaft scissor gear retaining

capscrew.
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Step 2 Rotate an additional 90 degrees
Loosen the capscrew 360 degrees and tighten again using
the toruqe-plus-angle method.
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]

Use hand pressure only to rotate the injector camshaft
gear clockwise until the gear train backlash is taken up.
Obtain tooth-to-tooth contact between the crankshaft gear
and the injector camshaft gear.
Tighten the injector camshaft non-scissor gear retaining

capscrew.
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Valve Camshaft Scissor Gear

Tighten the valve camshaft scissor gear retaining
capscrew.
Valve Camshaft Non-Scissor Gear

Use hand pressure, only, to rotate the valve camshaft
gear counterclockwise until the backlash between the
injector camshaft gear is taken up. Obtain tooth-to-tooth
contact between the injector camshaft gear and the valve
camshaft gear.
Tighten the valve camshaft non-scissor gear retaining

capscrew.
Coat the entire gear train with clean 15W-40 oil.
Use the access hole in the lower gear cover to lubricate

the lower idler gear and crankshaft.
Signature™, ISX, and QSX15 Air Compressor

Install
Pin the engine crankshaft. Refer to Procedure 001-088 in
Section 1.
Rotate the gear on the air compressor until the mark on
the gear is in line with the V-notch on the air compressor
housing, located at the three o'clock position as viewed
from the front.
Loctite™, Part Number 3824040 or equivalent, must be
used on the capscrews that mount the air compressor to
the gear housing. This seals the threads in the housing.
To evenly distribute the sealant as the capscrew is
torqued, a line of sealant should be placed along the
length of the capscrew.
Install the air compressor and the four capscrews onto the
front gear housing.

Tighten the capscrews again.
Install the air compressor mounting brace and four

capscrews on the block beneath the air compressor. Start
threading all four capscrews.
Air Compressor Coolant Lines Signature™, ISX, and QSX15
Tighten the capscrews on the cylinder block and air

compressor.
Install the air discharge line.

Install the air inlet line.
Tighten the hose clamp.
Install the air governor (if removed). Connect the air
governor pressure signal line. Refer to the OEM service
manual.

(012-004)
Install
Use two elbows and run the locking nuts all the way up
prior to installation.
Start threading the elbows into the cylinder head.
Use a 24 mm open-end wrench to position the elbows.
Push the tube nut away from the bell flare on the U-shaped
coolant supply line.
Position the sealing grommet behind the bell flare.
Signature™, ISX, and QSX15 Air Compressor Coolant Lines
Install the U-shaped coolant supply line into the coolant

supply elbow.
Verify the bell flare and grommet seat correctly in the
elbow.
Start threading the compression nut onto the elbow.
Install the other end of the coolant supply line into the
grommet in the cylinder block.
Push the tube nut away from the bell flare on the coolant
return line.
Install the coolant return line into the coolant return elbow.
elbow.
Gear Cover, Lower Signature™, ISX, and QSX15
Install the other end of the coolant return tube into the
Install the capscrews in the two locations designated by

the arrows.
Tighten the capscrews
Tighten the compression nuts and elbow locking nuts.

Install
Install a new strip seal.
Orient the overlap joint to the upper left of the gear
housing as shown.
Use a small amount of RTV at the overlap joint of strip
seal.
NOTE: Do not tighten the capscrews until the new

crankshaft seal is installed. The crankshaft seal must be
installed first to locate the gear cover properly.
Position the lower gear cover with the 15 capscrews.
Hand-tighten the capscrews.
Signature™, ISX, and QSX15 Crankshaft Seal, Front
Install a new crankshaft seal. Refer to Procedure 001-023

(Crankshaft Seal, Front) in Section 1.
Tighten the 15 capscrews in the sequence shown.


Install
The position of the front crankshaft seal on the crankshaft
is determined by the position of the lower gear cover.
The lower gear cover is mounted to the gear cover housing
using clearance holes. This allows for slight movement of
the cover when the mounting capscrews are loose.
The unitized crankshaft seal must be centered on the
crankshaft for correct operation.
The seal attaches to the lower gear cover, and must be
installed with the lower gear cover capscrews loose and
the cover free to move.
In order for the seal to be properly centered on the

crankshaft during assembly and maintain its location
during operation, the following installation instructions
must be followed.
The crankshaft seal removal and installation tool correctly
centers the seal and correctly positions the dust seal
portion of the seal on the crankshaft.
CAUTION
Failure to loosen and remove the mounting capscrews
from the gear cover can cause the front crankshaft
seal to be misaligned and cause premature seal wear.
The front gear cover must be aligned as follows:
Removing the gear cover mounting capscrews around the
crankshaft seal allows the replacer plate to set against the
gear cover during seal installation.
Remove the gear cover mounting capscrews around the
crankshaft seal.
Loosen the remaining mounting capscrews on the gear
cover so the cover can move freely.
CAUTION
Failure to follow the installation and tightening
sequence can lead to the crankshaft seal being off
center and installed at the wrong depth causing
premature seal wear.
CAUTION
Never use a hammer or mallet to install the seal. Use
of a hammer can damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool has provisions for
any seal nut orientation, although one seal nut must
always be located at the 11 o'clock position.
Do not use lubricants on the crankshaft seal.
Position the crankshaft seal (1) onto the crankshaft until
the gear cover studs are protruding through the seal
carrier mounting holes.
Place the replacer plate (1) against the crankshaft seal.

Make sure the welded nuts on the front crankshaft seal
are seated in their respective slots on the replacer plate
(1).
The large notch between the teeth must bridge the raised
gear cover surface.
Install three washers (4) and capscrews (5) through the

three slots in the replacer plate (1) and into the crankshaft
end.
The capscrews in the replacer plate must be equally
spaced. This allows the crankshaft seal to be installed
correctly.
Tighten the capscrews hand-tight.
CAUTION
The crankshaft seal must be pressed evenly. If the
crankshaft seal is not pressed in evenly the seal can
be damaged.
Inspect the crankshaft seal during installation to make
certain it is being pressed evenly.
Tighten the capscrew(s) no more than ½ of a revolution at
a time, alternating in a clockwise pattern until the replacer
plate (1) bottoms out against the face of the lower gear
cover.
To maintain the cover position while the replacer plate is

removed, tighten the two gear cover mounting capscrews,
as indicated by the arrows in the graphic.
Install the crankshaft seal mounting nuts (1) through the
holes provided in the replacer plate.
Tighten the mounting nuts in the sequence shown.
Install all the gear cover mounting capscrews.

The torque sequence must be followed to prevent the
gear cover strip seal from squeezing out of the groove.
Gear Cover, Upper Signature™, ISX, and QSX15

Install
Install a new strip seal. Orient the overlap at the top and
center of the gear housing.
Use a small amount of RTV at the overlap joint of the strip
seal.
WARNING
Install the cover with 16 capscrews.


seal.
WARNING
Install two guide pins in the gear housing.
Install the front gear cover over the guide pins.
Install the clamping plate, if used.
Install 14 capscrews.
Remove the two guide pins and install the last two
capscrews.

Install
Make sure the mounting surfaces of the crankshaft nose,
vibration damper, and the pulley are clean, dry, and free
from burrs.
Install two guide studs into the crankshaft nose.
Align the dowel pin in the crankshaft wit the dowel hole in
the vibration damper.
Install the vibration damper, pulley, and clamping plate
onto the guide plate.
Use clean 15W-40 oil to lubricate the capscrew threads.

Remove the two guide studs and install the remaining
capscrews.
Tighten the capscrews in a star pattern.

Fan or PTO
vibration dampers, mounting spacer, and pulley are clean,
dry, and free from burrs.
Install one of the vibration dampers (1), mounting spacer

(2), second vibration damper (3), and the pulley (4) onto
the guide studs.
Lubricate the capscrew threads with clean 15W-40 oil.

Install four capscrews.
Remove the two guide studs and install the remaining two
capscrews.
Tighten the six capscrews in a star pattern.
Install the crankshaft adapter (1).

Make sure the crank shaft adapter sets flush against the
pulley (2).
Install the six capscrews and tighten in a star pattern.

Fan or PTO

the guide studs.

Remove the two guide studs and install the two remaining
capscrews.
Tighten the 12 capscrews in a star pattern.
Injector Signature™, ISX, and QSX15
Eccentricity Check
All Applications
Clean the outside surface of the vibration damper.
To measure the vibration damper eccentricity (out of
round), install a dial indicator onto the gear cover as
indicated.
Rotate the crankshaft with the accessory driveshaft one
complete revolution (360 degrees), and record the total
indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
If the vibration damper is not within specifications, it
must be replaced.
Wobble Check
All Applications
To measure wobble (face alignment), install a dial
indicator as shown.
Push the crankshaft to the front or rear of the engine and
set the indicator to “0” (zero).
Rotate the crankshaft one complete revolution (360
degrees) while maintaining the position of the crankshaft,
either toward the front or rear of the engine.
Record the total indicator movement.
Vibration Damper Wobble Measurement

mm in
0.28 MAX 0.011
must be replaced.
Injector (006-026)
Install
Use clean 15W-40 lubricating oil to lubricate the o-rings.
CAUTION
Make sure the injector hold down clamp is properly
aligned before tightening the capscrew. It is possible
for the clamp to contact a nearby ledge, and result in
low clamp load.
Install the injector into the cylinder head.
Install the injector clamp and the capscrew with washer.
Tighten the capscrew.
Install the crossheads.

Install
Install the adjusting screw and locknut into each rocker
lever. Do not tighten the locknuts.
Install the injector rocker levers on the shaft.

Install the exhaust (1), intake (2), and engine brake (3)
rocker levers onto the shaft.
WARNING
Clear the rocker lever assembly mounting capscrew
holes of oil and debris. Extensive engine damage can
result if this warning instruction is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever assemblies onto the
cylinder head.
Rocker Lever Assembly Signature™, ISX, and QSX15
CAUTION
To reduce the possibility of valve rocker shaft damage
due to inadequate brake rocker lever running
clearance, follow the specified procedure to seat the
valve rocker shafts on the cylinder head pedestals (1).
Each valve rocker shaft must be seated in the cylinder
head pedestals prior to tightening the rocker shaft
capscrews.
The front and rear rocker lever shaft assemblies will seat
separately as the engine is rotated in the clockwise
direction.
Use the compressor drive or barring device to bar the

engine over in the direction of rotation, clockwise as
viewed from the front of the engine.
Align the A mark on the vibration damper with the timing
mark on the gear cover.
Either the front or the rear rocker shaft assembly will be

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

Align the B mark on the vibration damper with the timing
The remaining rocker shaft will be fully seated at this point.
CAUTION
front rocker shaft capscrew must be tightened first to
control brake rocker lever position. Brake lever
003-004.
Tighten the front mounting capscrew for the remaining
the shaft.
the center out.
Position the injector rocker lever assemblies onto the

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

using the torque-plus-angle method. Tighten capscrews
from center out.
Adjust the valve, injectors, and brake.
Refer to Procedure .
Signature™, ISX, and QSX15 Overhead Set
Overhead Set (003-004)

Measure
General Information
All overhead lash measurements must be made when the
engine is cold. Stabilized coolant temperature must be at
60°C [140°F] or below.
Remove the rocker lever cover. Refer to Procedure

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

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

Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
Overhead Set Signature™, ISX, and QSX15
WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise, as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
If the engine is not equipped with an air compressor:

Loosen the cover plate capscrews and rotate the cover or
remove the oil fill tube, if equipped.
Use a 1½ inch socket to push the barring gear into the

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

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

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

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

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

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

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

mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free
load.
Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
Adjust
Read the entire procedure for overhead adjustment before
attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped) must
be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be
performed using the values listed in this section.
After an engine rebuild or any major repair where the
injector and valve setting must be disturbed, set all of the
valves, injectors, and brakes.
Valve, Brake, and Injector Adjustment Values

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

damper.

cover.
compressor drive.
WARNING
damage.
The crankshaft rotation is clockwise as viewed from the
(1-2-3-4-5-6).

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


The valves, brakes, and injectors on the same cylinder are
adjusted at the same index mark on the vibration damper.

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

gear cover.

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

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

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

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

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

specification.
Valve Lash Specification

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

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

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

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

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

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

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

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

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

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

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

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

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

Install
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
Lubricate and install the new o-ring seal.
Install the two guide studs.
Install the water pump and three capscrews.

mounting capscrews.

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

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

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

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

CM570
CAUTION

Position the water pump on the engine.
Install the bottom two capscrews finger tight.

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

Torque Value:
and 3
5
Engines Without
Belt Tensioner
Bracket
Align the idler pulley (1) and the shaft of the pilot adapter
(2) with the belt tensioner bracket (3) using the guide pin
on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on the belt idler
bracket using one washer and capscrew.
Install the dust seal.
Signature™, ISX, and QSX15 Refrigerant Compressor Mounting Bracket
CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
Install a new water pump inlet o-ring seal and a new EGR
tube outlet o-ring seal.
Install the five water pump housing capscrews.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.

Install
Replace the o-ring and gasket.
Install the gasket, water inlet connection, and the four
capscrews.
Install the coolant hoses.

Bracket (009-055)
Install
Sanden
Install the two mounting capscrews and the refrigerant
compressor mounting bracket.
Refrigerant Compressor Mounting Bracket Signature™, ISX, and QSX15

Install the refrigerant compressor mounting bracket to the
refrigerant compressor. The refrigerant compressor is
positioned on top of the bracket ledge.
Install the four mounting capscrews and the refrigerant
compressor bracket.

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

housing with two long capscrews.
Position both links in the assembly with the part number

facing outward.
Insert one capscrew through the elongated hole in the
long link and attach the long link to the left side of the
refrigerant compressor bracket.
Insert one capscrew through the small hole in the short
link and attach the short link to the right side of the
Signature™, ISX, and QSX15 Alternator/Refrigerant Compressor Mounting Bracket
Install
Install the wire harness jumper to the alternator/refrigerant
Tap the split washers out slightly. This will ease the
installation.
Install the alternator/refrigerant compressor mounting
bracket to the gear housing.
Install the five mounting capscrews.

Torque Value:
(1, 2 3 and 4) 36 N•m [ 27 ft-lb ]
(5) 56 N•m [ 41 ft-lb ]

The alternator/refrigerant compressor mounting bracket
mounts to the gear housing at the top and the water pump
at the bottom.
Install the bracket and six mounting capscrews.
Tighten the capscrew that threads into the gear housing.
Tighten the short capscrew (1).

Tighten the remaining capscrews (2, 3, 4, and 5).
Torque Value:
(1, 2, 3, 4, and 5) 34 N•m [ 25 ft-lb ]
Coolant Thermostat Signature™, ISX, and QSX15
Install
Install the alternator and the four mounting capscrews.
No alignment is required for the alternator to the alternator
bracket.

Install the alternator, capscrew, washer, and nut to the
alternator mounting bracket. Tighten the nut.
Install the adjusting link and mounting capscrews. Tighten
the capscrews.

Install
Install the two thermostats into the thermostat housing
cover by pushing on the outer rims.
Install the thermostat housing cover, gasket, and four

capscrews on the cylinder head.
Tighten the capscrews to the values shown.
Torque Value:
Short Capscrews 34 N•m [ 25 ft-lb ]
Long Capscrews 56 N•m [ 41 ft-lb ]
Signature™, ISX, and QSX15 Coolant Thermostat
Connect the vent line. Refer to the OEM instructions.

Connect the coolant sensor connector.
Industrial engines use a thermostat housing cover with

either a cover plate or a water connection.
If removed, tighten the capscrews to the following
specification.
Install the upper radiator hose. Tighten the hose clamp.

Coolant Thermostat Housing Signature™, ISX, and QSX15

Install
Single Thermostat
To reduce the possibility of a coolant leak, the 90-degree
elbow on the thermostat housing must be positioned
appropriately and tightened before the thermostat housing
is installed on the cylinder head.
Use two thermostat housing capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and three
capscrews to the cylinder block.
Tighten the three thermostat housing mounting
capscrews.
Install the thermostat into the thermostat housing cover by

pushing on the outer rim.

capscrews.
Signature™, ISX, and QSX15 Coolant Thermostat Housing
Dual Thermostat
Use two thermostat housing cover capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and two capscrews
on the cylinder head.
Tighten the two thermostat housing capscrews.
Remove the two thermostat housing cover capscrews
used as guides.


Torque Value:
Short capscrews 34 N•m [ 25 ft-lb ]
Long capscrews 56 N•m [ 41 ft-lb ]

Engine Lifting Brackets Signature™, ISX, and QSX15
Install the upper radiator hose.


Install the thermostat cover if removed.
Automotive has a similar design with connector for
transmission cooler.

Install
Install the front bracket and four capscrews.
Install the rear bracket and four capscrews.

Install
All Applications
WARNING
When installing a new two-element oil cooler on an older
engine, be sure the cooler element mounting capscrews
do not interfere with the cylinder block.
Install the guide pins.
Remove the protective plugs from the oil passages. Make
sure no debris enters the lubrication system. Using a clean
shop towel, carefully wipe out the oil passages and inspect
to make sure no debris is left in these passages.
Install a new mounting gasket and the oil cooler housing
assembly.
Remove the guide pins and install the two capscrews.

Tighten the capscrews in a circular motion from the center
out.

Install
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
Install new o-rings on the coolant supply tube and vent

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

where it connects to the EGR cooler connection.
Apply a film of high-temperature anti-seize compound to
the inside of the v-band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp.
Install and hand-tighten the four mounting nuts and

capscrews. Tighten the capscrews and nuts in the
sequence shown.
Torque Value:
Capscrews 47 N•m [ 35 ft-lb ]
Torque Value:
Nuts 23 N•m [ 204 in-lb ]
Connect the EGR cooler to the new hose on the rear EGR
connection tube.
Tighten the hose clamps.

Torque Value:
Item 1 7 N•m [ 62 in-lb ]
Torque Value:
Item 2 5 N•m [ 44 in-lb ]
Tighten the v-band clamp between the EGR cooler

connection and the EGR cooler.
CAUTION
Keep all protective caps on the EGR cooler in place
while grinding clearance in the upper mounting
bracket. Failure to do so could cause progressive
damage to the engine once the EGR cooler is
installed. It's important to prevent any debris from
entering the cooler.
Inspect for an interference fit between the upper EGR
cooler mounting bracket and the lower portion of the
exhaust manifold flange. If this interference is present,
grind a clearance on the upper EGR cooler mounting
bracket in the area shown in the illustration.

Install a v-band clamp onto the exhaust manifold front
section.
Install a new gasket on the pilot end of the EGR cooler
where it connects to the exhaust manifold front section.
cooler assembly.
Install the EGR cooler bracket clamping plates.
Install the four EGR cooler mounting capscrews at the top

of the EGR cooler mounting bracket.
Install and hand-tighten the four mounting nuts. Tighten
the capscrews and nuts on the bottom EGR cooler
mounting bracket in the sequence shown.
Torque Value:
Torque Value:
CAUTION
Do not use air tools to remove or install the nut on the
v-band clamp. Use of these tools can seriously
damage the threads or the bolt and cause the clamp
to not be able to be reused.
Position the v-band clamp onto the EGR cooler inlet
connection.
Tighten the two retaining capscrews on the rear EGR

connection tube.
Signature™, ISX, and QSX15 EGR Connection Tubes

Install
Part Number 4919403 and Part Number 4919425, at the
end of the rear EGR connection tube that interfaces with
the EGR cooler before working the tube into position, to
reduce the possibility of introducing dirt or debris.
Install the p-clips onto the rear EGR connection tube.
Make sure the tube insulation is properly and fully located
under the p-clips and that the p-clip rubber sleeve does
not block the mounting hole.
Install the rear EGR connection tube and the p-clip
mounting capscrew and nuts.
Hand-tighten the capscrew and nuts.
Remove the protective caps from the component.

Install a new hose with the hose clamps loosely attached
between the rear EGR connection tube and the EGR
cooler.
Tighten the p-clip mounting capscrews, nuts, and hose
clamps.
Torque Value:
M10 P-clip nut 46 N•m [ 34 ft-lb ]
Torque Value:
M8 P-clip nut 23 N•m [ 204 in-lb ]
Torque Value:
P-clip capscrew and nut 45 N•m [ 33 ft-lb ]
Torque Value:
Breeze Clamp (1) 7 N•m [ 62 in-lb ]
Torque Value:
Norma Clamp (2) 5 N•m [ 44 in-lb ]
EGR Connection Tubes Signature™, ISX, and QSX15

on the rear EGR connection tube where it interfaces with
the front EGR connection tube.
Install the p-clips onto the front EGR connection tube.
Install the front EGR connection tube and the p-clip
mounting capscrews or nuts. Finger tighten the
capscrews or nuts.
Tighten the p-clip mounting capscrews or nuts and the
hose clamps.
Torque Value:
M10 p-clip nut 46 N•m [ 34 ft-lb ]
Torque Value:
Hose clamps 5 N•m [ 44 in-lb ]
Torque Value:
between the front EGR connection tube and the EGR
mixer.
Tighten the p-clip mounting capscrews, nuts, and clamps.
Torque Value:
P-clip capscrews and nut 45 N•m [ 33 ft-lb ]
Torque Value:

Apply lubricant to the hose end of the rear EGR
connection tube.
Loosely install the hose clamp and install the rear EGR
connection tube and gasket onto the EGR cooler and EGR
valve mounting bracket.
Tighten the two capscrews.
Make sure the indentation near the end of the hose slides
past the hose bead on the EGR valve mounting bracket.
Position the hose clamp on this indentation groove.
NOTE: Install the protective sleeve onto the exposed
threads of a T-bolt style clamp.
NOTE: Two different types of hose clamps can be used in
this location. The torque value for each clamp is the same,
regardless of which clamp is used.
Signature™, ISX, and QSX15 Exhaust Manifold, Dry
Loosen the two rear tail support mounting capscrews.

Install a new press-in place seal on the EGR venturi.
Install the EGR venturi on the air intake connection by
loosely installing all three capscrews. Hand-tighten all five
capscrews.
In order to reduce assembly stress, tighten the capscrews
in the following sequence:
Tighten the two front EGR venturi mounting capscrews.
Tighten the rear EGR venturi mounting capscrews.
Tighten the two rear tail support mounting capscrews.
Apply lubricant to the hose end of the front EGR

connection tube and the EGR venturi inlet.
Slide the new EGR connection hose on the EGR venturi
inlet and loosely install both retaining clamps.
Attach a new EGR gasket to the front EGR connection
tube flange, holding it in place with the two retaining
capscrews.
Insert the hose end of the EGR connection tube into the
EGR connection hose, and align the mounting flange with
the EGR valve outlet.
Install the two retaining capscrews into the EGR valve.
Tighten the capscrews in the following sequence:
Capscrew 1, Capscrew2, Capscrew 1.
Make sure to tighten Capscrew 1 twice.
Center the EGR connection hose evenly between the tube
and the EGR venturi and tighten both retaining clamps.

Install
Remove the tape from the open exhaust ports and cylinder
head.
Install two guide studs into the center section mounting
location.
Do not use adhesive, grease, or heavy grease to hold the
gaskets in place on the cylinder head.
Install a new center section gasket.
Exhaust Manifold, Dry Signature™, ISX, and QSX15
Special capscrews with spacers are required for this

particular manifold.
Do not use short capscrews.
WARNING
Install the exhaust manifold over the guide studs.
the capscrew threads to make sure of proper loading on
capscrews.
Slide each manifold gasket between the exhaust manifold
and the cylinder head.
Install the capscrews and spacers through the exhaust
manifold and gasket into the cylinder head.
capscrews.


Install two guide studs into center section mounting
location.
Signature™, ISX, and QSX15 Exhaust Manifold, Dry
Install the center mounting gasket over the guide studs.
WARNING
Install the exhaust manifold assembly on the guide pins.

Slide each exhaust manifold gasket between the manifold

and cylinder head.
Insert the exhaust manifold mounting capscrews and
spacer through the manifold and gasket and start
capscrews into the cylinder head.
EGR Valve Mounting Bracket Signature™, ISX, and QSX15
To aid in future capscrew removal, apply a film of high-

temperature anti-seize compound to the capscrew
threads.
Remove the guide studs and install the remaining two
capscrews.

Torque values given have been established using anti-
seize compound as a lubricant.

(011-033)
Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.

Install
Install the EGR valve mounting bracket onto the engine
block and the EGR valve mounting bracket rear support.
Install three capscrews into the engine block and the rear
support.
Tighten the two EGR valve mounting bracket capscrews
first (1).
Tighten the rear support bracket capscrew into the back
of the engine block (2).
Signature™, ISX, and QSX15 EGR Valve

(011-027)
Install
Apply a film of high temperature anti-seize compound to
the threads of the tube nuts.
Install the tube.
Connect and tighten the tube nuts.
EGR Valve (011-022)

Install
Before installing the v-band clamp, coat the clamping
surface with high temperature anti-seize compound.
Install the smaller v-band clamp on the EGR cooler

connection. Do not tighten.
Install the larger v-band clamp on the end of the EGR valve
that connects with the exhaust manifold. Do not tighten.
Install a new gasket on the piloted end of the EGR cooler
connection.
Install a new gasket on the piloted end of the EGR valve
where it connects to the exhaust manifold.
Install the EGR valve. Position the EGR connection v-band
clamp, as shown, and tighten.

Lubricate the EGR valve seal with clean engine oil.
Install the EGR valve onto the EGR valve mounting
bracket.
EGR Valve Coolant Lines Signature™, ISX, and QSX15
Install the four mounting capscrews into the EGR valve

mounting bracket.
NOTE: The longest capscrew passes through the EGR
valve and EGR valve mounting bracket and threads into
the engine block.
Connect the EGR valve connector.

Install
Connect the EGR valve coolant lines making sure the
sealing washers are in place on the banjo connector.
Tighten the EGR valve coolant line nut and capscrew.
Signature™, ISX, and QSX15 EGR Cooler Coolant Lines

Install
CAUTION
Do not use petroleum products on the EGR cooler
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install new the o-rings on the EGR cooler coolant return
line.
Lubricate the o-rings with clean engine coolant, soapy
water, or vegetable oil for easier installation.
Install the EGR cooler coolant return line from the EGR
cooler to the thermostat housing.
Tighten the mounting capscrews.
Install the EGR cooler coolant vent line. Attach the rigid
section of the vent line to the EGR cooler and the flexible
section to the EGR cooler coolant return line.
CAUTION
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
water, or vegetable oil to aid in installation.
EGR Cooler Coolant Lines Signature™, ISX, and QSX15
Install the EGR cooler coolant supply tube mounting

bracket and nuts.
Tighten the nuts.
Insert the EGR cooler coolant supply jumper tube into the
EGR cooler coolant supply tube.
Slide the EGR cooler coolant supply jumper tube into the
EGR cooler inlet.
Install the retaining clamp and capscrew to the EGR
cooler.
NOTE: Do not tighten at this time.
Insert the EGR cooler coolant supply tube into the water
pump outlet.
Install the EGR cooler coolant supply tube retaining clamp
and capscrew.
Tighten in the following sequence.

capscrew and tighten.
Tighten the EGR cooler coolant supply jumper tube
retaining clamp capscrew.
Tighten the EGR cooler coolant supply tube retaining
clamp capscrew.
Signature™, ISX, and QSX15 Heat Shield
Install the EGR cooler coolant vent line to the thermostat

housing and the EGR cooler.
Install the o-rings on the coolant return tube jumper tube.

water, or vegetable oil, for easier installation.
Install the jumper tube into the EGR cooler.
Install the press in place seal and the coolant return tube.
Install and tighten the capscrews.

Install
Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the three mounting capscrews and the heat shield.

mounting capscrews.
Install the four capscrews and the heat shield.
Assemble
• To install the turbine housing, position the V-band
clamp over the bearing housing and align the ink
marks applied during the disassembly process.
• Apply anti-seize compound to the bearing housing
locating bore of the turbine housing.
• Carefully slide the bearing and compressor housing
assembly into the turbine housing. Use the ink
alignment mark to locate the turbine housing assembly
in the correct orientation with the turbine housing.
Place the new V-band clamp in the correct orientation and

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

cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
turbocharger.
If a new turbocharger is being installed, the variable

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

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

The end rests on the oil cooler housing.
This brace requires longer, 1.25 mm [0.049 in],
capscrews.
Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean

engine oil into the turbocharger oil supply opening.
CAUTION
Proper routing of the turbocharger oil supply tube is
critical to prevent failure. Avoid any tube-to-metal
contact. (The inlet supply fitting must be oriented
slightly off vertical to allow proper alignment.)
If installing a new turbocharger, make sure the
turbocharger is aligned, loosen the compressor and
turbine v-bands, and adjust as needed. Tighten the v-
bands.
If installing a new turbocharger, install the male union
elbow.
Install the turbocharger oil supply tube on the elbow.
Install the intake and exhaust pipes to the turbocharger.

Tighten the clamp.

Variable Geometry
Part Number 3823097, to the turbocharger mounting
studs.
WARNING
CAUTION
When installing lifting eye, be sure the shoulder of the
lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of lifting eye and
personal injury.
CAUTION
If a lifting eye is installed in turbocharger bearing
housing, it is to be used exclusively for turbocharger
removal and installation. It is not to be used in
removal of the exhaust manifold, or engine. Doing so
will cause damage to the turbocharger.
CAUTION
Do not rotate the turbocharger turbine housing.
Loosening turbine v-band and rotating the turbine
housing can cause damage to internal variable
geometry mechanism.
The capscrew in the top of the turbocharger bearing
housing can be removed and replaced with a lifting eye to
aid in the installation of the turbocharger.
Install a new gasket, the turbocharger, and the four
mounting nuts. Tighten the mounting nuts.

turbocharger.

Tighten the clamp.

Install the intake and exhaust pipes to the turbocharger,

and tighten the clamps.

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

fittings into the bearing housing.
NOTE: Use a ratchet and deepwell socket to install these
fittings.
CAUTION
contact.
Install the turbocharger oil supply hose onto the oil supply
fitting. The oil supply hose must point directly downward
in order for it to properly connect to the oil supply fitting
on the lubricating oil filter head.
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
WARNING
lift this component.
CAUTION
geometry mechanism.
NOTE: Thread a lifting strap around the turbocharger
bearing housing. Take care not to bend the coolant lines
when lifting the turbocharger.
Care must be taken not to damage the turbocharger
compressor inlet air temperature sensor, the turbocharger
speed sensor, and the turbocharger actuator coolant lines
when installing the turbocharger.
Install a new o-ring seal, the clamp, and the discharge

elbow to the turbocharger.
Tighten the clamps.
Signature™, ISX, and QSX15 Turbocharger Coolant Hoses

Connect the oil supply hose to the oil supply fitting located
Tighten the oil supply hose.

Install
CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the hoses.
Install the turbocharger coolant supply hose to the bottom
of the turbocharger and the lubricating oil filter head.
Tighten the fittings.
while tightening the line.
CAUTION
can damage the lines.
Check the face of the coolant fittings on the engine and
on the turbocharger to be sure the o-ring is in place and
is not damaged.
A damaged or missing o-ring will result in a coolant leak.
Install the turbocharger coolant return hose to the top of
the turbocharger and the thermostat housing. Tighten the
fittings.
Turbocharger Coolant Hoses Signature™, ISX, and QSX15
Install the tube brace onto the turbocharger coolant return

hose and the air tube.
CAUTION
CAUTION
Do not use petroleum products on the turbocharger
coolant hose o-rings. The o-rings will swell and cause
Install the four new banjo sealing washers on the
turbocharger coolant supply hose.
Lubricate the sealing washers with clean engine coolant,
soapy water, or vegetable oil.
Install the turbocharger coolant supply hose to the
turbocharger bearing housing (3).
turbocharger actuator (2).
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
Signature™, ISX, and QSX15 Turbocharger, Variable Geometry Actuator
CAUTION
CAUTION
Install four new banjo sealing washers on the turbocharger
bearing housing coolant return hose and turbocharger
actuator coolant return tube.
Install the turbocharger coolant return hose to the
turbocharger. Tighten the fitting.
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
Install the turbocharger actuator coolant hose to the
thermostat housing. Tighten the fitting.
It is possible for the turbocharger actuator coolant return
hose to contact the turbocharger coolant return hose
when the fittings are torqued. Be sure to space the hoses
apart while the fittings are torqued. If the hoses are not
spaced apart, hose failure can result.
NOTE: Use a second wrench to hold the coolant line
coupling while tightening the line.
turbocharger actuator. Tighten the banjo fitting.

Actuator (010-113)
Install
Variable Geometry
WARNING
psi] regulated air pressure to the actuator.
Install the actuator on the turbocharger bearing housing.
Install and tighten the two capscrews.
Aftertreatment Adapter Pipe Signature™, ISX, and QSX15
Install the actuator rod to the turbocharger cross-shaft.

Install the snap ring.
Install and tighten the capscrew.

Install
Attach the heat shield to the injector.
Install a new high temperature EZ tie to hold the injector
harness to the heat shield.
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator will be against the injector.
Install the aftertreatment injector onto the adapter pipe.
Apply a coat of high temperature anti-seize compound to
the capscrews.
Install the capscrews and spacers.

Install
Install the aftertreatment injector assembly onto the
adapter pipe. Refer to Procedure 011-042 in Section 11.
Install new gaskets on each end of the adapter pipe.
Place the exhaust adapter pipe in position with the pin in
the correct location in the turbocharger.
Tighten the v-band clamps on each end.
Signature™, ISX, and QSX15 Turbocharger Control Shutoff Valve Filter Head

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

valve.
Connect the p-clip to the thermostat housings.
Connect the air supply line to the turbocharger actuator.
Start and run the engine.
Verify proper operation.
Check for air leaks.

Install
Variable Geometry
Install the two mounting capscrews and the turbocharger
control shutoff valve filter head.
Turbocharger Air Shutoff Valve Filter Signature™, ISX, and QSX15

(010-121)
Install
CAUTION
CAUTION
Mask both ends of the turbocharger control valve air
supply line before installing.
Install the turbocharger control valve air supply line.
Connect the air supply line to the turbocharger control

valve.
Connect the p-clips holding air line to engine.
shutoff valve.

(010-114)
Install
Variable Geometry
Apply a thin coat of lubricant on the filter gasket.
Install and hand tighten a new turbocharger control shutoff
valve filter on the turbocharger control shutoff valve body.
Use a filter wrench to tighten the filter full turn after gasket
contact.
Signature™, ISX, and QSX15 Integrated Fuel System Module (IFSM)

(005-073)
Install
Install two guide pins into the mounting holes on the
cylinder head.
Install a new gasket onto the guide pins.
WARNING
Install the IFSM on the guide pins.
Remove the guide pins.
Install and tighten the remaining capscrews.
Aftertreatment Fuel Shutoff Manifold Signature™, ISX, and QSX15

(011-052)
Install
NOTE: The pressure sensor and shutoff valve are located
on the same side of the shutoff manifold.
NOTE: The pressure sensor is mounted above the shutoff
valve.
Install the pressure sensor, the fuel shutoff valve, and the
fuel drain valve.
Torque Value:
Pressure Sensor 14 N•m [ 124 in-lb ]
Torque Value:
Fuel Shutoff Valve 14 N•m [ 124 in-lb ]
Torque Value:
Fuel Drain Valve 14 N•m [ 124 in-lb ]
Install the two capscrews to attach the aftertreatment fuel

shutoff manifold to the bracket on the engine.

valve.
fuel drain valve.
Torque Value:
Torque Value:
Torque Value:


(011-051)
Install
Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the EGR cooler.
Connect the aftertreatment injector coolant return line to

the oil cooler.
the aftertreatment injector.
Connect the aftertreatment injector fuel supply line to the

aftertreatment injector.
outlet of the union fitting, located just above the EGR
valve.
Install the P-clips.

inlet of the union fitting, located just above the EGR valve.
outlet of the fuel shutoff manifold.
Connect the fuel return line to the fuel shutoff valve

Torque Value:
O-ring joint 24 N•m [ 212 in-lb ]
Torque Value:
Banjo joint 15 N•m [ 133 in-lb ]


inlet of the shutoff manifold.
Torque Value:
Banjo joint 34 N•m [ 25 ft-lb ]
fuel rifle.
Torque Value:

the aftertreatment injector and the coolant heater housing.

the coolant return line to the coolant return manifold.


Install the P-clips
Torque Value:
O-ring fitting 24 N•m [ 212 in-lb ]
Torque Value:
Banjo fitting 15 N•m [ 133 in-lb ]
ECM Cooling Plate, Fuel Cooled Signature™, ISX, and QSX15

inlet of the shutoff valve manifold.
fuel rifle.

(006-006)
Install
Install five insulating washers. The one ground washer
must be installed in the upper left cooling plate mounting
capscrew hole.
CAUTION
Make sure that the insulating washers and the ground
washer are installed properly on the cooling plate or
malfunction of the ECM can occur.
Install the cooling plate gasket.
Install the six cooling plate mounting capscrews and
washers.
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Install the ECM cooling plate fuel supply line (bottom) to

the integrated fuel system module and the ECM cooling
plate.
Install the ECM cooling plate fuel return line (top) to the
fuel pump and the ECM cooling plate.
Signature™, ISX, and QSX15 Air Intake Connection

Install
Install the four mounting capscrews, air inlet connection,
and new gasket.
Install the four-step wastegate controller, mounting

capscrews, hose, and controller wires.
Connect the boost sensor wire.
Connect the air pipe from the charge air cooler to the air
inlet connection.

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

intake connection.
EGR Mixer (011-021)

Install
Install a new hose at the EGR mixer inlet.
Install a new o-ring between the EGR mixer and the air
intake connection. Install and tighten capscrews.

(007-011)
Install
Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.

Tighten the clamp.

Install
Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.
Signature™, ISX, and QSX15 Lubricating Oil Fill Tube
Install the oil fill connection to the lower gear cover.
Install the new ring seals on the bottom of the oil fill tube
(1) and on the oil fill tube cap (2).
Install the oil fill tube cap and the oil fill tube.
Install and tighten the tube brace gear cover capscrew (2).
Tighten the tube brace capscrew (1).

seal.
Install the new o-rings on the bottom of the oil fill tube and
a new ring seal on the oil fill tube cap.
Install and tighten the tube brace gear cover capscrews.


(003-001)
Install
Assemble the breather tube as shown.
Two p-clips attach the vent hose to the gear housing and
two p-clips attach the vent hose to the side of the block.
With the breather hose installed on the new cover, the
hose (3) must extend lower than the flywheel housing.
Install the crankcase vent hose (1). Use the four p-clips
(2), to secure the crankcase vent hose to the engine.
Refrigerant Compressor Signature™, ISX, and QSX15

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

Install
Sanden
Install the four mounting capscrews through the
refrigerant compressor and refrigerant compressor
bracket.

refrigerant compressor to the alternator/refrigerant
compressor mounting bracket. Make sure the roll pins
align properly.
Signature™, ISX, and QSX15 Fan Support

Install
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.

(009-054)
Install
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
NOTE: A special alignment procedure is not required for
the refrigerant compressor idler pulley to the alternator/

(009-052)
Install
Routing
CAUTION
Pivot counterclockwise and hold the belt tensioner.
Install the drive belt and relieve the tensioner.

Install
Install two guide studs into the upper gear cover.
Fan Support Signature™, ISX, and QSX15
Use clean 15W40 oil to lubricate the capscrew threads.

Install six capscrews.
capscrews.
Tighten the eight capscrews in the sequence shown.
Install the belt tensioner support bracket to the engine and

fan support.
Tighten all eight capscrews finger tight.
Tighten capscrew numbers 1 and 2 finger tight to mate the

surfaces of the belt tensioner support bracket to the fan
support.
Tighten capscrew numbers 3, 4, 5, and 6.

Signature™, ISX, and QSX15 Fan Hub, Belt Driven


Install
WARNING
Install the fan hub assembly and the capscrews.
WARNING
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
Install the fan hub and the capscrews.
Install the belt tensioner bracket.

CM570
The fan hub must be installed in the correct location on
the fan support to allow proper clearance between the fan
and fan shroud. Refer to the OEM service manual.
Belt Tensioner, Automatic (Water Pump) Signature™, ISX, and QSX15
Make certain the correct fan center is used for the

application.
Install the fan hub on the fan support using four capscrews
and washers.

Pump) (008-080)
Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
Install the belt tensioner bracket to the water pump.
Tighten capscrew.
Install the belt tensioner and capscrew.

Install the belt tensioner mounting capscrew and the belt
part of the water pump removal and installation due to
common capscrew usage. Refer to Procedure 008-062.
Signature™, ISX, and QSX15 Belt Tensioner, Automatic (Water Pump)

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

For the low-mount (large tensioner):


Starting Motor Signature™, ISX, and QSX15

Install
Drives Alternator
CAUTION
Pivot and hold the belt tensioner.
Install the drive belt and release the tensioner.

Install
CAUTION
Make sure to use the same thickness of starting motor
spacer (if used) as the one removed to install the
starting motor to reduce the possibility of engine or
starting motor damage.
Install the starting motor, spacer (if applicable) and the
three mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
39 MT Starters 129 N•m [ 95 ft-lb ]
(Aluminum
Flywheel
Housing)
(Cast Iron
Flywheel
Housing)
CAUTION
Install the starting motor, spacer (if applicable), and the
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
Assemble the upper bracket (1) to the block mounting stud

and to the starter motor end bracket. Tighten capscrews
and nuts finger tight.
Assemble the lower bracket (2) to the oil pan rail mounting
stud and to the starter motor end bracket.
Tighten the capscrews and nuts finger tight.
Tighten all capscrews and nuts.
Tighten all capscrews and nuts in the following sequence:

Torque Value:
(1) 45 N•m [ 33 ft-lb ]
(2) and (3) 23 N•m [ 17 ft-lb ]
(4) and (5) 41 N•m [ 30 ft-lb ]

Install
cover.
• If the cover gasket was removed, install the cover
gasket as soon as possible to avoid swelling of the
cover gasket as the cover gasket swells due to its
prior exposure to lubricating oil.
• If a new cover gasket is required, use P80
lubriplate™, Part Number 3163086, or soapy water to
lubricate the cover gasket.
If the cover gasket was removed or requires replacement,
start the installation of the cover gasket at each bolt hole
and press the cover gasket into the groove in the rocker
level cover around each bolt hole.
After the cover gasket is in place around all bolt holes,
press the cover gasket into the grove of the rocker level
cover starting from the bolt holes moving to the center of
each span.
Inspect and make certain that there are no kinks, twists or
other damage.
Fuel Filter (Spin-On Type) Signature™, ISX, and QSX15
Align the capscrew holes in the cylinder head to the cover

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

Install
Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent 15-micron
particle-removal efficiency.
Apply a thin coating of clean engine oil to the filter gasket
surface.
CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Do not prefill the fuel filter. Damage to the fuel
system may result.
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional ¾ of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
To perform the priming procedure, use the following items

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

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

must also have a minimum of 98.7 percent at 25-micron
surface and the center seal.
CAUTION
NOTE: Do not prefill the fuel filter. Damage to the fuel
system may result.
Tighten the filter an additional 3/4 of a turn after the gasket
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
NOTE: The engine will, perhaps, run rough for several

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

Pump
CAUTION
NOTE: If the filter is equipped with a water-in-fuel sensor,
rotate the sensor on the filter to the desired location and
connect the wiring harness. Fill the filter with clean fuel

manufacturer.

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

Install
CAUTION
Mechanical overtightening can distort the threads or
damage the filter head.
Apply a thin film of clean engine oil, or its equivalent, to
the coolant filter gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter ½ to ¾ of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Signature™, ISX, and QSX15 Lubricating Oil Filter (Spin-On)
Install the radiator pressure cap.
WARNING
Operate the engine until the coolant temperature is above
82°C [180°F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.

(007-013)
Install
NOTE: The o-ring can stick onto the filter head. Make sure
it is removed before installing a new filter.
Clean the oil filter head surface.
Use clean engine oil to lubricate the gasket surface of the
filter.
CAUTION
damage the filter element seal.
Fill the oil filter with clean 15W-40 oil.
Install the oil filter onto the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
3400157 to tighten the filter an additional 3/4 to 1 turn, or
follow the instructions supplied with the filter.
Confirm that the oil level in the pan is to the full mark.
82°C [180°F].
Check the oil pressure and for leaks.
Engine Installation (000-002)

Install

WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer to

Manual CM870 Electronic Control Systems Signature and
ISX Engines, Bulletin 4021334.
Power Generation

Lubricating Oil System Signature™, ISX, and QSX15
WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer

Manual Electronic Control System Signature, ISX and

Prime
CAUTION
The lubricating oil system must be primed before
operating the engine after any internal engine repairs
or extended engine storage (beyond 6 months) to
avoid internal component damage.
Bar the engine during oil priming.
Signature™, ISX, and QSX15 Lubricating Oil System
Remove the oil plug from the lubricating oil cooler housing
and install fitting and hose.
Use the coupler, Part Number 3376859, to connect the
priming pump to the coupling.
Connect the priming pump oil supply hose to the

lubricating oil pump coupling. Use clean 15W-40
lubricating oil from a drum or a container to supply oil to
the lubricating oil pump and engine.
Turn the priming pump on.
Allow the oil to flow until the oil pressure gauge indicates
a maximum pressure of 69 to 138 kPa [10 to 20 psi] at the
main oil rifle.
Turn the priming pump off.
Remove the priming pump oil supply hose and fitting.

Install the oil cooler housing plug.
Check the oil level on the dipstick before adding additional

oil.
If necessary, fill the engine with lubricating oil.
Fill
Fill and install the lubricating oil filter before putting oil into
the engine. Refer to Procedure 007-013.
Add the specified amount of clean 15W-40 oil to fill the oil
pan.
Oil Pan Capacity
Automotive and Industrial Power Generation
41.6 liters [11 gal] 83.3 liters [22 gal]
Check the oil level on the dipstick. It must be filled to the

H (high) mark.
Refer to Procedure 007-009 for dipstick calibration.
82°C [180°F], and check for leaks.
Shut off the engine. Wait 15 minutes for the oil to drain
back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H (high) mark on the dipstick.

Fill
CM570
CAUTION
The cooling system must be filled properly to prevent
air locks, or serious engine damage can result.
Close the radiator drain valve(s).
Install the lower radiator hose(s).
Tighten the hose clamps. Refer to the OEM service
manual.
Cummins Inc. recommends the use of either a 50/50

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

COMPLEAT™. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.
Refer to Cummins® Coolant Requirement and
Maintenance, Bulletin 3666132 for more engine coolant
specifications.
CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.

coolant fill requirements. Special instructions may also be
located near the cooling system access point or fill door
on the vehicle.
NOTE: The system has a designed fill rate of 19 liters [5
gal] per minute.
Fill the cooling system with heavy-duty coolant and install
the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature™ and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
Section V.
NOTE: Some radiators have two fill locations, both of

which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
CAUTION
If applicable, install the manual bleed valve or the pipe
plug after filling the cooling system. Refer to the OEM
service manual.
NOTE: All coolant shutoff valves should be returned to

their open positions once the system has been refilled and
the deaeration process is ready to begin. Refer to the
OEM service manual for specific instructions.
Install the radiator cap or expansion tank fill cap.
Turn the cab heater temperature switch to high to allow
maximum coolant flow through the heater core. The
blower does not have to be on.
Operate the engine at HIGH IDLE until the thermostat
opens, at least 93°C [200°F].
Operate the engine at LOW IDLE for 2 minutes before
shutting it down. This allows adequate cool down of
pistons, cylinders, bearings, and turbocharger
components.
Shut the engine off and allow it to cool.
WARNING
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] before adding coolant.
NOTE: If all coolant drained from the system was
collected, the same volume or more must go back into the
system. If any drained coolant remains after filling, this is
an indication of an air pocket which must be purged before
returning the vehicle to service.
Remove the radiator or expansion tank fill cap and check
the coolant level according to the OEM service manual.
Add coolant if necessary. Do not overfill.
CAUTION
air locks, or serious engine damage can result.
Close the radiator drain valve(s).
Tighten the hose clamps. Refer to the OEM service
manual.

Water Quality
(Hardness) MgCO3)

standards.
Refer to Cummins® Coolant Requirement and
Maintenance, Bulletin 3666132 for more engine coolant
specifications.
CAUTION

coolant fill requirements. Special instructions may also be
located near the cooling system access point or fill door
on the vehicle.
NOTE: The system has a designed fill rate of 19 liters [5
gal] per minute.
Section V.
Section V.

drained.
CAUTION
air locks or serious engine damage can result.
NOTE: Do not install the radiator cap or expansion tank
fill cap. The engine is operated without the cap in this step.
Wait 2 to 3 minutes without starting engine to allow the
system to deaerate and the fluid level to stabilize.
Add coolant to bring the level back to FULL COLD.
CAUTION
If applicable, install the manual bleed valve or the pipe
plug after filling the cooling system. Refer to the OEM
service manual.
CAUTION
air locks or serious engine damage can result.
NOTE: Do not install the radiator cap or expansion tank
fill cap. The engine is operated without the cap in this step.
With the radiator cap or expansion tank fill cap off:
• Operate the engine at LOW IDLE for 2 minutes.
• Turn the engine off and add clean water to bring the
level back to FULL COLD.
WARNING
WARNING
NOTE: All coolant shutoff valves should be returned to
their open positions once the system has been refilled and
the deaeration process is ready to begin. Refer to the
OEM service manual for specific instructions.
Operate the engine at HIGH IDLE until the thermostat
opens, at least 93°C [200°F].
Operate the engine at LOW IDLE for 2 minutes before
shutting it down. This allows adequate cool down of
pistons, cylinders, bearings, and turbocharger
components.
Shut the engine off and allow to cool.
WARNING
CAUTION
NOTE: If all coolant drained from the system was
collected, the same volume or more must go back into the
system. If any drained coolant remains after filling, this is
an indication of an air pocket which must be purged before
returning the vehicle to service.
Remove the radiator cap or expansion tank fill cap and
check the coolant level according to the OEM service
manual.
Add coolant if necessary. Do not overfill.
See Figure 1, illustrating the steps of the coolant fill and
deaeration process.
Figure 1: Coolant Fill and Deaeration Process

Section 1 - Cylinder Block - Group 01 Page 1-a
Section 1 - Cylinder Block - Group 01

Section Contents
Page
Bearings, Connecting Rod ................................................................................................................................1-5
Clean and Inspect for Reuse.............................................................................................................................1-6
Finishing Steps...............................................................................................................................................1-11
Install................................................................................................................................................................1-8
Remove............................................................................................................................................................1-5
Bearings, Main .................................................................................................................................................1-11
Clean and Inspect for Reuse...........................................................................................................................1-12
Finishing Steps...............................................................................................................................................1-19
Install..............................................................................................................................................................1-14
Preparatory Steps...........................................................................................................................................1-11
Remove.......................................................................................................................................................... 1-12
Bearings, Thrust ..............................................................................................................................................1-19
Finishing Steps...............................................................................................................................................1-22
Inspect for Reuse............................................................................................................................................1-21
Install..............................................................................................................................................................1-21
Remove.......................................................................................................................................................... 1-20
Block Stiffener Plate .....................................................................................................................................1-179
Finishing Steps.............................................................................................................................................1-180
Install............................................................................................................................................................1-180
Preparatory Steps.........................................................................................................................................1-179
Remove.........................................................................................................................................................1-179
Bracket, Accessory .......................................................................................................................................1-153
Inspect for Reuse..........................................................................................................................................1-155
Install............................................................................................................................................................1-155
Automotive Applications.............................................................................................................................1-155
Industrial and Power Generation.................................................................................................................1-157
Remove.........................................................................................................................................................1-153
Bracket, Retaining Brace ..............................................................................................................................1-149
Install............................................................................................................................................................1-151
Remove.........................................................................................................................................................1-149
Connecting Rod ...............................................................................................................................................1-23
Bend and Twist Inspect...................................................................................................................................1-27
Finishing Steps...............................................................................................................................................1-33
Magnetic Crack Inspect...................................................................................................................................1-30
Crankshaft .......................................................................................................................................................1-34
Bend and Twist Inspect...................................................................................................................................1-40
Finishing Steps...............................................................................................................................................1-51
Install..............................................................................................................................................................1-50
Remove.......................................................................................................................................................... 1-36
Rotation Check............................................................................................................................................... 1-34
Crankshaft Adapter .........................................................................................................................................1-51
Finishing Steps...............................................................................................................................................1-58
Page 1-b Section 1 - Cylinder Block - Group 01
Install..............................................................................................................................................................1-56
Remove.......................................................................................................................................................... 1-52
Crankshaft Gear, Front (Crankshaft Installed) ................................................................................................1-58
Finishing Steps...............................................................................................................................................1-63
Install..............................................................................................................................................................1-62
On-Engine Repair.........................................................................................................................................1-58
Remove.......................................................................................................................................................... 1-59
Crankshaft Pulley ............................................................................................................................................1-64
Install..............................................................................................................................................................1-66
Automotive Applications...............................................................................................................................1-66
Industrial and Power Generation...................................................................................................................1-66
Remove.......................................................................................................................................................... 1-64
Crankshaft Seal, Front ....................................................................................................................................1-68
Finishing Steps...............................................................................................................................................1-73
Install..............................................................................................................................................................1-70
Remove.......................................................................................................................................................... 1-69
Crankshaft Seal, Rear ..................................................................................................................................... 1-73
Finishing Steps...............................................................................................................................................1-77
Install..............................................................................................................................................................1-75
Measure..........................................................................................................................................................1-76
Remove.......................................................................................................................................................... 1-74
Crankshaft Tone Wheel .................................................................................................................................1-139
Finishing Steps.............................................................................................................................................1-140
Inspect..........................................................................................................................................................1-139
Install............................................................................................................................................................1-140
Remove.........................................................................................................................................................1-139
Cylinder Block .................................................................................................................................................1-77
Repair.............................................................................................................................................................1-78
Cylinder Block and Liner Seats ...................................................................................................................... 1-87
Leak Test........................................................................................................................................................1-87
Cylinder Liner ..................................................................................................................................................1-91
Finishing Steps...............................................................................................................................................1-99
Install..............................................................................................................................................................1-96
Measure..........................................................................................................................................................1-97
Remove.......................................................................................................................................................... 1-92
Engine Base Timing ......................................................................................................................................1-158
Adjust............................................................................................................................................................1-173
Finishing Steps.............................................................................................................................................1-177
General Information.......................................................................................................................................1-158
Install............................................................................................................................................................1-167
Remove.........................................................................................................................................................1-162
Gear Cover, Lower ........................................................................................................................................1-146
Clean and Inspect for Reuse.........................................................................................................................1-146
Finishing Steps.............................................................................................................................................1-149
Install............................................................................................................................................................1-148
Remove.........................................................................................................................................................1-146
Section 1 - Cylinder Block - Group 01 Page 1-c
Gear Cover, Upper .........................................................................................................................................1-141

All Applications...........................................................................................................................................1-142
Finishing Steps.............................................................................................................................................1-145
Install............................................................................................................................................................1-144
Remove.........................................................................................................................................................1-141
Gear Housing, Front ......................................................................................................................................1-100
Finishing Steps.............................................................................................................................................1-104
Install............................................................................................................................................................1-102
Remove.........................................................................................................................................................1-100
Idler Gear, Adjustable ...................................................................................................................................1-141
Idler Gear, Lower Scissor .............................................................................................................................1-141
Piston .............................................................................................................................................................1-104
Articulated Piston.......................................................................................................................................1-106
Single-Piece Piston.....................................................................................................................................1-107
Finishing Steps.............................................................................................................................................1-110
Piston and Connecting Rod Assembly .........................................................................................................1-128
Assemble......................................................................................................................................................1-132
Disassemble..................................................................................................................................................1-131
Finishing Steps.............................................................................................................................................1-138
Install............................................................................................................................................................1-135
Remove.........................................................................................................................................................1-129
Piston Cooling Nozzle ...................................................................................................................................1-111
Finishing Steps.............................................................................................................................................1-112
Install............................................................................................................................................................1-112
Remove.........................................................................................................................................................1-112
Piston Rings ..................................................................................................................................................1-114
Install............................................................................................................................................................1-116
Measure........................................................................................................................................................1-115
Remove.........................................................................................................................................................1-114
Service Tools ....................................................................................................................................................1-1
.........................................................................................................................................................................1-1
Vibration Damper, Viscous ...........................................................................................................................1-119
Eccentricity Check.........................................................................................................................................1-126
Finishing Steps.............................................................................................................................................1-126
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................1-127
Industrial and Power Generation without Crank-Driven Fan or PTO.............................................................1-127
Page 1-d Section 1 - Cylinder Block - Group 01
Install............................................................................................................................................................1-123
Remove.........................................................................................................................................................1-120
Wobble Check...............................................................................................................................................1-126
Section 1 - Cylinder Block - Group 01 Page 1-1
Service Tools
Cylinder Block
Repair Location.

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

Used to remove the main bearing caps from the cylinder block.
ST 1178
Connecting Rod Checking Fixture

Used with Guide Kit, Part Number 4918339, to inspect the connecting
ST 561 rods for bend, twist, and length.
Oil Seal Puller/Installer

Used to pull or install the rear crankshaft seal on both the REPTO
3164780 and Non REPTO applications. The previous kits 3162994 and
3164153 can be updated to work on REPTO applications by adding
the replacer plate, Part Number 3164763.
Oil Seal Puller/Installer

Used to pull or install the front crankshaft seal.
3162992
Connecting Rod Guide Pins (Two)

Used to protect the crankshaft journal by guiding the connecting rod
3163097 during installation or removal.
Service Tools Signature™, ISX, and QSX15
Page 1-2 Section 1 - Cylinder Block - Group 01

Universal Cylinder Liner Puller
Used to remove the cylinder liners from all present engine series.
3163745 Used with cylinder liner puller plate, Part Number 3162462, on
Signature engines. Cylinder liner remover, Part Number 3162873,
can also be used for this application.
Cylinder Liner Puller Plate

Used with the universal cylinder liner puller, Part Number 3162873,
3162462 to remove the cylinder liners.
Cylinder Liner Installation Tool

Used to install cylinder liners and clamp for protrusion readings into
3164606 the cylinder block. Cylinder liner installation tool, Part Number
3162461 can be also used for this application, if updated with the
cylinder liner installation plate, Part Number 3164606.
Safety Solvent
Used to clean machine surfaces prior to the installation of thread
3824510 repair inserts, coolant passage surfaces, and upper deck repair
sleeves.
Marked Socket
Used to tighten the rod capscrews and cylinder head bolts. Part
3165161 Number 3163059 is a 3/4 inch impact wrench with ample range to
tighten bolts.
Piston Ring Compressor

Used to install piston into cylinder block. The piston ring compressor,
3164846 Part Number 3163158, can also be used, if machined to work with
flat top cylinder liners.
Timing Pin and Wedges Kit

Kit contains a pin and three wedges. Used to set engine base timing.
3163021
Injector Cam and Valve Gear Puller

Used to pull the cam gear. The puller will only work on camshaft
3163069 gears with puller holes.

Mounting Plate
Used with either Part Number 3375193 or Part Number 3375194
3162464 engine stand.
Injector Installation and Removal Tool

Used to remove and install injectors.
3163483
Thick Wear Sleeve/Wet Flywheel Housing Oil Seal Installation

and Removal Tool
3163826 Used to remove and install the wear sleeve and wet flywheel housing
oil seal on QSX15 engines.
Crankshaft Adapter and Gear Removal Kit

Used to remove and install the crankshaft adapter and crankshaft
4918530 gear.
Loctite™ 518 Flexible Anerobic Gasket Sealant (Color Red)

Used to seal the main bearing cap to the mating surface of the
4918675 cylinder block.
Protective Plug
Used to plug the front oil passage of the cylinder block during a repair
4918874 process. For use on engines built after August 2006.
Protective Plug
Used to plug the rear oil passage of the cylinder block during a repair
4918875 process. For use on engines built after August 2006.
Thread Salvage Kit

Used to salvage/repair damaged cylinder head capscrew threads in
3164021 the cylinder block.

Regular Hexagon Jam Nut
3163842 the cylinder block. Used with Part Number 3164021 Thread Salvage
Kit.
Threaded Insert [50mm]

Kit.
Threaded Insert [76mm]

Kit.
Reamer
Kit.
Tap
Kit.
Drill
Kit.
Connecting Rod Checking Guide

Use with ST 561 Connecting Rod Checking Fixture to measure
4918339 stretch and twist in the connecting rod.

Preparatory Steps
WARNING
WARNING
• Drain the lubricating oil. Refer to Procedure 007-037.
• Remove the lubricating oil pan. Refer to Procedure
007-025.
• Remove the lubricating oil suction tube. Refer to
Procedure 007-035.
• Remove the lubricating oil pump. Refer to Procedure
007-031.
• Remove the block stiffener plate. Refer to Procedure
001-089.
• Remove the piston cooling nozzles. Refer to
Procedure 001-046.
Remove
Rotate the crankshaft so that two of the connecting rods
are at bottom dead center.
Do not remove the capscrews at this time.

Loosen the connecting rod capscrews.
Hit the connecting rod capscrews with a rubber hammer
to loosen the rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap and mark the
cylinder number and the letter "L” on the flat surface of
the bearing tangs.
Install two guide pins, Part Number 3163097, in the

connecting rod.
Push the rod up far enough to allow the upper bearing
shell to be removed. Use a T-handle piston pusher.
Remove the bearing shell and mark the cylinder number
and the letter "U" on the flat surface of the bearing tangs.
Clean and Inspect for Reuse
WARNING
personal injury.
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
Steam-clean the parts and dry with compressed air.
Inspect the rod caps, connecting rod bearing saddles, and

capscrews for nicks, cracks, burrs, scratches, or fretting.
Inspect the connecting rod journal of the crankshaft for

scratches or nicks.
Use crocus cloth to remove the nicks and scratches.
Inspect the bearings for damage.

Replace any bearings with the following damage:
• Pitting
• Flaking
• Corrosion
• Lock tang damage
• Scratches (deep enough to be felt with a fingernail).
Normal bearing wear produces a smooth finish that will

wear into the lining. Refer to the Parts Reuse Guidelines,
Bulletin 3810303.
For more detailed information of bearing damage, refer to

Analysis and Prevention of Bearing Failures, Bulletin
3810387.
Inspect the bearing seating surface for nicks or burrs.
If nicks or burrs can not be removed with a fine crocus
cloth, the bearings must be replaced.
Measure the rod bearing shell thickness with an outside

micrometer that has a ball tip.
Discard a bearing shell if its thickness is below the
minimum specification.
Standard Connecting Rod Bearing Thickness

mm in
2.366 MIN 0.093
2.378 MAX 0.094
Crankshafts that are ground undersize in the connecting

rod or the main bearing journals are marked on the front
counterweight. If the crankshaft is marked, check the
bearing shell part number to make sure the correct
bearing size is used.
Install
CAUTION
Connecting rod bearings must match the connecting
rod design. Drilled rods must use drilled rod bearings.
Non-drilled rods must use non-drilled bearings.
Mismatches will cause engine damage.
Connecting rod design must be matched with the proper
connecting rod bearing.
Drilled connecting rods must be fitted with drilled
Non-drilled connecting rods must be fitted with non-drilled
Drilled and non-drilled connecting rods can be mixed in

the same engine as long as the two piece piston is used.
Engines using single piece pistons can not use non-drilled
connecting rods.
CAUTION
The connecting rod and bearing shell mating surfaces
equivalent to lubricate the crankshaft journal mating
surface of the upper bearing shell.
Install the upper bearing shell into the connecting rod with
the tang of the bearing in the slot of the rod.
Install the bearing shell into the connecting rod cap with
the tang (2) of the bearing in the slot (1) of the cap.
equivalent to lubricate the bearing shell to crankshaft
journal mating surface and the connecting rod capscrews.
CAUTION
The rod cap alpha characters must match the alpha
characters on the connecting rod and must be
installed with the characters aligned to prevent
damage to the connecting rods and crankshaft. The
locking tang of the connecting rod cap must face
toward the intake side of the cylinder block. Rod and
cap mating surfaces must be clean or engine damage
can occur.
Install the cap onto the connecting rod.

oil.
tighten.
Torque Value:
Capscrews in lb ]
Numerical
Sequence
± 5 degrees
Torque Value:
Capscrews in lb ]
Numerical
Sequence
Step2 Loosen capscrews in
numerical sequence
Step3 70 ± 6 N•m[ 52 ± 4 ft-
lb ]
± 5 degrees
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
NOTE: The connecting rod must move freely from side to

side on the crankshaft journal. If the rod does not move
freely, remove the rod cap and make sure the bearing
shells are the correct size. Check for dirt or damage on
the crankshaft and the bearing shells.
Repeat the above steps to install the remaining bearing
shells and connecting rod caps.
Finishing Steps
CAUTION
to avoid internal component damage.
• Install the piston cooling nozzles. Refer to Procedure
001-046.
• Install the oil pump. Refer to Procedure 007-031.
• Install the block stiffener plate. Refer to Procedure
001-089.
• Install the lubricating oil suction tube. Refer to
Procedure 007-035.
• Install the lubricating oil pan. Refer to Procedure
007-025.
• Prime the lubricating oil system. Refer to Procedure
007-037.
• Operate the engine until it reaches a temperature of
82°C [180°F], and check for lubricating oil leaks.

Preparatory Steps
WARNING
WARNING
• Drain the lubricating oil. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
007-025 (Lubricating Oil Pan) in Section 7.
Procedure 007-035 (Lubricating Oil Suction Tube
(Block Mounted)) in Section 7.
007-031 (Lubricating Oil Pump) in Section 7.
001-089 (Block Stiffener Plate) in Section 1.
Remove
CAUTION
Mark any unmarked bearing caps before removing
them from the cylinder block. Do not remove main
bearing capscrews until the main bearing cap is
pulled, or the cap could fall out, causing personal
injury and parts damage.
If the crankshaft is not going to be removed, replace the
main bearings one at a time.
Loosen the main bearing cap capscrews.
Use the main bearing cap puller, Part Number ST-1178,
to remove the cap. The tool must be centered on the cap.
Remove the main bearing capscrews and cap.
Mark the bearing shells with the journal number from

which they were removed.
Remove the lower main bearing shell from the cap.
Rotate the crankshaft with the air compressor drive or a

barring device to remove the main bearing shell.
Mark each main bearing for location if they are to be
installed again in the engine.
WARNING
bodily injury.
Use a soft bristle brush to clean the parts.
Dry the parts with compressed air.
Inspect the main bearing cap and capscrews for damage.

Inspect the bearing shells and thrust bearings for nicks,
scratches, or other damage.
If the main bearings are damaged, inspect the crankshaft
main bearing journals. If the crankshaft is damaged, the
engine must be removed for repair. Refer to Procedure
000-001 (Engine Removal) in Section 0.
Cummins Inc. recommends replacing the thrust bearings
when the main bearings are replaced. Refer to Procedure
001-007 (Bearings, Thrust) in Section 1 for thrust bearing
replacement.
Use an outside diameter ball-tipped micrometer to

measure the main bearing shell thickness.
Standard Main Bearing Shell Thickness

mm in
3.196 MIN 0.126
3.214 MAX 0.127
If the bearing shell is not within specifications, it must be
replaced.
For more detailed information on bearing damage, refer
to Analysis and Prevention of Bearing Failures, Bulletin
3810387.
Crankshafts that are ground undersize in the connecting

rod and main bearing journals are marked on the front
counterweight. If the crankshaft is marked, check the
bearing shell part number to make sure the correct
bearing size is used.
Install
CAUTION
The cylinder block saddle and the cap mating surfaces
CAUTION
The bearing tang must fit into the slot in the bearing
saddle or engine damage can occur.
CAUTION
Do not use a capscrew or any hard metal object to
install bearings, as this can damage the crankshaft
and cause an engine failure.
equivalent, to lubricate the upper main bearing shell to
crankshaft journal mating surface.
Start the bearing into the upper saddle by hand. Slide the
bearing into position. Take care to not damage the
crankshaft journal while installing the bearing.

equivalent, to lubricate the inside diameter of the bearing
shells and the liner side of the upper thrust bearings.
Align the lower main bearing shell and push it into place.
CAUTION
in engine damage.
equivalent, to lubricate the liner side of the lower thrust
bearings.
CAUTION
in engine damage.
bearing saddle.
the front thrust bearing and toward the front of the engine
to install the rear thrust bearing.
CAUTION
Only use Loctite™ 518 thread sealant on the main cap
joint mating surface. Other sealants can become hard,
brittle, and allow oil and debris into the main bearing/
block joint, causing engine damage.
CAUTION
The bead must be 3 to 5 mm [0.12 to 0.20 in] wide and
must not enter the main bearing shell inside the main
bearing shell inside diameter. Sealant in the main
bearing can cause engine damage.
Apply a bead of Loctite™ 518 thread sealant to the two
main bearing cap surfaces on each main bearing cap as
shown.
Use clean 15W-40 engine oil to lubricate the capscrew

threads and flat washers (or the underside of the capscrew
heads if washers are not used).
Drain the excess oil from the capscrews before installing
them.
CAUTION
The main bearing caps are marked with a `V.' Position
the `V' mark so that it points to the front of the engine.
Incorrect positioning will result in severe engine
damage.
Align the capscrew holes in the cap with the holes in the
cylinder block. Make sure the lower bearing shell is in
position.
Install the capscrews through the cap and into the cylinder
block.
To reduce the possibility of bore size issues, clearance

issues, or both, the main bearing capscrews must be
tightened within 15 minutes of the Loctite™ 518 thread
sealant application.
Make sure the bearing shell does not move.

Tighten the capscrews in far enough to use a heel bar to
pry the caps into place.
Tighten both of the capscrews on a main bearing cap to

203 N•m [150 ft-lb].
Loosen both capscrews completely.
The remaining main bearings do not have thrust bearings.


socket, Tool Numbers 3163059 and 3163060, to rotate the
capscrews an additional 180 degrees.
Use the torque plus angle method to tighten the main
bearing capscrews in the sequence shown.
To measure the end clearance of the crankshaft, install a

dial indicator onto the oil pan flange.
Place the tip of the gauge against the crankshaft
counterweight.
Push the crankshaft toward the rear of the cylinder block.
Set the dial indicator at "0" (zero).

Push the crankshaft toward the front of the cylinder block.
If the end clearance is less than 0.10 mm [0.004 in], loosen

all main bearing capscrews one turn.
Push the crankshaft toward the front and then toward the
rear of the cylinder block.
Tighten the main bearing capscrews in sequence.

Torque Value:
Block Main Step1 149 N•m [ 110 ft-lb ]
Bearing
Capscrews
Measure the crankshaft end clearance.
Crankshaft End Clearance - New or Reground

mm in
0.10 MIN 0.004
0.50 MAX 0.020
Crankshafts that have been reground on the thrust

bearing surfaces are marked for oversize thrust bearings
on the rear crankshaft counterweight. If the crankshaft
counterweight is marked, check the thrust ring part
number to make sure the correct thrust ring size is used.
Example: F0.010 = front 0.25 mm [0.010 in]
Example: R0.020 = rear 0.51 mm [0.020 in]
If the crankshaft end play is more than 0.50 mm [0.020 in],

the engine must be removed to allow for replacement of
the crankshaft. Refer to Procedure 000-001 (Engine
Removal) in Section 0.
Finishing Steps
CAUTION
to avoid internal component damage.
001-089 (Block Stiffener Plate) in Section 1.
• Install the lubricating oil pump. Refer to Procedure
007-031 (Lubricating Oil Pump) in Section 7.
Procedure 007-035 (Lubricating Oil Suction Tube
(Block Mounted)) in Section 7.
• Prime the lubricating system. Refer to Procedure
007-037 (Lubricating Oil System) in Section 7.
• Fill the engine with lubricating oil. Refer to Procedure
007-037 (Lubricating Oil System) in Section 7.
• Operate the engine until it reaches a temperature of
82°C [180°F], and check for lubricating oil leaks.

Preparatory Steps
WARNING
WARNING
Cummins Inc. recommends replacing the thrust bearings
when the main bearings are replaced.
Remove the lubricating oil pan. Refer to Procedure

007-025.
Bearings, Thrust Signature™, ISX, and QSX15
Remove the oil suction tube. Refer to Procedure 007-035.
Remove the block stiffener plate. Refer to Procedure

001-089.
Remove the number four main bearing cap. Refer to
Procedure 001-006.
Remove
Remove the thrust bearings from the number four main
bearing cap.
Mark the thrust bearings as being lower, and front or rear
bearings.
CAUTION
To reduce the possibility of damage to the crankshaft,
use care when removing the upper thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark these bearings as being upper, and front or rear
bearings.
Inspect for Reuse

Inspect the thrust bearings for scratches, galling, uneven
wear, or other damage.
Replace the thrust bearings if damage is found.
If damage is found on any of the thrust bearings, be sure
to inspect the crankshaft, block, and main bearing cap for
damage as well.
Install
Use Lubriplate™ 105, or equivalent, to coat the upper
thrust bearings.

the rear thrust bearing, and to the front of the engine to
install the front thrust bearing.
bearing saddle.
The bevel must be toward the crankshaft.
Use Lubriplate™ 105, or equivalent, to coat the lower thrust

bearings.
The bevel of the thrust bearing must be toward the
crankshaft.
Bearings, Thrust Signature™, ISX, and QSX15
Finishing Steps
Install the main bearing cap. Refer to Procedure 001-006.
Install the block stiffener plate. Refer to Procedure
001-089.
Install the lubricating oil suction tube. Refer to Procedure

007-035.
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill the engine with clean lubricating oil. Refer to

Procedure 007-037.
Signature™, ISX, and QSX15 Connecting Rod
The engine must have adequate oil pressure within 15

seconds after starting. If the warning light indicating low
oil pressure has not gone out or there is no oil pressure
indicated on a gauge within 15 seconds, shut off the
engine immediately to avoid engine damage. Confirm that
the correct oil level is in the oil pan.
Operate the engine to normal operating temperature and
check for leaks.
Connecting Rod (001-014)

Preparatory Steps
NOTE: The piston and connecting rod must be removed
as an assembly on Signature™, ISX, and QSX15 engines.
• Remove and disassemble the piston and connecting
rod assembly. Refer to Procedure 001-054 in Section
1.

CAUTION
Prevent damage to the capscrews. Nicks in the body
of the capscrew can cause an area of stress that can
fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will
damage the mating parts.
Connecting Rod Signature™, ISX, and QSX15
WARNING
can cause serious injury.
WARNING
cleaning, follow manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce
the possibility of personal injury.
WARNING
personal injury.
Use solvent or steam to clean the capscrews, connecting
rod, and connecting rod cap.
Dry with compressed air.
Use a soft bristle brush to clean the oil drilling.
CAUTION
Repair of rolled threads by use of a thread die is not
recommended. The die can create a sharp corner on
the minor diameter (root) of the threads. This sharp
corner can cause an area of increased stress.
Inspect the capscrews for the following:
• Damaged threads
• Rust or corrosion-caused pitting
• Nicks, bent, stretched, or galled.
The capscrew must be replaced if it has any of the listed
damages.
Inspect the connecting rod and connecting rod cap for

damage.
Replace the connecting rod if the I-beam or connecting
rod cap is damaged.
Inspect the connecting rod and connecting rod cap for

fretting damage on the mating surfaces.
The connecting rod and connecting rod cap must be
replaced as an assembly if fretting damage is visible on
either piece.
Check the bearing surface for nicks or burrs.

If it is not possible to remove any nicks or burrs with a fine
emery cloth, the connecting rod must be replaced.
Inspect the rod pin bushing for damage.

Replace any piston pin bushing that has evidence of
scoring, galling, or scuffing.
Replace any bushing that has turned in the bore.
Special tools and precision machining are required to
replace bushings. If Cummins Inc. approved tools and
procedures are not available, the connecting rod must be
replaced.
CAUTION
The connecting rod cap alpha characters must match
the alpha characters on the connecting rod and must
be installed with the characters aligned to prevent
damage to the connecting rods and crankshaft.
CAUTION
Use a vise with brass jaws to hold the connecting rod.
Notches, scratches, or dents in the I-beam area can
cause engine failure.
Place the connecting rod into a vise with brass jaws.
Support the connecting rod at the large bearing end to
avoid I-beam damage.
Install the connecting rod cap onto the connecting rod.
oil.
tighten.
Torque Value:
Tighten Capscrews in Numerical Sequence
Step 1 70 ± 6 N•m [ 53 ± 4 ft-lb ]
Step 2 Rotate capscrews in numerical
sequence 60 ± 5 degrees
Torque Value:
Tighten Capscrews in Numerical Sequence
Step 1 40 ± 6 N•m [ 30 ± 4 ft-lb ]
Step 2 Loosen capscrews in numerical
sequence
Step 3 70 ± 6 N•m [ 53 ± 4 ft-lb ]
Step 4 Rotate capscrews in numerical
Measure the connecting rod crankshaft bore inside

diameter with a bore dial indicator.
Connecting Rod Crankshaft Bore Inside Diameter

mm in
98.801 MIN 3.890
98.839 MAX 3.891
If the connecting rod crankshaft bore inside diameter is
not within specifications, the connecting rod must be
replaced.
Measure the connecting rod piston pin bushing inside

diameter.
Connecting Rod Piston Pin Bushing Inside Diameter

mm in
63.55 MIN 2.502
63.57 MAX 2.503
If the connecting rod piston pin bushing inside diameter is
not within specifications, the connecting rod must be
replaced.
Bend and Twist Inspect

Calibration Procedure
A connecting rod of known length, bend, and twist is called
the reference connecting rod, and is required to calibrate
the fixture.
A new connecting rod, for which the distance from the
center of the crankshaft bore to the center of the piston
pin bore (rod length) is known, can also be used.
The connecting rod cap must be installed and tightened

to the correct specifications or the calibration will be
incorrect.
Install the connecting rod checking guides, Part Number
4918336 and Part Number 4918338, into the reference
connecting rod piston pin bore and center the guide.
Install the appropriate connecting rod checking guide into
the reference connecting rod crankshaft bore.
Make sure the pin on the guide is down and centered in
the connecting rod.
Lock the guide in position by rotating the end of the guide.
Install the reference connecting rod into the connecting

rod checking fixture.
Loosen the knob and move the indicator bracket until both
indicators touch the top of the piston pin guide.
Move the bracket toward the guide until the indicator
needles have moved approximately 0.25 mm [0.010 in].
Turn the knob to tighten the bracket.
Adjust the indicator needles to zero. Move the connecting
rod in and out to confirm the zero setting.
Remove the reference connecting rod from the fixture.

Rotate the connecting rod 180 degrees horizontally and
install it into the fixture.
Be sure the indicators are at the zero setting.

If the indicator needles do not return to zero, adjust the
indicator so the zero moves ½ of the indicated difference
from the needle to the zero established during the
previous step.
If the needle is more than 0.10 mm [0.004 in] from the zero
established during the previous step, check for dirt or
burrs on the connecting rod checking guides and fixture.
If the zero is still not within the specification, check to
make sure the reference connecting rod is not damaged.
Do not adjust the indicators after this step of the
procedure or the measurements will be incorrect.
After completing the calibration of the fixture, remove the
reference connecting rod.
Test
CAUTION
To reduce the possibility of engine damage, the
connecting rod testing fixture must be calibrated prior
to testing the connecting rod.
Install the appropriate mandrel in the piston pin end of the
connecting rod.
Make sure the locating pin in the mandrel for the crank pin
end is touching the connecting rod cap, directly opposite
the beam of the connecting rod.
Install the mandrel in the crank pin bore of the master
connecting rod.
Tighten the mandrel so it is centered in the bore correctly.
Install the master connecting rod in the testing fixture.
Loosen the knob and move the indicator bracket until both
indicators touch the top of the piston pin end mandrel.
Move the bracket toward the mandrel until the indicator
needles have moved approximately 0.25 mm [0.010 in].
Turn the knob to tighten the bracket.
Adjust the indicator needles to zero. Move the master
connecting rod in and out to confirm the zero setting.
Remove the master connecting rod from the fixture.
Rotate the connecting rod 180 degrees horizontally and
install it in the checking fixture.
Record the indicator reading. The difference calibrated
“0” of the indicator must be added or subtracted from the
known length of the master connecting rod to determine
the length of the connecting rod being measured.
Connecting Rod Length

mm in
261.45 MIN 10.293
261.55 MAX 10.297
If the connecting rod length is not within specifications,
the connecting rod must be replaced.
CAUTION
Never attempt to straighten a connecting rod with the
use of heat or force. The connecting rod can
eventually break and cause extensive engine damage.
Record indicator readings.
Remove the connecting rod from the fixture.
Turn the connecting rod 180 degrees horizontally and
install it into the checking fixture.
Compare the indicator readings with those noted in the
previous step. The difference between the indicator
readings is the amount of bend in the connecting rod.
Maximum Connecting Rod Bend (Bushing Installed)

mm in
0.021 MAX 0.0008
If the connecting rod bend is not within specification, the
connecting rod must be replaced.
CAUTION
Never attempt to straighten a connecting rod with the
use of heat or force. The connecting rod can
eventually break and cause extensive engine damage.
Check the fixture and mandrel in the piston pin end for a
gap between the two. If there is any twist in the connecting
rod, the mandrel will touch only one side of the fixture.
Hold the end of the mandrel that is touching the fixture
firmly against the fixture.
Use a feeler gauge to measure the gap between the
mandrel and the fixture. The amount of gap between the
mandrel and the fixture is the amount of connecting rod
twist.
Maximum Connecting Rod Twist (Bushing Installed)

mm in
0.05 MAX 0.002
If the connecting rod twist is not within specification, the
connecting rod must be replaced.
Magnetic Crack Inspect

This procedure describes the magnetic particle inspection
for the connecting rod and connecting rod cap.
Use a magnetic particle testing machine.
The connecting rod and connecting rod cap must be
assembled during this process.
Use the residual method. Apply head shot amperage.
Adjust the amperage to 1500 ampere direct current or
rectified alternating current.
Check for cracks.
The connecting rod must be replaced if any cracks are
visible.
Use the residual method. Apply coil shot amperage.

Amperage (Ampere Turns)
Minimum Maximum
2600 amps direct current 2800 amps direct current
Ampere turn is an electrical current of one ampere flowing
through the coil, multiplied by the number of turns in the
coil.
Check for cracks.

The connecting rod must be replaced if any indications
are visible in the critical (shaded) areas.
WARNING
can cause serious injury.
WARNING
cleaning, follow manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce
CAUTION
The connecting rod must be demagnetized
completely and cleaned thoroughly. Any small metal
particles will cause engine damage.
Demagnetize the connecting rod.
Use solvent or steam to clean the connecting rod.
This procedure describes the magnetic particle inspection

for the connecting rod capscrew.
Use a Magnaflux™ or similar magnetic particle testing

machine.
Use the continuous method. Apply a head shot of 300 to
400 amperes direct current or rectified alternating current.
Use an ultraviolet light. Check for indications of cracks.

The magnetic particles tend to form on sharp corners and
edges. Do not mistake these for cracks.
Any indications of cracks are not acceptable.
Prepare the machine for a coil shot.

Make sure the capscrew is near one side of the coil and
not in the center.
Apply 1000 to 1350 ampere-turns.
Use an ultraviolet light. Check for indications of cracks.

Any indications of cracks are not acceptable.
WARNING
When using solvents, acids or alkaline materials for
WARNING
Wear eye and face protection when using compressed
air. Flying debris and dirt can cause personal injury.
CAUTION
The connecting rod must be demagnetized
completely and cleaned thoroughly. Any small metal
particles will cause engine damage.
Demagnetize the capscrew thoroughly.
Use solvent to clean the capscrew and dry with
compressed air.
Finishing Steps
NOTE: The piston and connecting rod must be installed
as an assembly on Signature™, ISX, and QSX15 engines.
• Assemble and install the piston and connecting rod.
Crankshaft Signature™, ISX, and QSX15
Rotation Check
Use only the compressor drive or barring device to rotate
the crankshaft.
Rotate the crankshaft clockwise through two complete
revolutions.
If the engine does not turn freely, the equipment can have
a malfunction or was assembled incorrectly. Refer to the
OEM service manual.
Signature™, ISX, and QSX15 Crankshaft
Preparatory Steps
WARNING
WARNING
Coolant is toxic. Keep away from children or pets. If
WARNING
WARNING
• Drain the cooling system. Refer to Procedure 008-018
in Section 8.
• Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
• Remove the engine. Refer to Procedure 000-001 in
Section 0.
• Remove the cylinder heads. Refer to Procedure
• Remove the flywheel. Refer to Procedure 016-005 in
Section 16.
• Remove the flywheel housing. Refer to Procedure
• Remove the front gear housing. Refer to Procedure
• Remove the piston and connecting rod assemblies.
• Remove the main bearing caps. Refer to Procedure
Remove
WARNING
Use a hoist and a sling that to remove the crankshaft.

Use crocus cloth or a Scotch-Brite™ pad to remove
discoloration or light scratches from the machined
surfaces of the crankshaft.
WARNING
Use a bristle brush and solvent to clean all of the
crankshaft oil drillings.
WARNING
can cause personal injury.
WARNING
personal injury.
Steam clean the crankshaft and dry with compressed air.
WARNING
WARNING
personal injury.
CAUTION
Do not use a thread chaser to clean the capscrew
threads in the crankshaft, severe engine damage can
result.
ISX applications use rolled capscrew threads in the
capscrew holes of the crankshaft.
To clean the rolled threads, flush with solvent, and dry with
compressed air.
If additional cleaning is required, brush with a nylon bristle
brush.
Place tape over the threaded capscrew holes.
Inspect the machined surfaces for scratches or nicks.

Use a crocus cloth to remove any nicks and scratches.
If scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with crocus cloth, the
crankshaft must be replaced.
Inspect the crankshaft for dynamic balancing marks. One

or more of the crankshaft counterweights will contain a
drilled hole or drilled start point indicating that the
crankshaft has been balanced.
NOTE: This applies to engines built March 2009 or later
only.
Inspect the threaded capscrew holes for damage.
If the threaded capscrew holes are damaged, the
Inspect the crankshaft gear and tone wheel for excessive
wear or damage.
If any teeth on the crankshaft gear are missing, chipped,
or pitted, the crankshaft gear must be replaced.
If any teeth on the tone wheel are missing, the tone wheel
must be replaced.
Measure the crankshaft connecting rod journal outside

diameter.
Crankshaft Connecting Rod Journal Outside Diameter

mm in
93.98 MIN 3.700
94.02 MAX 3.702
If the crankshaft connecting rod journal outside diameter
is not within specifications, the crankshaft must be
replaced.
Measure the crankshaft main bearing journal outside

diameter.
Crankshaft Main Bearing Journal Outside Diameter

mm in
126.98 MIN 4.999
127.02 MAX 5.001
If the crankshaft main bearing journal outside diameter is
not within specifications, the crankshaft must be
replaced.
Measure the crankshaft thrust face width.
Crankshaft Thrust Face Width

mm in
54.95 MIN 2.163
55.05 MAX 2.167
If the crankshaft thrust face width is not within
specifications, the crankshaft must be replaced.
Measure the crankshaft rear oil seal flange outside

diameter.
Crankshaft Rear Oil Seal Flange Outside Diameter

mm in
Flange Diameter 164.964 MIN 6.495
Location (1)
165.035 MAX 6.497
Location (2)
165.525 MAX 6.517
If the crankshaft rear oil seal flange outside diameter is
replaced.
Check the crankshaft rear oil seal flange for nicks, burrs,
and grooves.
If a fingernail catches in a nick, burr, or groove, the
crankshaft must be replaced. Damage to the sealing
surface can result in a seal leak.
Measure the crankshaft front oil seal flange outside

diameter.
Crankshaft Front Oil Seal Flange Outside

mm in
Location (1)
139.63 MAX 5.497
Location (2)
140.04 MAX 5.513
If the crankshaft front oil seal flange outside diameter is
replaced.
Check the crankshaft front oil seal flange for nicks, burrs,
and grooves.
crankshaft must be replaced. Damage to the sealing
surface can result in a seal leak.
Measure the crankshaft damper pilot outside diameter.
Crankshaft Pilot Outside Diameter

mm in
49.985 MIN 1.968
50.015 MAX 1.969
If the crankshaft pilot outside diameter is not within
Lubricate the entire crankshaft with clean 15W-40 oil to

prevent rust.
Bend and Twist Inspect

The crankshaft alignment limits are based on total
indicator runout. The runout is measured as the
crankshaft is turned one revolution while recording the
total movement of the dial indicator.
When measuring the crankshaft alignment, four

measurements must be taken:
• Full length alignment
• Bearing to bearing runout
• Rear oil seal flange diameter runout
• Front oil seal crankshaft adapter diameter runout.
WARNING
CAUTION
Measuring from the top of the main bearing journal
will cause inaccurate alignment measurements
because of crankshaft sag.
To check the crankshaft full length alignment, support the
crankshaft on the number one and number seven main
bearing journals.
The dial indicator must be set up so the indicator is

located on the side of the number four main bearing
journal.
Set up the dial indicator.
Rotate the crankshaft one complete revolution and record

the total indicator runout.
Total Indicator Runout

mm in
0.200 MAX 0.008
If the crankshaft total indicator runout is not within
Bearing to bearing runout is defined as the relationship of

the total indicator runout of a main bearing journal as it is
rotated on a common axis to the total indicator runout of
an adjacent journal.
Bearing to bearing runout is often referred to as step
runout, adjacent runout or journal to journal runout.
The clock position is defined as the location of the journal

at the highest total indicator runout point. Compare its
angular relationship with the number one crankshaft pin,
as viewed from the front of the crankshaft.
In the illustration, the crankshaft pin is at the 8 o'clock
position. This is the clock position of the journal being
measured.
WARNING
CAUTION
Measuring from the top of the main bearing journal
will cause inaccurate alignment measurements
because of crankshaft sag.
To check the crankshaft full length alignment, support the
crankshaft on the number one and number seven main
bearing journals.
Set the dial indicator up on the side of the main bearing

journal.
Rotate the crankshaft and measure the total indicator

runout at each bearing journal.
Record the value and clock position for each location.
For each journal, plot the total indicator runout value at its
clock position on a polar chart.
The end journals, supported by vee blocks, must be
plotted at the center of the chart.
The illustration illustrates the plot points.
Journal Total Indicator Runout Clock Position
(1) 0 0
(2) 0.002 12
(3) 0.003 12
(4) 0.004 1
Draw a straight line between the plotted points. From
journal number one, to journal number two, to journal
number three, until all journals are plotted on the chart.
To determine the adjacent journal runout, measure the
length of the line from each journal to its corresponding
journal point.
In the above table journal number three and number four
are 51 mm [2 in]. This represents a runout of 0.051 mm
[0.002 in].
Record the adjacent runout for each main bearing journal.
Adjacent Journal Runout

mm in
0.075 MAX 0.003
If the alignment between adjacent journals is not within specifications, it can not be repaired by grinding. The
crankshaft must be replaced. ISX crankshafts are fully fillet hardened and can not be straightened.
Rear oil seal flange diameter runout measurement:

With the crankshaft supported on the number one and
number seven main bearing journals, position a dial
indicator 25.4 mm [1.0 in] from the flywheel mounting face
of the crankshaft.

Rear Oil Seal Flange Total Indicator Runout

mm in
0.03 MAX 0.0012
If the rear oil seal flange total indicator runout is not within
Front oil seal crankshaft adapter diameter runout

measurement:
With the crankshaft supported on the number one and
number seven main bearing journals, position a dial
indicator 25.4 mm [1.0 in] from the balancer mounting face
of the crankshaft.

Front Oil Seal Crankshaft Adapter Diameter Runout

mm in
0.05 MAX 0.002
If the front oil seal crankshaft adapter diameter runout is
replaced.

The crankshaft must be tested by the “continuous
method”. The entire surface must be wetted with the
magnetic bath solution before and during the flow of
magnetic current through the crankshaft.
For the head shot (longitudinal magnetization) method,
apply the magnetic bath solution to the crankshaft and use
3800 amperes with VDC or rectified VAC to magnetize the
crankshaft.
A minimum of three successive head shots are required

for each section of the crankshaft.
Flow the magnetic solution over the first 1/3-length of the
crankshaft and apply two head shots of magnetizing
current.
To prevent washing the metal particles off the crankshaft,
turn the magnetic solution flow off.
Apply a third head shot of magnetizing current.
Inspect the crankshaft for open indications.
Flow the magnetic solution over the second 1/3-length of

the crankshaft and apply two head shots of magnetizing
current.
Apply a third head shot of magnetizing current.
Flow the magnetic solution over the last 1/3-length of the

crankshaft and apply two head shots of magnetizing
current.
Apply a third shot of magnetizing current.
For the coil shot (circumferential magnetization) method,

apply the magnetic solution and magnetize the crankshaft
in a 51.35 mm [20.249 in] inside coil or equivalent. Use
3,600 to 4,000 ampere-turns with VDC or rectified VAC.
Amepere-turn is the amperage flowing through the coil
multiplied by the number of turns in the coil.
A minimum of three coil shots are required for each 457

mm [18 in] length to correctly magnetize the crankshaft.
Flow the magnetic solution over the crankshaft in 1/3
sections.
Apply two coil shots, after wetting with the magnetic
solution, with the coil placed at ¼-length points along the
crankshaft.
Apply the third coil shot with the coil placed at ¼-length
points along the crankshaft.
Inspect each 457 mm [18 in] section after the third coil shot
is completed.
An open indication is a crack open to the surface that can

be observed without using optical enhancement.
An open indication can sometimes be felt with a fingernail.
Do not mistake forging trim lines for crack indications.
If open indications are observed in the hardened fillet area
or the critical areas shown (A), the crankshaft must be
replaced.
Open indications longer than 6 mm [0.25 in] are not

acceptable.
Open indications in any fillets or the critical areas are

not acceptable.
Open indications on the crankpin or main bearing journal

surfaces that extend closer than 3 mm [0.12 in] to the fillet
but do not enter the fillet are acceptable.
Open indications in the longitudinal direction up to 12.5

mm [0.5 in] in length, but not closer than 3 mm [0.12 in]
to the oil hole chamfer are acceptable.
Open indications that enter the oil hole chamfer or
intersect the oil hole at 45 degrees ± 10 degrees are
not acceptable.
Any open indication in the crankpin bearing hole entrance

chamfer is not acceptable.
Open indications in the counterweights inside the critical
area are not acceptable.
Open indications that extend over the face of the

crankshaft or extend into the damper mounting capscrew
holes are not acceptable.
Subsurface indications can not be seen with the eye after

magnetic particles have been removed. These are
indications of open areas or foreign objects below the
surface.
Inspect for subsurface indications.
CAUTION
All magnetism must be removed from the crankshaft
completely and the crankshaft cleaned thoroughly.
Small metal particles will cause engine damage.
Demagnetize the crankshaft.
The maximum residual magnetic field on any pin or main
bearing journal is 8 gauss.
It will possibly be necessary to use reverse D.C.-30 point
step down equipment, or equivalent, to remove the
magnetism.
WARNING
can cause personal injury.
WARNING
personal injury.
Steam clean the crankshaft.
Dry the crankshaft with compressed air.
Use a light preservative oil to lubricate the crankshaft to

prevent rust.
If the crankshaft is not going to be used immediately,
protect it with a plastic cover to prevent dirt sticking to the
oil.
Install
WARNING
CAUTION
Do not drop the crankshaft on the bearings.
Install the main bearings. Refer to Procedure 001-006 in
Section 1.
The end of the crankshaft with the smallest diameter
must point toward the front of the cylinder block.
Install the crankshaft.
Signature™, ISX, and QSX15 Crankshaft Adapter
Finishing Steps
• Install the main bearing caps. Refer to Procedure
• Install the piston and connecting rod assemblies. Refer
• Install the lubricating oil pump. Refer to Procedure
• Install the front gear housing. Refer to Procedure
• Install the flywheel housing. Refer to Procedure
• Install the flywheel. Refer to Procedure 016-005 in
Section 16.
• Install the cylinder heads. Refer to Procedure 002-004
in Section 2.
• Install the engine. Refer to Procedure 000-002 in
Section 0.
• Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
Crankshaft Adapter (001-017)

Preparatory Steps
On-Engine Repair
CAUTION
To reduce the possibility of engine damage, the
removal of the lubrication oil pan is required to
prevent debris collection in the oil pan.
• Remove the radiator, charge air cooler, and the hood
if applicable. Refer to the OEM service manual.
• Remove the crankshaft pulley and vibration damper.
• Remove the lubrication oil pan. Refer to Procedure
Crankshaft Adapter Signature™, ISX, and QSX15
Remove
NOTE: If the threaded hole adjacent to the dowel pin is
selected, the dowel pin must be removed prior to drilling.
In most instances, this procedure is easiest to perform
when staring with a threaded hole near the 12 o'clock
position.
Use a 12.7-mm [1/2-in] drill bit, Part Number 4918535, or
equivalent, to ream out the threaded hole so the 6.35-mm
[1/4-in] bushing, Part Number 4918538, or equivalent, will
insert easily.
Install the stop collar, Part Number 4918541, or

equivalent, onto a 6.35-mm [1/4-in] drill bit, Part Number
4918533, or equivalent, at a depth of 60.3 mm [2.375 in].
WARNING
personal injury.
CAUTION
Do not drill holes completely through the crankshaft
adapter or gear. Damage to the engine, crankshaft,
and or tools can occur.
The use of a generous amount of cutting fluid will increase
tool life and ease the drilling operation.
A maximum drill speed of 850 rpm is recommended.
Insert a 6.35-mm [1/4-in] drill bushing, Part Number
4918538, or equivalent, into the reamed hole.
Drill a 6.35-mm [1/4-in] hole to the preset depth.
Clean out the debris using low pressure air and a shop
towel to cover the hole as necessary.
Install the stop collar, Part Number 4918542, or equivalent

onto a 12.7-mm [1/2-in] drill bit, Part Number 4918535, or
equivalent, at a depth of 54 mm [2.125 in].
WARNING
personal injury.
CAUTION
Remove the 6.35-mm [1/4-in] drill bushing, Part Number
4918538, or equivalent. Using the previously drilled 6.35-
mm [1/4-in] hole as a pilot, drill a 12.7-mm [1/2-in] hole to
the preset depth.
Install the drill guide adapter, Part Number 4918276, onto

the crankshaft nose so the drill guide bushing labeled "A"
is aligned with the previously drilled 21.7-mm [1/2-in] hole.
Install and tighten 2 existing damper capscrews through
the drill guide adapter.
WARNING
personal injury.
CAUTION
Install the 19.05-mm [3/4-in] drill bushing, Part Number
4918540, or equivalent, into the drill guide bushing "A".
Drill a 19.05-mm [3/4-in] hole using drill bit, Part Number
4918536, or equivalent, to a depth of the previous 21.7-
mm [1/2-in] hole.
Remove the 19.05-mm [3/4-in] drill bit.
Clean out the debris. Use low pressure air and a shop
WARNING
personal injury.
CAUTION
A right angle, clutched, 1/2-inch drive drill at a maximum
drill speed of 300 rpm is recommended.
Drill a 25.4-mm [1-in] hole using drill bit, Part Number
4918537, or equivalent, to a depth of the previous 19.05-
mm [3/4-in] hole.
Remove the 25.4-mm [1-in] drill bit.
Remove the drill guide adapter from the crankshaft and

rotate the drill guide adapter 180 degrees so the drill guide
bushing labeled "B" is aligned with the previously drilled
hole.
Install and tighten 2 existing damper capscrews through
the drill guide adapter.
Install the stop collar, Part Number 4918543, or

equivalent, onto a 19.05-mm [3/4-in] end mill, Part Number
4918532, at a depth of 111 mm [4.375-in].
WARNING
personal injury.
CAUTION
A right angle, clutched, 1/2-inch drive drill at a maximum
drill speed of 300 rpm is recommended.
Bore a 19.05-mm [3/4-in] hole to the preset depth.
Remove the 19.05-mm [3/4-in] end mill, the 2 damper
capscrews, and the drill guide adapter.
Remove the front crankshaft seal. Refer to Procedure

Remove the lower gear cover. Refer to Procedure 001-080
in Section 1.
Insert the wedge, Part Number 4918546, into the 19.05-

mm [3/4-in] drilled hole.
Strike the wedge firmly with a hammer until the crankshaft
adapter splits.
The crankshaft adapter will be easily removable by hand
after splitting, however, a suitable puller can be used to
facilitate the removal.

Inspect the crankshaft, tone wheel, and crankshaft gear
for damage.
Inspect the machined surface for scratches or nicks.
Use a crocus cloth to remove the scratches or nicks. If
scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with the crocus cloth, the
Inspect the crankshaft gear and tone wheel for excessive

wear or damage.
If any teeth on the tone wheel are missing, the tone wheel
must be replaced.
Install
WARNING
To reduce the possibility of personal injury, wear
protective gloves when handling parts that have been
heated.
NOTE: During the installation of the crankshaft adapter,
the pin located on the backside of the crankshaft adapter
must align with the slot on the front surface of the tone
wheel.
Do not lubricate the crankshaft prior to installing the
crankshaft adapter.
Heat the crankshaft adapter for 6 hours at 260°C [500°F]

before attempting the installation.
NOTE: The crankshaft adapter must be installed within

15 seconds after being removed from the oven.
Install the crankshaft adapter. Use a twisting motion until
the pin is aligned in the slot on the tone wheel.
Hold the crankshaft adapter against the tone wheel for
approximately 30 seconds.
To check the installation, attempt to insert a 0.25-mm

[0.010-in] feeler gauge between the crankshaft gear and
the tone wheel at 4 locations approximately 90 degrees
apart.
If the feeler gauge can be inserted, the tone wheel must
be removed and replaced.
Crankshaft Gear, Front (Crankshaft Installed) Signature™, ISX, and QSX15
Finishing Steps
• Install the lubrication oil pan. Refer to Procedure
• Install the lower gear cover. Refer to Procedure
• Statically time the engine. Refer to Procedure 001-088
in Section 1.
NOTE: If the timing pin, Part Number 3163020, can not
be inserted when the damper marking "Insert Pin" is
aligned with the marking on the lower gear, the tone wheel
or crankshaft adapter is not properly aligned with the
crankshaft.
NOTE: It will be necessary to remove the lower gear cover,
crankshaft seal, and vibration damper and check for
missing dowel pins and or misalignment in the crankshaft
adapter or tone wheel.
• Install the radiator, charge air cooler, and the hood, if
applicable. Refer to the OEM service manual.
Crankshaft Gear, Front (Crankshaft

Installed) (001-018)
Preparatory Steps
On-Engine Repair
WARNING
cable last.
• Disconnect the battery. Refer to Procedure 013-009
in Section 13.
• Remove the lower gear cover. Refer to Procedure
• Remove the crankshaft adapter. Refer to Procedure
• Remove the tone wheel. Refer to Procedure 001-069
in Section 1.
• Remove the alignment dowel pin.
• Remove the lubrication oil pan. Refer to Procedure
• Remove the lubrication oil pump. Refer to Procedure
• Remove the rocker lever cover and gasket. Refer to
• Disconnect and remove the engine brake wiring
harness. Refer to Procedure 020-015 in Section 20.
• Remove the rocker lever shaft. Refer to Procedure
• Remove the upper gear cover. Refer to Procedure
• Remove the valve camshaft gear, injector camshaft
gear, adjustable idler gear, and the lower idler gear.
Signature™, ISX, and QSX15 Crankshaft Gear, Front (Crankshaft Installed)
Remove
WARNING
personal injury.
CAUTION
Protect the engine internals from debris generated
during the drilling operation. Mask the engine
internals using tape, plugs, and or shields to prevent
debris from entering the engine internals. Failure to
do this will result in significant engine damage.
Install the plastic drill guide, Part Number 4918547, with
the "FRONT" facing the operator. Align the slot with the
crankshaft gear tooth root.
Install the stop collar, Part Number 4918541 or equivalent,

onto a 6.35-mm [0.250-in] drill bit at a depth of 111 mm
[4.375 in].
Tool life will be extended if the drill bit does not break
through the back of the crankshaft gear.
Drill a 6.35-mm [0.250-in] pilot hole to the preset depth.
Install the large drill guide adapter, Part Number 4918276,

onto the crankshaft nose with the hole labeled "C" aligned
with the pilot hole.
Use the alignment pin, Part Number 4918577, to align the

guide with the hole.
Tighten the 7.94-mm [5/16-in] set screw to hold the guide
to the crankshaft.
Install the countersink cutter, Part Number 4918578 or

equivalent, into a 102-mm [4-in] extension, Part Number
4918544 or equivalent.
Slide the 11.5-mm [29/64-in] drill bushing, Part Number
4918534 or equivalent, onto the shaft.
Install the assembly and lock the 11.5-mm [29/64-in] drill
bushing into the hole labeled "C".
Countersink the pilot hole until the outside diameter of the

countersink is approximately 1.6 to 3.2 mm [1/16 to 1/8 in]
deep.
Remove the countersink and the drill bushing.
Insert the drill bushing, Part Number 4918539, or

equivalent, into the hole labeled "C" and lock the 12.7-mm
[1/2-in] drill bushing into the drill guide.

Drill a 12.7-mm [1/2-in] hole to depth of the previously
6.35-mm [1/4-in] drilled hole.
Remove the tone wheel alignment dowel from the
crankshaft.
Install the locating gauge, Part Number 4918314, or other

suitable spacer, onto the crankshaft gear.
A spacer must be installed or the crankshaft will be
damaged during the crankshaft gear removal.
Insert the small splitting wedge, Part Number 4918545,

with the flatted area facing toward the crankshaft and into
the drilled hole.
Strike the small splitting wedge with a suitable hammer

until the crankshaft gear splits.
Remove the crankshaft gear by hand or use a suitable
puller if necessary.
WARNING
WARNING
personal injury.
NOTE: If scratches or nicks can be felt with a fingernail
after the crankshaft has been polished with a crocus cloth,
the crankshaft must be replaced.
Inspect the crankshaft for damage.
Inspect the machined surface for scratches or nicks.
Install
Install the locating gauge, Part Number 4918314, onto the
side of crankshaft gear.
Heat the crankshaft gear for 3 hours at 177°C [350°F]
before attempting the installation.
WARNING
heated.
NOTE: The crankshaft gear must be installed within 15
seconds after being removed from the oven.
Install the crankshaft gear until the locating gauges make
contact with the front crankshaft journal.
Hold the crankshaft gear in position for approximately 60
seconds to allow the shrink fit to properly hold the
components.
Remove the locating gauge from the crankshaft gear.
Use a brass hammer, tap the alignment dowel pin in the

crankshaft hole until the alignment dowel pin bottoms out.
Check the gap between the crankshaft gear and the
crankshaft first journal by inserting the locating gauge,
Part Number 4918314.
If the locating gauge is loose or can not be inserted,
replace the crankshaft gear.
Finishing Steps
WARNING
cable last.
• Install the valve camshaft gear, injector camshaft
gear, adjustable idler gear, and the lower idler gear.
• Install the upper gear cover. Refer to Procedure
• Install the rocker lever shaft. Refer to Procedure
• Connect the engine brake wiring harness. Refer to
• Install the rocker lever cover and gasket. Refer to
• Install the lubrication oil pump. Refer to Procedure
• Install the lubrication oil pan. Refer to Procedure
• Install the tone wheel. Refer to Procedure 001-069 in
Section 1.
• Install the crankshaft adapter. Refer to Procedure
• Install the lower gear cover. Refer to Procedure
• Connect the battery. Refer to Procedure 013-009 in
Section 13.
Crankshaft Pulley Signature™, ISX, and QSX15
Crankshaft Pulley (001-022)

Remove
Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the fan and water pump drive belt tensioner.
CAUTION
damper. These tools can damage the damper.
Remove two of the vibration damper and crankshaft pulley
retaining capscrews.
Remove the remaining 10 capscrews. Remove the pulley
and damper.

Remove the fan. Refer to the OEM service manual.
If equipped with a crank-driven fan, remove the crankshaft

adapter (1) from the pulley (2).
Signature™, ISX, and QSX15 Crankshaft Pulley

CAUTION
damper. These tools can damage the damper.
Remove the remaining 10 capscrews. Remove the pulley
(4), damper (3), mounting spacer (2), and second damper
(1).
Inspect for Reuse

Inspect the pulley for cracks, excessive wear in the belt
grooves, or other damage.
Crankshaft Pulley Signature™, ISX, and QSX15
Install
the vibration damper, and the pulley are clean, dry, and
free of burrs.
NOTE: Align dowel pin in crankshaft with dowel hole in
damper.
Install the vibration damper(s) and pulley on the guide
studs.

capscrews.
Install the fan and water pump belt tensioner. Refer to

Procedure 008-080.
NOTE: Align dowel of tensioner to bracket.
Install the fan and water pump drive belt. Refer to
Procedure 008-003.
Install alternator drive belt. Refer to Procedure 013-005.

the dampers, mounting spacer, and pulley are clean, dry,
and free of burrs.
Signature™, ISX, and QSX15 Crankshaft Pulley
Install one of the dampers (1), mounting spacer (2), the

second damper (3), and the pulley (4) onto the guide studs.

Install ten capscrews.
capscrews.
Tighten the twelve capscrews in a star pattern.
If equipped with a crank-driven fan, install the crankshaft

adapter (1), making sure it seats flush against the pulley
(2).
Install the fan and water pump belt tensioner. Refer to

Procedure 008-080.
NOTE: Align dowel of tensioner to bracket.
Install the alternator drive belt. Refer to Procedure

013-005.

Procedure 008-003.
Install the fan. Refer to the OEM service manual.

Preparatory Steps
WARNING
• Remove the fan and water pump drive belt. Refer to
Procedure 008-003 (Drive Belt, Water Pump) in
Section 8.
• Remove the fan and water pump belt tensioner.
Refer to Procedure 008-080 (Belt Tensioner,
Automatic (Water Pump) in Section 8.
• Remove the crankshaft pulley and vibration damper
(s). Refer to Procedure 001-052 (Vibration Damper,
Viscous) in Section 1.
Remove
Remove the eight mounting nuts from the gear cover
studs.
Position the replacer plate (1) over the crankshaft end and
against the crankshaft seal. The large notch between the
teeth needs to bridge the raised gear cover surface.
Make certain that the alignment of the three welded nuts
on the crankshaft seal are positioned into the counterbore
slots of the replacer plate (1).
Install a capscrew (4) with a flat washer (5) in the upper
slot of the replacer plate to hold it in position
CAUTION
Tighten the capscrews by hand until a slight
resistance is felt. Do not overtighten the capscrews or
the seal nuts can break off causing damage to the seal
and leading to front cover damage.
Use a small allen wrench to thread the removal tool
capscrews (2) through the replacer plate and into the seal
nuts.
Tighten the socket head capscrews (2) clockwise into the
three seal removal nuts that are welded on the crankshaft
seal until a slight resistance is felt.
Remove the capscrew in the upper slot of the replacer
plate (1).
Install the replacer screw (3) into the replacer plate (1).
Turn the screw (3) clockwise until the crankshaft seal is
removed from the crankshaft.

NOTE: All lower gear covers have either a beveled half
groove, or a full o-ring groove under the crankshaft seal
flange.
Full o-ring groove covers contain an o-ring in the lower
gear cover groove and were only used prior to June 5,
1999. The lower gear cover must be replaced if installing
a new seal. Refer to Procedure 001-080 (Gear Cover,
Lower).
Beveled half groove covers do not contain an o-ring and
only require replacement if damaged. Refer to Procedure
001-080 (Gear Cover, Lower).
Use a small magnet to remove any metal shavings.
Use a crocus cloth to remove any deposits from the
crankshaft and seal bore area.
Inspect the crankshaft for nicks, burrs, and grooves.

Damage to the sealing surface can result in seal leakage.
Install
The position of the front crankshaft seal on the crankshaft
is determined by the position of the lower gear cover.
The lower gear cover is mounted to the gear cover housing
using clearance holes. This allows for slight movement of
the cover when the mounting capscrews are loose.
The unitized crankshaft seal must be centered on the
crankshaft for correct operation.
The seal attaches to the lower gear cover, and must be
installed with the lower gear cover capscrews loose and
the cover free to move.
In order for the seal to be properly centered on the

crankshaft during assembly and maintain its location
during operation, the following installation instructions
must be followed.
The crankshaft seal removal and installation tool correctly
centers the seal and correctly positions the dust seal
portion of the seal on the crankshaft.
CAUTION
Failure to loosen and remove the mounting capscrews
from the gear cover can cause the front crankshaft
seal to be misaligned and cause premature seal wear.
The front gear cover must be aligned as follows:
Removing the gear cover mounting capscrews around the
crankshaft seal allows the replacer plate to set against the
gear cover during seal installation.
Remove the gear cover mounting capscrews around the
crankshaft seal.
Loosen the remaining mounting capscrews on the gear
cover so the cover can move freely.
CAUTION
Failure to follow the installation and tightening
sequence can lead to the crankshaft seal being off
center and installed at the wrong depth causing
premature seal wear.
CAUTION
Never use a hammer or mallet to install the seal. Use
of a hammer can damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool has provisions for
any seal nut orientation, although one seal nut must
always be located at the 11 o'clock position.
Do not use lubricants on the crankshaft seal.
Position the crankshaft seal (1) onto the crankshaft until
the gear cover studs are protruding through the seal
carrier mounting holes.
Place the replacer plate (1) against the crankshaft seal.

Make sure the welded nuts on the front crankshaft seal
are seated in their respective slots on the replacer plate
(1).
The large notch between the teeth must bridge the raised
gear cover surface.
Install three washers (4) and capscrews (5) through the

three slots in the replacer plate (1) and into the crankshaft
end.
The capscrews in the replacer plate must be equally
spaced. This allows the crankshaft seal to be installed
correctly.
Tighten the capscrews hand-tight.
CAUTION
The crankshaft seal must be pressed evenly. If the
crankshaft seal is not pressed in evenly the seal can
be damaged.
Inspect the crankshaft seal during installation to make
certain it is being pressed evenly.
Tighten the capscrew(s) no more than ½ of a revolution at
a time, alternating in a clockwise pattern until the replacer
plate (1) bottoms out against the face of the lower gear
cover.
To maintain the cover position while the replacer plate is

removed, tighten the two gear cover mounting capscrews,
as indicated by the arrows in the graphic.
Install the crankshaft seal mounting nuts (1) through the
holes provided in the replacer plate.
Tighten the mounting nuts in the sequence shown.
Install all the gear cover mounting capscrews.

The torque sequence must be followed to prevent the
gear cover strip seal from squeezing out of the groove.
Finishing Steps
WARNING
• Install the crankshaft pulley and vibration damper(s).
Refer to Procedure 001-052 (Vibration Damper,
Viscous) in Section 1.
• Install the fan and water pump belt tensioner. Refer
to Procedure 008-080 (Belt Tensioner, Automatic
(Water Pump) in Section 8.
• Install the fan and water pump drive belt. Refer to
Section 8.

Preparatory Steps
WARNING
• Disconnect the driveline. Remove the transmission
and clutch. Refer to the manufacturer's instructions.
• Remove the flywheel. Refer to Procedure 016-005 in
Section 16.
Remove
The rear crankshaft seal requires the rear crankshaft seal
replacer kit, Part Number 3164780, for the seal removal
and installation.
1 Replacer plate
2 Pilot drill
3 Replacer screw
4 Self-tapping screw x 10
5 Stud x 3
6 Hex nut x 3.
Use three flywheel mounting capscrews to secure the

replacer plate (1) to the crankshaft.
Install a pilot drill (2) into one of the holes in the rear
crankshaft seal tool and drill a hole through the seal
casing.
Remove the pilot drill (2) and repeat the procedure for at
least two more evenly spaced holes of the rear crankshaft
seal tool. As many as six holes may be drilled to assist in
removing the rear crankshaft seal.
NOTE: Three stud screws (3) and three hex nuts (4) are
required for some engines with flywheel mounting
capscrews that are too short to mount the replacer plate
(1) to the crankshaft.
Install at least three self-tapping screws (1) into the

replacer plate (2).
Remove the flywheel capscrews from the rear crankshaft
seal tool.
Install the replacer screw (3) into the center hole of the
replacer plate and turn clockwise to remove the seal.
WARNING
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
Clean the seal bore surface of the flywheel housing.
Use an emery cloth to remove any rust or other deposits

from the crankshaft flange.
Use a clean, lint-free cloth to clean the crankshaft flange
and to remove all traces of oil film.
Visible scratches can result in seal leakage.
Install
The rear crankshaft seal must be oriented with the engine
as shown in the illustration.
CAUTION
Never use a hammer or mallet to install the seal.
Damage to the seal can occur.
Do not use lubricants to install the seal. Apply a 10-
percent soap solution to the outer-ribbed surface of the
seal.
Guide the rear crankshaft seal (1), spacer (2), and replacer
plate (3) over the crankshaft.
NOTE: Spacer, Part Number 4918688, is used to make
sure of the correct installation depth of the crankshaft seal.
The flat side of the spacer should contact the crankshaft
seal during installation.
CAUTION
the bore. Misalignment of the seal can cause damage.
Install three flywheel mounting capscrews or replacer
screws and hex nuts, through the replacer plate and into
the end of the crankshaft.
Finger-tighten the three installation capscrews against the
replacer plate.
Tighten the screws not more than ½ of a turn at a time,
in a clockwise pattern, until the installation tool seats
against the flywheel housing.
Tighten the screws.
Measure
the seal.
0.5 mm [0.02 in].
installed.
Signature™, ISX, and QSX15 Cylinder Block
Finishing Steps
WARNING
• Install the flywheel. Refer to Procedure 016-005 in
Section 16.
• Install the clutch transmission and driveline. Refer to
the manufacturer's instructions.
• Operate the engine until it reaches normal operating
temperature and check for leaks.
Cylinder Block (001-026)

Inspect for Reuse
Inspect the cylinder block for cracks. If any cracks are
found, the cylinder block must be replaced.
If upper bore erosion is discovered during block

inspection, it must be disregarded. It is not a failure mode
and the use of new o-rings on the cylinder liner provides
an adequate seal.
If liner ledge pitting is discovered during block inspection,

the block can be reused, if no leak is evident in the liner-
to-liner ledge (block) interface.
Cylinder Block Signature™, ISX, and QSX15
The main bearing bore diameter must be measured with

the main bearings removed and the main bearing caps
assembled and torqued to the correct specification.
Main Bearing Bore Diameter
mm in
133.49 MIN 5.2555
133.52 MAX 5.2565
Repair
Follow this procedure to salvage capscrew holes that are
missing a portion of threads or that have cracks extending
into the threaded sidewall from the upper counterbore.
Cracks that extend into the capscrew bosses or the

coolant cavity below the upper counterbore can not be
salvaged using this procedure.
Remove any burrs from the top deck surface of the

cylinder block. A 12 inch flat surface mill file is effective
for this step. Burr removal is necessary to obtain an
accurate fixture location.
NOTE: The thread salvage kit is designed to be used with

the cylinder liner removed. If the cylinder liner remains in
the block, shims must be installed to both sides of the
base, equally, to bridge the liner.
NOTE: On some engines, it will be necessary to use the
spacer, Part Number 3376206, between the mounting
base and the drilling fixture.
Select two capscrew holes so the failed capscrew hole is
positioned approximately in the middle. Install the
mounting plate assembly onto the capscrew holes using
the appropriate spacers, four plain washers, and the
existing cylinder head capscrews.
Use a heavy washer and the 5/8-18 x 3 inch hex head
capscrew to attach the drilling fixture to the mounting plate
assembly.
For main bearing capscrew thread repair, mounting plate,

Part Number 3164014, will not accommodate all engines.
In those cases, the repair must be performed by a
qualified machine shop.
Slide the locating pin through the appropriate drilling

fixture bushing hole until it rests in the failed capscrew
hole of the cylinder block.
Center the drilling fixture guide bar and bushing over the
failed capscrew hole.
Tighten the three capscrews to secure the fixture
assembly.
Remove the locating pin.
Setting the stop collar is required only for repairs using

drills.
Drills are used in some kits to allow for quick removal of
waste material; however, care must be taken to make
certain the depth of the repaired capscrew hole is not
increased beyond specification.
The following steps will result in the drill stopping short of
the original hole depth. The remaining material is then
removed with the reamer.
Place a 0.76 mm [0.030 in] feeler gauge over the hole to
be repaired.
Insert the drill through the drill bushing until its tip rests
against the feeler gauge.
Place the thread insert to be installed between the drill
bushing and the stop collar.
Move the stop collar down until is rests against the insert
and tighten the stop collar.
Place the drill through the drill fixture bushing and let it
rest over the top of the failed capscrew hole.
Use a drill motor with a clutch and a maximum operating
speed of 300 rpm. Use a suitable cutting fluid. Operate the
drill motor until the stop collar contacts the drill bushing.
WARNING
personal injury.
Remove the chips with a chip vacuum.
Place the reamer through the drill fixture bushing and let
it rest over the top of the failed capscrew hole.
While reaming the hole, it will be necessary to stop
frequently to clean the hole with the chip vacuum.
speed of 300 rpm, a suitable cutting fluid and operate the
drill motor until the reamer reaches the bottom of the
original capscrew hole.
The reamer will stop cutting when it reaches the bottom of
the hole.
WARNING
personal injury.
Stop the tapping operation frequently to clean the bore

with a chip vacuum.
Install a ½ inch square drive socket on the end of the
appropriate tap.
When tapping, keep the tap well lubricated.
Install the tap (4), and use a suitable tapping fluid. Hand-
tap to the bottom of the failed capscrew hole.
Remove the tap.
WARNING
personal injury.
Remove the mounting capscrews, spacers, four plain

washers, and mounting plate assembly.
Thread the tap in and out of the newly-cut threads several

times to verify the thread condition and clean debris from
the threads.
WARNING
WARNING
Check the capscrew hole for evidence of porosity and
cracks.
Clean the threads and flush any debris from the tapped
hole using a solvent-degreasing agent.
WARNING
personal injury.
Remove the solvent-degreasing agent from the hole with
a chip vacuum.
Place the appropriate jam nut (1) on an appropriate

capscrew.
Install the appropriate thread insert (2) onto the cylinder
head mounting capscrew until it nears the bottom of the
insert.
Rotate the jam nut (1) until it contacts the thread insert (2)
to lock the insert and jam nut together.
WARNING
WARNING
Remove the preservative coating from the circumference
of the thread insert. Use a solvent-degreasing agent.
Install the thread insert, jam nut, and capscrew into the
newly-tapped hole. Make certain the thread insert threads
freely into the hole.
NOTE: For applications with a counterbore, measure the

protrusion depth starting at the counterbore face, which is
recessed into the hole.
Check for protrusion. Make certain the thread insert
protrusion is 0 to 1.0 mm [0 to 0.040 in] above the cylinder
block surface.
It is important to make certain the minimum required
thread depth is maintained after thread repair.
If the insert protrusion exceeds 1 mm [0.040 in], the
cylinder head capscrew can bottom out when tightened.
Record the amount the insert protrudes.
It is necessary to increase the depth of the original
capscrew hole.
If the insert protrusion is correct, install the insert.
If the protrusion is not correct, record the measurement
and adjust the bore depth.
Prior to increasing the capscrew hole depth, check the

following:
1 Make certain the correct thread insert is being used.
Two inserts are available, two inserts are identical
except for their length.
2 Make certain the insert used is the correct length.
3 Make certain the capscrew hole is threaded all the way
to the bottom.
4 Make certain there are no burrs or other damage that
would prevent the insert from threading to the bottom
of the capscrew hole.
After checking the above listed items, if the thread insert
protrusion still exceeds 1.0 mm [0.040 in], the depth of the
original capscrew hole must be increased.
NOTE: The thread salvage kit is designed to be used with

the cylinder liner removed. If the cylinder liner remains in
the block, shims must be installed to both sides of the
base, equally, to bridge the liner.
NOTE: On some engines, it will be necessary to use the
spacer, Part Number 3376206, between the mounting
base and drilling fixture.
Install the mounting plate assembly.
Do not tighten the fasteners.
Slide the drill through the drill bushing and into the
threaded hole until it rests at the bottom of the hole.
Tighten all fasteners.
The drill must slide freely in the bushing and threaded
hole, indicating that it is centered in the hole.
Do not increase the depth of the original capscrew hole

more than 3.0 mm [0.120 in].
Slide the stop collar over the drill bit.
Subtract 0.50 mm [0.020 in] from the insert protrusion.
Select a feeler gauge equivalent to this value.
With the drill resting at the bottom of the hole, insert the
feeler gauge between the stop collar and drill bushing.
Tighten the stop collar.
speed of 300 rpm, a suitable cutting fluid and operate the
drill motor until the stop collar contacts the drill bushing.
WARNING
personal injury.
It is not necessary to ream the hole prior to the second

tapping.
Install a ½ inch square drive socket on the end of the
appropriate tap.
When tapping, keep the tap well lubricated.
Install the tap (4), and use a suitable tapping fluid. Hand-
tap to the bottom of the failed capscrew hole.
Remove the tap.
WARNING
WARNING
Check the capscrew hole for evidence of porosity and
cracks.
Clean the threads, and flush any debris from the tapped
hole using a solvent-degreasing agent.
WARNING
personal injury.
Remove the chips and solvent-degreasing agent from the
hole with a chip vacuum.
Install the thread insert on a cylinder head capscrew and

lock in place with a jam nut.
Temporarily install the thread insert and check the
protrusion. Make certain that the protrusion is 0 to 1 mm
[0 to 0.040 in] above the cylinder block surface.
Remove the insert.
Apply a light coat of primer, Part Number 3824715, to the

thread insert and the threaded hole. Allow three to five
minutes to dry.
Apply four beads of thread locking compound, Part
Number 3824038, to the circumference of the thread
insert.
Each bead must be 0.8 mm [0.03 in] wide down the entire
length of the thread insert and the beads must be 90
degrees apart.
Install the thread insert until it is flush with the cylinder

block surface or it bottoms in the hole.
Allow to dry for three hours.
Signature™, ISX, and QSX15 Cylinder Block and Liner Seats
WARNING
personal injury.
Remove the capscrew and jam nut.
If necessary, file or machine the top of the thread insert so
it is flush with the cylinder block surface.
Make certain that the inner diameter of the thread insert
is free of burrs. Remove any file shavings or debris with
the chip vacuum.
For applications where the thread insert is recessed into

a counterbore, an end mill or a machine cutter will be
necessary to remove the excess length of the insert and
restore the alignment of counterbore.
Cylinder Block and Liner Seats

(001-027)
Leak Test
WARNING
WARNING
Drain the engine lubricating oil. Refer to Procedure
007-037.
007-025.
Cylinder Block and Liner Seats Signature™, ISX, and QSX15
Remove the lubricating oil suction tube. Refer to

Procedure 007-035.

001-089.
Pressurize the engine cooling system. Refer to Procedure

008-018.
NOTE: Apply the air pressure 15 minutes before
inspecting the cylinder liner seats. Be sure the system is
holding air pressure before beginning inspection.
Air Pressure: 138 kPa [ 20 psi ]
Inspect the outside circumference of the cylinder liners

and the area below the cylinder liner seats in the cylinder
block for coolant leaks.
If a leak is found:
• Remove and inspect the cylinder liners. Refer to
Procedure 001-028.
• Inspect the cylinder block liner bore area. If fretting
or wear is found, the cylinder block must be
replaced.
Signature™, ISX, and QSX15 Cylinder Block and Liner Seats
Install the block stiffener plate. Refer to Procedure

001-089.

007-035.
Fill the engine with lubricating oil. Refer to Procedure

007-037.
Cylinder Block and Liner Seats Signature™, ISX, and QSX15
Prime the lubricating oil system. Refer to Procedure

007-037.
Operate engine to normal operating temperature and

check for leaks.
Procedure 014-013.

Preparatory Steps
WARNING
Wait until the coolant temperature is below 50° C
WARNING
WARNING
WARNING
WARNING
ingestion and prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
in Section 8.
Section 7.
• Remove the cylinder head. Refer to Procedure
• Remove the piston and connecting rod assemblies.
Remove
The cylinder liners can be removed by using either:
• Cylinder liner puller (universal), Part Number 3163745,
and puller plate (S600), Part Number 3162462.
• Cylinder liner puller (universal), Part Number 3376015.
CAUTION
The cylinder puller must be installed and used as
described to reduce the possibility of damage to the
cylinder block. The puller plate must be parallel to the
main bearing saddles and must not overlap the
cylinder liner outside diameter.
Insert the cylinder liner puller onto the top of the cylinder
block.
The cylinder liner puller must be centered on the top of

the cylinder block.
Turn the puller jackscrew clockwise to loosen the cylinder
liner from the cylinder block.
Use both hands to remove the cylinder liner.
Remove and discard the o-ring seals.
Use Dykem™, or equivalent, to place a mark on the intake

air side of the cylinder liner to show cylinder liner
orientation.
Use Dykem™, or equivalent, to mark the cylinder number

on each cylinder liner.

CAUTION
silicon particles from emery cloth or sand paper can
be damaged.
Use a soft wire brush to clean the flange seating area.
7448, Part Number 3823258, or equivalent, to remove the
remaining scale and rust.
WARNING
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high
pressure water.
WARNING
personal injury.
Use solvent or steam clean the cylinder liners and dry with
compressed air.
Use clean 15W-40 oil to lubricate the inside circumference
of the cylinder liners.
Allow oil to soak into the cylinder liner for 5 to 10 minutes.
Use lint-free paper towels to wipe the oil from the inside
of the cylinder liners.
Continue to lubricate the inside of the cylinder liners and
wipe clean until the paper towel shows no gray or black
residue.
Inspect the cylinder liners for cracks on the inside and

outside circumferences.
Inspect for cracks under the cylinder liner flange.

Cracks can also be detected by using either magnetic
inspection or dye method.
Inspect the outside circumference for excessive corrosion

or pitting.
Cylinder liners with pitting generally can not be used.
However, if the pitting is light and can be removed with
fine emery cloth, the cylinder liner can be used.
Cylinder Liner Pitting Depth

mm in
1.60 MAX 0.060
Inspect the inside circumference for vertical scratches

deep enough to be felt with a fingernail.
If a fingernail catches in the scratch, the cylinder liner
must be replaced.
Inspect the inside circumference for scuffing or scoring.
Inspect the inside diameter for cylinder liner bore

polishing.
A moderate polish (A) produces a mirror finish in the worn
area with traces of the original hone marks or an indication
of an etch pattern.
A heavy polish (B) produces a bright mirror finish in the
worn area with no traces of hone marks or an etch pattern.
Replace the cylinder liner if a heavy polish is present over

20 percent of the piston ring travel area or 30 percent of
the piston ring travel has both moderate and heavy polish
and one half (15 percent) is heavy polish.
Use a dial bore gauge to measure the cylinder liner inside

diameter in four places, 90 degrees apart at the top and
bottom of the piston travel area.
Cylinder Liner Inside Diameter

mm in
137.14 MAX 5.40
Measure the cylinder liner top press fit area outside

diameter.
Cylinder Top Press Fit Outside Diameter

mm in
160.98 MAX 6.34
Install
CAUTION
same design.
There are two different designs of cylinder liners used.
The design used in a particular engine is dependent on
the engine's production vintage.
14022615 have groove-top cylinder liners. They are
characterized by a groove machined into the top surface
of the cylinder liner flange.
Engines with serial number 14022615, and after, are
assembled with flat-top cylinder liners. They are
characterized by a cylinder liner flange that is flat, except
for the fire dam.
Make sure the cylinder block and all parts are clean before
assembly.
Lubricate the two cylinder liner o-ring seals with vegetable
oil prior to assembly.
Install the two o-ring seals onto the cylinder liner.
CAUTION
same design.
Install the cylinder liner into the cylinder block.
When acceptable and used cylinder liners are installed,
rotate the cylinder liner 90 degrees from its original
position in the engine. The thrust and anti-thrust surfaces
must face the front and back of the cylinder block.
Use cylinder liner installation kit, Part Number 3162461,
to seat the liner.
If the cylinder liner does not seat properly, remove it and
inspect the cylinder liner bore seat and cylinder liner for
nicks, burrs, or dirt.
Install the cylinder liner again.
Measure
Liner Protrusion
Because of design differences, the cylinder liner's position
(relative to the cylinder top deck) will be different.
For groove-top cylinder liners, a recession measurement
is taken. This measures the depth of the groove relative
to the cylinder block deck regardless of the flange or fire
dam height.
For flat-top cylinder liners, a cylinder liner protrusion

measurement is taken which is the height of the cylinder
liner flange above the cylinder block surface regardless of
the flange or fire dam height.
Regardless of the cylinder liner design, the measurement
technique will be the same.
The cylinder liner measurement must be checked before

installing the pistons and connecting rods.
The cylinder liner measurement must be made with the
cylinder liners in the clamped state.
Install and tighten the cylinder liner installation tool.

clamped state at the intake side three times and average
the readings.
Measure the clamped state of the exhaust side three times
and average the readings.
Cylinder Liner Recession (Groove-Top Cylinder

Liners)
mm in
0.36 MIN 0.014
0.51 MAX 0.019
Cylinder Liner Protrusion (Flat-Top Cylinder Liners)

mm in
0.18 MIN 0.007
0.33 MAX 0.014
If the cylinder liner measurement on either the intake or
exhaust side is not within specifications, the cylinder liner
must be replaced.
For flat-top cylinder liners only:

• The difference between the lowest cylinder liner and
the highest cylinder liner can not be greater than 0.102
mm [0.004 in].
• The maximum allowable difference between adjacent
cylinders is 0.051 mm [0.002 in].
• The protrusion must be within 0.0381 mm [0.0015 in]
around any cylinder.
Before installing the piston and connecting rod

assemblies, wipe the inside of the cylinder liners.Use a
clean cloth with 15W-40 oil.
Finishing Steps
WARNING
• Install the piston and connecting rod assemblies. Refer
• Install the oil suction tube. Refer to Procedure 007-035
in Section 7.
• Install the cylinder head. Refer to Procedure 002-004
in Section 2.
• Fill the engine with clean lubricating oil. Refer to
Section 8.
• Operate the engine and check for leaks.

Preparatory Steps
WARNING
WARNING
• Before removing gears, read Engine Base Timing.
• Remove the water pump drive belt. Refer to
Procedure 008-003.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the fan hub assembly. Refer to Procedure
008-036.
• Remove the crankcase breather tube. Refer to
Procedure 003-018.
• Remove the alternator. Refer to Procedure 013-001.
• Drain coolant. Refer to Procedure 008-018.
• Remove the crankcase breather tube. Refer to
Procedure 003-001.
• Remove the upper and lower gear covers. Refer to
Procedures 001-079 and 001-080.
• Remove the water pump. Refer to Procedure
008-062.
• Remove the valve and injector camshaft scissor
gear. Refer to Procedure 001-088.
• Remove the adjustable idler gear. Refer to
Procedure 001-088.
• Remove the air compressor. Refer to Procedure
012-014.
• Remove the lower idler scissor gear. Refer to
Procedure 001-088.
• Remove the crankshaft position sensor and
capscrews from front of oil pan.
• Remove the retaining brace bracket. Refer to
Procedure 001-081.
• Remove the accessory bracket. Refer to Procedure
001-082.
Remove
WARNING
Remove two capscrews and install two guides.

Remove the housing and gasket.
Discard the gasket.
Remove the guide studs.
CAUTION
Immediately upon removal of the front gear housing a
plug must be inserted into the cylinder block oil
passage drilling. Failure to insert the oil passage plug
can result in a bearing failure, crankshaft failure, or
both.
protective plug kit, Part Number 4918319. This plug is
Insert the plug into the front oil passage.
the gasket surface.
WARNING
WARNING
When using a steam cleaner, wear protective clothing
and safety glasses, or a face shield. Hot steam can
cause serious personal injury.
WARNING
personal injury.
CAUTION
If the oil passages are not plugged before cleaning, a
crankshaft failure can occur.
Clean gasket surfaces by hand with a gasket scraper or
cleaning pad, Part Number 3823258. If the gasket material
residue can not be felt with a finger, the surface is ready
to accept the new gasket.
Use steam or solvent to clean the gear housing and dry
with compressed air.
WARNING
personal injury.
Use compressed air to clear the oil galley to the air
compressor and oil pump of any obstructions.
Inspect the gear housing for cracks or other damage.

Inspect the seal grooves of the housing for debris or
damage.
Install
Remove the protective plug from the cylinder block oil
passage. Make sure no debris enters the lubrication
system. Use a clean shop towel, carefully wipe out the oil
passages.

Install a new gear housing mounting gasket.
The gear housing has the words “Special Capscrew” cast

into the housing at the number 1 mounting location (see
illustration). This capscrew must be the short head
capscrew to prevent contact between the capscrew and
the idler gear.
WARNING
Install the gear housing.
Install the 18 mounting capscrews.

Four different length capscrews are utilized on the front
gear housing. Use the table below to identify the
capscrews and their mounting locations.
Capscrew Mounting Location
Location Size Quantity
14 M10 x 1.5 x 93 1
18, 19, 20 M10 x 1.5 x 70 3
1 M10 x 1.5 x 21.8 (Special 1
Short Head)
All remaining M10 x 1.5 x 2.5 15
Remove the guide studs and install two capscrews.

Torque Value:
All Capscrews Step1 20 N•m [ 15 ft-lb ]
Except (1)
Torque Value:
Capscrew (1) Step1 20 N•m [ 15 ft-lb ]
Piston Signature™, ISX, and QSX15
Finishing Steps
WARNING
• Install the accessory bracket. Refer to Procedure
001-082.
• Install the retaining brace bracket. Refer to
Procedure 001-081.
• Install the crankshaft position sensor. Refer to
Procedure 019-042 in the Signature, ISX, and
QSX15 Service Manual, Bulletin 4021334. Install the
capscrews at the front of the oil pan.
• Install the lower idler scissor gear. Refer to
Procedure 001-088.
• Install the air compressor. Refer to Procedure
012-014.
• Install the adjustable idler gear. Refer to Procedure
001-088.
• Install the valve and injector camshaft scissor gear.
• Install the water pump. Refer to Procedure 008-062.
• Install the upper and lower gear covers. Refer to
Procedures 001-079 and 001-080.
• Install the crankcase breather tube. Refer to
Procedure 003-001.
• Fill coolant. Refer to Procedure 008-018.
• Install the alternator. Refer to Procedure 013-001.
Procedure 003-018.
• Install the fan hub assembly. Refer to Procedure
008-036.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the water pump drive belt. Refer to Procedure
008-003.
• Operate the engine to normal operating temperature
and check for leaks.
Piston (001-043)
General Information
Some Signature, ISX, and QSX15 engines are equipped
with articulated pistons.
The articulated piston is a two-piece piston consisting of
a forged steel crown and an aluminum skirt.
An open chamber oil gallery is located on the underside
of the crown of the piston to provide more oil contact with
the piston and give better piston cooling. Piston cooling
nozzle targeting is critical because the oil is captured in
shaker trays.
Signature™, ISX, and QSX15 Piston
Some engines are equipped with single-piece pistons.

The single-piece piston is a one-piece piston, that does
not have a bushing and is forged from a high-strength,
alloy steel.
A cover plate, that is not removable, is located on the
underside of the piston to capture oil and cool the piston.
Do not remove this cover plate under any circumstances.
CAUTION
All pistons within a given engine must be of the same
design - all are to be either the articulated design or
the single-piece design. Do not mix piston designs in
the same engine. Single-piece pistons must have
drilled rods and rod bearings. Articulated pistons can
Preparatory Steps
All Applications
Remove the piston and connecting rod assemblies from
the engine. Refer to Procedure 001-054 (Piston and
Connecting Rod Assembly) in Section 1.
Disassemble the piston and connecting rod assembly.

Refer to Procedure 001-054 (Piston and Connecting Rod
Assembly) in Section 1.

Articulated Piston
WARNING
CAUTION
To reduce the possibility of damage to the piston
crown, the cleaning solvent must be approved for
bushing material. If necessary, brush the piston
crowns with a soft non-metallic brush. A metallic
brush can damage the piston ring grooves.
It is only necessary to remove the carbon buildup. It is
not necessary to make the crown appear to be new.
CAUTION
When using walnut shell blast to clean steel piston
crowns, use the minimum recommended pressure
and do not concentrate the blast in any one area for
extended lengths of time. Make sure the pin bore area
is protected from the blast so as not to damage the
surface finish. Do not use walnut shell blast to clean
aluminum piston skirts.
Do not use glass or plastic bead media to clean the piston
crowns.
Carbon deposits can be cleaned from the piston crowns
by soaking in an approved solution and/or by blasting with
walnut shell media.
Soak steel pistons for at least 30 minutes in an approved
cleaning solvent for steel and for brushing material. Use
a hot soapy solution with a non-metallic brush to remove
carbon deposits.
For best results, soak the pistons several hours or
overnight.
WARNING
CAUTION
If necessary, brush the piston crowns with a soft non-
metallic brush. A metallic brush can damage the
surface finish. Do not use glass, plastic, or walnut
media to clean the aluminum piston skirts. This can
damage the pin bore surface finish or prevent the
rings from seating correctly in the ring grooves.
Soak aluminum pistons for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for
aluminum. Use a hot soapy solution with a non-metallic
brush to remove carbon deposits. Anything more abrasive
will damage the surface finish.
WARNING
personal injury.
WARNING
Use steam to clean the pistons.
Single-Piece Piston
CAUTION
Never, under any circumstances, remove the flat, oil
cover plate located on the underside of the single-
piece pistons.
WARNING
CAUTION
To reduce the possibility of damage to the piston, the
cleaning solvent must be approved for bushing
material. If necessary, brush the pistons with a soft
non-metallic brush. A metallic brush can damage the
piston ring grooves.
It is only necessary to remove the carbon buildup. It is
not necessary to make the crown appear to be new.
CAUTION
When using walnut shell blast to clean steel pistons,
use the minimum recommended pressure and do not
concentrate the blast in any one area for extended
lengths of time. To prevent damage of the surface
finish, make sure the pin bore area is protected from
the blast.
Do not use glass or plastic bead media to clean the piston
crowns.
Carbon deposits can be cleaned from the pistons by
soaking in an approved solution and/or by blasting with
walnut shell media.
Soak steel pistons for at least 30 minutes in an approved
cleaning solvent for steel and for brushing material. Use
a hot soapy solution with a non-metallic brush to remove
carbon deposits.
For best results, soak the pistons several hours or
overnight.
WARNING
CAUTION
If necessary, brush the pistons with a soft non-
metallic brush. A metallic brush can damage the
surface finish.
WARNING
bodily injury.
WARNING
Use steam to clean the pistons.
Make certain there is not walnut shell blast media
remaining between the oil cover plate and the piston.
CAUTION
Do not use pistons with cracks. If the crown is
cracked, it must be replaced. Failure to replace the
damaged piston can cause serious engine damage.
Inspect the piston bowl for cracks or damage.
Inspect the piston pin bore for cracks, scratches, galling,
dents, or other damage.
Inspect the piston second land for scuffing. Refer to the
Single Piece, Open Skirt Piston Reuse Guidelines,
Service Bulletin 4021925.
CAUTION
Do not use pistons with cracks. If the skirt is cracked,
it must be replaced. Failure to replace the damaged
piston can cause serious engine damage.
Inspect the piston skirt pin bore (1) and sides (2) for cracks
or damage.
Also inspect the skirt for scratches. In general, if the
scratches can be felt with a fingernail, do not reuse the
skirts. Refer to Articulated Piston Skirt Reuse Guidelines
for Signature, ISX, and QSX15 Engines, Service Bulletin
4021468, if additional information is needed.
The ring groove can be inspected with a new ring and a

feeler gauge.
Hold a new ring in the groove even with the outside
diameter of the piston. Install a 0.15-mm [0.006-in] feeler
gauge. If the feeler gauge enters the groove without
resistance, there is too much wear. Replace the piston.
Measure the piston pin bore inside diameter on both the

crown and skirt on articulated pistons.
Articulated Piston Pin Bore Inside Diameter (Crown)

mm in
63.56 MIN 2.502
63.58 MAX 2.503
Articulated Piston Pin Bore Inside Diameter (Skirt)

mm in
63.513 MIN 2.5005
63.525 MAX 2.5010
The piston pin bore inside diameter is not a re-use criteria
measurement to be taken on single-piece pistons.
Inspect the piston pin for scratches, grooves, or other

damage. Do not reuse if visually unacceptable.
Measure the piston pin outside diameter. Piston pin
outside diameters are the same between articulated and
single-piece piston pins.
Piston Pin Outside Diameter

mm in
63.4670 MIN 2.4987
63.4999 MAX 2.5000
Also measure the piston pin lengths. Single-piece piston
pins are shorter than articulated piston pins.
Articulated Piston Pin Length

mm in
109.5 MIN 4.311
110.0 MAX 4.331
Single-Piece Piston Pin Length

mm in
84.6 MIN 3.331
85.1 MAX 3.350
Finishing Steps
All Applications
Assemble the piston and connecting rod. Refer to
Procedure 001-054 (Piston and Connecting Rod
Install the piston and connecting rod assembly. Refer to

Procedure 001-054 (Piston and Connecting Rod
Procedure 014-013 (Aftertreatment Testing) in Section 14.

Preparatory Steps
WARNING
WARNING
007-025.

Procedure 007-035.

001-089.
Piston Cooling Nozzle Signature™, ISX, and QSX15
Remove
The crankshaft must be rotated to allow access to remove
all the nozzles.
Remove the piston cooling nozzle capscrews and nozzles.
Install
CAUTION
Properly align the nozzles in the locator notch before
tightening the capscrews. Damage to the engine can
occur.
The crankshaft must be rotated to allow access to install
all the nozzles.
Install the nozzle, washers, and capscrews.
Finishing Steps
Install the block stiffener. Refer to Procedure 001-089.

007-035.

007-035.

007-037.
Fill the engine with clean lubricating oil. Refer to

Procedure 007-037.

check for oil leaks.

Remove
Articulated Piston
Remove the piston rings.

Single-Piece Piston
CAUTION
Do not over-expand the second piston ring on single-
piece pistons.
Use a universal ring expander to remove the second
piston ring on single-piece pistons.

Measure
Articulated Piston
To check the ring gap, install the piston rings into the
cylinder liner in which they were used below the ring
reversal area.
Use the top part of the piston to correctly position the ring
in the liner.
Use a feeler gauge to inspect the ring end gap.
Articulated Piston Ring Gap

mm in
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second 1.87 MIN 0.074
2.13 MAX 0.084
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Single-Piece Piston
To check the ring gap, install the piston rings into the
cylinder liner in which they were used below the ring
reversal area.
Use the top part of the piston to correctly position the ring
in the liner.
Use a feeler gauge to inspect the ring end gap.
Single-Piece Piston Ring Gap

mm in
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second (full blitz 0.97 MIN 0.038
chrome rings) Engine
assembled prior to
engine serial number
79383594.
1.23 MAX 0.048
Second (semi inlaid 1.87 MIN 0.074
rings) Engine
assembled prior to
engine serial number
79383594.
2.13 MAX 0.084
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Install
Articulated Piston
CAUTION
Place the connecting rod in a vise to hold the assembly in

piston.
either orientation.

For articulated pistons, the top piston ring (1) is a keystone
ring with no twist or cutback notch.
The intermediate ring (2) is a positive twist design with a
cutback notch (3) on the topside and a two-degree taper
face.

Single-Piece Piston
CAUTION
Install the connecting rod in a vise to hold the assembly in

piston.
either orientation.
For single-piece pistons, use a universal piston ring
expander to install the second ring into the piston.

The single-piece ring set is similar to the articulated ring
set, with the exception of the second ring. The second ring
has a rectangular cross-section (2) with an angled cut (3)
on the upper side of the inner diameter to induce a positive
twist. This design improves the slobber-resistance of the
ring pack.



Preparatory Steps
Procedure 008-003.
013-005.

Fan or PTO
• Remove the fan. Refer to the OEM service manual.
• Remove the fan and water pump drive belts. Refer
013-005.

Fan or PTO
• Remove the fan. Refer to the OEM service manual.
• Remove the fan and water pump drive belts. Refer
013-005.
• Remove the fan and water pump tensioner. Refer to
Procedure 008-080.
Remove
CAUTION
vibration damper(s). These tools can damage the
vibration damper(s).
Remove two of the vibration damper(s) and crankshaft
pulley retaining capscrews.
Remove the pulley and vibration damper(s).

Fan or PTO
Remove the crankshaft adapter (1) from the pulley (2).

CAUTION
vibration damper.
Remove the remaining four capscrews.
spacer (2) and second vibration damper (1).

Fan or PTO
Remove two of the pulley capscrews.
CAUTION
vibration damper.
spacer (2), and second vibration damper (1).


All Applications
WARNING
Clean the vibration damper(s) with a solvent cleaner.
Always replace the vibration damper(s) after a crankshaft

nose failure. Crankshaft nose breakages are primarily
caused by excessive torsional activity.
The vibration damper must always be measured after a
failure involving broken gears in the front gear train.
Check the mounting web for cracks.
Check the housing for dents or raised surfaces.
The vibration damper must be replaced if the mounting
web is cracked or the housing has dents or raised
surfaces.
Remove the paint on both sides of the vibration damper in

four locations spaced 90 degrees apart.
Measure and record the thickness at two points at each of

the four locations.
The difference between any two of the eight
measurements must not exceed 0.25 mm [0.010 in].
Spray the vibration damper with spot check developer,

Type SKD-NF, or equivalent.
Heat the vibration damper in an oven (rolled lip side down)
at 93°C [200°F] for two hours.
WARNING
Wear protective gloves when handling parts that have
been heated to reduce the possibility of personal
injury.
Remove the vibration damper from the oven and check for
fluid leakage.
If there is leakage, replace the vibration damper.
Install
vibration damper, and the pulley are clean, dry, and free
from burrs.
Align the dowel pin in the crankshaft wit the dowel hole in
the vibration damper.
Install the vibration damper, pulley, and clamping plate
onto the guide plate.

capscrews.

Fan or PTO

the guide studs.

Install four capscrews.
capscrews.
Tighten the six capscrews in a star pattern.
Install the crankshaft adapter (1).

Make sure the crank shaft adapter sets flush against the
pulley (2).

Fan or PTO

the guide studs.

capscrews.
Tighten the 12 capscrews in a star pattern.
Eccentricity Check
All Applications
Clean the outside surface of the vibration damper.
To measure the vibration damper eccentricity (out of
round), install a dial indicator onto the gear cover as
indicated.
Rotate the crankshaft with the accessory driveshaft one
complete revolution (360 degrees), and record the total
indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
must be replaced.
Wobble Check
All Applications
To measure wobble (face alignment), install a dial
indicator as shown.
Push the crankshaft to the front or rear of the engine and
set the indicator to “0” (zero).
Rotate the crankshaft one complete revolution (360
degrees) while maintaining the position of the crankshaft,
either toward the front or rear of the engine.
Record the total indicator movement.
Vibration Damper Wobble Measurement

mm in
0.28 MAX 0.011
must be replaced.
Finishing Steps
Procedure 008-002.
• Install alternator drive belt. Refer to Procedure
013-005.
• Operate the engine and check for proper operation.

Fan or PTO
013-005.
Procedure 008-002.
• Install the fan. Refer to the OEM service manual.

Fan or PTO
• Install the fan and water pump belt. Refer to
Procedure 008-080.
013-005.
Procedure 008-002.
• Install the fan. Refer to the OEM service manual.

(001-054)
Preparatory Steps
WARNING
To reduce the possibility of personal injury, reduce
the possibility of direct contact of hot oil with your
skin.
WARNING
reproductive toxicity. Reduce the possibility of
inhalation of vapors, ingestion, and prolonged contact
with used engine oil. If not reused, dispose of in
accordance with local environmental regulations.
WARNING
WARNING
WARNING
• Drain the lubricating oil. Refer to Procedure 007-037.
• Drain the cooling system. Refer to Procedure
008-018.
007-025.
Procedure 007-035.
001-089.
Procedure 001-046.
• Remove the connecting rod cap. Refer to Procedure
001-005.
• Remove the cylinder head. Refer to Procedure
002-004.
Remove
WARNING
cleaning, following the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.
WARNING
CAUTION
silicon particles from emery cloth or sandpaper can
be damaged.
7448, Part Number 3823258, or equivalent, and solvent to
remove the carbon.
Install two connecting rod guide pins, Part Number

3376038.
Use a T-handle piston pusher to push the connecting rod
away from the crankshaft.
Push the connecting rod until the piston rings are outside
of the top of the cylinder liner.
Remove the upper connecting rod bearing.

Mark the cylinder number and the letter U (upper) on the
flat surface of the bearing tang.
Use both hands to remove the piston and connecting rod

assembly.
reused.
CAUTION
To reduce the possibility of engine damage all pistons
within a given engine must be of the same design - all
are to be either the articulated design or the single-
piece design. Do not mix piston designs in the same
engine. Single-piece pistons must have drilled rods
and connecting rod bearings. Articulated pistons can
Place the connecting rod and piston assemblies in a

container to protect them from damage.
A unique number (not cylinder number) is stamped on the

connecting rod and matching connecting rod cap. When
the connecting rods and connecting rod cap are installed
in the engine, the numbers on the connecting rod and cap
must match and be installed on the same side (the
exhaust side) of the engine.
Disassemble
Articulated Piston
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
CAUTION
Do not use a hammer to remove the piston pins. The
piston can distort, causing it to seize in the liner.
If the piston pin can not be easily removed by hand, place
the piston and connecting rod assembly in a container of
water. Heat the piston in boiling water for 15 minutes.
Use a blunt tool to push the piston pin from the piston and
connecting rod assembly.
CAUTION
When the piston pin is removed from an articulated
piston, the skirt will separate from the crown. Use
care to prevent damage to the piston.
If they are to be reused, mark the number of the cylinder
that the piston, crown, skirt, and pin were removed from
on the parts to make sure they are installed in the correct
cylinder.
Single-Piece Piston
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
CAUTION
Do not use a hammer to remove the piston pins. The
If the piston pin can not be easily removed by hand, place
the piston and connecting rod assembly in a container of
water. Heat the piston in boiling water for 15 minutes.
Use a blunt tool to push the piston pin from the piston and
connecting rod assembly.

reused.
Assemble
Articulated Piston
All pistons (bushed and nonbushed) must be properly
lubricated prior to assembly.
For all pistons, use a clean, lint free cloth to apply a heavy
film of 85W-140 gear oil with EP additive to the following
locations:
• Piston pin bore inside diameter in the piston crown
• Piston pin bore inside diameter in the piston skirt
• Rod bushing inside diameter
• Piston pin.
Assemble the piston crown into the piston skirt.
CAUTION
The retainer snap ring must be seated completely in
the piston pin groove to prevent engine damage
during engine operation.
It is not necessary to heat the articulated pistons before
assembly. The piston pin is slip fitted.
The crown and skirt can only be assembled in one
position.
Install a new snap ring into one piston pin bore of each
piston skirt.
If the pistons are being reused, the crown, skirt, and pin
must be matched as they were when they were removed.
Position the skirt over the piston crown.
CAUTION
Do not use a hammer to install the piston pin. The
CAUTION
The lock tang on the connecting rod must be in line
with the cooling nozzle notch in the piston skirt and
on the side opposite the deep valve pocket of the
piston crown. Failure to follow this step will cause
CAUTION
The piston pin for the articulated piston is longer in
length than the pin for single-piece pistons. Do not
use articulated piston pins in single-piece pistons.
Likewise, do not use single-piece pins in articulated
pistons.
Align the pin bore of the connecting rod with the pin bore
of the piston skirt and crown, and install the piston pin.
On articulated pistons, make sure the locking tang on the
connecting rod is on the same side as the cooling nozzle
notch in the piston skirt and opposite the deep valve
pocket on the crown.
CAUTION
The snap ring must be seated completely in the piston
groove to prevent engine damage during engine
operation.
Install a new snap ring into the piston pin bore.
Install piston rings. Refer to Procedure 001-047.
Single-Piece Piston
CAUTION
The retainer snap ring must be seated completely in
the piston pin groove to prevent engine damage
during engine operation.
Install a new snap ring into one piston pin bore of each
single-piece piston.
If the pistons are being reused, the single-piece piston and
pin must be matched as they were when they were
removed.
CAUTION
Do not use a hammer to install the piston pin. The
CAUTION
The lock tang on the connecting rod must be in line
with the cooling nozzle notch in the piston skirt and
on the side opposite the deep valve pocket of the
piston crown. Failure to follow this step will cause
CAUTION
Generously coat both single-piece piston pin bores
with a heavy weight gear oil, such as 85W-140 EP,
when assembling single-piece pistons. Also lubricate
the connecting rod bushing. If gear oil is not available,
Lubriplate, Part Number 3163086, is permissible.
Failure to adequately lubricate the pin joint can result
in extensive engine damage, particularly with single-
piece pistons.
Use clean 85W-140 oil to coat the piston pin.
The single-piece piston requires a drilled connecting rod

and a drilled upper connecting rod bearing to lubricate the
pin joint. Do not assemble a single-piece piston with a
non-drilled connecting rod nor a non-drilled connecting
rod bearing. Make certain when assembling a single-piece
piston that the lubricating hole in the connecting rod
bearing lines up with lubricating hole in the connecting
rod.
CAUTION
The piston pin for single-piece pistons is shorter in
length than the pin for articulated pistons. Do not use
single-piece piston pins in articulated pistons.
Likewise, do not use articulated pins in single-piece
pistons.
On single-piece pistons, the locking tang on the

connecting rod is to be on the opposite side of the deep
valve pocket.
Install the piston pin.
CAUTION
The snap ring must be seated completely in the piston
groove to prevent engine damage during engine
operation.
Install a new snap ring into the piston pin bore.
Install the piston rings. Refer to Procedure 001-047.
Install
Immerse the piston in a container of clean 15W-40 oil.
Remove the piston from the container. Let the excess oil
drain from the piston.
Use piston ring compressor, Part Number 3164846, to

compress the rings.
The cylinder block and all parts must be clean before
assembly.
Inspect the cylinder liners for reuse. Refer to Procedure
001-028.
Use a clean, lint-free cloth to clean the connecting rods

and bearing shells.
Do not lubricate the backside of the bearing shells. The
operating clearance of the bearing will be reduced and the
bearing can be damaged during engine operation.
If new bearings are not used, the used bearings must be

installed on the same connecting rod from which they
were removed.
Install the upper bearing shell into the connecting rod.
The tang of the bearing shell (2) must be in the slot of the
cap (1). The end of the bearing shell must be even with
the cap mounting surface.
Use Lubriplate™ 105, Part Number 3163086, or

equivalent, to coat the entire inside circumference of the
bearing shell.
Apply a film of clean 15W-40 oil to the cylinder liner.
Install connecting rod guide pins, Part Number 3163097.

crankshaft so the connecting rod journal of the connecting
rod being installed is at bottom dead center.
CAUTION
Failure to align the deep valve pocket and the piston
skirt cooling nozzle notch correctly will result in
Align the piston crown deep valve pocket on the exhaust
side of the engine, and the piston skirt cooling nozzle
notch to the intake side of the engine.
If the deep valve pocket and the piston skirt cooling nozzle
notch are not on opposite sides, the piston and
connecting rod assembly are not assembled correctly.
Disassemble the piston and connecting rod and assemble
correctly.
Insert the connecting rod through the cylinder liner until
the ring compressor contacts the top of the liner.
Both articulated pistons and single-piece pistons have an

arrow on the top of the piston crown, which will point to
the front of the engine, when the piston is installed
properly.
CAUTION
Do not use a metal drift to push the piston into the
cylinder liner. The piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the
cylinder liner. Push the piston until the top ring is
completely in the cylinder liner.
If the piston does not move freely, remove the piston and
inspect for broken or damaged rings.
Use the nylon guide pins to align the connecting rod with
the crankshaft while pushing the piston and connecting
rod assembly into place.
Remove the nylon guide pins.
Finishing Steps
NOTE: When rebuilding an engine with single-piece
pistons that was originally built with articulated pistons,
stamp the dataplate with the letters SP. This will alert
future repair locations that this engine has been rebuilt
with single-piece pistons.
• Install the connecting rod cap. Refer to Procedure
001-005.
001-046.
001-089.
Procedure 007-035.
007-025.
• Install the cylinder head. Refer to Procedure
002-004.
007-037.
• Fill the coolings system with coolant. Refer to
Procedure 008-018.
• Fill the engine with clean lubricating oil. Refer to
Procedure 007-037.
Signature™, ISX, and QSX15 Crankshaft Tone Wheel
Crankshaft Tone Wheel (001-069)

Preparatory Steps
• Remove the vibration damper. Refer to Procedure
• Remove the crankshaft adapter. Refer to Procedure
• Remove the lower front gear cover. Refer to Procedure
Remove
Use care not to damage the crankshaft gear when
removing the tone wheel.
Use a suitable pry bar or a lady's foot to remove the tone
wheel from the crankshaft and discard the tone wheel.
Inspect
Inspect the crankshaft, crankshaft gear, and the tone
wheel alignment dowel for damage and replace
components as necessary.
Inspect the machined surfaces for scratches or nicks.
Inspect the tone wheel alignment dowel hole for damage.
If the dowel hole or the area surrounding the dowel hole
has been damaged, the crankshaft must be replaced.
Use a crocus cloth to remove scratches or nicks. If
scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with the crocus cloth, the
Inspect the crankshaft gear for excessive wear or damage.
Crankshaft Tone Wheel Signature™, ISX, and QSX15
Install
WARNING
heated.
Heat the tone wheel for 2 hours at 177°C [350°F] before
attempting the installation.
The tone wheel must be installed so the face labeled

"FRONT" faces away from the crankshaft gear.
The tone wheel is keyed to the crankshaft with a dowel.
The tone wheel alignment dowel slot on the inside
diameter of the tone wheel must align with the crankshaft
pin for proper installation.
The tone wheel must be installed within 30 seconds after
being removed from the oven.
Install the tone wheel so the slot on the inside diameter of
the tone wheel aligns with the tone wheel alignment pin.
Hold the tone wheel in position for approximately 90
seconds to allow the shrink fit to properly hold the
components.
Check the installation by attempting to insert a 0.25 mm

[0.010 in] feeler gauge between the crankshaft gear and
the tone wheel at 4 locations approximately 90 degrees
apart. If the feeler gauge can be inserted, the tone wheel
must be removed and replaced.
Finishing Steps
• Install the lower front gear cover. Refer to Procedure
• Install the crankshaft adapter. Refer to Procedure
• Install the vibration damper. Refer to Procedure

General Information
Idler Gear, Adjustable (001-077)

General Information
NOTE: Before installation or removal of any gears, you
must read Engine Base Timing. Refer to Procedure
001-088.

Preparatory Steps
All Applications
Procedure 008-003.
013-005.
• Remove the fan hub assembly. Refer to Procedure
008-036.
• Remove the breather tube and hose. Refer to
Procedure 003-001.
Remove
WARNING
Remove 16 capscrews and the upper gear cover.

Remove two capscrews and install two guide pins.
Remove the 14 vibration isolator capscrew assemblies.
WARNING
Remove the clamping plate and upper gear cover.

All Applications
WARNING
personal injury.
WARNING
WARNING
Use steam or solvent to clean the gear cover. Dry with
compressed air.
Clean the sealing surface on the rear face of the upper

gear cover and the seal groove on the gear housing.
Inspect the breather tube elbow and grommet. Refer to

Procedure 003-001.
Inspect the upper gear cover for cracks or damage.

If the cover is cracked, it must be replaced.
Put the upper gear cover on a flat surface and inspect it

for flatness.
It is an acceptable practice to use a mallet to straighten

an upper gear cover with minor bends.
If necessary, lay the gear cover on a flat surface and hit
the upper gear to remove minor bends.
Install
seal.
WARNING
Install the cover with 16 capscrews.


seal.
WARNING
Install two guide pins in the gear housing.
Install the front gear cover over the guide pins.
Install the clamping plate, if used.
Remove the two guide pins and install the last two
capscrews.
Finishing Steps
All Applications
008-036.
008-003.
013-005.
• Install the breather tube and hose. Refer to
Procedure 003-001.

Preparatory Steps
• Twist the oil filler connector counterclockwise and
remove
Section 8
013-005 (Drive Belt, Alternator) in Section 13
• Remove the crankshaft pulley and vibration damper
(s). Refer to Procedure 001-022 (Crankshaft Pulley)
in Section 1
• Remove the front crankshaft seal. Refer to
Procedure 001-023 (Crankshaft Seal, Front) in
Section 1.
Remove
NOTE: If the gear cover contains an o-ring seal groove for
the crankshaft seal and the seal needs to be replaced, the
lower gear cover must also be replaced. The new
crankshaft seal has the o-ring incorporated into the seal.
Remove the 15 capscrews and the lower gear cover.

NOTE: All lower gear covers have either a beveled half
groove or a full o-ring groove under the crankshaft seal
flange.
Full o-ring groove covers contain an o-ring in the lower
gear cover groove and were only used prior to June 5,
1999. The lower gear cover must be replaced if installing
a new seal.
Beveled half groove covers do not contain an o-ring and
only require replacement if damaged.
Signature™, ISX, and QSX15 Gear Cover, Lower
WARNING
personal injury.
WARNING
WARNING
personal injury.
Clean the sealing surface on the rear face of the lower
gear cover and seal groove on the gear housing.
Use steam or solvent to clean the lower gear cover. Dry
Inspect the lower gear cover for cracks or other damage.

If the cover is cracked, it must be replaced.
If the gear cover contains an o-ring groove for the
crankshaft seal and the cover is to be replaced, the
crankshaft seal must also be replaced.
Inspect the studs for damage. If the studs are damaged,
the cover must be replaced.
Place the lower gear cover on a flat surface and inspect it

for flatness.
It is an acceptable practice to use a mallet to straighten a

lower gear cover with minor bends.
If necessary, lay the gear cover on a flat surface and hit
the cover to remove minor bends.
Install
Install a new strip seal.
Orient the overlap joint to the upper left of the gear
housing as shown.
Use a small amount of RTV at the overlap joint of strip
seal.
NOTE: Do not tighten the capscrews until the new

crankshaft seal is installed. The crankshaft seal must be
installed first to locate the gear cover properly.
Position the lower gear cover with the 15 capscrews.
Hand-tighten the capscrews.
Install a new crankshaft seal. Refer to Procedure 001-023

(Crankshaft Seal, Front) in Section 1.
Signature™, ISX, and QSX15 Bracket, Retaining Brace
Tighten the 15 capscrews in the sequence shown.

Finishing Steps
WARNING
• Install the crankshaft pulley and vibration damper(s).
Refer to Procedure 001-022 (Crankshaft Pulley) in
Section 1
008-036 (Fan Hub, Belt Driver) in Section 8
013-005 (Drive Belt, Alternator) in Section 13
008-003 (Drive Belt, Water Pump) in Section 8
• Install the oil filler connector
Bracket, Retaining Brace (001-081)

Remove
Remove the two capscrews from the retaining brace
Bracket, Retaining Brace Signature™, ISX, and QSX15
Remove the two remaining capscrews, washers, and

retaining brace bracket from the cylinder head.

Remove the engine lifting bracket from the retaining
bracket.
Remove the retaining brace bracket and mounting

spacers (1).
Inspect for Reuse

Inspect the retaining brace bracket for cracks.
Signature™, ISX, and QSX15 Bracket, Retaining Brace
Install
NOTE: The two M10 x 1.5 x 25 capscrews attach the
bracket to the gear housing. The one M12 x 1.75 x 35
capscrew and washer attach the bracket to the cylinder
head through the engine lifting bracket. The one M12 x
1.75 x 30 capscrew and washer attach the bracket to the
cylinder head below the engine lifting bracket.
NOTE: Tighten the capscrews hand-tight.
Install the retaining brace bracket, four capscrews, and
two washers on the gear housing and cylinder head hand-
tight.
Tighten the two capscrews to the gear housing.

Tighten the two capscrews to the cylinder head.


Install the two mounting spacers (1) to the upper gear
cover.
Position the retaining brace bracket.
Install two capscrews into the threaded holes of the brace.
Hand tighten the capscrews.
Bracket, Retaining Brace Signature™, ISX, and QSX15
Install the capscrew into location (1) on the cylinder head.
Position the engine lifting bracket over the retaining brace

bracket and attach with the remaining capscrews (Nos. 2,
3, and 4).
Hand tighten the four capscrews.
Tighten the mounting spacer capscrews.

Tighten the four capscrews.

Signature™, ISX, and QSX15 Bracket, Accessory
Bracket, Accessory (001-082)

Remove
NOTE: Each nylon cover is attached to the engine by a
combination of push on and slide in tabs. The top two
covers are removed by first pulling (at the location marked
“Pull Here”) the bottom of the covers away from the engine
until the tabs are released, then sliding the covers upward
to remove them from the accessory bracket. The lower
cover is removed by pulling (at the location marked “Pull
Here”) the top of the cover away from the engine until the
tabs are released, then sliding downward.
Remove the three composite nylon covers.
Remove the OEM wiring harness and accessories

attached to the accessory bracket.
Disconnect the camshaft position sensor.

Remove the camshaft position sensor and capscrew.
Remove the four capscrews, the studded capscrew, and

the accessory bracket.
Bracket, Accessory Signature™, ISX, and QSX15

NOTE: Each nylon cover is attached to the engine by a
combination of push on and slide in tabs. The top two
covers are removed by first pulling (at the location marked
“Pull Here”) the bottom of the covers away from the engine
until the tabs are released, then sliding the covers upward
to remove them from the accessory bracket. The lower
cover is removed by pulling (at the location marked “Pull
Here”) the top of the cover away from the engine until the
tabs are released, then sliding downward.
Remove the three composite nylon covers.
Remove the OEM wiring harness and accessories

attached to the accessory bracket.
Remove the camshaft position sensor and capscrew.
Remove the three capscrews from the accessory bracket.

Remove the two mounting spacers from the accessory

bracket and upper gear housing.
Inspect for Reuse

Inspect the bracket for cracks in the bend radius.
Install
Liberally apply a heavy moly grease, Part Number
3824759, or equivalent, to the area of contact between the
brace and the cylinder head.
Install the accessory bracket, four capscrews, and
studded capscrew to the cylinder head, hand-tight.
Tighten the two capscrews to the gear housing.

Bracket, Accessory Signature™, ISX, and QSX15
Tighten the two capscrews and the studded capscrew to

the cylinder head.
Install the camshaft position sensor and the capscrew.

Connect the camshaft position sensor.
Install the OEM wiring harness and accessories to the

accessory bracket
NOTE: The top two covers are installed by sliding the

cover down into the slots on the accessory bracket, then
pushing the bottom of the cover toward the engine onto
the cover mounting tabs. Install the bottom cover by
sliding the cover upward into the slots on the accessory
bracket, mounted on the IFSM, then pushing the top of the
cover toward the engine onto the cover mounting tabs.
Install the three composite nylon covers.

Install the two mounting spacers to the accessory bracket
and upper gear housing using two capscrews.
Install the accessory bracket to the engine using three

capscrews.
Tighten the mounting spacer capscrews.

Install the camshaft position sensor and capscrew.

Connect the camshaft position sensor.
Install the OEM wiring harness and accessories to the

accessory bracket
NOTE: This step may not apply to Power Generation
applications.
NOTE: The top two covers are installed by sliding the

cover down into the slots on the accessory bracket, then
pushing the bottom of the cover toward the engine onto
the cover mounting tabs. Install the bottom cover by
sliding the cover upward into the slots on the accessory
bracket, mounted on the IFSM, then pushing the top of the
cover toward the engine onto the cover mounting tabs.
Install the three composite nylon covers.
NOTE: This step does not apply to Power Generation
applications.

General Information
Front Gear Assembly Configuration
Two front gear train combinations are currently utilized on
the Signature™, ISX, and QSX15 engines. Signature™,
ISX3, ISX2, and QSX15 engines use a scissor gear for the
lower idler gear and the injector cam gear. ISX1 does
not use a scissor gear at the idler location.
ISX2 engines built between January, 1999 and January,
2000 utilized a scissor gear for the lower idler gear only.
The injector cam gear was a straight cut spur gear, similar
to the ISX1. After January, 2000, the ISX2 has scissor
gears for both the cam and lower idler.
This procedure describes the removal, inspection, and
installation of the different gear combinations.
Front Gear Assembly without Scissor Gear

View shown is from left to right and top to bottom.
• Valve camshaft gear
• Injector camshaft gear
• Adjustable idler gear
• Lower idler gear
• Accessory gear
• Crankshaft gear.
Front Gear Assembly with Scissor Gear

View shown is from left to right and top to bottom.
• Valve camshaft gear
• Injector camshaft scissor gear
• Adjustable idler gear
• Lower idler scissor gear
• Accessory gear
• Crankshaft gear.
Scissor Gear Definitions
WARNING
Do not attempt to remove any gears before reading
scissor gear definitions. Serious personal injury or
engine damage can result if instructions are not
followed.
The following terms describe the conditions of the scissor
gears for removal, installation, and operation.
Unloaded:
The gear will be unloaded when removing, installing, and
setting gear backlash.
Unload the gear by backing out two gear adjusting screws
until the gear teeth align.
The idler scissor gear is loaded when the gear backlash
is set.
Loaded:
The gear teeth are loaded (functional) and are spread
between the mating gear teeth.
The gear is loaded by tightening all of the adjusting
screws. The gear teeth will be spread and no movement
will be felt against the valve cam gear. The gear will be in
the loaded condition for engine operation.
Preparatory Steps
All Applications
QSX15 engines are equipped with dual vibration dampers.
The crank pin mark is located on the damper closest to
the engine.
Rotate the crankshaft clockwise until the ”insert pin”
mark on the outside diameter of engine vibration damper
is aligned with the mark on the gear housing.
Insert the pin in the hole in the pin boss.

The green band on the timing pin will be lined up with the
surface of the timing pin boss of the block.
The pin is not correctly seated in the crank notch if the
green band is either completely visible outside the block,
or is not visible at all.
Lock the crankshaft in place with the crankshaft locking
pin, Part Number 3163020.
Remove the rocker lever cover and gasket.Refer to

Procedure 003-011 (Rocker Lever Cover) in Section 3.
Disconnect and remove the engine brake wiring

harness.Refer to Procedure 020-015 (Engine Brake
Wiring Harness) in Section 20.
Removing the rocker lever shafts removes the load from

the camshafts. This allows the camshafts to be rotated
when installing the timing wedges and the camshaft gears
are not installed.
Remove the rocker lever shafts.Refer to Procedure
003-009 (Rocker Lever Assembly) in Section 3.

plug.
It will be helpful to push the gear cover plug out from the
rear. It is not necessary to remove the lower gear cover to
push out the plug.
Remove the upper gear cover.Refer to Procedure 001-079

(Gear Cover, Upper) in Section 1.
Remove the lower gear cover, if needed.Refer to
Procedure 001-080 (Gear Cover, Lower) in Section 1.
Remove
Valve Camshaft Gear
during removal of the valve camshaft gear. To unload the
gear, two of the gear screws must be backed out far
enough to allow the teeth on the scissor gear to be aligned.
Unload the injector camshaft scissor gear.
Remove the valve camshaft gear mounting capscrew and
washer.
Early production engines were not equipped with puller

holes in the valve camshaft gear. A 3-jaw gear puller
must be used for gears that do not have puller holes. The
injector and valve gear puller, Part Number 3163069, can
be used for gears that have puller holes.
Install the gear puller, Part Number 3163069.
Install the valve camshaft gear mounting capscrew
completely.
Loosen the capscrew two turns.
Use the gear puller to remove the valve camshaft gear
from the camshaft nose.
Remove the puller.

Do not completely remove the camshaft gear mounting
capscrew when the 3-jaw puller is used. The capscrew
serves as a safety catch by preventing the gear from
shooting off of the camshaft nose.
Remove the valve camshaft gear mounting capscrew,
spacer, and valve camshaft gear.
WARNING
WARNING
CAUTION
Remove the injector camshaft scissor gear mounting

Install the injector camshaft scissor gear mounting
capscrew. Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft scissor

gear off the camshaft taper.
Remove the injector camshaft scissor gear.
WARNING
WARNING
CAUTION
Remove the injector camshaft gear mounting capscrew

and washer.
Install the injector camshaft gear mounting capscrew.
Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft gear off
the camshaft taper.
Remove the injector camshaft gear.
WARNING
WARNING

The adjustable idler gear shaft can fall out when the
adjustable idler gear is removed.
Remove the retainer capscrews, retainer, gear, and
adjustable idler gear shaft.
Remove the mounting spacer.

The lower idler scissor gear must be unloaded during
removal. To unload the gear, two of the gear screws
Unload the lower idler scissor gear.
Remove the idler scissor gear capscrews.
Remove the retainer, gear, shaft, and thrust bearing.


Remove the idler non-scissor gear capscrews and
retainer.
Remove the gear, shaft, and thrust bearing.
Inspect for Reuse

Inspect the gear teeth on all gears for pitting, heavy wear,
or breakage.
Inspect the gear for cracking around the puller holes.
Replace any pitted, heavily worn, or damaged gear and
inspect the mating gear for associated damage.
Inspect the lower idler shaft and adjustable idler shaft for
heavy wear.
Measure the idler shafts outside diameter.
Lower Idler Shaft Outside Diameter

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997
Adjustable Idler Shaft Outside Diameter

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997
Inspect the lower idler gear bore and adjustable idler gear
bore for heavy wear.
Measure the inside diameter of the lower idler and
adjustable idler gear bores.
Lower Idler Gear Bore Inside Diameter

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035
Adjustable Idler Gear Bore Inside Diameter

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035
Install
Timing Wedges:
The timing code is located on the engine dataplate.
• First number - injector wedge
• Second number - valve wedge.
position.
Insert the correct timing wedge to lock the injector
camshaft. Lightly tap the top of the timing wedge with a
mallet to be sure it is properly seated.
WARNING
Do not drive the wedges into place. Engine damage
can occur.
position.
Insert the correct timing wedge to lock the valve camshaft.
Lightly tap the top of the timing wedge with a mallet to be
sure it is properly seated.

The lower scissor idler gear must be unloaded during
installation. To unload the gear, two of the gear screws
scissor idler gear.
Install the thrust bearing, shaft, and lower scissor idler
the engine.
The lower idler scissor gear front retainer plate is larger in

diameter than the adjustable idler retainer plate. The slots
in the plate go toward the scissor gear
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
above.
CAUTION
Load the lower idler scissor gear by tightening all of the
gear screws.

non-scissor idler gear.
Install the thrust bearing, shaft, and lower non-scissor idler
the engine.
The lower idler non-scissor gear front retainer plate is

larger in diameter than the adjustable idler retainer plate.
The slots in the plate go toward the scissor gear
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
above.

The spacer plate is doweled to the block with two standard
dowels.
Install the mounting spacer plate.
Apply Lubriplate™ to the spacer, shaft, and adjustable idler

gear.
It is possible to install the shaft in an incorrect orientation;
however, it will not be possible to set the gear backlash
correctly.
Install the spacer, shaft and adjustable idler gear. The
shaft must be installed with the word “TOP” (stamped on
the front face of the shaft) oriented toward the top of the
engine.
The adjustable idler front retainer plate is smaller in

diameter than the lower idler scissor gear retainer plate.
The slots on the retainer plate go toward the gear.
The adjustable idler gear is installed loosely, because it is
moved into its final position later in the timing process.
Install the retainer and capscrews. Finger-tighten the
capscrews and then loosen by one “flat,” which is 60
degrees.

CAUTION
scissor gear must be clean and dry prior to assembly.
Wipe off the taper surface with a clean lint-free cloth
and apply a thin coat of Loctite™ 609, Part Number
3823718, to the inside diameter of the camshaft gear.
Use care not to contaminate the joint with oil prior to
assembly or engine damage may occur.
during installation. To unload the gear, two of the gear

The injector camshaft scissor gear needs to be fully

Install the injector camshaft scissor gear loosely on the
The injector camshaft scissor gear mounting washer is
larger in diameter than the valve camshaft mounting
washer.

The injector camshaft scissor gear is still loose at this
point, to allow the adjustable idler gear to be properly
positioned.

CAUTION
non-scissor gear must be clean and dry prior to
assembly. Wipe off the taper surface with clean a lint-
free cloth and apply a thin coat of Loctite™ 609, Part
Number 3823718, to the inside diameter of the
camshaft gear. Use care not to contaminate the joint
with oil prior to assembly or engine damage may
occur.

The injector camshaft non-scissor gear needs to be fully

Install the injector camshaft non-scissor gear loosely on
The injector camshaft non-scissor gear mounting washer
is larger in diameter than the valve camshaft mounting
washer.

The injector camshaft non-scissor gear is still loose at this
point to allow the adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
CAUTION
The valve camshaft nose and valve camshaft gear
must be clean and dry prior to assembly. Wipe off the
taper surface with a clean lint-free cloth and apply a
thin coat of Loctite™ 609, Part Number 3823718, to the
inside diameter of the camshaft gear. Use care not to
contaminate the joint with oil prior to assembly or
engine damage may occur.

The valve camshaft gear needs to be fully engaged on the

camshaft nose taper, yet loose enough so it can rotate on
the camshaft nose.
Install the valve camshaft gear loosely on the camshaft
nose taper.
The valve camshaft mounting washer is smaller in
diameter than the injector camshaft scissor gear mounting
washer.

The valve camshaft gear is still loose at this point to allow
the adjustable idler gear to be properly positioned.
Adjust
Backlash (Scissor Gear Combinations)
CAUTION
Do not set backlash between the adjustable idler gear
and the lower scissor idler gear. Severe engine
damage can occur.
This backlash step works with the scissor type injector
camshaft gear and lower idler gear, and the non-scissor
injector camshaft gear with a scissor type lower idler gear.
The injector camshaft scissor gear must still be unloaded
during this step. To unload the gear, two of the gear
Insert, as shown, a narrow shim (0.25 mm [0.010 in]) into
the gear teeth mesh between the adjustable idler gear and
the wide (rear side) gear of the injector camshaft scissor
gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The gear backlash set procedure for engines that

have a non-scissor injector camshaft gear and a scissor
type lower idler gear is the same as that of engines that
utilize two scissor type gears.
gear toward the center of the engine (into mesh), so there
is no gap on either side of the shim.
in and out.
Backlash (Non-Scissor Gear Combinations)

plug. The plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown with the lower gear
cover removed.

teeth mesh between the adjustable idler gear and the
injector camshaft gear. The shim is inserted on the load
teeth mesh between the adjustable idler and the lower
non-scissor idler gear. The shim is inserted on the load
gear so there is no gap between the teeth and either side
of the shims.
in and out.

While holding the adjustable idler gear in position, tighten
the adjustable idler gear mounting capscrews.
Torque Value:
Step 1 30 N•m [ 22 ft-lb ]
above.
CAUTION
Load the injector camshaft scissor gear by tightening all
of the gear screws.
The valve camshaft gear will rotate slightly on the valve
camshaft during this step.
Tighten the injector camshaft scissor gear retaining

capscrew.
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]

Use hand pressure only to rotate the injector camshaft
gear clockwise until the gear train backlash is taken up.
Obtain tooth-to-tooth contact between the crankshaft gear
and the injector camshaft gear.
Tighten the injector camshaft non-scissor gear retaining

capscrew.
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Torque Value:
Step 1 136 N•m [ 100 ft-lb ]
Valve Camshaft Scissor Gear

Tighten the valve camshaft scissor gear retaining
capscrew.
Valve Camshaft Non-Scissor Gear

Use hand pressure, only, to rotate the valve camshaft
gear counterclockwise until the backlash between the
injector camshaft gear is taken up. Obtain tooth-to-tooth
contact between the injector camshaft gear and the valve
camshaft gear.
Tighten the valve camshaft non-scissor gear retaining

capscrew.
Coat the entire gear train with clean 15W-40 oil.
Use the access hole in the lower gear cover to lubricate

the lower idler gear and crankshaft.
Finishing Steps
All Applications
Remove the injector and valve camshaft timing wedges.
A sudden jerking motion upwards is the most effective way
to remove wedges.
Remove the crankshaft locking pin.

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

Install the lower gear cover.Refer to Procedure 001-080
(Gear Cover, Lower) in Section 1.
Install the rocker lever shafts.Refer to Procedure 003-009

(Rocker Lever Assembly) in Section 3.
Install and connect the engine brake wiring harness.Refer

to Procedure 020-015 (Engine Brake Wiring Harness) in
Section 20.
Install the rocker lever cover and gasket.Refer to

If coolant, oil, excessive fuel, or excessive black smoke,
has entered the exhaust system, the aftertreatment
system must be inspected.Refer to Procedure 014-013
(Aftertreatment Testing) in Section 14.
Operate the engine and check for leaks.
Signature™, ISX, and QSX15 Block Stiffener Plate

Preparatory Steps
WARNING
WARNING
Remove the oil pan. Refer to Procedure 007-025.

Procedure 007-035.
Remove
Remove the 10 capscrews and the block stiffener plate.
Block Stiffener Plate Signature™, ISX, and QSX15
Install
Install the block stiffener plate and the 10 capscrews.
Finishing Steps
007-035.
Install the oil pan. Refer to Procedure 007-025.

007-037.
Signature™, ISX, and QSX15 Block Stiffener Plate
Fill the engine with lubricating oil. Refer to Procedure

007-037.
Operate the engine until it reaches a temperature of 82°

C [180°F], and check for lubricating oil leaks.
Block Stiffener Plate Signature™, ISX, and QSX15
Notes
Section 2 - Cylinder Head - Group 02 Page 2-a
Section 2 - Cylinder Head - Group 02

Section Contents
Page
Cylinder Head ....................................................................................................................................................2-5
Assemble........................................................................................................................................................2-32
Clean..............................................................................................................................................................2-10
Disassemble................................................................................................................................................... 2-17
Finishing Steps...............................................................................................................................................2-38
General Information..........................................................................................................................................2-5
Initial Check......................................................................................................................................................2-6
Inspect for Reuse..............................................................................................................................................2-9
Install..............................................................................................................................................................2-37
Leak Test........................................................................................................................................................2-11
Measure..........................................................................................................................................................2-27
Remove............................................................................................................................................................2-8
Vacuum Test...................................................................................................................................................2-15
Injector Camshaft Scissor Gear ......................................................................................................................2-86
Install..............................................................................................................................................................2-87
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft End Clearance, Valve .....................................................................................................2-81
Measure..........................................................................................................................................................2-81
Overhead Camshaft Bushings, Injector ..........................................................................................................2-69
Initial Check....................................................................................................................................................2-69
Install..............................................................................................................................................................2-74
Remove.......................................................................................................................................................... 2-69
Overhead Camshaft Bushings, Valve .............................................................................................................2-57
Initial Check....................................................................................................................................................2-57
Install..............................................................................................................................................................2-62
Remove.......................................................................................................................................................... 2-57
Overhead Camshaft End Clearance, Injector .................................................................................................2-83
Measure..........................................................................................................................................................2-83
Overhead Camshaft Gear, Valve .....................................................................................................................2-86
Install..............................................................................................................................................................2-86
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft, Injector ..........................................................................................................................2-51
Finishing Steps...............................................................................................................................................2-55
Install..............................................................................................................................................................2-55
Remove.......................................................................................................................................................... 2-53
Overhead Camshaft, Valve ..............................................................................................................................2-47
Finishing Steps...............................................................................................................................................2-50
Install..............................................................................................................................................................2-50
Remove.......................................................................................................................................................... 2-48
Service Tools ....................................................................................................................................................2-1
.........................................................................................................................................................................2-1
Valve Guide Seal, Cylinder Head ....................................................................................................................2-39
Finishing Steps...............................................................................................................................................2-47
On-Engine Repair.........................................................................................................................................2-47
Off-Engine Repair.........................................................................................................................................2-47
Install..............................................................................................................................................................2-43
Page 2-b Section 2 - Cylinder Head - Group 02
On-Engine Repair.........................................................................................................................................2-39
Remove.......................................................................................................................................................... 2-40
Section 2 - Cylinder Head - Group 02 Page 2-1
Service Tools
Cylinder Head
Repair Location.

Protective Plug Kit
4918319
Four-Valve Spring Compressor

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

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

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

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

Page 2-2 Section 2 - Cylinder Head - Group 02

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

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

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

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

Use to remove the valve seal.
3163293
Valve Guide Installer

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

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

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

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

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

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

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

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

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

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

Use to test the fuel passages in the cylinder head. Use with leak test
3164943 kit, Part Number 3164231, purchased separately.
Signature™, ISX, and QSX15 Cylinder Head

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

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

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

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

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


Inspect for Reuse

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

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

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

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

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

the oil passages.
See the Leak Test section of this procedure for more
cleaning details.
CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Make sure the plugs are installed in the oil passages of
the cylinder block deck.
Plug or cover the coolant passages in the cylinder block
deck.
WARNING
Use a gasket scraper to clean the cylinder block deck
surface.
equivalent, and solvent to remove any residual gasket
material from the cylinder block deck surface.
Use a chip vacuum to remove the excess oil and coolant
from the capscrew holes.
Make sure the cylinder head capscrew holes are clean
and free of debris, oil, and coolant.
Do not use power tools to clean the combustion face.
Leak Test
Fuel Passage
NOTE: This task can be preformed either on or off-engine.
The fuel system is split into two banks.
The front bank is for cylinders one through three, and the
rear bank is for cylinders four through six.
The banks are tested independently of each other. Use
test kit, Part Number 3164943.
The left three male connectors on the plate are for the front
bank and the right three male connectors are for the rear
bank.
The three male connectors on the plate are:
• Metering
• Timing
• Return.
Apply thread sealant to the male connectors and install

them into the plate, if they are not installed.
Install the gasket, plate, two short capscrews (5), and two
long capscrews (4).
Install the injector cavity plug (3) into the appropriate

injector bores.
Center the injector cavity plugs in the injector bores.
Install the injector hold-down clamps and capscrews.
Attach leak test kit, Part Number 3164231 or equivalent,

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

Apply thread sealant and install the male connector (7)

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

tank of water is to use a water and soap solution.
Spray the cylinder head with a mild water and soap
solution.
replaced.
Valve Seat
NOTE: This task is performed off-engine.
Set the head down with the intake ports on the bottom.
Pour fuel into the exhaust port until it is full.
Start the timer.
If a drop of fuel drips or runs down the face of the head

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

Turn the head over so the exhaust port is on the bottom.
Pour fuel into the intake ports until full.
Start the timer.

within 30 seconds, the valve and valve seat interface
must be checked using the vacuum test procedure.
sealing properly.
Vacuum Test
Use valve vacuum tester, Part Number ST-1257, to
inspect the seal between the valve and the valve seat. To
perform this test, the cylinder head must either be sitting
on its side or turned upside down so that the combustion
face can be accessed.
The valve vacuum tester can be used to test all Cummins®
engine models. The seal ring, Part Number ST-1257-35,
and vacuum cup, Part Number ST-1251-6, are used to
seal the cylinder head inserts.
Install the seal ring and vacuum cup to the vacuum line
(hose).
The valves and valve seats must be clean and dry when
vacuum testing.
Make sure the combustion face of the cylinder head is
clean and dry and there is no loose debris in the valve
recess.
This will help to provide a good vacuum cup to cylinder
head sealing surface.
Move the toggle switch (1) to the ON position.

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

specified vacuum.
Valve to Valve Seat Vacuum

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

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

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

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

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

NOTE: Only remove the valve guides if they were not

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

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

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

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

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

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

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

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

Wear in the area where the cylinder liner fire dam contacts
the head is acceptable.
Wear in the area where the fire ring combustion seal
To distinguish the difference, use one of the inspection
gauges detailed below.

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

Inspect the area within the narrow slots cut into the tool.
Rotate the tool to view the entire wire ring area on the
cylinder head combustion face.
Any wear that can be felt by fingernail within these slots
is unacceptable, making the cylinder head not reusable.
Wear outside the slots will have not have an effect on
head.
Inspect the valve spring retainers and valve spring guides

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

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

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

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

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

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

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

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

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

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

Measure the inside diameter of the valve guides in
locations 13 mm [½ in] from each end and at the center
as shown.
Used Valve Guide Inside Diameter (Installed)

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

mm in
44.77 MIN 1.763
45.77 MAX 1.802
If damage is found or the valve guide is not within


mm in
1.21 MAX 0.048
0.77 MAX 0.030

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

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

head.
Insert Bore Depth

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

mm in
49.54 MAX 1.950
47.54 MAX 1.872
If the valve seat insert bore inside diameter is not within

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

cylinder head.

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

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

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

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

cylinder head top deck surface.

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

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

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

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

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

Repeat the above steps for each cylinder as needed.
CAUTION
Before the cylinder head is assembled onto the block,
all oil passage plugs must be removed. Failure to
remove the oil plugs will result in extensive engine
damage.
Remove the oil plugs from the cylinder head and the
cylinder block.
Install
WARNING
position.

capscrews.
CAUTION
Torque Value:
Step 1 203 N•m [ 150 ft-lb ]
Step 2 407 N•m [ 300 ft-lb ]
Finishing Steps
NOTE: If the cylinder head or the cylinder head gasket is being replaced
due to a malfunction that caused an internal coolant leak, the external
crankcase breather element must be replaced, if the unit is equipped with
an external crankcase breather element.
WARNING
WARNING
personal injury, always ventilate the compartment before servicing
the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery
cable last.
• Install the overhead injector camshaft. Refer to Procedure 002-025 in
Section 2.
• Install the overhead valve camshaft. Refer to Procedure 002-024 in
Section 2.
• Install the accessory bracket. Refer to Procedure 001-082 in Section
1.
• Install the retaining brace bracket. Refer to Procedure 001-081 in
Section 1.
• Install the valve and injector camshaft gears. Refer to Procedure
• Install the upper front gear cover. Refer to Procedure 001-079 in
Section 1.
• Install the injectors. Refer to Procedure 006-026 in Section 6.
• Install the rocker lever shaft assemblies.Refer to Procedure 003-009
in Section 3.
• Adjust the overhead settings. Refer to Procedure 003-004 in Section
3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section
3.
• Install the air compressor air inlet hose. Refer to Procedure 012-014
in Section 12.
• Install the ECM. Use the following procedure for CM570 engines, in
the Signature™, ISX and QSX15 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin 3666259. Refer to
the Signature™ and ISX CM870 Electronic Control System,
Procedure 019-031 in Section 19
the ISX CM871 and ISM CM876 5 Electronic Control System,
• Install the integrated fuel system module.Refer to Procedure 005-073
in Section 5.
• Install the air intake connection. Refer to Procedure 010-080 in
Section 10.
• Install the thermostat housing. Refer to Procedure 008-014 in Section
8.
• Install the exhaust manifold. Refer to Procedure 011-007 in Section
11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Install the batteries or air supply to the air starter. Refer to the OEM
service manual.
• If a malfunction resulted in coolant, oil, excessive fuel or excessive
black smoke entering the exhaust system, the aftertreatment system
must be inspected.Refer to Procedure 014-013 in Section 14.
Signature™, ISX, and QSX15 Valve Guide Seal, Cylinder Head
Valve Guide Seal, Cylinder Head

(002-016)
General Information
on Signature™, ISX, and QSX15 engines.
guide seals.
Engine serial number (ESN) 14010274 and all engines

built after, use a larger valve guide seal. These seals are
designed to be installed by hand without the seal driver.
guide. The seals introduced into engines built after ESN
14010274 with the grooved valve guides are not
compatible with engines built with the non-grooved valve
guides and vice versa.
NOTE: The seals that mate with the grooved valve guides
had two iterations.
1. Engines built from May 15, 2000 to the end of
February, 2002 had separate intake and exhaust
valve guide seals which were color coded. Intake
valve guide seals had a brass-colored garter spring
and three raised dots molded into the rubber; the
exhaust valve guide seals had a silver-colored garter
spring and no raised dots.
2. Engines built after March, 2002 had only one valve
guide seal for both intake and exhaust valve guides.
These seals can be used on any engines built after
ESN 14010274.
Preparatory Steps
On-Engine Repair
WARNING
WARNING
• Drain the coolant to below the cylinder head level.
• Remove the rocker lever cover. Refer to Procedure
• Disconnect the engine brake solenoid wiring
• Remove the injector for the cylinder to be repaired.
Valve Guide Seal, Cylinder Head Signature™, ISX, and QSX15
Bar the engine over so the cylinder you are working on is

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

hold down bolt and injector hold down clamp.

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

to remove the valve guide seals.
Install
Grooved Valve Guide Seals:
had two iterations.
ESN 14010274.
Install the intake and exhaust valve guide seals by
snapping the seal by hand into the groove on the valve
guide.
Non-Grooved Valve Guide Seals:

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

Install the valve spring.
Install the valve spring guide.
WARNING
CAUTION
engine.
CAUTION
screw (1).
Tighten the nut finger tight.
WARNING
start to compress.
CAUTION
valve collets can be installed.
head.
WARNING

Signature™, ISX, and QSX15 Overhead Camshaft, Valve
Finishing Steps
On-Engine Repair
WARNING
• Install the injectors. Refer to Procedure 006-026 in
Section 6.
• Connect the engine brake solenoid wiring harness.
• Install the rocker lever cover. Refer to Procedure
• Fill the cooling system. Refer to Procedure 008-018
in Section 8.
• If failure resulted in coolant, oil, excessive fuel or
excessive black smoke entering the exhaust system,
the aftertreatment system must be inspected. Refer
• Operate the engine and check for leaks and proper
operation.
Off-Engine Repair
WARNING
assembly.
in Section 2.
operation.

Preparatory Steps
Remove the upper gear cover. Refer to Procedure
001-079.

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

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

001-088.
Remove
Signature™, ISX, and QSX15 Overhead Camshaft, Valve
CAUTION
WARNING
WARNING
personal injury.
Clean the valve camshaft and the bore of the valve
camshaft gear with Envirosol 655 solvent, or equivalent,
and a lint-free cloth.
Check the valve camshaft and valve camshaft gear for

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

bearing journals.
Valve Camshaft Bearing Journal Outside Diameter

mm in
64.987 MIN 2.5585
65.013 MAX 2.5596
If the camshaft journals are not within specifications, the
camshaft must be replaced.
Inspect the camshaft lobes for cracks, scratches, and

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

Finishing Steps
Install the valve camshaft gear. Refer to Procedure
001-088.
Install the rocker lever shafts. Refer to Procedure 003-009.

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


Preparatory Steps
001-079.
Overhead Camshaft, Injector Signature™, ISX, and QSX15

003-011.

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

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

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

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

CAUTION
WARNING
WARNING
Clean the injector camshaft and the bore of the injector
camshaft scissor gear with Envirosol 655 solvent, or
equivalent and a lint-free cloth.
Check the injector camshaft and injector camshaft scissor

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

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

damage.
Refer to the Camshaft Reuse Guidelines for Cummins®
Engines with Roller Tappets, Bulletin 3666052, for further
reuse guidelines.
Install
CAUTION


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

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

Procedure 001-088.


Signature™, ISX, and QSX15 Overhead Camshaft Bushings, Valve

check for leaks.
Overhead Camshaft Bushings, Valve

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

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

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

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

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

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

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

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

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

Step 14 (for front bushing only)

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

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

Inspect for Reuse

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

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

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

Install the puller shaft through the two installed centering
guides.

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

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

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

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

Step 12 (for rear bushings only)

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

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

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

Step 16 (for front bushings only)

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

CAUTION
engine.

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

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

Signature™, ISX, and QSX15 Overhead Camshaft Bushings, Injector

check for leaks.
Overhead Camshaft Bushings, Injector

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

Remove
Use service tool, Part Number 3164089, for injector

Overhead Camshaft Bushings, Injector Signature™, ISX, and QSX15
NOTE:
2, 3, 4, 5, 6, 7, 8, 9, and 10.
2, 3, 4, 5, 6, 11, 12, and 13.
2, 3, 4, 5, 6, 14, 15, and 16.
Step 1
CAUTION
ends.
Step 2
centering guides.
Step 3
injector camshaft bushing replacer kit, Part Number
Step 4
Step 5
Step 6
CAUTION


WARNING
pedal.

shaft.



WARNING
pedal.


camshaft bushing.

WARNING
pedal.

Inspect for Reuse

Install

NOTE:
1, 2, 5, 6, 7, 8, 9, 10, and 11.
1, 3, 5, 6, 7, 12, 13, 14, and 15.
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1
CAUTION

the same as above.

guides.

Step 5
Step 6
Step 7

CAUTION
equipment.

CAUTION

WARNING
pedal.


CAUTION
equipment.
shaft.

CAUTION
engine.

WARNING
pedal.


CAUTION
equipment.

CAUTION
engine.

WARNING
pedal.
bore.

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

Signature™, ISX, and QSX15 Overhead Camshaft End Clearance, Valve

check for leaks.
Overhead Camshaft End Clearance,

Valve (002-028)
Measure
003-011.

003-009.

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

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

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

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

Signature™, ISX, and QSX15 Overhead Camshaft End Clearance, Injector

check for leaks.

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

003-009.

001-079.

Procedure 001-088.
CAUTION
Injector Camshaft End Clearance

mm in
0.70 MAX 0.0276
injector overhead camshaft. Refer to Procedure 002-025.
Signature™, ISX, and QSX15 Overhead Camshaft End Clearance, Injector

001-088.

Injector Camshaft Scissor Gear Signature™, ISX, and QSX15

check for leaks.
Overhead Camshaft Gear, Valve

(002-030)
Remove
001-088.
Install
001-088.

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

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

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

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

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

(003-001)
Remove
engine.

cover and block.

pressure sensor.
clamp.
do not bend.
Disassemble
Disassemble the crankcase breather assembly. Refer to
Procedure 003-019.
NOTE: All capscrews are captive capscrews.

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

cracks or other damage. Replace if necessary.
WARNING
personal injury.
Clean breather crankcase housing and breather
crankcase cover with solvent.
Check for cracks in crankcase breather element housing
and crankcase breather cover. Replace if necessary.
Assemble
Assemble the crankcase breather assembly. Refer to
Procedure 003-019.
Install
Signature™, ISX, and QSX15 Crankcase Breather (Internal)

breather sensor.
Torque Value:
M10 47 N•m [ 35 ft-lb ]
M8 20 N•m [ 15 ft-lb ]
Crankcase Breather (Internal)

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

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

and remove the breather.

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

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

Install the upper gear cover. Refer to Procedure 001-079
Install the oil seal into the seal carrier.

The groove side (1) must be installed toward the engine.
Make sure the seal carrier is tight in the front cover. If not,
tighten the seal carrier.
Install the breather tube assembly into the seal carrier.
Torque to the breather tube assembly.
Finishing Steps
Procedure 003-001 (Crankcase Breather (External))
in Section 3.

Measure
General Information


damper.

cover.
compressor drive.
WARNING
damage.
(1-2-3-4-5-6).



damper.

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

gear cover.

the pointer again.
Valve Lash
this procedure.
the brake lash.



mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
load.
Preparatory Steps
WARNING
cable last.
Disconnect the battery.
Remove the rocker lever cover and gasket. Refer to

attempting to adjust/set the overhead. Refer to Procedure
001-088 (Engine Base Timing) in Section 1.
All overhead valve, injector, and brake adjustments
must be made when the engine is cold (any stabilized
coolant temperature at 60°C [140°F] or below).
Adjust


damper.

cover.
compressor drive.
WARNING
damage.
(1-2-3-4-5-6).




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

gear cover.

the pointer again.

cylinder.
as required.
be read accurately.
screw.
injector.



adjusting screws.

specification.

mm in


locknut.

CAUTION
and BRAKE SET 3-4.


the pointer again.



mm in
7.00 NOM 0.276


the locknut.
CAUTION
(neutral) position.

mm in
0.635 MIN 0.025
2.790 MAX 0.110
not completed.
specification.

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Finishing Steps
Procedure 003-011 (Rocker Lever Cover) in Section
3.
WARNING
cable last.
Connect the battery.
has entered the exhaust system, Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14..

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

shafts.
rocker levers.
rocker lever.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the rocker lever shaft.
Be sure to blow out the oil passages.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the valve crossheads,
rocker lever adjusting screw, and nuts.
Inspect the valve and brake rocker lever shaft for cracks
or damage.
Measure the valve and brake rocker lever shaft outside
diameter in the bushing wear area.
Valve and Brake Rocker Lever Shaft Outside Diameter

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

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

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

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

inside diameter.
Valve and Brake Rocker Lever Bushing Bore Inside

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

diameter.
Injector Rocker Lever Bushing Bore Inside Diameter

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

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

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

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

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

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

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

WARNING
cylinder head.
CAUTION
capscrews.
direction.


CAUTION
003-004.
the shaft.
the center out.

CAUTION
003-004.
the shaft.
the center out.

cylinder head.

from center out.
Rocker Lever Cover Signature™, ISX, and QSX15
Finishing Steps
Install the engine brake wiring harness. Refer to
Procedure 020-015.
Install the engine brake solenoid valve wiring harness.

Remove

cover.
assemblies.

Clean the contaminated lube oil from the cylinder head
cavities.
WARNING
WARNING
personal injury.
Steam clean the cover. Dry with compressed air.
CAUTION
Do not use solvent to clean the rocker lever cover
gasket. Solvent will damage the gasket material and
cause it to swell. Prolonged exposure can also cause
degradation of the gasket material.
Clean the reusable gasket with a dry, lint-free cloth,
making sure no oil remains between the sealing beads.
separate rocker lever cover and a separate cover gasket,
make certain that no lubricating oil remains between the
sealing beads.
Inspect the rocker lever cover for cracks or damage.

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

kinks, twists, wear, or other damage.
A gouged hole is acceptable if the bead is not damaged.
Crankcase Breather Element Signature™, ISX, and QSX15
Install
cover.
each span.
other damage.

Crankcase Breather Element (003-019)

Remove
Loosen the eight cover mounting captive capscrews.
Remove the element cover.
NOTE: Discard the crankcase breather element in
Remove and discard the crankcase breather element.
Wipe out any excess dirt or oil from the inside of the cover.
Signature™, ISX, and QSX15 Crankcase Breather Element
Install
Install the new crankcase breather element in the breather
housing.
Make sure the element is properly seated in the housing
so its seal will not be cut, crimped, or otherwise
compromised when installing the housing cover.
Install the cover.
Tighten the eight captive mounting capscrews.
Crankcase Breather Element Signature™, ISX, and QSX15
Notes
Index
Page X-1
About the Manual ..........................................................................................i-1 Preparatory Steps.......................................................................................1-5

General Information.....................................................................................i-1 Remove......................................................................................................1-5
Acronyms and Abbreviations ......................................................................i-15 Bearings, Main .........................................................................................DS-84
General Information...................................................................................i-15 Remove.................................................................................................DS-84
Aftertreatment Adapter Pipe ...................................................................DS-27 Bearings, Main ...........................................................................................AS-4
Remove.................................................................................................DS-27 Install.......................................................................................................AS-4
Aftertreatment Adapter Pipe .................................................................AS-122 Bearings, Main ............................................................................................1-11
Install...................................................................................................AS-122 Clean and Inspect for Reuse.....................................................................1-12
Aftertreatment Diesel Particulate Filter — Excessive Ash Cleaning.........TS-12 Finishing Steps.........................................................................................1-19
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary Install........................................................................................................1-14
Regeneration..............................................................................................TS-94 Preparatory Steps.....................................................................................1-11
Aftertreatment Diesel Particulate Filter — Excessive Soot Loading..........TS-11 Remove....................................................................................................1-12
Aftertreatment Fuel Injector ....................................................................DS-28 Bearings, Thrust ......................................................................................DS-83
Remove.................................................................................................DS-28 Remove.................................................................................................DS-83
Aftertreatment Fuel Injector ..................................................................AS-122 Bearings, Thrust .........................................................................................1-19
Install...................................................................................................AS-122 Finishing Steps.........................................................................................1-22
Aftertreatment Fuel Shutoff Manifold .....................................................DS-24 Inspect for Reuse......................................................................................1-21
Remove.................................................................................................DS-24 Install........................................................................................................1-21
Aftertreatment Fuel Shutoff Manifold ...................................................AS-126 Preparatory Steps.....................................................................................1-19
Install...................................................................................................AS-126 Remove....................................................................................................1-20
Aftertreatment Injector Lines ..................................................................DS-20 Belt Tensioner, Automatic (Water Pump) ...............................................DS-10
Aftertreatment Injector Lines ................................................................AS-127 Drives Alternator................................................................................DS-10
Install...................................................................................................AS-127 Automotive Applications.....................................................................DS-11
Air Compressor ........................................................................................DS-63 Industrial and Power Generation........................................................DS-11
Remove.................................................................................................DS-63 Belt Tensioner, Automatic (Water Pump) .............................................AS-140
Air Compressor ........................................................................................AS-57 Install...................................................................................................AS-140
Install.....................................................................................................AS-57 Drives Alternator..............................................................................AS-140
Air Compressor Air Pressure Rises Slowly ...............................................TS-3 Automotive Applications...................................................................AS-140
Air Compressor Coolant Lines ................................................................DS-63 Industrial and Power Generation.......................................................AS-141
Finishing Steps......................................................................................DS-63 Belt Tensioner, Refrigerant Compressor, Automatic .............................DS-14
Air Compressor Coolant Lines ................................................................AS-58 With Water Pump and Refrigerant Compressor Belt Routing..............DS-14
Finishing Steps......................................................................................AS-60 Belt Tensioner, Refrigerant Compressor, Automatic ...........................AS-137
Install.....................................................................................................AS-58 Install...................................................................................................AS-137
Air Compressor Cycles Frequently............................................................TS-4 With Water Pump and Refrigerant Compressor Belt Routing.............AS-137
Air Compressor Noise is Excessive...........................................................TS-5 Block Stiffener Plate ................................................................................AS-42
Air Compressor Pumping Excess Lubricating Oil into the Air System .......TS-6 Install.....................................................................................................AS-42
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Block Stiffener Plate ................................................................................1-179
Continuously)...............................................................................................TS-8 Finishing Steps.......................................................................................1-180
Air Compressor Will Not Pump Air............................................................TS-9 Install......................................................................................................1-180
Air Compressor Will Not Stop Pumping...................................................TS-10 Preparatory Steps...................................................................................1-179
Air Intake Connection ..............................................................................DS-19 Remove..................................................................................................1-179
Remove.................................................................................................DS-19 Block Stiffener Plate ................................................................................DS-72
Automotive with CM870......................................................................DS-19 Remove.................................................................................................DS-72
Automotive With CM871.....................................................................DS-19 Bracket, Accessory ..................................................................................1-153
Automotive, Industrial with CM570 and Power Generation without CM570.... Inspect for Reuse....................................................................................1-155
DS-19 Install......................................................................................................1-155
Air Intake Connection ............................................................................AS-131 Automotive Applications......................................................................1-155
Install...................................................................................................AS-131 Industrial and Power Generation.........................................................1-157
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove..................................................................................................1-153
AS-131 Automotive Applications......................................................................1-153
Automotive with CM870....................................................................AS-131 Industrial and Power Generation.........................................................1-154
Automotive With CM871...................................................................AS-131 Bracket, Retaining Brace .........................................................................1-149
Air Intake System - Overview ....................................................................F-34 Inspect for Reuse....................................................................................1-150
General Information..................................................................................F-34 Install......................................................................................................1-151
Variable Geometry................................................................................F-34 Automotive Applications......................................................................1-151
Automotive with CM870........................................................................F-34 Industrial and Power Generation.........................................................1-151
Automotive With CM871.......................................................................F-35 Remove..................................................................................................1-149
All Applications.....................................................................................F-36 Automotive Applications......................................................................1-149
Alternator .................................................................................................DS-53 Industrial and Power Generation.........................................................1-150
Remove.................................................................................................DS-53 Complete Engine - Overview .......................................................................F-1
Driven by Cooling Fan Drive Belt........................................................DS-53 General Information....................................................................................F-1
Automotive with CM870......................................................................DS-53 Compressed Air System - Overview ..........................................................F-51
Alternator .................................................................................................AS-92 General Information..................................................................................F-51
Install.....................................................................................................AS-92 Single Cylinder.....................................................................................F-51
Driven by Cooling Fan Drive Belt........................................................AS-92 Connecting Rod ..........................................................................................1-23
Automotive with CM870......................................................................AS-92 Bend and Twist Inspect.............................................................................1-27
Alternator Not Charging or Insufficient Charging.....................................TS-13 Clean and Inspect for Reuse.....................................................................1-23
Alternator/Refrigerant Compressor Mounting Bracket ...........................DS-54 Finishing Steps.........................................................................................1-33
Remove.................................................................................................DS-54 Magnetic Crack Inspect.............................................................................1-30
Automotive with CM870......................................................................DS-54 Preparatory Steps.....................................................................................1-23
Automotive with CM570......................................................................DS-54 Coolant Filter .............................................................................................DS-8
Alternator/Refrigerant Compressor Mounting Bracket ...........................AS-91 Remove...................................................................................................DS-8
Install.....................................................................................................AS-91 Coolant Filter .........................................................................................AS-146
Automotive with CM870......................................................................AS-91 Install...................................................................................................AS-146
Automotive with CM570......................................................................AS-91 Coolant in the Lubricating Oil..................................................................TS-27
Bearings, Connecting Rod ......................................................................DS-75 Coolant Loss - External...........................................................................TS-15
Remove.................................................................................................DS-75 Coolant Loss - Internal............................................................................TS-17
Bearings, Thrust ........................................................................................AS-9 Coolant Temperature Above Normal - Gradual Overheat.........................TS-20
Install.......................................................................................................AS-9 Coolant Temperature Above Normal - Sudden Overheat.........................TS-23
Bearings, Connecting Rod ......................................................................AS-36 Coolant Temperature Below Normal.......................................................TS-25
Install.....................................................................................................AS-36 Coolant Thermostat .................................................................................DS-52
Bearings, Connecting Rod ...........................................................................1-5 Remove.................................................................................................DS-52
Clean and Inspect for Reuse.......................................................................1-6 Coolant Thermostat .................................................................................AS-92
Finishing Steps.........................................................................................1-11 Install.....................................................................................................AS-92
Install..........................................................................................................1-8 Coolant Thermostat Housing ..................................................................DS-50
Index
Page X-2
Single Thermostat..............................................................................DS-50 Preparatory Steps.....................................................................................1-68
Dual Thermostat................................................................................DS-50 Remove....................................................................................................1-69
Coolant Thermostat Housing ..................................................................AS-94 Crankshaft Seal, Rear ..............................................................................DS-77
Install.....................................................................................................AS-94 Measure.................................................................................................DS-78
Single Thermostat..............................................................................AS-94 Remove.................................................................................................DS-77
Dual Thermostat.................................................................................AS-95 Crankshaft Seal, Rear ..............................................................................AS-31
Cooling System .........................................................................................DS-1 Install.....................................................................................................AS-31
Drain........................................................................................................DS-1 Measure.................................................................................................AS-32
Cooling System ......................................................................................AS-152 Crankshaft Seal, Rear ................................................................................1-73
Fill........................................................................................................AS-152 Clean and Inspect for Reuse.....................................................................1-75
Cooling System - Overview .......................................................................F-24 Finishing Steps.........................................................................................1-77
General Information..................................................................................F-24 Install........................................................................................................1-75
Crankcase Breather (External) ................................................................DS-15 Measure...................................................................................................1-76
Remove.................................................................................................DS-15 Preparatory Steps.....................................................................................1-73
Automotive with CM870......................................................................DS-15 Remove....................................................................................................1-74
Automotive With CM871.....................................................................DS-16 Crankshaft Tone Wheel ............................................................................1-139
Crankcase Breather (External) ..............................................................AS-135 Finishing Steps.......................................................................................1-140
Install...................................................................................................AS-135 Inspect....................................................................................................1-139
Automotive with CM870....................................................................AS-135 Install......................................................................................................1-140
Automotive With CM871...................................................................AS-136 Preparatory Steps...................................................................................1-139
Crankcase Breather (External) .....................................................................3-2 Remove..................................................................................................1-139
Assemble....................................................................................................3-4 Cylinder Block ............................................................................................1-77
Automotive With CM871.........................................................................3-4 Inspect for Reuse......................................................................................1-77
Clean and Inspect for Reuse.......................................................................3-3 Repair.......................................................................................................1-78
Automotive with CM870..........................................................................3-3 Cylinder Block - Overview ...........................................................................F-3
Automotive With CM871.........................................................................3-4 General Information....................................................................................F-3
Disassemble...............................................................................................3-3 Cylinder Block and Liner Seats .................................................................1-87
Automotive With CM871.........................................................................3-3 Leak Test..................................................................................................1-87
Install..........................................................................................................3-4 Cylinder Head ..........................................................................................DS-70
Automotive with CM870..........................................................................3-4 Remove.................................................................................................DS-70
Automotive With CM871.........................................................................3-5 Cylinder Head ..........................................................................................AS-44
Remove......................................................................................................3-2 Install.....................................................................................................AS-44
Automotive with CM870..........................................................................3-2 Cylinder Head ...............................................................................................2-5
Automotive With CM871.........................................................................3-2 Assemble..................................................................................................2-32
Crankcase Breather (Internal) ......................................................................3-5 Clean........................................................................................................2-10
Clean and Inspect for Reuse.......................................................................3-6 Clean and Inspect for Reuse.....................................................................2-21
Finishing Steps...........................................................................................3-8 Disassemble.............................................................................................2-17
Install..........................................................................................................3-7 Finishing Steps.........................................................................................2-38
Preparatory Steps.......................................................................................3-5 General Information....................................................................................2-5
Remove......................................................................................................3-6 Initial Check................................................................................................2-6
Crankcase Breather Element .....................................................................3-32 Inspect for Reuse........................................................................................2-9
Install........................................................................................................3-33 Install........................................................................................................2-37
Remove....................................................................................................3-32 Leak Test..................................................................................................2-11
Crankcase Coalescing Filter - Frequent Replacement.............................TS-30 Magnetic Crack Inspect.............................................................................2-30
Crankcase Gases (Blowby) Excessive.....................................................TS-29 Measure...................................................................................................2-27
Crankshaft ...............................................................................................DS-83 Preparatory Steps.......................................................................................2-7
Remove.................................................................................................DS-83 Remove......................................................................................................2-8
Crankshaft ................................................................................................AS-10 Vacuum Test.............................................................................................2-15
Install.....................................................................................................AS-10 Cylinder Head - Overview ............................................................................F-4
Crankshaft ..................................................................................................1-34 General Information....................................................................................F-4
Bend and Twist Inspect.............................................................................1-40 Cylinder Liner ..........................................................................................DS-85
Clean and Inspect for Reuse.....................................................................1-36 Remove.................................................................................................DS-85
Finishing Steps.........................................................................................1-51 Cylinder Liner ............................................................................................AS-1
Install........................................................................................................1-50 Install.......................................................................................................AS-1
Magnetic Crack Inspect.............................................................................1-46 Measure...................................................................................................AS-2
Preparatory Steps.....................................................................................1-35 Cylinder Liner .............................................................................................1-91
Remove....................................................................................................1-36 Clean and Inspect for Reuse.....................................................................1-93
Rotation Check.........................................................................................1-34 Finishing Steps.........................................................................................1-99
Crankshaft Adapter ....................................................................................1-51 Install........................................................................................................1-96
Clean and Inspect for Reuse.....................................................................1-56 Measure...................................................................................................1-97
Finishing Steps.........................................................................................1-58 Preparatory Steps.....................................................................................1-91
Install........................................................................................................1-56 Remove....................................................................................................1-92
Preparatory Steps.....................................................................................1-51 Drive Belt, Cooling Fan ...........................................................................DS-10
Remove....................................................................................................1-52 Remove.................................................................................................DS-10
Crankshaft Gear, Front (Crankshaft Installed) ...........................................1-58 Drives Alternator................................................................................DS-10
Clean and Inspect for Reuse.....................................................................1-62 Drive Belt, Cooling Fan .........................................................................AS-142
Finishing Steps.........................................................................................1-63 Install...................................................................................................AS-142
Install........................................................................................................1-62 Drives Alternator..............................................................................AS-142
Preparatory Steps.....................................................................................1-58 Drive Belt, Refrigerant Compressor ........................................................DS-14
On-Engine Repair.................................................................................1-58 Remove.................................................................................................DS-14
Remove....................................................................................................1-59 With Water Pump and Refrigerant Compressor Belt Routing..............DS-14
Crankshaft Pulley .......................................................................................1-64 Drive Belt, Refrigerant Compressor ......................................................AS-137
Inspect for Reuse......................................................................................1-65 Install...................................................................................................AS-137
Install........................................................................................................1-66 With Water Pump and Refrigerant Compressor Belt Routing.............AS-137
Automotive Applications........................................................................1-66 ECM Cooling Plate, Fuel Cooled .............................................................DS-20
Industrial and Power Generation...........................................................1-66 Remove.................................................................................................DS-20
Remove....................................................................................................1-64 ECM Cooling Plate, Fuel Cooled ...........................................................AS-130
Automotive Applications........................................................................1-64 Install...................................................................................................AS-130
Industrial and Power Generation...........................................................1-64 EGR Connection Tubes ...........................................................................DS-44
Crankshaft Seal, Front ............................................................................DS-62 Remove.................................................................................................DS-44
Remove.................................................................................................DS-62 EGR Connection Tubes .........................................................................AS-101
Crankshaft Seal, Front .............................................................................AS-61 Install...................................................................................................AS-101
Install.....................................................................................................AS-61 EGR Cooler ..............................................................................................DS-46
Crankshaft Seal, Front ...............................................................................1-68 Remove.................................................................................................DS-46
Clean and Inspect for Reuse.....................................................................1-70 EGR Cooler ..............................................................................................AS-97
Finishing Steps.........................................................................................1-73 Install.....................................................................................................AS-97
Index
Page X-3
EGR Cooler Coolant Lines .......................................................................DS-39 Engine Speed Surges in PTO or Cruise Control......................................TS-51
Remove.................................................................................................DS-39 Engine Starts But Will Not Keep Running...............................................TS-53
EGR Cooler Coolant Lines .....................................................................AS-109 Engine Storage - Long Term ......................................................................0-11
Install...................................................................................................AS-109 General Information..................................................................................0-11
EGR Mixer ................................................................................................DS-18 Engine Support Bracket, Front ...............................................................DS-71
EGR Mixer ..............................................................................................AS-132 Engine Support Bracket, Front ...............................................................AS-43
Install...................................................................................................AS-132 Install.....................................................................................................AS-43
EGR Valve ................................................................................................DS-41 Engine Testing - Overview .........................................................................F-56
Remove.................................................................................................DS-41 Fuel Flow Measurement on Engine or Chassis Dynamometer...................F-57
EGR Valve ..............................................................................................AS-107 General Information..................................................................................F-56
Install...................................................................................................AS-107 Engine Will Not Crank - (Electric Starter).................................................TS-56
EGR Valve Coolant Lines ........................................................................DS-41 Engine Will Not Crank or Cranks Slowly (Air Starter)...............................TS-60
Remove.................................................................................................DS-41 Engine Will Not Shut Off.........................................................................TS-61
EGR Valve Coolant Lines .......................................................................AS-108 Exhaust Gas Pressure Sensor Adapter ..................................................DS-43
Install...................................................................................................AS-108 Remove.................................................................................................DS-43
EGR Valve Mounting Bracket ..................................................................DS-42 All Applications..................................................................................DS-43
Remove.................................................................................................DS-42 Exhaust Gas Pressure Sensor Adapter .................................................AS-106
EGR Valve Mounting Bracket ................................................................AS-106 Install...................................................................................................AS-106
Install...................................................................................................AS-106 All Applications.................................................................................AS-106
Electrical Equipment - Overview ...............................................................F-54 Exhaust Gas Pressure Sensor Tube .......................................................DS-43
General Information..................................................................................F-54 Remove.................................................................................................DS-43
Engine Base Timing ................................................................................DS-64 Exhaust Gas Pressure Sensor Tube .....................................................AS-107
Remove.................................................................................................DS-64 Install...................................................................................................AS-107
Engine Base Timing .................................................................................AS-46 Exhaust Manifold, Dry .............................................................................DS-44
Adjust.....................................................................................................AS-53 Remove.................................................................................................DS-44
Install.....................................................................................................AS-46 Exhaust Manifold, Dry ...........................................................................AS-103
Engine Base Timing .................................................................................1-158 Install...................................................................................................AS-103
Adjust.....................................................................................................1-173 Automotive with CM870 and CM871.................................................AS-103
Finishing Steps.......................................................................................1-177 Automotive, Industrial with CM570 and Power Generation without CM570....
General Information................................................................................1-158 AS-104
Inspect for Reuse....................................................................................1-166 Exhaust System - Overview .......................................................................F-40
Install......................................................................................................1-167 General Information..................................................................................F-40
Preparatory Steps...................................................................................1-160 Automotive With CM871.......................................................................F-40
Remove..................................................................................................1-162 Automotive With CM871.......................................................................F-40
Engine Brake - Low Retarding Power or Slow to Activate........................TS-34 Automotive with CM870........................................................................F-43
Engine Brake — One or More Cylinders Braking with Power Switch Off.....TS- Fan Hub, Belt Driven ...............................................................................DS-12
37 Remove.................................................................................................DS-12
Engine Brake Does Not Operate.............................................................TS-31 Automotive with CM870......................................................................DS-12
Engine Cranks Slowly - (Electric Starter).................................................TS-58 Automotive with CM570......................................................................DS-12
Engine Decelerates Slowly.....................................................................TS-39 Industrial CM570 and Power Generation without CM570....................DS-13
Engine Diagrams ..........................................................................................E-3 Fan Hub, Belt Driven .............................................................................AS-139
Engine Views.............................................................................................E-3 Install...................................................................................................AS-139
Automotive with CM870..........................................................................E-4 Automotive with CM870....................................................................AS-139
Automotive With CM871.........................................................................E-7 Automotive with CM570....................................................................AS-139
Industrial CM570 and Power Generation without CM570.......................E-11 Industrial CM570 and Power Generation without CM570...................AS-139
Engine Identification ....................................................................................E-1 Fan Support .............................................................................................DS-13
ECM Dataplate...........................................................................................E-1 Remove.................................................................................................DS-13
Automotive with CM870 and CM871.......................................................E-1 Industrial and Power Generation........................................................DS-13
Automotive, Industrial with CM570 and Power Generation without CM570.... Fan Support ...........................................................................................AS-137
E-1 Install...................................................................................................AS-137
Power Generation...................................................................................E-2 Industrial and Power Generation.......................................................AS-137
Engine Dataplate........................................................................................E-1 Flow Diagram, Air Intake System ..............................................................F-37
Engine Installation .......................................................................................0-7 Flow Diagram...........................................................................................F-37
Finishing Steps...........................................................................................0-9 Automotive, Industrial with CM570 and Power Generation without CM570....
All Applications.......................................................................................0-9 F-37
Install..........................................................................................................0-7 With CM870..........................................................................................F-38
Automotive and Industrial.......................................................................0-7 Automotive With CM871.......................................................................F-39
Power Generation...................................................................................0-8 Flow Diagram, Compressed Air System ....................................................F-52
Engine Installation .................................................................................AS-148 Flow Diagram...........................................................................................F-52
Install...................................................................................................AS-148 Flow Diagram, Cooling System .................................................................F-26
Automotive and Industrial.................................................................AS-148 Flow Diagram...........................................................................................F-26
Power Generation.............................................................................AS-149 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Lifting Brackets ...........................................................................DS-49 F-26
Remove.................................................................................................DS-49 Automotive with CM870........................................................................F-29
Engine Lifting Brackets ...........................................................................AS-96 Automotive With CM871.......................................................................F-31
Install.....................................................................................................AS-96 Single Thermostat................................................................................F-33
Engine Noise Excessive.........................................................................TS-40 Flow Diagram, Exhaust System .................................................................F-44
Engine Noise Excessive — Combustion Knocks.....................................TS-43 Flow Diagram...........................................................................................F-44
Engine Noise Excessive — Connecting Rod...........................................TS-44 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Noise Excessive — Main Bearing................................................TS-45 F-44
Engine Noise Excessive — Piston..........................................................TS-47 With CM870..........................................................................................F-46
Engine Noise Excessive — Turbocharger...............................................TS-48 Automotive With CM871.......................................................................F-48
Engine Performance Troubleshooting Tree - ISX with CM871 ...............TT-64 Automotive With CM871.......................................................................F-49
Engine Performance Troubleshooting Tree - Signature™ and ISX CM870 ..... Automotive With CM871.......................................................................F-50
TT-1 Flow Diagram, Fuel System .........................................................................F-9
Engine Removal ...........................................................................................0-2 Flow Diagram.............................................................................................F-9
Preparatory Steps.......................................................................................0-2 Automotive with CM570..........................................................................F-9
All Applications.......................................................................................0-2 Automotive with CM870........................................................................F-11
Remove......................................................................................................0-3 Automotive With CM871.......................................................................F-12
Automotive and Industrial.......................................................................0-3 Industrial CM570 and Power Generation without CM570.......................F-13
Power Generation...................................................................................0-5 Flow Diagram, Lubricating Oil System ......................................................F-18
Engine Removal .........................................................................................DS-4 Flow Diagram...........................................................................................F-18
Remove...................................................................................................DS-4 Automotive, Industrial with CM570 and Power Generation without CM570....
Automotive and Industrial.....................................................................DS-4 F-18
Power Generation................................................................................DS-6 Automotive with CM870........................................................................F-20
Engine Shuts Off Unexpectedly or Dies During Deceleration...................TS-49 All Applications.....................................................................................F-21
Index
Page X-4
Automotive With CM871.......................................................................F-23 Heat Shield ..............................................................................................DS-38

Flywheel ...................................................................................................DS-77 Remove.................................................................................................DS-38
Remove.................................................................................................DS-77 Automotive with CM870......................................................................DS-38
Flywheel ...................................................................................................AS-32 Automotive With CM871.....................................................................DS-38
Install.....................................................................................................AS-32 Heat Shield .............................................................................................AS-111
Flywheel Housing ....................................................................................DS-79 Install...................................................................................................AS-111
Remove.................................................................................................DS-79 Automotive with CM870....................................................................AS-111
Flywheel Housing ....................................................................................AS-14 Automotive With CM871...................................................................AS-112
Install.....................................................................................................AS-14 How to Use the Manual .................................................................................i-2
Measure.................................................................................................AS-15 General Information.....................................................................................i-2
Bore Alignment..................................................................................AS-15 Idler Gear, Lower Scissor ........................................................................AS-43
Face Alignment..................................................................................AS-17 General Information................................................................................AS-43
Flywheel Housing, REPTO ......................................................................DS-80 Idler Gear, Adjustable ..............................................................................1-141
Remove.................................................................................................DS-80 General Information................................................................................1-141
Flywheel Housing, REPTO ......................................................................AS-19 Idler Gear, Lower Scissor ........................................................................DS-71
Install.....................................................................................................AS-19 General Information...............................................................................DS-71
Measure.................................................................................................AS-27 Idler Gear, Lower Scissor ........................................................................1-141
Bore Alignment..................................................................................AS-27 General Information................................................................................1-141
Face Alignment..................................................................................AS-29 Idler Pulley, Refrigerant Compressor .....................................................DS-14
Fuel Consumption Excessive..................................................................TS-62 Remove.................................................................................................DS-14
Fuel Economy Troubleshooting Tree ....................................................TT-112 With Water Pump and Refrigerant Compressor Belt Routing..............DS-14
Fuel Economy Troubleshooting Tree ....................................................TT-143 Idler Pulley, Refrigerant Compressor ....................................................AS-137
Fuel Filter (Spin-On Type) .........................................................................DS-9 Install...................................................................................................AS-137
Remove...................................................................................................DS-9 With Water Pump and Refrigerant Compressor Belt Routing.............AS-137
Fuel Filter (Spin-On Type) .....................................................................AS-144 Illustrations ....................................................................................................i-5
Install...................................................................................................AS-144 General Information.....................................................................................i-5
Fuel in Coolant.......................................................................................TS-67 Injector .....................................................................................................DS-58
Fuel in the Lubricating Oil.......................................................................TS-68 Remove.................................................................................................DS-58
Fuel System - Overview ...............................................................................F-5 Injector .....................................................................................................AS-68
General Information....................................................................................F-5 Install.....................................................................................................AS-68
Automotive with CM870..........................................................................F-6 Injector Camshaft Scissor Gear .................................................................2-86
Automotive With CM871.........................................................................F-7 Install........................................................................................................2-87
Installation Recommendations....................................................................F-7 Remove....................................................................................................2-86
Gear Cover, Lower ..................................................................................DS-63 Injectors and Fuel Lines - Overview ..........................................................F-15
Remove.................................................................................................DS-63 General Information..................................................................................F-15
Gear Cover, Lower ...................................................................................AS-60 Intake Manifold Air Temperature Above Specification.............................TS-70
Install.....................................................................................................AS-60 Intake Manifold Pressure (Boost) is Below Normal..................................TS-72
Gear Cover, Lower ...................................................................................1-146 Integrated Fuel System Module (IFSM) .................................................AS-125
Clean and Inspect for Reuse...................................................................1-146 Install...................................................................................................AS-125
Finishing Steps.......................................................................................1-149 Integrated Fuel System Module (IFSM) ...................................................DS-25
Install......................................................................................................1-148 Remove.................................................................................................DS-25
Preparatory Steps...................................................................................1-146 Lubricating Oil Consumption Excessive..................................................TS-75
Remove..................................................................................................1-146 Lubricating Oil Contaminated..................................................................TS-78
Gear Cover, Upper ...................................................................................DS-61 Lubricating Oil Cooler .............................................................................DS-48
Automotive Applications.....................................................................DS-61 All Applications..................................................................................DS-48
Industrial and Power Generation........................................................DS-61 Lubricating Oil Cooler .............................................................................AS-97
Gear Cover, Upper ...................................................................................AS-64 Install.....................................................................................................AS-97
Install.....................................................................................................AS-64 All Applications..................................................................................AS-97
Automotive Applications.....................................................................AS-64 Lubricating Oil Dipstick Tube .................................................................DS-18
Industrial and Power Generation.........................................................AS-64 Remove.................................................................................................DS-18
Gear Cover, Upper ....................................................................................1-141 Automotive with CM870......................................................................DS-18
Clean and Inspect for Reuse...................................................................1-142 Automotive With CM871.....................................................................DS-18
All Applications...................................................................................1-142 Lubricating Oil Dipstick Tube ................................................................AS-132
Finishing Steps.......................................................................................1-145 Install...................................................................................................AS-132
All Applications...................................................................................1-145 Automotive with CM870....................................................................AS-132
Install......................................................................................................1-144 Automotive With CM871...................................................................AS-132
Automotive Applications......................................................................1-144 Lubricating Oil Fill Tube ..........................................................................DS-16
Industrial and Power Generation.........................................................1-145 Remove.................................................................................................DS-16
Preparatory Steps...................................................................................1-141 Automotive with CM870......................................................................DS-16
All Applications...................................................................................1-141 Automotive With CM871.....................................................................DS-17
Remove..................................................................................................1-141 Lubricating Oil Fill Tube ........................................................................AS-132
Automotive Applications......................................................................1-141 Install...................................................................................................AS-132
Industrial and Power Generation.........................................................1-142 Automotive with CM870....................................................................AS-132
Gear Housing, Front ................................................................................DS-82 Automotive With CM871...................................................................AS-134
Remove.................................................................................................DS-82 Lubricating Oil Filter (Spin-On) .................................................................DS-8
Gear Housing, Front ................................................................................AS-12 Remove...................................................................................................DS-8
Install.....................................................................................................AS-12 Lubricating Oil Filter (Spin-On) .............................................................AS-147
Gear Housing, Front .................................................................................1-100 Install...................................................................................................AS-147
Clean and Inspect for Reuse...................................................................1-101 Lubricating Oil Filter Plugged..................................................................TS-79
Finishing Steps.......................................................................................1-104 Lubricating Oil in the Fuel.......................................................................TS-74
Install......................................................................................................1-102 Lubricating Oil Pan ..................................................................................DS-71
Preparatory Steps...................................................................................1-100 Remove.................................................................................................DS-71
Remove..................................................................................................1-100 Lubricating Oil Pan ..................................................................................AS-42
General Cleaning Instructions ....................................................................i-10 Install.....................................................................................................AS-42
Abrasive Pads and Abrasive Paper.............................................................i-10 Lubricating Oil Pressure High.................................................................TS-82
Definition of Clean......................................................................................i-10 Lubricating Oil Pressure Low..................................................................TS-83
Fuel System...............................................................................................i-13 Lubricating Oil Pump ...............................................................................DS-83
Gasket Surfaces........................................................................................i-11 Remove.................................................................................................DS-83
Plastic Bead Cleaning................................................................................i-12 Lubricating Oil Pump ...............................................................................AS-10
Solvent and Acid Cleaning.........................................................................i-11 Install.....................................................................................................AS-10
Steam Cleaning.........................................................................................i-12 Lubricating Oil Sludge in the Crankcase Excessive.................................TS-85
General Repair Instructions ..........................................................................i-8 Lubricating Oil Suction Tube (Block-Mounted) ......................................DS-72
General Information.....................................................................................i-8 Remove.................................................................................................DS-72
Welding on a Vehicle with an Electronic Controlled Fuel System..................i-9 Lubricating Oil Suction Tube (Block-Mounted) ......................................AS-42
General Safety Instructions ..........................................................................i-6 Install.....................................................................................................AS-42
Important Safety Notice................................................................................i-6 Lubricating Oil System ..............................................................................DS-3
Index
Page X-5
Drain........................................................................................................DS-3 Install.....................................................................................................AS-41
Lubricating Oil System ..........................................................................AS-150 Piston Cooling Nozzle ..............................................................................1-111
Fill........................................................................................................AS-152 Finishing Steps.......................................................................................1-112
Prime...................................................................................................AS-150 Install......................................................................................................1-112
Lubricating Oil System - Overview ............................................................F-15 Preparatory Steps...................................................................................1-111
General Information..................................................................................F-15 Remove..................................................................................................1-112
Lubricating Oil......................................................................................F-15 Piston Rings ............................................................................................DS-76
Lubricating Oil Filters............................................................................F-16 Remove.................................................................................................DS-76
Lubricating Oil System..............................................................................F-16 Piston Rings .............................................................................................AS-34
New Engine Break-in Oils.........................................................................F-17 Install.....................................................................................................AS-34
Oil Drain Intervals.....................................................................................F-17 Piston Rings .............................................................................................1-114
Lubricating Oil Temperature Above Specification....................................TS-87 Install......................................................................................................1-116
Lubricating or Transmission Oil in the Coolant........................................TS-89 Measure..................................................................................................1-115
Overhead Camshaft End Clearance, Valve ................................................2-81 Remove..................................................................................................1-114
Measure...................................................................................................2-81 Refrigerant Compressor ..........................................................................DS-14
Overhead Camshaft Bushings, Injector .....................................................2-69 Remove.................................................................................................DS-14
Initial Check..............................................................................................2-69 Sanden..............................................................................................DS-14
Inspect for Reuse......................................................................................2-74 Climate Control Incorporated..............................................................DS-15
Install........................................................................................................2-74 Refrigerant Compressor ........................................................................AS-136
Remove....................................................................................................2-69 Install...................................................................................................AS-136
Overhead Camshaft Bushings, Valve ........................................................2-57 Sanden............................................................................................AS-136
Initial Check..............................................................................................2-57 Climate Control Incorporated............................................................AS-136
Inspect for Reuse......................................................................................2-62 Refrigerant Compressor Mounting Bracket ............................................DS-54
Install........................................................................................................2-62 Remove.................................................................................................DS-54
Remove....................................................................................................2-57 Sanden..............................................................................................DS-54
Overhead Camshaft End Clearance, Injector ............................................2-83 Climate Control Incorporated..............................................................DS-55
Measure...................................................................................................2-83 Automotive, Industrial with CM570 and Power Generation without CM570....
Overhead Camshaft Gear, Valve ................................................................2-86 DS-55
Install........................................................................................................2-86 Refrigerant Compressor Mounting Bracket ............................................AS-89
Remove....................................................................................................2-86 Install.....................................................................................................AS-89
Overhead Camshaft, Injector ..................................................................DS-69 Sanden..............................................................................................AS-89
Remove.................................................................................................DS-69 Climate Control Incorporated..............................................................AS-90
Overhead Camshaft, Injector ..................................................................AS-45 Automotive, Industrial with CM570 and Power Generation without CM570....
Install.....................................................................................................AS-45 AS-90
Overhead Camshaft, Injector .....................................................................2-51 Rocker Lever Assembly ..........................................................................DS-57
Clean and Inspect for Reuse.....................................................................2-54 Remove.................................................................................................DS-57
Finishing Steps.........................................................................................2-55 Rocker Lever Assembly ...........................................................................AS-69
Install........................................................................................................2-55 Install.....................................................................................................AS-69
Preparatory Steps.....................................................................................2-51 Rocker Lever Assembly .............................................................................3-21
Overhead Camshaft, Valve ......................................................................DS-68 Finishing Steps.........................................................................................3-30
Overhead Camshaft, Valve ......................................................................AS-46 Preparatory Steps.....................................................................................3-21
Install.....................................................................................................AS-46 Remove....................................................................................................3-21
Overhead Camshaft, Valve ........................................................................2-47 Rocker Lever Cover ...................................................................................DS-9
Clean and Inspect for Reuse.....................................................................2-49 Remove...................................................................................................DS-9
Finishing Steps.........................................................................................2-50 Rocker Lever Cover ...............................................................................AS-143
Install........................................................................................................2-50 Install...................................................................................................AS-143
Preparatory Steps.....................................................................................2-47 Rocker Lever Cover ....................................................................................3-30
Overhead Set ...........................................................................................AS-73 Install........................................................................................................3-32
Adjust.....................................................................................................AS-77 Remove....................................................................................................3-30
Measure.................................................................................................AS-73 Rocker Levers - Overview ............................................................................F-5
General Information............................................................................AS-73 General Information....................................................................................F-5
Overhead Set ................................................................................................3-8 General Information................................................................................F-5
Adjust.......................................................................................................3-12 Service Tools ...............................................................................................0-1
Finishing Steps.........................................................................................3-20 Engine Removal and Installation.................................................................0-1
Measure.....................................................................................................3-8 Service Tools ...............................................................................................1-1
General Information................................................................................3-8 ...................................................................................................................1-1
Preparatory Steps.....................................................................................3-12 Service Tools ...............................................................................................2-1
Piston ........................................................................................................1-104 ...................................................................................................................2-1
Clean and Inspect for Reuse...................................................................1-106 Service Tools ...............................................................................................3-1
Articulated Piston................................................................................1-106 Rocker Levers.............................................................................................3-1
Single-Piece Piston.............................................................................1-107 Starting Motor ..........................................................................................DS-10
Finishing Steps.......................................................................................1-110 Remove.................................................................................................DS-10
All Applications...................................................................................1-110 All Except 50MT With Aluminum Flywheel Housing............................DS-10
General Information................................................................................1-104 50MT With Aluminum Flywheel Housing.............................................DS-10
Preparatory Steps...................................................................................1-105 Starting Motor ........................................................................................AS-142
All Applications...................................................................................1-105 Install...................................................................................................AS-142
Piston and Connecting Rod Assembly ...................................................DS-73 All Except 50MT With Aluminum Flywheel Housing..........................AS-142
Remove.................................................................................................DS-73 50MT With Aluminum Flywheel Housing...........................................AS-142
Piston and Connecting Rod Assembly ...................................................AS-39 Stationary Regeneration — Will Not Activate...........................................TS-91
Install.....................................................................................................AS-39 Stationary Regeneration - Will Not Complete..........................................TS-95
Piston and Connecting Rod Assembly ....................................................1-128 Symbols .........................................................................................................i-4
Assemble................................................................................................1-132 General Information.....................................................................................i-4
Articulated Piston................................................................................1-132 Troubleshooting Overview ......................................................................TS-97
Single-Piece Piston.............................................................................1-134 Connecting Rod Bearing Noise...............................................................TS-97
Disassemble...........................................................................................1-131 Coolant Loss Pre-Troubleshooting Guide..............................................TS-106
Articulated Piston................................................................................1-131 Driver Interview Questions................................................................TS-107
Single-Piece Piston.............................................................................1-131 Service History Review.....................................................................TS-108
Finishing Steps.......................................................................................1-138 ECM Data Review:...........................................................................TS-108
Install......................................................................................................1-135 Driveability - General Information............................................................TS-97
Preparatory Steps...................................................................................1-128 Driveability/Low Power - Customer Complaint Form................................TS-99
Remove..................................................................................................1-129 Driveability/Low Power/Excessive Fuel Consumption - Checklist...........TS-100
Piston Cooling Nozzle .............................................................................DS-72 Engine Noise Diagnostic Procedures - General Information.....................TS-97
Remove.................................................................................................DS-72 Fuel Consumption - Customer Complaint Form.....................................TS-103
Piston Cooling Nozzle .............................................................................AS-41 Fuel Consumption - General Information...............................................TS-102
Index
Page X-6
Main Bearing Noise................................................................................TS-97 Install......................................................................................................1-123

Oil Consumption...................................................................................TS-105 Automotive Applications......................................................................1-123
Piston Noise...........................................................................................TS-97 Industrial and Power Generation with Crank-Driven Fan or PTO..........1-124
Troubleshooting Procedures and Techniques ..........................................TS-1 Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
General Information..................................................................................TS-1 125
Troubleshooting Symptoms Charts ..........................................................TS-2 Preparatory Steps...................................................................................1-119
General Information..................................................................................TS-2 Automotive Applications......................................................................1-119
Turbocharger ...........................................................................................DS-30 Industrial and Power Generation with Crank-Driven Fan or PTO..........1-119
Clean.....................................................................................................DS-31 Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
Inspect for Reuse...................................................................................DS-32 119
Remove.................................................................................................DS-30 Remove..................................................................................................1-120
Turbocharger .........................................................................................AS-112 Automotive Applications......................................................................1-120
Assemble.............................................................................................AS-112 Industrial and Power Generation with Crank-Driven Fan or PTO..........1-120
Install...................................................................................................AS-113 Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
Turbocharger Air Shutoff Valve Filter ....................................................DS-25 121
Remove.................................................................................................DS-25 Wobble Check.........................................................................................1-126
Variable Geometry.............................................................................DS-25 All Applications...................................................................................1-126
Turbocharger Air Shutoff Valve Filter ...................................................AS-124 Vibration Excessive ................................................................................TT-148
Install...................................................................................................AS-124 Water Inlet Connection ............................................................................DS-55
Variable Geometry............................................................................AS-124 Remove.................................................................................................DS-55
Turbocharger Control Shutoff Valve Filter Head ....................................DS-26 Water Inlet Connection ............................................................................AS-89
Remove.................................................................................................DS-26 Install.....................................................................................................AS-89
Variable Geometry.............................................................................DS-26 Water Pump .............................................................................................DS-55
Turbocharger Coolant Hoses ..................................................................DS-29 Remove.................................................................................................DS-55
Remove.................................................................................................DS-29 Automotive with CM870......................................................................DS-55
Automotive with CM870......................................................................DS-29 Automotive with CM570......................................................................DS-56
Automotive With CM871.....................................................................DS-29 Industrial CM570 and Power Generation without CM570....................DS-56
Turbocharger Coolant Hoses ................................................................AS-119 Water Pump .............................................................................................AS-85
Install...................................................................................................AS-119 Install.....................................................................................................AS-85
Automotive with CM870....................................................................AS-119 Automotive with CM870......................................................................AS-85
Automotive With CM871...................................................................AS-120 Automotive with CM570......................................................................AS-86
Turbocharger Leaks Engine Oil or Fuel...................................................TS-90 Industrial CM570 and Power Generation without CM570.....................AS-87
Turbocharger Control Shutoff Valve Filter Head ..................................AS-123 Automotive With CM871.....................................................................AS-89
Install...................................................................................................AS-123
Variable Geometry............................................................................AS-123
Turbocharger, Variable Geometry Actuator ..........................................AS-121
Install...................................................................................................AS-121
Variable Geometry............................................................................AS-121
Turbocharger, Variable Geometry Actuator ...........................................DS-28
Remove.................................................................................................DS-28
Variable Geometry.............................................................................DS-28
Turbocharger, Variable Geometry Actuator Air Supply Line .................DS-27
Remove.................................................................................................DS-27
Turbocharger, Variable Geometry Actuator Air Supply Line ...............AS-123
Install...................................................................................................AS-123
Turbocharger, Variable Geometry Control Valve Air Supply Line .........DS-26
Remove.................................................................................................DS-26
Turbocharger, Variable Geometry Control Valve Air Supply Line .......AS-124
Install...................................................................................................AS-124
Valve Guide Seal, Cylinder Head ...............................................................2-39
Finishing Steps.........................................................................................2-47
On-Engine Repair.................................................................................2-47
Off-Engine Repair.................................................................................2-47
General Information..................................................................................2-39
Install........................................................................................................2-43
Preparatory Steps.....................................................................................2-39
On-Engine Repair.................................................................................2-39
Off-Engine Repair.................................................................................2-40
Remove....................................................................................................2-40
Vehicle Braking - Overview .......................................................................F-59
General Information..................................................................................F-59
Vibration Damper, Viscous .....................................................................DS-59
Remove.................................................................................................DS-59
Automotive Applications.....................................................................DS-59
Industrial and Power Generation with Crank-Driven Fan or PTO.........DS-59
Industrial and Power Generation without Crank-Driven Fan or PTO.....DS-
60
Vibration Damper, Viscous ......................................................................AS-65
Eccentricity Check..................................................................................AS-68
All Applications..................................................................................AS-68
Install.....................................................................................................AS-65
Automotive Applications.....................................................................AS-65
Industrial and Power Generation with Crank-Driven Fan or PTO.........AS-66
Industrial and Power Generation without Crank-Driven Fan or PTO.....AS-
67
Wobble Check........................................................................................AS-68
All Applications..................................................................................AS-68
Vibration Damper, Viscous ......................................................................1-119
Clean and Inspect for Reuse...................................................................1-122
All Applications...................................................................................1-122
Eccentricity Check..................................................................................1-126
All Applications...................................................................................1-126
Finishing Steps.......................................................................................1-126
Automotive Applications......................................................................1-126
Industrial and Power Generation with Crank-Driven Fan or PTO..........1-127
Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
127
Cummins Inc.
Service Manual
Service Manual Signature, ISX, and QSX15

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX, and QSX15
Registered Office
Cummins Ltd.
Volume 1
Staines,
Middlesex TW18 2BD,
England
Copyright© 2011
Cummins Inc.
Volume 1
Bulletin 3666239
Printed in U.S.A. 02-MAY-2011 p41
312382_Cummins_Vol1.indd 1 5/10/11 7:10 PM

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

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

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

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

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

Signature™, ISX, and QSX15 Eng [...] About the Manual
About the Manual

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

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

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

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

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

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

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

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

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

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

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

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

Section Contents
Page
Cylinder Head ....................................................................................................................................................2-5
Assemble........................................................................................................................................................2-32
Clean..............................................................................................................................................................2-10
Disassemble................................................................................................................................................... 2-17
Finishing Steps...............................................................................................................................................2-38
Initial Check......................................................................................................................................................2-6
Install..............................................................................................................................................................2-37
Leak Test........................................................................................................................................................2-11
Measure..........................................................................................................................................................2-27
Remove............................................................................................................................................................2-8
Vacuum Test...................................................................................................................................................2-15
Injector Camshaft Scissor Gear ......................................................................................................................2-86
Install..............................................................................................................................................................2-87
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft End Clearance, Valve .....................................................................................................2-81
Measure..........................................................................................................................................................2-81
Overhead Camshaft Bushings, Injector ..........................................................................................................2-69
Initial Check....................................................................................................................................................2-69
Install..............................................................................................................................................................2-74
Remove.......................................................................................................................................................... 2-69
Overhead Camshaft Bushings, Valve .............................................................................................................2-57
Initial Check....................................................................................................................................................2-57
Install..............................................................................................................................................................2-62
Remove.......................................................................................................................................................... 2-57
Overhead Camshaft End Clearance, Injector .................................................................................................2-83
Measure..........................................................................................................................................................2-83
Overhead Camshaft Gear, Valve .....................................................................................................................2-86
Install..............................................................................................................................................................2-86
Remove.......................................................................................................................................................... 2-86
Overhead Camshaft, Injector ..........................................................................................................................2-51
Finishing Steps...............................................................................................................................................2-55
Install..............................................................................................................................................................2-55
Remove.......................................................................................................................................................... 2-53
Overhead Camshaft, Valve ..............................................................................................................................2-47
Finishing Steps...............................................................................................................................................2-50
Install..............................................................................................................................................................2-50
Remove.......................................................................................................................................................... 2-48
Service Tools ....................................................................................................................................................2-1
.........................................................................................................................................................................2-1
Valve Guide Seal, Cylinder Head ....................................................................................................................2-39
Finishing Steps...............................................................................................................................................2-47
On-Engine Repair.........................................................................................................................................2-47
Install..............................................................................................................................................................2-43
Page 2-b Section 2 - Cylinder Head - Group 02
On-Engine Repair.........................................................................................................................................2-39
Remove.......................................................................................................................................................... 2-40
Signature™, ISX, and QSX15 Eng [...] Service Tools
Service Tools
Cylinder Head
Repair Location.

Protective Plug Kit
4918319
Four-Valve Spring Compressor

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

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

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

Injector Camshaft Bushing Installation and Removal Tool

Service Tools Signature™, ISX, and QSX15 Eng [...]

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

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

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

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

Use to remove the valve seal.
3163293
Valve Guide Installer

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

and all related components.
Preparatory Steps
WARNING
personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the negative
WARNING
Do not remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam can cause personal
injury.
WARNING
• Disconnect the batteries or air supply to the air starter to prevent
accidental engine starting. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section
8.
• Remove the turbocharger. Refer to Procedure 010-033 in Section
10.
• Remove the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
• Remove the thermostat housing. Refer to Procedure 008-014 in
Section 8.
• Remove the air intake connection.Refer to Procedure 010-080 in
Section 10.
• Remove the integrated fuel system module. Refer to Procedure
engines, in the Signature™, ISX and QSX15 Electronic Control
engines, in the Signature™ and ISX CM870 Electronic Control
engines, in the ISX CM871 and ISM CM876 5 Electronic Control
• Remove the air compressor air inlet hose.Refer to Procedure
• Remove the rocker lever cover.Refer to Procedure 003-011 in
Section 3.
• Remove the rocker lever shaft assemblies. Refer to Procedure
• Remove the injectors. Refer to ProcedureRefer to Procedure
• Remove the upper front gear cover. Refer to Procedure 001-079
in Section 1.
• Remove the valve and injector camshaft gears.Refer to Procedure
• Remove the retaining brace bracket. Refer to Procedure 001-081
in Section 1.
• Remove the accessory bracket. Refer to Procedure 001-082 in
Section 1.
• Remove the overhead valve camshaft. Refer to Procedure 002-024
in Section 2.
• Remove the overhead injector camshaft. Refer to Procedure
Remove
WARNING
gasket.
CAUTION
Immediately upon removal of the cylinder head, plugs
must be installed into the oil passage drillings in both
the cylinder head and the block. The plugs are
necessary to prevent debris from entering the
lubrication system during the repair. Failure to insert
the oil passage plugs can result in a connecting rod
bearing failure, crankshaft failure or both.
Reusable plugs, Part Number 4089255, are included in
the master plug kit, Part Number 4918319.
Install the plugs in the cylinder block and cylinder head oil
drillings.


Inspect for Reuse


mm in
1.21 MAX 0.048
0.77 MAX 0.030

mm in
If the valve recess is not within specifications, the cylinder
head must be reconditioned.
Prior to cleaning the cylinder head combustion surface,

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

Inspect the cylinder head combustion surface for pitting
or erosion.
located in the area where the cylinder liner fire dam
located inside the fire ring area is acceptable.
Clean
the oil passages.
the cylinder head.

the oil passages.
See the Leak Test section of this procedure for more
cleaning details.
CAUTION
Make sure the plugs are installed in the oil passages of
the cylinder block deck.
Plug or cover the coolant passages in the cylinder block
deck.
WARNING
Use a gasket scraper to clean the cylinder block deck
surface.
equivalent, and solvent to remove any residual gasket
material from the cylinder block deck surface.
Use a chip vacuum to remove the excess oil and coolant
from the capscrew holes.
Make sure the cylinder head capscrew holes are clean
and free of debris, oil, and coolant.
Do not use power tools to clean the combustion face.
Leak Test
Fuel Passage
NOTE: This task can be preformed either on or off-engine.
The fuel system is split into two banks.
The front bank is for cylinders one through three, and the
rear bank is for cylinders four through six.
The banks are tested independently of each other. Use
test kit, Part Number 3164943.
The left three male connectors on the plate are for the front
bank and the right three male connectors are for the rear
bank.
The three male connectors on the plate are:
• Metering
• Timing
• Return.
Apply thread sealant to the male connectors and install

them into the plate, if they are not installed.
Install the gasket, plate, two short capscrews (5), and two
long capscrews (4).
Install the injector cavity plug (3) into the appropriate

injector bores.

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

Apply thread sealant and install the male connector (7)

into the plate (3) if it is not installed.
Install the gasket (4) and plate (3) onto the cylinder head
at the thermostat location.
Install the capscrews (8) and washers (9).
to the male connector.
Install the injector cavity plugs (6) into the injector bores.
WARNING
Place the cylinder head into a tank of water.
replaced.
An alternate method to placing the cylinder head into a

tank of water is to use a water and soap solution.
Spray the cylinder head with a mild water and soap
solution.
replaced.
Valve Seat
Set the head down with the intake ports on the bottom.
Pour fuel into the exhaust port until it is full.
Start the timer.

within 30 seconds, inspect the valves and seats to
determine the necessity of parts replacement. The valve
and valve seat must be checked using the vacuum test
procedure.
sealing properly.
Drain the fuel from the exhaust side of the head.

Turn the head over so the exhaust port is on the bottom.
Pour fuel into the intake ports until full.
Start the timer.

within 30 seconds, the valve and valve seat interface
must be checked using the vacuum test procedure.
sealing properly.
Vacuum Test
Use valve vacuum tester, Part Number ST-1257, to
inspect the seal between the valve and the valve seat. To
perform this test, the cylinder head must either be sitting
on its side or turned upside down so that the combustion
face can be accessed.
The valve vacuum tester can be used to test all Cummins®
engine models. The seal ring, Part Number ST-1257-35,
and vacuum cup, Part Number ST-1251-6, are used to
seal the cylinder head inserts.
Install the seal ring and vacuum cup to the vacuum line
(hose).
The valves and valve seats must be clean and dry when
vacuum testing.
Make sure the combustion face of the cylinder head is
clean and dry and there is no loose debris in the valve
recess.
This will help to provide a good vacuum cup to cylinder
head sealing surface.
Move the toggle switch (1) to the ON position.

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

specified vacuum.
Valve to Valve Seat Vacuum

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

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

following checks:
• Repeat the test to be sure the equipment is operating
properly.
• Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
• Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage
between the valves and valve seat or the valve seat insert
Disassemble
Prior to disassembly, make sure the valve recess has been
measured and recorded.
WARNING
Place the cylinder head combustion face down on a clean,
smooth and level work surface that is sturdy enough to
support the weight of the cylinder head.
WARNING
CAUTION
engine.
The replacer screw pilots in the injector bore and is
secured using the injector hold-down clamp.
CAUTION
screw (1).
Tighten hand-tight.
WARNING
start to compress.
CAUTION
WARNING


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

NOTE: Only remove the valve guides if they were not

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

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

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

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

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

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

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

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

Wear in the area where the cylinder liner fire dam contacts
the head is acceptable.
Wear in the area where the fire ring combustion seal
To distinguish the difference, use one of the inspection
gauges detailed below.

top liners and a single-piece head gasket or, when
Inspect the area within 1/8-inch of the outside diameter of
the tool all the way around its perimeter. Any wear that can
be felt with a fingernail within the 1/8-inch area is
unacceptable, making the cylinder head not reusable.
Wear beyond this 1/8-inch area will have no effect on
head.

Inspect the area within the narrow slots cut into the tool.
Rotate the tool to view the entire wire ring area on the
cylinder head combustion face.
Any wear that can be felt by fingernail within these slots
is unacceptable, making the cylinder head not reusable.
Wear outside the slots will have not have an effect on
head.
Inspect the valve spring retainers and valve spring guides

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

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

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

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

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

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

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

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

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

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

Measure the inside diameter of the valve guides in
locations 13 mm [½ in] from each end and at the center
as shown.
Used Valve Guide Inside Diameter (Installed)

mm in
9.663 MIN 0.380
9.713 MAX 0.382
If the valve guide inside diameter is not within
Measure the valve guide installed height.

mm in
44.77 MIN 1.763
45.77 MAX 1.802
If damage is found or the valve guide is not within


mm in
1.21 MAX 0.048
0.77 MAX 0.030

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

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

head.
Insert Bore Depth

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

mm in
49.54 MAX 1.950
47.54 MAX 1.872
If the valve seat insert bore inside diameter is not within

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

cylinder head.

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

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

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

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

cylinder head top deck surface.

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

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

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

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

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

CAUTION
Before the cylinder head is assembled onto the block,
all oil passage plugs must be removed. Failure to
remove the oil plugs will result in extensive engine
damage.
Remove the oil plugs from the cylinder head and the
cylinder block.
Install
WARNING
position.

capscrews.
CAUTION
Torque Value:
Step 1 203 N•m [ 150 ft-lb ]
Step 2 407 N•m [ 300 ft-lb ]
Finishing Steps
NOTE: If the cylinder head or the cylinder head gasket is being replaced
due to a malfunction that caused an internal coolant leak, the external
crankcase breather element must be replaced, if the unit is equipped with
an external crankcase breather element.
WARNING
WARNING
personal injury, always ventilate the compartment before servicing
the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery
cable last.
• Install the overhead injector camshaft. Refer to Procedure 002-025 in
Section 2.
• Install the overhead valve camshaft. Refer to Procedure 002-024 in
Section 2.
• Install the accessory bracket. Refer to Procedure 001-082 in Section
1.
• Install the retaining brace bracket. Refer to Procedure 001-081 in
Section 1.
• Install the valve and injector camshaft gears. Refer to Procedure
• Install the upper front gear cover. Refer to Procedure 001-079 in
Section 1.
• Install the injectors. Refer to Procedure 006-026 in Section 6.
• Install the rocker lever shaft assemblies.Refer to Procedure 003-009
in Section 3.
• Adjust the overhead settings. Refer to Procedure 003-004 in Section
3.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section
3.
• Install the air compressor air inlet hose. Refer to Procedure 012-014
in Section 12.
the Signature™, ISX and QSX15 Electronic Control System,
the Signature™ and ISX CM870 Electronic Control System,
the ISX CM871 and ISM CM876 5 Electronic Control System,
• Install the integrated fuel system module.Refer to Procedure 005-073
in Section 5.
• Install the air intake connection. Refer to Procedure 010-080 in
Section 10.
• Install the thermostat housing. Refer to Procedure 008-014 in Section
8.
• Install the exhaust manifold. Refer to Procedure 011-007 in Section
11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Install the batteries or air supply to the air starter. Refer to the OEM
service manual.
• If a malfunction resulted in coolant, oil, excessive fuel or excessive
black smoke entering the exhaust system, the aftertreatment system
must be inspected.Refer to Procedure 014-013 in Section 14.
Signature™, ISX, and QSX15 Eng [...] Valve Guide Seal, Cylinder Head
Valve Guide Seal, Cylinder Head

(002-016)
General Information
on Signature™, ISX, and QSX15 engines.
guide seals.
Engine serial number (ESN) 14010274 and all engines

built after, use a larger valve guide seal. These seals are
designed to be installed by hand without the seal driver.
guide. The seals introduced into engines built after ESN
14010274 with the grooved valve guides are not
compatible with engines built with the non-grooved valve
guides and vice versa.
had two iterations.
ESN 14010274.
Preparatory Steps
On-Engine Repair
WARNING
WARNING
• Disconnect the engine brake solenoid wiring
• Remove the injector for the cylinder to be repaired.
Valve Guide Seal, Cylinder Head Signature™, ISX, and QSX15 Eng [...]
Bar the engine over so the cylinder you are working on is

at top-dead-center (TDC). Refer to Procedure 003-004 in
Section 3.
Repeat this step as needed for each cylinder.
Off-Engine Repair
WARNING
assembly.
• Remove the cylinder head and set it on a bench or
table. Refer to Procedure 002-004 in Section 2.
Remove
WARNING
CAUTION
engine.
NOTE: This step can be preformed either on or off-engine.
Use valve spring compressor, Part Number 4919358, to
compress the valve springs.
Remove the spring retainer collets.
CAUTION
screw (1).
Tighten finger tight.
WARNING
start to compress.
CAUTION
WARNING
Remove the replacer screw (1) by removing he injector


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

to remove the valve guide seals.
Install
Grooved Valve Guide Seals:
had two iterations.
ESN 14010274.
Install the intake and exhaust valve guide seals by
snapping the seal by hand into the groove on the valve
guide.
Non-Grooved Valve Guide Seals:

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

Install the valve spring.
Install the valve spring guide.
WARNING
CAUTION
engine.
CAUTION
screw (1).
Tighten the nut finger tight.
WARNING
start to compress.
CAUTION
valve collets can be installed.
head.
WARNING

Signature™, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
Finishing Steps
On-Engine Repair
WARNING
• Install the injectors. Refer to Procedure 006-026 in
Section 6.
• Connect the engine brake solenoid wiring harness.
in Section 8.
operation.
Off-Engine Repair
WARNING
assembly.
in Section 2.
operation.

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

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

Procedure 020-015.
003-009.

001-088.
Remove
Signature™, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
CAUTION
WARNING
WARNING
personal injury.
Clean the valve camshaft and the bore of the valve
camshaft gear with Envirosol 655 solvent, or equivalent,
and a lint-free cloth.
Check the valve camshaft and valve camshaft gear for

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

bearing journals.
Valve Camshaft Bearing Journal Outside Diameter

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

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

Finishing Steps
001-088.
Signature™, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector

Connect the engine brake wiring harness. Refer to
Procedure 020-015.


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

003-011.

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

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

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

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

CAUTION
WARNING
WARNING
Clean the injector camshaft and the bore of the injector
camshaft scissor gear with Envirosol 655 solvent, or
equivalent and a lint-free cloth.
Check the injector camshaft and injector camshaft scissor

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

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

damage.
Refer to the Camshaft Reuse Guidelines for Cummins®
Engines with Roller Tappets, Bulletin 3666052, for further
reuse guidelines.
Install
CAUTION


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

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

Procedure 001-088.


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

check for leaks.
Overhead Camshaft Bushings, Valve

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

Remove

Overhead Camshaft Bushings, Valve Signature™, ISX, and QSX15 Eng [...]
NOTE:
2, 3, 4, 5, 6, 7, 8, 9, and 10.
2, 3, 4, 5, 6, 11, 12, and 13.
2, 3, 4, 5, 6, 14, 15, and 16.
Step 1
CAUTION
ends.
Step 2
centering guides.
Step 3
valve camshaft bushing replacer kit, Part Number
Step 4
Step 5
Step 6
CAUTION


WARNING
pedal.

shaft.



WARNING
pedal.


camshaft bushing.

WARNING
pedal.

Inspect for Reuse

Install
The hydraulic camshaft bushing tool Kit, Part Number

NOTE:
1, 2, 5, 6, 7, 8, 9, 10, and 11.
1, 3, 5, 6, 7, 12, 13, 14, and 15.
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1
CAUTION

the same as above.

guides.

Step 5
Step 6
Step 7

CAUTION
equipment.

CAUTION

WARNING
pedal.


CAUTION
equipment.
shaft.

CAUTION
engine.

WARNING
pedal.


CAUTION
equipment.

CAUTION
engine.

WARNING
pedal.
bore.

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

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

check for leaks.
Overhead Camshaft Bushings, Injector

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

Remove

Overhead Camshaft Bushings, Injector Signature™, ISX, and QSX15 Eng [...]
NOTE:
2, 3, 4, 5, 6, 7, 8, 9, and 10.
2, 3, 4, 5, 6, 11, 12, and 13.
2, 3, 4, 5, 6, 14, 15, and 16.
Step 1
CAUTION
ends.
Step 2
centering guides.
Step 3
injector camshaft bushing replacer kit, Part Number
Step 4
Step 5
Step 6
CAUTION


WARNING
pedal.

shaft.



WARNING
pedal.


camshaft bushing.

WARNING
pedal.

Inspect for Reuse

Install

NOTE:
1, 2, 5, 6, 7, 8, 9, 10, and 11.
1, 3, 5, 6, 7, 12, 13, 14, and 15.
1, 4, 5, 6, 7, 16, 17, 18, and 19.
Step 1
CAUTION

the same as above.

guides.

Step 5
Step 6
Step 7

CAUTION
equipment.

CAUTION

WARNING
pedal.


CAUTION
equipment.
shaft.

CAUTION
engine.

WARNING
pedal.


CAUTION
equipment.

CAUTION
engine.

WARNING
pedal.
bore.

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

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

check for leaks.

Valve (002-028)
Measure
003-011.

003-009.

001-079.
Overhead Camshaft End Clearance, Valve Signature™, ISX, and QSX15 Eng [...]

Procedure 001-088.
CAUTION
Valve Camshaft End Clearance

mm in
0.70 MAX 0.0276
overhead valve camshaft. Refer to Procedure 002-024.

001-088.

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

check for leaks.

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

003-009.

001-079.

Procedure 001-088.
CAUTION
Injector Camshaft End Clearance

mm in
0.70 MAX 0.0276
injector overhead camshaft. Refer to Procedure 002-025.
Signature™, ISX, and QSX15 Eng [...] Overhead Camshaft End Clearance, Injector

001-088.

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

check for leaks.
Overhead Camshaft Gear, Valve

(002-030)
Remove
001-088.
Install
001-088.

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

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

Service Tools
Rocker Levers
Repair Location.

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

Used to adjust the engine brake.
3163530
Overhead Setting Kit
3163167
Inch Pound Torque Wrench
3376592
3163171
3163172
Crankcase Breather (External) Signature™, ISX, and QSX15 Eng [...]

(003-001)
Remove
engine.

cover and block.

pressure sensor.
clamp.
do not bend.
Signature™, ISX, and QSX15 Eng [...] Crankcase Breather (External)
Disassemble
Disassemble the crankcase breather assembly. Refer to
Procedure 003-019.
NOTE: All capscrews are captive capscrews.

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

cracks or other damage. Replace if necessary.
WARNING
personal injury.
Clean breather crankcase housing and breather
crankcase cover with solvent.
Check for cracks in crankcase breather element housing
and crankcase breather cover. Replace if necessary.
Assemble
Assemble the crankcase breather assembly. Refer to
Procedure 003-019.
Install
Signature™, ISX, and QSX15 Eng [...] Crankcase Breather (Internal)

breather sensor.
Torque Value:
M10 47 N•m [ 35 ft-lb ]
M8 20 N•m [ 15 ft-lb ]
Crankcase Breather (Internal)

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

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

and remove the breather.

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

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

Install the upper gear cover. Refer to Procedure 001-079
Install the oil seal into the seal carrier.

The groove side (1) must be installed toward the engine.
Make sure the seal carrier is tight in the front cover. If not,
tighten the seal carrier.
Install the breather tube assembly into the seal carrier.
Torque to the breather tube assembly.
Overhead Set Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
Procedure 003-001 (Crankcase Breather (External))
in Section 3.

Measure
General Information


damper.
Signature™, ISX, and QSX15 Eng [...] Overhead Set

cover.
compressor drive.
WARNING
damage.
(1-2-3-4-5-6).



damper.

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

gear cover.

the pointer again.
Valve Lash
this procedure.
the brake lash.



mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
load.
Preparatory Steps
WARNING
cable last.
Disconnect the battery.

attempting to adjust/set the overhead. Refer to Procedure
001-088 (Engine Base Timing) in Section 1.
All overhead valve, injector, and brake adjustments
must be made when the engine is cold (any stabilized
coolant temperature at 60°C [140°F] or below).
Adjust


damper.

cover.
compressor drive.
WARNING
damage.
(1-2-3-4-5-6).




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

gear cover.

the pointer again.

cylinder.
as required.
be read accurately.
screw.
injector.



adjusting screws.

specification.

mm in


locknut.

CAUTION
and BRAKE SET 3-4.


the pointer again.



mm in
7.00 NOM 0.276


the locknut.
CAUTION
(neutral) position.

mm in
0.635 MIN 0.025
2.790 MAX 0.110
not completed.
specification.

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Finishing Steps
Procedure 003-011 (Rocker Lever Cover) in Section
3.
Signature™, ISX, and QSX15 Eng [...] Rocker Lever Assembly
WARNING
cable last.
Connect the battery.
has entered the exhaust system, Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14..

Preparatory Steps
Remove the engine brake solenoid valve wiring harness.
003-011.
Remove the engine brake wiring harness. Refer to
Procedure 020-015.
Remove
CAUTION
can occur.
each rocker lever.
Rocker Lever Assembly Signature™, ISX, and QSX15 Eng [...]
CAUTION

shafts.
rocker levers.
rocker lever.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the rocker lever shaft.
Be sure to blow out the oil passages.
WARNING
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the valve crossheads,
rocker lever adjusting screw, and nuts.
Inspect the valve and brake rocker lever shaft for cracks
or damage.
Measure the valve and brake rocker lever shaft outside
diameter in the bushing wear area.
Valve and Brake Rocker Lever Shaft Outside Diameter

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

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

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

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

inside diameter.
Valve and Brake Rocker Lever Bushing Bore Inside

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

diameter.
Injector Rocker Lever Bushing Bore Inside Diameter

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

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

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

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

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

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

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

WARNING
cylinder head.
CAUTION
capscrews.
direction.


CAUTION
003-004.
the shaft.
the center out.

CAUTION
003-004.
the shaft.
the center out.

cylinder head.

from center out.
Rocker Lever Cover Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
Install the engine brake wiring harness. Refer to
Procedure 020-015.
Install the engine brake solenoid valve wiring harness.

Remove

cover.
assemblies.

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

Inspect the cover gasket beads for cuts, missing beads,

kinks, twists, wear, or other damage.
A gouged hole is acceptable if the bead is not damaged.
Crankcase Breather Element Signature™, ISX, and QSX15 Eng [...]
Install
cover.
each span.
other damage.

Crankcase Breather Element (003-019)

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

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

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

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

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

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

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

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

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

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

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

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

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

Remove the fuel control cover.
Clean the area surrounding the pump.
Remove the four fuel pump capscrews and remove the
fuel pump from the integrated fuel system module.
Discard the o-ring seals or gasket.

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

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

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

the fuel pump.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Industrial Engine Mounted

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

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

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

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

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

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

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

Connect the adapter and lift pump assembly.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Section 6 - Injectors and Fuel Lines - Group 06 Page 6-a
Section 6 - Injectors and Fuel Lines - Group 06

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

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

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

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

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

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

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

(006-006)
Preparatory Steps
NOTE: Some chassis will allow the ECM to be moved
aside with the wiring harness attached, for access to the
cooling plate.
• Disconnect the engine wiring harness and OEM
harness connectors, if necessary. Refer to
Repair Manual CM870 Electronic Control System
Signature™, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
Remove
Disconnect the ECM cooling plate fuel supply line (bottom)
from the integrated fuel system module and the ECM
cooling plate.
Disconnect the ECM cooling plate fuel return line (top)
from the fuel pump and the ECM cooling plate.
Remove the five ECM mounting capscrews and the ECM.

Remove the six cooling plate mounting capscrews and
washers.
Remove the cooling plate and gasket.
Remove five insulating washers and the one ground

washer from the cooling plate mounting holes.
WARNING
WARNING
personal injury.
Clean the cooling plate mounting surfaces with solvent.
ECM Cooling Plate, Fuel Cooled Signature™, ISX, and QSX15 Eng [...]
WARNING
personal injury.
NOTE: If the sealing bead or groove is dirty, a leak can
result.
Clean the ECM cooling plate gasket sealing bead with a
dry cloth.
Make sure no rust or soot has accumulated in the grooves
on either side of, or on top of, the sealing bead.
Use compressed air to remove debris from the grooves, if
necessary.
Inspect the five insulating washers and the one ground

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

Replace the cooling plate if cracks or damage is found.
Check the cooling plate fuel supply and return line fittings
on the ECM cooling plate, integrated fuel system module,
and fuel pump to make sure the o-rings are installed
properly and are not damaged.
Replace the o-ring, fitting, or cooling plate if damaged.
Signature™, ISX, and QSX15 Eng [...] ECM Cooling Plate, Fuel Cooled
Install
Install five insulating washers. The one ground washer
must be installed in the upper left cooling plate mounting
capscrew hole.
CAUTION
Make sure that the insulating washers and the ground
washer are installed properly on the cooling plate or
malfunction of the ECM can occur.
Install the cooling plate gasket.
Install the six cooling plate mounting capscrews and
washers.
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Install the ECM cooling plate fuel supply line (bottom) to

the integrated fuel system module and the ECM cooling
plate.
Install the ECM cooling plate fuel return line (top) to the
fuel pump and the ECM cooling plate.
Finishing Steps
• Connect the ECM harness and engine wiring
harness. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
• Start the engine and check for fuel leaks.
Fuel Filter (Spin-On Type) Signature™, ISX, and QSX15 Eng [...]
Fuel Drain Line Restriction (006-012)

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

mm Hg in Hg
With Check Valve 165 MAX 6.5
Without Check Valve 229 MAX 9
If restriction exceeds specifications, inspect the drain lines
for the cause of the restriction. Fuel coolers and fuel
heaters can cause excessive drain line restriction.
Excessive restriction can cause low power and poor fuel
economy.
Remove the adapter and pressure gauge. Install the fuel
drain hose.
If damage resulted in coolant, oil, excessive fuel or

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

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

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

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

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

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

the IFSM. Insert a Compuchek™ fitting in this location and
run a line to a catch container.
Start the engine.

After the fuel lift pump stops running and with the engine
operating at idle, disconnect the hose to the catch
container.
Connect the vacuum gauge to the Compuchek™ fitting and
measure the fuel inlet restriction.
Operate the engine at high idle and no load.
Fuel Inlet Restriction

mm Hg in Hg
Upper Location 356 MAX 14
Lower Location 305 MAX 12
An inlet restriction greater than specification indicates
either a dirty fuel filter or a restriction in the OEM fuel
supply plumbing. Inlet restriction at the fuel supply
connection must be checked to identify the correct
source of the restriction.
Remove
WARNING
3400157.
WARNING
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
3400158.
Signature™, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Clean
All Applications
Use a clean, lint-free cloth to clean the filter head gasket
surface.
Install
must also have a minimum of 98.7 percent 15-micron
surface.
CAUTION
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Tighten the filter an additional ¾ of a turn after the gasket
manufacturer.
To perform the priming procedure, use the following

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

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

CAUTION
manufacturer.
harness.

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

Pump
CAUTION
manufacturer.
harness.

position. The priming pump will operate for 2 minutes,
then be started.
Fuel Inlet Restriction (006-020)

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

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

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

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

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

Observe the reading on the vacuum gauge.

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

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

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

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

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

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

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

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

front three cylinders. Install the fuel-metering actuator
removed previously. Use the ISX Fuel System
Troubleshooting and Repair Manual, Bulletin 3666259.
Remove the fuel-metering actuator for the rear three
cylinders.
Install the Injector Leak Test Kit, Part Number 3164001, in
place of the rear fuel-metering actuator.
Place the flexible tubing into a container of water.
Repeat the above procedure for the rear three cylinders.
Bar the engine over and note between which two timing
marks the bubbles occur.
If the bubbles occur between:
• A and B (number 4 injector is leaking)
• B and C (number 6 injector is leaking)
• C and A (number 5 injector is leaking).
Replace the leaking injector(s). Go to the remove section

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

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

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

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

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

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

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

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

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

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

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

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

Slowly, remove pressure from the injector, releasing the

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Protective Plug Kit
4918319
Lubricating Oil Cooler Signature™, ISX, and QSX15 Eng [...]

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

WARNING
WARNING
WARNING
WARNING
008-018 (Cooling System) in Section 8.
007-013 (Lubricating Oil Filter (Spin-On)) in Section
7.
• Remove the turbocharger. This step is not required
with a die cast oil cooler. Refer to Procedure 010-033
• Remove the alternator. Refer to Procedure 013-001
(Alternator) in Section 13.
Remove
All Applications
Remove two oil cooler mounting capscrews and install the
guide pins.
Clean the area above the oil cooler to prevent debris entry
into the oil passages.
WARNING
Remove the remaining 18 capscrews, oil cooler, and
gasket. Discard the gasket.
CAUTION
Immediately upon removal of the lubricating oil cooler
assembly, a plug must be inserted into the housing
and cylinder block oil passage drillings. Failure to
insert the oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plugs, Part Numbers 4918322, 4918324,
and 4918340, are included in protective plug kit, Part
Number 4918319. These plugs are necessary to prevent
debris from entering the lubrication system during the
repair.
Plug the oil cooler housing filtered oil passage with plug,
Part Number 4918323, the block filtered oil passage with
plug, Part Number 4918340, and the block oil pump
passage with plug, Part Number 4918322.
Firmly push the plugs into the oil passages to prevent all
the gasket surface.

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

mm in
123.47 MIN 4.861
Install the oil thermostat. Refer to Procedure 007-039
(Lubricating Oil Thermostat) in Section 7.
CAUTION
Do not reuse an oil cooler core after a debris related
engine failure since there is no practical method for
cleaning the cooler core. Metal particles which can
circulate through the lubricating system can remain in
the cooler core and cause engine damage. Do not
allow dirt to enter the oil passages when cleaning the
oil cooler.
WARNING
personal injury.
WARNING
personal injury.
CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cooler housing when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages.
Plug the oil cooler passages with rubber plugs, Part
Numbers 4918322, 4918323, and 4918340, included in
kit, Part Number 4918319, to prevent debris from entering
the cooler when cleaning the gasket surface.
Clean gasket surfaces by hand with a gasket scraper or
cleaning pad, Part Number 3823258. If the gasket material
residue can not be felt with a finger, the surface is ready
to accept the new gasket.
Use solvent to clean and flush the oil cooler passages and
cores.
Blow dry with compressed air.
Remove the rubber plugs when cleaning is complete.
CAUTION
passages in the cylinder block when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages. Therefore, use of power tools combined
with abrasive pads to clean gasket surfaces is not
recommended.
Plug the oil passages in the cylinder block with rubber
plugs.
Clean the oil cooler to cylinder block gasket surface with
Scotch-Brite™ 7448 abrasive pad.
Remove the rubber plugs when cleaning is complete.
Leak Test
All Applications
It is important to leak test the oil cooler assembly as a unit,
so leaks at the mounting joints can be identified. These
leaks can not be found when testing individual elements
that have been removed from the assembly. An element
is replaced only if it is found to be leaking.
This procedure is most effective when the oil cooler
assembly is tested in water below 7°C [44°F].
Use the mounting capscrews from the lubricating oil
cooler to attach the two plates and corresponding o-rings
from oil cooler leak test kit, Part Number 4918200, to the
lubricating oil cooler housing.
Remove the threaded male union that connects to the

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

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

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

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

(007-007)
Preparatory Steps
Remove the lubricating oil cooler. Refer to Procedure
007-003.
Disassemble
Single-Element
Remove the element from the lubricating oil filter head.
Dual-Element
Remove the elements from the lubricating oil filter head.
Remove the oil cooler tube.
Lubricating Oil Cooler Element Signature™, ISX, and QSX15 Eng [...]
CAUTION
Do not damage the oil cooler tube when cutting the
vibration isolators to remove them. Engine damage
can occur.
Remove the vibration isolators by cutting a slit in them.
Discard the isolators.
WARNING
WARNING
personal injury.
CAUTION
passages in the cooler element when cleaning. Rod
bearing failures can be caused if debris is introduced
into the lube cooler housing oil passages.
Use solvent to clean the element.
Remove all old gasket material from the element.
Inspect the oil cooler tube for cracks. Replace the cooler
tube if cracks are found.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil Cooler Element
Pressure Test
NOTE: An oil cooler element pressure test plate can be
constructed from a thin aluminum plate that allows the oil
cooler element to be mounted and air pressure applied to
the element inlet. An oil cooler pressure test tool does
not exist.
Install the oil cooler element and gaskets to the pressure
test plate.
Apply 689 kPa [100 psi] regulated shop air.

Inspect the test plate and gaskets for leaks.
Submerge in a tank of room temperature water.
Replace the oil cooler element if a steady stream of
bubbles is observed from the element.
Slow forming bubbles (less than one rising to the surface
of the water every 30 seconds) do not constitute a leaking
oil cooler element.
Do not replace non-leaking oil cooler elements. If no oil
cooler element leaks are found install the existing oil
cooler element with new gaskets and new capscrews.
To clean contaminated lubricating oil from the engine,
refer to Procedure 007-037.
WARNING
personal injury.
CAUTION
Do not allow dirt or foreign material to enter the oil
cooler element passages when cleaning. Engine
damage can result.
Remove the cooler element from the tank.
Remove the test equipment and dry with compressed air.
Lubricating Oil Cooler Element Signature™, ISX, and QSX15 Eng [...]
Assemble
Single-Element
CAUTION
The single-element oil cooler assembly is for use only
on ISX1 and ISX2 engines. Engine oil overheating can
result if used on ISX3, and Signature 600 engines.
Install non-leaking lubricating oil cooler elements onto the
lubricating oil filter head with new gaskets and capscrews.
Assemble the cooler element(s) to the housing with the
following parts from the engine oil cooler kit.
Engine Oil Cooler Kit Contents

Quantity Description
4 Capscrews (short)
2 Capscrews (long)
3 Gaskets (rubber flash)

Install the lubricating oil cooler assembly. Refer to
Procedure 007-003.
Dual-Element
NOTE: The vibration isolators must be cut to allow
assembly over the cooler tube. Make sure the vibration
isolators are oriented so the slit is not tightened against
the oil cooler housing or the oil cooler elements.
Install two new vibration isolators onto the oil cooler tube
as shown.
Install new gaskets.

Install the oil cooler tube.
Re-install non-leaking lubricating oil cooler elements onto
the lubricating oil filter head.
Install new capscrews and tighten.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil Dipstick
Finishing Steps
Install the lubricating oil cooler. Refer to Procedure
007-003.
check for leaks.
Lubricating Oil Dipstick (007-009)

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

the oil level. Label the mark with an H to indicate the HIGH
oil level.

(007-011)
Remove
clamp.

clamp.
Install
Tighten the clamp.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)

Tighten the clamp.

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

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

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

Inspect the o-ring on the retaining plug for cuts or tears.
Replace the o-ring if damaged.
Lubricating Oil Filter Bypass Valve Signature™, ISX, and QSX15 Eng [...]
Use a spring compression tester, Part Number 3375182,

to measure the relief valve spring tension.
Compress the spring to 29.65-mm [1.17-in] height. The
force required to compress the spring must be:
Force Required to Compress Spring to 29.65 mm [1.17

in]
N lbf
115.7 NOM 26
If the spring does not meet this specification, it must be
replaced.
Install
CAUTION
The notched end of the bypass valve (3) must be
installed toward the spring (2). If the bypass valve is
installed incorrectly, it will bypass the filter
continuously which can cause engine damage.
Lubricate all pieces and the o-ring seal. Install the plunger
(3) with the notched end toward the spring into the
lubricating oil cooler housing (4).
Install the spring (2), and retaining plug (1) into the
lubricating oil cooler housing (4).
Tighten the retaining plug.

007-037.

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

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

4918222, to remove the adapter from the housing.
Lubricating Oil Filter Head Adapter Signature™, ISX, and QSX15 Eng [...]
WARNING
Clean the threads of both the adapter and the oil filter head
housing with a clean towel and contact cleaner to remove
any residual Loctite™ and lubricating oil.
Inspect the adapter for cracks or other damage.
Install
WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the installation of the
adapter.
CAUTION
Do not use an impact wrench, to reduce the possibility
of damage to the oil filter head housing, adapter, or
tool.
Apply clean engine oil to the adapter-to-housing interface.
Apply service tool Loctite™ 2760, Part Number 3165083 to
the adapter. Apply Loctite™ to three threads, starting three
threads down from the top of the adapter and around the
entire circumference of adapter.
Install the adapter hand-tight into the housing. Torque the

filter head adapter with service tool, Part Number 3165082
or Part Number 4918222.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil High Pressure Relief Valve
Finishing Steps
• Fill the new oil filter with clean lubricating oil.
• Install the lubricating oil filter. Refer to Procedure
Lubricating Oil High Pressure Relief

Valve (007-021)
General Information
The high-pressure relief valve (1) is held in the closed
position by spring force (2). The valve remains in the
closed position until the oil pressure exceeds 1034 kPa
[150 psi] in the lubricating oil pump.
When the oil pressure exceeds 1034 kPa [150 psi] in the
lubricating oil pump, for instance, during cold start-up, the
oil pressure in the pump overcomes the relief valve spring
force.
This allows the excess oil to return to the oil pan,
preventing possible damage to the lubricating system
components.
Remove
WARNING
WARNING
Remove and disassemble the lubricating oil pump. Refer
Lubricating Oil High Pressure Relief Valve Signature™, ISX, and QSX15 Eng [...]
Inspect for Reuse

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

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

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

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

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

General Information
The cause of external oil leaks is hard to diagnose and correct because of the potential number of factors involved.
Although the location of a leak can sometimes seem obvious, it can also be difficult to isolate the exact location due
to fan blast and road grime that would cause the leak to migrate.
Before doing any repairs, it is important to locate the exact root cause of the leak to prevent misdiagnosis and further
downtime. Please use the diagrams below to troubleshoot any external oil leaks.
Begin by determining which quadrant of the engine the leak is located in. It will be necessary to start out by steam
cleaning the engine and then operating it on a dynamometer to look for the leak. Keep in mind where the oil looks the
most concentrated before the steam clean, as this will give a good indication of where to start looking for leaks.
Once the quadrant has been determined, look at the following diagram to get a good indication of where the leak can
be coming from on the exhaust side of the engine.
1. Lower front gear cover gasket leak 6. Oil spill from oil filter change
2. Gear housing gasket leak 7. Oil slobber from exhaust manifold
3. Oil pan gasket leak 8. Cam cover gaskets leaks
4. Flywheel housing gasket leak 9. Valve cover gasket leak
5. Lube cooler gasket leak
Lubricating Oil Leaks Signature™, ISX, and QSX15 Eng [...]
Look at this diagram to get a good indication of where the leak can be coming from on the intake side of the engine.
1. Valve cover gasket leak 7. Crankshaft position sensor o-ring leak
2. Cam covers gaskets leaks 8. Gear cover gasket leak
3. Crankcase blowby tube 9. Air compressor or power steering pump gasket leak
4. Flywheel housing gasket leak 10. Oil fill tube cracked or leak
5. Dipstick tube leak 11. Upper front gear cover cracked or gasket leak
6. Gear housing gasket leak
WARNING
CAUTION
Protect all electrical components, openings, and
wiring from the full force of the cleaner spray nozzle.
Use a steam cleaner or a high-pressure washer to clean
the engine.
Check the engine crankcase breather element, hose, and

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

oil filler cap.

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

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

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

shown.
At the end of the sequence, loosen and tighten capscrew
number 1again.
Install the oil drain plug.
Finishing Steps
Fill the lubricating oil pan. Refer to Procedure 007-037
Lubricating Oil Pump Signature™, ISX, and QSX15 Eng [...]
Lubricating Oil Pressure Gauge

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

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

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

lubricating oil pump body.
WARNING
WARNING
CAUTION
Do not allow dirt or gasket material to enter the oil
passages. Bearing damage can result.
Clean the lubricating oil pump components with solvent.
Use a bristle brush to clean any internal ports.
WARNING
WARNING
personal injury.
Use a steam cleaner to rinse the components.
Inspect the following areas of the lubricating oil pump for

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

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

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

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

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

mm in
109.55 NOM 4.313

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

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

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

mm in
68.91 NOM 2.713

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

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

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

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

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

idler gear.
External Idler Gear Bushing Inside Diameter

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

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

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

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

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

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

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

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

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

Install the high pressure relief ball and spring into its bore
in the lube pump housing.
No gasket is used when installing the lube pump cover.

Install the cover to the lube pump.
Tighten the center capscrews first, then the outside
capscrews.
Install the six capscrews and tighten.
Install the external idler gear.

Insert the external idler gear retainer such that the holes
are at the 3 and 9 o'clock position.
The idler gear retaining capscrew has left-hand threads.
Lubricate the oil pressure regulator valve and bore with

clean engine oil.
Install the spring, valve, and cap with a new o-ring.
Use a new split pin to secure the cap to the lubricating oil
pump body.
Turn the main drive gear by hand to check the gears for
freedom of rotation.
Measure the end clearance of the external drive gear.
Drive Shaft End Clearance

mm in
0.100 MIN 0.003
0.163 MAX 0.006
Measure the gear backlash by mounting a dial indicator.

Position the dial indicator contact point onto the
lubricating oil pump external idler gear teeth.
With the external drive gear locked into place and the dial
indicator contact in place, rotate the external idler gear
clockwise and counterclockwise to measure the
backlash.
Use the backlash measurement to classify and mark the
pump per the following table.
Lubricating Oil Pump
Gear Backlash
Class mm in
1 0.457 to 0.610 0.018 to 0.024
2 0.152 to 0.305 0.006 to 0.012
3 0.000 to 0.152 0.000 to 0.006
4 0.305 to 0.457 0.012 to 0.018
Install
Align dowels on oil pump with mounting holes in the
cylinder block.
Install the oil pump, shims (if they were removed), and the
four capscrews.
Use a dial indicator, check the oil pump idler gear back
lash.
Oil Pump Idler Gear Backlash

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

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

Inspect the oil suction tube for cracks or damage.
Inspect the o-ring grooves for cavities or damage.
If cracks, damage, or cavities are found, the oil suction
tube must be replaced.
Lubricating Oil Suction Tube (Block-Mounted) Signature™, ISX, and QSX15 Eng [...]
Install
Lubricate the o-ring with clean 15W-40 engine oil.
Install the new o-ring on the oil suction tube.
Install the oil suction tube into the lubricating oil pump.
Install the lubricating oil suction tube capscrews. Tighten
capscrews.
Finishing Steps
Fill engine with oil. Refer to Procedure 007-037.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil System

Drain
WARNING
WARNING
60°C [140°F].
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.
If lubricating oil element failure occurs resulting in
contamination of the lubricating oil, the following is
recommended:
• Inspect the lubricating oil filter by cutting it open and
inspecting for debris. Refer to Procedure 007-083.
• If debris is not found, drain the lubricating oil and
remove the lubricating oil pan. Clean and reinstall
the lubricating oil pan. Refer to Procedure 007-025.
• Remove the valve cover and clean the contaminated
lubricating oil from the cylinder head cavities. This
can be done using a siphoning device. Refer to
Procedure 003-011.
• If debris is found, refer to the Cummins Warranty
Administration Manual, Bulletin 4021290.
Prime
CAUTION
or extended engine storage (beyond 6 months) to
avoid internal component damage.
Bar the engine during oil priming.
Lubricating Oil System Signature™, ISX, and QSX15 Eng [...]
Remove the oil plug from the lubricating oil cooler housing
and install fitting and hose.
Use the coupler, Part Number 3376859, to connect the
priming pump to the coupling.
Connect the priming pump oil supply hose to the

lubricating oil pump coupling. Use clean 15W-40
lubricating oil from a drum or a container to supply oil to
the lubricating oil pump and engine.
Turn the priming pump on.
Allow the oil to flow until the oil pressure gauge indicates
a maximum pressure of 69 to 138 kPa [10 to 20 psi] at the
main oil rifle.
Turn the priming pump off.
Remove the priming pump oil supply hose and fitting.

Install the oil cooler housing plug.
Check the oil level on the dipstick before adding additional

oil.
If necessary, fill the engine with lubricating oil.
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil System
Fill
Fill and install the lubricating oil filter before putting oil into
the engine. Refer to Procedure 007-013.
Add the specified amount of clean 15W-40 oil to fill the oil
pan.
Oil Pan Capacity
Automotive and Industrial Power Generation
41.6 liters [11 gal] 83.3 liters [22 gal]
Check the oil level on the dipstick. It must be filled to the

H (high) mark.
Refer to Procedure 007-009 for dipstick calibration.
Shut off the engine. Wait 15 minutes for the oil to drain
back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H (high) mark on the dipstick.
Lubricating Oil Thermostat Signature™, ISX, and QSX15 Eng [...]
Lubricating Oil Thermostat (007-039)

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

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

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


check for leaks.
Lubricating Oil Fill Tube Signature™, ISX, and QSX15 Eng [...]

Remove
CAUTION
breakage.
Loosen the tube brace capscrew (1).
Remove the tube brace capscrew from the gear cover (2).
Remove the oil fill tube (1) and the tube brace (2) from the
oil fill tube connection (3).
A smooth, rounded end bar can be used for leverage to

rotate the oil fill tube connection.
remove.
Ring seals:
2. Oil fill tube ring seal
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
CAUTION
breakage
Remove the tube brace capscrews from the gear cover.
Remove the oil fill tube from the oil fill tube connection.

remove. A smooth, rounded end, bar can be used for
leverage to rotate the oil fill tube connection.
Ring seals:
2. Oil fill tube o-rings

Clean the oil fill connection and gear cover seal surface.
Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Inspect the oil fill tube extrusion for cracks or damage.

Clean the oil fill connection and gear cover seal surface.
Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Install
seal.
Install the new ring seals on the bottom of the oil fill tube
(1) and on the oil fill tube cap (2).
Install and tighten the tube brace gear cover capscrew (2).
Tighten the tube brace capscrew (1).

seal.
Install the new o-rings on the bottom of the oil fill tube and
a new ring seal on the oil fill tube cap.
Install and tighten the tube brace gear cover capscrews.

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

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

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

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

particles.
Metal Probable Source

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

Section Contents
Page
Belt Tensioner, Automatic (Water Pump) .......................................................................................................8-68
CM570.........................................................................................................................................................8-72
Finishing Steps...............................................................................................................................................8-74
Drives Alternator.......................................................................................................................................... 8-74
Initial Check....................................................................................................................................................8-68
Install..............................................................................................................................................................8-72
Remove.......................................................................................................................................................... 8-69
Coolant Filter .....................................................................................................................................................8-5
Install................................................................................................................................................................8-6
Remove............................................................................................................................................................8-6
Coolant Filter Valve ...........................................................................................................................................8-7
Clean................................................................................................................................................................8-8
Install................................................................................................................................................................8-8
Remove............................................................................................................................................................8-7
Coolant Thermostat ..........................................................................................................................................8-9
Finishing Steps...............................................................................................................................................8-14
Out-of-Chassis Opening Temperature Test...................................................................................................8-12
Install..............................................................................................................................................................8-13
Leak Test..........................................................................................................................................................8-9
In-Chassis Opening Temperature Test..........................................................................................................8-11
Remove.......................................................................................................................................................... 8-11
Coolant Thermostat Housing ..........................................................................................................................8-15
Finishing Steps...............................................................................................................................................8-21
Install..............................................................................................................................................................8-18
Single Thermostat........................................................................................................................................8-18
Dual Thermostat...........................................................................................................................................8-19
Remove.......................................................................................................................................................... 8-16
Single Thermostat........................................................................................................................................8-16
Dual Thermostat...........................................................................................................................................8-16
Coolant Thermostat Seal ................................................................................................................................ 8-21
Install..............................................................................................................................................................8-22
Single Seal...................................................................................................................................................8-22
Dual Seal.....................................................................................................................................................8-22
Remove.......................................................................................................................................................... 8-21
Single Seal...................................................................................................................................................8-21
Dual Seal.....................................................................................................................................................8-22
Coolant Vent Lines ..........................................................................................................................................8-23
Initial Check....................................................................................................................................................8-23
Cooling System ...............................................................................................................................................8-23
Page 8-b Section 8 - Cooling System - Group 08
Drain...............................................................................................................................................................8-23
Fill...................................................................................................................................................................8-26
Flush...............................................................................................................................................................8-24
Pressure Test..................................................................................................................................................8-31
Cooling System - Air or Combustion Gas Test ..............................................................................................8-32
Initial Check....................................................................................................................................................8-32
Air in Cooling System...................................................................................................................................8-32
Leak Test........................................................................................................................................................8-34
Fan, Shutter, or Heater Air Control Valve......................................................................................................8-34
Air Compressor............................................................................................................................................8-34
Combustion Gas Leak..................................................................................................................................8-35
Overflow Method..........................................................................................................................................8-38
Drive Belt, Cooling Fan .....................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Install................................................................................................................................................................8-3
Remove............................................................................................................................................................8-3
Drive Belt, Water Pump ....................................................................................................................................8-4
Adjust...............................................................................................................................................................8-5
Install................................................................................................................................................................8-5
Remove............................................................................................................................................................8-4
Fan Clutch, On-Off ..........................................................................................................................................8-39
Initial Check....................................................................................................................................................8-39
With Low Temperature Fan-On Control.........................................................................................................8-39
With High Temperature Fan On....................................................................................................................8-40
Fan Drive Idler Pulley Assembly .....................................................................................................................8-42
Finishing Steps...............................................................................................................................................8-43
Install..............................................................................................................................................................8-42
Remove.......................................................................................................................................................... 8-42
Fan Hub, Belt Driven .......................................................................................................................................8-43
Finishing Steps...............................................................................................................................................8-46
Industrial CM570 and Power Generation without CM570...............................................................................8-47
Install..............................................................................................................................................................8-45
Remove.......................................................................................................................................................... 8-44
Fan Pulley ........................................................................................................................................................8-78
Install..............................................................................................................................................................8-79
Remove.......................................................................................................................................................... 8-78
Fan Shroud Assembly .....................................................................................................................................8-47
Initial Check....................................................................................................................................................8-47
Fan Support .....................................................................................................................................................8-75
Finishing Steps...............................................................................................................................................8-78
Section 8 - Cooling System - Group 08 Page 8-c

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

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

Pulley Alignment Tool
Used to align pulleys.
3163524
Thermostat Seal Driver

Used to install the thermostat seal in the thermostat housing to the
3164350 correct specification.
Fluorescent Tracer
Used with black light, Part Number 3824754, to find coolant leaks.
3377438
Optical Tachometer
Used to measure engine rpm using reflective tape, Part Number
3377462 3377464.
Reflective Tape (for optical tachometer, Part Number 3377462)

Used with optical tachometer, Part Number 3377462, to measure
3377464 rpm.
Fluke Digital Temperature Measuring Instrument Kit

Used to measure temperatures for the fuel pump and injector test
3822666 stands.
Page 8-2 Section 8 - Cooling System - Group 08

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

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

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

Remove
Drives Alternator
CAUTION
Pivot the automatic tensioner down to relieve tension on
the belt.
Remove the belt.

Drives Alternator
Inspect the alternator pulley, the water pump pulley, the
fan clutch pulley, and the crankshaft pulley for cracks,
burrs, and broken or deformed grooves.
Use a wire brush to clean debris found in the pulley
grooves.
Inspect the belt for cracks, glazing, tears or cuts, and

excessive wear.
Replace the belt if necessary.
Install
Drives Alternator
CAUTION
Pivot and hold the belt tensioner.
Drive Belt, Water Pump Signature™, ISX, and QSX15 Eng [...]
Drive Belt, Water Pump (008-003)

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

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

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

not exceed 0.5 mm per cm [0.0625 in per ft] of distance
between the pulley centers.
Replace the water pump if the pulleys are not in
alignment. Refer to Procedure 008-062.
Signature™, ISX, and QSX15 Eng [...] Coolant Filter
Install
CAUTION
The belt tensioner is spring-loaded and must be
tensioner.
Using a 1/2-inch square drive lift and hold the belt
tensioner. Install the drive belt and release the tensioner.
Adjust
Belt drive systems equipped with an automatic belt
tensioner can not be adjusted. A belt tension gauge will
not give an accurate measure of the belt tension. The
automatic belt tensioner is designed to maintain proper
belt tension over the life of the belt. Only inspection of the
tensioner is required.
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when the belt
length and geometry are correct.
If the tensioner is hitting either of the limits during
operation, check the mounting brackets and the belt
length. Loose brackets, bracket failure, alternator
movement, incorrect belt length, or belt failure can cause
the tensioner to hit the limits.

General Information
Refer to the Coolant Recommendations and Specification,
Procedure 018-004 in the Operation and Maintenance
Manual Signature and ISX Engines, Bulletin 3666251, the
Operation and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423, or the
Operation and Maintenance Manual Signature and ISX
Coolant Filter Signature™, ISX, and QSX15 Eng [...]
An on/off valve is provided to prevent coolant leakage

while changing the coolant filter.
With the valve in the ON position (1), the coolant flows to
and from the coolant filter. In the OFF position (2), the
coolant flow is cut off to and from the coolant filter.
Remove
WARNING
Remove the cooling system pressure cap.
WARNING
Turn the coolant on/off valve to the OFF position.
Do not use force to open or close the on/off valve. If the
valve does not turn freely, refer to Procedure 008-082.
Remove and discard the coolant filter. Clean the gasket
surface on the filter head.
Install
CAUTION
damage the filter head.
Apply a thin film of clean engine oil, or its equivalent, to
the coolant filter gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter ½ to ¾ of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Signature™, ISX, and QSX15 Eng [...] Coolant Filter Valve
Install the radiator pressure cap.
WARNING
Operate the engine until the coolant temperature is above
82°C [180°F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.
Coolant Filter Valve (008-009)

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

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

Inspect the valve for corrosion or other damage. Replace
if necessary.
Install
Install a new o-ring onto the valve.
Install the valve into the water inlet connection.
Signature™, ISX, and QSX15 Eng [...] Coolant Thermostat
Install the retaining capscrew and flat washer. Make sure

the flat washer fits in the notch in the valve.
While pushing the flat washer into the groove, tighten the
retaining capscrew.
Turn the valve to the ON position.

Operate engine and check for leaks.

Leak Test
Signature, ISX, and QSX engines use two engine coolant
thermostats.
The engine thermostat and thermostat seal must operate
properly in order for the engine to operate in the most
efficient heat range. Overheating or overcooling will
shorten engine life.
Refer to Procedure 008-016 to inspect the thermostat seal.
Coolant Thermostat Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
Drain the coolant to a level below the vent line in the
thermostat housing.
Disconnect and plug the vent line hose. Refer to
Procedure 008-017.
Remove the radiator hose from the radiator top tank.
The radiator hose must be at the point of overflowing

before the engine is run. Small amounts of leakage will
not be detected if the hose is not pre-filled.
Fill the radiator hose with coolant until coolant is just about
ready to flow out of the hose.
Place a dry container under the end of the hose.
Operate the engine at rated rpm for three minutes.

Shut off the engine and measure the amount of coolant
collected in the container.
The amount of coolant collected must not be more than
100 cc [3.3 fl oz].
If more than 100 cc ]3.3 fl oz] of coolant is collected, the

thermostat or thermostat seal is leaking.
Remove the thermostats and test their operation as
described in the Out-of-Chassis Opening Temperature
Test in this procedure.
Refer to Procedure 008-016 for thermostat seal
inspection.
In-Chassis Opening Temperature Test

NOTE: An electronic service tool can also be used to
monitor the thermostat opening temperature without
removing the radiator hose.
Remove the coolant temperature sensor and install a
thermocouple or temperature gauge, which is known to be
accurate, on the engine side of the thermostat housing.
Complete the following test in-chassis to test the

thermostat opening temperature.
Start the engine and monitor the water temperature and
the container.
Thermostat Initial Opening Temperature

°C °F
81 MIN 178
83 MAX 182
Shut off the engine when the coolant starts to flow.
If coolant does not start flowing into the container during
the initial opening temperature range, the thermostat
must be replaced.
Preparatory Steps
WARNING
WARNING
Coolant is toxic. If not reused, dispose of in
Drain the cooling system. Refer to Procedure 008-018.
Remove
housing cover.
Disconnect vent line.


the thermostat housing. Discard the gasket.

cover.
Inspect for Reuse

Out-of-Chassis Opening Temperature Test
Inspect the thermostat for damage.
Suspend the thermostat and a 100°C [212°F]

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

thermostat.
• The thermostat must begin to open within 1°C [2°F]
of nominal temperature.
• The thermostat must be fully open to at least 11 mm
[0.435 in] within 12°C [22°F] above nominal
temperature.
Replace the thermostat if it does not operate as
described.
Install

Tighten the capscrews to the values shown.
Torque Value:
Long Capscrews 56 N•m [ 41 ft-lb ]


If removed, tighten the capscrews to the following
specification.
Install the upper radiator hose. Tighten the hose clamp.

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

Preparatory Steps
WARNING
WARNING
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the charge air cooler piping. Refer to
Procedure 010-027.
• Remove the upper radiator hose. Refer to the OEM
service manual.
• Remove the vent line. Refer to the OEM service
manual.
• Remove the engine coolant temperature sensor.
Refer to Procedure 019-019 in the ISX CM871 and
ISM CM876 Electronic Control System
4021560.
• Remove the turbocharger coolant return line. Refer
• Remove the OEM coolant sensor(s). Refer to the
OEM service manual.
• Remove the exhaust gas pressure sensor. Refer to
019-376 in the ISX CM871 and ISM CM876
Electronic Control System Troubleshooting and
Repair Manual, Bulletin 4021560
• Remove the turbocharger actuator air line, if
required. Refer to Procedure 010-113.
• Remove the heat shield, if required. Refer to
Procedure 011-032.
• Remove the EGR valve. Refer to Procedure 011-022.
• Remove the EGR cooler connection tube, if required.
• Remove the EGR cooler coolant return tube, if
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
• Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
Coolant Thermostat Housing Signature™, ISX, and QSX15 Eng [...]
Remove
Single Thermostat
Remove the four thermostat housing cover capscrews.
Remove the thermostat cover and gasket.
Discard the gasket.
Remove the thermostat from the thermostat housing

cover.
Remove the three thermostat housing capscrews.

Remove the thermostat housing and gasket.
Discard the gasket.
Dual Thermostat
housing cover.
Disconnect vent line, if required.


the thermostat housing.
Discard the gasket.

cover.
Remove the two capscrews that attach the thermostat

housing to the cylinder head.
Remove the thermostat housing and gasket from the
cylinder head.
Discard the gasket.
Inspect for Reuse

Inspect the thermostat housing and thermostat cover for
cracks.
Inspect the bottom of the thermostat bores in thermostat

cover for corrosion, pitting, or erosion that would cause
leakage past the thermostats when they are in the open
position.
Replace the thermostat seals, if damaged. Refer to
Procedure 008-016.
Inspect the thermostats. Refer to Procedure 008-013.
Install
Single Thermostat
To reduce the possibility of a coolant leak, the 90-degree
elbow on the thermostat housing must be positioned
appropriately and tightened before the thermostat housing
is installed on the cylinder head.
Use two thermostat housing capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and three
capscrews to the cylinder block.
Tighten the three thermostat housing mounting
capscrews.
Install the thermostat into the thermostat housing cover by

pushing on the outer rim.

capscrews.
Dual Thermostat
Use two thermostat housing cover capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and two capscrews
on the cylinder head.
Tighten the two thermostat housing capscrews.
Remove the two thermostat housing cover capscrews
used as guides.


Torque Value:
Short capscrews 34 N•m [ 25 ft-lb ]
Long capscrews 56 N•m [ 41 ft-lb ]

Install the upper radiator hose.


Install the thermostat cover if removed.
Automotive has a similar design with connector for
transmission cooler.
Signature™, ISX, and QSX15 Eng [...] Coolant Thermostat Seal
Finishing Steps
• Install the refrigerant compressor mounting bracket.
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the EGR cooler coolant return tube, if
• Install the EGR cooler connection tube, if required.
• Install the EGR valve, if required. Refer to Procedure
011-022.
• Install the heat shield, If required. Refer to Procedure
011-032.
• Install the turbocharger actuator air line. Refer to
Procedure 010-113.
• Install the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the ISX CM871 and ISM
• Install the turbocharger coolant return line. Refer to
Procedure 010-041.
• Install the vent line. Refer to the OEM service
manual.
• Install the OEM coolant sensor(s). Refer to the OEM
service manual.
• Install the engine coolant temperature sensor. Refer
to Procedure 019-019 in the ISX CM871 and ISM
• Install the upper radiator hose. Refer to the OEM
service manual.
• Install the charge air cooler piping. Refer to
Procedure 010-027.
• Install the air intake piping. Refer to the OEM service
manual.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine until the coolant temperature
reaches 70°C [158°F] and check for leaks.
Coolant Thermostat Seal (008-016)

Remove
Single Seal
Remove the thermostat seal. Do not damage the
thermostat cover.
Coolant Thermostat Seal Signature™, ISX, and QSX15 Eng [...]
Dual Seal
NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
Remove the thermostat housing cover. Refer to Procedure
008-014.
Remove the thermostat seal. Do not damage the
thermostat cover.
Inspect for Reuse

Inspect the thermostat seal for cracks, corrosion, or other
damage. Replace if necessary.
Install
Single Seal
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3824716, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Dual Seal
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3164350, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Install the thermostat housing cover. Refer to Procedure
008-014.
Signature™, ISX, and QSX15 Eng [...] Cooling System
Coolant Vent Lines (008-017)

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

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

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

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

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

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

Water Quality
(Hardness) MgCO3)

standards.

Section V.
Section V.
CAUTION
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.

drained.
Install the radiator or expansion tank fill cap.

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

WARNING
CAUTION
Remove the radiator or fill cap and check the coolant level
according to the operator equipment manual
recommendations. Add coolant if necessary. Do not
overfill.

Close the radiator draincocks.

Water Quality
(Hardness) MgCO3)

standards.

Section V.
Section V.
CAUTION
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.

drained.
Without installing the coolant pressure cap, operate the

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

restriction.
The fan clutch must disengage before the coolant

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

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

Preparatory Steps
• Remove the cooling fan. Refer to Procedure
008-040.
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Remove the automatic belt tensioner (water pump).

008-040.
• Remove the water pump belt. Refer to Procedure
008-003.
• Remove the alternator belt Refer to Procedure
013-005.

CM570
008-040.
• Remove the fan and water pump belt. Refer to
Procedure 008-003.
013-005.
• Remove the fan hub and the fan hub support. Refer
Fan Hub, Belt Driven Signature™, ISX, and QSX15 Eng [...]
Remove
WARNING
Remove the mounting capscrews and the fan hub
assembly.
WARNING
Remove alternator belt tensioner and bracket.
Remove the capscrews and the fan hub assembly.

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

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

clearance is dependent upon the fan hub style.
Replace the fan hub if the end clearance is not within the
Refer to OEM service manual for additional inspection
steps.

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

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

mm in
0.08 MIN 0.003
0.25 MAX 0.009
Install
WARNING
Install the fan hub assembly and the capscrews.
Fan Hub, Belt Driven Signature™, ISX, and QSX15 Eng [...]
WARNING
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
Install the fan hub and the capscrews.
Install the belt tensioner bracket.

CM570
The fan hub must be installed in the correct location on
the fan support to allow proper clearance between the fan
and fan shroud. Refer to the OEM service manual.
Make certain the correct fan center is used for the

application.
Install the fan hub on the fan support using four capscrews
and washers.
Finishing Steps
• Install the automatic belt tensioner (water pump).
• Install the cooling fan drive belt. Refer to Procedure
008-002.
• Install the cooling fan. Refer to Procedure 008-040.
Signature™, ISX, and QSX15 Eng [...] Fan Shroud Assembly

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

CM570
• Install the fan hub and fan hub support. Refer to
Procedure 008-088.
013-005.
• Install the fan and water pump belt. Refer to
Procedure 008-003.
Fan Shroud Assembly (008-038)

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

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

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

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

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

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

NOTE: The radiator must be replaced due to bent or
broken fins that can cause the engine to overheat. Refer
to the manufacturer's replacement procedures.
Inspect the radiator for core and gasket leaks.
Radiator Pressure Cap Signature™, ISX, and QSX15 Eng [...]
WARNING
If a liquid refrigerant system must be removed before
removing the radiator, wear eye and face protection.
For environmental protection, federal law requires
that Freon be recycled and not vented into the
atmosphere. Wrap a cloth around the fittings before
removing. Liquid refrigerant can cause serious eye
and skin injury.
Radiator Hoses (008-045)

Inspect for Reuse
Inspect all hoses for cracks, cuts, or collapsing.
NOTE: The silicone engine coolant hose will exhibit
swelling due to the elasticity of the hose.
Radiator Pressure Cap (008-047)

Inspect for Reuse
WARNING
Remove the radiator pressure cap.
Inspect the rubber inner seal and the brass outer seal of
the pressure cap for damage.
Inspect the radiator or expansion tank fill neck for cracks
or other damage.
Refer to the radiator manufacturer's or vehicle
manufacturer's instructions if the fill neck is damaged.
Make sure the correct pressure cap is used. Refer to the
Cooling System Specifications.
Signature™, ISX, and QSX15 Eng [...] Water Pump
Pressure-test the radiator cap to the rated cap pressure.
Radiator Shutter Assembly (008-049)

General Information
NOTE: Shutters and fan clutch must be set to operate in
the same temperature range as the thermostat with which
they are used.
Check the shutters and the fan clutch every 1500 hours.
Every 192,000 km [120,000 mi], 3000 hours, or 2 years,
whichever comes first, check the shutters and the fan
clutch.
Check the shutters in the closed position to be sure they
are completely closed.
NOTE: If the shutters are not closed, refer to the
Be sure the shutters open completely at the desired
temperature setting.
NOTE: If the shutters are closed, refer to the

Preparatory Steps
WARNING
WARNING
008-018.
• Remove the water pump drive belt and tensioner.
• Remove the refrigerant compressor drive belt. Refer
Water Pump Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
008-018.
• Remove the water pump and fan drive belt. Refer to
Procedure 008-003.
013-005.
• Remove the water pump belt tensioner bracket and
belt tensioner. Refer to Procedure 008-080.
• If necessary, remove the vibration dampers. Refer to
Procedure 001-052.

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

and the o-ring seal.

Remove two water pump capscrews and install guide
studs.
Remove remaining three capscrews, water pump, and
water inlet o-ring seal.

CM570
Remove the pulley (1), pilot adapter (2), and belt tensioner
bracket (3).
Remove the remaining water pump capscrews, and water

inlet o-rings.
Discard the o-ring seals.

Remove the five water pump housing mounting
capscrews.
Remove the two bracket mounting capscrews
Remove the EGR tube outlet capscrew.
Remove the water pump housing and o-ring seals.
Discard the water inlet o-ring seal and EGR tube inlet and
outlet o-ring seal.
Clean
Clean the water pump and the water inlet connections.
Inspect the water pump housing for cracks.

Inspect the water pump weep hole for indication of leaks.
A streak or chemical buildup at the weep hole is not
justification for water pump replacement. If a steady flow
of coolant or oil is observed, recondition the existing water
pump or replace the water pump with a new or rebuilt unit.
WARNING
WARNING
personal injury.
Clean the water pump components with solvent and dry
Inspect the water pump housing for cracks and damage.

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

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

pulley facing up.
Press the pulley off of the water pump and shaft assembly.
Position the water pump with the pulley end facing up.
Remove the bearing bore retaining clip.
Support the water pump in a press with the impeller facing

up.
Press the shaft out of the impeller and through the pump
housing.
Remove the impeller from the housing.
Discard a phenolic impeller, retain a cast iron impeller.
Support the water pump in a press with the pulley end

facing up.
Press the seal out of the housing.
NOTE: Disassemble the shaft and bearings only if the

seal is leaking or the bearing is damaged.
Remove the retaining ring (1).
Use the water pump bearing separator, Part Number
3375326 to remove the:
Front bearing (2)
Rear bearing (3).
WARNING
WARNING
personal injury.
Clean the water pump components with solvent and dry
Inspect the water pump housing for cracks and damage.

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

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

Scratching on the inside face is acceptable.
If there is any damage to the outer o-ring area, the impeller
cover must be replaced.
Inspect the impeller cover retaining clip.

If the retaining clip is rusted or pitted, it must be replaced.
Inspect the pulley for cracks, wear, and damage.

Inspect the mating surface and pulley bore areas for
damage.
If the pulley is damaged, it must be replaced.
Measure
Measure the inside diameter of the water pump housing
large bearing bore.
Water Pump Housing Large Bearing Bore Inside

Diameter
mm in
71.988 MIN 2.834
72.018 MAX 2.835
If the water pump housing large bearing bore inside
diameter is not within specifications, the water pump
Measure the inside diameter of the cast iron impeller.
Cast Iron Impeller Inside Diameter

mm in
15.850 MIN 0.624
15.875 MAX 0.625
If the cast iron impeller inside diameter is not within
Measure the outside diameter of the water pump shaft.
Water Pump Shaft Diameter

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

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

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

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

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

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

impeller cover with a feeler gauge.
Impeller Clearance
mm in
0.29 MIN 0.011
1.24 MAX 0.049
Install
CAUTION
Lubricate and install the new o-ring seal.
Install the water pump and three capscrews.

mounting capscrews.

CAUTION

Install the water pump and two lower capscrews.
Tighten the capscrews to hold the pump in place.

aluminum belt tensioner bracket shown. Refer to
Procedure 008-088 for the appropriate tensioner bracket
installation.
Install the belt tensioner bracket, if equipped, and
capscrews in the location shown.

Torque Value:
and 3
5
Engines Without
Belt Tensioner
Bracket

CM570
CAUTION

Position the water pump on the engine.
Install the bottom two capscrews finger tight.

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

Torque Value:
and 3
5
Engines Without
Belt Tensioner
Bracket
Align the idler pulley (1) and the shaft of the pilot adapter
(2) with the belt tensioner bracket (3) using the guide pin
on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on the belt idler
bracket using one washer and capscrew.
Install the dust seal.
CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
Install a new water pump inlet o-ring seal and a new EGR
tube outlet o-ring seal.
Install the five water pump housing capscrews.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.
Finishing Steps
• Install the water pump drive belt and tensioner. Refer
• Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.

• Install the vibration dampers, if removed. Refer to
Procedure 001-052.
• Install the water pump belt tensioner bracket and belt
tensioner. Refer to Procedure 008-080.
013-005.
008-003.
• Fill the engine with heavy-duty coolant. Refer to
Procedure 008-018.

CM570
• Install the damper assembly, if removed. Refer to
Procedure 001-052.
013-005.
procedure 008-003.
Procedure 008-018.

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

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

cracks are noticed, the tensioner must be replaced.
Using a ½ inch square drive, lift belt tensioner to relieve

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

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

Remove the belt tensioner mounting capscrew and the
belt tensioner from the bracket.
part of the water pump removal and installation because
of common capscrew usage. Refer to Procedure 008-062.

For the low-mount (small version) belt tensioner:

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


support.

All Applications
WARNING
The belt tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe personal injury can
result.
WARNING
cleaning, follow the manufacturers recommendations
Check the tensioner for dirt buildup. If the tensioner has
dirt buildup, remove and clean with safety solvent.
Pivot the tensioner through the full range of motion.

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

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

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

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

Install the belt tensioner mounting capscrew and the belt
part of the water pump removal and installation due to
common capscrew usage. Refer to Procedure 008-062.

For the low-mount (small tensioner):

For the low-mount (large tensioner):

Water Inlet Connection Signature™, ISX, and QSX15 Eng [...]

Finishing Steps
Drives Alternator
CAUTION
tensioner or personal injury.
• Install the drive belt. Refer to Procedure 008-002.

Preparatory Steps
WARNING
WARNING
008-018.
• Remove the coolant filter. Refer to Procedure
008-006.
• Remove the water pump. Refer to Procedure
008-062.
Signature™, ISX, and QSX15 Eng [...] Fan Support
Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet connection,
gasket, and o-ring.
Install
Replace the o-ring and gasket.
Install the gasket, water inlet connection, and the four
capscrews.
Install the coolant hoses.
Finishing Steps
• Install the water pump. Refer to Procedure 008-062.
• Install the coolant filter. Refer to Procedure 008-006.
Procedure 008-018.

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

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

Install six capscrews.
capscrews.
Tighten the eight capscrews in the sequence shown.
Install the belt tensioner support bracket to the engine and

fan support.
Tighten all eight capscrews finger tight.
Tighten capscrew numbers 1 and 2 finger tight to mate the

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

Fan Pulley Signature™, ISX, and QSX15 Eng [...]

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

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

013-005.
Signature™, ISX, and QSX15 Eng [...] Fan Pulley
Remove six capscrews and the pulley from the fan

support.
Inspect for Reuse

Inspect the pulley for cracks, excessive wear in the belt
grooves, or other damage.
Install
Install the fan pulley using six capscrews.
Install the alternator drive belt. Refer to Procedure

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

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

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

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

Section Contents
Page
Alternator/Refrigerant Compressor Mounting Bracket .................................................................................. 9-13
Finishing Steps...............................................................................................................................................9-16
Install..............................................................................................................................................................9-15
Remove.......................................................................................................................................................... 9-13
Belt Tensioner, Refrigerant Compressor, Automatic .......................................................................................9-5
Finishing Steps.................................................................................................................................................9-6
With Water Pump and Refrigerant Compressor Belt Routing..........................................................................9-6
Initial Check......................................................................................................................................................9-5
Install................................................................................................................................................................9-6
Remove............................................................................................................................................................9-6
Drive Belt, Refrigerant Compressor .................................................................................................................9-3
Finishing Steps.................................................................................................................................................9-4
Install................................................................................................................................................................9-4
Remove............................................................................................................................................................9-3
Idler Pulley, Refrigerant Compressor ...............................................................................................................9-7
Finishing Steps.................................................................................................................................................9-8
Install................................................................................................................................................................9-7
Remove............................................................................................................................................................9-7
Refrigerant Compressor ....................................................................................................................................9-1
Climate Control Incorporated..........................................................................................................................9-2
Finishing Steps.................................................................................................................................................9-3
Install................................................................................................................................................................9-2
Sanden..........................................................................................................................................................9-2
Page 9-b Section 9 - Drive Units - Group 09

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

Preparatory Steps
Routing
WARNING
NOTE: If the refrigerant compressor is only being
removed to access other components, refrigerant system
depressurization is not required. Leave hoses connected
and properly support the refrigerant compressor to other
vehicle components.
• Depressurize the refrigerant system, only if
complete removal of the refrigerant compressor is
required. Refer to the OEM service manual for the
proper procedure.
Procedure 008-002.
• Refrigerant compressor belt. Refer to Procedure
009-052.
Remove
Sanden
capscrews.
Remove the refrigerant compressor.

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

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

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

refrigerant compressor to the alternator/refrigerant
compressor mounting bracket. Make sure the roll pins
align properly.
Signature™, ISX, and QSX15 Eng [...] Drive Belt, Refrigerant Compressor
Finishing Steps
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
• Fill the refrigerant system, if depressurized. Refer to
the OEM service manual.

(009-052)
Preparatory Steps
Routing
Procedure 008-002.
Remove
Routing
CAUTION
Pivot the automatic tensioner counterclockwise to
relieve tension on the belt.
Remove the belt.

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

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

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

are found, replace the tensioner.
Spin the tensioner pulley. The pulley must spin freely. If

not, replace the tensioner.
Belt Tensioner, Refrigerant Compressor, Automatic Signature™, ISX, and QSX15 Eng [...]
Preparatory Steps
Routing
• Remove the fan drive belt. Refer to Procedure
008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-052.
Remove
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.
Install
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.
Finishing Steps
Routing
Procedure 009-052.
Signature™, ISX, and QSX15 Eng [...] Idler Pulley, Refrigerant Compressor

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

Routing
Inspect the refrigerant compressor idler pulley for cracks
or broken grooves. Replace idler pulley if damage is
found.
Spin the refrigerant compressor idler pulley.
The refrigerant compressor idler pulley must rotate freely
when installed.
Install
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
NOTE: A special alignment procedure is not required for
the refrigerant compressor idler pulley to the alternator/
Refrigerant Compressor Mounting Bracket Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
Routing
Procedure 009-051.
008-002.

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

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

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

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

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

WARNING
WARNING
personal injury.
Clean the bracket, links, and mounting capscrews with
solvent.
Signature™, ISX, and QSX15 Eng [...] Refrigerant Compressor Mounting Bracket
Inspect the bracket and links for cracks.

Replace the bracket or links if damage is found.
Install
Sanden
Install the two mounting capscrews and the refrigerant

Install the refrigerant compressor mounting bracket to the
refrigerant compressor. The refrigerant compressor is
positioned on top of the bracket ledge.
Install the four mounting capscrews and the refrigerant
compressor bracket.

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

housing with two long capscrews.
Position both links in the assembly with the part number

facing outward.
Insert one capscrew through the elongated hole in the
long link and attach the long link to the left side of the
Insert one capscrew through the small hole in the short
link and attach the short link to the right side of the
Finishing Steps
Procedure 009-051.
Procedure 009-052.

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

• Remove the refrigerant compressor and alternator
belt. Refer to Procedure 013-005.
• Remove the refrigerant compressor. Refer to the
OEM service manual.
• Remove the upper belt tensioner. Refer to Procedure
013-021.
• Remove the lower belt tensioner. Refer to Procedure
008-080.
Remove
Disconnect the wire harness jumper from the EGR valve
motor, EGR valve position sensor and the main engine
wire harness.
Remove the five mounting capscrews from the alternator/
The split washers will create a slight friction fit between
the bracket and the gear housing.
Remove the wire harness jumper from the alternator/
Alternator/Refrigerant Compressor Mounting Bracket Signature™, ISX, and QSX15 Eng [...]

Remove the six mounting capscrews from the alternator/
The split washers will create a slight friction between the
Inspect for Reuse

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

Inspect the alternator/refrigerant compressor mounting
bracket for cracks.
Replace the bracket if necessary.
Inspect belt tensioners for excessive wear.

If worn excessively, replace the belt tensioners.
Signature™, ISX, and QSX15 Eng [...] Alternator/Refrigerant Compressor Mounting Bracket
Install
Install the wire harness jumper to the alternator/refrigerant
Tap the split washers out slightly. This will ease the
installation.
Install the alternator/refrigerant compressor mounting
bracket to the gear housing.
Install the five mounting capscrews.

Torque Value:
(1, 2 3 and 4) 36 N•m [ 27 ft-lb ]
(5) 56 N•m [ 41 ft-lb ]

The alternator/refrigerant compressor mounting bracket
mounts to the gear housing at the top and the water pump
at the bottom.
Install the bracket and six mounting capscrews.
Tighten the capscrew that threads into the gear housing.
Tighten the short capscrew (1).

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

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

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

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

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

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

Slack Tube Manometer
Used to measure pressure differential.
ST-1111-3
Black Light (100 watt)

Used to inspect for oil or fuel leak.
3163337
Black Light (50 watt)

Used to inspect for oil or fuel leak.
3163338
Fluorescent Tracer
Added to oil and used with black light to find oil leaks.
3376891
Fluke Digital Thermometer

Used to measure intake air temperature.
3822666
Thermocouple Wire Kit

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

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

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

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

Contains a variety of caps to prevent contamination of vehicle air
Signature™, ISX, and QSX15 Eng [...] Air Leaks, Air Intake and Exhaust Systems
Air Leaks, Air Intake and Exhaust

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

the exhaust back pressure is within specified limits. Refer
Operate the engine at full throttle and maximum load, and
check for air leaks. Listen for a whistling noise caused by
high-pressure air leaks.
CAUTION
The noise can be caused by an air leak from the following:
Turbocharger-to-charge-air cooler elbow connection.
• Inspect the connection and o-ring for damage.
• Tighten the v-band clamps.
Air Leaks, Air Intake and Exhaust Systems Signature™, ISX, and QSX15 Eng [...]
Any charge-air cooler piping or connecting hose.

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

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

• Tighten the v-band.
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger.
Check for soot streaks from the EGR connection tubes

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

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

Check for soot streaks from the EGR connection tubes
and hoses.
• Tighten the hose clamps. Refer to Procedure
011-025. Check for an exhaust leak. If an exhaust
leak is still present, remove and replace the EGR
crossover tube or hose.
Check for soot streaks from the EGR valve gasket and
seal rings.
• Inspect for signs of leakage such as soot streaks. If
signs of leakage are present, replace the EGR valve
gaskets. Refer to Procedure 011-022.
Check for leakage from the EGR valve weep hole.

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

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

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

• Inspect for signs of leakage such as soot streaks
which may appear yellowish brown or black. If signs
of leakage are present, replace the gasket and v-
band clamp. Refer to Procedure 011-007 for the
bellows and Procedure 011-019 for the exhaust
manifold.
Clean all soot stains and paint the components in order to
detect future leaks.
Check the aftertreatment adapter pipe.

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

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

If soot streaks are found, check for fault codes relating to
high differential pressure in the aftertreatment system. If
no fault codes are found, tighten the v-band clamp. Refer
If a leak is still present, remove and replace with a new
gasket and v-band clamp.
Check the catalyst to aftertreatment particulate trap

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

connection.
Check the aftertreatment outlet connection.

Check the aftertreatment diesel particulate filter

differential pressure sensor tube connections.
• Inspect for visible soot streaks at the threaded
bosses or hose connections.
If soot streaks are found at the threaded boss, loosen the
differential pressure sensor tube nut, apply a coating of
anti-seize compound, and tighten the differential pressure
sensor tube nut. Refer to Procedure 011-047.
If soot streaks are found at the hose connections, remove
and connect hose. Refer to Procedure 011-047.
If a leak is still present at the threaded boss, remove and
replace the differential pressure sensor tube.
If a leak is still present at the hose connection, replace the
differential pressure sensor tube or differential pressure
sensor, depending on which component the hose is
permanently attached to.
Procedure 014-013.
Signature™, ISX, and QSX15 Eng [...] Charge-Air Cooler
Charge-Air Cooler (010-027)

Clean
If the engine experiences a turbocharger failure or any
other occasion where oil or debris is put into the charge-
air cooler, the charge-air cooler must be cleaned.
Remove the charge-air cooler piping and charge-air cooler
from the vehicle. Refer to the manufacturer's instructions.
to cover open points on the plumbing and engine.
CAUTION
Do not use caustic cleaners to clean the charge-air
cooler. Damage to the charge-air cooler will result.
Flush the charge-air cooler internally with solvent in the
opposite direction of normal airflow. Shake the charge-air
cooler and lightly tap on the end tanks with a rubber mallet
to dislodge trapped debris. Continue flushing until all
debris or oil is removed.
NOTE: Make sure the tubes are in the vertical direction
when flushing.
If the debris can not be totally removed from the charge-
air cooler, the charge-air cooler must be replaced.
CAUTION
The charge-air cooler must be rinsed, dried, and free
of solvent, oil, and debris or engine damage will
result.
After the charge-air cooler has been thoroughly cleaned
of all oil and debris with solvent, wash the charge-air
cooler internally with hot soapy water to remove the
remaining solvent. Rinse thoroughly with clean water.
Blow compressed air through the inside of the charge-air
cooler in the opposite direction of normal air flow until the
charge-air cooler is dry internally.
to cover open points on the charge air cooler after
cleaning.
Inspect for Reuse

Inspect the charge-air cooler for cracks, holes, or damage.
Inspect the tubes, fins, and welds for tears, breaks, or
other damage. If any damage causes the charge-air cooler
to fail the air leak check, the charge-air cooler must be
replaced.
Install the charge-air cooler on the vehicle.
Charge-Air Cooler Signature™, ISX, and QSX15 Eng [...]
Leak Test
To check the charge-air cooler for cracked tubes or
header, remove the inlet and outlet hoses from the cooler.
The charge-air cooler does not have to be removed from
the chassis.
WARNING
To prevent possible injury if either plug blows off
during the test, secure safety chains on the test plugs
to any convenient capscrew on the radiator assembly.
This test must not be performed without securely
fastened safety chains.
Install the charge-air cooler tester, Part Number 3824556.
Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Determine if pressure decay is caused by a leak in the
charge-air cooler or from a leaky connection. Use a spray
bottle filled with soapy water and apply to all hose
connections. Watch for bubbles to appear at the location
of the leak.
If the pressure decay is caused by a leaky connection,

repair the connection and repeat the test. If the leak is
within the charge-air cooler, repeat the test to verify the
accuracy of the pressure decay measurement. Similar
pressure decay readings must be obtained in at least
three consecutive tests before the reading can be
considered accurate.
Monitor the pressure gauge and determine the rate of

pressure decay with a stopwatch.
Charge-Air Cooler Pressure Drop

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

charge-air cooler with protective caps from the Air
Handling Clean Care Kit.
Temperature Differential Test

Inspect the charge-air cooler fins for obstructions to
airflow. Remove obstructions such as a winterfront or
debris. Manually lock the shutters, if equipped, in the
OPEN position.
Charge-Air Cooler Signature™, ISX, and QSX15 Eng [...]
Install a fluke digital thermometer, Part Number 3822666,

and thermocouple wire kit, Part Number 3822988, into the
intake air connection.
Install another thermocouple at the air cleaner inlet to the
outside of the vehicle.
Perform a road test with the engine at peak power and a

vehicle speed of 30 mph or greater.
Record the intake air temperature and the ambient air
temperature.
Calculate the differential temperature:
Intake Air • Ambient = Differenti
Temperat Air al
ure Temperat Temperat
ure ure
If the temperature differential is greater than the

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

°C °F
11 MAX 20
Ambient above 0°C [32°F]
Pressure Differential Test
Preferred Method: Measure the charge-air cooler system

pressure drop with a manometer, Part Number ST 1111-3.
Install one end of the manometer to the tap in the

turbocharger compressor outlet elbow.
Install the other end of the manometer to the tap in the

intake air connection.
Operate the engine at the maximum advertised

horsepower and correlating rpm. Record the readings on
the manometer.
Charge-Air Cooler System Differential Pressure

mm Hg in Hg
152 MAX 6
Charge-Air Cooler System Differential Pressure

kPa psi
21 MAX 3
If the differential pressure is greater than the specification,
check the charge-air cooler and associated piping for
plugging. Clean or replace if necessary.
If damage resulted in oil, excessive fuel, or excessive
black smoke entering the exhaust system, the
Air Intake Restriction Signature™, ISX, and QSX15 Eng [...]
Air Intake Restriction (010-031)

Measure
Install a vacuum gauge or water manometer in the intake
air piping.
NOTE: The gauge adapter must be installed at a 90-
degree angle to the airflow in a straight section of pipe,
127 mm [5 in], before the turbocharger compressor inlet.
Operate the engine at full throttle and maximum

horsepower rpm with maximum load.
Record the reading on the gauge or manometer.
NOTE: Restriction must not exceed 635 mm H20 [25 in
H20].
If the restriction exceeds specifications, do the following:

• Replace or clean the air filter element. Refer to the
equipment manufacturer's instructions.
• Inspect the intake air piping for damage. Check for

collapsed and dented piping or elbows, and loose
connections. Refer to the equipment manufacturer's
repair instructions.
Signature™, ISX, and QSX15 Eng [...] Turbocharger
Remove the test equipment.

Procedure 014-013.
Initial Check
Flourescent Tracer Dye Test
Automotive with CM870 or CM871
• Add one unit of fluorescent tracer, Part Number
3376891, to each 38 liters [10 gal] of engine lubricating
oil.
• If a bearing housing coolant leak is suspected, use the
turbocharger coolant leak test kit, Part Number
3164682.
• Operate the engine at low idle for 10 minutes.
NOTE: Brush away any loose dirt from around the area of
air handling connections to avoid contamination of the
interior of the engine.
Allow the turbocharger to cool.
Remove the intake piping and compressor discharge
piping. Cover the openings in the pipes with caps from the
Air Handling and Vehicle Air Plumbing Clean Care Kits,
Part Numbers 4919403, and 4919425 respectively.
Inspect the turbocharger compressor impeller blades for

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

(100 watt), or equivalent, or Part Number 3163338 (50
watt), or equivalent, to inspect the compressor intake and
discharge for signs of oil.
If oil is present in the compressor intake, as well as the
discharge, check upstream of the turbocharger for the
source of the oil.
If oil is present only in the discharge side, check for intake
restriction.
If no intake restriction is found, replace the turbocharger.
If the compressor impeller is damaged, inspect the intake

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

Replace the turbocharger if damage is found.
Install the intake piping and compressor discharge piping.
Disconnect the exhaust pipe from the turbocharger.
Use a high-intensity black light, Part Number 3163337

(100 watt), or 3163338 (50 watt), to inspect the turbine
outlet for leaks.
A dark blue glow indicates a fuel leak. A yellow glow
indicates an oil leak.
If oil is found in the exhaust outlet of the turbine housing,

remove the oil drain line and check for restrictions.
Clear any restrictions found and/or replace damaged
components as required.
Check the engine breather or the crankcase vent tube for

restrictions.
Clear any restrictions and/or replace damaged
components. Refer to Procedure 003-001 in Section 3.
If equipped, check the engine crankcase ventilation filter
assembly for excessive restriction or blockage. Refer to
Inspect the bearing housing for external oil or coolant
leaks.
Remove the oil supply and oil drain tubes from the
turbocharger.
Discard the oil drain tube gasket.
fittings.
Test
Flourescent Tracer Dye Test
WARNING
WARNING
Variable Geometry
in Section 8.
• Inspect the bearing housing for external oil or coolant
leaks.
• Remove the oil supply, oil drain, coolant inlet, and
coolant outlet tubes from the turbocharger.
• Disconnect the variable geometry turbocharger
actuator air supply line (CM870 engines).
• Discard the oil drain tube gasket.
• Check for evidence of coolant in the oil supply and oil
drain fittings.
Leak Test
All Applications
Remove the air intake and charge-air cooler piping from
the turbocharger.
Examine the compressor intake and discharge for oil.

If oil is present in the compressor intake, as well as the
discharge, check upstream of the turbocharger for the
source of the oil.
If oil is present only in the discharge side, check for intake
restriction. Refer to Procedure 010-031 in Section 10.
If no intake restriction is found, replace the turbocharger.
Install the air intake and charge-air cooler piping to the

turbocharger and tighten the clamp.
Operate the engine at full throttle and maximum load, and
check for air leaks.

Connect a turbocharger coolant leak test kit, Part Number
3164682, to the coolant inlet and outlet.
Use shop air supply to pressurize the turbocharger to 276
kPa [40 psi].
Close the air pressure regulator.
Watch for the pressure to decrease. Pressure must not

decrease more than 34 kPa [5 psi] in 1 minute.
If the pressure decreases greater than 34 kPa [5 psi] in 1

minute, use a spray bottle of soapy water to wet all hose
connections. Bubbles will appear if the connections are
leaking.
If the pressure does decrease excessively, and the hose
connections are not leaking, replace the turbocharger.
Preparatory Steps
• Remove the wastegate actuator hose. Refer to
WARNING
WARNING
• Drain the coolant. Refer to Procedure 008-018 in
Section 8.
• Disconnect the turbocharger speed sensor. For
Signature™ and ISX engines, see the following
procedure in the Troubleshooting and Repair Manual,
CM870 Electronic Control System Signature™ and ISX
• Disconnect the turbocharger compressor air inlet
temperature sensor. For ISX engines, see the following
Engines, Bulletin 4021334.Refer to Procedure 019-395
in Section 19.
• Disconnect the variable geometry actuator air supply
line. Refer to Procedure 010-113 in Section 10.
• Remove the turbocharger coolant hoses. Refer to
WARNING
WARNING
the air handling connections to avoid contamination of the
• Drain the coolant. Refer to Procedure 008-018 in
Section 8.
• Disconnect the turbocharger speed sensor. For ISX
and ISM engines, see the following procedure in the
ISX CM871 and ISM CM876 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin
4021560. Refer to Procedure 019-390 in Section 19.
• Disconnect the turbocharger compressor air inlet
temperature sensor. For ISX and ISM engines, see the
following procedure in the ISX CM871 and ISM CM876
Electronic Control System, Troubleshooting and
• Remove the turbocharger coolant hoses. Refer to
• Remove the charge-air piping. Use protective caps
from the Air Handling Clean Care Kit, Paart Number
4919403. to cover open points.
• Remove the turbocharger air inlet piping. Use
protective caps from the Air Handling and Vehicle Air
Plumbing Clean Care Kits, Part Numbers 4919403,
and 4919425 respectively to cover open points.
• Disconnect the aftertreatment adapter pipe. Use
protective cap from the Air Handling Clean Care Kit,
Part Numbers 4919403 and 4919425 respectively, to
cover the turbocharger exhaust outlet.Refer to
Remove
WARNING
Automotive, Industrial, and Power Generation with
CM570
• Remove the oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.
Remove the intake and exhaust pipes from the

turbocharger.
elbow.

turbocharger.
Discard the o-ring.
NOTE: In some applications, the turbocharger will not

clear the lubricating oil cooler assembly during removal
and installation. It will, perhaps, be necessary to remove
the exhaust manifold and turbocharger together, and then
separate the two components. If the two components
must be removed together for the removal and installation
of the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
WARNING
CAUTION
When installing a lifting eye, be sure the shoulder of
the lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of the lifting eye
and personal injury.
CAUTION
If the lifting eye is installed in the turbocharger
bearing housing, it is to be used exclusively for
turbocharger removal and installation. It is not to be
used in removal of the exhaust manifold, or engine.
Doing so will cause damage to the turbocharger.
Remove the oil supply and the oil drain tube from the
turbocharger.
Remove the intake and the exhaust pipes from the

turbocharger.
elbow.

turbocharger.
Discard the o-ring.

aid in removal of the turbocharger.
WARNING
Thread a lifting strap around the turbocharger bearing
housing. Take care not to bend the coolant lines when
lifting the turbocharger.
when removing the turbocharger.
NOTE: If the turbocharger mounting nuts do not loosen
freely, split the nuts to avoid breaking a mounting stud.
Remove the turbocharger and discard the gaskets.
Cover the turbocharger exhaust inlet port with heavy tape

or a protective cap from the Air Handling and the Vehicle
Air Plumbing Clean Care Kit, Part Numbers 4919403 and
4919425 respectively. Cover the opening on the exhaust
manifold with heavy tape.
If the turbocharger is being replaced with a new
turbocharger, remove the variable geometry turbocharger
actuator.
Disassemble
Turbine Housing Replacement for ISX Automotive
with CM570, QSX15 with CM570, and Power
Generation with CM570
• Place the turbocharger outlet on a clean flat surface.
Create an alignment mark on the turbine housing,
bearing housing and the V-band clamp. This mark will
make certain the components are oriented correctly
during the assembly process.
Loosen the turbine side V-band locknut. Remove and

discard the V-band clamp.
CAUTION
required for the turbine housing removal process.
Use a soft hammer to tap the turbine housing down
against a soft bench surface.
As the bearing housing and compressor housing
assembly loosen, gently lift the assembly out of the turbine
housing.
Wastegate mounting is not affected by this disassembly
process.
Always clean the turbine housing before assembly,
paying particular attention to the surface close to the
turbine housing and the bearing housing location.
Clean
Turbine Housing Cleaning for ISX Automotive with
CM570, QSX15 with CM570, and Power Generation
with CM570
• The turbocharger turbine housing surface adjacent to
the turbine compressor wheels must be clean,
smooth, and free from deposits.
• Inspect the components to detect signs of burning and
other conditions, in order to obtain as much
information as possible before washing.
CAUTION
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.
CAUTION
personal injury.
Scale-like deposits, if any, must be removed by using a
non-metallic bristle brush. After removing the deposits,
wash and dry the components.
Dry the components with compressed air.
CAUTION
personal injury.
NOTE: Do not bead blast aluminum and cast iron
components together.
NOTE: To prevent bead spray impinging directly on the
clamp plate and turbine flange threads, mask and plug off
all items.
NOTE: Prevent the bead spray impinging directly on the
wastegate valve spindle, as beads can penetrate the
spindle bore, and lead to spindle seizure.
It is permissible to bead blast the turbocharger turbine
housing if chemical and brush cleaning is not effective.
After removing the deposits, wash and dry the

components.
Inspect for Reuse

• Clean the retaining nut mating surfaces of the
• Clean the mating surfaces with Scotch-Brite™ 7448
abrasive pad.
• The surface under the mounting nuts must be free of
dirt, rust, or any other debris, before applying anti-
seize compound, Part Number 3823097.
Inspect the wastegate actuator. Refer to Procedure

Inspect the turbocharger casings.
Replace the housing if through cracks are found in the
outer walls.
Cracking in the turbine housing inlet flange and the inlet

duct generally requires replacement of the turbine
housing. Acceptance and rejection guidelines are shown
in these illustrations. If an exhaust gasket is available,
always make certain that cracks do not exist within the
sealing area.
Check the turbine housing inlet flange flatness. It must be
within 0.1 mm [0.004 in] to be acceptable for reuse.
Flange Fasteners - Clearance Holes

Check the fastener hole diameter. It must not be more
than 1.5 mm [0.006 in] larger than the maximum thread
diameter of the fastener.
CAUTION
If external cracks are found on the turbine housing,
the turbine housing must be replaced.
CAUTION
required for the turbine housing installation process.
Cracking of the internal wall at the entry to the turbine
wheel (tongue) is acceptable as a service condition, and
the turbine housing can be re-used.

fretting.
Use dial depth gauge, Part Number ST-537.

Push the rotor assembly away from the gauge.
Set the gauge to zero (0).
Push the rotor assembly toward the gauge and record the
reading.

mm in
0.025 MIN 0.001
0.127 MAX 0.005
Use a dial indicator to check radial movement at the

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

mm in
0.406 MIN 0.016
0.610 MAX 0.024
If the turbocharger radial clearance is not within

Section 10.

casings.
walls are found.
are found.
Clean the retaining nut mating surfaces of the

abrasive pad.
rust, or any other debris before applying anti-seize

fretting.
turbocharger.
Section 10.

shaft.

mm in
0.025 MIN 0.001
0.127 MAX 0.005

and shaft.
housing.

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

casings.
walls are found.
are found.
NOTE: All openings on the turbocharger, including the

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

fittings.

fretting.
turbocharger.
Section 10.

shaft.

mm in
0.051 MIN 0.002
0.152 MAX 0.006

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

torque the locknut.
Loosen the locknut 180 degrees, and torque the locknut.
Make certain the rotor assembly rotates freely and neither
compressor wheel or turbine wheel is rubbing against the
housing.
Install
Part Number 3823097, or equivalent, to the
turbocharger mounting studs.
WARNING
NOTE: If the exhaust manifold and turbocharger were
removed together in order for the turbocharger to clear the
lubricating oil cooler assembly, see the following
procedure for installation of the exhaust manifold. Refer
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque value for the standard nut:
Torque value for the Spiralock™ nut (identified by "SPL"
on the nut flange):

turbocharger.
If a new turbocharger is being installed, the variable

geometry turbocharger actuator from the original
turbocharger must be reused.
Tighten the clamp.

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

The end rests on the oil cooler housing.
This brace requires longer, 1.25 mm [0.049 in],
capscrews.
Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean

engine oil into the turbocharger oil supply opening.
CAUTION
contact. (The inlet supply fitting must be oriented
slightly off vertical to allow proper alignment.)
If installing a new turbocharger, make sure the
turbocharger is aligned, loosen the compressor and
turbine v-bands, and adjust as needed. Tighten the v-
bands.
If installing a new turbocharger, install the male union
elbow.
Install the turbocharger oil supply tube on the elbow.
Install the intake and exhaust pipes to the turbocharger.

Tighten the clamp.

Variable Geometry
Part Number 3823097, to the turbocharger mounting
studs.
WARNING
CAUTION
When installing lifting eye, be sure the shoulder of the
lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of lifting eye and
personal injury.
CAUTION
If a lifting eye is installed in turbocharger bearing
housing, it is to be used exclusively for turbocharger
removal and installation. It is not to be used in
removal of the exhaust manifold, or engine. Doing so
will cause damage to the turbocharger.
CAUTION
geometry mechanism.
aid in the installation of the turbocharger.

turbocharger.

Tighten the clamp.

Install the intake and exhaust pipes to the turbocharger,

and tighten the clamps.

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

fittings into the bearing housing.
NOTE: Use a ratchet and deepwell socket to install these
fittings.
CAUTION
contact.
Install the turbocharger oil supply hose onto the oil supply
fitting. The oil supply hose must point directly downward
in order for it to properly connect to the oil supply fitting
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
WARNING
lift this component.
CAUTION
geometry mechanism.
NOTE: Thread a lifting strap around the turbocharger
bearing housing. Take care not to bend the coolant lines
when lifting the turbocharger.
when installing the turbocharger.
Install a new o-ring seal, the clamp, and the discharge

elbow to the turbocharger.
Tighten the clamps.

Connect the oil supply hose to the oil supply fitting located
Tighten the oil supply hose.
Finishing Steps
• Install the wastegate actuator hose. Refer to
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
CAUTION
Turbocharger speed sensor harness and turbocharger
compressor inlet air temperature sensor harnesses
must be tied securely and away from heat sources,
such as the exhaust manifold and exhaust pressure
sensor tube. Failure to do so can cause damage to the
sensor harness.
CAUTION
The turbocharger compressor inlet air temperature
sensor must be positioned so the sensor body is
pointing up and away from the exhaust manifold.
Failure to do so can cause sensor damage.
CAUTION
Do not twist coolant lines while tightening. Failure to
do so will damage coolant lines.
• Install the turbocharger coolant hoses. Refer to
• Connect the variable geometry actuator air supply line.
• Connect the electrical connectors on the turbocharger
speed sensor and the turbocharger compressor air
inlet temperature sensor. For ISX engines, see the
Manual, CM870 Electronic Control System Signature™
and ISX Engines, Bulletin 4021334.Refer to Procedure
019-395 in Section 19. Also, see the following
in Section 19.
• Fill the cooling system with coolant. Refer to Procedure
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.

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

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

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

Remove the turbocharger coolant supply hose from the
Remove the smaller banjo bolt from the turbocharger
electric actuator coolant inlet port (2) and the large banjo
bolt from the turbocharger bearing housing coolant inlet
port (3).

Remove the turbocharger bearing housing coolant return
hose from the top of the turbocharger and the thermostat
housing (1).
Remove the turbocharger actuator coolant return hose
from the top of the turbocharger and the thermostat
housing (2).
WARNING
WARNING
WARNING
personal injury.
Clean the turbocharger coolant hoses with solvent.
Check the o-rings for cuts or deformation. Replace as

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

is not damaged.
Install
CAUTION
Install the turbocharger coolant supply hose to the bottom
of the turbocharger and the lubricating oil filter head.
CAUTION
is not damaged.
Install the turbocharger coolant return hose to the top of
the turbocharger and the thermostat housing. Tighten the
fittings.
Install the tube brace onto the turbocharger coolant return

hose and the air tube.
CAUTION
CAUTION
coolant hose o-rings. The o-rings will swell and cause
Install the four new banjo sealing washers on the
turbocharger coolant supply hose.
Lubricate the sealing washers with clean engine coolant,
soapy water, or vegetable oil.
turbocharger bearing housing (3).
turbocharger actuator (2).
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
CAUTION
CAUTION
Install four new banjo sealing washers on the turbocharger
bearing housing coolant return hose and turbocharger
actuator coolant return tube.
Install the turbocharger coolant return hose to the
turbocharger. Tighten the fitting.
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
thermostat housing. Tighten the fitting.
It is possible for the turbocharger actuator coolant return
hose to contact the turbocharger coolant return hose
when the fittings are torqued. Be sure to space the hoses
apart while the fittings are torqued. If the hoses are not
spaced apart, hose failure can result.
NOTE: Use a second wrench to hold the coolant line
coupling while tightening the line.
turbocharger actuator. Tighten the banjo fitting.
Finishing Steps
WARNING
cable last.
• Install the turbocharger oil supply and oil drain hoses
from the turbocharger. Refer to Procedure 010-033
• Fill the engine with coolant. Refer to Procedure
008-018 (Coolant System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Signature™, ISX, and QSX15 Eng [...] Turbocharger Wastegate Actuator
WARNING
cable last.
• Install the turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033.
• Fill the engine with coolant. Refer to Procedure
008-018.
• Connect the batteries. Refer to Procedure 013-009.
Turbocharger Wastegate Actuator

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

Replace the hose if damaged.
CAUTION
A bent wastegate mounting bracket, actuator rod, or
lever can cause improper operation.
Inspect the wastegate mounting bracket, actuator rod,
and lever for damage.
If the wastegate mounting bracket, actuator rod, or lever
is bent, it must be replaced.
Turbocharger Wastegate Actuator Signature™, ISX, and QSX15 Eng [...]
WARNING
Exhaust and turbocharger components could be hot.
Use caution and wear protective clothing when
handling these components.
To verify the wastegate actuator travel, install Service
Tool, Part Number 3165168, on the wastegate cover with
the magnetic base and the dial indicator resting on the end
of the actuator end link.
Disconnect the air supply line from the wastegate actuator

and install the air line from the air control valve, Part
Number ST-990-40, to the wastegate actuator.
Install the male quick-connect fitting, Part Number

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

to the multimeter, Part Number 3164488 (2).
Air leaks should not be detected through a functional

wastegate capsule.
Connect the air supply to the control valve. Apply
regulated air pressure of 100 kPa [14.5 psi] to the
wastegate actuator to measure the travel.
Cycle the air pressure to the actuator assembly several
times to work the system. Do not exceed 100 kPa [14.5
psi].
Measure the actuator rod for correct travel. If the actuator

travel is not within the specifications, the wastegate
must be adjusted. If adjustment is required, remove the
turbocharger.
To make sure an accurate measurement is obtained, it is
essential to use the specified tools and procedures.
Turbocharger Wastegate Rod Travel at 100 kPa [14.5

psi]
mm in
0.356 MIN 0.014
3.810 MAX 0.150
Preparatory Steps
• Remove the turbocharger. Refer to Procedure
010-033 (Turbocharger) in Section 10.
Inspect
To obtain an accurate measurement, do not remove the
wastegate valve cover or take the measurement from the
top of the capscrew that secures the wastegate valve
cover.
Use a micrometer depth gauge. To made a measurement
from the face of the wastegate valve cover to the end of
the wastegate actuator end link. Do not apply air pressure
to the wastegate actuator.
If the wastegate wear measurement is less than 25.654
mm [1.010 in] then the turbocharger wastegate actuator
can be recalibrated and the turbocharger returned to
service. If the wastegate wear measurement is greater
than 25.654 mm [1.010 in], replace the turbocharger
turbine housing.
Remove
Remove the retaining clip from the control lever.
WARNING
bodily injury.
CAUTION
Be careful not to bend the control lever.
Air Regulator with Pressure Gauge
Slowly apply regulated air pressure to the boost capsule.
A maximum of 310 kPa [45 psi] can be used. Disconnect
the boost capsule actuator rod end from the turbocharger
wastegate lever rod when the rod is loose on the lever.
NOTE: If the boost capsule diaphragm material is

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

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

A new hose clamp is required to install the signal line.
Disconnect the actuator hose from the wastegate actuator
by cutting the crimped hose clamp.
Air leaks should not be detected through a functional

wastegate capsule.
Connect clean regulated air pressure and a pressure
gauge to the actuator.
Apply 100 kPa [14.5 psi] to make sure the wastegate is
functioning properly.
Measure the actuator rod for correct travel. If the actuator

travel is not within the specifications, the wastegate
must be calibrated.
Turbocharger Wastegate Rod Travel at 100 kPa [14.5

psi]
mm in
0.356 MIN 0.014
3.810 MAX 0.150
If no actuator travel is observed, inspect the wastegate
valve for seizure or damage. Refer to Procedure 010-055
(Turbocharger Wastegate Valve Body) in Section 10.
Adjust
CAUTION
If there is a turnbuckle with an adjusting link, do NOT
adjust the piston guided actuator by turning the rod
of the actuator. This will damage the rubber
diaphragm inside the actuator. The knurled
turnbuckle on the new end adjusting link must be
used.
Leave the setting pressure air supply connected to the
wastegate capsule.
Loosen the actuator end-link locknut.
CAUTION
To reduce the possibility of breaking the wastegate
pivot pin, use a wrench on the end link to support it
while loosening and/or tightening the actuator end-
link locknut.
Remove the actuator end-link retaining clip.
Remove the actuator end link from the wastegate lever.
CAUTION
If there is a turnbuckle with an adjusting link, do NOT
adjust the piston guided actuator by turning the rod
of the actuator. This will damage the rubber
diaphragm inside the actuator. The knurled
turnbuckle on the new end adjusting link must be
used.
Adjust the length of the end link by rotating to obtain
nominal travel.
Turbocharger Wastegate Actuator Rod Travel

mm in
0.78 NOM 0.031
After adjusting is completed, tighten the end-link locknut

against the end link.
Cycle the air pressure to the wastegate actuator several

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

Disconnect the regulated air pressure line from the
wastegate actuator.
Install
If a new actuator is being installed, install the adjusting
end link onto the shaft of the precalibrated wastegate
actuator assembly.
Thread the new end link several turns onto the shaft of the
new pre-set actuator assembly.
Install the new pre-set actuator assembly onto the bracket,

so the actuator clamp is in position to give access to the
capscrew.
If the capscrew can not be reached, remove the actuator
and carefully rotate the actuator assembly until the
capscrew is accessible.
Fit the actuator assembly and nuts.
With the valve held closed (pushed toward the compressor

housing), rotate the end link until the hole aligns with the
crank-arm pin, so the end link can be fitted over the pin
without using force.
The setting is correct if, by rotating the end link
clockwise an extra half-turn, the end link can no longer
be fitted onto the crank-arm pin.
Fit the new e-clip (snap ring) provided in the kit.
Tighten jam-nut against end link.

Signature™, ISX, and QSX15 Eng [...] Turbocharger Wastegate Valve Body
Remove the actuator clamp.
Finishing Steps
Turbocharger Wastegate Valve Body

(010-055)
Inspect for Reuse
The wastegate actuator end-link must be removed to
inspect the turbocharger wastegate. Refer to Procedure
010-050.
Inspect the lever pin.
If the lever pin is worn excessively, replace the
turbocharger. Refer to Procedure 010-033.
Rotate the lever by hand to verify that the shaft turns freely
and is not seized.
Check for excessive movement between the shaft and
bushing.
Replace the turbine housing if the shaft and bushing are
damaged or seized.
Refer to the Turbocharger Master Repair Manual, Bulletin
3580555.
Intake Manifold Pressure Signature™, ISX, and QSX15 Eng [...]
The turbocharger must be removed from the engine and

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

mm in
25.654 MAX 1.010
Calibrate the turbocharger wastegate actuator if the
wastegate wear measurement is less than specifications.
Refer to Procedure 010-050 for wastegate actuator
recalibration procedure.
Replace the turbocharger if the wastegate wear
measurement is greater than specifications. Refer to
Procedure 010-033 for the replacement procedure.
Intake Manifold Pressure (010-057)

Measure
Install a 0 to 2030 mm Hg [0 to 80 in Hg] manometer (or
gauge) in the straight threaded plug hole in the air inlet
connection.
Operate the engine at rated rpm and full load. Compare

the value to the specifications given in the engine
performance data sheets.
NOTE: Stall speed is not full power.
Signature™, ISX, and QSX15 Eng [...] Air Intake Connection

Preparatory Steps
• Disconnect the air pipe from the charge air cooler to
the air inlet connection.
• Disconnect the boost sensor wire.
• Remove the four-step wastegate controller wires,
hose, mounting capscrews, and controller.

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

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

Remove the four capscrews that hold the air intake
Cover all open points on the air intake connection and

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

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

All Applications
WARNING
Inspect the air intake connection for the amount of carbon
on the inside of the air intake connection.
Clean the air intake connection. Saturate the inside of the

air intake with safety solvent. Mineral based solvents can
be used if expected results with the safety solvent are
not acceptable.
Clean the debris with a non-abrasive brush. Dry the air
intake connection with compressed air.
Inspect for cracks or damage threads. Replace if
necessary.
Inspect the cylinder head air intake area.
Some soot build up inside the cylinder head is normal and
will not affect engine performance. Clean the air intake to
cylinder head surface with Scotch Brite™ 7448 abrasive
pad or a gasket scrapper. Do not use power tools
combined with an abrasive pad to clean the gasket
surfaces.
Install
Install the four mounting capscrews, air inlet connection,
and new gasket.
Air Intake Connection Signature™, ISX, and QSX15 Eng [...]
Install the four-step wastegate controller, mounting

Connect the boost sensor wire.
Connect the air pipe from the charge air cooler to the air
inlet connection.

intake connection.

intake connection.
Finishing Steps
• Connect the air pipe from the charge air cooler to the
air inlet connection.
• Connect the boost sensor wire.
• Install the four-step wastegate controller wires, hose,
mounting capscrews, and controller.
Signature™, ISX, and QSX15 Eng [...] Turbocharger Wastegate Controller

• Install the four-step wastegate controller, mounting
• Connect the boost sensor wire.
• Connect the air pipe from the charger air cooler to
the air inlet connection.
• Connect the engine wiring harness to the intake
manifold pressure sensor and intake manifold air
temperature sensor.
• Install the EGR mixer. Refer to Procedure 011-021 in
Section 11.
• Start and operate the engine. Check for air leaks.

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

(010-109)
Remove
Use a 3/8-inch wrench to remove the nut holding the
electrical connection of the four-step wastegate controller
coil.
Remove the connection.
Turbocharger Wastegate Controller Signature™, ISX, and QSX15 Eng [...]
Remove the four capscrews.

Remove the coil and the fuel shield.
Remove the spring washer, valve disc, and actuator
spacer from the valve housing.
Inspect for Reuse

Use mineral spirits. Clean all of the parts except the coil
assembly.
NOTE: Do not get solvent on the coil. Clean the coil with
a dry cloth. Use a 200-grit emery cloth and a flat surface
to polish the coil surface.
Check the valve disc, valve seat, and actuator disc for dirt,
metal parts, bonding separation, corrosion, cracks, or
wear. Replace if necessary.
Use a wire brush to clean any corrosion from the coil
terminal.
Check the coil assembly with a multimeter.

Replace the coil if not within specifications.
NOTE: If the coil assembly shows 0 ohm, there is an
electrical short in the coil.
Tighten the nut that holds the electrical connection post
on the coil.
Resistance
12-VDC 6 to 10 ohms
24-VDC 24 to 40 ohms
Install
Assemble the valve as shown.
Install these parts as follows:
• Install a new o-ring between the spacer and the
control valve body.
• Install the spacer o-ring groove toward the coil.
• Install the spring washer with the cup side toward the
coil.
Signature™, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
NOTE: The coil must be orientated with the electrical

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

• Install the nut on the threaded post of the coil.
• Use two wrenches to hold the post of the nut firmly
while tightening the connection nut.

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

performance by building boost more quickly during
acceleration.
Turbocharger, Variable Geometry Actuator Signature™, ISX, and QSX15 Eng [...]
The variable geometry turbocharger functions as a

standard turbocharger with the addition of the following:
• A speed sensor (1) in the bearing housing to monitor
turbocharger operation.
• Water-cooled bearing housings (in addition to oil
lubrication)
• The sliding nozzle (2) is actuated by a pneumatic
actuator attached to the vehicle (brake) air supply
system
• The pneumatic actuator (3) operated by an air control
valve (4)
• On some engines, a filter and shutoff valve (5) are
used in the air line between the control valve (4) and
the air supply tank (6)
• When the variable geometry turbocharger
mechanism opens, a noise can be heard as air is
released from the actuator (3) through the control
valve (4).
Preparatory Steps
Variable Geometry
CAUTION
• Remove the air line from the actuator.
Remove
Variable Geometry
CAUTION
Remove the capscrew holding the actuator rod to the
turbocharger cross-shaft.
Remove the snap ring from the cross-shaft.
Signature™, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
WARNING
Loosen the two capscrews holding the actuator to the
turbocharger bearing housing.
psi] regulated air pressure to the actuator air inlet, to
Remove the two loosened capscrews and actuator.
Inspect for Reuse

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

shaft pin.
Replace the turbocharger if wear is found.
Turbocharger, Variable Geometry Actuator Signature™, ISX, and QSX15 Eng [...]
Test
Variable Geometry
Attach a dial indicator as shown, so the shaft is in line with
the actuator rod.
Set the dial indicator to zero, with no air pressure applied
to the actuator.
Connect clean, regulated air pressure and a pressure
gauge to the actuator.
Apply a minimum of 414 kPa [60 psi] to make sure the
actuator is functioning properly.
The rod must move without any sticking.
Actuator Movement Range

mm in
12 MIN 0.472
Air must not be heard leaking through a functional
actuator.
Spray soapy water on the actuator housing to check for
air leaks.
Replace the actuator housing if leaks are found.
Replace the actuator if no movement of the actuator rod
is detected, the actuator is sticking, or an air leak is found.
This test can be performed with the actuator removed or
installed on the turbocharger.
Install
Variable Geometry
WARNING
psi] regulated air pressure to the actuator.
Install the actuator on the turbocharger bearing housing.
Install and tighten the two capscrews.
Install the actuator rod to the turbocharger cross-shaft.

Install the snap ring.
Install and tighten the capscrew.
Signature™, ISX, and QSX15 Eng [...] Turbocharger Air Shutoff Valve Filter
Finishing Steps
Variable Geometry
• Install actuator air line.
• Start and operate the engine.
• Verify proper operation and check for air leaks.
If a failure resulted in coolant, oil, excessive fuel, or
Procedure 014-013.

(010-114)
Preparatory Steps
Variable Geometry
WARNING
personal injury.
WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Release the air pressure from the compressed air
system.
Remove
Variable Geometry
Use filter wrench and remove the air filter from the
Turbocharger Air Shutoff Valve Filter Signature™, ISX, and QSX15 Eng [...]

Variable Geometry
WARNING
personal injury.
Clean the turbocharger control shutoff valve filter head
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Inspect the filter head for signs of water entrapment or
contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve lines,
turbocharger control shutoff valve, and turbocharger
control valve. Replace if signs of corrosion are found.
Use compressed air to clean fittings, lines, and
Install
Variable Geometry
Apply a thin coat of lubricant on the filter gasket.
Install and hand tighten a new turbocharger control shutoff
valve filter on the turbocharger control shutoff valve body.
Use a filter wrench to tighten the filter full turn after gasket
contact.
Finishing Steps
Variable Geometry
• Start the engine and verify proper operation.
• Inspect for air leaks and proper variable geometry
turbocharger operation.
Signature™, ISX, and QSX15 Eng [...] Turbocharger Control Shutoff Valve Filter Head

Preparatory Steps
Variable Geometry
WARNING
personal injury.
WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Remove the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
• Disconnect the air line from the air tank.
• Disconnect the electrical harness from the
turbocharger air control shutoff valve.
• Remove the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
Remove
Variable Geometry
Remove the turbocharger control shutoff valve filter head.
Turbocharger Control Shutoff Valve Filter Head Signature™, ISX, and QSX15 Eng [...]

Variable Geometry
WARNING
personal injury.
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Inspect the fittings and lines for signs of water entrapment
or contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve.
Use compressed air to clean the fittings, lines, and
turbocharger control shutoff valve and the turbocharger
control valve.
Inspect the vehicle air drier for proper operation.
Replace the lines and turbocharger control shutoff valve,
if necessary.
Repair the cause of water entrapment or contamination.
WARNING
personal injury.
WARNING
mounting surfaces with solvent.
Check for cracks or damage. Replace the turbocharger
control shutoff valve filter head, if cracks or damage are
found.
Install
Variable Geometry
Install the two mounting capscrews and the turbocharger
control shutoff valve filter head.
Signature™, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator Air Supply Lin [...]
Finishing Steps
Variable Geometry
• Install the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
• Connect the air line from the air tank.
• Install the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
• Install the turbocharger control shutoff valve filter.
• Connect the electrical harness to the turbocharger
control shutoff valve.

Remove
CAUTION
Disconnect the air line at the turbocharger actuator.
Mask the end of the air line and turbocharger actuator to
prevent contamination.
Remove the p-clip at the thermostat housing.

valve.
Remove the turbocharger control valve air line.
Turbocharger, Variable Geometry Actuator Air Supply Lin [...] Signature™, ISX, and QSX15 Eng [...]
Inspect for Reuse

Inspect the air line connections for wear, cracks, or other
damage.
Inspect the o-rings for signs of damage or distortion.
Replace as necessary.
Install
CAUTION
CAUTION
Mask both ends of the turbocharger actuator supply line
before installing.
Install the turbocharger actuator air supply line.
Connect the air supply line to the turbocharger air control

valve.
Connect the p-clip to the thermostat housings.
Connect the air supply line to the turbocharger actuator.
Signature™, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Control Valve Air Suppl [...]

(010-121)
Remove
CAUTION
Bleed the air from the control valve air supply line.
Disconnect the air line at the turbocharger control valve.
Remove the p-clips holding the air line to the engine.
shutoff valve.
Remove the turbocharger control valve air supply line.

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

Inspect the air line connections for wear, cracks, or other
damage.
Inspect the o-rings for signs of damage or distortion.
Turbocharger, Variable Geometry Control Valve Air Suppl [...] Signature™, ISX, and QSX15 Eng [...]
Install
CAUTION
CAUTION
Mask both ends of the turbocharger control valve air
supply line before installing.
Install the turbocharger control valve air supply line.

valve.
Connect the p-clips holding air line to engine.
shutoff valve.
Signature™, ISX, and QSX15 Eng [...] Variable Geometry Turbocharger Actuator, Electric
Variable Geometry Turbocharger

Actuator, Electric (010-134)
General Information
The purpose of the variable geometry turbocharger:
When the EGR flow is commanded, the variable
geometry turbocharger will close the nozzle in the
turbine housing to create more back pressure in the
exhaust manifold, to force the EGR flow back into the
engine.
Closing the variable geometry turbocharger will also
increase exhaust gas temperature under certain
normal engine operating conditions and during
aftertreatment regeneration events.
The turbocharger also functions to improve engine
performance by building boost more quickly during
acceleration.
Use the following procedure for further information
regarding variable geometry turbocharger and
aftertreatment system interactions. Refer to Procedure
011-999 in Section F.
This procedure provides service information for the
electronically controlled variable geometry turbocharger
actuators.
NOTE: To avoid improper installation of the turbocharger
actuator, follow each step in its entirety and in the proper
sequence.
The starting motor wiring can electrically interfere with the
VGT pigtail and wiring harness. The starting motor wiring
must be at least 152 mm [6 in] away from the actuator and
harness.
Preparatory Steps
WARNING
personal injury.
WARNING
WARNING
• Clean the area around the turbocharger actuator and
dry with compressed air.
• Drain the engine coolant. Refer to Procedure
• Disconnect the turbocharger actuator coolant supply
and return lines from the turbocharger actuator.
• Remove the turbocharger actuator wiring harness
zip ties.
Variable Geometry Turbocharger Actuator, Electric Signature™, ISX, and QSX15 Eng [...]
Remove
Disconnect the wiring harness from the turbocharger
actuator by sliding the locking tang to the open position,
and then pushing down on the release lever and pulling
the connection apart.
CAUTION
Make sure the coolant has been drained before the
actuator is removed. Failure to do so can result in
damage to the actuator.
Remove the four turbocharger actuator mounting
capscrews with a 5-mm Allen™ wrench and discard the
capscrews.
Remove the actuator.
Remove and discard the turbocharger actuator sealing
gasket.

Use a clean cloth to wipe around the surface where the
turbocharger actuator seals to the turbocharger.
NOTE: Take care not to drop any dirt or debris into the
turbocharger.
Inspect the sealing surfaces and the sealing gasket for
signs of leaks, cracks, or other damage.
If the sealing surface of the turbocharger is damaged and

causing a leak, the turbocharger must be replaced.
Discontinue work with this procedure. Refer to Procedure
If the sealing surface of the actuator is causing a leak,
replace only the actuator.
Inspect the pinion gear on the actuator for seizure,

excessive wear, or damaged teeth.
Confirm the actuator is disconnected from the engine
harness. Rotate the output pinion gear by hand. Do not
use any tools to turn the gear.
Replace the actuator if the pinion gear is seized or if the
teeth are worn or damaged.
Inspect the sector gear on the turbocharger for excessive

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

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

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

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

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

turbocharger compressor housing, until it stops. The edge
of the sector gear must be in the green acceptance zone
of the gage.
If the sector gear does not go through the full range of
motion, or if the sector gear requires excessive force to
move it by hand, replace the turbocharger.
Install
CAUTION
During the turbocharger actuator install procedure,
the pinion gear on the actuator will move. Keep hands
and tools away from the pinion gear during the
procedure.
Following these instructions in order is very important.
• Continue through the entire turbocharger actuator

installation procedure before attempting to
troubleshoot any other fault codes.
• Verify that the turbocharger actuator is removed
from the turbocharger bearing housing.
• Verify that the turbocharger actuator electrical
connector is disconnected from the engine wiring
harness.
• Turn the keyswitch ON. Connect INSITE™ electronic
service tool and wait 60 seconds.
• Connect the turbocharger actuator electrical
connector to the engine wiring harness.
If Fault Code 2634 becomes active, disconnect the
turbocharger actuator connector from the engine wiring
harness with the keyswitch ON. Connect the turbocharger
actuator electrical connector. Fault Code 2634 will go
inactive.
It is normal and expected to have Fault Code 2449 active
when a new turbocharger actuator is connected to the
engine, because it is not calibrated to the turbocharger.
Continue through the engine turbocharger actuator
installation procedure before attempting to troubleshoot
any other fault codes.
Use INSITE™ electronic service tool and go to the ECM

Diagnostic Tests screen.
From the list, select VGT Electronic Actuator Installation
and Calibration and click on the “next” button.
NOTE: The VGT Electronic Actuator Installation and
Calibration is not a diagnostic test. It is the procedure to
properly install and calibrate the turbocharger actuator.
Running this procedure improperly can result in additional
fault codes and/or damage to the turbocharger or
actuator.
INSITE™ electronic service tool “INSTALL ACTUATOR”
command must only be run with the actuator not
mounted to the turbocharger.
Locate the column labeled “Value” and left click on the
down arrow. Select “INSTALL ACTUATOR” and select
“START”.
This will set the actuator pinion gear to a known position
to prepare it for installation to the turbocharger. This step
should take less than 30 seconds to complete with
INSITE™ electronic service tool.
INSITE™ electronic service tool will indicate when this step
is complete.
Fault Code 2449 will be active at this point in the
procedure. Continue through the turbocharger actuator
procedure before troubleshooting fault codes.
If at any point, INSITE™ electronic service tool status
message indicates the procedure was stopped or failed,
leave the keyswitch ON and cycle the power to the
actuator by unplugging it from the harness, and then
reconnecting it.
If cycling the power to the actuator does not work, unplug
the actuator, turn the keyswitch OFF for 30 seconds, and
then restart INSITE™ electronic service tool. Then start
over, beginning with the “INSTALL ACTUATOR” step.
Grasp the sector gear by hand and rotate the sector gear
toward the turbocharger compressor housing. Make sure
the edge of the sector gear is rotated all the way towards
the “Install Position” arrow.
Coat the teeth on the sector gear with the grease packet
supplied in the installation kit.
NOTE: It is critical for smooth reliable operation of the
actuator to use the full amount of the Holset® supplied
grease.
CAUTION
Do not attempt to force the actuator onto the bearing
housing by using the capscrews. Misalignment can
cause damage to the actuator or turbocharger.
Align the actuator and gasket assembly with the
turbocharger bearing housing face with the two lower
capscrews. Be sure to use the new capscrews available
in the turbocharger actuator mounting kit.
Align the actuator to the bearing housing and slide the
actuator into place. The actuator pinion gear and the
turbocharger sector gear must engage smoothly. If not,
verify that the sector gear through-hole and the bearing
housing blind-hole are aligned.
It could be necessary to twist the actuator housing to align
it with the mounting holes.
With the actuator aligned on the bearing housing, install

the remaining two capscrews.
Tighten the four capscrews in a crisscross pattern.
Torque Value: Step1 3 N•m [ 27 in-lb ]
Step2 11 N•m [ 97 in-lb ]
Calibrate
The turbocharger actuator must be calibrated to the
turbocharger. This step must be performed to make sure
proper turbocharger operation is achieved.
Calibration instructions:
Within the INSITE™ electronic service tool screen labeled
“VGT Electric Actuator Install and Calibrate”, locate the
column labeled “Value” and left click on the down arrow.
Select “CALIBRATE ACTUATOR”.
INSITE™ electronic service tool “CALIBRATE
ACTUATOR” command must only be run with the
actuator mounted to the turbocharger.
Follow the instruction on the screen in order to calibrate
the turbocharger actuator to the turbocharger. INSITE™
electronic service tool will indicate when this step is
complete.
If INSITE™ electronic service tool status message
indicates the procedure was stopped or failed, turn the
keyswitch OFF for 30 seconds and key back ON. Then
start over, beginning with the “INSTALL ACTUATOR”
It is normal to have an active Fault Code 2387 at this point.
Turn the keyswitch in the OFF position for 30 seconds.
Then key ON and refresh the fault code screen. All
turbocharger actuator fault codes should be inactive. Use
INSITE™ electronic service tool to clear all fault codes.
NOTE: Make sure all fault codes are inactive and cleared
before adding coolant to the engine.
Finishing Steps
WARNING
• Install the turbocharger actuator coolant supply and
return lines. Refer to Procedure 010-041 in Section
10.
in Section 8.
• Operate the engine to make sure the turbocharger
actuator operates properly and all turbocharger
actuator fault codes are inactive.
• Check the engine for leaks.
Signature™, ISX, and QSX15 Eng [...] Variable Geometry Turbocharger Cross Shaft
The starting motor wiring can electrically interfere with the

VGT pigtail and wiring harness. The starting motor wiring
must be at least 152 mm [6 in] away from the actuator and
harness.
• Secure the turbocharger actuator wiring away from
hot and abrasive parts.
• Zip tie the turbocharger actuator harness to the two
ears on the actuator housing (1).
• Secure the turbocharger actuator harness,
turbocharger compressor inlet temperature sensor
harness, and the turbocharger speed sensor
harness to the turbocharger coolant outlet hose (2).
In order to prevent the wire harness from being
damaged, use two zip ties as shown.
• Secure the turbocharger actuator, speed sensor,
and compressor inlet temperature sensor wiring
harness as indicated (3).
Variable Geometry Turbocharger

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

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

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

clamp.
NOTE: Use care when removing the turbocharger

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

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

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

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

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

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

ring.
Remove the air supply line to the variable geometry

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

Remove the actuator from the turbocharger.
Rotate the cross shaft clockwise, by hand, to the end of

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

bearing housing.
NOTE: Use care when installing the turbocharger

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

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

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

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

Section Contents
Page
Aftertreatment Adapter Pipe .........................................................................................................................11-93
Finishing Steps............................................................................................................................................. 11-96
Install............................................................................................................................................................11-96
Remove.........................................................................................................................................................11-94
Aftertreatment Diesel Oxidation Catalyst ...................................................................................................11-113
Clean and Inspect for Reuse........................................................................................................................11-115
Finishing Steps............................................................................................................................................11-119
General Information.....................................................................................................................................11-113
Install..........................................................................................................................................................11-118
Preparatory Steps........................................................................................................................................11-113
Remove.......................................................................................................................................................11-114
Aftertreatment Diesel Particulate Filter ........................................................................................................11-82
Adjust............................................................................................................................................................11-87
Finishing Steps............................................................................................................................................. 11-88
Install............................................................................................................................................................11-87
Maintenance Check.......................................................................................................................................11-86
Remove.........................................................................................................................................................11-83
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket ...........................11-99
Finishing Steps............................................................................................................................................11-102
Install..........................................................................................................................................................11-102
Remove.......................................................................................................................................................11-100
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes ............................................11-103
Install..........................................................................................................................................................11-106
Remove.......................................................................................................................................................11-104
Aftertreatment Fuel Injector ..........................................................................................................................11-89
Finishing Steps............................................................................................................................................. 11-93
Install............................................................................................................................................................11-92
Remove.........................................................................................................................................................11-89
Aftertreatment Fuel Injector Coolant Test ..................................................................................................11-152
Finishing Steps............................................................................................................................................11-154
Setup..........................................................................................................................................................11-153
Test.............................................................................................................................................................11-153
Aftertreatment Fuel Injector Flow ...............................................................................................................11-140
Finishing Steps............................................................................................................................................11-145
Flow Test....................................................................................................................................................11-143
Initial Check................................................................................................................................................11-140
Leak Test....................................................................................................................................................11-144
Setup..........................................................................................................................................................11-140
Aftertreatment Fuel Shutoff Manifold .........................................................................................................11-134
Finishing Steps............................................................................................................................................11-139
Install..........................................................................................................................................................11-138
Remove.......................................................................................................................................................11-134
Page 11-b Section 11 - Exhaust System - Group 11
Aftertreatment Injector Lines ......................................................................................................................11-123

Finishing Steps............................................................................................................................................11-133
Install..........................................................................................................................................................11-130
Remove.......................................................................................................................................................11-124
Aftertreatment Inlet and Outlet ...................................................................................................................11-107
Assemble....................................................................................................................................................11-110
Disassemble................................................................................................................................................11-109
Finishing Steps............................................................................................................................................11-112
Install..........................................................................................................................................................11-111
Remove.......................................................................................................................................................11-109
Aftertreatment System ................................................................................................................................11-119
Assemble....................................................................................................................................................11-122
Disassemble................................................................................................................................................11-121
Finishing Steps............................................................................................................................................11-123
Install..........................................................................................................................................................11-122
Remove.......................................................................................................................................................11-120
EGR Connection Tubes .................................................................................................................................11-51
Finishing Steps............................................................................................................................................. 11-60
Install............................................................................................................................................................11-57
Remove.........................................................................................................................................................11-52
EGR Cooler ....................................................................................................................................................11-19
Finishing Steps............................................................................................................................................. 11-36
Install............................................................................................................................................................11-33
Pressure Test................................................................................................................................................11-29
Remove.........................................................................................................................................................11-21
EGR Cooler Connection ................................................................................................................................11-48
Finishing Steps............................................................................................................................................. 11-50
Install............................................................................................................................................................11-50
Remove.........................................................................................................................................................11-48
EGR Cooler Coolant Lines ............................................................................................................................ 11-70
Finishing Steps............................................................................................................................................. 11-77
Install............................................................................................................................................................11-75
Remove.........................................................................................................................................................11-71
EGR Differential Pressure Sensor Adapter ...................................................................................................11-67
Finishing Steps............................................................................................................................................. 11-68
Install............................................................................................................................................................11-68
Remove.........................................................................................................................................................11-67
EGR Differential Pressure Sensor Tubes ..................................................................................................... 11-61
Finishing Steps............................................................................................................................................. 11-65
Install............................................................................................................................................................11-64
Section 11 - Exhaust System - Group 11 Page 11-c

Remove.........................................................................................................................................................11-61
EGR Mixer ......................................................................................................................................................11-37
Finishing Steps.............................................................................................................................................11-39
Install............................................................................................................................................................11-39
Remove.........................................................................................................................................................11-38
EGR Valve ......................................................................................................................................................11-40
Assemble......................................................................................................................................................11-45
Disassemble..................................................................................................................................................11-42
Finishing Steps.............................................................................................................................................11-47
Install............................................................................................................................................................11-45
Remove.........................................................................................................................................................11-41
EGR Valve Coolant Lines ..............................................................................................................................11-68
Finishing Steps.............................................................................................................................................11-70
Install............................................................................................................................................................11-69
Remove.........................................................................................................................................................11-69
EGR Valve Mounting Bracket ........................................................................................................................11-96
Finishing Steps.............................................................................................................................................11-98
Install............................................................................................................................................................11-98
Remove.........................................................................................................................................................11-97
Exhaust Gas Pressure Sensor Adapter ........................................................................................................11-80
Finishing Steps.............................................................................................................................................11-81
Install............................................................................................................................................................11-81
Remove.........................................................................................................................................................11-80
Exhaust Gas Pressure Sensor Tube .............................................................................................................11-65
Finishing Steps.............................................................................................................................................11-66
Install............................................................................................................................................................11-66
Remove.........................................................................................................................................................11-65
Exhaust Manifold, Dry .....................................................................................................................................11-4
Assemble......................................................................................................................................................11-12
Automotive, Industrial with CM570 and Power Generation without CM570..................................................11-12
Automotive with CM870 and CM871.............................................................................................................11-9
Disassemble...................................................................................................................................................11-7
Page 11-d Section 11 - Exhaust System - Group 11
Finishing Steps.............................................................................................................................................11-16
Initial Check....................................................................................................................................................11-4
Install............................................................................................................................................................11-13
Automotive with CM870 and CM871...........................................................................................................11-13
Remove..........................................................................................................................................................11-7
Repair.............................................................................................................................................................11-4
Exhaust Restriction .......................................................................................................................................11-17
Initial Check..................................................................................................................................................11-17
Exhaust System Diagnostics .......................................................................................................................11-145
Heat Shield ....................................................................................................................................................11-78
Finishing Steps.............................................................................................................................................11-80
Install............................................................................................................................................................11-79
Remove.........................................................................................................................................................11-78
Service Tools ...................................................................................................................................................11-1
.......................................................................................................................................................................11-1
Section 11 - Exhaust System - Group 11 Page 11-1
Service Tools
Repair Location.

