Index Page 2 Crankshaft Gear - Replacement .............................................. 1-39 Inspection............................................................................... 1-39 Installation.............................................................................. 1-40 Removal................................................................................. 1-39 Crankshaft Magnetic Crack Inspection ................................... 1-30 Coil Shot (Circumferental Magnetization) ................................ 1-31 Head Shot (Longitudinal Magnetization).................................. 1-30 Magnetic Inspection - Limits of Acceptance ............................
1-32 Crankshaft Pulley - Cleaning and Inspection for Reuse ......... 1-41 Cleaning................................................................................. 1-41 Inspection............................................................................... 1-42 Cylinder Block - Exploded View ............................................... 1-6 Cylinder Block - General Information ....................................... 1-7 Cylinder Block - Inspection for Reuse .................................... 1-13 Camshaft Bushing Inside Diameter - ...................................... 1-20 Cylinder Liner Bores - Inspection............................................
1-13 High Oil Pressure Regulator Seat Depth - Measurement ........ 1-19 Idler Gear Ring Dowel Bore - Measurement............................ 1-19 Main Bearing Bore Alignment - Inspection.............................. 1-14 Main Bearing Bore Inside Diameter - Measurement................ 1-18 Main Oil Pressure Regulator Valve Bore - Measurement......... 1-19 Thrust Bearing Surface Width - Measurement ........................ 1-18 Cylinder Block ........................................................................... 1-7 Assembly ................................................................................ 1-11 Cam Follower Studs - Installation .........................................
1-12 Dowel Pins - Installation....................................................... 1-12 Pipe Plugs - Installation........................................................ 1-11 Cleaning................................................................................... 1-9 Disassembly............................................................................. 1-7 Cam Follower Studs - Removal .............................................. 1-9 Dowel Pins - Removal............................................................ 1-8 Idler Shaft Ring Dowels - Removal......................................... 1-9 Pipe Plugs - Removal ............................................................
1-8 Cylinder Head - Cleaning and Inspection for Reuse ................ 2-7 Cleaning................................................................................... 2-7 Inspection ................................................................................ 2-8 Cylinder Head - Exploded View ................................................ 2-6 Cylinder Head - General Information ........................................ 2-7 Cylinder Head - Pressure Test for Reuse ................................ 2-29 Cylinder Head - Rebuild ............................................................ 2-8 Assembly................................................................................
2-18 Disassembly............................................................................. 2-8 Inspection............................................................................... 2-10 Valve Seats - Grinding............................................................ 2-17 Cylinder Head - Vacuum Test Valve Seating ........................... 2-31 Cylinder Head - Valve Grinding ............................................... 2-25 Inspection............................................................................... 2-25 Cylinder Head Injector Sleeve - Replacement ........................ 2-26 Assembly................................................................................
2-27 Disassembly........................................................................... 2-26 Inspection............................................................................... 2-26 Cylinder Head Oversize Valve Seat Insert - Installation ......... 2-24 Cylinder Head Valve Guide - Replacement ............................. 2-20 Assembly................................................................................ 2-21 Disassembly........................................................................... 2-20 Inspection............................................................................... 2-20 Cylinder Head Valve Seat Insert - Replacement .....................
2-22 Assembly................................................................................ 2-23 Disassembly........................................................................... 2-22 Inspection............................................................................... 2-22 Cylinder Head Valves - Magnetic Crack Inspection ................ 2-33 Cylinder Liner - Cleaning and Inspection for Reuse .............. 1-22 Cleaning................................................................................. 1-22 Inspection...............................................................................
1-23 Definition Of Terms ................................................................... i-11 Dipstick Tube Bracket - Cleaning and Inspection for Reuse .. 1-65 Cleaning................................................................................. 1-65 Inspection............................................................................... 1-66 Drive Belt Tension ................................................................... V-42 Drive Units - General Information ............................................. 9-5 Fuel Pump and Compressor Drive............................................ 9-5 Hydraulic Pump Drive...............................................................
9-5 Dynamometer Worksheet ...................................................... 14-19 Electrical Equipment - General Information ........................... 13-2 Engine Assembly ..................................................................... 0-50 Accessory Drive Assembly - Installation.................................. 0-86 Accessory Drive Oil Seal - Installation ................................... 0-110 Accessory Drive Pulley - Installation ...................................... 0-111 Actuator Harness - Installation .............................................. 0-121 Air Compressor - Installation.................................................
0-126 Air Compressor Air Supply Tube - Installation ....................... 0-127 Air Compressor Coolant Inlet Tube Fitting - Installation ......... 0-125 Air Compressor Coolant Outlet Tube - Installation ................. 0-131 Air Intake Manifold - Installation............................................ 0-139 Alternator - Installation.......................................................... 0-142 Alternator and Bracket (Bus Applications) - Installation ......... 0-143 Alternator Belt (Non Bus Applications) - Installation .............. 0-143 Alternator Drive Belt (Bus Applications) - Installation.............
0-145 Alternator Drive Pulley - Installation ...................................... 0-136 Alternator Drive Seal - Installation......................................... 0-136 Automatic Belt Tensioner - Installation................................... 0-108 Cam Follower Assemblies - Installation ................................... 0-90 Camshaft and Gear Assembly - Installation ............................ 0-82 Connecting Rod Side Clearance Measurement....................... 0-79 Coolant Filter - Installation .................................................... 0-147 Crankshaft - Installation ..........................................................
0-57 Crossheads - Installation....................................................... 0-113 Cylinder Block - Installation On Rebuild Stand........................ 0-50 Cylinder Head - Installation..................................................... 0-92 Cylinder Liners - Installation ................................................... 0-50 Dipstick Tube Bracket - Installation ....................................... 0-138 Drain Plugs - Inspection ....................................................... 0-147 Electric Fan Clutch (Cummins) - Installation.......................... 0-132 Electronic Control Cooling Plate - Installation........................
0-129 Electronic Control Module - Installation................................. 0-129 Engine - Removal From The Rebuild Stand .......................... 0-133 Exhaust Manifold - Installation .............................................. 0-138 Fan Belt - Installation............................................................ 0-145 Fan Hub (Belt Driven) - Installation ....................................... 0-132 Fan Hub Support - Installation .............................................. 0-131 Fan Idler Pulley - Installation................................................. 0-132 Fan Pulley and Fan - Installation...........................................
0-145 Flywheel - Installation ............................................................. 0-72 Flywheel Bore Runout - Measurement .................................... 0-72 Flywheel Face Runout - Measurement.................................... 0-74 Flywheel Housing - Installation ............................................... 0-63 Flywheel Housing Bore Alignment - Measurement.................. 0-66 Flywheel Housing Face Alignment - Measurement.................. 0-67 Flywheel Housing, REPTO - Installation.................................. 0-64 Front Crankshaft Oil Seal - Installation ..................................
0-108 Fuel Filter - Installation ......................................................... 0-146 Fuel Filter Head and Bracket - Installation ............................ 0-130 Fuel Pump Plumbing - Installation ........................................ 0-130 Fuel Pump Support Bracket - Installation.............................. 0-126 Fuel Pump (With Air Compressor) - Installation..................... 0-128 Fuel Pump (Without Air Compressor) - Installation................ 0-128 Gear Cover - Installation ....................................................... 0-106 Gear Housing - Installation .....................................................
0-80 Hand Hole Cover (Exhaust Side of Engine) - Installation....... 0-138 Hand Hole Cover (Fuel Pump Side of Engine) - Installation .. 0-125 High Oil Pressure Regulator - Installation................................ 0-61 Hydraulic Pump Drive - Installation......................................... 0-85 Idler Gear Assemblies - Installation......................................... 0-87 Idler Gear (REPTO) - Installation............................................. 0-68 Injectors - Installation ............................................................ 0-112 Jacobs W Brake Housing Spacer - Installation .......................
0-124 Jacobs W Brake Oil Supply Hose - Installation....................... 0-138 Jacobs W Engine Brake - Installation...................................... 0-116 Lubricating Oil Cooler - Installation ....................................... 0-137 Lubricating Oil Filter - Installation ......................................... 0-146 Lubricating Oil Filter Head - Installation ................................ 0-136 Lubricating Oil Pan - Installation ............................................. 0-81 Lubricating Oil Pump - Installation .......................................... 0-84 Main Oil Pressure Regulator - Installation...............................
0-62 Overhead - Adjustment ......................................................... 0-117 Piston and Connecting Rod - Assembly.................................. 0-75 Piston and Connecting Rod - Installation ................................ 0-76 Piston Cooling Nozzle - Installation......................................... 0-79 Push Rods and Tubes - Installation ....................................... 0-116 Rear Crankshaft Oil Seal - Installation .................................... 0-71 Rocker Lever Assemblies - Installation .................................. 0-113 Rocker Lever Cover - Installation .......................................... 0-125