N14 Repair Manual 3666142-Vol1

Cummins Inc.
Troubleshooting and Repair Manual
Celect™, Celect Plus™ Volume 1

Troubleshooting and Repair Manual N14 Base Engine STC,
Box 3005
Columbus, Indiana, U.S.A., 47202 N14 Base Engine STC, Celect™, Celect Plus™
Registered Office Volume 1
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2010
Cummins Inc.
Bulletin 3666142
Printed in U.S.A. 06-APRIL-2010 p15
301657_Cummins_Vol1.indd 1 4/9/10 12:59 PM

N14 Base Engine STC, Celect™, Celect Plus™
Volume 1
Copyright© 2010 Bulletin 3666142

Cummins Inc. Printed 06-APRIL-2010
All rights reserved
Foreword
This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and
assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions
on how to use this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in
Service Literature (Section L).
The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the
use of special service tools. Use the correct tools as described.
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual are based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.
Table of Contents
Section
Introduction .............................................................................................................................................. i
Engine Identification ................................................................................................................................ E
Familiarization .......................................................................................................................................... F
Troubleshooting Symptoms ..................................................................................................................... TS
Complete Engine - Group 00 .................................................................................................................... 0
Cylinder Block - Group 01 ........................................................................................................................ 1
Cylinder Head - Group 02 ......................................................................................................................... 2
Rocker Levers - Group 03 ........................................................................................................................ 3
Cam Followers/Tappets - Group 04 ......................................................................................................... 4
Fuel System - Group 05 ........................................................................................................................... 5

N14
Section i - Introduction Page i-a
Section i - Introduction
Section Contents
Page
About the Manual ...............................................................................................................................................i-1
General Information...........................................................................................................................................i-1
Acronyms and Abbreviations ...........................................................................................................................i-14
General Information..........................................................................................................................................i-14
General Cleaning Instructions ...........................................................................................................................i-9
Abrasive Pads and Abrasive Paper.....................................................................................................................i-9
Definition of Clean..............................................................................................................................................i-9
Fuel System.....................................................................................................................................................i-12
Gasket Surfaces...............................................................................................................................................i-10
Plastic Bead Cleaning......................................................................................................................................i-11
Solvent and Acid Cleaning................................................................................................................................i-10
Steam Cleaning................................................................................................................................................i-11
General Repair Instructions ...............................................................................................................................i-7
Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-8
General Safety Instructions ...............................................................................................................................i-5
Important Safety Notice......................................................................................................................................i-5
How to Use the Manual ......................................................................................................................................i-2
Illustrations .........................................................................................................................................................i-4
Symbols ..............................................................................................................................................................i-3
N14
Page i-b Section i - Introduction
This Page Left Intentionally Blank

N14 About the Manual
Section i - Introduction Page i-1
About the Manual

General Information
This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and
to provide recommended repair procedures.
The manual is divided into sections. Each section is equivalent to a group used in Cummins' filmcard system. Some
sections contain reference numbers and procedure numbers. Reference numbers provide general information,
specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference
specific repair procedures for correcting the problem.
This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual,
if there are no electronic fault codes.
This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The
troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are
in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be
performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the
back of the manual to locate specific topics when not using the troubleshooting trees.
How to Use the Manual N14
Page i-2 Section i - Introduction
How to Use the Manual

General Information
This manual is organized to provide an easy flow from problem identification to problem correction.
A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms,
Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and
directing the end user to the correct procedure for making the repair. Complete the following steps to locate and
correct the problem.
1 Locate the symptom on the Section Contents pages of Section TS.
• Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the
symptom tree title.
3 The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the problem,
starting at the top with the simplest and easiest to repair, and continuing downward to the most difficult.
• The right column of boxes provides a brief description of the corrective action with a reference number to the
correct procedure used to make the repair.
5 Locate the probable cause in the left column then turn to the procedure referenced in the right column.
6 The Troubleshooting Symptom Charts are based on the following assumptions:
• The engine has been installed according to the manufacturer's specifications.
• The easiest repairs are done first.
• "Generic" solutions to cover problems with the most common applications and Original Equipment
Manufacturer (OEM).
Refer to the OEM service manual for OEM specifications.
This manual is divided into the same group system used for previous manuals and the Cummins' filmcard system.
Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical
sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired
information.
The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals
and the Cummins' filmcard system.
Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical
sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired
information.
Each section contains the following in sequence:
• Table of Contents
• Required Service Tool Listings
• General Information containing the basic service, maintenance, design and revision information necessary to assist
in the rebuild of an engine or a component
• Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild
an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included.
These procedures depend on the length of time an engine has been in service and the conditions of the parts.
All the procedures are identified with a name and a number. Each digit in the procedure number has a specific
meaning.
The first three digits of the number refer to the specific section that the procedure can be found within the manual. In
this example, “001” represents Section 01 - Cylinder Block. This number will range from 000 to 022.
The second three digits of the number are unique and refer to a specific subject. In this example, “028” represents
Cylinder Liner. This number will range from 001 to 999.
Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications
and torque values for each engine system are given in that section.
NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject
to a penalty of various monetary charges. Dispose of these substances in accordance with standards set by the EPA.
N14 Symbols
Symbols
General Information
The following symbols have been used in this manual to help communicate the intent of the instructions. When one
of the symbols appears, it conveys the meaning defined below:
Illustrations N14
Illustrations
General Information
Some of the illustrations throughout this manual are
generic and will not look exactly like the engine or parts
used in your application. The illustrations can contain
symbols to indicate an action required and an acceptable
or not acceptable condition.
The illustrations are intended to show repair or

replacement procedures. The procedure will be the same
for all applications, although the illustration can differ.
N14 General Safety Instructions
General Safety Instructions

Important Safety Notice
WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation
or other personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included
in the procedures when they apply.
• Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition
sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in
the operator's compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or
damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler
cap to relieve the pressure from the cooling system.
• Always use blocks or proper stands to support the product before performing any service work. Do not work on
anything that is supported ONLY by lifting jacks or a hoist.
• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed
or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid
refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be
properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capturing and recycling refrigerant.
• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23
kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of
the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The
lifting hooks must not be side-loaded.
• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes.
Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash
skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum
of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compartments.
• Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any service work. Use ONLY genuine Cummins® or Cummins ReCon® replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lesser quality if replacements are necessary.
• When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts
should only be carried out be a trained technician. Before removing any guards the engine must be turned off and
any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
General Safety Instructions N14
• Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
• Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.
• Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening
can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.
• Always test for fuel leaks as instructed, as odorant can fade.
• Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
• The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood
eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent
is ingested, contact a physician immediately.
• The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly.
Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of
water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin
with soap and water.
• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.
• California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
N14 General Repair Instructions
General Repair Instructions

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

- Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of
the engine. Some solvents and used engine oil have been identified by government agencies as toxic or
carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety
practices with tools and equipment.
• Provide a clean environment and follow the cleaning instructions specified in the procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine or components
will cause premature wear.
• Perform the inspections specified in the procedures
• Replace all components or assemblies which are damaged or worn beyond the specifications
• Use genuine Cummins new or ReCon® service parts and assemblies
- The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or
Cummins ReCon® components. All of the repair services described in this manual are available from all Cummins
Distributors and most Dealer locations.
• Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components
General Repair Instructions N14
Welding on a Vehicle with an Electronic Controlled Fuel System

CAUTION
Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the
vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not
connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine
mounted components is not recommended or damage to the engine or components can result.
N14 General Cleaning Instructions
General Cleaning Instructions

Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to
appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming
a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are
designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are
those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a
metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better
removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air
sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent
sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in
place a long time, has been overheated or the purpose of the release agent has been defeated by the application of
some sealant. The object however is just to remove the gasket without damaging the surfaces of the mating parts
without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon
build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning
later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal
is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be
destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium
bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and
there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are
more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible,
leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any
attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure
parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between
moving parts (or a good lube system priming process conducted before cranking the engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again
so all that needs happen is remove any loose paint.
Abrasive Pads and Abrasive Paper
The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all
supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material
in oil passages can cause bearing and bushing failures that can progress to major component damage beyond
reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled
engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles,
silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the
engine. Since they are harder, if they are pressed against softer material they will either damage the material or
become embedded in it. These materials fall off the holding media as the product is used. If the products are used
with power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage
to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger
than the running clearance then damage will occur when the parts move relative to each other (engine started). While
the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance
will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will
General Cleaning Instructions N14
abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades
the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine
as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with
compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket
surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket
surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which
can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary
because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much
of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination
of the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use
compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be
blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the
case when dealing with an assembled engine.
Gasket Surfaces
The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used,
check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of
the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered
gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See
Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90° to 95°
Celsius (180° to 200° Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.
Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the
parts before putting them in the cleaning tank.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners
should not be heated to temperature in excess of 77°C (170°F). The solution begins to break down at temperatures
in excess of 82°C (180°F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components.
They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline
solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away
from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high
pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method
for cleaning the oil drillings and coolant passages
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Do not steam clean the following components:
• Electrical Components
• Wiring Harnesses
• Injectors
• Fuel Pump
• Belts and Hoses
• Bearings (ball or taper roller)
• Electronic Control Module (ECM)
• ECM Connectors
• Dosing Control Unit
• NOx Sensor.
Plastic Bead Cleaning
Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins
Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use
sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media manufacturer's
recommendations can cause excess dust and can embed in engine parts that can result in premature failure of
components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and cleaning time.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result
in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.,
can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any
bead blasting media on piston pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and
cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
1. Bead size: U.S. size Number 16 — 20 for piston cleaning with plastic bead media, Part Number 3822735
2. Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
General Cleaning Instructions N14
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too
high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased
above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean
engine parts due to the risk media embedment and subsequent contamination of the engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily
embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's
recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in
contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats
easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water)
is used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may
remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure
washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then
use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of
damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are
dry and oil free before bead blasting to prevent clogging the return on the blasting machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the
unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place
too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or
carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough
movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across
the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing
to blast to remove the stain is a waste of time.
Fuel System
When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly,
clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas
are not cleaned, dirt or contaminants can be introduced into the fuel system.
The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some
fuel injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and
rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.
Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather
than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts
attracts airborne contaminants.
Choose lint free towels for fuel system work.
Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the
fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a
good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.
When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/
chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.
Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter.
The micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human
hair is 0.003 mm [3/1000 in] in diameter. One micron measures 0.00004 mm [4/100,000 in]. The contaminants being
filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.
The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:
• Fuel system tools are to be kept as clean as possible.

• Clean and dry the tools before returning them to the tool box.
• If possible, store fuel system tools in sealed containers.
• Make sure fuel system tools are clean before use.
Acronyms and Abbreviations N14
Acronyms and Abbreviations

General Information
The following list contains some of the acronyms and abbreviations used in this manual.
API American Petroleum Institute
ASTM American Society of Testing and Materials
BTU British Thermal Unit
BTDC Before Top Dead Center
°C Celsius
CO Carbon Monoxide
CCA Cold Cranking Amperes
CARB California Air Resources Board
C.I.B. Customer Interface Box
C.I.D. Cubic Inch Displacement
CNG Compressed Natural Gas
CPL Control Parts List
cSt Centistokes
DEF Diesel Exhaust Fluid
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency
°F Fahrenheit
ft-lb Foot-Pound Force
FMI Failure Mode Indentifier
GVW Gross Vehicle Weight
Hg Mercury
hp Horsepower
H2O Water
inHg Inches of Mercury
in H20 Inches of Water
ICM Ignition Control Module
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling
MIL Malfunction Indicator Lamp
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
N•m Newton-meter
NOx Mono-Nitrogen Oxides
NG Natural Gas
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer
PID Parameter Identification Descriptions
ppm Parts Per Million
N14 Acronyms and Abbreviations
psi Pounds Per Square Inch

PTO Power Takeoff
RGT Rear Gear Train
rpm Revolutions Per Minute
SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
SCR Selective Catalytic Reduction
STC Step Timing Control
SID Subsystem Identification Descriptions
VDC Volts of Direct Current
VS Variable Speed
VSS Vehicle Speed Sensor
Acronyms and Abbreviations N14
Notes
N14
Section E - Engine Identification Page E-a
Section E - Engine Identification

Section Contents
Page
Engine Diagrams ...............................................................................................................................................E-3
Engine Views....................................................................................................................................................E-3
Engine Identification .........................................................................................................................................E-1
Cummins® Engine Nomenclature......................................................................................................................E-2
ECM Dataplate.................................................................................................................................................E-1
CELECT™ Plus...............................................................................................................................................E-1
CENTRY™......................................................................................................................................................E-1
Engine Brake System.......................................................................................................................................E-2
Engine Dataplate..............................................................................................................................................E-1
Fuel Pump Dataplate........................................................................................................................................E-2
N14
Page E-b Section E - Engine Identification

N14 Engine Identification
Section E - Engine Identification Page E-1
Engine Identification
Engine Dataplate
The engine dataplate provides the model identification
and other important information about the engine.
The engine serial number and CPL provides data for
ordering parts and service.
The dataplate is located on the fuel pump side of engine
on the rocker lever housing.
The following information on the dataplate is mandatory

when sourcing service parts.
(1) Engine Serial Number
(2) Control Parts List
(3) Model.
ECM Dataplate
CELECT™ Plus
On CELECT™ Plus engines, the ECM dataplate is located
on the top of the ECM.
The abbreviations in the accompanying are explained as
follows:
P/N = part number
S/N = serial number
D/C = date code.
CENTRY™
The CENTRY™ system ECM dataplate is located on the
front of the ECM and contains the following information:
P/N = part number
S/N = serial number
D/C = date code (date ECM was manufactured)
ESN = engine serial number
ECM CODE = ECM calibration identifier.
Engine Identification N14
Page E-2 Section E - Engine Identification
Fuel Pump Dataplate

On STC engines the fuel pump dataplate is located on the
top of the fuel pump.
The fuel pump dataplate provides information for
calibration.
Engine Brake System

On engines equipped with engine brakes, the engine
brake dataplate is located on the exhaust side of the
engine brake housing.
Always record the brake model number and assembly
number on all parts orders.
Cummins® Engine Nomenclature

The Cummins® engine nomenclature provides the data as
illustrated in the graphic.
The following letters designate some of the different
applications for a Cummins® engine.
A = agriculture
C = construction
G = generator drive
M = marine.
N14 Engine Diagrams
Engine Diagrams
Engine Views
The illustrations that follow show the locations of the major external engine components, the filters, and other service
and maintenance points. Some external components will be at different locations for different engine models.
Engine Diagrams N14
Engine Diagrams
Engine Views
PT®-STC Industrial Engines (Fuel Pump Side)

1. PT® fuel pump 4. Lubricating oil pump
2. Aftercooler 5. Fuel filter.
3. STC valve
N14 Engine Diagrams
Engine Diagrams
Engine Views
PT®-STC Industrial Engines (Exhaust Side)

1. Oil cooler 8. Coolant filter
2. Turbocharger 9. Combination filter
3. Engine water outlet (to radiator) 10. Oil drain
4. Thermostat housing 11. Starting motor
5. Exhaust manifold 12. Dipstick
6. Remote filter bypass supply 13. Piston cooling nozzle.
7. Engine water inlet (from radiator)
Engine Diagrams N14
Engine Diagrams
Engine Views
CENTRY™ Engines (Fuel Pump Side)

1. Fuel shutoff valve 9. Rail pressure sensor and fuel block
2. Air-fuel control sensing line 10. Hydromechanical STC actuator
3. 5-amp fuses 11. Engine-side datalink connector
4. System ground connector 12. Engine harness
5. OEM C5 and C6 connector bracket 13. Fuel pump
6. Engine speed sensor 14. ECM
7. C5 connector 15. Electronic fuel control valve.
8. C6 connector
N14 Engine Diagrams
Engine Diagrams
Engine Views
CELECT™ Plus - Jacket Water Aftercooled Engines (Fuel Pump Side)

1. Compuchek® adapter fuel rail pressure 9. Fuel inlet fitting
2. Compuchek® adapter fuel inlet pressure 10. Starter motor
3. Aftercooler 11. Lubricating oil pressure sensor
4. Intake air temperature sensor 12. Fuel filter
5. Service tool datalink (engine mounted) 13. Lubricating oil temperature sensor
6. Intake manifold pressure sensor 14. Lubricating oil pump
7. Intake manifold 15. Engine position sensor (behind lubricating oil pump)
8. ECM 16. Fuel gear pump.
Engine Diagrams N14
Engine Diagrams
Engine Views
CELECT™ Plus - Jacket Water Aftercooled Engines (Exhaust Side)

1. Compuchek® adapter block pressure 10. Coolant filter
2. Turbocharger 11. Compuchek® adapter oil temperature
3. Coolant temperature sensor 12. Oil drain
4. Compuchek® adapter coolant temperature 13. Combination filter
5. Thermostat housing 14. Dipstick
6. Exhaust manifold 15. Compuchek® adapter flywheel ring gear sensor
7. Oil cooler 16. Compuchek® adapter oil rifle pressure
8. Compuchek® adapter water pump inlet pressure 17. Turbocharger oil supply check valve.
9. Engine water inlet (from radiator)
N14 Engine Diagrams
Engine Diagrams
Engine Views
CELECT™ Plus - Low Temperature Aftercooled Engines (Fuel Pump Side)

1. Aftercooler 4. Engine position sensor (behind lubricating oil pump
2. ECM 5. Fuel gear pump.
3. Fuel filter
Engine Diagrams N14
Engine Diagrams
Engine Views
CELECT™ Plus - Low Temperature Aftercooled Engines (Exhaust Side)

1. Turbocharger 8. Coolant filter
2. Engine water (aftercooler) outlet to front radiator 9. Combination filter
3. Engine water (jacket water) outlet to rear radiator 10. Dipstick
4. Thermostat housing 11. Oil drain
5. Exhaust manifold 12. Starting motor
6. Remote filter bypass supply 13. Piston cooling nozzle
7. Engine water inlet 14. Lubricating oil cooler.
N14 Engine Diagrams
Engine Diagrams
Engine Views
CELECT™ Plus - Charge Air Cooled Engines (Fuel Pump Side)

1. Compressor air discharge 11. Lubricating oil pressure sensor
2. Intake air temperature sensor 12. Fuel filter
3. Compuchek™ adapter intake manifold pressure (from 13. Compuchek® adapter fuel inlet pressure
charge air cooler) 14. Fuel gear pump
4. Engine-mounted service tool datalink 15. Lubricating oil pump
5. Intake manifold 16. Lubricating oil temperature sensor
6. Intake manifold pressure sensor 17. Air compressor
7. ECM 18. Engine piston sensor (behind lubricating oil pump)
8. Ambient air pressure sensor (when required) 19. Compuchek® adapter oil temperature
9. Fuel inlet fitting 20. Fuel temperature sensor.
10. Compuchek® adapter (oil rifle pressure)
Engine Diagrams N14
Engine Diagrams
Engine Views
CELECT™ Plus - Charge Air Cooled Engines (Exhaust Side)

1. Compuchek® adapter cycle event marker (behind 11. Turbocharger oil supply check valve (behind
breather tube) turbocharger)
2. Compuchek® adapter coolant temperature 12. Combination full-flow/bypass lubricating oil filter
3. Coolant temperature sensor 13. Oil drain
4. Engine water outlet (to radiator) 14. Compuchek® Adapter flywheel ring gear sensor
5. Thermostat housing 15. Dipstick
6. Compuchek® adapter water pump inlet pressure 16. Piston cooling nozzle
7. Oil cooler 17. Compuchek® adapter block pressure
8. Remote filter bypass supply 18. Turbocharger
9. Engine water outlet (from radiator) 19. Exhaust manifold.
10. Coolant filter
N14 Engine Diagrams
Engine Diagrams
Engine Views
Marine Engines (Port Side)

1. Coolant fill 7. Fuel filter
2. Aftercooler 8. Throttle lever
3. Air inlet piping 9. Front engine mount
4. Air cleaner 10. Sea water pump inlet
5. STC valve 11. Fuel pump.
6. Rear engine mount
Engine Diagrams N14
Engine Diagrams
Engine Views
Marine Engines (Starboard Side)

1. Aftercooler 9. Water filter (coolant)
2. Valve cover 10. Lubricating oil filter
3. Alternate oil fill 11. Oil filter
4. Coolant expansion tank 12. Dipstick
5. Heat exchanger 13. Starter
6. Thermostat housing 14. Rear engine mount
7. Sea water pump 15. Exhaust elbow.
8. Front engine mount
N14
Section F - Familiarization Page F-a
Section F - Familiarization
Section Contents
Page
Air Intake System - Overview .........................................................................................................................F-40
General Information........................................................................................................................................F-40
Complete Engine - Overview ............................................................................................................................F-1
General Information..........................................................................................................................................F-1
Compressed Air System - Overview ...............................................................................................................F-44
Cooling System - Overview ............................................................................................................................ F-31
Cylinder Block - Overview ................................................................................................................................F-1
Electrical Equipment - Overview .................................................................................................................... F-48
Engine Testing - Overview ..............................................................................................................................F-48
Fuel Flow Measurement on Engine or Chassis Dynamometer..........................................................................F-53
Operation.....................................................................................................................................................F-54
In Service Run-in..........................................................................................................................................F-49
Engine Dynamometer Run-in........................................................................................................................F-49
Cummins Heavy Duty Engine Operating Curve Definitions........................................................................... F-50
Run-In Instructions..........................................................................................................................................F-52
Flow Diagram, Air Intake System ...................................................................................................................F-41
Flow Diagram..................................................................................................................................................F-41
Flow Diagram, Compressed Air System .........................................................................................................F-45
Flow Diagram..................................................................................................................................................F-45
Flow Diagram, Cooling System ...................................................................................................................... F-32
Flow Diagram..................................................................................................................................................F-32
Flow Diagram, Exhaust System ......................................................................................................................F-43
Flow Diagram..................................................................................................................................................F-43
Flow Diagram, Fuel System ..............................................................................................................................F-8
Flow Diagram....................................................................................................................................................F-8
Flow Diagram, Lubricating Oil System ...........................................................................................................F-27
Flow Diagram..................................................................................................................................................F-27
Fuel System - Overview ....................................................................................................................................F-2
Installation Recommendations..........................................................................................................................F-5
Injectors and Fuel Lines - Overview ...............................................................................................................F-11
Theory of Operation - CELECT™ and CELECT™ Plus Fuel System...................................................................F-18
Hydromechanical Subsystem.......................................................................................................................F-20
Injection Cycle............................................................................................................................................. F-21
Theory of Operation - PT Fuel System.............................................................................................................F-11
Theory of Operation - STC Fuel System..........................................................................................................F-14
Lubricating Oil System - Overview .................................................................................................................F-26
N14
Page F-b Section F - Familiarization

N14 Cylinder Block - Overview
Section F - Familiarization Page F-1
Complete Engine - Overview (000-999)

General Information
WARNING
DO NOT OPERATE A DIESEL ENGINE WHERE THERE
ARE OR CAN BE COMBUSTIBLE VAPORS. These
vapors can be sucked through the air intake system
and cause engine acceleration and overspeeding that
can result in a fire, an explosion, and extensive
property damage. Numerous safety devices are
available, such as air intake shutoff devices, to
minimize the risk of overspeeding where an engine,
due to its application, might operate in a combustible
environment, such as due to a fuel spill or gas leak.
Remember, Cummins has no way of knowing the use
you have for your engine. THE EQUIPMENT OWNER
AND OPERATOR ARE RESPONSIBLE FOR SAFE
OPERATION IN A HOSTILE ENVIRONMENT.
CONSULT YOUR CUMMINS AUTHORIZED REPAIR
LOCATION FOR FURTHER INFORMATION.
The procedures required to replace an engine will vary
with different engine models, the type of equipment,
optional equipment, and the shop facilities. Use the
following procedures as a guide.
NOTE: All replacement steps will not apply to all types of
equipment. Complete only the steps which apply to the
equipment involved. Use the equipment manufacturer's
recommendations and precautions for removal of chassis
parts to gain access to the engine.
Cylinder Block - Overview (001-999)

General Information
Main bearing cap fretting is attributed to the failure of the main bearing capscrews to provide sufficient clamp load
for extreme duty cycles. Fretting at the block and main bearing cap interface results in an oval shape and an overall
decrease in the main bearing bore size. This decrease reduces the oil film thickness, which can lead to spun main
bearings. Fretting typically occurs on the number 2, 3, 5, or 6 main bearing caps; therefore, inspection of the number
2, 3, 5, and 6 main bearing caps only is sufficient.
If fretting on any of the main bearing caps is occurring, this inspection procedure must be performed. Before
performing the bore inspection, determine if the bearings are reusable according to Procedure 001-006. Also,
determine if there is side-to-side press fit of the main cap in the block. If there is, proceed with the inspection. If there
is not, a side-to-side press fit, a service cap must be used. If a service cap is required, the inspection procedure is
not required and the engine will need to be removed from the chassis and prepared for line boring.
The inspection must be performed with the main cap bearings that will be used in the engine after the inspection and/
or repair is completed.
Plastigage®
Plastigage® provides a fast and accurate method to check bearing clearances. Plastigage® is a special extruded plastic
thread of a definite diameter with accurately controlled crush properties. Plastigage® is packaged in calibrated
envelopes, 12 envelopes per box. There envelopes not only protect the plastic threads, but also serve directly as
scales to measure the bearing clearance. Both sides of the envelope have a printed scale of graduations. One side
is calibrated in inches, the other in millimeters. The numbers on the scale are the bearing clearances in thousandths
of an inch or millimeter. When the width of a compressed section of Plastigage® in a bearing or journal is compared
with the appropriate-numbered graduation, the bearing clearance can be read directly from the scale.
Plastigage® is available from a local parts store in four styles to cover different clearance rages. Both Plastigage®
thread and its matching envelope have a distinctive color for each clearance range.
Condemnation Limit
Fuel System - Overview N14
Page F-2 Section F - Familiarization
This condemnation limit was developed to make sure of the proper oil film thickness between the main bearings and
crankshaft.
Minimum N14 Series Engines Condemnation Limit 0.051 mm [ 0.002 in ]
Block Not Condemned
The main bearing bore passes inspection and can be reassembled with new standard bearing shells if all the following
conditions exist:
• Main cap and block mating surfaces exhibit little or no fretting
• Lower main bearing shells (2 through 6) do not show copper exposure or uneven wear
• Plastigage® (if done) is equal to or greater than 0.051 mm [0.002 in].
For clearance greater than or equal to 0.051 mm [0.002 in], reassemble the main caps. Use the torque specification
in use at the time the engine was built.
Block Condemned
The main bearing bore does not pass inspection if the following conditions exist:
• Main cap and block mating surfaces exhibit fretting and Plastigage® clearance or any main bearing (2 through
6) is less than 0.051 mm [0.002 in]
• No press fit on main cap.
Repair Options
Repair options for blocks that have been condemned:
• Replace block
• Replace block with ReCon® short block
• Machine main cap and block mating surfaces and line bore*
• Machine block mating surfaces and replace main caps and line bore*
• Replace engine with ReCon® engine.
* Refer to Procedure 001-020 in the Alternative Repair Manual, Bulletin 3379035 for line boring procedures.
NOTE: Cummins Inc. must approve all warrantable block repairs.
Fuel System - Overview (005-999)

General Information
The PT fuel system is used exclusively on Cummins® diesels. The identifying letters “PT” are an abbreviation of
pressure-time.
The PT fuel system consists of the fuel pump supply lines, drain lines, fuel passages, and injectors.
The STC system is used on Cummins diesels to advance the injection timing under idle or light load conditions.
The STC system includes fuel pump, supply lines, drain lines, fuel passages, oil passages, check valves, STC oil
control valve, and STC injectors.
The CELECT™ and CELECT™ Plus fuel systems are used exclusively on Cummins diesels.
The CELECT™ and CELECT™ Plus fuel systems consist of the fuel pump, Electronic Control Module (ECM), ECM
cooling plate, supply lines, drain lines, engine wiring harness, sensors, and injectors.
For repairs being made to the CELECT™ or CELECT™ Plus sensors, ECM, and engine wiring harness, refer to the
Troubleshooting and Repair Manual CELECT™ Plus engines, Bulletin 3666130.
N14 Fuel System - Overview
PT (Type G) AFC Fuel Pump

1. Tachometer drive 6. Gear pump cooling fitting
2. AFC air supply 7. Fuel inlet connection
3. Fuel to injectors 8. Idle speed screw location
4. Priming Plug 9. Fuel rate (pressure) screw.
5. Shutoff valve electric connection
Fuel System - Overview (005-999)

General Information
PT (Type G) VS AFC Fuel Pump

1. Tachometer drive 6. Gear pump cooling fitting
2. AFC air supply 7. Fuel inlet connection
3. Fuel to injectors 8. Idle speed screw location
4. VS high speed screw 9. Fuel rate (pressure) screw.
5. VS low (idle) speed screw
Installation Recommendations
The following publications are available to provide fuel
system installation recommendations approved by
Cummins Engine Inc.:
Automotive Installation Recommendations (Fuel System),
Bulletin 952849.
Contact the nearest Cummins® Authorized Repair
Location for engine fuel system specifications and
requirements provided on the "Engine Data Sheet" for
your specific engine and application.
If an overhead fuel tank is used the following requirements

must be used.
If the fuel filter is lower than the fuel pump, install a check
valve in the filter outlet fuel line. Refer to the OEM
Installation Recommendations.
The check valve on the outlet side of the fuel filter prevents
gear pump fuel drainback during filter removal.
Install a shutoff valve between the filter and the fuel tank.
WARNING
If the fuel line valve is not used, the overhead tank can
drain when the fuel filter is changed. Spilled fuel is a
fire hazard. Fuel is flammable, explosive and
hazardous to the environment to avoid severe
personally injury or death. Do not smoke or allow an
flame, pilot light, sparks, or arcing switches or
equipment in the area or areas sharing ventilation
when working on fuel systems. contain and clean up
spills immediately as required by local regulations.
When using fuel system gauges:

Make sure to always remove the air from the pressure
gauge line before taking a reading.
Loosen the connection at the gauge to remove the air.
Do not loosen the vacuum gauge connections when the
engine is operating.
Read the gauge in direct alignment with the gauge hand.
Read the flow meter in direct alignment with the float.

Read the level of the floats where indicated.
Portable fuel pressure gauges must be checked regularly

against a reference gauge or against the gauge on the fuel
pump test stand.
Adjust the valve on the gauge until the gauge needle stops
vibrating.
When measuring the fuel inlet and drain line restriction,

the manometer must be on the same level as the
connection point.
Always use the same size and material of line or hoses as

was originally supplied with the gauge.
The distance from the gauge to the connection point

must be as short as possible.
CAUTION
Never exceed the maximum capacity of the gauge or
flow meter. If the maximum is exceeded, check the
gauge against a reference gauge.
Flow Diagram, Fuel System N14
Flow Diagram, Fuel System (200-001)

Flow Diagram
1 2
11
© Cummins Inc. © Cummins

4 Inc.
9
7
© Cummins Inc. 10
© Cummins Inc. © Cummins Inc.

5
8 6 05100083
Step Timing Control (STC) Fuel System

1. Fuel rail pressure line 7. Gear pump cooling drain
2. Injector 8. Fuel pump
3. Injector fuel drain return 9. STC control valve
4. Fuel return to tank 10. STC fuel pressure sensing line
5. Fuel inlet supply 11. Fuel crossover.
6. Fuel filter
N14 Flow Diagram, Fuel System

Flow Diagram
3 2 4
5
6 Inc.
7
© Cummins Inc.

1 8
05100069
CELECT™ and CELECT™ Plus Fuel System

1. Fuel gear pump 5. Injector fuel drain return
2. Fuel rail pressure line 6. Cooling plate (behind ECM)
3. Fuel crossover tubes 7. Fuel inlet supply
4. Injector 8. Fuel filter.
Flow Diagram, Fuel System N14

Flow Diagram
© Cummins Inc.

fp800gc
CELECT™ and CELECT™ Plus Fuel Pump

N14 Injectors and Fuel Lines - Overview
Injectors and Fuel Lines - Overview

(006-999)
Theory of Operation - PT Fuel System
The following is a short description of the theory of
operation of the Cummins® PT fuel system.
The PT, or Pressure-Time, fuel system derives its name

from the two main variables that affect the amount of fuel
metered per cycle in the Cummins fuel system. “P” stands
for pressure at the inlet of the injectors. It is controlled by
the fuel pump. “T” refers to the time that is available for
fuel to flow into the injectors. It is controlled by engine
speed through the camshaft and injection train.
In the PT system, the amount of fuel burned by the engine

is the amount that is metered into the injector cup and
injected. The quantity metered is dependent on the fuel
pressure at the injector, the flow area of the injector and
the time the fuel is allowed to flow into the metering
chamber of the cup.
The fuel pressure at the injector is controlled by the PT

fuel pump. The pressure supplied by the pump varies
according to different operating conditions.
Injectors and Fuel Lines - Overview N14
The rail pressure supplied by the fuel pump is dependent

on the engine speed. It can also be varied by the operator
by changing the position of the throttle.
The main functions of the fuel pump are to provide:

• Transfer of fuel from tank to engine
• Rail pressure to injectors
• Idle speed governing
• Maximum speed governing
• Operator control of power output below governed
speed (throttle)
• Control of exhaust smoke during acceleration (AFC
— Air Fuel Control)
• Shutdown of the engine.
The flow area of the injectors is determined by the

calibration of a complete set of injectors. The injector
calibration is determined primarily by the parts which
make up the injector. The Control Parts List (CPL) manual
lists the injector assembly and flow plus the combination
of other basic engine parts which are necessary to
produce a given level of engine performance.
The calibration flow rate of the injectors is determined by

the size of an adjustable orifice. Each injector in the
engine is calibrated to the same flow rate. The flow rate
adjustment must be done by a Cummins® Authorized Fuel
Systems Location.
The time available for fuel to flow into the cup is

determined by the time which the metering orifice in the
barrel is uncovered by the plunger. The metering orifice is
uncovered while the cam follower roller is on the inner
base circle of the cam. The plunger is in the retracted
position during this time. The amount of time the metering
orifice is uncovered is dependent on engine speed.
Injection of the fuel in the cup occurs when the cam

follower roller travels up the injection ramp of the cam
forcing the injector plunger downward. The end of
injection occurs when the plunger bottoms in the cup.
The metering orifice is covered while the cam follower

roller is on the outer base circle of the camshaft. The
plunger is in the seated position during this time. Fuel
supplied to the injector during this time bypasses the
plunger through the drain port and is returned to the fuel
tank.
The engine will produce more horsepower at rated speed;

however, the engine will produce the most torque at the
torque peak speed. The rail pressure is lower at torque
peak speed, but the metering time is greater so more fuel
is metered per cycle.
Since more fuel is metered per cycle, more fuel is injected

per cycle and more torque is produced.
Theory of Operation - STC Fuel System

Step Timing Control, commonly referred to as STC,
controls the engine timing in an effort to minimize white
smoke at cold engine start-up.
Refer to Step Timing Control Familiarization, Bulletin
3387380, for addition information on STC.
STC has two stages of injection timing. The engine

operates in the ADVANCED mode of injection timing
during starting and light engine load conditions and at
NORMAL timing during medium to high engine load
conditions.
STC offers many advantages. During ADVANCED

injection timing, it:
• Improves cold weather idling characteristics
• Reduces cold weather white smoke
• Improves light load fuel economy
• Reduces injector carboning.
During NORMAL injection timing, STC:

• Controls cylinder pressures
• Reduces nitrogen oxide emissions.
The STC system consists primarily of:

• STC injectors
• STC oil control valve
• STC plumbing and check valve.
These components control injection timing based on fuel
pump rail pressure (engine load).
In the injector, injection timing is controlled by the STC

hydraulic tappet. The tappet has an inner piston (plunger)
and an outer piston (sleeve). These tappet components
work together with the injector plunger to control injection
timing.
In NORMAL timing, no oil is in the tappet. As the cam

follower starts up the camshaft injection ramp, the injector
rocker lever begins to force the inner piston downward.
Because no oil is in the tappet, the inner piston must make
direct contact with the outer piston before the injector
plunger can begin its downward travel.
In ADVANCED timing, the tappet is filled with oil and the

injector is metering fuel. As the cam follower starts up the
camshaft injection ramp, the injector lever begins to force
the inner piston downward. Since the oil between the
pistons forms a solid link, the downward pressure is
immediately transmitted to the outer piston and the
injector plunger begins its downward travel earlier than it
does in NORMAL timing. This causes the fuel to be
injected earlier.
Engine oil flows from the STC oil control valve through the
oil manifold to the tappets. Whenever the oil pressure in
the oil manifold exceeds 70 kPa [10 psi], it moves the
tappet inlet check ball from its seat and fills the cavity
between the inner and outer pistons.
During the injection cycle, the oil is held inside the tappet
by the inlet check ball and the load cell check ball. When
the rocker lever forces the inner piston downward, the
solid link of oil causes the injector plunger to contact the
fuel earlier; therefore, the injection timing is in the
ADVANCED mode. At the end of the injection cycle,
injection force increased the oil pressure in the tappet and
holds the injector plunger firmly in the cup.
This increased pressure moves the load cell check ball

from its seat. The oil drains past the load cell check ball
and through the drain holes in the injector adapter and
returns to the oil pan through drain passages in the
cylinder head and block. Meanwhile, with continued cam
lift, the inner piston makes mechanical contact with the
outer piston and maintains injector plunger seating force.
The STC control valve uses fuel pressure and spring force
to control the position of an AFC style plunger. The
position of the plunger dictates whether the oil passage to
the hydraulic tappets is open or closed. Fuel pressure acts
on the piston end of the plunger.
During ADVANCED timing (low fuel pressure), the spring

opposes the fuel pressure and holds the plunger in the
open position. Pressurized lube oil flows to the tappets
and initiates ADVANCED engine timing. As fuel pressure
increases, the spring holds the plunger in the open
position until the fuel pressure rises above the certified
switching pressure.
At this certified level, the higher fuel pressure overcomes

the spring. This action shifts the plunger and closes the
oil passage. The oil supply to the tappets is interrupted
and the engine begins to operate in the NORMAL timing
mode.
The control valve supplies oil to the STC rocker housing

connection through the STC valve oil outlet line (1).
A check valve in the elbow fitting (2) prevents the oil from
draining back into the engine when it is shut off. This
prevents any delay of oil to the tappets during cold starts.
An internal oil manifold connects the oil supply to each

STC injector in the rocker housing.
Fuel pressure to the STC valve is provided by a hose (1)

between the fuel inlet passages in the cylinder head and
the STC valve. The internal spring cavity of the valve is
vented to the engine crankcase by the crankcase vent line
(2) in order to allow the plunger to cycle freely.
The oil control valve is calibrated to a specific flow and

pressure using a fuel pump test stand. Tampering with the
valve or plumbing will result in the loss of both fuel
economy and engine durability. Correct valve operation is
necessary to maintain acceptable cylinder pressures and
white smoke levels and to assure optimum fuel economy.
Theory of Operation - CELECT™ and

CELECT™ Plus Fuel System
The following is a short description of the theory of
operation for the Cummins CELECT™ and CELECT™
Plus™ fuel system.
In the CELECT™ and CELECT™ Plus fuel system, the

amount of fuel burned by the engine is the amount of fuel
injected into the injector metering chamber and injected
into the cylinder. The quantity metered is dependent only
on the time that fuel is allowed to flow into the metering
chamber.
The fuel pump provides a constant fuel flow at a relatively

constant pressure to the injectors. The electronic control
module (ECM), controls the time of fuel metering.
The main functions of the injector are to provide:

• Metered fuel for injection
• Injection timing control
• Inject fuel into the cylinder.
The main functions of the ECM are to provide:

• Idle speed governing
• Maximum speed governing
• Operator control of power output below governed
speed (throttle, PTO, Cruise)
• Control of exhaust smoke during acceleration (AFC-
Air Fuel Control)
• Control fuel metering time
• Determine injection timing.
Hydromechanical Subsystem
The fuel pump is located in the same location as a PT fuel
pump.
The fuel pump is a gear type pump. The assembly

includes, a pressure regulator, pulsation damper and a
solenoid valve.
1. Pressure regulator
2. Pulsation damper
3. Solenoid valve.
The ECM mounts on a cooling plate. During engine

operation, fuel circulates through the cooling plate to
absorb heat generated by the ECM.
The injector assembly includes a solenoid valve, which

controls the end of the fuel metering and the beginning of
injection. The solenoid valve is normally open. An
electronic signal from the ECM closes the valve as
required.
As in the PT fuel system, the CELECT™ and CELECT™

Plus fuel systems use the camshaft to create adequate
pressure for injection.
Here is a cutaway view of the electronic controlled injector

with the internal components identified.
Injection Cycle
At the start of metering, the metering plunger and the
timing plunger are at the lower limits of their travel. The
injector control valve is closed.
As the camshaft rotates, the timing plunger return spring

forces the timing plunger upward.
Fuel flows past the metering check ball and into the
metering chamber. This flow continues as long as the
timing plunger is moving upward , and the injector control
valve is closed.
Supply pressure, acting on the bottom of the metering
piston, forces it to maintain contact with the timing
plunger.
The ECM determines the end of the metering by signaling

the injector control valve to open .
Fuel at supply pressure then flows into the timing

chamber, thereby stopping metering piston travel.
During this time, the bias spring makes sure the metering
plunger remains stationary, that it does not drift upward
as the timing plunger moves upward. This same force
against the metering plunger results in enough fuel
pressure below the piston to keep the metering check ball
seated.
A precisely metered quantity of fuel is now trapped in the
metering chamber. This determines the quantity of fuel
that will be injected.
The timing plunger continues to move upward, and the

timing chamber fills with fuel.
Now the timing plunger begins its downward travel.

Initially, the injector control valve remains open, allowing
fuel to flow from the timing chamber, through the injector
control valve, to the fuel supply passage.
At the appropriate time, as determined by the ECM, the

injector control valve closes, trapping fuel in the timing
chamber. This trapped fuel creates a solid, hydraulic link
between the timing plunger and metering plunger.
As a result, the metering plunger is forced to move

downward with the timing plunger.
Because the fuel is trapped, the downward force on the
timing plunger is transferred to the metering plunger,
thereby increasing pressure in the metering chamber.
When this pressure reaches approximately 5000 psi, the

needle valve begins to be forced upward.
Continued downward movement of the timing plunger and
metering plunger results in steadily increasing fuel
pressure. The result is that fuel is forced past the needle
valve, through the spray holes, and into the combustion
chamber.
Injection continues until the spill passage of the metering

plunger passes the metering spill port.
Metering chamber pressure drops rapidly, allowing the
needle valve to close abruptly. This action results in a
positive end of injection. The positive end of the injection
prevents dribble, and results in cleaner burning.
It is also at this point that the pressure relief valve "pops
off", thereby reducing the effects of the high pressure
"spike" that occurs at the time of metering spill.
Immediately after the metering spill port is opened, the

upper edge of the metering plunger passes the timing spill
port.
This action allows the fuel in the timing chamber to be

spilled back to the fuel drain as the timing plunger
completes its downward movement.
This completes the injection cycle.
General Information
Injector Drive Train - CELECT™ AND CELECT™ Plus

1. Injector 4. Push rod
2. Injector link 5. Cam follower
3. Rocker lever 6. Camshaft.
Lubricating Oil System - Overview N14
Injector Drive Train - PT (Type D) STC

1. Injector 4. Push rod
2. Injector link 5. Cam follower
3. Rocker lever 6. Camshaft.
Lubricating Oil System - Overview

(007-999)
General Information
The demand flow and cooling (DFC) lubricating system
incorporates a lubricating oil pump (1) with a pressure
sensitive regulator circuit (2) and a high pressure limit
valve (3).
N14 Flow Diagram, Lubricating Oil System
Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
6
7
4
2 9
3
© Cummins Inc.

5
Inc.
1 11
10 8 07100063
Lubricating Oil System

1. Lubricating oil pump 7. To overhead
2. To lubricating oil cooler 8. Main bearing
3. From lubricating oil cooler 9. Connecting rod drilling
4. Piston cooling nozzle 10. Rifle pressure signal line
5. Main oil rifle 11. Suction tube.
6. Camshaft bushings
Flow Diagram, Lubricating Oil System N14

Flow Diagram
3
1
6
© Cummins 7Inc. © Cummins Inc.
8
10 9
© Cummins Inc.
11
5
12
4 8 2 07100057
Lubricating Oil System

1. From lubricating oil pump 7. Turbocharger Drain
2. Lubricating oil cooler thermostat 8. Lubricating oil filter bypass valve
3. Lubricating oil cooler 9. From lubricating oil cooler
4. Combination full-flow/bypass lubricating oil filter 10. Bypass filter oil to sump
5. To main rifle 11. Full-flow filtration
6. Turbocharger lubricating oil supply 12. Bypass filtration.
N14 Flow Diagram, Lubricating Oil System

Flow Diagram
11 10 12 13
8
5
Inc.
6
9
© Cummins Inc. 7

3 1 2 4 07100064
Viscosity Sensor and STC Control Valve

1. Viscosity sensor 8. Lubricating oil to tappets
2. Rifle pressure supply line 9. Check valve
3. Regulator signal line 10. External oil manifold
4. Lubricating oil supply line 11. STC injector tapped (inside injector)
5. STC valve 12. Internal lubricating oil tube
6. Fuel rail pressure line 13. External lubricating oil manifold connector.
7. Lubricating oil supply line
Flow Diagram, Lubricating Oil System N14

Flow Diagram
© Cummins Inc.
Engine Brake Oil

N14 Cooling System - Overview
Cooling System - Overview (008-999)

General Information
The functions of the cooling system are to:
• absorb heat from the engine components,
• circulate the coolant in the engine,
• dissipate the heat through the radiator, and
• control coolant temperature by the thermostat.
The coolant must be made up of the correct proportions
of water, antifreeze, and supplemental coolant additives
(SCA) to properly perform these functions.
The accompanying chart illustrates the coolant flow

through the engine. For more detail, refer to the coolant
flow diagram.
Conventionally cooled engines with automatic

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

Authorized Repair Location, provide cooling system
installation recommendations and specifications
approved by Cummins Inc.:
• Data Sheets for specific engine models.
• Operation of Diesel Engines in Cold Climates, Bulletin
No. 3379009.
• Heavy Duty Coolant/SCA Maintenance Requirements,
Bulletin No. 3387910.
Flow Diagram, Cooling System N14
Flow Diagram, Cooling System (200-003)

Flow Diagram
3 7
© Cummins Inc. © Cummins Inc. 1
2
© Cummins Inc.
9
5
4
10 08100034
Automotive Cooling System Flow Diagram

1. Water pump 6. Thermostat
2. Oil cooler 7. Bypass
3. Water manifold 8. To radiator
4. Oil cooler supply 9. Water pump inlet
5. Oil cooler return 10. Coolant filter head shutoff valve.
N14 Flow Diagram, Cooling System

Flow Diagram
8
3
6
© Cummins
2 Inc. © Cummins
7 Inc.
1
© Cummins Inc.
5

10 4 9
08100038
Industrial Cooling System Flow Diagram

1. Water pump 6. Thermostat
2. Oil cooler 7. Bypass
3. Water manifold 8. To radiator
4. Oil cooler supply 9. Water pump inlet
5. Oil cooler return 10. Coolant filter head shutoff valve.

Flow Diagram
1
© Cummins Inc. © Cummins 2Inc.
© Cummins Inc.
3

4
08100017
CELECT™ Low Temperature Aftercooled (LTA) and Industrial Cooling System (LTA Thermostat Closed)
1. To Radiator 3. To Aftercooler
2. From Aftercooler 4. From Water Pump.

Flow Diagram
1 3
2

4
© Cummins Inc.
5
6
08100018
CELECT™ Low Temperature Aftercooled (LTA) and Industrial Cooling System (LTA Thermostat Open)
1. From Aftercooler Radiator 4. From Aftercooler
2. To Aftercooler Radiator 5. To Aftercooler
3. To Radiator 6. From Water Pump.

Flow Diagram
NOTE: The coolant plumbing has been modified to allow for the new shields.
10
9 1
2
3
© Cummins
1 Inc. © Cummins
4 Inc.
5
8
© Cummins Inc.
6
7
08100059
Marine Keeled Cooled and Heat Shields Cooling System Flows

1. Heat shield vent connections 6. Coolant pump
2. Coolant vent lines 7. Coolant pump inlet from keel cooler
3. Coolant outlet to keel cooler 8. Coolant cooled exhaust shield
4. Thermostat housing 9. Aftercooler to turbocharger shield
5. Keel cooler bypass return to coolant pump 10. Turbocharger shield to exhaust manifold shield.

Flow Diagram
2
4
3
2
1
15 16
14
13
12
© Cummins Inc.
5
11 6
7
© Cummins
10 Inc. © Cummins Inc.
9 8 08100058
Marine Heat Exchanger Seawater System Flows with Low Temperature Aftercooler
1. Coolant inlet to heat exchanger 9. Sea water inlet to heat exchanger
2. Heat shield vent lines 10. Heat exchanger
3. Thermostat vent lines 11. From heat exchanger to coolant pump
4. Aftercooler vent lines 12. Sea water outlet
5. From aftercooler to turbocharger shield 13. Expansion tank
6. From low temperature aftercooler 14. To low temperature thermostat
7. Sea water pump 15. From low temperature thermostat to low temperature
8. Sea water inlet aftercooler
16. Low temperature aftercooler bypass.

Flow Diagram
1
2
© Cummins Inc.

3 08100056
Marine Keeled Cooled Water Jacket Aftercooler

1. Aftercooler vent line
2. From aftercooler to turbocharger shield
3. From cylinder block to aftercooler.

Flow Diagram
6
4 3
4 2
© Cummins
6 Inc.
© Cummins
08100057
Marine Low Temperature Aftercooler Thermostat Flow

1. From low temperature aftercooler thermostat to low 4. To low temperature aftercooler thermostat
temperature aftercooler 5. Low temperature aftercooler bypass
2. Low temperature aftercooler thermostat open 6. Sacrificial zinc plugs.
3. Low temperature aftercooler thermostat closed
Air Intake System - Overview N14
Air Intake System - Overview (010-999)

General Information
The combustion air system consists of intake air piping,
turbocharger, charge air cooler (CAC) piping, CAC, and
exhaust piping.
The turbocharger uses exhaust gas energy to turn the

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

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

air is heated. This heated air is then passed through the
charge air cooler which cools the air. Cool air is more
dense which allows more air to be compressed into the
cylinder, yielding a much greater combustion efficiency.
N14 Flow Diagram, Air Intake System
Flow Diagram, Air Intake System (200-004)

Flow Diagram
2

4
© Cummins Inc.

20100437
Air Intake System

1. Turbocharger compressor 3. Intake manifold
2. Aftercooler 4. Intake valve ports.
Flow Diagram, Air Intake System N14
Flow Diagram, Air Intake System (200-004)

Flow Diagram
4 3
2
© Cummins Inc.

1
10100052
Charge Air Cooled Engines

1. Turbocharger compressor 3. Intake manifold
2. Charge air cooler 4. Intake valve ports.
N14 Flow Diagram, Exhaust System
Flow Diagram, Exhaust System (200-005)

Flow Diagram
2 3
© Cummins
© Cummins Inc.

11100004
Exhaust System
1. Exhaust valve ports 3. Turbocharger turbine.
2. Exhaust manifold
Compressed Air System - Overview N14
Compressed Air System - Overview

(012-999)
General Information
The compressed air system normally consists of a gear-
driven air compressor, an air governor, air tanks and all
necessary plumbing.
The Holset and Cummins single and two cylinder air
compressors are engine-driven, piston-type compressors
which supply compressed air to operate air activated
devices. The compressor runs continuously, but has a
loaded and unloaded operating mode.
E-Type Air Compressor

Holset SS and ST model air compressors built with the E-
Type unloader can be identified by the letter “E” (SS296E,
SS338E, ST676E, and ST773E), and by the caution on the
data plate.
All QE (QE296 and QE338) model air compressors are
equipped with the E-Type unloader.
E-Type System With Air Dryer

Vehicles equipped with air dryers vented to the
atmosphere during unloaded compressor operation, using
the Holset E-Type air compressor, require the installation
of an econ valve to prevent excessive oil consumption.
NOTE: Some air dryers can have a built-in econ valve.
Check with the manufacturer as to which type is installed.
E-Type System Without Air Dryer

Air systems without air dryers, or with air dryers not
vented to the atmosphere during unloaded compressor
operation, can use the Holset E-Type unloader valve
without modifying the air system.
N14 Flow Diagram, Compressed Air System
Flow Diagram, Compressed Air System (200-006)

Flow Diagram
2
1 2
© Cummins
4
Inc. © 1Cummins Inc.
4
© Cummins Inc.
3 3

12200009
Air Compressor
1. Air governor signal 3. Lubricant
2. Air 4. Coolant.
Flow Diagram, Compressed Air System N14

Flow Diagram
2 3
© Cummins Inc. © Cummins Inc.4
© Cummins Inc.
8
6
7
5
12100003
Holset E-Type System with Air Dryer

1. Governor 5. Reservoir (wet tank)
2. Discharge 6. Check valve
3. Intake 7. Air dryer
4. Air compressor 8. Econ valve.
N14 Flow Diagram, Compressed Air System

Flow Diagram
1 2 3

8 7
© Cummins
6 Inc.
5

12100004
Holset E-Type System without Air Dryer

1. Governor 5. Reservoir (wet tank)
2. From reservoir 6. Compressor
3. E-type unloader 7. Discharge
4. Intake 8. From unloader.
Engine Testing - Overview N14
Electrical Equipment - Overview

(013-999)
General Information
The basic heavy-duty electrical system consists of:
• Batteries and cables (1)
• A starting motor (2)
• An alternator (3)
• A magnetic switch (4)
• Keyswitch (5)
• A push button starter switch (6)
• Starting circuit wiring (7)
Refer to the vehicle manufacturer's service repair manual

for specific service information about the charging and
starting circuits.
Refer to the vehicle manufacturer's service repair manual

or the component manufacturer's service bulletins for
specific service information about the starting motor and
the alternator.
Engine Testing - Overview (014-999)

General Information
This section outlines engine testing and engine run-in
recommendations for N14 engines. All engines must be
run-in after a rebuild or a repair involving the replacement
of one or more piston ring sets, cylinder liners, or cylinder
kits.
Incorrect or insufficient break-in of the piston rings will
lead to early oil consumption or high blowby complaints.
Adherence to these run-in guidelines will allow the full
durability of new pistons, liners, and rings to be realized.
Before running the engine, make sure the engine is filled
with the correct coolant. Also, make sure the lubricating
oil system is filled and primed.
N14 Engine Testing - Overview
In Service Run-in
The majority of heavy duty diesel applications will provide sufficient run-in under normal loaded operations. However,
light load/high rpm operation must be avoided during the run-in period. The following in-service run-in guidelines are
recommended for N14 engines after a repair involving replacement of one or more of the piston ring sets, cylinder
liners, or cylinder kits where engine or an engine dynamometer and/or chassis dynamometer run-in can not be
performed.
Engine Dynamometer Run-in
This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical nor
recommended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair
has been performed in-chassis. There is not a requirement and it is not recommended for an engine that has been
run-in and tested on an engine dynamometer to be run-in again after it has been installed back into the vehicle or
equipment.
Cummins Heavy Duty Engine Operating Curve Definitions
1. Peak torque (N•m [ft-lb]) - Maximum torque that the 5. Command range (rpm) - The engine's operating
engine will produce. Also, sometimes referred to as range from command torque or peak torque up to the
command torque. This is listed on the engine engine's governed speed.
dataplate. 6. Command point - The point on the performance curve
2. Peak torque rpm (rpm) - Engine speed at which peak where maximum horsepower and optimum fuel
torque is generated. This is listed on the engine economy come together. This is the point where
dataplate. advertised horsepower occurs.
3. Maximum hp rpm (rpm) - Engine speed at which 7. Full load governed speed (rpm) - Defined as the upper
maximum power is developed. This is listed with end of the engine's full load operating range. This is
advertised horsepower on the engine dataplate. listed on the engine dataplate.
4. Advertised horsepower (hp) - Maximum power that
the engine will develop. This is provided on the engine
dataplate with its corresponding engine speed.
9. Line haul rating - An engine that has a line haul rating has a narrow operating range (rpm). A line haul rating is
typically used for on-highway applications. These engines are used with larger (more gears, 13 speeds, etc.)
transmissions with close ratio splits between gear shifts.
No-load governed speed (rpm) - (not shown) Maximum unloaded engine speed. This value is listed on the engine data
sheet and in the FPEPS publications.
Cummins Heavy Duty Engine Operating Curve Definitions
1. Peak torque (N•m [ft-lb]) - Maximum torque that the 5. Command range (rpm) - The engine's operating
engine will produce. Also, sometimes referred to as range from command torque or peak torque up to the
command torque. This is listed on the engine engine's governed speed.
dataplate. 6. Command point - The point on the performance curve
2. Peak torque rpm (rpm) - Engine speed at which peak where maximum horsepower and optimum fuel
torque is generated. This is listed on the engine economy come together. This is the point where
dataplate. advertised horsepower occurs.
3. Maximum hp rpm (rpm) - Engine speed at which 7. Full load governed speed (rpm) - Defined as the upper
maximum power is developed. This is listed with end of the engine's full load operating range. This is
advertised horsepower on the engine dataplate. listed on the engine dataplate.
4. Advertised horsepower (hp) - Maximum power that
the engine will develop. This is provided on the engine
dataplate with its corresponding engine speed.
10. Vocational rating - A vocational rated engine has a wider operating range (rpm). This rating is typically used for
on and off or off-highway applications. These engines are used with smaller (fewer gears, 9 speeds, etc.)
transmissions with large ratio splits between gear shifts.
No-load governed speed (rpm) - (not shown) Maximum unloaded engine speed. This value is listed on the engine data
sheet and in the FPEPS publications.
Run-In Instructions
CAUTION
Check the General Engine Test Specifications in this
section before operating the engine to avoid internal
component damage.
The amount of time specified for the following engine run-
in phases are minimums.
The engine can be operated for longer periods of time at
each operating range or phase with the exception of
engine idling which must be kept to five minutes or less.
Start the engine and idle for an initial check.

Avoid long idle periods. Operate the engine at low idle only
long enough (five minutes maximum) to check for correct
oil pressure and any fuel, oil, water, or air leaks.
Do not operate the engine at idle speed longer than
specified during engine run-in. Excessive carbon
formation will occur and cause damage to the engine.
CAUTION
To avoid internal component damage, do not allow the
engine speed to exceed 1,000 rpm before run-in.
While the engine is idling, listen for unusual noises; watch

for coolant, fuel, and lubricating oil leaks; and check for
correct engine operation in general.
Repair all leaks or component problems before continuing
the engine run-in.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
at low idle for a minimum of three minutes to avoid
internal component damage.
Fuel Flow Measurement on Engine or

Chassis Dynamometer
Accurate fuel flow measurement is important for
evaluation of engine performance and troubleshooting on
an engine or chassis dynamometer. The only way
accurate fuel flow measurement can be obtained is
through proper use of the available equipment. Below is a
description of the fuel measuring device, available from
Cummins Inc., along with installation and operation
recommendations. The fuel measuring device, Part
Number 3376375, can be used with either a chassis or
engine dynamometer.
When installing the fuel measuring device, it is important
to reduce the amount of air that can be introduced into the
system when the device is not in use. The plumbing used
must include non-restrictive shutoff valves, such as
ballcock valves, to contain fuel in the device after each
use. Additional installation considerations are:
• The fuel measuring device, Part Number 3376375,
must be mounted vertically for accuracy and proper
operation.
• A separate fuel supply for use on the dynamometer
is recommended. All fuel used in the measuring
device must be clean for consistent operation.
• Care must be taken to reduce fuel line restriction to
and from the engine. Minimum recommended hose
sizes are Number 10 for the engine fuel inlet, and
Number 8 for the engine fuel drain. The length of
either hose must not exceed 4.572 m [15 ft].
• For accurate fuel consumption or flow measurement
while testing on a chassis dynamometer, it is
recommended to use a fuel cooler to maintain inlet
temperature to the fuel gear pump at 49°C [120°F]
or below.
Operation
Fuel Measuring Device, Part Number 3376375

1. Fuel filter
2. Flow meter
3. To float tank
4. To fuel cooler
5. Injector return
NOTE: Fuel cooler is not a part of fuel measuring device, Part Number 3376375; however, must be used when
conducting test with the flow meter.
Operation
Fuel Measuring Device Connection Points

1. Fuel supply from tank
2. Fuel flow to fuel meter
3. Fuel flow from fuel meter
4. Fuel flow to fuel cooler
5. Injector return fuel
6. Fuel rail pressure.
The fuel measuring device recirculates return fuel to the engine fuel inlet by routing the return fuel to the top side of
the float tank. The fuel is deaerated as it passes through the baffling in the float tank. A ball float valve at the bottom
of the float tank maintains an adequate volume in the tank for deaeration. The fuel is then returned to the engine fuel
inlet. The illustration shows fuel line connection points on the fuel measuring device.
The fuel supply tank must be below the level of the fuel measuring device to prevent overflow of the float tank. If an
overhead fuel supply tank is used, a float controlled reservoir must be installed between the fuel supply tank and the
fuel measuring device, and below the level of the device.
Operation
On CELECT™ and CELECT™ Plus engines, the engine fuel inlet line must flow through the ECM cooling plate to
provide proper cooling of the ECM during engine operation.
The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity
of fuel being drawn through the flowmeter is know as "make up" fuel or the amount of fuel being burned by the engine.
The flowmeter is graduated to read fuel flow in pounds per hour. The flowmeter contains two floats with respective
scales on either side of the flowmeter. The small float is used to measure lower flows and must be read on the left
scale, as shown. The larger float is for measuring higher flows and must be read on the right scale.
To obtain an accurate fuel rate measurement, the flowmeter reading must be corrected based on the fuel temperature.
There is a fuel temperature gauge on the front panel of the fuel measuring device. The gauge is graduated in percent
of error by which the reading requires correction. An example is: The fuel of an engine reads 125 lbs/hr on the
flowmeter, and the temperature gauge reads +2 percent; the corrected fuel flow rate will be 125 plus 2 percent, or
127.5 lbs/hr.
N14
Section TS - Troubleshooting Symptoms Page TS-a
Section TS - Troubleshooting Symptoms

Section Contents
Page
.........................................................................................................................................................................TS-1
General Information........................................................................................................................................TS-1
Troubleshooting Symptoms Charts ...............................................................................................................TS-2
General Information........................................................................................................................................TS-2
Air Compressor Air Pressure Rises Slowly .....................................................................................................TS-3
Air Compressor Cycles Frequently..................................................................................................................TS-5
Air Compressor Noise is Excessive.................................................................................................................TS-6
Air Compressor Pumping Excess Lubricating Oil into the Air System .............................................................TS-7
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)....................................TS-9
Air Compressor Will Not Pump Air................................................................................................................ TS-10
Air Compressor Will Not Stop Pumping.........................................................................................................TS-11
Alternator Not Charging or Insufficient Charging...........................................................................................TS-12
Alternator Overcharging................................................................................................................................TS-14
Coolant in the Lubricating Oil........................................................................................................................TS-15
Coolant Loss - External.................................................................................................................................TS-16
Coolant Loss - Internal..................................................................................................................................TS-18
Coolant Temperature Above Normal - Gradual Overheat...............................................................................TS-20
Coolant Temperature Above Normal - Sudden Overheat...............................................................................TS-23
Coolant Temperature Below Normal..............................................................................................................TS-25
Crankcase Gases (Blowby) Excessive...........................................................................................................TS-27
Cranking Fuel Pressure is Low......................................................................................................................TS-28
Engine Acceleration or Response Poor.........................................................................................................TS-30
Engine Brake - Low Retarding Power or Slow to Activate (CELECT™ or CELECT™ Plus)................................TS-39
Engine Brake - Low Retarding Power or Slow to Activate (PT).......................................................................TS-41
Engine Brake — One or More Cylinders Braking with Power Switch Off (CELECT™ or CELECT™ Plus)..........TS-43
Engine Brake — One or More Cylinders Braking with Power Switch Off (PT).................................................TS-45
Engine Brake Does Not Operate (CELECT™ or CELECT™ Plus).................................................................... TS-35
Engine Brake Does Not Operate (PT)............................................................................................................TS-37
Engine Decelerates Slowly (CELECT™ or CELECT™ Plus).............................................................................TS-46
Engine Decelerates Slowly (PT)....................................................................................................................TS-47
Engine Difficult to Start or Will Not Start (Exhaust Smoke).............................................................................TS-48
Engine Difficult to Start or Will Not Start (No Exhaust Smoke).......................................................................TS-50
Engine Noise Excessive................................................................................................................................TS-52
Engine Noise Excessive — Combustion Knocks............................................................................................TS-55
Engine Noise Excessive — Connecting Rod..................................................................................................TS-56
Engine Noise Excessive — Main Bearing......................................................................................................TS-57
Engine Noise Excessive — Piston.................................................................................................................TS-59
Engine Noise Excessive — Turbocharger......................................................................................................TS-60
Engine Power Output Low (CELECT™ or CELECT™ Plus)..............................................................................TS-61
Engine Power Output Low (PT).....................................................................................................................TS-66
Engine Runs Rough at Idle...........................................................................................................................TS-70
Engine Runs Rough or Misfires.....................................................................................................................TS-73
Engine Shuts Off Unexpectedly or Dies During Deceleration.........................................................................TS-75
Engine Speed Surges at Low or High Idle.....................................................................................................TS-78
Engine Speed Surges Under Load or in Operating Range.............................................................................TS-81
Engine Starts But Will Not Keep Running......................................................................................................TS-84
Engine Vibration Excessive...........................................................................................................................TS-86
Engine Will Not Crank or Cranks Slowly (Air Starter).....................................................................................TS-88
Engine Will Not Crank or Cranks Slowly (Electric Starter)..............................................................................TS-90
Engine Will Not Shut Off...............................................................................................................................TS-92
Fuel Consumption Excessive (CELECT™ or CELECT™ Plus)......................................................................... TS-94
Fuel Consumption Excessive (PT).................................................................................................................TS-98
Fuel in Coolant...........................................................................................................................................TS-102
Fuel in the Lubricating Oil...........................................................................................................................TS-103
Intake Manifold Air Temperature Above Specification..................................................................................TS-104
Intake Manifold Pressure (Boost) is Below Normal.......................................................................................TS-106
Low Idle Adjust Switch Does Not Work (CELECT™ or CELECT™ Plus).........................................................TS-107
N14
Page TS-b Section TS - Troubleshooting Symptoms
Lubricating Oil Consumption Excessive.......................................................................................................TS-109

Lubricating Oil Contaminated......................................................................................................................TS-111
Lubricating Oil in the Fuel...........................................................................................................................TS-108
Lubricating Oil Pressure High.....................................................................................................................TS-112
Lubricating Oil Pressure Low......................................................................................................................TS-113
Lubricating Oil Sludge in the Crankcase Excessive.....................................................................................TS-116
Lubricating Oil Temperature Above Specification........................................................................................TS-118
Lubricating or Transmission Oil in the Coolant............................................................................................TS-119
Operating Fuel Pressure is Low..................................................................................................................TS-120
Smoke, Black — Excessive (CELECT™ or CELECT™ Plus)..........................................................................TS-121
Smoke, Black — Excessive (PT).................................................................................................................TS-124
Smoke, White — Excessive (CELECT™ or CELECT™ Plus)..........................................................................TS-126
Smoke, White — Excessive (PT).................................................................................................................TS-129
Step Timing Control (STC) Valve is Not Shifting Correctly...........................................................................TS-131
Turbocharger Leaks Engine Oil or Fuel.......................................................................................................TS-132
Variable Speed (VS) Governor — Fuel Leak at the Throttle Shaft................................................................TS-133
Variable Speed (VS) Governor — Speed is Not Set Correctly......................................................................TS-134
Variable Speed (VS) Governor — Surge with Engine Under Load................................................................TS-135
Troubleshooting Overview .........................................................................................................................TS-136
Connecting Rod Bearing Noise...................................................................................................................TS-136
Driveability - General Information................................................................................................................TS-137
Driveability/Low Power - Customer Complaint Form....................................................................................TS-139
Driveability/Low Power/Excessive Fuel Consumption - Checklist.................................................................TS-140
Engine Noise Diagnostic Procedures - General Information.........................................................................TS-136
Fuel Consumption - Customer Complaint Form...........................................................................................TS-142
Fuel Consumption - General Information.....................................................................................................TS-141
Main Bearing Noise.....................................................................................................................................TS-136
Oil Consumption.........................................................................................................................................TS-143
Piston Noise...............................................................................................................................................TS-136
Response Test............................................................................................................................................TS-138
N14
Section TS - Troubleshooting Symptoms Page TS-1
General Information
A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known
about a complaint, the faster and easier the problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the
easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts are designed to
stimulate a thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint
• Analyze the problem thoroughly
• Relate the symptoms to the basic engine systems and components
• Consider any recent maintenance or repair action that can relate to the complaint
• Double-check before beginning any disassembly
• Solve the problem by using the symptom charts and doing the easiest things first
• Determine the cause of the problem and make a thorough repair
• After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected
Troubleshooting Symptoms Charts N14
Page TS-2 Section TS - Troubleshooting Symptoms
Troubleshooting Symptoms Charts

General Information
Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row
of blocks from top to bottom. Follow through the chart to identify the corrective action.
WARNING
Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be
performed by trained, experienced technicians.
N14 Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly

This is symptom tree t004
Cause Correction
Replace the air compressor air cleaner (if
STEP 1 installed). Check the air intake piping. Check
Air intake system restriction to air compressor is ............ engine air intake restriction if the air compressor
excessive inlet is plumbed to the vehicle or equipment intake
system. Refer to Procedure 010-031.
OK
Go To Next Step
Block the vehicle wheels and check the air system
STEP 2 for leaks with spring brakes applied and released.
............ Check for leaks from the air compressor gaskets
Air system leaks
and the air system hoses, fittings, tanks, and
valves. Refer to Procedure 012-019.
OK
Go To Next Step
Check the air governor for correct operation. Make
STEP 3 sure the air governor is located less than 0.6 m [2
............
Air governor is malfunctioning or not set correctly ft] from the air compressor. Refer to Procedure
012-017.
OK
Go To Next Step
Check for carbon buildup. Replace the air
STEP 4 compressor discharge line, if necessary. Check
Carbon buildup is excessive in the air discharge ............ the turbocharger for oil leaks. Check the intake
line, check valve, or cylinder head tube for oil. Refer to Procedures 012-003, 010-040,
and 010-049.
OK
Go To Next Step
STEP 5 Install an Econ valve, a check valve, and system

............ hoses. Refer to the Master Repair Manual, Holset
E-type system is not plumbed correctly
Air Compressors, Bulletin 3666121.
OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 6 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to the
manufacturer's instructions.
OK
Go To Next Step
STEP 7 Check the unloader valve and unloader body seal.
............
Unloader valve is malfunctioning Refer to Procedure 012-013.
OK
Go To Next Step
Air Compressor Air Pressure Rises Slowly

Cause Correction
STEP 8 Inspect the air compressor intake and exhaust

............ valve assemblies. Refer to Procedure 012-103,
Air compressor intake or exhaust valve leaks air
012-104, or 012-106.
Air Compressor Cycles Frequently

Cause Correction
for leaks with spring brakes applied and released.
STEP 1 Check for leaks from the air compressor gaskets
............
Air system leaks and the air system hoses, fittings, tanks, and
valves. Refer to Procedure 012-019 and the OEM
service manual.
OK
Go To Next Step
............
012-017.
OK
Go To Next Step
............
OK
Go To Next Step

OK
Go To Next Step
and 010-049.
OK
Go To Next Step
Replace the desiccant cartridge on the Turbo/CR
2000 air dryer. Refer to the OEM service manual.
STEP 6 Check the air compressor duty cycle. Install a
............
Air compressor pumping time is excessive larger air compressor, if necessary. Refer to the
Master Repair Manual, Holset Air Compressors,
Bulletin 3666121.
OK
Go To Next Step
STEP 7 Lubricate or replace the air dryer outlet check valve

............ assembly. Refer to the manufacturer's
Air dryer outlet check valve is sticking
instructions.
Air Compressor Noise is Excessive

Cause Correction
and 010-049.
OK
Go To Next Step
For all models, check for ice in low spots of the air
STEP 2 discharge line, dryer inlet, and elbow fittings. On
............ Holset® models, also check the Econ valve (if
Ice buildup in the air system components
equipped). Refer to the manufacturer's
instructions.
OK
Go To Next Step
STEP 3
Install a ping tank between the air dryer and the
Air compressor is sending air pulses into the air ............
wet tank. Refer to the manufacturer's instructions.
tanks
OK
Go To Next Step
STEP 4
Check the accessory drive axial end play. Inspect
Accessory drive is worn (axial end play is out of ............
the shaft for wear. Refer to Procedure 009-001.
specification)
OK
Go To Next Step
STEP 5 Check the coupling for wear. Refer to Procedure
............
Splined drive coupling or gear is excessively worn 012-014.
OK
Go To Next Step
STEP 6 Check for pin bore wear. Refer to Procedure
............
Pin bore wear is excessive 012-010.
OK
Go To Next Step
STEP 7
Replace or rebuild the air compressor. Refer to the
Air compressor is excessively worn or internally ............
damaged
OK
Go To Next Step
STEP 8
Inspect the drive gears and gear train and repair
Air compressor drive gear or engine gear train is ............
as necessary. Refer to Procedure 009-001.
worn or damaged
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
STEP 1 Verify the correct lubricating oil drain interval.

............ Refer to the Operation and Maintenance Manual,
Lubricating oil drain interval is excessive
N14 Plus, Bulletin 3666136.
OK
Go To Next Step
Replace the air compressor air cleaner (if
STEP 2 installed). Check the air intake piping. Check
Air intake system restriction to air compressor is ............ engine air intake restriction if the air compressor
excessive inlet is plumbed to the vehicle or equipment intake
OK
Go To Next Step
STEP 3 Drain the reservoirs daily. Refer to the Operation
Contaminants are building up in the system ............ and Maintenance Manual, N14 Plus, Bulletin
reservoirs 3666136.
OK
Go To Next Step

OK
Go To Next Step
Replace the desiccant cartridge on the Turbo/CR
2000 air dryer. Refer to the OEM service manual.
STEP 5 Check the air compressor duty cycle. Install a
............
Air compressor pumping time is excessive larger air compressor, if necessary. Refer to the
Master Repair Manual, Holset Air Compressors,
Bulletin 3666121.
OK
Go To Next Step
and 010-049.
OK
Go To Next Step
STEP 7
Engine angularity during operation exceeds ............ Refer to the engine specification data sheet.
specification
OK
Go To Next Step
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
STEP 8 Check for excessive blowby. Refer to the

............ Crankcase Gases (Blowby) Excessive symptom
Crankcase pressure is excessive
tree.
OK
Go To Next Step
STEP 9 Check the oil pressure. Refer to Procedure
............
Lubricating oil pressure is above specification 007-028.
OK
Go To Next Step
STEP 10 If coolant temperature is above normal, refer to the

............ Coolant Temperature Above Normal - Gradual
Air compressor runs hot
Overheat symptom tree.
OK
Go To Next Step
STEP 11 Remove the air compressor and check the oil drain
............ holes in the air compressor and the accessory
Lubricating oil drain line is restricted
drive. Refer to Procedure 012-014.
OK
Go To Next Step
STEP 12 Replace or rebuild the air compressor. Refer to
Air compressor is excessively worn or internally ............ Procedure 012-014 and the Master Repair Manual
damaged for Holset Air Compressor, Bulletin 3666121.
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Cause Correction
............
service manual.
OK
Go To Next Step
............
012-017.
OK
Go To Next Step

012-104, or 012-106.
OK
Go To Next Step
STEP 4 Check the discharge line for blockage. Refer to
Cover gasket is ruptured (Holset® SS models ............ Procedure 012-013. Check the cover gasket for
only) flatness. Replace the cover gasket.
Air Compressor Will Not Pump Air

Cause Correction
............
012-017.
OK
Go To Next Step
............
OK
Go To Next Step

012-104, or 012-106.
OK
Go To Next Step
STEP 4 Replace or rebuild the air compressor. Refer to
Air compressor is excessively worn or internally ............ Procedure 012-014 and the Master Repair Manual
damaged for Holset Air Compressors, Bulletin 3666121.
OK
Go To Next Step
STEP 5 Check the discharge line for blockage. Refer to

Procedure 012-103, 012-104, or 012-106. Check
Cover gasket is ruptured (Holset® SS models ............
the cover gasket for flatness. Replace the cover
only)
gasket.
OK
Go To Next Step
STEP 6 Check the coupling for wear. Refer to Procedure
............
Splined drive coupling or gear is excessively worn 012-014.
Air Compressor Will Not Stop Pumping

Cause Correction
............
service manual.
OK
Go To Next Step
............
012-017.
OK
Go To Next Step
STEP 3 Inspect the signal line and actuator line. Refer to
............
Air governor signal line or actuator line is plugged the manufacturer's instructions.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step

012-104, or 012-106.
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 1 Check the alternator belt tension. Refer to
............
Alternator belt is loose Procedure 013-005.
OK
Go To Next Step
STEP 2 Tighten the pulley. Refer to the manufacturer's
............
Alternator pulley is loose on the shaft instructions.
OK
Go To Next Step
STEP 3
Make sure the drive pulley is tight on the shaft.
Alternator drive pulley is loose on the water pump ............
Refer to Procedure 009-004.
shaft
OK
Go To Next Step
STEP 4
Check the battery cables and connections. Refer
Battery cables or connections are loose, broken, or ............
to Procedure 013-009.
corroded (excessive resistance)
OK
Go To Next Step
STEP 5 Check the condition of the batteries, replace if
............
Batteries have failed necessary. Refer to Procedure 013-007.
OK
Go To Next Step
STEP 6 Check the vehicle gauge. Refer to the OEM service
............
Vehicle gauge is malfunctioning manual.
OK
Go To Next Step
STEP 7 Test the alternator output. Replace the alternator

............ or voltage regulator if necessary. Refer to
Alternator or voltage regulator is malfunctioning
Procedure 013-001.
OK
Go To Next Step
STEP 8 Check the fuses, wires, and connections. Refer to
Electrical system is "open" (blown fuses, broken ............ the OEM service manual and the manufacturer's
wires, or loose connections) wiring diagrams.
OK
Go To Next Step
STEP 9 Install an alternator with a higher capacity. Refer
Alternator is overloaded, or alternator capacity is ............ toProcedure 013-001 and the OEM service
below specification manual.
OK
Go To Next Step
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 10 Position the batteries away from heat sources.
............
Battery temperature is above specification Refer to the OEM service manual.
Alternator Overcharging
Cause Correction
STEP 1 Check the voltage regulator. Replace the voltage

............ regulator, if necessary. Refer to the OEM service
Voltage regulator is malfunctioning
manual.
OK
Go To Next Step
STEP 2 Check the condition of the batteries. Replace the

............ batteries, if necessary. Refer to the OEM service
Battery cell is damaged (open circuit)
manual.
Coolant in the Lubricating Oil

Cause Correction
STEP 1 Check for lubricating oil in the coolant. Refer to
............
Lubricating oil cooler is leaking Procedure 007-003.
OK
Go To Next Step
STEP 2
Check for air or combustion gases in the cooling
Air or combustion gases are entering the cooling ............
system
OK
Go To Next Step
STEP 3 Inspect the air compressor cylinder head and
Air compressor cylinder head is cracked or porous, ............ gasket. Refer to Procedures 012-103, 012-104, and
or has a leaking gasket 012-106.
OK
Go To Next Step
STEP 4 Check the cylinder head gasket. Refer to
............
Cylinder head gasket is leaking Procedure 002-021.
OK
Go To Next Step
Remove intake and exhaust manifolds. Check for
STEP 5 evidence of coolant leak. If necessary, operate
............
Cylinder head is cracked or porous engine at low idle. Pressure-test the cylinder head.
OK
Go To Next Step
STEP 6 Inspect the cylinder block. Refer to Procedure
............
Cylinder block is cracked or porous 001-027.
OK
Go To Next Step
STEP 7 Check the cylinder liners for corrosion or cracks.
............
Cylinder liner is corroded or cracked Refer to Procedure 001-027.
Coolant Loss - External

Cause Correction
STEP 1 Check the coolant level. Refer to the OEM service
............
Coolant level is above specification manual.
OK
Go To Next Step
Inspect the engine for coolant leaking from hoses,
draincocks, water manifold, jumper tubes,
expansion and pipe plugs, fittings, radiator core,
STEP 2 air compressor and cylinder head gaskets,
............
External coolant leak lubricating oil cooler, water pump seal, cylinder
block, and OEM-mounted components that have
coolant flow. If necessary, pressure-test the
cooling system. Refer to Procedure 008-018.
OK
Go To Next Step
STEP 3
............ Check the aftercooler and connections for leaks.
Aftercooler is leaking (aftercooled engines only)
OK
Go To Next Step
STEP 4
Check the radiator pressure cap. Refer to
Radiator cap is not correct, is malfunctioning, or ............
Procedure 008-047.
has low-pressure rating
OK
Go To Next Step
STEP 5
Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............
routing and for restriction. Procedure 008-047
not routed correctly
OK
Go To Next Step
STEP 6 Check the coolant fill line for restrictions or
............
Coolant fill line is restricted or obstructed obstructions. Refer to the OEM service manual.
OK
Go To Next Step
STEP 7
Cooling system hose is collapsed, restricted, or ............ Inspect the hoses. Refer to Procedure 008-045.
leaking
OK
Go To Next Step
STEP 8
system
OK
Go To Next Step
Coolant Loss - External

Cause Correction
STEP 9 Refer to the Coolant Temperature Above Normal
............
Engine is overheating symptom tree.
Coolant Loss - Internal

Cause Correction
STEP 1 Check the lubricating oil cooler for coolant leaks.
............
Lubricating oil cooler is leaking Refer to Procedure 007-003.
OK
Go To Next Step
STEP 2 Check the oil cooler transfer housing and the
Lubricating oil cooler transfer housing or ............ support. Refer to Procedures 007-047 and
lubricating oil cooler support is cracked or porous 007-003.
OK
Go To Next Step
STEP 3
Inspect the air compressor cylinder head and
Air compressor cylinder head is cracked or porous, ............
gasket. Refer to Procedure 012-003.
or has a leaking gasket
OK
Go To Next Step
STEP 4
............ Check the aftercooler and connections for leaks.
Aftercooler is leaking (aftercooled engines only)
OK
Go To Next Step
STEP 5 Inspect the rocker lever housing. Refer to
............
Rocker lever housing is cracked or porous Procedure 003-013.
OK
Go To Next Step
STEP 6
system
OK
Go To Next Step
............
OK
Go To Next Step
STEP 8
............ Check the cylinder head gasket. Refer to 002-004.
Cylinder head gasket is leaking
OK
Go To Next Step
STEP 9 Check the cylinder liners for corrosion or cracks.
............
Cylinder liner is corroded or cracked Refer to Procedure 001-027.
OK
Go To Next Step
Coolant Loss - Internal

Cause Correction
STEP 10 Check the fuel heater and replace, if necessary.
............
Fuel heater is malfunctioning (if equipped) Refer to the OEM service manual.
Coolant Temperature Above Normal - Gradual Overheat

Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1 Repair Manual, CELECT™ Plus Systems, Bulletin
Electronic fault codes active or high counts of ............ 3666130, or Section TF in the Troubleshooting and
inactive fault codes Repair Manual, CELECT™ Systems, Bulletin
3666084, for fault code troubleshooting.
OK
Go To Next Step
STEP 2 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
STEP 3
Inspect the charge air cooler, air conditioner
Charge air cooler fins, radiator fins, or air
............ condenser, and radiator fins. Clean, if necessary.
conditioner condenser fins are damaged or
Refer to Procedures 010-027 and 008-042.
obstructed with debris
OK
Go To Next Step
Open the cold weather radiator cover or the
STEP 4 winterfront. Maintain a minimum of 784 cm2 [122
............ in2] or approximately 28 x 28 cm [11 x 11 in] of
Cold weather radiator cover or winterfront is closed
opening at all times. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 5
leaking
OK
Go To Next Step
STEP 6 Check the belt tension and tighten if necessary.
............
Fan drive belt is loose Refer to Procedure 008-002.
OK
Go To Next Step
STEP 7 Check the oil level. Add or drain oil, if necessary.
............
Lubricating oil level is above or below specification Refer to Procedures 007-037 and 007-009..
OK
Go To Next Step
STEP 8 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedure 008-038 and the OEM service manual.
OK
Go To Next Step

Cause Correction
STEP 9
Procedure 008-047.
OK
Go To Next Step
STEP 10
Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............
routing and for restriction. Procedure 008-047
not routed correctly
OK
Go To Next Step
STEP 11 Test the temperature gauge. Refer to the Intake
Intake manifold temperature gauge is ............ Manifold Air Temperature Above Specification
malfunctioning, if equipped symptom tree.
OK
Go To Next Step
STEP 12 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to Procedure 008-004
Coolant temperature gauge is malfunctioning
and the OEM service manual.
OK
Go To Next Step
STEP 13 Check the thermostat for the correct part number

............ and for correct operation. Refer to Procedure
Thermostat is not correct or is malfunctioning
008-013.
OK
Go To Next Step
STEP 14 Inspect the radiator shutters. Repair or replace if
Radiator shutters are not opening completely or ............ necessary. Refer to Procedure 008-049. Check the
the shutterstat setting is wrong shutterstat setting.
OK
Go To Next Step
STEP 15
Check the swing check valve for correct operation.
Radiator swing check valve is malfunctioning (if ............
Refer to the OEM service manual.
equipped)
OK
Go To Next Step
STEP 16 Check the fan drive and controls. Refer to
............
Fan drive or fan controls are malfunctioning Procedure 008-026, 008-027, or 008-028.
OK
Go To Next Step
STEP 17
system
OK
Go To Next Step

Cause Correction
STEP 18 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
OK
Go To Next Step
STEP 19
Inspect the radiator and clean if necessary. Refer
Radiator core is internally obstructed or damaged, ............
to the OEM service manual.
or the check valve or J-tube is malfunctioning
OK
Go To Next Step
STEP 20
Inspect the check valve. Replace if necessary.
Check valve is damaged (with remote-mounted ............
Refer to the manufacturer's instructions.
engine coolant heater)
OK
Go To Next Step
STEP 21 Check the engine fuel rate. Refer to Procedure
............
Engine is overfueled 014-005.
OK
Go To Next Step
STEP 22 Verify that the engine and vehicle cooling systems

............ are using the correct components. Refer to the
Vehicle cooling system is not adequate
OEM specifications.
OK
Go To Next Step
STEP 23
Check the disc for correct installation. Refer to the
Torque converter cooler disc is not installed ............
OEM service manual.
correctly
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 1 Repair Manual for CELECT™ Plus Systems,
Electronic fault codes active or high counts of ............ Bulletin 3666130, or Section TF in the
inactive fault codes Troubleshooting and Repair Manual for CELECT™
Systems, Bulletin 3666084.
OK
Go To Next Step
STEP 2 Check the fan drive belt. Replace the belt, if
............
Fan drive belt is broken necessary. Refer to Procedure 008-002.
OK
Go To Next Step
STEP 3 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
STEP 4
OK
Go To Next Step
STEP 5
leaking
OK
Go To Next Step
STEP 6
Procedure 008-047.
OK
Go To Next Step
Radiator shutters are not opening completely or ............ necessary. Refer to Procedure 008-049. Check the
the shutterstat setting is wrong shutterstat setting.
OK
Go To Next Step
opening at all times. Refer to the OEM service
manual.
OK
Go To Next Step
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 9 Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............ routing and for restriction. Procedure 008-017 and
not routed correctly the OEM specifications
OK
Go To Next Step
STEP 10
equipped)
OK
Go To Next Step
............
Fan drive or fan controls are malfunctioning Procedure 008-027.
OK
Go To Next Step
STEP 12
system
OK
Go To Next Step
STEP 13
Check the disc for correct installation. Refer to the
Torque converter cooler disc is not installed ............
OEM service manual.
correctly
OK
Go To Next Step
STEP 14 Perform the cooling system diagnostics test. Refer
............
Cooling system component is malfunctioning to Procedure 008-019.
OK
Go To Next Step

008-013.
OK
Go To Next Step
STEP 16 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
Coolant Temperature Below Normal

Cause Correction
Bulletin 3666130, or Section TF in the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual for CELECT™
inactive fault codes
Systems, Bulletin 3666084, for fault code
troubleshooting.
OK
Go To Next Step
STEP 2 Check the shutters and engine compartment air.
............
Engine is operating at low ambient temperature Refer to the OEM service manual.
OK
Go To Next Step
STEP 3 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to the OEM service
Coolant temperature gauge is malfunctioning
manual.
OK
Go To Next Step
STEP 4 Use an electronic service tool to check the coolant

............ temperature sensor. Refer to Procedure 008-026,
Coolant temperature sensor is malfunctioning
008-027, or 008-028 and the OEM service manual.
OK
Go To Next Step
STEP 5 Check the shutter operation. Repair or replace the
............
Radiator shutters are stuck open or opening early shutters if necessary. Refer to Procedure 008-049.
OK
Go To Next Step
STEP 6
equipped)
OK
Go To Next Step
............
Fan drive or fan controls are malfunctioning Procedure 008-026.
OK
Go To Next Step

008-013.
OK
Go To Next Step
Coolant Temperature Below Normal

Cause Correction
STEP 9
Check the thermostat seal for damage and correct
Thermostat seal is damaged, missing, or not ............
installation. Refer to Procedure 008-016.
installed correctly.
OK
Go To Next Step
STEP 10 Check for correct coolant flow through the radiator.
............
Coolant flow through the radiator is not correct Refer to Procedure 008-042.
Crankcase Gases (Blowby) Excessive

Cause Correction
STEP 1 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-001.
OK
Go To Next Step
STEP 2 Check the turbocharger compressor and turbine
............
Turbocharger oil seal is leaking seals. Refer to Procedures 010-040 and 010-049.
OK
Go To Next Step
Isolate the air compressor by disconnecting the air
STEP 3 inlet and outlet lines. Refer to Procedure 012-014.
............
Air compressor is malfunctioning Check blowby. If blowby is within specifications,
rebuild or replace the air compressor.
OK
Go To Next Step
STEP 4 Check the valve guides for wear. Replace the

............ cylinder head if necessary. Refer to Procedure
Cylinder head valve guides are excessively worn
002-004.
OK
Go To Next Step
STEP 5
Inspect the air intake system for leads. Refer to
Piston, piston rings, or cylinder liner is worn or ............
Procedures 001-043, 001-047, and 001-028.
damaged
Cranking Fuel Pressure is Low

Cause Correction
Check the fuel shutoff valve and circuit. Refer to
STEP 1 Procedures 019-049 and 019-050 in the CELECT™
Fuel shutoff valve(s) closed (electronically ............ Plus Systems, Troubleshooting and Repair
controlled injection) Manual, Bulletin 3666130 and in the CELECT™
Systems Manual, Bulletin 3666084.
OK
Go To Next Step
STEP 2 Use the manual opening knob. Check the shutoff
Fuel shutoff valve(s) closed (mechanical fuel ............ valve and the electrical circuit. Refer to Procedure
system) 005-043. Replace the shutoff valve if necessary.
OK
Go To Next Step
STEP 3 Check for fuel inlet restriction. Refer to Procedure
............
Fuel inlet restriction 006-020.
OK
Go To Next Step
STEP 4
Check for fuel drain back. Refer to Procedure
Fuel leak is causing fuel to drain back in the suction ............
005-011.
line
OK
Go To Next Step
STEP 5 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003.
OK
Go To Next Step
STEP 6 Check the fuel pump for shaft rotation and fuel
............
Fuel pump (gear or shaft) is not rotating flow. Refer to Procedure 005-016.
OK
Go To Next Step
STEP 7 Check the in-line check valve(s) for the correct part
number. Check the arrow on the check valve(s) for
In-line check valve(s) is installed backward or has ............
the correct orientation. Refer to the OEM service
an incorrect part number
manual.
OK
Go To Next Step
STEP 8 Replace the check valve. Refer to Procedure
............
Fuel pump gear pump check valve is stuck open 005-026.
OK
Go To Next Step
STEP 9 Check the fuel pump pressure regulator and the

............ high pressure regulator. Refer to Procedure
Fuel pump pressure regulator is stuck
005-060.
OK
Go To Next Step
Cranking Fuel Pressure is Low

Cause Correction
STEP 10 Remove and check the injectors. Replace the
............
Injector o-rings are damaged or missing injector o-rings. Refer to Procedure 006-026.
Engine Acceleration or Response Poor

Cause Correction
Systems, Bulletin 3666084, for fault code
troubleshooting.
OK
Go To Next Step
If low power is relevant, refer to the OEM
STEP 2 instructions. If acceleration is poor, refer to the
............ Engine Acceleration or Response Poor symptom
Verify the complaint
tree. If fuel consumption is relevant, continue with
this tree.
OK
Go To Next Step
STEP 3 Perform a throttle response test. Refer to the OEM
............
Perform a throttle response test (if applicable) instructions.
OK
Go To Next Step
STEP 4 Perform a stall speed test. Refer to Procedure
............
Perform a stall speed test (if applicable) 005-054.
OK
Go To Next Step
STEP 5 Check throttle position sensor for proper
Throttle position sensor is misadjusted or ............ adjustment and operation. Refer to the OEM
malfunctioning specifications.
OK
Go To Next Step
STEP 6 Check the programmable parameters and the

selected features with an electronic service tool.
Programmable parameters or selected features ............
Set the parameters and features again if
are not correct
necessary. Refer to the OEM service manual.
OK
Go To Next Step
Repair Manual for CELECT™ Plus Systems,
STEP 7 Troubleshooting and Repair Manaul for CELECT™
............
Engine protection fault code(s) inactive Systems, Bulletin 3666084. View the fault codes
and the engine protection data with an electronic
service tool. Refer to the appropriate electronic
service tool manual.
OK
Go To Next Step

Cause Correction
Verify the ECM calibration is correct. Check the
calibration revision history for applicable fixes to
the calibration stored in the ECM. Refer to the
calibration history spreadsheet
ecm_calibration_rev_history.xlson QuickServe®
STEP 8 Online or the INCAL™ CD-ROM. Compare the
calibration stored in the ECM with the engine rating
Electronic control module (ECM) calibration is ............
and the Control Parts List (CPL), Bulletin 4021326
malfunctioning
or 4021327. If necessary, recalibrate the ECM.
Refer to Procedure 019-032 in the Troubleshooting
and Repair Manual, CELECT™ Plus Systems,
Bulletin 3666130, or the Troubleshooting and
Repair Manual, CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 10 Check or replace the fuel lines, check valves, or
............
Fuel drain line restriction tank vents as needed. Refer to Procedure 006-012.
OK
Go To Next Step
STEP 11 and Repair Manual for CELECT™ Plus Systems,
Intake manifold pressure (boost) is below ............ Bulletin 3666130, or the Troubleshooting and
specification Repair Manual for CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
Use an electronic service tool to check the coolant
temperature sensor. Refer to Procedure 019-019 in
STEP 12 the Troubleshooting and Repair Manual for
............
Coolant temperature sensor is malfunctioning CELECT™ Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
Check the intake manifold temperature sensor.
STEP 13 Refer to Procedure 019-059 in the Troubleshooting
and Repair Manual for CELECT™ Plus Systems,
Intake manifold temperature sensor is ............
malfunctioning
Repair Manual for CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step

Cause Correction
Check the ambient air pressure sensor. Refer to
Procedure 019-135 in the Troubleshooting and
............
Ambient air pressure sensor is malfunctioning Bulletin 3666130, or the Troubleshooting and
3666084.
OK
Go To Next Step
STEP 15 Check throttle position sensor for proper
Throttle position sensor is misadjusted or ............ adjustment and operation. Refer to the OEM
malfunctioning instructions.
OK
Go To Next Step
STEP 16 Check the fuel pump throttle linkage adjustment.
............
Throttle linkage adjustment is not correct Refer to Procedure 005-035.
OK
Go To Next Step
............
Engine is operating at low ambient temperature Refer to the OEM service manual.
OK
Go To Next Step
STEP 18 Check the air intake system for restriction. Clean

............ or replace the air filter and inlet piping as
Air intake system restriction is above specification
necessary. Refer to Procedure 010-031.
OK
Go To Next Step
STEP 19 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.
OK
Go To Next Step
STEP 20 Inspect the air intake and exhaust systems for air
............
Air intake or exhaust leaks leaks. Refer to Proedure 010-024.
OK
Go To Next Step
............
OK
Go To Next Step
Check the vehicle brakes for dragging,
STEP 22 transmission malfunction, cooling fan operation
............
Vehicle parasitics are excessive cycle time, and engine-driven units. Refer to the
OEM service manual.
OK
Go To Next Step

Cause Correction
STEP 23 Fill the fuel tanks. Turn off or bypass the fuel
............ heater, if equipped. Refer to the OEM service
Fuel temperature is above specification
manual.
OK
Go To Next Step
STEP 24 Operate the engine from a tank of high-quality fuel.
Fuel grade is not correct for the application or the ............ Refer to Fuels for Cummins Engines, Bulletin
fuel quality is poor 3379001.
OK
Go To Next Step
STEP 25 Check for correct gearing and drivetrain

............ components. Make sure the propeller size is
Drivetrain is not correctly matched to the engine
correct.
OK
Go To Next Step
STEP 26
Refer to the Intake Manifold Pressure (Boost) is
Intake manifold pressure (boost) is below ............
Below Normal symptom tree.
specification
OK
Go To Next Step
STEP 27 Check the fuel supply line from the fuel pump to
Fuel supply line restriction between the fuel pump ............ the cylinder head for sharp bends that can cause
and the injectors restrictions. Refer to Procedure 005-060.
OK
Go To Next Step
STEP 28 Engine power decreases above recommended

............ altitude. Refer to the Engine Data Sheet for
Engine is operating above recommended altitude
specifications.
OK
Go To Next Step
STEP 29 Derate the engine by four percent for every 300

............ meters [1000 feet] of altitude above 3000 m [10,000
Engine is operating above recommended altitude
ft]. Refer to the OEM service manual.
OK
Go To Next Step
STEP 30 Remove the PT® fuel pump and check the

calibration. Check the AFC for proper operation.
PT fuel pump AFC operation is malfunctioning or ............
Refer to the PT Fuel Pump Rebuild and Calibration
pump is not calibrated correctly
Manual, Bulletin 3379084.
OK
Go To Next Step

Cause Correction
STEP 31 Calibrate the injectors. Refer to Procedure
............
Injector calibration is not correct 006-026.
Engine Brake Does Not Operate (CELECT™ or CELECT™ Plus)

This is symptom tree t036-155
Cause Correction
inactive fault codes Troubleshooting and Repair Manaul for CELECT™
OK
Go To Next Step
STEP 2 Check the engine brake piston(s) for freedom of

............ movement. Replace the engine brake piston(s) if
Engine brake piston(s) is stuck
OK
Go To Next Step
Check the engine brake control valve(s). Replace
the engine brake control valve(s) if necessary.
STEP 3 Refer to Procedure 019-034 and 019-035 in the
............ Troubleshooting and Repair Manual for CELECT™
Engine brake control valve(s) is malfunctioning
Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
Check the engine brake harness connectors.
Check the engine brake harness for continuity.
STEP 4 Procedure 019-136 in the Troubleshooting and
Engine brake harness connectors are loose or ............ Repair Manual for CELECT™ Plus Systems,
broken Bulletin 3666130, or the Troubleshooting and
3666084
OK
Go To Next Step
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedures 019-009 and 019-010
STEP 5 in the Troubleshooting and Repair Manual for
............
Clutch switch or circuit is malfunctioning CELECT™ Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
Check throttle position sensor for proper
adjustment and operation. Refer to Procedures
STEP 6 019-085 and 019-086 in the Troubleshooting and
Throttle position sensor is misadjusted or ............ Repair Manual for CELECT™ Plus Systems,
malfunctioning Bulletin 3666130, or the Troubleshooting and
3666084.
OK
Go To Next Step
Engine Brake Does Not Operate (CELECT™ or CELECT™ Plus)

Cause Correction
STEP 7
Check the service brake pressure switch and
Service brake pressure switch or circuit is ............
circuit. Refer to the OEM service manual.
malfunctioning
OK
Go To Next Step
Check the engine brake enable circuit. Refer to
............
Engine brake enable circuit is malfunctioning Bulletin 3666130, or the Troubleshooting and
3666084.
OK
Go To Next Step
STEP 9 Check engine ground to chassis and chassis

............ ground to battery negative (-) post. Refer to
Engine electrical ground is malfunctioning
Procedure 013-009.
OK
Go To Next Step
STEP 10 Check for voltage at the solenoid valve. Procedure
............
Solenoid valve is malfunctioning 013-009
OK
Go To Next Step
STEP 11 Remove the solenoid valve and clean or replace
............
Solenoid valve filter screen is covered with debris the screen. Procedure 013-009
OK
Go To Next Step
STEP 12 Check the engine brake hose connections, the

............ engine brake housing, and the jumper tube o-rings
Lubricating oil leak (internal)
for oil leaks. Procedure 013-009
OK
Go To Next Step
STEP 13 Remove the oil supply line. Inspect the supply line
............
Engine brake lubricating oil supply line is restricted for a restriction.
OK
Go To Next Step
STEP 14 Adjust the engine brakes. Refer to Procedure
............
Engine brake adjustment is not correct 020-001.
Engine Brake Does Not Operate (PT)

Cause Correction
STEP 1 Check the engine brake piston(s) for freedom of

............ movement. Replace the engine brake piston(s) if
Engine brake piston(s) is stuck
OK
Go To Next Step
Check the engine brake power supply circuit.
STEP 2 Check for blown fuses in the power supply wiring.
............
Engine brake power supply connection is loose Check the on/off switch for correct operation.
Procedure 020-001
OK
Go To Next Step
STEP 3 Check the clutch switch adjustment and the clutch
............
Clutch switch is malfunctioning switch circuit. Refer to the OEM service manual.
OK
Go To Next Step
STEP 4 Check the engine brake throttle switch (fuel pump
............
Engine brake throttle switch is malfunctioning switch). the OEM service manual
OK
Go To Next Step
STEP 5
malfunctioning
OK
Go To Next Step
STEP 6 Check engine ground to chassis and chassis

............ ground to battery negative (-) post. Refer to
Engine electrical ground is malfunctioning
Procedure 013-009 and the OEM service manual.
OK
Go To Next Step
............
Solenoid valve is malfunctioning 013-009 and the OEM service manual
OK
Go To Next Step

............ the screen. Procedure 013-009 and the OEM
Solenoid valve filter screen is covered with debris
service manual
OK
Go To Next Step
Check the engine brake hose connections, the
STEP 9 engine brake housing, and the jumper tube o-rings
............
Lubricating oil leak (internal) for oil leaks. Procedure 013-009 and the OEM
service manual
OK
Go To Next Step
Engine Brake Does Not Operate (PT)

Cause Correction
............
OK
Go To Next Step
............
Engine Brake - Low Retarding Power or Slow to Activate (CELECT™ or CELECT™ Plus)
Cause Correction
OK
Go To Next Step
Allow the engine to warm to operating temperature.
STEP 2 If the engine will not reach operating temperature,
............
Engine is cold refer to the Coolant Temperature Below Normal
symptom tree.
OK
Go To Next Step
STEP 3 Check the oil pressure. If the pressure is low, refer
............
Lubricating oil pressure is below specification to Procedure 007-028.
OK
Go To Next Step
STEP 4 Check the oil level. If level is high, check for a
............
Air in the lubricating oil system cracked suction tube. Refer to Procedure 007-025.
OK
Go To Next Step
STEP 5 Check the engine brake hose connections, the

............ engine brake housing, and the jumper tube o-rings
Lubricating oil leak (internal)
for oil leaks. Procedure 007-025
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
Check the engine brake harness connectors.
Check the engine brake harness for continuity.
STEP 8 Refer to the wiring diagrams in the
Engine brake harness connectors are loose or ............ Troubleshooting and Repair Manual for CELECT™
broken Plus Systems, Bulletin 3666130, or
OK
Go To Next Step
Engine Brake - Low Retarding Power or Slow to Activate (CELECT™ or CELECT™ Plus)
Cause Correction
Check the master piston for freedom of movement.
Replace the master piston if necessaryRefer to the
STEP 9 wiring diagrams in the Troubleshooting and Repair
............
Master piston is stuck Manual for CELECT™ Plus Systems, Bulletin
3666130, or Troubleshooting and Repair Manual
for CELECT™ Systems, Bulletin 3666084..
OK
Go To Next Step
STEP 10
Remove the solenoid valves and replace the center
Engine brake solenoid valve has a leaking center ............
o-rings if necessary.
o-ring seal
Engine Brake - Low Retarding Power or Slow to Activate (PT)

Cause Correction
Allow the engine to warm to operating temperature.
STEP 1 If the engine will not reach operating temperature,
............
Engine is cold refer to the Coolant Temperature Below Normal
symptom tree.
OK
Go To Next Step
............
Lubricating oil pressure is below specification toProcedure 007-028.
OK
Go To Next Step
STEP 3 Check the oil level. If level is high, check for a
............
Air in the lubricating oil system cracked suction tube. Refer to Procedure 007-025.
OK
Go To Next Step
STEP 4 Check the outside of the brake housing for oil leaks
............ and missing or loose plugs. Replace the plugs if
Engine brake housing oil plug is missing or loose
necessary.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 8 Remove the solenoid valve and inspect the top and
............ bottom o-rings. Replace the o-rings if necessary.
Solenoid valve o-ring seals are leaking
Procedure 020-001
OK
Go To Next Step
............
Solenoid valve filter screen is covered with debris the screen. Procedure 020-001
OK
Go To Next Step
Engine Brake - Low Retarding Power or Slow to Activate (PT)

Cause Correction
STEP 10
Inspect the outer control valve springs and control
Outer control valve spring is broken or control ............
valve. Procedure 020-001
valve is sticking
OK
Go To Next Step
STEP 11 Check the master piston for freedom of movement.

............ Replace the master piston if necessary Procedure
Master piston is stuck
020-001.
Engine Brake — One or More Cylinders Braking with Power Switch Off (CELECT™ or
CELECT™ Plus)
Cause Correction
OK
Go To Next Step
STEP 2 Check the engine brake enable circuit. Refer to

Engine brake enable circuit is malfunctioning ............
(CELECT™ system only)
3666084.
OK
Go To Next Step
Check the engine brake on/off switch and circuit.
STEP 3 Refer to Procedure 019-035 in the CELECT™ Plus
Systems Troubleshooting and Repair Manual,
Engine brake on/off switch or circuit is ............
Bulletin 3666130, or the CELECT™ System
malfunctioning
Troubleshooting and Repair Manual, Bulletin
3666084.
OK
Go To Next Step
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedure 019-009 and 019-010 in
STEP 4 the CELECT™ Plus Systems Troubleshooting and
............
Clutch switch or circuit is malfunctioning Repair Manual, Bulletin 3666130, or the CELECT™
System Troubleshooting and Repair Manual,
Bulletin 3666084.
OK
Go To Next Step
Check throttle position sensor for proper
adjustment and operation. Refer to Procedures
STEP 5 019-085 and 019-086 in the CELECT™ Plus
Throttle position sensor is misadjusted or ............ Systems Troubleshooting and Repair Manual,
malfunctioning Bulletin 3666130, or the CELECT™ System
3666084.
OK
Go To Next Step
STEP 6
malfunctioning
OK
Go To Next Step
Engine Brake — One or More Cylinders Braking with Power Switch Off (CELECT™ or
CELECT™ Plus)
Cause Correction
............
OK
Go To Next Step
Procedure 020-001
OK
Go To Next Step
............
OK
Go To Next Step
STEP 10 Inspect the inner control valve springs and the

control valve. Refer to the Troubleshooting and
Inner control valve spring is broken or the control ............
Repair Manual, C-Brake, Bulletin 3810473.
valve is stuck in the on position
Replace the springs or control valve as necessary.
Engine Brake — One or More Cylinders Braking with Power Switch Off (PT)
Cause Correction
Check the engine brake on/off switch and circuit.
Engine brake on/off switch or circuit is ............
malfunctioning
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4
malfunctioning
OK
Go To Next Step
............
OK
Go To Next Step
Procedure 020-001
OK
Go To Next Step
............
OK
Go To Next Step
STEP 8 Inspect the inner control valve springs and the

control valve. Refer to the Troubleshooting and
Inner control valve spring is broken or the control ............
Repair Manual, C-Brake , Bulletin 3810473.
valve is stuck in the on position
Replace the springs or control valve as necessary.
Engine Decelerates Slowly (CELECT™ or CELECT™ Plus)

Cause Correction
Electronic fault codes active or high counts of ............ 3666130, or Section T in the Troubleshooting and
3666084.
OK
Go To Next Step
STEP 2 Check the fuel pump throttle linkage and return

............ spring for free movement. Adjust if
Throttle linkage or return spring is binding
necessary.Refer to the OEM service manual.
OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step
STEP 4 Perform the automated cylinder performance test.

............ Replace injectors as necessary. Refer to
Injector is malfunctioning
Procedure 006-026.
OK
Go To Next Step
STEP 5 Inspect the fuel pump pulsation damper. Replace

............ the pulsation damper if necessary. Refer to
Fuel pump pulsation damper is cracked
Procedure 005-011.
Engine Decelerates Slowly (PT)

Cause Correction
STEP 1 Check the fuel pump throttle linkage and return

............ spring for free movement. Adjust if
Throttle linkage or return spring is binding
necessary.Refer to the OEM service manual.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3 Remove and clean the tank vents. Replace the

............ vents if necessary. Refer to the OEM service
Fuel tank vents are plugged or damaged
manual.
OK
Go To Next Step
STEP 4 Check the fuel tank check valve for debris. Check
Overhead fuel tank check valve is restricted or is ............ the valve for the correct plumbing arrangement.
not opening Refer to the OEM service manual.
OK
Go To Next Step

Procedure 005-011.
OK
Go To Next Step
STEP 6 Remove the fuel pump. Refer to the PT Fuel Pump
............
PT fuel pump throttle leakage is excessive Rebuild and Calibration Manual, Bulletin 3379084.
OK
Go To Next Step
STEP 7
Check the injectors. Repair or replace the injectors
Injector check ball is not seating correctly or is ............
missing
OK
Go To Next Step
STEP 8 Remove and check the injectors. Replace injectors
............
Injector is malfunctioning (PT/STC) as necessary. Refer to Procedure 006-026.
Engine Difficult to Start or Will Not Start (Exhaust Smoke)

Cause Correction
OK
Go To Next Step
Check the engine cranking speed with a handheld
STEP 2 tachometer or electronic service tool. If the
............ cranking speed is slower than 150 rpm, refer to the
Engine cranking speed is too slow
Engine Will Not Crank or Cranks Slowly symptom
tree.
OK
Go To Next Step
STEP 3 Check the fuel pressure. Refer to Procedure
Cranking fuel pressure at the fuel pump is below ............ 005-011. If fuel pressure is low, refer to the
specification Cranking Fuel Pressure is Low symptom tree.
OK
Go To Next Step
OK
Go To Next Step
and the injectors restrictions. Refer to Procedure 005-011.
OK
Go To Next Step
............
OK
Go To Next Step

OK
Go To Next Step
STEP 8 Check for a plastic fuel passage plug blocking the

............ fuel supply to the injectors. Refer to Procedure
Fuel drillings in the cylinder head are plugged
002-004.
OK
Go To Next Step
Engine Difficult to Start or Will Not Start (Exhaust Smoke)

Cause Correction
STEP 9 Check for correct operation of the cold weather
Starting aid, if necessary for cold weather, is ............ starting aid. Refer to Operation of Diesel Engines
malfunctioning in Cold Climates, Bulletin 3379009.
OK
Go To Next Step
STEP 10 Remove the PT® fuel pump and check the

calibration. Check the AFC for proper operation.
PT fuel pump AFC operation is malfunctioning or ............
Refer to Procedure 005-016 and the PT Fuel Pump
pump is not calibrated correctly
Rebuild and Calibration Manual, Bulletin 3379084.
OK
Go To Next Step
STEP 11 Measure and adjust the overhead settings. Refer
............
Overhead adjustments are not correct to Procedure 003-004.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
Injector is malfunctioning (CELECT™ and ............ Replace injectors as necessary. Refer to
CELECT™ Plus) Procedure 006-026.
OK
Go To Next Step
STEP 15 Check the valve protrusion. Replace the valve seat

............ inserts or the cylinder head. Refer to Procedure
Valve protrusion is below specification
002-004.
OK
Go To Next Step
Compare the Control Parts List (CPL) to the engine
STEP 16 components. Replace components that do not
............
Engine components are not correct meet CPL requirements. Refer to the OEM service
manual.
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)

Cause Correction
STEP 1 Repair Manual, CELECT™ Plus systems, Bulletin
3666084.
OK
Go To Next Step
STEP 2 Fill the supply tank. Refer to the OEM service
............
Fuel level is low in the tank manual.
OK
Go To Next Step
STEP 3 Check the direction of crankshaft rotation. Replace

............ the starting motor if necessary. Refer to Procedure
Starting motor rotation is not correct
013-020.
OK
Go To Next Step
STEP 4 Procedures Procedures 019-049 and 019-050 in
the Troubleshooting and Repair Manual,
Fuel shutoff valve(s) closed (electronically ............
CELECT™ Plus Systems, Bulletin 3666130, or the
controlled injection)
Troubleshooting and Repair Manual, CELECT™
OK
Go To Next Step
OK
Go To Next Step
STEP 6
Auxiliary shutdown device (Skinner valve) is Repair or replace the shutdown device or external
............
closed. External governor is malfunctioning or governor.
not installed correctly
OK
Go To Next Step
Check the battery connections. Check the fuses
and the unswitched battery supply circuit. Refer to
STEP 7 Procedures 019-198 and 019-087 in the
Battery voltage supply to the electronic control ............ Troubleshooting and Repair Manual, CELECT™
module (ECM) has been lost Plus Systems, Bulletin 3666130, or the
Troubleshooting and Repair Manual, CELECT™
OK
Go To Next Step
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)

Cause Correction
STEP 8 Replace the fuel filter. Refer to Procedure 006-015.

............ Check the fuel suction line for restriction
Fuel filter or fuel suction line is restricted
Procedure 006-015.
OK
Go To Next Step
STEP 9
Tighten all fuel fittings and connections between
Fuel connections on the low-pressure side of the ............
the fuel tanks and the fuel pump.
pump are loose
OK
Go To Next Step
............
OK
Go To Next Step
STEP 11 Check and repair the standpipe, if necessary.
............
Fuel suction standpipe in the fuel tank is broken Refer to the OEM service manual.
OK
Go To Next Step
STEP 12
Inspect the check valve(s) for correct installation
In-line check valve(s) are installed backwards or ............
and part number.
have incorrect part number
OK
Go To Next Step
Replace the fuse(s) in the OEM interface harness.
............
Fuse(s) malfunctioning and Repair Manual, CELECT™ Plus Systems,
Bulletin 3666130.
OK
Go To Next Step
Check the air actuated RSG piston o-ring seal.
STEP 14 Refer to PT Fuel Pump Rebuild and Calibration
PT fuel pump air actuated RSG piston o-ring seal ............ Manual, Bulletin 3379084. When the seal leaks,
is leaking the RSG air pressure pumps fuel from the pump
into the supply line.
OK
Go To Next Step
CELECT™ Plus) Procedure 006-026.
Engine Noise Excessive

When troubleshooting engine noise complaints, make sure the engine accessories (air compressor, fan clutch, freon
compressor, or hydraulic pump) are not the cause of the noise. Refer to Engine Noise Diagnostic Procedures - General
Information at the end of Section TS before using this symptom tree.
Cause Correction
............
Lubricating oil pressure is below specification tothe Lubricating Oil Pressure Low symptom tree.
OK
Go To Next Step
Check the oil level. Verify the dipstick calibration
STEP 2 and the oil pan capacity. Fill the system to the
............
Lubricating oil level is below specification specified level. Refer to Procedures 007-009 and
007-037.
OK
Go To Next Step
Check the coolant level. Refer to the Coolant
STEP 3 Temperature is Above Normal - Sudden Overheat
............
Coolant temperature is above specification or the Coolant Temperature is Above Normal -
Gradual Overheat symptom tree.
OK
Go To Next Step
STEP 4 Refer to Lubricating Oil Contaminated symptom
............
Lubricating oil is thin or diluted tree.
OK
Go To Next Step
STEP 5 Check the fan drive belt. Refer to Procedure
............
Fan drive belt is loose, tight, or not in alignment 008-002.
OK
Go To Next Step
STEP 6
Fan is loose, damaged, or has excessive hub ............ Check the fan. Refer to Procedure 008-040.
bearing end play
OK
Go To Next Step
STEP 7 Check the engine mounts. Refer to Procedure
............
Engine mounts are worn, damaged, or not correct 016-010.
OK
Go To Next Step
STEP 8
Inspect the air piping, chassis, and cab for contact
Air intake or exhaust piping is contacting the ............
points. Refer to the OEM service manual.
chassis or cab
OK
Go To Next Step

Cause Correction
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.
OK
Go To Next Step
STEP 10 Refer to the Engine Noise Excessive -
............
Turbocharger noise Turbocharger symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 12 Perform the single-cylinder cutout test. Replace

............ the injectors as necessary. Refer to Procedures
006-005 and 006-026.
OK
Go To Next Step
Inspect the rocker levers, rocker shafts, cam
STEP 13 followers or tappets, push rods, and valves for
............
Overhead components are damaged damage or excessive wear. Refer to Procedures
003-009, 004-001, 004-014, and 002-004.
OK
Go To Next Step
STEP 14
Check the accessory drive axial end play. Inspect
Accessory drive is worn (axial end play is out of ............
the shaft for wear. Refer to Procedure 009-001.
specification)
OK
Go To Next Step
STEP 15 Check the static injection timing. Refer to
............
Static injection timing is not correct Procedure 006-025.
OK
Go To Next Step
STEP 16 Inspect the vibration damper. Refer to Procedure
............
Vibration damper is damaged 001-052.
OK
Go To Next Step
STEP 17 Refer to the Engine Noise Excessive — Air
............
Air compressor noise is excessive Compressor symptom tree.
OK
Go To Next Step

Cause Correction
STEP 18
Isolate each component and check for noise. Refer
Fan clutch, hydraulic pump, or freon compressor ............
to the OEM service manual.
noise is excessive
OK
Go To Next Step
STEP 19 Disconnect the drivetrain. Check for engine noise.
............
Drivetrain noise is excessive Refer to the OEM service manual.
OK
Go To Next Step
STEP 20
Check the gear backlash and the gear teeth. Refer
Gear train backlash is excessive or the gear teeth ............
to Procedures 001-013 and 001-018.
are damaged
OK
Go To Next Step
STEP 21 Refer to the Engine Noise Excessive — Main
............
Main bearing or connecting rod bearing noise Bearing symptom tree.
OK
Go To Next Step
STEP 22
Check the flywheel or flexplate and the mounting
Flywheel or flexplate capscrews are loose or ............
capscrews. Refer to Procedure 016-005.
broken
OK
Go To Next Step
STEP 23
Inspect the air intake system for leads. Refer to the
Engine Noise Excessive - Piston symptom tree.
damaged
OK
Go To Next Step
STEP 24 Check the PTO for damage and correct
............
Power take-off (PTO) is damaged installation. Refer to the OEM service manual.
Engine Noise Excessive — Combustion Knocks

Refer to Engine Noise Diagnostic Procedures - General Information at the end of Section TS before using this symptom
tree.
Cause Correction

............ Refer to the Operation of Diesel Engines in Cold
Engine is operating at low ambient temperature
Climates, Bulletin 3379009.
OK
Go To Next Step
STEP 2 Repair or replace the ether starting aids. Refer to
............
Ether starting aid is malfunctioning the manufacturer's instructions.
OK
Go To Next Step
OK
Go To Next Step
............
OK
Go To Next Step
STEP 5 Refer to the Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step

006-005 and 006-026.
OK
Go To Next Step
............
Engine Noise Excessive — Connecting Rod

tree.
Cause Correction
OK
Go To Next Step

............ 007-028. If the pressure is low, refer to the
Lubricating oil pressure is below specification
Lubricating Oil Pressure Low symptom tree.
OK
Go To Next Step
............
007-025.
OK
Go To Next Step
STEP 4 Refer to Section 7. If the oil pressure is low, refer
............
Lubricating oil is thin or diluted to the Lubricating Oil Pressure Low symptom tree.
OK
Go To Next Step
STEP 5
Check the torque on the connecting rod
Connecting rod capscrews are loose or not ............
tightened correctly
OK
Go To Next Step
STEP 6
Inspect the connecting rod bearings. Refer to
Connecting rod bearings are damaged or worn, are ............
Procedure 001-014.
not assembled correctly, or are the wrong bearings
OK
Go To Next Step
STEP 7 Remove and inspect the connecting rods. Refer to
............
Connecting rod is bent or out of alignment Procedure 001-014.
OK
Go To Next Step
STEP 8 Inspect the crankshaft journals. Refer to Procedure
............
Crankshaft journals are damaged or out of round 001-016.
Engine Noise Excessive — Main Bearing

tree.
Cause Correction
OK
Go To Next Step
............
Lubricating oil pressure is below specification toProcedure 007-028.
OK
Go To Next Step
............
007-037.
OK
Go To Next Step
STEP 4 Refer to Section 7. If the oil pressure is low, refer
............
Lubricating oil is thin or diluted to the Lubricating Oil Pressure Low symptom tree.
OK
Go To Next Step
STEP 5
broken
OK
Go To Next Step
STEP 6 Check the torque converter. Refer to the OEM
............
Torque converter is loose service manual.
OK
Go To Next Step
STEP 7
............ Refer to Procedure 001-006.
Main bearing or connecting rod bearing noise
OK
Go To Next Step
STEP 8 Inspect the main bearings for damage, excessive
Main bearings are damaged or worn, or the wrong ............ wear, and the correct part number. Refer to
bearings are installed Procedure 001-006.
OK
Go To Next Step
Engine Noise Excessive — Main Bearing

tree.
Cause Correction
STEP 9 Inspect the crankshaft journals. Refer to Procedure
............
Crankshaft journals are damaged or out of round 001-016.
Engine Noise Excessive — Piston

tree.
Cause Correction
OK
Go To Next Step
............
OK
Go To Next Step

006-005 and 006-026.
OK
Go To Next Step
Remove the cylinder head and check for carbon
STEP 4 deposits on the pistons. If deposits are excessive,
Carbon deposits on the top of the pistons are ............ remove and clean the pistons. Check the piston
contacting the cylinder head rings for damage or wear. Refer to Procedures
002-004, 001-054, 001-043, and 001-047.
OK
Go To Next Step
STEP 5 Remove the pistons and inspect the piston pin and
Piston pin or bushing is loose, worn, or not ............ bushing for damage, wear, and correct installation.
installed correctly Refer to Procedure 001-043.
OK
Go To Next Step
STEP 6
Inspect the air intake system for leads. Refer to
Procedures 001-043, 001-047, and 001-028.
damaged
OK
Go To Next Step
STEP 7 Remove and inspect the connecting rods. Refer to
............
Connecting rod is bent or out of alignment Procedure 001-014.
Engine Noise Excessive — Turbocharger

tree.
Cause Correction
Check the turbocharger part number and compare
STEP 1 it to the Control Parts List (CPL), Bulletin 3379133
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
OK
Go To Next Step
STEP 2
Inspect the air piping, chassis, and cab for contact
Air intake or exhaust piping is contacting the ............
points. Refer to the OEM service manual.
chassis or cab
OK
Go To Next Step
............
OK
Go To Next Step

OK
Go To Next Step
............
OK
Go To Next Step
STEP 6 Check the turbocharger for damage. Measure the

............ turbine and compressor wheel clearances. Refer
Turbocharger is worn or damaged
to Procedures 010-039 .
Engine Power Output Low (CELECT™ or CELECT™ Plus)

Cause Correction
inactive fault codes Repair Manaul, CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
Refer to Driveability - General Information, the
STEP 2 Driveability/Low Power Customer Complaint Form,
............ and the Driveability Checklist at the end of Section
Interview the operator to verify the complaint
TS. Follow the instructions on the form before
continuing with this tree.
OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step
Check the programmable parameters and the
Set the parameters and features again if
STEP 4 necessary. Refer to the appropriate electronic
Programmable parameters or selected features ............ service tool manual and Procedure 019-078 in the
are not correct Troubleshooting and Repair Manual for CELECT™
OK
Go To Next Step
............
Drivetrain is not correctly matched to the engine components. Refer to the OEM service manual.
OK
Go To Next Step

Cause Correction
STEP 6 Check the oil level. Verify the dipstick calibration

............ and oil pan capacity. Fill the system to the specified
Lubricating oil level is above specification
level. Refer to Procedures 007-009 and 007-037.
OK
Go To Next Step
STEP 7
Operate the engine from a tank of good fuel. Refer
Fuel grade is not correct for the application, or the ............
to Fuels for Cummins Engines, Bulletin 3379001.
fuel quality is poor
OK
Go To Next Step
............
OK
Go To Next Step
STEP 9 Fill the fuel tank, turn off or bypass the fuel heaters,
Fuel inlet temperature to pump is above ............ and check the fuel cooler. Refer to the OEM
specification service manual.
OK
Go To Next Step
STEP 10 Check the air intake system for restriction. Refer to
............
Air intake system restriction Procedure 010-031.
OK
Go To Next Step
STEP 11
Refer to the Intake Manifold Air Temperature
Intake manifold air temperature is above ............
Above Specification symptom tree.
specification
OK
Go To Next Step
STEP 12 Inspect the charge air cooler for air restrictions or
............
Charge air cooler is restricted or leaking leaks. Refer to Procedure 010-027.
OK
Go To Next Step
STEP 13
specification
OK
Go To Next Step
Check the throttle position sensor and circuit.
STEP 14 Refer to the Troubleshooting and Repair Manual
Throttle position sensor or circuit malfunctioning (if ............ for CELECT™ Plus Systems, Bulletin 3666130, or
equipped with a throttle position sensor) the Troubleshooting and Repair Manual for
CELECT™ Systems, Bulletin 3666084.
OK
Go To Next Step

Cause Correction
Compare the vehicle tachometer and speedometer
STEP 15 readings with an electronic service tool reading.
Check the calibration values for the flywheel teeth,
Tachometer or speedometer is not calibrated or is ............
rear axle ratio, and tire revolutions. Adjust the
malfunctioning
values if necessary. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 16 Derate the engine by 4 percent for every 300
Engine is operating above recommended altitude ............ meters [1000 feet] of altitude above 3600 meters
(STC engines only) [12,000 ft]. Refer to the Engine Data Sheet.
OK
Go To Next Step
STEP 17 Troubleshooting and Repair Manaul for CELECT™
............
Engine protection fault code(s) inactive Systems, Bulletin 3666084. View the fault codes
and the engine protection data with an electronic
service tool. Refer to the appropriate electronic
service tool manual.
OK
Go To Next Step
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
Refer to the appropriate electronic service tool
STEP 18 manual. If the monitor shows speed, check the
Vehicle speed sensor (VSS) or circuit is ............ sensor and circuit. Refer to Procedure 019-090 or
malfunctioning 019-091 in the Troubleshooting and Repair Manual
for CELECT™ Plus Systems, Bulletin 3666130, or
the Troubleshooting and Repair Manual for
OK
Go To Next Step
STEP 19 Refer to Procedures 019-059 and 019-060 in the
malfunctioning
OK
Go To Next Step
Check the coolant temperature sensor. Refer to
............ CELECT™ Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step

Cause Correction
Check the ambient air pressure sensor. Refer to
Ambient air pressure sensor is malfunctioning (if ............
equipped)
3666084.
OK
Go To Next Step
Check the boost sensor and circuit. Refer to
Intake manifold pressure (boost) sensor or circuit ............
is malfunctioning
3666084.
OK
Go To Next Step
STEP 23 Verify if the driver is accustomed to the automotive

governor or the VS governor. Change the governor
Governor setting is not correct in the ............
setting if necessary. Refer to the appropriate
programmable parameters
electronic service tool manual.
OK
Go To Next Step
STEP 24 Measure the fuel supply pressure. Refer to the
............
Fuel supply pressure is below specification OEM service manual.
OK
Go To Next Step
and the injectors restrictions. Refer to the OEM service manual.
OK
Go To Next Step
STEP 26 Check the radial bearing clearance and axial

clearance. Inspect the turbocharger. Repair or
Turbocharger wheel clearance is out of ............
replace the turbocharger if necessary. Refer to
specification
Procedures 010-038 and 010-047.
OK
Go To Next Step
............
Engine components are not correct meet CPL requirements. Refer to the Control Parts
List, Bulletin 3379133.
OK
Go To Next Step

Cause Correction
STEP 28 Check and adjust the overhead settings. Refer to
............
Overhead adjustments are not correct Procedure 003-004.
OK
Go To Next Step

tree.
OK
Go To Next Step
STEP 30
............ Use outside air to the turbocharger in hot weather.
Engine is operating at high ambient temperature
OK
Go To Next Step
Check the winterfront, shutters, and under-the-
STEP 31 hood air. Use under-the-hood intake air in cold
............
Engine is operating at low ambient temperature weather. Refer to Operation of Diesel Engines in
Cold Climates, Bulletin 3379009.
OK
Go To Next Step
manual.
OK
Go To Next Step
STEP 33 Check for a plastic fuel passage plug blocking the

............ fuel supply to the injectors. Refer to Procedure
Fuel drillings in the cylinder head are plugged
002-004.
OK
Go To Next Step
Check the vehicle, equipment, or vessel keyswitch
circuit. Refer to Procedure 019-064 in the
STEP 34 Troubleshooting and Repair Manual for CELECT™
............
Keyswitch circuit is malfunctioning Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
STEP 35 Check for air in the fuel system. Completely vent

............ air from the fuel system. Refer to Procedure
Air in the fuel system
006-003.
Engine Power Output Low (PT)

Cause Correction
Refer to Driveability - General Information, the
STEP 1 Driveability/Low Power Customer Complaint Form,
............ and the Driveability Checklist at the end of Section
Interview the operator to verify the complaint
TS. Follow the instructions on the form before
OK
Go To Next Step

............ components. Refer to the OEM vehicle
specifications.
OK
Go To Next Step

level. Refer to Procedures 007-009 and 007-025..
OK
Go To Next Step
STEP 4
Operate the engine from a tank of good fuel. Refer
Fuel grade is not correct for the application, or the ............
to Fuels for Cummins Engines, Bulletin 3379001.
fuel quality is poor
OK
Go To Next Step
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024..
OK
Go To Next Step
STEP 6 Fill the fuel tank, turn off or bypass the fuel heaters,
Fuel inlet temperature to pump is above ............ and check the fuel cooler. Refer to the OEM
specification service manual.
OK
Go To Next Step
STEP 7 Inspect the air intake system for restriction. Clean

............ or replace filter and inlet piping as necessary.
OK
Go To Next Step
STEP 8
Refer to the Intake Manifold Air Temperature
Intake manifold air temperature is above ............
Above Specification symptom tree.
specification
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
STEP 10
specification
OK
Go To Next Step
............
OK
Go To Next Step
Compare the vehicle tachometer and speedometer
STEP 12 readings with an electronic service tool reading.
Check the calibration values for the flywheel teeth,
Tachometer or speedometer is not calibrated or is ............
rear axle ratio, and tire revolutions. Adjust the
malfunctioning
values if necessary. Refer to the OEM service
manual.
OK
Go To Next Step
OK
Go To Next Step
............
Engine components are not correct meet CPL requirements. Refer to Control Parts
List, Bulletin 3379133.
OK
Go To Next Step
Measure the fuel supply pressure. Refer to
STEP 15 Procedure 005-011. If the fuel pressure is low, refer
............
Fuel supply pressure is below specification to the Operating Fuel Pressure is Low symptom
tree.
OK
Go To Next Step
and the injectors restrictions. Refer to the OEM service manual.
OK
Go To Next Step

Cause Correction

specification
OK
Go To Next Step

tree.
OK
Go To Next Step
STEP 19 Check and adjust the overhead settings. Refer to
............
Overhead adjustments are not correct Procedure 003-004.
OK
Go To Next Step
STEP 20
............ Use outside air to the turbocharger in hot weather.
Engine is operating at high ambient temperature
OK
Go To Next Step
............
OK
Go To Next Step
manual.
OK
Go To Next Step
STEP 23 Check the AFC signal line for restriction and leaks.
............ Refer to Injector Specifications Manual, Bulletin
AFC signal line is restricted or leaking
3379664.
OK
Go To Next Step
Remove the injectors. Check the injectors for the
STEP 24 correct calibration. Check the inlet screen for
Injector calibration is not correct or the fuel supply ............ restriction. Check for carbon buildup on the
to the injector is restricted (PT injectors) plungers. Refer to Procedure 006-026 and the
Injector Specifications Manual, Bulletin 3379664.
OK
Go To Next Step

Cause Correction
STEP 25 Check the vehicle, equipment, or vessel keyswitch
............
Keyswitch circuit is malfunctioning circuit. Refer to the OEM specifications.
Engine Runs Rough at Idle

Cause Correction
STEP 1
Idle characteristics of CELECT™ and CELECT™ Normal performance. No corrections are
............
Plus systems are different than characteristics of necessary.
the PT® system
OK
Go To Next Step
Electronic fault codes active or high counts of ............ Bulletin 3666130, or the Troubleshooting and
inactive fault codes Repair Manual for CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
............ CELECT™ Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step
STEP 5
Adjust the fuel pump idle speed. Refer to
Engine idle speed is set too low (mechanical fuel ............
Procedure 005-029.
systems)
OK
Go To Next Step
STEP 6
Verify the correct idle speed setting. Increase the
Engine idle speed is set too low (electronically ............
idle speed with INSITE™.
controlled fuel systems)
OK
Go To Next Step

Cause Correction
OK
Go To Next Step
............
OK
Go To Next Step
STEP 9 Measure the fuel supply pressure. Refer to
............
Fuel supply pressure is below specification Procedure 005-011.
OK
Go To Next Step
............
OK
Go To Next Step

Procedure 005-031.
OK
Go To Next Step
OK
Go To Next Step
STEP 13 Check the STC plumbing to each cylinder for

............ restriction or loss of flow. Refer to Procedures
White smoke is present
006-045 and 006-046.
OK
Go To Next Step
............
Engine mounts are worn, damaged, or not correct 016-010 and the OEM service manual.
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction
CELECT™ Plus) Procedures 006-005 and 006-026.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 18 Compare the injector top link part number to the
............
STC injector top link is not correct injector parts listing. Refer to Procedure 006-025.
OK
Go To Next Step
STEP 19 Check the camshaft end clearance. Refer to
............
Camshaft end clearance is excessive Procedure 001-065.
OK
Go To Next Step
STEP 20 Check the cylinder head for fuel leaks between the
............ valves and valve seats. Refer to Procedure
Cylinder head valve leak
002-004.
OK
Go To Next Step
Analyze the oil and inspect the filters to locate an
STEP 21 area of probable damage. Inspect for damaged
............
Internal engine damage crankshaft, pistons, and liners. Refer to
Engine Runs Rough or Misfires

Cause Correction
STEP 1 Refer to Section TF in the Troubleshooting and

Repair Manual CELECT™ Plus Systems, Bulletin
3666130, or Section TF of the CELECT™ Systems,
Bulletin 3666084.
OK
Go To Next Step
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4 Refer to the Engine Runs Rough at Idle symptom
............
Condition occurs only at idle tree.
OK
Go To Next Step

............ Refer to Operation of Diesel Engines in Cold
OK
Go To Next Step
Verify the electronic control module (ECM)
calibration is correct. Check the calibration
revision history for applicable fixes to the
calibration stored in the ECM. Refer to the
STEP 6 Online Internet Website or the INCAL™ calibration
Electronic control module (ECM) calibration is ............ CD. Compare the calibration stored in the ECM
malfunctioning with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to Procedure 019-032
in the Troubleshooting and Repair Manual for
OK
Go To Next Step
OK
Go To Next Step
Engine Runs Rough or Misfires

Cause Correction
............
OK
Go To Next Step
............
OK
Go To Next Step

Procedure 005-031.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 13 Check the cylinder head for fuel leaks between the
............ valves and valve seats. Refer to Procedure
Cylinder head valve leak
002-004.
OK
Go To Next Step
STEP 14 Inspect the camshaft for damage. Refer to
............
Camshaft is damaged Procedure 001-008.
OK
Go To Next Step
............
Internal engine damage crankshaft, pistons, and liners. Refer to Procedure
007-083.
Engine Shuts Off Unexpectedly or Dies During Deceleration

Cause Correction
Refer to Section TF in the Troublshooting and
STEP 1 Repair Manual CELECT™ Plus Systems, Bulletin
inactive fault codes Repair Manual for the CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
Check the battery connections, the fuses, and the
unswitched battery supply circuit. Refer to
STEP 2 Procedure 013-009 or Procedures 019-198 and
Battery voltage supply to the electronic control ............ 019-087 in the Troublshooting and Repair Manual
module (ECM) is low, interrupted, or open for CELECT™ Plus Systems, Bulletin 3666130, or
OK
Go To Next Step
STEP 3 Perform a manual start. If engine will not start,

............ refer to the Engine Difficult to Start or Will Not Start
Engine will not restart
symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 6
Procedure 005-029.
systems)
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction
STEP 9 Isolate the OEM engine protection system. Follow

............ the OEM service manuals to check for a
OEM engine protection system is malfunctioning
malfunction.
OK
Go To Next Step
Check the batteries and the unswitched battery
supply circuit. Refer to Procedure 013-009 or
STEP 10 Procedure 019-087 in the Troublshooting and
............ Repair Manual for CELECT™ Plus Systems,
Battery voltage is low
3666084 and the OEM service manual.
OK
Go To Next Step
STEP 11 Procedures Procedures 019-049 and 019-050 in
the Troublshooting and Repair Manual for
Fuel shutoff valve(s) closed (electronically ............
controlled injection)
OK
Go To Next Step
OK
Go To Next Step
Check the fuel pump output pressure with
STEP 13 INSITE™, an electronic service tool. Replace the
............
Fuel pump is malfunctioning fuel pump if necessary. Refer to Procedures
005-016 and 005-031.
OK
Go To Next Step
OK
Go To Next Step
STEP 15 Check the engine brake operation, adjustment,

............ and solenoid resistance. Repair or adjust as
Engine brakes are malfunctioning
OK
Go To Next Step

Cause Correction
STEP 16 Remove the injectors and verify the injector sealing

............ washer thickness. Refer to Procedures 006-005
Injector sealing washer is not correct
and 006-026.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
Engine Speed Surges at Low or High Idle

Cause Correction
Refer to Section TF in the Troublshooting and
inactive fault codes Repair Manual for the CELECT™ Systems, Bulletin
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3 Fill the supply tank. Refer to the OEM vehicle
............
Fuel level is low in the tank specifications.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 5
OK
Go To Next Step
STEP 6
Procedure 005-029.
systems)
OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
OK
Go To Next Step
Check the engine position sensor and circuit. Refer
STEP 10 to Procedures 019-038 and 019-039 in the
Troubleshooting and Repair Manual CELECT™
Engine position sensor (EPS) or circuit is ............
malfunctioning
Troubleshooting and Repair Manual CELECT™
OK
Go To Next Step
Vehicle speed sensor (VSS) or circuit is ............ sensor and circuit. Refer to Procedures 019-090
malfunctioning and 019-091 in the Troubleshooting and Repair
Manual CELECT™ Plus Systems, Bulletin
3666130, or the Troubleshooting and Repair
Manual CELECT™ Systems, Bulletin 3666084.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 13
Adjust the automotive and VS idle speeds. Refer to
Automotive and variable speed (VS) governor idle ............
speeds are set too close (STC engines only)
OK
Go To Next Step
STEP 14 Adjust the idle speed above the engine fuel pump
Auxiliary governor (if equipped) is not adjusted ............ idle speed setting. Refer to the manufacturer's
correctly instructions.
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
STEP 16 Remove the fuel pump. Check the calibration.

............ Refer to Procedure 005-016 and PT Fuel Pump
PT fuel pump calibration is not correct
OK
Go To Next Step
Check the fuel pump for correct assembly and
STEP 17 installation. Refer to Procedure 005-016 and PT
............
PT fuel pump is not assembled correctly Fuel Pump Rebuild and Calibration Manual,
Bulletin 3379084.
OK
Go To Next Step
............
Engine Speed Surges Under Load or in Operating Range

Cause Correction
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
malfunctioning
and Repair Manual For CELECT ™ Plus Systems,
3666084.
OK
Go To Next Step

Cause Correction
Check for foot pedal restriction. Check the
accelerator pedal or lever position sensor and
STEP 7 circuit. Refer to Procedures 019-085 and 019-086
Accelerator pedal or lever position sensor or circuit ............ in the Troubleshooting and Repair Manual
is malfunctioning CELECT ™ Plus Systems, Bulletin 3666130, or the
Troubleshooting and Repair Manual for CELECT ™
OK
Go To Next Step
Check the cruise control/PTO selector switch and
STEP 8 circuit. Refer to Procedures 019-023 and 019-024
in the Troubleshooting and Repair Manual
Cruise control/PTO selector switch or circuit is ............
CELECT ™ Plus Systems, Bulletin 3666130, or the
malfunctioning
OK
Go To Next Step
Check the engine position sensor and circuit. Refer
STEP 9 to Procedures 019-038 and 019-039 in the
Troubleshooting and Repair Manual CELECT ™
Engine position sensor (EPS) or circuit is ............
malfunctioning
OK
Go To Next Step
Vehicle speed sensor (VSS) or circuit is ............ sensor and circuit. Refer to Procedures 019-090,
malfunctioning 019-091, and 019-093 in the Troubleshooting and
Repair Manual CELECT ™ Plus Systems, Bulletin
3666130, or the Troubleshooting and Repair
Manual for CELECT ™ Systems, Bulletin 3666084.
OK
Go To Next Step
STEP 11 Perform the cylinder performance test. Replace

............ injectors as necessary. Refer to Procedures
006-005 and 006-026.
OK
Go To Next Step

Procedure 005-031.
OK
Go To Next Step

Cause Correction
STEP 13
Adjust the automotive and VS idle speeds. Refer to
Automotive and variable speed (VS) governor idle ............
speeds are set too close (STC engines only)
OK
Go To Next Step

OK
Go To Next Step
Check the fuel pump for correct assembly and
STEP 15 installation. Refer to Procedure 005-016 and PT
............
PT fuel pump is not assembled correctly Fuel Pump Rebuild and Calibration Manual,
Bulletin 3379084.
OK
Go To Next Step
............
Engine Starts But Will Not Keep Running

Cause Correction
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3
Procedure 005-029.
systems)
OK
Go To Next Step
STEP 4
Turn OFF the keyswitch for 5 seconds. Turn ON
Idle shutdown or PTO shutdown features are ............
the keyswitch and check fault lamp operation.
activated
OK
Go To Next Step
............
OK
Go To Next Step
STEP 6
............ Disengage engine-driven units.
Engine-driven units are engaged
OK
Go To Next Step
STEP 7 Check the fuel heater, if installed. Weather
............
Fuel is waxing due to cold weather conditions sometimes require a fuel heater.
OK
Go To Next Step
............
OK
Go To Next Step
Engine Starts But Will Not Keep Running

Cause Correction
Check the fuel shutoff valve and the electrical
circuit. Refer to Procedure 019-050 in the
STEP 9 Troubleshooting and Repair Manual CELECT™
............
Fuel shutoff valve (FSOV) is closed Plus Systems, Bulletin 3666130, or Section TF in
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
Fuel grade is not correct for the application or the ............ Refer to Fuel for Cummins Engines, Bulletin
OK
Go To Next Step
Check the fuel pump output pressure with
STEP 13 INSITE™, an electronic service tool. Replace the
............
Fuel pump is malfunctioning fuel pump if necessary. Refer to Procedure
005-016.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 15 Remove and clean the injectors. Refer to
............
Injector cup spray holes are plugged Procedure 006-026.
OK
Go To Next Step
............
Engine Vibration Excessive

Cause Correction
3666084.
OK
Go To Next Step
STEP 2 Refer to the Engine Runs Rough or Misfires
............
Engine is misfiring symptom tree.
OK
Go To Next Step
STEP 3
OK
Go To Next Step
STEP 4
Procedure 005-029.
systems)
OK
Go To Next Step
STEP 5
............ Check the fan. Refer to Procedure 008-040.
Fan is loose, damaged, or not balanced
OK
Go To Next Step
STEP 6 Inspect and isolate belt driven accessories and
............
Belt driven accessories are malfunctioning check for vibration.
OK
Go To Next Step
Check the hydraulic pump and air compressor.
STEP 7 Isolate gear-driven accessories and check for
............
Gear-driven accessories are malfunctioning vibration. Refer to Procedures 009-001 and
012-014.
OK
Go To Next Step
............
Engine mounts are worn, damaged, or not correct 016-010.
OK
Go To Next Step
STEP 9 Inspect the vibration damper. Refer to Procedure
............
Vibration damper is damaged 001-052.
OK
Go To Next Step
Engine Vibration Excessive

Cause Correction
STEP 10 Compare the drivetrain components to the engine

and equipment specifications. Isolate the
Drivetrain components are malfunctioning or are ............
drivetrain components and check for vibrations.
not correct
Refer to the OEM specifications.
OK
Go To Next Step
STEP 11 Check the PTO for damage and correct

............ installation. Refer to the manufacturer's
Power take-off (PTO) is damaged
instructions.
OK
Go To Next Step
STEP 12 Check the flywheel housing alignment. Refer to
............
Flywheel housing is not aligned correctly Procedure 016-006.
OK
Go To Next Step
STEP 13
broken
Engine Will Not Crank or Cranks Slowly (Air Starter)

Cause Correction
STEP 1 Increase air pressure with an external air source.
............
Air pressure is low in the air tanks Refer to the OEM service manual.
OK
Go To Next Step
STEP 2
OK
Go To Next Step
STEP 3
Install an oil pan heater, or drain the oil and fill the
Lubricating oil temperature is below specification ............
system with warm oil.
the OEM service manual
OK
Go To Next Step
STEP 4
Change the oil and filters. Refer to Procedure
Lubricating oil does not meet specifications for ............
007-013.
operating conditions
OK
Go To Next Step
STEP 5 Check the crankshaft for ease of rotation. Refer to
............
Crankshaft rotation is impaired Procedure 001-016.
OK
Go To Next Step
STEP 6 Check the starting motor operation. Compare the

starting motor with the engine and vehicle
Starting motor is malfunctioning or starting motor ............
specifications. Refer to the manufacturer's
is not correct
instructions.
OK
Go To Next Step
STEP 7 Remove the starting motor, and inspect the gear.

............ Refer to Procedure 013-020 and the
Starting motor pinion or ring gear is damaged
OK
Go To Next Step
STEP 8 Engine is hot and experiencing vapor lock. Refer
............
Hot stall (hot start) in engine to the OEM service manual.
OK
Go To Next Step
STEP 9 Remove the injectors and rotate the crankshaft.

............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
OK
Go To Next Step
Engine Will Not Crank or Cranks Slowly (Air Starter)

Cause Correction
STEP 10 Analyze the oil and inspect the filters to locate an

............ area of probable damage. Refer to Procedure
Internal engine damage
007-083.
Engine Will Not Crank or Cranks Slowly (Electric Starter)

Cause Correction
Check the batteries and the unswitched battery
supply circuit. Refer to Procedure 013-009 or
............ Repair Manual CELECT™ Plus Systems, Bulletin
Battery voltage is low
3666130, or Troubleshooting and Repair Manual
CELECT™ Systems, Bulletin 3666084 and the
OEM service manual.
OK
Go To Next Step
STEP 2
Check the battery cables and connections. Refer
Battery cables or connections are loose, broken, or ............
corroded (excessive resistance)
OK
Go To Next Step
STEP 3
OK
Go To Next Step
STEP 4
Install an oil pan heater, or drain the oil and fill the
Lubricating oil temperature is below ............
system with warm oil.
specificationProcedure 013-009
OK
Go To Next Step
STEP 5
007-013.
OK
Go To Next Step
STEP 6 Check the crankshaft for ease of rotation. Refer to
............
Crankshaft rotation is impaired Procedure 001-016.
OK
Go To Next Step
STEP 7 Refer to the manufacturer's instructions. Replace
............
Battery capacity is below specification the batteries if necessary.
OK
Go To Next Step
STEP 8 Check the battery heater. Refer to the
............
Batteries are cold manufacturer's instructions.
OK
Go To Next Step
Engine Will Not Crank or Cranks Slowly (Electric Starter)

Cause Correction
STEP 9 Replace the battery cables with larger gauge or

............ shorter length cables. Refer to Electrical System
Battery cables are not the correct gauge or length
Specifications in Section 13.
OK
Go To Next Step
STEP 10 Check the starting circuit components. Refer to the
............
Starting circuit component is malfunctioning OEM service manual.
OK
Go To Next Step
STEP 11 Remove the starting motor, and inspect the gear.

............ Refer to Procedure 013-020 and the
Starting motor pinion or ring gear is damaged
OK
Go To Next Step
STEP 12 Engine is hot and experiencing vapor lock. Refer
............
Hot stall (hot start) in engine to the OEM service manual.
OK
Go To Next Step
STEP 13 Remove the injectors and rotate the crankshaft.

............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
OK
Go To Next Step
............
Internal engine damage crankshaft, pistons, and liners. Refer to Procedure
007-083.
Engine Will Not Shut Off

Cause Correction
OK
Go To Next Step
Check the vehicle keyswitch circuit. Refer to
............ Repair Manual CELECT™ Systems, Bulletin
Keyswitch circuit is malfunctioning
3666130, and the Troubleshooting and Repair
Manual CELECT™ Systems, Bulletin 3666084.
OK
Go To Next Step
STEP 3 Check the manual opening knob to be sure it is in

the fully counterclockwise position. Refer to
PT fuel pump fuel shutoff valve manual opening is ............
Procedure 005-043 and PT Fuel Pump Rebuild and
engaged
Calibration Manual, Bulletin 3379084.
OK
Go To Next Step
STEP 4
Fuel shutoff valve (FSOV) solenoid or circuit is
............ Check the fuel shutoff valve solenoid and circuit.
malfunctioning (electronically controlled fuel
systems)
OK
Go To Next Step
Verify that the solenoid or coil is not being
energized by a short in the wiring. Remove the
STEP 5 FSOV and check the valve disc and spring washer.
............ Refer to Procedure 019-050 in the Troubleshooting
Fuel shutoff valve (FSOV) is stuck open
and Repair Manual CELECT™ Plus Systems,
Bulletin 3666130, or Troubleshooting and Repair
Manual for CELECT™ Systems, Bulletin 3666084.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 7 Check the fuel tank check valve for debris. Check
Overhead fuel tank check valve is restricted or is ............ the valve for the correct plumbing arrangement.
not opening Refer to the OEM service manual.
OK
Go To Next Step
Engine Will Not Shut Off

Cause Correction
............
OK
Go To Next Step
STEP 9
Check the injectors. Repair or replace the injectors
Injector check ball is not seating correctly or is ............
missing
OK
Go To Next Step
STEP 10 Check the air intake ducts. Locate and isolate the
Engine is running on fumes drawn into the air ............ source of the fumes. Repair as necessary. Refer to
intake the OEM service manual.
OK
Go To Next Step
STEP 11 Remove and clean the tank vents. Replace the

............ vents if necessary. Refer to the OEM service
Fuel tank vents are plugged or damaged
manual.
Fuel Consumption Excessive (CELECT™ or CELECT™ Plus)

If the Fuel Consumption Complaint also includes a driveability or low power complaint, refer to the Driveability/Low
Power Customer Complaint Form at the end of Section TS.
Cause Correction
Refer to the Fuel Consumption - General
STEP 1 Information and Customer Complaint Form at the
............
Interview the operator to verify the complaint end of Section TS. Follow the instructions on the
forms before continuing with this tree.
OK
Go To Next Step
Verify what factors compose the operator's
expectations. Run a VE/VMS® simulation for
STEP 2 automotive applications to determine the expected
............
Fuel economy expectations are not reasonable fuel economy or perform a trial run to establish the
actual fuel economy. Refer to the OEM
specfications.
OK
Go To Next Step
STEP 3 Review fuel consumption records for the past 3 to
Fuel consumption is changing due to seasonal or ............ 6 months to determine the effects of seasonal or
operational changes operational changes.
OK
Go To Next Step

correct.
OK
Go To Next Step
Consider operating environment and its effect on
STEP 5 fuel economy. Adverse weather, strong head
............
Vehicle has changed routes or loads winds, variable routes, and heavier loads can
increase fuel consumption.
OK
Go To Next Step
Number 1 diesel fuel and other light winter fuels
STEP 6 are lower in heat content than number 2 diesel fuel
............ and result in higher fuel consumption. Evaluate
Fuel grade has changed
fuel consumption using number 2 diesel fuel. Fuel
additives also result in lower heat content.
OK
Go To Next Step
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
STEP 9
Lubricating oil temperature is below Install an oil pan heater, or drain the oil and fill the
............
specificationthe Coolant Temperature Below system with warm oil.
Normal symptom tree
OK
Go To Next Step
STEP 10 Check the brakes for dragging. Refer to the OEM
............
Vehicle or trailer brakes are dragging service manual.
OK
Go To Next Step
STEP 11 Check the wheel alignment. Refer to the OEM

............ service manual and the manufacturer's
Wheel alignment is not correct (tractor or trailer)
instructions.
OK
Go To Next Step
New tires add up to 3 percent to rolling radius.
STEP 12 Verify tire revolutions per mile with new tires and
............ calculate fuel consumption. For electronic
Tires on the tractor or trailer are new
engines, enter the correct value for tire revolutions
per mile in the ECM.
OK
Go To Next Step
Check the hubometer and odometer calibrations.
STEP 13 Calibrate or replace the hubometer or odometer, if
............
Hubometer or odometer is miscalibrated necessary. Calculate fuel consumption with new
mileage figures.
OK
Go To Next Step
STEP 14 Check the tires on the tractor and trailer. Repair or
Tires on the tractor or trailer are worn or have low- ............ inflate the tires as necessary. Evaluate fuel
pressure consumption again.
OK
Go To Next Step
STEP 15 Evaluate the engine repair to determine its effect

on fuel consumption. Check part numbers to make
Fuel consumption has increased after an engine ............
sure the correct parts were used. Refer to the
repair
Control Parts List (CPL), Bulletin 3379133.
OK
Go To Next Step

Cause Correction
STEP 16 Explain correct engine operation to the operator.
............
Operator technique is not correct Refer to the OEM service manual.
OK
Go To Next Step
STEP 17 Check the fuel lines, fuel connections, and fuel

............ filters for leaks using the combustible gas detector
Fuel leak
service tool. Refer to Procedure 006-024.
OK
Go To Next Step
Check the vehicle speed sensor and circuit for
tampering. Check for Fault Code 242. Repair the
STEP 18 circuit as necessary. Refer to Procedures 019-090
Vehicle speed sensor (VSS) tampering has ............ and 019-091 in the Troubleshooting and Repair
occurred Manual for CELECT™ Plus Systems, Bulletin
3666130, or in the Troubleshooting and Repair
Manual for CELECT™ Systems, Bulletin 3666084.
OK
Go To Next Step

OK
Go To Next Step
Check the programmable parameters and the
Make sure that gear-down protection road speeds
STEP 20 are set to the same values as in comparable
Programmable parameters or selected features vehicles. Refer to the appropriate electronic
............
are not correct or are not set the same as the service tool manual and Procedure 019-078 in the
values in comparable vehicles Troubleshooting and Repair Manual for CELECT™
OK
Go To Next Step

Cause Correction
Verify the electronic control module (ECM)
calibration is correct. Check the calibration
revision history for applicable fixes to the
calibration stored in the ECM. Refer to the
STEP 21 Online Internet Website or the INCAL™ calibration
Electronic control module (ECM) calibration is ............ CD. Compare the calibration stored in the ECM
malfunctioning with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to Procedure 019-032
in the Troubleshooting and Repair Manual for
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 24
specification
OK
Go To Next Step
............
OK
Go To Next Step
............
Fuel Consumption Excessive (PT)

Cause Correction
Refer to Fuel Consumption - General Information
STEP 1 and Customer Complaint form at the end of Section
............
Interview the operator to verify the complaint TS. Follow the instructions on the forms before
OK
Go To Next Step
Verify what factors compose the operator's
expectations. Run a VE/VMS® simulation for
STEP 2 automotive applications to determine the expected
............
Fuel economy expectations are not reasonable fuel economy or perform a trial run to establish the
actual fuel economy. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 3 Review fuel consumption records for the past 3 to
Fuel consumption is changing due to seasonal or ............ 6 months to determine the effects of seasonal or
operational changes operational changes.
OK
Go To Next Step

correct.
OK
Go To Next Step
STEP 5
Verify fuel consumption and/or oil consumption
Fuel consumption and/or oil consumption data are ............
data. Refer to the OEM specifications.
inaccurate
OK
Go To Next Step
Consider operating environment and its effect on
STEP 6 fuel economy. Adverse weather, strong head
............
Vehicle has changed routes or loads winds, variable routes, and heavier loads can
increase fuel consumption.
OK
Go To Next Step
Number 1 diesel fuel and other light winter fuels
STEP 7 are lower in heat content than number 2 diesel fuel
............ and result in higher fuel consumption. Evaluate
Fuel grade has changed
fuel consumption using number 2 diesel fuel. Fuel
additives also result in lower heat content.
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
STEP 9
Lubricating oil temperature is below Install an oil pan heater, or drain the oil and fill the
............
specificationthe Coolant Temperature Below system with warm oil.
Normal symptom tree
OK
Go To Next Step
STEP 10 Check the brakes for dragging. Refer to the OEM
............
Vehicle or trailer brakes are dragging service manual.
OK
Go To Next Step
STEP 11 Check the wheel alignment. Refer to the OEM

............ service manual and the manufacturer's
Wheel alignment is not correct (tractor or trailer)
instructions.
OK
Go To Next Step
New tires add up to 3 percent to rolling radius.
STEP 12 Verify tire revolutions per mile with new tires and
............ calculate fuel consumption. For electronic
Tires on the tractor or trailer are new
engines, enter the correct value for tire revolutions
per mile in the ECM.
OK
Go To Next Step
STEP 13 Check the hour meter. Calibrate or replace the

............ hour meter if necessary. Calculate fuel
Hour meter is miscalibrated
consumption with new figures.
OK
Go To Next Step
STEP 14 Check the tires on the tractor and trailer. Repair or
Tires on the tractor or trailer are worn or have low- ............ inflate the tires as necessary. Evaluate fuel
pressure consumption again.
OK
Go To Next Step
STEP 15 Evaluate the engine repair to determine its effect

on fuel consumption. Check part numbers to make
Fuel consumption has increased after an engine ............
sure the correct parts were used. Refer to the
repair
Control Parts List (CPL), Bulletin 3379133.
OK
Go To Next Step

Cause Correction
STEP 16 Explain correct engine operation to the operator.
............
Operator technique is not correct Refer to the OEM service manual.
OK
Go To Next Step
STEP 17 Check the fuel lines, fuel connections, and fuel

............ filters for leaks using the combustible gas detector
Fuel leak
service tool. Refer to Procedure 006-024.
OK
Go To Next Step

OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 21
specification
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 24 Check the injector cups for damage and for correct
............
Injector cup is damaged or is not correct part numbers. Refer to Procedure 006-026.
OK
Go To Next Step

Cause Correction
............
OK
Go To Next Step
STEP 26 Check the fuel drain line. Repair if necessary.
............
Fuel drain line is bent Refer to Procedure 006-012.
OK
Go To Next Step
STEP 27 Calibrate the injectors. Refer to Procedure
............
Injector calibration is not correct 006-026.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 29
Inspect step timing control operation. Refer to
Step timing control system not switching to ............
Procedure 006-037.
advanced timing mode
OK
Go To Next Step
Fuel in Coolant
Cause Correction
Check the bulk coolant supply. Drain the coolant
STEP 1 and replace with noncontaminated coolant.
............
Bulk coolant supply is contaminated Replace the coolant filters. Refer to Procedure
008-018.
OK
Go To Next Step
STEP 2 Check the fuel heater and replace, if necessary.
............
Fuel heater is malfunctioning (if equipped) Refer to the manufacturer's instructions.
OK
Go To Next Step
STEP 3
Pressure-test the cylinder head and inspect the
Cylinder head is cracked or porous, or an injector ............
injector sleeves. Refer to Procedure 002-004.
sleeve is leaking
OK
Go To Next Step
............
Fuel in the Lubricating Oil

Cause Correction
STEP 1 Check the bulk oil supply. Drain the oil and replace
............ with noncontaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
OK
Go To Next Step
Low oil and coolant temperatures can be caused
STEP 2 by long idle time (greater than 10 minutes). Shut
............ off the engine rather than idle for long periods. If
Engine idle time is excessive
idle time is necessary, raise the idle speed.
Procedures 007-037 and 007-013
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4 Perform the fluorescent dye tracer test to find the
Top injector o• ring is damaged or injector is ............ bad injector. Replace the injector or o• ring. Refer
damaged to Procedure 007-044.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 7 Check the gear pump main shaft and seals. Refer
............
Fuel pump gear pump main shaft seals are leaking to Procedure 005-016.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 9 Remove and inspect the STC valve. Refer to
............
STC oil control valve is damaged Procedure 006-037.
Intake Manifold Air Temperature Above Specification

Cause Correction
Electronic fault codes active or high counts of ............ Bulletin 3666130, or the Troubleshooting and
3666084.
OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step
STEP 3
Test the temperature gauge. Refer to the OEM
Intake manifold temperature gauge is ............
service manual.
malfunctioning, if equipped
OK
Go To Next Step
STEP 4
Reduce the engine load. Increase the engine (fan)
Vehicle speed is too low for adequate cooling with ............
rpm by downshifting.
high engine load
OK
Go To Next Step
Radiator shutters are not opening completely or ............ necessary. Refer to the manufacturer's
the shutterstat setting is wrong instructions. Check the shutterstat setting.
OK
Go To Next Step
opening at all times. Refer to Operation of Diesel
Engines in Cold Climate, Bulletin 3379009.
OK
Go To Next Step
STEP 7
OK
Go To Next Step
Intake Manifold Air Temperature Above Specification

Cause Correction
STEP 8 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedures 008-038.
OK
Go To Next Step
STEP 9 Check the belt tension and tighten if necessary.
............
Fan drive belt is loose Refer to Procedure 008-002.
OK
Go To Next Step
............
Fan drive or fan controls are malfunctioning Procedures 008-026, 008-027, and 008-028.
OK
Go To Next Step
STEP 11 Verify that the fan is the correct size. Refer to the
............
Fan is not an adequate size for the application engine and OEM specifications.
Intake Manifold Pressure (Boost) is Below Normal

Cause Correction
3666084.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4 Inspect the air cooler for internal and external

............ restrictions. Replace the restricted cooler if
Charge air cooler restricted (if equipped)
OK
Go To Next Step
STEP 5 Check the connection between the manifold and
............
Air compressor connection is loose or damaged the air compressor. Repair or replace if necessary.
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 8 Check the turbocharger for damage. Measure the

............ turbine and compressor wheel clearances. Refer
Turbocharger is worn or damaged
to Procedures 010-039.
OK
Go To Next Step
STEP 9 Refer to the Engine Power Output Low symptom
............
Engine power output is low tree.
Low Idle Adjust Switch Does Not Work (CELECT™ or CELECT™ Plus)
This is symptom tree t099.155
Cause Correction
OK
Go To Next Step
Check the idle adjust switch and circuit. Refer to
Procedures 019-052 and 019-053 in the
STEP 2 Troubleshooting and Repair Manual for CELECT™
............
Low-idle adjust switch and circuit is malfunctioning Plus Systems, Bulletin 3666130, or the
OK
Go To Next Step
STEP 3 Check the low-idle adjust switch feature with an

............ electronic service tool. Refer to the appropriate
Low-idle adjust switch feature is not enabled
electronic service tool manual.
Lubricating Oil in the Fuel

Cause Correction
STEP 1
Remove the STC valve and inspect the barrel o-
STC oil control valve barrel o-rings are missing,
............ rings, check for a retaining ring, and inspect for
hardened or cut; retaining ring is missing; barrel
excessive wear. Refer to Procedure 006-037.
and plunger class fit is excessive
OK
Go To Next Step
STEP 2 Check the STC valve plumbing. Refer to Procedure
............
STC oil control valve plumbing is not correct 006-037.
Lubricating Oil Consumption Excessive

Cause Correction
STEP 1
............ Check the amount of oil added versus the mileage.
Verify the oil consumption rate
OK
Go To Next Step
Inspect the engine for external oil leaks. Tighten
STEP 2 the capscrews, pipe plugs, and fittings. Replace
............
Lubricating oil leak (external) gaskets, if necessary. Refer to the OEM
specifications.
OK
Go To Next Step
............
Crankcase ventilation system is plugged tube. Refer to Procedures 003-001.
OK
Go To Next Step
STEP 4 Check the air lines for carbon buildup and

lubricating oil. Refer to the Air Compressor is
Air compressor is pumping lubricating oil into the ............
Pumping Excessive Lubricating Oil into the Air
air system
System symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 6 Refer to the Lubricating Oil Temperature Above
............
Lubricating oil temperature is above specification Specification symptom tree.
OK
Go To Next Step
STEP 7 Check for lubricating oil in the coolant. Refer to the

............ Lubricating or Transmission Oil in the Coolant
Lubricating oil cooler is leaking
symptom tree.
OK
Go To Next Step
STEP 8 Refer to the Lubricating Oil Contaminated
............
Lubricating oil is contaminated with coolant or fuel symptom tree.
OK
Go To Next Step
STEP 9 Check the dipstick calibration. Refer to Procedure
............
Lubricating oil dipstick calibration is not correct 007-009.
OK
Go To Next Step
Lubricating Oil Consumption Excessive

Cause Correction
STEP 10
007-013.
OK
Go To Next Step
STEP 11 Verify the correct lubricating oil drain interval.

............ Refer to Section 2 in the Operation and
Lubricating oil drain interval is excessive
Maintenance Manual, N14 Plus, Bulletin 3666136.
OK
Go To Next Step
STEP 12
Procedure 006-045.
OK
Go To Next Step
STEP 13 Check blowby. Refer to Section 14. If blowby is
Piston rings are not seated correctly (after an ............ excessive, check the piston rings for correct
engine rebuild or piston installation) seating. Refer to Procedures 001-043 and 001-047.
OK
Go To Next Step
STEP 14 Check the pistons, piston rings, and cylinder liner.
Cylinder liner, pistons, or piston rings are worn or ............ Refer to Procedures 001-043, 001-047, and
damaged 001-028.
Lubricating Oil Contaminated

Cause Correction
STEP 1 Perform an oil analysis to determine the
............
Identify lubricating oil contamination contaminants.
OK
Go To Next Step
OK
Go To Next Step
STEP 3
............ Refer to the Coolant Loss - Internal symptom tree.
Internal coolant leaks
OK
Go To Next Step
STEP 4 Refer to the Lubricating Oil Sludge in the
............
Lubricating oil sludge is excessive Crankcase is Excessive symptom tree.
OK
Go To Next Step
STEP 5 Refer to the Fuel in the Lubricating Oil symptom
............
Fuel in the lubricating oil tree.
Lubricating Oil Pressure High

Cause Correction
Electronic fault codes active or high counts of ............ 3666130, or Section T in the Troubleshooting and
3666084.
OK
Go To Next Step
STEP 2 Check the oil pressure switch, gauge, or sensor for
Lubricating oil pressure switch, gauge, or sensor is ............ correct operation and location. Refer toProcedure
malfunctioning or is not in the correct location 007-028.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4 Change the oil and filters. Refer to Procedure
Lubricating oil does not meet specifications for ............ 007-013. Use the oil type recommended in Section
operating conditions V of the operation and maintenance manual.
OK
Go To Next Step
STEP 5 Check the main oil pressure regulator assembly.
............
Main oil pressure regulator is malfunctioning Refer to Procedure 007-029.
OK
Go To Next Step
STEP 6 Make sure the correct lubricating oil is being used.
............
Lubricating oil viscosity not correct Refer to Procedure 007-041.
OK
Go To Next Step
STEP 7 Remove and inspect the high• pressure relief
Lubricating oil high• pressure relief valve is ............ valve or lubricating pump pressure regulator. Refer
malfunctioning to Procedure 007-021.
OK
Go To Next Step
STEP 8 Check the bypass valve. Refer to Procedure
............
Lubricating oil filter bypass valve is malfunctioning 007-014.
Lubricating Oil Pressure Low

This is symptom tree t-105
Cause Correction
STEP 1 Repair Manual for CELECT ™ Plus Systems,
OK
Go To Next Step
STEP 2 Check the oil level. Add or drain oil if necessary.

............ Refer to Procedure 007-009 and 007-037. Check
Lubricating oil level is above or below specification
the dipstick calibration.
OK
Go To Next Step
Inspect the engine for external oil leaks. Tighten
STEP 3 the capscrews, pipe plugs, and fittings. Replace
............
Lubricating oil leak (external) gaskets, if necessary. Refer to Section V and the
OEM specifications.
OK
Go To Next Step
STEP 4
Engine angularity during operation exceeds ............ Refer to the engine specification data sheet.
specification
OK
Go To Next Step
STEP 5 Check the oil pressure switch, gauge, or sensor for
Lubricating oil pressure switch, gauge, or sensor is ............ correct operation and location. Refer toProcedure
malfunctioning or is not in the correct location 007-028.
OK
Go To Next Step
STEP 6 Check the oil pressure switch or circuit. Refer to
Lubricating oil pressure sensor or circuit is ............ the CELECT™ System Troubleshooting and Repair
malfunctioning Manual, Bulletin 3666084.
OK
Go To Next Step
STEP 7 Use Cummins recommended lubricating oil type.

............ Refer to the Cummins Engine Oil
Lubricating oil does not meet specifications
Recommendations, Bulletin 3810340.
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction
STEP 9 Change the oil and filter. Refer to Procedures
............
Lubricating oil filter is plugged 007-037 and 007-013.
OK
Go To Next Step
STEP 10 Check the viscosity sensor. Clean or replace if
............
Sensor plugged or damaged necessary. Refer to the OEM specifications.
OK
Go To Next Step
STEP 11
Clean or replace the signal tube. Refer to
Lubricating oil pump signal tube is plugged or ............
Procedure 007-034.
damaged
OK
Go To Next Step
STEP 12
Inspect the lubricating oil pump and o-rings. Refer
Lubricating oil pump is malfunctioning or the o- ............
rings are damaged
OK
Go To Next Step
STEP 13 Remove and inspect the high• pressure relief
Lubricating oil high• pressure relief valve is ............ valve or lubricating pump pressure regulator. Refer
malfunctioning to Procedure 007-021.
OK
Go To Next Step
STEP 14 Check the main oil pressure regulator assembly.
............
Main oil pressure regulator is malfunctioning Refer to Procedure 007-029.
OK
Go To Next Step
STEP 15 Refer to the Lubricating Oil Temperature Above
............
Lubricating oil temperature is above specification Specification symptom tree.
OK
Go To Next Step
STEP 16
Remove and inspect the oil pan or suction tube.
Lubricating oil suction or transfer tube is loose or ............
broken, or the gasket or o-rings are leaking
OK
Go To Next Step
STEP 17
Check the piston cooling nozzles for damage and
Piston cooling nozzles are damaged or are not ............
correct installation. Refer to Procedure 001-046.
installed correctly
OK
Go To Next Step

Cause Correction
STEP 18
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is plugged
OK
Go To Next Step
STEP 19 Analyze the oil and inspect the filters to locate an

............ area of probable damage. Refer to Procedure
Internal engine damage
007-083.
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
OK
Go To Next Step
STEP 2
007-013.
OK
Go To Next Step
Verify the correct lubricating oil drain interval.
STEP 3 Refer to Procedure 102-002 (Maintenance
............
Lubricating oil drain interval is excessive Schedule) in Section 2 of the Operation and
Maintenance Manual, N14 Plus, Bulletin 3666136.
OK
Go To Next Step
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step

tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 9 Check the electrical STC oil control valve and
............
STC system malfunction circuit. Refer to Procedure 006-037.
OK
Go To Next Step
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
............
OK
Go To Next Step
............
Lubricating Oil Temperature Above Specification

Cause Correction
Electronic fault codes active or high counts of ............ Bulletin No. 3666130, or Section TF in the
inactive fault codes Troubleshooting and Repair for CELECT™
Systems, Bulletin No. 3666084.
OK
Go To Next Step
STEP 2 Check the oil level. Add or drain oil, if necessary.
............
Lubricating oil level is above or below specification Refer to Procedure 007-025.
OK
Go To Next Step
STEP 3 Refer to the Coolant Temperature is Above Normal

............ - Sudden Overheat or the Coolant Temperature is
Coolant temperature is above specification
Above Normal - Gradual Overheat symptom tree.
OK
Go To Next Step
STEP 4 Check the oil temperature switch, gauge, or sensor
Lubricating oil temperature switch, gauge, or ............ for correct operation and location. Refer to the
sensor malfunctioning or not in the correct location OEM service manual.
OK
Go To Next Step
STEP 5 Check the lubricating oil temperature sensor and

circuit. Refer to the CELECT™ Systems
Lubricating oil temperature sensor or circuit is ............
malfunctioning (electronic controlled fuel system)
3666084.
OK
Go To Next Step
STEP 6 Check the oil thermostat. Refer to Procedure
............
Lubricating oil thermostat is malfunctioning 007-039.
OK
Go To Next Step
STEP 7
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning
Lubricating or Transmission Oil in the Coolant

Cause Correction
Check the bulk coolant supply. Drain the coolant
STEP 1 and replace with noncontaminated coolant.
............
Bulk coolant supply is contaminated Replace the coolant filters. Refer to Procedure
008-018.
OK
Go To Next Step
STEP 2 Check the oil cooler transfer housing and the
Lubricating oil cooler transfer housing or ............ support. Refer to Procedures 007-047 and
lubricating oil cooler support is cracked or porous 007-003.
OK
Go To Next Step
STEP 3 Check the lubricating oil cooler for coolant leaks
............
Lubricating oil cooler is leaking and cracks. Refer to Procedure 007-003.
OK
Go To Next Step
STEP 4
Remove and inspect the cooler cores and o-rings.
Torque converter cooler or hydraulic oil cooler is ............
malfunctioning
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 7 Inspect the cylinder block. Refer to Procedure
............
Cylinder block is cracked or porous 001-027.
Operating Fuel Pressure is Low

Cause Correction
............
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3
Inspect the check valve(s) for correct installation
In-line check valve(s) are installed backwards or ............
and part number.
have incorrect part number
OK
Go To Next Step
STEP 4 Check the fuel pump pressure regulator and the

............ high pressure regulator. Refer to Procedure
Fuel pump pressure regulator is stuck
005-060.
OK
Go To Next Step
............
OK
Go To Next Step

Smoke, Black — Excessive (CELECT™ or CELECT™ Plus)

Cause Correction
3666084.
OK
Go To Next Step
malfunctioning
and Repair Manual for CELECT ™ Plus Systems,
3666084.
OK
Go To Next Step

OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction
STEP 8
specification
OK
Go To Next Step
............
OK
Go To Next Step
OK
Go To Next Step
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step

specification
OK
Go To Next Step
STEP 15
Fuel rate is low, fuel pressure is okay, intake No corrections are required. This is normal
............
manifold pressure is high, and ambient air performance at temperatures below 0°C [32° F].
temperature is below 0°C [32° F]
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction

tree.
Smoke, Black — Excessive (PT)

Cause Correction
STEP 1
specification
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
OK
Go To Next Step
STEP 7 Remove the fuel pump and check the calibration.
PT fuel pump rated or no-air fuel pressure is above ............ Refer to Procedure 005-016 and PT Fuel Pump
specification Rebuild and Calibration Manual, Bulletin 3379084.
OK
Go To Next Step
STEP 8 Remove the fuel pump and check the calibration.
Fuel rate and fuel pressure are high and intake ............ Refer to Procedure 005-016 and PT Fuel Pump
manifold pressure is okay Rebuild and Calibration Manual, Bulletin 3379084.
OK
Go To Next Step
STEP 9
Remove the injectors and check the calibration.
Fuel rate is high, fuel pressure is okay or low, and ............
intake manifold pressure is okay
OK
Go To Next Step
Smoke, Black — Excessive (PT)

Cause Correction

specification
OK
Go To Next Step
............
OK
Go To Next Step
............
OK
Go To Next Step
............
Smoke, White — Excessive (CELECT™ or CELECT™ Plus)

Cause Correction
3666084.
OK
Go To Next Step
STEP 2 Check the electrical sources and wiring to the

............ cylinder block heater. Replace the block heater, if
Engine block heater is malfunctioning (if equipped)
OK
Go To Next Step
............
OK
Go To Next Step
............
Coolant temperature sensor is malfunctioning Repair Manual CELECT Plus System, Bulletin
3666130.
OK
Go To Next Step

OK
Go To Next Step
malfunctioning
3666084.
OK
Go To Next Step

Cause Correction
malfunctioning
and Repair Manual For CELECT ™ Plus Systems,
3666084.
OK
Go To Next Step
OK
Go To Next Step
............
OK
Go To Next Step
STEP 10 Replace the malfunctioning injector. Refer to
............
Injector is malfunctioning Procedures 006-005 and 006-026.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 12
Coolant is leaking into the combustion chamber
OK
Go To Next Step
............
OK
Go To Next Step

Cause Correction

............ inserts or the cylinder head. Refer to Procedure
002-004 and the Engine Shop Manual.
OK
Go To Next Step
STEP 15 Check the injector protrusion. Refer to Procedure
............
Injector protrusion is not correct 006-026.
OK
Go To Next Step
Check the pistons for correct part numbers. Refer
STEP 16 to Control Parts List (CPL), Bulletin 3379133 or
Pistons or piston rings are worn, damaged, or not ............ 4021327. Check the pistons and rings for wear and
correct damage. Refer toProcedures 001-043 and
001-047.
Smoke, White — Excessive (PT)

Cause Correction
STEP 1 Check the electrical sources and wiring to the

............ cylinder block heater. Replace the block heater, if
Engine block heater is malfunctioning (if equipped)
OK
Go To Next Step
............
OK
Go To Next Step

OK
Go To Next Step
OK
Go To Next Step
STEP 5
Check the viscosity sensor. Refer to Procedure
Lubricating oil rifle pressure during cold start is ............
007-041.
below specification
OK
Go To Next Step
STEP 6
OK
Go To Next Step
............
OK
Go To Next Step
STEP 8 Check the intake manifold for fuel. Refer to

............ Procedures 010-023 and 003-004. Locate the fuel
Raw fuel in the intake manifold
source and repair as necessary.
OK
Go To Next Step
............
OK
Go To Next Step
Smoke, White — Excessive (PT)

Cause Correction

006-005 and 006-026.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 12
Coolant is leaking into the combustion chamber
OK
Go To Next Step

............ inserts or the cylinder head. Refer to Procedures
002-004.
OK
Go To Next Step
STEP 14 Check the injector protrusion. Refer to Procedure
............
Injector protrusion is not correct 002-004.
OK
Go To Next Step
Check the pistons for correct part numbers. Refer
STEP 15 to Control Parts List (CPL), Bulletin 3379133 or
Pistons or piston rings are worn, damaged, or not ............ 4021327. Check the pistons and rings for wear and
correct damage. Refer toProcedures 001-043, 001-047
and 003-004.
Step Timing Control (STC) Valve is Not Shifting Correctly

Cause Correction
............
OK
Go To Next Step

............ Procedure 007-028. If the pressure is low, refer to
Lubricating oil pressure is below specification
the Lubricating Oil Pressure Low symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 4
............ Check the rail pressure sensing line for restriction.
Rail pressure sensing line is restricted
Turbocharger Leaks Engine Oil or Fuel

Cause Correction
STEP 1
Review the engine operating instructions. Refer to
Engine is operating for extended periods under ............
the OEM instructions.
light or no-load conditions (slobbering)
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3 Remove the intake and exhaust piping, and check
............
Lubricating oil or fuel is entering the turbocharger for oil or fuel.
OK
Go To Next Step
STEP 4 Remove the turbocharger drain line and check for

............ restriction. Clean or replace the drain line. Refer to
Turbocharger drain line is restricted
Procedure 010-033.
OK
Go To Next Step

tree.
OK
Go To Next Step
............
Variable Speed (VS) Governor — Fuel Leak at the Throttle Shaft

Cause Correction
STEP 1
Remove the jam nuts and locknuts. Install new
Variable speed (VS) speed adjusting screw has ............
copper washers. Refer to Procedure 005-056.
missing or damaged washers
OK
Go To Next Step
STEP 2 Check the o-rings, shaft, and housing bushings for
............
Throttle shaft is damaged damage. Refer to Procedure 005-038.
Variable Speed (VS) Governor — Speed is Not Set Correctly

Cause Correction
STEP 1 Make sure the lower throttle lever linkage opens
............
Lower throttle lever is not locked wide open the throttle wide open. Refer to Procedure 005-035.
OK
Go To Next Step
STEP 2
Adjust the throttle linkage. Refer to Procedure
Variable speed (VS) governor linkage is not fully ............
005-036.
open or is set to idle
OK
Go To Next Step
STEP 3 Loosen the locknut and adjust the rear screw.
............
Low speed screw is not adjusted correctly Refer to Procedure 005-029.
OK
Go To Next Step
STEP 4 Loosen the locknut, and adjust the high-speed
............
High-speed screw is not adjusted correctly (top-0) screw. Refer to Procedure 005-029.
OK
Go To Next Step
STEP 5 Remove the fuel pump and change the spring.
............
High• speed spring is not correct Refer to Procedure 005-016.
OK
Go To Next Step
STEP 6
Remove the fuel pump. Refer to Procedure
Lever screw does not allow the throttle lever ............
005-016.
plunger to move
Variable Speed (VS) Governor — Surge with Engine Under Load

Cause Correction
............
OK
Go To Next Step
STEP 2 Adjust the external idle and high• speed screws.
............
Variable speed (VS) speed settings are not correct Refer to Procedures 005-028 and 005-029.
OK
Go To Next Step
STEP 3 Check the fuel pump code for idle spring

............ requirements. Remove the VS idle spring if it is
Idle spring is not required
not required. Refer to Procedure 005-057.
OK
Go To Next Step
STEP 4 Check the fuel pump code. Replace the fuel pump
............
Governor springs are not correct if necessary. Refer to Procedure 005-016.
Troubleshooting Overview N14
Troubleshooting Overview
Engine Noise Diagnostic Procedures - General Information
When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air compressor
and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise caused
by these units. Noise will also travel to other metal parts not related to the problem. The use of a stethoscope can
help locate an engine noise.
Engine noises heard at the crankshaft speed, engine rpm, are noises related to the crankshaft, rods, pistons, and
piston pins. Noises heard at the camshaft speed, one-half of the engine rpm, are related to the valve train. A hand-
held digital tachometer can help to determine if the noise is related to components operating at the crankshaft or
camshaft speed.
There is not a definite rule or test that will positively determine the source of a noise complaint.
Engine driven components and accessories, such as gear-driven fan clutches, hydraulic pumps, belt-driven
alternators, air-conditioning compressors, and turbochargers can contribute to engine noise. Use the following
information as a guide to diagnosing engine noise.
Main Bearing Noise
(Refer to Engine Noise Excessive - Main Bearing symptom tree)
The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main
bearings are loose, a loud clatter will be heard. The knock is heard regularly every other revolution. The noise is the
loudest when the engine is lugging or under heavy load. The knock is duller than a connecting rod noise. Low oil
pressure can also accompany this condition.
If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there
is no oil at the bearing.
An irregular noise can indicate worn crankshaft thrust bearings.
An intermittent sharp knock indicates excessive crankshaft end clearance. Repeated clutch disengagements can
cause a change in the noise.
Connecting Rod Bearing Noise
(Refer to Engine Noise Excessive - Connecting Rod symptom tree)
Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When
the bearings begin to become loose, the noise can be confused with piston slap or loose piston pins. The noise
increases in volume with engine speed. Low oil pressure can also accompany this condition.
Piston Noise
(Refer to Engine Noise Excessive - Piston symptom tree)
It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a
loud double knock which is usually heard when the engine is idling. When the injector to this cylinder is cut out, a
noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes
more noticeable when the vehicle is operated on the road at steady speed condition.
N14 Troubleshooting Overview
Driveability - General Information

Driveability is a term which in general describes vehicle performance on the road. Driveability problems for an engine
can be caused by several different factors. Some of the factors are engine related and some are not.
Before troubleshooting, it is important to determine the exact complaint and whether the engine has a real driveability
problem or if it simply does not meet driver expectations. The Driveability-Low Power Customer Complaint Form is a
valuable list of questions that must be used to assist the service technician in determining what type of driveability
problem the vehicle is experiencing. Complete the checklist before troubleshooting the problem. The form can be
found at the end of this section. If an engine is performing to factory specifications but does not meet the customer's
expectations, it must be explained to the customer that nothing is wrong with the vehicle and why.
The troubleshooting symptom charts have been set up to divide driveability problems into two different symptoms:
Engine Power Output Low and Engine Acceleration or Response Poor.
Low power is a term that is used in the field to describe many different performance problems. However, in this manual
low power is defined as the inability of the engine to produce the power necessary to move the vehicle at a speed that
can be reasonably expected under the given conditions of load, grade, wind, and so on. Low power is usually caused
by the lack of fuel flow which can be caused by any of the following factors:
• Lack of full travel of the throttle pedal
• Failed boost sensor
• Excessive fuel inlet, intake, exhaust, or drain line restriction
• Loose fuel pump suction lines.
Low power is not the inability of the vehicle to accelerate satisfactorily from a stop or the bottom of a grade. Refer to
the performance tree Engine Power Output Low for the proper procedures to locate and correct a low power problem.
The chart starts off with basic items which can cause lower power.
Poor acceleration or response is described in this manual as the inability of the vehicle to accelerate satisfactorily
from a stop or from the bottom of a grade. It can also be the lag in acceleration during an attempt to pass or overtake
another vehicle at conditions less than rated speed and load. Poor acceleration or response is difficult to troubleshoot
since it can be caused by factors such as:
• Engine or pump related factors
• Driver technique
• Improper gearing
• Improper engine application
• Worn clutch or clutch linkage.
Engine related poor acceleration or response can be caused by several different factors such as:
• Failed boost sensor
• Excessive drain line restriction
• Throttle dead band.
Refer to the performance tree Engine Acceleration or Response Poor for the proper procedures to locate and correct
a poor acceleration or response complaint.
Response Test
This procedure can be used for testing response on heavy-duty CELECT™ and CELECT™ Plus engines.
For this test, a boost pressure gauge, associated plumbing lines, and a stop watch will be needed.
1. Attach the tractor to a loaded trailer (GVW) and must be 65,000 to 80,000 pounds.
2. Make sure the engine is warmed to operating temperature.
3. Determine the full boost pressure at torque peak engine speed while applying full throttle. The trailer brakes can
also be applied for additional loading, if required. Record the boost pressure at torque peak engine speed.
4. Perform the coast down test. Select a secondary road that is level and has minimal traffic. Accelerate the vehicle
up through the gears to direct gear (1 to 1) and to an engine speed at least 300 rpm above torque peak engine
speed. From this point, allow the vehicle to coast down to torque peak engine speed then snap the throttle.
Measure the time required to develop 50 percent of torque peak boost (determined in Step 3 above).
5. Repeat Step 4 two more times for a total of three data points.
6. Calculate the average time to 50 percent boost: Average time to 50 percent boost = (time 1 plus time 2 divided
by time 3)/3.
The average time must be 3 seconds or less for acceptable performance.
Driveability/Low Power - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
1. How did the problem occur?....Suddenly ________ Gradually ________
2. At what hour/mileage did the problem begin?....Hours ________ Miles ________ Since New ________
• After engine repair?....Yes ________ No ________
• After equipment repair?....Yes ________ No ________
• After change in equipment use?....Yes ________ No ________
• After change in selectable programmable parameters?....Yes ________ No ________
• If so, what was repaired and when?______________________________________________________________
• Does the vehicle also experience poor fuel economy?....Yes ________ No ________
Answer questions 4 through 8 using selections (A through F) listed below. Circle the letter or letters that best describes
the complaint.
A. Compared to fleet D. Personal expectation
B. Compared to competition E. Will not pull on hill
C. Compared to previous engine F. Will not pull on flat.
ABCDEF
• Can the vehicle obtain the expected road speed?....Yes ________ No ________
• What is desired speed?....rpm/mph ________
• What is achieved speed?....rpm/mph ________
• GVW ________________
ABCD
• Is the vehicle able to pull the load?....Yes ________ No ________
When?
• ________ In the hills
• ________ With a loaded trailer
• ________ On the flat
• ________ Other ___________________________________________________________________________________
If question 4 or 5 was answered no, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist and go
to the Low Power performance tree. A B C D E F
• Is the vehicle slow to accelerate or respond?....Yes ________ No ________
• From a stop?....Yes ________ No ________
• After a shift?....Yes ________ No ________ rpm ________
• Before a shift?....Yes ________ No ________ rpm ________
• No shift?....Yes ________ No ________ rpm ________
ABCD
• Does the vehicle hesitate after periods of long deceleration or coasting?....Yes ________ No ________
rpm ________
If question 6 or 7 was answered Yes, fill out the Driveability/Low Power/ Excessive Fuel Consumption Checklist and
go to the Poor Acceleration/Response performance tree.
ABCDEF
Additional Comments:
_____________________________________________________________________________________________________
_________________________________
_____________________________________________________________________________________________________
_________________________________
_____________________________________________________________________________________________________
_________________________________
This form can be copied for convenience.
Driveability/Low Power/Excessive Fuel Consumption - Checklist

Vehicle/Equipment Specifications
Year, Type and Model: ____________________________________________________________________________________
Transmission (RT 14609, etc.): ________________________, Duty Cycle: ________________________________________
Rear Axle Ratio, No. of Axles: ________, Application: Industrial ____, Marine ____. Genset ____. Automotive ____
Typical GVW: _________________________, Engine Rating: _________________________
Trailer Type and Size: _______________________________________, Height: __________, Weight: __________
Tire Size (11R x 24.5, Low Profile, etc.) ________________________________________________________
Tire Type: Radial __________, Standard Tread __________, Extra Tread __________
Fan Type: Direct Drive __________, Viscous __________, Clutch __________
Power Steering:....Yes ________ No ________
Air Conditioner:....Yes ________ No ________
Air Shield:....Yes ________ No ________
Freon Compressor:....Yes ________ No ________
General Information:
DO Number: SC Number:
Fuel Pump Code: Fuel Pump Serial Number:
Mileage: Engine Serial Number:
Date in Service: Engine Model and Rating:
Cruise Speed and rpm: Rated Speed and rpm:
Road Speed Governor: Yes No Type:
Engine Brake: Yes No Type/Brand:
Chassis and Other Related Items

Tank Vents: OK Not OK Obvious Fuel Leaks: Yes NO
Brake Drag: OK Not OK Axel Alignment: OK Not OK
Altitude: Ambient Temperature:
Typical Terrain: Flat Hilly Other
Fuel Heater: Percent Asphalt: Percent Concrete:
Additional Comments:
_____________________________________________________________________________________________________
_____
_____________________________________________________________________________________________________
_____
This checklist can be copied for convenience.
Fuel Consumption - General Information

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

Customer Name/Company __________________________________________________________ Date ________________
Answer the following questions. Some questions require making an X next to the appropriate answer.
1. What fuel mileage is expected? ________ Expected mpg
2. What are the expectations based on? Original mileage ________, Other units in fleet ________, Competitive
engines ________Previous engine owned ________, Expectations only ________, VE/VMS report ________
3. When did the problem occur? Since New ________, Suddenly ________, Gradually ________
4. Did the problem start after a repair? Yes ________ No ________ If so, what was repaired and when?
____________________________________________________________
5. Is the vehicle also experiencing a Driveability problem (Low Power or Poor Acceleration/Response)? Yes
________ No ________
If answered Yes, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist and go to the Engine Power
Output Low performance tree.
6. Is the problem seasonal? Yes ________ No ________
7. Weather conditions during fuel consumption check? Rain _____, Snow _____, Windy _____, Hot Temperatures
_____, Cold Temperatures _____
8. How is the fuel mileage measured? Tank _____, Trip _____, Month _____, Year _____ Hubometer _____, Odometer
_____
9. Are accurate records kept of fuel added on the road? Yes ________ No ________
10. Do routes vary between compared vehicles? Yes ________ No ________
11. Have routes changed for the engine being checked? Yes ________ No ________
12. What are the loads hauled, compared to comparison unit? GVW _______________ Heavier ________, Lighter
________
13. What is the altitude during operation? Below 10,000 feet ________, Above 10,000 feet ________
14. How much of the time is the truck spent idling? Hours/day __________
15. Is the driver technique or operating practices affecting fuel economy?
• High road speed: mph __________
• Operate at rated speed or above: rpm __________
• Incorrect shift rpm: Shift rpm __________, Torque Peak __________
• Operate at a cruise speed: rpm __________
• Believe compensating for low power: Yes ________ No _______
If after filling out this form it appears that the problem is not caused by vehicle factors, environmental factors, or driver
technique, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist and go to the Fuel Consumption
Excessive performance tree.
This form can be copied for convenience.
Oil Consumption
In addition to the information that follows, a service publication is available entitled Technical Overview of Oil
Consumption, Bulletin No. 3379214.
Cummins Engine Company, Inc. defines “Acceptable Oil Usage” as outlined in the following table.
Acceptable Oil Usage

Any Time During Coverage Period
Hours Hours Hours per Miles Miles per Miles per KM per KM per KM per
Engine Family per per Imperial Per Liter Imperial Quart Liter Imperial
Quart Liter Quart Quart Quart Liter
A 10.0 10.6 12.0 400 425 475 650 675 775
4B 10.0 10.6 12.0 400 425 475 650 675 775
6B 10.0 10.6 12.0 400 425 475 650 675 775
6C 10.0 10.6 12.0 400 425 475 650 675 775
V/VT-378 4.0 4.3 5.0 - - - - - -
V/VT-504 4.0 4.3 5.0 250 265 310 400 425 485
V/VT-555 4.0 4.3 5.0 250 265 310 400 425 485
L Series 4.0 4.3 5.0 250 265 310 400 425 485
M Series 4.0 4.3 5.0 250 265 310 400 425 485
N Series 4.0 4.3 5.0 250 265 310 400 425 485
V/VT/VTA-903 4.0 4.3 5.0 250 265 310 400 425 485
KT/KTA-19 3.0 3.2 3.75 200 210 250 320 340 390
QSK23 1.7 1.8 2.0 - - - - - -
V/VT/VTA28 2.0 2.1 2.5 - - - - - -
KT/KTA38 1.5 1.6 1.8 - - - - - -
KTA50 1.1 1.2 1.3 - - - - - -
Acceptable Oil Useage (Transit Bus, Shuttle Bus and School Bus)
Any Time During Coverage Period
Engine Family Hours Hours Hours per Miles per Miles per Miles per KM per KM per KM per
per per Imperial Quart Liter Imperial Quart Liter Imperial
Quart Liter Quart Quart Liter
B 10.0 10.6 12.0 200 210 240 320 340 385
C 8.0 8.5 10.0 150 160 180 240 255 290
L, M, N 4.0 4.3 5.0 100 105 120 160 170 195
Oil Consumption
Engine Lubricating Oil Consumption Report

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

___________________________________
Equals Test Mileage/Hours/Kilometers ____________________________ Divided By Oil Added
__________________________________________
Equals ___________________________________________ Usage
Rate________________________________________________________________
Customer Signature Cummins Dealer Cummins Distributor
Cummins Inc. Form 4755
Oil Consumption
Oil Consumption Report

Customer Name: Dist/Dir:
Engine Model: Mi/Km/Hr:
Engine Serial No.: CPL No.:
Vehicle Make/Model: Date:
• Review of maintenance history:
• List any previous failures that could have had a detrimental effect on cylinder component life. Failures could include
fuel, coolant, and/or foreign abrasives in the oil, second ring groove beat-out, filter plugging, etc.
• Lube Oil Used: - Brand - Viscosity - Change Interval (mi/km/hr)
• Combination Oil Filter: - Model - Element - Change Interval (mi/km/hr)
• Bypass Oil Filter: - Model - Element - Change Interval (mi/km/hr)
• Full Flow Oil Filter: - Model - Element - Change Interval (mi/km/hr)
• Air Cleaner: - Make and Model - Change Interval

• List any external engine leaks.
• Visually check for any internal leaks and list. Check turbocharger seals, valve guides, air compressor, etc.
• Had the fuel pump been tampered with? __________ What is maximum rail pressure readings? __________ If yes,
the pump must be reset to factory specifications and the customer sent out to re-evalute his oil consumption rate
and the eligibility requirements must be met again.
• Warning: Governmental agencies have determined that used engine oil is toxic and carcinogenic. Avoid
breathing, injestion, and excessive contact. Drain and refill oil pan to check dipstick markings and notes
findings.
• Only after above checks are completed, leaks corrected and proper documentation is completed, disassemble
engine to determine cause for the failure and repair as required.
• State reason for oil consumption.
Signed: __________________________________________________
Notes
N14
Section 0 - Complete Engine - Group 00 Page 0-a
Section 0 - Complete Engine - Group 00

Section Contents
Page
Engine Installation ............................................................................................................................................0-7
General Information..........................................................................................................................................0-7
Engine Removal ................................................................................................................................................0-2
Service Tools ....................................................................................................................................................0-1
Engine Removal and Installation.......................................................................................................................0-1
N14
Page 0-b Section 0 - Complete Engine - Group 00

N14 Service Tools
Section 0 - Complete Engine - Group 00 Page 0-1
Service Tools
Engine Removal and Installation
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized
Repair Location.
Tool No. Tool Description Tool Illustration

Engine Lifting Fixture
Designed to lift all H/NH engines except 5 1/8-inch bore with top
ST-125 mounted turbocharger.
Engine Lifting Fixture

Used with a hoist to lift the engine.
3822512
Rear Engine Service Lifting Bracket

Used with a hoist to lift the engine.
3823920
Engine Removal N14
Page 0-2 Section 0 - Complete Engine - Group 00
Engine Removal (000-001)

General Information
NOTE: Place a tag on all hoses, lines, linkage, and
electrical connections as they are removed to identify their
locations on the engine.
Disconnect the battery cables.

Drain the engine coolant. Refer to Procedure
008-018-005.
NOTE: If the coolant is not going to be used again,
dispose of used coolant or antifreeze in accordance with
federal, state, and local laws and regulations.
Drain the lubricating oil. Refer to Procedure 007-025-005.

Disconnect the starting motor cable, the engine ground
straps, the cab or chassis to engine hoses, the tubing, the
electrical wires, and the hydraulic lines.
NOTE: Dispose of used oil in accordance with federal,
state, and local laws and regulations.
Disconnect the intake and the exhaust air pipes.

Disconnect all chassis mounted "engine driven"
accessories.
N14 Engine Removal
Disconnect the drive units from the flywheel.
NOTE: If the rear engine mounts are attached to the

transmission, it may be necessary to remove the engine
and the transmission as an assembly.
Most cab-over configuration vehicles will have the
Cummins factory installed rear engine lifting bracket still
installed.
In installations such as short and medium nose

conventional chassis, the factory installed rear engine
lifting bracket is usually removed due to space
constraints. In this case, the service rear engine lifting
bracket, Part No. 3823920, will be required to remove the
engine from the chassis.
The service rear engine lifting bracket, Part No. 3823920,

consists of the bracket and eight 3/8-16x1 inch UNC
(Grade 8) mounting capscrews and flat washers.
Use the following steps to install the service rear engine
lifting bracket.
Engine Removal N14
Remove the injector wiring harness.
Position the service lifting bracket, Part No. 3823920, over

the rear rocker lever housing being careful not to damage
the injector wiring rocker lever housing pass through
connectors.
Attach the left plate of the lifting bracket to the fuel pump
side of the rear rocker lever housing. Install the four
3/8-16x1 inch UNC (Grade 8) mounting capscrews and
washers.
Torque Value: 75 N•m [ 55 ft-lb ]
CAUTION
If all fasteners are not installed and tightened to the
correct torque value, the lifting bracket will fail.
Severe engine damage and personal injury are
possible.
CAUTION
possible.
Attach the right plate of the lifting bracket to the exhaust
side of the rear rocker lever housing. Install the four
3/8-16x1 inch UNC (Grade 8) mounting capscrews and
washers.
N14 Engine Removal
WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection and wrap a cloth around
the fittings before removal. Liquid refrigerant can
cause serious eye and skin injury.
Remove all chassis components necessary to remove the

engine from the equipment.
WARNING
The engine lifting equipment must be designed to
safely lift the engine and the transmission as an
assembly. The dry weight of the standard engine with
accessories is 1256 kg [2770 lbs]. Refer to the
equipment manufacturer's specifications for the
transmission weight.
Use a correctly rated hoist; and attach engine lifting
fixture, Part No. ST-125 or Part No. 3822512, to the engine
mounted lifting brackets to remove the engine.
NOTE: If the transmission is not removed, place a support
under the transmission to prevent it from falling.
Conventional chassis configurations will require use of the

portable rear lifting bracket.
Attach lifting fixture, Part No. ST-125 or Part No. 3822512,
to the engine mounted lifting brackets to remove the
engine.
Engine Removal N14
Remove the CELECT™ injector wiring harness. Refer to

the CELECT™ System Troubleshooting and Repair
Manual, Bulletin No. 3666084.
Engines with stamped steel rocker lever covers require

removal of the No. 3 (rear) cover.
Position the service lifting bracket, Part No. 3823920, over
the rear rocker lever housing, being careful not to damage
the CELECT™ injector wiring rocker lever housing pass
through connector.
CAUTION
possible.
Attach the lifting bracket to the fuel pump side of the rear
rocker lever housing. Install the 3/8 - 16 X 1 inch UNC
(Grade 8) mounting capscrews and washers into the
rocker lever housing.
Attach the right plate of the lifting bracket to the exhaust

side of the rear rocker lever housing. Install the 3/8 - 16 X
1 inch UNC (Grade 8) mounting capscrews and washers
into the rocker lever housing.
CAUTION
possible.
N14 Engine Installation
Cover all engine openings to prevent dirt and debris from

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

with the replacement engine.
Remove the service engine lifting bracket, if used, to

remove the engine from the chassis. Refer to Procedure
016-001-002.
Engine Installation (000-002)

General Information
Install all accessories and brackets that were removed
from the previous engine.
Engine Installation N14
In installations such as short and medium nose

conventional chassis, the factory installed rear engine
lifting bracket is usually removed due to space
constraints. In this case, the portable rear engine lifting
bracket, Part No. 3823920, will be required to install the
engine into the chassis. Follow instructions for the rear
engine service lifting bracket installation in Procedure
000-001-999.
NOTE: If the rear engine mounts are attached to the

transmission, it may be necessary to install the engine and
the transmission as an assembly.
WARNING
The engine lifting equipment must be designed to
safely lift the engine and the transmission as an
assembly. The dry weight of the standard engine with
accessories is 1256 kg [2770 lbs.]. Refer to the
equipment manufacturer's specifications for the
transmission weight.
Use a correctly rated hoist; and attach engine lifting
fixture, Part No. ST-125 or Part No. 3822512, to the engine
mounted lifting brackets to install the engine.
Align the engine in the chassis, and tighten the engine

mounting capscrews. Refer to the equipment
manufacturer's torque specifications.
Connect all engine and chassis mounted accessories
which were removed.
NOTE: Make sure all lines, hoses, and tubes are correctly
routed and fastened to prevent damage.
Remove the four mounting capscrews and washers from

the right plate of the lifting bracket on the exhaust side of
the engine.
Remove the four mounting capscrews and washers from

the left plate of the lifting bracket on the fuel pump side of
the engine.
Remove the service lifting bracket assembly from the

engine.
Install the wiring harness to the CELECT™ injectors. Refer

to the CELECT™ System Troubleshooting and Repair
Manual, Bulletin No. 3666084.
Install the stamped steel rocker lever cover if it was
removed. Refer to Procedure 003-011-026.
Fill the engine with clean 15W-40 lubricating oil. Refer to

Procedure 007-025-028.
NOTE: The total oil capacity of the standard engine,
including combination full flow/bypass oil filter, is 42 liters
[11.0 U.S. Gallons].
NOTE: The engine lubricating oil system must be
pressurized. Refer to Procedure ?????.
Fill the cooling system with 50 percent water, 50 percent

ethylene glycol base antifreeze, and DCA corrosion
protection. Refer to Procedure 008-018-028.
NOTE: The total coolant capacity (engine only) is 18.9
liters [20 U.S. Qts.].
NOTE: Refer to the equipment manufacturer's
specifications for radiator and system capacity.
Make a final inspection to make sure all hoses, wires,

linkages, and components have been correctly installed
and tightened.
WARNING
Do not remove the radiator cap from a hot engine. Hot
steam can cause serious personal injury. The engine
coolant temperature must be below 70°C [160°F].
Operate the engine at low idle for 2 to 3 minutes.
Stop the engine and wait 5 to 7 minutes for the oil to drain
to the oil pan. Check the oil and the coolant levels again.
Fill the engine to the correct oil and coolant levels if

necessary. Refer to Procedures 007-025-028 and
008-018-028, respectively.
Operate the engine for 8 to 10 minutes to check for correct

engine operation, unusual noises, and coolant, fuel, or
lubricating oil leaks.
Repair all leaks and component problems. Refer to the
appropriate sections.
Notes
N14
Section 1 - Cylinder Block - Group 01 Page 1-a
Section 1 - Cylinder Block - Group 01

Section Contents
Page
Accessory Drive Seal ........................................................................................................................................1-4
Clean and Inspect for Reuse.............................................................................................................................1-4
Finishing Steps.................................................................................................................................................1-6
Install................................................................................................................................................................1-5
Preparatory Steps.............................................................................................................................................1-4
Remove............................................................................................................................................................1-4
Bearings, Connecting Rod ................................................................................................................................1-6
Finishing Steps...............................................................................................................................................1-10
Install................................................................................................................................................................1-9
Remove............................................................................................................................................................1-6
Bearings, Main .................................................................................................................................................1-11
Clean and Inspect for Reuse...........................................................................................................................1-13
Finishing Steps...............................................................................................................................................1-22
Install..............................................................................................................................................................1-16
Preparatory Steps...........................................................................................................................................1-11
Remove.......................................................................................................................................................... 1-11
Bearings, Thrust ..............................................................................................................................................1-23
Inspect for Reuse............................................................................................................................................1-24
Install..............................................................................................................................................................1-24
Remove.......................................................................................................................................................... 1-23
Camshaft ..........................................................................................................................................................1-28
Clean..............................................................................................................................................................1-29
Install..............................................................................................................................................................1-31
Remove.......................................................................................................................................................... 1-28
Camshaft Bearing Support ..............................................................................................................................1-34
Finishing Steps...............................................................................................................................................1-37
Install..............................................................................................................................................................1-35
Remove.......................................................................................................................................................... 1-34
Camshaft Bushings .........................................................................................................................................1-37
Finishing Steps...............................................................................................................................................1-42
Install..............................................................................................................................................................1-39
Remove.......................................................................................................................................................... 1-38
Camshaft End Clearance ...............................................................................................................................1-191
Measure........................................................................................................................................................1-191
Camshaft Gear (Camshaft Removed) ..............................................................................................................1-43
Install..............................................................................................................................................................1-45
Remove.......................................................................................................................................................... 1-43
Connecting Rod ...............................................................................................................................................1-47
Install..............................................................................................................................................................1-49
Remove.......................................................................................................................................................... 1-47
Crankshaft .......................................................................................................................................................1-50
Finishing Steps...............................................................................................................................................1-64
Grind...............................................................................................................................................................1-64
Install..............................................................................................................................................................1-56
Remove.......................................................................................................................................................... 1-51
N14
Page 1-b Section 1 - Cylinder Block - Group 01
Rotation Check............................................................................................................................................... 1-50

Crankshaft Gear, Front (Crankshaft Installed) ................................................................................................1-65
Clean..............................................................................................................................................................1-66
Install..............................................................................................................................................................1-67
Remove.......................................................................................................................................................... 1-65
Crankshaft Pulley ............................................................................................................................................1-69
Install..............................................................................................................................................................1-69
Remove.......................................................................................................................................................... 1-69
Crankshaft Seal, Front ....................................................................................................................................1-70
Clean..............................................................................................................................................................1-71
Install..............................................................................................................................................................1-71
Remove.......................................................................................................................................................... 1-70
Crankshaft Seal, Rear ..................................................................................................................................... 1-72
Clean..............................................................................................................................................................1-73
Install..............................................................................................................................................................1-74
Remove.......................................................................................................................................................... 1-72
Cylinder Block .................................................................................................................................................1-77
Camshaft Bore.............................................................................................................................................1-81
Main Bearing Bore....................................................................................................................................... 1-81
Head Deck Surface......................................................................................................................................1-87
Liner Protrusion............................................................................................................................................1-87
Counterbore.................................................................................................................................................1-90
Finishing Steps.............................................................................................................................................1-119
Machine..........................................................................................................................................................1-95
Counterbore for Oversize Lower Press Fit Liner............................................................................................1-95
Counterbore Ledge.....................................................................................................................................1-106
Cylinder Block and Liner Seats ....................................................................................................................1-119
Leak Test......................................................................................................................................................1-119
Cylinder Block Counterbore ..........................................................................................................................1-179
Initial Check..................................................................................................................................................1-179
Leak Test......................................................................................................................................................1-181
Cylinder Head Mounting Capscrew Holes ....................................................................................................1-184
Preparatory Steps.........................................................................................................................................1-184
Repair...........................................................................................................................................................1-186
Cylinder Liner ................................................................................................................................................1-121
Clean and Inspect for Reuse.........................................................................................................................1-123
Finishing Steps.............................................................................................................................................1-136
Install............................................................................................................................................................1-132
Remove.........................................................................................................................................................1-122
Gear Cover Accessory Drive Bushing ..........................................................................................................1-193
Finishing Steps.............................................................................................................................................1-197
Inspect for Reuse..........................................................................................................................................1-195
Install............................................................................................................................................................1-195
Remove.........................................................................................................................................................1-193
Gear Cover, Front ..........................................................................................................................................1-137
Clean............................................................................................................................................................1-140
Install............................................................................................................................................................1-141
Remove.........................................................................................................................................................1-137
Piston .............................................................................................................................................................1-144
Assemble......................................................................................................................................................1-148
Clean............................................................................................................................................................1-145
Disassemble..................................................................................................................................................1-145
General Information.......................................................................................................................................1-144
N14
Section 1 - Cylinder Block - Group 01 Page 1-c
Install............................................................................................................................................................1-148
Remove.........................................................................................................................................................1-144
Piston and Connecting Rod Assembly .........................................................................................................1-167
Assemble......................................................................................................................................................1-172
Disassemble..................................................................................................................................................1-170
Finishing Steps.............................................................................................................................................1-179
Install............................................................................................................................................................1-174
Remove.........................................................................................................................................................1-168
Piston Cooling Nozzle ...................................................................................................................................1-148
Clean............................................................................................................................................................1-149
Install............................................................................................................................................................1-149
Remove.........................................................................................................................................................1-148
Piston Rings ..................................................................................................................................................1-151
Finishing Steps.............................................................................................................................................1-163
Install............................................................................................................................................................1-156
Remove.........................................................................................................................................................1-151
Service Tools ....................................................................................................................................................1-1
Cylinder Block...................................................................................................................................................1-1
Vibration Damper, Viscous ...........................................................................................................................1-163
N14
Page 1-d Section 1 - Cylinder Block - Group 01

N14 Service Tools
Section 1 - Cylinder Block - Group 01 Page 1-1
Service Tools
Cylinder Block
Repair Location.

Main Bearing Cap Puller
Use to remove the main bearing caps from the cylinder block.
ST-1178
Camshaft Bushing Drive Set

Use to replace cylinder block camshaft bushings.
ST-1228
Oil Seal Puller/Installation

Use to pull or install the front crankshafts. Includes: Top plate, Part
ST-1259 No. ST-1259-1, and seal puller screw, Part No. ST1259-6.
Crack Detection Kit

Use to check or inspect components for cracks.
3375432
Oil Seal Puller Drill Pilots (Front Seal)

Used for drilling into the front oil seat to provide a pilot hole for the
3375496 puller screws. Use two No. 31 (0.120) drills.
Connecting Rod Guide Pins (Two)

Use to protect the crankshaft journal by guiding the connecting rod
3375601 during installation or removal.
Service Tools N14
Page 1-2 Section 1 - Cylinder Block - Group 01

Universal Cylinder Liner Puller
Use to remove the cylinder liners from all current engine series.
3375629
Camshaft Bushing Driver

Use to remove camshaft bushings.
3375861
Capscrew Thread Salvage Tool Kit

Use to salvage cylinder blocks with damaged cylinder head capscrew
3376208 threads.
Chip control Plug

Use to prevent contamination of the engine block during counterbore
3823231 repairs.
Depth Gauge
Use to measure the counterbore ledge.
3823495
Liner Installation Tool

Use to install cylinder liners into the block.
3823615
Safety Solvent
Use to clean machine surfaces prior to the installation of thread repair
3823717 inserts, coolant passage surfaces, and upper deck repair sleeves.
Cylinder Block Pressure Test Fixture

Use to check cylinder block counterbore leaks.
3823745
N14 Service Tools

Main Bering Roll-Out Tool
Use to remove and install main bearings.
3823818
Piston Ring Expander

Designed to install piston rings on the piston without damaging or
3823871 distorting the rings.
Accessory Drive Seal Installation Tool

Use to drive the accessory drive oil seal and wear sleeve into the gear
3824451 cover while mounted.
Marked Socket
Use to tighten the rod capscrews
3824520
Accessory Drive Seal N14
Accessory Drive Seal (001-003)

Preparatory Steps
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Remove the water pump drive belt. Refer to
Procedure 008-003.
• Remove the freon compressor drive belt, if
equipped. Refer to the manufacturer's instructions.
• Remove the accessory drive pulley. Refer to
Procedure 009-004.
Remove
Drill two 3 mm [1/8 in] holes 180 degrees apart in the seal
casing.
Use a number 10 sheet metal screw and a slide hammer
puller or a suitable pry bar to remove the seal.
Clean and Inspect for Reuse

Use a small magnet and a clean cloth to remove any
shavings from the seal bore and the accessory drive shaft.
Inspect the seal bore for nicks, scratches, and sharp

edges.
Use a 240 grit emery cloth dipped in clean lubricating oil
to remove any minor defects.
N14 Accessory Drive Seal
Use a crocus cloth to remove any deposits from the seal

bore as a final polishing operation.
Clean the seal bore and the accessory drive shaft with a
clean cloth.
Install
A guide must be used to prevent damage by reversing
the main sealing lip because of incorrect contact with the
shaft.
• An oil seal that is red is used on new assemblies and
as a service replacement when the shaft does not
have a groove in it.
• An oil seal that is blue is used when the shaft has a
groove worn in it from the seal lip and requires a wear
sleeve to restore it.
Do not use any kind of lubricant to install the seal. The

oil seal must be installed with the lip of the seal and the
seal wear area of the accessory drive shaft clean and dry.
Use of lubricant will result in oil leakage at the seal.
Place the correct oil seal and guide onto the shaft.
Thread the inner piece of pulley assembly tool, Part

Number 3376085 (Kit Part Number 3376362), onto the
accessory drive shaft.
Install the oil seal driver, Part Number 3824451, onto the
shaft.
Bearings, Connecting Rod N14
Install the outer piece of the oil seal driver onto the inner
piece.
Apply a thin coat of grease to the contact surface of the
outer piece of the oil seal driver, Part Number 3376085.
Drive the seal into the seal bore until the seal drive
contacts the gear cover.
Rotate the outer piece of the driver clockwise until the oil
seal driver stops on the hub of the gear cover.
The seal must be installed flush to the gear cover oil seal
hub.
Finishing Steps
• Install the accessory drive pulley. Refer to Procedure
009-004.
• Install the freon compressor drive belt, if removed.
• Install the water pump drive belt. Refer to Procedure
008-003.
• Install the cooling fan drive belt. Refer to Procedure
008-002.
Bearings, Connecting Rod (001-005)

Preparatory Steps
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
environmental regulations.
• Drain the lubricating oil. Refer to Procedure 007-025.
• Remove the lubricating oil pan. Refer to Procedure
007-025.
Remove
Rotate the crankshaft to position two of the connecting
rods at bottom dead center (BDC).
Use the accessory drive pulley to rotate the crankshaft.
N14 Bearings, Connecting Rod
Loosen the connecting rod capscrews.

Do not remove the capscrews.
Hit the connecting rod capscrews with a rubber hammer
to loosen the rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap, and mark the
cylinder number and the letter "L" in the flat surface of the
bearing tangs.
After installing two guide pins, Part Number 3375601, in

the connecting rod, push the rod up far enough to allow
the upper bearing shell to be removed. Use a dead blow
mallet to push the rod away from the crankshaft.
NOTE: The mallet must be wood or plastic. Do not pound
or strike the rod or bearings. Use the mallet only to push
the rod.
Remove the bearing shell, and mark the cylinder number
and the letter "U" in the flat surface of the bearing tangs.
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Steam clean the parts, and dry with compressed air.
NOTE: Refer to Parts Reuse Guidelines, Bulletin
3810303, for information on bearing inspection.
• Inspect the rod caps, connecting rod bearing

saddles, and capscrews for nicks, cracks, burrs,
scratches, or fretting.
• Inspect the bearings for damage.

Replace any bearings with lock tang damage or scratches
(deep enough to be felt with a fingernail). Also replace any
bearings which show pitting, flaking, or corrosion in the
copper lining.
NOTE: Normal bearing wear produces a smooth finish

which will wear into the copper lining. Exposed copper
does not always indicate worn bearings. If large areas of
copper lining are visible in the bearings before the engine
has accumulated 240,000 kilometers [150,000 miles] or
3,750 hours, inspect the engine for contamination from
fine dirt particles and correct the problem.
• Inspect the bearing seating surface for nicks or

burrs.
• If nicks or burrs can not be removed with a fine
crocus cloth, the bearings must be replaced.
NOTE: For more detailed information of bearing damage,
refer to Analysis and Prevention of Bearing Failures,
Bulletin 3810387.
N14 Bearings, Connecting Rod
• Measure the rod bearing shell thickness with an

outside micrometer that has a ball tip.
Standard Connecting Rod Bearing

mm in
2.362 MIN 0.093
2.405 MAX 0.0947
• Discard a bearing shell if its thickness is below the
minimum specification.
NOTE: Bearing shells are available for crankshafts which

are 0.25 mm [0.010 in], 0.51 mm [0.020 in], 0.76 mm
[0.030 in], or 1.02 mm [0.040 in] undersize. Crankshafts
which are ground undersize in the connecting rod or the
main bearing journals are marked on the front counter
weight. If the crankshaft is marked, check the bearing
shell part number to make sure the correct bearing size is
used.
Install
CAUTION
The connecting rod and bearing shell mating surfaces
must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their
original location.
Use Lubriplate® 105, or equivalent, to lubricate the
crankshaft journal mating surface of the upper bearing
shell.
Install the upper bearing shell into the connecting rod with
the tang of the bearing in the slot of the rod.
Install the bearing shell into the connecting rod cap with
the tang (2) of the bearing in the slot (1) of the cap.
Use Lubriplate® 105, or equivalent, to lubricate the
bearing shell to crankshaft journal mating surface and the
connecting rod capscrews.
CAUTION
The rod cap alpha characters must match the alpha
characters on the connecting rod and must be
installed with the characters aligned to prevent
damage to the connecting rods and crankshaft. The
locking tang of the connecting rod cap must be
toward the camshaft side of the cylinder block.
CAUTION
Rod and cap mating surfaces must be clean.
Install the cap onto the connecting rod.
Tighten the connecting rod capscrews in alternating

sequence. Refer to Torque Plus Turn in Procedure
001-047.
Measure the connecting rod side clearance. Refer to
Procedure 001-054.
Repeat installation steps above, and install the remaining
bearing shells and connecting rod caps.
Finishing Steps
CAUTION
The lubricating oil system must be primed before
operating the engine after any internal engine repairs,
to reduce the possibility of internal component
damage.
• Install the lubricating oil pan. Refer to Procedure
007-025.
• Prime the lubricating system. Refer to Procedure
007-037.
• Fill the lubricating oil pan. Refer to Procedure
007-025.
• Operate the engine until it reaches a temperature of
82°C [180°F], and check for lubricating oil leaks.
N14 Bearings, Main
Bearings, Main (001-006)

Preparatory Steps
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
WARNING
Drain the lubricating oil. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
Remove the lubricating oil pan. Refer to Procedure
007-025 (Lubricating Oil Pan) in Section 7.
Remove
CAUTION
The main bearing caps are marked for position (1) on
the camshaft side and the cylinder block identification
(2) on the exhaust side. Mark any caps that are not
marked before removing them from the cylinder
block.
NOTE: Replace main bearings one at a time.
Remove the number 7 main bearing cap capscrews and
washers.
NOTE: The number 7 main bearing cap has thrust
bearings and dowel pins.
NOTE: The service tool listed below must be centered on
the cap.
Use the main bearing cap puller, Part Number ST-1178,
to remove the cap.
Remove the lower main bearing shell from the crankshaft

journal.
NOTE: Mark the bearing shells with the journal number
from which they were removed.
Remove the dowel ring.
Bearings, Main N14
Remove the thrust bearings from the number 7 cap.

Mark these bearings as the bottom front and the bottom
rear thrust bearings.
CAUTION
Do not damage the crankshaft when removing the
thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark these bearings as the top front and the top rear thrust
bearings.
To remove the upper main bearing shell, install the main

bearing roll out tool, Part Number 3823818, into the oil
hole of the main bearing journal.
CAUTION
Do not use a capscrew or any hard metal object as this
can damage the crankshaft and cause serious engine
failure.
Rotate the crankshaft with the accessory drive pulley to
remove the main bearing shell. Mark each main bearing
for location if they are to be installed again in the engine.
N14 Bearings, Main

Use a soft bristle brush to clean the parts, and dry with
compressed air.
Plastigage®
CAUTION
To reduce the possibility of the crankshaft falling, two
evenly spaced main bearing caps must always be on
the engine to support the engine crankshaft.
The inspection must be performed with the main cap
bearings that will be used in the engine after the
inspection and/or repair is completed.
The PR-1 (red) style Plastigage®, clearance range of 0.05
to 0.152 mm [0.002 to 0.006 in], is required for this
procedure.
Do not destroy evidence. Go slowly and observe all
conditions.
To Plastigage® the main bearing journal clearance on an
in-chassis engine, shims must be inserted into the main
caps on both sides of the journal being Plastigaged®.
Shims support the crankshaft so an accurate clearance
measurement can be made on the lower bearing.
Use a main bearing cap puller, Part Number ST-1178, to
remove the caps. The main bearing cap puller must be
centered on the cap. Pull straight down to remove the cap.
Remove the lower bearings.
Shims push the crankshaft up against adjoining upper

bearings so an accurate clearance measurement can be
made on the lower bearing.
The shims can be manufactured from a piece of 4-inch-
diameter, schedule 40 PVC pipe. The dimensions of the
fabricated shims must be as follows:
Width = 38.1 mm [1.5 in]
Thickness = 6.35 mm 0.25 in] (approximate thickness of
schedule 40 PVC pipe)
Diameter = 101.6 mm [4.0 in].
Cut the pipe in half. The shims must be fabricated to the
above-specified dimensions and be less than 180 degrees
in circumference.
Bearings, Main N14
NOTE: Two fabricated shims are required for this

procedure.
Install the shims in the main bearing caps on both sides
of the bore being checked. (For example, to check the
number 4 main bearing cap, install the shims on the
number 3 and number 5 main bearing caps. To check the
number 5 and number 7 main bearing caps.)
Install the main bearing caps.
Install and tighten the capscrews.
Remove the main bearing cap to be Plastigaged®.

Wipe the oil from the bearing and crankshaft journal.
Cut or tear a piece of Plastigage® the full width of the
bearing.
Do not squeeze the gauge material as this can result in a
false reading.
Tear through both the envelope and plastic thread at the
same time. Open the envelope lengthwise by cutting the
edge with scissors or a knife or by tearing.
With the envelope open, lift out the Plastigage® by one
end. Roll the material out with a thumb if the material is
stuck lightly to the paper.
Occasionally, the color in the Plastigage® material will
transfer to the paper. This has no effect on accuracy.
Place the piece of Plastigage® in the bearing shell
approximately at the 6-o'clock position.
The Plastigage® clearance check procedure must be
performed with the original bearings.
Do not disturb the Plastigage® before reading the

measurement. Disturbing the Plastigage® can result in an
incorrect measurement.
Install the main bearing cap using the appropriate torque
procedure.
Remove the main bearing cap. The compressed
Plastigage® will be located adhering to either the bearing
shell or the crankshaft.
N14 Bearings, Main
Compare the width of the compressed Plastigage® at its

widest point, to the graduations on the envelope
(regardless of taper). The number within the graduation on
the envelope indicates the bearing clearance in
thousandths of an inch or millimeters, depending on which
side of the envelope is used.
Taper does not affect the clearance measurement.
Clearance is still measured at the widest point on the
Plastigage® strip.
If the compressed Plastigage® is less than 0.051 mm
[0.002 in] at its widest point, the block must be pulled from
service and repaired or replaced.
If the compressed Plastigage® is greater than 0.051 mm
[0.002 in], reassemble the main bearing caps with either
the existing or new main bearings.
Inspect the main bearing cap and capscrews for damage.

Inspect the bearing shells and the thrust bearings for
nicks, scratches, or damage.
NOTE: If the main bearings are damaged, refer to the N14
Shop Manual, Bulletin 3810487 to inspect the crankshaft
main bearing journals. If the crankshaft is damaged, the
engine must be removed for repair. Refer to Procedure
000-001 (Engine Removal) in the N14 Shop Manual,
Bulletin 3810487.
Use an outside diameter ball tipped micrometer to

measure the main bearing shell thickness.
Standard Main Bearing Shell Thickness

mm in
3.086 MIN 0.1215
3.145 MAX 0.1238
Discard a main bearing shell if its thickness is below the
Bulletin 3810387.

are 0.25 mm [0.010 in], 0.51 mm [0.020 in], 0.76 mm
which are ground undersize in the connecting rod and
used.
Bearings, Main N14
Install
NOTE: The upper main bearing shells have a groove and
an oil hole to provide crankshaft lubrication. The lower
main bearing shells do not have grooves or holes. The
groove for the number 7 shell is not in the center of the
shell. The wider part of the number 7 shell must be
installed toward the flywheel end of the cylinder block.
CAUTION
The cylinder block saddle and the cap mating surfaces
must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their
original location.
CAUTION
The groove for the dowel ring must be next to the
dowel ring counterbore in the cylinder block.
Use clean Lubriplate® 105 or its equivalent to lubricate the
upper main bearing shell to crankshaft journal mating
surface.
CAUTION
Do not use a capscrew or any hard metal object as this
can damage the crankshaft and cause serious engine
failure.
To install the upper main bearing shell, install main
bearing roll out tool, Part Number 3823818, into the oil
hole of the main bearing journal. Start the bearing into the
upper saddle by hand. Take care that the roll-in tool does
not slip between the bearing and the crank journal.

upper thrust bearings.
N14 Bearings, Main
CAUTION
The grooves must be toward the crankshaft. Incorrect
thrust bearing installation will result in engine
damage.
Install the upper thrust bearings in the number 7 main
bearing saddle.
NOTE: Push the crankshaft toward the rear of the engine
to install the front bearing and to the front of the engine to
install the rear bearing.
Install the dowel ring in the dowel ring counterbore of the

cylinder block.
Install the lower main bearing shell as follows:
a Use clean Lubriplate® 105 or its equivalent to lubricate
the bearing shell to the crankshaft journal mating
surface.
a Align the bearing shell with the dowel ring.

b Push on the side of the bearing shell opposite the
dowel ring to install the bearing shell.
CAUTION
The grooves of the thrust bearing must be toward the
crankshaft. The locating dowels must not protrude
above the thrust bearing surface. Incorrect thrust
bearing installation will result in engine damage.
lower thrust bearings.
Install the lower thrust bearings in the number 7 main
bearing cap as shown.
Bearings, Main N14
Use clean 15W-40 oil to lubricate the capscrew threads

and the flat washers.
Drain the excess oil from the capscrews before installing
them.
CAUTION
(2) on the exhaust side. The cylinder block
identification number (3) is stamped on the pan rail on
the camshaft side of the block. Install the caps in the
correct position with the position number to the
camshaft side and its part number toward the rear of
the engine. Installation of main bearing caps into
incorrect positions will result in severe engine
damage.
Install the main bearing caps as follows:
a Align the capscrew holes in the cap with the holes in
the cylinder block. Make sure the ring dowel and the
lower bearing shell are in position.
a Install the capscrews and the washers through the cap

and into the cylinder block.
b Hand tighten the capscrews two to three threads.
NOTE: When hitting the cap, make sure the bearing shell
and dowel ring do not move.
a Hit the cap with a rubber mallet to push it into the
correct position.
N14 Bearings, Main
Tighten all older block (prior to engine serial number

(ESN) 11875596) main bearing capscrews in alternating
sequence to the following torque values:
Torque Value:
Step 1 122 N•m [ 90 ft-lb ]
Step 2 230 N•m [ 170 ft-lb ]
Step 3 346 N•m [ 255 ft-lb ]
Step 4 Loosen completely
Step 5 122 N•m [ 90 ft-lb ]
Step 6 230 N•m [ 170 ft-lb ]
Step 7 346 N•m [ 255 ft-lb ]
All newer blocks (ESN first 11875596) must be tightened
in alternating sequence to the following torque values:
Torque Value:
Step 1 68 N•m [ 50 ft-lb ]
Step 2 136 N•m [ 100 ft-lb ]
Step 3 190 N•m [ 140 ft-lb ]
Step 5 68 N•m [ 50 ft-lb ]
Step 6 136 N•m [ 100 ft-lb ]
Step 7 190 N•m [ 140 ft-lb ]
Step 8 Rotate 90 degrees
Replace the main bearing shells number 1 through
number 6.
NOTE: Main bearings number 1 through number 6 do
not have thrust bearings.
Tighten the main bearing capscrews in the sequence

shown.
Measure the end clearance of the crankshaft as follows:

a Install a dial indicator to the oil pan flange.
b Put the tip of the gauge against the crankshaft counter
weight.
c Push the crankshaft toward the rear of the cylinder
block.
Bearings, Main N14
a Set the dial indicator to zero.

b Push the crankshaft toward the front of the cylinder
block.
c If the end clearance is less than 0.10 mm [0.004 in], do
the following:
Loosen all main bearing capscrews one turn.

Push the crankshaft toward the front and then toward the
rear of the cylinder block.
Tighten all older block (prior to engine serial number

(ESN) 11875596) main bearing capscrews in alternating
sequence to the following torque values:
Torque Value:
Step 1 122 N•m [ 90 ft-lb ]
Step 2 230 N•m [ 170 ft-lb ]
Step 3 346 N•m [ 255 ft-lb ]
Step 5 122 N•m [ 90 ft-lb ]
Step 6 230 N•m [ 170 ft-lb ]
Step 7 346 N•m [ 255 ft-lb ]
Torque Value:
Step 1 68 N•m [ 50 ft-lb ]
Step 2 136 N•m [ 100 ft-lb ]
Step 3 190 N•m [ 140 ft-lb ]
Step 5 68 N•m [ 50 ft-lb ]
Step 6 136 N•m [ 100 ft-lb ]
Step 7 190 N•m [ 140 ft-lb ]
Step 8 Rotate 90 degrees
N14 Bearings, Main

shown.
Measure the crankshaft end clearance. The end clearance

specification for a new or reground crankshaft with new
thrust bearings is 0.10 to 0.45 mm [0.004 to 0.018 in].
NOTE: Crankshafts that have been reground on the thrust

bearing surfaces are marked for oversize thrust bearings
on the rear crankshaft counter weight. If the crankshaft
counter weight is marked, check the thrust ring part
number to make sure the correct thrust ring size is used.
Example: F.010 = Front 0.25 mm [0.010 in]
Example: R.020 = Rear 0.51 mm [0.020 in]
If the crankshaft end play is more than 0.56 mm [0.022 in],

the crankshaft must be removed from the engine and
repaired. Refer to the Alternate Repair Manual, Bulletin
3379035.
Bearings, Main N14
Finishing Steps
Install the lubricating oil pan. Refer to Procedure 007-025
(Lubricating Oil Pan) in Section 7.
CAUTION
operating the engine after any internal engine repairs
to avoid internal component damage.
Remove the temperature sensor from the lubricating oil
pump cover.
Prime the lubricating system. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
Fill the engine with lubricating oil. Refer to Procedure

007-025 (Lubricating Oil Pan) in Section 7.
Operate the engine until it reaches a temperature of 82°

C [180°F], and check for lubricating oil leaks.
N14 Bearings, Thrust
Bearings, Thrust (001-007)

Remove
1. Drain the lubricating oil. Refer to Procedure
007-025-005.
2. Remove the lubricating oil pan. Refer to Procedure
007-025-002.
WARNING
Used engine oil has been identified by the state of
California as causing cancer and reproductive
toxicity. Do not breathe, ingest or excessively contact
used engine oil.
CAUTION
(2) on the exhaust side. Mark any caps that are not
marked before removing them from the cylinder
block.
3. Remove the No. 7 main bearing cap capscrews and

washers.
NOTE: The No. 7 main bearing cap has thrust bearings
and dowel pins.
NOTE: The service tool listed below must be centered on
the cap.
4. Use the main bearing cap puller, Part No. ST-1178,
to remove the cap.
5. Remove the thrust bearings from the No. 7 cap.

6. Mark these bearings as the bottom front and the
bottom rear thrust bearings.
Bearings, Thrust N14
CAUTION
thrust bearings.
7. Use a blunt tool to remove the upper thrust bearings.
8. Mark these bearings as the top front and the top rear
thrust bearings.
Inspect for Reuse

1. Visually inspect the main cap and capscrews for
damage.
2. Visually inspect the thrust bearings for nicks,
scratches, or damage.
NOTE: If the main bearings are damaged, refer to the
Engine Shop Manual to inspect the crankshaft main
bearing journals. If the crankshaft is damaged, the engine
must be removed for repair. Refer to Procedure
000-001-999.
Install
1. Use clean Lubriplate® 105 or its equivalent to
lubricate the upper thrust bearings.
CAUTION
The grooves must be toward the crankshaft. Incorrect
thrust bearing installation will result in engine
damage.
2. Install the upper thrust bearings in the No. 7 main
bearing saddle.
3. Use clean Lubriplate® 105 or its equivalent to

lubricate the lower thrust bearings.
CAUTION
The grooves of the thrust bearing must be toward the
crankshaft. The locating dowels must not protrude
above the thrust bearing surface. Incorrect thrust
bearing installation will result in engine damage.
4. Install the lower thrust bearings in the No. 7 main
bearing cap as shown.
5. Use clean 15W-40 oil to lubricate the capscrew

threads and the flat washers.
6. Drain the excess oil from the capscrews before
installing them.
CAUTION
the engine. Installation of main bearing caps into
incorrect positions will result in severe engine
damage.
7. Install the main bearing caps as follows:
a. Align the capscrew holes in the cap with the holes in
the cylinder block. Make sure the ring dowel and the
lower bearing shell are in position.
b. Install the capscrews and the washers through the

cap and into the cylinder block.
c. Use your hand to tighten the capscrews two to three
threads.
Bearings, Thrust N14
NOTE: When hitting the cap, make sure the bearing shell
and dowel ring do not move.
d. Hit the cap with a rubber mallet to push it into the
correct position.
8. Tighten the capscrews on a main bearing cap to the

following torque values:
a. Tighten both to 122 N•m [90 ft-lb].
b. Tighten both to 230 N•m [170 ft-lb].
c. Tighten both to 346 N•m [255 ft-lb].
d. Loosen both completely.
e. Repeat steps a. through c.
9. Replace the main bearing shells No. 1 through No.
6.
NOTE: Main bearings No. 1 through No. 6 do not have
thrust bearings.

thrust bearings is 0.10 mm [0.004-inch] to 0.45 mm [0.018-
inch].

Example: F-.010 = Front 0.25 mm [0.010-inch]
Example: R-.020 = Rear 0.51 mm [0.020-inch]
a. If the crankshaft end play is more than 0.56 mm

[0.022-inch], the crankshaft must be removed from
the engine and repaired. Refer to the Alternative
Repair Manual, Bulletin No. 3379035.
10. Install the lubricating oil pan. Refer to Procedure

007-025-026.
CAUTION
11. Remove the temperature sensor from the lubricating
oil pump cover.
12. Prime the lubricating system. Refer to Procedure
007-037-050.
13. Fill the engine with lubricating oil. Refer to Procedure

007-025-028.
Camshaft N14
14. Operate the engine until it reaches a temperature of

82°C [180°F], and check for lubricating oil leaks.
Camshaft (001-008)
Remove
Remove the accessory drive pulley. Refer to Procedure
009-004-002.
Remove the vibration damper and the crankshaft pulley.
Refer to Procedures 001-052-002 and 001-022-002,
respectively.
Remove the front crankshaft seal and the accessory drive

seal. Refer to Procedures 001-023-002 and 001-003-002,
respectively.
Remove the gear cover. Refer to Procedure 001-031-002.

Remove the cam follower assemblies. Refer to Procedure
004-001-002.
N14 Camshaft
Install four camshaft pilots, Part No. 3824285, over the

outer base circle of the valve lobes between the camshaft
journals.
Use a rubber band to hold the installation pilots in place.
The rubber band must straddle the valve lobe.
Use one hand to slowly rotate and pull the camshaft from
the cylinder block and the other hand to balance the
camshaft as it is removed.
Remove the camshaft thrust washer from the camshaft.
Clean
Clean the camshaft with solvent, and dry with compressed
air.
NOTE: After the camshaft has been steam cleaned, do

not touch the machined surfaces with bare hands. This
will cause rust to form. Lubricate the camshaft with clean
15W-40 oil before handling.
Camshaft N14
Inspect for Reuse

Use a feeler gauge to measure the clearance between the
gear and the shoulder on the camshaft.
NOTE: The clearance must not exceed 0.13 mm [0.005-
inch].
Measure the seven camshaft bushing journals.
Camshaft Bushing Journal O.D.

mm in
63.37 MIN 2.495
63.42 MAX 2.497
Replace the camshaft if the journal dimensions do not
meet specifications.
Visually inspect the camshaft lobes for cracks, scratches,

or other damage.
Measure the camshaft thrust washer.
Camshaft Thrust Washer Thickness

mm in
2.29 MIN 0.090
2.49 MAX 0.098
Replace the thrust washer if it does not meet
specifications.
N14 Camshaft
Measure the camshaft bushings in the cylinder block.

Refer to Procedure 001-010-026.
Install
Apply a film of Lubriplate® 105 or its equivalent to both
sides of the camshaft thrust washer.
CAUTION
The oil grooves on the thrust washer must be toward
the camshaft gear to prevent thrust washer failure.
Install the thrust washer onto the camshaft.
Install four camshaft pilots, Part No. 3375268, over the

outer base circle of the valve lobes between the camshaft
journals.
Use a rubber band to hold the installation pilots in place.
The rubber band must straddle the valve lobes.
Apply a film of Lubriplate® 105 or its equivalent to the

camshaft journals and the camshaft bushings.
Rotate the camshaft slowly as it is being installed into the
cylinder block.
Camshaft N14
Align the "O" mark on the camshaft gear with the "O" mark
on the crankshaft gear.
Align the timing marks on the camshaft gear with the
timing marks on the accessory drive gear.
After aligning the "O" marks, push the camshaft into the
bore until the thrust washer fits against the cylinder block.
Remove the camshaft installation pilots. Do not allow the

rubber bands to fall into the camshaft cavity of the cylinder
block when removing the installation pilots.
Use a dial indicator to check the backlash between the

camshaft gear and the crankshaft gear.
Put the tip of the dial indicator against a tooth on the
camshaft gear.
Turn the camshaft gear by hand as far as it will freely

move, and set the dial indicator at "0" (zero).
N14 Camshaft
Turn the camshaft gear by hand in the opposite direction

as far as it will freely move, and read the dial indicator.
Backlash Between the Camshaft and the Crankshaft

Gears
mm in
0.08 MIN 0.003
0.46 MAX 0.018
If the backlash is excessive, inspect the camshaft and
crankshaft gears for tooth wear and replace if necessary.
If the backlash is tight, inspect for debris or damage to the
gear teeth and check again.
Install the gear cover. Refer to Procedure 001-031-026.

Install the front crankshaft seal. Refer to Procedure
001-023-026.
Install the accessory drive seal at this time. Refer to
Lubricate the valve and the injector camshaft lobes with
15W-40 lubricating oil, and install the cam follower
assemblies. Refer to Procedure 004-001-026.
Install the crankshaft pulley and the vibration damper.

respectively.
Install the accessory drive pulley. Refer to Procedure
009-004-026.

C [180°F], and check for coolant or lubricating oil leaks.
Camshaft Bearing Support N14
Camshaft Bearing Support (001-009)

Preparatory Steps
Remove the alternator drive belt. Refer to Procedure
013-001.
Remove the vibration damper. Refer to Procedure
001-052.
Remove the crankshaft pulley. Refer to Procedure
001-022.
Remove
Remove the three capscrews from the support.
Use a rubber or plastic mallet to rotate the bearing support
approximately 60 degrees.
Be careful not to damage the bearing support surfaces

when removing the bearing support.
Use a suitable pry bar to remove the bearing support from
the gear cover.
Remove the o-ring and the shims from the bearing

support. Do not dispose of the shims.
N14 Camshaft Bearing Support
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
personal injury.
Clean the bearing support and the shims with solvent.
Dry with compressed air.
Inspect the bearing support for cracks or damage on the

thrust surface.
Install
Install the support bearing into the bore of the gear cover.
Do not install the o-ring onto the support at this time.
Push the support against the camshaft so the camshaft
gear rests against the camshaft thrust washer.
Hold the support against the camshaft, and use a feeler

gauge to measure the space between the gear cover
flange and the support bearing.
Camshaft Bearing Support N14
The clearance between the bearing support thrust face

and the camshaft gear must be 0.20 mm to 0.33 mm
[0.008 to 0.013 inch].
After measuring the space between the bearing support

and the gear cover flange, add an additional 0.20 to 0.33
mm [0.008 to 0.013 in] to that number to determine the
thickness of the shims required. Example: Space of 1.52
mm [0.060 in], measured with a feeler gauge, plus 0.25
mm [0.010 in] for clearance will require 1.77 mm [0.070 in]
shims.
Use a micrometer to measure the shims removed from the

support at the time of disassembly. Add or remove shims
as required to obtain the correct clearance between the
bearing support and the camshaft gear. Shims are
available in the following thicknesses:
Shim Thicknesses
mm in
0.05 0.002
0.13 0.005
0.25 0.010
0.63 0.025
Install the required number of shims and a new o-ring on

the support bearing.
N14 Camshaft Bushings
CAUTION
Do not use lubricating oil on the o-ring. The o-ring will
increase in size when in contact with lubricating oil.
Use vegetable oil to lubricate the o-ring.
Lubricate the o-ring, and install the support bearing into
the gear cover.
Tighten the capscrews.
Finishing Steps
Install the crankshaft pulley. Refer to Procedure 001-022.
Install the vibration damper 001-052.
Install and adjust the alternator drive belt. Refer to
Procedure 013-005.
Camshaft Bushings (001-010)

Preparatory Steps
009-004.
Remove the vibration damper. Refer to Procedure
001-052.
Remove the crankshaft pulley. Refer to Procedure
001-022.
Remove the gear cover. Refer to Procedure 001-031.

Remove the cam followers. Refer to Procedure 004-001.
Remove the camshaft. Refer to Procedure 001-008.
Camshaft Bushings N14
Remove
Use the camshaft bushing driver set, Part Number
ST-1228, and driver, Part Number 3375861, to remove
bushings number one through number six.
Use the camshaft bushing driver set, Part Number

ST-1228, and puller, Part Number 3822782, to remove the
number seven bushing.
Remove the number one bushing first and then the
remaining six bushings in order from front to rear.
To remove bushings number one through number six

insert the tool assembly through the camshaft bore until
the driver is against the bushing.
Hit the slide hammer against the shaft assembly until the
bushing is driven from the bore.
To remove the number seven bushing, insert the tool

assembly through the bore until the pins of the puller
assembly are engaged behind the bushing.
Hit the slide hammer against the T-handle until the
bushing is removed from the bore.

Use a fine emery cloth to remove burrs, and clean the
bushing bores.
Measure the cylinder block camshaft bore inside

diameter.
Camshaft Bore Inside Diameter

mm in
68.237 MIN 2.686
68.275 MAX 2.688
Camshaft bores not meeting specifications can be
repaired with sleeves. Refer to the Alternative Repair
Manual, Bulletin 3379035. This is an out of chassis repair.
Install
CAUTION
Incorrect installation will result in severe damage to
the engine. Refer to the numbers stamped on the
bushings to determine the correct cylinder block cam
bore location in which the bushings are to be
installed.
Install the camshaft bushings in the following order:

numbers seven, six, five, four, three, two, and one.
Refer to the procedure outlined below.
CAUTION
The locating notch in the number seven bushing must
be toward the rear of the engine and be located at the
6:00 o'clock position.
Install the tool assembly through the camshaft bore until
the driver, Part Number 3375861, is in the cavity between
the number six and the number seven bores.
Install the camshaft bushing guide, Part Number
ST-1228-6, into the number five and the number six bores.
Install the bushing marked number seven onto the driver

with the location notch to the rear of the engine and at the
Push the bushing into the bore until the oil holes in the
bushing are aligned with the drillings in the bore.
Use a 2.39 mm [0.094-inch] diameter rod to check the

position and the location of the oil hole in the bushing and
the cylinder block.
The rod must pass through the oil holes in the bushing
and into the oil supply drillings in the cylinder block.
CAUTION
The locating notch in the number two through the
number six bushings must face the rear of the engine
and be located at the 9:00 o'clock position when
looking at it from the front of the engine.
Install the number six through the number two bushings

in the same manner as number seven was installed.
Use the bushing driver, Part Number 3375861, (1) to
install bushing numbers one, two, four, and six.
Use the bushing driver, Part Number 3376412, (2) to
install bushing numbers three and five.
Install the tool assembly through the camshaft bore until

the driver is in the cavity between the bores where the
bushing is to be installed.
Install the bushing guide into the camshaft bore next to
the bore where the bushing is to be installed.
Install the bushing marked for that location onto the driver
with the locating notch to the rear of the engine and at the

the cylinder block.
NOTE: Camshaft bushing guide, Part Number ST-1228-6,

is not used to install the number 1 bushing.
Install a new bushing onto the driver, Part Number
3375861, with the notch to the rear of the engine and at
the 9:00 o'clock position when looking at it from the front
of the engine.

position and the location of the oil holes in the bushing and
the cylinder block.
Measure the camshaft bushings inside diameter

(installed).
Camshaft Bushing Inside Diameter (Installed)

mm in
63.457 MIN 2.498
63.558 MAX 2.502
If the camshaft bushing installed diameter is not within
specifications, remove the bushings and refer to the
Alternative Repair Manual, Bulletin 3379035, for repair
options.
Finishing Steps
Install the camshaft. Refer to Procedure 001-008.
Install the cam followers. Refer to Procedure 004-001.
Install the gear cover. Refer to Procedure 001-031.
N14 Camshaft Gear (Camshaft Removed)
Install the crankshaft pulley. Refer to Procedure 001-022.

Install the vibration damper. Refer to Procedure 001-052.
009-004.

Camshaft Gear (Camshaft Removed)

(001-013)
Remove
Remove the camshaft. Refer to Procedure 001-008.
CAUTION
Place a wooden block under the camshaft to avoid
damage as the camshaft drops free from the cam
gear.
Install the camshaft and gear assembly into a hydraulic
press. Place V-blocks under the gear. Make sure the V-
blocks support the hub area of the gear.
NOTE: Do not use a heating torch to remove the gear. If

you use a heating torch, a new gear must be installed.
Push the shaft from the gear.
NOTE: If the camshaft key is marked with an arrow, record
the direction in which it is pointed.
Use a flat chisel and hammer to remove the camshaft key.
Camshaft Gear (Camshaft Removed) N14
Inspect for Reuse

CAUTION
If the inside diameter of the gear is damaged or has
fretting in excess of a 3.175 mm [0.125 in] wide band,
do not use the gear. Fretting or other damage can
result in gear movement on the camshaft nose, which
can cause camshaft nose failure.
Inspect the camshaft gear for cracks, chipped, or broken
teeth.
Scratches must not exceed 0.79 mm [0.031 in] depth, and
must be at least 3.2 mm [0.125 in] apart.
Inspect the bore of the gear for fretting or burrs.
NOTE: If the fretting, burrs, or raised material can not be
removed with a fine crocus cloth, replace the gear.
Inspect the gear keyway for burrs.

Remove burrs with a fine crocus cloth.
NOTE: If the keyway is damaged or the burrs can not be
removed with a fine crocus cloth, the gear must be
replaced.
Measure the inside diameter of the gear bore.
Camshaft Gear Bore Inside Diameter

mm in
Flangless 45.662 MIN 1.7977
Camshaft 45.682 MAX 1.7985
Replace the camshaft gear if it does not meet
specifications.
N14 Camshaft Gear (Camshaft Removed)
CAUTION
If the area of fretting is wider than a 3.175 mm [0.125
in] wide longitudinal band, do not use the camshaft.
Fretting or other damage can result in gear movement
on the camshaft nose and can cause a camshaft nose
failure.
Inspect the camshaft nose in the gear fit area for fretting
or burrs.
NOTE: If fretting, burrs, or other raised material can not
be removed with a fine crocus cloth, replace the camshaft.
Measure the outside diameter of the camshaft nose in the

gear press fit area.
Camshaft Gear Press Fit Outside Diameter.

mm in
Flangeless 45.733 MIN 1.8005
Camshaft 45.745 MAX 1.8010
Replace the camshaft if it does not meet specifications.
Install
Use a plastic mallet to install the camshaft gear key.
NOTE: If the same camshaft and gear are used again, use
the same part number key as the one that was removed.
Make sure the arrow on the key is pointing in the same
direction as when it was removed.
See the engine dataplate and the Control Parts List
Manual, Bulletin Number 3379133, for the correct key part
number and key orientation.
Put the camshaft in a vertical position with the gear fit area
(nose) pointing up.
Wipe off the gear fit area to remove any grease or oil
before installing the gear.
Camshaft Gear (Camshaft Removed) N14
CAUTION
Wear protective gloves when handling parts that have
been heated to prevent personal injury.
Heat the gear in an oven at 191°C to 204°C [375°F to
400°F] for 1 to 4 hours. Do not heat the gear in an oven
for more than 4 hours.
Remove the gear from the oven.
NOTE: Install the gear on the camshaft within 30 seconds
after it is removed from the oven.
Align the gear keyway with the key in the camshaft, and
install the gear. The timing marks and the gear part
number must be facing away from the camshaft.
NOTE: Keep the camshaft in a vertical position with the
gear up until the gear has cooled.
If the gear does not seat against the locating shoulder on

the camshaft, remove the gear and install it again. Make
sure to inspect the camshaft again each time the gear is
removed.
Use a feeler gauge to check the clearance between the
camshaft gear and the shoulder. The clearance must
not exceed 0.13 mm [0.005 in].
Install the camshaft. Refer to Procedure 001-008.

Install the gear cover and related components. Refer to
Procedure 001-031.
N14 Connecting Rod
Install the cam follower assemblies. Refer to Procedure

004-001.
Check the engine timing. Refer to Procedure 006-025.
Connecting Rod (001-014)

Remove
Remove the piston and connecting rod assemblies from
the engine. Refer to Procedure 001-054 in Section 1.
NOTE: The piston and connecting rod assemblies must
be installed in the same cylinder number from which they
were removed, to make sure there is a correct fit of worn
mating surfaces if parts are used again.
Use a tag to mark the cylinder number from which each
piston and rod assembly was removed.
WARNING
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
WARNING
WARNING
personal injury.
Use a nylon bristle brush to clean the oil drillings.
Steam clean or use solvent to clean the connecting rods.
Connecting Rod N14
Inspect the rods and the caps for damage.

Replace the rod if the "I-beam" is nicked or damaged.
Inspect the connecting rod and the cap for fretting damage
on the mating surfaces.
The rod and the cap must be replaced as an assembly if
any fretting damage is visible on either piece.
Inspect the rod pin bore bushing for damage or

misalignment of the oil passage and the bushing.
Replace any piston pin bushing that has evidence of
scoring, galling, or scuffing. Replace any bushing that has
turned.
Special tools and precision machining are required to
replace bushings. If Cummins® approved tools and
procedures are not available, the connecting rod must
be replaced.
CAUTION
damage to the connecting rods and crankshaft.
Install the connecting rod caps and the capscrews.
Refer to Procedure 001-047 in Section 1.
N14 Connecting Rod
Measure the rod crankshaft bore inside diameter.
Connecting Rod Crankshaft Bore (Inside Diameter)

mm in
93.731 MIN 3.6902
93.769 MAX 3.6917
If any of the measurements are not within the
specifications, the rod must be repaired or replaced.
Measure the piston pin bushing inside diameter.
Piston Pin Bushing (Inside Diameter)

mm in
63.543 MIN 2.5017
63.564 MAX 2.5025
If any of the measurements are not within the
specifications, the rod must be repaired or replaced.
The bushing must be precision machined after
installation. If machining capability is available, the
bushing can be replaced. Refer to the Alternative Repair
Remove the capscrews and the rod caps.

NOTE: Refer to the Engine Shop Manual to measure the
bend and twist of the rods.
Measure the connecting rod capscrew outside diameter.
Connecting Rod Capscrew (Outside Diameter)

mm in
14.50 MIN 0.571
14.99 MAX 0.590
Install
Install the piston and connecting rod assembly. Refer to
Procedure 001-054 in Section 1.
Crankshaft N14
Crankshaft (001-016)
Rotation Check
Use only the accessory drive shaft to rotate the
crankshaft.
Rotate the crankshaft clockwise through two complete
revolutions.
If the engine does not turn freely, the equipment can have
a malfunction. Refer to the manufacturer's instructions.
The engine can have internal problems. Reference the
correct procedure for inspection and replacement of
internal engine components.
Inspect for Reuse

Rail Applications
Inspect the crankshaft for dirt or damage
NOTE: If the crankshaft is found to be damaged, replace
it.
Inspect the flywheel mating face of the crankshaft for

signs of pitting, fretting, or corrosion.
NOTE: If the crankshaft is found to be damaged, replace

it.
Reference the Grind section of this procedure for
guidelines for reuse and grinding mating faces of
crankshafts for rail engines.
N14 Crankshaft
Preparatory Steps
• Disconnect the batteries to prevent accidental engine
starting.
• Make sure vehicle is immobilized and safe to work on.
Refer to the end-user procedures.
• Remove the vehicle driveline and the transmission.
• Remove the engine from vehicle. Refer to the
007-025 in Section 7.
• Remove the flywheel housing. Refer to Procedure
Remove
CAUTION
The main bearing caps must be marked for position
and cylinder block identification.
The position number (1) of the cap is stamped on the
camshaft side and the block identification number (2) is
stamped on the exhaust side of the cap.
The cylinder block identification number is stamped on the

front and the rear of the oil pan flange on the camshaft
side of the engine.
Check and mark all caps that are not marked before
removing them from the cylinder block.
NOTE: The number 7 main bearing cap has thrust

bearings and dowel pins.
Remove the main bearing capscrews and the washers.
Crankshaft N14
Use main bearing cap puller, Part Number ST-1178, or

equivalent to remove the caps. The service tool must be
centered on the main bearing cap.

from which they were removed if they are to be used again
or if failure analysis is required.
Remove the lower main bearing shell from the crankshaft
journal.
Remove the dowel ring.
Remove the thrust bearings from the number 7 cap.

Mark these bearings as the front and rear thrust bearings.
CAUTION
thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark the bearings in the notched area as the front and
rear thrust bearings.
NOTE: If necessary, slide the crankshaft to the front or to
the rear to allow the thrust bearings to be removed.
N14 Crankshaft
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
Use a hoist and a lifting sling to remove the crankshaft.
Push the upper main bearing on the end that does not
have the dowel ring groove.
from which they were removed if they are to be used again
or if failure analysis is required.

Use a soft bristle brush to clean the parts, and dry with
compressed air.
Crankshaft N14
Plastigage
CAUTION
To reduce the possibility of the crankshaft falling, two
evenly spaced main bearing caps must always be on
the engine to support the engine crankshaft.
The inspection must be performed with the main cap
bearings that will be used in the engine after the
inspection and/or repair is completed.
The PR-1 (red) style Plastigage, clearance range of 0.05
to 0.152 mm [0.002 to 0.006 in], is required for this
procedure.
Do not destroy useful evidence. Go slowly and observe all
conditions.
To measure the main bearing journal clearance on an in-
chassis engine, shims must be inserted into the main
caps on both sides of the journal being checked.
Use a main bearing cap puller, Part Number ST-1178, or
equivalent to remove the caps. The main bearing cap
puller must be centered on the cap. Pull straight down to
remove the cap.
Remove the lower bearings.
Shims push the crankshaft up against adjoining upper

bearings so an accurate clearance measurement can be
made on the lower bearing.
The shims can be manufactured from a piece of 4-inch-
diameter, schedule 40 PVC pipe. The dimensions of the
fabricated shims must be as follows:
Width = 38.1 mm [1.5 in]
Thickness = 6.35 mm 0.25 in] (approximate thickness of
schedule 40 PVC pipe)
Diameter = 101.6 mm [4.0 in].
Cut the pipe in half. The shims must be fabricated to the
above-specified dimensions and be less than 180 degrees
in circumference.
NOTE: Two fabricated shims are required for this

procedure.
Install the shims in the main bearing caps on both sides
of the bore being checked. (For example, to check the
number 3 and number 5 main bearing caps. To check the
number 5 and number 7 main bearing caps.)
Install the main bearing caps.
Install and tighten the capscrews.
N14 Crankshaft
Remove the main bearing cap to be checked.

Wipe the oil from the bearing and crankshaft journal.
Cut or tear a piece of Plastigage the full width of the
bearing.
Do not squeeze the gauge material as this can result in a
false reading.
Tear through both the envelope and plastic thread at the
same time. Open the envelope lengthwise by cutting the
edge with scissors or a knife or by tearing.
With the envelope open, lift out the Plastigage by one end.
Roll the material out with a thumb if the material is stuck
lightly to the paper.
Occasionally, the color in the Plastigage material will
transfer to the paper. This has no effect on accuracy.
Place the piece of Plastigage in the bearing shell
approximately at the 6-o'clock position.
The Plastigage clearance check procedure must be
performed with the original bearings.
Do not disturb the Plastigage before reading the

measurement. Disturbing the Plastigage can result in an
incorrect measurement.
Install the main bearing cap using the appropriate torque
procedure.
Remove the main bearing cap. The compressed
Plastigage will be located adhering to either the bearing
shell or the crankshaft.
Compare the width of the compressed Plastigage at its

widest point, to the graduations on the envelope
(regardless of taper). The number within the graduation on
the envelope indicates the bearing clearance in
thousandths of an inch or millimeters, depending on which
side of the envelope is used.
Taper does not affect the clearance measurement.
Clearance is still measured at the widest point on the
Plastigage strip.
If the compressed Plastigage is less than 0.051 mm [0.002
in] at its widest point, the block must be removed and
repaired or replaced.
If the compressed Plastigage is greater than 0.051 mm
[0.002 in], reassemble the main bearing caps with either
the existing or new main bearings.
Crankshaft N14
Inspect the main bearing cap and capscrews for damage.

Inspect the bearing shells and the thrust bearings for
nicks, scratches, or other damage.
NOTE: If the main bearings are damaged, reference the
N14 Shop Manual, Bulletin 3810487, to inspect the
crankshaft main bearing journals. If the crankshaft is
damaged, the engine must be removed for repair. Refer
to Procedure 000-001 (Engine Removal) in the N14 Shop
Use an outside diameter ball tipped micrometer to

measure the main bearing shell thickness.
Standard Main Bearing Shell Thickness

mm in
3.086 MIN 0.1215
3.145 MAX 0.1238
Discard a main bearing shell if its thickness is below the
Bulletin 3810387.

are 0.25 mm [0.010 in], 0.51 mm [0.020 in], 0.76 mm
which are ground undersize in the connecting rod and
used.
Install
Use a lint free cloth to clean the crankshaft bearing
journals.
N14 Crankshaft
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
CAUTION
Use a lifting strap that will not damage the crankshaft.
Do not drop the crankshaft on the bearings.
The end of the crankshaft with the smallest diameter
must point toward the front of the block. Install the
crankshaft.
Use a lint free cloth to clean the thrust bearings, the main
bearing shells, and the main bearing caps.
NOTE: If used thrust bearings are to be installed, each

must be installed in its original location in the engine. The
bearing journal numbers must have been marked on the
bearing during disassembly.
Use clean Lubriplate™ 105 or equivalent to lubricate the
upper thrust bearings.
CAUTION
The grooves must be toward the crankshaft.
Install the upper thrust bearings in the number 7 main
bearing saddle.
The end of the thrust bearing must be even with the main
bearing cap mounting surface.
Crankshaft N14
CAUTION
Do not intermix the main bearing dowel ring and the
main bearing capscrew washers. The hardened main
bearing capscrew washer (1) is approximately 0.76
mm [0.030 in] thicker than the soft main bearing dowel
ring (2). Intermixing the capscrew washers and the
dowel rings will result in main bearing failure.
Install the dowel ring in the dowel ring counterbore of the

cylinder block.
Install the lower main bearing shells as follows:
• Use clean Lubriplate™ 105 or its equivalent to lubricate
the bearing shell to the crankshaft journal mating
surface.
Align the dowel ring groove in the bearing with the dowel
ring.
The dowel ring grooves (1) and (2) in the bearings must
be engaged with the dowel ring (3).
N14 Crankshaft
Push on the side of the bearing shell opposite the dowel

ring to install the bearing shell.
The end of the lower main bearing shell opposite the

dowel ring must be engaged between the crankshaft and
the cylinder block and be seated against the end of the
upper bearing shell.
NOTE: If installed correctly, the ends of the bearing shells
(1) will meet approximately 1.50 mm [0.060 in] below the
cylinder block main bearing mounting surface.
NOTE: If used thrust bearings are to be installed, each

must be installed in its original location in the engine. The
bearing journal numbers must have been marked on the
bearing during disassembly.
Use Lubriplate® 105 or its equivalent to lubricate the lower
thrust bearings.
Put the lower thrust bearings around the No. 7 main

journal with the grooves facing the thrust surface on the
crankshaft.
NOTE: The notch (1) on the outside diameter of the lower
thrust bearings must align with the locating pins in the
number 7 main bearing cap.
Crankshaft N14
CAUTION
Drain the excess oil from the capscrews before
installing them in the cylinder block to prevent
hydraulic lock and possible damage to the cylinder
block during the capscrew torquing operation.
Use clean 15W-40 oil to lubricate the capscrew threads
and flat washers.
CAUTION
the engine.
Install the main bearing caps as follows:
• Align the capscrew holes in the cap with the holes in
the cylinder block. Make sure the dowel ring and lower
bearing shell are in position.
• Install the capscrews and the washers through the cap

• Hand tighten the capscrews two to three threads.
CAUTION
Do not use impact wrenches. The main bearing shells
can become dislocated.
Use both of the capscrews to pull the main bearing cap
into position.
Use two wrenches. Tighten both of the capscrews at the
same time.
Make sure the cap is touching the block. If it is not, check
for a bearing out-of-location.
N14 Crankshaft
CAUTION
Do not rotate the crankshaft until the main bearing
capscrews are tightened. This will keep the bearings
in place.
shown in the illustration.
Tighten the main bearing capscrews on engines built with

1 inch diameter main bearing capscrews to the following
torque values:
a Tighten to 150 N•m [111 ft-lb].
b Tighten to 285 N•m [210 ft-lb].
c Tighten to 415 N•m [306 ft-lb].
d Loosen completely.
e Repeat steps a. through c.
Tighten the main bearing capscrews on engines built with

¾ inch diameter main bearing capscrews to the following
torque values:
a Tighten to 120 N•m [89 ft-lb].
b Tighten to 230 N•m [170 ft-lb].
c Tighten to 345 N•m [254 ft-lb].
d Loosen completely.
e Repeat steps a. through c.
Turn the crankshaft by hand. If it does not turn freely,

loosen the main bearing capscrews one cap at a time. This
will help locate the bearing that is too tight.
Crankshaft N14
Remove the main bearing cap and the bearing. Check for
an incorrect or mislocated bearing or main bearing cap,
for incorrect oversize bearing, or debris between the main
bearing and the cap.

shown and to the torque values shown above.
Measure the end clearance of the crankshaft as follows:

a Install a dial indicator to the rear face of the cylinder
block.
b Put the tip of the gauge against the end of the
crankshaft.
c Push the crankshaft toward the rear of the cylinder
block.
a Set the dial indicator to "0".

b Push the crankshaft toward the front of the cylinder
block.
c If the end clearance is less than 0.18 mm [0.007 in], do
the following:
N14 Crankshaft
• Loosen the main bearing capscrew one turn.

• Push the crankshaft toward the front and then toward
the rear of the cylinder block.
• Tighten the main bearing capscrews in the sequence

shown in the illustration.

thrust bearings is 0.18 mm [0.007 in] to 0.45 mm [0.018
in].

Example: F.-.010 - Front 0.25 mm [0.010-in]
Example: R.-.020 - Front 0.51 mm [0.020-in]
Crankshaft N14
If the crankshaft end clearance is more than 0.56 mm

[0.022 in], use oversize thrust bearings to adjust the end
clearance to the correct specification.
Finishing Steps
• Install the flywheel housing. Refer to Procedure
016-006.
007-025.
• Install the engine into vehicle. Refer to the
• Install the vehicle driveline and the transmission. Refer
to the manufacturer's instructions.
• Connect the batteries.
• Mobilize the vehicle. Reference the end-user
procedures.
Grind
Rail Applications
This procedure is designed to extend the usable life of the
crankshaft and to maintain the integrity of the crankshaft/
flywheel bolted joint.
In order to maintain maximum clamping loads, it is
permissible to grind the flywheel mounting face of the
crankshaft.
Following a re-grind, a minimum thickness of 54.483 mm

[2.145 inch] from the thrust bearing face must remain.
If the grinding process reaches the minimum dimension,
and there are still signs of imperfections, the crankshaft
must be replaced.
N14 Crankshaft Gear, Front (Crankshaft Installed)
The grinding process should be carried out in increments

of 0.0254 mm [0.001 inch] or less, to avoid burn damage
to the crankshaft or unnecessary removal of material.
The new crankcase surface finish must be 125 microns of
an inch or better.
Crankshaft Gear, Front (Crankshaft

Installed) (001-018)
Remove
Remove the front engine mount, vibration damper, and
the crankshaft pulley. Refer to Procedures 001-052-002
and 001-022-002, respectively.
009-004-002.
Remove the front crankshaft seal and the accessory drive

seal. Refer to Procedures 001-023-002 and 001-003-002,
respectively.
Remove the gear cover. Refer to Procedure 001-031-002.

Crankshaft Gear, Front (Crankshaft Installed) N14
Install the crankshaft gear puller, Part No. 3375840, and

jaw onto the gear, Part No. 3824284.
Turn the pressure screw clockwise to remove the gear.
CAUTION
key.
Use a flat chisel and a mallet to remove the crankshaft
gear key.
Clean
Clean the gear with solvent. Dry with compressed air.
Inspect for Reuse

Visually inspect the crankshaft gear for cracks and broken
or chipped teeth.
Remove any burrs with a fine crocus cloth.

N14 Crankshaft Gear, Front (Crankshaft Installed)
Visually inspect the crankshaft gear fit area for burrs.

Remove any burrs with a fine crocus cloth.
Scratches must not exceed 0.79 mm [0.031 inch] depth,
and must be at least 3.2 mm [0.125 inch] apart.
Measure the crankshaft gear bore.
Crankshaft Gear Bore I.D.

mm in
95.394 MIN 3.7557
95.415 MAX 3.7565
Replace the crankshaft gear if it does not meet diameter
specifications.
Measure the crankshaft gear fit area outside diameter.
Crankshaft Gear Fit Area O.D.

mm in
95.504 MIN 3.7599
95.522 MAX 3.7607
Replace the crankshaft if it does not meet diameter
specifications.
Install
Use a leather mallet to install a new key into the crankshaft
keyway.
Heat the gear in an oven for a minimum of 1 hour at 204°
C [400°F] not to exceed 4 hours maximum.
Crankshaft Gear, Front (Crankshaft Installed) N14
CAUTION
been heated to prevent personal injury.
Remove the gear from the oven.
NOTE: The gear must be installed within 30 seconds after
being removed from the oven.
CAUTION
The timing mark (1) and the gear part number (2) must
be facing away from the crankshaft.
Align the gear keyway and the key, and install the gear
firmly on the crankshaft.
CAUTION
If any gears were rotated, it will be necessary to align
the timing marks of the crankshaft and the camshaft
gears.
Install the gear cover. Refer to Procedure 001-031-026.

009-004-026.
Install the accessory drive seal. Refer to Procedure
001-003-026.
001-023-026.
Install the crankshaft pulley, the vibration damper, and the
front engine mount. Refer to Procedures 001-022-026 and
001-052-026, respectively.

C [180°F], and check for lubricating oil leaks.
N14 Crankshaft Pulley
Crankshaft Pulley (001-022)

Remove
Remove the alternator drive belts. Refer to Procedure
013-001-002.
Inspect for Reuse

Visually inspect the pulley for cracks, wear in the belt
grooves, or other damage.
Install
Install the pulley and the vibration damper. Refer to
Install and adjust the alternator drive belts. Refer to

Crankshaft Seal, Front N14
Crankshaft Seal, Front (001-023)

Remove
013-001-002.
respectively.
Remove the dust excluder from the front of the seal.
Use three of the damper mounting capscrews to secure

the top plate, Part No. ST-1259-1 (from oil seal puller/
installer, Part No. ST-1259), to the front of the crankshaft.
Install the drill pilot, Part No. 3375496, into one of the 1/4-
inch holes in the top plate, Part No. ST-1259-1.
Insert a No. 31 [0.120-inch] drill bit into the drill pilot, and
drill a hole through the seal casing.
Remove the drill pilot, and repeat the same procedure in
the two remaining holes in top plate, Part No. ST-1259-1.
Install three of seal puller screws, Part No. ST-1259-6, into

the plate. Tighten the screws until the shoulder on the
screw contacts the seal casing.
Remove the three damper mounting capscrews from the
puller plate.
N14 Crankshaft Seal, Front
Install the center puller screw in the plate. Continue to turn

the center screw clockwise until the seal is removed from
the gear cover.
Clean
Use a magnet to remove any shavings from the seal bore
or the crankshaft.
Use a crocus cloth to polish and remove any deposits from
the crankshaft or the seal bore. Visible scratches on the
sealing surface can result in seal leakage.
Use a clean cloth and a safety solvent, Part No. 3823717,
or equivalent, to clean the crankshaft flange and the seal
bore and to remove all traces of oil film.
Inspect for Reuse

Mount a dial indicator onto the front of the crankshaft.
Check the concentricity of the seal bore. The total
indicator reading must not exceed 0.38 mm [0.015-inch].
If the reading exceeds 0.38 mm [0.015-inch], remove the
gear cover; and check for burrs between the mounting
surfaces, damaged dowel pins, or the dowel holes. Refer
Install
NOTE: "LDL TFE" (Lay-Down Lip, Teflon) oil seals for
service replacement have an assembly tool which protects
the seal lip during shipment and installation. The "LDL
TFE" oil seal must be installed with the lip of the seal and
the crankshaft clean and dry. Do not use any kind of
lubricant. The use of lubricant will result in oil leakage at
the seal.
Use hand pressure to push the oil seal from the assembly
tool onto the crankshaft as far as possible. Remove the
assembly tool.
Crankshaft Seal, Rear N14
Install a 3/16 inch spacer ring, Part No. ST-1259-2, onto

the top plate, Part No. ST-1259-1, with the three allen head
screws, Part No. ST-1259-3, provided.
Install the top plate, Part No. ST-1259, (with a 3/16 inch
spacer mounted) on the crankshaft, and use three
vibration damper mounting capscrews and flat washers.
Tighten the three capscrews alternately in 1/2-turn
increments until the oil seal is installed flush with the gear
cover bore.
Install the dust excluder seal by hand, flush to +0.38 mm

[+0.015 inch] from the case of the oil seal.
NOTE: The dust excluder must be installed dry. Do not
use any lubricant.

respectively.
Crankshaft Seal, Rear (001-024)

Remove
NOTE: On wet housing applications, the flywheel housing
must be removed to replace the rear crankshaft seal.
Disconnect the driveline, and remove the transmission (if
equipped). Refer to the manufacturer's instructions.
N14 Crankshaft Seal, Rear
Remove the clutch and the flywheel (if equipped). Refer to

Loosen the oil pan mounting capscrews four to five turns.
Remove the four oil pan mounting capscrews which

secure the oil pan to the rear cover.
CAUTION
Use extreme care when releasing the oil pan gasket
from the rear cover to prevent damage to the gasket.
If the gasket is damaged, the oil pan must be removed
and the gasket replaced. Refer to Procedure
007-025-002.
Insert a feeler gauge or a shim stock between the rear
cover and the oil pan gasket. Move the feeler gauge or the
shim stock back and forth to release the gasket from the
rear cover.
Remove the capscrews from the rear cover, and remove

the cover from the crankshaft flange.
Remove the seal from the rear cover.
Clean
Clean the gasket surface of the cylinder block and the rear
cover.
Use a crocus cloth to remove any rust or other deposits

from the crankshaft flange. Visible scratches can result in
seal leakage.
Use a clean cloth and a safety solvent, Part No. 3823717,
or its equivalent to clean the crankshaft flange and to
remove all traces of oil film.
Inspect for Reuse

Inspect the rear cover for cracks or other damage.
Install
Install a new gasket onto the cylinder block.
Install the rear cover and the eight capscrews and
washers. Tighten the capscrews just enough to hold the
rear cover in position.
Remove the pins from the crankshaft oil seal driver, Part
No. 3824211, and use the driver to align the rear cover
with the crankshaft.
Install the seal driver onto the crankshaft flange and into
the bore of the rear cover.
N14 Crankshaft Seal, Rear
Align the rear cover pan flange such that it is parallel to

the cylinder block pan rail within 0.10 mm [0.004 inch].
Tighten the rear cover mounting capscrews.
Remove the crankshaft oil seal driver, Part No. 3824211.
Trim the excess gasket material from the ends of the rear
cover gasket so the gasket is even or does not extend
more than 0.25 mm [0.010-inch] beyond the pan flange.
Use the installation sleeve provided with the seal to install

the seal onto the crankshaft.
NOTE: Do not use any kind of lubricant to install the
seal. The oil seal must be installed with the lip of the seal
and the crankshaft clean and dry.
Push the oil seal over the installation sleeve onto the
crankshaft, and remove the sleeve.
Install the pins into the crankshaft oil seal driver, Part No.
3824211.
Use the crankshaft oil seal driver, Part No. 3824211, to
install the oil seal into the rear cover.
Install the four capscrews which hold the oil pan to the rear
cover.
Tighten one of the 7/16-inch oil pan mounting capscrews

on each side of the oil pan, halfway between the front and
the rear of the oil pan.
Tighten the four 5/16-inch capscrews in the rear of the oil

pan in the sequence shown.
Tighten the thirty-two (32) 7/16-inch capscrews in the
sequence shown.
Install the flywheel and the clutch (if equipped). Refer to

Install the transmission and the driveline. Refer to the
N14 Cylinder Block

C [180°F], and check for leaks.
Cylinder Block (001-026)

Preparatory Steps
• Check for main cap fretting. Refer to Procedure
• Remove the cup plugs. Refer to Procedure 017-002
in Section 17.
• Remove the straight thread plugs. Refer to
Procedure 017-011 in Section 17.
• Remove the pipe plugs. Refer to Procedure 017-007
in Section 17.
• Remove the dowel pins. Refer to Procedure 017-003
in Section 17.
• Remove the camshaft bushings. Refer to Procedure

CAUTION
Do not damage the machined gasket surfaces or the
camshaft bushings if the bushings have not been
removed.
Use a gasket scraper, wire brush, or a fibrous abrasive
pad such as Scotch-Brite™ Number 7447, Part Number
3823258, or its equivalent to clean heavy deposits from
the cylinder block.
Clean the cylinder liner counterbore ledge and press fit

area.
Cylinder Block N14
Clean the cylinder liner packing ring bore area.
Clean the cylinder head deck surface.
Clean the main bearing saddles and caps.
Clean the camshaft bore cup plug area.

N14 Cylinder Block
Clean all gasket surfaces.
Clean all component mounting surfaces.
Clean all oil passages. Use a bottle brush with a long

handle.
WARNING
WARNING
NOTE: Cummins Inc. does not recommend any specific
cleaning solution.
Remove the block from the engine stand. Put the block in
a cleaning tank.
Follow the instructions of the manufacturer of the cleaning
tank and the manufacturer of the cleaning solution.
Cylinder Block N14
The best results can be obtained by using a cleaning

solution that can be heated to 80°C to 95°C [180°F to
200°F].
Use a cleaning tank that will mix and filter the cleaning
solution to get the best results.
WARNING
WARNING
personal injury.
CAUTION
Make sure all the water is removed from the capscrew
holes and the oil passages to prevent rust formation
in the cylinder block.
Remove the cylinder block from the cleaning tank.
Clean the oil passages using a steam cleaner. Dry with
compressed air.
WARNING
Starting fluid is highly flammable and explosive. Keep
flames, sparks, and arcing switches away from
starting fluid.
Clean the cylinder block counterbores with a suitable
hydrocarbon solvent such as naptha, methyl ethyl ketone
(MEK), or trichlorethane 1, 1, 1 (methyl chloroform).
N14 Cylinder Block
If the cylinder block is not going to be used immediately,

apply a coating of preservative oil to prevent rust. Cover
the block to prevent dirt from sticking to the oil.
Use fine emery cloth to remove burrs from the camshaft

bushing bore.
Clean the bushing bores.
Camshaft Bore
Measure the cylinder block camshaft bore inside
diameter.
Camshaft Bore Inside Diameter

mm in
68.237 MIN 2.6865
68.262 MAX 2.6875
If the bore inside diameter is not within specifications, the
bore must be repaired.
Main Bearing Bore

Main bearing service caps do not have the bore machined
to a final specification. If the cap is replaced, the main
bearing bore must be machined. Use the correct parts of
the main bearing boring tool, Part Number ST-1177.
Cylinder Block N14
Use two centering rings, Part Number ST-1177-39 [4.750-

in diameter]. Put the rings in the Number 2 and Number 6
main bearing locations.
Use clean 15W-40 oil to lubricate the main bearing

capscrew threads and the flat washers.
Drain the excess oil from the capscrews before installing
them.
CAUTION
the engine.
Align the capscrew holes in the cap with the holes in the
cylinder block.
Install the capscrews and the washers through the cap

Hand tighten the capscrews two to three threads.
N14 Cylinder Block
• Hit the cap with a rubber mallet to push it into the

correct position.
The main bearing caps must not have any side clearance
with the block.
Cylinder Block to Main Bearing Cap Press Fit

mm in
0.03 MIN 0.001
0.15 MAX 0.006
Put the checking ring into the cylinder block main bearing
saddle.
Put the main bearing cap over the checking ring.
Tighten all older block (prior to ESN 11875596) main

bearing capscrews in alternating sequence to the
following torque values:
Torque Value: Step1 122 N•m [ 90 ft-lb ]
Step2 230 N•m [ 170 ft-lb ]
Step3 346 N•m [ 255 ft-lb ]
Step4 Loosen completely
Step5 122 N•m [ 90 ft-lb ]
Step6 230 N•m [ 170 ft-lb ]
Step7 346 N•m [ 255 ft-lb ]
Step2 136 N•m [ 100 ft-lb ]
Step3 190 N•m [ 140 ft-lb ]
Step4 Loosen completely
Step5 68 N•m [ 50 ft-lb ]
Step6 136 N•m [ 100 ft-lb ]
Step7 190 N•m [ 140 ft-lb ]
Step8 Rotate 90 degrees
Replace the main bearing shells number one through
number six.
NOTE: Main bearings number one through number six do
not have thrust bearings.
Cylinder Block N14
Use clean 15W-40 oil to lubricate the bores of the two

centering rings, Part Number ST-1177-39, and the
checking bar, Part Number ST-1177-16.
Insert the bar through the centering rings while slowly

rotating the bar. The bar must turn easily.
If the bar does not turn easily, check to make sure the
main bearing caps are installed correctly. If they appear
to be okay, move one of the centering rings to another
bearing location.
Slide one end of the bar out of a centering ring.

Slide the checking ring, Part Number ST-1177-13, onto
the bar.
Insert the bar into the centering ring.
Apply lubrication to the outside diameter of the checking

ring.
N14 Cylinder Block
Use your hands to install the checking ring into the main
bearing bore. If the ring will not slide through the bore,
check the bore for burrs. If the ring will still not slide
through the bore, the bore is undersize and must be
repaired.
Use a 0.08 mm [0.003 in] feeler gauge that is not more

than 13 mm [0.50 in] wide.
Center the checking ring in the bore.
Try to put the feeler gauge between the checking ring and
the bore.
Rotate the gauge in the bore at both sides of the checking
ring.
The bore alignment of the main bearing is okay if:

• the gauge does not enter at any point
• the gauge will enter but will not slide through or
around the bore and the alignment bar will rotate with
the gauge inserted.
The bore alignment of the main bearing is not okay if:

• the gauge enters and slides around the bore. This
means that the bore is oversize and must be
repaired.
• the gauge will enter on one side only, but can slide
around the bore. This means that the bore is tapered
and must be repaired.
Cylinder Block N14
NOTE: This procedure does not check main bearing bore

alignment but will identify bore diameters that do not meet
specifications.
If the tools to check the main bearing bore alignment are
not available, use a dial bore indicator to measure the
main bearing bore inside diameters.
Support the rear portion of the block on a flat surface to
obtain the most accurate measurement of the inside
diameter.
Measure the inside diameter in the three positions shown.

The inside diameter must be completely round within
0.0190 mm [0.00075 in].
Main Bearing Bore Inside Diameter (Capscrews

Torqued to Specification)
mm in
120.599 MIN 4.7480
120.637 MAX 4.7495
CAUTION
All measurements of the cylinder block must be made
when the block is positioned on a flat surface. If the
block is mounted on the engine stand, the
measurements can be wrong because of distortion.
Inspect the gasket surfaces.
Inspect for burrs or damage.
Use an Arkansas stone or a crocus cloth to remove the
burrs.
Check the top surface of the block for wear. If fretting

damage, scratches, cracks, or corrosion deeper than 0.08
mm [0.003 in] are present in an area where a head gasket
seal ring or a grommet makes contact, the surface must
be repaired. There must not be any defect which extends
more than 2.41 mm [0.095 in] from the edge of the coolant
passage.
Fretting damage in any other area is acceptable if it does
not change the protrusion measurement of the
counterbore or the cylinder liner.
N14 Cylinder Block
Head Deck Surface

Use a 610 mm [24 in] caliper to measure the height of the
cylinder block from the main bearing bore outside
diameter to the cylinder head deck surface.
Cylinder Block Height

mm in
421.87 MIN 16.609
422.45 MAX 16.632
If the height of the block is less than 422.12 mm [16.619
in], a 0.25 mm [0.010 in] oversize head gasket must be
used.
The height of the block must not vary more than 0.05 mm
[0.002 in] from end to end of the block. If the block height
is not within specifications, the top surface of the block
must be machined or the block must be replaced.
If the top surface of the block is machined, the ledge depth
of the cylinder liner counterbore must be machined.
Liner Protrusion
Liner installation tool, Part Number 3823615, is used to
press the cylinder liner into the cylinder block. Protrusion
can be checked while the liner is held down by the
installation tool.
Put the force plate (3) across the top of the liner with the
step in the liner bore. Tap the top of the force plate with a
soft hammer to square up and start the liner into the press
fit bore.
Cylinder Block N14
Put the installation tool bridge (1) across the liner and
install the two cylinder head capscrews finger tight to hold
the bridge down. Rotate the force plate until the areas
where the protrusion measurements will be taken are
exposed.
CAUTION
Do not use an impact wrench to tighten the liner force
plate screw.
Tighten the forcing screw (2).
Check for correct protrusion.
Use a depth gauge, Part Number 3823495, to measure the

liner protrusion at four points 90 degrees apart.
Cylinder Liner Protrusion

mm in
0.10 MIN 0.004
0.18 MAX 0.007
The following equipment is needed to measure the

counterbore and the liner press fit area.
• Dial bore gauge kit, Part Number 3375072, or the
equivalent
• Extension, Part Number 3375073.
N14 Cylinder Block
Use dual gauge set ring, Part Number 3823292, (159.86

mm [6.294 in] and 160.88 mm [6.334 in]) to set the dial
bore gauge.
Concentricity gauge, Part Number ST-1252.
Depth gauge, Part Number 3823495.
Use Scotch-Brite™, Part Number 3823258, and a medium

grit hone to clean the head deck and the liner counterbore.
Wipe clean. Do not use compressed air to clean the block
if done in chassis. Compressed air tends to blow dirt and
debris into engine cavities and oil passages.
Cylinder Block N14
Counterbore
Measure below the counterbore in two directions as
shown.
Standard LPF Bore

mm in
159.842 MIN 6.2930
159.893 MAX 6.2950
Oversize LPF Bore

mm in
160.858 MIN 6.3330
160.909 MAX 6.3350
If the bore measures other than the above tolerances, it
must be bored again or sleeved to the correct lower press
fit.
Use inside micrometers or the correct liner flange as a go/

no-go gauge to check the upper bore.
Standard LPF Counterbore

mm in
166.73 MIN 6.564
166.88 MAX 6.570
Preferred Oversize LPF Counterbore

mm in
167.23 MIN 6.584
167.39 MAX 6.590
If the counterbore is less than 167.23 mm [6.584 in], it
must be machined again.
Use concentricity gauge, Part Number ST-1252, to

measure the relationship between the upper and the lower
bore. The dial indicator reading must not exceed 0.279
mm [0.011 in].
Make sure that the contact points rest against the press
fit area below the counterbore when setting and reading
the indicator.
N14 Cylinder Block
Check the counterbore for cracks or porosity.
If there is a crack, it usually can be seen in the corner

between the upper bore area and the ledge.
Most cracks will run horizontally around the counterbore.
If any cracks of any size can be seen running horizontally
around the counterbore, all the coolant passages that are
close to the bore must be repaired.
Circumferential cracks in the counterbore ledge that do

not extend more than one-half the width of the ledge are
acceptable.
Circumferential cracks that extend more than one-half the

width of the ledge must be repaired with a sleeve.
Cylinder Block N14
If there is a porous area below the counterbore ledge that

is close to a capscrew hole, the hole must be repaired.
If there is a porous area above the counterbore ledge that
is closer to a coolant passage, the passage must be
repaired.
Cylinder blocks with vertical cracks that extend down over

the counterbore ledge that can not be machined out using
a 0.750-in long sleeve can not be repaired.
If the liner has not been removed, do so at this time.

Use liner puller ring, Part Number 3823264, and a liner
puller, either Part Number 3375627 or Part Number
3376015, to remove all liners.
The liner puller ring is used to retain an upper deck repair
sleeve when removing a cylinder liner.
To use, put the puller ring around the liner being removed
and position with the flat side clearing the adjacent liner.
Rest the feet of the puller on the top of the puller ring and
use the puller as instructed.
A depth gauge, Part Number 3823495 or its equivalent, is

required to check the counterbore depth and the ledge
angle.
N14 Cylinder Block
CAUTION
Make sure the indicator does not contact the
counterbore radius. It will not give you a true
indication of the ledge angle and can cause liner
damage.
Use a depth gauge, Part Number 3823495. Measure the
angle of the counterbore ledge at four equally spaced
points.
Measurement (2) must never exceed measurement (1) or

be less than measurement (1) by more than 0.025 mm
[0.001 in].
Machine the ledge again if the measurement near the
counterbore edge (2) exceeds the measurement near the
radius (1).
Cylinder Block N14
The desired protrusion is the total sum of the thickness of

the liner flange and the seal rings minus the counterbore
depth.

mm in
0.10 MIN 0.004
0.18 MAX 0.007
Cylinder liners and sealing rings are available in the
following sizes:
Lower Press Fit Liners and Sealing Rings
Standard LPF Liner Oversize LPF Liner
Part Name Thickness Part Name Thickness
mm [in] mm [in]
Sealing ring 0.50 [0.0195] Sealing ring 0.46
[0.0180]
[0.0200]
[0.0220]
[0.0310]
Sealing ring 0.60 [0.0235]
If the ledge angle is okay and a sealing ring is available

that will give you the correct protrusion, use that sealing
ring.
Two sealing rings can be used to achieve correct
protrusion.
N14 Cylinder Block
Machine
Counterbore for Oversize Lower Press Fit Liner
When machining work is done on an assembled block,
special precautions are required to protect other engine
components from contamination. To protect cam
bushings, main bearings, crankshaft rod journals, and
coolant passages, the areas listed below must be covered
as noted:
• Put chip control plugs, Part Number 3823231, into
the lower liner bores to catch metal chips and dust.
• Cover the coolant passages in the liner cavity, on the
exhaust side, with Damtite, Part Number 3823232,
or some type of formable substance such as
modeling clay.
• Cover the push tube openings, on the cylinder not
being machined, with masking tape.
• Cover the oil transfer holes with masking tape or
plastic plugs.
• The boring tool will cover the oil transfer hole and
partially cover the push tube opening on the cylinder
being machined. Cover the part of the push tube
opening not covered by the boring tool base with
Damtite, Part Number 3823232, or modeling clay.
• Wrap the crankshaft rod journals with clean shop
towels and tape to prevent dirt entry into the oil holes.
• After machining, clean the liner cavities and
capscrew holes of dirt and metal dust with a wet and
dry vacuum cleaner.
Read the complete procedure before beginning to

machine the block.
This procedure describes how to machine the counterbore
ledge and the diameter to accept a 20/40 oversize lower
press fit liner.
To machine for the oversize lower press fit liner, the

following tools are required.
Counterbore boring machine, Part Number 3377356, or
Porta-Tool®, Part Number PT-2050.
Cylinder Block N14
Locator plate/tool holder, Part Number 3822955.
Cutting tool, Part Number ST-1168-91 (2 each).
The following tools are required to check the bore after

machining:
• Dial bore gauge kit, Part Number 3375072 or its
equivalent
• Extension, Part Number 3375073.
Gauge set ring (6.334 in), Part Number 3822913 or Part

Number 3823292, for dial bore gauge.
N14 Cylinder Block
Concentricity gauge, Part Number ST-1252.
Check the counterbore tool for bearing wear at least every

6 months or after cutting each 100 counterbores.
Check the machine oil level. Low oil level can cause
incorrect bore diameter or poor surface finish.
Use the cylinder liner counterbore tool, Part Number
3377356 or Part Number PT-2050, to machine the
counterbore to accept the upper deck repair sleeve.
The jaws of the vise must have copper plate to prevent

damage to the counterbore tool.
To check for bearing wear, clamp the counterbore tool in
a vise.
Mount a Starrett® “Last Word,” Gem 222, or its equivalent
dial indicator on the base with the indicator point against
the shaft.
Install a driver shaft, Part Number ST-1168-46, contained

in counterbore tool kit, Part Number 3377356, or its
equivalent on the shaft of the counterbore tool for greater
leverage.
Adjust the dial indicator to read “0”. Move the shaft toward
and away from the indicator.
If the total indicator reading exceeds 0.088 mm [0.0035
in], the bearings are excessively worn and must be
replaced. Excessive oil loss can indicate a worn bearing.
Cylinder Block N14
Install the drive unit, Part Number 3377350 or Part

Number ST-1168-1, on the base plate, Part Number
ST-1168-28, if not already installed.
Position the cutter plate assembly with the taper edge

away from the base plate.
Align the keyway in the plate with the key in the shaft.
Install the cutter plate on the shaft. Install the washer and
the nut.
Align the counterbore tool with the counterbore by

unlocking the drive mechanism and pushing down the
drive shaft until the taper cutter seats in the counterbore.
Make sure the cutter plate is in complete contact with the
counterbore. This will make sure there is correct
alignment.
Rotate the base plate until the mounting holes align with
the cylinder head mounting capscrew locations.
Install the four cylinder head capscrews, the square
washers, and the standard adapters.
Raise the drive shaft to the full upright position and lock it
in place.
N14 Cylinder Block
A micrometer block, Part Number 3376552, is used to set

the cutting tool.
The micrometer block is preset at the factory.
Occasionally, because of rough handling, the micrometer
block can become miscalibrated.
Verify the accuracy of the micrometer block before setting
the cutting tool.
The setting standard, Part Number ST-1168-52, is

precision machined and marked with the serial number of
the counterbore tool with which it was shipped. Do not
intermix setting standards between counterbore tools.
Use setting standard, Part Number ST-1168-52, to verify
the micrometer reading.
Put the setting standard (1) with the side stamped “UP”
between the cutter stop (2) and the micrometer spindle (3).
Turn the micrometer thimble (4) until the spindle (3) fits
snugly against the setting standard (1).
The micrometer must read 5.000 in.
Do not overtighten the micrometer against the setting
standard.
Cylinder Block N14
When micrometer adjustment is required, loosen the

socket head screw (5) and move the cutter stop (2) slightly
away from the micrometer (4).
Set the micrometer to read 5.000 in.
Slide the cutter stop (2) to fit snugly against the setting
standard (1) and securely tighten the socket head
capscrew (5).
Loosen the micrometer thimble (4) and tighten it to fit

snugly against the setting standard (1).
The micrometer must read 5.000 in.
Repeat the adjustment procedure if the micrometer
reading is not correct.
Two machining cuts are required to machine the cylinder

block to accept a 20/40 oversize lower press fit cylinder
liner.
Use a micrometer block, Part Number 3376552. Set one
cutting tool, Part Number ST-1168-91, to 6.334 in for the
lower press fit diameter. Set a second cutting tool, Part
Number ST-1168-91, to 6.588 in for the upper counterbore
area.
N14 Cylinder Block
Loosen the set screw in the back of the cutting tool.

Push the spring-loaded adjusting pin all the way into the
body of the cutting tool.
Tighten the set screw.
Set the micrometer to the desired dimension for the

specific cutting tool (upper press fit or lower press fit).
Put the cutting tool into the micrometer block and hold it
firmly against the cutter stop.
Loosen the set screw on the cutting tool and allow the
adjusting pin to extend out against the micrometer
spindle.
When loosening the adjusting screw, do not allow the
adjusting pin to contact hard against the micrometer
spindle. Tool damage can occur.
Tighten the set screw.

Check the cutting tool length by loosening the micrometer.
Turn the micrometer until the spindle touches the cutting
tool, and read the micrometer.
Repeat the setting process until the cutting tool length is
accurately set.
Loosen the micrometer and remove the cutting tool from

the micrometer block.
Cylinder Block N14
Retract the cutter plate from the bore and lock the drive in
the full upright position.
The cutting tool must be inserted into the cutter holder slot
with the puller hole down.
Install the 6.334-in cutting tool for the lower press fit area
in the cutter plate. The tool must extend a minimum of 3.0
mm [0.12 in] over the edge of the counterbore. Tighten the
set screw for the cutting tool.
Unlock the drive and gently push down on the drive shaft
until the cutting tool contacts the top of the block.
Put the 23.6 mm [0.930 in] side of the depth set block, Part
Number 3823291, between the set collar and the
counterbore tool housing.
Move the set collar down against the set block and tighten
the set screw in the stop collar.
CAUTION
Do not leave the cutting tool extended. Failure to push
the tool all the way into the cutter plate will result in
major damage to the cylinder block.
Loosen the set screw for the cutting tool.
Push the cutting tool into the cutter plate until it fully
contacts the main shaft of the counterbore tool.
Tighten the set screw for the cutting tool.
CAUTION
The load will increase when the cutter contacts the
counterbore ledge. Keep a firm grip and a balanced
stance to maintain control and to avoid personal
injury.
Attach a 450 maximum RPM drill and machine until the
stop collar contacts the counterbore tool housing.
N14 Cylinder Block
After the machining is complete, remove the drill. Unlock

and raise the drive to the full upright position.
Loosen the set screw for the cutting tool. Insert the cutter
key into the small hole in the cutting tool.
Pull the cutting tool from the cutter plate.
Insert the 6.588-in cutting tool for the upper counterbore

into the cutter plate. It must extend a minimum of 3.0 mm
[0.12 in] over the edge of the counterbore.
The cutting tool must be inserted into the cutter holder slot
with the puller hole down.
Unlock the drive and gently push down on the drive shaft
until the cutting tool contacts the top of the block.
Put the 9.53 mm [0.375 in] side of the depth set block, Part
Number 3823291, between the set collar and the
counterbore tool housing.
Move the set collar down against the set block and tighten
the set screw in the stop collar.
CAUTION
Do not leave the cutting tool extended. Failure to push
the tool all the way into the cutter plate will result in
major damage to the cylinder block.
Push the cutting tool into the cutter plate until it fully
contacts the main shaft of the counterbore tool.
Tighten the set screw for the cutting tool.
Cylinder Block N14
Attach a 450 maximum RPM drill and machine until the

stop collar contacts the counterbore tool housing.
Keep a firm grip and a balanced stance.
After the machining is complete, remove the drill. Unlock

and raise the drive to the full upright position.
Insert the cutter key into the small hole in the cutting tool.
Pull the cutting tool from the cutter plate.
Remove the counterbore tool mounting capscrews, the

spacers, and the washers.
Remove the counterbore tool.
Use a medium grit hone to remove any burrs and sharp

edges from the counterbore area.
Wipe the counterbore area with a clean cloth. Do not use
compressed air in chassis. Compressed air tends to blow
dirt and debris into engine cavities and oil passages.
N14 Cylinder Block
Use dial bore gauge, Part Number 3375072, with

extension, Part Number 3375073, or equivalent, to
measure the lower bore. Use gauge set ring, Part Number
3822913 or Part Number 3823292 (160.88 mm [6.334 in]
diameter), to set the dial bore gauge. The lower bore
must be 160.85 to 160.90 mm [6.333 to 6.335 in].
If the lower bore diameter is less than 160.85 mm [6.333
in], it must be machined again to the correct dimensions
using this same procedure.
If the bore diameter is greater than 160.90 mm [6.335 in],
the bore must be fitted with an upper deck repair sleeve.
If the bore is already sleeved, continue with the remaining
inspections in this procedure.
Use inside micrometers or the liner flange as a go/no-go

gauge to check the upper bore.
Check to see if the liner flange fits into the counterbore. If
it does not, use an inside micrometer to verify that the
press fit will be less than 0.05 mm [0.002 in] on the liner
flange.
The oversize lower press fit counterbore must check
167.23 to 167.39 mm [6.584 to 6.590 in]. If the counterbore
is less than 167.23 mm [6.584 in], it must be machined
again. If the counterbore is greater than 167.39 mm [6.590
in] but less than 167.89 mm [6.610 in], it is acceptable.
Use concentricity gauge, Part Number ST-1252, to

measure the relationship between the upper and lower
bore. The total indicator reading must not exceed 0.279
mm [0.011 in].
Make sure that the contact points rest against the press
fit area below the counterbore when setting and reading
the indicator.
After machining, check the counterbore for cracks or

porosity.
Cylinder Block N14
Counterbore Ledge
If the counterbore depth and the ledge angle have been
measured and are correct, do not continue with this
procedure. If either the depth or the ledge angle is
incorrect, this procedure must be followed.
After the block counterbore and lower bore are machined
to 20/40 oversize lower press fit, an upper deck repair
sleeve is installed, or protrusion is not correct, the
counterbore ledge must be machined to obtain the correct
liner protrusion.
The desired counterbore depth is the total sum of the

thickness of the liner flange and the seal rings minus the
cylinder liner protrusion.

mm in
0.10 MIN 0.004
0.18 MAX 0.007
CAUTION
Make sure the micrometer is not resting on the liner
bead when measuring the flange thickness.
Protrusion is measured from the top of the flange. If
taken from the bead, protrusion will be low, resulting
in a loss of engine compression.
Measure the liner flange thickness of the liner to be
installed with micrometers and record.
N14 Cylinder Block
Measure the sealing ring that will be installed into the

cylinder block being machined. Reference the following
table:
Cylinder liners and sealing rings are availability in the
following sizes:
mm [in] mm [in]
[0.0180]
[0.0200]
[0.0220]
[0.0310]
Use a medium grit hone. Remove any nicks and burrs

from the cylinder block head deck surface and the
counterbore ledge. Nicks and burrs will prevent the tool
from seating correctly.
Use a depth micrometer or a depth gauge, Part Number
3823495, to measure the counterbore depth. Measure at
four equally spaced points. Record the measurements.
This will assist in determining the amount of material that
must be removed from the counterbore.
Use any of the following counterbore ledge boring

machines:
Boring Machine Locator Plate Cutting Tool

Part Number Tool Holder Part Part Number
Number
3376684 3377235 ST-1059-17
3823326 (was 3823483 ST-1255-10
ST-1255)
3823327 3823484 ST-1255-10
Cylinder Block N14

coolant passages, the areas listed below must be covered
as noted:
• Put chip control plug, Part Number 3823231, into the
lower liner bores to catch metal chips and dust.
• Cover the coolant passages in the liner cavity, on the
exhaust side, with Damtite, Part Number 3823232,
or some type of formable substance such as
modeling clay.
• Cover the push tube openings, on the cylinder not
being machined, with masking tape.
• Cover the oil transfer holes with masking tape or
plastic plugs.
• The boring tool will cover the oil transfer hole and
partially cover the push tube opening on the cylinder
being machined. Cover the part of the push tube
opening not covered by the boring tool base with
Damtite, Part Number 3823232, or modeling clay.
• Wrap the crankshaft rod journals with clean shop
towels and tape to prevent dirt entry into the oil holes.
• After machining, clean the liner cavities and
capscrew holes of dirt and metal dust with a wet and
dry vacuum cleaner.
Set the cylinder block counterbore tool over the cylinder

bore to be machined.
Lower the cutter plate until it touches the counterbore
ledge. The taper on the cutter plate will center the tool in
the cylinder bore.
There must be clearance between the stop collar and the

housing. Turn the collar until there is clearance.
Make sure the cutter plate is in complete contact with the
counterbore. This will make sure there is correct
alignment.
N14 Cylinder Block
Align the holes in the adapter plate (4) with four cylinder
head capscrew holes in the block. Install the washers, the
spacers, and the cylinder head capscrews.
Raise the cutter plate and insert the C-spacer, Part

Number 3823608, between the lower stop collar and the
housing.
Turn the bottom stop collar down and raise the cutting tool
until it is above the counterbore ledge.
Use an Allen wrench. Turn the bit extending device until

the tool bit touches the counterbore inside diameter.
Cylinder Block N14
CAUTION
Do not turn the handle clockwise. The tool will
damage the bore.
Use the handle to turn the tool counterclockwise. Listen
for the sound of the tool bit scraping the bore wall as it is
turned a minimum one-half turn.
If the sound is not continuous as the handle is turned, use

the bit extending device to push the toll bit against the
bore opposite the first position.
Turn the tool another one-half turn and listen again for the
sound of the bit.
Check for a burr that can mislocate the ledge cutting
machine if it touches at only one point.
Use an Allen wrench. Tighten the two tool bit locking

screws.
Back off the lower stop collar and allow the bit to contact
the ledge.
Back off the upper stop collar, if necessary.
Make sure there is space between the lower stop collar
and the C-spacer.
N14 Cylinder Block
Put a feeler gauge less than the depth you wish to remove
but not more than 0.08 mm [0.003 in] between the stop
collar and the C-spacer.
Tighten the thumb screw on the bottom stop collar.
Apply downward pressure to keep the tool bit against the

ledge while turning the handle clockwise.
Machine the bore until the bottom stop collar contacts the
C-spacer.
Extend the handle toward the tool side of the cutter plate
and turn clockwise with light downward pressure.
Measure the counterbore depth with depth gauge, Part

Number 3823495.
Subtract the actual counterbore measurement from the

desired depth of the counterbore calculated earlier.
Cylinder Block N14
Put a feeler gauge the thickness of the material to be

removed on top of the lower stop collar and turn the top
stop collar down until it touches the feeler gauge.
Tighten the thumb screw to lock the top stop collar.
Each of the marks on the lower stop collar is

approximately 0.025 mm [0.001 in].
Turn the bottom stop collar counterclockwise three
marks to lower the cutting tool.
Cut the ledge until the lower stop collar touches the C-
spacer.
Adjust the lower stop collar up three marks or less each
time and cut until there are three marks, 0.08 mm [0.003
in], left before the lower stop collar touches the upper stop
collar.
Extend the handle toward the cutting tool side.

Apply light downward pressure and cut until the cutting
stops.
N14 Cylinder Block
There is approximately 0.08 mm [0.003 in] left to remove.
Move the lower stop collar up one mark for each remaining
0.025 mm [0.001 in]. Do not exceed 0.08 mm [0.003 in].
Lock the lower stop collar and cut the remaining material.
Move the upper stop collar, if necessary, to attain the
desired depth.
Extend the handle, apply downward pressure, and cut.
Measure the counterbore ledge depth.

The ledge must be to the desired depth.
Cylinder Block N14
If the ledge depth is complete, move the upper stop collar

until it is in contact with the lower stop collar and lock the
upper stop collar.
This presets the depth of any additional counterbores to
the same depth of the counterbore just cut.
Make a pencil mark to highlight a line extending from the

upper to the lower stop collars.
Lower the bottom stop collar to raise the cutter plate until
the cutting tool clears the top of the counterbore ledge.
Loosen the two tool locking screws and retract the cutting
tool.
N14 Cylinder Block
Remove the counterbore ledge cutting tool.
Use a depth micrometer and measure the counterbore

depth in the four places shown.
The four measurements must not vary more than 0.025
mm [0.001 in]. If the measurements exceed the
specification, the counterbore ledge must be machined
again.
CAUTION
damage.
Use a depth gauge, Part Number 3823495, and measure
the angle of the counterbore ledge at four equally spaced
points.
The measurement of the ledge depth must be taken as

near to the counterbore radius (1) as possible and as near
to the counterbore edge (2) as possible.
Cylinder Block N14

[0.001 in].
radius (1).
If additional counterbore ledges are to be cut to the same

depth, put the machine over the bore to be cut.
Remove the C-spacer and allow the cutter plate to fully
contact the bore.
Install the mounting capscrews and the washers.
Raise the cutter plate and insert the C-spacer between the
lower stop collar and the housing.
Adjust the lower stop collar until the cutting tool clears the
counterbore ledge.
Extend the cutting tool until it touches the counterbore.
Rotate counterclockwise to check alignment.
Tighten the two screws to lock the tool.
N14 Cylinder Block
Back off the lower stop collar and lower the cutting tool
until it contacts the counterbore ledge.
Back off three additional marks.
Cut the counterbore ledge.

Back off the lower stop collar and cut again in three-mark
increments until there are three marks left before touching
the upper stop collar.
Move the handle toward the cutting tool side and finish
with light downward pressure.
Measure the counterbore depth.
Move the lower stop collar one mark for each remaining
0.025 mm [0.001 in] and finish cutting.
Move the handle toward the cutting tool side and finish
with light downward pressure.
Cylinder Block N14
Loosen the two tool locking screws and retract the cutting
tool.
Remove the counterbore ledge cutting tool.
Use a depth micrometer and measure the counterbore

depth in the four places shown.
The four measurements must not vary more than 0.025
mm [0.001 in]. If the measurements exceed the
specifications, the counterbore ledge must be machined
again.
CAUTION
damage.
Use depth gauge, Part Number 3823495, and measure
the angle of the counterbore ledge at four equally spaced
points.
N14 Cylinder Block and Liner Seats
The measurement of the ledge depth must be taken as

near to the counterbore radius (1) as possible and as near
to the counterbore edge (2) as possible.

[0.001 in].
radius (1).
Repeat this process for each counterbore ledge being cut.
Finishing Steps
• Install the camshaft bushings. Refer to Procedure
• Install the dowel pins. Refer to Procedure 017-003 in
Section 17.
• Install the pipe plugs. Refer to Procedure 017-007 in
Section 17.
• Install the straight thread plugs. Refer to Procedure
• Install the cup plugs. Refer to Procedure 017-002 in
Section 17.
Cylinder Block and Liner Seats

(001-027)
Leak Test
Drain the engine lubricating oil. Refer to Procedure
007-025-005.
007-025-002.
Cylinder Block and Liner Seats N14
Pressurize the engine cooling system. Refer to Procedure

008-018-013.
NOTE: Apply the air pressure 15 minutes before
inspecting the cylinder liner seats. Be sure the system is
holding air pressure before beginning inspection.
Air Pressure 138 kPa [ 20 psi ]
Visually inspect the outside diameter of the cylinder liners

and the area below the cylinder liner seats in the cylinder
block for coolant leaks.
If a leak is found:
• Remove the cylinder liner(s). Inspect the sealing ring
and cylinder liner. Refer to Procedure 001-028-002.
If a leak is found in the cylinder liner seat:
• Remove the cylinder liners. Refer to Procedure
001-028. Inspect the cylinder block liner counterbore
area. Refer to the
• M11 Shop Manual, Bulletin No. 3666075. If fretting
or wear is found, the cylinder block liner counterbore
can be repaired. Refer to the L10 and M11
Alternative Repair Manual, Bulletin No. 3810310.
Install a new gasket and the lubricating oil pan. Refer to

Procedure 007-025-026. Tighten the oil pan drain plug.
Fill the engine with clean 15W-40 oil. Refer to Procedure
007-025-028.
Operate engine until it reaches a temperature of 80°C
[180°F] and check for coolant or lubricating oil leaks.
N14 Cylinder Liner
Cylinder Liner (001-028)

Preparatory Steps
WARNING
WARNING
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused dispose of in accordance with local
Drain the lubricating oil. Refer to Procedure 007-025.
Drain the coolant. Refer to Procedure 008-018.
Remove the rocker lever covers. Refer to Procedure
003-011.
Remove the compression brakes, if equipped. Refer to
Procedure 020-001.
Remove the rocker lever assemblies. Refer to Procedure
003-009.
Remove the rocker lever housings. Refer to Procedure
003-013.
Remove the injectors. Refer to Procedure 006-026.
Remove the cylinder heads. Refer to Procedure 002-004.

007-025.
Remove the piston cooling nozzles. Refer to Procedure
001-046.
Cylinder Liner N14
Remove the pistons and the connecting rods. Refer to

Procedure 001-054.
Remove
CAUTION
The liner puller must be installed and used as
described to avoid damage to the cylinder block.
The following steps use liner puller, Part Number
3376015.
Insert the liner puller into the top of the cylinder block.
The liner puller must be centered on the top of the cylinder
block. The feet on the extension arms must be extended
below the bottom of the liner.
Turn the puller jackscrew clockwise .

Use both hands to remove the liners.
Remove and discard the o-rings and the crevice seals.
Do not discard the sealing rings which are located under
the cylinder liner flange. Sealing rings can be used again.
Use a liquid metal marker to mark the cylinder number on

each liner.
If the sealing rings were removed, do the following:
• Use a tag to mark the cylinder number.
• Measure in several places and record the thickness
of the sealing rings used in each cylinder. The
thickness of the sealing ring is one factor in
determining liner protrusion. This information must
be known when the liners are installed in the engine.
N14 Cylinder Liner
CAUTION
The liner puller must be installed and used as
described to avoid damage to the cylinder block.
CAUTION
The puller plate must not overlap the liner outside
diameter.
The following steps us liner puller, Part Number 3375629.
Insert the liner puller into the top of the cylinder block.
The liner puller must be centered on the top of the cylinder
block.
The puller plate must be parallel to the main bearing
saddles.
Turn the puller jackscrew clockwise .

Use both hands to remove the liner.
Remove and discard the crevice seals and the o-rings.
Do not discard the sealing rings which are located under
the liner flange. Sealing rings can be used again.
Use a liquid metal marker to mark the cylinder number on

each liner.
If the sealing rings were removed, do the following:
• Use a tag to mark the cylinder number.
• Measure in several places and record the thickness
of the sealing rings used in each cylinder. The
thickness of the sealing ring is one factor in
determining liner protrusion. This information must
be known when the liners are installed in the engine.
WARNING
Wear eye protection. Make sure the wire brush is
rated for the RPM being used if the brush is motor
driven.
CAUTION
Do not use a hone, deglazing, or prebrushing to clean
the cylinder liners. Abrasives can damage the finish
and the crosshatch pattern and can contaminate the
liner.
Use a high quality steel wire brush to clean the liner flange
seating area.
Cylinder Liner N14
WARNING
WARNING
When using solvents, aids, or alkaline materials for
WARNING
personal injury.
Use a non-metallic bristle brush, detergent soap, and
warm water to clean the inside diameter.
Use a steam cleaner or solvent tank to clean the liners.
Inspect the liners for cracks on the inside and the outside
diameters.
Inspect for cracks under the flange.

Cracks can also be detected by using either magnetic
inspection or the dye method. Refer to the N14 Shop
N14 Cylinder Liner
Inspect the outside diameter for excessive corrosion or

pitting. Liners with pitting generally can not be used
again. However, if the pitting is light (the bottom is easily
seen), the liner can be turned 90 degrees from its original
position and used again. The liner pitting must not be
orientated on the intake or the exhaust side of the block.
Replace the liner if the pits are too deep or if the corrosion
can not be removed with a fine emery cloth.
Inspect the inside diameters for vertical scratches deep

enough to be felt with a fingernail.
If a fingernail catches in the scratch, the liner must be
replaced.
Inspect the inside diameter for scuffing or scoring.
Inspect the inside diameter for liner 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.
Refer to the Generic Service Literature Reuse/Repair
Practices, Bulletin 3810303, for further information on
liner bore polishing.
Replace the liner if:

• A heavy polish is present over 20 percent of the
piston ring travel area.
• Thirty percent (30%) of the piston ring travel area has
both moderate and heavy polish, and one-half (15
percent) is heavy polish.
Cylinder Liner N14
Use a dial bore gauge to measure the liner inside diameter

in four places 90 degrees apart at the top and the bottom
of the ring travel area.
Cylinder Liner Inside Diameter

mm in
139.694 MIN 5.499
139.827 MAX 5.505
Measure the upper press fit liner flange diameter.
Upper Press Fit Liner Flange Diameter

mm in
Standard 166.72 MIN 6.564
166.77 MAX 6.566
Oversize 167.74 MIN 6.604
167.79 MAX 6.606
The liner design incorporates a press fit between the

upper liner bore and the area of the liner directly below the
liner flange. This is referred to as the lower press fit
design.
Cylinder liners with standard and oversize press fit
diameters are available.
Lower Press Fit Liner Flange Diameter

mm in
159.96 MAX 6.298
160.98 MAX 6.338
Measure the liner flange thickness.
Lower Press Fit Design Liner Flange Thickness

mm in
9.04 MAX 0.356
9.55 MAX 0.376
N14 Cylinder Liner
Measure the lower press fit diameter.
Lower Press Fit Design Lower Press Fit Area Outside

Diameter
mm in
159.96 MAX 6.298
160.98 MAX 6.338
Apply a thick film of clean 15W-40 oil to the bores of the

liners for final cleaning. Leave the oil on for five to 10
minutes.
Use a clean, lint-free paper towel, not cloth, to wipe the
oil from the bores until the black and gray deposits are
removed.
Do not set the liners in an area where dirty air flow can
contaminate the liners.
If the block surface needs to be resurfaced, the engine

must be removed from the chassis.
Refer to the Alternative Repair Manual, Bulletin 3379035.
Cylinder Liner N14
WARNING
Do not smoke or allow any flame, pilot light, sparks,
arcing switch or equipment in area or area sharing
ventilation. Solvents may be identified by state or
federal agencies as carcinogenic or cause
reproductive toxicity. See manufacturer's Material
Safety Data Sheet for product warnings. Naptha and
methyl ethyl ketone (MEK) are flammable. Do not use
starting fluid as a cleaning agent.
When cleaning the liner counterbore in-chassis, install the
chip control plug, Part Number 3823231, in the lower bore
to prevent contamination of the crankshaft.
Inspect the liner counterbore as follows:
• Clean the cylinder block counterbores with a suitable
hydrocarbon solvent such as naptha, methyl ethyl
ketone (MEK) or trichlorethane 1, 1, 1 (methyl
chloroform).
Check the counterbore for cracks or porosity.
If there is a crack, it usually can be seen in the corner

between the upper bore area and the ledge.
If any cracks of any size can be seen running horizontally
around the counterbore, all the coolant passages that are
close to the bore must be repaired. Refer to the NH/NT
Counterbore Troubleshooting and Repair Manual, Bulletin
3810450, for repair.
N14 Cylinder Liner
Circumferential cracks in the counterbore ledge that do

not extend more than one-half the width of the ledge are
acceptable.
• Inspect the liner counterbore for cracks. If cracks are

present, the cylinder block can be used without
salvage if:
• Circumferential cracks do not extend into a cylinder
head capscrew hole or a water jacket hole.
• Circumferential cracks do not extend beyond one-
half the width of the counterbore ledge from the
radius.
Circumferential cracks that extend more than one-half the

width of the ledge must be repaired with a sleeve.
Refer to the Counterbore Troubleshooting and Repair
Manual, Bulletin 3810450, for repair instructions.
If there is a porous area below the counterbore ledge that

is close to a capscrew hole, the hole must be repaired.
If there is a porous area above the counterbore ledge that
is close to a coolant passage, the passage must be
repaired. Refer to the Counterbore Troubleshooting and
Repair Manual, Bulletin 3810450, for repair instructions.
Cylinder Liner N14
Cylinder blocks with vertical cracks that extend down over

the counterbore ledge that can not be machined out
using an 17.907 mm [0.750 in] long sleeve can not be
repaired.
Measure below the counterbore in two directions as

shown.
A standard LPF bore must check 159.842 to 159.893 mm
[6.293 to 6.295 in] in the press fit area below the
counterbore.
If the bore exceeds the maximum specifications, it needs
to be machined for an oversize LPF liner.
An oversize LPF bore must check 160.858 to 160.909 mm
[6.333 to 6.3350 in] in the press fit area below the
counterbore.
If the bore measures other than the above tolerances, it
must be bored again or sleeved to the correct lower press
fit.
Use inside micrometers or the correct liner flange as a go/

no go gauge to check the upper bore.
A standard LPF counterbore must check 166.88 to
166.78 mm [6.570 to 6.564 in].
The preferred dimension for an oversize LPF counterbore
is between 167.39 to 167.23 mm [6.590 to 6.584 in]. If the
counterbore is less than 167.23 mm [6.584 in] for oversize
LPF, or 166.78 mm [6.564 in] for standard LPF, it must
be machined again.
Measure the diameter of the counterbore area as follows:

Measure the counterbore diameter from the top deck to
2.54 mm [0.100 in] below the top deck of the cylinder
block.
The counterbore diameter must be measured 45 degrees
to the crankshaft and measured at two places as shown.
Refer to the NH/NT Counterbore Troubleshooting and
Repair Manual, Bulletin 3810450, for machining
instructions.
N14 Cylinder Liner
CAUTION
counterbore radius. It will not give a true indication of
the ledge angle and can cause liner damage.
Use a depth gauge, Part Number 3823495. Measure the
angle of the counterbore ledge at four equally spaced
points.
Measurement (2) must never exceed measurement (1)

or be less than measurement (1) by more than 0.025 mm
[0.001 in].
radius (1).
The desired protrusion is the total sum of the thickness of

the liner flange and the seal rings minus the counterbore
depth.

mm in
0.10 MIN 0.004
0.18 MAX 0.007
Cylinder liners and sealing rings are available in the
following sizes:
mm [in] mm [in]
[0.0180]
[0.0200]
[0.0220]
[0.0310]
Cylinder Liner N14
1. Standard Lower Press Fit (LPF)

Standard flange outside diameter (1) and thickness (2)
2. Oversize Lower Press Fit (LPF) 0.020/0.040
Oversize flange outside diameter (3) (plus 0.51 mm
[0.020 in])
Oversize flange thickness (4) (plus 0.51 mm [0.020
in]),
Oversize lower press fit diameter (5) (plus 1.02 mm
[0.040 in]).
If the ledge angle is okay and a sealing ring(s) is available
that will give you the correct protrusion, use that sealing
ring(s). If the ledge must be cut again to achieve correct
protrusion or ledge angle, refer to the NH/NT Counterbore
Troubleshooting and Repair Manual, Bulletin 3810450, for
machining instructions. Two sealing rings can be used to
achieve correct protrusion.
Install
Make sure the cylinder block and all parts are clean before
assembly. If used liners are being installed again, any
sealing rings removed must be installed with the same
liner in the same cylinder.
Use vegetable oil to lubricate the new liner o-rings and the
crevice seals.
Use vegetable oil to lubricate the o-rings. Do not use
lubricating oil on the o-rings. The o-rings will increase in
size after they have been lubricated with oil.
Install the crevice seal (1) into the top groove.

Install the black o-rings (2 and 3) into the center and the
bottom grooves.
N14 Cylinder Liner
Do not apply sealant to the counterbore.

Put a sealing ring into position on the counterbore ledge.
Do not get excessive oil on the counterbore or the liner

flange. Excessive oil can result in a hydraulic lock
condition and generate inaccurate liner protrusion. Make
sure that the o-rings do not move from the grooves.
Lubricate the crevice seal and the o-rings with vegetable
oil. Install the liner in the bore with a quick push.
Liner installation tool, Part Number 3823615, is used to

press the cylinder liner into the cylinder block. Protrusion
can be checked while the liner is held down by the
installation tool.
Put the force plate (3) across the top of the liner with the
step in the liner bore. Tap the top of the force plate with a
soft hammer to square up and start the liner into the press
fit bore.
Cylinder Liner N14
Put the installation tool bridge (1) across the liner and
install the two cylinder head capscrews finger tight to hold
the bridge down. Rotate the force plate until the areas
where the protrusion measurements will be taken are
exposed.
CAUTION
Do not use an impact wrench to tighten the liner force
plate screw.
Tighten the forcing screw (2).
Check for correct protrusion.
Use a depth gauge, Part Number 3823495, to measure the

liner protrusion at four points 90 degrees apart.
The protrusion must be from 0.10 to 0.18 mm [0.004 to
0.007 in].
If correct liner protrusion is not attained, remove the liner

from the cylinder block.
N14 Cylinder Liner
The desired counterbore depth is the total sum of the

thickness of the liner flange and the seal rings minus the
cylinder liner protrusion.

mm in
0.10 MIN 0.0004
0.18 MAX 0.0007
Check for twisted liner o-rings.

Clean the liner flange and the cylinder block liner
counterbore.
Inspect the liner flange for burrs.

Inspect the cylinder block liner counterbore for burrs.
Remove the burrs, or replace the damaged parts.
Install the liner.

Cylinder Liner N14
Finishing Steps
Install the pistons and the connecting rods. Refer to
Procedure 001-054.
Install the piston cooling nozzles. Refer to Procedure

001-046.
Install the lubricating oil pan. Refer to Procedure 007-025.

Install the cylinder heads. Refer to Procedure 002-004.
Install the rocker lever housings. Refer to Procedure
003-013.
Install the injectors. Refer to Procedure 006-026.
Installl the rocker lever assemblies. Refer to Procedure
003-009.
Adjust the valves and injectors. Refer to Procedure
003-004.
Install and adjust the compression brakes, if equipped.
Install the rocker lever covers. Refer to Procedure
003-011.
CAUTION
to avoid internal component damage. Do not prime
the system from the bypass filter; the filter will be
damaged.
Prime the lubricating system. Refer to Procedure 007-037.
N14 Gear Cover, Front

007-025.
Fill the cooling system. Refer to Procedure 008-018.

Do not overfill the cooling system.
If new rings, liners, or pistons were installed, perform the

engine run-in. Refer to Procedure 014-004.
Gear Cover, Front (001-031)

Remove
Remove the fan. Refer to Procedure 008-036-002.
Remove the fan drive belts and the water pump belt. Refer
to Procedures 008-002-002 and 008-003-002,
respectively.
013-001-002.
Gear Cover, Front N14

009-004-002.
CAUTION
If the accessory drive dowel pin has been installed in
the accessory drive shaft, the dowel pin must be
removed before attempting to remove the gear cover
to prevent damage to the accessory drive bushing.
Remove the camshaft support and the thrust bearing. Do

not discard the shims. Refer to Procedure 001-009-002.
respectively.
Remove the four capscrews which hold the oil pan to the
gear cover.
Loosen all remaining oil pan mounting capscrews four to
five turns.
Use an overhead hoist or a hydraulic arm to support the

engine.
Remove the capscrews which hold the front engine
support to the crossmember of the equipment.
Remove the eight capscrews and the front engine support.
CAUTION
Use extreme care when releasing the oil pan gasket
from the gear cover to prevent damage to the gasket.
If the gasket is damaged, the oil pan must be removed
and the gasket replaced. Refer to Procedure
007-025-002.
Insert a feeler gauge or a shim stock between the gear
cover and the oil pan gasket. Move the feeler gauge or the
shim stock back and forth to release the gasket from the
gear cover.
Remove one capscrew on each side of the gear cover, and

install a 7/16 - 20 x 4-inch guide stud in each location to
support the cover during removal.
Remove the remaining gear cover capscrews, and remove
the gear cover.
Remove the front crankshaft seal. Refer to Procedure

001-023-002.
Remove the accessory drive seal. Refer to Procedure
001-003-002.
Clean
Clean the gasket surface of the cylinder block.
Clean the gear cover.
Inspect for Reuse

Inspect the gear cover for cracks or damage.
Measure the accessory drive seal bore.
Accessory Drive Seal Bore I.D.

mm in
80.962 MIN 3.1875
81.038 MAX 3.1905
NOTE: Replace the gear cover if the accessory drive seal
bore is not within specifications.
Measure the crankshaft seal bore.
Crankshaft Seal Bore I.D.

mm in
120.611 MIN 4.7485
120.688 MAX 4.7515
NOTE: Replace the gear cover if the crankshaft seal bore
is not within specifications
Measure the accessory drive bushing inside diameter.
Accessory Drive Bushing Diameter.

mm in
39.75 MIN 1.9990
39.90 MAX 2.0015
NOTE: Replace the bushing if it is not within
specifications. Refer to Procedure 001-066.
Install
Install one 7/16 - 20 x 4-inch guide stud into each side of
the gear cover mounting flange to align the cover.
Install the gear cover gasket over the guide studs and the
dowel pins.
NOTE: Use a film of Lubriplate® 105 or its equivalent or
grease to hold the gear cover gasket in place, if
necessary.
Install the gear cover and the mounting capscrews.

Tighten the capscrews to the following torque sequence
as shown:
Cut off the ends of the gasket even with the oil pan
mounting flange.
Mount a dial indicator on the front face of the crankshaft.

Put the indicator plunger against the oil seal bore, and set
the dial indicator at "0" (zero).
Rotate the crankshaft one complete revolution while
monitoring the indicator. Use the accessory drive nut to
bar the engine over. The total indicator reading must
not exceed 0.38 mm [0.015-inch].
If the total indicator reading exceeds 0.38 mm [0.015-

inch], remove the gear cover. Check the cover and the
housing for nicks or burrs.
Clean the gear cover and the housing surfaces
thoroughly.
Repeat the gear cover installation procedure, and check

the total indicator reading again.
Install the front engine support and the eight mounting
capscrews. Tighten the capscrews.
Lower the engine to the crossmember. Install and tighten

the capscrews which hold the front engine support to the
crossmember. Refer to the manufacturer's torque
specifications.
001-023-026.

respectively.
Install a new accessory drive seal. Refer to Procedure
001-003-026.
Install the dowel pin into the accessory drive shaft (if
removed).
009-004-026.
Install the camshaft support and the thrust shims into the
gear cover. Refer to Procedure 001-009-026.
Install the water pump belt and the fan drive belts. Refer
to Procedures 008-003-026 and 008-002-026,
respectively.
Install the fan. Refer to Procedure 008-036-026.

Install the four capscrews which hold the oil pan to the
gear cover.
Tighten one of the 7/16-inch oil pan mounting capscrews

on each side of the oil pan, halfway between the front and
the rear of the oil pan.
Piston N14
Tighten the four 5/16-inch capscrews in the rear of the oil

pan in the sequence shown.
Tighten the thirty-two (32) 7/16-inch capscrews in the
sequence shown.

Piston (001-043)
General Information
All N14 Plus and N14 Industrial engines are equipped with
articulated pistons.
The articulated piston is a two piece piston consisting of
a forged steel crown and an aluminum skirt.
Remove
Remove the piston and connecting rod assemblies from
the engine. Refer to Procedure 001-054-002.
NOTE: The piston and connecting rod assemblies must
be installed in the same cylinder number from which they
were removed to make sure there is a correct fit of worn
mating surfaces if parts are used again.
piston and rod assembly was removed.
N14 Piston
Disassemble
Refer to Procedure 001-054-003 to disassemble the piston
and connecting rod assembly.
NOTE: Refer to Procedure 001-047 for piston ring
inspection.
Clean
CAUTION
To avoid damage to the piston crown, the cleaning
solvent must be approved for bushing material.
Allow the pistons to soak for a minimum of 30 minutes in
a tank containing an approved cleaning solvent for
aluminum.
Use a hot, soapy solution and a non-metallic brush to
remove carbon deposits.
NOTE: A plastic bead, Part No. 3822735, is available

which can be used to clean pistons, including aluminum
ring grooves. Do not bead blast pin bores.
CAUTION
Do not use a metal brush. A metal brush will damage
the piston ring grooves. Do not use glass beads to
clean the grooves. Walnut shell blasting can be used
on grooves with a ni-resist insert and on the dome or
crown of the piston. Use the minimum effective
pressure and do not concentrate the spray in one area
for an extended period of time. Do not use glass
beads or walnut shell blasting on the aluminum
grooves or pin bores. This can damage the pin bore
surface finish or prevent the rings from seating
correctly in the ring grooves.
Steam clean the pistons, and dry with compressed air.

Piston N14
Inspect for Reuse

Visually inspect both the crown and skirt. Do not use the
crown or skirt if cracks or scuff marks are found. Scratches
in the skirt are not acceptable if they are visually not
acceptable.
Use crack detection kit, Part No. 3375432, or its
equivalent to check for cracks on the piston crown and in
and around the piston pin bore. Do not use if cracked or
scuffed. If the crown is not acceptable, replace the crown
and pin.
Visually inspect the piston ring lands and ring grooves for
wear. A worn groove will have a detectable step at the
back of the groove and a rolled edge at the surface of the
piston or the ring groove outside diameter. Pistons
exhibiting this wear are not acceptable for reuse.
Refer to the Parts Reuse Guidelines, Bulletin No.
3810303.
Measure the outside diameter of the piston as follows:

• Measure at right angles to the piston pin bore.
• Piston temperature must be between 21°C [70°F] to
32°C [90°F].
• Replace pistons that measure less than 139.50 mm
[5.4922 inch] outside diameter.
Use piston ring groove wear gauges, Part Nos. 3823870

and 3823869, and a 5 to 6 inch micrometer to inspect the
top and second grooves (compression rings).
NOTE: The piston must be replaced if measured
dimensions are less than those in the table below.
Measure each ring groove (diameter over pins) when the
piston temperature is at 21°C [70°F] in two places 90
degrees apart as shown.
Ring Groove Wer Limits (Diameter Over Pins)

mm in
Top Ring Groove: 140.2 MIN 5.515
2nd Ring Groove 140.1 MAX 5.514
N14 Piston
Measure the piston pin bore when the piston temperature

is at 20°C [68°F].
Piston Pin Bore (Crown Bore)

mm in
63.530 MIN 2.5012
64.548 MAX 2.5019
NOTE: Add 0.013 mm [0.0005-inch] to the bore inside
diameter per 5°C [10°F] temperature rise up to 32°C [90°
F].
Visually inspect the piston pin for scratches, grooves, or

other damage. Do not reuse if it is visually not
acceptable.
Measure the piston pin outside diameter at both ends as
shown in two places 90 degrees apart.
Piston Pin Outside Diameter

mm in
63.4928 MIN 2.49972
63.4997 MAX 2.4999
NOTE: Discard the piston pin if it is more than 0.03 mm
[0.001 In] out of round. If piston pin measurements exceed
those in the table, do not reuse. If the piston pin is not
acceptable for reuse, do not use the matching piston.
Cummins recommends replacing pistons and pins in sets.
Inspect the connecting rod pin bushing bore and the

crankshaft bore. Refer to Procedure 001-054-007.
To check the ring gap, install the new piston rings into the
cylinder liner in which they will be used.
Use the top part of the piston to correctly position the ring
in the liner.
Piston Cooling Nozzle N14
Use a feeler gauge to inspect the ring gap. Replace the

ring if it does not meet the following specifications:
Piston Ring Gap

mm in
Top 0.43 MIN 0.017
0.68 MAX 0.027
Second 0.51 MIN 0.020
0.76 MAX 0.030
Oil 0.25 MIN 0.010
0.64 MAX 0.025
NOTE: Add 0.08 mm [0.003-inch] to the maximum limit for
each 0.03 mm [0.001-inch] wear in the cylinder liner wall.
Assemble
Refer to Procedure 001-054-025 for poston and
connecting rod assembly instructions.
Install
Install the piston and connecting rod. Refer to Procedure
001-054-026.
Piston Cooling Nozzle (001-046)

Remove
Remove the lubricating oil filter. Refer to Procedure
007-013-002.
Remove the starting motor (if required). Refer to
Remove the alternator and the lubricating oil fill tube.
respectively.
NOTE: Some construction and industrial engines have the
starting motor mounted on the right side of the engine.
N14 Piston Cooling Nozzle
Remove the piston cooling nozzles.

Remove and discard the o-rings.
Clean
Clean the piston cooling nozzles with solvent, and dry with
compressed air.
Blow out the oil passages with compressed air.
Inspect for Reuse

Visually inspect the piston cooling nozzles for cracks or
damage.
Visually inspect the screws for damaged or mutilated
threads.
Replace any parts that are damaged.
Install
Use vegetable oil to lubricate the new o-rings. Do not soak
the new o-rings in engine oil.
Install the o-rings into the groove of the piston cooling
nozzle.
Piston Cooling Nozzle N14
Install the nozzles into the cylinder block.

NOTE: Make sure the oil passage opening in the piston
cooling nozzle is pointing up toward the piston.
CAUTION
Do not use the capscrew to pull the nozzle into the
cylinder block. Nozzles and o-ring damage or external
oil leaks can result.
Install the capscrews as follows:

• Tighten the Nyloc capscrews.
Torque Value: 25 N•m [ 220 in-lb ]
Install the starting motor (if removed). Refer to Procedure

013-020-026.
Fill and install the lubricating oil filter. Refer to Procedure
007-013-026.

C [180°F], and check for oil leaks.
N14 Piston Rings
Piston Rings (001-047)

Preparatory Steps
WARNING
To reduce the possibility of personal injury, reduce
the possibility of direct contact of hot oil with your
skin.
WARNING
WARNING
WARNING
not reused, dispose of in accordance with local
• Drain the lubricating oil. Refer to Procedure 007-025.
• Drain the cooling system. Refer to Procedure
008-018.
007-025.
• Remove the rocker lever covers. Refer to Procedure
003-011.
• Remove the compression brakes, if equipped. Refer
• Remove the rocker lever assemblies. Refer to
Procedure 003-009.
• Remove the injectors. Refer to Procedure 006-026.
• Remove the rocker lever housings. Refer to
Procedure 003-013.
• Remove the push tubes. Refer to Procedure
004-014.
• Remove the cylinder heads. Refer to Procedure
002-004.
• Remove the piston cooling nozzles. Refer to
Procedure 001-046.
Remove
WARNING
When performing the following procedures, wear eye
protection. Also, make sure the wire brush is rated for
the RPM being used if the brush is motor driven.
CAUTION
Do not use abrasive paper to remove the carbon ring.
Small particles of abrasive material will cause severe
engine damage.
Piston Rings N14
Plug the overhead oil rifle push tube cavities and coolant
passages in the block, and use a rotary wire brush to
remove the carbon ring from the top of the cylinder liner.
Use a scraper that has an aluminum blade if a rotary wire
brush is not available.
Use lint-free paper to remove all the broken wire bristles
and loose carbon from the cylinders.

Rotate the crankshaft to position two of the connecting
rods at bottom dead center.
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.140 MIN 0.005
0.330 MAX 0.013
If the side clearance does not meet these specifications,

do the following:
• Remove the rod caps. Inspect the rod caps for dirt,
damage, and correct bearings.
N14 Piston Rings
• Install and tighten the rod caps.

• Measure the side clearance again.
If the side clearance does not meet the specifications, the
connecting rod must be replaced.
NOTE: Do not remove the capscrews.

to loosen the rod caps from the dowels.
Remove the connecting rod capscrews and the rod caps.

Remove the bearing shell from the rod cap, and mark the
cylinder number and the letter "L" in the flat surface of the
bearing tang.
Install two connecting rod guide pins, Part Number

3375601.
Use a dead blow mallet to push the rod away from the
crankshaft.
Push the rod away from the crankshaft, cover the
crankshaft rod journal, and push the rod until the piston
rings are outside of the top of the cylinder liner.
Piston Rings N14
Remove the piston and rod assembly.

The piston crown and skirt and connecting rod assemblies
must be installed in the same cylinder number they were
removed from to make sure there is a correct fit of worn
mating surfaces if parts are used again. Also, the piston
skirt and crown must be reinstalled together.
piston and rod assembly was removed. Make sure to mark
both the skirt and crown on the piston.
The pistons crown must have the cylinder numbers
stamped on the piston top toward the camshaft side of the
engine. The skirt must also be stamped so it can be
matched with the piston crown.
Place the rod and piston assemblies in a stand to protect

them from damage.
CAUTION
damage to the connecting rods and the crankshaft.
Remove the upper rod bearing.

Mark the cylinder number and the letter "U" in the flat
surface of the bearing tang.
N14 Piston Rings
CAUTION
To reduce the possibility of damage to the piston
rings, do not over expand the piston rings - maximum
dimension.
Use the piston ring expander, Part Number 3823871, to
remove the piston rings.
Place a tag on the rings, and record the cylinder number
of the piston on the tag for future reference (if required).
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
The piston pin can be easily removed at room temperature

by using a blunt tool to manually push the pin from the rod
assembly.
Make sure the piston and rod assembly are correctly

marked.
If the pin can not be removed, it is acceptable to put the
piston in 66°C [150°F] water for 15 minutes and then
manually remove the pin with a blunt tool.
Piston Rings N14
Manually remove the piston skirt from the crown. Extreme

caution must be taken to prevent damage to both the
crown and skirt.
Inspect for Reuse

To check the ring gap, install the new piston rings in the
cylinder liner in which they will be used.
Use the top part of the piston to position the ring in the
liner correctly.
Use a feeler gauge to inspect the ring gap. Replace the

ring if it does not meet the following specifications:
Piston Ring Gap

mm in
Top Ring 0.43 MIN 0.017
0.66 MAX 0.027
Second Ring 0.51 MIN 0.020
0.76 MAX 0.030
Oil Ring 0.25 MIN 0.010
0.64 MAX 0.025
Install
NOTE: The cylinder block must be clean before
assembly. Refer to Procedure 001-028 to inspect the
cylinder liners for reuse.
Align the piston skirt and crown.
N14 Piston Rings
Install a new snap ring in one of the snap ring grooves of

the piston pin bore on each piston.
Heat the pistons in hot tap water, 66°C [150°F], for 15 to
30 minutes.
Use clean 15W-40 oil to lubricate the connecting rod

piston pin bore and the piston pin.
Remove the piston from the water and lubricate the pin
bore with clean 15W-40 oil.
Align the pin bore of the rod with the pin bore of the piston,
and install the piston pin. Do not use a hammer to install
the piston pin. The piston will be damaged.
The cylinder number of the piston top (1) must be toward
the bearing tang (2) side of the rod.
The pin must easily assemble without force; if it does
not, inspect it for damage, dirt, poor lubrication, etc.
Install a new snap ring in the second piston pin bore snap
ring groove. The snap ring must be seated completely in
the snap ring groove.
Piston Rings N14
CAUTION
To reduce the possibility of damage to the piston
rings, do not over expand the piston rings - maximum
dimension.
The oil control ring is symmetrical and can be installed in
either orientation.
Use piston ring expander, Part Number 3823871, to install
the piston rings with the part number, mark, or the word
"TOP" toward the top of the piston.
The ring gap of each ring must not be aligned with the
piston pin or with any other ring.
A cross-sectioned view of an oil control ring is shown. The
two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring.
Install the upper bearing shell in the connecting rod. If

used bearing shells are to be installed, each bearing shell
must be installed in its original location.
The tang (1) of the bearing shell must be in the slot (2) of
the rod.

bearing shell.
Apply a heavy film of clean 15W-40 oil to the liner.
N14 Piston Rings
Lubricate the piston and the ring assembly by hand with

clean 15W-40 oil. Dipping is okay, but draining is very
difficult because the piston does not have drain holes. If
dipping, only dip up to the pin bore and then hand
lubricate it and the remaining skirt.
Install connecting rod guide pins, Part Number 3375601.

Use piston ring compressor, Part Number 3822736, to
compress the rings.
Install the bearing in the connecting rod cap.

The tang (2) of the bearing must be in the slot (1) of the
cap.
Lubricate the bearing shell with Lubriplate® 105 or its
equivalent. Lubricate the connecting rod capscrew
threads and the washer face with 140W oil.

Rotate the crankshaft to position the journal for the
connecting rod at bottom dead center.
Piston Rings N14
CAUTION
To reduce the possibility of piston damage, do not use
a metal object to push the piston into the liner.
The tang of the connecting rod must be toward the
camshaft side of the cylinder block.
CAUTION
Do not use a hammer or its equivalent to install the
piston into the cylinder liner. The piston rings can be
damaged.
Install the connecting rod into the cylinder liner, and push
the piston down. If the piston does not move freely,
remove the piston. Inspect for broken or damaged rings.
When installing the connecting rod, pay close attention to
make sure the rod is aligned with the crankshaft rod
journal. If the rod is misaligned, it can bind or scrape the
crankshaft connecting rod journal side walls.
Use the guide pins to pull the connecting rod against the
crankshaft.
Remove the guide pins.

cap.
Lubricate the bearing shell with Lubriplate® 105 or its
threads and the washer face with 140W oil.
N14 Piston Rings
CAUTION
The connecting rod has changed on the 1994 Certification

Level engine to accommodate the increased loading of the
articulated pistons. The torquing procedure for the
connecting rod capscrews has also changed. The new
torque specification is 129 N•m [95 ft-lb] plus 60 degrees
± 5 degrees.
To facilitate this new torquing procedure, the torque angle
socket gauge, Part Number 3824520, was developed.
The torque angle socket is marked with a zero (start) point,

a specification window, and a out of limits (OOL) line.
The tightening procedure is to pre-tighten both of the

capscrews 129 N•m [95 ft-lb].
With the socket on the capscrew, draw a line from the zero
(start) point across the capscrew head to a point on the
rod cap.
This line is the gauge line for the angle portion of the
specification (60 degrees ± 5 degrees).
Piston Rings N14
With the zero point on the socket gauge aligned with the
mark on the capscrew head, tighten the capscrew.
With the socket gauge in position, check to see if the fixed
mark (on rod cap) is within the window of the gauge.
If the fixed line is between the "0" line and the "Out Of Line
(OOL)" line, tighten or loosen until it is within the window.
If the fixed line is past the "OOL" line, replace the
capscrew and repeat the tightening sequence.
Measure the connecting rod side clearance. The side

clearance must be between 0.140 mm [0.0055-inch] and
0.33 mm [0.013-inch].
The connecting rod must move freely from side to side on
the crankshaft journal. If the rod does not move freely,
remove the rod cap and make sure the bearing shells are
the correct size. Check for dirt or damage on the
crankshaft and the bearing shells.
N14 Vibration Damper, Viscous
Finishing Steps
CAUTION
to reduce the possibility of internal component
damage. Do not prime the system from the bypass
filter; the filter will be damaged.
• Install the piston cooling nozzles. Refer to Procedure
001-046.
007-025.
• Install the cylinder heads. Refer to Procedure
002-004.
• Install the push tubes. Refer to Procedure 004-014.
• Install the rocker lever housings. Refer to Procedure
003-013.
• Install the rocker lever assemblies. Refer to
Procedure 003-009.
• Install the injectors. Refer to Procedure 006-026.
• Adjust the valves and injectors. Refer to Procedure
003-004.
• Install and adjust the compression brakes, if
equipped. Refer to Procedure 020-001.
• Install the rocker lever covers. Refer to Procedure
003-011.
• Prime the lubricating system. Refer to Procedure
007-037.
• Fill the engine with lubricating oil. Refer to Procedure
007-025.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine until it reaches a temperature of
82°C [180°F], and check for leaks.
Vibration Damper, Viscous (001-052)

WARNING
Clean the vibration damper with solvent.
Vibration Damper, Viscous N14
Inspect the vibration damper mounting area for cracks.

Check the housing for dents or raised surfaces.
Replace the damper if any defects are identified.
Record the vendor identification, date code, and part

number.
Using the date code, determine the type of bearing

material in the damper.
• Date codes followed by a “P” represent dampers with
teflon bearing material.
• Date codes that are not followed by a “P” represent
dampers with nylon bearing material.
Determine if the vibration damper is a cast type or

fabricated type.
Fabrication vibration dampers are the most common type
and can be identified by a weld bead on the front center
section of the damper where the housing joins the
mounting flange.
N14 Vibration Damper, Viscous
Remove the paint on both sides of the damper in four

locations spaced 90 degrees apart.
Measure and record the thickness at two points on each

of the four locations.
• Measure the thickness at 3.18 mm [0.125 in] from the
outer lip.
• Measure the thickness at 25.4 mm [1.0 in] from the
outer lip.
This procedure will result in a total of eight measurements.
If the variations between any of the eight measurements
exceeds 0.25 mm [0.010 in], or if the thickness at any point
exceeds the maximum thickness dimensions indicated
below in the table, the damper must be replaced.
Engine Housing Bearing Maximum

Model Type Material Thickness
Teflon and
NT Cast 39.37 mm [1.550 in]
nylon
NT Fabricated Nylon 39.88 mm [1.570 in]
NT Fabricated Teflon 39.62 mm [1.560 in]
NT and Teflon and
Cast 44.20 mm [1.740 in]
N14 nylon
NT and Teflon and
Fabricated 44.24 mm [1.663 in]
N14 nylon
Replace the small vibration damper with a large vibration

damper, if the small vibration damper fails inspection or
the engine experienced a camshaft nose failure.
Spray the rolled lip of the vibration damper with crack

detection developer, Part Number 3375434, or equivalent.
Heat the damper in an oven, rolled side down, at 93°C
[200°F] for two hours.
Vibration Damper, Viscous N14
WARNING
been heated to reduce the possibility of personal
injury.
Remove the damper from the oven and check for fluid
leakage around the rolled lip.
If the vibration damper has leaks, it must be replaced.
N14 Piston and Connecting Rod Assembly
Piston and Connecting Rod Assembly

(001-054)
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. Wear
goggles and protective clothing to reduce the
possibility of serious personal injury.
WARNING
WARNING
WARNING
not reused, dispose of in accordance with local
WARNING
Disconnect the batteries. Refer to Procedure 013-009.
Drain the lubricating oil. Refer to Procedure 007-037.
Drain the cooling system. Refer to Procedure 008-018.
003-011.
Remove the C-Brakes, if equipped. Refer to Procedure
020-001.
Remove the rocker lever assemblies, rocker lever
housings, and injectors. Refer to Procedures 003-009,
003-013, and 006-026, respectively.
Remove the cylinder heads. Refer to Procedure 002-004.
007-025.
Remove the piston cooling nozzles. Refer to Procedure
001-046.
Piston and Connecting Rod Assembly N14
Remove
WARNING
wire brushes to remove carbon from the cylinder
block. Flying debris and dirt can cause personal
injury. Also, make sure the wire brush is rated for the
rpm being used if the brush is motor driven.
CAUTION
Do not use abrasive paper to remove the carbon ring.
Small particles of abrasive material will cause severe
engine damage.
Plug the overhead oil rifle push tube cavities and coolant
passages in the cylinder block, and use a rotary wire brush
to remove the carbon ring from the top of the cylinder liner.
Use a scraper that has an aluminum blade, if a rotary wire
brush is not available.
Use lint-free paper to remove all the broken wire bristles
and loose carbon from the cylinders.
Use the accessory drive pulley to rotate the crankshaft to

position two of the connecting rods at bottom-dead-center.
NOTE: Do not remove the capscrews.

to loosen the connecting rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap and mark the
cylinder number and the letter “L” in the flat surface of the
bearing tangs.
Install two connecting rod guide pins, Part Number

3375601.
Use a mallet to push the rod away from the crankshaft.
NOTE: Push the connecting rod away from the crankshaft,
cover the crankshaft rod journal, and push the connecting
rod until the piston rings are outside of the top of the
cylinder liner.
Remove the piston and connecting rod assembly.

NOTE: The piston crown, skirt, and the connecting rod
assemblies must be installed in the same cylinder number
they were removed from to make sure proper fit of worn
mating surfaces, if parts are used again. Also, the piston
skirt and crown must be reinstalled together.
Use a tag to mark the cylinder number that each piston
and connecting rod assembly was removed from. Be sure
to mark both the skirt and crown on the piston.
NOTE: The piston crown must have the cylinder numbers
stamped on the piston top toward the camshaft side of the
engine. The skirt must also be stamped so it can be
matched with the piston crown.
Remove the upper rod bearing.

Mark the cylinder number and the letter “U” in the flat
surface of the bearing tang.
Place the connecting rod and piston assemblies in a stand

to protect them from damage.
Disassemble
CAUTION
Do not over-expand the piston ring's maximum
dimension. The piston ring will break.
Use piston ring expander, Part Number 3823871, to
remove the piston rings.
Place a tag on the rings, and record the cylinder number
of the piston on the tag for future reference (if required).
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
The piston pin must be removed at room temperature by

using a blunt tool to manually push the pin from the rod
assembly.
NOTE: Make sure the piston and connecting rod

assembly are correctly marked.
If the piston pin can not be removed at room temperature,
it is acceptable to put the piston in 66°C [151°F] water for
15 to 30 minutes, then manually remove the piston pin with
a blunt tool.
Manually remove the piston skirt from the crown. Extreme

caution must be taken to prevent damage to both the
crown and skirt.

Clean the pistons. Refer to Procedure 001-043.
Inspect the pistons. Refer to Procedure 001-043.

Inspect the piston rings for failure and wear analysis.

Inspect the connecting rods. Refer to Procedure 001-014.
Assemble
Align the piston skirt and crown.
Install a new snap ring in one of the snap ring grooves of

the piston pin bore on each piston.
Heat the pistons in hot tap water, 66°C [151°F], for 15 to
30 minutes.
Use clean 15W-40 lubricating oil to lubricate the

connecting rod piston pin bore and the piston pin.
Remove the piston from the water and lubricate the piston
pin bore with clean 15W-40 lubricating oil.
Align the pin bore of the connecting rod with the pin bore
of the piston, and install the piston pin. Do not use a
hammer to install the piston pin. The piston will be
damaged.
NOTE: The cylinder number of the piston top (1) must be
toward the bearing tang (2) side of the connecting rod.
The pin must easily assemble without force, if not, inspect
the pin, connecting rod bushing and piston for damage,
dirt, and poor lubrication.
Install a new snap ring in the second piston pin bore snap
ring groove. The snap ring must be seated completely in
the snap ring groove.
CAUTION
Do not over-expand the piston ring's maximum
dimension. The piston ring will break.
Use piston ring expander, Part Number 3823871, to install
new piston rings with the part number, mark, or the word
“TOP” toward the top of the piston.
NOTE: The oil control ring is symmetrical and can be
installed in either orientation.
The ring gap of each ring must not be aligned with the
piston pin or with any other ring.
A cross-sectioned view of an oil control ring is shown. The
two-piece oil control ring must be installed with the
expander rig gap 180 degrees from the gap of the oil ring.
Install
Install the upper bearing shell in the connecting rod. If
used bearing shells are to be installed, each bearing shell
must be installed in its original location.
The tang (1) of the bearing shell must be in the slot (2) of
the rod.
Use clean Lubriplate® 105, or its equivalent, to lubricate

the bearing shell.
Apply a heavy film of clean 15W-40 lubricating oil to the
liner.
Lubricate the piston and the ring assembly by hand with

clean 15W-40 lubricating oil. Dipping is okay, but draining
is very difficult because the piston does not have drain
holes. If dipping, only dip up to the pin bore, then hand
lubricate it and the remaining skirt.
Install connecting rod guide pins, Part Number 3375601.

Use piston ring compressor, Part Number 3822736, to
compress the piston rings.

Rotate the crankshaft to position the journal for the
connecting rod at bottom-dead-center.
CAUTION
To reduce the possibility or piston damage, do not use
a metal object to push the piston into the liner.
The tang of the connecting rod must be toward the
camshaft side of the cylinder block.
CAUTION
Do not use a hammer or its equivalent to install the
piston into the cylinder liner. The piston rings can be
damaged.
Install the connecting rod into the cylinder liner, and push
the piston down. If the piston does not move freely,
remove the piston.
Inspect for broken or damaged rings.
When installing the connecting rod, pay close attention to
make sure the rod is aligned with the crankshaft rod
journal. If the rod is misaligned, it can bind or scrape the
crankshaft connecting rod journal side walls.
Use the guide pins to pull the connecting rod against the
crankshaft.
Remove the guide pins.

connecting rod cap.
Lubricate the bearing shell with Lubriplate® 105, or its
threads and the washer face with 15W-40 lubricating oil.
CAUTION
The connecting rod cap alpha characters must match
the alpha characters on the connecting rod and must
be installed with the characters aligned to prevent
The connecting rod has changed on the 1994 Certification

Level engine to accommodate the increased loading of the
articulated pistons. The torquing procedure for the
connecting rod capscrews has also changed. The new
torque specification is 129 N•m [95 ft-lb] plus 60 degrees
± 5 degrees.
To facilitate this new torquing procedure, the torque angle
socket gauge, Part Number 3824520, was developed.
The torque angle socket is marked with a zero (start) point,

a specification window, and an Out-of-Limits (OOL) line.
The tightening procedure is to pre-tighten both of the

capscrews to 129 N•m [95 ft-lb].
With the socket on the capscrew, draw a line from the zero
(start) point across the capscrew head to a point on the
rod cap.
This line is the gauge line for the angle portion of the
specification (60 degrees ± 5 degrees).
With the “0” line on the socket gauge aligned with the line
on the connecting rod cap, tighten the capscrew.
With the socket gauge in position, check to see if the fixed
line (on the connecting rod cap) is within the window on
the gauge.
If the fixed line is between the “0” line and the “Out-of-
Limits (OOL)” line, tighten or loosen the capscrew until the
line is within the window.
If the fixed line is past the “OOL” line, replace the
capscrew and repeat the tightening sequence.
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.140 MIN 0.0055
0.330 MAX 0.0130
NOTE: If the side clearance does not meet these

specifications, do the following.
Remove the rod caps. Inspect the rod caps for dirt,
damage, and correct bearings.
Install the connecting rod caps and tighten the connecting

rod capscrews.
Measure the side clearance again.
NOTE: If the side clearance does not meet the
specifications, the connecting rod must be replaced.
N14 Cylinder Block Counterbore
Finishing Steps
WARNING
compartment before servicing the batteries. Wear
goggles and protective clothing to reduce the
possibility of serious personal injury.
CAUTION
Install the piston cooling nozzles. Refer to Procedure
001-046.
Install the lubricating oil pan. Refer to Procedure 007-025.
Install the cylinder heads. Refer to Procedure 002-004.
Install the rocker lever housings, injectors, and rocker
lever assemblies. Refer to Procedures 003-013, 006-026,
and 003-009, respectively.
003-004.
Install and adjust the C-Brakes, if equipped. Refer to
Procedures 020-001.
Install the rocker lever covers with their original reusable
gasket if they are not damaged. Refer to Procedure
003-011.
Prime the lubricating system. Refer to Procedure 007-037.
007-025.
Fill the cooling system. Refer to Procedure 008-018.
Connect the batteries. Refer to Procedure 013-009.
Operate the engine until it reaches a water temperature of
82°C [180°F], and check for coolant or lubricating oil
leaks.
Cylinder Block Counterbore (001-058)

Initial Check
Before starting this procedure, confirm or verify the
presence of an engine coolant leak from the cylinder head
or the block head deck area.
Cylinder Block Counterbore N14
Look for signs of coolant leakage down the side of the

engine block.
Operate the engine to verify the coolant leak.

Use black light service tool, Part Number 3377308 or
3377293, and fluorescent tracer, Part Number 3377438,
to pinpoint difficult to find leaks.
Remove the cylinder head(s) where the leak is being

generated. Inspect the cylinder head capscrews for signs
of a coolant leak.
When the cylinder head(s) is removed, cover the oil holes

and tape off the push tube areas.
Inspect the gasket surfaces.

Visually inspect for burrs or damage.
Use a medium grit hone or a crocus cloth to remove the
burrs.
If the block surface needs to be resurfaced, the engine

must be removed from the vehicle at this time. Refer to
the Alternative Repair Manual, Bulletin Number 3379035.
Leak Test
Use cylinder block pressure test fixture, Part Number
3823745, to perform this test.
Clean the cylinder block deck surface with solvent on a

shop towel.
Cylinder Block Counterbore N14
Install the cylinder block pressure test fixture, Part

Number 3823745.
If less than three fixtures are used, all open coolant
passage holes must be plugged. Check for leaks only
around the cylinders covered by a fixture.
Use clean engine oil to lubricate the cylinder head

capscrews.
Allow the excess oil to drain from the threads.
Install 12 cylinder head capscrews and washers into each
cylinder block pressure test fixture, Part Number 3823745.
Tighten the cylinder head capscrews in the sequence

shown.
Tighten down the eight coolant passage plugs. These

plugs seal the coolant during the pressure test.
Fill the cooling system with coolant. Refer to Procedure

008-018 (Cooling System) in Section 8. Pressurize the
block between 70 kPa to 85 kPa [10 psi to 12 psi] for 15
minutes.
Make sure all of the air is purged from the cooling system,
at least to the level of the block head deck. One coolant
passage plug (highest) can be loosened to act as a vent
while filling the cooling system.
Check for coolant leakage.

If leakage is observed in a capscrew hole, repair the
capscrew hole. Refer to Procedure 001-059 (Cylinder
Head Mounting Capscrew Holes) in Section 1. After
repairing the capscrew hole, repeat the Cylinder Block
Counterbore Procedure from the beginning.
If leakage is observed in any other place besides the

capscrew holes, refer to the NH/NT Counterbore
Troubleshooting and Repair Manual, Bulletin Number
3810450.
If no leaks are found at 68 N•m [50 ft-lb], tighten the

cylinder head capscrews in the sequence shown.
Cylinder Head Mounting Capscrew Holes N14
Check for coolant leakage.

If leakage is observed in a capscrew hole, repair the
capscrew hole. Refer to Procedure 001-059 (Cylinder
Head Mounting Capscrew Holes) in Section 1. After
repairing the capscrew hole, repeat the Cylinder Block
Counterbore Procedure from the beginning.
If leakage is observed in any other place besides the

capscrew holes, refer to the NH/NT Counterbore
Troubleshooting and Repair Manual, Bulletin Number
3810450.
If a capscrew hole(s) was the only leak found and no leaks

are observed after the retest, the repair is complete.
Cylinder Head Mounting Capscrew

Holes (001-059)
Preparatory Steps
Inspect the capscrew bosses for cracks or porosity that
extend into the coolant cavities or that have damaged
threads.
N14 Cylinder Head Mounting Capscrew Holes
Mark all cylinder head capscrew holes that are to be

repaired. Refer to Procedure 001-028.

coolant passages, the areas listed below must be
covered as noted:
• If the cylinder liners are removed, put chip control
plugs, Part Number 3823231, into the lower liner
bores to catch metal chips and dust.
• If the cylinder liners are removed, cover the coolant
passages in the liner cavity, on the exhaust side, with
Damtite, Part Number 3823232, or some type of
formable substance such as modeling clay.
• Cover the push tube openings with masking tape.
If cylinder head capscrew threads in the cylinder block are

stripped or the thread area is cracked, blocks can be
repaired by using a closed end thread insert.
The following kit contains the necessary components
needed to repair cylinder head capscrew holes.
Components included in the capscrew thread repair kit,

Part Number 3376208, are as follows:
Reference
Tool Number Description
Number
Insert (short
1 ST-1272-15
counterbore)
2 3377135 Insert (long counterbore)
3 3376006 Reamer
4 3376007 Tap
5 ST-1272-5 Locator
6 ST-1272-11 Chip removal unit
7 ST-1272-13 Loctite® Primer-T
ST-1272-12 or
8 Retaining compound
3823718
9 ST-1272-9 Stop collar
Repair
Burr removal is necessary for an accurate fixture location.
Remove any burrs from the top deck surface of the
cylinder block.
A flat mill file is very effective for this process.
Align the fixture with the failed capscrew hole.

Install the reamer base plate and the guide bar to the
cylinder block.
Position the guide bar over the capscrew hole to be
repaired.
Using a tapered locator, center the guide bar and the
bushing over the capscrew hole.
Tighten the guide bar and bushing assembly.

Remove the tapered locator.
Ream the failed capscrew hole to the full depth of the hole.
Use a chip removing unit to remove reamer chips from the

capscrew hole.
Set the tap stop collar to the correct height, using the
insert to be installed.
Tap the hole.
It can be necessary to stop, remove the tap, and remove
chips from the hole several times before achieving full
depth.
Remove the tap.

Use a chip removing unit to clean the capscrew hole of
shavings and debris.
WARNING
Clean and flush the newly cut threads with safety solvent.
Use a chip removing unit to clean the capscrew hole of
shavings and debris and allow to dry.
Lightly spray the threads with Loctite® Primer-T and allow
to dry.
Prepare the thread insert for installation.

Put the jam nut on a cylinder head capscrew.
Install the repair insert onto the capscrew until it contacts
the jam nut.
WARNING
Clean and flush the outside diameter of the repair insert
with safety solvent and allow to dry.
Lightly spray with Loctite® Primer-T and allow to dry.
Apply four beads of sealant to the outside diameter of the

closed end thread insert.
The beads of sealant must be approximately 8 mm [1/32
in] wide and 90 degrees apart.
Each bead must be the full length of the external
threaded portion of the insert.
Install and tighten the repair insert.
Loosen the jam nut. Remove the cylinder head capscrew

and jam nut arrangement.
Correct installation will provide 0.00 to 0.50 mm [0.000 to

0.020 in] protrusion above the cylinder block surface.
File the top of the thread repair insert even with the
cylinder head mounting surface.
Make sure the inside portion of the repair insert is clean.

Remove any file shavings or debris.
Before tightening the cylinder head capscrews, allow the

sealant to cure for three hours.
N14 Camshaft End Clearance
Camshaft End Clearance (001-065)

Measure
A condition on CELECT™ and CELECT™ Plus engines
where the engine will not start or is difficult to start can be
caused by excessive clearance between the engine
position sensor and the pickup on the back of the
camshaft gear. This condition prevents the engine
position sensor from sending the necessary signal to the
electronic control module. The excessive clearance can
be caused by a failed thrust bearing on the camshaft. Use
this procedure to measure the camshaft end clearance in-
chassis on CELECT™ and CELECT™ Plus engines without
removing the front gear cover. If the end clearance is
not within the specifications given, the gear cover must
be removed and the cause of the excessive end clearance
repaired.
To measure the camshaft end clearance without removing

the front gear cover, first remove the rocker lever cover.
Loosen the locknut and turn out the adjusting screw on

each injector and valve rocker lever. The overhead load
on the camshaft must be released to allow free movement
of the camshaft.
NOTE: It is not necessary to remove the push rods or
push tubes.
Camshaft End Clearance N14
Remove the inspection plug in the front of the gear cover.

Use a rod against the camshaft gear to push the camshaft
as far as possible towards the rear of the engine.
Setup a dial indicator gauge, Part No. 3376050, and

extension, Part No. ST-537-4, with a magnetic base on the
front of the cylinder head or vibration damper. Place the
tip of the indicator on the face of the camshaft gear
through the gear cover inspection hole.
Set the dial indicator to zero.
Remove the engine position sensor from the rear of the

gear housing.
Use a rod to reach inside the gear housing through the
engine position sensor mounting hole and push the
camshaft gear as far as possible toward the front of the
engine.
NOTE: If access limits make it difficult to push the
camshaft by hand, a threaded bolt (3/4 x 16) can be
threaded into the hole and used as a pushing device
against the back of the cam gear. The capscrew needs to
have the threads ground off, approximately 25.4 mm [1
inch] back from the end. Although the hole is threaded
clear through the gear housing, this will make sure the
capscrew does not contact anything but the camshaft
gear.
Record the measurement on the dial indicator.
Camshaft End Clearance

mm in
0.13 MIN 0.005
0.33 MAX 0.013
If the camshaft end clearance does not meet the above
specifications, the front cover must be removed and the
camshaft thrust plate inspected. Refer to Procedure
001-008.
N14 Gear Cover Accessory Drive Bushing
Adjust the valve and injectors. Refer to Procedure

003-004.
Install the camshaft inspection plug in the gear cover.
Install the engine position sensor.
Gear Cover Accessory Drive Bushing

(001-066)
Preparatory Steps
NOTE: This procedure requires the Accessory Drive
Removal and Installation Kit, Part Number 3824703.
Remove the following:
• Accessory drive pulley. Refer to Procedure 009-004
(Accessory Drive Pulley) in Section 9.
• Accessory drive seal. Refer to Procedure 001-003
(Accessory Drive Seal) in Section 1.
• Fuel pump. Refer to Procedure 005-016 (Fuel Pump)
in Section 5.
• Air compressor. Refer to Procedure 012-014 (Air
Compressor) in Section 12.
• Accessory drive. Refer to Procedure 009-001
(Accessory Drive) in Section 9.
In order to correctly align the oil hole in the bushing with
the hole in the gear cover, scribe a line on the outside
diameter and face of the bushing, centered through the oil
hole.
Scribe another line on the face of the gear cover, centered
through the oil hole.
Remove
Tighten the 1/4 inch socket head capscrew (1) securely on
the bushing driver mandrel (4).
Gear Cover Accessory Drive Bushing N14
Assemble the bushing drive plate (3), thrust bearing (2),

and the accessory drive forcing screws (5).
Position the bushing driver plate (3), thrust bearing (2),

and the accessory drive forcing screw (5) over the block
face where the accessory drive is mounted.
Rotate the accessory drive forcing screw (5) clockwise in
Insert a 1/4 inch Allen wrench in the capscrew (1) to keep

the bushing driver mandrel (4) from rotating when turning
the accessory drive forcing screw (5).
Turn the accessory drive forcing screw (5) clockwise
while holding the bushing driver mandrel (4).
Turn the forcing screw clockwise until the bushing slips

out of the gear cover.
Inspect for Reuse

Measure the gear cover accessory drive bushing bore.
Accessory Drive Bushing Bore I.D.

mm in
54.03 MIN 2.127
54.05 MAX 2.128
NOTE: Replace the gear cover if the bore is not within
specifications or if the bore is cracked or damaged.
Install
Tighten the 1/4 inch socket head capscrew (1) securely on
Insert a bushing over the bushing driver mandrel (4).
Assemble the bushing driver plate (3), thrust bearing (2),

and the accessory drive forcing screw (5).
Align the scribe line on the bushing with the scribe line on
the face of the gear cover.
Position the bushing driver plate (3), thrust bearing (2),

and the accessory drive forcing screw (5) over the block
face where the accessory drive is mounted.
Rotate the accessory drive forcing screw (5) clockwise
into the bushing driver mandrel (4).
NOTE: Make sure the scribe line on the bushing stays
aligned with the scribe line on the face of the gear cover.
NOTE: Make sure the scribe line on the bushing stays

aligned with the scribe line on the face of the gear cover.
Insert a 1/4 inch Allen wrench in the capscrew (1) to keep
the bushing driver mandrel (4) from rotating when turning
the accessory drive forcing screw (5).
Turn the accessory drive forcing screw (5) clockwise
while holding the bushing driver mandrel (4).
Stop turning the accessory drive forcing screw (5) when

the bushing becomes fully seated in the gear cover hole.
CAUTION
Failure to align the bushing oil hole with the hole in
the gear cover will stop oil from circulating through
engine and cause damage to the engine.
Remove the bushing drive mandrel (4) from the gear cover
by turning the accessory drive screw (5)
counterclockwise.
Check the bushing oil hole alignment with the gear cover
oil hole.

the gear cover.
The rod must pass through the oil hole in the bushing and
into the oil supply drilling in the gear cover.
Finishing Steps
Install the following:
• Accessory drive. Refer to Procedure 009-001
(Accessory Drive) in Section 9.
• Air compressor. Refer to Procedure 012-014 (Air
Compressor) in Section 12.
• Fuel pump. Refer to Procedure 005-016 (Fuel Pump)
in Section 5.
• Accessory drive seal. Refer to Procedure 001-003
(Accessory Drive Seal) in Section 1.
• Accessory drive pulley. Refer to Procedure 009-004
(Accessory Drive Pulley) in Section 9.
Operate the engine and check for leaks.
Notes
N14
Section 2 - Cylinder Head - Group 02 Page 2-a
Section 2 - Cylinder Head - Group 02

Section Contents
Page
Cylinder Head ....................................................................................................................................................2-1
Finishing Steps...............................................................................................................................................2-13
Install..............................................................................................................................................................2-11
Leak Test..........................................................................................................................................................2-8
Pressure Test....................................................................................................................................................2-6
Remove............................................................................................................................................................2-3
Cylinder Head Gasket ......................................................................................................................................2-15
General Information.........................................................................................................................................2-15
N14
Page 2-b Section 2 - Cylinder Head - Group 02

N14 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-1
Cylinder Head (002-004)

Preparatory Steps
WARNING
Drain the cooling system. Refer to Procedure 008-018.
Remove the charge air cooler connections or tube.

Remove the crankcase breather. Refer to Procedure
003-001.
003-011.
Remove the air intake manifold assembly. Refer to
Procedure 010-023.
Remove the turbocharger. Refer to Procedure 010-033.

Remove the exhaust manifold. Refer to Procedure
011-007.
Remove the injector wiring harness connectors.

Cylinder Head N14
Page 2-2 Section 2 - Cylinder Head - Group 02
Remove the engine brake if equipped. Refer to Procedure

020-001.
003-009.
Remove the push rods. Refer to Procedure 004-014.
Mark the location and orientation of the valve crossheads.

Remove the valve crossheads.
Remove the fuel supply and the fuel drain tubes.
Remove all the necessary brackets and clamps.
Disconnect the injector wiring at the pass through

connector.
Remove the injector. Refer to Procedure 006-026.

N14 Cylinder Head
Remove the rocker lever housing. Refer to Procedure

003-013.
Remove the two fuel crossover connections and the o-
rings.
Remove
WARNING
This component weighs 23 kg [50 lb or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this assembly.
To prevent increased wear, mark each cylinder head as it
is removed so it can be installed back in its original
location.
Remove the 12 capscrews and washers from each
cylinder head.
Lift the cylinder heads from the block, and remove the
cylinder head gaskets.
CAUTION
To prevent damage to the head gasket surface, put
the cylinder heads on wooden blocks when they are
removed.

Inspect the push rods. Refer to Procedure 004-014.
Cylinder Head N14
Put a clean, lint-free rag into each push rod cavity in the
cylinder block, and plug the overhead oil supply rifle.
Use a gasket scraper to remove heavy dirt and debris from
the head gasket surface of the cylinder block.
WARNING
Use a razor blade scraper and solvent to remove any
remaining material from the cylinder block surface.
WARNING
WARNING
personal injury.
Clean with solvent, and dry with compressed air.
Remove the rags after the cylinder block is cleaned.
WARNING
WARNING
personal injury.
Steam clean the cylinder heads, and dry with compressed
air.
Blow out all capscrew holes, fuel passages, and oil
passages.
N14 Cylinder Head
Use a gasket scraper to remove heavy dirt and debris from

the cylinder head gasket surface and the exhaust manifold
gasket surface.
WARNING
Use a razor blade scraper and solvent to remove any
remaining material from the cylinder head gasket surface
and the exhaust manifold gasket surface.
WARNING
WARNING
personal injury.
Clean with solvent, and dry with compressed air.
Clean the rocker lever housing gasket surface on each

cylinder head.
Inspect the cylinder heads for cracks or damage.
If a crack in a cylinder head is suspected, pressure test
the cylinder head.
Cylinder Head N14
Inspect the valves for indications of leakage or burning.

If indications of leakage or burning are found, the valves
and the seats must be resurfaced. Refer to the N14 Shop
Pressure Test
Mark each valve as it is removed to identify its location in
the cylinder head.
Use valve spring compressor stand, Part Number
ST-1022, and valve spring compressor plate, Part Number
ST-1026, to remove the valves.
Install two injector sleeve holding tools, Part Number

ST-1179, into each cylinder head.
The following components are included in the injector
sleeve holding:
• Hexagon head capscrew
• Flat washer
• Anvil, Part Number ST-1179-4
• Mandrel, Part Number ST-1179-2
• Hexagon head capscrew.
Tighten the injector sleeve holding tool capscrews.

Torque Value: Step1 5 N•m [ 45 in-lb ]
Step2 10 N•m [ 90 in-lb ]
Step3 15 N•m [ 130 in-lb ]
N14 Cylinder Head
Install the cylinder head in hydrostatic tester, Part Number

ST-1012, and hydrostatic tester adapter plate, Part
Number ST-1013.
Connect a regulated air supply hose to the test fixture

plate.
Apply 280 kPa [40 psi] air pressure.
Use a hoist to place the cylinder head in a tank of warm
water heated to 60°C [140°F].
Completely submerge the cylinder head in the water.

Inspect for air bubbles rising from the water.
If air bubbles are seen, replace or rebuild the cylinder
head. Refer to the N14 Shop Manual, Bulletin 3810487 for
rebuild procedures.
Remove the test equipment.

Cylinder Head N14
Install the valves in their original positions in the cylinder

head and the valve springs in the cylinder head as follows:
A. Valve
B. Valve Spring Guide and Stem Seal
C. Valve Spring
D. Valve Spring Retainer
E. Collets
Leak Test
Test the cylinder head for damage.
Set the head down with the intake ports on the bottom.
Pour fuel into the exhaust port until it is full.
Set the container of fuel down and start the timer.
If a drop of fuel drips or runs down the face of the head

within 30 seconds, the exhaust valves and the seats must
be resurfaced. Refer to the N14 Shop Manual, Bulletin
3810487.
If a drop of fuel has not run down the face of the head in
30 seconds, the exhaust side is okay.
Drain the fuel from the exhaust side of the head.

Turn the head over so the exhaust port is on the bottom.
Pour fuel into the intake ports until full.
Set the container of fuel down and start the timer.
N14 Cylinder Head
If a drop of fuel drips or runs down the face of the head

within 30 seconds, the intake valves and the seats must
be resurfaced. Refer to the N14 Shop Manual, Bulletin
3810487.
If a drop of fuel has not run down the face of the head in
30 seconds, the intake side is okay.
WARNING
CAUTION
Do not use caustic or acid solutions to clean the
cylinder head capscrews.
Use a petroleum-based solvent to clean the capscrews.
Clean the capscrews thoroughly with a wire brush, with a
wire wheel (soft), or use a non-abrasive bead blast to
remove deposits from the shank and the threads.
Inspect the cylinder head capscrews for damaged

threads, corroded surfaces, or a reduced diameter
(because of capscrew stretching).
Do not use a capscrew that has damaged threads or a
reduced diameter from having been stretched.
Do not use cylinder head capscrews under the following

conditions:
• Visible corrosion or pitting exceeds 1 sq. cm [0.155
sq. in] in area.
For example, acceptable is 0.952 x 0.952 mm [3/8 x
3/8 in] and not acceptable is 12.7 x 12.7 mm [½ x ½
in]
• Visible corrosion or pitting exceeds 0.12 mm [0.005
in] in depth.
Cylinder Head N14
• Visible corrosion or pitting is located within 3.2 mm

[1/8 in] of the fillet.
• Visible corrosion or pitting is located within 3.2 mm
[1/8 in] of the threads.
Using flange head capscrews with the torque plus angle

method of installation places the capscrew beyond the
yield point, and permanently stretches the capscrew at
each use. These capscrews can be reused throughout the
life of the engine unless the capscrew exceeds the
specified free length. The capscrew free length must be
checked to avoid bottoming out in the cylinder block
during installation.
Use capscrew length gauge, Part Number 3823546, to
check capscrew free length.
The capscrews can be checked by using a set of calipers

if capscrew length gauge, Part Number 3823546, is not
available.
The maximum allowable free length (dimension `X'),
measured from the bottom of the flange to the end of the
capscrew, is 185.6 mm [7.310 in].
To check the capscrew free length, place the head of the

capscrew in the appropriate slot with the flange against
the base of the slot.
Capscrew length must be checked without the hardened
washer.
N14 Cylinder Head
If the end of the capscrew touches the foot of the gauge,

the capscrew is too long and must be discarded.
The capscrew can be used again if there is clearance

between the end of the capscrew and the bottom base of
the tool.
Immediately after cleaning and inspecting, apply a film of

clean engine lubricating oil to capscrews that are to be
used again.
Install
Install new gaskets on the dowel pins in the cylinder block.
Make sure the side of the gasket marked "TOP" is up.
Cylinder Head N14
Install the cylinder heads in their original locations over

the dowel pins.
Use clean 15W-40 oil to lubricate the cylinder head

capscrews and both sides of the flat washers.
Allow the excess oil to drain from the threads.
Install 12 capscrews and washers in each cylinder head.
Complete the following steps to tighten the capscrews to

the specified torque values in the sequence shown:
Step2 298 N•m [ 220 ft-lb ]
Step3 Rotate 90 degrees.
Not less than one flat, and not more than two flats.
Repeat the tightening sequence to install each cylinder
head.
The markings on the head of the flange head capscrews

serve as an aid during installation.
After tightening the capscrew to 298 N•m [220 ft-lb], mark
the cylinder head adjacent to one of the two single marks
"A" or "B" on the capscrew head.
N14 Cylinder Head
After all 12 capscrews on one head have been tightened

to 298 N•m [220 ft-lb], they must be rotated in the
tightening direction an additional 90 degrees. Rotate the
capscrew until the mark on the cylinder head is between
the next two marks joined by an arc (more than one flat
and less than two flats).
When using torque plus angle, the tolerance on the 90
degree angle of rotation is one to two flats (90°± 30°). If
the capscrew is rotated beyond two flats, do not loosen
the capscrew.
The clamp load is still acceptable; however, rotating the
capscrew beyond two flats causes additional stretch and
reduces the number of reuses.
With correct tightening, the capscrew can typically be
reused for the life of the engine.
Finishing Steps
Use new o-rings and install the fuel crossover
connections.
Install the rocker lever housings. Refer to Procedure
003-013.
Install the injectors and the hold down clamps. Refer to

Procedure 006-026.
Install the CELECT™ injector solenoid wire connector to
the pass through connector.
Install the fuel supply and the fuel drain tubes.

Install all the brackets and the clamps.
Install the valve crossheads in their original location and
orientation.
Lubricate the valve stems with clean 15W-40 oil.
The large pocket of the crosshead goes toward the
exhaust side.
Cylinder Head N14
Use a wire gauge to check the clearance between the

crosshead and the valve spring retainer. The clearance
must be a minimum of 0.65 mm [0.025 in].
Install the push rods into their original location. Refer to

Procedure 004-014.
Install the rocker lever assemblies. Refer to Procedure
003-009.
Adjust the valves and the injectors. Refer to Procedure
003-004.
On CELECT™ engines, connect the injector wiring

harness connector.
Install the exhaust manifold. Refer to Procedure 011-007.

N14 Cylinder Head Gasket
Install the turbocharger. Refer to Procedure 010-033.
Install and adjust the brakes, if applicable. Refer to

Procedures 020-001.
Install the air intake manifold assembly. Refer to
Procedure 010-023.
Install the rocker lever covers with the original reusable
gaskets if they are not damaged. Refer to Procedure
003-011.
Install the charge air cooler connections or tubes.
Install the crankcase breather. Refer to Procedure
003-001.
Cylinder Head Gasket (002-021)

General Information
NOTE: If the cylinder head gasket(s) is being replaced
because of coolant, lubricating oil, or compression leaks,
use the following procedure:
Define the type of leak as follows:

• Compression (Refer to Procedure 008-019).
• Coolant leak from block upper deck/counterbore
area (Refer to Procedure 001-058-014).
• Lubricating oil (refer to the following).
Cylinder Head Gasket N14
Remove the cylinder head(s). Refer to Procedure

002-004-002.
Clean and inspect the cylinder head and the cylinder
block. Refer to Procedures 002-004-006 and 002-004-007,
respectively.
Inspect the cylinder head(s) for surface damage, flatness,

and dowel hole depth.
Inspect the cylinder block for surface damage and
flatness.
Repair the damaged surface. Refer to the Alternative
Repair Manual, Bulletin No. 3379035.
Check the cylinder liner protrusion. Refer to Procedure
001-028-026.
Inspect the gasket grommets for defects.
Install the new cylinder head gasket(s).
Install the cylinder head(s). Refer to Procedure

002-004-026.
N14 Cylinder Head Gasket
Fill the cooling system. Refer to Procedure 008-018-028.

Fill the engine with clean 15W-40 lubricating oil if the
cylinder liners were removed. Refer to Procedure
007-025-028.
Operate the engine until the coolant temperature is above
82°C [180°F], and check for leaks.
Cylinder Head Gasket N14
Notes
N14
Section 3 - Rocker Levers - Group 03 Page 3-a
Section 3 - Rocker Levers - Group 03

Section Contents
Page
Crankcase Breather (External) ..........................................................................................................................3-2
Clean................................................................................................................................................................3-2
Inspect for Reuse..............................................................................................................................................3-3
Install................................................................................................................................................................3-3
Remove............................................................................................................................................................3-2
Overhead Set .....................................................................................................................................................3-3
Adjust...............................................................................................................................................................3-5
CELECT™ or CELECT™ Plus..........................................................................................................................3-5
STC............................................................................................................................................................. 3-11
Finishing Steps...............................................................................................................................................3-14
Rocker Lever Assembly ..................................................................................................................................3-15
Clean..............................................................................................................................................................3-16
Install..............................................................................................................................................................3-18
Remove.......................................................................................................................................................... 3-15
Rocker Lever Cover .........................................................................................................................................3-20
Install..............................................................................................................................................................3-21
Remove.......................................................................................................................................................... 3-20
Rocker Lever Housing .....................................................................................................................................3-22
Clean..............................................................................................................................................................3-25
Install..............................................................................................................................................................3-26
Remove.......................................................................................................................................................... 3-22
Service Tools ....................................................................................................................................................3-1
Rocker Levers...................................................................................................................................................3-1
N14
Page 3-b Section 3 - Rocker Levers - Group 03

N14 Service Tools
Section 3 - Rocker Levers - Group 03 Page 3-1
Service Tools
Rocker Levers
Repair Location.

Torque Wrench Adapter
Use to torque the lock nut without disturbing the setting of the valve,
ST-669 injector, or crosshead.
Jumper Tube Removal Extractor

Use to remove the water manifold tube and plug.
3823819
Cam Box Dowel Extractor

Use to pull dowel pins and ring dowels from rocker housing assembly.
3823821
Crankcase Breather (External) N14
Page 3-2 Section 3 - Rocker Levers - Group 03
Crankcase Breather (External)

(003-001)
Remove
Loosen the hose clamp at the breather vent tube.
Remove the tube support bracket capscrew and the
bracket.
Remove the tube and the hose from the engine.
Disassemble the breather tube, vapor barrier, and rubber

gasket.
Clean
Use solvent to clean the inside of the crankcase breather
tube, and dry with compressed air.
Use air pressure to blow through the vent tube.
Replace the vent tube if it is clogged or dented.
Use solvent to clean the breather tube, vapor barriers, and

rubber grommet. Dry with compressed air.
N14 Overhead Set
Inspect for Reuse

Inspect the breather tube, the baffle plate, the rubber
grommet, and the rocker lever cover for cracks or other
damage. Replace if necessary.
Install
Assemble the breather vent tube as shown.
Install the breather vent tube onto the breather tube, and
tighten the hose clamps.
Install and tighten the tube support brackets and
capscrews.
Overhead Set (003-004)

General Information
WARNING
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
Overhead Set N14
NOTE: Read the entire procedure for overhead

adjustment before attempting to perform this operation.
Valves and injectors must be correctly adjusted for the
engine to operate efficiently. Valve and injector
adjustment must be performed using the values listed in
this section.
Table 1, CELECT™ Plus Valve and Injector
Adjustment Values
CELECT™ Plus Injector Adjustment: Bottom plunger,
release, and bottom timing plunger. Back out two
flats (120 degrees).
mm in
Intake Valve 0.35 0.014
Exhaust Valve 0.68 0.027
Engine brake 0.58 0.023
The preferred method of performing normal valve and step

timing control (STC) injector overhead adjustment is to
use the outer base circle (OBC) method, where the crush
of the injector plunger to cup is set by tightening the
injector rocker lever adjusting screw to a prescribed
torque. If the STC injectors have been removed for
cleaning and calibration, or if new ReCon injectors are
being installed, use the OBC overhead set procedure.
Table 2, STC Valve and Injector Adjustment Values
STC Injector Adjustment (OBC Method): Torque to 14
N•m [125 in-lb].
mm in
Intake Valve 0.35 0.014
Exhaust Valve 0.68 0.027
Engine brake 0.58 0.023
Preparatory Steps
• Disconnect the batteries. Refer to Procedure
013-009
• Remove the rocker lever covers. Refer to Procedure
003-011
• Remove the engine brakes, if applicable. Refer to
Procedure 020-001.
N14 Overhead Set
Adjust
CELECT™ or CELECT™ Plus
All overhead (valve and injector) adjustments must be
made when the engine is cold (any stabilized coolant
temperature at 60°C [140°F] or below).
NOTE: After an engine rebuild or any major repair where

the injector setting must be disturbed, set all the valves
and injectors.
CELECT™ Plus injectors will provide acceptable engine
performance with lash (OBC) anywhere from 0.51 to 2.04
mm [0.020 to 0.080 in]. The procedure for CELECT™ Plus
injector reset will produce lash between 0.51 and 0.74 mm
[0.020 and 0.029 in]. Under normal operation, there is
never be a reason to adjust CELECT™ Plus injectors for
excessive lash between scheduled maintenance intervals.
Tighten the rocker lever shaft capscrews.

Tighten the rocker lever housing capscrews in the

sequence shown (1 through 6).
sequence shown (7 and 8).
Torque Value:
1 Through 6 115 N•m [ 85 ft-lb ]
Torque Value:
7 and 8 47 N•m [ 35 ft-lb ]
Overhead Set N14
Tighten the injector hold down capscrews.

WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The valve set marks are located on the accessory drive
pulley. The marks align with a pointer on the gear cover.
Use the accessory drive shaft to rotate the crankshaft.
The crankshaft rotation is clockwise when viewed from

the front of the engine.
The cylinders are numbered from the front end of the
engine.
The engine firing order is 1-5-3-6-2-4.
Each cylinder has three rocker levers. The rocker lever

nearest to the center of the housing is the intake lever.
Exhaust rocker lever (1)
Injector rocker lever (2)
Intake rocker lever (3)
The two levers closest to the center of each rocker housing
are the intake rocker levers. The two levers closest to the
ends of the rocker housing are the exhaust levers.
N14 Overhead Set
The valves and the injectors on the same cylinder are

adjusted at the same index mark on the accessory drive
pulley.
One pair of valves and one injector are adjusted at each
pulley index mark before rotating the accessory drive to
the next index mark.
Two crankshaft revolutions are required to adjust all of the
valves and injectors.
Table 3, CELECT™ Plus Engines
Injector and Valve Adjustment Sequence
Bar Engine in Pulley Set Cylinder
Direction of Position Injector Valve
Rotation
Start A 1 1
Advance to B 5 5
Advance to C 3 3
Advance to A 6 6
Advance to B 2 2
Advance to C 4 4
Firing Order: 1-5-3-6-2-4
Rotate the accessory drive in the direction of engine

rotation. The accessory drive will rotate clockwise , on a
right hand engine, when looking at the front of the engine.
Align the "A" or "1-6 VS" mark on the accessory drive
pulley with the pointer on the gear cover.
Check the valve rocker levers on cylinder number 1 to see

if both valves are closed.
Both valves are closed when both rocker levers are loose
and can be moved from side to side. If both valves are
not closed, rotate the accessory drive one complete
revolution; and align the "A" mark with the pointer again.
If the valve rocker lever adjusting screws have been
loosened and not yet adjusted, watch the valve push
tubes as the engine rolls upon the "A" mark. Both valve
push tubes will have moved to the downward (valve
closed) position if the engine is on the correct stroke.
Overhead Set N14
WARNING
WARNING
Clean the timing plunger to remove the varnish from the
top edge.
Apply a non-chlorinated carburetor cleaner (Pyroil or
equivalent) using a narrow bore orifice or extension tube
of 2 mm [0.79 in] maximum outside diameter, into the
injector weep hole.
If the entire overhead is to be reset, every injector is to be
sprayed at this time.
Loosen the injector adjusting screw lock nut on cylinder

number 1. Bottom the injector timing plunger by tightening
and loosening the adjusting screw three or four times to
remove the fuel.
When removing the excess fuel, do not apply crush to the
injector timing plunger by further tightening the adjusting
screw after the plunger is bottomed.
CAUTION
Do not apply crush to the injector timing plunger by
further tightening the adjusting screw. Doing so will
result in an incorrect injector lash setting and can
cause excessive injection train wear.
Tighten the adjusting screw on the injector rocker lever
until the timing plunger just touches bottom.
N14 Overhead Set
CAUTION
After bottoming the CELECT™ Plus injector timing
plunger, make certain to back out the adjusting screw
two flats (120 degrees) or damage to the injector will
result.
Back out the adjusting screw on the injector rocker lever
two flats (120 degrees).
Two flats will provide 0.56 mm [0.022 in] lash. The
specification is 0.50 to 0.74 mm [0.020 to 0.029 in] lash.
Hold the adjusting screw and tighten the lock nut.

After setting the injector on a given cylinder, set the valves

on the same cylinder.
With the "A" set mark aligned with the pointer on the gear
cover and both valves closed on cylinder number 1, loosen
the lock nuts on the intake and the exhaust valve adjusting
screws.
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specifications
Intake Exhaust
0.35 mm [0.014 in] 0.68 mm [0.027 in]
Insert the feeler gauge between the top of the crosshead

and the rocker lever pad.
Overhead Set N14
Two different methods for establishing valve lash

clearance are described below. Either method can be
used; however, the torque wrench method has proven to
be the most consistent.
• Torque Wrench Method: Use the inch pound torque
wrench, Part Number 3376592, and tighten the
adjusting screw.
Torque Value: 0.68 N•m [ 6 in-lb ]
• Feel Method: Tighten the adjusting screw until a
slight drag is felt on the feeler gauge.
Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened.
Torque Value:
Without Torque 68 N•m [ 50 ft-lb ]
Wrench Adapter:
Torque Value:
With Torque 54 N•m [ 40 ft-lb ]
Wrench Adapter,
Part Number
ST-669:
After tightening the lock nut to the correct torque value,

check to make sure the feeler gauge will slide backward
and forward between the crosshead and the rocker lever
with only a slight drag.
If using the feel method, attempt to insert a feeler gauge

that is 0.03 mm [0.001 in] thicker between the crosshead
and the rocker lever pad. The valve lash is not correct
when a thicker feeler gauge will fit.
N14 Overhead Set
After adjusting the injector on cylinder number 1 and the

valves on cylinder number 1, rotate the accessory drive;
and align the next valve set mark with the pointer.
Adjust the appropriate injector and valves following the

Injector and Valve Adjustment Sequence in Table 4.
Repeat the process to adjust all injectors and valves
correctly.
Table 4, CELECT™ Plus Engines
Rotation
Start A 1 1
Advance to B 5 5
Advance to C 3 3
Advance to A 6 6
Advance to B 2 2
Advance to C 4 4
STC
Loosen the lock nut on the injector adjusting screw on the
cylinder number 5.
Overhead Set N14
CAUTION
An overtightened setting on the injector adjusting
screw will produce increased stress on the injector
train and the camshaft injector lobes, which can result
in engine damage.
Use a dial type torque wrench to tighten the injector rocker
lever adjusting screw to the specified torque. If the screw
causes chattering during setting, repair the screw and
lever as required.
Hold the torque wrench in a position that allows the direct
view of the dial. This is to make certain that the reading
on the dial is accurate.
Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened.
Tighten the lock nut.
With the “B” mark aligned with the pointer on the gear
cover and both valves closed on cylinder number 5, loosen
the locknuts on the intake and the exhaust valve adjusting
screws.
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specifications

mm in
Intake 0.35 NOM [0.014]
Exhaust 0.68 NOM [0.027]
Insert the feeler gauge between the top of the crosshead
and the rocker lever nose.
N14 Overhead Set
Two different methods for establishing valve lash

clearance are described below. Either method can be
used: however, the torque wrench method has proven to
be the most consistent.
Torque Wrench Method
• Use the inch-pound torque wrench, Part Number
3376592, or equivalent, (normally used to set
preload on STC injectors), and tighten the adjusting
screw.
Torque Value: 0.56 to 0.68 N•m [ 5 to 6 in-lb ]
Feel Method
• Hold the adjusting screw in this position. The
adjusting screw must not turn when the locknut is
tightened. Tighten the locknut.
With torque wrench adapter, Part Number 3163196,
or equivalent:
Without torque wrench adapter:
After tightening the locknut to the correct torque value,

check to make sure the feeler gauge will slide backward
and forward between the crosshead and the rocker lever
with only a slight drag.
If using the feel method, attempt to insert a feeler gauge

that is 0.03 mm [0.001 in] thicker between the crosshead
and the rocker lever pad. The valve lash is not correct
when a thicker feeler gauge will fit.
Overhead Set N14
After adjusting the injector on cylinder number 5 and the

valves on cylinder number 5, rotate the accessory drive.
Align the next valve set mark with the pointer.
Adjust the appropriate injector and valves following the

Injector and Valve Adjustment Sequence in Table 5.
Repeat the process to adjust all injectors and valves
correctly.
Table 5, STC Engine Outer Base Circle (OBC)
Rotation
Start B 5 5
Advance to C 3 3
Advance to A 6 6
Advance to B 2 2
Advance to C 4 4
Advance to A 1 1
Finishing Steps
• Install the rocker lever covers. Refer to Procedure
003-011
• Install the engine brakes, if applicable. Refer to
Procedure 020-001
• Connect the batteries. Refer to Procedure 013-009
N14 Rocker Lever Assembly
Rocker Lever Assembly (003-009)

Remove
003-011-002.
Remove the engine brake. Refer to Procedure
020-001-002.
Loosen the valve and injector adjusting screw lock nuts on

each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
CAUTION
Do not attempt to remove or install the rocker lever
shaft assemblies without resetting the lash.
Remove the rocker lever shaft capscrews and the rocker

lever shaft assemblies.
NOTE: To prevent increased wear, mark each rocker lever
as it is removed so it can be installed back in its original
location.
Remove the rocker levers from the shaft.

Remove the lock nuts and the adjusting screws from the
rocker lever.
NOTE: To prevent increased wear, mark each adjusting
screw as it is removed so it can be installed back in its
original rocker lever.
Rocker Lever Assembly N14
Clean
WARNING
When using a steam cleaner, wear protective clothing,
and safety glasses or a face shield. Hot steam can
cause serious personal injury.
Use steam or solvent to clean the rocker lever shaft. Dry
with compressed air.
Be sure to blow out the oil passages.
Inspect for Reuse

Visually inspect the shaft for cracks or damages.
Measure the rocker lever shaft's outside diameter in the
bushing wear area.
Rocker Lever Shaft O.D.

mm in
34.82 MIN 1.3710
34.86 MAX 1.3725
Replace the rocker lever shafts as necessary.
Use steam or solvent to clean the rocker levers, and dry

with compressed air.
NOTE: Make sure to blow out the oil passages.
Visually inspect the rocker levers for cracks or unusual

wear and thread condition.
Measure the rocker lever bushing bore inside diameter.
Rocker Lever Bushing I.D. (Installed)

mm in
34.89 MIN 1.3735
34.96 MAX 1.3765
NOTE: Replace the rocker lever bushings which are worn
beyond the maximum limit. Refer to the Engine Shop
Manual for detailed instructions.
Use steam or solvent to clean the rocker lever adjusting

screw and nuts.
Visually inspect the adjusting screws and the nuts for

distorted threads.
Visually inspect the adjusting screw. The contact area

must be smooth with an even seating pattern.
If parallel scratches are found in the contact area, the
adjusting screw must be replaced. This condition is
normally found with worn push rods that will also require
replacement.
Rocker Lever Assembly N14
Install
Install the adjusting screw and the lock nut in each rocker
lever. Do not tighten the lock nuts.
Install the exhaust (1), injector (2), and intake (3) rocker
levers onto the shaft.
The two levers closest to the center of the rocker housing
are the intake valve rocker levers. The levers closest to
the end of the rocker housing are the exhaust valve rocker
levers.
CAUTION
If the adjusting screws protrude beyond the maximum
listed below, the push rods can be damaged when the
rocker shaft capscrews are tightened. Do not attempt
to install the rocker lever shaft assemblies again
without resetting the lash.
Loosen the rocker lever adjusting screws so there is a
maximum of 32 mm [1.250 inch] from the top surface of
the lever and the ball end of the adjusting screw.
Place the rocker lever assembly over the dowel pin and
dowel ring located in the rocker housing.
NOTE: Do not damage the dowel pin and ring located in
the rocker housing.
Make sure the push rods are in the cam follower sockets
and align the push rods with the injector and valve rocker
lever adjusting screws.
Alternately tighten the rocker shaft capscrews:
• Tighten to 54 N•m [40 ft-lb]

003-004-029.
Install and adjust the engine brakes. Refer to Procedures

020-001-026 and 020-001-029, respectively.

003-011-026.
Rocker Lever Cover N14
Rocker Lever Cover (003-011)

Remove
Remove the hose from the crankcase breather.
Remove the ten capscrews from each rocker lever cover.
Remove the rocker lever covers.
WARNING
WARNING
personal injury.
NOTE: The rocker lever cover gaskets are reusable. Do
not damage the gasket when removing or cleaning.
NOTE: Do not use solvent to clean the rocker lever cover
gaskets. Solvent will damage the o-ring material and
cause them to swell.
Remove the crankcase breather element, if used, and the
oil filler cap. Refer to Procedure 003-001.
Remove the gaskets.
Steam clean the covers, and dry with compressed air.
WARNING
WARNING
personal injury.
Steam clean the reusable gaskets, dry with compressed
air, and check for cuts or deformations in the silicone
bead.
Replace the gaskets if there are any cuts, abrasions, or
deformations in the silicone bead. Check to see if the
nylon carrier is cracked or broken. Replace if necessary.
N14 Rocker Lever Cover
Inspect each cover for cracks or damage and replace if

necessary.
Install
NOTE: The rocker lever cover gaskets are reusable. Do
not replace the gaskets unless they are damaged.
Install the rocker lever cover gasket onto each rocker lever
housing. The tabs at each end must point down toward
the rocker lever housing.
Install the rocker lever covers on the rocker lever

housings.
Install the ten capscrews and washers in each rocker lever
cover.
Tighten the capscrews in each rocker lever cover in the

sequence shown.
Rocker Lever Housing N14
Install the crankcase breather tube, if used, and the oil

filler cap. Refer to Procedure 003-001.
Install the hose on the crankcase breather.
Tighten the hose clamp.
Rocker Lever Housing (003-013)

Remove
Drain the cooling system. Refer to Procedure
008-018-005.
003-011-002.
Remove the engine brake. Refer to Procedure
020-001-002.
Release the fan drive belt tension.

Remove the engine lifting brackets if the rocker lever
housings are being replaced. Refer to Procedure
016-001-002.
Remove the fan bracket brace between the fan bracket
and the lifting bracket.
Loosen the valve and injector adjusting screw lock nuts on

each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
CAUTION
Do not attempt to remove or install the rocker lever
shaft assemblies without resetting the lash.
N14 Rocker Lever Housing

003-009-002.
housing as it is removed so it can be installed back in its
original location.
Remove the crossheads. Make sure to mark them

appropriately so they can be installed in the same location
and orientation during the installation procedure.
NOTE: Excessive crosshead wear can result if the
crossheads are not installed in their original locations.
The larger hole on the underside of the crosshead must
be oriented toward the exhaust side of the engine.
Disconnect the injector solenoid leads from the pass

through connector in the rocker lever housing.
Remove the injector hold down clamp capscrew.

Remove the injector hold down clamp.
Remove the water manifold tube clamps. Use jumper tube

removal tool, Part No. 3823819, to push or pry the
adjacent water tubes into the rocker lever housing cavity.
For example, the tube between housing No. 1 and No. 2
must be pushed into housing No. 2. The tube between
housing No. 2 and No. 3 must be pushed into housing No.
3.
Remove the coolant thermostat housing from the front

rocker lever housing. Refer to Procedure 008-014-002.
Remove the rocker lever housing mounting capscrews.

housing as it is removed so it can be installed back in its
original location.
Remove the rocker lever housings.

Remove the gaskets.
NOTE: On CELECT™ engines while handling the rocker
lever housings, protect the wiring harness pass through
connectors. Do not subject the pass through connectors
to impact forces and do not rest the housing on the face
with the pass through connectors.
Clean
Remove the o-ring, o-ring plug, and water tube from the
water manifold with jumper tube removal tool, Part No.
3823819.
Inspect the o-rings, o-ring plugs, and water tubes. Replace

if necessary.
NOTE: Do not remove the rocker shaft dowel pins, dowel

rings, or brass cup plug for cleaning.
Steam clean the rocker lever housings.
NOTE: Make sure the oil supply hole is free of dirt or other
deposits.
Inspect for Reuse

Visually inspect the housings for cracks or damage, and
replace if necessary.
Visually inspect the capscrew holes for damaged threads.
If threads are damaged, refer to the Alternative Repair
Manual, Bulletin No. 3379035, for thread repair
instructions.
Visually inspect the rocker lever shaft dowel rings (1) and
the dowel pins (2). Replace if necessary.
Use cam box dowel extractor, Part No. 3823821, to
remove the dowel pins and dowel rings.
Install
Install two o-rings (1) on each of the two water tubes (2).
Install one o-ring (1) on each of the two water plugs (3).
Install the o-rings on the water tubes and plugs.
Apply soap to the o-rings on the tubes and plugs.
Install the water tubes (A) in the front of the No. 2 and No.
3 rocker lever housings. Install the plugs (B) in the front to
the No. 1 rocker lever housing and in the rear of the No.
3 rocker lever housing.
Install new rocker lever housing gaskets onto the cylinder

heads.
Install the rocker lever housings.

sequence shown (1 thru 6).
sequence shown (7 and 8).
Use jumper tube removal tool, Part No. 3823819, to slide

the two water tubes into the adjacent water manifold.
Install the two water tube retainer clamps.
Install and tighten the retainer clamp capscrews.
Install the injectors.
Install the wiring harness pass through. Tighten the 5/16-

inch pass through mounting capscrew.
WARNING
The injector must be fully seated before installing the
hold down clamp. The hold down clamp can not pull
the injector into the bore. Engine damage can occur
if the injector is not fully seated.
Install the hold down clamp capscrew.
Take care to route the injector solenoid leads to avoid

contact with the valve and injector push tubes.
Connect the injector solenoid wiring to the rocker lever

housing pass through.
Install the valve crossheads.
CAUTION
housing capscrews are tightened. Do not attempt to
install the rocker lever shaft assemblies again without
resetting the lash.

003-009-026.

003-004-029.
Install the coolant thermostat housing. Refer to Procedure

008-014-026.
Connect the wiring harness.
Install and adjust the engine brakes. Refer to Procedures

020-001-026 and 020-001-029, respectively.

003-011-026.
Install the engine lifting brackets. Refer to Procedure

016-001-026.
Install the fan bracket brace between the fan bracket and
the lifting bracket.
Tighten the fan drive belt. Refer to Procedure
008-002-026.
Fill the cooling system. Refer to Procedure 008-018-028.

Notes
N14
Section 4 - Cam Followers/Tappets - Group 04 Page 4-a
Section 4 - Cam Followers/Tappets - Group 04

Section Contents
Page
Cam Follower Assembly ...................................................................................................................................4-2
Assemble..........................................................................................................................................................4-6
Clean................................................................................................................................................................4-4
Disassemble.....................................................................................................................................................4-3
Install................................................................................................................................................................4-7
Remove............................................................................................................................................................4-2
Push Rods or Tubes .........................................................................................................................................4-9
Install..............................................................................................................................................................4-10
Remove............................................................................................................................................................4-9
Service Tools ....................................................................................................................................................4-1
Cam Followers/Tappets.....................................................................................................................................4-1
N14
Page 4-b Section 4 - Cam Followers/Tappets - Group 04

N14 Service Tools
Section 4 - Cam Followers/Tappets - Group 04 Page 4-1
Service Tools
Cam Followers/Tappets
Repair Location.

Expansion Plug Driver
Use to install a cup plug into the end of the cam follower shaft.
3376813
Cam Follower Assembly N14
Page 4-2 Section 4 - Cam Followers/Tappets - Group 04
Cam Follower Assembly (004-001)

Remove
003-011-002.
Remove the C-Brake, if equipped. Refer to Procedure
020-001-002.
003-009-002.
Remove the push rods. Refer to Procedure 004-014-002.
Remove the fuel pump. Refer to Procedure 005-016-002.
Remove the air compressor (if used). Refer to Procedure
012-014-002.
Remove the accessory drive. Refer to Procedure
009-001-002.
NOTE: The fuel pump, air compressor, and accessory
drive can be removed as an assembly.
Remove the cam follower housing assemblies as follows:

• Remove the six capscrews and studs from each cam
follower housing.
NOTE: Record the position of the studs prior to
removal.
• Remove the cam follower housings and gaskets.
NOTE: To prevent increased wear, mark the cam follower
housing assemblies as they are removed so they can be
installed back into their original location on the block.
• Measure and record the thickness of the gaskets

used between each cam follower housing and the
block.
NOTE: The thickness of the gaskets controls the
injection timing.
• Discard the gaskets.
N14 Cam Follower Assembly
Disassemble
Remove the two locking screws.
NOTE: Each cam follower housing assembly consists of
two shaft assemblies secured in a common center support
with two locking screws.
Remove the two cup plugs from the housing. Refer to the
Engine Shop Manual.
CAUTION
Do not push the cup plug through the cam follower
lever shaft bores. The bores will be damaged.
Use expansion plug driver, Part No. 3376813, and a mallet
to remove the cup plugs. Push the cup plug and the shafts
through one end of the housing until the cup plug on the
opposite end of the housing is pushed from the housing
bore.
Push the shafts the opposite direction through the

housing until the cup plug on the other end of the housing
is pushed from the housing bore.
Remove the shafts and the cam follower levers from the
housings.
NOTE: To prevent increased wear, mark the cam follower
shafts and the levers as they are removed so they can be
installed back into their original positions in the housing.
Clean
Clean the cam follower parts with solvent, and dry with
compressed air.
Clean the cam follower shafts with solvent, and dry with
compressed air.
Make sure the oil drillings are not restricted or plugged.
Inspect for Reuse

Visually inspect the cam follower housings for cracks or
damage.
Visually inspect the locking screw holes for damaged or
distorted threads.
Visually inspect the cam follower shafts for scoring or

damage.
Visually inspect the locking screw holes in each shaft. The
grooves must be clean and not damaged.
Visually inspect the cam followers for cracks or other

damage.
Measure the cam follower roller side clearance.
Roller Side Clearance

mm in
0.23 MIN 0.009
0.61 MAX 0.024
NOTE: If the roller side clearance is not within these
specifications, the roller must be replaced. Refer to the
Engine Shop Manual.
Use a dial indicator to measure the cam follower to roller

pin clearance.
Roller to Pin Clearance

mm in
0.08 MIN 0.003
0.20 MAX 0.008
NOTE: If the roller pin clearance is not within these
specifications, the roller and the pin must be replaced.
Refer to the Engine Shop Manual.
Visually inspect the rollers for flat spots, restriction of

rotation, or other damage.
NOTE: Refer to the Engine Shop Manual for further repair
or rebuild of the cam follower lever assemblies.
Visually inspect the sockets for excessive wear or

damage.
A good even seating pattern must be seen when
inspecting the cam follower socket.
When parallel grooves and scratches are observed or the
contact area extends into the oil hole chamfer of the
socket, the worn socket must be replaced.
NOTE: If excessive wear or damage is found in the
sockets, Refer to Procedure 004-014-007 to inspect the
push rods. Do not use push rods with worn balls in cam
followers with new sockets.
NOTE: The N14 cam follower sockets are identified by two

grooves 180 degrees apart from one another.
Use clean 15W-40 oil to lubricate the cam follower

sockets.
Assemble
bushingless cam followers and cam follower shafts.
Install the levers and the shafts in the housings back into
their original locations.
Install the cup plugs in the housings as follows:

• Install two temporary capscrews in the shafts to
prevent breaking the locking screws.
• Put sealant in the cup plug holes.
• Use the 7/8-inch cup plug driver (1), Part No.
3376813, to install the cup plugs.
• Remove the temporary screws.
• Install the two locking screws in the shafts.
Install
Install the new cam follower gaskets to the block as
follows:
• Obtain gaskets with the same thickness as the
gaskets removed.
• Install the gaskets over the dowel pins in the block.
Oil the camshaft prior to installing the cam followers.
NOTE: The Print-o-Seal gasket must be against the
cylinder block with the sealing bead toward the cam
follower housing.
Install the cam follower assembly as follows:

• Install the capscrews and the studs in the same
position from where they were removed.
• Tighten the capscrews in the alternating sequence

shown to the following torque values:
Step2 47 N•m [ 35 ft-lb ]
Check the injection timing. Refer to Procedure

006-025-010.
Install the accessory drive. Refer to Procedure
009-001-026.
Install the air compressor (if used). Refer to Procedure
012-014-026.
Install the fuel pump. Refer to Procedure 005-016-026.
NOTE: The fuel pump, air compressor, and accessory
drive can be installed as an assembly.
Install the push rods. Refer to Procedure 004-014-026.

003-009-026.
003-004-029.
Install and adjust the C-Brake, if applicable. Refer to

Procedures 020-001-026 and 020-001-029, respectively.
Install the rocker lever covers with the original reusable
gaskets if they are not damaged. Refer to Procedure
003-011-026.
Operate the engine, and check for leaks and engine
operation.
N14 Push Rods or Tubes
Push Rods or Tubes (004-014)

Remove
003-011-002.

003-009-002.
Remove the push rods.

NOTE: To prevent increased wear, mark each push rod
as it is removed so it can be installed back in its original
location.
Inspect for Reuse

Inspect for engine oil in the push rods as follows:
• Hold the push rod horizontally and drop it from a
height of 6 inches onto a concrete floor or a metal
surface.
• The push rod can be used if a ringing sound is heard.
• If a dull (or non-ringing) sound is heard, the push rod
contains engine oil and must be discarded.
Push Rods or Tubes N14
Inspect the straightness of the push rod by rolling it on a

level bench. Replace the push rod if it is bent. Do not use
a bent push rod.
Visually inspect the socket end of the push rod for uneven
wear, scratches, or separation of the insert from the tube.
If a worn push rod is found, the mating adjusting screw
must also be replaced.
When parallel scratches are found in the contact area, the
push rods must be replaced.
Visually inspect the ball end of the push rod.

The contact area must show a smooth seating pattern.
If the ball end of the push rod has parallel grooves and
scratches or a nipple in the center, the push rod must be
replaced. If a worn push rod is found, the mating cam
follower socket must be replaced. Refer to the Engine
Shop Manual for cam follower rebuild instructions.
Install
Use clean 15W-40 oil to lubricate the ball end of the push
rods.
NOTE: The injector push rods (1) are larger in diameter
than the valve push rods (2).
N14 Push Rods or Tubes
Install the push rods into the corresponding numbered

location.
Visually inspect the adjusting screw. The contact area

must be smooth with an even seating pattern.
If parallel scratches are found in the contact area, the
adjusting screw must be replaced. This condition is
normally found with worn push rods that will also require
replacement.
CAUTION
housing capscrews are tightened. Do not attempt to
install the rocker lever shaft assemblies again without
resetting the lash.

003-009-026.
Push Rods or Tubes N14
Adjust the valves and the injectors. Refer to Procedure

003-004-029.
Install the rocker lever cover gasket. The rocker lever

cover gaskets can be used again if not damaged.
003-011-026.
N14
Section 5 - Fuel System - Group 05 Page 5-a
Section 5 - Fuel System - Group 05

Section Contents
Page
Fuel Consumption .............................................................................................................................................5-4
Maintenance Check..........................................................................................................................................5-4
Fuel Flow ...........................................................................................................................................................5-7
Initial Check......................................................................................................................................................5-7
Leak Test..........................................................................................................................................................5-8
Pressure Test....................................................................................................................................................5-8
Fuel Pump .........................................................................................................................................................5-9
All Applications.............................................................................................................................................5-11
Finishing Steps...............................................................................................................................................5-13
All Applications.............................................................................................................................................5-13
Install..............................................................................................................................................................5-12
CELECT™ or CELECT™ Plus.........................................................................................................................5-12
STC............................................................................................................................................................. 5-12
All Applications..............................................................................................................................................5-9
Prime..............................................................................................................................................................5-14
General Information......................................................................................................................................5-14
STC............................................................................................................................................................. 5-15
Remove.......................................................................................................................................................... 5-10
STC............................................................................................................................................................. 5-10
Rotation Check............................................................................................................................................... 5-16
Fuel Pump Gear Pump Check Valve ...............................................................................................................5-17
Install..............................................................................................................................................................5-17
Remove.......................................................................................................................................................... 5-17
Fuel Pump High Idle Speed ............................................................................................................................5-18
Adjust............................................................................................................................................................. 5-18
Fuel Pump Idle Speed .....................................................................................................................................5-19
Adjust............................................................................................................................................................. 5-19
Fuel Pump Pressure Regulator .......................................................................................................................5-37
Initial Check....................................................................................................................................................5-37
Fuel Pump Pulsation Damper .........................................................................................................................5-21
Fuel Pump Throttle Lever ...............................................................................................................................5-22
Adjust............................................................................................................................................................. 5-22
Fuel Pump Throttle Linkage ........................................................................................................................... 5-22
Adjust............................................................................................................................................................. 5-22
Fuel Pump VS Throttle Shaft Housing ........................................................................................................... 5-23
Install..............................................................................................................................................................5-25
Remove.......................................................................................................................................................... 5-23
Fuel Shutoff Valve ...........................................................................................................................................5-27
Initial Check....................................................................................................................................................5-27
Install..............................................................................................................................................................5-30
Remove.......................................................................................................................................................... 5-28
Service Tools ....................................................................................................................................................5-1
Fuel System......................................................................................................................................................5-1
Stall Speed Test ..............................................................................................................................................5-30
Stall Speed Check...........................................................................................................................................5-30
Time Speed Check..........................................................................................................................................5-33
Stall Speed Too Low.................................................................................................................................... 5-34
Stall Speed Too High....................................................................................................................................5-35
VS Governor Adjusting Screw Sealing Washers ............................................................................................5-35
Install..............................................................................................................................................................5-36
Remove.......................................................................................................................................................... 5-35
N14
Page 5-b Section 5 - Fuel System - Group 05
VS Governor Idle Spring .................................................................................................................................5-36

Install..............................................................................................................................................................5-36
Remove.......................................................................................................................................................... 5-36
N14 Service Tools
Section 5 - Fuel System - Group 05 Page 5-1
Service Tools
Fuel System
Repair Location.

Vacuum Gauge (0-30 in. Hg)
Used to check intake air restriction, and also check fuel filter
ST-434 restriction on the suction side of the gear pump. Fuel Restriction
Adapters, Part No. ST-434-1, 3375845 and 3376922, are required
and must be ordered separately.
Hose Adapter
Used with Part No. ST-434 Vacuum Gauge. Use Part No. ST-434-1
ST-434-1 with No. 8 hose. Use Part No. ST-434-2 with No. 10 hose.
ST-434-2
Torque Wrench Adapter

Used to torque lock nut without disturbing the valve or injector setting.
ST-669
Sight Glass
ST-998 Check for air in fuel suction line. Use Part No. 3375362 with No. 12
3375362 hose, and Part No. 3375808 with No. 16 hose.
3375808
Mercury Filled Slack Tube Manometer

Use to measure fuel drain line restriction.
ST-1111-3
Chip Removing Unit

ST-1272-1 1 Used to remove carbon from the top of the piston. Refer to Capscrew
or Salvage Thread Kit, Part No. 3376208. Chip Unit, Part No. 3823461,
3823461 is a vacuum tool.
Service Tools N14
Page 5-2 Section 5 - Fuel System - Group 05

Control Pressure Pump
Check AFC setting.
3375515
Digital Tachometer Kit

Used to measure engine rpm.
3375631
Drive Line Dynamometer

Used to measure engine horsepower.
3375710
Pressure Gauge and Hose (0-300 psi)

Used to measure oil pressure or measure fuel pump pressure.
3375932 Includes necessary hoses and hardware to attach to a fuel pump.
Part No. ST-435-1 is the hose and Part No. ST-435-6 is the pressure
gauge.
Fuel Measurement Device

Used to measure fuel rate on the engine.
3376375
Remote Starter Switch

Turn engine on and off from a remote location.
3376506
Inch Pound Torque Wrench

Required to make consistent settings of the valves.
3376592
Filter Wrench
Used to remove or tighten spin on fuel filters.
3376807
N14 Service Tools

Pressure Gauge (0-100 psi)
Used to measure fuel pressure during cranking.
3375388
Injector Puller — STC Engines

Used to remove STC injectors from the engine.
3823024
Fuel Idle Adjusting Tool

Used to adjust the idle speed while the engine is running.
3823480
Safety Solvent
Used to safely clean parts and tools.
3823717
CELECT™ Injector Puller and Driver Assembly

Use to remove and install CELECT™ injectors.
3823579
Fuel Consumption N14
Fuel Consumption (005-010)

Maintenance Check
Refer to the fuel consumption check list sheets in the back
of Section T.
NOTE: The most accurate method to check the fuel
consumption is to weigh the fuel used. Use a scale
capable of measuring within 0.045 kg [0.1 lb] to weigh the
fuel tank. Use a remote mount tank with enough capacity
to run 80 kilometers [50 miles].
Fill the fuel tank. Weigh the tank with the fuel. The weight
on No. 2 diesel fuel is nominally 0.844 kg per liter [7.03
pounds per gallon].
Install the remote tank (1).
Measure the distance traveled with an accurate odometer.

The odometer accuracy can be checked by using
measured miles, or kilometers.
After traveling the route, remove the tanks and weigh the
fuel remaining. Compute the fuel used in liters [gallons] as
required.
N14 Fuel Consumption
Compute the kilometers per liter or miles per gallon.
In addition to the measurement of the fuel used, the

following factors provide points for running a test similar
to the recognized Type II Society of Automotive Engineers
Fuel Test.
These procedures are helpful to determine differences in
fuel consumption between two vehicles under the same
environmental, road, and test conditions.
Perform the test with the test vehicle and a control vehicle.
The control vehicle compensates for changes in traffic
conditions.
The vehicles must stay close together to experience the
same varying traffic and weather conditions, but not so
close as to affect other's driving or headwind.
The test course must be 65 to 80 kilometers [40 to 50

miles] long.
Fuel Consumption N14
This test route and truck weights must not change during
the test.
All of the test results are based on comparing the fuel used
by the test truck to the fuel used by the control truck.
Drive the truck on a warm up test run. Drive enough tests

to achieve: > >Difference in elapsed time between each
test run can only be plus or minus 0.5 percent. This will
be ± 15 seconds on 80 kilometers [50 miles] at 60 miles
per hour.
The fuel usage of the test truck between test drives

must fall within a 2 percent range, (6.00 mpg vs. 6.12
mpg).
The same range also applies between drives of the control
truck.
NOTE: The differences in traffic and driving practices can
make the test drive fall out of the 2 percent range.
N14 Fuel Flow
A minimum of three test drives that meet these conditions

make a valid test. A single test drive is unreliable.
Use the same experienced drivers for all of the tests.

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

temperature, Humidity, Barometric pressure, Wind
velociy, Wind direction
NOTE: Avoid testing under any extreme conditions.
Fuel Flow (005-011)

Initial Check
Loosen the fuel line at the shutoff valve while the engine
is cranking. If fuel does not come out of the connection,
the pump must be primed.
Fuel Flow N14
Pressure Test
Connect a pressure gauge to the quick disconnect fitting
of the fuel pump.
Start cranking the engine and observe the cranking fuel
pressure.
Minimum Cranking Fuel Pressure

kPa psi
CELECT™ or 172 25
CELECT Plus™
STC 34 5
If the fuel pressure is below the specification, check to be

sure there is a fuel supply to the pump and that it is not
restricted. Refer to Procedure 006-020 in Section 6. Prime
the fuel pump if necessary. Refer to Procedure 005-016 in
Section 5.
Minimum Operating Pressure

Connect a 0-2068 kPa [0-300 psi] pressure gauge to the
quick disconnect fitting to the fuel pump.
Minimum Fuel Pressure

kPa psi
During Cranking 172 25
1200 rpm 827 120
Governed rpm 1034 to 1241 150 to 180
Leak Test
Install an 457 mm [18 inch] piece of clear tubing on the
suction side of the gear pump or the fuel filter head.
Tygon™ R-3603 is the correct size for use with standard
Stratoflex™ Number 10 hose fittings.
NOTE: Add the 457 mm [18 inch] piece of clear tubing to
the existing fuel suction line. Do not replace any portion
of the suction line to install the 457 mm [18 inch] piece of
clear tubing.
N14 Fuel Pump
Start the engine and allow the air to purge from the clear
tubing. No air bubbles can appear.
Shut off the engine and observe the clear tubing.
NOTE: Generally an air space that is drawn from the top
of the fuel filter, will appear in the clear tubing.
Observe the fuel in the clear tubing. It must stop moving

within 1 minute if the system is leak free. If the fuel
continues to move toward the fuel tank, there is a leak in
the system. Observe from which direction air bubbles are
coming into the clear tubing. If they are coming from the
fuel tank side, the leak is in the cooling plate, fittings, fuel
line, or fuel tank.
If the fuel did not move immediately, let the vehicle sit for
about 1 hour. If there is no movement of the fuel, the
system is sealed and will not cause a hard start due to
drain-back of the suction lines.
Remove the clear tubing and connect the suction line back
to the original connection.
Fuel Pump (005-016)

Preparatory Steps
All Applications
WARNING
cable last.
• Disconnect the battery cables.
Fuel Pump N14
Remove
NOTE: On some fuel pumps the cooling drain line (3) has
been rerouted from the injector drain line fitting to the gear
pump using a new tapped hole in the side of the gear
pump housing. The cooling drain line does not need to be
removed to allow the removal of the fuel pump.
Clean the supply pump and the surrounding area.
Remove the electric wire to the fuel shutoff solenoid.
Remove the fuel plumbing.
Remove the two support bracket capscrews from the
cylinder block bracket.
Remove the four fuel pump mounting capscrews and
remove the fuel pump.
STC
Clean the fuel pump and the surrounding area before
removing it from the engine.
Remove the wire to the fuel shutoff valve.

Remove the linkage from the throttle lever.
N14 Fuel Pump
Remove the fuel tubing and air tube:

• Fuel drain line from the T-block connection (1)
• Gear pump cooling drain (2)
• Gear pump suction line (3)
• Fuel supply to the injectors (4)
• AFC air supply tube (5)
• Tachometer cable (if used) (6)
Remove the two fuel pump support bracket to cylinder

block bracket mounting capscrews.
Remove the four fuel pump mounting capscrews and the
fuel pump.
Remove the drive coupling.

All Applications
Clean the gasket surfaces of the pump support and the
compressor.
Inspect the mounting surfaces for damage.

Inspect the jaw coupling spider and the jaw coupling hub
for damage or wear.
Fuel Pump N14
Install
Install the jaw coupling spider, the mounting gasket, and
the fuel pump.
Install the two outside mounting capscrews.
Install the two fuel pump support brackets to cylinder

block bracket capscrews.
Tighten the support bracket to engine mounting
capscrews.
Tighten the fuel pump mounting capscrews.
Connect the fuel plumbing.

Connect the electric wire to the shutoff solenoid.
STC
Install the fuel pump drive coupling.
Use a new gasket when installing the fuel pump.
Install the four 12 point fuel pump mounting capscrews.
N14 Fuel Pump
Install the two fuel pump support bracket capscrews to the

cylinder block bracket. Tighten the four fuel pump
mounting capscrews.
Tighten the two support bracket to cylinder block
capscrews.
Install the AFC air tube and fuel tubing:

• Fuel drain from the T-block connection (1)
• Gear pump cooling drain (2)
• Gear pump suction line (3)
• Fuel supply to the injectors (4)
• AFC air supply tube (5)
• Tachometer cable (if used) (6)
Install the electric wire to the fuel shutoff valve. The wire
connection nut must be clean and tight.
Install the linkage to the throttle lever.
Finishing Steps
All Applications
WARNING
cable last.
• Connect the battery cables.
Fuel Pump N14
Prime
General Information
To reduce engine cranking time, prime the fuel supply
pump.
NOTE: If the fuel supply pump is dirty, clean the outside
of the pump.

Remove the filter cap from the top of the front support.
Fill the pump with clean fuel oil.
Install and tighten the filter cap.

If the filter cap opening can not be used, remove the fuel
supply hose to the gear pump.
Fill the pump with clean fuel.
N14 Fuel Pump
Install the fuel supply hose to the gear pump.
STC
Remove the plug from the top of the housing.
Fill the housing with clean fuel oil.
Install the plug into the top of the housing.

If the priming plug is hard to remove or the fuel pump is a

VS type, remove the fuel supply hose to the gear pump.
Fill the hose and gear pump with clean fuel.
Install the fuel supply hose to the filter head.
Fuel Pump N14
Rotation Check
Remove the fuel supply hose and the fuel inlet fitting from
the gear pump.
Look into the gear pump and crank the engine. The gear
pump gears must turn.
If the supply pump gears do not turn, remove the fuel

pump.
Crank the engine and check the air compressor or the

accessory drive shaft for rotation.
If the shaft turns, the fuel pump is damaged and must be
replaced or repaired.
N14 Fuel Pump Gear Pump Check Valve
Fuel Pump Gear Pump Check Valve

(005-026)
Remove
If the check valve in the gear pump return elbow stays
open or closed, replace the elbow.
NOTE: Check the elbow threads. Do not install an elbow

that has straight machine threads in a hole that has a pipe
tap thread. A gear pump that has a straight thread will
have a 19 mm [0.750 inch] spotface in the valve area. A
gear pump that has a pipe tap thread will have a 16 mm
[0.625 inch] spotface or no spotface.
Remove the drain line.

Remove the check valve elbow.
Install
Install the check valve elbow.
• If the check valve elbow has machine threads to the
maximum thread depth, turn the elbow out until it is
pointed toward the drain line. Tighten the jam nut.
• If the check valve has a pipe thread, install the elbow
until it is tight and pointed toward the drain line.
Fuel Pump High Idle Speed N14
Install the drain line.
Fuel Pump High Idle Speed (005-028)

Adjust
Idle Speed
To adjust the VS idle speed, remove the locknut and jam
nut from the screw in the rear of the VS cover.
Install a new copper washer and the jam nut.
Start the engine. Hold the VS lever counterclockwise in

the idle position. Adjust the idle screw to the correct rpm
and tighten the jam nut.
Install a new copper washer and locknut.
High Speed
To adjust the VS high speed, remove the locknut and jam
nut from the top screw of the VS cover. Discard the copper
washers.
Install a new copper washer and the jam nut.
N14 Fuel Pump Idle Speed
Start the engine. Hold the VS lever clockwise in the high

speed position. Adjust the screw to the correct rpm and
tighten the jam nut.
Install a new copper washer and the locknut.
Fuel Pump Idle Speed (005-029)

Adjust
To check the engine speed, use digital tachometer kit,
Part No. 3375631, or optical tachometer, Part No.
3377462.
The remote starter, Part No. 3376506, can be used to start

the engine. The leads are marked for their connection
points.
NOTE: The idle speed can vary on some applications.

Refer to the fuel pump code for the specified engine idle
speed.
Adjust the engine low idle speed between 600 and 800
rpm.
NOTE: This adjustment is sometimes necessary on a new
engine to compensate for the added engine driven
accessories that are installed by the truck or vehicle
manufacturer.
Fuel Pump Idle Speed N14
Shut off the engine.

Remove the plug from the spring pack cover.
Install the fuel pump idle adjusting tool into the plug hole.
Use tool, Part No. 3375981, for holes with pipe threads
and tool, Part No. 3823480, for holes with straight threads.
Operate the engine for 30 seconds at high idle to remove

the air from the fuel system.
NOTE: Make sure the engine is at or above 70°C [160°

F].
Adjust the idle speed. Turn the tool clockwise to increase
the idle speed and counterclockwise to decrease the idle
speed.
Shut off the engine.

Remove the tool and install the plug.
N14 Fuel Pump Pulsation Damper
Operate the engine until the rpm is constant and all of the
air is out of the fuel system.
Check the idle speed again.
Fuel Pump Pulsation Damper

(005-031)
Inspect for Reuse
Remove the fuel inlet connection and pulsation damper or
the filter head damper assembly. Discard the rubber o-
rings.
Remove the housing from the cover. Remove the spring

steel diaphragm. Discard the o-rings. Inspect the nylon
washer and discard it if it is damaged.
Check for corrosion, wear, or cracks in the cover or the
diaphragm. Replace the damaged parts.
To check the diaphragm for hidden cracks, drop it on a flat
hard surface. It must have a clear ring. If it has a flat
sound, replace the diaphragm.
Fuel Pump Throttle Linkage N14
Install new o-rings in the grooves and a new nylon washer.

Clean the diaphragm. Coat the diaphragm with clean
engine oil. Install the diaphragm in the cover.
Assemble the cover to the housing. Tighten the
capscrews.
Remove the two damper mounting capscrews. Install the

damper assembly with a new o-ring on the gear pump.
NOTE: If a fuel filter and damper assembly are mounted
on the gear pump, remove the four mounting capscrews.
Install the fuel inlet connection. Be careful not to let dirt
enter the fuel pump.
Check for free rotation of the gear pump.
Fuel Pump Throttle Lever (005-035)

Adjust
CAUTION
Do not make any adjustments to the throttle stop
screws. If the throttle does not break over correctly,
adjust the throttle lever or linkage.
Make sure the throttle linkage is adjusted so the throttle
lever breaks over 3 to 6 mm [1/8 to 1/4 inch] when the lever
is in the full throttle position.
NOTE: The throttle lever stop must contact the rear
throttle stop screw.
Fuel Pump Throttle Linkage (005-036)

Adjust
Remove the throttle linkage from the throttle lever.
Hold the VS lever counterclockwise in the idle position.
Move the linkage to the idle position.
N14 Fuel Pump VS Throttle Shaft Housing
If the lever and the linkage are not aligned, adjust the
linkage.
Move the VS lever linkage clockwise to the maximum

speed position.
If the lever and the linkage are not aligned, adjust the
linkage.
Install the linkage on the lever.
Fuel Pump VS Throttle Shaft Housing

(005-038)
Remove
Mark the angle of the VS throttle lever on the VS throttle
shaft. Remove the VS throttle lever.
Fuel Pump VS Throttle Shaft Housing N14
NOTE: Make sure the components in the spring pack

guide do not fall out when the cover is removed.
Remove the VS spring pack housing cover.
Loosen the set screw in the VS throttle stop.
Remove the VS throttle shaft from the cover. Discard the

o-rings.
Remove the shaft dust seals from the cover and discard.
If fuel is leaking between the bushings and the cover,

replace the bushings.
• Press the bushings from the cover
N14 Fuel Pump VS Throttle Shaft Housing
• Install the new bushings into the cover
Examine the o-ring for excessive wear.

If the o-ring wear is due to inadequate surface finish in the
throttle shaft o-ring groove, replace the throttle shaft.
NOTE: Before installing the new shaft, mark the end of the
new shaft in the same location as the mark on the old shaft
to allow correct alignment of the VS throttle lever.
Install
Install new dust seals into the cover.
Install an o-ring on the shaft near the lever end.
Apply clean vegetable oil to the o-ring before installation.
Place the throttle stop into the cover.

NOTE: The longest lever on the stop goes toward the rear
adjustment screw.
Install the shaft into the cover and through the stop.
Fuel Pump VS Throttle Shaft Housing N14
Push the shaft out of the other side of the cover.

Install the other shaft o-ring and apply clean vegetable oil
to the o-ring before installation.
Push the shaft back into the cover.
Align the setscrew hole in the stop with the hole in the
shaft.
Install the setscrew into the stop and tighten.
Assemble the cover to the fuel pump with a new gasket.
Align the lever with the mark on the throttle shaft to install
the lever.
Tighten the lever retaining nut to secure the lever to the
shaft.
Check the throttle linkage for binding.
N14 Fuel Shutoff Valve
Fuel Shutoff Valve (005-043)

Initial Check
Remove the wire. Make sure the remaining wire
connection nut is tight. Tighten the nut.
Make sure the post is tight and secure in the coil.
NOTE: Only single post coils can be used on the
CELECT™ fuel system. Two post coils will interfere with
the cooling line.
Use a wire brush to clean any corrosion from the coil

terminal.
CAUTION
This must be the only wire connected to the shutoff
valve.
Connect the wire. Make sure the shutoff valve coil is the
correct voltage.
The coil voltage and part number are cast into the terminal
connection end of the coil.
Turn the vehicle keyswitch to the "ON" position.

Check the voltage to the coil with a multimeter, Part
Number 3377161, or equivalent.
The voltage must be the same as the battery voltage.
Turn the vehicle keyswitch to the "OFF" position.
Fuel Shutoff Valve N14
Make sure the coil wire is not connected before checking

the coil resistance.
Check the coil resistance with a multimeter.
Fuel System Shutoff Valve Solenoid Specifications

Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735
Replace the coil if the resistance does not meet the

specifications.
Turn the vehicle keyswitch to the "ON" position. Listen for

the valve to "click" when the wire is touched to the coil
terminal. If the valve does not "click", repair or replace the
fuel shutoff valve.
Remove
Remove the coil housing and the fuel shield. Discard the
o-ring.
Remove the spring washer, valve disc, actuator disc, and
actuator spacer from the valve housing. Discard the o-
ring.
N14 Fuel Shutoff Valve
WARNING
WARNING
WARNING
personal injury.
NOTE: Do not get the coil wet with solvent. Clean the coil
with a dry cloth. Polish the coil face with a 200 grit emery
cloth on a flat surface.
Clean all of the parts except the coil assembly in solvent.
Visually check the valve disc, valve seal, and actuator disc
for dirt, metal parts, bonding separation, corrosion, cracks
or wear. Replace if necessary.
Measure the coil resistance with a multimeter.
Fuel System Shutoff Valve Solenoid Specifications

Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735
Replace the coil if the resistance does not meet the

specifications.
NOTE: If the coil assembly shows 0 ohms, there is an
electrical short in the coil.
Stall Speed Test N14
Install
Install these parts as follows.
Install the spacer (7) o-ring groove toward the coil.
Install the actuator disc (5) with the cup side toward the
coil.
Install the spring washer (3) with the cup side toward the
coil.
Align the actuator disc (5), spacer (7), and valve disc (4)
on the front cover (8). Install a new o-ring (6).
Put the spring washer (3) on the valve disc (4), cavity side
up, in a position around the valve locator.
Install the fuel shield (2) and coil (1) on the front cover (8).
Install a new o-ring and tighten the capscrews.
Stall Speed Test (005-054)

Stall Speed Check
Converter Transmissions Stall Speed
The stall speed is the engine speed (rpm) obtained at full
throttle when the converter output shaft is locked.
NOTE: It is possible the vehicle brakes will not hold an
electronically controlled transmission.
CAUTION
Do not exceed 120°C [250°F] converter oil
temperature. Overheating which can result and
converter damage can occur. If the oil temperature
exceeds 120°C [250°F], put the transmission in
neutral and operate the engine until the oil
temperature is below 120°C [250°F]. Check the
converter oil level.
N14 Stall Speed Test
The following equipment is needed for this check:

• Stop watch
• Digital tachometer kit, Part No. 3375631, or optical
tachometer, Part No. 3377462
• Equipment manufacturer's stall speed and time to
stall specifications
Install the tachometer on the fuel pump.
Place the gear selector in the highest gear or full forward.
Make sure the vehicle has good brakes and air pressure
in the brake system.
NOTE: The brakes must prevent the vehicle from moving
when the engine is at full throttle. Engage the vehicle
brakes to keep the vehicle from moving.
Operate the engine until the converter temperature is 80°

C [180°F] or above.
Bring the engine speed back to low idle.
CAUTION
Do not exceed 120°C [250°F] converter oil
temperature. Overheating and damage to the
converter can occur.
Quickly move the throttle to the full open position.
Check the engine speed (rpm) at the point of stall:

• Always hold the speed until it is stable
• Take several readings
• Make sure the readings are accurate
N14 Stall Speed Test
Check the speed (rpm) against the specifications for the

equipment, converter, or automatic transmission.
NOTE: The stall speed for the engine and converter/
transmission can vary ± 8 percent from the
manufacturer's specifications.
If the stall speed is not within the specifications, refer to

the stall speed check list at the end of this section.
Check the equipment manufacturer's troubleshooting
procedures for other reasons for stall speed problems.
Adjust the throttle shaft plunger screw, if necessary, to

change the stall speed. Refer to Procedure 005-028.
NOTE: Do not increase the fuel rate unless it is the true
cause for the low stall speed. Overfueling of the engine
and poor durability can result.
Time Speed Check

Perform the previous Stall Speed Check procedure
through the “check the engine speed (rpm) at the point of
stall” step then:
• Quickly move the throttle to the full open position and
start the stop watch at the same time
• When the engine speed is 90 percent of the stall

speed rpm, stop the stop watch
Example: Stall speed 2089, [2089 X .90 = 1880 rpm]
NOTE: The type of unit and the stall speed rpm can make
the stall speed time a maximum of 10 seconds.
Check the equipment manufacturer's specifications for

the time to stall or the acceleration time.
If the time is excessive, check the fuel pump AFC for an
air leak. Refer to Procedure 006-047 and the Stall Speed
Check List at the end of this procedure.
Stall Speed Too Low
Yes No
1. The tachometer is in error.
2. The engine is up to or above 70°C [160°F].
3. The converter oil is up to temperature 80°C [180°F].
4. The stall has been held long enough for the engine to accelerate to full
power.
5. The match curve stall speed was recorded correctly.
6. The converter oil is to the converter manufacturer's recommendation (SAE
30 instead of SAE 10 for instance).
7. The engine driven accessory power requirements exceed 10 percent of the
gross engine power. Check for abnormal accessory horsepower losses
such as hydraulic pumps, large fans, oversize compressors, and so on.
Either remove the accessory or accurately determine the power
requirement and adjust accordingly.
8. The Air Fuel Control (AFC) is properly adjusted.
9. The unit is operating at an altitude high enough to affect the engine power.
10. The converter charging pressure is correct.
11. The tailshaft governor is interfering with and preventing a full throttle
opening. Disconnect the tailshaft governor. Do not exceed the
manufacturers maximum output speed.
12. The converter blading is interfering, or in a stage of failure. Check the sump
or filter for particles.
13. The converter stators are free-wheeling instead of locking up.
14. The engine is set for power other than that specified on the power curve.
15. The converter is wrong due to improper build or rebuild of unit.
16. The converter is performing to the published absorption curve.
N14 VS Governor Adjusting Screw Sealing Washers
17. The engine and converter match is correct. Check the engine and
converter models for the proper match.
18. The engine is matched to too large of a converter. If this condition is
believed to exist, please report the engine-converter-accessory information
to the factory.
19. The engine power is down. The engine torque rise could be less than
shown on the standard engine curve. See the fuel setting adjustments and
the turbocharger air manifold pressure check.
It is sometimes easier to change the engine fuel rate than to determine the true cause for low stall speed, but
the customer ends up with an over-fueled engine which will also negatively affect durability. Do not increase
the fuel rate as a “cure-all”.
Stall Speed Too High
Yes No
1. The engine is high in power.
2. The tachometer is in error.
3. The accessory power requirements are less than 10 percent of the gross
engine power.
4. The converter oil is aerating or foaming. Check for low oil level, air leaks
in suction line, lack of foam inhibitor in the oil, or suction screen or filter.
Would be accompanied by a noticeable loss of machine performance.
5. The converter is being held at full stall. Check for slipping front disconnect
clutch or a rotating output shaft. On the converter-transmission package,
this can be impossible to check.
6. The converter turbine element is beginning to fail and losing blades, or the
converter was originally built with the wrong size element.
7. The engine and converter match is correct. Due to a revision in the engine
rating or the converter performance.
8. If the oil level is too high on the transmission-converter units with the oil
sump in the transmission, it can cause severe aeration due to parts dipping
in the oil.
9. The converter is performing to the published absorption curve.
10. The converter charging pressure is correct.
The reasons for abnormal stall speeds listed above are some which have been encountered by Cummins
representatives and probably do not include all possible causes. The correction of the problem is either covered in
the vehicle service manual, the converter service manual, or is self-explanatory.
VS Governor Adjusting Screw Sealing

Washers (005-056)
Remove
Remove the locknuts and jam nuts.
Discard the copper washers.
VS Governor Idle Spring N14
Install
Install new copper washers between the jam nuts and the
locknuts.
Install the jam nuts.
Check the governor speed adjustments. Refer to
VS Governor Idle Spring (005-057)

Remove
Remove the linkage from the VS throttle lever.
Remove the following parts:

• VS housing cover
• Gasket
• Throttle lever plunger
• High speed spring and the shims
• Plunger assist spring, if required
• Spring guide
• Idle spring
Install
Install the following parts:
• Spring guide
• High speed spring and the shims
• Plunger assist spring, if required
• Throttle lever plunger
• New cover gasket
• VS housing cover
N14 Fuel Pump Pressure Regulator
Install the linkage to the VS throttle lever.
Fuel Pump Pressure Regulator

(005-060)
Initial Check
To check for a sticking pressure regulator, install a
pressure gauge on the Compuchek fitting in the side of
the fuel shutoff valve.
Start cranking the engine.
The pressure gauge must start moving immediately and
increase rapidly until the engine fires (approximately 172
kPa [25 psi]). This should take 3 to 5 seconds.
If the pressure gauge does not move or increases very

slowly for more than 6 seconds, the regulator plunger is
stuck open and will not let pressure build up quickly for a
normal start. This can be caused by dirt, rust, or burrs on
the plunger, or burrs on the plunger bore.
If the plunger is sticking, the gear pump must be replaced
with a new or ReCon® unit. Refer to the N14 Shop Manual,
Bulletin 3810487.
Fuel Pump Pressure Regulator N14
Notes
Index
Page X-1
About the Manual ..........................................................................................i-1 Install..........................................................................................................3-3

General Information.....................................................................................i-1 Remove......................................................................................................3-2
Accessory Drive Seal ...................................................................................1-4 Crankcase Gases (Blowby) Excessive.....................................................TS-27
Clean and Inspect for Reuse.......................................................................1-4 Cranking Fuel Pressure is Low...............................................................TS-28
Finishing Steps...........................................................................................1-6 Crankshaft ..................................................................................................1-50
Install..........................................................................................................1-5 Clean and Inspect for Reuse.....................................................................1-53
Preparatory Steps.......................................................................................1-4 Finishing Steps.........................................................................................1-64
Remove......................................................................................................1-4 Grind........................................................................................................1-64
Acronyms and Abbreviations ......................................................................i-14 Inspect for Reuse......................................................................................1-50
General Information...................................................................................i-14 Install........................................................................................................1-56
Air Compressor Air Pressure Rises Slowly ...............................................TS-3 Preparatory Steps.....................................................................................1-51
Air Compressor Cycles Frequently............................................................TS-5 Remove....................................................................................................1-51
Air Compressor Noise is Excessive...........................................................TS-6 Rotation Check.........................................................................................1-50
Air Compressor Pumping Excess Lubricating Oil into the Air System .......TS-7 Crankshaft Gear, Front (Crankshaft Installed) ...........................................1-65
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Clean........................................................................................................1-66
Continuously)...............................................................................................TS-9 Inspect for Reuse......................................................................................1-66
Air Compressor Will Not Pump Air..........................................................TS-10 Install........................................................................................................1-67
Air Compressor Will Not Stop Pumping...................................................TS-11 Remove....................................................................................................1-65
Air Intake System - Overview ....................................................................F-40 Crankshaft Pulley .......................................................................................1-69
General Information..................................................................................F-40 Inspect for Reuse......................................................................................1-69
Alternator Not Charging or Insufficient Charging.....................................TS-12 Install........................................................................................................1-69
Alternator Overcharging..........................................................................TS-14 Remove....................................................................................................1-69
Bearings, Connecting Rod ...........................................................................1-6 Crankshaft Seal, Front ...............................................................................1-70
Clean and Inspect for Reuse.......................................................................1-7 Clean........................................................................................................1-71
Finishing Steps.........................................................................................1-10 Inspect for Reuse......................................................................................1-71
Install..........................................................................................................1-9 Install........................................................................................................1-71
Preparatory Steps.......................................................................................1-6 Remove....................................................................................................1-70
Remove......................................................................................................1-6 Crankshaft Seal, Rear ................................................................................1-72
Bearings, Main ............................................................................................1-11 Clean........................................................................................................1-73
Clean and Inspect for Reuse.....................................................................1-13 Inspect for Reuse......................................................................................1-74
Finishing Steps.........................................................................................1-22 Install........................................................................................................1-74
Install........................................................................................................1-16 Remove....................................................................................................1-72
Preparatory Steps.....................................................................................1-11 Cylinder Block ............................................................................................1-77
Remove....................................................................................................1-11 Clean and Inspect for Reuse.....................................................................1-77
Bearings, Thrust .........................................................................................1-23 Camshaft Bore......................................................................................1-81
Inspect for Reuse......................................................................................1-24 Main Bearing Bore................................................................................1-81
Install........................................................................................................1-24 Head Deck Surface...............................................................................1-87
Remove....................................................................................................1-23 Liner Protrusion....................................................................................1-87
Cam Follower Assembly ..............................................................................4-2 Counterbore..........................................................................................1-90
Assemble....................................................................................................4-6 Finishing Steps.......................................................................................1-119
Clean..........................................................................................................4-4 Machine....................................................................................................1-95
Disassemble...............................................................................................4-3 Counterbore for Oversize Lower Press Fit Liner....................................1-95
Inspect for Reuse........................................................................................4-4 Counterbore Ledge.............................................................................1-106
Install..........................................................................................................4-7 Preparatory Steps.....................................................................................1-77
Remove......................................................................................................4-2 Cylinder Block - Overview ...........................................................................F-1
Camshaft .....................................................................................................1-28 General Information....................................................................................F-1
Clean........................................................................................................1-29 Cylinder Block and Liner Seats ...............................................................1-119
Inspect for Reuse......................................................................................1-30 Leak Test................................................................................................1-119
Install........................................................................................................1-31 Cylinder Block Counterbore .....................................................................1-179
Remove....................................................................................................1-28 Initial Check............................................................................................1-179
Camshaft Bearing Support .........................................................................1-34 Leak Test................................................................................................1-181
Clean and Inspect for Reuse.....................................................................1-35 Cylinder Head ...............................................................................................2-1
Finishing Steps.........................................................................................1-37 Clean and Inspect for Reuse.......................................................................2-3
Install........................................................................................................1-35 Finishing Steps.........................................................................................2-13
Preparatory Steps.....................................................................................1-34 Install........................................................................................................2-11
Remove....................................................................................................1-34 Leak Test....................................................................................................2-8
Camshaft Bushings ....................................................................................1-37 Preparatory Steps.......................................................................................2-1
Clean and Inspect for Reuse.....................................................................1-39 Pressure Test.............................................................................................2-6
Finishing Steps.........................................................................................1-42 Remove......................................................................................................2-3
Install........................................................................................................1-39 Cylinder Head Gasket .................................................................................2-15
Preparatory Steps.....................................................................................1-37 General Information..................................................................................2-15
Remove....................................................................................................1-38 Cylinder Head Mounting Capscrew Holes ...............................................1-184
Camshaft End Clearance ..........................................................................1-191 Preparatory Steps...................................................................................1-184
Measure..................................................................................................1-191 Repair.....................................................................................................1-186
Camshaft Gear (Camshaft Removed) .........................................................1-43 Cylinder Liner ...........................................................................................1-121
Inspect for Reuse......................................................................................1-44 Clean and Inspect for Reuse...................................................................1-123
Install........................................................................................................1-45 Finishing Steps.......................................................................................1-136
Remove....................................................................................................1-43 Install......................................................................................................1-132
Complete Engine - Overview .......................................................................F-1 Preparatory Steps...................................................................................1-121
General Information....................................................................................F-1 Remove..................................................................................................1-122
Compressed Air System - Overview ..........................................................F-44 Electrical Equipment - Overview ...............................................................F-48
General Information..................................................................................F-44 General Information..................................................................................F-48
Connecting Rod ..........................................................................................1-47 Engine Acceleration or Response Poor...................................................TS-30
Clean and Inspect for Reuse.....................................................................1-47 Engine Brake - Low Retarding Power or Slow to Activate (CELECT™ or
Install........................................................................................................1-49 CELECT™ Plus)..........................................................................................TS-39
Remove....................................................................................................1-47 Engine Brake - Low Retarding Power or Slow to Activate (PT).................TS-41
Coolant in the Lubricating Oil..................................................................TS-15 Engine Brake — One or More Cylinders Braking with Power Switch Off
Coolant Loss - External...........................................................................TS-16 (CELECT™ or CELECT™ Plus).....................................................................TS-43
Coolant Loss - Internal............................................................................TS-18 Engine Brake — One or More Cylinders Braking with Power Switch Off (PT)....
Coolant Temperature Above Normal - Gradual Overheat.........................TS-20 TS-45
Coolant Temperature Above Normal - Sudden Overheat.........................TS-23 Engine Brake Does Not Operate (CELECT™ or CELECT™ Plus)..............TS-35
Coolant Temperature Below Normal.......................................................TS-25 Engine Brake Does Not Operate (PT)......................................................TS-37
Cooling System - Overview .......................................................................F-31 Engine Decelerates Slowly (CELECT™ or CELECT™ Plus).......................TS-46
General Information..................................................................................F-31 Engine Decelerates Slowly (PT)..............................................................TS-47
Crankcase Breather (External) .....................................................................3-2 Engine Diagrams ..........................................................................................E-3
Clean..........................................................................................................3-2 Engine Views.............................................................................................E-3
Inspect for Reuse........................................................................................3-3 Engine Difficult to Start or Will Not Start (Exhaust Smoke)......................TS-48
Index
Page X-2
Engine Difficult to Start or Will Not Start (No Exhaust Smoke).................TS-50 Initial Check..............................................................................................5-37
Engine Identification ....................................................................................E-1 Fuel Pump Pulsation Damper ....................................................................5-21
Cummins® Engine Nomenclature................................................................E-2 Inspect for Reuse......................................................................................5-21
ECM Dataplate...........................................................................................E-1 Fuel Pump Throttle Lever ..........................................................................5-22
CELECT™ Plus.......................................................................................E-1 Adjust.......................................................................................................5-22
CENTRY™..............................................................................................E-1 Fuel Pump Throttle Linkage ......................................................................5-22
Engine Brake System.................................................................................E-2 Adjust.......................................................................................................5-22
Engine Dataplate........................................................................................E-1 Fuel Pump VS Throttle Shaft Housing ......................................................5-23
Fuel Pump Dataplate..................................................................................E-2 Install........................................................................................................5-25
Engine Installation .......................................................................................0-7 Remove....................................................................................................5-23
General Information....................................................................................0-7 Fuel Shutoff Valve ......................................................................................5-27
Engine Noise Excessive.........................................................................TS-52 Clean and Inspect for Reuse.....................................................................5-29
Engine Noise Excessive — Combustion Knocks.....................................TS-55 Initial Check..............................................................................................5-27
Engine Noise Excessive — Connecting Rod...........................................TS-56 Install........................................................................................................5-30
Engine Noise Excessive — Main Bearing................................................TS-57 Remove....................................................................................................5-28
Engine Noise Excessive — Piston..........................................................TS-59 Fuel System - Overview ...............................................................................F-2
Engine Noise Excessive — Turbocharger...............................................TS-60 General Information....................................................................................F-2
Engine Power Output Low (CELECT™ or CELECT™ Plus)........................TS-61 Installation Recommendations....................................................................F-5
Engine Power Output Low (PT)...............................................................TS-66 Gear Cover Accessory Drive Bushing .....................................................1-193
Engine Removal ...........................................................................................0-2 Finishing Steps.......................................................................................1-197
General Information....................................................................................0-2 Inspect for Reuse....................................................................................1-195
Engine Runs Rough at Idle.....................................................................TS-70 Install......................................................................................................1-195
Engine Runs Rough or Misfires..............................................................TS-73 Preparatory Steps...................................................................................1-193
Engine Shuts Off Unexpectedly or Dies During Deceleration...................TS-75 Remove..................................................................................................1-193
Engine Speed Surges at Low or High Idle...............................................TS-78 Gear Cover, Front .....................................................................................1-137
Engine Speed Surges Under Load or in Operating Range.......................TS-81 Clean......................................................................................................1-140
Engine Starts But Will Not Keep Running...............................................TS-84 Inspect for Reuse....................................................................................1-140
Engine Testing - Overview .........................................................................F-48 Install......................................................................................................1-141
Fuel Flow Measurement on Engine or Chassis Dynamometer...................F-53 Remove..................................................................................................1-137
Operation.............................................................................................F-54 General Cleaning Instructions ......................................................................i-9
General Information..................................................................................F-48 Abrasive Pads and Abrasive Paper..............................................................i-9
In Service Run-in..................................................................................F-49 Definition of Clean.......................................................................................i-9
Engine Dynamometer Run-in................................................................F-49 Fuel System...............................................................................................i-12
Cummins Heavy Duty Engine Operating Curve Definitions....................F-50 Gasket Surfaces........................................................................................i-10
Run-In Instructions....................................................................................F-52 Plastic Bead Cleaning................................................................................i-11
Engine Vibration Excessive.....................................................................TS-86 Solvent and Acid Cleaning.........................................................................i-10
Engine Will Not Crank or Cranks Slowly (Air Starter)...............................TS-88 Steam Cleaning.........................................................................................i-11
Engine Will Not Crank or Cranks Slowly (Electric Starter)........................TS-90 General Repair Instructions ..........................................................................i-7
Engine Will Not Shut Off.........................................................................TS-92 General Information.....................................................................................i-7
Flow Diagram, Air Intake System ..............................................................F-41 Welding on a Vehicle with an Electronic Controlled Fuel System..................i-8
Flow Diagram...........................................................................................F-41 General Safety Instructions ..........................................................................i-5
Flow Diagram, Compressed Air System ....................................................F-45 Important Safety Notice................................................................................i-5
Flow Diagram...........................................................................................F-45 How to Use the Manual .................................................................................i-2
Flow Diagram, Cooling System .................................................................F-32 General Information.....................................................................................i-2
Flow Diagram...........................................................................................F-32 Illustrations ....................................................................................................i-4
Flow Diagram, Exhaust System .................................................................F-43 General Information.....................................................................................i-4
Flow Diagram...........................................................................................F-43 Injectors and Fuel Lines - Overview ..........................................................F-11
Flow Diagram, Fuel System .........................................................................F-8 General Information..................................................................................F-25
Flow Diagram.............................................................................................F-8 Theory of Operation - CELECT™ and CELECT™ Plus Fuel System.............F-18
Flow Diagram, Lubricating Oil System ......................................................F-27 Hydromechanical Subsystem................................................................F-20
Flow Diagram...........................................................................................F-27 Injection Cycle......................................................................................F-21
Fuel Consumption ........................................................................................5-4 Theory of Operation - PT Fuel System.......................................................F-11
Maintenance Check....................................................................................5-4 Theory of Operation - STC Fuel System....................................................F-14
Fuel Consumption Excessive (CELECT™ or CELECT™ Plus)...................TS-94 Intake Manifold Air Temperature Above Specification............................TS-104
Fuel Consumption Excessive (PT)...........................................................TS-98 Intake Manifold Pressure (Boost) is Below Normal.................................TS-106
Fuel Flow ......................................................................................................5-7 Low Idle Adjust Switch Does Not Work (CELECT™ or CELECT™ Plus).....TS-
Initial Check................................................................................................5-7 107
Leak Test....................................................................................................5-8 Lubricating Oil Consumption Excessive................................................TS-109
Pressure Test.............................................................................................5-8 Lubricating Oil Contaminated................................................................TS-111
Fuel in Coolant.....................................................................................TS-102 Lubricating Oil in the Fuel.....................................................................TS-108
Fuel in the Lubricating Oil.....................................................................TS-103 Lubricating Oil Pressure High...............................................................TS-112
Fuel Pump ....................................................................................................5-9 Lubricating Oil Pressure Low................................................................TS-113
Clean and Inspect for Reuse.....................................................................5-11 Lubricating Oil Sludge in the Crankcase Excessive...............................TS-116
All Applications.....................................................................................5-11 Lubricating Oil System - Overview ............................................................F-26
Finishing Steps.........................................................................................5-13 General Information..................................................................................F-26
All Applications.....................................................................................5-13 Lubricating Oil Temperature Above Specification..................................TS-118
Install........................................................................................................5-12 Lubricating or Transmission Oil in the Coolant......................................TS-119
CELECT™ or CELECT™ Plus.................................................................5-12 Operating Fuel Pressure is Low............................................................TS-120
STC......................................................................................................5-12 Overhead Set ................................................................................................3-3
Preparatory Steps.......................................................................................5-9 Adjust.........................................................................................................3-5
All Applications.......................................................................................5-9 CELECT™ or CELECT™ Plus...................................................................3-5
Prime........................................................................................................5-14 STC......................................................................................................3-11
General Information..............................................................................5-14 Finishing Steps.........................................................................................3-14
CELECT™ or CELECT™ Plus.................................................................5-14 General Information....................................................................................3-3
STC......................................................................................................5-15 Preparatory Steps.......................................................................................3-4
Remove....................................................................................................5-10 Piston ........................................................................................................1-144
CELECT™ or CELECT™ Plus.................................................................5-10 Assemble................................................................................................1-148
STC......................................................................................................5-10 Clean......................................................................................................1-145
Rotation Check.........................................................................................5-16 Disassemble...........................................................................................1-145
Fuel Pump Gear Pump Check Valve ..........................................................5-17 General Information................................................................................1-144
Install........................................................................................................5-17 Inspect for Reuse....................................................................................1-146
Remove....................................................................................................5-17 Install......................................................................................................1-148
Fuel Pump High Idle Speed .......................................................................5-18 Remove..................................................................................................1-144
Adjust.......................................................................................................5-18 Piston and Connecting Rod Assembly ....................................................1-167
Fuel Pump Idle Speed ................................................................................5-19 Assemble................................................................................................1-172
Adjust.......................................................................................................5-19 Clean and Inspect for Reuse...................................................................1-171
Fuel Pump Pressure Regulator ..................................................................5-37 Disassemble...........................................................................................1-170
Index
Page X-3
Finishing Steps.......................................................................................1-179
Install......................................................................................................1-174
Preparatory Steps...................................................................................1-167
Remove..................................................................................................1-168
Piston Cooling Nozzle ..............................................................................1-148
Clean......................................................................................................1-149
Inspect for Reuse....................................................................................1-149
Install......................................................................................................1-149
Remove..................................................................................................1-148
Piston Rings .............................................................................................1-151
Finishing Steps.......................................................................................1-163
Inspect for Reuse....................................................................................1-156
Install......................................................................................................1-156
Preparatory Steps...................................................................................1-151
Remove..................................................................................................1-151
Push Rods or Tubes ....................................................................................4-9
Inspect for Reuse........................................................................................4-9
Install........................................................................................................4-10
Remove......................................................................................................4-9
Rocker Lever Assembly .............................................................................3-15
Clean........................................................................................................3-16
Inspect for Reuse......................................................................................3-16
Install........................................................................................................3-18
Remove....................................................................................................3-15
Rocker Lever Cover ....................................................................................3-20
Clean and Inspect for Reuse.....................................................................3-20
Install........................................................................................................3-21
Remove....................................................................................................3-20
Rocker Lever Housing ................................................................................3-22
Clean........................................................................................................3-25
Inspect for Reuse......................................................................................3-25
Install........................................................................................................3-26
Remove....................................................................................................3-22
Service Tools ...............................................................................................0-1
Engine Removal and Installation.................................................................0-1
Service Tools ...............................................................................................1-1
Cylinder Block............................................................................................1-1
Service Tools ...............................................................................................3-1
Rocker Levers.............................................................................................3-1
Service Tools ...............................................................................................4-1
Cam Followers/Tappets..............................................................................4-1
Service Tools ...............................................................................................5-1
Fuel System................................................................................................5-1
Smoke, Black — Excessive (CELECT™ or CELECT™ Plus)....................TS-121
Smoke, Black — Excessive (PT)...........................................................TS-124
Smoke, White — Excessive (CELECT™ or CELECT™ Plus)....................TS-126
Smoke, White — Excessive (PT)...........................................................TS-129
Stall Speed Test .........................................................................................5-30
Stall Speed Check....................................................................................5-30
Time Speed Check....................................................................................5-33
Stall Speed Too Low.............................................................................5-34
Stall Speed Too High............................................................................5-35
Step Timing Control (STC) Valve is Not Shifting Correctly.....................TS-131
Symbols .........................................................................................................i-3
General Information.....................................................................................i-3
Troubleshooting Overview ....................................................................TS-136
Connecting Rod Bearing Noise.............................................................TS-136
Driveability - General Information..........................................................TS-137
Driveability/Low Power - Customer Complaint Form..............................TS-139
Driveability/Low Power/Excessive Fuel Consumption - Checklist...........TS-140
Engine Noise Diagnostic Procedures - General Information...................TS-136
Fuel Consumption - Customer Complaint Form.....................................TS-142
Fuel Consumption - General Information...............................................TS-141
Main Bearing Noise..............................................................................TS-136
Oil Consumption...................................................................................TS-143
Piston Noise.........................................................................................TS-136
Response Test......................................................................................TS-138
....................................................................................................................TS-1
General Information..................................................................................TS-1
Troubleshooting Symptoms Charts ..........................................................TS-2
General Information..................................................................................TS-2
Turbocharger Leaks Engine Oil or Fuel.................................................TS-132
Variable Speed (VS) Governor — Fuel Leak at the Throttle Shaft..........TS-133
Variable Speed (VS) Governor — Speed is Not Set Correctly................TS-134
Variable Speed (VS) Governor — Surge with Engine Under Load..........TS-135
Vibration Damper, Viscous ......................................................................1-163
Clean and Inspect for Reuse...................................................................1-163
VS Governor Adjusting Screw Sealing Washers .......................................5-35
Install........................................................................................................5-36
Remove....................................................................................................5-35
VS Governor Idle Spring ............................................................................5-36
Install........................................................................................................5-36
Remove....................................................................................................5-36
Cummins Inc.
Celect™, Celect Plus™ Volume 1

Troubleshooting and Repair Manual N14 Base Engine STC,
Box 3005
Columbus, Indiana, U.S.A., 47202 N14 Base Engine STC, Celect™, Celect Plus™
Registered Office Volume 1
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright© 2010
Cummins Inc.
Bulletin 3666142
Printed in U.S.A. 06-APRIL-2010 p15
301657_Cummins_Vol1.indd 1 4/9/10 12:59 PM

N14 Repair Manual 3666142-Vol1

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Cummins Inc.

Troubleshooting and Repair Manual

Celect™, Celect Plus™ Volume 1

301657_Cummins_Vol1.indd 1 4/9/10 12:59 PM

Copyright© 2010 Bulletin 3666142

Engine Identification ................................................................................................................................ E

Troubleshooting Symptoms ..................................................................................................................... TS

Complete Engine - Group 00 .................................................................................................................... 0

Cylinder Block - Group 01 ........................................................................................................................ 1

Cylinder Head - Group 02 ......................................................................................................................... 2

Rocker Levers - Group 03 ........................................................................................................................ 3

Cam Followers/Tappets - Group 04 ......................................................................................................... 4

Fuel System - Group 05 ........................................................................................................................... 5

This Page Left Intentionally Blank

About the Manual

How to Use the Manual

The illustrations are intended to show repair or

General Safety Instructions

General Repair Instructions

• Follow all safety instructions noted in the procedures

Welding on a Vehicle with an Electronic Controlled Fuel System

General Cleaning Instructions

• Fuel system tools are to be kept as clean as possible.

Acronyms and Abbreviations

psi Pounds Per Square Inch

Section E - Engine Identification

This Page Left Intentionally Blank

The following information on the dataplate is mandatory

Fuel Pump Dataplate

Engine Brake System

Cummins® Engine Nomenclature

PT®-STC Industrial Engines (Fuel Pump Side)

PT®-STC Industrial Engines (Exhaust Side)

CENTRY™ Engines (Fuel Pump Side)

CELECT™ Plus - Jacket Water Aftercooled Engines (Fuel Pump Side)

CELECT™ Plus - Jacket Water Aftercooled Engines (Exhaust Side)

CELECT™ Plus - Low Temperature Aftercooled Engines (Fuel Pump Side)

CELECT™ Plus - Low Temperature Aftercooled Engines (Exhaust Side)

CELECT™ Plus - Charge Air Cooled Engines (Fuel Pump Side)

CELECT™ Plus - Charge Air Cooled Engines (Exhaust Side)

Marine Engines (Port Side)

Marine Engines (Starboard Side)

This Page Left Intentionally Blank

Complete Engine - Overview (000-999)

Cylinder Block - Overview (001-999)

Fuel System - Overview (005-999)

PT (Type G) AFC Fuel Pump

Fuel System - Overview (005-999)

PT (Type G) VS AFC Fuel Pump

If an overhead fuel tank is used the following requirements

When using fuel system gauges:

Read the gauge in direct alignment with the gauge hand.

Read the flow meter in direct alignment with the float.

Portable fuel pressure gauges must be checked regularly

When measuring the fuel inlet and drain line restriction,

Always use the same size and material of line or hoses as

The distance from the gauge to the connection point

Flow Diagram, Fuel System (200-001)

© Cummins Inc. © Cummins

© Cummins Inc. © Cummins Inc.

Step Timing Control (STC) Fuel System

Flow Diagram, Fuel System (200-001)

© Cummins Inc. © Cummins Inc.

CELECT™ and CELECT™ Plus Fuel System