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Internal Engine Brake Harness Repair

Preparatory Steps
Repair
Finishing Steps

Preparatory Steps
Remove the engine brake solenoid valve wiring harness.
Remove the rocker lever cover. Refer to Procedure 003-011 in
Section 3
Remove the engine brake wiring harness. Refer to Procedure
020-015 in Section 20

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Next

Repair – Prepare the Cylinder Head

Locate the
Center Engine
Brake Wiring
Harness
Support Leg
hole in the
Cylinder Head.

It is
adjacent
to the
center
cam
journal
on the
valve
cover
gasket
surface.

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Using a 17/64 inch (6.75mm) Drill,

enlarge the Center Engine Brake
Wiring Harness Support Leg hole to a
minimum depth of 0.71 inches (18
mm) or to the bottom of the existing

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hole at a maximum depth of 0.79

inches (20mm).

Cover the camshafts and other

adjacent internal engine
components to ensure that no
chips or debris from this
operation contaminate the
inside of the engine.

Obtain the required Drill size –

(17/64 inch (6.75 mm))

Set the Drill Depth using either

a Drill Bit Lock Collar or by
marking the bit at the specified
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minimum depth. -– (0.71 inches
(18 mm) to 0.79 inches (20mm))

Using Cutting Oil, drill the hole

until the desired depth is
reached. – (0.71 inches (18
mm) to 0.79 inches (20mm))
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Using Chip Removal Vacuum,
remove any machining chips
from the hole.

Using a M8 x 1.25 tap, tap the

Center Engine Brake Wiring Harness
Support Leg hole.

Obtain the required Tap size –

(M8 x 1.25)

Using Cutting Oil, tap the hole

until the tap makes contact
with the bottom of the hole,
creating a minimum of 15mm
of full threads.

Use a fast drying degreaser to

remove the oil film and clean SMALL | MEDIUM | LARGE

the newly cut threads.

Using Chip Removal Vacuum,

remove any machining chips
from the hole. Previous Next

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Repair – Prepare/Install The Engine Brake Wiring Harness

Remove the Center Support

Leg from the new Wiring
Harness.

Cut the support leg off

using either a hack saw
or cut-off wheel.

Be sure that all sharp

surfaces are ground
down and removed.

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Install the P-Clip onto the Engine Brake Wiring Harness.

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Install the Engine

Brake Wiring Harness
on to the Cylinder
Head.

Place one Flat

Washer in
between the
Cylinder Head
and the P-clip.

Place a
second Flat
Washer on top

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of the P-clip.

Apply medium
strength
Thread Locker
to the
M8x1.25x16
Capscrew.

Install the
Capscrew
through the
Washers and
P-Clip and into
the newly
threaded hole.
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Torque the
Capscrew to
17 ft-lbs (23
nm).

Be sure that
the second
wiring harness
support leg is
fully installed
into its locating
hole.

Bend the P-clip

as necessary
to ensure that Previous Next
the harness
has sufficient
clearance.

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Finishing Steps

Install the rocker lever cover. Refer to Procedure 003-011 in

Section 3
Install the engine brake solenoid valve wiring harness.

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Previous

Last Modified: 20-Sept-2012

Copyright © 2000-2010 Cummins Inc. All rights reserved.

8:56:16 AM 9/27/2012