Manometer
Used to measure exhaust restriction.
ST-1111-3
Pressure Gauge
Used to measure inches of mercury (in Hg) pressure.
ST-1273
EGR Cooler Leak Check Kit

Used to identify leaks and clean the EGR cooler on ISX with CM870
3164225 engines.
Infrared Thermometer
Used to measure the surface temperature of the exhaust
3824941 components.
EGR Cooler Leak Check Kit

Used to pressure test and clean the EGR cooler on ISX with CM871
4918655 engines.
Exhaust Seal Installer

Use to install the exhaust manifold seal on the ISX with CM871
4918709 engines.
Page 11-2 Section 11 - Exhaust System - Group 11

Pressure Adapter Fitting
This fitting is inserted into the thermistor ports of the aftertreatment
4918756 system in order to measure the pressure and pressure differences at
various points in the aftertreatment system.
Diesel Particulate Filter Cleaner HEPA Filter

Used to replace the HEPA filter on diesel particulate filter cleaner,
4918839 Part Number 4918840.
Diesel Particulate Filter Cleaner

This machine is used with diesel particulate filter cleaner adapter kit,
4918840 Part Number 4918893 or 4919182, to clean the diesel particulate filter
once it is removed from the vehicle. (U.S.A. only. Not intended for
use in Canada.)
Diesel Particulate Filter Cleaner Vacuum Filter

Used to replace the vacuum filter on diesel particulate filter cleaner,
4918841 Part Number 4918840.
Diesel Particulate Filter Cleaner Canister Filter

Used to replace the canister filters on diesel particulate filter cleaner,
4918842 Part Number 4918840. Two are required per machine.
Diesel Particulate Filter Cleaner Water Separator

Used to replace the water separator on diesel particulate filter
4918851 cleaner, Part Number 4918840.
Diesel Particulate Filter Cleaner Adapter Kit

Used with Part Number 4918840 to adapt the diesel particulate filter
4918893 to the cleaner.
Diesel Particulate Filter Cleaner Oil Separator Filter

Used to replace the oil separator filter on diesel particulate filter
4918896 cleaner, Part Number 4918840.

Diesel Particulate Filter Cleaner
This machine is used with diesel particulate filter cleaner adapter kit,
4919052 Part Number 4919172 or 4919182, to clean the diesel particulate filter
once it is removed from the vehicle. (For use in the U.S.A. and
Canada.)
Diesel Particulate Filter Cleaner Canister Filter

Used to replace the canister filters on diesel particulate filter cleaner,
4919053 Part Number 4919052. Two are required per machine.
Diesel Particulate Filter Cleaner HEPA Filter

Used to replace the HEPA filter on diesel particulate filter cleaner,
4919054 Part Number 4919052.
Diesel Particulate Filter Cleaner Mounting Adapter Kit

Used with Diesel Particulate Filter Cleaner, Part Number 4919052, to
4919172 adapt the diesel particulate filter to the cleaner. Software unlock card,
Part Number 4919055, is included in this adapter kit to upload the
required cleaning parameters.
Diesel Particulate Filter Cleaner Mounting Adapter Kit

Used with Diesel Particulate Filter Cleaner, Part Number 4919052 or
4919182 4918840, to adapt the diesel particulate filter to the cleaner.
Air Handling Clean Care Kit for Vehicle Plumbing

Air Handling Clean Care Kit for ISX Engine Components

Exhaust Manifold, Dry Signature™, ISX, and QSX15 Eng [...]

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

NOTE: Some ISX CM871 engines are equipped with
exhaust seal rings at the slip joints.
Operate the engine and inspect the exhaust manifold for
leaks at the slip joints.
If the exhaust manifold is leaking at the slip joints, it
must be repaired.
Repair
WARNING
To reduce the possibility of personal injury from hot
surfaces, allow the engine to cool before beginning
work. Wear appropriate hand and eye protection.
Exhaust Manifold Slip Joint Seal Kit Contents

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

service manual.
Twist the graphite seal in order to open it, allowing it to be
placed onto the exhaust manifold.
Signature™, ISX, and QSX15 Eng [...] Exhaust Manifold, Dry
The chamfered edge of the graphite seal faces the

exhaust manifold center section.
Slide the graphite seal ring over the exhaust manifold end
section and press it against the center section.
Align the split in the graphite ring so the open ends point
towards the parting line in the exhaust manifold, as shown
in the illustration.
NOTE: The EGR water return tube was removed in the

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

illustration in order to show the seal kit installation. The
return tube.
Place the bottom cover over the slip joint and graphite seal
with the notch in the cover towards the center of the
CAUTION
To reduce the possibility of damage to the EGR cooler
bellows, do not use the cooler bellows as a pivot point
for a pry bar when compressing the covers.
illustration, in order to show the seal kit installation. The
return tube.
Compress the two covers together. The use of a pry bar
and/or mallet to accommodate the T bolt clamp will
possibly be necessary.
The T bolt of the clamp can be removed to aid in
installation.
Separate the clamp and place it over the two covers.
Tighten the clamp.
Or until the ends of the cover make contact.
Preparatory Steps
WARNING
WARNING
• Remove the charge air cooler piping. Refer to the
OEM service manual.
• Remove the variable geometry turbocharger. Refer
• Remove the heat shield. Refer to Procedure 011-032
in Section 11.
• Remove the EGR valve. Refer to Procedure 011-022
in Section 11.

• Remove the turbocharger. Refer to Procedure
WARNING
WARNING
• Remove the charge air cooler piping. Refer to the
OEM service manual. Use protective caps from the
Air Handling Clean Care Kit to cover the connection
points.
• Remove the air intake pipe to the turbocharger.
Refer to the OEM service manual. Use protective
caps from the Cummins® Vehicle Air Plumbing Clean
Care Kit to cover the connection points.
• Remove the variable geometry turbocharger (VGT).
• Remove the exhaust gas pressure sensor tube.
Remove
WARNING
Remove two mounting capscrews and install two guide
studs.
Remove the remaining mounting capscrews, the spacers,
the exhaust manifold assembly and the gaskets.
Cover open points on the exhaust manifold and cylinder
head using heavy tape.
Disassemble
Disassemble the exhaust manifold end sections.
Discard the exhaust seal ring on the slip-joint, if equipped.

Remove the exhaust manifold end sections.

Disassemble the exhaust manifold end sections.

WARNING
personal injury when using a steam cleaner or high-
pressure water.
WARNING
personal injury.
Use a 240-grit emery cloth to remove carbon deposits from
the sealing surfaces.
Steam-clean and dry with compressed air.
NOTE: A charge air cooler failure can cause progressive

damage to the exhaust manifold. If the exhaust manifold
is damaged, check the charge air cooler. Refer to
Inspect for cracks or other damage.
Inspect the manifold seal bore for wear.
Inspect the exhaust manifold turbocharger mounting
flange for warping.
WARNING
personal injury when using a steam cleaner or high
pressure water.
WARNING
personal injury.
Steam clean and dry with compressed air.
Use a soft cloth or a shop towel wetted with a safety

solvent to remove carbon deposits from the sealing
surfaces.
Inspect the exhaust manifold turbocharger mounting

flange for warpage. The exhaust manifold mounting
surface must be flat to within 0.25 mm [0.010 in]. The
turbocharger mounting flange must have a surface
flatness of 0.13 mm [0.005 in].
NOTE: A charge air cooler failure can cause progressive

damage to the exhaust manifold. If the exhaust manifold
is damaged, check the charge air cooler. Refer to
Inspect for cracks or other damage.
Check that the exhaust seal is fully seated against the

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

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

excessive wear and the exhaust seal must be replaced.
The wear width must be uniform around the seal ring. If

one side of the exhaust seal ring is worn more than the
other, the exhaust seal ring must be replaced.
Inspect the exhaust manifold slip-joints for signs of soot

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

joint.
Use tin snips or side cuts, to cut half way through the seal
in two locations about 25.4 mm [1 in] apart.
NOTE: Take care not to damage the seal carrier surface.

Grasp the portion of the seal between the cuts with a pair
of pliers.
Twist and pull the seal off of the exhaust manifold end
sections.
Discard the exhaust seal rings.
Inspect the exhaust seal ring mating surfaces of the male

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

tape to prevent engine contamination.
Assemble
The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
Install exhaust seal rings, if equipped.
Install the exhaust manifold end sections to the center
section.

The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
section.

Place the exhaust seal ring onto the lip of the Exhaust Seal
Installer, Part Number 4918709.
Use a light coat of grease or clean engine oil to lubricate
the exhaust seal ring during assembly onto the male and
female sections of the exhaust manifolds.
Position the seal installer and seal ring in line with the
sealing surface on the exhaust manifold and strike with a
lead or dead blow hammer until the seal is fully seated.

section.
The end section bolt holes must be 152.4 mm [6 in] center
to center before installing onto the cylinder head.
Install
Remove the tape from the open exhaust ports and cylinder
head.
Install two guide studs into the center section mounting
location.
Do not use adhesive, grease, or heavy grease to hold the
gaskets in place on the cylinder head.
Install a new center section gasket.

WARNING
Install the exhaust manifold over the guide studs.
the capscrew threads to make sure of proper loading on
capscrews.
Slide each manifold gasket between the exhaust manifold
Install the capscrews and spacers through the exhaust
manifold and gasket into the cylinder head.
capscrews.


Install two guide studs into center section mounting
location.
Install the center mounting gasket over the guide studs.
WARNING
Install the exhaust manifold assembly on the guide pins.

Slide each exhaust manifold gasket between the manifold

and cylinder head.
Insert the exhaust manifold mounting capscrews and
spacer through the manifold and gasket and start
capscrews into the cylinder head.
To aid in future capscrew removal, apply a film of high-

temperature anti-seize compound to the capscrew
threads.
Remove the guide studs and install the remaining two
capscrews.

Torque values given have been established using anti-
seize compound as a lubricant.
Finishing Steps
• Install the EGR valve. Refer to Procedure 011-022 in
Section 11.
• Install the heat shield. Refer to Procedure 011-032 in
Section 11.
• Install the variable geometry turbocharger (VGT).
• Install the charge air cooler piping. Refer to the OEM
service manual.
• Fill the cooing system. Refer to Procedure 008-018
in Section 8.
• Operate the engine and check for air leaks and
exhaust gas leaks.

in Section 10.
exhaust gas leaks.
Signature™, ISX, and QSX15 Eng [...] Exhaust Restriction

• Install the exhaust gas pressure sensor tube. Refer
• Install the variable geometry tubes. Refer to
• Remove the protective caps and heavy tape.
• Install the charge air cooler piping. Refer to the OEM
service manual.
in Section 8.
exhaust gas leaks.
Exhaust Restriction (011-009)

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

reading on the manometer.
Exhaust Restriction
mm Hg in Hg
Without Aftertreatment 75.0 MAX 3.0
With Aftertreatment 305.0 MAX 12.0
Exhaust Restriction Signature™, ISX, and QSX15 Eng [...]
If the exhaust pressure exceeds the specifications,

inspect the exhaust piping for damage. Refer to the OEM
troubleshooting and repair manual.
If the vehicle is equipped with an aftertreatment system,
inspect the aftertreatment system for a plugged
aftertreatment diesel particulate filter and/or a plugged
aftertreatment diesel oxidation catalyst.
Extended engine operation with high exhaust restriction
can lead to damaged turbocharger oil seals. Refer to
Procedure 010-033 to inspect the turbocharger for
progressive damage.
Remove the test equipment and install the aftertreatment

diesel oxidation catalyst inlet temperature sensor.
Operate the engine and verify that all fault codes are
inactive.
Signature™, ISX, and QSX15 Eng [...] EGR Cooler

Preparatory Steps
WARNING
WARNING
NOTE: If the EGR cooler is being replaced due to an
internal coolant leak, the EGR differential pressure tubes
must be replaced.
NOTE: Brush away all loose dirt from around the area of
NOTE: If the Exhaust Gas Recirculation (EGR) cooler is
being replaced due to an internal coolant leak, the EGR
differential pressure tubes must be replaced.
the air-handling connections to avoid contamination of the
• Drain the engine coolant. Refer to Procedure 008-018
in Section 8.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual. Use protective caps from the
Cummins® Vehicle Air Pumping Clean Care Kit, Part
Number 4912425, to cover the connection points.
• Remove the charge-air cooler pipe between the
turbocharger and charge-air cooler. Refer to the OEM
service manual. Use protective caps from the
Cummins® Vehicle Plumbing Clean Care Kit, Part
• Remove the turbocharger. Refer to Procedure 010-033
in Section 10.
• Remove the exhaust gas pressure sensor tube. Refer
• Remove the EGR cooler coolant lines. Refer to
EGR Cooler Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
NOTE: If the EGR cooler is being replaced due to a
malfunction that caused an internal coolant leak, the
crankcase breather element must be replaced.
malfunction that caused an internal coolant leak, the EGR
differential pressure sensor tubes should be inspected for
deposits. If deposits are found, replace the EGR
differential pressure tubes.
NOTE: If pressure testing the EGR cooler on ISX CM871
engines, do not remove the aftertreatment injector or
turbocharger before pressure testing the EGR cooler.
in Section 8.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual. Use protective caps from the
Cummins® Vehicle Air Plumbing Clean Care Kit, Part
• Remove the charge-air cooler pipe between the
turbocharger and charge-air cooler. Refer to the OEM
service manual. Use protectve caps from the
Cummins® Vehicle Plumbing Clean Care Kit, Part
• Remove the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedure
011-051 in Section 11. Refer to Procedure 011-043 in
Section 11.
• Remove the turbocharger. Refer to Procedure 010-033
in Section 10.
• Remove the EGR cooler coolant lines. Refer to
Remove
Loosen the hose clamps at the rear EGR connection tube.

Remove and discard the EGR hose.
CAUTION
The straps on the EGR cooler are not serviceable.
Adjusting or removing the straps can damage the EGR
cooler.
the block.
Remove the coolant supply and vent jumper tubes if they
remain in the block after the cooler is removed.

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

Part Number 4919403, to cover the open points on both
the EGR cooler and EGR plumbing.

the block.
Remove the EGR cooler bracket clamping plates from the
EGR cooler.
to cover the open ports on the EGR cooler and exhaust
manifold.

Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.
Inspect the hose clamps for damage. Replace if damage
is found.
WARNING
Cap the outlet end of the EGR cooler with parts supplied
in the EGR cooler leak check kit, Part Number 3164225.
Completely fill the EGR cooler with mineral spirits.
Cap the gas inlet end of the EGR cooler with parts
supplied in the EGR cooler leak check kit, Part Number
3164225.
Lay the EGR cooler on its side.

Allow the EGR cooler to soak for approximately 20
minutes.
Drain approximately 25 percent of the liquid from the
cooler and recap.
Shake the cooler by hand, from end to end, for
WARNING
WARNING
personal injury.
Drain the mineral spirits from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with parts supplied
in service kit, Part Number 3164225.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with parts
supplied in service kit, Part Number 3164225.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the EGR valve with safety solvent where the EGR
cooler connection attaches to the EGR valve. Refer to
Clean the EGR cooler connection with safety solvent and
Inspect the EGR valve where the EGR cooler connection
attaches to the EGR valve. Replace the EGR valve if
cracks or other damage is found. Refer to Procedure
Replace the EGR cooler if cracks or other damage is found
on the EGR cooler.
WARNING
WARNING
personal injury.
With the EGR connection tube attached, clean the cooler
end of the EGR connection tube with safety solvent.
Inspect the EGR connection tube for cracks or other
damage, while still attached to the block. Replace the
EGR connection tube if necessary. Refer to Procedure
WARNING
WARNING
personal injury.
Clean the EGR cooler connection with safety solvent and
Inspect the EGR cooler connection for cracks or other
damage. Replace the EGR cooler connection if cracks or
other damage is found. Refer to Procedure 011-024 in
Section 11.
WARNING
Clean the mounting surfaces with safety solvent to remove
any coolant deposits or debris.
Clean the opening in the block where the EGR cooler

coolant supply and vent jumper tubes are installed to
remove any coolant deposits or debris. Otherwise, the o-
ring joint can leak.
Clean the coolant supply and vent jumper tubes to remove
WARNING
personal injury.
WARNING
Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.
Inspect the EGR cooler and the EGR cooler clamping

plates for cracks or other damage. Replace the EGR
cooler or EGR cooler clamping plates if cracks or other
damage is found.
WARNING
Do not use chlorinated water to clean or rinse the EGR
cooler. Chlorides are very corrosive to the stainless
alloys internal and external to the EGR cooler.
Cap the outlet end of the EGR cooler with the plastic caps
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with safety solvent.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.
Lay the EGR cooler on its side.

Allow the EGR cooler to soak for approximately 20
minutes.
Drain approximately 25 percent of the liquid from the
cooler and recap. Dispose of the liquid properly.
WARNING
personal injury.
WARNING
Drain the safety solvent from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with the plastic cap
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the exhaust manifold with safety solvent, where the
EGR cooler connection attaches to the exhaust manifold.
Inspect the exhaust manifold where the EGR cooler
connection attaches to the exhaust manifold. Replace the
exhaust manifold if cracks or other damage is found. Refer
Replace the EGR cooler if cracks or other damage is
found.
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
Clean the EGR cooler exhaust gas outlet with safety
solvent.
Inspect the EGR cooler exhaust gas outlet for signs of
fretting, cracks, or other damage.
Replace the EGR cooler if damage is found. Refer to
WARNING
personal injury.
WARNING
Clean the EGR cooler bellows with safety solvent and dry
Inspect the EGR cooler bellows for cracks or other
damage.
Replace the EGR cooler bellows if cracks or other damage
is found.
WARNING
Clean the mounting surfaces with safety solvent to remove
Clean the opening in the block where the EGR cooler

coolant return elbow connection is installed, to remove
any coolant deposits or debris. Otherwise, the press-in-
place seal joint can leak.
Clean the EGR cooler coolant supply and return jumper
tubes to remove any coolant deposits or debris.
Pressure Test
Automotive with CM870 - Off Engine Repair
Cap off the coolant inlet and vents of the cooler with the
parts supplied in the EGR cooler leak check kit, Part
Number 3164225. Jumper tube, Part Number 3683068,
and jumper tube, Part Number 3682540, from the cooler,
are also used.
Cap off the coolant outlet with the plugged jumper tube
and pressure regulator assembly. Secure the jumper tube
with a hose clamp.
Make sure the air pressure regulator is closed and

connect compressed air to the pressure regulator.
Completely submerge the EGR cooler in room
temperature water. Make sure to submerge the cooler
vertically with the outlet end down so that air can not be
left in the open (gas) side of the cooler.
Apply 206 kPa [30 psi] of air pressure to the cooler.
Inspect for bubbles escaping from uncapped gas ports of
the EGR cooler or from the exterior shell of the cooler.
Verify that bubbles are not a result of loose fittings or
trapped air.
Bubbles coming from a damaged EGR cooler can be very
small and/or not in a steady stream.
If bubbles are not observed, the EGR cooler is reusable.
If the EGR cooler is not reusable, inspect the turbocharger
turbine housing for any signs of coolant deposits.
If coolant deposits are found, run the variable geometry
operational test with INSITE™ electronic service tool to
make sure the turbocharger is operating properly.
Coolant deposits can be identified as dried white deposits
coating the inside of the turbine housing.
Remove the parts supplied in the EGR cooler leak check
kit, Part Number 3164225.
WARNING
personal injury.
Drain all of the water from the gas side of the EGR cooler
before reuse.
Dry the cooler with compressed air.
Automotive with CM871 - On Engine Repair

Install the plug with the o-ring supplied in Service Kit, Part
Number 4918655, into the coolant inlet side of the EGR
cooler, use a M8 x 1.25 capscrew.
Install the two straight threaded plugs (1) from Service Kit,
Part Number 4918655, into the coolant line and vent ports.
Install the collet and cap over the pipe coupling and
coolant outlet and secure with the hose clamp provided in
Service Kit, Part Number 4918655.
NOTE: This step is necessary to prevent debris or

moisture from entering the EGR piping or EGR valve.
WARNING
personal injury.
NOTE: Air pressure regulator kit, Part Number 3164231,
or equivalent, is suitable for use during this step.
Install air pressure regulator and hose assembly onto the
test fitting on the coolant inlet of the EGR cooler.
Install a ball type shutoff valve onto the inlet side of the air
pressure regulator to allow the air supply to be shutoff
during testing.
WARNING
personal injury.
Make sure the air pressure regulator and ball-type valve
are closed and connect compressed air supply to the
pressure regulator.
Apply 620 kPa [90 psi] of air pressure to the EGR cooler.
Inspect for air escaping the EGR cooler assembly as a
result of loose fittings by spraying the exterior of the EGR
cooler and all lines and fittings with a mixture of mild soap
and water.
WARNING
personal injury.
Shut off the air supply to the regulator by using the ball-
valve and disconnect the compressed air supply.
Record the time at which the air supply was shutoff and
the air pressure shown on the air pressure regulator
gauge.
Measure and record the air pressure after 15 minutes.
If the measured pressure loss in the EGR cooler is more
than 35 kPa [5 psi] in 15 minutes, the EGR cooler is not
reusable.
NOTE: If the EGR cooler is not reusable, inspect the air
pressure regulator, air lines, ball-valve, o-rings and other
components carefully for leaks. A mixture of mild soap
and water may be sprayed onto the assembly to aid in leak
detection.
If the EGR cooler is not reusable, inspect the turbocharger

turbine housing and rear EGR connection tube for any
signs of coolant deposits.
coating the inside of the turbine housing.
If coolant deposits are found in the turbocharger turbine
housing, inspect the turbocharger for progressive
damage.
Coolant can cause the turbocharger to stick. Inspect the
turboscharger for reuse. Refer to Procedure 010-033 in
Section 10.
If coolant deposits are found in the rear EGR connection
tube, inspect the EGR valve for progressive damage.
Coolant can cause the EGR valve to stick and allow
coolant to collect.
coating the inside of the EGR valve passages.
If coolant deposits are found, remove the EGR valve and
inspect for reuse. Refer to Procedure 011-022 in Section
11.
Install the parts supplied in the EGR cooler leak test kit:
• EGR Cooler Coolant Lines. Refer to Procedure
• EGR Connection Tubes. Refer to Procedure 011-025
in Section 11.
Properly fill the cooling system. Refer to Procedure
Install
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
Install new o-rings on the coolant supply and vent tubes

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

where it connects to the EGR cooler connection.
Install a v-band clamp.
Install and hand tighten the four mounting nuts and

capscrews. Tighten the capscrews and nuts in the
sequence shown.
Torque Value:
Torque Value:
Connect the EGR cooler to the new hose on the rear EGR
connection tube.

Torque Value:
Torque Value:
Normal Clamp (2) 5 N•m [ 44 in-lb ]
Tighten the v-band clamp between the EGR cooler

connection and the EGR cooler.
CAUTION
Keep all protective caps on the EGR cooler in place
while grinding clearance in the upper mounting
bracket. Failure to do so could cause progressive
damage to the engine once the EGR cooler is
installed. It's important to prevent any debris from
entering the cooler.
Inspect for an interference fit between the upper EGR
cooler mounting bracket and the lower portion of the
exhaust manifold flange. If this interference is present,
grind a clearance on the upper EGR cooler mounting
bracket in the area shown in the illustration.

Install a v-band clamp onto the exhaust manifold front
section.
where it connects to the exhaust manifold front section.
cooler assembly.
Install the EGR cooler bracket clamping plates.
Install the four EGR cooler mounting capscrews at the top

of the EGR cooler mounting bracket.
Install and hand tighten the four mounting nuts. Tighten
the capscrews and nuts in the sequence shown.
Torque Value:
Torque Value:
CAUTION
Position the v-band clamp onto the EGR cooler inlet
connection.
Tighten the two retaining capscrews on the rear EGR

connection tube.
Finishing Steps
NOTE: If the EGR cooler is being replaced due to an
internal coolant leak, the EGR differential pressure tubes
must be replaced.
• Install the EGR cooler coolant lines. Refer to
• Install the exhaust gas pressure sensor tube. Refer to
• Install the turbocharger. Refer to Procedure 010-033 in
Section 10.
• Remove the protective caps used to cover the charge-
air cooler pipe connection points.
• Install the charge-air cooler pipe. Refer to the OEM
service manual.
• Remove the protective caps used to cover the air
intake pipe to the turbocharger
• Install the air intake pipe to the turbocharger. Refer to
OEM service manual.
• Fill the engine cooling system. Refer to Procedure
• Start the engine, check for leaks, and verify proper
operation.
Signature™, ISX, and QSX15 Eng [...] EGR Mixer

malfunction that caused an internal coolant leak, the
crankcase breather element must be replaced.
malfunction that caused an internal coolant leak, the EGR
differential pressure sensor tubes should be inspected for
deposits. If deposits are found, replace the EGR
differential pressure tubes.
NOTE: If a malfunction resulted in oil, excessive fuel, or
aftertreatment system must be inspected. Refer to the
Aftertreatment Diesel Oxidation Catalyst and
Aftertreatment Diesel Particulate Filter Reuse Guidelines,
Bulletin 4021600.
NOTE: If a malfunction resulted in coolant entering the
exhaust system, the aftertreatment system can be
recovered. Refer to Procedure 014-013 in Section 14.
• Install the EGR cooler coolant lines. Refer to
• Install the turbocharger. Refer to Procedure 010-033 in
Section 10.
• Install the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedure
011-043 and Refer to Procedure 011-051 in Section 11.
• Remove the protective caps used to cover the charge-
air cooler pipe connection points.
• Install the charge-air cooler pipe. Refer to the OEM
service manual.
• Remove the protective caps used to cover the air
intake pipe connection points.
• Start the engine, check for leaks, and verify proper
operation.
EGR Mixer (011-021)

Preparatory Steps
• Remove the charge air cooler connection hose and
hose clamp from the EGR mixer inlet. Refer to
Procedure 010-027.
• Remove the air compressor supply line. Refer to
Procedure 012-014.
• Remove the v-band clamp between the EGR mixer
and the charge air cooler inlet adapter.
EGR Mixer Signature™, ISX, and QSX15 Eng [...]
Remove
Do not remove the EGR inlet pipe into the EGR mixer.
This is a precision interface and performance will be
affected if disturbed. There is no service procedure for this
and none is required.
Remove the capscrews at the four-bolt flange between the
EGR mixer and the air intake horn.
WARNING
personal injury.
WARNING
Use compressed air to blow out any debris or soot buildup
inside the EGR mixer.
Clean all mounting surfaces with solvent.
Inspect the EGR mixer for cracks. Replace the EGR mixer
if cracks are found.
Inspect the v-band clamps for signs of overextension. The

band must not be bent or cracked.
Inspect the v-band clamp thread for damage.
Replace the v-band clamp if damage is found.
Signature™, ISX, and QSX15 Eng [...] EGR Mixer
Install
Install a new hose at the EGR mixer inlet.
Install a new o-ring between the EGR mixer and the air
intake connection. Install and tighten capscrews.
Finishing Steps
• Install the v-band clamp on the inlet adapter and the
EGR mixer.
• Install the air compressor supply line. Refer to
Procedure 012-014.
• Install the charge air cooler connection. Refer to
Procedure 010-027.
• Start and operate the engine and check for leaks at
the air connections.
Procedure 014-013.
EGR Valve Signature™, ISX, and QSX15 Eng [...]
EGR Valve (011-022)

Preparatory Steps
WARNING
environmental regulators.
WARNING
in Section 8.
• Remove the water pump drive belt. Refer to Procedure
• On some applications, removal of the alternator is
required. Refer to Procedure 013-001 in Section 13.
• Remove the air intake pipe to the turbocharger. Refer
• Remove the heat shield. Refer to Procedure 011-032
in Section 11.
• Disconnect the EGR valve motor and position sensor
connectors from the harness.
• Remove the EGR valve coolant lines. Refer to

• Disconnect EGR temperature sensor. See the
Manual CM871 and CM876 Electronic Control System,
ISX and ISM Engines, Bulletin 4021560.Refer to
• Remove the front EGR connection tube from the EGR
valve. Refer to Procedure 011-025 in Section 11.
• Disconnect the OEM fuel return hose from the
integrated fuel system module. Refer to the OEM
service manual. Or, loosen the fuel hose enough to
position it away from the EGR valve mounting
capscrew and tighten the fuel line.
• Remove the EGR valve heat shield. Refer to Procedure
• Disconnect the OEM air compressor discharge line.
Signature™, ISX, and QSX15 Eng [...] EGR Valve
Remove
exhaust manifold.
Remove the EGR valve and v-band clamps.


Disconnect the EGR valve electrical connector.
Make sure to support the EGR valve by hand before

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

capscrews.
Remove the EGR valve from the EGR valve support
bracket.
The EGR valve will need to be moved at an angle forward
and downward in order to disengage it from the EGR valve
support bracket.
Use protective caps from the Air Handling Clear Care Kit
to cover open points on the EGR valve and bracket.
Disassemble
NOTE: Be careful not to nick the EGR valve housing when
removing the seal.
Remove the pipe seal from the EGR valve inlet port.
Pry the lip of the pipe seal up from the EGR valve with a
small flat headed screwdriver.
Discard the pipe seal.

WARNING
personal injury.
WARNING
reduce the possibility of injury.
Check to make sure the EGR poppet head is present. If
the poppet head is missing, run a stiff wire through every
port of the exhaust manifold to locate the missing poppet
head.
Do not assemble the engine without finding the missing
poppet head.
Clean the mounting surfaces with a shop towel wetted with
a safety solvent to remove any deposits or debris.
Inspect the mounting surfaces for cracks, fretting, or other
damage. Inspect the EGR motor and position sensor for
damage.
Replace the valve if damage is found.

Inspect the v-band clamp threads for damage.
WARNING
WARNING
personal injury.
Clean the EGR valve mounting and sealing surfaces with
a shop towel wetted with safety solvent to remove any
deposits or debris.
Clean the accumulated soot from the EGR valve inlet port
using a wire brush, then soaking with carburetor cleaner
and cleaning again with a wire brush. Be sure the loose
soot is removed from the EGR valve housing. This can be
done by vacuuming the soot out of the EGR valve inlet
port.
Inspect the mounting surfaces for cracks, fretting, or other
damage.
Inspect the EGR valve poppets for a stuck open condition.

If the EGR valve is stuck open, replace the EGR valve. Do
not try to pry the poppets open or closed.
Inspect the EGR valve actuator for cracks or other

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

connector for corrosion, worn receptacles, or other
damage.
Replace the engine wiring harness EGR valve connector
if corrosion, worn receptacles, or other damage is found.
Soot leakage at the EGR valve weep hole is normal and

is to be expected. Do not replace the EGR valve if soot
streaks are found at the EGR valve weep hole.
Inspect the EGR valve mounting bracket for soot leaks at

the EGR valve joint. If a leak is found, replace the EGR
valve seal.
Assemble
Use a light coat of clean engine oil to lubricate the outer
diameter of the EGR valve seal during assembly on to the
EGR valve. Push the EGR valve seal into the EGR valve
inlet port by hand. The EGR seal must remain square in
the EGR valve inlet port during installation.
Hammer the EGR valve seal fully; use a flat piece of steel
across the EGR valve seal. The EGR valve seal must be
fully seated onto the EGR valve inlet port shoulder.
Install
Before installing the v-band clamp, coat the clamping
Install the smaller v-band clamp on the EGR cooler

connection. Do not tighten.
Install the larger v-band clamp on the end of the EGR valve
that connects with the exhaust manifold. Do not tighten.
Install a new gasket on the piloted end of the EGR cooler
connection.
Install a new gasket on the piloted end of the EGR valve
where it connects to the exhaust manifold.
Install the EGR valve. Position the EGR connection v-band
clamp, as shown, and tighten.

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

mounting bracket.
NOTE: The longest capscrew passes through the EGR
valve and EGR valve mounting bracket and threads into
the engine block.
Connect the EGR valve connector.

Finishing Steps
• Install the EGR valve coolant lines. Refer to Procedure
• Connect the EGR valve motor and position sensor
connectors to the harness (clean off the wiring harness
and connector before connecting to the valve).
• Install the heat shield. Refer to Procedure 011-032 in
Section 11.
• Install the alternator, if removed. Refer to Procedure
• Operate the engine and check for exhaust and coolant
leaks.

• Install the EGR heat shield. Refer to Procedure
• Connect the OEM air compressor discharge line. Refer
to the OEM troubleshooting and repair manual.
• Install the front EGR connection tube. Refer to
• Connect the OEM fuel return hose from the integrated
fuel system module. Refer to the OEM troubleshooting
and repair manual.
• Connect the EGR temperature sensor. See the
Manual CM871 and CM876 Electronic Control System
ISX and ISM Engines, Bulletin 4021560. Refer to
• Operate the engine and check for exhaust or coolant
leaks.
• Verify active fault codes. If a failure resulted in coolant,
oil, excessive fuel or excessive black smoke entering
the exhaust system, the aftertreatment system must
be inspected. Refer to Procedure 014-013 in Section
14.
EGR Cooler Connection Signature™, ISX, and QSX15 Eng [...]
EGR Cooler Connection (011-024)

Preparatory Steps
WARNING
environmental regulators.
WARNING
Drain the cooling system. Refer to Procedure 008-018.
Remove or loosen the following:
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
• Heat shield. Refer to Procedure 011-032.
• EGR cooler coolant line. Refer to Procedure
011-031.
• V-band clamp that holds the EGR valve to the
exhaust manifold. Rotate the V-band clamp out of
the way to access the V-band clamp that holds the
EGR cooler connection to the EGR valve. Refer to
Procedure 011-022.
Remove
Loosen the V-band clamps on each end of the exhaust gas
recirculation (EGR) cooler connection.
Remove the EGR cooler connection and V-bands.
Remove the gaskets and discard.
WARNING
WARNING
personal injury.
Clean the EGR cooler connection with safety solvent.
Inspect the EGR cooler connection for cracks or other
damage.
Signature™, ISX, and QSX15 Eng [...] EGR Cooler Connection
Clean the EGR cooler mounting flange with safety solvent.

Inspect the EGR cooler mounting flange for cracks or
damage. Replace the EGR cooler, if cracks or other
damage is found.
Clean the EGR valve with safety solvent.

Inspect the EGR valve where the EGR cooler connection
interfaces for cracks or damage. Replace the EGR valve
if necessary.
Inspect the hose clamps for damage. Replace if damage

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

Inspect the V-band clamp threads for damage.
Replace the V-band clamp if damage is found.
EGR Cooler Connection Signature™, ISX, and QSX15 Eng [...]
Install
Before installing the V-band clamp, coat the clamping
The EGR cooler connection has a male and female end.

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

Position V-band clamps that hold the EGR cooler
connection between the EGR cooler and the EGR valve,
as shown. Tighten the V-band clamps.
Rotate the exhaust manifold V-band clamp into position,
as shown and tighten the V-band clamps.
Finishing Steps
• EGR cooler coolant line. Refer to Procedure
011-031.
• Heat Shield. Refer to Procedure 011-032.
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
Fill the engine cooling system. Refer to Procedure
008-018.
Start engine and verify proper operation.
Signature™, ISX, and QSX15 Eng [...] EGR Connection Tubes

Preparatory Steps
WARNING
pressure water.
WARNING
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Use steam or high-pressure water to clean the rear of
the engine, specifically around the rear EGR
connection tube area.
Section 6.
• Remove the engine wiring harness from the exhaust
temperature sensor. See the following procedure in the
• Remove the dipstick tube. Refer to Procedure 007-011
in Section 7.
• Remove the differential pressure sensor tubes from
the connection tube and the sensor adapter. Refer to
• Remove the oil pressure sensor. See the following
CM870 Electronic Control System, Signature™ and ISX
EGR Connection Tubes Signature™, ISX, and QSX15 Eng [...]
WARNING
pressure water.
WARNING
the air handling connections to prevent contamination of
the interior of the engine.
• Use steam or high-pressure water to clean the engine,
specifically around the EGR connection tube joints.
• Remove the engine wiring harness from the exhaust
temperature sensor. See the following procedure in the
Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control System, ISX and ISM
• Remove the EGR differential pressure sensing tubes
from the EGR venturi. Refer to Procedure 011-026 in
Section 11.
Remove
WARNING
before removing.
Loosen all hose clamps on the EGR connection tubes and
remove the two p-clip mounting capscrews or nuts
(depending on the vintage of the engine) on the front EGR
connection tube.
Remove the one capscrew and one nut or the two nuts
that attach the rear section of the connection tube to the
cylinder block.
Remove the front EGR connection tube.
Remove the one capscrew and one nut that attach the rear
section of the connection tube to the cylinder block.
Remove the rear EGR connection tube from the EGR
cooler.
WARNING
before removing.
Loosen the hose clamps on the front EGR connection tube
and remove the hose.
Remove the two retaining capscrews on the lower portion
of the tube at the EGR valve housing outlet.
Remove the front EGR connection tube and hose.
Discard the hose.
Remove the three EGR venturi mounting capscrews.

Remove the EGR venturi.
Cover the irregular openings on the venturi and air intake

connections with protective caps from the Air Handling
Clean Care Kit, Part Number 4919403 and Part Number
4919425.
Remove the two rear EGR connection capscrews from the

EGR cooler.
Loosen the hose clamp on the rear EGR connection tube.
Pull the EGR cooler outlet connection tube from the EGR
cooler.

WARNING
WARNING
personal injury.
Clean the connection tubes with solvent.
Inspect the ends and mating joints of the connection tubes
for cracks or other damage. Replace the tube if cracks or
other damage is found.
Inspect the p-clips for missing or torn rubber sleeves.

Replace the p-clips if the rubber sleeve is missing or torn.
Inspect the band section of the clamp(s) for cracks or other

damage.
Inspect the threaded section of the clamps for cracks or
other damage.
Replace clamp(s) if cracks or other damage is present.
WARNING
WARNING
personal injury.
Clean the connection tubes with solvent.
Make sure that gasket sealing surfaces at the EGR valve
outlet and EGR cooler outlet are free of packed soot and
other debris. Avoid wiping dirt or debris down into the
tubes or valve.
Inspect the EGR measurement venturi for soot plugging

at the EGR differential pressure sensing tube ports. The
port labeled R has a hook inside that makes visual
inspection difficult.
Insert a flexible pipe cleaner or wire through this port to
verify the port is not plugged inside the tube, past the
bend.
Inspect the band section of the clamp(s) for cracks or other

damage.
Inspect the threaded section of the clamps for cracks or
other damage.
Replace the clamp(s) if cracks or other damage is present.
Inspect the ends and mating joints of the connection tubes

for signs of fretting, or material transfer, cracks, or other
damage.
Replace the tube if fretting, material transfer, cracks, or
other damage is found.
Inspect the rear EGR connection hose for cracks, fraying,
or tearing.
Replace the entire rear EGR crossover tube if the hose is
damaged or if hose material is found on the EGR valve
mounting bracket.
Install
Part Number 4919403 and Part Number 4919425, at the
end of the rear EGR connection tube that interfaces with
the EGR cooler before working the tube into position, to
reduce the possibility of introducing dirt or debris.
Install the p-clips onto the rear EGR connection tube.
Make sure the tube insulation is properly and fully located
under the p-clips and that the p-clip rubber sleeve does
not block the mounting hole.
Install the rear EGR connection tube and the p-clip
mounting capscrew and nuts.
Hand-tighten the capscrew and nuts.

between the rear EGR connection tube and the EGR
cooler.
Tighten the p-clip mounting capscrews, nuts, and hose
clamps.
Torque Value:
M10 P-clip nut 46 N•m [ 34 ft-lb ]
Torque Value:
M8 P-clip nut 23 N•m [ 204 in-lb ]
Torque Value:
Torque Value:
Torque Value:
Norma Clamp (2) 5 N•m [ 44 in-lb ]

on the rear EGR connection tube where it interfaces with
the front EGR connection tube.
Install the p-clips onto the front EGR connection tube.
Install the front EGR connection tube and the p-clip
mounting capscrews or nuts. Finger tighten the
capscrews or nuts.
Tighten the p-clip mounting capscrews or nuts and the
hose clamps.
Torque Value:
M10 p-clip nut 46 N•m [ 34 ft-lb ]
Torque Value:
Torque Value:
between the front EGR connection tube and the EGR
mixer.
Tighten the p-clip mounting capscrews, nuts, and clamps.
Torque Value:
P-clip capscrews and nut 45 N•m [ 33 ft-lb ]
Torque Value:

Apply lubricant to the hose end of the rear EGR
connection tube.
Loosely install the hose clamp and install the rear EGR
connection tube and gasket onto the EGR cooler and EGR
valve mounting bracket.
Tighten the two capscrews.
Make sure the indentation near the end of the hose slides
past the hose bead on the EGR valve mounting bracket.
Position the hose clamp on this indentation groove.
NOTE: Install the protective sleeve onto the exposed
threads of a T-bolt style clamp.
Loosen the two rear tail support mounting capscrews.

Install a new press-in place seal on the EGR venturi.
Install the EGR venturi on the air intake connection by
loosely installing all three capscrews. Hand-tighten all five
capscrews.
In order to reduce assembly stress, tighten the capscrews
in the following sequence:
Tighten the two front EGR venturi mounting capscrews.
Tighten the rear EGR venturi mounting capscrews.
Tighten the two rear tail support mounting capscrews.
Apply lubricant to the hose end of the front EGR

connection tube and the EGR venturi inlet.
Slide the new EGR connection hose on the EGR venturi
inlet and loosely install both retaining clamps.
Attach a new EGR gasket to the front EGR connection
tube flange, holding it in place with the two retaining
capscrews.
Insert the hose end of the EGR connection tube into the
EGR connection hose, and align the mounting flange with
the EGR valve outlet.
Install the two retaining capscrews into the EGR valve.
Tighten the capscrews in the following sequence:
Capscrew 1, Capscrew2, Capscrew 1.
Make sure to tighten Capscrew 1 twice.
Center the EGR connection hose evenly between the tube
and the EGR venturi and tighten both retaining clamps.
Finishing Steps
WARNING
pressure water.
WARNING
• Install the oil pressure sensor. Use the following
CM870 Electronic Control System, Signature™ and ISX
in Section 19.
• Install the differential pressure sensor tubes to the
front connection tube and the sensor adapter. Refer to
• Install the lubricating oil dipstick tube. Refer to
• Install the engine wiring harness to the exhaust
temperature sensor. Use the following procedure in
the Troubleshooting and Repair Manual, CM870
Electronic System, Signature™ and ISX Engines,
Section 19.
Section 6.
WARNING
pressure water.
WARNING
• Install the EGR differential pressure sensing tubes to
the EGR venturi. Refer to Procedure 011-026 in
Section 11.
• Install the engine wiring harness to the exhaust
temperature sensor. Use the following procedure in
the Troubleshooting and Repair Manual CM871 and
CM876 Electronic Control System ISX and ISM
Signature™, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Tubes
EGR Differential Pressure Sensor

Tubes (011-026)
Preparatory Steps
• If necessary, remove the EGR differential pressure
sensor. Refer to Procedure 019-370 in Section 19.
Remove
For engines beginning with ESN 14040552, the pressure
sensor does not have to be removed to allow the removal
of the EGR differential pressure sensor tubes.
Pressure sensor removal is necessary only if the sensor
adapter is being replaced. Refer to Procedure 011-028 in
Section 11.
Tag the ends of the tubes before removing the sensor
tubes. Incorrectly installing the tubes to the sensor
adapter will result in a fault code.
Loosen the tube nuts at the front EGR connection tube
and the sensor adapter.
Remove the tubes.

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

Carbon deposits inside the tubes can cause an amber
CHECK ENGINE light, in addition to any combination of
the following:
• Low power
• Black smoke
• Engine surge
• Engine runs rough
• Exhaust gas recirculation valve delta pressure fault
code.
EGR Differential Pressure Sensor Tubes Signature™, ISX, and QSX15 Eng [...]
Check the inside of the tubes.

If a tube is clogged or partially clogged, replace the tube.
WARNING
WARNING
personal injury.
Inspect the mating orifices for the EGR crossover tubes.
If clogged, saturate the carbon deposit with a mineral-
based solvent, or equivalent.
Carefully clean debris from the mouth of the tube, making
sure not to damage the orifice.

CHECK ENGINE light, in addition to any combination of
the following:
• Low power
• Black smoke
• Engine surge
• Engine runs rough
• Exhaust gas recirculation valve differential pressure
fault code
• Progressive damage to the Cummins® particulate
filter.
Signature™, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Tubes
WARNING
WARNING
personal injury.
NOTE: If coolant is found in the EGR differential pressure
sensor tubes, they must be replaced.
Check the inside of the tubes.
If a tube is partially clogged, saturate the inside of the tube
with mineral based solvent, or equivalent.
Carefully clean the debris from the mouth of the tube.
Make sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Check the tubes, hose, and hose clamps for cracks or
other damage.
Replace the tubes if the tubes or hose is damaged.
Replace the hose clamps if damaged.
WARNING
WARNING
personal injury.
Inspect the mating orifices of the EGR crossover tubes.
If clogged, saturate the carbon deposit with a mineral-
based solvent, or equivalent.
Carefully clean the debris from the mouth of the orifice,
make sure not to damage the orifice.
EGR Differential Pressure Sensor Tubes Signature™, ISX, and QSX15 Eng [...]
Install
For engines beginning with ESN 14040552, the tubes
must be installed so they do not cross over each other.
Apply a light lubricant (CRC 3-36, WD-40, or equivalent)
to the tube threads and install the tubes. The lubricant is
to be applied inside the tube nut, directing the spray on
the threads and around the sleeve and flange area.
Position the insulation on the differential pressure sensor
tubes so the tube nuts at the venturi connections are
covered.
This insulation is designed to only cover the bottom
portion of the tube which threads to the EGR tube. This
location proves to be most effective and prevents heat
soaking of the EGR differential pressure sensor.

The tubes must be installed so they do not cross each
other.
Apply a light lubricant (CRC 3-36, WD-40, or equivalent)
to the tube threads and install the tubes. The lubricant is
to be applied inside the tube nut, directing the spray on
the threads and around the sleeve and flange area.
Tighten the tube nuts at the EGR venturi connection.
Tighten the hose clamps at the differential pressure

sensor adapter.
Position the insulation on the differential pressure sensor
tubes so the tube nuts at the venturi connection are
covered.
The insulation on the pressure tubes is designed to only
cover the bottom portion of the tube which threads into the
EGR transfer tube. This is the most effective location and
also reduces the possibility of heat soaking of the EGR
differential pressure sensor.
Signature™, ISX, and QSX15 Eng [...] Exhaust Gas Pressure Sensor Tube
Finishing Steps
• If removed, install the EGR differential pressure
• Check for fault codes.

• If removed, install the EGR differential pressure
• If damage resulted in coolant, oil, excessive fuel or

(011-027)
Preparatory Steps
NOTE: Removal of the sensor plumbing does not require
the sensor removal. Remove the sensor only if the sensor
adapter is being replaced.
• Disconnect the electrical connector to the exhaust
gas pressure sensor. Refer to Procedure 019-376 in
the Troubleshooting and Repair Manual CM870
Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.
Exhaust Gas Pressure Sensor Tube Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
personal injury.
Inspect the inside of the tube. If clogged, use compressed
air to remove debris or soot buildup.
Clean the outside of the tube with solvent.
Check the tube for cracks and thread damage. Replace
the tube, if cracks or damage are found.
Install
Apply a film of high temperature anti-seize compound to
the threads of the tube nuts.
Install the tube.
Connect and tighten the tube nuts.
Finishing Steps
• Connect the electrical connectors to the exhaust gas
pressure sensor. Refer to Procedure 019-376 in the
Procedure 014-013.
Signature™, ISX, and QSX15 Eng [...] EGR Differential Pressure Sensor Adapter
EGR Differential Pressure Sensor

Adapter (011-028)
Preparatory Steps
Remove or disconnect the following:
• EGR differential pressure sensor connector from the
engine wiring harness.
Procedure 011-026.
Remove
Remove the mounting capscrews.
Remove the EGR pressure sensor adapter.
WARNING
personal injury.
WARNING
Inspect the EGR pressure sensor adapter tube holes for
clogging.
If clogged, use compressed air to remove debris or soot
buildup. Clean the outside of the adapter with solvent.
Inspect the EGR pressure sensor adapter for cracks or
fretting. Replace the EGR pressure sensor adapter if
cracks are found.
EGR Valve Coolant Lines Signature™, ISX, and QSX15 Eng [...]
Install
Install the EGR pressure sensor adapter and capscrews.
Finishing Steps
Procedure 011-026.
• EGR differential pressure sensor connector to the
engine wiring harness.

Preparatory Steps
WARNING
WARNING
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the heat shield. Refer to Procedure
011-032.
Signature™, ISX, and QSX15 Eng [...] EGR Valve Coolant Lines
Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.
WARNING
WARNING
personal injury.
Clean the EGR valve coolant lines with solvent.
Inspect the EGR valve coolant lines and rubber grommets
for cracks or damage.
Replace the lines, if cracks or damage is found.
Install
Connect the EGR valve coolant lines making sure the
sealing washers are in place on the banjo connector.
Tighten the EGR valve coolant line nut and capscrew.
EGR Cooler Coolant Lines Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
• Install the heat shield. Refer to Procedure 011-032.
manual.
008-018.
• Start and operate the engine. Check for leaks.

Preparatory Steps
WARNING
WARNING
in Section 8.
• Remove the air intake piping. Refer to the OEM service
manual. Use protective caps from the Air Handling
Clean Care Kit, Part Number 4919425, to cover the
connection points.
• Remove the exhaust gas pressure sensor tube. Refer
WARNING
WARNING
in Section 8.
• Remove the air intake piping. Refer to the OEM service
manual. Use protective caps from the Air Handling
Clean Care Kit, Part Number 4919425, to cover the
connection points.
Signature™, ISX, and QSX15 Eng [...] EGR Cooler Coolant Lines
Remove
Disconnect the EGR cooler coolant vent line from the EGR
cooler coolant return line and the EGR cooler.
Remove the two mounting capscrews from the EGR cooler

coolant return line.
Disconnect the EGR cooler coolant return line from the
EGR cooler and the elbow connection on the thermostat
housing.
CAUTION
Be sure all the components are clean and free of
debris that can cause damage to o-ring seals.
Disconnect the EGR cooler coolant vent line from the
thermostat housing and the EGR cooler.
Remove the two EGR cooler coolant return tube mounting

capscrews.
Remove the EGR cooler coolant return jumper tube from

the EGR cooler.
Remove the EGR cooler coolant supply tube mounting

capscrew.
Slide the EGR cooler coolant supply jumper tube all the
way rearward inside the EGR cooler coolant supply tube.
Remove the EGR cooler coolant supply tube retaining
clamp capscrew from the water pump housing.
Slide the EGR cooler coolant supply tube rearward until

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

WARNING
WARNING
personal injury.
Clean the EGR cooler coolant vent and the EGR cooler
coolant return line with solvent.
Inspect the EGR cooler coolant vent and the EGR cooler
coolant return line for cracks or other damage. Replace
the lines if cracked or otherwise damaged.
Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.
WARNING
WARNING
personal injury.
Clean the EGR cooler coolant vent line and the EGR
cooler coolant supply and return tubes with solvent.
Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.
Inspect the EGR cooler for cracks or other damage.

Replace the lines if cracked or otherwise damaged.
Install
CAUTION
Install new the o-rings on the EGR cooler coolant return
line.
water, or vegetable oil for easier installation.
Install the EGR cooler coolant return line from the EGR
cooler to the thermostat housing.
Install the EGR cooler coolant vent line. Attach the rigid
section of the vent line to the EGR cooler and the flexible
section to the EGR cooler coolant return line.
CAUTION
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
water, or vegetable oil to aid in installation.

bracket and nuts.
Tighten the nuts.
Insert the EGR cooler coolant supply jumper tube into the
EGR cooler coolant supply tube.
Slide the EGR cooler coolant supply jumper tube into the
EGR cooler inlet.
Install the retaining clamp and capscrew to the EGR
cooler.
Insert the EGR cooler coolant supply tube into the water
pump outlet.
Install the EGR cooler coolant supply tube retaining clamp
and capscrew.
Tighten in the following sequence.

capscrew and tighten.
Tighten the EGR cooler coolant supply jumper tube
retaining clamp capscrew.
Tighten the EGR cooler coolant supply tube retaining
clamp capscrew.
Install the EGR cooler coolant vent line to the thermostat

housing and the EGR cooler.
Install the o-rings on the coolant return tube jumper tube.

water, or vegetable oil, for easier installation.
Install the jumper tube into the EGR cooler.
Install the press in place seal and the coolant return tube.
Finishing Steps
• Install the exhaust gas pressure sensor tube. Refer to
• Remove the protective caps from the intake piping.
manual.
Section 8.
• Operate the engine and check for leaks. Check for
leaks.
Heat Shield Signature™, ISX, and QSX15 Eng [...]

• Remove the protective caps from the intake piping.
• Install the intake piping. Refer to the OEM service
manual.
Section 8.

Preparatory Steps
• Remove the air intake piping from the turbocharger.
Refer to the OEM troubleshooting and repair
manual.
Remove
Remove the three mounting capscrews from the EGR
valve.

Remove the four EGR valve heat shield mounting
capscrews from the EGR valve.
Signature™, ISX, and QSX15 Eng [...] Heat Shield
WARNING
WARNING
personal injury.
Clean the heat shield with solvent.
Inspect the heat shield for cracks or any other damage.
Replace the heat shield, if cracks or any other damage is
found.
Install
mounting capscrews.
Install the three mounting capscrews and the heat shield.

mounting capscrews.
Install the four capscrews and the heat shield.
Exhaust Gas Pressure Sensor Adapter Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
Install the air intake piping to the turbocharger. Refer to
the OEM troubleshooting and repair manual.

(011-033)
Preparatory Steps
• Remove the exhaust gas pressure sensor. Refer to
• Remove the exhaust pressure sensor tube. Refer to
Procedure 011-027.
Remove
All Applications
Remove the p-clamp mounting capscrew and remove the
adapter.
Inspect for Reuse

All Applications
Inspect the sensor adapter for cracks or fretting.
Inspect the p-clamp for cracks.
Signature™, ISX, and QSX15 Eng [...] Exhaust Gas Pressure Sensor Adapter
Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.
Finishing Steps
• Install the exhaust pressure sensor tube. Refer to
Procedure 011-027.
• Install the exhaust gas pressure sensor. Refer to
Aftertreatment Diesel Particulate Filter Signature™, ISX, and QSX15 Eng [...]
Aftertreatment Diesel Particulate Filter

(011-041)
General Information
WARNING
During regeneration, exhaust gas temperature could
reach 800°C [1500°F], and exhaust system surface
temperature could exceed 700°C [1300°F], which is
hot enough to ignite or melt common materials, and
to burn the skin. The exhaust and exhaust
components can remain hot after the vehicle has
stopped moving. To avoid the risk of fire, property
damage, burns or personal injury, allow the exhaust
system to cool before beginning this procedure or
repair and make sure that no combustible materials
are located where they are likely to come in contact
with hot exhaust or exhaust components.
CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
Due to the number of various exhaust aftertreatment
applications, this procedure contains generic information.
Not all illustrations within this procedure will represent the
applications being serviced.
The aftertreatment system is composed of four sections.
These sections are:
1 Inlet
2 Aftertreatment Diesel Oxidation Catalyst
3 Aftertreatment Diesel Particulate Filter
4 Outlet.
NOTE: In some applications, the aftertreatment diesel
oxidation catalyst can be integrated into the inlet of the
exhaust aftertreatment system.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Diesel Particulate Filter
Preparatory Steps
WARNING
cable last.
• Disconnect the vehicle batteries. Refer to the OEM
service manual.
• Disconnect the exhaust gas pressure sensor tubes, if
necessary.
- For ISX engines, use this procedure in the Signature™,
ISX and QSX Service Manual, Bulletin 3666239.Refer
- For ISM engines, use this procedure in the ISM, ISMe,
and QSM11 Service Manual, Bulletin 3666322. Refer
• Disconnect the aftertreatment particulate filter
differential pressure sensor tubes, if necessary. Refer
• Disconnect the exhaust gas temperature sensor
electrical connector(s) from wiring harness.
• Use this procedure in the Troubleshooting and Repair
System, ISX and ISM Engines, Bulletin 4021560. Refer
Remove
Mark the direction of the exhaust flow on the outside of
the aftertreatment system to aid in assembly.
WARNING
CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
NOTE: If necessary, remove any additional mounting
hardware to remove the aftertreatment diesel particulate
filter from the vehicle.
Remove the v-band clamps from the inlet and outlet
flanges of the aftertreatment diesel particulate filter.
Separate the flanges by approximately 25 mm [1 in] to
allow removal over the gasket retainer rings.
Inspect for Reuse

CAUTION
Do not use a grinder or abrasive air tool to remove
residual gasket material, as this can damage the
flange and cause the connection to leak. Do not use
an open flame to burn off soot accumulation from the
face of the aftertreatment diesel particulate filter. Do
not scrape off soot accumulation from the face of the
CAUTION
Do not use an open flame to burn off soot
accumulation from the face of the aftertreatment
CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
NOTE: The aftertreatment diesel particulate filter relies on
gas flow through the walls to collect soot. To accomplish
gas flow through the walls of the filter, every other cell on
the face of the filter is plugged with a ceramic material.
Therefore it is not possible to see light straight through
the holes in the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a scraping
tool.
Avoid dropping fragments of gasket material into the
NOTE: It is not possible to inspect the outlet of the
aftertreatment diesel oxidation catalyst and inlet of the
aftertreatment diesel particulate filter on aftertreatment
systems with a joined aftertreatment diesel oxidation
catalyst - aftertreatment diesel particulate filter.
Refer to the Catalyst and Aftertreatment Particulate Filter

Reuse Guidelines, Bulletin 4021600, to inspect the inlet
and outlet faces of the aftertreatment diesel particulate
filter for signs of damage. Replace the aftertreatment
diesel particulate filter if damage is found.
If the aftertreatment diesel particulate filter has been
removed for cleaning and is considered reusable
according to the Catalyst and Aftertreatment Particulate
Filter Reuse Guidelines, Bulletin 4021600, the filter can be
cleaned using diesel particulate filter cleaner, Part
Number 4918840, with adapter kit, Part Number 4918893,
or diesel particulate filter cleaner, Part Number 4919052,
with adapter kit, Part Number 4919172, or other Cummins
Inc. approved cleaning machine if cleaning an aftermarket
or retro-fit filter, either the Part Number 4918840 or
4919052 diesel particulate filter cleaner can be used with
adapter kit, Part Number 4919182. Refer to the
manufacturer's service manual for appropriate cleaning
procedures.
NOTE: If the aftertreatment diesel particulate filter was
removed due to an active Fault Code 1981 or Fault Code
1922 and is contaminated with coolant, it must be
replaced with a new aftertreatment diesel particulate filter.
Inspect the V-band clamps and mounting straps for signs

of over extension. The band must not be bent or
damaged.
Inspect the V-band clamps and mounting strap threads for
damage.
Replace the V-band clamp or strap if damage is found.
Maintenance Check
If the aftertreatment diesel particulate filter is being
removed for an ash cleaning or soot cleaning
maintenance interval, the aftertreatment diesel particulate
filter will need to be removed and cleaned using a cleaning
tool approved by Cummins Inc. Consult the Service Tool
Instruction, Bulletins 3400284 and 3400253, for
information regarding parts and operation of Cummins
Inc. approved cleaning tools. Conventional cleaning can
not be used to clean aftertreatment diesel particulate
filters.
Because it can be difficult to determine if an aftertreatment
diesel particulate filter is plugged with ash or soot, it will
be necessary to clean the aftertreatment diesel particulate
filter before performing a stationary regeneration to
prevent any system damage from occurring. For
information on how to perform a stationary regeneration
use the following procedre. Refer to Procedure 014-013 in
Section 14.
Performing the ash and/or soot cleaning procedure will:
• Remove excess soot to allow a stationary regeneration
without damaging the aftertreatment diesel particulate
filter
• Allow the aftertreatment diesel particulate filter to be
reused after a 1981 and/or 1922 fault code occurs
• Remove excess ash and improve regeneration
frequency.
Performing a stationary regeneration after cleaning the
aftertreatment diesel particulate filter for ash and/or soot
will:
• Remove any residual soot from the system that was
not removed during the cleaning procedure
• Test the diesel oxidation catalyst efficiency
• Test the aftertreatment system functionality.
NOTE: Soot will plug the cleaning machine filter quicker
than ash. Cleaning soot from a DPF using Cummins Inc.
approved machines can result in the need for increased
maintenance intervals of the cleaning machine filter.
Install
WARNING
Install new gaskets on the inlet and outlet of the
aftertreatment diesel particulate filter canister.
NOTE: In some applications, a locating tab was integrated
into the gasket retaining ring. The locating tab will prevent
the jointed aftertreatment diesel oxidation catalyst -
aftertreatment diesel particulate filter from being installed
backwards, and will restrict the rotational orientation that
the filter can be installed.
NOTE: On vertical aftertreatment orientations, an
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure that the
support is aligned with the tube prior to installing the filter.
Loosely tighten the v-band clamps to allow rotation for
final alignment of the differential pressure sensor tubes.
NOTE: Some accumulation of exhaust residue/soot is

normal and does not indicate a malfunctioning
A heavy buildup of exhaust residue/soot can indicate a
malfunction of the aftertreatment diesel particulate filter.
If the aftertreatment diesel particulate filter is being
replaced due to black smoke, and the exhaust stack is
found to have heavy black soot accumulation, clean the
last 152 to 254 mm [6 to 10 in] of the exhaust system
outlet.
Adjust
If the aftertreatment diesel particulate filter was replaced
or cleaned due to Fault Code 1922, it will be necessary to
reset the stored soot load in the engine's ECM.
Advanced ECM Data
• Use INSITE™ electronic service tool to perform the
Aftertreatment Maintenance Reset Procedure.
• Use INSITE™ electronic service tool or the in cab
switch, if equipped, to perform a stationary
regeneration.Refer to Procedure 014-013 in Section 14
• In situations where Fault Code 1981 is active and Fault
Codes 2639, 1921, and 1922 are not active, it is not
necessary to perform a stationary regeneration after
replacing the aftertreatment diesel particulate filter
• In situations where Fault Code 1981 and/or 1922 are
active and the aftertreatment diesel particulate filter
was cleaned,a stationary regeneration must be
performed after installing the filter on the vehicle.
Finishing Steps
WARNING
cable last.
• Connect the exhaust gas temperature sensor electrical
connector(s) to the wiring harness, if necessary.
• Use this procedure in the Troubleshooting and Repair
System, ISX and ISM Engines, Bulletin 4021560. Refer
• Connect the aftertreatment particulate filter differential
pressure sensor tubes, if necessary.
• Connect the exhaust gas pressure sensor tubes, if
necessary.
- For ISX engines, use this procedure in the Signature™,
ISX and QSX Service Manual, Bulletin 3666239.Refer
- For ISM engines, use this procedure in the ISM, ISMe,
• Tighten the V-band clamps.
• Connect the vehicle batteries. Refer to the OEM
service manual.
• Operate the vehicle on an engine dynamometer or
perform a road test with the engine at rated load for a
minimum of 5 minutes to make sure the aftertreatment
system is performing properly. Refer to Procedure
• Check for exhaust leaks.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector

Preparatory Steps
WARNING
WARNING
• Drain the coolant.
- For Signature™, ISX, and QSX15 engines, use the
QSX15 Service Manual, Bulletin 3666239. Refer to
- For ISM, ISMe, and QSM11 engines, use the following
procedure in the ISM, ISMe, and QSM11 Service
Manual, Bulletin 3666322.Refer to Procedure
• Disconnect the fuel lines and coolant lines. Refer to
• Disconnect the wiring harness from the aftertreatment
injector.
• Remove the adapter tube and injector as an assembly.
Remove
Remove the adaptor tube gasket.
Remove the capscrews holding the injector.

Remove the injector assembly.
Cut the EZ tie holding the injector harness to the heat
shield.
Discard the metal gasket.
Discard the fibrous insulator.
Remove the capscrew spacers.
Aftertreatment Fuel Injector Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
personal injury.
Inspect the injector tip.
Some carboning can occur on the tip of the injector.
Spray the tip of the aftertreatment fuel injector with

carburetor cleaner. When spraying, focus the spray on the
tip of the injector. Use enough carburetor cleaner to fill the
cavity surrounding the tip and to cover the tip.
Allow the carburetor cleaner to sit for 15 seconds so that
it can break down and penetrate the debris that has
collected in the tip area.
NOTE: Carburetor cleaner is the most effective solvent for
this procedure. Do not substitute any other cleaning
solvent.
CAUTION
Use only a stiff brass brush with undamaged bristles
to clean the tip of the aftertreatment fuel injector.
CAUTION
The use of a brush with damaged bristles will not be
as effective.
CAUTION
The use of a steel wire brush or a steel wire wheel will
cause permanent damage to the aftertreatment fuel
injector.
Use a brass brush to agitate the carburetor cleaner,
focusing on the tip of the injector.
Repeat spraying and brushing for 1 minute. Often the
carbon will be removed from the tip in a short period, but
cleaning for a full minute will remove the carbon built up
in the nozzle.
NOTE: The carbon this procedure is attempting to remove
can often not be seen with the unaided eye. This carbon
builds up in the nozzle tip area of the injector.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector
Inspect the injector tip for cracks or other damage.

Clean the adapter tube injector mounting surface.Refer to
Use safety solvent to clean the capscrews.

Clean the capscrews thoroughly with a wire brush, a soft
wire wheel, or use a non-abrasive bead blast to remove
deposits from the shaft and the threads.
Inspect the capscrews for damaged threads, corroded

surfaces, or a reduced diameter (due to capscrew
stretching).
Inspect the harness and connector pins for the following:
• Loose connector
• Corroded pins
• Bent or broken pins
• Pushed back or expanded pins
• Moisture in or on the connector
• Missing or damaged connector seals
• Dirt or debris in or on the connector pins
• Connector shell broken
• Wire insulation damage
• Damaged connector locking tab.
For general inspection techniques, reference the following
procedure in the CM871 and CM876 Electronic Control
Systems, ISX and ISM Engines Troubleshooting and
Aftertreatment Fuel Injector Signature™, ISX, and QSX15 Eng [...]
Inspect the heat shield for the following:

• Cracks
• Dents
Install
Attach the heat shield to the injector.
Install a new high temperature EZ tie to hold the injector
harness to the heat shield.
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator will be against the injector.
Install the aftertreatment injector onto the adapter pipe.
Apply a coat of high temperature anti-seize compound to
the capscrews.
Install the capscrews and spacers.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Adapter Pipe
Finishing Steps
WARNING
• Connect the fuel line and coolant lines. Refer to
• Connect the adapter pipe to the turbocharger. Refer to
• Connect the wiring harness to the aftertreatment
injector.
• Fill the cooling system.
- For Signature™, ISX, and QSX15 engines, use the
- For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322.Refer to Procedure 008-018
in Section 8.
aftertreatment system must be inspected. In the ISM,
ISMe, and QSM11 Service Manual, Bulletin 3666322,
reference the following procedure. Refer to Procedure

Preparatory Steps
WARNING
WARNING
environment regulations.
• Drain the coolant.
• For Signature™, ISX, and QSX15 engines, use the
• For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322. Refer to Procedure 008-018
in Section 8.
• Disconnect the aftertreatment injector and coolant
lines. Refer to Procedure 011-051 in Section 11.
• Disconnect the electrical connection.
Aftertreatment Adapter Pipe Signature™, ISX, and QSX15 Eng [...]
WARNING
WARNING
environment regulations.
NOTE: Determine the appropriate radiator or coolant
expansion tank cap adapter for the vehicle being serviced.
A list of available caps and applications can be found in
Section 14 of the Service Products Catalog, Bulletin
3377710.
Use a vacuum pump type device on the cooling system.
Install the adapter on the radiator or coolant expansion
tank. Connect an automotive hand held vacuum pump and
apply 3 in Hg [40 in H2O] of vacuum.
NOTE: Depending on the cooling system configuration,
more vacuum may be required to keep the cooling system
in balance.
Place a container under the aftertreatment fuel injector.
There may be a small quantity of coolant that drains from
the coolant lines when disconnected.
• Disconnect the aftertreatment injector and coolant
lines. Refer to Procedure 011-051 in Section 11.
• Disconnect the electrical connection.
• Remove the aftertreatment injector from the adapter
pipe. Refer to Procedure 011-042 in Section 11.
• Remove the NOx sensor module from the adapter
pipe.
Remove
pipe and the turbocharger.
pipe and the OEM exhaust down-pipe.
Remove the adapter pipe assembly from engine.
Remove the gasket from each end and discard. Do not use
a screwdriver or other sharp tool to remove the gaskets.
This will damage the gasket seating area.
Remove the aftertreatment injector from the adapter pipe.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Adapter Pipe
WARNING
WARNING
personal injury.
Saturate the inside of the adapter pipe with safety solvent.
Mineral based solvents can be used if results from safety
solvent are not acceptable.
Clean the inside of the adapter pipe with a non-abrasive
brush.
Saturate the injector mounting pad with safety solvent.
Clean the mounting surface with a non-abrasive brush.
Make sure the locator pin is in the adapter pipe. Replace

the adapter if necessary.
Inspect all mating surfaces for cracks or any other
damage. Replace the adapter if necessary.

EGR Valve Mounting Bracket Signature™, ISX, and QSX15 Eng [...]
Install
Install the aftertreatment injector assembly onto the
adapter pipe. Refer to Procedure 011-042 in Section 11.
Install new gaskets on each end of the adapter pipe.
Place the exhaust adapter pipe in position with the pin in
the correct location in the turbocharger.
Tighten the v-band clamps on each end.
Finishing Steps
• Connect the electrical connection.
• Connect the aftertreatment injector coolant lines.
• Fill the cooling system.
• For Signature™, ISX, and QSX15 engines, use the
• For ISM, ISMe, and QSM11 engines, use the following
Manual, Bulletin 3666322. Refer to Procedure 008-018
in Section 8.

Preparatory Steps
• Remove the EGR valve heat shield. Refer to
• Remove the front and rear EGR connection tubes.
• Remove the EGR valve and remove the EGR valve
seal from the EGR valve outlet port. Refer to
• Disconnect the aftertreatment fuel injector lines and
bulkhead support bracket from the EGR valve
mounting bracket. Refer to Procedure 011-051 in
Section 11.
Signature™, ISX, and QSX15 Eng [...] EGR Valve Mounting Bracket
Remove
Remove one of the EGR valve bracket rear support
mounting capscrews (2) from the EGR valve mounting
bracket and cylinder head.
Remove the remaining two EGR valve mounting bracket
capscrews (1).
to cover open points.

Inspect the ends and mating joints of the bracket for signs
of fretting or material transfer, cracks, or other damage.
Replace the EGR valve support bracket if fretting or
material transfer, cracks, or other damage is found.
Corrosion is normal and will be found at the EGR valve to

bracket joint. Clean the corrosion off the sealing surface
using safety solvent, or a Scotch Brite™ 7448 abrasive
pad.
The new seal will not function properly if the bracket
sealing surface have been cleaned with a power tool
combined with abrasive pads.
Inspect the sealing surface for signs of excessive pitting
at the EGR connection jumper seals. If the pitting is large
enough to catch a fingernail, replace the EGR valve
support bracket.
EGR Valve Mounting Bracket Signature™, ISX, and QSX15 Eng [...]
Install
Install the EGR valve mounting bracket onto the engine
block and the EGR valve mounting bracket rear support.
Install three capscrews into the engine block and the rear
support.
Tighten the two EGR valve mounting bracket capscrews
first (1).
Tighten the rear support bracket capscrew into the back
of the engine block (2).
Finishing Steps
• Connect the aftertreatment fuel injector lines and
bulkhead support bracket to the EGR valve mounting
bracket. Refer to Procedure 011-051 in Section 11.
• Install the EGR valve and a new EGR seal. Refer to
• Install the front and rear EGR connection tubes.
Refer to Procedure011-025 in Section 11.
• Install the EGR valve heat shield. Refer to Procedure
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Diesel Particulate Filter Differential P [...]

Differential Pressure Sensor Mounting
Bracket (011-046)
General Information
CAUTION
The catalyst elements contained in the aftertreatment
system are made of brittle material. Do not drop or
strike the side of the aftertreatment system, as
damage to the catalyst element can result.
Due to the number of exhaust aftertreatment applications,
this procedure is generic. Not all illustrations within the
procedure will represent all applications.
The exhaust aftertreatment system is composed for four
sections. These sections are:
1 Inlet
2 Aftertreatment Diesel Oxidation Catalyst
3 Aftertreatment Diesel Particulate Filter
4 Outlet
NOTE: In some applications, the catalyst can be
integrated into the inlet of the exhaust aftertreatment.
NOTE: On some vertically oriented aftertreatment
systems, the differential pressure sensor mounting
bracket may be welded to the outlet section of the
aftertreatment system. The outlet section of this type of
aftertreatment system must be replaced if the differential
pressure sensor mounting bracket is damaged.
Aftertreatment Diesel Particulate Filter Differential P [...] Signature™, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable last.
CAUTION
The aftertreatment diesel particulate filter and
catalyst can remain hot for long periods of time after
the engine has stopped.
• Disconnect the batteries. Refer to the OEM service
manual.
• Disconnect the aftertreatment wiring harness from the
aftertreatment diesel particulate filter differential
pressure sensor. Refer to Procedure 019-443 in
Section 19. This procedure can be located in the
Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines,
Bulletin 4021560.
• Remove the aftertreatment diesel particulate filter
differential pressure sensor tubes. Refer to Procedure
• Remove the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure
019-376 in Section 19. This procedure can be located
in the Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
• Mark the orientation and location of the bracket before
it is removed, to aid installation if there is not a locating
tab present.
Remove
Remove the nut on the aftertreatment diesel particulate
filter differential pressure sensor mounting bracket strap.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket. Note the orientation of
the mounting bracket prior to removal.
NOTE: Remove the differential pressure sensor mounting
bracket and strap.

Inspect the differential pressure sensor mounting bracket
for cracks, damaged threads, or broken studs.
Replace the differential pressure sensor mounting bracket
if it is damaged.
Inspect the differential pressure sensor mounting bracket

strap for cracks, damaged threads, or bends.
Replace the differential pressure sensor mounting bracket
strap if it is damaged.
Install
CAUTION
The aftertreatment system must be installed so the
pressure sensor tubes slope downward to drain
condensation away from the differential pressure
sensor.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket.
NOTE: Make sure the aftertreatment system is oriented
so the aftertreatment diesel particulate filter differential
pressure sensor is installed in the same orientation noted
during disassembly.
Install the differential pressure sensor mounting bracket
and strap. Be sure to align the cylindrical locating tab, if
present, with the mounting bracket, as noted during
removal.
If there is not a locating tab, use the reference mark that
was made during removal.
Apply a coating of anti-seize compound to the threads of
the aftertreatment diesel particulate filter differential
pressure sensor mounting bracket strap.
Install the nut on the aftertreatment diesel particulate filter
differential pressure sensor mounting bracket strap.
Tighten the differential pressure sensor mounting bracket
strap.
Finishing Steps
WARNING
cable last.
• Install the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure
in the Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
• Install the aftertreatment diesel particulate filter
differential pressure sensor tubes. Refer to Procedure
• Connect the aftertreatment wiring harness from the
pressure sensor. Refer to Procedure 019-443 in
Section 19. This procedure can be located in the
Troubleshooting and Repair CM871 and CM876
Bulletin 4021560.
• Connect the batteries. Refer to the OEM service
manual.

Differential Pressure Sensor Tubes
(011-047)
General Information
The aftertreatment diesel particulate filter differential
pressure sensor tubes connect the differential pressure
sensor to the ports on the aftertreatment system. There
are two aftertreatment diesel particulate filter differential
pressure sensor tubes. One tube connects to the
aftertreatment system upstream of the aftertreatment
diesel particulate filter and the other connects
downstream of the aftertreatment diesel particulate filter.
Due to the number of exhaust gas aftertreatment
configurations, this procedure is generic. Not all
illustrations within this procedure will represent all
applications.
CHECK ENGINE light.
Remove
CAUTION
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Mark the differential pressure
sensor tube connection port locations before
disconnecting.
CAUTION
If the flexible hose section between the differential
pressure sensor tube and the differential pressure
sensor are difficult to remove, cut and replace the
hose. Twisting or bending the hose can damage the
pressure sensor.
NOTE: The mounting location of the aftertreatment diesel
particulate filter differential pressure sensor varies with
exhaust aftertreatment orientation and OEM mounting
location.
Remove the spring clamps from the stainless steel tube
end of the flexible hose sections attached to the exhaust
gas filter pressure sensor.
Loosen the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
If p-clips or tube clamps are used to hold the exhaust gas
filter pressure sensor tubes on the exhaust aftertreatment
system, mark their location prior to removal.
Remove the p-clips or tube clamp mounting capscrews, if
necessary.
WARNING
WARNING
personal injury.
Inspect the inside of the tube.
If the tube is partially clogged, saturate the inside of the
tube with a mineral based solvent, or equivalent.
Carefully clean debris from the mouth of the tubes, make
sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry the tube with compressed air.
Check the tube for cracks and thread damage. Replace
the tube, if damage is found.
Inspect the inside of the threaded bosses on the

aftertreatment canister.
Clean debris from the inside of the threaded bosses, while
being careful to not damage the threads.
Install
CAUTION
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
CAUTION
The aftertreatment system must be installed so the
condensation away from the differential pressure
sensor.
pressure sensor port closest to the sensor mounting
bracket connects upstream of the aftertreatment diesel
particulate filter.
NOTE: In vertical aftertreatment orientations, an
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure the
differential pressure tubes are seated in the support clip.
Apply a coating of Locite™ 80209, 51002, 76732, copper
or silver grade, or equivalent to the threads on the
differential pressure sensor tubes prior to assembly. Do
not allow Loctite™ to enter inside of the differential
pressure sensor tubes. This can cause a blockage.
Minimum Loctite™ Anti-Seize Temperature Range

°C °F
870° MIN 1600°
Install the differential pressure sensor tubes on the
Attach the flexible hose sections of the differential
pressure sensor tubes to the differential pressure sensor
using two spring clamps.
NOTE: Make sure the differential pressure sensor tubes
are not making contact with each other or any other
vehicle components prior to tightening the differential
pressure sensor tube nuts.
NOTE: Tighten the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
Install the p-clips or the tube clamps that hold the exhaust
gas filter pressure sensor tubes on the exhaust
Tighten the p-clips or the tube clamp bolts, if necessary.
Operate the vehicle on a dynamometer or perform a road
test with the engine at rated load for a minimum of 5
minutes to make sure the aftertreatment system is
performing properly.
Check for fault codes and exhaust leaks.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Inlet and Outlet
Aftertreatment Inlet and Outlet

(011-048)
General Information
WARNING
During regeneration, exhaust gas temperature could
reach 800°C [1500°F], and exhaust system surface
temperature could exceed 700°C [1300°F], which is
hot enough to ignite or melt common materials, and
to burn people. The exhaust and exhaust components
can remain hot after the vehicle has stopped moving.
To avoid the risk of fire, property damage, burns or
other serious personal injury, allow the exhaust
system to cool before beginning this procedure or
repair and make sure that no combustible materials
are located where they are likely to come in contact
with hot exhaust or exhaust components.
CAUTION
strike the side of the aftertreatment system as damage
to the catalyst element can result.
Due to the number of various exhaust aftertreatment
applications, this procedure has been written to be
generic. Illustrations within this procedure will not
represent all applications.
These sections are:
1 Inlet
2 Aftertreatment diesel oxidation catalyst
3 Aftertreatment diesel particulate filter
4 Outlet.
integrated into the inlet of the exhaust aftertreatment
system.
Aftertreatment Inlet and Outlet Signature™, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable last.
CAUTION
to the correct port. Mark the differential pressure
sensor tube connection locations before
disconnecting.
• Disconnect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Mark the direction of exhaust flow to aid in assembly.
• Draw an orientation reference line across each of the
v-band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in
returning the sections and the v-band clamps to their
original orientation during installation.
• Mark the number of each exhaust gas temperature
sensor connector prior to disconnecting the exhaust
temperature sensor from the wiring harness.
• Disconnect the aftertreatment gas temperature sensor
wiring harness connectors. Refer to Procedure
019-449 (Aftertreatment Gas Temperature Sensor) in
Section 19 of the Troubleshooting and Repair Manual,
CM871 and CM876 Electronic Control Systems, ISX
and ISM Engines, Bulletin 4021560.
• Remove the mounting straps or bolts from the inlet, if
necessary. Refer to the OEM troubleshooting and
repair manual.
• Remove the mounting straps or bolts from the outlet,
if necessary. Refer to the OEM troubleshooting and
repair manual.
• Disconnect the aftertreatment diesel particulate filter
differential pressure sensor tube from the outlet, if
(Aftertreatment Diesel Particulate Filter Differential
Pressure Sensor Tubes) in Section 11.
Remove
WARNING
CAUTION
In some applications, the catalyst is integrated into the
aftertreatment inlet.Refer to Procedure 011-046
Pressure Sensor Mounting Bracket) in Section 11 for
removal of the differential pressure sensor mounting
bracket.
Support the catalyst and aftertreatment diesel particulate
filter to avoid applying a cantilevered load on the v-band
joints.
Remove the Torca™ or v-band clamp used to connect the
aftertreatment system to the exhaust pipe, if necessary.
Remove the v-band clamp connecting the inlet to the
catalyst, if necessary.
Remove the v-band clamp connecting the outlet to the
aftertreatment diesel particulate filter, if necessary.
Disassemble
Remove the aftertreatment gas temperature sensor from
the boss in the inlet and/or outlet, if necessary. Refer to
Procedure 019-449 (Aftertreatment Gas Temperature
Sensor) in Section 19 of the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control Systems,

Inspect the aftertreatment inlet and outlet canisters for
cracks or other damage.
Inspect the aftertreatment gas temperature sensor boss
threads for damage, if the sensor was removed.
Inspect the aftertreatment diesel particulate filter
differential pressure sensor tube boss threads for
damage, if the tube was removed.
If thread damage is found on the aftertreatment gas
temperature sensor boss threads or differential pressure
sensor tube boss threads, a helicoil must be used for
repair.
Flange Preparation - Use a putty knife to remove any

residual gasket material from the flanges on the
Do not use compressed air to remove fragments of gasket
material that have fallen into the filter during gasket
removal.
Do not grind on the flange surface, as this can damage
the flange and cause the connection to leak.
Inspect the v-band clamps and mounting straps for signs

of over-extension.
The band must not be bent or damaged.
Inspect the v-band clamp and mounting strap threads for
damage.
Replace the v-band clamp or mounting strap if damage is
found.
Assemble
Install the aftertreatment gas temperature sensor in the
boss on the inlet and/or outlet. Refer to Procedure 019-449
(Aftertreatment Gas Temperature Sensor) in Section 19 of
the Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control Systems, ISX and ISM Engines,
Bulletin 4021560.
Install
Apply a coat of anti-seize compound on the treads of the
v-band clamps and Torca™ clamps.
The aftertreatment outlet section contains a differential
pressure sensor tube boss. Align the differential pressure
sensor tube boss with the differential pressure sensor tube
nut prior to tightening the v-band clamp or the Torca™
clamp.
NOTE: If the Torca™ clamp is replaced during service, be
sure to replace it with another Torca™ clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Tighten the Torca™ clamps or v-band clamps used to

secure the inlet and outlet of the aftertreatment to the
exhaust pipe.
Torque Value:
Torca™ Clamp
Step 1 55 N•m [ 41 ft-lb ]
Torque Value:
V-Band Clamp
Step 1 14 N•m [ 124 in-lb ]
Install a new gasket between the v-band clamp joints that
have been disconnected.
Install the v-band clamp used to connect the outlet to the
aftertreatment diesel particulate filter, if necessary.
Install the v-band clamp use to connect the inlet to the
catalyst, if necessary.
Tighten the v-band clamps.
Finishing Steps
WARNING
cable last.
CAUTION
If the temperature sensor wire connectors are not
connected to the proper locations after installation,
aftertreatment system damage can result.
CAUTION
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
• Install the mounting straps or bolts to the inlet, if
repair manual.
• Install the mounting straps or bolts from the outlet, if
repair manual.
• Connect the aftertreatment gas temperature sensor
wiring harness connectors, if necessary. Refer to
Procedure 019-449 (Aftertreatment Gas Temperature
Sensor) in Section 19 of the Troubleshooting and
Repair Manual, CM871 and CM876 Electronic Control
• Connect the aftertreatment diesel particulate filter
differential pressure sensor tube to the outlet, if
Pressure Sensor Tubes) in Section 11.
• Connect the vehicle batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Operate the vehicle on a dynamometer or perform a
road test with the engine at rated load for a minimum
of 5 minutes to make sure the aftertreatment system is
performing properly. Refer to Procedure For ISX
engines, 010-024 (Air Leaks, Air Intake and Exhaust
Systems) in Section 10 in the Signature™, ISX, and
Procedure For ISM engines, 010-024 (Air Leaks, Air
Intake and Exhaust Systems) in Section 10 in the ISM,
ISMe, and QSM11 Engines Service Manual, Bulletin
3666322.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Diesel Oxidation Catalyst
Aftertreatment Diesel Oxidation

Catalyst (011-049)
General Information
CAUTION
Due to number of exhaust aftertreatment applications, this
procedure is generic. Illustrations within this procedure
will not represent all applications.
The exhaust aftertreatment is composed of four sections.
These sections are:
1 Inlet
2 Aftertreatment diesel oxidation catalyst
4 Outlet.
NOTE: In some applications the catalyst can be integrated
into the inlet of the exhaust aftertreatment.
Preparatory Steps
WARNING
reduce the possibility of arching, remove the negative
(-) battery cable first and attach the negative (-) batter
cable last.
CAUTION
The catalyst can remain hot for a long time after the
engine has stopped.
• Disconnect the batteries. Refer to the OEM service
manual.
• Disconnect the aftertreatment exhaust gas
temperature sensor electrical connector(s) from the
wiring harness, if necessary. Refer to Procedure
in the Troubleshooting and Repair Manual, ISX and
differential pressure sensor mounting bracket, and
strap if applicable. Refer to Procedure 011-046 in
Section 11.
Aftertreatment Diesel Oxidation Catalyst Signature™, ISX, and QSX15 Eng [...]
Remove
Draw an orientation reference line across each of the v-
band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in returning
the sections and v-band clamps to their original orientation
during installation.
Mark the direction of exhaust flow on both the catalyst
section and the aftertreatment diesel particulate filter
section to aid in assembly.
WARNING
The component weighs 23 kg [50 lbs] or more. To
CAUTION
CAUTION
damage the threads or the bolt and cause the camp to
not be reusable.
NOTE: If necessary, remove additional mounting
hardware to remove the catalyst from the vehicle.
Remove the v-band clamps from the inlet and outlet of the
catalyst.
Separate the component sections by approximately one-
half inch to allow removal over the gasket retainer rings.

CAUTION
Do not use a grinder or abrasive air tool to remove
residual gasket material, as this can damage the
flange and cause the connection to leak.
CAUTION
Do not use an open flame to burn off soot
accumulation from the face of the aftertreatment
CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a putty
knife.
NOTE: If the aftertreatment diesel particulate filter is being
inspected due to progressive damage that introduced
engine oil or excessive fuel into the exhaust, inspect the
tailpipe from the turbocharger outlet to the aftertreatment
diesel oxidation catalyst.
If a trail of liquid engine oil or fuel can be seen from the
turbocharger outlet to the aftertreatment diesel oxidation
catalyst, the aftertreatment diesel oxidation catalyst
must be replaced.
If a trail of engine oil or fuel can be seen exiting the
turbocharger outlet, the tailpipe between the turbocharger
outlet and aftertreatment diesel oxidation catalyst must be
cleaned. Refer to Procedure 011-048 in Section 11.
WARNING
The material captured in a diesel particulate filter may
contain elevated concentrations of metals, primarily
zinc and molybdenum, and possibly polynuclear
aromatic hydrocarbons that may be regulated. These
materials must be characterized, handled, and
disposed of according to applicable local regulations.
In addition, due to the presence of the above-listed
chemicals and other potentially toxic components
such as oxides of calcium, zinc, phosphorous,
silicone, sulfur, and iron, exhaust filter maintenance
must be completed only by appropriately trained
personnel.
WARNING
personal injury.
Inspect the outlet of the aftertreatment diesel oxidation
catalyst for loose debris and soot. Use a rag to wipe off
any soot. Use a HEPA vacuum to remove any remaining
loose debris.
NOTE: Use a vacuum bag, such as a drywall dust bag, to
capture the soot that is removed.
Attach the Cummins® aftertreatment diesel particulate

filter cleaning machine cone, Part Number 4918850, to the
inlet and outlet sides of the aftertreatment diesel oxidation
catalyst with the adapter rings, Part Number 4918847 and
4918848. Evenly space 4 to 5 spring clamps or C-clamps
around the circumference of the aftertreatment diesel
oxidation catalyst to seal the cone and adapter ring to the
aftertreatment diesel oxidation catalyst.
Service tool kit, Part Number 4918877 contains the cones
and rings needed for this procedure.
If the aftertreatment diesel oxidation catalyst is integrated
into the aftertreatment inlet, use one cone only, and attach
it to the outlet side of the unit.
Use tape to seal any open ports.
Obtain a 76 mm to 51 mm [3 in to 2 in] rubber pipe reducer

from a local supplier. If the aftertreatment diesel oxidation
catalyst is integrated into the aftertreatment inlet, obtain a
102 mm to 51 mm [4 in to 2 in] rubber pipe reducer.
Attach the vacuum hose to the 51 mm [2 in] end of the

pipe reducer. Attach the larger end of the reducer to the
aftertreatment diesel particulate filter cleaning machine
cone attached to the inlet side of the diesel oxidation
catalyst. If the aftertreatment diesel oxidation catalyst is
integrated into the inlet, install the larger end of the
reducer onto the aftertreatment inlet.
CAUTION
Use only a rubber-tipped air gun near the catalyst
material. Damage will result if a metal air gun strikes
the catalyst material.
Adjust the air supply for a rubber-tipped air gun to 621 kPa
[90 psi].
Switch on the vacuum. The vacuum and service tool kit is
properly installed if the air flow through the aftertreatment
diesel oxidation catalyst is opposite to exhaust flow.
Exhaust flow is indicated by an arrow on the canister of
the diesel oxidation catalyst.
Blow compressed air across the outlet face of the
aftertreatment diesel oxidation catalyst for approximately
5 minutes.
After 5 minutes, remove the aftertreatment diesel

particulate filter cleaning machine cone and continue
blowing compressed air into the outlet of the diesel
oxidation catalyst for an additional 10 to 15 minutes.
Maintain a 13 mm to 25 mm [1/2 in to 1 in] distance
between the air gun and diesel oxidation catalyst face.
Use a sweeping motion across the entire face of the diesel
oxidation catalyst and attempt to blow air through every
cell.
Allow the vacuum to operate for 1 minute after blowing out
the aftertreatment diesel oxidation catalyst. After the
vacuum is switched off, disconnect the cleaning machine
cone and inspect the cells of the diesel oxidation catalyst.
Inspect the cells of the diesel oxidation catalyst by looking

through each cell. Shine a light on the opposite side of the
diesel oxidation catalyst to aid inspection. If the cell is
clear of soot, it is possible to see straight through the
diesel oxidation catalyst.
Upon inspection, if less than 50 percent of the cells are

blocked (1) the aftertreatment diesel oxidation catalyst can
be reused. If more than 50 percent of the cells remain
blocked (2), repeat the cleaning procedure.
NOTE: It should not take more than two attempts to clean
the face of the DOC.
If the catalyst section has shifted, moved, or is loose inside

the canister, replace the catalyst section.
Inspect the inlet and outlet faces of the aftertreatment
diesel oxidation catalyst for signs of damage. Refer to
Additional Aftertreatment Diesel Oxidation Catalyst and
Aftertreatment Diesel Particulate Filter Reuse Guidelines,
Bulletin 4021600.
Inspect the v-band clamps and catalyst mounting straps

for signs of over-extension. The v-band must not be bent
or damaged.
Replace the v-band clamps or catalyst mounting straps if
damage is found.
Install
Install the exhaust gas temperature sensor into the
catalyst section, if necessary. Refer to Procedure 019-449
in Section 19. This procedure can be located in the
Troubleshooting and Repair Manual, ISX and ISM
NOTE: If the engine had turbocharger damage or any
other damage that introduced foreign objects into the
exhaust system, the aftertreatment exhaust gas
temperature 1 sensor must be inspected for damage. If
the sensor is broken or damaged it must be replaced.
WARNING
The component weighs 23 kg [50 lbs] or more. To
Install new gaskets on the inlet and outlet of the exhaust
gas catalyst.
Install the catalyst.
Tighten the v-band clamps
Install the aftertreatment diesel particulate filter
differential pressure sensor tubes into the catalyst section.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment System
Finishing Steps
WARNING
(-) battery cable first and attach the negative (-) batter
cable last.
• Connect the aftertreatment gas temperature sensor
electrical connector(s) to the wiring harness, if
necessary. Refer to Procedure 019-449 in Section 19.
differential pressure sensor mounting bracket and
strap if necessary. Refer to Procedure 011-046 in
Section 11.
• Connect the batteries. Refer to Procedure 013-009 in
Section 13.
• Operate the engine. Check for fault codes and exhaust
leaks.
Aftertreatment System (011-050)

General Information
CAUTION
Due to the number of exhaust aftertreatment applications,
this procedure has been written to be generic. Illustrations
within this procedure will not represent all applications.
These sections are:
1 Inlet
2 Catalyst
4 Outlet.
integrated into the inlet of the exhaust aftertreatment.
Aftertreatment System Signature™, ISX, and QSX15 Eng [...]
Preparatory Steps
WARNING
cable first.
• Refer to the OEM service manual for aftertreatment
system removal instructions. The OEM will designate
whether aftertreatment system components are to be
removed as individual components or as a complete
system for service.
• Mark the direction of exhaust flow on the outside of the
aftertreatment system to aid in installation.
• Mark the orientation of the exhaust gas particulate trap
differential pressure sensor to aid in installation.
• Disconnect the vehicle batteries. Refer to Procedure
Remove
System - Remove the straps or bolts securing the
aftertreatment system to the vehicle chassis. Refer to the
OEM service manual.
Remove the v-band from the inlet, and the Torca™ clamp
from the outlet of the aftertreatment system. Refer to
Disconnect the aftertreatment diesel particulate filter
differential pressure sensor wiring harness connector.
This procedure is found in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control System,
Component - To remove the aftertreatment inlet or outlet

sections: Refer to Procedure 011-048 in Section 11.
To remove the aftertreatment diesel particulate filter and
the joined catalyst - aftertreatment diesel particulate filter:
Remove the catalyst: Refer to Procedure 011-049 in
Section 11.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment System
Disassemble
Us this procedure to remove the aftertreatment inlet or
outlet sections. Refer to Procedure 011-048 in Section 11.
Use this procedure to remove the catalyst. Refer to
Use this procedure to remove the aftertreatment diesel
particulate filter. Refer to Procedure 011-041 in Section
11.
Use this procedure for aftertreatment diesel particulate
filter cleaning instructions. Refer to Procedure 011-041 in
Section 11.

Inspect inlet or outlet canister. Refer to Procedure 011-048
in Section 11.
Inspect the aftertreatment diesel particulate filter canister.
Inspect the catalyst canister. Refer to Procedure 011-049
in Section 11.
Inspect the exhaust gas temperature sensors. Refer to
Inspect the differential pressure sensor. Refer to
Inspect the differential pressure sensor tubes. Refer to
Inspect the aftertreatment system wire harness.
Inspect the Torca™ clamps and/or v-band clamps for
leaks. Refer to Procedure 010-024 in Section 10.
This procedure is found in the Signature™, ISX, and
This procedure is found in the ISM, ISMe, and QSM11
Service Manual, Bulletin 3666322.
Aftertreatment System Signature™, ISX, and QSX15 Eng [...]
Assemble
Install the aftertreatment inlet or outlet sections. Refer to
Install the aftertreatment diesel particulate filter. Refer to
Install the catalyst. Refer to Procedure 011-049 in Section
11.
Install
NOTE: Make sure that the aftertreatment system is
oriented so that the aftertreatment diesel particulate filter
differential pressure sensor is installed in the same
orientation noted during disassembly.
NOTE: The aftertreatment system must be installed so
that the aftertreatment diesel particulate filter differential
condensation away from the differential pressure sensor.
NOTE: Make sure that the differential pressure sensor
tubes are not making contact with each other or any other
vehicle components prior to tightening the Torca™ clamps
or v-band clamps.
System - Install the straps or bolts that secure the
aftertreatment system to the vehicle chassis. Refer to the
OEM service manual.
Install the inlet and outlet of the aftertreatment on to the
exhaust pipe. Refer to Procedure 011-048 in Section 11.
NOTE: If a Torca™ clamp is replaced during service, be
sure to replace it with another Torca™ clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Tighten the Torca™ clamps used to secure the inlet and
outlet of the aftertreatment to the exhaust pipe. Refer to
Connect the exhaust temperature sensor to the wiring
harness connectors. Refer to Procedure 011-048 in
Section 11.
Connect the aftertreatment diesel particulate filter
differential pressure sensor wiring harness connector.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Injector Lines
Component - To install the aftertreatment inlet or outlet

sections: Refer to Procedure 011-048 in Section 11.
To install the catalyst: Refer to Procedure 011-049 in
Section 11.
To install the aftertreatment diesel particulate filter or
joined catalyst-aftertreatment diesel particulate filter:
Finishing Steps
WARNING
cable first.
• Connect the battery. Refer to Procedure 013-009 in
Section 13.
• If the aftertreatment system was being serviced for an
aftertreatment diesel particulate filter cleaning, use
INSITE™ electronic service tool to clear related fault
codes.

(011-051)
Preparatory Steps
WARNING
WARNING
in Section 8.
Aftertreatment Injector Lines Signature™, ISX, and QSX15 Eng [...]
Remove
at the EGR cooler.

at the oil cooler.
WARNING
repairs in the fuel system, to reduce the impossibility
of fire and resulting severe personal injury, death or
3375249.
Disconnect the wiring harness from the shut off valve, fuel
drain valve, and pressure sensor.

For access lower the fuel shutoff manifold by removing the

two mounting capscrews.


Disconnect the fuel lines from the union fitting, located just
above the EGR valve.
the inlet to the aftertreatment injector, use a 9/16 inch
wrench. In some applications, access to the
aftertreatment injector is difficult and requires removal of
the exhaust adapter pipe. Refer to Procedure 011-043 in
Section 11.

at the coolant heater housing.

at the coolant return manifold.


Remove the P-clips.

the inlet to the aftertreatment injector. In some
applications, access to the aftertreatment injector is
difficult and requires removal of the exhaust adapter pipe.

WARNING
cleaning, follow the manufacture's recommendations
WARNING
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
Inspect the aftertreatment injector coolant line threads for

Make sure the aftertreatment injector coolant lines are
clear of debris.
Use compressed air to flush the lines and remove any
Check the o-ring for cuts and wear. Replace if necessary.

Clean the aftertreatment injector fuel lines with a safety

solvent.
Inspect the threads and banjo fittings on the

aftertreatment injector fuel lines. Replace is necessary.
Make sure that the aftertreatment injector fuel lines are
clear of debris.
Inspect the face of the banjo connection for sealing

surface damage.
Inspect the straight thread fittings and fuels lines for
cracks, bends or other damage.
WARNING
cleaning, follow the manufacture's recommendations
WARNING
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
Inspect the aftertreatment injector coolant line threads for

Make sure the aftertreatment injector coolant lines are
clear of debris.
Check the o-ring for cuts and wear. Replace if necessary.
Clean the aftertreatment injector fuel lines with a safety

solvent.
Inspect the threads and banjo fittings on the

aftertreatment injector fuel lines. Replace if necessary.
Make sure the aftertreatment injector fuel lines are clear
of debris.
Inspect the face of the banjo connector for sealing surface

damage.
Inspect the straight thread fittings and fuels for cracks,
bends or other damage.
Install
the aftertreatment injector and the EGR cooler.

the oil cooler.

outlet of the union fitting, located just above the EGR
valve.

inlet of the union fitting, located just above the EGR valve.

Torque Value:
Torque Value:
Banjo joint 15 N•m [ 133 in-lb ]


inlet of the shutoff manifold.
Torque Value:
Banjo joint 34 N•m [ 25 ft-lb ]
fuel rifle.
Torque Value:

the aftertreatment injector and the coolant heater housing.

the coolant return line to the coolant return manifold.


Install the P-clips
Torque Value:
O-ring fitting 24 N•m [ 212 in-lb ]
Torque Value:
Banjo fitting 15 N•m [ 133 in-lb ]

inlet of the shutoff valve manifold.
fuel rifle.
Finishing Steps
Connect the wiring harness to pressure sensor, shutoff
valve, and fuel drain valve.
Install the fuel filter.

Aftertreatment Fuel Shutoff Manifold Signature™, ISX, and QSX15 Eng [...]

(011-052)
Preparatory Steps
WARNING
personal injury.
• Make sure the area around the fuel shutoff manifold is
clear of debris. Use compressed air to clean the area
and remove any loose dirt particles.
• Disconnect the wiring harness from the aftertreatment
fuel shutoff valve, aftertreatment fuel drain valve, and
aftertreatment pressure sensor.
• Remove the aftertreatment fuel injector lines from the
fuel shutoff manifold. Refer to Procedure 011-051 in
Section 11.
Remove
WARNING
personal injury.

Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Shutoff Manifold

WARNING
personal injury.



WARNING
WARNING
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor - Clean
the shutoff valve, drain valve, and pressure sensor with
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace damaged components if necessary.
WARNING
WARNING
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold and
remove any debris.
Make sure the filter screen and orifice are in the fuel inlet
side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damaged, replace the shutoff manifold.

surfaces, or a reduced diameter (capscrew stretching).
WARNING
WARNING
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor - Clean
the shutoff valve, drain valve, and pressure sensor with
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace damaged components if necessary.
WARNING
WARNING
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold and
remove any debris.
Make sure the filter screen and orifice are in the fuel inlet
side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damaged, replace the shutoff manifold.

surfaces, or a reduced diameter (capscrew stretching).
Install
valve.
fuel drain valve.
Torque Value:
Torque Value:
Torque Value:


valve.
fuel drain valve.
Torque Value:
Torque Value:
Torque Value:

Finishing Steps
• Install the aftertreatment injector lines. Refer to
• Connect the wiring harness to the fuel shutoff valve,
fuel drain valve and pressure sensor. Use the following
procedure in the Electronic Control System
Troubleshooting and Repair Manual, Bulletin 4021560.
Aftertreatment Fuel Injector Flow Signature™, ISX, and QSX15 Eng [...]
Aftertreatment Fuel Injector Flow

(011-054)
Initial Check
WARNING
WARNING
WARNING
repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death or
• Drain the engine cooling system. For ISX engines, use
the following procedure in the Signature™, ISX, QSX15
Service Manual, Bulletin 3666239. Refer to Procedure
008-018 in Section 8. For ISM engines, use the
following procedure in the ISM, ISMe, and QSM11
• Disconnect the fuel line to aftertreatment fuel injector.
• Disconnect the coolant lines to the aftertreatment fuel
injector. Refer to Procedure 011-051 in Section 11.
• Remove the aftertreatment fuel injector from the
exhaust adapter pipe. Refer to Procedure 011-042 in
Section 11.
Setup
Remove the fibrous insulator from the aftertreatment fuel
injector face.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Flow
Connect the fuel extension line, Part Number 4918519, to

the aftertreatment fuel injector fuel supply line that was
connected to the injector.
Connect the aftertreatment fuel injector to the fuel line

extension.
CAUTION
Do not connect a 12-VDC supply to the injector as this
will cause permanent damage to the injector.
Connect the aftertreatment fuel injector electrical harness
extension, Part Number 4918518, to the engine harness
and the aftertreatment fuel injector.
On ISX applications, install a threaded plug, Part Number

3089567, at the coolant outlet on the EGR cooler.
Install a threaded plug, Part Number 4918690, in the
coolant hose.
On ISM applications, install two threaded plugs, Part

Number 4918690, in the coolant inlet and outlet hoses.
Block the opening in the exhaust adapter pipe.

Install the cover plate, Part Number 4918522, with two
capscrews, Part Number 3913638.
Obtain a clear graduated cylinder (large enough to hold

the aftertreatment injector) that is marked in cubic
centimeters; example: graduated beaker, Part Number
3823705, or equivalent. A measurement cup that is
marked in milliliters (ml) or ounces (oz) can also be used.
The measuring device must be capable of measuring
between 0 ml [0.0 oz] and 500 ml [17.0 oz] in 10 ml [0.34
oz] increments.
Place the aftertreatment fuel injector in the graduated
cylinder or cup.
NOTE: It is usually easier to capture the fuel in a clean
container and transfer the fuel to the measuring device for
the final measurement.
Cover the aftertreatment fuel injector and graduated

cylinder so the fuel spray is contained.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Flow
Turn the keyswitch to the ON position.

Use INSITE™ electronic service tool to perform the
aftertreatment "Reset All" function.
This function can be found under the Advanced ECM
Data, Aftertreatment Maintenance screen in INSITE™
electronic service tool.
Flow Test
NOTE: This test should only be performed after
completing the "Reset All" as described above.
Start the engine and allow it to idle for 5 minutes.
Use INSITE™ electronic service tool to select System Test
in the test mode section of the Aftertreatment Shutoff
Valve and Injector Override Test.
Use INSITE™ electronic service tool to enter a time delay,
if needed.
Click the Start button when ready to perform the test.
Click the OK button when the warning windows pop up, if
the conditions are met.
INSITE™ electronic service tool will start the test and will
inject fuel for 2 minutes and 30 seconds. INSITE™
electronic service tool will automatically disable the
injector at the end of the test. If the test needs to be
stopped before finishing, click the Stop button.
Record the amount of fuel that was collected in the

graduated cylinder during the 2 minutes and 30 seconds
test period.
Perform the test 3 times and average the results of the
three tests.
The average amount of fuel collected must be between
200 and 400 ml [6.8 and 13.5 oz].
Clean the tip of the aftertreatment fuel injector. Refer to

NOTE: The aftertreatment injector is to be cleaned at this
step, regardless of the flow in the previous step.
If the average amount collected before cleaning is not

within the specified limits, perform the flow test a second
time.
Record the amount of fuel that was collected in the
graduated cylinder during the 2 minutes and 30 seconds
test period.
Perform the test 3 times and average the results of the
three tests.
The average amount of fuel collected must be between
200 and 400 ml [6.8 and 13.5 oz].
If the average amount collected is not within this
specification, return to the fault code troubleshooting tree
for next steps.
Leak Test
NOTE: This test does not need to be performed for Fault
Codes 2728, 2638, and 1691.
To perform the Aftertreatment Fuel Injector Leak Test,
start the engine and allow it to idle for 5 minutes.
Hold the aftertreatment fuel injector over the graduated
cylinder.
Use INSITE™ electronic service tool to select Injector Leak

in the test mode section of the Aftertreatment Shutoff
Valve and Injector Override Test.
Click the Start button to initiate the test.
Record the amount of fuel collected during the 1 minute
INSITE™ electronic service tool test.
If more than 60 ml [2 oz] of fuel is collected during the 1
minute INSITE™ electronic service tool test, replace the
aftertreatment fuel injector. Refer to Procedure 011-042 in
Section 11.
Return the collected fuel to the fuel tank.
Signature™, ISX, and QSX15 Eng [...] Exhaust System Diagnostics
Finishing Steps
• Drain the engine cooling system. For ISX engines, use
the following procedure in the Signature™, ISX, QSX15
008-018 in Section 8. For ISM engines, use the
following procedure in the ISM, ISMe, and QSM11
• Remove the injector spray tester service tool kit, Part
Number 4918517.
• Install a new fibrous insulator.
• Install a new metal gasket.
• Install the aftertreatment fuel injector assembly onto
the adapter pipe. Refer to Procedure 011-042 in
Section 11.
• Connect the fuel line to the aftertreatment fuel injector.
• Fill the engine cooling system. For ISX engines,
reference the following procedure in the Signature™,
ISX, QSX15 Service Manual, Bulletin 3666239. Refer
to Procedure 008-018 in Section 8. For ISM engines,
reference the following procedure in the ISM, ISMe,
• Start the engine, check for leaks, and verify that all
fault codes are inactive.
Exhaust System Diagnostics (011-056)

General Information
The following procedure contains troubleshooting steps
and information regarding the aftertreatment system.
Leaks in the exhaust system can cause exhaust odor or

white smoke.
Inspect the exhaust piping for leaks, cracks, and loose
connections. Refer to Procedure 010-024 (Air Leaks, Air
Intake and Exhaust Systems) in Section 10.
Tighten the exhaust clamps, if necessary. Refer to the
OEM specifications and the correct torque value.
It may be necessary to perform a stationary (parked)
regeneration to locate exhaust leaks. Refer to Procedure
014-013 (Aftertreatment Testing) in Section 14.
Exhaust System Diagnostics Signature™, ISX, and QSX15 Eng [...]
The ambient temperature affects the length of time it will

take to perform a stationary (parked) regeneration
because the engine must work harder to increase the
exhaust temperatures to the appropriate levels in cold
ambient temperatures.
In cold ambient temperatures (approximately -18°C [0°F]
or colder), stationary (parked) regeneration may take
longer to complete. In extremely cold ambient
temperatures, stationary (parked) regeneration may not
complete.
In these cases, it may be necessary to warm the engine
to operating temperature before starting the stationary
(parked) regeneration, or to move the vehicle to a location
with higher ambient temperatures.
The vehicle manufacturer has the option of installing two switches

that control aftertreatment function: the start switch and the permit
switch.
The start switch (called the Diesel Particulate Filter Regeneration
Start Switch in INSITE™ electronic service tool) is used to start a
stationary (parked) regeneration. The vehicle manufacturer may
also reference this switch as a "stationary regeneration switch,"
"start switch," or "parked regeneration switch".
The permit switch (called the Diesel Particulate Filter Permit
Switch in INSITE™ electronic service tool) is used to allow the
operator to disable active regeneration, if necessary. The vehicle
manufacturer may also reference this switch as an "inhibit switch,"
"stop switch," or "disable switch".
The start switch can be hardwired to the ECM, or it can be
multiplexed over J1939 multiplexing.
If the start switch is hardwired, it shares an ECM pin with the
diagnostic switch. When the switch is turned ON and the engine
is OFF, the ECM interprets this signal as the diagnostic switch.
When the switch is turned ON and the engine is running, the ECM
interprets this signal as the start switch.
If the start switch is J1939-multiplexed, the signal for this switch
is broadcast over the J1939 data link.
A J1939-multiplexed start switch signal has priority over a
hardwired start switch signal, therefore if the start switch is
enabled over J1939, the hardwired signal is ignored by the engine
ECM.
The default setting for the start switch is OFF. If the start switch
is enabled to INSITE™ electronic service tool, but no switch is
installed (either hardwired of J1939-multiplexed), the switch status
will remain OFF.
The position of the start switch can be monitored with INSITE™
electronic service tool in the data monitor/logger screen.
The default setting for the permit switch is ENABLED.
If the permit switch is enabled with INSITE™ electronic service
tool, but no switch is installed (either hardwired or J1939
multiplexed), the switch status will remain OFF.
If the vehicle is operated for an extended period of time with the
permit switch OFF, fault codes for the above normal levels of
aftertreatment diesel particulate filter soot load may result (Fault
Codes 1921, 1922, and 2639).
If the aftertreatment diesel particulate filter soot load reaches the
moderately severe level (Fault Code 2639), and the permit switch
is OFF, the ECM will also log a Fault Code 2777.
If the permit switch is multiplexed, and therefore ENABLED, in the
J1939 section of Features and Parameters in INSITE™ electronic
service tool, it must also be enabled in the aftertreatment section
of Features and Parameters in INSITE™ electronic service tool. If
is is not, regeneration will be inhibited.
The permit switch can be hardwired to the ECM only in
emergency vehicle calibrations. For all other non-emergency
calibrations, the permit switch can only be J1939-multiplexed
over the J1939 data link.
In emergency vehicle calibrations where the permit switch is
hardwired, the permit switch replaces the governor type switch.
A J1939-multiplexed permit switch signal has priority over a
hardwired start switch signal, so if the permit switch is enabled
over J1939, the hardwired signal is ignored by the engine ECM.
The position of the permit switch can be monitored with INSITE™
electronic service tool in the data monitor/logger screen:
• When the permit switch is ON, active regeneration is
allowed.
• When the permit switch is OFF, active regeneration is not
allowed.
If the aftertreatment exhaust gas temperature sensors are

not connected properly, or if the wiring in the harness
between the engine and aftertreatment is not correct, the
engine may experience frequent DPF lamp illuminations,
or stationary (parked) regenerations that do not complete.
Inspect the exhaust aftertreatment temperature sensor
connectors to verify they are connected to the correct
connector on the aftertreatment system wiring harness.
Two of the temperature sensors have identical wiring
harness connectors. Because the sensors are the same
part number, it is possible to install the wiring harness
connectors to the wrong sensor.
To verify the correct sensor locations, use INSITE™
electronic service tool to monitor the following parameters
with the ignition key ON, but with the engine not running.
• Aftertreatment Diesel Oxidation Catalyst Inlet
Temperature Sensor Signal Voltage (V)
• Aftertreatment Diesel particulate Filter Inlet
Temperature Sensor Signal Voltage (V)
• Aftertreatment Diesel Particulate Filter Outlet
Temperature Sensor Signal Voltage (V).
Unplug each of the aftertreatment exhaust gas
temperature sensors, one at a time.
If the voltage changes when the sensor is unplugged, the
wiring harness connector is connected to the correct
sensor.
If the voltage does not change when the sensor is
unplugged, switch the connector location to the other
temperature sensor, unplug it, and check for a voltage
change.
An incorrectly assembled aftertreatment wiring harness
can not be checked by unplugging each of the
aftertreatment exhaust gas temperature sensors.
The only method to check for a misassembled
aftertreatment wiring harness is to check the wiring
harness connectors for correct pin installation. Refer to
the engine wiring diagram for connector pin identification
and location.
When performing a stationary (parked) regeneration,

monitor the exhaust temperatures in the aftertreatment to
determine why a stationary (parked) regeneration will
not complete.
Possible causes for stationary (parked) regenerations that
will not complete include:
• Misassembled aftertreatment wiring harness
• Aftertreatment exhaust gas temperature sensors
installed in the wrong location
• A plugged aftertreatment diesel oxidation catalyst
• A malfunctioning turbocharger.
A normal stationary (parked) regeneration will follow the
pattern shown.
• The dashed line is for the aftertreatment diesel
oxidation catalyst inlet temperature sensor.
• The dotted line is for the aftertreatment diesel
particulate filter inlet temperature sensor.
• The solid line is for the aftertreatment diesel
particulate filter outlet temperature sensor.
When the stationary (parked) regeneration begins (1), all
three temperatures should be approximately the same,
and should increase at the same rate.
The wiring to the aftertreatment temperature sensors
appears to be correct in this example because they all
read approximately the same temperature at the
beginning of the stationary (parked) regeneration and
increase at the same rate.
Aftertreatment injection begins when all three
temperatures reach approximately 288°C [550°F] (2).
Once aftertreatment injection begins, the aftertreatment
diesel oxidation catalyst inlet temperature may vary
slightly, but will typically remain between 260 and 399°C
[500 and 750°F].
The aftertreatment diesel particulate filter inlet and outlet
temperatures will increase to approximately 482 to 649°C
[900 to 1200°F]. The temperatures may vary during the
stationary (parked) regeneration as the amount of fuel
injected during aftertreatment injection is changed to
maintain a constant temperature.
The aftertreatment diesel particulate filter inlet and outlet
temperatures will remain at this temperature for the
duration of the stationary (parked) regeneration.
This graph illustrates a stationary (parked) regeneration

where the inlet of the aftertreatment diesel oxidation
catalyst is blocked.
In this condition, the engine speed will increase to the
stationary (parked) regeneration speed of 1000 to 1400
rpm.
Raising the aftertreatment temperature to the
aftertreatment injection temperature may take longer to
complete than normal if the inlet to the aftertreatment
diesel oxidation catalyst is plugged, restricting some of the
exhaust flow.
Once aftertreatment injection begins (2), the
aftertreatment diesel particulate filter inlet and outlet
temperatures will differ greatly due to the plugged
aftertreatment diesel oxidation catalyst being unable to
oxidize the injected fuel. The aftertreatment diesel
particulate filter has some capability to oxidize the injected
fuel, but can not maintain this condition without damaging
the filter material over time. It is possible that white smoke
would be present from the vehicle tailpipe during this
condition.
The wiring to the aftertreatment temperature sensors
read approximately the same temperature at the
beginning of the stationary (parked) regeneration and they
increase at the same rate.
The possible cause of this condition is a plugged
aftertreatment diesel oxidation catalyst. Refer to
Procedure 011-049 (Aftertreatment Diesel Oxidation
Catalyst) in Section 11 to inspect the aftertreatment diesel
oxidation catalyst.

where the engine can not build enough heat to start
aftertreatment injection.
The engine speed will likely increase to the stationary
(parked) regeneration speed of 1000 to 1400 rpm, but
because the aftertreatment temperatures do not increase
enough to start aftertreatment injection, the stationary
(parked) regeneration will not complete.
The wiring to the aftertreatment temperature sensor
read approximately the same temperature for the same
conditions.
Possible causes of this issue include:
• A malfunctioning turbocharger. Refer to Procedure
010-134 (Variable Geometry Turbocharger Actuator,
Electric) in Section 10 to verify the turbocharger
sector gear has full travel.
• Low ambient temperatures. Move the vehicle to a
location with higher ambient temperatures.

where the wiring to the aftertreatment temperature
sensors is incorrect.
stationary (parked) regeneration speed of 1000 to 1400
rpm.
Aftertreatment injection will not occur in this condition
because the aftertreatment diesel oxidation catalyst inlet
temperature does not reach the required temperature.
Because aftertreatment injection is not occurring, the
aftertreatment temperatures should not read differently.
The possible cause of this condition is an incorrectly
assembled aftertreatment wiring harness. See the
aftertreatment exhaust gas temperature sensor wiring
section of this procedure.
Aftertreatment Fuel Injector Coolant Test Signature™, ISX, and QSX15 Eng [...]

where the connectors to the aftertreatment diesel
oxidation catalyst inlet temperature sensor and the
aftertreatment diesel particulate filter outlet temperature
sensor are reversed.
stationary regeneration speed of 1000 to 1400 rpm.
Aftertreatment injection may occur in this condition (2).
However, the aftertreatment diesel oxidation catalyst inlet
temperature increases after aftertreatment injection
begins, while the aftertreatment diesel particulate filter
outlet temperature remains constant.
The possible cause of this condition is that the connectors
to the aftertreatment diesel oxidation catalyst inlet
temperature sensor and the aftertreatment diesel
particulate filter outlet temperature sensor are reversed.
See the aftertreatment exhaust gas temperature sensor
wiring section of this procedure.
Aftertreatment Fuel Injector Coolant

Test (011-061)
Preparatory Steps
WARNING
WARNING
• Drain the cooling system. Use the following procedure
in the Signature™, ISX, and QSX15 Service Manual,
Section 8. Use the following procedure in the ISM,
ISMe, and QSM11 Service Manual, Bulletin
3666322.Refer to Procedure Procedure 008-018 in
Section 8.
• Disconnect the fuel line to the aftertreatment fuel
• Disconnect the coolant lines to the aftertreatment fuel
• Remove the aftertreatment fuel injector from the
exhaust adapter pipe. Refer to Procedure 011-042 in
Section 11.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Fuel Injector Coolant Test
Setup
Plug one of the coolant connections with an M16 x 1.5
plug.
Fill the nozzle area with water.
Test
WARNING
personal injury.
Apply compressed air regulated at 241 kpa [35 psi] to the
opposite coolant connection.
If air bubbles are seen in the nozzle area, the
aftertreatment injector has a crack that is allowing coolant
to leak through.
The injector must be replaced.
Aftertreatment Fuel Injector Coolant Test Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
WARNING
• Remove the plug and compressed air connection from
the coolant connection points.
• Install a new fibrous insulator.
• Install a new metal gasket.
• Install the aftertreatment fuel injector assembly onto
the adapter pipe. Refer to Procedure 011-042 in
Section 11.
• Connect the fuel line to the aftertreatment fuel injector.
• Connect the coolant lines to the aftertreatment fuel
• Connect the wiring harness to the aftertreatment
injector.
• Fill the cooling system. Use the following procedure in
the Signature™, ISX, and QSX15 Service Manual,
Section 8. Use the following procedure in the ISM,
ISMe, and QSM11 Service Manual, Bulletin
3666322.Refer to Procedure Procedure 008-018 in
Section 8.
• Start the engine, check for leaks, and verify all fault
codes are inactive.
Section 12 - Compressed Air System - Group 12 Page 12-a
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Compressor ...............................................................................................................................................12-9
Finishing Steps............................................................................................................................................. 12-12
Install............................................................................................................................................................12-10
Remove..........................................................................................................................................................12-9
Air Compressor Carbon Buildup .....................................................................................................................12-1
Clean..............................................................................................................................................................12-2
Initial Check....................................................................................................................................................12-1
Air Compressor Coolant Lines ........................................................................................................................12-3
Finishing Steps...............................................................................................................................................12-6
Initial Check....................................................................................................................................................12-3
Install..............................................................................................................................................................12-4
Remove..........................................................................................................................................................12-4
Air Compressor Cylinder Head, Single Cylinder ............................................................................................12-6
Finishing Steps...............................................................................................................................................12-8
Initial Check....................................................................................................................................................12-6
Install..............................................................................................................................................................12-7
Remove..........................................................................................................................................................12-7
Air Compressor Unloader and Valve Assembly .............................................................................................12-8
Air Governor (Air Compressor Pumps Continuously) ..................................................................................12-13
Initial Check..................................................................................................................................................12-13
Air Governor (Air Compressor Will Not Pump) .............................................................................................12-12
Remove.........................................................................................................................................................12-12
Air Leaks, Compressed Air System ..............................................................................................................12-14
Initial Check..................................................................................................................................................12-14
Air Pressure Relief Valve ..............................................................................................................................12-15
Initial Check..................................................................................................................................................12-15
Page 12-b Section 12 - Compressed Air System - Group 12

Signature™, ISX, and QSX15 Eng [...] Air Compressor Carbon Buildup
Section 12 - Compressed Air System - Group 12 Page 12-1
Air Compressor Carbon Buildup

(012-003)
Initial Check
WARNING
bodily injury.
Open the drain cock on the wet tank to release
compressed air from the system.
WARNING
Air discharge lines can be very hot. Be sure the lines
are cool before handling to prevent personal injury.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air

discharge line as shown.
NOTE: The carbon deposit thickness must not exceed
1.6 mm [0.06 in].
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. Refer to the
OEM specifications.
NOTE: If the total carbon deposit thickness exceeds
specification, remove and clean, or replace the air
discharge line.
Continue to check for carbon buildup in the air discharge
line connections up to the first connection or wet tank.
Clean or replace any lines and fittings with carbon
deposits thicker than 1.6 mm [0.06 in]. Refer to the OEM
specifications for cleaning or replacement instructions.
Air Compressor Carbon Buildup Signature™, ISX, and QSX15 Eng [...]
Page 12-2 Section 12 - Compressed Air System - Group 12
Clean
WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
WARNING
personal injury.
CAUTION
Do not use a sharp object to remove carbon. The
sealing surfaces can be damaged.
CAUTION
Avoid getting debris and solvents into the clearance
between the piston and bore.
CAUTION
Avoid the use of abrasive products similar to “Scotch
Brite™” because any abrasive grit left after cleaning
will shorten the life of the air compressor.
Remove the compressor head and valve assembly. Refer
Remove carbon from the compressor head and valve

assembly components with solvent and a nonmetallic
brush.
Blow out passages with compressed air.
Clean the compressor cylinder.

Rotate the crankshaft until the piston is at the top of the
cylinder bore.
Remove any accumulated carbon and varnish by careful
scraping and light application of solvents.
Signature™, ISX, and QSX15 Eng [...] Air Compressor Coolant Lines
Install the compressor head and valve assembly. Refer to


(012-004)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
personal injury.
in Section 8.
• Use steam to clean the air compressor. Dry with
compressed air.
Initial Check
Inspect the coolant hoses for splits, cracks, hardening, or
other damage.
Inspect the metal coolant lines for kinks, corrosion,
cracks, or other damage.
Air Compressor Coolant Lines Signature™, ISX, and QSX15 Eng [...]
Remove
Remove the coolant lines from the air compressor.
Inspect for Reuse

Inspect the drive clips or the connectors for damaged
threads.
Inspect the coolant hoses for splits, cracks, hardening, or
other damage.
Inspect the coolant lines for restrictions of coolant flow.
Replace the coolant lines if any damage is found.
Install
Use two elbows and run the locking nuts all the way up
Start threading the elbows into the cylinder head.
Use a 24 mm open-end wrench to position the elbows.
Push the tube nut away from the bell flare on the U-shaped
coolant supply line.
Signature™, ISX, and QSX15 Eng [...] Air Compressor Coolant Lines
Install the U-shaped coolant supply line into the coolant

supply elbow.
elbow.
Install the other end of the coolant supply line into the
Push the tube nut away from the bell flare on the coolant
return line.
Install the coolant return line into the coolant return elbow.
elbow.
Air Compressor Cylinder Head, Single Cylinder Signature™, ISX, and QSX15 Eng [...]
Install the other end of the coolant return tube into the
Install the capscrews in the two locations designated by

the arrows.
Tighten the capscrews
Tighten the compression nuts and elbow locking nuts.
Finishing Steps
WARNING
Section 8.
Air Compressor Cylinder Head, Single

Cylinder (012-007)
Initial Check
Remove the air inlet and outlet lines from the air
compressor.
• For Signature™, ISX, and QSX15 engines, use this
procedure. Refer to Procedure 012-014 in Section 12.
• For ISM, ISMe and QSM!1 engines, use this
procedure. Refer to Procedure 012-014 in Section 12.
Inspect the lines for signs of a coolant leak.
If signs of a leak are found, the cylinder head must be
replaced.
Signature™, ISX, and QSX15 Eng [...] Air Compressor Cylinder Head, Single Cylinder
Preparatory Steps
WARNING
WARNING
• Drain the cooling system. For Signature™, ISX, and
QSX15 engines, use this procedure. Refer to
Procedure 008-018 in Section 8. For ISM, ISMe and
QSM!1 engines, use this procedure. Refer to
Remove
Remove the air governor or air governor signal line (if
equipped).
Remove the air inlet and outlet connections from the air
compressor.
Remove the four 8-mm capscrews.
Remove the air compressor head and gasket.
Install
Assemble the air compressor using a new gasket.
Install the head and gasket.
Install the four 8-mm capscrews.
Tighten the capscrews in the sequence shown. Use the
torque plus angle method.
Torque Value:
Step 1 25 N•m [ 221 in-lb ]
Air Compressor Unloader and Valve Assembly Signature™, ISX, and QSX15 Eng [...]
If a new head assembly is being installed, tighten the five

small head cover bolts in the sequence shown.
Torque Value:
Step 1 6 N•m [ 53 in-lb ]
Finishing Steps
WARNING
• Fill the cooling system. For Signature™, ISX, and
QSX15 engines, use this procedure. Refer to
Procedure 008-018 in Section 8. For ISM, ISMe and
QSM!1 engines, use this procedure. Refer to
operation.
Air Compressor Unloader and Valve

Assembly (012-013)
Preparatory Steps
Remove the air governor or air governor signal line from
the air compressor.
Operate the engine to activate the air compressor.

If the air compressor is not pumping, replace the
compressor cylinder head. Refer to Procedure 012-007.
Signature™, ISX, and QSX15 Eng [...] Air Compressor

Preparatory Steps
WARNING
WARNING
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
WARNING
personal injury.
in Section 8.
• Use steam to clean the air compressor. Dry with
compressed air.
• Remove the coolant lines from the air compressor.
Remove
Remove the air connections from the air compressor.
Remove or disconnect the air governor. Refer to the OEM
service manual.
Remove the air compressor support bracket and

capscrews.
Remove the four mounting capscrews and the air
compressor.
Discard the gasket.
Air Compressor Signature™, ISX, and QSX15 Eng [...]

Inspect the compressor housing for cracks or other
damage.
Inspect the compressor drive gear for cracks or other
damage.
Make sure the gasket surfaces of the front gear housing

and the air compressor are clean and not damaged.
Install
Pin the engine crankshaft. Refer to Procedure 001-088 in
Section 1.
Rotate the gear on the air compressor until the mark on
the gear is in line with the V-notch on the air compressor
housing, located at the three o'clock position as viewed
from the front.
Loctite™, Part Number 3824040 or equivalent, must be
used on the capscrews that mount the air compressor to
the gear housing. This seals the threads in the housing.
To evenly distribute the sealant as the capscrew is
torqued, a line of sealant should be placed along the
length of the capscrew.
Install the air compressor and the four capscrews onto the
front gear housing.
Signature™, ISX, and QSX15 Eng [...] Air Compressor

Tighten the capscrews again.
Install the air compressor mounting brace and four

capscrews on the block beneath the air compressor. Start
threading all four capscrews.
Tighten the capscrews on the cylinder block and air

compressor.
Install the air discharge line.

Install the air inlet line.
Install the air governor (if removed). Connect the air
governor pressure signal line. Refer to the OEM service
manual.
Air Governor (Air Compressor Will Not Pump) Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
• Install the air compressor coolant lines. Refer to
Air Governor (Air Compressor Will Not

Pump) (012-017)
Remove
Remove the air governor or air governor signal line from
the air compressor.
Inspect for Reuse

If the air compressor is pumping, the air governor is
malfunctioning and must be replaced. Refer to the
If the compressor does not pump with the governor

removed, the unloader valve is malfunctioning. Replace
the compressor cylinder head. Refer to Procedure
012-003.
Signature™, ISX, and QSX15 Eng [...] Air Governor (Air Compressor Pumps Continuously)
Air Governor (Air Compressor Pumps

Continuously) (012-018)
Initial Check
Remove the air accessory air lines from the air
compressor governor and install pipe plugs in the air
governor unloader ports.
If the air compressor stops pumping (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. Refer to the equipment
manufacturer's instructions for troubleshooting and
repair.
If the air compressor does not stop pumping (air pressure

continues to rise) at the governed air pressure, connect a
regulated shop air pressure line to the air compressor
unloader valve port.
NOTE: Be sure the air pressure gauge is accurate, and

the supply lines and fittings are in good condition before
performing any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply 690 kPa [100 psi] air pressure to the unloader port.
If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. Refer to the manufacturer's instructions.
Air Leaks, Compressed Air System Signature™, ISX, and QSX15 Eng [...]
If the air compressor continues to pump (air pressure

continues to rise), the unloader valve is malfunctioning
and must be replaced. Refer to Air Compressor Unloader
Valve, Procedure 012-013.
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines.
Connect the line to the unloader valve.
Operate the engine and check for air leaks.
Air Leaks, Compressed Air System

(012-019)
Initial Check
WARNING
bodily injury.
Open the drain cock on the wet tank to release air from
the system. Close the drain cock after the pressure is
released.
Signature™, ISX, and QSX15 Eng [...] Air Pressure Relief Valve

With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
• Air compressor head gasket
• Air compressor cover gasket
• Hose and fitting leaks.
If air leaks are found, verify that the air compressor head
and cover bolts are torqued properly. Make sure hoses
and fittings are tight. Replace if necessary.
Air Pressure Relief Valve (012-024)

Initial Check
Remove the air governor or air governor line from the air
compressor. Remove the air intake line from the air
compressor cylinder head.
CAUTION
Do not hold hand too close to the intake port of the
air compressor. Personal injury can result.
Hold your hand 5 cm [2 in] from the air compressor intake
port. If air is coming out of the intake port, the pressure
relief valve is malfunctioning and the air compressor
cylinder head must be replaced. Refer to Procedure
If no air is felt from the intake port, check downstream air

system components for damage or restrictions.
Air Pressure Relief Valve Signature™, ISX, and QSX15 Eng [...]
Install the air intake line to the cylinder head. Install the
air governor or air governor line to the air compressor.
Section 13 - Electrical Equipment - Group 13 Page 13-a
Section 13 - Electrical Equipment - Group 13

Section Contents
Page
Alternator .........................................................................................................................................................13-2
Driven by Cooling Fan Drive Belt..................................................................................................................13-5
Finishing Steps...............................................................................................................................................13-6
Initial Check....................................................................................................................................................13-2
Alternator Wiring Test...................................................................................................................................13-2
Alternator Voltage Output Check..................................................................................................................13-2
Alternator Current Output Test......................................................................................................................13-3
Install..............................................................................................................................................................13-6
Remove..........................................................................................................................................................13-5
Alternator Idler Pulley ...................................................................................................................................13-24
Clean............................................................................................................................................................13-24
Install............................................................................................................................................................13-25
Remove.........................................................................................................................................................13-24
Alternator Pulley .............................................................................................................................................13-8
Clean..............................................................................................................................................................13-9
Install..............................................................................................................................................................13-9
Remove..........................................................................................................................................................13-8
Alternator Spacer ..........................................................................................................................................13-22
Finishing Steps............................................................................................................................................. 13-24
Install............................................................................................................................................................13-23
Remove.........................................................................................................................................................13-22
Batteries ........................................................................................................................................................ 13-10
Initial Check..................................................................................................................................................13-10
Battery Cables and Connections .................................................................................................................. 13-11
Initial Check..................................................................................................................................................13-11
Belt Tensioner, Automatic (Alternator) .........................................................................................................13-20
Clean............................................................................................................................................................13-20
Install............................................................................................................................................................13-21
Automotive Applications............................................................................................................................. 13-21
Remove.........................................................................................................................................................13-20
Bracket, Idler Pulley and Alternator Belt Tensioner ....................................................................................13-25
Clean............................................................................................................................................................13-26
Finishing Steps............................................................................................................................................. 13-28
Install............................................................................................................................................................13-27
Page 13-b Section 13 - Electrical Equipment - Group 13

Remove.........................................................................................................................................................13-26
Drive Belt, Alternator ......................................................................................................................................13-7
Adjust.............................................................................................................................................................13-8
Install..............................................................................................................................................................13-7
Remove..........................................................................................................................................................13-7
Service Tools ...................................................................................................................................................13-1
Electrical Equipment.......................................................................................................................................13-1
Starter Magnetic Switch ................................................................................................................................13-12
Current Check...............................................................................................................................................13-12
Starter Solenoid .............................................................................................................................................13-15
Voltage Check...............................................................................................................................................13-15
Starter Switch ................................................................................................................................................13-14
Voltage Check...............................................................................................................................................13-14
Starting Motor ................................................................................................................................................13-17
Finishing Steps............................................................................................................................................. 13-19
Install............................................................................................................................................................13-18
All Except 50MT With Aluminum Flywheel Housing.....................................................................................13-18
50MT With Aluminum Flywheel Housing.....................................................................................................13-19
Remove.........................................................................................................................................................13-18
All Except 50MT With Aluminum Flywheel Housing.....................................................................................13-18
50MT With Aluminum Flywheel Housing.....................................................................................................13-18
Section 13 - Electrical Equipment - Group 13 Page 13-1
Service Tools
Electrical Equipment
Repair Location.

Refractometer
The Fleetguard® refractometer is used to check the charge condition
CC-2800 of a conventional battery.
Clamp-On Current Probe

Used to measure AC and DC currents. This unit must be used with
3823574 digital multimeter, Part No. 3377161.
Digital Multimeter
Used to test various electrical circuits.
3377161
Harness and Wire Repair Kit

This kit contains various connectors and tools to repair wiring
3162899 harnesses.
Alternator Signature™, ISX, and QSX15 Eng [...]
Page 13-2 Section 13 - Electrical Equipment - Group 13
Initial Check
Alternator Wiring Test
WARNING
cable last.
WARNING
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing
agent when servicing batteries. Wear goggles and
protective clothing to avoid serious personal injury.
Systems that are 24 VDC must be connected into a
temporary 12 VDC configuration.
Attach the carbon-pile and clip-on ammeter as shown.
Adjust the load from the carbon-pile tester to the rated
performance of the alternator.
Measure the voltage drop in both the positive and negative
circuits.
Add these together and compare the sum to the table
below.
System Voltage Maximum Voltage Drop

12 0.5
24 1.0
Repair or replace the wiring as required to meet the above

specifications.
Alternator Voltage Output Check

Attach the multimeter to the alternator as shown in the
illustration.
With the batteries in a fully charged condition and all the
accessories off, start the engine and run it at high idle.
Allow time for the voltage to stabilize before taking any
readings.
Signature™, ISX, and QSX15 Eng [...] Alternator
Measure the alternator output voltage.
System Voltage Maximum Output Voltage

Limit
12 15.5
24 31.0
Repair or replace the alternator or regulator if the voltage

limit exceeds the value in the table.
Refer to the manufacturer's specifications for minimum
voltage output.
Alternator Current Output Test

Connect the carbon-pile tester to the batteries in parallel.
If more than one wire is connected to the alternator output
terminal, clamp the ammeter around all wires.
Clamp the induction ammeter around the alternator output
wire.
The alternator must be turning at approximate rated

speed.
Most heavy-duty alternators are rated at 5000 rpm. Check
the manufacturer's specifications for the specific
alternator being tested.
Make sure that all vehicle electrical loads are turned off.
Start the engine and operate at high idle.
Check the speed of the alternator using a digital optical
tachometer. A slipping alternator drive belt can result in a
low output reading. The alternator output is directly related
to the speed it is turning.
Turn on the carbon-pile tester and adjust until the

ammeter reaches its highest reading. Record this value.
Turn off the carbon-pile tester and shut off the engine.
If reading on the ammeter is zero (no output), magnetize
the rotor with the alternator hooked up normally.
Momentarily connect a jumper lead from the battery
positive (+) to the alternator relay (R) or indicator (I)
terminal.
This procedure applies to both negative (-) and positive
(+) ground systems, and will restore the normal residual
magnetism.
Repeat the test. If the output is still zero, replace the
alternator.
If the alternator output is not within 10 percent of the rated
output (stamped on the alternator case), replace the
alternator.
Preparatory Steps
WARNING
cable last.
• Remove the battery cables.
• Remove the electrical connection from alternator.
Procedure 008-002.
WARNING
cable last.
• Disconnect the battery cables.
• Disconnect the electrical connections from the
alternator.
013-005.
Signature™, ISX, and QSX15 Eng [...] Alternator
Remove
Remove the four alternator mounting capscrews.
Remove the alternator from the alternator spacers.

Loosen the alternator support link capscrews.
Remove the support link capscrew from the alternator.
Remove alternator to alternator support capscrews, nut,

washer, and alternator.

Inspect the alternator pulley for cracks or broken grooves.
Replace if pulley is damaged.
Install
Install the alternator and the four mounting capscrews.
No alignment is required for the alternator to the alternator
bracket.

Install the alternator, capscrew, washer, and nut to the
alternator mounting bracket. Tighten the nut.
Install the adjusting link and mounting capscrews. Tighten
the capscrews.
Finishing Steps
WARNING
cable last.
008-002.
• Install the electrical connection to alternator.
• Install the battery cables.
WARNING
cable last.
013-005.
• Install the electrical connections to the alternator.
• Connect the battery cables.
Signature™, ISX, and QSX15 Eng [...] Drive Belt, Alternator
Drive Belt, Alternator (013-005)

Remove
Using a 1/2-inch drive ratchet and extension, force the belt
tensioner away from belt and remove the belt.
Inspect for Reuse

Inspect the belt for cracks, glazing, tears, or cuts. Replace
the belt if damage is found.
Install
Using a 1/2-inch drive ratchet and extension, force the belt
tensioner down, install belt, and release tensioner.
Check belt for proper fit into pulley grooves.
Alternator Pulley Signature™, ISX, and QSX15 Eng [...]
Adjust
Belt drive systems equipped with an automatic belt
tensioner can not be adjusted. A belt tension gauge will
not give an accurate measure of the belt tension. The
automatic belt tensioner is designed to maintain proper
belt tension over the life of the belt. Only inspection of the
tensioner is required.
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when the belt
length and geometry are correct.
If the tensioner is hitting either of the limits during
operation, check the mounting brackets and the belt
length. Loose brackets, bracket failure, alternator
movement, incorrect belt length, or belt failure can cause
the tensioner to hit the limits.
Alternator Pulley (013-006)

Remove
Remove the alternator belt. Refer to Procedure 013-005.
Remove the alternator pulley. Use a strap wrench to hold

the alternator pulley.
Use a ratchet or impact wrench to loosen the nut securing
the pulley to the shaft.
Remove the nut and pulley.
Signature™, ISX, and QSX15 Eng [...] Alternator Pulley
Clean
WARNING
Clean the pulley with solvent.
Inspect for Reuse

Inspect the pulley for cracks and damaged grooves or
keyways. Replace the pulley if damage is found.
Install
Install key into shaft keyway (if equipped).
Install the alternator pulley with the shoulder of the pulley
towards the alternator.
Lubricate the threads with engine oil and install the nut.
Torque locking nut, hold the shaft with an allen wrench, if
necessary.
Install alternator belt. Refer to Procedure 013-005.

Batteries Signature™, ISX, and QSX15 Eng [...]
Batteries (013-007)
Initial Check
If conventional batteries (not maintenance-free batteries)
are used, check the electrolyte level in each cell. If it is
low, add distilled water to bring the level up to the top of
all plates. Refer to the battery manufacturer's
specifications.
NOTE: If water is added to the battery, the battery must
be charged before any testing can be accomplished.
With conventional batteries, check the electrolyte specific
gravity with a hydrometer. To check the specific gravity,
the battery temperature will be 26.67°C [80°F]. All cells
will not be less than 1.230. The difference between high
and low readings will not exceed 0.050. If the readings
indicate a difference of more than 0.050, replace the
battery. If the readings indicate less than 0.050 difference
but one or more cells indicate less than 1.230, recharge
the battery.
Battery Specific Gravity at 26.67°C [80°F]

Specific Gravity State of Charge
1.260 to 1.280 100 percent
1.230 to 1.250 75 percent
1.200 to 1.220 50 percent
1.170 to 1.190 25 percent
1.100 to 1.130 Discharged
Check the “eye” on the maintenance-free battery. Refer to

the manufacturer's specifications.
NOTE: For conventional batteries, remove the vent caps

prior to removing surface charge. If a blue haze is
observed in any cell while removing the surface charge,
replace the battery. After the surface charge has been
removed, install all vent caps.
Remove the surface charge by attaching the battery to a
300-amp load for 15 seconds for heavy-duty batteries.
Signature™, ISX, and QSX15 Eng [...] Battery Cables and Connections
Remove the load and wait 1 minute; if the battery voltage

is greater than or equal to 12.4 VDC, continue testing. If
the voltage is below 12.4 VDC, recharge or replace the
battery.
Load-test the batteries at 1/2 of the cold cranking amp

rating of the battery (rating at -18°C [0°F]) for 15 seconds.
Check the battery voltage and compare to the table below:
Temperature and Voltage Relationship

Temp (F) 70 60 50 40 30 20 10 0
Temp (C) 21 16 10 4 -1 -7 -12 -18
Minimum 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
Voltage (VDC)
Turn the load off.

Replace the battery if it does not meet the above
specifications.
Battery Cables and Connections

(013-009)
Initial Check
There are two possible heavy-duty battery connections:
• Battery terminal and clamp (1)
• Threaded battery terminal and nut (2).
Starter Magnetic Switch Signature™, ISX, and QSX15 Eng [...]
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
Remove and inspect the battery cables and connections
for cracks or corrosion.
Replace broken terminals, connectors, or cables.
If the connections are corroded, use a battery brush or

wire brush to clean the connections until shiny.
Make sure all debris is removed from the connecting
surfaces.
WARNING
Install the cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.
Starter Magnetic Switch (013-017)

Current Check
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of the digital multimeter, Part Number
3377161, to the two large switch terminals.
Signature™, ISX, and QSX15 Eng [...] Starter Magnetic Switch
Set the multimeter to measure resistance (ohms).

With the starter switch off, the multimeter must indicate
resistance at infinity (open circuit).
Turn the starter switch to the START position.
The multimeter must indicate zero resistance (closed
circuit).
If the multimeter indicates resistance at infinity with the

starter switch in the START position:
• Turn the starter switch off.
• Remove the ground wire connected to one of the
small magnetic switch terminals.
• Set the multimeter scale to indicate volts, 24 VDC or

more.
• Connect the positive lead of the multimeter to the
magnetic switch ground terminal and the other lead
to the ground wire.
• Turn the starter switch to the START position.
• The multimeter must indicate vehicle electrical
system voltage.
• If the multimeter does not indicate voltage, refer to

Procedure 013-018.
Starter Switch Signature™, ISX, and QSX15 Eng [...]
• Turn the starter switch to the OFF position.

• Remove the multimeter leads.
• Connect the starter solenoid cable to the magnetic
switch terminal and the ground wire to its
corresponding terminal on the magnetic switch.
Starter Switch (013-018)

Voltage Check
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive lead of digital multimeter, Part
Number 3377161, to the starter switch terminal and the
negative lead to the chassis or an engine ground location.
• Set the multimeter to indicate DC volts.

With the starter switch in the OFF position, there must
not be a voltage reading. If the meter indicates voltage,
the starter switch is malfunctioning and must be replaced.
Turn the starter switch to the START position.

The multimeter must indicate voltage in order for this
check to be normal.
Signature™, ISX, and QSX15 Eng [...] Starter Solenoid
If there is not voltage:

• Turn the starter switch to the OFF position.
• Check the cable from the positive (+) voltage
terminal of the starter solenoid to the starter switch
for breaks.
• Check for loose or corroded connections.
If the cable is good and the connections are clean and

tight, the starter switch is malfunctioning and must be
replaced.
Starter Solenoid (013-019)

Voltage Check
Use digital multimeter, Part No. 3377161, with the switch
set to indicate DC volts.
Connect the multimeter positive (+) lead to the starter
solenoid positive (+) cable terminal and the negative (• )
lead to a chassis or engine ground location.
The multimeter must show voltage with the starter switch
off to be normal.
If the multimeter does not indicate voltage, check the

cable connecting the starter solenoid and battery for
breaks. Also, check for loose or corroded connections.
Starter Solenoid Signature™, ISX, and QSX15 Eng [...]
If the multimeter indicates voltage but the starter will not

operate, check the wire connecting the starter solenoid to
the starter switch for breaks, and also check for loose or
corroded connections.
If the wire connecting the starter solenoid and starter

switch is not loose or damaged and the starter will not
operate:
• Remove the cable connecting the starter and starter
solenoid from the solenoid terminal.
• Connect the multimeter positive (+) lead to the
solenoid positive (+) terminal and the negative (• )
lead to the chassis or an engine ground location.
• Turn the starter switch to the START position.

• If the multimeter indicates voltage, the starter
solenoid is malfunctioning and must be replaced.
If the multimeter does not indicate voltage, check the wire

connecting the starter solenoid to the magnetic switch for
breaks and loose or corroded connections.
Signature™, ISX, and QSX15 Eng [...] Starting Motor
If the wire connecting the starter solenoid to the magnetic

switch is not loose or damaged and the starter will not
operate:
• Check the cable connecting the starter solenoid to
the starting motor for breaks and loose or corroded
connections.
• Check the cable connecting the starting motor to the

battery for breaks and loose or corroded
connections.
If the cables are not loose or damaged, the starting motor

is defective and must be replaced.

Preparatory Steps
All Applications
WARNING
cable last.
• Remove the electrical connections from the
batteries.
• Remove the electrical connections from the starting
motor.
Starting Motor Signature™, ISX, and QSX15 Eng [...]
Remove
Remove the three capscrews, starting motor, and starting
motor spacer (if used).

Remove the three mounting capscrews, starting motor,
and starting motor spacer (if used), as well as the
necessary starting motor brackets.
Install
CAUTION
Install the starting motor, spacer (if applicable) and the
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
(Aluminum
Flywheel
Housing)
(Cast Iron
Flywheel
Housing)
Signature™, ISX, and QSX15 Eng [...] Starting Motor
CAUTION
Install the starting motor, spacer (if applicable), and the
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
Assemble the upper bracket (1) to the block mounting stud

and to the starter motor end bracket. Tighten capscrews
and nuts finger tight.
Assemble the lower bracket (2) to the oil pan rail mounting
stud and to the starter motor end bracket.
Tighten the capscrews and nuts finger tight.
Tighten all capscrews and nuts.
Tighten all capscrews and nuts in the following sequence:

Torque Value:
(1) 45 N•m [ 33 ft-lb ]
(2) and (3) 23 N•m [ 17 ft-lb ]
(4) and (5) 41 N•m [ 30 ft-lb ]
Finishing Steps
All Applications
WARNING
cable last.
• Install the electrical connections to the starting
motor.
• Install the electrical connections to the batteries.
Belt Tensioner, Automatic (Alternator) Signature™, ISX, and QSX15 Eng [...]
Belt Tensioner, Automatic (Alternator)

(013-021)
Remove
NOTE: The belt tensioner is spring-loaded and must be
pivoted away from the drive belt. Pivoting in the wrong
direction can result in damage to the belt tensioner.
All accessory belt routings are not depicted. Tensioner
and tensioner bracket locations are representative.
Remove the capscrew and belt tensioner from the bracket.
Clean
WARNING
cleaned.
Inspect for Reuse

With the engine turned off and the alternator belt installed,
verify that neither the top nor bottom tensioner arm stop
is touching the cast boss on the tensioner body. If either
of the stops is touching a boss, the alternator belt must
be replaced. Check to make sure the correct belt part
number is being used if either condition exists.
Signature™, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Alternator)
Check the tensioner pulley and body for cracks. If any

cracks are noticed, the tensioner must be replaced.
cleaned.
Check that the bottom tensioner arm stop is in contact with

the bottom tensioner arm stop boss on the tensioner body.
If these two are not contacting, the tensioner must be
replaced.
Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular base. If
there is evidence of these two areas contacting, the pivot
tube bushing has failed and the tensioner must be
replaced.
Install
Install the tensioner and capscrew.
Alternator Spacer Signature™, ISX, and QSX15 Eng [...]
Using a 1/2-inch square drive, lift and hold the tensioner.

Alternator Spacer (013-036)

Preparatory Steps
Remove the following:
• Cooling fan drive belt. Refer to Procedure 008-002.
• Alternator. Refer to Procedure 013-001.
Remove
Remove the two alternator spacer mounting capscrews.
Remove the alternator spacers.
Signature™, ISX, and QSX15 Eng [...] Alternator Spacer
WARNING
WARNING
WARNING
personal injury.
Clean the alternator spacers with solvents.
Inspect the alternator spacers for cracks. Replace the

spacers if cracks are found.
have any damage. Replace the alternators spacers if the
roll pins are loose or damaged.
Install
NOTE: No special alignment process is required for
alternator spacers to the alternator/refrigerant
Install the alternator spacers with roll pins and two
capscrews.
Alternator Idler Pulley Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
Install the following:
• Alternator. Refer to Procedure 013-001.
• Cooling fan drive belt. Refer to Procedure 008-002.
Alternator Idler Pulley (013-039)

Remove
Remove the mounting capscrew and idler pulley.
Clean
WARNING
WARNING
personal injury.
Clean the pulley with solvent and dry with compressed air.
Signature™, ISX, and QSX15 Eng [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Inspect for Reuse

Inspect the idler pulley for belt groove damage. The pulley
should rotate freely.
Replace the pulley if damage is found.
Install
Install the idler pulley and mounting capscrew.
Install the alternator belt. Refer to Procedure 013-005.
Bracket, Idler Pulley and Alternator

Belt Tensioner (013-040)
Preparatory Steps
Remove the alternator belt tensioner. Procedure 013-021.
Remove the alternator belt idler pulley. Refer to Procedure
013-039.
Bracket, Idler Pulley and Alternator Belt Tensioner Signature™, ISX, and QSX15 Eng [...]

Remove the alternator belt tensioner. Refer to Procedure
013-021.
Remove the alternator belt idler pulley. Refer to Procedure
013-039.
Remove
Remove the tensioner and idler mounting bracket.

Remove the tensioner and idler mounting bracket.
Remove the spacer.
Clean
WARNING
WARNING
personal injury.
Clean the parts with solvent.
Signature™, ISX, and QSX15 Eng [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Inspect for Reuse

Inspect the bracket and spacer for cracks. Replace if
damaged.
Install
Install the mounting bracket.
Install the alternator belt pulley. Refer to Procedure

013-039.
Install the alternator belt tensioner. Refer to Procedure
013-021.

Install the spacer.
Install the mounting bracket.
Bracket, Idler Pulley and Alternator Belt Tensioner Signature™, ISX, and QSX15 Eng [...]
Install the alternator belt idler pulley. Refer to Procedure

013-039.
013-021.
Finishing Steps
Install the alternator belt pulley. Refer to Procedure
013-039.
013-021.

Install the alternator belt idler pulley. Refer to Procedure
013-039.
013-021.
Section 14 - Engine Testing - Group 14 Page 14-a
Section 14 - Engine Testing - Group 14

Section Contents
Page
Aftertreatment Testing ..................................................................................................................................14-42
Finishing Steps............................................................................................................................................. 14-48
Setup............................................................................................................................................................14-46
Test...............................................................................................................................................................14-46
Crankcase Blowby, Measure .........................................................................................................................14-30
Initial Check..................................................................................................................................................14-34
Measure........................................................................................................................................................14-35
Dynamometer Worksheet ................................................................................................................................14-4
Worksheet.......................................................................................................................................................14-4
Engine Run-in (Chassis Dynamometer) ........................................................................................................14-12
Run-In Instructions........................................................................................................................................14-12
Engine Run-in (Engine Dynamometer) ..........................................................................................................14-25
Engine Run-in (Without Dynamometer) ........................................................................................................14-16
Engine Testing (Chassis Dynamometer) ........................................................................................................14-6
Setup..............................................................................................................................................................14-6
Test................................................................................................................................................................14-9
Engine Testing (Engine Dynamometer) ........................................................................................................14-17
Setup............................................................................................................................................................14-17
Test...............................................................................................................................................................14-22
Engine Testing (In Chassis) ..........................................................................................................................14-29
Setup............................................................................................................................................................14-29
Engine Testing (Portable Dynamometer or Load Bank) ...............................................................................14-29
Service Tools ...................................................................................................................................................14-1
Engine Testing................................................................................................................................................14-1
Page 14-b Section 14 - Engine Testing - Group 14

Section 14 - Engine Testing - Group 14 Page 14-1
Service Tools
Engine Testing
Repair Location.

Manometer
Use for measuring blowby and intake air restriction
ST-1111-3
Engine Lifting Fixture

Use to lift the engine.
3162871
Datalink Adapter Kit — Inline II

Inline adapter and associated cables are used to connect a computer
3163682 to an engine datalink.
Engine Controller
Use to test engine separate from the chassis system.
3163890
Harness Extension
Extends engine controller harness, Part Number 3164242, 20 ft.
3163895
Benchtop Calibration Cable

Use with parent cable, Part Number 3163151, power adapter, Part
3164185 Number 3824102, and the Inline II adapter, Part Number 3163095.
Page 14-2 Section 14 - Engine Testing - Group 14

ISX/ISM Engine Controller Harness (10ft)
Use to connect the engine controller, Part Number 3163890, to a
3164242 CM870 ECM.
Fuel Measuring Device

Use to measure the rate of fuel consumption of a Cummins diesel
3376375 engine.
Digital Multimeter
Use to measure pressures, vacuums, and temperatures.
3377161
Blow-by Tool (0.354 orifice)

Used with manometer, Part Number ST-1111-3, to check engine
3822567 crankcase blow-by.
Pressure Gauge (0 to 60 psi)

Use to measure coolant pressure.
3822995
Dyno-Room Charge Air Cooler

Use to cool intake air when an air to air engine is used on an engine
3823978 dyno.
Thermocouple Module
This module converts the digital multimeter into a thermometer via
3824963 standard banana plugs.
Temperature Immersion Probe
3824965

INSITE™ Software Kit
This kit contains INSITE™ software for use with Cummins engines.
3886388 The kits are used to troubleshoot, program, and adjust electronic
features.
Dynamometer Worksheet Signature™, ISX, and QSX15 Eng [...]
Dynamometer Worksheet (014-001)

Worksheet
With EGR
Date: Repair Oder Number: Operator:
ESN: CPL: ECM Code:
Complaint:
Parameter Code Specifications Actual Reading
Intake Air Restriction (in H2O)1, 2
Exhaust Restriction (in Hg)1, 2
Fuel Inlet Restriction (in Hg)1, 2
Fuel Drain Line Restriction (in Hg)1, 2
Engine Blowby (in H2O)1, 2
1 Record at advertised horsepower rpm and full load
2 Reference Specifications - Engine Testing
Engine Set Up for Dyno with INSITE™ Electronic Service Tool? (Circle One) Yes No
Road Speed Limit
Check Oil Level Low High OK Fuel Quality OK Not OK
(Circle One) (Circle One)
Engine Horsep EGR Turboch Fuel Rail Fuel Intake Intake Coolant Coolant Engine
Speed ower Valve arger Rate Fuel
Temper Manifol Manifol Temper Pressur Oil
or Position Control (lb/hr)1 Pressur ature d d ature e Pressur
Torque Valve e Air Pressur (psi) e
(psi) e
Comma Temper (psi)
nd ature (in Hg)
1 Be sure that the fuel rate is corrected for temperature, see table below.
Fuel Temperature Correction for Flow Rate
Less than 7°C [45°F] Flow meter is not accurate
7 to 13°C [45 to 55° F] Subtract 2 percent from flow rate reading
13 to 20°C [55 to 68°F] Subtract 1 percent from flow rate reading
20 to 29°C [68 to 85°F] No Correction
29 to 42°C [85 to 108°F] Add 1 percent to flow rate reading
56°C [132°F] above Flowmeter not accurate
Signature™, ISX, and QSX15 Eng [...] Dynamometer Worksheet
Pressure Conversions
1 in H20 = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H20 = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H20
NOTE: This Page Can Be Copied for Your Convenience.

Without EGR
Date: Repair Oder Number: Operator:
ESN: CPL: ECM Code:
Complaint:
Parameter Code Specifications Actual Reading

Intake Air Restriction (in H2O)1, 2
Exhaust Restriction (in Hg)1, 2
Fuel Inlet Restriction (in Hg)1, 2
Fuel Drain Line Restriction (in Hg)1, 2
Engine Blowby (in H2O)1, 2
1 Record at advertised horsepower rpm and full load
2 Reference Specifications - Engine Testing
Engine Set Up for Dyno with INSITE™ Electronic Service Tool? (Circle One) Yes No
Road Speed Limit:
Check Oil Level Low High OK Fuel Quality OK Not OK
(Circle One) (Circle One)
Engine Horsepowe Fuel Fuel Intake Intake Coolant Coolant Engine
r
Speed Rate Temperat Manifold Manifold Temperat Pressure Oil
or ure ure
(lb/hr)1 Air Pressure (psi) Pressure
Torque Temperat (in Hg) (psi)
ure
1 Be sure that the fuel rate is corrected for temperature, see table below.
Fuel Temperature Correction for Flow Rate
Less than 7°C [45°F] Flow meter is not accurate
7 to 13°C [45 to 55° F] Subtract 2 percent from flow rate reading
13 to 20°C [55 to 68°F] Subtract 1 percent from flow rate reading
20 to 29°C [68 to 85°F] No Correction
56°C [132°F] above Flowmeter not accurate
Engine Testing (Chassis Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Pressure Conversions
1 in H20 = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H20 = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H20
NOTE: This Page Can Be Copied for Your Convenience.
Engine Testing (Chassis

Dynamometer) (014-002)
Setup
The performance of an engine installed in “on-highway”
vehicles can be tested on a chassis dynamometer.
NOTE: Due to driveline inefficiencies and engine-driven
accessories, the rated horsepower will be reduced by
approximately:
• 20 percent for single-axle vehicles
• 25 percent for tandem-axle vehicles.
The net horsepower available is called wheel horsepower.
NOTE: These percentages are used for engine run-in
only and are not to be used as absolute figures.
WARNING
Before installing or operating a vehicle on a chassis
dynamometer, follow all the vehicle manufacturer's
safety precautions.
CAUTION
Low-profile radial tires are more sensitive to heat than
bias ply tires. Excessive operating time at full load can
damage tires due to overheating. Check the tire
manufacturers's recommendations for the maximum
allowable chassis dynamometer operating time.
Signature™, ISX, and QSX15 Eng [...] Engine Testing (Chassis Dynamometer)
The following are general safety precautions to be

observed while operating the chassis dynamometer.
• Use tires that have more than 160 km [100 mi] on them.
Do not use new tires.
• Do not use recapped tires or tires of different sizes or
designs.
• Make sure the tires are inflated to the manufacturer's

specifications.
• Remove all rocks or other material from the treads of
all tires that will be rotating on the dynamometer
rollers.
• Make sure there is correct overhead clearance for

exhaust stacks, air deflectors, or other attachments
above the cab.
CAUTION
The “tie-down” chains must have slack to prevent
damage to the chassis dynamometer.
• Carefully position the vehicle on the rollers.
• Attach the “tie-down” chains to the rear of the vehicle,
and put wheel chocks in front of the front wheels.
• Adjust the vehicle and dynamometer room exhaust

system to make sure all exhaust gases are removed
from the room.
• Reference the chassis dynamometer and vehicle
manufacturer's recommendations and specifications
for testing procedures.
Check the engine coolant level to be sure it is filled to the

proper level.
WARNING
Check the coolant level only when the engine is
stopped. Wait until the coolant temperature is below
50°C [120°F] before removing the pressure cap.
Failure to do so can cause personal injury from heated
coolant spray.
CAUTION
Check the engine lubricating oil level to be sure it is filled

to the proper level.
NOTE: Use a known source of good quality Number 2

diesel fuel. Number 1 diesel fuels, along with most other
alternate fuels, are lighter (lower specific gravity, higher
API gravity) than Number 2 diesel fuel. The lighter the fuel,
the lower the energy content (BTU) per gallon (liter).
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE™ electronic
service tool to make as many checks as possible.
• Engine speed (rpm)
• Fuel rate
• Intake manifold air temperature
• Engine blowby
• Engine coolant pressure
• Engine coolant temperature
• Rail fuel pressure. Use the following reference for ISM
applications. Refer to Procedure 005-016 in Section 5.
Use the following reference for ISX applications. Refer
• Engine fuel temperature (if needed to correct fuel rate).
• Fuel inlet restriction. Use the following reference for
ISM applications. Refer to Procedure 006-020 in
Section 6. Use the following reference for ISX
• Fuel drain line restriction. Use the following reference
for ISM applications. Refer to Procedure 006-012 in
• Intake manifold pressure. Use the following reference
applications. Refer to Procedure 010-024 in Section
10.
• Intake air restriction. Use the following reference for
10.
• Exhaust restriction. Use the following reference for
11.
• Engine oil pressure. Use the following reference for
Engine Speed (rpm)

Use INSITE™ electronic service tool to monitor engine
speed.
Observe and record the engine speed.
Fuel Rate
Reference the Fuel Flow Measurement on Engine or
Chassis Dynamometer in this section.
NOTE: Adjust the fuel rate reading to compensate for
temperature variation, if required.
Fuel Inlet Temperature

°C °F
7.2 MIN 45
55.5 MAX 132
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
When operating an engine on a chassis dynamometer,
lock the cooling fan in the ON position for best results.
If the unit does not have a manual fan switch, use
INSITE™ electronic service tool Set Up for Dynamometer
feature to lock the fan in the ON position. Refer to
Use INSITE™ electronic service tool to monitor the intake

manifold air temperature.
Observe and record the intake manifold air temperature.
The intake manifold air temperature must not exceed the
maximum allowable temperature. Reference the
Specifications - Engine Testing page in this section for the
maximum allowable intake manifold air temperature. The
engine protection system will disrupt performance if the
temperature exceeds this level. Maintain the intake
manifold air temperature below the maximum allowable
temperature during chassis dynamometer operation.
If the intake manifold air temperature exceeds the

maximum allowable temperature during the test, unload
the dynamometer and allow the engine to cool.
Shut the engine off and inspect the charge-air cooler fins
for obstructions to the airflow.
Check the fan drive. Make sure the fan is locked in the ON
position.
Remove any obstructions, such as a winterfront or debris.
Manually lock the shutters in the OPEN position, if
equipped.
Inspect the dynamometer room for an adequate supply of
suitably cool or outside air. Make sure that dynamometer
room air recirculation is not an issue.
Engine Blowby
Use blowby checking tool, Part Number 3822566 (ISM) or
Part Number 3822567 (ISX), and water manometer, Part
Number ST-1111-3, to measure the engine crankcase
pressure.
Install the blowby checking tool to the end of the blowby

tube. Install the water manometer to the blowby checking
tool. Operate the engine at advertised horsepower rpm at
full load. Observe and record the blowby.
Engine blowby must not exceed the maximum allowable
specifications. Refer to Procedure 014-010 in Section 14.
Engine Coolant Pressure

Use pressure gauge, Part Number 3822995, to measure
engine coolant pressure.
Observe and record engine coolant pressure.
Reference the Specifications - Engine Testing page in this
section for the maximum allowable coolant temperature.
Engine Run-in (Chassis Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Engine Coolant Temperature

coolant temperature.
Observe and record the engine coolant temperature.
Reference the Specifications - Engine Testing page in this
If the coolant temperature exceeds the maximum

allowable coolant temperature, unload the dynamometer
and allow the engine to cool.
Shut the engine off and inspect the radiator fins for
obstructions to the airflow.
position.
equipped.
suitable cool or outside air. Make sure that dynamometer
Engine Fuel Temperature

Use immersion probe, Part Number 3824965, with a
digital multimeter, Part Number 3377161, and a
thermocouple module, Part Number 3824963, to monitor
fuel temperature.
Observe and record the engine fuel temperature.
Engine Run-in (Chassis Dynamometer)

(014-003)
Run-In Instructions
Use the following procedure for general operating
procedures and safety precautions. Refer to Procedure
Operate the vehicle in a gear that produces a road speed
of 90 to 100 Km/h [55 to 60 mph] at advertised horsepower
rpm.
Signature™, ISX, and QSX15 Eng [...] Engine Run-in (Chassis Dynamometer)
Use the Dynamometer Worksheet to record all of the

engine performance parameters. Refer to Procedure
014-001 in Section 14. Cummins Inc. recommends
monitoring block coolant pressure during run-in to aid in
early indication of a cooling system problem.
NOTE: INSITE™ electronic service tool must be used to

confirm that the ECM code on the ECM dataplate is the
same as the one installed in the ECM. There is an
associated fuel pump code with all ECM codes.
Use INSITE™ electronic service tool to obtain the ECM
code and the fuel pump code from the ECM dataplate.
During the test, if a sudden increase in blowby occurs or

if blowby exceeds the maximum allowable limit during any
run-in, return to the previous step of the test and continue
the run-in. If blowby does not reach an acceptable level
during the next step, discontinue the run-in and determine
the cause.
Do not proceed to the next step until a steady, acceptable
blowby reading is obtained.
NOTE: Blowby must be measured with the blowby
checking tool, Part Number 3822566 (ISM) or Part
Number 3822567 (ISX) and water manometer, Part
Number ST-1111-3.
Do not idle the engine for more than 5 minutes at any one
time during the first 160 km [100 mi] of operation.
Engine Run-in (Chassis Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Adjust the engine speed to 1200 rpm. Apply a test load

sufficient to develop 25 percent of advertised horsepower
of the engine.
Operate the engine at this speed and load level until the
coolant temperature reaches 70°C [160°F].
Check for leaks. Repair all leaks.
Check all gauges and record the data.
Do not proceed to the next step until the blowby becomes
stable and within specifications.
Open the throttle to obtain the engine speed at which

advertised horsepower is developed, and adjust the
dynamometer load to achieve 75 percent of advertised
horsepower on the engine.
Operate the engine at this speed and load level for 3
minutes.
Maintain the engine speed at which advertised

horsepower is developed. Move the throttle lever to its fully
opened position, and increase the dynamometer load until
100 percent advertised horsepower of the engine is
developed.
minutes.
Increase the dynamometer load until the engine speed

reduces to the engine's peak torque rpm.
minutes.
Signature™, ISX, and QSX15 Eng [...] Engine Run-in (Chassis Dynamometer)
Reduce the dynamometer load until the engine speed

increases to the engine speed at which advertised
horsepower is developed.
minutes.
Remove the dynamometer load completely and reduce

the engine rpm to idle.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of three to five
minutes to avoid internal damage. This allows the
turbocharger and other components to cool.

Engine Run-in (Without Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Make sure all instrumentation is removed before removing

the vehicle from the dynamometer.
Engine Run-in (Without Dynamometer)

(014-004)
Run-In Instructions
On-Highway Applications
WARNING
Refer to Engine Testing - General Information and
Specifications- Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the vehicle pulling the heaviest available trailer
allowed for the first 80 to 160 Km [50 to 100 mi] after
rebuild. Operate the vehicle in the highest gear possible
within the normal operating rpm range of the engine. It will
be necessary to operate the engine at or near full throttle
at 75 to 85 percent of maximum horsepower rpm indicated
on the dataplate.
time during the first 160 Km [100 mi] of operation.
Signature™, ISX, and QSX15 Eng [...] Engine Testing (Engine Dynamometer)
Off-Highway Applications
WARNING
Refer to Engine Testing - General Information and
Specifications- Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the engine under the highest load possible at full
throttle within the normal operating rpm range of the
engine for the first 3 hours of operation after rebuild.
time during the first 3 hours of operation after a rebuild.
Engine Testing (Engine Dynamometer)

(014-005)
Setup
NOTE: Make sure the dynamometer capacity is sufficient
to permit testing at 100 percent of the engine's rated
horsepower. If the capacity is not enough, the testing
procedure must be modified to the restrictions of the
dynamometer.
Use engine lifting fixture, Part Number 3162871, to install
the engine test stand. Align and connect the
dynamometer. Refer to the manufacturer's instructions for
aligning and testing the engine.
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs and close all of the water drain
cocks.
Engine Testing (Engine Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Intake Air Temperature Control

The use of a remote aftercooler is mandatory whenever a
Cummins® charge-air cooled engine is attached to an
engine dynamometer for the purpose of engine run-in,
performance testing, and/or engine diagnostics. Do not
attempt to run a Cummins® charge-air cooled engine
without a means of controlling the intake manifold air
temperature. Dynamometer-room charge-air cooler, Part
Number 3823978, utilizes twin Big Cam™ III aftercooler
assemblies arranged for parallel air and water flow to cool
the intake air to acceptable levels.
The parallel airflow circuit heat exchangers provide

optimum performance by delivering air to the mixer at
temperatures no higher than 66°C [151°F] and with less
than the maximum allowable intake air pressure drop. The
remote aftercooler removes energy from the intake air
compressed and heated by the turbocharger to
temperatures as high as 210°C [410°F] and then cooled
to temperatures of 66°C [151°F] using city water at 16°C
[61°F].
1 Water in
2 Aftercooler number 1 (2 pass)
3 Aftercooler number 2 (2 pass)
4 Water out
5 Condensate
6 From turbocharger
7 To intake manifold
8 Thermocouple (fluke).
Water from a city tap line flows to the aftercooler via a 25.4
mm [1-inch] inner diameter neoprene hose. Testing has
shown that 45.4 liter [12 gal] per minute city water flow is
required (22.7 liter [6 gal] per minute per aftercooler core)
to adequately cool the intake air for the 435 through 500
horsepower-rated engines. A typical garden hose is not
suitable for this flow, due to the excessive restriction. A
low-restriction ball-type or gate valve is suitable for the
operation, provided that the required flow rates are
achieved.
Water returns to the drain or reservoir from the
aftercoolers via a 25.4 mm [1-inch] inner diameter hose.
A low-restriction gate valve or ball valve must be placed
on the drain line(s) to regulate water flow through the
aftercoolers. This provides the ability to maintain optimum
intake air temperature during the test or run-in procedure.
The condensate that will develop as the intake air is
cooled in the remote aftercooler is allowed to drain at all
times through a hole at the bottom of the tubular steel
manifold between the aftercoolers. This fitting must
remain unobstructed throughout each use of the
aftercoolers.
NOTE: Some air will escape through the condensate drain
opening, but it is insignificant compared to the total
airflow.
1 Air in from turbocharger compressor outlet
2 Lifting eye
3 Air out to engine intake manifold
4 Water in to aftercooler
5 Water out to drain
6 Condensate drain.
The airflow piping requires a 101.6 mm [4 in] inner

diameter aluminum steel piping. The flow circuit must
have as few bends as possible, maximizing the length of
straight sections. However, when bends are required, use
long elbows. Do not use square elbows or anything that
changes the airflow direction quickly. To reduce intake air
restriction, airflow direction changes must occur
gradually.
Air Compressor
NOTE: All air compressors manufactured by Cummins
Inc. must operate during the engine run-in. During the
performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
665 kPa [96 psi] to the air compressor unloader (1). This
air line must contain a valve between the air source and
the unloader.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet
(2).
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345 to 517 kPa [50 to 75 psi] of air pressure
at both minimum and maximum engine rpm.
Install a steel tube or high temperature hose (1).
Hose Temperature
°C °F
235 MIN 500
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
WARNING
cable last.
Install the electrical wiring to the starting motor and
batteries, if used.
If another method of starting the engine is used, follow the
manufacturer's instructions to make the necessary
connections.
Engine Throttle Control

Engines operating on an engine dynamometer require the
engine harness be installed and connected to the engine.
Additionally, the engine controller harness, Part Number
3164242, and engine controller, Part Number 3163890,
must be used to properly control the engine during the
dynamometer run.
Connect the engine controller harness Deutsch™
connector to the ECM, OEM port.
Return parameters to their original value when the test or

run-in is complete.
Connect battery power to the starter.
WARNING
cable last.
Connect the dynamometer test OEM wiring harness
starter solenoid lead (yellow) to the starter solenoid.
Connect the ground lead (black) to the starter or battery
negative (-) or ground side. Connect the +12-VDC power
lead (red) to either the starter or battery positive (+12-
VDC) side.
Connect the keyswitch panel data link cable to the

Cummins® electronic service tool.
Use INSITE™ electronic service tool to set the engine up
the for dynamometer. Refer to Procedure 014-008 in
Section 14 for more information on this feature.
The setup is now complete, and the auto/manual throttle
can be used to control engine speed.
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE™ electronic
service tool to make as many checks as possible.
• Engine speed (RPM)
• Fuel rate
• Intake manifold air temperature
• Engine blowby
• Engine coolant pressure
• Engine coolant temperature
• Rail fuel pressure. Use the following reference for ISM
Use the following reference for ISX applications. Refer
• Engine fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction. Use the following reference for
• Fuel drain line restriction. Use the following reference
• Intake manifold pressure. Use the following reference
10.
• Intake air restriction. Use the following reference for
10.
• Exhaust restriction. Use the following reference for
11.
• Engine oil pressure. Use the following reference for
Engine Speed (rpm)

speed.
Observe and record the engine speed.
Fuel Rate
See the Fuel Flow Measurement on Engine or Chassis
Dynamometer in this section.
Adjust the fuel rate reading to compensate for
temperature variation if required.
Fuel Inlet Temperature

°C °F
7.2 MIN 45
55.5 MAX 132
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
When operating an engine on a chassis dynamometer,
lock the cooling fan in the ON position for best results.
If the unit does not have a manual fan switch, use INSITE™
electronic service tool/Set Up for Dynamometer feature to
lock the fan in the ON position. Refer to Procedure
Use INSITE™ electronic service tool to monitor the intake

manifold air temperature.
Observe and record the intake manifold air temperature.
The intake manifold air temperature must not exceed the
maximum allowable temperature. See the Specifications
- Engine Testing page in this section for the maximum
allowable intake manifold air temperature. The engine
protection system will disrupt performance if the
temperature exceeds this level. Maintain the intake
manifold air temperature below the maximum allowable
temperature during chassis dynamometer operation.
If the intake manifold air temperature exceeds the

maximum allowable temperature during the test, unload
the dynamometer and allow the engine to cool.
Shut the engine off and inspect the charge air cooler fins
for obstructions to the airflow.
position.
equipped.
suitably cool or outside air. Make sure that dynamometer
Engine Blowby
Use blowby checking tool, Part Number 3822566 (ISM) or
Part Number 3822567 (ISX), and water manometer, Part
Number ST-1111-3, to measure the engine crankcase
pressure.
Install the blowby checking tool to the end of the blowby

tube. Install the water manometer to the blowby checking
tool. Operate the engine at advertised horsepower rpm at
full load. Observe and record the blowby.
Engine blowby must not exceed the maximum allowable
specifications. Refer to Procedure 014-010 in Section 14.
Engine Coolant Pressure

Use pressure gauge, Part Number 3822995, to measure
engine coolant pressure.
Observe and record engine coolant pressure.
See the Specifications - Engine Testing page in this
section for the maximum allowable engine coolant
pressure.
Signature™, ISX, and QSX15 Eng [...] Engine Run-in (Engine Dynamometer)
Engine Coolant Temperature

coolant temperature.
Observe and record the engine coolant temperature.
See the Specifications - Engine Testing page in this
If the coolant temperature exceeds the maximum

allowable coolant temperature, unload the dynamometer
and allow the engine to cool.
Shut the engine off and inspect the radiator fins for
obstructions to the airflow.
position.
equipped.
suitable cool or outside air. Make sure that dynamometer
Engine Fuel Temperature

Use immersion probe, Part Number 3824965, with a
digital multimeter, Part Number 3377161, and a
thermocouple module, Part Number 3824963, to monitor
fuel temperature.
Observe and record the engine fuel temperature.
Engine Run-in (Engine Dynamometer)

(014-006)
Run-In Instructions
Follow the general operating procedures and safety
precautions when performing the engine run-in. Refer to
Engine Run-in (Engine Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Use the Dynamometer Worksheet to record all of the

engine performance parameters. Refer to Procedure
Cummins Inc. recommends monitoring block coolant
pressure during run-in to aid in early indication of a cooling
system problem.
NOTE: INSITE™ electronic service tool must be used to

confirm that the ECM code on the ECM dataplate is the
same as the one installed in the ECM. There is an
associated fuel pump code with all ECM codes.
Use INSITE™ electronic service tool to obtain the ECM
code and the fuel pump code from the ECM dataplate.
During the test, if a sudden increase in blowby occurs or

if blowby exceeds the maximum allowable limit during any
run-in, return to the previous step of the test and continue
the run-in. If blowby does not reach an acceptable level
during the next step, discontinue the run-in and determine
the cause.
Do not proceed to the next step until a steady, acceptable
blowby reading is obtained.
NOTE: Blowby must be measured by the blowby checking
tool, Part Number 3822566 (ISM) or Part Number 3822567
(ISX), and water manometer, Part Number ST-1111-3.
time during the first 3 hours or 160 km [100 mi] of
operation.
Signature™, ISX, and QSX15 Eng [...] Engine Run-in (Engine Dynamometer)
Adjust the engine speed to 1200 rpm. Apply a test load

sufficient to develop 25 percent of advertised horsepower
of the engine.
Operate the engine at this speed and load level until the
coolant temperature is 71°C [160°F].
Check for leaks. Fix all leaks.
stable within specifications.
Open the throttle to obtain the engine speed at which

advertised horsepower is developed, and adjust the
dynamometer load to achieve 75 percent of advertised
horsepower on the engine.
minutes.
Maintain the engine speed at which advertised

horsepower is developed. Move the throttle lever to its fully
opened position, and increase the dynamometer load until
100 percent advertised horsepower of the engine is
developed.
minutes.
Increase the dynamometer load until the engine speed

reduces to the engine's peak torque rpm.
minutes.
Engine Run-in (Engine Dynamometer) Signature™, ISX, and QSX15 Eng [...]
Reduce the dynamometer load until the engine speed

increases to the engine speed at which advertised
horsepower is developed.
minutes.
Remove the dynamometer load completely.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of 3 to 5 minutes
to avoid internal damage. This allows the
turbocharger and other components to cool.

Make sure all instrumentation is removed before removing
the engine from the engine dynamometer.
Signature™, ISX, and QSX15 Eng [...] Engine Testing (Portable Dynamometer or Load Bank)
Engine Testing (In Chassis) (014-008)

Setup
The Setup for Dynamometer function is used to prepare
the engine ECM for an advanced diagnostic test run on
the chassis dynamometer. For purposes of this test, the
maximum engine speed without Vehicle Speed Sensor
(VSS), the maximum vehicle speed in top gear, and the
maximum vehicle speed in lower gear are set to their
maximum values. The idle shutdown feature is disabled
and the fan is locked in the ON mode. All of these values
are automatically reset to their previous values when the
engine keyswitch is turned to the OFF position.
• Maximum Engine Speed without VSS: 2500 rpm for

testing purposes, this speed is temporarily set to the
maximum value allowed.
• Maximum Vehicle Speed in Top Gear: 120 mph for
• Maximum Vehicle Speed in Lower Gear: 120 mph for
• Gear-Down Protection: This feature is temporarily
disabled for testing purposes.
• Fan Clutch: On.
• Idle Shutdown: This feature is temporarily disabled
for testing purposes.
Some SAE J1939 electronic subsystems must be
disabled. The user has the ability to enable or disable the
SAE J1939 data link with the service tool.
Refer to the INSITE™ Help File for detailed setup for
dynamometer instructions.
Engine Testing (Portable

Dynamometer or Load Bank) (014-009)
General Information
When it is not possible to load an engine immediately after
rebuild or repair (for example, on-highway tractor that
must be “bobtailed” for delivery, a standby generator or
fire pump that can not be operated because of customer
restrictions, a fire truck that can not be loaded with the
water pump, etc.), the engine must be run in on a chassis
dynamometer, portable dynamometer, or load bank
following the recommendations outlined in the preceding
procedures.
Crankcase Blowby, Measure Signature™, ISX, and QSX15 Eng [...]
Crankcase Blowby, Measure (014-010)

General Information
Excessive crankcase blowby can indicate an engine or
engine related component malfunction that allows
combustion gasses or air to enter the crankcase. This
results in the buildup of higher than normal crankcase
pressure, which results in increased levels of blowby.
This procedure describes how to measure crankcase
blowby and how to determine which component is
malfunctioning.
Blowby is typically measured for the following situations:
• Verifying engine break-in after an engine rebuild
• Troubleshooting for excessive lubricating oil out of the
crankcase breather tube, commonly referred to as oil
carryover (for open crankcase ventilation systems)
• Troubleshooting oil in the air intake system (for closed
crankcase ventilation systems)
• Troubleshooting high crankcase pressure (for engines
equipped with a crankcase pressure sensor)
• Troubleshooting possible internal engine damage
(worn piston rings, valve stem seals or guides,
turbocharger, air compressor, etc.).
This procedure provides general guidelines for measuring
blowby relative to the above situations.
NOTE: Some illustrations in this procedure do not show
actual engine configurations. The procedure, however, is
the same.
Signature™, ISX, and QSX15 Eng [...] Crankcase Blowby, Measure
It is important to note that the terms blowby and carryover

(oil out of the breather tube) are commonly used
interchangeably.
When measuring blowby, and there is an excessive
amount of oil coming out of the breather tube, the quantity
of oil can affect the blowby measurement.
The blowby measurement is affected by the oil collecting
on the orifice of the blowby measurement service tool.
This reduces the size of the orifice, which results in higher
than actual blowby measurements.
If this occurs, it will be necessary to:
• Find a different location on the engine to measure
blowby (oil fill, oil fill cap, unused turbocharger drain
location, etc.)
• Clean any oil residue from the breather and dry
thoroughly before measuring blowby
• Determine if there is an issue causing the breather to
be flooded with oil, for example:
- Incorrect oil level
- Vehicle operation (excessive angularity, excessive
engine side to side movement)
- Internal engine components are deflecting oil toward
the breather cavity (piston cooling nozzles, accessory
oil drains, etc.)
• Determine if another breather option is available for the
engine being serviced.
The tools used to measure blowby are similar in design.

The difference between the tools is in the size of the
orifice. Different size orifices are available to more
accurately measure blowby and to accommodate the wide
variety of engine configurations and ratings. This is due to
the fact thatengine blowby is dependent on the volume of
intake airflow.
For example:
• If measuring blowby on two identically configured and
size engines, but the horsepower rating and rated
speed are different, the maximum blowby value
measured will be different.
The engine with the higher horsepower rating and rated
speed will have a higher volume of intake airflow, which
will result in higher blowby. This means that if the smaller
orifice blowby tool was used on the engine with a higher
horsepower rating and rated speed, the measurement can
exceed the limits of the pressure measuring tool.
Heavy Duty 15L Orifice Size
Blowby Tool Part Number
3822567 8.99 mm [0.354 in]
Heavy Duty 10.9 - 13L Orifice Size
Blowby Tool Part Number
3822566 7.67 mm [0.302 in]
To measure the crankcase blowby pressure, connect a
water manometer, Part Number ST1111-3 or equivalent,
pressure gauge or transducer to the blowby tool.
NOTE: Water manometer, Part Number ST1111-3, can
measure a maximum of 944 mm [36 in] of water.
The following chart shows the relationship of measured pressure to flow rate for a 8.99-mm [0.354-in] orifice.
Blowby Conversion Table with 8.99 mm [0.354 in] Orifice and Blowby
mm H2O [in H2O] Liter [cfm] per Minute
25.4 [1] 70 [1.766]
50.8 [2] 100 [3.531]
76.2 [3] 120 [4.238]
101.6 [4] 140 [4.944]
127 [5] 158 [5.580]
152.4 [6] 172 [6.074]
177.8 [7] 185 [6.533]
203.2 [8] 198 [6.992]
228.6 [9] 210 [7.416]
254 [10] 220 [7.769]
279.4 [11] 231 [8.158]
304.8 [12] 241 [8.511]
330.2 [13] 252 [8.899]
355.6 [14] 260 [9.182]
381 [15] 270 [9.535]
406.4 [16] 280 [9.888]
431.8 [17] 289 [10.206]
457.2 [18] 298 [10.524]
482.6 [19] 305 [10.771]
508 [20] 312 [11.018]
533.4 [21] 320 [11.301]
558.8 [22] 328 [11.583]
584.2 [23] 335 [11.830]
609.6 [24] 341 [12.042]
The following chart shows the relationship of measured pressure to flow rate for a 7.67-mm [0.302-in] orifice.
25.4 [1] 50 [1.766]
50.8 [2] 84 [2.966]
76.2 [3] 103 [3.637]
101.6 [4] 119 [4.202]
127 [5] 133 [4.697]
152.4 [6] 145 [5.121]
177.8 [7] 155 [5.474]
203.2 [8] 164 [5.792]
228.6 [9] 172 [6.074]
254 [10] 180 [6.357]
279.4 [11] 187 [6.604]
304.8 [12] 193 [6.816]
330.2 [13] 200 [7.063]
355.6 [14] 206 [7.275]
381 [15] 211 [7.451]
406.4 [16] 217 [7.663]
431.8 [17] 222 [7.840]
457.2 [18] 226 [7.981]
482.6 [19] 229 [8.087]
508 [20] 235 [8.299]
533.4 [21] 239 [8.440]
558.8 [22] 242 [8.546]
584.2 [23] 246 [8.687]
609.6 [24] 248 [8.758]
NOTE: If internal engine damage is suspected to be the
cause of the excessive blowby condition, other steps can
be taken to confirm this.
Measuring blowby must only be considered when
confirming engine break-in after a rebuild, or if another
symptom is present. These symptoms can include:
• Excessive carryover (oil out of the crankcase breather
tube)
• High crankcase pressure (for engines equipped with a
crankcase pressure sensor)
• Low power
• Oil consumption
• Exhaust smoke.
If no other symptom is present, blowby measurements
need not be taken.
If internal engine damage is suspected to be the cause of

the excessive blowby condition, other steps can be taken
to confirm this. The steps include:
• Confirm engine maintenance practices
• Cut the oil filter open and check for debris
• Take an oil sample and inspect for contamination. Use
the following procedure for ISM engines. Refer to
Procedure 007-044 in Section 7. Use the following
procedure for ISX engines. Refer to Procedure
Initial Check
NOTE: The location and type of crankcase breathers vary
by engine configuration (front gear train or rear gear train)
and/or engine application.
Prior to measuring blowby pressure, check the crankcase
breather tube for obstructions. Use the following
procedure for ISM engines. Refer to Procedure 003-002 in
Section 3. Use the following procedure for ISX engines.
If troubleshooting a complaint of excessive oil out of the
breather tube, it can be necessary to remove the breather
components to clean and remove any lubricating oil
buildup before performing any blowby measurements.
Check the engine oil level and, if necessary, proper

calibration of the dipstick. If the level is too high, it can
cause a higher than normal blowby pressure and/or
excessive carryover. Use the following procedure for ISM
engines. Refer to Procedure 007-009 in Section 7. Use the
following procedure for ISX engines. Refer to Procedure
Measure
Choose the appropriate blowby measurement service tool
to use for the engine being serviced.
Heavy Duty 15L Blowby Tool Part Orifice Size
Number
3822567 8.99 mm [0.354
in]
Heavy Duty 10.9 - 13L Blowby Tool Orifice Size
Part Number
3822566 7.67 mm [0.302
in]
To measure the crankcase blowby pressure, connect a

water manometer, Part Number ST1111-3, pressure
gauge, or transducer to the blowby measurement service
tool.
NOTE: The location of the crankcase breather tube can
vary by engine configuration and/or application.
Install the appropriate blowby service tool(s):
• For typical open crankcase breather/ventilation
systems, connect the appropriate blowby service tool
to the end of the crankcase breather tube. Connect a
water manometer pressure gauge or transducer to the
blowby service tool.
• For engines with closed crankcase ventilation systems
(without a crankcase ventilation filter), disconnect the
breather tube and plug the intake manifold or
turbocharger compressor housing port. Connect the
appropriate blowby service tool to the end of the
crankcase breather tube. Connect a water manometer
pressure gauge or transducer to the blowby service
tool.
Check the following for engine blowby contributon.

Operate the engine at rated speed and under load by
either:
• For engine run-in, a chassis dynamometer or engine
dynamometer.
• For engine testing, a chassis dynamometer or engine
dynamometer.
• A stall speed test (for engines equipped with automatic
transmissions only).
CAUTION
When measuring blowby and there is an excessive
amount of oil coming out of the breather tube, the
quantity of oil can affect the blowby measurement.
For specific instructions for the appropriate engine test,
reference the appropriate procedure number listed below.
Operate the engine at rated rpm and full load until a steady
reading is obtained.
NOTE: When measuring blowby, the value can “spike”
initially as the engine reaches peak power and rated
speed. Wait for the blowby measurement to stabilize
before taking a reading.
NOTE: For engine run-in, if a sudden increase in blowby
occurs, or if blowby exceeds the maximum allowable limit
during any run-in step, return to the previous step and
continue the run-in. If blowby does not reach an
acceptable level, discontinue the run-in and determine the
cause.
Record the steady blowby measurement.
Remove the engine blowby service tool and water
manometer or pressure gauge, if the blowby is within
specification.
Check the following for turbocharger blowby contribution.

With the engine blowby service tool and water manometer
or pressure gauge still installed:
• Isolate the turbocharger, if equipped, to determine if
the high blowby pressure is due to turbocharger seal
leakage
• To measure the turbocharger blowby contribution,
disconnect the turbocharger oil drain line. For ISM
engines, use the following procedure. Refer to
Procedure 010-045 in Section 10. For ISX engines, use
the following procedure. Refer to Procedure 010-045
in Section 10.
This describes the preferred turbocharger isolation

method.
Install a hose assembly with two shutoff valves (A and B),
installed as shown in the illustration, between the
turbocharger and turbocharger drain line location in the
cylinder block. The valves must have a minimum inside
diameter of 19 mm [0.75 in]. Place the other hose in a 8
to 9 liter [2 to 5 gal] container.
NOTE: Some turbocharger oil drain tubes are a single one
piece tube. It can be necessary to create a turbocharger
isolation tool. Use a new or used turbocharger drain line
and cut a middle section out of the turbocharger drain line
to fit the check valves and hoses.
Close the valve (A) that allows oil to drain into the bucket.
Open the valve (B) that allows oil to drain into the engine.

either of the following:
dynamometer
WARNING
To reduce the possibility of personal injury, keep
hands, long hair, jewelry, and loose fitting or torn
clothing away from fans and other moving parts.
WARNING
Troubleshooting presents the risk of equipment
damage, personal injury, or death. Troubleshooting
must be performed by trained, experienced
technicians.
CAUTION
Do not operate the engine with valve (A) open and
valve (B) closed for more than 1 minute. Monitor the
amount of oil accumulating in the bucket. The engine
can run out of lubricating engine oil and severe engine
damage will occur.
Continue operating at rated speed and load.
Open valve (A) and close valve (B).
Record the blowby pressure reading.
CAUTION
Do not operate the engine for more than 1 minute.
Monitor the amount of oil accumulating in the
container. The engine can be run out of lubricating
engine oil and severe engine damage will result.
These steps describe the alternate turbocharger isolation
method:
With the turbocharger oil drain line disconnected from the
cylinder block, run the turbocharger drain line into a large
container.
Plug the turbocharger oil drain port in the cylinder block.
either:
dynamometer
Record the peak blowby pressure measurement.
Determine the turbocharger blowby pressure contribution

by determining the difference in the blowby pressure
measurement with the turbocharger drain isolated, valve
(A) open, and turbocharger drain not isolated, valve (A)
closed.
Blowby Pressure Differential
Turbocharger Blowby Maximum: 30 percent
Contribution
If the turbocharger blowby contribution is out of
specification, inspect the compressor and turbine areas of
the turbocharger for signs of an oil leak. Replace the
turbocharger, if necessary. For ISM engines, use the
following procedure. Refer to Procedure 010-033 in
Section 10. For ISX engines, use the following procedure.
NOTE: The air compressor governor/unloader location

can vary on each engine application. The air governor/
unloader can be air compressor mounted or chassis
mounted.
Disconnect the air signal line from the air compressor
governor/unloader air signal port.
Disconnect the air compressor discharge line and air
intake hose from the air compressor.
NOTE: On turbocharged air compressors, make sure to
plug the air intake hose going to the engine intake
manifold or the engine will not reach full power during test.
To unload the air compressor, determine the pressure

needed at the governor/unloader air signal port to start
and stop the air compressor from pumping.
NOTE: Typically, 621 kPa [90 psi] of air pressure is the set
point between starting and stopping of the air compressor
pumping. Refer to the OEM service manual.
Connect a regulated shop air pressure line, with pressure
gauge, to the air compressor governor/unloader air signal
port.
NOTE: When performing the test, make sure that the air
system pressure does not exceed the manufacturer's
maximum allowable pressure.
Run the engine and increase the signal pressure to the air
governor/unloader to determine when the air compressor
will stop pumping (system pressure stops rising at this
point). Record the signal line pressure.
Reduce the signal pressure to determine when system
pressure starts the air compressor pumping again (system
pressure will begin to rise again at this point). Record the
signal line pressure.
NOTE: Allow the air compressor to pump long enough to
build enough pressure in the system to release and
operate the air brakes.
With the regulated shop air pressure line still connected

to the air compressor governor/unloader air signal port,
regulate the signal pressure so that the air compressor
starts pumping (system pressure will begin to rise again
at this point). Use the pressure value recorded previously
as a set point.
either:
dynamometer
Continue operating the engine at rated speed and load.

Increase the signal pressure (system pressure stops rising
at this point). Use the pressure value recorded previously
as a set point.
Determine the air compressor blowby pressure

contribution by determining the difference in the blowby
pressure measurement with the air compressor pumping
and the air compressor not pumping.
Blowby Pressure Differential
Air Compressor Maximum: 30 percent
Contribution
If the air compressor blowby contribution is out of
specification, replace the air compressor. Refer to
WARNING
personal injury.
With the engine shut off, bleed the vehicle's air system
down by opening the draincock on the wet tank to release
compressed air from the system.
Disconnect the regulated shop air pressure line, with

pressure gauge, from the air compressor governor/
unloader air signal port.
Connect the air signal line. Refer to the OEM service
manual.
manometer or pressure gauge if the blowby is within
specification.
NOTE: On turbocharged air compressors, make sure to
remove the plug previously installed in the air intake hose
going to the engine's intake.
Connect the air compressor discharge line and air intake
hose from the air compressor.
Exhaust Brake Blowby Contribution:

NOTE: Not all vehicles are equipped with an exhaust
brake.
With the engine blowby service tool and water manometer
or pressure gauge still installed, measure blowby pressure
during exhaust brake operation, if equipped.
Operate the vehicle going down a long inclined road such
as a highway or interstate off ramp. Begin exhaust brake
operation at rated engine speed while measuring blowby
pressure during exhaust brake operation.
Aftertreatment Testing Signature™, ISX, and QSX15 Eng [...]
Also, measure exhaust back pressure during exhaust

brake operation.
Operate the engine until a steady reading is obtained.
If blowby pressure is above specification during exhaust
brake operation and exhaust back pressure is above
specification, repair or replace the exhaust brake. See the
If the blowby pressure is above specification during
exhaust brake operation and the exhaust back pressure
is within specification, check the turbocharger blowby
contribution. Reference the turbocharger oil drain
isolation step previously in this procedure.
manometer or pressure gauge.
Remove the pressure gauge used to measure exhaust
back pressure during exhaust brake operation.
Install a plug in the test port.
Aftertreatment Testing (014-013)

General Information
The Snap-Acceleration Test is used to check the
aftertreatment diesel particulate filter for cracks or other
progressive damage, without removing the filter system.
It is used to test the functionality of the aftertreatment
The INSITE™ electronic service tool Aftertreatment Diesel
Particulate Filter Stationary Regeneration Test is used to:
• Regenerate an aftertreatment diesel particulate filter
• Recover the aftertreatment diesel oxidation catalyst
and aftertreatment diesel particulate filter after coolant
contamination
• Check the aftertreatment diesel oxidation catalyst
efficiency
• Check for the correct installation of the aftertreatment
temperature sensors
• Reset the stored soot load in the engine ECM
• Check the aftertreatment fuel injector, shutoff valve,
and drive train functionality.
Check for active fault codes prior to performing either of
these procedures. If any active fault codes are present,
follow the appropriate fault code troubleshooting tree.
Signature™, ISX, and QSX15 Eng [...] Aftertreatment Testing
The INSITE™ electronic service tool Aftertreatment Diesel

Particulate Filter Stationary Regeneration Test can be
used to regain functionality of the Aftertreatment Diesel
Oxidation Catalyst (DOC) and Aftertreatment Diesel
Particulate Filter (DPF) after either, or both, have been
exposed to coolant.
NOTE: If the DOC and DPF are suspected of having
coolant contamination, they do not need to be removed
and inspected. Consult the Preparatory Steps section of
this procedure for further details.
The temperatures that are achieved during the
Regeneration are high enough to evaporate the coolant
out of both components and return both components to
normal operating specifications.
NOTE: If these components are suspected of having
coolant contamination, do not perform the snap
acceleration test before performing the regeneration.
This section outlines the Exhaust System Outlet

Inspection.
Inspection of the exhaust system outlet can reveal the
condition of the aftertreatment diesel particulate filter. The
exhaust system outlet should appear clean with little to no
exhaust residue/soot buildup.
The aftertreatment diesel particulate filter is not 100
percent efficient. Some accumulation of exhaust residue/
soot is normal, and does not indicate a malfunctioning
A heavy buildup of exhaust residue/soot can indicate a
malfunction of the aftertreatment diesel particulate filter.
To determine if the exhaust residue/soot accumulation on
the exhaust system outlet is the result of a malfunctioning
aftertreatment diesel particulate filter, perform one of the
following:
1 Snap Acceleration Test as outlined in this procedure.
2 Clean the last 152 to 254 mm [6 to 10 in] of the exhaust
system outlet. Operate the vehicle for one shift or trip
and inspect the exhaust system outlet for exhaust
residue/soot accumulation.
3 Inspect the aftertreatment diesel particulate filter.
Snap Acceleration Test

• The vehicle transmission must be in neutral.
• The vehicle parking brake must be applied.
Start and idle the engine.
Rapidly depress the accelerator pedal from 0 percent to
100 percent. This can be performed multiple times, if
necessary.
During this test, visually check for black smoke exiting the
exhaust stack, as the engine is accelerated from low idle
to high idle
NOTE: In some applications, a snap acceleration test may
not provide the conditions necessary to reveal a
malfunctioning aftertreatment diesel particulate filter. If
there is a heavy buildup of exhaust residue/soot on the
exhaust system outlet and a snap acceleration does not
reveal a condition outlined in the following steps, it can be
necessary to perform:
• A stall test. Refer to Procedure 014-008 in Section 14.
• A brief acceleration run under partial to full load.
Refer to the Catalyst and Aftertreatment Particulate Filter
Reuse Guidelines, Bulletin 4021600, for pass or fail
guidelines.
If gray smoke or faint black smoke is present, refer to the

Catalyst and Aftertreatment Particulate Filter Reuse
Guidelines, Bulletin 4021600, for pass or fail guidelines.
White smoke during the snap-acceleration test does not
indicate a failure. No repair is necessary.
Preparatory Steps
WARNING
During regeneration, exhaust gas temperature could reach 800°C [1500°F]
and exhaust system surface temperature can exceed 700°C [1300°F], which
is hot enough to ignite or melt common materials, and cause severe burn
injuries. The exhaust and exhaust components can remain hot after the vehicle
stopped moving. To avoid the risk of fire, property damage, burns or other
serious personal injury, allow the exhaust system to cool before beginning this
procedure or repair and make sure that no combustible materials are located
where they are likely to come in contact with hot exhaust or exhaust
components.
To perform a stationary regeneration, connect INSITE™ electronic service tool and
check for active fault codes. If any fault codes are present other than Fault Codes
2639 or 1921, go to Section TF for any fault code troubleshooting before proceeding.
Do not perform a stationary regeneration with active fault codes other than Fault
Codes 2639 or 1921, unless guided to do so by the fault code troubleshooting.
NOTE: If the stationary regeneration is being performed to recover either the DOC,
the DPF, or both after coolant contamination, the DOC does not need to be removed
or inspected unless there are active fault codes that require inspection as part of the
fault code troubleshooting steps.
NOTE: Unless there are complaints of black smoke during operation and the
exhaust stack is black, the DPF does not need to be removed or inspected during
this process.
Before performing a stationary regeneration, follow the steps listed below:
1 Select an appropriate location to park the vehicle.
a On a surface that will not burn or melt under high temperatures (such as clean
concrete or gravel, not grass or asphalt)
b Away from anything that can burn, melt, or explode
- Nothing within 0.6 m [2 ft] of the exhaust outlet
- Nothing that can burn, melt, or explode within 1.5 m [5 ft] (such as gasoline,
wood, paper, plastics, fabric, compressed gas containers, hydraulic lines)
- No gas or vapors nearby that could burn, explode, or contribute to a fire (such
as LP gas, gasoline vapors, oxygen, nitrous oxide).
2 Park the truck securely.
a Set the parking brake.
b Place transmission in Park, if provided; otherwise in Neutral.
c Set wheel chocks at the front and rear of at least one tire.
3 Set up a safe exhaust area.
a If bystanders might enter the area, set up barriers to keep people at least 1.5
m [5 ft] from the exhaust outlet during regeneration.
b When indoors, attach an exhaust discharge pipe rated for at least 800°C [1500°
F]
c Keep a fire extinguisher nearby.
4 Check exhaust system surfaces.
a Confirm that nothing is on or near the exhaust system surfaces (such as tools,
rags, grease, or debris).
5 Prepare for engine speed changes during regeneration.
a Do not operate any PTO-powered devices. Disconnect these devices before
starting regeneration.
b Stay clear of the engine compartment.
6 Begin the stationary regeneration. This can be performed in two ways:
a Vehicles equipped with a stationary regeneration switch in the cab must also
have the stationary regeneration switch parameter enabled in the ECM. The
stationary regeneration switch can be a stand-alone switch, or can be combined
with a diagnostic switch, at the choice of the vehicle manufacturer.
b The INSITE™ electronic service tool can be used to perform regeneration by
starting the Aftertreatment Diesel Particulate Filter Regeneration Test.
c In either case, the engine will create enough heat to regenerate the aftermarket
diesel particulate filter. Engine speed will increase and the turbocharger can
whistle loudly during the regeneration process. Once the aftermarket diesel
particulate filter is regenerated, the engine will automatically return to normal
idle speed.
7 Monitor the area.
a Make sure that the vehicle and surrounding area are monitored during
regeneration. If any unsafe condition occurs, shut off the engine immediately.
To stop a stationary regeneration, engage the clutch, brake, or throttle pedal; or turn
off the engine.
Once regeneration is complete, exhaust gas and exhaust surface temperatures will
remain elevated for 3 to 5 minutes.
Setup
Start and idle the engine.
Prior to the Aftertreatment Diesel Particulate Filter
Regeneration Test, inspect the exhaust piping for leaks,
cracks, and loose connections.
• For ISM engines, use the following procedure. Refer to
• For ISX engines, use the following procedure. Refer to
Tighten the exhaust clamps if necessary.
Consult the OEM specifications for the correct torque
value.
Any leaks in the exhaust system will cause the
Aftertreatment Diesel Particulate Filter Regeneration Test
to be less efficient in reducing the soot load of the filter.
Test
The Aftertreatment Diesel Particulate Filter Regeneration
Test can be found under the ECM Diagnostic Test menu
in the INSITE™ electronic service tool.
If INSITE™ electronic service tool is not available, some

vehicles can be equipped with a stationary regeneration
switch in the cab. The switch can be a stand-alone switch
or can be combined with the diagnostic switch. Check with
the OEM for the location and availability of the switch.
NOTE: In order for the stationary regeneration switch to
function, the stationary regeneration switch must be
enabled in the ECM.
Unlike the Aftertreatment Diesel Particulate Filter
Regeneration Test with the INSITE™ electronic service
tool, this switch will only start a stationary regeneration if
the soot load of the filter is high enough. This is indicated
by the aftertreatment lamp being illuminated or flashing.
NOTE: A stationary regeneration can not be initiated
through the use of the cab switch if regeneration inhibit is
enabled. INSITE™ electronic service tool must then be
used to initiate the stationary regeneration.
NOTE: If the Aftertreatment Diesel Particulate Filter

Regeneration Test will not initiate, use the Stationary
Regeneration - Will Not Start troubleshooting symptom
tree.
When the test is started, the engine idle speed will be
raised automatically to the required level. Expected
engine speed can reach between 1000 and 1500 rpm.
The engine will then, through the engine controls, operate
in a manner to build exhaust heat. The turbocharger can
emit a slight “whining” noise during the test. This is
normal.
The Aftertreatment Diesel Particulate Filter Regeneration
can take up to two and one half hours to complete,
depending on the soot loading of the filter as well as
conditions of the environment, such as but not limited to
the temperature and humidity.
Once the Aftertreatment Diesel Particulate Filter
Regeneration Test is complete, the engine will
automatically return to normal idle speed.
During the Aftertreatment Diesel Particulate Filter

Regeneration Test, the following items will be monitored:
• Aftertreatment Injector Status - Informs the user when
fuel is being injected, in small quantity, into the
exhaust system upstream of the diesel oxidation
catalyst
• Aftertreatment Diesel Particulate Filter outlet
temperature
• Aftertreatment Diesel Particulate Filter inlet
temperature
• Aftertreatment Diesel Oxidation Catalyst inlet
temperature
• Aftertreatment Diesel Particulate Filter Soot Load -
Informs the user of the current soot load of the filter:
- Normal - No regeneration is necessary
- Above Normal; Least Severe Level - A stationary
regeneration can be performed
- Above Normal; Moderately Severe Level - A stationary
regeneration can be performed
- Above Normal; Most Severe Level - A stationary
regeneration must not be performed unless the filter
was cleaned or a new filter has been installed and the
troubleshooting steps indicate to perform.
CAUTION
During the stationary regeneration, the exhaust gas
temperature can reach 800°C [1500°F] and the
surface temperature can exceed 700°C [1300°F].
The stationary regeneration can take up to 2-1/2 hours to
complete, depending on the soot loading of the filter. At
any time the stationary regeneration can be aborted by
clicking on the “Stop” button in the INSITE™ electronic
service tool.
The stationary regeneration will be aborted if:
• A fault becomes active
• The accelerator is depressed
• The clutch pedal is depressed
• The brake pedal is depressed
• The transmission is put into gear.
NOTE: If a stationary regeneration can not be initiated or
is aborted, and the engine has a low power complaint,
Pass or Fail Criteria
• Pass: Aftertreatment Testing Procedure 014-013 in
Section 14 has passed, if there is no visible black
smoke and the stationary regeneration completes with
no aftertreatment fault codes being generated.
• Fail: Aftertreatment Testing Procedure 014-013 in
Section 14 has failed, if there is visible black smoke
and/or aftertreatment fault codes are generated.
Repair the cause of the black smoke and/or correct the
fault codes.
Finishing Steps
Allow the engine and exhaust system to cool down.
Temperatures can maintain an elevated state for several
minutes.
Check to make sure the diesel particulate filter lamp is
not illuminated.
NOTE: If the diesel particulate filter lamp is illuminated
and Fault Code 2639 or 1921 are still active, a second
regeneration will be needed. If the fault is still active after
a second regeneration, the filter needs to be cleaned of
ash or soot. Refer to Procedure 011-041 in Section 11.
Check for any active fault codes. If active fault codes are
present, use Section TF for fault code troubleshooting.
Use INSITE™ electronic service tool to clear all inactive
fault codes.
Section 16 - Mounting Adaptations - Group 16 Page 16-a
Section 16 - Mounting Adaptations - Group 16

Section Contents
Page
Engine Lifting Brackets ...................................................................................................................................16-2
Finishing Steps...............................................................................................................................................16-4
Install..............................................................................................................................................................16-3
Remove..........................................................................................................................................................16-2
Engine Mounts ...............................................................................................................................................16-41
Install............................................................................................................................................................16-44
Remove.........................................................................................................................................................16-43
Engine Support Bracket, Front .......................................................................................................................16-4
Finishing Steps...............................................................................................................................................16-6
Install..............................................................................................................................................................16-6
Remove..........................................................................................................................................................16-4
Flywheel ..........................................................................................................................................................16-7
Finishing Steps............................................................................................................................................. 16-13
Initial Check....................................................................................................................................................16-7
Bore Runout.................................................................................................................................................16-7
Face Runout................................................................................................................................................16-8
Install............................................................................................................................................................16-12
Remove.........................................................................................................................................................16-10
Flywheel Housing ..........................................................................................................................................16-14
Finishing Steps............................................................................................................................................. 16-23
Install............................................................................................................................................................16-17
Measure........................................................................................................................................................16-18
Bore Alignment...........................................................................................................................................16-18
Face Alignment..........................................................................................................................................16-21
Remove.........................................................................................................................................................16-14
Flywheel Housing, REPTO ............................................................................................................................16-24
Finishing Steps............................................................................................................................................. 16-40
Install............................................................................................................................................................16-29
Measure........................................................................................................................................................16-36
Bore Alignment...........................................................................................................................................16-36
Face Alignment..........................................................................................................................................16-38
Remove.........................................................................................................................................................16-24
Flywheel Ring Gear .......................................................................................................................................16-41
Install............................................................................................................................................................16-41
Remove.........................................................................................................................................................16-41
Service Tools ...................................................................................................................................................16-1
Mounting Adaptations......................................................................................................................................16-1
Page 16-b Section 16 - Mounting Adaptations - Group 16

Section 16 - Mounting Adaptations - Group 16 Page 16-1
Service Tools
Mounting Adaptations
Repair Location.

Dial Gauge Attachment
Used to check the bore and face of the flywheel and flywheel housing
ST-1325 relative to the center line of the crankshaft.
Crack Detection Kit

Used to check or inspect components for cracks.
3375432
Dial Indicator and Sleeve Assembly

Used with dial indicator attachment, Part No. ST-1325, for checking
3376050 the bore and face of the flywheel and flywheel housing.
Flywheel Socket - 21 mm 12 point

Used to remove capscrews.
3162813
Guide Pin Kit

This kit contains various size guide pins that are used during
3163157 assembly and/or disassembly to align parts and aid in the control of
parts.
Barring Tool
This tool provides a way of barring over most engines when making
3163160 valve and injector adjustments or checking engine timing.
Engine Lifting Brackets Signature™, ISX, and QSX15 Eng [...]
Page 16-2 Section 16 - Mounting Adaptations - Group 16

Preparatory Steps
• Remove the retaining brace bracket. Refer to
Procedure 001-081.
Remove
NOTE: Newer models use three mounting capscrews.
Remove the four capscrews and the rear lifting bracket.
Remove the four capscrews and the front lifting bracket.

Signature™, ISX, and QSX15 Eng [...] Engine Lifting Brackets
WARNING
WARNING
WARNING
bodily injury.
Clean with steam or solvent.
Inspect the lifting brackets for cracks or damage.

Inspect the capscrew threads for damage.
Install
Install the front bracket and four capscrews.
Install the rear bracket and four capscrews.
Engine Support Bracket, Front Signature™, ISX, and QSX15 Eng [...]
Finishing Steps
• Install the retaining brace bracket. Refer to
Procedure 001-081.

(016-002)
Preparatory Steps
WARNING
• Use a hoist or lifting fixture to support the front of the
engine.
Procedure 008-003.
• Remove the fan and water pump belt tensioner if a
low mount tensioner is used. Refer to Procedure
008-080.
• Remove the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
Remove
WARNING
Remove the two capscrews that attach the support to the
equipment frame.
Use the hoist to lift the weight of the engine off the front
support.
Signature™, ISX, and QSX15 Eng [...] Engine Support Bracket, Front
Remove the six mounting capscrews and the front engine

support.
Remove the rubber engine mounts.
WARNING
WARNING
WARNING
personal injury.
Clean the parts with steam or solvent.
Inspect the engine mounts for cracks or deterioration.

Engine Support Bracket, Front Signature™, ISX, and QSX15 Eng [...]
Inspect the engine support bracket for cracks or damage.

Inspect the capscrew threads for damage.
Install
Install the engine support bracket and the six mounting
capscrews.
Torque: 97 N•m + 60 deg [72 ft-lb + 60 deg]
Install the rubber engine mounts into the crossmember.
WARNING
Lower the front of the engine to the rubber engine mounts.
The capscrew holes in the support bracket must be
aligned with the capscrew holes in the engine mounts.
Install the two capscrews in the support bracket and
engine mount. Tighten to the manufacturer's
specifications.
Remove the lifting fixture or the hoist from the engine.
Finishing Steps
• Install the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
• Install the fan and water pump drive belt tensioner.
Procedure 008-003.
Signature™, ISX, and QSX15 Eng [...] Flywheel
Flywheel (016-005)
Initial Check
Bore Runout
Use dial indicator gauge (1), Part Number 3376050, or
equivalent, and dial gauge attachment (2), Part Number
ST-1325, to inspect the flywheel bore (3) and face (4)
runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside of
the flywheel bore.

crankshaft one complete revolution (360-degrees).
Measure the bore runout.
Flywheel Bore Runout

mm in
0.127 MAX 0.005
If the total indicator reading is greater than the

specification, remove the flywheel.
Inspect the flywheel mounting surface for dirt or damage.

Flywheel Signature™, ISX, and QSX15 Eng [...]
Inspect the crankshaft for dirt or damage.
Install the flywheel and inspect the bore runout again.
Replace the flywheel if the runout does not meet

specifications.
Face Runout
Install the contact tip of the indicator against the flywheel
face as close to the outside as possible to inspect the face
(4) runout.
Push the flywheel forward to remove the crankshaft end
thrust.

crankshaft one complete revolution (360-degrees) while
keeping the crankshaft end thrust pushed forward.
The total indicator reading must not exceed the following

specifications:
Flywheel Face Runout Total Indicator Reading

Maximum (Total Indicator
Flywheel Radius (A)
Reading) of Flywheel Face
203 mm [8 in] 0.203 mm [0.008 in]
254 mm [10 in] 0.254 mm [0.010 in]
305 mm [12 in] 0.305 mm [0.012 in]
356 mm [14 in] 0.356 mm [0.014 in]
406 mm [16 in] 0.406 mm [0.016 in]
Preparatory Steps
WARNING
cable last.
WARNING
• Disconnect the batteries or air starter to prevent
accidental engine starting.
• Remove the transmission, clutch, and all related
components. See the equipment manufacturer's
instructions.
Remove
WARNING
Use two M6 x 1.5 guide studs to prevent the flywheel from
rotating. Remove two capscrews and install the guide
studs.
Use a hoist, two t-handles, and a lifting sling. Install the
tee-handles. Remove the remaining ten capscrews.
Remove the flywheel.
Use a soft faced mallet to tap the flywheel from the
crankshaft, if necessary. Damage to the clutch surface
can occur if a hard faced hammer is used.
Remove the pilot bearing spacer from the rear of the

crankshaft.
Use a mandrel and hammer to remove the pilot bearing
from the flywheel.
WARNING
WARNING
WARNING
personal injury.
Use a wire brush to clean the crankshaft pilot bore.
Use a wire brush to clean the flywheel pilot bore.
Clean with steam or solvent.
Inspect for nicks or burrs.

Use a fine crocus cloth to remove small nicks and burrs.
WARNING
Do not use a cracked or resurfaced flywheel. These
can break, causing serious personal injury or property
damage.
Use the crack detection kit, Part Number 3375432, to
check for cracks in the flywheel. Follow the instructions
provided with the kit.
Inspect the flywheel ring gear teeth for cracks and chips.
If the ring gear teeth are cracked or broken, the ring gear
must be replaced. Refer to Procedure 016-008 (Flywheel
Ring Gear) in Section 16.
Inspect the pilot bearing spacer for cracks or damage,

replace if necessary.
Install
Install the pilot bearing spacer into the rear of the
crankshaft with the spacer lip oriented outward.
NOTE: A small amount of clean Lubriplate™ 105 multi-
purpose lubricant, or its equivalent, can be used to help
keep the pilot bearing spacer in position until the flywheel
is assembled.
CAUTION
The flywheel mounting capscrews must be a minimum
of SAE Grade 8 with rolled threads. Use identical
replacements to avoid possible flywheel failure
resulting in personal injury or property damage.
capscrews with clean 15W-40 oil. Allow the excess oil to
drip off the parts. Do not lubricate the threads of the
crankshaft.
WARNING
lift the component.
Use two M6 x 1.5 guide studs during assembly.
Install the flywheel. The flywheel must be firmly against
the crankshaft.
Install the ten capscrews.

Remove the t-handles and the guide studs.
Install the remaining two capscrews into the holes from
which the guide studs were removed.
Tighten the capscrews in two steps, use the sequence
shown.
Step2 250 N•m [ 184 ft-lb ]
Use a mandrel and hammer to install the pilot bearing.

The pilot bearing must be installed even with the pilot bore
surface.
Finishing Steps
WARNING
WARNING
cable last.
• Perform the bore runout check and face runout
check located in this procedure.
• Install the clutch discs, pressure plate, transmission,
and driveline, if equipped, in reverse order of
removal. See the manufacturer's instructions.
• Align the universal joints on each end of the
driveshaft to prevent vibration.
• Connect batteries and air starter.
• Start the engine and check the operation of the
equipment.
Flywheel Housing Signature™, ISX, and QSX15 Eng [...]

Preparatory Steps
WARNING
WARNING
lift the component.
WARNING
WARNING
WARNING
Adequately support the engine to prevent damage and
personal injury.
• Disconnect the batteries and air starter to prevent
accidental engine starting.
components. Refer to the equipment manufacturer's
instructions.
• Remove the flywheel. Refer to Procedure 016-005.
• Drain the oil. Refer to Procedure 007-037.
• Remove the oil pan. Refer to Procedure 007-025.
• Remove the rear crankshaft seal. Refer to Procedure
001-024.
• Remove the starting motor. Refer to Procedure
013-020.
• Remove the rear engine mounts from the flywheel
housing.
Remove
Remove the two top exterior capscrews from the flywheel
housing.
Signature™, ISX, and QSX15 Eng [...] Flywheel Housing
WARNING
avoid personal injury, use a hoist or get assistance.
Use a hoist and lifting sling. Install the lifting sling around
both sides of the upper housing. Adjust the hoist until
there is tension in the lifting sling. Remove the remaining
capscrews.
Use a mallet to tap the flywheel housing off the two

locating dowels.
Remove two capscrews, cover plate, and gasket. Discard

the gasket.
CAUTION
4918321.
Firmly push plug into oil passage to prevent all debris from
entering the lubricating system when cleaning the gasket
surface.

CAUTION
gasket sealing surfaces. Main or connecting rod
into the lubrication system. Therefore, use of power
tools combined with abrasive pads to clean gasket
surfaces is not recommended.
Clean the gasket surfaces by hand with a gasket scraper
or cleaning pad Part Number 3823258
If the residual gasket material can not be felt with a finger,
the surface is ready to accept the new gasket.
WARNING
WARNING
personal injury.
WARNING
bodily injury.
Steam-clean or use solvent to clean the housing.
Inspect all surfaces for nicks, burrs, or cracks.

Use a fine crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Install
Make sure debris does not enter the lubrication system.
passage.
Install the cover plate and two capscrews. Tighten the

capscrews.
Install two guide studs into the cylinder block to help

support and align the housing during installation.
engine block using the guide pins.
Install the flywheel housing over the guide studs.

capscrews with clean 15W-40 lubricating oil.
Install capscrews 1, 2, 3, and 4, and tighten in the
sequence shown.
The flywheel housing is located on the block by two ring

dowels from the factory. If a flywheel housing is removed,
it can be reinstalled with the ring dowels in place, but
alignment must be checked with the following alignment
procedure.
If the alignment does not meet specification, the ring
dowels must be removed and the housing must be
realigned without the ring dowels.
CAUTION
The flywheel housing bore and surface must be in
alignment with the crankshaft to prevent possible
Measure the flywheel housing alignment.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting tool
Part Number ST-1325 and indicator Part Number
3376050.
obtained will be inaccurate.
gauge at zero.

CAUTION

values.
Example:
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Using the work sheet and the numbers from the example,
the total horizontal value equals 0.006, and the total

housings.

housings.

housings.

repositioned.
Face Alignment
CAUTION



Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]

00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
½ 584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]

Step2 197 N•m [ 145 ft-lb ]
Finishing Steps
WARNING
WARNING
lift the component.
• Install the rear engine mounts on the flywheel
housing.
• Install the starting motor capscrews, starter, and
spacer. Refer to Procedure 013-020.
• Install the rear crankshaft seal. Refer to Procedure
001-024.
• Install the oil pan. Refer to Procedure 007-025.
• Fill the oil. Refer to Procedure 007-037.
• Install the flywheel. Refer to Procedure 016-005.
• Install the transmission, clutch, and all related
instructions.
• Connect the batteries and air starter.
Flywheel Housing, REPTO Signature™, ISX, and QSX15 Eng [...]

Preparatory Steps
WARNING
compartment before servicing batteries. To reduce
the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery
cable last.
WARNING
WARNING
WARNING
• Disconnect the batteries or air supply to the starter
to prevent accidental engine starting.
• Drain the oil. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
instructions.
• Remove the flywheel. Refer to Procedure 016-005
(Flywheel) in Section 16.
• Remove the starter motor. Refer to Procedure
013-020 (Starting Motor) in Section 13.
Remove
Remove the three capscrews from the rear of the oil pan.
Signature™, ISX, and QSX15 Eng [...] Flywheel Housing, REPTO
WARNING
Remove the 10 10-mm capscrews from the hydraulic
housing.
Remove the hydraulic housing from the REPTO flywheel
housing.
Remove the spray nozzle from the oil supply line hole.
Remove the 12 capscrews (1) from the seal carrier.

Remove the seal carrier (2) from the REPTO flywheel
housing.
Remove oil seal (4) and discard. Refer Procedure 001-024
(Crankshaft Seal, Rear) in Section 1.
Remove the o-ring (3) from the groove on the REPTO
flywheel housing.
Remove the four plugs (1) and o-rings (2) from the REPTO
flywheel housing.
Remove the crankshaft gear.

Remove the idler gear shaft capscrew and washer.
Remove the three guide pins.
If the idler gear shaft can not be removed with the handle,
a slide hammer similar to Snap-On, Part Number CJ114,
can be used.
Position the replacer idler plate, Part Number 3164762, on
the idler gear shaft. Install and tighten the two idler gear
capscrews. Install the handle, Part Number 3163089.
Remove the idler shaft, idler gear, and bearing from the
Remove two capscrews from the REPTO flywheel

housing.
Install the two guide pins, Part Number 3164764.
Install the two eye bolts, Part Number 3164767, on the top
of the REPTO flywheel housing. Install the lifting slings to
the eye hooks. Adjust the hoist until there is tension in the
lifting sling.
Remove the remaining capscrews.
WARNING
Use a mallet to tap the REPTO flywheel housing off the
two locating dowels. Remove and discard the gasket.
CAUTION
4918321.
debris from entering the lubricating system when cleaning
the gasket surface.

CAUTION
gasket sealing surfaces. Main or connecting rod
into the lubrication system. Therefore, use of power
tools combined with abrasive pads to clean gasket
surfaces is not recommended.
Clean the gasket surfaces by hand with a gasket scraper
or cleaning pad, Part Number 3823258. If the residue
gasket material can not be felt with a finger, the surface
is ready to accept the new gasket.
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the REPTO flywheel
housing.
Inspect all surfaces for nicks, burrs, or cracks.

Use a crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
Inspect the idler shaft, bearing, and gear for nicks, burrs,
or cracks. Replace if damaged.
Inspect the four o-rings from the plugs and the one large
o-ring from the REPTO flywheel housing for cuts or tears.
Replace the o-rings if damaged.
Install
Make sure no debris enters the lubrication system.
passage.
Install the two guide pins (3), Part Number 3164764, into
the cylinder block.
cylinder block using guide pins.
WARNING
Install the two eye hooks (4) in the top of the REPTO
flywheel housing. Install the lifting slings to the eye hooks
and push the REPTO flywheel housing onto the two
guides pins (3).
Install the six short capscrews (2) and four long capscrews
(1) in the locations shown.
Remove the two guide pins and install the two other long
capscrews.
Tighten capscrews (1), (2), (9) and (10).

Tighten the remaining capscrews in the sequence shown.
CAUTION
The REPTO flywheel housing bore and face must be
in alignment with the crankshaft to prevent possible
Use the measure step in this procedure to align the
housing.

Step2 197 N•m [ 145 ft-lb ]
Install the three oil pan capscrews.

Install the large o-ring seal (1) and the small o-ring seal (2)
onto the idler shaft.
Assemble the replacer idler shaft plate and handle.

Install the two capscrews in the idler shaft holes and
tighten.
Use clean 15W-40 oil to lubricate the idler shaft.
The two cones (2) are loose and will fall out if not
contained.
Make sure the gear (4), two bearing snap rings (1), and the
two cups (3) are pressed in place before inserting the
assemblies through the center or sides of the REPTO
flywheel housing openings.
Use clean 15W-40 oil to lubricate the bearing snap rings,
cones, cups, idler shaft, and gear.
Make sure the idler shaft plug (1) is facing upward when
installing it into the bore.
Install the gear and bearing assembly through the center
or sides of the REPTO flywheel housing holes. Position
the bearing races together and insert the idler shaft with
the tool through the first bear bore. The running clearance
is 0 to 0.025 mm [0.000 to 0.001 in].
Make sure the idler shaft is properly aligned and seated
against the shoulder of the internal bore.
Repeat the procedure if installing a second gear.

Remove the two capscrews, replacer idler plate, and
handle from the idler shaft.
clean 15W-40 oil.
A second idler gear can be installed or an insert shaft can

be used without the idler gear and roller.
Install the o-rings onto the insert shaft. Lubricate the o-
rings with clean 15W-40 oil.
Install the insert shaft into the flywheel housing hole where
the cover plate will be installed (opposite pump location).
Align the hole with the tapped hole in the block.
clean 15W-40 oil.
Install the three guide pins, Part Number 3164765, equally

spaced through the crankshaft gear and into the
crankshaft.
Rotate the idler gears, as necessary, to mesh the
crankshaft gear with the idler gear(s).
Install the crankshaft gear.
Make sure the o-rings are properly seated into the groove
before installation.
Use clean 15W40 oil to lubricate the o-rings.
Install four plugs (1) with o-rings (2) into the REPTO
flywheel housing holes.
Install the o-ring in the REPTO flywheel housing groove.

Install the seal carrier over the two dowels pins on the

Tighten the capscrews in the sequence shown to secure
the seal carrier.
Install the three flywheel mounting capscrews and

spacers. Tighten the flywheel mounting capscrews.
Remove the three flywheel mounting capscrews and
spacers.
CAUTION
the bore. If the crankshaft and crankshaft seal is not
pressed evenly into the bore, the oil seal can cause
equipment damage.
Install the rear crankshaft oil seal over the rear crankshaft
seal replacer, Part Number 3164780, and onto the three
guide pins.
Install three flywheel mounting capscrews (without the
washers) through the three holes in the rear crankshaft
seal replacer.
CAUTION
To reduce the possibility of damage to the oil seal and
crankshaft, never use a hammer or mallet to install the
rear crankshaft oil seal.
Do not use lubricants during the installation process.
Apply a 10 percent soap solution to the outer ribbed
surface of the rear crankshaft oil seal.
Tighten the flywheel mounting capscrews no more than ½
revolution at a time, alternating capscrews in a
clockwise pattern, until the rear crankshaft seal replacer,
Part Number 3164780, seats against the REPTO flywheel
housing.
Remove the rear crankshaft seal replacer and the three

flywheel mounting capscrews.
Install the flywheel. Refer to Procedure 016-005 (Flywheel)
in Section 16.
If one side of the REPTO flywheel housing cover access

hole does not use a hydraulic housing, the opening
must be covered in conjunction with the oil supply line
hole and plugging the straight thread plug hole.
Install the 1/8-inch pipe plug (1) into the oil supply line
hole. Make sure the pipe plug is flush with the mounting
surface.
Install the straight thread plug (2) into the flywheel housing
hole. Make sure pipe plug is flush with the mounting
surface.

15W-40 oil on the diamond seal.
Install the cover plate to the REPTO flywheel housing
cover access hole. Install the 10 capscrews and tighten.
Make sure the idler gear is locked in position. Use a dial

gauge to check the backlash.
Idler Gear to Crankshaft Gear Backlash

mm in
0.15 MIN 0.006
0.28 MAX 0.011
If the backlash is not within specifications, replace the
idler gear, REPTO hub gear, or both.
NOTE: The spray nozzle and diamond seal are only

installed if a hydraulic housing is used.
Install the spray nozzle (1) into the oil supply line hole.
Tighten the spray nozzle.
clean 15W-40 oil on the diamond seal.
Apply clean 15W-40 oil on the gear teeth and bearings.

Install the hydraulic housing over the dowel pins. The gear
inside the hydraulic housing is free to rotate and will locate
the position of the idler gear as the hydraulic housing is
being installed over the dowel pins.
Install the 10 capscrews and tighten in the sequence

shown.
Verify that backlash exists between the Hydrive housing

gear and idler gear by inserting a tool into the spline to
help rotate the gear.
A small amount of backlash must be present, although
obtaining a measurement is not required.
If no backlash is present, disassemble the Hydrive
housing from the flywheel housing, and assemble the
Hydrive housing to the opposite flywheel housing
mounting pad and check for backlash.
If no backlash is present when assembled on either
flywheel housing mounting pad, the Hydrive housing
must be replaced.
If backlash is present on only one side, the flywheel
Install the threaded plug (1) in the bottom hole of the

hydraulic housing. Tighten the threaded plug.
Install the oil line hose on the straight connectors. Tighten
the hose and check for leaks.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting
tool, Part Number ST-1325, and indicator Part Number
3376050.
obtained will not be accurate.
gauge at zero.

CAUTION

values.
Example:
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Use the work sheet and the numbers from the example.
The total horizontal value equals 0.006, and the total

housings.

housings.

housings.

repositioned.
Face Alignment
CAUTION



Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]

00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
½ 584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]

Step2 197 N•m [ 145 ft-lb ]
Finishing Steps
WARNING
WARNING
compartment before servicing batteries. To reduce
the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery
cable last.
• Install the starting motor. Refer to Procedure
013-020 (Starting Motor) in Section 13.
• Connect the batteries or air starter supply.
• Fill the engine with clean oil. Refer to Procedure
• Install the transmission, clutch, and all related
instructions.
Signature™, ISX, and QSX15 Eng [...] Engine Mounts
Flywheel Ring Gear (016-008)

Remove
CAUTION
Do not use a cutting torch to heat the ring gear. The
flywheel can be damaged.
Heat the outside of the ring gear with a heating torch.
Use a blunt chisel and a hammer to remove the gear from
the flywheel.
Install
Heat the new ring gear in an oven heated to 316°C [600°
F] for a minimum of 1-hour.
NOTE: Do not overheat the ring gear. The metal hardness
will be changed.
WARNING
Wear protective gloves when handling parts that have
been heated to prevent personal injury.
Remove the gear from the oven and install it on the
flywheel before it cools.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 316°C
[600°F]. Use a Tempilstik® crayon, or its equivalent, to
check the gear temperature before installing it on the
flywheel.
Engine Mounts (016-010)

General Information
Some vibration exists in all piston type engines, due to the pulsating power inputs and reciprocating components.
Some of these vibrations are internal to the engine and are compensated, or balanced, by opposing forces within the
engine structure. These are generally not of interest to vibration isolation designs. The vibrations that are offset or
balanced internally will cause shaking moments and forces that must be reacted to by the engine mounts. If these
moments and forces are not adequately reduced by the engine mounting and isolation systems, they can cause
customer dissatisfaction and/or damage, due to component fatigue.
The effectiveness of an engine mounting system in isolating the vehicle structure from engine vibration depends on
the relationship between the frequency of the vibration coming from the engine and the natural frequency of the engine
mounting system. The mounting system effectiveness is commonly measured with the term “transmissibility”.
Transmissibility is the amount of engine vibration which is transmitted through the mounting system to the vehicle
structure.
Transmissibility values greater than one indicate the engine mounting system is actually transmitting more vibration
into the vehicle structure than is coming from the engine. This is possible if the natural frequency of the mounting
Engine Mounts Signature™, ISX, and QSX15 Eng [...]
system is close to the frequency of the engine vibration. This can result in the mounting system operating at or near
resonance, with a resulting magnification of the input vibration. This is obviously an undesirable situation.
Transmissibility values of less than one indicate the mounting system is transmitting only a fraction of the vibration
input from the engine, thus isolating the vehicle from engine vibration. Good engine mounts will reduce the amount
of engine vibration transmitted to the chassis frame by at least 50 percent at idle.
Stiffness (durometer) and size of the isolator, along with the weight of the engine or component applied, are the
determining factors when designing a mounting system. An isolator that is correct for one engine may not be right
for another. Likewise, because of weight differential, a particular isolator designed for the rear of an engine probably
will not be ideal for the front. Hard engine mounts will give little or no isolation, and can actually magnify the vibration
transmitted to the chassis.
The following are illustrations of typical FRONT engine mounts.
1. Bolt 5. Bonded metal center
2. Supported member 6. Locknut
3. Snubbing washer (or flat bracket surface of equal 7. Supporting member
diameter 8. Rubber mount.
4. Rebound tail
The following are illustrations of typical REAR engine mounts.

Signature™, ISX, and QSX15 Eng [...] Engine Mounts
Remove
WARNING
the engine and transmission as an assembly without
causing personal injury.
WARNING
Use a hoist or lifting fixture to support the engine.
NOTE: When removing the engine mount fasteners, note
the location of any shims or spacers used.
Remove the capscrews from the engine mounts.
NOTE: Certain applications will require loosening of the
rear engine mount fasteners to allow removal of the front
engine support bracket.
Inspect for Reuse

CAUTION
Damaged engine mounts and brackets can cause
engine misalignment. Drivetrain component damage
can result in excessive vibration complaints.
Inspect all rubber-cushioned mounts for cracks and other
damage. Look for interference or contact between metal
components.
Inspect all mounting brackets for cracks and damaged
bolt holes.
Inspect the mounting capscrew to make sure it is not too
long, which will not provide enough preload on the mount.
Replace any damaged parts as necessary.
NOTE: Damaged engine mounts, brackets, and mounting
hardware can cause the engine to move out of alignment
and damage the driveline components in the equipment.
This can result in vibration complaints.
Engine Mounts Signature™, ISX, and QSX15 Eng [...]
Inspect the capscrew for the following:

• Damaged threads
• Rust or corrosion-caused pitting
• Nicked, bent, stretched, or galled.
The capscrew must be replaced if it has any of the listed
damages.
For barrel mounts, inspect for signs of contact between

the side brackets and the front engine support bracket.
Contact between the engine mount and side brackets can
cause vibration complaints. If contact is found, replace the
front engine support bracket.
Install
NOTE: Make sure to install any shims or spacers in the
same location as removed.
Align the engine in the chassis.
Install the engine mount fasteners and tighten. Refer to
the OEM for torque specifications.
Remove the lifting fixture or hoist from the engine lifting
brackets.
Connect all engine and chassis mounted accessories that
were removed.
Section 20 - Vehicle Braking - Group 20 Page 20-a
Section 20 - Vehicle Braking - Group 20

Section Contents
Page
Engine Brake Assembly ..................................................................................................................................20-1
Adjust.............................................................................................................................................................20-4
Initial Check....................................................................................................................................................20-2
Engine Brake Solenoid.................................................................................................................................20-2
Engine Brake Rocker Lever..........................................................................................................................20-3
Resistance Check...........................................................................................................................................20-1
Voltage Check.................................................................................................................................................20-1
Engine Brake Control Valve ..........................................................................................................................20-13
Install............................................................................................................................................................20-14
Remove.........................................................................................................................................................20-13
Engine Brake Piston ......................................................................................................................................20-15
Install............................................................................................................................................................20-16
Remove.........................................................................................................................................................20-15
Engine Brake Solenoid Valve ........................................................................................................................20-10
Finishing Steps............................................................................................................................................. 20-11
Install............................................................................................................................................................20-11
Remove.........................................................................................................................................................20-10
Engine Brake Wiring Harness .......................................................................................................................20-11
Install............................................................................................................................................................20-13
Threaded Brake Pass-Through...................................................................................................................20-13
Non-Threaded Brake Pass-Through............................................................................................................20-13
Remove.........................................................................................................................................................20-11
Threaded Brake Pass-Through...................................................................................................................20-11
Non-Threaded Brake Pass-Through............................................................................................................20-12
Page 20-b Section 20 - Vehicle Braking - Group 20

Signature™, ISX, and QSX15 Eng [...] Engine Brake Assembly
Section 20 - Vehicle Braking - Group 20 Page 20-1
Engine Brake Assembly (020-004)

Resistance Check
CAUTION
Do not connect the engine breakout cable to the
engine wiring harness connector. Connecting the
engine brake breakout cable to the engine wiring
harness will give a false reading when checking the
resistance.
Disconnect the engine wiring harness connector from the
cylinder head pass-through connector.
Connect one end of the engine brake breakout cable, Part
Number 3163150, to the cylinder pass-through connector.
NOTE: The black test port on the engine brake breakout

cable box is the common ground for all three solenoids.
The white test ports (1, 2, and 3) are used to test the
resistance of the corresponding brake solenoids (1, 2, and
3).
NOTE: The ignition key must be in the OFF position.

Check the resistance of each solenoid.
12 volt
• Cold engine - 8 to 10 ohms
• Hot engine - 16 to 20 ohms.
24 volt
• Cold engine - 32 to 40 ohms
• Hot engine - 60 to 80 ohms.
NOTE: If not within specification, using the engine brake
breakout tool, the engine brake wiring harness and
solenoids must be checked separately to identify the
faulty component. Refer to Procedure 020-012 (Engine
Brake Solenoid Valve) in Section 20. Refer to Procedure
020-015 (Engine Brake Wiring Harness) in Section 20.
Voltage Check
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
Engine Brake Assembly Signature™, ISX, and QSX15 Eng [...]
Page 20-2 Section 20 - Vehicle Braking - Group 20
Connect the red alligator clip of the engine brake breakout

cable to battery voltage and the black alligator clip to
ground.
NOTE: The black test port on the engine brake breakout

cable box is the common ground for all three solenoids.
The white test ports (1, 2, and 3) are used to read the
voltage of the corresponding brake solenoids 1, 2, and 3.
NOTE: The ignition key must be in the ON position.

Check the voltage of each solenoid.
The voltage should be 12-VDC for each solenoid.
NOTE: If not within specification, using the engine brake
breakout tool, the engine brake wiring harness and
solenoids must be checked separately to identify the
faulty component. Refer to Procedure 020-012 (Engine
Brake Solenoid Valve) in Section 20. Refer to Procedure
020-015 (Engine Brake Wiring Harness) in Section 20.
Initial Check
Engine Brake Solenoid
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
NOTE: The ignition key must be in the OFF position.

• Button No. 1 actuates solenoid No. 1 and brake
Number 1.
• Button No. 2 actuates solenoid No. 2 and brakes
Number 2 and 3.
• Button No. 3 actuates solenoid No. 3 and brakes
Number 4, 5, and 6.
Press the engine brake breakout cable box button (1, 2,

or 3) to activate the corresponding engine brake solenoid
(1, 2, or 3).
Listen for a clicking sound when activating the brake
solenoid. If no clicking sound can be heard when the
button is pressed, the corresponding solenoid valve and
the engine brake wiring harness must be checked
separately to identify the faulty component. Refer to
Procedure 020-012 (Engine Brake Solenoid Valve) in
Section 20. Refer to Procedure 020-015 (Engine Brake
Wiring Harness) in Section 20.
Engine Brake Rocker Lever

Install the splash shield , Part Number 3163092, to reduce

the amount of oil being thrown by the fuel pump drive gear.
Start the engine.
Press the engine brake breakout cable box button (1, 2,

or 3) to activate the corresponding engine brake solenoid
(1, 2, or 3).
Check the corresponding engine brake lever(s) and
solenoid for the following:
• Engine brake piston deployment
• Leakage from upper seals of solenoid.
Replace parts as needed. Refer to Procedure 020-012
(Engine Brake Solenoid Valve). Refer to Procedure
020-017 (Engine Brake Control Valve). Refer to Procedure
020-019 (Engine Brake Piston) in Section 20.
Adjust
All overhead adjustments must be made when the engine
is cold (any stabilized coolant temperature at 60°C [140°
F] or below).
CAUTION
Do not use solvent to clean the rocker cover gasket.
Solvent can damage the gasket material and cause it
to swell.
NOTE: Early engine vibration dampers are marked with

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

cover.
compressor drive.
WARNING
damage.
(1-2-3-4-5-6).
Without Air Compressor:

Use a 1 1/2-inch socket, push the barring gear into the

gear mesh and bar engine over counterclockwise.
NOTE: Rock the barring device back and forth until it
disengages.

NOTE: The intake valve rocker lever is always the long
lever on the valve rocker lever shaft.
NOTE: Early engine vibration dampers are marked with

BRAKE SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The
engine brakes must be set at the appropriate mark on
these engines. Newer engine vibration dampers are
marked with only A, B, or C, and are adjusted with the
valves and injector on the same cylinder.
damper.
Signature, ISX and QSX15

Brake Adjustment Sequence
Bar Engine in Direction of Pulley Brake

Rotation Position
Start A 1
Advance to B 5
Advance to C 3
Advance to A 6
Advance to B 2
Advance to C 4
Rotate the compressor drive or barring device in the

direction of engine rotation, clockwise. Align the A mark
on the vibration damper with the pointer on the gear cover.

NOTE: Both sets of valves are closed when the rocker
levers and the brake lever are loose. If both sets of valves
are not closed, rotate the compressor drive gear one
complete revolution, and align the A mark on the front
damper with the pointer again.
CAUTION
and BRAKE SET 3-4.
Rotate the compressor drive or barring device in the

direction of engine rotation, clockwise. Align the A mark
on the vibration damper with the pointer on the gear cover.

NOTE: Both sets of valves are closed when the rocker
levers and the brake lever are loose. If both sets of valves
are not closed, rotate the compressor drive gear one
complete revolution, and align the A mark on the front
damper with the pointer again.
Press the engine brake lever down to verify that the

camshaft follower is in contact with the camshaft.

the bottom of the engine brake piston and the top of

mm in
7.00 NOM 0.276

Hold the engine brake lever adjusting screw, and tighten

the locknut.
CAUTION
Engine damage can occur if running clearance is not
within specifications.
1. Rotate the engine brake rocker lever to the detent
(neutral) position.
Engine Brake Lever Running Clearance

mm in
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not fall in the given
specifications, loosen the rocker lever shaft and rotate the
rocker lever shaft, slightly, in the direction required to
bring the running clearance within specifications.
Recheck the brake running clearance.
NOTE: The rocker lever shafts must be adjusted so that
all three engine brake levers fall within the given running
clearance specification.
Repeat the process to adjust all engine brakes according

to the chart shown earlier in this procedure.
Install the rocker lever cover and gasket. Refer to

Procedure 014-013 (Aftertreatment Testing) in Section 14.
Engine Brake Solenoid Valve Signature™, ISX, and QSX15 Eng [...]
Engine Brake Solenoid Valve (020-012)

Preparatory Steps
003-011.
Remove
Disconnect the engine brake wiring harness from the
solenoid.
Use a 3/4 inch socket to remove the solenoid from the
manifold.
Discard the three solenoid o-rings.
Inspect for Reuse

Check the resistance of each solenoid with the wiring
harness disconnected from the solenoid.
Measure the resistance from the terminal to the body of
the solenoid, as indicated in the illustration.
12-VDC
Cold Engine 5 to 20 ohms
Hot Engine 5 to 20 ohms
24-VDC
Cold Engine 32 to 40 ohms
Hot Engine 60 to 80 ohms
Replace the solenoid if not within specifications.
Inspect the engine brake wiring harness, if the solenoids
are within specifications.
Signature™, ISX, and QSX15 Eng [...] Engine Brake Wiring Harness
Install
Lubricate the seal rings with clean engine oil.
Install the upper (1) and center (2) seal ring on the
solenoid.
Coat the inside of the manifold with oil and place the lower
seal ring (3) in the bottom of the manifold.
Install the solenoid into the manifold.
Tighten the solenoid.
Connect the engine brake wiring harness to the solenoid.
Finishing Steps
003-011.
• Operate the engine and check for proper operation and
leaks.
Engine Brake Wiring Harness

(020-015)
Remove
Threaded Brake Pass-Through
NOTE: Early engines used a threaded brake pass-through
connector. A retaining nut was used to hold the pass-
through connector in place. Current production engines
utilize a clip to retain the pass-through connector.
Remove rocker lever cover. Refer to Procedure 003-011.
Disconnect the engine wiring harness from the brake
pass-through.
Remove the pass-through retaining nut.
Remove the brake pass-through connector from the
cylinder head.
Engine Brake Wiring Harness Signature™, ISX, and QSX15 Eng [...]
Non-Threaded Brake Pass-Through

Disconnect the engine wiring harness from the brake
harness pass-through connector.
Remove the brake pass-through retaining clip.
Remove the pass-through connector from the head.
NOTE: The engine brake harness can be laid over the side
of the engine to service overhead components. It is not
necessary to remove the brake pass-through connector.
Disconnect the solenoid wires.
With your hands about 18 inches apart, grasp the engine
brake wiring harness support bracket and pull it up and
out of the cylinder head.
Inspect for Reuse

With the wiring harness isolated from the solenoids,
inspect the wiring harness for broken wires or connectors.
Check the engine brake wiring harness for shorts. Refer

to fault codes 388, 392, and 393 in the Fuel Systems
Troubleshooting and Repair manual for procedures on
checking harness resistance.
Signature™, ISX, and QSX15 Eng [...] Engine Brake Control Valve
Install
Threaded Brake Pass-Through
Install the engine brake wiring harness support bracket
into the cylinder head.
Connect the solenoid wires.
Install and connect the brake pass-through connector to

the cylinder head.
Install and connect the brake pass-through retaining nut.
Install and connect the engine wiring harness to the brake
pass-through.
Non-Threaded Brake Pass-Through

Install and connect the brake pass-through connector to
the cylinder head.
Install and connect the brake pass-through retaining clip.
Install and connect the engine wiring harness.
Install and connect the rocker lever cover. Refer to
Procedure 003-011.
Engine Brake Control Valve (020-017)

Remove
003-011.
Engine Brake Control Valve Signature™, ISX, and QSX15 Eng [...]
WARNING
The control valve is spring-loaded. To avoid personal
injury, apply thumb pressure to the control valve
cover, slowly remove cover until spring pressure
ceases, and then remove the valve.
Use snap ring pliers to remove the snap ring and control
valve from rocker lever assembly.
Inspect for Reuse

Inspect the brake lever for wear in the control valve
counterbore area.
Replace the brake lever if the counterbore wear extends
beyond the snap ring groove diameter.
Inspect the control valve spring for breakage and free

length.
Spring Free Length

mm in
44.45 NOM 1.75
Replace the control valve spring if the free length is less
than the specification.
Install
Move the control valve in the bore to insure free
movement.
Lubricate the control valve assembly.
Install the control valve into rocker lever assembly and
snap ring.
Signature™, ISX, and QSX15 Eng [...] Engine Brake Piston
Engine Brake Piston (020-019)

Remove
003-011.
Rotate the engine to the appropriate valve set mark.
Loosen the locknut and back off exhaust valve lash

adjusting screw. Refer to Procedure 003-004.
Remove exhaust valve crosshead and crosshead guide
pin.
Remove the engine brake valve lash adjusting screw

locknut.
Turn the piston adjusting screw clockwise until piston
comes out of the Jake Brake® lever, catch it with your
hand.
NOTE: If the actuator piston is seized or stuck in the lever,
replace the Jake Brake® lever.
Engine Brake Piston Signature™, ISX, and QSX15 Eng [...]
Inspect for Reuse

Inspect the actuator piston face and the lever piston bore
for wear. Replace the Jake Brake® Lever, if excessive
wear is found on either the actuator piston or the lever
piston bore. Refer to Procedure 003-009 for rocker lever
inspection.
NOTE: Normal wear creates a uniform pattern around the
piston face. A piston exhibiting normal wear can be used
again, if proper running clearance can be obtained.
Install
Place the piston into the rocker arm.
Holding the piston in place, turn the adjusting screw
counterclockwise until the piston is seated. Install the
locknut.
Install the exhaust valve crosshead and crosshead guide

pin.
Adjust the appropriate exhaust valve and engine brake
lever. Refer to Procedure 003-004.

Cummins Service Publications Electronic Books on CD-ROM
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Cummins Service Publications Electronic Books on CD-ROM Information
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(continued)
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(continued)
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after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its
replacement by providing you an RMA#, you may send back the CD-ROM for a free replacement. To do so, you must
package the CD-ROM and ship/mail, with postage pre-paid by you, to the below address. You must also include a
photocopy of the original invoice for proof of purchase of the publication clearly indicating the bulletin # and the purchase
date. The RMA# must be on the address information of the package. If the proof of purchase copy of the invoice is not
enclosed, your request will not be able to be processed and will not be returned. Delivery of the replacement will be
shipped to you at no charge. Allow 3 to 4 weeks for your receipt of replacement copy. Note: Return only the non-
functional CD-ROM, do not return the entire printed publication. The replacement CD-ROM maintains the original
purchase/invoice date for the purposes of this replacement policy. This policy is subject to change at any time, without
notice. For a copy of the most current replacement options policy, please e-mail ebooksupport@merrickind.com with your
request.
Media Replacement Ship to Address:

Attn: Cummins Service Publications Electronic Books Technical Support
RMA#: XXXXXX (where XXXXXX is the RMA#)
808 E. Liberty Street
Louisville, KY 40204 U.S.A.
Cummins Service Publications Electronic Books on CD-ROM are Copyright © Cummins Inc.
Adobe Acrobat Reader is a registered trademark of Adobe Systems Incorporated.
Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation.
Intel and Pentium are trademarks of Intel Corporation.
HexaLock is Copyright © HexaLock, Ltd.
All other names and products used herein are trademarks for their respective owner.
Section L - Service Literature Page L-a
Section L - Service Literature

Section Contents
Page
Additional Service Literature ............................................................................................................................L-1
General Information..........................................................................................................................................L-1
Cummins Customized Parts Catalog ................................................................................................................L-3
General Information..........................................................................................................................................L-3
Ordering the Customized Parts Catalog.............................................................................................................L-3
Ordering by Telephone...................................................................................................................................L-3
Ordering On-Line...........................................................................................................................................L-3
Service Literature Ordering Location ...............................................................................................................L-2
Contact Information...........................................................................................................................................L-2
Page L-b Section L - Service Literature

Signature™, ISX, and QSX15 Eng [...] Additional Service Literature
Section L - Service Literature Page L-1
Additional Service Literature

General Information
The following publications can be purchased:
Bulletin Number Title of Publication
3666259 Troubleshooting and Repair Manual, Electronic Control System, Signature™, ISX and QSX15
Engines
3666393 Troubleshooting and Repair Manual, Generator-Drive Control System, QSX15, QSK45, and QSK60
Engines
3666394 Troubleshooting and Repair Manual, PowerCommand® Control, QSX15, QSK45, and QSK60
Engines
4021334 Troubleshooting and Repair Manual, CM870 Electronic Control System, Signature™, and ISX
Engines
4021560 ISM CM876 / ISX CM871 Electronic Control System, Troubleshooting and Repair Manual
3666268 Signature™ and ISX Wiring Diagram
3666414 QSX15 Industrial Wiring Diagram
3666349 QSX15 Generator Drive Wiring Diagram
3666466 QSX15 PowerCommand™ Wiring Diagram
4021341 Signature™ and ISX CM870 Control Module Wiring Diagram
4021575 ISX CM871 Wiring Diagram
3666311 Operation and Maintenance Manual - Signature™ and ISX Engines
4021345 Owner's Manual, Signature™, and ISX Engines
3666251 ISX CM871 Operation and Maintenance Manual
3379000 Air for Your Engines
3379001 Fuels for Cummins® Engines
3387266 Cold Weather Operation
3666132 Coolant Requirements and Maintenance Bulletin
3666209 Cooling System Maintenance Extended Interval
3810340 Cummins® Engine Oil Recommendations
Service Literature Ordering Location Signature™, ISX, and QSX15 Eng [...]
Page L-2 Section L - Service Literature
Service Literature Ordering Location

Contact Information
Region Ordering Location

United States and Canada Cummins Distributors
or
Credit Cards at 1-800-646-5609
or
Order online at www.powerstore.cummins.com
All Other Countries Cummins Distributors or Dealers
Signature™, ISX, and QSX15 Eng [...] Cummins Customized Parts Catalog
Section L - Service Literature Page L-3
Cummins Customized Parts Catalog

General Information
Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic
versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains
only the new factory parts that were used to build your engine.
The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite,
or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone
number. Your name and engine model identification even appears on the catalog spine. Everybody will know that
Cummins created a catalog specifically for you.
This new catalog was designed to provide you with the exact information you need to order parts for your engine. This
will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins
Parts Microfilm System.
Additional Features of the Customized Catalog include:
• Engine Configuration Data
• Separate Option and Parts Indexes
• Service Kits (when applicable)
• ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog
Ordering by Telephone
North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at
1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett
at (++)502-454-6660.
Ordering On-Line
The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card.
Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense.
Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the
CPC.
• Customer Name
• Street Address
• Company Name (optional)
• Telephone no.
• Credit Card No.
• Cummins Engine Serial Number (located on the engine data plate)
• Please identify the required media: Printed Catalog, CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer
than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs
and explain why we are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a
refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.
Cummins Customized Parts Catalog Signature™, ISX, and QSX15 Eng [...]
Page L-4 Section L - Service Literature
Notes
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Air Intake System ............................................................................................................................................V-77
Specifications.................................................................................................................................................V-77
Air Intake System - Group 10 - Specifications ...............................................................................................V-45
Charge-Air Cooler.................................................................................................................................................... V-45
Turbocharger............................................................................................................................................................V-45
Turbocharger Wastegate Actuator...........................................................................................................................V-45
Turbocharger Wastegate Valve Body...................................................................................................................... V-46
Turbocharger, Variable Geometry Actuator............................................................................................................. V-46
Air Intake System - Group 10 - Torque Values ..............................................................................................V-47
Air Intake Connection...............................................................................................................................................V-50
Air Leaks, Air Intake and Exhaust Systems............................................................................................................. V-47
Turbocharger............................................................................................................................................................V-47
Turbocharger Control Shutoff Valve Filter Head......................................................................................................V-51
Turbocharger Coolant Hoses...................................................................................................................................V-49
Turbocharger Wastegate Actuator...........................................................................................................................V-50
Turbocharger Wastegate Controller.........................................................................................................................V-50
Turbocharger, Variable Geometry Actuator............................................................................................................. V-51
Turbocharger, Variable Geometry Actuator Air Supply Line....................................................................................V-51
Turbocharger, Variable Geometry Control Valve Air Supply Line............................................................................V-51
Variable Geometry Turbocharger Actuator, Electric.................................................................................................V-52
Variable Geometry Turbocharger Cross Shaft.........................................................................................................V-52
Capscrew Markings and Torque Values .........................................................................................................V-85
Capscrew Markings and Torque Values - Metric..............................................................................................V-85
Capscrew Markings and Torque Values - U.S. Customary...............................................................................V-86
General Information........................................................................................................................................V-85
Compressed Air System .................................................................................................................................V-80
Cummins 18.7 CFM Model...........................................................................................................................V-80
Compressed Air System - Group 12 - Torque Values ....................................................................................V-62
Air Compressor........................................................................................................................................................ V-62
Air Compressor Coolant Lines................................................................................................................................. V-62
Cooling System ...............................................................................................................................................V-75
Automotive Applications...............................................................................................................................V-75
Industrial and Generator Drive..................................................................................................................... V-76
Cooling System - Group 08 - Specifications ..................................................................................................V-36
Coolant Thermostat..................................................................................................................................................V-36
Fan Hub, Belt Driven................................................................................................................................................V-36
Water Pump............................................................................................................................................................. V-36
Cooling System - Group 08 - Torque Values .................................................................................................V-38
Belt Tensioner, Automatic (Water Pump).................................................................................................................V-41
Coolant Filter Valve..................................................................................................................................................V-38
Coolant Thermostat..................................................................................................................................................V-38
Coolant Thermostat Housing....................................................................................................................................V-38
Cooling System........................................................................................................................................................V-39
Fan Drive Idler Pulley Assembly.............................................................................................................................. V-39
Fan Hub, Belt Driven................................................................................................................................................V-40
Fan Pulley................................................................................................................................................................ V-42
Fan Support..............................................................................................................................................................V-42
Water Inlet Connection.............................................................................................................................................V-42
Water Pump............................................................................................................................................................. V-40
Water Pump Cartridge..............................................................................................................................................V-42
Cylinder Block - Group 01 - Specifications ......................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Connecting Rod..........................................................................................................................................................V-1
Page V-b Section V - Specifications
Crankshaft..................................................................................................................................................................V-2
Cylinder Liner.............................................................................................................................................................V-3
Engine Base Timing...................................................................................................................................................V-5
Piston.........................................................................................................................................................................V-4
Piston Rings...............................................................................................................................................................V-4
Vibration Damper, Viscous.........................................................................................................................................V-4
Cylinder Block - Group 01 - Torque Values .....................................................................................................V-6
Bearings, Connecting Rod.........................................................................................................................................V-6
Bearings, Main...........................................................................................................................................................V-6
Block Stiffener Plate.................................................................................................................................................V-11
Bracket, Accessory.....................................................................................................................................................V-9
Bracket, Retaining Brace............................................................................................................................................V-8
Connecting Rod..........................................................................................................................................................V-6
Crankshaft Adapter....................................................................................................................................................V-6
Crankshaft Pulley.......................................................................................................................................................V-7
Crankshaft Seal, Front...............................................................................................................................................V-7
Crankshaft Seal, Rear................................................................................................................................................V-7
Engine Base Timing.................................................................................................................................................V-10
Gear Cover, Lower.....................................................................................................................................................V-8
Gear Cover, Upper.....................................................................................................................................................V-8
Gear Housing, Front...................................................................................................................................................V-8
Piston Cooling Nozzle................................................................................................................................................V-8
Vibration Damper, Viscous.........................................................................................................................................V-8
Cylinder Head - Group 02 - Specifications .....................................................................................................V-12
Cylinder Head...........................................................................................................................................................V-12
Overhead Camshaft End Clearance, Injector...........................................................................................................V-14
Overhead Camshaft End Clearance, Valve............................................................................................................. V-14
Overhead Camshaft, Injector................................................................................................................................... V-14
Overhead Camshaft, Valve......................................................................................................................................V-13
Cylinder Head - Group 02 - Torque Values ....................................................................................................V-15
Cylinder Head...........................................................................................................................................................V-15
Overhead Camshaft, Injector................................................................................................................................... V-15
Overhead Camshaft, Valve......................................................................................................................................V-15
Valve Guide Seal, Cylinder Head.............................................................................................................................V-15
Drive Belt Tension ..........................................................................................................................................V-82
Tension Chart.................................................................................................................................................V-82
Drive Units - Group 09 - Torque Values .........................................................................................................V-43
Alternator/Refrigerant Compressor Mounting Bracket............................................................................................. V-44
Belt Tensioner, Refrigerant Compressor, Automatic................................................................................................V-43
Idler Pulley, Refrigerant Compressor.......................................................................................................................V-43
Refrigerant Compressor...........................................................................................................................................V-43
Refrigerant Compressor Mounting Bracket..............................................................................................................V-43
Electrical Equipment - Group 13 - Torque Values .........................................................................................V-63
Alternator..................................................................................................................................................................V-63
Alternator Idler Pulley...............................................................................................................................................V-64
Alternator Pulley.......................................................................................................................................................V-63
Alternator Spacer..................................................................................................................................................... V-64
Belt Tensioner, Automatic (Alternator).....................................................................................................................V-64
Bracket, Idler Pulley and Alternator Belt Tensioner..................................................................................................V-64
Starting Motor...........................................................................................................................................................V-63
Electrical System ............................................................................................................................................V-79
Engine Testing ................................................................................................................................................V-81
Engine Testing - Group 14 - Specifications ...................................................................................................V-65
Engine Testing (Chassis Dynamometer)..................................................................................................................V-65
Engine Testing (Engine Dynamometer)...................................................................................................................V-65
Exhaust System ..............................................................................................................................................V-78
Automotive Applications...............................................................................................................................V-78
Industrial and Generator Drive..................................................................................................................... V-78
Automotive With CM871...............................................................................................................................V-78
Exhaust System - Group 11 - Specifications ................................................................................................. V-53
Section V - Specifications Page V-c
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes............................................................V-53

Exhaust Restriction..................................................................................................................................................V-53
Exhaust System - Group 11 - Torque Values .................................................................................................V-54
Aftertreatment Adapter Pipe.....................................................................................................................................V-58
Aftertreatment Diesel Oxidation Catalyst.................................................................................................................V-59
Aftertreatment Diesel Particulate Filter.....................................................................................................................V-58
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting Bracket..........................................V-58
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes............................................................V-59
Aftertreatment Fuel Injector......................................................................................................................................V-58
Aftertreatment Fuel Injector Flow.............................................................................................................................V-61
Aftertreatment Fuel Shutoff Manifold........................................................................................................................V-60
Aftertreatment Injector Lines....................................................................................................................................V-59
Aftertreatment Inlet and Outlet.................................................................................................................................V-59
EGR Connection Tubes...........................................................................................................................................V-55
EGR Cooler..............................................................................................................................................................V-54
EGR Cooler Connection...........................................................................................................................................V-55
EGR Cooler Coolant Lines.......................................................................................................................................V-57
EGR Differential Pressure Sensor Adapter..............................................................................................................V-56
EGR Differential Pressure Sensor Tubes.................................................................................................................V-56
EGR Mixer................................................................................................................................................................V-55
EGR Valve................................................................................................................................................................V-55
EGR Valve Coolant Lines.........................................................................................................................................V-57
EGR Valve Mounting Bracket...................................................................................................................................V-58
Exhaust Gas Pressure Sensor Adapter...................................................................................................................V-58
Exhaust Gas Pressure Sensor Tube........................................................................................................................V-56
Exhaust Manifold, Dry..............................................................................................................................................V-54
Heat Shield...............................................................................................................................................................V-57
Fraction, Decimal, Millimeter Conversions ....................................................................................................V-83
Conversion Chart............................................................................................................................................V-83
Fuel System ....................................................................................................................................................V-73
Fuel System - Group 05 - Torque Values .......................................................................................................V-20
Fuel Inlet Pre-Filter...................................................................................................................................................V-26
Fuel Lift Pump..........................................................................................................................................................V-21
Fuel Pump................................................................................................................................................................V-20
Fuel Pump Pulsation Damper..................................................................................................................................V-20
Fuel Shutoff Valve....................................................................................................................................................V-20
Integrated Fuel System Module (IFSM)...................................................................................................................V-21
General Engine ................................................................................................................................................V-72
Automotive with CM870...............................................................................................................................V-72
Automotive With CM871...............................................................................................................................V-72
Injectors and Fuel Lines - Group 06 - Specifications ....................................................................................V-28
Fuel Filter (Spin-On Type)........................................................................................................................................V-28
Fuel Inlet Restriction.................................................................................................................................................V-28
Injectors and Fuel Lines - Group 06 - Torque Values ....................................................................................V-29
ECM Cooling Plate, Fuel Cooled..............................................................................................................................V-29
Fuel Drain Line Restriction.......................................................................................................................................V-29
Injector......................................................................................................................................................................V-29
Lubricating Oil System ...................................................................................................................................V-74
Lubricating Oil System - Group 07 - Specifications ......................................................................................V-30
Lubricating Oil Cooler...............................................................................................................................................V-30
Lubricating Oil Filter Bypass Valve...........................................................................................................................V-30
Lubricating Oil High Pressure Relief Valve..............................................................................................................V-30
Lubricating Oil Pump................................................................................................................................................V-30
Lubricating Oil System - Group 07 - Torque Values ......................................................................................V-33
Lubricating Oil Cooler...............................................................................................................................................V-33
Lubricating Oil Cooler Element.................................................................................................................................V-33
Lubricating Oil Dipstick Tube....................................................................................................................................V-33
Lubricating Oil Fill Tube............................................................................................................................................V-35
Lubricating Oil Filter Bypass Valve...........................................................................................................................V-33
Lubricating Oil Filter Head Adapter..........................................................................................................................V-34
Page V-d Section V - Specifications
Lubricating Oil Pan...................................................................................................................................................V-34

Lubricating Oil Pump................................................................................................................................................V-34
Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-34
Lubricating Oil System.............................................................................................................................................V-34
Lubricating Oil Thermostat.......................................................................................................................................V-35
Mounting Adaptations - Group 16 - Specifications ........................................................................................V-66
Flywheel...................................................................................................................................................................V-66
Flywheel Housing, REPTO.......................................................................................................................................V-66
Mounting Adaptations - Group 16 - Torque Values .......................................................................................V-67
Engine Lifting Brackets.............................................................................................................................................V-67
Flywheel...................................................................................................................................................................V-67
Flywheel Housing.....................................................................................................................................................V-67
Flywheel Housing, REPTO.......................................................................................................................................V-67
Newton-Meter to Foot-Pound Conversions ....................................................................................................V-87
Pipe Plug Torque Values ................................................................................................................................V-88
Torque Table..................................................................................................................................................V-88
Rocker Levers - Group 03 - Specifications ....................................................................................................V-16
Overhead Set...........................................................................................................................................................V-16
Rocker Lever Assembly...........................................................................................................................................V-16
Rocker Levers - Group 03 - Torque Values ...................................................................................................V-18
Crankcase Breather (External).................................................................................................................................V-18
Crankcase Breather (Internal)..................................................................................................................................V-18
Overhead Set...........................................................................................................................................................V-18
Rocker Lever Assembly...........................................................................................................................................V-19
Rocker Lever Cover.................................................................................................................................................V-19
Tap-Drill Chart - U.S. Customary and Metric .................................................................................................V-89
Vehicle Braking - Group 20 - Specifications ..................................................................................................V-70
Engine Brake Assembly...........................................................................................................................................V-70
Engine Brake Control Valve.....................................................................................................................................V-70
Vehicle Braking - Group 20 - Torque Values .................................................................................................V-71
Engine Brake Assembly...........................................................................................................................................V-71
Engine Brake Solenoid Valve...................................................................................................................................V-71
Engine Brake Wiring Harness..................................................................................................................................V-71
Weights and Measures - Conversion Factors ................................................................................................V-84
Signature™, ISX, and QSX15 Eng [...] Cylinder Block - Group 01 - Specifications
Section V - Specifications Page V-1
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Cylinder Block - Group 01 - Specifications

Standard Connecting Rod Bearing 2.366 mm MIN 0.093 in
Thickness
2.378 mm MAX 0.094 in

Standard Main Bearing Shell Thickness 3.196 mm MIN 0.126 in
3.214 mm MAX 0.127 in
Crankshaft End Clearance - New or 0.10 mm MIN 0.004 in

Reground
0.50 mm MAX 0.020 in

Connecting Rod Crankshaft Bore Inside 98.801 mm MIN 3.890 in
Diameter
98.839 mm MAX 3.891 in
Connecting Rod Piston Pin Bushing Inside 63.55 mm MIN 2.502 in

Diameter
63.57 mm MAX 2.503 in
Connecting Rod Length 261.45 mm MIN 10.293 in

261.55 mm MAX 10.297 in
Maximum Connecting Rod Bend (Bushing 0.021 mm MAX 0.0008 in

Installed)
Cylinder Block - Group 01 Signature™, ISX, and QSX15 Eng [...]
Page V-2 Section V - Specifications
Ref.No./
Steps
.
Maximum Connecting Rod Twist (Bushing 0.05 mm MAX 0.002 in

Installed)
Crankshaft Connecting Rod Journal Outside 93.98 mm MIN 3.700 in
Diameter
94.02 mm MAX 3.702 in
Crankshaft Main Bearing Journal Outside 126.98 mm MIN 4.999 in

Diameter
127.02 mm MAX 5.001 in
Crankshaft Thrust Face Width 54.95 mm MIN 2.163 in

55.05 mm MAX 2.167 in
Flange Diameter Location (1) 164.964 MIN 6.495

165.035 MAX 6.497
165.525 MAX 6.517

139.63 MAX 5.497
140.04 MAX 5.513
Crankshaft Pilot Outside Diameter 49.985 mm MIN 1.968 in

50.015 mm MAX 1.969 in
Signature™, ISX, and QSX15 Eng [...] Cylinder Block - Group 01
Ref.No./
Steps
.
Total Indicator Runout 0.200 mm MAX 0.008 in
Adjacent Journal Runout 0.075 mm MAX 0.003 in
Rear Oil Seal Flange Total Indicator Runout 0.03 mm MAX 0.0012 in
Front Oil Seal Crankshaft Adapter Diameter 0.05 mm MAX 0.002 in

Runout

Cylinder Liner Pitting Depth 1.60 mm MAX 0.060 in
Cylinder Liner Inside Diameter 137.14 mm MAX 5.40 in
Cylinder Top Press Fit Outside Diameter 160.98 mm MAX 6.34 in

Ref.No./
Steps
.
Cylinder Liner Recession (Groove-Top 0.36 mm MIN 0.014 in

Cylinder Liners)
0.51 mm MAX 0.019 in
Cylinder Liner Protrusion (Flat-Top Cylinder 0.18 mm MIN 0.007 in
Liners)
0.33 mm MAX 0.014 in
Piston (001-043)
Articulated Piston Pin Bore Inside Diameter 63.56 mm MIN 2.502 in
(Crown)
63.58 mm MAX 2.503 in
Articulated Piston Pin Bore Inside Diameter 63.513 mm MIN 2.5005 in
(Skirt)
63.525 mm MAX 2.5010 in
Piston Pin Outside Diameter 63.4670 MIN 2.4987 in

mm
63.4999 MAX 2.5000 in
mm
Articulated Piston Pin Length 109.5 mm MIN 4.311 in
110.0 mm MAX 4.331 in
Single-Piece Piston Pin Length 84.6 mm MIN 3.331 in
85.1 mm MAX 3.350 in
Articulated Piston Ring Gap
Top 0.33 MIN 0.013
0.53 MAX 0.021
2.13 MAX 0.084
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Single-Piece Piston Ring Gap
Top 0.33 MIN 0.013
0.53 MAX 0.021
1.23 MAX 0.048
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Vibration Damper Eccentricity 0.28 mm MAX 0.011 in
Vibration Damper Wobble Measurement 0.28 mm MAX 0.011 in

Ref.No./
Steps
.

Lower Idler Shaft Outside Diameter 88.88 mm MIN 3.4992 in
88.89 mm MAX 3.4997 in
Adjustable Idler Shaft Outside Diameter 88.88 mm MIN 3.4992 in
88.89 mm MAX 3.4997 in
Lower Idler Gear Bore Inside Diameter 88.962 mm MIN 3.5024 in

88.988 mm MAX 3.5035 in
Adjustable Idler Gear Bore Inside Diameter 88.962 mm MIN 3.5024 in
88.988 mm MAX 3.5035 in
Shim Tolerance 0.225 mm MIN 0.009 in

0.275 mm MAX 0.011 in
Cylinder Block - Group 01 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cylinder Block - Group 01 - Torque Values

Used Connecting Rod Capscrews Tighten 1 70 ± 6 [ 52 ± 4 ft-
Capscrews In Numerical Sequence N•m lb ]
New Connecting Rod Capscrews Tighten 2 Rotate capscrews in numerical
Capscrews In Numerical Sequence sequence 60 ± 5 degrees
1 40 ± 6 [ 29 ± 4 ft-
N•m lb ]
2 Loosen capscrews in numerical
sequence
3 70 ± 6 [ 52 ± 4 ft-
N•m lb ]
4 Rotate capscrews in numerical
Old Blocks Main Bearing Cap Capscrews 1 149 N•m [ 110 ft-lb ]
2 Rotate 180 degrees.
Block Main Bearing Capscrews 1 149 N•m [ 110 ft-lb ]

2 Rotate 180 degrees.

Used Connecting Rod Capscrews Tighten 1 70 ± 6 [ 52 ± 4 ft-
Capscrews In Numerical Sequence N•m lb ]
New Connecting Rod Capscrews Tighten 2 Rotate capscrews in numerical
Capscrews In Numerical Sequence sequence 60 ± 5 degrees
1 40 ± 6 [ 29 ± 4 ft-
N•m lb ]
2 Loosen capscrews in numerical
sequence
3 70 ± 6 [ 52 ± 4 ft-
N•m lb ]
4 Rotate capscrews in numerical
Crankshaft Adapter (001-017)
13.6 N•m [ 120 in-lb ]
13.6 N•m [ 120 in-lb ]

Ref.No./
Steps
.
Crankshaft Pulley (001-022)

Crankshaft Pulley Mounting Capscrews - 175 N•m [ 130 ft-lb ]
Automotive
Crankshaft Pulley Mounting Capscrews - 175 N•m [ 130 ft-lb ]

Industrial And Power Generation
Crankshaft Pulley Mounting Capscrews 175 N•m [ 130 ft-lb ]

With Crank Driven Fan

Crankshaft Seal Replacer Plate Capscrews 20 N•m [ 177 in-lb ]
Front Crankshaft Seal Capscrews 8 N•m [ 71 in-lb ]
Lower Gear Cover Mounting Capscrews 28 N•m [ 248 in-lb ]

Rear Crankshaft Seal Replacer Plate 16 N•m [ 142 in-lb ]
Capscrews
Ref.No./
Steps
.

Front Gear Housing Capscrews All 1 20 N•m [ 15 ft-lb ]
Capscrews Except (1) 2 72 N•m [ 53 ft-lb ]
Front Gear Housing Capscrews Capscrew 1 20 N•m [ 15 ft-lb ]
(1) 2 56 N•m [ 41 ft-lb ]

Piston Cooling Nozzle Capscrews 65 N•m [ 48 ft-lb ]

Vibration Damper Mounting Capscrew 175 N•m [ 130 ft-lb ]

Upper Gear Cover Capscrews - Automotive 28 N•m [ 21 ft-lb ]
Upper Gear Cover Capscrews - Industrial 28 N•m [ 21 ft-lb ]

And Power Generation

Lower Gear Cover Capscrews 28 N•m [ 248 in-lb ]
Bracket, Retaining Brace (001-081)

Retaining Brace Bracket To Gear Housing 45 N•m [ 33 ft-lb ]
Capscrews
Ref.No./
Steps
.
Retaining Brace Bracket To Cylinder Head 100 N•m [ 74 ft-lb ]

Capscrews
Mounting Spacer Capscrews 105 N•m [ 75 ft-lb ]
Engine Lifting Bracket Capscrews 80 N•m [ 60 ft-lb ]
Bracket, Accessory (001-082)

Accessory Bracket To Gear Housing 45 N•m [ 33 ft-lb ]
Mounting Capscrews - Automotive
Accessory Bracket To Cylinder Head 45 N•m [ 33 ft-lb ]

Mounting Capscrews - Automotive
Camshaft Position Sensor Capscrew - 25 N•m [ 221 in-lb ]

Automotive
Accessory Bracket Capscrews - Industrial 28 N•m [ 248 in-lb ]

And Power Generation
Ref.No./
Steps
.
Accessory Bracket Mounting Spacer 105 N•m [ 77 ft-lb ]

Capscrews - Industrial And Power
Generation
Camshaft Position Sensor Capscrew - 25 N•m [ 221 in-lb ]

Industrial And Power Generation

Lower Idler Scissor Gear Loading Screws 28 N•m [ 248 in-lb ]
Injector Camshaft Rear Cover Plate 40 N•m [ 30 ft-lb ]
Injector Camshaft Rear Cover Plate 40 N•m [ 30 ft-lb ]
Injector Camshaft Scissor Gear Loading 28 N•m [ 248 in-lb ]

Screws
Valve Camshaft Scissor Gear Retaining 148 N•m [ 109 ft-lb ]

Capscrew
Ref.No./
Steps
.
Valve Camshaft Non-Scissor Gear 148 N•m [ 109 ft-lb ]

Retaining Capscrew

Block Stiffener Plate Capscrews 137 N•m [ 102 ft-lb ]
Cylinder Head - Group 02 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cylinder Head - Group 02 - Specifications

1.21 MAX 0.048
0.77 MAX 0.030
Valve to Valve Seat Vacuum 508 mm MIN 20 in Hg

Hg
685 mm MAX 25 in Hg
Hg
A to A 0.15 MAX 0.006

B to B 0.15 MAX 0.006
C to C 0.15 MAX 0.006
Valve Spring Load at 61.75 mm [2.431 in] 1511 N MIN 339.5 lbf
1604 N MAX 360.5 lbf
Valve Stem Outside Diameter 9.593 mm MIN 0.378 in

9.627 mm MAX 0.379 in
Used Valve Guide Inside Diameter (Installed) 9.663 mm MIN 0.380 in

9.713 mm MAX 0.382 in
Valve Guide Height (Installed) 44.77 mm MIN 1.763 in

45.77 mm MAX 1.802 in
Signature™, ISX, and QSX15 Eng [...] Cylinder Head - Group 02
Ref.No./
Steps
.

1.21 MAX 0.048
0.77 MAX 0.030
Valve Guide Bore Inside Diameter 16.48 mm MIN 0.649 in

16.50 mm MAX 0.650 in

9.48 MAX 0.373
10.48 MAX 0.413

49.54 MAX 1.950
47.54 MAX 1.872
Valve Guide Height (Installed) 44.77 mm MIN 1.763 in

45.77 mm MAX 1.802 in
New Valve Guide Inside Diameter (Installed) 9.66 mm MIN 0.380 in

9.71 mm MAX 0.382 in

Valve Camshaft Bearing Journal Outside 64.987 mm MIN 2.5585 in
Diameter
65.013 mm MAX 2.5596 in
Cylinder Head - Group 02 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.

Injector Camshaft Bearing Journal Outside 84.987 mm MIN 3.3459 in
Diameter
85.013 mm MAX 3.3469 in
Overhead Camshaft End Clearance, Valve (002-028)

Valve Camshaft End Clearance 0.70 mm MAX 0.0276 in
Overhead Camshaft End Clearance, Injector (002-029)

Injector Camshaft End Clearance 0.70 mm MAX 0.0276 in
Signature™, ISX, and QSX15 Eng [...] Cylinder Head - Group 02 - Torque Values
Ref.No./
Steps
.
Cylinder Head - Group 02 - Torque Values

54 N•m [ 40 ft-lb ]
54 N•m [ 40 ft-lb ]
Valve Guide Seal, Cylinder Head (002-016)

54 N•m [ 40 ft-lb ]
54 N•m [ 40 ft-lb ]

Valve Camshaft Retainer Plate Capscrews 40 N•m [ 30 ft-lb ]

Injector Camshaft Retainer Plate 40 N•m [ 30 ft-lb ]
Capscrews
Injector Camshaft Cover Plate 40 N•m [ 30 ft-lb ]

Rocker Levers - Group 03 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Rocker Levers - Group 03 - Specifications

Brake Running Clearance 0.635 mm MIN 0.025 in
2.79 mm MAX 0.110 in

Engine Brake Rocker Lever Running 0.635 mm MIN 0.025 in

Clearance
2.790 mm MAX 0.110 in

Valve and Brake Rocker Lever Shaft Outside 34.950 mm MIN 1.3760 in
Diameter
35.000 mm MAX 1.3780 in
Injector Rocker Lever Shaft Outside 44.950 mm MIN 1.7697 in

Diameter
45.000 mm MAX 1.7717 in
Valve and Brake Rocker Lever Bushing Bore 35.037 mm MIN 1.3794 in
Inside Diameter
35.138 mm MAX 1.3834 in
Signature™, ISX, and QSX15 Eng [...] Rocker Levers - Group 03
Ref.No./
Steps
.
Injector Rocker Lever Bushing Bore Inside 45.037 mm MIN 1.7731 in

Diameter
45.138 mm MAX 1.7771 in
Intake and Exhaust Valve Adjusting Screw 46 mm MIN 1.81 in

Length
Rocker Lever Spacer Width 11.5 mm MIN 0.453 in

Rocker Levers - Group 03 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Rocker Levers - Group 03 - Torque Values

Crankcase Breather (External) (003-001)
Crankcase Vent Hose 28 N•m [ 21 ft-lb ]
M10 47 N•m [ 35 ft-lb ]

M8 20 N•m [ 15 ft-lb ]
Crankcase Breather (Internal) (003-002)

Crankcase Breather 45 N•m [ 33 ft-lb ]
Seal Carrier 20 N•m [ 177 in-lb ]

20 N•m [ 15 ft-lb ]

Injector Lever Adjusting Screw 8 N•m [ 71 in-lb ]
Injector Lever Adjusting Screw Locknut 75 N•m [ 55 ft-lb ]
Valve Adjusting Screw 0.6 N•m [ 5 in-lb ]

Signature™, ISX, and QSX15 Eng [...] Rocker Levers - Group 03
Ref.No./
Steps
.
Valve Lever Adjusting Screw Locknut 45 N•m [ 33 ft-lb ]
Engine Brake Lever Adjusting Screw 20 N•m [ 177 in-lb ]

Locknut

Valve Rocker Lever Front Mounting 30 N•m [ 22 ft-lb ]
Capscrew 1 30 N•m [ 22 ft-lb ]
2 Rotate 60 degrees
Valve Rocker Lever Front Mounting 30 N•m [ 22 ft-lb ]

Capscrew 1 30 N•m [ 22 ft-lb ]
2 Rotate 60 degrees
68 N•m [ 50 ft-lb ]
1 30 N•m [ 22 ft-lb ]
2 Rotate 60 degrees

Rocker Lever Cover Capscrews 25 N•m [ 18 ft-lb ]
Fuel System - Group 05 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Fuel System - Group 05 - Torque Values

Fuel Pump (005-016)
Fuel Pump Capscrews 6.5 N•m [ 50 in-lb ]
13 N•m [ 100 in-lb ]
Cooling Plate Return Line 25 N•m [ 221 in-lb ]
Fuel Pump Torx® Head Screws 7 N•m [ 62 in-lb ]
Fuel Pump Pulsation Damper (005-031)

Pulsation Damper Capscrew Lower 9.5 N•m [ 84 in-lb ]
9.5 N•m [ 84 in-lb ]
Fuel Pump Pulsation Damper Screws A And 9.5 N•m [ 84 in-lb ]

B 5.5 N•m [ 48 in-lb ]
Fuel Pump Pulsation Damper Screw C
Fuel Shutoff Valve (005-043)

Fuel Shutoff Valve Coil Allen Head 3.4 N•m [ 30 in-lb ]
Capscrews
Fuel Shutoff Valve Electrical Connection 3 N•m [ 25 in-lb ]

Nut
Signature™, ISX, and QSX15 Eng [...] Fuel System - Group 05
Ref.No./
Steps
.
Fuel Lift Pump (005-045)

Fuel Lift Pump Assembly Bolts 12.5 N•m [ 110 in-lb ]
18 N•m [ 159 in-lb ]
Industrial Fuel Lift Pump Mounting 25 N•m [ 212 in-lb ]

Capscrews
Industrial Fuel Lift Pump Outlet Line 27 N•m [ 239 in-lb ]
Remote Mount Lift Pump Filter Screen 23 N•m [ 204 in-lb ]

Retaining Plug
Remote Mount Fuel Lift Pump Mounting 45 N•m [ 33 ft-lb ]

Capscrews
Integrated Fuel System Module (IFSM) (005-073)

Ifsm 1724-Kpa [250-Psi] Fuel Pressure 27 N•m [ 239 in-lb ]
Regulator (Without Egr)
Fuel System - Group 05 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Ifsm 2206-Kpa [320-Psi] Fuel Pressure 27 N•m [ 239 in-lb ]

Regulator (Without Egr)
Ifsm Fuel Inlet Check Valves (Without Egr) 17 N•m [ 150 in-lb ]
Fuel Control Damper 9.5 N•m [ 84 in-lb ]
Fuel Pressure Regulators 27 N•m [ 239 in-lb ]
Fuel Pressure Sensor 23 N•m [ 204 in-lb ]
Temperature Sensor 23 N•m [ 204 in-lb ]
Compuchek Fitting 9.5 N•m [ 84 in-lb ]

Ref.No./
Steps
.
Check Valve 17 N•m [ 150 in-lb ]
Cooling Plate Supply Fitting 27 N•m [ 239 in-lb ]
Fuel Drain Fitting 45 N•m [ 33 ft-lb ]
Metering Actuator 15 N•m [ 133 in-lb ]
Timing Actuator 15 N•m [ 133 in-lb ]
Assembly To Housing 5.5 N•m [ 49 in-lb ]
Threaded Plugs 17 N•m [ 150 in-lb ]

14 N•m [ 124 in-lb ]

27 N•m [ 239 in-lb ]
Ref.No./
Steps
.
Fitting To Gear Pump 27 N•m [ 239 in-lb ]
Pump To Ifsm 11 N•m [ 97 in-lb ]
Lift Pump To Housing 18 N•m [ 159 in-lb ]
Fuel Control Damper 9.5 N•m [ 84 in-lb ]
Fuel Pressure Sensor 23 N•m [ 204 in-lb ]
Air Bleed 7.9 N•m [ 70 in-lb ]

Ref.No./
Steps
.
Compuchek Fitting 9.5 N•m [ 84 in-lb ]
Check Valve 17 N•m [ 150 in-lb ]
Cooling Plate Supply Fitting 17 N•m [ 150 in-lb ]
Filter Screen And Filter Cap 17 N•m [ 150 in-lb ]
Fuel Drain Fitting 45 N•m [ 33 ft-lb ]
Metering Actuator 15 N•m [ 133 in-lb ]
Timing Actuator 15 N•m [ 133 in-lb ]
Assembly To Housing 5.5 N•m [ 49 in-lb ]

Ref.No./
Steps
.

14 N•m [ 124 in-lb ]
Fitting To Gear Pump 27 N•m [ 239 in-lb ]
Pump To Ifsm 11 N•m [ 97 in-lb ]
Lift Pump To Housing 18 N•m [ 159 in-lb ]
Integrated Fuel System Module (With Egr) 45 N•m [ 33 ft-lb ]
Fuel Inlet Pre-Filter (005-096)

Inlet Pre-Filter 60 N•m [ 44 ft-lb ]
Inlet Pre-Filter 60 N•m [ 44 ft-lb ]

Ref.No./
Steps
.
Fuel Pump Screen Cap 17 N•m [ 150 in-lb ]

Injectors and Fuel Lines - Group 06 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Specifications

Fuel Filter Restriction 517 kPa MAX 75 psi
Upper Location 356 MAX 14

Lower Location 305 MAX 12
Fuel Inlet Restriction (006-020)

Without remote fuel filter 76 MAX 3
With remote fuel filter 254 MAX 10
Signature™, ISX, and QSX15 Eng [...] Injectors and Fuel Lines - Group 06 - Torque Values
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Torque Values

ECM Cooling Plate, Fuel Cooled (006-006)
20 N•m [ 15 ft-lb ]
20 N•m [ 15 ft-lb ]
25 N•m [ 18 ft-lb ]
Fuel Drain Line Restriction (006-012)

Fuel Drain Hose 35 N•m [ 26 ft-lb ]
Injector (006-026)
Front Mounting Plate Capscrews 15.3 N•m [ 135 in-lb ]
Rear Mounting Plate Capscrews 15.3 N•m [ 135 in-lb ]
Injector Spring Retainer Capscrew 30 N•m [ 22 ft-lb ]
Injector Retaining Capscrew 80 N•m [ 59 ft-lb ]

Lubricating Oil System - Group 07 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Specifications

Lubricating Oil Cooler Housing Seat Depth 123.47 mm MIN 4.861 in
Lubricating Oil Filter Bypass Valve (007-014)
Lubricating Oil High Pressure Relief Valve (007-021)
High Pressure Relief Valve Spring 281.47 N MIN 63.277 lbf

(Compressed Length) Load at 45.82 mm
[1.804 in]
298.87 N MAX 67.189 lbf

Regulator Bore Depth Specification 186.95 mm MIN 7.3602 in
187.45 mm MAX 7.380 in
Lubricating Oil Pressure Regulator Spring 131.8 N MIN 29.6 lbf

Load at 70 mm [2.756 in]
135.3 N MAX 30.4 lbf
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07
Ref.No./
Steps
.
High Pressure Relief Valve Spring 281.5 N MIN 63.3 lbf

(Compressed Length) Load at 45.82 mm
[1.804 in]
298.9 N MAX 67.2 lbf
External Idler Gear Bushing Inside Diameter 32.044 mm MIN 1.2616 in

32.069 mm MAX 1.2626 in
External Drive Gear Inside Diameter (No 24.909 mm MIN 0.9807 in

Bushing)
24.935 mm MAX 0.9817 in
Internal Idler Gear Inside Diameter 24.909 mm MIN 0.9807 in

24.935 mm MAX 0.9817 in
Internal Idler Shaft Outside Diameter 24.858 mm MIN 0.9787 in

24.871 mm MAX 0.9792 in
Internal Drive Gear Shaft Outside Diameter 24.858 mm MIN 0.9787 in

24.871 mm MAX 0.9792 in
Drive Shaft End Clearance 0.100 mm MIN 0.003 in

0.163 mm MAX 0.006 in
Lubricating Oil System - Group 07 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Oil Pump Idler Gear Backlash 0.18 mm MIN 0.008 in

0.46 mm MAX 0.018 in
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07 - Torque Values
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Torque Values

Dual-Element Lubricating Oil Cooler (With 47 N•m [ 35 ft-lb ]
Egr)
Lubricating Oil Cooler Element (007-007)

Lubricating Oil Cooler Pressure Test Plate 20 N•m [ 15 ft-lb ]
Single-Element Lubricating Oil Cooler 20 N•m [ 15 ft-lb ]

Element Capscrew
Dual-Element Lubricating Oil Cooler 20 N•m [ 15 ft-lb ]

Element Capscrew
Lubricating Oil Dipstick Tube (007-011)

Lubricating Oil Dipstick Tube Nut 70 N•m [ 52 ft-lb ]
70 N•m [ 52 ft-lb ]
Lubricating Oil Filter Bypass Valve (007-014)

Lubricating Oil Cooler Transfer Housing 45 N•m [ 33 ft-lb ]
Retaining Plug
Lubricating Oil System - Group 07 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Lubricating Oil Filter Head Adapter (007-018)

Lubricating Oil Filter Head Adapter 450 N•m [ 332 ft-lb ]

Lubricating Oil Pan Mounting Capscrews 55 N•m [ 41 ft-lb ]
47 N•m [ 35 ft-lb ]

Lubricating Oil Pump Cover Capcrews 29 N•m [ 21 ft-lb ]
External Idler Gear Retainer Capscrew 115 N•m [ 85 ft-lb ]
Lubricating Oil Pump Mounting Capscrews 56 N•m [ 41 ft-lb ]
Lubricating Oil Suction Tube (Block-Mounted) (007-035)

Lubricating Oil Suction Tube Capscrews 47 N•m [ 35 ft-lb ]

Lubricating Oil Cooler Housing Plug 34 N•m [ 25 ft-lb ]
Signature™, ISX, and QSX15 Eng [...] Lubricating Oil System - Group 07
Ref.No./
Steps
.
Lubricating Oil Thermostat (007-039)

Lubricating Oil Thermostat Retaining Plug 100 N•m [ 74 ft-lb ]

Lubricating Oil Tube Brace Gear Cover 28 N•m [ 21 ft-lb ]
Capscrew
28 N•m [ 21 ft-lb ]
Cooling System - Group 08 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cooling System - Group 08 - Specifications

Thermostat Initial Opening Temperature 81 °C MIN 178 °F
83 °C MAX 182 °F

Fan Hub End Clearance 0.08 mm MIN 0.003 in
0.25 mm MAX 0.009 in

Water Pump Housing Large Bearing Bore 71.988 mm MIN 2.834 in
Inside Diameter
72.018 mm MAX 2.835 in
Cast Iron Impeller Inside Diameter 15.850 mm MIN 0.624 in

15.875 mm MAX 0.625 in
Water Pump Shaft Diameter

Small End 25.015 MIN 0.9848
25.002 MAX 0.9843
Large End 29.015 MIN 1.1423
29.002 MAX 1.1418
Pulley Bore Inside Diameter 28.936 mm MIN 1.139 in

29.964 mm MAX 1.140 in
Water Pump Seal Installed Height 10.919 mm MIN 0.430 in

11.679 mm MAX 0.460 in
Signature™, ISX, and QSX15 Eng [...] Cooling System - Group 08
Ref.No./
Steps
.
Impeller Clearance 0.29 mm MIN 0.011 in

1.24 mm MAX 0.049 in
Cooling System - Group 08 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Cooling System - Group 08 - Torque Values

Coolant Filter Valve (008-009)
Coolant Filter Valve Retaining Capscrew 7 N•m [ 60 in-lb ]

Thermostat Housing Cover Capscrews 34 N•m [ 25 ft-lb ]
Thermostat Housing Cover Capscrews
Long Capscrews
Thermostat Housing Cover Plate 28 N•m [ 20 ft-lb ]

Capscrews
Upper Radiator Hose Clamp 5 N•m [ 40 in-lb ]

Thermostat Housing Mounting Capscrews 45 N•m [ 33 ft-lb ]
Thermostat Housing Cover 45 N•m [ 33 ft-lb ]
Thermostat Housing Capscrews 56 N•m [ 41 ft-lb ]

Ref.No./
Steps
.
Thermostat Housing Cover Capscrews 34 N•m [ 25 ft-lb ]

Thermostat Housing Cover Capscrews
Long Capscrews
Upper Radiator Hose Clamp 5 N•m [ 40 in-lb ]
Thermostat Housing Cover Plate 28 N•m [ 20 ft-lb ]

Capscrews

Lower Radiator Hose Clamp 5 N•m [ 44 in-lb ]
Lower Radiator Hose Clamp 5 N•m [ 44 in-lb ]
Fan Drive Idler Pulley Assembly (008-030)

Fan Drive Idler Pulley Bracket Capscrew 18 N•m [ 159 in-lb ]
M8x60mm
Fan Drive Idler Pulley Assembly Capscrew 54 N•m [ 40 ft-lb ]

M10x80mm
Cooling System - Group 08 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.

Fan Hub Assembly Capscrew 113 N•m [ 83 ft-lb ]
Fan Hub Capscrews 90 N•m [ 66 ft-lb ]
Fan Hub Capscrews 90 N•m [ 66 ft-lb ]

Water Pump Mounting Capscrews (With 72 N•m [ 53 ft-lb ]
Egr)
Automotive Water Pump Mounting 58 N•m [ 43 ft-lb ]

Capscrews Capscrews 1, 2, And 3 72 N•m [ 53 ft-lb ]
Capscrews Capscrews 4 And 5
Automotive Water Pump Mounting
Capscrews All Capscrews, Engines Without
Belt Tensioner Bracket
Capscrews Capscrews 1, 2, And 3 72 N•m [ 53 ft-lb ]
Capscrews Capscrews 4 And 5
Automotive Water Pump Mounting
Capscrews All Capscrews, Engines Without
Belt Tensioner Bracket
Belt Idler Pulley Capscrew 30 N•m [ 25 ft-lb ]
Ref.No./
Steps
.
72 N•m [ 53 ft-lb ]
30 N•m [ 25 ft-lb ]
30 N•m [ 25 ft-lb ]
Belt Tensioner, Automatic (Water Pump) (008-080)

Belt Tensioner And Mounting Capscrew 50 N•m [ 37 ft-lb ]
Automatic Belt Tensioner Bracket Mounting 34 N•m [ 25 ft-lb ]

Capscrew 34 N•m [ 25 ft-lb ]
Industrial Low-Mount (Small Tensioner) 56 N•m [ 41 ft-lb ]

Bracket

Bracket

Cooling System - Group 08 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.

Coolant Filter Head Mounting Capscrews 56 N•m [ 41 ft-lb ]

Fan Support Capscrews 56 N•m [ 41 ft-lb ]
Belt Tensioner Support Bracket Capscrews 90 N•m [ 66 ft-lb ]
Belt Tensioner Support Bracket Capscrews 56 N•m [ 41 ft-lb ]
Fan Pulley (008-089)

Fan Pulley Capscrews 95 N•m [ 70 ft-lb ]
Water Pump Cartridge (008-102)

48 N•m [ 36 ft-lb ]
Signature™, ISX, and QSX15 Eng [...] Drive Units - Group 09 - Torque Values
Ref.No./
Steps
.
Drive Units - Group 09 - Torque Values

18 N•m [ 115 in-lb ]
36 N•m [ 27 ft-lb ]
Belt Tensioner, Refrigerant Compressor, Automatic (009-053)

45 N•m [ 33 ft-lb ]
Idler Pulley, Refrigerant Compressor (009-054)

36 N•m [ 27 ft-lb ]
Refrigerant Compressor Mounting Bracket (009-055)

Refrigerant Compressor Mounting Bracket 7 N•m [ 62 in-lb ]
Capscrew
41 N•m [ 30 ft-lb ]
Refrigerant Compressor Bracket Mounting 56 N•m [ 41 ft-lb ]

Capscrews
Drive Units - Group 09 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Alternator/Refrigerant Compressor Mounting Bracket (009-056)

Alternator/Refrigerant Compressor Bracket 18 N•m [ 14 ft-lb ]
Wire Harness Capscrews
Alternator/Refrigerant Compressor 36 N•m [ 27 ft-lb ]

Mounting Bracket Capscrews (1, 2 3 And 4) 56 N•m [ 41 ft-lb ]
Mounting Bracket Capscrews (5)

Mounting Bracket To Gear Housing
Capscrews

Mounting Bracket Capscrews (1, 2, 3, 4,
And 5)
Signature™, ISX, and QSX15 Eng [...] Air Intake System - Group 10 - Specifications
Ref.No./
Steps
.
Air Intake System - Group 10 - Specifications

Charge-Air Cooler (010-027)
Charge-Air Cooler Pressure Drop 49 kPa MAX 5 psi
Charge Air Cooler Temperature Rise 11 °C MAX 20 °F
Charge-Air Cooler System Differential 152 mm MAX 6 in Hg

Pressure Hg
Charge-Air Cooler System Differential 21 kPa MAX 3 psi
Pressure
Turbocharger Axial Clearance 0.025 mm MIN 0.001 in
0.127 mm MAX 0.005 in
Turbocharger Radial Bearing Clearance 0.406 mm MIN 0.016 in

0.610 mm MAX 0.024 in
Turbocharger Axial Clearance 0.025 mm MIN 0.001 in

0.127 mm MAX 0.005 in
Turbocharger Wastegate Actuator (010-050)

Turbocharger Wastegate Rod Travel at 100 0.356 mm MIN 0.014 in
kPa [14.5 psi]
3.810 mm MAX 0.150 in
Air Intake System - Group 10 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Turbocharger Wastegate Rod Travel at 100 0.356 mm MIN 0.014 in

kPa [14.5 psi]
3.810 mm MAX 0.150 in
Turbocharger Wastegate Valve Body (010-055)

Wastegate Wear Measurement 25.654 mm MAX 1.010 in
Turbocharger, Variable Geometry Actuator (010-113)

Actuator Movement Range 12 mm MIN 0.472 in
Signature™, ISX, and QSX15 Eng [...] Air Intake System - Group 10 - Torque Values
Ref.No./
Steps
.
Air Intake System - Group 10 - Torque Values

Air Leaks, Air Intake and Exhaust Systems (010-024)
Turbocharger-To-Charge-Air Cooler V- 9 N•m [ 80 in-lb ]
Band Clamp
Charge-Air Cooler Piping Clamp 9 N•m [ 80 in-lb ]
Turbine Housing V-Band Clamp 14 N•m [ 124 in-lb ]
Compressor Housing V-Band Clamp 9 N•m [ 80 in-lb ]
Charge Air Cooling Piping 8.5 N•m [ 75 in-lb ]
18 N•m [ 159 in-lb ]

11.3 N•m [ 100 in-lb ]
18 N•m [ 159 in-lb ]
11.3 N•m [ 100 in-lb ]
Turbocharger Mounting Nuts 61 N•m [ 45 ft-lb ]

81 N•m [ 60 ft-lb ]
Ref.No./
Steps
.
Turbocharger Discharge Elbow Clamp 9 N•m [ 80 in-lb ]
Oil Drain Tube Capscrew 25 N•m [ 221 in-lb ]
Oil Drain Tube Capscrew 25 N•m [ 221 in-lb ]
Compressor V-Bands 9 N•m [ 80 in-lb ]

12 N•m [ 106 in-lb ]
30 N•m [ 22 ft-lb ]
30 N•m [ 22 ft-lb ]
Intake And Exhaust Pipe Clamps 9 N•m [ 80 in-lb ]
102 N•m [ 75 ft-lb ]
Turbocharger Discharge Elbow Clamp 9 N•m [ 80 in-lb ]
Oil Drain Tube Capscrew 30 N•m [ 22 ft-lb ]

Signature™, ISX, and QSX15 Eng [...] Air Intake System - Group 10
Ref.No./
Steps
.
Intake And Exhaust Pipe Clamps 9 N•m [ 80 in-lb ]
30 N•m [ 22 ft-lb ]
30 N•m [ 22 ft-lb ]
102 N•m [ 75 ft-lb ]
9 N•m [ 80 in-lb ]
25 N•m [ 221 in-lb ]

30 N•m [ 22 ft-lb ]

Turbocharger Coolant Supply Line 46 N•m [ 34 ft-lb ]
Turbocharger Coolant Return Line 46 N•m [ 34 ft-lb ]

Ref.No./
Steps
.
Turbocharger Tube Brace 18 N•m [ 159 in-lb ]
41 N•m [ 30 ft-lb ]
15 N•m [ 133 in-lb ]
54 N•m [ 40 ft-lb ]
46 N•m [ 34 ft-lb ]
24 N•m [ 18 ft-lb ]
16 N•m [ 142 in-lb ]
24 N•m [ 18 ft-lb ]
Turbocharger Wastegate Actuator (010-050)

Turbocharger Wastegate Actuator End-Link 8.5 N•m [ 75 in-lb ]
Locknut

Air Intake Connection Mounting Capscrew 45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Turbocharger Wastegate Controller (010-109)

Electrical Connection Post Nut 3 N•m [ 25 in-lb ]
Signature™, ISX, and QSX15 Eng [...] Air Intake System - Group 10
Ref.No./
Steps
.
Coil Capscrews 3 N•m [ 25 in-lb ]
Electrical Connection Nut 3 N•m [ 25 in-lb ]
Turbocharger, Variable Geometry Actuator (010-113)

Turbocharger Actuator Capscrews 17 N•m [ 150 in-lb ]
Turbocharger Actuator Rod Capscrew 23 N•m [ 17 ft-lb ]
Turbocharger Control Shutoff Valve Filter Head (010-115)

45 N•m [ 33 ft-lb ]
Turbocharger, Variable Geometry Actuator Air Supply Line (010-120)

Turbocharger Air Supply Line To 16 N•m [ 12 ft-lb ]
Turbocharger Air Control Valve 20 N•m [ 15 ft-lb ]
16 N•m [ 12 ft-lb ]
Turbocharger, Variable Geometry Control Valve Air Supply Line (010-121)

Turbocharger Air Supply Line To 20 N•m [ 15 ft-lb ]
Turbocharger Air Control Valve 20 N•m [ 15 ft-lb ]
16 N•m [ 12 ft-lb ]
Ref.No./
Steps
.
Variable Geometry Turbocharger Actuator, Electric (010-134)

Actuator Mounting Capscrews 1 3 N•m [ 27 in-lb ]
2 11 N•m [ 97 in-lb ]
Variable Geometry Turbocharger Cross Shaft (010-137)

Vgt Yoke Retaining Capscrew 37 N•m [ 27 ft-lb ]
Diffuser Mounting Capscrews 1 4 N•m [ 35 in-lb ]

2 8 N•m [ 71 in-lb ]
Turbocharger Compressor Impeller Nut 17 N•m [ 150 in-lb ]
Turbocharger V-Band Clamp 9 N•m [ 80 in-lb ]

Signature™, ISX, and QSX15 Eng [...] Exhaust System - Group 11 - Specifications
Ref.No./
Steps
.
Exhaust System - Group 11 - Specifications

Exhaust Restriction (011-009)
Without Aftertreatment 75.0 MAX 3.0
With Aftertreatment 305.0 MAX 12.0
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes

(011-047)
Minimum Loctite™ Anti-Seize Temperature 870° °C MIN 1600° °F
Range
Exhaust System - Group 11 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Exhaust System - Group 11 - Torque Values

Slip Joint Seal Clamp 11 N•m [ 97 in-lb ]
Exhaust Manifold Capscrews 60 N•m [ 44 ft-lb ]
Exhaust Manifold Mounting Capscrews 1 30 N•m [ 22 ft-lb ]

2 55 N•m [ 41 ft-lb ]

17 N•m [ 150 in-lb ]
23 N•m [ 204 in-lb ]
17 N•m [ 150 in-lb ]
47 N•m [ 35 ft-lb ]
23 N•m [ 204 in-lb ]
Signature™, ISX, and QSX15 Eng [...] Exhaust System - Group 11
Ref.No./
Steps
.
17 N•m [ 150 in-lb ]
20 N•m [ 177 in-lb ]
EGR Mixer (011-021)

34 N•m [ 25 ft-lb ]
EGR Valve (011-022)

17 N•m [ 150 in-lb ]
54 N•m [ 40 ft-lb ]
EGR Cooler Connection (011-024)

17 N•m [ 150 in-lb ]

27 N•m [ 239 in-lb ]
Exhaust System - Group 11 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
7 N•m [ 62 in-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
27 N•m [ 239 in-lb ]

7 N•m [ 62 in-lb ]
EGR Differential Pressure Sensor Tubes (011-026)

26 N•m [ 230 in-lb ]
1.5 N•m [ 13 in-lb ]
Exhaust Gas Pressure Sensor Tube (011-027)

Exhaust Gas Pressure Sensor Tube Nuts 16 N•m [ 146 in-lb ]
EGR Differential Pressure Sensor Adapter (011-028)

18 N•m [ 13 ft-lb ]
Ref.No./
Steps
.

10 N•m [ 88 in-lb ]

25 N•m [ 221 ft-lb ]
34 N•m [ 25 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
21 N•m [ 186 in-lb ]
47 N•m [ 35 ft-lb ]

23 N•m [ 17 ft-lb ]
23 N•m [ 17 ft-lb ]
Ref.No./
Steps
.
Exhaust Gas Pressure Sensor Adapter (011-033)

23 N•m [ 17 ft-lb ]
Aftertreatment Diesel Particulate Filter (011-041)

20 N•m [ 177 in-lb ]

14 N•m [ 124 in-lb ]

11 N•m [ 97 in-lb ]

40 N•m [ 30 ft-lb ]
40 N•m [ 30 ft-lb ]
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Mounting

Bracket (011-046)
7 N•m [ 62 in-lb ]
Ref.No./
Steps
.
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes

(011-047)
17 N•m [ 150 in-lb ]
14 N•m [ 124 in-lb ]
Aftertreatment Inlet and Outlet (011-048)

Torca™ Clamp 55 41 V-Band Clamp 14
124
20 N•m [ 177 in-lb ]
Aftertreatment Diesel Oxidation Catalyst (011-049)

20 N•m [ 177 in-lb ]
17 N•m [ 150 in-lb ]
Aftertreatment Injector Lines (011-051)

24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]

24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]

24 N•m [ 212 in-lb ]
Ref.No./
Steps
.
24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]

34 N•m [ 25 ft-lb ]
24 N•m [ 212 in-lb ]

24 N•m [ 212 in-lb ]
Aftertreatment Fuel Shutoff Manifold (011-052)

14 N•m [ 124 in-lb ]
14 N•m [ 124 in-lb ]
14 N•m [ 124 in-lb ]
25 N•m [ 221 in-lb ]
14 N•m [ 124 in-lb ]

14 N•m [ 124 in-lb ]
14 N•m [ 124 in-lb ]
Ref.No./
Steps
.
25 N•m [ 221 in-lb ]
Aftertreatment Fuel Injector Flow (011-054)

24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]
14 N•m [ 124 in-lb ]

Compressed Air System - Group 12 - Torque Values Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Compressed Air System - Group 12 - Torque Values

Air Compressor Coolant Lines (012-004)
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]

Air Compressor Mounting Capscrews 45 N•m [ 33 ft-lb ]
Air Compressor Mounting Brace Capscrews 45 N•m [ 33 ft-lb ]
Air Compressor Air Discharge Line 60 N•m [ 44 ft-lb ]

8 N•m [ 71 in-lb ]
Signature™, ISX, and QSX15 Eng [...] Electrical Equipment - Group 13 - Torque Values
Ref.No./
Steps
.
Electrical Equipment - Group 13 - Torque Values

Alternator Mounting Capscrews 36 N•m [ 27 ft-lb ]
Alternator Mounting Bracket Capscrews 86 N•m [ 63 ft-lb ]

56 N•m [ 41 ft-lb ]
Alternator Pulley (013-006)

Alternator Pulley Locking Nut 100 N•m [ 74 ft-lb ]

Starting Motor Mounting Capscrews 5/8-11 140 N•m [ 103 ft-lb ]
X 1.75 In Capscrew 201 N•m [ 148 ft-lb ]
Starting Motor Mounting Capscrews 5/8-11 129 N•m [ 95 ft-lb ]
X 2.00 In Capscrew 163 N•m [ 120 ft-lb ]
Starting Motor Mounting Capscrews 39 Mt
Starters (Aluminum Flywheel Housing)
Starting Motor Mounting Capscrews 39 Mt
Starters (Cast Iron Flywheel Housing)
Starter Motor Mounting With Aluminum 140 N•m [ 103 ft-lb ]
Flywheel Housing 5/8-11 X 1.75 In 201 N•m [ 148 ft-lb ]
Capscrew
Starter Motor Mounting With Aluminum
Flywheel Housing 5/8-11 X 2.00 In
Capscrew
3 N•m [ 26 in-lb ]
Starter Motor Mounting Brackets (High And 45 N•m [ 33 ft-lb ]

Low Mounted) (1) 23 N•m [ 17 ft-lb ]
Starter Motor Mounting Brackets (High And 41 N•m [ 30 ft-lb ]
Low Mounted) (2) And (3)
Starter Motor Mounting Brackets (High And
Low Mounted) (4) And (5)
Electrical Equipment - Group 13 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Belt Tensioner, Automatic (Alternator) (013-021)

Belt Tensioner Mounting Capscrew 56 N•m [ 41 ft-lb ]
Alternator Spacer (013-036)

36 N•m [ 27 ft-lb ]
Alternator Idler Pulley (013-039)

Alternator Idler Pulley Mounting Capscrew 60 N•m [ 44 ft-lb ]
Bracket, Idler Pulley and Alternator Belt Tensioner (013-040)

Idler Pulley And Alternator Belt Tensioner 56 N•m [ 41 ft-lb ]
Bracket
Idler Pulley And Alternator Belt Tensioner 90 N•m [ 66 ft-lb ]

Bracket Spacer 56 N•m [ 41 ft-lb ]
Signature™, ISX, and QSX15 Eng [...] Engine Testing - Group 14 - Specifications
Ref.No./
Steps
.
Engine Testing - Group 14 - Specifications

Engine Testing (Chassis Dynamometer) (014-002)
Fuel Inlet Temperature 7.2 °C MIN 45 °F
55.5 °C MAX 132 °F
Engine Testing (Engine Dynamometer) (014-005)

Hose Temperature 235 °C MIN 500 °F
Fuel Inlet Temperature 7.2 °C MIN 45 °F

55.5 °C MAX 132 °F
Mounting Adaptations - Group 16 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Specifications

Flywheel (016-005)
Flywheel Bore Runout 0.127 mm MAX 0.005 in

Idler Gear to Crankshaft Gear Backlash 0.15 mm MIN 0.006 in
0.28 mm MAX 0.011 in
Signature™, ISX, and QSX15 Eng [...] Mounting Adaptations - Group 16 - Torque Values
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Torque Values

Lifting Bracket Capscrews 108 N•m [ 80 ft-lb ]
Flywheel (016-005)
Flywheel Mounting Capscrews 1 125 N•m [ 92 ft-lb ]
2 250 N•m [ 184 ft-lb ]

Cover Plate Capscrews 11 N•m [ 97 in-lb ]
Flywheel Housing Capscrews 7 N•m [ 62 in-lb ]
Flywheel Housing Mounting Capscrews 1 100 N•m [ 74 ft-lb ]

2 197 N•m [ 145 ft-lb ]

14 N•m [ 124 in-lb ]

2 197 N•m [ 145 ft-lb ]
Mounting Adaptations - Group 16 Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Replacer Idler Shaft Capscrews 14 N•m [ 124 in-lb ]
100 N•m [ 74 ft-lb ]
100 N•m [ 74 ft-lb ]
28 N•m [ 21 ft-lb ]
28 N•m [ 21 ft-lb ]
60 N•m [ 44 ft-lb ]
20 N•m [ 177 in-lb ]
20 N•m [ 177 in-lb ]

35 N•m [ 26 ft-lb ]
Signature™, ISX, and QSX15 Eng [...] Mounting Adaptations - Group 16
Ref.No./
Steps
.
65 N•m [ 48 ft-lb ]
20 N•m [ 15 in-lb ]
65 N•m [ 48 ft-lb ]
32 N•m [ 24 ft-lb ]
32 N•m [ 24 ft-lb ]

2 197 N•m [ 145 ft-lb ]
Vehicle Braking - Group 20 - Specifications Signature™, ISX, and QSX15 Eng [...]
Ref.No./
Steps
.
Vehicle Braking - Group 20 - Specifications

Engine Brake Lever Running Clearance 0.635 mm MIN 0.025 in

2.790 mm MAX 0.110 in
Engine Brake Control Valve (020-017)

Signature™, ISX, and QSX15 Eng [...] Vehicle Braking - Group 20 - Torque Values
Ref.No./
Steps
.
Vehicle Braking - Group 20 - Torque Values

Engine Brake Lever Adjusting Screw 20 N•m [ 177 in-lb ]
Locknut
Engine Brake Solenoid Valve (020-012)

Engine Brake Solenoid 20 N•m [ 15 ft-lb ]
Engine Brake Wiring Harness (020-015)

Deutsch Connector Retaining Clip 5 N•m [ 50 in-lb ]
23 N•m [ 18 ft-lb ]
General Engine Signature™, ISX, and QSX15 Eng [...]
General Engine
Specifications
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
400 to 450 hp.........................................................................................................Refer to the engine dataplate.
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:
Automotive................................................................................................................................1202 kg [2650 lb]
Industrial...................................................................................................................................1524 kg [3360 lb]
Power Generation.....................................................................................................................1370 kg [3020 lb]
Wet Engine Weight:
Automotive................................................................................................................................1266 kg [2790 lb]
Industrial...................................................................................................................................1628 kg [3590 lb]
Power Generation.....................................................................................................................1474 kg [3250 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 N•m [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:........................................................................................................................1403 kg [3093 lb]
Wet Engine Weight........................................................................................................................1472 kg [3246 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 N•m [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Signature™, ISX, and QSX15 Eng [...] Fuel System
Fuel System
Specifications
Maximum Allowable Restriction to Pump With or Without Fuel Cooler:
With Clean Filter..................................................................................................................203 mm Hg [8 in Hg]
With Dirty Filter..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Fuel Return Line Restriction......................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71°C [160°F]
Fuel Shutoff Solenoid Resistance..........................................................................................................6 to 10 ohms
Maximum Allowable Pressure Drop Across Pressure Fuel Filter.......................................................517 kPa [75 psi]
Maximum Allowable Fuel Return Line Restriction
With Check Valve.............................................................................................................165 mm Hg [6.5 in Hg]
Without Check Valve............................................................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71°C [160°F]
Fuel Shutoff Solenoid Resistance..........................................................................................................6 to 10 ohms
Maximum Allowable Inlet Restriction at the IFSM - high idle, no load:
Upper Location..................................................................................................................355 mm Hg [14 in Hg]
Lower Location..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Inlet Restriction at OEM Fuel Inlet:
Without Remote Mount Filter.................................................................................................76 mm Hg [3 in Hg]
With Remote Mount Filter..................................................................................................254 mm Hg [10 in Hg]
Lubricating Oil System Signature™, ISX, and QSX15 Eng [...]

Specifications
Oil Pressure at Idle (minimum allowable at 93°C [200°F] oil temperature)........................................103 kPa [15 psi]
Oil Pressure at No-Load Governed Speed (automotive and industrial only)...................241 to 276 kPa [35 to 40 psi]
Pressure Drop Across Oil Filter (maximum allowable with 15W40 oil at operating temperature)........172 kPa [25 psi]
Oil Capacity of Standard Engine:
Combination Full-Flow/Bypass Filter Capacity............................................................................3.78 liters [1 gal]
Oil Pan Capacity: Automotive and Industrial
High....................................................................................................................................41.6 liters [11 gal]
Low.......................................................................................................................................34.1 liters [9 gal]
Oil Pan Capacity: Power Generation (for oil pan option OP1493)
High....................................................................................................................................83.3 liters [22 gal]
Low.....................................................................................................................................72.0 liters [19 gal]
Oil Change Capacity (oil pan and filter filled to capacity):
Automotive and Industrial....................................................................................................41.6 liters [11 gal]
Power Generation (for oil pan option OP1493).....................................................................87.0 liters [23 gal]
Total Lubricating Oil System Capacity Including Filter:
Automotive and Industrial.........................................................................................................45.4 liters [12 gal]
Power Generation (for oil pan option OP1493)..........................................................................90.8 liters [24 gal]
Oil Pressure Range:
Cold Engine...................................................................................................................Up to 1034 kPa [150 psi]
Warm Engine...........................................................................................................241 to 276 kPa [35 to 40 psi]
Cooling System
General Information
Cummins Inc. recommends the use of fully-formulated antifreeze or coolant containing a precharge of supplemental
coolant additive (SCA). The antifreeze or coolant must meet the specifications outlined in the Technology and
Maintenance Council (TMC) Recommended Practice (RP) 329 (ethylene glycol) or Recommended Practice (RP) 330
(propylene glycol). The use of fully-formulated antifreeze or coolant significantly simplifies cooling system
maintenance.
Copies of Technology and Maintenance Council (TMC) specifications can be obtained through Cummins Inc., or by
contacting:
Technology and Maintenance Council
American Trucking Association
2200 Mill Road
Alexandria, VA 33314-5388
Phone: (703) 838-1763
Fax (703) 836-6070
Fully-formulated antifreeze contains balanced amounts of antifreeze, SCA, and buffering compounds, but does not
contain 50 percent water. Fully-formulated coolant contains balanced amounts of antifreeze, SCA, and buffering
compounds already premixed 50/50 with deionized water.
Alternative maintenance practices for cooling systems can be found in Cummins® Coolant Requirements and
Maintenance, Bulletin 3666132.
Specifications
Coolant Capacity (engine only)
With EGR...................................................................................................................................26.5 liters [28 qt]
Without EGR.................................................................................................................................24 liters [25 qt]
Standard Modulating Thermostat
Temperature Range.....................................................................................................82 to 93°C [180 to 200°F]
Maximum Coolant Pressure (exclusive of pressure cap - closed thermostat at the maximum no-load governed
speed)
With EGR.....................................................................................................................................434 kPa [63psi]
Without EGR...............................................................................................................................227 kPa [33 psi]
Coolant Alarm Activation Temperature
With EGR - Ratings Below 565 Horsepower...................................................................................107°C [225°F]
With EGR - Ratings of 565/600 Horsepower..................................................................................110°C [230°F]
Without EGR.................................................................................................................................110°C [230°F]
Maximum Allowable Top Tank Temperature
Ratings Below 565 Horsepower with EGR and without EGR Engines.............................................107°C [225°F]
Ratings of 565/600 Horsepower with EGR only..............................................................................110°C [230°F]
Minimum Recommended Top Tank Temperature
Minimum Temperature....................................................................................................................70°C [160°F]
Minimum Allowable Draw Down
With EGR............................................................................................................................................11 Percent
Without EGR............................................2.4 liters [2.5 qt] 10 Percent of System Capacity (whichever is greater)
Minimum Recommended Pressure Cap
With EGR....................................................................................................................................103 kPa [15 psi]
Without EGR..................................................................................................................................50 kPa [7 psi]
Preferred......................................................................................................................................69 kPa [10 psi]
Minimum Fill Rate
Without Low-Level Alarm......................................................................................................19 liters/min [5 gpm]
Maximum Deaeration Time
Maximum Time...................................................................................................................................25 minutes
Fan-on Coolant Temperature
With EGR........................................................................................................................................99°C [210°F]
Without EGR...................................................................................................................................99°C [210°F]
Fan-on Intake Air Temperature
With EGR........................................................................................................................................93°C [200°F]
Without EGR...................................................................................................................................88°C [190°F]
Shutter Opening Temperature
Coolant - with EGR..........................................................................................................................96°C [205°F]

Coolant - without EGR.....................................................................................................................85°C [185°F]
Intake Air - with EGR.....................................................................................................................104°C [220°F]
Intake Air - without EGR..................................................................................................................66°C [150°F]
Winterfronts
Air passage area.....................................................................................................................774 cm 2 [120 in 2]
Industrial and Generator Drive
Coolant Capacity
Engine Only..................................................................................................................................24 liters [25 qt]
Standard Modulating Thermostat
Temperature Range.....................................................................................................82 to 93°C [180 to 200°F]
Maximum Coolant Pressure
Exclusive of pressure cap - closed thermostat at the maximum no-load governed speed.............227 kPa [33 psi]
Coolant Alarm Activation Temperature
Ratings Below 565 Horsepower.....................................................................................................107°C [225°F]
Ratings of 565/600 Horsepower.....................................................................................................110°C [230°F]
Maximum Allowable Top Tank Temperature
Ratings Below 565 Horsepower.....................................................................................................107°C [225°F]
Ratings of 565/600 Horsepower.....................................................................................................110°C [230°F]
Power Generation, Standby...........................................................................................................110°C [230°F]
Power Generation, Prime..............................................................................................................104°C [220°F]
Minimum Recommended Top Tank Temperature
Minimum Temperature ...................................................................................................................70°C [160°F]
Minimum Allowable Draw Down.....................2.4 liters [2.5 qt] 10 Percent of System Capacity (whichever is greater)
Minimum Recommended Pressure Cap
Industrial........................................................................................................................................50 kPa [7 psi]
Power Generation.........................................................................................................................69 kPa [10 psi]
Minimum Fill Rate
Without low-level alarm........................................................................................................19 liters/min [5 gpm]
Maximum Deaeration
Time...................................................................................................................................................25 minutes
Fan-on Coolant Temperature
Temperature...................................................................................................................................95°C [203°F]
Fan-on Intake Air Temperature
Industrial Only.................................................................................................................................88°C [190°F]
Shutter Opening Temperature - Industrial Only
Coolant...........................................................................................................................................85°C [185°F]
Intake.............................................................................................................................................66°C [150°F]
Signature™, ISX, and QSX15 Eng [...] Air Intake System
Air Intake System

Specifications
CAUTION
Engine intake air must be filtered to prevent dirt and debris from entering the engine. If air intake piping is
damaged or loose, unfiltered air will enter the engine and cause premature wear.
Maximum Temperature Rise between Ambient Air and Engine Air Inlet (ambient above 0°C [32°F])......17°C [30°F]
Maximum Inlet Restriction (clean filter) Normal-Duty Element..............................................250 mm H2O [10 in H2O]
Maximum Inlet Restriction (dirty filter).................................................................................635 mm H2O [25 in H2O]
Maximum Allowable Pressure Drop across Charge Air Cooler
psi..................................................................................................................................................14 kPa [2 psi]
Hg (mercury)........................................................................................................................102 mm Hg [4 in Hg]
Four-Step Wastegate Controller Solenoid Resistance..............................................................................7 to 8 ohms
Maximum Temperature Rise between Ambient Air and Engine Air Inlet (ambient above 0°C [32°F])
Industrial...........................................................................................................................................17°C [30°F]
Maximum Inlet Restriction (clean filter) Normal-Duty Element:
Industrial.......................................................................................................................250 mm H2O [10 in H2O]
Power Generation..........................................................................................................381 mm H2O [15 in H2O]
Maximum Inlet Restriction (dirty filter).................................................................................635 mm H2O [25 in H2O]
Maximum Allowable Pressure Drop across Charge Air Cooler:
Industrial
psi.............................................................................................................................................14 kPa [2 psi]
Hg (mercury)...................................................................................................................102 mm Hg [4 in Hg]
Maximum Allowable Pressure Drop from Turbocharger Outlet to Intake Manifold:
Power Generation:
psi.............................................................................................................................................14 kPa [2 psi]
Hg (mercury)...................................................................................................................102 mm Hg [4 in Hg]
Four-Step Wastegate Controller Solenoid Resistance..............................................................................7 to 8 ohms
Exhaust System Signature™, ISX, and QSX15 Eng [...]
Exhaust System
Specifications
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer
Hg (mercury)..........................................................................................................................76 mm Hg [3 in Hg]
H2O (water).................................................................................................................1016 mm H2O [40 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter).....................................................................127 mm [5 in]
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer:
Industrial:
Hg (mercury)....................................................................................................................76 mm Hg [3 in Hg]
H2O (water)............................................................................................................1016 mm H2O [40 in H2O]
Power Generation:
Hg (mercury)....................................................................................................................51 mm Hg [2 in Hg]
H2O (water)..............................................................................................................682 mm H2O [27 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter):
Industrial........................................................................................................................................127 mm [5 in]
Power Generation...........................................................................................................................152 mm [6 in]
Automotive and Industrial:
Hg (mercury).................................................................................................................305 mm Hg [12 in Hg]
H20 (water).............................................................................................................4145 mm H20 [163 in H20]
Exhaust Pipe Size (normally acceptable inside diameter):
Automotive and Industrial...............................................................................................................127 mm [5 in]
Signature™, ISX, and QSX15 Eng [...] Electrical System
Electrical System
Specifications
Minimum Recommended Battery Capacity:
System Ambient Temperatures

Voltage
-18°C [0°F]
Cold Reserve
Cranking Capacity*
Amperes Amperes
12 VDC
Automotive and Power Generation 1800 540
Industrial 2700 360
24 VDC**
Automotive and Power Generation 900 270
Industrial 1350 360
* The number of plates within a given battery size determines reserve capacity. Reserve capacity determines the
length of time that sustained cranking can occur.
**CCA ratings are based on two 12-VDC batteries in series.
A minimum of 6 VDC at the OEM connector is required to power up the ECM.
Minimum Battery Capacity:
12-VDC Starter......................................................400 ampere-hours to 1800 cold cranking amps @ -18°C [0°F]
24-VDC Starter........................................................200 ampere-hours to 900 cold cranking amps @ -18°C [0°F]
Maximum Starting Circuit Resistance:
12-VDC Starter................................................................................................................................0.00075 ohm
24-VDC Starter................................................................................................................................0.00200 ohm
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
12-VDC:
No. 00..........................................................................................................................................3.7 m [12 ft]
No. 000........................................................................................................................................4.9 m [16 ft]
No. 0000 or Two No. 0*................................................................................................................6.1 m [20 ft]
Two No. 00...................................................................................................................................7.6 m [25 ft]
12-VDC High Output:
No. 00............................................................................................................................................2.1 m [7 ft]
No. 000..........................................................................................................................................2.7 m [9 ft]
No. 0000 or Two No. 0*................................................................................................................3.7 m [12 ft]
Two No. 00...................................................................................................................................4.3 m [14 ft]
24 to 32 VDC:
No. 00..........................................................................................................................................6.1 m [20 ft]
No. 000........................................................................................................................................8.2 m [27 ft]
No. 0000 or Two No. 0*..............................................................................................................10.7 m [35 ft]
Two No. 00.................................................................................................................................13.7 m [45 ft]
Minimum Ambient Air Temperature without Starting Aid..........................................................................-1°C [30°F]
Minimum Cranking Speed without Starting Aid.............................................................................................130 rpm
* Two strands of No. 0 cable can be used in place of one No. 0000 cable, provided that connections are carefully
made to make sure equal current flow exists in each parallel cable.
Compressed Air System Signature™, ISX, and QSX15 Eng [...]
Compressed Air System

Specifications
Cummins 18.7 CFM Model
Cylinders................................................................................................................................................................1
Compressor Swept Volume @ 1250 RPM.................................................................................6.6 L/sec. [14.0 CFM]
Piston Displacement................................................................................................................318 cc [19.405 C.I.D.]
Bore................................................................................................................................................85 mm [3.346 in]
Stroke............................................................................................................................................ 56 mm [2.204 in]
Speed.................................................................................................................................................Engine Speed
Cooling.............................................................................................................................................Engine Coolant
Lubrication.............................................................................................................................Engine Lubricating Oil
Plumbing Line Sizes:
Coolant Inlet and Outlet................................................................................................................3/4 x 16 STOR
Air Inlet............................................................................................................................25.4 mm [1 in] Nominal
Air Outlet......................................................................................................................................M27 x 2 STOR
Unloader Port................................................................................................................................M10 x 1 STOR
Governor Mounting Direct.....................................................................................................................M8 x 1.25
Height, Overall (Approximate).......................................................................................................217.4 mm [8.56 in]
Width, Overall (Approximate) ..........................................................................................................142 mm [5.59 in]
Length, Overall (Approximate).........................................................................................................216 mm [8.50 in]
Weight (Approximate).......................................................................................................................15 Kg [35.0 lbs]
Signature™, ISX, and QSX15 Eng [...] Engine Testing
Engine Testing
Specifications
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum).......................................................................................76.2 mm Hg [3.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................103.0 kPa [15.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum).................................................262.0 kPa [38.0 psi]
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107°C [225°F]
Fuel Inlet Temperature (maximum).......................................................................................................71°C [160°F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum)...................................................................................304.8 mm Hg [12.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................103.0 kPa [15.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum)..................................331 kPa [48 psi] @ 1600 RPM
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107°C [225°F]
Fuel Inlet Temperature (maximum).......................................................................................................71°C [160°F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Drive Belt Tension Signature™, ISX, and QSX15 Eng [...]
Drive Belt Tension

Tension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
31 rib - 3164750 1668 375 1330 to 1560 300 to 350
NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Signature™, ISX, and QSX15 Eng [...] Fraction, Decimal, Millimeter Conversions
Fraction, Decimal, Millimeter Conversions

Conversion Chart
Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm

Weights and Measures - Conversion Factors Signature™, ISX, and QSX15 Eng [...]
Weights and Measures - Conversion Factors

Conversion Chart
From U.S. From Metric
Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
Unit Name Abbreviation Unit Name Abbreviation
sq. inch in2 sq. millimeters mm2 645.16 0.001550
Area sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
Fuel miles per gallon mpg kilometers per liter km/l 0.4251 2.352
Performance gallons per mile gpm liters per kilometer l/km 2.352 0.4251
Force pounds force lbf Newton N 4.4482 0.224809
inch in millimeters mm 25.40 0.039370
Length
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
pounds force per psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mm Hg 25.40 0.039370
Pressure mercury
inches of water in H2O millimeters of mm H2O 25.40 0.039370
water
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit °F centigrade °C (°F-32) ÷1.8 (1.8 x °C) +32
pound force per ft-lb Newton-meter N•m 1.35582 0.737562
foot
Torque
pound force per in-lb Newton-meter N•m 0.113 8.850756
inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
gallon (U.S.) gal. liter l 3.7853 0.264179
Volume: gallon (Imp*) gal. liter l 4.546 0.219976
liquid
displacement
cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic centimeter cm3 16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
British Thermal BTU joules J 1054.5 0.000948
Unit
Work British Thermal BTU kilowatt-hour kW-hr 0.000293 3414
Unit
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Signature™, ISX, and QSX15 Eng [...] Capscrew Markings and Torque Values
Capscrew Markings and Torque Values

General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew
being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
• Always use the torque values listed in the following tables when specific torque values are not available.
• Do not use the torque values in place of those specified in other sections of this manual.
• The torque values in the table are based on the use of lubricated threads.
• When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
• Always use the torque values listed in the following tables when specific torque values are not available.
• Do not use the torque values in place of those specified in other sections of this manual.
• The torque values in the table are based on the use of lubricated threads.
• When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body Torque Torque Torque

Size
Diamet Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
er
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
Capscrew Markings and Torque Values Signature™, ISX, and QSX15 Eng [...]
Body Torque Torque Torque

Size
Diamet Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
er
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 — — 550 400 — — — — — —
Capscrew Markings and Torque Values - U.S. Customary
Capscrew Cast Iron Aluminium Cast Iron Aluminium

Body Size
N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
Signature™, ISX, and QSX15 Eng [...] Newton-Meter to Foot-Pound Conversions
Newton-Meter to Foot-Pound Conversions

Conversion Chart
N•m ft-lb N•m ft-lb N•m ft-lb
1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
12 106 in-lb 95 70 195 144
14 124 in-lb 100 74 200 148
15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Pipe Plug Torque Values Signature™, ISX, and QSX15 Eng [...]
Pipe Plug Torque Values

Torque Table
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or
Steel Components
in in N•m ft-lb N•m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
Signature™, ISX, and QSX15 Eng [...] Tap-Drill Chart - U.S. Customary and Metric
Tap-Drill Chart - U.S. Customary and Metric

General Information
NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60%
range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
Tap-Drill Chart - U.S. Customary and Metric Signature™, ISX, and QSX15 Eng [...]
Notes
Index
Page X-1
About the Manual ..........................................................................................i-1 Preparatory Steps.................................................................................11-120

General Information.....................................................................................i-1 Remove................................................................................................11-120
Acronyms and Abbreviations ......................................................................i-15 Aftertreatment Testing .............................................................................14-42
General Information...................................................................................i-15 Finishing Steps.......................................................................................14-48
Additional Service Literature .......................................................................L-1 General Information................................................................................14-42
General Information....................................................................................L-1 Preparatory Steps...................................................................................14-45
Aftertreatment Adapter Pipe ....................................................................11-93 Setup......................................................................................................14-46
Clean and Inspect for Reuse...................................................................11-95 Test........................................................................................................14-46
Finishing Steps.......................................................................................11-96 Air Compressor ..........................................................................................12-9
Install......................................................................................................11-96 Clean and Inspect for Reuse...................................................................12-10
Preparatory Steps...................................................................................11-93 Finishing Steps.......................................................................................12-12
Remove..................................................................................................11-94 Install......................................................................................................12-10
Aftertreatment Diesel Oxidation Catalyst ..............................................11-113 Preparatory Steps.....................................................................................12-9
Clean and Inspect for Reuse.................................................................11-115 Remove....................................................................................................12-9
Finishing Steps.....................................................................................11-119 Air Compressor Carbon Buildup ................................................................12-1
General Information...............................................................................11-113 Clean........................................................................................................12-2
Install....................................................................................................11-118 Initial Check..............................................................................................12-1
Preparatory Steps.................................................................................11-113 Air Compressor Coolant Lines ...................................................................12-3
Remove................................................................................................11-114 Finishing Steps.........................................................................................12-6
Aftertreatment Diesel Particulate Filter ...................................................11-82 Initial Check..............................................................................................12-3
Adjust.....................................................................................................11-87 Inspect for Reuse......................................................................................12-4
Finishing Steps.......................................................................................11-88 Install........................................................................................................12-4
General Information................................................................................11-82 Preparatory Steps.....................................................................................12-3
Inspect for Reuse....................................................................................11-84 Remove....................................................................................................12-4
Install......................................................................................................11-87 Air Compressor Cylinder Head, Single Cylinder .......................................12-6
Maintenance Check................................................................................11-86 Finishing Steps.........................................................................................12-8
Preparatory Steps...................................................................................11-83 Initial Check..............................................................................................12-6
Remove..................................................................................................11-83 Install........................................................................................................12-7
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Preparatory Steps.....................................................................................12-7
Mounting Bracket .....................................................................................11-99 Remove....................................................................................................12-7
Clean and Inspect for Reuse.................................................................11-101 Air Compressor Unloader and Valve Assembly ........................................12-8
Finishing Steps.....................................................................................11-103 Preparatory Steps.....................................................................................12-8
General Information................................................................................11-99 Air Governor (Air Compressor Pumps Continuously) .............................12-13
Install....................................................................................................11-102 Initial Check............................................................................................12-13
Preparatory Steps.................................................................................11-100 Air Governor (Air Compressor Will Not Pump) ........................................12-12
Remove................................................................................................11-100 Inspect for Reuse....................................................................................12-12
Aftertreatment Diesel Particulate Filter Differential Pressure Sensor Tubes Remove..................................................................................................12-12
.................................................................................................................11-103 Air in Fuel .....................................................................................................6-2
Clean and Inspect for Reuse.................................................................11-104 Initial Check................................................................................................6-2
General Information...............................................................................11-103 Air Intake Connection ...............................................................................10-59
Install....................................................................................................11-106 Clean and Inspect for Reuse...................................................................10-61
Remove................................................................................................11-104 All Applications...................................................................................10-61
Aftertreatment Fuel Injector .....................................................................11-89 Finishing Steps.......................................................................................10-62
Clean and Inspect for Reuse...................................................................11-90 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.......................................................................................11-93 10-62
Install......................................................................................................11-92 Automotive with CM870......................................................................10-63
Preparatory Steps...................................................................................11-89 Automotive With CM871......................................................................10-63
Remove..................................................................................................11-89 Install......................................................................................................10-61
Aftertreatment Fuel Injector Coolant Test .............................................11-152 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-154 10-61
Preparatory Steps.................................................................................11-152 Automotive with CM870......................................................................10-62
Setup....................................................................................................11-153 Automotive With CM871......................................................................10-62
Test......................................................................................................11-153 Preparatory Steps...................................................................................10-59
Aftertreatment Fuel Injector Flow ..........................................................11-140 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-145 10-59
Flow Test..............................................................................................11-143 Automotive with CM870......................................................................10-59
Initial Check..........................................................................................11-140 Automotive With CM871......................................................................10-59
Leak Test..............................................................................................11-144 Remove..................................................................................................10-60
Setup....................................................................................................11-140 Automotive with CM870......................................................................10-60
Aftertreatment Fuel Shutoff Manifold ....................................................11-134 Automotive With CM871......................................................................10-60
Clean and Inspect for Reuse.................................................................11-136 Automotive, Industrial with CM570 and Power Generation without CM570....
Finishing Steps.....................................................................................11-139 10-60
Install....................................................................................................11-138 Air Intake Restriction ...............................................................................10-14
Preparatory Steps.................................................................................11-134 Measure..................................................................................................10-14
Remove................................................................................................11-134 Air Intake System .......................................................................................V-77
Aftertreatment Injector Lines .................................................................11-123 Specifications...........................................................................................V-77
Clean and Inspect for Reuse.................................................................11-127 Air Leaks, Air Intake and Exhaust Systems ..............................................10-3
Finishing Steps.....................................................................................11-133 Initial Check..............................................................................................10-3
Install....................................................................................................11-130 Automotive With CM871........................................................................10-5
Preparatory Steps.................................................................................11-123 Air Leaks, Compressed Air System .........................................................12-14
Remove................................................................................................11-124 Initial Check............................................................................................12-14
Aftertreatment Inlet and Outlet ..............................................................11-107 Air Pressure Relief Valve .........................................................................12-15
Assemble..............................................................................................11-110 Initial Check............................................................................................12-15
Clean and Inspect for Reuse.................................................................11-110 Alternator ....................................................................................................13-2
Disassemble.........................................................................................11-109 Clean and Inspect for Reuse.....................................................................13-5
Finishing Steps.....................................................................................11-112 Driven by Cooling Fan Drive Belt...........................................................13-5
General Information...............................................................................11-107 Finishing Steps.........................................................................................13-6
Install....................................................................................................11-111 Driven by Cooling Fan Drive Belt...........................................................13-6
Preparatory Steps.................................................................................11-108 Automotive with CM870........................................................................13-6
Remove................................................................................................11-109 Initial Check..............................................................................................13-2
Aftertreatment System ...........................................................................11-119 Alternator Wiring Test...........................................................................13-2
Assemble..............................................................................................11-122 Alternator Voltage Output Check...........................................................13-2
Clean and Inspect for Reuse.................................................................11-121 Alternator Current Output Test..............................................................13-3
Disassemble.........................................................................................11-121 Install........................................................................................................13-6
Finishing Steps.....................................................................................11-123 Driven by Cooling Fan Drive Belt...........................................................13-6
General Information...............................................................................11-119 Automotive with CM870........................................................................13-6
Install....................................................................................................11-122 Preparatory Steps.....................................................................................13-4
Index
Page X-2
Driven by Cooling Fan Drive Belt...........................................................13-4 Automotive Applications......................................................................13-25

Automotive with CM870........................................................................13-4 Industrial and Power Generation.........................................................13-26
Remove....................................................................................................13-5 Remove..................................................................................................13-26
Driven by Cooling Fan Drive Belt...........................................................13-5 Automotive Applications......................................................................13-26
Automotive with CM870........................................................................13-5 Industrial and Power Generation.........................................................13-26
Alternator Idler Pulley ..............................................................................13-24 Capscrew Markings and Torque Values ....................................................V-85
Clean......................................................................................................13-24 Capscrew Markings and Torque Values - Metric........................................V-85
Inspect for Reuse....................................................................................13-25 Capscrew Markings and Torque Values - U.S. Customary.........................V-86
Install......................................................................................................13-25 General Information..................................................................................V-85
Remove..................................................................................................13-24 Centinel™ System .......................................................................................7-58
Alternator Pulley ........................................................................................13-8 General Information..................................................................................7-58
Clean........................................................................................................13-9 Charge-Air Cooler .......................................................................................10-9
Inspect for Reuse......................................................................................13-9 Clean........................................................................................................10-9
Install........................................................................................................13-9 Inspect for Reuse......................................................................................10-9
Remove....................................................................................................13-8 Leak Test................................................................................................10-10
Alternator Spacer .....................................................................................13-22 Pressure Differential Test........................................................................10-12
Clean and Inspect for Reuse...................................................................13-23 Temperature Differential Test..................................................................10-11
Finishing Steps.......................................................................................13-24 Compressed Air System ............................................................................V-80
Install......................................................................................................13-23 Specifications...........................................................................................V-80
Preparatory Steps...................................................................................13-22 Cummins 18.7 CFM Model...................................................................V-80
Remove..................................................................................................13-22 Coolant Filter ................................................................................................8-5
Alternator/Refrigerant Compressor Mounting Bracket .............................9-13 General Information....................................................................................8-5
Finishing Steps.........................................................................................9-16 Install..........................................................................................................8-6
Automotive with CM870........................................................................9-16 Remove......................................................................................................8-6
Automotive with CM570........................................................................9-16 Coolant Filter Valve ......................................................................................8-7
Inspect for Reuse......................................................................................9-14 Clean..........................................................................................................8-8
Automotive with CM870........................................................................9-14 Inspect for Reuse........................................................................................8-8
Automotive with CM570........................................................................9-14 Install..........................................................................................................8-8
Install........................................................................................................9-15 Remove......................................................................................................8-7
Automotive with CM870........................................................................9-15 Coolant Thermostat .....................................................................................8-9
Automotive with CM570........................................................................9-15 Finishing Steps.........................................................................................8-14
Preparatory Steps.....................................................................................9-13 Inspect for Reuse......................................................................................8-12
Automotive with CM870........................................................................9-13 Out-of-Chassis Opening Temperature Test............................................8-12
Automotive with CM570........................................................................9-13 Install........................................................................................................8-13
Remove....................................................................................................9-13 Leak Test....................................................................................................8-9
Automotive with CM870........................................................................9-13 In-Chassis Opening Temperature Test..................................................8-11
Automotive with CM570........................................................................9-14 Preparatory Steps.....................................................................................8-11
Batteries ...................................................................................................13-10 Remove....................................................................................................8-11
Initial Check............................................................................................13-10 Coolant Thermostat Housing .....................................................................8-15
Battery Cables and Connections .............................................................13-11 Finishing Steps.........................................................................................8-21
Initial Check............................................................................................13-11 Inspect for Reuse......................................................................................8-18
Belt Tensioner, Automatic (Alternator) ....................................................13-20 Install........................................................................................................8-18
Clean......................................................................................................13-20 Single Thermostat.................................................................................8-18
Inspect for Reuse....................................................................................13-20 Dual Thermostat...................................................................................8-19
Install......................................................................................................13-21 Preparatory Steps.....................................................................................8-15
Automotive Applications......................................................................13-21 Remove....................................................................................................8-16
Remove..................................................................................................13-20 Single Thermostat.................................................................................8-16
Automotive Applications......................................................................13-20 Dual Thermostat...................................................................................8-16
Belt Tensioner, Automatic (Water Pump) ..................................................8-68 Coolant Thermostat Seal ...........................................................................8-21
Clean and Inspect for Reuse.....................................................................8-71 Inspect for Reuse......................................................................................8-22
All Applications.....................................................................................8-71 Install........................................................................................................8-22
CM570..................................................................................................8-72 Single Seal...........................................................................................8-22
Finishing Steps.........................................................................................8-74 Dual Seal..............................................................................................8-22
Drives Alternator...................................................................................8-74 Remove....................................................................................................8-21
Initial Check..............................................................................................8-68 Single Seal...........................................................................................8-21
All Applications.....................................................................................8-68 Dual Seal..............................................................................................8-22
Install........................................................................................................8-72 Coolant Vent Lines .....................................................................................8-23
Drives Alternator...................................................................................8-72 Initial Check..............................................................................................8-23
Automotive Applications........................................................................8-72 Cooling System ..........................................................................................8-23
Industrial and Power Generation...........................................................8-73 Drain.........................................................................................................8-23
Preparatory Steps.....................................................................................8-69 Fill............................................................................................................8-26
Drives Alternator...................................................................................8-69 Flush........................................................................................................8-24
Remove....................................................................................................8-69 Pressure Test...........................................................................................8-31
Drives Alternator...................................................................................8-69 Cooling System ..........................................................................................V-75
Automotive Applications........................................................................8-69 General Information..................................................................................V-75
Industrial and Power Generation...........................................................8-70 Specifications...........................................................................................V-75
Belt Tensioner, Refrigerant Compressor, Automatic ..................................9-5 Automotive Applications.......................................................................V-75
Finishing Steps...........................................................................................9-6 Industrial and Generator Drive..............................................................V-76
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Cooling System - Air or Combustion Gas Test .........................................8-32
Initial Check................................................................................................9-5 Initial Check..............................................................................................8-32
With Water Pump and Refrigerant Compressor Belt Routing...................9-5 Air in Cooling System............................................................................8-32
Install..........................................................................................................9-6 Leak Test..................................................................................................8-34
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Fan, Shutter, or Heater Air Control Valve..............................................8-34
Preparatory Steps.......................................................................................9-6 Air Compressor.....................................................................................8-34
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Combustion Gas Leak...........................................................................8-35
Remove......................................................................................................9-6 Overflow Method...................................................................................8-38
With Water Pump and Refrigerant Compressor Belt Routing...................9-6 Crankcase Blowby, Measure ....................................................................14-30
Bracket, Idler Pulley and Alternator Belt Tensioner ...............................13-25 General Information................................................................................14-30
Clean......................................................................................................13-26 Initial Check............................................................................................14-34
Finishing Steps.......................................................................................13-28 Measure..................................................................................................14-35
Automotive Applications......................................................................13-28 Crankcase Breather (External) .....................................................................3-2
Industrial and Power Generation.........................................................13-28 Assemble....................................................................................................3-4
Inspect for Reuse....................................................................................13-27 Automotive With CM871.........................................................................3-4
Install......................................................................................................13-27 Clean and Inspect for Reuse.......................................................................3-3
Automotive Applications......................................................................13-27 Automotive with CM870..........................................................................3-3
Industrial and Power Generation.........................................................13-27 Automotive With CM871.........................................................................3-4
Preparatory Steps...................................................................................13-25 Disassemble...............................................................................................3-3
Index
Page X-3
Automotive With CM871.........................................................................3-3 Remove..................................................................................................11-21

Install..........................................................................................................3-4 EGR Cooler Connection ...........................................................................11-48
Automotive with CM870..........................................................................3-4 Clean and Inspect for Reuse...................................................................11-48
Automotive With CM871.........................................................................3-5 Finishing Steps.......................................................................................11-50
Remove......................................................................................................3-2 Install......................................................................................................11-50
Automotive with CM870..........................................................................3-2 Preparatory Steps...................................................................................11-48
Automotive With CM871.........................................................................3-2 Remove..................................................................................................11-48
Crankcase Breather (Internal) ......................................................................3-5 EGR Cooler Coolant Lines .......................................................................11-70
Clean and Inspect for Reuse.......................................................................3-6 Clean and Inspect for Reuse...................................................................11-73
Finishing Steps...........................................................................................3-8 Finishing Steps.......................................................................................11-77
Install..........................................................................................................3-7 Install......................................................................................................11-75
Preparatory Steps.......................................................................................3-5 Preparatory Steps...................................................................................11-70
Remove......................................................................................................3-6 Remove..................................................................................................11-71
Crankcase Breather Element .....................................................................3-32 EGR Differential Pressure Sensor Adapter ..............................................11-67
Install........................................................................................................3-33 Clean and Inspect for Reuse...................................................................11-67
Remove....................................................................................................3-32 Finishing Steps.......................................................................................11-68
Cummins Customized Parts Catalog ...........................................................L-3 Install......................................................................................................11-68
General Information....................................................................................L-3 Preparatory Steps...................................................................................11-67
Ordering the Customized Parts Catalog......................................................L-3 Remove..................................................................................................11-67
Ordering by Telephone...........................................................................L-3 EGR Differential Pressure Sensor Tubes ................................................11-61
Ordering On-Line....................................................................................L-3 Clean and Inspect for Reuse...................................................................11-61
Cylinder Head ...............................................................................................2-5 Automotive with CM870......................................................................11-61
Assemble..................................................................................................2-32 Automotive With CM871......................................................................11-62
Clean........................................................................................................2-10 Finishing Steps.......................................................................................11-65
Clean and Inspect for Reuse.....................................................................2-21 Automotive with CM870......................................................................11-65
Disassemble.............................................................................................2-17 Automotive With CM871......................................................................11-65
Finishing Steps.........................................................................................2-38 Install......................................................................................................11-64
General Information....................................................................................2-5 Automotive with CM870......................................................................11-64
Initial Check................................................................................................2-6 Automotive With CM871......................................................................11-64
Inspect for Reuse........................................................................................2-9 Preparatory Steps...................................................................................11-61
Install........................................................................................................2-37 Automotive With CM871......................................................................11-61
Leak Test..................................................................................................2-11 Remove..................................................................................................11-61
Magnetic Crack Inspect.............................................................................2-30 Automotive with CM870......................................................................11-61
Measure...................................................................................................2-27 Automotive With CM871......................................................................11-61
Preparatory Steps.......................................................................................2-7 EGR Mixer .................................................................................................11-37
Remove......................................................................................................2-8 Clean and Inspect for Reuse...................................................................11-38
Vacuum Test.............................................................................................2-15 Finishing Steps.......................................................................................11-39
Drive Belt Tension .....................................................................................V-82 Install......................................................................................................11-39
Tension Chart...........................................................................................V-82 Preparatory Steps...................................................................................11-37
Drive Belt, Alternator .................................................................................13-7 Remove..................................................................................................11-38
Adjust.......................................................................................................13-8 EGR Valve .................................................................................................11-40
Inspect for Reuse......................................................................................13-7 Assemble................................................................................................11-45
Install........................................................................................................13-7 Clean and Inspect for Reuse...................................................................11-42
Remove....................................................................................................13-7 Disassemble...........................................................................................11-42
Drive Belt, Cooling Fan ................................................................................8-3 Finishing Steps.......................................................................................11-47
Clean and Inspect for Reuse.......................................................................8-3 Install......................................................................................................11-45
Drives Alternator.....................................................................................8-3 Preparatory Steps...................................................................................11-40
Install..........................................................................................................8-3 Remove..................................................................................................11-41
Drives Alternator.....................................................................................8-3 EGR Valve Coolant Lines .........................................................................11-68
Remove......................................................................................................8-3 Clean and Inspect for Reuse...................................................................11-69
Drives Alternator.....................................................................................8-3 Finishing Steps.......................................................................................11-70
Drive Belt, Refrigerant Compressor ............................................................9-3 Install......................................................................................................11-69
Clean and Inspect for Reuse.......................................................................9-3 Preparatory Steps...................................................................................11-68
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Remove..................................................................................................11-69
Finishing Steps...........................................................................................9-4 EGR Valve Mounting Bracket ...................................................................11-96
With Water Pump and Refrigerant Compressor Belt Routing...................9-4 Clean and Inspect for Reuse...................................................................11-97
Install..........................................................................................................9-4 Finishing Steps.......................................................................................11-98
With Water Pump and Refrigerant Compressor Belt Routing...................9-4 Install......................................................................................................11-98
Preparatory Steps.......................................................................................9-3 Preparatory Steps...................................................................................11-96
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Automotive With CM871......................................................................11-96
Remove......................................................................................................9-3 Remove..................................................................................................11-97
With Water Pump and Refrigerant Compressor Belt Routing...................9-3 Electrical System .......................................................................................V-79
Drive Belt, Water Pump ...............................................................................8-4 Specifications...........................................................................................V-79
Adjust.........................................................................................................8-5 Engine Brake Assembly .............................................................................20-1
Inspect for Reuse........................................................................................8-4 Adjust.......................................................................................................20-4
Install..........................................................................................................8-5 Initial Check..............................................................................................20-2
Remove......................................................................................................8-4 Engine Brake Solenoid..........................................................................20-2
Dynamometer Worksheet ...........................................................................14-4 Engine Brake Rocker Lever..................................................................20-3
Worksheet................................................................................................14-4 Resistance Check.....................................................................................20-1
ECM Cooling Plate, Fuel Cooled ..................................................................6-2 Voltage Check..........................................................................................20-1
Clean and Inspect for Reuse.......................................................................6-3 Engine Brake Control Valve .....................................................................20-13
Finishing Steps...........................................................................................6-5 Inspect for Reuse....................................................................................20-14
Install..........................................................................................................6-5 Install......................................................................................................20-14
Preparatory Steps.......................................................................................6-2 Remove..................................................................................................20-13
Remove......................................................................................................6-3 Engine Brake Piston .................................................................................20-15
EGR Connection Tubes ............................................................................11-51 Inspect for Reuse....................................................................................20-16
Clean and Inspect for Reuse...................................................................11-55 Install......................................................................................................20-16
Finishing Steps.......................................................................................11-60 Remove..................................................................................................20-15
Install......................................................................................................11-57 Engine Brake Solenoid Valve ...................................................................20-10
Preparatory Steps...................................................................................11-51 Finishing Steps.......................................................................................20-11
Remove..................................................................................................11-52 Inspect for Reuse....................................................................................20-10
EGR Cooler ...............................................................................................11-19 Install......................................................................................................20-11
Clean and Inspect for Reuse...................................................................11-22 Preparatory Steps...................................................................................20-10
Finishing Steps.......................................................................................11-36 Remove..................................................................................................20-10
Install......................................................................................................11-33 Engine Brake Wiring Harness ..................................................................20-11
Preparatory Steps...................................................................................11-19 Inspect for Reuse....................................................................................20-12
Pressure Test..........................................................................................11-29 Install......................................................................................................20-13
Index
Page X-4
Threaded Brake Pass-Through............................................................20-13 Automotive, Industrial with CM570 and Power Generation without CM570....
Non-Threaded Brake Pass-Through....................................................20-13 11-6
Remove..................................................................................................20-11 Automotive With CM871........................................................................11-7
Threaded Brake Pass-Through............................................................20-11 Remove....................................................................................................11-7
Non-Threaded Brake Pass-Through....................................................20-12 Repair.......................................................................................................11-4
Engine Lifting Brackets ..............................................................................16-2 Automotive with CM870........................................................................11-4
Clean and Inspect for Reuse.....................................................................16-3 Exhaust Restriction ..................................................................................11-17
Finishing Steps.........................................................................................16-4 Initial Check............................................................................................11-17
Install........................................................................................................16-3 Exhaust System .........................................................................................V-78
Preparatory Steps.....................................................................................16-2 Specifications...........................................................................................V-78
Remove....................................................................................................16-2 Automotive Applications.......................................................................V-78
Engine Mounts ..........................................................................................16-41 Industrial and Generator Drive..............................................................V-78
General Information................................................................................16-41 Automotive With CM871.......................................................................V-78
Inspect for Reuse....................................................................................16-43 Exhaust System Diagnostics ..................................................................11-145
Install......................................................................................................16-44 General Information...............................................................................11-145
Remove..................................................................................................16-43 Fan Clutch, On-Off .....................................................................................8-39
Engine Run-in (Chassis Dynamometer) ...................................................14-12 Initial Check..............................................................................................8-39
Run-In Instructions..................................................................................14-12 With Low Temperature Fan-On Control.................................................8-39
Engine Run-in (Engine Dynamometer) .....................................................14-25 With High Temperature Fan On............................................................8-40
Run-In Instructions..................................................................................14-25 Fan Drive Idler Pulley Assembly ................................................................8-42
Engine Run-in (Without Dynamometer) ...................................................14-16 Finishing Steps.........................................................................................8-43
Run-In Instructions..................................................................................14-16 Install........................................................................................................8-42
Engine Support Bracket, Front ..................................................................16-4 Preparatory Steps.....................................................................................8-42
Clean and Inspect for Reuse.....................................................................16-5 Remove....................................................................................................8-42
Finishing Steps.........................................................................................16-6 Fan Hub, Belt Driven ..................................................................................8-43
Install........................................................................................................16-6 Clean and Inspect for Reuse.....................................................................8-44
Preparatory Steps.....................................................................................16-4 Automotive with CM870........................................................................8-44
Remove....................................................................................................16-4 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Testing ...........................................................................................V-81 8-45
Specifications...........................................................................................V-81 Finishing Steps.........................................................................................8-46
Engine Testing (Chassis Dynamometer) ...................................................14-6 Automotive with CM870........................................................................8-46
Setup........................................................................................................14-6 Automotive with CM570........................................................................8-47
Test..........................................................................................................14-9 Industrial CM570 and Power Generation without CM570.......................8-47
Engine Testing (Engine Dynamometer) ...................................................14-17 Install........................................................................................................8-45
Setup......................................................................................................14-17 Automotive with CM870........................................................................8-45
Test........................................................................................................14-22 Automotive with CM570........................................................................8-46
Engine Testing (In Chassis) .....................................................................14-29 Industrial CM570 and Power Generation without CM570.......................8-46
Setup......................................................................................................14-29 Preparatory Steps.....................................................................................8-43
Engine Testing (Portable Dynamometer or Load Bank) ..........................14-29 Automotive with CM870........................................................................8-43
General Information................................................................................14-29 Automotive with CM570........................................................................8-43
Exhaust Gas Pressure Sensor Adapter ...................................................11-80 Industrial CM570 and Power Generation without CM570.......................8-43
Finishing Steps.......................................................................................11-81 Remove....................................................................................................8-44
Automotive with CM870......................................................................11-81 Automotive with CM870........................................................................8-44
Inspect for Reuse....................................................................................11-80 Automotive with CM570........................................................................8-44
All Applications...................................................................................11-80 Industrial CM570 and Power Generation without CM570.......................8-44
Install......................................................................................................11-81 Fan Pulley ...................................................................................................8-78
All Applications...................................................................................11-81 Inspect for Reuse......................................................................................8-79
Preparatory Steps...................................................................................11-80 Install........................................................................................................8-79
Automotive with CM870......................................................................11-80 Industrial and Power Generation...........................................................8-79
Remove..................................................................................................11-80 Remove....................................................................................................8-78
All Applications...................................................................................11-80 Industrial and Power Generation...........................................................8-78
Exhaust Gas Pressure Sensor Tube ........................................................11-65 Fan Shroud Assembly ................................................................................8-47
Clean and Inspect for Reuse...................................................................11-66 Initial Check..............................................................................................8-47
Finishing Steps.......................................................................................11-66 Fan Support ................................................................................................8-75
Install......................................................................................................11-66 Finishing Steps.........................................................................................8-78
Preparatory Steps...................................................................................11-65 Industrial and Power Generation...........................................................8-78
Remove..................................................................................................11-65 Install........................................................................................................8-76
Exhaust Manifold, Dry ................................................................................11-4 Industrial and Power Generation...........................................................8-76
Assemble................................................................................................11-12 Preparatory Steps.....................................................................................8-75
Automotive with CM870......................................................................11-12 Industrial and Power Generation...........................................................8-75
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove....................................................................................................8-76
11-12 Industrial and Power Generation...........................................................8-76
Automotive With CM871......................................................................11-13 Fan, Cooling ...............................................................................................8-48
Clean and Inspect for Reuse.....................................................................11-8 Inspect for Reuse......................................................................................8-48
Automotive, Industrial with CM570 and Power Generation without CM570.... Install........................................................................................................8-49
11-8 Remove....................................................................................................8-48
Automotive with CM870 and CM871......................................................11-9 Flywheel .....................................................................................................16-7
Disassemble.............................................................................................11-7 Clean and Inspect for Reuse...................................................................16-10
Automotive with CM870........................................................................11-7 Finishing Steps.......................................................................................16-13
Automotive, Industrial with CM570 and Power Generation without CM570.... Initial Check..............................................................................................16-7
11-8 Bore Runout.........................................................................................16-7
Automotive With CM871........................................................................11-8 Face Runout.........................................................................................16-8
Finishing Steps.......................................................................................11-16 Install......................................................................................................16-12
Automotive with CM870......................................................................11-16 Preparatory Steps.....................................................................................16-9
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove..................................................................................................16-10
11-16 Flywheel Housing .....................................................................................16-14
Automotive With CM871......................................................................11-17 Clean and Inspect for Reuse...................................................................16-16
Initial Check..............................................................................................11-4 Finishing Steps.......................................................................................16-23
Automotive with CM870........................................................................11-4 Install......................................................................................................16-17
Automotive With CM871........................................................................11-4 Measure..................................................................................................16-18
Install......................................................................................................11-13 Bore Alignment...................................................................................16-18
Automotive with CM870 and CM871....................................................11-13 Face Alignment...................................................................................16-21
Automotive, Industrial with CM570 and Power Generation without CM570.... Preparatory Steps...................................................................................16-14
11-14 Remove..................................................................................................16-14
Preparatory Steps.....................................................................................11-6 Flywheel Housing, REPTO .......................................................................16-24
Automotive with CM870........................................................................11-6 Clean and Inspect for Reuse...................................................................16-27
Finishing Steps.......................................................................................16-40
Index
Page X-5
Install......................................................................................................16-29 Automotive With CM871.......................................................................V-72

Measure..................................................................................................16-36 General Repair Instructions ..........................................................................i-8
Bore Alignment...................................................................................16-36 General Information.....................................................................................i-8
Face Alignment...................................................................................16-38 Welding on a Vehicle with an Electronic Controlled Fuel System..................i-9
Preparatory Steps...................................................................................16-24 General Safety Instructions ..........................................................................i-6
Remove..................................................................................................16-24 Important Safety Notice................................................................................i-6
Flywheel Ring Gear ..................................................................................16-41 Heat Shield ...............................................................................................11-78
Install......................................................................................................16-41 Clean and Inspect for Reuse...................................................................11-79
Remove..................................................................................................16-41 Finishing Steps.......................................................................................11-80
Fraction, Decimal, Millimeter Conversions ...............................................V-83 Automotive with CM870......................................................................11-80
Conversion Chart......................................................................................V-83 Install......................................................................................................11-79
Fuel Consumption ........................................................................................5-3 Automotive with CM870......................................................................11-79
Maintenance Check....................................................................................5-3 Automotive With CM871......................................................................11-79
Fuel Drain Line Restriction ..........................................................................6-6 Preparatory Steps...................................................................................11-78
Measure.....................................................................................................6-6 Automotive with CM870......................................................................11-78
Fuel Filter (Spin-On Type) ............................................................................6-6 Remove..................................................................................................11-78
Clean..........................................................................................................6-9 Automotive with CM870......................................................................11-78
Initial Check................................................................................................6-6 Automotive With CM871......................................................................11-78
Install..........................................................................................................6-9 How to Use the Manual .................................................................................i-2
Remove......................................................................................................6-8 General Information.....................................................................................i-2
Fuel Inlet Pre-Filter .....................................................................................5-47 Idler Pulley, Refrigerant Compressor ..........................................................9-7
Clean........................................................................................................5-49 Finishing Steps...........................................................................................9-8
General Information..................................................................................5-47 With Water Pump and Refrigerant Compressor Belt Routing...................9-8
Install........................................................................................................5-50 Inspect for Reuse........................................................................................9-7
Remove....................................................................................................5-48 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Fuel Inlet Restriction ..................................................................................6-11 Install..........................................................................................................9-7
Measure...................................................................................................6-11 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
With Pressurized Fuel Filtering.............................................................6-11 Preparatory Steps.......................................................................................9-7
With Vacuum Fuel Filtering...................................................................6-12 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Fuel Lift Pump ............................................................................................5-14 Remove......................................................................................................9-7
Clean and Inspect for Reuse.....................................................................5-20 With Water Pump and Refrigerant Compressor Belt Routing...................9-7
Finishing Steps.........................................................................................5-24 Illustrations ....................................................................................................i-5
Initial Check..............................................................................................5-14 General Information.....................................................................................i-5
Install........................................................................................................5-22 Injector ........................................................................................................6-14
Preparatory Steps.....................................................................................5-17 Assemble..................................................................................................6-23
Pressure Test...........................................................................................5-16 Disassemble.............................................................................................6-19
Remove....................................................................................................5-17 Finishing Steps.........................................................................................6-27
Replace....................................................................................................5-21 Inspect for Reuse......................................................................................6-18
Resistance Check.....................................................................................5-14 Install........................................................................................................6-27
Test..........................................................................................................5-16 Leak Test..................................................................................................6-14
Voltage Check..........................................................................................5-15 Preparatory Steps.....................................................................................6-16
Fuel Pump ....................................................................................................5-4 Remove....................................................................................................6-17
Clean and Inspect for Reuse.......................................................................5-6 Injector Camshaft Scissor Gear .................................................................2-86
Finishing Steps...........................................................................................5-7 Install........................................................................................................2-87
Install..........................................................................................................5-6 Remove....................................................................................................2-86
Leak Test....................................................................................................5-4 Intake Manifold Pressure .........................................................................10-58
Preparatory Steps.......................................................................................5-5 Measure..................................................................................................10-58
Pressure Test.............................................................................................5-4 Integrated Fuel System Module (IFSM) .....................................................5-30
Prime..........................................................................................................5-8 Assemble..................................................................................................5-34
Remove......................................................................................................5-5 Clean and Inspect for Reuse.....................................................................5-32
Fuel Pump Pulsation Damper ......................................................................5-9 Disassemble.............................................................................................5-32
Clean and Inspect for Reuse.....................................................................5-10 Finishing Steps.........................................................................................5-46
Automotive with CM870........................................................................5-10 Install........................................................................................................5-44
Automotive, Industrial with CM570 and Power Generation without CM570.... Preparatory Steps.....................................................................................5-30
5-10 Remove....................................................................................................5-31
Finishing Steps.........................................................................................5-11 Lubricating Oil and Filter Analysis ............................................................7-58
All Applications.....................................................................................5-11 Inspect......................................................................................................7-58
Install........................................................................................................5-10 Lubricating Oil......................................................................................7-58
Automotive with CM870........................................................................5-10 Lubricating Oil Filter..............................................................................7-59
Automotive, Industrial with CM570 and Power Generation without CM570.... Lubricating Oil Cooler ..................................................................................7-4
5-11 Clean and Inspect for Reuse.......................................................................7-6
Preparatory Steps.......................................................................................5-9 All Applications.......................................................................................7-6
All Applications.......................................................................................5-9 Finishing Steps.........................................................................................7-10
Remove......................................................................................................5-9 Automotive with CM870........................................................................7-10
Automotive with CM870..........................................................................5-9 Automotive, Industrial with CM570 and Power Generation without CM570....
Automotive, Industrial with CM570 and Power Generation without CM570.... 7-11
5-10 Install........................................................................................................7-10
Fuel Shutoff Valve ......................................................................................5-11 All Applications.....................................................................................7-10
Inspect for Reuse......................................................................................5-12 Leak Test....................................................................................................7-8
Install........................................................................................................5-13 All Applications.......................................................................................7-8
Remove....................................................................................................5-11 Preparatory Steps.......................................................................................7-4
Fuel Supply Lines .......................................................................................6-13 Automotive with CM870..........................................................................7-4
Inspect for Reuse......................................................................................6-13 Automotive, Industrial with CM570 and Power Generation without CM570....
Remove....................................................................................................6-13 7-5
Fuel System ...............................................................................................V-73 Remove......................................................................................................7-5
Specifications...........................................................................................V-73 All Applications.......................................................................................7-5
General Cleaning Instructions ....................................................................i-10 Lubricating Oil Cooler Element ..................................................................7-11
Abrasive Pads and Abrasive Paper.............................................................i-10 Assemble..................................................................................................7-14
Definition of Clean......................................................................................i-10 Single-Element.....................................................................................7-14
Fuel System...............................................................................................i-13 Dual-Element........................................................................................7-14
Gasket Surfaces........................................................................................i-11 Clean and Inspect for Reuse.....................................................................7-12
Plastic Bead Cleaning................................................................................i-12 Disassemble.............................................................................................7-11
Solvent and Acid Cleaning.........................................................................i-11 Single-Element.....................................................................................7-11
Steam Cleaning.........................................................................................i-12 Dual-Element........................................................................................7-11
General Engine ...........................................................................................V-72 Finishing Steps.........................................................................................7-15
Specifications...........................................................................................V-72 Preparatory Steps.....................................................................................7-11
Automotive with CM870........................................................................V-72 Pressure Test...........................................................................................7-13
Index
Page X-6
Lubricating Oil Dipstick ..............................................................................7-15 Install........................................................................................................2-62

Calibrate...................................................................................................7-15 Remove....................................................................................................2-57
Lubricating Oil Dipstick Tube ....................................................................7-16 Overhead Camshaft End Clearance, Injector ............................................2-83
Install........................................................................................................7-16 Measure...................................................................................................2-83
Automotive with CM870........................................................................7-16 Overhead Camshaft Gear, Valve ................................................................2-86
Automotive With CM871........................................................................7-17 Install........................................................................................................2-86
Remove....................................................................................................7-16 Remove....................................................................................................2-86
Automotive with CM870........................................................................7-16 Overhead Camshaft, Injector .....................................................................2-51
Automotive With CM871........................................................................7-16 Clean and Inspect for Reuse.....................................................................2-54
Lubricating Oil Fill Tube ............................................................................7-52 Finishing Steps.........................................................................................2-55
Clean and Inspect for Reuse.....................................................................7-54 Install........................................................................................................2-55
Automotive With CM871........................................................................7-54 Remove....................................................................................................2-53
Install........................................................................................................7-55 Overhead Camshaft, Valve ........................................................................2-47
Automotive with CM870........................................................................7-55 Clean and Inspect for Reuse.....................................................................2-49
Automotive With CM871........................................................................7-56 Finishing Steps.........................................................................................2-50
Remove....................................................................................................7-52 Install........................................................................................................2-50
Automotive With CM871........................................................................7-53 Remove....................................................................................................2-48
Lubricating Oil Filter (Spin-On) ..................................................................7-17 Overhead Set ................................................................................................3-8
General Information..................................................................................7-17 Adjust.......................................................................................................3-12
Install........................................................................................................7-19 Finishing Steps.........................................................................................3-20
Measure...................................................................................................7-18 Measure.....................................................................................................3-8
Remove....................................................................................................7-19 General Information................................................................................3-8
Lubricating Oil Filter Bypass Valve ...........................................................7-20 Preparatory Steps.....................................................................................3-12
Clean........................................................................................................7-21 Pipe Plug Torque Values ...........................................................................V-88
General Information..................................................................................7-20 Torque Table............................................................................................V-88
Inspect for Reuse......................................................................................7-21 Radiator ......................................................................................................8-49
Install........................................................................................................7-22 Initial Check..............................................................................................8-49
Remove....................................................................................................7-20 Radiator Hoses ...........................................................................................8-50
Lubricating Oil Filter Head Adapter ...........................................................7-23 Inspect for Reuse......................................................................................8-50
Clean and Inspect for Reuse.....................................................................7-24 Radiator Pressure Cap ...............................................................................8-50
Finishing Steps.........................................................................................7-25 Inspect for Reuse......................................................................................8-50
Install........................................................................................................7-24 .............................................................................................................8-50
Preparatory Steps.....................................................................................7-23 Radiator Shutter Assembly ........................................................................8-51
Remove....................................................................................................7-23 General Information..................................................................................8-51
Lubricating Oil High Pressure Relief Valve ...............................................7-25 Refrigerant Compressor ...............................................................................9-1
General Information..................................................................................7-25 Clean and Inspect for Reuse.......................................................................9-2
Inspect for Reuse......................................................................................7-26 With Water Pump and Refrigerant Compressor Belt Routing...................9-2
Install........................................................................................................7-26 Climate Control Incorporated..................................................................9-2
Remove....................................................................................................7-25 Finishing Steps...........................................................................................9-3
Lubricating Oil Leaks .................................................................................7-27 With Water Pump and Refrigerant Compressor Belt Routing...................9-3
General Information..................................................................................7-27 Install..........................................................................................................9-2
Lubricating Oil Pan .....................................................................................7-29 Sanden...................................................................................................9-2
Clean and Inspect for Reuse.....................................................................7-30 Climate Control Incorporated..................................................................9-2
Finishing Steps.........................................................................................7-31 Preparatory Steps.......................................................................................9-1
Install........................................................................................................7-30 With Water Pump and Refrigerant Compressor Belt Routing...................9-1
Preparatory Steps.....................................................................................7-29 Remove......................................................................................................9-1
Remove....................................................................................................7-30 Sanden...................................................................................................9-1
Lubricating Oil Pressure Gauge .................................................................7-32 Climate Control Incorporated..................................................................9-1
Test..........................................................................................................7-32 Refrigerant Compressor Mounting Bracket .................................................9-8
Lubricating Oil Pump .................................................................................7-32 Clean and Inspect for Reuse.....................................................................9-10
Assemble..................................................................................................7-40 Automotive with CM870........................................................................9-10
Clean and Inspect for Reuse.....................................................................7-34 Automotive, Industrial with CM570 and Power Generation without CM570....
Disassemble.............................................................................................7-33 9-10
Finishing Steps.........................................................................................7-44 Finishing Steps.........................................................................................9-12
Install........................................................................................................7-42 Automotive with CM870........................................................................9-12
Preparatory Steps.....................................................................................7-32 Automotive, Industrial with CM570 and Power Generation without CM570....
Remove....................................................................................................7-32 9-12
Lubricating Oil Suction Tube (Block-Mounted) .........................................7-45 Install........................................................................................................9-11
Finishing Steps.........................................................................................7-46 Sanden.................................................................................................9-11
Inspect for Reuse......................................................................................7-45 Climate Control Incorporated................................................................9-11
Install........................................................................................................7-46 Automotive, Industrial with CM570 and Power Generation without CM570....
Preparatory Steps.....................................................................................7-45 9-11
Remove....................................................................................................7-45 Preparatory Steps.......................................................................................9-8
Lubricating Oil System ...............................................................................7-47 Automotive with CM870..........................................................................9-8
Drain.........................................................................................................7-47 Automotive, Industrial with CM570 and Power Generation without CM570....
Fill............................................................................................................7-49 9-8
Prime........................................................................................................7-47 Remove......................................................................................................9-9
Lubricating Oil System ..............................................................................V-74 Sanden...................................................................................................9-9
Specifications...........................................................................................V-74 Climate Control Incorporated..................................................................9-9
Lubricating Oil Thermostat ........................................................................7-50 Automotive, Industrial with CM570 and Power Generation without CM570....
Inspect for Reuse......................................................................................7-50 9-9
Install........................................................................................................7-51 Rocker Lever Assembly .............................................................................3-21
Newton-Meter to Foot-Pound Conversions ...............................................V-87 Finishing Steps.........................................................................................3-30
Conversion Chart......................................................................................V-87 Install........................................................................................................3-26
Overhead Camshaft End Clearance, Valve ................................................2-81 Preparatory Steps.....................................................................................3-21
Measure...................................................................................................2-81 Remove....................................................................................................3-21
Overhead Camshaft Bushings, Injector .....................................................2-69 Rocker Lever Cover ....................................................................................3-30
Initial Check..............................................................................................2-69 Clean and Inspect for Reuse.....................................................................3-30
Inspect for Reuse......................................................................................2-74 Install........................................................................................................3-32
Install........................................................................................................2-74 Remove....................................................................................................3-30
Remove....................................................................................................2-69 Service Literature Ordering Location ..........................................................L-2
Overhead Camshaft Bushings, Valve ........................................................2-57 Contact Information....................................................................................L-2
Initial Check..............................................................................................2-57 Service Tools ...............................................................................................2-1
Inspect for Reuse......................................................................................2-62 ...................................................................................................................2-1
Index
Page X-7
Service Tools ...............................................................................................3-1 Automotive with CM870......................................................................10-46

Rocker Levers.............................................................................................3-1 Automotive With CM871......................................................................10-47
Service Tools ...............................................................................................5-1 Preparatory Steps...................................................................................10-43
Fuel System................................................................................................5-1 Automotive with CM870......................................................................10-43
Service Tools ...............................................................................................6-1 Automotive With CM871......................................................................10-43
...................................................................................................................6-1 Remove..................................................................................................10-44
Service Tools ...............................................................................................7-1 Automotive with CM870......................................................................10-44
...................................................................................................................7-1 Automotive With CM871......................................................................10-44
Service Tools ...............................................................................................8-1 Turbocharger Wastegate Actuator ..........................................................10-49
Cooling System...........................................................................................8-1 Adjust.....................................................................................................10-54
Service Tools ..............................................................................................10-1 Finishing Steps.......................................................................................10-57
.................................................................................................................10-1 Initial Check............................................................................................10-49
Service Tools ..............................................................................................11-1 Inspect....................................................................................................10-52
.................................................................................................................11-1 Inspect for Reuse....................................................................................10-53
Service Tools ..............................................................................................13-1 Install......................................................................................................10-55
Electrical Equipment.................................................................................13-1 Preparatory Steps...................................................................................10-51
Service Tools ..............................................................................................14-1 Remove..................................................................................................10-52
Engine Testing..........................................................................................14-1 Turbocharger Wastegate Controller ........................................................10-63
Service Tools ..............................................................................................16-1 Inspect for Reuse....................................................................................10-64
Mounting Adaptations...............................................................................16-1 Install......................................................................................................10-64
Stall Speed Test .........................................................................................5-25 Remove..................................................................................................10-63
Stall Speed Check....................................................................................5-25 Turbocharger Wastegate Valve Body ......................................................10-57
Stall Speed Check List..............................................................................5-28 Inspect for Reuse....................................................................................10-57
Stall Speed Too Low.............................................................................5-28 Turbocharger, Variable Geometry Actuator ............................................10-65
Stall Speed Too High............................................................................5-29 Finishing Steps.......................................................................................10-69
Time Speed Check....................................................................................5-27 Variable Geometry..............................................................................10-69
Starter Magnetic Switch ...........................................................................13-12 General Information................................................................................10-65
Current Check.........................................................................................13-12 Variable Geometry..............................................................................10-65
Starter Solenoid ........................................................................................13-15 Inspect for Reuse....................................................................................10-67
Voltage Check.........................................................................................13-15 Variable Geometry..............................................................................10-67
Starter Switch ...........................................................................................13-14 Install......................................................................................................10-68
Voltage Check.........................................................................................13-14 Variable Geometry..............................................................................10-68
Starting Motor ...........................................................................................13-17 Preparatory Steps...................................................................................10-66
Finishing Steps.......................................................................................13-19 Variable Geometry..............................................................................10-66
All Applications...................................................................................13-19 Remove..................................................................................................10-66
Install......................................................................................................13-18 Variable Geometry..............................................................................10-66
All Except 50MT With Aluminum Flywheel Housing.............................13-18 Test........................................................................................................10-68
50MT With Aluminum Flywheel Housing.............................................13-19 Variable Geometry..............................................................................10-68
Preparatory Steps...................................................................................13-17 Turbocharger, Variable Geometry Actuator Air Supply Line ..................10-73
All Applications...................................................................................13-17 Inspect for Reuse....................................................................................10-74
Remove..................................................................................................13-18 Install......................................................................................................10-74
All Except 50MT With Aluminum Flywheel Housing.............................13-18 Remove..................................................................................................10-73
50MT With Aluminum Flywheel Housing.............................................13-18 Turbocharger, Variable Geometry Control Valve Air Supply Line ..........10-75
Symbols .........................................................................................................i-4 Inspect for Reuse....................................................................................10-75
General Information.....................................................................................i-4 Install......................................................................................................10-76
Tap-Drill Chart - U.S. Customary and Metric ............................................V-89 Remove..................................................................................................10-75
General Information..................................................................................V-89 Valve Guide Seal, Cylinder Head ...............................................................2-39
Turbocharger ............................................................................................10-15 Finishing Steps.........................................................................................2-47
Assemble................................................................................................10-33 On-Engine Repair.................................................................................2-47
Clean......................................................................................................10-26 Off-Engine Repair.................................................................................2-47
Disassemble...........................................................................................10-25 General Information..................................................................................2-39
Finishing Steps.......................................................................................10-40 Install........................................................................................................2-43
Initial Check............................................................................................10-15 Preparatory Steps.....................................................................................2-39
Inspect for Reuse....................................................................................10-27 On-Engine Repair.................................................................................2-39
Install......................................................................................................10-34 Off-Engine Repair.................................................................................2-40
Leak Test................................................................................................10-18 Remove....................................................................................................2-40
Preparatory Steps...................................................................................10-19 Variable Geometry Turbocharger Actuator, Electric ...............................10-77
Remove..................................................................................................10-21 Calibrate.................................................................................................10-84
Test........................................................................................................10-17 Clean and Inspect for Reuse...................................................................10-78
Turbocharger Air Shutoff Valve Filter .....................................................10-69 Finishing Steps.......................................................................................10-84
Clean and Inspect for Reuse...................................................................10-70 General Information................................................................................10-77
Variable Geometry..............................................................................10-70 Install......................................................................................................10-80
Finishing Steps.......................................................................................10-70 Preparatory Steps...................................................................................10-77
Variable Geometry..............................................................................10-70 Remove..................................................................................................10-78
Install......................................................................................................10-70 Variable Geometry Turbocharger Cross Shaft ........................................10-85
Variable Geometry..............................................................................10-70 Assemble................................................................................................10-92
Preparatory Steps...................................................................................10-69 Clean and Inspect for Reuse...................................................................10-92
Variable Geometry..............................................................................10-69 Disassemble...........................................................................................10-86
Remove..................................................................................................10-69 Finishing Steps.......................................................................................10-99
Variable Geometry..............................................................................10-69 Initial Check............................................................................................10-85
Turbocharger Control Shutoff Valve Filter Head .....................................10-71 Preparatory Steps...................................................................................10-86
Clean and Inspect for Reuse...................................................................10-72 Steam Cleaning......................................................................................10-86
Variable Geometry..............................................................................10-72 Water Inlet Connection ..............................................................................8-74
Finishing Steps.......................................................................................10-73 Finishing Steps.........................................................................................8-75
Variable Geometry..............................................................................10-73 Install........................................................................................................8-75
Install......................................................................................................10-72 Preparatory Steps.....................................................................................8-74
Variable Geometry..............................................................................10-72 Remove....................................................................................................8-75
Preparatory Steps...................................................................................10-71 Water Pump ................................................................................................8-51
Variable Geometry..............................................................................10-71 Assemble..................................................................................................8-60
Remove..................................................................................................10-71 Clean........................................................................................................8-55
Variable Geometry..............................................................................10-71 Automotive With CM871........................................................................8-55
Turbocharger Coolant Hoses ...................................................................10-43 Clean and Inspect for Reuse.....................................................................8-57
Clean and Inspect for Reuse...................................................................10-45 Disassemble.............................................................................................8-56
Finishing Steps.......................................................................................10-48 Finishing Steps.........................................................................................8-67
Automotive with CM870......................................................................10-48 Automotive with CM870........................................................................8-67
Automotive With CM871......................................................................10-49 Automotive with CM570........................................................................8-67
Install......................................................................................................10-46 Industrial CM570 and Power Generation without CM570.......................8-67
Index
Page X-8
Automotive With CM871........................................................................8-67

Install........................................................................................................8-63
Automotive with CM870........................................................................8-63
Industrial CM570 and Power Generation without CM570.......................8-65
Measure...................................................................................................8-59
Remove....................................................................................................8-53
Water Pump Cartridge ................................................................................8-80
Clean and Inspect for Reuse.....................................................................8-81
Finishing Steps.........................................................................................8-81
Install........................................................................................................8-81
Remove....................................................................................................8-80
Weights and Measures - Conversion Factors ...........................................V-84
Conversion Chart......................................................................................V-84
NOTES
NOTES
Cummins Inc.
Service Manual
Service Manual Signature, ISX and QSX15 Volume 2

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

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Copyright© 2011 Bulletin 3666239

Engine and System Identification ............................................................................................................ E

Troubleshooting Symptoms ..................................................................................................................... TS

Troubleshooting Symptoms (New Format) .............................................................................................. TT

Complete Engine - Group 00 .................................................................................................................... 0

Engine Disassembly Group 00 ................................................................................................................. DS

Engine Assembly - Group 00 ................................................................................................................... AS

Cylinder Block - Group 01 ........................................................................................................................ 1

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

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

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

This Page Left Intentionally Blank

About the Manual

How to Use the Manual

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

The illustrations are intended to show repair or

General Safety Instructions

General Repair Instructions

• Follow all safety instructions noted in the procedures

Welding on a Vehicle with an Electronic Controlled Fuel System

General Cleaning Instructions

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

Acronyms and Abbreviations

ppm Parts Per Million

Section E - Engine and System Identification

This Page Left Intentionally Blank

Automotive, Industrial with CM570 and Power

Automotive with CM870

ISX Automotive with CM870 - Left Side View

Automotive with CM870

ISX Automotive with CM870 - Right Side View

Automotive with CM870

ISX Automotive with CM870 - Front View

Automotive With CM871

ISX Automotive with CM871 - Front View

Automotive With CM871

ISX Automotive with CM871 - Left Side View

Automotive With CM871

ISX Automotive with CM871 — Rear View

Automotive With CM871

ISX Automotive with CM871 - Right Side View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Front View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Left Side View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Right Side View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Front View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Left Side View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Right Side View

Industrial CM570 and Power Generation without CM570

Fuel System - Left Side View

Industrial CM570 and Power Generation without CM570

Fuel System - Left Side View (continued)

Industrial CM570 and Power Generation without CM570

Fuel Delivery Housing - Front View

Industrial CM570 and Power Generation without CM570