Engine Repair PDF

REPAIR MANUAL
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
Contents
INTRODUCTION
POWER PRODUCTION B
87372074 3 15/11/2005
INTRODUCTION
87372074 3 15/11/2005
1
Contents
INTRODUCTION
Safety rules ( - A.50.A.10) 3

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Basic instructions ( - A.90.A.05) 4

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Torque ( - A.90.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Definition ( - A.92.A.15) 10
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Conversion factors ( - A.92.A.21) 13

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Product identification ( - A.80.A.10) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
2
INTRODUCTION
Safety rules ( - A.50.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
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 for your personal safety. Additional safety precautions are
included in the procedures where they apply.
General safety precautions

• The work area around the engine must be dry, well lit, ventilated, free from clutter, ignition sources and
hazardous substances.
• Always wear protective glasses and protective shoes when working.
• Stay clear of rotating parts which can cut, mutilate or strangle.
• 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.
Put a “Do NOT Operate” tag in the cab or on the controls.
• Only use proper engine barring techniques when rotating the engine manually. Do NOT attempt to rotate the
crankshaft by pulling or prying on the fan. This practice may cause serious personal injury, property damage,
fan damage or premature fan failure.
• When coolant is hot from engine operation, allow the engine to cool before slowly loosening the pressure cap
to relieve pressure in the cooling system.
• ALWAYS use blocks or the proper engine stand to support the engine before performing any repair work. Do
NOT work on an engine which is only supported by floor jacks or a hoist.
• Relieve all pressure in the air, oil and cooling systems before any lines, fittings or related items are removed or
disconnected. Be alert for possible pressure when disconnecting any component from a system that uses
pressure. Do NOT check for leaks with your hand. High pressure oil or fuel can cause personal injury.
• To reduce the possibility of personal injury, use a hoist or an assistant when lifting components that weigh 23
kg (50 lb) or more. Make sure all lifting equipment – such as chains, hooks or slings – is in good condition and
of the correct capacity. Make sure all lift hooks are positioned correctly. ALWAYS use a spreader bar when
necessary; lifting hooks must NOT be side-loaded.
• Corrosion inhibitor, a component of coolant additives 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 THE
REACH OF CHILDREN.
• Naptha and Methy Ethyl Ketone (MEK) are flammable materials and MUST be used with caution. Follow the
manufacturer’s instructions when using these materials. KEEP OUT OF THE REACH OF CHILDREN.
• To prevent burns, be aware of heated parts and hot fuel in lines, tubes and compartments on recently
operated engines.
• ALWAYS use tools that are in good condition. Understand the correct use of the tool before performing repair
work. Use ONLY genuine CNH replacement parts.
• ALWAYS use the same fastener part number (or equivalent) when replacing fasteners. Do NOT use a fastener
of lesser quality when replacing components.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some government agencies 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.
• Coolant is toxic. If NOT reused, follow local environmental regulations for proper disposal.
87372074 3 15/11/2005
3
INTRODUCTION
Basic instructions ( - A.90.A.05)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Definition of “clean”
Parts must be free of debris that can contaminate any engine system. This does not mean that cleaned parts
have to appear to be new.
Abrasive pads and abrasive paper

There is no part of an engine designed to withstand abrasion. All engine components are designed to lock together
or slide across each other. Abrasives and dirt particles will degrade both functions.
CNH does NOT recommend the use of emery cloth or sand paper on any part of an ASSEMBLED engine or
component, especially for removing the carbon ridge from cylinder liners or to clean block decks or counterbores.
Use abrasive products with great care when cleaning engine parts, particularly on partially assembled engines.
These cleaning products come in many forms and sizes. All contain aluminum oxide particles, silicon carbide, sand
or some other similar hard material. These materials are harder than most parts of the engine. When pressed
against a softer material, they will either damage the material or become embedded in it.
Once embedded in a part, the abrasive particle will abrade the other part it contacts until contact is no longer
made between the two parts. If the damage sufficiently degrades the oil film, the two parts may fail prematurely
from ineffective lubrication.
In addition, particles fall off of the holding material as the abrasive product is being used.
Gasket surface
The object in cleaning gasket surfaces is to remove gasket material, not to refinish the gasket surface on the part.
CNH does NOT recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used, check
the manufacturer’s directions to make sure the part being cleaned will not be damaged.
Air powered gasket scrapers can save time, but the surface cannot be damaged in the process.
All old gasket material must be removed from the gasket mating 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 sealing surface. Surface finish and flatness tolerances must be maintained to form a quality sealing surface.
Solvents and acid cleaning

Solvents and acid-type cleaner can be used to clean disassembled engine parts (with the exception of pistons). The
best results are obtained with a cleaner that can be heated to 90 - 95 °C (180 - 200 °F). CNH does NOT recommend
any specific brand of cleaner. Always follow the manufacturer’s instructions when using cleaning solutions.
WARNING
M995 - When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Kerosene emulsion based cleaners work the best for cleaning pistons. These cleaners should NOT be heated to
temperatures in excess of 82 °C (180 °F). The cleaners begin to break down at temperatures in excess of 82 °C
(180 °F) and will be less effective.
Do NOT use solutions composed primarily of chlorinated hydrocarbons with cresols, phenols and/or cresylic
components. These solutions often do NOT clean well and are costly to dispose of properly.
Solutions with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. The solutions become highly
alkaline or highly acidic the further they move from the neutral 7.0. Solutions with a pH above approximately 9.5
cause aluminum to turn black; highly alkaline solutions must NOT be used.
87372074 3 15/11/2005
4
INTRODUCTION
A cleaning tank that provides a constant mixing and filtering of the cleaning solution will yield the best results.
• Remove all gasket material, O-rings and sludge or carbon deposits with a wire brush or scraper before putting
the parts in the cleaning tank.
• When possible, use high pressure water or steam clean the parts before submerging them in the tank.
Removing the heaviest dirt before tank cleaning will allow the cleaner to work more effectively.
• Rinse all parts in hot water after cleaning. Dry completely with clean shop air. Use air to remove the rinse
water from all cap screw holes and the oil drillings.
• If the parts are NOT to be used immediately after cleaning, dip them in a suitable rust proofing compound.
This 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 may contaminate the cleaning tank. Steam cleaning is
an excellent method for cleaning oil drillings and coolant passages.
WARNING
M927 - Always wear protective clothing, safety glasses or a face shield when using a steam cleaner or
power washer. Failure to wear protective equipment can cause serious injury.
The following components should NEVER be steam cleaned:
– electrical components – belts and hoses

– wiring harnesses – bearings (ball or tapper roller)
– injectors – electronic control module (ECM)
– fuel pump – ECM connectors
Plastic bead cleaning

CNH recommends using ONLY plastic bead media on any engine part.
CNH does NOT recommend the use of glass bead blast or walnut shell media on ANY engine part. NEVER use
sand as a blast media on any engine part. Glass and walnut shell media can cause excess dust and can embed in
engine parts, which can result in premature component failure from abrasive wear.
Plastic beading 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 the cleaning time.
CAUTION
M1064 - Do not use the bead blasting cleaning method on aluminum piston skirts or bore pins 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 methods specified in the procedure.
CAUTION
M1065 - Do not contaminate wash tanks and tank type solvent cleaners with 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 and 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 material (U.S. size 16-20) can be used to clean piston ring grooves. Do NOT use bead blasting
media on piston pin bores or aluminum skirts. Bead blasting is best used on stubborn dirt or carbon build-up that
has NOT been removed by steam or high pressure washing, followed by cleaning in a heated wash tank. This
is particularly true of pistons: steam and soak the pistons first and then use the plastic bead method to safely
remove the carbon remaining in the grooves.
87372074 3 15/11/2005
5
INTRODUCTION
Follow the equipment manufacturer’s cleaning instructions. Adjust the air pressure in the blasting machine to
the manufacturer’s recommendation. Use these guidelines when plastic bead blasting recommendations are
not available:
• Use plastic bead size 16-20 (U.S. size) or equivalent.

• Use an operating pressure of 270 kPa (40 psi) for piston cleaning. Pressure should not cause the beads to
break.
• Steam clean or wash the parts with solvent to remove all foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
CAUTION
M1066 - Bead blasting must not disturb the metal surface of the component. 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. Removing the carbon
on the rim and from the ring grooves IS necessary. Direct the blast across the part rather than straight at the
part. If machining marks are disturbed by the blasting process, 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.
• Always direct the bead blast nozzle across rather than at the part. This allows the beading to get under the
unwanted material. Keep the nozzle moving, rather than held in one spot, to prevent surface damage.
• 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 then straight at them.
87372074 3 15/11/2005
6
INTRODUCTION
Torque ( - A.90.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
IMPORTANT: When replacing cap screws, always use a cap screw of the same measurement and strength as
the cap screw being replaced.
Metric cap screws and nuts are identified by the grade number stamped on the head of the cap screw or on the
surface of the nuts. U.S. customary cap screws are identified by radial lines stamped on the head of the cap screw.
Cap screw marking and torque value – Metric

Commercial steel class
8.8 10.9 12.9
Cap screw head marking
rh04h178 1 rh04h179 2 rh04h180 3
Dia. Cast iron Aluminum Cast iron Aluminum Cast iron Aluminum
mm Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm 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
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 – – – – – –
NOTES
1. Always use the torque values listed in the above table when specific torque values are not supplied in a
procedure.
2. Do NOT use these torque values in place of specified torque values in a procedure.
3. The values in the table are based on lubricated threads.
87372074 3 15/11/2005
7
INTRODUCTION
Cap screw marking and torque value – U.S. Customary

Cap screw head marking
SAE Grade 5 SAE Grade 8
rh04h175 4 rh04h176 5
Cast iron Aluminum Cast iron Aluminum

Body size Nm ft lb Nm ft lb Nm ft lb Nm 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
NOTES
1. Always use the torque values listed in the above table when specific torque values are not supplied in a
procedure.
2. Do NOT use these torque values in place of specified torque values in a procedure.
3. The values in the table are based on lubricated threads.
4. When a ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb wrench.
Pipe plug torque values

Size Torque
Thread Actual thread OD In aluminum housing In cast iron or steel housing
in in Nm ft-lb Nm ft-lb
1/16 0.32 5 45 lb in 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 75
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
87372074 3 15/11/2005
8
INTRODUCTION
Newton-meter to pound-foot conversion

N•m lb-in/lb-ft N•m lb-ft N•m lb-ft
1 9 lb in 55 41 155 114
5 44 lb in 60 44 160 118
6 53 lb in 65 48 165 122
7 62 lb in 70 52 170 125
8 71 lb in 75 55 175 129
9 80 lb in 80 59 180 133
10 89 lb in 85 63 185 136
11 97 lb in 90 66 190 140
12 106 lb in 95 70 195 144
14 124 lb in 100 74 200 148
15 133 lb in 105 77 205 151
16 142 lb in 110 81 210 155
18 159 lb in 115 85 215 159
20 15 lb ft 120 89 220 162
25 18 lb ft 125 92 225 165
30 22 lb ft 130 96 230 170
35 26 lb ft 135 100 235 173
40 30 lb ft 140 103 240 177
45 33 lb ft 145 107 245 180
50 37 lb ft 150 111 250 184
87372074 3 15/11/2005
9
INTRODUCTION
Definition ( - A.92.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Polishing
Polishing is a normal surface condition where machining
lines have been smoothed from contact between mating
parts.
RCPH05CDC003AAA 1
Denting
A dent is a depression left in the surface by a piece of
foreign material that is trapped between two parts. A
dent has a relatively smooth, shiny bottom and does
NOT have rough or sharp edges.
RCPH05CDC004AAA 2
Frosted bands
Frosted bands are created by high density micro-denting.
The bands are “frosted” or white in appearance. Frosted
bands are not detectable with a fingernail.
RCPH05CDC005AAA 3
87372074 3 15/11/2005
10
INTRODUCTION
Galling
Galling is the transfer of material from one part to the
surface of another mating part. Galling typically occurs
when one part skids, rather than glides, on the surface
of another part – e.g., a roller tappet on the camshaft
lobe. The extent of the galling determines whether the
part must be replaced.
RCPH05CDC006AAA 4
Surface distress: conditional reuse
RCPH05CDC007AAA 5
Major surface distress: no reuse
Pitting
Pitting is the loss of material from a part resulting in a
hole that is visible to the naked eye. Pits typically have
rough dark bottoms and sharp edges, and usually occur
in heavily-loaded areas on the part.
RCPH05CDC008AAA 6
87372074 3 15/11/2005
11
INTRODUCTION
Macro-Spalling
Macro-spalling is the loss of large material from the
surface of a part. This amount of damage will affect the
operation of the engine.
RCPH05CDC009AAA 7
87372074 3 15/11/2005
12
INTRODUCTION
Conversion factors ( - A.92.A.21)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Weights and measures

Category Metric U.S. Customary Metric to U.S. U.S.
Unit name Abbreviation Unit name Abbreviation Customary – Customary
Multiply by to Metric –
Multiply by
Area sq. millimeter mm² sq. inch in² 0.001550 645.16
sq. centimeter cm² 0.155 6.452
sq. meter m² sq. foot ft² 10.764 0.0929
Fuel gram per g/kW-hr pound per lb/hp-hr 0.001645 608.277
consumption kilowatt hour horsepower
hour
Fuel kilometer per km/l mile per gallon mpg 2.352 0.4251
performance liter
liter per l/km gallon per mile gpm 0.4251 2.352
kilometer
Force Newton N pound force lbf 0.224809 4.4482
Length millimeter mm inch in 0.039370 25.40
millimeter mm foot ft 0.00328 304.801
Power kilowatt kW horsepower hp 1.341 0.746
Pressure kilopascal kPa pound force psi 0.145037 6.8948
per sq. inch
kilopascal kPa inch of mercury in Hg 0.29613 3.3769
kilopascal kPa inch of water in H2O 4.019299 0.2488
millimeter of mm Hg inch of mercury in Hg 0.039370 25.40
mercury
millimeter of mm H2O inch of water in H2O 0.039370 25.40
water
kilopascal kPa bar bar 0.00999 100.001
millimeter of mm Hg bar bar 0.001333 750.06
mercury
Temperature centigrade °C fahrenheit °F (1.8 x °C) + 32 (°F-32)/1.8
Torque Newton-meter N•m pound force lb-ft 0.737562 1.35582
per foot
Newton-meter N•m pound force lb-in 8.850756 0.113
per inch
Velocity kilometer/hour kph mile/hour mph 0.6214 1.6093
Volume (liquidliter l U.S. gallon gal. 0.264179 3.7853
displacement) liter l Imperial gallon gal. 0.219976 4.546
liter l cubic inch in³ 61.02545 0.01639
cubic cm³ cubic inch in³ 0.06102 16.387
centimeter
Weight (mass) kilogram kg pounds lb. 2.204623 0.4536
Work joule J British Thermal BTU 0.000948 1054.5
Unit
kilowatt-hour kW-hr British Thermal BTU 3414 0.000293
Unit
kilowatt-hour kW-hr horsepower hp-hr 1.341 0.746
hour
87372074 3 15/11/2005
13
INTRODUCTION
Product identification ( - A.80.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC183ABA 1
Data plate locations
A — Engine data plate

B — Fuel injection pump data plate
C — Engine control module (ECM) data plate
87372074 3 15/11/2005
14
INTRODUCTION
RCIL05CDC005CAA 2
Engine data plate
1 — Engine serial number (ESN)

2 — Part number
3 — Engine model (e.g., 6TAA-8304 or 6TAA-9004)
4 — Horsepower and RPM rating
The engine data plate is located on top of the timing gear housing.
The engine data plate contains specific information about your engine. The engine serial number (ESN) and part
number are used when ordering service parts. The data plate MUST not be changed unless approved by CNH.
87372074 3 15/11/2005
15
INTRODUCTION
RCPH05CDC184ABA 3
Engine serial number (ESN)
If the engine data plate is not readable, the engine serial number is also stamped into the top of the oil cooler housing.
RCIL05CDC007AAA 4
Fuel injection pump data plate
1 — Part number
2 — Pump serial number
3 — Factory code
The fuel pump data plate is located on the side of the injection pump.
87372074 3 15/11/2005
16
INTRODUCTION
RCIL05CDC006CAA 5
Engine control module
P/N — Part number

S/N — Serial number
D/C — Date code
ESN — Engine serial number
ECM CODE — Software programming code
The engine control module data plate is located above the module connectors on the left hand side of the engine.
The data plate contains hardware and software programming information about the control module, as well as
the engine serial number (ESN).
87372074 3 15/11/2005
17
INTRODUCTION
87372074 3 15/11/2005
18
REPAIR MANUAL
POWER PRODUCTION
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B
Contents
POWER PRODUCTION - B
ENGINE B.10.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
FUEL AND INJECTION SYSTEM B.20.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
AIR INTAKE SYSTEM B.30.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
EXHAUST SYSTEM B.40.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
ENGINE COOLANT SYSTEM B.50.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
LUBRICATION SYSTEM B.60.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
STARTING SYSTEM B.80.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B
ENGINE - 10.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.10.A / 1
Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE - Special tools (B.10.A - D.20.A.40) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - General specification (B.10.A - D.40.A.10) 12

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive
Valve drive Rocker assembly - Torque (B.10.A.40.43 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Service limits (B.10.A.40.43 - D.20.A.20) 13

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Special tools (B.10.A.40.43 - D.20.A.40) 13

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Torque (B.10.A.40.43.05 - D.20.A.10) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Rocker arm - Service limits (B.10.A.40.43.10 - D.20.A.20) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Shaft - Service limits (B.10.A.40.43.20 - D.20.A.20) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Torque (B.10.A.40.44 - D.20.A.10) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Service limits (B.10.A.40.44 - D.20.A.20) 16

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Special tools (B.10.A.40.44 - D.20.A.40) 17

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Service limits (B.10.A.40.44.10 - D.20.A.20) 18

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Service limits (B.10.A.40.44.25 - D.20.A.20) 19

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Service limits (B.10.A.40.44.30 - D.20.A.20) 21

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Special tools (B.10.A.40.44.30 - D.20.A.40) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Journal - Service limits (B.10.A.40.44.35 - D.20.A.20) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Lobe - Service limits (B.10.A.40.44.40 - D.20.A.20) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Service limits (B.10.A.40.46.10 - D.20.A.20) 26

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Special tools (B.10.A.40.46.10 - D.20.A.40) 26

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Service limits (B.10.A.40.46.15 - D.20.A.20) 27

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Special tools (B.10.A.40.46.15 - D.20.A.40) 27

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft
87372074 3 15/11/2005
B.10.A / 2
Crankshaft - Service limits (B.10.A.43 - D.20.A.20) 29
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Special tools (B.10.A.43 - D.20.A.40) 29

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Torque (B.10.A.43.01 - D.20.A.10) 30

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Special tools (B.10.A.43.01 - D.20.A.40) 30

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Special tools (B.10.A.43.02 - D.20.A.40) 31

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Special tools (B.10.A.43.05 - D.20.A.40) 31

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Special tools (B.10.A.43.06 - D.20.A.40) 32

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Service limits (B.10.A.43.10 - D.20.A.20) 32

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Torque (B.10.A.43.15 - D.20.A.10) 33

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Special tools (B.10.A.43.15 - D.20.A.40) 33

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Service limits (B.10.A.43.15 - D.20.A.20) 35

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Torque (B.10.A.43.20 - D.20.A.10) 35

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing

Timing gear housing - Torque (B.10.A.46 - D.20.A.10) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston

Connecting rod and piston - Special tools (B.10.A.47 - D.20.A.40) 38
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Torque (B.10.A.47.10 - D.20.A.10) 38

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Service limits (B.10.A.47.10 - D.20.A.20) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Piston - Service limits (B.10.A.47.15 - D.20.A.20) 41

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Service limits (B.10.A.47.15.05 - D.20.A.20) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Pin - Service limits (B.10.A.47.15.10 - D.20.A.20) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel
Flywheel - Torque (B.10.A.50 - D.20.A.10) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Service limits (B.10.A.50 - D.20.A.20) 43

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Special tools (B.10.A.50 - D.20.A.40) 44

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Vibration damper
Vibration damper - Torque (B.10.A.68 - D.20.A.10) 46
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Vibration damper - Service limits (B.10.A.68 - D.20.A.20) 46

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block
Cylinder block Bore - Service limits (B.10.A.70.10 - D.20.A.20) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 3
Cylinder block Liner - Torque (B.10.A.70.15 - D.20.A.10) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Service limits (B.10.A.70.15 - D.20.A.20) 48

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Special tools (B.10.A.70.15 - D.20.A.40) 50

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head
Cylinder head - Torque (B.10.A.72 - D.20.A.10) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Service limits (B.10.A.72 - D.20.A.20) 53

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Special tools (B.10.A.72 - D.20.A.40) 55

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve seat - Service limits (B.10.A.72.10 - D.20.A.20) 59

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Service limits (B.10.A.72.15 - D.20.A.20) 59

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover
Valve cover - Torque (B.10.A.74 - D.20.A.10) 61
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover
Front cover - Torque (B.10.A.75 - D.20.A.10) 62
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover
Rear cover - Torque (B.10.A.76 - D.20.A.10) 63
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control
Electronic control Control module - Torque (B.10.A.92.91 - D.20.A.10) 64
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Speed sensor - Torque (B.10.A.95.80 - D.20.A.10) 65
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Service limits (B.10.A.95.80 - D.20.A.20) 65

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Torque (B.10.A.95.82 - D.20.A.10) 65

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Service limits (B.10.A.95.82 - D.20.A.20) 66

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
Timing gear
Timing gear - Static description (B.10.A.45 - C.30.A.20) 67
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Wiring harness
Wiring harness - Component identification (B.10.A.88 - C.40.C.20) 68
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system - Component identification (B.10.A.95 - C.40.C.20) 72
MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
ENGINE - Place on stand (B.10.A - F.35.A.10) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Check (B.10.A - F.40.A.11) 78

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 4
Valve drive
Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11) 80
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Remove (B.10.A.40.43 - F.10.A.10) 82

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Disassemble (B.10.A.40.43 - F.10.A.25) 84

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Visual inspection (B.10.A.40.43 - F.40.A.10) 85

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16) 87

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Assemble (B.10.A.40.43 - F.10.A.20) 88

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15) 89

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Remove (B.10.A.40.43.05 - F.10.A.10) 90

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Visual inspection (B.10.A.40.43.05 - F.40.A.10) 92

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Install (B.10.A.40.43.05 - F.10.A.15) 93

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Remove (B.10.A.40.43.25 - F.10.A.10) 95

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Visual inspection (B.10.A.40.43.25 - F.40.A.10) 96

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Install (B.10.A.40.43.25 - F.10.A.15) 97

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Preliminary test (B.10.A.40.44 - F.40.A.20) 98

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10) 100

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Visual inspection (B.10.A.40.44 - F.40.A.10) 102

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16) 103

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15) 105

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10) 107

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15) 108

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Remove (B.10.A.40.44.10 - F.10.A.10) 109

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10) 110

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Install (B.10.A.40.44.10 - F.10.A.15) 112

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Remove (B.10.A.40.44.20 - F.10.A.10) 114

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Visual inspection (B.10.A.40.44.20 - F.40.A.10) 115

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Install (B.10.A.40.44.20 - F.10.A.15) 117

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Remove (B.10.A.40.44.25 - F.10.A.10) 118

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 5
Camshaft Tappet - Visual inspection (B.10.A.40.44.25 - F.40.A.10) 120
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Install (B.10.A.40.44.25 - F.10.A.15) 121

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Remove (B.10.A.40.44.30 - F.10.A.10) 124

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16) 126

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Install (B.10.A.40.44.30 - F.10.A.15) 127

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01) 128

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Disassemble (B.10.A.40.46 - F.10.A.25) 130

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Cleaning (B.10.A.40.46.10 - F.30.A.10) 132

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Visual inspection (B.10.A.40.46.10 - F.40.A.10) 133

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01) 134

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01) 135

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Assemble (B.10.A.40.46 - F.10.A.20) 136

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft
Crankshaft - Remove (B.10.A.43 - F.10.A.10) 139
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Install (B.10.A.43 - F.10.A.15) 140

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - End play (B.10.A.43 - F.40.E.10) 141

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10) 142

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Visual inspection (B.10.A.43.01 - F.40.A.10) 144

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15) 145

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Remove (B.10.A.43.02 - F.10.A.10) 148

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Visual inspection (B.10.A.43.02 - F.40.A.10) 149

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Install (B.10.A.43.02 - F.10.A.15) 150

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Remove (B.10.A.43.05 - F.10.A.10) 153

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Visual inspection (B.10.A.43.05 - F.40.A.10) 154

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Install (B.10.A.43.05 - F.10.A.15) 155

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Remove (B.10.A.43.06 - F.10.A.10) 158

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Visual inspection (B.10.A.43.06 - F.40.A.10) 161

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Install (B.10.A.43.06 - F.10.A.15) 163

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 6
Crankshaft Gear - Remove (B.10.A.43.10 - F.10.A.10) 169
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Visual inspection (B.10.A.43.10 - F.40.A.10) 170

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16) 171

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Install (B.10.A.43.10 - F.10.A.15) 172

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Remove (B.10.A.43.15 - F.10.A.10) 174

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Visual inspection (B.10.A.43.15 - F.40.A.10) 178

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16) 179

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Install (B.10.A.43.15 - F.10.A.15) 180

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01) 186

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Remove (B.10.A.43.20 - F.10.A.10) 187

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Visual inspection (B.10.A.43.20 - F.40.A.10) 188

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Install (B.10.A.43.20 - F.10.A.15) 189

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing

Timing gear housing - Remove (B.10.A.46 - F.10.A.10) 190
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10) 192

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Install (B.10.A.46 - F.10.A.15) 193

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston

Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10) 195
MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25) 199

MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20) 201

MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15) 204

MX215, MX245, MX275, STX280, 2388, 2377

MX305

MX305

MX305

MX305
Connecting rod and piston Connecting rod - Visual inspection (B.10.A.47.10 - F.40.A.10) 228
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.A.16) 230
MX215, MX245, MX275, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 7
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.E.01) 233
MX305
Connecting rod Bearing - Remove (B.10.A.47.10.05 - F.10.A.10) 236

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Visual inspection (B.10.A.47.10.05 - F.40.A.10) 237

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Measure (B.10.A.47.10.05 - F.40.A.16) 239

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Install (B.10.A.47.10.05 - F.10.A.15) 240

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Piston - Cleaning (B.10.A.47.15 - F.30.A.10) 241

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.A.16) 243

MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.E.01) 245

MX305
Piston Ring - Remove (B.10.A.47.15.05 - F.10.A.10) 247

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16) 248

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Install (B.10.A.47.15.05 - F.10.A.15) 249

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Pin - Measure (B.10.A.47.15.10 - F.40.A.16) 251

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel
Flywheel - Remove (B.10.A.50 - F.10.A.10) 252
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Visual inspection (B.10.A.50 - F.40.A.10) 254

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Install (B.10.A.50 - F.10.A.15) 256

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Measure (B.10.A.50 - F.40.A.16) 259

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Vibration damper
Vibration damper - Remove (B.10.A.68 - F.10.A.10) 261
MX215, MX245, MX275, STX280, 2377
Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10) 262

MX215, MX245, MX275, STX280, 2377
Vibration damper - Install (B.10.A.68 - F.10.A.15) 264

MX215, MX245, MX275, MX305, STX280, 2377

MX305, 2388

MX305, 2388

MX305, 2388
Cylinder block
Cylinder block - Cleaning (B.10.A.70 - F.30.A.10) 269
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block - Measure (B.10.A.70 - F.40.A.16) 270

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Bore - Measure (B.10.A.70.10 - F.40.A.16) 271

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Preliminary test (B.10.A.70.15 - F.40.A.20) 272

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 8
Cylinder block Liner - Remove (B.10.A.70.15 - F.10.A.10) 275
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Visual inspection (B.10.A.70.15 - F.40.A.10) 277

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16) 281

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15) 282

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head
Cylinder head - Remove (B.10.A.72 - F.10.A.10) 292
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25) 294

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Cleaning (B.10.A.72 - F.30.A.10) 297

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10) 300

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Measure (B.10.A.72 - F.40.A.16) 302

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Pressure test (B.10.A.72 - F.40.A.30) 304

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve seat - Vacuum test (B.10.A.72.10 - F.40.A.25) 307

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Cleaning (B.10.A.72.15 - F.30.A.10) 308

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16) 309

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Assemble (B.10.A.72 - F.10.A.20) 311

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Install (B.10.A.72 - F.10.A.15) 314

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover
Valve cover - Remove (B.10.A.74 - F.10.A.10) 316
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Visual inspection (B.10.A.74 - F.40.A.10) 317

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Install (B.10.A.74 - F.10.A.15) 318

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover
Front cover - Remove (B.10.A.75 - F.10.A.10) 319
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Visual inspection (B.10.A.75 - F.40.A.10) 320

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Install (B.10.A.75 - F.10.A.15) 321

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover
Rear cover - Remove (B.10.A.76 - F.10.A.10) 324
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover - Install (B.10.A.76 - F.10.A.15) 326

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Wiring harness
Wiring harness - Disconnect (B.10.A.88 - F.10.A.11) 327
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 9
Wiring harness - Connect (B.10.A.88 - F.10.A.16) 328
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control
Electronic control - Check (B.10.A.92 - F.40.A.11) 329
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control Control module - Remove (B.10.A.92.91 - F.10.A.10) 331

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control Control module - Install (B.10.A.92.91 - F.10.A.15) 334

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Speed sensor - Remove (B.10.A.95.80 - F.10.A.10) 337
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Visual inspection (B.10.A.95.80 - F.40.A.10) 338

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01) 339

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Install (B.10.A.95.80 - F.10.A.15) 340

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Remove (B.10.A.95.82 - F.10.A.10) 341

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Visual inspection (B.10.A.95.82 - F.40.A.10) 342
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Test (B.10.A.95.82 - F.40.C.01) 343

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Install (B.10.A.95.82 - F.10.A.15) 344

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
ENGINE - Problem solving (B.10.A - G.40.A.30) 345
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Testing (B.10.A - G.40.A.20) 348

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 10
POWER PRODUCTION - ENGINE
ENGINE - Special tools (B.10.A - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
The Revolver® engine repair stand – OEM4137

The Revolver® includes OEM205061 which permits use
of engine mounting plates. Engine capacity: 2,722 kg
(6000 lb).
RCSC05CDC137AAA 1
Universal engine adapter – OEM205061 (SPX)

This assembly, included with OEM4137, is required to
add engine mounting plates to The Revolver®.
RCPH05CDC996AAC 2
Engine mounting plate – OEM218099 (SPX)

This plate is bolted to the CNH “C” Series engines so the
engine can be installed on The Revolver® engine repair
stand, OEM4137.
RCPH05CDC121AAA 3
3 15/11/2005
B.10.A / 11
Load-Rotor® positioning sling – OEM4130

This sling is used for the handling and positioning of
engines, transmissions and other bulky components
during installation and removal.
RCSC05CDC138AAA 4
ENGINE - General specification (B.10.A - D.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Horsepower Refer to engine dataplate.

Firing order 1.5.3.6.2.4
Displacement 8.3 L (504.5 in³)
8.9 L (540.0 in³)
Bore and stroke
6TAA-8304 114 mm (4.49 in) x 135 mm (5.32 in)
6TAA-9004 114 mm (4.49 in) x 144.5 mm (5.69 in)
Dry weight
6TAA-8304 694 kg (1530 lb)
6TAA-9004 706 kg (1555 lb)
Wet weight
6TAA-8304 723 kg (1595 lb)
6TAA-9004 738 kg (1625 lb)
Overhead adjustment
Intake valve adjustment 0.305 mm (0.012 in)
Exhaust valve adjustment 0.559 mm (0.022 in)
3 15/11/2005
B.10.A / 12
Valve drive Rocker assembly - Torque (B.10.A.40.43 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component N·m Identification lb-ft

Rocker arm cap screws 65 Nm 48 lb ft
RCPH05CDC855AAA 1
Valve drive Rocker assembly - Service limits (B.10.A.40.43 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Lash check limits

Reference: Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11)
Intake
Minimum 0.152 mm 0.006 in
Maximum 0.559 mm 0.022 in
Exhaust
RCPH05CDC227AAA 1
Lash reset
Intake 0.305 mm 0.012 in
Exhaust 0.559 mm 0.022 in
RCPH05CDC223AAA 2
3 15/11/2005
B.10.A / 13
Valve drive Rocker assembly - Special tools (B.10.A.40.43 -

D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Telescoping gauge set – OEM1015

The gauges in this set permit accurate measurement
of small bores, e.g., the rocker arm bore diameter.
The gauge is inserted into the piece and tightened;
measurement is read with an appropriate micrometer.
Range is 8 - 54 mm (0.3125 - 2.125 in).
RCPH05CDC273AAA 1
Rocker assembly Housing - Torque (B.10.A.40.43.05 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Housing cap screws 24 Nm 18 lb ft
RCPH05CDC286AAA 1
3 15/11/2005
B.10.A / 14
Rocker assembly Rocker arm - Service limits (B.10.A.40.43.10 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker arm shaft bore

Reference: Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16)
RCPH05CDC275AAA 1
Rocker assembly Shaft - Service limits (B.10.A.40.43.20 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker arm shaft

Reference: Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16)
RCPH05CDC274AAB 1
3 15/11/2005
B.10.A / 15
Valve drive Camshaft - Torque (B.10.A.40.44 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Thrust plate cap screws 24 Nm 18 lb ft
RCPH05CDC250AAA 1
Valve drive Camshaft - Service limits (B.10.A.40.44 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft intake or exhaust lobe lift

Reference: Valve drive Camshaft - Preliminary test (B.10.A.40.44 - F.40.A.20)
Exhaust lobe lift (approximate)
Intake lobe lift (approximate)
RCPH05CDC366ABA 1
Camshaft bearing journal

Reference: Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16)
RCPH05CDC327AAB 2
3 15/11/2005
B.10.A / 16
Camshaft thrust plate

RCPH05CDC341AAB 3
Camshaft end play

Reference: Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10)
RCPH05CDC776AAA 4
Valve drive Camshaft - Special tools (B.10.A.40.44 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Roller tappet removal tool – 3165088 (Cummins)

This tool is used to raise the tappets, remove the
camshaft and then remove the tappets without further
disassembly of the block.
RCPH05CDC779AAA 1
3 15/11/2005
B.10.A / 17
Dial indicator set – OEM1026

With a powerful magnetic base, the dial is both
continuous and balanced with revolution counter and
may be rotated for setting at any point. The gauge is
used to measure camshaft end play and exhaust and
intake lobe lift.
RCPH05CDC702AAA 2
Magnetic base – OEM1030

Magnetic base with flexible arm to position dial indicators
for testing.
RCPH05CDC701AAA 3
Camshaft Gear - Service limits (B.10.A.40.44.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft gear backlash

Reference: Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15)
RCPH05CDC777AAA 1
3 15/11/2005
B.10.A / 18
Camshaft gear
Reference: Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10)
Replace the camshaft gear:
• if the teeth are cracked, chipped or broken,
• if fretting, burrs or raised material cannot be removed
from the bore with a Scotch-Brite™ pad,
• if the keyway is damaged or the burrs in the keyway
cannot be removed with a Scotch-Brite™ pad,
• if the speed sensor targets are damaged.
RCPH05CDC337AAB 2
Camshaft Tappet - Service limits (B.10.A.40.44.25 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Roller tappet reuse guidelines

NOTE: Refer to Definition ( - A.92.A.15) for definitions of the conditions. Refer to Camshaft Tappet - Visual
inspection (B.10.A.40.44.25 - F.40.A.10) for tappet inspection.
Roller Tappet Reuse Example

Condition
New Unconditional reuse
Polish present, no Unconditional reuse
damage
RCPH05CDC003AAA 1
Denting Unconditional reuse
RCPH05CDC004AAA 2
3 15/11/2005
B.10.A / 19

Condition
Frosted bands Unconditional reuse
RCPH05CDC005AAA 3
Galling (1) Conditional reuse (2)

– Less than 1.5 mm
(0.0625 in) wide
surface distress, no
pits
RCPH05CDC006AAA 4
Galling (1) Conditional reuse

– More than 1.5 mm
(0.0625 in) wide
pits
RCPH05CDC007AAA 5
3 15/11/2005
B.10.A / 20

Condition
Pitting Replace
RCPH05CDC008AAA 6
Macro-spalling Replace
RCPH05CDC009AAA 7
(1) If multiple gall streaks are present but are NOT connected, apply the width criteria to each streak individually.
(2) Do NOT reuse if the engine is being overhauled or if the camshaft is out of the engine for any reason.
Camshaft Bushing - Service limits (B.10.A.40.44.30 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft bushing bore diameter – Without bushing

Reference: Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16)
RCPH05CDC487AAA 1
3 15/11/2005
B.10.A / 21
Camshaft bushing bore diameter – With bushing

Reference: Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16)
RCPH05CDC489AAA 2
Camshaft Bushing - Special tools (B.10.A.40.44.30 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft bushing removal/install tool – 3165045 (Cummins)

The tool includes the driver bar, driver bar extension,
centering guide, bushing replacer/installer, cap screw
and hex wrench for removal and installation of the
camshaft bushings in the block.
RCPH05CDC778AAA 1
Camshaft Journal - Service limits (B.10.A.40.44.35 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft bearing journal

RCPH05CDC327AAB 1
3 15/11/2005
B.10.A / 22
Camshaft Lobe - Service limits (B.10.A.40.44.40 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft reuse guidelines

If macro-spalling is observed, inspect the lubricating oil filter for metallic debris. If metallic debris is found in the
filter, inspect and replace as necessary:
• the main bearings and rod bearings,
• camshaft bushings,
• turbocharger,
• oil pump and pressure regulator,
• and the lubricating oil cooler.
NOTE: Refer to Definition ( - A.92.A.15) for definitions of the conditions.
Camshaft Lobe Reuse Example

Condition
New Unconditional reuse
Polish present, Unconditional reuse
no damage
RCPH05CDC003AAA 1
Denting Unconditional reuse
RCPH05CDC004AAA 2
3 15/11/2005
B.10.A / 23

Condition
Frosted bands Unconditional reuse
RCPH05CDC005AAA 3
Galling (1) Conditional reuse (2)

– Less than 1.5 mm
(0.0625 in) wide
pits
RCPH05CDC006AAA 4
Galling (1) Conditional reuse

– More than 1.5 mm
(0.0625 in) wide
pits
RCPH05CDC007AAA 5
3 15/11/2005
B.10.A / 24

Condition
Pitting Replace
RCPH05CDC008AAA 6
Macro-spalling Replace
RCPH05CDC009AAA 7
(1) If multiple gall streaks are present but are NOT connected, apply the width criteria to each streak individually.
(2) Do NOT reuse if the engine is being overhauled or if the camshaft is out of the engine for any reason.
Camshaft lobe
The area of edge deterioration must NOT be greater than
the equivalent area of a 2.0 mm (0.079 in) circle within ±20
° of the nose of the cam. Inset (A) shows acceptable wear,
inset (B) shows unacceptable wear.
RCSC05CDC106AAA 8
3 15/11/2005
B.10.A / 25
Outside the ±20 ° of the nose of the cam, the areas of edge
deterioration must NOT be greater than the equivalent area
of a 6.0 mm (0.236 in) circle. Inset (A) shows acceptable
wear, inset (B) shows unacceptable wear.
RCSC05CDC107AAA 9
Valve assembly Valve - Service limits (B.10.A.40.46.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve stem diameter

Reference: Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01)
RCPH05CDC389AAB 1
Valve rim thickness

Reference: Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01)
Exhaust valve
Intake valve
RCPH05CDC390AAB 2
3 15/11/2005
B.10.A / 26
Valve assembly Valve - Special tools (B.10.A.40.46.10 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve spring compressor – 3164321 (Cummins)

Used to compress the valve springs and remove the
valve stem collets, this tool simplifies the removal of the
valves, springs, spring retainers and seals.
RCPH05CDC805AAA 1
Valve assembly Spring - Service limits (B.10.A.40.46.15 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve spring – Free length (approximate)

Reference: Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01)
Length: 59.18 mm 2.330 in
RCPH05CDC270AAB 1
Valve spring – Compression

Reference: Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01)
Load 906 - 1007 N 204 - 226 lb
Height 30.6 mm 1.20 in
Replace the valve spring if the load required to compress
the spring is outside the specification.
RCSC05CDC130AAA 2
3 15/11/2005
B.10.A / 27
Valve assembly Spring - Special tools (B.10.A.40.46.15 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve spring tester – OEM1281

The valve spring tester has a range of 0 - 160 kg (0 - 350
lb) and handles springs up to 127 mm (5.0 in) in length
and is used to test the valve springs for reuse.
RCSC05CDC130AAA 1
3 15/11/2005
B.10.A / 28
Crankshaft - Service limits (B.10.A.43 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft – Main bearing journal

Reference: Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01).
Out of roundness 0.050 mm 0.002 in
Taper 0.013 mm 0.0005 in
RCPH05CDC478AAC 1
Crankshaft – Connecting rod journal

Reference: Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.A.16).
Taper 0.013 mm 0.0005 in
RCPH05CDC680AAA 2
Crankshaft gear journal – Outside diameter

Reference: Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16)
RCPH05CDC503AAA 3
3 15/11/2005
B.10.A / 29
Crankshaft - Special tools (B.10.A.43 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

With a powerful magnetic base, the dial is both
continuous and balanced with revolution counter and
may be rotated for setting at any point. The gauge is
used to measure crankshaft end play and gear backlash.
RCPH05CDC702AAA 1

Magnetic base with flexible arm to position dial indicators
for testing.
RCPH05CDC701AAA 2
Crankshaft Front seal - Torque (B.10.A.43.01 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component N·m Identification lb-in

Seal carrier mounting nuts 10 Nm 88 lb in
RCPH05CDC095ABA 1
3 15/11/2005
B.10.A / 30
Crankshaft Front seal - Special tools (B.10.A.43.01 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft front seal installer – CAS2430 or CNH299106

This tool is used to install the front crankshaft seal in the
carrier on the front cover. The tool is used with standard
and oversized seals.
RCPH05CDC088ABA-2 1
Crankshaft Rear seal - Special tools (B.10.A.43.02 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft rear seal installer – CNH299155

This tool is used to install the rear crankshaft seal on
CDC engines with or without a wear sleeve. When a dust
seal is present, tool 380002456 is also needed.
RCPH05CDC936AAA 1
Dust exclusion seal tool – 380002456

The ring is added to the rear crankshaft seal tool
CNH299155, when a dust exclusion seal is present, to
seat the rear seal an additional 4 mm.
RCPH05CDC938AAA 2
3 15/11/2005
B.10.A / 31
Crankshaft Front wear sleeve - Special tools (B.10.A.43.05 -

D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft front wear sleeve installer – 3165112 (Cummins)

This tool is used to install a wear sleeve on the front
crankshaft. The tool may be used on crankshafts with
a four or five hole pattern.
RCPH05CDC105ABA 1
Crankshaft Rear wear sleeve - Special tools (B.10.A.43.06 -

D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft rear seal installer – CNH299155

This tool is used to install the rear crankshaft seal on
CDC engines with or without a wear sleeve. When a dust
seal is present, tool 380002456 is also needed.
RCPH05CDC936AAA 1
Dust exclusion seal tool – 380002456

The ring is added to the rear crankshaft seal tool
CNH299155, when a dust exclusion seal is present, to
seat the rear seal an additional 4 mm.
RCPH05CDC938AAA 2
3 15/11/2005
B.10.A / 32
Crankshaft Gear - Service limits (B.10.A.43.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Gear bore inside diameter

Reference: Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16)
RCPH05CDC506AAB 1
Crankshaft Main bearing - Torque (B.10.A.43.15 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component Step N·m Identification lb-ft

Main bearing cap 1 50 Nm 37 lb ft
128 mm (5.0 in) cap 2 Loosen. Loosen.
screws 3 95 Nm 70 lb ft
4 Advance 60 °. Advance 60 °.
RCPH05CDC771AAA 1

Main bearing cap 1 170 Nm 125 lb ft
135 mm (5.3 in) cap 2 Loosen. Loosen.
screws 3 50 Nm 37 lb ft
RCPH05CDC771AAA 2
3 15/11/2005
B.10.A / 33
Crankshaft Main bearing - Special tools (B.10.A.43.15 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Main bearing rollout tool – Cummins 3823818

Made of brass to avoid scratching the crankshaft, this
tool is used to install and remove the main bearings with
the crankshaft installed.
RCPH05CDC705AAA 1
Main bearing rollout tool – Shop Made

A 6 mm x 30 mm cap screw (B) can be modified to
create a main bearing rollout tool.
RCSC05CDC082AAA 2
Grind and polish the head of the cap screw to a thickness

(A) of 2.5 mm (0.098 in). The edge must be tapered
and rounded to prevent scratching of the crankshaft or
bearing.
RCSC05CDC084AAA 3
3 15/11/2005
B.10.A / 34
Torque angle gauge – OEM4554 (SPX)

This tool measures angle of rotation after pre-torque in
torque-and advance applications. The 360 ° scale is
marked in 2 ° , 10 ° and 30 ° intervals. The gauge is
zeroed by turning the housing. The gauge is equipped
with 0.5 in male and female square drives for a torque
wrench and socket.
RCPH05CDC775AAA 4
Crankshaft Main bearing - Service limits (B.10.A.43.15 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Main bearing thickness – Standard

Reference: Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16)
RCPH05CDC458AAA 1
Crankshaft end play limits

Reference: Crankshaft - End play (B.10.A.43 - F.40.E.10)
RCPH05CDC451AAA 2
3 15/11/2005
B.10.A / 35
Crankshaft Speed ring - Torque (B.10.A.43.20 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Speed ring cap screws 8 Nm 71 lb in
RCPH05CDC490AAA 1
3 15/11/2005
B.10.A / 36
Timing gear housing - Torque (B.10.A.46 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Gear housing cap screws 40 Nm 30 lb ft
RCPH05CDC107ABA 1
3 15/11/2005
B.10.A / 37
Connecting rod and piston - Special tools (B.10.A.47 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston ring expander – OEM6262

This tool is used to remove and install piston rings to
prevent over expansion and ring breakage.
RCPH05CDC533AAA 1
Band type ring compressor – OEM6268

This tool is used to compress the piston rings for installing
the connecting rod and piston assembly in the cylinder
liner. Two-band ratchet type. 89 - 179 mm (3.5 - 7.0 in)
RCPH05CDC541AAA 2

This tool is used to measure the connecting rod pin
bore and piston pin bore. Gauges permit accurate
measurement of small bores. Gauge is inserted
into piece and tightened; measurement is read with
micrometer. 8.0 - 54.0 mm (0.3125 - 2.125 in)
RCPH05CDC273AAA 3
3 15/11/2005
B.10.A / 38
Connecting rod and piston Connecting rod - Torque (B.10.A.47.10 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Connecting rod cap 1 60 Nm 44 lb ft
screw – Straight rod 2 Loosen. Loosen.
3 70 Nm 52 lb ft
RCPH05CDC787AAA 1

Connecting rod cap 1 60 Nm 44 lb ft
screw – Angle split 2 Loosen. Loosen.
rod 3 70 Nm 52 lb ft
RCPH05CDC793AAA 2
Connecting rod and piston Connecting rod - Service limits

(B.10.A.47.10 - D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod – Piston pin bushing diameter

Reference: Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.A.16)
RCPH05CDC666AAB 1
3 15/11/2005
B.10.A / 39
Connecting rod – Crankshaft bore diameter (Bearings removed)

Reference: Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.A.16)Reference:
Engines –
RCPH05CDC667AAB 2
Connecting rod – Crankshaft bore

Taper 0.013 mm 0.0005 in
RCPH05CDC680AAA 3
Connecting rod – Bearing clearance

RCPH05CDC678AAA 4
3 15/11/2005
B.10.A / 40
Connecting rod to crankshaft side clearance

Reference: Connecting rod and piston - Install (B.10.A.47 - F.10.A.15)
RCPH05CDC789AAA 5
Connecting rod and piston Piston - Service limits (B.10.A.47.15 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston, articulated – Piston pin bore inside diameter

Reference: Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.E.01)
Crown
RCPH05CDC551AAB 1
Skirt
RCPH05CDC550AAB 2
3 15/11/2005
B.10.A / 41
Piston, single piece – Piston pin bore diameter

Reference: Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.A.16)
RCPH05CDC549AAA 3
Piston Ring - Service limits (B.10.A.47.15.05 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston ring gap

Reference: Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16)
Top ring
Intermediate ring
Oil control ring
RCPH05CDC532AAA 1
Piston Pin - Service limits (B.10.A.47.15.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston pin diameter

Reference: Piston Pin - Measure (B.10.A.47.15.10 - F.40.A.16)
RCPH05CDC439AAB 1
3 15/11/2005
B.10.A / 42
Flywheel - Torque (B.10.A.50 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Flywheel mounting cap screws 137 Nm 101 lb ft
RCPH05CDC139ABA 1
Shock plate cap screws 115 Nm 85 lb ft
RCPH05CDC144ABA 2
Rear engine support plate cap 115 Nm 85 lb ft

screws
RCPH05CDC133ABA 3
3 15/11/2005
B.10.A / 43
Flywheel - Service limits (B.10.A.50 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel
Reference: Flywheel - Visual inspection (B.10.A.50 - F.40.A.10)
• Replace the flywheel if the flywheel is cracked.
• Replace the ring gear if the teeth are cracked or
damaged.
RCPH05CDC130ABB 1
Flywheel bore runout

Reference: Flywheel - Measure (B.10.A.50 - F.40.A.16)
RCPH05CDC143ABA 2
Flywheel face runout

Reference: Flywheel - Measure (B.10.A.50 - F.40.A.16)
RCPH05CDC141ABA 3
3 15/11/2005
B.10.A / 44
Flywheel - Special tools (B.10.A.50 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

This tool is used to inspect bore and face runout on the
flywheel. The dial is both continuous and balanced with
a revolution counter and may be rotated for setting at
any point. The set includes a powerful magnetic base.
RCPH05CDC702AAA 1

The magnetic base, with the flexible arm to position a
dial indicator for testing, is used to inspect bore and face
runout on the flywheel.
RCPH05CDC701AAA 2
3 15/11/2005
B.10.A / 45
Vibration damper - Torque (B.10.A.68 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Damper mounting cap screws 200 Nm 148 lb ft
RCPH05CDC240AAA 1
Vibration damper - Service limits (B.10.A.68 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rubber vibration damper

Reference: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
Replace the damper:
• if the index lines on the damper hub and inertia
member are more than 1.59 mm (0.0625 in) out of
alignment,
• if the hub is cracked,
• if forward movement on the damper ring is detected,
• if the elastic member is more than 3.18 mm (0.125 in)
below the metal surface.
RCPH05CDC127ABB 1
RCPH05CDC127ABC 2
3 15/11/2005
B.10.A / 46
Viscous vibration damper

Reference: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
Replace the damper:
• if the mounting web is cracked,
• if there are dents or raised surfaces on the housing,
• if measured thickness of the damper at four locations
varies by more than 0.25 mm (0.010 in),
• if leakage is detected after the damper is heated in an
oven for two hours at a temperature of 93 °C (200 °F).
RCPH05CDC124ABB 3
3 15/11/2005
B.10.A / 47
Cylinder block Bore - Service limits (B.10.A.70.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder liner bore in block – press fit bore

Reference: Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)
Minimum 130.900 mm 5.1535 in
Maximum 130.950 mm 5.1555 in
RCPH05CDC749AAA 1
Cylinder block Liner - Torque (B.10.A.70.15 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Cylinder liner hold down bar 68 Nm 50 lb ft
RCPH05CDC757AAA 1
3 15/11/2005
B.10.A / 48
Cylinder block Liner - Service limits (B.10.A.70.15 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder liner maximum dimensions

Reference: Cylinder block Liner - Preliminary test (B.10.A.70.15 - F.40.A.20)
Taper 0.04 mm 0.0016 in
Out of round 0.04 mm 0.0016 in
Bore diameter 114.04 mm 4.4898 in
RCSC05CDC105AAA 1
Cylinder liner protrusion

RCPH05CDC760AAA 2
Cylinder liner inside diameter

Minimum 114.000 mm 4.4882 in
Maximum 114.040 mm 4.4898 in
RCSC05CDC095AAA 3
3 15/11/2005
B.10.A / 49
Cylinder liner outside diameter – top press fit

Minimum 130.938 mm 5.1550 in
Maximum 130.958 mm 5.1558 in
RCPH05CDC743AAB 4
Cylinder liner to block clearance

RCPH05CDC765AAA 5
Cylinder block Liner - Special tools (B.10.A.70.15 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder liner removal tool – OEM4083

This manually operated, screw powered tool is used
for cylinder liner removal with or without the crankshaft
installed in the block. A remover plate that fits the specific
liner is also required and is not included in this tool set.
RCPH05CDC724AAA 1
3 15/11/2005
B.10.A / 50
Cylinder liner removal plate – 380002492

Used with OEM4083, this plate is required for all CNH
6TAA-8304 and 6TAA-9004 engines using the High
Pressure Common Rail fuel system to prevent damage
to the block bore when the cylinder liner is removed.
RCPH05CDC756AAA 2
Cylinder liner installer tool – OEM6527

These additional components allow OEM4083 (liner
removal tool set) to also install cylinder liners when the
crankshaft is removed from the block. Only the yoke
assembly (A) and triangular bar (B) are used on these
engines. An installer plate that fits the specific liner is
also required and is not included with this tool.
RCPH05CDC326AAA 3
Cylinder liner installer plate – OEM1255

Used with components from OEM4083 and OEM6527,
this plate is used to install cylinder liners when the
crankshaft is removed from the engine. The plate fits
cylinder liners from 111 - 120 mm (4.375 - 4.750 in) .
RCPH05CDC762AAA 4
3 15/11/2005
B.10.A / 51
Cylinder liner protrusion tool – OEM6459

The hold down bar is used to properly seat the cylinder
liner before it is measured. The mounted gauge is then
used to measure liner protrusion. Two 14 mm x 70 mm
cap screws and flat washers are required to use the hold
down bar on this engine family, but are not included in
the kit.
RCPH05CDC761AAA 5
Dial bore gauge – OEM1032

This tool is used to measure the diameter, taper and
roundness of cylinder liners and the diameter of the
block bores. The correct combination of extensions are
selected and installed for the bore diameter using an
included chart.
RCPH05CDC611AAA 6
A micrometer is used to adjust the tool to the minimum

dimension of the bore to be measured. When installed
in the bore and rocked, the gauge reports any plus or
minus deviation from the required dimension.
RCPH05CDC609AAA 7
3 15/11/2005
B.10.A / 52
Cylinder head - Torque (B.10.A.72 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Cylinder head cap screws – Leak 80 Nm 59 lb ft
test fixture
RCSC05CDC122AAA 1

Cylinder head cap 1 150 Nm 111 lb ft
screws 2 Loosen. Loosen.
3 110 Nm 81 lb ft
RCPH05CDC814AAA 2
Cylinder head - Service limits (B.10.A.72 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head crack – Injector bore to valve seat

Reference: Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10)
If a crack extends from the injector bore into or through the
valve seat, the cylinder head MUST be replaced.
RCPH05CDC383AAC 1
3 15/11/2005
B.10.A / 53
Cylinder head crack – Valve seat

If the valve seat is cracked, the cylinder head MUST be
replaced.
RCPH05CDC383AAD 2
Cylinder head flatness – End to end

Reference: Cylinder head - Measure (B.10.A.72 - F.40.A.16)
RCPH05CDC384AAA 3
Cylinder head flatness – Side to side

RCPH05CDC385AAB 4
3 15/11/2005
B.10.A / 54
Cylinder head cap screws – Corrosion or pitting

Do NOT reuse cap screws under the following conditions:
• if visible corrosion or pitting exceeds 1.0 cm² (0.155
in²) in area: for example, a 9.525 mm x 9.525 mm
(0.375 in x 0.375 in) area is acceptable, but a 12.7
mm x 12.7 mm (0.5 in x 0.5 in) area is not acceptable,
• if visible corrosion exceeds 0.12 mm (0.005 in) in
depth,
• if visible corrosion or pitting is located within 3.2 mm
(0.125 in) of the fillets or threads.
RCPH05CDC402AAB 5
Cylinder head cap screw – Free length

RCPH05CDC403AAA 6
Cylinder head – Valve recess

Reference: Cylinder head - Assemble (B.10.A.72 - F.10.A.20)
RCPH05CDC386AAB 7
3 15/11/2005
B.10.A / 55
Cylinder head - Special tools (B.10.A.72 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve spring compressor – 3164321 (Cummins)

Used to compress the valve springs and remove the
valve stem collets, this tool simplifies the removal of the
valves, springs, spring retainers and seals.
RCPH05CDC805AAA 1
Injector protrusion gauge block – OEM6459

The gauge block from this tool, also used to measure
cylinder liner protrusion, is used to measure injector
protrusion on the cylinder head combustion deck.
RCPH05CDC761AAA 2
Injector bore brush – 3822509 (Cummins)

This tool is used to remove carbon build up and other
debris from the injector bore in the cylinder head.
RCPH05CDC804AAA 3
3 15/11/2005
B.10.A / 56
Defect detector kit – OEM1272

This kit is used to detect defects in solid materials –
e.g., cracks in the cylinder head. The kit includes brush,
cleaner, penetrant and developer.
RCPH05CDC820AAA 4
Cap screw gauge – 380000863

This gauge is used to measure the free length of the
cylinder head cap screw to determine reuse.
RCPH05CDC819AAA 5
Valve vacuum tester cup – ST-1257-6 (Cummins)

This tool – with a vacuum pump, pressure regulator
and digital or mechanical vacuum gauge – is used to
test engine valves and valve seats for leaking after the
cylinder head is assembled, but not installed on the
block.
RCPH05CDC822AAA 6
3 15/11/2005
B.10.A / 57
Pressure/vacuum module – 3164491 (Cummins)

Any digital voltmeter capable of accepting a good-quality
pressure/vacuum module can also be used to check
for leakage between the valves and valve seats. The
module shown features ranges of 0 - 3447 kPa (0 - 500
psi) for pressure and 0 - 760 mm Hg (0 - 29.99 in Hg)
for vacuum.
Basic accuracy is 1%.
RCPH05CDC612AAA 7
Depth micrometer – OEM1013

Metric or U.S. Standard for measuring valve guide
height. Range 0 - 150 mm (0 - 6 in). Graduations in
0.001 mm (0.001 in). Range is covered through insertion
of different rods. The base provides stability.
RCPH05CDC699AAA 8

Gauges permit accurate measurement of small bores,
e.g., the valve guide bore diameter. Gauge is inserted
into piece and tightened; measurement is read with
micrometer. Range is 8 - 54 mm (0.3125 - 2.125 in).
RCPH05CDC273AAA 9
3 15/11/2005
B.10.A / 58
Torque angle gauge – OEM4554 (SPX)

This tool measures angle of rotation after pre-torque in
torque and advance applications. The 360 degree scale
is marked in 2 degree increments and intervals of 10
and 30 degrees.
This tool must be ordered directly from SPX.
RCPH05CDC775AAA 10
Cylinder head Valve seat - Service limits (B.10.A.72.10 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve seat – Valve leak test

Reference: Cylinder head Valve seat - Vacuum test (B.10.A.72.10 - F.40.A.25)
Vacuum must not drop more than 25.4 mm Hg (1.0 in Hg)
in five (5) seconds.
RCPH05CDC373AAA 1
Cylinder head Valve guide - Service limits (B.10.A.72.15 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve guide – Inner diameter

Reference: Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16)
RCPH05CDC392AAB 1
3 15/11/2005
B.10.A / 59
Valve guide height – Installed

Reference: Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16)
RCPH05CDC394AAB 2
3 15/11/2005
B.10.A / 60
Valve cover - Torque (B.10.A.74 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Valve cover cap screws 12 Nm 106 lb in
RCPH05CDC823AAA 1
3 15/11/2005
B.10.A / 61
Front cover - Torque (B.10.A.75 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Front cover cap screws 24 Nm 18 lb ft
RCPH05CDC102ABD 1
3 15/11/2005
B.10.A / 62
Rear cover - Torque (B.10.A.76 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Rear cover cap screws 10 Nm 86 lb in
RCPH05CDC953AAA 1
3 15/11/2005
B.10.A / 63
Electronic control Control module - Torque (B.10.A.92.91 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

ECM cap screws and nut 25 Nm 18 lb ft
RCPH05CDC175ABA 1
Connector hex head cap screws 2 Nm 18 lb in
RCPH05CDC163ABA 2
3 15/11/2005
B.10.A / 64
Sensing system Speed sensor - Torque (B.10.A.95.80 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft speed sensor

Crankshaft speed sensor cap screw 25 Nm 34 lb ft
RCPH05CDC347ABA 1
Sensing system Speed sensor - Service limits (B.10.A.95.80 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Reference: Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01)
Replace the crankshaft speed sensor:
• if the sensor is chipped, cracked or damaged,
• if the speed sensor state does NOT change from high
to low or low to high OR if the speed sensor state does
NOT show triggered during the INSITE® monitoring
test.
RCPH05CDC346ABA 1
3 15/11/2005
B.10.A / 65
Sensing system Camshaft speed sensor - Torque (B.10.A.95.82 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Camshaft speed sensor cap screw 10 Nm 89 lb in
RCPH05CDC349ABA 1
Sensing system Camshaft speed sensor - Service limits

(B.10.A.95.82 - D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Reference: Sensing system Camshaft speed sensor - Test (B.10.A.95.82 - F.40.C.01)

Replace the camshaft speed sensor:
• if the sensor is chipped, cracked or damaged,
• if the speed sensor state does NOT change from high
to low or low to high OR if the speed sensor state does
NOT show triggered during the INSITE® monitoring
test.
RCPH05CDC350ABA 1
3 15/11/2005
B.10.A / 66
Timing gear - Static description (B.10.A.45 - C.30.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC106ABA 1
Correct Timing Gear Location
A. Crankshaft to camshaft gear timing marks

B. Camshaft to fuel pump gear timing marks
C. Top dead center timing mark on the fuel pump gear
3 15/11/2005
B.10.A / 67
Wiring harness - Component identification (B.10.A.88 - C.40.C.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC247ABA 1
Connector identification – Engine harness
A. Engine control module (ECM) power E. Priming pump connector, if present

B. Engine harness connector F. Oil pressure sensor connector
C. Vehicle harness connector G. Crankshaft speed sensor connector
D. Suspended axle connector, if present H. Water-in-fuel sensor connector
3 15/11/2005
B.10.A / 68
RCPH05CDC247ABA 2
Harness clamp locations
RCPH05CDC220ABA 3
A. Injector 1-2 harness connector D. Pressure regulator valve harness connector

B. Injector 3-4 harness connector E. Camshaft speed sensor harness connector
C. Pressure relief valve harness connector F. Front engine harness pigtail connector
3 15/11/2005
B.10.A / 69
RCPH05CDC220ABA 4
RCPH05CDC221ABA 5
A. Injector 3-4 harness connector C. Air to air temperature sensor harness connector
B. Injector 5-6 harness connector D. Ambient air temperature sensor harness connector
3 15/11/2005
B.10.A / 70
RCPH05CDC221ABA 6
RCPH05CDC222ABB 7 RCPH05CDC205ABA 8

A harness clamp is located behind the fuel filter and A. Clamp not used in this application.
pre-filter if present.
3 15/11/2005
B.10.A / 71
Sensing system - Component identification (B.10.A.95 - C.40.C.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC004GAA 1
Engine left hand side
A. Camshaft speed sensor B. Crankshaft speed sensor
3 15/11/2005
B.10.A / 72
ENGINE - Place on stand (B.10.A - F.35.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Refer to the engine removal section of the chassis repair manual. In addition to these operations,
the following components must be removed from the engine before it can be installed on the engine repair stand:
Prior operation: Electronic control Control module - Remove (B.10.A.92.91 - F.10.A.10)
Prior operation: Fuel line Cooling plate - Remove (B.20.A.36.30 - F.10.A.10)
Prior operation: Sensing system Oil level indicator - Remove (B.60.A.95.90 - F.10.A.10)
1. Remove the ground wire for the engine control

module (ECM).
RCPH05CDC137AAA 1
2. Disconnect the blowby recirculation drain tube from

the oil fill assembly .
RCPH05CDC138AAA 2
3. Remove the cap screws and remove the oil fill

assembly.
RCPH05CDC248ABA 3
3 15/11/2005
B.10.A / 73
4. Remove the oil pressure sensor.
RCPH05CDC140AAA 4
5. Remove the indicated plugs to provide a flat surface

for the engine adapter plate.
RCPH05CDC141AAA 5
6. Use the indicated holes to install the engine adapter

plate OEM218099 – on the block.
RCPH05CDC249ABB 6
3 15/11/2005
B.10.A / 74
7. Install the engine adapter plate – OEM218099 – on

the engine with the supplied hardware.
RCPH05CDC142AAA 7
8. Install the rectangular plates from the universal

engine adapter – OEM205061 – to the engine
mounting plate.
RCPH05CDC143AAA 8
9. Using an appropriate positioning sling – OEM4130

or equivalent – and hoist, move the engine to the
repair stand – OEM4137 or equivalent. Secure the
engine to the stand at the universal adapter.
RCPH05CDC144AAA 9
3 15/11/2005
B.10.A / 75
Alternator/AC compressor bracket removal

10. Remove the alternator.
RCPH05CDC162AAA 10
11. Remove the air conditioning compressor.
RCPH05CDC163AAA 11
12. Remove the idler pulley to access the bracket cap

screw.
RCPH05CDC166AAA 12
3 15/11/2005
B.10.A / 76
13. Remove the front cap screw for the bracket.
RCPH05CDC167AAA 13
14. Remove the three side cap screws and remove the
bracket.
RCPH05CDC168AAA 14
3 15/11/2005
B.10.A / 77
ENGINE - Check (B.10.A - F.40.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Electronic control - Check (B.10.A.92 - F.40.A.11)

Prior operation: FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11)
Overhead adjustment check

1. Check the overhead adjustment. Refer to Valve
drive Rocker assembly - Check (B.10.A.40.43 -
F.40.A.11).
If the overhead settings are within the reset limits,

continue with Step 2.
If the overhead settings are NOT within the

reset limits, adjust the overhead settings. Check
operation of the engine.
RCPH05CDC223AAA 1
Air cooler check

2. Inspect the air cooler for cracks, holes or damage.
Refer to Air cooler - Visual inspection (B.30.A.32
- F.40.A.10).
Leak test the air cooler. Refer to Air cooler -

Leakage test (B.30.A.32 - F.40.A.40).
If the air cooler is free of damage, continue with

Step 3.
If the air cooler is damaged, repair or replace the

air cooler.
RCPH05CDC530AAA 2
Air intake restriction check

3. Check for air intake system restriction. Remove
the air cleaner restriction sensor and install a test
fitting for a vacuum gauge. Refer to AIR INTAKE
SYSTEM - Supply restriction (B.30.A - F.40.C.21).
If air intake restriction is greater than 63.5 cm H2O

(25.0 in H2O), locate and repair the source of the
restriction. Check for a plugged air filter or restricted
air intake piping.
If air intake restriction is within specification,

RCPH05CDC578AAA 3
3 15/11/2005
B.10.A / 78
Exhaust restriction check

4. Check exhaust system back pressure. Refer to
EXHAUST SYSTEM - Return restriction (B.40.A -
F.40.C.22).
If exhaust back pressure is greater than 76 mm

Hg (3.0 in Hg), inspect the exhaust system for the
source of the high restriction.
If exhaust back pressure is less than 76 mm Hg

(3.0 in Hg), continue with Step 5.
RCPH05CDC565AAA 4
Engine blow by check

5. Measure engine blowby. Refer to Blowby
re-circulation system - Blow by (B.60.A.26 -
F.40.E.20).
Record the blowby reading, noting whether the

value in outside the maximum specification: 30.5
cm H2O (12.0 in H2O).
Continue with Step 6 to clarify the result.
RCPH05CDC635AAA 5
Turbocharger blowby contribution check

6. Measure the turbocharger contribution to engine
blowby. Refer to Refer to Blowby re-circulation
system - Blow by (B.60.A.26 - F.40.E.20).
If the turbocharger contributes more than 30 % of

the blowby measurement, replace the turbocharger.
Refer to Turbocharger - Remove (B.30.A.31 -
F.10.A.10).
If the turbocharger contributes less than 30 % of

the blowby measurement, the engine requires
rebuilding. Refer to the engine rebuild specification.
RCPH05CDC780AAA 6
3 15/11/2005
B.10.A / 79
Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Remove the blowby recirculation tube and drain tube. See Blowby re-circulation system -
Remove (B.60.A.26 - F.10.A.10).
Prior operation: Remove the fuel pump cover plate. See High pressure common rail Gear pump - Remove
(B.20.A.30.10 - F.10.A.10)
Prior operation: Valve cover - Remove (B.10.A.74 - F.10.A.10)
1. Use the engine barring tool – 380000732 – to rotate

the crankshaft and align the top dead center marks
on the gear cover and the fuel pump gear.
CAUTION
M1032 - Engine coolant temperature should be less
than 60 degrees C (140 degrees F) when performing
this procedure.
RCPH05CDC222AAB 1
2. With the engine in this position, lash can be checked

on the following rocker arms: 1-intake, 1-exhaust,
2-intake, 3-exhaust, 4-intake and 5-exhaust.
Intake lash must be within 0.152 - 0.559 mm (0.006

- 0.022 in).
Exhaust lash must be within 0.381 - 0.813 mm

(0.015 - 0.032 in).
NOTE: Lash is checked during a troubleshooting
procedure and resetting is NOT required as long as the
lash measurements are within the stated ranges.
RCPH05CDC223AAA 2
3 15/11/2005
B.10.A / 80
3. Measure lash by inserting a feeler gauge between

the crosshead and the rocker arm ball insert and
socket, while lifting up on the rocker arm. If lash is
out of specification, loosen the lock nut and adjust
lash to nominal specifications.
The nominal intake lash specification is 0.305 mm

(0.012 in).
The nominal exhaust lash specification is 0.559 mm

(0.022 in).
Tighten the lock nut and measure again. When

adjustment is complete, torque the lock nut to 24
Nm (18 lb ft).
3
IMPORTANT: Lash resets are only required (A) at the RCPH05CDC224AAA
interval specified in the operator or maintenance manual,

(B) when lash is measured and found out of specification,
or (C) when engine repair includes removal of the rocker
arms or loosening of the adjusting screws.
4. Using the engine barring tool, rotate the crankshaft
360 °, and measure lash for rocker arms 2-exhaust,
3-intake, 4-exhaust, 5-intake, 6-intake and
6-exhaust. Reset the lash if it is out of specification.
RCPH05CDC227AAA 4
Next operation: Valve cover - Install (B.10.A.74 - F.10.A.15)

Next operation: Install the blowby recirculation tube and drain tube. See Blowby re-circulation system - Install
(B.60.A.26 - F.10.A.15).
Next operation: Install the fuel gear pump cover plate. See High pressure common rail Gear pump - Install
(B.20.A.30.10 - F.10.A.15).
3 15/11/2005
B.10.A / 81
Valve drive Rocker assembly - Remove (B.10.A.40.43 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
1. Loosen the cap screw from the exhaust rocker arm

and remove the arm.
RCPH05CDC854AAA 1
2. Mark the arm by its location.

IMPORTANT: The rocker assemblies MUST be installed
in their original location and position.
RCPH05CDC933AAA 2
3. Loosen the cap screw from the intake rocker arm

and remove the arm. Mark the arm by its location.
RCPH05CDC934AAA 3
3 15/11/2005
B.10.A / 82
4. Remove the pedestal and mark it by its location.
RCPH05CDC850AAA 4
5. The rocker arms may also be removed as a

complete assembly by loosening both cap screws
and lifting the assembly off the head by the pedestal.
RCPH05CDC858AAA 5
Next operation: Valve drive Rocker assembly - Disassemble (B.10.A.40.43 - F.10.A.25)
3 15/11/2005
B.10.A / 83
Valve drive Rocker assembly - Disassemble (B.10.A.40.43 -

F.10.A.25)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Rocker assembly - Remove (B.10.A.40.43 - F.10.A.10)
1. Remove the shaft from the exhaust (E) and intake

(I) rocker arm.
RCPH05CDC794AAA 1
2. Remove the adjustable socket from the exhaust and

intake rocker arm.
RCPH05CDC795AAA 2
Next operation: Valve drive Rocker assembly - Visual inspection (B.10.A.40.43 - F.40.A.10)
3 15/11/2005
B.10.A / 84
Valve drive Rocker assembly - Visual inspection (B.10.A.40.43 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Rocker assembly - Disassemble (B.10.A.40.43 - F.10.A.25)
1. Clean all parts in a strong solution of laundry

detergent and hot water. Rinse with clean hot water.
RCPH05CDC237AAC 1
2. Dry with compressed air.

NOTE: The oil drillings in the rocker arms and shafts must
be unobstructed.
NOTE: The pedestals are made from powdered metal
and will continue to show wetness after they have been
cleaned and dried.
WARNING
M994 - Wear appropriate eye and face protection
when using compressed air. Flying debris and dirt
can cause personal injury.
3. Inspect for cracks and excessive wear in the rocker

arm bore.
RCPH05CDC276AAB 2
3 15/11/2005
B.10.A / 85
4. Inspect for wear on the nose of the socket. The

socket should move freely and the plastic socket
retainer should be present and not cracked.
RCPH05CDC276AAC 3
Next operation: Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16)
3 15/11/2005
B.10.A / 86
Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Rocker assembly - Visual inspection (B.10.A.40.43 - F.40.A.10)
1. Use OEM1015 or equivalent to measure the rocker

arm bore. The minimum bore diameter must be
25.095 mm (0.988 in).
RCPH05CDC275AAA 1
2. Inspect the pedestal and rocker arm shaft. Measure

the shaft diameter with a micrometer. The minimum
shaft diameter must be 25.044 mm (0.986 in).
RCPH05CDC274AAB 2
Next operation: Valve drive Rocker assembly - Assemble (B.10.A.40.43 - F.10.A.20)
3 15/11/2005
B.10.A / 87
Valve drive Rocker assembly - Assemble (B.10.A.40.43 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16)
1. Install the adjustable socket on the intake and

exhaust rocker arms.
RCPH05CDC795AAA 1
2. Install the shaft in the rocker arms.
RCPH05CDC794AAA 2
Next operation: Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15)
3 15/11/2005
B.10.A / 88
Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Rocker assembly - Assemble (B.10.A.40.43 - F.10.A.20)
1. Install the pedestal in its original location in the

housing.
RCPH05CDC851AAA 1
2. Lubricate the cap screw for the intake rocker arm

with clean engine oil. Install the arm on the pedestal.
Tighten and then torque to 65 Nm (48 lb ft).
RCPH05CDC852AAA 2
3. Lubricate the cap screw for the exhaust rocker arm

with clean engine oil. Install the arm on the pedestal.
Tighten and then torque to 65 Nm (48 lb ft).
RCPH05CDC853AAA 3
Next operation: Adjust valve lash. See Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11).
(B.60.A.26 - F.10.A.15)
3 15/11/2005
B.10.A / 89
Rocker assembly Housing - Remove (B.10.A.40.43.05 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
Prior operation: Remove the harness leads to the injectors. See Fuel injector - Remove (B.20.A.29 - F.10.A.10)
1. Remove the harness clamp on the left hand side

of the housing.
RCPH05CDC284AAA 1
2. Disconnect the three injector harness connectors on

the left hand side of the housing.
RCPH05CDC285AAA 2
3. Remove the seven cap screws securing the housing

to the cylinder head. Remove the housing. Remove
and discard the gasket from the housing.
RCPH05CDC286AAA 3
3 15/11/2005
B.10.A / 90
4. Remove the clips securing the injector harnesses

to the housing.
RCPH05CDC293AAA 4
5. Remove the cap screws securing the three

pass-through connectors for the injector harnesses.
Tag the harnesses by their location, and remove the
harnesses from the housing.
RCPH05CDC294AAA 5
Next operation: Rocker assembly Housing - Visual inspection (B.10.A.40.43.05 - F.40.A.10)
3 15/11/2005
B.10.A / 91
Rocker assembly Housing - Visual inspection (B.10.A.40.43.05 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Rocker assembly Housing - Remove (B.10.A.40.43.05 - F.10.A.10)
1. Clean the housing with solvent.
WARNING
M995 - When using solvents, acids or alkaline
materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.
WARNING
M996 - Some solvents are flammable and toxic.
Read the manufacturer’s instructions before using.
Personal injury can result from misuse.
RCSC05CDC136AAA 1
WARNING
3. Inspect the rocker housing for cracks or other

damage, particularly on the cylinder head mounting
surface. Inspect the bridge areas across the center
of the housing for cracks.
RCPH05CDC295AAB 2
Next operation: Rocker assembly Housing - Install (B.10.A.40.43.05 - F.10.A.15)
3 15/11/2005
B.10.A / 92
Rocker assembly Housing - Install (B.10.A.40.43.05 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Rocker assembly Housing - Visual inspection (B.10.A.40.43.05 - F.40.A.10)
1. Install the three injector harnesses in the housing

in their original locations. Install the pass-through
connectors with the original cap screws.
RCPH05CDC294AAA 1
2. Install the harness hold down clips in the housing.
RCPH05CDC293AAA 2
3. Install a new gasket on the housing using this

sequence:
(A) Press the gasket into the corners.

(B) Press the gasket around the holes for the cap
screws.
(C) Press the remaining gasket into the housing.
RCPH05CDC292AAA 3
3 15/11/2005
B.10.A / 93
4. Install the housing on the cylinder head and secure

with the original cap screws. Tighten the screws
from the center outward. Torque the cap screws to
24 Nm (212 lb in).
RCPH05CDC286AAA 4
5. Connect the three engine harness connectors to

the injector harnesses.
RCPH05CDC285AAA 5
6. Install the engine harness clamp on the housing.
RCPH05CDC284AAA 6
Next operation: Connect the harness leads to the injectors. See Fuel injector - Install (B.20.A.29 - F.10.A.15).
(B.60.A.26 - F.10.A.15).
3 15/11/2005
B.10.A / 94
Rocker assembly Crosshead - Remove (B.10.A.40.43.25 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
1. Remove the crossheads from the exhaust (A) and

intake (B) valve springs. Mark each crosshead by
its location.
IMPORTANT: If the crossheads are going to be reused,
they must be installed in their original location and
orientation.
RCPH05CDC847AAA 1
Next operation: Rocker assembly Crosshead - Visual inspection (B.10.A.40.43.25 - F.40.A.10)
3 15/11/2005
B.10.A / 95
Rocker assembly Crosshead - Visual inspection (B.10.A.40.43.25 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Rocker assembly Crosshead - Remove (B.10.A.40.43.25 - F.10.A.10)
1. Clean the crossheads with solvent.
WARNING
personal injury.
WARNING
WARNING
3. Inspect the crossheads for cracks or excessive

wear on the mating surfaces to the rocker arm and
valve tip. Inspect the contact pad for cracks or other
damage.
RCPH05CDC845AAB 1
Next operation: Rocker assembly Crosshead - Install (B.10.A.40.43.25 - F.10.A.15)
3 15/11/2005
B.10.A / 96
Rocker assembly Crosshead - Install (B.10.A.40.43.25 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Rocker assembly Crosshead - Visual inspection (B.10.A.40.43.25 - F.40.A.10)
1. Install the crossheads on the valve stems.

NOTE: The crosshead has an oval and a round hole.
There is no requirement to place either end in a particular
position.
NOTE: When reusing the crossheads, install them in their
original location and orientation.
RCPH05CDC847AAA 1

Next operation: Adjust valve lash. See Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11).
(B.60.A.26 - F.10.A.15)
3 15/11/2005
B.10.A / 97
Valve drive Camshaft - Preliminary test (B.10.A.40.44 - F.40.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
Prior operation: Remove the intake and exhaust rocker arm assemblies. See Valve drive Rocker assembly -
Remove (B.10.A.40.43 - F.10.A.10).
NOTE: This test is used to check for flattening of the camshaft intake and exhaust lobes without removing the
camshaft from the engine.
1. Use a gauge and magnetic base – OEM1026 and
OEM1030 or equivalent – to measure lift from the
camshaft lobes at the exhaust and intake push rods.
RCPH05CDC367ABA 1

the camshaft until the push rod for the exhaust
rocker arm is at its lowest point. Zero the gauge.
Rotate the camshaft until the gauge shows the

maximum lift height of the push rod.
Maximum lift height from a new exhaust lobe is

approximately 7.747 mm (0.305 in).
RCPH05CDC366ABA 2
3. Move the gauge to the push rod for the intake rocker
arm.
Rotate the camshaft until the push rod for the intake
rocker arm is at its lowest point. Zero the gauge.
Rotate the camshaft until the gauge shows the

maximum lift height of the push rod.
Maximum lift height from a new intake lobe is

approximately 7.747 mm (0.305 in).
RCPH05CDC365ABA 3
3 15/11/2005
B.10.A / 98
4. Repeat the tests on the remaining cylinders.
Next operation: Install the intake and exhaust rocker assemblies. See Valve drive Rocker assembly - Install
(B.10.A.40.43 - F.10.A.15).
(B.60.A.26 - F.10.A.15)
3 15/11/2005
B.10.A / 99
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive Belt - Remove (B.50.A.54.44 - F.10.A.10)

Prior operation: Fan and drive - Remove (B.50.A.54 - F.10.A.10)
Prior operation: Vibration damper - Remove (B.10.A.68 - F.10.A.10)
Prior operation: Remove the rocker arms. SeeValve drive Rocker assembly - Remove (B.10.A.40.43 -
F.10.A.10).
Prior operation: Camshaft Push rod - Remove (B.10.A.40.44.20 - F.10.A.10)
Prior operation: Front cover - Remove (B.10.A.75 - F.10.A.10)
Prior operation: Camshaft Tappet - Remove (B.10.A.40.44.25 - F.10.A.10)
1. Rotate the crankshaft to align the crankshaft and

camshaft timing marks.
RCPH05CDC763AAA 1
2. The thrust plate extends more than 180 ° around

the camshaft and can ONLY be removed from the
camshaft, after the cam gear is removed from the
shaft.
RCPH05CDC245AAA 2
3 15/11/2005
B.10.A / 100
3. Remove the cap screws from the thrust plate.
RCPH05CDC250AAA 3
4. Remove the camshaft and thrust plate assembly.
RCPH05CDC251AAA 4
Next operation: Valve drive Camshaft - Visual inspection (B.10.A.40.44 - F.40.A.10)
3 15/11/2005
B.10.A / 101
Valve drive Camshaft - Visual inspection (B.10.A.40.44 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10)
1. Inspect the lobes and journals on the shaft for

cracking, pitting and scoring.
RCPH05CDC328AAB 1
2. Inspect the teeth on the camshaft gear for pitting.

Check for cracks at the base of the teeth. If the
gear requires replacement, see Camshaft Gear -
Remove (B.10.A.40.44.10 - F.10.A.10).
RCPH05CDC337AAB 2
Next operation: Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16)
3 15/11/2005
B.10.A / 102
Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Camshaft - Visual inspection (B.10.A.40.44 - F.40.A.10)
1. Measure the bearing journals. The journal diameter

must be within 59.962 - 60.013 mm (2.3607 -
2.3627 in).
Replace the camshaft if the outside diameter of any

bearing surface is less than 59.962 mm (2.3607 in).
RCPH05CDC327AAB 1
2. Refer to Camshaft Lobe - Service limits

(B.10.A.40.44.40 - D.20.A.20) for reuse guidelines
when pitting is present.
RCPH05CDC328AAB 2
3. The area of edge deterioration must NOT be

greater than the equivalent area of a 2.0 mm (0.079
in) circle within ±20 ° of the nose of the cam.
Inset (A) shows acceptable wear, inset (B) shows
unacceptable wear.
RCSC05CDC106AAA 3
3 15/11/2005
B.10.A / 103
4. Outside the ±20 ° of the nose of the cam, the areas

of edge deterioration must NOT be greater than
the equivalent area of a 6.0 mm (0.236 in) circle.
Inset (A) shows acceptable wear, inset (B) shows
unacceptable wear.
NOTE: If the camshaft shows any pitting or wear, remove
and inspect the tappets before installing the camshaft.
See Camshaft Tappet - Remove (B.10.A.40.44.25 -
F.10.A.10).
NOTE: If a new camshaft is installed, new tappets MUST
be installed.
RCSC05CDC107AAA 4
5. Measure the thrust plate thickness. Thrust plate

thickness must be within 9.40 - 9.60 mm (0.370
- 0.378 in).
RCPH05CDC341AAB 5
Next operation: Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15)
3 15/11/2005
B.10.A / 104
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16)
1. Lubricate the front camshaft bore with CASE

AKCELA EP-0 GREASE.
RCPH05CDC773AAA 1
2. Lubricate the camshaft lobes, journals and thrust

plate with CASE AKCELA EP-0 GREASE.
RCPH05CDC767AAA 2
3. Install the camshaft: Push in slightly while rotating

the camshaft to work the camshaft through the
camshaft bushings. As each journal passes through
a bushing, the camshaft will drop slightly and the
camshaft lobes will catch on the bushings. Rotating
the camshaft will free the lobe from the bushing and
allow the camshaft to progress into the bore.
CAUTION
M1012 - Do not force the camshaft into the camshaft
bore. The camshaft bushing can be damaged.
RCPH05CDC251AAB 3
3 15/11/2005
B.10.A / 105
4. Before the camshaft gear engages the crankshaft

gear, check the camshaft for freedom of rotation.
When installed properly, the camshaft MUST rotate
freely.
RCPH05CDC251AAA 4
5. Align the timing marks between the camshaft gear

and the crankshaft gear, and completely install the
camshaft.
RCPH05CDC763AAA 5
6. Install the cap screws on the thrust plate. Torque

the cap screws to 24 Nm (18 lb ft).
RCPH05CDC250AAA 6
Next operation: Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10)
3 15/11/2005
B.10.A / 106
Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15)
1. Use a gauge and magnetic base to verify that the

camshaft has proper end play.
Camshaft end play must be within 0.12 - 0.50 mm

(0.005 - 0.020 in).
RCPH05CDC776AAA 1
Next operation: Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15)
3 15/11/2005
B.10.A / 107
Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10)
1. Use a gauge and magnetic base to verify that the

camshaft gear has proper backlash.
Gear backlash must be within 0.08 - 0.33 mm

(0.003 - 0.013 in).
RCPH05CDC777AAA 1
Next operation: Front cover - Install (B.10.A.75 - F.10.A.15)

Next operation: Camshaft Tappet - Install (B.10.A.40.44.25 - F.10.A.15)
Next operation: Camshaft Push rod - Install (B.10.A.40.44.20 - F.10.A.15)
Next operation: Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01)
Next operation: Vibration damper - Install (B.10.A.68 - F.10.A.15)
Next operation: Fan and drive - Install (B.50.A.54 - F.20.A.20)
Next operation: Fan and drive Belt - Install (B.50.A.54.44 - F.10.A.15)
3 15/11/2005
B.10.A / 108
Camshaft Gear - Remove (B.10.A.40.44.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Support the shaft and gear assembly in a press, and

press the camshaft from the gear and thrust plate.
RCPH05CDC335AAA 1
2. If required, remove the alignment pin from the

camshaft.
RCPH05CDC343AAA 2
Next operation: Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10)
3 15/11/2005
B.10.A / 109
Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Gear - Remove (B.10.A.40.44.10 - F.10.A.10)
1. Inspect the gear for cracked, chipped or broken

teeth.
RCPH05CDC337AAB 1
2. Inspect the gear bore for fretting or burrs. If the

fretting, burrs or raised material cannot be removed
with a Scotch-Brite™ pad, the gear MUST be
replaced.
RCPH05CDC338AAB 2
3. Inspect the gear alignment groove for burrs. If the

keyway is damaged or the burrs cannot be removed
with a Scotch-Brite™ pad, the gear MUST be
replaced.
RCPH05CDC338AAA 3
3 15/11/2005
B.10.A / 110
4. Inspect the speed sensor targets on the gear.

Replace the gear if any of the targets are damaged.
RCPH05CDC340AAA 4
5. Inspect the camshaft nose for fretting or burrs.

If the fretting or burrs cannot be removed with
a Scotch-Brite™ pad, the camshaft MUST be
replaced.
RCPH05CDC343AAB 5
Next operation: Camshaft Gear - Install (B.10.A.40.44.10 - F.10.A.15)
3 15/11/2005
B.10.A / 111
Camshaft Gear - Install (B.10.A.40.44.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10)
1. Lubricate the camshaft surface with CASE AKCELA

EP-0 GREASE.
RCPH05CDC767AAA 1
2. If required, install the alignment pin the camshaft.
RCPH05CDC343AAA 2
3. Place the camshaft in a press and support it with a

gear puller. Install the thrust plate on the camshaft.
NOTE: The thrust plate MUST be installed before
installing the gear on the camshaft.
RCPH05CDC467AAA 3
3 15/11/2005
B.10.A / 112
4. Heat the gear for 45 minutes in an oven at a

temperature of 204 °C (400 °F).
CAUTION
M1009 - The component will be permanently distorted
if overheated. The oven temperature should never
exceed 204 degrees C (400 degrees F).
RCSC05CDC110AAA 4
5. Install the gear with the timing marks away from

the camshaft.
WARNING
M943 - ALWAYS wear protective gloves when handling
heated parts. Failure can cause injury.
RCPH05CDC470AAA 5
6. Use a 0.02 mm (0.001 in) feeler gauge to check if

the gear is seated against the camshaft shoulder. If
the feeler gauge can be inserted between the gear
and shoulder, the gear is NOT properly seated.
RCPH05CDC766AAA 6
3 15/11/2005
B.10.A / 113
Camshaft Push rod - Remove (B.10.A.40.44.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Remove the blowby recirculation system tube and the drain tube. See Blowby re-circulation
system - Remove (B.60.A.26 - F.10.A.10).
Prior operation: Remove the rocker arms. See Valve drive Rocker assembly - Remove (B.10.A.40.43 -
F.10.A.10).
1. Mark the push rods – intake or exhaust and the

cylinder number – to identify their location. Remove
the push rods.
RCPH05CDC848AAA 1
Next operation: Camshaft Push rod - Visual inspection (B.10.A.40.44.20 - F.40.A.10)
3 15/11/2005
B.10.A / 114
Camshaft Push rod - Visual inspection (B.10.A.40.44.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Clean the push rods in hot soapy water.
RCSC05CDC114AAA 1
WARNING
3. Inspect the push rod ball for scoring. Check for

cracks where the ball is welded to the rod.
RCPH05CDC279AAB 2
4. Inspect the push rod sockets for scoring. Check for

cracks where the socket is welded to the rod.
RCPH05CDC278AAB 3
3 15/11/2005
B.10.A / 115
5. Check the push rods for straightness by rolling them

across a flat surface.
RCPH05CDC238AAB 4
3 15/11/2005
B.10.A / 116
Camshaft Push rod - Install (B.10.A.40.44.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Push rod - Visual inspection (B.10.A.40.44.20 - F.40.A.10)
1. Different adjusting screws are used depending on

engine configuration. When replacing components,
make sure the correct parts are installed.
CAUTION
M1033 - Mismatched push tubes, rocker levers and
rocker lever adjusting screws can cause engine
damage. The components are matched to the engine.
When replacing components, make sure the correct
push tubes, rocker levers and adjusting screws are
used for this engine.
RCSC05CDC112AAA 1
2. Install the push rods into the sockets of the roller

tappets. If reused, the push rods must be returned
to their original location.
RCPH05CDC848AAA 2
3. Lubricate the push rod sockets with clean engine oil.
RCPH05CDC849AAA 3
Next operation: Install the rocker arms. See Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15).
Next operation: Adjust valve lash. See Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01).
Next operation: Install the blowby recirculation system tube and drain tube. See Blowby re-circulation system -
Install (B.60.A.26 - F.10.A.15).
3 15/11/2005
B.10.A / 117
Camshaft Tappet - Remove (B.10.A.40.44.25 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Prior operation: Remove the blowby recirculation system tube and drain tube. See Blowby re-circulation
Prior operation: Remove the rocker arms. See Valve drive Rocker assembly - Remove (B.10.A.40.43
- F.10.A.10)
Prior operation: Remove the push tubes. See Camshaft Push rod - Remove (B.10.A.40.44.20 - F.10.A.10).
1. Use the tappet removal tool – 3165088 (CUMMINS)

– to remove the tappets.
2. Insert the extractor tool into the tappet bore.
RCPH05CDC247AAA 1
3. Turn the upper knob (A) counterclockwise while

holding the lower knob (B) to expand and secure
the tool in the tappet. Raise the extractor until it
stops against the inner block, and push the tab (C)
against the head to hold the captured tappet in the
raised position.
RCPH05CDC249AAB 2
4. Repeat for the remaining tappets.

5. Remove the camshaft. Refer to Valve drive
Camshaft - Remove (B.10.A.40.44 - F.10.A.10).
3 15/11/2005
B.10.A / 118
6. Insert the tappet holder into the camshaft bore.

NOTE: The holes must be in the upper position.
RCPH05CDC252AAA 3
7. Lower the extractor and seat the tappet in the holder.

Turn the upper knob clockwise (A) while holding
the lower knob (B) to disengage the extractor from
the tappet.
Remove the extractor tool.
RCPH05CDC248AAC 4
8. Repeat for the other tappets.

9. Remove the holder and tappets from the camshaft
bore.
RCPH05CDC253AAA 5
Next operation: Camshaft Tappet - Visual inspection (B.10.A.40.44.25 - F.40.A.10)
3 15/11/2005
B.10.A / 119
Camshaft Tappet - Visual inspection (B.10.A.40.44.25 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Tappet - Remove (B.10.A.40.44.25 - F.10.A.10)
1. Inspect the tappet body for cracks or other damage.

NOTE: If the tappets are to be reused, use the holder to
store the tappets so they are installed in their original
position.
RCPH05CDC254AAA 1
2. Inspect the tappets for flat spots or pitting. See

the guidelines for roller tappet reuse – Camshaft
Tappet - Service limits (B.10.A.40.44.25 -
D.20.A.20). If excessive wear is found, replace the
tappet and inspect the camshaft.
The roller MUST rotate freely. if it does not, replace

the tappet.
RCSC05CDC111AAA 2
Next operation: Camshaft Tappet - Install (B.10.A.40.44.25 - F.10.A.15)
3 15/11/2005
B.10.A / 120
Camshaft Tappet - Install (B.10.A.40.44.25 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Tappet - Visual inspection (B.10.A.40.44.25 - F.40.A.10)
1. Lubricate the rollers and cylindrical surface of the

tappets with CASE AKCELA EP-0 GREASE.
RCPH05CDC774AAA 1
2. The tappets must be installed with the pin slots

toward the intake manifold side of the block. If the
tappets are being reused, they must be reinstalled
in their original position.
RCPH05CDC254AAA 2
3. Insert the holder with the tappets into the camshaft

bore.
RCPH05CDC253AAA 3
3 15/11/2005
B.10.A / 121
4. Insert the extractor tool into the tappet bore.
RCPH05CDC247AAA 4
5. Turn the upper knob (A) counterclockwise while

holding the lower knob (B) to expand and secure
the tool in the tappet. Raise the extractor until it
stops against the inner block, and push the tab (C)
against the head to hold the captured tappet in the
raised position.
RCPH05CDC249AAB 5

7. Remove the tappet holder.
RCPH05CDC252AAA 6
8. Install the camshaft. Refer to Valve drive Camshaft

- Install (B.10.A.40.44 - F.10.A.15).
3 15/11/2005
B.10.A / 122
9. Lower the extractor and seat the tappet on the

camshaft lobe. Turn the upper knob clockwise (A)
while holding the lower knob (B) to disengage the
extractor from the tappet.
Remove the extractor tool.
RCPH05CDC248AAC 7

Next operation: Install the push rods. See Camshaft Push rod - Install (B.10.A.40.44.20 - F.10.A.15)
Next operation: Install the rocker arms. See Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15)
Next operation: Adjust valve lash. Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01)
(B.60.A.26 - F.10.A.15)
3 15/11/2005
B.10.A / 123
Camshaft Bushing - Remove (B.10.A.40.44.30 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use the bushing replacer tool – 3165045 (CUMMINS)

– to remove the camshaft bushings.
2. Install the extension on the driver bar. Slide the
driver bar (A) through the centering guide (B) from
the front of the cylinder block through the camshaft
bores.
RCPH05CDC483AAA 1
3. Install the bushing remover/installer (A) on the drive

bar with the cap screw (B).
RCPH05CDC494AAA 2
4. Drive the rear bushing (number 7) and pipe plug

from its bore first.
RCPH05CDC482AAA 3
3 15/11/2005
B.10.A / 124
5. Remove the bushing remover/installer and install

the driver from the rear of the engine. Drive the front
bushing out of its bore.
Reinstall the driver from the front of the engine

and drive the remaining bushings from the block in
succession, starting with the number 2 bushing.
RCPH05CDC485AAA 4
6. Remove the remover/installer, drive bar and

centering guide from the block.
Next operation: Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16)
3 15/11/2005
B.10.A / 125
Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Bushing - Remove (B.10.A.40.44.30 - F.10.A.10)
1. Inspect the camshaft bore for damage and

excessive wear. Measure the bore.
Without the bushing, the bore diameter must be

64.013 mm (2.5202 in).
RCPH05CDC487AAB 1
2. With the bushing installed, the bore diameter must

be 60.120 mm (2.3669 in).
RCPH05CDC489AAA 2
Next operation: Camshaft Bushing - Install (B.10.A.40.44.30 - F.10.A.15)
3 15/11/2005
B.10.A / 126
Camshaft Bushing - Install (B.10.A.40.44.30 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16)
1. The bushing and camshaft bore have two lubricating

oil holes. The larger hole (A), located next to
the notch (B) on the bushing, is visible during
installation. The smaller bore (C) is not visible
during installation.
RCPH05CDC495AAA 1
2. Mark the bushing and the block to align the larger

oil holes in the block bore and the bushing during
installation. Slide the replacement bushing on
the remover/installer and drive the bushing to the
correct depth – that is, when the oil holes are
aligned to each other.
RCPH05CDC486AAA 2
3. Install the bushings in succession, working

from the rear to the front. Remove the bushing
remover/installer, drive bar and centering guide
from the block.
4. Check that the lubricating oil holes are aligned. A
3.2 mm (0.128 in) diameter rod MUST be able to
pass through the aligned holes.
NOTE: The front bore (number 1) does not have oil holes
in the block bore.
RCPH05CDC488AAA 3
3 15/11/2005
B.10.A / 127
Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
Prior operation: Remove the fuel pump cover plate. See High pressure common rail Gear pump - Remove
(B.20.A.30.10 - F.10.A.10)

the crankshaft and align the top dead center marks
on the gear cover and the fuel pump gear.
CAUTION
M1032 - Engine coolant temperature should be less
than 60 degrees C (140 degrees F) when performing
this procedure.
RCPH05CDC222AAB 1
2. With the engine in this position, lash can be checked

on the following rocker arms: 1-intake, 1-exhaust,
2-intake, 3-exhaust, 4-intake and 5-exhaust.
Intake lash must be within 0.152 - 0.559 mm (0.006

- 0.022 in).
Exhaust lash must be within 0.381 - 0.813 mm

(0.015 - 0.032 in).
NOTE: Lash is checked during a troubleshooting
procedure and resetting is NOT required as long as the
lash measurements are within the stated ranges.
RCPH05CDC223AAA 2
3 15/11/2005
B.10.A / 128
3. Measure lash by inserting a feeler gauge between

the crosshead and the rocker arm ball insert and
socket, while lifting up on the rocker arm. If lash is
out of specification, loosen the lock nut and adjust
lash to nominal specifications.
The nominal intake lash specification is 0.305 mm

(0.012 in).
The nominal exhaust lash specification is 0.559 mm

(0.022 in).
Tighten the lock nut and measure again. When

adjustment is complete, torque the lock nut to 24
Nm (18 lb ft).
3
IMPORTANT: Lash resets are only required (A) at the RCPH05CDC224AAA
interval specified in the operator or maintenance manual,

(B) when lash is measured and found out of specification,
or (C) when engine repair includes removal of the rocker
arms or loosening of the adjusting screws.
4. Using the engine barring tool, rotate the crankshaft
360 °, and measure lash for rocker arms 2-exhaust,
3-intake, 4-exhaust, 5-intake, 6-intake and
6-exhaust. Reset the lash if it is out of specification.
RCPH05CDC227AAA 4

(B.60.A.26 - F.10.A.15).
Next operation: Install the fuel gear pump cover plate. See High pressure common rail Gear pump - Install
(B.20.A.30.10 - F.10.A.15).
3 15/11/2005
B.10.A / 129
Valve drive Valve assembly - Disassemble (B.10.A.40.46 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)
1. The valve spring compressor tool 3164329

(CUMMINS) is installed at the same location as the
injector retainer.
2. Install the replacer screw from the kit using the cap
screws from the kit. Torque the cap screws to 5
Nm (44 lb in).
IMPORTANT: Lubricate the threads and base of the
replacer screw with clean engine oil to prevent damage
to the tool.
RCPH05CDC836AAA 1
3. Install the compressor plate, washer and nut from

the kit over the screw, aligning the slots in the plate
with the cap screws.
RCPH05CDC825AAA 2
4. Turn the forcing nut clockwise until the springs are

compressed enough to remove the collets. Use a
magnetic tool to remove the collets.
RCPH05CDC826AAA 3
3 15/11/2005
B.10.A / 130
5. Turn the forcing screw counterclockwise until

tension is completely removed from the springs.
Remove the tool.
RCPH05CDC828AAA 4
6. Remove the spring retainers (A) and springs (B). If

the retainers and springs are to be reused, tag or
mark them so they can be returned to the original
location from which they were removed.
RCPH05CDC829AAA 5
7. Use a pliers with a 90 ° head to remove the seals

from the valve stems. Discard the seals.
RCPH05CDC830AAA 6
Next operation: Return to Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)
3 15/11/2005
B.10.A / 131
Valve assembly Valve - Cleaning (B.10.A.40.46.10 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Pressure test (B.10.A.72 - F.40.A.30)
1. Clean the head of the valves with a soft wire wheel.

Polish the stem of the valve with a Scotch-Brite™
pad and diesel fuel or solvent.
NOTE: Since head cleaning may erase or blur the valve
marking, store the valves in a labeled rack so they can be
returned to their original location in the head.
WARNING
personal injury.
RCSC05CDC125AAA 1
WARNING
Next operation: Valve assembly Valve - Visual inspection (B.10.A.40.46.10 - F.40.A.10)
3 15/11/2005
B.10.A / 132
Valve assembly Valve - Visual inspection (B.10.A.40.46.10 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve assembly Valve - Cleaning (B.10.A.40.46.10 - F.30.A.10)
1. Inspect the head and stem of the valve for abnormal

wear.
RCPH05CDC389AAC 1
2. Check the stem tip for flatness. Inspect for bend

in the valve stem.
RCPH05CDC389AAD 2
Next operation: Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01)
3 15/11/2005
B.10.A / 133
Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve assembly Valve - Visual inspection (B.10.A.40.46.10 - F.40.A.10)
1. Measure the diameter of the valve stem. The

diameter MUST be within 7.96 - 7.98 mm (0.313 -
0.314 in). Replace any valve outside of this range.
RCPH05CDC389AAB 1
2. Measure the rim thickness. The rim on the intake

valve (A) is thicker than the rim on an exhaust valve
(B)). Do not confuse the two when measuring.
RCPH05CDC388AAA 2
3. The minimum thickness for the exhaust valve rim is

1.83 mm (0.072 in).
The minimum thickness for the intake valve rim is

2.20 mm (0.087 in).
If the valve rim thickness is NOT within the limit, a

new valve must be used.
RCPH05CDC390AAB 3
Next operation: Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01)
3 15/11/2005
B.10.A / 134
Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01)
1. Inspect the spring and retainer for damage or wear.
RCPH05CDC269AAA 1
2. Measure the height of the valve spring. Approximate

free length should be 59.18 mm (2.330 in).
RCPH05CDC270AAB 2
3. Use OEM1281 or equivalent to test spring tension.

With a load of 906 - 1007 N (204 - 226 lb), the spring
should compress to a height of 30.6 mm (1.2 in).
Replace the spring if the load required to compress

the spring is less than the specified load.
RCSC05CDC130AAA 3
Next operation: Cylinder head Valve guide - Cleaning (B.10.A.72.15 - F.30.A.10)
3 15/11/2005
B.10.A / 135
Valve drive Valve assembly - Assemble (B.10.A.40.46 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Assemble (B.10.A.72 - F.10.A.20)
Black or blue colored seals

1. Use a 13 mm deep well socket to install the black
valve seals over the exhaust valve guides.
Install the blue valve seals over the intake valve

guides.
RCPH05CDC831AAA 1
Yellow or green colored seals

2. Use a 13 mm deep well socket to install the green
Install the yellow valve seals over the intake valve

guides.
RCPH05CDC831AAA 2
3. Install the springs and spring retainers on the valve

stems. If the springs and retainers are being reused,
they must be installed at the location from which
they were removed.
RCPH05CDC829AAA 3
3 15/11/2005
B.10.A / 136
4. Install the replacer screw from the spring

compressor tool 3164329 (CUMMINS) at the location
of the injector retainer, using the cap screws from
the kit. Torque the cap screws to 5 Nm (41 lb in).
NOTE: Springs shown removed for photo clarity.
RCPH05CDC832AAA 4
5. Install the compressor plate, washer and forcing nut

from the tool kit on the replacer screw, aligning the
slots in the plate with the cap screws.
RCPH05CDC833AAA 5
6. Turn the forcing nut clockwise until the springs are

compressed enough to install the collets.
RCPH05CDC835AAA 6
3 15/11/2005
B.10.A / 137
7. Install the collets with a magnetic tool.
RCPH05CDC826AAA 7
8. Turn the forcing nut counterclockwise until the

collets retain the springs and the tool can be
removed. Remove the tool.
RCPH05CDC825AAA 8
9. Hit the valve stems with a plastic hammer to make

sure the collets are seated.
RCPH05CDC837AAA 9
Next operation: Return to Cylinder head - Assemble (B.10.A.72 - F.10.A.20)
3 15/11/2005
B.10.A / 138
Crankshaft - Remove (B.10.A.43 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
M941 - DO NOT remove coolant system pressure cap while coolant is HOT. Wait until the coolant
temperature is below 50 degrees C (120 degrees F) before removing the system pressure cap. Failure to
do so will cause injury.
WARNING
M940 - Coolant can be toxic. Keep away from children and pets. Avoid prolong contact. If not reused,
dispose of in accordance with local environmental regulations.
WARNING
M929 - Avoid direct contact of hot oil with your skin. Hot oil will cause injury.
WARNING
M939 - Some local and government agencies have determined that used engine oil can be toxic and
hazardous to your health. Avoid inhalation of vapors, ingestion and prolonged contact with used engine oil.
Prior operation: ENGINE COOLANT SYSTEM - Emptying (B.50.A - F.35.A.01)

Prior operation: LUBRICATION SYSTEM - Emptying (B.60.A - F.35.A.01)
Prior operation: Oil pan - Remove (B.60.A.23 - F.10.A.10)
Prior operation: Timing gear housing - Remove (B.10.A.46 - F.10.A.10)
Prior operation: Rear cover - Remove (B.10.A.76 - F.10.A.10)
Prior operation: Remove the rod caps and lower bearings. See Connecting rod and piston - Remove (B.10.A.47
- F.10.A.10).
Prior operation: Remove the main bearing caps and lower main bearings. See Crankshaft Main bearing -
Remove (B.10.A.43.15 - F.10.A.10).
1. Install appropriate lifting straps to balance and

protect the crankshaft during removal. Use
appropriate lifting equipment and remove the
crankshaft.
WARNING
M997 - The component weighs 23kg (50 lbs) or more.
To avoid personal injury, use a hoist or get assistance
from another person to lift the component.
RCPH05CDC476AAA 1
Next operation: Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01)

Next operation: Crankshaft Gear - Remove (B.10.A.43.10 - F.10.A.10)
Next operation: Crankshaft Speed ring - Remove (B.10.A.43.20 - F.10.A.10)
3 15/11/2005
B.10.A / 139
Crankshaft - Install (B.10.A.43 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01)

Prior operation: Crankshaft Gear - Install (B.10.A.43.10 - F.10.A.15)
Prior operation: Crankshaft Speed ring - Install (B.10.A.43.20 - F.10.A.15)
1. Lubricate the upper main bearings with CASE

AKCELA EP-0 GREASE before installing the
crankshaft.
RCPH05CDC492AAA 1
2. Use appropriate lifting straps and equipment to

lower the crankshaft into the block. Remove the
lifting equipment.
WARNING
RCPH05CDC476AAA 2
Next operation: Install the lower main bearings and bearing caps. See Crankshaft Main bearing - Install
(B.10.A.43.15 - F.10.A.15).
Next operation: Crankshaft - End play (B.10.A.43 - F.40.E.10)
Next operation: Install the lower rod bearings and rod caps. See Connecting rod and piston - Install (B.10.A.47
- F.10.A.15).
Next operation: Rear cover - Install (B.10.A.76 - F.10.A.15)
Next operation: Timing gear housing - Install (B.10.A.46 - F.10.A.15)
Next operation: Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10)
Next operation: Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15)
Next operation: Oil pan - Install (B.60.A.23 - F.10.A.15)
Next operation: LUBRICATION SYSTEM - Filling (B.60.A - F.60.A.10)
Next operation: ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)
3 15/11/2005
B.10.A / 140
Crankshaft - End play (B.10.A.43 - F.40.E.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: Crankshaft end play can be measured anytime the front cover is removed and the crankshaft is exposed.
1. Measure the crankshaft end play with a dial indicator
and magnetic or clamp on base. The measurement
can be taken on the shaft or the crankshaft gear.
The required end play range is 0.085 - 0.385 mm

(0.003 - 0.015 in).
NOTE: The dimensions of the thrust bearing and the
crankshaft journal determine end play.
RCPH05CDC782AAA 1
2. If the end play is out of range, check the main

bearing installation, the size of the main bearings
and the crankshaft journals.
3 15/11/2005
B.10.A / 141
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Remove the seal carrier from the front cover.
RCPH05CDC966AAA 1
2. Use a seal scraper to remove the silicone sealant

from the carrier.
RCPH05CDC968AAA 2
3. Press the seal from the back side of the carrier

toward the front side of the carrier, while supporting
the carrier.
RCPH05CDC969AAA 3
3 15/11/2005
B.10.A / 142
4. Press the seal from the carrier.
RCPH05CDC970AAA 4
Next operation: Crankshaft Front seal - Visual inspection (B.10.A.43.01 - F.40.A.10)
3 15/11/2005
B.10.A / 143
Crankshaft Front seal - Visual inspection (B.10.A.43.01 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10)
1. Clean any seal residue from the carrier seal bore.
RCPH05CDC090ABA 1
2. Clean and dry the crankshaft sealing area. If the

crankshaft has excessive wear, a wear sleeve is
available. See Crankshaft Front wear sleeve -
Install (B.10.A.43.05 - F.10.A.15).
IMPORTANT: The crankshaft sealing area must be clean,
dry and free of oil for proper seal installation.
RCPH05CDC079ABA 2
Next operation: Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15)
3 15/11/2005
B.10.A / 144
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Front seal - Visual inspection (B.10.A.43.01 - F.40.A.10)
1. Leave the plastic pilot in the seal until the seal and
carrier are installed on the cover.
Place the seal in the seal installation tool –

CAS2430 or CNH299106 – with the seal dust lip
facing outward.
NOTE: This is the same tool available under two different
part numbers.
RCPH05CDC089ABA 1
2. Place the tool and seal assembly on the back side

of the carrier.
RCPH05CDC091ABA 2
3. Press the seal into the carrier from the back side of
the carrier toward the front side of the carrier. Tool
CAS2430 or CNH299106 will bottom on the carrier,
setting the seal to the proper depth.
NOTE: The ring included with seal installation tool may be
installed under the carrier to prevent damage to the seal
when it is pressed.
RCPH05CDC092ABA 3
3 15/11/2005
B.10.A / 145
4. Use Permatex™ Ultra Grey (87307915) silicone

sealant to seal the carrier on the cover. Apply a
bead of this silicon to the inside of the carrier. There
MUST be sealant on the inside carrier surface for all
the through holes.
RCPH05CDC093ABA 4
5. Install the carrier on the front cover.
RCPH05CDC094ABA 5
6. Torque the carrier nuts to 10 Nm (88 lb in).
RCPH05CDC095ABA 6
3 15/11/2005
B.10.A / 146
7. Remove the plastic pilot if the front cover is installed

on the engine.
RCPH05CDC098ABA 7
Next operation: If required, Front cover - Install (B.10.A.75 - F.10.A.15)

3 15/11/2005
B.10.A / 147
Crankshaft Rear seal - Remove (B.10.A.43.02 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Refer to the chassis service manual to remove the components required to access the flywheel.
Prior operation: Flywheel - Remove (B.10.A.50 - F.10.A.10)
1. This procedure is used for standard rear seals

(A) when no wear sleeve (B) is present. See
Crankshaft Rear wear sleeve - Remove
(B.10.A.43.06 - F.10.A.10) if a wear sleeve is
installed.
RCPH05CDC935AAA 1
2. Drill two holes 180 ° apart into the dust exclusion

seal and crankshaft seal.
RCPH05CDC939AAA 2
3. Use a slide hammer with a threaded insert or a dent

puller to remove the existing seal.
RCPH05CDC940AAA 3
Next operation: Crankshaft Rear seal - Visual inspection (B.10.A.43.02 - F.40.A.10)
3 15/11/2005
B.10.A / 148
Crankshaft Rear seal - Visual inspection (B.10.A.43.02 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Rear seal - Remove (B.10.A.43.02 - F.10.A.10)
1. Clean and dry the sealing surface on the rear

crankshaft.
CAUTION
M1014 - The seal lip and the sealing surface on the
crankshaft must be free from all oil residue to prevent
seal leaks.
RCPH05CDC925AAA 1
2. Inspect the crankshaft for excessive wear.

NOTE: If excessive wear is present, a wear sleeve is
available. Refer to Crankshaft Rear wear sleeve - Install
(B.10.A.43.06 - F.10.A.15) for the proper installation.
RCPH05CDC924AAA 2
Next operation: Crankshaft Rear seal - Install (B.10.A.43.02 - F.10.A.15)
3 15/11/2005
B.10.A / 149
Crankshaft Rear seal - Install (B.10.A.43.02 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Rear seal - Visual inspection (B.10.A.43.02 - F.40.A.10)
1. Install the new rear seal on the driver screw from

seal installer tool CNH299155. The seal must be
installed from the front of the tool to protect the lip.
RCPH05CDC974AAA 1
2. Install the driver screw and seal assembly on the

crankshaft.
RCPH05CDC975AAA 2
3. Lubricate the outside diameter of the new seal with

a mild liquid soap.
RCPH05CDC976AAA 3
3 15/11/2005
B.10.A / 150
4. Install the dust exclusion spacer (A) – 380002456

– and the cup (B) from seal installer tool –
CNH299155 – on the driver screw. Align the spacer
with the cup and tighten the forcing nut (C).
RCPH05CDC977AAA 4
5. Turn the forcing nut clockwise until the seal is

completely seated on the crankshaft.
RCPH05CDC949AAA 5
6. Remove the cup and check that the seal is properly

seated. Install the dust exclusion seal on the driver
screw.
RCPH05CDC950AAA 6
3 15/11/2005
B.10.A / 151
7. Install the cup on the driver screw and turn the

forcing nut clockwise until the dust seal is completely
seated.
RCPH05CDC949AAA 7
8. Remove the tool and check that the seal is properly

seated.
Next operation: Flywheel - Install (B.10.A.50 - F.10.A.15)

Next operation: Refer to the chassis repair manual for installation of the components removed to access the
flywheel.
3 15/11/2005
B.10.A / 152
Crankshaft Front wear sleeve - Remove (B.10.A.43.05 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Use a hammer and chisel which is only as wide as

the wear sleeve to remove the sleeve. Make several
chisel marks across the wear sleeve to expand it.
Remove the wear sleeve.
CAUTION
M1015 - Do not nick or gouge the crankshaft with
the chisel. If the crankshaft is damaged, it must be
replaced.
RCPH05CDC100ABA 1
Next operation: Crankshaft Front wear sleeve - Visual inspection (B.10.A.43.05 - F.40.A.10)
3 15/11/2005
B.10.A / 153
Crankshaft Front wear sleeve - Visual inspection (B.10.A.43.05 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Front wear sleeve - Remove (B.10.A.43.05 - F.10.A.10)
1. Use a Scotch-Brite™ pad to remove any rust or

other deposits from the crankshaft flange. Clean the
crankshaft flange with a clean shop rag.
NOTE: The front crankshaft seal used with a wear sleeve
has a larger inside diameter than a standard seal. The
two seals are NOT interchangeable.
RCPH05CDC079ABA 1
Next operation: Crankshaft Front wear sleeve - Install (B.10.A.43.05 - F.10.A.15)
3 15/11/2005
B.10.A / 154
Crankshaft Front wear sleeve - Install (B.10.A.43.05 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Front wear sleeve - Visual inspection (B.10.A.43.05 - F.40.A.10)
1. Use the front wear sleeve installation tool – 3165112

(CUMMINS) – to install the sleeve to the correct depth
on the crankshaft.
RCPH05CDC105ABA 1
2. Lubricate the inside diameter and the cap screws

on the tool with clean engine oil.
RCPH05CDC081ABA 2
3. Lubricate the crankshaft flange with clean engine oil.
RCPH05CDC080ABA 3
3 15/11/2005
B.10.A / 155
4. Place the chamfered end of the wear sleeve on the

crankshaft.
RCPH05CDC082ABA 4
5. Install the tool without the spacers on the crankshaft.

Install the cap screws finger tight.
NOTE: This tool can be used on a four hole or five hole
crankshaft. Select the tool holes which align with your
shaft.
RCPH05CDC083ABA 5
6. Alternating between cap screws, tighten the screws

until the wear sleeve is installed to an approximate
depth of 16 mm (0.625 in).
IMPORTANT: To prevent damage to the wear sleeve,
alternately tighten each cap screw one-half revolution at
a time.
RCPH05CDC084ABA 6
3 15/11/2005
B.10.A / 156
7. When the 16 mm (0.625 in) depth is achieved, add

a spacer for the tool to each cap screw one at a time.
RCPH05CDC085ABA 7
8. Continue to alternately tighten the cap screws until

the bottom of the tool contacts the crankshaft.
RCPH05CDC086ABA 8
9. Remove the tool from the crankshaft.
RCPH05CDC087ABA 9
Next operation: Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15)

3 15/11/2005
B.10.A / 157
Crankshaft Rear wear sleeve - Remove (B.10.A.43.06 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Refer to the chassis service manual to remove the components required to access the flywheel.
1. This procedure is used for oversized rear seals (B)

when a wear sleeve is present. See Crankshaft
Rear seal - Remove (B.10.A.43.02 - F.10.A.10) if a
standard seal without a wear sleeve (A) is required.
RCPH05CDC935AAA 1
2. Loosen the four cap screws at the rear of the oil pan.
RCPH05CDC941AAA 2
3. Use a feeler gauge and carefully separate the oil

pan gasket from the rear cover. Work the gauge
from the side to side to release the gasket from the
rear cover.
IMPORTANT: Use extreme care not to damage the
gasket. If the gasket is damaged, it must be repaired or
replaced.
RCPH05CDC942AAA 3
4. When the gasket is free of the cover, remove the

four oil pan cap screws.
3 15/11/2005
B.10.A / 158
5. Remove the eight cap screws securing the rear

cover.
RCPH05CDC971AAA 4
6. Pry the rear cover, cover gasket and shaft seal

assembly off the crankshaft.
RCPH05CDC954AAA 5
7. Use the cup (A) from the seal installer tool

CNH299155 to press the seal from the cover.
RCPH05CDC466AAA 6
3 15/11/2005
B.10.A / 159
8. Using a dull chisel no wider than the wear sleeve

and hammer, strike the wear sleeve several times
to expand the sleeve, allowing it to be removed.
Remove the sleeve.
CAUTION
M1015 - Do not nick or gouge the crankshaft with
the chisel. If the crankshaft is damaged, it must be
replaced.
RCPH05CDC956AAA 7
Next operation: Crankshaft Rear wear sleeve - Visual inspection (B.10.A.43.06 - F.40.A.10)
3 15/11/2005
B.10.A / 160
Crankshaft Rear wear sleeve - Visual inspection (B.10.A.43.06 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Rear wear sleeve - Remove (B.10.A.43.06 - F.10.A.10)
1. Clean the gasket surface of the cylinder block and

rear cover.
RCPH05CDC972AAA 1
2. Use crocus cloth to remove any rust or other

deposits from the crankshaft flange.
RCPH05CDC944AAB 2
3. Clean the crankshaft flange with a clean cloth.
RCPH05CDC943AAA 3
3 15/11/2005
B.10.A / 161
4. Inspect the crankshaft flange for nicks or other

damage.
RCPH05CDC944AAC 4
5. Inspect the rear cover for cracks or other damage.
RCPH05CDC973AAB 5
Next operation: Crankshaft Rear wear sleeve - Install (B.10.A.43.06 - F.10.A.15)
3 15/11/2005
B.10.A / 162
Crankshaft Rear wear sleeve - Install (B.10.A.43.06 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Rear wear sleeve - Visual inspection (B.10.A.43.06 - F.40.A.10)
IMPORTANT: Do not use any lubricant on the crankshaft sealing surface or the seal surface which mates with it.
These surfaces must be clean and dry for proper oil sealing. If required, clean and dry the crankshaft sealing
surface before proceeding.
NOTE: If the oil pan gasket was damaged during removal, see Step 12 in this procedure before proceeding.
1. Install a new rear cover gasket and the rear cover.
Do not completely tighten the cover cap screws at
this time.
NOTE: Seal installation will properly align the rear cover
for final torquing. Do NOT realign the cover after the seal
is installed; this may distort the seal lip preventing proper
sealing.
RCPH05CDC991AAA 1
2. Install the driver screw from the rear seal installation

tool – CNH299155 – on the crankshaft.
RCPH05CDC945AAA 2
3. Install the new seal with wear sleeve on the driver

screw.
NOTE: The combination oil seal and wear sleeve service
part is installed on the crankshaft as an assembly. Do
NOT separate the oil seal from the wear sleeve.
RCPH05CDC946AAA 3
3 15/11/2005
B.10.A / 163
4. Lubricate the outside diameter of the seal with a

mild liquid soap.
RCPH05CDC947AAA 4
5. Install the dust exclusion spacer (A) – 380002456

– and the cup (B) from the seal installer tool –
CNH299155 – on the driver screw. Align the spacer
with the cup and tighten the forcing nut (C).
RCPH05CDC948AAA 5
6. Turn the forcing nut clockwise until the wear sleeve

and seal are completely seated on the crankshaft.
RCPH05CDC949AAA 6
3 15/11/2005
B.10.A / 164
7. Remove the cup and check that the seal is properly

seated. Install the dust exclusion seal on the driver
screw.
RCPH05CDC950AAA 7
8. Install the cup on the driver screw.
RCPH05CDC951AAA 8
9. Turn the forcing nut clockwise until the dust seal

is fully seated. Remove the cup and check seal
installation.
RCPH05CDC952AAA 9
3 15/11/2005
B.10.A / 165
10. Remove the driver screw from the crankshaft.

Tighten and then torque the rear cover cap screws
to 10 Nm (86 lb in).
RCPH05CDC953AAA 10
11. Install the four oil pan cap screws. Torque the cap
screws to 28 Nm (21 lb ft).
RCPH05CDC941AAA 11
Gasket repair
12. If the oil pan gasket was damaged during separation
from the rear cover and damage does not extend
beyond the rear cover, the gasket can be repaired.
Cut the damaged gasket at both sides of the rear
cover.
RCPH05CDC957AAA 12
3 15/11/2005
B.10.A / 166
13. Using the damaged section as a template, mark and

cut a replacement section from a new gasket.
RCPH05CDC958AAA 13
14. Apply Permatex™ Ultra Grey (87307915) silicone

sealant to the oil pan surface at the rear cover
where the gaskets sections will meet.
RCPH05CDC959AAA 14
15. Install the replacement gasket section on the oil pan.
RCPH05CDC960AAA 15
3 15/11/2005
B.10.A / 167
16. Use thin wire or thread to hold the gasket section in

position while the rear cover is installed. Proceed
with Step 1 to install the rear cover. Do NOT remove
the thread or thin wire until the center cap screws
are installed to hold the gasket in place.
RCPH05CDC961AAA 16

Next operation: Refer to the chassis repair manual for installation of the components removed to access the
flywheel.
3 15/11/2005
B.10.A / 168
Crankshaft Gear - Remove (B.10.A.43.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft - Remove (B.10.A.43 - F.10.A.10)
1. The forcing screw (A) on the tool used for gear

removal must be equipped with a flat tip to prevent
damage to the crankshaft.
RCPH05CDC501AAB 1
2. Use a heavy duty bearing separator or gear puller

and remove the gear from the crankshaft.
RCPH05CDC502AAA 2
3. Remove the alignment pin from the gear journal if

required.
RCPH05CDC505AAA 3
Next operation: Crankshaft Gear - Visual inspection (B.10.A.43.10 - F.40.A.10)
3 15/11/2005
B.10.A / 169
Crankshaft Gear - Visual inspection (B.10.A.43.10 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Gear - Remove (B.10.A.43.10 - F.10.A.10)
1. Inspect the gear for cracks and broken or chipped

teeth. The gear must be replaced if it is damaged.
RCPH05CDC507AAB 1
2. Inspect the gear and keyway for nicks or burrs. Use

fine crocus cloth to remove the nicks or burrs.
RCPH05CDC508AAB 2
3. Inspect the gear journal and dowel pin hole for burrs
or damage. Use fine crocus cloth to remove the
burrs.
RCPH05CDC504AAB 3
Next operation: Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16)
3 15/11/2005
B.10.A / 170
Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Gear - Visual inspection (B.10.A.43.10 - F.40.A.10)
1. Use OEM1012 or equivalent to measure the gear

bore inside diameter. The diameter must be within
75.898 - 75.923 mm (2.9881 - 2.9891 in).
RCPH05CDC506AAB 1
2. Measure the gear journal outside diameter. The

outside diameter must be within 75.987 - 76.006
mm (2.9916 - 2.9924 in).
RCPH05CDC503AAA 2
Next operation: Crankshaft Gear - Install (B.10.A.43.10 - F.10.A.15)
3 15/11/2005
B.10.A / 171
Crankshaft Gear - Install (B.10.A.43.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16)
1. If removed, use a soft hammer to install the

alignment pin into the crankshaft. The pin MUST be
1.02 mm (0.040 in) above the crankshaft surface.
RCPH05CDC511AAB 1
2. Heat the gear in a 177 °C (350 °F) oven for a

minimum of 45 minutes, but NOT more than 2 hours.
CAUTION
M1010 - Do not exceed the specified heating time or
temperature. The component can be damaged.
RCSC05CDC134AAA 2
3. Use CASE AKCELA EP-0 GREASE to lubricate the

outside diameter of the gear journal.
RCPH05CDC512AAA 3
3 15/11/2005
B.10.A / 172
4. Install the gear within 30 seconds after removing

it from the oven. Align the gear keyway with the
alignment pin and install the gear.
WARNING
CAUTION
M1013 - The timing mark and part number on the gear
must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear
is installed backwards.
RCPH05CDC513AAA 4
CAUTION
M1011 - Do not use water or oil to reduce the cooling
time. The component can crack. Allow the component
to air cool.
5. If the gear cools and binds on the crankshaft before

it is seated, use a driver to complete the installation.
RCSC05CDC133AAA 5
Next operation: Crankshaft - Install (B.10.A.43 - F.10.A.15)
3 15/11/2005
B.10.A / 173
Crankshaft Main bearing - Remove (B.10.A.43.15 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING

1. Mark the bearing caps by their location on the oil

cooler side of the bearing cap.
RCPH05CDC717AAA 1
2. To support the crankshaft during bearing removal,

replace the number 2 through 6 bearings, while
the number 1 and number 7 caps support the
crankshaft. After replacing number 2 through 6,
replace the number 1 and number 7 bearings.
RCPH05CDC783AAB 2
3 15/11/2005
B.10.A / 174
3. Remove the number 2 through 6 bearing caps and

lower bearings as an assembly.
RCPH05CDC717AAA 3
4. Remove the lower bearing shell from the bearing

cap, and mark it with the bearing number.
RCPH05CDC456AAA 4
5. Install special tool 3823818 (CUMMINS) in the oil hole

of the crankshaft main bearing journal.
NOTE: This tool can be shop made. See Crankshaft
Main bearing - Special tools (B.10.A.43.15 - D.20.A.40).
RCPH05CDC445AAA 5
3 15/11/2005
B.10.A / 175
6. Rotate the crankshaft so the tool contacts the upper

main bearing on the side opposite the tang.
NOTE: Thrust bearing shown.
RCPH05CDC446AAA 6
7. Continue to rotate the crankshaft in the direction

that will remove the tang end of the bearing first.
RCSC05CDC088AAA 7
8. Remove the bearing and the tool.

IMPORTANT: This same process can be used to remove
the number 2 through 7 upper bearings. The front main
bearing, number 1, does NOT have an oil hole in the
journal so the tool CANNOT be used. See Steps 9 and 10
for removing the number 1 upper main bearing.
9. Use a small, flat blade screwdriver to loosen the
number 1 upper bearing from the block.
CAUTION
M1006 - Use care so the screw driver does not damage
the crankshaft or cylinder block.
RCPH05CDC447AAA 8
3 15/11/2005
B.10.A / 176
10. Use finger pressure against the bearing shell while

rotating the crankshaft to roll the upper bearing out.
RCPH05CDC449AAA 9
Next operation: Crankshaft Main bearing - Visual inspection (B.10.A.43.15 - F.40.A.10)
3 15/11/2005
B.10.A / 177
Crankshaft Main bearing - Visual inspection (B.10.A.43.15 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Main bearing - Remove (B.10.A.43.15 - F.10.A.10)
1. Steam clean the main bearing caps.

NOTE: If the upper and lower bearing shells are to be
reused, they also must be cleaned and inspected.
WARNING
M927 - Always wear protective clothing, safety
glasses or a face shield when using a steam cleaner or
power washer. Failure to wear protective equipment
can cause serious injury.
RCSC05CDC081AAA 1
WARNING
3. Inspect all main bearing caps, bearing shells, cap

screws and the crankshaft journals for damage.
RCPH05CDC723AAA 2
Next operation: Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16)
3 15/11/2005
B.10.A / 178
Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Main bearing - Visual inspection (B.10.A.43.15 - F.40.A.10)
1. Measure the bearing shell thickness with an outside

micrometer that has a ball tip.
The required range is 3.446 - 3.454 mm (0.1357 -

0.1360 in).
Discard a bearing shell if its thickness is below the

minimum specification.
RCPH05CDC458AAA 1
2. If the crankshaft is removed from the engine,

measure the main bearing journals. See Crankshaft
Journal - Measure (B.10.A.43.16 - F.40.E.01).
RCPH05CDC478AAB 2
Next operation: Crankshaft Main bearing - Install (B.10.A.43.15 - F.10.A.15)
3 15/11/2005
B.10.A / 179
Crankshaft Main bearing - Install (B.10.A.43.15 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16)
1. Identify the upper main bearing shell by the

engraved marking on its back.
IMPORTANT: The upper and lower main bearing shells
are NOT interchangeable.
IMPORTANT: The main bearing being installed must
be the same size as the bearing removed. The size is
engraved on the back of the bearing shell.
RCPH05CDC457AAA 1
2. Apply a coat of CASE AKCELA EP-0 GREASE to

the inside surface of the upper main bearing shell.
NOTE: Do NOT lubricate the side of the shell which is
against the block when installed.
NOTE: The crankshaft thrust bearing must be installed on
the number 4 journal.
RCPH05CDC719AAA 2
3. Insert the side of the main upper bearing shell

opposite the tang first. Install as far as possible by
hand.
NOTE: When installing the thrust bearing on the number
4 journal, push the crankshaft to the front or rear of the
cylinder block for easier installation.
RCSC05CDC087AAA 3
3 15/11/2005
B.10.A / 180
4. Install special tool 3823818 (CUMMINS) in the oil hole

of the bearing journal and rotate the crankshaft to
finish the installation.
RCPH05CDC445AAA 4
5. The tang on the bearing shell must be located in the

notch on the block when properly installed.
RCPH05CDC475AAA 5
6. Install the lower bearing shell in the bearing cap.

Lubricate the inside surface of the shell with CASE
AKCELA EP-0 GREASE.
RCPH05CDC718AAA 6
3 15/11/2005
B.10.A / 181
7. Install a bearing cap assembly after each upper

bearing shell is installed to hold the bearing in place
while the other bearings are being installed.
RCSC05CDC085AAA 7
8. Lubricate the underside of the cap and the threads

on the cap screws with clean engine oil. Tighten
the cap screws.
NOTE: The bearing caps MUST be installed with their
number towards the oil cooler side of the engine; the word
“BACK” cast in the cap must face the rear of the engine.
RCPH05CDC721AAA 8
9. Torque the cap screws to 50 Nm (37 lb ft). Do not

tighten to the final torque value at this time.
RCPH05CDC473AAA 9
10. Repeat this process to install the remaining bearing

shells and caps except for main bearing number 1.
NOTE: The thrust bearing MUST be installed on the
number 4 journal.
NOTE: The number 1 main bearing does not have an oil
hole in the journal so the special tool cannot be used to
install the upper bearing shell.
3 15/11/2005
B.10.A / 182
11. Lubricate and install the upper bearing shell for the
number 1 journal. Insert the side of the main bearing
shell opposite the tang first. Install as far as possible
by hand. Use a small, flat blade screwdriver to push
the shell into position as the crankshaft is rotated.
RCSC05CDC090AAA 10
12. When all the bearings are installed, tighten the main
bearing cap screws evenly and in the sequence
shown. The crankshaft must rotate freely. Check
crankshaft rotation after the two cap screws for each
bearing cap are tightened.
CAUTION
M1007 - Some engines use 128 mm (5.0 inch) long
main bearing cap capscrews. Others use 135 mm (5.3
inch) long main bearing cap capscrews. Failure to
use the correct torque value for either size capscrew
can result in engine damage.
RCPH05CDC783AAC 11
13. For 128 mm (5.0 in) cap screws, use the torque
and advance method:
Step 1 – Torque to 50 Nm (37 lb ft).

Step 2 – Loosen the cap screws.
Step 4 – Advance 60 degrees.
RCPH05CDC771AAA 12
3 15/11/2005
B.10.A / 183
14. For 135 mm (5.3 in) cap screws, use the torque
and advance method:

Step 2 – Loosen the cap screws.
RCPH05CDC771AAA 13
15. Check rotation of the crankshaft. Check the main

bearing installation and the size of the main bearings
if the crankshaft does NOT rotate freely.
RCPH05CDC772AAA 14
Next operation: Crankshaft - End play (B.10.A.43 - F.40.E.10)
3 15/11/2005
B.10.A / 184
Crankshaft - End play (B.10.A.43 - F.40.E.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Main bearing - Install (B.10.A.43.15 - F.10.A.15)
1. Measure the crankshaft end play with a dial indicator

and magnetic or clamp on base. The required end
play range is 0.085 - 0.385 mm (0.003 - 0.015 in).
NOTE: The dimensions of the thrust bearing and the
crankshaft journal determine end play.
RCPH05CDC451AAA 1
2. If the end play is out of range, check the main

bearing installation, the size of the main bearings
and the crankshaft journals.

3 15/11/2005
B.10.A / 185
Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Measure the diameter of the main bearing journal

on the crankshaft. The acceptable range for the
main bearing journal is 98.006 - 98.032 mm (3.8585
- 3.8595 in).
Check the journal for out of roundness. The

maximum acceptable deviation is 0.050 mm (0.002
in).
Measure journal taper. The maximum acceptable

deviation is 0.013 mm (0.0005 in).
If the main bearing journals are NOT within the given

specifications, the crankshaft must be machined
under size or replaced.
NOTE: If the crankshaft is machined under size, over RCPH05CDC478AAC 1
sized main bearings must be used.
3 15/11/2005
B.10.A / 186
Crankshaft Speed ring - Remove (B.10.A.43.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove and discard the four speed ring mounting

cap screws.
NOTE: The cap screws are single use screws. They can
NOT be reused.
RCPH05CDC490AAA 1
Next operation: Crankshaft Speed ring - Visual inspection (B.10.A.43.20 - F.40.A.10)
3 15/11/2005
B.10.A / 187
Crankshaft Speed ring - Visual inspection (B.10.A.43.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Speed ring - Remove (B.10.A.43.20 - F.10.A.10)
1. Clean any oil from the spring ring. Clean the cap
screw holes in the crankshaft with a degreasing
solvent.
WARNING
personal injury.
WARNING
2. Inspect the speed ring for missing, bent or damaged

teeth. Inspect for cracks or damaged surfaces.
If any visual damage is found, the ring MUST be
replaced.
RCPH05CDC491AAB 1
Next operation: Crankshaft Speed ring - Install (B.10.A.43.20 - F.10.A.15)
3 15/11/2005
B.10.A / 188
Crankshaft Speed ring - Install (B.10.A.43.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Crankshaft Speed ring - Visual inspection (B.10.A.43.20 - F.40.A.10)
1. Install the speed indicator ring with new cap screws.

Tighten the cap screws in an alternating pattern.
Torque the cap screws to 8 Nm (71 lb in).
RCPH05CDC490AAA 1
3 15/11/2005
B.10.A / 189
Timing gear housing - Remove (B.10.A.46 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Perform the complete procedure for camshaft removal. See Valve drive Camshaft - Remove
(B.10.A.40.44 - F.10.A.10).
Prior operation: If the fuel pump must also be removed, see High pressure common rail Pump head and
housing - Remove (B.20.A.30.15 - F.10.A.10).
1. Remove the four oil pan cap screws.
RCPH05CDC996AAA 1
2. Remove the five timing gear housing cap screws.
RCPH05CDC107ABA 2
3. Use a feeler gauge to separate the oil pan gasket

from the gear housing. Work the gauge from side to
side to carefully separate the gasket without tearing
it.
RCSC05CDC141AAA 3
3 15/11/2005
B.10.A / 190
4. Remove the housing from the block, and remove

the gasket for the housing.
RCPH05CDC108ABA 4
Next operation: Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10)
3 15/11/2005
B.10.A / 191
Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Timing gear housing - Remove (B.10.A.46 - F.10.A.10)
1. Clean the gasket material from the block and from

the housing.
RCSC05CDC144AAA 1
2. Inspect the timing gear housing for cracks or

damaged sealing surfaces.
RCSC05CDC142AAA 2
3. If the fuel pump was removed, inspect the pump

mounting studs for damage. If a stud requires
replacement, lock two nuts together on the stud to
remove it.
RCSC05CDC143AAA 3
3 15/11/2005
B.10.A / 192
Timing gear housing - Install (B.10.A.46 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10)
1. If the oil pan gasket was damaged during housing

removal, see Oil pan - Reseal (B.60.A.23 -
F.75.C.15) for gasket repair procedures.
2. Install the housing gasket on the block.
RCPH05CDC108ABA 1
3. Apply a bead of Permatex™ Ultra Grey (87307915)

silicone sealant to the oil pan gasket. There must
be a bead of sealant at the intersecting joint of the
cylinder block, oil pan and gear housing.
RCSC05CDC049AAA 2
4. Carefully install the timing gear housing so both

gaskets remain in place. Install the five cap screws
to secure the housing.
Torque the cap screws to 40 Nm (30 lb ft).
RCPH05CDC107ABA 3
5. Install the four oil pan cap screws. Torque the cap
Next operation: If the fuel pump was removed, see High pressure common rail Pump head and housing -
Install (B.20.A.30.15 - F.10.A.15).
3 15/11/2005
B.10.A / 193
Next operation: Perform the complete camshaft installation procedure. See Valve drive Camshaft - Install
(B.10.A.40.44 - F.10.A.15).
3 15/11/2005
B.10.A / 194
Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10)

MX215, MX245, MX275, STX280, 2388, 2377
WARNING
WARNING
WARNING
WARNING

Prior operation: Cylinder head - Remove (B.10.A.72 - F.10.A.10)
Horizontal split connecting rods

1. Horizontal split connecting rods with single piece
pistons are used on 6TAA-8304 engines in this
series.
RCPH05CDC657AAA 1
3 15/11/2005
B.10.A / 195
2. Rotate the crankshaft until the pistons are below the

carbon deposits located above the ring travel area.
Use a Scotch-Brite™ pad or equivalent and solvent
to remove the carbon deposits.
WARNING
personal injury.
WARNING
M996 - Some solvents are flammable and toxic. RCPH05CDC429AAA 2
3. Mark each piston according to its cylinder location.

NOTE: Do NOT stamp on the coated area or the outer rim
of pistons with anodized coating. Do NOT stamp on the
aluminum piston crown above the piston pin axis.
RCSC05CDC054AAA 3
4. Rotate the crankshaft to position the rod caps at

bottom dead center (BDC) for removal.
RCPH05CDC220AAA 4
3 15/11/2005
B.10.A / 196
5. Mark each connecting rod and rod cap as it is

removed according to its cylinder location.
RCSC05CDC055AAA 5
6. Remove the nuts from the rod cap. Use a rubber

hammer to hit the screws and release the rod cap
from the rod.
RCPH05CDC785AAA 6
7. Remove the rod cap and bearing. Mark the cylinder

number and the letter “L” (lower) on the flat surface
of the bearing tang.
RCPH05CDC788AAA 7
3 15/11/2005
B.10.A / 197
8. Push the connecting rod and piston assembly out

of the cylinder bore. Use both hands to remove the
assembly. Care must be taken not to damage the
upper bearing or connecting rod with the selected
tool.
RCSC05CDC116AAA 8
9. Remove the upper rod bearing. Mark the cylinder

number and the letter “U” (upper) on the flat surface
RCSC05CDC053AAA 9
10. Use a tag to mark the cylinder number on each

piston and rod assembly as it is removed. Place the
rod and piston assemblies in a container to protect
them from damage.
IMPORTANT: The piston and connecting rod assemblies
MUST be installed in the same cylinder number from
which they were removed if parts are to be reused.
The wear surfaces are matched to each other on used
components.
RCSC05CDC050AAA 10
Next operation: Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25)
3 15/11/2005
B.10.A / 198
Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25)

MX215, MX245, MX275, STX280, 2388, 2377
Prior operation: Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10)
1. Use piston ring expander OEM6262 or equivalent to

remove the piston rings.
NOTE: If the piston rings are to be reused, see Piston
Ring - Measure (B.10.A.47.15.05 - F.40.A.16) to measure
the ring gap.
RCPH05CDC537AAA 1
2. Use an internal snap ring pliers to remove the snap

rings from both sides of the piston.
RCPH05CDC400AAA 2
3. Remove the piston pin. See Piston Pin - Measure

(B.10.A.47.15.10 - F.40.A.16) if the piston pin must
be measured.
NOTE: Heating the piston pin is NOT required.
RCPH05CDC401AAA 3
3 15/11/2005
B.10.A / 199
4. Clean the pistons. See Connecting rod and piston

Piston - Cleaning (B.10.A.47.15 - F.30.A.10).
RCSC05CDC032AAA 4
5. Inspect the pistons. See Connecting rod

and piston Piston - Measure (B.10.A.47.15 -
F.40.A.16).
RCPH05CDC547AAB 5
6. Inspect the connecting rod. See Connecting rod

and piston Connecting rod - Visual inspection
(B.10.A.47.10 - F.40.A.10) and Connecting
rod and piston Connecting rod - Measure
(B.10.A.47.10 - F.40.A.16).
RCPH05CDC663AAA 6
Next operation: Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20)
3 15/11/2005
B.10.A / 200
Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20)

MX215, MX245, MX275, STX280, 2388, 2377
Prior operation: Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25)
1. Install the retaining ring in the pin groove on one

side of the piston.
RCPH05CDC681AAA 1
2. Lubricate the pin and pin bores with clean engine oil.
RCPH05CDC682AAA 2
3. Install the pin through the piston and connecting rod.

NOTE: The pistons must be at room temperature or
above, but the pistons do not have to be heated to install
the pin.
RCPH05CDC683AAA 3
3 15/11/2005
B.10.A / 201
4. Install the second retaining ring.
RCPH05CDC684AAA 4
5. Locate the top surface of the upper and intermediate

rings. The top is identified with the word “TOP” or
a supplier identification mark – for example, a dot.
Always assemble the rings with “TOP” or the mark
facing upward.
The oil control ring can be installed with either side

facing upward.
CAUTION
M1026 - Most piston rings are similar in appearance
but are significantly different. Make sure the correct
rings for this engine are used in the correct locations
to avoid damage.
RCPH05CDC542AAA 5
6. Always install the oil control ring with the expander

ring gap 180 ° from the gap on the oil ring.
RCPH05CDC544AAA 6
3 15/11/2005
B.10.A / 202
7. Use ring expander OEM6262 or equivalent to install

the rings on the piston.
RCPH05CDC537AAA 7
8. Position the oil ring expander in the oil control ring

groove.
RCPH05CDC536AAA 8
Next operation: Connecting rod and piston - Install (B.10.A.47 - F.10.A.15)
3 15/11/2005
B.10.A / 203
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15)

MX215, MX245, MX275, STX280, 2388, 2377
Prior operation: Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20)
1. The cylinder block and all parts MUST be clean

before assembly. See Cylinder block Liner -
Visual inspection (B.10.A.70.15 - F.40.A.10) to
inspect the cylinder liners for reuse.
Use a clean, lint-free cloth to clean the connecting

rods, rod caps and bearing shells.
RCSC05CDC057AAA 1
2. If new bearings are NOT used, the used bearings

MUST be installed on the same connecting rod and
cylinder from which they were removed.
Install the upper bearing shell (A) into the connecting

rod.
The tang of the shell MUST be in the slot of the rod.

The end of the shell MUST be even with the cap
mounting surface.
RCPH05CDC669AAA 2
3. Coat the inside surface of the bearing shell with

CASE AKCELA EP-0 GREASE. Apply clean
engine oil to the cylinder liner.
RCSC05CDC058AAB 3
3 15/11/2005
B.10.A / 204
4. Lubricate the piston rings with clean engine oil.
RCSC05CDC060AAA 4
5. Rotate the rings to position the rings gaps as shown.

NOTE: The gap of any ring must NOT be aligned with the
piston pin or with the gap of any other ring. If the ring gaps
are not aligned correctly, the rings will not seal properly.
RCSC05CDC064AAA 5
6. Install piston ring compressor OEM6268 or

equivalent to compress the rings.
RCPH05CDC694AAA 6
3 15/11/2005
B.10.A / 205
7. Rotate the crankshaft so the journal for the

connecting rod being installed is at bottom dead
center (BDC).
RCSC05CDC062AAA 7
8. Insert the connecting rod through the cylinder liner

until the spring compressor OEM6268 or equivalent
contacts the top of the liner.
RCPH05CDC695AAA 8
9. Hold the ring compressor against the cylinder liner.

Push the piston through the ring compressor and
into the cylinder liner. Push the piston until the top
ring is completely in the cylinder liner.
NOTE: If the piston does not move freely, remove the
piston and inspect for broken or damaged rings.
RCPH05CDC696AAA 9
3 15/11/2005
B.10.A / 206
10. Carefully push the piston into the bore while guiding
the connecting rod to the crankshaft journal.
RCSC05CDC061AAA 10
11. Install the lower bearing shell in the connecting rod

cap. The tang of the bearing shell MUST be in the
slot of the cap. Coat the inside surface of the lower
shell (A) with CASE AKCELA EP-0 GREASE.
Lubricate the threads on the connecting rod screws
(B) with clean engine oil.
RCPH05CDC669AAA 11
12. The connecting rod and cap MUST have the same
number and MUST be installed in the proper
cylinder. The connecting rod cap number and rod
number must be on the same side of the connecting
rod to prevent engine damage.
RCPH05CDC670AAA 12
3 15/11/2005
B.10.A / 207
13. Install the connecting rod cap and nuts.
RCPH05CDC785AAA 13
14. Use a torque wrench and torque angle gauge –

OEM4554 (SPX) or equivalent – to tighten the rod
nuts. Using the torque plus angle method, tighten
the nuts in alternating sequence.

Step 2 – Loosen the nuts.
RCPH05CDC787AAA 14
15. Measure the side clearance between the connecting

rod and crankshaft. The required clearance is 0.10 -
0.30 mm (0.004 - 0.012 in).
NOTE: Do NOT mistakenly measure the clearance
between the rod cap and crankshaft.
RCPH05CDC789AAA 15
3 15/11/2005
B.10.A / 208
16. Check for freedom of rotation as the connecting rod

caps are installed. If the crankshaft does NOT rotate
freely, check the installation of the rod bearings and
the bearing size.
RCPH05CDC772AAA 16
Next operation: Piston lubrication Spray nozzle - Install (B.60.A.29.29 - F.10.A.15)

Next operation: Cylinder head - Install (B.10.A.72 - F.10.A.15)
3 15/11/2005
B.10.A / 209
Connecting rod and piston - Remove (B.10.A.47 - F.10.A.10)

MX305
WARNING
WARNING
WARNING
WARNING

Angle split connecting rods

1. Angle split connecting rods with articulated pistons
are used on 6TAA-9004 engines in this series.
RCPH05CDC655AAA 1
3 15/11/2005
B.10.A / 210
2. Rotate the crankshaft until the pistons are below the

carbon deposits located above the ring travel area.
Use a Scotch-Brite™ pad or equivalent and solvent
to remove the carbon deposits.
WARNING
personal injury.
WARNING
M996 - Some solvents are flammable and toxic. RCPH05CDC429AAA 2
3. Mark each piston according to its cylinder location.

NOTE: Do NOT stamp on the coated area or the outer rim
of pistons with anodized coating. Do NOT stamp on the
aluminum piston crown above the piston pin axis.
RCSC05CDC054AAA 3
4. Rotate the crankshaft to position the rod caps at

bottom dead center (BDC) for removal.
RCPH05CDC220AAA 4
3 15/11/2005
B.10.A / 211
5. Mark each connecting rod and rod cap as it is

removed according to its cylinder location.
RCSC05CDC055AAA 5
6. Loosen the connecting rod cap screws, but do not

remove at this time.
RCPH05CDC432AAA 6
7. Use a rubber hammer to hit the cap screws to

loosen the caps from the dowels.
RCPH05CDC433AAA 7
3 15/11/2005
B.10.A / 212
8. Finish loosening the connecting rod cap screws and

then remove the cap screws, rod cap and lower rod
bearing as an assembly.
RCPH05CDC661AAA 8
9. Mark the cylinder number and the letter “L” (lower)

on the flat surface of the bearing tang.
RCPH05CDC435AAA 9
10. Push the connecting rod and piston assembly out

of the cylinder bore. Use both hands to remove the
assembly. Care must be taken not to damage the
upper bearing or connecting rod with the selected
tool.
RCSC05CDC116AAA 10
3 15/11/2005
B.10.A / 213
11. Remove the upper rod bearing. Mark the cylinder

number and the letter “U” (upper) on the flat surface
RCSC05CDC053AAA 11
12. Use a tag to mark the cylinder number on each

piston and rod assembly as it is removed. Place the
rod and piston assemblies in a container to protect
them from damage.
IMPORTANT: The piston and connecting rod assemblies
MUST be installed in the same cylinder number from
which they were removed if parts are to be reused.
The wear surfaces are matched to each other on used
components.
RCSC05CDC050AAA 12
Next operation: Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25)
3 15/11/2005
B.10.A / 214
Connecting rod and piston - Disassemble (B.10.A.47 - F.10.A.25)

MX305
1. Use piston ring expander OEM6262 or equivalent to

remove the piston rings.
NOTE: If the piston rings are to be reused, see Piston
Ring - Measure (B.10.A.47.15.05 - F.40.A.16) to measure
the ring gap.
RCPH05CDC538AAA 1
2. Use an internal snap ring pliers to remove the snap

rings from both sides of the piston.
RCPH05CDC400AAA 2
3. Remove the piston pin. See Piston Pin - Measure

(B.10.A.47.15.10 - F.40.A.16) if the piston pin must
be measured.
NOTE: When the piston pin is removed from an articulated
piston, the skirt (A) will separate from the crown (B).
RCSC05CDC065AAA 3
4. Mark each part – crown, skirt and pin – with the

cylinder number from which they were removed
if they are to be reused. Do not stamp on the
anodized coating area of the crown.
3 15/11/2005
B.10.A / 215
5. Clean the pistons. See Connecting rod and piston

Piston - Cleaning (B.10.A.47.15 - F.30.A.10).
RCSC05CDC032AAA 4
6. Inspect the pistons. See Connecting rod

and piston Piston - Measure (B.10.A.47.15 -
F.40.E.01).
RCPH05CDC548AAB 5
7. Inspect the connecting rod. See Connecting rod

and piston Connecting rod - Visual inspection
(B.10.A.47.10 - F.40.A.10) and Connecting
rod and piston Connecting rod - Measure
(B.10.A.47.10 - F.40.A.16).
RCPH05CDC675AAA 6
3 15/11/2005
B.10.A / 216
Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20)

MX305
1. Install the retaining ring in the pin groove on one

side of the piston skirt.
RCPH05CDC685AAA 1
2. Lubricate the pin and pin bores with engine oil.
RCPH05CDC686AAA 2
3. Position the skirt (A) over the piston crown (B).

NOTE: If the pistons are being reused, the same skirt,
crown and pin must be reassembled to each other and
installed on the same cylinder from which they were
removed.
NOTE: The articulated pistons do NOT need to be heated
before assembly. The piston pin is slip fit.
RCPH05CDC687AAA 3
3 15/11/2005
B.10.A / 217
4. Align the connecting rod with the piston assembly

so the lock tang on the rod is on the opposite side of
the deep valve pocket on the crown.
CAUTION
M1027 - Do not use a hammer to install the piston pin.
The piston can distort, causing it to seize in the liner.
CAUTION
M1028 - The lock tang on the connecting rod must
be on the opposite side of the deep valve pocket of
the piston crown.
RCSC05CDC059AAA 4
5. Align the rod pin bore with the skirt and crown pin
bores, and install the piston pin.
RCPH05CDC688AAA 5
6. Install the second retaining ring.
CAUTION
M1029 - The snap ring must be seated completely in
the piston groove to prevent engine damage during
operation.
RCPH05CDC689AAA 6
3 15/11/2005
B.10.A / 218
7. Locate the top surface of the upper and intermediate

rings. The top is identified with the word “TOP” or
a supplier identification mark – for example, a dot.
Always assemble the rings with “TOP” or the mark
facing upward.

facing upward.
CAUTION
to avoid damage.
RCPH05CDC542AAA 7
8. Always install the oil control ring with the expander

ring gap 180 ° from the gap on the oil ring.
RCPH05CDC544AAA 8
9. Use ring expander OEM6262 or equivalent to install

the rings on the piston.
RCPH05CDC538AAA 9
3 15/11/2005
B.10.A / 219
10. Position the oil ring expander in the oil control ring
groove.
RCPH05CDC534AAA 10
3 15/11/2005
B.10.A / 220
Connecting rod and piston - Install (B.10.A.47 - F.10.A.15)

MX305
Prior operation: Connecting rod and piston - Assemble (B.10.A.47 - F.10.A.20)
1. The cylinder block and all parts MUST be clean

before assembly. See Cylinder block Liner -
Visual inspection (B.10.A.70.15 - F.40.A.10) to
inspect the cylinder liners for reuse.
Use a clean, lint-free cloth to clean the connecting

rods, rod caps and bearing shells.
RCSC05CDC057AAA 1
2. If new bearings are NOT used, the used bearings

MUST be installed on the same connecting rod and
cylinder from which they were removed.
Install the upper bearing shell (A) into the connecting

rod.
The tang of the shell MUST be in the slot of the rod.

The end of the shell MUST be even with the cap
mounting surface.
RCPH05CDC674AAA 2
3. Coat the inside surface of the bearing shell with

CASE AKCELA EP-0 GREASE.
RCPH05CDC690AAA 3
3 15/11/2005
B.10.A / 221
4. Apply clean engine oil to the cylinder liner.
RCPH05CDC697AAA 4
5. Lubricate the piston rings with clean engine oil.
RCPH05CDC691AAA 5
6. Rotate the rings to position the rings gaps as shown.

NOTE: The gap of any ring must NOT be aligned with the
piston pin or with the gap of any other ring. If the ring gaps
are not aligned correctly, the rings will not seal properly.
RCSC05CDC064AAA 6
3 15/11/2005
B.10.A / 222
7. Install piston ring compressor OEM6268 or

equivalent to compress the rings.
RCPH05CDC694AAA 7
8. Rotate the crankshaft so the journal for the

connecting rod being installed is at bottom dead
center (BDC).
RCSC05CDC062AAA 8
9. When the piston and rod assembly is installed, the

deep valve pocket (A) on the piston crown MUST
face the exhaust manifold side of the engine.
The tang on the connecting rod (B) MUST face the

intake manifold side of the engine.
The word “FRONT” stamped on the piston crown

(C) must face the front of the engine.
CAUTION
M1030 - Failure to follow this step will result in
extensive engine damage.
RCSC05CDC059AAA 9
3 15/11/2005
B.10.A / 223
10. Insert the connecting rod through the cylinder liner

until the ring compressor OEM6268 or equivalent
contacts the top of the liner.
RCPH05CDC695AAA 10
11. Hold the ring compressor against the cylinder liner.

Push the piston through the ring compressor and
into the cylinder liner. Push the piston until the top
ring is completely in the cylinder liner.
NOTE: If the piston does not move freely, remove the
piston and inspect for broken or damaged rings.
RCPH05CDC696AAA 11
12. Carefully push the piston into the bore while guiding
the connecting rod to the crankshaft journal.
RCSC05CDC061AAA 12
3 15/11/2005
B.10.A / 224
13. Install the lower bearing shell in the connecting rod

cap. The tang of the bearing shell MUST be in the
slot of the cap.
Coat the inside surface of the lower shell (A) with

CASE AKCELA EP-0 GREASE.
RCPH05CDC692AAA 13
14. Lubricate the threads on the cap screws with clean

engine oil.
RCPH05CDC693AAA 14
15. The connecting rod and cap MUST have the same
number and MUST be installed in the proper
cylinder. The connecting rod cap number and rod
number must be on the same side of the connecting
rod to prevent engine damage.
RCPH05CDC677AAA 15
3 15/11/2005
B.10.A / 225
16. Install the connecting rod cap and cap screws.
RCPH05CDC432AAA 16
17. Use a torque wrench and torque angle gauge –

OEM4554 (SPX) or equivalent – to tighten the rod
nuts. Using the torque plus angle method, tighten
the nuts in alternating sequence.

Step 2 – Loosen the nuts.
RCPH05CDC793AAA 17
18. Measure the side clearance between the connecting

rod and crankshaft. The required clearance is 0.10 -
0.30 mm (0.004 - 0.012 in).
NOTE: Do NOT mistakenly measure the clearance
between the rod cap and crankshaft.
RCPH05CDC790AAA 18
3 15/11/2005
B.10.A / 226
19. Check for freedom of rotation as the connecting rod

caps are installed. If the crankshaft does NOT rotate
freely, check the installation of the rod bearings and
the bearing size.
RCPH05CDC772AAA 19

3 15/11/2005
B.10.A / 227
Connecting rod and piston Connecting rod - Visual inspection

(B.10.A.47.10 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
WARNING
WARNING

1. Use steam or solvent to clean the connecting rods

and end caps.
WARNING
WARNING
protective clothing to reduce the possibility of RCPH05CDC663AAA 1
personal injury.
WARNING
3 15/11/2005
B.10.A / 228
2. Use a nylon bristle brush to clean the oil drilling, if

present.
RCPH05CDC664AAA 2
WARNING
4. Inspect the connecting rod and rod cap for damage.

Replace the rod if the “I-beam” is nicked or
damaged.
RCPH05CDC675AAA 3
5. Inspect the piston pin bore for damage or

misalignment of the oil passage, if present, and the
bushing. If the bushing requires replacement, the
connecting rod must be replaced.
RCPH05CDC665AAA 4
Next operation: 6TAA-8304 engines with single piece pistons – Connecting rod and piston Connecting rod -
Measure (B.10.A.47.10 - F.40.A.16)
Next operation: 6TAA-9004 engines with articulated pistons – Connecting rod and piston Connecting rod -
Measure (B.10.A.47.10 - F.40.E.01)
3 15/11/2005
B.10.A / 229
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10

- F.40.A.16)
MX215, MX245, MX275, STX280, 2388, 2377
Prior operation: Connecting rod and piston Connecting rod - Visual inspection (B.10.A.47.10 - F.40.A.10)
1. Measure the connecting rod pin bushing inside

diameter. Replace the connecting rod if the bushing
is outside the specified range: 45.023 - 45.035 mm
(1.7726 - 1.7730 in).
RCPH05CDC666AAB 1
2. Measure the connecting rod crankshaft bore with the

bearing shells removed and the rod caps tightened.

Step 2 – Loosen cap screws.
With the bearings removed, the connecting rod bore

diameter must be 80.987 - 81.013 mm (3.1885 -
3.1895 in).
RCPH05CDC667AAB 2
3. Measure the diameter of the rod journal on the

crankshaft. The acceptable range for the rod journal
is 76.000 - 76.026 mm (2.9921 - 2.9931 in).

in).

NOTE: If the crankshaft journals are NOT within the given
specifications, the crankshaft MUST be replaced.
RCPH05CDC680AAA 3
3 15/11/2005
B.10.A / 230
4. To determine bearing clearance, measure the

connecting rod crankshaft bore with the bearing
shells installed and the rod caps tightened.

RCPH05CDC668AAB 4
5. Subtract the crankshaft journal diameter from the

rod inside diameter (with bearings) to determine
bearing clearance.
The bearing clearance acceptable range is 0.038 -

0.116 mm (0.0015 - 0.0045 in).
RCPH05CDC678AAA 5
6. Bearing clearance can also be determined with

plastigage™ during engine assembly. Place the
plastigage™ on the crankshaft, and install the lower
bearing and rod cap.

RCPH05CDC791AAA 6
3 15/11/2005
B.10.A / 231
7. Remove the rod cap and bearing and measure the

plastigage™. The bearing clearance acceptable
range is 0.038 - 0.116 mm (0.0015 - 0.0045 in).
RCPH05CDC792AAA 7

3 15/11/2005
B.10.A / 232
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10

- F.40.E.01)
MX305
Prior operation: Connecting rod and piston Connecting rod - Visual inspection (B.10.A.47.10 - F.40.A.10)
1. Measure the connecting rod pin bushing inside

diameter. Replace the connecting rod if the bushing
is outside the specified range: 45.023 - 45.035 mm
(1.7726 - 1.7730 in).
RCPH05CDC672AAB 1
2. Measure the connecting rod crankshaft bore with the

bearing shells removed and the rod caps tightened.

With the bearings removed, the connecting rod bore

diameter must be 80.987 - 81.013 mm (3.1885 -
3.1895 in).
RCPH05CDC676AAB 2
3. Measure the diameter of the rod journal on the

crankshaft. The acceptable range for the rod journal
is 76.000 - 76.026 mm (2.9921 - 2.9931 in).

in).

NOTE: If the crankshaft journals are NOT within the given
specifications, the crankshaft MUST be replaced.
RCPH05CDC680AAA 3
3 15/11/2005
B.10.A / 233
4. To determine bearing clearance, measure the

connecting rod crankshaft bore with the bearing
shells installed and the rod caps tightened.

RCPH05CDC671AAB 4
5. Subtract the crankshaft journal diameter from the

rod inside diameter (with bearings) to determine
bearing clearance.
The bearing clearance acceptable range is 0.038 -

0.116 mm (0.0015 - 0.0045 in).
RCPH05CDC679AAA 5
6. Bearing clearance can also be determined with

plastigage™ during engine assembly. Place the
plastigage™ on the crankshaft, and install the lower
bearing and rod cap.

RCPH05CDC791AAA 6
3 15/11/2005
B.10.A / 234
7. Remove the rod cap and bearing and measure the

plastigage™. The bearing clearance acceptable
range is 0.038 - 0.116 mm (0.0015 - 0.0045 in).
RCPH05CDC792AAA 7

3 15/11/2005
B.10.A / 235
Connecting rod Bearing - Remove (B.10.A.47.10.05 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

NOTE: When inspecting or replacing the connecting rod bearings, the cylinder head does not need to be removed.
1. Remove the connecting rod caps.
See Connecting rod and piston - Remove

(B.10.A.47 - F.10.A.10).
RCPH05CDC432AAA 1
2. Remove the upper bearing shell. Mark the shell with

the letter “U” and the cylinder number from which it
was removed.
RCSC05CDC053AAA 2
Next operation: Connecting rod Bearing - Visual inspection (B.10.A.47.10.05 - F.40.A.10)
3 15/11/2005
B.10.A / 236
Connecting rod Bearing - Visual inspection (B.10.A.47.10.05 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Connecting rod Bearing - Remove (B.10.A.47.10.05 - F.10.A.10)
1. Clean the bearing and connecting rod cap with

solvent or steam.
WARNING
RCPH05CDC659AAA 1
WARNING
3. Inspect the rod caps, bearing saddles and cap

screws for nicks, cracks, burrs, scratches or fretting.
RCPH05CDC662AAA 2
3 15/11/2005
B.10.A / 237
4. Inspect the bearings for damage. Replace any

bearing with this type of damage:
Pitting
Flaking
Corrosion
Lock tang damage
Scratches.
RCSC05CDC056AAA 3
5. Inspect the surface of the bearing which contacts

the saddle. If nicks or burrs cannot be removed with
a Scotch-Brite™ pad or equivalent, the bearings
MUST be replaced.
NOTE: Bearings must always be replaced as a set.
RCPH05CDC461AAA 4
Next operation: Connecting rod Bearing - Measure (B.10.A.47.10.05 - F.40.A.16)
3 15/11/2005
B.10.A / 238
Connecting rod Bearing - Measure (B.10.A.47.10.05 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Connecting rod Bearing - Visual inspection (B.10.A.47.10.05 - F.40.A.10)
1. Measure the bearing shell thickness with an outside

micrometer with a ball tip. Replace any bearing if its
thickness is below the minimum specification: 2.459
- 2.471 mm (0.0968 - 0.0973 in).
RCPH05CDC462AAA 1
2. Determine the size of the removed bearing and

obtain a set of the same size.
NOTE: Connecting rod bearings are stamped with a size
and part number on the side which contacts the saddle.
The size will be standard or oversized. Standard bearings
(STD) have one thickness – the original equipment
thickness. Oversized bearings have multiple thicknesses
to match crankshafts that have been machined
undersized. Refer to the appropriate parts catalog.
RCPH05CDC653AAA 2
Next operation: Connecting rod Bearing - Install (B.10.A.47.10.05 - F.10.A.15)
3 15/11/2005
B.10.A / 239
Connecting rod Bearing - Install (B.10.A.47.10.05 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Connecting rod Bearing - Measure (B.10.A.47.10.05 - F.40.A.16)
1. Install the connecting rod bearing.
See Connecting rod and piston - Install

(B.10.A.47 - F.10.A.15).
RCSC05CDC067AAA 1

3 15/11/2005
B.10.A / 240
Connecting rod and piston Piston - Cleaning (B.10.A.47.15 -

F.30.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
WARNING
WARNING

1. Soak the piston for a minimum of 30 minutes in a

tank with cleaning solvent suitable for steel.
CAUTION
M1021 - Do not use the bead blast method to clean the
component. The component will be damaged by blast
material embedded in the aluminum.
CAUTION
M1022 - Do not clean the component in an acid tank.
RCSC05CDC033AAA 1
3 15/11/2005
B.10.A / 241
2. Wash the pistons (and connecting rods) in a strong

solution of laundry detergent in hot water. Use a
non-metallic brush to remove carbon deposits.
CAUTION
M1023 - Do not use a metal brush to clean the
component. A metal brush will damage the
component.
RCSC05CDC030AAA 2
3. Clean any remaining carbon deposits from the ring

grooves with the square end of a broken piston ring.
CAUTION
M1024 - Do not use a ring groove cleaner to clean the
ring grooves. The cleaner can scratch the ring sealing
surface in the piston groove.
RCSC05CDC031AAA 3
4. Wash the pistons again in a detergent solution or

with a solvent.
WARNING
personal injury.
WARNING
RCSC05CDC030AAA 4
5. Rinse the piston. Dry with compressed air.
WARNING
Next operation: 6TAA-8304 engines with single piece pistons – Connecting rod and piston Piston - Measure
(B.10.A.47.15 - F.40.A.16)
Next operation: 6TAA-9004 engines with articulated pistons – Connecting rod and piston Piston - Measure
(B.10.A.47.15 - F.40.E.01)
3 15/11/2005
B.10.A / 242
Connecting rod and piston Piston - Measure (B.10.A.47.15 -

F.40.A.16)
MX215, MX245, MX275, STX280, 2388, 2377
Prior operation: Connecting rod and piston Piston - Cleaning (B.10.A.47.15 - F.30.A.10)
Single Piece pistons

1. Inspect the piston for damage and excessive wear.
Check the top (A), the skirt area (B) and pin bore
(C) for cracks or other damage. Replace the piston
if damaged.
NOTE: If severe piston damage is present, check the
turbocharger and other exhaust components for damage
from debris.
RCPH05CDC545AAA 1
2. Check the ring grooves for wear or damage.
RCPH05CDC547AAB 2
3. Measure the ring grooves with new rings and a

feeler gauge. Hold the new ring in the groove even
with the outside diameter of the piston.
Try to insert a 0.15 mm (0.006 in) feeler gauge

between the ring and the groove.
If the feeler gauge enters the groove without

resistance, there is too much wear. Replace the
piston.
RCPH05CDC540AAA 3
3 15/11/2005
B.10.A / 243
4. Measure the pin bore when the piston temperature

is at 20 °C (68 °F).
IMPORTANT: Add 0.013 mm (0.0005 in) to the expected
bore diameter for each 5 °C (10 °F) temperature increase
over 20 °C (68 °F), up to 32 °C (90 °F).
RCPH05CDC549AAA 4
5. Measure the bore at the points indicated. The

expected bore diameter range is 45.006 - 45.012
mm (1.7719 - 1.7721 in).
RCIL05CDC002AAA 5
6. Inspect the piston pin for nicks, gouges

and excessive wear. Inspect the piston pin
outside diameter. See Piston Pin - Measure
(B.10.A.47.15.10 - F.40.A.16) for expected
dimensions.
RCPH05CDC438AAB 6

3 15/11/2005
B.10.A / 244
Connecting rod and piston Piston - Measure (B.10.A.47.15 -

F.40.E.01)
MX305
Prior operation: Connecting rod and piston Piston - Cleaning (B.10.A.47.15 - F.30.A.10)
Articulated pistons
1. Inspect the piston for damage and excessive wear.
Check the crown (A), the skirt (B) and pin bores
on the crown and the skirt (C) for cracks or other
damage. Replace the piston if damaged.
NOTE: If severe piston damage is present, check the
turbocharger and other exhaust components for damage
from debris.
RCPH05CDC534AAA 1
2. Check the ring grooves for wear or damage.
RCPH05CDC548AAB 2
3. Measure the ring grooves with new rings and a

feeler gauge. Hold the new ring in the groove even
with the outside diameter of the piston.
Try to insert a 0.15 mm (0.006 in) feeler gauge

between the ring and the groove.
If the feeler gauge enters the groove without

resistance, there is too much wear. Replace the
piston.
RCPH05CDC539AAA 3
3 15/11/2005
B.10.A / 245
4. Measure the pin bore inside diameter on the crown.

The expected diameter is 45.016 - 45.036 mm
(1.7723 - 1.7731 in).
RCPH05CDC551AAB 4
5. Measure the pin bore inside diameter on the skirt.

The expected diameter is 45.012 - 45.026 mm
(1.7721 - 1.7727 in).
RCPH05CDC550AAB 5
6. Inspect the piston pin for nicks, gouges

and excessive wear. Inspect the piston pin
outside diameter. See Piston Pin - Measure
(B.10.A.47.15.10 - F.40.A.16) for expected
dimensions.
RCPH05CDC438AAB 6

3 15/11/2005
B.10.A / 246
Piston Ring - Remove (B.10.A.47.15.05 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use piston ring expander OEM6262 or equivalent

to remove the upper and intermediate ring from the
piston.
NOTE: Articulated piston shown.
RCPH05CDC538AAA 1
2. Remove the two-piece oil control ring from the

piston.
NOTE: Single piece piston shown.
RCPH05CDC536AAA 2
Next operation: Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16)
3 15/11/2005
B.10.A / 247
Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Piston Ring - Remove (B.10.A.47.15.05 - F.10.A.10)

1. To check ring gap, install the piston rings in the

cylinder liner in which they were used. Position the
rings below the ring reversal area.
RCPH05CDC552AAA 1
2. Use the piston crown or head to level and correctly

position the ring in the liner.
RCPH05CDC553AAA 2
3. Use a feeler gauge to measure the ring end gap.

The expected gap for the top ring is 0.30 - 0.45 mm
(0.012 - 0.018 in).
The expected gap for the intermediate ring is 0.85 -

1.15 mm (0.033 - 0.045 in).
The expected gap for the oil control ring is 0.30 -

0.73 mm (0.012 - 0.028 in).
RCPH05CDC532AAA 3
Next operation: Piston Ring - Install (B.10.A.47.15.05 - F.10.A.15)

3 15/11/2005
B.10.A / 248
Piston Ring - Install (B.10.A.47.15.05 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16)
1. The top surface of the upper and intermediate rings

are identified with the word “TOP” or a supplier
identification mark, such as a dot. Always assemble
the ring to the piston with the word “TOP” or supplier
mark facing upward.

up.
CAUTION
to avoid damage.
RCPH05CDC542AAA 1
2. The two piece oil control ring MUST be installed

with the expander ring gap (A) 180-degrees from
the gap on the oil ring (B).
RCPH05CDC554AAA 2
3. Use piston ring expander OEM6262 or equivalent

to install the rings on the piston.
RCPH05CDC537AAA 3
3 15/11/2005
B.10.A / 249
4. Install the oil ring expander in the oil control ring

groove, so the expander ring gap is 180 ° from the
oil ring gap.
RCPH05CDC536AAA 4
3 15/11/2005
B.10.A / 250
Piston Pin - Measure (B.10.A.47.15.10 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Inspect the piston pin for nicks, gouges and

excessive wear.
RCPH05CDC438AAB 1
2. Measure the outside diameter of the pin at the points

indicated in the two illustrations. The expected
outside diameter is 44.997 - 45.003 mm (1.7715 -
1.7718 in).
Discard the piston pin if it is more than 0.003 mm

(0.0001 in) out of round.
RCPH05CDC439AAB 2
3 15/11/2005
B.10.A / 251
Flywheel - Remove (B.10.A.50 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Refer to the chassis service manual for removal of the components to expose the flywheel.
1. Remove the six cap screws and remove the shock

plate from the flywheel.
RCPH05CDC145ABA 1
2. Remove the top mounting cap screw on the

flywheel. Install a guide stud.
Remove the six remaining cap screws.
RCPH05CDC138ABA 2
3. Install a lift bracket and use appropriate lifting

equipment to remove the flywheel from the engine.
WARNING
RCPH05CDC136ABA 3
3 15/11/2005
B.10.A / 252
4. Remove the eight cap screws and remove the rear

engine support plate from engine.
RCPH05CDC134ABA 4
5. If ring gear teeth damage was the reason for

removing the flywheel, use a brass drift to drive the
ring gear from the flywheel. Continue with Flywheel
- Install (B.10.A.50 - F.10.A.15).
RCSC05CDC151AAA 5
Next operation: Flywheel - Visual inspection (B.10.A.50 - F.40.A.10)
3 15/11/2005
B.10.A / 253
Flywheel - Visual inspection (B.10.A.50 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use steam or solvent to clean the flywheel.
WARNING
WARNING
RCSC05CDC150AAA 1
personal injury.
WARNING
3. Inspect the shock plate for damage or broken

springs. Replace broken springs as needed.
RCPH05CDC129ABA 2
3 15/11/2005
B.10.A / 254
4. Use defect detector kit OEM1272 or equivalent to

check for cracks in the flywheel.
RCPH05CDC130ABB 3
5. Inspect the ring gear teeth for cracks or chips. If

the ring gear teeth are cracked or chipped, the ring
gear must be replaced.
RCPH05CDC131ABB 4
3 15/11/2005
B.10.A / 255
Flywheel - Install (B.10.A.50 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Flywheel - Visual inspection (B.10.A.50 - F.40.A.10)
1. If a damaged ring gear was removed, heat the

replacement ring gear for 20 minutes in an oven
pre-heated to 127 °C (260 °F).
RCSC05CDC152AAA 1
2. Install the ring gear with the bevel on the teeth

toward the crankshaft side of the flywheel.
WARNING
RCPH05CDC132ABB 2
3. Install the rear engine support plate with the eight

cap screws. Torque the cap screws to 115 Nm (85
lb ft).
RCPH05CDC133ABA 3
3 15/11/2005
B.10.A / 256
4. Install a guide stud in the top hole of the crankshaft.
RCPH05CDC135ABA 4
5. Use appropriate lifting equipment to support the

flywheel, and install the flywheel on the guide stud.
WARNING
RCPH05CDC136ABA 5
6. Lubricate the threads and underside of the heads

of the cap screws with clean engine oil. Install the
seven cap screws.
Remove the lift equipment and the guide stud.

Install the top cap screw.
RCPH05CDC138ABA 6
3 15/11/2005
B.10.A / 257
7. Use the engine barring tool – 380000732 – to hold

the crankshaft while tightening the flywheel cap
screws. Tighten the cap screws in a star pattern.
Torque to 137 Nm (101 lb ft).
RCPH05CDC139ABA 7
8. Install the shock plate with the six cap screws.

RCPH05CDC144ABA 8
Next operation: Flywheel - Measure (B.10.A.50 - F.40.A.16)
3 15/11/2005
B.10.A / 258
Flywheel - Measure (B.10.A.50 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Flywheel - Install (B.10.A.50 - F.10.A.15)
Bore runout
1. Use a dial gauge – OEM1026 or equivalent – and
a magnetic base with a flexible arm – OEM1030 or
equivalent – to check for bore runout.
Install the test set on the head. The test tip of the
gauge must contact an inside diameter of the bore.
Zero the dial gauge.
RCPH05CDC142ABA 1

the crankshaft one complete revolution.
The total indicator reading must NOT exceed 0.127

mm (0.005 in).
RCPH05CDC143ABA 2
3. If the total indicator reading is greater than the

specification:
• Remove the flywheel.
• Inspect the flywheel mounting surface for dirt or
damage.
• Inspect the crankshaft for dirt or damage.
• Reinstall the flywheel and retest for bore runout
again.
• Replace the flywheel if the runout does NOT meet
specifications.
RCPH05CDC132ABA 3
Face runout
4. Use the same dial gauge – OEM1026 or equivalent
– and a magnetic base with a flexible arm –
OEM1030 or equivalent – to check for face runout.
3 15/11/2005
B.10.A / 259
5. The test tip of the gauge must be positioned on the

flywheel face. Push the flywheel forward to remove
the crankshaft end clearance. Zero the dial gauge.
RCPH05CDC140ABA 4

the crankshaft one complete revolution. Measure
the flywheel runout at four equal points on the
flywheel face.
The total indicator reading must NOT exceed 0.127

mm (0.005 in).
NOTE: The flywheel MUST be pushed toward the front of
the engine to remove the crankshaft end clearance each
time a point is measured.
RCPH05CDC141ABA 5
7. If the 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.
3 15/11/2005
B.10.A / 260
Vibration damper - Remove (B.10.A.68 - F.10.A.10)

MX215, MX245, MX275, STX280, 2377
1. Remove the four cap screws securing the vibration

damper.
RCSC05CDC146AAA 1
Next operation: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
3 15/11/2005
B.10.A / 261
Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)

MX215, MX245, MX275, STX280, 2377
1. Check the index lines (A) on the damper hub (B)

and the inertia member (C). If the lines are more
than 1.59 mm (0.0625 in) out of alignment, replace
the damper.
RCPH05CDC127ABB 1
2. Inspect the damper hub for cracks. Replace the

damper if the hub is cracked.
RCPH05CDC128ABB 2
3. Inspect the rubber member for deterioration. If

pieces of rubber are missing, replace the damper.
4. Inspect the elastic member. If the member is more
than 3.18 mm (0.125 in) below the metal surface,
replace the damper.
RCPH05CDC127ABC 3
5. Check for forward movement of the damper ring

on the hub. Replace the damper if any movement
is detected.
3 15/11/2005
B.10.A / 262
3 15/11/2005
B.10.A / 263
Vibration damper - Install (B.10.A.68 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2377
Prior operation: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
1. Install the damper with the four cap screws. Tighten

and torque in a star pattern to 200 Nm (148 lb ft).
RCSC05CDC146AAA 1
3 15/11/2005
B.10.A / 264
Vibration damper - Remove (B.10.A.68 - F.10.A.10)

MX305, 2388
1. Remove the five cap screws securing the vibration

damper.
RCPH05CDC240AAA 1
Next operation: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
3 15/11/2005
B.10.A / 265
Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)

MX305, 2388
1. Inspect the mounting web for cracks. Inspect the

housing for dents or raised surfaces. Replace the
damper if these defects are found.
RCPH05CDC126ABB 1
2. To check damper thickness, remove paint from four

locations on both sides of the damper. Measure and
record the thickness at the four locations.
The thickness should be measured just within the

rolled edge of the damper – 3.175 mm (0.125 in)
from the edge.
Replace the damper if thickness varies by more

than 0.25 mm (0.010 in).
NOTE: The viscous damper is filled with a silicone fluid.
After many hours of use, the silicone fluid may become
thicker and expand.
RCPH05CDC124ABB 2
3. Spray the damper with spot check developer. Heat

the damper in an oven with the rolled lip down for
two hours at a temperature of 93 °C (200 °F).
RCSC05CDC148AAA 3
3 15/11/2005
B.10.A / 266
4. Remove the damper from the oven and check

for fluid leakage. If there is leakage, replace the
damper.
WARNING
RCSC05CDC149AAA 4
3 15/11/2005
B.10.A / 267
Vibration damper - Install (B.10.A.68 - F.10.A.15)

MX305, 2388
Prior operation: Vibration damper - Visual inspection (B.10.A.68 - F.40.A.10)
1. Install the damper with the five cap screws. Tighten

the torque the cap screws in a start pattern to 200
Nm (148 lb ft).
RCPH05CDC240AAA 1
3 15/11/2005
B.10.A / 268
Cylinder block - Cleaning (B.10.A.70 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)
1. Clean the combustion deck with a gasket scraper or

with a Scotch-Brite® pad and diesel fuel or solvent.
WARNING
personal injury.
WARNING
Personal injury can result from misuse. RCPH05CDC748AAA 1
2. Thoroughly flush the block with mineral spirits or

cleaning solvent. Dry with compressed air.
WARNING
3 15/11/2005
B.10.A / 269
Cylinder block - Measure (B.10.A.70 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block - Cleaning (B.10.A.70 - F.30.A.10)
1. Measure the overall flatness of the cylinder block

with a straight edge and a feeler gauge.
The overall flatness, end to end and side to side,

MUST not exceed 0.075 mm (0.003 in).
RCPH05CDC734AAA 1
2. Measure the local combustion surfaces with a 50

mm (2.0 in) straight edge and 0.025 mm (0.001 in)
feeler gauge. Check between the cylinder bores
and also between the coolant passages.
If the 0.025 mm (0.001 in) feeler gauge fits under

the straight edge, the cylinder block MUST be
replaced.
If the cylinder block is pitted, grooved or has other

damage, the cylinder block MUST be replaced.
RCPH05CDC735AAA 2
Next operation: Cylinder block Bore - Measure (B.10.A.70.10 - F.40.A.16)
3 15/11/2005
B.10.A / 270
Cylinder block Bore - Measure (B.10.A.70.10 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block - Measure (B.10.A.70 - F.40.A.16)
1. Use the cylinder bore gauge – OEM1032 – to

measure the block bore. Use a micrometer to set
the gauge to the minimum bore dimension.
RCPH05CDC609AAA 1
2. Measure the press fit area of the liner bore in the

block.
The bore diameter must be between 130.900 -

130.950 mm (5.1535 - 5.1555 in).
RCPH05CDC749AAA 2
Next operation: Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15)
3 15/11/2005
B.10.A / 271
Cylinder block Liner - Preliminary test (B.10.A.70.15 - F.40.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
WARNING
WARNING

Prior operation: If required, Crankshaft - Remove (B.10.A.43 - F.10.A.10)
IMPORTANT: CNH does NOT recommend removing the cylinder liners to repair an oil consumption problem if the
liners are within the inspection limits offered in this procedure. Careful inspection of the liner bores, piston rings and
pistons can result in the restoration of cylinder sealing with a minimum of replacement parts.
1. Before removing the liners, inspect their condition
to determine reuse. Inspect the inside of the liners
for cracks, scuffing and scoring.
Inspect the inside of the liners for vertical scratches

deep enough to be felt with a fingernail. If a
fingernail catches in a scratch, the liner must be
replaced.
RCSC05CDC103AAA 1
3 15/11/2005
B.10.A / 272
2. Inspect the inside of the liner for bore polishing.
A moderate polish produces a bright mirror finish in

the worn area with traces of the original hone marks
or an indication of an etch pattern.
A heavy polish produces a bright mirror finish in the

worn area with no traces of hone marks or an etch
pattern.
Do NOT reuse liners with heavy polish or any

indication of particle embedment from a failure.
Severely worn liners will have a ridge near the top
of the liner bore.
RCSC05CDC104AAA 2
3. If the wear pattern indicates the liner bore is NOT

straight or NOT round, use a dial bore gauge –
OEM1032 or equivalent – to measure the liner
inside diameter in four places, 90 ° apart, at the
top and bottom of the piston travel area. Maximum
acceptable liner dimensions are:
Taper – 0.04 mm (0.0016 in)

Out of round – 0.04 mm (0.0016 in)
Bore diameter – 114.04 mm (4.4898 in)
RCSC05CDC105AAA 3
4. If a liner is NOT acceptable for reuse, it MUST be

replaced. Damaged liners CANNOT be honed or
deglazed.
NOTE: Do NOT remove or disturb the liner seals for liners
which pass the inspection criteria.
RCSC05CDC098AAA 4
3 15/11/2005
B.10.A / 273
5. Before removing the liners, check liner protrusion

in the “unclamped” condition. Use the gauge from
OEM6459 to measure the liner protrusion.
The acceptable range for liner protrusion is 0.026 -

0.122 mm (0.0010 - 0.0048 in).
NOTE: Liner protrusion is the distance the liner protrudes
above the block face.
RCPH05CDC760AAA 5
Next operation: Cylinder block Liner - Remove (B.10.A.70.15 - F.10.A.10)
3 15/11/2005
B.10.A / 274
Cylinder block Liner - Remove (B.10.A.70.15 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Preliminary test (B.10.A.70.15 - F.40.A.20)
1. If the crankshaft was not removed, use clean shop

rags to cover the crankshaft and prevent debris from
entering the main journal area and the oil drilling on
the journals for the connecting rod.
RCSC05CDC100AAA 1
2. Install the liner plate – 380002492 – on the

OEM4083, the cylinder liner removal tool.
RCPH05CDC725AAA 2
3. Lower the liner puller through the cylinder, while

installing OEM4083 on top of the cylinder block.
The tool must be centered over the cylinder liner
to be removed. The puller plate must be installed
parallel with the main bearing saddles and must not
contact the block castings at the points indicated.
CAUTION
M1016 - The liner puller must be installed and used
as described to avoid damage to the cylinder block.
The puller must not contact the block casting at the
points indicated.
CAUTION RCPH05CDC729AAA 3
M1017 - The liner puller must be installed and used
as described to avoid damage to the cylinder block.
The puller plate must be installed parallel to the main
bearing saddles and must not overlap the outside
diameter of the liner.
3 15/11/2005
B.10.A / 275
4. Turn the forcing nut clockwise to loosen the liner

from the block.
RCPH05CDC727AAA 4
5. Remove OEM4083 and use both hands to remove

the liner.
RCPH05CDC728AAA 5
6. Use Dykem® or equivalent to mark the cylinder

number on each liner as it is removed. Place the
mark on the cylinder so it references the front of the
engine as it was installed. If the cylinder is reused,
the reference mark can used to properly rotate the
cylinder during installation later.
RCSC05CDC094AAA 6
Next operation: Cylinder block Liner - Visual inspection (B.10.A.70.15 - F.40.A.10)
3 15/11/2005
B.10.A / 276
Cylinder block Liner - Visual inspection (B.10.A.70.15 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Remove (B.10.A.70.15 - F.10.A.10)
1. Use a soft wire brush or a Scotch-Brite® pad to

clean the flange seating area.
RCPH05CDC737AAA 1
2. Use solvent or steam to clean the liners.
WARNING
WARNING
personal injury.
WARNING
WARNING
3 15/11/2005
B.10.A / 277
4. Use clean engine oil to lubricate the inside of the

liners. Allow the oil to soak in the liner for 5-10
minutes.
RCPH05CDC738AAA 2
5. Use lint-free paper towels to wipe the oil from the

inside of the liners. Repeat the lubricating, soaking
and wiping process until the paper towel does not
show gray or black residue from the liner.
RCPH05CDC739AAA 3
6. Inspect the inside and outside of the liners for

cracks.
RCPH05CDC740AAB 4
3 15/11/2005
B.10.A / 278
7. Inspect the flange area for cracks.
RCPH05CDC753AAB 5
8. Inspect the outside and seat area for excessive

corrosion or pitting. Pits must NOT be more than
1.6 mm (0.06 in) deep.
Replace the liner if the pits are too deep or the

corrosion cannot be removed with a fine emery
cloth.
RCPH05CDC741AAB 6
9. Inspect the inside of the liners for vertical scratches

deep enough to be felt with a fingernail. If a
fingernail catches in a scratch, the liner MUST be
replaced.
Inspect the inside of the liners for scuffing or scoring.
RCPH05CDC740AAD 7
3 15/11/2005
B.10.A / 279
10. Inspect the inside of the liners for polishing.
A moderate polish (A) produces a bright mirror finish

in the worn area with traces of the original hone
marks or an indication of an etch pattern.
A heavy polish (B) produces a bright mirror finish in

the worn area with no trace of hone marks or an
etch pattern.
RCPH05CDC740AAC 8
11. Replace the liner:
– if a heavy polish is present over 20% of the piston

ring travel area.
– if moderate and heavy polish are present over

30% of the piston ring travel area and 15% (of the
30%) is heavy polish.
RCSC05CDC096AAA 9
Next operation: Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)
3 15/11/2005
B.10.A / 280
Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Visual inspection (B.10.A.70.15 - F.40.A.10)
1. Use dial bore gauge OEM1032 or equivalent to

measure the liner inside diameter. Measure the
diameter at four places, 90 ° apart, at the top and
bottom of the piston travel area.
The liner inside diameter must be between 114.000

- 114.040 mm (4.4882 - 4.4898 in).
RCSC05CDC095AAA 1
2. Measure the outside diameter of the press fit area

at the top of the liner.
The liner outside diameter must be between

130.938 - 130.958 mm (5.1550 - 5.1558 in).
RCPH05CDC743AAB 2
3. Measure the press fit area of the liner bore in the

block.
The bore diameter must be between 130.900 -

130.950 mm (5.1535 - 5.1555 in).
RCPH05CDC749AAA 3
Next operation: Cylinder block - Cleaning (B.10.A.70 - F.30.A.10)

Next operation: Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15)
3 15/11/2005
B.10.A / 281
Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)
1. Clean all deposits and debris from sealing surfaces

(A), (B) and (C). Use a Scotch-Brite™ pad or
equivalent and solvent to polish the surfaces. Due
to critical machining tolerances, care must be taken
not to remove additional material.
WARNING
personal injury.
WARNING RCPH05CDC731AAA 1
2. If surface (C) has cracks or signs of the extreme

wear, the counterbore requires machining and the
installation of shims for the correct liner protrusion.
RCPH05CDC733AAA 2
3. Use Cummins Counterbore Cutter 3163785 to

machine the counterbore to the proper depth.
NOTE: Cummins cutter plate 3823567 and cutter bit
3823570 MUST be used with the counterbore machining
tool.
RCSC05CDC099AAA 3
3 15/11/2005
B.10.A / 282
4. Clean the combustion deck with a gasket scraper or

with a Scotch-Brite® pad and diesel fuel or solvent.
WARNING
personal injury.
WARNING
5. Thoroughly flush the block with mineral spirits or

cleaning solvent.
Remove the shop rags and clean the crankshaft

with a cleaning solvent.
Use compressed air to dry the cylinder bores and

crankshaft, and wipe them clean with lint-free cloth.
WARNING
RCSC05CDC091AAA 5
personal injury.
WARNING
WARNING
3 15/11/2005
B.10.A / 283
6. Lubricate surfaces (A) and (B) with clean engine oil.
RCPH05CDC731AAA 6
7. Use clean engine oil to coat the O-ring for each liner.
RCPH05CDC744AAA 7
8. Install a new O-ring on each liner.
RCPH05CDC745AAA 8
3 15/11/2005
B.10.A / 284
9. When liners are reused, they must be installed in

the same cylinder from which they were removed
BUT rotated 45 ° from their original position. This
moves any existing pitted surface on the liner 45 °
from the source of the pitting to extend the service
life of the liner.
RCSC05CDC101AAA 9
10. If the crankshaft is NOT removed, use a liner driver

to install the liner in the cylinder block.
RCSC05CDC097AAA 10
11. If the crankshaft is removed, use the components

shown from the liner removal tool OEM4083 (A),
liner installer add-on set OEM6527 (B) and installer
plate OEM1255 (C) to install the liners in the cylinder
bores.
RCPH05CDC752AAA 11
3 15/11/2005
B.10.A / 285
12. With the liner in the bore, install the assembly –

without the triangular bar – from the top of the liner.
RCPH05CDC750AAA 12
13. Install the triangular bar (A) through the yoke (B)
under the block.
NOTE: The triangular bar and yoke MUST be angled
across the block as shown to avoid interference from the
engine mounting plate when installing the center cylinders.
RCPH05CDC754AAA 13
14. Turn the forcing nut clockwise to press the liner into
the bore.
RCPH05CDC750AAA 14
3 15/11/2005
B.10.A / 286
15. Use the hold down bar from the liner protrusion
gauge OEM6459, two 14 mm x 70 mm cap screws
and two 14 mm flat washers to fully seat the liner
in bore.
Tighten and torque the cap screws to 68 Nm (50

lb ft).
Remove the hold down bar and repeat this

procedure until all liners have been clamped and
released.
NOTE: The two 14 mm x 70 mm cap screws and two 14
mm flat washers are not included with OEM6459.
RCPH05CDC757AAA 15
Next operation: Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)
3 15/11/2005
B.10.A / 287
Cylinder block Liner - Measure (B.10.A.70.15 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15)
Liner protrusion
1. Liner protrusion is the distance the liner protrudes
above the block. Measure liner protrusion at four
points 90 ° apart using the gauge from OEM6459.
RCPH05CDC755AAB 1
2. Zero the gauge against the block before taking each

measurement.
RCPH05CDC758AAA 2
3. Liner protrusion must be within 0.026 - 0.122 mm

(0.0010 - 0.0048 in).
RCPH05CDC760AAA 3
3 15/11/2005
B.10.A / 288
4. If liner protrusion varies more than 0.025 mm

(0.0010 in) for 180 °, install the hold down bar again.
RCPH05CDC757AAA 4
5. Measure the liner protrusion again at four points

90 ° apart.
RCPH05CDC760AAA 5
6. If liner protrusion still varies more than 0.025 mm

(0.0010 in):
Step A – Remove the liner.

Step B – Inspect the liner upper sealing edge for
burrs, dirt or damage.
Step C – Replace the liner if it is damaged.
Step D – Install a liner.
Step E – Measure liner protrusion.
RCPH05CDC747AAB 6
3 15/11/2005
B.10.A / 289
7. If the out of specification reading is minimal,

the correct protrusion values can sometimes
be obtained by using another new liner in the
out-of-specification bore.
RCSC05CDC102AAA 7
8. If liner protrusion still does NOT meet specifications,

the cylinder liner bore must be machined and shims
used to bring liner protrusion within tolerances. Use
Cummins Counterbore Cutter 3163785 to machine
the counterbore to the proper depth.
NOTE: Cummins cutter plate 3823567 and cutter bit
3823570 MUST be used with the counterbore machining
tool.
RCSC05CDC099AAA 8
Liner to block clearance

9. Use a feeler gauge to inspect the liner to block
clearance at the four block casting points. The
clearance must be 0.229 mm (0.009 in).
RCPH05CDC765AAA 9
3 15/11/2005
B.10.A / 290
10. If the clearance is less than 0.229 mm (0.009 in),

remove the liner. Inspect the casting points for dirt
or damage.
RCPH05CDC732AAA 10
11. Inspect the liner for dirt or damage. Replace the

liner if it is damaged. Install a new or cleaned liner.
RCPH05CDC741AAA 11
Out-of-round
12. Measure the liner bore for out-of-roundness at
points (A), (B), (C), (D), and (E).
Measure once and then at a 90 ° angle to the original

location at each point, comparing the two readings.
The liner bore must NOT be more than 0.04 mm

(0.002 in) out of round at any point.
NOTE: If the liner bore is more than 0.04 mm (0.002 in)
out of round, the block bore must be measured with the
liner removed.
RCSC05CDC092AAA 12
Next operation: If required, see Crankshaft - Install (B.10.A.43 - F.10.A.15)

3 15/11/2005
B.10.A / 291
Cylinder head - Remove (B.10.A.72 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING

Prior operation: Refer to the engine removal section of the chassis manual and remove all overhead water and
heating lines, air conditioning lines, and air intake lines to the turbocharger and the intake manifold.
Prior operation: Remove the alternator, air conditioning compressor and their support bracket. See ENGINE -
Place on stand (B.10.A - F.35.A.10).
Prior operation: Turbocharger - Remove (B.30.A.31 - F.10.A.10)
Prior operation: Exhaust manifold - Remove (B.40.A.38 - F.10.A.10)
Prior operation: Remove the low pressure return line(s). See Fuel line Low pressure - Remove (B.20.A.36.10 -
F.10.A.10).
Prior operation: Remove the high pressure fuel supply line to the fuel rail. See Fuel line High pressure - Remove
(B.20.A.36.20 - F.10.A.10).
Prior operation: Remove the fuel connector supply lines and fuel rail. See High pressure common rail Common
rail - Remove (B.20.A.30.25 - F.10.A.10).
Prior operation: Cold start aid Grid heater - Remove (B.80.A.30.40 - F.10.A.10)
Prior operation: Air intake manifold - Remove (B.30.A.38 - F.10.A.10)
Prior operation: Fuel connector - Remove (B.20.A.37 - F.10.A.10)
Remove (B.60.A.26 - F.10.A.10).
Prior operation: Rocker assembly Crosshead - Remove (B.10.A.40.43.25 - F.10.A.10)
1. Remove the cylinder head cap screws.
RCPH05CDC002AAC 1
3 15/11/2005
B.10.A / 292
2. Connect appropriate lift equipment to the cylinder

head or use an assistant to move the head to a work
bench or head holding fixture.
WARNING
RCPH05CDC370AAA 2
Next operation: Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)
3 15/11/2005
B.10.A / 293
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Mark the valves to identify their location. Any

numbering method can be used as long as the
valves are reinstalled to the same location from
which they were removed.
RCPH05CDC381AAB 1
2. Use the gauge from OEM6459 to measure the

injector protrusion before removing the injectors
from the head.
Place the tool on the flat surface of head, and zero

the gauge.
RCPH05CDC801AAA 2
3. Measure injector protrusion at the highest point on

the injector. The protrusion MUST be within 2.25 -
2.80 mm (0.088 - 0.110 in).
RCPH05CDC802AAA 3
3 15/11/2005
B.10.A / 294
4. Remove the injector. Refer to Fuel injector -

Remove (B.20.A.29 - F.10.A.10).
RCPH05CDC377AAA 4
5. If the injector protrusion was out of specification,

check the thickness of the injector sealing washer.
The sealing washer thickness MUST be 2.5 mm
+/- 0.05 mm.
RCPH05CDC282AAB 5
6. If the sealing washer is the correct thickness, check

if the injector bore is clean and free or debris or
if more than one sealing washer is stacked in the
injector bore.
RCPH05CDC796AAA 6
3 15/11/2005
B.10.A / 295
7. Use the valve spring compressor – 3164329

(CUMMINS) – to compress the valve springs and
remove the valve stem collets. Release the valve
springs and remove the spring retainers and springs.
See Valve drive Valve assembly - Disassemble
(B.10.A.40.46 - F.10.A.25).
RCPH05CDC379AAA 7
8. Use a pliers with a 90 ° head to remove the valve

stem seals. Discard the seals.
RCPH05CDC380AAA 8
9. Remove the valves from the head.

NOTE: Keep the valves in a labeled rack for a correct
match with its seat while making measurements.
RCPH05CDC381AAB 9
Next operation: Cylinder head - Cleaning (B.10.A.72 - F.30.A.10)
3 15/11/2005
B.10.A / 296
Cylinder head - Cleaning (B.10.A.72 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
M995 - When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
WARNING
M996 - Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.
WARNING
M998 - Wear eye protection while removing carbon deposits to prevent personal injury.
WARNING
M994 - Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can
cause personal injury.
Prior operation: Cylinder head - Disassemble (B.10.A.72 - F.10.A.25)
1. Use the injector bore brush – 3822509 (CUMMINS) –

to clean the carbon from the injector nozzle seat.
RCPH05CDC314ABA 1
2. Scrape the gasket material from gasket surfaces on

the block and on the head.
3 15/11/2005
B.10.A / 297
3. Remove any deposit build up from the coolant

passages. An acid tank can be used to remove
excessive deposits, but the expansion plugs MUST
be removed first.
RCSC05CDC131AAA 2
4. Clean the cylinder head combustion deck with a

Scotch-Brite™ pad and diesel fuel or solvent.
5. Clean carbon deposits from the valve pockets with
a high quality steel wire wheel installed in a drill or
die grinder.
6. Wash the cylinder head in hot soapy water.
RCSC05CDC117AAA 3

8. Use a petroleum-based solvent to clean the cap
screws. Clean the cap screw thoroughly with a wire
brush, a soft wire wheel or a non-abrasive bead
blast to remove deposits from the shanks and the
threads.
RCSC05CDC118AAA 4
3 15/11/2005
B.10.A / 298
9. Measure the overall flatness of the cylinder block

with a straight edge and feeler gauge. Measure end
to end and side to side and between the cylinder
bores and coolant passages. See Cylinder block -
Measure (B.10.A.70 - F.40.A.16).
RCPH05CDC734AAA 5
Next operation: Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10)
3 15/11/2005
B.10.A / 299
Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Cleaning (B.10.A.72 - F.30.A.10)
1. Inspect the head for cracks at the injector bore. If

a crack is present and does NOT extend into the
valve seat, the cylinder head is reusable.
RCPH05CDC383AAB 1
2. If a crack is present and does extend into or through

the valve seat bore, the cylinder head MUST be
replaced.
Use the defect detector kit – OEM1272 – to help

identify cylinder head cracks.
RCPH05CDC383AAC 2
3. Inspect the valve seats for cracks or burnt spots.

Replace the cylinder head if the valve seats are
damaged.
RCPH05CDC383AAD 3
3 15/11/2005
B.10.A / 300
4. Visually verify that the valve sealing area is in the

center of the valve seat insert. If the sealing area
extends to the top or bottom of the valve seat insert,
the valve should be replaced.
After replacing the valve, recheck the valve sealing

area. If the sealing area still extends to the top or
bottom of the valve seat insert, the cylinder head
MUST be replaced.
RCPH05CDC381AAC 4
5. Inspect the cap screws for damaged threads,

corroded surfaces or a reduced diameter (due to
cap screw stretching).
RCPH05CDC402AAC 5
6. Do NOT reuse cap screws under the following

conditions:
– if visible corrosion or pitting exceeds 1.0 cm²

(0.155 in²) in area: for example, a 9.525 mm x
9.525 mm (0.375 in x 0.375 in) area is acceptable,
but a 12.7 mm x 12.7 mm (0.5 in x 0.5 in) area is
not acceptable,
– if visible corrosion exceeds 0.12 mm (0.005 in)

in depth,
– if visible corrosion or pitting is located within 3.2

mm (0.125 in) of the fillets or threads,
– if the cap screw is stretched beyond the “free RCPH05CDC402AAB 6

length” maximum. See Cylinder head - Measure
(B.10.A.72 - F.40.A.16).
Next operation: Cylinder head - Measure (B.10.A.72 - F.40.A.16)
3 15/11/2005
B.10.A / 301
Cylinder head - Measure (B.10.A.72 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10)
1. Measure the cylinder head combustion surface for

flatness with a straight edge and a feeler gauge.
The overall flatness from end to end MUST not

exceed 0.203 mm (0.008 in).
The overall flatness from side to side MUST not

exceed 0.075 mm (0.003 in).
RCPH05CDC384AAA 1
2. Use a 50 mm (2.0 in) straight edge and a 0.025

mm (0.001 in) feeler gauge to measure local
cylinder head combustion surface flatness. Check
between the cylinder bores and between the coolant
passages.
If the 0.025 mm (0.001 in) gauge fits under the

straight edge, the cylinder head MUST be replaced.
If the cylinder head is pitted, grooved or has other

damage, the cylinder head MUST be replaced.
RCPH05CDC385AAA 2
3. To check cap screw free length, place the head of

the cap screw in the length gauge – 380000863 –
with the flange against the base of the slot.
NOTE: If the cap screws are NOT damaged, they can be
used throughout the life of the engine unless the specified
“free length” is exceeded.
RCPH05CDC403AAA 3
3 15/11/2005
B.10.A / 302
4. If the end of the screw touches the foot of the gauge,

the cap screw is too long and must be replaced.
The maximum cap screw free length is 162.6 mm

(6.4 in).
RCSC05CDC120AAA 4
Next operation: Cylinder head - Pressure test (B.10.A.72 - F.40.A.30)
3 15/11/2005
B.10.A / 303
Cylinder head - Pressure test (B.10.A.72 - F.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10)
1. A cylinder head test fixture can be shop made from

a steel or aluminum plate. Use the cylinder head
gasket as a template for drilling the cap screw holes
in a plate of these dimensions:
Thickness (A) – 16.0 mm (0.630 in)

Length (B) – 749.0 mm (29.5 in)
Width (C) – 193.0 mm (7.6 in).
RCSC05CDC121AAA 1
2. To assemble the test fixture, install a new head

gasket on the cylinder head. Install the shop made
plate on the assembly with 26 12 mm x 180 mm
cap screws, 26 12 mm x 1.75 mm hex flange nuts
and 52 12 mm washers.
NOTE: Place the washers between the cap screw head
and gasket and between the cylinder head and nut to
protect the head surface.
RCSC05CDC122AAA 2
3. Tighten the cap screws in the sequence shown.

RCPH05CDC002AAD 3
3 15/11/2005
B.10.A / 304
4. Connect a regulated air supply to the test fixture

plate and apply air pressure to 276 kPa (40 psi).
RCSC05CDC123AAA 4
5. Use appropriate lift equipment to move the test

assembly and submerge the head in a tank of
heated water.
NOTE: Heat the water to 60 °C (140 °F).
NOTE: The head MUST be completely submerged in the
water.
WARNING
6. Inspect the cylinder head. Bubbles indicate an

air leak. If the cylinder head leaks, it MUST be
replaced.
RCSC05CDC124AAA 5
7. Remove the test assembly from the tank. Remove

the test fixture from the cylinder head. Dry with
compressed air.
WARNING
3 15/11/2005
B.10.A / 305
8. If a leaking valve is suspected, perform the valve

seat vacuum test. See Cylinder head Valve seat -
Vacuum test (B.10.A.72.10 - F.40.A.25).
RCPH05CDC373AAA 6
Next operation: Valve assembly Valve - Cleaning (B.10.A.40.46.10 - F.30.A.10)
3 15/11/2005
B.10.A / 306
Cylinder head Valve seat - Vacuum test (B.10.A.72.10 - F.40.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. If a leaking valve is suspected, vacuum test the

valves and the valve seats after the cylinder head
has been assembled. Use the valve vacuum cup
– ST-1257-6 (CUMMINS) – to check for leaks on
the combustion deck at the suspected valve(s). In
addition, these tools or components are required:
– vacuum pump (A) capable of drawing vacuum to

at least 635 mm Hg (25 in Hg),
– pressure regulator valve (B),
– vacuum gauge (C), digital or analog,
– tee connector,
– and appropriately rated pressure hose.
RCSC05CDC132AAA 1
2. Regulate the vacuum to more than 457 mm Hg (18

in Hg) for a used valve or more than 635 mm Hg
(25 in Hg) for a new valve. Apply the vacuum cup
to the suspected valve(s) and close the regulator.
RCPH05CDC373AAA 2
3. Vacuum must NOT drop more than 25.4 mm Hg

(1.0 in Hg) in five (5) seconds.
RCPH05CDC823AAA 3
3 15/11/2005
B.10.A / 307
Cylinder head Valve guide - Cleaning (B.10.A.72.15 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01)
1. Use a bristle brush to clean the inside diameter of

the valve guide bore. Clean out with compressed air.
WARNING
RCPH05CDC391AAA 1
2. Inspect the valve guides for scuffing or scoring.
Next operation: Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16)
3 15/11/2005
B.10.A / 308
Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head Valve guide - Cleaning (B.10.A.72.15 - F.30.A.10)
1. Use the smallest gauge from OEM1015 or

equivalent to measure the valve guide inside
diameter.
RCPH05CDC392AAB 1
2. The inner diameter must be within 8.019 - 8.071

mm (0.3157 - 0.3178 in).
If the valve guide bore is worn larger than the

maximum specified, the cylinder head MUST be
replaced.
RCPH05CDC393AAA 2
3. Use a depth micrometer – OEM1013 or equivalent

– to measure the valve guide installed height.
Measure from the top of the valve guide to the
bottom of the recess area.
RCPH05CDC394AAB 3
3 15/11/2005
B.10.A / 309
4. The valve guide installed height must be within

13.15 - 13.65 mm (0.518 - 0.537 in).
If the valve guide height is outside of the

specification, the cylinder head must be replaced.
RCPH05CDC394AAA 4
Next operation: Cylinder head - Assemble (B.10.A.72 - F.10.A.20)
3 15/11/2005
B.10.A / 310
Cylinder head - Assemble (B.10.A.72 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16)
1. Lubricate the valve stems with clean engine oil and

install the valves in the head.
NOTE: If the valves are being reused, they MUST be
installed in the same location from which they came.
RCPH05CDC800AAA 1
Black or blue-colored valve seals

2. Use a 13 mm deep well socket to install the black
Install the blue valve seals over the intake valve

guides.
RCPH05CDC803AAA 2
3 15/11/2005
B.10.A / 311
Yellow or green-colored valve seals

3. Use a 13 mm deep well socket to install the green
Install the yellow valve seals over the intake valve

guides.
RCPH05CDC803AAA 3
4. Use the spring compressor tool – 3164329

(CUMMINS) – to install the valves springs and
retainers. Install the new collets and release
spring tension. See Valve drive Valve assembly -
Assemble (B.10.A.40.46 - F.10.A.20).
RCPH05CDC379AAA 4
5. After assembly hit the valve stems with a plastic

hammer to make sure that the collets are seated.
RCPH05CDC824AAA 5
3 15/11/2005
B.10.A / 312
6. Use a depth micrometer – OEM1013 or equivalent –

to measure the valve recess. The acceptable range
is 0.84 - 1.32 mm (0.033 - 0.052 in).
If the valve recess is outside of the specification,

replace the valve.
If the valve recess is still outside of the specification,

the cylinder head MUST be replaced.
RCPH05CDC386AAB 6
7. Before installing the cylinder head, check liner

protrusion. See Cylinder block Liner - Measure
(B.10.A.70.15 - F.40.A.16).
RCPH05CDC760AAA 7
3 15/11/2005
B.10.A / 313
Cylinder head - Install (B.10.A.72 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cylinder head - Assemble (B.10.A.72 - F.10.A.20)
1. Place a new cylinder head gasket over the dowels

on the block.
NOTE: Do NOT attempt to reuse a cylinder head gasket.
RCPH05CDC817AAA 1
2. Use appropriate lift equipment or an assistant to

carefully place the cylinder head on the block and
seat it on the dowels.
NOTE: The cylinder head weighs 75 kg (157 lb).
WARNING
RCSC05CDC129AAA 2
3. Lubricate the threads and head of the cap screws

with clean engine oil.
RCPH05CDC799AAA 3
3 15/11/2005
B.10.A / 314
4. If new cap screws are used, the threads must be

burnished: Perform the complete torque sequence
in the next Step to burnish the threads, loosen all
cap screws and then repeat the entire sequence.
RCPH05CDC002AAD 4
5. Tighten and torque the cap screws:

Step 2 – Loosen all cap screws.
RCPH05CDC814AAA 5
Next operation: Fuel injector - Install (B.20.A.29 - F.10.A.15)

Next operation: Rocker assembly Crosshead - Install (B.10.A.40.43.25 - F.10.A.15)
(B.60.A.26 - F.10.A.15).
Next operation: Air intake manifold - Install (B.30.A.38 - F.10.A.15)
Next operation: Install the fuel connector supply lines and fuel rail. See High pressure common rail Common
rail - Install (B.20.A.30.25 - F.10.A.15).
Next operation: Install the high pressure fuel supply line to the fuel rail. See Fuel line High pressure - Install
(B.20.A.36.20 - F.10.A.15).
Next operation: Install the low pressure fuel return line(s). See Fuel line Low pressure - Install (B.20.A.36.10 -
F.10.A.15).
Next operation: Cold start aid Grid heater - Install (B.80.A.30.40 - F.10.A.15)
Next operation: Exhaust manifold - Install (B.40.A.38 - F.10.A.15)
Next operation: Turbocharger - Install (B.30.A.31 - F.10.A.15)
Next operation: Refer to the chassis service manual and install the alternator, air conditioning compressor and
their support bracket.
Next operation: Refer to the engine installation section of the chassis manual and install all overhead water and
heating lines, air conditioning lines, and air intake lines to the turbocharger and the intake manifold.
3 15/11/2005
B.10.A / 315
Valve cover - Remove (B.10.A.74 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Remove (B.60.A.26 - F.10.A.10).
1. Remove the cap screws and remove the valve

cover and gasket.
RCPH05CDC198AAA 1
Next operation: Valve cover - Visual inspection (B.10.A.74 - F.40.A.10)
3 15/11/2005
B.10.A / 316
Valve cover - Visual inspection (B.10.A.74 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Check the isolators for cracks, tears or brittleness.

Replace the isolator if damage is found.
RCPH05CDC196AAB 1
2. Check the cover gasket for cracks on the sealing

surface or stretching. Replace the gasket if damage
is found.
RCPH05CDC200AAB 2
3. Replace the gasket if it is removed from the cover

groove for any reason.
RCPH05CDC201AAA 3
3 15/11/2005
B.10.A / 317
Valve cover - Install (B.10.A.74 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Valve cover - Visual inspection (B.10.A.74 - F.40.A.10)
1. Use this sequence when installing a new gasket:
Step 1 – Press the gasket into the corners of the

cover.
Step 2 – Press the gasket around the holes for the
cap screws.
Step 3 – Press the remaining gasket into the cover.
NOTE: If the gasket was removed from the valve cover, a
new gasket MUST be installed.
RCPH05CDC199AAA 1
2. Install the valve cover and cap screws. Tighten and

torque to 12 Nm (106 lb in).
RCPH05CDC823AAA 2
(B.60.A.26 - F.10.A.15).
3 15/11/2005
B.10.A / 318
Front cover - Remove (B.10.A.75 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Remove the 26 cap screws from the front cover.

Use a gasket scraper to separate the front cover
from the engine, and remove the front cover.
NOTE: Note the location of the longer cap screws used to
secure the front cover.
RCPH05CDC102ABB 1
Next operation: Front cover - Visual inspection (B.10.A.75 - F.40.A.10)
3 15/11/2005
B.10.A / 319
Front cover - Visual inspection (B.10.A.75 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Clean the silicon sealant from the front cover and

from the housing gasket surface.
RCSC05CDC140AAA 1
2. Inspect the front cover for cracks at the seal carrier

bore and the mounting holes.
RCPH05CDC965AAB 2
3 15/11/2005
B.10.A / 320
Front cover - Install (B.10.A.75 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Front cover - Visual inspection (B.10.A.75 - F.40.A.10)
1. If required, install the seal carrier in the front cover.

See Crankshaft Front seal - Install (B.10.A.43.01
- F.10.A.15).
RCPH05CDC095ABA 1
2. Clean and dry the crankshaft sealing area.
CAUTION
M1020 - The crankshaft must be clean, dry and oil free
before installing the gear cover. Failure to properly
clean the sealing surface will result in an oil leak.
RCPH05CDC079ABA 2
3. Apply a thin bead of Permatex™ Ultra Grey

(87307915) silicone sealant to the cover side of the
front cover only. Apply the sealant around the cap
screw holes.
RCPH05CDC096ABA 3
3 15/11/2005
B.10.A / 321
4. Install the front cover on the housing. Install the cap

screws in the front cover with the longer cap screws
at the locations shown.
RCPH05CDC102ABB 4
5. Tighten and torque the cap screws to 24 Nm (18 lb

ft) in the pattern shown.
RCPH05CDC102ABD 5
6. Remove the plastic pilot from the front seal if

required.
RCPH05CDC098ABA 6
3 15/11/2005
B.10.A / 322
7. Install a dust exclusion seal over the front crankshaft

seal.
RCPH05CDC104ABA 7

3 15/11/2005
B.10.A / 323
Rear cover - Remove (B.10.A.76 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. If the oil pan is removed, go to Step 5. If the oil pan

is installed, go to Step 2.
2. Loosen the four cap screws at the rear of the oil pan.
RCPH05CDC941AAA 1
3. Use a feeler gauge and carefully separate the oil

pan gasket from the rear cover. Work the gauge
from the side to side to release the gasket from the
rear cover.
IMPORTANT: Use extreme care not to damage the
gasket. If the gasket is damaged, it must be repaired or
replaced.
RCPH05CDC942AAA 2
4. When the gasket is free of the cover, remove the

four oil pan cap screws.
5. Remove the eight cap screws securing the rear
cover.
RCPH05CDC971AAA 3
3 15/11/2005
B.10.A / 324
6. Remove the rear cover, cover gasket and shaft seal

assembly.
RCPH05CDC954AAA 4
3 15/11/2005
B.10.A / 325
Rear cover - Install (B.10.A.76 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Install a new rear cover gasket and the rear cover.

Do not completely tighten the cover cap screws at
this time.
RCPH05CDC991AAA 1
2. Install the rear crankshaft seal.
If a crankshaft wear sleeve is NOT installed, see

Crankshaft Rear seal - Install (B.10.A.43.02 -
F.10.A.15).
If a crankshaft wear sleeve IS installed,

see Crankshaft Rear wear sleeve - Install
(B.10.A.43.06 - F.10.A.15).
3 15/11/2005
B.10.A / 326
Wiring harness - Disconnect (B.10.A.88 - F.10.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Harness removal or disconnection varies with the

component which requires service. Refer to Wiring
harness - Component identification (B.10.A.88
- C.40.C.20) for engine harness routing, clamping
and connection points. Refer to the individual
procedures for special instructions.
RCPH05CDC247ABA 1
3 15/11/2005
B.10.A / 327
Wiring harness - Connect (B.10.A.88 - F.10.A.16)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Harness installation or connection varies with the

component which requires service. Refer to Wiring
harness - Component identification (B.10.A.88
- C.40.C.20) for engine harness routing, clamping
and connection points. Refer to the individual
procedures for special instructions.
RCPH05CDC247ABA 1
3 15/11/2005
B.10.A / 328
Electronic control - Check (B.10.A.92 - F.40.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: AIR INTAKE SYSTEM - Check (B.30.A - F.40.A.11)
Throttle travel
1. Connect INSITE® service tool.
Keyswitch ON.
Use INSITE® to monitor throttle position throughout

its range.
If throttle position reads 0 % with the throttle

completely closed and 100 % with the throttle fully
open, continue with Step 2.
If the throttle position reads greater than 0 % with

the throttle completely closed and/or less than 100
% with the throttle fully open, determine and correct
the source of the problem.
RCPH05CDC325ABA 1
Barometric pressure sensor check

Keyswitch ON.
Use the data monitor/logger in INSITE® and

compare the INSITE® reading for barometric air
pressure with the local barometric pressure. Use
the table in Sensing system Air pressure sensor
- Service limits (B.30.A.95.81 - D.20.A.20) to
approximate the local pressure value.
If the INSITE® reading is within 102 mm Hg (4 in

Hg) of the local pressure value, continue with Step
3.
If the INSITE® reading is NOT within 102

mm Hg (4 in Hg) of the local pressure value, RCPH05CDC315ABA 2
replace the barometric pressure sensor. Refer to
Sensing system Air pressure sensor - Remove
(B.30.A.95.81 - F.10.A.10).
3 15/11/2005
B.10.A / 329
Temperature sensor check

3. Remove the temperature sensor from the intake
manifold cover. See Sensing system Air
temperature sensor - Remove (B.30.A.95.80 -
F.10.A.10).
Connect the INSITE® service tool.

Keyswitch ON.
Use INSITE® to monitor the temperature sensor in

ambient air. Use the table at Sensing system Air
temperature sensor - Service limits (B.30.A.95.80
- D.20.A.20) to perform a rationale check on sensor
operation.
If the temperature/resistance value reported by

INSITE® for the sensor does NOT correspond to the RCPH05CDC315ABA 3
ambient temperature value from the table, replace
the sensor.
If the temperature/resistance value reported by

INSITE® for the sensor does correspond to the
ambient temperature value from the table, continue
with Step 4.
Feature settings check

4. Connect the INSITE® service tool.
Keyswitch ON.
Use INSITE® to verify that these adjustable

parameters are set correctly:
• Maximum vehicle speed

• Power train protection
• Rear axle ratio
• Tail shaft teeth
• Tire revolutions per mile
• Gear-down protection
If the electronic features are set incorrectly, use

INSITE® to correct the programmable features.
RCPH05CDC325ABA 4
If the electronic features are set correctly, continue
with the next sequence in the performance tree.
Next operation: ENGINE - Check (B.10.A - F.40.A.11)
3 15/11/2005
B.10.A / 330
Electronic control Control module - Remove (B.10.A.92.91 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
M1001 - Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate
the battery compartment before servicing the batteries. To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the negative (-) battery cable last. Wash your hands after handling
battery components.
Prior operation: Disconnect the batteries.
1. Disconnect the power connector to the engine

control module (ECM).
RCPH05CDC162ABA 1
2. Loosen the hex head cap screws and remove the

engine harness connector (shown) and the vehicle
harness connector (A) to the ECM.
RCPH05CDC163ABA 2
3 15/11/2005
B.10.A / 331
3. Remove the cap screw for the ground connector at

the bottom of the ECM.
RCPH05CDC164ABA 3
4. Remove the nut and clamp from the right hand side
of the ECM.
RCPH05CDC165ABA 4
5. Remove the cap screws and harness clamps on the

left hand side of the ECM.
NOTE: Some components shown removed for photo
clarity.
RCPH05CDC127AAA 5
3 15/11/2005
B.10.A / 332
6. Remove the control module from the cooling plate.
RCPH05CDC166ABA 6
Next operation: Electronic control Control module - Install (B.10.A.92.91 - F.10.A.15)
3 15/11/2005
B.10.A / 333
Electronic control Control module - Install (B.10.A.92.91 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Position the control module over the cooling plate.
RCPH05CDC166ABA 1
2. Install the harness clamps and cap screws on the

left hand side of the ECM.
RCPH05CDC127AAA 2
3. Install the clamp and nut on the right hand side of

the ECM.
RCPH05CDC165ABA 3
3 15/11/2005
B.10.A / 334
4. Install the ground connector and cap screw at the

bottom of the ECM.
RCPH05CDC164ABA 4
5. Torque the cap screws and nut to 24 Nm (18 lb ft).
RCPH05CDC175ABA 5
6. Install the engine harness connector (shown) and

vehicle harness connector (A). Torque the cap
screws to 2 Nm (18 lb in).
RCPH05CDC163ABA 6
3 15/11/2005
B.10.A / 335
7. Connector the ECM power connector.
RCPH05CDC162ABA 7
3 15/11/2005
B.10.A / 336
Sensing system Speed sensor - Remove (B.10.A.95.80 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Slide the locking tab (A) sideways to the open
position and depress the tab (B) at the rear of the
connector to remove the engine harness connector
from the sensor.
RCPH05CDC345ABA 1
2. Remove the cap screw and remove the sensor from

the block.
RCPH05CDC251ABA 2
Next operation: Sensing system Speed sensor - Visual inspection (B.10.A.95.80 - F.40.A.10)
3 15/11/2005
B.10.A / 337
Sensing system Speed sensor - Visual inspection (B.10.A.95.80 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Speed sensor - Remove (B.10.A.95.80 - F.10.A.10)

1. Inspect the sensor and harness connectors for:
• Loose connector
• Corroded pins
• Bent or broken pins
• Pushed back or expanded pins
• Moisture in the connector
• Missing or damaged connector seals
• Dirt or debris in or on the connector pins
• Wire insulation damage
• Connector shell breakage or damage.
Repair or replace pins, wires or connectors as

required.
RCPH05CDC348ABA 1
2. Inspect the crankshaft speed sensor for debris or

cracks.
If debris is present, clean the sensor.
If the sensor is chipped, cracked or damaged,

replace the sensor.
RCPH05CDC252ABA 2
Next operation: Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01)
3 15/11/2005
B.10.A / 338
Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Speed sensor - Visual inspection (B.10.A.95.80 - F.40.A.10)
IMPORTANT: This test ONLY verifies operation of the sensor and assumes the ECM and wiring circuits to the
sensor are fault free.

1. Connect the crankshaft speed sensor to the engine
harness connector.

NOTE: The sensor must be removed from the block for
this test.
RCPH05CDC325ABA 1
2. Remove the socket from the ratchet used to

remove the sensor from the block. Slowly slide the
socket across the face of the sensor in a direction
perpendicular to its mounting bracket or the line
across the face of the sensor.
RCPH05CDC346ABA 2
3. Use INSITE® to monitor the state of the speed

sensor as the socket is moved across the face.
If the speed sensor state does NOT change from

high to low or low to high OR if the speed sensor
state does NOT show triggered, the sensor MUST
be replaced.
Next operation: Sensing system Speed sensor - Install (B.10.A.95.80 - F.10.A.15)
3 15/11/2005
B.10.A / 339
Sensing system Speed sensor - Install (B.10.A.95.80 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01)
1. Install a new O-ring on the sensor. Lubricate the

O-ring with clean engine oil.
RCPH05CDC252ABA 1
2. Install the sensor in the block and secure with the

cap screw. Torque the cap screw to 25 Nm (34 lb ft).
RCPH05CDC347ABA 2
3. Connect the engine harness connector to the

sensor. Slide the locking tab to the locked position.
RCPH05CDC250ABA 3
3 15/11/2005
B.10.A / 340
Sensing system Camshaft speed sensor - Remove (B.10.A.95.82 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Slide the locking tab sideways to the open position

and depress the tab at the rear of the connector
to remove the engine harness connector from the
sensor.
RCPH05CDC253ABA 1

the gear housing.
RCPH05CDC254ABA 2
Next operation: Sensing system Camshaft speed sensor - Visual inspection (B.10.A.95.82 - F.40.A.10)
3 15/11/2005
B.10.A / 341
Sensing system Camshaft speed sensor - Visual inspection

(B.10.A.95.82 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Camshaft speed sensor - Remove (B.10.A.95.82 - F.10.A.10)
• Loose connector
• Corroded pins

required.
RCPH05CDC253ABA 1
2. Inspect the camshaft speed sensor for debris or

cracks.
If debris is present, clean the sensor.
If the sensor is chipped, cracked or damaged,

replace the sensor.
RCPH05CDC255ABA 2
Next operation: Sensing system Camshaft speed sensor - Test (B.10.A.95.82 - F.40.C.01)
3 15/11/2005
B.10.A / 342
Sensing system Camshaft speed sensor - Test (B.10.A.95.82 -

F.40.C.01)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Camshaft speed sensor - Visual inspection (B.10.A.95.82 - F.40.A.10)
1. Connect the camshaft speed sensor to the engine
harness connector.

NOTE: The sensor must be removed from the gear
housing for this test.
RCPH05CDC325ABA 1
2. Remove the socket from the ratchet used to

remove the sensor from the block. Slowly slide the
socket across the face of the sensor in a direction
perpendicular to its mounting bracket or the line
across the face of the sensor.
RCPH05CDC350ABA 2
3. Use INSITE® to monitor the state of the speed

sensor as the socket is moved across the face.
If the speed sensor state does NOT change from

high to low or low to high OR if the speed sensor
state does NOT show triggered, the sensor MUST
be replaced.
Next operation: Sensing system Camshaft speed sensor - Install (B.10.A.95.82 - F.10.A.15)
3 15/11/2005
B.10.A / 343
Sensing system Camshaft speed sensor - Install (B.10.A.95.82 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Camshaft speed sensor - Test (B.10.A.95.82 - F.40.C.01)

RCPH05CDC255ABA 1
2. Install the sensor in the gear housing and secure

with the cap screw. Torque the cap screw to 10 Nm
(89 lb in).
RCPH05CDC349ABA 2

sensor. Slide the locking tab to the locked position.
RCPH05CDC253ABA 3
3 15/11/2005
B.10.A / 344
ENGINE - Problem solving (B.10.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
This guided procedure is designed to deal with a broad base of symptoms related to driveability, performance
and power.
• In general, driveability describes vehicle performance on the job. Driveability problems for an engine can be
caused by several different factors. Some factors are engine-related; others are not. Before troubleshooting,
determine the exact complaint and whether the engine has a real driveability problem or if it simply does not
meet the owner/operator expectations.
• Low power is a phrase used to describe many different performance problems. Low power is herein
understood as “the inability of the engine to produce the power necessary to move the vehicle at a speed that
can be reasonably expected under the given conditions of load, grade, wind, etc.
• Poor acceleration or response is described as the inability of the vehicle to accelerate from a stop or from
the bottom of a grade under the given load conditions. It can also refer to a lag in acceleration when the
vehicle is working at less than rated speed and load.
• This guided procedure can be used to troubleshoot all the performance based symptoms listed in the table
below:
TROUBLESHOOTING
Begin by performing basic troubleshooting procedures:

1. Check for active fault codes or high counts of inactive fault codes.
• Turn keyswitch ON.
• Connect INSITE® electronic service tool.
• Use INSITE® to review fault codes.
• Follow the guided troubleshooting for the fault code(s).
2. Verify the following items before continuing:
• Verify the fuel level in the tanks.
• Verify that there have NOT been any changes to control part list components on the engine.
• Verify fuel grade is correct for application.
• Verify the engine is operating within the recommended altitude.
• Verify engine oil is at the correct level.
• Verify engine parasitics have NOT changed.
• Verify engine duty cycle has NOT changed.
• Verify engine cranking speed is greater than 150 rpm.
• Verify battery voltage is correct.
3. Proceed to ENGINE - Testing (B.10.A - G.40.A.20) to clarify the symptom while interviewing the
owner/operator.
3 15/11/2005
B.10.A / 345
WARNING
M1161 - Troubleshooting presents the risk of death, personal injury or equipment damage. Troubleshooting
must be performed by trained, experienced technicians.
Problem Possible Cause Correction

Engine acceleration or If the owner/operator interview indicates Perform the troubleshooting steps in the
response poor the problem is low power, poor acceleration sequence below:
or poor response,
• Fuel and injection system check
• Air intake system check
• Electronic control check
• Engine check
Begin with ENGINE - Testing (B.10.A -

G.40.A.20).
Cranking fuel pressure is If the owner/operator interview indicates Perform the troubleshooting steps in the
low the problem is low power, poor acceleration sequence below:
or poor response,
• Engine check

G.40.A.20).
Engine operating fuel If the owner/operator interview indicates Perform the troubleshooting steps in the
pressure is low the problem is low power, poor acceleration sequence below:
or poor response,
• Engine check

G.40.A.20).
Engine decelerates slowly If the owner/operator interview indicates Perform the troubleshooting steps in the
the problem is low power, poor acceleration sequence below:
or poor response,
• Engine check

G.40.A.20).
Engine difficult to start If the owner/operator interview indicates Perform the troubleshooting steps in the
or will not start (Exhaust the problem is engine will not start, sequence below:
smoke) engine difficult to start, or engine shuts off
unexpectedly, • Starting system check

G.40.A.20).
3 15/11/2005
B.10.A / 346

Engine difficult to start or If the owner/operator interview indicates Perform the troubleshooting steps in the
will not start (No exhaust the problem is engine will not start, sequence below:
smoke) engine difficult to start, or engine shuts off

G.40.A.20).
Engine power output low If the owner/operator interview indicates Perform the troubleshooting steps in the
the problem is low power, poor acceleration sequence below:
or poor response,
• Engine check

G.40.A.20).
Engine runs rough at idle If the owner/operator interview indicates Perform the troubleshooting steps in the
the problem is engine misfire, engine sequence below:
speed surge, or engine speed unstable,

G.40.A.20).
Engine runs rough or If the owner/operator interview indicates Perform the troubleshooting steps in the
misfires the problem is engine misfire, engine sequence below:

G.40.A.20).
Engine speed surges at If the owner/operator interview indicates Perform the troubleshooting steps in the
low or high idle the problem is engine misfire, engine sequence below:

G.40.A.20).
Engine speed surges If the owner/operator interview indicates Perform the troubleshooting steps in the
under load or in operating the problem is engine misfire, engine sequence below:
range speed surge, or engine speed unstable,

G.40.A.20).
3 15/11/2005
B.10.A / 347

Excessive black smoke If the owner/operator interview indicates Perform the troubleshooting steps in the
the problem is excessive white or black sequence below:
smoke,

G.40.A.20).
Excessive white smoke If the owner/operator interview indicates Perform the troubleshooting steps in the
the problem is excessive white or black sequence below:
smoke,

G.40.A.20).
Engine shuts off or dies If the owner/operator interview indicates Perform the troubleshooting steps in the
unexpectedly or dies the problem is engine will not start, sequence below:
during deceleration engine difficult to start, or engine shuts off

G.40.A.20).
Engine starts but will not If the owner/operator interview indicates Perform the troubleshooting steps in the
keep running the problem is engine will not start, sequence below:
engine difficult to start, or engine shuts off

G.40.A.20).
Engine will not reach If the owner/operator interview indicates Perform the troubleshooting steps in the
rated speed (RPM) the problem is low power, poor acceleration sequence below:
or poor response,
• Engine check

G.40.A.20).
Intake manifold pressure If the owner/operator interview indicates Perform the troubleshooting steps in the
(boost) is below normal the problem is low boost pressure, sequence below:

• Engine check

G.40.A.20).
3 15/11/2005
B.10.A / 348
ENGINE - Testing (B.10.A - G.40.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
N° Test Point Expected Result Other Result (Possible Cause)

1 • Turn the keyswitch ON. Active faults or high counts of Active faults or high counts of
• Connect the INSITE® electronic inactive faults found. inactive faults NOT found.
service tool.
Follow the guided troubleshooting Perform basic troubleshooting

Use INSITE® to check for active for the fault conditions. checks. Go to Step 2.
faults codes or high counts of
inactive fault codes.
2 Check the following items before All items are NOT correct. All items are correct.
continuing:
• Verify the fuel level in the tank(s). Correct the failure and verify the Determine the engine symptoms.
• Verify there have not been any complaint is no longer present after Go to Step 3.
changes to the control part list the repair.
components on the engine.
• Verify that fuel grade is correct for
the application.
• Verify engine is operating at
recommended altitude.
• Verify engine oil at the correct
level.
• Verify that engine parasitics have
NOT changed.
• Verify that engine duty cycle has
NOT changed.
• Verify that engine cranking speed
is greater than 150 rpm.
• Verify that battery voltage is
adequate.
3 • Interview the owner/operator and YES NO
verify the complaint.
Perform the troubleshooting steps in Go to Step 4.

Is the engine symptom low power, the order listed below:
poor acceleration or poor response?
FUEL AND INJECTION SYSTEM -
Check (B.20.A - F.40.A.11)
AIR INTAKE SYSTEM - Check

(B.30.A - F.40.A.11)
Electronic control - Check

(B.10.A.92 - F.40.A.11)
ENGINE - Check (B.10.A -

F.40.A.11)
3 15/11/2005
B.10.A / 349


Is the engine symptom engine the order listed below:
misfire, engine speed surge or
engine speed unstable? FUEL AND INJECTION SYSTEM -
Check (B.20.A - F.40.A.11)

(B.30.A - F.40.A.11)
Electronic control - Check

(B.10.A.92 - F.40.A.11)

Is the engine symptom excessive the order listed below:
white or black smoke?
(B.30.A - F.40.A.11)

Check (B.20.A - F.40.A.11)
Perform the troubleshooting steps in Return to Step 3 and locate the

Is the engine symptom engine will the order listed below: correct symptom.
not start, difficult to start or engine
shuts off unexpectedly? STARTING SYSTEM - Check
(B.80.A - F.40.A.11)

(B.30.A - F.40.A.11)

Check (B.20.A - F.40.A.11)
ENGINE - Check (B.10.A -

F.40.A.11)
3 15/11/2005
B.10.A / 350
ENGINE - Problem solving (B.10.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
When diagnosing engine noise problems, make sure the noises caused by the accessories – air conditioning
compressor, alternator, PTO – are NOT mistaken for engine noises. Remove the accessory drive belts to eliminate
noises from these sources. Noise will travel to other metal parts NOT related to the problem. The use of a
stethoscope can help locate engine noise.
TROUBLESHOOTING
• Engine noises heard at crankshaft speed timing – engine rpm – are noises related to the crankshaft, rods,
pistons and piston pins. Noises heard at the camshaft speed timing – one-half of the engine RPM – are related
to the valve train. A handheld digital tachometer can help determine if the noise is related to crankshaft or
camshaft components.
• Engine noise can sometimes be isolated by performing a cylinder cutout test. If the volume of the noise
decreases or disappears, it is related to that particular cylinder.
• There is NO definite rule or test or determining the source of a noise complaint.
• Main bearing
• The noise caused by a loose main bearing is a loud, dull knock heard when an engine is pulling a load.
If all main bearings are loose, a loud clatter will be heard. The knock is heard regularly every other
revolution. The noise is the loudest when the engine is lugging under heavy load. The knock is duller
than a connecting rod noise. Low oil pressure can also accompany this condition.
• If the bearing is NOT loose enough to produce a knock by itself, the bearing can knock if the oil too
thin or if there is no oil on the bearing.
• An irregular noise can indicate worn crankshaft thrust bearings.
• An intermittent, sharp knock indicates excessive crankshaft end clearance.
• Connecting rod
• Connecting rods with excessive clearance will knock at all engine speeds under both idle and load
conditions. When the bearings begin to come loose, the noise can be confused with piston slap or loose
piston pins. The noise increases in volume with engine speed. Low oil pressure can also accompany this
condition.
• Piston
• Distinguishing between the noise from the piston pin, connecting rod and piston is difficult. A loose piston
pin causes a loud double knock that is usually heard when the engine is idling. When the injector to the
cylinder is cutout, a noticeable change in knocking noise is heard. However, on some engines the knock
becomes more pronounced when the vehicle is operated at steady transport speed.
WARNING
IMPORTANT: When troubleshooting engine noise complaints, make sure the engine accessories are not the
cause of the noise.
IMPORTANT: Read and understand the guidelines specific to each component in TROUBLESHOOTING before
using the symptom table for main bearings, connecting rods or pistons.
3 15/11/2005
B.10.A / 351

Engine noise excessive Step 1: Check the belt condition. Refer to Fan
Loose fan drive belt. and drive Belt - Visual inspection
(B.50.A.54.44 - F.40.A.10).
Check the belt tensioner. Refer to Fan and

drive Belt tensioner - Visual inspection
(B.50.A.54.49 - F.40.A.10).
Step 2: Check the fan.
Fan is loose, damaged or out of balance.
Refer to Fan and drive - Disassemble
(B.50.A.54 - F.10.A.25).
Step 3: Isolate the compressor and check for
Air conditioning compressor noise is noise.
excessive.
Step 4: Inspect the air intake and exhaust systems
Air intake or exhaust leaks. for leaks.
Refer to AIR INTAKE SYSTEM - Leakage

test (B.30.A - F.40.A.40).
Step 5: Inspect the chassis and piping for contact
Air intake or exhaust piping is contacting points.
the chassis.
Step 6: Check the oil level. Add or drain oil, as
Oil level is above or below specification. required.
Step 7: Submit an oil sample for analysis.
Oil is thin or diluted.
If the oil pressure is low, refer to the
“lubricating oil pressure low” symptom
table. See LUBRICATION SYSTEM -
Problem solving (B.60.A - G.40.A.30).
Step 8: Check the oil pressure.
Oil pressure is below specification.
If the pressure is low, refer to the
“lubricating oil pressure low” symptom
table. See LUBRICATION SYSTEM -
Step 9: Inspect the vibration damper.
Vibration damper is damaged.
Refer to Vibration damper - Visual
inspection (B.10.A.68 - F.40.A.10).
Step 10: Refer to the “coolant temperature above
Coolant temperature is above normal – gradual overheat” symptom table.
specification.
See ENGINE COOLANT SYSTEM -
Step 11: Disconnect the drivetrain and check
Drivetrain noise is excessive. for noise. Refer to the chassis service
manual.
Step 12: Check the engine mounts. Refer to the
Engine mounts are worn, damaged or chassis service manual.
incorrect.
Step 13: Measure and adjust the overhead settings.
Overhead adjustments are NOT correct.
See Valve drive Rocker assembly -
Check (B.10.A.40.43 - F.40.A.11).
Step 14: Inspect the rocker arms, rocker shafts and
Overhead components are damaged. valves for damage or excessive wear.
Refer to Valve drive Rocker assembly -

Remove (B.10.A.40.43 - F.10.A.10).
3 15/11/2005
B.10.A / 352

Step 15: Perform the cylinder cutout test. Replace
Injector is malfunctioning. the injector(s) as required.
Step 16: Check the flywheel and shock plate cap
Flywheel or shock plate cap screws are screws.
loose or broken.
Refer to Flywheel - Remove (B.10.A.50 -
F.10.A.10).
Step 17: Check the gear backlash and the gear
Gear train backlash is excessive or the teeth.
gear teeth are damaged.
Refer to Valve drive Camshaft - Backlash
(B.10.A.40.44 - F.40.E.15).
Step 18: Refer to the “engine noise excessive –
Main bearing or connecting rod bearing connecting rod” symptom table in this
noise. document.
Step 19: Refer to the “engine noise excessive
Turbocharger noise. – turbocharger” symptom tree in this
document.
Step 20: Refer to the “engine noise excessive –
Combustion noise excessive. combustion knock” symptom tree in this
document.
Step 21: Check for air intake system leaks. Refer
Piston or piston rings are worn or to AIR INTAKE SYSTEM - Leakage test
damaged. (B.30.A - F.40.A.40).
Check the pistons and piston rings for

wear or damage. Refer to Piston Ring -
Measure (B.10.A.47.15.05 - F.40.A.16).
Excessive noise emission Step 1: Operate the engine from a tank of high
– Combustion knock Fuel grade is NOT correct for the quality fuel.
application or the fuel quality is poor.
Step 2: Test for air in the fuel system.
Air in the fuel system.
Refer to FUEL AND INJECTION SYSTEM
- Air in fuel (B.20.A - F.40.C.20).
Step 3: Drain and decontaminate the coolant
Coolant temperature above specification. system. Refer to ENGINE COOLANT
SYSTEM - Decontaminating (B.50.A -
F.30.A.60).
Use the analyzer to test the coolant

system. Refer to ENGINE COOLANT
SYSTEM - Test (B.50.A - F.40.C.01).
Step 4: Perform the automated cylinder
Injector malfunction performance test. Replace injectors as
required.
Check (B.10.A.40.43 - F.40.A.11).
Step 6: Check the gear train timing alignment.
Camshaft timing is NOT correct (after
engine rebuild or repair). Refer to Valve drive Camshaft - Install
(B.10.A.40.44 - F.10.A.15).
Engine noise excessive – Step 1: Check the oil level. Verify the dipstick
Connecting rod Oil level below specification. calibration and oil pan capacity. Fill the
system to the specified level.
3 15/11/2005
B.10.A / 353

Step 2: Check the oil pressure. If the pressure is
Oil pressure below specification. low, refer to the “oil pressure low symptom”
table.
Refer to LUBRICATION SYSTEM -

Step 3: Submit an oil sample for analysis. If the oil
Oil is thin or diluted. pressure is low, refer to the “oil pressure
low” symptom table.

Step 4: Remove and inspect the oil suction tube.
Oil suction tube is assembled incorrectly.
Refer to Oil pan - Remove (B.60.A.23 -
F.10.A.10).
Step 5: Check the torque on the connecting rod
Connecting rod cap screws are loose or cap screws.
not tightened correctly.
For 6TAA-8304 engines, see Connecting
rod and piston - Install (B.10.A.47 -
F.10.A.15).
For 6TAA-9004 engines, see Connecting

rod and piston - Install (B.10.A.47 -
F.10.A.15).
Step 6: Remove and inspect the connecting rods.
Connecting rod is bent or out of alignment.
For 6TAA-8304 engines, refer to
Connecting rod and piston - Remove
(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
Step 7: Inspect the connecting rod and bearings.
Connecting rod and bearings are damaged
or worn, are NOT assembled correctly or For 6TAA-8304 engines, refer to
are the wrong part number for the engine. Connecting rod and piston - Remove
(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
Engine noise excessive – Step 1: Check the oil pressure. If the pressure is
Main bearing Oil pressure below specification. low, refer to the “oil pressure low” symptom
table.

Step 2: Check the oil level. Verify the dipstick
Oil level below specification. calibration and oil pan capacity. Fill the
Step 3: Submit an oil sample for analysis. If the oil
Oil is thin or diluted. pressure is low, refer to the “oil pressure
low” symptom table.

3 15/11/2005
B.10.A / 354

Step 4: Check the torque on the main bearing cap
Main bearing cap screws are loose, worn screws.
or NOT tightened correctly.
Refer to Crankshaft Main bearing -
Install (B.10.A.43.15 - F.10.A.15).
Step 5: Inspect the main bearings for damage,
Main bearings are damaged or worn, or excessive wear and the correct part
the wrong bearings are installed. number.
Refer to Crankshaft Main bearing -

Remove (B.10.A.43.15 - F.10.A.10).
Step 6: Inspect the crankshaft journals.
Crankshaft journals are damaged or out
of round. Refer to Crankshaft Journal - Measure
(B.10.A.43.16 - F.40.E.01).
Step 7: Check the flywheel and the cap screws.
Flywheel or shock plate cap screws are
loose or broken. Refer to Flywheel - Remove (B.10.A.50 -
F.10.A.10).
Engine noise excessive – Step 1: Operate the engine from a tank of high
Piston Fuel grade is NOT correct for the quality fuel.
Check (B.10.A.40.43 - F.40.A.11).
Step 3: Perform the automated cylinder
Injector is malfunctioning. performance test. Replace injectors as
required.
Step 4: Remove and inspect the connecting rods.
Connecting rod is bent or out of alignment.
(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
Step 5: Remove and inspect the connecting rod.
Connecting rod is NOT assembled
correctly. For 6TAA-8304 engines, refer to
(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
Step 6: Remove and inspect the piston.
Piston is NOT assembled correctly.
(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
3 15/11/2005
B.10.A / 355

Step 7: Remove the pistons and inspect the piston
Piston pin or bushing is loose, worn or pin and bushing for damage, wear and
NOT installed correctly. correct installation.

(B.10.A.47 - F.10.A.10).

(B.10.A.47 - F.10.A.10).
Engine noise excessive – Step 1: Check the turbocharger part number.
Turbocharger Turbocharger is NOT correct for the Replace the turbocharger if required.
engine.
Step 2: Test the air intake system for restriction.
Air intake system restriction is above
specification. Refer to AIR INTAKE SYSTEM - Supply
restriction (B.30.A - F.40.C.21).
Clean or replace the air filter and inlet

piping as required.
Air intake or exhaust leaks. for leakage.

test (B.30.A - F.40.A.40).
Step 4: Inspect the piping and chassis for contact
Air intake or exhaust piping is contacting points.
the chassis.
Step 5: Test the exhaust system for restriction.
Exhaust system restriction is NOT within
specification. Refer to EXHAUST SYSTEM - Return
Step 6: Check the turbocharger for damage.
Turbocharger is worn or damaged. Refer to Turbocharger - Preliminary test
(B.30.A.31 - F.40.A.20).
Measure the turbine and compressor

wheel clearances. Refer to Turbocharger
- Check (B.30.A.31 - F.40.A.11).
Engine vibration Step 1: Refer to the engine performance guided
excessive Engine misfiring troubleshooting.
Refer to ENGINE - Problem solving

(B.10.A - G.40.A.30).
Step 2: Verify the correct idle speed setting.
Engine idle speed set too low. Increase the idle speed with the electronic
service tool.
Step 3: Check the fan hub, alternator, air
Belt-driven accessories malfunctioning. conditioning compressor for interference.
Insolate the accessories and check for

vibration.
Step 4: Check the fan. Refer to Fan and drive -
Fan is loose, damaged or NOT balanced. Disassemble (B.50.A.54 - F.10.A.25).
Step 5: Check the engine mounts. Refer to the
Engine mounts are worn, damaged or chassis service manual.
NOT correct for the engine.
3 15/11/2005
B.10.A / 356

Step 6: Inspect the vibration damper.
Vibration damper is damaged.
Refer to Vibration damper - Visual
inspection (B.10.A.68 - F.40.A.10).
Step 7: Isolate the drivetrain components and
Drivetrain components are malfunctioning check for vibrations.
or are NOT correct.
Step 8: Check the flywheel and shock plate and
Flywheel or shock plate cap screws are cap screws.
loose or broken.
Refer to Flywheel - Remove (B.10.A.50 -
F.10.A.10).
Step 9: Check the flywheel housing alignment.
Flywheel housing is NOT correctly aligned.
Refer to Flywheel - Measure (B.10.A.50 -
F.40.A.16).
Step 10: Check PTO for damage and correct
Power takeoff (PTO) is damaged. installation.
Step 11: Analyze the oil and inspect the filter to
Internal engine damage. locate the probable area of damage.
Refer to Oil filter - Visual inspection

(B.60.A.24 - F.40.A.10).
3 15/11/2005
B.10.A / 357
Index
ENGINE - 10.A
Camshaft Bushing - Install (B.10.A.40.44.30 - F.10.A.15) 127
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Measure (B.10.A.40.44.30 - F.40.A.16) 126
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Remove (B.10.A.40.44.30 - F.10.A.10) 124
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Service limits (B.10.A.40.44.30 - D.20.A.20) 21
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Bushing - Special tools (B.10.A.40.44.30 - D.20.A.40) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Install (B.10.A.40.44.10 - F.10.A.15) 112
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Remove (B.10.A.40.44.10 - F.10.A.10) 109
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Service limits (B.10.A.40.44.10 - D.20.A.20) 18
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Gear - Visual inspection (B.10.A.40.44.10 - F.40.A.10) 110
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Journal - Service limits (B.10.A.40.44.35 - D.20.A.20) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Lobe - Service limits (B.10.A.40.44.40 - D.20.A.20) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Install (B.10.A.40.44.20 - F.10.A.15) 117
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Remove (B.10.A.40.44.20 - F.10.A.10) 114
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Push rod - Visual inspection (B.10.A.40.44.20 - F.40.A.10) 115
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Install (B.10.A.40.44.25 - F.10.A.15) 121
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Remove (B.10.A.40.44.25 - F.10.A.10) 118
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Service limits (B.10.A.40.44.25 - D.20.A.20) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Camshaft Tappet - Visual inspection (B.10.A.40.44.25 - F.40.A.10) 120
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, STX280, 2388, 2377
MX305
MX215, MX245, MX275, STX280, 2388, 2377
MX305
MX215, MX245, MX275, STX280, 2388, 2377
MX305
MX215, MX245, MX275, STX280, 2388, 2377
MX305
87372074 3 15/11/2005
B.10.A / 358
Connecting rod and piston - Special tools (B.10.A.47 - D.20.A.40) 38
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.A.16) 230
MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Measure (B.10.A.47.10 - F.40.E.01) 233
MX305
Connecting rod and piston Connecting rod - Service limits (B.10.A.47.10 - D.20.A.20) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Torque (B.10.A.47.10 - D.20.A.10) 38
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Connecting rod - Visual inspection (B.10.A.47.10 - F.40.A.10) 228
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Piston - Cleaning (B.10.A.47.15 - F.30.A.10) 241
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.A.16) 243
MX215, MX245, MX275, STX280, 2388, 2377
Connecting rod and piston Piston - Measure (B.10.A.47.15 - F.40.E.01) 245
MX305
Connecting rod and piston Piston - Service limits (B.10.A.47.15 - D.20.A.20) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Install (B.10.A.47.10.05 - F.10.A.15) 240
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Measure (B.10.A.47.10.05 - F.40.A.16) 239
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Remove (B.10.A.47.10.05 - F.10.A.10) 236
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Connecting rod Bearing - Visual inspection (B.10.A.47.10.05 - F.40.A.10) 237
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Install (B.10.A.43 - F.10.A.15) 140
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Remove (B.10.A.43 - F.10.A.10) 139
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Service limits (B.10.A.43 - D.20.A.20) 29
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft - Special tools (B.10.A.43 - D.20.A.40) 29
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Install (B.10.A.43.01 - F.10.A.15) 145
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Remove (B.10.A.43.01 - F.10.A.10) 142
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Special tools (B.10.A.43.01 - D.20.A.40) 30
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Torque (B.10.A.43.01 - D.20.A.10) 30
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front seal - Visual inspection (B.10.A.43.01 - F.40.A.10) 144
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Install (B.10.A.43.05 - F.10.A.15) 155
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Remove (B.10.A.43.05 - F.10.A.10) 153
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Special tools (B.10.A.43.05 - D.20.A.40) 31
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Front wear sleeve - Visual inspection (B.10.A.43.05 - F.40.A.10) 154
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Install (B.10.A.43.10 - F.10.A.15) 172
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Measure (B.10.A.43.10 - F.40.A.16) 171
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Remove (B.10.A.43.10 - F.10.A.10) 169
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 359
Crankshaft Gear - Service limits (B.10.A.43.10 - D.20.A.20) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Gear - Visual inspection (B.10.A.43.10 - F.40.A.10) 170
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Journal - Measure (B.10.A.43.16 - F.40.E.01) 186
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Install (B.10.A.43.15 - F.10.A.15) 180
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Measure (B.10.A.43.15 - F.40.A.16) 179
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Remove (B.10.A.43.15 - F.10.A.10) 174
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Service limits (B.10.A.43.15 - D.20.A.20) 35
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Special tools (B.10.A.43.15 - D.20.A.40) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Torque (B.10.A.43.15 - D.20.A.10) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Main bearing - Visual inspection (B.10.A.43.15 - F.40.A.10) 178
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Install (B.10.A.43.02 - F.10.A.15) 150
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Remove (B.10.A.43.02 - F.10.A.10) 148
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Special tools (B.10.A.43.02 - D.20.A.40) 31
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear seal - Visual inspection (B.10.A.43.02 - F.40.A.10) 149
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Install (B.10.A.43.06 - F.10.A.15) 163
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Remove (B.10.A.43.06 - F.10.A.10) 158
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Special tools (B.10.A.43.06 - D.20.A.40) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Rear wear sleeve - Visual inspection (B.10.A.43.06 - F.40.A.10) 161
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Install (B.10.A.43.20 - F.10.A.15) 189
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Remove (B.10.A.43.20 - F.10.A.10) 187
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Torque (B.10.A.43.20 - D.20.A.10) 35
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankshaft Speed ring - Visual inspection (B.10.A.43.20 - F.40.A.10) 188
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block - Cleaning (B.10.A.70 - F.30.A.10) 269
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block - Measure (B.10.A.70 - F.40.A.16) 270
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Bore - Measure (B.10.A.70.10 - F.40.A.16) 271
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Bore - Service limits (B.10.A.70.10 - D.20.A.20) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Install (B.10.A.70.15 - F.10.A.15) 282
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Preliminary test (B.10.A.70.15 - F.40.A.20) 272
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Remove (B.10.A.70.15 - F.10.A.10) 275
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Service limits (B.10.A.70.15 - D.20.A.20) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 360
Cylinder block Liner - Special tools (B.10.A.70.15 - D.20.A.40) 50
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Torque (B.10.A.70.15 - D.20.A.10) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder block Liner - Visual inspection (B.10.A.70.15 - F.40.A.10) 277
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Assemble (B.10.A.72 - F.10.A.20) 311
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Cleaning (B.10.A.72 - F.30.A.10) 297
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Disassemble (B.10.A.72 - F.10.A.25) 294
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Install (B.10.A.72 - F.10.A.15) 314
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Measure (B.10.A.72 - F.40.A.16) 302
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Pressure test (B.10.A.72 - F.40.A.30) 304
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Remove (B.10.A.72 - F.10.A.10) 292
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Service limits (B.10.A.72 - D.20.A.20) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Special tools (B.10.A.72 - D.20.A.40) 55
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Torque (B.10.A.72 - D.20.A.10) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head - Visual inspection (B.10.A.72 - F.40.A.10) 300
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Cleaning (B.10.A.72.15 - F.30.A.10) 308
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Measure (B.10.A.72.15 - F.40.A.16) 309
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve guide - Service limits (B.10.A.72.15 - D.20.A.20) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve seat - Service limits (B.10.A.72.10 - D.20.A.20) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cylinder head Valve seat - Vacuum test (B.10.A.72.10 - F.40.A.25) 307
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control - Check (B.10.A.92 - F.40.A.11) 329
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control Control module - Install (B.10.A.92.91 - F.10.A.15) 334
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control Control module - Remove (B.10.A.92.91 - F.10.A.10) 331
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Electronic control Control module - Torque (B.10.A.92.91 - D.20.A.10) 64
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Check (B.10.A - F.40.A.11) 78
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - General specification (B.10.A - D.40.A.10) 12
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Place on stand (B.10.A - F.35.A.10) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Special tools (B.10.A - D.20.A.40) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE - Testing (B.10.A - G.40.A.20) 348
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Install (B.10.A.50 - F.10.A.15) 256
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Measure (B.10.A.50 - F.40.A.16) 259
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 361
Flywheel - Remove (B.10.A.50 - F.10.A.10) 252
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Service limits (B.10.A.50 - D.20.A.20) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Special tools (B.10.A.50 - D.20.A.40) 44
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Torque (B.10.A.50 - D.20.A.10) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Flywheel - Visual inspection (B.10.A.50 - F.40.A.10) 254
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Install (B.10.A.75 - F.10.A.15) 321
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Remove (B.10.A.75 - F.10.A.10) 319
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Torque (B.10.A.75 - D.20.A.10) 62
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Front cover - Visual inspection (B.10.A.75 - F.40.A.10) 320
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Pin - Measure (B.10.A.47.15.10 - F.40.A.16) 251
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Pin - Service limits (B.10.A.47.15.10 - D.20.A.20) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Install (B.10.A.47.15.05 - F.10.A.15) 249
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Measure (B.10.A.47.15.05 - F.40.A.16) 248
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Remove (B.10.A.47.15.05 - F.10.A.10) 247
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston Ring - Service limits (B.10.A.47.15.05 - D.20.A.20) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover - Install (B.10.A.76 - F.10.A.15) 326
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover - Remove (B.10.A.76 - F.10.A.10) 324
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rear cover - Torque (B.10.A.76 - D.20.A.10) 63
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Install (B.10.A.40.43.25 - F.10.A.15) 97
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Remove (B.10.A.40.43.25 - F.10.A.10) 95
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Crosshead - Visual inspection (B.10.A.40.43.25 - F.40.A.10) 96
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Install (B.10.A.40.43.05 - F.10.A.15) 93
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Remove (B.10.A.40.43.05 - F.10.A.10) 90
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Torque (B.10.A.40.43.05 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Housing - Visual inspection (B.10.A.40.43.05 - F.40.A.10) 92
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Rocker arm - Service limits (B.10.A.40.43.10 - D.20.A.20) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Rocker assembly Shaft - Service limits (B.10.A.40.43.20 - D.20.A.20) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system - Component identification (B.10.A.95 - C.40.C.20) 72
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Install (B.10.A.95.82 - F.10.A.15) 344
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Remove (B.10.A.95.82 - F.10.A.10) 341
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Service limits (B.10.A.95.82 - D.20.A.20) 66
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Test (B.10.A.95.82 - F.40.C.01) 343
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 362
Sensing system Camshaft speed sensor - Torque (B.10.A.95.82 - D.20.A.10) 65
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Camshaft speed sensor - Visual inspection (B.10.A.95.82 - F.40.A.10) 342
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Install (B.10.A.95.80 - F.10.A.15) 340
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Remove (B.10.A.95.80 - F.10.A.10) 337
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Service limits (B.10.A.95.80 - D.20.A.20) 65
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Test (B.10.A.95.80 - F.40.C.01) 339
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Torque (B.10.A.95.80 - D.20.A.10) 65
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Speed sensor - Visual inspection (B.10.A.95.80 - F.40.A.10) 338
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear - Static description (B.10.A.45 - C.30.A.20) 67
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Install (B.10.A.46 - F.10.A.15) 193
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Remove (B.10.A.46 - F.10.A.10) 190
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Torque (B.10.A.46 - D.20.A.10) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10) 192
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Measure (B.10.A.40.46.15 - F.40.E.01) 135
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Service limits (B.10.A.40.46.15 - D.20.A.20) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Spring - Special tools (B.10.A.40.46.15 - D.20.A.40) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Cleaning (B.10.A.40.46.10 - F.30.A.10) 132
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Measure (B.10.A.40.46.10 - F.40.E.01) 134
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Service limits (B.10.A.40.46.10 - D.20.A.20) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Special tools (B.10.A.40.46.10 - D.20.A.40) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve assembly Valve - Visual inspection (B.10.A.40.46.10 - F.40.A.10) 133
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Install (B.10.A.74 - F.10.A.15) 318
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Remove (B.10.A.74 - F.10.A.10) 316
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Torque (B.10.A.74 - D.20.A.10) 61
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve cover - Visual inspection (B.10.A.74 - F.40.A.10) 317
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Backlash (B.10.A.40.44 - F.40.E.15) 108
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - End play (B.10.A.40.44 - F.40.E.10) 107
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Install (B.10.A.40.44 - F.10.A.15) 105
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Measure (B.10.A.40.44 - F.40.A.16) 103
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Preliminary test (B.10.A.40.44 - F.40.A.20) 98
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Remove (B.10.A.40.44 - F.10.A.10) 100
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Service limits (B.10.A.40.44 - D.20.A.20) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 363
Valve drive Camshaft - Special tools (B.10.A.40.44 - D.20.A.40) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Torque (B.10.A.40.44 - D.20.A.10) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Camshaft - Visual inspection (B.10.A.40.44 - F.40.A.10) 102
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Assemble (B.10.A.40.43 - F.10.A.20) 88
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Check (B.10.A.40.43 - F.40.A.11) 80
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Disassemble (B.10.A.40.43 - F.10.A.25) 84
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Install (B.10.A.40.43 - F.10.A.15) 89
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Measure (B.10.A.40.43 - F.40.A.16) 87
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Remove (B.10.A.40.43 - F.10.A.10) 82
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Service limits (B.10.A.40.43 - D.20.A.20) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Special tools (B.10.A.40.43 - D.20.A.40) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Torque (B.10.A.40.43 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Rocker assembly - Visual inspection (B.10.A.40.43 - F.40.A.10) 85
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Adjust (B.10.A.40.46 - F.45.A.01) 128
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Assemble (B.10.A.40.46 - F.10.A.20) 136
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Valve drive Valve assembly - Disassemble (B.10.A.40.46 - F.10.A.25) 130
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2377
MX305, 2388
MX215, MX245, MX275, STX280, 2377
MX305, 2388
Vibration damper - Service limits (B.10.A.68 - D.20.A.20) 46
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Vibration damper - Torque (B.10.A.68 - D.20.A.10) 46
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, STX280, 2377
MX305, 2388
Wiring harness - Component identification (B.10.A.88 - C.40.C.20) 68
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Wiring harness - Connect (B.10.A.88 - F.10.A.16) 328
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Wiring harness - Disconnect (B.10.A.88 - F.10.A.11) 327
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.10.A / 364
FUEL AND INJECTION SYSTEM - 20.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.20.A / 1
Contents
TECHNICAL DATA
FUEL AND INJECTION SYSTEM - General specification (B.20.A - D.40.A.10) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Service limits (B.20.A - D.20.A.20) 9

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve
Regulator valve High pressure - Torque (B.20.A.14.10 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Service limits (B.20.A.14.10 - D.20.A.20) 13

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Torque (B.20.A.14.30 - D.20.A.10) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Service limits (B.20.A.14.30 - D.20.A.20) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve
Relief valve - Torque (B.20.A.16 - D.20.A.10) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve - Service limits (B.20.A.16 - D.20.A.20) 16

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve - Special tools (B.20.A.16 - D.20.A.40) 17

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system

Fuel filter system Fuel filter - Torque (B.20.A.24.22 - D.20.A.10) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector
Fuel injector - Torque (B.20.A.29 - D.20.A.10) 20
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Service limits (B.20.A.29 - D.20.A.20) 21

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Special tools (B.20.A.29 - D.20.A.40) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail

High pressure common rail Gear pump - Torque (B.20.A.30.10 - D.20.A.10) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Service limits (B.20.A.30.10 - D.20.A.20) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Special tools (B.20.A.30.10 - D.20.A.40) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Torque (B.20.A.30.15 - D.20.A.10) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 2
High pressure common rail Pump head and housing - Service limits (B.20.A.30.15 - 29
D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Special tools (B.20.A.30.15 - 31
D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Torque (B.20.A.30.20 - D.20.A.10) 32

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Service limits (B.20.A.30.20 - D.20.A.20) 32

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Torque (B.20.A.30.25 - D.20.A.10) 33

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel transfer pump

Fuel transfer pump - Service limits (B.20.A.34 - D.20.A.20) 34
2388, 2377
Fuel transfer pump - Special tools (B.20.A.34 - D.20.A.40) 34

2388, 2377
Priming pump
Priming pump - Torque (B.20.A.35 - D.20.A.10) 35
MX215, MX245, MX275, MX305, STX280
Priming pump - Service limits (B.20.A.35 - D.20.A.20) 35

MX215, MX245, MX275, MX305, STX280
Priming pump - Special tools (B.20.A.35 - D.20.A.40) 35

MX215, MX245, MX275, MX305, STX280
Fuel line
Fuel line Low pressure - Torque (B.20.A.36.10 - D.20.A.10) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line High pressure - Torque (B.20.A.36.20 - D.20.A.10) 38

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Torque (B.20.A.36.30 - D.20.A.10) 39

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector
Fuel connector - Torque (B.20.A.37 - D.20.A.10) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Service limits (B.20.A.37 - D.20.A.20) 41

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Special tools (B.20.A.37 - D.20.A.40) 41

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Pressure sensor - Torque (B.20.A.95.81 - D.20.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Service limits (B.20.A.95.81 - D.20.A.20) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Torque (B.20.A.95.85 - D.20.A.10) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Service limits (B.20.A.95.85 - D.20.A.20) 43

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
FUEL AND INJECTION SYSTEM - Dynamic description (B.20.A - C.30.A.10) 44
MX215, MX245, MX275, MX305, STX280

2388, 2377
FUEL AND INJECTION SYSTEM - Static description (B.20.A - C.30.A.20) 66

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 3
FUEL AND INJECTION SYSTEM - Component identification (B.20.A - C.40.C.20) 68
MX215, MX245, MX275, MX305, STX280

2388, 2377
Check valve
Check valve - Dynamic description (B.20.A.11 - C.30.A.10) 71
MX215, MX245, MX275, MX305, STX280

2388, 2377
SERVICE
FUEL AND INJECTION SYSTEM - Air in fuel (B.20.A - F.40.C.20) 73
MX215, MX245, MX275, MX305, STX280

2388, 2377
FUEL AND INJECTION SYSTEM - Supply restriction (B.20.A - F.40.C.21) 75

MX215, MX245, MX275, MX305, STX280

2388, 2377
FUEL AND INJECTION SYSTEM - Return restriction (B.20.A - F.40.C.22) 79

MX215, MX245, MX275, MX305, STX280

2388, 2377
FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11) 83

MX215, MX245, MX275, MX305, STX280

2388, 2377
Regulator valve
Regulator valve High pressure - Remove (B.20.A.14.10 - F.10.A.10) 89
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10) 90

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Electrical test (B.20.A.14.10 - F.40.A.50) 91

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Install (B.20.A.14.10 - F.10.A.15) 92

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Remove (B.20.A.14.30 - F.10.A.10) 99

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Visual inspection (B.20.A.14.30 - F.40.A.10) 100

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Install (B.20.A.14.30 - F.10.A.15) 101

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve
Relief valve - Leakage test (B.20.A.16 - F.40.A.40) 102
MX215, MX245, MX275, MX305, STX280
Relief valve - Remove (B.20.A.16 - F.10.A.10) 107

MX215, MX245, MX275, MX305, STX280
Relief valve - Visual inspection (B.20.A.16 - F.40.A.10) 108

MX215, MX245, MX275, MX305, STX280
87372074 3 15/11/2005
B.20.A / 4
Relief valve - Install (B.20.A.16 - F.10.A.15) 109
MX215, MX245, MX275, MX305, STX280

2388, 2377

2388, 2377

2388, 2377

2388, 2377
Fuel filter system

Fuel filter system Pre-filter - Remove (B.20.A.24.10 - F.10.A.10) 115
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Pre-filter - Install (B.20.A.24.10 - F.10.A.15) 116

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Remove (B.20.A.24.22 - F.10.A.10) 117

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Visual inspection (B.20.A.24.22 - F.40.A.10) 119
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Install (B.20.A.24.22 - F.10.A.15) 120

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector
Fuel injector - Leakage test (B.20.A.29 - F.40.A.40) 122
MX215, MX245, MX275, MX305, STX280

2388, 2377
Fuel injector - Remove (B.20.A.29 - F.10.A.10) 136

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Electrical test (B.20.A.29 - F.40.A.50) 138

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Visual inspection (B.20.A.29 - F.40.A.10) 139

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Install (B.20.A.29 - F.10.A.15) 140

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Measure (B.20.A.29 - F.40.E.01) 145

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail

High pressure common rail Gear - Timing check (B.20.A.30.05 - F.40.B.12) 147
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Remove (B.20.A.30.05 - F.10.A.10) 149

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Visual inspection (B.20.A.30.05 - F.40.A.10) 150
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Install (B.20.A.30.05 - F.10.A.15) 152

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Pressure test (B.20.A.30.10 - F.40.C.30) 153
MX215, MX245, MX275, MX305, STX280
2388, 2377
High pressure common rail Gear pump - Check (B.20.A.30.10 - F.40.A.11) 157
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Remove (B.20.A.30.10 - F.10.A.10) 158
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Visual inspection (B.20.A.30.10 - F.40.A.10) 159
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 5
High pressure common rail Gear pump - Install (B.20.A.30.10 - F.10.A.15) 160
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Leakage test (B.20.A.30.15 - 162
F.40.A.40)
MX215, MX245, MX275, MX305, STX280
High pressure common rail Pump head and housing - Leakage test (B.20.A.30.15 - 167
F.40.A.40)
2388, 2377
High pressure common rail Pump head and housing - Remove (B.20.A.30.15 - 169
F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15 - 172
F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Install (B.20.A.30.15 - F.10.A.15) 174
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Disassemble (B.20.A.30.15 - 178
F.10.A.25)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15 - 181
F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Assemble (B.20.A.30.15 - 184
F.10.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Remove (B.20.A.30.20 - F.10.A.10) 187

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Visual inspection (B.20.A.30.20 - F.40.A.10) 188
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Install (B.20.A.30.20 - F.10.A.15) 189

MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Remove (B.20.A.30.25 - F.10.A.10) 191
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Visual inspection (B.20.A.30.25 - F.40.A.10) 193
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Install (B.20.A.30.25 - F.10.A.15) 194
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Disassemble (B.20.A.30.25 - F.10.A.25) 195
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Assemble (B.20.A.30.25 - F.10.A.20) 196
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel transfer pump

Fuel transfer pump - Pressure test (B.20.A.34 - F.40.C.30) 197
2388, 2377
Priming pump
Priming pump - Pressure test (B.20.A.35 - F.40.C.30) 199
MX215, MX245, MX275, MX305, STX280
Priming pump - Remove (B.20.A.35 - F.10.A.10) 201

MX215, MX245, MX275, MX305, STX280
Priming pump - Disassemble (B.20.A.35 - F.10.A.25) 203

MX215, MX245, MX275, MX305, STX280
Priming pump - Visual inspection (B.20.A.35 - F.40.A.10) 204

MX215, MX245, MX275, MX305, STX280
Priming pump - Assemble (B.20.A.35 - F.10.A.20) 206

MX215, MX245, MX275, MX305, STX280
87372074 3 15/11/2005
B.20.A / 6
Priming pump - Install (B.20.A.35 - F.10.A.15) 207
MX215, MX245, MX275, MX305, STX280
Fuel line
Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10) 209
MX215, MX245, MX275, MX305, STX280
Fuel line Low pressure - Visual inspection (B.20.A.36.10 - F.40.A.10) 211

MX215, MX245, MX275, MX305, STX280
Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15) 212

MX215, MX245, MX275, MX305, STX280

2388, 2377

2388, 2377

2388, 2377

MX215, MX245, MX275, MX305, STX280

MX215, MX245, MX275, MX305, STX280

MX215, MX245, MX275, MX305, STX280

2388, 2377

2388, 2377

2388, 2377
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10) 229

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10) 230

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15) 231

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Remove (B.20.A.36.30 - F.10.A.10) 235

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Visual inspection (B.20.A.36.30 - F.40.A.10) 237

2388, 2377
Fuel line Cooling plate - Install (B.20.A.36.30 - F.10.A.15) 238

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector
Fuel connector - Remove (B.20.A.37 - F.10.A.10) 241
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10) 242

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Install (B.20.A.37 - F.10.A.15) 244

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Pressure sensor - Preliminary test (B.20.A.95.81 - F.40.A.20) 245
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 7
Sensing system Pressure sensor - Remove (B.20.A.95.81 - F.10.A.10) 246
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Visual inspection (B.20.A.95.81 - F.40.A.10) 247

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Install (B.20.A.95.81 - F.10.A.15) 248

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Remove (B.20.A.95.85 - F.10.A.10) 249

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Visual inspection (B.20.A.95.85 - F.40.A.10) 250

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01) 251

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Install (B.20.A.95.85 - F.10.A.15) 252

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
FUEL AND INJECTION SYSTEM - Problem solving (B.20.A - G.40.A.30) 253
MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Testing (B.20.A - G.40.A.20) 254

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 8
POWER PRODUCTION - FUEL AND INJECTION SYSTEM
FUEL AND INJECTION SYSTEM - General specification (B.20.A -

D.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Maximum fuel return line pressure 254 mm Hg (10 in Hg)

Maximum fuel inlet restriction (gear pump inlet) 254 mm Hg (10 in Hg)
Maximum fuel inlet restriction – Dirty filter 152 mm Hg (6 in Hg)
Minimum gear pump pressure (during cranking) 69 kPa (10 psi)
Maximum filter pressure drop 138 kPa (20 psi)
Minimum priming pump pressure (gear pump inlet during 35 kPa (5 psi)
cranking)
Minimum engine cranking speed 150 RPM
FUEL AND INJECTION SYSTEM - Service limits (B.20.A - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air in fuel
FUEL AND INJECTION SYSTEM - Air in fuel (B.20.A - F.40.C.20)
Observe the fuel flow exiting the diagnostic fuel line while
the engine runs at idle.
A few bubbles exiting the line is acceptable.
A foamy appearance is an indication of an air leak, a severe

inlet restriction that causes cavitation or a system that is
NOT yet primed.
RCIL05CDC012AAA 1
3 15/11/2005
B.20.A / 9
Supply restriction
FUEL AND INJECTION SYSTEM - Supply restriction (B.20.A - F.40.C.21)
Maximum fuel inlet restriction (dirty filter) at the gear pump
inlet must be 304.8 mm Hg (10.0 in Hg).
RCPH05CDC121ABA 2
RCPH05CDC238ABA 3
Maximum fuel inlet restriction (dirty filter) at the 2 micron

filter outlet must be 203.2 mm Hg (8.0 in Hg).
RCPH05CDC116ABA 4
RCPH05CDC236ABA 5
3 15/11/2005
B.20.A / 10
Low pressure fuel line restriction

FUEL AND INJECTION SYSTEM - Return restriction (B.20.A - F.40.C.22)
Maximum fuel drain line pressure must be 254.0 mm Hg
(10 in Hg).
RCPH05CDC293ABA 6
RCPH05CDC298ABB 7
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
10 mm Compucheck® fitting– 3824842 (Cummins)

This 10 mm x 1.0 in O-ring fitting is used to attach test
equipment for fuel pressure or restriction. The fitting is
used at the test ports on the fuel filter head and the gear
pump.
RCSC05CDC153AAA 1
3 15/11/2005
B.20.A / 11
Orificed diagnostic fuel line – 3164621 (Cummins)

This 1.09 mm (0.043 in) orificed fuel line is used to
create rated flow through the low pressure fuel system
without the need to run the engine under load.
RCPH05CDC291ABA 2
Gauge adapter – Shop made

A gauge adapter can be constructed to measure
pressure or vacuum at any banjo connector on the
fuel return manifold for the low pressure fuel system.
Make the gauge adapter by drilling and tapping the hex
face of a 12 mm x 1.5 in banjo bolt. Drill and tap the
banjo bolt for a 0.125 in NPT pipe thread fitting and
connect the gauge, whether an analog gauge or digital
pressure/vacuum module.
RCSC05CDC169AAA 3

pressure/vacuum module can also be used to measure
pressure or vacuum in the fuel lines. The module shown
features ranges of 0 - 3447 kPa (0 - 500 psi) for pressure
and 0 - 760 mm Hg (0 - 29.99 in Hg) for vacuum.
RCPH05CDC612AAA 4
3 15/11/2005
B.20.A / 12
Regulator valve High pressure - Torque (B.20.A.14.10 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component Step N·m Identification lb-in

Pressure regulator valve cap 1 3 Nm 26.5 lb in
screws 2 6 Nm 53 lb in
RCPH05CDC046ABA 1

Pressure regulator valve housing 34 Nm 25 lb ft
cap screws
RCPH05CDC038ABA 2
3 15/11/2005
B.20.A / 13
Regulator valve High pressure - Service limits (B.20.A.14.10 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure regulator valve

Reference: Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10)
Reference: Regulator valve High pressure - Electrical test (B.20.A.14.10 - F.40.A.50)
Inspect the valve plunger through the four passage
windows. A shinny scratch free surface indicates the valve
is acceptable for reuse.
Any sign of scuffing, when accompanied by fault code 449,

indicates the valve needs to be replaced.
RCPH05CDC043ABA 1
A resistance reading between 1.5 - 5.0K ohms is acceptable,

when measured pin to pin on the pigtail connector.
RCPH05CDC041ABA 2
Regulator valve Injection return - Torque (B.20.A.14.30 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Injector return valve (banjo bolt) 24 Nm 18 lb ft
RCPH05CDC918AAA 1
3 15/11/2005
B.20.A / 14
Regulator valve Injection return - Service limits (B.20.A.14.30 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Injector return check valve

Reference: Regulator valve Injection return - Visual inspection (B.20.A.14.30 - F.40.A.10)
Inspect the valve for freedom of movement with an O-ring
pick. Replace if damaged.
RCPH05CDC911AAA 1
3 15/11/2005
B.20.A / 15
Relief valve - Torque (B.20.A.16 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Pressure relief valve 100 Nm 74 lb ft
RCPH05CDC318ABA 1
Relief valve - Service limits (B.20.A.16 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve leakage test

Relief valve - Leakage test (B.20.A.16 - F.40.A.40)
Engine at idle (without INSITE® test active):
Less than 30 drops per minute MUST drain from the
pressure relief valve.
Engine at idle with INSITE® high pressure leak test active:

RCPH05CDC306ABA 1
RCPH05CDC242ABB 2
3 15/11/2005
B.20.A / 16
Reference: Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)

Replace the valve (and fuel rail) if the high pressure sealing
surface on the valve and the fuel rail are damaged.
RCPH05CDC893AAB 3
Relief valve - Special tools (B.20.A.16 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Return fuel test tool – 3164618 (Cummins)

This connector and hose assembly is used to test return
flow from injectors, the pressure relief valve and fuel
pump head when a drain manifold is present.
RCPH05CDC290ABA 1
Injection pump test fitting – 380002498

This 12 mm x 1.5 in fitting is used to isolate return fuel
flow at the pump head on engines where a common
return line is shared by the injectors, relief valve and
injection pump.
RCPH05CDC161ABA 2
3 15/11/2005
B.20.A / 17
Relief valve test fitting – 380002500

flow at the relief valve on engines where a common
injection pump.
RCPH05CDC161ABA 3
3 15/11/2005
B.20.A / 18
Fuel filter system Fuel filter - Torque (B.20.A.24.22 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Filter head cap screws 43 Nm 32 lb ft
RCPH05CDC352AAA 1
3 15/11/2005
B.20.A / 19
Fuel injector - Torque (B.20.A.29 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector and fuel connector torque sequence

Component Step N·m Identification lb-ft/lb-in
Injector clamp cap 1 Install loosely. Install loosely.
screws
RCPH05CDC216AAA 1
Fuel connector 2 13.6 Nm 10 lb ft

retaining nut
RCPH05CDC218AAA 2
3 15/11/2005
B.20.A / 20
Fuel injector and fuel connector torque sequence

Component Step N·m Identification lb-ft/lb-in
Injector clamp cap 3 10 Nm 89 lb in
screws
RCPH05CDC219AAA 3
Fuel connector 4 41 Nm 31 lb ft
retaining nut
RCPH05CDC218AAA 4

Injector isolation tool – 3164325 43 Nm 32 lb ft
(CUMMINS)
RCPH05CDC233ABA 5
3 15/11/2005
B.20.A / 21
Fuel injector - Service limits (B.20.A.29 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector resistance test

Reference: Fuel injector - Electrical test (B.20.A.29 - F.40.A.50)
Replace the injector if resistance measured through the
solenoid is NOT less than 0.5K ohms.
RCPH05CDC283AAA 1
Injector fuel return leakage test

Fuel injector - Leakage test (B.20.A.29 - F.40.A.40)
Engine will start:
Maximum fuel collected during 45 seconds MUST be 300
cm³ (10.1 US fl oz).
Engine will NOT start:

Maximum fuel collected during 30 seconds of cranking
MUST be 100 cm³ (3.38 US fl oz).
RCPH05CDC150ABA 2
RCPH05CDC292ABB 3
3 15/11/2005
B.20.A / 22
Fuel injector - Special tools (B.20.A.29 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Return fuel test connector – 3164618 (Cummins)

flow from the injectors, the pressure relief valve and the
fuel pump head when a drain manifold is present.
RCPH05CDC290ABA 1

injection pump.
RCPH05CDC161ABA 2

injection pump.
RCPH05CDC161ABA 3
3 15/11/2005
B.20.A / 23
Injector isolation tool – 3164325 (Cummins)

This tool is used to isolate flow from individual injectors at
the fuel rail to locate a problem injector or fuel connector.
RCPH05CDC288ABA 4
3 15/11/2005
B.20.A / 24
High pressure common rail Gear pump - Torque (B.20.A.30.10 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Gear pump cap screws 34 Nm 25 lb ft
RCPH05CDC004ABA 1
3 15/11/2005
B.20.A / 25
High pressure common rail Gear pump - Service limits (B.20.A.30.10

- D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Gear pump pressure test

Reference: High pressure common rail Gear pump - Pressure test (B.20.A.30.10 - F.40.C.30)
Minimum gear pump pressure while cranking MUST be 69
kPa (10 psi).
RCPH05CDC109ABA 1
RCPH05CDC234ABA 2
Engine will start:

Minimum gear pump pressure MUST be 483 kPa (70 psi)
with the engine running at high idle.
RCPH05CDC116ABA 3
RCPH05CDC236ABA 4
3 15/11/2005
B.20.A / 26
High pressure common rail Gear pump - Special tools (B.20.A.30.10

- D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Compucheck® fitting – 3824842 (Cummins)

equipment for fuel pressure or restriction testing.
RCSC05CDC153AAA 1
Orificed diagnostic fuel line – 3164621 (Cummins)

This 1.09 mm (0.043 in) orificed fuel line is used to
create rated flow through the low pressure fuel system
without the need to run the engine under load.
RCPH05CDC291ABA 2

pressure or vacuum in the fuel system. The module
shown features ranges of 0 - 3447 kPa (0 - 500 psi)
for pressure and 0 - 760 mm Hg (0 - 29.99 in Hg) for
vacuum.
RCPH05CDC612AAA 3
3 15/11/2005
B.20.A / 27
High pressure common rail Pump head and housing - Torque

(B.20.A.30.15 - D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Pump mounting nuts 44 Nm 32 lb ft
RCPH05CDC060ABA 1
Pump head cap screws 68 Nm 50 lb ft
RCPH05CDC037ABA 2
3 15/11/2005
B.20.A / 28

Drive gear nut 180 Nm 132 lb ft
RCPH05CDC063ABA 3
Pump support cap screws 65 Nm 48 lb ft
RCPH05CDC062ABA 4
3 15/11/2005
B.20.A / 29
High pressure common rail Pump head and housing - Service limits
(B.20.A.30.15 - D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pump head leakage test

Reference: High pressure common rail Pump head and housing - Leakage test (B.20.A.30.15 - F.40.A.40)
If MORE THAN 200 cm³ (7.0 US fl oz) of fuel is collected
in 30 seconds of cranking, the pump head has failed and
MUST be replaced.
Engine will start:

If 300 cm³ (10 US fl oz) of fuel is collected in less than 30
seconds, the pump head has failed and MUST be replaced.
RCPH05CDC152ABA 1
RCPH05CDC241ABB 2
Pump camshaft, guide pins and tappet pin groove

Reference: High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15 -
F.40.A.10)
Replace the pump:
• if excessive pitting on the lobes of the camshaft is
present,
• if more than 25 % guide pin wear is present,
• if more than 25 % groove wear is present on the tappet
guide pin grooves.
RCPH05CDC028ABB 3
3 15/11/2005
B.20.A / 30
Pump housing roller tappet

F.40.A.10)
Replace the tappet:
• if excessive pitting on the rollers is present.
RCPH05CDC031ABB 4
Pump head plungers

F.40.A.10)
Replace the pump head:
• if scoring or scratches are present that can be felt on
the plungers.
RCPH05CDC065ABB 5
High pressure common rail Pump head and housing - Special tools
(B.20.A.30.15 - D.20.A.40)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Return fuel test connector – 3164618 (Cummins)

flow from the injectors, the pressure relief valve and the
fuel pump head when a drain manifold is present.
RCPH05CDC290ABA 1
3 15/11/2005
B.20.A / 31

injection pump.
RCPH05CDC161ABA 2

injection pump.
RCPH05CDC161ABA 3
High pressure common rail Outlet - Torque (B.20.A.30.20 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component Step N·m Identification lb·in

Outlet fitting 1 5.6 Nm 50 lb in
RCPH05CDC015ABA 1
3 15/11/2005
B.20.A / 32
High pressure common rail Outlet - Service limits (B.20.A.30.20 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pump high pressure outlet

Reference: High pressure common rail Outlet - Visual inspection (B.20.A.30.20 - F.40.A.10)
Replace the outlet:
• if the crown on the seal surface end of the outlet is
damaged or severely flattened.
RCPH05CDC008ABA 1
High pressure common rail Common rail - Torque (B.20.A.30.25 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component N·m Identification lb·ft

Fuel rail cap screws 43 Nm 32 lb ft
RCPH05CDC898AAA 1
3 15/11/2005
B.20.A / 33
Fuel transfer pump - Service limits (B.20.A.34 - D.20.A.20)

2388, 2377
Fuel transfer pump pressure test

Reference: Fuel transfer pump - Pressure test (B.20.A.34 - F.40.C.30)
Minimum pressure must be 34 kPa (5 psi) OR there MUST
be sufficient fuel flow to prime the gear pump.
RCPH05CDC238ABA 1
Fuel transfer pump - Special tools (B.20.A.34 - D.20.A.40)

2388, 2377
Compucheck® fitting – 3824842 (Cummins)

equipment for fuel pressure or restriction testing.
RCSC05CDC153AAA 1

pressure or vacuum in the fuel system. The module
vacuum.
RCPH05CDC612AAA 2
3 15/11/2005
B.20.A / 34
Priming pump - Torque (B.20.A.35 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280

Priming pump cap screws 10 Nm 89 lb in
RCPH05CDC151AAA 1
Priming pump - Service limits (B.20.A.35 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280
Priming pump pressure – Measured at gear pump test port

Reference: Priming pump - Pressure test (B.20.A.35 - F.40.C.30)
Minimum 34 kPa 5 psi
RCPH05CDC121ABA 1
Priming pump - Special tools (B.20.A.35 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280

fuel pressure or restriction. The module shown features
ranges of 0 - 3447 kPa (0 - 500 psi) for pressure and 0 -
760 mm Hg (0 - 29.99 in Hg) for vacuum.
RCPH05CDC612AAA 1
3 15/11/2005
B.20.A / 35
Compucheck® 10 mm fitting – 3824842 (Cummins)

equipment to the gear pump to measure fuel pressure
from the priming pump.
RCSC05CDC153AAA 2
3 15/11/2005
B.20.A / 36
Fuel line Low pressure - Torque (B.20.A.36.10 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

12 mm banjo bolt 24 Nm 18 lb ft
RCPH05CDC918AAA 1
RCPH05CDC920AAA 2
14 mm banjo bolt 34 Nm 25 lb ft
RCPH05CDC919AAA 3
3 15/11/2005
B.20.A / 37

Quick disconnect fuel line bracket 24 Nm 18 lb ft
cap screw
RCPH05CDC219ABA 4
Fuel line clamping plate cap screw 24 Nm 18 lb ft
RCPH05CDC219ABA 5
3 15/11/2005
B.20.A / 38
Fuel line High pressure - Torque (B.20.A.36.20 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Fuel rail supply line 38 Nm 28 lb ft
RCPH05CDC922AAA 1
Injector connector supply line 38 Nm 28 lb ft
RCPH05CDC901AAA 2
RCPH05CDC904AAA 3
3 15/11/2005
B.20.A / 39
Fuel line Cooling plate - Torque (B.20.A.36.30 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Plate cap screws 25 Nm 18 lb ft
RCPH05CDC172ABA 1
3 15/11/2005
B.20.A / 40
Fuel connector - Torque (B.20.A.37 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Fuel connector nut 41 Nm 31 lb ft
RCPH05CDC218AAA 1
Fuel connector - Service limits (B.20.A.37 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector
Reference: Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10)
Replace the fuel connector:
• if the injector is being replaced,
• if small lines or cuts are eroded into the seating surface
of the outlet, indicating a high pressure fuel leak,
• if burrs or deformation are present around the inlet or
outlet of the connector.
RCPH05CDC284ABB 1
Fuel connector - Special tools (B.20.A.37 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector remover – 3154025 (Cummins)

This tool is used to remove the fuel connector from the
cylinder head on high pressure common rail engines.
RCPH05CDC187ABA 1
3 15/11/2005
B.20.A / 41
Sensing system Pressure sensor - Torque (B.20.A.95.81 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Fuel rail pressure sensor 50 Nm 70 lb ft
RCPH05CDC359ABA 1
Sensing system Pressure sensor - Service limits (B.20.A.95.81 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel rail pressure sensor

Pressure Voltage (VDC)
bar psi
0 0 0.50
400 5801 1.39
700 10153 2.06
1000 14504 2.72
1400 20305 3.61
1800 26107 4.5

Reference: Sensing system Pressure sensor - Preliminary test (B.20.A.95.81 - F.40.A.20)
Use INSITE® to monitor the fuel rail pressure sensor
(measured) with the engine running.
The measured value from the fuel rail pressure sensor

MUST be less than 30 bar (435 psi).
If the measured value is greater than 30 bar (435 psi),

replace the pressure sensor.
RCPH05CDC358ABA 1
3 15/11/2005
B.20.A / 42
Sensing system Water sensor - Torque (B.20.A.95.85 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Water in fuel sensor 4 Nm 35 lb in
RCPH05CDC363ABA 1
Sensing system Water sensor - Service limits (B.20.A.95.85 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water in fuel sensor

Reference: Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01)
Use a digital voltmeter to measure resistance between the
pins in the sensor connector.
If resistance is less than 100K ohms, replace the fuel

pre-filter.
RCPH05CDC361ABA 1
NOTE: The sensor is integrated into the fuel pre-filter and is not serviced separately. The sensor is replaced
whenever the pre-filter is replaced.
3 15/11/2005
B.20.A / 43
FUEL AND INJECTION SYSTEM - Dynamic description (B.20.A -

C.30.A.10)
MX215, MX245, MX275, MX305, STX280
Fuel drawn from the tank flows to the suction side filter.
This filter is a 10 micron filter with a water in fuel sensor.
RCPH05CDC089AAA 1
Fuel leaves the suction filter and flows to the inlet of the
ECM (engine control module) cooling plate (1).
A priming pump, located behind the cooling plate and

controlled by the ECM, runs for approximately 30
seconds whenever the keyswitch is turned to the ON
or START position. The fuel output from the electric
priming pump ensures that the gear pump is primed so
the engine can start quickly.
Fuel flows from the upper plate inlet through the pump
and returns through the lower plate outlet.
RCPH05CDC090AAA 2
RCPH05CDC091AAA 3
3 15/11/2005
B.20.A / 44
A check valve (1) incorporated into the outlet fitting of

the ECM cooling plate ensures that the output from the
priming pump goes to the gear pump and not through
the ECM cooling plate.
RCPH05CDC092AAA 4
When the gear pump speed reaches sufficient levels, it

pulls fuel directly through the ECM cooling plate and
the open check valve that is installed in parallel with the
priming pump.
RCPH05CDC094AAA 5
Fuel enters the gear pump (1) where it is pressurized to

a minimum of 69 kPa (10 psi) at cranking speed and
483 kPa (70 psi) with the engine under load.
RCPH05CDC095AAA 6
3 15/11/2005
B.20.A / 45
Before the fuel leaves the gear pump it passes a

pressure regulator valve (1). When fuel pressure is
above 1207 kPa (175 psi), it acts against spring tension
to open the valve. The fuel is returned to the inlet side
(2) of the fuel pump.
RCPH05CDC097AAA 7
The output from the gear pump flows to the pressure

side fuel filter. This filter has a 2 micron rating.
RCPH05CDC098AAA 8
Fuel from the filter (1) returns to the high pressure

regulator housing (2).
RCPH05CDC100AAA 9
3 15/11/2005
B.20.A / 46
An air bleed orifice (1) in the housing allows a small

amount of fuel to flow to the drain. Any air in the fuel is
pushed through this orifice and prevented from entering
the high pressure pump.
RCPH05CDC101AAA 10
The fuel pump regulator (1) receives a pulse width

modulated signal from the ECM (engine control module)
(2).
RCPH05CDC102AAA 11
The fuel pump regulator (1) controls the amount of fuel

metered into the high pressure pumping chambers (2).
Controlling the fuel flow into the high pressure pump
prevents pressurizing more fuel than is needed.
RCPH05CDC103AAA 12
3 15/11/2005
B.20.A / 47
This regulator is a normally open valve. Current is

increased to reduce flow to the pump, thus lowering fuel
rail pressure.
RCPH05CDC104AAA 13
In the high pressure pump, the fuel is pressurized by

the cam driven barrel and plunger assemblies (1).
These assemblies create the high pressure needed for
injection.
RCPH05CDC106AAA 14
Inlet (1) and outlet (2) check valves act to develop and
hold fuel rail pressure.
RCPH05CDC107AAA 15
3 15/11/2005
B.20.A / 48
The inlet check valve holds fuel inside the pumping

chamber so it can be pressurized.
RCPH05CDC108AAA 16
The outlet check valve holds the fuel rail pressure

inside the rail so it does not leak back into the pumping
chamber.
RCPH05CDC109AAA 17
A failure of a single pumping chamber results in a

pressure imbalance and possibly low rail pressure. The
ECM can detect this condition and will register a fault
code.
Fuel that leaks past the barrel and plunger is collected in

a drilling (1) in the pump head and routed to the air bleed
circuit (2) for return to the fuel tank via the fuel cooler.
RCPH05CDC110AAA 18
3 15/11/2005
B.20.A / 49
The pressurized fuel leaves the high pressure pump and

flows through piping to the fuel rail (1). The rail and the
high pressure fuel lines serve as an accumulator, storing
the fuel under pressure until it is needed for injection.
RCPH05CDC111AAA 19
Because the actuator is a normally open valve, any

circuit problem such as an inadvertently disconnected
actuator wire will cause the actuator to open. This
results in maximum flow to the high pressure pump,
leading to the opening of the fuel rail pressure relief
valve (1). This valve protects the rail, lines and injectors
from any malfunction causing over-pressurization.
When the fuel in the rail exceeds the valve setting, the
valve opens and fuel is returned to drain.
The ECM can detect this condition and will register a

fault code.
RCPH05CDC114AAA 20
The fuel rail pressure relief valve is a two stage valve.

When closed, only a small area is exposed to the fuel
in the rail. This makes the valve a fast acting valve that
opens at approximately 1800 bar (26100 psi).
RCPH05CDC112AAA 21
3 15/11/2005
B.20.A / 50
Once open, the outer plunger moves to its stop, and a

larger area is exposed to the high pressure fuel. This
causes the inner plunger to open and rail pressure drops
to 1000 bar (14500 psi). After the fuel rail pressure
relief valve opens, rail pressure must approach 0 bar
(0 psi) to close the valve.
Fuel released by the relief valve is piped to the fuel tank

(via the fuel cooler) on a common return line shared with
the pump head.
RCPH05CDC113AAA 22
RCSC05CDC001ACA 23
The fuel rail is connected to each of the injectors by a high pressure line and a high pressure connector.
3 15/11/2005
B.20.A / 51
Edge filters in the high pressure connectors (1) collect

large particle debris. If an injector is replaced, a new
high pressure connector must be installed.
RCPH05CDC272ABA 24
At the injector, fuel flows through the injector inlet

passage (1), pressurizing the injector nozzle (2) and the
control chamber (3) above the injector plunger (4).
RCPH05CDC521AAA 25
RCPH05CDC522AAA 26
Injection begins when the ECM energizes the coil and

allows the valve ball to lift off of its seat. This allows fuel
to flow out of the control chamber to drain, reducing the
pressure in the chamber. The reduced pressure in the
control chamber above the plunger allows the needle to
lift off of its seat and high pressure fuel to flow into the
cylinder from the nozzle.
RCPH05CDC523AAA 27
3 15/11/2005
B.20.A / 52
Since the drain passage is slightly larger than the supply

passage, the fuel pressure above the control plunger
does not build as long as the valve ball is off of its seat.
RCPH05CDC524AAA 28
To end injection, the ECM deenergizes the coil which

seats the valve ball. The pressure above the control
chamber and the force of the spring cause the needle
to seat in nozzle and end injection.
RCPH05CDC525AAA 29
Return fuel from the injector flows through a drain line

check valve (1) back to tank on the common fuel return
piping, shared with the relief valve and the pump head.
RCPH05CDC117AAA 30
3 15/11/2005
B.20.A / 53
The injector drain line check valve is installed in the

banjo bolt at the rear of the head. This check valve
maintains 0.7 bar (10 psi) back pressure on the injector
bypass flow.
RCPH05CDC119AAA 31
The drain line routes return flow from the injectors, fuel
rail and fuel pump head to the fuel cooler. From the
cooler, fuel returns to tank.
3 15/11/2005
B.20.A / 54
FUEL AND INJECTION SYSTEM - Dynamic description (B.20.A -

C.30.A.10)
2388, 2377
Fuel drawn from the tank flows to the suction side filter
(1). This filter is a 10 micron filter with a water in fuel
sensor.
Fuel leaves the suction filter and flows to the fuel transfer
pump (2). The pump runs continuously whenever the
keyswitch is in the ON or START positions to transfer
fuel from the tank to the gear pump.
During the engine starting sequence, the pump runs

for approximately 30 seconds before the keyswitch is
moved to the START position. This primes the gear
pump so the engine can start quickly.
RCPH05CDC813AAA 1
Fuel leaves the fuel transfer pump and flows to the inlet
of the ECM (engine control module) cooling plate (1).
Fuel flows from the upper plate inlet through the plate
and returns through the lower plate outlet.
RCPH05CDC256ABA 2
A check valve (1) incorporated into the outlet fitting

of the ECM cooling plate prevents fuel from flowing
backward through the circuit.
When the gear pump speed reaches sufficient levels, it

pulls fuel directly through the ECM cooling plate.
(The pump shown in the background is not present in

the combine fuel system.)
RCPH05CDC258ABA 3
3 15/11/2005
B.20.A / 55
Fuel enters the gear pump (1) where it is pressurized to

a minimum of 69 kPa (10 psi) at cranking speed and
483 kPa (70 psi) with the engine under load.
RCPH05CDC259ABA 4
Before the fuel leaves the gear pump it passes a

pressure regulator valve (1). When fuel pressure is
above 1207 kPa (175 psi), it acts against spring tension
to open the valve. The fuel is returned to the inlet side
(2) of the fuel pump.
RCPH05CDC097AAA 5
The output from the gear pump (1) flows to the pressure
side fuel filter (2). This filter has a 2 micron rating.
RCPH05CDC261ABA 6
3 15/11/2005
B.20.A / 56
Fuel from the filter (1) returns to the high pressure

regulator housing (2).
RCPH05CDC100AAA 7
An air bleed orifice (1) in the housing allows a small

amount of fuel to flow to the drain. Any air in the fuel is
pushed through this orifice and prevented from entering
the high pressure pump.
RCPH05CDC101AAA 8
The fuel pump regulator (1) receives a pulse width

modulated signal from the ECM (engine control module)
(2).
RCPH05CDC102AAA 9
3 15/11/2005
B.20.A / 57
The fuel pump regulator (1) controls the amount of fuel

metered into the high pressure pumping chambers (2).
Controlling the fuel flow into the high pressure pump
prevents pressurizing more fuel than is needed.
RCPH05CDC103AAA 10
This regulator is a normally open valve. Current is

increased to reduce flow to the pump, thus lowering fuel
rail pressure.
RCPH05CDC104AAA 11
In the high pressure pump, the fuel is pressurized by

the cam driven barrel and plunger assemblies (1).
These assemblies create the high pressure needed for
injection.
RCPH05CDC106AAA 12
3 15/11/2005
B.20.A / 58
Inlet (1) and outlet (2) check valves act to develop and
hold fuel rail pressure.
RCPH05CDC107AAA 13
The inlet check valve holds fuel inside the pumping

chamber so it can be pressurized.
RCPH05CDC108AAA 14
The outlet check valve holds the fuel rail pressure

inside the rail so it does not leak back into the pumping
chamber.
RCPH05CDC109AAA 15
3 15/11/2005
B.20.A / 59
A failure of a single pumping chamber results in a

pressure imbalance and possibly low rail pressure. The
ECM can detect this condition and will register a fault
code.
Fuel that leaks past the barrel and plunger is collected

in a drilling (1) in the pump head and routed to the air
bleed circuit (2) for return to the fuel tank. Bypassed fuel
leaves the pump head and is piped to the low pressure
return manifold on the rear left hand side of the engine.
RCPH05CDC110AAA 16
The pressurized fuel leaves the high pressure pump and

flows through piping to the fuel rail (1). The rail and the
high pressure fuel lines serve as an accumulator, storing
the fuel under pressure until it is needed for injection.
RCPH05CDC267ABA 17
Because the actuator is a normally open valve, any

circuit problem such as an inadvertently disconnected
actuator wire will cause the actuator to open. This
results in maximum flow to the high pressure pump,
leading to the opening of the fuel rail pressure relief
valve (1). This valve protects the rail, lines and injectors
from any malfunction causing over-pressurization.
When the fuel in the rail exceeds the valve setting, the
valve opens and fuel is returned to drain.
The ECM can detect this condition and will register a

fault code.
RCPH05CDC114AAA 18
3 15/11/2005
B.20.A / 60
The fuel rail pressure relief valve is a two stage valve.

When closed, only a small area is exposed to the fuel
in the rail. This makes the valve a fast acting valve that
opens at approximately 1800 bar (26100 psi).
RCPH05CDC112AAA 19
Once open, the outer plunger moves to its stop, and a

larger area is exposed to the high pressure fuel. This
causes the inner plunger to open and rail pressure drops
to 1000 bar (14500 psi). After the fuel rail pressure
relief valve opens, rail pressure must approach 0 bar
(0 psi) to close the valve.
Fuel released by the relief valve is piped to the fuel

return manifold on the rear left hand side of the engine.
RCPH05CDC113AAA 20
3 15/11/2005
B.20.A / 61
The fuel rail is connected to each of the injectors by a

high pressure line and a high pressure connector (1).
Edge filters in the high pressure connectors collect large

particle debris. If an injector is replaced, a new high
pressure connector must be installed.
RCPH05CDC271ABA 21
RCPH05CDC272ABA 22
3 15/11/2005
B.20.A / 62
At the injector, fuel flows through the injector inlet

passage (1), pressurizing the injector nozzle (2) and the
control chamber (3) above the injector plunger (4).
RCPH05CDC521AAA 23
RCPH05CDC522AAA 24
Injection begins when the ECM energizes the coil and

allows the valve ball to lift off of its seat. This allows fuel
to flow out of the control chamber to drain, reducing the
pressure in the chamber. The reduced pressure in the
control chamber above the plunger allows the needle to
lift off of its seat and high pressure fuel to flow into the
cylinder from the nozzle.
RCPH05CDC523AAA 25
Since the drain passage is slightly larger than the supply

passage, the fuel pressure above the control plunger
does not build as long as the valve ball is off of its seat.
RCPH05CDC524AAA 26
3 15/11/2005
B.20.A / 63
To end injection, the ECM deenergizes the coil which

seats the valve ball. The pressure above the control
chamber and the force of the spring causes the needle
to seat in nozzle and end injection.
RCPH05CDC525AAA 27
Fuel flowing out the return from the injector flows back
to the fuel drain block to the drain line check valve (1).
RCPH05CDC273ABA 28
3 15/11/2005
B.20.A / 64
The drain line check valve is installed in the banjo bolt at

the rear of the head. This check valve maintains 0.7 bar
(10 psi) back pressure on the injector bypass flow.
Fuel from the injectors is piped to the return manifold on

the rear left hand side of the engine.
RCPH05CDC119AAA 29
The drain lines route drain fuel from the injectors, fuel
rail and fuel pump to the fuel cooler. From the cooler,
fuel returns to tank.
RCIL05CDC009AAA 30
3 15/11/2005
B.20.A / 65
FUEL AND INJECTION SYSTEM - Static description (B.20.A -

C.30.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Excessive fuel consumption

Excessive fuel consumption is difficult to diagnose and correct because of the potential number of causes. These
factors can cause or contribute to poor fuel economy:
• Engine factors
• Vehicle factors and specifications
• Environmental factors
• Driving technique and operating practices
• Fuel system factors
• Low power or driveability concerns
Before troubleshooting, determine the exact complaint. Is the complaint base based on a real problem or a
perceived problem (fuel consumption does not meet operator’s expectations)? Consider these factors when
troubleshooting fuel consumption complaints:
• Low power/driveability problem: An operator will change driving style to compensate for a low power/driveability
problem. The operator may (a) shift to a higher engine rpm or (b) run on the droop curve in a lower gear
instead of upshifting to drive at partial-throttle conditions. These changes increase fuel consumption.
• Driving technique and operating practices: Increasing field operating speed increases fuel consumption.
• Environmental and seasonal weather changes: Seasonal changes and weather conditions can increase or
decrease fuel consumption by as much as 0.4 - 0.6 km/L (1.0 - 1.5 mpg).
• Excessive idling time: Idling the engine can use from 1.9 - 5.7 L/hour (0.5 - 1.5 US gal/hour), depending on
the engine idle speed.
• Change of terrain or soil type: Hilly terrain versus flat terrain and the type of soil worked can increase
or decrease fuel consumption.
• Vehicle or implement configuration: Changing an implement or vehicle configuration – adding or removing
accessories – can change both drag and wind resistance and influence fuel consumption.
• Rolling resistance: Changing type of tire and tread design can increase or decrease rolling resistance, and
thereby increase or decrease fuel consumption.
• Added accessories/functions: Two identical vehicles with the same fuel tank capacity will consume different
quantities of fuel if one is operated with a single accessory engaged and the other is not.
The Fuel Consumption – Customer Complaint form offers a valuable list of questions for determining the cause of
the problem.
3 15/11/2005
B.20.A / 66
Fuel Consumption – Customer Complaint Form

Name/Customer:
What fuel mileage is expected? ____________ Expected kpl (mpg)
What are the expectations based on? ______ Original mileage
______ Other vehicles on site
______ Competitive engines
______ Previously owned engine/vehicle
______ Expectations only
When did the problem occur? ______ Since new
______ Suddenly
______ Gradually
Did the problem start after a repair? ______ Yes ______ No
If yes, what was repaired and when?
Is the vehicle also experiencing a ______ Yes ______ No

driveability issue (low power or poor
acceleration/response)?
Is the problem seasonal? ______ Yes ______ No
Weather conditions during fuel ______ Rain
consumption check? ______ Snow
______ Wind
______ Hot temperatures
______ Cold temperatures
How is the fuel mileage measured? ______ Tank
______ Work session
______ Vehicle hours
______ Month
______ Year
______ Hectares/Acres
Are accurate records kept of fuel ______ Yes ______ No
added?
Is the workload different between the ______ Yes ______ No
compared vehicles?
Is the load (gross weight) different ______ Gross vehicle weight
between the compared vehicles? ______ Heavier
______ Lighter
What is the altitude during operation? ______ Below 3048 m (10,000 ft)
______ Above 3048 m (10,000 ft)
How much vehicle time is spent idling? ______ Hours/day
Is driving technique or operating ______ Yes ______ No
practices affecting fuel economy?
• High operating speed: ____________ kph (mph)
• Operate at rated speed or above ____________ rpm
• Incorrect shift rpm: _________ Shift rpm, _________ Torque peak
• Compensating for low power: ______ Yes ______ No
If, after filling out this form, vehicle factors, environmental factors or driving technique are not the indicated cause of
the complaint, go to the fuel consumption excessive troubleshooting tree.
3 15/11/2005
B.20.A / 67
FUEL AND INJECTION SYSTEM - Component identification (B.20.A

- C.40.C.20)
MX215, MX245, MX275, MX305, STX280
RCPH05CDC004GAA 1
Left hand engine view
A. Fuel pressure regulator valve H. Pressure relief valve

B. Low pressure return to fuel cooler J. ECM cooling plate (located behind the ECM)
C. Regulator valve housing K. Priming pump (located behind the cooling plate)
D. High pressure connector L. 2 micron final fuel filter
E. High pressure injection pump M. Pre-filter (water in fuel)
F. Gear pump N. Fuel supply from tank
G. Fuel pressure sensor O. Injector low pressure return
P. Common high pressure fuel rail
3 15/11/2005
B.20.A / 68
FUEL AND INJECTION SYSTEM - Component identification (B.20.A

- C.40.C.20)
2388, 2377
RCIL05CDC013AAA 1
Left hand engine side
A. High pressure fuel regulator valve H. Fuel supply manifold

B. High pressure connector J. Fuel supply from tank
C. Regulator valve housing K. Fuel return to fuel cooler
D. High pressure injection pump L. Fuel return manifold
E. Gear pump M. High pressure common fuel rail
F. ECM cooling plate (located under the ECM) N. Pressure relief valve
G. 2 micron final fuel filter O. Fuel pressure sensor
3 15/11/2005
B.20.A / 69
P. Fuel transfer pump
Q. Fuel pre-filter (water in fuel)
RCPH05CDC813AAA 2
3 15/11/2005
B.20.A / 70
Check valve - Dynamic description (B.20.A.11 - C.30.A.10)

MX215, MX245, MX275, MX305, STX280
A priming pump is mounted on the

back of the ECM cooling plate.
A check valve in the cooling plate

insures that fuel flows in the direction
required for the gear pump.
During the 30 seconds when the

priming pump is operating, the check
valve is closed.
Once the engine is started, the check

valve opens under vacuum created
RCPH05CDC148AAA 1
by the gear pump. High vacuum
measured between the priming pump
and the gear pump may indicate that
the check valve is plugged.
See Priming pump - Pressure test

(B.20.A.35 - F.40.C.30) to test for
high vacuum.
See Fuel line Cooling plate -

Remove (B.20.A.36.30 - F.10.A.10)
to remove the cooling plate and
inspect the check valve.
RCPH05CDC155AAA 2
3 15/11/2005
B.20.A / 71
Check valve - Dynamic description (B.20.A.11 - C.30.A.10)

2388, 2377
A check valve in the cooling plate

insures that fuel flows in the direction
required from the fuel transfer pump
to the gear pump.
With the engine running, the check

valve opens under vacuum created
by the gear pump. High vacuum
measured between the transfer pump
and the gear pump may indicate that
the check valve is plugged.
See Priming pump - Pressure test

RCPH05CDC181ABA 1
(B.20.A.35 - F.40.C.30) to check for
high vacuum.
See Fuel line Cooling plate -

Remove (B.20.A.36.30 - F.10.A.10)
to remove the cooling plate and
inspect the check valve.
RCPH05CDC155AAA 2
3 15/11/2005
B.20.A / 72

MX215, MX245, MX275, MX305, STX280
NOTE: A symptom of air-in-fuel is an audible surge from fuel system pressure fluctuations due to air in the fuel
supply. The following test simulates rated fuel flow through the system so that air in fuel problems may be diagnosed.
1. Install a 10 mm Compucheck® fitting (A) at the inlet
to the 2 micron fuel filter; this is special tool 3824842
(CUMMINS).
Connect the 1.09 mm (0.043 in) diagnostic fuel

line (B) to the fitting; this is special tool 3164621
(CUMMINS).
RCPH05CDC119ABA 1
2. Route the diagnostic fuel line to a suitable container.

NOTE: A 19 L (5 US gal) bucket is recommended.
3. Start the engine and switch from idle to high idle
several times to purge the air introduced while
installing the diagnostic fuel line.
4. Observe the fuel flow exiting the diagnostic fuel line
while the engine runs at idle.
A foamy appearance is an indication of an air leak,

a severe inlet restriction that causes cavitation or a
system that is NOT yet primed.
RCIL05CDC012AAA 2
5. If fuel inlet restriction is NOT excessive, the source

of the air leak should be from one of the following:
• Suction fuel lines

• Cooling plate assembly
• Fuel lines from the tank
• Fuel pre-filter assembly or
• Fuel tank outlet piping.
6. Remove the test tools.
3 15/11/2005
B.20.A / 73

2388, 2377
NOTE: A symptom of air-in-fuel is an audible surge from fuel system pressure fluctuations due to air in the fuel
supply. The following test simulates rated fuel flow through the system so that air in fuel problems may be diagnosed.
1. Install a 10 mm Compucheck® fitting (A) at the inlet
to the 2 micron fuel filter; this is special tool 3824842
(CUMMINS).
Connect the 1.09 mm (0.043 in) diagnostic fuel

line (B) to the fitting; this is special tool 3164621
(CUMMINS).
RCPH05CDC295ABA 1
2. Route the diagnostic fuel line to a suitable container.

NOTE: A 19 L (5 US gal) bucket is recommended.
3. Start the engine and switch from idle to high idle
several times to purge the air introduced while
installing the diagnostic fuel line.
4. Observe the fuel flow exiting the diagnostic fuel line
while the engine runs at idle.
A foamy appearance is an indication of an air leak,

a severe inlet restriction that causes cavitation or a
system that is NOT yet primed.
RCIL05CDC012AAA 2
5. If fuel inlet restriction is NOT excessive, the source

of the air leak should be from one of the following:
• Suction fuel lines

• Cooling plate assembly
• Fuel lines from the tank
• Fuel pre-filter assembly or
• Fuel tank outlet piping.
6. Remove the test tools.
3 15/11/2005
B.20.A / 74
FUEL AND INJECTION SYSTEM - Supply restriction (B.20.A -

F.40.C.21)
MX215, MX245, MX275, MX305, STX280
1. The testing tools shown in this procedure use a

digital voltmeter (DVM) with a pressure/vacuum
module – 3164491 (CUMMINS) (A). Wherever the
pressure transducer (B) for the module is shown
a conventional analog gauge can be substituted.
Other required components for this procedure are:
• two 10 mm Compucheck® fittings – 3824842

(CUMMINS) – which connect to the test fixture at
point (C),
• the orificed diagnostic fuel line (D) – 3164621
(CUMMINS),
• and a Tee fitting (E).
RCPH05CDC114ABA 1
2. Install a 10 mm Compucheck® fitting – 3824842

(CUMMINS) – in the test port at the inlet to the gear
pump.
NOTE: Some components removed for photo clarity.
RCPH05CDC997AAA 2
3. Connect an analog or digital pressure gauge to the

fitting. The gauge range must be from 0 - 762 mm
Hg (0 - 30 in Hg).
NOTE: A 90 ° fitting and quick disconnect coupler to the
transducer for a digital pressure/vacuum module is shown.
RCPH05CDC121ABA 3
3 15/11/2005
B.20.A / 75

(CUMMINS) – at the 2 micron filter outlet.
RCPH05CDC115ABA 4
5. Connect the 1.09 mm (0.043 in) diagnostic fuel line

– 3164621 (CUMMINS) (A) – to the Compucheck®
fitting with a Tee fitting. Route the fuel line to the
fuel tank. Connect a analog or digital gauge (B) to
the Tee fitting.
NOTE: If quick disconnect couplers are used to connect
the test equipment, a single analog or digital gauge can
be used for the readings at the two test locations.
RCPH05CDC116ABA 5
6. Operate the engine at idle and measure the vacuum

at the pump inlet. Record the reading.
7. Record the reading at the 2 micron filter.
8. Maximum fuel inlet restriction (dirty filter) at the gear
pump inlet must be 304.8 mm Hg (10.0 in Hg).
Maximum fuel inlet restriction (dirty filter) at the 2

micron filter outlet must be 203.2 mm Hg (8.0 in
Hg).
NOTE: Units shown are 12.6 cm Hg or 126.0 mm Hg.
RCPH05CDC123ABB 6
9. If the inlet restriction is excessive, check for the

following:
• Plugged suction side fuel filter,

• Plugged ECM cooling plate,
• Check valve restriction in the ECM cooling plate,
• Pinched or restricted fuel lines, or
• Restricted fuel tank piping.
3 15/11/2005
B.20.A / 76
FUEL AND INJECTION SYSTEM - Supply restriction (B.20.A -

F.40.C.21)
2388, 2377
1. The testing tools shown in this procedure use a

digital voltmeter (DVM) with a pressure/vacuum
module – 3164491 (CUMMINS) (A). Wherever the
pressure transducer (B) for the module is shown
a conventional analog gauge can be substituted.
Other required components for this procedure are:
• two 10 mm Compucheck® fittings – 3824842

(CUMMINS) – which connect to the test fixture at
point (C),
• the orificed diagnostic fuel line (D) – 3164621
(CUMMINS),
• and a Tee fitting (E).
RCPH05CDC114ABA 1

(CUMMINS) – in the test port at the inlet to the gear
pump.
NOTE: Some components removed for photo clarity.
RCPH05CDC997AAA 2
3. Connect an analog or digital pressure gauge to the

fitting. The gauge range must be from 0 - 762 mm
Hg (0 - 30 in Hg).
NOTE: A 90 ° fitting and quick disconnect coupler to the
transducer for a digital pressure/vacuum module is shown.
RCPH05CDC238ABA 3
3 15/11/2005
B.20.A / 77

(CUMMINS) – at the 2 micron filter outlet.
RCPH05CDC243ABA 4
5. Connect the 1.09 mm (0.043 in) diagnostic fuel line

– 3164621 (CUMMINS) (A) – to the Compucheck®
fitting with a Tee fitting. Route the fuel line to the
fuel tank. Connect a analog or digital gauge (B) to
the Tee fitting.
NOTE: If quick disconnect couplers are used to connect
the test equipment, a single analog or digital gauge can
be used for the readings at the two test locations.
RCPH05CDC236ABA 5
6. Operate the engine at idle and measure the vacuum

at the pump inlet. Record the reading.
7. Record the reading at the 2 micron filter.
8. Maximum fuel inlet restriction (dirty filter) at the gear
pump inlet must be 304.8 mm Hg (10.0 in Hg).
Maximum fuel inlet restriction (dirty filter) at the 2

micron filter outlet must be 203.2 mm Hg (8.0 in
Hg).
RCPH05CDC240ABB 6
9. If the inlet restriction is excessive, check for the

following:
• Plugged suction side fuel filter,

• Plugged ECM cooling plate,
• Check valve restriction in the ECM cooling plate,
• Pinched or restricted fuel lines, or
• Restricted fuel tank piping.
3 15/11/2005
B.20.A / 78
FUEL AND INJECTION SYSTEM - Return restriction (B.20.A -

F.40.C.22)
MX215, MX245, MX275, MX305, STX280
1. Remove the return fuel line from the regulator valve

housing at the fuel pump head.
RCPH05CDC157ABA 1
2. Install a tee-fitting equipped with hose barb

fittings(B) between the housing fitting and the return
fuel line (A).
Connect an analog or digital gauge to the adapter.

The gauge range must be from 0 - 762 mm Hg (0 -
30 in Hg).
NOTE: A quick disconnect with the pressure/vacuum
transducer (C) for a digital gauge is shown.
NOTE: The inside diameter of the Tee fitting and hose
bard fittings should match the housing fitting, or return
flow may be restricted by the fittings during the test.
RCPH05CDC293ABA 2
3. Operate the engine at rated speed and no load.

Observe the reading on the gauge.
Maximum fuel drain line pressure must be 254.0

mm Hg (10 in Hg).
NOTE: The reading shown is 11.5 cm Hg or 115.0 mm
Hg.
RCPH05CDC294ABA 3
4. If the reading is out of specification, check for bends

or kinks in the low pressure drain line – the common
piping from the pump head to the injector drain.
Look for pinched fuel lines (by clamps, tie straps,
p-clamps). Check for blockage in the fuel tank
venting.
3 15/11/2005
B.20.A / 79
5. Remove the test fittings and install the return fuel

line to the pump head.
3 15/11/2005
B.20.A / 80
FUEL AND INJECTION SYSTEM - Return restriction (B.20.A -

F.40.C.22)
2388, 2377
1. A gauge adapter can be constructed to measure

pressure or vacuum at any banjo connector on the
fuel return manifold for the low pressure fuel system.
Make the gauge adapter by drilling and tapping the
hex face of a 12 mm x 1.5 in banjo bolt.
RCSC05CDC177AAA 1
2. Drill and tap the banjo bolt to accept a 0.125 in

NPT pipe thread for connecting an analog gauge or
digital pressure/vacuum module.
3. Assemble the banjo gauge adapter: Install the 0.125
in fitting in the hex face of the banjo bolt. Attach a
hose and analog gauge or a digital pressure gauge
to the adapter fitting.
RCSC05CDC169AAA 2
4. Remove the banjo bolt for the injector drain line at

the fuel return manifold. Install the gauge adapter in
place of the banjo bolt.
Connect an analog or digital gauge to the adapter.

The gauge range must be from 0 - 762 mm Hg (0 -
30 in Hg).
NOTE: A quick disconnect with the pressure/vacuum
transducer for a digital gauge is shown.
RCPH05CDC298ABB 3
3 15/11/2005
B.20.A / 81
5. Operate the engine at rated speed and no load.

Observe the reading on the gauge.
Maximum fuel drain line pressure must be 254.0

mm Hg (10 in Hg).
6. If the reading is out of specification, check for bends
or kinks in the low pressure line from the injector
drain. Look for pinched fuel lines (by clamps, tie
straps, p-clamps). Check for blockage in the fuel
tank venting.
7. Remove the test fitting and install the original banjo
bolt at the return manifold.
3 15/11/2005
B.20.A / 82
FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11)

MX215, MX245, MX275, MX305, STX280
Prior operation: ENGINE - Testing (B.10.A - G.40.A.20)

Fault code check

Turn the keyswitch ON.
Use INSITE® to read the fault code information.

Determine if there are active fuel system fault codes
related to the complaint.
If relevant fault codes are found, use the guided

troubleshooting to resolve the problem.
If no relevant fault codes are found, go to Step 2.
RCPH05CDC325ABA 1
Air in fuel supply check

2. Check for air in the fuel.
Refer to FUEL AND INJECTION SYSTEM - Air in

fuel (B.20.A - F.40.C.20).
If air is present in the fuel supply, locate and correct

the cause; Sources of air ingestion include:
– loose fuel filters,
– loose or damaged fuel lines and fuel connectors,
– loose or cracked fuel tank piping,
– or severe restriction in the fuel supply lines and
filters.
If the fuel supply is free of air ingestion, go to Step 3.
RCPH05CDC119ABA 2
Gear pump pressure check

3. Check the gear pump pressure.
Refer to High pressure common rail Gear pump -

Pressure test (B.20.A.30.10 - F.40.C.30).
If the gear pump pressure is within specification,

go to Step 5.
If the gear pump pressure is NOT within

specification, continue with Step 4.
RCPH05CDC116ABA 3
3 15/11/2005
B.20.A / 83
Fuel inlet restriction check

4. Check for restriction at the inlet to the gear pump.
Refer to FUEL AND INJECTION SYSTEM - Supply

If the fuel supply restriction is above specification,

locate and repair:
– the plugged pre-filter,

– a restricted ECM cooling plate,
– restricted check valve in the ECM cooling plate,
– pinched fuel lines,
– or restricted piping in the fuel tank.
If the fuel supply restriction is within specification,

replace the gear pump. RCPH05CDC121ABA 4
Cylinder cutout check

Turn keyswitch ON.
Operate engine at low idle.
Operate the engine under load, and use INSITE® to

perform the cylinder cutout test to disable individual
injectors.
If the complaint – miss or excessive smoke – is

originating from a single cylinder, investigate the
cause: check valve lash and check for excessive
crankcase pressure which could indicate cylinder
damage or camshaft lobe wear. If no other damage
is found, replace the fuel injector for the cylinder
identified by the cutout test. Refer to Fuel injector - RCPH05CDC327ABA 5
Remove (B.20.A.29 - F.10.A.10).
If the complaint is not caused by a single cylinder,

Cylinder balance check

Turn keyswitch ON.
Use the cylinder performance test in INSITE® to

determine if a single cylinder is contributing to the
engine symptom.
If the test identifies a cylinder that is contributing

to a power imbalance, investigate the cause of
the imbalance: check valve lash and check for
excessive crankcase pressure which could indicate
cylinder damage or camshaft lobe wear. If no other
damage is found, replace the fuel injector for the
cylinder contributing to the power imbalance. Refer
to Fuel injector - Remove (B.20.A.29 - F.10.A.10). RCPH05CDC327ABA 6

3 15/11/2005
B.20.A / 84
Fuel return restriction check

7. Check the fuel drain circuit for return restriction.
Refer to FUEL AND INJECTION SYSTEM - Return

If the fuel return restriction is higher than the

specification, locate and repair the cause of the
restriction – for example, kinked or blocked fuel
lines.
If the fuel return restriction is within specification,

RCPH05CDC293ABA 7
Fuel pressure check

Start the engine.
Operate the engine at idle for at least one minute to

purge the air introduced from the previous steps.
Use INSITE® to monitor commanded fuel rail

pressure and measured fuel rail pressure for
minimum of 10 seconds.
If the measured fuel rail pressure deviates more

than 200 bar (2,900 psi) , and/or if the complaint
is engine surge at idle or engine start and stall,
replace the high pressure regulator valve. Refer
to Regulator valve High pressure - Remove
(B.20.A.14.10 - F.10.A.10).
RCPH05CDC325ABA 8
If the measured fuel pressure does NOT deviate

more than 200 bar (2,900 psi) , and/or if the
complaint is NOT engine surge at idle or engine
start and stall, continue with the next sequence in
the performance tree.
Next operation: AIR INTAKE SYSTEM - Check (B.30.A - F.40.A.11)

3 15/11/2005
B.20.A / 85
FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11)

2388, 2377

Fault code check

Use INSITE® to read the fault code information.

Determine if there are active fuel system fault codes
related to the complaint.
If relevant fault codes are found, use the guided

If no relevant fault codes are found, go to Step 2.
RCPH05CDC325ABA 1
Air in fuel supply check

2. Check for air in the fuel.
Refer to FUEL AND INJECTION SYSTEM - Air in

fuel (B.20.A - F.40.C.20).
If air is present in the fuel supply, locate and correct

the cause; Sources of air ingestion include:
– loose fuel filters,
– loose or damaged fuel lines and fuel connectors,
– loose or cracked fuel tank piping,
– or severe restriction in the fuel supply lines and
filters.
If the fuel supply is free of air ingestion, go to Step 3.
RCPH05CDC295ABA 2

3. Check the gear pump pressure.

If the gear pump pressure is within specification,

go to Step 5.
If the gear pump pressure is NOT within

RCPH05CDC236ABA 3
3 15/11/2005
B.20.A / 86
Fuel inlet restriction check

4. Check for restriction at the inlet to the gear pump.
Refer to FUEL AND INJECTION SYSTEM - Supply

If the fuel supply restriction is above specification,

locate and repair:
– the plugged pre-filter,

– a restricted ECM cooling plate,
– restricted check valve in the ECM cooling plate,
– pinched fuel lines,
– or restricted piping in the fuel tank.
If the fuel supply restriction is within specification,

replace the gear pump. RCPH05CDC238ABA 4
Cylinder cutout check

Turn keyswitch ON.
Operate engine at low idle.
Operate the engine under load, and use INSITE® to

perform the cylinder cutout test to disable individual
injectors.
If the complaint – miss or excessive smoke – is

originating from a single cylinder, investigate the
cause: check valve lash and check for excessive
crankcase pressure which could indicate cylinder
damage or camshaft lobe wear. If no other damage
is found, replace the fuel injector for the cylinder
identified by the cutout test. Refer to Fuel injector - RCPH05CDC327ABA 5
Remove (B.20.A.29 - F.10.A.10).

Cylinder balance check

Turn keyswitch ON.
Use the cylinder performance test in INSITE® to

determine if a single cylinder is contributing to the
engine symptom.
If the test identifies a cylinder that is contributing

to a power imbalance, investigate the cause of
the imbalance: check valve lash and check for
excessive crankcase pressure which could indicate
cylinder damage or camshaft lobe wear. If no other
damage is found, replace the fuel injector for the
cylinder contributing to the power imbalance. Refer
to Fuel injector - Remove (B.20.A.29 - F.10.A.10). RCPH05CDC327ABA 6

3 15/11/2005
B.20.A / 87
Fuel return restriction check

7. Check the fuel drain circuit for return restriction.
Refer to FUEL AND INJECTION SYSTEM - Return

If the fuel return restriction is higher than the

specification, locate and repair the cause of the
restriction – for example, kinked or blocked fuel
lines.
If the fuel return restriction is within specification,

RCPH05CDC298ABB 7
Fuel pressure check

Start the engine.
Operate the engine at idle for at least one minute to

purge the air introduced from the previous steps.
Use INSITE® to monitor commanded fuel rail

pressure and measured fuel rail pressure for
minimum of 10 seconds.
If the measured fuel rail pressure deviates more

than 200 bar (2,900 psi) , and/or if the complaint
is engine surge at idle or engine start and stall,
replace the high pressure regulator valve. Refer
to Regulator valve High pressure - Remove
(B.20.A.14.10 - F.10.A.10).
RCPH05CDC325ABA 8
If the measured fuel pressure does NOT deviate

more than 200 bar (2,900 psi) , and/or if the
complaint is NOT engine surge at idle or engine
start and stall, continue with the next sequence in
the performance tree.

3 15/11/2005
B.20.A / 88
Regulator valve High pressure - Remove (B.20.A.14.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: The pump area around the high pressure regulator valve must be clean and free of fuel, oil and debris
before the valve is removed.
1. Remove the fuel supply line (A) for the common rail
from the pump head.
Disconnect the engine harness connector (B) to the

regulator valve pigtail.
RCPH05CDC067ABA 1
2. Remove the three cap screws that secure the

regulator valve to the housing. Remove the valve.
RCPH05CDC039ABA 2
Next operation: Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10)
3 15/11/2005
B.20.A / 89
Regulator valve High pressure - Visual inspection (B.20.A.14.10 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve High pressure - Remove (B.20.A.14.10 - F.10.A.10)
1. Inspect the valve plunger through the four passage

windows. A shinny scratch free surface indicates
the valve is acceptable for reuse.
Any sign of scuffing, when accompanied by fault

code 449, indicates the valve needs to be replaced.
RCPH05CDC043ABA 1
2. Inspect the O-rings on the valve.
If the outer O-ring (A) is damaged, fuel will leak past

the closed valve, triggering fault codes 449.
If the inner O-ring (B) is damaged, an external fuel

leak should be observed.
RCPH05CDC043ABA 2
Next operation: Regulator valve High pressure - Electrical test (B.20.A.14.10 - F.40.A.50)
3 15/11/2005
B.20.A / 90
Regulator valve High pressure - Electrical test (B.20.A.14.10 -

F.40.A.50)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10)
1. Inspect the pins and cavities on the engine harness

and pigtail connector for damage or corrosion.
Inspect the pigtail for insulation damage.
RCPH05CDC042ABA 1
2. Measure resistance pin to pin on the pigtail

connector. A resistance reading between 1.5 - 5.0K
ohms is acceptable.
RCPH05CDC041ABA 2
3. Measure resistance between the positive pin on the

engine harness connector and ground. If resistance
is less than 100K ohms, there is no open circuit in
power to the regulator valve.
Next operation: Regulator valve High pressure - Install (B.20.A.14.10 - F.10.A.15)
3 15/11/2005
B.20.A / 91
Regulator valve High pressure - Install (B.20.A.14.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve High pressure - Electrical test (B.20.A.14.10 - F.40.A.50)
1. Lubricate the O-rings on the regulator valve with

clean engine oil.
RCPH05CDC044ABA 1
2. While rotating the valve CLOCKWISE, install the

regulator valve in the housing. Do NOT use the cap
screws to draw the valve into the housing.
RCPH05CDC045ABA 2
3. Install the cap screws and use a two step method to

torque the cap screws:
Step 1 – Torque to 3 Nm (26.5 lb in).

Step 2 – Torque to 6 Nm (53 lb in).
RCPH05CDC046ABA 3
3 15/11/2005
B.20.A / 92
4. Install the fuel supply line (A) for the common rail
to the outlet fitting.
Connect the engine harness connector (B) to the

pressure regulator valve.
RCPH05CDC067ABA 4
3 15/11/2005
B.20.A / 93
Regulator valve High pressure - Remove (B.20.A.14.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: The pump surface around the regulator valve housing must be clean and free of fuel, oil and other debris
before the housing is serviced.
Regulator valve housing

from the valve housing.
Disconnect the fuel return lines (B) from the valve

housing.
RCPH05CDC068ABA 1
2. Disconnect the fuel supply line (A) to the regulator

valve housing.
Disconnect the engine harness connector (B) to the

regulator valve.
RCPH05CDC067ABA 2
3. Remove the cap screw for the housing support

bracket. Loosen the cap screw (A) for the support
on the head.
RCPH05CDC017ABA 3
3 15/11/2005
B.20.A / 94
4. Remove the three cap screws that secure the

regulator valve housing to the pump head.
RCPH05CDC018ABA 4
5. Remove the housing and gasket.
RCPH05CDC019ABA 5
Next operation: Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10)
3 15/11/2005
B.20.A / 95
Regulator valve High pressure - Visual inspection (B.20.A.14.10 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve High pressure - Remove (B.20.A.14.10 - F.10.A.10)

1. Inspect the gasket for the valve housing. Do NOT
reuse the gasket if the material is damaged, cracked
or torn.
RCPH05CDC020ABB 1
2. Clean the surface of the housing with contact

cleaner.
NOTE: The screen (A) located on the sealing surface of
the housing is NOT serviceable.
RCPH05CDC024ABA 2
3. Clean the mating surface on the pump head with

contact cleaner.
RCPH05CDC021ABA 3
Next operation: Regulator valve High pressure - Install (B.20.A.14.10 - F.10.A.15)
3 15/11/2005
B.20.A / 96
Regulator valve High pressure - Install (B.20.A.14.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve High pressure - Visual inspection (B.20.A.14.10 - F.40.A.10)

1. Install the three cap screws through the housing.
Install the gasket over the cap screws.
NOTE: The gasket must be installed dry.
RCPH05CDC072ABA 1
2. Install the assembly on the pump head.
RCPH05CDC073ABA 2
3. Tighten and torque the cap screws to 34 Nm (25

lb ft).
RCPH05CDC038ABA 3
3 15/11/2005
B.20.A / 97
4. Install the support cap screw and tighten the

regulator valve housing cap screw. Torque to 65
Nm (48 lb ft).
RCPH05CDC062ABA 4
5. Connect the fuel supply line (A) to the regulator

valve housing.
Connect the engine harness connector (B) to the

regulator valve.
RCPH05CDC067ABA 5
6. Connect the fuel return line (A) to the regulator

valve housing.
Connect the fuel supply line (B) to the outlet fitting.
RCPH05CDC068ABA 6
7. Operate the engine and check for leaks.
3 15/11/2005
B.20.A / 98
Regulator valve Injection return - Remove (B.20.A.14.30 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: If the engine is installed in the chassis, refer to the chassis repair manual, if required, to gain
access to the check valve.
1. Remove the banjo bolt (with the integral check

valve) and washers, and disconnect the fuel line at
the injector return port at the rear of the head.
RCPH05CDC916AAA 1
Next operation: Regulator valve Injection return - Visual inspection (B.20.A.14.30 - F.40.A.10)
3 15/11/2005
B.20.A / 99
Regulator valve Injection return - Visual inspection (B.20.A.14.30 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve Injection return - Remove (B.20.A.14.30 - F.10.A.10)
1. Inspect the valve for freedom of movement with an

O-ring pick. Check for plugging or damage.
NOTE: The injector drain line check valve is installed in
the banjo bolt. The check valve maintains 0.7 bar (10 psi)
back pressure on injector bypass flow.
RCPH05CDC911AAA 1
Next operation: Regulator valve Injection return - Install (B.20.A.14.30 - F.10.A.15)
3 15/11/2005
B.20.A / 100
Regulator valve Injection return - Install (B.20.A.14.30 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Regulator valve Injection return - Visual inspection (B.20.A.14.30 - F.40.A.10)
1. Connect the fuel return line with the banjo bolt and
washers at the injector return port at the rear of the
head.
RCPH05CDC916AAA 1
2. Torque the 12 mm bolt to 24 Nm (18 lb ft).
RCPH05CDC918AAA 2
3 15/11/2005
B.20.A / 101

MX215, MX245, MX275, MX305, STX280
1. Operate the engine and check for external leaks.
WARNING
M1003 - The pressure within the fuel rail is extremely
high. Fuel under high pressure can penetrate the
skin. Stand clear of the engine while it is running.
WARNING
M1042 - Do NOT loosen or tighten high pressure fuel
lines while the engine is running.
RCPH05CDC303ABA 1
2. The injection pump, relief valve and injectors share

a common fuel return line to the fuel cooler. To test
for excessive leakage at the relief valve, fuel flow
from all three sources MUST be isolated for proper
measuring and to prevent damage to the system.
IMPORTANT: The fittings and methods described in this
procedure MUST be used to prevent damage to the fuel
system.
RCPH05CDC312ABA 2
3. Remove the fuel line to the fuel cooler on the

regulator valve housing at the pump head.
RCPH05CDC157ABA 3
3 15/11/2005
B.20.A / 102
4. Remove the banjo bolt fitting and fuel connector

from the housing.
RCPH05CDC158ABA 4
5. Install the 12 mm x 1.5 in special test fitting –

380002498 – in the housing port. Attach a hose to
the fitting and route the hose into the fuel tank.
NOTE: The hose from 3164618 (CUMMINS) connects
directly to this fitting without need for an adapter and is
long enough to reach the fuel tank.
RCPH05CDC152ABA 5
6. Remove the banjo bolt and fuel line from the

RCPH05CDC159ABA 6
3 15/11/2005
B.20.A / 103

380002500 – in the pressure relief valve. Attach a
hose to the fitting and route the hose into the fuel
tank.
RCPH05CDC306ABA 7
8. Support a 19.0 L (5.0 US gal) container and allow

the fuel line, which is only connected to the injector
return at this point, to drain into the container during
the test.
RCPH05CDC311ABA 8
9. Start the engine and allow the engine to idle.

IMPORTANT: If fault code 449 is active, do NOT replace
the relief valve without first determining the cause of the
fault condition. Refer to the troubleshooting procedure
in INSITE®.
10. Remove the hose to the relief valve from the fuel
tank, and measure the leakage.

relief valve while the engine runs at idle.
If relief valve leakage is excessive, it MUST be

replaced. See Relief valve - Remove (B.20.A.16 -
F.10.A.10).
RCPH05CDC313ABA 9
3 15/11/2005
B.20.A / 104
11. While the engine is running at idle, use the high

pressure leak test in INSITE® to create high fuel rail
pressure. INSITE® will command 1500 bar (21,756
psi) fuel rail pressure while the engine runs at idle.
CAUTION
M1040 - Fuel is at high pressure during this test. After
connecting the test fitting, close the hood and stand
clear of the high pressure fuel lines.
RCSC05CDC169AAA 10
12. Less than 30 drops per minute MUST drain from

the pressure relief valve.

F.10.A.10).
NOTE: Check that fault code 449 is NOT active before
replacing the valve. This codes indicates that a system
failure is causing the relief valve to open.
RCPH05CDC313ABA 11
13. If return flow from the injectors and/or injection

pump must also be measured, see Fuel injector
- Leakage test (B.20.A.29 - F.40.A.40) and High
pressure common rail Pump head and housing -
Leakage test (B.20.A.30.15 - F.40.A.40).
14. Remove the test equipment from the relief valve
and housing. Reinstall the fuel line at the pressure
relief valve.
RCPH05CDC159ABA 12
3 15/11/2005
B.20.A / 105
15. Reinstall the fuel connector on the regulator valve

housing. Connect the line to the fuel cooler to the
fitting.
RCPH05CDC157ABA 13
3 15/11/2005
B.20.A / 106
Relief valve - Remove (B.20.A.16 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280
1. Remove the banjo bolt and washers to disconnect

the fuel return line from the pressure relief valve.
RCPH05CDC912AAA 1
2. Remove the pressure relief valve from the common

rail.
RCPH05CDC317ABA 2
Next operation: Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)
3 15/11/2005
B.20.A / 107
Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280
Prior operation: Relief valve - Remove (B.20.A.16 - F.10.A.10)
1. Do NOT reuse the relief valve if it failed the leakage

test.
Inspect the high pressure sealing surface on the

valve and the fuel rail for damage. Do NOT reuse
either component if the seal joint is damaged.
RCPH05CDC893AAB 1
Next operation: Relief valve - Install (B.20.A.16 - F.10.A.15)
3 15/11/2005
B.20.A / 108
Relief valve - Install (B.20.A.16 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280
Prior operation: Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)
1. Lubricate the threads of the relief valve with CASE

AKCELA EP-0 GREASE. Install the relief valve in
the fuel rail and torque to 100 Nm (74 lb ft).
RCPH05CDC318ABA 1
2. Connect the return fuel line with the banjo bolt and
washers. Torque the 14 mm banjo bolt to 34 Nm
(25 lb ft). Refer to Fuel line Low pressure - Install
(B.20.A.36.10 - F.10.A.15).
RCPH05CDC912AAA 2
3 15/11/2005
B.20.A / 109

2388, 2377
WARNING
WARNING
RCPH05CDC811AAA 1
2. To check if the relief valve is leaking excessive

fuel to drain, remove the left hand banjo bolt and
washers at the fuel return manifold. Install the return
fuel test tool – 3164618 (CUMMINS) (A) – at the
fuel return manifold. Route the hose to a suitable
container for collecting fuel.
IMPORTANT: If fault code 449 is active, do NOT replace
the relief valve without first determining the cause of the
fault condition. Refer to the troubleshooting procedure
in INSITE®.
RCPH05CDC242ABB 2
3. Start the engine and allow the engine to idle.

4. Measure the leakage.

relief valve while the engine runs at idle.

F.10.A.10).
RCPH05CDC246ABA 3
3 15/11/2005
B.20.A / 110

CAUTION
RCSC05CDC169AAA 4
6. Less than 30 drops per minute MUST drain from


F.10.A.10).
NOTE: Check that fault code 449 is NOT active before
replacing the valve. This code indicates that a system
failure is causing the relief valve to open.
RCPH05CDC246ABA 5
7. Remove the test equipment (A) from the return

manifold. Install the banjo bolt and washers.
RCPH05CDC242ABB 6
3 15/11/2005
B.20.A / 111
Relief valve - Remove (B.20.A.16 - F.10.A.10)

2388, 2377
1. Remove the banjo bolt and washers and remove

the return fuel line from the relief valve.
RCIL05CDC009AAA 1
2. Remove the pressure relief valve from the fuel rail.
RCSC05CDC173AAA 2
Next operation: Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)
3 15/11/2005
B.20.A / 112
Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)

2388, 2377
Prior operation: Relief valve - Remove (B.20.A.16 - F.10.A.10)
1. Do NOT reuse the relief valve if it failed the leakage

test.
Inspect the high pressure sealing surface on the

valve and the fuel rail for damage. Do NOT reuse
either component if the seal joint is damaged.
RCPH05CDC893AAB 1
Next operation: Relief valve - Install (B.20.A.16 - F.10.A.15)
3 15/11/2005
B.20.A / 113
Relief valve - Install (B.20.A.16 - F.10.A.15)

2388, 2377
Prior operation: Relief valve - Visual inspection (B.20.A.16 - F.40.A.10)
1. Lubricate the threads of the relief valve with CASE

AKCELA EP-0 GREASE. Install the relief valve in
the fuel rail and torque to 100 Nm (74 lb ft).
RCSC05CDC173AAA 1
2. Connect the return fuel line to the relief valve with

the banjo bolt and washers. Torque the 14 mm
banjo bolt to 34 Nm (25 lb ft).
RCIL05CDC009AAA 2
3 15/11/2005
B.20.A / 114
Fuel filter system Pre-filter - Remove (B.20.A.24.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Disconnect the harness connector to the water in

fuel sensor.
RCPH05CDC225ABA 1
2. Remove the pre-filter from the filter head.
RCPH05CDC226ABA 2
Next operation: Fuel filter system Fuel filter - Remove (B.20.A.24.22 - F.10.A.10)
Next operation: Fuel filter system Pre-filter - Install (B.20.A.24.10 - F.10.A.15)
3 15/11/2005
B.20.A / 115
Fuel filter system Pre-filter - Install (B.20.A.24.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Fill the pre-filter with clean diesel fuel. Lubricate the

seal with clean engine oil or CASE AKCELA EP-0
GREASE and install the filter.
RCPH05CDC176ABA 1
2. Install the filter in the filter head.
RCPH05CDC227ABA 2
3. Connect the harness connector to the water in fuel

sensor.
RCPH05CDC225ABA 3
3 15/11/2005
B.20.A / 116
Fuel filter system Fuel filter - Remove (B.20.A.24.22 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel filter system Pre-filter - Remove (B.20.A.24.10 - F.10.A.10)
1. Remove the fuel lines from the front of the filter

head.
RCPH05CDC124AAA 1
2. Remove the fuel lines from the rear of the filter head.
RCPH05CDC354AAA 2
3. Remove the fuel filter from the filter head.
RCPH05CDC125AAA 3
3 15/11/2005
B.20.A / 117
4. Remove the three cap screws and remove the filter

head from the block.
RCPH05CDC352AAA 4
Next operation: Fuel filter system Fuel filter - Visual inspection (B.20.A.24.22 - F.40.A.10)
3 15/11/2005
B.20.A / 118
Fuel filter system Fuel filter - Visual inspection (B.20.A.24.22 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel filter system Fuel filter - Remove (B.20.A.24.22 - F.10.A.10)
1. Inspect the filter head for cracks, passage blockage

or debris on the sealing surfaces.
RCPH05CDC431AAB 1
Next operation: Fuel filter system Fuel filter - Install (B.20.A.24.22 - F.10.A.15)
3 15/11/2005
B.20.A / 119
Fuel filter system Fuel filter - Install (B.20.A.24.22 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel filter system Fuel filter - Visual inspection (B.20.A.24.22 - F.40.A.10)
1. Install the filter head on the engine block with the

three cap screws. Torque the cap screws to 43 Nm
(32 lb ft).
RCPH05CDC352AAA 1
2. Install the fuel lines at the rear of the filter head.
RCPH05CDC354AAA 2
3. Install the fuel lines at the front of the filter head.
RCPH05CDC124AAA 3
3 15/11/2005
B.20.A / 120
4. Lubricate the seal with clean engine oil or CASE

AKCELA EP-0 GREASE and install the filter.
RCPH05CDC176ABA 4
Next operation: Fuel filter system Pre-filter - Install (B.20.A.24.10 - F.10.A.15)
3 15/11/2005
B.20.A / 121

MX215, MX245, MX275, MX305, STX280
WARNING
WARNING
RCPH05CDC917AAA 1

for excessive leakage at the injector return, fuel flow
from all three sources MUST be isolated for proper
measuring and to prevent damage to the system.
system.
RCPH05CDC312ABA 2
3. Remove the fuel line to the fuel cooler from the

RCPH05CDC157ABA 3
3 15/11/2005
B.20.A / 122
4. Remove the banjo bolt fitting and fuel line from the
housing.
RCPH05CDC158ABA 4

RCPH05CDC152ABA 5

RCPH05CDC159ABA 6
3 15/11/2005
B.20.A / 123

tank.
RCPH05CDC306ABA 7

return at this point, to drain into the container until
test measurements are required.
RCPH05CDC311ABA 8
Engine will not start

9. If the engine will not start, drain flow from the
injectors must be measured while engaging the
starter 30 seconds at a time. Use an assistant to
crank the engine while fuel is collected.
Remove the fuel line from the 19.0 L (5.0 US gal)

container. Collect the flow in a graduated beaker
from the connector for the relief valve during the 30
seconds.
Maximum fuel collected during 30 seconds of

cranking MUST be 100 cm³ (3.38 US fl oz).
RCPH05CDC150ABA 9
3 15/11/2005
B.20.A / 124
10. If return flow is excessive during cranking and the

engine will NOT start, check the following:
• Fuel connector installation; see Fuel connector

- Remove (B.20.A.37 - F.10.A.10) and Fuel
connector - Visual inspection (B.20.A.37 -
F.40.A.10).
• Fuel connector damage; see Fuel connector -

Visual inspection (B.20.A.37 - F.40.A.10).
• Use the injector isolation tool – 3164325 (CUMMINS)

– to isolate injectors from the fuel rail one at a time.
RCPH05CDC272ABB 10
Engine will start

CAUTION
RCSC05CDC169AAA 11
12. Record the amount of time to collect 300 cm³ (10.1

US fl oz) of fuel from the injector return line. Collect
the flow in a graduated beaker from the connector
for the relief valve.
Maximum fuel collected during 45 seconds MUST

be 300 cm³ (10.1 US fl oz).
RCPH05CDC150ABA 12
13. If 300 cm³ (10.1 US fl oz) is collected in less than

45 seconds, there is at least one loose or damaged
fuel connector and/or injector.
NOTE: Fuel temperature will influence this measurement.
As the engine is warmed up and the injectors become hot,
the leakage rate will increase. The above specification is
correct where fuel inlet temperature is less than 49 °C
(120 °F).
3 15/11/2005
B.20.A / 125
14. Record the fuel leakage rate, stop the INSITE™

leak test and turn the keyswitch OFF.
15. If return flow is excessive, verify that the fuel
connectors are properly tightened. See Fuel
connector - Install (B.20.A.37 - F.10.A.15). If loose
retaining nut(s) are found, perform the leak test
again after tightening the retaining nut(s).
NOTE: A loose fuel connector retaining nut causes a poor
seal between the fuel connector and injector. This loose
condition causes high pressure fuel to leak to the injector
drain.
RCPH05CDC272ABB 13
16. If the fuel connectors are properly torqued, isolate

the injector(s) or fuel connector(s) with the damaged
or worn parts with the injector isolation test.
Injector isolation test

17. Use the special isolation tool – 3164325 (CUMMINS)
– to isolate excessive fuel drain from the injectors
or fuel connectors.
CAUTION
M1041 - Do not install the isolation tool at the high
pressure pump outlet fitting. Severe engine damage
will result. This tool must only be installed on the
fuel rail to isolate an individual injector from the high
pressure fuel supply.
CAUTION
lines while the engine is running. RCPH05CDC288ABA 14
18. Disconnect the high pressure fuel line for the fuel
connector/injector to be tested at the fuel rail.
RCPH05CDC231ABA 15
3 15/11/2005
B.20.A / 126
19. Loosen the retaining nut at the fuel connector for

the same line.
RCPH05CDC232ABA 16
20. Install the isolation tool – 3164325 (CUMMINS) – at

the fuel rail. Torque to 43 Nm (32 lb ft).
RCPH05CDC233ABA 17
21. Use the INSITE™ high pressure leak test to record

the amount of time required to collect 300 cm³ (10.1
US fl oz) of fuel from the injector drain line.
RCSC05CDC169AAA 18
3 15/11/2005
B.20.A / 127
22. Perform this isolation test up to six times, once while

each fuel supply line is isolated.
If isolating a single injector/fuel connector causes

the leakage time to increase significantly (compared
to the rest of the set), that injector/fuel connector
must be inspected.
RCIL05CDC008AAA 19
23. Inspect the indicated fuel connector. See Fuel

F.40.A.10).
If the fuel connector is NOT damaged, then both the

injector and the fuel connector MUST be replaced.
RCPH05CDC272ABB 20
24. If return flow from the relief valve and/or injection

pump must also be measured, see Relief valve -
Leakage test (B.20.A.16 - F.40.A.40) and High
pressure common rail Pump head and housing -
Leakage test (B.20.A.30.15 - F.40.A.40).
25. Remove the test equipment from the relief valve
and regulator valve housing. Reinstall the fuel line
at the pressure relief valve.
RCPH05CDC159ABA 21
3 15/11/2005
B.20.A / 128
26. Reinstall the fuel connector at the regulator valve

housing. Connect the line to the fuel cooler at the
housing fitting.
RCPH05CDC157ABA 22
3 15/11/2005
B.20.A / 129

2388, 2377
1. Return fuel from the injectors (A), the fuel rail relief
valve (B) and the fuel pump head (C) is piped on
three different lines to the fuel return manifold (D).
RCIL05CDC009AAA 1
2. Use the special tool – 3164618 (CUMMINS) – to

isolate the return fuel flow for just the injectors so
that it can be measured in a graduated beaker at
the fuel return manifold.
CAUTION
M1039 - Installation of the banjo flow adapter at any
location other than the fuel drain manifold can cause
damage to high pressure fuel system components.
RCPH05CDC290ABA 2
3. Remove the 12 mm banjo bolt that connects the

fuel injector drain line to the fuel return manifold.
Install special tool 3164618 (CUMMINS) at the same

location. Route the hose to a clean container.
NOTE: A graduated beaker marked in cubic centimeters
which will hold at least 300 cm³ is REQUIRED for the
actual testing.
RCPH05CDC292ABB 3
4. Start the engine and allow the engine to idle until fuel
from the injectors begins to drain into the container.
Connect the INSITE® electronic service tool.
3 15/11/2005
B.20.A / 130

5. If the engine will not start, this test is still valid with
a different pass/fail specification. If the engine will
NOT start, drain flow must be measured while
engaging the starter for 30 seconds at a time.
Collect the flow in a graduated beaker during the

30 seconds.
Maximum fuel collected during 30 seconds of

cranking MUST be 100 cm³ (3.38 US fl oz).
RCPH05CDC246ABA 4
6. If return flow is excessive during cranking and the

engine will NOT start, check the following:
– Fuel connector installation; see Fuel connector

- Remove (B.20.A.37 - F.10.A.10) and Fuel
F.40.A.10).
– Fuel connector damage; see Fuel connector -

Visual inspection (B.20.A.37 - F.40.A.10).
– Use the injector isolation tool – 3164325

(CUMMINS) – to isolate injectors from the fuel rail
one at a time.
RCPH05CDC272ABB 5
Engine will start

pressure leak test in INSITE® to create high fuel
rail pressure. INSITE® creates 1500 bar (21,776
psi) fuel rail pressure while the engine is at idle with
this test.
CAUTION
RCSC05CDC169AAA 6
3 15/11/2005
B.20.A / 131
8. Record the amount of time to collect 300 cm³ (10.1

US fl oz) of fuel from the injector return line.
Maximum fuel collected during 45 seconds MUST

be 300 cm³ (10.1 US fl oz).
RCPH05CDC246ABA 7
9. If 300 cm³ (10.1 US fl oz) is collected in less than

45 seconds, there is at least one loose or damaged
fuel connector and/or injector.
NOTE: Fuel temperature will influence this measurement.
As the engine is warmed up and the injectors become hot,
the leakage rate will increase. The above specification is
correct where fuel inlet temperature is less than 49 °C
(120 °F).
10. Record the fuel leakage rate, stop the INSITE® leak
test and turn the keyswitch OFF.
11. If return flow is excessive, verify that the fuel
connectors are properly tightened. See Fuel
connector - Install (B.20.A.37 - F.10.A.15). If loose
retaining nut(s) are found, perform the leak test
again after tightening the retaining nut(s).
NOTE: A loose fuel connector retaining nut causes a poor
seal between the fuel connector and injector. This loose
condition causes high pressure fuel to leak to the injector
drain.
RCPH05CDC272ABB 8
12. If the fuel connectors are properly torqued, isolate

the injector(s) or fuel connector(s) with the damaged
or worn parts with the injector isolation test.
3 15/11/2005
B.20.A / 132
Injector isolation test

13. Use the special isolation tool – 3164325 (CUMMINS)
– to isolate excessive fuel drain from the injectors
or fuel connectors.
CAUTION
M1041 - Do not install the isolation tool at the high
pressure pump outlet fitting. Severe engine damage
will result. This tool must only be installed on the
fuel rail to isolate an individual injector from the high
pressure fuel supply.
CAUTION
lines while the engine is running. RCPH05CDC288ABA 9
14. Disconnect the high pressure fuel line for the fuel
connector/injector to be tested at the fuel rail.
RCPH05CDC231ABA 10
15. Loosen the retaining nut at the fuel connector for

the same line.
RCPH05CDC232ABA 11
3 15/11/2005
B.20.A / 133
16. Install the isolation tool – 3164325 (CUMMINS) – at

the fuel rail. Torque to 43 Nm (32 lb ft).
RCPH05CDC233ABA 12
17. Use the INSITE® high pressure leak test to record

the amount of time required to collect 300 cm³ (10.1
US fl oz) of fuel from the injector drain line.
RCSC05CDC169AAA 13
18. Perform this isolation test up to six times, once while

each fuel supply line is isolated.
If isolating a single injector/fuel connector causes

the leakage time to increase significantly (compared
to the rest of the set), that injector/fuel connector
must be inspected.
RCIL05CDC008AAA 14
3 15/11/2005
B.20.A / 134
19. Inspect the indicated fuel connector. See Fuel

F.40.A.10).
If the fuel connector is NOT damaged, then both the

injector and the fuel connector MUST be replaced.
RCPH05CDC272ABB 15
20. Remove special tool 3164618 (CUMMINS) from the

fuel return manifold and install the 12 mm banjo
fitting.
RCPH05CDC292ABB 16
21. Remove the isolation tool 3164325 (CUMMINS) from

the fuel rail.
RCPH05CDC233ABA 17
22. Install all fuel lines. Operate the engine and check
for leaks.
3 15/11/2005
B.20.A / 135
Fuel injector - Remove (B.20.A.29 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
M1043 - Attempting to remove the injector without first removing the fuel connector will cause damage to
the injector body and/or the fuel connector.

1. Disconnect the harness leads to the injector.

NOTE: Tag the location of the harness lead for installation
later.
RCPH05CDC208AAA 1
2. Remove the exhaust rocker arm.
RCPH05CDC209AAA 2
3. Remove the two cap screws and remove the injector

clamp (A).
RCPH05CDC211AAA 3
3 15/11/2005
B.20.A / 136
4. Use a small heel bar to pry up on the flange and

remove the injector from the bore.
IMPORTANT: Do NOT grasp, pull or pry on the injector
solenoid or solenoid retaining nut. The injector will be
damaged.
NOTE: If the injector washer is not removed with the
injector, use an O-ring pick to remove the washer from
the bore.
RCPH05CDC212AAA 4
Next operation: Fuel injector - Electrical test (B.20.A.29 - F.40.A.50)
3 15/11/2005
B.20.A / 137
Fuel injector - Electrical test (B.20.A.29 - F.40.A.50)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel injector - Remove (B.20.A.29 - F.10.A.10)
1. Check resistance through the injector solenoid with

a digital voltmeter.
Resistance MUST be less than 0.5K ohms or the

injector must be replaced.
RCPH05CDC283AAA 1
Next operation: Fuel injector - Visual inspection (B.20.A.29 - F.40.A.10)
3 15/11/2005
B.20.A / 138
Fuel injector - Visual inspection (B.20.A.29 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel injector - Electrical test (B.20.A.29 - F.40.A.50)
1. Inspect the tip of the injector for corrosion or carbon

build up.
RCPH05CDC282AAA 1
2. Inspect the sealing surface for the fuel connector for

erosion from a high pressure fuel leak.
Replace both the injector and the fuel connector if

erosion is present.
RCPH05CDC282AAA 2
Next operation: Fuel injector - Install (B.20.A.29 - F.10.A.15) l
3 15/11/2005
B.20.A / 139
Fuel injector - Install (B.20.A.29 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel injector - Visual inspection (B.20.A.29 - F.40.A.10)
1. Install a new O-ring on the injector body. Apply a

light coat of clean engine oil to the O-ring.
RCPH05CDC281AAA 1
2. Check if the injector bore is clean.
RCPH05CDC796AAA 2
3. Apply a light cost of engine oil to a new washer

and install only ONE sealing washer on the injector
nozzle.
RCPH05CDC282AAA 3
3 15/11/2005
B.20.A / 140
4. Place the injector in the bore in the correct

orientation: The fuel inlet MUST face the fuel
connector.
RCPH05CDC213AAA 4
5. Place the plastic shipping sleeve over the injector.

Firmly press down with the palm of your hand to
seat the injector in the bore.
NOTE: If the injector is not installed in the proper
orientation, the fuel connector will be damaged during
installation.
RCPH05CDC214AAA 5
6. Install the clamp over the injector. The flat surface of

clamp must face down, and the notch in the clamp
must align with the pin on the injector.
RCPH05CDC215AAA 6
3 15/11/2005
B.20.A / 141
7. Install the cap screws for the clamp but do NOT

tighten.
RCPH05CDC216AAA 7
8. Apply clean engine oil to the O-ring and threads on

the fuel connector.
Insert the fuel connector while aligning the guide

pin (A) with the slot in the cylinder head at the 12
o’clock position.
The end of the fuel connector MUST engage the

injector inlet port when fully installed.
RCPH05CDC347AAA 8
9. Install the retaining nut on the fuel connector.

Torque to NO MORE than 13.6 Nm (10 lb ft).
NOTE: This is not the final torque value for the fuel
connector.
RCPH05CDC218AAA 9
3 15/11/2005
B.20.A / 142
10. Tighten the cap screws for the injector clamp evenly
so the clamp is evenly spaced around the injector
body. Torque the cap screws to 10 Nm (89 lb in).
RCPH05CDC219AAA 10
11. Torque the fuel connector retaining nut to 41 Nm

(31 lb ft).
RCPH05CDC218AAA 11
12. Install the exhaust rocker arm. Torque to 65 Nm

(48 lb ft).
RCPH05CDC209AAA 12
3 15/11/2005
B.20.A / 143
13. Connect the harness leads to the injectors, using

the tags as a guide.
NOTE: When tightening, position the leads so they will
not come into contact with the rocker arm during engine
operation.
CAUTION
M1045 - Do not overtighten the injector harness
connectors. The injector terminals will be damaged
if over-torqued.
RCPH05CDC208AAA 13
RCPH05CDC001EAA 14
Injector wiring connections by color
1 – Brown harness lead 3 – Yellow harness lead

2 – Red harness lead 4 – Orange harness lead
Next operation: Install the fuel supply line to the fuel connector.
3 15/11/2005
B.20.A / 144
Fuel injector - Measure (B.20.A.29 - F.40.E.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use the gauge from OEM6459 to measure the

injector protrusion when removing the cylinder head
from the block.
Place the tool on the flat surface of head, and zero

the gauge.
RCPH05CDC801AAA 1
2. Measure injector protrusion at the highest point on

the injector. The protrusion MUST be within 2.25 -
2.80 mm (0.088 - 0.110 in).
RCPH05CDC802AAA 2
3. Remove the injector. Refer to Fuel injector -

Remove (B.20.A.29 - F.10.A.10).
RCPH05CDC377AAA 3
3 15/11/2005
B.20.A / 145
4. If the injector protrusion was out of specification,

check the thickness of the injector sealing washer.
The sealing washer thickness MUST be 2.5 mm
+/- 0.05 mm.
RCPH05CDC282AAB 4
5. If the sealing washer is the correct thickness, check

if the injector bore is clean and free or debris or
if more than one sealing washer is stacked in the
injector bore.
RCPH05CDC796AAA 5
3 15/11/2005
B.20.A / 146
High pressure common rail Gear - Timing check (B.20.A.30.05 -

F.40.B.12)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Locate top dead center (TDC) for cylinder number

1 with the engine barring tool – 380000732. Align
the timing line on the fuel pump gear with the front
cover mark for top dead center.
RCPH05CDC048ABB 1
2. Remove the front cover. See Front cover - Remove

(B.10.A.75 - F.10.A.10)
RCPH05CDC102ABB 2
3. Remove the nut and washer from the fuel pump

gear.
RCPH05CDC879AAA 3
3 15/11/2005
B.20.A / 147
4. Check that the alignment pin is present in the gear

keyway. If the pin is not visible, remove the fuel
pump gear and determine the cause:
A – Gear keyway
B – Alignment pin
C – Pump camshaft or
D – Pump gear.
RCPH05CDC887AAA 4
5. If a performance complaint caused this inspection

and the problem appeared after gear train removal
and replacement, check the timing of the crankshaft
gear to the camshaft gear to the fuel pump gear.
RCPH05CDC246AAA 5
Next operation: High pressure common rail Gear - Remove (B.20.A.30.05 - F.10.A.10)
3 15/11/2005
B.20.A / 148
High pressure common rail Gear - Remove (B.20.A.30.05 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear - Timing check (B.20.A.30.05 - F.40.B.12)
1. Use the puller tool – 3163381 (CUMMINS) – to

separate the pump gear from the pump shaft.
RCPH05CDC881AAA 1
Next operation: High pressure common rail Gear - Visual inspection (B.20.A.30.05 - F.40.A.10)
3 15/11/2005
B.20.A / 149
High pressure common rail Gear - Visual inspection (B.20.A.30.05 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear - Remove (B.20.A.30.05 - F.10.A.10)
1. Inspect the keyway on the gear for damage.

Replace the gear if the keyway is damaged.
RCPH05CDC884AAA 1
2. Inspect the alignment pin on the pump camshaft.

Replace the timing pin if damaged.
RCPH05CDC883AAA 2
3. Inspect the pump camshaft for damage. Replace

the pump if the camshaft is damaged.
RCPH05CDC882AAA 3
3 15/11/2005
B.20.A / 150
4. Inspect the gear teeth for damage. Replace the

gear if the teeth are damaged.
RCPH05CDC886AAA 4
Next operation: High pressure common rail Gear - Install (B.20.A.30.05 - F.10.A.15)
3 15/11/2005
B.20.A / 151
High pressure common rail Gear - Install (B.20.A.30.05 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear - Visual inspection (B.20.A.30.05 - F.40.A.10)
1. Install the gear on the pump camshaft with the

alignment pin in the gear keyway and pump gear
timing mark aligned with the camshaft gear timing
mark.
RCPH05CDC877AAA 1
2. Install the washer and nut on the shaft.
RCPH05CDC880AAA 2
3. Torque the nut to 180 Nm (132 lb ft).
RCPH05CDC888AAA 3

3 15/11/2005
B.20.A / 152
High pressure common rail Gear pump - Pressure test (B.20.A.30.10

- F.40.C.30)
MX215, MX245, MX275, MX305, STX280
Engine will not run

1. Install a 10 mm x 1.5 in Compucheck® fitting –
3824842 (CUMMINS) – in the inlet port of the 2 micron
fuel filter. Connect a digital or analog pressure
gauge to the fitting.
NOTE: The gauge range should be 0 - 1034 kPa (0 -
150 psi).
RCPH05CDC109ABA 1
2. While cranking the engine, monitor the gear pump

pressure.
Minimum gear pump pressure while cranking MUST

be 69 kPa (10 psi).
RCPH05CDC112ABA 2
3. If the gear pump pressure is lower than 69 kPa (10

psi):
• Check that engine cranking speed is at least 150

RPM.
• Check that the priming pump pressure during
cranking is at least 35 kPa (5 psi) OR there is
sufficient flow to prime the gear pump. See Priming
pump - Pressure test (B.20.A.35 - F.40.C.30).
3 15/11/2005
B.20.A / 153
Engine will run

4. To measure gear pump pressure at rated condition,
install a 10 mm x 1.5 in Compucheck® fitting (A)
– 3824842 (CUMMINS) – in the outlet port of the 2
micron fuel filter.
RCPH05CDC115ABA 3
5. Connect a Tee fitting (B) to the Compucheck® fitting.
Connect the orificed diagnostic fuel line (C) –

3164621 (CUMMINS) – to the Tee. Route the hose
back to the fuel tank.
Connect an analog or digital pressure gauge (D) to

the open port on the Tee.
150 psi).
RCPH05CDC116ABA 4
6. Operate the engine at high idle and observe the

gear pump pressure.
Minimum gear pump pressure MUST be 483 kPa

(70 psi).
NOTE: Value shown in psi.
RCPH05CDC118ABA 5
7. If the gear pump pressure is low, check for excessive

supply restriction. See FUEL AND INJECTION
3 15/11/2005
B.20.A / 154
High pressure common rail Gear pump - Pressure test (B.20.A.30.10

- F.40.C.30)
2388, 2377
Engine will not run

1. Install a 10 mm x 1.5 in Compucheck® fitting –
3824842 (CUMMINS) – in the inlet port of the 2 micron
fuel filter. Connect a digital or analog pressure
gauge to the fitting.
150 psi).
RCPH05CDC234ABA 1
2. While cranking the engine, monitor the gear pump

pressure.
Minimum gear pump pressure while cranking MUST

be 69 kPa (10 psi).
RCPH05CDC240ABB 2
3. If the gear pump pressure is lower than 69 kPa (10

psi):
• Check that engine cranking speed is at least 150

RPM.
• Check that the fuel transfer pump pressure during
cranking is at least 35 kPa (5 psi) OR there is
sufficient flow to prime the gear pump. See Fuel
transfer pump - Pressure test (B.20.A.34 -
F.40.C.30).
3 15/11/2005
B.20.A / 155
Engine will run

4. To measure gear pump pressure at rated condition,
install a 10 mm x 1.5 in Compucheck® fitting (A)
– 3824842 (CUMMINS) – in the outlet port of the 2
micron fuel filter.
Connect a Tee fitting (B) to the Compucheck® fitting.
Connect the orificed diagnostic fuel line (C) –

3164621 (CUMMINS) – to the Tee. Route the hose
back to the fuel tank.
Connect an analog or digital pressure gauge (D) to

the open port on the Tee.
150 psi).
RCPH05CDC236ABA 3
5. Operate the engine at high idle and observe the

gear pump pressure.
Minimum gear pump pressure MUST be 483 kPa

(70 psi).
NOTE: Value shown in psi.
RCPH05CDC237ABA 4
6. If the gear pump pressure is low, check for excessive

supply restriction. See FUEL AND INJECTION
3 15/11/2005
B.20.A / 156
High pressure common rail Gear pump - Check (B.20.A.30.10 -

F.40.A.11)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Thoroughly clean the gear pump and the area

around the pump if leakage is noted.
2. Use an index card or a clean rag inserted under the
pump to determine if the leak is from the gasket or
from the weep hole.
If the leak is from the gasket, the front area of the

card will be stained – that is, the area where the
gear pump and injection pump housing join.
The weep hole is located on the back of the gear

pump slightly above its middle point. If the leak is
from the weep hole, the rear area of the card will
be stained.
If fuel or oil is visibly dripping from the weep hole

area, a shaft seal failure is likely and the pump
MUST be replaced. RCPH05CDC316ABA 1
Next operation: High pressure common rail Gear pump - Remove (B.20.A.30.10 - F.10.A.10)
3 15/11/2005
B.20.A / 157
High pressure common rail Gear pump - Remove (B.20.A.30.10 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear pump - Check (B.20.A.30.10 - F.40.A.11)
NOTE: The gear pump and surrounding surfaces must be clean and free of fuel, oil and debris prior to removal.
1. Loosen the fuel line clamp (A).
Remove the inlet and outlet fuel lines (B) to the gear
pump.
Remove the fuel supply line (C) to the pump head.
RCPH05CDC067ABA 1
2. Remove the four cap screws that secure the gear

pump to the camshaft housing.
NOTE: Remove the drive coupling if it remains with the
camshaft.
RCPH05CDC999AAA 2
3. Remove the gear pump gasket by the tab.
RCPH05CDC001ABA 3
Next operation: High pressure common rail Gear pump - Visual inspection (B.20.A.30.10 - F.40.A.10)
3 15/11/2005
B.20.A / 158
High pressure common rail Gear pump - Visual inspection

(B.20.A.30.10 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear pump - Remove (B.20.A.30.10 - F.10.A.10)
1. Inspect the drive coupling for wear. If worn, the

coupling MUST be replaced.
RCPH05CDC003ABC 1
Next operation: High pressure common rail Gear pump - Install (B.20.A.30.10 - F.10.A.15)
3 15/11/2005
B.20.A / 159
High pressure common rail Gear pump - Install (B.20.A.30.10 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Gear pump - Visual inspection (B.20.A.30.10 - F.40.A.10)
1. Install the drive coupling on the camshaft.
RCPH05CDC069ABA 1
2. Install a new gasket on the gear pump.
RCPH05CDC070ABA 2
3. If required, adjust the gear pump shaft to align with

the drive coupling. Install the gear pump and secure
it with the four cap screws.
RCPH05CDC071ABA 3
3 15/11/2005
B.20.A / 160
4. Torque the cap screws to 34 Nm (25 lb ft).
RCPH05CDC004ABA 4
5. Install the inlet and outlet fuel lines (A) to the gear
pump.
Install the fuel supply line (B) to the pump head.
Tighten the fuel line clamp (C).
RCPH05CDC067ABA 5
3 15/11/2005
B.20.A / 161
High pressure common rail Pump head and housing - Leakage test
(B.20.A.30.15 - F.40.A.40)
MX215, MX245, MX275, MX305, STX280
WARNING
WARNING
RCPH05CDC068ABA 1

for excessive leakage at the injection pump head,
fuel flow from all three sources MUST be isolated
for proper measuring and to prevent damage to the
system.
system.
RCPH05CDC312ABA 2
3. Remove the fuel line to the fuel cooler on the

RCPH05CDC157ABA 3
3 15/11/2005
B.20.A / 162
4. Remove the banjo bolt fitting and fuel line from the
valve housing.
RCPH05CDC158ABA 4

RCPH05CDC152ABA 5

RCPH05CDC159ABA 6
3 15/11/2005
B.20.A / 163

tank.
RCPH05CDC306ABA 7

return at this point, to drain into the container during
the test.
RCPH05CDC311ABA 8

9. Turn the keyswitch ON and allow the priming pump
to complete its cycle. After the cycle is complete,
crank the engine until fuel exists the test hose
attached to the pump head.
10. When fuel begins to exist the test hose from the
pump head, route the hose to a graduated beaker
and continue cranking for 30 seconds.
If 200 cm³ (7.0 US fl oz) of fuel from the pump head

is collected in less than 30 seconds, the pump head
has failed and MUST be replaced.
See High pressure common rail Pump head and

housing - Disassemble (B.20.A.30.15 - F.10.A.25).
RCPH05CDC313ABA 9
3 15/11/2005
B.20.A / 164
Engine will run

CAUTION
RCSC05CDC169AAA 10
12. Measure the time necessary to collect 300 cm³

(10.0 US fl oz) of fuel from the pump head during
the high pressure leak test.
If 300 cm³ (10.0 US fl oz) of fuel from the pump

head is collected in less than 30 seconds, the pump
head has failed and MUST be replaced.
See High pressure common rail Pump head and

housing - Disassemble (B.20.A.30.15 - F.10.A.25).
RCPH05CDC313ABA 11
13. If return flow from the injectors and/or relief valve

must also be measured, see Fuel injector -
Leakage test (B.20.A.29 - F.40.A.40) and Relief
valve - Leakage test (B.20.A.16 - F.40.A.40).
14. Remove the test equipment from the relief valve and
the regulator valve housing. Reinstall the fuel line at
RCPH05CDC159ABA 12
3 15/11/2005
B.20.A / 165
15. Reinstall the fuel connector on the valve housing.

Connect the line to the fuel cooler at the housing
fitting.
RCPH05CDC157ABA 13
3 15/11/2005
B.20.A / 166
High pressure common rail Pump head and housing - Leakage test
(B.20.A.30.15 - F.40.A.40)
2388, 2377
1. Remove the middle banjo bolt and washer for the

pump head drain line at the fuel return manifold.
Install the return fuel test tool – 3164618 (CUMMINS)
– in the manifold. Route the hose to a suitable
container for collecting fuel.
RCPH05CDC241ABB 1
2. Close the engine covers while performing these

tests.
CAUTION
M1034 - The high pressure leakage test causes the
engine to operate at elevated pressures while the
engine idles. The engine noise changes during the
test 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 this test is in progress.

3. Turn the keyswitch ON and allow the fuel transfer
pump to complete its cycle. After the 30 second
cycle is completed, crank the engine until fuel exits
the test hose.
4. Move the test hose to a graduated beaker and
continue cranking for 30 seconds.
If MORE THAN 200 cm³ (7.0 US fl oz) is collected

in 30 seconds of cranking, the pump head has failed
and MUST be replaced.
RCPH05CDC246ABA 2
3 15/11/2005
B.20.A / 167
Engine will start

5. Use the high pressure leak test in INSITE® to create
high pressure in the fuel rail with the engine running
at idle.
CAUTION
RCSC05CDC169AAA 3
6. Measure the time necessary to collect 300 cm³ (10

US fl oz) while running the high pressure leakage
test. Use a graduated beaker to collect the fuel.
If 300 cm³ (10 US fl oz) is collected in less than 30

seconds, the pump head has failed and MUST be
replaced.
RCPH05CDC246ABA 4
7. Remove the test equipment and install the banjo

bolt and washer in the fuel return manifold.
RCPH05CDC241ABB 5
3 15/11/2005
B.20.A / 168
High pressure common rail Pump head and housing - Remove

(B.20.A.30.15 - F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
from the outlet fitting.
Disconnect the low pressure return line (B) from the

regulator valve housing.
RCPH05CDC068ABA 1
2. Loosen the fuel line clamp (A).
Disconnect the fuel inlet and outlet lines (B) to the

gear pump.
Disconnect the fuel supply line (C) to the regulator

valve housing.
RCPH05CDC067ABA 2
3. Disconnect the engine harness connector (A) for

the regulator valve.
RCPH05CDC067ABA 3
3 15/11/2005
B.20.A / 169
4. Loosen the regulator valve housing cap screw to the

support bracket. Remove the support cap screw (A).
RCPH05CDC017ABA 4
5. Remove the access cover to the fuel pump gear.
RCPH05CDC047ABA 5

Remove the nut and washer from the fuel pump

gear.
RCPH05CDC048ABB 6
3 15/11/2005
B.20.A / 170
7. Use the puller tool – 3163381 (CUMMINS) – to

separate the pump gear from the pump shaft.
RCPH05CDC049ABA 7
8. Remove the four nuts that secure the pump to the

gear housing.
RCPH05CDC050ABA 8
9. Remove the fuel pump from the housing.
RCPH05CDC059ABA 9
Next operation: High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15
- F.40.A.10)
3 15/11/2005
B.20.A / 171
High pressure common rail Pump head and housing - Visual

inspection (B.20.A.30.15 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Pump head and housing - Remove (B.20.A.30.15 - F.10.A.10)
1. Check the alignment pin in the pump drive shaft. If

sheared, the gear pump and the drive gear MUST
be replaced.
RCPH05CDC051ABA 1
2. Check that the pilot O-ring is not cut or damaged.
RCPH05CDC052ABB 2
3. Check that the lubricating oil bore is not obstructed.
RCPH05CDC052ABA 3
3 15/11/2005
B.20.A / 172
4. Check that the pump oil supply O-ring on the gear

housing is not damaged.
RCPH05CDC056ABB 4
Next operation: High pressure common rail Pump head and housing - Install (B.20.A.30.15 - F.10.A.15)
3 15/11/2005
B.20.A / 173
High pressure common rail Pump head and housing - Install

(B.20.A.30.15 - F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15
- F.40.A.10)
IMPORTANT: The engine number 1 cylinder must be at top dead center before the gear pump is installed. Align the
pump gear timing mark with the top dead center mark on the front cover.
1. Lubricate the pilot O-ring with clean engine oil.
RCPH05CDC055ABA 1
2. Clean the pump shaft with contact cleaner.
RCPH05CDC054ABA 2
3. Lubricate the oil supply O-ring with clean engine oil

and properly seat it in the gear housing.
RCPH05CDC057ABA 3
3 15/11/2005
B.20.A / 174
4. Clean the pump gear inside diameter with contact

cleaner.
NOTE: The gear inside diameter and pump shaft must be
clean and dry before the pump is installed.
RCPH05CDC058ABA 4
5. Align the pin on the pump shaft with the gear

keyway. Install the pump shaft through the gear and
place the pump on the mounting studs.
RCPH05CDC059ABA 5
6. Loosely install the pump mounting nuts. Loosely

install the pump support cap screw.
7. Tighten the pump mounting nuts. Torque to 44 Nm
(32 lb ft).
RCPH05CDC060ABA 6
3 15/11/2005
B.20.A / 175
8. Install the support cap screw and tighten the

regulator valve housing cap screw. Torque to 65
Nm (48 lb ft).
RCPH05CDC062ABA 7
9. Install the washer and nut on the gear. Torque the

nut to 180 Nm (132 lb ft).
RCPH05CDC063ABA 8
10. Install the access cover on the front cover.
RCPH05CDC064ABA 9
3 15/11/2005
B.20.A / 176
11. Connect the engine harness connector to the fuel

pressure regulator.
RCPH05CDC067ABA 10
12. Connect the fuel inlet and outlet lines (A) to the gear
pump.
Connect the fuel supply line (B) to the regulator

valve housing.
Tighten the fuel line clamp (C).
RCPH05CDC067ABA 11
13. Connect the fuel return lines (A) to the regulator

valve housing.
Install the fuel supply line (B) for the common rail
RCPH05CDC068ABA 12
3 15/11/2005
B.20.A / 177
High pressure common rail Pump head and housing - Disassemble

(B.20.A.30.15 - F.10.A.25)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the access cover to the fuel pump gear.
RCPH05CDC047ABA 1

RCPH05CDC048ABB 2
3. Disconnect the fuel supply line (A) for the common

rail from the outlet fitting.
RCPH05CDC068ABA 3
3 15/11/2005
B.20.A / 178
4. Completely loosen two of the four cap screws

located diagonally to one another on the pump head.
CAUTION
M1035 - Do not use an air tool. The use of an air tool
may damage the component.
RCPH05CDC025ABA 4
5. Slowly loosen the remaining two cap screws.

Loosen each cap screw about one turn at a time to
avoid binding.
Lift the head assembly with the tappet springs from

the cam housing and move it to clean work surface.
RCPH05CDC036ABA 5
6. Remove the retainers and springs from the barrel

retainers. Mark each component as it is removed
for installation to the same location.
RCPH05CDC035ABA 6
3 15/11/2005
B.20.A / 179
7. If required, remove the ceramic plungers from the

barrels. Mark the plungers for installation to the
same location.
CAUTION
M1037 - Each plunger must be installed in the same
orientation and in the same barrel or engine damage
can occur.
RCPH05CDC034ABA 7
8. Do NOT remove the barrel retainers.
CAUTION
M1036 - Do not remove the barrel retainers. Damage
to the pump head and barrel retainers will occur.
RCPH05CDC033ABA 8
9. Use an O-ring pick to remove the tappets from

the pump camshaft housing. Mark the tappets for
installation to the same location.
RCPH05CDC026ABA 9
Next operation: High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15
- F.40.A.10)
3 15/11/2005
B.20.A / 180
High pressure common rail Pump head and housing - Visual

inspection (B.20.A.30.15 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Pump head and housing - Disassemble (B.20.A.30.15 - F.10.A.25)
1. Only use contact cleaner to clean the components:

springs, retainers, plungers, tappets and housing
surfaces. Special care must be taken to keep
these components extremely clean. Cover the
camshaft housing with a clean shop towel while the
components are removed.
2. Inspect the pump camshaft for wear. If excessive
pitting on the lobes of the camshaft is present, the
pump MUST be replaced.
RCPH05CDC028ABB 1
3. Inspect the tappet guide pins in the housing. If more

than 25 % guide pin wear is present, the pump
MUST be replaced.
RCPH05CDC027ABB 2
3 15/11/2005
B.20.A / 181
4. Inspect the tappet guide pin grooves. If more than

25 % groove wear is present, the pump MUST be
replaced.
RCPH05CDC032ABB 3
5. Inspect the tappet rollers for wear. If excessive

pitting on the rollers is present, the tappet(s) must
be replaced.
RCPH05CDC031ABB 4
6. Inspect the plungers if removed. Some discoloration

may be evident and is acceptable.
RCPH05CDC030ABA 5
3 15/11/2005
B.20.A / 182
7. Deep scoring is NOT acceptable. If scoring or

scratches are present that can be felt, the pump
head MUST be replaced.
RCPH05CDC065ABB 6
8. If damage to the camshaft, shaft housing or tappets

is present, the pump may not be receiving adequate
lubricating oil. When the pump is replaced, inspect
the gear housing O-ring and bore for blockage in
the oil supply to the pump.
RCPH05CDC056ABB 7
Next operation: High pressure common rail Pump head and housing - Assemble (B.20.A.30.15 - F.10.A.20)
3 15/11/2005
B.20.A / 183
High pressure common rail Pump head and housing - Assemble

(B.20.A.30.15 - F.10.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15
- F.40.A.10)
1. Install the plungers in their original location on the

pump head.
RCPH05CDC034ABA 1
2. Install the springs and retainers in their original

locations.
NOTE: If a new pump head is installed, install the springs
and retainers provided with the new head.
RCPH05CDC035ABA 2
3. Install new O-rings on the camshaft housing.
RCPH05CDC028ABA 3
3 15/11/2005
B.20.A / 184
4. Install the tappets in their original locations. The

guide pins must engage the grooves in the tappets.
RCPH05CDC026ABA 4
5. Place the head assembly on the cam housing. Draw

the head down by alternately tightening the four cap
screws until the head contacts the cam housing.
RCPH05CDC036ABA 5
RCPH05CDC037ABA 6
3 15/11/2005
B.20.A / 185
7. Connect the fuel supply line (A) for the common rail
RCPH05CDC068ABA 7
8. Install the access cover on the front cover.
RCPH05CDC064ABA 8
3 15/11/2005
B.20.A / 186
High pressure common rail Outlet - Remove (B.20.A.30.20 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Disconnect the fuel supply line for the common rail

from the outlet fitting on the pump head.
RCPH05CDC068ABA 1
2. Remove the outlet fitting and the seal washer from

the pump head.
RCPH05CDC006ABA 2
3. If required, use a tapered punch to remove the seal

washer. Insert the punch in the center of the washer
and work the washer out of the bore.
RCPH05CDC007ABB 3
Next operation: High pressure common rail Outlet - Visual inspection (B.20.A.30.20 - F.40.A.10)
3 15/11/2005
B.20.A / 187
High pressure common rail Outlet - Visual inspection (B.20.A.30.20

- F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Outlet - Remove (B.20.A.30.20 - F.10.A.10)
1. Clean the threaded bore in the pump head with

contact cleaner.
RCPH05CDC012ABA 1
2. Inspect the threads and cavity for burrs or debris.

Clean any burrs with a wire brush then flush the
bore clean.
RCPH05CDC011ABB 2
3. Inspect the seal washer end of the outlet fitting. The

crown should be polished and free of any nicks or
inclusions. If the crown is damaged or severely
flattened, the fitting must be replaced.
RCPH05CDC008ABA 3
Next operation: High pressure common rail Outlet - Install (B.20.A.30.20 - F.10.A.15)
3 15/11/2005
B.20.A / 188
High pressure common rail Outlet - Install (B.20.A.30.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Outlet - Visual inspection (B.20.A.30.20 - F.40.A.10)
1. Install a NEW seal washer in the outlet fitting. The

washer should pilot into the outlet fitting.
IMPORTANT: This joint is designed to seal in excess of
179,264 kPa (26,000 psi). Seal washers MUST NOT be
reused.
NOTE: A small amount of CASE AKCELA EP-0 GREASE
may be used to keep the washer attached to the fitting
during installation.
RCPH05CDC013ABA 1
2. Install the outlet fitting in the pump head. Torque to

5.6 Nm (50 lb in).
RCPH05CDC014ABA 2
3. Advance the fitting 120 degrees.
RCPH05CDC015ABA 3
3 15/11/2005
B.20.A / 189
4. Connect the fuel supply line for the common rail to

the outlet fitting.
RCPH05CDC068ABA 4
5. Operate the engine and check for leaks. Perform

several throttle snaps so that increased fuel rail
pressure may be developed.
3 15/11/2005
B.20.A / 190
High pressure common rail Common rail - Remove (B.20.A.30.25 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Inspect the fuel pressure sensor and high pressure

fuel line connections for signs of leakage.
WARNING
WARNING
RCPH05CDC304ABA 1
2. Disconnect the harness connector to the fuel rail

pressure sensor.
RCPH05CDC303ABA 2
3. Remove the high pressure fuel line between the

fuel pump high pressure connector and the fuel
rail. Refer to Fuel line High pressure - Remove
(B.20.A.36.20 - F.10.A.10).
RCPH05CDC921AAA 3
3 15/11/2005
B.20.A / 191
4. Loosen the connector for each fuel connector supply

line at the fuel rail.
RCPH05CDC904AAA 4
5. Disconnect the supply line from each fuel connector.
RCPH05CDC901AAA 5
6. Remove the three cap screws and remove the fuel

rail from the block.
RCPH05CDC898AAA 6
Next operation: High pressure common rail Common rail - Visual inspection (B.20.A.30.25 - F.40.A.10)
3 15/11/2005
B.20.A / 192
High pressure common rail Common rail - Visual inspection

(B.20.A.30.25 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Common rail - Remove (B.20.A.30.25 - F.10.A.10)
1. Inspect the fuel rail for damage or signs of fuel

leakage. See Sensing system Pressure sensor
- Remove (B.20.A.95.81 - F.10.A.10) for sensor
replacement.
RCPH05CDC889AAA 1
2. Check the ferrules of the supply lines to the fuel

connectors for burrs or foreign material.
Inspect the sealing surface of the cone for

deformation that would prevent reuse.
Check for cracks or deformation.
RCPH05CDC896AAB 2
3. If a high pressure fitting at the ends of the rail shows

signs of leakage, see High pressure common
rail Common rail - Disassemble (B.20.A.30.25 -
F.10.A.25).
RCPH05CDC894AAA 3
Next operation: High pressure common rail Common rail - Install (B.20.A.30.25 - F.10.A.15)
3 15/11/2005
B.20.A / 193
High pressure common rail Common rail - Install (B.20.A.30.25 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Common rail - Visual inspection (B.20.A.30.25 - F.40.A.10)
1. Install the fuel rail on the block with the three cap
screws. Install the cap screws finger tight.
Loosely connect the fuel supply lines to the fuel

connectors.
Tighten and torque the fuel rail cap screws to 43

Nm (32 lb ft).
RCPH05CDC898AAA 1
2. Tighten and torque the supply lines at the fuel

connectors and at the fuel rail to 38 Nm (28 lb ft).
RCPH05CDC902AAA 2
3. Connect the harness connector to the pressure

sensor.
RCPH05CDC303ABA 3
3 15/11/2005
B.20.A / 194
High pressure common rail Common rail - Disassemble

(B.20.A.30.25 - F.10.A.25)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: Remove the high pressure fitting from the fuel rail only if a leak is detected.
1. Remove the fuel supply line to the high pressure
fitting.
2. Remove the high pressure fitting.
RCSC05CDC174AAA 1
Next operation: High pressure common rail Common rail - Assemble (B.20.A.30.25 - F.10.A.20)
3 15/11/2005
B.20.A / 195
High pressure common rail Common rail - Assemble (B.20.A.30.25 -

F.10.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: High pressure common rail Common rail - Disassemble (B.20.A.30.25 - F.10.A.25)
1. Clean the fitting with contact cleaner. Apply CASE

AKCELA EP-0 GREASE to the threads on the
fitting.
Install the fitting and torque to 100 Nm (74 lb ft).
RCSC05CDC174AAA 1
2. Install the injector supply line to the fitting.
3 15/11/2005
B.20.A / 196
Fuel transfer pump - Pressure test (B.20.A.34 - F.40.C.30)

2388, 2377
1. To check the output pressure of the fuel transfer

pump, measure the pressure at the inlet test port
on the gear pump.
RCPH05CDC998AAA 1
2. Install a digital (A) or analog pressure gauge to the

test port. A Compucheck® 10 mm x 1.5 in O-ring
fitting (B) – 3824842 (CUMMINS) – is required for this
test port.
RCPH05CDC238ABA 2
3. Turn the keyswitch ON; the pump will run for 30

seconds and then an indicator lamp will signal that
the engine is ready to start. Cycle the keyswitch
OFF and then ON again, and measure the fuel
transfer pump pressure at the gear pump.
4. Minimum pressure must be 34 kPa (5 psi) OR there
MUST be sufficient fuel flow to prime the gear pump.
IMPORTANT: The gauge used may not accurately
measure low pressures. The pressure reading is better
interpreted as sufficient fuel flow to prime the gear pump.
RCPH05CDC239ABA 3
3 15/11/2005
B.20.A / 197
5. If no flow or very little flow is present, check if

the cooling plate check valve is stuck or plugged,
check for pre-filter or line restriction and check the
condition of the transfer pump.
NOTE: If the 2 micron fuel filter was replaced prior to this
test, the fuel transfer pump must be cycled three or four
times to purge air from the fuel circuit before this test will
be valid.
RCPH05CDC182ABA 4
3 15/11/2005
B.20.A / 198
Priming pump - Pressure test (B.20.A.35 - F.40.C.30)

MX215, MX245, MX275, MX305, STX280
1. To check the output pressure of the priming pump,

measure the pressure at the inlet test port on the
gear pump.
RCPH05CDC998AAA 1
2. Install a digital (A) or mechanical pressure gauge

to the test port. A Compucheck® 10 mm x 1.5 in
O-ring fitting (B) – 3824842 (CUMMINS) – is required
for this test port.
RCPH05CDC121ABA 2
3. Turn the keyswitch ON; the pump will run for 30

seconds and then stop. Cycle the keyswitch OFF
and then ON again, and measure the priming pump
pressure at the gear pump.
4. Minimum pressure must be 34 kPa (5 psi).
RCPH05CDC110ABA 3
3 15/11/2005
B.20.A / 199
5. If the priming pump pressure is low while it is

running, check if the cooling plate check valve is
stuck open.
NOTE: If the fuel filter was replaced prior to this test, the
priming pump must be cycled three or four times to purge
air from the fuel circuit before this test will be valid.
RCPH05CDC182ABA 4
3 15/11/2005
B.20.A / 200
Priming pump - Remove (B.20.A.35 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280
WARNING
M1110 - Before carrying out any operation or service work on electrical system components, turn the starter
switch key to the "OFF" position and remove the key. When disconnecting batteries, always disconnect the
negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.
Disconnect the batteries.

Thoroughly clean the components and the fittings prior to removal. Debris, water, steam or solvent must NOT
enter the fuel system

1. Remove the inlet fuel connector to the priming

pump.
RCPH05CDC149AAA 1
2. Remove the outlet fuel connector to the pump and

remove the fuel line.
RCPH05CDC150AAA 2
3 15/11/2005
B.20.A / 201
3. Remove the cap screws for the bracket.
RCPH05CDC151AAA 3
4. Remove the bracket and vibration isolator.
RCPH05CDC152AAA 4
5. Slide the pump out of the other bracket and remove

the pump.
RCPH05CDC153AAA 5
Next operation: Priming pump - Disassemble (B.20.A.35 - F.10.A.25)
3 15/11/2005
B.20.A / 202
Priming pump - Disassemble (B.20.A.35 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280
Prior operation: Priming pump - Remove (B.20.A.35 - F.10.A.10)
1. Remove the check valve fitting (shown) and fuel

fitting from the cooling plate.
RCPH05CDC154AAA 1
2. Disassemble the remaining pump bracket.
RCPH05CDC157AAA 2
Next operation: Priming pump - Visual inspection (B.20.A.35 - F.40.A.10)
3 15/11/2005
B.20.A / 203
Priming pump - Visual inspection (B.20.A.35 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280
Prior operation: Priming pump - Disassemble (B.20.A.35 - F.10.A.25)
1. Inspect the check valve fitting for free operation.

Check the O-ring and washers for proper sealing.
RCPH05CDC155AAA 1
2. Inspect the pump brackets and vibration isolators

for wear or damage.
RCPH05CDC156AAA 2
3. Inspect the fuel lines and connectors for wear,

leakage or damage.
RCPH05CDC158AAA 3
3 15/11/2005
B.20.A / 204
4. Inspect the cooling plate vibration isolators for wear

or damage.
RCPH05CDC158AAA 4
Next operation: Priming pump - Assemble (B.20.A.35 - F.10.A.20)
3 15/11/2005
B.20.A / 205
Priming pump - Assemble (B.20.A.35 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280
Prior operation: Priming pump - Visual inspection (B.20.A.35 - F.40.A.10)
1. Install the fuel lines and fittings to the cooling plate.
RCPH05CDC154AAA 1
2. Install the inner plate bracket and isolator for the

priming pump.
Next operation: Priming pump - Install (B.20.A.35 - F.10.A.15)
3 15/11/2005
B.20.A / 206
Priming pump - Install (B.20.A.35 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280
Prior operation: Priming pump - Assemble (B.20.A.35 - F.10.A.20)
1. Install the priming pump in the inner bracket.
RCPH05CDC153AAA 1
2. Install the bracket and vibration isolator and secure

with the two cap screws. Torque all cap screws to
10 Nm (89 lb in).
RCPH05CDC151AAA 2
3. Install the fuel line and connector to pump outlet

port.
RCPH05CDC150AAA 3
3 15/11/2005
B.20.A / 207
4. Install the fuel line and connector to the pump inlet

port.
NOTE: The fuel lines must not contact each other or the
engine block as assembled.
RCPH05CDC149AAA 4
Next operation: Fuel line Cooling plate - Install (B.20.A.36.30 - F.10.A.15)

3 15/11/2005
B.20.A / 208
Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280
Fuel return line

1. Low pressure return flow from the injectors (A), the
fuel rail relief valve (B) and fuel pump head (C) is
piped on a common return line to the fuel cooler.
RCPH05CDC302ABA 1

valve) and washers, and disconnect the line at the
injector return port at the rear of the head.
RCPH05CDC916AAA 2
3. Remove the banjo bolt and washers, and disconnect

the line at the fuel rail pressure relief valve.
RCPH05CDC912AAA 3
3 15/11/2005
B.20.A / 209
4. Remove the clamp and fuel line from the banjo fitting
on the regulator valve housing at the pump head.
RCPH05CDC915AAA 4
5. Remove the banjo bolt and washers, and remove

the low pressure return line from the engine.
RCPH05CDC914AAA 5
Next operation: Fuel line Low pressure - Visual inspection (B.20.A.36.10 - F.40.A.10)
3 15/11/2005
B.20.A / 210
Fuel line Low pressure - Visual inspection (B.20.A.36.10 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280
Prior operation: Fuel line Low pressure - Remove (B.20.A.36.10 - F.10.A.10)
Fuel return line

1. Inspect the line for damage at the three connections.
RCPH05CDC907AAB 1
2. Inspect the joints and flexible piping for damage or

signs of leakage.
RCPH05CDC909AAA 2
3. Inspect the banjo bolt connectors and washers for

damage.
RCPH05CDC910AAA 3
Next operation: Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15)
3 15/11/2005
B.20.A / 211
Fuel line Low pressure - Install (B.20.A.36.10 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280
Prior operation: Fuel line Low pressure - Visual inspection (B.20.A.36.10 - F.40.A.10)
Fuel return line

1. Connect the fuel return line with the banjo bolt (with
the integral check valve) and washers at the injector
return port at the rear of the head.
RCPH05CDC916AAA 1
2. Torque the 12 mm bolt to 24 Nm (18 lb ft).
RCPH05CDC918AAA 2
3. Connect the fuel line at the fuel rail pressure relief

valve with the banjo bolt and washers.
RCPH05CDC912AAA 3
3 15/11/2005
B.20.A / 212
4. Torque the 14 mm banjo bolt to 34 Nm (25 lb ft).
RCPH05CDC919AAA 4
5. Connect the fuel line to the regulator valve housing

at the pump head with the banjo bolt and washers.
RCPH05CDC914AAA 5
6. Torque the 12 mm bolt to 24 Nm (18 lb ft). If

required, reconnect the fuel line to the fuel cooler to
the fitting with the clamp removed earlier.
RCPH05CDC920AAA 6
3 15/11/2005
B.20.A / 213

2388, 2377
Fuel return lines
RCIL05CDC007CAA 1
Fuel return manifold
A - Regulator valve housing B - Fuel rail relief valve C - Injector return D - Return manifold
1. Bypassed flow from the fuel pump head (through the
regulator valve housing) (A), flow from the fuel rail
relief valve (B) and return flow from the fuel injectors
(C) is routed on separate lines to a common return
manifold (D), located on the left hand rear corner
of the engine.
RCIL05CDC013AAA 2
3 15/11/2005
B.20.A / 214

valve) and washers, and disconnect the line at the
injector return port at the rear of the head.
RCPH05CDC916AAA 3

the line at the fuel rail pressure relief valve.
the line at the regulator valve housing.
5. Remove the three banjo bolts and washers at the
return manifold and remove the three fuel lines.
3 15/11/2005
B.20.A / 215

2388, 2377
Fuel return line

1. Inspect the three lines for damage at the connectors.
RCPH05CDC907AAB 1
2. Inspect the joints and flexible piping for damage or

signs of leakage.
RCPH05CDC909AAA 2
3. Inspect the banjo bolt connectors and washers for

damage.
RCPH05CDC910AAA 3
3 15/11/2005
B.20.A / 216

2388, 2377
Fuel return lines
RCIL05CDC007CAA 1
Fuel return manifold
A - Regulator valve housing B - Fuel rail relief valve C - Injector return D - Return manifold
1. Connect the injector return line with the banjo bolt
(with the integral check valve) and washers at the
injector return port at the rear of the head. Connect
the same line to the right hand port of the return
manifold with a banjo bolt and washers.
RCPH05CDC916AAA 2
3 15/11/2005
B.20.A / 217
2. Torque the 12 mm bolts to 24 Nm (18 lb ft).
RCPH05CDC918AAA 3
3. Connect the fuel line for the regulator valve housing

with the banjo bolt and washers. Connect the same
line to the middle port of the return manifold with a
banjo bolt and washers.
Torque the 12 mm bolts to 24 Nm (18 lb ft).

4. Connect the fuel line for the fuel rail relief valve with
the 14 mm banjo bolt and washers. Connect the
same line to the left hand port of the return manifold
with a 12 mm banjo bolt and washers.
Torque the 14 mm banjo bolt to 34 Nm (25 lb ft).
Torque the 12 mm bolt to 24 Nm (18 lb ft).
3 15/11/2005
B.20.A / 218

MX215, MX245, MX275, MX305, STX280
Quick disconnect fuel lines

1. Remove the quick disconnect fuel lines by pressing
in the tangs on both sides of the fitting.
NOTE: A screwdriver may be inserted between the
connector and the male fitting to aid removal. Twist the
flat blade while pressing the tangs.
RCPH05CDC124AAA 1
2. Remove the cap screw and clamping plate.
RCPH05CDC219ABA 2
3. Remove the fuel line between the gear pump outlet

and the 2 micron filter inlet port.
RCPH05CDC218ABA 3
3 15/11/2005
B.20.A / 219
4. Remove the fuel line between the 2 micron filter

outlet and the pressure regulator valve housing.
NOTE: This is the supply line to the high pressure pump
chamber.
RCPH05CDC217ABA 4
5. Remove the fuel line between the gear pump inlet

and the cooling plate lower outlet.
If required, remove the cap screw and bracket for

the fuel lines.
NOTE: This is the supply line to the gear pump.
RCPH05CDC216ABA 5
3 15/11/2005
B.20.A / 220

MX215, MX245, MX275, MX305, STX280

1. Inspect the male fittings to the lines for burrs or
debris which may cause leaks.
Inspect the O-rings for deterioration, breaks or cuts.

Inspect the tangs for damage. Replace the fuel line
if the line is leaking or will not seal at a connection.
RCSC05CDC176AAA 1
3 15/11/2005
B.20.A / 221

MX215, MX245, MX275, MX305, STX280

1. If required, install the fuel line bracket and cap
screw. Torque the cap screw to 24 Nm (18 lb ft).
Install the fuel line between the gear pump inlet and
the cooling plate lower outlet.
RCPH05CDC216ABA 1
2. Install the fuel line between the 2 micron filter outlet

and the pressure regulator valve housing.
chamber.
RCPH05CDC217ABA 2
3. Install the fuel line between the gear pump outlet

RCPH05CDC218ABA 3
3 15/11/2005
B.20.A / 222
4. Install the clamping plate and cap screw. Torque the

cap screw to 24 Nm (18 lb ft).
RCPH05CDC219ABA 4
3 15/11/2005
B.20.A / 223

2388, 2377

1. Remove the quick disconnect fuel lines by pressing
in the tangs on both sides of the fitting.
NOTE: A screwdriver may be inserted between the
connector and the male fitting to aid removal. Twist the
flat blade while pressing the tangs.
RCSC05CDC175AAA 1
2. Remove the cap screw and clamping plate.
RCPH05CDC219ABA 2
RCSC05CDC006CAA 3
3 15/11/2005
B.20.A / 224
Front view
RCSC05CDC005CAA 4
Rear view
3. Remove the fuel line (A) between the gear pump
outlet and the 2 micron filter inlet port.
4. Remove the fuel line (B) between the 2 micron filter
chamber.
5. Remove the fuel line (C) between the gear pump
inlet and the cooling plate lower outlet.
6. If required, remove the cap screw (A) and bracket
(B) for the fuel lines.
RCPH05CDC900AAA 5
3 15/11/2005
B.20.A / 225

2388, 2377

1. Inspect the male fittings to the lines for burrs or
debris which may cause leaks.
Inspect the O-rings for deterioration, breaks or cuts.

Inspect the tangs for damage. Replace the fuel line
if the line is leaking or will not seal at a connection.
RCSC05CDC176AAA 1
3 15/11/2005
B.20.A / 226

2388, 2377

1. If required, install the fuel line bracket (B) and cap
screw (A). Torque the cap screw to 24 Nm (18 lb ft).
RCPH05CDC900AAA 1
RCSC05CDC006CAA 2
Front view
3 15/11/2005
B.20.A / 227
RCSC05CDC005CAA 3
Rear view
2. Install the fuel line (C) between the gear pump inlet
and the cooling plate lower outlet.
3. Install the fuel line (B) between the 2 micron filter
chamber.
4. Install the fuel line (A) between the gear pump outlet
5. Install the clamping plate and cap screw. Torque the
cap screw to 24 Nm (18 lb ft).
RCPH05CDC219ABA 4
3 15/11/2005
B.20.A / 228
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel rail supply

1. Remove the high pressure fuel line between the fuel
pump high pressure connector and the fuel rail.
WARNING
RCPH05CDC921AAA 1
Next operation: Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)
3 15/11/2005
B.20.A / 229
Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10)
Fuel rail supply

1. Check the ferrules for burrs or foreign material.
Inspect the cone sealing surface for deformation

that would prevent reuse.
Check for cracks or other damage.
RCPH05CDC905AAB 1
Next operation: Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15)
3 15/11/2005
B.20.A / 230
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)
Fuel rail supply

1. Install the fuel line between the fuel pump high
pressure connector and the fuel rail. Torque both
line connections to 38 Nm (28 lb ft).
RCPH05CDC922AAA 1
3 15/11/2005
B.20.A / 231
Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector/injector supply

1. Disconnect the fuel line at the fuel connector.
RCPH05CDC901AAA 1
2. Disconnect the fuel line at the fuel rail, and remove

the fuel line.
RCPH05CDC904AAA 2
Next operation: Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)
3 15/11/2005
B.20.A / 232
Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel line High pressure - Remove (B.20.A.36.20 - F.10.A.10)

1. Check the ferrules for burrs or foreign material.
Inspect the sealing surface of the cones for

deformation that would prevent reuse.
Check for cracks or deformation.
RCPH05CDC896AAB 1
Next operation: Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15)
3 15/11/2005
B.20.A / 233
Fuel line High pressure - Install (B.20.A.36.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel line High pressure - Visual inspection (B.20.A.36.20 - F.40.A.10)

1. Connect the fuel line at the fuel connector finger
tight.
Connect the fuel line at the fuel rail finger tight.
Tighten and torque the fuel line at both connectors

to 38 Nm (28 lb ft).
RCPH05CDC902AAA 1
3 15/11/2005
B.20.A / 234
Fuel line Cooling plate - Remove (B.20.A.36.30 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the 2 micron fuel filter.
RCPH05CDC167ABA 1
2. Remove the fuel connectors on the right hand side

of the cooling plate.
RCPH05CDC168ABA 2
3. Plug or cap all ports.
RCPH05CDC169ABA 3
3 15/11/2005
B.20.A / 235
4. Disconnect the harness connector to the integral

priming pump, if present.
RCPH05CDC173ABA 4
5. Remove the cap screws from the four corners of the

cooling plate.
RCPH05CDC170ABA 5
6. Remove the cooling plate.
RCPH05CDC171ABA 6
Next operation: Combines – Fuel line Cooling plate - Visual inspection (B.20.A.36.30 - F.40.A.10)
Next operation: Tractors – Priming pump - Remove (B.20.A.35 - F.10.A.10)
3 15/11/2005
B.20.A / 236
Fuel line Cooling plate - Visual inspection (B.20.A.36.30 - F.40.A.10)

2388, 2377
1. Inspect the cooling plate for damage. Check the

vibration isolators for leakage or damage, and
replace as required.
RCPH05CDC181ABA 1
2. Inspect the check valve fitting (A) for proper

operation. Check both fittings for plugging, damage
and proper sealing.
RCPH05CDC182ABA 2
Next operation: Fuel line Cooling plate - Install (B.20.A.36.30 - F.10.A.15)
3 15/11/2005
B.20.A / 237
Fuel line Cooling plate - Install (B.20.A.36.30 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Combines – Fuel line Cooling plate - Visual inspection (B.20.A.36.30 - F.40.A.10)
Prior operation: Tractors – Priming pump - Install (B.20.A.35 - F.10.A.15)
1. Position the cooling plate on the engine block.
RCPH05CDC171ABA 1
2. Install the cap screws in the four corners of the

cooling plate.
RCPH05CDC170ABA 2
RCPH05CDC172ABA 3
3 15/11/2005
B.20.A / 238
4. Connect the harness connector for the priming

pump, if present.
RCPH05CDC173ABA 4
5. Remove the plugs and install the fuel connectors on

the right hand side of the plate.
RCPH05CDC174ABA 5
6. Lubricate the seal on the final fuel filter with clean

engine oil or CASE AKCELA EP-0 GREASE.
RCPH05CDC176ABA 6
3 15/11/2005
B.20.A / 239
7. Install the 2 micron fuel filter.
RCPH05CDC179ABA 7
3 15/11/2005
B.20.A / 240
Fuel connector - Remove (B.20.A.37 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the fuel supply line to the connector.
RCPH05CDC203AAA 1
2. Remove the fuel retaining nut.
RCPH05CDC204AAA 2
3. Use the fuel connector tool – 3164025 (CUMMINS)

(A) – to remove the fuel connector from the head.
RCPH05CDC206AAA 3
Next operation: Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10)
3 15/11/2005
B.20.A / 241
Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: A new fuel connector MUST be installed whenever a new injector is installed.
1. Inspect the fuel connector. Look for burrs or
deformation around the inlet side of the connector.
Check the edge filter for signs of plugging or material

contamination. Do NOT reuse a fuel connector if
debris is present.
RCPH05CDC286ABB 1
2. Check the connector outlet for burrs or deformation.
RCPH05CDC284ABC 2
3. Inspect the outlet sealing surface for wear, an

uneven seating surface or signs of leakage.
When a high pressure fuel leak is present, small

lines or cuts will be eroded into the sealing surface
of the connector.
Both the injector and connector MUST be replaced

when this failure is observed.
RCPH05CDC284ABB 3
3 15/11/2005
B.20.A / 242
4. Check the O-ring for tearing or deterioration.
RCPH05CDC285ABB 4
Next operation: Fuel connector - Install (B.20.A.37 - F.10.A.15)
3 15/11/2005
B.20.A / 243
Fuel connector - Install (B.20.A.37 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10)
IMPORTANT: If the injector was removed along with the fuel connector, the procedure at Fuel injector - Install
(B.20.A.29 - F.10.A.15) MUST be used rather than this procedure.
NOTE: A new fuel connector MUST be installed whenever a new injector is installed.
1. Apply clean engine oil to the O-ring and threads on
the connector.
Carefully insert the fuel connector while aligning the

guide pin (A) with the slot in the cylinder head at
the 12 o’clock position.
RCPH05CDC347AAA 1
2. Install and tighten the connector retaining nut.

Torque the nut to 41 Nm (31 lb ft).
RCPH05CDC218AAA 2
3. Install the fuel supply line to the connector. Torque

the fuel line to 38 Nm (28 lb ft).
RCPH05CDC203AAA 3
3 15/11/2005
B.20.A / 244
Sensing system Pressure sensor - Preliminary test (B.20.A.95.81 -

F.40.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Use INSITE® to monitor the fuel rail pressure

sensor (measured) with the engine running.
The measured value from the fuel rail pressure

sensor MUST be less than 30 bar (435 psi).
If the measured value is greater than 30 bar (435

psi), replace the pressure sensor.
RCPH05CDC325ABA 1
Next operation: Sensing system Pressure sensor - Remove (B.20.A.95.81 - F.10.A.10)
3 15/11/2005
B.20.A / 245
Sensing system Pressure sensor - Remove (B.20.A.95.81 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Pressure sensor - Preliminary test (B.20.A.95.81 - F.40.A.20)

1. Clean the area around the fuel pressure sensor.
RCPH05CDC355ABA 1
2. Disconnect the engine harness connector from the

pressure sensor.
RCPH05CDC356ABA 2
3. Remove the sensor from the fuel rail.
RCPH05CDC358ABA 3
Next operation: Sensing system Pressure sensor - Visual inspection (B.20.A.95.81 - F.40.A.10)
3 15/11/2005
B.20.A / 246
Sensing system Pressure sensor - Visual inspection (B.20.A.95.81 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Pressure sensor - Remove (B.20.A.95.81 - F.10.A.10)

• Loose connector
• Corroded pins

required.
RCPH05CDC357ABA 1
2. Inspect the sensor for the following:
• Damaged seal surface in the rail,

• Damaged seal surface on the sensor,
• Thread damage.
Replace the sensor if damage is found. Replace the

fuel rail if the seal surface for the sensor is damaged.
RCPH05CDC892AAA 2
Next operation: Sensing system Pressure sensor - Install (B.20.A.95.81 - F.10.A.15)
3 15/11/2005
B.20.A / 247
Sensing system Pressure sensor - Install (B.20.A.95.81 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Pressure sensor - Visual inspection (B.20.A.95.81 - F.40.A.10)

1. Install the sensor in the fuel rail. Torque the sensor
RCPH05CDC359ABA 1

sensor. Start the engine and check for leaks. Verify
operation of the fuel sensor with INSITE®.
RCPH05CDC356ABA 2
3 15/11/2005
B.20.A / 248
Sensing system Water sensor - Remove (B.20.A.95.85 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Disconnect the engine harness connector to the
water in fuel sensor.
RCPH05CDC225ABA 1
2. Remove the sensor from the fuel pre-filter.
RCPH05CDC229ABA 2
Next operation: Sensing system Water sensor - Visual inspection (B.20.A.95.85 - F.40.A.10)
3 15/11/2005
B.20.A / 249
Sensing system Water sensor - Visual inspection (B.20.A.95.85 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Water sensor - Remove (B.20.A.95.85 - F.10.A.10)

1. Inspect the harness connector for:
• Loose connector
• Corroded cavities
• Dirt or debris in the connector cavities
Repair or replace cavities, wires or the harness

connector as required.
If the sensor connector is damaged, replace the fuel

filter.
1
NOTE: The sensor is integrated into the fuel pre-filter RCPH05CDC225ABA
and is not serviced separately. The sensor is replaced

whenever the pre-filter is replaced.
Next operation: Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01)
3 15/11/2005
B.20.A / 250
Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Water sensor - Visual inspection (B.20.A.95.85 - F.40.A.10)

1. Use a digital voltmeter to measure resistance
between the pins in the sensor connector.
If resistance is less than 100K ohms, replace the

fuel pre-filter.
RCPH05CDC361ABA 1
Next operation: Sensing system Water sensor - Install (B.20.A.95.85 - F.10.A.15)
3 15/11/2005
B.20.A / 251
Sensing system Water sensor - Install (B.20.A.95.85 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01)

1. Install the sensor in the pre-filter. Torque the sensor
to 4 Nm (35 lb in).
RCPH05CDC363ABA 1

sensor.
RCPH05CDC225ABA 2
3 15/11/2005
B.20.A / 252
FUEL AND INJECTION SYSTEM - Problem solving (B.20.A -

G.40.A.30)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Tractors – Refer to FUEL AND INJECTION SYSTEM - Dynamic description (B.20.A - C.30.A.10) for fuel
system operation.
Combines – Refer to FUEL AND INJECTION SYSTEM - Dynamic description (B.20.A - C.30.A.10) for fuel
system operation.
TROUBLESHOOTING
• A thorough analysis of a customer’s complaint is the key to successful troubleshooting. The more information
known about a complaint, the faster and easier the problem can resolved.
• The tables are organized to locate a problem by doing the easiest and most logical things first. Complete
all steps in the sequence from top to the bottom.
• It is NOT possible to list all possible solutions to all possible problems; however, these tables are organized to
stimulate a thought process that will lead to the cause and correction of the problem.
• Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint.
• Analyze the problem thoroughly.
• Relate the symptoms to the basic engine systems and components.
• Consider any recent maintenance or repair work that might relate to the complaint.
• Double check before beginning any disassembly.
• Use the order in the tables to eliminate the simplest problems first.
• When the problem is located, perform a thorough repair.
• When the repair is complete, operate the engine to make sure the complaint has been corrected.
WARNING

Fuel in the lubricating oil Step 1: Low oil and coolant temperatures can be
Engine idle time is excessive. caused by long idle time (greater than 10
minutes).
Instruct the owner/operator to shut off

the engine rather than idle for long
periods. If idle time is required, instruct the
owner/operator to raise the idling speed.
Step 2: Remove and inspect the injectors.
Injector O-rings are damaged or missing. Replace the injector O-rings.
Refer to Fuel injector - Remove

(B.20.A.29 - F.10.A.10).
Step 3: Use INSITE® to perform the automated
Injector is malfunctioning. cylinder performance test. Replace
injectors as required.
3 15/11/2005
B.20.A / 253

Step 4: Inspect the cam housing for cracks and
Fuel injection pump is malfunctioning. damage. Inspect the pump shaft, tappets
and lobes.
Refer to High pressure common rail

Pump head and housing - Disassemble
(B.20.A.30.15 - F.10.A.25).
Step 5: Inspect the gear pump oil seal. Replace
Gear pump is malfunctioning. the gear pump if there are signs of leakage
from the weep hole.
Refer to High pressure common rail

Gear pump - Check (B.20.A.30.10 -
F.40.A.11).
Step 6: Remove the intake and exhaust manifolds.
Cylinder head is cracked or porous. Refer to Air intake manifold - Remove
(B.30.A.38 - F.10.A.10) and Exhaust
manifold - Remove (B.40.A.38 -
F.10.A.10).
Check for evidence of a coolant leak

(indicating head damage). If required,
operate the engine at low idle.
Pressure test the cylinder head. Refer to

Cylinder head - Pressure test (B.10.A.72
- F.40.A.30).
Step 7: Check the bulk oil supply. Drain the oil
Bulk oil supply is contaminated. and replace with non contaminated oil.
Replace the oil filter.
Step 8: Analyze the oil. Inspect the filter to locate
Internal engine damage an area of probable damage.

(B.60.A.24 - F.40.A.10).
Fuel consumption is Step 1: Use the fuel consumption complaint form
excessive. False expectations to verify the nature of the complaint – that
is, fuel consumption versus a power or
performance complaint.
See FUEL AND INJECTION SYSTEM -

Static description (B.20.A - C.30.A.20)
for the form and background.
Step 2: Use the guided troubleshooting in FUEL
System problem AND INJECTION SYSTEM - Testing
(B.20.A - G.40.A.20) to locate the cause.
FUEL AND INJECTION SYSTEM - Testing (B.20.A - G.40.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1 Turn the keyswitch On. Active fault codes or large count of No fault codes (active or inactive)
Connect the INSITE® service tool. inactive fault codes found. found.
Check for active fault codes or a Use the guided troubleshooting Go to Step 2.
large count of inactive fault codes. in INSITE® to resolve the faults.
Repair complete.
3 15/11/2005
B.20.A / 254

2 Turn the keyswitch On. Features and parameters set Features and parameters NOT set
Connect the INSITE® service tool. correctly. correctly.
Check that the programmable Go to Step 3. Reset the features and parameters
features and parameters are set to their appropriate values.
correctly.
Repair complete.
3 Turn the keyswitch On. Calibration is correct. Calibration is NOT correct.
Go to Step 4. Recalibrate the ECM with the correct

Check the engine control module ECM code.
(ECM) calibration.
Repair complete.
Compare the ECM code with the
engine rating and control parts list,
and verify that the calibration is
correct.
4 Turn the keyswitch On. Vehicle speed reads 0 (zero) when Vehicle speed does NOT read
Connect the INSITE® service tool. the vehicle is NOT moving. 0 (zero) when the vehicle is not
moving.
Use INSITE® to verify vehicle speed Go to Step 7.

when the vehicle is not moving. Go to Step 5.
5 Check for loose or corroded All grounds tight and free of All grounds are NOT correct.
engine, chassis or battery ground corrosion.
connection:
• Check the engine ground Replace, clean or tighten the
connection. Go to Step 6. grounds.
• Check the chassis ground
connection. Repair complete.
• Check the battery terminal
connections.
6 Check the vehicle speed sensor Circuits operate correctly. Circuit defective.
circuits. Refer to the chassis manual
for transmission speed sensor
and/or ground speed sensor (radar) Go to Step 7. Repair defective circuit of replace
troubleshooting. sensor.
Repair complete.
7 Perform the fuel systems checks, Poor fuel economy complaint Poor fuel economy complaint
air handling checks and base unresolved. resolved.
engine checks found in the engine
performance troubleshooting tree.
Perform the fuel systems checks, Repair complete.
air handling checks and base
engine checks found in the engine
performance troubleshooting tree.
Repair complete.
3 15/11/2005
B.20.A / 255
Index

MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
FUEL AND INJECTION SYSTEM - General specification (B.20.A - D.40.A.10) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Problem solving (B.20.A - G.40.A.30) 253
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
FUEL AND INJECTION SYSTEM - Service limits (B.20.A - D.20.A.20) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Special tools (B.20.A - D.20.A.40) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUEL AND INJECTION SYSTEM - Static description (B.20.A - C.30.A.20) 66
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
FUEL AND INJECTION SYSTEM - Testing (B.20.A - G.40.A.20) 254
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Install (B.20.A.37 - F.10.A.15) 244
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Remove (B.20.A.37 - F.10.A.10) 241
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Service limits (B.20.A.37 - D.20.A.20) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Special tools (B.20.A.37 - D.20.A.40) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Torque (B.20.A.37 - D.20.A.10) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel connector - Visual inspection (B.20.A.37 - F.40.A.10) 242
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 256
Fuel filter system Fuel filter - Install (B.20.A.24.22 - F.10.A.15) 120
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Remove (B.20.A.24.22 - F.10.A.10) 117
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Torque (B.20.A.24.22 - D.20.A.10) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Fuel filter - Visual inspection (B.20.A.24.22 - F.40.A.10) 119
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Pre-filter - Install (B.20.A.24.10 - F.10.A.15) 116
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel filter system Pre-filter - Remove (B.20.A.24.10 - F.10.A.10) 115
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Electrical test (B.20.A.29 - F.40.A.50) 138
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Install (B.20.A.29 - F.10.A.15) 140
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
Fuel injector - Measure (B.20.A.29 - F.40.E.01) 145
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Remove (B.20.A.29 - F.10.A.10) 136
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Service limits (B.20.A.29 - D.20.A.20) 21
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Special tools (B.20.A.29 - D.20.A.40) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Torque (B.20.A.29 - D.20.A.10) 20
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel injector - Visual inspection (B.20.A.29 - F.40.A.10) 139
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Install (B.20.A.36.30 - F.10.A.15) 238
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Remove (B.20.A.36.30 - F.10.A.10) 235
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Torque (B.20.A.36.30 - D.20.A.10) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line Cooling plate - Visual inspection (B.20.A.36.30 - F.40.A.10) 237
2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fuel line High pressure - Torque (B.20.A.36.20 - D.20.A.10) 38
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
87372074 3 15/11/2005
B.20.A / 257
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
Fuel line Low pressure - Torque (B.20.A.36.10 - D.20.A.10) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
Fuel transfer pump - Pressure test (B.20.A.34 - F.40.C.30) 197
2388, 2377
Fuel transfer pump - Service limits (B.20.A.34 - D.20.A.20) 34
2388, 2377
Fuel transfer pump - Special tools (B.20.A.34 - D.20.A.40) 34
2388, 2377
High pressure common rail Common rail - Assemble (B.20.A.30.25 - F.10.A.20) 196
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Disassemble (B.20.A.30.25 - F.10.A.25) 195
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Install (B.20.A.30.25 - F.10.A.15) 194
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Remove (B.20.A.30.25 - F.10.A.10) 191
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Torque (B.20.A.30.25 - D.20.A.10) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Common rail - Visual inspection (B.20.A.30.25 - F.40.A.10) 193
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Install (B.20.A.30.05 - F.10.A.15) 152
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Remove (B.20.A.30.05 - F.10.A.10) 149
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Timing check (B.20.A.30.05 - F.40.B.12) 147
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear - Visual inspection (B.20.A.30.05 - F.40.A.10) 150
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Check (B.20.A.30.10 - F.40.A.11) 157
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Install (B.20.A.30.10 - F.10.A.15) 160
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
High pressure common rail Gear pump - Remove (B.20.A.30.10 - F.10.A.10) 158
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Service limits (B.20.A.30.10 - D.20.A.20) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Special tools (B.20.A.30.10 - D.20.A.40) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Torque (B.20.A.30.10 - D.20.A.10) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Gear pump - Visual inspection (B.20.A.30.10 - F.40.A.10) 159
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Install (B.20.A.30.20 - F.10.A.15) 189
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Remove (B.20.A.30.20 - F.10.A.10) 187
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 258
High pressure common rail Outlet - Service limits (B.20.A.30.20 - D.20.A.20) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Torque (B.20.A.30.20 - D.20.A.10) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Outlet - Visual inspection (B.20.A.30.20 - F.40.A.10) 188
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Assemble (B.20.A.30.15 - F.10.A.20) 184
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Disassemble (B.20.A.30.15 - F.10.A.25) 178
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Install (B.20.A.30.15 - F.10.A.15) 174
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Leakage test (B.20.A.30.15 - F.40.A.40) 162
MX215, MX245, MX275, MX305, STX280
High pressure common rail Pump head and housing - Leakage test (B.20.A.30.15 - F.40.A.40) 167
2388, 2377
High pressure common rail Pump head and housing - Remove (B.20.A.30.15 - F.10.A.10) 169
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Service limits (B.20.A.30.15 - D.20.A.20) 29
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Special tools (B.20.A.30.15 - D.20.A.40) 31
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Torque (B.20.A.30.15 - D.20.A.10) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15 - F.40.A.10) 172
MX215, MX245, MX275, MX305, STX280, 2388, 2377
High pressure common rail Pump head and housing - Visual inspection (B.20.A.30.15 - F.40.A.10) 181
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Priming pump - Assemble (B.20.A.35 - F.10.A.20) 206
MX215, MX245, MX275, MX305, STX280
Priming pump - Disassemble (B.20.A.35 - F.10.A.25) 203
MX215, MX245, MX275, MX305, STX280
Priming pump - Install (B.20.A.35 - F.10.A.15) 207
MX215, MX245, MX275, MX305, STX280
Priming pump - Pressure test (B.20.A.35 - F.40.C.30) 199
MX215, MX245, MX275, MX305, STX280
Priming pump - Remove (B.20.A.35 - F.10.A.10) 201
MX215, MX245, MX275, MX305, STX280
Priming pump - Service limits (B.20.A.35 - D.20.A.20) 35
MX215, MX245, MX275, MX305, STX280
Priming pump - Special tools (B.20.A.35 - D.20.A.40) 35
MX215, MX245, MX275, MX305, STX280
Priming pump - Torque (B.20.A.35 - D.20.A.10) 35
MX215, MX245, MX275, MX305, STX280
Priming pump - Visual inspection (B.20.A.35 - F.40.A.10) 204
MX215, MX245, MX275, MX305, STX280
Regulator valve High pressure - Electrical test (B.20.A.14.10 - F.40.A.50) 91
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Service limits (B.20.A.14.10 - D.20.A.20) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve High pressure - Torque (B.20.A.14.10 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 259
Regulator valve Injection return - Install (B.20.A.14.30 - F.10.A.15) 101
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Remove (B.20.A.14.30 - F.10.A.10) 99
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Service limits (B.20.A.14.30 - D.20.A.20) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Torque (B.20.A.14.30 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Regulator valve Injection return - Visual inspection (B.20.A.14.30 - F.40.A.10) 100
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
Relief valve - Service limits (B.20.A.16 - D.20.A.20) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve - Special tools (B.20.A.16 - D.20.A.40) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Relief valve - Torque (B.20.A.16 - D.20.A.10) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
Sensing system Pressure sensor - Install (B.20.A.95.81 - F.10.A.15) 248
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Preliminary test (B.20.A.95.81 - F.40.A.20) 245
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Remove (B.20.A.95.81 - F.10.A.10) 246
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Service limits (B.20.A.95.81 - D.20.A.20) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Torque (B.20.A.95.81 - D.20.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Pressure sensor - Visual inspection (B.20.A.95.81 - F.40.A.10) 247
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Install (B.20.A.95.85 - F.10.A.15) 252
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Remove (B.20.A.95.85 - F.10.A.10) 249
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Service limits (B.20.A.95.85 - D.20.A.20) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Test (B.20.A.95.85 - F.40.C.01) 251
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Torque (B.20.A.95.85 - D.20.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Water sensor - Visual inspection (B.20.A.95.85 - F.40.A.10) 250
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.20.A / 260
AIR INTAKE SYSTEM - 30.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.30.A / 1
Contents
TECHNICAL DATA
AIR INTAKE SYSTEM - Service limits (B.30.A - D.20.A.20) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Special tools (B.30.A - D.20.A.40) 5

MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - General specification (B.30.A - D.40.A.10) 5

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger
Turbocharger - Torque (B.30.A.31 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Service limits (B.30.A.31 - D.20.A.20) 8

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Special tools (B.30.A.31 - D.20.A.40) 8

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler
Air cooler - Torque (B.30.A.32 - D.20.A.10) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Service limits (B.30.A.32 - D.20.A.20) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Special tools (B.30.A.32 - D.20.A.40) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold

Air intake manifold - Torque (B.30.A.38 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Air temperature sensor - Torque (B.30.A.95.80 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Service limits (B.30.A.95.80 - D.20.A.20) 14

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Torque (B.30.A.95.81 - D.20.A.10) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Service limits (B.30.A.95.81 - D.20.A.20) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Service limits (B.30.A.95.95 - D.20.A.20) 16

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
AIR INTAKE SYSTEM - Dynamic description (B.30.A - C.30.A.10) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Component identification (B.30.A - C.40.C.20) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
87372074 3 15/11/2005
B.30.A / 2
AIR INTAKE SYSTEM - Leakage test (B.30.A - F.40.A.40) 24
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Supply restriction (B.30.A - F.40.C.21) 31

MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Check (B.30.A - F.40.A.11) 33

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger
Turbocharger - Preliminary test (B.30.A.31 - F.40.A.20) 35
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Check (B.30.A.31 - F.40.A.11) 37

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Leakage test (B.30.A.31 - F.40.A.40) 39

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Remove (B.30.A.31 - F.10.A.10) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Visual inspection (B.30.A.31 - F.40.A.10) 45

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Install (B.30.A.31 - F.10.A.15) 47

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Preliminary test (B.30.A.31.30 - F.40.A.20) 51

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Pressure test (B.30.A.31.30 - F.40.C.30) 52

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Remove (B.30.A.31.30 - F.10.A.10) 54

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Visual inspection (B.30.A.31.30 - F.40.A.10) 56

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Install (B.30.A.31.30 - F.10.A.15) 57

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler
Air cooler - Cleaning (B.30.A.32 - F.30.A.10) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Visual inspection (B.30.A.32 - F.40.A.10) 62

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Pressure test (B.30.A.32 - F.40.C.30) 63

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Leakage test (B.30.A.32 - F.40.A.40) 67

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold

Air intake manifold - Remove (B.30.A.38 - F.10.A.10) 70
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Visual inspection (B.30.A.38 - F.40.A.10) 71

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Install (B.30.A.38 - F.10.A.15) 72

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Air temperature sensor - Remove (B.30.A.95.80 - F.10.A.10) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Visual inspection (B.30.A.95.80 - F.40.A.10) 74

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Test (B.30.A.95.80 - F.40.C.01) 75

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Install (B.30.A.95.80 - F.10.A.15) 76

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.30.A / 3
Sensing system Air pressure sensor - Preliminary test (B.30.A.95.81 - F.40.A.20) 77
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Remove (B.30.A.95.81 - F.10.A.10) 78

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Visual inspection (B.30.A.95.81 - F.40.A.10) 79

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Install (B.30.A.95.81 - F.10.A.15) 80

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Remove (B.30.A.95.95 - F.10.A.10) 81

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Visual inspection (B.30.A.95.95 - F.40.A.10) 82

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Test (B.30.A.95.95 - F.40.C.01) 83

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Install (B.30.A.95.95 - F.10.A.15) 84

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
AIR INTAKE SYSTEM - Problem solving (B.30.A - G.40.A.30) 85
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.30.A / 4
POWER PRODUCTION - AIR INTAKE SYSTEM
AIR INTAKE SYSTEM - Service limits (B.30.A - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air supply restriction

Reference: AIR INTAKE SYSTEM - Supply restriction (B.30.A - F.40.C.21)
If the restriction exceeds 63.5 cm H2O (25.0 in H2O),
Replace or clean the air filter element.
Inspect the intake piping for damage.
RCPH05CDC579AAA 1
AIR INTAKE SYSTEM - Special tools (B.30.A - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Digital manometer
This tool is used to measure positive and differential
pressure. Units of measurement are selectable: mm Hg,
in Hg, kPa, psi, mm H2O and in H2O. The operating
range depends on the model selected.
The operating range required to measure air system

supply restriction is 0 - 76 cm H2O (0 - 30 in H2O).
The operating range required to measure differential

pressure across the air intake system is 0 - 254 mm Hg
(0 - 10 in Hg).
RCPH05CDC648AAA 1

pressure or vacuum in the air intake system. The module
vacuum.
RCPH05CDC612AAA 2
3 15/11/2005
B.30.A / 5
AIR INTAKE SYSTEM - General specification (B.30.A - D.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Maximum intake restriction (clean air filter) 24.5 cm H2O (10.0 in H2O)
Maximum intake restriction (dirty air filter) 63.5 cm H2O (25.0 in H2O)
Maximum air cooler restriction 152 mm Hg (6.0 in Hg)
3 15/11/2005
B.30.A / 6
Turbocharger - Torque (B.30.A.31 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component N·m Identification lb-ft/lb-in

Turbocharger mounting nuts 45 Nm 33 lb ft
RCPH05CDC172AAA 1
Turbocharger oil drain line cap 27 Nm 20 lb ft

screws
RCPH05CDC629AAA 2
Turbocharger oil supply line fitting 24 Nm 18 lb ft
RCPH05CDC180AAA 3
Turbocharger actuator capsule nuts 8 Nm 71 lb in
RCPH05CDC178AAA 4
3 15/11/2005
B.30.A / 7

Turbocharger inlet/outlet piping
– Compressor outlet V-band clamp 8 Nm 71 lb in
(A)
– Compressor inlet clamp (B) 8 Nm 71 lb in
RCPH05CDC616AAA 5
Turbocharger - Service limits (B.30.A.31 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger axial clearance

Reference: Turbocharger - Check (B.30.A.31 - F.40.A.11)
RCPH05CDC600AAA 1
Wastegate radial bearing clearance

Reference: Turbocharger - Check (B.30.A.31 - F.40.A.11)
RCPH05CDC601AAA 2
3 15/11/2005
B.30.A / 8
Turbocharger - Special tools (B.30.A.31 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
4 in 1 dye – OEM16259 (SPX)

This fluorescent dye is used to check for oil leaks in the
turbocharger. The dye is added to the engine lubrication
system to detect the presence of diesel fuel or engine
oil with an ultraviolet lamp.
RCSC05CDC042AAA 1
Cordless UV lamp – OEM16273 (SPX)

This battery powered UV lamp is used to detect the
presence of fluorescent dye during leak detection.
Includes a 110-volt battery charger and ultraviolet
shield/enhancer goggles. (The same lamp and goggles
are available with a 220-volt battery charger by ordering
OEM16274.)
RCSC05CDC043AAA 2
Dial indicator set – OEM1026 or equivalent

Mounted to a stationary bar, the dial indicator is used to
measure axial clearance on the turbocharger.
RCPH05CDC702AAA 3
3 15/11/2005
B.30.A / 9
Wire feeler gauge

A standard wire feeler gauge found in most automotive
supply shops offers the small gauge or wire size needed
to measure radial bearing clearance on the turbocharger.
Required range is 0.330 - 0.508 mm (0.013 - 0.020 in).
RCPH05CDC623AAA 4
Wastegate actuator testing tools

NOTE: The pressure regulator with gauge from special tool OEM5039 (SPX) can be used to pressurize the capsule
when measuring actuator movement.
Dial indicator set – OEM1026 or equivalent

Mounted to the flexible arm on a magnetic base
OEM1030, the dial indicator is used to measure
movement of the wastegate actuator.
RCPH05CDC702AAA 5
Magnetic base
The magnetic base is used to support the dial indicator
when testing wastegate actuator movement.
RCPH05CDC701AAA 6
3 15/11/2005
B.30.A / 10
Air cooler - Torque (B.30.A.32 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Air cooler to intake manifold 5 Nm 44 lb in
connector clamps
RCPH05CDC583AAA 1
Air cooler - Service limits (B.30.A.32 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Differential pressure
Reference: Air cooler - Pressure test (B.30.A.32 - F.40.C.30)
If the differential pressure is greater than 152 mm Hg (6 in
Hg), check the air cooler and associated piping for plugging,
restrictions or damage.
RCPH05CDC561AAA 1
Air cooler leakage test

Reference: Air cooler - Leakage test (B.30.A.32 - F.40.A.40)
If the pressure drop is greater than 48 kPa (7 psi) in 15
seconds, replace the air cooler.
RCPH05CDC527AAA 2
3 15/11/2005
B.30.A / 11
Air cooler - Special tools (B.30.A.32 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler tester – OEM5039 (SPX)

This tool is used to test the integrity of the air cooler by
pressurizing the unit with common shop air. Plugs are
installed and anchored with safety cables in the cooler
inlet and outlet ports. The 0 - 60 psi pressure regulator
with gauge is included and features a safety relief valve
and a quick disconnect coupler.
RCPH05CDC322AAA 1
3 15/11/2005
B.30.A / 12
Air intake manifold - Torque (B.30.A.38 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Air intake manifold cover cap screw 24 Nm 18 lb ft
RCPH05CDC876AAA 1
Air intake manifold elbow connector 24 Nm 18 lb ft
RCPH05CDC589AAA 2
3 15/11/2005
B.30.A / 13
Sensing system Air temperature sensor - Torque (B.30.A.95.80 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Intake manifold air temperature and 23 Nm 17 lb ft
pressure sensor Torx® screw
RCPH05CDC322ABA 1
Sensing system Air temperature sensor - Service limits

(B.30.A.95.80 - D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Intake manifold air temperature and pressure sensor – Pressure versus voltage
Pressure Voltage (VDC)
mm Hg in Hg psia
0 0 0 0.90 - 1.06 volts DC
381 15 22 1.30 - 1.53 volts DC
635 25 27 1.57 - 1.84 volts DC
1549 61 45 2.53 - 2.96 volts DC
2057 81 55 3.07 - 3.60 volts DC
2590 102 65 3.61 - 4.23 volts DC
Intake manifold air temperature and pressure sensor – Temperature versus resistance
Temperature Resistance (Ω)
C° F°
-10 14 8.7K - 9.7K ohms
0 32 5.5K - 6.1K ohms
20 68 2.4K - 2.5K ohms
40 104 1.1K - 1.2K ohms
70 158 418 - 436 ohms
3 15/11/2005
B.30.A / 14
Intake manifold air temperature and pressure sensor

Reference: Sensing system Air temperature sensor - Test (B.30.A.95.80 - F.40.C.01)
Reference: Electronic control - Check (B.10.A.92 - F.40.A.11)
Replace the sensor if the resistance reading from INSITE®
does NOT approximately correspond to the indicated
resistance from the table above for the current ambient
temperature.
Replace the sensor if the voltage reading from INSITE®

does NOT correspond to the indicated voltage for a 0 (zero)
pressure condition – 0.90 - 1.06 volts DC.
RCPH05CDC343ABA 1
Sensing system Air pressure sensor - Torque (B.30.A.95.81 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Barometric air pressure sensor cap 9 Nm 80 lb in
screw
RCPH05CDC320ABA 1
Sensing system Air pressure sensor - Service limits (B.30.A.95.81 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Barometric pressure sensor – Altitude versus pressure

Altitude Pressure
(m) (ft) (mm-Hg) (in-Hg)
0 (sea level) 0 759.5 mm Hg 29.9 in Hg
915 3,000 683.3 mm Hg 26.9 in Hg
1830 6,000 609.6 mm Hg 24.0 in Hg
2744 9,000 543.6 mm Hg 21.4 in Hg
3659 12,000 482.6 mm Hg 19.0 in Hg
3 15/11/2005
B.30.A / 15
Barometric air pressure sensor

Reference: Sensing system Air pressure sensor - Preliminary test (B.30.A.95.81 - F.40.A.20)
Reference: Electronic control - Check (B.10.A.92 - F.40.A.11)
If the barometric air pressure reading from INSITE® is less
than or equal to 523 mm Hg (20.6 in Hg), and the current
elevation is less than 3.048 km (10,000 ft), replace the
sensor.
The INSITE® reading must be within 102 mm Hg (4.0 in

Hg) of local barometric pressure.
RCPH05CDC315ABA 1
Sensing system Air cleaner restriction - Service limits (B.30.A.95.95

- D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cleaner restriction sensor

Reference: Sensing system Air cleaner restriction - Test (B.30.A.95.95 - F.40.C.01)
If resistance measured through the sensor with a digital
voltmeter is less than 100K ohms, the sensor has failed
closed and must be replaced.
RCPH05CDC580AAA 1
3 15/11/2005
B.30.A / 16
AIR INTAKE SYSTEM - Dynamic description (B.30.A - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
The combustion air system consists of an air pre-cleaner

and cleaner, intake air piping, turbocharger, charge air
piping, air cooler and air heater.
RCSC05CDC078AAB 1
Air drawn through the air pre-cleaner and cleaner and

into the compression side of the turbocharger. It is forced
through piping from the discharge to the air cooler, the
intake air heater and into the intake manifold. From the
manifold, air is forced into the cylinders and used for
combustion.
The turbocharger uses exhaust gas energy to turn the

turbine wheel. The turbine wheel drives the compressor
impeller that provides compressed air to the engine
for combustion. The additional air provided by the
turbocharger allows more fuel to be injected to increase
the power output from the engine.
RCSC05CDC073AAA 2
The turbine, compressor wheel and shaft are supported

by two rotating bearings in the bearing housing.
Passages in the bearings housing direct filtered,
pressurized engine oil to the shaft and thrust bearings.
The oil is used to lubricate and cool the rotating
components. Oil then drains from the bearing housing to
the cylinder block to return to the oil pan.
RCSC05CDC074AAA 3
An adequate supply of good, filtered oil is very important

to the life of the turbocharger. A high quality oil must be
used, and the oil and filter must be changed following the
recommended maintenance schedule.
3 15/11/2005
B.30.A / 17
Wastegated turbochargers are used to optimize

performance. The wastegated design allows maximum
boost to be developed quickly and prevents the
turbocharger from overspeeding at higher engine rpms.
Wastegate operation is controlled by an actuator (A) that

senses compressor pressure and balances it against a
preset spring load. The wastegate valve (B) is located in
the turbine inlet passage. When open, it diverts a portion
of the exhaust gas away from the turbine wheel, thereby
controlling the shaft speed and boost.
RCPH05CDC172AAA 4
Malfunctioning turbocharger
Failure of the internal components of the turbocharger
can reduce its effectiveness and also cause excessive
smoke and low power. A bearing failure can produce
friction that slows the speed of the rotor assembly. Failed
bearings can also cause the rotor blades to rub the
housing, reducing the rotor speed.
RCSC05CDC080AAA 5
A malfunctioning or miscalibrated wastegate can create

excessively high or low boost pressures. Low boost
pressures can cause excessive smoke and low power.
High boost pressures can cause major engine damage.
3 15/11/2005
B.30.A / 18
Oil consumption and leaks

Engine oil is used to lubricate the bearings and provide
some cooling for the turbocharger. The supply line from
the oil filter head supplies oil to the bearings. The return
line from the bottom of the turbocharger routes the oil
back to the oil pan.
RCSC05CDC019AAB 6
Seal rings are used on each end of the rotor assembly.

The seals prevent exhaust gases and pressurized air
from entering the turbocharger housing. Oil leakage from
the seals is rare, but it can occur.
RCSC05CDC075AAA 7
Excessive crankcase pressure can prevent oil from

draining to the oil pan. This can load the bearing housing
and cause oil to leak past the compressor seals and into
the engine.
3 15/11/2005
B.30.A / 19
A restricted or damaged oil return line will pressurize the

turbocharger housing, causing oil to migrate past the
seals.
RCSC05CDC178AAA 8
Additionally, high intake or exhaust restrictions can cause

a vacuum between the compressor and the turbocharger
housing, also resulting in oil leaking past the seal.
RCSC05CDC069AAA 9
If oil leaks past the compressor housing seal, the air

cooler must be cleaned and inspected.
3 15/11/2005
B.30.A / 20
Turbocharger noise
A whining sound that varies in intensity depending on
engine speed and load is normal from the turbocharger.
The sound is caused by the very high rotational speed of
the rotor assembly and the method used to balance the
rotor assembly at the time of manufacture. At full speed,
consequently, the sound will be loudest.
RCSC05CDC070AAA 10
Leaks in the air system intake and/or exhaust

components can also produce excessive engine noise.
Leak noise is typically a high pitched whine or sucking
sound. When present, the intake and exhaust system
should be checked for leaks and proper clamping.
RCSC05CDC071AAA 11
Lower pitched sounds or rattles at lower engine speeds

can indicate debris in the system or contact between
the rotor and the housing. When present, remove the
turbocharger inlet and check for foreign objects; check
for blade damage and bearing clearance. If leaks, blade
damage or improper clearances are found, replace the
turbocharger.
RCSC05CDC072AAA 12
3 15/11/2005
B.30.A / 21
AIR INTAKE SYSTEM - Component identification (B.30.A - C.40.C.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC003GAA 1
Engine right hand side
A. Compressor outlet to the air cooler E. Wastegate actuator rod

B. Turbocharger compressor housing F. Exhaust manifold
C. Compressor air inlet G. Turbine outlet to exhaust
D. Wastegate capsule H. Turbocharger turbine housing
3 15/11/2005
B.30.A / 22
RCPH05CDC002GAA 2
A. Compressor outlet to the air cooler L. Barometric pressure sensor

J. Manifold inlet from the air cooler M. Intake manifold cover
K. Intake manifold air temperature and pressure sensor N. Grid heater
3 15/11/2005
B.30.A / 23
AIR INTAKE SYSTEM - Leakage test (B.30.A - F.40.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Initial check
1. Leaks in the intake air system are most commonly
identified by:
• Inspection of piping for cracked or loose clamps.
• Applying a solution of soapy water in the suspected

area and checking for bubbles.
• A high-pitched whining or sucking sound from the

suspected area.
CAUTION
M1056 - 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
RCIL05CDC001AAA 1
the engine and cause premature wear.
2. 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 is present, the soap bubbles will be

drawn in with the air.
RCPH05CDC588AAB 2
3. Replace damaged pipes and tighten loose clamps

to make sure that the air system does NOT leak.
Check for corrosion under the clamps and hoses.

Disassemble and clean as necessary.
RCSC05CDC040AAA 3
3 15/11/2005
B.30.A / 24
System pressure side

4. Operate the engine at full throttle and rated rpm
with maximum load.
NOTE: Leaks in the intake system reduce the amount of
air to the cylinders during engine operation and decrease
engine performance.
RCPH05CDC807AAA 4
5. Listen for a high-pitch whistling sound from the

turbocharger, nearby piping and connections.
RCPH05CDC586AAB 5
6. Operate the engine at high idle, and apply a soapy

water solution to sealing surfaces
RCPH05CDC588AAB 6
3 15/11/2005
B.30.A / 25
7. Inspect the turbocharger outlet connection for

leaks. Inspect for damage. Tighten loose clamps.
If required, disassemble and replace the sealing
O-ring.
RCPH05CDC586AAB 7
Pre-Cleaner
8. Inspect the hose connection (A) to the pre-cleaner
(B).
RCPH05CDC572AAA 8
9. Inspect the pre-cleaner hose at its exhaust system

connector.
RCPH05CDC570AAA 9
3 15/11/2005
B.30.A / 26
Air cooler outlet, inlet and hoses

10. Inspect the outlet, inlet and hoses to the air cooler
for damage. Tighten loose clamps.
RCPH05CDC583AAA 10
Intake manifold
11. Inspect the intake manifold connector for damage.
Tighten loose clamps. If required, disassemble and
replace the gasket.
RCPH05CDC589AAA 11
12. Inspect the intake manifold for damage. If required,

disassemble, check for damage and reseal during
assembly.
RCPH05CDC614AAA 12
3 15/11/2005
B.30.A / 27
Turbocharger
13. Inspect the capsule and hose on the turbocharger
wastegate for damage.
RCPH05CDC566AAA 13
14. Inspect the compressor housing sealing surface on

the turbocharger for damage. Check for oil leaking
at the seal area.
RCPH05CDC602AAA 14
System exhaust side

15. Operate the engine at full throttle and rated rpm
with maximum load. Identify leaking by noise,
discoloration from escaping gases or with soapy
water.
NOTE: Leaks in the exhaust system cause the
turbocharger to operate at a lower speed, reducing
the amount of air going to the cylinders during engine
operation.
RCPH05CDC807AAA 15
3 15/11/2005
B.30.A / 28
16. Inspect the exhaust manifold gasket area for leaks.
RCPH05CDC610AAA 16
17. Inspect the turbocharger mounting gasket area for

leaks.
RCPH05CDC571AAA 17
18. Inspect the turbine housing sealing surface for

leaks.
RCPH05CDC586AAA 18
3 15/11/2005
B.30.A / 29
19. Operate the engine at full throttle and rated rpm with
maximum load. listen and inspect again for leaks.
RCPH05CDC807AAA 19
3 15/11/2005
B.30.A / 30
AIR INTAKE SYSTEM - Supply restriction (B.30.A - F.40.C.21)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the clip and disconnect the harness

connector to the air cleaner restriction sensor on
the intake air piping to the turbocharger. Remove
the sensor.
RCPH05CDC577AAA 1
2. Install a test fitting at the sensor location and

connect a test line from a digital manometer or
tube manometer to the fitting. See AIR INTAKE
SYSTEM - Special tools (B.30.A - D.20.A.40).
RCPH05CDC578AAA 2
3. Operate the engine at full throttle and rated rpm with

maximum load. Record the data on the manometer.
NOTE: The digital manometer must be zeroed to obtain
a valid reading.
RCPH05CDC579AAA 3
4. If the restriction exceeds 63.5 cm H2O (25.0 in

H2O) with a dirty air filter,
Replace or clean the air filter element.
Inspect the intake piping for damage.

NOTE: With a clean air filter, the restriction must not
exceed 25.4 cm H2O (10.0 in H2O).
3 15/11/2005
B.30.A / 31
5. Remove the test equipment and reinstall the air

cleaner restriction sensor.
3 15/11/2005
B.30.A / 32
AIR INTAKE SYSTEM - Check (B.30.A - F.40.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Prior operation: FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11)
Prior operation: STARTING SYSTEM - Check (B.80.A - F.40.A.11)
Turbocharger blade check

1. Keyswitch OFF.
Remove the intake and exhaust pipes to the
turbocharger.
Inspect the turbocharger compressor and turbine

blades for damage or wear. Refer to Turbocharger
- Preliminary test (B.30.A.31 - F.40.A.20).
If the blades are damaged, replace the turbocharger.

Refer to Turbocharger - Remove (B.30.A.31 -
F.10.A.10).
If the blades are NOT damaged, continue with Step

2.
RCPH05CDC605AAA 1
Axial and radial clearance check

2. Keyswitch OFF.
Check the axial and radial clearances at the

turbocharger turbine and compressor. Refer to
Turbocharger - Check (B.30.A.31 - F.40.A.11).
If the radial and axial clearances are outside

specification, replace the turbocharger. Refer to
Turbocharger - Remove (B.30.A.31 - F.10.A.10).
If the radial and axial clearances are within

RCPH05CDC600AAA 2
3 15/11/2005
B.30.A / 33
Wastegate actuator check

3. Keyswitch OFF.
Inspect the boost line (hose) to the wastegate

actuator for cracks or holes.
If holes, cracks or other damage are found, replace

the hose.
If no damage is found, continue with Step 4.
RCPH05CDC607AAA 3
Actuator rod travel check

4. Keyswitch OFF.
Disconnect the boost line (hose) from the wastegate
capsule.
Apply a regulated air supply of 128 kPa (20 psi) to

the capsule, and check for rod movement. Refer
to Turbocharger Exhaust waste gate actuator -
If the actuator rod moves, continue with the next

sequence in the performance tree.
If the actuator rod does not move, continue with

Step 5.
RCPH05CDC649AAA 4
Rod and lever travel check

5. Keyswitch OFF.
Remove the retaining clip and remove the actuator

rod from the lever. Refer to Turbocharger Exhaust
waste gate actuator - Pressure test (B.30.A.31.30
- F.40.C.30).
Apply a regulated air supply of 128 kPa (20 psi) to

the capsule, and check for rod movement.
If the actuator rod moves, check the wastegate lever

on the turbocharger for movement back and forth
and smooth operation. If the lever is seized, replace
the turbocharger. See Turbocharger - Remove
(B.30.A.31 - F.10.A.10).
RCPH05CDC177AAB 5
If the actuator rod does NOT move, replace
the wastegate actuator. Refer to Turbocharger
Exhaust waste gate actuator - Remove
(B.30.A.31.30 - F.10.A.10).
Next operation: Electronic control - Check (B.10.A.92 - F.40.A.11)

Next operation: FUEL AND INJECTION SYSTEM - Check (B.20.A - F.40.A.11)
3 15/11/2005
B.30.A / 34
Turbocharger - Preliminary test (B.30.A.31 - F.40.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: Refer to Turbocharger - Remove (B.30.A.31 - F.10.A.10) throughout this procedure for removal of
turbocharger piping and the turbocharger.
1. Remove the inlet piping to the turbocharger.
RCPH05CDC586AAA 1
2. Inspect the compressor impeller for damage.

Replace the turbocharger if damage is found.
RCPH05CDC615AAA 2
3. If the compressor impeller is damaged, inspect the

inlet piping and air filtration system for damage.
Repair any damage before operating the engine.
4. Remove the exhaust pipe from the turbocharger.
RCPH05CDC625AAA 3
3 15/11/2005
B.30.A / 35
5. Inspect the turbine wheel for damage. Replace the

turbocharger if damage is found.
RCPH05CDC605AAA 4
Next operation: Turbocharger - Check (B.30.A.31 - F.40.A.11)
3 15/11/2005
B.30.A / 36
Turbocharger - Check (B.30.A.31 - F.40.A.11)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Turbocharger - Preliminary test (B.30.A.31 - F.40.A.20)
Axial clearance check

1. Use a dial depth gauge mounted to a horizontal bar
to measure axial clearance on the rotor assembly:
Push the rotor assembly away from the gauge.
Zero the gauge.
RCPH05CDC599AAA 1
2. Push the rotor assembly toward the gauge and

record the reading. The required axial clearance is
0.025 - 0.127 mm (0.001 - 0.005 in).
RCPH05CDC600AAA 2
3. Replace the turbocharger if the clearance is outside

the specification range. See Turbocharger -
Remove (B.30.A.31 - F.10.A.10).
Radial clearance check

4. Use a wire-type feeler gauge to measure the
clearance between the compressor impeller and the
compressor housing.
NOTE: The smaller feeler gauges used to set gap can
also be used for this measurement.
RCPH05CDC623AAA 3
3 15/11/2005
B.30.A / 37
5. Push the compressor impeller assembly toward the

compressor housing, and select the proper gauge
for this clearance. Record the clearance.
RCPH05CDC601AAA 4
6. Measuring at the same location, push the impeller

assembly away from the housing, and select
the proper gauge for this clearance. Record the
clearance.
RCPH05CDC601AAA 5
7. Substract the smaller clearance from the larger

clearance. This is the radial bearing clearance. The
required clearance must be within 0.330 - 0.508
mm (0.013 - 0.020 in).
8. Repeat the procedure on the turbine wheel.
9. Replace the turbocharger if the radial bearing
clearance is outside the specification. See
Turbocharger - Remove (B.30.A.31 - F.10.A.10).
Next operation: Turbocharger - Leakage test (B.30.A.31 - F.40.A.40)
3 15/11/2005
B.30.A / 38
Turbocharger - Leakage test (B.30.A.31 - F.40.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the turbocharger inlet and discharge

piping. See Turbocharger - Remove (B.30.A.31 -
F.10.A.10).
2. Inspect the turbocharger inlet (A) and discharge
outlet (B) for oil. If oil is present at the inlet and the
discharge, check upstream in the turbocharger for
the source of the oil with the fluorescent tracer test.
NOTE: The fluorescent tracer test is explained later in
Step 5.
RCPH05CDC621AAA 1
3. If oil is present ONLY in the discharge, check for an

air supply restriction. See Air intake line - Supply
restriction (B.30.A.37 - F.40.C.21).
RCPH05CDC579AAA 2
4. If no supply restriction is found, the turbocharger

must be replaced. See Turbocharger - Remove
(B.30.A.31 - F.10.A.10).
NOTE: If the turbocharger fails or any other occasion
where oil is introduced into the air cooler, the air cooler
MUST be cleaned and inspected. See Air cooler -
Cleaning (B.30.A.32 - F.30.A.10).
Fluorescent tracer test

5. Add fluorescent tracer (4-in-1 Dye OEM16259
or equivalent) to the engine oil, according to the
manufacturer’s instructions. Operate the engine at
low idle for 10 minutes.
6. Shut off the engine. Allow the turbocharger to cool.
3 15/11/2005
B.30.A / 39
7. Remove the exhaust pipe from the turbine housing.
RCPH05CDC563AAA 3
8. Use a high intensity black light (OEM16273 or

equivalent) to inspect the turbine outlet for oil leaks.
A yellow glow indicates an oil leak.
NOTE: A dark blue glow indicates fuel in the oil.
RCPH05CDC622AAA 4
9. If oil is found on the turbine housing, remove the oil

drain line from the bottom of the turbocharger and
check for restrictions.
RCPH05CDC626AAA 5
3 15/11/2005
B.30.A / 40
10. Clear any restrictions found. Replace the gasket if

damaged during removal, and reinstall the drain line.
RCPH05CDC596AAA 6
11. If the drain line was not restricted, remove the

turbocharger. See Turbocharger - Remove
(B.30.A.31 - F.10.A.10).
RCPH05CDC624AAA 7
12. Use a high intensity black light to inspect the turbine

inlet for leaks. A yellow glow indicates an oil leak
from the engine.
RCPH05CDC606AAA 8
13. If oil is NOT found in the turbine inlet, replace

the turbocharger. See Turbocharger - Install
(B.30.A.31 - F.10.A.15).
14. If oil is found in the turbine inlet, install the exhaust
pipe to the turbine outlet and tighten the clamp.
Install the inlet pipe to the compressor and tighten
the clamp. See Turbocharger - Install (B.30.A.31 -
F.10.A.15).
3 15/11/2005
B.30.A / 41
Turbocharger - Remove (B.30.A.31 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Disconnect the air cleaner restriction sensor, if

required, from the air inlet piping.
RCPH05CDC577AAA 1
2. Loosen the clamps (A) and remove the air inlet pipe
(B) to the turbocharger.
RCPH05CDC323ABA 2
3. Loosen the clamps (A) and remove the piping to

the discharge outlet.
RCPH05CDC617AAA 3
3 15/11/2005
B.30.A / 42
4. Loosen the clamps (A) to disconnect or remove

the exhaust piping to the turbocharger. If required,
remove the clamp (B) and loosen the heat blanket
(C) for clearance to remove the piping.
RCPH05CDC625AAA 4
5. Disconnect the oil supply line from the bearing

housing on the turbocharger.
RCPH05CDC628AAA 5
6. Disconnect the oil supply line from the oil filter head.
RCPH05CDC627AAA 6
3 15/11/2005
B.30.A / 43
7. Disconnect the oil drain tube for the bearings at the

engine block between the coolant and oil filters.
RCPH05CDC182AAA 7
8. Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.
RCPH05CDC630AAA 8
9. Remove the oil drain tube and gasket from the

bottom of the turbocharger.
RCPH05CDC629AAA 9
Next operation: Turbocharger - Visual inspection (B.30.A.31 - F.40.A.10)
3 15/11/2005
B.30.A / 44
Turbocharger - Visual inspection (B.30.A.31 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove all carbon deposits and gasket material

from the indicated surfaces.
RCPH05CDC606AAA 1
2. Use solvent or steam to clean the exterior of the

turbocharger, the oil drain tube and supply line.
WARNING
personal injury.
WARNING
power washer. Failure to wear protective equipment RCPH05CDC603AAA 2
WARNING
3 15/11/2005
B.30.A / 45
4. Inspect the turbine (A) and compressor (B)

housings. If cracks that penetrate through the
housing are present, the turbocharger must be
replaced.
NOTE: An air cooler failure can cause progressive
damage to the turbine housing. If the turbine housing is
damaged, check the air cooler for damage as well. See
Air cooler - Visual inspection (B.30.A.32 - F.40.A.10).
NOTE: Whenever a turbocharger fails or any occasion
where oil and debris are put into the air cooler, the air
cooler must be cleaned and inspected. See Air cooler -
Cleaning (B.30.A.32 - F.30.A.10).
RCPH05CDC604AAA 3
5. Inspect the condition of the O-rings for the oil supply

line. Replace as required. Inspect the supply line
for leaks or damage. Replace as necessary.
NOTE: The O-rings for the oil supply line are located in
the fittings on the bearing oil filter head and the bearing
housing.
RCPH05CDC185AAA 4
6. Inspect the oil drain tube for blockage or damage.

Correct as required.
RCPH05CDC596AAA 5
3 15/11/2005
B.30.A / 46
Turbocharger - Install (B.30.A.31 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Turbocharger - Visual inspection (B.30.A.31 - F.40.A.10)
1. Install a new gasket on the oil drain tube and

install the tube on the turbocharger with the original
screws. Torque the screws to 27 Nm (20 lb ft).
RCPH05CDC629AAA 1
2. Apply high-temperature anti-seize compound to the

turbocharger mounting studs.
RCPH05CDC646AAA 2
3. Use a new gasket and install the turbocharger with

the four nuts. Torque the nuts to 60 Nm (44 lb ft).
NOTE: The torque values were established using
anti-seize compound as a lubricant.
RCPH05CDC186AAA 3
3 15/11/2005
B.30.A / 47
4. Install the oil drain tube in the return hose to the

block between the filters.
RCPH05CDC182AAA 4
5. Lubricate the bearings by pouring 59 - 89 mL (2 -

3 US fl oz) of clean engine oil into the supply port.
Rotate the turbine wheel while pouring to allow oil to
enter the bearing housing.
RCPH05CDC184AAA 5
6. Replace the O-ring in the bearing supply port if

required. Use the two hand, two wrench method to
install the oil supply line.
RCPH05CDC180AAA 6
3 15/11/2005
B.30.A / 48
7. Use the two hand, two wrench method to connect

the supply line to the port on the oil filter head.
RCPH05CDC627AAA 7
8. Reinstall the exhaust pipe on the turbocharger with

the original clamps (A). Torque the clamps to 8 Nm
(71 lb in). If required, reinstall the heat blanket (C)
with the original clamp (B).
RCPH05CDC625AAA 8
9. Replace the O-ring on the turbocharger discharge

elbow.
RCPH05CDC620AAA 9
3 15/11/2005
B.30.A / 49
10. Install the discharge piping on the turbocharger with

(71 lb in).
RCPH05CDC617AAA 10
11. Install the intake piping (B) on the turbocharger with

(71 lb in).
RCPH05CDC323ABA 11
12. Reconnect the harness to the air cleaner restriction

sensor, if required.
RCPH05CDC577AAA 12
13. Operate the engine and check for air, exhaust and
oil leaks. Check operation of the turbocharger.
3 15/11/2005
B.30.A / 50
Turbocharger Exhaust waste gate actuator - Preliminary test

(B.30.A.31.30 - F.40.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
CAUTION
M1059 - All wastegates are precalibrated and cannot be adjusted in the field. Adjusting the wastegate
1. Inspect the wastegate actuator boost line for cracks

or holes. Replace the line if damaged.
NOTE: Turbocharger shown removed for photo clarity.
RCPH05CDC607AAA 1
2. Inspect the bracket (A), actuator rod (B) and lever

(C) for damage. If any component is bent, it will
affect operation and must be replaced.
RCPH05CDC607AAA 2
Next operation: Turbocharger Exhaust waste gate actuator - Pressure test (B.30.A.31.30 - F.40.C.30)
3 15/11/2005
B.30.A / 51
Turbocharger Exhaust waste gate actuator - Pressure test

(B.30.A.31.30 - F.40.C.30)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Turbocharger Exhaust waste gate actuator - Preliminary test (B.30.A.31.30 - F.40.A.20)
1. Disconnect the boost line (A) from the wastegate

capsule (B).
RCPH05CDC171AAA 1
2. Support a dial indicator (A) so that its shaft is in line

with the actuator rod (B). Zero the indicator.
RCPH05CDC650AAA 2
3. Connect a regulated air supply to the capsule.

Apply 200 kPa (29 psi) to make sure the wastegate
is functioning properly.
NOTE: Some small travel is normal when air pressure is
first applied as the system adjusts. The measurable travel
only occurs very close to the 200 kPa (29 psi) value.
RCPH05CDC649AAA 3
4. The rod MUST move approximately 5 mm (0.2 in)

without sticking or air leakage.
NOTE: Air must NOT be heard escaping from the capsule
during the test; this would indicate a defective capsule.
3 15/11/2005
B.30.A / 52
5. If no movement of the actuator rod occurs, remove

the retaining clip (A) and remove the rod (B) from
the lever (C).
RCPH05CDC174AAA 4
6. Check that the lever moves back and forth freely

and is not seized.
If the lever cannot be moved by hand, replace

the turbocharger. See Turbocharger - Remove
(B.30.A.31 - F.10.A.10).
If the lever moves freely by hand, replace the

wastegate actuator. See Turbocharger Exhaust
waste gate actuator - Remove (B.30.A.31.30 -
F.10.A.10).
RCPH05CDC177AAB 5
Next operation: Turbocharger Exhaust waste gate actuator - Remove (B.30.A.31.30 - F.10.A.10)
3 15/11/2005
B.30.A / 53
Turbocharger Exhaust waste gate actuator - Remove (B.30.A.31.30 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Turbocharger Exhaust waste gate actuator - Pressure test (B.30.A.31.30 - F.40.C.30)
1. Remove the retaining clip from the control lever.
RCPH05CDC174AAA 1
2. Remove the boost line from the wastegate capsule.
RCPH05CDC171AAA 2
3. Connect a regulated air supply with gauge to the

capsule.
RCPH05CDC651AAA 3
3 15/11/2005
B.30.A / 54
4. Slowly apply air pressure until the actuator rod can

be removed from the control level.
NOTE: If the capsule diaphragm is ruptured and does
not hold air pressure, pull the actuator rod outward to
overcome the spring tension and remove the rod.
RCPH05CDC177AAA 4
5. Disconnect the air supply to the capsule. Remove

the cap screws and remove the rod assembly from
the bracket.
RCPH05CDC178AAA 5
Next operation: Turbocharger Exhaust waste gate actuator - Visual inspection (B.30.A.31.30 - F.40.A.10)
3 15/11/2005
B.30.A / 55
Turbocharger Exhaust waste gate actuator - Visual inspection

(B.30.A.31.30 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Turbocharger Exhaust waste gate actuator - Remove (B.30.A.31.30 - F.10.A.10)
1. Inspect the wastegate actuator boost line for cracks

or holes. Replace the line if damaged.
NOTE: Turbocharger shown removed for photo clarity.
RCPH05CDC607AAA 1
2. Inspect the bracket (A), actuator rod (B) and lever

(C) for damage. If any component is bent, it will
affect operation and must be replaced.
RCPH05CDC607AAA 2
Next operation: Turbocharger Exhaust waste gate actuator - Install (B.30.A.31.30 - F.10.A.15)
3 15/11/2005
B.30.A / 56
Turbocharger Exhaust waste gate actuator - Install (B.30.A.31.30 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
CAUTION
M1059 - All wastegates are precalibrated and cannot be adjusted in the field. Adjusting the wastegate
Prior operation: Turbocharger Exhaust waste gate actuator - Visual inspection (B.30.A.31.30 - F.40.A.10)
Pre-calibrated actuator
1. Install the capsule studs in the bracket, and the rod
on the control lever.
NOTE: A replacement actuator is equipped with a spacer
(A) which retains the calibration setting during shipping.
Do not remove the spacer until the actuator is installed or
the calibration setting will be lost.
RCSC05CDC051AAA 1
2. Install the nuts on the capsule and torque to 8 Nm

(71 lb in).
3. Install the retaining clip on the control lever.
RCPH05CDC174AAA 2
4. Cut the tie strap and remove the spacer.
3 15/11/2005
B.30.A / 57
5. Install the boost line on the capsule with the new

clamp provided.
RCPH05CDC171AAA 3
3 15/11/2005
B.30.A / 58
Air cooler - Cleaning (B.30.A.32 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
If the engine experiences turbocharger failure or whenever oil and debris is blown into the air cooler, the cooler
MUST be cleaned.
Remove the piping and air cooler from the vehicle. Refer to the chassis repair manual for the procedure.
1. Air coolers come in many different sizes and are

installed in various orientations. Position the air
cooler in the best orientation for effective flushing.
RCSC05CDC040AAA 1
2. Flush the inside of the air cooler with solvent in the

opposite direction of normal air flow.
WARNING
personal injury.
WARNING
M1057 - Do not use caustic cleaners to clean this
component. The component will be damaged.
RCSC05CDC041AAA 2
3 15/11/2005
B.30.A / 59
3. Shake the cooler, and lightly tap on the sides with a

rubber mallet to dislodge trapped debris.
RCSC05CDC043AAA 3
4. Continue flushing until all debris and oil is removed –

that is, when the solution flows clear as it emerges.
5. When solvent flushing is finished, wash the inside
of the air cooler with hot soapy water to remove the
solvent.
RCSC05CDC041AAA 4
6. Rinse thoroughly with clean water.
3 15/11/2005
B.30.A / 60
7. Dry the inside of the air cooler with compressed air.

Blow air in the opposite direction of normal air flow
until the inside of the cooler is dry.
WARNING
CAUTION
M1058 - The charge air cooler must be rinsed, dried
and free of solvent, oil and debris or engine damage
will occur.
RCSC05CDC042AAA 5
Next operation: Air cooler - Visual inspection (B.30.A.32 - F.40.A.10)
3 15/11/2005
B.30.A / 61
Air cooler - Visual inspection (B.30.A.32 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Air cooler - Cleaning (B.30.A.32 - F.30.A.10)
1. Inspect the air cooler for cracks, holes or damage.
RCSC05CDC044AAA 1
2. Inspect the tubes, fins and welds for tears, breaks or

other damage. If damage is noted and the air cooler
fails the leak test, the cooler must be replaced.
NOTE: Always clean and inspect the charge air cooler
piping and hoses prior to installation.
Next operation: Air cooler - Pressure test (B.30.A.32 - F.40.C.30)
3 15/11/2005
B.30.A / 62
Air cooler - Pressure test (B.30.A.32 - F.40.C.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Air cooler - Visual inspection (B.30.A.32 - F.40.A.10)
Preferred method
1. Measure the air cooler system pressure drop with
a digital manometer with dual inputs for measuring
differential pressure. See AIR INTAKE SYSTEM -
Special tools (B.30.A - D.20.A.40).
NOTE: A tube style mercury manometer can be used for
this test. However, due to the safety and environmental
concerns with the proper handling, spillage and disposal
of mercury, digital testers are more widely used for
obtaining readings in mm Hg (in Hg).
2. If required, drill and tap a hole for a 3 mm (0.125 in)
fitting in the turbocharger compressor outlet pipe.
Install the fitting.
NOTE: The pipe should be removed during drilling and
tapping to avoid sending debris into the air cooler.
RCPH05CDC558AAA 1

fitting in the manifold inlet pipe. Install the fitting.
NOTE: The pipe should be removed during drilling and
tapping to avoid sending debris into the manifold.
RCPH05CDC555AAA 2
3 15/11/2005
B.30.A / 63
4. Connect a test line from one port on the digital

manometer to the fitting at the turbocharger outlet.
Connect a test line from the other port on the digital
manometer to the fitting at the manifold.
RCPH05CDC560AAA 3
5. Operate the engine at rated rpm and load. Record

the readings on the manometer.
RCPH05CDC807AAA 4
6. Refer to the instructions for your manometer to read

and/or calculate differential pressure.
IMPORTANT: The manometer must be zeroed before
valid readings can be obtained.
RCPH05CDC561AAA 5
7. If the differential pressure is greater than 152 mm

Hg (6 in Hg), check the air cooler and associated
piping for plugging, restrictions or damage. Clean
or replace if necessary.
3 15/11/2005
B.30.A / 64
8. Remove the test fittings and install plugs in the

piping before returning the vehicle to service.
RCPH05CDC562AAA 6
Optional method
9. Use two digital voltmeters with pressure modules
or two analog pressure gauges to perform the test.
See AIR INTAKE SYSTEM - Special tools (B.30.A
- D.20.A.40)
The pressure modules must be zeroed before valid

readings can be obtained.
Check both gauges at a regulated pressure of 206

kPa (30 psi) to maintain consistency. Use low
pressure gauges – 0 - 345 kPa (0 - 50 psi) – to
accurately read the expected pressures.
10. Connect one pressure module or gauge to the fitting
at the turbocharger. Connect the other pressure
module or gauge to the fitting at the manifold.
RCPH05CDC591AAA 7
3 15/11/2005
B.30.A / 65
11. Operate the engine at rated rpm and load. Record

the readings.
RCPH05CDC807AAA 8
12. Convert the reading from each voltmeter to mm Hg

or in Hg using a formula below:
kPa x 7.5006156 = mm Hg
psi x 2.0360207 = in Hg
NOTE: The pressure module must be zeroed before a
valid reading can be obtained.
RCPH05CDC592AAA 9
13. If the differential pressure between the two

readings is greater than 152 mm Hg (6 in Hg),
check the air cooler and associated piping for
plugging, restrictions or damage. Clean or replace if
necessary.
14. Remove the test fittings and install plugs in the
piping before returning the vehicle to service.
RCPH05CDC562AAA 10
Next operation: Air cooler - Leakage test (B.30.A.32 - F.40.A.40)
3 15/11/2005
B.30.A / 66
Air cooler - Leakage test (B.30.A.32 - F.40.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
To check the air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler. The cooler
does NOT have to be removed from the chassis to perform the leakage test.
If the charge air cooler is hot from operation, the plug with the bleed valve ideally should be installed at the outlet of
the air cooler. Due to space limitations around the inlet and outlet, this may not always be possible. The plugs can
be reversed without reducing the effectiveness of the test.
Prior operation: Air cooler - Pressure test (B.30.A.32 - F.40.C.30)
IMPORTANT: Air coolers are not designed to be leak-proof. Do NOT test the cooler for leakage by submerging it in
a test tank. Almost all air coolers will show excessive leakage if submerged.
1. Install a plug (A) from special tool OEM5039 (SPX)
or equivalent to the inlet side of the cooler. Connect
the cable (B) to a convenient cap screw.
NOTE: The plug with the bleed valve is shown.
WARNING
M1005 - Secure safety chains between the test
plugs and any convenient capscrew on the radiator
assembly to prevent personal injury if a plugs blows
off during the test. The test must be performed with
securely fastened safety chains.
RCPH05CDC529AAA 1
2. Install the remaining plug (A) from the kit to the

outlet. Connect the cable (B) to a convenient cap
screw.
NOTE: The plug with the male air coupler is shown.
RCPH05CDC528AAA 2
3 15/11/2005
B.30.A / 67
3. Install the regulated air supply with gauge from the

kit to the plug with the air valve.
NOTE: This air supply features a shut-off valve (A), an
air regulator (B), a relief valve (C) and a 0 - 400 kPa (0 -
60 psi) pressure gauge (D).
RCPH05CDC530AAA 3
4. Close the shut-off valve on the air supply, and then

connect shop air to the air supply.
RCPH05CDC531AAA 4
5. Open the air regulator and slowly increase air

pressure until the gauge reads 205 kPa (30 psi).
Close the shut-off valve and start a stopwatch at the
same time. Monitor the gauge for 15 seconds and
record any pressure drop.
RCPH05CDC527AAA 5
6. If the pressure drop is 48 kPa (7 psi) or less in 15

seconds, the air cooler is operational.
If the pressure drop is greater than 48 kPa (7 psi) in

15 seconds, determine whether the leakage is from
the air cooler or from a leaky connection.
7. Check the connections for the test plugs at the inlet
and outlet. Retest the air cooler. Similar pressure
drop readings from three consecutive tests should
be recorded before the reading is considered
accurate.
3 15/11/2005
B.30.A / 68
8. If the pressure drop is greater than 48 kPa (7 psi)

in 15 seconds, replace the air cooler. Refer to the
chassis repair manual for replacement procedures.
NOTE: Air coolers are not designed to be 100% leak-free.
If the pressure drop is 48 kPa (7 psi) or less in 15
seconds, the air cooler does NOT need to be replaced.
3 15/11/2005
B.30.A / 69
Air intake manifold - Remove (B.30.A.38 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Refer to the chassis manual and disconnect the air intake line to the manifold connector.
Prior operation: Disconnect the engine harness from the sensors. See Sensing system Air temperature sensor
- Remove (B.30.A.95.80 - F.10.A.10) and Sensing system Air pressure sensor - Remove (B.30.A.95.81 -
F.10.A.10).
Prior operation: Remove the supply lines between the common rail and injector connectors 1-5. See Fuel line
High pressure - Remove (B.20.A.36.20 - F.10.A.10).
1. Remove the cap screws securing the intake cover.

Use a thin scraper or feeler gauge to separate the
cover from the manifold.
RCPH05CDC862AAA 1
Next operation: Air intake manifold - Visual inspection (B.30.A.38 - F.40.A.10)
3 15/11/2005
B.30.A / 70
Air intake manifold - Visual inspection (B.30.A.38 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Air intake manifold - Remove (B.30.A.38 - F.10.A.10)
1. Remove the gasket material from the sealing

surfaces on the cover and the manifold.
NOTE: Keep the material out of the air intake.
RCPH05CDC863AAA 1
2. Inspect the manifold cover 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.
RCPH05CDC866AAB 2
3. Inspect the manifold sealing surface for cracks or

other damage.
RCPH05CDC873AAB 3
Next operation: Air intake manifold - Install (B.30.A.38 - F.10.A.15)
3 15/11/2005
B.30.A / 71
Air intake manifold - Install (B.30.A.38 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Air intake manifold - Visual inspection (B.30.A.38 - F.40.A.10)
1. Apply a thin bead of Permatex™ Ultra Grey

(87307915) silicone sealant to a sealing surface on
the manifold or the cover.
NOTE: Apply sealant around the cap screw holes.
RCPH05CDC874AAA 1
2. Install the manifold cover.
RCPH05CDC875AAA 2
3. Install and torque the cap screws to 24 Nm (18 lb ft).
RCPH05CDC876AAA 3
Next operation: Install the high pressure fuel lines injectors 1-5. See Fuel line High pressure - Install
(B.20.A.36.20 - F.10.A.15).
Next operation: Connect the engine harness to the sensors. See Sensing system Air temperature sensor -
Install (B.30.A.95.80 - F.10.A.15) and Sensing system Air pressure sensor - Install (B.30.A.95.81 - F.10.A.15).
Next operation: Refer to the chassis manual and connect the air inlet line to the manifold connector.
3 15/11/2005
B.30.A / 72
Sensing system Air temperature sensor - Remove (B.30.A.95.80 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

combination air temperature and pressure sensor
on the manifold cover.
RCPH05CDC343ABA 1
2. Remove the Torx® screw and remove the sensor

from the cover.
RCPH05CDC321ABA 2
Next operation: Sensing system Air temperature sensor - Visual inspection (B.30.A.95.80 - F.40.A.10)
3 15/11/2005
B.30.A / 73
Sensing system Air temperature sensor - Visual inspection

(B.30.A.95.80 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air temperature sensor - Remove (B.30.A.95.80 - F.10.A.10)

• Loose connector
• Corroded pins

required.
RCPH05CDC344ABA 1
2. Inspect the sensing component for damage.
RCPH05CDC869AAA 2
Next operation: Sensing system Air temperature sensor - Test (B.30.A.95.80 - F.40.C.01)
3 15/11/2005
B.30.A / 74
Sensing system Air temperature sensor - Test (B.30.A.95.80 -

F.40.C.01)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air temperature sensor - Visual inspection (B.30.A.95.80 - F.40.A.10)

1. With the sensor removed from the manifold cover,
connect the sensor to the engine harness connector
so the sensor reads ambient air temperature and
pressure.
2. Connect the INSITE® service tool, and turn the
keyswitch ON.
3. Use INSITE® to monitor the temperature resistance
reading from the sensor. Refer to the temperature
versus resistance table at Sensing system Air
- D.20.A.20).
Replace the sensor if the resistance reading from

INSITE® does NOT approximately correspond
to the indicated resistance from the table for the
current ambient temperature.
RCPH05CDC325ABA 1
4. Use INSITE® to monitor the pressure voltage

reading from the sensor. Refer to the pressure
versus voltage table at Sensing system Air
- D.20.A.20).
Replace the sensor if the voltage reading from

INSITE® does NOT correspond to the indicated
voltage for a 0 (zero) pressure condition – 0.90 -
1.06 volts DC.
Next operation: Sensing system Air temperature sensor - Install (B.30.A.95.80 - F.10.A.15)
3 15/11/2005
B.30.A / 75
Sensing system Air temperature sensor - Install (B.30.A.95.80 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air temperature sensor - Test (B.30.A.95.80 - F.40.C.01)

1. Install the sensor on the manifold cover and secure
with the Torx® screw. Torque the screw to 17 Nm
(23 lb ft).
RCPH05CDC322ABA 1

sensor. Use INSITE® to monitor the sensor and
verify its correct operation.
RCPH05CDC343ABA 2
3 15/11/2005
B.30.A / 76
Sensing system Air pressure sensor - Preliminary test (B.30.A.95.81

- F.40.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Connect the INSITE® service tool to the vehicle
data link. Turn the keyswitch ON.
RCPH05CDC325ABA 1
2. Monitor the barometric air pressure.
If the barometric air pressure reading from INSITE®

is less than or equal to 523 mm Hg (20.6 in Hg),
and the current elevation is less than 3.048 km
(10,000 ft), replace the sensor.
Next operation: Sensing system Air pressure sensor - Remove (B.30.A.95.81 - F.10.A.10)
3 15/11/2005
B.30.A / 77
Sensing system Air pressure sensor - Remove (B.30.A.95.81 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air pressure sensor - Preliminary test (B.30.A.95.81 - F.40.A.20)

1. Slide the locking tab (A) for the sensor connector
sideways.
Push down on the connector tab (B) and remove

the engine harness connector from the sensor.
RCPH05CDC341ABA 1

the manifold cover.
RCPH05CDC319ABA 2
Next operation: Sensing system Air pressure sensor - Visual inspection (B.30.A.95.81 - F.40.A.10)
Next operation: Sensing system Air pressure sensor - Install (B.30.A.95.81 - F.10.A.15)
3 15/11/2005
B.30.A / 78
Sensing system Air pressure sensor - Visual inspection

(B.30.A.95.81 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air pressure sensor - Remove (B.30.A.95.81 - F.10.A.10)
• Loose connector
• Corroded pins

required.
RCPH05CDC342ABA 1
2. Inspect the sensing component for physical

damage.
RCPH05CDC870AAA 2
Next operation: Sensing system Air pressure sensor - Install (B.30.A.95.81 - F.10.A.15)
3 15/11/2005
B.30.A / 79
Sensing system Air pressure sensor - Install (B.30.A.95.81 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Barometric pressure sensor

1. Install the pressure sensor on the intake manifold
cover with the cap screw removed earlier.
Torque the cap screw to 9 Nm (80 lb in).
RCPH05CDC320ABA 1
2. Install the engine harness connector on the sensor.

Move the locking tab to the lock position. Use
INSITE® to verify the proper operation of the sensor.
RCPH05CDC341ABA 2
3 15/11/2005
B.30.A / 80
Sensing system Air cleaner restriction - Remove (B.30.A.95.95 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the clip securing the harness connector,

and remove the connector from the sensor.
RCPH05CDC577AAA 1
2. Remove the sensor from air inlet piping to the

turbocharger.
Next operation: Sensing system Air cleaner restriction - Visual inspection (B.30.A.95.95 - F.40.A.10)
3 15/11/2005
B.30.A / 81
Sensing system Air cleaner restriction - Visual inspection

(B.30.A.95.95 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air cleaner restriction - Remove (B.30.A.95.95 - F.10.A.10)
• Loose connector
• Corroded pins

required.
2. Inspect the air inlet for the sensor pressure
transducer. Remove any obstruction.
RCPH05CDC580AAA 1
Next operation: Sensing system Air cleaner restriction - Test (B.30.A.95.95 - F.40.C.01)
3 15/11/2005
B.30.A / 82
Sensing system Air cleaner restriction - Test (B.30.A.95.95 -

F.40.C.01)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air cleaner restriction - Visual inspection (B.30.A.95.95 - F.40.A.10)

through the sensor.
If measured resistance is less than 100K ohms, the

sensor has failed closed and must be replaced.
NOTE: The sensor is normally open. The sensor closes
when air restriction attains 63.5 cm H2O (25 in H2O).
RCPH05CDC580AAA 1
Next operation: Sensing system Air cleaner restriction - Install (B.30.A.95.95 - F.10.A.15)
3 15/11/2005
B.30.A / 83
Sensing system Air cleaner restriction - Install (B.30.A.95.95 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Air cleaner restriction - Test (B.30.A.95.95 - F.40.C.01)
1. Install the sensor in the air inlet piping to the

turbocharger.
RCPH05CDC577AAA 1
2. Connect the harness lead to the sensor and secure

with the clip.
3 15/11/2005
B.30.A / 84
AIR INTAKE SYSTEM - Problem solving (B.30.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Refer to AIR INTAKE SYSTEM - Dynamic description (B.30.A - C.30.A.10).
TROUBLESHOOTING
WARNING

Intake manifold air Step 1: Check the drive belt. Replace the belt, if
temperature above Fan drive belt is broken. required.
specification
Refer to Fan and drive Belt - Install
(B.50.A.54.44 - F.10.A.15).
Step 2: Open the cold weather winter front.
Cold weather winter front is closed.
Maintain a minimum opening of 384 cm²
(60 in²) – or approximately 19.6 cm (7.5
in) x 19.6 cm (7.5 in).
Step 3: Inspect all components. Clean as required.
Air cooler, radiator, hydraulic fluid cooler,
condenser and/or fuel cooler fins are Refer to Radiator - Visual inspection
damaged or obstructed with debris. (B.50.A.32 - F.40.A.10).
Step 4: Use INSITE® to view active and inactive
Electronic fault codes active or high counts fault codes.
of inactive fault codes.
Step 5: Check the programmable parameters and
Programmable parameters or selected the selected features with the electronic
features are NOT correct. service tool.
3 15/11/2005
B.30.A / 85

Step 6: Check the fan drive pulleys and belt
Fan drive or controls are malfunctioning. tensioner; refer to Fan and drive
Belt tensioner - Visual inspection
(B.50.A.54.49 - F.40.A.10).
Refer to the chassis service manual and

test the viscous drive.
Step 7: Check the fan part number. Replace the
Fan is the wrong part number for the fan, if required.
engine.
Step 8: Inspect the fan shroud. Repair, replace or
Fan shroud is damaged. install as needed.
Step 9: Reduce the engine load. Increase the
Vehicle speed is too low for adequate engine (fan) rpm by downshifting.
cooling with the high engine load.
Step 10: Check the exhaust plumbing for leaks or
Exhaust system leaking hot air into the broken components.
engine compartment.
test (B.30.A - F.40.A.40).
Intake manifold pressure sensor is fault codes; if faults are present, use the
malfunctioning. guided fault resolution.
Check the intake manifold pressure

sensor. Refer to Sensing system Air
pressure sensor - Test (B.30.A.95.81 -
F.40.C.01).
Step 12: Check the coolant mix.
Cooling system is malfunctioning or using
the incorrect components. Check coolant system performance. Refer
to ENGINE COOLANT SYSTEM - Test
(B.50.A - F.40.C.01).
Check the thermostat and pressure cap

for proper rating. Refer to Thermostat
- Remove (B.50.A.18 - F.10.A.10) and
Pressure cap - Visual inspection
(B.50.A.26 - F.40.A.10).
Intake manifold pressure Step 1: Use INSITE® to view active and inactive
(Boost) is below normal Electronic fault codes active or high counts fault codes; if faults are present, use the
of inactive fault codes. guided fault resolution.
Air intake or exhaust leaks. for leaks.

test (B.30.A - F.40.A.40).
Step 3: Check the air intake system for restriction.
Air intake restriction is above specification. Refer to AIR INTAKE SYSTEM - Supply

piping as necessary.
Step 4: Inspect the air cooler for air restriction.
Air cooler is restricted or leaking. Refer to Air cooler - Visual inspection
(B.30.A.32 - F.40.A.10).
Test the air cooler for leaking; see Air

cooler - Leakage test (B.30.A.32 -
F.40.A.40).
3 15/11/2005
B.30.A / 86

Intake manifold pressure sensor is fault codes; if faults are present, use the
malfunctioning. guided fault resolution.
Check the intake manifold pressure

sensor. Refer to Sensing system Air
pressure sensor - Test (B.30.A.95.81 -
F.40.C.01).
Step 6: Check the exhaust system for restrictions.
Step 7: Inspect the wastegate for damage. Refer
Turbocharger wastegate is damaged or to Turbocharger Exhaust waste gate
stuck open. actuator - Preliminary test (B.30.A.31.30
- F.40.A.20).
Check the wastegate for freedom of

movement. Refer to Turbocharger
Exhaust waste gate actuator - Pressure
test (B.30.A.31.30 - F.40.C.30).
Step 8: Check the turbocharger part number.
Turbocharger is not the correct part Replace if required.
number for the engine.
Step 9: Check the turbocharger for damage.
Turbocharger is worn or damaged. Refer to Turbocharger - Preliminary test
(B.30.A.31 - F.40.A.20).
Measure the turbine and compressor

wheel clearances. Refer to Turbocharger
- Check (B.30.A.31 - F.40.A.11).
Step 10: Refer to the engine performance
Engine power output is low. troubleshooting:
See ENGINE - Problem solving (B.10.A -

G.40.A.30).
Step 11: Reduce vehicle load or use lower gear.
Excessive load for engine horsepower
rating.
Turbocharger leaks Step 1: Review the operating instructions with the
engine oil or fuel Engine is operating for extended owner/operator.
periods under light or no load conditions
(slobbering).
Step 2: Refer to the “excessive white smoke”
White smoke is present. symptom table in the engine performance
troubleshooting tree.
Tractors – ENGINE - Problem solving

(B.10.A - G.40.A.30)
Combines – ENGINE - Problem solving

(B.10.A - G.40.A.30)
Step 3: Check all oil lines and fittings for leaks.
Lubricating oil lines leak oil.
Tighten loose fittings and replace worn or
damaged oil lines as necessary.
3 15/11/2005
B.30.A / 87

Step 4: Remove the turbocharger oil drain line and
Turbocharger oil drain line is restricted. check for restriction. Clean or replace the
oil drain line.
Refer to Turbocharger - Remove

(B.30.A.31 - F.10.A.10) for drain line
removal, inspection and installation.
Step 5: Remove, check and clean the recirculation
Blowby recirculation system is plugged. tube, drain line and recirculation device.
Refer to Blowby re-circulation system -

Remove (B.60.A.26 - F.10.A.10).
Step 6: Remove the intake and exhaust piping to
Lubricating oil or fuel is entering the the turbocharger. Use the fluorescent dye
turbocharger. test to check for the presence of oil or fuel.
Refer to Turbocharger - Leakage test

(B.30.A.31 - F.40.A.40).
Step 7: Check the air intake system for restriction.
Air intake restriction is above specification. Refer to AIR INTAKE SYSTEM - Supply

piping as necessary.
Step 9: Check the compressor and turbine seals
Turbocharger oil seal is leaking. for leaking.
Refer to Turbocharger - Leakage test

(B.30.A.31 - F.40.A.40).
Step 10: Check the radial bearing and axial
Turbine or compressor wheel clearances clearance on the turbine and compressor:
are out of specification.
Refer to Turbocharger - Check
(B.30.A.31 - F.40.A.11).
Step 11: Check the valve stems and seals. Refer to
Valve stem clearance is excessive or the cylinder head removal and disassembly:
valve stem seals are damaged.
Cylinder head - Remove (B.10.A.72 -
F.10.A.10)
Cylinder head - Disassemble (B.10.A.72

- F.10.A.25)
3 15/11/2005
B.30.A / 88
Index

Air cooler - Cleaning (B.30.A.32 - F.30.A.10) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Leakage test (B.30.A.32 - F.40.A.40) 67
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Pressure test (B.30.A.32 - F.40.C.30) 63
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Service limits (B.30.A.32 - D.20.A.20) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Special tools (B.30.A.32 - D.20.A.40) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Torque (B.30.A.32 - D.20.A.10) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air cooler - Visual inspection (B.30.A.32 - F.40.A.10) 62
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Install (B.30.A.38 - F.10.A.15) 72
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Remove (B.30.A.38 - F.10.A.10) 70
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Torque (B.30.A.38 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Air intake manifold - Visual inspection (B.30.A.38 - F.40.A.10) 71
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Check (B.30.A - F.40.A.11) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Component identification (B.30.A - C.40.C.20) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Dynamic description (B.30.A - C.30.A.10) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - General specification (B.30.A - D.40.A.10) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Leakage test (B.30.A - F.40.A.40) 24
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Problem solving (B.30.A - G.40.A.30) 85
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Service limits (B.30.A - D.20.A.20) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Special tools (B.30.A - D.20.A.40) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
AIR INTAKE SYSTEM - Supply restriction (B.30.A - F.40.C.21) 31
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Install (B.30.A.95.95 - F.10.A.15) 84
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Remove (B.30.A.95.95 - F.10.A.10) 81
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Service limits (B.30.A.95.95 - D.20.A.20) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Test (B.30.A.95.95 - F.40.C.01) 83
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air cleaner restriction - Visual inspection (B.30.A.95.95 - F.40.A.10) 82
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Install (B.30.A.95.81 - F.10.A.15) 80
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.30.A / 89
Sensing system Air pressure sensor - Preliminary test (B.30.A.95.81 - F.40.A.20) 77
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Remove (B.30.A.95.81 - F.10.A.10) 78
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Service limits (B.30.A.95.81 - D.20.A.20) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Torque (B.30.A.95.81 - D.20.A.10) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air pressure sensor - Visual inspection (B.30.A.95.81 - F.40.A.10) 79
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Install (B.30.A.95.80 - F.10.A.15) 76
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Remove (B.30.A.95.80 - F.10.A.10) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Service limits (B.30.A.95.80 - D.20.A.20) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Test (B.30.A.95.80 - F.40.C.01) 75
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Torque (B.30.A.95.80 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Air temperature sensor - Visual inspection (B.30.A.95.80 - F.40.A.10) 74
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Check (B.30.A.31 - F.40.A.11) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Install (B.30.A.31 - F.10.A.15) 47
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Leakage test (B.30.A.31 - F.40.A.40) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Preliminary test (B.30.A.31 - F.40.A.20) 35
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Remove (B.30.A.31 - F.10.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Service limits (B.30.A.31 - D.20.A.20) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Special tools (B.30.A.31 - D.20.A.40) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Torque (B.30.A.31 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger - Visual inspection (B.30.A.31 - F.40.A.10) 45
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Install (B.30.A.31.30 - F.10.A.15) 57
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Preliminary test (B.30.A.31.30 - F.40.A.20) 51
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Pressure test (B.30.A.31.30 - F.40.C.30) 52
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Remove (B.30.A.31.30 - F.10.A.10) 54
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger Exhaust waste gate actuator - Visual inspection (B.30.A.31.30 - F.40.A.10) 56
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.30.A / 90
EXHAUST SYSTEM - 40.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.40.A / 1
Contents
TECHNICAL DATA
EXHAUST SYSTEM - General specification (B.40.A - D.40.A.10) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
EXHAUST SYSTEM - Special tools (B.40.A - D.20.A.40) 3

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold
Exhaust manifold - Torque (B.40.A.38 - D.20.A.10) 4
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Service limits (B.40.A.38 - D.20.A.20) 4

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
EXHAUST SYSTEM - Dynamic description (B.40.A - C.30.A.10) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
EXHAUST SYSTEM - Return restriction (B.40.A - F.40.C.22) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold
Exhaust manifold - Remove (B.40.A.38 - F.10.A.10) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Visual inspection (B.40.A.38 - F.40.A.10) 9

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Measure (B.40.A.38 - F.40.E.01) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Install (B.40.A.38 - F.10.A.15) 12

MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.40.A / 2
POWER PRODUCTION - EXHAUST SYSTEM
EXHAUST SYSTEM - General specification (B.40.A - D.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Maximum exhaust back pressure 76 mm Hg (3.0 in Hg)
EXHAUST SYSTEM - Special tools (B.40.A - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure/Vacuum Module – 3164491 (Cummins)

exhaust restriction. The module shown features ranges
of 0 - 3447 kPa (0 - 500 psi) for pressure and 0 - 760
mm Hg (0 - 29.99 in Hg) for vacuum.
RCPH05CDC704AAA 1
3 15/11/2005
B.40.A / 3
Exhaust manifold - Torque (B.40.A.38 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Exhaust manifold cap screws 43 Nm 32 lb ft
RCPH05CDC988AAA 1
Exhaust manifold - Service limits (B.40.A.38 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold flatness

Reference: Exhaust manifold - Measure (B.40.A.38 - F.40.E.01)
RCPH05CDC981AAA 1
3 15/11/2005
B.40.A / 4
EXHAUST SYSTEM - Dynamic description (B.40.A - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCSC05CDC002CAA 1
The exhaust system is equipped with a wastegated

turbocharger – Holset® Model HX40. The unit consists
of a turbocharger (A), wastegate actuator (B) and
wastegate valve (C) in the turbine housing (D).
RCPH05CDC604AAA 2
A wastegated turbocharger provides improved response

at low engine speeds without sacrificing turbocharger
durability at high speeds. This is accomplished by
allowing exhaust gases to bypass the turbine wheel
during certain modes of engine operation.
RCPH05CDC604AAA 3
3 15/11/2005
B.40.A / 5
During low rpm operation, the turbocharger acts as a

closed system where the gases’ energy is transferred to
the compressor wheel and used to compress intake air.
During high rpm operation, the turbocharger becomes

an open system and allows exhaust gas to bypass the
turbine. Since exhaust gas is gated around the turbine
wheel, less energy is absorbed through the turbine and
transferred to the compressor, reducing intake manifold
pressures and turbine speed.
The wastegate actuator is mounted on the turbocharger

and consists of a pressure capsule (A), diaphragm
(located inside the capsule) and rod (B). As pressure
changes in the capsule, the actuator rod adjusts the
wastegate valve accordingly.
RCPH05CDC607AAA 4
The wastegate valve is mounted inside the turbocharger

in the turbine housing. As the valve opens, exhaust gas
is allowed to bypass the turbine wheel, lowering turbine
speed to adjust intake manifold pressure.
3 15/11/2005
B.40.A / 6
EXHAUST SYSTEM - Return restriction (B.40.A - F.40.C.22)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the clamp (A) and partially remove the heat

blanket (B) from the exhaust pipe.
RCPH05CDC563AAA 1

fitting in the exhaust pipe. Install the fitting.
RCPH05CDC564AAA 2
3. Connect a test line from a digital manometer to the

fitting.
Operate the engine at full throttle and rated rpm with

maximum load. Record the data on the manometer.
NOTE: A tube style mercury manometer can be used for
this test. However, due to the safety and environmental
concerns with the proper handling, spillage and disposal
of mercury, digital testers are more widely used for
obtaining readings in mm Hg (in Hg).
NOTE: The digital manometer must be zeroed to obtain
a valid reading.
RCPH05CDC565AAA 3
4. If the restriction exceeds 76 mm Hg (3.0 in Hg),

inspect the exhaust piping for damage.
5. Remove the test equipment. Install a plug at the test
point. Reinstall the heat blanket and clamp.
3 15/11/2005
B.40.A / 7
Exhaust manifold - Remove (B.40.A.38 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the support bracket from the exhaust

manifold.
RCPH05CDC989AAA 1
2. Remove the heat shield from the manifold.
RCPH05CDC987AAA 2
3. Remove the exhaust manifold and gaskets from the

head.
RCPH05CDC986AAA 3
Next operation: Exhaust manifold - Visual inspection (B.40.A.38 - F.40.A.10)
3 15/11/2005
B.40.A / 8
Exhaust manifold - Visual inspection (B.40.A.38 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Exhaust manifold - Remove (B.40.A.38 - F.10.A.10)
1. Clean the sealing surface of the head. Use 240-grit

cloth to remove carbon deposits from the surface.
RCPH05CDC978AAA 1
2. Clean the sealing surfaces on the manifold.
RCPH05CDC979AAA 2
3. Clean the sealing joint for manifold sections. Use

240-grit cloth to remove carbon deposits from the
sealing surfaces.
RCPH05CDC980AAA 3
3 15/11/2005
B.40.A / 9
4. Use steam to clean the exhaust manifold.
WARNING
WARNING
6. Inspect the head for cracks, burnout or damaged

threads at the manifold.
NOTE: If the exhaust manifold is damaged, check the
air cooler. An air cooler failure can cause progressive
damage to the exhaust manifold.
RCPH05CDC982AAB 4
7. Inspect the gasket surfaces for gouges, scratches

or burnout.
RCPH05CDC597AAB 5
Next operation: Exhaust manifold - Measure (B.40.A.38 - F.40.E.01)
3 15/11/2005
B.40.A / 10
Exhaust manifold - Measure (B.40.A.38 - F.40.E.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Exhaust manifold - Visual inspection (B.40.A.38 - F.40.A.10)
1. Measure the manifold surface for flatness. Place a

straight edge over the exhaust ports. Use a feeler
gauge to measure the gap between the straight
edge and the port surface.
The maximum acceptable gap is 0.20 mm (0.008

in).
If any port measures out of specification, replace

the manifold.
RCPH05CDC981AAA 1
2. Check the manifold to cylinder head fit. If the

manifold cap screws do NOT line up with the tapped
holes in the head, replace the exhaust manifold.
RCPH05CDC985AAB 2
Next operation: Exhaust manifold - Install (B.40.A.38 - F.10.A.15)
3 15/11/2005
B.40.A / 11
Exhaust manifold - Install (B.40.A.38 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Exhaust manifold - Measure (B.40.A.38 - F.40.E.01)
1. Apply a thin coating of nickel-based high

temperature compound to the threads of the
manifold cap screws.
RCPH05CDC983AAB 1
2. Assemble new gaskets and the original cap screws

on the manifold.
RCPH05CDC984AAA 2
3. Install the manifold on the head.
RCPH05CDC985AAA 3
3 15/11/2005
B.40.A / 12
4. Tighten and torque the cap screws to 43 Nm (32 lb

ft) following the sequence shown.
RCSC05CDC154AAA 4
5. Install the heat shield on the manifold.
RCPH05CDC987AAA 5
6. Install the support bracket.
RCPH05CDC990AAA 6
3 15/11/2005
B.40.A / 13
Index

Exhaust manifold - Install (B.40.A.38 - F.10.A.15) 12
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Measure (B.40.A.38 - F.40.E.01) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Remove (B.40.A.38 - F.10.A.10) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Service limits (B.40.A.38 - D.20.A.20) 4
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Torque (B.40.A.38 - D.20.A.10) 4
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Exhaust manifold - Visual inspection (B.40.A.38 - F.40.A.10) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
EXHAUST SYSTEM - Dynamic description (B.40.A - C.30.A.10) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
EXHAUST SYSTEM - General specification (B.40.A - D.40.A.10) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
EXHAUST SYSTEM - Return restriction (B.40.A - F.40.C.22) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
EXHAUST SYSTEM - Special tools (B.40.A - D.20.A.40) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.40.A / 14
ENGINE COOLANT SYSTEM - 50.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.50.A / 1
Contents
TECHNICAL DATA
ENGINE COOLANT SYSTEM - Special tools (B.50.A - D.20.A.40) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - General specification (B.50.A - D.40.A.10) 5

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat
Thermostat - Torque (B.50.A.18 - D.20.A.10) 6
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Service limits (B.50.A.18 - D.20.A.20) 6

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump
Water pump - Torque (B.50.A.20 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter
Water filter - Torque (B.50.A.24 - D.20.A.10) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap
Pressure cap - Service limits (B.50.A.26 - D.20.A.20) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line
Coolant line - Torque (B.50.A.36 - D.20.A.10) 10
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive

Fan and drive - Torque (B.50.A.54 - D.20.A.10) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Torque (B.50.A.54.49 - D.20.A.10) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Service limits (B.50.A.54.49 - D.20.A.20) 12

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Coolant temperature - Torque (B.50.A.95.90 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Service limits (B.50.A.95.90 - D.20.A.20) 13

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
ENGINE COOLANT SYSTEM - Dynamic description (B.50.A - C.30.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20) 20

MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Component identification (B.50.A - C.40.C.20) 21

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat
87372074 3 15/11/2005
B.50.A / 2
Thermostat - Dynamic description (B.50.A.18 - C.30.A.10) 23
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump
Water pump - Dynamic description (B.50.A.20 - C.30.A.10) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap
Pressure cap - Dynamic description (B.50.A.26 - C.30.A.10) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
ENGINE COOLANT SYSTEM - Decontaminating (B.50.A - F.30.A.60) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Emptying (B.50.A - F.35.A.01) 29

MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Test (B.50.A - F.40.C.01) 30

MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Tool connection (B.50.A - F.40.D.21) 33

MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 37

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat
Thermostat - Remove (B.50.A.18 - F.10.A.10) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Test (B.50.A.18 - F.40.C.01) 40

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Install (B.50.A.18 - F.10.A.15) 41

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump
Water pump - Remove (B.50.A.20 - F.10.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Visual inspection (B.50.A.20 - F.40.A.10) 43

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Install (B.50.A.20 - F.10.A.15) 44

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter
Water filter - Remove (B.50.A.24 - F.10.A.10) 45
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Disassemble (B.50.A.24 - F.10.A.25) 46

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Assemble (B.50.A.24 - F.10.A.20) 47

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Install (B.50.A.24 - F.10.A.15) 48

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap
Pressure cap - Visual inspection (B.50.A.26 - F.40.A.10) 50
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap - Pressure test (B.50.A.26 - F.40.C.30) 51

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Radiator
Radiator - Visual inspection (B.50.A.32 - F.40.A.10) 52
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line
87372074 3 15/11/2005
B.50.A / 3
Coolant line - Remove (B.50.A.36 - F.10.A.10) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line - Visual inspection (B.50.A.36 - F.40.A.10) 54

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line - Install (B.50.A.36 - F.10.A.15) 55

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive

Fan and drive - Remove (B.50.A.54 - F.10.A.10) 56
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Install (B.50.A.54 - F.20.A.20) 57

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Remove (B.50.A.54.44 - F.10.A.10) 58

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Visual inspection (B.50.A.54.44 - F.40.A.10) 59

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Install (B.50.A.54.44 - F.10.A.15) 60

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Disassemble (B.50.A.54 - F.10.A.25) 61

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Visual inspection (B.50.A.54 - F.40.A.10) 63

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Assemble (B.50.A.54 - F.10.A.20) 65

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Visual inspection (B.50.A.54.49 - F.40.A.10) 67

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Remove (B.50.A.54.49 - F.10.A.10) 69

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Install (B.50.A.54.49 - F.10.A.15) 70

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Coolant temperature - Remove (B.50.A.95.90 - F.10.A.10) 71
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Visual inspection (B.50.A.95.90 - F.40.A.10) 72

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Test (B.50.A.95.90 - F.40.C.01) 73

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Install (B.50.A.95.90 - F.10.A.15) 74

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
ENGINE COOLANT SYSTEM - Problem solving (B.50.A - G.40.A.30) 75
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.50.A / 4
POWER PRODUCTION - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Special tools (B.50.A - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Combustion gas leak test kit – 3822985 (Cummins)

This tool is used to check for the presence of combustion
gases in the coolant system. The tool includes the test
instrument and test fluid 3822986 (CUMMINS).
RHPH05CDC306ABA 1
Coolant Pressure/Temperature/Flow Analyzer – 3822994 (Cummins)

The analyzer is used to determine the cause(s) of
pressure loss, restriction, improper temperature control
and entrained air in the coolant system. The analyzer is
used with the engine running, the coolant system filled
and the pressure cap removed.
RCPH05CDC335ABA 2
ENGINE COOLANT SYSTEM - General specification (B.50.A -

D.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant capacity (engine only) 11.1 L (11.7 US qt)

Standard modulating thermostat range 82 - 93 °C (180 - 200 °F)
Minimum recommended pressure cap 48 kPa (7 psi)
Minimum fill rate (without low-level alarm) 19 L/min (5 US gpm)
Maximum deaeration time 25 minutes
3 15/11/2005
B.50.A / 5
Thermostat - Torque (B.50.A.18 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Coolant outlet connection cap 24 Nm 18 lb ft
screws
RCPH05CDC297AAA 1
Thermostat - Service limits (B.50.A.18 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat
Reference: Thermostat - Test (B.50.A.18 - F.40.C.01)
The thermostat MUST begin to open within 1 °C (2 °F) of the
nominal temperature – 82 °C (180 °F).
The thermostat MUST be completely open within 12 °C (22

°F) of the nominal temperature – 82 °C (180 °F).
RCSC05CDC155AAA 1
The fully open distance between the flange on the thermostat

and the housing is 9.4 mm (0.370 in).
RCSC05CDC157AAA 2
3 15/11/2005
B.50.A / 6
Water pump - Torque (B.50.A.20 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Water pump cap screws 24 Nm 18 lb ft
RCPH05CDC077ABA 1
3 15/11/2005
B.50.A / 7
Water filter - Torque (B.50.A.24 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Coolant filter head cap screws 24 Nm 18 lb ft
RCPH05CDC330AAA 1
Filter head valve screw 1.2 Nm 12.0 lb in
RCPH05CDC324ABA 2
3 15/11/2005
B.50.A / 8
Pressure cap - Service limits (B.50.A.26 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap
Reference: Pressure cap - Pressure test (B.50.A.26 - F.40.C.30)
The pressure cap MUST seal within 14 kPa (2 psi) of the
cap rating – 103 kPa (15 psi).
RCPH05CDC224ABA 1
3 15/11/2005
B.50.A / 9
Coolant line - Torque (B.50.A.36 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Coolant supply connector 24 Nm 18 lb ft
RCPH05CDC196ABA 1
3 15/11/2005
B.50.A / 10
Fan and drive - Torque (B.50.A.54 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Fan and shaft pulley support cap 43 Nm 32 lb ft
screws
RCPH05CDC206ABA 1
Idler pulley cap screw 43 Nm 32 lb ft
RCPH05CDC207ABA 2
Shaft plate cap screws 43 Nm 32 lb ft
RCPH05CDC212ABA 3
3 15/11/2005
B.50.A / 11
Fan and drive Belt tensioner - Torque (B.50.A.54.49 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Belt tensioner cap screw 43 Nm 32 lb ft
RCSC05CDC167AAA 1
Fan and drive Belt tensioner - Service limits (B.50.A.54.49 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Belt tensioner
Reference: Fan and drive Belt tensioner - Visual inspection (B.50.A.54.49 - F.40.A.10)
Replace the belt tensioner:
• if a tensioner arm stop is in contact with the spring
casing stop with a new belt installed,
• if cracks are present on the tensioner arm, pulley or
stops,
• if the tensioner arm stop is NOT in contact with the
spring casing stop with the belt removed,
• if the clearance between the tensioner spring case and
the tensioner arm exceeds 3.0 mm (0.12 in),
• if the tensioner arm contacts the tensioner cap.
RCPH05CDC208ABA 1
3 15/11/2005
B.50.A / 12
Sensing system Coolant temperature - Torque (B.50.A.95.90 -

D.20.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Coolant temperature sensor 23 Nm 17 lb ft
RCPH05CDC188ABA 1
Sensing system Coolant temperature - Service limits (B.50.A.95.90 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Temperature Resistance Ω
C° F°
0 32 30 - 37K ohms
25 77 9.3 - 10.7K ohms
50 122 3.2 - 3.8K ohms
80 176 1.1 - 1.3K ohms
95 203 700 - 800 ohms
Coolant temperature sensor

Reference: Sensing system Coolant temperature - Test (B.50.A.95.90 - F.40.C.01)
Compare the INSITE® reading from the sensor for
the ambient temperature condition with the data in the
temperature versus resistance table.
If the reading from the sensor does not correspond to the

data in the temperature versus resistance table, replace the
sensor.
RCPH05CDC187ABA 1
3 15/11/2005
B.50.A / 13
ENGINE COOLANT SYSTEM - Dynamic description (B.50.A -

C.30.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant is circulated within the engine by the integrally

mounted water pump.
RCPH05CDC011AAA 1
The output from the water pump empties into the oil
cooler cavity in the cylinder block. This provides the oil
cooler with the coolest possible coolant.
RCPH05CDC014AAA 2
From the oil cooler cavity, coolant flows into the lower
water manifold.
RCPH05CDC016AAA 3
3 15/11/2005
B.50.A / 14
From the lower water manifold, the coolant enters the

jacket cavity. Coolant travels around the liners, carrying
combustion heat to the top of the block.
RCPH05CDC017AAA 4
The head gasket has orifices to control coolant flow into

the cylinder head.
RCPH05CDC018AAA 5
Coolant flowing through the single passage per cylinder

in the right side of the cylinder head gasket, flows to the
lower water cavity through drillings in the cylinder head.
This flow cools the valve seat and the injector area.
This coolant continues its flow into the upper cavity of
the cylinder head.
RCPH05CDC019AAA 6
3 15/11/2005
B.50.A / 15
Coolant flowing through the two passages per cylinder

in the left side of the cylinder head gasket flows to the
upper water cavity in the cylinder head, crosses over
the valve seats and bridges.
RCPH05CDC021AAA 7
RCPH05CDC022AAA 8
The coolant in the lower water jacket in the cylinder

head connects to the upper water jacket through a
series of passages in the cylinder head.
RCPH05CDC023AAA 9
The coolant then flows across the cylinder head, down

into the upper water manifold in the engine block, and
then forward to the integral thermostat housing.
RCPH05CDC026AAA 10
3 15/11/2005
B.50.A / 16
When the engine is below 82 °C (180 °F), the thermostat

is closed, allowing the coolant to bypass the radiator and
flow back to the water pump inlet through an internal
drilling in the cylinder block.
As the coolant temperature increases to 82 °C (180 °F),

the thermostat starts to open and coolant flow to the
bypass begins to be restricted.
RCPH05CDC027AAA 11
When the engine operating temperature increases to 91

°C (195 °F), the thermostat completely opens blocking
the bypass passage to the water pump and opening the
outlet to the radiator.
The engine must never be operated without a

thermostat. Without a thermostat the coolant
recirculates, bypassing the radiator, causing the engine
to overheat.
RCPH05CDC028AAA 12
With the positive flow deaerating cooling system, water

supply to the inlet side of the water pump is supplied by
three sources: the bypass passage (1), the radiator (2)
and from the deaeration tank (3).
RCPH05CDC029AAA 13
When the thermostat is closed, the pressure in the block

circuit causes the supply to the water pump to flow from
the bypass passage.
RCPH05CDC030AAA 14
3 15/11/2005
B.50.A / 17
When the engine reaches operating temperature and

the thermostat opens, the pressure in that part of the
circuit causes the flow to come from the radiator.
RCPH05CDC031AAA 15
The line from the deaeration tank insures that there is

a positive flow of coolant at the water pump inlet at all
times.
As the water pump increases in speed, more coolant is

needed to increase the coolant flow. When the block
and radiator circuit cannot supply enough coolant,
the low pressure at the pump draws coolant from the
deaeration tank.
RCPH05CDC032AAA 16
3 15/11/2005
B.50.A / 18
At the coolant filter, a portion of the coolant flows

through the filter on the right side of the engine. The
coolant filter helps to maintain the proper additive level
in the cooling system and should be changed at the
appropriate maintenance interval.
RCPH05CDC033AAA 17
RCPH05CDC034AAA 18
The higher pressure coolant in the lower manifold

pushes the coolant through the filter. After passing
through the filter, the coolant returns to the lower
pressure upper manifold. The orifices in the cylinder
head gasket provide the pressure differential in the
upper and lower manifold to force flow through the filter.
RCPH05CDC035AAA 19
3 15/11/2005
B.50.A / 19
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: This form is used in conjunction with ENGINE COOLANT SYSTEM - Test (B.50.A - F.40.C.01).
Test Analyzer INSITE®

Block Pressure Coolant Temperature Coolant Temperature
Block pressure 60 °C (140 °F)
Thermostat opens
Fan begins to fully engage
3 15/11/2005
B.50.A / 20
ENGINE COOLANT SYSTEM - Component identification (B.50.A -

C.40.C.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC001GAA 1
Engine front
A. Vibration damper (rubber or viscous) F. Alternator

B. Belt tensioner G. Idler puller
C. Water pump H. Fan pulley
D. Water inlet from radiator J. Top dead center (TDC) mark
E. Compressor K. Drive belt
3 15/11/2005
B.50.A / 21
RCPH05CDC003GAA 2
L. Water filter O. Viscous drive

M. Block heater P. Water outlet to radiator (located behind the alternator)
N. Fan Q. Coolant temperature sensor
3 15/11/2005
B.50.A / 22
Thermostat - Dynamic description (B.50.A.18 - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
The thermostat controls coolant temperature. When

coolant temperature is below operating temperature,
coolant is bypassed to the inlet of the water pump.
RCSC05CDC158AAA 1
When coolant temperature reaches the operating range,

the thermostat opens, sealing off the bypass, and forcing
flow to the radiator.
RCSC05CDC159AAA 2
3 15/11/2005
B.50.A / 23
The thermostat begins opening at 82 °C (180 °F).
The thermostat must be completely open at 93 °C (200

°F).
RCPH05CDC298AAA 3
WARNING
M1052 - Never operate the engine without a thermostat. Without a thermostat, coolant will return through
the bypass to the pump inlet, causing the engine to overheat.
3 15/11/2005
B.50.A / 24
Water pump - Dynamic description (B.50.A.20 - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
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 cause the engine to run hot.
RCSC05CDC162AAA 1
The pump is belt-driven from the crankshaft pulley. An

automatic tensioner is used to prevent the belt from
slipping on the pulley. Tensioner malfunction will cause
the water pump impeller to rotate at a slower speed,
reducing coolant flow through the engine.
RCSC05CDC160AAA 2
Coolant flow may also be reduced if the inlet lines to the

water pump collapse. A hose usually does NOT collapse
while the engine is running at low speed. Check the lines
while the engine is running at rated speed.
RCSC05CDC161AAA 3
A worn or malfunctioning water pump will NOT produce

the flow required to prevent the engine from running
hot. Check all possibilities in the troubleshooting tree for
coolant temperature above normal, before checking the
pump flow rate or replacing the water pump.
3 15/11/2005
B.50.A / 25
Pressure cap - Dynamic description (B.50.A.26 - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
The coolant system uses a pressure cap to prevent

boiling of the coolant. The cap pressure rating is
stamped on the exterior of the cap: 103 kPa (15 psi).
An incorrect or malfunctioning cap can result in coolant

leaking and the engine running hot.
RCPH05CDC224ABA 1
Air in the coolant can cause coolant leakage from the

deaeration tank when aerated coolant is hot. The heated
air expands, increasing the pressure in the coolant
system, causing the cap to open.
Similarly, coolant can be displaced through the

deaeration tank if the head gasket leaks compressed
gases into the coolant system.
The operating pressure of the coolant system and the

lubrication system can result in mixing of the fluids, if
there is a leak between systems: for example, at the
head gasket or the oil cooler.
RCPH05CDC251ABA 2
3 15/11/2005
B.50.A / 26
ENGINE COOLANT SYSTEM - Decontaminating (B.50.A - F.30.A.60)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
IMPORTANT: Do NOT install the pressure cap. The engine is to be operated without the pressure cap for this
procedure.
IMPORTANT: Do NOT remove the coolant filter for this procedure.
IMPORTANT: The coolant system must be filled properly to prevent air locks. During filling, air must be purged
from the engine coolant passages. Wait 2 to 3 minutes after the initial fill to allow air to vent; then add mixture to
being the level to the top.
1. Fill the system with a mixture of sodium carbonate
and water (or an equivalent off the shelf product).
Use 0.5 kg (1.0 lb) of sodium carbonate for every
23 L (6 US gal) of water.
2. Operate the engine for 5 minutes with the coolant
temperature above 80 °C (176 °F).
RCIL05CDC008AAA 1
3. Shut off the engine. Allow the engine to cool to 50

°C (122 °F) and drain the cooling system.
RCPH05CDC249ABA 2
4. Fill the cooling system with clean water.

NOTE: Do not install the pressure cap or a new water filter.
3 15/11/2005
B.50.A / 27
5. Operate the engine for 5 minutes with the coolant

temperature above 80 °C (176 °F).
RCIL05CDC008AAA 3
6. Shut off the engine. Allow the engine to cool to 50

°C (120 °F) and drain the cooling system.
NOTE: If the water drained is still dirty, continue flushing
the system until the water is clean.
RCPH05CDC249ABA 4
3 15/11/2005
B.50.A / 28
ENGINE COOLANT SYSTEM - Emptying (B.50.A - F.35.A.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the pressure cap to allow the coolant to

drain efficiently.
WARNING
M941 - DO NOT remove coolant system pressure
cap while coolant is HOT. Wait until the coolant
temperature is below 50 degrees C (120 degrees F)
before removing the system pressure cap. Failure
to do so will cause injury.
RCPH05CDC251ABA 1
2. Open the drain valve for the radiator to remove

the coolant from the system. A 19 L (5 US gal)
container is adequate for most procedures.
WARNING
M940 - Coolant can be toxic. Keep away from children
and pets. Avoid prolong contact. If not reused,
dispose of in accordance with local environmental
regulations.
RCPH05CDC249ABA 2
3. Open the drain valve for the oil cooler to remove the
trapped coolant from the system.
RCPH05CDC252ABA 3
3 15/11/2005
B.50.A / 29
ENGINE COOLANT SYSTEM - Test (B.50.A - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cooling system analyzer

1. Remove the pressure cap from the deaeration tank,
and leave it off for this test.
RCPH05CDC251ABA 1
2. Install the combustion gas leak test kit – 3822985

(CUMMINS). When the combustion gas leak test kit
is used with the analyzer, the test tube is installed
without the bulb. The pressure cap is removed
from the deaeration tank, and the test tube is
firmly seated in the neck. Any combustion gases
released into the coolant system should be dispelled
through the test tube, causing the test fluid to turn
a yellow-green in color.
See ENGINE COOLANT SYSTEM - Test (B.50.A -

F.40.C.01) for additional instructions on its use.
RCPH05CDC340ABA 2
3. Connect the analyzer – 3822994 (CUMMINS) – to

the coolant system . Refer to ENGINE COOLANT
SYSTEM - Tool connection (B.50.A - F.40.D.21).
Pressure readings
4. To read block pressure:
• Turn the knob for pressure selection (A) to the

thermostat housing position.
• Turn the knob for temperature selection (B) to OFF.
NOTE: The temperature selection knob MUST be in the
OFF position for pressure readings to be accurate.
RCPH05CDC330ABA 3
3 15/11/2005
B.50.A / 30
Temperature readings
5. To read coolant temperature:
• Turn the knob for temperature selection (A) to the

thermostat housing position.
• Turn the knob for pressure selection (B) to the
OFF position.
NOTE: On start up, allow 15 seconds to pass for the
temperature gauge to stabilize.
NOTE: The temperature reading on the gauge will
fluctuate whenever the temperature selection knob is
turned. This fluctuation – caused by temperature loss in
the line – is normal. The temperature will stabilize after
a few seconds.
NOTE: Due to heat loss through analyzer plumbing, RCPH05CDC332ABA 4
temperature gauge readings are approximately 2.5 °C (5
°F) lower than actual engine temperature.
Sight glass readings

6. Monitor the sight glass installed on the analyzer
throughout the test. If air is observed, finish the
test and perform the INSITE® cylinder cutout test
in conjunction with the combustion gas test to
determine the source of the leak.
NOTE: Partially closing the temperature valve to slow
coolant flow will make any air bubbles in the sight glass
more visible. Completely open the valve again to measure
temperature.
RCPH05CDC331ABB 5
Testing
7. Start the engine and run at high idle.
8. Perform the combustion gas test in conjunction
with the pressure and temperature readings from
the analyzer. This information, along with the sight
glass observations, can isolate the source of air in
the cooling system, if present.
9. Record the block pressure at 60 °C (140 °F).
If block pressure is less than 138 kPa (20 psi) at

high idle without a pressure cap, check the following:
• Remove the water pump. Inspect the impeller for

wear and damage and for slippage on the shaft.
• Check belt tension and condition.
3 15/11/2005
B.50.A / 31
10. If block pressure drops by more than 34 kPa (5 psi)

during this test, check for the following:
• Air in the system.

• Incorrect initial cooling system fill.
• Less than 50/50 antifreeze mixture.
• (Engine is at high altitude.)
11. Verify that the thermostat opens close to the nominal
temperature. The thermostat should begin to open
within 2.5 °C (5 °F) of the nominal temperature – 82
°C (180 °F), adjusting for the loss of temperature as
coolant flows through the analyzer.
The temperature gauge on the analyzer will show

a steady rise toward the opening set point as heat
in the block builds. When the thermostat begins
to open, the temperature gauge will pause at the
opening temperature. Verify coolant flow to the
radiator by momentary hand contact on the piping
or with a surface thermal probe.
RCPH05CDC338ABA 6
12. Connect the INSITE® service tool. Compare

the temperature reading from INSITE® from the
coolant temperature sensor with the reading from
the analyzer for coolant temperature. Replace the
temperature sensor if it is not within ±3.9 °C (±7 °F)
of the correct reading.
RCPH05CDC325ABA 7
13. Check and record coolant temperature when the fan

begins to fully engage. The fan should begin to fully
engage 2.5 °C (5 °F) of 96 °C (206 °F), adjusting
for the loss of temperature as coolant flows through
the analyzer.
If the fan does not perform as specified, refer to the

chassis repair manual for the viscous fan drive test
procedure.
RCPH05CDC339ABA 8
14. Use the form at ENGINE COOLANT SYSTEM -

Static description (B.50.A - C.30.A.20) to record
the readings.
3 15/11/2005
B.50.A / 32
ENGINE COOLANT SYSTEM - Tool connection (B.50.A - F.40.D.21)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant pressure/temperature/flow analyzer

1. The analyzer – 3822994 (CUMMINS) – is used
to check for pressure loss, restriction, improper
temperature control and entrained air in the coolant
system.
Drain approximately 15 - 19 L (4 - 5 US gal) of

coolant from the system to install the analyzer.
2. The analyzer connects to the engine coolant system
with two hoses equipped with 0.25 in quick connect
couplers.
NOTE: The coupler on the red hose is not used for this
engine.
RCPH05CDC335ABA 1
3. Remove the coolant hose to the cab heater from the

shutoff valve on the right hand side of the engine.
Plug the hose.
Locate a 2 m (6 ft) section of coolant hose. Clamp

one end of the hose to the shutoff valve. Install a
0.25 in male quick coupler on the other end of the
hose.
NOTE: This port taps into flow in the upper water jacket
on its way to the thermostat.
RCPH05CDC329ABA 2
4. Remove the 22 mm plug from the engine block

under the compressor. Use any combination of
fittings to install a 0.25 in male quick coupler at the
location.
NOTE: This port taps into flow from the water pump.
RCPH05CDC328ABA 3
3 15/11/2005
B.50.A / 33
5. Return the coolant drained earlier to the coolant

system.
6. Since the hoses from the analyzer are 1.2 m (4 ft)
in length, the analyzer must be supported on a tall
stand or tool chest on the right hand side of the
engine.
7. Route the hose from the shutoff valve away from the
exhaust assembly, and connect the male coupler to
the 0.25 in female quick coupler on the YELLOW
hose from the analyzer.
RCPH05CDC334ABA 4
8. Connect the 0.25 in female quick coupler on the

BLACK hose from the analyzer to the male coupler
in the engine block.
RCPH05CDC333ABA 5
Next operation: ENGINE COOLANT SYSTEM - Test (B.50.A - F.40.C.01)
3 15/11/2005
B.50.A / 34
ENGINE COOLANT SYSTEM - Test (B.50.A - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
NOTE: Combustion produces carbon dioxide. Carbon dioxide dissolved in engine coolant forms carbon acid. The
combustion gas leak tester – 3822985 (CUMMINS) – checks for the presence of carbon acid in the coolant.
Combustion gas leak test

1. Remove the pressure cap, and check if the coolant
level in the deaeration tank is low enough to prevent
contamination of the test tool – 3822985 (CUMMINS).
The instrument tests the air at the top of the
deaeration tank, not the coolant. If required, drain
sufficient coolant so the level is 50 - 100 mm (2.0 -
3.0 in) below the neck of the tank.
WARNING
RCPH05CDC251ABA 1
2. Operate the engine at low idle during the test.

Coolant must be warm and circulating while the test
is performed.
RHPH05CDC307ABA 2
3. Remove the bulb from the top of the test tube. Fill
the tube with test fluid to the level line. Install the
bulb on the tube with the air valve up.
RHPH05CDC308ABA 3
3 15/11/2005
B.50.A / 35
4. Rotate the test assembly into the neck of the tank so

a seal is formed. Squeeze the bulb to force coolant
gases into the test tube. Continue to force coolant
gases into the instrument for about 1 minute
IMPORTANT: Do NOT allow coolant to be drawn into
the test instrument and contaminate the test fluid. If this
happens, discard the contaminated test fluid, rinse the
instrument with clean water several times, remove as
much water as possible and retest.
RHPH05CDC309ABA 4
5. If the test fluid turns yellow-green or yellow, a

combustion leak is present. If the test fluid remains
blue, no combustion leak is present.
NOTE: Do NOT rule out combustion gas leaks on the
basis of this test alone. The tester is not sensitive
enough to detect very small combustion gas leaks. Use
sight glass observation with the analyzer to detect small
combustion gas leaks.
RHPH05CDC310ABA 5
6. If the test fluid turns yellow-green or yellow, use the

cylinder cutout test in INSITE® to check if the leak
is associated with a specific cylinder(s).
Disable a cylinder, allow the coolant to circulate for a

short time and then retest with 3822985 (CUMMINS).
If the test fluid remains yellow-green or yellow, the
disabled cylinder is not the source of the leak.
Repeat until all the cylinders are tested.
RCSC05CDC168AAB 6
7. Promptly remove the test equipment when finished

so the cooling coolant does not draw the test fluid
into the tank. Discard the test fluid and flush the
test tube with clean water.
NOTE: Always discard test fluid to avoid contamination
regardless if the results were positive or negative.
8. Check coolant level and adjust if required.
3 15/11/2005
B.50.A / 36
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Fill the cooling system with a fully formulated coolant

or a 50/50 mixture of recommended antifreeze and
clean, good quality water.
NOTE: The fully formulated antifreeze must meet the
TMC RP329 or TMC RP330 specification.
CAUTION
M1054 - Never use water alone for coolant. This
can result in damage from corrosion. Always use a
mixture of ethylene glycol or propylene glycol and
distilled water for coolant.
RCSC05CDC168AAA 1
2. Install the pressure cap. Operate the engine to a

temperature of 80 °C (180 °F) and check for coolant
leaks.
RCPH05CDC251ABA 2
3. Check the coolant level again. Adjust as required.
RCPH05CDC250ABA 3
3 15/11/2005
B.50.A / 37
4. Use a refractometer to check the freeze point

protection of the coolant
WARNING
3 15/11/2005
B.50.A / 38
Thermostat - Remove (B.50.A.18 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
1. Remove the hose from the radiator (A) to the

coolant outlet connection (B). Remove the outlet
connection.
RCPH05CDC297AAA 1
2. Remove the thermostat.
RCPH05CDC299AAA 2
Next operation: Thermostat - Test (B.50.A.18 - F.40.C.01)
3 15/11/2005
B.50.A / 39
Thermostat - Test (B.50.A.18 - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Thermostat - Remove (B.50.A.18 - F.10.A.10)
1. Clean the mating surfaces on the outlet connector

and block.
NOTE: Do NOT allow debris to fall into the thermostat
cavity during cleaning.
2. Inspect the O-rings and the thermostat for damage.
RCPH05CDC303AAB 1
3. Suspend the thermostat and a 100 °C (212 °F)

thermometer in a container of water. Heat the water
and observe the thermostat.
NOTE: The thermostat and thermometer must come into
contact with the container.
RCSC05CDC155AAA 2
4. The nominal operating temperature is stamped

on the thermostat. The thermostat MUST operate
within these specifications:
The thermostat MUST begin to open within 1 °C (2

°F) of the nominal temperature – 82 °C (180 °F).
The thermostat MUST be completely open within

12 °C (22 °F) of the nominal temperature – 82 °C
(180 °F).
The fully open distance between the flange on the

thermostat and the housing is 9.4 mm (0.370 in).
RCSC05CDC157AAA 3
Next operation: Thermostat - Install (B.50.A.18 - F.10.A.15)
3 15/11/2005
B.50.A / 40
Thermostat - Install (B.50.A.18 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Thermostat - Test (B.50.A.18 - F.40.C.01)
1. Check that the O-rings are in place and install the

thermostat.
RCPH05CDC299AAA 1
2. Install the coolant outlet connection and connect the

hose to the radiator. Torque the cap screws for the
outlet connection to 24 Nm (18 lb ft).
RCPH05CDC297AAA 2
3 15/11/2005
B.50.A / 41
Water pump - Remove (B.50.A.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING

1. Remove the cap screws and remove the water

pump.
RCPH05CDC074ABA 1
Next operation: Water pump - Visual inspection (B.50.A.20 - F.40.A.10)
3 15/11/2005
B.50.A / 42
Water pump - Visual inspection (B.50.A.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Water pump - Remove (B.50.A.20 - F.10.A.10)
1. Clean the sealing surface on the water pump

housing.
2. Inspect the pump housing and impeller for cracks or
damage. Inspect the pump weep hole (A) for an
indication of a steady leak.
RCPH05CDC075ABB 1
3. Chemical build up at the weep hole is NOT

justification for pump replacement. If a steady flow
of coolant or oil is observed in the exterior area of
the weep hole, replace the pump with a new or
rebuilt unit.
RCPH05CDC078ABA 2
Next operation: Water pump - Install (B.50.A.20 - F.10.A.15)
3 15/11/2005
B.50.A / 43
Water pump - Install (B.50.A.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Water pump - Visual inspection (B.50.A.20 - F.40.A.10)
1. Install a new O-ring on the pump.
RCPH05CDC076ABA 1
2. Install the pump. Torque the cap screws to 24 Nm

(18 lb ft).
RCPH05CDC077ABA 2

Next operation: Operate the engine until it reaches a temperature of 80 °C (180 °F), and check for coolant leaks.
3 15/11/2005
B.50.A / 44
Water filter - Remove (B.50.A.24 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the coolant system pressure cap.
WARNING
RCPH05CDC251ABA 1
2. Turn the valve on the filter head to the OFF position.

The knob must be in the horizontal position to close
the valve.
WARNING
M1004 - 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 the hot coolant.
WARNING
M940 - Coolant can be toxic. Keep away from children
and pets. Avoid prolong contact. If not reused,
dispose of in accordance with local environmental RCSC05CDC166AAB 2
regulations.
3. Remove and discard the coolant filter.
RCPH05CDC199ABA 3
Next operation: Water filter - Disassemble (B.50.A.24 - F.10.A.25)
3 15/11/2005
B.50.A / 45
Water filter - Disassemble (B.50.A.24 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Drain at least 11.3 L (3.0 US gal) of coolant from the coolant system. See ENGINE COOLANT
SYSTEM - Emptying (B.50.A - F.35.A.01).
Prior operation: Water filter - Remove (B.50.A.24 - F.10.A.10)
1. Remove the four cap screws and remove the filter

head and gasket.
RCPH05CDC330AAA 1
2. Clean the mating surfaces on the block and on the

filter head.
RCPH05CDC333AAA 2
3. Remove the screw from the knob on one end of the

shutoff valve. Remove the two-piece valve from the
filter head.
RCPH05CDC331AAA 3
Next operation: Water filter - Assemble (B.50.A.24 - F.10.A.20)
3 15/11/2005
B.50.A / 46
Water filter - Assemble (B.50.A.24 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Water filter - Disassemble (B.50.A.24 - F.10.A.25)
1. Replace the three O-rings on the valve. Lubricate

the new O-rings with CASE AKCELA EP-0
GREASE before reinstalling the valve.
RCPH05CDC332AAA 1
2. Install the shutoff valve in the filter head. Install the

screw in the knob and torque to 1.5 Nm (12.0 lb in).
RCPH05CDC331AAA 2
3. Install a new gasket and the filter head on the block.

RCPH05CDC330AAA 3
Next operation: Water filter - Install (B.50.A.24 - F.10.A.15)
3 15/11/2005
B.50.A / 47
Water filter - Install (B.50.A.24 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Water filter - Assemble (B.50.A.24 - F.10.A.20)
1. Lubricate the filter gasket with clean engine oil or

with CASE AKCELA EP-0 GREASE.
CAUTION
M1050 - Do not allow oil to get into the filter. Oil will
damage the filter.
CAUTION
M1038 - Overtightening can damage the filter
components: threads, seal, head or canister.
RCPH05CDC198ABA 1
2. Install the filter on the filter head. Tighten the filter

until the gasket contacts the filter head.
Tighten an additional one-half turn.
RCPH05CDC200ABA 2
3. Turn the valve on the filter head to the ON position.

The knob must be in the vertical position to open
the valve.
CAUTION
M1051 - The valve must be in the ON position to
prevent engine damage.
RCSC05CDC165AAB 3
4. If the filter head was removed, fill the coolant

system. See ENGINE COOLANT SYSTEM - Filling
(B.50.A - F.60.A.10)
3 15/11/2005
B.50.A / 48
5. Install the system pressure cap.
RCPH05CDC251ABA 4
6. Operate the engine and check for leaks. After air

has been removed from the system, check the
coolant level again.
3 15/11/2005
B.50.A / 49
Pressure cap - Visual inspection (B.50.A.26 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Check that the proper pressure cap is installed. The

cap should be stamped 103 kPa (15 psi) for this
cooling system.
RCPH05CDC224ABA 1
2. Inspect the rubber seal of the pressure cap for

damage.
RCPH05CDC223ABB 2
3. Inspect the neck on the deaeration tank for cracks

or other damage.
RCPH05CDC251ABA 3
Next operation: Pressure cap - Pressure test (B.50.A.26 - F.40.C.30)
3 15/11/2005
B.50.A / 50
Pressure cap - Pressure test (B.50.A.26 - F.40.C.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Pressure cap - Visual inspection (B.50.A.26 - F.40.A.10)
1. Use a pressure cap tester – OEM1041 or equivalent

– to pressure test the cap.
The pressure cap MUST seal within 14 kPa (2 psi)

of the cap rating – 103 kPa (15 psi).
Replace the cap if it is out specification.
RCSC05CDC163AAA 1
3 15/11/2005
B.50.A / 51
Radiator - Visual inspection (B.50.A.32 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Inspect the radiator for plugging. Inspect the

condenser/fuel cooler and hydraulic fluid cooler at
the same time.
Use compressed air to remove dirt and debris.

NOTE: Air pressure should not exceed 552 kPa (80 psi)
when cleaning the radiator.
WARNING
RCSC05CDC164AAA 1
2. Inspect the radiator for bent or broken fins.
Inspect the radiator core for seal leaks.
If the radiator must be replaced, refer to the

appropriate section in the chassis service manual.
RCPH05CDC253ABB 2
3. Inspect the piping and hoses to the radiator for

cracks, cuts or collapsing.
RCSC05CDC166AAA 3
3 15/11/2005
B.50.A / 52
Coolant line - Remove (B.50.A.36 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Supply connector
1. Remove the two cap screws and remove the coolant
supply connector and gasket from the engine block.
RCPH05CDC196ABA 1
Next operation: Coolant line - Visual inspection (B.50.A.36 - F.40.A.10)
3 15/11/2005
B.50.A / 53
Coolant line - Visual inspection (B.50.A.36 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Coolant line - Remove (B.50.A.36 - F.10.A.10)
Supply connector
1. Clean the connector and block sealing surface.
Inspect the connector and gasket for wear or

damage. Replace as required.
RCPH05CDC197ABA 1
Next operation: Coolant line - Install (B.50.A.36 - F.10.A.15)
3 15/11/2005
B.50.A / 54
Coolant line - Install (B.50.A.36 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Coolant line - Visual inspection (B.50.A.36 - F.40.A.10)
Supply connector
1. Install the gasket and supply connector with two cap
screws. Tighten and torque the cap screws to 24
Nm (18 lb ft).
RCPH05CDC196ABA 1
3 15/11/2005
B.50.A / 55
Fan and drive - Remove (B.50.A.54 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the four cap screws and remove the fan

and shaft plate (A) assembly and the spacer (B)
if equipped. Remove the drive pulley (C) and fan
belt (D).
RCPH05CDC161AAA 1
3 15/11/2005
B.50.A / 56
Fan and drive - Install (B.50.A.54 - F.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Install the drive pulley (A) and fan belt (B).
Install the spacer (C) if equipped and the fan and

shaft plate assembly (D).
Secure with the four cap screws. Torque the cap

RCPH05CDC161AAA 1
3 15/11/2005
B.50.A / 57
Fan and drive Belt - Remove (B.50.A.54.44 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use a 0.5 in socket drive to lift the tensioner and

release the belt for removal.
NOTE: The belt-tensioner is spring-loaded and MUST be
pivoted away from the belt.
RCPH05CDC213ABA 1
Next operation: Fan and drive Belt - Visual inspection (B.50.A.54.44 - F.40.A.10)
3 15/11/2005
B.50.A / 58
Fan and drive Belt - Visual inspection (B.50.A.54.44 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Inspect the belt for cracks, glazing, tears, cuts or

excessive wear.
RCPH05CDC202ABB 1
2. Transverse (across the belt width) cracks are

acceptable. Longitudinal (direction of the belt
length) cracks that intersect with transverse cracks
are NOT acceptable.
Replace the belt if it is frayed or any pieces of

material are missing.
RCPH05CDC202ABC 2
3. Inspect the belt pulleys and idlers for damage

– cracks or broken grooves. Replace damaged
components.
3 15/11/2005
B.50.A / 59
Fan and drive Belt - Install (B.50.A.54.44 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive Belt - Visual inspection (B.50.A.54.44 - F.40.A.10)
1. Use a 0.5 in socket drive to raise and hold the belt

tensioner. Install the belt and release the tensioner.
NOTE: The belt tensioner is spring-loaded and MUST be
pivoted away from the belt.
NOTE: Position the belt over the grooved pulleys first.
While raising the tensioner, slide the belt over the coolant
pump pulley.
RCPH05CDC213ABA 1
3 15/11/2005
B.50.A / 60
Fan and drive - Disassemble (B.50.A.54 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the fan assembly from the shaft plate.
RCPH05CDC215ABA 1
2. Remove the four cap screws and remove the shaft

plate (A), spacer (B) if equipped and drive pulley
(C).
RCPH05CDC211ABA 2
3. If required, remove the four cap screws, and remove

the fan shaft and pulley support from the block.
NOTE: The bearings in the support are not serviceable.
If the fan and pulley are exhibiting wobble, replace the
support.
RCPH05CDC206ABA 3
3 15/11/2005
B.50.A / 61
4. If required, remove the cap screw and remove the

idler pulley.
RCPH05CDC164AAA 4
Next operation: Fan and drive - Visual inspection (B.50.A.54 - F.40.A.10)
3 15/11/2005
B.50.A / 62
Fan and drive - Visual inspection (B.50.A.54 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive - Disassemble (B.50.A.54 - F.10.A.25)
1. Inspect the drive pulley for cracks or other damage.
RCPH05CDC201ABB 1
2. Inspect the shaft plate, spacer if equipped and cap

screws for damage.
RCPH05CDC203ABB 2
3. Inspect the fan blades for tears, bend or other

damage.
WARNING
M936 - 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 injury or property
damage.
RCPH05CDC204ABA 3
3 15/11/2005
B.50.A / 63
4. Inspect the belt tensioner. See Fan and drive Belt

tensioner - Visual inspection (B.50.A.54.49 -
F.40.A.10).
RCPH05CDC210ABA 4
Next operation: Fan and drive - Assemble (B.50.A.54 - F.10.A.20)
3 15/11/2005
B.50.A / 64
Fan and drive - Assemble (B.50.A.54 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive - Visual inspection (B.50.A.54 - F.40.A.10)
1. If required, install the fan shaft and pulley support

on the block. Torque the cap screws to 43 Nm (32
lb ft).
RCPH05CDC206ABA 1
2. If required, install the idler pulley. Torque the cap

screw to 43 Nm (32 lb ft).
RCPH05CDC207ABA 2
3. Install the drive pulley, spacer if present, and shaft

plate with the four cap screws.
Install the fan belt.
RCPH05CDC212ABA 3
3 15/11/2005
B.50.A / 65
4. Install the fan assembly on the shaft plate.
RCPH05CDC215ABA 4
3 15/11/2005
B.50.A / 66
Fan and drive Belt tensioner - Visual inspection (B.50.A.54.49 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. With the fan belt installed, check that neither

tensioner arm stop (A) is in contact with the spring
casing stop (B). If either stop is touching, the drive
belt MUST be replaced.
After replacing the drive belt, if a tensioner arm stop

is still in contact with the spring casing stop, the
tensioner MUST be replaced.
RCPH05CDC214ABB 1
2. Remove the fan belt.

3. Check the belt tensioner arm, pulley and stops for
cracks. If cracks are present, the tensioner MUST
be replaced.
NOTE: If the tensioner must be replaced, the belt also
must be replaced.
RCPH05CDC210ABB 2
4. Check that the tensioner arm stop is in contact with

the spring casing stop. If the two stops are not
touching, the tensioner MUST be replaced.
RCPH05CDC209ABA 3
3 15/11/2005
B.50.A / 67
5. Check the clearance between the tensioner spring

case and the tensioner arm for tensioner wear and
uneven bearing wear. If the clearance (A) exceeds
3.0 mm (0.12 in), the tensioner must be replaced.
NOTE: A new tensioner is shown with no visible gap.
RCPH05CDC208ABA 4
6. Inspect the tensioner for damage from the tensioner

arm (A) contacting the tensioner cap (B). If the
two components are making contact, the tensioner
MUST be replaced.
RCPH05CDC210ABA 5
Next operation: If required, Fan and drive Belt tensioner - Remove (B.50.A.54.49 - F.10.A.10)
3 15/11/2005
B.50.A / 68
Fan and drive Belt tensioner - Remove (B.50.A.54.49 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive Belt tensioner - Visual inspection (B.50.A.54.49 - F.40.A.10)
1. Remove the cap screw and belt tensioner from the

arm.
RCSC05CDC167AAA 1
Next operation: Fan and drive Belt tensioner - Install (B.50.A.54.49 - F.10.A.15)
3 15/11/2005
B.50.A / 69
Fan and drive Belt tensioner - Install (B.50.A.54.49 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Fan and drive Belt tensioner - Remove (B.50.A.54.49 - F.10.A.10)
1. Install the belt tensioner on the arm with the single

cap screw. Torque the cap screw to 43 Nm (32 lb ft).
RCSC05CDC167AAA 1
3 15/11/2005
B.50.A / 70
Sensing system Coolant temperature - Remove (B.50.A.95.90 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Drain approximately 15 - 19 L (4 - 5 US gal) of

coolant from the system.
sensor.
RCPH05CDC169AAA 1
3. Remove the sensor from the block.
RCPH05CDC186ABA 2
Next operation: Sensing system Coolant temperature - Visual inspection (B.50.A.95.90 - F.40.A.10)
3 15/11/2005
B.50.A / 71
Sensing system Coolant temperature - Visual inspection

(B.50.A.95.90 - F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Coolant temperature - Remove (B.50.A.95.90 - F.10.A.10)
• Loose connector
• Corroded pins

required.
RCPH05CDC187ABA 1
Next operation: Sensing system Coolant temperature - Test (B.50.A.95.90 - F.40.C.01)
3 15/11/2005
B.50.A / 72
Sensing system Coolant temperature - Test (B.50.A.95.90 -

F.40.C.01)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Coolant temperature - Visual inspection (B.50.A.95.90 - F.40.A.10)

sensor. Connect the INSITE® service tool. Turn
the keyswitch ON.
RCPH05CDC325ABA 1
2. Compare the INSITE® reading from the sensor for

the ambient temperature condition with the data in
the temperature versus resistance table at Sensing
system Coolant temperature - Service limits
(B.50.A.95.90 - D.20.A.20).
If the reading from the sensor does not correspond

to the data in the temperature versus resistance
table, replace the sensor.
Next operation: Sensing system Coolant temperature - Install (B.50.A.95.90 - F.10.A.15)
3 15/11/2005
B.50.A / 73
Sensing system Coolant temperature - Install (B.50.A.95.90 -

F.10.A.15)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Coolant temperature - Test (B.50.A.95.90 - F.40.C.01)
1. Install a new O-ring on the sensor, and lubricate the

RCPH05CDC187ABA 1
2. Install the sensor in the block and torque to 23 Nm

(17 lb ft).
RCPH05CDC188ABA 2
3. Fill the coolant system. Operate the engine and

check for leaks. Check the sensor for proper
operation with INSITE®.
3 15/11/2005
B.50.A / 74
ENGINE COOLANT SYSTEM - Problem solving (B.50.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Refer to ENGINE COOLANT SYSTEM - Dynamic description (B.50.A - C.30.A.10).
TROUBLESHOOTING
WARNING

Coolant temperature Step 1: Check the fan drive and controls.
above normal – gradual Fan drive or controls are malfunctioning.
overheat Refer to Fan and drive - Disassemble
(B.50.A.54 - F.10.A.25).
Refer to the chassis service manual for fan

control testing.
Cold weather winter front is closed. Maintain a minimum opening of 384 cm²
in) x 19.6 cm (7.5 in).
Step 4: Inspect the engine and cooling system for
Coolant level is below specification. external coolant leaks. Add coolant.
Step 5: Check the concentration of antifreeze in
Coolant mixture of antifreeze and water is the coolant with a refractometer. Add water
NOT correct. or antifreeze to correct the concentration.
Step 6: Inspect the fan shroud. Repair, replace or
Fan shroud is damaged. install as needed.
3 15/11/2005
B.50.A / 75

Step 7: Check the fan drive belt. Refer to Fan
Fan drive belt is loose or broken. and drive Belt - Visual inspection
(B.50.A.54.44 - F.40.A.10).

(B.50.A.54.49 - F.40.A.10).
Step 8: Test the temperature gauge.
Coolant temperature in-cab gauge is
malfunctioning.
Step 9: Check the pressure cap. Refer to
Pressure cap is NOT correct, is Pressure cap - Visual inspection
malfunctioning or has the wrong pressure (B.50.A.26 - F.40.A.10) and Pressure cap
rating. - Pressure test (B.50.A.26 - F.40.C.30).
Step 10: Check the thermostat for correct part
Thermostat is the wrong part for the engine number and for proper operation.
or is malfunctioning.
Refer to Thermostat - Test (B.50.A.18 -
F.40.C.01).
Step 11: Inspect the hoses.
Cooling system hose is restricted,
collapsed or leaking.
Step 12: Check the lines for correct routing and
Fill lines or vent lines are restricted, restriction.
obstructed or NOT routed correctly.
Step 13: Refer to the “intake manifold air
Intake manifold air temperature is above temperature above specification” symptom
specification. table.
See AIR INTAKE SYSTEM - Problem

solving (B.30.A - G.40.A.30).
Lubricating oil level is above or below required.
specification.
Step 15: Refer to “lubricating oil contaminated”
Lubricating oil is contaminated with coolant symptom table.
or fuel.
See LUBRICATION SYSTEM - Problem
solving (B.60.A - G.40.A.30).
Step 16: Remove and inspect the water pump.
Water pump is malfunctioning.
Refer to Water pump - Remove
(B.50.A.20 - F.10.A.10).
Step 17: Inspect the radiator and flush or replace
Radiator core is internally obstructed or if necessary.
damaged.
Refer to ENGINE COOLANT SYSTEM -
Decontaminating (B.50.A - F.30.A.60).
Step 18: Check the cylinder head gasket.
Cylinder head gasket is leaking.
Refer to Cylinder head - Remove
(B.10.A.72 - F.10.A.10).
Step 19: Check the engine fuel rate. Refer to the
Engine is over fueled. “fuel consumption excessive” symptom
table.

Coolant temperature Step 1: Inspect the engine and cooling system for
above normal – Sudden Coolant level is below specification. external coolant leaks. Add coolant.
overheat
3 15/11/2005
B.50.A / 76

Step 2: Check the fan drive and controls.
Fan drive or controls are malfunctioning.
Refer to Fan and drive - Disassemble
(B.50.A.54 - F.10.A.25).

control testing.
Step 3: Check the fan drive belt. Refer to Fan
Fan drive belt is loose or broken. and drive Belt - Visual inspection
(B.50.A.54.44 - F.40.A.10).

(B.50.A.54.49 - F.40.A.10).
Cold weather winter front is closed. Maintain a minimum opening of 384 cm²
in) x 19.6 cm (7.5 in).
Thermostat is the wrong part for the engine number and for proper operation.
F.40.C.01).
Step 7: Test the temperature gauge.
Coolant temperature in-cab gauge is
malfunctioning.
Step 8: Inspect the hoses.
Cooling system hose is restricted,
collapsed or leaking.
Step 9: Check the lines for correct routing and
Fill lines or vent lines are restricted, restriction.
obstructed or NOT routed correctly.
Step 10: Remove and inspect the water pump.
Water pump is malfunctioning.
Refer to Water pump - Remove
(B.50.A.20 - F.10.A.10).
Step 11: Check the pressure cap.
Pressure cap is NOT correct, is
malfunctioning or has wrong pressure Refer to Pressure cap - Visual inspection
rating. (B.50.A.26 - F.40.A.10) and Pressure cap
- Pressure test (B.50.A.26 - F.40.C.30).
Step 12: Use the analyzer to perform cooling
Cooling system component is system diagnostics.
malfunctioning.
Test (B.50.A - F.40.C.01).
Coolant temperature Step 1: Test the temperature gauge.
below normal Coolant temperature in-cab gauge is
malfunctioning.
3 15/11/2005
B.50.A / 77

Step 2: Test the temperature sensor.
Coolant temperature sensor is
malfunctioning. Use INSITE® to check for active or a high
count of inactive fault codes related to
the temperature sensor. If present, use
the guided troubleshooting to resolve the
problem.
If fault codes are not present, refer to

Sensing system Coolant temperature -
Test (B.50.A.95.90 - F.40.C.01).
Thermostat is wrong part for this engine number and for proper operation.
F.40.C.01).
Step 4: Check the winter front and under-the-hood
Engine is operating at low ambient air.
temperature.
Step 5: Check the fan drive and the fan controls.
Fan drive or fan controls are
malfunctioning. Refer to Fan and drive - Disassemble
(B.50.A.54 - F.10.A.25).

control testing.
Step 6: Use the analyzer to perform cooling
Cooling system component is system diagnostics.
malfunctioning.
Test (B.50.A - F.40.C.01).
Internal coolant loss Step 1: Pressure test the oil cooler.
Oil cooler is leaking.
See Oil cooler - Leakage test (B.60.A.32
- F.40.A.40).
(B.10.A.72 - F.10.A.10).
Step 3: Pressure test the cylinder head.
Cylinder head is cracked or porous.
Refer to Cylinder head - Pressure test
(B.10.A.72 - F.40.A.30).
Step 4: Remove the oil pan. Refer to Oil pan -
Cylinder block is cracked or porous. Remove (B.60.A.23 - F.10.A.10).
Pressure test the cooling system to check

for leaks. Refer to ENGINE COOLANT
Fuel in coolant Step 1: Check the bulk coolant supply.
Bulk coolant supply is contaminated.
Drain the coolant and replace with non
contaminated coolant.
Replace the coolant filter.
3 15/11/2005
B.50.A / 78

F.10.A.10). Check for evidence of a
coolant leak. If necessary, operate the
engine at low idle.

- F.40.A.30).
Oil in the coolant Step 1: Check the oil cooler.
Oil cooler is faulty.
Refer to Oil cooler - Remove (B.60.A.32
- F.10.A.10).
(B.10.A.72 - F.10.A.10).
F.10.A.10). Check for evidence of a
coolant leak. If necessary, operate the
engine at low idle.

- F.40.A.30).
Step 4: Inspect the cylinder block.
Cylinder block is cracked or porous.
Test (B.50.A - F.40.C.01).
3 15/11/2005
B.50.A / 79
Index

Coolant line - Install (B.50.A.36 - F.10.A.15) 55
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line - Remove (B.50.A.36 - F.10.A.10) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line - Torque (B.50.A.36 - D.20.A.10) 10
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Coolant line - Visual inspection (B.50.A.36 - F.40.A.10) 54
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Component identification (B.50.A - C.40.C.20) 21
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Decontaminating (B.50.A - F.30.A.60) 27
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Dynamic description (B.50.A - C.30.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Emptying (B.50.A - F.35.A.01) 29
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Filling (B.50.A - F.60.A.10) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - General specification (B.50.A - D.40.A.10) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Problem solving (B.50.A - G.40.A.30) 75
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Special tools (B.50.A - D.20.A.40) 5
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Static description (B.50.A - C.30.A.20) 20
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
ENGINE COOLANT SYSTEM - Tool connection (B.50.A - F.40.D.21) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Assemble (B.50.A.54 - F.10.A.20) 65
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Disassemble (B.50.A.54 - F.10.A.25) 61
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Install (B.50.A.54 - F.20.A.20) 57
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Remove (B.50.A.54 - F.10.A.10) 56
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Torque (B.50.A.54 - D.20.A.10) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive - Visual inspection (B.50.A.54 - F.40.A.10) 63
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Install (B.50.A.54.44 - F.10.A.15) 60
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Remove (B.50.A.54.44 - F.10.A.10) 58
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt - Visual inspection (B.50.A.54.44 - F.40.A.10) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Install (B.50.A.54.49 - F.10.A.15) 70
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.50.A / 80
Fan and drive Belt tensioner - Remove (B.50.A.54.49 - F.10.A.10) 69
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Service limits (B.50.A.54.49 - D.20.A.20) 12
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Torque (B.50.A.54.49 - D.20.A.10) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Fan and drive Belt tensioner - Visual inspection (B.50.A.54.49 - F.40.A.10) 67
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap - Dynamic description (B.50.A.26 - C.30.A.10) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap - Pressure test (B.50.A.26 - F.40.C.30) 51
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap - Service limits (B.50.A.26 - D.20.A.20) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Pressure cap - Visual inspection (B.50.A.26 - F.40.A.10) 50
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Radiator - Visual inspection (B.50.A.32 - F.40.A.10) 52
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Install (B.50.A.95.90 - F.10.A.15) 74
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Remove (B.50.A.95.90 - F.10.A.10) 71
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Service limits (B.50.A.95.90 - D.20.A.20) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Test (B.50.A.95.90 - F.40.C.01) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Torque (B.50.A.95.90 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Coolant temperature - Visual inspection (B.50.A.95.90 - F.40.A.10) 72
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Dynamic description (B.50.A.18 - C.30.A.10) 23
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Install (B.50.A.18 - F.10.A.15) 41
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Remove (B.50.A.18 - F.10.A.10) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Service limits (B.50.A.18 - D.20.A.20) 6
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Test (B.50.A.18 - F.40.C.01) 40
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Thermostat - Torque (B.50.A.18 - D.20.A.10) 6
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Assemble (B.50.A.24 - F.10.A.20) 47
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Disassemble (B.50.A.24 - F.10.A.25) 46
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Install (B.50.A.24 - F.10.A.15) 48
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Remove (B.50.A.24 - F.10.A.10) 45
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water filter - Torque (B.50.A.24 - D.20.A.10) 8
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Dynamic description (B.50.A.20 - C.30.A.10) 25
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Install (B.50.A.20 - F.10.A.15) 44
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Remove (B.50.A.20 - F.10.A.10) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Torque (B.50.A.20 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Water pump - Visual inspection (B.50.A.20 - F.40.A.10) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.50.A / 81
87372074 3 15/11/2005
B.50.A / 82
LUBRICATION SYSTEM - 60.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.60.A / 1
Contents
TECHNICAL DATA
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10) 6
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump
Oil pump - Torque (B.60.A.20 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Service limits (B.60.A.20 - D.20.A.20) 7

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan
Oil pan - Torque (B.60.A.23 - D.20.A.10) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve

Oil pressure regulator valve - Torque (B.60.A.25 - D.20.A.10) 10
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system

Blowby re-circulation system - Service limits (B.60.A.26 - D.20.A.20) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Special tools (B.60.A.26 - D.20.A.40) 11

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve

Oil filter bypass valve - Torque (B.60.A.27 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication
Piston lubrication Spray nozzle - Torque (B.60.A.29.29 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler
Oil cooler - Torque (B.60.A.32 - D.20.A.10) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Service limits (B.60.A.32 - D.20.A.20) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Special tools (B.60.A.32 - D.20.A.40) 15

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Torque (B.60.A.32.20 - D.20.A.10) 16

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Service limits (B.60.A.32.20 - D.20.A.20) 17

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Oil pressure - Torque (B.60.A.95.91 - D.20.A.10) 18
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Service limits (B.60.A.95.91 - D.20.A.20) 18

MX215, MX245, MX275, MX305, STX280, 2388, 2377
FUNCTIONAL DATA
87372074 3 15/11/2005
B.60.A / 2
LUBRICATION SYSTEM - Dynamic description (B.60.A - C.30.A.10) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Component identification (B.60.A - C.40.C.20) 28

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Blowby re-circulation system - Dynamic description (B.60.A.26 - C.30.A.10) 30
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Oil filter bypass valve - Dynamic description (B.60.A.27 - C.30.A.10) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
LUBRICATION SYSTEM - Emptying (B.60.A - F.35.A.01) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Filling (B.60.A - F.60.A.10) 34

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump
Oil pump - Remove (B.60.A.20 - F.10.A.10) 36
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Disassemble (B.60.A.20 - F.10.A.25) 37

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Visual inspection (B.60.A.20 - F.40.A.10) 39

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Assemble (B.60.A.20 - F.10.A.20) 40

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Install (B.60.A.20 - F.10.A.15) 42

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Backlash (B.60.A.20 - F.40.E.15) 43

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan
Oil pan - Remove (B.60.A.23 - F.10.A.10) 44
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Visual inspection (B.60.A.23 - F.40.A.10) 46

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Install (B.60.A.23 - F.10.A.15) 47

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Reseal (B.60.A.23 - F.75.C.15) 50

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter
Oil filter - Remove (B.60.A.24 - F.10.A.10) 52
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter - Visual inspection (B.60.A.24 - F.40.A.10) 53

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter - Install (B.60.A.24 - F.10.A.15) 55

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve

Oil pressure regulator valve - Remove (B.60.A.25 - F.10.A.10) 56
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Visual inspection (B.60.A.25 - F.40.A.10) 57

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Install (B.60.A.25 - F.10.A.15) 58

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.60.A / 3
Blowby re-circulation system - Tool connection (B.60.A.26 - F.40.D.21) 63
MX215, MX245, MX275, MX305, STX280, 2388, 2377

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Remove (B.60.A.26 - F.10.A.10) 67

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Visual inspection (B.60.A.26 - F.40.A.10) 68

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Install (B.60.A.26 - F.10.A.15) 69

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Oil filter bypass valve - Remove (B.60.A.27 - F.10.A.10) 70
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Visual inspection (B.60.A.27 - F.40.A.10) 72

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Install (B.60.A.27 - F.10.A.15) 73

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication
Piston lubrication Spray nozzle - Remove (B.60.A.29.29 - F.10.A.10) 75
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Visual inspection (B.60.A.29.29 - F.40.A.10) 77

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Install (B.60.A.29.29 - F.10.A.15) 79

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler
Oil cooler - Remove (B.60.A.32 - F.10.A.10) 80
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Cleaning (B.60.A.32 - F.30.A.10) 83

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Leakage test (B.60.A.32 - F.40.A.40) 84

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Install (B.60.A.32 - F.10.A.15) 85

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Remove (B.60.A.32.20 - F.10.A.10) 87

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01) 88

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Install (B.60.A.32.20 - F.10.A.15) 90

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system
Sensing system Oil level indicator - Remove (B.60.A.95.90 - F.10.A.10) 91
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil level indicator - Install (B.60.A.95.90 - F.10.A.15) 92

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Remove (B.60.A.95.91 - F.10.A.10) 94

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Visual inspection (B.60.A.95.91 - F.40.A.10) 95

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01) 96

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Install (B.60.A.95.91 - F.10.A.15) 97

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
87372074 3 15/11/2005
B.60.A / 4
LUBRICATION SYSTEM - Problem solving (B.60.A - G.40.A.30) 98
MX215, MX245, MX275, MX305, STX280, 2388, 2377

Blowby re-circulation system - Problem solving (B.60.A.26 - G.40.A.30) 103
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.60.A / 5
POWER PRODUCTION - LUBRICATION SYSTEM
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure
At low idle (minimum allowable) 69 kPa (10 psi)
At rated speed (minimum allowable) 517 kPa (75 psi)
Regulated oil pressure 207 kPa (30 psi)
Lubricating oil filter capacity 3.78 L (4.0 US qt)
Oil pan capacity, Low to high – Standard oil pan
6TAA-8304 engines 15.1 - 18.9 L (16.0 - 20.0 US qt)
6TAA-9004 engines 18.9 - 22.7 L (20.0 - 24.0 US qt)
Total system capacity (Oil pan and new oil filter)
6TAA-8304 engines 22.7 L (24 US qt)
6TAA-9004 engines 26.5 L (28 US qt)
3 15/11/2005
B.60.A / 6
Oil pump - Torque (B.60.A.20 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Mounting cap screw 24 Nm 18 lb ft
RCPH05CDC405AAA 1
Oil pump - Service limits (B.60.A.20 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Tip clearance
Reference: Oil pump - Assemble (B.60.A.20 - F.10.A.20)
RCPH05CDC413AAA 1
Drive and planetary to port plate clearance

RCPH05CDC412AAA 2
3 15/11/2005
B.60.A / 7
Planetary to body bore clearance

RCPH05CDC414AAA 3
Gear backlash limits (Used pump)

RCPH05CDC498AAB 4
Gear backlash limits (Installed pump)

Reference: Oil pump - Backlash (B.60.A.20 - F.40.E.15)
(A)
(B)
RCPH05CDC244AAB 5
3 15/11/2005
B.60.A / 8
Oil pan - Torque (B.60.A.23 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Oil pan mounting cap screw 28 Nm 21 lb ft
RCPH05CDC423AAA 1
Suction tube flange cap screw 10 Nm 89 lb in
RCPH05CDC424AAA 2
Suction tube bracket cap screw 10 Nm 89 lb in
RCPH05CDC426AAA 3
3 15/11/2005
B.60.A / 9
Oil pressure regulator valve - Torque (B.60.A.25 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Pressure regulator valve 80 Nm 59 lb ft
RCPH05CDC301AAA 1
3 15/11/2005
B.60.A / 10
Blowby re-circulation system - Service limits (B.60.A.26 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankcase blowby
Reference: Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20)
Maximum 30.5 cm H2O 12.0 in H2O
RCPH05CDC633AAA 1
Turbocharger blowby contribution

Reference: Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20)
Maximum 30% 30%
RCPH05CDC780AAA 2
Blowby re-circulation system - Special tools (B.60.A.26 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
CAS1692A-3 – Crankcase blowby measuring tool

This tool is used to measure engine blowby by attaching
the test set to the blowby recirculation system on the
engine. The tool is equipped with a 7.67 mm (0.302
in) orifice for this engine’s horsepower rating and rated
speed. The tool must be connected to a tube-style or
digital manometer to capture the readings in mm H2O
or cm H2O (in H2O).
RCPH05CDC647AAA 1
3 15/11/2005
B.60.A / 11
Turbocharger isolation tool

This shop-made tool is used to isolate the turbocharger
contribution to crankcase blowby and thereby determine
the turbocharger contribution to overall crankcase
blowby. See Blowby re-circulation system - Tool
connection (B.60.A.26 - F.40.D.21) for tool creation and
connection.
RCPH05CDC641AAA 2
Digital manometer
This tool is used to measure positive and differential
pressure. Units of measurement are selectable: mm Hg,
in Hg, kPa, psi, mm H2O and in H2O. The operating
range depends on the model selected. The operating
range required to measure crankcase blowby is 0 - 45
cm H2O (0 - 18 in H2O).
RCPH05CDC648AAA 3
Tube-style manometer
This tool is used to measure positive pressure in mm
H2O and in H2O. The operating range required to
measure crankcase blowby is 0 - 45 cm H2O (0 - 18
in H2O).
RCPH05CDC430AAA 4
3 15/11/2005
B.60.A / 12
Oil filter bypass valve - Torque (B.60.A.27 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Component N·m Identification ft-lb

Access plug on the filter head 45 Nm 33 lb ft
RCPH05CDC319AAA 1
Adapter cap screws 24 Nm 18 lb ft
RCPH05CDC314AAA 2
3 15/11/2005
B.60.A / 13
Piston lubrication Spray nozzle - Torque (B.60.A.29.29 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Spray nozzle mounting cap screw 33 Nm 24 lb ft
RCPH05CDC443AAA 1
3 15/11/2005
B.60.A / 14
Oil cooler - Torque (B.60.A.32 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Mounting cap screw 24 Nm 18 lb ft
RCPH05CDC305AAB 1
Oil cooler - Service limits (B.60.A.32 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Leakage test
Reference: Oil cooler - Leakage test (B.60.A.32 - F.40.A.40)
Minimum 449 kPa 65 psi
Maximum 518 kPa 75 psi
No air bubbles should be observed when the oil cooler is
pressurized to 449 - 518 kPa (65 - 75 psi) with clean shop
air.
RCSC05CDC029AAA 1
3 15/11/2005
B.60.A / 15
Oil cooler - Special tools (B.60.A.32 - D.20.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler leak tester – 3823876 (Cummins)

The test kit is used to seal and pressurize the lubricating
oil cooler to test for leaks.
The kit contains:

• a tapped aluminum cooler sealing plate (1),
• pressure regulator (2),
• pressure gauge 0 - 1100 kPa (0 - 160 psi) (3),
• O-rings (4),
• and installation hardware.
RCIL05CDC004ACA 1
This tool can be shop made by using the oil cooler

gasket as a template to cut, shape and drill 7 mm (0.25
in) aluminum stock to fit the cooler. The plate must
be tapped at one port for an air fitting. An appropriate
pressure regulator with gauge must be used to test the oil
cooler in the specified range: 449 - 518 kPa (65 - 75 psi).
RCSC05CDC039AAA 2
3 15/11/2005
B.60.A / 16
Oil cooler Bypass valve - Torque (B.60.A.32.20 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Bypass valve 50 Nm 37 lb ft
RCPH05CDC300AAA 1
Oil cooler Bypass valve - Service limits (B.60.A.32.20 - D.20.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Extension test
Reference: Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01)
Replace if the valve is NOT fully extended to 45.9 mm (1.8
in) at a temperature of 104 °C (220 °F) when suspended
in heated oil.
RCSC05CDC025AAA 1
3 15/11/2005
B.60.A / 17
Sensing system Oil pressure - Torque (B.60.A.95.91 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Oil pressure sensor 23 Nm 18 lb ft
RCPH05CDC354ABA 1
Sensing system Oil pressure - Service limits (B.60.A.95.91 -

D.20.A.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure sensor

Reference: Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01)
There must be continuity between pin 2 and 3 and no
continuity between the remaining pin combinations on the
sensor connector.
Replace the sensor if the correct continuity is not present.
RCPH05CDC362ABA 1
3 15/11/2005
B.60.A / 18
LUBRICATION SYSTEM - Dynamic description (B.60.A - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Lubricating oil flow begins as oil is drawn by the

geroter pump from the oil pan through the rigid
internal suction tube.
RCPH05CDC038AAA 1
The suction tube delivers oil to the geroter pump.
RCPH05CDC039AAA 2
The pump then delivers the oil through an internal

drilling in the cylinder block to the bottom of the oil
cooler.
RCPH05CDC041AAA 3
The oil flows to the top of the oil cooler through the
internal channels of the oil cooler cover.
RCPH05CDC042AAA 4
3 15/11/2005
B.60.A / 19
At the top of the oil cooler, oil flows to the oil cooler
bypass valve. If the oil is cold, the bypass valve will
be open, allowing some oil to bypass the cooler
and flow to the filter, which reduces engine parasitic
loads and improves efficiency. This also helps the
oil reach operating temperature quicker.
RCPH05CDC043AAA 5
As the temperature of the oil increases and the

viscosity decreases, the bypass valve closes and
directs the flow through the oil cooler element.
RCPH05CDC044AAA 6
The oil cooler element cools the oil as it moves

through the plates. Coolant is passed on the outside
of the plates.
RCPH05CDC046AAA 7
3 15/11/2005
B.60.A / 20
From the cooler the oil flows to the combination oil

filter (1), the filter bypass valve (2) and the pressure
regulator (3).
RCPH05CDC048AAA 8
RCSC05CDC019AAA 9
The regulator valve remains closed until the main oil

rifle pressure is approximately 345 kPa (50 psi).
RCPH05CDC050AAA 10
As pressure increases the valve opens, uncovering

the dump port and allowing some oil to drain to the
oil pan. This allows the pump to bypass enough
oil to regulate the oil pressure to the desired
range without too much restriction to the flow of
oil. At normal operating temperature, minimum oil
pressure at low idle is 70 kPa (10 psi), at rated
speed minimum pressure is 207 kPa (30 psi).
RCPH05CDC052AAA 11
3 15/11/2005
B.60.A / 21
A combination filter is used on the engine. The

upper section of the filter contains the full flow
element while the lower section contains the bypass
element. Oil passing through the full flow portion of
the filter flows to the main oil rifle; oil flowing through
the bypass portion of the filter returns to the inlet
side of the oil pump.
RCPH05CDC054AAA 12
During normal engine operation, oil flows through

the full flow section of the combination filter and into
the main oil rifle. However, if the full flow section
becomes plugged to the point that a 345 kPa (50
psi) pressure difference exists between the filter in
and filter out, the bypass valve opens in the oil filter
head and routes unfiltered oil to the main oil rifle
to lubricate the engine.
RCPH05CDC055AAA 13
To measure the pressure difference across the filter,

a filter-in pressure port and a filter-out pressure port
are integral parts of the filter head.
RCPH05CDC056AAA 14
The turbocharger oil supply line is connected with

a straight thread O-ring supply fitting in the filter
head. The supply line directs the filtered oil under
pressure to the turbocharger.
RCPH05CDC058AAA 15
3 15/11/2005
B.60.A / 22
Once in the turbocharger, the oil flows to the bearing

journals and the thrust bearing.
RCPH05CDC059AAA 16
Once the oil has passed through the bearings,

it flows under gravity back into the oil pan sump
through the turbocharger drain line.
RCPH05CDC060AAA 17
Once the oil is cooled and filtered, a cross drilling

over the number three main bearing carries it across
the block to the main oil rifle. The main oil rifle
runs the length of the block and carries oil to the
crankshaft, camshaft and the overhead through
individual drillings.
RCPH05CDC062AAA 18
The transfer oil drilling from the main oil rifle

intersects the drilling between the main bearing
bore and the camshaft bushing bore. These drillings
supply oil to the cam bushings and main bearings.
RCPH05CDC063AAA 19
3 15/11/2005
B.60.A / 23
The J-jet piston cooling nozzles are mounted and

supplied oil by the piston cooling nozzle rifle.
RCPH05CDC065AAA 20
From the main bearings, oil enters the crankshaft

and lubricates the connecting rod bearings through
internal cross drillings.
RCPH05CDC067AAA 21
RCPH05CDC068AAA 22
Drillings in the block and gear housing connect to

the external groove on the number one cam bushing
to provide oil to the fuel injection pump rollers and
tappets. A return hole in the fuel injection pump
camshaft housing allows oil to return to the oil pan.
RCPH05CDC070AAA 23
3 15/11/2005
B.60.A / 24
From the top drilling in the cam bushing bore, oil

is carried to the cylinder block deck by individual
vertical drillings, one per cylinder. For cylinder
number one, this drilling aligns with a vertical drilling
in the cylinder head.
RCPH05CDC072AAA 24
For cylinders two through six, the oil then flows

through a transfer slot in the head gasket.
RCPH05CDC074AAA 25
RCPH05CDC075AAA 26
From each of the transfer slots in the head gasket,

oil flows from a vertical drilling in the cylinder block
to the base of the rocker arm pedestal.
RCPH05CDC077AAA 27
3 15/11/2005
B.60.A / 25
The oil travels through a groove in the bottom of the

pedestal plate.
RCPH05CDC079AAA 28
Then it flows around the rocker arm mounting cap

screws to the rocker shaft. Oil flows through angle
drillings to each end of the shaft.
RCPH05CDC081AAA 29
At each end of the shaft, the drilling intersecting

the angle drilling allows oil to flow from the inside
diameter of the shaft to the groove in the shaft which
lubricates the rocker arm bore.
RCPH05CDC083AAA 30
The lubrication groove in each end of the shaft also

directs oil to two drillings. These drillings provide
a path for oil flow. One drilling directs oil flow to
the foot pad that contacts the crosshead. Oil from
this drilling then travels down the crosshead and
lubricates the valve stems.
RCPH05CDC084AAA 31
3 15/11/2005
B.60.A / 26
The second drilling in the rocker arm directs oil to

the adjusting screw. Oil flow around the adjusting
screw lubricates the push rod sockets.
RCPH05CDC085AAA 32
The front gear train assembly receives lubrication

from oil splash and the drain from the fuel injection
pump camshaft housing. The oil pump idler gear is
pressure lubricated. After lubricating the front gear
train, the oil drains back to the pan for recirculation.
RCPH05CDC088AAA 33
3 15/11/2005
B.60.A / 27
LUBRICATION SYSTEM - Component identification (B.60.A -

C.40.C.20)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
RCPH05CDC003GAA 1
A. Filter bypass valve D. Oil pan

B. Oil filter E. Oil cooler
C. Pressure regulator valve F. Oil cooler bypass valve
3 15/11/2005
B.60.A / 28
RCPH05CDC004GAA 2
G. Dipstick oil level indicator L. Oil pressure sensor

H. Oil fill port M. Recirculation tube – blowby recirculation system
J. Oil pan drain N. Blowby recirculation device
K. Oil return line – blowby recirculation system
3 15/11/2005
B.60.A / 29
Blowby re-circulation system - Dynamic description (B.60.A.26 -

C.30.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
General Information
Excessive crankcase blowby can indicate an engine or engine-related component malfunction which allows
combustion gases or air to enter the crankcase. This creates higher than normal crankcase pressure, which
produces increased levels of blowby.
The procedure in Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20) describes how to measure
crankcase blowby and how to determine which component is malfunctioning.
Blowby is measured in the following circumstances:

• Verifying engine break-in after an engine is rebuilt
• Troubleshooting for excessive lubricating oil out of the crankcase blowby recirculation tube, commonly referred
to as “oil carryover”
NOTE: “Blowby” and “carryover” are used interchangeably in common speech.
The procedure provides guidelines for measuring blowby in these circumstances.
Excessive oil
When measuring blowby in the presence of excessive
oil discharging at the recirculation tube, the oil quantity
can affect blowby measurement. Oil may collect on the
orifice of the blowby measurement tool (CAS1692A-3),
reducing the size of the orifice and creating false
measurements – higher than actual blowby readings.
RCPH05CDC644AAA 1
When this occurs, it is necessary:

• To find a different location on the engine to measure blowby (oil fill, oil fill cap, unused turbocharger drain
location, etc.),
• To clean oil residue from the recirculation system and dry thoroughly before measuring blowby,
• To determine if there is an unusual cause for flooding the recirculation system with oil – for example, incorrect
oil level, excessive engine side to side movement, excessive engine angularity, internal engine components
deflecting oil towards the recirculation system cavity.
When to measure
Measuring blowby MUST ONLY be considered when confirming engine break-in after a rebuild or if another
symptom is present. This symptom may be:
• Excessive carryover (oil out of the crankcase recirculation system tube)
• Low power
• Oil consumption
• Exhaust smoke
If no other symptom is present, blowby measurements are not necessary.
3 15/11/2005
B.60.A / 30
If internal engine damage is suspected as the cause of excessive blowby, other actions can be performed to
confirm the damage. These actions include:
• Confirming engine maintenance practices
• Opening the oil filter and checking for debris
• Taking an oil sample and inspecting for contamination
Blowby conversion
mm (in) of H2O Liter (cfm) per minute
This table is only valid for the blowby test tool using the 7.67 mm (0.302 in) orifice.
25.4 mm (1.0 in) 50 l/min (1.766 cfm)
50.8 mm (2.0 in) 84 l/min (2.966 cfm)
76.2 mm (3.0 in) 103 l/min (3.637 cfm)
101.6 mm (4.0 in) 119 l/min (4.202 cfm)
127.0 mm (5.0 in) 133 l/min (4.697 cfm)
152.4 mm (6.0 in) 145 l/min (5.121 cfm)
177.8 mm (7.0 in) 155 l/min (5.474 cfm)
203.2 mm (8.0 in) 164 l/min (5.792 cfm)
228.6 mm (9.0 in) 172 l/min (6.074 cfm)
254.0 mm (10.0 in) 180 l/min (6.357 cfm)
279.4 mm (11.0 in) 187 l/min (6.604 cfm)
304.8 mm (12.0 in) 193 l/min (6.816 cfm)
330.2 mm (13.0 in) 200 l/min (7.063 cfm)
355.6 mm (14.0 in) 206 l/min (7.275 cfm)
381.0 mm (15.0 in) 211 l/min (7.451 cfm)
406.4 mm (16.0 in) 217 l/min (7.663 cfm)
431.8 mm (17.0 in) 222 l/min (7.840 cfm)
457.2 mm (18.0 in) 226 l/min (7.981 cfm)
482.6 mm (19.0 in) 229 l/min (8.087 cfm)
508.0 mm (20.0 in) 235 l/min (8.299 cfm)
533.4 mm (21.0 in) 239 l/min (8.440 cfm)
558.8 mm (22.0 in) 242 l/min (8.546 cfm)
584.2 mm (23.0 in) 246 l/min (8.687 cfm)
609.6 mm (24.0 in) 248 l/min (8.758 cfm)
3 15/11/2005
B.60.A / 31
Oil filter bypass valve - Dynamic description (B.60.A.27 - C.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Whenever the pressure drop across the oil filter (filter in, filter
out) exceeds 345 kPa (50 psi), the oil filter bypass valve in the
filter head opens and routes unfiltered oil to the main oil rifle
to lubricate the engine.
This condition can occur during cold ambient (cold oil) engine
start-up or because of filter restriction.
The purpose of the bypass valve is to maintain oil flow to the

engine and prevent an oil filter collapse.
RCPH05CDC055AAA 1
3 15/11/2005
B.60.A / 32
LUBRICATION SYSTEM - Emptying (B.60.A - F.35.A.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
1. Operate the engine until the coolant temperature

reaches 60 °C (140 °F). Shut off the engine.
2. Remove the oil drain plug.
NOTE: Drain the oil immediately to make sure all the
oil and suspended contaminants are removed from the
engine.
NOTE: Use a container that can hold at least 23.6 L (25
US qt) of oil.
RCSC05CDC014AAA 1
3 15/11/2005
B.60.A / 33
LUBRICATION SYSTEM - Filling (B.60.A - F.60.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Clean and inspect the drain plug threads and

sealing surface. Install the drain plug. Torque to 80
Nm (59 lb ft).
RCSC05CDC015AAA 1
2. Fill the engine with clean lubricating oil to the proper

level. Use the dipstick to monitor oil level.
NOTE: Use the recommended oil for your operating
climate as described in the Operator’s Manual.
RCPH05CDC519AAA 2
3. Operate the engine at low idle to inspect for leaks

at the locations serviced.
CAUTION
M1049 - If no oil pressure is reported within 15
seconds after the engine is started, shut down the
engine to reduce the possibility of internal damage.
4. Shut off the engine. Wait approximately 10 minutes

for the oil to drain from the upper engine into the oil
pan. Check the oil level again.
RCPH05CDC519AAA 3
3 15/11/2005
B.60.A / 34
5. Add oil as necessary to bring the level to the proper

operating level.
3 15/11/2005
B.60.A / 35
Oil pump - Remove (B.60.A.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

1. Remove the four cap screws and remove the pump

from the bore in the cylinder block.
RCPH05CDC405AAA 1
Next operation: If the oil pump is being inspected for reuse, go to Oil pump - Disassemble (B.60.A.20 - F.10.A.25)
Next operation: If the oil pump is being replaced, go to Oil pump - Install (B.60.A.20 - F.10.A.15).
3 15/11/2005
B.60.A / 36
Oil pump - Disassemble (B.60.A.20 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pump - Remove (B.60.A.20 - F.10.A.10)
1. Inspect the gears for chips, cracks or excessive

wear.
RCPH05CDC496AAA 1
2. Remove the back plate.
RCPH05CDC407AAA 2
3. Mark the top position of the gerotor planetary for

reassembly later.
RCPH05CDC499AAA 3
3 15/11/2005
B.60.A / 37
4. Remove the planetary and inspect for excessive

wear.
RCPH05CDC410AAA 4
Next operation: Oil pump - Visual inspection (B.60.A.20 - F.40.A.10)
3 15/11/2005
B.60.A / 38
Oil pump - Visual inspection (B.60.A.20 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pump - Disassemble (B.60.A.20 - F.10.A.25)
1. Clean all parts in solvent.
WARNING
personal injury.
WARNING
RCPH05CDC500AAA 1
2. Dry all parts with compressed air.
WARNING
3. Inspect the pump housing and gerotor drive for

damage and excessive wear.
RCPH05CDC408AAA 2
Next operation: Oil pump - Assemble (B.60.A.20 - F.10.A.20)
3 15/11/2005
B.60.A / 39
Oil pump - Assemble (B.60.A.20 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pump - Visual inspection (B.60.A.20 - F.40.A.10)
1. Install the gerotor planetary.
CAUTION
M1047 - The gerotor planetary must be installed in its
original position or pump damage will occur.
RCPH05CDC410AAA 1
2. Measure the tip clearance – gerotor drive to the

planetary. The clearance must be within 0.025 -
0.1778 mm (0.001 - 0.007 in).
RCPH05CDC413AAA 2
3. Measure the clearance of the drive and planetary to

the port plate. The clearance must be within 0.025 -
0.127 mm (0.001 - 0.005 in).
RCPH05CDC412AAA 3
3 15/11/2005
B.60.A / 40
4. Measure the clearance of the planetary to the bore

body. The clearance must be within 0.1778 - 0.381
mm (0.007 - 0.015 in).
RCPH05CDC414AAA 4
5. Measure the gear to gear backlash. The acceptable

range is 0.076 - 0.330 mm (0.003 - 0.013 in).
RCPH05CDC416AAA 5
6. Install the back plate.
RCPH05CDC407AAA 6
Next operation: Oil pump - Install (B.60.A.20 - F.10.A.15)
3 15/11/2005
B.60.A / 41
Oil pump - Install (B.60.A.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pump - Assemble (B.60.A.20 - F.10.A.20)
1. Lubricate the oil pump with clean engine oil.
CAUTION
M1048 - Failure to fill the pump with oil during
installation can prevent the lubricating oil pump from
priming at engine startup, resulting in severe engine
damage.
RCPH05CDC497AAA 1
2. Align the pin on the pump with the pin bore in the
block, and install the oil pump.
IMPORTANT: The back plate on the pump fits flush
against the pump bore in the block; the pump flange does
not fit flush against the gear housing. When tightening the
pump cap screws, the crossing pattern is used to properly
seat the pump plate against the block.
RCPH05CDC415AAA 2
3. Tighten the cap screws in an X-pattern, starting with

the upper right cap screw. Torque the cap screws
RCPH05CDC405AAA 3
Next operation: Oil pump - Backlash (B.60.A.20 - F.40.E.15)
3 15/11/2005
B.60.A / 42
Oil pump - Backlash (B.60.A.20 - F.40.E.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pump - Install (B.60.A.20 - F.10.A.15)
NOTE: When installing a new oil pump, the gear backlash must be correct.
1. Measure the gear backlash with the pump installed.
The pump gear to gear backlash must be within
0.076 - 0.330 mm (0.003 - 0.013 in).
NOTE: If the adjoining gear moves when backlash is
measured, the reading is incorrect.
RCPH05CDC396AAA 1
2. The idler gear to crankshaft gear backlash must be

within 0.076 - 0.330 mm (0.003 - 0.013 in).
RCPH05CDC395AAA 2
3. Lubricate the front gear train with clean engine oil.

NOTE: Clean any oil from the sealing surface on the
crankshaft before installing the front cover. The sealing
surface on the crankshaft must be free from all oil residue
to prevent seal leaks.
RCPH05CDC244AAA 3

3 15/11/2005
B.60.A / 43
Oil pan - Remove (B.60.A.23 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
1. Remove the cap screws and remove the oil pan.
RCPH05CDC423AAA 1
2. Remove the gasket.
RCPH05CDC427AAA 2
3 15/11/2005
B.60.A / 44
3. Remove the cap screws for the suction tube flange

from the block.
RCPH05CDC424AAA 3
4. Remove the cap screws for the tube bracket and

remove the suction tube.
RCPH05CDC426AAA 4
Next operation: Oil pan - Visual inspection (B.60.A.23 - F.40.A.10)
3 15/11/2005
B.60.A / 45
Oil pan - Visual inspection (B.60.A.23 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove all gasket material from the cylinder block

and oil pan surface.
RCSC05CDC021AAA 1
2. Steam clean the oil pan.
WARNING
WARNING
4. Inspect the oil pan, suction tube and tube bracket for
damage. If cracks are found, replace the damaged
part.
NOTE: Do not attempt to repair the oil pan by welding.
RCSC05CDC020AAA 2
3 15/11/2005
B.60.A / 46
Oil pan - Install (B.60.A.23 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pan - Visual inspection (B.60.A.23 - F.40.A.10)
1. Install a new gasket on the mounting flange of the

suction tube.
RCPH05CDC428AAA 1
2. Install the suction tube. Install all cap screws finger

tight and check alignment.
3. Torque the suction tube to engine block cap screws
to 10 Nm (89 lb in).
RCPH05CDC424AAA 2
4. Torque the tube brace to block cap screws to 10

Nm (89 lb in).
RCPH05CDC426AAA 3
3 15/11/2005
B.60.A / 47
5. Torque the brace to suction tube cap screws to 10

Nm (89 lb in).
RCPH05CDC426AAA 4
6. Use Permatex™ Ultra Grey (87307915) silicone

sealant to fill the joints between the oil pan rail, gear
housing and rear seal housing.
RCSC05CDC024AAA 5
7. Apply the silicone so it creates a seal between the

various gasket surfaces.
RCPH05CDC425AAA 6
3 15/11/2005
B.60.A / 48
8. Install a new gasket and the oil pan on the block.
RCSC05CDC022AAA 7
9. If removed, install the corner braces.

10. Assemble the washers and cap screws to the oil
pan. Tighten the cap screws in the sequence
shown. Torque to 28 Nm (21 lb ft).
RCIL05CDC001ACA 8
3 15/11/2005
B.60.A / 49
Oil pan - Reseal (B.60.A.23 - F.75.C.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
This procedure is only used when the oil pan gasket is torn during gear housing removal.
Prior operation: Timing gear housing - Visual inspection (B.10.A.46 - F.40.A.10)
(For gear housing removal/installation)

1. Cut the torn gasket off even with the front of the
cylinder block.
RCSC05CDC046AAA 1
2. Use the old gasket as a pattern to cut a replacement

from the front section of a new gasket.
RCSC05CDC047AAA 2
3. Clean the sealing surfaces. Coat the replacement

gasket section with Permatex™ Ultra Grey
(87307915) silicone sealant. There must be a bead
of sealant at the intersecting joint of the cylinder
block, oil pan and gear housing.
NOTE: The gear housing must be installed within 10
minutes of sealant application.
RCSC05CDC049AAA 3
3 15/11/2005
B.60.A / 50
4. Use thread or very fine wire to hold the new gasket

section in position during gasket and gear housing
installation.
RCSC05CDC048AAA 4
5. Remove the threads AFTER the gasket and gear

housing are installed AND the oil pan cap screws
are started to hold the gasket in position.
RCSC05CDC044AAA 5
3 15/11/2005
B.60.A / 51
Oil filter - Remove (B.60.A.24 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Clean the area around the filter head.
RCPH05CDC514AAA 1
2. Remove the filter with a filter wrench.
RCPH05CDC515AAA 2
3. Clean the gasket surface area of the filter head.
RCPH05CDC518AAA 3
Next operation: Oil filter - Visual inspection (B.60.A.24 - F.40.A.10)

Next operation: Oil filter - Install (B.60.A.24 - F.10.A.15)
3 15/11/2005
B.60.A / 52
Oil filter - Visual inspection (B.60.A.24 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil filter - Remove (B.60.A.24 - F.10.A.10)
1. Clamp the filter or install it in a vise to prevent

movement.
WARNING
M930 - Restrain the full flow lubricating oil filter and
carefully cut the filter (upper section of combination
filter) open. The filter element spring is under
compression and can cause injury.
2. Use a tube cutter to open the upper section of the

filter (full flow area), or carefully open the seal with a
pry bar and pliers.
RCPH05CDC312AAA 1
3. Inspect the filter element for the presence of

moisture or metal particles. If the filter contains
metal particles, use the table below to find the
source of the problem and repair the damage. Refer
to the appropriate section in this manual for the
suggested cause.
RCPH05CDC313AAA 2
Filter Analysis
Metal Possible Source

Copper Bearings and bushings
Chromium Piston rings
Iron Cylinder liners
3 15/11/2005
B.60.A / 53
Metal Possible Source

Lead Bearing overlay material
Aluminum Piston wear or scuffing
3 15/11/2005
B.60.A / 54
Oil filter - Install (B.60.A.24 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Prior operation: Oil filter - Visual inspection (B.60.A.24 - F.40.A.10)
1. Fill the filter with clean engine oil. Lubricate the filter
gasket with clean engine oil.
RCPH05CDC516AAA 1
2. Install the filter on the filter head. Tighten until the

gasket contacts the head surface.
RCPH05CDC517AAA 2
3. Follow the instructions provided with the filter, or

tighten the filter an additional ½ to ¾ turn.
3 15/11/2005
B.60.A / 55
Oil pressure regulator valve - Remove (B.60.A.25 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Thoroughly clean the area around the pressure

regulator plug to avoid introducing debris into the
lubrication system.
RCPH05CDC305AAA 1
2. Remove the threaded plug (1), spring (2) and

plunger (3).
NOTE: If the plunger cannot be removed by inserting
a finger in the plunger bore and pulling downward,
the plunger is stuck. The oil cooler housing must be
disassembled and cleaned to remove the plunger.
RCSC05CDC006AAA 2
Next operation: Oil pressure regulator valve - Visual inspection (B.60.A.25 - F.40.A.10)
3 15/11/2005
B.60.A / 56
Oil pressure regulator valve - Visual inspection (B.60.A.25 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pressure regulator valve - Remove (B.60.A.25 - F.10.A.10)
1. Thoroughly clean all components with cleaning

solvent.
WARNING
personal injury.
WARNING
WARNING
3. Inspect the plunger and the plunger bore. Polished

areas on the plunger and bore are acceptable.
4. Verify that the plunger moves freely in the bore.
RCSC05CDC004AAA 2
Next operation: Oil pressure regulator valve - Install (B.60.A.25 - F.10.A.15)
3 15/11/2005
B.60.A / 57
Oil pressure regulator valve - Install (B.60.A.25 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil pressure regulator valve - Visual inspection (B.60.A.25 - F.40.A.10)
1. Install a new O-ring seal on the threaded plug and

lubricate with clean engine oil.
RCSC05CDC003AAA 1
2. Install the pressure regulator assembly. Torque the

plug to 80 Nm (59 lb ft).
RCPH05CDC301AAA 2
3 15/11/2005
B.60.A / 58
Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Read and understand the information in Blowby re-circulation system - Dynamic description (B.60.A.26 -
C.30.A.10) when this measurement is to be performed.
Initial check
1. Check the tube on the blowby recirculation system
for obstructions. If required, clean the tube to
remove the obstructions.
RCIL05CDC007AAA 1
2. If excessive oil is discharging from the tube,

remove the recirculation system components to
clean and remove oil buildup before performing
any measurements. See Blowby re-circulation
3. Check the engine oil level. If the level is too
high, excessive carryover and higher than normal
blowby pressure is expected. Adjust the oil level
as required.
Measure – engine blowby contribution

4. Connect the blowby measuring tool to the
recirculation system. See Blowby re-circulation
system - Tool connection (B.60.A.26 - F.40.D.21).
RCPH05CDC635AAA 2
5. Connect a water manometer or a digital manometer

to the tool. See Blowby re-circulation system -
Special tools (B.60.A.26 - D.20.A.40).
3 15/11/2005
B.60.A / 59
6. Operate the engine at rated speed and under full

load with a dynamometer. Operate the engine until
a steady reading is obtained.
NOTE: When measuring blowby, the value can “spike”
initially as the engine achieves peak power and rated
speed. Wait for the blowby measurement to stabilize
before recording a reading.
NOTE: During engine run-in, if a sudden increase of
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.
RCPH05CDC807AAA 3
7. Record the steady blowby measurement. Compare

the reading to the specification – 30.5 cm H2O
(12.0 in H2O).
RCPH05CDC634AAA 4
8. If blowby is within specification, remove the

service tool and manometer. If blowby is outside
of specification, continue with measuring the
turbocharger blowby contribution.
Measure – turbocharger blowby contribution

9. Isolate the turbocharger to determine if the high
blowby pressure is due to turbocharger seal
leakage. Install the shop made turbocharger
isolation tool. See Blowby re-circulation system
- Tool connection (B.60.A.26 - F.40.D.21) for
instructions to make and connect this tool.
RCPH05CDC780AAA 5
3 15/11/2005
B.60.A / 60
10. Close the valve (A) which allows oil to drain into
the container.
RCPH05CDC780AAA 6
11. Open the valve (B) that allows oil to drain into the
engine.
RCPH05CDC780AAA 7
12. Operate the engine at rated speed and under full

load with a dynamometer. Operate the engine until
a steady reading is obtained.
NOTE: When measuring blowby, the value can “spike”
initially as the engine achieves peak power and rated
speed. Wait for the blowby measurement to stabilize
before recording a reading.
RCPH05CDC807AAA 8
3 15/11/2005
B.60.A / 61
13. Continue operating at rated speed and load. Open

valve (A) and close valve (B).
WARNING
M1161 - Troubleshooting presents the risk of
death, personal injury or equipment damage.
Troubleshooting must be performed by trained,
experienced technicians.
WARNING
M563 - Rotating Parts. Stay clear, DO NOT wear
jewelry or loose fitting clothing that may get caught in
moving parts.
RCPH05CDC780AAA 9
CAUTION
M1163 - Do not operate the engine with valve (A)
open and valve (B) closed for more than one minute.
Monitor the amount of oil accumulating in the
container. The engine can run out of lubricating
engine oil and severe engine damage can occur.
14. Record the blowby pressure reading. Open valve

(B) and close valve (A).
15. Determine the turbocharger blowby pressure
contribution using the formula and the two blowby
pressure readings, where
x = the blowby reading without the turbocharger

isolated,
y = the blowby reading with the turbocharger

isolated, and
% = the percentage of turbocharger contribution to

blowby.
RCIL05CDC002AAA 10
16. The turbocharger should NOT contribute more than

30%. 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 required.
17. Remove the shop made tool from the turbocharger.
Reconnect the turbocharger drain line.
18. Remove the blowby service tool and manometer.
19. Check the engine oil level and add oil if necessary.
3 15/11/2005
B.60.A / 62
Blowby re-circulation system - Tool connection (B.60.A.26 -

F.40.D.21)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Crankcase blowby measuring tool

1. At the left hand rear side of the top cover, remove
the mounting nut (A) for the clamp holding the
blowby recirculation tube (B). Remove the clamp
from the mounting stud.
NOTE: Windshield washer tank shown removed for photo
clarity.
NOTE: On some vehicles, it will be necessary to loosen
the mounting nuts (C) for the windshield washer tank
bracket to remove the clamp.
RCPH05CDC639AAA 1
2. Disconnect the blowby tube (A) from the

recirculation system. Move the tube (A) backward
and forward to loosen it from the lower tube (B) at
the 90 ° elbow (C). Separate the upper tube from
the lower tube.
RCPH05CDC637AAA 2
3. Connect the crankcase blowby measuring tool (A) –

CAS1692A-3 – to the tube (B) and reinstall the tube
on the recirculation system.
RCPH05CDC632AAA 3
3 15/11/2005
B.60.A / 63
4. Connect the air line from blowby measuring tool to

a tube-style or digital manometer to measure cm
H2O (in H2O). See Blowby re-circulation system
- Special tools (B.60.A.26 - D.20.A.40).
NOTE: A digital manometer must be zeroed before valid
readings can be obtained.
RCPH05CDC633AAA 4
Next operation: Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20)
3 15/11/2005
B.60.A / 64
Blowby re-circulation system - Tool connection (B.60.A.26 -

F.40.D.21)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Turbocharger blowby isolation tool

1. Create a turbocharger isolation tool with two shutoff
valves installed between the bearing drain from the
turbocharger and the cylinder block.
RCPH05CDC780AAA 1
2. The shutoff valves must have a minimum inside

diameter of 19 mm (0.75 in).
RCPH05CDC641AAA 2
3. Use a new or used turbocharger drain tube (PART

NO. J945108) to move the tool away from the
exhaust manifold and the filters. Cut two sections
from the drain tube as shown in the side view to
create the isolation tool.
RCPH05CDC645AAA 3
3 15/11/2005
B.60.A / 65
4. Connect the flange portion of the tube (A) to the

bearing drain on the turbocharger with the existing
screws and gasket. Connect the bottom portion of
the tube (B) to the drain hose at the block.
RCPH05CDC642AAA 4
5. Connect a hydraulic hose to the valve (A) and route

it to a 8 - 19 L (2 - 5 US gal) container.
RCPH05CDC641AAA 5
Next operation: Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20)
3 15/11/2005
B.60.A / 66
Blowby re-circulation system - Remove (B.60.A.26 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the blowby tube (1) from the recirculation

device (2). Disconnect the oil drain line (3) from the
system.
RCPH05CDC187AAA 1
2. Remove the two cap screws.
RCPH05CDC189AAA 2
3. Pull straight up on the system to remove it from the

cover.
RCPH05CDC190AAA 3
Next operation: Blowby re-circulation system - Visual inspection (B.60.A.26 - F.40.A.10)
3 15/11/2005
B.60.A / 67
Blowby re-circulation system - Visual inspection (B.60.A.26 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Blowby re-circulation system - Remove (B.60.A.26 - F.10.A.10)
1. Use hot soapy water and a soft brush to clean the

recirculation device.
RCSC05CDC007AAB 1
WARNING
3. Inspect the device for cracks or other damage.
RCSC05CDC008AAB 2
Next operation: Blowby re-circulation system - Install (B.60.A.26 - F.10.A.15)
3 15/11/2005
B.60.A / 68
Blowby re-circulation system - Install (B.60.A.26 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Blowby re-circulation system - Visual inspection (B.60.A.26 - F.40.A.10)
1. Install a new O-ring on the recirculation device.
RCPH05CDC190AAA 1
2. Lubricate the O-ring and cover with clean engine oil.

3. Install the device on the engine cover.
4. Install the original cap screws. Torque to 7 Nm (62
lb in).
RCPH05CDC189AAA 2
5. Install the blowby tube and the drain line.
RCPH05CDC187AAA 3
3 15/11/2005
B.60.A / 69
Oil filter bypass valve - Remove (B.60.A.27 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the two screws from the filter adapter under

the head.
RCPH05CDC314AAA 1
2. Use a rubber hammer to release the adapter.

Remove the adapter gasket.
RCPH05CDC315AAA 2
3. Remove the plug from the end of the filter head.
RCPH05CDC319AAA 3
3 15/11/2005
B.60.A / 70
4. Use a screwdriver to push down on the bypass

valve and remove it from the bore.
RCPH05CDC320AAA 4
Next operation: Oil filter bypass valve - Visual inspection (B.60.A.27 - F.40.A.10)
3 15/11/2005
B.60.A / 71
Oil filter bypass valve - Visual inspection (B.60.A.27 - F.40.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil filter bypass valve - Remove (B.60.A.27 - F.10.A.10)
1. Use solvent to clean the adapter and the bypass

valve.
WARNING
personal injury.
WARNING
WARNING
3. Inspect the adapter for cracks or other damage.
Inspect the valve seat for damage. Check that the

valve fully closes.
RCPH05CDC321AAA 2
Next operation: Oil filter bypass valve - Install (B.60.A.27 - F.10.A.15)
3 15/11/2005
B.60.A / 72
Oil filter bypass valve - Install (B.60.A.27 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil filter bypass valve - Visual inspection (B.60.A.27 - F.40.A.10)
1. Install the bypass valve in the bore in the orientation

shown. Use a deep well socket to seat the valve
in the bore.
RCPH05CDC321AAA 1
2. Install the plug in the filter head. Torque the plug

RCPH05CDC319AAA 2
3 15/11/2005
B.60.A / 73
3. Install the gasket (A) and filter adapter (B) into the
head with the cap screws (C) removed earlier.
NOTE: Replace the adapter gasket if it was damaged
during removal.
RCSC05CDC018AAA 3
4. Tighten and then torque the cap screws to 24 Nm

(18 lb ft).
RCPH05CDC314AAA 4
3 15/11/2005
B.60.A / 74
Piston lubrication Spray nozzle - Remove (B.60.A.29.29 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING


the crankshaft for access to the individual nozzles.
RCPH05CDC220AAA 1
2. Remove the piston cooling nozzle cap screws and

nozzles.
RCPH05CDC443AAA 2
3 15/11/2005
B.60.A / 75
3. Because of the location of the speed ring, the

number six piston cooling nozzle requires a metric
crow’s foot to remove the cap screw.
RCPH05CDC440AAA 3
Next operation: Piston lubrication Spray nozzle - Visual inspection (B.60.A.29.29 - F.40.A.10)
3 15/11/2005
B.60.A / 76
Piston lubrication Spray nozzle - Visual inspection (B.60.A.29.29 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Piston lubrication Spray nozzle - Remove (B.60.A.29.29 - F.10.A.10)
1. Clean the nozzle and cap screw with solvent.
WARNING
personal injury.
WARNING
Read the manufacturer’s instructions before using. RCSC05CDC009AAA 1
WARNING
RCPH05CDC442AAA 2
3. Inspect the nozzle for flow restriction or other

damage. Replace as required.
RCPH05CDC441AAA 3
3 15/11/2005
B.60.A / 77
4. Compare the curvature of the used nozzle with a

new or known good nozzle(A). Replace the nozzle
if it will no longer correctly direct flow to the piston
as designed.
RCPH05CDC526AAA 4
3 15/11/2005
B.60.A / 78
Piston lubrication Spray nozzle - Install (B.60.A.29.29 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Piston lubrication Spray nozzle - Visual inspection (B.60.A.29.29 - F.40.A.10)
1. Install the nozzles and cap screws.

NOTE: Use the engine barring tool –380000732 – to
rotate the crankshaft and access the nozzles.
RCPH05CDC443AAA 1
2. Use a metric crow’s foot to install the nozzle and

cap screw for the number six piston.
RCPH05CDC440AAA 2
3. Tighten the cap screw. Torque to 33 Nm (24 lb ft).
Next operation: Oil pan - Reseal (B.60.A.23 - F.75.C.15)

3 15/11/2005
B.60.A / 79
Oil cooler - Remove (B.60.A.32 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
WARNING
WARNING

Prior operation: If required, Oil filter - Remove (B.60.A.24 - F.10.A.10)
1. Clean the area around the oil cooler cover.
RCPH05CDC305AAA 1
3 15/11/2005
B.60.A / 80
2. Remove the turbocharger oil supply line.
RCPH05CDC181AAA 2
3. Remove the oil cooler cover.
RCPH05CDC306AAA 3
4. Remove the cover gasket.
RCPH05CDC311AAA 4
3 15/11/2005
B.60.A / 81
5. Remove the cooler element.
RCPH05CDC310AAA 5
6. Remove the element gasket from the housing.
RCPH05CDC307AAA 6
Next operation: Oil cooler - Cleaning (B.60.A.32 - F.30.A.10)
3 15/11/2005
B.60.A / 82
Oil cooler - Cleaning (B.60.A.32 - F.30.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil cooler - Remove (B.60.A.32 - F.10.A.10)
1. Clean the sealing surface of the block cooler

housing and the cooler cover.
RCSC05CDC325AAA 1
Next operation: Oil cooler - Leakage test (B.60.A.32 - F.40.A.40)
3 15/11/2005
B.60.A / 83
Oil cooler - Leakage test (B.60.A.32 - F.40.A.40)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil cooler - Cleaning (B.60.A.32 - F.30.A.10)
1. Pressure test the cooler element using special tool

3823876 (CUMMINS) or a shop made test kit. See
Oil cooler - Special tools (B.60.A.32 - D.20.A.40)
for more information on the shop made tool.
RCSC05CDC029AAA 1
2. Install an O-ring seal in both cooler element ports.

Install the test plate on the cooler element. Connect
the test plate fitting to a regulated air supply.
3. Submerge the element in a tank of clean water. No
air bubbles should be observed when the element
is pressurized to 449 - 518 kPa (65 - 75 psi) with
clean shop air.
Next operation: Oil cooler - Install (B.60.A.32 - F.10.A.15)
3 15/11/2005
B.60.A / 84
Oil cooler - Install (B.60.A.32 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil cooler - Leakage test (B.60.A.32 - F.40.A.40)
1. When a new cooler element is installed, remove the

shipping plugs from the ports.
RCPH05CDC308AAA 1
2. Install the gasket on the cooler element.
RCPH05CDC309AAA 2
3. Install the element assembly in the housing.
RCPH05CDC310AAA 3
3 15/11/2005
B.60.A / 85
4. Install the cover gasket and cover.
RCPH05CDC311AAA 4
5. Tighten the cap screws in the sequence shown.

RCPH05CDC305AAB 5
6. Install the turbocharger supply line.
RCPH05CDC181AAA 6
Next operation: If required, Oil filter - Install (B.60.A.24 - F.10.A.15)

3 15/11/2005
B.60.A / 86
Oil cooler Bypass valve - Remove (B.60.A.32.20 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Clean the area around the bypass valve at the top

of the oil cooler.
2. Remove the bypass valve.
RCPH05CDC300AAA 1
Next operation: Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01)
3 15/11/2005
B.60.A / 87
Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil cooler Bypass valve - Remove (B.60.A.32.20 - F.10.A.10)
1. Inspect the valve for a damaged O-ring, broken

spring or other damage.
RCPH05CDC302AAA 1
2.
CAUTION
M928 - The flash point of new lubricating oil is
approximately 221 degrees C (430 degrees F). DO
NOT allow oil temperature in the container to exceed
150 degrees C (300 degrees F). DO NOT allow water
droplets to enter the container of hot oil. Water
droplets will cause a violent reaction which can cause
injury.
RCSC05CDC026AAA 2
3. Suspend the bypass valve and a thermometer in a

container of new oil. Do NOT allow the valve or the
thermometer to touch the sides of the container.
IMPORTANT: The thermometer must be capable of
reading at least 116 °C (240 °F).
RCSC05CDC027AAA 3
4. Heat the oil.
3 15/11/2005
B.60.A / 88
5. Note the temperature at which the valve is fully

extended. The valve must be fully extended – at
least 45.9 mm (1.8 in) (A) – when the temperature
reaches 104 °C (220 °F).
RCSC05CDC028AAA 4
6. Replace the bypass valve if it does not operate as

described.
Next operation: Oil cooler Bypass valve - Install (B.60.A.32.20 - F.10.A.15)
3 15/11/2005
B.60.A / 89
Oil cooler Bypass valve - Install (B.60.A.32.20 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01)
1. Install the bypass valve. Torque the valve to 50 Nm

(37 lb ft).
RCPH05CDC300AAA 1
3 15/11/2005
B.60.A / 90
Sensing system Oil level indicator - Remove (B.60.A.95.90 -

F.10.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Use a small pry bar under the flange on the dipstick

guide tube to remove the assembly from the engine
block.
If the guide tube breaks off at the block, use an 8

mm x 1.25 in x 21 mm self-tapping cap screw to
remove the guide tube. Thread the cap screw into
the guide tube section in the block and remove the
tube.
RCPH05CDC136AAA 1
Next operation: Sensing system Oil level indicator - Install (B.60.A.95.90 - F.10.A.15)
3 15/11/2005
B.60.A / 91
Sensing system Oil level indicator - Install (B.60.A.95.90 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Oil level indicator - Remove (B.60.A.95.90 - F.10.A.10)
1. Remove any remaining Loctite™ from the bore in

the block for the oil level indicator.
RCPH05CDC280ABA 1
2. Apply Loctite™ 277 to the mounting surface of the

dipstick guide tube.
RCPH05CDC281ABA 2
3. Install the guide tube in the engine block.

NOTE: Use a brass drift and hammer on the flange to
seat the tube in the block bore.
RCPH05CDC282ABA 3
3 15/11/2005
B.60.A / 92
4. Install the dipstick in the guide tube.
RCPH05CDC283ABA 4
3 15/11/2005
B.60.A / 93
Sensing system Oil pressure - Remove (B.60.A.95.91 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

sensor.
RCPH05CDC352ABA 1
2. Remove the sensor from the block.
RCPH05CDC360ABA 2
Next operation: Sensing system Oil pressure - Visual inspection (B.60.A.95.91 - F.40.A.10)
3 15/11/2005
B.60.A / 94
Sensing system Oil pressure - Visual inspection (B.60.A.95.91 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Oil pressure - Remove (B.60.A.95.91 - F.10.A.10)
• Loose connector
• Corroded pins

required.
RCPH05CDC353ABA 1
Next operation: Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01)
3 15/11/2005
B.60.A / 95
Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Oil pressure - Visual inspection (B.60.A.95.91 - F.40.A.10)

between the pins at the sensor connector.
There must be continuity between pin 2 and 3

and no continuity between the remaining pin
combinations.
Replace the sensor if the correct continuity is not

present.
RCPH05CDC362ABA 1
Next operation: Sensing system Oil pressure - Install (B.60.A.95.91 - F.10.A.15)
3 15/11/2005
B.60.A / 96
Sensing system Oil pressure - Install (B.60.A.95.91 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01)

O-ring with clean engine oil. Install the sensor in
the block.
Torque the sensor to 23 Nm (17 lb ft).
RCPH05CDC354ABA 1

sensor.
RCPH05CDC352ABA 2
3 15/11/2005
B.60.A / 97
LUBRICATION SYSTEM - Problem solving (B.60.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Refer to LUBRICATION SYSTEM - Dynamic description (B.60.A - C.30.A.10).
TROUBLESHOOTING
WARNING

Oil consumption Step 1: Check the amount of oil added versus
excessive Oil consumption rate inaccurate. hours of usage.
Step 2: Inspect the engine for external oil leaks.
External oil leakage. Tighten the cap screws, pipe plugs and
fittings. Replace gaskets, if required.
Step 3: Check and clean the blowby recirculation
Blowby recirculation system is plugged. system. Refer to Blowby re-circulation
Step 4: Change the oil and filter.
Oil does NOT meet specification for the
operating conditions.
Step 5: Verify the correct change interval.
Interval between oil change is too long.
Step 6: Pressure test the oil cooler. Refer to
Oil cooler is leaking. Oil cooler - Leakage test (B.60.A.32 -
F.40.A.40).
Oil level is above specification. calibration and oil pan capacity. Fill the
Step 8: Check the turbocharger compressor and
Turbocharger oil seal is leaking. turbine seals. Refer to Turbocharger -
Preliminary test (B.30.A.31 - F.40.A.20).
3 15/11/2005
B.60.A / 98

Step 9: Check blowby. Refer to Blowby
Piston rings are NOT seated correctly re-circulation system - Blow by
(after an engine rebuild or piston (B.60.A.26 - F.40.E.20). If blowby is
installation). excessive, check the piston rings for
correct seating. Refer to Piston Ring -
Measure (B.10.A.47.15.05 - F.40.A.16).
Step 10: Refer to the “lubricating oil contaminated”
Oil is contaminated with coolant or fuel. symptom table in this document.
Step 11: Check for air intake system leaks.
Piston or piston rings are worn or
damaged. Refer to AIR INTAKE SYSTEM - Leakage
test (B.30.A - F.40.A.40).
Check the pistons and piston rings for wear

or damage. See Connecting rod and
piston - Remove (B.10.A.47 - F.10.A.10).
Step 12: Analyze the oil and inspect the filter to
Internal engine damage. locate an area of probable damage. Refer
to Oil filter - Visual inspection (B.60.A.24
- F.40.A.10).
Oil contaminated Step 1: Submit sample for oil analysis to determine
Identify the contaminant. the contaminant.
Step 2: Refer to the “fuel in the lubricating oil”
Fuel in lubricating oil. symptom table.

Step 3: Refer to the “internal coolant loss”
Internal coolant leaks. symptom table.

Step 4: Check the bulk oil supply.
Bulk oil supply is contaminated.
Drain the oil and replace with
non-contaminated oil. Replace the
oil filter.
Oil sludge in the Step 1: Check the bulk oil supply.
crankcase excessive Bulk oil supply is contaminated.
Drain the oil and replace with
non-contaminated oil. Replace the
oil filter.
Oil does NOT meet specifications for
Step 3: Verify the correct change interval.
Interval between oil change is too long.
Step 4: Check and clean the blowby recirculation
Blowby recirculation system is plugged. system.

Remove (B.60.A.26 - F.10.A.10).
Step 5: Operate the engine with high quality fuel.
Fuel grade is NOT correct for the
Step 6: Refer to the “coolant temperature is below
Coolant temperature is below specification. normal” symptom table.

3 15/11/2005
B.60.A / 99

Step 8: Check for excessive blowby.
Crankcase pressure is excessive.
Blow by (B.60.A.26 - F.40.E.20).
Coolant temperature is above normal – gradual overheat” or “coolant
specification. temperature above normal – sudden
overheat” symptom tables.

Coolant in the lubricating Step 1: Pressure test the oil cooler.
oil Oil cooler is leaking.
See Oil cooler - Leakage test (B.60.A.32
- F.40.A.40).
Step 2: Check the cylinder head.
Cylinder head core and expansion plugs
leaking or incorrectly assembled. Refer to Cylinder head - Remove
(B.10.A.72 - F.10.A.10).
(B.10.A.72 - F.10.A.10).
Step 4: Pressure test the cylinder head.
Cylinder head is cracked or porous.
Refer to Cylinder head - Pressure test
(B.10.A.72 - F.40.A.30).
Step 5: Remove the oil pan.
Cylinder block is cracked or porous.
Refer to Oil pan - Remove (B.60.A.23 -
F.10.A.10).
Pressure test the cooling system to check

for leaks. Refer to ENGINE COOLANT
Oil pressure high Step 1: Refer to the “coolant temperature below
Coolant temperature is below specification. normal” symptom table.

Step 2: Change the oil and filter. Use the
Oil does NOT meet specifications for the recommended oil for the engine.
Step 3: Check the oil pressure sensor for proper
Oil pressure sensor is malfunctioning or is operation and correct location.
NOT in the correct location.
Use INSITE® to check for active or a larger
number of inactive fault codes related to
the sensor. If present, use the guided

Sensing system Oil pressure - Test
(B.60.A.95.91 - F.40.C.01).
3 15/11/2005
B.60.A / 100

Step 4: Troubleshoot the sensor circuit.
Oil pressure sensor or circuit is
malfunctioning. Use INSITE® to check for active or a larger

(B.60.A.95.91 - F.40.C.01).
Step 5: Check the oil pressure regulator.
Oil pressure regulator is malfunctioning.
Refer to Oil pressure regulator valve -
Remove (B.60.A.25 - F.10.A.10).
Oil pressure low Step 1: Check the oil pressure gauge for proper
Oil pressure in-cab gauge is malfunctioning operation.
or the pressure sensor is NOT in the
correct location. Check the sensor for correct location.
Step 2: Check the oil level. Add or drain oil, if
Step 3: Inspect the engine for external oil leaks.
External oil leakage. Tighten the cap screws, pipe plugs and
fittings. Replace gaskets, if required.
Oil does NOT meet specification for the
operation conditions.
Step 6: Refer to the engine performance curves
Engine angle during operation exceeds and data sheet.
specification.
Step 7: Check the oil pressure sensor and sensor
Oil pressure sensor or sensor circuit is circuit for proper operation.
faulty.
Use INSITE® to check for active or a larger

(B.60.A.95.91 - F.40.C.01).
Step 8: Check the oil pressure regulator.
Oil pressure regulator is malfunctioning.
Refer to Oil pressure regulator valve -
Remove (B.60.A.25 - F.10.A.10).
Step 9: Remove and inspect the suction tube.
Oil suction tube is loose or broken, or the
gaskets and/or O-rings are leaking. Refer to Oil pan - Remove (B.60.A.23 -
F.10.A.10).
Step 10: Inspect the oil pump.
Oil pump is malfunctioning.
Refer to Oil pump - Remove (B.60.A.20 -
F.10.A.10).
Step 11: Check the oil cooler.
Oil cooler is plugged.
- F.10.A.10).
3 15/11/2005
B.60.A / 101

Step 12: Check the piston cooling nozzles.
Piston cooling nozzles are damaged or
are NOT installed correctly. Refer to Piston lubrication Spray nozzle
- Remove (B.60.A.29.29 - F.10.A.10).
Step 13: Analyze the oil. Inspect the oil filter.
Internal engine damage or internal oil leak.
(B.60.A.24 - F.40.A.10).
Check the main bearings, rod bearings,

cam bushings and rocker lever bushings
for excessive wear.
Oil temperature above Step 1: Use INSITE® to check for active or a high
specification Active fault codes or high counts of inactive count of inactive fault codes related to the
fault codes. oil temperature.
Follow the guided troubleshooting to

resolve the problem.
Coolant temperature is above normal” symptom table.
specification.
Step 4: Check the temperature gauge for correct
Oil temperature in-cab gauge is operation.
malfunctioning.
Step 5: Check the oil cooler.
Oil cooler is plugged.
- F.10.A.10).
Internal engine damage. the area of probable damage.

(B.60.A.24 - F.40.A.10).
3 15/11/2005
B.60.A / 102
Blowby re-circulation system - Problem solving (B.60.A.26 -

G.40.A.30)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Refer to Blowby re-circulation system - Dynamic description (B.60.A.26 - C.30.A.10).
TROUBLESHOOTING
WARNING

Crankcase gases (blowby) Step 1: Check and clean the blowby recirculation
excessive Blowby recirculation system is plugged. system.

Remove (B.60.A.26 - F.10.A.10).
Turbocharger oil seal is leaking. turbine oil seals.
Refer to Turbocharger - Preliminary test

(B.30.A.31 - F.40.A.20).
Step 3: Check the valve stems and seals.
Valve stem clearance is excessive or the
valve stem seals are damaged. Refer to Cylinder head - Remove
(B.10.A.72 - F.10.A.10).
Step 4: Check the valve guides for wear. Replace
Cylinder head valve guides are excessively the cylinder head if required.
worn.
(B.10.A.72 - F.10.A.10).
Step 5: Check the pistons, piston rings and
Cylinder liners, pistons or piston rings are cylinder liner.
worn or damaged.
Refer to Connecting rod and piston -
Remove (B.10.A.47 - F.10.A.10).
3 15/11/2005
B.60.A / 103
Index

Blowby re-circulation system - Blow by (B.60.A.26 - F.40.E.20) 59
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Dynamic description (B.60.A.26 - C.30.A.10) 30
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Install (B.60.A.26 - F.10.A.15) 69
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Problem solving (B.60.A.26 - G.40.A.30) 103
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Remove (B.60.A.26 - F.10.A.10) 67
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Service limits (B.60.A.26 - D.20.A.20) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Special tools (B.60.A.26 - D.20.A.40) 11
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Blowby re-circulation system - Visual inspection (B.60.A.26 - F.40.A.10) 68
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Component identification (B.60.A - C.40.C.20) 28
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Dynamic description (B.60.A - C.30.A.10) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Emptying (B.60.A - F.35.A.01) 33
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Filling (B.60.A - F.60.A.10) 34
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - General specification (B.60.A - D.40.A.10) 6
MX215, MX245, MX275, MX305, STX280, 2388, 2377
LUBRICATION SYSTEM - Problem solving (B.60.A - G.40.A.30) 98
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Cleaning (B.60.A.32 - F.30.A.10) 83
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Install (B.60.A.32 - F.10.A.15) 85
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Leakage test (B.60.A.32 - F.40.A.40) 84
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Remove (B.60.A.32 - F.10.A.10) 80
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Service limits (B.60.A.32 - D.20.A.20) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Special tools (B.60.A.32 - D.20.A.40) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler - Torque (B.60.A.32 - D.20.A.10) 15
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Install (B.60.A.32.20 - F.10.A.15) 90
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Remove (B.60.A.32.20 - F.10.A.10) 87
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Service limits (B.60.A.32.20 - D.20.A.20) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.60.A / 104
Oil cooler Bypass valve - Test (B.60.A.32.20 - F.40.C.01) 88
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil cooler Bypass valve - Torque (B.60.A.32.20 - D.20.A.10) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter - Install (B.60.A.24 - F.10.A.15) 55
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter - Remove (B.60.A.24 - F.10.A.10) 52
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter - Visual inspection (B.60.A.24 - F.40.A.10) 53
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Dynamic description (B.60.A.27 - C.30.A.10) 32
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Install (B.60.A.27 - F.10.A.15) 73
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Remove (B.60.A.27 - F.10.A.10) 70
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Torque (B.60.A.27 - D.20.A.10) 13
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil filter bypass valve - Visual inspection (B.60.A.27 - F.40.A.10) 72
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Install (B.60.A.23 - F.10.A.15) 47
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Remove (B.60.A.23 - F.10.A.10) 44
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Reseal (B.60.A.23 - F.75.C.15) 50
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Torque (B.60.A.23 - D.20.A.10) 9
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pan - Visual inspection (B.60.A.23 - F.40.A.10) 46
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Install (B.60.A.25 - F.10.A.15) 58
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Remove (B.60.A.25 - F.10.A.10) 56
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Torque (B.60.A.25 - D.20.A.10) 10
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pressure regulator valve - Visual inspection (B.60.A.25 - F.40.A.10) 57
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Assemble (B.60.A.20 - F.10.A.20) 40
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Backlash (B.60.A.20 - F.40.E.15) 43
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Disassemble (B.60.A.20 - F.10.A.25) 37
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Install (B.60.A.20 - F.10.A.15) 42
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Remove (B.60.A.20 - F.10.A.10) 36
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Service limits (B.60.A.20 - D.20.A.20) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Torque (B.60.A.20 - D.20.A.10) 7
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Oil pump - Visual inspection (B.60.A.20 - F.40.A.10) 39
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Install (B.60.A.29.29 - F.10.A.15) 79
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Remove (B.60.A.29.29 - F.10.A.10) 75
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Torque (B.60.A.29.29 - D.20.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Piston lubrication Spray nozzle - Visual inspection (B.60.A.29.29 - F.40.A.10) 77
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil level indicator - Install (B.60.A.95.90 - F.10.A.15) 92
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.60.A / 105
Sensing system Oil level indicator - Remove (B.60.A.95.90 - F.10.A.10) 91
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Install (B.60.A.95.91 - F.10.A.15) 97
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Remove (B.60.A.95.91 - F.10.A.10) 94
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Service limits (B.60.A.95.91 - D.20.A.20) 18
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Test (B.60.A.95.91 - F.40.C.01) 96
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Torque (B.60.A.95.91 - D.20.A.10) 18
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Sensing system Oil pressure - Visual inspection (B.60.A.95.91 - F.40.A.10) 95
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.60.A / 106
STARTING SYSTEM - 80.A
2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280
87372074 3 15/11/2005
B.80.A / 1
Contents
TECHNICAL DATA
Cold start aid
Cold start aid Grid heater - Torque (B.80.A.30.40 - D.20.A.10) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Torque (B.80.A.30.83 - D.20.A.10) 3

MX215, MX245, MX275, MX305, STX280, 2388, 2377
SERVICE
STARTING SYSTEM - Check (B.80.A - F.40.A.11) 4
MX215, MX245, MX275, MX305, STX280

2388, 2377
Cold start aid

Cold start aid Grid heater - Remove (B.80.A.30.40 - F.10.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Visual inspection (B.80.A.30.40 - F.40.A.10) 16

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Disassemble (B.80.A.30.40 - F.10.A.25) 17

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Assemble (B.80.A.30.40 - F.10.A.20) 19

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Install (B.80.A.30.40 - F.10.A.15) 20

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Remove (B.80.A.30.83 - F.10.A.10) 22

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Visual inspection (B.80.A.30.83 - F.40.A.10) 23

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Install (B.80.A.30.83 - F.10.A.15) 24

MX215, MX245, MX275, MX305, STX280, 2388, 2377
DIAGNOSTIC
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.80.A / 2
POWER PRODUCTION - STARTING SYSTEM
Cold start aid Grid heater - Torque (B.80.A.30.40 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Grid heater cap screws 24 Nm 16 lb ft
RCPH05CDC716AAA 1
Cold start aid Engine heater - Torque (B.80.A.30.83 - D.20.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377

Block heater 75 Nm 55 lb ft
RCPH05CDC194ABA 1
3 15/11/2005
B.80.A / 3
STARTING SYSTEM - Check (B.80.A - F.40.A.11)

MX215, MX245, MX275, MX305, STX280
Starting aids check

1. Turn the keyswitch ON.
Verify the operation of the cold weather starting

aids – the intake manifold grid heater and the block
heater, if equipped.
Refer to Cold start aid Grid heater - Remove

(B.80.A.30.40 - F.10.A.10).
Refer to Cold start aid Engine heater - Remove

(B.80.A.30.83 - F.10.A.10).
RCPH05CDC708AAA 1
Low pressure fuel line check

2. Verify that the low pressure fuel lines are routed
correctly at the engine control module (ECM) cooling
plate. The lines can be installed improperly.
The upper connection (A) to the cooling plate must

be the fuel supply line from the fuel tank (via the
supply manifold where applicable).
The lower connection (B) must be the outlet line to

the gear pump.
NOTE: Check these connections if the low pressure lines
have been removed and reinstalled on the engine.
RCSC05CDC180AAA 2
3 15/11/2005
B.80.A / 4
ECM keyswitch voltage check

3. Disconnect the vehicle connector from the engine
Check the ECM keyswitch voltage:
• Measure the signal voltage from the keyswitch

between pin 39 of the vehicle connector and engine
block ground.
• Measure the voltage with the keyswitch in the ON
position and then in the START position.
The measured voltage MUST be equal to battery

voltage. RCSC05CDC182AAA 3
If the measured voltage is incorrect in either switch

position, repair or replace the vehicle harness or the
keyswitch. Check the battery connections. Check
engine operation.
ECM supply voltage check

4. Turn the keyswitch OFF.
Disconnect the power connector from the ECM.
Measure the supply voltage to the ECM:
• Measure the voltage between pin 3 (+) and pin 1

(-) on the connector.
position and in the START position.

voltage.
RCSC05CDC181AAA 4
position, repair or replace the vehicle harness.
Check the battery connections and fused power.
Check engine operation.
Engine speed check

Use INSITE® to monitor engine speed while

cranking the engine.
Engine cranking speed must be greater than 150

RPM.
If the engine cranking speed is below specification,

check the batteries and starting motor. Refer
to “engine will not crank or cranks slowly”
troubleshooting table at STARTING SYSTEM -
RCPH05CDC325ABA 5
3 15/11/2005
B.80.A / 5
Fuel rail sensor check




psi), replace the pressure sensor. Refer to Sensing
system Pressure sensor - Remove (B.20.A.95.81
- F.10.A.10).

RCPH05CDC325ABA 6
Fuel rail pressure check

Check fuel rail pressure while cranking the engine:
• Attempt to start the engine by engaging the starting

motor for at least 30 continuous seconds.
• Use INSITE® to monitor fuel rail pressure
(measured) and fuel rail pressure (commanded)
while cranking.
• Use INSITE® to read any fault codes which
become active.
Attempting to start the engine for 30 seconds allows

the fault code logic time to run. If fault code 2215
becomes active, fuel rail pressure is NOT being
RCPH05CDC325ABA 7
developed. Go to Step 8.
If the engine starts during this attempt, fuel prime to

the high pressure pump may have been temporarily
lost. Check for loose or damaged fuel lines and
fuel connectors or loose filters that are preventing
proper priming of the high pressure pump. Continue
with Step 10 if this does not resolve the problem.
3 15/11/2005
B.80.A / 6

8. Measure the fuel gear pump output pressure while

If fuel gear pump pressure is GREATER than

69 kPa (10 psi) while cranking, use the guided
troubleshooting for fault code xxx to resolve the
problem.
If fuel gear pump pressure is LESS than 69 kPa (10

psi) while cranking, go to Step 9.
RCPH05CDC109ABA 8
Priming pump pressure check

9. Measure the priming pump output pressure.
Refer to Priming pump - Pressure test (B.20.A.35

- F.40.C.30).
If the priming pump pressure is GREATER than 34

kPa (5 psi), replace the gear pump. Refer to High
pressure common rail Gear pump - Remove
(B.20.A.30.10 - F.10.A.10).
If the priming pump pressure is LESS than 34 kPa

(5 psi), verify fuel priming to the gear pump:
• Check that the pre-filter is full of fuel.

• Check that air is purged from the filter and low
pressure fuel lines. RCPH05CDC121ABA 9
• Perform the INSITE® lift pump override test if
necessary.
If the low pressure fuel system is primed, replace

the priming pump. Check engine operation.
Fault code check

Turn keyswitch ON.
Use INSITE® to read fault code information. Check

for fault codes that come active during a failed start
attempt that may cause of a no-start condition.
If fault codes become active during cranking

which may cause a no-start condition, follow the
guided troubleshooting for the faults. Check engine
operation.
If no relevant fault codes become active, continue

with the next sequence in the low performance tree.
RCPH05CDC325ABA 10
3 15/11/2005
B.80.A / 7

3 15/11/2005
B.80.A / 8
STARTING SYSTEM - Check (B.80.A - F.40.A.11)

2388, 2377
Starting aids check

1. Turn the keyswitch ON.
Verify the operation of the cold weather starting

aids – the intake manifold grid heater and the block
heater, if equipped.
Refer to Cold start aid Grid heater - Remove

(B.80.A.30.40 - F.10.A.10).
Refer to Cold start aid Engine heater - Remove

(B.80.A.30.83 - F.10.A.10).
RCPH05CDC708AAA 1
Low pressure fuel line check

2. Verify that the low pressure fuel lines are routed
correctly at the engine control module (ECM) cooling
plate. The lines can be installed improperly.
The upper connection (A) to the cooling plate must

be the fuel supply line from the fuel tank (via the
supply manifold where applicable).
The lower connection (B) must be the outlet line to

the gear pump.
NOTE: Check these connections if the low pressure lines
have been removed and reinstalled on the engine.
RCSC05CDC180AAA 2
3 15/11/2005
B.80.A / 9
ECM keyswitch voltage check

3. Disconnect the vehicle connector from the engine
Check the ECM keyswitch voltage:
• Measure the signal voltage from the keyswitch

between pin 39 of the vehicle connector and engine
block ground.
position and then in the START position.

voltage. RCSC05CDC182AAA 3

position, repair or replace the vehicle harness or the
keyswitch. Check the battery connections. Check
engine operation.
ECM supply voltage check

4. Turn the keyswitch OFF.
Disconnect the power connector from the ECM.
Measure the supply voltage to the ECM:
• Measure the voltage between pin 3 (+) and pin 1

(-) on the connector.
position and in the START position.

voltage.
RCSC05CDC181AAA 4
position, repair or replace the vehicle harness.
Check the battery connections and fused power.
Engine speed check

Use INSITE® to monitor engine speed while

Engine cranking speed must be greater than 150

RPM.
If the engine cranking speed is below specification,

check the batteries and starting motor. Refer
to “engine will not crank or cranks slowly”
troubleshooting table at STARTING SYSTEM -
RCPH05CDC325ABA 5
3 15/11/2005
B.80.A / 10
Fuel rail sensor check




psi), replace the pressure sensor. Refer to Sensing
system Pressure sensor - Remove (B.20.A.95.81
- F.10.A.10).

RCPH05CDC325ABA 6
Fuel rail pressure check

Check fuel rail pressure while cranking the engine:
• Attempt to start the engine by engaging the starting

motor for at least 30 continuous seconds.
• Use INSITE® to monitor fuel rail pressure
(measured) and fuel rail pressure (commanded)
while cranking.
• Use INSITE® to read any fault codes which
become active.
Attempting to start the engine for 30 seconds allows

the fault code logic time to run. If fault code 2215
becomes active, fuel rail pressure is NOT being
RCPH05CDC325ABA 7
developed. Go to Step 8.
If the engine starts during this attempt, fuel prime to

the high pressure pump may have been temporarily
lost. Check for loose or damaged fuel lines and
fuel connectors or loose filters that are preventing
proper priming of the high pressure pump. Continue
with Step 10 if this does not resolve the problem.
3 15/11/2005
B.80.A / 11

8. Measure the fuel gear pump output pressure while

If fuel gear pump pressure is GREATER than

69 kPa (10 psi) while cranking, use the guided
troubleshooting for fault code xxx to resolve the
problem.
If fuel gear pump pressure is LESS than 69 kPa (10

psi) while cranking, go to Step 9.
RCPH05CDC234ABA 8
Fuel transfer pump pressure check

9. Measure the fuel transfer pump output pressure.
Refer to Fuel transfer pump - Pressure test

(B.20.A.34 - F.40.C.30).
If the priming pump pressure is GREATER than 34

kPa (5 psi), replace the gear pump. Refer to High
pressure common rail Gear pump - Remove
(B.20.A.30.10 - F.10.A.10).
If the priming pump pressure is LESS than 34 kPa

(5 psi), verify fuel priming to the gear pump:
• Check that the pre-filter is full of fuel.

• Check that air is purged from the filter and low
pressure fuel lines. RCPH05CDC238ABA 9
• Perform the INSITE® lift pump override test if
necessary.
If the low pressure fuel system is primed, replace

the priming pump. Check engine operation.
Fault code check

Turn keyswitch ON.
Use INSITE® to read fault code information. Check

for fault codes that come active during a failed start
attempt that may cause of a no-start condition.
If fault codes become active during cranking

which may cause a no-start condition, follow the
guided troubleshooting for the faults. Check engine
operation.
If no relevant fault codes become active, continue

with the next sequence in the low performance tree.
RCPH05CDC325ABA 10
3 15/11/2005
B.80.A / 12

3 15/11/2005
B.80.A / 13
Cold start aid Grid heater - Remove (B.80.A.30.40 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Disconnect the batteries. Refer to the chassis repair

manual.
WARNING
M1001 - Batteries can emit explosive gases. To
reduce the possibility of personal injury, always
ventilate the battery compartment before servicing
the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach
the negative (-) battery cable last. Wash your hands
after handling battery components.
2. Use compressed air or a power washer as required

to thoroughly clean the area around the intake
manifold before opening the air intake system.
WARNING
WARNING
3. Remove the two nuts to disconnect the vehicle

harness to the grid heater.
RCPH05CDC706AAA 1
3 15/11/2005
B.80.A / 14
4. If required, remove the elbow connector to the

intake manifold connector (A) by removing the lower
and upper clamp.
RCPH05CDC707AAA 2
5. Remove the four cap screws securing the air

connector (A) and grid heater (B) to the intake
manifold.
NOTE: The fourth cap screw is hidden behind the
connector.
RCPH05CDC716AAA 3
6. Remove the grid heater assembly and both gaskets

– the grid heater to connector gasket and the grid
heater to intake manifold cover gasket.
RCPH05CDC715AAA 4
7. If the intake manifold will be exposed for a prolonged

time, use tape to seal the manifold cover.
Next operation: Cold start aid Grid heater - Visual inspection (B.80.A.30.40 - F.40.A.10)
3 15/11/2005
B.80.A / 15
Cold start aid Grid heater - Visual inspection (B.80.A.30.40 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
1. Remove the top and bottom gaskets from the grid

heater.
RCPH05CDC709AAA 1
2. Clean the sealing surfaces on the grid heater, the

air connector to the heater and the intake manifold
cover.
RCPH05CDC708AAA 2
3. Inspect the grid heater for damage.
Next operation: For grid heater repair, see Cold start aid Grid heater - Disassemble (B.80.A.30.40 - F.10.A.25)
Next operation: For grid heater installation, see Cold start aid Grid heater - Install (B.80.A.30.40 - F.10.A.15)
3 15/11/2005
B.80.A / 16
Cold start aid Grid heater - Disassemble (B.80.A.30.40 - F.10.A.25)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cold start aid Grid heater - Visual inspection (B.80.A.30.40 - F.40.A.10)
1. The grid heater contains an upper and lower heating

element. Note the location of the fiber washer (A),
metal washer (B) and insulator (C) as the hardware
for each element is removed.
RCPH05CDC713AAA 1
2. Remove the hardware (A) on both sides of the

upper heater element (B), and remove the element.
RCPH05CDC714AAA 2
3. Remove the hardware (A) on both sides of the lower

heater element (B), and remove the element.
RCPH05CDC712AAA 3
3 15/11/2005
B.80.A / 17
4. Inspect all components and replace as required.
RCPH05CDC710AAA 4
Next operation: Cold start aid Grid heater - Assemble (B.80.A.30.40 - F.10.A.20)
3 15/11/2005
B.80.A / 18
Cold start aid Grid heater - Assemble (B.80.A.30.40 - F.10.A.20)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cold start aid Grid heater - Disassemble (B.80.A.30.40 - F.10.A.25)
1. Install the fiber washer (A) to the inside of the heater

body on both heater elements.
RCPH05CDC713AAA 1
2. Install the lower heater element.
RCPH05CDC712AAA 2
3. Install the upper heater element.
RCPH05CDC714AAA 3
3 15/11/2005
B.80.A / 19
Cold start aid Grid heater - Install (B.80.A.30.40 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cold start aid Grid heater - Visual inspection (B.80.A.30.40 - F.40.A.10)
Prior operation: Cold start aid Grid heater - Assemble (B.80.A.30.40 - F.10.A.20)
1. Install a new gasket on the bottom and top of the

grid heater.
RCPH05CDC709AAA 1
2. Install the heater assembly.
RCPH05CDC715AAA 2
3. Install the four cap screws. Torque the cap screws

RCPH05CDC716AAA 3
3 15/11/2005
B.80.A / 20
4. Connect the power harness to the grid heater.
RCPH05CDC706AAA 4
5. If required, install the elbow connection on the

intake manifold connector with the original clamps.
RCPH05CDC707AAA 5
Next operation: Reconnect the batteries. See the chassis repair manual.
3 15/11/2005
B.80.A / 21
Cold start aid Engine heater - Remove (B.80.A.30.83 - F.10.A.10)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
WARNING
WARNING
Prior operation: Drain at least 19 L (5 US gal) of coolant. See ENGINE COOLANT SYSTEM - Emptying (B.50.A -
F.35.A.01).
1. Disconnect the power cord to the block heater.
RCPH05CDC189ABA 1
2. Remove the block heater from the block.
RCPH05CDC190ABA 2
Next operation: Cold start aid Engine heater - Visual inspection (B.80.A.30.83 - F.40.A.10)
3 15/11/2005
B.80.A / 22
Cold start aid Engine heater - Visual inspection (B.80.A.30.83 -

F.40.A.10)
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cold start aid Engine heater - Remove (B.80.A.30.83 - F.10.A.10)
1. Clean the threads for the heater in the block.
RCPH05CDC193ABA 1
2. Inspect the heater for damage.
RCPH05CDC191ABA 2
Next operation: Cold start aid Engine heater - Install (B.80.A.30.83 - F.10.A.15)
3 15/11/2005
B.80.A / 23
Cold start aid Engine heater - Install (B.80.A.30.83 - F.10.A.15)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
Prior operation: Cold start aid Engine heater - Visual inspection (B.80.A.30.83 - F.40.A.10)
1. Apply pipe sealant to the threads on the heater.
RCPH05CDC192ABA 1
2. Install the heater in the block.
RCPH05CDC195ABA 2
3. Torque to 75 Nm (55 lb ft).
RCPH05CDC194ABA 3
3 15/11/2005
B.80.A / 24
4. Connect the electrical cord.
RCPH05CDC189ABA 4
3 15/11/2005
B.80.A / 25
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30)

MX215, MX245, MX275, MX305, STX280, 2388, 2377
OPERATION
Refer to the chassis service for a dynamic description of the starting control system.
TROUBLESHOOTING
WARNING

Engine will not crank or Step 1: Check the batteries and the unswitched
cranks slowly Battery voltage is low. battery supply circuit.
Refer to STARTING SYSTEM - Check

(B.80.A - F.40.A.11) for testing the battery
supply circuit.
Step 2: Check the battery cables and connections.
Battery cables or connections are loose,
broken or corroded.
Step 3: Replace the batteries.
Battery capacity is below specification.
Step 4: Replace the battery cables with larger
Battery cables are NOT the correct gauge gauge or shorter length.
or length (too long).
Step 5: Refer to the chassis repair manual.
Starter interlock devices engaged or
malfunctioning.
Step 6: Check the oil pressure sensor.
Lubricating oil pressure sensor is
malfunctioning or is NOT in the correct Refer to Sensing system Oil pressure -
location. Test (B.60.A.95.91 - F.40.C.01).
Step 7: Check the starting circuit components.
Starting circuit component is Refer to the chassis repair manual.
malfunctioning.
3 15/11/2005
B.80.A / 26

Step 8: Remove the starting motor and inspect the
Starting motor pinion or ring gear is gear. Refer to the chassis repair manual
damaged. for instructions.
Lubricating oil level is above specification. calibration and oil pan capacity. Adjust
level to meet specification.
Lubricating oil does NOT meet
specifications for operating conditions.
Step 11: Check the crankshaft for ease of rotation.
Crankshaft rotation is impaired. Use the engine barring tool to rotate the
engine.
Step 12: Remove the injectors and rotate the
Cylinder is hydraulically locked by fluid. crankshaft. Look for the source of the fluid
in the cylinder.
Refer to Fuel injector - Remove

(B.20.A.29 - F.10.A.10).
Internal engine damage. an area of probable damage.

(B.60.A.24 - F.40.A.10).
Engine will not shut off. Step 1: Check the vehicle keyswitch circuit. Refer
Keyswitch circuit is malfunctioning. to the chassis repair manual.
See also STARTING SYSTEM - Check

(B.80.A - F.40.A.11).
Step 2: Check operation of the grid heater and
Starting aid is malfunctioning. block heater.
Refer to Cold start aid Grid heater -

Remove (B.80.A.30.40 - F.10.A.10).
Refer to Cold start aid Engine heater -

Remove (B.80.A.30.83 - F.10.A.10).
Turbocharger oil seal is leaking. turbine oil seals.
Refer to Turbocharger - Preliminary test

(B.30.A.31 - F.40.A.20).
Step 4: Check the air intake ducts. Locate and
Engine is running on fumes drawn into the isolate the source of the fumes. Repair as
air intake. required.
Step 5: Replace the ECM.
Electronic control module (ECM) is
malfunctioning. Refer to Electronic control - Check
(B.10.A.92 - F.40.A.11).
3 15/11/2005
B.80.A / 27
Index

Cold start aid Engine heater - Install (B.80.A.30.83 - F.10.A.15) 24
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Remove (B.80.A.30.83 - F.10.A.10) 22
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Torque (B.80.A.30.83 - D.20.A.10) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Engine heater - Visual inspection (B.80.A.30.83 - F.40.A.10) 23
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Assemble (B.80.A.30.40 - F.10.A.20) 19
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Disassemble (B.80.A.30.40 - F.10.A.25) 17
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Install (B.80.A.30.40 - F.10.A.15) 20
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Remove (B.80.A.30.40 - F.10.A.10) 14
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Torque (B.80.A.30.40 - D.20.A.10) 3
MX215, MX245, MX275, MX305, STX280, 2388, 2377
Cold start aid Grid heater - Visual inspection (B.80.A.30.40 - F.40.A.10) 16
MX215, MX245, MX275, MX305, STX280, 2388, 2377
MX215, MX245, MX275, MX305, STX280
2388, 2377
STARTING SYSTEM - Problem solving (B.80.A - G.40.A.30) 26
MX215, MX245, MX275, MX305, STX280, 2388, 2377
87372074 3 15/11/2005
B.80.A / 28
87372074 3 15/11/2005
B.80.A / 29
CNH America LLC 700 STATE STREET RACINE, WI 53404 - U.S.A
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2005 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASEIH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notice is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASEIH Dealer.
87372074 3 15/11/2005
87372074 3 15/11/2005
CNH America LLC 700 STATE STREET RACINE, WI 53404 - U.S.A
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2005 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASEIH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notice is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASEIH Dealer.
87372074 3 15/11/2005

Engine Repair PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine Repair PDF

Uploaded by

Copyright:

Available Formats

REPAIR MANUAL

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280

Safety rules ( - A.50.A.10) 3

Basic instructions ( - A.90.A.05) 4

Conversion factors ( - A.92.A.21) 13

Product identification ( - A.80.A.10) 14

Safety rules ( - A.50.A.10)

General safety precautions

Basic instructions ( - A.90.A.05)

Abrasive pads and abrasive paper

Solvents and acid cleaning

The following components should NEVER be steam cleaned:

– electrical components – belts and hoses

Plastic bead cleaning

• Use plastic bead size 16-20 (U.S. size) or equivalent.

Cap screw marking and torque value – Metric

rh04h178 1 rh04h179 2 rh04h180 3

Cap screw marking and torque value – U.S. Customary

Cast iron Aluminum Cast iron Aluminum

Pipe plug torque values

Newton-meter to pound-foot conversion

Surface distress: conditional reuse

Major surface distress: no reuse

Conversion factors ( - A.92.A.21)

Weights and measures

Product identification ( - A.80.A.10)

A — Engine data plate

1 — Engine serial number (ESN)

P/N — Part number

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280

FUEL AND INJECTION SYSTEM B.20.A

AIR INTAKE SYSTEM B.30.A

EXHAUST SYSTEM B.40.A

ENGINE COOLANT SYSTEM B.50.A

LUBRICATION SYSTEM B.60.A

STARTING SYSTEM B.80.A

2377 , 2388 , MX215 , MX245 , MX275 , MX305 , STX280

ENGINE - General specification (B.10.A - D.40.A.10) 12

Valve drive Rocker assembly - Service limits (B.10.A.40.43 - D.20.A.20) 13

Valve drive Rocker assembly - Special tools (B.10.A.40.43 - D.20.A.40) 13

Rocker assembly Housing - Torque (B.10.A.40.43.05 - D.20.A.10) 14

Rocker assembly Rocker arm - Service limits (B.10.A.40.43.10 - D.20.A.20) 14

Rocker assembly Shaft - Service limits (B.10.A.40.43.20 - D.20.A.20) 15

Valve drive Camshaft - Torque (B.10.A.40.44 - D.20.A.10) 15

Valve drive Camshaft - Service limits (B.10.A.40.44 - D.20.A.20) 16

Valve drive Camshaft - Special tools (B.10.A.40.44 - D.20.A.40) 17

Camshaft Gear - Service limits (B.10.A.40.44.10 - D.20.A.20) 18

Camshaft Tappet - Service limits (B.10.A.40.44.25 - D.20.A.20) 19

Camshaft Bushing - Service limits (B.10.A.40.44.30 - D.20.A.20) 21

Camshaft Bushing - Special tools (B.10.A.40.44.30 - D.20.A.40) 22

Camshaft Journal - Service limits (B.10.A.40.44.35 - D.20.A.20) 22

Camshaft Lobe - Service limits (B.10.A.40.44.40 - D.20.A.20) 22

Valve assembly Valve - Service limits (B.10.A.40.46.10 - D.20.A.20) 26

Valve assembly Valve - Special tools (B.10.A.40.46.10 - D.20.A.40) 26

Valve assembly Spring - Service limits (B.10.A.40.46.15 - D.20.A.20) 27

Valve assembly Spring - Special tools (B.10.A.40.46.15 - D.20.A.40) 27

Crankshaft - Special tools (B.10.A.43 - D.20.A.40) 29

Crankshaft Front seal - Torque (B.10.A.43.01 - D.20.A.10) 30

Crankshaft Front seal - Special tools (B.10.A.43.01 - D.20.A.40) 30

Crankshaft Rear seal - Special tools (B.10.A.43.02 - D.20.A.40) 31

Crankshaft Front wear sleeve - Special tools (B.10.A.43.05 - D.20.A.40) 31

Crankshaft Rear wear sleeve - Special tools (B.10.A.43.06 - D.20.A.40) 32

Crankshaft Gear - Service limits (B.10.A.43.10 - D.20.A.20) 32