Rocker Lever Housing Page 1 of 11

003-013 Rocker Lever Housing

Preparatory Steps

WARNING
Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.

• Drain the cooling system. Refer

to Procedure 008-018 in Section
8.
• Remove the rocker lever covers.
Refer to Procedure 003-011 in
Section 3.
• Remove the engine brake.
Refer to Procedure 020-024 in
Section 20.
• Release the fan drive belt
tension.
• Remove the engine lifting
brackets if the rocker lever
housings are being replaced.
Refer to Procedure 016-001 in
Section 16.
• Remove the fan bracket brace
between the fan bracket and the
lifting bracket.

Remove

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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 assemblies.

Refer to Procedure 003-009 in
Section 3.

NOTE: To prevent increased wear,

mark each rocker lever 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.

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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 Number 3823819, to push
or pry the adjacent water tubes into
the rocker lever housing cavity.

For example, the tube between

housing Number 1 and Number 2
must be pushed into housing Number
2. The tube between housing Number
2 and Number 3 must be pushed into
housing Number 3.

Disconnect the wiring harness.

Remove the coolant thermostat

housing from the front rocker lever
housing. Refer to Procedure 008-014
in Section 8.

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Remove the rocker lever housing

mounting capscrews.

NOTE: To prevent increased wear,

mark each rocker lever housing as
it is removed so it can be installed
back in its original location.

Remove the rocker lever housings

and 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 and Inspect for Reuse

Remove the o-ring, o-ring plug, and

water tube from the water manifold
with jumper tube removal tool, Part
Number 3823819.

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Inspect the o-rings, o-ring plugs, and

water tubes. Replace if necessary.

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.

WARNING
Wear appropriate eye and face
protection when using compressed
air. Flying debris and dirt can
cause personal injury.

NOTE: Do not remove the rocker

shaft dowel pins, dowel rings, or
brass cup plug for cleaning.

Steam clean the rocker lever

housings.

Dry with compressed air.

NOTE: Make sure the oil supply

hole is free of dirt or other
deposits.

Inspect the housings for cracks or

damage, and replace if necessary.

Inspect the capscrew holes for

damaged threads. If threads are

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Rocker Lever Housing Page 6 of 11

damaged, repair the threads.

Reference the Alternative Repair
Manual, Bulletin 3379035.

Inspect the rocker lever shaft dowel

rings (1) and the dowel pins (2).
Replace if necessary.

Use cam box dowel extractor, Part

Number 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.

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Install the water tubes (A) in the front

of the Number 2 and Number 3 rocker
lever housings. Install the plugs (B) in
the front to the Number 1 rocker lever
housing and in the rear of the Number
3 rocker lever housing.

Install new rocker lever housing

gaskets onto the cylinder heads.

Install the rocker lever housings.

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Tighten the rocker lever housing

capscrews in sequence as illustrated
(1 thru 6).

Torque Value: 115 n.m [85 ft-lb]

Tighten the rocker lever housing

capscrews in sequence as illustrated
(7 and 8).

Torque Value: 47 n.m [35 ft-lb]

Use jumper tube removal tool, Part

Number 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.

Torque Value: 45 n.m [33 ft-lb]

Install the injectors.

Install the wiring harness pass

through. Tighten the 5/16-inch pass
through mounting capscrew.

Torque Value: 15 n.m [133 in-lb]

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.

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Engine damage can occur if the

injector is not fully seated.

Install the hold down clamp capscrew.

Torque Value: 41 n.m [30 ft-lb]

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

If the adjusting screws protrude

beyond the maximum listed below,
the push rods can be damaged
when the housing 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 32.0
mm [1.25 in] from the top surface of
the lever and the ball end of the
adjusting screw.

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Install the rocker lever assemblies.

Refer to Procedure 003-009 in
Section 3.

Adjust the valves and injectors. Refer

to Procedure 003-004 in Section 3.

Install the coolant thermostat housing.

Refer to Procedure 008-014 in
Section 8.

Connect the wiring harness.

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Rocker Lever Housing Page 11 of 11

Finishing Steps

WARNING
Coolant is toxic. Keep away from
children and pets. If not reused,
dispose of in accordance with local
environmental regulations.

• Install the fan bracket brace

between the fan bracket and the
lifting bracket.
• Install the engine lifting
brackets. Refer to Procedure
016-001 in Section 16.
• Tighten the fan drive belt. Refer
to Procedure 008-002 in Section
8.
• Install and adjust the engine
brakes. Refer to Procedure 020-
024 in Section 20.
• Install the rocker lever covers.
Refer to Procedure 003-011 in
Section 3.
• Fill the cooling system. Refer to
Procedure 008-018 in Section 8.
• Operate the engine until it
reaches a temperature of 82°C
[180°F], and check for leaks.

Last Modified: 21-Sep-2011

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

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