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100% found this document useful (8 votes)

4K views506 pages

Cumm ISM Repair Manual Vol 3

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Manuel Chaucanes Casanova

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Troubleshooting and Repair Manual

ISM, ISMe, and QSM11 Engines Volume 1

Troubleshooting and Repair Manual
Cummins Inc.
Box 3005 e
Columbus, Indiana, U.S.A., 47202 ISM, ISM , and QSM11 Engines
Registered Office Volume 1
Cummins Engine Company, Ltd
Unit 1-B Uniongate, Ridgeway Trading Estate,
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England

Bulletin 3666322
Printed in U.S.A. 15-AUGUST-2005 p63
Service Bulletin

Subject
Camshaft Reuse Guidelines for Cummins Engines with Roller Followers or Roller Tappets

Bulletin No. Date:

3666052-02 01-Dec-2002

General Information
This bulletin applies specific visual inspection criteria for all Cummins engines with roller followers or roller tappets
in contact with the camshaft lobe surfaces. This bulletin addresses the instances in which surface deterioration is
predominately the result of galling or spalling. An additional resource for camshaft information is Technical Overview
of Camshaft Durability, Bulletin 3379031. Cummins Distributors and Dealers are encouraged to use their technical
expertise to implement these guidelines for low cost, high quality repair of Cummins products.
Although this bulletin applies to all Cummins engines with roller followers or roller tappets, it was revised to include
knowledge gained from an injector camshaft engineering project completed on the Signature, ISX, QSX15 Heavy Duty
engine. Based on the results of engineering analysis and endurance testing, the acceptable width for lobe galling
damage on the injector camshaft was increased specifically for the Signature, ISX, QSX15, and ISX with CM870
controller engines. The updated lobe galling width limit applies for the surface damage indicated in Figures E and F.
Definitions
Polishing
• Normal surface condition where machining lines have been smoothed from contact between mating parts (see
Figure B).
Denting
• A depression left in the surface by a piece of foreign material that is trapped between the lobe and roller. A dent
has a relatively smooth, shiny bottom and does not have rough or sharp edges (see Figure C).
Frosted Bands
• High-density microdenting. Frosted (white) in appearance. Frosted bands are not detectable with a fingernail
(see Figure D).
Galling
• Transfer of small pieces of material between the follower roller and the camshaft lobe surface by welding one
surface to the other (see Figures E and F). Galling typically occurs when a follower roller skids on the camshaft
lobe surface. This damage is detectable with a fingernail.
Pitting
• Loss of a piece of material from the lobe resulting in a hole that is visible to the naked eye. Pits typically have
rough, dark bottoms and sharp edges, and usually occur in the heavily-loaded areas of the lobe (see Figure G).
Macro-Spalling
• Loss of large pieces of material from the lobe surface (see Figure H). This amount of damage will affect the
operation of the engine.
Reuse Guidelines
Analysis of lobe deterioration, as represented in the photographs in Figures A through H, can be made objective by
following the reuse information presented in Table 1, Figures A through D and Table 2, Figures E through H.
Camfollower Roller Inspection
Inspect and replace as necessary all camfollower rollers and pins, or assemblies. Use the criteria from this bulletin for
visual inspection of the rollers. Refer to the appropriate Engine Shop Manual for other reuse guidelines.

Cummins Inc., Columbus, Indiana 47202-3005

Cummins Engine Company Ltd., Daventry, Northants, England NN11 5NU
Registered Office: 46-50 Coombe Road, New Malden, Surrey KT3 4QL
Registered No. 573951 England
Copyright 䊚 2003
Cummins Inc. Page 1 of 3
All rights reserved
Camshaft Reuse Guidelines for Cummins Engines with Roller Followers or Roller Tappets
Page 2

Lubricating Oil System Inspection

In the event that macrospalling is observed, inspect the lubricating oil filter for metallic debris. If metallic debris is found
in the filter, inspect and replace as necessary the main and rod bearings, camshaft bushings, turbocharger, lubricating
oil pump and pressure regulator, and the lubricating oil cooler. For additional detail, refer to the Camshaft Lobe
Breakdown progressive damage limits published in the Cummins Warranty Administration Manual.

A. New Lobe B. Polishing: Unconditional Reuse

C. Denting: Unconditional Reuse D. Frosted Bands: Unconditional Reuse

Table 1: Unconditional Reuse Guidelines for Figures A, B, C, and D

Figure Condition of Lobe Reuse Engines Affected
A New Unconditional reuse All
B Polish, no damage Unconditional reuse All
C Denting Unconditional reuse All
D Frosted bands Unconditional reuse All
Camshaft Reuse Guidelines for Cummins Engines with Roller Followers or Roller Tappets
Page 3

E. Galling Surface Distress: Conditional Reuse F. Galling Surface Distress: Do Not Reuse

G. Pitting: Do Not Reuse H. Macrospalling: Do Not Reuse

Table 2: Conditional Reuse and Replacement Guidelines for Figures E, F, G, and H

Figure Condition of Lobe Reuse Engines Affected
1 2
E Galling - Less than 1.5 mm [1/16 in] Conditional reuse All - Except injector camshaft
wide surface distress, no pits for ISX, Signature, QSX15
and ISX with CM870 Control-
ler
Galling1 - Less than 5 mm [3/16 in] Conditional reuse3 ISX, Signature, QSX15 and
wide surface distress, no pits ISX with CM870 Controller -
injector camshaft only
F Galling1 - More than 1.5 mm [1/16 in] Replace All - Except injector camshaft
wide surface distress, no pits for ISX, Signature, QSX15
and ISX with CM870 Control-
ler
Galling1 - More than 5 mm [3/16 in] Replace ISX, Signature, QSX15 and
wide surface distress, no pits ISX with CM870 Controller -
injector camshaft only
G Pitting Replace All
H Macrospalling Replace All
Explanation of Notes:
1. If multiple gall streaks are present but not connected, apply the width criteria to each streak individually.
2. Do not reuse the camshaft if the engine is being overhauled or if the camshaft is out of the engine.
3. Do not reuse the camshaft if the engine is being overhauled.
Troubleshooting and Repair Manual
ISM, ISMe, and QSM11 Engines
Volume 1

Copyright© 2005 Bulletin 3666322

Cummins Inc. Printed 15-AUGUST-2005
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. These parts
can be identified by the following trademarks:
Table of Contents
Section

Introduction .............................................................................................................................................. i

Engine Identification ................................................................................................................................ E

Familiarization .......................................................................................................................................... F

Troubleshooting Symptoms ..................................................................................................................... TS

Engine Performance Features ................................................................................................................ TT

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

ISM, ISMe, and QSM11
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-12
General Information..........................................................................................................................................i-12
General Cleaning Instructions ...........................................................................................................................i-8
Abrasive Pads and Abrasive Paper.....................................................................................................................i-8
Definition of Clean..............................................................................................................................................i-8
Gasket Surfaces.................................................................................................................................................i-9
Plastic Bead Cleaning......................................................................................................................................i-10
Solvent and Acid Cleaning.................................................................................................................................i-9
Steam Cleaning................................................................................................................................................i-10
General Repair Instructions ...............................................................................................................................i-7
General Information...........................................................................................................................................i-7
Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-7
General Safety Instructions ...............................................................................................................................i-5
Important Safety Notice......................................................................................................................................i-5
How to Use the Manual ......................................................................................................................................i-2
General Information...........................................................................................................................................i-2
Illustrations .........................................................................................................................................................i-4
General Information...........................................................................................................................................i-4
Symbols ..............................................................................................................................................................i-3
General Information...........................................................................................................................................i-3
ISM, ISMe, and QSM11
Page i-b Section i - Introduction

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 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 ISM, ISMe, and QSM11
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.

(Step 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.
(Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the
problem, starting at the top with the simplest and easiest to repair, and continuing downward to the
most difficult.
The right column of boxes provides a brief description of the corrective action with a reference number
to the correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the right column.
(Step 4) 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).
ISM, ISMe, and QSM11 Symbols
Section i - Introduction Page i-3

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 ISM, ISMe, and QSM11
Page i-4 Section i - Introduction

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.
ISM, ISMe, and QSM11 General Safety Instructions
Section i - Introduction Page i-5

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, 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.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• 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.
• Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas.
• Natural gas is lighter than air and can accumulate under hood and awnings.
• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas
and liquified petroleum gas lines in a well ventilated area.
• 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.
General Safety Instructions ISM, ISMe, and QSM11
Page i-6 Section i - Introduction

• 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.
ISM, ISMe, and QSM11 General Repair Instructions
Section i - Introduction Page i-7

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.
• 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 12. Flywheel Mounting Capscrews
2. Air Controls 13. Fuel Shutoff Assemblies
3. Air Shutoff Assemblies 14. Fuel Supply Tubes
4. Balance Weights 15. Lifting Brackets
5. Cooling Fan 16. Throttle Controls
6. Fan Hub Assembly 17. Turbocharger Compressor Casing
7. Fan Mounting Bracket(s) 18. Turbocharger Oil Drain Line(s)
8. Fan Mounting Capscrews 19. Turbocharger Oil Supply Line(s)
9. Fan Hub Spindle 20. Turbocharger Turbine Casing
10. Flywheel 21. Vibration Damper Mounting Capscrews
11. Flywheel Crankshaft Adapter
• 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
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins
Authorized Repair Location. Refer to Section L — Service Literature for ordering instructions.
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.
General Cleaning Instructions ISM, ISMe, and QSM11
Page i-8 Section i - Introduction

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
ISM, ISMe, and QSM11 General Cleaning Instructions
Section i - Introduction Page i-9

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 particulary 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
General Cleaning Instructions ISM, ISMe, and QSM11
Page i-10 Section i - Introduction

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
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 psd) for piston cleaning. Pressure should not cause beads to break.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.

CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.
ISM, ISMe, and QSM11 General Cleaning Instructions
Section i - Introduction Page i-11

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.
Acronyms and Abbreviations ISM, ISMe, and QSM11
Page i-12 Section i - Introduction

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
°C Celsius
CARB California Air Resources Board
C.I.D. Cubic Inch Displacement
CNG Compressed Natural Gas
CPL Control Parts List
cSt Centistokes
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency
°F Fahrenheit
FMI Failure Mode Indentifier
GVW Gross Vehicle Weight
LPG Liquified Petroleum Gas
Hg Mercury
hp Horsepower
H2O Water
ICM Ignition Control Module
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LTA Low Temperature Aftercooling
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
N•m Newton-meter
NG Natural Gas
OEM Original Equipment Manufacturer
PID Parameter Identification Descriptions
ppm Parts Per Million
psi Pounds Per Square Inch
PTO Power Takeoff
rpm Revolutions Per Minute
SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
STC Step Timing Control
SID Subsystem Identification Descriptions
VS Variable Speed
VSS Vehicle Speed Sensor
ISM, ISMe, and QSM11
Section E - Engine Identification Page E-a

Section E - Engine Identification

Section Contents
Page
Engine Diagrams ...............................................................................................................................................E-4
Engine Views....................................................................................................................................................E-4
With CM870...................................................................................................................................................E-5
Without CM870............................................................................................................................................E-12
Industrial and Generator Drive.....................................................................................................................E-14
Marine Applications......................................................................................................................................E-16
Engine Identification .........................................................................................................................................E-1
Cummins Engine Nomenclature........................................................................................................................E-3
ECM Dataplate.................................................................................................................................................E-2
With CM870 and CM570................................................................................................................................E-2
Without EGR..................................................................................................................................................E-2
Engine Dataplate..............................................................................................................................................E-1
ISM, ISMe, and QSM11
Page E-b Section E - Engine Identification

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Engine Identification
Section E - Engine Identification Page E-1

Engine Identification
Engine Dataplate
The engine dataplate shows important facts about your
engine. The engine serial number and CPL provide data
for ordering parts and service. The engine dataplate must
not be changed unless approved by Cummins Inc.
The dataplate is located on the fuel pump side of the
engine, on the rocker housing. Have the following engine
data available when communicating with a Cummins
Authorized Repair Location. The following information on
the dataplate is mandatory when sourcing service parts:
Engine Identification ISM, ISMe, and QSM11
Page E-2 Section E - Engine Identification

1. Engine serial number

2. Model
3. Horsepower and rpm rating
4. CPL
5. Emission statement (if applicable).
ECM Dataplate
With CM870 and CM570
The CM870 is the primary electronic control module
(ECM) for the engine.
The ECM dataplate is located on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:

The CM570 is the fuel control module for the engine.

The fuel control module dataplate is located on the front
of the fuel control module.
The abbreviations on the dataplate are explained as
follows:
• P/N = part number
• S/N = serial number
• D/C = date code.

Without EGR
The ECM dataplate is located on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:
• P/N = part number
• S/N = serial number
• D/C = date code.
ISM, ISMe, and QSM11 Engine Identification
Section E - Engine Identification Page E-3

Cummins Engine Nomenclature

The Cummins engine nomenclature provides the data as
illustrated in the graphics.
Engine Diagrams ISM, ISMe, and QSM11
Page E-4 Section E - Engine Identification

Engine Diagrams
Engine Views
The following illustrations contain information about engine components, filter locations, drain points, and access
locations for instrumentation and engine controls. The information and configuration of components shown in these
drawings are of a general nature. Some component locations will vary depending on applications and installations.
ISM, ISMe, and QSM11 Engine Diagrams
Section E - Engine Identification Page E-5

With CM870

Marine - Top View

1. Alternator 5. Coolant fill
2. Oil fill (alternate) 6. Air cleaner
3. Intake manifold temperature sensor 7. Turbocharger
4. Intake manifold pressure sensor 8. Exhaust elbow.
ISM, ISMe, and QSM11
Section F - Familiarization Page F-a

Section F - Familiarization
Section Contents
Page
Air Intake System - Overview .........................................................................................................................F-36
General Information........................................................................................................................................F-36
Complete Engine - Overview ............................................................................................................................F-1
General Information..........................................................................................................................................F-1
Compressed Air System - Overview ...............................................................................................................F-51
General Information........................................................................................................................................F-51
Cooling System - Overview ............................................................................................................................F-21
General Information........................................................................................................................................F-21
Injection Cycle.............................................................................................................................................F-21
Cylinder Block - Overview ................................................................................................................................F-1
General Information..........................................................................................................................................F-1
Electrical Equipment - Overview ....................................................................................................................F-55
General Information........................................................................................................................................F-55
Engine Testing - Overview ..............................................................................................................................F-56
Fuel Flow Measurement on Engine or Chassis Dynamometer..........................................................................F-59
General Information........................................................................................................................................F-56
Exhaust System - Overview ............................................................................................................................F-42
General Information........................................................................................................................................F-42
Flow Diagram, Air Intake System ...................................................................................................................F-38
Flow Diagram..................................................................................................................................................F-38
Automotive Applications with EGR................................................................................................................F-38
Automotive Applications Without EGR..........................................................................................................F-39
Marine Applications......................................................................................................................................F-40
Industrial and Generator Drive......................................................................................................................F-41
Flow Diagram, Compressed Air System .........................................................................................................F-53
Compressed Air System..................................................................................................................................F-53
Cummins.....................................................................................................................................................F-53
Holset® Models............................................................................................................................................F-54
Flow Diagram, Cooling System ......................................................................................................................F-22
Flow Diagram..................................................................................................................................................F-22
Automotive Applications with EGR................................................................................................................F-22
Automotive Applications Without EGR..........................................................................................................F-24
Marine Applications......................................................................................................................................F-26
Industrial and Generator Drive......................................................................................................................F-34
Flow Diagram, Exhaust System ......................................................................................................................F-44
Flow Diagram..................................................................................................................................................F-44
Automotive Applications with EGR................................................................................................................F-44
Automotive Applications Without EGR..........................................................................................................F-46
Marine Applications......................................................................................................................................F-48
Industrial and Generator Drive......................................................................................................................F-49
Flow Diagram, Fuel System ............................................................................................................................F-11
Fuel System....................................................................................................................................................F-11
Automotive Applications...............................................................................................................................F-11
Marine Applications......................................................................................................................................F-12
Industrial and Generator Drive......................................................................................................................F-13
Flow Diagram, Lubricating Oil System ...........................................................................................................F-19
Flow Diagram..................................................................................................................................................F-19
Automotive, Industrial, and Generation-Drive Applications............................................................................F-19
Fuel System - Overview ....................................................................................................................................F-2
Installation Recommendations..........................................................................................................................F-2
ISM................................................................................................................................................................F-2
Injectors and Fuel Lines - Overview .................................................................................................................F-5
Theory of Operation..........................................................................................................................................F-5
Hydromechanical Subsystem.........................................................................................................................F-5
Injection Cycle...............................................................................................................................................F-6
ISM..............................................................................................................................................................F-10
Lubricating Oil System - Overview .................................................................................................................F-14
ISM, ISMe, and QSM11
Page F-b Section F - Familiarization

General Information........................................................................................................................................F-14
With EGR.....................................................................................................................................................F-14
Maximum Oil Drain Intervals........................................................................................................................F-15
Without EGR................................................................................................................................................F-15
Vehicle Braking - Overview .............................................................................................................................F-61
General Information........................................................................................................................................F-61
Engine Brake Solenoid.................................................................................................................................F-61
ISM, ISMe, and QSM11 Cylinder Block - Overview
Section F - Familiarization Page F-1

Complete Engine - Overview (000-999)

General 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.
All replacement steps will not apply to all types of
equipment. Complete only the steps that 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
CAUTION
Do not replace main bearing shells without performing this inspection. Engine damage is possible if the main
bearing shells are replaced without performing this inspection.
Fretting is micro-motion between the main bearing cap and block that results in material loss at the joint. This motion
causes a loss of crankshaft to main bearing running clearance that can lead to a spun main bearing, a spun connecting
rod bearing, and/or a broken crankshaft.
There is risk when overhauling or replacing the main bearings in a block that has incurred main cap fretting. Inserting
new standard main bearing shells into a joint that has sustained sufficient loss of material can lead to zero crankshaft/
bearing clearance. This can cause the crankshaft to lock in place.
Recent long-hour engineering tests have shown the addition of Loctite® 518, a block stiffener plate, and increased
main bearing clamp loads reduces torsional motions in the main cap/block joint. Loctite® 518 adds an additional shear
strength and seals the main bearing cap/block joint from oil and debris. The stiffener plate increases block stiffness
by 15 percent and the new torque-plus-angle method increases main bearing clamp load by 1588 kg [3500 lb].
NOTE: The inspection must be performed with the original main cap and bearing shells. During the reduction of
bearing running clearance, the original main bearing develops a wear pattern, which is an indicator of main cap
fretting.
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. These 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 ranges. Both Plastigage®
thread and its matching envelope have a distinctive color for each clearance range.
Acceptance limits were developed to make sure of proper oil film thickness between the main bearings and crankshaft.
The minimum acceptable clearance is 0.051 mm [.002 in] for the ISM series engines. Blocks not condemned can be
up-fitted with the block stiffener plate.
The block meets acceptance limits if the main bearing bore passes inspection and can be reassembled with new
standard bearing shells if all of 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 0.05 mm [0.002 in]
The block main bearing bore does not pass inspection when the two following conditions exist.
• Main cap and block mating surfaces exhibit fretting.
• Plastigage® clearance on any main bearing (2 through 6) is less than 0.05 mm [0.002 in].
Repair options for blocks with one main journal that does not meet acceptance limits and have not spun a main
bearing:
Fuel System - Overview ISM, ISMe, and QSM11
Page F-2 Section F - Familiarization

• Install an undersized main bearing kit to incrase bearing clearance.

Repair options for blocks with multiple main journals that do not meet acceptance limits or have spun a main bearing:
• Replace block with service block kit
• Replace block with ReCon® service block kit
• Replace block with ReCon® short block
• Replace engine with ReCon® engine.
NOTE: Cummins must approve all warrantable block repairs.

Fuel System - Overview (005-999)

Installation Recommendations
ISM
Installation Publications
The following publications are available to provide fuel
system installation recommendations approved by
Cummins Inc.:
Automotive Installation Recommendations (Fuel System),
Bulletin 3382707.
Construction, Mining, Logging, and Agriculture
Installation Recommendations (Fuel System), Bulletin
3382015.

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.

Overhead Fuel Tank Requirements

If the fuel filter is lower than the fuel pump, install a check
valve in the filter outlet fuel line. Refer to the 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
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
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.
ISM, ISMe, and QSM11 Fuel System - Overview
Section F - Familiarization Page F-3

Proper Use of Fuel System Gauges

To be sure the reading is correct, 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.
Fuel System - Overview ISM, ISMe, and QSM11
Page F-4 Section F - Familiarization

When measuring the fuel inlet and drain line restriction,

the manometer or gauges 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.
ISM, ISMe, and QSM11 Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-5

Injectors and Fuel Lines - Overview (006-999)

Theory of Operation
Hydromechanical Subsystem
Injector
The 2002 ISM engine utilizes a different injector than the previous ISM engine with flow characteristic changes and
improved reliability. The injector is specially designed to maximize the benefit of cooled EGR and lower the emission
levels.
The fuel pump is located in the same location as a
CELECT™ Plus fuel pump.

The fuel pump is a gear type of pump. The assembly

includes a pressure regulator, pulsation damper, and
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.
Injectors and Fuel Lines - Overview ISM, ISMe, and QSM11
Page F-6 Section F - Familiarization

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.

The fuel system uses the camshaft to create adequate

pressure for injection.

A cutaway view of the electronically controlled injector

with the internal components identified is illustrated in the
graphic.

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.
ISM, ISMe, and QSM11 Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-7

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.
Injectors and Fuel Lines - Overview ISM, ISMe, and QSM11
Page F-8 Section F - Familiarization

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, and into 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 3473 kPa

[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.
ISM, ISMe, and QSM11 Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-9

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.
Injectors and Fuel Lines - Overview ISM, ISMe, and QSM11
Page F-10 Section F - Familiarization

ISM

Injector Drivetrain
1. Injector 4. Push rod
2. Injector link 5. Cam follower
3. Rocker lever 6. Camshaft.
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ISM, ISMe, and QSM11 Flow Diagram, Fuel System

Section F - Familiarization Page F-11

Flow Diagram, Fuel System (200-001)

Fuel System
Automotive Applications

1. Fuel inlet supply 5. Fuel drain return

2. Fuel pump 6. Fuel to injector
3. Fuel filter 7. ECM cooling plate.
4. Injector
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Flow Diagram, Fuel System ISM, ISMe, and QSM11

Page F-12 Section F - Familiarization

Marine Applications

1. Fuel inlet supply 6. Fuel drain to fuel drain

2. Fuel filter 7. Injector
3. Fuel pump 8. Fuel cooler
4. ECM cooling plate 9. Fuel return to supply tank.
5. Fuel to injector
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ISM, ISMe, and QSM11 Flow Diagram, Fuel System

Section F - Familiarization Page F-13

Industrial and Generator Drive

1. Fuel inlet supply 5. Fuel drain return

2. Fuel pump 6. Fuel to injector
3. Fuel filter 7. ECM cooling plate.
4. Injector
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Lubricating Oil System - Overview ISM, ISMe, and QSM11

Page F-14 Section F - Familiarization

Lubricating Oil System - Overview (007-999)

General Information
With EGR
The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical
factor in maintaining engine performance and durability.
Cummins Inc. recommends engines using exhaust gas recirculation (EGR) must use a high quality 15W-40
multiviscosity heavy-duty engine oil that meets the requirements of Cummins engineering specification CES 20078
(such as Valvoline® Premium Blue or Premium Blue Extreme). American Petroleum Institute (API) specification CI-4
meets the CES 20078 requirement. The oil grades CC, CD, CE, CF or CG must not be used.
If oils meeting CES 20078 are not available, CES 20071, 20072, or 20077 can possibly be used for EGR equipped
engines at reduced oil drain intervals. Consult the operation and maintenance manual for the particular engine model
and duty cycle for more detailed recommendations.
Shortened drain intervals can possibly be required with monograde oils as determined by close monitoring of the oil
condition with scheduled oil sampling. Use of single-grade oils can possibly affect engine oil control.
For further details and an explanation of engine lubricating oils for Cummins engines, refer to Cummins Engine Oil
Recommendations, Bulletin 3810340.
Additional information regarding lubricating oil availability throughout the world is available in the Engine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines. The
data book can be ordered from:
Engine Manufacturer's Association
One Illinois Center
111 East Wacker Drive
Chicago, IL 60601 U.S.A.
(312) 644-6610
The API service symbols are shown in the accompanying
illustration.
1. The upper half of the symbols display the
appropriate oil categories.
2. The lower half contains words to describe oil energy-
conserving features.
3. The center section identifies the SAE oil viscosity
grade.

Oil viscosity must be chosen according to the typical

climate conditions experienced by the user. Use of 15W-
40 viscosity is recommended for the best engine durability
at higher ambient temperature. For cold temperature
conditions, 10W-30 or 5W-30 viscosity can be used for
easier starting, improved oil flow, and improved fuel
economy.
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ISM, ISMe, and QSM11 Lubricating Oil System - Overview

Section F - Familiarization Page F-15

New Engine Break-in Oil

Special “break-in” engine lubricating oils are not
recommended for new or rebuilt Cummins engines. In
general, use the same oil during break-in as that used in
normal operation. To make sure the piston rings seat
properly, use a high quality petroleum-based engine
lubricating oil during the first engine oil drain period.

Maximum Oil Drain Intervals

As the engine oil becomes contaminated, essential oil
additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.
Progressive contamination of the oil between oil and filter
change intervals is normal. The amount of contamination
will vary depending on the operation of the engine,
kilometers or miles on the oil, fuel consumed, and new oil
added.
Extending oil and filter change intervals beyond the
recommendations will decrease engine life due to factors
such as corrosion, deposits, and wear.
Refer to the oil drain chart in this section to determine
which oil drain interval to use for your application.

Without EGR
The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical
factor in maintaining engine performance and durability.
Cummins Inc. recommends the use of a high quality 15W-40 multiviscosity heavy-duty engine oil that meets the
requirements of Cummins Engineering Specification CES 20071 or CES 20076 (such as Valvoline Premium Blue or
Premium Blue 2000). American Petroleum Institute (API) specification CH-4 can be used as an alternative to CES
20071. Oils that meet API specification CG-4 can be used, but at a reduced drain interval according to the Oil Drain
Intervals by Severity of Service mi [km] chart. Find the chart in the ISM Auto/Transit Bus Operation and Maintenance
Manual, Bulletin 3666319. The oil grades CC, CD, CE, or CF has been obsoleted by API and must not be used.
Shortened drain intervals can be required with monograde oils as determined by close monitoring of the oil condition
with scheduled oil sampling. Use of single-grade oils may affect engine oil control.
Synthetic engine oils, API category III, are recommended for use in Cummins engines operating in ambient
temperature conditions consistently below -25°C [-13°F]. Above this temperature it is recommended the petroleum
based multigrade lubricants be used. Synthetic 0W-30 oils that meet API category III can be used in operations where
the ambient temperature never exceeds 0°C [32°F]. 0W-30 oils do not offer the same level of protection against fuel
dilution as do higher multigrade oils. Higher cylinder wear can be experienced when using 0W-30 oils in high-load
situations.
For further details and an explanation of engine lubricating oils for Cummins engines, refer to Cummins Engine Oil
Recommendations, Bulletin 3810340.
Additional information regarding lubricating oil availability throughout the world is available in the Engine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines. The
data book can be ordered from:
Engine Manufacturer's Association
One Illinois Center
111 East Wacker Drive
Chicago, IL 60601 U.S.A.
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Lubricating Oil System - Overview ISM, ISMe, and QSM11

Page F-16 Section F - Familiarization

(312) 644-6610
The API service symbols are shown in the accompanying
illustration.
1. The upper half of the symbols display the
appropriate oil categories.
2. The lower half contains words to describe oil energy-
conserving features.
3. The center section identifies the SAE oil viscosity
grade.

Oil viscosity must be chosen according to the typical

ISM, ISMe, and QSM11 Lubricating Oil System - Overview

Section F - Familiarization Page F-17

New Engine Break-in Oil

Special “break-in” engine lubricating oils are not recommended for new or rebuilt Cummins engines. In general, use
the same oil during break-in as that used in normal operation. Synthetic or partially synthetic engine lubricating oils,
however, can not be used during break-in of a new or rebuilt engine. To make sure the piston rings seat properly,
use a high quality petroleum-based engine lubricating oil during the first engine oil drain period.
Oil Drain Interval
As the engine oil becomes contaminated, essential oil
additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.
Progressive contamination of the oil between oil and filter
change intervals is normal. The amount of contamination
will vary depending on the operation of the engine,
kilometers or miles on the oil, fuel consumed, and new oil
added.
Extending oil and filter change intervals beyond the
recommendations will decrease engine life due to factors
such as corrosion, deposits, and wear.
Refer to the oil drain chart in this section to determine
which oil drain interval to use.

Centinel™ System (ISM Engines)

The integrated Centinel™ system is continuous oil
replacement system of electromechanical design. The
Centinel™ system extends oil and filter change intervals
through continuous oil exchange. This is accomplished by
injecting engine oil at a controlled rate, proportional to fuel
consumed, into the fuel system for consumption. Makeup
oil (fresh) is introduced into the engine at a rate equal to
the oil consumed by Centinel™. The Centinel™ system also
monitors the oil level in the makeup tank.
1. Control module
2. Maintenance/fluids lamp
3. OEM interface connector on the engine control
module
4. Makeup tank wiring harness
5. Return fuel line
6. Fresh oil to oil control valve
7. Remote oil level switch
8. Makeup oil tank
9. Main oil rifle
10. Hose from makeup oil tank to oil control valve
11. Fresh oil to oil pan
12. Fuel/lube oil blend to engine
13. Oil control valve
14. Vehicle fuel tank.
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Lubricating Oil System - Overview ISM, ISMe, and QSM11

Page F-18 Section F - Familiarization

System Description
The integrated Centinel™ system consists of an oil
management valve, remote oil level switch, makeup tank,
plumbing and wiring.
The control valve is mounted on the engine and is
electronically controlled by the ECM. The ECM controls
the timing and number of oil management pump piston
strokes based on the engine's duty cycle. By using the
engine's ECM, any integrated Centinel™ faults light the
Maintenance (fluids) lamp on the dash (INSITE™ also
reads these faults and Road Relay displays them). The
lamp also illuminates for low oil level in the makeup tank.
The oil control valve is plumbed to the engine oil rifle,
block (or hand hole cover) and fuel drain connection.
There is also a makeup port (1-1/16-12 UNF-2B; straight
thread o-ring) in the oil control valve for plumbing from the
OEM supplied makeup tank.
The makeup tank and plumbing is OEM supplied and
mounted. In addition, the makeup tank has an OEM
supplied remote oil level switch which is wired to the OEM
interface connector on the engine control module (refer to
appropriate wiring diagram). The makeup tank is plumbed
to the oil management pump.
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ISM, ISMe, and QSM11 Flow Diagram, Lubricating Oil System

Section F - Familiarization Page F-19

Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
Automotive, Industrial, and Generation-Drive Applications

1. Oil pump 7. Oil cooler

2. Pressure regulator valve 8. Combination oil filter
3. Oil return to pan 9. Filter bypass valve
4. High pressure relief valve 10. Accessory drive or air compressor
5. Oil return to pan 11. Idler gears
6. Oil thermostat 12. Viscosity sensor.
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Flow Diagram, Lubricating Oil System ISM, ISMe, and QSM11

Page F-20 Section F - Familiarization

Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
Automotive, Industrial, and Generation-Drive Applications

Centinel™ (optional)
1. Oil burn line (used oil to fuel return) 5. OEM fresh oil supply (from makeup tank)
2. Oil rifle hose (used oil inlet) 6. Handhole cover
3. Oil replenishment hose (clean oil to pan) 7. Rifle check valve
4. Control valve 8. Outlet check valve.
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ISM, ISMe, and QSM11 Cooling System - Overview

Section F - Familiarization Page F-21

Cooling System - Overview (008-999)

General Information
Injection Cycle
Water Pump With Exhaust Gas Recirculation (EGR)
On the 2002 ISM engine the water pump is built with an impeller similar to that used on the QSK19 engine to maximize
the cooling capacity of the water pump. The water pump pulley drive ratio was increased to provide faster pump
speeds to increase the cooling capacity. Increased cooling capacity is required due to the extra flow and heat
associated with EGR.
The primary function of the cooling system is to remove
the heat created by the engine and its support
components. The excess heat energy that is not removed
by the cooling system is carried away by exhaust gases
and radiation into the atmosphere.
The coolant must be made up of proper proportions of
water, antifreeze and supplemental coolant additives
(SCA) to properly perform these functions.

The chart in the graphic illustrates the coolant flow

through the engine. For more detail, refer to the coolant
flow diagrams.
• Charge Air Cooled Engines

The following publications, available through Cummins

Distributors or Dealers, provide cooling system installation
recommendations and specifications approved by
Cummins Inc.:
• Automotive Installation Recommendations (Cooling
System), Bulletin 3382413.
• Construction, Mining, Logging, and Agriculture
Installation Recommendations (Cooling System),
Bulletin 3382171.
• Data Sheets for specific engine models.
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Flow Diagram, Cooling System ISM, ISMe, and QSM11

Page F-22 Section F - Familiarization

Flow Diagram, Cooling System (200-003)

Flow Diagram
Automotive Applications with EGR

1. Water pump coolant inlet 9. EGR valve coolant return to water manifold
2. Coolant supply to block 10. EGR cooler coolant return to low pressure cavity
3. Coolant supply to cylinder head 11. Coolant supply to turbocharger
4. Coolant return to low pressure cavity 12. Turbocharger coolant return to water manifold
5. Cylinder head coolant vent to water manifold 13. Oil cooler
6. Coolant return to thermostat housing 14. Heater housing
7. Coolant supply to EGR cooler 15. Coolant filter
8. Coolant supply to EGR valve 16. Coolant return from thermostat housing.
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ISM, ISMe, and QSM11 Flow Diagram, Cooling System

Section F - Familiarization Page F-23

Flow Diagram, Cooling System (200-003)

Flow Diagram
Automotive Applications with EGR

Thermostat Closed and Opened

1. Water pump coolant inlet 9. Coolant to air compressor
2. Coolant to block 10. Coolant supply to EGR cooler
3. Upper manifold cavity (coolant to thermostat) 11. Coolant from EGR cooler to block
4. Coolant outlet (coolant to radiator) 12. Coolant supply to turbocharger
5. Coolant bypass (return to water pump) 13. Coolant from turbocharger to water manifold
6. Lower manifold cavity to lubricating oil cooler 14. Coolant supply to EGR valve
7. Lubricating oil cooler to upper manifold cavity (before 15. Coolant return from EGR valve to water manifold
thermostat) 16. Coolant return from water manifold to thermostat
8. Coolant from air compressor housing (before thermostat).
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Flow Diagram, Cooling System ISM, ISMe, and QSM11

Page F-24 Section F - Familiarization

Automotive Applications Without EGR

Coolant Flow, Heat Exchanger (two of three)

Thermostat Open (1-5)
Thermostat Closed (6-9)
1. Water pump coolant inlet 6. Upper manifold cavity (coolant to thermostat)
2. Upper manifold cavity 7. Coolant bypass (return to water pump)
3. Coolant outlet 8. Lower manifold cavity to cooler
4. Lower manifold cavity to cooler 9. Cooler to upper manifold cavity (before thermostat).
5. Cooler to upper manifold cavity (before thermostat).
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ISM, ISMe, and QSM11 Flow Diagram, Cooling System

Section F - Familiarization Page F-33

Marine Applications

Coolant Flow, Heat Exchanger (three of three)

1. Flow from heat exchanger to water pump 6. Flow from cylinder head to upper manifold cavity
2. Flow to oil cooler and lower manifold cavity 7. Flow to coolant filter
3. Flow from lower manifold cavity to cylinder liners 8. Flow from coolant filter
4. Flow from oil cooler to thermostat housing 9. Coolant heater - optional.
5. Flow to cylinder head
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Flow Diagram, Cooling System ISM, ISMe, and QSM11

Page F-34 Section F - Familiarization

Industrial and Generator Drive

1. Water pump coolant inlet 5. Coolant to upper manifold cavity

ISM, ISMe, and QSM11 Flow Diagram, Cooling System

Section F - Familiarization Page F-35

Industrial and Generator Drive

Open (1-5)
Closed (6-9)
1. Water pump coolant inlet 6. Upper manifold cavity (coolant to thermostat)
2. Upper manifold cavity (coolant to thermostat) 7. Coolant bypass (return to water pump)
3. Coolant outlet 8. Lower manifold cavity to cooler
4. Lower manifold cavity to cooler 9. Cooler to upper manifold cavity (before thermostat).
5. Cooler to upper manifold cavity (before thermostat).
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Air Intake System - Overview ISM, ISMe, and QSM11

Page F-36 Section F - Familiarization

Air Intake System - Overview (010-999)

General Information
Variable Geometry Turbocharger
A variable geometry turbocharger is used on the 2002 ISM engine to maximize the performance of the engine and
also to help decrease emissions levels. The variable geometry turbocharger is pneumatically actuated with air from
the Original Equipment Manufacturer's (OEM's) air tanks. High air pressure from the turbocharger control valve closes
the variable geometry mechanism, which increases the exhaust pressure and facilitates Exhaust Gas Recirculation
(EGR) flow through the engine. A closing variable geometry mechanism also increases turbocharger speed and intake
manifold pressure under certain engine operating conditions. Lower air pressure from the turbocharger control valve
opens the variable geometry mechanism which decreases exhaust pressure, turbocharger speed, and intake manifold
pressure under certain engine operating conditions.
Due to the variable geometry mechanism being contained inside the turbine housing, it is mandatory that the V-band
clamp is not disturbed during turbocharger servicing. Loosening the V-band clamp and rotating the bearing housing
or turbine housing can cause the variable geometry mechanism to jam and the turbocharger to fail. Service
turbochargers will be supplied with the proper turbine housing orientation so that no adjustments will be necessary.
When removing the turbocharger actuator, regulated air pressure must be applied to the actuator air inlet to reduce
spring load at the linkage.
Turbocharger Control Valve
The turbocharger control valve modulates air pressure to the variable geometry actuator. The Electronic Control
Module (ECM) sends a pulse width modulated signal to the turbocharger control valve in order to control the variable
geometry turbocharger. As the signal increases, more air pressure is applied to the variable geometry actuator.
Conversely, when the signal decreases, less air pressure is applied to the variable geometry actuator. The
turbocharger control valve has both low and high voltage fault codes.
Turbocharger Control Shutoff Valve
The turbocharger control shutoff valve is actuated by the ECM and is energized only when the engine is running or
when the INSITE™ turbocharger actuator test is active. This allows air pressure from the OEM air tanks to fill the air
lines from the turbocharger control shutoff valve to the turbocharger control valve. The turbocharger control shutoff
valve has both low and high voltage fault codes.
Turbocharger Control Shutoff Valve Filter
The turbocharger control valve for the 2002 ISM engine requires filtration to protect it from debris. The turbocharger
control shutoff valve filter is located downstream of the turbocharger control shutoff valve and upstream of the
turbocharger control valve. The filter collects debris from the OEM air tanks that could potentially damage the
turbocharger control valve. This filter has a maintenance interval of two years or 250,000 miles.

WARNING
Air pressure must be released from the system before removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure and can cause personal injury.

WARNING
Wear apppropriate eye and face protectin when using compressed air. Flying debris and dirt can cause
personal injury.
The Combustion Air System on M Series engines consists
of intake air piping, turbocharger, charge air piping,
charge air cooler and exhaust gas piping.
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ISM, ISMe, and QSM11 Air Intake System - Overview

Section F - Familiarization Page F-37

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.

An adequate supply of good, filtered oil is very important

to the life of the turbocharger.
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. A restricted oil drain line can
cause the turbocharger bearing housing to be
pressurized, causing oil to leak past the seal rings.
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Flow Diagram, Air Intake System ISM, ISMe, and QSM11

Page F-38 Section F - Familiarization

Flow Diagram, Air Intake System (200-004)

Flow Diagram
Automotive Applications with EGR

1. Intake air inlet to turbocharger 5. Air intake connection

2. Turbocharger air to charge air cooler 6. Intake valve port
3. Charge air cooler to intake manifold 7. Intake valves.
4. Exhaust gas to EGR mixer
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ISM, ISMe, and QSM11 Flow Diagram, Air Intake System

Section F - Familiarization Page F-39

Automotive Applications Without EGR

1. Filtered intake air to turbocharger 4. Intake manifold

2. Turbocharger air to charge air cooler 5. Intake valve ports
3. Charge air cooler intake air to intake manifold 6. Intake valves.
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Flow Diagram, Air Intake System ISM, ISMe, and QSM11

Page F-40 Section F - Familiarization

Marine Applications

1. Filtered intake air to turbocharger 4. Aftercooled air through intake manifold

2. Turbocharger air to aftercooler 5. Intake valve ports.
3. Intake air through the aftercooler
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ISM, ISMe, and QSM11 Flow Diagram, Air Intake System

Section F - Familiarization Page F-41

Industrial and Generator Drive

1. Filtered intake air to turbocharger 4. Intake manifold

2. Turbocharger air to charge air cooler 5. Intake valve ports
3. Charge air cooler intake air to intake manifold 6. Intake valves.
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Exhaust System - Overview ISM, ISMe, and QSM11

Page F-42 Section F - Familiarization

Exhaust System - Overview (011-999)

General Information
Exhaust Gas Recirculation (EGR)
In the 2002 ISM engine, exhaust gas is recirculated through the engine to reduce the amount of oxides of Nitrogen
(NOx) emitted from the engine. The exhaust gas is cooled as it flows through the EGR cooler. It is then mixed with
the compressed fresh air from the turbocharger before entering the intake manifold. EGR is introduced to reduce the
amount of in-cylinder oxygen available for combustion while maintaining the same amount of flow through the engine.
Exhaust gases present during the start of combustion are very stable and have a very slow reaction rate. During
combustion they absorb heat, resulting in lower in-cylinder peak flame temperatures and therefore lower NOx
emissions.
EGR Mixer
The EGR mixer is designed to completely mix the EGR gas with the turbocharged air from the charge air cooler.
Complete mixing is necessary to provide smooth operation and decreased emissions.

EGR Valve
The EGR valve is controlled by a pulse width modulated signal sent by the Electronic Control Module (ECM) and
operates between 0 percent and 100 percent open. When the EGR valve is open, exhaust gas flows from the hot side
of the engine, through the EGR cooler, and into the EGR mixer.
EGR Connection Tube
The EGR connection tube allows the flow of cooled exhaust gas from the EGR cooler outlet connection at the rear of
the engine to the EGR mixer before the intake manifold. The EGR connection tube is a one-piece design. The EGR
connection tube contains a flow orifice that is used to measure the amount of exhaust gas flow using an EGR
differential pressure sensor.
Exhaust Manifold - With EGR
The exhaust manifold for the 2002 ISM engine was strengthened as a result of the added weight of the turbocharger
and the EGR valve. The exhaust manifold also has a port near the number 1 exhaust port for the exhaust pressure
sensor. The exhaust manifold to EGR valve joint is a three-bolt flange.
The wastegated turbocharger is a Holset model HX55. It
is comprised of a turbocharger, wastegate actuator, and
wastegate valve in the turbine housing. A wastegated
turbocharger provides improved response at low engine
speeds without sacrificing turbocharger durability at high
speeds. This is accomplished by allowing exhaust gases
to bypass the turbine wheel during certain modes of
engine operation. During low rpm operation, the
turbocharger operates as a closed-system turbocharger
where the gases' energy is transferred to the compressor
wheel and used to compress intake air. During high rpm
operation however, the turbocharger becomes an open-
system turbocharger and allows exhaust gas to bypass
the turbine. Since exhaust gas is gated around the turbine
wheel, less energy is absorbed through the turbine and
transferred to the compressor, reducing intake manifold
pressures and turbine speeds.
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ISM, ISMe, and QSM11 Exhaust System - Overview

Section F - Familiarization Page F-43

The wastegate controller in mounted on the rear of the

intake manifold on the turbocharger side of the engine and
is controlled by the ECM. The wastegate controller
regulates the percentage of the intake manifold pressures
sent to the wastegate actuator. Two solenoids, similar to
the fuel pump shutoff valves of the Celect™ product, are
used in conjunction with four orifices to regulate this
percentage.

The wastegate actuator is mounted on the turbocharger

and consists of a pressure canister, diaphragm, and rod.
As pressure changes in the canister, as dictated by the
wastegate controller, the actuator rod adjusts the
wastegate valve accordingly.

The wastegate valve is mounted inside the turbocharger

in the turbine housing. As the valve opens, exhaust gas is
allowed to bypass the turbine wheel, lowering turbine
speed to adjust intake manifold pressure.
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Flow Diagram, Exhaust System ISM, ISMe, and QSM11

Page F-44 Section F - Familiarization

Flow Diagram, Exhaust System (200-005)

Flow Diagram
Automotive Applications with EGR

1. Exhaust gas to manifold 5. EGR valve

2. Exhaust manifold 6. Exhaust gas to EGR cooler connection
3. Exhaust gas to turbocharger 7. EGR cooler
4. Exhaust gas to EGR valve 8. Cooled exhaust gas to EGR connection tube and
EGR mixer.
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ISM, ISMe, and QSM11 Flow Diagram, Exhaust System

Section F - Familiarization Page F-45

Flow Diagram, Exhaust System (200-005)

Flow Diagram
Automotive Applications with EGR

Variable Geometry Turbocharger - Opened and Closed

1. Exhaust in 4. Sliding nozzle closed
2. Sliding nozzle open 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow
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Flow Diagram, Exhaust System ISM, ISMe, and QSM11

Page F-46 Section F - Familiarization

Automotive Applications Without EGR

1. Exhaust valve ports 3. Turbocharger turbine.

2. Exhaust manifold
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ISM, ISMe, and QSM11 Flow Diagram, Exhaust System

Section F - Familiarization Page F-47

Automotive Applications Without EGR

Wastegate Actuation - Opened and Closed

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Flow Diagram, Exhaust System ISM, ISMe, and QSM11

Page F-48 Section F - Familiarization

Marine Applications

1. Exhaust valve ports 3. Turbocharger exhaust outlet.

2. Exhaust manifold
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ISM, ISMe, and QSM11 Flow Diagram, Exhaust System

Section F - Familiarization Page F-49

Industrial and Generator Drive

1. Exhaust valve ports 3. Turbocharger exhaust outlet.

2. Exhaust manifold
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Flow Diagram, Exhaust System ISM, ISMe, and QSM11

Page F-50 Section F - Familiarization

Industrial and Generator Drive

Wastegate Actuation OPEN and CLOSED

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ISM, ISMe, and QSM11 Compressed Air System - Overview

Section F - Familiarization Page F-51

Compressed Air System - Overview (012-999)

General Information
Air Compressor Air Inlet Line
In the 2002 ISM engine the air compressor receives turbocharged air from the charged air supply before it mixes with
the exhaust gas. Since no exhaust gas will be drawn into the air compressor, Original Equipment Manufacturers
(OEMs) are able to utilize the same style air compressor and the air tank setup as with the previous ISM engine. This
is a two piece line with a hose connection at the rear of the engine.
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.
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Compressed Air System - Overview ISM, ISMe, and QSM11

Page F-52 Section F - Familiarization

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.

Cummins Single Cylinder Air System:

1. Air Governor
2. Discharge Line
3. Air Dryer
4. Supply Tank
5. Check Valve
6. Primary Tank
7. Secondary Tank
8. Check Valve
9. Air Compressor

Holset Single Cylinder Air System QE and SS-E-Type:

1. Air Governor
2. Discharge Line
3. Air Dryer *
4. Supply Tank
5. Check Valve
6. Primary Tank
7. Secondary Tank
8. Check Valve
9. Air Compressor
NOTE: * Any dryer that will maintain air pressure in the
discharge line when the compressor is in the unloaded
mode can be used.

Typical Twin Cylinder Air System:

1. Air Compressor
2. Air Governor
3. Discharge Line
4. Safety Valve
5. Supply Tank
6. Purge Tank
7. Air Dryer
8. Air Governor
9. Supply Tank
10. Check Valve
11. Primary Tank
12. Secondary Tank
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ISM, ISMe, and QSM11 Flow Diagram, Compressed Air System

Section F - Familiarization Page F-53

Flow Diagram, Compressed Air System (200-006)

Compressed Air System
Cummins

1. Coolant 3. Lubricant.
2. Air
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Flow Diagram, Compressed Air System ISM, ISMe, and QSM11

Page F-54 Section F - Familiarization

Holset® Models

1. Air governor signal 3. Lubricant

2. Air 4. Coolant.
ISM, ISMe, and QSM11 Electrical Equipment - Overview
Section F - Familiarization Page F-55

Electrical Equipment - Overview (013-999)

General Information
Alternator
The 2002 ISM engine has a new pad-mount alternator option.
The basic heavy-duty electrical system consists of:
• Batteries (1) (usually three or four connected in
parallel)
• A starting motor (2)
• An alternator (3)
• A magnetic switch (4)
• An ignition switch (5)
• A push-button switch (6)
• All necessary wiring.
All components must be carefully matched.

The accompanying illustrations show typical parallel and

series battery connections:
• Parallel connection.

• Series connection.
Engine Testing - Overview ISM, ISMe, and QSM11
Page F-56 Section F - Familiarization

Engine Testing - Overview (014-999)

General Information

CAUTION
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.
This section outlines engine testing and engine run-in
recommendations for M series 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.
Before running the engine, make sure the engine is filled
with the proper coolant. Also, be sure the lubricating oil
system is filled and primed.

In-Service Run-In:
The majority of heavy-duty diesel applications will provide
sufficient run-in under normally 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 M series 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 neither 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. It is neither
required nor recommended that an engine, which has
been run-in and tested on a dynamometer, be run-in again
after having been reinstalled in the vehicle.
ISM, ISMe, and QSM11 Engine Testing - Overview
Section F - Familiarization Page F-57

Definition of terms on engine performance curve.

Cummins M Series Heavy-Duty Engine Operating Curve Definitions:

1. Peak Torque (N•m [ft-lb]) - Maximum torque that the engine will produce. This is listed on the engine dataplate.
2. Peak Torque rpm - Engine speed at which peak torque is generated. This is listed on the engine dataplate.
3. Maximum hp rpm - Engine speed at which maximum power is developed. This is listed with advertised
horsepower 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.
5. Operating Range - The engine's operating range from peak torque up to the engine's governed speed.
6. Full-Load Governed Speed - Defined as the upper end of the engine's full-load operating range. This is listed on
the engine dataplate.
7. No-Load Governed Speed - ( not shown) Maximum unloaded engine speed. This value is listed on the engine
data sheet and in the FPEPS publications.
8. 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 speed, and so
forth) transmissions with close ratio splits between gear shifts.
9. 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, and so
forth) transmissions with large ratio splits between gear shifts.
CAUTION
Refer to General Engine Test Specifications in this
section before operating the engine to avoid internal
component damage.
General Run-in Procedures:
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 5 minutes or less.
Engine Testing - Overview ISM, ISMe, and QSM11
Page F-58 Section F - Familiarization

CAUTION
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.
Start the engine and idle for initial check.
Avoid long idle periods. Operate the engine at low idle
only long enough (5 minutes maximum) to check for
correct oil pressure and any fuel, oil, water, or air leaks.

CAUTION
To avoid internal component damage, do not allow the
engine speed to exceed 1000 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 3 minutes to avoid
internal component damage.
ISM, ISMe, and QSM11 Engine Testing - Overview
Section F - Familiarization Page F-59

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 Engine Company, along with installation and
operation recommendations. The fuel measuring device,
Part Number 3376375, can be used with either a chassis
or engine dynamometer.
Installation:
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. Therefore, the
plumbing used must include nonrestrictive 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 to maintain 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 15 feet.
• 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.
Engine Testing - Overview ISM, ISMe, and QSM11
Page F-60 Section F - Familiarization

Operation:
This is a schematic of the fuel measuring device, Part Number 3376375. The device consists of the following
components:
• Fuel filter
• Flow meter
• Float tank
• Fuel rail pressure gauge
• Fuel cooler is not a part of fuel measuring device, Part Number 3376375; however, it must be used when
conducting a test with the flow meter.

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 de-aerated 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 de-aeration. The fuel is then returned to the engine fuel
inlet. Refer to the sketch for fuel line connection points on the fuel measuring device.
ISM, ISMe, and QSM11 Vehicle Braking - Overview
Section F - Familiarization Page F-61

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 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.

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 flow meter is know as "makeup" fuel, or the amount of fuel being burned by the engine.
The flow meter is graduated to read fuel flow in pounds per hour. The flow meter contains two floats with respective
scales on either side of the flow meter. 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 flow meter 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 flow
meter, and the temperature gauge reads +2 percent; the corrected fuel flow rate will be 125 plus 2 percent, or 127.5
lbs/hr.

Vehicle Braking - Overview (020-999)

General Information
Engine Brake Solenoid
The 2002 ISM engine uses case-grounded engine brake solenoids for a more direct and reliable ground. The engine
brake solenoids have both low voltage and high voltage fault codes.
Vehicle Braking - Overview ISM, ISMe, and QSM11
Page F-62 Section F - Familiarization

Notes
ISM, ISMe, and QSM11
Section TS - Troubleshooting Symptoms Page TS-a

Section TS - Troubleshooting Symptoms

Section Contents
Page
Troubleshooting Procedures and Techniques ...............................................................................................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-7
Air Compressor Pumping Excess Lubricating Oil into the Air System .............................................................TS-8
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)..................................TS-10
Air Compressor Will Not Pump Air................................................................................................................TS-11
Air Compressor Will Not Stop Pumping.........................................................................................................TS-12
Alternator Not Charging or Insufficient Charging...........................................................................................TS-13
Alternator Overcharging................................................................................................................................TS-15
Coolant in the Lubricating Oil........................................................................................................................TS-25
Coolant Loss - External.................................................................................................................................TS-16
Coolant Loss - Internal..................................................................................................................................TS-17
Coolant Temperature Above Normal - Gradual Overheat...............................................................................TS-18
Coolant Temperature Above Normal - Sudden Overheat...............................................................................TS-21
Coolant Temperature Below Normal..............................................................................................................TS-23
Crankcase Gases (Blowby) Excessive...........................................................................................................TS-26
Engine Brake - Low Retarding Power or Slow to Activate..............................................................................TS-29
Engine Brake Does Not Operate...................................................................................................................TS-27
Engine Brake — One or More Cylinders Braking with Power Switch Off........................................................TS-31
Engine Decelerates Slowly............................................................................................................................TS-32
Engine Noise Excessive................................................................................................................................TS-33
Engine Noise Excessive — Combustion Knocks............................................................................................TS-36
Engine Noise Excessive — Connecting Rod..................................................................................................TS-37
Engine Noise Excessive — Main Bearing......................................................................................................TS-38
Engine Noise Excessive — Piston.................................................................................................................TS-39
Engine Noise Excessive — Turbocharger......................................................................................................TS-40
Engine Speed Surges in PTO or Cruise Control............................................................................................TS-41
Engine Starts But Will Not Keep Running......................................................................................................TS-43
Engine Vibration Excessive...........................................................................................................................TS-45
Engine Will Not Crank or Cranks Slowly (Air Starter).....................................................................................TS-47
Engine Will Not Crank or Cranks Slowly (Electric Starter)..............................................................................TS-48
Engine Will Not Shut Off...............................................................................................................................TS-50
Fuel Consumption Excessive........................................................................................................................TS-51
Fuel in Coolant.............................................................................................................................................TS-55
Fuel in the Lubricating Oil.............................................................................................................................TS-56
Intake Manifold Air Temperature Above Specification....................................................................................TS-57
Intake Manifold Pressure (Boost) is Below Normal.........................................................................................TS-59
Low Idle Adjust Switch Does Not Work..........................................................................................................TS-61
Lubricating Oil Consumption Excessive........................................................................................................TS-62
Lubricating Oil Contaminated........................................................................................................................TS-64
Lubricating Oil Degradation (Centinel)...........................................................................................................TS-65
Lubricating Oil Pressure High.......................................................................................................................TS-66
Lubricating Oil Pressure Low........................................................................................................................TS-67
Lubricating Oil Sludge in the Crankcase Excessive.......................................................................................TS-70
Lubricating Oil Temperature Above Specification..........................................................................................TS-71
Lubricating or Transmission Oil in the Coolant..............................................................................................TS-72
Oil Pan Level Incorrect - High (Centinel)........................................................................................................TS-74
Oil Pan Level Incorrect - Low (Centinel).........................................................................................................TS-73
Operating Fuel Pressure is Low....................................................................................................................TS-75
Turbocharger Leaks Engine Oil or Fuel.........................................................................................................TS-76
Troubleshooting Overview ...........................................................................................................................TS-77
Connecting Rod Bearing Noise.....................................................................................................................TS-77
Driveability/Low Power - Customer Complaint Form......................................................................................TS-79
ISM, ISMe, and QSM11
Page TS-b Section TS - Troubleshooting Symptoms

Driveability/Low Power/Excessive Fuel Consumption - Checklist...................................................................TS-77

Driveability/Low Power/Excessive Fuel Consumption - Checklist...................................................................TS-80
Engine Noise Diagnostic Procedures - General Information...........................................................................TS-77
Fuel Consumption - Customer Complaint Form.............................................................................................TS-82
Fuel Consumption - General Information.......................................................................................................TS-81
Main Bearing Noise......................................................................................................................................TS-77
Oil Consumption...........................................................................................................................................TS-83
Piston Noise.................................................................................................................................................TS-77
Response Test..............................................................................................................................................TS-86
ISM, ISMe, and QSM11 Troubleshooting Procedures and Techniques
Section TS - Troubleshooting Symptoms Page TS-1

Troubleshooting Procedures and Techniques

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 ISM, ISMe, and QSM11
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.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-3

Air Compressor Air Pressure Rises Slowly

This is symtom 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
for leaks with spring brakes applied and released.
STEP 2 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
STEP 3 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly 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 and 010-
033.

OK
Go To Next Step
STEP 5 Install an Econ valve, a check valve, and system
E-type system is not plumbed correctly (Holset® ............ hoses. Refer to the Master Repair Manual, Holset®
only) 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
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-4 Section TS - Troubleshooting Symptoms

Air Compressor Air Pressure Rises Slowly

This is symtom tree t004
Cause Correction
Inspect the air compressor intake and exhaust
STEP 8 valve assemblies. Refer to the Master Repair
............
Air compressor intake or exhaust valve leaks air Manual, Holset® Air Compressors, Bulletin
3666121.

OK
Go To Next Step

STEP 9
Refer to the Automotive and Bus Installation
............ Recommendations - Air Compressor Systems,
Air installation issues
Bulletin 3884946.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-5

Air Compressor Cycles Frequently

This is symtom tree t005
Cause Correction
Block the vehicle wheels and check the air system
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
STEP 2 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly to Procedure 012-017.

OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 3 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to manufacturer's
instructions.

OK
Go To Next Step
STEP 4 Install an Econ valve, a check valve, and system
E-type system is not plumbed correctly (Holset® ............ hoses. Refer to the Master Repair Manual, Holset®
only) Air Compressors, Bulletin 3666121.

OK
Go To Next Step

STEP 5
Check for carbon buildup. Replace the air
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, 010-033.

OK
Go To Next Step
STEP 6 Replace the desiccant cartridge on the air dryer (if
............
Air dryer desiccant cartridge needs replaced equipped). Refer to the OEM service manual.

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.

OK
Go To Next Step

STEP 8
Refer to the Automotive and Bus Installation
............ Recommendations - Air Compressor Systems,
Air installation issues
Bulletin 3884946.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-6 Section TS - Troubleshooting Symptoms

Air Compressor Cycles Frequently

This is symtom tree t005
Cause Correction
Check the air compressor duty cycle. Install a
STEP 9 larger air compressor, if necessary. Refer to
............
Air compressor not designed for application Section G in the Master Repair Manual, Holset® Air
Compressors, Bulletin 3666121.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-7

Air Compressor Noise is Excessive

This is symtom tree t006
Cause Correction
Check for carbon buildup. Replace the air
STEP 1 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 and 010-
033.

OK
Go To Next Step
STEP 2
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 3 Check the accessory drive axial end play. Inspect
Accessory drive is worn (axial end play is out of ............ the shaft for wear. Refer to Shop Manual, M11
specification) Series Engines, Bulletin 3666075.

OK
Go To Next Step
STEP 4 Check the air compressor timing. Refer to
............
Air compressor timing is not correct Procedure 012-014.

OK
Go To Next Step
STEP 5 Inspect the accessory drive gears and gear train.
Air compressor drive gear or engine gear train is ............ Refer to Procedures 001-036, 001-039, and 001-
worn or damaged 040.

OK
Go To Next Step
STEP 6
............ Check for ice in low spots of the air discharge line.
Ice buildup in the air system components

OK
Go To Next Step
STEP 7 Check for pin bore wear. Refer to Procedure 012-
............
Pin bore wear is excessive 010.

OK
Go To Next Step
STEP 8
Replace or rebuild the air compressor. Refer to
Air compressor is excessively worn or internally ............
Procedure 012-014.
damaged
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-8 Section TS - Troubleshooting Symptoms

Air Compressor Pumping Excess Lubricating Oil into the Air System
This is symtom tree t007
Cause Correction

STEP 1
Verify the correct lubricating oil drain interval.
............ Refer to the correct operation and maintenance
Lubricating oil drain interval is excessive
manual.

OK
Go To Next Step
STEP 2 Replace or rebuild the air compressor. Refer to
Air compressor is excessively worn or internally ............ Procedure 012-014. Refer to the manufacturer's
damaged instructions.

OK
Go To Next Step

STEP 3
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 4
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 5 Check the oil pressure. Refer to Procedure 007-
............
Lubricating oil pressure is above specification 028.

OK
Go To Next Step

STEP 6
Check for excessive blowby. Refer to Section 14.
............ Refer to the Crankcase Gases (Blowby) Excessive
Crankcase pressure is excessive
symptom tree.

OK
Go To Next Step
STEP 7 Check the air governor for correct operation. Refer
............
Air compressor pumping too high air pressure to Procedure 012-017.

OK
Go To Next Step
STEP 8
Engine angularity during operation exceeds ............ Refer to the Engine Specification data sheet.
specification

OK
Go To Next Step
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-9

Air Compressor Pumping Excess Lubricating Oil into the Air System
This is symtom tree t007
Cause Correction
Check for carbon buildup. Replace the air
STEP 9 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 and 010-
033.

OK
Go To Next Step
STEP 10 Replace the desiccant cartridge on the air dryer (if
............
Air dryer desiccant cartridge needs replaced equipped). Refer to the OEM service manual.

OK
Go To Next Step
STEP 11 Drain the reservoirs daily. Refer to the Operation
Contaminants are building up in the system ............ and Maintenance Manual ISM and ISMe Series
reservoirs Engines, Bulletin 3666319.

OK
Go To Next Step
Replace the air compressor air cleaner (if
STEP 12 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.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-10 Section TS - Troubleshooting Symptoms

Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
This is symtom tree t008
Cause Correction
Block the vehicle wheels and check the air system
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
STEP 2 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly to Procedure 012-013.

OK
Go To Next Step
Inspect the air compressor intake and exhaust
STEP 3 valve assemblies. Refer to the Master Repair
............
Air compressor intake or exhaust valve leaks air Manual, Holset® Air Compressors, Bulletin
3666121.

OK
Go To Next Step
STEP 4
Check the torque on the unloader screws. Refer to
Cover gasket is leaking internally (Holset® SS ............
Procedure 012-013.
models only)

OK
Go To Next Step

STEP 5
Refer to the Automotive and Bus Installation
............ Recommendations - Air Compressor Systems,
Air installation issues
Bulletin 3884946.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-11

Air Compressor Will Not Pump Air

This is symtom tree t009
Cause Correction
STEP 1 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly to Procedure 012-017.

OK
Go To Next Step
STEP 2 Check the unloader valve and unloader body seal.
............
Unloader valve is malfunctioning Refer to Procedure 012-013.

This is symtom tree t023
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to Section TF in the
STEP 1 Troubleshooting and Repair Manual, Electronic
Electronic fault codes active or high counts of ............ Control System, ISM and QSM11 Engines, Bulletin
inactive fault codes 3666266 or the Troubleshooting and Repair
Manual, CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

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
Refer to Procedure 008-018.

OK
Go To Next Step
STEP 4 Inspect engine for internal coolant leaks. Refer to
............
Coolant level is below specification the Coolant Loss - Internal symptom tree.

OK
Go To Next Step
STEP 5
Inspect the radiator hoses. Refer to Procedure 008-
Cooling system hose is collapsed, restricted, or ............
045.
leaking

OK
Go To Next Step

STEP 6
Inspect the radiator shutters. Repair or replace if
necessary. Refer to the manufacturer's
Radiator shutters are not opening completely or ............
instructions. Check the shutterstat setting. Refer to
the shutterstat setting is wrong
Procedure 008-020 or 008-049.

OK
Go To Next Step

STEP 7
Check the fan drive and controls. Refer to
............ Procedure 008-024, 008-025, 008-026, 008-027, or
Fan drive or fan controls are malfunctioning
008-028.

OK
Go To Next Step
STEP 8 Perform the cooling system diagnostics test. Refer
............
Cooling system component is malfunctioning to Procedure 008-020.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-22 Section TS - Troubleshooting Symptoms

Coolant Temperature Above Normal - Sudden Overheat

This is symtom tree t023
Cause Correction

STEP 9
Check the thermostat for the correct part number
............ and for correct operation. Refer to Procedure 008-
Thermostat is not correct or is malfunctioning
013.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-23

Coolant Temperature Below Normal

This is symtom tree t024
Cause Correction

STEP 1
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
Check the winterfront, shutters, and under-the-
hood air. Use under-the-hood intake air in cold
STEP 2 weather. Refer to Operation of Diesel Engines in
............ Cold Climates, Bulletin 3379009, and the
Engine is operating at low ambient temperature
Operation and Maintenance Manual ISM and
ISMe Engines, Bulletin 3666319.

OK
Go To Next Step
STEP 3 Check the routing of the coolant fill line. Refer to
............
Coolant fill line is not routed correctly the OEM service manual.

OK
Go To Next Step
Check the shutter operation. Repair or replace the
STEP 4 shutters if necessary. Refer to Procedure 019-019
............
Radiator shutters are stuck open or opening early in the Troubleshooting and Repair Manual
CELECT™ Plus System, Bulletin 3666130.

OK
Go To Next Step
View and troubleshoot the fault codes with
INSITE™. Refer to the corresponding fault code in
STEP 3
Section TF in the Troubleshooting and Repair
Manual Electronic Control System ISM and
Electronic fault codes active or high counts of ............
QSM11 Series Engines, Bulletin 3666266 and the
inactive fault codes
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 4 Check the engine brake harness connectors.
Engine brake harness connectors are loose or ............ Check the engine brake harness for continuity.
broken Refer to the manufacturer's instructions.

OK
Go To Next Step
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedure 019-009 or 019-010 in
STEP 5
the Troubleshooting and Repair Manual Electronic
............ Control System ISM and QSM11 Series Engines,
Clutch switch or circuit is malfunctioning
Bulletin 3666266 and the Troubleshooting and
Repair Manual CM870 Electronic Control System
ISM Engines, Bulletin 4021381.

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
Repair Manual Electronic Control System ISM and
Throttle position sensor is misadjusted or ............
QSM11 Series Engines, Bulletin 3666266 and the
malfunctioning
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-28 Section TS - Troubleshooting Symptoms

Engine Brake Does Not Operate

This is symtom tree t036
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
STEP 8 Check for voltage at the solenoid valve. Refer to
............
Solenoid valve is malfunctioning the manufacturer's instructions.

OK
Go To Next Step

STEP 9
Remove the solenoid valve and clean or replace
............ the screen. Refer to the manufacturer's
Solenoid valve filter screen is covered with debris
instructions.

OK
Go To Next Step
Check the engine brake hose connections, the
STEP 10 engine brake housing, and the jumper tube o-rings
............
Lubricating oil leak (internal) for oil leaks. Refer to the manufacturer's
instructions.

OK
Go To Next Step
STEP 11 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 12 Adjust the engine brakes. Refer to Procedure 003-
............
Engine brake adjustment is not correct 004.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-29

Engine Brake - Low Retarding Power or Slow to Activate

This is symtom tree t037
Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1
Repair Manual Electronic Control System ISM and
QSM11 Engines, Bulletin 3666266 and the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381.

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. Refer to Procedure 007-
............ 028. If the pressure is low, refer to the Lubricating
Lubricating oil pressure is below specification
Oil Pressure Low symptom tree.

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
STEP 6 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 7 Adjust the engine brakes. Refer to Procedure 003-
............
Engine brake adjustment is not correct 004.

OK
Go To Next Step
STEP 8 Check the engine brake harness connectors.
Engine brake harness connectors are loose or ............ Check the engine brake harness for continuity.
broken Refer to the manufacturer's instructions.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-30 Section TS - Troubleshooting Symptoms

Engine Brake - Low Retarding Power or Slow to Activate

This is symtom tree t037
Cause Correction

STEP 9
Check the master piston for freedom of movement.
............ Replace the master piston if necessary. Refer to
Master piston is stuck
the manufacturer's instructions.

OK
Go To Next Step
STEP 10
............ Refer to Procedure 020-024.
Engine brake solenoid(s) is malfunctioning
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-31

Engine Brake — One or More Cylinders Braking with Power Switch Off
This is symtom tree t038
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to Section TF in the
STEP 1 Troubleshooting and Repair Manual, Electronic
Electronic fault codes active or high counts of ............ Control System ISM and QSM11 Engines, Bulletin
inactive fault codes 3666266 or the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

This is symtom tree t047
When troubleshooting for the cause of engine noise, make sure that the engine accessories (air compressor, fan
clutch, freon compressor, or hydraulic pump) are not causing the noise. Refer to Engine Noise Diagnostic Procedures
— General Information at the end of this section before using this symptom tree.
Cause Correction
STEP 18 Disconnect the drivetrain. Check for engine noise.
............
Drivetrain noise is excessive Refer to the OEM service manual.

OK
Go To Next Step
STEP 19
Check the gear backlash and the gear teeth. Refer
Gear train backlash is excessive or the gear teeth ............
to Procedures 001-036, 001-039. and 001-040.
are damaged

OK
Go To Next Step
STEP 20 Refer to the Engine Noise Excessive - Main
............
Main bearing or connecting rod bearing noise Bearing symptom tree.

OK
Go To Next Step
STEP 21
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 22 Check the static injection timing. Refer to
............
Static injection timing is not correct Procedure 006-025.

OK
Go To Next Step
STEP 23
Refer to Engine Noise Excessive - Piston symptom
Piston, piston rings, or cylinder liner is worn or ............
tree.
damaged

OK
Go To Next Step
STEP 24 Disassemble and repair the REPTO as necessary.
Rear engine power take-off (REPTO) noise is ............ Refer to the Shop Manual, M11 Series Engines,
excessive Bulletin 3666075.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-36 Section TS - Troubleshooting Symptoms

Engine Noise Excessive — Combustion Knocks

This is symtom tree t048
Refer to Engine Noise Diagnostic Procedures — General Information at the end of this section before using this
symptom tree.
Cause Correction
STEP 1 Repair or replace the ether starting aids. Refer to
............
Ether starting aid is malfunctioning the manufacturer's instructions.

OK
Go To Next Step

STEP 2
Perform the single-cylinder cutout test. Replace
............ the injectors as necessary. Refer to Procedure
Injector is malfunctioning
006-026.

OK
Go To Next Step
STEP 3 Measure and adjust the overhead settings. Refer
............
Overhead adjustments are not correct to Procedure 003-004.

OK
Go To Next Step
STEP 4 Refer to the Engine Smoke Excessive (White)
............
Incomplete combustion (white smoke) symptom tree.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-37

Engine Noise Excessive — Connecting Rod

This is symtom tree t049
Refer to Engine Noise Diagnostic Procedures — General Information at the end of this section before using this
symptom tree.
Cause Correction

STEP 1
Check the oil pressure. Refer to Procedure 007-
............ 028. If the pressure is low, refer to the Lubricating
Lubricating oil pressure is below specification
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
007-025.

OK
Go To Next Step
Refer to the Lubricating Oil System - General
STEP 3 Information in Section F. If the oil pressure is low,
............
Lubricating oil is thin or diluted refer to the Lubricating Oil Pressure Low symptom
tree.

OK
Go To Next Step
STEP 4
Check the torque on the connecting rod
Connecting rod capscrews are loose or not ............
capscrews. Refer to Procedure 001-014.
tightened correctly

OK
Go To Next Step
STEP 5
Connecting rod and bearings are damaged or Inspect the connecting rod and bearings. Refer to
............
worn, are not assembled correctly, or are the Procedure 001-005.
wrong bearings

OK
Go To Next Step

STEP 6
Remove and inspect the connecting rods. Refer to
............ Procedure 001-014 and the Shop Manual, M11
Connecting rod is bent or out of alignment
Series Engines, Bulletin 3666075.

This is symtom tree t068
Cause Correction
Refer to the Troubleshooting and Repair Manual
STEP 1
Electronic Control System ISM and QSM11
Engines, Bulletin 3666266 and the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
Check the cruise control/PTO on/off switch and the
circuit. Refer to Procedures 019-021 and 019-022
STEP 2
in the Troubleshooting and Repair Manual
Electronic Control System ISM and QSM11
Cruise control/PTO on/off switch or circuit is ............
Engines, Bulletin 3666266 and the
malfunctioning
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
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
STEP 3 ecm_calibration_rev_history.xlson QuickServe®
Electronic control module (ECM) calibration is ............ Online or the INCAL™ CD-ROM. Compare the
malfunctioning calibration stored in the ECM with the engine rating
and the Control Parts List (CPL), Bulletin 4021326
or 4021327. If necessary, recalibrate the ECM.
Refer to the appropriate electronic service tool
manual.

OK
Go To Next Step
Check the engine position sensor and circuit. Refer
to Procedures 019-038 and 019-039 in the
STEP 4 Troubleshooting and Repair Manual Electronic
Engine position sensor (EPS) or circuit is ............ Control System ISM and QSM11 Engines, Bulletin
malfunctioning 3666266 and the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

OK
Go To Next Step
Check the vehicle speed sensor and circuit. Refer
to Procedures 019-090 and 019-091 in the
STEP 5 Troubleshooting and Repair Manual Electronic
Vehicle speed sensor (VSS) or circuit is ............ Control System ISM and QSM11 Engines, Bulletin
malfunctioning 3666266 and the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-42 Section TS - Troubleshooting Symptoms

Engine Speed Surges in PTO or Cruise Control

This is symtom tree t068
Cause Correction
STEP 6 Dry the connectors with Cummins electronic
............
Moisture in the wiring harness connectors cleaner, Part Number 3824510.

OK
Go To Next Step
Check the fuel pump output pressure, pulsation
STEP 7 damper, and pressure regulator. Replace the fuel
............
Fuel pump is malfunctioning pump if necessary. Refer to Procedures 005-011,
005-016, and 005-031.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-43

Engine Starts But Will Not Keep Running

This is symtom tree t072
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to the ISM INSITE™ software user
manual, Bulletin 3666894. Refer to the
STEP 1 corresponding fault code in Section TF the
Electronic fault codes active or high counts of ............ Troubleshooting and Repair Manual Electronic
inactive fault codes Control System ISM and QSM11 Engines, Bulletin
3666266 and the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

OK
Go To Next Step
STEP 2
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
STEP 3 Fill the supply tank. Refer to the OEM service
............
Fuel level is low in the tank manual.

OK
Go To Next Step
STEP 4 Check the batteries and the unswitched battery
............
Battery voltage is low supply circuit. Refer to Procedure 013-007.

OK
Go To Next Step
STEP 5 Check the vehicle, equipment, or vessel keyswitch
............
Keyswitch circuit is malfunctioning circuit. Refer to Procedure 013-019.

OK
Go To Next Step

STEP 6
Check for transmission malfunctioning, cooling fan
............ operation cycle time, and engine-driven units.
Vehicle parasitics are excessive
Refer to the OEM Service manual..

OK
Go To Next Step
STEP 7 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003.

OK
Go To Next Step

STEP 8
Check the gear pump output pressure. Replace the
............ gear pump if necessary. Refer to Procedure 005-
Gear pump is malfunctioning
060.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-44 Section TS - Troubleshooting Symptoms

Engine Starts But Will Not Keep Running

This is symtom tree t072
Cause Correction
STEP 9 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 10 Adjust the engine brakes. Refer to Procedure 020-
............
Engine brake adjustment is not correct 024.

OK
Go To Next Step
STEP 11 Check the static injection timing. Refer to
............
Static injection timing is not correct Procedure 006-025.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-45

Engine Vibration Excessive

This is symtom tree t075
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to the ISM INSITE™ software user
manual, Bulletin 3666894. Refer to the
STEP 1 corresponding fault code in Section TF in the
Electronic fault codes active or high counts of ............ Troubleshooting and Repair Manual Electronic
inactive fault codes Control System ISM or QSM11 Engines, Bulletin
3666266 or the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

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
Verify the correct idle speed setting. Increase the
STEP 3 idle speed with the idle increment switch or an
Engine idle speed is set too low (electronically ............ electronic service tool. Refer to the Fuel System
controlled fuel systems) Specifications in Section V and the appropriate
electronic service tool manual.

OK
Go To Next Step
STEP 4
............ Check the fan. Refer to Procedure 008-040.
Fan is loose, damaged, or not balanced

OK
Go To Next Step
Check the fan hub, alternator, refrigerant
STEP 5 compressor, and hydraulic pump for interference.
............
Belt-driven accessories are malfunctioning Isolate belt-driven accessories and check for
vibration. Refer to the OEM service manual.

OK
Go To Next Step
STEP 6
Verify the condition of the mounts. Refer to
Engine mounts are worn, damaged, loose, or not ............
Procedure 016-010 and the OEM service manual.
correct

OK
Go To Next Step
STEP 7
............ Inspect the vibration damper. Refer to 001-052.
Vibration damper is damaged

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-46 Section TS - Troubleshooting Symptoms

Engine Vibration Excessive

This is symtom tree t075
Cause Correction

STEP 8
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 9
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
Check the hydraulic pump and air compressor.
STEP 10 Isolate gear-driven accessories and check for
............
Gear-driven accessories are malfunctioning vibration. Refer to Procedures 009-001 and 009-
016.

OK
Go To Next Step
STEP 11 Check the flywheel housing alignment. Refer to
............
Flywheel housing is not aligned correctly Procedure 016-006.

OK
Go To Next Step
STEP 12
Check the flywheel or flexplate and the mounting
Flywheel or flexplate capscrews are loose or ............
capscrews. Refer to Procedure 016-005.
broken
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-47

Engine Will Not Crank or Cranks Slowly (Air Starter)

This is symtom tree t077
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
............ Disengage engine-driven units.
Engine-driven units are engaged

OK
Go To Next Step
STEP 3
Install an oil pan heater, or drain the oil and fill the
Lubricating oil temperature is below ............
system with warm oil.
specificationthe OEM service manual

OK
Go To Next Step

STEP 4
Change the oil and filters. Refer to Procedure 007-
013 or 007-025. Use the oil type recommended in
Lubricating oil does not meet specifications for ............
Section V of the engine operation and
operating conditions
maintenance manual.

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
manufacturer's instructions..

OK
Go To Next Step

STEP 8
Remove the injectors and rotate the crankshaft.
............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
Procedures 006-026 and 001-016.

OK
Go To Next Step

STEP 9
Analyze the oil and inspect the filters to locate an
............ area of probable damage. Refer to Procedure 007-
Internal engine damage
002.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-48 Section TS - Troubleshooting Symptoms

Engine Will Not Crank or Cranks Slowly (Electric Starter)

This is symtom tree t078
Cause Correction
Inspect the batteries and the unswitched battery
supply circuit. Refer to Procedure 013-009, and
Procedure 019-087 in the Troubleshooting and
STEP 1 Repair Manual Electronic Control System ISM and
............
Battery voltage is low QSM11 Engines, Bulletin 3666266 or the
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 2
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 3
............ Disengage engine-driven units.
Engine-driven units are engaged

OK
Go To Next Step
STEP 4 Install an oil pan heater, or drain the oil and fill the
............
Lubricating oil temperature is below specification system with warm oil.

OK
Go To Next Step

STEP 5
Change the oil and filters. Refer to Procedure 007-
013 or 007-025. Use the oil type recommended in
Lubricating oil does not meet specifications for ............
Section V of the engine operation and
operating conditions
maintenance manual.

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 Electrical Systems Specifications in
............
Battery capacity is below specification Section V. Replace the batteries if necessary.

OK
Go To Next Step

STEP 8
Replace the battery cables with larger gauge or
............ shorter length cables. Refer to the Electrical
Battery cables are not the correct gauge or length
Systems Specifications in Section V.

OK
Go To Next Step
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-49

Engine Will Not Crank or Cranks Slowly (Electric Starter)

This is symtom tree t078
Cause Correction
STEP 9 Check the starting circuit components. Refer to the
............
Starting circuit component is malfunctioning OEM service manual.

OK
Go To Next Step

STEP 10
Remove the starting motor, and inspect the gear.
............ Refer to Procedure 013-020 and the
Starting motor pinion or ring gear is damaged
manufacturer's instructions.

OK
Go To Next Step

STEP 11
Remove the injectors and rotate the crankshaft.
............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
Procedures 006-026 and 001-016.

OK
Go To Next Step

STEP 12
Analyze the oil and inspect the filters to locate an
............ area of probable damage. Refer to Procedure 007-
Internal engine damage
002.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-50 Section TS - Troubleshooting Symptoms

Engine Will Not Shut Off

This is symtom tree t081
Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1
Repair Manual, Electronic Control System ISM and
QSM11 Engines Bulletin 3666266 or the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381 for fault code troubleshooting.

OK
Go To Next Step
Check the vehicle, equipment, or vessel keyswitch
circuit. Refer to Procedure 019-064 in the
STEP 2
Troubleshooting and Repair Manual Electronic
............ Control System ISM and QSM11 Engines, Bulletin
Keyswitch circuit is malfunctioning
3666266 or the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

OK
Go To Next Step
Check the fuel shutoff valve solenoid and circuit.
Refer to Procedure 019-049 in the Troubleshooting
STEP 3 and Repair Manual Electronic Control System ISM
Fuel shutoff valve solenoid or circuit is ............ and QSM11 Engines, Bulletin 3666266 or the
malfunctioning (electronic controlled fuel systems) Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 4 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.

Fuel Consumption Excessive

This is symtom tree t087
Cause Correction
Refer to Fuel Consumption General Information
STEP 1 and Customer Complaint Form at the end of
............
Interview the operator to verify the complaint Section TS. Follow the instructions on the form
before continuing with this tree.

OK
Go To Next Step
Explain correct engine operation to the operator.
STEP 2 Refer to Section 1 of the Operation and
............
Operator technique is not correct Maintenance Manual ISM and ISMe Engines,
Bulletin 3666319.

OK
Go To Next Step
Review the VE/VMS® data and compare to the
STEP 3 vehicle and engine specifications. Do not use
............
VE/VMS® analysis uses incorrect data more than 20 percent for the Aero value. Refer to
the VE/VMS User's Manual.

OK
Go To Next Step
STEP 4 Consider ambient temperatures, wind, tire size,
Equipment and environmental factors are affecting ............ axle alignment, routes, and use of aerodynamic
fuel consumption aids when evaluating fuel consumption.

OK
Go To Next Step

STEP 5
Check for correct gearing and drivetrain
............ components. Refer to the OEM vehicle
Drivetrain is not correctly matched to the engine
specifications.

OK
Go To Next Step
Read the fault codes with an electronic service
tool. Refer to Section TF in the Troubleshooting
STEP 6 and Repair Manual Electronic Control System ISM
Electronic fault codes active or high counts of ............ and QSM11 Engines, Bulletin 3666266 and the
inactive fault codes Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
Check the programmable parameters and the
STEP 7 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 appropriate electronic
service tool manual.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-52 Section TS - Troubleshooting Symptoms

Fuel Consumption Excessive

This is symtom tree t087
Cause Correction
Check the turbocharger part number and compare
STEP 8 it to the Control Parts List (CPL), Bulletin number
............
Turbocharger is not correct 3379133 or 4021327. Replace the turbocharger if
necessary. Refer to Procedure 010-033.

OK
Go To Next Step
Check the fuel lines, fuel connections, and fuel
STEP 9 filters for leaks. Check the fuel lines to the supply
............
Fuel leak tanks. Refer to Procedure 006-024 and the OEM
service manuals.

OK
Go To Next Step
Check the hubometer and odometer calibrations.
STEP 10 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 11 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 12
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 Procedure 007-009 or 007-025.

OK
Go To Next Step
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®
Online or the INCAL™ CD-ROM. Compare the
STEP 13 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 Electronic Control System ISM
and QSM11 Engines, Bulletin 3666266 and the
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines Bulletin
4021381.

OK
Go To Next Step
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-53

Fuel Consumption Excessive

This is symtom tree t087
Cause Correction
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
Refer to the appropriate electronic service tool
STEP 14 manual. If necessary, install the correct VSS. Refer
............ to in the Troubleshooting and Repair Manual
Vehicle speed sensor (VSS) is not correct
Electronic Control System ISM and QSM11
Engines Bulletin 3666266 and the Troubleshooting
and Repair Manual CM870 Electronic Control
System ISM Engines, Bulletin 4021381.

OK
Go To Next Step

STEP 15
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 16
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 17 Inspect the air intake and exhaust systems for air
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.

OK
Go To Next Step
STEP 18 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 19 Check the exhaust system for restrictions. Refer to
............
Exhaust system restriction is above specification Procedure 011-009.

OK
Go To Next Step

STEP 20
Perform the single-cylinder cutout test. Replace
............ the injectors as necessary. Refer to Procedure
Injector is malfunctioning
006-026 or 014-002.

OK
Go To Next Step
STEP 21 Measure and adjust the overhead settings. Refer
............
Overhead adjustments are not correct to Procedure 003-004.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-54 Section TS - Troubleshooting Symptoms

Fuel Consumption Excessive

This is symtom tree t087
Cause Correction

STEP 22
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

STEP 23
Analyze the oil and inspect the filters to locate an
............ area of probable damage. Refer to Procedure 007-
Internal engine damage
002.

OK
Go To Next Step
Check the vehicle speed sensor and circuit. Refer
to Procedures 019-090 and 019-091 in the
STEP 24 Troubleshooting and Repair Manual Electronic
Vehicle speed sensor (VSS) or circuit is ............ Control System ISM and QSM11 Engines, Bulletin
malfunctioning 3666266, or the Troubleshooting and Repair
Manual CM 870 Electronic Control System ISM
Engines, Bulletin 4021381.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-55

Fuel in Coolant
This is symtom tree t091
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
Remove and check the injectors. Check o-rings
Injector o-rings and sleeves are damaged. Injector ............
and injector sleeves. Refer to Procedure 006-026.
o-rings are missing

OK
Go To Next Step
STEP 4
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
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-56 Section TS - Troubleshooting Symptoms

Fuel in the Lubricating Oil

This is symtom tree t092
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
Refer to Procedure 007-025.

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.
Procedure 007-025

OK
Go To Next Step
STEP 3 Perform the fluorescent dye tracer test to find the
Top injector o-ring or injector timing plunger is ............ bad injector. Replace the injector or o-ring. Refer
damaged to Procedure 006-026.

OK
Go To Next Step
STEP 4
Check the injectors for damage. Refer to
Injector adapter wall is damaged behind the ............
Procedure 006-026.
balance orifice

OK
Go To Next Step
STEP 5 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

STEP 6
Check the gear pump main shaft and seals. Refer
............ to the Shop Manual, M11 Series Engines, Bulletin
Fuel pump gear pump main shaft seals are leaking
3666075.

OK
Go To Next Step
Remove intake and exhaust manifolds. Check for
STEP 7 evidence of coolant leak. If necessary, operate
............
Cylinder head is cracked or porous engine at low idle. Pressure-test the cylinder head.
Refer to Procedure 002-004.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-57

Intake Manifold Air Temperature Above Specification

This is symtom tree t096
Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1
Repair Manual Electronic Control System ISM and
QSM11 Engines, Bulletin 3666266 and the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
Check the intake manifold temperature sensor.
Refer to Procedure 019-059 Troubleshooting and
STEP 2 Repair Manual Electronic Control System ISM and
Intake manifold temperature sensor is ............ QSM11 Engines, Bulletin 3666266 and the
malfunctioning Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 3
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

STEP 4
Inspect the radiator shutters. Repair or replace if
necessary. Refer to the manufacturer's
Radiator shutters are not opening completely or ............
instructions. Check the shutterstat setting. Refer to
the shutterstat setting is wrong
Procedure 008-020 or 008-049.

OK
Go To Next Step
Open the cold weather radiator cover or the
STEP 5 winterfront. Maintain a minimum of 384 cm2 [60
............
Cold weather radiator cover or winterfront is closed in2] or approximately 19.6 x 19.6 cm [7.5 x 7.5 in]
of opening at all times.

OK
Go To Next Step
STEP 7 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
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-58 Section TS - Troubleshooting Symptoms

Intake Manifold Air Temperature Above Specification

This is symtom tree t096
Cause Correction
STEP 8 Check the belt tension and tighten if necessary.
............
Fan drive belt is loose Refer to Procedure 008-002.

OK
Go To Next Step

STEP 9
Check the fan drive and controls. Refer to
............ Procedure 008-024, 008-025, 008-026, 008-027, or
Fan drive or fan controls are malfunctioning
008-028.

OK
Go To Next Step
STEP 10 Verify that the fan is the correct size. Refer to the
............
Fan is not an adequate size for the application engine and OEM specifications.

OK
Go To Next Step
STEP 11 Check the EGR cooler. Refer to Procedure 011-
............
EGR cooler malfunctioning 019.

OK
Go To Next Step
STEP 12 Refer to Procedure 010-024 or the Engine
............
Intake air or exhaust leaks Performance Troubleshooting Tree in Section TT.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-59

Intake Manifold Pressure (Boost) is Below Normal

This is symtom tree t097
Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1
Repair Manual Electronic Control System ISM and
QSM11 Engines, Bulletin 3666266 and the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
Check the intake manifold pressure sensor. Refer
to Procedure 019-061 in the Troubleshooting and
STEP 2
Repair Manual Electronic Control System ISM and
............ QSM11 Engines, Bulletin 3666266 and the
Intake manifold pressure sensor is malfunctioning
Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 3 Inspect the air intake and exhaust systems for air
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.

OK
Go To Next Step
STEP 4 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

OK
Go To Next Step
STEP 6 Check the wastegate for freedom of movement.
Turbocharger wastegate is damaged or is stuck ............ Inspect the wastegate for damage. Refer to
open Procedure 010-050.

OK
Go To Next Step

STEP 7
Check the turbocharger for damage. Measure the
............ turbine and compressor wheel clearances. Refer
Turbocharger is worn or damaged
to Procedure 010-033.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-60 Section TS - Troubleshooting Symptoms

Intake Manifold Pressure (Boost) is Below Normal

This is symtom tree t097
Cause Correction
Perform the variable geometry operational test and
STEP 8 the variable geometry actuator test within INSITE™.
............
Turbocharger is malfunctioning Refer to the appropriate electronic service tool
manual.

OK
Go To Next Step
STEP 9 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
Check the turbocharger part number and compare
STEP 10 it to the Control Parts List (CPL), Bulletin 3379133
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
necessary. Refer to Procedure 010-033.

OK
Go To Next Step
STEP 11 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.

OK
Go To Next Step
STEP 12 Refer to Engine Performance Troubleshooting in
............
Engine power output is low Section TT.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-61

Low Idle Adjust Switch Does Not Work

This is symtom tree t099
Cause Correction
Refer to Section TF in the Troubleshooting and
STEP 1
Repair Manual Electronic Control System ISM and
QSM11 Engines, Bulletin 3666266 or the
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual CM870
inactive fault codes
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 2
Refer to the Coolant Temperature is Below Normal
Intake manifold air temperature is below ............
symptom tree.
specification

OK
Go To Next Step
Check the idle adjust switch and circuit. Refer to
Procedures 019-052 and 019-053 in the
STEP 3
Troubleshooting and Repair Manual Electronic
............ Control System ISM and QSM11 Engines, Bulletin
Low-idle adjust switch and circuit is malfunctioning
3666266 or the Troubleshooting and Repair
Manual, CM870 Electronic Control System ISM
Engines, Bulletin 4021381.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-62 Section TS - Troubleshooting Symptoms

Lubricating Oil Consumption Excessive

This is symtom tree t102
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 Section V for
specifications.

OK
Go To Next Step
STEP 3 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-002.

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
STEP 5 Check the turbocharger compressor and turbine
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033.

OK
Go To Next Step

STEP 6
Check for lubricating oil in the coolant. Refer to the
............ Lubricating Oil or Transmission Oil in the Coolant
Lubricating oil cooler is leaking
symptom tree.

OK
Go To Next Step
STEP 7 Change the oil and filters. Refer to the Lubricating
............
Lubricating oil is contaminated with coolant or fuel Oil Contaminated symptom tree.

OK
Go To Next Step
STEP 8 Check the dipstick calibration. Refer to Procedure
............
Lubricating oil dipstick calibration is not correct 007-009.

OK
Go To Next Step
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-63

Lubricating Oil Consumption Excessive

This is symtom tree t102
Cause Correction
Change the oil and filters. Refer to the Operation
STEP 9 and Maintenance Manual ISM and ISMe Engines,
Lubricating oil does not meet specifications for ............ Bulletin 3666319. Use the oil type recommended
operating conditions in Section V of the engine operation and
maintenance manual.

OK
Go To Next Step

STEP 10
Verify the correct lubricating oil drain interval.
............ Refer to the Operation and Maintenance Manual
Lubricating oil drain interval is excessive
ISM and ISMe Engines, Bulletin 3666319.

OK
Go To Next Step
STEP 11
Check for air intake system leaks. Refer to
Piston, cylinder liner, or piston rings are worn or ............
Procedure 010-024.
damaged

OK
Go To Next Step
STEP 12 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.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-64 Section TS - Troubleshooting Symptoms

Lubricating Oil Contaminated

This is symtom tree t103
Cause Correction
STEP 1 Perform an oil analysis to determine the
............
Identify lubricating oil contamination contaminants.

OK
Go To Next Step

STEP 2
Check the bulk oil supply. Drain the oil and replace
............ with noncontaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
Refer to Procedure 007-025.

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
Change the oil and filters. Refer to Lubricating Oil
............ Sludge in the Crankcase is Excessive symptom
Lubricating oil sludge is excessive
tree.

OK
Go To Next Step
STEP 5 Refer to the Fuel in the Lubricating Oil symptom
............
Fuel in the lubricating oil tree.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-65

Lubricating Oil Degradation (Centinel)

This is symtom tree t103-2
Cause Correction
STEP 1 Check makeup tank oil level daily. Add oil if
............
Centinel makeup tank is empty necessary.

OK
Go To Next Step
STEP 2 Check to see that all oil lines are free of crimps and
............
Lubricating oil lines are bent or crimped sharp bends.

OK
Go To Next Step

STEP 3
Check all oil lines and fittings for leaks. Tighten
............ loose fittings and replace leaking oil lines if
Lubricating oil lines leak oil
necessary.

OK
Go To Next Step
STEP 4 ECM will not cycle valve below 125 degree
Oil temperature never sensed above 125 degrees ............ Fahrenheit. Confirm proper operation of oil
Fahrenheit. pressure temperature sensor.

OK
Go To Next Step
STEP 5 Check for restriction from the oil rifle to the
............
Oil rifle supply never exceeds 20 psi Centinel™ valve solenoid.

OK
Go To Next Step
STEP 6 Perform priming procedure. Refer to the Master
............
Make-up system not primed Repair Manual Centinel™, Bulletin 3666231.

OK
Go To Next Step
STEP 7 Replace Centinel™ valve. Refer to the Master
............
Internal Centinel™ valve failure Repair Manual Centinel™, Bulletin 3666231.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-66 Section TS - Troubleshooting Symptoms

Lubricating Oil Pressure High

This is symtom tree t104
Cause Correction
STEP 1 Check the oil pressure switch, gauge, or sensor for
Lubricating oil pressure switch, gauge, or sensor is ............ correct operation and location. Refer to Procedure
malfunctioning or is not in the correct location 007-028.

OK
Go To Next Step
STEP 2 Refer to Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.

OK
Go To Next Step
STEP 3 Change the oil and filters. Refer to Procedure 007-
Lubricating oil does not meet specifications for ............ 013 or 007-025 and the Cummins Engine Oil
operating conditions Recommendations, Bulletin 3810340.

OK
Go To Next Step
STEP 4 Check the main oil pressure regulator assembly.
............
Main oil pressure regulator is malfunctioning Refer to Procedure 007-029.

OK
Go To Next Step
STEP 5 Check the viscosity sensor. Clean or replace if
............
Sensor plugged or damaged necessary. Refer to Procedure 007-041.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-67

Lubricating Oil Pressure Low

This is symtom tree t105
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to Section TF in the
STEP 1 Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System ISM and QSM11 Engines, Bulletin
inactive fault codes 3666266 or the Troubleshooting and Repair
Manual CM870 Electronic Control System ISM
Engines, Bulletin 4021381.

OK
Go To Next Step

STEP 2
Check the oil level. Add or drain oil if necessary.
............ Refer to Procedures 007-025 and 007-009. 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 for
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 or gauge for correct
Lubricating oil pressure sensor or gauge is ............ operation and location. Refer to Procedure 007-
malfunctioning or is not in the correct location 028.

OK
Go To Next Step
Check the oil pressure switch or circuit. Refer to
Procedure 019-066 in the Troubleshooting and
STEP 6 Repair Manual Electronic Control System ISM and
Lubricating oil pressure sensor or circuit is ............ QSM11 Engines, Bulletin 3666266 or the
malfunctioning Troubleshooting and Repair Manual CM870
Electronic Control System ISM Engines, Bulletin
4021381.

OK
Go To Next Step
STEP 7 Refer to the Lubricating Oil Temperature Above
............
Lubricating oil temperature is above specification Specification symptom tree.

OK
Go To Next Step
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-68 Section TS - Troubleshooting Symptoms

Lubricating Oil Pressure Low

This is symtom tree t105
Cause Correction
Change the oil and filter. Refer to Procedures 007-
STEP 8 013 and 007-025. Verify the oil change interval is
............
Lubricating oil filter is plugged correct. Refer to the operation and maintenance
manual.

OK
Go To Next Step
STEP 9 Change the oil and filters. Refer to Procedures 007-
Lubricating oil does not meet specifications for ............ 013, 007-025, and the Cummins Engine Oil
operating conditions Recommendations, Bulletin 3810340.

OK
Go To Next Step
STEP 10 Change the oil and filters. Refer to the Lubricating
............
Lubricating oil is contaminated with coolant or fuel Oil Contaminated symptom tree.

OK
Go To Next Step
STEP 11
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is plugged

OK
Go To Next Step
STEP 12
Remove and inspect the oil pan or suction tube.
Lubricating oil suction or transfer tube is loose or ............
Refer to Procedure 007-025.
broken, or the gasket or o-rings are leaking

OK
Go To Next Step
STEP 13
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
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 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 16
Inspect the lubricating oil pump and o-rings. Refer
Lubricating oil pump is malfunctioning or the o- ............
to Procedure 007-031.
rings are damaged

OK
Go To Next Step
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-69

Lubricating Oil Pressure Low

This is symtom tree t105
Cause Correction

STEP 17
Analyze the lubricating oil. Inspect the oil filter.
Check the main bearings, rod bearings, cam
Internal engine damage or internal lubricating oil ............
bushings, and rocker lever bushings for excessive
leak
wear. Refer to Procedure 007-002 and Section 1.
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-70 Section TS - Troubleshooting Symptoms

Lubricating Oil Sludge in the Crankcase Excessive

This is symtom tree t106
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
Refer to Procedure 007-025.

OK
Go To Next Step
STEP 2 Change the oil and filters. Refer to Procedure 007-
Lubricating oil does not meet specifications for ............ 013 or 007-025, and the Cummins Engine Oil
operating conditions Recommendations, Bulletin 3810340.

OK
Go To Next Step
Verify the correct lubricating oil drain interval.
STEP 3 Refer to Section 2 of the Operation and
............
Lubricating oil drain interval is excessive Maintenance Manual ISM and ISMe Engines,
Bulletin 3666319.

OK
Go To Next Step
STEP 4 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 5 Change the oil and filters. Refer to the Lubricating
............
Lubricating oil is contaminated with coolant or fuel Oil Contaminated symptom tree.

OK
Go To Next Step
STEP 6 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
STEP 7
............ Check the static injection timing. Refer to 006-025.
Static injection timing is not correct
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-71

Lubricating Oil Temperature Above Specification

This is symtom tree t107
Cause Correction
View and troubleshoot the fault codes with
INSITE™. Refer to Section TF in the
STEP 1 Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System ISM and QSM11 Engines, Bulletin
inactive fault codes 3666266 or the Troubleshooting and Repair
Manual CM870 Electronic Control System, ISM
Engines 4021381.

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

OK
Go To Next Step
STEP 4 Check the oil pressure switch or gauge for correct
Lubricating oil pressure sensor or gauge is ............ operation and location. Refer to Procedure 007-
malfunctioning or is not in the correct location 028.

OK
Go To Next Step
Check the oil pressure switch or circuit. Refer to
STEP 5
Procedure 019-066 in the Troubleshooting and
Repair Manual Electronic Control System ISM and
Lubricating oil pressure sensor or circuit is ............
QSM11 Engines, Bulletin 3666266 or the
malfunctioning
Troubleshooting and Repair Manual CM870
Electronic Control System, ISM Engines 4021381.

OK
Go To Next Step
STEP 6 Check the oil thermostat. Refer to Procedure 007-
............
Lubricating oil thermostat is malfunctioning 039.

OK
Go To Next Step
STEP 7
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning
Troubleshooting Symptoms Charts ISM, ISMe, and QSM11
Page TS-72 Section TS - Troubleshooting Symptoms

Lubricating or Transmission Oil in the Coolant

This is symtom tree t108
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. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning

OK
Go To Next Step
STEP 3
Remove and inspect the cooler cores and o-rings.
Torque converter cooler or hydraulic oil cooler is ............
Refer to the OEM service manual.
malfunctioning

OK
Go To Next Step
STEP 4 Check the cylinder head gasket. Refer to
............
Cylinder head gasket is leaking Procedure 002-004.

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.
Refer to Procedure 002-004.

OK
Go To Next Step

STEP 6
Remove the oil pan. Pressure-test the cooling
............ system to check for leaks. Refer to Procedure 001-
Cylinder block is cracked or porous
027.
ISM, ISMe, and QSM11 Troubleshooting Symptoms Charts
Section TS - Troubleshooting Symptoms Page TS-73

This is symtom tree t122
Cause Correction
STEP 1 Review the engine operating instructions. Refer to
Engine is operating for extended periods under ............ Section 1 in the Operating and Maintenance
light or no-load conditions (slobbering) Manual ISM and ISMe Engines, Bulletin 3666319.

OK
Go To Next Step

STEP 3
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

STEP 4
Check for excessive blowby. Refer to Section 14
............ and the Crankcase Gases (Blowby) Excessive
Crankcase pressure is excessive
symptom tree.

OK
Go To Next Step
STEP 5 Check the turbocharger compressor and turbine
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033.
ISM, ISMe, and QSM11 Troubleshooting Overview
Section TS - Troubleshooting Symptoms Page TS-77

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.
Engine noise can sometimes be isolated by performing a cylinder cutout test. Refer to Procedure 006-005. If the
volume of the noise decreases or the noise disappears, it is related to that particular engine cylinder.
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.
Driveability/Low Power/Excessive Fuel Consumption - Checklist
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.
Troubleshooting Overview ISM, ISMe, and QSM11
Page TS-78 Section TS - Troubleshooting Symptoms

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. For additional information, see Troubleshooting Driveability Complaints,
Bulletin 3387245.
ISM, ISMe, and QSM11 Troubleshooting Overview
Section TS - Troubleshooting Symptoms Page TS-79

Driveability/Low Power - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
How did the problem occur? Suddenly ________ Gradually ________
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 the following questions using selections (A through F) listed below. Circle the letter or letters that best
describes the complaint.
A. Compared to fleet
B. Compared to competition
C. Compared to previous engine
D. Personal expectation
E. Will not pull on hill
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 no was the answer to the previous questions, 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 yes was the answer to the previous two questions, 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.
Troubleshooting Overview ISM, ISMe, and QSM11
Page TS-80 Section TS - Troubleshooting Symptoms

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 Axle Alignment: OK Not OK
Altitude: Ambient Temperature:
Fuel Heater:
Fuel Type: Number 1D Number 2D Other
Typical Terrain: Flat Hilly % Asphalt % Concrete

Additional Comments:
___________________________________________________________________________________________________
___________________________________________________________________________________________________

Recommended Literature:
Troubleshooting Driveability Complaints, Bulletin Number 3387137
Guide to Troubleshooting, Bulletin Number 3379090
Professional Driver Techniques, Bulletin Number 3804818
Guide to LCPM, Bulletin Number 3382021
Troubleshooting Excessive Fuel Consumption, Bulletin Number 3387245

This checklist can be copied for convenience.

ISM, ISMe, and QSM11 Troubleshooting Overview
Section TS - Troubleshooting Symptoms Page TS-81

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. For additional
information on troubleshooting fuel consumption complaints, refer to Troubleshooting Excessive Fuel Consumption,
Bulletin 3387245.
Troubleshooting Overview ISM, ISMe, and QSM11
Page TS-82 Section TS - Troubleshooting Symptoms

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 ________
11. Is the problem seasonal? Yes ________ No ________
12. Weather conditions during fuel consumption check? Rain _____, Snow _____, Windy _____, Hot Temperatures
_____, Cold Temperatures _____
13. How is the fuel mileage measured? Tank _____, Trip _____, Month _____, Year _____ Hubometer _____, Odometer
_____
14. Are accurate records kept of fuel added on the road? Yes ________ No ________
15. Do routes vary between compared vehicles? Yes ________ No ________
16. Have routes changed for the engine being checked? Yes ________ No ________
17. What are the loads hauled, compared to comparison unit? GVW _______________ Heavier ________, Lighter
________
18. What is the altitude during operation? Below 10,000 feet ________, Above 10,000 feet ________
19. How much of the time is the truck spent idling? Hours/day __________
20. Is the driver technique or operating practices affecting fuel economy?
If answered Yes, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist and go to the Engine Power
Output Low performance tree.
• 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.
ISM, ISMe, and QSM11 Troubleshooting Overview
Section TS - Troubleshooting Symptoms Page TS-83

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
ENGINE HRS HRS HOURS MILES MILES MILES PER KM PER KM PER KM PER
FAMILY PER PER PER PER PER IMPERIAL QUART LITER IMPERIAL
QT LITER IMPERIAL QUART LITER QUART QUART
QUART
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
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 USAGE (Transit Bus, Shuttle Bus and School Bus)
ANY TIME DURING COVERAGE PERIOD
ENGINE HRS HRS HOURS MILES MILES MILES PER KM PER KM PER KM PER
FAMILY PER PER PER PER PER IMPERIAL QUART LITER IMPERIAL
QT LITER IMPERIAL QUART LITER QUART QUART
QUART
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
Troubleshooting Overview ISM, ISMe, and QSM11
Page TS-84 Section TS - Troubleshooting Symptoms

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 No.
No.
Engine Application (Describe) Oil and Filter Change Interval Complaint Originally Registered
Oil Filters Date Mile/Hours/Kilometers
Lubricating Oil Added
Date Added Oil Engine Operation Quarts - Liters Brand and Viscosity
Miles/Hours/Kilometers Oil Added of Oil Used
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 Engine Company, Inc.
Form 4755
ISM, ISMe, and QSM11 Troubleshooting Overview
Section TS - Troubleshooting Symptoms Page TS-85

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.
• Drain and refill oil pan to check dipstick markings and notes findings. Warning: Governmental agencies have
determined that used engine oil is toxic and carcinogenic. Avoid breathing, injestion, and excessive
contact.
• 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: __________________________________________________
Troubleshooting Overview ISM, ISMe, and QSM11
Page TS-86 Section TS - Troubleshooting Symptoms

Response Test
This procedure can be used for testing response on heavy duty 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 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 fear (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 Number 3 above).
5. Repeat Step Number 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 + time 2 ÷ time 3)/3.
The average time must be 3 seconds or less for acceptable performance.
ISM, ISMe, and QSM11
Section TT - Engine Performance Features Page TT-a

Section TT - Engine Performance Features

Section Contents
Page
Engine Performance Troubleshooting Tree ...................................................................................................TT-1
ISM, ISMe, and QSM11
Page TT-b Section TT - Engine Performance Features

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-1

Engine Performance Troubleshooting Tree

This troubleshooting procedure should be followed for the following symptoms:
• Engine Acceleration or Response Poor
• Cranking Fuel Pressure is Low
• Engine Operating Fuel Pressure is Low
• Engine Difficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
• Engine Power Output Low
• Engine Runs Rough at Idle
• Engine Runs Rough or Misfires
• Engine Speed Surges at Low or High Idle
• Engine Speed Surges Under Load or in Operating Range
• Smoke, Black - Excessive
• Smoke, White - Excessive
• Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
• Engine Starts But Will Not Keep Running
• Engine Will Not Reach Rated Speed (RPM)

How to Use This Troubleshooting Procedure:

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing
Step 1 troubleshooting. Step 2 will ask a series of questions and will provide a list of troubleshooting steps to perform
depending on the symptom.

Shop Talk:
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-2 Section TT - Engine Performance Features

TROUBLESHOOTING SUMMARY

STEPS SPECIFICATIONS SRT CODE

STEP 1: Perform basic troubleshooting procedures.
STEP 1A: Check for active fault codes or Active fault codes or high counts
high counts of inactive fault of inactive fault codes?
codes.
STEP 1B: Perform basic troubleshooting All steps have been verified to
checks. be correct?
STEP 2: Determination of engine symptom.
STEP 2A: Low power, poor acceleration, Is the engine symptom low
or poor response. power, poor acceleration, or
poor response?
STEP 2B: Engine runs rough or misfires. Is the engine symptom Engine
Runs Rough or Misfires?
STEP 2C: Excessive black smoke. Is the engine symptom
Excessive Black Smoke?
STEP 2D: Excessive white smoke. Is the engine symptom
Excessive White Smoke and the
engine is using coolant?
STEP 2D-1: Excessive white smoke. Is the engine symptom
Excessive White Smoke and the
engine is not using coolant?
STEP 2E: Engine speed surge or engine Is the engine symptom Engine
speed unstable. Speed Surge or Engine Speed
Unstable?
STEP 2F: Engine will not start or difficult Is the symptom Engine Difficult
to start, engine shuts off to Start or Will Not Start, or
unexpectedly. Engine Shuts Off Unexpectedly?
STEP 3: No-start troubleshooting procedures.
STEP 3A: Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage
greater than 11 VDC?
STEP 3B: Determine if engine is equipped Is the engine equipped with a
with a fuel control module. separate fuel control module?
STEP 3B-1: Check the ECM connector Dirty or damaged pins?
and pins.
STEP 3B-2: Check the ECM keyswitch Keyswitch voltage equal to
voltage. battery voltage?
STEP 3B-3: Check the ECM battery Voltage equal to battery voltage?
supply voltage.
STEP 3B-4: Check the ECM actuator Dirty or damaged pins?
connector and pins.
STEP 3B-5: Check for a pin-to-pin short Greater than 100k ohms?
circuit in the engine
harness.
STEP 3B-6: Check for a short circuit to Greater than 100k ohms?
ground in the engine
harness.
STEP 3B-7: Check the continuity of the Less than 10 ohms?
fuel shutoff valve circuit.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-3

STEP 3C: Check the fuel control module Dirty or damaged pins?
and fuel control module power
connector pins.
STEP 3D: Check for a pin-to-pin short Greater than 100k ohms?
circuit at the fuel control
module.
STEP 3E: Check for a short circuit to Greater than 100k ohms?
ground in the engine harness.
STEP 3F: Check for a pin-to-pin short Greater than 100k ohms?
circuit in the engine harness.
STEP 3G: Check ground connections. Ground connections clean and
tight?
STEP 3H: Check the fuel shutoff valve Is the fuel shutoff solenoid
resistance. resistance 1 to 5 ohms for 6-VDC
solenoids,
6 to 15 ohms for 12-VDC
solenoids,
24 to 50 ohms for 24-VDC
solenoids,
42 to 80 ohms for 32-VDC
solenoids,
46 to 87 ohms for 36-VDC
solenoids,
92 to 145 ohms for 48-VDC
solenoids,
315 to 375 ohms for 74-VDC
solenoids,
645 to 735 ohms for 115-VAC
solenoids?
STEP 3I: Check the engine position Is the engine position sensor
sensor installation. installed correctly?
STEP 3J: Determine if engine is equipped Is the engine equipped with a
with a EGR. separate fuel control module?
STEP 3K: Check for coolant in the EGR Is coolant present in the
transfer tube. crossover tube?
STEP 4: Fuel system checks.
STEP 4A: Check for air in the fuel. Air bubbles visible in the sight
glass?
STEP 4B: Check fuel inlet restriction. Is fuel inlet restriction less than
the specifications?
STEP 4C: Check drain line restriction. Is fuel drain line restriction less
than 89 mm Hg [3.5 in Hg]?
STEP 4D: Check pump output pressure. Does the fuel pressure meet the
specification?
STEP 4E: Check fuel gear pump check Is check valve installed and
valve. operating correctly?
STEP 4F: Check fuel supply line for Are fuel lines free from
restrictions. restrictions?
STEP 4G: Check for plugged fuel drillings Has plastic insert been removed
in the cylinder head. from the fuel supply passage in
the cylinder head?
STEP 5: Injector diagnostics.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-4 Section TT - Engine Performance Features

STEP 5A: Perform the INSITE™electronic Do all cylinders pass the cylinder
service tool cylinder cutout test. cutout test?
STEP 6: Air handling diagnostic checks.
STEP 6A: Start engine and read fault Active fault codes?
codes.
STEP 6B: Inspect the turbocharger blades Damage found on turbocharger
for damage. fins?
STEP 6C: Determination of turbocharger Is the turbocharger a variable
type. geometry turbocharger?
STEP 6D: Check the variable geometry Does the turbocharger actuator
actuator rod for correct travel. rod extend between 7 and 9 mm
[0.276 and 0.354 in]?
STEP 6D-1: Check for air leaks and Air leaks found in the system?
inspect air lines.
STEP 6D-2: Check the engine and Connections tight and corrosion
vehicle grounds. free?
STEP 6D-3: Check for air pressure at the Is vehicle air tank pressure
turbocharger control valve present at the turbocharger
outlet. control valve outlet?
STEP 6D-4: Check for air pressure at the Does the pressure gauge read
turbocharger control valve more than 103 kPa [15 psi] after
outlet. five minutes?
STEP 6D-5: Check for correct Does the turbocharger actuator
turbocharger actuator rod travel at least 12 mm [0.472
travel. in]?
STEP 6D-6: Determine if the engine is Is the engine equipped with a
equipped with a turbocharger air control shutoff
turbocharger control shutoff valve?
valve.
STEP 6D-7: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve outlet. valve outlet?
STEP 6D-8: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve inlet. valve inlet?
STEP 6D-9: Check for plugged Is an air leak present at the
turbocharger control shutoff turbocharger control shutoff
valve filter. valve filter head?
STEP 6D-10: Verify the OEM air supply Can air be heard escaping from
line is connected to the the turbocharger control valve
correct port on the inlet?
turbocharger control valve.
STEP 6E: Perform the INSITE™ electronic Does the Turbocharger
service tool EGR Valve/ Operational Test pass?
Turbocharger Operational Test.
STEP 6E-1: Check the engine and Connections tight and corrosion
vehicle grounds. free?
STEP 6F: Inspect the wastegate actuator Holes or cracks found in the
hose. wastegate actuator hose?
STEP 6G: Inspect the wastegate actuator Does the wastegate actuator rod
rod for travel. move?
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-5

or Engine Speed Unstable?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-10 Section TT - Engine Performance Features

STEP 2F: Engine will not start or difficult to start, engine shuts off unexpectedly.
Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Is the symptom Engine Difficult to Start or Perform the
Will Not Start, or Engine Shuts Off troubleshooti
Unexpectedly? ng steps
YES suggested in
the repair
Repair: procedure
Perform the troubleshooting steps in the
recommended order listed below:
• Step 3 - No Start Checks
• Step 4 - Fuel System Checks
• Step 5 - Injector Checks
• Step 6 - Air Handling Checks
• Step 8 - Electronics Checks
• Step 9 - Base Engine Checks

Is the symptom Engine Difficult to Start or Return to

Will Not Start, or Engine Shuts Off correct
Unexpectedly? symptom
NO tree

STEP 3: No-start troubleshooting procedures.

STEP 3A: Check fuel shutoff valve voltage.
Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Measure the voltage from the fuel shutoff valve Is the fuel shutoff valve voltage greater than 3H
post to engine block ground. 11 VDC?
YES

Is the fuel shutoff valve voltage greater than 3B

11 VDC?
NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-11

STEP 3B: Determine if engine is equipped with a fuel control module.

Condition:
• Connect all components.

Action Specification/Repair Next Step

Determine if the engine is equipped with a Is the engine equipped with a separate fuel 3C
separate fuel control module. control module?
YES

Is the engine equipped with a separate fuel 3B-1

control module?
NO

STEP 3B-1: Check the ECM connector and pins.

Condition:
• Turn keyswitch OFF.
• Disconnect the OEM harness connector from the ECM.

Action Specification/Repair Next Step

Inspect the OEM harness connector and ECM Dirty or damaged pins? Repair
pins for the following: YES complete
• Loose connector
• Corroded pins Repair:
• Bent or broken pins Clean the connector and pins.
• Pushed back or expanded pins
• Moisture in or on the connector Repair the damaged harness, connector, or
• Dirt or debris in or on the connector pins pins if possible.
• Missing or damaged connector seals
• Wire insulation damage Dirty or damaged pins? 3B-2
• Connector shell broken
NO
• Damaged locking tab connector.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-12 Section TT - Engine Performance Features

STEP 3B-2: Check the ECM keyswitch voltage.

Condition:
• Turn keyswitch OFF.
• Disconnect the OEM harness connector from the ECM.
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check the ECM keyswitch voltage. Keyswitch voltage equal to battery voltage? 3B-3
• Measure the voltage from the keyswitch input YES
SIGNAL pin of the OEM connector to ground.
Keyswitch voltage equal to battery voltage? Repair
NO complete

Repair:
Repair the OEM keyswitch circuit.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-064. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-064 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-064.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-13

STEP 3B-3: Check the ECM battery supply voltage.

Condition:
• Turn keyswitch OFF.
• Disconnect the OEM or 4 pin power harness connector from the ECM.

Action Specification/Repair Next Step

Check the ECM battery supply. Voltage equal to battery voltage? 3B-4
• Measure the voltage from the battery SUPPLY YES
(+) pins of the OEM or 4 pin power harness
connector to the battery SUPPLY (-) pins of the
connector. Voltage equal to battery voltage? Repair
NO complete

Repair:
Repair the OEM battery supply or keyswitch
circuit.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-14 Section TT - Engine Performance Features

STEP 3B-4: Check the ECM actuator connector and pins.

Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness or engine harness actuator connector from the ECM.

Action Specification/Repair Next Step

Inspect the engine harness or engine harness Dirty or damaged pins? Repair
actuator connector and ECM pins for the YES complete
following:
• Loose connector Repair:
• Corroded pins Clean the connector and pins.
• Bent or broken pins
• Pushed back or expanded pins Repair the damaged harness, connector, or
• Moisture in or on the connector pins if possible.
• Dirt or debris in or on the connector pins
• Missing or damaged connector seals Dirty or damaged pins? 3B-5
• Wire insulation damage
NO
• Connector shell broken
• Damaged locking tab connector.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-15

STEP 3B-5: Check for a pin-to-pin short circuit in the engine harness.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness or engine harness actuator connector from the ECM.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check for a pin to pin short circuit. Greater than 100k ohms? 3B-6
• Measure the resistance between the fuel YES
shutoff valve SIGNAL pin of the engine
harness or engine harness actuator connector,
and all pins in the connector. Greater than 100k ohms? Repair
NO complete

Repair:
Repair or replace the engine harness.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-043. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-043 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-043.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-16 Section TT - Engine Performance Features

STEP 3B-6: Check for a short circuit to ground in the engine harness.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness or engine harness actuator connector from the ECM.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check for a short circut to ground. Greater than 100k ohms? 3B-7
• Measure the resistance between the fuel YES
shutoff valve SIGNAL pin of the engine
harness or engine harness actuator connector
and ground. Greater than 100k ohms? Repair
NO complete

Repair:
Repair or replace the engine harness.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-043. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-043 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-043.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-17

STEP 3B-7: Check the continuity of the fuel shutoff valve circuit.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness or engine harness actuator connector from the ECM.
• Disconnect the fuel shutoff valve wire from the valve terminal post.

Action Specification/Repair Next Step

Check the continuity of the fuel shutoff valve Less than 10 ohms? Repair
circuit. YES complete
• Measure the resistance of the fuel shutoff
valve SIGNAL circuit between the engine Repair:
harness or engine harness actuator connector Replace the ECM.
and the fuel shutoff valve eyelet.
Call for authorization.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-031. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-031 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-031.

Less than 10 ohms? Repair

NO complete

STEP 3C: Check the fuel control module and fuel control module power connector pins.
Condition:
• Turn keyswitch OFF.
• Disconnect the fuel control module actuator connector from the fuel control module.

Action Specification/Repair Next Step

Inspect the fuel control module and the fuel Dirty or damaged pins? Repair
control module actuator connector pins for the YES complete
following:
• Loose connector Repair:
• Corroded pins Clean the connector and pins.
• