Troubleshooting and Repair Manual Isc, Isce, Qsc8.3, Isl, Isle3, Isle4 and Qsl9 Engines

Troubleshooting and Repair Manual
ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and

QSL9 Engines
Volume 2
Troubleshooting and Repair Manual
ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and
QSL9 Engines
Volume 2
Copyright© 2014 Bulletin 4021418

Cummins Inc. Printed 23-JULY-2014
All rights reserved
To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
Foreword
This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and
assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions
on how to use 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.
A series of specific service manuals (for example: Shop, 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).
The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the
use of special service tools. Use the correct tools as described.
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 are 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
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
Miscellaneous - Group 17 ................................................................................................................................. 17
Vehicle Braking - Group 20 ............................................................................................................................... 20
Service Literature .............................................................................................................................................. L
Specifications .................................................................................................................................................... V
Back .................................................................................................................................................................... back
ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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-17
General Information...................................................................................................................................................i-17
General Cleaning Instructions ..................................................................................................................................i-12
Abrasive Pads and Abrasive Paper...........................................................................................................................i-12
Definition of Clean......................................................................................................................................................i-12
Fuel System...............................................................................................................................................................i-15
Gasket Surfaces........................................................................................................................................................ i-13
Plastic Bead Cleaning................................................................................................................................................i-14
Solvent and Acid Cleaning.........................................................................................................................................i-13
Steam Cleaning......................................................................................................................................................... i-14
General Repair Instructions ......................................................................................................................................i-10
General Information...................................................................................................................................................i-10
Welding on a Vehicle with an Electronic Controlled Fuel System..............................................................................i-11
General Safety Instructions ........................................................................................................................................i-8
Important Safety Notice...............................................................................................................................................i-8
How to Use the Manual ................................................................................................................................................i-2
Illustrations ...................................................................................................................................................................i-7
Symbols ........................................................................................................................................................................i-3
Page i-b Section i - Introduction
This Page Left Intentionally Blank

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] About the Manual
Section i - Introduction Page i-1
About the Manual

General Information
This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and to
provide recommended repair procedures.
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.
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 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-2 Section i - Introduction
How to Use the Manual

General Information
This manual is organized to provide an easy flow from problem identification to problem correction.
A list of troubleshooting symptoms containing the most common 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.
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.
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.
3 Locate the probable cause in the left column then turn to the procedure referenced in the right column.
4 The Troubleshooting Symptom Charts are based on the following assumptions:
• The components have been installed according to the manufacturer's specifications.
• The easiest repairs are done first.
• All generic solutions are designed for the most common applications and Original Equipment Manufacturer
(OEM).
Refer to the Original Equipment Manufacturer's service manual for their specifications.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Symbols
Symbols
General Information
The 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.
NOTE: It is possible to have four symbols for each text and graphic combination.
WARNING
Serious personal injury or extensive property damage
can result if the warning instructions are not followed.
CAUTION
Minor personal injury can result or a part, and
assembly, or the engine can be damaged if the
caution instructions are not followed.
Indicates a REMOVAL or Dissassembly step.
Symbols ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Symbols
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Symbols ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Refer to another location in this manual or another

publication for additional information.
The component weighs 23kg [50 lbs] or more. To reduce

the possibility of personal injury, use a hoist or get
assistance to lift the component.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
General Repair Instructions

General Information
This system 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.
WARNING
Cummins Inc. does not recommend or authorize any modifications or repairs to 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
22 Manual Service Disconnect
23 High Voltage Interlock Loop
24 High Voltage Connectors/Connections and Harnesses
25 High Voltage Battery System
26 Power Inverter
27 Generator Motor
28 Clutch Pressure Plate
• Follow all safety instructions noted in the procedures

• Follow the manufacturer's recommendations for cleaning solvents and other substances used during repairs. Some
solvents 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
• All components must be kept clean during any repair. Contamination of the 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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Repair Instructions
• 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
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, electronic control units or the
components. Direct welding of any electronic components must not be attempted. Sensors, wiring harness,
and electronic control unit should be removed if nearby welding will expose these components to
temperatures beyond normal operation. Additionally, all electronic control unit connectors must be
disconnected
General Cleaning Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high
pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method for
cleaning the oil drillings and coolant passages
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Do not steam clean the following components:
• Electrical Components
• Wiring Harnesses
• Belts and Hoses
• Bearings (ball or taper roller)
• Electronic Control Module (ECM)
• ECM Connectors
• Capacitive Coil Driver Module (CCD)
• Ignition Coils and Leads
• NOx Sensor
• Fuel Control Valve
• Throttle Driver and Actuator.
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Cleaning Instructions
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.
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 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 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.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Acronyms and Abbreviations
Acronyms and Abbreviations

General Information
The following list contains some of the acronyms and abbreviations used in this manual.
ANSI American National Standards Institute
API American Petroleum Institute
ASTM American Society of Testing and Materials
ATDC After Top Dead Center
BTU British Thermal Unit
BTDC Before Top Dead Center
°C Celsius
CAN Controller Area Network
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 Engine Control Module
EFC Electronic Fuel Control
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
IEC International Electrotechnical Commission
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling
MCRS Modular Common Rail System
MIL Malfunction Indicator Lamp
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
N•m Newton-meter
Acronyms and Abbreviations ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
NOx Mono-Nitrogen Oxides

NG Natural Gas
O2 Oxygen
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer
OSHA Occupational Safety and Health Administration
PID Parameter Identification Descriptions
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
TDC Top Dead Center
VDC Volts of Direct Current
VGT Variable Geometry Turbocharger
VS Variable Speed
VSS Vehicle Speed Sensor
Section 5 - Fuel System - Group 05 Page 5-a
Section 5 - Fuel System - Group 05

Section Contents
Page
Engine Fuel Heater, Electric ......................................................................................................................................5-3
Finishing Steps...........................................................................................................................................................5-5
Initial Check................................................................................................................................................................5-3
Install..........................................................................................................................................................................5-5
Preparatory Steps.......................................................................................................................................................5-4
Remove......................................................................................................................................................................5-4
Fuel Consumption ......................................................................................................................................................5-6
Measure......................................................................................................................................................................5-6
Fuel Injection Pump ..................................................................................................................................................5-80
Clean and Inspect for Reuse....................................................................................................................................5-82
Finishing Steps.........................................................................................................................................................5-84
General Information..................................................................................................................................................5-80
Install........................................................................................................................................................................ 5-82
Preparatory Steps.....................................................................................................................................................5-80
Remove.................................................................................................................................................................... 5-81
Fuel Lift Pump ...........................................................................................................................................................5-23
Finishing Steps.........................................................................................................................................................5-29
Initial Check..............................................................................................................................................................5-23
Install........................................................................................................................................................................ 5-28
Remove.................................................................................................................................................................... 5-27
Fuel Pump ..................................................................................................................................................................5-11
Finishing Steps.........................................................................................................................................................5-15
Inspect for Reuse......................................................................................................................................................5-13
Install........................................................................................................................................................................ 5-13
Remove.................................................................................................................................................................... 5-12
Fuel Pump Accumulator Module .............................................................................................................................5-43
Finishing Steps.........................................................................................................................................................5-49
Install........................................................................................................................................................................ 5-47
Remove.................................................................................................................................................................... 5-44
Fuel Pump Actuator Housing .................................................................................................................................. 5-78
Finishing Steps.........................................................................................................................................................5-80
Install........................................................................................................................................................................ 5-79
Remove.................................................................................................................................................................... 5-79
Fuel Pump Cam Housing Module ............................................................................................................................5-54
Finishing Steps.........................................................................................................................................................5-58
Install........................................................................................................................................................................ 5-57
Remove.................................................................................................................................................................... 5-55
Fuel Pump Delivery Valve ........................................................................................................................................5-15
Finishing Steps.........................................................................................................................................................5-17
Install........................................................................................................................................................................ 5-17
Remove.................................................................................................................................................................... 5-16
Fuel Pump Distributor and Injection Control Valve Module .................................................................................5-49
Page 5-b Section 5 - Fuel System - Group 05

Finishing Steps.........................................................................................................................................................5-54
Install........................................................................................................................................................................ 5-51
Remove.................................................................................................................................................................... 5-50
Fuel Pump Distributor Inlet Fitting ..........................................................................................................................5-40
Finishing Steps.........................................................................................................................................................5-43
Install........................................................................................................................................................................ 5-43
Remove.................................................................................................................................................................... 5-41
Fuel Pump Gear Pump ............................................................................................................................................. 5-17
Finishing Steps.........................................................................................................................................................5-21
Initial Check..............................................................................................................................................................5-17
Install........................................................................................................................................................................ 5-21
Remove.................................................................................................................................................................... 5-20
Fuel Pump Gear Pump Module ................................................................................................................................5-58
Finishing Steps.........................................................................................................................................................5-61
Initial Check..............................................................................................................................................................5-58
Install........................................................................................................................................................................ 5-60
Remove.................................................................................................................................................................... 5-59
Fuel Pump Head ........................................................................................................................................................5-66
Finishing Steps.........................................................................................................................................................5-77
Initial Check..............................................................................................................................................................5-67
Install........................................................................................................................................................................ 5-76
Remove.................................................................................................................................................................... 5-72
Fuel Pump Head Outlet Fitting ................................................................................................................................ 5-63
Finishing Steps.........................................................................................................................................................5-66
Install........................................................................................................................................................................ 5-65
Remove.................................................................................................................................................................... 5-65
Fuel Pump Rate Shape Tube ................................................................................................................................... 5-61
Finishing Steps.........................................................................................................................................................5-63
Install........................................................................................................................................................................ 5-63
Remove.................................................................................................................................................................... 5-62
Fuel Pump Timing .....................................................................................................................................................5-22
Finishing Steps.........................................................................................................................................................5-23
Injection Control Valve .............................................................................................................................................5-32
Click Test..................................................................................................................................................................5-35
Finishing Steps.........................................................................................................................................................5-36
Install........................................................................................................................................................................ 5-34
Remove.................................................................................................................................................................... 5-33
Pumping Control Valve ............................................................................................................................................ 5-36
Section 5 - Fuel System - Group 05 Page 5-c
Click Test..................................................................................................................................................................5-36
Cutout Test...............................................................................................................................................................5-37
Rotor, CAPS Fuel Injection Pump ...........................................................................................................................5-29
Finishing Steps.........................................................................................................................................................5-32
Install........................................................................................................................................................................5-31
Remove....................................................................................................................................................................5-30
Service Tools ..............................................................................................................................................................5-1
Fuel System................................................................................................................................................................5-1
Snubber, Rate Shape ................................................................................................................................................5-38
Finishing Steps.........................................................................................................................................................5-40
Install........................................................................................................................................................................5-39
Remove....................................................................................................................................................................5-38
Page 5-d Section 5 - Fuel System - Group 05

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Service Tools
Section 5 - Fuel System - Group 05 Page 5-1
Service Tools
Fuel System
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

Remover Fixture
Used to remove the air/fuel mixer venturi from the intake manifold.
2892416
Fuel Pump Mounting Plate

Used to hold the fuel pump in the ball joint vise during service.
3162897
Fuel Pump Gear Puller

Used to pull the fuel pump gear. Includes Part Number 3900633,
3163381 capscrews.
Multimeter
Used to measure voltage, resistance, and current in electrical
3164488 circuits.
Pressure and Vacuum Module

Used with multimeter, Part Number 3164488, to measure pressures
3164491 and restrictions in the fuel system.
12 mm Banjo Adapter Fitting (Leakage Flow Adapter)

Used to isolate drain flow from the fuel drain lines where they
3164618 connect to the fuel drain manifold. Allows fuel leakage measurement
from the fuel pump, injector, or fuel rail pressure relief valve drain
lines.
Service Tools ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 5-2 Section 5 - Fuel System - Group 05

0.043-Inch Diagnostic Fuel Line
Used to create rated fuel flows through the low-pressure fuel system
3164621 without loading the engine.
Combustible Gas Detector

Used to check for gas leaks at connections.
3823984
Fuel Pump Gear Puller

Fuel pump gear puller, Part Number 3824469, has been obsoleted.
3824469 This tool can be used with M8-1.25 x 50 capscrews, Part Number
3900633, grade 8.8 flange head capscrews or equivalent.
Electrical Contact Cleaner

Non-petroleum cleaner used to clean electrical connections and fuel
3824510 pump internal parts.
M10 Compucheck® Fitting

Used to measure fuel system pressure at the fuel filter head.
3824842
Ball Joint Vise

Used with the fuel pump mounting plate for holding the fuel pump
ST 302 during service.
1000 cc Graduated Cylinder

Used to measure high-pressure pump drain flow (leakage).
Not Applicable
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Fuel Heater, Electric
Engine Fuel Heater, Electric (005-008)

Initial Check
The fuel heater is an optional device installed on the fuel
filter head. It is held on the filter head by the threaded filter
spud.
NOTE: The fuel heater is not controlled by the electronic
control module (ECM). A bimetallic switch on the filter
head acts as a thermostat. The fuel heater will turn on at
approximately 1°C [34°F] and turn off at approximately
18°C [65°F].
The switch should register as an open circuit above 18°C
[65°F] and register as a closed circuit below 1°C [34°F].
Remove the 2-pin connector from the fuel heater.

Check for proper voltage to the fuel heater.
NOTE: Minimum voltage is 12 VDC with keyswitch ON
(separate 24 volt heaters are used on vehicles with a 24-
volt charging system).
If the voltage is not within specifications, refer to the OEM
troubleshooting and repair manual.
Engine Fuel Heater, Electric ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
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.
WARNING
Drain the fuel-water separator into a container, and
dispose of contents in accordance with local
environmental regulations.
• Disconnect the batteries. Refer to Procedure 013-009
in Section 13.
• Disconnect the OEM power supply connector from the
fuel heater.
• Disconnect the engine harness connector from the
water-in-fuel sensor.
• Drain a small quantity of fuel from the filter water drain
to reduce fuel spillage during filter removal.
• Remove the spin-on fuel filter. Refer to Procedure
006-015 in Section 6.
Remove
Remove the threaded filter spud and fuel heater.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Fuel Heater, Electric
Install
Install a new gasket onto the fuel heater.
Place the fuel heater, gasket side facing up, against the
filter head with the electrical connector facing away from
the engine block.
Apply thread-locker, Part Number 3375068, to the filter

spud threads where they will engage the filter head.
Install the fuel filter spud.
Torque Value: 30 N•m [ 22 ft-lb ]
Finishing Steps
WARNING
battery cable last.
• Install the fuel filter. Refer to Procedure 006-015 in
Section 6.
• Connect the fuel heater.
• Connect the water-in-fuel sensor.
• Connect the batteries. Refer to Procedure 013-009.
Fuel Consumption ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Consumption (005-010)

Measure
All Applications Except Marine
See the Fuel Consumption Checklist sheets in 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
of Number 2 diesel fuel is nominally 0.844 kg per liter
[7.03 pounds per gal].
Install the remote tank (1).

Install the return fuel line to the test tank or the results will
not be accurate.
Measure the distance traveled with an accurate odometer.

The odometer accuracy can be checked by using
measured kilometers [miles].
After traveling the route, remove the tanks and weigh the
fuel remaining. Compute the fuel used in liters [gal] as
required.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Consumption
Compute the kilometers per liter or miles per gallon:

• Miles (÷) Gallons (=) MPG
• Kilometers (÷) Liters (=) KPL
In addition to the measurement of the fuel used, the
following factors provide points for running a test similar to
the recognized Type II Society of Automotive Engineers
Fuel Test.
These procedures are helpful to determine differences in
fuel consumption between two vehicles under the same
environmental, road, and test conditions.
Perform the test with the test vehicle and a control

vehicle. The control vehicle compensates for changes in
traffic conditions.
The vehicles must stay close together to experience the
same varying traffic and weather conditions, but not so
close as to affect each other's driving or headwind.
The test course must be 65 to 80 km [40 to 50 mi] long.
The test route and truck weights must not change during
the test.
All of the test results are based on comparing the fuel

used by the test truck to the fuel used by the control truck.
Drive the truck on a warm-up test run. Drive enough tests

to achieve:
• The difference in elapsed time between each test run
can only be ±0.5 percent. This will be ±15 seconds on
80 km [50 mi] at 97 km/h [60 mph].
The fuel usage of the test truck between test drives must
fall within a 2-percent range, e.g., 2.55 vs. 2.60 km/l [6.00
vs. 6.12 mpg].
The same range also applies between test drives of the
control truck.
NOTE: The differences in traffic and driving practices can
make the test drive fall out of the 2-percent range.
A minimum of three test drives that meet these conditions

make a valid test. A single test drive is unreliable.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Consumption
Use the same experienced drivers for all of the tests.

NOTE: The vehicle speeds must be representative of a
typical operation.
During the test, record the following:

• Ambient temperature
• Humidity
• Barometric pressure
• Wind velocity
• Wind direction.
NOTE: Avoid testing under any extreme conditions.
Marine Applications
See the Fuel Consumption Checklist sheets in Section
TS.
The most accurate method to check the fuel consumption
is to weigh the fuel used.
WARNING
WARNING
Do not vent the fuel system on a hot engine; this can
cause fuel to spill onto a hot exhaust manifold, which
can cause a fire.
CAUTION
Use caution when disconnecting or removing fuel
lines, replacing filters and priming the fuel system
that fuel is not spilled or drained into the bilge area.
Do not drop or throw filter elements into the bilge
area. The fuel and fuel filters must be discarded in
accordance with local environmental regulations.
Install a remote fuel tank (1) with enough capacity to run 1
hour.
Fill and weigh the fuel tank. The weight of Number 2
diesel fuel is nominally 0.844 kg per liter [7.03 lb per
gallon].
NOTE: Use a scale capable of measuring within 0.045 kg
[0.1 lb] to weigh the fuel tank.
Measure the time with a stopwatch.
After one hour of operation, weigh the fuel remaining, and

compute the fuel used in liters [gallons] as required.
Compute the fuel consumption. Fuel used divided by the
time equals the fuel consumption rate.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump
Fuel Pump (005-016)

General Information
This procedure refers to the Cummins® Common Rail fuel
system.
Preparatory Steps
WARNING
battery cable last.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
CAUTION
Clean all fittings before disassembly. Dirt or
contaminants can damage the fuel system.
Before servicing any fuel system components, (such as
fuel lines, fuel pump, injectors, etc.) which would expose
the fuel system or internal engine component to potential
contaminants prior to disassembly, clean the fittings,
mounting hardware, and the area around the component
to be removed. Dirt or contaminants can be introduced
into the fuel system and engine if the surrounding areas
are not cleaned, resulting in damage to the fuel system
and engine. Refer to Procedure 000-009 in Section 0.
• Disconnect the batteries. Refer to the OEM service
manual.
• Remove the fuel supply lines from the fuel pump.
Refer to Procedure 006-024 in Section 6.
• Remove the fuel drain line from the fuel pump. Refer
to Procedure 006-013 in Section 6.
• Remove the fuel pump gear access cover.
Fuel Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
Normal engine operation creates highly pressurized
fuel in the fuel line which will remain in the fuel line
after engine shutdown. Never open the fuel system
when the engine is operating. Before servicing the
fuel system, always loosen the pump-to-rail fuel line
at the rail to vent the pressure. Keep hands clear of
the line when loosening. High-pressure fuel spray can
penetrate the skin, resulting in serious personal injury
or death.
Before servicing the fuel system, loosen the pump-to-rail
line at the rail to vent the pressure.
Keep hands clear of the line when loosening.
Tighten the fuel rail nut.
NOTE: A machined slot in this fitting directs the fuel spray
towards the engine block.
Remove
Remove the fuel pump upper support bracket.
Locate top dead center for cylinder Number 1 by barring
the engine until the line on the fuel pump gear aligns with
the front cover mark for top dead center.
NOTE: Depending on the build year of the engine, the fuel
pump support bracket can be mounted on the fuel pump
head or the fuel pump actuator housing.
Remove the fuel pump gear nut and washer.

Use fuel pump gear puller, Part Number 3824469, to pull
the fuel injection pump drive gear loose from the fuel
pump drive shaft.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump
Remove the four mounting nuts that hold the fuel pump to
the gear housing.
Remove the fuel pump.
Inspect for Reuse

The dowel pin in the fuel pump drive shaft must not be
sheared.
If the dowel is sheared, the camshaft housing or fuel
pump must be replaced, and the drive gear must be
replaced.
Be sure the pilot o-ring is not cut or otherwise damaged.

The pump oil supply o-ring must be replaced. Make sure
it is not damaged.
Install
Make sure the engine is at Number 1 cylinder, top dead
center. The fuel pump gear timing mark must align with
the top dead center mark on the front cover.
Make sure the o-ring seals for the oil feed orifice (A) and
pilot (B) are installed correctly.
Lubricate the pilot o-ring (B) with clean engine oil.
Clean the nose of the drive shaft and the fuel pump gear
inside diameter with electrical contact cleaner, Part
Number 3824510, or equivalent.
The fuel pump drive gear inside diameter and the drive
shaft outside diameter must be clean and dry before
installing the gear.
Fuel Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Slide the fuel injection pump shaft through the drive gear
and position the fuel injection pump flange onto the
mounting studs.
Make sure the dowel pin in the drive shaft lines up with
the keyway in the fuel injection pump gear.
Installation sequence for fuel pump head mounted support

bracket:
1 Install the pump mounting nuts (leave loose).
2 Install the support bracket bolts (leave loose).
3 Tighten the pump mounting nuts.
1 Tighten the support bracket bolts.
Installation sequence for fuel pump actuator housing

mounted support bracket:
1 Install the pump mounting nuts (leave loose).
2 Install the bolt to the cylinder head (1) and the bolt
through the pump flange (2) into the support bracket
(leave loose).
3 Tighten the pump mounting nuts.
1 Tighten the bolt into the cylinder head (1).
1 Tighten the bolt into the pump flange (2).
Tighten the fuel injection pump drive gear nut.

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Delivery Valve
Finishing Steps
• Install the access cover in the front cover.
• Install the fuel supply lines to the fuel pump. Refer to
Procedure 006-024 in Section 6.
• Install the fuel drain line to the fuel pump. Refer to
• Connect the wire harness to the fuel pump actuator.
• Install the fuel filter head bracket (marine applications
only. Refer to Procedure 006-018 in Section 6.
• Install the system integration module mounting
capscrews and nuts (marine applications only).
• Connect the batteries. Refer to the OEM service
manual.
• Open the fuel supply valve. Refer to the OEM service
manual.
• Operate the engine and check for leaks.
Fuel Pump Delivery Valve (005-020)

General Information
This procedure refers to the CAPS fuel system.
Preparatory Steps
WARNING
WARNING
personal injury.
Thoroughly steam-clean the distributor outlet fitting and
fuel pump area.
Dry with compressed air.
Remove the high-pressure fuel supply lines. Refer to
Fuel Pump Delivery Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Remove the distributor outlet fitting and the seal disk.
NOTE: A tool like the one shown here can be made from
a 1/8 in or 3/16 in allen wrench. Use it to remove the seal
disc. Use the following procedure for instructions to make
the tool. Refer to Procedure 005-084 in Section 5.
NOTE: The outlet fitting valve and seat are a matched set;
do not “mix and match” valves and seats with other outlet
fitting assemblies.
If either the outlet fitting valve or seat is damaged, the
entire outlet fitting assembly must be replaced. Also, the
seal washers must always be replaced.
Clean and Inspect for Reuse

Check for broken parts, debris, or sticking of the outlet
fitting valve. Replace the outlet fitting assembly if any
parts are damaged. Always replace the seal washer.
Use QD™ contact cleaner, Part Number 3824510, to

clean the delivery valve port in the distributor.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Gear Pump
Install
Install a new seal washer into the distributor outlet fitting
hole. Make sure the washer is fully seated in the bottom of
the hole.
Install the outlet fitting assembly hand tight.
Tighten the outlet fitting assemblies.
Finishing Steps
Install the high-pressure fuel supply lines. Refer to
Operate the engine and inspect for fuel leaks.
Fuel Pump Gear Pump (005-025)

General Information
system.
Initial Check
The gear pump shaft incorporates a double seal. The first
seals oil in the fuel pump camshaft housing; the second
seals fuel in the gear pump. If either seal fails, fluid will
drip from the weep hole. The weep hole is located near
the gear pump mounting flange on the inboard side
(toward the engine block).
A gear pump gasket seals oil at the gear pump to
camshaft housing interface.
Fuel Pump Gear Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Measuring Gear Pump Pressure with the Engine Cranking

(useful if engine will not start).
1 Install a pressure gauge at the on engine fuel filter
head (M10 x 1.5 Compuchek™ fitting, Part Number
3824842).
NOTE: If there is not enough clearance to install the
female Compuchek™ fitting, Part Number 3824842, an
adapter fitting, Part Number 3932302, and an 1/8-NPT
male Compuchek™ fitting, Part Number 3377244, may be
used to aid accessibility.
1 Monitor the gear pump pressure while the engine is
cranking.
Minimum Gear Pump Pressure at Cranking

kPa psi
105 MIN 15
If the gear pump pressure is lower than 105 kPa [15 psi]
during cranking, make sure that the engine cranking
speed is at least 150 rpm. Make sure that the lift pump
pressure during cranking is at least 35 kPa [5 psi]. Refer
NOTE: For optional test points on the fuel system, a banjo

pressure gauge adapter can be constructed.
Construction of Banjo Pressure Gauge Adapter
A banjo-style pressure gauge adapter can be used to
measure pressure or vacuum at any point in the low-
pressure fuel system where a banjo bolt exists at a fuel
line.
The ISC and ISL engines with high-pressure common rail
fuel systems use a M12 x 7/16-inch banjo bolt connection.
This tool can be used for measurement of drain line
restriction (pressure) at the fuel drain manifold.
Make a banjo bolt flow adapter tool by drilling and tapping
the hex face of an M12 x 7/16-inch banjo bolt, Part
Number 3903035, or similar banjo bolt.
Drill and tap the banjo bolt to the size of the
Compuchek™ fitting (or other hose union) being used
(example 1/8-inch NPT Compuchek™ fitting, Part Number
3377244, or M10 Compuchek™ fitting, Part Number
3824842).
Assemble the banjo pressure gauge adapter as follows.

1 Install the Compuchek™ fitting, or other type fitting, in
the hexagonal face of the banjo bolt.
2 Attach a hose or pressure gauge to the banjo pressure
adapter.
Measuring Gear Pump Pressure at Rated Condition

1 Install a M10 x 1.5 Compuchek™ fitting, Part Number
3824842, at the diagnostic port on the outlet of the fuel
filter head.
2 Construct a "T" adapter fitting using one quick-
disconnect, Part Number 3376859, and two 1/8-inch
NPT Compuchek™ fittings, Part Number 3042618.
3 Install a 0.043-inch orificed diagnostic fuel line, Part
Number 3164621, at the outlet of the fuel filter head.
Run the fuel hose back to the fuel tank.
4 Install a 0 to 1034 kPa [0 to 150 psi] pressure gauge at
the "T" adapter fitting.
Operate the engine at high idle and observe the gear

pump pressure.
Minimum Gear Pump Pressure 483 kPa [ 70 psi ]
If the gear pump pressure is low, check for excessive inlet
vacuum. Refer to Procedure 006-020 in Section 6.
Fuel Pump Gear Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
WARNING
Depending on the circumstance, diesel 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.
WARNING
can cause a fire.
CAUTION
manual.
• Shut off the fuel supply. Refer to the OEM service
manual.
• Clean any fuel, oil, and debris from the gear pump.
• Remove the fuel supply lines from the gear pump.
Remove
Remove the four bolts that hold the gear pump to the fuel
pump.
Remove the drive coupling if it remains attached to the
rear of the fuel pump camshaft.
Remove the gear pump gasket.

Inspect the gear pump for damage.
NOTE: Gear pump coupling wear is normal. The gear
pump should not be replaced due to coupling or shaft
wear.
Install
Install the drive coupling into the back of the high-
pressure pump camshaft.
Insert the mounting bolts through the gear pump flange.
Install a new gasket onto the bolts.
Index the gear pump input shaft to engage the drive
coupling and install the gear pump.
Install the four gear pump bolts and tighten.
Finishing Steps
WARNING
battery cable last.
• Install the fuel supply lines. Refer to Procedure
manual.
manual.
Fuel Pump Timing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Pump Timing (005-037)

Preparatory Steps
WARNING
battery cable last.
in Section 13.
• Remove the gear cover. Refer to Procedure 001-031
in Section 1.
• Remove the fuel pump camshaft nut. Refer to
Inspect for Reuse

Check that the fuel pump camshaft alignment dowel is
present in the fuel pump drive gear keyway. If the
alignment dowel is not visible, remove the injection pump,
determine the cause of misalignment, and repair or
replace any damaged components.
1 Fuel pump gear keyway
2 Fuel pump timing dowel pin
3 Fuel pump camshaft
4 Fuel pump gear
If this inspection is being performed due to a performance

complaint, and the problem first occurred after gear train
removal and replacement, then check the timing of the
camshaft gear to the crankshaft gear and the camshaft
gear to the fuel pump drive gear.
If this inspection is being performed due to a performance
complaint, and the problem first occurred after gear train
removal and replacement, then check the timing of the
camshaft gear to the crankshaft gear and the camshaft
gear to the fuel pump drive gear. Refer to Procedure
If the engine camshaft gear is mistimed in relation to the
crankshaft gear, intake and exhaust valve events will not
be optimized. Also, for CAPS injection pump fuel systems,
the primary speed sensor reads the tonewheel on the
camshaft gear and fuel injection timing will be incorrect.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Lift Pump
Finishing Steps
Install and tighten the injection pump camshaft nut. Refer
to Procedure 005-016 in Section 5. Refer to Procedure
Install the front gear cover. Refer to Procedure 001-031 in
Section 1.
Fuel Lift Pump (005-045)

Initial Check
A malfunctioning electric fuel lift pump can cause slow
engine starts or can result in an engine failing to start. The
fuel lift pump can be cleaned and repaired to a limited
extent.
The lift pump will operate for 30 to 60 seconds when the
key is switched ON. The lift pump will also operate while
the engine is cranking.
Block Mounted Lift Pump

The lift pump is contained in an assembly that includes
fuel supply and drain manifolds. These manifolds provide
for OEM connection of fuel supply and return hoses. The
fuel supply manifold also contains M10 STORM fittings
which allow for pressure and vacuum measurement of the
fuel supply at the electric lift pump.
A bypass check valve in the fuel supply manifold makes
sure the system is primed by the lift pump. This check
valve opens under vacuum created by the fuel injection
pump, once the engine is started. High vacuum measured
between the electric lift pump and the fuel filter can
indicate this check valve has become plugged.
The output of the fuel lift pump can be checked through

the following test:
• Measure the output pressure. Use a pressure gauge at
the lift pump outlet port.
Fuel Lift Pump Output Pressure

kPa psi
35 MIN 5
Fuel Lift Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
The lift pump check valve restriction can be determined

using the following test:
1 Install a 0 to 762 mm Hg [0 to 30 in Hg] vacuum gauge
at the inlet and outlet M10 STORM ports on the
electric lift pump head
2 Operate the engine at rated power condition
3 Record the inlet restriction at the inlet and outlet of the
lift pump. Refer to Procedure 006-020 in Section 6.
Fuel Lift Pump Inlet Restriction

mm Hg in Hg
102 MAX 4
ECM Cooling Plate Mounted Lift Pump

A lift pump is mounted to the back of the ECM cooling
plate.
A bypass check valve in the ECM cooling plate makes
sure the system is primed by the lift pump. This check
valve opens under vacuum created by the gear pump,
once the engine is started. High vacuum measured
between the electric lift pump and the gear pump can
indicate this check valve has become plugged.
The ECM cooling plate check valve is integral with the
lower (outlet) fitting of the ECM cooling plate.
Fuel Lift Pump Flow Test Setup

Remove the clasp from the fuel line brace. This will allow
the fuel lines to move so that test equipment can be
installed properly.
Disconnect the quick disconnect style fuel line from the

gear pump inlet by pressing in the locking tangs on both
sides of the quick disconnect fitting.
To aid in the removal of quick disconnect style fuel lines,
slide removal tools, Part Number 4918878, over the
locking tangs. Make sure the tool is removed from the fuel
line as soon as possible after the line has been
disconnected.
Inadvertently leaving the tool in place can result in fuel
leaks.
To aid in removal, a screwdriver may be inserted between

the fuel line end and quick disconnect male union. After
pressing the opposing locking tangs, twisting the flat blade
of the screwdriver helps to remove the fuel line.
Install diagnostic fuel line, Part Number 4918895,

between the gear pump fuel supply line and the gear
pump innlet.
Connect orifice diagnostic fuel line, Part Number
3164621, to the Compuchek™ fitting on the diagnostic
fuel line, Part Number 4918895, and run hose into a
collection device.
NOTE: At initial key-on, the lift pump will run for 30

seconds and then stop.
Turn key switch to the "On" position and allow fuel to flow
into a collection device for 10 seconds (or until fuel stream
is continuous.)
NOTE: It may take longer than 10 seconds for fuel stream
to flow continuously during the first key-on cycle due to air
in the diagnostic fuel lines.
Once fuel flow is continuous, transfer the orifice diagnostic
fuel line to a clear graduated cylinder and allow fuel to
flow into the graduated cylinder for 10 seconds.
Remove the orifice diagnostic fuel line from graduated
cylinder after 10 seconds and turn key switch to the "Off"
position.
Record the volume of fuel collected over 10 seconds.
Repeat this test 3 times and take an average of the flow
rates.
Minimum volume of fuel during 10 second fuel lift
pump flow test 100 ml [ 3.4 fl-oz ]
NOTE: If the lift pump flow is low while the lift pump runs,
make sure the ECM cooling plate check valve is not
blocked open. Also, make sure the OEM connection inlet
restriction is within specification.
NOTE: If the lift pump flow is low while the lift pump runs,
make sure fuel is primed. For example, following fuel filter
replacement; it is necessary to cycle the fuel lift pump
three or four times before the air is purged.
Preparatory Steps
WARNING
battery cable last.
• Disconnect the battery cables. Refer to Procedure
• Thoroughly clean the fittings and components before
removal. Make sure that debris, water, steam, or
cleaning solution do not get inside the fuel system.
• Remove the fuel lift pump inlet and outlet fuel lines.
• Disconnect the fuel pump power lead.
WARNING
battery cable last.
CAUTION
• Disconnect the negative (-) battery cable first. Refer to
• Disconnect the electric fuel priming pump from the
engine wiring harness.
• Shut off the fuel supply valve. Refer to the OEM
service manual.
NOTE: Thoroughly clean fittings and components before
removal. Make sure that debris, water, steam or cleaning
solution do not get inside the fuel system.
• Remove the fuel supply lines. Refer to Procedure
• Remove the ECM cooling plate. Refer to Procedure
Remove
CAUTION
The lift pump contains loose parts and is sensitive to
debris. Use care when removing the lift pump body
from the adapter to make sure the parts are intact and
the pump is not exposed to any debris. Failing to do
so can cause the pump to malfunction or have
premature wear.
Remove the three capscrews at the top of the lift pump
adapter.
Remove the three bolts which connect the adapter to the

lift pump body.
Replace the fuel lift pump gasket.
Connect the adapter and lift pump assembly.

Tighten the bolts.
Torque Value: 12.4 N•m [ 110 in-lb ]

Remove the electric lift pump from the ECM cooling plate.
Install
Install the fuel lift pump adapter to the block. Use the
three capscrews.
Tighten the capscrews.

Install the electric lift pump to the ECM cooling plate.
Tighten the mounting capscrews.
Torque Value: 10 N•m [ 89 in-lb ]
NOTE: The ECM cooling plate check valve must be free
of debris and installed into the lower ECM cooling plate
port (outlet port).
NOTE: Hold the fuel lines, as shown, so they can not
come into contact with each other or the engine block.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Rotor, CAPS Fuel Injection Pump
Finishing Steps
WARNING
battery cable last.
• Connect the power lead to the fuel lift pump.
• Install all removed fuel lines. Refer to Procedure
• Connect the battery cables. Refer to Procedure
• Turn the key on with the engine off. The lift pump will
run for 30 to 60 seconds.
Verify that the lift pump is not leaking.
WARNING
battery cable last.
• Install the ECM cooling plate to the engine block.
• Install all fuel lines. Refer to Procedure 006-024 in
Section 6.
• Connect the battery, negative (-) cable last. Refer to
• Open the fuel valve. Refer to the OEM service manual.
Rotor, CAPS Fuel Injection Pump

(005-072)
General Information
Rotor, CAPS Fuel Injection Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
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.
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
WARNING
personal injury.
Steam clean the fuel injection pump and the engine in the
vicinity of the fuel pump.
Dry with compressed air. Pay special attention to the
distributor area.
Entfernen Sie
CAUTION
The rotor can slide out during the removal of the
distributor plug. If the rotor is dropped, the entire
distributor module must be replaced. Do not attempt
to start the engine with the distributor plug removed.
Doing so can cause the rotor to be ejected from the
distributor, causing damage to the rotor.
ISL Only: Remove the air bleed line. Refer to Procedure
006-056.
Remove the distributor plug, being sure the rotor does not
fall out.

Check the position of the notch on the rotor. It must line
up with the alignment mark (A) on the outside of the
distributor (when the engine is barred to top dead center
(TDC) for the number 1 cylinder). If the alignment is
correct, the rotor is properly timed to the engine.
If a mechanical problem exists, indicated by misalignment
of the rotor, the entire fuel pump will have to be replaced;
Refer to Procedure 005-016.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Rotor, CAPS Fuel Injection Pump
Clean the rotor bore with QD contact cleaner, Part

Number 3824510.
Install
Use Lubriplate™ 105, or equivalent, between the drive
coupling and the rotor to prevent it from falling off during
assembly.
CAUTION
The rotor must be properly timed to the fuel pump
camshaft. Improper assembly will cause the rotor to
be 180 degrees out of time.
Insert the rotor and coupling into the distributor module
completely.
Lightly rotate the rotor with finger-pressure until it drops
into the slot in the drive coupling.
When properly engaged, the notch in the rotor will align
with the hole in the distributor while the engine is at
Number 1 cylinder TDC.
If the rotor will not engage, remove the rotor and drive
coupling and try again. Do not tighten the rotor cap if the
coupling will not engage.
If not properly timed, remove the rotor and drive coupling
and repeat the previous step. Make sure the fuel pump
camshaft dowel pin is pointing toward the top of the fuel
pump before installing.
Injection Control Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install the distributor plug and torque.

NOTE: Be sure the rotor is fully engaged before replacing
the plug.
ISL Only: Install the air bleed line. Refer to Procedure
Finishing Steps
Injection Control Valve (005-078)

General Information
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injection Control Valve
Preparatory Steps
WARNING
WARNING
personal injury.
CAUTION
Fault codes can occur if steam sprays directly on the
electrical connections on top of the accumulator
block.
• Thoroughly steam-clean the entire fuel pump.
• Dry the fuel pump with compressed air.
• Remove the fuel injection pump accumulator. Refer to
Remove
Unplug the engine wiring harness from the injection
control valve connector.
Remove the injection control valve drain line.

Remove the six injection control valve mounting screws.
Remove the injection control valve from the distributor
module.
Do not misplace parts during disassembly.
Secure the six bolts, sealing plate, and both crush tubes
into a parts bag. The parts are to be returned with the
core.
Injection Control Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Clean the mounting surface of the distributor module and
injection control valve.
Use QD™ contact cleaner, Part Number 3824510.
Spray or wipe debris away from the three distributor
module drillings. Do not allow debris to enter the
distributor module drillings.
Inspect the distributor module sealing face for cracks,
indentations, and damage.
Replace the distributor module if damage is found.
Install
Install guide pins, Part Number 3165166, in the upper left
and lower right corner of the distributor module.
Install the o-rings into the sealing plate using Lubriplate™
to hold them in place.
Slide the sealing plate down over the guide pins.
The o-rings must be securely seated in the sealing plate
before proceeding.
Insert crush tubes into the sealing plate.
Check the position of the crush tubes. They must sit flush
on the distributor module and must not be installed at an
angle.
Install the injection control valve on top of the distributor

module using guide pins.
Check that the o-rings are still in their grooves.
Install four bolts through the injection control valve and
tighten finger tight.
Remove the two guide pins.
Install the two remaining bolts, finger-tight, through the
injection control valve.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injection Control Valve
CAUTION
Bolts must be torqued as described or the injection
control valve/distributor module will not function
properly. Use a high-quality, calibrated torque
wrench.
Tighten the bolts in sequence for each step. Refer to the
accompanying illustration for the torque sequence.
Torque Value:
Step 1 1.8 N•m [ 16 in-lb ]
Step 2 3.6 N•m [ 32 in-lb ]
Step 3 5.6 N•m [ 50 in-lb ]
Step 4 Torque to 5.6 N•m [50 in-lb] three more
times following the torque sequence
Install the injection control valve drain line.
Click Test
Use INSITE™ electronic service tool, with the keyswitch
in the ON position, to run the Control Valve Click Test.
Select Injection Control Valve to initiate the test.

A click will be heard until None is selected on the Control
Valve Click Test screen.
If no click is heard, troubleshoot any active fault codes.
The click test will need to be performed after any repairs
are made to clear the fault codes.
Pumping Control Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
• Install the fuel injection pump accumulator. Refer to
• Install the air bleed line. Refer to Procedure 006-056 in
Section 6.
• Install the drive gear cover.
• Connect the fuel pressure sensor and the fuel
temperature sensors to the engine harness.
• Connect the pumping control valve connector to the
engine harness.
• Connect the stator connector to the engine harness.
• Click test the injection control valve stator to check for
proper operation. Refer to click test in this procedure.
• Start the engine and check for fuel leaks or active fault
codes.
• Check for fuel leaks or active fault codes.
Pumping Control Valve (005-079)

General Information
Click Test
Use INSITE™ electronic service tool, with the keyswitch
in the ON position, to run the Control Valve Click Test.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Pumping Control Valve
Select the pumping control valve to be tested to initiate

the test. Select either front control valve or rear control
valve.
A “click” will be heard until the other pumping control valve
is selected, or None is selected on the Control Valve Click
Test screen.
If no “click” is heard, troubleshoot any active fault codes.
NOTE: The click test will need to be performed after any
repairs are made to clear the fault codes.
Cutout Test
The Plunger Cutout Test can be used to check
performance of the front and rear pumping plungers.
NOTE: When performing this test, the engine load must
be the same when each pumping plunger is cut out.
Use INSITE™ electronic service tool, with the engine
running at idle, to perform this test.
Select the pumping control valve to be cut out.

Select the monitor button and monitor valve close angle,
engine speed, and accumulator pressure while the
selected plunger is cut out.
Record valve close angle, engine speed, and accumulator
pressure after the engine stabilizes.
After testing with one pumping control valve disabled,
select “None” so that the engine will run with both valves
enabled. Switching directly from “Front” to “Rear” or
“Rear” to “Front” will cause the engine to misfire or
hesitate.
Cut out the other pumping control valve, and record valve
close angle, engine speed, and accumulator pressure
after the engine stabilizes.
Compare the results when the rear pumping control valve
is cut out against the results when the front pumping
control valve is cut out.
If the engine dies when one of the pumping control valves
is cut out, replace the accumulator. Refer to Procedure
005-085.
NOTE: The valve close angle must not vary more than
15 degrees crank angle.
If the valve close angle varies more than 15 degrees
between the front and rear valves, then replace the
accumulator module. Refer to Procedure 005-085 in
Section 5.
NOTE: Troubleshoot any active fault codes before
replacing the pump.
Snubber, Rate Shape ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Snubber, Rate Shape (005-081)

General Information
Preparatory Steps
WARNING
cleaning, follow the manufacturer's recommendations
WARNING
WARNING
personal injury.
• Thoroughly steam-clean the rate shape tube and fuel
pump area.
• Dry with compressed air.
• Remove the rate shape tube assembly. Refer to
Remove
Remove the rate shape snubber assembly.
Use a center punch to pry the seal disc from the
accumulator.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Snubber, Rate Shape
Inspect for Reuse

The parts in the assembly are as shown:
1 Snubber valve seat
2 Spring
3 Rate shape snubber body
4 Seal disc
5 Snubber valve
6 Spring post.
Replace the snubber assembly if the snubber spring is
broken.
Do not reuse snubber seal discs.
Early design snubber valves are not reusable.

1 Part Number 3800351, first snubber valve assembly
released for CAPS (one groove, not reusable)
2 Part Number 3800764, second snubber valve
assembly released for CAPS (two grooves, not
reusable)
3 Part Number 4010544, current snubber valve
assembly released for CAPS (no grooves, may be
reused); always replace the seal disk.
Install
Clean the bore for the distributor outlet fitting with QD
cleaner prior to installation of the new snubber assembly.
Install a new seal disc into the accumulator.
Apply lubricating oil to the face of the snubber seat and to

the face and threads of the snubber fitting.
Fuel Pump Distributor Inlet Fitting ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install the snubber assembly.

Torque Value:
Step 1 14 N•m [ 124 in-lb ]
Step 2 Rotate 80 degrees
Finishing Steps
• Install the rate shape tube assembly. Refer to
Fuel Pump Distributor Inlet Fitting

(005-084)
General Information
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Distributor Inlet Fitting
Preparatory Steps
WARNING
WARNING
personal injury.
CAUTION
block.
• Thoroughly steam-clean the distributor inlet fitting and
fuel pump area.
• Remove the fuel pump distributor and injection control
valve module assembly. Refer to Procedure 005-086
in Section 5.
NOTE: Injection control valve does not need to be
removed from the distributor module.
Remove
Remove the distributor inlet fitting and the seal disc.
NOTE: A tool like the one shown in this procedure can be
made from a 1/8-inch or 3/16-inch Allen wrench. Use it to
remove the seal disc.
Two types of inlet fittings and sealing washers may be in

use. A flat washer will be installed in most new pumps and
a piloted washer (2) will be installed in some ReCon®
pumps.
Different removal techniques are necessary based on the
type of sealing washer being removed.
Fuel Pump Distributor Inlet Fitting ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Removal of “piloted seal washer”

Use a plastic hammer to tap a spiral easy out into the
center hole of the sealing washer. Turn the easy out
counterclockwise to dislodge the washer.
Removal of a “flat washer”

The flat sealing washer is swaged into the inlet fitting bore
during installation. A special tool can be made to aid in its
removal by grinding the short leg of a 1/8-inch or 3/16-
inch Allen wrench so that the wrench is no longer than 13-
mm [1/2-in] long (measured from the outside of the long
leg). This tool acts as a mini heel bar to pry out the
sealing washer without damaging the back of the hole.
Pry out the old sealing washer with the modified Allen
wrench.
Substantial of force is required to remove the sealing
washer.
CAUTION
Any debris left in this fitting during assembly will run
through the fuel pump. Damage to the fuel pump can
occur.
clean the inlet fitting bore from the bottom of the bore
outward.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Accumulator Module
Install
CAUTION
Any dirt trapped in this fitting during assembly will
run through the fuel pump. Damage to the fuel pump
can occur.
Install the sealing washer into the distributor. Make sure
the sealing washer is seated correctly in the distributor
bore before installing the inlet fitting.
Install the new inlet fitting.
Torque Value:
Step 1 5.7 N•m [ 50 in-lb ]
Step 2 Rotate 120 degrees clockwise
Finishing Steps
• Install the fuel pump distributor and injection control
valve module assembly. Refer to Procedure 005-086
in Section 5.
• Start the engine and check for fuel leaks at the rate
shape tube connections.
• Road-test the vehicle. Check again for fuel leaks or
active fault codes.
Fuel Pump Accumulator Module

(005-085)
General Information
Fuel Pump Accumulator Module ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
WARNING
personal injury.
CAUTION
Make sure that steam does not spray directly on the
electrical connections on the top of the accumulator
block, or fault codes will possibly occur.
• Thoroughly steam-clean the entire fuel pump.
Remove
Remove the fuel pump drive gear cover.
Locate top dead center for cylinder number 1 by barring
the engine slowly until the line on the pump gear lines up
with the line on the gear cover.
Remove the rate shape tube assembly. Refer to

Remove the air bleed line. Refer to Procedure 006-056 in
Section 6.
Remove the fuel pump upper support bracket.
Disconnect the 4-pin Deutsch™ connector for the

pumping control valves.
Disconnect the pressure and temperature sensors.
NOTE: The pressure sensor connector has a potted
pigtail connector. This sensor can only be disconnected
at the engine harness end of the pigtail harness.
WARNING
The accumulator module weighs 11 kg [25 lb] and is
free to move once the capscrews are removed. Do not
drop; personal injury can occur.
CAUTION
Do not use air tools. The use of air tools will possibly
damage the fuel pump.
Remove two of the four capscrews that are located
diagonally from one another.
Remove the last two capscrews. Alternately loosen the

capscrew to avoid binding. Loosen each capscrew about
one turn at a time.
WARNING
The accumulator module weighs 11 kg [25 lb] and is
free to move once the capscrews are removed. Do not
drop; personal injury can occur.
Remove the accumulator module.
Use as much care as possible to avoid dislodging the
springs from the bottom of the accumulator.
If the springs are dislodged, the ceramic plungers can fall

out. The plungers are matched to each bore.
Reseat the springs fully onto plunger barrels.
Do not interchange the plungers.
NOTE: Before replacing a ceramic plunger, special care
needs to be taken to clean it.
clean the plunger.
Remove the oil seal ring and fuel passage o-rings.

Clean the small fuel passage using the plastic tube
provided with the contact cleaner.
Clean the o-ring groove and mounting surface on the cam

housing and the accumulator.
Make sure the top of the tappets in the camshaft housing
are clean. Wipe out debris with a clean towel.
Check the tappets for proper alignment.

The tappets have a slot on the side that engages a pin on
the engine side of the camshaft housing. The pin keeps
the roller aligned with the camshaft. Make sure the tappet
assembly is properly aligned. Make sure the tappet guide
pins and guide pin grooves are not worn excessively.
With the tappets removed, the tappet rollers and camshaft
can be inspected. Linear scratches on the camshaft and
rollers is expected; pitting on the nose of the camshaft is
not.
Install
Install a new oil ring seal and fuel passage o-ring.
Apply Lubriplate™ 105, or equivalent, to the o-ring
grooves to hold the o-rings in place.
CAUTION
The ceramic plungers can fall out when removing the
plastic caps or old springs. Do not interchange the
plungers. If they fall out, use QD™ contact cleaner,
Part Number 3824510, to clean the plungers
thoroughly before replacing them.
If replacing the accumulator module with a new one,
remove the springs from the old accumulator module.
Fully install the springs on the plunger barrels of the new
accumulator module.
NOTE: The use of two 10-mm x 80-mm studs will aid in

the installation.
Install the accumulator module.
NOTE: Use care to avoid dislodging the springs on the
accumulator and the o-rings on the camshaft housing.
CAUTION
Do not use air tools. The use of air tools will possibly
Install two of the four capscrews.
Draw the accumulator module down evenly. Only turn
each capscrew about one turn at a time.
Make sure the o-rings are still in their grooves before the
accumulator is fully tightened to the camshaft housing.
Use a mirror if necessary.
Install the remaining two capscrews.

Tighten the four capscrews.
Install the upper support bracket.

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Distributor and Injection Control Valve Modul [...]
Finishing Steps
• Install rate shape tube assembly. Refer to Procedure
Section 6.
• Install the drive gear cover.
• Connect the fuel pressure sensor and the fuel
temperature sensors to the engine harness.
• Connect the pumping control valve connector to the
engine harness.
codes.
• Road-test the vehicle.
• Check for fuel leaks or active fault codes.
Fuel Pump Distributor and Injection

Control Valve Module (005-086)
General Information
Fuel Pump Distributor and Injection Control Valve Modul [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
can cause personal injury.
WARNING
personal injury.
CAUTION
block.
• Thoroughly steam clean the entire fuel pump.
• Remove the air bleed line. Refer to Procedure 006-056
in Section 5.
• Remove the fuel pump from the engine, if necessary.
• Mount the fuel pump in the vise ring if removed. Orient
the pump with the distributor facing upward to aid in
disassembly.
• Remove the rate shape tube assembly. Refer to
Entfernen Sie
CAUTION
The capscrews also fasten the gear pump module.
The gear pump is free to move after the capscrews
are removed.
Loosen, but do not remove, the distributor plug.
Remove the four mounting capscrews on the distributor.
Remove the injection control valve/distributor module.

Remove the drive coupling.
Discard the two o-rings.
Place the injection control valve/distributor module in a
clean bench vise.
Remove the injection control valve from the distributor

module and install the injection control valve on the new
distributor module. Refer to Procedure 005-078 in Section
5.
NOTE: Injection control valves built before January, 2001
are not reusable. If removing an injection control valve
built before January, 2001, use the appropriate injection
control valve kit to complete the repair.

Inspect coupling and gear pump shaft ends for excessive
wear. Wear could be found on the inside corners of the
coupling groove; such wear, however, is not common.
A polished surface is acceptable.
CAUTION
A distributor rotor seizure can cause damage to the
gear pump.
If rotor seizure is suspected, inspect the gear pump. Refer
Replace the gear pump module if wear is visible.
Replace the gear pump module if the gear pump
driveshaft is damaged.
Install
Install the drive coupling.
Center the coupling on the gear pump shaft.
Apply Lubriplate™ 105, or equivalent, to the coupling to
keep it from sliding in the shaft groove during assembly.
Fuel Pump Distributor and Injection Control Valve Modul [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install new o-rings.

Apply Lubriplate™ 105, or equivalent, to the o-rings to
keep them from falling out during assembly.
NOTE: This step is not necessary if you replace the

distributor without removing the fuel pump from the
engine.
The dowel pin must be facing up toward the top of the
pump.
If the shaft needs to be rotated, install the fuel pump drive
nut onto the shaft to provide a means for rotating the
shaft.
CAUTION
The rotor can slide out once the distributor plug is
removed.
CAUTION
Do not drop the rotor. Damaging the rotor will
necessitate replacement of the entire distributor
module.
Remove the large plug from the end of the distributor.
Do not remove the rotor.
Install the distributor module.

Lightly rotate the rotor with finger pressure until it drops
into the slot in the drive coupling.
When properly engaged, the notch in the rotor will align
with the hole in the distributor (when the engine is at top
dead center for number 1 cylinder).
Do not pinch the o-rings.

Install the four distributor capscrews.
CAUTION
The rotor must be properly timed to the fuel pump
camshaft. Improper assembly will cause the rotor to
be 180 degrees out of time.
If not properly timed, install the drive coupling and rotor
again. Refer to Procedure 005-072 in Section 5.
Install a new o-ring on the distributor plug.

Install the large plug at the end of the distributor.
Tighten the distributor plug.
Fuel Pump Cam Housing Module ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
• Install the rate shape tube assembly. Refer to
• Install the fuel pump on the engine, if removed. Refer
Section 6.
• Use INSITE™ electronic service tool to run the
Injection Control Valve Click Test. Refer to Procedure
codes.
• Road-test the vehicle for at least 1 mile. Check for fuel
leaks or active fault codes.
Fuel Pump Cam Housing Module

(005-088)
General Information
Preparatory Steps
WARNING
WARNING
personal injury.
CAUTION
Thoroughly steam-clean the entire fuel pump.
Dry the pump with compressed air.
Bar the engine to top dead center (TDC).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Cam Housing Module
Remove
CAPS Fuel System
Remove the air bleed line (1). Refer to Procedure 006-056
in Section 6.
Remove the fuel pump from the engine. Refer to
Mount the fuel pump to the mounting plate, Part Number
3162897, and orient the fuel pump with the distributor
facing upward to aid in disassembly.
Remove the rate shape tube assembly. Refer to
Remove the accumulator module. Refer to Procedure
Remove the distributor module. Refer to Procedure
Remove the gear pump module. Refer to Procedure

Clean the mounting surfaces of the cam housing.
Inspect the camshaft coupling interface for wear. If the
camshaft is worn excessively, replace the camshaft
housing module.
CAUTION
If the tappets are removed, be sure to install them in
the same bore they were removed from.
Remove the roller tappets from the camshaft housing
bores.
Inspect the roller surfaces for pitting and wear.
Make sure the roller rotates freely and smoothly.
Replace the camshaft housing module if the rollers are
worn.
NOTE: It is normal to see lines (scratches) worn in the
direction of roller travel. The camshaft housing or tappets
should be replaced if the rollers are pitted.
Examine the tappets guide pin slots. If the guide pin slot is
worn more than 25-percent of its original width, the tappet
must be replaced.
Fuel Pump Cam Housing Module ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the guide pins. If the guide pins are worn or if oil
leaks at the cam housing guide pin press fit, the camshaft
housing must be replaced.
Inspect the camshaft lobes for pitting and wear. Replace
the camshaft housing if there is any pitting or wear.
Inspect for raised burrs in the tappet bore. Replace the
camshaft housing if raised burrs are present. Scratching
or polishing is normal.
Inspect the tappet bores for scuffing or wear leading into

the housing.
Polishing will occur in vertical bands at many places
around the inside of the bores.
Polish in the bores is acceptable.
Replace the camshaft housing if there is severe tappet
guide pin wear (more than 25-percent of tappet pin is
worn).
Using fingers, make sure the camshaft turns freely. The

bearings must turn smoothly and freely during rotation.
Replace the camshaft housing if the bearings are tight or
rough.
Check the camshaft for end clearance.
Camshaft End Clearance

mm in
0.05 MAX 0.002
Inspect the oil feed and pump mounting o-ring.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Cam Housing Module
Install
CAPS Fuel System
Make sure the timing dowel pin in the camshaft points
toward the top of the fuel pump.
Lubricate the tappets and camshaft lobes with clean

15W-40 engine oil.
Install the roller tappets into the camshaft housing. Be
sure that the tappets guide grooves are oriented correctly
onto the tappet guide pins. Also, be sure that the tappet
assemblies are installed in their original bores.
Check the tappets for proper alignment.
The tappets have a slot on the side that engages a pin on
the engine side of the camshaft housing. The pin keeps
the roller aligned with the camshaft. Make sure the tappet
is properly aligned.
CAUTION
The ceramic plungers will possibly fall out when
removing the springs. Do not interchange the
plungers or change their upward orientation. If the
plungers are removed, use QD™ contact cleaner, Part
Number 3824510, to clean them before replacing.
NOTE: When assembling the fuel injection pump, take
care to keep the ceramic pumping plungers in their
original orientation in the accumulator module.
If not already done, install the spring and tappet retainers
onto the accumulator or fuel pump barrel assemblies.
Install the gear pump module. Refer to Procedure

Install the distributor module. Refer to Procedure 005-086
in Section 5.
Install the accumulator module. Refer to Procedure
Install the rate shape tube assembly. Refer to Procedure
Install the fuel pump onto the engine. Refer to Procedure
Install the air bleed line. Refer to Procedure 006-056 in
Section 6.
Fuel Pump Gear Pump Module ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
Start the engine and check for fuel leaks or active fault
codes.
Perform repeat throttle snaps to create increased
accumulator or fuel rail pressure.
Fuel Pump Gear Pump Module

(005-089)
General Information
Initial Check
Measure the outlet pressure at the diagnostic fitting on the
CAPS pump at a rated flow condition and compare to the
following chart.
Engine Speed (rpm) Gear Pump Pressure kPa
[psi]
200 14 [2]
700 138 [20]
1300 379 [55]
2200 827 [120]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Gear Pump Module
Preparatory Steps
WARNING
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
CAUTION
Dry the fuel pump with compressed air.
Remove the air bleed line. Refer to Procedure 006-056 in
Section 6.
Remove the fuel pump from the engine. Refer to
Mount the fuel pump in a vise ring. Orient the pump with
the distributor facing upward to aid in disassembly.
Remove the rate shape tube. Refer to Procedure 005-090
in Section 5.
Remove the distributor module. Refer to Procedure
Remove
Remove the gear pump module.
NOTE: Do not remove the two capscrews. The gear
pump will slide off the dowel pins once the distributor is
removed.

Clean the mounting surfaces of the gear pump and
camshaft housing.
Fuel Pump Gear Pump Module ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the drive coupling and shaft ends for excessive

wear.
A polished surface is acceptable.
Replace the coupling if wear is visible.
Install
CAUTION
The larger o-rings on either end of the gear pump
differ in size. The longer o-ring goes to the side facing
the camshaft housing.
Install new o-rings.
Apply Lubriplate™ 105, or equivalent, to the o-rings to
keep them from falling out during assembly.
Install the drive coupling.

Center the coupling in the shaft.
Align the gear pump shaft with the drive coupling and
install the gear pump module.
Make sure the o-rings are not pinched.
Make sure the timing dowel pin is facing toward the top of
the fuel pump.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Rate Shape Tube
Finishing Steps
Install the distributor module. Refer to Procedure 005-086
in Section 5.
Install the rate shape tube. Refer to Procedure 005-090 in
Section 5.
Install the fuel pump on the engine. Refer to Procedure
Install the air bleed line. Refer to Procedure 006-056 in
Section 6.
Start the engine and check for fuel leaks or active fault
codes.
Road-test the vehicle for at least one mile. Recheck for
fuel leaks or active fault codes.
Fuel Pump Rate Shape Tube (005-090)

General Information
Preparatory Steps
WARNING
WARNING
WARNING
personal injury.
CAUTION
Make sure that direct steam spray stream does not
contact the electrical connections on the top of the
accumulator block; fault codes will possibly occur.
Fuel Pump Rate Shape Tube ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Loosen the two rate shape tube nuts (1).
Remove the two bracket capscrews (2).
Remove the rate shape tube assembly.
Do not loosen or remove the isolator capscrews (3).

Clean the ends of the rate shape tube.
Clean out the rate shape tube with contact cleaner if
debris is suspected of entering the tube.
Flush any dirt from the snubber fitting and distributor inlet
fitting.
Inspect isolators for signs of wear or cracks.

Replace the rate shape tube assembly if any isolator is
worn, cracked, or missing.
Inspect the ends of the rate shape tube for damage.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Head Outlet Fitting
Install
Install the rate shape tube assembly using the following
steps:
1 Install the tube nuts (1) and capscrews (2) finger-tight
2 Tighten the rate shape tube nuts (1)
1 Tighten the two bracket capscrews (2).
Torque Value:
Capscrew
Step 1 41 N•m [ 30 ft-lb ]
Torque Value:
Thermistor Adapter
Step 1 34 N•m [ 25 ft-lb ]
NOTE: If any force is required to flex the rate shape tube
in order to start the tube nuts, the rate shape tube must
be replaced with a new tube.
NOTE: Make sure the harness clip is installed between
the bracket and capscrew, not between the bracket and
accumulator.
Finishing Steps
Start the engine and check for fuel leaks at the rate shape
tube connections.
Fuel Pump Head Outlet Fitting

(005-226)
General Information
system.
Fuel Pump Head Outlet Fitting ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
The fuel pump, high-pressure fuel lines, and fuel rail
contain very high-pressure fuel. Do not loosen any
fittings while the engine is running. Wait at least 10
minutes after shutting down the engine before
loosening any fittings in the high-pressure fuel
system to allow pressure to decrease to a lower level.
WARNING
battery cable last.
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
WARNING
WARNING
can cause a fire.
CAUTION
manual.
• Thoroughly clean the entire fuel pump. Dry the fuel
pump with compressed air.
• Close the fuel supply valve. Refer to the OEM service
manual.
• Remove the high-pressure fuel line from the fuel pump
actuator housing. Refer to Procedure 006-051 in
Section 6.
• Remove the fuel drain line from the actuator housing.
• Remove the fuel supply line from the fuel pump
Section 6.
• Remove the fuel pump actuator housing from the high-
pressure fuel pump. Refer to Procedure 005-228 in
Section 5.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Head Outlet Fitting
Remove
Remove the fuel pump head outlet fitting and the seal
washer from the threaded hole in the back of the high-
pressure pump head.
NOTE: It is necessary to remove the seal washer with the
aid of a tapered punch. Insert a tapered punch into the
center of the seal washer and work the seal out from the
bore in the back of the high-pressure pump head.

Clean the threaded hole in the high-pressure pump head
with electrical contact cleaner, Part Number 3824510, or
equivalent.
Inspect the threads and cavity in the high-pressure pump
head for burrs or debris.
Inspect the seal washer end of the outlet fitting. There
should be a polished crown that is free of nicks or
inclusions. If the crown is damaged or severely flattened,
the male union must be replaced.
Clean any burrs with a wire brush, then flush the bore
clean.
Install
NOTE: This joint is designed to seal in excess of 179,264
kPa [26,000 psi]. Seal washers must not be reused.
Install a new seal washer onto the outlet fitting. The seal
washer should pilot into the outlet fitting. A small amount
of clean grease, such as assembly lubricant, will help in
keeping the seal attached to the outlet fitting during
installation.
Torque Value:
Step 1 13.6 N•m [ 120 in-lb ]
Fuel Pump Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the fuel pump actuator housing to the high-
pressure fuel pump. Refer to Procedure 005-228 in
Section 5.
• Install the high-pressure fuel line to the fuel pump
Section 6.
• Install the fuel drain line to the actuator housing. Refer
• Install the fuel supply line to the fuel pump actuator
housing. Refer to Procedure 006-024 in Section 6.
manual.
manual.
• Perform several throttle snaps so that increased fuel
rail pressure will be developed.
Fuel Pump Head (005-227)

General Information
system.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Head
Initial Check
WARNING
WARNING
Depending on the circumstances, 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
This fuel pump head leakage test uses a flow adapter
fitting. The purpose of the flow adapter fitting is to route
the drain flow of the fuel pump only into a collection
device so that leakage may be measured.
Perform the Fuel Pump Head Leakage Test described
below.
This tool, Part Number 3164618, can be purchased or
constructed according to provided instructions. Refer to
Fuel Pump Head Leakage Test Setup

Remove the banjo bolt from the fuel pump drain line at the
fuel drain manifold.
Install a banjo flow adapter fitting at the fuel drain manifold
and route a hose from this adapter to a bucket or the
vehicle's fuel tanks.
The pump drain line connects at the center connection
point on the fuel drain manifold.
Fuel Pump Head Leakage Alternate Test Setup

If the drain manifold is not easily accessed, an M14 banjo
may be attached at the pump head drain port with a fuel
hose that is routed to the collection container.
In this setup, a bolt, nut, and washers are needed to
prevent fuel from flowing backwards and leaking from the
unused drain line.
CAUTION
The high-pressure leakage test in INSITE™ electronic
service tool will cause the engine to operate at
elevated pressures while the engine idles. The engine
noise will change when this test is being performed
due to the higher fuel injection pressures. Safety
glasses should be worn while working near the
running engine. Fuel lines should not be adjusted
while performing this test.
Close the engine cover(s) while performing these tests.
Fuel Pump Head Leakage Test (Engine Will Not Start)

Turn the keyswitch ON and allow the lift pump to complete
its cycle. After the cycle is completed, begin cranking the
engine until fuel exits the drain line.
When fuel begins to exit the drain line, route the drain flow
to a graduated cylinder and continue cranking for 30
seconds.
Maximum Volume of Fuel During Cranking
cc [oz] seconds
200 [7] 30
Fuel Pump Head Leakage Test (Engine Will Start)

If the engine will start, perform INSITE™ electronic
service tool High-Pressure Leakage Test.
• Connect INSITE™ electronic service tool.
• Start the engine and allow the engine to idle with fuel
flowing into a collection device.
• Begin the High-Pressure Leakage Test.
• Measure the time necessary to collect 300 cc [10 oz]
of fuel pump head drain flow while performing the
High-Pressure Leakage Test.
Use a graduated cylinder for this measurement.
This specification is valid for engines operating on diesel

fuels. Low fuel viscosity will increase the leakage rate; for
example, kerosene or aviation fuels will result in
excessive leakage. Verify the fuel type before replacing a
fuel pump head for excessive leakage.
Maximum Volume of Fuel During Fuel Pump Head
Leakage Test
cc [oz] seconds
300 [10] 30
Fuel Pump Head Flow Test

Disconnect the high-pressure fuel line from the fuel rail at
the fuel rail connector.
Clamp a hose to the end of the fuel line.
Route a hose into a clean graduated cylinder.
Crank the engine for 30 seconds.
The fuel pump head flow must be greater than 100 cc
[3.4 oz] in 30 seconds of cranking.
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
Do not bleed the fuel system of a hot engine; this can
result in fuel spilling onto a hot exhaust manifold,
which can cause a fire.
manual.
• Close the fuel supply and drain valves. Refer to the
OEM service manual.
• Remove the high-pressure fuel line from the high-
pressure pump. Refer to Procedure 006-051 in Section
6.
• Remove the fuel drain line from the fuel pump actuator
Section 6.
• Disconnect the wire harness from the fuel pump
actuator.
• Remove the fuel pump actuator housing. Refer to
Marine Applications
WARNING
battery cable last.
WARNING
WARNING
Do not bleed the fuel system of a hot engine; this can
result in fuel spilling onto a hot exhaust manifold,
which can cause a fire.
CAUTION
manual.
OEM service manual.
• Remove the high-pressure fuel line from the high-
pressure pump. Refer to Procedure 006-051 in Section
6.
• Remove the fuel drain line from the fuel pump actuator
Section 6.
actuator.
• Remove the fuel filter head bracket. Refer to
• Remove the fuel pump actuator housing. Refer to
Remove
Remove the fuel pump drive gear cover.
CAUTION
Do not use air tool. The use of air tools will possibly
Remove the upper support bracket.
Remove two of the four capscrews that are located
diagonally from one another.
Remove the last two capscrews. Alternately loosen the

capscrews to avoid binding. Loosen each capscrew about
one turn at a time.
Carefully lift the fuel pump head from the camshaft
housing, being careful to keep the tappet springs attached
to the pump head. Place the head on a clean surface.
WARNING
personal injury.
Special care must be taken to be sure these parts are
kept extremely clean if removed. Cover the camshaft
housing with a clean shop towel while the head is
removed.
Do not use cleaning agents, other than contact cleaner,
on pump components.
NOTE: Do not perform the following test without the
springs and spring retainers installed.
With the springs and spring retainers installed, blow
compressed air (at least 138 kPa [20 psi]) into the fuel
inlet port of the fuel pump head.
The plungers should extend to the tappet spring retainers.
If the pumping plungers are stuck and do not extend to
the tappet spring retainers, replace the fuel pump head.
Remove the springs and spring retainers from the barrel

retainers.
Make certain to keep track of which springs came from
the front and rear. It is recommended that these parts be
installed in the same location, even if a new high-pressure
pump head is installed.
CAUTION
Do not remove the barrel retainers. Damage to the
pump head and barrel retainers will result.
Press on the pumping plungers to make sure they are not

binding in the barrel.
If the pump head check valves are working correctly, the
pumping plungers will spring back to their original
position. If the plungers do not spring back, replace the
fuel pump head.
CAUTION
Each plunger must be installed in the same
orientation and in the same barrel, or engine damage
can result. Marking the bottoms of the plungers with a
felt tip marker will help to make sure that correct
orientation is maintained.
If the plungers are removed, inspect the plungers. Slight
discoloration can be evident. Deep scoring must not be
present. If scoring or scratches exist that can be felt, the
fuel pump head must be replaced.
NOTE: Some fuel pump heads are built with non-
symmetric pumping plungers. The crowned end of the
pumping plunger must be installed into the barrel. If the
plunger is installed in the wrong orientation, fuel pump
head damage will result.
While the fuel pump head is removed, inspect the

camshaft housing. The tappets can be removed. Use an
o-ring pick as the removal tool.
Inspect the tappet guide pins and tappet guide pin

grooves for excessive wear. If more than 25-percent guide
pin or groove wear is observed, the fuel pump must be
replaced.
Normal operation creates vertical grooves in the cylinder

bores of the fuel pump camshaft housing. These grooves
are not an indication of a malfunction.
Camshaft housings with grooves are acceptable for reuse.
With the camshaft housing tappets removed, inspect the

camshaft for wear. If excessive pitting on the nose of the
camshaft is observed, the fuel pump must be replaced.
Inspect the tappet rollers for wear. If excessive pitting on

the rollers is observed, the tappet(s) must be replaced.
If damage to the camshaft, tappets, or camshaft housing

is observed, it is possible the fuel pump is not receiving
adequate lubricating oil. When replacing the fuel pump,
inspect the gear housing to make sure no blockages exist
in the oil supply to the fuel pump.
Install
Install the tappets in the original tappet bores.
Be certain the tappets are installed in the original
locations.
Be certain that the tappet guide pins engage the guide pin
grooves.
Install new fuel pump head o-rings onto the camshaft

housing.
If installing a new or rebuilt pump head, install the new
tappet springs and retainers provided with the pump head.
Place the high-pressure pump head onto the high-
pressure pump camshaft housing.
Draw the high-pressure pump head down by alternately
tightening the four high-pressure pump head capscrews
until the head just contacts the camshaft housing.
Tighten the four high-pressure pump head capscrews to
the final torque.
Connect the upper support bracket to the high-pressure

pump head in the following order:
• Connect the upper support bracket capscrews to the
high-pressure pump head and tighten hand-tight.
• Connect the upper support bracket capscrews to the
cylinder head and tighten to the final torque.
• Tighten the capscrews that attach to the high-pressure
pump head to the final torque.
Finishing Steps
WARNING
battery cable last.
• Install the fuel pump actuator housing. Refer to
• Connect the high-pressure fuel supply line. Refer to
• Connect the fuel drain line to the fuel pump actuator
• Connect the fuel supply line to the fuel pump actuator
• Connect the engine harness to the fuel pump actuator.
manual.
• Open the fuel supply and drain valves. Refer to the
OEM service manual.
Marine Applications
WARNING
battery cable last.
• Install the fuel pump actuator housing. Refer to
• Connect the high-pressure fuel supply line. Refer to
• Connect the fuel drain line to the fuel pump actuator
• Connect the fuel supply line to the fuel pump actuator
• Connect the engine harness to the fuel pump actuator.
• Install the fuel filter head bracket. Refer to Procedure
manual.
OEM service manual.
Fuel Pump Actuator Housing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Pump Actuator Housing (005-228)

General Information
system.
Preparatory Steps
WARNING
WARNING
battery cable last.
in Section 13.
actuator.
• Disconnect the fuel supply line from the fuel pump
Section 6.
• Disconnect the high-pressure fuel line from the fuel
pump actuator housing. Refer to Procedure 006-051 in
Section 6.
• Disconnect the fuel drain from the fuel pump actuator
• Remove the upper support bracket from the fuel pump
actuator bracket. Refer to Procedure 005-016 in
Section 5.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Actuator Housing
Remove
Remove the three bolts that hold the fuel pump actuator
housing to the high-pressure fuel pump head.
Remove the fuel pump actuator housing and the gasket.

Inspect the fuel pump actuator housing gasket. Do not
reuse the gasket if the material is cracked, torn, or
otherwise damaged.
Be sure that the mounting surfaces of the high-pressure
pump head and the fuel control valve adapter block are
clean. Use contact cleaner to clean these surfaces.
Install
Insert the three mounting bolts through the fuel pump
actuator housing.
Install the gasket over the bolts. The gasket must be
installed dry.
Install the actuator housing.
Tighten the mounting bolts.
Fuel Injection Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the upper support bracket. Refer to Procedure
• Connect the high-pressure fuel line to the fuel pump.
• Connect the fuel supply line to the fuel pump. Refer to
• Connect the fuel drain line to the fuel pump. Refer to
• Connect the wire harness to the fuel pump actuator.
manual.
Fuel Injection Pump (005-229)

General Information
Preparatory Steps
• Disconnect the injection pump supply line. Refer to
• Remove the injector supply lines. Refer to Procedure
• Disconnect the fuel drain line. Refer to Procedure
• Disconnect the pumping control valve 4-pin Deutsch™
connector.
• Disconnect the injection control valve 4-pin Deutsch™
connector.
• Disconnect the accumulator pressure sensor.
• Disconnect the accumulator temperature sensor.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Injection Pump
Remove
Remove the injection pump upper support bracket.
Remove the injection pump tail support bracket.
Remove the fuel pump gear access plug.

Remove the fuel pump drive gear retaining nut and
washer.
Pull the fuel injection pump drive gear loose from the
pump driveshaft.
Remove the four mounting nuts.

Remove the fuel injection pump.

The fuel pump driveshaft key must not be sheared.
If the key is sheared, the camshaft housing module of the
fuel pump must be replaced and the drive gear must be
replaced.
Check that the locating dowel is installed in the camshaft
housing.
Install
Be sure the engine is at number 1 cylinder top dead
center. The fuel pump gear timing mark should align with
the top dead center mark on the gear housing.
Clean the fuel injection pump drive shaft with an
evaporative cleaner.
Clean the fuel pump gear inside diameter with an
evaporative cleaner.
The fuel pump drive gear inside diameter and the drive
shaft outside diameter must be clean and dry before
installing the gear.
Make sure the fuel injection pump is at its top dead center
position.
The fuel injection pump is at number 1 cylinder top dead
center when the dowel pin in the shaft (A) is perpendicular
to the top of the accumulator.
Be sure that the dowel is installed in the pump driveshaft.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Injection Pump
Make sure the o-ring seals for the oil feed orifice (A) and
pilot (B) are correctly installed and are not damaged.
Lubricate the mounting flange with cleaner.
The fuel pump drive gear inside diameter and the shaft
outside diameter must be clean and dry before installing
the gear.
Slide the fuel injector pump shaft through the drive gear
and position the fuel injection pump flange onto the
mounting studs.
Make sure the dowel pin in the shaft (A) lines up with the
keyway in the fuel injection pump gear.
Make sure the dowel pin in the fuel injection pump flange
lines up with the hole in the gear housing.
Install the mounting nuts.

Install the fuel injection pump upper support bracket.
Install the fuel injection pump tail support bracket.
Torque Value:
Fuel Pump Mounting Nuts 44 N•m [ 32 ft-lb ]
Torque Value:
Fuel Pump Upper Support Brackets (8.8 or 9.8 bracket
capscrews) 44 N•m [ 32 ft-lb ]
Torque Value:
Fuel Pump Tail Support Bracket (10.9 capscrews) 68 N•m
[ 48 ft-lb ]
Tighten the fuel injection pump drive gear nut.

Finishing Steps
• Install the gear cover access cap hand tight.
• Connect the injection pump supply line. Refer to
• Connect the injector supply lines. Refer to Procedure
• Connect the fuel drain line. Refer to Procedure
• Connect the pumping control valve 4-pin Deutsch™
connector.
• Connect the injection control valve 4-pin Deutsch™
connector.
• Connect the accumulator pressure sensor to the
engine harness.
• Connect the accumulator temperature sensor to the
engine harness.
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 ....................................................................................................................................................................6-4
Finishing Steps...........................................................................................................................................................6-7
Measure......................................................................................................................................................................6-5
Setup..........................................................................................................................................................................6-4
Engine Control Module Cooling Plate, Fuel Cooled ................................................................................................6-7
Assemble..................................................................................................................................................................6-10
Disassemble.............................................................................................................................................................6-10
Finishing Steps.........................................................................................................................................................6-12
Initial Check................................................................................................................................................................6-7
Install........................................................................................................................................................................ 6-11
Remove.................................................................................................................................................................... 6-10
Fuel Connector (Head Mounted) ............................................................................................................................. 6-58
Finishing Steps.........................................................................................................................................................6-60
Install........................................................................................................................................................................ 6-59
Remove.................................................................................................................................................................... 6-58
Fuel Cooler ................................................................................................................................................................6-73
QSL Engines..........................................................................................................................................................6-74
Finishing Steps.........................................................................................................................................................6-75
QSL Engines..........................................................................................................................................................6-75
QSL Engines..........................................................................................................................................................6-73
Install........................................................................................................................................................................ 6-75
QSL Engines..........................................................................................................................................................6-75
QSL Engines..........................................................................................................................................................6-73
Remove.................................................................................................................................................................... 6-74
QSL Engines..........................................................................................................................................................6-74
Fuel Drain Line Restriction ......................................................................................................................................6-13
Finishing Steps.........................................................................................................................................................6-15
Measure....................................................................................................................................................................6-15
Fuel Drain Lines ........................................................................................................................................................6-15
Finishing Steps.........................................................................................................................................................6-19
Initial Check..............................................................................................................................................................6-15
Install........................................................................................................................................................................ 6-18
Remove.................................................................................................................................................................... 6-16
Fuel Filter (Spin-On Type) ........................................................................................................................................6-20
Finishing Steps.........................................................................................................................................................6-22
Install........................................................................................................................................................................ 6-21
Measure....................................................................................................................................................................6-20
Prime........................................................................................................................................................................ 6-22
Remove.................................................................................................................................................................... 6-21
Fuel Filter Head .........................................................................................................................................................6-23
Assemble..................................................................................................................................................................6-25
Disassemble.............................................................................................................................................................6-24
Finishing Steps.........................................................................................................................................................6-26
Install........................................................................................................................................................................ 6-25
Page 6-b Section 6 - Injectors and Fuel Lines - Group 06
Remove.................................................................................................................................................................... 6-23
Fuel Filter Head Bracket ...........................................................................................................................................6-27
Finishing Steps.........................................................................................................................................................6-29
Install........................................................................................................................................................................ 6-28
Remove.................................................................................................................................................................... 6-28
Fuel Inlet Restriction ................................................................................................................................................ 6-30
Finishing Steps.........................................................................................................................................................6-33
Measure....................................................................................................................................................................6-32
Fuel Pressure Relief Valve .......................................................................................................................................6-68
Finishing Steps.........................................................................................................................................................6-72
Initial Check..............................................................................................................................................................6-68
Install........................................................................................................................................................................ 6-72
Remove.................................................................................................................................................................... 6-71
Test...........................................................................................................................................................................6-69
Fuel Pump Air Bleed Line ........................................................................................................................................ 6-60
Finishing Steps.........................................................................................................................................................6-64
Install........................................................................................................................................................................ 6-62
ISC and QSC8.3 With CAPS Injection Pump........................................................................................................6-62
ISL and QSL9 With CAPS Injection Pump............................................................................................................ 6-63
Remove.................................................................................................................................................................... 6-61
ISC and QSC8.3 With CAPS Injection Pump........................................................................................................6-61
ISL and QSL9 With CAPS Injection Pump............................................................................................................ 6-61
Fuel Rail .....................................................................................................................................................................6-64
Finishing Steps.........................................................................................................................................................6-67
Initial Check..............................................................................................................................................................6-64
Install........................................................................................................................................................................ 6-67
Remove.................................................................................................................................................................... 6-66
Fuel Rail High Pressure Fitting ................................................................................................................................6-75
Initial Check..............................................................................................................................................................6-75
Install........................................................................................................................................................................ 6-76
Remove.................................................................................................................................................................... 6-76
Fuel Supply Lines .....................................................................................................................................................6-33
Finishing Steps.........................................................................................................................................................6-40
Initial Check..............................................................................................................................................................6-33
Install........................................................................................................................................................................ 6-38
Remove.................................................................................................................................................................... 6-34
Injector .......................................................................................................................................................................6-41
Assemble..................................................................................................................................................................6-49
Disassemble.............................................................................................................................................................6-48
Finishing Steps.........................................................................................................................................................6-52
Initial Check..............................................................................................................................................................6-41
Install........................................................................................................................................................................ 6-50
Remove.................................................................................................................................................................... 6-46
Test...........................................................................................................................................................................6-47
Injector Supply Lines (High Pressure) ....................................................................................................................6-53
Finishing Steps.........................................................................................................................................................6-57
Initial Check..............................................................................................................................................................6-53
Install........................................................................................................................................................................ 6-55
Remove.................................................................................................................................................................... 6-54
Service Tools ..............................................................................................................................................................6-1
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-c
Injectors and Fuel Lines..............................................................................................................................................6-1
Page 6-d Section 6 - Injectors and Fuel Lines - Group 06

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

Fuel Sight Glass Assembly, Number 10 SAE
Used to observe fuel flow to detect air in fuel.
3164383
Injector Nozzle Tester

Used to test opening pressure, leakage, chatter and spray pattern.
3376946
Injector Bore Brush

Used to clean the injector bore.
3822509
Injector Puller
Used to pull the injectors on CAPS fuel system.
3825156
Fuel Connector Puller

Used to pull the fuel connector.
3825157
Pressure Gauge (0 to 1905 mm Hg [0 to 75 in Hg])

Used to measure engine intake manifold pressure, exhaust
ST-1273 restriction, lift pump output pressure, and pressure drop across fuel
filter.
Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06

Vacuum Gauge (0 to 762 mm Hg [0 to 30 in Hg])
Used to measure lift pump inlet restriction. Hose adaptor, Part
ST-434 Number ST-434-2 and vacuum gauge, Part Number ST-434-12 are
used to perform the test.
Fuel System Leak Tester

Used to block a single injector and high pressure fuel connector from
3164325 pressurized fuel. This tool helps identify a failed injector when injector
return flow is excessive.
Fuel System Leak Tester

Used to block a single injector and high pressure fuel connector from
4918563 pressurized fuel. This tool helps identify a failed injector when injector
return flow is excessive.
Fuel Return Flow Hose

This tool uses a special fitting to connect to the fuel return circuits to
3164618 measure return flow from the injectors and fuel pump.
Fuel Connector Remover

Used to pull the fuel connector.
3164025
M10 STORM Compuchek™ Diagnostic Fitting

Used to measure fuel pressure or vacuum wherever STORM M10
3824842 diagnostic ports exist.
Fuel line with 1.09 mm [0.043 in] orifice.

Used in procedures to create rated flow through the low pressure fuel
3164621 system without the need to operate the engine under load.
Fuel Pressure Test Kit

Used with a vacuum gauge, Part Number ST-434 or equivalent,
4918324 along with quick-disconnect fitting, Part Number 3972088, to check
the fuel inlet restriction.

Banjo Fitting
A banjo-style pressure gauge adapter may be used to measure
pressure or vacuum at any point in the low-pressure fuel system
4918413
where a banjo bolt exists at a fuel line.
Fitting, Quick-Disconnect Male

Used to perform a pressure-side air-in-fuel test.
3377244
Combustible Gas Detector

Use to check for gas leaks at connections.
3823984
Fuel Return Flow Hose (fuel pressure relief valve)

The tool uses a special banjo fitting to connect to the fuel return
3164617 circuit to measure the return flow from the fuel pressure relief valve.
Fuel Line Quick Disconnect Tool

Used to remove 3/8 quick disconnect fittings female connectors.
4918878
Air in Fuel ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Air in Fuel (006-003)

Setup
Obtain a 1.09 mm [0.043 in] orificed diagnostic fuel line,
Part Number 3164621.
A 1.09 mm [0.043-inch] orificed diagnostic fuel line is used
in procedures to create rated flow through the low
pressure fuel system, without the need to operate the
engine under load.
Obtain a container suitable for collection of fuel that exits
the diagnostic fuel line (a 19 liter [5 gal] bucket is
recommended).
Construct a sight tube (CAPS) fuel systems only):
Assemble two (one male and one female, 7.8-14 thread
barb-tite fittings and hose clamps to a 61 cm [2 ft] long
number-10 clear hose approved for use with diesel fuel.
If 1.09 mm [0.043 in] orificed diagnostic fuel line, Part

Number 3164621 can not be obtained, construct a 1.09
mm [0.043 in] orificed diagnostic fuel line, use the
following steps:
Tap a female quick connect, Part Number 3376859.
Tap size 8-36 national fine (U.S.).
WARNING
personal injury.
Clean the female quick connect, Part Number 3376859,
with compressed air.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air in Fuel
Assemble a 1.09 mm [0.043 in] injector orifice, Part

Number 3045018, with washer, to the female quick
connect, Part Number 3376859.
NOTE: To obtain correct flow, use a 1.09 mm [0.043 in]
injector orifice, Part Number 3045018.
Attach the orifice to an appropriate length (it must reach

from the fuel pump to the fuel tank) of 1/4-inch, or larger,
tubing.
NOTE: It is recommended that this tool be marked and
identified as having a 1.09 mm [0.043 in] orifice installed.
This is to make sure that there is no confusion when using
this tool in the future.
Measure
CAPS Fuel System
Attach the 1.09 mm [0.043 in] diagnostic fuel line at the
fuel injection pump's diagnostic fitting.
Run the outlet of the diagnostic fuel line into the fuel
collection container (or the vehicles fuel tank).
Install the sight glass between the fuel filter head and the
fuel injection pump inlet.
Air in Fuel ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Run the engine from idle to high idle several times to

purge the air induced while installing the diagnostic fuel
line.
Run the engine up to high idle while another technician
checks for air in the system.
NOTE: A small amount of air in the inlet line is
acceptable. Ignore any air that is observed in the tube
running back to the fuel tank.
Operate the engine at idle and observe any air in the fuel
supply. If air is observed, isolate the air to the following
components:
• Fuel filter assembly
• Fuel heater
• Fuel lift pump assembly
• OEM fuel plumbing
• Fuel tank stand-pipe.
Cummins® Common Rail Fuel System

NOTE: A symptom of air-in-fuel for the engines equipped
with a common rail fuel system is an audible surge
associated with fuel system pressure fluctuations, due to
air in the fuel supply.
The following test method will simulate rated fuel flow
through the system so that air in fuel problems may be
diagnosed.
Install a Compuchek™ fitting, Part Number 3824842, at
the inlet to the 2 micron fuel filter and attach the 1.09 mm
[0.043 in] diagnostic fuel line.
male Compuchek™ fitting, Part Number 3377244, can be
Route the outlet of the 1.09 mm [0.043 in] diagnostic fuel

line into a collection device of suitable size (a 19 liter [5
gal] bucket is recommended).
Start the engine and operate the engine speed from idle
to high idle several times to purge the air introduced while
installing the diagnostic fuel line.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Control Module Cooling Plate, Fuel Cooled
Observe the fuel flow exiting the diagnostic fuel line while
the engine operates at idle speed.
Bubbles are an indication of a leak that allows air to enter,
a severe inlet restriction that causes cavitation, or a
system that is not yet primed. Refer to Procedure
006-020 Section 6.
• Suction fuel lines
• ECM cooling plate assembly
• OEM fuel lines
• Suction-side fuel filter assemblies
• Stand-pipe(s) in the fuel tank(s).
If diagnostic fuel lines, Part Number 4918895, are unable

to be installed, observe the fuel flow exiting the diagnostic
fuel line while the engine operates at idle speed.
Bubbles are an indication of a leak that allows air to enter,
a severe inlet restriction that causes cavitation, or a
system that is not yet primed. Refer to Procedure
006-020 Section 6.
• Suction fuel lines
• ECM cooling plate assembly
• OEM fuel lines
• Suction-side fuel filter assemblies
• Stand-pipe(s) in the fuel tank(s).
• Gear pump shaft seal leak.
Finishing Steps
• Remove all test fuel lines. Refer to Procedure 006-024
in Section 6.
Engine Control Module Cooling Plate,

Fuel Cooled (006-006)
Initial Check
The ECM cooling plate assembly provides a vibration
isolated mounting location for the ECM. The cooling plate
also provides ECM cooling and incorporates the fuel lift
pump. A check valve at the outlet port in the ECM cooling
plate makes sure that the fuel system is primed while the
fuel lift pump is running.
Check the ECM cooling plate for damaged vibration
isolators, loose capscrews, or fuel leaks.
Engine Control Module Cooling Plate, Fuel Cooled ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Make sure that the ground strap is properly installed. A

missing or poorly connected ground strap may cause
intermittent engine performance problems.
The ground strap must be connected between the head
of the ECM mounting bolt and the ECM.
The ground strap must be connected to an unpainted
block surface that is free of corrosion.
Preparatory Steps
WARNING
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
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
WARNING
personal injury.
WARNING
face shield, as well as protective clothing. Hot steam can
cause serious personal injury.
CAUTION
Use caution when disconnecting or removing fuel lines,
replacing filters and priming the fuel system that fuel is
not spilled or drained into the bilge area. Do not drop or
throw filter elements into the bilge area. The fuel and
fuel filters must be discarded in accordance with local
CAUTION
Before servicing any fuel system components, (such as fuel
lines, fuel pump, injectors, etc.) which would expose the fuel
system or internal engine component to potential
mounting hardware, and the area around the component to
be removed. Dirt or contaminants can be introduced into the
fuel system and engine if the surrounding areas are not
cleaned, resulting in damage to the fuel system and engine.
• Disconnect the batteries. Refer to Procedure 013-009 in
Section 13.
• Disconnect the harness connections from the ECM.
• Disconnect the unswitched battery power at the batteries,
marine engines only.
• Disconnect the unswitched ECM power connection on
the SIM mounting plate, marine engines only.
• Disconnect the ECM ground strap.
• Disconnect the engine harness from the electric fuel
priming pump.
• Close the fuel supply and drain valves, if equipped.
• Disconnect the fuel supply lines. Refer to Procedure
• Remove the ECM from the cooling plate. Refer to
Remove
NOTE: The electric fuel priming pump and priming pump
fuel lines will be attached to the ECM cooling plate while
the cooling plate is being removed.
Remove the ECM cooling plate capscrews and the ECM
cooling plate from the engine block.
Disassemble
Remove the following components from the ECM cooling
plate:
• Male banjo quick disconnect fitting
• Male banjo check valve fitting
• Fuel lift pump supply lines
• Fuel lift pump brackets
• Fuel lift pump.
Inspect for Reuse

Inspect the ECM cooling plate for leaks (note that the fuel
passages are contained in a tube that is cast into the
cooling plate).
Replace any damaged vibration isolators.
Inspect for leaks in the electric fuel supply pump priming
circuit. Look for cracked fuel tubes, damaged o-rings, or
damaged seal washers.
Inspect the check valve for debris or damage.
Assemble
Install the electric fuel priming pump and the priming
circuit fuel lines. Refer to Procedure 005-045 in Section 5.
Be sure the lines are supported while tightening the banjo
screws. The lines must not be permitted to bind.
Be sure the ECM check valve is installed into the bottom
(outlet) fitting of the ECM cooling plate.
Install
Install the ECM cooling plate assembly on the engine
block. Tighten the capscrews.
Finishing Steps
WARNING
battery cable last.
CAUTION
Failure to properly install the ECM ground strap may
cause intermittent engine symptoms including
intermittent engine stalls. One end of the ground
strap must be installed between the ECM housing and
the head of the bottom most ECM mounting
capscrew. The other end of the ground strap must be
tightly bolted to an unpainted block surface that is
free from corrosion.
NOTE: Be sure the vibrations isolators are installed
correctly. The isolators fit in a single direction into the
chamfered locators.
• Install the ECM on the ECM cooling plate. Refer to
• Install the suction fuel lines, if removed.
• Connect the fuel supply lines. Refer to Procedure
• Connect the engine harness to the electric fuel priming
pump.
• Connect the ECM ground strap.
• Connect the unswitched ECM power connection on
the SIM mounting plate, marine engines only.
• Connect the harness connections to the ECM.
• Connect the unswitched battery power at the batteries,
marine engines only.
• Connect the batteries. Refer to Procedure 013-009 in
Section 13.
• Open the fuel supply valves, if equipped.
• Cycle the keyswitch and allow the lift pump to operate
for 30 seconds. Afterwards, turn the keyswitch OFF
and back ON again allowing the lift pump to operate
again.
• Allow the lift pump to operate for three or four 30-
second cycles before attempting to start the engine.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Drain Line Restriction
Fuel Drain Line Restriction (006-012)

Preparatory Steps
Obtain a M12 banjo pressure gauge tool, Part Number
4918413.
A banjo-style pressure gauge adapter may be used to
measure pressure or vacuum at any point in the low-
pressure fuel system where a banjo bolt exists at a fuel
line.
The engines use M12 x 1.5 banjo bolt connections. Part
Number 4918413 may be used for measurement of drain
line restriction (pressure) at the fuel drain manifold.
Make a banjo bolt pressure gauge tool by drilling and
tapping the hex face of a M12 x 1.5 banjo bolt, Part
Number 3903035, or equivalent.
Drill and tap the banjo bolt to the size of Compuchek™
fitting, or other hose union, being used (example 1/8-inch
NPT Compuchek™ fitting, Part Number 3377244, or M10
Compuchek™ fitting, Part Number 3824842).
Assemble the banjo pressure gauge adapter.

1 Install the Compuchek™ fitting, Part Number 3377244,
or other type fitting in the hex face of the banjo bolt.
2 Attach a hose or pressure gauge to the banjo pressure
adapter.

Install the M12 banjo pressure gauge adapter in place of
the injector drain line banjo at the fuel drain manifold.
Install the M12 banjo pressure gauge adapter in place of
the banjo bolt that attaches the injector drain line to the
electric lift pump drain manifold (CAPS fuel systems).
Install a 0 to 762 mm Hg [0 to 30 in Hg] pressure gauge at
the M12 banjo pressure gauge adapter.
Fuel Drain Line Restriction ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
CAUTION
On QSC8.3 engines, install a Compucheck™, or other
type fitting, in the fuel outlet side of the fuel cooler, if one
is not already installed.
Connect a 0 to 762 mm Hg [0 to 30 in Hg] pressure gauge
with a flexible hose at the fuel outlet fitting.
CAUTION
On QSL9 engines with sea water cooling, install a
Compucheck™, or other type fitting, in the fuel outlet side
of the fuel cooler, if one is not already installed.
with a flexible hose at the fuel outlet fitting.
CAUTION
NOTE: QSL9 engines with keel coolers do not have fuel
coolers.
On QSL9 engines with keel cooling, install the M12 banjo
pressure gauge adapter in place of the injector drain line
banjo at the fuel drain manifold.
with a flexible hose at the M12 banjo pressure gauge
adapter.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Drain Lines
Measure
Operate the engine at rated speed and no load.
Observe the reading on the gauge.
Fuel Drain Line Pressure

mm Hg in Hg
All Applications Except 254.0 MAX 10.0
Marine
Marine Applications 101.6 MAX 4.0
If the drain line pressure is out of specification, check for
bends or kinks in the drain lines. Look for places where
the OEM fuel lines may be pinched by wire ties or p-clips.
Check for blocked fuel tank vents.
Finishing Steps
• Remove all test fittings and install the drain lines.
Fuel Drain Lines (006-013)

Initial Check
Inspect the drain lines for any signs of leaks, cracks,
chafing, or loose or broken brackets.
Preparatory Steps
WARNING
battery cable last.
in Section 13.
Fuel Drain Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
personal injury.
WARNING
CAUTION
Remove
CAPS Fuel System
WARNING
WARNING
can cause a fire.
There are two drain lines on the engine:
1 The fuel injection pump drain line routes fuel from the
fuel injection pump to the fuel lift pump drain manifold.
This line has a p-clip brace that attaches to the
cylinder head.
2 The injector drain line which routes fuel from the rear
of the cylinder head to the fuel lift pump drain manifold.
These lines are removed by removing the banjo bolts and
sealing washers.
WARNING
WARNING
can cause a fire.
CAUTION
There are three drain lines on the engine:
1 The fuel pump drain line connects the fuel pump to the
fuel drain manifold. This line has a p-clip brace that
attaches to the engine cylinder head.
2 The fuel rail pressure relief valve drain line connects
the fuel rail pressure relief valve to the fuel drain
manifold.
3 The injector drain line connects the back of the
cylinder head to the fuel drain manifold.
These lines are removed by removing the banjo bolts and
sealing washers.
NOTE: QSL9 marine applications, which are keel cooled,

do not have fuel coolers.
QSC8.3 and QSL9 marine applications, which are sea
water cooled, have an additional drain line which transfers
the fuel from the fuel drain manifold to the fuel cooler.
This line is removed by loosening the compression nuts.
Fuel Drain Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect for Reuse

Inspect the lines for damage.
Inspect the banjo seal washers for damage.
Install
CAPS Fuel System
Connect the fuel drain line at the fuel pump banjo fitting at
the rear of the cylinder head and at the lift pump. Use two
(2) wrenches when installing the drain line at the fuel
pump return.
Torque Value:
Style One (1)
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
Style Two (2)
Step 1 24 N•m [ 212 in-lb ]
Use the following procedure for air bleeding installation.
Install and tighten the clamp capscrews.

Torque Value:
M12 banjo bolts
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
P-clip capscrew
Step 1 24 N•m [ 212 in-lb ]

Install the three drain lines on the engine.
High pressure fuel pump drain:
• Install the p-clip bracket
• Install the banjo bolt at the fuel drain manifold
• Install the banjo bolt at the fuel pump.
Pressure relief valve drain line:
• Install the banjo bolt at the fuel drain manifold
• Install the banjo bolt at the pressure relief valve. Hold
the line so that it will not twist and wear against the
bottom of the cylinder head.
Injector drain line.
Torque Value:
M12 banjo bolts
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
M16 banjo bolts
Step 1 43 N•m [ 32 ft-lb ]
Torque Value:
P-clip capscrew
Step 1 24 N•m [ 212 in-lb ]
On marine applications, install the additional fuel drain line

from the fuel drain manifold to the fuel cooler.
Finishing Steps
WARNING
battery cable last.
manual.
Fuel Filter (Spin-On Type) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Filter (Spin-On Type) (006-015)

General Information
CAPS Fuel System
The CAPS fuel system requires the use of a single fuel filter. The filter must have the following characteristics:
• Water-separating
• 10-micron rating
• Water-in-fuel sensor
• Water drain valve
• Engine mounted or chassis mounted.
Fleetguard® FS1022 meets these requirements.
The Cummins® Common Rail fuel system requires the use of two fuel filters. The suction-side filter must have the
following characteristics:
• Water-separating
• 10-micron rating
• Water-in-fuel sensor with shunt resistor
• Water-drain valve
• Always chassis mounted.
Fleetguard® FS1003 meets these requirements.
Racor™ model 1000MA meets these requirements for marine applications.
The pressure-side filter must have the following characteristics:
• 3-micron rating
• Engine mounted or chassis mounted.
Fleetguard® FF5488 meets these requirements.
The fuel supply and return valves must be closed when servicing the fuel filters on marine applications.
Identify the engine for the correct filters.
Refer to Procedure 100-001 in Section E.
The CM554 engine uses the CAPS fuel system.
Measure
Operate the engine at high idle and record the fuel
pressure at the inlet and outlet of the fuel filter. Subtract
the outlet reading from the inlet reading to determine the
restriction.
Maximum Allowable Pressure Drop Across Fuel Filter

kPa psi
80 MAX 11.7
If the pressure drop is greater than the specified value,
the fuel filter must be replaced.
Remove the Compuchek™ fittings and install the
threaded plugs into the diagnostic ports. See Section 17
for the correct torque value.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Filter (Spin-On Type)
Entfernen Sie
WARNING
fire and resulting severe personal injury, death, or
Close the fuel supply and return valves, if equipped.
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
Disconnect the wiring harness from the fuel heater, if
equipped.
Loosen and remove the fuel filter.
Make sure the seal ring does not stick to the filter head.
Remove the ring with an o-ring pick, if necessary.
Install
CAPS Fuel System
CAUTION
Mechanical overtightening can distort the threads as
well as damage the filter element seal or filter
canister.
Do not fill the fuel filter with fuel before installation;
instead, prime the fuel system using the fuel lift pump.
Be sure the center seal ring is installed onto the filter
spud.
Install the filter as specified by the filter manufacturer.
Connect the water-in-fuel sensor and the fuel heater, if
equipped.
CAUTION
Mechanical overtightening can distort the threads as
well as damage the filter element seal or filter
canister.
It will be necessary to fill the 10-micron water stripping
(suction-side) fuel filter with fuel.
Do not fill the 3-micron (pressure-side) fuel filter with fuel
before installation; instead, prime the fuel system using
the fuel lift pump.
Make sure the center seal ring is installed onto the filter
spud.
Install the filter as specified by the filter manufacturer.
Connect the water-in-fuel sensor and the fuel heater, if
equipped.
Fuel Filter (Spin-On Type) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
The Cummins® Common Rail fuel system is capable of

detecting the presence of the correct water-in-fuel sensor.
If the water-in-fuel sensor is incompatible or disconnected,
the engine WARNING lamp will illuminate.
Prime
WARNING
Do not open the high-pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High-pressure fuel spray can cause serious
injury or death.
Open the fuel supply and return valves, if equipped.
Cycle the keyswitch and allow the lift pump to operate for
30 seconds. Then turn the keyswitch OFF and back ON
again, allowing the lift pump to operate again.
Allow the lift pump to operate for three or four 30-second
cycles before attempting to start the engine.
Finishing Steps
• Operate the fuel lift pump to help prime the fuel
system. Turn the keyswitch to RUN, but do not
attempt to start the engine. This will cause the engine
control module (ECM) to operate the fuel lift pump
through a priming cycle which lasts at least 30
seconds. Cycle the lift pump several times by keying
OFF, waiting 10 seconds, and keying ON again.
• Once the engine is started, slowly increase the engine
speed while air is purged from the fuel plumbing.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Filter Head
Fuel Filter Head (006-017)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
Drain the fuel-water separator into a container, and
dispose of contents in accordance with local
CAUTION
lines. Replacing filters and priming the fuel system
NOTE: Some of the graphics used in this procedure may
not match all applications. However, the procedure is the
same except where noted.
• Disconnect the batteries. See equipment manufacturer
service information.
• Close the fuel supply valve, if equipped. See
equipment manufacturer service information.
• Remove the fuel filter. Refer to Procedure 006-015 in
Section 6.
Remove
Remove the fuel filter head mounting capscrews.
Fuel Filter Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
NOTE: Mark the location of the fuel inlet port to aid in the
installation.
Remove the four filter head mounting capscrews and the
fuel filter head.
Disconnect the fuel inlet and outlet lines from the filter
head.
Disassemble
Remove the fuel heater, if equipped. Refer to Procedure
Marine Applications
Remove the fuel line connections and compression o-ring
seals.
Remove the test port access plugs.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Filter Head
Inspect for Reuse

Inspect the fuel filter head for cracks, passage blockage,
and material or debris on the sealing surfaces.
Assemble
Apply thread locker, Part Number 3375068, or equivalent
to only the filter adapter threads that are engaging the
fuel filter head.
Install the fuel filter adapter and fuel heater. Refer to
NOTE: Make sure there is an o-ring between the fuel filter
head and the heater.
Marine Applications
Use new compression seal rings and install the 90-degree
straight thread o-ring elbows in the fuel filter head. Tighten
the elbows.
Use new compression seal rings and install the test port
plugs. Tighten the plugs.
Install
Install the fuel filter head.
Tighten the retaining capscrews.
Fuel Filter Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
Align the installation markings for the fuel inlet port.
Install the fuel filter head.
Finishing Steps
WARNING
battery cable last.
• Connect the fuel return and supply lines. Refer to
Section 6.
• Open the fuel supply valve, if equipped. See
equipment manufacturer service information.
• Connect the batteries. See equipment manufacturer
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Filter Head Bracket
Fuel Filter Head Bracket (006-018)

Preparatory Steps
WARNING
battery cable last.
WARNING
Section 6.
• Remove the fuel supply lines from the filter head.
• Remove the fuel filter head. Refer to Procedure
Marine Applications
WARNING
CAUTION
• Close the fuel supply and drain valves. See equipment
manufacturer service information.
Section 6..
• Disconnect the fuel supply lines. Refer to Procedure
• Remove the fuel filter head; note the port location (in
and out) marking. Refer to Procedure 006-017 in
Section 6.
Fuel Filter Head Bracket ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Remove the filter head bracket from the engine.
Marine Applications
Remove the fuel filter head bracket mounting capscrews
from the cylinder head.
Remove the bracket mounting capscrew, if equipped,
from the gear housing.
Inspect for Reuse

Inspect the filter head bracket mounting for cracks and
signs of fretting on the mounting holes.
Replace the bracket if it is cracked or has signs of fretting.
Install
Install the fuel filter head bracket and filter head.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Filter Head Bracket
Marine Applications
Install the fuel filter head bracket. Tighten the retaining
capscrews.
Finishing Steps
WARNING
battery cable last.
• Install the fuel filter head. Refer to Procedure 006-017
in Section 6.
Section 6.
• Install the fuel supply lines. Refer to Procedure
Marine Applications
• Install the fuel filter head with the fuel inlet and outlet
ports in the original location. Refer to Procedure
006-017 in Section 6..
• Connect the fuel supply lines. Refer to Procedure
OEM service manual.
Fuel Inlet Restriction ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Inlet Restriction (006-020)

Preparatory Steps
CAPS Fuel System
• Obtain a 1.09-mm [0.043-in] orificed diagnostic fuel
line, Part Number 3164621. This tool can also be
constructed. Refer to Procedure 006-003 in Section 6.
• Obtain a container suitable for collection of fuel that
exits the diagnostic fuel line. A 19-liter [5-gal] bucket is
recommended.
Install a 1/8-inch NPT Compuchek™ diagnostic fitting,

Part Number 3042618, at the inlet to the fuel injection
pump (Cummins® Accumulator Pump System only).
Attach the 1.09-mm [0.043-in] orificed diagnostic fuel line
at the fuel injection pump cam housing Compuchek™
fitting. Route this hose into a collection container or into
the fuel tank.
Attach a 0 to 762 mm-Hg [0 to 30 in-Hg] vacuum gauge at
the gear pump inlet Compuchek™ port.
CAUTION
lines, replacing filters and priming the fuel system.
The fuel and fuel filters must be discarded in
Automotive and Industrial Applications
Obtain a 1.09-mm [0.043-in] orificed diagnostic fuel line,
Part Number 3164621.
Obtain a pressure gauge adapter, Part Number 4918324.
Obtain fuel line connector fitting, Part Number 3972088.
Obtain a container suitable for collection of fuel that exits
the diagnostic fuel line. A 19-liter [5-gal] bucket is
recommended.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Inlet Restriction
Install a pressure gauge adapter, Part Number 4918324.

Use fuel line connector fitting, Part Number 3972088, at
the inlet to the gear pump.
Install a vacuum gauge that has a range of at least 0 to
762 mm-Hg [0 to 30 in-Hg] onto the pressure gauge
adapter.
Install an M10 Compuchek™ fitting, Part Number
3824842, at the fuel filter head.
male Compuchek™ fitting, Part Number 3377244, may be
Attach the 1.09-mm [0.043-in] orificed diagnostic fuel line
at the fuel filter head Compuchek™ fitting. Route this
hose into a collection container or into the vehicle fuel
tank.
Marine Applications
CAUTION
such that fuel is not spilled or drained into the bilge
area. Do not drop or throw filter elements into the
bilge area. The fuel and fuel filters must be discarded
in accordance with local environmental regulations.
Attach a 0 to 762 mm-Hg [0 to 30 in-Hg] vacuum gauge at
the Compuchek™ port at the OEM fuel inlet connection.
Fuel Inlet Restriction ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Measure
Operate the engine at high idle and measure the inlet
vacuum.
Maximum Fuel Inlet Restriction (CAPS Fuel
Systems)
mm-Hg - in-Hg
102.0 At OEM 4.0
connection
254.0 At inlet to fuel 10.0
gear pump (dirty
filter)
Maximum Fuel Inlet Restriction (Cummins®
Common Rail Fuel System)
mm-Hg - in-Hg
203.2 At OEM 8.0
connection (dirty
filter) loaded
condition
304.8 At inlet to fuel 10.0
gear pump (dirty
filter) loaded
condition
Marine Applications
Operate the engine at rated rpm and measure the inlet
vacuum.
Maximum Fuel Inlet Restriction (Cummins®
Common Rail Fuel System)
mm-Hg - in-Hg
102 Dirty filter (rated 4.0
speed and load)
63.5 Clean filter (rated 2.5
speed and load)
If the inlet restriction is excessive, look for the root cause:

• Suction side fuel filters plugged
• Fuel heater valves restricted
• ECM cooling plate plugged
• ECM cooling plate check valve restricted
• OEM fuel lines pinched or restricted
• Fuel tank stand pipes restricted.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Supply Lines
Finishing Steps
NOTE: Do not leave Compuchek™ fittings installed on
the suction side of the gear pump. A Compuchek™ fitting
on the suction side of the gear pump can allow air to enter
the fuel flow, resulting in performance problems.
• Disconnect all diagnostic test fittings and install all
components removed during testing.
Marine Applications
• Disconnect the vacuum gauge from the Compuchek™
fitting. Leave the Compuchek™ fitting installed.
Fuel Supply Lines (006-024)

Initial Check
Inspect all fuel supply lines and fittings. Look for cracks in
the lines or leaking fittings.
Inspect the straight thread o-ring metric hose fitting. Make
sure the lock nuts tighten against the o-ring rather than
bottom out against the end of the fitting's threads
(example: Cummins® Accumulator Pump System fuel
pump inlet and Cummins® Accumulator Pump System
fuel filter head).
Inspect the quick-disconnect style fittings for damaged o-
ring connections or broken locking tangs.
Inspect the banjo style fittings for leaks at the sealing

washers.
Fuel Supply Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
in Section 13.
• Close the fuel supply and return valves. Refer to the
OEM service manual.
• Clean all fittings before disassembly. Dirt or
WARNING
personal injury.
WARNING
CAUTION
fuel lines, fuel pump, injectors, etc.) which can expose the
fuel system or internal engine component to potential
Remove
WARNING
Remove the fuel supply lines.
For quick disconnect style fuel lines, remove the clasp

from the fuel line brace. This will allow the lines to move
so they can be disconnected.
Loosen all quick disconnect lines from the brace.

To remove the gear pump outlet line, the gear pump inlet
line must be removed first.
Remove the quick disconnect style fuel lines by pressing

in the locking tangs on both sides of the quick disconnect
fitting.
To aid in the removal of quick disconnect style fuel lines,
slide removal tool, Part Number 4918878, over the locking
tangs. Make sure the tool is removed from the fuel line as
soon as possible after the line has been disconnected.
Inadvertently leaving the tool in place can result in fuel
leaks.
To aid removal, a screwdriver may be inserted between

the fuel line end and quick disconnect male union. After
pressing the opposing locking tangs, twisting the flat blade
of the screwdriver helps to remove the fuel line.
If fuel leaks or suction-side air entry is suspected, remove

the fuel hoses or quick disconnect fittings.
Marine Applications
WARNING
CAUTION
Disconnect the OEM fuel supply line.
Disconnect the fuel line from the fuel line mounting
bracket and the upper ECM cooler fuel connection.
Disconnect the fuel supply line from the lower ECM cooler
connection and the upper gear pump connection.
Disconnect the fuel supply line from the lower gear pump
connection and the inlet to the fuel filter head.
Disconnect the fuel supply line from the fuel filter head
outlet connection and the high-pressure pump connection.
Inspect for Reuse

Inspect for burrs or debris on metal connectors that may
cause leaks.
On straight thread o-ring metric connectors, be certain the
o-rings are not frayed or cut.
On quick disconnect style fittings, be certain the o-rings
are not frayed or cut, and the lock tangs are not
damaged.
The lower quick disconnect fitting on the cooling plate has
a check valve built in to it.
• 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 face of the banjo connector for sealing surface

damage.
Replace the banjo bolts, sealing washers, or fuel lines, as
necessary.
Inspect the straight thread fittings and fuel lines for cracks,
bends, or any other damage.
Replace the fuel lines as necessary.
Install
Install the fuel supply lines.
Torque Value:
Number 10 Flare Fitting 37 N•m [ 27 ft-lb ]
Torque Value:
M12 Quick Disconnect Union 24 N•m [ 212 in-lb ]
Install the quick disconnect fuel lines (Cummins®

Common Rail Fuel Systems only).
Install the quick disconnect fittings.
Make sure the quick disconnect style fuel lines clasp onto
the quick disconnect fittings.
Make sure the lines are routed and connected correctly. If
the lines are connected incorrectly, the engine will not
operate.
For quick disconnect style lines used with the Cummins®
Common Rail Fuel System, fuel lines are routed in the
following order:
1 OEM connection to the upper fitting at the ECM
cooling plate.
2 Lower ECM cooling plate fitting to the upper gear
pump fitting.
3 Lower gear pump fitting to the pressure-side fuel filter
inlet.
4 Pressure-side fuel filter outlet to the fuel pump fuel
control actuator housing.
The fuel supply line brace holds the fuel lines in the
following order:
1 The inside line connects the upper gear pump fitting to
the lower ECM cooling plate fitting.
2 The middle line connects the pressure-side fuel filter
outlet to the fuel pump fuel control actuator housing.
3 The outside line connects the lower gear pump fitting
to the pressure-side fuel filter inlet.
Install the fuel line brace clasp (quick disconnect style fuel
lines only) and the brace, if necessary.
Torque Value:
Fuel Line Brace 24 N•m [ 212 in-lb ]
Torque Value:
Fuel Line Brace Clasp 24 N•m [ 212 in-lb ]
Marine Applications
Connect the fuel supply hose to the fuel pump and the
outlet of the fuel filter. Use new sealing washers as
needed
Connect the supply hose from the inlet side of the fuel
filter and the lower gear pump connection. Use new
sealing washers as needed.
Tighten the filter connection.
Tighten the gear pump connection.
Connect the supply line to the upper gear pump
connection and the lower ECM cooler connection. Use
new sealing washers as needed.
Tighten the connection.
Connect the fuel supply line to the upper ECM cooling

plate connection.
Install the fuel supply line on the fuel line connector
bracket.
Connect the OEM fuel supply hose. Refer to the OEM
service manual.
Finishing Steps
WARNING
reduce the possibility of arching, remove the negative
battery cable last.
• Open the fuel supply and return valves, if equipped.
Section 13.
• Prime the fuel system. Refer to Procedure 006-015 in
Section 6.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injector
Injector (006-026)
Initial Check
WARNING
fittings while the engine is operating. Wait at least 10
CAUTION
lines, replacing filters, and priming the fuel system,
CAUTION
Installation of the banjo flow adapter at any place
other than the fuel drain manifold can cause damage
to high pressure fuel system components.
Return fuel is routed from the injectors, the fuel rail
pressure relief valve, and the fuel pump head through
three different drain lines.
Measurement of fuel injector leakage requires the use of a
fuel return hose, Part Number 3164618.
The tool is used to isolate the leakage from just the
injectors, so it can be measured with a graduated cylinder.
If necessary, this tool can be constructed using the steps

outlined below.
To make a banjo bolt flow adapter tool, drill and tap the
hex face of a M12 x 1.5 banjo bolt, Part Number 3903035,
or equivalent.
Drill and tap the hex face of the banjo bolt to the size of a
male union (or other hose fitting) being used (example
1/8-inch NPT hose barb).
Injector ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Drill and tap the open end of the banjo bolt for the
installation of a 5/16-24 set screw.
WARNING
CAUTION
Remove the M12 banjo bolt that connects the fuel injector
drain line to the fuel drain manifold.
Install the M12 fuel return hose, Part Number 3164618, at
the fuel drain manifold.
Route the fuel return hose into a collection device.
Obtain a graduated cylinder that is marked in cubic
centimeters; example: graduated beaker, Part Number
3823705, or equivalent. A kitchen style measurement cup
that is marked in cubic centimeters (cc's) also works well.
Start the engine and allow the engine to idle until drain
fuel from the injector drain line begins to flow into the
collection container.
Connect INSITE™ electronic service tool.
If the engine will not start, these procedures are still valid;
however, the pass/fail specification is different.
If the engine will not start, drain flow must be measured
while engaging the starter for 30 seconds at a time.
Leakage Specification if Engine Will Not Start
Maximum Leakage During 100 cc [3.38 oz]
30 Seconds of Cranking
If the injector leakage is excessive during cranking and

the engine will not start, check the following:
• High pressure fuel connector installation. Refer to
• High pressure fuel connector damage. Refer to
• Use the fuel leak test tool, Part Number 3164325, to
isolate injectors from the fuel rail, one at a time.
CAUTION
Fuel is at high pressure during this test. After
connecting the test fitting, close the engine cover and
stand clear of high-pressure fuel lines.
If the engine will start, the following steps will determine if
the injector drain flow is excessive.
While the engine is operating at idle, use INSITE™
electronic service tool High Pressure Leak Test to create
high fuel rail pressure. INSITE™ electronic service tool
will command 1500 BAR [21,756 psi] fuel rail pressure
while the engine is at idle during this test.
Record the amount of time it takes for 300 cc [10.1 oz] of

fuel to flow from the injector drain line when performing
INSITE™ electronic service tool High Pressure Leak Test.
Leakage Specification With Engine operating
Maximum Leakage During 300 cc [10.1 oz]
45 Seconds
If 300 cc [10.1 oz] of fuel leaks from the injectors in less
than 45 seconds, there is at least one loose or damaged
high pressure fuel connector and/or injector.
NOTE: Fuel temperature and fuel type will influence this
measurement. For example; as the engine is warmed up
and the injectors become hot, the leakage rate will
increase. Also, low viscosity fuels, such as kerosene, will
cause the leakage rate to increase. The above
specification is correct for on-highway diesel fuels where
fuel inlet temperature is less than 49°C [120°F].
After recording the fuel leakage rate, stop INSITE™
electronic service tool High Pressure Leak Test and turn
the keyswitch to OFF.
If injector drain flow is excessive, it will be necessary to

isolate the injector(s) or fuel connector(s) that are
damaged or worn.
A loose fuel connector retaining nut results in a poor seal
at the interface between the fuel connector and the
injector. This loose condition will result in a leak of high-
pressure fuel to the injector drain.
Verify first that the fuel connectors are properly tightened.
If loose retaining nut(s) are found, test for leakage after
tightening the retaining nut(s).
CAUTION
Do not install the isolation tool at the high pressure
pump outlet fitting. Severe engine damage will result.
This tool must only be installed at the fuel rail for the
purpose of isolating the high-pressure fuel supply
from individual injectors.
CAUTION
Make certain the keyswitch is in the OFF position
(engine not operating) when loosening or tightening
high-pressure fuel lines.
Use leak test isolation tool, Part Number 3164325, to
isolate excessive fuel drainage from injectors or fuel
connectors.
Isolate the injector and fuel connector for each cylinder by

installing the isolation tool at the fuel rail in place of the
high-pressure fuel line that supplies the fuel connector.
Record the amount of time it takes for 300 cc [10.1 oz] of

fuel to flow from the injector drain line while the engine is
operating. Use INSITE™ electronic service tool High
Pressure Leak Test. Do this up to six (6) times, once while
each line is isolated.
If isolating a single injector and high-pressure fuel
connector causes the leakage time to increase
significantly compared to the rest of the set, that injector
and fuel connector must be inspected.
Inspect the suspect fuel connector. Refer to Procedure
006-052 in Section 6. If the fuel connector is not
damaged, replace both the injector and the fuel
connector.
Remove the M12 diagnostic flow adapter from the fuel

drain manifold and install the M12 banjo. Refer to
Install all high-pressure fuel lines. Refer to Procedure
Operate the engine and check for leaks.
Preparatory Steps
CAPS Fuel System
CAUTION
Attempting to remove the injector without first
removing the fuel connector will cause damage to the
injector body and/or fuel connector.
• Remove the rocker lever cover. Refer to Procedure
• Remove the engine brake, if equipped. Refer to
• Remove the fuel connector. Refer to Procedure
WARNING
battery cable last.
CAUTION
CAUTION
Attempting to remove the injector without first
removing the fuel connector will cause damage to the
injector body and/or fuel connector.
NOTE: All fuel system diagnostics procedures and
component specifications have been moved. Refer to
in Section 13.
• Remove the high-pressure fuel line. Refer to
• Remove the engine brake, if equipped. Refer to
• Remove the fuel connector. Refer to Procedure
• Remove the exhaust rocker lever assembly. Refer to
Remove
CAPS Fuel System
Remove the injector hold-down clamp capscrew that is
nearest the exhaust manifold side of the engine.
Remove the injector hold-down clamp.
Remove the high-pressure fuel connector. Refer to
Use the injector puller, Part Number 3825156, to pull the

injector out of the head.
Alternatively, a rocker cover capscrew can be installed
into the top of the injector and used to pull the injector
from the cylinder head.
Be sure the injector seal washer is removed from the
injector bore.

Disconnect the injector wire harness from the injector.
Remove the two injector hold-down clamp capscrews and
remove the injector hold-down clamp.
Use a small heel-bar to pry up on the injector clamp hold-
down flange (part of the injector body just above the
cylinder head casting).
Test
Mechanical Injectors
WARNING
While testing the injectors, keep hands and body
parts away from the injector nozzle. Fuel coming from
the injector is under extreme pressure and can cause
serious injury by penetrating the skin.
Install the injectors on an injector test stand. Open the
bypass valve for the pressure gauge, so the spray pattern
can be checked.
Use the injector test fixture, Part Number 3162269, with
the injector nozzle test, Part Number 3376946.
Operate the test stand lever quickly several times to

check the spray pattern of the injectors. Verify that the
correct number of plumes are present for the number of
holes in the injector. Also pay close attention to the size
and shape of each plume. If possible, compare the spray
pattern to that of a new injector with the same assembly
number.
NOTE: The injector spray pattern is an excellent indicator
of the nozzle hole condition. Check each plume carefully.
It is possible that only a single hole has been damaged,
resulting in degraded engine performance.
Close the bypass valve for the pressure gauge and

operate the test stand lever to check the nozzle opening
pressure. There must be a good crisp "pop" when the
nozzle opens and the pressure must be within the
specification for the assembly number.
The injector will pop between 275 bar [3,989 psi] and 300
bar [4,351 psi].
If the nozzle opening pressure is excessively low and/or

the nozzle sprays excessive fuel, the injector needle can
be sticking. The needle can be stuck due to poor
lubrication or debris.
Sometimes it is possible to unstick an injector needle by
using the injector test stand. Open the bypass valve for
the pressure gauge and operate the test stand lever
rapidly for 10 to 20 strokes.
Recheck the nozzle opening pressure and spray pattern
to see if the injector has returned to normal operation.
If the injector is still out of specification, replace the
injector.
Check the injector for drip and/or excessive leak down.

Close the bypass valve for the pressure gauge and build
pressure to within 10 bars [145 psi]of the opening
pressure of the nozzle.
A drop of fuel must not form within 15 seconds.
Disassemble
Place the injector in the injector clamp and remove the
nozzle retaining nut.
NOTE: Injectors covered under warranty by the
manufacturer must not be repaired. See the
manufacturer's warranty instructions.
Remove the nozzle, intermediate plate, spring, and shims
from the injector.
WARNING
avoid personal injury.
WARNING
CAUTION
Do not use any abrasives (such as glass beading,
sand paper, emery cloth, Scotch-Brite™ pads, etc) or
metallic items (including wire brushes made of any
metallic material) to clean the injectors. The use of
any cleaning method other than safety solvent and a
soft, clean, lint-free cloth will damage the nozzle holes
and cause performance issues.
Clean the injector tip and body with safety solvent and a
soft, clean cloth.
Assemble
Clean the injector internal components with clean diesel
fuel and a clean cloth. Make sure there is no debris in the
internal parts of the injector.
Install shims, as necessary, to modify the nozzle opening

pressure. More shims raise the nozzle opening pressure,
fewer shims lower the nozzle opening pressure.
Install the spring, button, intermediate plate, and nozzle/

needle.
Make sure the intermediate plate is in the correct
orientation with the supply hole on the plate lining up with
the supply hole on the holder.
Install the retaining nut finger tight. Place the injector in

the injector clamp and tighten the retaining nut. Install the
sealing washer and body o-ring.
Install
CAPS Fuel System
NOTE: If a new injector is being installed, a new fuel
connector must be used
Make sure the injector bore is clean and that only one (1)
sealing washer is installed on the injector nozzle.
Lubricate the injector o-ring with clean engine oil.
Place the injector in the head in the proper orientation.
Place the injector hold-down clamp on top of the injector
and make sure the injector is fully seated in the injector
bore.
Install the injector hold-down clamp and tighten.

Make sure the injector bore is clean and that only one (1)
sealing washer is installed on the injector nozzle.
Lubricate the injector o-ring with clean engine oil.
Place the injector in the cylinder head in the proper
orientation (fuel inlet toward the high-pressure fuel
connector).
Use the injector shipping sleeve to make sure the injector
is seated in the injector bore.
NOTE: If a new injector is being installed, a new fuel

connector must be used.
Start the injector hold-down clamp capscrews, and tighten
hand-tight.
Install the high-pressure fuel connector, making sure the
end of the high-pressure fuel connector is in the injector
inlet port.
NOTE: The high-pressure fuel connector should click into
place if it is seated in the injector inlet port correctly.
Start the high-pressure fuel connector retaining nut and
tighten partially.
NOTE: This is not the final torque for the high-pressure
fuel connector retaining nut.
Tighten the injector hold-down clamp capscrews.

NOTE: Make sure to tighten the hold-down clamp
capscrews evenly. Check to make sure the gap between
the hold-down clamp and the injector is equally spaced
around the injector body.
Tighten the high pressure fuel connector retaining nut.

Use the following procedure for the final torque value.
NOTE: The high-pressure fuel connector must be
properly tightened or an internal fuel leak can result,
causing poor engine performance. A torque wrench must
be used.
CAUTION
Do not overtighten the injector harness. The injector
terminals will be damaged if excessively over-
tightened.
Install the injector wiring harness to the injector.
NOTE: Orient the injector wires so they will not interfere
with a rocker lever or engine brake housing. If the rocker
lever is able to come into contact with the injector
harness, it will rub through the wire insulation and cause
injector circuit fault codes.
NOTE: Polarity of the wiring is not significant. The signal
and return wires can be connected to either injector
terminal.
Finishing Steps
CAPS Fuel System
• Install the fuel connector. Refer to Procedure 006-052
in Section 6.
• Install the rocker lever cover. Refer to Procedure
• Install the high pressure fuel lines. Refer to Procedure
WARNING
battery cable last.
• Install the exhaust rocker lever assembly. Refer to
• Install the engine brake, if equipped. Refer to
• Install the high pressure fuel lines. Refer to Procedure
• Open the fuel supply and return valves. Refer to the
OEM service manual.
Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injector Supply Lines (High Pressure)
Injector Supply Lines (High Pressure)

(006-051)
Initial Check
CAPS Fuel System
Inspect the lines for cracks, chafing, or leaks. Make sure
the lines are tightened to the proper specification.
Check the fuel pump connections.
Check the cylinder head connections.
Check the fuel line isolators for loose capscrews.
If the capscrew is loose, replace the isolator capscrew
and bracket. The isolator capscrew and bracket can not
be used twice.

Check the fuel pump connection.
Check the cylinder head connections.
Check the fuel rail connections.
Check the bracket capscrews that support the high-

pressure rail supply line.
Torque Value:
High-Pressure Fuel Supply Line Bracket Capscrew (1) 24
N•m [ 212 in-lb ]
Check the bracket isolator capscrew.
Torque Value:
Bracket Isolator Capscrew (2) 9 N•m [ 80 in-lb ]
Injector Supply Lines (High Pressure) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
WARNING
battery cable last.
WARNING
in Section 13.
• Clean the area around the fuel lines with solvent.
OEM service manual.
Remove
CAPS Fuel System
WARNING
Remove the fuel lines from the fuel pump.
NOTE: Use two (2) wrenches to prevent the outlet fitting
from turning.
Remove the fuel line clamp capscrews from the intake
cover. This must be done before the injection lines can be
pulled loose from the cylinder head.
Remove the fuel lines from the cylinder head.
WARNING
CAUTION
If necessary, remove the air intake connection or
turbocharger control actuator.
Loosen the fuel lines at the fuel rail, the fuel connector,
and the high-pressure fuel pump outlet fitting.
Loosen the capscrews on the fuel line support bracket
and isolator.
Remove the high-pressure fuel lines.
Install
CAPS Fuel System
Before installing the injector supply lines, make sure the
fuel connector is fully and properly seated against the
injector.
Install the fuel lines in the reverse order of removal.

Tighten the fuel pump connection.
Tighten the cylinder head connection.
Tighten the fuel line isolators.
If the capscrew is loose, replace the isolator capscrew
and bracket. The isolator capscrew and bracket can not
be used twice.
Injector Supply Lines (High Pressure) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Before installing the injector supply lines, make sure the
fuel connector is fully and properly seated against the
injector. Make sure the high-pressure connector retaining
nut is tightened. Refer to Procedure 006-052 in Section 6.
Install the fuel lines in the reverse order of removal.

Position the fuel lines from the fuel rail to the cylinder
head and tighten the lines finger tight.
Tighten the fuel rail connections.
Tighten the cylinder head connections.
Position the fuel line from the pump to the rail and tighten
the line finger tight.
Install the fuel line bracket and bracket isolator capscrews
finger tight.
Tighten the fuel line from the fuel pump to the fuel rail at
the fuel rail end first.
Tighten the fuel rail connections.
Tighten the fuel pump connections.
Tighten the fuel line bracket capscrews.

Tighten the fuel line bracket isolator capscrew.
Finishing Steps
WARNING
battery cable last.
• Install the air intake connection and turbocharger
control actuator, if removed. Refer to Procedure
Section 13.
• Open the fuel supply and drain valves. Refer to OEM
service manual.
Fuel Connector (Head Mounted) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Connector (Head Mounted)

(006-052)
Preparatory Steps
WARNING
WARNING
battery cable last.
WARNING
WARNING
The pressure of the fuel in the line is sufficient to
penetrate the skin and cause serious personal injury.
Wear gloves and protective clothing.
CAUTION
in Section 13.
• Shut off the fuel supply and drain valves. Refer to the
OEM service manual.
• Remove the high-pressure fuel supply lines. Refer to
Remove
CAPS Fuel System
Use fuel connector puller, Part Number 3825157, to
remove the fuel connector from the cylinder head.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Connector (Head Mounted)

Remove the fuel connector retaining nut.
Use fuel connector puller, Part Number 3164025, to
remove the fuel connector from the cylinder head.
Inspect for Reuse

A new high-pressure connector must be installed if a new
injector is being installed.
Inspect the fuel connector. Look for burrs or deformation
around the inlet and outlet sides of the connector.
Check the edge filter for signs of plugging or material
contamination. Do not reuse a high-pressure fuel
connector if debris is present.
Check the o-ring for tearing or deterioration.
Inspect the outlet sealing surface of the high-pressure

connector for wear, an uneven seating surface, or signs of
leakage.
When a high-pressure fuel leak is present, small lines or
cuts in the connector will be eroded into the seating
surface.
The high-pressure connector and injector must be
replaced when this condition is observed.
Install
CAPS Fuel System
Coat the fuel connector o-ring with clean engine oil.
NOTE: If a new injector has been installed, a new fuel
Carefully push the fuel connector into the head until it
stops against the injector. Be certain the injector is fully
seated in the injector bore before installing the fuel
connector. Refer to Procedure 006-026 in Section 6.
Fuel Pump Air Bleed Line ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

NOTE: If a new injector has been installed, a new fuel
Lubricate the fuel connector o-ring and the threads on the
fuel connector retaining nut.
Carefully insert the fuel connector, aligning the guide pin
with the slot in the cylinder head at the 12-o'clock position.
NOTE: If the injector was removed along with the high-
pressure fuel connector, the installation steps must be
followed. Refer to Procedure 006-026 in Section 6.
Tighten the fuel connector retaining nut.
Finishing Steps
WARNING
battery cable last.
• Install the high-pressure fuel supply lines. Refer to
OEM service manual.
Section 13.
Fuel Pump Air Bleed Line (006-056)

Preparatory Steps
WARNING
WARNING
personal injury.
CAUTION
Do not use the air bleed line as a handle or step.
Doing this may result in cracks or damaged air bleed
line that will cause fuel leaks. Make sure that steam
does not spray directly on the electrical connections
on the top of the accumulator block or fault codes will
possibly occur.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Air Bleed Line
Remove
ISC and QSC8.3 With CAPS Injection Pump
WARNING
To reduce the possibility of an air bleed line leak due
to a broken air bleed line, use two wrenches during
removal and installation. Failure to do so may result
in a cracked fuel line. In certain applications, with the
fuel tank above the head of the engine, this will result
in fuel draining from the fuel tank.
NOTE: There are three styles of air bleed lines. Identify
your style and use the appropriate procedures that follow.
Style One (1):
Remove the banjo capscrew at the injection control
valve drain fitting of the fuel pump. Use two wrenches
to prevent the line from being bent.
Style Two (2):
Remove the banjo capscrew at the injection control
valve drain fitting of the fuel pump. Remove the hollow
banjo fitting holding the air bleed line. Use two
wrenches to prevent the line from being bent.
Remove the banjo capscrew at the air bleed fitting on top

of the fuel pump. It is located on the accumulator module
next to the two pumping control valves.
Use two wrenches to prevent the air bleed fitting from
turning.
ISL and QSL9 With CAPS Injection Pump

Remove the banjo bolt from the injection control valve
drain fitting and the distributor plug.
Fuel Pump Air Bleed Line ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove the banjo capscrew at the air bleed fitting on top

of the fuel pump. It is located on the accumulator module
next to the two pumping control valves.
Use two wrenches to prevent the air bleed fitting from
turning.
Inspect for Reuse

Inspect the lines for pinches, bends, or damaged
connectors.
Install
ISC and QSC8.3 With CAPS Injection Pump
WARNING
To reduce the possibility of an air bleed line leak due
to a broken air bleed line, use two wrenches during
removal and installation. Failure to do so may result
in a cracked fuel line. In certain applications, with the
fuel tank above the head of the engine, this will result
in fuel draining from the fuel tank.
Install the banjo capscrew at the air bleed fitting on top of
the fuel pump. Use two wrenches to prevent the line from
being bent.
NOTE: Use new sealing washers.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pump Air Bleed Line
Style One (1):

Install the banjo capscrew drain fitting on the fuel pump at
the injection control valve. Use two wrenches to prevent
the line from being bent.
Style Two (2):
Install the hollow banjo fitting at the injection control valve
drain fitting to secure the air bleed line. Use two wrenches
to prevent the line from being bent.
Install banjo capscrew. Use two wrenches to prevent the
line from being bent.
ISL and QSL9 With CAPS Injection Pump

Install the banjo capscrew at the air bleed fitting on top of
the fuel pump. Use two wrenches to prevent the air bleed
fitting from turning.
Install the banjo capscrew in the injection control valve

drain fitting and the distributor plug.
Fuel Rail ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
Fuel Rail (006-060)

Initial Check
WARNING
WARNING
The pressure within the fuel rail is extremely high.
High pressure can penetrate the skin. Stand clear of
the engine while it is running.
WARNING
The fuel pump high-pressure fuel lines and fuel rail
contain very high-pressure fuel. To reduce the
possibility of personal injury and property damage,
never loosen any fittings while the engine is running.
Inspect the fuel pressure sensor, high-pressure fuel line
connections, and male unions for leaks.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Rail
Preparatory Steps
WARNING
personal injury.
WARNING
CAUTION
fuel lines, fuel pump, injectors, etc.) which can expose the
fuel system or internal engine component to potential
Fuel Rail ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
battery cable last.
WARNING
CAUTION
in Section 13.
• Shut off the fuel supply and drain valves. Refer to the
OEM service manual.
• Disconnect the fuel pressure sensor from the engine
wiring harness. Refer to Procedure 019-115 in Section
19. This procedure is found in the Troubleshooting and
Repair Manual, CM850 Electronic Control System, ISC
and ISL Engines, Bulletin 4021416.
• Remove the high-pressure fuel lines from the fuel rail.
• Remove the fuel drain line from the fuel pressure relief
valve. Refer to Procedure 006-013 in Section 6.
Remove
Remove the capscrews that secure the fuel rail to the
cylinder head.
Remove the fuel rail assembly.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Rail
Install
Install the fuel rail assembly. Follow the proper sequence
to make sure that high-pressure fuel lines are properly
aligned.
• Install the fuel rail assembly capscrews finger-tight.
• Install the high-pressure fuel lines finger-tight.
• Tighten the fuel rail assembly capscrews.
• Tighten the high-pressure fuel lines. Refer to
Procedure 006-051
Finishing Steps
WARNING
battery cable last.
• Install the fuel drain line to the fuel pressure relief
• Install the fuel pressure sensor to the engine wiring
harness. Refer to Procedure 019-115 in Section 19.
This procedure can be found in the Troubleshooting
and Repair Manual, CM850 Electronic Control System,
ISC and ISL Engines, Bulletin 4021416.
OEM service manual.
Section 13.
Fuel Pressure Relief Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fuel Pressure Relief Valve (006-061)

Initial Check
WARNING
WARNING
The pressure within the fuel rail is extremely high.
High-pressure can penetrate the skin. Stand clear of
the engine while it is running.
WARNING
contain very high-pressure fuel. To reduce the
possibility of personal injury, never loosen any
fittings while the engine is running.
CAUTION
Operate the engine and check for external fuel leaks.
Check for a fuel pressure relief valve that leaks excessive

fuel to drain.
The measurement of fuel pressure relief valve leakage
requires use of a fuel return flow hose, Part Number
3164618. This tool is used to isolate the leakage from just
the fuel pressure relief valve, so the leakage can be
measured in a graduated cylinder.
NOTE: If Fault Code 449 or 2311 is active, do not replace
the fuel pressure relief valve without first determining the
cause of the fault condition. See the appropriate
troubleshooting tree(s).
Remove the M12 banjo bolt that connects the fuel
pressure relief valve drain line to the fuel drain manifold.
Install a fuel return flow hose, Part Number 3164618, at
the fuel drain manifold.
Route the fuel return flow hose into a collection device.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pressure Relief Valve
Alternatively, fuel pressure relief valve leakage

measurement tool, Part Number 3164617, can be
installed at the fuel pressure relief valve.
Test
Engine Running
Start the engine and let it idle.
Measure the leakage.
Specification:
Less than 30 drops per minute must drain from the fuel
pressure relief valve while the engine operates at idle.
CAUTION
Fuel is at high pressure during this test. After
connecting the test fitting, close the engine cover and
stand clear of high-pressure fuel lines.
Start the engine.
NOTE: Make certain the engine is at operating
temperature before running the test.
While the engine is operating at idle, use INSITE™
electronic service tool High Pressure Leak Test to create
higher fuel rail pressure. INSITE™ electronic service tool
will command 1500 BAR fuel rail pressure while the
engine is at idle during this test.
Specification:
Less than 30 drops (1.95 ml [0.07 oz]) of fuel per 30
second are permitted to drain from the fuel pressure relief
valve.
NOTE: For an accurate measurement, collect three
different flows and average the results.
Remove the fuel return flow hose and install the fuel drain
line banjo bolt. Refer to Procedure 006-013 in Section 6.
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Pressure Relief Valve
WARNING
personal injury.
WARNING
CAUTION
and engine.
• Clean the engine. Refer to Procedure 000-009 in
Section 0.
manual.
OEM service manual.
• Remove the fuel drain line from the fuel rail pressure
relief valve. Refer to Procedure 006-013 in Section 6.
• Remove the fuel pressure relief valve adapter and
copper seal washer.
Remove
Remove the fuel pressure relief valve.
Inspect for Reuse

If the fuel pressure relief valve exhibits excessive leakage
to drain, it must not be reused.
Inspect the high-pressure seal surface on the fuel
pressure relief valve and in the fuel rail for damage. Do
not reuse components if the high-pressure seal joint is
damaged.
Install
Install the fuel pressure relief valve and a new sealing
washer. Use assembly lubricant, Part Number 3163087 or
equivalent, on the threads.
If the reducer has been removed from the fuel rail
pressure relief valve, install the reducer with a new copper
seal washer.
Finishing Steps
WARNING
battery cable last.
• Install the fuel drain line to the fuel pressure relief
OEM service manual.
manual.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Cooler
Fuel Cooler (006-062)

General Information
QSL Engines
This procedure applies to QSL9 marine sea water cooled
(heat exchanger) engines only.
Preparatory Steps
QSL Engines
WARNING
CAUTION
CAUTION
Zinc plugs expand and can break off during removal.
Inspect the zinc plug to make sure it is in one piece. If
not, it must be replaced with a new zinc plug, and the
broken pieces must be retrieved from the aftercooler
to prevent damage to components downstream in the
sea water system.
NOTE: This procedure applies to QSL9 engines only.
Refer to Procedure 008-129 for QSC8.3 engines.
• Shut off the sea water supply valve(s). Refer to the
OEM service manual.
• Drain the sea water system by removing a zinc plug
from the aftercooler. Refer to Procedure 010-005.
• Shut off the fuel supply and return valves to the
engine. Refer to the OEM service manual.
• Disconnect the fuel drain line from the combined fuel
manifold to the fuel cooler at the fuel cooler
connection. Refer to Procedure 006-013.
• Disconnect the fuel drain line from the fuel cooler to
the fuel tanks.
Fuel Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
QSL Engines
Remove the hose clamps at the top and bottom of the fuel
cooler.
Remove the fuel cooler.

QSL Engines
Clean the hose sealing surfaces of the fuel cooler.
Inspect the core area of the fuel cooler for debris. Clean if
required.
Inspect the core for damage to the inter core surfaces.
Pressure test the fuel side of the fuel cooler.

Install a plug in one end of the cooler.
Install fittings and apply shop air pressure.
Air Pressure 172 kPa [ 25 psi ]
Place the cooler in a tank of water and check for leaks.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel Rail High Pressure Fitting
Install
QSL Engines
Install the fuel cooler into the sea water hoses.
Tighten the hose clamps.
Finishing Steps
QSL Engines
CAUTION
Failure to properly prime the fuel system on marine
engines can result in damage to the fuel cooler. Be
sure the drain valve(s) are open. Be sure a good flow
of fuel is present through the fuel cooler by cycling
the keyswitch at least five times before starting the
engine. Refer to Procedure 005-016.
• Connect the fuel drain line from the fuel cooler to the
fuel tanks. Refer to the OEM service manual.
• Connect the fuel drain line from the combined fuel
manifold to the fuel cooler at the fuel cooler
• Open the supply and return valves to the engine.
Refer to the OEM service manual.
• Open the sea water supply line(s). Refer to the OEM
service manual.
• Prime the fuel system. Refer to Procedure 005-016.
Fuel Rail High Pressure Fitting

(006-067)
Initial Check
WARNING
Operate the engine and check for external leaks.
Fuel Rail High Pressure Fitting ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Remove the high-pressure fitting only if a leak is
detected.
Install
Flush the outlet fitting using contact cleaner.
Apply Lubriplate™ to the high-pressure fitting threads.
Install the high-pressure fitting.
Reinstall the high-pressure fuel line. Refer to Procedure
006-051.
Operate the engine and check for leaks. If a leak occurs
after replacing the fitting, replace the rail.
Section 7 - Lubricating Oil System - Group 07 Page 7-a
Section 7 - Lubricating Oil System - Group 07

Section Contents
Page
Engine Oil Heater ........................................................................................................................................................7-2
Finishing Steps...........................................................................................................................................................7-3
Install..........................................................................................................................................................................7-2
Remove......................................................................................................................................................................7-2
Lubricating Oil and Filter Analysis ..........................................................................................................................7-49
Inspect......................................................................................................................................................................7-49
Lubricating Oil Contamination ................................................................................................................................ 7-47
Fluorescent Dye Tracer............................................................................................................................................7-47
Lubricating Oil Cooler ................................................................................................................................................7-3
Clean and Inspect for Reuse......................................................................................................................................7-5
Finishing Steps...........................................................................................................................................................7-7
Install..........................................................................................................................................................................7-6
Leak Test....................................................................................................................................................................7-6
Remove......................................................................................................................................................................7-5
Lubricating Oil Dipstick ..............................................................................................................................................7-8
Calibrate.....................................................................................................................................................................7-8
Lubricating Oil Dipstick Tube ....................................................................................................................................7-9
Finishing Steps.........................................................................................................................................................7-10
Install........................................................................................................................................................................ 7-10
Remove......................................................................................................................................................................7-9
Lubricating Oil Filter (Spin-On) ............................................................................................................................... 7-11
Install........................................................................................................................................................................ 7-12
Measure....................................................................................................................................................................7-11
Remove.................................................................................................................................................................... 7-12
Lubricating Oil Filter Bypass Valve ........................................................................................................................ 7-13
Finishing Steps.........................................................................................................................................................7-16
Install........................................................................................................................................................................ 7-15
Remove.................................................................................................................................................................... 7-14
Lubricating Oil Filter Head .......................................................................................................................................7-17
Finishing Steps.........................................................................................................................................................7-19
Install........................................................................................................................................................................ 7-18
Remove.................................................................................................................................................................... 7-18
Lubricating Oil Filter Head (Remote-Mounted) ......................................................................................................7-19
Assemble..................................................................................................................................................................7-21
Disassemble.............................................................................................................................................................7-20
Finishing Steps.........................................................................................................................................................7-22
Install........................................................................................................................................................................ 7-21
Remove.................................................................................................................................................................... 7-20
Lubricating Oil Filter Head Adapter ........................................................................................................................ 7-22
Finishing Steps.........................................................................................................................................................7-24
Install........................................................................................................................................................................ 7-23
Remove.................................................................................................................................................................... 7-23
Lubricating Oil High Pressure Relief Valve ............................................................................................................7-24
Page 7-b Section 7 - Lubricating Oil System - Group 07
Install........................................................................................................................................................................ 7-25
Remove.................................................................................................................................................................... 7-24
Lubricating Oil Leaks ............................................................................................................................................... 7-25
Initial Check..............................................................................................................................................................7-25
Lubricating Oil Lines ................................................................................................................................................7-51
Install........................................................................................................................................................................ 7-52
Remove.................................................................................................................................................................... 7-51
Lubricating Oil Pan ...................................................................................................................................................7-27
Finishing Steps.........................................................................................................................................................7-30
Install........................................................................................................................................................................ 7-29
Remove.................................................................................................................................................................... 7-27
Lubricating Oil Pressure Regulator (Main Rifle) ....................................................................................................7-30
Install........................................................................................................................................................................ 7-32
Remove.................................................................................................................................................................... 7-30
Lubricating Oil Pump ................................................................................................................................................7-32
Assemble..................................................................................................................................................................7-39
Disassemble.............................................................................................................................................................7-33
Finishing Steps.........................................................................................................................................................7-41
Install........................................................................................................................................................................ 7-39
Measure....................................................................................................................................................................7-34
Modify.......................................................................................................................................................................7-36
Remove.................................................................................................................................................................... 7-32
Lubricating Oil Suction Tube (Block-Mounted) ..................................................................................................... 7-42
Finishing Steps.........................................................................................................................................................7-44
Install........................................................................................................................................................................ 7-43
Remove.................................................................................................................................................................... 7-42
Lubricating Oil System .............................................................................................................................................7-44
Drain.........................................................................................................................................................................7-44
Fill.............................................................................................................................................................................7-45
Service Tools ..............................................................................................................................................................7-1
Lubricating Oil System................................................................................................................................................7-1
Section 7 - Lubricating Oil System - Group 07 Page 7-1
Service Tools
Lubricating Oil System
Repair Location.

Tube (Filter) Cutter
Used to cut open the filter to permit inspection of the filter element.
3376579
Lubricating Oil Cooler Pressure Test Kit

Used to seal and pressurize the lube oil cooler to test for leaks.
3823876 Requires regulated pressure supply, Part Number 3164231, or
equivalent (purchased separately).
Oil Filter Wrench

Used to remove the oil filter.
3375049
Black Light Lamp (12 VDC)

Black light with rechargeable battery and charger used with
3163338 fluorescent tracer, Part Number 3376891, to locate oil leaks.
Engine Oil Heater ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 7-2 Section 7 - Lubricating Oil System - Group 07
Engine Oil Heater (007-001)

Preparatory Steps
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
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
• Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
Remove
Disconnect the oil heater electrical cord.
Remove the heater element.
Install
Install the heater element.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Cooler
Finishing Steps
• Connect the oil heater electrical cord.
• Fill the engine with lubricating oil. Refer to Procedure
Lubricating Oil Cooler (007-003)

Preparatory Steps
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
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
WARNING
State and federal agencies have determined that used
engine oil can be carcinogenic and cause
• Drain the coolant. Refer to Procedure 008-018 in
Section 8.
• Clean the area around the lubricating oil cooler cover.
• Remove the coolant filter head. Refer to Procedure
• Remove the lubricating oil filter. Refer to Procedure
• Remove the turbocharger oil supply line. Refer to
Lubricating Oil Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
WARNING
WARNING
WARNING
WARNING
State and federal agencies have determined that used
engine oil can be carcinogenic and cause
CAUTION
Use caution when draining oil or replacing filters that
oil is not spilled or drained into the bilge area. The oil
and oil filters must be discarded in accordance with
local environmental regulations.
• Close the sea water supply and return valves. Refer to
the original equipment manufacturer (OEM) service
manual.
Section 8.
• Remove the heat exchanger/expansion tank
assembly, if equipped. Refer to Procedure 008-053 in
Section 8.
• Clean the area around the lubricating oil cover.
• Remove the heat exchanger coolant return
connection.
• Remove the turbocharger oil supply line. Refer to
Remove
Remove the lubricating oil cooler cover, gaskets and
cooler element.
WARNING
cleaning, follow the manufacturer’s recommendations
CAUTION
Use a solvent that will not harm copper to clean the
oil cooler elements.
Use solvent to clean the oil cooler housing and cover.
Clean the sealing surfaces of the cylinder block and the oil
cooler cover.
NOTE: Replace the elements if any debris is found or the
engine has had debris-causing damage.
Inspect the capscrews. If they are Grade 10.9 or higher,

they can be reused.
If the capscrews are lower than Grade 10.9, they must be
replaced with Grade 10.9 or higher capscrews.
Lubricating Oil Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
If any debris is suspected to have gone through the

engine or if troubleshooting a lubricating oil pressure
issue, remove and inspect the lubricating oil pressure
regulator located in the lubricating oil cooler cover.
Replace if necessary.
• For All Applications Except Marine: Refer to Procedure
• For Marine Applications: Refer to Procedure 007-029
in Section 7.
If any debris is suspected to have gone through the

engine, inspect the oil filter bypass valve located in the
lubricating cooler cover. Make sure the valve is fully
seated and opens and closes freely. Replace if
necessary.
The bypass valve requires a 345 kPa [50 psi] pressure
differential to open.
Leak Test
Use leak test kit, Part Number 3823876, to pressure-test
the lubricating oil cooler element.
Air Pressure Test

kPa psi
449 MIN 65
518 MAX 75
Install
NOTE: Be sure to remove the shipping plugs from a new
element.
Assemble the lubricating oil cooler gaskets, element, and
cooler cover.
If the oil cooler cover does not have a dimple, tighten the
capscrews in the sequence shown.
If the oil cooler cover does have a dimple, tighten the

capscrews in the sequence shown in the illustration, in
two steps. The arrow (A) points to the dimple.
Torque Value:
Step 1 24 N•m [ 212 in-lb ]
Step 2 32 N•m [ 24 ft-lb ]
Finishing Steps
• Install the turbocharger oil supply line. Refer to
• Install the lubricating oil filter. Refer to Procedure
• Install the coolant filter head. Refer to Procedure
• Fill the engine with coolant. Refer to Procedure
• Stop the engine and check the coolant and lubricating
oil level.
Lubricating Oil Dipstick ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
• Install the heat exchanger/expansion tank, if equipped.
• Install the heat exchanger coolant return line.
• Open the sea water supply line valves. Refer to the
OEM service manual.
• Stop the engine and check the coolant and lubricating
oil levels.
Lubricating Oil Dipstick (007-009)

Calibrate
WARNING
that used engine oil can be carcinogenic and can
cause reproductive toxicity. Avoid inhalation of
vapors, ingestion, and prolonged contact with used
engine oil. If not reused, dispose of in accordance
with local environmental regulations.
WARNING
Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
Install the dipstick in the dipstick tube housing.
Use clean lubricating oil to fill the oil pan to the specified
LOW oil level. Refer to Procedure 018-017 in Section V.
CAUTION
Use care when marking the dipstick. 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.
NOTE: If a new blank dipstick is being used, cut the
dipstick off approximately 38 mm [1.5 in] below the LOW
oil level mark.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Dipstick Tube
Wipe off the dipstick and install it in the dipstick tube

housing.
Use clean lubricating oil to fill the oil pan to the specified
HIGH oil level. Refer to Procedure 018-017 in Section V.
CAUTION
Use care when marking the dipstick. 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 H to indicate the
HIGH oil level.
Lubricating Oil Dipstick Tube

(007-011)
Preparatory Steps
• Clean the area around the dipstick tube before
removal to prevent debris from entering the oil system.
Remove
Remove the dipstick from the dipstick tube.
Remove the dipstick tube from the cylinder block.
Service Tip: Use a dent puller and a M8 x 1.25 x 21-mm
self-tapping capscrew. Thread the capscrew into the
dipstick tube and remove the tube.
Lubricating Oil Dipstick Tube ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Apply a thin bead of sleeve retaining compound, Part
Number 3823718 or equivalent, around the bottom of the
knurled end of the tube.
Place the knurled end of the tube into the dipstick tube
bore in the cylinder block.
Use a flat washer and hex head capscrew to drive the
tube into the cylinder block.
Lightly drive the dipstick tube until it seats against the
block casting.
Install the dipstick into the dipstick tube.
Finishing Steps
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter (Spin-On)
Lubricating Oil Filter (Spin-On)

(007-013)
Measure
Remove the oil plugs from the lubricating oil cooler
housing at the filter inlet and outlet pressure ports and
install manual gauges.
The following parts, or equivalent, are available for use:
Part Number Description
3377244 Compuchek™ fitting (1/8
inch 27 NPT)
3376920 Compuchek™ coupling
(1/4 inch pipe thread)
3164491 Electronic pressure
adapter for multimeter
(1/4-NPT pipe)
3164488 or 3164489 Electronic digital
multimeter
Engine Information
Oil Filter Type
Miles on Filter
Oil Type
Lubricating Oil Filter (Spin-On) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Operate the engine at each rpm indicated and record the corresponding pressure values:
Engine RPM Oil Pressure Oil Filter Inlet - Outlet = INSITE™
Filter Inlet Pressure Outlet Differential electronic service
Pressure 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.
Use the following procedure to check for possible fluid contamination. Refer to Procedure 007-083 in Section 7.
Change both the lubricating oil and the lubricating oil filter, if the filter is plugged.
See the following bulletin for additional information about lubricating oil filter plugging. Refer to Cummins® Engine Oil
and Oil Analysis Recommendations, Bulletin 3810340.
Remove
CAUTION
Use caution when replacing filters that oil is not
spilled or drained into the bilge area. Do not drop or
throw filter elements into the bilge area. The oil and
oil filters must be discarded in accordance with local
Clean the area around the lubricating oil filter head.
Use oil filter wrench, Part Number 3375049, to remove the
lubricating oil filter.
Clean the gasket surface of the filter head with a clean
lint-free cloth.
Install
CAUTION
The lubricating oil filter should be full of oil at start-up
to prevent engine damage.
Use clean 15W-40 oil to coat the gasket surface of the
filter.
Fill the filter with clean 15W-40 oil.
NOTE: Lubricating oil filters must have a filter bypass
valve. Using a lubricating oil filter without a filter bypass
valve will result in low engine oil pressure if the filter
becomes plugged.
Lubricating oil filter recommendations are provided. Refer
to Procedure 018-024 in Section V.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Bypass Valve
CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
Install the filter on the oil filter head. Tighten the filter until
the gasket contacts the filter head surface.
Use an oil filter wrench to tighten the filter. See the filter
manufacturer's instructions supplied with the filter.
CAUTION
If no oil pressure is noted within 15 seconds after the
engine is started, shut down the engine to reduce the
possibility of internal engine damage.
NOTE: Confirm that the oil pan has the correct oil level.
Lubricating Oil Filter Bypass Valve

(007-014)
General Information
If the pressure drop across the lubricating oil filter
exceeds a predetermined set point, 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 to prevent an oil filter collapse.
Lubricating Oil Filter Bypass Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
WARNING
CAUTION
Use caution when disconnecting or removing oil
filters and that oil is not spilled or drained into the
bilge area. Do not drop or throw filter elements into
the bilge area. The oil and oil filters must be
discarded in accordance with local environmental
regulations.
in Section 13.
• Remove the lubricating oil filter head. Refer to
• Remove the 3/4-inch pipe plug from the end of the oil
filter head.
Remove
Use a screwdriver to gently push down on the top of the
bypass valve to remove it from the bore.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Bypass Valve
WARNING
WARNING
WARNING
personal injury.
Clean the bypass valve with solvent.
Inspect the bypass valve seat for damage. Make sure the
valve fully closes.
Install
Insert the bypass valve into the bore. The spring should
be pointing upward into the bore.
Gently push the bypass valve into the bore until it seats.
Install the 3/4-inch pipe plug into the end of the oil filter
head.
Lubricating Oil Filter Bypass Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the lubricating oil filter head. Refer to Procedure
Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Head
Lubricating Oil Filter Head (007-015)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
WARNING
CAUTION
Use caution when draining coolant that coolant is not
spilled or drained into the bilge area. Do not pump the
coolant overboard. If the coolant is not reused, it
must be discarded in accordance with local
CAUTION
in Section 13.
Section 8.
• Remove the lubricating oil cooler. Refer to Procedure
Lubricating Oil Filter Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Remove the lubricating oil filter head adapter capscrews,
filter head adapter, and gasket.
WARNING
WARNING
Use solvent to clean the filter head adapter.
Inspect the filter head adapter for cracks and other

damage.
Install
Install the gasket, lubricating oil filter head adapter, and
capscrews.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Head (Remote-Mounted)
Finishing Steps
WARNING
battery cable last.
• Install the lubricating oil cooler. Refer to Procedure
• Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
Section 13.
Lubricating Oil Filter Head (Remote-

Mounted) (007-017)
Preparatory Steps
WARNING
WARNING
WARNING
battery cable last.
CAUTION
• Disconnect the battery. Refer to Procedure 013-009.
007-013.
• Disconnect the lubricating oil lines to the filter head.
Lubricating Oil Filter Head (Remote-Mounted) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Loosen, but do not remove, the inlet and outlet lubricating
oil filter head face seal connection locknuts.
Remove the four mounting capscrews and the lubricating

oil filter head.
Disassemble
CAUTION
To prevent the possibility of high filter restriction after
installation and causing filter damage, be sure to
mark the lubricating lines, oil filter head inlet and
outlet ports. Failure to do so can cause the center
filter media to break up and be pumped through the
engine.
Label the filter head connectors to identify the lubricating
oil connections and fitting orientation.
Remove the fittings from the lubricating oil filter head.
Inspect for Reuse

Inspect the lubricating oil filter head sealing surfaces and
bypass, if equipped.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Head (Remote-Mounted)
Assemble
Replace the compression o-ring seals and o-rings on all
face sealing connections.
Lubricate o-ring with clean engine oil.
Install the inlet and outlet connections into the filter heads.
Be sure the lubricating oil connections are orientated
correctly and they are installed to their proper depth.
Do not torque or tighten the fitting locknuts at this time.
Install
CAUTION
To prevent the possibility of high filter restriction after
installation and causing filter damage, be sure the
lubricating lines, oil filter head inlet and outlet ports
are orientated correctly to the bracket prior to
installation. Failure to do so can cause the center
filter media to break up and be pumped through the
engine.
Install the filter head assembly to the bracket and tighten
the capscrews.
Tighten the lubricating oil filter inlet and outlet connection

locking nuts.
Lubricating Oil Filter Head Adapter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the lubricating oil filter flex hoses to the face
seal connection and tighten the tube nuts finger
tight. Be sure the o-rings are in place and properly
located.
• Tighten the lubricating oil supply and return lines.
• Install a new lubricating oil filter. Refer to Procedure
007-013.
• Connect the battery. Refer to Procedure 013-009.
• Operate the engine and check for leaks and proper
oil pressure.
• Check the lubricating oil level.
Lubricating Oil Filter Head Adapter

(007-018)
Preparatory Steps
WARNING
WARNING
CAUTION
Use caution when disconnecting or removing
lubricating oil lines and replacing filters that oil is not
spilled or drained into the bilge area. Do not drop or
throw filter elements into the bilge area. The oil and
oil filters must be discarded in accordance with local
NOTE: The face seal washers can fall when removing the
oil lines. Use care not to damage or lose the washers.
• Clean the area around the lubricating oil cooler
cover.
• Tag for location and remove the lubricating oil lines
for the oil filter. Refer to Procedure 007-092.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Filter Head Adapter
Remove
Make a mark on the lubricating oil cooler housing filter
head adapter and the lubricating oil cooler housing to
align the filter head adapter during installation.
Remove the lubricating oil filter head adapter by removing
the center hose connection.
WARNING
WARNING
Use solvent to clean the parts.
Inspect the sealing surfaces for signs of leakage or burrs.

Use a fine crocus cloth to remove burrs.
Install
NOTE: Use new o-rings and seal rings when installing the
filter head adapter.
Install a new o-ring in the groove on the underside of the
filter head cover.
Install a small o-ring in the groove on the other side of the
filter head cover.
Lubricate the o-rings with clean 15W-40 engine oil or
Lubriplate™ multi-purpose lubricant.
Lubricating Oil High Pressure Relief Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install a new o-ring in the groove of the center hose

connector.
Lubricate the o-rings with clean 15W-40 engine oil or
Lubriplate™ multi-purpose lubricant.
Install the outer hose connector, on the oil filter adapter, to

the rear of the engine and align the marks made before
removal.
Push the center connector through the adapter and install
the filter head adapter to the engine.
Tighten the center connector while keeping the markings
made before the removal step aligned.
Finishing Steps
Install the lubricating oil lines for the oil filter. Refer to
Procedure 007-092.
Lubricating Oil High Pressure Relief

Valve (007-021)
Entfernen Sie
Remove the oil cooler bypass valve.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Leaks
Inspect for Reuse

Inspect for a damaged o-ring, broken spring or other
damage.
Install
Install the oil cooler bypass valve.
Lubricating Oil Leaks (007-024)

Initial Check
External
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
Use a steam cleaner or high-pressure washer to clean the
engine.
Add fluorescent tracer, Part Number 3376891, before

running the engine.
Use black light kit, Part Number 3163338, to help identify
the source of an oil leak.
The tracer will be highlighted by the black light to help
identify the source of the oil leak.
Lubricating Oil Leaks ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Operate the engine until the coolant temperature reaches

82°C [180°F]. If necessary, run the engine under load to
create the conditions of the oil leak. Perform stall tests or
a road test. Inspect the exterior of the engine for leaking
gaskets, seals, o-rings, pipe plugs, or fittings.
NOTE: Before replacing any gaskets, check the
capscrews to make sure they are tightened to the correct
torque values.
Inspect the engine crankcase breather tube and hose for

restriction or leaks. Refer to Procedure 003-018 in Section
3.
Check for a loose or missing oil dipstick tube, dipstick, or

oil fill cap.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Pan
Lubricating Oil Pan (007-025)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
NOTE: The engines use a variety of combinations of
gaskets and/or RTV for sealing. When installing the oil
pan, use the correct combinations of gaskets and/or RTV
that were on the pan.
Section 7.
Remove
Remove the lubricating oil pan and gasket/RTV.
Remove the suction tube, if necessary. Refer to
Remove the block stiffener plate. Reference Procedure
001-089 in Section 1, if equipped.
Lubricating Oil Pan ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
WARNING
personal injury.
Remove all gasket material from the cylinder block and
lubricating oil pan surface.
Steam clean the lubricating oil pan.
Inspect the oil pan, suction tube, and tube braces for
cracks or other damage.
NOTE: If cracks or other damage is found, replace the
damaged part. Do not attempt to repair the oil pan by
welding.
Use the following procedure if the suction tube must be
replaced. Refer to Procedure 007-035 in Section 7.
Composite Oil Pan Only

Make sure the bulkhead fitting is tight. If it is found to be
loose, replace the o-ring and tighten the bulkhead.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Pan
Install
NOTE: The engines use a variety of combinations of
gaskets and/or RTV for sealing. When installing the oil
pan, use the correct combinations of gasket and/or RTV
that were on the pan.
NOTE: To achieve a proper seal, never use an old
gasket.
Use RTV sealant, Part Number 3164067, or equivalent, to
fill the joints between the lubricating oil pan rail, gear
housing, and rear seal housing.
NOTE: Install three guide pins, Part Number 3164977, to
improve the alignment of the oil pan sealing components
to the cylinder block.
Install the suction tube, if applicable. Refer to Procedure
Install the block stiffener plate. Reference Procedure
001-089 in Section 1, if equipped.
Install the gasket and lubricating oil pan.

Install the oil pan corner braces, if equipped.
NOTE: New noise isolators must be used with oil pans
having the isolated gasket system.
Assemble the washers and capscrews to secure the

lubricating oil pan as illustrated.
Tighten all capscrews in the sequence shown in the
accompanying chart.
Lubricating Oil Pressure Regulator (Main Rifle) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Fill the lubricating oil system. Refer to Procedure
Lubricating Oil Pressure Regulator

(Main Rifle) (007-029)
Entfernen Sie
WARNING
WARNING
Thoroughly clean the area around the pressure regulator
plug with clean solvent to prevent debris from falling into
the plunger bore when the plug is removed.
Remove the threaded plug, spring, and plunger.

Service Tip: The plunger normally can be removed by
inserting one finger into the plunger bore until snug and
pulling down. If the plunger can not be removed in this
manner, the plunger is probably stuck and will require
removal of the housing for cleaning the plunger.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Pressure Regulator (Main Rifle)
WARNING
WARNING
WARNING
personal injury.
NOTE: If the plunger bore requires cleaning, remove the
housing to avoid flushing debris into the engine.
Thoroughly clean all components with clean solvent.
Inspect the plunger and plunger bore. Polished areas on

the plunger and bore are acceptable.
Verify that the plunger moves freely in the bore.
Lubricating Oil Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install a new sealing o-ring on the threaded plug and
lubricate with clean engine oil. Install the pressure
regulator assembly.
Lubricating Oil Pump (007-031)

Preparatory Steps
WARNING
battery cable last.
in Section 13.
• Remove the belt guard, if equipped. Refer to
• Remove the drive belt. Refer to Procedure 008-002 in
Section 8.
• On Marine engines, remove the belt tensioner. Refer
• Remove the rubber vibration damper, if installed. Refer
to Procedure 001-051 if installed, in Section 1.
• Remove the viscous vibration damper, if installed.
Refer to Procedure 001-052 if installed, in Section 1.
• Remove the front cover. Refer to Procedure 001-031
in Section 1.
Remove
Remove the four mounting capscrews.
Remove the lubricating oil pump from the bore in the
cylinder block.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Pump
Disassemble
If the lubricating oil pump is to be inspected for reuse,
follow these steps.
Inspect the lubricating oil pump gears for chips, cracks, or
excessive wear.
Remove the back plate.

NOTE: The ISC, QSC8.3, ISL, and QSL9 lubricating oil
pump uses a large diameter 5/6 rotor set. The graphics in
this manual illustrate a 4/5 rotor set.
Mark TOP on the gerotor planetary.
Remove the gerotor planetary.
WARNING
WARNING
WARNING
personal injury.
Clean all parts in solvent.
Inspect the lubricating oil pump housing, gerotor drive,

and gerotor for damage and excessive wear.
Measure
CAUTION
Make sure that the gerotor planetary is installed in the
original position.
Install the gerotor planetary.
Measure the tip clearance.
Tip Clearance
mm in
0.0254 MIN 0.001
0.1778 MAX 0.007
Replace the lubricating oil pump if the tip clearance is out
of specification.
Measure the clearance of the gerotor drive/gerotor

planetary to port plate.
Gerotor Drive/Gerotor Planetary to Port Plate

Clearance
mm in
0.0254 MIN 0.001
0.1270 MAX 0.005
Replace the lubricating oil pump if the geroter drive/
geroter planetary to port plate clearance is out of
specification.
Measure the clearance of the gerotor planetary to the

body bore.
Gerotor Planetary to Body Bore Clearance

mm in
0.1778 MIN 0.007
0.3810 MAX 0.015
Replace the lubricating oil pump if the geroter planetary to
body bore clearance is out of specification.
Measure the backlash.
Lubricating Oil Pump Gears Backlash Limits (Used

Pump)
mm in
0.0762 MIN 0.003
0.3302 MAX 0.013
NOTE: Hold the adjoining gears to keep them from
moving when checking backlash or else the reading will
be the total of both gears.
Replace the lubricating oil pump if the gear backlash is
out of specification.
Modify
If a customer reports high oil pressure on an ISC engine
with an engine serial number (ESN) less than 45803926,
follow the instructions outlined below. If a customer
reports high oil pressure on an ISC engine with an ESN
greater than 45803925, see the following symptom tree
t104 (Lubricating Oil Pressure High) to locate the source
of the high lubricating oil pressure in the Troubleshooting
and Repair Manual, ISC, ISCe, QSC8.3, ISL, ISLe3,
ISLe4, and QSL9 Engines, Bulletin 4021418.
Instructions to modify the ISC Engine from Dump-to-Pump
to Dump-to-Sump.
Required materials:
• New pressure regulator plunger
• Long 13 mm [1/2-in] drill bit (preferably 203 mm [8 in])
• Loctite™ Blue, or equivalent (not shown)
• 9/16-inch x 18 tap
• 9/16-inch x 18 STOR plug
• Tap Magic or other cutting fluid (not shown).
WARNING
Coolant Is toxic. Keep away from pets and children. If
not reused, dispose of In accordance with local
WARNING
Wait until the temperature is below 49°C [120°F] to
avoid personal injury from hot coolant.
Drain the coolant. Refer to Procedure 008-018 in Section
8.
WARNING
WARNING
Drain the lubricating oil and then remove the lubricating oil
pan and gasket. Refer to Procedure 007-037 and Refer to
Remove the lubricating oil cooler. Refer to Procedure

Use a long 1/2-inch drill bit to drill out the angled hole at
the bottom of the oil cooler cavity in the block. This is the
left most of the two holes located on the bottom of the oil
cooler cavity on the gasket surface of the block. Make
sure to apply sufficient cutting fluid to cool the bit, and
remove the drill frequently to clear debris from the hole.
There is approximately 30 mm (1 .18 in) of material to drill
through.
CAUTION
Any burrs or sharp edges must be removed prior to
installing the STOR plug so that damage to the o-ring
will not occur.
Use a 9/16-inch x 18 tap to tap the hole in the lower
lubricating oil pump cavity. This passage is the original
dump-to-pump circuit to the lubricating oil pump.
CAUTION
Any material left In the lubricating oil system after this
modification will cause engine damage.
Thoroughly clean the angled dump-to-pump drilling, the
tapped hole, and the inside block wall.
Coat the threads of the 9/16-inch x 18 STOR plug with

Loctite™ Blue, or equivalent.
Install the plug in the tapped hole.
Install the lubricating oil cooler. Refer to Procedure

NOTE: The pressure regulator plunger shown in this

illustration is the old-style pressure regulator plunger.
Remove the old pressure regulator plunger and install the
new plunger. Refer to Procedure 007-029 in Section 7.
Install the lubricating oil pan and gasket Refer to

Fill the engine with coolant. Refer to Procedure 008-018 in

Section 8.
Fill the engine with lubricating oil. Refer to Procedure

Crank the engine without starting until lubricating oil
pressure registers on the lubricating oil pressure gauge.
Assemble
Install the back plate.
Install
CAUTION
Failure to fill the pump with oil at installation can
result in the lubricating oil pump not priming at initial
engine start-up, resulting in severe engine damage.
Lubricate the lubricating oil pump with clean 15W-40
engine oil.
CAUTION
Make sure the idler gear pin is installed in the locating
bore in the cylinder block.
Install the lubricating oil pump.
Tighten the capscrews in a crisscross pattern, starting

with the upper right capscrew.
NOTE: Be sure the gear backlash is correct if installing a

new lubricating oil pump.
Measure the gear backlash.
Lubricating Oil Pump Gears Backlash Limits

(Installed)
mm in
A 0.0762 MIN 0.003
0.3302 MAX 0.013
B 0.0762 MIN 0.003
0.3302 MAX 0.013
NOTE: If the adjoining gear moves when you measure the
backlash, the reading will be incorrect.
Lubricate the front gear train with clean 15W-40 engine

oil.
CAUTION
The seal lip and the sealing surface on the crankshaft
must be free from all oil residue to prevent seal leaks.
Thoroughly clean the front seal area of the crankshaft.
NOTE: Always replace the front seal when removing and
installing the front cover. Refer to Procedure 001-031 in
Section 1.
Finishing Steps
WARNING
battery cable last.
• Install the front cover. Refer to Procedure 001-031 in
Section 1.
• Install the rubber vibration damper, if removed. Refer
• Install the viscous vibration damper, if removed. Refer
• On Marine engines, install the belt tensioner. Refer to
• Install the drive belt. Refer to Procedure 008-002 in
Section 8.
• Install the belt guard, if equipped. Refer to Procedure
Section 13.
Lubricating Oil Suction Tube (Block-Mounted) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
in Section 13.
Section 7.
• Remove the lubricating oil pan and gasket. Refer to
Remove
Remove the lubricating oil suction tube.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Suction Tube (Block-Mounted)

Clean the gasket surfaces.
Inspect the suction tube for cracks.
Install
Install the lubricating oil suction tube and new gasket.
• Install all capscrews finger tight and check for correct
alignment.
• Torque the lubricating oil suction tube to the block.
• Torque the lubricating oil suction tube brace to the
engine block.
• Torque the lubricating oil suction tube to the brace.
Use RTV sealant, Part Number 3164067, or equivalent, to

fill the joints between the lubricating oil pan rail, gear
housing, and rear seal housing.
Lubricating Oil System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the lubricating oil pan and gasket. Refer to
• Fill the lubricating oil system. Refer to Procedure
Section 13.
Lubricating Oil System (007-037)

Drain
WARNING
WARNING
NOTE: Use a container that can hold at least 23.6 liters
[25 qt] of lubricating oil.
• Operate the engine until the coolant temperature
reaches 60°C [140°F]. Shut the engine OFF.
• Remove the oil drain plug.
• Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the
engine.
• If performing an oil drain as part of a service
maintenance interval, remove and replace the oil filter.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil System
Marine Applications
WARNING
WARNING
CAUTION
NOTE: Use a container that can hold at least 23.6 liters
[25 qt] of lubricating oil.
• Operate the engine until the coolant temperatures
60°C [140°F]. Shut off the engine.
• Place the lubricating oil pump-out device hose, if
equipped, into a suitable container to hold the used
lubricating oil.
• Open the inlet valve to the lubricating oil pump-out
device.
• Start the pump-out device and drain the lubricating oil
from the engine immediately to be sure all of the
lubricating oil and suspended contaminants are
removed from the engine.
• Shut off the pump-out device after all of oil has been
drained.
• If an oil pump-out device was used, close the inlet
valve.
Fill
Clean and check the lubricating oil drain plug threads and
sealing surface.
Install the lubricating oil pan drain plug.
Torque Value:
Steel Oil Pan 80 N•m [ 59 ft-lb ]
Torque Value:
Cast Aluminum Oil Pan 60 N•m [ 44 ft-lb ]
Torque Value:
Composite Oil Pan 60 N•m [ 44 ft-lb ]
NOTE: Use a high quality 15W-40 multi-viscosity oil, such

as Cummins® Premium Blue™, or equivalent, in
Cummins® engines. Choose the correct oil for your
operating climate as outlined in the Section V.
Fill the engine with clean lubricating oil to the proper level.
NOTE: When filling the oil pan, use the fill tube on the
side of the engine rather than on top of the rocker lever
cover.
NOTE: White, tan, or brown foam or froth is sometimes
found under the oil fill cap, inside the valve cover, or in the
crankcase breather. Foam or froth can occur if the engine
operates below thermostat opening temperature for
sustained periods. This type of foam or froth will not affect
the function of the engine. Foam or froth can also occur if
there is an internal coolant leak. If an internal coolant leak
is suspected, perform the Coolant Leak - Internal
troubleshooting tree.
Verify lubricating oil pan capacities. Refer to Procedure
018-017 in Section V.
CAUTION
If no oil pressure is noted within 15 seconds after the
engine is started, shut down the engine to reduce the
possibility of internal engine damage.
Idle the engine to inspect for leaks at the drain plug.
Shut the engine OFF. Wait approximately 10 minutes to

let the oil drain from the upper parts of the engine. Check
the level again.
Add oil as necessary to bring the oil level to the "H" (high)
mark on the dipstick.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Contamination
Lubricating Oil Contamination

(007-044)
General Information
A used oil analysis can help diagnose internal damage
and determine if it was caused by one of the following:
• Oil diluted with coolant
• Oil diluted with fuel.
Fluorescent Dye Tracer

NOTE: This test is not effective on a cold engine, less
than 21°C [70°F] coolant temperature, or with a loose
overhead setting.
Install an isolated fuel supply tank at the fuel inlet supply
line and at the fuel drain line.
Add fluorescent tracer, Part Number 3376891, to the
isolated fuel supply tank. Reference the instructions on
the fluorescent tracer bottle for the proper tracer-to-fuel
ratio.
CAPS Fuel System

• Start the engine.
• Operate the engine at idle for 6 minutes.
• Shut the engine down.
NOTE: Do not allow the engine to operate from a remote
fuel source for more than 10 minutes.

• Connect INSITE™ electronic service tool.
• Start the engine.
• Operate the engine at idle for 3 minutes.
• After 3 minutes, use INSITE™ electronic service tool
High-Pressure Leakage Test to create high fuel rail
pressure.
• Operate the engine at high fuel pressure for 3 minutes.
• Shut the engine down.
NOTE: Do not allow the engine to operate from a remote

fuel source for more than 10 minutes.
Lubricating Oil Contamination ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
Normal engine operation creates highly pressurized
fuel in the fuel line which will remain in the fuel line
after engine shutdown. Never open the fuel system
when the engine is operating. Before servicing the
fuel system, always loosen the pump to rail fuel line
at the rail to vent the pressure. Keep hands clear of
the line when loosening. High pressure fuel spray can
penetrate the skin, resulting in serious personal injury
or death.
Remove the fuel pump head or accumulator.
Use the following procedure for CAPS Fuel System. Refer
Use the following procedure for Cummins® Common Rail
Fuel System. Refer to Procedure 005-227 in Section 5.
Use a black light, Part Number 3163337, to inspect the
fuel pump head and camshaft housing for signs of fuel.
Fuel will appear to be yellow.
NOTE: A small amount of fuel on the pumping plungers is
normal.
If there are signs of a significant amount of fuel in the
camshaft housing or on the fuel pump head, replace the
fuel pump head.
Install the fuel pump head or accumulator.
Use the following procedure for CAPS Fuel System. Refer
Use the following procedure for Cummins® Common Rail
Fuel System. Refer to Procedure 005-227 in Section 5.
Remove the rocker lever cover. Refer to Procedure

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil and Filter Analysis
Use a black light to find fuel leaks from inside or around

the injectors.
Fuel will appear to be yellow.
If there is excess leakage around the outside of the

injector,
• Check the injector hold-down clamp capscrew torque.
• Remove the injectors and inspect the injector o-rings
and injector body for damage.
• Replace the injector o-rings and the injector sealing
washers if the injector is reinstalled.
• Replace the injector if injector body damage is
present.
Install the rocker lever cover. Refer to Procedure 003-011

in Section 3.
Lubricating Oil and Filter Analysis

(007-083)
Inspect
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.
Lubricating Oil and Filter Analysis ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
For additional oil analysis information, refer to Cummins®

Engine Oil and Oil Analysis Recommendations, Bulletin
3810340.
NOTE: Do not disassemble an engine for repair based
solely on the results of an oil analysis. Inspect the oil
filters. If an oil filter shows evidence of internal engine
damage, find the source of the problem and repair the
damage. Reference the appropriate procedure(s) based
on the following oil filter inspection.
WARNING
Restrain the full flow lubricating oil filter and use care
when cutting open the upper section of the
combination filter. The filter element spring is under
compression and can cause personal injury.
Use tube cutter, Part Number 3376579, to open the upper

section of the bypass full-flow oil filter.
Inspect the filter element for evidence of moisture or metal
particles.
Metal Possible Source

Copper Bearings and bushings
Chromium Piston rings
Iron Cylinder liners
Lead Bearing overlay material
Aluminum Piston wear or scuffing
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Lines
Lubricating Oil Lines (007-092)

Entfernen Sie
WARNING
WARNING
CAUTION
Use caution when draining oil that oil is not spilled or
drained into the bilge area. The oil must be disposed
CAUTION
Before disconnecting the lubricating oil lines, tag the
oil lines for correct location to prevent filter and
engine damage due to incorrect installation.
Verify and mark the hoses and adapter head for correct
location.
A Oil inlet
B Oil outlet.
Disconnect the lubricating oil lines from the lubricating oil
cooler housing filter adapter.
Lubricating Oil Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
WARNING
CAUTION
Use caution when draining oil that oil is not spilled or
drained into the bilge area. The oil must be disposed
CAUTION
Before disconnecting the lubricating oil lines, tag the
oil lines for correct location to prevent filter and
engine damage due to incorrect installation.
Verify and mark the hoses and oil filter head for correct
location.
A Oil outlet
B Oil inlet.
Disconnect the lubricating oil lines from the lubricating oil
filter head.
Inspect for Reuse

Inspect the hoses and o-ring sealing surfaces for damage.
Install
CAUTION
When installing the lubricating oil lines, make sure
the oil lines are not touching or rubbing each other or
any other engine parts. Damage to the lines can result
in a loss of engine lubricating oil pressure.
Install the hoses to the lubricating oil filter adapter head
and tighten finger tight.
A Oil inlet
B Oil outlet.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil Lines
Install the hoses on the remote oil filter head and tighten
finger tight.
a Oil outlet
B Oil inlet.
Verify the correct location of the oil lines on the adapter
plate and remote oil filter housing.
Torque the hoses on the adapter plate and the remote oil
filter head.
Operate the engine and check for leaks and proper oil
pressure.
Shut down the engine and check the oil level; add
lubricating oil as necessary.
Lubricating Oil Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Notes
Section 8 - Cooling System - Group 08 Page 8-a
Section 8 - Cooling System - Group 08

Section Contents
Page
Belt Guard ....................................................................................................................................................................8-3
Inspect for Reuse........................................................................................................................................................8-3
Install..........................................................................................................................................................................8-4
Remove......................................................................................................................................................................8-3
Belt Tensioner, Automatic (Water Pump) .............................................................................................................8-119
Finishing Steps.......................................................................................................................................................8-123
Initial Check............................................................................................................................................................8-119
Inspect for Reuse....................................................................................................................................................8-121
Install......................................................................................................................................................................8-122
Preparatory Steps...................................................................................................................................................8-121
Remove..................................................................................................................................................................8-121
Bracket, Fan Idler Pulley ........................................................................................................................................8-138
Finishing Steps.......................................................................................................................................................8-139
Install......................................................................................................................................................................8-139
Remove..................................................................................................................................................................8-138
Coolant Filter .............................................................................................................................................................8-11
Install........................................................................................................................................................................ 8-12
Remove.................................................................................................................................................................... 8-11
Coolant Filter Head ...................................................................................................................................................8-14
Finishing Steps.........................................................................................................................................................8-17
Install........................................................................................................................................................................ 8-16
Remove.................................................................................................................................................................... 8-15
Coolant Filter Valve .................................................................................................................................................. 8-18
Finishing Steps.........................................................................................................................................................8-21
Install........................................................................................................................................................................ 8-20
Remove.................................................................................................................................................................... 8-19
Coolant Heater .......................................................................................................................................................... 8-22
Clean........................................................................................................................................................................ 8-23
Finishing Steps.........................................................................................................................................................8-24
Install........................................................................................................................................................................ 8-23
Remove.................................................................................................................................................................... 8-22
Coolant Return Junction Block .............................................................................................................................8-140
Clean and Inspect for Reuse..................................................................................................................................8-141
Finishing Steps.......................................................................................................................................................8-143
Install......................................................................................................................................................................8-142
QSL Engines........................................................................................................................................................8-142
QSC Engines.......................................................................................................................................................8-142
Remove..................................................................................................................................................................8-140
QSL Engines........................................................................................................................................................8-140
QSC Engines.......................................................................................................................................................8-141
Coolant Thermostat ..................................................................................................................................................8-24
Finishing Steps.........................................................................................................................................................8-32
Install........................................................................................................................................................................ 8-31
Leak Test..................................................................................................................................................................8-25
Remove.................................................................................................................................................................... 8-29
Coolant Thermostat Housing ...................................................................................................................................8-32
Page 8-b Section 8 - Cooling System - Group 08
Assemble..................................................................................................................................................................8-36
QSL Engines..........................................................................................................................................................8-36
QSL Engines..........................................................................................................................................................8-35
Disassemble.............................................................................................................................................................8-35
QSL Engines..........................................................................................................................................................8-35
Finishing Steps.........................................................................................................................................................8-37
QSL Engines..........................................................................................................................................................8-37
QSL Engines..........................................................................................................................................................8-32
Install........................................................................................................................................................................ 8-36
QSL Engines..........................................................................................................................................................8-36
Leak Test..................................................................................................................................................................8-34
QSL Engines..........................................................................................................................................................8-34
QSL Engines..........................................................................................................................................................8-33
Remove.................................................................................................................................................................... 8-33
QSL Engines..........................................................................................................................................................8-33
Coolant Thermostat Housing Support ....................................................................................................................8-37
QSL Engines..........................................................................................................................................................8-38
Finishing Steps.........................................................................................................................................................8-39
QSL Engines..........................................................................................................................................................8-39
QSL Engines..........................................................................................................................................................8-37
Install........................................................................................................................................................................ 8-39
QSL Engines..........................................................................................................................................................8-39
QSL Engines..........................................................................................................................................................8-37
Remove.................................................................................................................................................................... 8-38
QSL Engines..........................................................................................................................................................8-38
Coolant Thermostat Seal ..........................................................................................................................................8-39
Finishing Steps.........................................................................................................................................................8-41
Install........................................................................................................................................................................ 8-40
Marine Applications............................................................................................................................................... 8-39
Remove.................................................................................................................................................................... 8-40
Coolant Vent Lines ................................................................................................................................................... 8-41
Finishing Steps.........................................................................................................................................................8-45
Install........................................................................................................................................................................ 8-43
Remove.................................................................................................................................................................... 8-42
Cooling System .........................................................................................................................................................8-45
Coolant Replacer Method.........................................................................................................................................8-45
Drain.........................................................................................................................................................................8-52
Fill.............................................................................................................................................................................8-53
Flush.........................................................................................................................................................................8-53
Cooling System Diagnostics ................................................................................................................................... 8-57
Analyzing the Data....................................................................................................................................................8-73
Initial Check..............................................................................................................................................................8-63
Pressure Test........................................................................................................................................................... 8-64
Setup........................................................................................................................................................................ 8-68
Test...........................................................................................................................................................................8-68
Worksheet.................................................................................................................................................................8-74
Drive Belt, Cooling Fan ..............................................................................................................................................8-5
Clean and Inspect for Reuse......................................................................................................................................8-8
Finishing Steps.........................................................................................................................................................8-10
General Information....................................................................................................................................................8-5
Install........................................................................................................................................................................ 8-10
Remove......................................................................................................................................................................8-8
Section 8 - Cooling System - Group 08 Page 8-c
Troubleshooting..........................................................................................................................................................8-5
Expansion Tank ........................................................................................................................................................8-93
Finishing Steps.........................................................................................................................................................8-97
QSL Engines..........................................................................................................................................................8-97
Initial Check..............................................................................................................................................................8-94
QSL Engines..........................................................................................................................................................8-94
QSL Engines..........................................................................................................................................................8-96
Install........................................................................................................................................................................8-96
QSL Engines..........................................................................................................................................................8-96
QSL Engines..........................................................................................................................................................8-94
Remove....................................................................................................................................................................8-95
QSL Engines..........................................................................................................................................................8-95
Fan Clutch, On-Off ....................................................................................................................................................8-75
Fan Shroud Assembly ..............................................................................................................................................8-76
Initial Check..............................................................................................................................................................8-76
Fan Spacer and Pulley .............................................................................................................................................8-76
Finishing Steps.........................................................................................................................................................8-78
Install........................................................................................................................................................................8-78
Remove....................................................................................................................................................................8-77
Fan, Cooling ..............................................................................................................................................................8-78
Finishing Steps.........................................................................................................................................................8-80
Install........................................................................................................................................................................8-80
Remove....................................................................................................................................................................8-79
Heat Exchanger .........................................................................................................................................................8-97
Assemble................................................................................................................................................................8-102
Disassemble...........................................................................................................................................................8-101
Finishing Steps.......................................................................................................................................................8-104
Install......................................................................................................................................................................8-103
Pressure Test.........................................................................................................................................................8-102
Remove....................................................................................................................................................................8-99
Keel Cooler ..............................................................................................................................................................8-125
General Information................................................................................................................................................8-125
QSL Engines........................................................................................................................................................8-125
Pressure Differential Test.......................................................................................................................................8-126
QSL Engines........................................................................................................................................................8-126
Temperature Differential Test.................................................................................................................................8-125
QSL Engines........................................................................................................................................................8-125
Marine Gear Oil and Fuel Cooler Assembly .........................................................................................................8-143
Assemble................................................................................................................................................................8-148
Disassemble...........................................................................................................................................................8-146
Finishing Steps.......................................................................................................................................................8-150
Flush.......................................................................................................................................................................8-143
Install......................................................................................................................................................................8-149
Remove..................................................................................................................................................................8-145
Marine Gear Oil Cooler .............................................................................................................................................8-81
Assemble..................................................................................................................................................................8-88
QSL Engines..........................................................................................................................................................8-88
QSC Engines.........................................................................................................................................................8-88
Disassemble.............................................................................................................................................................8-84
QSL Engines..........................................................................................................................................................8-84
Page 8-d Section 8 - Cooling System - Group 08
QSC Engines.........................................................................................................................................................8-84
Finishing Steps.........................................................................................................................................................8-90
Flush.........................................................................................................................................................................8-81
QSL Engines..........................................................................................................................................................8-84
QSC Engines.........................................................................................................................................................8-86
Install........................................................................................................................................................................8-88
QSL Engines..........................................................................................................................................................8-88
QSC Engines.........................................................................................................................................................8-89
Remove....................................................................................................................................................................8-83
QSL Engines..........................................................................................................................................................8-83
QSC Engines.........................................................................................................................................................8-83
Pulley, Fan Idler ......................................................................................................................................................8-137
Finishing Steps.......................................................................................................................................................8-138
Install......................................................................................................................................................................8-138
Remove..................................................................................................................................................................8-137
Radiator .....................................................................................................................................................................8-90
Initial Check..............................................................................................................................................................8-90
Radiator Hoses .........................................................................................................................................................8-91
Radiator Pressure Cap .............................................................................................................................................8-91
Radiator Shutter Assembly ......................................................................................................................................8-93
Sea Water Hoses .....................................................................................................................................................8-136
Inspect....................................................................................................................................................................8-136
Sea Water Pump .....................................................................................................................................................8-104
Finishing Steps.......................................................................................................................................................8-111
Initial Check............................................................................................................................................................8-104
Install......................................................................................................................................................................8-110
Remove..................................................................................................................................................................8-109
Repair.....................................................................................................................................................................8-106
Sea Water Strainer ..................................................................................................................................................8-116
Assemble................................................................................................................................................................8-118
Marine Applications.............................................................................................................................................8-118
Clean......................................................................................................................................................................8-118
Disassemble...........................................................................................................................................................8-117
Prime......................................................................................................................................................................8-118
Sea Water System Diagnostics .............................................................................................................................8-127
Initial Check............................................................................................................................................................8-127
Pressure Differential Test.......................................................................................................................................8-131
QSL Engines........................................................................................................................................................8-131
QSC Engines.......................................................................................................................................................8-133
Pressure Test.........................................................................................................................................................8-130
QSL Engines........................................................................................................................................................8-134
QSC Engines.......................................................................................................................................................8-135
Test.........................................................................................................................................................................8-128
Service Tools ..............................................................................................................................................................8-1
Cooling System...........................................................................................................................................................8-1
Water Inlet Connection ...........................................................................................................................................8-123
Section 8 - Cooling System - Group 08 Page 8-e

Finishing Steps.......................................................................................................................................................8-125
Install......................................................................................................................................................................8-124
Remove..................................................................................................................................................................8-124
Water Pump .............................................................................................................................................................8-113
Finishing Steps.......................................................................................................................................................8-116
Install......................................................................................................................................................................8-115
Remove..................................................................................................................................................................8-114
Zinc Anode ..............................................................................................................................................................8-111
Install......................................................................................................................................................................8-112
Remove..................................................................................................................................................................8-111
Page 8-f Section 8 - Cooling System - Group 08

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

Combustion Gas Leak Test Kit
Used to detect leaks. Includes Part Number 3822986, test fluid, Part
3822985 Number 3822987, adapter, and Part Number 3877612, instructions.
Cooling System Test Kit

The Fleetguard® coolant test kit is used to check the concentration of
coolant additives in the cooling system.
CC-2626
Refractometer
The Fleetguard® refractometer is used to measure the freezing point
CC-2800 protection and antifreeze concentration.
Engine Coolant Analyzer

The Engine Coolant Analyzer is used to troubleshoot pressure loss,
3822994 restriction, and improper temperature control.
Belt Tension Gauge

Used to measure the tension in the drive belt.
ST 1293
Thermostat Seal Mandrel

Used to install new thermostat seals on QSL9 marine keel cooled
3375411 engines.
Page 8-2 Section 8 - Cooling System - Group 08

Coolant Dam/Pressure Tester
Using shop air pressure, the coolant dam creates a vacuum, holding
3824319 the coolant in with little or no coolant loss.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Belt Guard
Belt Guard (008-001)

Entfernen Sie
Remove the four fasteners on the belt guard.
Remove the belt guard.
Remove the four rubber isolators from the belt guard

mounting studs.
Remove the four studs.

Remove the two mounting capscrews and the belt guard
mounting bracket.
Inspect for Reuse

Inspect the belt guard and bracket for cracks or other
damage. If damaged, they must be replaced.
Inspect the isolators for damage. If the isolators are hard
and brittle, they must be replaced.
If damaged or bent, replace the belt guard studs.
Belt Guard ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install the belt guard mounting bracket and tighten the two
capscrews.
Install and tighten the four studs.
Install the four rubber isolators onto the four studs.
Align the belt guard holes and install the belt guard.
Install and tighten the wing nuts finger tight.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Drive Belt, Cooling Fan
Drive Belt, Cooling Fan (008-002)

General Information
Due to the number of drive belt arrangements, this
procedure does not cover all available cooling fan drive
belt routing.
To make sure the cooling fan drive belt is routed correctly
upon installation, make a diagram of the cooling fan belt
routing prior to removing the belt, as shown in the
illustration.
The cooling fan belt routing typically consists of the
following components, but may not include all of them:
1 Crankshaft pulley/vibration damper
2 Fan pulley
3 Water pump pulley
4 Refrigerant compressor pulley
5 Alternator pulley
6 Belt tensioner pulley.
NOTE: Some engine-driven belts are installed/supplied by
the vehicle original equipment manufacturer (OEM). See
the OEM service manual for removal and installation
instructions.
Troubleshooting
NOTE: This content in this section is generic and may not apply to all available cooling fan drive belt systems.
The following section contains diagnostic information and procedures to aid in identifying drive belt and accessory
drive issues. These issues may include:
• Belt noise (squeal and chirp)
• Belt tracking (jumping)
• Belt fraying
• Snub breaks and punctures.
Common causes of drive belt noise, fraying, and breaks are:
• Drive pulley misalignment
• Embedded debris in drive pulley grooves
• Incorrect belt material and/or belt length
• Damaged or incorrect automatic belt tensioner
• Improper drive belt routing
• Improper fan size and/or fan clutch.
The original drive belt and tensioner should be used, if possible, while troubleshooting drive belt issues. Replacement
of a belt and/or tensioner prior to troubleshooting may mask the root cause of the issue due to the break-in time
required for a belt and tensioner.
Drive Belt, Cooling Fan ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
NOTE: A newly installed belt and/or tensioner will not

come to rest properly until the engine is operated. Always
operate the engine for a brief period of time prior to
verifying the tensioner resting location.
Inspect the automatic belt tensioner. Refer to Procedure
008-080 in Section 8. If the belt tensioner does not meet
the reuse criteria, the belt tensioner must be replaced.
With the belt installed, check the automatic belt tensioner
resting position. If the belt tensioner arm stop is contacting
either of the spring case stops:
• Verify the correct belt part number is installed
• If the correct belt is installed, replace the belt.
Verify all accessory drive components and pulleys are

correct. Components yielding incorrect part numbers, or
installed without the appropriate spacers and/or brackets
may contribute to gross drive belt misalignment.
Verify proper drive belt routing, if available. Refer to the
OEM service manual.
Isolating the source of drive belt noise may be done by

use of an electronic stethoscope, or an equivalent device
designed to block audible noise other than that desired,
by use of a microphone.
Drive belt noise may be difficult to isolate and

troubleshoot. The origin of drive belt noise may not be
located at the pulley out of alignment, rather ‘upstream’
from the noise origin.
Troubleshooting should always be completed in a
direction opposite belt travel (i.e. counter clockwise)
beginning at the pulley where the noise originates.
Arrow number (1) indicates belt travel direction, whereas
arrow number (2) represents the direction in which
troubleshooting should be conducted.
• Flat pulleys should be inspected for uneven wear
patterns
• Grooved pulleys should be inspected for embedded
debris, belt dust buildup, and pulley alignment.
NOTE: The belt alignment laser tool can identify

misalignment of pulleys down to ½ of a belt rib. The
capability of the alignment fixture is contingent upon
proper calibration. Make sure all set-up and calibration
procedures are followed before verifying pulley alignment.
Use a Belt Alignment Laser Tool, Part Number 3163524,
or equivalent, to verify all pulleys are aligned correctly.
Pulley alignment should always be checked from the fan
pulley, and crankshaft pulley to other front end mounted
grooved pulleys. Contact a Cummins® Authorized Repair
Location for drive belt alignment.
If a pulley is identified as out of alignment, verify the

component mounting bracket installation.
Certain engines feature an automatic belt tensioner
mounted to the water inlet connection. Verify the locating
roll pins (1) are:
• Installed into the connection
• In contact with the cylinder block
• Do not appear to be bent or out of place.
If the water inlet connection and/or roll pins are not
installed correctly, remount the water inlet connection.
Certain alternator mounting brackets are aligned to the

cylinder head by roll pins. Verify the locating roll pins (1)
are:
• Installed into the alternator bracket
• In contact with the cylinder head
• Do not appear to be bent or out of place.
If the alternator bracket and/or roll pins are not installed
correctly, remount the alternator bracket. Refer to
Check drive pulley alignment with the belt alignment laser

tool, Part Number 3163524, or equivalent, after any
bracket adjustments are made.
Certain ‘pad mounted’ components which do not contain
locating features can be positioned on the mounting
brackets for fine adjustments.
Preparatory Steps
WARNING
battery cable last.
in Section 13.
Entfernen Sie
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.
CAUTION
Applying excessive force in the opposite direction of
windup or after the tensioner has been wound up to
the positive stop can cause the tensioner arm to
crack or break
CAUTION
Using a socket extension is not recommended
because it can cause axial twisting damage to the belt
tensioner.
Lift the tensioner to remove the drive belt.
NOTE: If a socket extension is necessary, support the
head of the ratchet with one hand to prevent the belt
tensioner arm from unintended loading.

Inspect the drive belt for damage.
Transverse (across the belt) cracks are acceptable.
Longitudinal (direction of belt ribs) cracks that intersect
with transverse cracks are not acceptable.
If the belt is frayed, punctured, or material is missing, the
belt is unacceptable for reuse and must be replaced.
Inspect the belt grooves for:

• Embedded debris
• Uneven/excessive rib wear
• Exposed belt cords.
Inspect the backside of the belt for:
• Glazing (high heat)
• Uneven/excessive rib wear
• Exposed belt cords.
If any of the above conditions are present, the belt is
unacceptable for reuse and must be replaced.
Inspect the idler and drive pulleys for wear or cracks..

Plastic pulleys often have a buildup of road dirt and belt
material that is not to be confused with wear.
The dirt can be removed with a suitable tool to check for
wear.
Clean, check, and reuse all pulleys in the front end
accessory drive if not damaged, rather than replacing.
Pulleys damaged from embedded debris MUST be
replaced.
Inspect the tensioner. Refer to Procedure 008-080 in
Section 8.
Inspect all system pulleys for embedded debris:

• Rocks, stones
• Metal
• Belt material.
Remove any debris from the grooves of the pulley. If the
pulley has been deformed as a result of foreign material
embedment, the pulley MUST be replaced.
Inspect the drive belt pulleys and idlers for cracked or

broken grooves.
Reference the following procedures if a pulley or idler is
damaged:
• Inspect the fan pulley. Refer to Procedure 008-039 in
Section 8.
• Inspect the crankshaft pulley. Refer to Procedure
• Inspect the belt tensioner pulley. Refer to Procedure
Install
Route the drive belt on the engine. Use the belt diagram
created in the Remove section. Do not install the belt over
the water pump pulley at this time.
CAUTION
tensioner.
CAUTION
windup or after the tensioner has been wound up to
the positive stop can cause the tensioner arm to
crack or break.
CAUTION
Using a socket extension is not recommended
tensioner.
Pivot the tensioner in the direction of the spring tang and
install the drive belt, slipping the belt over the water pump
pulley last.
Slowly, release the belt tensioner to apply tension to the
drive belt.
Check the alignment of the belt with the tensioner and the
rest of the front-end accessory drive.
Finishing Steps
WARNING
battery cable last.
• Disconnect the battery. Refer to Procedure 013-009 in
Section 13.
• Operate the engine and check for belt squeal.
Excessive belt squeal indicates excessive belt slip.
• If belt squeal is present, check the routing of the belt to
make sure the belt is installed correctly on each pulley.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter
Coolant Filter (008-006)

Entfernen Sie
WARNING
NOTE: Some engine models do not require coolant
filters.
Remove the coolant system pressure cap.
Turn the shutoff valve to the OFF position by rotating the
knob from the vertical to the horizontal position, as shown.
WARNING
A small amount of coolant can leak when servicing
the coolant filter with the shutoff valve in the OFF
position. To reduce the possibility of personal injury,
avoid contact with hot coolant.
WARNING
Remove and discard the coolant filter.
Marine Applications
WARNING
NOTE: It is possible that some marine engine models do
not have coolant filters.
Remove the coolant system pressure cap.
Turn the inlet and outlet shutoff valves to the OFF position
by rotating the knobs from the horizontal to the vertical
direction as shown.
Coolant Filter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
A small amount of coolant can leak when servicing
the coolant filter with the shutoff valve in the OFF
position. To reduce the possibility of personal injury,
avoid contact with hot coolant.
WARNING
CAUTION
Remove and discard the coolant filter.
Install
CAUTION
Do not allow oil to get into the filter. Oil will damage
the DCA.
CAUTION
Mechanical over tightening can distort the threads or
damage the filter head.
Apply a thin film of lubricating oil to the gasket sealing
surface before installing the new coolant filter.
Install the coolant filter on the filter head. Tighten the filter
until the gasket contacts the filter head surface.
Tighten the coolant filter an additional 1/2 to 3/4 of a turn,
or as specified by the filter manufacturer.
See Section V for coolant filter recommendations.
CAUTION
The valve must be in the ON position to prevent
engine damage.
Turn the shutoff to the ON position by rotating the knob
from the horizontal to the vertical position, as shown.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter
Install the coolant system pressure cap.
Operate the engine and check for coolant leaks.

After the air has been purged from the system, check the
coolant level again.
Marine Applications
CAUTION
Do not allow oil to get into the filter. Oil will damage
the DCA.
CAUTION
Mechanical over tightening can distort the threads or
damage the filter head.
Apply a thin film of lubricating oil to the gasket sealing
surface before installing the new coolant filter.
Install the coolant filter on the filter head. Tighten the filter
until the gasket contacts the filter head surface.
Tighten the coolant filter an additional 1/2 to 3/4 of a turn,
or as specified by the filter manufacturer.
CAUTION
The valve must be in the ON position to prevent
engine damage.
Turn the shutoff valves to the ON position by rotating the
knobs from the vertical to the horizontal position in the
directions shown.
Coolant Filter Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install the coolant system pressure cap.
Operate the engine and check for coolant leaks.

After the air has been purged from the system, check the
coolant level again.
Coolant Filter Head (008-007)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
• Remove the coolant filter. Refer to Procedure 008-006
in Section 8.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter Head
Marine Applications
WARNING
WARNING
CAUTION
Section 8.
in Section 8.
• Remove the water inlet and outlet hoses from the filter
head.
• Remove the water inlet and outlet valves from the filter
head.
Remove
Loosen the four filter head capscrews.
Remove the filter head and gasket.
Marine Applications
Mark the inlet and outlet sides of the filter head for correct
installation.
Loosen the four filter head mounting capscrews.
Remove the filter head from the mounting bracket.
Coolant Filter Head ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Clean the mating surfaces.
Inspect the filter head for cracks, burrs or other damage.

Replace the filter head if it is damaged.
Install
Install a new gasket and the filter head.
Tighten the four capscrews.
Marine Applications
NOTE: Be sure to install the filter head with the inlet and
outlet in the same position as removed.
Install the filter head to the mounting bracket.
Tighten the four mounting capscrews.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter Head
Finishing Steps
WARNING
battery cable last.
• Install the coolant filter. Refer to Procedure 008-006 in
Section 8.
• Fill the cooling system with either a 50/50 mixture of
good-quality water and fully formulated antifreeze or
fully formulated coolant. The fully formulated antifreeze
or coolant must meet ASTM D6210 (EG) and ASTM
D6211 (PG) specifications. Refer to Procedure
• Connect the battery. See equipment manufacturer
Marine Applications
• Install the coolant inlet and outlet valves to the filter
head.
• Install the coolant inlet and outlet hoses and tighten
the hose clamps. Refer to the OEM specification.
Section 8.
• Open the inlet and outlet valves.
or coolant must meet ASTM D6210 (EG) and ASTM
D6211 (PG) specifications. Refer to Procedure
Coolant Filter Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Coolant Filter Valve (008-009)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
in Section 13.
• Drain the engine coolant. Refer to Procedure 008-018
in Section 8.
in Section 8.
• Remove the coolant filter head. Refer to Procedure
Marine Applications
WARNING
WARNING
CAUTION
in Section 8.
• Remove the coolant filter inlet and outlet hoses.
• Remove the hose fittings from the shutoff valves.
• Remove the coolant filter head, if necessary. Refer to
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter Valve
Remove
Loosen the shutoff valve screw from the end of the valve.
Remove the two pieces of the shutoff valve from both

sides of the valve bore.
Marine Applications
Remove the shutoff valves from the filter head.
Inspect for Reuse

Marine Applications
Inspect the coolant filter valves and filter head for
corrosion, cracks, and damaged threads.
Make sure the valves will fully open and close.
Coolant Filter Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Replace the shutoff valve o-rings.
Lubricate the o-rings before installing the valve pieces
back into the bore.
Tighten the shutoff valve screw to tighten the two pieces

of the valve together.
Marine Applications
Install the shutoff valves to the filter head.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Filter Valve
Finishing Steps
WARNING
battery cable last.
• Install the coolant filter head on the engine. Refer to
Section 8.
or coolant must meet TMC RP329 or TMC RP330
specifications. Refer to Procedure 008-018 in Section
8.
• Connect the battery. Refer to Procedure 013-009 in
Section 13.
Marine Applications
• Install the coolant filter head, if removed. Refer to
• Install the coolant hose connections to the inlet and
outlet valves.
• Connect the coolant inlet and outlet lines and tighten
the hose connections.
or coolant must meet TMC RP329 or TMC RP330
specifications. Refer to Procedure 008-018 in Section
8.
Coolant Heater ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Coolant Heater (008-011)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Section 13.
• Drain at least 19 liters [5 U.S. gal] of coolant. Refer to
Remove
Disconnect the coolant heater electrical cord.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Heater
Loosen the coolant heater, and remove it from the

cylinder block.
Clean
Clean the coolant heater and block threads thoroughly.
Install
Lubricate the new coolant heater threads with clean
engine oil.
Install the coolant heater.

Coolant Thermostat ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Attach the coolant heater electrical cord.
Finishing Steps
WARNING
battery cable last.
Section 8.
Section 13.
Coolant Thermostat (008-013)

General Information
The thermostat controls the coolant temperature. When
the coolant temperature is below operating temperature,
coolant is bypassed to the inlet of the water pump. When
the coolant temperature reaches the operating range, the
thermostat opens, seals off the bypass, and forces
coolant to flow to the radiator or the keel cooler on QSL9
marine engines. The thermostat begins opening at 82°C
[180°F].
NOTE: Some applications use an original equipment
manufacturer (OEM) supplied remote mounted
thermostat. Refer to the OEM manual for location. Refer
to the OEM service manual for remote mounted
thermostat removal and installation instructions.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Thermostat
CAUTION
Never operate the engine without a thermostat.
Without a thermostat, the path of least resistance for
the coolant is through the bypass to the pump inlet.
This will cause the engine to overheat.
An incorrect or malfunctioning thermostat can cause the
engine to run too hot or too cold.
Leak Test
NOTE: The leak test portion of this procedure does not
apply to QSL9 keel cooled marine engines. To test QSL9
keel cooled engines. Refer to Procedure 008-014 in
Section 8.
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.
WARNING
WARNING
CAUTION
On marine engines, use caution when draining
coolant that coolant is not spilled or drained into the
bilge area. Do not pump the coolant overboard. If the
coolant is not reused, it must be discarded in
Drain the coolant. Refer to Procedure 008-018 in Section
8.
Remove the radiator hose from the water outlet
connection.
Use an electronic service tool to monitor the coolant

temperature, or install a thermocouple or temperature
gauge, which is known to be accurate, in the cylinder
block on the engine side of the thermostat.
Install a hose of the same size on the water outlet

connection. It must be long enough to reach a remote, dry
container used to collect coolant.
Install and tighten a hose clamp on the housing outlet.
Place the other end of the hose in a dry container.
CAUTION
Always vent the engine and aftercooler during filling
to remove air from the coolant system, or overheating
will result.
Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
NOTE: The engine coolant temperature must be below

the thermostat opening temperature to perform this test.
Operate the engine at rated speed for 1 minute.
Shut the engine OFF 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 is leaking and must be replaced.
Complete the following test in-chassis to determine the

thermostat opening temperature.
Start the engine and monitor the coolant temperature with
INSITE™ electronic service tool or a gauge. Keep the
engine speed below 1500 rpm during the test.
Thermostat Initial Opening Temperature

°C °F
81 MIN 178
83 MAX 182
Shut the engine OFF 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
battery cable last.
WARNING
WARNING
Section 8.
• Remove the radiator hose from the water outlet
connection.
Marine Applications
WARNING
WARNING
CAUTION
in Section 8.
• On QSC8.3 and QSL9 engines with heat exchangers,
remove the coolant hose from the water outlet
connection.
• On QSL9 engines with keel cooling, remove the

coolant hose from the inlet side of the keel cooler
thermostat housing.
Remove
Remove the water outlet connection capscrews and water
outlet connection.
Remove the thermostat.
Marine Applications
On marine engines with heat exchangers, remove the
water outlet connection capscrews and the water outlet
connection from the top of the cylinder head.
On QSL9 engines with keel cooling, remove the water

inlet connection capscrews and the water inlet connection
from the keel cooled thermostat housing.

Clean all of the mating surfaces.
NOTE: Do not let any debris fall into the thermostat cavity
when cleaning the surfaces.
Inspect the thermostat for damage.

Inspect the thermostat gasket for damage. If the gasket is
damaged, it must be replaced.
The nominal operating temperature is stamped on the

thermostat. The thermostat must meet the following
criteria:
• The thermostat must begin to open within 1°C or 2°F
of this nominal temperature.
• The thermostat must be fully open within 12°C or 22°F
of this nominal temperature.
The fully open distance between the thermostat flange
and housing is 9.4 mm [0.370 in].
Heat the water and check the thermostat as follows:

• Suspend the thermostat and a 100°C [212°F]
thermometer in a container of water.
• Do not allow the thermostat or the thermometer to
touch the sides of the container.
Install
Install the new thermostat into the water outlet connection.
Make sure the top and bottom o-rings are in place. If the
o-rings are damaged, replace with new o-rings.
Install the water outlet connection and mounting
capscrews.
Marine Applications
On QSC8.3 and QSL9 engines with heat exchangers,
install the thermostat into the water outlet connection.
Make sure that the top and bottom o-rings are in place.
Install the water outlet connection and mounting
capscrews.
On QSL9 engines with keel cooling, install the thermostat

into the water inlet connection of the keel cooled
thermostat housing.
Install the water outlet connection.
Coolant Thermostat Housing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
CAUTION
Always vent the engine and aftercooler during filling
to remove air from the coolant system, or overheating
will result.
Section 8.
• Connect the batteries. Reference the equipment
Coolant Thermostat Housing (008-014)

General Information
QSL Engines
This procedure applies to QSL9 keel cooled engines only.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Thermostat Housing
Preparatory Steps
QSL Engines
WARNING
battery cable last.
WARNING
WARNING
CAUTION
• Disconnect the batteries. Refer to Procedure
013-009.
• Drain the engine coolant. Refer to Procedure
008-018.
• Disconnect the keel cooler inlet and outlet
connections. Refer to the OEM service manual.
• Disconnect the coolant vent line from the thermostat
housing. Refer to Procedure 008-017.
• Disconnect the thermostat housing coolant inlet and
outlet hoses.
Remove
QSL Engines
Remove the four thermostat housing mounting
capscrews.
Remove the two clamps and the thermostat housing.
Remove the two vibration isolators.
Leak Test
QSL Engines
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.
Fabricate a test fixture to seal all of the water outlet

connections except the outlet port to the keel cooler and
the inlet port of the thermostat housing.
For the outlet port to the keel cooler (1), install a hose
long enough to reach a remote, dry container used to
collect water. Place the open end of the hose in the dry
container.
Connect a water hose to the inlet port (2) of the
thermostat housing capable of regulating 152 kPa [22 psi]
of filtered tap water.
Apply 152 kPa [22 psi] of water pressure to the thermostat

housing for one minute.
The maximum allowable leakage is 100 cc [3.4 fl oz] per
minute.
If more than 100 cc [3.4 fl oz] of coolant is collected, the

thermostat or thermostat seal is leaking and must be
replaced. Refer to Procedure 008-016 to replace the
thermostat seal.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Thermostat Housing
Disassemble
QSL Engines
Remove the three capscrews and hose connections from
the ends of the thermostat housing.
Remove the o-rings from the ends of the housing.
Remove the keel cooler hose connections.
Remove the coolant vent fitting and pipe plugs from the
housing.

QSL Engines
Clean the parts with soap and water.
Inspect the components for cracks, nicks, or other

damage.
Inspect the thermostat seal for damage. Replace the seal
if damaged. Refer to Procedure 008-016.
Inspect the isolators for damage or cracks.
Replace any damaged parts.
Assemble
QSL Engines
Install the thermostat into the thermostat housing.
Install a new o-ring on the thermostat housing.
Install the water inlet connection and three mounting
capscrews. Tighten the capscrews.
Install a new o-ring on the other end of the thermostat
housing and the water outlet connection. Install the three
capscrews and tighten.
Install the two pipe plugs and tighten.
Install the coolant vent line fitting. Tighten the fitting so it
faces the thermostat housing inlet end.
Install the keel cooler inlet and outlet fittings. Refer to the
OEM service manual.
Install
QSL Engines
Place the vibration isolators on top of the thermostat
housing support bracket.
Install the thermostat housing onto the isolators using

clamps and capscrews as shown.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Thermostat Housing Support
Finishing Steps
QSL Engines
• Install the coolant inlet and outlet hoses.
• Install the coolant vent line. Refer to Procedure
008-017.
• Install the keel cooler inlet and outlet hoses. Refer to
the OEM service manual.
008-018.
Coolant Thermostat Housing Support

(008-015)
General Information
QSL Engines
This procedure applies to marine QSL9 keel cooled
engines only.
Preparatory Steps
QSL Engines
WARNING
WARNING
CAUTION
008-018.
• Remove the thermostat housing. Refer to Procedure
008-014.
Coolant Thermostat Housing Support ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
QSL Engines
Remove the three thermostat housing support mounting
capscrews and the thermostat housing support.

QSL Engines
WARNING
WARNING
WARNING
personal injury.
Use solvent to clean the bracket.
Inspect the bracket for cracks or other damage.

Repair or replace the bracket, if damaged.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Thermostat Seal
Install
QSL Engines
Install the thermostat housing bracket and mounting
capscrews.
Finishing Steps
QSL Engines
• Install the thermostat housing. Refer to Procedure
008-014.
008-018.
Coolant Thermostat Seal (008-016)

Preparatory Steps
Marine Applications
WARNING
WARNING
CAUTION
NOTE: This procedure applies only to QSL9 engines with
keel cooling.
008-018.
• Remove the coolant thermostat housing. Refer to
Procedure 008-014.
• Remove the coolant thermostat. Refer to Procedure
008-013.
Coolant Thermostat Seal ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Entfernen Sie
CAUTION
Use care when removing the thermostat seal, the
thermostat housing can be damaged.
Use a punch and hammer to remove the seal from the
housing.
WARNING
WARNING
personal injury.
Use solvent to clean the thermostat housing.
Inspect the thermostat housing for cracks, pits, or other

damage.
Install
When installing a new seal, the part number side of the
seal must be facing the mandrel.
Use thermostat seal mandrel, Part Number 3375411, and
a hammer to install the seal.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Vent Lines
Install the thermostat in the housing.

Install a new o-ring in the groove on the thermostat
housing mounting surface.
Install the thermostat housing cap over the end of the
housing using three capscrews. Tighten the capscrews.
Finishing Steps
• Install the thermostat housing. Refer to Procedure
008-014.
008-018.
Coolant Vent Lines (008-017)

General Information
This procedure applies to the QSL9 and QSC8.3 marine
engines only.
Coolant Vent Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
WARNING
CAUTION
in Section 8.
Remove
QSL Engines
Disconnect the exhaust manifold vent line from the
expansion tank and the top of the exhaust manifold.
Disconnect the cylinder head vent line from the expansion
tank and the top of the cylinder head.
Disconnect the turbocharger vent line from the top of the
expansion tank.
Disconnect the turbocharger vent line from the top of the

turbocharger.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Vent Lines
If the engine is keel cooled, disconnect the vent line from

the top of the expansion tank and the top of the
thermostat housing.
QSC Engines
Disconnect the vent line from the front of the expansion
tank and the top of the exhaust manifold.
Disconnect the vent line from the front of the expansion
tank and the top of the cylinder head.
Disconnect the vent line from the rear of the expansion

tank and the turbocharger.
Install
QSL Engines
Connect the vent line at the top of the expansion tank and
the top of the exhaust manifold.
Connect the vent line for the turbocharger at the top of the
expansion tank.
Connect the vent line at the top of the expansion tank and
the top of the cylinder head.
Coolant Vent Lines ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Connect the coolant vent line to the top of the

turbocharger.
If the engine is keel cooled, connect the vent line from the
top of the expansion tank and to the top of the thermostat
housing.
QSC Engines
Connect the vent line at the front of the expansion tank
and the top of the exhaust manifold.
Connect the vent line at the front of the expansion tank
and the top of the cylinder head.
Connect the vent line at the rear of the expansion tank

and the turbocharger.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System
Finishing Steps
WARNING
battery cable last.
Section 8.
Cooling System (008-018)

Coolant Replacer Method
Evacuation
The following steps are used to evacuate the cooling
system using the coolant replacer tool, Part Number
2892459.
NOTE: When the vehicle/equipment or engine is
equipped with a quick disconnect fitting in the cooling
system package, the Coolant Replacer Method is the
preferred method for coolant removal. Use the coolant
replacer tool, Part Number 2892459. If the vehicle/
equipment or engine does not have a quick disconnect
fitting presently installed, one can be installed in the
cooling system package to utilize the Coolant Replacer
Method; otherwise the coolant drain and fill method must
be used.
Position the equipment on level ground.
Cooling System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
CAUTION
Do not use the coolant replacement tool to evacuate
contaminated coolant or a system that is suspected
of contamination. This could result in cross
contamination of coolant. The coolant drain method
should be used for removing contaminated coolant.
Refer to the manufacturer’s manual for specific
instructions on cleaning the tool of contaminants.
NOTE: See equipment manufacturer service information
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
with several feet of plumbing and multiple heater cores.
Remove the radiator cap.
WARNING
The coolant replacement tool tank capacity of 68 Liters
[18 gal] is adequate for most applications. An additional
storage tank can be used for cooling system packages
with more than 68 Liters [18 gal] capacity.
Be sure there is no air pressure in the coolant
replacement tool tank by opening the pressure relief valve
(1) located on the control block of the coolant replacement
tool.
Connect the coolant replacement tool to a shop air supply

regulated at 621 kPa [90 psi].
Switch the coolant replacement tool control lever (1) to
“VAC” and leave the service hose valve (2) closed. This
will create a vacuum in the tank to evacuate coolant from
the cooling system package.
Monitor the gauge (3) and build a vacuum of
approximately 508 mm-Hg [20 in-Hg] in the coolant
replacement tool tank. Once the vacuum has been
achieved, move the control valve lever (1) to the middle
position.
Maintain approximately a 508 mm-Hg [20 in-Hg] vacuum
to achieve a faster drain.
Attach the fill hose quick disconnect coupling (1) of the

coolant replacement tool to the quick disconnect fitting.
Location of the fitting may vary between OEMs, but the
fitting is generally located in the lowest point of the
vehicle/equipment cooling system package.
NOTE: Most Volvos are equipped with a different style
fitting located in the radiator. An adapter hose is needed
to connect the Cummins® coolant replacement tool to the
fitting. The adapter hose is included in accessory kit.
Open the service hose valve (1) by turning it clockwise

until it is completely open (approximately ¼ turn).
Additional shop air may be required to maintain enough of
a system vacuum to remove the coolant from the system.
This can be done by moving the control valve lever (2)
back to the VAC position.
When the cooling system has been evacuated, a coolant

and air mixture will be visible in the clear section of the
coolant replacement tool fill hose.
NOTE: Some residual coolant will settle in the coolant
package as the recessed areas of the block continue to
drain down over the next few minutes.
Once the system has been evacuated, turn the service
hose valve (1) to the closed position by turning the valve
counterclockwise a ¼ turn. Disconnect the shop air
connection from the coolant replacer tool.
Disconnect the fill hose quick disconnect coupling (2) on
the coolant replacement tool from the quick disconnect
fitting.
Injection
CAUTION
The cooling system must be filled properly to prevent
air locks or serious engine damage can result.
The following steps are used to inject coolant into the
cooling system using the coolant replacer tool, Part
Number 2892459.
NOTE: When the vehicle/equipment or engine is
equipped with a quick disconnect fitting in the cooling
system package, the Coolant Replacer Method is the
preferred method for coolant removal. Use the coolant
replacer tool, Part Number 2892459. If the vehicle/
equipment or engine does not have a quick disconnect
fitting presently installed, one can be installed in the
cooling system package to utilize the Coolant Replacer
Method; otherwise the coolant drain and fill method must
be used.
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 (Cl)
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.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.

tool.
Connect the coolant replacement tool to a shop air supply

Attach the fill hose quick disconnect coupling (1) of the
coolant replacement tool to the quick disconnect fitting
located in the vehicle/equipment cooling system package.
With the service hose valve (2) in the closed position,
switch the coolant replacement tool control lever (3) to “P”
and build 172 kPa [25 psi] pressure on the gauge.
Slowly open the service hose valve (2) part way by turning
it counterclockwise approximately 1/8 turn.
Do not open the ball valve completely as this will increase
the coolant flow rate and increase the amount of air
pockets created in the cooling system; This will provide a
more complete injection of coolant.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill or recovery/expansion tank or until
the coolant replacer tool is empty (whichever occurs first).
On applications that use a coolant recovery system, check
to make sure the coolant is at the appropriate level in the
coolant recovery tank for the engine temperature.
Many coolant recovery/expansion tanks, also called
auxiliary tanks, have sight glasses or are made of a clear
material (not shown) to aid in checking the coolant level
without removing the radiator cap.
It is important to understand the impact of temperature on
the expansion of the coolant. Most auxiliary tanks do not
have a provision for a "FULL HOT" coolant level. Filling
the "top tank" while hot will result in a low operating level
once the system has cooled.
CAUTION
The cooling system must be filled properly to prevent
air locks or serious engine damage can result.
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 in the tool after
filling, this is an indication of an air pocket in the cooling
system package which must be purged before returning
the vehicle to service.
NOTE: Top off of coolant might be necessary for repairs
that were performed to correct a coolant loss issue.
If all coolant drained from the system would not return to
the system or the level is above the maximum level. This
is an indication of an air pocket in the cooling system
package, which must be purged before returning the
vehicle to service.
To remove an air pocket from the cooling system, the
coolant replacement tool can be used. Refer to the
vacuum section of this procedure.
Once the coolant level has been returned to the correct

level, close the service hose valve (1) by turning the valve
clockwise until closed.
Remove pressure from the coolant replacement tool tank
by opening the pressure release valve on the back of the
control block (2).
Disconnect the service hose quick disconnect coupling (3)
from the quick disconnect fitting of the vehicle/equipment.
Vacuum
The following steps are used to place a vacuum on the
cooling system using the coolant replacer tool, Part
Number 2892459.
tool.
Clamp off any vent hoses/connections or overflow to the
cooling system.
Attach the coolant dam handle (1) to the fill hose of the
coolant replacement tool.
Attach the appropriate size coolant dam rubber adapter

(1) onto the coolant dam handle.
The size of the fill neck will differ between OEMs choose
the appropriate sized coolant dam rubber adapters.
Connect the coolant replacement tool to shop air
Place the coolant dam over the coolant fill neck in the
radiator or overflow tank.
The size of the fill neck will differ between OEMs. Choose
the appropriate sized coolant dam rubber adapters.
Switch the coolant replacement tool control lever (1) to
“VAC” and leave the service hose valve (2) closed. This
will create a vacuum in the tank to evacuate coolant from
the cooling system package.
Monitor the gauge (3) and build a vacuum of
approximately 508 mm-Hg [20 in-Hg] in the coolant
replacement tool tank.
Slowly open the service hose valve (2) by turning it
clockwise until it is completely open approximately ¼
turn.
Once the cooling system is put into a vacuum, any air
trapped in the cooling system will be evacuated through
the top of the system. This is noticed as air bubbles
through the overflow tank or top of the radiator.
When air bubbles are no longer being drawn to the top of

the cooling system move the control lever to the middle
position. Remove the vacuum on the coolant replacement
tool tank by opening the pressure relief valve located on
the control block of the coolant replacement tool (1).
Remove the coolant dam from the radiator fill neck or
overflow tank.
Disconnect the coolant replacement tool from the
regulated shop air supply.
Install the radiator cap.
Drain
WARNING
Remove the pressure cap.
WARNING
Drain the cooling system by opening the drain valve on
the radiator and by opening the drain valve on the bottom
of the engine oil cooler housing. A drain pan with a
capacity of 57 liters [15 gal] is adequate in most
applications.
After the cooling system is completely drained, close the
drain valves. Refer to the equipment manufacturer service
information for complete cooling system drain information.
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 required.
Fill
CAUTION
Opening the manual bleed valve on applicable
installations is critical. Failure to do so can result in
engine damage.
that is required to be opened to properly fill the system.
The upper radiator pipe is a common location for bleed
valves. The illustration is for reference only.
If applicable, open the manual bleed valve before filling
the cooling system.
Once filled, close the manual bleed valve.
CAUTION
The system must be filled properly to prevent air
locks or serious engine damage can result. During
filling, air must be purged from the engine coolant
passages. Be sure to open the petcock on the
aftercooler for aftercooled engines. Wait 2 to 3
minutes to allow the air to be vented; then add the
mixture to bring the coolant level to the top.
CAUTION
During all coolant fill procedures, all coolant flow
valves to equipment heating systems must be opened
in order to purge air from those systems as well as
from the base engine cooling system. These valves
must remain open during the engine cooling system
deaeration process. Make sure adequate coolant
levels are maintained in the coolant reservoir during
the entire fill procedure. Special care must be taken
when filling EGR cooler equipped engines to make
sure all air is purged from the cooling system or
serious engine damage can result.
CAUTION
Never use water alone for coolant. This can result in
damage from corrosion.
The system has a designed fill rate of up to 19 liters [5
gal] per minute.
Refer to Procedure 018-018 in Section V.
Flush
Fleetguard® Restore™ is a heavy-duty cooling system
cleaner that removes corrosion, silica gel, and other
deposits. The performance of Fleetguard® 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 Fleetguard® Restore™ can be
used safely. Fleetguard® 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.
CAUTION
Opening the manual bleed valve on applicable
installations is critical. Failure to do so can result in
engine damage.
that is required to be opened to properly fill the system.
The upper radiator pipe is a common location for bleed
valves. The illustration is for reference only.
If applicable, open the manual bleed valve before filling
the cooling system.
WARNING
Do not stand near the surge tank or radiator while operating
the engine with the pressure cap off. If the vehicle is
equipped with a fill door on the side of the surge tank, keep it
closed due to coolant expansion.
CAUTION
Fleetguard® Restore™ contains no antifreeze. Do not allow
the cooling system to freeze during the cleaning operation.
CAUTION
Opening the manual bleed valve on applicable installations is
critical. Failure to do so can result in engine damage.
CAUTION
The system must be filled properly to prevent air locks or
serious engine damage can result. During filling, air must be
purged from the engine coolant passages. Make sure to open
the petcock on the aftercooler for aftercooled engines. Wait 2
to 3 minutes to allow the air to be vented; then add the
mixture to bring the coolant level to the top.
NOTE: Some applications can have a manual bleed valve that is
required to be opened to properly fill the system. The upper
radiator pipe is a common location for bleed valves. The
illustration is for reference only.
If applicable, open the manual bleed valve before filling the
cooling system.
NOTE: 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.
Fill the cooling system to the capacity or level stated in the OEM
service manual.
Use plain water.
Open all coolant flow valves to equipment heating systems. See
the OEM service manual for valve locations.
Wait 2 to 3 minutes, without starting the engine, to allow the
coolant level to stabilize.
Add plain water to bring the level back to FULL.
Turn all cab heater switches to HIGH in order to allow maximum
coolant flow through the heater core(s). The blower does not
have to be ON.
With the pressure cap off:
• Operate the engine at LOW IDLE for 2 minutes.
• Shut the engine OFF and add plain water to bring the level
back to FULL.
• Operate the engine at LOW IDLE for 1 minute to allow
adequate oil pressure to build throughout the engine.
• Operate the engine at HIGH IDLE until the thermostat opens.
Operate the engine at low idle 2 minutes before shutting it down.
This allows adequate cool down of pistons, cylinders, bearings,
and turbocharger components.
Shut the engine OFF and check the coolant level according to the
OEM service manual recommendations and add coolant, if
necessary, to bring it back to the FULL level.
Install the pressure cap.
WARNING
WARNING
Operate the engine at normal operating temperatures, at
least 85°C [185°F], for 1 to 1 ½ hours.
Shut the engine OFF allow to cool to 50°C [122°F], and
drain the cooling system.
WARNING
Do not stand near the surge tank or radiator while
operating engine with the pressure cap OFF. If the
vehicle is equipped with fill door on the side of the
surge tank, keep it closed due to coolant expansion.
Remove the pressure cap.
Fill the cooling system to the capacity or level stated in the
OEM service manual.
Open all coolant flow valves to equipment heating
systems. See the OEM service manual for valve locations.
Wait 2 to 3 minutes without starting the engine to allow
the system to naturally purge entrained air and the coolant
level to stabilize.
Add plain water to bring the level back to FULL.
Turn all cab heater switches to HIGH in order to allow
maximum coolant flow through the heater core(s). The
blower must be turned ON.
• Operate the engine at LOW IDLE for 2 minutes.
• Shut the engine OFF and add plain water to bring the
level back to FULL.
• Operate the engine al LOW Idle for 1 minute to allow
adequate oil pressure to build throughout the engine.
• Operate the engine at HIGH Idle until the thermostat
opens.
Continue to operate the engine at HIGH idle for 5 minutes
with the coolant temperature above 85°C [185°F].
Allow the engine to idle 2 minutes before shutting it down.
This allows adequate cool down of pistons, cylinders,
bearings, and turbocharger components.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System Diagnostics
WARNING
WARNING
Shut the engine OFF. Allow it to cool to 50°C [122°F], and
drain the cooling system.
If the water being drained is still dirty, the system must be
flushed again, until the drained water is clean.
Cooling System Diagnostics (008-020)

General Information
The following procedure covers common troubleshooting
steps to help identify:
• Engine overheating causes. See the Initial Check
section of this procedure.
NOTE: At the end of this procedure, a worksheet is
provided to record any measured values taken during
troubleshooting. The worksheet will help in gathering and
analyzing the data.
• External and internal coolant leaks/loss. See the
Pressure Test section of this procedure.
• Combustion gas leaks into the cooling system. See the
Test section of this procedure.
If the coolant reaches an unacceptable level in the
recovery/expansion tank, a fault code should become
active that will illuminate an instrument lamp and impose a
power derate. This low level is detected by a coolant level
switch mounted in the coolant surge/recovery tank.
In the event of a cooling system-related malfunction, it is
recommended that the coolant level switches be checked
for proper operation. Refer to the OEM service manual for
operational checks and repairs.
Removal and installation of the coolant level switch for
diagnostics is NOT recommended. This poses a high
likelihood of damage, due to the plastic construction of the
switch. The coolant level switch must only be removed
from the surge/recovery tank when replacing it with a new
switch. Be certain not to overtighten the switch when
installing. Most switches have a very low torque value,
which can be found in the OEM service manual.
Coolant level switches are very susceptible to improper
pH levels. For this reason, it is imperative that coolant be
maintained in accordance with Cummins® Coolant
Requirements and Maintenance, Bulletin 3666132.
Cooling System Diagnostics ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
CAUTION
Never operate the engine without a thermostat.
Without a thermostat, the path of least resistance for
the coolant is through the bypass to the water pump
inlet. This can cause the engine to overheat.
Thermostat
There are different temperature range thermostats
available, depending on the engine type and application.
The part number and nominal operating temperature are
stamped on the thermostat. To verify that the correct
temperature range and part number thermostat is
installed, make sure to reference the appropriate part
information resources. Refer to Procedure 008-013 in
Section 8.
Water Pump
A damaged or an incorrect water pump can lead to an
engine overheating condition. To verify that the correct
water pump is installed, make sure to reference the
appropriate parts information resources. Refer to
Belt and Belt Tensioner

A worn/incorrect belt, belt tensioner, or misaligned pulley
can cause:
• Belt slip
• Belt jump or "walk off"
• Noise
• Belt breaks and shredding
• Component bearing seizure.
Refer to Procedure 008-002 or Refer to Procedure
Pressure Cap
A commonly overlooked item when troubleshooting the
cooling system is the radiator pressure/expansion tank
cap. The cooling system is designed to use a pressure
cap to prevent boiling of the coolant. An incorrect,
damaged, or malfunctioning cap can result in the loss of
coolant and in an engine overheating condition.
For information for pressure cap specifications, refer to
An incorrect or malfunctioning cap can also result in the

loss of coolant and in an engine overheat condition.
Pressure test the radiator cap. Refer to the OEM service
manual.
The pressure cap must seal within 14 kPa [2 psi] of the
value stated on the cap, or it must be replaced.
Air forced through the fins of the radiator by a fan cools

the coolant pumped through the radiator. Environmental
debris (such as paper, straw, lint, and dust) can obstruct
the fins and reduce the flow of air, which will reduce the
cooling effect of the radiator.
The radiator must be inspected for bent/broken fins and

coolant leaks periodically.
For maintenance, removal, or installation of the radiator,
refer to the OEM service manual.
NOTE: The silicone engine coolant hose will exhibit

swelling due to the elasticity of the hose.
Coolant Hoses
Collapsed or damaged coolant hoses can result in engine
heating problems. Make sure to inspect all hoses for
cracks, cuts, or collapsing. Replace any damaged hoses.
Inspect the coolant vent lines from the EGR cooler,

cylinder head and variable geometry actuator (VGT).
Make sure the lines are not pinched and that there are no
sharp turns or dips in the vent lines from the engine
connection point to the surge tank.
Blow shop air through the suspected lines to make sure
there is no excessive restriction inside the lines.
Cooling Fan
The engine cooling fan is typically driven by a crankshaft
driven belt. In some applications, the fan is located off the
engine for a remote mounted cooling system.
The cooling fan is supplied by the OEM. The OEM must
be contacted for any service-related information. This
procedure only highlights some of the items related to
cooling fans.
If the fan is belt-driven, a slipping belt will result in a

slower fan speed and reduced cooling. A malfunctioning
automatic belt tensioner can be the problem. Refer to
Check the bearings in the fan hub and other pulleys to
make sure they are not causing excessive belt vibration
and slippage. Refer to Procedure 008-036 in Section 8.
The cooling fan must be inspected periodically. Check for

cracks, loose rivets, and bent or loose blades.
Check the fan to make sure it is securely mounted.
Tighten the capscrews, if necessary.
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.
Only replace a damaged cooling fan with an exact

equivalent cooling fan. Although same size cooling fans
can appear similar, there can be differences in the blade
pitch and profile.
Fan Drive
A malfunctioning fan drive can cause engine cooling
problems.
Various fan drive configurations are used to determine
when the fan is driven, which include:
• Direct drive - the fan is engaged all of the time
• Air engaged/disengaged clutch
• Electric/electromagnetic clutch
• Viscous clutch
• Hydraulic drive
• Crankshaft/PTO driven.
Use the following procedure for additional information on
electromagnetic fan clutches supplied by Cummins Inc.
For other fan clutches, refer to the OEM service manual.
Fan Shroud Assembly

A fan shroud assembly is used to direct air flow provided
by the cooling fan. A missing or damaged fan shroud will
reduce the amount of air flow provided by the cooling fan
and can cause an engine coolant overheating condition.
Check the fan shroud for damage and/or contact with the
cooling fan. Replace any damaged components. Refer to
Radiator Shutters
NOTE: Make sure the air temperature sensor is
functioning correctly. Check the air-operated shutter
controls. Check for air leaks. Refer to the OEM service
manual.
Radiator shutters are designed to control airflow across
the radiator. If the shutters fail to open when needed, the
engine can run hot. Inability of the shutters to close can
result in too much airflow and the engine running cold.
Winter Fronts
Winter fronts can be used to reduce the engine warm up
time and help maintain engine heat in cold climate
locations.
The winter fronts should only cover part of the frontal
area of the cooling system, leaving part of the frontal area
open to air flow.
Failure to leave part of the front area open to air flow or
leaving the winter fronts installed when ambient
temperatures increase can lead to an engine overheating
condition.
Initial Check
Connect an electronic service tool to the vehicle's data
link.
Turn the keyswitch to the ON position.
Monitor the coolant temperature with the electronic
service tool.
If equipped with an in dash coolant temperature gauge,

monitor coolant temperature with an electronic service
tool and compare the cab temperature gauge reading.
Replace the cab temperature gauge if it is not within the
manufacturer's specifications of the correct reading.
If the manufacturer's specifications are not available,
replace the gauge if it is not within ±3.9°C or ±7°F of the
correct reading.
For vehicles equipped with temperature controlled

shutters, check the coolant temperature at which the
shutters open and close. Compare this value to what is
stamped on the shutter control.
Cummins Inc. recommends that the shutters open at 85°C
[185°F] engine coolant temperature.
If equipped with a temperature controlled cooling fan

clutch, check the coolant temperature at which the fan
clutch engages.
If the fan clutch engagement is controlled by a fan control
on the vehicle, compare the recorded value to what is
stamped on the fan control and/or reference the OEM
service manual.
If the fan clutch engagement is controlled by the engine's
electronic control module (ECM), the engagement coolant
temperature is a set value that can not be changed. If the
fan clutch does not engage, check to make sure the fan
control logic parameter is set correctly.
The ECM is capable of using either a zero (“0”) VDC or 12
VDC signal to engage the fan clutch. The exact enable
logic can be selected in the Features and Parameters
section of INSITE™ electronic service tool.
Cummins Inc. recommends that the fan engage at 96°C
If equipped with a viscous fan drive, check the coolant

temperature at which the fan engages. Viscous fan
clutches are typically activated by a built-in sensor behind
the radiator that monitors air temperature.
NOTE: Some viscous fan drives could possibly be
electronically controlled.
When the air temperature reaches a specific level,
depending on the temperature setting of the sensor used,
the temperature-sensing control moves an actuator that
allows viscous fluid to engage the fan drive and increase
the fan speed. For more information, refer to the OEM
service manual.
Cummins Inc. recommends that the fan engage at 96°C
Pressure Test
The operating pressure of the coolant system and the
lubricating system can result in the mixing of the fluids if
there is a leak between the systems:
• Cylinder head gasket
• Lubricating oil cooler, etc.
Transmission/power steering/hydraulic fluid can also leak
into the coolant through radiator fluid coolers, if equipped.
Check the coolant level and fill if necessary. Refer to

To aid in determining the location of the coolant leak, it

may be necessary to add fluorescent tracer, Part Number
3377438, to the coolant.
Add one unit of fluorescent tracer to each 38 liters [10 gal]
of coolant .
Idle the engine for 5 to 10 minutes or until normal
operating temperature is reached, to allow the dye to
circulate through the cooling system.
Use a high intensity black light, Part Number 3163337, or

equivalent, to illuminate the dye.
CAUTION
Do not apply more than 138 kPa [20 psi] air pressure
to the cooling system or damage to the water pump
seal can result.
If the radiator is equipped with a pressure relief valve,
plug the overflow line (1).
Install the pressure tester to the radiator fill neck or surge
tank, if equipped, and apply air pressure.
Air Pressure 138 kPa [ 20 psi ]
The Coolant Dam™/Pressure Tester service tool, Part

Number 3824319, can also be used to pressurize the
cooling system. The Coolant Dam™/Pressure Tester uses
shop air rather than a hand air pump.
For external coolant leaks, inspect the exterior of the

engine and repair if necessary.
Pay close attention to areas around the:
• Lubricating oil cooler. Refer to Procedure 007-003 in
Section 7.
• Water pump. Refer to Procedure 008-062 in Section 8.
• Air compressor head gasket. Refer to Procedure
• Cup plugs. Refer to Procedure 017-002 in Section 17.
• Pipe plugs. Refer to Procedure 017-007 in Section 17.
• EGR cooler. Refer to Procedure 011-019 in Section
11.
• EGR cooler coolant line. Refer to Procedure 011-031
in Section 11.
• Variable geometry turbocharger. Refer to Procedure
• Turbocharger coolant lines. Refer to Procedure
For internal coolant leaks, inspect the interior of the

engine. It may be necessary to remove the following
components to look for signs of a coolant leak:
• Rocker lever cover. Refer to Procedure 003-011 in
Section 3.
• Lubricating oil pan. Refer to Procedure 007-025 in
Section 7.
• Turbocharger oil drain line. Refer to Procedure
For suspected fuel in the coolant or coolant in the fuel,

disconnect the fuel drain connection at the rear of the
cylinder head. Refer to Procedure 006-013 in Section 6.
Coolant Pressure Check

Measure the coolant pressure at the coolant tap number 5
(1) or coolant tap number 6 (2) on the exhaust side of the
cylinder head.
Coolant pressure can be affected by the following:
• Radiator pressure cap
• Debris in the cooling system
• OEM cooling options such as in-cab heaters and
torque converter cooling
• Air in the cooling system
• Incorrect initial cooling system fill
• Less than 50/50 antifreeze mixture
• Engine operation at high altitude.
Record the block pressure at 60°C [140°F], closed

thermostat, at high idle.
If the block coolant pressure is less than 138 kPa [20 psi]
at high idle and without a pressure cap, do the following:
• Check the belt tension and condition
• Remove the water pump, inspect the impeller integrity,
and check for slippage on the shaft. Refer to
Setup
WARNING
NOTE: All cab heaters and air conditioners must be
turned to the OFF position, and the engine fan control
must be turned to the AUTOMATIC position, if applicable.
Remove the radiator cap, and leave it off for the following
test.
Install the combustion gas leak test instrument, Part

Number 3822985, into the radiator cap opening.
Install the analyzer kit, Part Number 3822994.

• Red line - plugged
• Yellow line - cylinder block pressure
• Black line - water pump inlet.
Test
Pressure Readings:
Turn the pressure selection valve to the position
corresponding to the desired reading. Turn the
temperature selection valve to the OFF position.
NOTE: When the cylinder block pressure reading is taken,
the valve must be turned to the thermostat housing
pressure location.
Start the engine and run at high idle.
Monitor the sight glass installed on the service tool

throughout the test. If air is observed, finish the test, and
examine the combustion leak tester. This will determine
the origin of the leak.
Temperature Readings:
There will be temperature fluctuations when switching the
temperature selection valve. This fluctuation is normal and
is caused by temperature loss in the line. The temperature
will stabilize after a few seconds.
Air in the coolant can result in loss of coolant from the

overflow when the aerated coolant is hot. The heated air
expands, increasing the pressure in the system, causing
the cap to open.
Similarly, coolant can be displaced through the overflow if
the head gasket or a crack in the cylinder head leaks
compression gases into the cooling system.
Combustion Gas Leak

Use a combustion gas tester, Part Number 3822985, or its
equivalent, to test for combustion gases in the cooling
system.
It is recommended that the cooling system contain a
mixture of 50 percent antifreeze and 50 percent water
during the combustion gas leak test. The use of water
only can result in a color change in the test fluid from blue
to turquoise or light green during the test. This is not an
indication of a combustion gas leak.
WARNING
Drain the coolant level down approximately 76 mm [3 in]
below the radiator cap seal ledge in the radiator fill neck.
If the coolant is above this point, the coolant can
contaminate the test fluid, causing the test to be
ineffective.
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 certain that
an airtight seal is formed between the tester and the
radiator fill neck.
Start the engine and run at 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.
If the color of the test fluid changes from blue to yellow or

green anytime during the test, combustion gases are
leaking into the cooling system. Discontinue the test if the
color of the test fluid changes from blue to yellow or
green.
If the color of the test fluid does not change from blue to
yellow or green 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 yellow or green,
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 yellow or green is the
only indication of combustion gas in the cooling system.
NOTE: Discard the tester fluid if it has indicated positive.

A positive result from the combustion gas leak tester
indicates cylinder head gasket or cylinder head casting
leakage. Refer to Procedure 002-004 in Section 2.
A negative result from the combustion gas leak tester,

coupled with a continuous flow of air bubbles from the
previous test, indicates the following:
• Damaged fan, shutter, or heater air control valve
• Air compressor head or head gasket leakage
Overflow Method
WARNING
Allow the engine to cool and remove the radiator cap.
Install a radiator pressure cap that has had the spring and
the pressure relief valve removed to allow free flow from
the overflow tube.
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.
NOTE: The pressure cap must be tightly sealed in the top
of the radiator fill neck.
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.
NOTE: 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.
Analyzing the Data

Check the color of fluid in the combustion gas leak tester.
A yellow or green (not shown in the illustration) color will
indicate a combustion leak. A blue color will indicate there
is no leak. This information will help isolate the source of
air in the cooling system, if any.
NOTE: The test kit is not sensitive enough to detect very
small combustion gas leaks.
Do not rule out combustion gas leaks if the combustion
gas leak test does not indicate a combustion gas leak.
Check the recorded coolant temperature when the

shutters are opened. Compare this value to the stamp on
the shutter control. Cummins Inc. recommends that the
shutters open at 85°C [185°F].
Check the recorded coolant temperature when the fan is

engaged. Cummins Inc. recommends that the fan engage
at 96°C [205°F].
Compare the cab temperature gauge reading with the

block temperature. Replace the cab temperature gauge if
it is not within the manufacturer's specifications for the
correct reading. If no manufacturer's specifications are
available, replace the gauge if it is not within ±3.9°C [7°F]
of the correct reading.
Read the recorded block pressure at 60°C [140°F]. If the

block pressure is less than 138 kPa [20 psi] at high idle
and without a pressure cap, check the following:
• Remove the water pump
• Inspect the impeller's integrity, and for slippage on the
shaft
• Check the belt tension and condition.
If there is a drop in block pressure of more than 34 kPa [5

psi] during the test, check the following:
• Air in the system
• Incorrect initial cooling system fill
• Less than 50/50 antifreeze mixture, or the engine is at
high altitude.
Worksheet
Fill in the blanks with the test data as the test is being run. Mark when the radiator line gets hot, when the fan starts
operating, and when the shutters open.
Coolant Pressure
Temperature
(°F)
Thermostat Cab Gauge Cylinder Head Radiator “In Fan Starts Shutters Open Notes
Housing Line” Starts Operating
Getting Hot
140 Engine at high
idle throughout
test
145 Monitor for air
throughout test
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fan Clutch, On-Off
150 Start
monitoring
radiator “in”
line
155
160
165 Check water
filter
170
175
180
185
190
195
200
205 Cool engine
down
Fan Clutch, On-Off (008-027)

General Information
Many fan clutches can be controlled by the engine's
electronic control module (ECM). The ECM monitors
coolant temperature and intake manifold temperature to
determine when to engage the cooling fan. Some
applications have additional sensors monitored by the
ECM for fan control (for example, air conditioner pressure
and transmission temperature). These are various fan
clutch types, such as air-engaged, air-disengaged,
electric, viscous, and on/off. Refer to the OEM service
manual to determine fan clutch type.
The ECM is capable of using either a 0-VDC or 12-VDC

signal to engage the fan clutch. The enable logic is
contained in the ECM calibration and can be programmed
using INSITE™ electronic service tool.
Refer to the OEM service manual for fan clutch
troubleshooting and repair information.
Fan Spacer and Pulley ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Fan Shroud Assembly (008-038)

General Information
The radiator or fan shroud is used to direct all air-flow
across the radiator fins rather than around the edges of
the radiator.
An incorrect fan shroud or obstructions can reduce air-
flow and cause the engine to run hot.
NOTE: Check to be sure air is not recirculating. Check for
missing baffles.
Initial Check
CAUTION
The fan shroud must be installed correctly, be in good
condition, and the shroud-to-fan clearance must be
within the manufacturer's specifications to allow
proper airflow through the radiator to provide
adequate engine cooling.
Inspect the fan shroud for proper fan clearance, cracks,
air leaks, and damage. Replace if necessary. Refer to the
equipment manufacturer's service manual for instructions.
Cummins Inc. recommends that fan clearance be

between 5.08 to 10.16 cm [2 to 4 in] from the radiator
core. Refer to the equipment manufacturer's service
manual for alternative positions.
Fan Spacer and Pulley (008-039)

Preparatory Steps
WARNING
battery cable last.
• Remove the fan drive belt. Refer to Procedure

• Remove the cooling fan. Refer to Procedure 008-040
in Section 8.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fan Spacer and Pulley
Remove
Remove the fan spacer and the fan pulley.
Inspect for Reuse

Check the spacer and pulley for cracks or damage.
If damage is found on the fan pulley, the fan hub must
also be inspected.
Inspect the fan hub for indications of oil seal leakage.

Inspect the fan hub for cracks or other damage.
Inspect the fan hub chamfer and fan pulley mating surface
for damage.
Replace the fan hub if damage is found.
Turn the fan hub by hand to check for freedom of rotation.

The fan hub must spin freely without any wobble or
excessive end clearance.
Fan, Cooling ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the fan hub bearing for wear.

The bearing must have a minimal amount of side-to-side
or end-play movement.
Replace the fan hub if there is more than 0.15 mm [0.006
in] of end play in the fan hub.
Fan Hub End Play

mm in
0.15 MAX 0.006
NOTE: Some fan hub assemblies can be rebuilt with new
bearings and related components. Check for part
availability before disassembling the fan hub.
Install
Install the fan pulley and the fan spacer.
Finishing Steps
WARNING
battery cable last.
• Install the cooling fan. Refer to Procedure 008-040 in
Section 8.
• Install the fan drive belt. Refer to Procedure 008-002 in
Section 8.
• Operate the engine and check for proper operation.
Fan, Cooling (008-040)

Preparatory Steps
Remove the fan drive belt. Refer to Procedure 008-002.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fan, Cooling
Remove
Remove the fan capscrews, the fan and the spacer.
Inspect for Reuse
WARNING
Do not rotate the engine by pulling or prying on the
fan. The fan blade(s) can be damaged and cause the
fan to fail and cause personal injury or property
damage. Use the accessory drive shaft or the
crankshaft barring tool to rotate the crankshaft.
A visual inspection of the cooling fan is required daily.

Check for cracks, loose rivets, and bent or loose blades.
Check the fan to make sure it is securely mounted.
Tighten the capscrews, if necessary.
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.
Fan, Cooling ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Replace original equipment fan that is damaged with a fan

of the identical part number. Cummins Inc. must approve
any other fan changes to be covered under warranty.
Refer to the vehicle or equipment manufacturer's
specifications for capscrew torque.
Install
Install the fan capscrews, the fan and the spacer.
Finishing Steps
Install the fan drive belt. Refer to Procedure 008-002.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Marine Gear Oil Cooler
Marine Gear Oil Cooler (008-041)

Preparatory Steps
WARNING
battery cable last.
CAUTION
NOTE: This procedure applies to marine engines only.
013-009 (Battery Cables and Connections) in
Section 13.
• Shut off the sea water inlet valve(s) on the vessel
hull, if equipped. Refer to the OEM service manual.
NOTE: This procedure applies to QSL9 and QSC8.3 with
oil cooler marine engines only. For the QSC engine with
combination cooler, refer to Procedure 008-129 (Marine
Gear Oil and Fuel Cooler Assembly) in Section 8.
NOTE: Some QSL engines are keel cooled, so not all of
the steps will apply.
• Disconnect the oil temperature and pressure sensor
connectors from the OEM harness.
Flush
Shut off the sea water inlet valve on the vessel hull, if
equipped.
Marine Gear Oil Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove the marine gear oil cooler drain plug and drain
the sea water from the marine gear oil cooler.
Disconnect the sea water inlet and outlet connections.
Use clean water to back flush all the debris from the
cooler.
Make sure the debris flushed from the cooler does not
enter the water supply hoses.
Install the drain plug and sea water hose connections.
Open the sea water valve on the vessel hull, if closed.
Remove
QSL Engines
CAUTION
Removing the sea water supply line for the shaft log
seal will allow sea water to leak into the vessel, if the
line is not plugged. To reduce the possibility of
damage, be sure to plug the supply line and prevent
sea water from leaking into the vessel.
Remove the aftercooler sea water discharge hose from
the gear cooler.
Remove the marine gear cooler sea water discharge hose
form the gear cooler.
Remove and plug the sea water supply line for the shaft
log seal from the gear oil cooler (if equipped).
Remove the transmission oil supply and return lines; mark
their locations.
Disconnect the marine gear oil pressure/temperature

sensor (if equipped).
Remove the bracket to cooler mounting capscrew.
QSC Engines
Drain the sea water system by removing the two plugs at
the bottom of the marine gear oil cooler assembly. Refer
to Procedure 008-059 (Zinc Anode) in Section 8.
Disconnect the sea water inlet and outlet pipes.
Remove the capscrews mounting the gear cooler to the
aftercooler.
Turn the cooler so the transmission oil supply and return
lines can be removed.
Remove the transmission oil supply and return lines and
mark their locations.
sensor, if equipped.
Disassemble
QSL Engines
Place the cooler in a vise and remove the two oil line
fittings from the gear cooler, if necessary.
Mark the fitting locations prior to removal.
QSC Engines
fittings from the gear cooler, if necessary.
Mark the fitting locations prior to removal.
Remove the sensors, if equipped.
Do not tighten the vise to the extent that the cooler case
can be damaged.
Inspect for Reuse

QSL Engines
Plug one gear oil port and attach an air supply line to the
other gear oil port with a quick disconnect fitting. Apply
thread sealant to the threads to prevent leaks. Do not
allow sealant to enter the gear oil cooler.
WARNING
Troubleshooting with high pressure air presents the
risk of equipment damage, personal injury, or death.
Troubleshooting must be performed by trained,
experienced technicians.
WARNING
personal injury.
Attach a high-pressure air supply source (air cylinder or
other suitable source) with an air pressure regulator and
an inline shutoff valve to the quick disconnect fitting.
Set the regulator test pressure to 276 kPa [40 psi].
Submerge the gear oil cooler into a tank of water. Rotate
the cooler to allow any trapped air to escape. Allow the
cooler to remain submerged for 1 minute.
Inspect for air bubbles at the fitting braze joints.

Inspect for air bubbles at the opening at each end of the
cooler.
If leaks are detected, replace the gear oil cooler.
Remove the cooler from the tank. Shut off the air supply
and disconnect the air supply.
Remove the plug and test fitting.
Fabricate a test fixture to seal the sea water connections,

or use connector hoses with a quick disconnect air
connection to supply a regulated test pressure of 276 kPa
[40 psi] to the sea water side of the gear oil cooler.
Submerge the cooler into a tank of water for 1 minute.

Inspect for air leaks at the braze joints of the end caps
and any bubbles from the gear oil ports. If leaks are
detected, replace the gear oil cooler.
Remove the cooler from the tank.
Shut off the air supply and disconnect the air supply.
Remove the test equipment.
WARNING
WARNING
WARNING
personal injury.
Drain the water from the cooler.
Flush the oil side of the cooler with clean solvent.
Use compressed air to dry the cooler.
QSC Engines
Plug one gear oil port and sensor ports, as needed.
Attach an air supply line to the other gear oil port with a
quick disconnect fitting.
Apply thread sealant to the threads to prevent leaks.
Do not allow sealant to enter the gear oil cooler.
Attach a high-pressure air supply source, such as an air
cylinder or other suitable source, with an air pressure
regulator and an inline shutoff valve to the quick
disconnect fitting.
Submerge the gear oil cooler into a tank of water.

Rotate the cooler to allow any trapped air to escape.
Allow the cooler to remain submerged for 1 minute.
cooler.

Remove the test fitting and install a plug. This is to keep
water from contaminating the oil side of the cooler.
WARNING
personal injury.
Submerge the cooler into a tank of water for 1 minute.
Inspect for air leaks at the braze joints.
Flush the oil and fuel sides of the cooler with clean
solvent.
Assemble
QSL Engines
Coat the threads with thread sealant and install the two
line fittings into the gear cooler, if removed. Be sure they
are oriented in the same direction as they were removed.
Tighten the two locknuts.
QSC Engines
Place the cooler in a vise.
Do not tighten the vise to the extent that the cooler case
could be damaged.
(1) Coat the threads with thread sealant and install the
two line fittings into the gear cooler, if removed. They
must be oriented in the same direction as they were
removed.
(2) Install the oil temperature sensor on the right and the
oil pressure sensor on the left.
Tighten the oil temperature sensor.
Tighten the oil pressure sensor.
Install
QSL Engines
Install the marine gear oil cooler to the mounting bracket
with two mounting capscrews. Tighten the capscrews.
Install the mounting bracket to the engine block with two
mounting capscrews. Tighten the capscrews.
Install the marine gear oil cooler inlet and outlet hoses
and tighten the hose clamps.
Install the aftercooler discharge hose and tighten the hose
clamp.
Install the transmission oil supply and return hoses to the

gear cooler.
Install the sea water supply for the shaft log seal to gear
oil cooler (if equipped).
Connect the gear oil pressure/temperature sensor wiring
harness connector (if equipped).
QSC Engines
Connect the transmission oil supply and return lines to
their original locations and tighten.
Install the marine gear oil cooler to the aftercooler.
Connect the sea water inlet and outlet pipe.

Radiator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Connect the aftercooler air inlet connection and air
crossover to the aftercooler. Refer to Procedure
010-019 (Air Crossover) in Section 10, and
Procedure 010-131 Air Intake Connection Adapter)
in Section 10.
• If the engine is sea water cooled, open the sea
water valve. Refer to the OEM service manual.
• If the engine is keel cooled, fill the cooling system.
Refer to Procedure 008-018 (Cooling System) in
Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Radiator (008-042)
General Information
Air forced through the fins of the radiator by a fan cools
the coolant pumped through the radiator. Environmental
debris (such as paper, straw, lint, and dust) can obstruct
the fins and stop the flow of air, which will reduce the
cooling effect of the radiator.
Initial Check
WARNING
personal injury.
CAUTION
Keep the compressed air nozzle a minimum of 15cm
[6 in] from the radiator core to avoid damaging the
fins. See call out 1 in the illustration
Inspect for plugged radiator fins.
Use compressed air to blow out the dirt and debris.
Air Pressure: 552 kPa [ 80 psi ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Radiator Pressure Cap
Inspect the radiator for bent or broken fins.

Inspect the radiator core and gasket for leaks.
If the radiator must be replaced, see equipment
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 injuries.
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.
Use care in removing the refrigerant system, if equipped,
before removing the radiator.
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)

General Information
The system is designed to use a pressure cap to prevent
boiling of the coolant.
Different caps are specified for the two recommended
systems:
Radiator Cap Pressure Test

System Cap
A (Normal-Duty) 104°C [220°F] 103 kPa [15 psi]
B (Light-Duty) 99°C [210°F] 48 kPa [7 psi]
Radiator Pressure Cap ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
An incorrect or malfunctioning cap can result in the loss of

coolant and the engine running hot.
Air in the coolant can result in loss of coolant from the

overflow when the aerated coolant is hot. The heated air
expands, increasing the pressure in the system, causing
the cap to open.
Similarly, coolant can be displaced through the overflow if
the head gasket leaks compression gases to the coolant
system.
The operating pressure of the cooling system and the

lubricating system can result in the mixing of the fluids if
there is a leak between the systems such as the head
gasket or oil cooler. Refer to Section 7, Lubricating Oil
System.
NOTE: Transmission fluid can also leak into the coolant
through radiator bottom tank transmission oil coolers.
Inspect for Reuse

Be sure the correct radiator cap is being used. Refer to
the Cooling System Specifications in Section V.
Inspect the rubber seal of the pressure cap for damage.
Inspect the radiator fill neck for cracks or other damage.
Refer to the equipment manufacturer's service manual for
instructions if the fill neck is damaged.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Expansion Tank
Pressure-test the radiator cap.

The pressure cap must seal within 14 kPa [2 psi] of the
value stated on the cap, or it must be replaced.
radiator cap test procedure.
Radiator Shutter Assembly (008-049)

General Information
Shutters are designed to control air-flow across the
radiator. If the shutters fail to open when needed, the
engine can run hot. Failure of the shutters to close can
result in too much air-flow and the engine running cold.
NOTE: Make sure that the air temperature sensor is
functioning correctly. Check the air-operated shutter
controls. Check for air leaks. Refer to the OEM service
manual.
Winterfronts can be used on a charge air cooled engine,

but must be designed to cover part of the frontal area of
the cooling system. A minimum of 77419 sq mm [120 sq
in] of charge air cooled frontal area must be left open to
air-flow.
Expansion Tank (008-052)

General Information
This procedure applies to QSL9 engines only. The
expansion tank on the QSC8.3 engine is part of the heat
exchanger component. Refer to Procedure 008-053.
The graphics in this procedure are of the QSL9 engine
with keel cooling. The expansion tank and mounting
bracket on the QSL9 engine with sea water cooling (heat
exchanger) is different; however, all of the hose and vent
line connections are the same.
Expansion Tank ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Initial Check
QSL Engines
Check the expansion tank, hoses and vent line
connections for signs of leaks.
Preparatory Steps
QSL Engines
WARNING
battery cable last.
WARNING
WARNING
CAUTION
013-009.
008-018.
• Disconnect the coolant level sensor connector.
Refer to Procedure 019-017 in Troubleshooting and
Repair Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC,
QSC8.3, ISL, QSL9 Engines, CM850 Electronic
Control System, Bulletin 4021416, or Procedure
019-017 in Troubleshooting and Repair Manual,
ISC, QSC8.3, ISL and QSL9 Engines, Bulletin
3666271.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Expansion Tank
Remove
QSL Engines
Disconnect the coolant make-up hose from the expansion
tank and the coolant transfer tube.
Remove the vent lines from the rear of the expansion

tank.
Remove the four mounting capscrews and lift the

expansion tank from the engine.
Remove the four bracket mounting capscrews and the

expansion tank mounting bracket.
Remove the rubber isolators.
Expansion Tank ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect for Reuse

QSL Engines
Inspect the mounting areas for cracks.
Inspect all connection points for cracks or signs of
leakage.
Inspect the fill neck and pressure cap for leakage or
cracks.
Inspect the rubber isolators for damage. Replace the

isolators, if necessary.
Inspect the mounting bracket for cracks at the bolt hole
areas or at the bend in the bracket.
Install
QSL Engines
Install the mounting bracket to the engine. Tighten the
four mounting capscrews.
Install the expansion tank onto the bracket with a rubber

vibration isolator and plain washer between the tank and
the bracket.
Install the four mounting capscrews, rubber vibrations
isolators and plain washers from the bottom of the
bracket. Tighten the capscrews.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Heat Exchanger
Install the vent line connections at the rear of the

expansion tank to the turbocharger, exhaust manifold and
thermostat housing.
Install the coolant make-up hose and clamps to the

expansion tank and coolant transfer tube. Tighten the
hose clamps.
Finishing Steps
QSL Engines
• Connect the coolant level sensor connector. Refer to
Procedure 019-017 in Troubleshooting and Repair
Manual, ISB, QSB4.5, QSB5.9, QSB6.7, ISC,
QSC8.3, ISL, QSL9 Engines, CM850 Electronic
Control System, Bulletin 4021416, or Procedure
019-017 in Troubleshooting and Repair Manual,
ISC, QSC8.3, ISL and QSL9 Engines, Bulletin
3666271.
• Fill the cooling system. Refer to Procedure 008-018.
Heat Exchanger (008-053)

General Information
Marine Applications
This procedure applies to marine engines only.
The heat exchanger and the expansion tank is a one
piece component on the QSC8.3 marine engine.
The heat exchanger and expansion tank are separate
components on the QSL9 marine engine.
Heat Exchanger ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
QSL Engines
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Use caution when draining the coolant. Do not spill
coolant into the bilge area. Coolant must not be
pumped overboard. The coolant must be disposed of
in Section 13.
• Shut off the sea water valve. Refer to the OEM service
manual.
in Section 8.
• Disconnect the coolant make-up hose from the
expansion tank to the coolant transfer tube. Refer to
• Drain the sea water system. Refer to Procedure
QSC Engines
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Use caution when draining the coolant. Do not spill
coolant into the bilge area. Coolant must not be
pumped overboard. The coolant must be disposed of
• Disconnect the batteries. Refer to Procedure 013-009.
• Shut off the sea water valve. Refer to the OEM service
manual.
in Section 8.
• Drain the sea water system. Refer to Procedure
• Disconnect the vent lines from the turbocharger,
exhaust manifold, and cylinder head. Refer to
Remove
QSL Engines
Disconnect the engine coolant heat exchanger inlet hose
(1).
Disconnect the engine coolant heat exchanger outlet hose
(2).
Disconnect the sea water coolant heat exchanger inlet
hose (3).
Disconnect the sea water coolant heat exchanger outlet
hose (4).
Remove the four mounting capscrews, retaining clamps

and isolators, and the heat exchanger.
QSC Engines
Remove the engine coolant water inlet (1) and outlet (2)
tubes from the heat exchanger.
Disconnect and remove the sea water inlet (1) from the
heat exchanger and the aftercooler.
Remove the outlet hose (2) from the heat exchanger.
Remove the two mounting capscrews at the bottom of the

heat exchanger and the four mounting capscrews at the
heat exchanger to exhaust manifold mounting.
Remove the heat exchanger.
Disassemble
QSL Engines
Remove the two end caps from the heat exchanger.
QSC Engines
Note the orientation of the zinc plug locations so they are
installed in the same location.
Remove the two end caps from the heat exchanger.
WARNING
personal injury.
NOTE: The heat exchanger core can be cleaned and leak
tested by a radiator cleaning facility. An ultrasonic cleaner
is the preferred method of cleaning.
Clean the end caps and the housing with soap and water.
Inspect the housing and caps for cracks or other damage.

Inspect the housing for deterioration of the sealing
surfaces.
Assemble
QSL Engines
Install a new gasket, seal, spacer and washer.
Install and tighten the end cap mounting capscrews.
QSC Engines
Install new o-rings on both end caps.
Install the end caps with the zinc anodes orientated in the
same location as they were removed. Tighten the
capscrews.
Install the zinc anodes.
Pressure Test
[40 psi] to the sea water side of the heat exchanger.
WARNING
personal injury.
Submerge the expansion tank into a tank of water for one
minute. Inspect for air leaks at the end caps and bubbles
at the zinc anode plugs. If leaks are detected, replace the
cooler.
Remove the test equipment and dry the cooler with
compressed air.
Install
QSL Engines
Install the coolant heat exchanger with the retaining
clamps and four mounting capscrews.
Hand-tighten the capscrews at this time.
Connect the engine coolant heat exchanger inlet hose (1).

Connect the engine coolant heat exchanger outlet hose
(2) to the heat exchanger and water pump inlet
connection.
Connect the sea water coolant heat exchanger inlet hose
(3).
Connect the sea water coolant heat exchanger outlet
hose (4).
Tighten all of the hose clamps.
Tighten the heat exchanger mounting capscrews.
QSC Engines
Install the heat exchanger to the exhaust manifold first
with the four mounting capscrews. Do not tighten these
capscrews at this time.
Install the two capscrews at the bottom of the heat
exchanger. Tighten the capscrews.
Tighten the four upper capscrews.
Connect the sea water inlet tube (1) to the heat exchanger
and the aftercooler. Tighten the capscrews on the
aftercooler connection.
Connect the sea water outlet connection (2) to the heat
exchanger and exhaust riser.
Tighten the host clamps on the heat exchanger and the
exhaust riser.
Sea Water Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Use new o-rings and install the engine coolant heat

exchanger inlet (1) and outlet (2) tubes.
Finishing Steps
QSL Engines
• Connect the coolant make-up hose from the expansion
tank to the coolant transfer tube. Refer to Procedure
• Fill the engine cooling system. Refer to Procedure
• Open the sea water valve. Refer to the OEM service
manual.
Section 13.
QSC Engines
• Connect the vent lines from the turbocharger, exhaust
manifold, and cylinder head. Refer to Procedure
• Open the sea water valve. Refer to the OEM service
manual.
Section 13.
Sea Water Pump (008-057)

Initial Check
Inspect the sea water pump for evidence of water or oil,
indicating seal leakage. If seal leakage is evident, the
pump must be repaired or replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Sea Water Pump
CAUTION
Inspect the zinc plug to make sure it is in one piece.
Refer to Procedure 008-059. If not, it must be replaced
with a new zinc plug, and the broken pieces must be
retrieved from the aftercooler to prevent damage to
components downstream in the sea water system.
Shut off the sea water supply.
Drain the sea water pump by removing the zinc plug from
the aftercooler on QSL engines. Refer to Procedure
010-005. On QSC engines, remove the plug at the bottom
of the marine gear oil/fuel cooler assembly.
Remove the cover from the back of the sea water pump.
Inspect the cover for signs of grooves worn into the cover
surface.
Inspect the impeller for missing, badly worn vanes, or
chunks of vanes missing.
If the cover is badly grooved or the impeller is badly
damaged, the pump must be repaired or replaced. See
the Repair step in this procedure for replacing the sea
water pump impeller without removing the pump from the
engine.
If the impeller is damaged, the sea water circuit down
stream (marine gear oil cooler, fuel cooler, aftercooler and
aftercooler element) of the pump must be checked and
cleaned.
Inspect the cover o-ring for cuts or other damage.
Install the cover on the back of the pump with the three
mounting capscrews.
Repair
CAUTION
If the impeller has failed and pieces are missing, all
pieces must be retrieved. The engine heat exchanger,
marine gear oil cooler, marine gear oil cooler and fuel
cooler assembly, and sea water aftercooler must be
flushed. Refer to procedures 008-053, 008-041,
008-129, and 010-005 for flushing these components.
Failure to do so can result in overheating and damage
to engine can occur.
Impeller debris can also drop into the inlet piping. Make
sure all debris is removed before installing a new impeller;
otherwise, additional impeller failures or engine
overheating will occur.
CAUTION
Inspect the zinc plug to make sure it is in one piece.
Refer to Procedure 008-059. If not, it must be replaced
with a new zinc plug, and the broken pieces must be
Shut off the sea water supply.
Drain the sea water pump by removing the zinc plug from
the aftercooler on QSL engines. Refer to Procedure
010-005. On QSC engines, remove the plug at the bottom
of the marine gear oil/fuel cooler assembly.
Remove the cover from the back of the sea water pump.
Use a small screwdriver to remove the o-ring (A).

Use a small screwdriver to remove the inner cap (B), if
equipped.
Clean the o-ring groove.
CAUTION
Do not pry against the pump housing to remove the
impeller as this can cause damage to the liner.
Be sure to note the direction of impeller vanes for proper
re-installation. Mark the outer surface.
An impeller removal tool is available from Sherwood
Pumps, Part Number 23631.
If the impeller is equipped with a threaded insert, use the
special tool or a ¾-NFT bolt (1) to insert in the impeller to
pull the impeller out.
If the impeller does not have a threaded bore, grasp the

hub of the impeller with pliers and remove the impeller
from the impeller bore.
Inspect for damage such as rips, tears, chunks of material

missing, or wear on the edges of the vanes.
Replace the impeller if damage is found.
Clean the internal pump surfaces.

Lubricate the housing with silicone or glycerine non-
petroleum-based lubricant. Petroleum-based lubricant will
damage the rubber impeller.
If non-petroleum-based lubricant is not readily available,
use soapy water to ease installation.
If the impeller is in good shape and will be reused, install it

in the same direction from which it was removed. See the
mark you made during removal.
If the impeller was not marked and the original rotation or
direction can not be determined, replace the impeller with
a new one.
An oil filter strap wrench or even plastic wire straps can be

used as an installation aid to hold the vanes.
Guide the impeller into the housing, twisting it
counterclockwise as it is advanced so that the vanes will
be deflected in the proper direction.
Continue to turn the impeller while pushing it into the

housing. It will slide all the way in when the keyway lines
up with the key.
Insert the new o-ring into the impeller housing. Use a light
coat of silicone grease to hold the o-ring in place.
Install the rubber impeller cap into the center hub of the
impeller, if equipped.
Install the cover plate and capscrews.

Preparatory Steps
CAUTION
sea water system.
• Shut off the sea water supply. Refer to the OEM
service manual.
• Drain the sea water system by removing the zinc
plug from the bottom of the aftercooler of QSL
engines. Refer to Procedure 010-005. On QSC
engines, remove the plug at the bottom of the
marine gear oil/fuel cooler assembly.
Remove
Remove the upper and lower water connections from the
sea water pump.
Remove the o-rings.
Remove the sea water pump mounting capscrews.

Remove the sea water pump.
Inspect for Reuse

Inspect the pump for cracks, leakage points or other
exterior damage.
Remove the rear cover and inspect the impeller.
Repair or replace the sea water pump if damage is found.
Inspect the water inlet and outlet connection o-rings.
Replace if damaged.
Install
NOTE: If a new sea water pump is being installed, the sea
water pump must be painted before installation.
Install the sea water pump.
Install the sea water pump mounting capscrews and
tighten.
Install the o-rings onto the water inlet and outlet

connections. Use a light coat of silicone grease to hold the
o-rings in place.
Install the upper and lower water connections from the
sea water pump.
Install the capscrews and tighten.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Zinc Anode
Finishing Steps
• Install the zinc plug in the aftercooler on QSL
engines. Refer to Procedure 010-005. On QSC
engines, install the plug in the bottom of the marine
gear oil/fuel cooler assembly.
• Open the sea water supply.
Zinc Anode (008-059)

Entfernen Sie
CAUTION
Zinc anode plugs expand and can break off during
removal. Inspect the zinc anode plug to make sure it
is in one piece. If not, it must be replaced with a new
zinc anode plug, and the broken pieces must be
CAUTION
In some cases, it will be necessary to hold the welded
fitting on the heat exchanger with an additional
wrench to prevent damage to the heat exchanger.
The QSC8.3 marine engine has two zinc anode plugs in
the heat exchanger and two in the aftercooler. The QSL9
sea water cooled engine (heat exchanger) has one zinc
anode plug in the heat exchanger and two in the
aftercooler.
The QSL9 keel cooled marine engine does not use zinc
anode plugs.
Shut off the sea water supply valve(s) and remove the
zinc anode plugs from the bottom and top of the
aftercooler assembly.
Remove the zinc anode plug from the bottom of the heat
exchanger.
Zinc Anode ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the sacrificial zinc anode plug and replace as

required.
Place the zinc portion of the plug on a metal surface and
strike the plug with a small hammer to remove loose
material. This will help to determine the actual amount of
material remaining.
Check the length of all the zinc anode plugs in the heat
exchanger and aftercooler, and replace them if they are
50 percent eroded. Frequency of replacement depends
upon the chemical reaction of raw water circulated
through the heat exchanger and aftercooler.
Zinc anode Plug Erosion Limits

mm in
A 19.0 MIN 0.750
New 51.0 MAX 2.000
B 6.4 MIN 0.250
New 16.0 MAX 0.630
If any zinc anode plug does not meet specification,
replace it with a new zinc anode plug.
Install
CAUTION
Do not use thread sealant or Teflon™ tape on the zinc
anodes. The use of any type of thread sealant will
insulate the zinc anode and prevent a good ground.
Install the zinc anode plugs in the aftercooler assembly.
Install the zinc anode plug in the bottom of the heat

exchanger.
Open the sea water supply valve(s).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Water Pump
Water Pump (008-062)

General Information
On all applications except marine, the water pump pulls
coolant from the bottom of the radiator and pumps it
through the engine and back to the top of the radiator for
cooling. Reduced or interrupted flow will result in the
engine operating hot.
On marine applications, the water pump pulls water
through a coolant return line from the heat exchanger, if
equipped, and exhaust manifold. A makeup line from an
expansion tank is also plumbed into the coolant return
line.
The pump is belt-driven from the crankshaft pulley. An

automatic belt tensioner is used to prevent the belt from
slipping on the pump pulley. A malfunction of the
tensioner will cause the water pump impeller to rotate at a
slower speed, reducing the amount of coolant flow.
The coolant flow can also be reduced if the inlet hose to

the water pump collapses. A hose will usually not
collapse while the engine is running at low speed. Check
the hose while the engine is operating at rated speed.
NOTE: Be sure the engine is warm, a minimum of 91°C
[195°F], so the thermostat is open.
A worn or malfunctioning water pump will not produce the

flow required to prevent the engine from running hot.
However, be sure to check the other possibilities indicated
in the Coolant Temperature above Normal symptom chart
in Section TS before checking the flow or replacing the
pump.
Water Pump ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Section 8.
Section 8.
Remove
Remove the water pump capscrews and the water pump.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Water Pump

Clean the o-ring sealing surface on the water pump
housing and the cylinder block.
Inspect the water pump housing and impeller for cracks or

damage.
Inspect the water pump weep hole for an indication of a
steady leak.
NOTE: 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, replace the water pump
with a new or rebuilt unit.
Install
Install a new sealing ring into the groove in the water
pump housing.
Install the water pump.

Sea Water Strainer ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
• Lift the tensioner and install the belt. Refer to
Section 8.
Section 13.
Sea Water Strainer (008-067)

General Information
Marine Applications
NOTE: Most sea water systems for heat exchanger
cooled engines use a sea water strainer. The strainer
removes debris from the sea water before it enters the
sea water pump.
NOTE: Sea water strainer arrangements may differ.

Inspect the sea water strainer daily for any foreign objects
that could restrict water flow.
CAUTION
A restricted or clogged sea water strainer can result
in hotter than normal, or overheated, engine coolant
and marine gear oil temperatures.
For more detailed information, refer to Sea Water Strainer
Cleaning in this section.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Sea Water Strainer
NOTE: If the sea water strainer is below the water level,

close the sea water inlet valves before servicing the sea
water strainer.
Disassemble
Marine Applications
Loosen and remove the sea water strainer wing nut(s) as
required.
Remove the sea water strainer assembly. Be careful not

to damage o-ring. Retain and inspect for damage.
Remove the sea water strainer basket.
Sea Water Strainer ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Clean
Marine Applications
Empty all debris from the sea water strainer basket.
Clean the sea water strainer.
Prime
Marine Applications
Prime the sea water strainer with clean water.
Assemble
Marine Applications
Install the sea water strainer.
Inspect o-ring seal for tears or damage. Replace if
necessary. Be sure o-ring is seated properly.
Install and tighten the wing nut(s).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Belt Tensioner, Automatic (Water Pump)
Open the sea water inlet valves.
Belt Tensioner, Automatic (Water

Pump) (008-080)
Initial Check
Check the belt deflection at the longest span of the belt.
The deflection must be checked at the center (1) of the
span.
The maximum deflection allowed in the belt is 9.5 to 12.7
mm [3/8 to 1/2-in].
Use belt tensioner gauge, Part Number ST-1293, to

measure the tension in the drive belt.
Belt Tension
N lbf
356 MIN 80
534 MAX 120
If the measurement is out of the specified range, replace
only the belt and perform the tension test again. If the
measurement is still outside of the specified rang after the
new belt has been installed, replace the belt tensioner.
Check the tensioner arm, pulley, and stops for cracks. If

any cracks are observed, the tensioner must be replaced.
Belt Tensioner, Automatic (Water Pump) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
With the belt installed, verify that neither tensioner arm

stop is in contact with the spring casing stop. If either stop
is touching, replace the drive belt. Refer to Procedure
After replacing the belt, if the tensioner arm stops are still
in contact with the spring case stop, replace the tensioner.
Check the location of the drive belt on the belt tensioner

pulley. The belt must be centered on, or close to the
middle of, the pulley. Misaligned belts, either too far
forward or backward, can cause belt wear, belt roll-off
failures, or increase uneven tensioner bushing wear.
Remove the drive belt. Refer to Procedure 008-002 in

Section 8.
With the belt removed, verify that the tensioner arm stop
is in contact with the spring case stop. If they are not
touching, the tensioner must be replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Belt Tensioner, Automatic (Water Pump)
Preparatory Steps
WARNING
battery cable last.
Section 13.
Section 8.
• Lift the belt tensioner to relieve tension in the belt.
Section 8.
Remove
Remove the capscrew and belt tensioner from the
bracket.
NOTE: Most belt tensioners are mounted to the water
inlet connection. Some belt tensioners are mounted to a
separate mounting bracket and use internal fasteners for
clearance.
Inspect for Reuse

Inspect the cooling fan drive belt for reuse. Refer to
Belt Tensioner, Automatic (Water Pump) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Measure the clearance between the tensioner spring case

and the tensioner arm to verify tensioner wear-out and
uneven bearing wear. If the clearance at the
measurement point 5 exceeds 3 mm [0.12 in], the
tensioner is damaged and must be replaced as a
complete assembly.
Tensioners generally will show a larger clearance gap
near the lower portion of the spring case, resulting in the
upper portion rubbing against the tensioner arm.
1 Tensioner cap
2 Tensioner arm
3 Spring case
4 Tensioner pulley
5 Clearance gap.
NOTE: Always replace the belt when a tensioner is
replaced. However, it is not always necessary to replace
a tensioner when a belt is replaced.
Inspect the tensioner for evidence of the tensioner arm

contacting the tensioner cap. If there is evidence of the
two areas making contact, the pivot tube bushing has
failed and the tensioner must be replaced.
Install
If removed, install the belt tensioner mounting bracket and
mounting bracket capscrews.
NOTE: Some belt tensioner mounting brackets use
internal fasteners for clearance.
Install the belt tensioner and capscrew.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Water Inlet Connection
Finishing Steps
• Lift and hold the tensioner using a 3/8-inch square
drive.
• Install the drive belt and release the tensioner.
Service Tip: If difficulty is experienced installing the drive
belt or if the belt seems too short, position the belt over
the grooved pulleys first. Then, while holding the tensioner
up, slide the belt over the water pump pulley.
Water Inlet Connection (008-082)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Section 8.
• Disconnect the coolant hose to the water inlet
connection. Refer to Procedure 008-045 in Section 8.
Water Inlet Connection ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Remove the water inlet connection capscrews.

Clean all the mating surfaces.
Install
Install a new water inlet connection gasket.
Install the water inlet connection and mounting
capscrews.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Keel Cooler
Finishing Steps
WARNING
battery cable last.
• Connect the coolant hose to the water inlet
Section 13.
Keel Cooler (008-083)

General Information
QSL Engines
The temperature and pressure differential tests can be
conducted at the same time, if the pressure connection
allows the temperature probe to enter the coolant flow
completely.
Temperature Differential Test

QSL Engines
NOTE: This test must be done using a blocked open
thermostat.
Install temperature probes into the inlet and outlet test
ports of the keel cooler thermostat housing.
Keel Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Operate the engine under rated rpm and load until the
engine temperature reaches its maximum. Record the
inlet and outlet coolant temperature.
A temperature differential of 25°C [45°F] or greater is
required for adequate system cooling. If the temperature
differential meets this specification, test the coolant
pressure differential.
If the temperature difference is less than 25°C [45°F],
inspect the vessel's keel coolers. Some problems with
keel coolers that can cause a high coolant temperature
differential include:
1. keel cooler size is too small
2. seawater temperature is too hot
3. marine growth on the keel cooler
4. fouling to the inside of the keel cooler
5. internal damage to the keel cooler
6. external damage to the keel cooler.
Refer to the keel cooler OEM for troubleshooting and
repair manual.
Pressure Differential Test

QSL Engines
Install test fittings and gauges into the inlet and outlet of
the keel cooler thermostat housing.
Operate the engine under rated rpm and load until the
engine temperature reaches it's maximum. Record the
inlet and outlet coolant pressure. If the pressure difference
is less than 34 kPa [5 psi], remove and test the keel
cooler thermostat. Refer to Procedure 008-014.
If the pressure difference is greater than 34 kPa [5 psi],
inspect the vessel's keel coolers. Some problems with
keel coolers that can cause high differential pressure are:
1. blockage in the keel cooling system
2. internal damage to the keel cooler.
Refer to the OEM for troubleshooting and repair manual.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Sea Water System Diagnostics
Sea Water System Diagnostics

(008-103)
General Information
NOTE: This procedure is for marine applications only.
Refer to Procedure 008-020 for engine coolant diagnostic
procedures.
This is a typical sea water cooling system. For more
engine specific system identification, refer to Procedure
200-003.
1. Grate-type strainer located on the bottom of the boat
hull
2. Vessel bottom/hull
3. Sea water inlet valve
4. Hose
5. Sea water strainer
6. Sea water pump

7. Fuel cooler
8. Aftercooler
9. Marine gear oil cooler
10. Heat exchanger
11. Sea water outlet.
Initial Check
Locate and verify that the sea water inlet valve is in the
full open position. If it is closed or partially closed, open
the valve and recheck the engine temperature.
Sea Water System Diagnostics ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the sea water strainer for foreign objects that

could restrict the water flow.
Some strainers have clear covers for easy inspection. If
the strainer has to be opened for inspection, refer to
Procedure 008-067.
If the engine was in operation with the sea water system

highly restricted due to a closed sea water inlet valve or a
clogged sea water strainer, the sea water impeller must
be inspected for damage.
If the hours in service of the sea water impeller is
unknown, then inspection of the sea water impeller is
advisable. Refer to Procedure 008-057.
If the engine continues to overheat, perform the following

procedures. If the engine does not overheat at the dock,
perform a sea trial and check for overheating under way.
Test
Attach a vacuum gauge to the inlet side of the sea water
pump.
Start the engine.
Record the sea water inlet restriction from low idle to rated
speed at 500 rpm increments. This test can be conducted
while the vessel is at the dock and not in gear or
underway.
Refer to Procedure 018-018 for Marine engine
specifications.
If the sea water inlet restriction is above specification, the

source of the restriction must be found. Troubleshooting
and repair of excessive sea water restriction is a boat
manufacturer or boat owner responsibility. Refer to the
vessel's OEM service manual. If the inlet restriction is
within the specification and the complaint can not be
verified at the dock, the test must be repeated underway.
Areas to inspect for restriction are a plugged sea water
strainer, sea water valve not fully open, defective hose
liner in a supply hose, or debris in the inlet hose.
If the sea water inlet restriction readings fluctuate during

the test, inspect the sea water supply for leaks or air
intrusion. Troubleshooting and repair of excessive sea
water restriction is a boat manufacturer or boat owner
responsibility. Refer to the vessel's OEM service manual.
Troubleshooting and repair for sea water aeration is not
covered under Cummins warranty.
Areas to inspect for a source of air are the sea water
strainer inspection cover seal, sea water valve shaft seal
packing, or loose hose clamps.
It is possible that aeration (gauge fluctuation) will only

occur while the vessel is underway due to the introduction
of air. Refer to the vessel's OEM service manual.
Areas to inspect for a source of aeration are water inlet
scoop installed backwards, incorrect water inlet scoop, or
water inlet location on the hull in aerated water flow.
Pressure Test
Attach a pressure gauge to the outlet side of the sea
water pump to check pump outlet pressure.
Start the engine and record the sea water outlet pressure
from low idle to rated speed at 500 rpm increments. This
test can be conducted while the vessel is at dock and not
in gear or underway.
specifications.
If the sea water pump outlet pressure is within
specifications, see the Temperature Differential Test step
in this procedure.
If sea water pressure is not present, check the pump for

damage. Refer to Procedure 008-057.
If the sea water pump outlet pressure is above the

maximum specification test the individual sea water
system components for excessive pressure drop as
described in the Pressure Differential Test step.
specifications.
Pressure Differential Test

QSL Engines
Check the sea water pressure at the inlet side of the
aftercooler at the rated rpm. Record the reading. If the
pressure drop between the sea water pump outlet and the
aftercooler inlet exceeds the maximum specification,
check or replace the fuel cooler.
specifications.
If the pressure drop is within specification, check the sea

water pressure at the discharge side of the aftercooler
outlet. Record the reading.
If the pressure drop between the inlet side of the
aftercooler exceeds the maximum, check for blockage in
the lower cap area of the aftercooler. Clean or replace if
necessary. Refer to Procedure 010-005.
Shut off the sea water supply valve and remove the lower
aftercooler sea water supply hose. Clean the debris from
the aftercooler and cap. Remove the upper sea water
hose and back flush the system.
specifications.

aftercooler and the outlet side of the aftercooler is within
specification, attach the pressure gauge to the gear oil
cooler drain plug located on the outlet and check for
pressure drop across the gear oil cooler.
If the pressure drop between the inlet side (1) and the
outlet side (2) of the gear cooler is greater than the
maximum specification, check for blockage in the gear
cooler. Clean or replace if necessary. Refer to Procedure
008-041.
specifications.
If the pressure drop in the gear oil cooler is within

specification, test the pressure drop across the engine
heat exchanger.
Fabricate a sea water test tool by using a 38 mm [1-1/2 in]
pipe with a fitting in the center to connect a pressure
gauge.
Install the fabricated test tool between the outlet side of

the heat exchanger and the exhaust elbow. Check the
pressure drop across the heat exchanger.
If the pressure drop is greater than the maximum
specification, check for blockage in the heat exchanger.
Clean or replace if necessary.
specifications.
If the pressure drop across the heat exchanger is within

specification, determine the pressure drop across the
exhaust elbow (diffuser). This is done by subtracting the
heat exchanger outlet pressure form the sea water pump
outlet pressure. If this pressure exceeds the maximum
specification, check for blockage in the exhaust elbow
(diffuser) and exhaust system of the vessel. Clean or
replace if necessary.
specifications.
Some vessels are equipped with a sea water bypass
valve to divert sea water flow from the exhaust elbow. If
the valve is adjusted to the lowest system pressure, be
sure the exhaust piping does not overheat under all
operating conditions.
QSC Engines
Check the sea water pressure at the inlet side of the
aftercooler at the rated rpm.
Record the reading. Refer to Procedure 018-018 for
marine engine specifications.
If the pressure drop between the sea water pump outlet
and the aftercooler inlet exceeds the maximum
specification, check for blockage or damage to the marine
gear oil/fuel cooler.
Shut off the sea water supply valve. Refer to the OEM
service manual.
Remove the marine gear oil/fuel cooler inlet and outlet
hoses. Refer to Procedure 008-129.
Clean the debris from the inlet side. Use a hose and back
flush the cooler. Refer to Procedure 008-129.
If the pressure drop is within specification, check the sea

water pressure at the discharge side of the aftercooler
outlet. Record the reading.
aftercooler exceeds the maximum, check for blockage in
the lower cap area of the aftercooler. Refer to Procedure
018-018 for marine engine specifications.
Clean or replace if necessary. Refer to Procedure
010-005.

aftercooler and the outlet side of the aftercooler is within
specification, check for pressure drop across the engine
heat exchanger.
pipe with a fitting in the center to connect a pressure
gauge.

the heat exchanger and the exhaust elbow.
Check the pressure drop across the heat exchanger.
Refer to Procedure 018-018 for marine specifications.
If the pressure drop is greater than the maximum
specification, check for blockage in the heat exchanger.
Clean or replace the heat exchanger if necessary. Refer
to Procedure 008-053.
If the pressure drop across the heat exchanger is within

specification, determine the pressure drop across the
exhaust elbow (diffuser). This is done by subtracting the
heat exchanger outlet pressure from the sea water pump
outlet pressure. Refer to Procedure 018-018 for marine
specifications.
If the pressure exceeds the maximum specification, check
for blockage in the exhaust elbow (diffuser) and exhaust
system of the vessel.
Clean or replace the elbow if necessary.
Some vessels are equipped with a sea water bypass
valve to divert sea water flow from the exhaust elbow. If
the valve is adjusted to the lowest system pressure, be
sure the exhaust piping does not overheat under all
operating conditions.

QSL Engines
pipe with a fitting in the center to connect a temperature
probe.
Install the sea water test tool with a temperature probe

between the outlet side of the heat exchanger and the
exhaust elbow (1). Operate the engine at rated rpm and
load and record the temperature.
Install the temperature probe in the outlet side of the

aftercooler (1). Operate the engine at the rated rpm and
load and record the temperature. If the temperature
difference between the aftercooler outlet and the engine
heat exchanger outlet is greater than 20°C [40°F], check
the sea water pump for water flow problems. Refer to
Procedure 008-057.
If the sea water temperature difference is less than 3°C

[5°F], check the heat exchanger for possible plating to the
heat exchanger core. Excessive plating or coating to the
inside or outside of the cooling tubes will effect the
efficiency of the heat exchanger. Refer to Procedure
008-053.
QSC Engines
pipe with a fitting in the center to connect a temperature
gauge.

the heat exchanger and the exhaust elbow.
Operate the engine at rated rpm and load and record the
temperature.
Refer to Procedure 018-018 for marine specifications.
Sea Water Hoses ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

marine gear oil/fuel cooler. Operate the engine at the
rated rpm and load.
Record the reading. Refer to Procedure 018-018 for

aftercooler. Operate the engine at the rated rpm and load.
Record the reading. Refer to Procedure 018-018. for
If the temperature difference between the marine gear oil/
fuel cooler outlet and heat exchanger outlet, or the
aftercooler outlet and the marine gear oil/fuel cooler outlet
is greater than 20°C [40°F], check the sea water pump for
water flow problems. Refer to Procedure 008-057.
If the sea water temperature difference is less than 3°C

[5°F], check the heat exchanger and marine gear oil/fuel
cooler for possible plating to the cores. Excessive plating
or coating to the inside or outside of the cooling tubes will
effect the efficiency.
Sea Water Hoses (008-104)

Inspect
Start engine, and inspect all hoses and connections for
deterioration. Particles of deteriorated hose can be carried
through the sea water system and restrict or clog small
passages, especially the heat exchanger, and partially
stop circulation. Replace as necessary.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Pulley, Fan Idler
Inspect the sea water system hoses and hose

connections for leaks. Replace damaged hoses and
clamps, if necessary.
Pulley, Fan Idler (008-111)

Preparatory Steps
• Remove the belt guard. Refer to Procedure 008-001.
008-002.
Remove
Remove the dust shield.
Remove the fan idler pulley capscrew and the fan idler
pulley.
Inspect for Reuse

Inspect the pulley for nicks, cracks or any other type of
damage.
Replace the pulley if it is damaged.
Bracket, Fan Idler Pulley ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install the fan idler pulley and capscrew.
Tighten the capscrew.
Finishing Steps
• Install the fan drive belt. Refer to Procedure
008-002.
• Install the belt guard. Refer to Procedure 008-001.
Bracket, Fan Idler Pulley (008-112)

Preparatory Steps
• Remove the belt guard. Refer to Procedure 008-001.
008-002.
• If necessary, remove the fan idler pulley(s). Refer to
Procedure 008-111.
Remove
Remove the mounting capscrews and the pulley bracket.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Bracket, Fan Idler Pulley
Inspect for Reuse

Inspect the bracket for cracks near the bolt holes or any
other type of damage.
Replace the bracket if it is cracked or damaged.
Install
Install the fan idler pulley bracket and mounting
capscrews.
Finishing Steps
• Install the fan idler pulley(s), if removed. Refer to
Procedure 008-111.
• Install the fan drive belt. Refer to Procedure
008-002.
• Install the belt guard. Refer to Procedure 008-001.
Coolant Return Junction Block ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Coolant Return Junction Block

(008-113)
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
CAUTION
Use caution when draining the coolant system that
coolant is not spilled or drained into the bilge area.
The coolant must be disposed of in accordance with
013-009.
008-018.
Remove
QSL Engines
NOTE: Some QSL9 marine engines are keel cooled and
some are sea water (heat exchanger) cooled. These first
two steps apply to the keel cooled engine.
Loosen the hose clamps at the marine gear oil cooler.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Coolant Return Junction Block
Remove the expansion tank coolant fill tube from the

coolant return junction.
Loosen the hose clamps at the water pump inlet
connection.
Remove the p-clip and the coolant return tube from the
engine.
NOTE: This step applies to the QSL9 sea water (heat

exchanger) cooled engine.
Disconnect the engine coolant return from the heat
exchanger and the water pump inlet port.
Remove the coolant return pipe.
QSC Engines
Remove the two capscrews at the water pump inlet port.
Loosen the clamps at the heat exchanger connection.
Remove the coolant return tube from the water pump inlet
port and the heat exchanger.

Clean the inlet connection of the coolant return junction.
Inspect the connection ends for cracks or other damage.
Coolant Return Junction Block ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
QSL Engines
NOTE: These steps apply to the QSL9 keel cooled
engine.
Install the coolant return tube to the water inlet connection
and the marine gear oil cooler.
Install the p-clip over the tube and to the exhaust
manifold.
Position the hose clamps and tighten.

exchanger) cooled engine.
Install the coolant return to the water pump inlet port and
heat exchanger outlet.

exchanger) cooled engine and the QSL9 keel cooled
engine.
Install the expansion tank fill line tube to the coolant return
junction and tighten the hose clamp.
QSC Engines
Install a new o-ring onto the coolant tube, if a flanged
tube.
Install the tube onto the heat exchanger first.
Install the tube onto the water pump inlet port.
Install the two mounting capscrews and tighten.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Marine Gear Oil and Fuel Cooler Assembly
Finishing Steps
008-018.
Marine Gear Oil and Fuel Cooler

Assembly (008-129)
Flush
Shut off the sea water inlet valve on the vessel hull, if
equipped.
Remove the marine gear oil cooler drain plug and drain
the sea water from the gear oil cooler.
Disconnect the sea water inlet and outlet connections.
Use clean water to back flush all the debris from the
cooler.
Make sure the debris flushed from the cooler does not
enter the water supply hoses.
Marine Gear Oil and Fuel Cooler Assembly ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install the drain plug and sea water hose connections.
Open the sea water valve on the vessel hull, if equipped.
Preparatory Steps
WARNING
battery cable last.
WARNING
CAUTION
Use caution when disconnecting or removing oil lines
that oil is not spilled or drained into the bilge area.
The oil must be drained into a suitable container and
disposed of in accordance with local environmental
regulations.
NOTE: This procedure applies to QSC8.3 marine engine
only. Refer to Procedure 008-041 for QSL9 marine
engines.
013-009.
• Shut off the fuel supply and drain valves. Refer to
• Disconnect the OEM fuel supply and OEM drain
lines from the fuel cooler side of the assembly.
• Shut off the sea water inlet valve(s) on the vessel
hull, if equipped. Refer to the OEM service manual.
• Disconnect the oil temperature and pressure sensor
• Drain the sea water system by removing the two
plugs at the bottom of the marine gear oil and fuel
cooler assembly. Refer to Procedure 008-059.
• Disconnect the sea water inlet and outlet pipes.
Remove
Disconnect the fuel supply hose from the lift pump to the
fuel cooler at the fuel cooler.
Remove the mounting capscrews from the gear cooler to

aftercooler.
Twist the cooler so the transmission oil supply and return
lines can be removed.
Remove the transmission oil supply and return lines; mark

their locations.
sensor (if equipped).
Disconnect the braided fuel return hose from the rear of
the cooler.
Disassemble
fittings from the gear cooler, if necessary. Mark the fitting
locations prior to removal.
Inspect for Reuse

Plug one gear oil port and attach an air supply line to the
other gear oil port with a quick disconnect fitting. Apply
thread sealant to the threads to prevent leaks. Do not
allow sealant to enter the gear oil cooler.
Repeat the leak test for the fuel side of the cooler
assembly.
WARNING
Troubleshooting with high pressure air presents the
risk of equipment damage, personal injury, or death.
Troubleshooting must be performed by trained,
experienced technicians.
WARNING
personal injury.
Attach a high-pressure air supply source (air cylinder or
other suitable source) with an air pressure regulator and
an inline shutoff valve to the quick disconnect fitting.
Submerge the gear oil cooler into a tank of water. Rotate
the cooler to allow any trapped air to escape. Allow the
cooler to remain submerged for one minute.

cooler.
Remove the cooler from the tank. Shut off the air supply
and disconnect the air supply.
Remove the plug and test fitting.

Submerge the cooler into a tank of water for one minute.

Inspect for air leaks at the braze joints of the end caps
and any bubbles from the gear oil ports. If leaks are
detected, replace the gear oil cooler.
WARNING
WARNING
WARNING
personal injury.
Flush the oil and fuel sides of the cooler with clean
solvent.
Assemble
Coat the threads with thread sealant and install the two
line fittings into the gear cooler, if removed. Be sure they
are oriented in the same direction as they were removed.
Install the oil temperature sensor on the right and the oil
pressure sensor on the left. Tighten the sensors.
Install
Connect the transmission oil supply and return lines to
their original locations and tighten.
Connect the braided fuel return line to the fuel cooler and
tighten.
Install the marine gear oil cooler to the aftercooler.

Install the fuel supply hose from the lift pump through the
cooler housing using two jam nuts.
Finishing Steps
• Connect the oil temperature and pressure sensor
• Connect the sea water inlet and outlet pipe. Refer to
• Connect the OEM fuel supply and drain lines to the
fuel cooler.
• Install the plugs in the bottom of the marine gear oil
and fuel cooler assembly. Refer to Procedure
008-059.
• Open the sea water inlet valve(s). Refer to the OEM
service manual.
OEM service manual.
Section 9 - Drive Units - Group 09 Page 9-a
Section 9 - Drive Units - Group 09

Section Contents
Page
Belt Tensioner, Refrigerant Compressor, Automatic ..............................................................................................9-8
Finishing Steps.........................................................................................................................................................9-11
Initial Check................................................................................................................................................................9-8
Install........................................................................................................................................................................ 9-10
Install........................................................................................................................................................................ 9-11
Remove......................................................................................................................................................................9-9
Drive Belt, Refrigerant Compressor ..........................................................................................................................9-6
Finishing Steps...........................................................................................................................................................9-8
Install..........................................................................................................................................................................9-7
Remove......................................................................................................................................................................9-6
Engine Barring Device ...............................................................................................................................................9-3
Finishing Steps...........................................................................................................................................................9-3
Install..........................................................................................................................................................................9-3
Hydraulic Pump Drive ................................................................................................................................................9-1
Clean..........................................................................................................................................................................9-1
Install..........................................................................................................................................................................9-2
Remove......................................................................................................................................................................9-1
Refrigerant Compressor ............................................................................................................................................9-4
Finishing Steps...........................................................................................................................................................9-5
Install..........................................................................................................................................................................9-5
Remove......................................................................................................................................................................9-4
Refrigerant Compressor Mounting Bracket ...........................................................................................................9-12
Finishing Steps.........................................................................................................................................................9-14
Install........................................................................................................................................................................ 9-13
Remove.................................................................................................................................................................... 9-12
Page 9-b Section 9 - Drive Units - Group 09

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Hydraulic Pump Drive
Section 9 - Drive Units - Group 09 Page 9-1
Hydraulic Pump Drive (009-016)

Entfernen Sie
Disconnect all hydraulic lines from the pump.
Remove the hydraulic pump and gear assembly.

removal procedures.
Clean
Clean the gasket material from the hydraulic pump.
Hydraulic Pump Drive ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 9-2 Section 9 - Drive Units - Group 09
WARNING
WARNING
WARNING
personal injury.
Clean the hydraulic pump gear with solvent.
Inspect for Reuse

Inspect the hydraulic pump drive gear for damage.
Install
Use a new gasket and install the hydraulic pump.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Barring Device
Connect all hydraulic lines to the pump.
Tighten mounting bolts.

Engine Barring Device (009-035)

Install
Rear Barring
• Remove the plastic cover in the flywheel
housing. Insert Cummins® service tool, Part Number
3824591, into the flywheel housing. Use a 1/2-inch
breaker bar and rotate it counterclockwise, when
viewed from the front of the engine.
Finishing Steps
Rear Barring
• Make sure that the Cummins® service tool, Part
Number 3824591, has been removed from the
flywheel housing and the plug has been installed.
Refrigerant Compressor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Refrigerant Compressor (009-051)

Preparatory Steps
WARNING
battery cable last.
• Disconnect the battery. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13 of
the ISBe, ISB, and QSB (Common Rail Fuel
System) Service Manual, Bulletin 4021271, or
Procedure 013-009 (Battery Cables and
Connections) in Section 13 of the ISC, ISCe,
QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines
Troubleshooting and Repair Manual, Bulletin
4021418.
Procedure 008-001 (Belt Guard) in Section 8 of the
ISBe, ISB, and QSB (Common Rail Fuel System)
Service Manual, Bulletin 4021271, or Procedure
008-001 (Belt Guard) in Section 8 of the ISC, ISCe,
4021418.
• Remove the drive belt from the refrigerant
compressor pulley. Refer to Procedure 009-052
(Drive Belt, Refrigerant Compressor) in Section 9.
Remove
Remove the refrigerant compressor mounting capscrew.
Remove the refrigerant compressor.
Refer to the OEM service manual for information on
disconnecting refrigerant lines.
Inspect for Reuse

Refer to the OEM service manual for refrigerant
compressor cleaning and inspection procedures.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Refrigerant Compressor
Install
Install the refrigerant compressor and the refrigerant
compressor mounting capscrews.
Reference the compressor manufacturer's guidelines for
torque values.
NOTE: Due to the availability of different front end
accessory drive configurations, this procedure is meant to
be generic. Some front end accessory drive configurations
may require the refrigerant compressors to be aligned
with the other pulleys. Make sure all drive pulleys and
idler pulleys are in alignment with one another. The
components with shorter belt spans are the most critical
and require special attention. Cummins Inc. recommends
the use of the laser alignment tool, Part Number 3163524.
Finishing Steps
WARNING
battery cable last.
• Install the drive belt. Refer to Procedure 009-052
• Install the belt guard, if equipped. Refer to
4021418.
• Connect the battery. Refer to Procedure 013-009
4021418.
Drive Belt, Refrigerant Compressor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Drive Belt, Refrigerant Compressor

(009-052)
Preparatory Steps
WARNING
battery cable last.
4021418.
4021418.
Entfernen Sie
CAUTION
tensioner.
CAUTION
windup or after the tensioner has been wound to the
positive stop can cause the tensioner arm to crack or
break.
CAUTION
The use of a socket extension is not recommended
tensioner.
Lift the tensioner to remove the refrigerant compressor
drive belt.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Drive Belt, Refrigerant Compressor
Inspect for Reuse

Inspect the belt for:
• Cracks
• Glazing
• Tears or cuts
• Hardening
• Excessive wear.
Check the belt for damage.

Transverse (across the belt width) cracks are acceptable.
Longitudinal (direction of the belt length) cracks that
intersect with transverse cracks are not acceptable.
If the belt is frayed or has any piece of material missing,
the belt is unacceptable and must be replaced.
Install
CAUTION
tensioner.
Lift and hold the belt tensioner.
Install the drive belt and release the tensioner.
NOTE: Due to the availability of different belt run
configurations, this procedure is meant to be generic.
Reference the application manufacturer's manuals for the
correct belt run.
Belt Tensioner, Refrigerant Compressor, Automatic ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
4021418.
4021418.
Belt Tensioner, Refrigerant

Compressor, Automatic (009-053)
Initial Check
Check the tensioner arm, pulley, and stops for cracks.
If cracks are found, the tensioner must be replaced.
With the belt on, verify that neither of the tensioner arm
stops are in contact with the spring casing stop.
If either stop is touching, the drive belt must be replaced.
If the tensioner arm stops are still in contact with the
spring case stop after replacing the belt, replace the
tensioner.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Belt Tensioner, Refrigerant Compressor, Automatic
Check the location of the drive belt on the belt tensioner

pulley. The belt should be centered on, or close to the
middle of, the pulley.
Misaligned belts, either too far forward or backward, can
cause belt wear, belt roll-off failures, or increase uneven
tensioner bushing wear.
Preparatory Steps
WARNING
battery cable last.
4021418.
4021418.
• Remove the drive belt. Refer to Procedure 009-052
Remove
Remove the capscrew and belt tensioner from the
mounting location.
Belt Tensioner, Refrigerant Compressor, Automatic ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
With the belt removed, verify the tensioner arm stop is in
contact with the spring casing stop.
If these two are not touching, the tensioner must be
replaced.
Measure the clearance between the tensioner spring

casing and the tensioner arm to verify tensioner wear-out
and uneven bearing wear.
If the clearance exceeds 3 mm [0.12 in] at any point, the
tensioner must be replaced as a complete assembly.
Tensioners usually show a larger clearance gap near the
lower portion of the spring casing, resulting in the upper
portion rubbing against the tensioner arm. Always replace
the belt when a tensioner is replaced.
1. Tensioner cap
2. Tensioner arm
3. Spring case
4. Tensioner pulley
5. Clearance gap.
Inspect the tensioner for evidence of the tensioner arm

contacting the tensioner cap.
If there is evidence of the two areas making contact, the
pivot tube bushing has failed and the tensioner must be
replaced.
Inspect the mating surface for debris. The tensioner can

become misaligned if particles are trapped between the
mating surfaces.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Belt Tensioner, Refrigerant Compressor, Automatic
Install
Install the belt tensioner and capscrew.
Finishing Steps
WARNING
battery cable last.
• Lift and hold the tensioner, use a 3/8-inch square
drive.
• Install the drive belt and release the tensioner. Refer
to Procedure 009-052 (Drive Belt, Refrigerant
Compressor) in Section 9.
4021418.
4021418.
Refrigerant Compressor Mounting Bracket ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Refrigerant Compressor Mounting

Bracket (009-055)
Preparatory Steps
WARNING
battery cable last.
4021418.
4021418.
• Remove the drive belt from the refrigerant
compressor. Refer to Procedure 009-052 (Drive Belt,
Refrigerant Compressor) in Section 9.
• Remove the refrigerant compressor. Refer to
Procedure 009-051 (Refrigerant Compressor) in
Section 9.
Remove
Remove the refrigerant compressor bracket mounting
capscrews and bracket.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Refrigerant Compressor Mounting Bracket
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the refrigerant compressor
mounting brackets.
Inspect the refrigerant compressor mounting brackets for
cracks or damage.
If cracks are found on the refrigerant compressor
mounting brackets, they must be replaced.
Install
Install the refrigerant compressor mounting bracket and
bracket mounting capscrews.
NOTE: Due to the availability of different bracket
configurations, this procedure is meant to be generic.
Note any knife edges or alignment pins on the bracket
that need to be used and make sure the mating or
alignment features are free from debris.
Refrigerant Compressor Mounting Bracket ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the refrigerant compressor. Refer to
Procedure 009-051 (Refrigerant Compressor) in
Section 9.
• Install the drive belt from the refrigerant compressor.
Refer to Procedure 009-052 (Drive Belt, Refrigerant
Compressor) in Section 9.
4021418.
4021418.
Section 10 - Air Intake System - Group 10 Page 10-a
Section 10 - Air Intake System - Group 10

Section Contents
Page
Aftercooler Assembly (Sea Water) ..........................................................................................................................10-3
Assemble..................................................................................................................................................................10-8
Disassemble.............................................................................................................................................................10-6
Finishing Steps.......................................................................................................................................................10-10
QSL Engines........................................................................................................................................................10-10
QSC Engines.......................................................................................................................................................10-10
Initial Check..............................................................................................................................................................10-3
Install........................................................................................................................................................................10-8
QSL Engines..........................................................................................................................................................10-8
QSC Engines.........................................................................................................................................................10-9
QSL Engines..........................................................................................................................................................10-4
QSC Engines.........................................................................................................................................................10-5
Pressure Test...........................................................................................................................................................10-8
Remove....................................................................................................................................................................10-6
QSL Engines..........................................................................................................................................................10-6
QSC Engines.........................................................................................................................................................10-6
Air Cleaner Assembly (Engine-Mounted) .............................................................................................................10-11
Clean...................................................................................................................................................................... 10-12
Initial Check............................................................................................................................................................10-11
Install...................................................................................................................................................................... 10-13
Remove.................................................................................................................................................................. 10-11
Air Crossover ..........................................................................................................................................................10-13
Install...................................................................................................................................................................... 10-14
Remove.................................................................................................................................................................. 10-13
Air Inlet Connection ................................................................................................................................................10-15
Finishing Steps.......................................................................................................................................................10-16
Install...................................................................................................................................................................... 10-16
Remove.................................................................................................................................................................. 10-15
Air Intake Connection .............................................................................................................................................10-59
Finishing Steps.......................................................................................................................................................10-60
Install...................................................................................................................................................................... 10-60
Remove.................................................................................................................................................................. 10-59
Air Intake Connection Adapter ..............................................................................................................................10-67
Finishing Steps.......................................................................................................................................................10-69
Install...................................................................................................................................................................... 10-68
Remove.................................................................................................................................................................. 10-67
Air Intake Manifold Cover ...................................................................................................................................... 10-61
Finishing Steps.......................................................................................................................................................10-62
Install...................................................................................................................................................................... 10-62
Remove.................................................................................................................................................................. 10-61
Air Intake Restriction ..............................................................................................................................................10-30
Measure..................................................................................................................................................................10-30
Air Leaks, Air Intake and Exhaust Systems .........................................................................................................10-16
Initial Check............................................................................................................................................................10-16
Charge-Air Cooler ...................................................................................................................................................10-21
Page 10-b Section 10 - Air Intake System - Group 10
Clean...................................................................................................................................................................... 10-25
Finishing Steps.......................................................................................................................................................10-26
Initial Check............................................................................................................................................................10-21
Install...................................................................................................................................................................... 10-25
Leak Test................................................................................................................................................................10-21
Pressure Test......................................................................................................................................................... 10-22
Remove.................................................................................................................................................................. 10-24
Cold Starting Aid .....................................................................................................................................................10-26
Finishing Steps.......................................................................................................................................................10-29
Install...................................................................................................................................................................... 10-29
Remove.................................................................................................................................................................. 10-28
Inline Air Filter .........................................................................................................................................................10-69
Finishing Steps.......................................................................................................................................................10-70
Install...................................................................................................................................................................... 10-70
Remove.................................................................................................................................................................. 10-70
Intake Manifold Pressure .......................................................................................................................................10-58
Measure..................................................................................................................................................................10-58
Service Tools ............................................................................................................................................................10-1
Air Intake System......................................................................................................................................................10-1
Turbocharger .......................................................................................................................................................... 10-31
Finishing Steps.......................................................................................................................................................10-45
Initial Check............................................................................................................................................................10-31
Install...................................................................................................................................................................... 10-43
Prime...................................................................................................................................................................... 10-44
Remove.................................................................................................................................................................. 10-40
Turbocharger Actuator Air Line ............................................................................................................................ 10-65
Finishing Steps.......................................................................................................................................................10-66
Install...................................................................................................................................................................... 10-66
Remove.................................................................................................................................................................. 10-65
Turbocharger Coolant Hoses ................................................................................................................................ 10-46
Finishing Steps.......................................................................................................................................................10-50
Install...................................................................................................................................................................... 10-49
Remove.................................................................................................................................................................. 10-47
Turbocharger Exhaust Connection Adapter ........................................................................................................10-71
Finishing Steps.......................................................................................................................................................10-72
Install...................................................................................................................................................................... 10-72
Remove.................................................................................................................................................................. 10-71
Turbocharger Oil Drain Line ..................................................................................................................................10-51
Initial Check............................................................................................................................................................10-51
Install...................................................................................................................................................................... 10-52
Remove.................................................................................................................................................................. 10-51
Turbocharger Oil Supply Line ............................................................................................................................... 10-52
Initial Check............................................................................................................................................................10-52
Install...................................................................................................................................................................... 10-53
Remove.................................................................................................................................................................. 10-52
Turbocharger Wastegate Actuator ........................................................................................................................10-53
Section 10 - Air Intake System - Group 10 Page 10-c
Initial Check............................................................................................................................................................10-53
Install......................................................................................................................................................................10-57
Remove..................................................................................................................................................................10-55
Test.........................................................................................................................................................................10-54
Turbocharger Wastegate Valve Body ...................................................................................................................10-57
Finishing Steps.......................................................................................................................................................10-58
Maintenance Check................................................................................................................................................10-57
Variable Geometry Turbocharger Actuator, Pneumatic ......................................................................................10-63
Finishing Steps.......................................................................................................................................................10-65
Install......................................................................................................................................................................10-64
Remove..................................................................................................................................................................10-63
Test.........................................................................................................................................................................10-64
Page 10-d Section 10 - Air Intake System - Group 10

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

Fluorescent Tracer
Add to oil. Used with black light, Part Number 3163338 to find oil
3376891 leaks.
Fluke Digital Thermometer

Used to measure voltage.
3822666
Thermocouple Wire Kit

Used to check temperature. Used with fluke digital multimeter, Part
3822988 Number 3164488.
Black Light (VDC)

Used to inspect for oil or fuel leak.
3163338
Manometer
Used to measure pressure, restriction (0 to 10 in H 2O) with more
ST-1111-3 accuracy.
Pressure Gauge (0 to 75 in Hg)

Used to measure the intake manifold pressure and exhaust back
ST-1273 pressure.
Page 10-2 Section 10 - Air Intake System - Group 10

Dial Depth Gauge
Used to measure turbocharger axial motion.
ST-537
Coupling
Used to apply regulated shop air pressure to variable geometry
3824843 turbocharger actuator.
Charge Air Cooler Tester

Used to pressure test the charge air cooler.
3824556
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftercooler Assembly (Sea Water)
Aftercooler Assembly (Sea Water)

(010-005)
Initial Check
A turbocharger or sea water pump failure can cause
damage to the aftercooler assembly.
If a turbocharger failure or a sea water pump failure has
occurred, remove the aftercooler element and inspect the
element and housing for damage.
Inspect the zinc anodes to make sure they are still in one
piece and have not broken.
See the Inspect step within this procedure.
Aftercooler Assembly (Sea Water) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
QSL Engines
WARNING
battery cable last.
WARNING
CAUTION
CAUTION
sea water system.
• Shut off the sea water supply and return line(s).
• Shut off the fuel supply and return lines. Refer to the
OEM service manual.
• Disconnect the battery power from the engine. Refer
• Drain the sea water by removing the zinc anode plug
at the bottom of the aftercooler. Refer to Procedure
008-059.
• Loosen the aftercooler top and bottom air
connection hose clamps.
• If necessary, remove the aftercooler air discharge
• Disconnect the aftercooler air inlet connection. Refer
• If necessary, remove the fuel drain flex hoses at the
fuel cooler.
• Remove the fuel cooler clip and mounting capscrew.
• Remove the fuel cooler lower molded sea water
hose from the aftercooler. Support the cooler to
prevent damage to the fuel lines.
• Loosen the hose clamp on the upper water transfer
connection and remove the aftercooler sea water
discharge hose.
QSC Engines
WARNING
battery cable last.
WARNING
CAUTION
CAUTION
sea water system.
• Shut off the sea water supply and return lines. Refer
to the OEM service manual.
• Shut off the fuel supply and return lines. Refer to the
OEM service manual.
013-009.
• Drain the sea water system by removing the plugs at
the bottom of the marine gear oil and fuel cooler.
• Remove the aftercooler air box drain plug and drain
the condensation from the aftercooler housing core.
• Remove the air crossover and air outlet tube. Refer
• Remove the sea water lines. Refer to Procedure
008-056.
• Remove the marine gear oil and fuel cooler
assembly. Refer to Procedure 008-129.
Remove
QSL Engines
Loosen the aftercooler mounting capscrews at the
flywheel housing (1), the cylinder block (2), and the
cylinder head (3).
Remove the aftercooler assembly.
QSC Engines
Remove the upper mounting capscrews and loosen the
bracket mounting capscrews in the cylinder block.
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.
Attach a lifting strap and use a suitable hoist to lift the
assembly.
Remove the lower mounting capscrews.
Slide the assembly from the bracket and away from the
engine.
Disassemble
NOTE: Although the QSC8.3 and QSL9 aftercoolers look
different, the following steps will apply to both.
Mark or note the aftercooler inlet and outlet water
connection locations.
Remove the zinc plugs from the upper water transfer
connection.
Remove the three capscrews and the upper water
connection.
CAUTION
The aftercooler core assembly will slide out of the
cooler housing when removing the lower aftercooler
water connection. To reduce the possibility of
damaging the core, lay the aftercooler assembly on
its side to remove the connection and the core.
Lay the aftercooler assembly on its side.
The core assembly has two flat sides which must be
orientated toward the aftercooler air intake and outlet
sides of the aftercooler.
Remove the lower connection cover and the core.
Remove the upper and lower sealing o-rings.
WARNING
personal injury.
NOTE: The aftercooler core can be cleaned and tested by
a radiator cleaning facility. Ultrasonic cleaner is the
preferred method of cleaning.
Use soap and water to clean the aftercooler and end
caps.
Inspect the housing and caps for cracks or other damage.

Inspect the aftercooler housing for deterioration of the
sealing surfaces.
Assemble
Assemble the aftercooler in a vertical position. Install the
aftercooler core into the aftercooler housing. Align the
marks so one flat side of the core is facing the air inlet
side of the housing.
Install a new o-ring around the lower core O.D. Install the
water end cap and tighten the capscrews.
Install a new o-ring around the upper core O.D. Install the
water end cap and tighten the capscrews.
Install the zinc plugs and tighten.
Pressure Test
WARNING
personal injury.
Pressure test the sea water side of the aftercooler
assembly.
Apply 276 kPa [40 psi] air pressure.
Lower the assembly into a tank of water and check for
leaks.
Completely dry the aftercooler with compressed air.
Install
QSL Engines
Loosely install the aftercooler assembly to the flywheel
housing first using two mounting capscrews.
Install the upper capscrews first.
Install the aftercooler to bracket mounting capscrews.

Tighten all capscrews.
Torque Value:
Bracket to100 N•m [ 74 ft-lb ]
Flywheel Housing
Bracket to44 N•m [ 32 ft-lb ]
Cylinder Head
Aftercooler to35 N•m [ 26 ft-lb ]
Bracket
QSC Engines
Attach a lifting strap and use a suitable hoist to lift the
aftercooler assembly into place.
Slide the assembly onto the lower support bracket and
install the lower mounting capscrews.
Install the upper bracket to the aftercooler mounting

capscrews. Tighten all of the upper bracket mounting
capscrews finger tight.
Tighten the bracket to the cylinder block mounting
capscrews.
Tighten the bracket to aftercooler mounting capscrews.
Finishing Steps
QSL Engines
• Install the fuel cooler lower molded sea water hose
to the aftercooler.
• Install the fuel cooler clip and mounting capscrew.
• If removed, install the fuel drain flex hoses at the fuel
cooler.
• Connect the aftercooler air inlet connection from the
turbocharger.
• Install the aftercooler sea water discharge to marine
gear cooler hose and tighten the hose clamps.
• If removed, install the aftercooler air discharge to the
intake air connection. Refer to Procedure 010-131.
• Tighten the aftercooler top and bottom air
connection hose clamps.
• Connect the battery power to the engine. Refer to
Procedure 013-009.
• Open the sea water supply and return line(s). Refer
• Open the fuel supply and return lines. Refer to the
OEM service manual.
QSC Engines
• Install the marine gear oil and fuel cooler assembly.
• Install the sea water lines. Refer to Procedure
008-056.
• Install the air crossover and air outlet tube. Refer to
Procedure 010-019.
• Open the fuel supply and return valves. Refer to the
OEM service manual.
• Open the sea water supply and return valves. Refer
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Cleaner Assembly (Engine-Mounted)
Air Cleaner Assembly (Engine-

Mounted) (010-013)
General Information
Some marine engines are equipped with a factory
installed closed crankcase breather system which is
connected to the engine intake air cleaner. Aftermarket
(non-factory installed) closed crankcase breather systems
can not be installed on Cummins marine engines.
Installing such non-factory devices will void the warranty.
The closed crankcase system has three major parts.
1. The air cleaner assembly; this filters the incoming air
and a oil blow-by filter element called a coalescing
filter.
2. Vacuum brake assembly; this keeps the engine from
drawing oil directly into the turbocharger if the air
cleaner is plugged.
3. Closed crankcase drain plumbing; this includes the
drain hoses and check valve. The check valve
prevents crankcase pressure from flowing
backwards in the air cleaner.
Initial Check
Check the restriction gauge on the air filter assembly. If
the gauge is red, the air filter element must be cleaned or
replaced.
Entfernen Sie
CAUTION
Use caution when disconnecting or removing oil
lines, or replacing filters that oil is not drained into
the bilge area. Do not drop or throw filter elements
into the bilge area. The oil and filters must be
discarded in accordance with local environmental
regulations.
Release the clamp and remove the air cleaner element.
Remove the turbocharger silencer cone from inside of the
filter element.
Air Cleaner Assembly (Engine-Mounted) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Clean
NOTE: It is possible a filter which is damaged or clogged
with soot due to an exhaust leak will not be able to be
cleaned to maximum efficiency. Replacement of the
element will be necessary.
Tap the filter element to dislodge any large embedded
particles or dirt.
Gently brush the filter element with a soft bristle brush.
CAUTION
To avoid damage to the components, do not use
gasoline, high-pressure water or air, caustic cleaning
solutions, or parts-cleaning solvents to clean the air
filter.
CAUTION
To avoid damage to the components, do not use
compressed air, an open flame or heat dryers to dry
the air filter.
NOTE: Always flush from the clean side to the dirty side.
This will remove the particles and dirt, and not drive it into
the air filter.
Rinse the air filter element with low pressure water. Tap
water is okay.
After rinsing the air filter, shake off all the excess water
and let the filter element air dry.
NOTE: Do not use automatic transmission fluid, motor oil,

diesel fuel, WD-40® lubricant, or any other light weight oil.
Use approved filter oil.
After cleaning the air filter, always re-oil the filter element
with oil before using. The effectiveness of the air filter is
greatly reduced if it is used without oiling. Sparingly
squeeze small amounts of oil out of a bottle across the top
of each pleat.
Let the oil wick into the filter element for twenty minutes.
Then re-oil any dry area that are showing.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Crossover
Install
Install the turbocharger silencer cone.
Install the o-ring around the outside of the filter base.
Install the filter onto the engine and secure with the clamp.
Air Crossover (010-019)

Entfernen Sie
NOTE: Brush away all loose dirt from around the area of
the air handling connections to avoid contamination of the
interior of the engine.
Loosen the hose clamps and position the crossover tube
so it can be removed.
Remove the crossover tube.
Install the protective caps from the Air Handling Clean
Care Kit, Part Number 4919508, on all open connection
points, including inlet to the engine, charge-air cooler, and
ends of the crossover tube.
Marine Applications
NOTE: The graphics used in this procedure are of the
QSL9 engine; however, the procedure is the same for the
QSC8.3 engine.
Remove the flange clamp from the turbocharger outlet.
Loosen the hose clamps and pull the air crossover from
the aftercooler housing air inlet.
Discard the turbocharger flange o-ring.

Check the crossover tube for cracks, holes, and worn
sections.
Also check for poor sealing between the hose and tube.
Inspect the clamps for wear.
Replace damaged components with a new hose and
clamps if necessary.
Air Crossover ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
WARNING
WARNING
WARNING
personal injury.
Use solvent to clean the air crossover tube.
Inspect the tube for damage to the sealing flange or

cracks in the tube.
Replace the tube if excessive damage is found.
Replace any hose that has extruded or cracked.
Replace any cracked or damaged clamps.
Install
Remove all protective caps from the components.
Install the crossover tube and clamps in the reverse order
of removal.
Tighten the clamps. Refer to the OEM service manual for
the torque specification.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Inlet Connection
Marine Applications
Install a new o-ring seal on the turbocharger flange.
Install the hose and clamps.
Install the air crossover tube and the flange clamp.
Tighten the flange clamp.
Air Inlet Connection (010-022)

Preparatory Steps
NOTE: Brush away all loose dirt from around the area of
the air handling connections to avoid contamination of the
interior of the engine.
• Remove the air crossover pipe that is attached to the
intake connection. Refer to Procedure 010-019 in
Section 10.
Remove
Remove the v-band clamp, air inlet connection and seat.

Inspect the air inlet connection and seal for cuts, cracks,
holes, or worn sections.
Air Leaks, Air Intake and Exhaust Systems ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install the seal, air inlet connection and v-band clamp.
Tighten v-band clamp.
Finishing Steps
• Install the air crossover pipe that is attached to the
Air Leaks, Air Intake and Exhaust

Systems (010-024)
Initial Check
Leaks in the intake air system are most commonly
identified by:
1 Inspection of piping for cracked or loose clamps.
2 Applying a solution of soapy water in the suspected
area and inspecting for bubbles.
3 Listening for a high-pitched whining or sucking noise in
the suspected area.
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.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Leaks, Air Intake and Exhaust Systems
Inspect the inlet air piping for cracked hoses and

damaged or loose clamps.
Operate the engine at high idle, and use a solution of
soapy water to spot intake air leaks.
If an air leak exists, the soap bubbles will be drawn in with
the air.
Replace damaged pipes and tighten loose clamps to

make sure the air inlet system does not leak.
Check for corrosion of the inlet system piping under the
clamps and hoses. Corrosion can allow corrosive
products and dirt to enter the intake system.
Disassemble and clean as required.
Pressure Side Intake System:

Leaks in the intake system will reduce the amount of air to
the cylinders during engine operation and decrease
engine performance.
Operate the engine at full throttle and rated rpm with

maximum load.
Listen for a high-pitched whistling sound from the
turbocharger, nearby piping, and connections.
Apply a soapy water solution to sealing surfaces and
inspect for bubbles. Bubbles can be easily detected.
Leaks can also be found at the turbocharger compressor

outlet connection.
Inspect for damage, replace sealing o-ring, and tighten
loose clamps. Refer to Procedure 010-033 in Section 10.
Charge Air Cooler Tubing or Connecting Hoses:

Inspect the hose and tubing for damage. Refer to
Tighten loose clamps.
See the equipment manufacturer's specifications for the
correct torque value.
Aftercooler or Aftercooler Hose Connections:

Inspect the aftercooler housing end caps, zinc anode
plugs, and condensation valve for leaks. Refer to
Inspect the air connection hoses and tubes for leaks.
Air Intake Connection:

Inspect for damage.
If necessary, replace the gasket or tighten loose clamps.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Leaks, Air Intake and Exhaust Systems
Intake Manifold:
Inspect for damage.
Replace the gasket, if necessary. Refer to Procedure
Wastegate Capsule/Plumbing:
Inspect for damage. Refer to Procedure 010-033 in
Section 10.
Variable Geometry Turbocharger Actuator Plumbing:

Inspect for cracks and/or air leaks. Refer to Procedure
Compressor Housing Sealing Surface:

Inspect for damage. Refer to Procedure 010-033 in
Section 10.
Clean surface with a clean cloth.
Exhaust System:
Leaks in the exhaust system will cause the turbocharger
to operate at a lower speed, reducing the amount of air
going to the cylinders during engine operation.

maximum load.
Leaks can be identified by noise, soapy water, or
discoloration caused by the escaping hot gases.
Inspect the exhaust manifold gaskets for leaks. Refer to

Inspect the turbocharger mounting gaskets for leaks.

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Charge-Air Cooler
Inspect the turbine housing sealing surface for leaks.


maximum load.
Listen and inspect again for leaks.
Charge-Air Cooler (010-027)

Initial Check
Inspect the charge-air cooler for cracks, holes, and other
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.
Inspect the charge air cooler plumbing for cracks and
other damage.
Leak Test
WARNING
To reduce the possibility of 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 be performed with securely
fastened safety chains.
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.
Use protective caps from the Air Handling Clean Care Kit,
Part Number 4919508, to cover open points on the
plumbing, engine, and charge-air cooler.
Charge-Air Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Apply air pressure to the cooler until the pressure gauge

reads a steady 207 kPa [30 psi] of air pressure.
Shut off the air flow to the cooler, and start a stopwatch at
the same time. Record the leakage at 15 seconds.
If the pressure drop is 48 kPa [7 psi] or less in 15
seconds, the cooler is operational.
If the pressure drop is greater than 48 kPa [7 psi] in 15
seconds, check all connections again.
Determine if the pressure drop is caused by a leak in the

charge-air cooler or by a leaky connection. Use a spray
bottle filled with soapy water, applied to all hose
connections. Watch for bubbles to appear at the location
of the leak.
If the pressure drop 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 drop measurement. Similar
pressure drop readings must be obtained at least three
consecutive tests before the reading can be considered
accurate.
NOTE: If a charge-air cooler leak causes a pressure drop
of more than 48 kPa [7 psi] in 15 seconds, it will appear
as a major leak in a leak tank.
If the pressure drop is greater than 48 kPa [7 psi] in 15

seconds, the charge air cooler must be replaced.
Refer to the OEM service manual for replacement
instructions.
NOTE: Charge-air coolers are not designed to be 100-
percent leak-free. If the pressure drop is less than 48 kPa
[7 psi] in 15 seconds, the charge-air cooler does not need
to be replaced.
Pressure Test
Obtain two pressure gauges, Part Number 3823205.
Check both gauges on the same pressure source at 206
kPa [30 psi] to verify consistency.
Install one pressure gauge in the 1/8-inch fitting in the
turbocharger compressor outlet elbow. Install the other
pressure gauge in the intake manifold.
Another alternative to measure the intake manifold
pressure is to use the monitor mode on INSITE™
electronic service tool.
Operate the engine at rated rpm and load. Record the

readings on the two gauges.
If the differential pressure is greater than 20.6 kPa [3 psi],
check the charge air cooler and associated piping for
plugging, restrictions, or damage.
Clean or replace, if necessary.

Inspect the charge-air cooler fins for obstructions to air
flow. Remove obstructions such as a winterfront or debris.
Manually lock the shutters in the OPEN position, if
equipped.
Lock the fan drive in the ON mode to prevent erratic test
results. This can be done by installing a jumper wire
across the temperature switch.
Install fluke digital thermometer, Part Number 3822666,

into the intake manifold at the 1/8-inch NPT tap near the
air horn connection with the intake manifold.
Install the thermocouple bead probe, Part Number
3164498.
Connect the digital multimeter, Part Number 3164488,
and the temperature adaptor, Part Number 3164499, to
the thermocouple bead probe to read intake air
temperature.
Another alternative is to use the monitor mode on the
INSITE™ electronic service tool.
Install another thermocouple at the air cleaner inlet to
measure ambient air temperature.
Perform a road test with the engine at peak power and a

vehicle speed of 48 kph [30 mph] or greater.
Record the intake manifold temperature and the ambient
air temperature.
Calculate the differential temperature:
• Intake manifold temperature - ambient air temperature
= differential temperature
• Maximum Differential Temperature: 21°C [38°F].
Charge-Air Cooler ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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 radiator.
Confirm full fan engagement.
Preparatory Steps
WARNING
personal injury.
• Use compressed air to clean debris from the outside of
the charge-air cooler.
• Remove the charge-air cooler piping. Refer to
Remove
Remove the charge-air cooler. Refer to the OEM service
manual.
Clean
WARNING
CAUTION
Do not use caustic cleaners to clean the charge-air
cooler. Damage to the charge-air cooler will result.
NOTE: 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.
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 (i.e., the water runs clear).
NOTE: Make sure that the tubes are in the upright
position when flushing.
If the debris can not be totally removed from the charge-
air cooler, the charge air cooler must be replaced.
WARNING
personal injury.
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.
Install
Install the charge-air cooler.
Refer to the OEM service manual for instructions.
Cold Starting Aid ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
• Install the charge-air cooler piping. Refer to Procedure
Cold Starting Aid (010-029)

General Information
The cold starting aid is not a serviceable part.
If the cold starting aid has cracked, broken, or melted
elements, the entire air intake manifold must be replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cold Starting Aid
ISC, ISL CM554 preheat/post-heat cycle information:

The intake air heaters are used in B and C engines to aid starting in cold ambient conditions. There are two phases of
intake air heater operation:
• Preheat (after key on and before cranking)
• Post-heat (just after a successful engine start).
The intake air heater is used in starting during cold temperatures and to reduce white smoke after such a start.
The intake air heaters or grid heaters are energized or de-energized from two relays controlled by the ECM. The
amount of time the intake air heaters stay on in the preheat phase is a function of the intake manifold temperature at
key on; preheat time increases with colder intake manifold temperatures. The maximum duration of preheat is 45
seconds and no engine preheat is needed for coolant or intake air temperatures exceeding 4.4°C [40 °F] for ISC/ISL
engines.
A “Wait-to-Start” lamp is also controlled by the ECM and is illuminated (to indicate that the driver must not crank the
engine) while the intake air heaters are activated just after key on, during the preheat phase.
During cranking, the intake air heater is turned off to allow maximum current to be used by the starter. The post-heat
cycle can operate for several minutes on very cold days before the intake air heaters are de-energized.
QSC, QSL CM554 preheat cycle information:
The preheat cycle of the electric intake heater varies by ambient temperature and is controlled by the ECM. During the
preheat cycle, the ECM sends power to the OEM-supplied “Wait-to-Start” lamp. The operator must not crank the
engine until the “Wait-to-Start” lamp is deactivated. Consult the Operation and Maintenance Manual for further details
on start procedures. Figure 1 illustrates the intake heater preheat cycle.
Cold Starting Aid ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
Section 13.
• Disconnect the grid heater wiring.
• Disconnect the air intake heater wiring. Refer to the
OEM service manual.
• Remove the charge-air piping from the air intake
connection adapter. Refer to Procedure 010-019 in
Section 10.
• Remove the air inlet connection, if equipped. Refer to
• Remove the turbocharger control valve, if equipped.
Refer to Procedure 019-388 In Section 19.
Section 13.
Remove
NOTE: If the grid heater is to be removed for any length of
time, apply tape over the hole to keep debris out of the air
intake manifold.
Remove the intake air heater.
The intake heater is installed under the intake manifold
cover on some engines. Use the following procedure if
removing the intake manifold cover is required. Refer to

Inspect the air intake manifold heater for plugging or soot
build up. If plugged, check for the source; turbocharger,
air compressor, temperature/pressure sensor, relay, and
wiring harness.
Soot only covering individual elements is acceptable.
Soot bridging the heating elements is not acceptable.
Replace the air intake manifold heater if necessary.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cold Starting Aid
Keep the gasket material and any other material out of the
cylinder head intake manifold.
Clean the intake air heater sealing surfaces.
Clean the air intake manifold cover sealing surface.
Clean the air intake connection sealing surface.
Install
Install the grid heater.
• Use the following procedure if the grid heater is
located under the intake manifold cover. Refer to
Finishing Steps
WARNING
battery cable last.
• Install the injector supply lines. Refer to Procedure
• Install the air intake connection. Refer to Procedure
• Install the air inlet connection, if equipped. Refer to
• Install the turbocharger control valve, if equipped.
Refer to Procedure 019-388 In Section 19.
• Connect the grid heater wiring.
• Connect the air intake heater wiring. Refer to the OEM
service manual.
• Install the charge- air piping to the air intake
connection adapter. Refer to Procedure 010-019 (Air
Crossover) in Section 10.
Section 13.
Air Intake Restriction ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Air Intake Restriction (010-031)

Measure
Install a vacuum gauge or water manometer in the intake
air piping.
The gauge adapter must be installed at a 90-degree
angle to the airflow in a straight section of pipe, one pipe
diameter before the turbocharger.
NOTE: On marine applications, remove the pop-up flag
restriction gauge from the base of the air filter and install
the vacuum gauge or water manometer.

maximum load.
Record the data on the gauge or manometer.
Inlet Air Restriction (All Applications Except Marine)
cm H2O in H2O
63.5 MAX 25.0
Intake Air Restriction (Marine Applications)
cm H2O in H2O
Dirty Filter 63.5 MAX 25.0
Clean Filter 38.1 MAX 15.0
If restriction exceeds specifications, replace or clean the

air filter element. Refer to the OEM service manual.
Inspect the intake piping for damage. Refer to the OEM

service manual.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger
Turbocharger (010-033)
Initial Check
Remove the intake pipe from the turbocharger. See the
Remove section in this procedure.
Use the following procedure if equipped with an engine
mounted air cleaner. Refer to Procedure 010-013 in
Section 10.
Inspect the turbocharger compressor impeller blades for
damage.
Replace the turbocharger if damage is found. See the
Remove and Install sections in this procedure.
If the compressor impeller is damaged, inspect the intake
piping and filter element for damage.
Repair any damage before operating the engine.
CAUTION
Be sure to tie the exhaust piping up above the water
line to prevent water from feeding back into the
vessel while the exhaust piping is removed. Failure to
do so can result in the vessel sinking.
Remove the exhaust pipe from the turbocharger. See the
Remove section in this procedure.
Use the following procedure if equipped with sea water
cooled exhaust outlet. Refer to Procedure 011-017 in
Section 11.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage is found. See the
Remove and Install sections in this procedure.
Axial Clearance Check:

• Use dial depth gauge, Part Number ST-537.
• Push the rotor assembly away from the gauge.
• Set the gauge on zero.
Turbocharger ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Push the rotor assembly toward the gauge and record the
reading.
Axial Clearance (HX40WG - Wastegate)

mm in
0.025 MIN 0.001
0.127 MAX 0.005
Axial Clearance (HY40V - Variable Geometry)

mm in
0.025 MIN 0.001
0.127 MAX 0.005
Axial Clearance (HX55 - Wastegate, Water Cooled)

mm in
0.038 MIN 0.0015
0.093 MAX 0.0037
Replace the turbocharger if the clearance does not meet
the specifications. See the Remove and Install sections in
this procedure.
Radial Clearance Check:

Use a wire-type feeler gauge to measure the clearance
between the turbocharger compressor wheel and the
turbocharger compressor housing.
Gently push the compressor wheel toward the
compressor housing and gauge.
Record the clearance.
With the feeler gauge in the same location, gently push

the turbocharger compressor wheel away from the
turbocharger compressor housing and measure the
clearance between the compressor wheel and the
housing.
Subtract the smaller clearance from the larger clearance.
This is the radial bearing clearance.
Wastegate Radial Bearing Clearance (HX40WG -

Wastegate)
mm in
0.330 MIN 0.013
0.508 MAX 0.020
Radial Bearing Clearance (HX55 - Wastegate, Water

Cooled)
mm in
0.044 MIN 0.0172
0.608 MAX 0.0239
For variable geometry turbochargers, check the radial
movement of the rotor system by pushing the
turbocharger compressor wheel toward the wall of the
compressor cover with light finger pressure. The
turbocharger passes inspection if the wheel does not
contact the compressor cover wall.
Repeat the procedure on the turbocharger turbine wheel.
Replace the turbocharger if the radial bearing clearance
does not meet specifications. See the Remove and Install
sections in this procedure.
Leak Check
• Inspect the turbocharger compressor intake and
discharge for oil.
• If oil is present in the compressor intake as well as in
the discharge, check upstream in the turbocharger for
the source of the oil.
NOTE: Some marine engines have a closed crankcase
breather system which is connected to the engine
mounted air cleaner assembly. Check the closed
crankcase breather system. Refer to Procedure 010-013
in Section 10.
If oil is present only in the discharge side, install the air

intake and charge-air cooler piping. Refer to the original
equipment manufacturer (OEM) service manual.
Check for intake restriction. Refer to Procedure 010-031
in Section 10.
NOTE: If the engine experiences a turbocharger
malfunction or any other occasion where oil is put into the
charge-air system, the charge-air system must be
inspected and cleaned. Refer to Procedure 010-027 in
Section 10. Use the following procedure if the engine is
equipped with an aftercooler. Refer to Procedure 010-005
in Section 10.
NOTE: If the engine experiences a turbocharger
malfunction that results in coolant or oil entering the
intake, the charge-air cooler system as well as the fuel
control housing must be inspected and cleaned. Use the
following procedure for the charge-air cooler. Refer to
Procedure 010-027 in Section 10. Use the following
procedure for the fuel control housing. Refer to Procedure
Add one unit of fluorescent tracer, Part Number 3376891,

to each 38 liters [10 gal] of engine lubricating oil.
Operate the engine at low idle for 10 minutes.
NOTE: Do not operate the engine with the charge-air
piping removed. The lack of boost pressure on the outlet
side of the compressor can cause progressive damage to
the turbocharger.
Shut the engine OFF.

Allow the turbocharger to cool.
Remove the exhaust pipe from the turbine housing. See
the Remove section in this procedure.
Use the following procedure if equipped with a sea water
cooled exhaust outlet. Refer to Procedure 011-017 in
Section 11.
Use a high-intensity black light, Part Number 3163339, to

inspect the turbine outlet for leaks.
A yellow glow indicates an oil leak. A dark blue glow
indicates fuel in the oil.
If oil is found in the turbine housing, remove the oil drain

line and check for restrictions. Refer to Procedure
Clear any restrictions found.
Install the turbocharger drain line. Refer to Procedure
If the oil drain line was not restricted, remove the

turbocharger. See the Remove and Install sections in this
procedure.
If these checks do not reveal the problem, remove the

procedure.
Use a high-intensity black light, Part Number 3163339, to

inspect the turbine inlet for leaks.
A yellow glow indicates an oil leak from the engine.
If a yellow glow is not seen in the turbine inlet, replace the
procedure.
Install the exhaust pipe to the turbocharger turbine outlet

and tighten the clamp. Use the following procedure if the
exhaust outlet is sea water cooled. Refer to Procedure
Install the intake pipe to the turbocharger compressor inlet
and tighten the clamp. Use the following procedure if
equipped with an engine mounted air cleaner. Refer to
Locally manufacture a turbocharger coolant leak test kit to

connect to the coolant inlet and outlet.
• An air pressure regulator is required to control shop air
pressure during the test.
• A M14x1.5 male plug is required to block the water
outlet.
• A hose with an appropriate fitting to connect to the air
pressure regulator and a 13/16”-16 female flat face o-
ring fitting is required to connect to the water inlet.
Apply shop air supply to pressurize the turbocharger

coolant passage to 276 kPa [40 psi].
Close the air pressure regulator.
Check the gauge for a pressure decrease. The pressure
must not decrease more than 34 kPa [5 psi] in 1 minute.
If the pressure decrease is more 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 decreases and the hose connections are
not leaking, replace the turbocharger.
Preparatory Steps
WARNING
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
WARNING
Coolant is toxic. Keep away from children and pets. If not
reused, dispose of in accordance with local environmental
regulations.
WARNING
Some state and federal agencies have determined that
used engine oilcan be carcinogenic and cause
ingestion, and prolonged contact with used engine oil. If
environmental regul
• Disconnect the batteries. Refer to the original equipment
manufacturer (OEM) service manual.
• Drain the cooling system, variable geometry turbocharger
• Remove the oil supply line from the turbocharger. Refer to
• Remove the oil drain line from the turbocharger. Refer to
• Remove the turbocharger coolant lines, variable geometry
turbocharger only. Refer to Procedure 010-041 in Section
10.
• Disconnect the turbocharger actuator air supply line,
variable geometry turbocharger only. Refer to Procedure
• This procedure is for engines equipped with CM850 fuel
system. Disconnect the turbocharger speed sensor,
variable geometry turbocharger only. See the following
procedure in the Troubleshooting and Repair Manual, ISB,
ISBe2, ISB3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC,
QSC8.3, ISL, ISLe3, ISLe4, and QSL9, CM850, Electronic
Control System, Bulletin 4021416. Refer to Procedure
• This procedure is for engines equipped with CM850 fuel
system. Disconnect the turbocharger compressor air inlet
temperature sensor, if equipped. See the following
procedure in the Troubleshooting and Repair Manual, ISB,
ISBe2, ISB3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC,
QSC8.3, ISL, ISLe3, ISLe4, and QSL9, CM850, Electronic
Control System, Bulletin 4021416.Refer to Procedure
• This procedure is for engines equipped with CAPS fuel
system. Disconnect the turbocharger compressor air inlet
procedure in the Troubleshooting and Repair Manual, ISC,
QSC8.3, and ISL Engines, Bulletin 3666271. Refer to
Marine Applications
WARNING
WARNING
CAUTION
CAUTION
CAUTION
• Shut off the sea water supply valve(s). Refer to the
original equipment manufacturer (OEM) service
manual.
• Disconnect the battery. Refer to the OEM service
manual.
• Drain the cooling system. Refer to Procedure 008-018
in Section 8.
• Remove the wastegate actuator heat shield. Refer to
• Remove the oil supply line from the turbocharger.
• Remove the oil drain line from the turbocharger. Refer
• Remove the turbocharger coolant lines. Refer to
• Remove the engine mounted air cleaner. Refer to
• Disconnect the sea water cooled exhaust outlet. Refer
• Disconnect the air crossover pipe. Refer to Procedure
Remove
Remove the exhaust piping.
Remove the turbocharger compressor air inlet pipe.
Remove the turbocharger compressor outlet elbow, V-

band clamp, and o-ring from the turbocharger compressor
outlet.
WARNING
This component or assembly weights greater than 25
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift the component or assembly.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and gasket.
Marine Applications
WARNING
CAUTION
The gasket water ports are larger on the top and
bottom passages. The gasket is also marked
“Turbocharger” on the side facing the turbocharger.
The gasket must be installed with the port size
matching the ports of the exhaust manifold and
turbocharger, and with the “Turbocharger” marking
facing the turbocharger to prevent damage to the
turbocharger from overheating.
Remove the turbocharger mounting nuts and
turbocharger.
Remove the gasket.

Clean the turbocharger and exhaust manifold gasket
surfaces.
Inspect the turbocharger and exhaust manifold gasket
surfaces, and the mounting studs for cracks or other
damage.
For wet manifolds, use the following procedure. Refer to
Cracking of the turbine housing inlet flange may require

turbocharger replacement.
Acceptance and rejection guidelines are shown in this
illustration.
If the exhaust gasket is available, always make sure that
any cracks lie within its sealing area.
Acceptable cracks must:
• be 10 mm [0.39 in] or less in length.
• be separated from each other by no less than 10 mm
[0.39 in].
• not extend to the edge of the flange.
Replace the exhaust manifold if any cracks or other
damage is found in the mounting flange surfaces. Refer to
For wet manifolds, use the following procedure. Refer to
Turbocharger Flatness Check

• Place a straightedge over the turbocharger manifold
mounting surface.
• Measure the gap between the port surface and the
ruler with a feeler gauge.
Mounting Surface Flatness Specification

mm in
0.1 MAX 0.004
If the mounting surface is out of specification, the
turbocharger must be replaced.
WARNING
WARNING
WARNING
personal injury.
Remove all carbon deposits and gasket material from
surfaces.
Use solvent or steam to clean the exterior of the
turbocharger.
Inspect the turbine and compressor housings.

If cracks that go all the way through the outer walls are
found, the turbocharger must be replaced.
NOTE: A charge-air cooler malfunction can cause
progressive damage to the turbine housing. If the turbine
housing is damaged, check the charge-air cooler. Refer to
Install
WARNING
Apply a film of high-temperature anti-seize compound to
the turbocharger mounting studs.
Install a new gasket and install the turbocharger.
Install and tighten the four mounting nuts.
NOTE: The torque values have been established with
anti-seize compound as a lubricant.
Torque Value:
Variable Geometry Turbocharger 60 N•m [ 44 ft-lb ]
Torque Value:
Wastegate Turbocharger 45 N•m [ 33 ft-lb ]
Install the turbocharger compressor outlet elbow, V-band

clamp, and new o-ring seal on the turbocharger
compressor discharge outlet.
Tighten the clamp.
Install the intake pipe to the turbocharger compressor inlet

and tighten the clamp.
Install the exhaust pipe to the turbocharger turbine outlet
and tighten the clamp.
Marine Applications
WARNING
CAUTION
The gasket water ports are larger on the top and
bottom passages. The gasket is also marked
“Turbocharger” on the side facing the turbocharger.
The gasket must be installed with the port size
matching the port size of the exhaust manifold and
turbocharger, and with the “Turbocharger” marking
facing the turbocharger to prevent damage to the
turbocharger from overheating.
Apply a film of high-temperature anti-seize compound to
the turbocharger mounting studs.
Use a new gasket and install the turbocharger.
Install and tighten the four mounting nuts.
NOTE: The torque values given have been established
using anti-seize compound as a lubricant.
Prime
Install the turbocharger oil drain line. Refer to Procedure
Lubricate the bearings by pouring 59 to 89 ml [2 to 3 oz]

of clean 15W-40 engine oil into the turbocharger oil supply
line fitting. Rotate the turbine wheel to allow oil to enter
the bearing housing.
Finishing Steps
WARNING
battery cable last.
NOTE: If a stationary aftertreatment regeneration is
needed to complete repair, make sure that the engine is
brought up to operating temperature before the
regeneration is started.
• Connect the turbocharger coolant lines, variable
geometry turbocharger only. Refer to Procedure
• Connect the turbocharger speed sensor, variable
geometry turbocharger only. See the following
procedure in the Troubleshooting and Repair Manual,
ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB8.3, ISL,
ISLe3, ISLe4, and QSL9, CM850 Electronic Control
System, Bulletin 4021416. Refer to Procedure 019-390
in Section 19.
• Connect the turbocharger speed sensor. See the
following procedure in the Troubleshooting and Repair
Manual, ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB8.3,
ISL, ISLe3, ISLe4, and QSL9, CM850 Electronic
Control System, Bulletin 4021416. Refer to Procedure
• Connect the turbocharger compressor air inlet
procedure in the Troubleshooting and Repair Manual,
ISC, QSC8.3, and ISL Engines, Bulletin 3666271.
• Fill the cooling system.Refer to Procedure 008-018 in
Section 8.
• Connect the turbocharger compressor air inlet
temperature sensor. See the following procedure in
the Troubleshooting and Repair Manual, ISC, QSC8.3,
and ISL Engines, Bulletin 3666271. Refer to
• Fill the cooling system, variable geometry turbocharger
• Connect the battery. Refer to the OEM service
manual.
Turbocharger Coolant Hoses ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
• Connect the turbocharger coolant lines. Refer to
• Install the engine mounted air cleaner. Refer to
• Install the sea water cooled exhaust outlet. Refer to
• Connect the air crossover pipe. Refer to Procedure
• Install the heat shield. Refer to Procedure 011-032 in
Section 10.
Section 8.
manual.
• Open the sea water valve(s). Refer to the OEM service
manual.
Turbocharger Coolant Hoses (010-041)

Preparatory Steps
Variable Geometry
WARNING
battery cable last.
WARNING
WARNING
• Disconnect the batteries. Reference the equipment
Section 8.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Coolant Hoses
Marine Applications
WARNING
WARNING
CAUTION
Section 8.
• Remove the heat shield. Refer to Procedure 011-032
in Section 11.
Remove
Variable Geometry
NOTE: Use a second wrench to hold the coolant line
coupling while loosening the line.
Remove the turbocharger coolant supply line from the
turbocharger and cylinder block.
Remove the turbocharger coolant return line from the
turbocharger and the cylinder block.
Marine Applications
NOTE: The graphic shown here is of the QSC8.3 marine
engine. The QSL marine engine is different only in that
the expansion tank is located on the front of the engine
and the vent line has P-clips securing the line.
Remove the coolant vent line from the side of the
turbocharger turbine housing and the coolant expansion
tank.
On QSL9 engines, remove the p-clips which secure the
line to the rocker lever housing.
Remove the coolant vent line.
Remove the coolant inlet hose clamps from the

turbocharger turbine housing connection and the rear of
the cylinder block. Remove the coolant inlet hose.
Remove the hose pipe fittings from the turbocharger
turbine housing and the rear of the cylinder block.

All Applications
WARNING
WARNING
WARNING
personal injury.
Clean the turbocharger coolant hoses with solvent.
Inspect for burrs or debris around the banjo fittings.

Inspect for cracks in the lines and connectors. Replace as
necessary.
Inspect the hose fittings and clamps for cracks or other
damage.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Coolant Hoses
Check the o-rings for cuts or deformation. Replace as

necessary.
Check the turbocharger coolant lines for cracks or other
damage. Replace if damage is found.
Check the face of the coolant fittings on the engine and on

the turbocharger to make sure the o-ring is in place and is
not damaged. A damaged or missing o-ring will result in a
coolant leak.
Install
Variable Geometry
Install the turbocharger coolant return line to the top of the
turbocharger and the block.
Install the turbocharger coolant supply line to the bottom
of the turbocharger and the block.
Check the face of the coolant fittings on the engine and on
the turbocharger to make sure the o-ring is in place and is
not damaged. A damaged or missing o-ring will result in a
coolant leak.
NOTE: Use a second wrench to hold the coolant line
coupling while tightening the line.
Tighten the fittings.
Marine Applications
Install the pipe nipple at the rear of the cylinder block and
the elbow at the bottom of the turbocharger turbine
housing.
Align the elbow and tighten the banjo capscrew.
Install the molded coolant supply hose to the rear of the
cylinder block and the bottom of the turbocharger turbine
housing. Install the hose clamps and tighten.
Install the coolant vent line to the side of the turbocharger

turbine housing.
Install the coolant vent line to the rear of the coolant
expansion tank and tighten.
On QSL9 engines, install the p-clips to the rocker lever
housing.
Finishing Steps
WARNING
battery cable last.
• Install the heat shield. Refer to Procedure 011-032 in
Section 11, if installed.
• Connect the battery. Reference the equipment
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Oil Drain Line
Turbocharger Oil Drain Line (010-045)

Initial Check
Inspect the turbocharger oil drain line for oil leaks or
damage.
Repair as necessary.
Entfernen Sie
CAUTION
Remove the capscrews from the oil drain tube.
Loosen the hose clamps on the connecting hoses, if
equipped.
Pull the drain line out of the drain line boss.

Clean the gasket sealing surfaces.
Clean the o-ring seating bore and make sure it is free of
dirt and debris.
Inspect the line for cracks, wear, and damage.

Inspect the o-ring for fretting and cracking. Replace if
necessary.
Check the rubber section of the drain line for deterioration.
Inspect the connector hoses and clamps for cracks or
wear. Replace if necessary.
Turbocharger Oil Supply Line ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Apply a thin film of clean engine oil to the drain line o-
rings.
Push the oil drain line into the drain line boss. Make sure
both o-rings are completely seated in the bore.
Install a new gasket to the oil drain line.
Install the turbocharger oil drain line mounting capscrews.
Install the hose and hose clamps, if equipped. Tighten the
hose clamps.
Turbocharger Oil Supply Line

(010-046)
Initial Check
Inspect the line for oil leaks or damage. Replace as
necessary.
Remove
Remove the oil supply line from the oil filter head (1).
Remove the oil supply line from the turbocharger bearing
housing (2).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Wastegate Actuator
Inspect for Reuse

Inspect the line for cracks, wear, and damage.
Inspect o-rings for cracking and fretting. Replace as
necessary.
Install
CAUTION
Maintain a minimum distance of 10 mm [0.39 in]
between the oil supply line and the turbine housing or
exhaust manifold, and 5 mm [0.20 in] between the oil
supply line and other components to prevent oil line
high temperature damage and chafing.
Apply a thin film of oil to the o-ring seals.
Fill the turbocharger oil inlet with clean oil.
Install the oil supply line at both the filter head and the
turbo bearing housing.
Tighten the oil supply line to final torque.
Turbocharger Wastegate Actuator

(010-050)
Initial Check
CAUTION
All wastegates come precalibrated and can not be
adjusted in the field. Attempts to adjust the wastegate
can result in engine damage.
The integral wastegate line takes boost from the
turbocharger compressor outlet to the wastegate capsule.
Inspect the integral wastegate actuator hose for cracks or

holes. Replace the hose if damaged.
Turbocharger Wastegate Actuator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the wastegate mounting bracket, actuator rod, and

lever for damage. A bent wastegate mounting bracket,
actuator rod, or lever can cause improper operation.
If the wastegate mounting bracket, actuator rod, or lever is
bent, it must be replaced.
Test
In some applications the turbocharger must be removed
to test the wastegate actuator. Refer to Procedure .
Disconnect the integral boost line from the wastegate

capsule.
Attach a dial indicator (1) as shown, so that its shaft is in
line with the wastegate actuator rod. Set the indicator to
zero.
Connect clean, regulated air pressure and a pressure
gauge to the capsule. Apply 200 kPa [29 psi] to make
sure the wastegate is functioning properly.
The rod must move approximately 5 mm [0.200 in]
without any sticking or air leakage.
Air must not be heard, such as air leaking through a
functional wastegate capsule.
A small amount of travel when air pressure is first applied
is normal. The tolerance is being removed from the
system.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Wastegate Actuator
If no movement of the actuator rod is detected, detach the

actuator control rod from the wastegate lever pin.
Actuate the lever by hand to be sure that the shaft rotates
freely and is not seized.
If the wastegate lever can not be moved by hand, replace
the turbocharger. Refer to Procedure .
If the wastegate lever moves freely by hand, replace the
turbocharger wastegate actuator.
Remove
In some applications the turbocharger must be removed
in order to remove the wastegate actuator. Refer to
Procedure .
Prior to removal, note position length of the control rod

from the boost capsule housing and orientation of the
boost capsule hose connector in relation to the mounting
bracket.
Remove the retaining clip from the control lever.

Remove the integral boost line from the wastegate
capsule.
Turbocharger Wastegate Actuator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
CAUTION
Be careful not to bend the control lever. Engine
damage can result.
Remove the boost capsule actuator rod end from the
turbocharger wastegate lever. This can be accomplished
by slowly applying regulated air pressure to the boost
capsule until the control rod is activated.
Remove the control rod from the turbocharger wastegate
lever pin.
If the boost capsule diaphragm material is ruptured and

will not hold air pressure, 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.
Loosen the boost capsule mounting capscrews,
disconnect the air supply hose, and remove the assembly
from the mounting bracket.

Inspect the wastegate actuator hose for cracks or holes.
Replace the hose if damaged.
Inspect the wastegate mounting bracket, actuator rod, and

lever for damage. A bent wastegate mounting bracket,
actuator rod, or lever can cause improper operation.
If the wastegate mounting bracket, actuator rod, or lever is
bent, it must be replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Wastegate Valve Body
Install
Fit the actuator mounting studs into the holes in the
bracket, and fit both actuator mounting capscrews.
Refit the end-link onto the crank-pin. Install the control rod
retaining clip.
Cut the tie wrap and remove the tie wrap and spacer
piece.
Refit the air supply hose to the actuator, use the new hose
clamp provided.
Turbocharger Wastegate Valve Body

(010-055)
Preparatory Steps
Marine Applications
NOTE: This step applies to marine engines only.
Remove the actuator heat shield. Refer to Procedure
011-032.
Remove the exhaust connection from the turbocharger.
Remove the round inspection plate from the turbocharger.
Maintenance Check
Inspect the lever pin.
Replace the turbocharger if worn excessively, Refer to
Procedure 010-033.
Intake Manifold Pressure ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect the valve and valve seat for cracks or erosion.

Replace the turbocharger if damage is found. Refer to
Procedure 010-033.
Actuate the lever by hand to verify that the shaft rotates

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.
Finishing Steps
Marine Applications
NOTE: This step applies to marine engines only.
Install the inspection plate.
Install the exhaust connection. Refer to Procedure
011-017.
Install the actuator heat shield. Refer to Procedure
011-032.
Intake Manifold Pressure (010-057)

Measure
Measure the boost pressure at the intake manifold. Use
INSITE™ electronic service tool for hookup and
monitoring procedures.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake Connection
Operate the engine at rated rpm and full load. Record the
boost reading.
NOTE: Reference the Sales Performance Curve and the
Data Sheet for specifications.
Air Intake Connection (010-080)

Preparatory Steps
WARNING
battery cable last.
Section 13.
• Disconnect the grid heater wiring.
• Remove the air inlet crossover tube. Refer to
• Remove the air inlet connection, if equipped. Refer to
• Remove the injector supply lines, if required. Refer to
• Disconnect the injector pass-through for the number 3
and 4 cylinders.
• Disconnect the air compressor air supply tube from the
bottom of the air intake connection.
Remove
Remove the mounting capscrews.
Remove the air intake connection.
Tape off the intake manifold opening to prevent debris
from entering the intake system.
NOTE: Be sure not to tape over the entire manifold edges
so that the surface can be cleaned.
NOTE: On engines with the grid heater mounted on top of
the intake manifold cover, the grid heater will now be
loose.
Air Intake Connection ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Clean the sealing surfaces.
NOTE: Keep gasket material and any other material out of
the air intake.
Inspect the air intake connection for cracks or other
damage.
Install
Install the air intake connection. Use a new gasket.
NOTE: Some capscrews are shared with fuel line braces
on some engines.
NOTE: On some engines, the air intake connection
mounts on top of the grid heater and shares capscrews.
Finishing Steps
WARNING
battery cable last.
• Connect the electrical connections to the injector pass-
through for the number 3 and 4 cylinders.
• Install the injector supply lines, if removed. Refer to
• Connect the air inlet connection, if equipped. Refer to
• Install the air crossover tube. Refer to Procedure
• Connect the cold starting aid.
• Connect the air compressor air supply tube to the
bottom of the air intake connection using a new o-ring
seal.
Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake Manifold Cover
Air Intake Manifold Cover (010-108)

Preparatory Steps
WARNING
battery cable last.
Section 13.
• Disconnect the cold starting aid.
• Remove the air crossover tube. Refer to Procedure
• Disconnect the air inlet connection, if equipped. Refer
• Remove the air intake connection. Refer to Procedure
• Remove the injector supply lines, if required. Refer to
• Remove the turbocharger control valve, if equipped.
Refer to Procedure 019-388 in Section 19. It can be
found in the Troubleshooting and Repair Manual,
CM870 Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
Remove
Some engines have a grid heater mounted on top of the
intake manifold cover. Remove the grid heater, if
equipped. Refer to Procedure 010-029 in Section 10.
Remove the mounting capscrews and the air intake
manifold cover.
Tape off the intake manifold opening to prevent debris
from entering the intake system.
NOTE: Be sure not to tape over the entire manifold
edges, so the surface can be cleaned.

Clean the sealing surfaces.
NOTE: Keep the gasket material and any other material
out of the air intake.
Remove the tape.
Inspect the intake manifold for cracks or other damage.
NOTE: When inspecting the intake manifold for oil or
debris from an air system failure, also inspect the cylinder
head for oil and debris.
Air Intake Manifold Cover ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install the air intake manifold cover with intake air heater
(if equipped) and a new gasket.
Install the air intake manifold cover and a new gasket.
FIPG gasket manifold cover to head joint
• Apply FIPG to mating face side of intake manifold
cover.
• Assemble grid heater /spacer, air intake connection
and gasket to cylinder head.
• Tighten the capscrews within 15 minutes of RTV
application
Standard gasket manifold cover to head joint
• Assemble the intake manifold cover and gasket to the
cylinder head
• Tighten the capscrews.
NOTE: Some capscrews are shared with fuel line braces
on some engines.
Finishing Steps
WARNING
battery cable last.
• Install the grid heater, if equipped. Refer to Procedure
• Install the injector supply lines, if removed. Refer to
• Install the air intake connection. Refer to Procedure
• Install the air inlet connection, if used. Refer to
• Install the turbocharger control valve, if equipped.
Refer to Procedure 019-388 in Section 19. It can be
found in the Troubleshooting and Repair Manual,
CM870 Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
• Install the air crossover tube. Refer to Procedure
• Connect the cold starting aid.
Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Variable Geometry Turbocharger Actuator, Pneumatic
Variable Geometry Turbocharger

Actuator, Pneumatic (010-113)
Entfernen Sie
Remove the air line from the actuator.
Remove the capscrew holding the actuator rod to the
turbocharger cross-shaft.
Remove the snap ring from the cross-shaft.
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 spring load at the linkage.
Remove the two loosened capscrews and actuator.

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
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.
Variable Geometry Turbocharger Actuator, Pneumatic ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Test
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 a clean, regulated air pressure supply and a
pressure gauge to the actuator. Apply a minimum of 414
kPa [60 psi] air pressure to make sure the actuator is
functioning properly.
The rod must move without any sticking.
Actuator Movement Range 10.8 mm [ 0.425 in ]
NOTE: No air must 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.
NOTE: This test can be performed with the actuator
removed or installed on the turbocharger.
Install
Use coupling, Part Number 3824843, to apply 414 kPa
[60 psi] regulated air pressure to the actuator.
Install the actuator on the turbocharger bearing housing.
Install and tighten the two capscrews.
Install the actuator rod to the turbocharger cross-shaft.

Install the snap ring.
Install and tighten the capscrew.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Actuator Air Line
Finishing Steps
• Install the turbocharger actuator air supply line to the
actuator. Refer to Procedure 010-118.
Turbocharger Actuator Air Line

(010-118)
Preparatory Steps
Remove the turbocharger control valve, if necessary.
Refer to Procedure 019-388 (Turbocharger Control Valve)
in Section 19, in Troubleshooting and Repair Manual,
CM850 Electronic Control System, ISC and ISL Engines,
Bulletin 4021416.
Remove
Disconnect the air line from the turbocharger actuator.
Disconnect the air line from the quick-connect fitting on
the intake side of the engine.
Remove the mounting capscrew from the crankcase
breather.
Disconnect the banjo fitting from the turbocharger control
valve.
Use masking tape to tape the end of the air line and
turbocharger control valve to prevent contamination.

Inspect the air line for wear or damage.
Inspect the o-rings for signs of damage or distortion.
Replace as necessary.
Turbocharger Actuator Air Line ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Remove the masking tape from the ends of the
turbocharger actuator supply line before installing the line.
Install the air line and the mounting capscrew to the
crankcase breather.
Connect the flexible elbow to the turbocharger control

valve, use new sealing washers.
Install the quick connect fitting to the air line.
Connect the air supply line to the turbocharger actuator.

Finishing Steps
Operate the engine and check for proper operation.
Check for air leaks.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake Connection Adapter
Air Intake Connection Adapter

(010-131)
Preparatory Steps
WARNING
battery cable last.
in Section 13.
Remove
QSC Engines
This step applies to the QSC8.3 marine engine.
Loosen the clamp at the air intake connection.
Remove the two capscrews and the retaining brace from
the aftercooler.
Remove the air intake connection adapter.
Discard the o-ring.
QSL Engines
This step applies to the QSL9 marine engine.
Loosen the hose clamps at the aftercooler outlet
connection.
Loosen the clamp at the air intake connection.
Remove the air intake connection adapter.
Discard the o-ring.
Air Intake Connection Adapter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
WARNING
WARNING
personal injury.
Clean the parts with solvent.
Inspect the parts for cracks or other damage.

Inspect the o-rings for damage.
Replace the parts if damaged.
Install
QSC Engines
This step applies to the QSC8.3 marine engine.
Install a new o-ring on the air intake connection adapter.
Lubricate the o-ring with clean engine oil.
Install the adapter to the aftercooler and the air intake
connection.
Install the retaining clip at the aftercooler.
Install the clamp at the air intake connection. Tighten the
clamp.
Tighten the retaining clip at the aftercooler.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Inline Air Filter
QSL Engines
This step applies to the QSL9 marine engine.
Install a new o-ring on the air intake connection adapter.
Lubricate the o-ring with clean engine oil.
Install the adapter to the aftercooler outlet and the air
intake connection. Tighten the clamp.
Tighten the hose clamps at the aftercooler.
Finishing Steps
WARNING
battery cable last.
Section 13.
• Operate the engine and check for boost leaks.
Inline Air Filter (010-133)

General Information
The inline air filter is in the line that feeds the dosing
control unit. It is in the system to protect the dosing control
unit from excessive oil carryover.
WARNING
personal injury.
Drain down the vehicle air system before removing this
filter. Refer to OEM service manual.
Preparatory Steps
Locate the inline air filter. Refer to the OEM service
manual.
Drain down the vehicle air system. Refer to OEM service
manual.
Inline Air Filter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Clean the area around the inline air filter head.
Use the oil filter wrench, Part Number 3400158, to remove
the filter.
Clean the sealing surface of the filter head.
Install
Use the correct inline air filter.
See Cummins/Fleetguard®/Nelson filter specifications for
the correct inline air filter part number.
NOTE: Be careful that nothing enters into the filter. Be
careful to peel the seal back. Puncturing the seal with a
knife or sharp object can create debris in the inline air
filter container.
Use clean 15W-40 oil to coat the gasket surface of the
filter.
CAUTION
Mechanical overtightening of filter can distort the
threads or damage the filter element seal.
Install the filter on the inline air filter head. Tighten the
filter until the gasket contacts the filter head surface.
Tighten 3/4 to 1 turn after gasket makes contact with the
filter head.
Finishing Steps
Start engine and check for leaks.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Turbocharger Exhaust Connection Adapter
Turbocharger Exhaust Connection

Adapter (010-141)
Preparatory Steps
WARNING
The exhaust and exhaust components can remain hot
after the engine has been shut down or secured. 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 might come in contact with hot exhaust or
exhaust components.
• Remove the exhaust piping from the exhaust outlet
connection adapter. Refer to the OEM service manual.
Remove
Remove the five mounting capscrews and the exhaust
connection adapter from the turbocharger.
WARNING
personal injury.
WARNING
WARNING
Clean the exhaust outlet connection adapter with solvent.
Inspect all of the sealing surfaces for damage or other
signs of leakage.
Turbocharger Exhaust Connection Adapter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install a new gasket and the exhaust outlet connection
adapter to the turbocharger.
Finishing Steps
• Install the exhaust piping to the exhaust outlet
connection adapter. Refer to the OEM service manual.
Section 11 - Exhaust System - Group 11 Page 11-a
Section 11 - Exhaust System - Group 11

Section Contents
Page
Aftertreatment Diesel Exhaust Fluid Dosing Unit ................................................................................................11-34
Finishing Steps.......................................................................................................................................................11-37
Initial Check............................................................................................................................................................11-35
Install...................................................................................................................................................................... 11-37
Remove.................................................................................................................................................................. 11-35
Test.........................................................................................................................................................................11-36
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing .................................................................11-30
Finishing Steps.......................................................................................................................................................11-34
Flush.......................................................................................................................................................................11-32
Initial Check............................................................................................................................................................11-31
Test.........................................................................................................................................................................11-33
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter ......................................................................................11-38
Finishing Steps.......................................................................................................................................................11-41
Initial Check............................................................................................................................................................11-38
Install...................................................................................................................................................................... 11-40
Remove.................................................................................................................................................................. 11-39
Aftertreatment Diesel Exhaust Fluid Line Restriction Test ................................................................................11-43
Finishing Steps.......................................................................................................................................................11-46
Initial Check............................................................................................................................................................11-44
Remove.................................................................................................................................................................. 11-44
Test.........................................................................................................................................................................11-45
Aftertreatment Diesel Exhaust Fluid Tank Filter ..................................................................................................11-41
Finishing Steps.......................................................................................................................................................11-43
Install...................................................................................................................................................................... 11-42
Remove.................................................................................................................................................................. 11-42
Aftertreatment Nozzle .............................................................................................................................................11-27
Finishing Steps.......................................................................................................................................................11-30
Initial Check............................................................................................................................................................11-27
Install...................................................................................................................................................................... 11-29
Remove.................................................................................................................................................................. 11-28
Aftertreatment Selective Catalytic Reduction (SCR) Catalyst ............................................................................11-18
Assemble................................................................................................................................................................11-23
Disassemble...........................................................................................................................................................11-20
Finishing Steps.......................................................................................................................................................11-24
Install...................................................................................................................................................................... 11-23
Remove.................................................................................................................................................................. 11-19
Test.........................................................................................................................................................................11-23
Exhaust Gas Pressure Sensor .............................................................................................................................. 11-26
Install...................................................................................................................................................................... 11-27
Page 11-b Section 11 - Exhaust System - Group 11
Remove.................................................................................................................................................................. 11-26
Exhaust Gas Temperature Sensor ........................................................................................................................11-24
Install...................................................................................................................................................................... 11-25
Remove.................................................................................................................................................................. 11-24
Exhaust Gas Treatment Monitor Harness ............................................................................................................11-25
Finishing Steps.......................................................................................................................................................11-26
Install...................................................................................................................................................................... 11-26
Remove.................................................................................................................................................................. 11-25
Exhaust Gas Treatment Monitor Unit ....................................................................................................................11-17
Install...................................................................................................................................................................... 11-17
Remove.................................................................................................................................................................. 11-17
Exhaust Manifold, Dry ..............................................................................................................................................11-4
Disassemble.............................................................................................................................................................11-5
Finishing Steps.........................................................................................................................................................11-8
Install........................................................................................................................................................................11-7
Remove....................................................................................................................................................................11-4
Exhaust Manifold, Wet ..............................................................................................................................................11-9
Finishing Steps.......................................................................................................................................................11-12
Install...................................................................................................................................................................... 11-11
Remove.................................................................................................................................................................. 11-10
Exhaust Outlet Connection ....................................................................................................................................11-14
Finishing Steps.......................................................................................................................................................11-15
Install...................................................................................................................................................................... 11-14
Remove.................................................................................................................................................................. 11-14
Exhaust Restriction ................................................................................................................................................11-12
Initial Check............................................................................................................................................................11-13
Measure..................................................................................................................................................................11-13
Heat Shield ..............................................................................................................................................................11-15
Install...................................................................................................................................................................... 11-16
Remove.................................................................................................................................................................. 11-15
Service Tools ............................................................................................................................................................11-1
Exhaust System........................................................................................................................................................11-1
Section 11 - Exhaust System - Group 11 Page 11-1
Service Tools
Exhaust System
Repair Location.

Manometer
Used to measure exhaust restriction.
ST-1111-3
Infrared Thermometer
Used to measure the surface temperature of exhaust components.
3824941
Infrared Thermometer
Used to measure the surface temperature of exhaust components.
3164487
Pressure Gauge
Used to measure inches of mercury (in Hg) pressure.
ST-1273
Exhaust Restriction/Pressure Adapter

Used to convert aftertreatment temperature sensor ports to 1/8" NPT
4918576 pipe thread so that service tool ST-1273 can be used to measure
exhaust pressure.
EGR Cooler Leak Check Kit

Used to pressure test the EGR cooler.
4918625
Page 11-2 Section 11 - Exhaust System - Group 11

Exhaust Manifold Seal Installer
Used to install the exhaust manifold seal.
4918709
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 HEPA Filter

Used to replace the HEPA filter on diesel particulate filter cleaner,
4919054 Part Number 4919052.
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

This machine is used with diesel particulate filter cleaner adapter kit,
4919052 Part Number 4918893 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 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 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 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 4919052 to adapt the diesel particulate filter
4919172 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 Oil Separator Filter

Used to replace the oil separator filter on diesel particulate filter
4918896 cleaner, Part Number 4918840.
Air Handling Clean Care Kit

Contains a variety of caps to prevent contamination of vehicle air
4919508 handling plumbing during service procedures.
Diesel Particulate Filter Cleaner Adapter Kit

Used with Part Number 4919052 or 4918840, to adapt an
4919182 aftermarket or reto-fit diesel particulate filter to the cleaner.
Diesel Exhaust Fluid Leak Test Kit

Used with vacuum pump, Part Number 3162422, to identify leaks,
5298701 restrictions and malfunctioning connectors in diesel exhaust fluid
lines.
Exhaust Manifold, Dry ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Exhaust Manifold, Dry (011-007)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
NOTE: Brush away all dirt from around the area of the air
handling connections to avoid contamination of the interior
of the engine.
WARNING
battery cable last.
in Section 13.
• Remove the air crossover tube and charge-air cooler
hose. Refer to Procedure 010-019 in Section 10.
• Disconnect the air intake and exhaust piping. Refer to
• Remove the turbocharger. Refer to Procedure 010-033
in Section 10.
Remove
NOTE: Apply a thin coating of nickel-based, high-
temperature compound grease to the coarse threads of
the manifold capscrews, after removal.
Remove the capscrews, exhaust manifold, and gaskets.
Use heavy tape to cover open points in the exhaust
manifold and cylinder head.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Manifold, Dry
Disassemble
Use a vise to clamp on one section of the exhaust
manifold.
Do not allow the jaws of the vise to contact the exhaust
manifold sealing surfaces.
Use a soft-faced mallet to lightly tap on the other section
of the exhaust manifold to separate it from the section
held in the vise.
Use heavy tape to cover open points in the exhaust
manifold and cylinder head.
NOTE: If the exhaust manifold will not separate, it may be
necessary to heat the manifold in the slip joint area to
allow for separation of the manifold.

Clean the sealing surfaces of the head and exhaust
manifold.
Use 240-grit emery cloth to remove carbon deposits from
the sealing surfaces.
Take caution to keep debris out of the cylinder head.
Multi-piece Only:
Clean the multi-piece sealing joint.
WARNING
personal injury.
WARNING
Use steam to clean the exhaust manifold.
Inspect the cylinder head bosses and turbocharger

mounting studs for damage. Repair or replace as
necessary.
NOTE: If the exhaust manifold is damaged, check the
charge-air cooler. A damaged charge-air cooler can cause
progressive damage to the exhaust manifold. Refer to
Inspect the gasket surfaces for gouges, scratches, or

burnout.
Inspect the exhaust manifold for cracks, soot streaking,
leaks, and burnout.
Measure the manifold surface for flatness. Place a ruler

over all exhaust ports in the manifold section . Measure,
with a feeler gauge, the gap between the port surface and
the ruler.
Exhaust Manifold Flatness

mm in
0.30 MAX 0.012
If any port measures out of specification, replace the
manifold.
NOTE: For multi-piece manifolds, each section must be
verified to be flat independently.
The assembled two-piece or three-piece manifold are not
required to meet the flatness specification of an one piece
manifold, as some misalignment is allowed for in the
design of the manifold. Some misalignment will be
eliminated when the manifold capscrews are tightened to
specification during installation.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Manifold, Dry
Check the manifold-to-cylinder head fit. If the manifold

mounting capscrew holes do not line up with the tapped
holes in the cylinder head, replace the exhaust manifold.
Install
Measure the distance between the center of the mounting
holes of the ports with a slip joint between them.
If the distance is not within specification, put the manifold
on a flat surface with the ports face down and lightly tap
the manifold with a soft-faced mallet until the
measurements are within specification.
Manifold Section Distance

mm in
136 MIN 5.35
138 MAX 5.43
Install the manifold assembly on the engine by first

inserting the capscrews through the top of the port. Use
new gaskets on all cylinders.
Lubricate the capscrews prior to installation.
Insert the capscrews into the bottom of the exhaust ports
and gaskets.
Tighten the exhaust manifold mounting capscrews.
Torque Value:
Exhaust Manifold Mounting Capscrews 53 N•m [ 39 ft-lb ]
Follow the tightening sequence as shown in the
illustration.
Finishing Steps
WARNING
battery cable last.
• Install the turbocharger. Refer to Procedure 010-033 in
Section 10.
• Connect the air intake and exhaust pipe. Refer to
• Connect the charge-air cooler hose and crossover
tube. Refer to Procedure 010-019 in Section 10.
Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Manifold, Wet
Exhaust Manifold, Wet (011-008)

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
Coolant is toxic. Keep away from children and pets. If not
reused, dispose of in accordance with local environmental
regulations.
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.
CAUTION
Use caution when draining coolant that coolant is not spilled or
drained into the bilge area. Do not pump the coolant overboard.
If the coolant is not reused, it must be discarded in accordance
with local environmental regulations.
CAUTION
Zinc plugs expand and can break off during removal. Inspect the
zinc plug to make sure it is in one piece. If not, it must be
replaced with a new zinc plug, and the broken pieces must be
retrieved from the heat exchanger to prevent damage to
NOTE: This procedure applies to marine engines only.
NOTE: If a check for a turbocharger gasket leak is being performed,
do not break the seal between the turbocharger and the exhaust
manifold. Remove the two components as one assembly.
• Disconnect the batteries. Refer to Procedure 013-009.
• Close the sea water supply valve(s). Refer to the OEM service
manual.
• Drain the sea water from the heat exchanger by removing the
zinc plug from the bottom of the heat exchanger. Refer to
Procedure 008-052 or 008-053.
• Drain the engine coolant. Refer to Procedure 008-018.
• Remove the exhaust outlet connection. Refer to Procedure
011-017.
• Remove the turbocharger heat shield. Refer to Procedure
011-032.
• Remove the coolant expansion tank, if equipped. Refer to
Procedure 008-052.
• Remove the coolant heat exchanger. Refer to Procedure
008-053.
NOTE: If the turbocharger and exhaust manifold are to be removed
as an assembly, then continue on with the following steps. If not,
refer to Procedure 010-033.
• Disconnect the closed crankcase system from the rocker lever
cover, if equipped. Refer to Procedure 003-020.
• Remove the air crossover from the turbocharger. Refer to
Procedure 010-019.
• Remove the turbocharger coolant hoses from the turbocharger.
• Remove the turbocharger oil drain line from the turbocharger.
• Remove the turbocharger oil supply line from the turbocharger.
Refer to procedure 010-046.
• Remove the coolant vent line. Refer to Procedure 008-017.
Exhaust Manifold, Wet ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Entfernen Sie
WARNING
This assembly weighs 23 kg [50 lb] or more. To
or get assistance to lift this assembly.
Remove the coolant supply line.
Loosen two capscrews and leave them in place to hold
the weight of the exhaust manifold.
Remove the remaining 10 exhaust manifold mounting
capscrews.
Attach a lifting device to support the weight of the exhaust
manifold.
Remove the two remaining mounting capscrews and the
exhaust manifold.

Inspect all the sealing surfaces.
Inspect the inside of the exhaust manifold for possible
signs of leakage (rust marks, antifreeze stains, carbon
washed away).
CAUTION
If the turbocharger was not removed from the exhaust
manifold, do not place the turbocharger into water.
Damage to the turbocharger will occur if water enters
any of the turbocharger openings.
Plug all open coolant passages.
If the turbocharger was not removed from the exhaust
manifold, pressure test the exhaust manifold and
turbocharger as a unit.
Check all sealing surfaces with soapy water for possible
leaks.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Manifold, Wet
WARNING
WARNING
WARNING
personal injury.
CAUTION
Cover all openings of the turbocharger before
cleaning or repainting the exhaust manifold. Damage
will result if paint enters the turbocharger.
If no leaks are found, clean and repaint the exterior
surfaces of the exhaust manifold.
Use solvent to clean the turbocharger and exhaust
manifold assembly.
Install
WARNING
This assembly weighs 23 kg [50 lb] or more. To
or get assistance to lift this assembly.
NOTE: The exhaust manifold gaskets are bi-directional
and can be installed in either direction.
Install six guide pins into the cylinder head to aid in
installing the exhaust manifold assembly.
Install new exhaust manifold gaskets over the studs.
Use a hoist to install the exhaust manifold over the guide
studs.
Install the upper six capscrews, but do not tighten at this

time.
Remove the guide pins one at a time and install the
mounting capscrew. Make sure the gaskets stay in place
during this process.
Tighten the capscrews in a crisscross pattern from the
center out.
Install the exhaust manifold coolant supply line.
Exhaust Restriction ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
WARNING
battery cable last.
• Install the coolant vent lines. Refer to Procedure
008-017.
NOTE: If the turbocharger and exhaust manifold were
removed as an assembly, then continue on with the
following steps. If not, refer to Procedure 010-033 to
install the turbocharger.
• Install the turbocharger oil supply line to the
turbocharger. Refer to Procedure 010-046.
• Install the turbocharger oil drain line to the
turbocharger. Refer to Procedure 010-045.
• Install the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Install the air crossover to the turbocharger. Refer to
Procedure 010-019.
• Connect the closed crankcase system, if equipped.
• Install the coolant heat exchanger. Refer to
Procedure 008-053.
• Install the coolant expansion tank, if equipped. Refer
• Install the turbocharger heat shield. Refer to
Procedure 011-032.
• Install the exhaust outlet connection. Refer to
Procedure 011-017.
008-018.
• Open the sea water supply valve(s).
Exhaust Restriction (011-009)

General Information
When measuring exhaust restriction, it is preferred that
the measurement point be within one pipe diameter of the
turbocharger outlet.
If this requirement can not be met, make sure to inspect
the exhaust outlet tubing between the turbocharger outlet
and the exhaust pressure tap location for damage to the
exhaust piping.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Restriction
Initial Check
Use INSITE™ electronic service tool to check for fault
codes. If any are present, follow the troubleshooting steps
as outlined in the corresponding fault code
troubleshooting procedure.
Measure
Connect pressure gauge, Part Number ST-1273, to the
pressure tap in the exhaust head pipe or at the inlet of the
muffler, diesel oxidation catalyst, or exhaust gas filter.
Operate the engine at rated speed and load. Record the
exhaust restriction. Compare the measured restriction to
the exhaust system specifications in the following
procedure. Refer to Procedure 018-020 in Section V.
If the exhaust restriction exceeds the specifications

inspect:
1 The exhaust piping for damage. Refer to the original
2 The diesel oxidation catalyst and/or muffler. Refer to
3 The exhaust gas filter (if equipped). Refer to the OEM
service manual.

Install and tighten the pipe plug.
Exhaust Outlet Connection ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Exhaust Outlet Connection (011-017)

Preparatory Steps
CAUTION
Before disconnecting the exhaust outlet piping, be
sure to fasten the piping above the water level to
prevent the vessel from taking on water and possibly
sinking.
• Close the sea water supply valve(s). Refer to the
OEM service manual.
• Remove the exhaust piping from the exhaust outlet
connection. Refer to the OEM service manual.
Remove
Loosen the hose clamps and remove the hose from the
heat exchanger and the exhaust outlet connection.
Remove the mounting capscrews and the exhaust outlet
connection from the turbocharger.

Inspect all the sealing surfaces and gasket for damage or
other signs of leakage.
Inspect the inside of the connection to make sure no
water passages are blocked.
Install
Install a new gasket and the exhaust outlet connection to
the turbocharger.
Install the hose on the heat exchanger and the exhaust
outlet connection. Tighten the hose clamps.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Heat Shield
Finishing Steps
• Install the exhaust piping to the exhaust outlet
connection. Refer to the OEM service manual.
• Open the sea water supply valve(s). Refer to the
OEM service manual.
Heat Shield (011-032)

Entfernen Sie
Remove the heat shield insulation wrapping from the
turbine housing.
Remove the wastegate actuator heat shield mounting

capscrews.
Remove the insulation and heat shield.
CAUTION
Remove the exhaust outlet connection. Refer to
Procedure 011-017.
Tap the heat shield mounting bracket and remove the
bracket from the exhaust flange.
Heat Shield ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Clean the gasket sealing surfaces.
Inspect the mounting area and the sheet metal for cracks.
Replace the heat shield if damage or cracks are found.
Install
Install two guide pins in the turbine outlet to hold the
gasket and heat shield mount.
Install a new gasket.
Place the heat shield mount on the guide pins.
Install a new exhaust outlet gasket.
Install the exhaust outlet connection and the lower

mounting capscrews.
Remove the guide pins.
Install the wastegate actuator heat shield mounting

capscrews.
Install the insulating wrap.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Gas Treatment Monitor Unit
Exhaust Gas Treatment Monitor Unit

(011-035)
General Information
The exhaust gas treatment monitor unit needs to be reset
after removal and installation of the following components:
• exhaust gas pressure sensor
• exhaust gas temperature sensor
• exhaust gas treatment monitor harness.
To reset, pass a magnet over the white strip in the center
of the exhaust gas treatment monitor unit. The exhaust
gas treatment fault code and maintenance lamps on the
vehicle dashboard will flash twice to signify that the
exhaust gas treatment monitor unit has been reset.
Remove
Disconnect the power leads. Refer to the vehicle
manufacturer's service manual.
Disconnect the exhaust gas treatment monitor harness.
Inspect for Reuse

Inspect the connectors for any damage, or bent or broken
pins. Repair or replace, if necessary.
Inspect for damaged or exposed wires. Repair or replace,
if necessary.
Install
Connect the exhaust gas treatment monitor harness.
Connect the power leads. Refer to the vehicle
Aftertreatment Selective Catalytic Reduction (SCR) Cata [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Aftertreatment Selective Catalytic

Reduction (SCR) Catalyst (011-036)
General Information
ISLe4 Engines
WARNING
after the vehicle stopped moving. To reduce 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.
WARNING
The catalyst substrate contains Vanadium Pentoxide.
Vanadium Pentoxide has been determined by the
State of California to cause cancer. Always wear
protective gloves, dust mask 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. Refer to the Materials
Safety Data Sheet (MSDS) for additional information.
WARNING
State of California to cause cancer. In the event the
catalyst is being replaced, dispose of in accordance
with local regulations. Do not cut open the exhaust
catalyst assembly.
WARNING
This component or assembly weighs greater than 23
equipment to lift this component or assembly.
Due to the number of various exhaust aftertreatment
applications, this procedure has been written to be
generic. Not all illustrations within this procedure will
represent the application being serviced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Selective Catalytic Reduction (SCR) Cata [...]
Preparatory Steps
ISL Engines
WARNING
exhaust components.
• Disconnect the exhaust gas temperature sensor, if
necessary. Refer to Procedure 011-037 in Section 11.
• Disconnect the exhaust gas pressure sensor, if
ISLe4 Engines
WARNING
exhaust components.
• Disconnect the exhaust gas temperature sensor, if
Remove
ISL Engines
WARNING
Remove the exhaust gas filter assembly from the vehicle.
Refer to the vehicle manufacturer's service manual.
NOTE: It may be possible to remove the V-band clamps
and separate the exhaust gas filter as listed in the
Disassemble step with the exhaust gas filter assembly still
installed in the vehicle.
ISLe4 Engines
Disconnect the OEM exhaust connections. Refer to the
OEM service manual.
WARNING
Lower the exhaust catalyst from the underside of the
vehicle/application.
Disassemble
ISL Engines
Mark the direction of exhaust flow on both the exhaust
gas filter catalyst section and the exhaust gas filter section
to aid in assembly.
Remove the V-band clamps holding the sections together.

Separate the mating sections by approximately 13 mm
[0.5 in] to allow removal over the gasket retainer rings.
Discard the gaskets.

ISL Engines
Check the inlet and outlet sections for any cracks or
damage. Replace if necessary.
Check the inlet and outlet face of the catalyst section for:
Fuel, oil, or coolant buildup. A fluid soaked exhaust gas
catalyst will have a glossy sheen and a strong fuel or oil
odor. Replace the exhaust gas filter catalyst section if any
damage is found.
Cracks or gouges deeper than 4 mm [0.156 in]. Replace
the exhaust gas filter catalyst section if any damage is
found.
If the exhaust gas filter catalyst section has shifted,
moved or is loose inside the canister, replace the exhaust
gas filter catalyst.
Inspect the exhaust gas filter for any cracks or gouges.

Replace the exhaust gas filter section if any damage is
found.
Inspect the outlet face of the exhaust gas filter for any
black areas. Replace the exhaust gas filter section if there
are more than 20 damaged cells.
Return the exhaust gas filter section to the nearest
Cummins® Authorized Repair Location for cleaning.
Inspect the V-band clamps for signs of over-extension.

The band must not be bent or damaged.
Inspect the V-band clamp threads for damage.
Replace the V-band clamp if damage is found.
ISLe4 Engines
WARNING
State of California to cause cancer. Always wear
protective gloves, dust mask and eye protection when
handling the catalyst assembly. Do not get the
catalyst material in your eyes. In case of contact,
wash skin with soap and water. Refer to the Materials
Safety Data Sheet (MSDS) for additional information.
Remove any loose paint, corrosion, from exhaust catalyst
sealing surfaces with a wire brush.
Excessive fuel or oil buildup will damage the exhaust
catalyst. If oil from an upstream engine failure is visible in
the exhaust plumbing, replace the catalyst. If evidence of
fuel in the exhaust stream is apparent and Fault Code
1687 occurs, replace the catalyst.
NOTE: Prior to the replacement of the exhaust catalyst,
the source of the upstream failure must be identified and
corrected. If the exhaust catalyst is replaced due to
progressive damage from engine oil or fuel contamination,
clean the tailpipe from the turbocharger outlet to the
exhaust catalyst.
Inspect exhaust catalyst for:

• Loose paint
• Excess Corrosion
• Damage to the body of exhaust catalyst, i.e. splits or
cracks to the body of the exhaust catalyst or
connecting pipe work.
Inspect exhaust catalyst for signs of catalyst solution
leaks.
Check/inspect all fittings and supports brackets before

reuse.
Assemble
ISL Engines
Assemble the sections of the exhaust gas filter. Use the
V-band clamps and new gaskets. Make sure marks on the
exhaust side of the catalyst and filter sections are aligned
with the outlet.
Tighten the V-band clamp.
Install
ISL Engines
WARNING
Install the exhaust gas filter assembly into the vehicle.
ISLe4 Engines
NOTE: Check the correct catalyst part number is
selected.
The exhaust catalyst is marked with “INLET” for
assembly, (INLET to engine).
Lift catalyst into position.
Connect OEM holding clamps.
Connect each end of exhaust catalyst to the vehicle
exhaust pipe work.
Test
Use INSITE™ electronic service tool to initiate a
aftertreatment SCR catalyst efficiency test.
Exhaust Gas Temperature Sensor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
ISL Engines
• Connect the exhaust gas temperature sensor, if
• Connect the exhaust gas pressure sensor, if
• Operate the vehicle and check for leaks.
ISLe4 Engines
WARNING
State of California to cause cancer. In the event the
catalyst is being replaced, dispose of in accordance
with local regulations. Do not cut open the exhaust
catalyst assembly.
• Connect the exhaust gas temperature sensor, if
• Operate the vehicle and check for leaks.
Exhaust Gas Temperature Sensor

(011-037)
Entfernen Sie
Slide the locking tab on the top side of the connector to
the unlock position.
Press down on the tab near the end of the harness
connector where the harness wires lead into the
connector.
Pull outward on the connector away from the sensor to
disconnect.
Remove the sensor from the mounting boss in the

exhaust piping.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust Gas Treatment Monitor Harness

Inspect for damaged or exposed wires, bent or broken
pins, damaged connectors, or damaged threads.
Replace if any damage is found.
Install
Put a light coating of anti-seize on the exhaust gas
temperature sensor mounting threads.
Install the sensor into the mounting boss in the exhaust
piping.
Tighten the sensor.
Push the connectors together until they lock.
Slide the locking tab to the lock position.
Reset the exhaust gas treatment monitor unit. Refer to
Procedure 011-035.
Exhaust Gas Treatment Monitor

Harness (011-038)
Preparatory Steps
Disconnect the exhaust gas treatment monitor diagnostic
lamps and the OEM harness connector to the exhaust gas
treatment monitor harness. Refer to the vehicle
Disconnect the exhaust gas temperature sensor. Refer to
Procedure 011-037.
Disconnect the exhaust gas pressure sensor. Refer to
Procedure 011-039.
Remove
Disconnect the exhaust gas treatment monitor harness
from the exhaust gas treatment monitor unit by pulling up
on the tab and releasing the connector.
Exhaust Gas Pressure Sensor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect for Reuse

Inspect the connectors for any damage or bent or broken
pins. Repair or replace if necessary.
Inspect for damaged or exposed wires. Repair or replace
if necessary.
Install
Connect the exhaust gas treatment monitor harness to the
exhaust gas treatment monitor unit.
Finishing Steps
Connect the exhaust gas pressure sensor. Refer to
Procedure 011-039.
Connect the exhaust gas temperature sensor. Refer to
Procedure 011-037.
Connect the exhaust gas treatment monitor diagnostic
lamps and the OEM harness. Refer to the vehicle
Procedure 011-035.
Exhaust Gas Pressure Sensor

(011-039)
Entfernen Sie
Push down on the locking tab and pull the connector
apart.
Disconnect the hose from the inlet fitting.
Remove the sensor from the mounting location. Refer to
the vehicle manufacturer's service manual.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Nozzle
Install
Connect the hose to the inlet fitting.
Connect the sensor to the exhaust gas treatment monitor
unit harness.
Attach the sensor to the mounting location. Refer to the
vehicle manufacturer's service manual.
Procedure 011-035.
Aftertreatment Nozzle (011-040)

General Information
WARNING
The aftertreatment diesel exhaust fluid (DEF) 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
WARNING
The exhaust system may remain hot for an extended
length of time.
The aftertreatment nozzle is used to spray DEF into the
exhaust system.
It is made from stainless steel.
Care should be taken when handling the aftertreatment
nozzle, to prevent damage or bending of the nozzle
locating pin or DEF intake connector.
Initial Check
Check the pipework going to and coming from the
aftertreatment DEF dosing control unit for any signs of a
leak.
DEF leaks will leave a white deposit around the fittings.
Aftertreatment Nozzle ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Preparatory Steps
WARNING
battery cable last.
in Section 13.
Remove
Disconnect the aftertreatment DEF supply pipework from
the aftertreatment nozzle and drain any excess
aftertreatment DEF into a suitable container. The fitting is
a quick release fitting; to release, press both sides of the
fitting.
Remove the aftertreatment nozzle retaining nut.
The aftertreatment nozzle will then lift out of the exhaust

system locating boss.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Nozzle
WARNING
The aftertreatment DEF contains urea. Do not get the
substance in your eyes. In case of contact,
wash skin with soap and water. Do not swallow
internally. In the event the catalyst reagent is
WARNING
personal injury.
NOTE: It may be necessary to warm the aftertreatment
nozzle in the exhaust system prior to testing for blockage.
This helps to soften the normal buildup that can form in
the nozzle holes while cold.
To clean the nozzle, use only clean, very warm water (+
40°C (104°F]).
Immerse the aftertreatment nozzle in a suitable container
of clean, warm, and demineralized water.
Connect an air line with a pressure of no more than 69
kPa [10 psi], and blow through the injector. When
immersed in water, the different spray angles from each
hole will be clearly visible.
Inspect the tip of the aftertreatment nozzle.

All spray holes should be clearly visible.
Check the body of the injector for damage.
NOTE: If shaken, there may be a slight noise from the
aftertreatment nozzle. This is normal.
Install
Install the aftertreatment nozzle into the exhaust system
locating boss. Make sure the aftertreatment nozzle
locating pin is located correctly in the exhaust system
locating boss. Care must be taken not to damage the
locating pin.
Apply high temperature anti-seize compound to the
threads of the locating boss.
Install the aftertreatment nozzle retaining nut.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Connect the aftertreatment DEF supply to the

aftertreatment nozzle.
Finishing Steps
WARNING
battery cable last.
Section 13.
• Operate the engine and check for proper operation.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing (011-082)
General Information
WARNING
Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact,
immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event
the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for
additional information.
WARNING
The aftertreatment system will stay hot to touch for long periods of time after the engine has been shut down.
To reduce the possibility of personal injury, avoid direct contact of hot components with your skin
WARNING
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. Refer to the Materials Safety Data Sheet (MSDS)
for additional information.
NOTE: The DEF dosing unit is not serviceable. Do not open the case.
This procedure is used to flush the DEF dosing unit if DEF crystals have built up in the air circuit of the pump. A
blockage in the DEF injector circuit can result in DEF entering the air system. Over time, urea crystal growth in the air
circuit leads to a reduction or total loss of air flow and failure of the component.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...]
Initial Check
Locate the DEF dosing unit on the vehicle.
The DEF dosing unit dataplate is located either on the top
or the side of the unit, as shown in the illustration (1).
Check the pipework going to and returning from the DEF
dosing unit for any signs of a leak.
Remove the aftertreatment nozzle and make sure that it is
completely clear of blockage. Refer to Procedure 011-040
in Section 11.
Connect the air flow meter from service tool kit, Part
Number 5296510, to the aftertreatment nozzle DEF
supply line.
Start and operate the engine. The DEF dosing unit will go
through its priming cycle. After a maximum of 140
seconds, air should pass through the dosing line and
through the air flow meter.
Specification: Air flow greater than 25 liters [6.6 gal] per
minute.
Perform the DEF flushing procedure, regardless of the
initial air flow measurement.
Preparatory Steps
WARNING
battery 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 the batteries. Wear goggles and
protective clothing to reduce the possibility of serious
personal injury.
WARNING
personal injury.
manual.
• Release the pressure in all vehicle air tanks. Refer to
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Flush
CAUTION
Fluid can attempt to force through the solenoid
exhaust port on the doser. Damage to the selective
catalytic reduction (SCR) dosing unit can occur.
The DEF dosing unit must be wiped with a clean damp
cloth and/or a wash bottle with mild detergent. This will
remove any contamination and reduce the risk of debris
entering the DEF dosing unit.
The dosing control unit connections are listed below:
1 Compressed air supply
2 Air solenoid connector (2-pin)
3 ITT Cannon™ on connector (37-pin)
4 DEF supply to aftertreatment nozzle (PTFE line)
5 DEF supply to pump
6 DEF return.
Lines 4, 5, and 6 have quick-fit connections. A quick
release fitting is also used for the air connection at the top
of the diesel exhaust fluid dosing unit. To release the
fitting, apply equal pressure to both sides of the release
collar, and pull the pipe from the fitting.
NOTE: Make sure the vehicle air supply to the DEF

dosing unit is either drained down or isolated before
removing the air supply line.
• Disconnet the air supply line to the dosing unit.
• Coil the polytetrafluoroethylene (PTFE) pipe and

fasten using tape. Fill the piping with clean water.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...]
• Connect one end of the coiled PTFE pipe to the dosing

pump air supply port (1), and the opposite end to the
regulated vehicle air supply (2), using the barrel
connector from service tool kit, Part Number 5296510.
• Remove the air flow meter from the aftertreatment
nozzle DEF supply line and direct the line into a
suitable container away from electrical components.
• Start and operate the engine. The DEF dosing unit will
go through its priming cycle After a maximum of 140
seconds, the water will attempt to force through the
aftertreatment nozzle DEF supply line.
• Collect the fluid in a container.
• If INSITE™ electronic service tool is available, the
Diesel Exhaust Fluid Doser Pump Air Solenoid Click
Test can be used during the flush to toggle the
solenoid valve. This will improve the effectiveness of
the procedure.
• If all the water has been forced out of the air solenoid
exhaust port, the flush procedure should be repeated
(no more than three attempts should be necessary).
• Once all the water is delivered from the injector line,
wait for 30 seconds for clear air flow.
NOTE: Make sure the vehicle air supply to the DEF

dosing unit is either drained down or isolated before
removing the air supply line.
• Remove the coiled PTFE pipe and barrel connector
from the DEF dosing unit air supply line.
• Connect the OEM air supply line to the dosing unit.
Test
WARNING
Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact,
immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event
the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for
additional information.
WARNING
Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause
personal injury.
Connect the air flow meter from service tool kit, Part Number 5296510, to the aftertreatment nozzle DEF supply line.
Start and operate the engine. The DEF dosing unit will go through its priming cycle. After a maximum of 140 seconds,
air should pass through the dosing line and through the air flow meter.
Specification: Air flow greater than 25 liters [6.6 gal] per minute.
If the air flow is less than the specification, or if air leaks from the air regulating unit, the dosing unit will require
replacement. Refer to the OEM service manual or contact a Cummins® Authorized Repair Location.
Remove the air flow meter from the aftertreatment nozzle DEF supply line and connect the diesel exhaust fluid supply
to the aftertreatment nozzle. Refer to Procedure 011-040 in Section 11.
Aftertreatment Diesel Exhaust Fluid Dosing Unit ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
manual.
• Start and operate the engine to build up air pressure.
• Check for air or DEF leaks.
• Check for active fault codes.
Aftertreatment Diesel Exhaust Fluid

Dosing Unit (011-058)
General Information
WARNING
DEF contains urea. Do not get the substance in your
eyes. In case of contact, immediately flush eyes with
large amounts of water for a minimum of 15 minutes.
Do not swallow. In the event the DEF is ingested,
contact a physician immediately. Reference the
materials safety data sheet (MSDS) for additional
information.
WARNING
exhaust components
The diesel exhaust fluid (DEF) dosing unit connections
are illustrated:
2 Air solenoid connector (2-pin)
3 37-pin ITT Cannon™ connector
4 DEF supply to aftertreatment nozzle
polytetrafluoroethylene (PTFE) line.
6 DEF return
Lines 4, 5, and 6 have quick-fit connections.
This procedure describes a method for testing the air flow
from the aftertreatment nozzle line.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Dosing Unit
Initial Check
©heck the DEF nozzle supply line for signs of damage or
leaks.
DEF will leave white deposits if a leak exists.
Preparatory Steps
WARNING
battery cable last.
• Disconnect the batteries. Refer to the original
Entfernen Sie
WARNING
information.
Disconnect the DEF pipework from the aftertreatment
nozzle and drain any excess DEF into a suitable
container. The fitting is a quick release fitting. To release,
press both sides of the fitting.
Connect the aftertreatment nozzle line to the air flow

meter, Part Number 5296510.
Aftertreatment Diesel Exhaust Fluid Dosing Unit ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Test
WARNING
information.
Start the vehicle and wait 140 seconds for the pump to
begin the prime cycle.
WARNING
personal injury.
NOTE: Some early calibrations do not have the 140
second delay, and the pump will begin the prime cycle
when the vehicle is started.
Thirty seconds after the prime cycle is completed, the
dosing unit will exhaust air down the aftertreatment
injection line.
NOTE: The DEF dosing unit could take up to 20 attempts
to prime. Each prime attempt will last 30 seconds.
WARNING
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 might come in contact with hot
exhaust or exhaust components
NOTE: Make sure that the airflow meter flow adjustment
is set to allow maximum airflow, in order to prevent a false
reading.
Record the reading from the airflow meter.
The airflow should be a minimum of 25 liters per minute
[6.6 gallons per minute].
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Dosing Unit
Install
WARNING
information.
Remove the airflow meter from the aftertreatment nozzle
line.
Connect the aftertreatment nozzle line to the
aftertreatment nozzle.
Finishing Steps
WARNING
battery cable last.
• Connect the batteries. Refer to OEM service manual.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Dosing Unit Filter (011-060)
General Information
WARNING
Diesel exhaust fluid (DEF) contains urea. Do not get
the substance in your eyes. In case of contact,
immediately flush eyes with large amounts of water
for a minimum of 15 minutes. Do not swallow. In the
event the DEF is ingested, contact a physician
immediately. Reference the materials safety data
sheet (MSDS) for additional information.
WARNING
exhaust components.
are as illustrated:
2 Air solenoid connector (2 pin)
6 DEF return
The DEF supply line contains a screen filter.
Initial Check
Visually check the DEF supply and return lines and fittings
for signs of damage, leaks, or faulty connectors.
If accessible, make sure that the primary filter fitted to the
DEF tank is a 35 micron filter. (Previously, this was a 70
micron filter).
Make sure that any contaminants found prior to carrying
out this check have been removed and that the DEF lines
have been cleared.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
Preparatory Steps
WARNING
battery cable last.
NOTE: Do not power wash or steam clean this unit. Use
compressed air to remove any loose debris.
Entfernen Sie
WARNING
Diesel exhaust fluid (diesel exhaust fluid) contains
of contact, immediately flush eyes with large amounts
of water for a minimum of 15 minutes. Do not
swallow. In the event the diesel exhaust fluid is
ingested, contact a physician immediately. Reference
the Materials Safety Data Sheet (MSDS) for additional
information.
cloth and/or a spray bottle with mild detergent. This will
NOTE: Do not power wash or steam clean this unit.
Disconnect the DEF supply pipework from the DEF dosing
unit and drain any excess catalyst solution into a suitable
container. The fitting is a quick release fitting; to release,
press both sides of the fitting.
NOTE: The inline screen filter is not a serviceable part.
Therefore, it can not be cleaned. If it is found to be
blocked or damaged, it must be replaced.
Remove the DEF supply line fitting.

The inlet fitting and screen filter as illustrated:
1 Inlet fitting and screen filter housing
2 100 micron screen filter
NOTE: The screen filter is not removable from the
connector. This is for illustration purposes only.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect for Reuse
WARNING
information.
To inspect the screen filter, shine a light through one end
of the screen filter to determine whether or not it is
blocked.
If the filter is blocked or restricted, it should not be reused.

It must be replaced.
NOTE: A white bead of adhesive may be visible in the
inlet fitting. This adhesive is used to bond the screen filter
to the inlet fitting, and is normal.
Install
WARNING
information.
Install the inline screen filter assembly into the diesel
exhaust fluid dosing unit.
Connect the DEF supply line to the DEF dosing unit.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Tank Filter
Finishing Steps
WARNING
battery cable last.
manual.

Tank Filter (011-083)
General Information
WARNING
WARNING
To reduce the possibility of personal injury, wear
goggles and protective clothing.
Preparatory Steps
WARNING
battery cable last.
Aftertreatment Diesel Exhaust Fluid Tank Filter ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Entfernen Sie
WARNING
Disconnect the electrical connections and pipework from
the DEF tank level sensor assembly.
Remove the DEF tank level sensor assembly from the
DEF tank. Refer to the OEM service manual.
NOTE: In some cases, the DEF tank is bonded to the
vehicle chassis, leaving no access to the DEF tank level
sensor assembly. If this is the case, contact the OEM to
arrange for the tank to be removed and inspected.
Inspect for Reuse
WARNING
Inspect the inlet filter attached to the DEF tank level
sensor assembly. Confirm that the filter is a 35 micron
filter, per the illustration.
Inspect the DEF tank level sensor assembly inlet filter for
dirt or contamination. If signs of dirt or contamination are
found, replace the inlet filter.
NOTE: If the inlet filter is not a 35 micron filter, then
replace the inlet filter with a 35 micron filter.
Install
WARNING
NOTE: Make sure that the DEF tank level sensor
assembly is kept free from any contamination during
installation to the vehicle.
Install the electrical connections and pipework that is
attached to the DEF tank level sensor assembly.
Refer to the OEM service manual for instructions.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...]
Finishing Steps
WARNING
battery cable last.
manual.

Line Restriction Test (011-086)
General Information
WARNING
The diesel exhaust fluid contains urea. Do not get the
substance in your eyes. In case of contact,
wash skin with soap and water. Do not swallow
internally. In the event the diesel exhaust fluid is
WARNING
exhaust components.
are illustrated:
2 Air solenoid connector (2 pin)
6 DEF return
This procedure describes a method for testing the diesel
exhaust fluid supply and return lines for leaks and/or
restrictions.
Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Initial Check
Visually check the DEF supply and return lines and fittings
for signs of damage, leaks, or faulty connectors.
A hand vacuum pump is required for this procedure.
Check the performance of the hand vacuum pump prior to
carrying out this test.
This can be done by blocking the pump nozzle and
pumping until a vacuum of 15 kPa [2 psi] is generated.
The vacuum pump gauge should show no noticeable
change to the vacuum over the next 60 seconds.
NOTE: Always use the collection cup with the vacuum
pump during testing to make sure that no diesel exhaust
fluid reaches the vacuum pump, as this could potentially
result in corrosion or damage to the vacuum pump’s
internal components.
Preparatory Steps
WARNING
battery cable last.
Remove
Make sure that the dosing unit and diesel exhaust fluid
lines are free from dirt and debris.
Connect the vacuum pump to the collection cup using the
tube supplied in the kit.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...]
Test
WARNING
information.
cloth and/or a spray bottle with mild detergent. This will
NOTE: Do not power wash or steam clean this unit.
Leak Test
1 Disconnect the DEF supply pipework from the DEF
dosing unit and drain any excess DEF into a suitable
container, then remove the DEF supply line connection
from the DEF tank.
2 Block one end of the DEF supply line and attach the
male J2044 line from the vacuum test kit to the
opposite end.
3 Slowly operate the vacuum pump until a vacuum of 15
kPa [2 psi] is achieved, then hold for 60 seconds.
Observe the gauge to confirm that the pump holds the
vacuum, with no noticeable change to gauge reading.
If the gauge value changes in this time, a leak exists in
the system. Disconnect the vacuum pump and
investigate / repair the source of the leak.
4 Connect the DEF supply line to the DEF tank.
5 Repeat these steps with the DEF return line.
NOTE: Consult the OEM service manual for information
regarding DEF line routing and repair/replacement
procedures.
Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Supply Line Restriction

1 Connect the male J2044 line from the vacuum test kit
to the DEF supply line to dosing unit connector.
2 Gradually operate the vacuum pump while observing
the clear pipe lines that leads to the collection cup. At
the moment when fluid reaches the collection cup and
is static in the line, record the pressure displayed by
the vacuum gauge.
3 If the vacuum gauge reads 20 kPa [3 psi] or less, the
restriction in the line is acceptable and fluid can be
drained back to the tank. However, if the pressure
exceeds 20 kPa [3 psi] at any time, a restriction or
blockage has been detected. Disconnect the vacuum
pump and look for the routing of the DEF line that
could result in restriction. If no routing issues are
found, replace the line.
4 Connect the DEF supply line to the DEF dosing unit.
regarding DEF line routing and repair/replacement
procedures.
Return Line Restriction

1 Connect the male J2044 line from the vacuum test kit
to the DEF return line to dosing unit connector.
2 Operate the vacuum pump continuously for 30
seconds while observing the clear pipe lines that lead
to the collection cup. The vacuum pump should not
draw DEF from the tank, although some DEF may still
remain in the lines.
3 The vacuum pump gauge should not read above 0
kPa [0 psi] during this test. If the vacuum gauge reads
above 0 kPa [0 psi] during this test, a line restriction or
blockage has been detected. Disconnect the vacuum
pump and look for the routing of the DEF line that
could result in restriction. If no routing issues are
found, replace the line.
4 Connect all DEF lines.
regarding DEF line routing and repair / replacement
procedures.
Finishing Steps
WARNING
battery cable last.
• Connect the batteries. Refer to OEM service manual.
Section 12 - Compressed Air System - Group 12 Page 12-a
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Compressor .......................................................................................................................................................12-16
Finishing Steps.......................................................................................................................................................12-22
Install...................................................................................................................................................................... 12-19
Pressure Test......................................................................................................................................................... 12-16
Remove.................................................................................................................................................................. 12-17
Air Compressor (Oil Carryover) ............................................................................................................................ 12-24
Air Compressor Carbon Buildup .............................................................................................................................12-2
Clean........................................................................................................................................................................12-3
Initial Check..............................................................................................................................................................12-2
Air Compressor Coolant Lines ................................................................................................................................12-7
Finishing Steps.........................................................................................................................................................12-8
Install........................................................................................................................................................................12-8
Remove....................................................................................................................................................................12-7
Air Compressor Cylinder Head, Single Cylinder ...................................................................................................12-8
Assemble................................................................................................................................................................12-12
Disassemble...........................................................................................................................................................12-12
Finishing Steps.......................................................................................................................................................12-15
Initial Check..............................................................................................................................................................12-8
Install...................................................................................................................................................................... 12-14
Remove....................................................................................................................................................................12-9
Air Compressor Rear Bearing Housing, Two Cylinder ....................................................................................... 12-28
Finishing Steps.......................................................................................................................................................12-31
Install...................................................................................................................................................................... 12-30
Remove.................................................................................................................................................................. 12-29
Air Compressor Unloader and Valve Assembly ..................................................................................................12-15
Air Governor ............................................................................................................................................................12-22
Pressure Test......................................................................................................................................................... 12-22
Air Leaks, Compressed Air System ......................................................................................................................12-23
Initial Check............................................................................................................................................................12-23
Air Pressure Relief Valve .......................................................................................................................................12-27
Test.........................................................................................................................................................................12-27
Service Tools ............................................................................................................................................................12-1
Compressed Air System...........................................................................................................................................12-1
Page 12-b Section 12 - Compressed Air System - Group 12

Section 12 - Compressed Air System - Group 12 Page 12-1
Service Tools
Compressed Air System
Repair Location.

Barring Tool
Used to engage the flywheel ring gear to rotate the crankshaft.
3824591
Air Compressor Adapter Replacer (11-tooth Spline)

Used to address wear problems on the air compressor spline
3165101 adapter.
Air Compressor Adapter Replacer (13-tooth Spline)

Used to address wear problems on the air compressor spline
3165102 adapter.
Air Compressor Discharge Tool

Used to measure acceptable oil carryover on Knorr-Bremse™ air
4918883 compressors.
Air Compressor Cleaning Kit

Used to clean and remove internal carbon deposits and other foreign
2892280 material from WABCO™ air compressor cylinder heads.
Air Compressor Carbon Buildup ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 12-2 Section 12 - Compressed Air System - Group 12
Air Compressor Carbon Buildup

(012-003)
Initial Check
WARNING
bodily injury.
Open the petcock on the wet tank to release the
compressed air from the system.
WARNING
Air discharge lines can be very hot. Be sure the lines
are cool before handling to reduce the possibility of
personal injury.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon buildup thickness inside the air

discharge line as shown.
NOTE: The carbon buildup 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
the possibility of personal injury and property
damage. Refer to the orginal equipment manufacturer
(OEM) service manual.
NOTE: If the total carbon deposit thickness exceeds
specification, remove and clean, or replace the air
discharge line. Refer to the OEM service manual for
specifications.
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 buildup
thicker than 1.6 mm [0.06 in]. Refer to the OEM service
manual for cleaning or replacement instructions.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Carbon Buildup
Clean
Use the Air Compressor Cleaning Kit, Part Number
2892280, to clean and remove internal carbon deposits
and other foreign material from the air compressor
cylinder head.
The items below are not included in the air compressor
cleaning kit, Part Number 2892280, but are required to
perform the repair.
• Regulated shop air 621 kPa [90 psi]
• Automatic transmission fluid (ATF)
• Shop rags, and a 19 liter [5 gallon] bucket
• INSITE™ electronic service tool.
Park the vehicle on a level surface and in an area where it

is safe to idle for an extended period of time. Chock the
vehicle wheels, and completely drain the vehicle air
system.
Remove the air compressor discharge line (1), air

compressor intake line (2), and air governor signal line (3)
at the air compressor.
Install and tighten the M10 connector (1) into the unloader
port of the air compressor housing.
Install and tighten the unloader control valve hose to the
M10 connector installed into the air compressor housing.
NOTE: Some air compressors have two unloader ports in
the air compressor housing. Make sure that one of the
ports is plugged with an appropriate pipe plug.
CAUTION
While cleaning the air compressor cylinder head, do
NOT install the original intake or discharge plumbing.
Only use the intake and discharge lines and fitting
supplied with the air compressor cleaning kit during
this procedure.
Install the discharge line and clamp from kit, Part Number
2892280, onto the discharge port fitting on the air
compressor cylinder head.
Place the discharge line into a 19 liter [5 gallon] bucket

and cover with several oil absorption pads.
Pour 89 ml [3 fluid ounces] of automatic transmission fluid

into the dispensing bottle.
Install the dispensing bottle onto the dispensing hose
assembly.
NOTE: For best results, use Dexron III automatic
transmission fluid or equivalent.
Install and tighten the dispensing hose assembly and

clamp to the intake port of the air compressor cylinder
head.
Connect the regulated shop air at 621 kPa [90 psi] to the
air compressor cleaner.
NOTE: The next three steps will happen quickly. For best
results, read the remaining instructions prior to continuing
with the cleaning procedure. Do not cycle the unloader
until all 89 ml [3 fluid ounces] of ATF have been applied.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Carbon Buildup
Start the engine, and let it idle for 1 minute.

The air compressor may draw in the automatic
transmission fluid naturally (no forced air applied). If the
fluid is not pulled from the dispensing bottle, press and
hold the ‘Clean’ button (1) on the air compressor cleaner
until all 89 ml [3 fluid ounces] of automatic transmission
fluid have been dispensed.
Pour 89 ml [3 fluid ounces] of automatic transmission fluid

into the dispensing bottle, and install back onto the
dispensing hose assembly.
Toggle the ‘Unloader’ switch (2) on to apply air pressure
to the unloader signal port.
Do not relieve pressure at the unloader valve at this time.
Start the engine.

Immediately depress and hold the ‘Clean’ button on the
air compressor cleaner until all 89 ml [3 fluid ounces] of
automatic transmission fluid have been dispensed.
Continue to hold the ‘Clean’ button down for an additional
10 to 20 seconds.
NOTE: A heavy mist of automatic transmission fluid
should be coming from the discharge hose.

Remove the discharge hose assembly from the air
compressor cylinder head intake port.
Start the engine.
Continuously cycle the ‘Unloader’ switch on the air

compressor cleaner for up to 25 cycles.
NOTE: When the air compressor cylinder head has been
adequately cleaned, there should be an audible difference
between loaded and unloaded states of the air
compressor. Installation of a 1.5 m [5 ft] length of rubber
hose over the intake port may help to audibly identify
when the unloader is functioning properly.
Verify constant suction at the air compressor cylinder

head intake port when the air compressor is loaded
(unloader switch OFF), and fluctuating air flow when
unloaded (unloader switch ON). If constant suction is not
present in a loaded state, repeat the cleaning process one
additional time.
CAUTION
Operating the air compressor with no filter in place at
the intake port may allow dust or debris to enter the
air compressor. A rubber hose should be placed over
the intake port and routed to an area free of air born
dust and debris.
With the discharge hose still installed, relieve the pressure
at the unloader port (switch OFF), and operate the engine
at high idle for 3 - 5 minutes to remove any excess
automatic transmission fluid.
Allow engine to return to low idle. Shut the engine OFF.

Remove the unloader control valve hose and M10
connector (1).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Coolant Lines
Install the vehicle air governor and/or signal line (3) and
air inlet (2) and outlet (1) connections on the air
compressor.
Operate the engine and verify the air compressor is
functioning properly.
Air Compressor Coolant Lines

(012-004)
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
• Drain the cooling system. Refer to Procedure 008-018
in Section 8.
Remove
NOTE: The air compressor cooling lines illustrated can
differ depending on the compressor installed. Although
different, the procedure remains the same.
Remove the coolant lines from the air compressor.
Remove the coolant lines from the air compressor cylinder
head and cylinder block.
Air Compressor Cylinder Head, Single Cylinder ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Inspect for Reuse

Inspect the coolant hoses and coolant lines for restriction
of coolant flow.
Install
NOTE: The air compressor cooling lines illustrated can
differ depending on compressor installed. Although
different, the procedure remains the same.
Install the coolant lines.
Finishing Steps
WARNING
battery cable last.
Section 8.
Section 13.
Air Compressor Cylinder Head, Single

Cylinder (012-007)
Initial Check
Inspect the cylinder head for signs of a coolant leak. A
coolant leak will be identified by an area of engine paint
appearing to have been washed away. White crystalline
clusters of material are not a sign of a coolant leak. If a
leak is found, rebuild the air compressor head using a
gasket kit. Go to the Disassemble section below.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Cylinder Head, Single Cylinder
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
WARNING
Air pressure must be released from the system before
removing the air governor. The governor can be
under pressure and cause personal injury.
Section 8.
• Remove the air compressor coolant lines. Refer to
• Remove the air governor or air governor signal line, if
necessary. Refer to the OEM service manual.
Remove
Remove the four 8-mm capscrews.
Do not remove the three M6 internal hex capscrews at
this time.
Remove the head and gasket.
NOTE: Due to an interference with the fuel pump on some
applications, it can be difficult to remove all four mounting
capscrews completely from the air compressor cylinder
head while the air compressor is still mounted to the
engine. To remove the cylinder head, completely remove
the front two capscrews and completely loosen the rear
two capscrews. Simultaneously lift the left rear capscrew
and cylinder head to unseat the locating dowel from the
air compressor housing. Slowly rotate the head
counterclockwise, using the right rear locating dowel as
a pivot point until enough clearance is available to lift the
cylinder head off the air compressor.

NOTE: The below clean and inspect steps are only to be
completed if the air compressor cylinder head was
removed as part of another repair.The air compressor
cylinder head does not need to be removed if the
unloader and valve assembly are determined to be stuck/
seized. Refer to Procedure 012-003 in Section 12.
Inspect the cylinder head for signs of an external coolant
leak. A large coolant leak from the air compressor cylinder
head will have blistered/removed paint and/or have a
white deposit build up.
If a large coolant leak is observed, the head must be
rebuilt with a gasket kit. Refer to the Cylinder Head
Gasket Kit in the Install section.
Inspect the unloader valve plate and cylinder head for

deep scratching or scoring. If the cylinder head is
scratched or scored deeply, it must be replaced.
Verify that the unloader piston is in the proper orientation

and operates properly. If, upon inspection, the unloader
piston and plate are stuck open, exposing any area of the
relief chamber, carefully remove the unloader plate from
the unloader piston pinions.
NOTE: The unloader piston and plate must always
default to the fully closed position.
Place a few drops of automatic transmission fluid into the

unloader piston bore. Coat the front and back side of the
piston with fluid.
Use a stiff wooden handle to apply pressure to the
unloader valve against the spring. Slide the unloader
piston through the full range of rearward travel. When the
spring is fully compressed, quickly let the pressure off,
allowing the spring to drive the piston back to its closed
state. Repeat cycling the unloader piston in this manner 5
to 10 times.
If the unloader piston continues to demonstrate any
resistance to movement, or slow response while returning
to the default closed position, the cylinder head must be
replaced.
NOTE: The above steps can be completed without
removing the air compressor cylinder head from the air
compressor by using the Air Compressor Cleaning Kit,
Part Number 2882280. Refer to Procedure 012-003 in
Section 12.
Inspect the unloader channel and governor supply port, as

well as the unloader piston, for signs of rust.
NOTE: Rust present in the unloader channel and/or
governor feed port indicates that either the air dryer has
malfunctioned, or improper draining of the vehicle air
tanks. Use the following procedure to check the air
governor for proper operation. Refer to Procedure
012-016 in Section 12. Refer to the OEM service manual
for troubleshooting the air dryer, as well as proper
maintenance intervals for the vehicle compressed air
tanks.
Inspect the intake and discharge ports for heavy carbon

buildup. Use the following procedure for proper reuse
guidelines. Refer to Procedure 012-003 in Section 12.
While the air compressor cylinder head is removed,

inspect the rotating components and the cylinder bore of
the air compressor for damage. Refer to Procedure
Disassemble
Air compressor cylinder heads can be rebuilt with new
gaskets if air or coolant leaks are detected.
Disassemble the cylinder head by removing the five
internal hex capscrews.
Separate the cylinder head.
Remove and discard the old gasket.
Inspect the sealing surface on both the upper and lower

sections of the cylinder head for damage.
Replace the exhaust valve if there was a coolant related
failure, or it is suspected that it is not sealing.
Do not reuse the exhaust valve capscrews.
Clean and inspect sealing surface.
Assemble
Place the new exhaust valve with the flat surface down.
Torque Value:
Step 1 5 N•m [ 44 in-lb ]
Step 2 10 N•m [ 89 in-lb ]
Carefully place a new gasket on the lower section of the
cylinder head.
Place the upper section of the cylinder head and insert
five internal hex capscrews, and finger tighten.
NOTE: If installing a new air compressor cylinder head

assembly, the following steps should not be performed.
New cylinder head assemblies are already assembled per
the instructions below. Skip to placement of the cylinder
head assembly onto the air compressor housing.
Apply a light coating of assembly lubricant, Part Number
3163087 or equivalent, to the unloader plate recess of the
cylinder head.
Place the unloader plate onto the unloader piston pinion,
as well as the stationary pinion, and press the unloader
plate into the assembly lubricant.
Install the air compressor intake valve.

Make sure the intake valve is oriented so the unloader
channel of the cylinder head is exposed by four holes (1).
Install the sealing gasket in a similar manner.

Make sure to orient the gasket so the four holes are not
blocked by the sealing gasket.
Install
NOTE: A new gasket kit must be used each time the air
compressor cylinder head is removed and installed. Do
not reuse the cylinder head mounting capscrews.
NOTE: Due to an interference with the fuel pump on some
applications, following a specific installation sequence of
the air compressor cylinder head and mounting
capscrews will make installation possible with the air
compressor still installed on the engine.
Before placing the cylinder head on the air compressor
housing, insert the rear right capscrew (1) through the
mounting hole. Place the cylinder head on the air
compressor housing such that the right rear locating
dowel and mounting capscrew engage the mounting hole
in the air compressor housing.
Insert the rear left capscrew through the cylinder head
mounting hole. Rotate the cylinder head clockwise into
position, using the rear right capscrew and locating dowel
as a pivot. Once the cylinder head has been properly set
onto the air compressor housing, insert the front two
capscrews.
Install the cylinder 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 ]
Step 2 Rotate capscrews 90 degrees.
NOTE: If a new head assembly is being installed, the five
small head cover bolts MUST be tightened.
If a new head assembly is being installed, tighten the five

small head cover capscrews in the sequence shown.
Torque Value:
Step 2 Rotate 90 degrees.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Unloader and Valve Assembly
Finishing Steps
WARNING
battery cable last.
• Install the air compressor coolant lines. Refer to
• Install the air inlet and outlet connections from the air
compressor. Refer to Procedure 012-004 in Section
12.
• Install the air governor or air governor signal line, if
Section 8.
manual.
Air Compressor Unloader and Valve

Assembly (012-013)
Preparatory Steps
WARNING
Air pressure must be released from the system before
removing the air governor. The governor can be
under pressure and cause personal injury.
Remove the air governor or air governor signal line from
the air compressor. Install the pipe plugs into all of the air
governor unloader ports on the air compressor.
Operate the engine to activate the air compressor.
If the air system pressure does not rise, the unloader
valve assembly is malfunctioning. Clean the air
compressor cylinder head. Refer to Procedure 012-003 in
Section 12.
If the air compressor has multiple air governor unloader

ports, install a pipe plug into one of the ports, and a shop
air fitting into the other unloader port.
Connect a regulated shop air hose to the fitting in the
unloader port.
When the air system pressure has reached 586 kPa [85
PSI], apply 698 kPa [100 psig] of shop air pressure to the
unloader port. If the vehicle air system pressure continues
rising, the unloader valve assembly is malfunctioning.
Clean the air compressor cylinder head. Refer to
Air Compressor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Connect the OEM air governor signal line to the air

compressor unloader port.
Operate the engine to activate the air compressor. Verify
that the system still builds pressure properly.
If the air system pressure continues to build beyond the
governed point, the air governor is malfunctioning. Refer
Air Compressor (012-014)

Pressure Test
WARNING
The external pressure tank used must meet Society of Automotive Engineers (SAE) J10 and FMVSS121
standards, and have a safety pressure relief valve which opens between 1034 to 1207 kPa [150 to 175 psi].
Failure to use the proper pressure vessel and plumbing can result in property damage and serious personal
injury.
Start the engine and operate at idle engine speed.
NOTE: Once the external pressure tank pressure reaches 862 kPa [125 psi], shut the engine OFF. Depending on the
size of the external tank and the diameter/length of the discharge hose being used, the buildup time will vary.
For example, a single cylinder (318 cc) compressor filled an 42 liters [11 gal] tank to 862 kPa [125 psi] with a (#10 x 6ft
length) discharge hose in 90 seconds. This was considered to be the specification for this setup.
Verify that the air compressor will build pressure in the external tank. If air pressure successfully builds to 862 kPa
[125 psi], the air compressor functions properly. Remove the external air discharge hose from the air compressor and
install the vehicle air discharge hose and air governor signal hose to the compressor. Reference the symptom tree
being utilized to inspect the rest of the air system components for leaks and proper operation.
If the air compressor fails to build to 862 kPa [125 psi], the air compressor is malfunctioning and the cylinder head
needs to be repaired based on the marking scribed on the head. Refer to Procedure 012-003 in Section 12.
Air Compressor Diagnostic Test
1 Park the vehicle. Use wheel chocks or an appropriate anti-roll device to stabilize the vehicle.
• Drain the vehicle air system.
• Remove the air discharge hose and air govenor signal hose from the air compressor. Install pipe plugs into the air
compressor unloader signal ports.
• Plumb the air compressor discharge hose into an external pressure tank. The external pressure tank must be
equipped with a pressure gauge and pressure relief valve. Make sure that the fittings are installed with appropriate
thread sealant and do not leak.
Start the engine and operate at rated engine speed.
Verify that the air compressor will build pressure in the external tank. If air pressure fails to build in the pressure tank,
the air compressor has malfunctioned. Refer to Procedure 012-013 in Section 12.
NOTE: Once the external pressure tank pressure reaches 689 kPa [100 psi], shut the engine OFF.
Monitor the pressure gauge on the external tank for rapid leak down of the air pressure. If the air tank loses more than
138 kPa [20 psi] in a 5 minute period, the pressure relief valve, intake valve, or exhaust valve has malfunctioned. The
air compressor cylinder head intake and exhaust valve are not serviceable. Replace the air compressor cylinder head.
NOTE: Do not cycle air accessories such as seats, doors, wipers, air bags, etc.
1 If there is any noticeable decrease of the air gauge readings, or if the air dryer cycled during the 10 minute test,
repair the leaks.
NOTE: Leaks in systems that hold pressure for 5 to 10 minutes may be hard to find.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
WARNING
personal injury.
Remove
Remove the air compressor support brackets and
capscrews.
Remove the two capscrews and the air compressor.

Inspect the compressor housing for cracks or other
damage.
Inspect the 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.
Power Steering Coupling (if applicable)

Inspect the power steering coupling for wear or cracks.
Replace the coupling, if damaged. Refer to the OEM
service manual.
Remove the air compressor cylinder head if it is not
already removed. Refer to Procedure 012-007 in Section
12.
Inspect the inside circumference for vertical scratches
deep enough to be felt with a fingernail.
If a fingernail catches in the scratch, the air compressor
must be replaced.
Inspect the inside circumference for scuffing, scoring, or
polishing.
If the cylinder head is removed, inspect the bore and

rotating components within the air compressor.
Inspect the air compressor bore for signs of scoring and
polishing.
NOTE: A cross hatch honing pattern must be visible
within the bore. If any part of the bore is scored or
polished, the air compressor must be replaced.
If internal damage to the rotating assembly (crankshaft,

piston, and connecting rod) is suspected, the plug on the
bottom of the air compressor must be removed to inpect
the rotating assembly.
NOTE: A replacement plug and gasket kit is available for
assembling the air compressor.
Install
Air Compressor Timing (for Single-Cylinder Air
Compressor Only)
Rotate the engine so that the number 1 cylinder is at top
dead center (TDC). This is done by aligning the timing
mark on the fuel pump gear with the TDC mark.
NOTE: There are two similar marks on the air compressor

gear that look like “[I]” and “I”. The timing mark to be used
when timing the air compressor to the engine is “I”.
Cummins® Single-Cylinder Air Compressors
Viewing the compressor from the gear end (with the
compressor in a vertical position), rotate the gear so the
“I” timing mark is at the 3-o'clock position. The Cummins®
single-cylinder air compressor will have a divot on the
housing at the 3-o'clock position to aid in timing the
compressor. Once the timing mark is at the 3-o'clock
position, this will set the compressor at 60-degrees before
TDC of the compressor's compression stroke.
Holset® Air Compressors

Viewing the compressor from the gear end (with the
compressor in a vertical position), rotate the gear so the
“I” timing mark is at the 12-o'clock position. This will set
the compressor at 60-degrees before TDC of the
compressor's compression stroke.
NOTE: Some Holset® compressors have a divot or
drilling on the housing at the 10-o'clock position; IGNORE
this mark.
Air Compressor Timing (for Single-Cylinder Air

Compressor Only, Other than Holset® or Cummins®)
Locate TDC on the compressor crankshaft by removing
the unloader valve or head. See the respective air
compressor manual. TDC does not have to be exact. The
system is tolerant of some misalignment.
Use ink or a Dykem® marking pen to mark the air

compressor gear face at TDC (12-o'clock position when
viewed from the front).
Rotate the compressor TDC mark to 60-degrees, or six

teeth on a 36-tooth gear, before TDC. This is
approximately 10-o'clock when viewed from the front of
the air compressor.
Install the air compressor and new gasket to the gear

housing.
Install the brace to the air compressor.

Install the spacer to brace capscrews and hand-tighten.

Make sure there are no gaps between the spacer and the
brace, and no gaps between the spacer and the cylinder
block.
Install the capscrews that connect the spacer to the

cylinder block and hand-tighten.
Make sure there are no gaps between the spacer and the
brace, and no gaps between the spacer and the cylinder
block.
Air Governor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
WARNING
• Install the oil supply line. Refer to Procedure 012-110
in Section 12.
• Install the air inlet and air outlet connections to the air
compressor.
• Install the air governor or air governor signal line, if
• Install the air compressor coolant lines. Refer to
• Install the air lines.
• Install any attachments to the rear of the air
compressor. Refer to the OEM service manual.
• Fill the engine cooling system. Refer to Procedure
manual.
• Operate the engine to activate the air compressor and
check for leaks.
Air Governor (012-016)

Pressure Test
The air compressor governor location can vary. The air
governor can be air compressor mounted or chassis
mounted.
If the air pressure is being governed at either a higher or
lower pressure than the equipment manufacturer's
specification, connect a regulated shop air pressure line to
the air compressor governor air signal port.
NOTE: Be positive the 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.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Leaks, Compressed Air System
NOTE: When performing the test, be sure the air system

pressure does not exceed the manufacturer's maximum
allowable pressure.
NOTE: Make sure the governor vent port (A) is open to
the atmosphere. If this port is plugged, the air governor
will malfunction.
• Inspect the governor control lines for restrictions.
• Drain the air system and install a gauge of known
accuracy onto the unloader port (B) of the air
governor. If the governor has two unloader ports,
make sure one is plugged.
• Start the engine and apply the brakes to initiate air

compressor pumping. Note the governor cut-out
pressure (pressure at which the compressor stops
pumping).
• Apply the brakes until the compressor starts to pump.
Note the cut-in pressure.
NOTE: Zero pressure in the governor unloader line will
allow the compressor to start pumping.
• Allow the system to build pressure until the air
compressor unloads.
• Apply the brakes until the compressor starts to pump.
Note the time it takes for the governor unloader port to
go from system pressure to 0 kPa [0 psi]. The cycle
should take less than 2 seconds.
• Repeat steps three through six for a total of three runs.
Air Leaks, Compressed Air System

(012-019)
Initial Check
WARNING
Wear appropriate eye and face protection when
releasing air pressure from the compressed air
system. Flying debris and dirt can cause personal
injury.
Shut off the engine.
Open the drain cock on the wet tank to release air from
the system. Close the draincock after the pressure is
released.
Air Compressor (Oil Carryover) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

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 Compressor (Oil Carryover)

(012-020)
Inspect for Reuse
Perform this test in conjunction with troubleshooting the
air compressor pumping oil into the air system.
NOTE: Small oil deposits at the air dryer purge valve are
normal. The air compressor is lubricated with engine oil,
and small amounts of carryover are to be expected. Oil
carryover is more common on naturally aspirated air
compressors. Oil or moisture can be expected at any
purge or drain valves up to and including the air dryer,
which will include ping tanks and/or cooling or
condesation tanks. If there is no oil or condensation found
at the tanks after the air dryer, then the air dryer is
working correctly and sized adequately.
WARNING
The air discharge line and other equipment will
become hot during the course of the test. To prevent
burns, use protective gloves when touching heated
surfaces.
Operate the engine until the coolant temperature reaches
normal operating temperature. Once the coolant has
reached operating temperature, shut the engine down and
completely drain the vehicle air system.
NOTE: Failure to warm the engine adequately can result
in false test results.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor (Oil Carryover)
WARNING
The discharge from the air compressor will be hot,
possibly contain oil vapors, and will be noisy. Make
sure there is adequate ventilation and hearing
protection is worn, particularly if the type of vehicle
requires the test be conducted in an enclosed
environment.
Disconnect the discharge pipe from the air compressor
cylinder head.
Disconnect the air inlet plumbing at the air compressor
cylinder head.
Connect the oil carryover test tool, Part Number 4918883,

to the air compressor cylinder head discharge port.
NOTE: If the application presents restricted access to the
air compressor, a high temperature flexible hose
(minimum 15 mm [0.6 in] inside diameter) can be
connected directly to the discharge port of the compressor
in order to carry out the test outside the engine
compartment. Be sure to have a 90 degree bend near the
end of the flexible hose during testing.
Install the test paper into the service tool, Part Number
4918883. Make sure it is held at a right angle to and in
line with the flow of compressed air, at a distance not to
exceed 100 mm [3.9 in] from the end of the compressor
discharge pipe or flexible hose, if fitted.
The test paper can be standard clean copier paper,
typically 80 grams/sq meter. It must be mounted in the air
compressor discharge line tool, leaving a 70 mm [2.76 in]
diameter circle of the paper exposed. The outline of the
circle in the mask must be drawn onto the test paper to
later aid in comparison.
NOTE: It may be necessary to use INSITE™ electronic

service tool to increase the maximum engine speed,
without vehicle speed sensor (VSS), to 2100 rpm.
Air Compressor (Oil Carryover) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
To perform the test, start the engine and run at high idle.
Leave the test paper in the airflow for exactly 5 minutes.
Remove the test paper, or rotate the tool mask exposing a
new circular test area.
Repeat this test until three comparable circular test areas
are generated.
Shut the engine down.
NOTE: If the maximum engine speed, without VSS, was
adjusted in the previous step, change it back to the
original value upon completion of the test.
NOTE: Compare the test results with the reference results

shown below.
Time Air Compressor Has Been In Service (Months/
Years):
• Less Than 6 Months - Compressor in good condition
• 6 Months to 2 Years - Compressor in good condition
• Greater Than 2 Years - Compressor in good condition.

Years):
• Less Than 6 Months - Compressor needs to be
replaced
• 6 Months to 2 Years - Compressor in acceptable
condition
• Greater Than 2 Years - Compressor in good condition.

Years):
• Less Than 6 Months - Compressor needs to be
replaced
• 6 Months to 2 Years - Compressor needs to be
replaced
• Greater Than 2 Years - Compressor needs to be
replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Pressure Relief Valve
NOTE: This step must be completed if the compressor

assembly is replaced as a result of this test and is
requested to be returned via the CORE, or enhanced
parts return (EPR) return process.
If the compressor is deemed failed and needs to be
replaced, please place the test paper, with results of Oil
Carryover Test, in a sealable plastic bag, seal to prevent
oil contamination, and include with the failed compressor.
Air Pressure Relief Valve (012-024)

Test
Remove the air governor or air governor line from the air
compressor.
Remove the air intake line from the air compressor
cylinder head.

Under normal operating conditions, the air compressor
intake port will create a vacuum.
To check for the presence of a vacuum, hold a piece of
paper or cardstock 5 cm [2 in] in front of the air
compressor intake port.
Observe the response of the paper.
Shut the engine off.
If the paper is blown away from the air compressor intake

port, replace these components:
• Air pressure relief valve. See equipment manufacturer
NOTE: For engines equipped with Wabco™ air
compressors, the air pressure relief valve is an integral
part of the air compressor cylinder head.
• Air compressor cylinder head. Refer to Procedure
Air Compressor Rear Bearing Housing, Two Cylinder ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
If the paper does not move:

• Check the downstream air system components for
damage or restrictions.
• Make sure the intake and exhaust valves are
functioning properly. Refer to Procedure 012-014 in
Section 12.
If the paper is pulled toward the air compressor intake, the

air compressor relief valve is working properly.
Install the air intake line to the cylinder head.

Install the air governor or air governor line to the air
compressor.
Air Compressor Rear Bearing

Housing, Two Cylinder (012-112)
General Information
Before removing the rear bearing housing of the air
compressor, always check to make sure parts are
available for the type of air compressor being serviced. If
parts are not available, it will be necessary to replace the
entire air compressor.
NOTE: The following procedure has been specifically
designed to cover Knorr-Bremse™ air compressor
configurations.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Rear Bearing Housing, Two Cylinder
Cummins® engines are equipped with a variety of air

compressors. This procedure will cover the removal,
cleaning, inspection, and installation of rear bearing
housing of the Knorr-Bremse™ brand of air compressors
with two cylinders.
To determine what brand air compressor your specific
engine has, look on the air compressor dataplate, usually
located on the side of the air compressor.
Preparatory Steps
WARNING
• Remove the air compressor. Refer to Procedure
Remove
Remove the drive adapter capscrew (1) and drive adapter
(2).
Remove the rear bearing housing mounting capscrews
(3).
Remove the rear bearing housing (4).
WARNING
Remove the o-ring seal.

Gasket sealing surfaces must be clean and free of all old
gasket material, carbon, rust, and other buildup. Surfaces
must be free of scratches, gouges, burrs, and other
deformities.
Inspect the air compressor rear bearing.
Replace the complete air compressor assembly, if any
damage is found.
Install
Knorr-Bremse™ Air Compressors
Install a new o-ring seal in the compressor rear bearing
housing.
Install the rear bearing housing.

Install the mounting capscrews.
Tighten the capscrews in the sequence shown.

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Compressor Rear Bearing Housing, Two Cylinder
Install the drive adapter and mounting capscrew.

NOTE: Loctite™ 638, or equivalent must be applied to
the capscrew during installation.
Finishing Steps
• Install the air compressor. Refer to Procedure 012-014
in Section 12.
Notes
Section 13 - Electrical Equipment - Group 13 Page 13-a
Section 13 - Electrical Equipment - Group 13

Section Contents
Page
Alternator ...................................................................................................................................................................13-2
Finishing Steps.........................................................................................................................................................13-8
Initial Check..............................................................................................................................................................13-2
Install........................................................................................................................................................................13-7
Remove....................................................................................................................................................................13-6
Test...........................................................................................................................................................................13-2
Alternator Bracket ....................................................................................................................................................13-8
Finishing Steps.........................................................................................................................................................13-9
Install........................................................................................................................................................................13-9
Remove....................................................................................................................................................................13-8
Batteries .................................................................................................................................................................. 13-11
Initial Check............................................................................................................................................................13-11
Battery Cables and Connections .......................................................................................................................... 13-12
Initial Check............................................................................................................................................................13-12
Charging System Indicator ....................................................................................................................................13-24
Initial Check............................................................................................................................................................13-24
Drive Belt, Alternator ................................................................................................................................................13-9
Finishing Steps.......................................................................................................................................................13-10
Install...................................................................................................................................................................... 13-10
Remove.................................................................................................................................................................. 13-10
ECM Unswitched Power Terminal Blocks ............................................................................................................13-25
Finishing Steps.......................................................................................................................................................13-28
Initial Check............................................................................................................................................................13-26
Install...................................................................................................................................................................... 13-28
Remove.................................................................................................................................................................. 13-27
Service Tools ............................................................................................................................................................13-1
Electrical Equipment.................................................................................................................................................13-1
Starter Magnetic Switch .........................................................................................................................................13-12
Initial Check............................................................................................................................................................13-12
Resistance Check...................................................................................................................................................13-13
Voltage Check........................................................................................................................................................ 13-13
Starter Solenoid ......................................................................................................................................................13-15
Initial Check............................................................................................................................................................13-15
Voltage Check........................................................................................................................................................ 13-17
Starter Switch ..........................................................................................................................................................13-14
Voltage Check........................................................................................................................................................ 13-14
Starting Motor ......................................................................................................................................................... 13-19
Finishing Steps.......................................................................................................................................................13-24
Install...................................................................................................................................................................... 13-22
Measure..................................................................................................................................................................13-22
Remove.................................................................................................................................................................. 13-21
Rotation Check.......................................................................................................................................................13-19
Page 13-b Section 13 - Electrical Equipment - Group 13

Section 13 - Electrical Equipment - Group 13 Page 13-1
Service Tools
Electrical Equipment
Repair Location.

Digital Multimeter
Used to measure electrical circuits: voltage (volts), resistance
3164488 or (ohms), and current (amperes). Standard meter, Part Number
3164489 3164488, Automotive meter, Part Number 3164489, with built-in
temperature adapter and tachometer.
Clamp-on Current Probe

Used to measure DC current from 0 to 1000 amperes or AC current
3164490 from 0 to 1000 amperes.
Barring Tool
3824591
Refractometer
The Fleetguard® refractometer is used to check the charge condition
CC-2800 of a conventional battery.
Alternator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 13-2 Section 13 - Electrical Equipment - Group 13
Alternator (013-001)
Initial Check
Check the drive belt and alternator pulley to be sure the
alternator is rotating.
WARNING
battery cable last.
Check the battery and all wiring connections.
Inspect the wiring for defects.
Check all connections for tightness and cleanliness,
including the slip connectors at the alternator and engine
compartment bulkhead, and connections at the battery.
Test
NOTE: This test applies to Bosch® alternators.
With the ignition switch "ON" and all wiring harness leads
connected, connect a voltmeter from:
Bosch®
• Alternator "BAT" "B+" terminal to ground
• Alternator Number 1 to ground
• Alternator Number 2 to ground
• Alternator D+ K1 to ground.
A zero reading indicates an open circuit between the
alternator connections and the battery.
Locate and repair the open circuit.
Digital Multimeter, Part Number 3164488; Clamp-on

Current Probe, Part Number 3823574:
Connect a carbon pile load (battery tester) across the
battery posts of the battery boxes.
Clamp an induction pickup type amp meter around the
battery cable, or use the digital multimeter, Cummins®
Part Number 3164488, with the clamp-on current probe,
Cummins® Part Number 3823574.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Alternator
Digital Multimeter, Part Number 3164488:

Disconnect any cables that lead to any other battery
boxes in the circuit, negative (-) cables first.
Operate the engine at high idle and measure the
alternator voltage output to the batteries with digital
multimeter, Part Number 3164488. See the alternator
manufacturer's specifications.
Operate the engine at high idle and adjust the systems

analyzer/battery tester to apply the maximum rated
amperage load to the alternator. See the alternator
NOTE: The alternator maximum rated amperage output is
normally stamped or labeled on the alternator.
Measure the alternator amperage output. See the
alternator manufacturer's specifications.
If the gauge on the carbon pile load testing equipment

does not indicate approximately the same output as the
induction-type ampmeter, determine which is defective
and replace it. See the alternator manufacturer's
specifications.
If the alternator output (amps) is not within 10 percent of
rated output, repair or replace the alternator. See the
alternator manufacturer's instructions for repair
procedures.
Shut off the engine and remove the test equipment.

Connect all battery cables, negative (-) cable last.
NOTE: This test applies to Delco alternators.

NOTE: Any multimeter reading of zero voltage indicates
an open circuit.
Check for open circuits.
Turn the keyswitch to the ON position.
Connect a multimeter, Cummins® Part Number 3164488
or 3164489, to the following locations:
Delco Alternators
• Alternator "BAT" terminal to ground
• Alternator blade terminal "Number 1" to ground
• Alternator blade terminal "Number 2" to ground
Locate and repair the open circuit.
Connect a carbon-pile load (battery/alternator tester)

across the battery posts of the battery boxes.
Clamp an induction pickup-type ampere-hour meter
around the battery cable; or use the digital multimeter,
Part Number 3164488 or 3164489, with the clamp-on
current probe, Part Number 3164490.
WARNING
battery cable last.
WARNING
personal injury.
Disconnect any cables that lead to any other battery
boxes in the circuit, negative (-) cables first.
Operate the engine at high idle; and measure the
alternator voltage output to the batteries with digital
multimeter, Part Number 3164488 or 3164489. Refer to
the OEM specifications.
Operate the engine at high idle and adjust the carbon-pile

load-testing equipment to apply the maximum rated
amperage load to the alternator. Refer to the OEM
specifications.
NOTE: The alternator maximum rated amperage output is
normally stamped or labeled on the alternator.
Measure the alternator amperage output. Refer to the
OEM specifications.
If the alternator output (amps) is not within 10 percent of
rated output, repair or replace the alternator. Refer to the
OEM service manual for repair procedures.
WARNING
battery cable last.
WARNING
personal injury.
Shut off the engine and remove the test equipment.
Connect all battery cables, negative (-) cable last.
Preparatory Steps
WARNING
battery cable last.
Remove and tag all wires and complete the following
steps:
in Section 13.
• Disconnect the battery ground cable.
• Remove the drive belt from the alternator pulley. Refer
• Tag and label wires attached to the alternator.
• Remove the wires attached to the alternator.
Remove
Remove the alternator link capscrew.
Remove the alternator mounting capscrew.

Remove the alternator.
Marine Applications
Loosen the alternator link capscrew at the engine
mounting location.
Loosen the alternator link capscrew at the alternator.
Loosen the alternator mounting capscrew.
Remove the alternator link capscrew at the alternator.
Remove the alternator mounting capscrew.

Remove the alternator.
Install
Install the alternator and alternator capscrews in the
reverse order of removal.
Install the alternator link capscrew.

Marine Applications
Install the alternator upper mounting bracket capscrew.
Do not tighten at this time.
Install the alternator link capscrew at the alternator.

Tighten the upper mounting bracket capscrew.
Torque Value:
Upper Mounting Capscrew
Step 1 77 N•m [ 57 ft-lb ]
Tighten the lower mounting link at the alternator and
engine mounting location.
Torque Value:
Alternator Link at Alternator
Step 1 44 N•m [ 32 ft-lb ]
Torque Value:
Alternator Link at Engine Mounting Location
Step 1 24 N•m [ 18 ft-lb ]
Alternator Bracket ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
• Install the drive belt. Refer to Procedure 008-002 in
Section 8.
• Operate the engine and verify proper alternator
operation.
Alternator Bracket (013-003)

Preparatory Steps
WARNING
battery cable last.
manual.
• Remove the alternator. Refer to Procedure 013-001 in
Section 13.
Remove
Side Mounted Bracket
Remove the bracket mounting capscrews and the side
mounted bracket.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Drive Belt, Alternator
Install
Side Mounted Bracket
Install the side mounted bracket and bracket mounting
capscrews.
Finishing Steps
WARNING
battery cable last.
• Install the alternator. Refer to Procedure 013-001 in
Section 13.
manual.
• Start the engine and check for proper operation.
Drive Belt, Alternator (013-005)

Preparatory Steps
CAUTION
Make sure that the engine is shut off and any starting
mechanisms are isolated before any maintenance is
performed.
CAUTION
The removal and replacement of any guards covering
rotating components, drives and/or belts, must only
be accomplished by a trained and certified technician.
All fasteners removed must be replaced when
installing the guards. If fastener replacement is
required, verify the correct part number (or
equivalent) is used. Do not substitute a fastener of
lesser quality. Possible equipment damage or serious
personal injury can occur.
Drive Belt, Alternator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
Lift the belt tensioner to relieve tension on the belt and
remove the drive belt.
Install
NOTE: If difficulty is experienced installing the drive belt
(i.e., the belt seems too short), position the belt over the
grooved pulleys first and then, while holding the tensioner
up, slide the belt over the water pump pulley.
• Lift and hold the belt tensioner. Install the drive belt
and release the tensioner.
• Refer to Procedure 008-002 in Section 8.
Finishing Steps
CAUTION
The removal and replacement of any guards covering
rotating components, drives and/or belts, must only
be accomplished by a trained and certified technician.
All fasteners removed must be replaced when
installing the guards. If fastener replacement is
required, verify the correct part number (or
equivalent) is used. Do not substitute a fastener of
lesser quality. Possible equipment damage or serious
personal injury can occur.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Batteries
Batteries (013-007)
Initial Check
WARNING
personal injury.
If conventional batteries are used, remove the cell caps or
covers and check the electrolyte level.
NOTE: Maintenance-free batteries are sealed and do not
require the addition of water.
Fill each battery cell with distilled water. Refer to the
battery manufacturer's specifications.
Use the Fleetguard® Refractometer, Part Number

CC-2800, to check the specific gravity of the battery
electrolyte.
Refer to the battery fluid column in the refractometer to
determine the state-of-charge of each battery cell.
If water has been added to a dry cell, recharge the battery
to mix the added water with the existing battery electrolyte
to prevent inaccurate readings.
Use a battery tester to test the output amperage of

maintenance-free or conventional vent cap batteries.
If the output amperage is low, use a battery charger to
charge the battery. Refer to the manufacturer's
instructions.
Replace the battery if it will not charge to the
manufacturer's specifications, or will not maintain a
charge.
Starter Magnetic Switch ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Battery Cables and Connections

(013-009)
Initial Check
WARNING
battery cable last.
Inspect the battery terminals for loose, broken, or
corroded connections.
Repair or replace broken cables or terminals.
If the connections are corroded, remove the cables and

use a battery brush to clean the cable and battery
terminals.
Install and tighten the battery cables.
Use grease to coat the battery terminals to prevent
corrosion.
Starter Magnetic Switch (013-017)

Initial Check
CAUTION
Improper installation of the starter magnetic switch
can result in starter over-run damage.
To make sure that the magnetic switch is not activated by
vehicle movement, the axis of the plunger must be
horizontal to the ground and perpendicular to vehicle
travel.
Do not mount an external magnetic switch on the engine
or on any metal that can possibly resonate as the result of
road or engine vibration.
• Refer to the OEM service manual for proper magnetic
switch installation.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Starter Magnetic Switch
Resistance Check
Remove the cable connecting the magnetic switch to the
starting motor solenoid from the magnetic switch terminal.
Set the digital multimeter, Cummins® Part Number
3164488, to measure resistance (ohms).
Connect the leads to the two large switch terminals.

With the starting motor switch in the OFF position, the
multimeter must indicate resistance greater than 100k
ohms.
Turn the starting motor switch to the START position.
The multimeter must indicate less than 10 ohms. If not
within specifications, replace the starter magnetic switch
according to the manufacturer's instructions.
Voltage Check
If the multimeter indicates resistance at greater than 100k
ohms with the starting motor switch in the "START"
position, turn the starting motor switch to the "OFF"
position.
Set the multimeter scale to read DC voltage.
Connect one multimeter lead to the magnetic switch

terminal marked "S" and the other lead to ground.
Turn the starting motor switch to the "START" position.
If the multimeter indicates no voltage, the magnetic switch
is not the cause of the complaint. Refer to Procedure
If the starter magnetic switch is not within specification,
replace the switch according to the manufacturer's
instructions.
Starter Switch ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Turn the starting motor switch to the "OFF" position.

Remove the multimeter leads and connect the magnetic
switch to the starting motor solenoid wire.
Starter Switch (013-018)

Voltage Check
WARNING
Be sure the starting motor switch is in the "OFF"
position to prevent electrical shock and personal
injury.
Remove the wire connecting the starting motor switch to
the magnetic switch (marked “S” or “START”) from the
starter switch terminal.
Connect the positive (+) lead of the digital multimeter,
Cummins Part Number 3164488, or equivalent to the
starter switch terminal and the negative (-) lead to a
chassis or engine ground location.
NOTE: Set the multimeter to indicate DC volts with the

starting motor switch in the "OFF" position, there must not
be voltage at the starter switch terminal. If the meter
indicates voltage, the starter switch is malfunctioning and
must be replaced.
Turn the starting motor switch to the “START” position.

The multimeter must indicate system voltage.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Starter Solenoid
If there is no voltage, turn the starting motor switch to the

“OFF” position.
Connect the multimeter positive (+) lead to the starter
switch terminal having a wire connecting the starter switch
to the starting motor solenoid B terminal.
Turn the starting motor switch to the “START” position.

If the meter indicates system voltage at the starter switch
input terminal, the starter switch is defective and must be
replaced. Refer to the manufacturer's procedure for
replacement.
If the meter indicates no voltage, the switch is not the

cause of the complaint.
Check the wiring from the starter switch to the starting
motor solenoid B terminal and from the starting motor
solenoid to the battery for broken or damaged wires.
Starter Solenoid (013-019)

Initial Check
Before troubleshooting the starting motor, make sure the
battery terminals are not loose or corroded. Refer to
Starter Solenoid ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
If the starting motor solenoid does not make an audible

sound, check for loose wiring connections.
Use a digital multimeter, Cummins® Part Number

3164488, or equivalent, to set the voltage scale.
Check for system voltage at the starting motor solenoid
battery terminal.
If the multimeter indicates system voltage at the starting

motor battery terminal, check the voltage at the starting
motor solenoid S terminal, when the starting switch is
energized.
If the multimeter indicates system voltage at the S
terminal, but the starter does not engage, the starting
motor solenoid is malfunctioning and the starter must be
replaced. Refer to Procedure 013-020 in Section 13.
If the multimeter does not indicate system voltage at the

S terminal, check:
• Fuses
• Voltage to the ignition switch and magnetic switch.
Refer to Procedure 013-018 in Section 13. Refer to
• Application safety shutoff systems
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Starter Solenoid
Voltage Check
Set the digital multimeter, Part Number 3164488, to
measure DC voltage.
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 a voltage with the starter
switch “OFF” to be normal.
If the multimeter does not indicate a voltage, check the

cable connecting the starter solenoid and battery for
breaks.
Also check for loose or corroded connections.
If the multimeter indicates a voltage, but the starter will

not operate, check the wire connecting the starter
solenoid to the starter switch for breaks.
Also check for loose or corroded connections.
Be sure to check for:
• Fuses
• Application engine shutoff systems.
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.
Starter Solenoid ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Turn the starter switch to the ”START” position.

If the multimeter indicates a voltage, the starter solenoid is
malfunctioning and must be replaced. Refer to Procedure
If the multimeter does not indicate a voltage, check the

wire connecting the starter solenoid to the magnetic
switch for breaks, and for loose or corroded connections.
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 for loose or corroded
connections.
Check the cable connecting the starting motor to the

battery for breaks, and for loose or corroded connections.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Starting Motor
If the cables are not loose or damaged, the starting motor

is defective and must be replaced. Refer to Procedure
Starting Motor (013-020)

Rotation Check
If the starting motor solenoid is making a sound but the
engine is not rotating, turn the keyswitch to the OFF
position, and attempt to bar the crankshaft in both
directions.
Bar the engine with the barring tool, Part Number
3824591.
If the crankshaft will bar over, attempt to start the engine.
If the starting motor cranks the engine, check the starting
motor pinion gear and flywheel ring gear for damage.
If damage to the starting motor pinion gear and/or
flywheel ring gear is found when replacing the
components, make sure to measure the distance from the
starting motor mounting flange to the forward face of the
front side of the flywheel ring gear. Follow the measure
step of this procedure .
If the crankshaft does not rotate or requires more than the

normal effort to bar, check for an internal malfunction or a
problem with the drive unit and/or accessories.
Starting Motor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
If the engine cranking speed is too slow or will not crank

at all, and the engine rotates freely:
• Make sure the wiring connections are clean, tight, and
not damaged
• Check the battery voltage. Refer to Procedure 013-007
in Section 13.
Check the voltage at the starting motor during cranking. If

the voltage drops more than 2.4 VDC on a 12 volt system,
or 4.8 VDC on a 24 volt system, check that all
connections are clean and tight.
If the cables are correct and the voltage drop exceeds the
limit, replace the starting motor.
Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
personal injury.
• Disconnect the battery cables from the battery
terminals. 013-009 in Section 13.
• If equipped with a jump start protection cover, remove
the jump start protection cover nut (M5) and jump start
protection cover to gain access to the electrical
connections.
• Identify each wire with a tag indicating its location on
the starting motor.
• Remove the electrical connections from the starting
motor.
• Prior to removing the starter, use steam to clean the
area around the starting motor, to prevent debris from
entering the flywheel housing.
Entfernen Sie
Remove the three capscrews and the starting motor.

If equipped with a System Integration Module relay,
remove the relay support bracket from the starting motor
mounting capscrew.
If equipped with a starting motor spacer, remove the
spacer and clean all surfaces between the starting motor,
starting motor spacer, and flywheel housing with a wire
brush.
Starting Motor ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

For engines that use wet flywheel housing, clean any left
over sealant from the starting motor mounting flange on
both the flywheel housing and starting motor. Make sure
these surfaces are clean of oil and debris.
Inspect the starting motor pinion gear and/or flywheel/

flexplate ring gear for chipping or uneven wear.
If the start motor pinion gear and/or flywheel ring gear
teeth are damaged, they must be replaced. Refer to
Procedure 016-005 in Section A.
Measure
Use a depth micrometer or vernier caliper to measure the
distance from the starting motor mounting flange to the
forward face of the front side of the flywheel ring gear.
NOTE: Include any spacers previously removed when
completing the measurement.
Starting Motor Spacing

mm in
49.28 MIN 1.94
52.32 MAX 2.06
Add or remove spacers as necessary to achieve the
correct starting motor spacing.
Install
For engines with wet flywheel housings, apply a 1.5 to 2.0
mm [0.06 to 0.09 in] wide bead of sealant, Part Number
3164067, to the flywheel housing starting motor mounting
flange.
NOTE: If a starting motor spacer is required, make sure to
apply sealant to the side of the spacer that contacts the
starting motor.
If equipped, install the system integration module relay

support bracket mounting capscrews.
Install the three capscrews, the starting motor, and
starting motor spacer, if required.
Cummins® Branded Starters
CAUTION
Do not overtighten the electrical connections. Starting
motor damage can result.
NOTE: Use the location tags to help identify where each
wire connection goes.
Connect the electrical connections to the starting motor.
Torque Value:
M5 4 N•m [ 35 in-lb ]
Torque Value:
M10 21 N•m [ 186 in-lb ]
If starter came installed with the the jump start protection
cover, install the jump start protection and jump start
protection cover nut on the M terminal post.
Torque Value:
M5 4 N•m [ 35 in-lb ]
NOTE: The jump start protection cover nut is the third nut
on the M terminal, M5 terminal size. Failure to observe the
proper torque specification can result in loss of
conductivity to the M lead and result in a no crank
condition for the starter and engine.
Non-Cummins® Branded Starters
CAUTION
Do not overtighten the electrical connections. Starting
motor damage can result.
NOTE: Use the location tags to help identify where each
wire connection goes.
Connect the electrical connections to the starting motor.
For Non-Cummins® branded starters, refer to the
equipment manufacturer service information for torque
specifications.
Charging System Indicator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
Cummins® Branded Starters
WARNING
battery cable last.
• Connect the battery cables to the battery terminals.
Charging System Indicator (013-023)

Initial Check
Be sure the correct terminals are being used on the
alternator. The R terminal (Delco®) or W terminal
(Bosch® K1) provide half of the system voltage and is
used to operate accessories such as the tachometer on
generator sets.
Trouble with the starting system can be indicated by the

indicator lamp or ampmeter.
Check the indicator lamp for normal operation as shown

below:
Engine Switch Lamp Ampmeter

Stopped OFF OFF 0
Stopped ON ON -
Running ON OFF +
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] ECM Unswitched Power Terminal Blocks
If the lamp is on when the switch is OFF and the engine is

not running, disconnect the lamp lead at the ignition
switch.
• If the lamp stays on, there is a short to a positive
wire.
• If the lamp goes out, there is a short in the switch.
If the lamp goes off when the switch is ON and the engine
is not running, there can be an open in the circuit.
Check for a blown fuse, a burned out bulb, defective bulb
socket, or an open in the No. 1 or D (+) lead circuit
between alternator and ignition switch.
If the lamp is on when the switch is ON and the engine is

running, disconnect the lead to the alternator.
• If the lamp stays on, there is a short to the ground in
the lamp circuit.
• If the lamp goes out, inspect the alternator.
ECM Unswitched Power Terminal

Blocks (013-047)
General Information
In addition to the heavy duty battery connections used for
the starter, marine engines equipped with an Electronic
Control Module (ECM) and the SmartCraft system use an
additional unswitched power supply. The connection is
installed directly from the battery to lug style connectors
mounted on the side of the engine.
These terminal lug blocks are located on the left side of
the engine near the OEM interface connector and the
service tool datalink connection. The positive terminal
block is red and the negative terminal block is black.
ECM Unswitched Power Terminal Blocks ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Initial Check
WARNING
battery cable last.
The unswitched power supply wires connect from the
battery to the positive and negative terminal blocks. These
wires are supplied by the OEM.
Before removing the unswitched power supply wires from

the engine, be sure the positive and negative wires are
disconnected from the battery. Refer to procedure
013-009.
Always install the unswitched positive and negative wire

connectors to the terminal blocks before installing the
connections to the battery.
Torque the connections to the terminal blocks to the
specified value.
If for some reason the terminal blocks are damaged, new

terminal blocks can be obtained and installed.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] ECM Unswitched Power Terminal Blocks
Preparatory Steps
WARNING
battery cable last.
Before removing the unswitched power supply wires from
the engine, be sure the positive and negative wires are
disconnected from the battery. Refer to Procedure
013-009.
If a battery switch is being used on the vessel, be sure to
disconnect all batteries.
Remove the external unswitched power supply battery
connection from the battery.
Remove the unswitched wire connectors from the positive
and negative terminal blocks.
Remove
Remove the engine wiring harness connectors from the
back of the positive or negative terminals. Some plates
may have to be removed to complete this operation.
Remove the upper and lower mounting capscrews from

the positive or negative terminal blocks. Slide the terminal
blocks out the back of the mounting plate.
Some plates may have to be removed to complete this
operation.
ECM Unswitched Power Terminal Blocks ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
Install the new positive or negative terminal block through
the rear of the mounting plate. On some models the plate
will have to be removed to complete this operation.
Install the mounting capscrews and torque to the specified
value.
Install the engine wiring harness positive or negative wire

connectors to the correct positive and negative terminal
blocks located on the back of the mounting plate.
Some plates may have to be removed to complete this
operation.
Torques to the specified value.
Finishing Steps
WARNING
battery cable last.
Install the unswitched power supply connectors to the
positive and negative terminal blocks.
Install the unswitched power supply connectors to the
battery and tighten the battery connection.
Ensure the positive and negative wires are connected to
the proper battery terminals. Refer to Procedure 013-009.
Section 14 - Engine Testing - Group 14 Page 14-a
Section 14 - Engine Testing - Group 14

Section Contents
Page
Aftertreatment Testing ........................................................................................................................................... 14-54
Regeneration..........................................................................................................................................................14-54
Crankcase Blowby, Measure .................................................................................................................................14-27
Initial Check............................................................................................................................................................14-34
Measure..................................................................................................................................................................14-36
Engine Run-in (Chassis Dynamometer) ............................................................................................................... 14-10
Test.........................................................................................................................................................................14-10
Engine Run-in (Engine Dynamometer) .................................................................................................................14-18
Run-In Instructions..................................................................................................................................................14-18
Engine Run-in (Without Dynamometer) ................................................................................................................14-12
Test.........................................................................................................................................................................14-12
Engine Testing (Chassis Dynamometer) ................................................................................................................14-4
Setup........................................................................................................................................................................14-4
Test...........................................................................................................................................................................14-7
Engine Testing (Engine Dynamometer) ................................................................................................................14-12
Setup...................................................................................................................................................................... 14-12
Engine Testing (In Chassis) ...................................................................................................................................14-24
Automated Cylinder Performance Test...................................................................................................................14-25
Cylinder Cutout Test...............................................................................................................................................14-26
Setup...................................................................................................................................................................... 14-24
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.

Pressure Gauge (0 to 1103 kPa [0 to 160 psi])
Used to measure lubricating oil pressure.
3375275
Digital Optical Tachometer

Used to measure engine speed (rpm)
3377462
Blowby Checking Tool

Used to check engine crankcase blowby.
3822566
Engine Lifting Fixture

Used to remove and install the engine.
3162871
Compuchek™ Fitting
Used for connection to diagnostics machine.
3824843
Manometer
Used with the blowby check tool to measure engine crankcase
ST-1111-3 pressure.
Page 14-2 Section 14 - Engine Testing - Group 14

Pressure Gauge
Used to measure engine intake manifold pressure, exhaust
ST-1273 restriction, lift pump output pressure, and pressure drop across fuel
filter.
Vacuum gauge
Used to measure lift pump inlet restriction. Hose adapter, Cummins®
ST-434 Part Number ST-434-2, and Vacuum Gauge, ST-434-12, are used to
perform the test.
Multimeter
Used to measure electrical circuits: Voltage (volts), resistance
3164488 or (ohms), and current (amps). 3164488 - Standard meter. 3164489 -
3164489 Automotive meter with built in temperature adapter and tachometer.
Digital Optical Tachometer

Used to measure engine speed (rpm).
3377462
Engine Lifting Fixture

Used to remove and install the engine.
3162871
Blowby Tool
Used to check engine crankcase blowby.
3822566
Oil Fill Adapter

Used to measure blowby from the oil fill port in the rocker lever cover.
3990099 NOTE: Will not work with all rocker lever cover oil fill ports. Thread
type and size can be different.
Compuchek™ Fitting
Used to connect to the diagnostics machine. With 1/8 NPT
3377244 connection.

Drivetrain Dynomometer
Used to measure engine horsepower.
3375710
Engine Testing (Chassis Dynamometer) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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: Because of driveline efficiency and engine-driven
accessories, the engine horsepower when measured at
the rear wheels will be reduced by approximately:
• 20 percent for single-axle vehicles
• 25 percent for tandem-axle vehicles
• 35 percent for recreational vehicles.
NOTE: These percentages are used for engine run-in
only and are not to be used as absolute figures.
WARNING
Follow all of the vehicle manufacturer's safety
precautions before installing or operating a vehicle on
a chassis dynamometer. Failure to do so can cause
damage to the vehicle and/or harm personnel.
CAUTION
Low-profile tires are more sensitive to heat than bias
ply tires. Excessive operating time at full load can
damage the tires due to overheating. Check the tire
manufacturer's recommendations for the maximum
allowable chassis dynamometer operating time.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Testing (Chassis Dynamometer)
While operating the chassis dynamometer, follow the

general safety precautions listed below:
• Use tires that have more than 160 km [100 mi] of use.
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 materials from the treads of
the 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
To prevent damage to the chassis dynamometer,
make sure there is enough slack in the tie-down
chains.
Carefully position the vehicle on the rollers.
Attach the tie-down chains to the rear of the vehicle.
Place wheel chocks in front of the front tires.
WARNING
Some exhaust gas constituents may be toxic and/or
carcinogenic. Make sure the ventilation hose does not
leak.
Adjust the vehicle and dynamometer room exhaust
system to make sure all the exhaust gases are removed
from the room.
Read the chassis dynamometer and vehicle
manufacturer's recommendations and specifications for
testing procedures.
Test
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.
The following procedure assumes that the lubricating oil
and fuel systems were correctly primed, the dipstick
calibrated, and the engine filled to the correct levels with
lubricating oil and coolant during installation of the engine
into the chassis. If these systems were not serviced
during installation of the engine.
Use the following procedures for instructions on priming
the lubricating oil and the fuel system and calibrating the
dipstick.
• Use the following procedure in the Service Manual,
ISF2.8 CM2220 F101. Refer to Procedure 014-006 in
Section 14.
ISF2.8 CM2220 E and ISF2.8 CM2220 AN Bulletin
4022178. Refer to Procedure 014-006 in Section 14.
ISF2.8 CM2220 E and ISF2.8 CM2220 AN Bulletin
ISF3.8 CM2220 Bulletin 4021704. Refer to Procedure
• Use the following procedure in the Troubleshooting
and Repair Manual, ISB and QSB5.9 Engines, Bulletin
and Repair Manual, B3.9, B4.5, and B5.9 Series
Engines, Bulletin 3666087. Refer to Procedure
and Repair Manual, ISC, ISCe, QSC8.3, ISL and
QSL9 Engines, Bulletin 4021418. Refer to Procedure
and Repair Manual, C Series, Bulletin 3666003. Refer
and Repair Manual, ISB, ISBe 4 and 6 Cylinder,
Bulletin 4021271. Refer to Procedure 014-006 in
Section 14.
and Repair Manual, B Series, Bulletin 3810207. Refer
• Use the following procedure in the QSL9 CM2350
L102 Service Manual, Bulletin 4332796. Refer to
Reference the Operation and Maintenance Manual for
instructions on filling the lubricating oil and the cooling
systems.
The number of instruments and gauges required to

perform a chassis dynamometer test will vary according to
type and the capability of the test equipment used.
See the service tools listed at the beginning of this
section.
To correctly monitor an engine's performance, record the following parameters:
• Lubricating oil pressure (vehicle instrument panel)
• Engine speed (rpm) (vehicle instrument panel)
• Wheel horsepower (whp) (dynamometer controls)
• Blowby: Refer to Procedure 014-010 in Section 14.
• Exhaust back pressure:
• Use the following procedure in the Service Manual, ISF2.8 CM2220 F101, Bulletin 4310846. Refer to Procedure 011-009 in Section 14.
• Use the following procedure in the Service Manual, ISF2.8 CM2220 E and ISF2.8 CM2220 AN Bulletin 4022178. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the Service Manual, ISF3.8 CM2220 Bulletin 4021704. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the Troubleshooting and Repair Manual, ISB and QSB5.9 Engines, Bulletin 3666193. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the Troubleshooting and Repair Manual, B3.9, B4.5, and B5.9 Series Engines, Bulletin 3666087. Refer to Procedure 011-009 in
Section 11.
• Use the following procedure in the Troubleshooting and Repair Manual, ISC, ISCe, QSC8.3, ISL and QSL9 Engines, Bulletin 4021418. Refer to Procedure
• Use the following procedure in the Troubleshooting and Repair Manual, C Series, Bulletin 3666003. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the Troubleshooting and Repair Manual, ISB, ISBe 4 and 6 Cylinder, Bulletin 4021271. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the Troubleshooting and Repair Manual, B Series, Bulletin 3810207. Refer to Procedure 011-009 in Section 11.
• Use the following procedure in the QSL9 CM2350 L102 Service Manual, Bulletin 4332796. Refer to Procedure 011-009 in Section 11.
• Coolant temperature (vehicle instrument panel):
Section 8.
• Coolant pressure:
Section 8.
• Intake manifold pressure:
Section 10.
• Inlet air restriction:
Section 10.
• Fuel supply pressure:
Section 6.
Engine Run-in (Chassis Dynamometer) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Engine Run-in (Chassis

Dynamometer) (014-003)
Test
CAUTION
Prior to operating the engine and to reduce the
possibility of internal component damage. Refer to
NOTE: For general operating procedures and safety
precautions. Refer to Procedure 014-005 in Section 14.
NOTE: Operate the vehicle in a gear that produces a road
speed of 90 to 95 kph [55 to 60 mph].
Operate the engine at 1200 rpm and 25 percent of torque

peak load until the water temperature reaches 70°C
[160°F].

peak load for 2 minutes. Check the gauges and record the
readings.

peak load for 5 minutes. Check the gauges and record the
readings.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Run-in (Chassis Dynamometer)
Operate the engine at torque peak rpm and full load for 4
minutes. Check the gauges and record the readings.
NOTE: See the engine data sheet for the torque peak rpm
of the engine model being tested.

full load for 5 minutes. Check the gauges and record the
readings. Compare the readings to those published in the
appropriate engine data sheet.
Operate the engine at torque peak rpm and full load for 4
minutes. Check the gauges and record the readings.
NOTE: See the engine data sheet for the torque peak rpm
of the engine model being tested.
CAUTION
Do not shut off the engine immediately after the run-in
is complete. Allow the engine to cool by operating it
at low idle for a minimum of 3 minutes to avoid
internal component damage.
Operate the engine at rated speed (rpm) and full load for
4 minutes. Check the gauges and record the readings.
Compare the readings to those published in the
appropriate engine data sheet.
Engine Testing (Engine Dynamometer) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Make sure to remove all dynamometer instrumentation

from the vehicle.
Engine Run-in (Without Dynamometer)

(014-004)
Test
CAUTION
Refer to Engine Test (Engine Dynamometer) (014-005)
before operating the engine to avoid internal
component damage.
Operate the engine at 1500 to 1800 rpm in high gear for
the first 80 to 160 km [50 to 100 mi] after rebuild.
NOTE: Do not idle the engine for more than 5 minutes at

any one time during the first 160 km [100 mi] of operation.
Engine Testing (Engine Dynamometer)

(014-005)
Setup
Use engine lifting fixture, Part Number 3162871, to install
the engine to the test stand. Align and connect the
dynamometer. Refer to the manufacturer's instructions for
aligning and testing the engine.
NOTE: Make sure the dynamometer capacity is sufficient
to permit testing at 100 percent of the engines rated
horsepower. If the capacity is not enough, the testing
procedure must be modified to the restrictions of the
dynamometer.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Testing (Engine Dynamometer)
Connect the coolant supply to the water inlet connection

(1).
Connect the coolant return to the water outlet connection
(2).
Install the drain plugs, close all the water drain cocks, and
make sure all the clamps and fittings are tight.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Inspect the engine for coolant leaks at connections,

fittings, plates, and plugs. Repair if necessary.
Air Inlet Restriction

Connect a water manometer, Part Number ST-1111-3, to
the turbocharger air inlet pipe to test air restriction.
NOTE: The manometer connection must be installed at a
90-degree angle to the airflow in a straight section of pipe,
one pipe diameter before the turbocharger.
NOTE: A vacuum gauge, Part Number ST-434, can be
used in place of the water manometer.
Minimum Gauge Capacity 760 mm H2O [ 30 in H2O ]
Exhaust Restriction
Connect a mercury manometer to a straight section of the
exhaust piping near the turbocharger outlet to check
exhaust restriction.
NOTE: A pressure gauge, Cummins Part Number
ST-1273, can be used in place of the mercury
manometer.
NOTE: For automotive applications, a tapped hole is
provided on the inlet side of the catalyst for checking
exhaust restrictions.
Minimum Gauge Capacity 254 mm Hg [ 10 in Hg ]
Attach the lubricating oil temperature sensor in the

location shown.
Minimum Gauge Capacity 150 °C [ 300 °F ]
CAUTION
The lubricating oil system must be primed before
operating the engine after if has been rebuilt to avoid
internal damage.
To prime the lubricating oil system using external
pressure, connect the supply to a tapped hole in the main
lubricating oil rifle.
Use a pump capable of supplying 210 kPa [30 psi] of

continuous pressure. Connect the pump to the port on the
main lubricating oil rifle as shown.
Use clean lubricating oil to prime the system until the oil
pressure registers on the gauge.
Remove the lubricating oil supply tube and install the plug.
Make sure the lubricating oil has had time to drain to the
lubricating oil pan and fill the engine to the high mark as
measured on the dipstick.
Use the correct lubricating oil as specified in the
Operation and Maintenance Manual.
If an external pressure pump is not available, prime the

lubricating system according to the following procedure.
Fill the engine with lubricating oil to the high-level mark on
the dipstick.
Disconnect the turbocharger lubricating oil supply tube.
Pour 50 to 60 cc [2.0 to 3.0 fl oz] of clean 15W-40
lubricating oil into the turbocharger lubricating oil supply
hole.
Connect the lubricating oil supply tube to the
turbocharger.
CAUTION
Mechanical overtightening can distort the threads or
damage the filter element seal.
Fill the lubricating oil filters with clean 15W-40 lubricating
oil.
Screw the filters onto the filter head fitting until the gasket
contacts the filter head surface.
Tighten the filter as specified by the manufacturer.
CM850 Control Module - Disconnect the 4-pin power

connector from the ECM to prevent the engine from
starting.
CM554 Control Module -Disconnect the CAPS injection
control valve connector so that the engine does not start.
CAUTION
Do not crank the starting motor for periods longer
than 30 seconds. Excessive heat will damage the
starting motor.
Crank the engine until the lubricating oil pressure gauge
indicates system pressure.
NOTE: Allow two minutes between the 30-second
cranking periods so the starter motor can cool.
NOTE: If pressure is not indicated, find and correct the
problem before continuing.
CM850 Control Module - Connect the 4-pin power

connector to the ECM.
CM554 Control Module - Connect the injection control
valve connector.
Allow the lubricating oil to drain into the lubricating oil pan
and measure the lubricating oil level with the dipstick.
Add lubricating oil as necessary to bring the level to the
high-level mark.
Lubricate the gasket on the oil filter with clean 15W-40

lubricating oil.
Screw the oil filter onto the filter head until the gasket
contacts the filter head surface.
Tighten the filter as specified by the manufacturer.
CAUTION
Do not attempt to install pipe thread fittings in plastic
or rubber intake piping.
If INSITE™ electronic service tool is available, use it to
monitor intake manifold pressure during the test. This
eliminates the need to install a gauge as shown below.
If the air crossover tube does not have a pipe plug and
tapped hole, perform the following procedure:
• Remove the charge air cooler air crossover tube
from the engine.
• Drill and tap a 1/8-inch pipe thread hole in the tube
four to six inches from intake opening.
• Clean all metal shavings from the air crossover tube.
• Install the crossover tube.
To determine the amount of turbocharger boost, remove

the pipe plug in the air crossover tube and install the
intake manifold pressure sensor or pressure gauge, Part
Number ST-1273.
Minimum Gauge Capacity 1905 mm Hg [ 75 in Hg ]
For an accurate engine crankcase blowby measurement,
insert a blowby checking tool in the crankcase breather
vent.
Connect a water manometer to the blowby tool. A
pressure gauge can be used in place of the manometer.
Minimum Gauge Capacity 1270 mm H2O [ 50 in H2O ]
To be able to unload the compressor, connect a source of

compressed air to the unloader (1). This air line must
contain a valve between the source and the unloader.
NOTE: All air compressors manufactured by Cummins
Inc. must be loaded during engine run-in. All air
compressors must be unloaded during the engine
performance check.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet
(2).
Engine Run-in (Engine Dynamometer) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
To provide a load on the air compressor, connect an air

tank (2) to the compressor outlet, use steel tubing or a
high-temperature hose (1).
Install an air regulator (3) that can maintain tank air
pressure of 345 to 517 kPa [50 to 75 psi] at both the
minimum and the maximum engine rpm.
Hose Temperature (Minimum) 260 °C [ 500 °F ]
NOTE: If the engine is equipped with a variable geometry
turbocharger, the turbocharger control valve will require a
continous air supply of at least 621 kPa [90 psi].
Inspect the voltage rating on the starter motor before

installing the electrical wiring.
Attach electrical wires to the starter motor and the
batteries, if used.
NOTE: If another method of starting the engine is used,
follow the manufacturer's instructions to make the
necessary connections.
Engine Run-in (Engine Dynamometer)

(014-006)
Run-In Instructions
The engine run-in period allows the tester to detect
assembly errors and to make final adjustments needed for
performance that meets specifications.
NOTE: The amount of time specified for the following
engine run-in phases are minimums. Additional time can
be used, if desired, at each phase except engine idle
periods.
Measurements from these indicators and gauges must be

observed closely during all phases of the engine run-in
period.
• Engine speed
• Torque
• Oil pressure
• Coolant outlet temperature
• Lube oil temperature
• Blowby.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Run-in (Engine Dynamometer)
To evaluate the engine performance correctly, this

additional measurement must be observed during engine
run-in phases:
• Intake manifold pressure.
It is good practice to observe these measurements even if

engine performance meets specifications. If engine
performance does not meet specifications, these
measurements can indicate possible reasons for under
performance.
• Fuel inlet restriction
• Exhaust back pressure
• Air inlet restriction
• Fuel drain pressure
• Coolant pressure.
CAUTION
Do not crank the engine for more than 30 seconds.
Excessive heat will damage the starting motor.
Crank the engine and observe the lubricating oil pressure
when the engine starts. If the engine fails to start within 30
seconds, allow the starting motor to cool for 2 minutes
before cranking the engine again.
CAUTION
If the lubricating oil pressure is not within
specifications, shut off the engine immediately. Low
lubricating oil pressure will cause engine damage.
Engine lubricating oil pressure must be at least 70 kPa
[10 psi] at 700 rpm.
Correct the problem if the lubricating oil pressure is not
within specifications.
CAUTION
Do not operate the engine at idle speed longer than
specified during engine run-in. Excessive carbon
formation will cause damage to the engine.
Operate the engine at approximately 700 rpm for 3 to 5
minutes.
Listen for unusual noises and watch for coolant, fuel,

lubricating oil leaks. Check for correct engine operation in
general.
NOTE: Repair all leaks or component problems before
continuing the engine run-in.
Move the throttle to obtain 1200-rpm engine speed, and

set the test load to 25 percent of the rated load.
Operate the engine at this speed and load level until the
coolant temperature is 70°C [160°F]. Check all gauges
and record the data.
NOTE: Do not proceed to the next step until a steady
blowby reading is obtained.
Open the throttle to the speed that peak torque occurs,

and adjust the dynamometer load to 50 percent of torque
peak load. Operate the engine at this speed and load
level for 2 minutes.
Check all gauges and record the data.
NOTE: Do not proceed to the next step until blowby is
stable within specifications.
With the engine speed remaining at torque peak rpm,

increase the dynamometer load to 75 percent of torque
peak load. Operate the engine at this speed and load
level for 2 minutes. Check all gauges and record the data.
NOTE: Do not proceed to the next step until blowby is
Move the throttle lever to its fully opened position, and

increase the dynamometer load until the engine speed is
at torque peak rpm. Operate the engine at this speed and
load level for 10 minutes or until the blowby becomes
Reduce the dynamometer load until the engine speed

increases to the engine's rated rpm.
Operate the engine at rated rpm for 5 minutes.
CAUTION
Shutting off the engine immediately after operating at
full load will damage the turbocharger and internal
components. Always allow the engine to cool before
shutting it off.
Remove the dynamometer load completely, and operate
the engine at 700 rpm for 3 to 5 minutes. This period will
allow the turbocharger and other components to cool.
Shut off the engine.
Engine Dynamometer Test - Performance Checking

Make sure the air compressor is unloaded during the
performance check.
Apply regulated air pressure of 655 kPa [95 psi] to the air
compressor unloader (1).
NOTE: If the engine is equipped with a variable geometry
turbocharger, the turbocharger control valve will require a
continuous air supply of at least 621 kPa [90 psi].
CAUTION
Do not crank the engine for more than 30 seconds.
Excessive heat will damage the starter motor.
Crank the engine and observe the oil pressure when the
engine starts. If the engine fails to start within 30 seconds,
allow the starter motor to cool for 2 minutes before
cranking the engine again.
CAUTION
If the lubricating oil pressure is not within
specifications, shut off the engine immediately. Low
lubricating oil pressure will cause engine damage.
Correct the problem if lubricating oil pressure is not
Engine lubricating oil pressure must be at least 69 kPa
[10 psi] at approximately 700 rpm.
Make sure the engine is at operating temperature.

Move the throttle to the fully depressed position. Adjust
the dynamometer load until the engine maintains the rated
rpm.
Allow the readings to stabilize. Read the horsepower.
Check all the gauges and record the readings.
NOTE: The horsepower reading will not be accurate if the
lubricating oil temperature and fuel temperature are not
Lubricating Oil Temperature

°C °F
90 MAX 194
Fuel Temperature
°C °F
65 MAX 149
CAUTION
Do not shut off the engine immediately after it has
been loaded. It must be allowed to sufficiently cool.
Remove the dynamometer load completely, and operate
the engine at idle speed for 3 to 5 minutes. This will allow
the turbocharger and other components to cool.
NOTE: Idle periods longer than 5 minutes are to be
avoided.
Shut off the engine after the cool down period.
Engine Testing (In Chassis) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove all test instrumentation. Remove the engine from

the dynamometer.
NOTE: If the engine is to be stored temporarily and does
not have permanent-type antifreeze, it is necessary to
drain all coolant. Drain locations are identified on the
engine side views. Refer to Procedure 008-018 in Section
8.
Engine Testing (In Chassis) (014-008)

Setup
The Setup for Dynamometer function is used to prepare
the attached electronic control module (ECM) for
advanced diagnostic tests run on the dynamometer. For
purposes of this test, the Maximum Engine Speed without
a 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. All of these values are
automatically reset to their previous values when the
engine keyswitch is turned off.
Einstellungen
Maximum Engine Speed without VSS: For testing
purposes, this speed is temporarily set to the maximum
value allowed (3000 rpm).
Maximum Vehicle Speed in Top Gear: For testing
value allowed (120 mph).
Maximum Vehicle Speed in Lower Gear: For testing
value allowed (120).
Idle Shutdown: This feature is temporarily disabled for
testing purposes (Disable).
Some J1939 electronic subsystems must be disabled.
The user has the ability to enable or disable the J1939
datalink with the service tool.
Refer to the INSITE™ user's manual for detailed setup for
Dynamometer Instructions.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Testing (In Chassis)
Automated Cylinder Performance Test

The automated cylinder performance test is the most
thorough test of cylinder performance (versus the single-
cylinder cutout test, which tests the performance of
individual cylinders only). The service tool must be
attached to an electronic control module (ECM) to perform
this test. Follow the steps outlined in Preparing to Run the
Automated Cylinder Performance Test, to make sure the
best possible outcome is achieved.
This test is automated in the sense that, once the test is
started, the service tool controls what cylinders are
disabled or enabled, what ECM values are recorded, and
what information displays as a result of the test. Once the
test is finished, follow the steps outlined in After Running
the Automated Cylinder Performance Test to make sure
the engine returns to its original state.
This test will produce a Pass or Fail message for each
cylinder. Its percent contribution value is also displayed.
Preparing to Run the Automated Cylinder Performance

Test
Before performing this test, make sure you:
1. Clear the areas around the engine and the fan, and
make sure the exhaust is vented correctly.
2. Operate the engine until the coolant temperature is a
minimum of 76.7°C [170°F].
3. Shut off the engine.
4. Lock the fan clutch in the ON position for continuous
operation.
5. Shut off the air conditioning.
6. Disengage any devices that can cause the load on
the engine to vary.
7. With the vehicle stationary, start the engine and let it
idle.
8. Start the test using INSITE™.
Refer to the INSITE™ user's manual for detailed

automated cylinder performance test instructions.
Engine Testing (In Chassis) ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
After Running the Automated Cylinder Performance Test

It is normal for the engine rpm to vary during the test, but
if the engine rpm goes to high idle for more than 5
seconds at a time, shut off the engine.
Once the test is complete, make sure to:
1. Shut off engine.
2. Return the fan to normal operation, if necessary.
3. Perform the suggested repairs that resulted from the
test.
4. Return any disengaged devices to their normal
mode of operation.
Cylinder Cutout Test

Use the single-cylinder cutout test to remove individual
cylinders from the engine firing cycle and to monitor a
running engine while the selected cylinder is disabled.
The system displays the percent load and rpm values
while the cylinder is disabled.
The service tool must be attached to a running engine in
a nonmoving vehicle to perform this test.
Refer to the INSITE™ user's manual for detailed cylinder
cutout test instructions.
Cylinder to be Cut Out
None: Select this option to run all cylinders.
1 through 6: Select one of these options to shut off
cylinder Nos. 1 through 6, respectively. Only one cylinder
can be shut off at a time.
Monitor
Percent Load: The percent of load that the engine is
carrying.
rpm: The engine's revolutions per minute.
Turbocharger Actuator Test

Use the turbocharger actuator test to verify the correct
functioning of the variable geometry turbocharger
actuator. During the test, air pressure is applied to the
actuator and rod travel is measured.
The service tool must be attached to an ECM to perform
this test.
Refer to INSITE™ user's manual for detailed turbocharger
actuator test instructions.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Crankcase Blowby, Measure
Use INSITE™ to extend and retract the turbocharger

actuator rod several times.
Measure the distance the actuator rod travels when
extended.
Turbocharger Actuator Rod Travel

mm in
10.8 MIN 0.40
11.8 MAX 0.46
Crankcase Blowby, Measure (014-010)

General Information
Excessive crankcase blowby can indicate an engine or
engine-related component malfunction that allows
combustion gases 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 what 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.).
NOTE: For specific crankcase gases (blowby) symptom
information and direction, reference the Crankcase Gases
(Blowby) Excessive troubleshooting symptom tree in
Section TS of the appropriate engine service manual.
The following measure step will give general guidelines
for measuring blowby relative to the above situations.
NOTE: Some illustrations in this procedure do not show
actual engine configurations. However, the procedure is
the same.
Crankcase Blowby, Measure ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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 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 by accommodating the wide
variety of engine configurations and ratings. This is due to
the fact that engine blowby is dependent on the volume of
intake airflow.
For example:
If measuring blowby on two identically configured and
sized engines, but the horsepower ratings and rated
speed are different, the maximum blowby values
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.
Blowby Tool Part Number Orifice Size mm [in]
3822476 5.61 mm [0.221 in]
3822566 7.67 mm [0.302 in]
To measure the crankcase blowby pressure, connect a
Cummins® water manometer, Part Number ST1111-3, or
equivalent, pressure gauge, or transducer to the blowby
tool.
NOTE: Cummins® water manometer, Part Number
ST1111-3, can measure a maximum of 944 mm [36 in] of
water.
The following charts show the relationship of measured pressure to flow rate, depending on the blowby tool used.
Blowby Conversion Table (5.61-mm [0.221-in] orifice, Blowby Tool, Part Number 3822476)
mm [in] of H2O Liter [cfm] per Minute
25.4 [1] 27 [0.953]
50.8 [2] 40 [1.413]
76.2 [3] 48 [1.695]
101.6 [4] 58 [2.048]
127 [5] 64 [2.260]
152.4 [6] 71 [2.507]
177.8 [7] 76 [2.684]
203.2 [8] 81 [2.860]
228.6 [9] 86 [3.037]
254 [10] 90 [3.178]
279.4 [11] 94 [3.320]
304.8 [12] 98 [3.461]
330.2 [13] 102 [3.602]
355.6 [14] 105 [3.708]
381 [15] 109 [3.849]
406.4 [16] 112 [3.955]
431.8 [17] 115 [4.061]
457.2 [18] 118 [4.167]
482.6 [19] 121 [4.723]
508 [20] 124 [4.379]
533.4 [21] 128 [4.520]
558.2 [22] 131 [4.626]
584.2 [23] 135 [4.767]
609.6 [24] 137 [4.838]
635 [25] 140 [4.944]
660.4 [26] 144 [5.085]
685.8 [27] 147 [5.191]
711.2 [28] 150 [5.297]
736.6 [29] 154 [5.438]
762 [30] 157 [5.544]
787.4 [31] 160 [5.650]
812.8 [32] 163 [5.756]
838.2 [33] 166 [5.862]
863.6 [34] 169 [5.968]
889 [35] 172 [6.074]
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]
The following chart contains general blowby specifications
for MidRange engines. Due to the wide variety of engine
types, configurations, and ratings, these specifications are
intended to only be used as a guide to help identify if a
problem exists. These specifications are not intended to
be used as engine condemnation limits.
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.
MidRange Blowby Specifications Chart

Blowby Specification For New or Rebuild - Blowby Specification For Troubleshooting -
mm [in] H2O mm [in] H2O
Engine Model Blowby Tool Blowby Tool Blowby Tool Blowby Tool
3822476-5.61 mm 3822566-7.67 mm 3822476-5.61 mm 3822566-7.67 mm
[0.221 in] Orifice [0.302 in] Orifice [0.221 in] Orifice [0.302 in] Orifice
A1400 and A1700 25.4 [1] 25.4 [1]
(Naturally Aspirated)
A2000 and A2300 25.4 [1] 38.1 [1.5]
(Naturally Aspirated)
A2000 and A2300 38.1 [1.5] 50.8 [2]
(Turbocharged)
ISF2.8 147.3 [5.8] 711.2 [28]
ISF3.8 71.1 [2.8] 254 [10]
B3.3 Tier 1, 2 50.8 [2] 101.6 [4]
B3.3, QSB3.3 Tier 3 101.6 [4] 152.04 [6]
B3.3, QSB3.3 Tier 4 50.8 [2] 101.6 [4]
Interim (Less than 74
HP)
B3.9, QSB3.9-30, 25.4 [1] 76.2 [3]
B4.5, QSB4.5-30, and
B4.5s (Naturally
Aspirated) (Less than
250 hp)
B3.9, QSB3.9-30, 101.6 [4] 431.8 [17]
B4.5, QSB4.5-30, and
B4.5s (Turbocharged)
( Less than 250 hp)
B3.9, QSB3.9-30, 25.4 [1] 127 [5]
B4.5, QSB4.5-30, and
B4.5s (Turbocharged)
(Greater than 250 hp)
B5.9 (Naturally 50.8 [2]
Aspirated)
B5.9, and QSB5.9-30, 228 .6 [9] 863.6 [34]
(Less than 250 hp)
B5.9, and QSB5.9-30, 50.8 [2] 228.6 [9]
(Greater than 250 hp)
ISB, ISBe, QSBe, 101.6 [4] 254 [10]
ISDe, QSB5.9-44,
ISB6.7, and QSB6.7
C8.3 203 [8] 457 [18]
ISC, ISCe, QSC8.3, 203.2 [8] 304.8 [12]
ISL, ISLe, and QSL9
B Gas International, B 228.6 [9] 889 [35]
Gas Plus, B LPG
Plus, B5.9G, B5.9
LPG
C8.3G, C Gas Plus, 203 [8] 457 [18]
ISL G, L Gas Plus
ISB4.5 CM2350 B104 152.4 330.2
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 (Marine, Industrial, and
Automotive).
Prior to measuring blowby pressure, check the crankcase breather tube for obstructions.
• Use the following procedure in the C Series Engines Troubleshooting and Repair
Manual, Bulletin 3666003. Refer to Procedure 003-018 in Section 3.
• Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service
• Use the following procedure in the ISB and QSB5.9-44 Engines Troubleshooting
and Repair Manual, Bulletin 3666193. Refer to Procedure 003-018 in Section 3.
• Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel
System) Service Manual, Bulletin 4021271. Refer to Procedure 003-018 in Section
3.
• Use the following procedure in the Industrial QSB3.9-30, QSB4.5-30, and
QSB5.9-30 Series Engines Troubleshooting and Repair Manual, Bulletin 4021398.
• Use the following procedure in the ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and
QSL9 Engines Troubleshooting and Repair Manual, Bulletin 4021418. Refer to
• Use the following procedure in the B3.3 and QSB3.3 CM2150 Service Manual,
Bulletin 4021540. Refer to Procedure 003-018 in Section 3.
• Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin
• Use the following procedure in the ISB CM2100 and CM2150 Service Manual,
• Use the following procedure in the ISBe and ISDe CM2150 Service Manual,
• Use the following procedure in the ISLe CM2150 Service Manual, Bulletin
• Use the following procedure in the ISL G CM2180 Service Manual, Bulletin
• Reference the ISF3.8 CM2220, ISF3.8 CM2220 AN and ISF3.8 CM2220 IAN
Service Manual, Bulletin 4021704.
• Use the following procedure for Open Crankcase Ventilation systems. Refer to
• Use the following procedure for Closed Crankcase Ventilation systems. Refer to
• Use the following procedure in the ISB4.5, ISB6.7, ISD4.5 and ISD6.7 CM2150 SN
Service Manual, Bulletin 4022188. Refer to Procedure 003-018 in Section 3.
• Use the following procedure in the B4.5s and B6.7s Series Engines
Troubleshooting and Repair Manual, Bulletin 4095243. Refer to Procedure
• Use the following procedure in the ISF2.8 CM2220, ISF2.8 CM2220E, ISF2.8
CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin 4022178. Refer to
Procedure 003-024 in Section 3. Refer to Procedure 003-026 in Section 3.
• Use the following procedure in the ISB6.7 Service Manual, Bulletin 4022254. Refer
• Use the following procedure in the ISB6.7 CM2350 B101 Service Manual, Bulletin
• Use the following procedure in the QSB6.7 CM2350 B105 Service Manual, Bulletin
• Use the following procedure in the QSL9 CM2350 L102 Service Manual, Bulletin
• Use the following procedure in the ISF3.8 CM2220 L110 Service Manual, Bulletin
• Use the following procedure in the ISL9 CM2350 L101 Service Manual, Bulletin
• Use the following procedure in the QSL9 M CM2250 L106 Service Manual, Bulletin
• Use the following procedure in the QSB6.7 CM2350 B112 Service Manual, Bulletin
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 in the C Series Engines Troubleshooting and
Repair Manual, Bulletin 3666003. Refer to Procedure 007-011 in Section 7.
• Use the following procedure in the ISB and QSB5.9-44 Engines
System) Service Manual, Bulletin 4021271. Refer to Procedure 007-011 in
Section 7.
QSB5.9-30 Series Engines Troubleshooting and Repair Manual, Bulletin
• Use the following procedure in the ISC and ISL CM2150 Service Manual,
• Use the following procedure in the ISF3.8 CM2220, ISF3.8 CM2220 AN and
ISFF3.8 CM2220 IAN Service Manual, Bulletin 4021704. Refer to Procedure
• Use the following procedure in the ISB4.5, ISB6.7, ISD4.5 and ISD6.7 CM2150
SN Service Manual, Bulletin 4022188. Refer to Procedure 007-011 in Section
7.
CM2220 AN, and ISF2.8 CM2220 IAN Service Manual, Bulletin 4022178.
• Use the following procedure in the ISB6.7 Service Manual, Bulletin 4022254.
• Use the following procedure in the ISB6.7 CM2350 B101 Service Manual,
• Use the following procedure in the QSB6.7 CM2350 B105 Service Manual,
• Use the following procedure in the QSL9 CM2350 L102 Service Manual,
• Use the following procedure in the ISF3.8 CM2220 F110 Service Manual,
• Use the following procedure in the ISL9 CM2350 L101 Service Manual,
• Use the following procedure in the QSL9 M CM2250 L106 Service Manual,
Measure
Choose the appropriate blowby measurement service tool
to use for the engine being serviced. Reference the
MidRange Blowby Specifications Chart in this procedure
and determine the appropriate blowby measurement
service tool to use, based on engine type and/or
horsepower.
Blowby Tool Part Number Orifice Size mm [in]
3822476 5.61 mm [0.221 in]
3822566 7.67 mm [0.302 in]
NOTE: Either service tool can be used to measure
blowby, as long as the blowby measurement is correctly
matched to the correct flow rate. Reference the flow rate
conversion tables in this procedure for the correct orifice.
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 (front gear train or rear gear
train) and/or application (Marine, Industrial, and
Automotive). See Section E for crankcase breather tube
locations.
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.
• For crankcase breather/ventilation systems with
crankcase ventilation filters, follow the proceeding
steps on connecting the blowby measurement
equipment.
For ISB CM2150 engines that have the crankcase

ventilation filter located on top of the rocker lever cover,
use the following steps to connect the blowby
measurement tools.
• Disconnect the crankcase ventilation line from the
turbocharger/original equipment manufacturer (OEM)
intake plumbing. If the crankcase ventilation line is
connected to the turbocharger housing, remove the
inlet fitting.
• If the crankcase ventilation line is connected to the

turbocharger housing, install a straight thread plug,
Part Number 3089567. Plug the crankcase ventilation
line with a suitable fitting.
NOTE: If the crankcase ventilation line is connected to the
OEM intake plumbing (not shown), use a suitable fitting to
plug the port in the intake plumbing. Also plug the
crankcase ventilation line coming from the engine with a
suitable fitting.
• Remove the oil fill cap from the rocker lever cover.
Install an oil fill adapter, Part Number 3990099.
• Connect the appropriate blowby service tool to the

outlet of the oil fill adapter. Connect a water
manometer, pressure gauge, or transducer to the
blowby service tool.
For ISB CM2150 engines that have the crankcase

ventilation filter located at the rear of the engine, use the
following steps to connect the blowby measurement tools.
• Disconnect the crankcase ventilation line from the
crankcase ventilation filter housing. Plug or cap the
crankcase ventilation filter housing.

crankcase ventilation line exiting the flywheel housing.
Connect a water manometer, pressure gauge, or
transducer to the blowby service tool.
For ISC and ISL CM2150 and QSL CM2250 engines, use
the following steps to connect the blowby measurement
tools.
• Remove the oil fill cap from the rocker lever cover.
Install an oil fill adapter, Part Number 3990099.

outlet of the oil fill adapter. Connect a water
manometer, pressure gauge, or transducer to the
blowby service tool.
• Use a suitable fitting to plug the crankcase breather

tube.
Engine Blowby Contribution:

Operate the engine at rated speed and under load by:
• 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.
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 the water
manometer, pressure gauge, or transducer, if the blowby
is within specification.
Turbocharger Blowby Contribution:

NOTE: For engines equipped with dual turbochargers, the Turbocharger Oil Drain
Line Isolation Test may need to be conducted twice to determine which turbocharger
is contributing high blowby. The first test should be conducted with both turbocharger
drain lines isolated. If the blowby contribution is above specifications, conduct a
second test with only the low pressure turbocharger oil drain line isolated. If the
blowby contribution is within specification, inspect the compressor and turbine areas of
the low pressure turbocharger for signs of an oil leak. Replace the low pressure
turbocharger, if necessary. If the blowby contribution is out of specification, replace the
high pressure turbocharger.
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.
• Use the following procedure in the C Series Engines Troubleshooting and Repair
• Use the following procedure in the ISB and QSB5.9-44 Engines Troubleshooting
and Repair Manual, Bulletin 3666193. Refer to Procedure 010-045 in Section 10.
Section 10.
• Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin
ISF3.8 CM2220 IAN Service Manual, Bulletin 4021704. Refer to Procedure
SN Service Manual, Bulletin 4022188. Refer to Procedure 010-045 in Section 10.
CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin 4022178. Refer to
• Use the following procedure in the QSL9 CM2350 L102 Service Manual, Bulletin
• Use the following procedure in the ISF3.8 CM2220 F110 Service Manual, Bulletin
• Use the following procedure in the ISL9 CM2350 L101 Service Manual, Bulletin
Preferred Turbocharger Isolation Method:

Install a hose assembly with two shutoff valves (A and B),
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 3 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.
Operate the engine at rated speed and under load by

either:
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.
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 Contribution Maximum: 30 percent
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.
Section 10.
010-033 in Section 10 (single turbocharger). Refer to Procedure 010-034 in
Section 10 (dual turbocharger). Refer to Procedure 010-035 in Section 10
(dual turbocharger).
• Use the following procedure in the ISB4.5, ISB6.7, ISD4.5 and (dual
turbocharger applications) ISD6.7 CM2150 SN Service Manual, Bulletin
CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin 4022178 for
single turbocharger applications. Refer to Procedure 010-033 in Section 10.
If installed, remove the turbocharger oil drain line assembly and shutoff valves.
Section 10.
SN Service Manual, Bulletin 4022188. Refer to Procedure 010-045 in Section
10.
• Use the following procedure in the ISF2.8 CM2220, ISF2.8 CM2220 E, ISF2.8
CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin 4022178. Refer
Check the engine oil level and add oil, if necessary.
WARNING
personal injury.
Air Compressor Blowby Contribution:
With the engine blowby service tool and the water
manometer, pressure gauge, or transducer still installed,
isolate the air compressor, if equipped, to determine if
there is internal damage to the air compressor
contributing to high engine crankcase pressure. The air
compressor can be isolated by unloading the air
compressor.
With the engine shut off, bleed the vehicle's air system
down by opening the drain cock on the wet tank to release
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 connected 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: Typical 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 Contribution Maximum: 30 percent
If the air compressor blowby contribution is out of specification, replace the

air compressor.
• Use the following procedure in the C Series Engines Troubleshooting
and Repair Manual, Bulletin 3666003. Refer to Procedure 012-014 in
Section 12.
• Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9
Service Manual, Bulletin 3666087. Refer to Procedure 012-014 in
Section 12.
Troubleshooting and Repair Manual, Bulletin 3666193. Refer to
• Use the following procedure in the ISBe, ISB, and QSB (Common Rail
Fuel System) Service Manual, Bulletin 4021271. Refer to Procedure
• Use the following procedure in the Industrial QSB3.9-30, QSB4.5-30,
and QSB5.9-30 Series Engines Troubleshooting and Repair Manual,
• Use the following procedure in the ISC, ISCe, QSC8.3, ISL, ISLe3,
ISLe4 and QSL9 Engines Troubleshooting and Repair Manual, Bulletin
• Use the following procedure in the ISC and ISL CM2150 Service
• Use the following procedure in the ISB CM2100 and CM2150 Service
• Use the following procedure in the ISBe and ISDe CM2150 Service
• Use the following procedure in the ISLe CM2150 Service Manual,
• Use the following procedure in the ISL G CM2180 Service Manual,
• Use the following procedure in the ISF3.8 CM2220, ISF3.8 CM2220 AN
and ISF3.8 CM2220 IAN Service Manual, Bulletin 4021704. Refer to
• Use the following procedure in the ISB4.5, ISB6.7, ISD4.5 and ISD6.7
CM2150 SN Service Manual, Bulletin 4022188. Refer to Procedure
• Use the following procedure in the ISB6.7 Service Manual, Bulletin
• Use the following procedure in the ISB6.7 CM2350 B101 Service
• Use the following procedure in the QSB6.7 CM2350 B105 Service
• Use the following procedure in the ISF3.8 CM2220 F110 Service
WARNING
personal injury.
With the engine shut off, bleed the vehicle's air system
down by opening the drain cock on the wet tank to release
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.
Remove the engine blowby service tool and water
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
connected to the engine intake manifold.
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 the water
manometer, pressure gauge, or transducer 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.
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
manufacturer's instructions.
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.
Remove the engine blowby service tool and the water
manometer, pressure gauge, or transducer.
Remove the pressure gauge used to measure exhaust
back pressure during exhaust brake operation.
Install a plug in the test port.
Base Engine Component Blowby Contribution:

Base engine components can also be contributing factors
of increased crankcase blowby and higher than normal
crankcase pressure. Reference the Crankcase Gases
(Blowby) Excessive troubleshooting symptom tree in
Section TS of the appropriate engine service manual to
evaluate the remaining possible causes for increased
blowby and higher than normal crankcase pressure. The
following are listed as possible base engine component
causes:
Valve stem clearance is excessive or the valve stem seals are damaged.
Repair Manual, Bulletin 3666003. Refer to Procedure 002-004 in Section
2.
Service Manual, Bulletin 3666087. Refer to Procedure 002-004 in Section
2.
• Use the following procedure in the ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4
and QSL9 Engines Troubleshooting and Repair Manual, Bulletin 4021418.
• Use the following procedure in the ISF2.8 CM2220, ISF2.8 CM2220 E,
ISF2.8 CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin
• Use the following procedure in the QSL9 M CM2250 L106 Service
Cylinder head valve guides are excessively worn.

Section 2.
Section 2.
• Use the following procedure in the ISF2.8 CM2220, ISF2.8 CM2220E,
ISF2.8 CM2220AN and ISF2.8 CM2220 IAN Service Manual, Bulletin
• Use the following procedure in the QSL9 CM2350 L102 Service
Air compressor is malfunctioning.

• Use the following procedure in the C Series Engines
• Use the following procedure in the B3.9, B4.5, B4.5 RGT, and
B5.9 Service Manual, Bulletin 3666087. Refer to Procedure
• Use the following procedure in the ISBe, ISB, and QSB (Common
Rail Fuel System) Service Manual, Bulletin 4021271. Refer to
• Use the following procedure in the Industrial QSB3.9-30,
QSB4.5-30, and QSB5.9-30 Series Engines Troubleshooting and
Repair Manual, Bulletin 4021398. Refer to Procedure 012-014 in
Section 12.
ISLe4 and QSL9 Engines Troubleshooting and Repair Manual,
Manual, Bulletin 4021569. Refer to Procedure 012-014 in Section
12.
• Use the following procedure in the ISB CM2100 and CM2150
Section 12.
• Use the following procedure in the ISBe and ISDe CM2150
Section 12.
• Use the following procedure in the ISF3.8 CM2220 Service
12.
• Use the following procedure in the ISB4.5, ISB6.7, ISD4.5 and
ISD6.7 CM2150 SN Service Manual, Bulletin 4022188. Refer to
12.
12.
12.
12.
• Use the following procedure in the QSL9 CM2350 L102 Service
12.
12.
• Use the following procedure in the ISL9 CM2350 L101 Service
12.
12.
Piston or piston rings are worn or damaged.

Section 1.
Section 1.
• Use the following procedure in the ISF2.8 CM2220, ISF2.8 CM2220 E,
ISF2.8 CM2220 AN and ISF2.8 CM2220 IAN Service Manual, Bulletin
4022178. Refer to Procedure 001-043 in Section 1.Refer to Procedure
Aftertreatment Testing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Aftertreatment Testing (014-013)

Regeneration
CAUTION
Engine systems equipped with exhaust aftertreatment must operate on low sulphur diesel with a maximum
sulfur content of 50 parts per million. The use of high sulfur fuel will shorten the life of certain components in
the exhaust system, including the diesel oxidation catalyst. This damage could cause the engine to become
inoperable and affect the warranty coverage on the engine system. Refer to Fuels for Cummins Engines,
Bulletin 3379001.
Under some operating conditions, such as low speed, low load, or stop and go duty cycles, the engine aftertreatment
catalyst may not be operating at very high temperatures, and if non-approved high sulfur content fuel is used, there is
a probability that ammonium sulphate will accumulate on the catalyst, which will consequently reduce the
effectiveness of NOx conversion in the SCR system.
To rectify this problem, a Cummins® Authorized Repair Location will need to perform a Stationary (Parked) De-Sulfur
Regeneration of the aftertreatment catalyst. This must be performed at a Cummins® Authorized Repair Location.
A stationary regeneration can only be performed with the use of the INSITE™ electronic service tool, which is initiated
by selecting the feature option "De-Sulfur Regeneration Test". INSITE™ electronic service tool will then perform a
timed engine warm-up and will then raise the engine speed to between 2380 to 2450 RPM for a defined period. A
stationary (parked) regeneration will typically take approximately 2 hours to complete, and the vehicle must not be left
unattended during this period.
WARNING
During regeneration, exhaust gas temperature can 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 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.
NOTE: When the stationary regeneration process has been completed and before the vehicle is returned to service,
the lubricating oil and filter must be changed.
To perform a stationary (parked) regeneration, follow the steps listed:
1 Prepare the vehicle.
• Make sure that the fuel tank is full and that the oil quantity is sufficient.
• Inspect the exhaust piping and components for leaks, cracks, and loose connections. Reference Procedure
010-024 in Section 10 of the appropriate Service Manual. Tighten exhaust clamps, if necessary. Refer to the OEM
service manual.
2 Select an appropriate external location to park the vehicle.
• Preferably on a surface that will not burn or melt under high exhaust temperatures (such as clean concrete or
gravel, not grass or asphalt). Any Items that can burn, melt or explode (such as gasoline, paper, plastics, fabrics,
compressed gas containers, hydraulic lines) must be placed at least 3 m [10 ft] from the exhaust outlet.
3 Park the vehicle securely and make sure that the parking brake is applied.
• Set the transmission in Park, if provided; otherwise in Neutral.
• Place heavy duty wheel chocks at the front and rear of at least two tires.
4 Set up a safe area around the vehicle exhaust, and use barriers to prevent any bystanders from entering within 1.5
m [5 ft] of the exhaust outlet.
• Make sure that a serviceable fire extinguisher is nearby.
• Check the exhaust system components, and confirm that there is nothing on or near the exhaust system surfaces
(such as tools, shop cloths, grease, debris or organic material).
5 Connect the INSITE™ electronic service tool and make sure that it is placed on a stable surface. Check that any
additional fault codes have been resolved and cleared. Initiate the stationary regeneration by selecting the "De-
Sulfur Regeneration Test" and follow the on-screen instructions to perform the process.
• Once the regeneration commences, the engine speed will initially remain at idle to allow the engine to warm-up.
This will be followed by a slow controlled acceleration to attain the appropriate elevated speed for regeneration. At
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Aftertreatment Testing
this point, the fuel injection sequencing is adjusted and it will be noted that the engine running tone will change.
This is normal during the regeneration process. At the end of this elevated speed period, the engine will decelerate
to idle for a short cooling phase, whereby the regeneration process will be completed.
• Select the stop button on the INSITE™ electronic service tool monitor screen
• Depress the clutch (if equipped)
• Depress the brake
• Depress the acceleration pedal
• Switch the engine OFF.
6 Monitor the area.
• Make sure that the vehicle and surrounding area is monitored during regeneration. If any unsafe condition occurs,
shut down the engine immediately.
When the stationary regeneration process is completed, the temperature of the exhaust aftertreatment components
will remain elevated for at least 5 minutes.
WARNING
The exhaust and exhaust components can remain hot after the engine has been shut down or secured. 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 might come in contact with hot exhaust or exhaust components.
Take the vehicle for a short test drive, and operate the vehicle as instructed by INSITE™ electronic service tool, so
that the Aftertreatment High NOx fault code can be reset. Reference the Fault Code Troubleshooting Manual, Bulletin
4021677.
Change the lubricating oil and filter before the vehicle is returned to service. Reference Procedure 007-002 in the
appropriate Operation and Maintenance Manual.
Aftertreatment Testing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Notes
Section 16 - Mounting Adaptations - Group 16 Page 16-a
Section 16 - Mounting Adaptations - Group 16

Section Contents
Page
Engine Drive Shaft ..................................................................................................................................................16-63
Adjust......................................................................................................................................................................16-66
Finishing Steps.......................................................................................................................................................16-68
Install...................................................................................................................................................................... 16-67
Measure..................................................................................................................................................................16-65
Remove.................................................................................................................................................................. 16-63
Setup...................................................................................................................................................................... 16-64
Engine Mounts ........................................................................................................................................................16-52
Install...................................................................................................................................................................... 16-55
Remove.................................................................................................................................................................. 16-54
Engine Support Bracket, Front ................................................................................................................................16-3
Finishing Steps.........................................................................................................................................................16-5
Install........................................................................................................................................................................16-4
Remove....................................................................................................................................................................16-3
Engine Support Bracket, Rear .................................................................................................................................16-6
Install........................................................................................................................................................................16-7
Remove....................................................................................................................................................................16-6
Flexplate ....................................................................................................................................................................16-8
Finishing Steps.......................................................................................................................................................16-12
Initial Check..............................................................................................................................................................16-9
Install...................................................................................................................................................................... 16-11
Remove.................................................................................................................................................................. 16-10
Flywheel ...................................................................................................................................................................16-13
Finishing Steps.......................................................................................................................................................16-19
Install...................................................................................................................................................................... 16-15
Measure..................................................................................................................................................................16-17
Remove.................................................................................................................................................................. 16-14
Flywheel Housing ................................................................................................................................................... 16-20
Assemble................................................................................................................................................................16-23
Disassemble...........................................................................................................................................................16-22
Finishing Steps.......................................................................................................................................................16-30
Install...................................................................................................................................................................... 16-24
Measure..................................................................................................................................................................16-26
Remove.................................................................................................................................................................. 16-21
Flywheel Housing, REPTO .....................................................................................................................................16-32
Assemble................................................................................................................................................................16-40
Disassemble...........................................................................................................................................................16-37
Exploded View........................................................................................................................................................16-32
Finishing Steps.......................................................................................................................................................16-50
Install...................................................................................................................................................................... 16-45
Remove.................................................................................................................................................................. 16-35
Flywheel Ring Gear ................................................................................................................................................ 16-50
Page 16-b Section 16 - Mounting Adaptations - Group 16
Finishing Steps.......................................................................................................................................................16-51
Initial Check............................................................................................................................................................16-50
Install...................................................................................................................................................................... 16-51
Remove.................................................................................................................................................................. 16-51
Marine Vibration Isolator ........................................................................................................................................16-58
Finishing Steps.......................................................................................................................................................16-62
Initial Check............................................................................................................................................................16-58
Install...................................................................................................................................................................... 16-62
Remove.................................................................................................................................................................. 16-61
Propeller Shaft ........................................................................................................................................................16-55
Out of Water........................................................................................................................................................... 16-56
Alignment.............................................................................................................................................................16-56
Specifications..........................................................................................................................................................16-57
Service Tools ............................................................................................................................................................16-1
..................................................................................................................................................................................16-1
Section 16 - Mounting Adaptations - Group 16 Page 16-1
Service Tools
Mounting Adaptations
Repair Location.

Pipe Sealant
Used on capscrew threads and pipe plugs.
3375066
Cup Plug Sealant

Used when installing cup plugs.
3375068
Crack Detection Kit

Used to detect cracks.
3375432
Dial Indicator and Sleeve Assembly

Used with dial gauge attachment, Part Number ST-1325, to measure
3376050 flywheel and flywheel housing run-out.
Cup Plug Driver

Used to install cup plug in flywheel housing.
3376812
Three-bond Sealant
Heavy duty silicone-type cup plug sealant.
3823494
Page 16-2 Section 16 - Mounting Adaptations - Group 16

Idler Shaft Puller and Capscrew
Used to remove idler shaft from idler gear and flywheel housing.
3823709
Gear Locking Tool

Used to prevent rotation of the power take-off (PTO) output shaft
3823891 while tightening the output flange capscrew.
Bearing Race Driver

Used to install output shaft bearing races.
3823893
Barring Tool
3824591
Offset Wrench (C-Series Engine)

Used to tighten the hidden capscrews in the rear engine power take-
3824928 off (REPTO) flywheel housing.
Dial Indicator Attachment

Attaches to crankshaft flange to provide measuring of flywheel and
ST-1325 flywheel housing runout with dial bore gauge.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Support Bracket, Front
Engine Support Bracket, Front

(016-002)
Preparatory Steps
Marine Applications
• Remove the belt guard. Refer to Procedure 008-001 in
Section 8.
Remove
Use a hoist or lifting fixture to support the front of the
engine.
Remove the capscrews from the front engine mount.
NOTE: Make sure to save any shims or spacers removed
and record their location.
Remove the four mounting capscrews and the front

engine support.
Marine Applications
WARNING
The engine lifting equipment must be designed to lift
the engine and transmission as an assembly without
causing personal injury.
Use a hoist or lifting fixture to support the front of the
engine.
Remove the brackets and spacer (if equipped) from the
mounting frame and front engine support.
Engine Support Bracket, Front ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove the mounting capscrews and the front engine

support.
WARNING
WARNING
personal injury.
Use steam or solvent to clean the front engine support.
Inspect the support for cracks or other damage.

If the support is cracked or otherwise damaged, it must
be replaced.
Install
Install the front support and mounting capscrews.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Support Bracket, Front
Lower the front of the engine.

Install the front engine mount capscrews.
Tighten the capscrews to the manufacturer's
specifications.
Remove the lifting fixture or hoist from the front of the
engine.
Marine Applications
Install the front engine mount and mounting capscrews.
Lightly coat the threads with Loctite™ 277, or equivalent.
Install the support brackets and spacers (if required) to

the engine mounting frame and front engine support.
Remove the lifting fixture or hoist from the front engine
lifting bracket.
Finishing Steps
Marine Applications
• Install the belt guard. Refer to Procedure 008-001 in
Section 8.
Engine Support Bracket, Rear ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Engine Support Bracket, Rear

(016-003)
Entfernen Sie
WARNING
Use a hoist or lifting fixture to support the rear of the
engine.
Remove the capscrew from the rear engine mount.
Remove the four capscrews and rear support bracket.
Marine Applications
Remove the rear mounting supports.
Refer to the marine gear OEM service manual or the
Marine Recreational B and C Installation Directions,
Bulletin 3884649.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Support Bracket, Rear
WARNING
WARNING
WARNING
personal injury.
Use steam or solvent to clean the rear engine support.
Inspect the support bracket for cracks or damage. If the
support bracket is cracked, it must be replaced.
Install
Install the support bracket and mounting capscrews.
Lower the rear of the engine.

Install the rear engine mount capscrews.
Tighten to the manufacturer's specifications.
Remove the lifting fixture or hoist from the rear of the
engine.
Flexplate ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
Install the rear mounting bracket. Refer to the marine gear
OEM service manual for bracket torque specifications.
Refer to the vessel OEM service manual for engine
isolator torque specifications or the Marine Recreational B
and C Installation Directions, Bulletin 3884649.
Flexplate (016-004)
Preparatory Steps
Automotive and Industrial
WARNING
battery cable last.
WARNING
Section 13.
• Remove the transmission and related components.
Marine Applications
WARNING
battery cable last.
WARNING
in Section 13.
• Remove the drive gear. Refer to OEM service manual.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flexplate
Initial Check
For automotive and industrial applications, inspect the
flexplate ring gear teeth for damage.
If the flexplate ring gear is damaged, make sure to
evaluate the following possible causes prior to replacing
the flexplate.
Mechanical
A mechanical issue can typically be identified by seeing
damage to the ring gear of the flexplate in 3 distinct
locations for 6 cylinder engines (commonly called 120
degree milling), and 2 locations for 4 cylinder engines
(commonly called 180 degree milling). The following can
be causes for mechanical issues:
1 The possibility of improper starter motor spacing.
2 The interference between the ring gear land area and
the starting motor pinion. The wrong starting motor
might be installed, refer to the original equipment
3 The possibility of a damaged starter motor pinion.
Inspect the pinion for nicks and burrs. If replacement
of the starting motor is necessary. Refer to Procedure
4 The torque converter/transmission is damaged or
incorrectly mounted. Refer to the OEM service
manual.
5 Incorrect starting motor pinion to flexplate ring gear
pitch and teeth match. Refer to the OEM service
manual.
Electrical
An electrical issue can typically be identified by seeing
damage to the ring gear of the flexplate 360 degrees
around the circumference of the ring gear (commonly
called 360 degree milling). The following can be causes
for electrical issues:
1 The operator is attempting to start engine while engine
is already running. Check if a starter lockout feature is
available through the OEM (activated with INSITE™
electronic service tool) or the starting motor
manufacturer.
2 The key switch is causing intermittent starting motor
engagement when the engine is running. Inspect the
key switch. Refer to Procedure 013-020 in Section 13.
3 The orientation of the starter relay, where in the
direction of the pull contact is in the direction of the
vehicle's travel. This results in intermittent starter
motor engagement when the engine is running.
Relocate the starter relay. Refer to the OEM service
manual.
4 Intermittent starter motor wiring issues. Refer to the
OEM service manual.
Remove
Remove the flexplate capscrews and flexplate.
NOTE: Some flexplates require mounting plates and/or
adapters. It may be necessary to remove any mounting
plates and/or adapters prior to or with the flexplate. Make
sure to note the location of any mounting plates and/or
adapters for later installation.
Marine Applications
Remove the nine flex-coupling guard capscrews, harness
connector, and the flex-coupling guard (if equipped).
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flexplate
Remove the flexplate mounting capscrews.

Remove the flexplate from the flywheel.
Inspect for Reuse

Inspect the teeth of the ring gear for chips or uneven
wear.
Check the flexplate for cracks.
Replace the flexplate if any damage is found.
Marine Applications
Check the flexplate for cracks at the mounting holes, drive
splines, and the inner drive plate.
Replace the flexplate if any damage is found.
Install
NOTE: Some flexplates require mounting plates and/or
clamp rings. It may be necessary to install any mounting
plates and/or clamp rings prior to or with the flexplate as
noted during removal.
Install the flexplate, the flexplate capscrews, and tighten.
Torque Value:
Flexplate Capscrews
Step 1 30 N•m [ 22 ft-lb ]
Step 2 Plus 60-degree turn
Marine Applications
Install the flexplate and flexplate mounting capscrews.
If the engine is equipped with a flex-coupling guard plate,

install the flex-coupling guard plate onto the flywheel
housing. Position the wiring harness connector at the 11
o'clock position, as shown in the illustration. Install a
capscrew to hold it in place.
Install the remaining eight capscrews.
Finishing Steps
WARNING
battery cable last.
WARNING
Section 13.
• Install the transmission and related components. Refer
• Operate the engine and check for noise or vibration.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flywheel
Marine Applications
WARNING
battery cable last.
WARNING
Section 13.
• Install the drive gear. Refer to OEM service manual.
• Check the crankcase end play.Refer to Procedure
Flywheel (016-005)
Preparatory Steps
WARNING
battery cable last.
in Section 13.
• Remove the vehicle driveline and transmission. See
the manufacturer's service manual.
• Remove the clutch discs and the pressure plate.
Marine Applications
WARNING
• Use a hoist or suitable lifting device to support the rear
of the engine if the engine supports are mounted to the
marine gear.
• Remove the propeller shaft, marine gear and drive
plate. Refer to the vessel OEM or marine gear OEM
service manual.
• Remove the marine gear housing adapter, if used.
Refer to the marine gear OEM service manual.
Flywheel ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Remove
NOTE: Use the barring tool, Part Number 3824591, to
hold the flywheel to prevent rotation.
Remove two capscrews 180 degrees apart.
Install two M12 x 1.25 x 90-mm guide pins.
NOTE: If a clutch is used in the equipment, the threads in
the clutch pressure plate mounting capscrew holes can be
metric or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size, and
install two T-handles in the flywheel at points (1) and (2).
Remove the remaining six flywheel mounting capscrews.
WARNING
Remove the flywheel from the guide pins.
WARNING
WARNING
personal injury.
WARNING
If the pilot bearing was removed, use a wire brush to
clean the crankshaft pilot bore.
Use steam or solvent to clean the flywheel.
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.
NOTE: If the ring gear teeth are cracked or broken, the
ring gear must be replaced. Refer to Procedure 016-008
in Section 16.
Install
NOTE: Use a new pilot bearing when installing a new or
rebuilt clutch.
Use a mandrel and a hammer to remove the pilot bearing.
Use Scotch-Brite™ 7448 or equivalent to clean the pilot
bore.
Use a mandrel and hammer to install the pilot bearing.

NOTE: The pilot bearing must be installed even with the
pilot bore surface.
Install two M12 x 1.25 x 90-mm guide pins into the

crankshaft flange 180 degrees apart.
NOTE: If a clutch is used in the equipment, the threads in
the clutch pressure plate mounting capscrew holes can be
metric or standard. Be sure to use the correct capscrews.
Determine the capscrew thread design and size, and
install two T-handles into the flywheel at points (1) and
(2).
WARNING
Inspect the rear face of crankshaft and flywheel mounting
flange for cleanliness and nicks or burrs.
Install the flywheel on the guide pins.
Lubricate the threads of the capscrews and the surface of

the washers with clean lubricating engine oil.
Install the six capscrews.
Remove the T-handle and guide pins.
Install the remaining capscrews into the holes from where
the guide pins were removed.
Hold the crankshaft when tightening the flywheel

capscrews, use the barring tool, Part Number 3824591.
Tighten the capscrews in a star pattern.
Measure
Bore Runout
Use the dial indicator gauge (1), Part Number 3376050, or
its equivalent and dial gauge attachment (2), Part Number
ST-1325, to inspect the flywheel bore (3) and the surface
(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
diameter of the flywheel bore, and set the dial indicator at
zero.
Use the barring tool, Cummins Part Number 3374591, to

rotate the crankshaft one complete revolution.
Flywheel Total Indicator Reading

mm in
0.127 MAX 0.0050
WARNING
NOTE: If the total indicator reading (TIR) is greater than
the specification, do the following:
Remove the flywheel.
Inspect the flywheel mounting surface for dirt or damage.
Inspect the crankshaft for dirt or damage.
WARNING
Install the flywheel.
Inspect the bore runout.
Replace the flywheel if the runout does not meet

specifications.
Face Runout
Install the contact tip of the indicator against the flywheel
face.
When locating the contact tip, see the Flywheel Face
Runout Total Indicator Reading Table later in this
procedure. Locate the contact tip so that it corresponds
with a radius listed in the table, but is still as close to the
outside diameter of the flywheel as possible, to inspect
the flywheel face (1) runout.
Push the flywheel forward to remove the crankshaft end
clearance. Adjust the dial on the indicator until the needle
points to zero.
Use the barring tool, Part Number 3824591, to rotate the

crankshaft one complete revolution. Measure and record
the flywheel runout at four equal points on the flywheel.
The flywheel must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a point is measured.
Determine the total indicator reading (TIR).
TIR is determined by calculating the difference between
the highest and lowest measurement from the four
locations measured.
If the flywheel face runout is not within specifications,

remove the flywheel. Check for nicks, burrs, or foreign
material between the flywheel mounting surface and the
crankshaft flange.
Replace the flywheel if the runout is not within
specification.
Finishing Steps
WARNING
battery cable last.
• Install the clutch discs and the pressure plate.
NOTE: Use the barring tool, Part Number 3824591, to
hold the flywheel to prevent rotation.
• Install the vehicle driveline and transmission. See the
• Connect the battery. Refer to Procedure 013-009.
Flywheel Housing ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Marine Applications
• Install the drive plate, marine gear drive adapter and
the marine drive gear. Refer to the marine drive OEM
service manual.
• Install the engine supports, if removed. Refer to the
vessel OEM service manual.
• Install the propeller drive. Refer to the vessel OEM
service manual.
Flywheel Housing (016-006)

Preparatory Steps
WARNING
battery cable last.
WARNING
WARNING
Support the rear of the engine using the rear support
attached to the cylinder head. Failure to support the
engine can cause personal injury.
in Section 13.
• If equipped with a wet flywheel housing, drain the oil
from the flywheel housing by removing the plug in the
bottom of the flywheel housing. Use a container that
can hold at least 28 liters [30 qt] of lubricating oil.
• Remove the starting motor. Refer to Procedure
• Remove the transmission, clutch, and all related
components, if equipped. See equipment
• Remove the flywheel/ring gear assembly. Refer to
• Remove the rear engine mounts. Refer to Procedure
• Remove any original equipment manufacturer (OEM)
attached components (mufflers, shift mechanisms, air
filters, etc.) to the flywheel housing. See equipment
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flywheel Housing
Marine Applications
WARNING
battery cable last.
WARNING
WARNING
in Section 13.
• Remove the propeller shaft. Refer to the vessel OEM
service manual.
• Remove the marine drive gear, drive gear adapter, if
equipped, and the drive plate.
• Use a hoist or suitable lifting device to lift the rear of
the engine. Remove the rear engine mounts. Refer to
• Remove the flywheel. Refer to Procedure 016-005 in
Section 16.
• Remove the aftercooler mounting capscrews. Refer to
Entfernen Sie
WARNING
While supporting the flywheel housing, remove the
mounting capscrews.
Use a rubber hammer to loosen the flywheel housing.

Remove the flywheel housing and rectangular seal.
Disassemble
Remove and note the location of any threaded plugs in
the flywheel housing.
Remove the access plate and, if equipped, the gasket.
Remove the plug from the barring gear hole.
WARNING
avoid personal injury.
WARNING
When using a steam cleaner, wear glasses or a face
shield, as well as protective clothing. Hot steam can
cause serious personal injury.
WARNING
personal injury.
Use steam or solvent to clean the flywheel housing.
Inspect the flywheel housing for cracks, especially in the
bolt pattern area.
Inspect all surfaces for nicks, burrs, or cracks.
Use a fine crocus cloth to remove small nicks and burrs.
Inspect for damaged threads commonly caused by cross

threaded capscrews or installing an incorrect capscrew.
Heli-coils are available to repair damaged threads.
Assemble
For wet flywheel housings, apply pipe sealant, Part
Number 3375066, to any threaded plugs previously
removed.
Install and tighten the plugs. Refer to Procedure 017-007
in Section 17.
Install the access plate and new gasket.

NOTE: If a gasket was not previously installed, apply
sealant, Part Number 3164067, to the perimeter of the
access plate.
Install a new o-ring. Install the barring gear hole plug.
Install
Install rectangular seal and lubricate with Lubriplate™ 105
multi-purpose lubricant, or equivalent.
Wet Flywheel Applications

Apply a continuous bead of Three-Bond™, or equivalent,
around all capscrew holes on the mounting surface of the
flywheel housing.
Wet Flywheel Applications

NOTE: The capscrew holes on the mounting pads are
drilled through. Coat set screws with Loctite™ 277, or
equivalent, and install into holes.
Set Screw Installation Depth (Flywheel Housing)

mm in
3.00 MAX 0.118
Inspect the rear face of the cylinder block and flywheel

housing mounting surface for cleanliness and nicks or
burrs.
Install the flywheel housing over the two ring dowels.
NOTE: Be sure the sealing ring is not damaged during
installation.
Tighten the flywheel housing capscrews in sequence

shownn.
Install the plastic plug in the tachometer drive access

hole.
• Coat the flywheel housing drain plug with pipe sealant

and install in the hole in the bottom of the flywheel
housing.
• Tighten the plug.
• Refer to Procedure 018-012 in Section V.
Install the access plate and new gasket.

Install the plug into the barring gear hole.
Measure
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.
NOTE: The extension bar for the indicator must be rigid
for an accurate reading. It must not sag. Position the
indicator at the 12 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the 3

o'clock, 6 o'clock, and 9 o'clock positions.
NOTE: 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 o'clock position. Check the indicator to make sure
the needle points to zero. If it does not, the readings will
be incorrect.
Determine the Total Indicator Reading (TIR).

Example: mm in
12 o'clock 0.00 0.000
3 o'clock +0.08 +0.003
6 o'clock - 0.05 - 0.002
9 o'clock +0.08 +0.003
Equals TIR 0.13 0.005
The maximum allowable TIR is determined by the

diameter of the housing bore. If out of specifications,
replace the housing.
Flywheel Housing Bore Size/TIR
SAE No. Bore TIR Max
Diameter
- mm in mm in
2 447.68 to 17.625 to 0.20 0.008
447.80 17.30
3 409.58 to 16.125 to 0.20 0.008
409.70 16.130
Bore Alignment
Attach a dial indicator gauge, Part Number 3376050, to
the crankshaft. 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 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9 o'clock, 12 o'clock, and 3 o'clock
positions as (a), (b), and (c) in the concentricity work
sheet. Recheck 0 at the 6 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
See 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 could
cause false bearing clearance readings.
Rotate the crankshaft until the dial indicator is at the 12
o'clock position and 0 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.
Be careful not to damage the sealing surface when using
a pry bar on the crankshaft.
Use the concentricity work sheet to determine the values

for the total vertical, and total horizontal values.
The total horizontal is equal to the 9-o'clock reading, (a),
minus the 3-o'clock reading, (c).
The total vertical is equal to the 12-o'clock reading, (b),
plus the bearing clearance, (d).
Example:
6 o'clock = ref = 0
9 o'clock = [a] = 0.004
12 o'clock = [b] = 0.003
3 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 straight edge 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.
Use the total horizontal and total vertical values from the
previous example to the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for (Society of Automotive
Engineers) SAE 1, 2, and 3 flywheel housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
NOTE: 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, torque the capscrews to the specified value.
Finishing Steps
WARNING
battery cable last.
• Install both rear engine mounts. Refer to Procedure
• Install the flywheel/ring gear assembly. Refer to
• Install the starting motor. Refer to Procedure 013-020
in Section 13.
• Install the clutch, transmission, and all related
components, if equipped. See the OEM service
manual.
• Install the transmission and related components, if
equipped. See equipment manufacturer service
information.
• If equipped with a wet flywheel housing, fill the
flywheel housing with oil. See equipment manufacturer
• If previously removed, attach any OEM components
(mufflers, shift mechanisms, air filters, etc.) to the
flywheel housing. See equipment manufacturer service
information.
Section 13.
• Operate the engine and check for leaks or vibration.
Marine Applications
WARNING
battery cable last.
• Install the two aftercooler mounting capscrews into the
flywheel housing. Refer to Procedure 010-005 in
Section 10.
• Install the flywheel. Refer to Procedure 016-005 in
Section 16.
in Section 13.
• Install the drive plate, marine drive adapter, if
equipped, and the marine drive gear. Refer to the
marine drive gear OEM service manual.
• Install the rear engine mounts. Refer to Procedure
• Install the propeller drive. Refer to the vessel OEM
service manual.
Section 13.
• Operate the engine and check for leaks or vibration.
Flywheel Housing, REPTO ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Flywheel Housing, REPTO (016-007)

Exploded View
Rear Engine Power Takeoff

1 Housing, flywheel - 1
2 Cover, access hole - 1
3 Gasket, cover plate - 1
4 Plug, threaded drain - 1
5 Shaft, accessory drive output - 1
6 Flange, power takeoff - 1
7 Bearing, roller (large) - 1
8 Bearing, roller (medium) - 1
9 Seal, rectangular ring (tetra) - 1
10 Plate, cover (ribbed) - 1
11 Capscrew - 4
12 Washer, plain - 4
13 Seal, oil (output shaft) - 1
14 Shims (see next page)
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flywheel Housing, REPTO
16 Washer, plain (PTO flange) - 1
17 Screw, hexagon head cap - 1
18 Retainer, shaft - 1
19 Gear, idler - 1
20 Assembly, bearing and race - 2
21 Shaft, idler - 1
22 Seal, o-ring - 2
24 Gear, crankshaft - 1
27 Gasket, carrier - 1
28 Kit, seal - 1
29 Screw, captive washer cap - 12
33 Plug, expansion - 1
34 Hose, flexible oil supply - 1
35 Connection, mate oil supply - 1
36 Ring, clamping - 1
37 Seal, dust - 1.

Exploded View
NOTE: There are seven shims available. A given REPTO can have any combination of these shims.
Reference Number Description mm in
14 Shim 0.127 0.005
14 Shim 0.254 0.010
14 Shim 0.381 0.015
14 Shim 0.051 0.002
14 Shim 0.076 0.003
14 Shim 0.508 0.020
14 Shim 1.016 0.040
Preparatory Steps
WARNING
battery cable last.
• Disconnect the battery. Refer to the OEM service
manual.
• Remove the transmission, clutch, and all related
components, if equipped. Refer to the OEM service
manual.
• Remove the flywheel/ring gear assembly. Refer to
• Adequately support the engine to prevent damage.
• Remove both rear engine mounts. Refer to Procedure
Remove
Remove the REPTO oil supply line.
Remove the oil seal capscrews, oil seal, and gasket.
To gain access to the housing capscrews, use a drift to

drive the cup plugs straight through into the housing.
Retrieve the plugs from inside the housing.
Do not attempt to back the plugs out or rotate the plugs
out of the housing. The cup plug bore will be damaged
and oil leakage will occur.
Install two crankshaft locator studs, Part Number

3822784, into the crankshaft flywheel mounting flange,
180 degrees apart.
Remove the crankshaft drive gear.
CAUTION
The idler gear will fall when the shaft is removed.
Use the idler shaft puller, Part Number 3823709, to
remove the idler shaft.
Remove the idler gear to gain access to the rest of the

housing capscrews.
Remove two of the capscrews and install two guide pins,

Part Number 3376638, to support the housing during
removal.
Use an offset wrench, Part Number 3823892, to remove
the capscrews that are not visible.
WARNING
Remove the remaining capscrews. Use a rubber hammer
to loosen the housing.
Remove the housing.
Disassemble
Use gear locking tool, Part Number 3823891, to prevent
the output shaft from turning when removing the retainer
capscrew.
Remove the capscrew and washer that secures the output
flange to the output shaft.
Use a rawhide hammer to remove the output flange and
flat washer from the output shaft.
Use a dent puller to remove the seal. Do not damage the

surface of the housing or seal bore.
When the housing is turned over, the bearing will fall out.
Do not allow the bearing to be damaged.
Turn the housing over so the four cover plate capscrews
are accessible. Be careful not to damage the output shaft.
Remove the capscrews and ribbed cover plate from the
output gear housing.
Remove and discard the square cut o-ring.
Save the original shims for rebuild purposes. They will be

used to set the proper end clearance on the output shaft
and bearing assembly.
Turn the housing over and use a rawhide hammer to hit
the end of the output shaft to remove the output shaft sub-
assembly from the REPTO housing.
With the housing positioned so the cylinder block mating

surface is down, use a hammer and brass punch to drive
the bearing outer races out of the output shaft housing
bore.
Support the housing in a press with the cylinder block

mating surface down.
With a long mandrel, press out the idler shaft bushing.
Remove and discard the o-ring.
Use a hammer and brass drift to remove the two bearing

outer races from the bore of the idler gear. Discard the
outer races.
Remove the large spacer ring from the center groove of
the gear. Discard the spacer ring.
WARNING
Use a steam cleaner to clean all areas of the idler gear.
Inspect the output shaft and bearings for wear.
Inspect the output gear for damage.
Inspect the output flange for damage or wear grooves
from the oil seal.
Inspect the REPTO housing for cracks at the rear engine

mounting surfaces and the flywheel bore.
Replace the housing if cracked.
Inspect the idler shaft bushing for wear.
Replace the bushing if worn.
Inspect the bore, side faces, and teeth of the idler gear.
Replace the gear if there are cracks or discoloration from
heat damage, or any other damage.
Assemble
Install a new o-ring on the idler shaft bushing.
Use assembly lubricant, Part Number 3163087, or
equivalent, to lubricate the o-ring.
Support the housing evenly with the engine mating

surface up.
Press the new bushing into the housing until it is below
the surface of the cylinder block mating surface.

equivalent, to lubricate the larger bearing race.
Use the larger end of the driver, Part Number 3823893, to
press the bearing race to the shoulder in the housing.
Turn the housing over and support it evenly in the press.

equivalent, to lubricate the smaller bearing race.
Use the smaller end of the driver, Part Number 3893893,
to press the bearing race to the shoulder in the housing.

equivalent, to lubricate the output shaft and larger
bearing.
Install the larger bearing onto the output shaft.
Position the housing on the table so the cylinder block

mating surface is up.
Install the output shaft assembly into the housing.
The correct end clearance (rolling resistance) is

determined by the number and thickness of shims used
between the two bearings.
When the shim thickness is increased, there is more shaft
end clearance and less rolling resistance.
When the shim thickness is decreased, there is less shaft
end clearance and more rolling resistance.
Turn the housing over with the engine mating surface

down, while holding the output shaft and gear in place.
If the original thickness of shims is not available for reuse,
a beginning thickness of 1.47 mm [0.058 in] can be used
as a starting point.
Install the original thickness of shims.

equivalent, to lubricate the smaller bearing.
Install the smaller bearing onto the shaft.
Temporarily install the output flange before installing the

oil seal.
Use clean 15W-40 engine oil to lubricate the splines.
Install the flat washer and capscrew. Use the gear locking
tool, Part Number 3823891, to hold the output shaft while
tightening the capscrew.
Measure the shaft end play.
Shaft End Play

mm in
0.0 MIN 0.0
0.03 MAX 0.001
Check the output shaft rolling resistance with a torque

wrench.
Rolling Resistance 0.6 to 1.1 N•m [ 5 to 10 in-lb ]
If the rolling resistance is not within specification, remove

the output flange and smaller bearing.
Add or subtract shims to obtain the correct rolling
resistance.
Adding more shims will decrease the resistance and
removing shims will increase resistance. Any combination
of shims can be used.
Once the correct rolling resistance is obtained, remove

the output flange and install a new oil seal.
Press the oil seal flush with the housing surface.
Apply pipe sealant, Part Number 3375066, to the output

flange capscrew and under the washer.
Install the output flange flat washer and capscrew.
Install a new o-ring on the bearing housing cover.

Use clean vegetable oil to lubricate the o-ring.
Install and tighten the cover and four capscrews.

Insert a new spacer ring into the bore of the idler gear.
Push until it snaps into place in the center groove.

equivalent, to lubricate the bearing outer races.
Press the two new bearing outer races into the bore of the
idler gear.
The larger side of the taper must face toward the outside
of the gear.
Do not interchange individual parts that make up the idler

gear bearing assembly. Rebuild the idler gear with
bearings that are packaged together.
Keep the two roller bearing assemblies and the spacer
ring with the idler gear.
Install
Install the rectangular seal on the rear seal carrier and
lubricate with assembly lubricant, Part Number 3163087,
or equivalent.
Apply a continuous bead of RTV sealant, Part Number

3164067, or equivalent, around all capscrew holes on the
mounting surface of the flywheel housing.
WARNING
kg {50 lb]. To prevent serious personal injury, be sure
Inspect the rear face of the cylinder block and flywheel
housing mounting surface for cleanliness and nicks or
burrs.
Install the flywheel housing over the two ring dowels.
Be sure the sealing ring is not damaged during
installation.
Install the capscrews and tighten in the sequence shown.

Use an offset wrench, Part Number 3823892, for
capscrews hidden from view.
Before installing the idler gear, measure the flywheel

housing bore and face alignment. Refer to Procedure
Fabricate a sleeve from 38.10 mm [1.50 in] PVC (or

equivalent) to the following dimensions:
Length: 25.4 mm [1.0 in]
Slot: 12.70 mm [0.50 in]
The outer bearing races of new replacement gears are

already pressed into the gear.
Apply a thin film of assembly lubricant, Part Number
3163087, or equivalent, on the outer races and bearings.
Install the bearing and spacer into the idler gear. Use the
babricated PVC (or equivalent) sleeve to hold the bearing
assembly together when installing the idler gear
assembly.
Apply a thin film of assembly lubricant, Part Number

3163087, or equivalent, into the idler shaft bore of the
housing and on the idler shaft.
NOTE: For idler scissor gears, loosen the screws in the
scissor gear by turning counterclockwise until they will
no longer turn. The screws will not come out of the gear
Install the idler gear assembly with snap ring facing out
into the flywheel housing.
Hold the idler gear and bearing in place and remove the
plastic sleeve.
Use clean assembly lubricant, Part Number 3163087, or

equivalent, to lubricate the idle shaft o-ring and install the
o-ring into the shaft.
Hold the gear assembly in place and insert the idler shaft
through the housing and idler gear bearings.
Do not use a hammer when installing the idler shaft and
capscrew or the part can be damaged.
Apply assembly lubricant, Part Number 3163087, or

equivalent, under the head of the idler shaft capscrew.
Insert the capscrew through the idler shaft. Tighten the
installation capscrew with a torque wrench.
The torque needed to draw the idler shaft in place must
not exceed 88 N•m [65 ft-lb]. If installation torque exceeds
this amount, it is an indication of misalignment between
the bore and the shaft. Remove the idler shaft and install
it again.
When the idler shaft has been seated, remove the

capscrew.
Apply pipe sealant, Part Number 3375066, to the threads
of the idler shaft capscrew. Apply assembly lubricant, Part
Number 3163087, or equivalent, under the head of the
capscrew and tighten to the final torque value.
Apply a film of cup plug sealant, Part Number 3375068, to

the outside diameter of the cup plugs.
Use a driver, Part Number 3823710, to install the cup
plugs into the housing, as illustrated.
When installing cup plugs, make sure they are flush with
the spot face on the flywheel housing and are not cocked.
Coat the flywheel housing drain plug with pipe sealant and
install it in the hole in the bottom of the flywheel housing.
Tighten the plug. Refer to Procedure 017-007 in Section
17.
Turn the output flange so that the flat sides are on the top
and bottom. This prevents any interference when the
transmission is installed onto the housing.
Install two crankshaft locator studs, Part Number

3822784, into the crankshaft flywheel mounting flange
180 degrees apart.
Make sure the crankshaft and the crankshaft gear are
clean.
Install the crankshaft gear in the locator studs.
Do not use any lubricant to install the seal. The oil seal
must be installed with the crankshaft gear seal contact
surface and the lip of the seal clean and dry to provide a
proper oil sealing surface.
Install a new gasket (1) in the flywheel housing.
Install a new seal over the crankshaft gear seal contact

surface.
Apply sealant, Part Number 3375066, to seal the retainer

capscrews.
Install the capscrews and tighten in a star pattern.
Torque Value:
Step 2 19 N•m [ 168 in-lb ]
Flywheel Ring Gear ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Finishing Steps
WARNING
battery cable last.
in Section 13.
• Install the rear engine mounts. Refer to Procedure
• Install the flexplate, if installed. Refer to Procedure
• Install the flywheel, if installed. Refer to Procedure
• Install the transmission, clutch, and all related
components, if equipped. Refer to the OEM service
manual.
manual.
Flywheel Ring Gear (016-008)

Initial Check
Remove the transmission. See the equipment
manufacturer's instructions.
Remove the flywheel/ring gear assembly. Refer to
Inspect the ring gear teeth for cracks and chips.

NOTE: If the ring gear teeth are damaged, the ring gear
must be replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flywheel Ring Gear
Remove
Use the drift pin to drive the ring gear from the flywheel.
Install
Heat the ring gear for 20 minutes in an oven pre-heated to
127°C [260°F].
Install the ring gear. The ring gear must be installed so

the bevel on the teeth is toward the crankshaft side of the
flywheel.
Finishing Steps
• Install the transmission, clutch, and all related
components (if equipped). See the manufacturer's
instructions.
Engine Mounts ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
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
2 Supported member
3 Snubbing washer (or flat bracket surface of equal diameter
4 Rebound tail
5 Bonded metal center
6 Locknut
7 Supporting member
8 Rubber mount.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Mounts
The following are illustrations of typical REAR engine mounts.
Engine Mounts ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Entfernen Sie
WARNING
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.
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.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Propeller Shaft
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 service manual for torque specifications.
Remove the lifting fixture or hoist from the engine lifting
brackets.
Connect all engine and chassis mounted accessories that
were removed.
Propeller Shaft (016-025)

General Information
Improper alignment of the propeller shaft can result in
many problems. Vibration is usually the first indicator.
Failure of the shaft seal or stuffing box can also occur. If
damaged shaft seals, stuffing box, strut, cutlass bearing,
or propeller are found, refer to an authorized OEM repair
location.
Preparatory Steps
Shaft alignment is checked when isolators are replaced,
adjusted, or any time excessive vibration has been
noticed. Also, any time the vessel has been taken out of
the water and stored or blocked minor changes can take
place in the shape of the hull. The shaft is checked and
realigned as necessary after the vessel has been placed
back in the water.
Propeller Shaft ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Out of Water
Inspect the propeller shaft for debris and burrs. Clean the
propeller shaft.
Check that the shaft is centered in the opening of the
stuffing box flange. The specifications will vary by
manufacturer. If any problems are noted, refer to an
authorized OEM service location.
Inspect the strut. Make sure the strut is mounted solidly to

the hull.
Check that the shaft is aligned with the cutlass bearing,
and that the bearing is not worn.
If any problems are noted, refer to an authorized OEM
service location.
A misaligned shaft will cause uneven wear of the cutlass

bearing.
If the strut or cutlass bearing needs to be repaired or
replaced, refer to an authorized OEM service location.
NOTE: Initially align the shaft out of the water using the
following instructions, then perform a final alignment after
the vessel is in the water.
Alignment
Check that the shaft is centered in the opening of the
stuffing box flange.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Propeller Shaft
Unbolt the propeller shaft coupling from the marine gear

coupling.
The faces of the marine gear (1) couplings and propeller
(2) must be parallel.
The couplings must be aligned.

A straight edge can be used to help align the couplings
Use a feeler gauge (3) to check the alignment of the

coupling in four different places, 90 degrees apart. The
variation is to be within 0.051 to 0.102 mm [0.002 to 0.004
in].
If the flange is out of alignment the engine mounting will
need to be adjusted until the alignment is correct. Refer to
Engine Mounting/Drive Systems section in the Marine
Recreational Installation Directions, Bulletin 3884649.
Make sure all mounting bolts and nuts are torqued to the
proper specifications. Refer to Procedure 016-026, or the
OEM literature.
Bolt the coupling in place and torque to the specifications
for the capscrew and bolt size.
Specifications
Capscrews, Bolts and Nuts Torque for Fine and Coarse Threads
SAE Grade 5 SAE Grade 8
(1) As Received (2) Lubricated (1) As Received (2) Lubricated
N•m [ft-lb] N•m [ft-lb] N•m [ft-lb] N•m [ft-lb]
1/4 12 ± 1 [9 ± 1] 9 ± 1 [7 ± 1] 19 ± 1 [14 ± 1] 15 ± 1 [11 ± 1]
5/16 26 ± 3 [19 ± 2] 20 ± 3 [15 ± 2] 37 ± 3 [27 ± 2] 30 ± 3 [22 ± 2]
3/8 45 ± 4 [33 ± 3] 37 ± 3 [27 ± 2] 62 ± 5 [46 ± 4] 52 ± 4 [38 ± 3]
7/16 71 ± 5 [52 ± 4] 54 ± 4 [40 ± 3] 99 ± 8 [73 ± 6] 81 ± 7 [60 ± 5]
1/2 108 ± 8 [80 ± 6] 88 ± 7 [65 ± 5] 152 ± 11 [112 ± 8] 122 ± 9 [90 ± 7]
9/16 152 ± 11 [112 ± 8] 112 ± 11 [90 ± 8] 214 ± 16 [158 ± 12] 176 ± 14 [130 ± 10]
5/8 214 ± 16 [158 ± 12] 176 ± 14 [130 ± 10] 304 ± 22 [224 ± 16] 244 ± 20 [180 ± 15]
Marine Vibration Isolator ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Capscrews, Bolts and Nuts Torque for Fine and Coarse Threads
SAE Grade 5 SAE Grade 8
3/4 380 ± 27 [280 ± 20] 305 ± 27 [225 ± 20] 529 ± 41 [390 ± 30] 434 ± 34 [320 ± 25]
7/8 607 ± 43 [448 ± 32] 488 ± 41 [360 ± 30] 854 ± 68 [630 ± 50] 691 ± 54 [510 ± 40]
1 922 ± 68 [680 ± 50] 732 ± 61 [540 ± 45] 1302 ± 95 [960 ± 70] 1051 ± 81 [775 ± 60]
1 1/8 1152 ± 81 [850 ± 60] 915 ± 81 [675 ± 60] 1844 ± 136 [1360 ± 100] 1491 ± 115 [1100 ± 85]
1 1/4 1593 ± 115 [1175 ± 85] 1254 ± 102 [925 ± 75] 2508 ± 203 [1850 ± 150] 2034 ± 169 [1500 ± 125]
1. Use for all capscrews, bolts, and nuts coated only with the fastener manufacturer's rust preventive oil and use for
parts wiped or washed nearly free of oil. Do not use for plated parts.
2. Use for all capscrews and nuts whose threads and washer faces are lubricated.
Marine Vibration Isolator (016-026)

General Information
This illustration shows the different types of marine
isolators, and the location of the snubber and
corresponding gap used to determine loading of the
isolator.
1 Top nut
2 Leveling stud
3 Adjusting nut
4 Jam nut
5 Snubber gap.
Generally, it is recommended to replace isolators as a set,
but the age of the isolators and the conditions that caused
the damage need to be reviewed.
Isolators of different designs should not be mixed in the
same installation.
Initial Check
Check that the rubber portion of the isolator is not
cracked, damaged, or pushed out from the isolator
housing.
If the rubber is damaged, the isolator will need to be
replaced.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Marine Vibration Isolator
Check that the isolator is not fully compressed. If an

isolator is in the fully compressed condition, there will be
no clearance in the snubber gap.
If only one isolator is compressed, then the loading of the
isolators may be unbalanced. Reference the Install
Section of this procedure for steps to balance the load. If
the isolator is still compressed after adjusting the load,
then the isolator will need to be replaced.
If two isolators that are diagonally across from each other
are significantly more compressed or fully compressed,
then the loading on the isolators is unbalanced. Reference
the Install Section of this procedure for steps to balance
the load.
If two isolators that are both on one side of the engine or
both at the front or rear of the engine are fully
compressed, then the isolators will need to be replaced.
Check that the metal parts of the isolator are not

damaged, cracked, bent, or warped. If they are, the
isolator will need to be replaced.
Check for excessive corrosion. If corrosion is enough to
weaken the structure or impede the function of the
isolator, it will need to be replaced.
If an isolator is damaged or worn and less than one year
old, check that the isolator part number is correct for the
engine.
Check that the isolator mounting base is parallel with the

engine crankshaft centerline and that the stud is
perpendicular to the base, when looking from the side of
the engine. The oil pan flange can be used as a visual
reference. The engine support brackets must also be
parallel.
The alignment of the isolator base to the crank centerline
should be within four degrees of parallel.
The alignment of the isolator stud to the base should be
within four degrees of perpendicular.
Check that the isolator mounting base is parallel to the

transverse crankshaft centerline and that the stud is
perpendicular to the base when looking from the front or
back of the engine. The engine support brackets must
also be parallel.
The alignment of the isolator base to the transverse
crankshaft centerline should be within two degrees of
parallel.
The alignment of the isolator stud to the base should be
within two degrees of perpendicular.
Check that the isolator mounting base is parallel to the

crankshaft centerline when looking from the top of the
engine.
The alignment of the isolator base to the crankshaft
centerline should be within two degrees of parallel.
If the isolator is out of alignment, the mounting will need to

be adjusted. Wedges can be used to shim the base to
achieve proper alignment. Shims must be made of a solid
material that will not compress under the weight of the
engine.
Preparatory Steps
WARNING
battery cable last.
• Disconnect the battery. Refer to the original equipment
manufacturer (OEM) service manual.
• Disconnect the propeller shaft. Disengage the flange.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Marine Vibration Isolator
Entfernen Sie
WARNING
The engine needs to be supported before removing the
isolators. The amount of space available will determine
the best method for this support.
Remove the top nut from the isolator's adjusting stud.
Remove the bolts or capscrews retaining the isolator
base.
Raise the engine if necessary to facilitate the removal of
the isolator.
Make sure that any equipment used for hoisting of jacking
the engine is capable of handling the weight of the engine
and marine gear. Any engine component used for
attaching or support such as the lifting brackets or engine
supports must be correct for the engine. Reference the
appropriate manual for General Engine information in
Section V for the engine weight.
Remove the isolator.
If reusing the isolator, mark the position of the isolator
relative to the engine to make sure of installation in the
same location.
If replacing the worn or damaged isolator with a new
isolator, measure the height of the adjusting nut on the
stud to assist in setting the new isolator adjusting nut
height.
Inspect for Reuse

Inspect the vessel stringers or engine bed to make sure
they have not been damaged and that they can continue
to support the weight of the engine. This is especially true
of stringers constructed of wood, wood core, or hollow
fiberglass.
Inspect the mounting holes in the stringers or the engine
bed for damage. If the stringers, engine bed, or mounting
holes need to be repaired, contact an OEM qualified
repair location.
Install
Set the new isolator in place. Check that the isolator is
properly aligned. Reference the Initial Check section in
this procedure for alignment information.
Set the adjusting nut at the approximate height of the
isolator removed.
Replace other isolators that need to be changed using the
same technique.
Install the washer and top nut.
Lower the engine so that its weight is fully supported by
the isolators.
Verify that the isolators are loaded evenly. Depending on

the configuration of the engine, the weight may not be
evenly distributed on all four corners.
The engine will be heavier at either the front or back,
depending the on configuration. Therefore, the isolators
on the heavier end will be compressed more.
Check the snubber gap on all isolators.
If only one isolator or two isolators that are diagonally
across from each other are significantly more
compressed, the loading on the isolators is unbalanced.
Adjust the loading on the isolators by raising or lowering
the adjusting nut on the stud. Raising the adjusting nut will
increase the load. Lowering the adjusting nut will
decrease the load.
The engine should be lifted and the load removed from
the isolator before moving the adjusting nut, to prevent
damage to the threads.
Finishing Steps
WARNING
battery cable last.
• Align the propeller shaft. Refer to Procedure 016-025
in Section 16.
• Connect the battery cables. Refer to the OEM service
manual.
• Start the engine and check for proper operation.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Drive Shaft
Engine Drive Shaft (016-027)

General Information
Marine Applications
These instructions are for a single unit drive shaft, which
attaches to the engine and transmission with flange mount
U-joints. Some marine engines are equipped with drive
shafts that are various lengths, depending on the boat
builder design. This allows the engine to be mounted
some distance from the propulsion system drives. The
drive system discussed in this procedure is the Pod drive
shaft. This procedure will cover removal, alignment, and
installation.
Preparatory Steps
Marine Applications
WARNING
battery cable last.
in Section 13.
Remove
Marine Applications
Back out the capscrews (2) supporting the engine end
shield (1).
Support the shield while removing the last capscrew.
Remove the shield.
Back out the bolts (4) that are holding the two halves of
the transmission end shield together.
Back out the capscrews (2) that are supporting the upper
half of the drive shaft shield (1).
Remove the upper half of the shield.
Back out the capscrews, that are supporting the lower half
of the shield (3).
Remove the shield.
Engine Drive Shaft ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
WARNING
NOTE: The longer drive shafts can be very heavy. The
technician should consider whether two technicians are
needed for the procedure.
Back out the capscrews (1) from each end of the drive
shaft (2). Support the shaft while removing the last
capscrew from each end. Set the drive shaft to one side.
Setup
Marine Applications
Alignment Kit, Part Number 2892196
• Check the engine side coupler flange for proper
seating prior to alignment tool installation.
• Check all mating surfaces and magnets for debris
which could interfere with the alignment tool seating.
Install the alignment tool marked “ENGINE” to the engine

drive coupling flange with the blade parallel to the ground.
Install the alignment tool marked “GEAR” to the
transmission input flange with the blade parallel to the
ground.
Confirm that the tools are firmly attached with no
movement of any kind.
Pull out on the release lever to release the tools for

changing position or removal.
Do not pry the alignment tools off with a pry bar,
screwdriver, or similar tool, because damage can occur.
Make sure the release lever is disengaged when

measuring.
For drive shafts longer than 254 mm [10 in]:

• Insert the indicator line into the holes in the tool blades
using the pegs to hold the line tight.
• Install the line in the tool so not to interfere with free
movement of the line.
Make sure the line is tight and does not sag.
The alignment tool blades overlap with the 254 mm [10 in]
drive shaft installation and no indicator line is necessary.
When installing the alignment tools, confirm that the
blades are not against each other, and that the blades are
parallel to the ground.
Measure
Marine Applications
Drive shafts longer than 254 mm [10 in]:
• Check the horizontal alignment of the engine and pod.
Read the end of the tool where the line crosses the
degree scale.
Move the engine side to side to get as close to “0” as
possible.
Rotate both tools 180 degrees.
Confirm that the readings in this position are the same as
the previous test. If not, check the tool fit-up to the flanges
again.
Horizontal Alignment: 0 degrees ± 1/2 degree.
Check the vertical alignment:

• Rotate both tools 90 degrees so they are
perpendicular to the ground.
Read the angles of the pod and engine where the lines
cross the scales at the free end of the blades. This gives
the operator the vertical angles of the engine and pod.
The readings on both scales should be very close to the
same.
Vertical Alignment: 2 degrees ± 1 degree.
Drive shafts 254 mm [10 in]:

• Check the horizontal alignment of the pod and engine
read the angle where the tool center lines cross the
scale at the free end of the blades.
Move the engine side to side to get as close to “0”
degrees as possible on the pod and engine ends.
Horizontal Alignment: 0 degrees ± 1/2 degree.
Rotate both tools 90 degrees so they are perpendicular to

the ground.
Check the vertical alignment of the engine and pod:
• Read the angle where the tool center lines cross the
scales at the free ends of the blades.
Adjust
Marine Applications
Adjust the engine mounts to get as close to 2 degrees as
possible on both the engine and pod ends.
The readings on both scales should be very close to the
same.
Vertical alignment: 2 degrees ± 1 degree.
Install
Marine Applications
WARNING
NOTE: The longer drive shafts can be very heavy. The
technician should consider whether two technicians are
needed for this procedure.
Fully collapse (push) the splined portion of the drive shaft
(1) together.
Attach the drive shaft to the transmission input shaft
flange (2).
Tighten the four locknuts (3) on the four (1/2-20 x 1.12 in
long) transmission input shaft flange bolts.
Attach the drive shaft (1) to the engine coupler (2).

Tighten the four capscrews (3) (1/2-20 x 2-1/ 2 in long) on
the engine coupler (2).
Lubricate the drive shaft slip-joint (1) through the grease

fitting (2) by applying approximately 3 to 6 pumps of the
specified grease from a typical hand-operated grease
gun.
Use Mercury™ Engine Coupler Spline Grease, Part
Number 92-802869A1, or equivalent.
Drive shafts over 254 mm [10 in] have a grease fitting in

the cross member of the U joints (1). These should be
lubricated with the specified grease.
Use Mercury™ U-joint and Gimbal Bearing Grease, Part
Number 92-802870A1, or equivalent.
Install the top (1) and bottom (3) drive shaft shields on the
transmission end as shown.
Coat the capscrew threads with Loctite™ 277, or
equivalent.
Install the bolts (4) which are securing the two halves of
the drive shaft shield.
Tighten the drive shaft shield retaining capscrews (2),
capscrews (4) and nuts on the transmission end.
Torque Value:
Socket Head Capscrew (2) 36 N•m [ 27 ft-lb ]
Torque Value:
Capscrew and Nut (4) 23 N•m [ 204 in-lb ]
Install the engine end drive shaft shield (1) in the flywheel
housing cover.
Coat the capscrew threads with Loctite™ 277, or
equivalent.
Tighten the drive shaft shield retaining capscrews (2).
Finishing Steps
Marine Applications
WARNING
battery cable last.
Section 13.
• Operate the equipment and check for operation and
loose components.
Section 17 - Miscellaneous - Group 17 Page 17-a
Section 17 - Miscellaneous - Group 17

Section Contents
Page
Cup Plug ....................................................................................................................................................................17-1
Install........................................................................................................................................................................17-2
Remove....................................................................................................................................................................17-1
Expansion Plug .........................................................................................................................................................17-6
Install........................................................................................................................................................................17-7
Remove....................................................................................................................................................................17-6
Pipe Plug ....................................................................................................................................................................17-2
Install........................................................................................................................................................................17-3
Remove....................................................................................................................................................................17-2
Straight Thread Plug .................................................................................................................................................17-4
Install........................................................................................................................................................................17-5
Remove....................................................................................................................................................................17-4
Page 17-b Section 17 - Miscellaneous - Group 17

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cup Plug
Section 17 - Miscellaneous - Group 17 Page 17-1
Cup Plug (017-002)

Entfernen Sie
CAUTION
Do not allow metal shavings to fall in the engine when
drilling a hole in the cup plug. Damage to engine
components can occur.
Use a center punch to mark the cup plug for drilling.
Drill an 1/8-inch hole into the cup plug.
Use a dent puller to remove the plug.

Discard all used cup plugs. Do not use them again.

Thoroughly clean the cup plug hole using Scotch-Brite™,
or equivalent. Use spray cleaner, Cummins Part Number
3375433, or equivalent, to perform a final clean of the
bore.
Inspect the cup plug bores for damage.
Pipe Plug ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 17-2 Section 17 - Miscellaneous - Group 17
Install
CAUTION
Excessive sealant can run back into the engine and
cause damage to other components. Allow the
sealant to dry for a minimum of 2 hours before
operating the engine. The plug can come out of the
bore if the sealant is not dry.
Apply a 2 mm [1/16 in] bead of cup plug sealant, Part
Number 3375068, or equivalent to the outside
circumference of the cup plug and the inside diameter of
cup plug bore.
NOTE: Do not install a used cup plug. Discard all plugs
after removal.
Install the cup plug with the appropriate cup plug driver.
See the Service Tools Catalog, Bulletin Number 3377710.
CAUTION
Do not install the cup plug too deeply. If the cup plug
is not installed straight and flat, it must be replaced
with a new cup plug.
The cup plug must be installed with the edge of the cup
plug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than the
leading chamber of the bore.
Pipe Plug (017-007)

Entfernen Sie
Remove the pipe plug.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Pipe Plug

Center Sump Pan
Use spray cleaner, Part Number 3375433, or equivalent
to clean the threads of the pipe plugs and threaded bores.
Inspect the threads of the pipe plugs for mutilation or

damage.
Inspect the threaded bores for damage.
Install
Apply a film of pipe plug sealant, Part Number 3375066,
or equivalent to the threads.
Install and tighten the pipe plugs.
Refer to the following illustration for torque values.
Tighten pipe plugs to the appropriate torque values.
Straight Thread Plug ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Straight Thread Plug (017-011)

General Information
Two types of straight thread plugs are used:
1 Straight thread plug with o-ring
2 Straight thread plug with formed in-place sealant.
The two plugs are interchangeable and reusable. The
only difference between the two plugs is the installation
torque value. See the install step of this procedure.
Remove
Select the appropriate size Allen wrench or socket, and
remove the plug.

Use spray cleaner, Part Number 3375433, or equivalent,
to clean the threads of the straight-thread plugs and
threaded bores.
Inspect the threads of the pipe plugs for mutilation or

damage.
Replace the plugs, if damaged.
Inspect the threaded bores for damage.
Repair the bores, if necessary.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Straight Thread Plug
For straight thread plugs with an o-ring, inspect the o-ring

for cuts, tears, or deformation. Replace the o-ring if
necessary.
For straight thread plugs with formed in-place sealant,
inspect the sealant for damage. If damaged, replace the
entire plug.
Install
If equipped with a straight thread plug with o-ring, install a
new o-ring on the straight-thread plug, if required.
Lubricate the o-ring with clean 15W-40 oil.
Install and tighten the plug.
Torque Value:
M10 10 N•m [ 89 in-lb ]
Torque Value:
M12 20 N•m [ 177 in-lb ]
Torque Value:
M14 25 N•m [ 221 in-lb ]
Torque Value:
M16 35 N•m [ 25 ft-lb ]
Torque Value:
M18 45 N•m [ 33 ft-lb ]
If equipped with a straight thread plug with formed in-

place sealant, install and tighten the plug.
Torque Value:
M10 18 N•m [ 160 in-lb ]
Torque Value:
M12 25 N•m [ 221 in-lb ]
Torque Value:
M14 30 N•m [ 22 ft-lb ]
Torque Value:
M16 40 N•m [ 30 ft-lb ]
Torque Value:
M18 50 N•m [ 37 ft-lb ]
Expansion Plug ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Expansion Plug (017-015)

Entfernen Sie
CAUTION
Do not allow metal shavings to fall in the engine when
drilling a hole in the expansion plug. Damage to
engine components can occur.
Use a center punch to mark the expansion plug for
drilling.
Drill an 1/8-inch hole into the expansion plug.
Use a dent puller to remove the plug.

Discard all used expansion plugs and expansion plug o-
rings. Do not use them again.

Thoroughly clean the expansion plug hole using Scotch-
Brite™ or equivalent. Use spray cleaner, Cummins® Part
Number 3375433 or equivalent, to perform a final cleaning
of the bore.
Inspect the expansion plug bores for damage.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Expansion Plug
Install
Install the expansion plug o-ring into the bore.
Install the expansion plug with the convex side facing out.
Use a hammer and a flat driver to strike the expansion

plug twice to flatten the plug against the o-ring.
Check the plug for proper installation.

• The installed plug must not protrude above the edge
of the bore.
• The installed plug must not be more than 1 to 3.5 mm
[0.04 to 0.14 in] below the edge of the bore.
Expansion Plug ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Notes
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
Finishing Steps.........................................................................................................................................................20-9
Install........................................................................................................................................................................20-2
Remove....................................................................................................................................................................20-1
Engine Brake Housing Spacer ................................................................................................................................20-9
Finishing Steps.......................................................................................................................................................20-10
Install...................................................................................................................................................................... 20-10
Remove....................................................................................................................................................................20-9
Engine Brake Solenoid Valve ................................................................................................................................20-10
Finishing Steps.......................................................................................................................................................20-11
Install...................................................................................................................................................................... 20-11
Remove.................................................................................................................................................................. 20-11
Engine Brake Wiring Harness ............................................................................................................................... 20-12
Finishing Steps.......................................................................................................................................................20-14
Install...................................................................................................................................................................... 20-13
Remove.................................................................................................................................................................. 20-12
Resistance Check...................................................................................................................................................20-13
Page 20-b Section 20 - Vehicle Braking - Group 20

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Brake Assembly
Section 20 - Vehicle Braking - Group 20 Page 20-1
Engine Brake Assembly (020-004)

Preparatory Steps
WARNING
battery cable last.
in Section 13.
Remove
Disconnect the wiring harness from the electrical
connectors in the rocker lever housing.
NOTE: It is easier to remove the wire from the rocker

lever housing after the brake is removed.
Unplug the wires from the brake solenoid.
NOTE: Use only grade 12.9 mounting capscrews for

engine brake assemblies. Verify all mounting capscrews
are grade 12.9. If any capscrews are found that are not
grade 12.9, replace the capscrews.
Remove the six mounting capscrews and flat washers
from one or both of the engine brake assemblies, as
required.
NOTE: Engines with an engine serial number (ESN) of
73001424 and higher use a bracket underneath the
mounting capscrews above cylinders 1 and 4 in place of a
hardened washer. This bracket is used to route the
solenoid wire away from moving parts and prevent wire
chaffing.
Engine Brake Assembly ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page 20-2 Section 20 - Vehicle Braking - Group 20
Remove the brake assembly or assemblies, as required.

Remove the adjusting cap from the exhaust rocker arms.
Remove the rocker lever housing, if necessary. Refer to
WARNING
WARNING
Clean the engine brake assembly with solvent and a
brush.
Inspect the engine brake assembly for cracks or any other
damage.
Install
If necessary, check and set the valve lash prior to
installing the engine brake. Refer to Procedure 003-004 in
Section 3.
To install the engine brake specific crossheads and rocker
lever hold-downs. Refer to Procedure 003-008 in Section
3.
If necessary, install the rocker lever housing and mounting
bolts. Refer to Procedure 003-013 in Section 3.
At the intake mounting stud (cylinder 1 and/or cylinder 4)

lubricate the oil adapter and o-ring with lubricating oil.
Install the engine brake overhead assembly.
NOTE: Make sure the oil supply adapter at the intake
manifold stud is fitted into the oil supply hole in the brake
assembly.
CAUTION
Use only grade 12.9 mounting capscrews for engine
brake assemblies. Verify all mounting capscrews are
grade 12.9. If any capscrews are found that are not
grade 12.9, replace the capscrews.
Install the six 10-mm mounting capscrews (three for the
front brake assembly, three for the rear brake assembly)
with flat washers at the brake mounting spacers (exhaust
side of engine) and hand-tighten.
mounting capscrews above cylinders numbers 1 and 4 in
place of a hardened washer. This bracket is used to route
the solenoid wire away from moving parts and prevent
wire chaffing.
NOTE: Do not tighten the capscrews to their final torque
specification at this time.
Turn the adjusting sleeves in the engine brake housing

until they make contact with the rocker arm pedestals. No
preload must be imparted on the housing.
Install the six 10-mm mounting capscrews (three for the

front brake assembly, three for the rear brake assembly)
with flat washers (intake side of the engine).
mounting capscrews above cylinders 1 and 4 in place of a
hardened washer. This bracket is used to route the
solenoid wire away from moving parts and prevent wire
chaffing.
Tighten the six 10-mm mounting capscrews for the front
brake assembly and the six 10-mm mounting capscrews
for the rear brake assembly.
NOTE: No tightening sequence is required but the
capscrews can be tightened in a crossing sequence.
Install the wires to the terminals on the inside of the

spacer.
NOTE: The longer wire must be connected to the front
engine brake solenoid. It is possible to install the wires in
the incorrect orientation, which will result in an
interference with the rocker levers.
NOTE: On engines equipped with a bracket to prevent the

wire from chaffing, secure the wire to the bracket, Part
Number 4890404.
Connect the wires from the terminals on the inside of the
spacer to the solenoid.
Adjust
Use barring tool, Part Number 3824591, to rotate the

crankshaft to align the mark on the fuel pump gear with
the top dead center mark on the gear cover.
When the engine is in the top dead center position, brake

lash can be set on cylinders 1, 3, and 5.
Use two wrenches to hold the adjusting nut and loosen
the lock nuts on the brake at cylinders 1, 3, and 5.
Brake Lash - Feeler Gauge Method

Insert the appropriate brake lash feeler gauge between
the brake slave piston and exhaust crosshead pin on
cylinder 1.
Brake Lash - Feeler Gauge
Tool Part Lash
Number Specification
3163681 2.286 mm
[0.090 in]
NOTE: If the correct size feeler gauge is not available
there is an alternate dial indicator method for setting the
brake lash following in this procedure.
Use the 0.68 N•m [6 in-lb] torque wrench, Part Number

3376592, to tighten the adjusting nut until the torque
wrench "clicks" or until drag is felt on the feeler gauge.
Remove the feeler gauge. Use two wrenches to hold the

adjusting nut and tighten the locknut.
Repeat for cylinders 3 and 5.
Use the engine barring tool, Part Number 3824591, to

rotate the crankshaft 360 degrees to align the mark on the
fuel pump gear with the mark on the gear cover that is
180 degrees away from top dead center.
When the engine is in position, brake lash can be set on
cylinders 2, 4, and 6.
Insert the appropriate brake lash feeler gauge between

the brake sleeve piston and the exhaust crosshead pin on
cylinder 2.
Brake Lash - Feeler Gauge
Tool Part Lash
Number Specification
3163681 2.286 mm
[0.090 in]
Use a 6 in-lb torque wrench, Part Number 3376592, to

tighten the adjusting nut until the torque wrench "clicks" or
until drag is felt on the feeler gauge.
Remove the feeler gauge. Use two wrenches to hold the

adjusting nut and tighten the locknut.
The following method can be used instead of the feeler

gauge method if a feeler gauge of the proper size is not
available.
Use barring tool, Part Number 3824591, to rotate the
crankshaft to align the mark on the fuel pump gear with
the top dead center mark on the gear cover.
Brake Lash - Dial Indicator

Tighten the backlash adjusting nut on cylinder 1 until
resistance is felt. Place the dial indicator tip on the
adjusting nut and zero the dial indicator. Turn the lash
adjusting nut in a counterclockwise direction until the
appropriate lash is reached.
Brake Lash Specification 2.286 mm [ 0.090 in ]
Use two wrenches to hold the adjusting nut and tighten

the locknut.
Use engine barring tool, Part Number 3824591, to rotate

the crankshaft 360 degrees to align the mark on the fuel
pump gear with the mark on the gear cover that is 180
degrees away from top dead center.
When the engine is in position, brake lash can be set on
cylinders 2, 4, and 6.
Tighten the backlash adjusting nut on cylinder number 2

until resistance is felt. Place the dial indicator tip on the
adjusting nut and zero the dial indicator. Turn the lash
adjusting nut in a counterclockwise direction until the
appropriate lash is reached.
Brake Lash Specification 2.286 mm [ 0.090 in ]
Use two wrenches, hold the adjusting nut and tighten the
locknut.
Install the plastic fuel pump drive cover located on the

front of the engine.
Install the rocker lever cover.

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Brake Housing Spacer
Finishing Steps
WARNING
battery cable last.
• Operate the engine and verify proper engine brake
operation.
Engine Brake Housing Spacer

(020-007)
Preparatory Steps
003-011.
Remove the engine brake assemblies. Refer to Procedure
020-004.
Entfernen Sie
CAUTION
Do not damage the mounting surface of the spacer
when removing it from the cylinder head, or oil leaks
can result when the spacer is installed.
Remove the engine brake spacer 5 mounting capscrews.
Carefully remove the engine brake spacer from the
cylinder head.
CAUTION
Be sure to remove all RTV from the groove in the
mounting surface spacer, or oil leaks can result after
installation.
Carefully clean the RTV from the mounting surface of the
spacer.
Clean all RTV from the top of cylinder head where the
spacer is mounted.
Inspect the engine brake spacer for cracks or any other
damage, especially on the cylinder head mounting
surface.
Engine Brake Solenoid Valve ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Install
CAUTION
To minimize the possibility of oil leaks, allow the RTV
to cure for at minimum 1 hour prior operating the
engine.
NOTE: Once the RTV has been applied, make sure to
install the spacer within 15 minutes.
Apply a continuous bead of RTV in the groove around the
brake spacer.
Install the engine brake spacer and the 5 mounting

capscrews.
Finishing Steps
Install the engine brake assemblies. Refer to Procedure
020-004.
Install the rocker lever cover. Refer to Procedure 003-011.
Engine Brake Solenoid Valve (020-012)

Preparatory Steps
WARNING
battery cable last.
in Section 13.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Brake Solenoid Valve
Remove
Disconnect the engine brake wiring harness from the
solenoid.
Remove the solenoid and discard the o-rings.
Install
Install new o-rings and the solenoid.
Tighten the solenoid.
Connect the engine brake wiring harness to the solenoid.
Finishing Steps
WARNING
battery cable last.
Section 13.
• Operate the engine, check for leaks, and verify proper
engine brake operation.
Engine Brake Wiring Harness ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Engine Brake Wiring Harness

(020-015)
Preparatory Steps
WARNING
battery cable last.
in Section 13.
Remove
Remove the engine plug connector at the engine brake
spacer.
Remove the engine receptacle connector retaining nut
and o-ring.
Remove the engine receptacle from the engine brake
spacer.
Disconnect the solenoid wires.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Brake Wiring Harness
Resistance Check
Insert a test lead into pin A in the brake harness.
Insert the other test lead into the corresponding engine
pass-through terminal connector in the brake harness.
Measure the resistance. The multimeter must read a
closed circuit (10 ohms or less).
Remove the test lead from pin A and insert it into pin B.
Insert the other test lead into the corresponding engine
pass-through terminal connector.
Measure the resistance. The multimeter must read a
closed circuit (10 ohms or less).
If the resistance values are not correct, inspect the wires
for an open circuit.
Install
Install the engine receptacle into the engine brake spacer.
Install the engine receptacle connector retaining o-ring
and tighten the nut.
Install the engine plug connector at the rocker lever

housing.
Engine Brake Wiring Harness ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Connect the solenoid wires.
Finishing Steps
WARNING
battery cable last.
Section 13.
• Operate the engine and verify proper engine brake
operation.
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
Service Literature Ordering Location .......................................................................................................................L-2
Contact Information....................................................................................................................................................L-2
Page L-b Section L - Service Literature

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Additional Service Literature
Section L - Service Literature Page L-1
Additional Service Literature

General Information
The following publications can be purchased.
Bulletin Title of Publication

Number
3666271 ISC, QSC8.3, and ISL Electronic Control System Troubleshooting and Repair Manual
4021416 ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL, ISLe3, ISLe4, and QSL9
CM850 Electronic Control System Troubleshooting and Repair Manual
4021418 ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Troubleshooting and Repair Manual
3666121 Holset® Air Compressors Master Repair Manual
4022281 SmartCraft™ Marine Control System
3666267 ISC CM554 Wiring Diagram
3666395 QSC CM554 Wiring Diagram
3666416 ISL CM554 Wiring Diagram
3666478 QSL9 CM554 Wiring Diagram
4021421 ISC and ISL CM850 Electronic Control Module Wiring Diagram
4021524 QSB4.5, QSB6.7, QSC8.3 and QSL9 CM850 Electronic Control System Wiring Diagram
4021598 ISLe4 CM850 Wiring Diagram
4081885 QSL9 and QSC8.3 Marine CM850 Electronic Control Module with SmartCraft™ 1.0 Wiring Diagram
4082045 SmartCraft™ 2.2 Zeus™ Wiring Diagram
4082050 SmartCraft™ 2.2 Digital Throttle and Shift (DTS) Wiring Diagram
4082051 SmartCraft™ 2.2 Non-Digital Throttle and Shift (Non-DTS) Wiring Diagram
4082052 Asius System Wiring Diagram
4021428 OISC, ISCe, and ISL Operation and Maintenance Manual
4021518 QSC8.3 and QSL9 Operation and Maintenance Manual
4021557 ISLe3 and ISLe4 (Common Rail Fuel System) Operation and Maintenance Manual
4021571 ISLe3 and ISLe4 (Common Rail Fuel System) Operation and Maintenance Manual
4081893 CMD Smartcraft™ Diesel View Configuration and Operation Manual
4081961 CMD System Speedometer and Tachometer Operation Manual
4021481 QSC8.3 and QSL9 Marine Owners Manual
4915536 QSC8.3 and QSL9 Owners Manual
3379000 Air for Your Engine
3379001 Fuel for Cummins® Engines
3379009 Operation of Diesel Engines in Cold Climates
3666132 Cummins® Coolant Requirements and Maintenance
3810303 Parts Reuse Guidelines
3810340 Cummins® Engine Oil and Oil Analysis Recommendations
3884649 Marine Recreational B and C Installation Directions
4021566 Diesel Exhaust Fluid (DEF) Specifications for Cummins® Selective Catalytic Reduction (SCR)
Systems
Service Literature Ordering Location ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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 https://
store.cummins.com
All Other Countries Cummins Distributors or Dealers
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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 contain 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.
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 Cummins QuickServe Online.
Additional Features of the Customized Catalog include:
• Engine Configuration Data
• Table of Contents
• Separate Option and Parts Indexes
• Service Kits (when applicable)
• ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog

Ordering by Telephone
• North American Distributors, Original Equipment Manufacturers and Cummins Factory personnel order by calling
Iron Mountain Fulfillment Services (IMFS) at 1-800-646-5609.
• International Distributors and Original Equipment Manufacturers order the CPC from their regional Cummins Parts
Distribution Centers (PDC).
• International PDC orders are called into Iron Mountain at (++) 630-283-2420.
• Retail Credit Card Orders require a 2 step ordering process.
Ordering On-Line
Access the Cummins QSOL store at https://store.cummins.com
• Find the Customized Parts Catalog button located on the left of the homepage
• Select format. Your Price is also shown here
• Finalize Shopping Cart and Check Process as described on the website
North America call Iron Mountain Fulfillment Services (IMFS) at 800-646-5609, International customers call (++)
630-283-2420. Provide IMFS the catalog detail as described on the website. This step is required until we have our On
Line form available.
Required information needed for your Customized Parts Catalog Order.
• Customer Name
• Street Address
• Company Name (optional)
• Telephone no.
• Credit Card No.
• Cummins Engine Serial Number (located on the engine data plate)
Unfortunately not all Cummins Engines can be supported by Customized Parts Catalogs. 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 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page L-4 Section L - Service Literature
Notes
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Air Intake System .....................................................................................................................................................V-67
Specifications...........................................................................................................................................................V-67
Air Intake System - Group 10 - Specifications .......................................................................................................V-42
Turbocharger............................................................................................................................................................V-42
Air Intake System - Group 10 - Torque Values ......................................................................................................V-43
Aftercooler Assembly (Sea Water)...........................................................................................................................V-43
Air Crossover............................................................................................................................................................V-43
Air Inlet Connection..................................................................................................................................................V-43
Air Intake Connection...............................................................................................................................................V-45
Air Intake Connection Adapter................................................................................................................................. V-46
Air Intake Manifold Cover.........................................................................................................................................V-45
Turbocharger............................................................................................................................................................V-43
Turbocharger Actuator Air Line................................................................................................................................V-45
Turbocharger Coolant Hoses...................................................................................................................................V-44
Turbocharger Exhaust Connection Adapter.............................................................................................................V-46
Turbocharger Oil Drain Line.....................................................................................................................................V-44
Turbocharger Oil Supply Line...................................................................................................................................V-44
Turbocharger Wastegate Actuator...........................................................................................................................V-45
Variable Geometry Turbocharger Actuator, Pneumatic........................................................................................... V-45
Barometric Pressure at Altitude ............................................................................................................................. V-81
Cam Followers/Tappets - Group 04 - Specifications .............................................................................................V-17
Tappet......................................................................................................................................................................V-17
Cam Followers/Tappets - Group 04 - Torque Values ............................................................................................V-18
Tappet......................................................................................................................................................................V-18
Capscrew Markings and Torque Values ................................................................................................................ V-74
Capscrew Markings and Torque Values - Metric..................................................................................................... V-74
Capscrew Markings and Torque Values - U.S. Customary......................................................................................V-75
General Information..................................................................................................................................................V-74
Compressed Air System ..........................................................................................................................................V-70
Cummins 18.7 CFM Model....................................................................................................................................V-70
Compressed Air System - Group 12 - Torque Values ...........................................................................................V-50
Air Compressor........................................................................................................................................................ V-50
Air Compressor Cylinder Head, Single Cylinder...................................................................................................... V-50
Air Compressor Rear Bearing Housing, Two Cylinder.............................................................................................V-51
Cooling System ........................................................................................................................................................ V-66
Cooling System - Group 08 - Specifications ..........................................................................................................V-34
Belt Tensioner, Automatic (Water Pump).................................................................................................................V-34
Coolant Thermostat..................................................................................................................................................V-34
Fan Spacer and Pulley.............................................................................................................................................V-34
Zinc Anode...............................................................................................................................................................V-34
Cooling System - Group 08 - Torque Values ......................................................................................................... V-35
Belt Guard................................................................................................................................................................V-35
Belt Tensioner, Automatic (Water Pump).................................................................................................................V-39
Bracket, Fan Idler Pulley..........................................................................................................................................V-40
Coolant Filter Head.................................................................................................................................................. V-35
Coolant Filter Valve..................................................................................................................................................V-35
Coolant Heater.........................................................................................................................................................V-35
Coolant Return Junction Block.................................................................................................................................V-40
Coolant Thermostat..................................................................................................................................................V-35
Coolant Thermostat Housing....................................................................................................................................V-35
Coolant Thermostat Housing Support......................................................................................................................V-36
Coolant Thermostat Seal..........................................................................................................................................V-36
Expansion Tank........................................................................................................................................................V-37
Fan, Cooling.............................................................................................................................................................V-36
Page V-b Section V - Specifications
Heat Exchanger........................................................................................................................................................V-38
Marine Gear Oil and Fuel Cooler Assembly.............................................................................................................V-40
Marine Gear Oil Cooler............................................................................................................................................ V-36
Pulley, Fan Idler....................................................................................................................................................... V-39
Sea Water Pump......................................................................................................................................................V-38
Water Inlet Connection.............................................................................................................................................V-39
Water Pump............................................................................................................................................................. V-39
Zinc Anode...............................................................................................................................................................V-39
Cummins®/Fleetguard® Filter Specifications .......................................................................................................V-72
Cylinder Block - Group 01 - Specifications ..............................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Camshaft....................................................................................................................................................................V-1
Camshaft Bushings....................................................................................................................................................V-1
Camshaft Gear (Camshaft Installed)..........................................................................................................................V-2
Connecting Rod..........................................................................................................................................................V-2
Crankshaft..................................................................................................................................................................V-3
Crankshaft Gear, Front (Crankshaft Removed).........................................................................................................V-4
Cylinder Block............................................................................................................................................................V-4
Cylinder Liner.............................................................................................................................................................V-5
Piston.........................................................................................................................................................................V-6
Piston and Connecting Rod Assembly.......................................................................................................................V-6
Piston Rings...............................................................................................................................................................V-6
Cylinder Block - Group 01 - Torque Values .............................................................................................................V-7
Bearings, Main...........................................................................................................................................................V-7
Camshaft....................................................................................................................................................................V-7
Camshaft Gear (Camshaft Installed)..........................................................................................................................V-7
Camshaft Gear (Camshaft Removed)........................................................................................................................V-7
Crankshaft Seal, Front...............................................................................................................................................V-7
Crankshaft Speed Indicator Ring...............................................................................................................................V-9
Crankshaft Wear Sleeve, Front..................................................................................................................................V-8
Crankshaft Wear Sleeve, Rear...................................................................................................................................V-9
Cylinder Block............................................................................................................................................................V-8
Cylinder Liner.............................................................................................................................................................V-8
Gear Cover, Front......................................................................................................................................................V-8
Gear Housing, Front...................................................................................................................................................V-8
Piston and Connecting Rod Assembly.......................................................................................................................V-9
Piston Cooling Nozzle................................................................................................................................................V-8
Vibration Damper, Rubber..........................................................................................................................................V-9
Vibration Damper, Viscous.........................................................................................................................................V-9
Cylinder Head - Group 02 - Specifications .............................................................................................................V-10
Cylinder Head...........................................................................................................................................................V-10
Cylinder Head - Group 02 - Torque Values ............................................................................................................ V-13
Cylinder Head...........................................................................................................................................................V-13
Valve Guide Seal, Cylinder Head.............................................................................................................................V-13
Drive Belt Tension ....................................................................................................................................................V-73
Tension Chart...........................................................................................................................................................V-73
Drive Units - Group 09 - Torque Values ..................................................................................................................V-41
Belt Tensioner, Refrigerant Compressor, Automatic................................................................................................V-41
Hydraulic Pump Drive...............................................................................................................................................V-41
Refrigerant Compressor Mounting Bracket..............................................................................................................V-41
Electrical Equipment - Group 13 - Specifications ................................................................................................. V-52
Starting Motor...........................................................................................................................................................V-52
Electrical Equipment - Group 13 - Torque Values .................................................................................................V-53
Alternator..................................................................................................................................................................V-53
Alternator Bracket.....................................................................................................................................................V-53
ECM Unswitched Power Terminal Blocks................................................................................................................V-53
Starting Motor...........................................................................................................................................................V-53
Electrical System ......................................................................................................................................................V-69
Batteries (Specific Gravity).......................................................................................................................................V-69
Engine Testing ..........................................................................................................................................................V-71
Engine Testing - Group 14 - Specifications ...........................................................................................................V-55
Section V - Specifications Page V-c
Engine Run-in (Engine Dynamometer).................................................................................................................... V-55

Engine Testing (In Chassis).....................................................................................................................................V-55
Exhaust System ........................................................................................................................................................V-68
Exhaust System - Group 11 - Specifications .........................................................................................................V-47
Exhaust Manifold, Dry..............................................................................................................................................V-47
Exhaust System - Group 11 - Torque Values .........................................................................................................V-48
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter............................................................................................V-49
Aftertreatment Nozzle...............................................................................................................................................V-48
Aftertreatment Selective Catalytic Reduction (SCR) Catalyst..................................................................................V-48
Exhaust Gas Temperature Sensor...........................................................................................................................V-48
Exhaust Manifold, Dry..............................................................................................................................................V-48
Exhaust Manifold, Wet.............................................................................................................................................V-48
Exhaust Outlet Connection.......................................................................................................................................V-48
Fraction, Decimal, Millimeter Conversions ............................................................................................................V-76
Conversion Chart.....................................................................................................................................................V-76
Fuel System ..............................................................................................................................................................V-63
Fuel System - Group 05 - Specifications ................................................................................................................V-19
Fuel Lift Pump..........................................................................................................................................................V-19
Fuel Pump Cam Housing Module............................................................................................................................V-19
Fuel Pump Gear Pump.............................................................................................................................................V-19
Fuel System - Group 05 - Torque Values ...............................................................................................................V-20
Engine Fuel Heater, Electric.....................................................................................................................................V-20
Fuel Injection Pump..................................................................................................................................................V-23
Fuel Lift Pump..........................................................................................................................................................V-21
Fuel Pump................................................................................................................................................................V-20
Fuel Pump Accumulator Module..............................................................................................................................V-22
Fuel Pump Actuator Housing...................................................................................................................................V-23
Fuel Pump Delivery Valve........................................................................................................................................V-20
Fuel Pump Distributor and Injection Control Valve Module......................................................................................V-22
Fuel Pump Distributor Inlet Fitting............................................................................................................................V-21
Fuel Pump Gear Pump.............................................................................................................................................V-20
Fuel Pump Head......................................................................................................................................................V-22
Fuel Pump Head Outlet Fitting.................................................................................................................................V-22
Fuel Pump Rate Shape Tube...................................................................................................................................V-22
Injection Control Valve.............................................................................................................................................V-21
Rotor, CAPS Fuel Injection Pump............................................................................................................................V-21
Snubber, Rate Shape...............................................................................................................................................V-21
General Engine .........................................................................................................................................................V-62
Injectors and Fuel Lines - Group 06 - Specifications ............................................................................................V-24
Fuel Drain Line Restriction.......................................................................................................................................V-24
Fuel Filter (Spin-On Type)........................................................................................................................................V-24
Injectors and Fuel Lines - Group 06 - Torque Values ...........................................................................................V-25
Engine Control Module Cooling Plate, Fuel Cooled.................................................................................................V-25
Fuel Connector (Head Mounted)..............................................................................................................................V-28
Fuel Cooler...............................................................................................................................................................V-29
Fuel Drain Lines.......................................................................................................................................................V-25
Fuel Filter Head........................................................................................................................................................V-25
Fuel Filter Head Bracket...........................................................................................................................................V-26
Fuel Pressure Relief Valve.......................................................................................................................................V-29
Fuel Pump Air Bleed Line.........................................................................................................................................V-28
Fuel Rail...................................................................................................................................................................V-29
Fuel Rail High Pressure Fitting.................................................................................................................................V-29
Fuel Supply Lines.....................................................................................................................................................V-26
Injector......................................................................................................................................................................V-27
Injector Supply Lines (High Pressure)......................................................................................................................V-28
Lubricating Oil System ............................................................................................................................................V-64
Lubricating Oil System - Group 07 - Specifications ..............................................................................................V-30
Lubricating Oil Cooler...............................................................................................................................................V-30
Lubricating Oil Pump................................................................................................................................................V-30
Lubricating Oil System - Group 07 - Torque Values .............................................................................................V-31
Page V-d Section V - Specifications
Engine Oil Heater.....................................................................................................................................................V-31

Lubricating Oil Cooler...............................................................................................................................................V-31
Lubricating Oil Filter Bypass Valve...........................................................................................................................V-31
Lubricating Oil Filter Head........................................................................................................................................V-31
Lubricating Oil Filter Head (Remote-Mounted).........................................................................................................V-31
Lubricating Oil Filter Head Adapter..........................................................................................................................V-32
Lubricating Oil High Pressure Relief Valve..............................................................................................................V-32
Lubricating Oil Lines.................................................................................................................................................V-33
Lubricating Oil Pan...................................................................................................................................................V-32
Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-32
Lubricating Oil Pump................................................................................................................................................V-32
Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-32
Lubricating Oil System.............................................................................................................................................V-33
Miscellaneous - Group 17 - Torque Values ............................................................................................................V-60
Mounting Adaptations - Group 16 - Specifications ...............................................................................................V-56
Flywheel...................................................................................................................................................................V-56
Flywheel Housing.....................................................................................................................................................V-56
Flywheel Housing, REPTO.......................................................................................................................................V-56
Mounting Adaptations - Group 16 - Torque Values ...............................................................................................V-57
Engine Drive Shaft...................................................................................................................................................V-59
Engine Support Bracket, Front.................................................................................................................................V-57
Engine Support Bracket, Rear..................................................................................................................................V-57
Flexplate...................................................................................................................................................................V-57
Flywheel...................................................................................................................................................................V-58
Flywheel Housing.....................................................................................................................................................V-58
Flywheel Housing, REPTO.......................................................................................................................................V-58
Newton-Meter to Foot-Pound Conversions ...........................................................................................................V-77
Pipe Plug Torque Values .........................................................................................................................................V-78
Torque Table............................................................................................................................................................V-78
Rocker Levers - Group 03 - Specifications ............................................................................................................V-14
Overhead Set...........................................................................................................................................................V-14
Rocker Lever............................................................................................................................................................V-14
Rocker Levers - Group 03 - Torque Values ............................................................................................................V-15
Crankcase Breather (External).................................................................................................................................V-15
Crankcase Breather (Internal)..................................................................................................................................V-15
Crankcase Breather Tube........................................................................................................................................V-16
Overhead Set...........................................................................................................................................................V-15
Rocker Lever............................................................................................................................................................V-15
Rocker Lever Cover.................................................................................................................................................V-16
Rocker Lever Housing..............................................................................................................................................V-16
Tap-Drill Chart - U.S. Customary and Metric ..........................................................................................................V-79
Vehicle Braking - Group 20 - Torque Values .........................................................................................................V-61
Engine Brake Assembly...........................................................................................................................................V-61
Engine Brake Housing Spacer.................................................................................................................................V-61
Engine Brake Solenoid Valve...................................................................................................................................V-61
Engine Brake Wiring Harness..................................................................................................................................V-61
Weights and Measures - Conversion Factors .......................................................................................................V-80
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cylinder Block - Group 01 - Specifications
Section V - Specifications Page V-1
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Cylinder Block - Group 01 - Specifications

Bearings, Connecting Rod (001-005)
Standard 2.457 MIN 0.0968
2.469 MAX 0.0972
Bearings, Main (001-006)

Standard 3.446 MIN 0.1357
3.454 MAX 0.1360
Crankshaft End Play Limits 0.085 mm MIN 0.003 in

0.385 mm MAX 0.015 in
Camshaft (001-008)
Camshaft Bearing Journal Diameter 59.962 MIN 2.3607 in
mm
60.013 MAX 2.3627 in
mm
Camshaft Thrust Plate 9.40 mm MIN 0.370 in

9.60 mm MAX 0.378 in
Camshaft End Play (A) 0.12 mm MIN 0.005 in

0.50 mm MAX 0.020 in
Camshaft Gear Backlash Limits (B) 0.08 mm MIN 0.003 in
0.33 mm MAX 0.013 in
Camshaft Bushings (001-010)

Without bushing 64.013 MAX 2.5202
With bushing 60.120 MAX 2.3669
Cylinder Block - Group 01 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page V-2 Section V - Specifications
Ref.No./
Steps
.
Camshaft Gear (Camshaft Installed) (001-012)
Camshaft End Play (A) 0.12 mm MIN 0.005 in
0.50 mm MAX 0.020 in
Camshaft Gear Backlash Limits (B) 0.08 mm MIN 0.003 in
0.33 mm MAX 0.013 in
Connecting Rod (001-014)

Connecting Rod Piston Pin Bushing 45.023 MIN 1.7726 in
Diameter mm
45.035 MAX 1.7730 in
mm
Connecting Rod Crank Bore Diameter 80.987 MIN 3.1885 in

(Bearings Removed) mm
81.013 MAX 3.1895 in
mm
Out-of-Roundness 0.050 mm MAX 0.002 in

Taper 0.013 mm MAX 0.0005 in
Bearing Clearance 0.038 mm MIN 0.0015 in

0.116 mm MAX 0.0045 in
Straight Split Connecting Rod Length 215.975 MIN 8.5029 in

mm
216.025 MAX 8.5049 in
mm
Angle Split Connecting Rod Length 215.950 MIN 8.5020 in
mm
216.050 MAX 8.5059 in
mm
Bushing removed 0.20 MAX 0.008

Bushing installed 0.30 MAX 0.012
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cylinder Block - Group 01
Ref.No./
Steps
.
Crankshaft (001-016)
Crankshaft Front and Rear Oil Seal Wear 0.25 mm MAX 0.010 in
Groove
Crankshaft Connecting Rod Journal 76.000 MIN 2.9921 in

Diameter mm
76.026 MAX 2.9931 in
mm
Crankshaft Connecting Rod Out of 0.050 mm MAX 0.002 in
Roundness
Crankshaft Connecting Rod Journal Taper 0.013 mm MAX 0.0005 in
Crankshaft Main Bearing Journal Diameter 98.006 MIN 3.8585 in
mm
98.032 MAX 3.8595 in
mm
Crankshaft Main Bearing Journal Out of 0.050 mm MAX 0.002 in
Roundness
Crankshaft Main Bearing Journal Taper 0.013 mm MAX 0.0005 in
Crankshaft Thrust Face Width (Standard) 42.98 mm MIN 1.692 in
43.08 mm MAX 1.696 in
Crankshaft Rear Oil Seal Flange Outside 129.98 MIN 5.117 in

Diameter mm
130.03 MAX 5.119 in
mm
Crankshaft Damper Pilot Outside Diameter 23.92 mm MIN 0.942 in

24.00 mm MAX 0.945 in
Crankshaft Gear Journal Outside Diameter 75.987 MIN 2.9916 in

mm
76.006 MAX 2.9924 in
mm
Ref.No./
Steps
.
Crankshaft Gear, Front (Crankshaft Removed) (001-019)
Crankshaft Gear Bore Inside Diameter 75.898 MIN 2.9881 in
mm
75.923 MAX 2.9891 in
mm
Crankshaft Gear Journal Outside Diameter 75.987 MIN 2.9916 in

mm
76.006 MAX 2.9924 in
mm
Cylinder Block (001-026)

Cylinder Liner Bore in Block (Press Fit Bore) 130.900 MIN 5.1535 in
mm
130.950 MAX 5.1555 in
mm
Cylinder Block Counterbore Depth from 122.930 MIN 4.8397 in

Cylinder Block Head Deck mm
123.000 MAX 4.8425 in
mm
Camshaft Bore Diameter (Without Bushing) 64.01 mm MAX 2.520 in
Tappet Bore Diameter 31.295 MIN 1.2321 in

mm
31.325 MAX 1.2333 in
mm
Main Bearing Bore Diameter 104.982 MIN 4.1331 in

mm
105.018 MAX 4.1346 in
mm
Ref.No./
Steps
.
Cylinder Liner (001-028)
Taper 0.04 MAX 0.0016
Out Of Round 0.04 MAX 0.0016
Bore Diameter 114.04 MAX 4.4898
Cylinder Liner Protrusion 0.026 mm MIN 0.0010 in

0.122 mm MAX 0.0048 in
Cylinder Liner Inside Diameter 114.000 MIN 4.4882 in

mm
114.040 MAX 4.4898 in
mm
Cylinder Liner Out Diameter (Top Press Fit) 130.938 MIN 5.1550 in
mm
130.958 MAX 5.1558 in
mm
Cylinder Liner Bore in Block (Press Fit Bore) 130.900 MIN 5.1535 in
mm
130.950 MAX 5.1555 in
mm
Cylinder Liner Protrusion 0.026 mm MIN 0.0010 in

0.122 mm MAX 0.0048 in
Cylinder Liner to Block Clearance 0.229 mm MIN 0.009 in
Ref.No./
Steps
.
Piston (001-043)
Crown 45.016 MIN 1.7723
45.036 MAX 1.7731
Skirt 45.012 MIN 1.7721
45.026 MAX 1.7727
Piston Pin Bore Diameter 45.006 MIN 1.7719 in

mm
45.012 MAX 1.7721 in
mm
Piston Pin Diameter 44.997 MIN 1.7715 in

mm
45.003 MAX 1.7718 in
mm
Piston Rings (001-047)

Top Ring 0.35 MIN 0.014
0.60 MAX 0.024
Intermediate Ring 0.35 MIN 0.014
0.65 MAX 0.026
Oil Control Ring 0.30 MIN 0.012
0.60 MAX 0.023
0.50 MAX 0.020
1.15 MAX 0.045
0.60 MAX 0.023
0.45 MAX 0.017
0.70 MAX 0.027
0.60 MAX 0.023
0.45 MAX 0.018
1.15 MAX 0.045
0.60 MAX 0.023
Piston and Connecting Rod Assembly (001-054)
Connecting Rod and Crankshaft Side 0.10 mm MIN 0.004 in
Clearance
0.30 mm MAX 0.012 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cylinder Block - Group 01 - Torque Values
Ref.No./
Steps
.
Cylinder Block - Group 01 - Torque Values

Bearings, Main (001-006)
Main Bearing Cap Initial Torque 50 N•m [ 37 ft-lb ]
Torque Value:
128 mm [5 in] Capscrew
Step 1 50 N•m [ 37 ft-lb ]
Step 2 95 N•m [ 70 ft-lb ]
Torque Value:
135 mm [5.3 in] Capscrew
Step 1 170 N•m [ 125 ft-lb ]
Step 2 Loosen all capscrews
Step 3 50 N•m [ 37 ft-lb ]
Camshaft (001-008)
Camshaft Thrust Plate Capscrews 24 N•m [ 212 in-lb ]
Camshaft Gear (Camshaft Installed) (001-012)

Camshaft Thrust Plate Capscrews 24 N•m [ 212 in-lb ]
Camshaft Gear (Camshaft Removed) (001-013)

Camshaft Gear Timing Plate Capscrews 7 N•m [ 62 in-lb ]
Crankshaft Seal, Front (001-023)

Front Seal Carrier Mounting Nuts 8 N•m [ 71 in-lb ]
Ref.No./
Steps
.
Crankshaft Wear Sleeve, Front (001-025)
Wear Sleeve Installation Capscrews 20 N•m [ 180 in-lb ]
Cylinder Block (001-026)

Main Bearing Cap Capscrews 176 N•m [ 130 ft-lb ]
Cylinder Liner (001-028)

68 N•m [ 50 ft-lb ]
68 N•m [ 50 ft-lb ]
Gear Cover, Front (001-031)

Torque Value:
10 mm Front Cover Mounting Capscrews
Step 1 30 N•m [ 22 ft-lb ]
Torque Value:
11 mm Front Cover Mounting Capscrews
Step 1 40 N•m [ 30 ft-lb ]
Gear Housing, Front (001-033)
Gear Housing Mounting Capscrews 40 N•m [ 30 ft-lb ]
Piston Cooling Nozzle (001-046)

Banjo Mounted Piston Cooling Nozzle 25 N•m [ 221 in-lb ]
Ref.No./
Steps
.
Flange Head Capscrew Mounted Piston 33 N•m [ 24 ft-lb ]
Cooling Nozzles
Vibration Damper, Rubber (001-051)

Vibration Damper, Rubber 200 N•m [ 148 ft-lb ]
Vibration Damper, Viscous (001-052)

Vibration Damper, Viscous 200 N•m [ 148 ft-lb ]
Connecting Rod Nuts 60 44 Loosen capscrews 70 52 Advance 90 degrees

Piston and Connecting Rod Assembly (001-054)
Torque Value:
Connecting Rod Capscrews
Step 1 60 N•m [ 44 ft-lb ]
Step 2 Loosen capscrews
Step 3 70 N•m [ 52 ft-lb ]
Step 4 Advance 60 degrees
Crankshaft Wear Sleeve, Rear (001-067)

Rear Seal Installation Tool 20 N•m [ 180 in-lb ]
Crankshaft Speed Indicator Ring (001-071)

Crankshaft Speed Indicator Ring 8 N•m [ 71 in-lb ]
Capscrews
Cylinder Head - Group 02 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Cylinder Head - Group 02 - Specifications

Cylinder Head (002-004)
Injector Protrusion (CAPS Fuel System) 2.60 mm MIN 0.102 in
3.40 mm MAX 0.134 in
Injector Protrusion (Cummins® Common 2.25 mm MIN 0.088 in
Rail Fuel System)
2.80 mm MAX 0.110 in
Standard Head Valve Recess in Cylinder 0.84 mm MIN 0.033 in

Head
1.32 mm MAX 0.052 in
Scallop Head Valve Recess in Cylinder 0.69 mm MIN 0.027 in

Head
1.17 mm MAX 0.046 in
Cylinder Head Insert Bore Inside Diameter 39.371 MIN 1.550 in

mm
39.401 MAX 1.551 in
mm
Cylinder Head Insert Bore Inside Diameter 39.625 MIN 1.560 in
for Oversized Seats mm
39.655 MAX 1.561 in
mm
End to End 0.203 MAX 0.008
Side to Side 0.075 MAX 0.003
Valve Guide Inside Diameter 8.019 mm MIN 0.316 in

8.081 mm MAX 0.318 in
Valve Guide Height (Installed) 13.15 mm MIN 0.518 in

13.65 mm MAX 0.537 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cylinder Head - Group 02
Ref.No./
Steps
.
Valve Stem Diameter 7.96 mm MIN 0.313 in
7.98 mm MAX 0.314 in
Exhaust 1.83 MIN 0.072

Intake 2.20 MIN 0.087
Cylinder Head Capscrew Free Length 162.6 mm MAX 6.4 in
Amount of Material Removed 0.5 MAX 0.02

Surface Finish 3.2 µM MAX 125 µ in
Perpendicularity With Combustion Face 0.30 MAX 0.012
Flatness 0.025 mm MAX 0.001 in
per 25.4 per 1.0 in
mm
(Full Length of Cylinder Head) 0.20 MAX 0.008
1.62 MAX 0.064
1.12 MAX 0.044
Oversize Valve Guide Bore Dimensions 16.441 MIN 0.6473 in

mm
16.481 MAX 0.6489 in
mm
Intake - 3824058 54.151 MIN 2.1319

54.181 MAX 2.1331
Exhaust - 3824060 47.251 MIN 1.8603
47.281 MAX 1.8615
Intake - 3824059 54.405 MIN 2.1419
54.435 MAX 2.1431
Exhaust - 3824061 47.505 MIN 1.8703
47.535 MAX 1.8715
Cylinder Head - Group 02 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Intake - Standard 53.897 MIN 2.1219

53.927 MAX 2.1231
Exhaust - Standard 46.997 MIN 1.8503
47.027 MAX 1.8515
Intake - 3824058 54.151 MIN 2.1319
54.181 MAX 2.1331
Exhaust - 3824060 47.251 MIN 1.8603
47.281 MAX 1.8615
Intake - 3824059 54.405 MIN 2.1419
54.435 MAX 2.1431
Exhaust - 3824061 47.505 MIN 1.8703
47.535 MAX 1.8715
4.14 MAX 0.163
3.63 MAX 0.143
Valve Guide Height (Installed) 13.15 mm MIN 0.518 in
13.65 mm MAX 0.537 in
Valve Seat-to-Valve Guide Runout 0.2 mm MAX 0.008 in
Standard Head Valve Recess in Cylinder 0.84 mm MIN 0.033 in

Head
1.32 mm MAX 0.052 in
Scallop Head Valve Recess in Cylinder 0.69 mm MIN 0.027 in

Head
1.17 mm MAX 0.046 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cylinder Head - Group 02 - Torque Values
Ref.No./
Steps
.
Cylinder Head - Group 02 - Torque Values

Cylinder Head (002-004)
80 N•m [ 59 ft-lb ]
Torque Value:
CAPS Fuel System
Step 1 50 N•m [ 37 ft-lb ]
Step 2 148 N•m [ 109 ft-lb ]
Step 3 148 N•m [ 109 ft-lb ]
Step 4 Advance 90 degrees.
Torque Value:
Step 1 50 N•m [ 37 ft-lb ]
Step 2 150 N•m [ 111 ft-lb ]
Step 3 Loosen all capscrews
Step 4 115 N•m [ 85 ft-lb ]
Step 5 115 N•m [ 85 ft-lb ]
Step 6 Advance 120 degrees.
Valve Guide Seal, Cylinder Head (002-016)
Cylinder Head Valve Guide Seal 5 N•m [ 44 in-lb ]
Capscrews
Cylinder Head Valve Guide Seal 5 N•m [ 44 in-lb ]

Capscrews
Rocker Levers - Group 03 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Rocker Levers - Group 03 - Specifications

Overhead Set (003-004)
0.559 MAX 0.022
0.813 MAX 0.032
Intake 0.305 NOM 0.012

Exhaust 0.559 NOM 0.022
Rocker Lever (003-008)

Rocker Lever Bore 24.987 MIN 0.984 in
mm
25.013 MAX 0.985 in
mm
Rocker Lever Shaft 24.950 MIN 0.982 in

mm
24.962 MAX 0.983 in
mm
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Rocker Levers - Group 03 - Torque Values
Ref.No./
Steps
.
Rocker Levers - Group 03 - Torque Values

Crankcase Breather (External) (003-001)
Crankcase Breather (External) 7 N•m [ 62 in-lb ]
Crankcase Breather (Internal) (003-002)

Crankcase Breather (Internal) 10 N•m [ 89 in-lb ]
Overhead Set (003-004)

Valve Adjusting Screw Locknut 24 N•m [ 212 in-lb ]
Rocker Lever (003-008)

Pedestal Capscrews 65 N•m [ 48 ft-lb ]
Engine Brake Oil Supply Studs 65 N•m [ 48 ft-lb ]
Exhaust Rocker Lever Mounting Studs 65 N•m [ 48 ft-lb ]
Intake Pedestal Capscrews 65 N•m [ 48 ft-lb ]
Rocker Levers - Group 03 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
24 N•m [ 212 in-lb ]
Rocker Lever Cover (003-011)

Center Bolted Rocker Lever Cover 12 N•m [ 106 in-lb ]
Mounting Capscrews
Perimeter Rocker Lever Cover Mounting 12 N•m [ 106 in-lb ]

Capscrews
12 N•m [ 106 in-lb ]
Rocker Lever Housing (003-013)

Perimeter Bolted Rocker Lever Housing 24 N•m [ 212 in-lb ]
Mounting Capscrews
Crankcase Breather Tube (003-018)

Crankcase Breather Drain Line Cover 45 N•m [ 33 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cam Followers/Tappets - Group 04 - Specifications
Ref.No./
Steps
.
Cam Followers/Tappets - Group 04 - Specifications

Tappet (004-015)
Valve Tappet Stem Diameter 15.936 MIN 0.627 in
mm
15.977 MAX 0.629 in
mm
Cam Followers/Tappets - Group 04 - Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Cam Followers/Tappets - Group 04 - Torque Values

Tappet (004-015)
Tappet Guide Screw 10 N•m [ 89 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Group 05 - Specifications
Ref.No./
Steps
.
Fuel System - Group 05 - Specifications

Minimum Gear Pump Pressure at Cranking 105 kPa MIN 15 psi
Fuel Lift Pump Output Pressure 35 kPa MIN 5 psi

Fuel Lift Pump Inlet Restriction 102 mm MAX 4 in Hg
Hg
Fuel Pump Cam Housing Module (005-088)

Camshaft End Clearance 0.05 mm MAX 0.002 in
Fuel System - Group 05 - Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Fuel System - Group 05 - Torque Values

Engine Fuel Heater, Electric (005-008)
Fuel Filter Spud 30 N•m [ 22 ft-lb ]
Fuel Pump (005-016)

Fuel Rail Nut 65 N•m [ 48 ft-lb ]
Fuel Pump Mounting Nuts 44 N•m [ 32 ft-lb ]

65 N•m [ 48 ft-lb ]
44 N•m [ 32 ft-lb ]
65 N•m [ 48 ft-lb ]
80 N•m [ 59 ft-lb ]
Fuel Injection Pump Gear Nut 180 N•m [ 133 ft-lb ]
Fuel Pump Delivery Valve (005-020)

Fuel Delivery Valve Outlet Fitting 81 N•m [ 60 ft-lb ]
Assemblies

Fuel Pump Gear Pump Mounting Bolts 34 N•m [ 25 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Group 05
Ref.No./
Steps
.
Adapter And Lift Pump Assembly Bolts 12.4 N•m [ 110 in-lb ]
Block Mounted Lift Pump 43 N•m [ 32 ft-lb ]
Ecm Cooling Plate Mounted Lift Pump 10 N•m [ 89 in-lb ]
Rotor, CAPS Fuel Injection Pump (005-072)

14 N•m [ 10 ft-lb ]
Injection Control Valve (005-078)

Torque Value:
Step 1 1.8 N•m [ 16 in-lb ]
Step 2 3.6 N•m [ 32 in-lb ]
Step 3 5.6 N•m [ 50 in-lb ]
Step 4 Torque to 5.6 N•m [50 in-lb] three more times following the torque
sequence
Snubber, Rate Shape (005-081)

Torque Value:
Step 1 14 N•m [ 124 in-lb ]
Fuel Pump Distributor Inlet Fitting (005-084)

Torque Value:
Step 1 5.7 N•m [ 50 in-lb ]
Step 2 Rotate 120 degrees clockwise
Fuel System - Group 05 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Fuel Pump Accumulator Module (005-085)
68 N•m [ 50 ft-lb ]
44 N•m [ 32 ft-lb ]
Fuel Pump Distributor and Injection Control Valve Module (005-086)

Distributor Capscrews 48 N•m [ 35 ft-lb ]
Distributor Plug 14 N•m [ 120 in-lb ]
Fuel Pump Rate Shape Tube (005-090)

Fuel Pump Rate Shape Tube Nuts 46 N•m [ 34 ft-lb ]
Capscrew 41 30 Thermistor Adapter 34 25
Fuel Pump Head Outlet Fitting (005-226)

Torque Value:
Step 1 13.6 N•m [ 120 in-lb ]
Fuel Pump Head (005-227)

68 N•m [ 50 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Group 05
Ref.No./
Steps
.
43 N•m [ 32 ft-lb ]
43 N•m [ 32 ft-lb ]
Fuel Pump Actuator Housing (005-228)

Fuel Pump Actuator Housing 34 N•m [ 25 ft-lb ]
Fuel Injection Pump (005-229)

Fuel Pump Mounting Nut 44 N•m [ 32 ft-lb ]
44 N•m [ 32 ft-lb ]
68 N•m [ 48 ft-lb ]
Fuel Injection Pump 180 N•m [ 132 ft-lb ]
Injectors and Fuel Lines - Group 06 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Specifications

Fuel Drain Line Restriction (006-012)
All Applications Except Marine 254.0 MAX 10.0
Marine Applications 101.6 MAX 4.0
Fuel Filter (Spin-On Type) (006-015)

Maximum Allowable Pressure Drop Across 80 kPa MAX 11.7 psi
Fuel Filter
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injectors and Fuel Lines - Group 06 - Torque Values
Ref.No./
Steps
.
Injectors and Fuel Lines - Group 06 - Torque Values

Engine Control Module Cooling Plate, Fuel Cooled (006-006)
Ecm Cooling Plate Mounting Capscrews 24 N•m [ 212 in-lb ]
Fuel Drain Lines (006-013)

Torque Value:
Style One (1)
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
Style Two (2)
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
M12 banjo bolts
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
P-clip capscrew
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
M12 banjo bolts
Step 1 24 N•m [ 212 in-lb ]
Torque Value:
M16 banjo bolts
Step 1 43 N•m [ 32 ft-lb ]
Torque Value:
P-clip capscrew
Step 1 24 N•m [ 212 in-lb ]
Marine Fuel Line 37 N•m [ 27 ft-lb ]
Fuel Filter Head (006-017)

Fuel Filter Adapter 30 N•m [ 22 ft-lb ]
Fuel Filter Head Test Port Plugs 27 N•m [ 239 in-lb ]

14 N•m [ 124 in-lb ]
Injectors and Fuel Lines - Group 06 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
24 N•m [ 212 in-lb ]
Fuel Filter Head Mounting Capscrews 30 N•m [ 22 ft-lb ]
Fuel Filter Head Bracket (006-018)

Fuel Filter Head Bracket Capscrews 43 N•m [ 32 ft-lb ]
43 N•m [ 32 ft-lb ]
37 N•m [ 27 ft-lb ]
24 N•m [ 212 in-lb ]
Fuel Supply Lines (006-024)
24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]
37 N•m [ 27 ft-lb ]
37 N•m [ 27 ft-lb ]
37 N•m [ 27 ft-lb ]
24 N•m [ 212 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injectors and Fuel Lines - Group 06
Ref.No./
Steps
.
24 N•m [ 212 in-lb ]
37 N•m [ 27 ft-lb ]
Injector (006-026)
Isolation Tool, Part Number 3164325 38 N•m [ 28 ft-lb ]
Mechanical Injector Retaining Nut 47 N•m [ 35 ft-lb ]
Injector Hold-Down Clamp 10 N•m [ 89 in-lb ]
15 N•m [ 133 in-lb ]
Injector Hold-Down Capscrews 10 N•m [ 89 in-lb ]
Injector Wiring Harness 1.25 N•m [ 11 in-lb ]
Injectors and Fuel Lines - Group 06 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Injector Supply Lines (High Pressure) (006-051)
24 N•m [ 212 in-lb ]
38 N•m [ 28 ft-lb ]
3 N•m [ 27 in-lb ]
38 N•m [ 28 ft-lb ]
38 N•m [ 28 ft-lb ]
38 N•m [ 28 ft-lb ]
24 N•m [ 212 in-lb ]

9 N•m [ 80 in-lb ]
24 N•m [ 212 in-lb ]
38 N•m [ 28 ft-lb ]
3 N•m [ 27 in-lb ]
38 N•m [ 28 ft-lb ]
38 N•m [ 28 ft-lb ]
38 N•m [ 28 ft-lb ]
38 N•m [ 28 ft-lb ]
24 N•m [ 212 in-lb ]
9 N•m [ 80 in-lb ]
Fuel Connector (Head Mounted) (006-052)

55 N•m [ 41 ft-lb ]
Fuel Pump Air Bleed Line (006-056)

Banjo Capscrew At Air Bleed Fitting 8 N•m [ 70 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injectors and Fuel Lines - Group 06
Ref.No./
Steps
.
Banjo Capscrew Drain Fitting 8 N•m [ 70 in-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
Banjo Capscrew Distributor Plug 8 N•m [ 70 in-lb ]
Fuel Rail (006-060)

Fuel Rail Assembly Capscrews 43 N•m [ 32 ft-lb ]
Fuel Pressure Relief Valve (006-061)

Fuel Pressure Relief Valve 100 N•m [ 74 ft-lb ]
37 N•m [ 27 ft-lb ]
Fuel Cooler (006-062)

Fuel Cooler Sea Water Hose Clamps 8 N•m [ 71 in-lb ]
Fuel Rail High Pressure Fitting (006-067)

Fuel Pressure Relief Valve 100 N•m [ 74 ft-lb ]
Lubricating Oil System - Group 07 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Specifications

Air Pressure Test 449 kPa MIN 65 psi
518 kPa MAX 75 psi

Tip Clearance 0.0254 MIN 0.001 in
mm
0.1778 MAX 0.007 in
mm
Gerotor Drive/Gerotor Planetary to Port Plate 0.0254 MIN 0.001 in

Clearance mm
0.1270 MAX 0.005 in
mm
Gerotor Planetary to Body Bore Clearance 0.1778 MIN 0.007 in

mm
0.3810 MAX 0.015 in
mm
Lubricating Oil Pump Gears Backlash Limits 0.0762 MIN 0.003 in

(Used Pump) mm
0.3302 MAX 0.013 in
mm
A 0.0762 MIN 0.003

0.3302 MAX 0.013
B 0.0762 MIN 0.003
0.3302 MAX 0.013
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil System - Group 07 - Torque Values
Ref.No./
Steps
.
Lubricating Oil System - Group 07 - Torque Values

Engine Oil Heater (007-001)
Engine Oil Heater Element 120 N•m [ 89 ft-lb ]
24 N•m [ 212 in-lb ]

Torque Value:
Step 1 24 N•m [ 212 in-lb ]
Step 2 32 N•m [ 24 ft-lb ]
Lubricating Oil Filter Bypass Valve (007-014)

Lubricating Oil Bypass Valve Pipe Plug 45 N•m [ 33 ft-lb ]
Lubricating Oil Filter Head (007-015)

Lubricating Oil Filter Head Mounting 24 N•m [ 212 in-lb ]
Capscrews
Lubricating Oil Filter Head (Remote-Mounted) (007-017)

Lubricating Oil Filter Head Assembly 24 N•m [ 18 ft-lb ]
Lubricating Oil Filter Tube Locking Nut 100 N•m [ 74 ft-lb ]
Lubricating Oil System - Group 07 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Lubricating Oil Filter Head Adapter (007-018)
Lubricating Oil Filter Head Adapter 100 N•m [ 74 ft-lb ]
Lubricating Oil High Pressure Relief Valve (007-021)

Lubricating Oil High Pressure Relief Valve 50 N•m [ 37 ft-lb ]
Lubricating Oil Pan (007-025)

Composite Oil Pan Bulkhead Fitting 24 N•m [ 212 in-lb ]
Lubricating Oil Pan Mounting Capscrews 28 N•m [ 248 in-lb ]
Lubricating Oil Pressure Regulator (Main Rifle) (007-029)

Lubricating Oil Pressure Regulator (Main 80 N•m [ 59 ft-lb ]
Rifle)
36 N•m [ 27 ft-lb ]
Lubricating Oil Pump Mounting Capscrews 24 N•m [ 212 in-lb ]
Lubricating Oil Suction Tube (Block-Mounted) (007-035)

Lubricating Oil Suction Tube To Block 10 N•m [ 89 in-lb ]
10 N•m [ 89 in-lb ]
10 N•m [ 89 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil System - Group 07
Ref.No./
Steps
.
Lubricating Oil System (007-037)
Lubricating Oil Drain Plug 80 N•m [ 59 ft-lb ]
60 N•m [ 44 ft-lb ]
60 N•m [ 44 ft-lb ]
Lubricating Oil Lines (007-092)

Adapter Plate And Remote Oil Filter Head 100 N•m [ 74 ft-lb ]
Hoses
Cooling System - Group 08 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Cooling System - Group 08 - Specifications

Thermostat Initial Opening Temperature 81 °C MIN 178 °F
83 °C MAX 182 °F
Fan Spacer and Pulley (008-039)

Fan Hub End Play 0.15 mm MAX 0.006 in

Zinc anode Plug Erosion Limits
A 19.0 MIN 0.750
New 51.0 MAX 2.000
B 6.4 MIN 0.250
New 16.0 MAX 0.630
Belt Tensioner, Automatic (Water Pump) (008-080)

Belt Tension 356 N MIN 80 lbf
534 N MAX 120 lbf
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System - Group 08 - Torque Values
Ref.No./
Steps
.
Cooling System - Group 08 - Torque Values

Belt Guard (008-001)
Belt Guard Mounting Bracket 20 N•m [ 15 ft-lb ]
15 N•m [ 133 in-lb ]
Coolant Filter Head (008-007)

Coolant Filter Head Mounting Capscrews 24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]

Coolant Filter Valve (008-009)
Coolant Filter Valve Shutoff Screw 1.5 N•m [ 12 in-lb ]
Coolant Heater (008-011)

Coolant Heater 75 N•m [ 55 ft-lb ]

Water Outlet Connection Mounting 24 N•m [ 212 in-lb ]
Capscrews
24 N•m [ 212 in-lb ]

24 N•m [ 212 in-lb ]
Coolant Thermostat Housing (008-014)
Keel Cooled Thermostat Housing Inlet Port 44 N•m [ 32 ft-lb ]
44 N•m [ 32 ft-lb ]
15 N•m [ 133 in-lb ]
Cooling System - Group 08 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Thermostat Housing Mounting Capscrews 44 N•m [ 32 ft-lb ]
Coolant Thermostat Housing Support (008-015)

Thermostat Housing Support Bracket 44 N•m [ 32 ft-lb ]
Coolant Thermostat Seal (008-016)

Thermostat Housing Hose Connection 44 N•m [ 32 ft-lb ]
Fan, Cooling (008-040)

Cooling Fan Mounting Capscrews 43 N•m [ 32 ft-lb ]
Marine Gear Oil Cooler (008-041)

Marine Gear Oil Cooler Fitting Locknuts 24 N•m [ 212 in-lb ]
Marine Gear Cooler Oil Temperature 30 N•m [ 22 ft-lb ]

Sensor 15 N•m [ 133 in-lb ]
Marine Gear Oil Cooler 18 N•m [ 159 in-lb ]

44 N•m [ 32 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System - Group 08
Ref.No./
Steps
.
Marine Gear Cooler Sea Water Discharge 8 N•m [ 71 in-lb ]
Hose Clamp 8 N•m [ 71 in-lb ]
Transmission Oil Supply And Return Hoses 30 N•m [ 22 ft-lb ]
Marine Gear Oil Cooler Capscrews 30 N•m [ 22 ft-lb ]
Sea Water Inlet And Outlet Pipe 24 N•m [ 212 in-lb ]
Expansion Tank (008-052)

Expansion Tank Mounting Bracket 43 N•m [ 32 ft-lb ]
Capscrews
Expansion Tank Mounting Capscrews 43 N•m [ 32 ft-lb ]
Expansion Tank Vent Lines 14 N•m [ 124 in-lb ]
Ref.No./
Steps
.
Expansion Tank Make-Up Hoses Clamps 8 N•m [ 70 in-lb ]
Heat Exchanger (008-053)

Qsl Heat Exchanger End Caps 8 N•m [ 71 in-lb ]
Qsc Heat Exchanger End Caps 44 N•m [ 32 ft-lb ]

55 N•m [ 41 ft-lb ]
Heat Exchanger Hose Clamps 8 N•m [ 71 in-lb ]

44 N•m [ 32 ft-lb ]
Qsc Lower Heat Exchanger Mounting 44 N•m [ 32 ft-lb ]

Capscrews 44 N•m [ 32 ft-lb ]
24 N•m [ 212 in-lb ]

8 N•m [ 71 in-lb ]
24 N•m [ 212 in-lb ]
Sea Water Pump (008-057)
Sea Water Pump Cover Capscrews 24 N•m [ 212 in-lb ]
24 N•m [ 212 in-lb ]

Sea Water Pump Mounting Capscrews 24 N•m [ 18 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System - Group 08
Ref.No./
Steps
.
Sea Water Pump Inlet And Outlet 133 N•m [ 15 in-lb ]
Connections

Aftercooler Zinc Anodes 45 N•m [ 35 ft-lb ]
Heat Exchanger Zinc Anode 45 N•m [ 35 ft-lb ]
Water Pump (008-062)

Water Pump Mounting Capscrews 24 N•m [ 212 in-lb ]
Belt Tensioner, Automatic (Water Pump) (008-080)

Tensioner Mounting Capscrews 24 N•m [ 212 in-lb ]
43 N•m [ 32 ft-lb ]
Water Inlet Connection (008-082)

Water Inlet Mounting Capscrews 24 N•m [ 212 in-lb ]
Pulley, Fan Idler (008-111)

Fan Idler Pulley Mounting Capscrew 52 N•m [ 38 ft-lb ]
Ref.No./
Steps
.
Bracket, Fan Idler Pulley (008-112)
Fan Idler Pulley Bracket Capscrews 52 N•m [ 38 ft-lb ]
Coolant Return Junction Block (008-113)

Junction Block Hose Clamps 8 N•m [ 71 in-lb ]
8 N•m [ 71 in-lb ]
Expansion Tank Fill Line Tube 8 N•m [ 71 in-lb ]
24 N•m [ 18 ft-lb ]
Marine Gear Oil and Fuel Cooler Assembly (008-129)
Marine Gear Oil Cooler Fittings 30 N•m [ 22 ft-lb ]
15 N•m [ 133 in-lb ]
Transmission Oil Lines To Cooler 30 N•m [ 22 ft-lb ]

24 N•m [ 18 ft-lb ]
Marine Gear Oil Cooler Mounting 30 N•m [ 22 ft-lb ]

Capscrews
Fuel Supply Hose Jam Nuts 30 N•m [ 22 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Drive Units - Group 09 - Torque Values
Ref.No./
Steps
.
Drive Units - Group 09 - Torque Values

Hydraulic Pump Drive (009-016)
Hydraulic Pump Mounting Bolts 43 N•m [ 32 ft-lb ]
Belt Tensioner, Refrigerant Compressor, Automatic (009-053)

Belt Tensioner Capscrew 43 N•m [ 32 ft-lb ]
Refrigerant Compressor Mounting Bracket (009-055)

Refrigerant Compressor Mounting Bracket 46 N•m [ 34 ft-lb ]
Air Intake System - Group 10 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Air Intake System - Group 10 - Specifications

Axial Clearance (HX40WG - Wastegate) 0.025 mm MIN 0.001 in
0.127 mm MAX 0.005 in
Axial Clearance (HY40V - Variable 0.025 mm MIN 0.001 in
Geometry)
0.127 mm MAX 0.005 in
Axial Clearance (HX55 - Wastegate, Water 0.038 mm MIN 0.0015 in
Cooled)
0.093 mm MAX 0.0037 in
Wastegate Radial Bearing Clearance 0.330 mm MIN 0.013 in
(HX40WG - Wastegate)
0.508 mm MAX 0.020 in
Radial Bearing Clearance (HX55 - 0.044 mm MIN 0.0172 in
Wastegate, Water Cooled)
0.608 mm MAX 0.0239 in
Mounting Surface Flatness Specification 0.1 mm MAX 0.004 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake System - Group 10 - Torque Values
Ref.No./
Steps
.
Air Intake System - Group 10 - Torque Values

Aftercooler Assembly (Sea Water) (010-005)
Aftercooler Assembly End Cap 43 N•m [ 32 ft-lb ]
43 N•m [ 32 ft-lb ]
55 N•m [ 41 ft-lb ]
Aftercooler Assembly Mounting Capscrews 100 N•m [ 74 ft-lb ]

Bracket To Flywheel Housing 44 N•m [ 32 ft-lb ]
Aftercooler Assembly Mounting Capscrews 35 N•m [ 26 ft-lb ]
Bracket To Cylinder Head
Aftercooler Assembly Mounting Capscrews
Aftercooler To Bracket
Qsc Aftercooler Lower Mounting 35 N•m [ 26 ft-lb ]

Capscrews
Qsc Aftercooler To Cylinder Block 44 N•m [ 32 ft-lb ]

35 N•m [ 26 ft-lb ]
Air Crossover (010-019)

Air Crossover Flange Clamp 8 N•m [ 71 in-lb ]
8 N•m [ 71 in-lb ]
Air Inlet Connection (010-022)

Air Inlet Connection V-Band Clamp 8 N•m [ 71 in-lb ]
60 N•m [ 44 ft-lb ]
45 N•m [ 33 ft-lb ]
Turbocharger Compressor Outlet V-Band 8 N•m [ 71 in-lb ]
Air Intake System - Group 10 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Turbocharger Compressor Inlet 8 N•m [ 71 in-lb ]
8 N•m [ 71 in-lb ]
Turbocharger Mounting Nuts (Marine 43 N•m [ 32 ft-lb ]

Applications)
Turbocharger Coolant Hoses (010-041)

Turbocharger Coolant Lines 46 N•m [ 34 ft-lb ]
Turbocharger Coolant Line Banjo Capscrew 160 N•m [ 118 ft-lb ]

8 N•m [ 71 in-lb ]
Coolant Vent Line At Turbocharger 15 N•m [ 133 in-lb ]

15 N•m [ 133 in-lb ]
Turbocharger Oil Drain Line (010-045)

Turbocharger Oil Drain Line Hose Clamps 5.6 N•m [ 50 in-lb ]
27 N•m [ 239 in-lb ]
Turbocharger Oil Supply Line (010-046)

Turbocharger Oil Supply Line Torque 24 N•m [ 212 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake System - Group 10
Ref.No./
Steps
.
Turbocharger Wastegate Actuator (010-050)
Actuator Mounting Capscrews 8 N•m [ 71 in-lb ]
Air Intake Connection (010-080)

Air Intake Connection 24 N•m [ 212 in-lb ]
Air Intake Manifold Cover (010-108)

Intake Manifold 24 N•m [ 212 in-lb ]
Variable Geometry Turbocharger Actuator, Pneumatic (010-113)

Actuator Housing Capscrews 17 N•m [ 150 in-lb ]
Actuator Rod Capscrew 23 N•m [ 17 ft-lb ]
Turbocharger Actuator Air Line (010-118)

Turbocharger Actuator Air Line Mounting 5 N•m [ 44 in-lb ]
Flexible Elbow Mounting 8 N•m [ 71 in-lb ]
Air Intake System - Group 10 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Actuator Air Supply Line 24 N•m [ 18 ft-lb ]
8 N•m [ 71 in-lb ]
Air Intake Connection Adapter (010-131)
Air Intake Connection Clamp 8 N•m [ 71 in-lb ]
8 N•m [ 71 in-lb ]
Turbocharger Exhaust Connection Adapter (010-141)

Turbocharger Exhaust Connection Adapter 25 N•m [ 221 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust System - Group 11 - Specifications
Ref.No./
Steps
.
Exhaust System - Group 11 - Specifications

Exhaust Manifold Flatness 0.30 mm MAX 0.012 in
Manifold Section Distance 136 mm MIN 5.35 in

138 mm MAX 5.43 in
Exhaust System - Group 11 - Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Exhaust System - Group 11 - Torque Values

Exhaust Manifold, Wet (011-008)

Exhaust Outlet Connection (011-017)

Exhaust Outlet Connection 24 N•m [ 18 ft-lb ]
8 N•m [ 71 in-lb ]
Aftertreatment Selective Catalytic Reduction (SCR) Catalyst (011-036)

V-Band Clamp Torque 20 N•m [ 177 in-lb ]
Exhaust Gas Temperature Sensor (011-037)

Exhaust Gas Temperature Sensor 30 N•m [ 22 ft-lb ]
Aftertreatment Nozzle (011-040)

Aftertreatment Nozzle Retaining Nut. 60 N•m [ 44 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Exhaust System - Group 11
Ref.No./
Steps
.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter (011-060)
Aftertreatment Diesel Exhaust Fluid Dosing 15 N•m [ 133 in-lb ]
Unit Filter Equalizing Element Cap
Compressed Air System - Group 12 - Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Compressed Air System - Group 12 - Torque Values

Air Compressor Cylinder Head, Single Cylinder (012-007)
Torque Value:
Step 2 10 N•m [ 89 in-lb ]
Torque Value:
Step 1 25 N•m [ 221 in-lb ]
Step 2 Rotate capscrews 90 degrees.
Torque Value:
Step 2 Rotate 90 degrees.
Air Compressor (012-014)

Air Compressor Mounting Nuts 77 N•m [ 57 ft-lb ]
Air Compressor Support Brace Capscrews 43 N•m [ 32 ft-lb ]
Air Compressor Support Brace Capscrews 43 N•m [ 32 ft-lb ]
Support Brace To Cylinder Block 43 N•m [ 32 ft-lb ]

Capscrews
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Compressed Air System - Group 12
Ref.No./
Steps
.
Air Compressor Rear Bearing Housing, Two Cylinder (012-112)
22 N•m [ 195 in-lb ]
25 N•m [ 221 in-lb ]
Electrical Equipment - Group 13 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Electrical Equipment - Group 13 - Specifications

Starting Motor Spacing 49.28 mm MIN 1.94 in
52.32 mm MAX 2.06 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Electrical Equipment - Group 13 - Torque Values
Ref.No./
Steps
.
Electrical Equipment - Group 13 - Torque Values

Alternator (013-001)
Alternator Mounting (All Except Marine) 43 N•m [ 32 ft-lb ]
Alternator Link (All Except Marine) 24 N•m [ 18 ft-lb ]
Torque Value:
Upper Mounting Capscrew
Step 1 77 N•m [ 57 ft-lb ]
Torque Value:
Alternator Link at Alternator
Step 1 44 N•m [ 32 ft-lb ]
Torque Value:
Alternator Link at Engine Mounting Location
Step 1 24 N•m [ 18 ft-lb ]
Alternator Bracket (013-003)
Alternator Mounting Bracket Capscrews 24 N•m [ 212 in-lb ]

Starter Motor Mounting Capscrews 43 N•m [ 32 ft-lb ]
4 N•m [ 35 in-lb ]
21 N•m [ 186 in-lb ]
4 N•m [ 35 in-lb ]
ECM Unswitched Power Terminal Blocks (013-047)
5 N•m [ 45 in-lb ]
Electrical Equipment - Group 13 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
3.5 N•m [ 30 in-lb ]
5 N•m [ 45 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Testing - Group 14 - Specifications
Ref.No./
Steps
.
Engine Testing - Group 14 - Specifications

Engine Run-in (Engine Dynamometer) (014-006)
Lubricating Oil Temperature 90 °C MAX 194 °F
Fuel Temperature 65 °C MAX 149 °F
Engine Testing (In Chassis) (014-008)

Turbocharger Actuator Rod Travel 10.8 mm MIN 0.40 in
11.8 mm MAX 0.46 in
Mounting Adaptations - Group 16 - Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Specifications

Flywheel (016-005)
Flywheel Total Indicator Reading 0.127 mm MAX 0.0050 in

Set Screw Installation Depth (Flywheel 3.00 mm MAX 0.118 in
Housing)

Shaft End Play 0.0 mm MIN 0.0 in
0.03 mm MAX 0.001 in
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Mounting Adaptations - Group 16 - Torque Values
Ref.No./
Steps
.
Mounting Adaptations - Group 16 - Torque Values

Engine Support Bracket, Front (016-002)
Front Engine Support Bracket Mounting 112 N•m [ 83 ft-lb ]
Capscrews
Front Engine Mount Capscrews 126 N•m [ 93 ft-lb ]
Front Engine Support Brackets 112 N•m [ 83 ft-lb ]
Engine Support Bracket, Rear (016-003)

Rear Engine Support Bracket Mounting 71 N•m [ 52 ft-lb ]
Capscrews
Flexplate (016-004)
Torque Value:
Flexplate Capscrews
Step 1 30 N•m [ 22 ft-lb ]
Step 2 Plus 60-degree turn
Flexplate Mounting Capscrews 44 N•m [ 32 ft-lb ]
Flex-Coupling Guard Plate Mounting 36 N•m [ 27 ft-lb ]

Capscrews
Mounting Adaptations - Group 16 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Flywheel (016-005)
Flywheel Capscrews 137 N•m [ 101 ft-lb ]

Access Cover Capscrews 24 N•m [ 212 in-lb ]
Flywheel Housing Mounting Capscrews 77 N•m [ 57 ft-lb ]
Flywheel Housing Access Plate Capscrew 24 N•m [ 212 in-lb ]

Flywheel Housing Flat Washer And 205 N•m [ 151 ft-lb ]
Capscrew
Output Flange Flat Washer And Capscrew 205 N•m [ 151 ft-lb ]
Housing Cover Capscrews 18 N•m [ 159 in-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Mounting Adaptations - Group 16
Ref.No./
Steps
.
Flywheel Housing Capscrews 77 N•m [ 57 ft-lb ]
Idler Shaft Capscrew 105 N•m [ 77 ft-lb ]
Torque Value:
Step 2 19 N•m [ 168 in-lb ]
Engine Drive Shaft (016-027)

149 N•m [ 110 ft-lb ]
149 N•m [ 110 ft-lb ]
36 N•m [ 27 ft-lb ]
23 N•m [ 204 in-lb ]
36 N•m [ 27 ft-lb ]
Miscellaneous - Group 17 - Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Ref.No./
Steps
.
Miscellaneous - Group 17 - Torque Values

10 N•m [ 89 in-lb ]
20 N•m [ 177 in-lb ]
25 N•m [ 221 in-lb ]
35 N•m [ 25 ft-lb ]
45 N•m [ 33 ft-lb ]
18 N•m [ 160 in-lb ]
25 N•m [ 221 in-lb ]
30 N•m [ 22 ft-lb ]
40 N•m [ 30 ft-lb ]
50 N•m [ 37 ft-lb ]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Vehicle Braking - Group 20 - Torque Values
Ref.No./
Steps
.
Vehicle Braking - Group 20 - Torque Values

Engine Brake Assembly (020-004)
Engine Brake Mounting Capscrews 32 N•m [ 24 ft-lb ]
Engine Brake Adjusting Locknut 35 N•m [ 26 ft-lb ]
35 N•m [ 26 ft-lb ]
35 N•m [ 26 ft-lb ]
35 N•m [ 26 ft-lb ]
Engine Brake Housing Spacer (020-007)
Engine Brake Spacer Mounting Capscrews 32 N•m [ 23 ft-lb ]
Engine Brake Solenoid Valve (020-012)

Engine Brake Solenoid 20 N•m [ 177 in-lb ]
Engine Brake Wiring Harness (020-015)

Engine Brake Wiring Harness Receptacle 11 N•m [ 97 in-lb ]
Connector
General Engine ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
General Engine
Specifications
Listed below are the general specifications for this engine.
Horsepower.......................................................................................................................................See engine dataplate
Firing Order.......................................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)........................................................................................... Clockwise
Bore and Stroke
8.3 liters................................................................................................................114 mm [4.49 in] x 135 mm [5.32 in]
8.9 liters.............................................................................................................114 mm [4.49 in] x 144.5 mm [5.69 in]
Dry Weight
8.3 liters...............................................................................................................................................694 kg [1530 lb]
8.9 liters...............................................................................................................................................706 kg [1555 lb]
Wet Weight
8.3 liters...............................................................................................................................................723 kg [1595 lb]
8.9 liters...............................................................................................................................................738 kg [1625 lb]
Overhead Adjustment
Intake Valve Adjustment................................................................................................................0.305 mm [0.012 in]
Exhaust Valve Adjustment.............................................................................................................0.559 mm [0.022 in]
Engine Brake Adjustment....................................................................................................................2.286 mm [0.090 in]
Marine Applications
Listed below are the general specifications for this engine.
Horsepower.......................................................................................................................................See engine dataplate
Firing Order.......................................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)........................................................................................... Clockwise
Displacement
QSC8.3..............................................................................................................................................8.3 liters [505 in3]
QSL9.................................................................................................................................................8.9 liters [540 in3]
Bore and Stroke
8.3 liters (QSC8.3 Engine)...................................................................................114 mm [4.49 in] x 135 mm [5.31 in]
8.9 liters (QSL9 Engine).......................................................................................114 mm [4.49 in] x 145 mm [5.71 in]
Dry Weight
8.3 liters (QSC8.3 Engine)...................................................................................................................880 kg [1940 lb]
8.9 liters (QSL9 Engine).......................................................................................................................891 kg [1965 lb]
Dry Weight - Engine with Heat Exchanger System - Average
8.3 liters (QSC8.3 Engine)...................................................................................................................896 kg [1975 lb]
8.9 liters (QSL9 Engine).......................................................................................................................907 kg [2000 lb]
Overhead Adjustment
Intake Valve Adjustment................................................................................................................0.305 mm [0.012 in]
Exhaust Valve Adjustment.............................................................................................................0.559 mm [0.022 in]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System
Fuel System
Specifications
Maximum Fuel Return Line Pressure
All Applications Except Marine...................................................................................................254 mm-Hg [10 in-Hg]
Marine Applications......................................................................................................................102 mm-Hg [4 in-Hg]
Maximum Fuel Inlet Restriction (gear pump inlet)
All Applications Except Marine...................................................................................................254 mm-Hg [10 in-Hg]
Maximum Fuel Inlet Restriction - at original equipment manufacturer (OEM) Connection (Dirty Filter) Loaded
Condition
All Application Except Marine....................................................................................................203.2 mm-Hg [8 in-Hg]
Marine Applications......................................................................................................................102 mm-Hg [4 in-Hg]
Maximum Fuel Inlet Restriction - at OEM Connection (Clean Filter) Loaded Condition
Marine Applications..................................................................................................................63.5 mm-Hg [2.5 in-Hg]
Minimum Gear Pump Pressure (during cranking)
During Cranking Condition...................................................................................................................105 kPa [15 psi]
During Rated Condition.......................................................................................................................483 kPa [70 psi]
Maximum Filter Pressure Drop.................................................................................................................138 kPa [20 psi]
Minimum Lift Pump Pressure (gear pump inlet during cranking)..................................................................35 kPa [5 psi]
Minimum Engine Cranking Speed.........................................................................................................................150 rpm
Primary Off engine fuel filter element..................................................................................................................10 Micron
Secondary On engine fuel filter element...............................................................................................................3 Micron
CAPS Fuel System
Maximum Fuel Inlet Restriction at Rated (measured at lift pump inlet).............................................102 mm-Hg [4 in-Hg]
Maximum Fuel Inlet Restriction at Rated (measured at CAPS pump inlet).....................................254 mm-Hg [10 in-Hg]
Minimum Lift Pump Pressure........................................................................................................................35 kPa [5 psi]
Maximum Filter Pressure Drop at Rated...........................................................................................102 mm-Hg [4 in-Hg]
Minimum Gear Pump Pressure (during cranking).......................................................................................69 kPa [10 psi]
Minimum Engine Cranking Speed.........................................................................................................................150 rpm
Lubricating Oil System

Specifications
Oil Pressure
At Low Idle (minimum allowable)...........................................................................................................69 kPa [10 psi]
At Rated Speed (minimum allowable).................................................................................................207 kPa [30 psi]
Regulated Oil Pressure.............................................................................................................................517 kPa [75 psi]
Lubricating Oil Filter Capacity....................................................................................................................3.78 liters [4 qt]
Oil Pan Capacity, Low to High (8.3 liter engines)
Standard Oil Pan............................................................................................................15.1 to 18.9 liters [16 to 20 qt]
Standard Oil Pan with Cylinder Block Stiffener Plate.....................................................16.1 to 19.9 liters [17 to 21 qt]
Total System Capacity (Oil Pan and New Oil Filter) (8.3 liter engines)
Standard Oil Pan.................................................................................................................................22.7 liters [24 qt]
Standard Oil Pan with Cylinder Block Stiffener Plate..........................................................................23.7 liters [25 qt]
Oil Pan Capacity, Low to High (8.9 liter engines)
Standard Oil Pan............................................................................................................18.9 to 22.7 liters [20 to 24 qt]
Standard Oil Pan with Cylinder Block Stiffener Plate.....................................................19.9 to 23.7 liters [21 to 25 qt]
Large Oil Pan "Power Generation" with Cylinder Block Stiffener Plate...................20.5 to 29.9 liters [21.1 to 31.7 qt]
Total System Capacity (Oil Pan and New Oil Filter) (8.9 liter engines)
Standard Oil Pan.................................................................................................................................26.5 liters [28 qt]
Standard Oil Pan With Cylinder Block Stiffener Plate.........................................................................27.4 liters [29 qt]
Large Oil Pan "Power Generation" with Cylinder Block Stiffener Plate............................................33.7 liters [35.7 qt]
Oil Pressure at Normal Operating Temperature
QSC8.3 Engines
Idle Speed - Minimum in Filter Head Upstream of Filter....................................................................................N/A
Idle Speed - Minimum in Main Oil Gallery......................................................................................138 kPa [20 psi]
Rated Speed - Measured in Filter Head Upstream of Filter (Low).....................................................................N/A
Rated Speed - Measured in Filter Head Upstream of Filter (High)....................................................................N/A
Rated Speed - Measured in Main Oil Gallery (Low).......................................................................276 kPa [40 psi]
Rated Speed - Measured in Main Oil Gallery (High)......................................................................483 kPa [70 psi]
Oil Pressure at Normal Operating Temperature
QSL9 Engines
Idle Speed - Minimum in Filter Head Upstream of Filter....................................................................................N/A
Idle Speed - Minimum in Main Oil Gallery......................................................................................179 kPa [26 psi]
Rated Speed - Measured in Filter Head Upstream of Filter (Low).....................................................................N/A
Rated Speed - Measured in Filter Head Upstream of Filter (High)....................................................................N/A
Rated Speed - Measured in Main Oil Gallery (Low).......................................................................386 kPa [56 psi]
Rated Speed - Measured in Main Oil Gallery (High)......................................................................490 kPa [71 psi]
Oil Pan Capacity - Shallow (Option 9351)
QSC8.3 Engines
Low...............................................................................................................................................15.1 liter [4.0 gal]
High..............................................................................................................................................18.9 liter [5.0 gal]
Total System Capacity (Maximum Sump and Filter)....................................................................21.6 liter [5.7 gal]
By-Pass Oil Filter Capacity.............................................................................................................2.6 liter [0.7 gal]
Oil Pan Capacity - Shallow (Option 9467)
QSL9 Engines
Low...............................................................................................................................................17.0 liter [4.5 gal]
High..............................................................................................................................................20.8 liter [5.5 gal]
Oil Pan Capacity - Deep (Option 9397)
QSL9 Engines
Low...............................................................................................................................................18.9 liter [5.0 gal]
High..............................................................................................................................................22.7 liter [6.0 gal]
Oil Temperature
QSC8.3 and QSL9 Engines
Maximum Allowable Oil Temperature (Sump)...................................................................................121°C [250°F]
Oil Consumption Rate
QSC8.3 and QSL9 Engines
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Lubricating Oil System
Volume Percent of Fuel Consumption Rate.........................................................................................0.08 percent
Cooling System
Specifications
Coolant Capacity (engine only)............................................................................................................11.1 liters [11.7 qt]
Standard Modulating Thermostat Range...................................................................................82 to 93°C [180 to 200°F]
Recommended Pressure Cap...................................................................................................................103 kPa [15 psi]
Minimum Fill Rate (without low-level alarm).......................................................................................19 liters/min [5 gpm]
Maximum Deaeration Time...............................................................................................................................25 minutes
Maximum Top Tank Coolant Temperature With CAPS Fuel System...........................................................100°C [212°F]
Maximum Top Tank Coolant Temperature With Cummins Common Rail Fuel System..............................107°C [225°F]
Winterfronts - Automotive Only
Air Passage Area...............................................................................................................................774 cm2 [120 in2]
Marine Applications
Coolant Capacity
Engine Only .........................................................................................................................................25 liter [6.5 gal]
Engine Including Heat Exchanger and Integral...................................................................................29 liter [7.75 gal]
Minimum Coolant Makeup Capacity........................................................................................................1.4 liter [0.38 gal]
Maximum Pressure Drop Across Any External Cooling System Circuit........................................................34 kPa [5 psi]
Maximum Allowable Block Coolant System Pressure...............................................................................483 kPa [70 psi]
Maximum Coolant Head From Crankshaft Centerline With 15 psi Pressure Cap..........................................34 m [112 ft]
Maximum Coolant Temperature at Engine Outlet..........................................................................................96°C [205°F]
Minimum Allowable Coolant Expansion Space.........................................................................6 percent system capacity
Maximum Sea Water Pressure.................................................................................................................103 kPa [15 psi]
Maximum Sea Water Pressure Drop Across Heat Exchanger......................................................................34 kPa [5 psi]
Maximum Sea Water Inlet Restriction.....................................................................................................-17 kPa [-5 in Hg]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Air Intake System
Air Intake System

Specifications
CAUTION
Engine intake air must be filtered to prevent dirt and debris from entering the engine. If the air intake piping is
damaged or loose, unfiltered air will enter the engine and cause premature wear.
Maximum Intake Restriction
Clean Air Filter Element.........................................................................................................254 mm H2O [10 in H2O]
Dirty Air Filter Element...........................................................................................................635 mm H2O [25 in H2O]
Charge-Air Cooler Restriction (maximum)......................................................................................152 mm Hg [6.0 in Hg]
Marine Applications
Maximum Allowable Intake Restriction QSL and QSC 540 metric horse power and below
Clean Filter ...........................................................................................................................381 mm H2O [15 in H2O]
Dirty Filter...............................................................................................................................635 mm H2O [25 in H2O]
Maximum Air Cleaner Inlet Temperature Rise Over Ambient..........................................................................17°C [30°F]
Maximum Allowable Intake Restriction QSC 550 metric horse power and above
Clean Filter............................................................................................................................254 mm H2O [10 in H2O]
Dirty Filter....................................................................................................................................381 mm H2O [15 in H2O]
Maximum Air Cleaner Inlet Temperature Rise Over Ambient..........................................................................17°C [30°F]
Exhaust System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Exhaust System
Specifications
Maximum Exhaust Restriction - Muffler
Hg...................................................................................................................................................76 mm-Hg [3 in-Hg]
H2O.....................................................................................................................................1016 mm-H2O [40 in-H2O]
Exhaust Restriction - Diesel Oxidation Catalyst.............................................................................114 mm-Hg [4.5 in-Hg]
Exhaust Restriction - Exhaust Gas Filter........................................................................................140 mm-Hg [5.5 in-Hg]
Exhaust Restriction - Selective Catalytic Reduction..................................................................................15 kPa [2.2 psi]
Marine Applications
Exhaust Restriction QSL9 Engines...........................................................................................................10 kPa [3 in-Hg]
Exhaust Restriction QSC8.3 Engines built before July 1, 2008................................................................10 kPa [3 in-Hg]
Exhaust Restriction QSC8.3 Engines built on or after July 1, 2008..........................................................17 kPa [5 in-Hg]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Electrical System
Electrical System
Batteries (Specific Gravity)
Specific Gravity at 27°C [80°F] 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
1.110 to 1.130 Discharged
Compressed Air System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Compressed Air System

Specifications
Cummins 18.7 CFM Model
Cylinders...........................................................................................................................................................................1
Compressor Swept Volume at 1250 RPM...........................................................................................6.6 l/sec. [14.0 cfm]
Piston Displacement..........................................................................................................................31 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 116 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 lb]
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Testing
Engine Testing
Specifications
Engine Blowby Specifications................................................................................................. 30.5 cm H2O [12.0 in H2O]
Cummins®/Fleetguard® Filter Specifications ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Cummins®/Fleetguard® Filter Specifications

General Information
Cummins Filtration™ is a subsidiary of Cummins Inc. Cummins Filtration™ filters are developed through joint testing
at Cummins Inc. and Cummins Filtration™. Cummins Filtration™ filters are standard on new Cummins® engines.
Cummins Inc. recommends their use.
Cummins Filtration™ products meet all Cummins® Source Approval Test standards to provide the quality filtration
necessary to achieve the engine's design life. If other brands are substituted, the purchaser should insist on products
that the supplier has tested to meet Cummins® quality standards.
Cummins Inc. can not be responsible for problems caused by non-genuine filters that do not meet Cummins Inc.
performance or durability requirements.
Filter Part Numbers (All Applications Except Marine)

- Water-separating Fuel Filter Lubricating Oil Filter Inline Air Filter
Filter (ISLe4 only)
Without CM850 - - - -
Cummins® Part 3944269 N/A 3401544 N/A
Number
Cummins Filtration™ FS1022 N/A LF9009 N/A
Part Number
With CM850 - - - -
Cummins® Part 4070801 3959612 3401544 N/A
Number
Cummins Filtration™ FS1003 FF5488 LF9009 AS0247400
Part Number
Filter Part Numbers (Marine Applications)

- Water-separating Filter Fuel Filter Lubricating Oil Filter
Cummins® Part Number 3971757 3959612 3401544
Racor® Part Number 1000MA - -
Cummins Filtration™ Part - FF5488 LF9009
Number
NOTE: LF9009 must be used. A venturi type filter must be used in order to benefit from the bypass filtration section
of the oil filter. Do not use LF3000. Engine durability will be reduced by the use of the wrong lubricating oil filter.
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Drive Belt Tension
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.
Capscrew Markings and Torque Values ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Capscrew Markings and Torque Values
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
Fraction, Decimal, Millimeter Conversions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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 ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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.
Weights and Measures - Conversion Factors ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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
cubic inch in3 liter l 0.01639 61.02545
displacement
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
ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Barometric Pressure at Altitude
Barometric Pressure at Altitude

Specifications
Barometric Pressure at Altitude
Pressure Altitude
kPa PSI mm Hg in Hg m ft.
103.2 14.96 773.9 30.47 -152 -500
101.3 14.69 760.0 29.92 0 0
99.5 14.43 746.3 29.38 152 500
97.7 14.17 733.0 28.86 305 1000
96.0 13.92 719.8 28.34 458 1500
94.2 13.66 706.6 27.82 610 2000
92.5 13.42 693.9 27.32 762 2500
90.8 13.17 681.2 26.82 914 3000
89.2 12.93 668.8 26.33 1067 3500
87.5 12.69 656.3 25.84 1219 4000
85.9 12.46 644.3 25.37 1372 4500
84.3 12.23 632.2 24.89 1524 5000
82.8 12.01 620.7 24.44 1677 5500
81.2 11.78 609.1 23.98 1829 6000
79.7 11.56 597.8 23.54 1982 6500
78.2 11.34 586.5 23.09 2134 7000
76.7 11.13 575.5 22.66 2286 7500
75.2 10.91 564.4 22.22 2438 8000
73.8 10.71 553.8 21.80 2591 8500
72.4 10.50 543.1 21.38 2743 9000
71.1 10.31 532.8 20.98 2896 9500
69.7 10.11 522.5 20.57 3048 10,000
67.1 9.73 502.8 19.80 3353 11,000
64.4 9.34 483.1 19.02 3658 12,000
62.0 8.99 464.7 18.30 3963 13,000
59.5 8.63 446.3 17.57 4267 14,000
57.2 8.30 429.0 16.89 4572 15,000
54.9 7.96 411.7 16.21 4877 16,000
Barometric Pressure at Altitude ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Notes
Index
Page X-1
About the Manual ................................................................................................i-1 Air Compressor ..............................................................................................12-16

General Information...........................................................................................i-1 Clean and Inspect for Reuse........................................................................12-17
Acronyms and Abbreviations ...........................................................................i-17 Finishing Steps.............................................................................................12-22
General Information.........................................................................................i-17 Install.............................................................................................................12-19
Additional Service Literature ............................................................................L-1 Preparatory Steps.........................................................................................12-17
General Information..........................................................................................L-1 Pressure Test................................................................................................12-16
Aftercooler Assembly (Sea Water) .................................................................10-3 Remove.........................................................................................................12-17
Assemble........................................................................................................10-8 Air Compressor (Oil Carryover) ....................................................................12-24
Clean and Inspect for Reuse..........................................................................10-7 Inspect for Reuse..........................................................................................12-24
Disassemble...................................................................................................10-6 Air Compressor Carbon Buildup ....................................................................12-2
Finishing Steps.............................................................................................10-10 Clean...............................................................................................................12-3
QSL Engines............................................................................................10-10 Initial Check....................................................................................................12-2
QSC Engines............................................................................................10-10 Air Compressor Coolant Lines .......................................................................12-7
Initial Check....................................................................................................10-3 Finishing Steps...............................................................................................12-8
Install...............................................................................................................10-8 Inspect for Reuse............................................................................................12-8
QSL Engines..............................................................................................10-8 Install...............................................................................................................12-8
QSC Engines..............................................................................................10-9 Preparatory Steps...........................................................................................12-7
Preparatory Steps...........................................................................................10-4 Remove...........................................................................................................12-7
QSL Engines..............................................................................................10-4 Air Compressor Cylinder Head, Single Cylinder ...........................................12-8
QSC Engines..............................................................................................10-5 Assemble......................................................................................................12-12
Pressure Test..................................................................................................10-8 Clean and Inspect for Reuse........................................................................12-10
Remove...........................................................................................................10-6 Disassemble.................................................................................................12-12
QSL Engines..............................................................................................10-6 Finishing Steps.............................................................................................12-15
QSC Engines..............................................................................................10-6 Initial Check....................................................................................................12-8
Aftertreatment Diesel Exhaust Fluid Dosing Unit .......................................11-34 Install.............................................................................................................12-14
Finishing Steps.............................................................................................11-37 Preparatory Steps...........................................................................................12-9
General Information......................................................................................11-34 Remove...........................................................................................................12-9
Initial Check..................................................................................................11-35 Air Compressor Rear Bearing Housing, Two Cylinder ...............................12-28
Install.............................................................................................................11-37 Clean and Inspect for Reuse........................................................................12-29
Preparatory Steps.........................................................................................11-35 Finishing Steps.............................................................................................12-31
Remove.........................................................................................................11-35 General Information......................................................................................12-28
Test...............................................................................................................11-36 Install.............................................................................................................12-30
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing .........11-30 Preparatory Steps.........................................................................................12-29
Finishing Steps.............................................................................................11-34 Remove.........................................................................................................12-29
Flush.............................................................................................................11-32 Air Compressor Unloader and Valve Assembly ..........................................12-15
General Information......................................................................................11-30 Preparatory Steps.........................................................................................12-15
Initial Check..................................................................................................11-31 Air Crossover ..................................................................................................10-13
Preparatory Steps.........................................................................................11-31 Clean and Inspect for Reuse........................................................................10-13
Test...............................................................................................................11-33 Install.............................................................................................................10-14
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter .............................11-38 Remove.........................................................................................................10-13
Finishing Steps.............................................................................................11-41 Air Governor ...................................................................................................12-22
General Information......................................................................................11-38 Pressure Test................................................................................................12-22
Initial Check..................................................................................................11-38 Air in Fuel ............................................................................................................6-4
Inspect for Reuse..........................................................................................11-40 Finishing Steps.................................................................................................6-7
Install.............................................................................................................11-40 Measure............................................................................................................6-5
Preparatory Steps.........................................................................................11-39 Setup.................................................................................................................6-4
Remove.........................................................................................................11-39 Air Inlet Connection .......................................................................................10-15
Aftertreatment Diesel Exhaust Fluid Line Restriction Test ........................11-43 Clean and Inspect for Reuse........................................................................10-15
Finishing Steps.............................................................................................11-46 Finishing Steps.............................................................................................10-16
General Information......................................................................................11-43 Install.............................................................................................................10-16
Initial Check..................................................................................................11-44 Preparatory Steps.........................................................................................10-15
Preparatory Steps.........................................................................................11-44 Remove.........................................................................................................10-15
Remove.........................................................................................................11-44 Air Intake Connection ....................................................................................10-59
Test...............................................................................................................11-45 Clean and Inspect for Reuse........................................................................10-60
Aftertreatment Diesel Exhaust Fluid Tank Filter .........................................11-41 Finishing Steps.............................................................................................10-60
Finishing Steps.............................................................................................11-43 Install.............................................................................................................10-60
General Information......................................................................................11-41 Preparatory Steps.........................................................................................10-59
Inspect for Reuse..........................................................................................11-42 Remove.........................................................................................................10-59
Install.............................................................................................................11-42 Air Intake Connection Adapter ......................................................................10-67
Preparatory Steps.........................................................................................11-41 Clean and Inspect for Reuse........................................................................10-68
Remove.........................................................................................................11-42 Finishing Steps.............................................................................................10-69
Aftertreatment Nozzle ....................................................................................11-27 Install.............................................................................................................10-68
Clean and Inspect for Reuse........................................................................11-29 Preparatory Steps.........................................................................................10-67
Finishing Steps.............................................................................................11-30 Remove.........................................................................................................10-67
General Information......................................................................................11-27 Air Intake Manifold Cover ..............................................................................10-61
Initial Check..................................................................................................11-27 Clean and Inspect for Reuse........................................................................10-61
Install.............................................................................................................11-29 Finishing Steps.............................................................................................10-62
Preparatory Steps.........................................................................................11-28 Install.............................................................................................................10-62
Remove.........................................................................................................11-28 Preparatory Steps.........................................................................................10-61
Aftertreatment Selective Catalytic Reduction (SCR) Catalyst ...................11-18 Remove.........................................................................................................10-61
Assemble......................................................................................................11-23 Air Intake Restriction .....................................................................................10-30
Clean and Inspect for Reuse........................................................................11-21 Measure........................................................................................................10-30
Disassemble.................................................................................................11-20 Air Intake System .............................................................................................V-67
Finishing Steps.............................................................................................11-24 Specifications.................................................................................................V-67
General Information......................................................................................11-18 Air Leaks, Air Intake and Exhaust Systems .................................................10-16
Install.............................................................................................................11-23 Initial Check..................................................................................................10-16
Preparatory Steps.........................................................................................11-19 Air Leaks, Compressed Air System ..............................................................12-23
Remove.........................................................................................................11-19 Initial Check..................................................................................................12-23
Test...............................................................................................................11-23 Air Pressure Relief Valve ...............................................................................12-27
Aftertreatment Testing ...................................................................................14-54 Test...............................................................................................................12-27
Regeneration................................................................................................14-54 Alternator ..........................................................................................................13-2
Air Cleaner Assembly (Engine-Mounted) .....................................................10-11 Finishing Steps...............................................................................................13-8
Clean.............................................................................................................10-12 Initial Check....................................................................................................13-2
General Information......................................................................................10-11 Install...............................................................................................................13-7
Initial Check..................................................................................................10-11 Preparatory Steps...........................................................................................13-5
Install.............................................................................................................10-13 Remove...........................................................................................................13-6
Remove.........................................................................................................10-11 Test.................................................................................................................13-2
Index
Page X-2
Alternator Bracket ............................................................................................13-8 QSC Engines............................................................................................8-142

Finishing Steps...............................................................................................13-9 Preparatory Steps.........................................................................................8-140
Install...............................................................................................................13-9 Remove.........................................................................................................8-140
Preparatory Steps...........................................................................................13-8 QSL Engines............................................................................................8-140
Remove...........................................................................................................13-8 QSC Engines............................................................................................8-141
Barometric Pressure at Altitude .....................................................................V-81 Coolant Thermostat .........................................................................................8-24
Specifications.................................................................................................V-81 Clean and Inspect for Reuse..........................................................................8-30
Batteries ..........................................................................................................13-11 Finishing Steps...............................................................................................8-32
Initial Check..................................................................................................13-11 General Information........................................................................................8-24
Battery Cables and Connections ..................................................................13-12 Install...............................................................................................................8-31
Initial Check..................................................................................................13-12 Leak Test........................................................................................................8-25
Belt Guard ...........................................................................................................8-3 Preparatory Steps...........................................................................................8-28
Inspect for Reuse..............................................................................................8-3 Remove...........................................................................................................8-29
Install.................................................................................................................8-4 Coolant Thermostat Housing ..........................................................................8-32
Remove.............................................................................................................8-3 Assemble........................................................................................................8-36
Belt Tensioner, Automatic (Water Pump) ....................................................8-119 QSL Engines..............................................................................................8-36
Finishing Steps.............................................................................................8-123 Clean and Inspect for Reuse..........................................................................8-35
Initial Check..................................................................................................8-119 QSL Engines..............................................................................................8-35
Inspect for Reuse..........................................................................................8-121 Disassemble...................................................................................................8-35
Install.............................................................................................................8-122 QSL Engines..............................................................................................8-35
Preparatory Steps.........................................................................................8-121 Finishing Steps...............................................................................................8-37
Remove.........................................................................................................8-121 QSL Engines..............................................................................................8-37
Belt Tensioner, Refrigerant Compressor, Automatic .....................................9-8 General Information........................................................................................8-32
Finishing Steps...............................................................................................9-11 QSL Engines..............................................................................................8-32
Initial Check......................................................................................................9-8 Install...............................................................................................................8-36
Install...............................................................................................................9-10 QSL Engines..............................................................................................8-36
Install...............................................................................................................9-11 Leak Test........................................................................................................8-34
Preparatory Steps.............................................................................................9-9 QSL Engines..............................................................................................8-34
Remove.............................................................................................................9-9 Preparatory Steps...........................................................................................8-33
Bracket, Fan Idler Pulley ................................................................................8-138 QSL Engines..............................................................................................8-33
Finishing Steps.............................................................................................8-139 Remove...........................................................................................................8-33
Inspect for Reuse..........................................................................................8-139 QSL Engines..............................................................................................8-33
Install.............................................................................................................8-139 Coolant Thermostat Housing Support ...........................................................8-37
Preparatory Steps.........................................................................................8-138 Clean and Inspect for Reuse..........................................................................8-38
Capscrew Markings and Torque Values ........................................................V-74 Finishing Steps...............................................................................................8-39
Capscrew Markings and Torque Values - Metric............................................V-74 QSL Engines..............................................................................................8-39
Capscrew Markings and Torque Values - U.S. Customary............................V-75 General Information........................................................................................8-37
General Information........................................................................................V-74 QSL Engines..............................................................................................8-37
Charge-Air Cooler ..........................................................................................10-21 Install...............................................................................................................8-39
Clean.............................................................................................................10-25 QSL Engines..............................................................................................8-39
Initial Check..................................................................................................10-21 QSL Engines..............................................................................................8-37
Install.............................................................................................................10-25 Remove...........................................................................................................8-38
Leak Test......................................................................................................10-21 QSL Engines..............................................................................................8-38
Preparatory Steps.........................................................................................10-24 Coolant Thermostat Seal .................................................................................8-39
Pressure Test................................................................................................10-22 Clean and Inspect for Reuse..........................................................................8-40
Remove.........................................................................................................10-24 Finishing Steps...............................................................................................8-41
Temperature Differential Test.......................................................................10-23 Install...............................................................................................................8-40
Charging System Indicator ............................................................................13-24 Preparatory Steps...........................................................................................8-39
Initial Check..................................................................................................13-24 Marine Applications....................................................................................8-39
Cold Starting Aid ............................................................................................10-26 Remove...........................................................................................................8-40
Clean and Inspect for Reuse........................................................................10-28 Coolant Vent Lines ...........................................................................................8-41
Finishing Steps.............................................................................................10-29 Finishing Steps...............................................................................................8-45
General Information......................................................................................10-26 General Information........................................................................................8-41
Install.............................................................................................................10-29 Install...............................................................................................................8-43
Preparatory Steps.........................................................................................10-28 Preparatory Steps...........................................................................................8-42
Remove.........................................................................................................10-28 Remove...........................................................................................................8-42
Compressed Air System .................................................................................V-70 Cooling System ................................................................................................8-45
Specifications.................................................................................................V-70 Coolant Replacer Method...............................................................................8-45
Cummins 18.7 CFM Model........................................................................V-70 Drain...............................................................................................................8-52
Coolant Filter ....................................................................................................8-11 Fill...................................................................................................................8-53
Install...............................................................................................................8-12 Flush...............................................................................................................8-53
Remove...........................................................................................................8-11 Cooling System ................................................................................................V-66
Coolant Filter Head ..........................................................................................8-14 Specifications.................................................................................................V-66
Clean and Inspect for Reuse..........................................................................8-16 Cooling System Diagnostics ...........................................................................8-57
Finishing Steps...............................................................................................8-17 Analyzing the Data..........................................................................................8-73
Install...............................................................................................................8-16 General Information........................................................................................8-57
Preparatory Steps...........................................................................................8-14 Initial Check....................................................................................................8-63
Remove...........................................................................................................8-15 Pressure Test..................................................................................................8-64
Coolant Filter Valve ..........................................................................................8-18 Setup...............................................................................................................8-68
Finishing Steps...............................................................................................8-21 Test.................................................................................................................8-68
Inspect for Reuse............................................................................................8-19 Worksheet.......................................................................................................8-74
Install...............................................................................................................8-20 Crankcase Blowby, Measure .........................................................................14-27
Preparatory Steps...........................................................................................8-18 General Information......................................................................................14-27
Remove...........................................................................................................8-19 Initial Check..................................................................................................14-34
Coolant Heater ..................................................................................................8-22 Measure........................................................................................................14-36
Clean...............................................................................................................8-23 Cummins Customized Parts Catalog ...............................................................L-3
Finishing Steps...............................................................................................8-24 General Information..........................................................................................L-3
Install...............................................................................................................8-23 Ordering the Customized Parts Catalog...........................................................L-3
Preparatory Steps...........................................................................................8-22 Cummins®/Fleetguard® Filter Specifications ...............................................V-72
Remove...........................................................................................................8-22 General Information........................................................................................V-72
Coolant Return Junction Block .....................................................................8-140 Cup Plug ............................................................................................................17-1
Clean and Inspect for Reuse........................................................................8-141 Clean and Inspect for Reuse..........................................................................17-1
Finishing Steps.............................................................................................8-143 Install...............................................................................................................17-2
Install.............................................................................................................8-142 Remove...........................................................................................................17-1
QSL Engines............................................................................................8-142 Drive Belt Tension ...........................................................................................V-73
Index
Page X-3
Tension Chart.................................................................................................V-73 Install.................................................................................................................7-2

Drive Belt, Alternator .......................................................................................13-9 Preparatory Steps.............................................................................................7-2
Finishing Steps.............................................................................................13-10 Remove.............................................................................................................7-2
Install.............................................................................................................13-10 Engine Run-in (Chassis Dynamometer) .......................................................14-10
Preparatory Steps...........................................................................................13-9 Test...............................................................................................................14-10
Remove.........................................................................................................13-10 Engine Run-in (Engine Dynamometer) .........................................................14-18
Drive Belt, Cooling Fan ......................................................................................8-5 Run-In Instructions........................................................................................14-18
Clean and Inspect for Reuse............................................................................8-8 Engine Run-in (Without Dynamometer) .......................................................14-12
Finishing Steps...............................................................................................8-10 Test...............................................................................................................14-12
General Information..........................................................................................8-5 Engine Support Bracket, Front .......................................................................16-3
Install...............................................................................................................8-10 Clean and Inspect for Reuse..........................................................................16-4
Preparatory Steps.............................................................................................8-8 Finishing Steps...............................................................................................16-5
Remove.............................................................................................................8-8 Install...............................................................................................................16-4
Troubleshooting................................................................................................8-5 Preparatory Steps...........................................................................................16-3
Drive Belt, Refrigerant Compressor .................................................................9-6 Remove...........................................................................................................16-3
Finishing Steps.................................................................................................9-8 Engine Support Bracket, Rear ........................................................................16-6
Inspect for Reuse..............................................................................................9-7 Clean and Inspect for Reuse..........................................................................16-7
Install.................................................................................................................9-7 Install...............................................................................................................16-7
Preparatory Steps.............................................................................................9-6 Remove...........................................................................................................16-6
Remove.............................................................................................................9-6 Engine Testing .................................................................................................V-71
Electrical System .............................................................................................V-69 Specifications.................................................................................................V-71
Batteries (Specific Gravity).............................................................................V-69 Engine Testing (Chassis Dynamometer) .......................................................14-4
Engine Barring Device .......................................................................................9-3 Setup...............................................................................................................14-4
Finishing Steps.................................................................................................9-3 Test.................................................................................................................14-7
Install.................................................................................................................9-3 Engine Testing (Engine Dynamometer) .......................................................14-12
Engine Brake Assembly ..................................................................................20-1 Setup.............................................................................................................14-12
Adjust..............................................................................................................20-4 Engine Testing (In Chassis) ..........................................................................14-24
Clean and Inspect for Reuse..........................................................................20-2 Automated Cylinder Performance Test.........................................................14-25
Finishing Steps...............................................................................................20-9 Cylinder Cutout Test.....................................................................................14-26
Install...............................................................................................................20-2 Setup.............................................................................................................14-24
Preparatory Steps...........................................................................................20-1 Exhaust Gas Pressure Sensor ......................................................................11-26
Remove...........................................................................................................20-1 Install.............................................................................................................11-27
Engine Brake Housing Spacer ........................................................................20-9 Remove.........................................................................................................11-26
Clean and Inspect for Reuse..........................................................................20-9 Exhaust Gas Temperature Sensor ................................................................11-24
Finishing Steps.............................................................................................20-10 Clean and Inspect for Reuse........................................................................11-25
Install.............................................................................................................20-10 Install.............................................................................................................11-25
Preparatory Steps...........................................................................................20-9 Remove.........................................................................................................11-24
Remove...........................................................................................................20-9 Exhaust Gas Treatment Monitor Harness ....................................................11-25
Engine Brake Solenoid Valve ........................................................................20-10 Finishing Steps.............................................................................................11-26
Finishing Steps.............................................................................................20-11 Inspect for Reuse..........................................................................................11-26
Install.............................................................................................................20-11 Install.............................................................................................................11-26
Preparatory Steps.........................................................................................20-10 Preparatory Steps.........................................................................................11-25
Remove.........................................................................................................20-11 Remove.........................................................................................................11-25
Engine Brake Wiring Harness .......................................................................20-12 Exhaust Gas Treatment Monitor Unit ...........................................................11-17
Finishing Steps.............................................................................................20-14 General Information......................................................................................11-17
Install.............................................................................................................20-13 Inspect for Reuse..........................................................................................11-17
Preparatory Steps.........................................................................................20-12 Install.............................................................................................................11-17
Remove.........................................................................................................20-12 Remove.........................................................................................................11-17
Resistance Check.........................................................................................20-13 Exhaust Manifold, Dry ......................................................................................11-4
Engine Control Module Cooling Plate, Fuel Cooled .......................................6-7 Clean and Inspect for Reuse..........................................................................11-5
Assemble........................................................................................................6-10 Disassemble...................................................................................................11-5
Disassemble...................................................................................................6-10 Finishing Steps...............................................................................................11-8
Finishing Steps...............................................................................................6-12 Install...............................................................................................................11-7
Initial Check......................................................................................................6-7 Preparatory Steps...........................................................................................11-4
Inspect for Reuse............................................................................................6-10 Remove...........................................................................................................11-4
Install...............................................................................................................6-11 Exhaust Manifold, Wet .....................................................................................11-9
Preparatory Steps.............................................................................................6-9 Clean and Inspect for Reuse........................................................................11-10
Remove...........................................................................................................6-10 Finishing Steps.............................................................................................11-12
ECM Unswitched Power Terminal Blocks ....................................................13-25 Install.............................................................................................................11-11
General Information......................................................................................13-25 Remove.........................................................................................................11-10
Initial Check..................................................................................................13-26 Exhaust Outlet Connection ...........................................................................11-14
Install.............................................................................................................13-28 Clean and Inspect for Reuse........................................................................11-14
Preparatory Steps.........................................................................................13-27 Finishing Steps.............................................................................................11-15
Remove.........................................................................................................13-27 Install.............................................................................................................11-14
Engine Drive Shaft .........................................................................................16-63 Preparatory Steps.........................................................................................11-14
Adjust............................................................................................................16-66 Remove.........................................................................................................11-14
Finishing Steps.............................................................................................16-68 Exhaust Restriction ........................................................................................11-12
General Information......................................................................................16-63 General Information......................................................................................11-12
Measure........................................................................................................16-65 Measure........................................................................................................11-13
Preparatory Steps.........................................................................................16-63 Exhaust System ...............................................................................................V-68
Remove.........................................................................................................16-63 Specifications.................................................................................................V-68
Setup.............................................................................................................16-64 Expansion Plug ................................................................................................17-6
Engine Fuel Heater, Electric ..............................................................................5-3 Clean and Inspect for Reuse..........................................................................17-6
Finishing Steps.................................................................................................5-5 Install...............................................................................................................17-7
Initial Check......................................................................................................5-3 Remove...........................................................................................................17-6
Install.................................................................................................................5-5 Expansion Tank ................................................................................................8-93
Preparatory Steps.............................................................................................5-4 Finishing Steps...............................................................................................8-97
Remove.............................................................................................................5-4 QSL Engines..............................................................................................8-97
Engine Mounts ................................................................................................16-52 General Information........................................................................................8-93
General Information......................................................................................16-52 Initial Check....................................................................................................8-94
Inspect for Reuse..........................................................................................16-54 QSL Engines..............................................................................................8-94
Install.............................................................................................................16-55 Inspect for Reuse............................................................................................8-96
Engine Oil Heater ...............................................................................................7-2 Install...............................................................................................................8-96
Finishing Steps.................................................................................................7-3 QSL Engines..............................................................................................8-96
Index
Page X-4
Preparatory Steps...........................................................................................8-94 Initial Check....................................................................................................6-15

QSL Engines..............................................................................................8-94 Inspect for Reuse............................................................................................6-18
Remove...........................................................................................................8-95 Install...............................................................................................................6-18
QSL Engines..............................................................................................8-95 Preparatory Steps...........................................................................................6-15
Fan Clutch, On-Off ...........................................................................................8-75 Remove...........................................................................................................6-16
General Information........................................................................................8-75 Fuel Filter (Spin-On Type) ...............................................................................6-20
Fan Shroud Assembly .....................................................................................8-76 Finishing Steps...............................................................................................6-22
General Information........................................................................................8-76 General Information........................................................................................6-20
Initial Check....................................................................................................8-76 Install...............................................................................................................6-21
Fan Spacer and Pulley .....................................................................................8-76 Measure..........................................................................................................6-20
Finishing Steps...............................................................................................8-78 Prime...............................................................................................................6-22
Inspect for Reuse............................................................................................8-77 Remove...........................................................................................................6-21
Install...............................................................................................................8-78 Fuel Filter Head ................................................................................................6-23
Preparatory Steps...........................................................................................8-76 Assemble........................................................................................................6-25
Remove...........................................................................................................8-77 Disassemble...................................................................................................6-24
Fan, Cooling ......................................................................................................8-78 Finishing Steps...............................................................................................6-26
Finishing Steps...............................................................................................8-80 Inspect for Reuse............................................................................................6-25
Inspect for Reuse............................................................................................8-79 Install...............................................................................................................6-25
Install...............................................................................................................8-80 Preparatory Steps...........................................................................................6-23
Remove...........................................................................................................8-79 Fuel Filter Head Bracket ..................................................................................6-27
Flexplate ............................................................................................................16-8 Finishing Steps...............................................................................................6-29
Finishing Steps.............................................................................................16-12 Inspect for Reuse............................................................................................6-28
Initial Check....................................................................................................16-9 Install...............................................................................................................6-28
Inspect for Reuse..........................................................................................16-11 Preparatory Steps...........................................................................................6-27
Install.............................................................................................................16-11 Remove...........................................................................................................6-28
Preparatory Steps...........................................................................................16-8 Fuel Injection Pump .........................................................................................5-80
Remove.........................................................................................................16-10 Clean and Inspect for Reuse..........................................................................5-82
Flywheel ..........................................................................................................16-13 Finishing Steps...............................................................................................5-84
Clean and Inspect for Reuse........................................................................16-14 General Information........................................................................................5-80
Finishing Steps.............................................................................................16-19 Install...............................................................................................................5-82
Install.............................................................................................................16-15 Preparatory Steps...........................................................................................5-80
Measure........................................................................................................16-17 Remove...........................................................................................................5-81
Preparatory Steps.........................................................................................16-13 Fuel Inlet Restriction ........................................................................................6-30
Flywheel Housing ...........................................................................................16-20 Measure..........................................................................................................6-32
Assemble......................................................................................................16-23 Preparatory Steps...........................................................................................6-30
Clean and Inspect for Reuse........................................................................16-23 Fuel Lift Pump ..................................................................................................5-23
Disassemble.................................................................................................16-22 Finishing Steps...............................................................................................5-29
Finishing Steps.............................................................................................16-30 Initial Check....................................................................................................5-23
Install.............................................................................................................16-24 Install...............................................................................................................5-28
Measure........................................................................................................16-26 Preparatory Steps...........................................................................................5-26
Preparatory Steps.........................................................................................16-20 Remove...........................................................................................................5-27
Remove.........................................................................................................16-21 Fuel Pressure Relief Valve ..............................................................................6-68
Flywheel Housing, REPTO ............................................................................16-32 Finishing Steps...............................................................................................6-72
Assemble......................................................................................................16-40 Initial Check....................................................................................................6-68
Clean and Inspect for Reuse........................................................................16-39 Inspect for Reuse............................................................................................6-72
Disassemble.................................................................................................16-37 Install...............................................................................................................6-72
Exploded View..............................................................................................16-32 Preparatory Steps...........................................................................................6-70
Finishing Steps.............................................................................................16-50 Remove...........................................................................................................6-71
Install.............................................................................................................16-45 Test.................................................................................................................6-69
Preparatory Steps.........................................................................................16-35 Fuel Pump .........................................................................................................5-11
Flywheel Ring Gear ........................................................................................16-50 General Information........................................................................................5-11
Finishing Steps.............................................................................................16-51 Inspect for Reuse............................................................................................5-13
Initial Check..................................................................................................16-50 Install...............................................................................................................5-13
Install.............................................................................................................16-51 Preparatory Steps...........................................................................................5-11
Remove.........................................................................................................16-51 Remove...........................................................................................................5-12
Fraction, Decimal, Millimeter Conversions ...................................................V-76 Fuel Pump Accumulator Module ....................................................................5-43
Conversion Chart............................................................................................V-76 Clean and Inspect for Reuse..........................................................................5-46
Fuel Connector (Head Mounted) .....................................................................6-58 Finishing Steps...............................................................................................5-49
Finishing Steps...............................................................................................6-60 General Information........................................................................................5-43
Inspect for Reuse............................................................................................6-59 Install...............................................................................................................5-47
Remove...........................................................................................................6-58 Fuel Pump Actuator Housing ..........................................................................5-78
Fuel Consumption ..............................................................................................5-6 Clean and Inspect for Reuse..........................................................................5-79
Measure............................................................................................................5-6 Finishing Steps...............................................................................................5-80
Fuel Cooler ........................................................................................................6-73 General Information........................................................................................5-78
Clean and Inspect for Reuse..........................................................................6-74 Install...............................................................................................................5-79
Finishing Steps...............................................................................................6-75 Remove...........................................................................................................5-79
QSL Engines..............................................................................................6-75 Fuel Pump Air Bleed Line ................................................................................6-60
General Information........................................................................................6-73 Finishing Steps...............................................................................................6-64
QSL Engines..............................................................................................6-73 Inspect for Reuse............................................................................................6-62
Install...............................................................................................................6-75 Install...............................................................................................................6-62
QSL Engines..............................................................................................6-75 ISC and QSC8.3 With CAPS Injection Pump.............................................6-62
Preparatory Steps...........................................................................................6-73 ISL and QSL9 With CAPS Injection Pump.................................................6-63
Remove...........................................................................................................6-74 Remove...........................................................................................................6-61
QSL Engines..............................................................................................6-74 ISC and QSC8.3 With CAPS Injection Pump.............................................6-61
Fuel Drain Line Restriction ..............................................................................6-13 ISL and QSL9 With CAPS Injection Pump.................................................6-61
Finishing Steps...............................................................................................6-15 Fuel Pump Cam Housing Module ...................................................................5-54
Measure..........................................................................................................6-15 Clean and Inspect for Reuse..........................................................................5-55
Preparatory Steps...........................................................................................6-13 Finishing Steps...............................................................................................5-58
Fuel Drain Lines ...............................................................................................6-15 General Information........................................................................................5-54
Index
Page X-5
Preparatory Steps...........................................................................................5-54 Fuel System.....................................................................................................i-15

Remove...........................................................................................................5-55 Gasket Surfaces...............................................................................................i-13
Fuel Pump Delivery Valve ................................................................................5-15 Plastic Bead Cleaning......................................................................................i-14
Clean and Inspect for Reuse..........................................................................5-16 Solvent and Acid Cleaning...............................................................................i-13
Finishing Steps...............................................................................................5-17 Steam Cleaning................................................................................................i-14
General Information........................................................................................5-15 General Engine .................................................................................................V-62
Install...............................................................................................................5-17 Specifications.................................................................................................V-62
Preparatory Steps...........................................................................................5-15 General Repair Instructions .............................................................................i-10
Remove...........................................................................................................5-16 General Information.........................................................................................i-10
Fuel Pump Distributor and Injection Control Valve Module .........................5-49 Welding on a Vehicle with an Electronic Controlled Fuel System....................i-11
Clean and Inspect for Reuse..........................................................................5-51 General Safety Instructions ................................................................................i-8
Finishing Steps...............................................................................................5-54 Important Safety Notice......................................................................................i-8
General Information........................................................................................5-49 Heat Exchanger ................................................................................................8-97
Install...............................................................................................................5-51 Assemble......................................................................................................8-102
Preparatory Steps...........................................................................................5-50 Clean and Inspect for Reuse........................................................................8-101
Remove...........................................................................................................5-50 Disassemble.................................................................................................8-101
Fuel Pump Distributor Inlet Fitting .................................................................5-40 Finishing Steps.............................................................................................8-104
Clean and Inspect for Reuse..........................................................................5-42 General Information........................................................................................8-97
Finishing Steps...............................................................................................5-43 Install.............................................................................................................8-103
General Information........................................................................................5-40 Preparatory Steps...........................................................................................8-98
Install...............................................................................................................5-43 Pressure Test................................................................................................8-102
Remove...........................................................................................................5-41 Heat Shield ......................................................................................................11-15
Fuel Pump Gear Pump .....................................................................................5-17 Clean and Inspect for Reuse........................................................................11-16
Clean and Inspect for Reuse..........................................................................5-21 Install.............................................................................................................11-16
Finishing Steps...............................................................................................5-21 Remove.........................................................................................................11-15
General Information........................................................................................5-17 How to Use the Manual .......................................................................................i-2
Initial Check....................................................................................................5-17 General Information...........................................................................................i-2
Install...............................................................................................................5-21 Hydraulic Pump Drive ........................................................................................9-1
Preparatory Steps...........................................................................................5-20 Clean.................................................................................................................9-1
Remove...........................................................................................................5-20 Inspect for Reuse..............................................................................................9-2
Fuel Pump Gear Pump Module .......................................................................5-58 Install.................................................................................................................9-2
Clean and Inspect for Reuse..........................................................................5-59 Remove.............................................................................................................9-1
Finishing Steps...............................................................................................5-61 Illustrations ..........................................................................................................i-7
General Information........................................................................................5-58 General Information...........................................................................................i-7
Initial Check....................................................................................................5-58 Injection Control Valve ....................................................................................5-32
Install...............................................................................................................5-60 Clean and Inspect for Reuse..........................................................................5-34
Preparatory Steps...........................................................................................5-59 Click Test........................................................................................................5-35
Remove...........................................................................................................5-59 Finishing Steps...............................................................................................5-36
Fuel Pump Head ...............................................................................................5-66 General Information........................................................................................5-32
Clean and Inspect for Reuse..........................................................................5-73 Install...............................................................................................................5-34
Finishing Steps...............................................................................................5-77 Preparatory Steps...........................................................................................5-33
General Information........................................................................................5-66 Remove...........................................................................................................5-33
Initial Check....................................................................................................5-67 Injector ..............................................................................................................6-41
Install...............................................................................................................5-76 Assemble........................................................................................................6-49
Preparatory Steps...........................................................................................5-70 Clean and Inspect for Reuse..........................................................................6-49
Remove...........................................................................................................5-72 Disassemble...................................................................................................6-48
Fuel Pump Head Outlet Fitting ........................................................................5-63 Finishing Steps...............................................................................................6-52
Clean and Inspect for Reuse..........................................................................5-65 Initial Check....................................................................................................6-41
General Information........................................................................................5-63 Preparatory Steps...........................................................................................6-45
Install...............................................................................................................5-65 Remove...........................................................................................................6-46
Preparatory Steps...........................................................................................5-64 Test.................................................................................................................6-47
Remove...........................................................................................................5-65 Injector Supply Lines (High Pressure) ...........................................................6-53
Fuel Pump Rate Shape Tube ...........................................................................5-61 Clean and Inspect for Reuse..........................................................................6-55
Clean and Inspect for Reuse..........................................................................5-62 Finishing Steps...............................................................................................6-57
Finishing Steps...............................................................................................5-63 Initial Check....................................................................................................6-53
General Information........................................................................................5-61 Install...............................................................................................................6-55
Remove...........................................................................................................5-62 Inline Air Filter ................................................................................................10-69
Fuel Pump Timing ............................................................................................5-22 Finishing Steps.............................................................................................10-70
Finishing Steps...............................................................................................5-23 General Information......................................................................................10-69
Inspect for Reuse............................................................................................5-22 Install.............................................................................................................10-70
Preparatory Steps...........................................................................................5-22 Preparatory Steps.........................................................................................10-69
Fuel Rail ............................................................................................................6-64 Remove.........................................................................................................10-70
Finishing Steps...............................................................................................6-67 Intake Manifold Pressure ...............................................................................10-58
Initial Check....................................................................................................6-64 Measure........................................................................................................10-58
Install...............................................................................................................6-67 Keel Cooler .....................................................................................................8-125
Remove...........................................................................................................6-66 QSL Engines............................................................................................8-125
Fuel Rail High Pressure Fitting .......................................................................6-75 Pressure Differential Test.............................................................................8-126
Initial Check....................................................................................................6-75 QSL Engines............................................................................................8-126
Install...............................................................................................................6-76 Temperature Differential Test.......................................................................8-125
Remove...........................................................................................................6-76 QSL Engines............................................................................................8-125
Fuel Supply Lines .............................................................................................6-33 Lubricating Oil and Filter Analysis .................................................................7-49
Finishing Steps...............................................................................................6-40 Inspect............................................................................................................7-49
Initial Check....................................................................................................6-33 Lubricating Oil Contamination ........................................................................7-47
Inspect for Reuse............................................................................................6-37 Fluorescent Dye Tracer..................................................................................7-47
Preparatory Steps...........................................................................................6-34 Lubricating Oil Cooler ........................................................................................7-3
Remove...........................................................................................................6-34 Clean and Inspect for Reuse............................................................................7-5
Fuel System ......................................................................................................V-63 Finishing Steps.................................................................................................7-7
Specifications.................................................................................................V-63 Install.................................................................................................................7-6
General Cleaning Instructions .........................................................................i-12 Leak Test..........................................................................................................7-6
Abrasive Pads and Abrasive Paper.................................................................i-12 Preparatory Steps.............................................................................................7-3
Definition of Clean............................................................................................i-12 Remove.............................................................................................................7-5
Index
Page X-6
Lubricating Oil Dipstick .....................................................................................7-8 Remove.........................................................................................................8-145

Calibrate............................................................................................................7-8 Marine Gear Oil Cooler ....................................................................................8-81
Lubricating Oil Dipstick Tube ...........................................................................7-9 Assemble........................................................................................................8-88
Finishing Steps...............................................................................................7-10 QSL Engines..............................................................................................8-88
Install...............................................................................................................7-10 QSC Engines..............................................................................................8-88
Preparatory Steps.............................................................................................7-9 Disassemble...................................................................................................8-84
Remove.............................................................................................................7-9 QSL Engines..............................................................................................8-84
Lubricating Oil Filter (Spin-On) .......................................................................7-11 QSC Engines..............................................................................................8-84
Install...............................................................................................................7-12 Finishing Steps...............................................................................................8-90
Measure..........................................................................................................7-11 Flush...............................................................................................................8-81
Remove...........................................................................................................7-12 Inspect for Reuse............................................................................................8-84
Lubricating Oil Filter Bypass Valve ................................................................7-13 QSL Engines..............................................................................................8-84
Clean and Inspect for Reuse..........................................................................7-15 QSC Engines..............................................................................................8-86
General Information........................................................................................7-13 QSL Engines..............................................................................................8-88
Install...............................................................................................................7-15 QSC Engines..............................................................................................8-89
Preparatory Steps...........................................................................................7-14 Preparatory Steps...........................................................................................8-81
Remove...........................................................................................................7-14 Remove...........................................................................................................8-83
Lubricating Oil Filter Head ..............................................................................7-17 QSL Engines..............................................................................................8-83
Clean and Inspect for Reuse..........................................................................7-18 QSC Engines..............................................................................................8-83
Finishing Steps...............................................................................................7-19 Marine Vibration Isolator ...............................................................................16-58
Install...............................................................................................................7-18 Finishing Steps.............................................................................................16-62
Remove...........................................................................................................7-18 Initial Check..................................................................................................16-58
Lubricating Oil Filter Head (Remote-Mounted) ..............................................7-19 Inspect for Reuse..........................................................................................16-61
Assemble........................................................................................................7-21 Install.............................................................................................................16-62
Disassemble...................................................................................................7-20 Preparatory Steps.........................................................................................16-60
Finishing Steps...............................................................................................7-22 Remove.........................................................................................................16-61
Inspect for Reuse............................................................................................7-20 Newton-Meter to Foot-Pound Conversions ...................................................V-77
Install...............................................................................................................7-21 Conversion Chart............................................................................................V-77
Preparatory Steps...........................................................................................7-19 Pipe Plug ...........................................................................................................17-2
Remove...........................................................................................................7-20 Clean and Inspect for Reuse..........................................................................17-3
Lubricating Oil Filter Head Adapter ................................................................7-22 Install...............................................................................................................17-3
Clean and Inspect for Reuse..........................................................................7-23 Remove...........................................................................................................17-2
Finishing Steps...............................................................................................7-24 Pipe Plug Torque Values .................................................................................V-78
Install...............................................................................................................7-23 Torque Table..................................................................................................V-78
Preparatory Steps...........................................................................................7-22 Propeller Shaft ................................................................................................16-55
Remove...........................................................................................................7-23 General Information......................................................................................16-55
Lubricating Oil High Pressure Relief Valve ...................................................7-24 Out of Water..................................................................................................16-56
Inspect for Reuse............................................................................................7-25 Alignment..................................................................................................16-56
Install...............................................................................................................7-25 Preparatory Steps.........................................................................................16-55
Remove...........................................................................................................7-24 Specifications................................................................................................16-57
Lubricating Oil Leaks .......................................................................................7-25 Pulley, Fan Idler ..............................................................................................8-137
Initial Check....................................................................................................7-25 Finishing Steps.............................................................................................8-138
Lubricating Oil Lines ........................................................................................7-51 Inspect for Reuse..........................................................................................8-137
Remove...........................................................................................................7-51 Remove.........................................................................................................8-137
Lubricating Oil Pan ..........................................................................................7-27 Pumping Control Valve ....................................................................................5-36
Clean and Inspect for Reuse..........................................................................7-28 Click Test........................................................................................................5-36
Finishing Steps...............................................................................................7-30 Cutout Test.....................................................................................................5-37
Preparatory Steps...........................................................................................7-27 Radiator .............................................................................................................8-90
Remove...........................................................................................................7-27 General Information........................................................................................8-90
Lubricating Oil Pressure Regulator (Main Rifle) ...........................................7-30 Initial Check....................................................................................................8-90
Clean and Inspect for Reuse..........................................................................7-31 Radiator Hoses .................................................................................................8-91
Install...............................................................................................................7-32 Inspect for Reuse............................................................................................8-91
Remove...........................................................................................................7-30 Radiator Pressure Cap .....................................................................................8-91
Lubricating Oil Pump .......................................................................................7-32 General Information........................................................................................8-91
Assemble........................................................................................................7-39 Inspect for Reuse............................................................................................8-92
Clean and Inspect for Reuse..........................................................................7-34 Radiator Shutter Assembly .............................................................................8-93
Disassemble...................................................................................................7-33 General Information........................................................................................8-93
Finishing Steps...............................................................................................7-41 Refrigerant Compressor ....................................................................................9-4
Install...............................................................................................................7-39 Finishing Steps.................................................................................................9-5
Measure..........................................................................................................7-34 Inspect for Reuse..............................................................................................9-4
Modify.............................................................................................................7-36 Install.................................................................................................................9-5
Preparatory Steps...........................................................................................7-32 Preparatory Steps.............................................................................................9-4
Remove...........................................................................................................7-32 Remove.............................................................................................................9-4
Lubricating Oil Suction Tube (Block-Mounted) .............................................7-42 Refrigerant Compressor Mounting Bracket ...................................................9-12
Clean and Inspect for Reuse..........................................................................7-43 Clean and Inspect for Reuse..........................................................................9-13
Finishing Steps...............................................................................................7-44 Finishing Steps...............................................................................................9-14
Install...............................................................................................................7-43 Install...............................................................................................................9-13
Preparatory Steps...........................................................................................7-42 Preparatory Steps...........................................................................................9-12
Remove...........................................................................................................7-42 Remove...........................................................................................................9-12
Lubricating Oil System ....................................................................................7-44 Rotor, CAPS Fuel Injection Pump ...................................................................5-29
Drain...............................................................................................................7-44 Clean and Inspect for Reuse..........................................................................5-30
Fill...................................................................................................................7-45 Finishing Steps...............................................................................................5-32
Lubricating Oil System ....................................................................................V-64 General Information........................................................................................5-29
Specifications.................................................................................................V-64 Install...............................................................................................................5-31
Marine Gear Oil and Fuel Cooler Assembly .................................................8-143 Preparatory Steps...........................................................................................5-30
Assemble......................................................................................................8-148 Remove...........................................................................................................5-30
Disassemble.................................................................................................8-146 Sea Water Hoses ............................................................................................8-136
Finishing Steps.............................................................................................8-150 Inspect..........................................................................................................8-136
Flush.............................................................................................................8-143 Sea Water Pump .............................................................................................8-104
Inspect for Reuse..........................................................................................8-146 Finishing Steps.............................................................................................8-111
Preparatory Steps.........................................................................................8-145 Inspect for Reuse..........................................................................................8-110
Index
Page X-7
Install.............................................................................................................8-110 Prime.............................................................................................................10-44
Preparatory Steps.........................................................................................8-109 Remove.........................................................................................................10-40
Remove.........................................................................................................8-109 Turbocharger Actuator Air Line ....................................................................10-65
Repair...........................................................................................................8-106 Clean and Inspect for Reuse........................................................................10-65
Sea Water Strainer .........................................................................................8-116 Finishing Steps.............................................................................................10-66
Assemble......................................................................................................8-118 Install.............................................................................................................10-66
Marine Applications..................................................................................8-118 Preparatory Steps.........................................................................................10-65
Clean.............................................................................................................8-118 Remove.........................................................................................................10-65
Marine Applications..................................................................................8-118 Turbocharger Coolant Hoses ........................................................................10-46
Disassemble.................................................................................................8-117 Clean and Inspect for Reuse........................................................................10-48
Marine Applications..................................................................................8-117 Finishing Steps.............................................................................................10-50
General Information......................................................................................8-116 Install.............................................................................................................10-49
Marine Applications..................................................................................8-116 Preparatory Steps.........................................................................................10-46
Prime.............................................................................................................8-118 Remove.........................................................................................................10-47
Marine Applications..................................................................................8-118 Turbocharger Exhaust Connection Adapter ................................................10-71
Sea Water System Diagnostics .....................................................................8-127 Clean and Inspect for Reuse........................................................................10-71
General Information......................................................................................8-127 Finishing Steps.............................................................................................10-72
Initial Check..................................................................................................8-127 Install.............................................................................................................10-72
Pressure Differential Test.............................................................................8-131 Preparatory Steps.........................................................................................10-71
QSL Engines............................................................................................8-131 Remove.........................................................................................................10-71
QSC Engines............................................................................................8-133 Turbocharger Oil Drain Line ..........................................................................10-51
Pressure Test................................................................................................8-130 Clean and Inspect for Reuse........................................................................10-51
Temperature Differential Test.......................................................................8-134 Initial Check..................................................................................................10-51
QSL Engines............................................................................................8-134 Install.............................................................................................................10-52
QSC Engines............................................................................................8-135 Remove.........................................................................................................10-51
Test...............................................................................................................8-128 Turbocharger Oil Supply Line .......................................................................10-52
Service Literature Ordering Location ...............................................................L-2 Initial Check..................................................................................................10-52
Contact Information...........................................................................................L-2 Inspect for Reuse..........................................................................................10-53
Service Tools ......................................................................................................5-1 Install.............................................................................................................10-53
Fuel System......................................................................................................5-1 Remove.........................................................................................................10-52
Service Tools ......................................................................................................6-1 Turbocharger Wastegate Actuator ...............................................................10-53
Injectors and Fuel Lines....................................................................................6-1 Clean and Inspect for Reuse........................................................................10-56
Service Tools ......................................................................................................7-1 Initial Check..................................................................................................10-53
Lubricating Oil System......................................................................................7-1 Install.............................................................................................................10-57
Service Tools ......................................................................................................8-1 Remove.........................................................................................................10-55
Cooling System.................................................................................................8-1 Test...............................................................................................................10-54
Service Tools ....................................................................................................10-1 Turbocharger Wastegate Valve Body ...........................................................10-57
Air Intake System............................................................................................10-1 Finishing Steps.............................................................................................10-58
Service Tools ....................................................................................................11-1 Marine Applications..................................................................................10-58
Exhaust System..............................................................................................11-1 Maintenance Check......................................................................................10-57
Service Tools ....................................................................................................12-1 Preparatory Steps.........................................................................................10-57
Compressed Air System.................................................................................12-1 Marine Applications..................................................................................10-57
Service Tools ....................................................................................................13-1 Variable Geometry Turbocharger Actuator, Pneumatic .............................10-63
Electrical Equipment.......................................................................................13-1 Clean and Inspect for Reuse........................................................................10-63
Service Tools ....................................................................................................14-1 Finishing Steps.............................................................................................10-65
Engine Testing................................................................................................14-1 Install.............................................................................................................10-64
Service Tools ....................................................................................................16-1 Remove.........................................................................................................10-63
........................................................................................................................16-1 Test...............................................................................................................10-64
Snubber, Rate Shape .......................................................................................5-38 Water Inlet Connection ..................................................................................8-123
Finishing Steps...............................................................................................5-40 Clean and Inspect for Reuse........................................................................8-124
General Information........................................................................................5-38 Finishing Steps.............................................................................................8-125
Preparatory Steps...........................................................................................5-38 Remove.........................................................................................................8-124
Remove...........................................................................................................5-38 Water Pump ....................................................................................................8-113
Starter Magnetic Switch .................................................................................13-12 Clean and Inspect for Reuse........................................................................8-115
Initial Check..................................................................................................13-12 Finishing Steps.............................................................................................8-116
Resistance Check.........................................................................................13-13 General Information......................................................................................8-113
Voltage Check...............................................................................................13-13 Install.............................................................................................................8-115
Starter Solenoid ..............................................................................................13-15 Preparatory Steps.........................................................................................8-114
Initial Check..................................................................................................13-15 Remove.........................................................................................................8-114
Voltage Check...............................................................................................13-17 Weights and Measures - Conversion Factors ...............................................V-80
Starter Switch .................................................................................................13-14 Conversion Chart............................................................................................V-80
Voltage Check...............................................................................................13-14 Zinc Anode ......................................................................................................8-111
Starting Motor .................................................................................................13-19 Install.............................................................................................................8-112
Clean and Inspect for Reuse........................................................................13-22 Remove.........................................................................................................8-111
Finishing Steps.............................................................................................13-24
Install.............................................................................................................13-22
Measure........................................................................................................13-22
Preparatory Steps.........................................................................................13-21
Remove.........................................................................................................13-21
Rotation Check.............................................................................................13-19
Straight Thread Plug ........................................................................................17-4
Clean and Inspect for Reuse..........................................................................17-4
General Information........................................................................................17-4
Install...............................................................................................................17-5
Remove...........................................................................................................17-4
Symbols ................................................................................................................i-3
General Information...........................................................................................i-3
Tap-Drill Chart - U.S. Customary and Metric .................................................V-79
General Information........................................................................................V-79
Turbocharger ..................................................................................................10-31
Clean and Inspect for Reuse........................................................................10-41
Finishing Steps.............................................................................................10-45
Initial Check..................................................................................................10-31
Install.............................................................................................................10-43
Preparatory Steps.........................................................................................10-38
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202
Registered Office
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2014
Cummins Inc.
Bulletin 4021418
Printed in U.S.A. 23-JULY-2014

Troubleshooting and Repair Manual Isc, Isce, Qsc8.3, Isl, Isle3, Isle4 and Qsl9 Engines

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Troubleshooting and Repair Manual Isc, Isce, Qsc8.3, Isl, Isle3, Isle4 and Qsl9 Engines

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Troubleshooting and Repair Manual

ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and

Copyright© 2014 Bulletin 4021418

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

Miscellaneous - Group 17 ................................................................................................................................. 17

Vehicle Braking - Group 20 ............................................................................................................................... 20

Service Literature .............................................................................................................................................. L

Back .................................................................................................................................................................... back

This Page Left Intentionally Blank

About the Manual

How to Use the Manual

Indicates a REMOVAL or Dissassembly step.

Indicates an INSTALLATION or ASSEMBLY step.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another

The component weighs 23kg [50 lbs] or more. To reduce

The illustrations are intended to show repair or

General Safety Instructions

General Repair Instructions

• Follow all safety instructions noted in the procedures

• Use genuine Cummins new or ReCon® service parts and assemblies

Welding on a Vehicle with an Electronic Controlled Fuel System

General Cleaning Instructions

Plastic Bead Cleaning

Acronyms and Abbreviations

NOx Mono-Nitrogen Oxides

Section 5 - Fuel System - Group 05

Clean and Inspect for Reuse....................................................................................................................................5-51

This Page Left Intentionally Blank

Tool No. Tool Description Tool Illustration

Fuel Pump Mounting Plate

Fuel Pump Gear Puller

Pressure and Vacuum Module

12 mm Banjo Adapter Fitting (Leakage Flow Adapter)

Tool No. Tool Description Tool Illustration

Combustible Gas Detector

Fuel Pump Gear Puller

Electrical Contact Cleaner

M10 Compucheck® Fitting

Ball Joint Vise

1000 cc Graduated Cylinder

Engine Fuel Heater, Electric (005-008)

Remove the 2-pin connector from the fuel heater.

Apply thread-locker, Part Number 3375068, to the filter

Fuel Consumption (005-010)

Install the remote tank (1).

Measure the distance traveled with an accurate odometer.

Compute the kilometers per liter or miles per gallon: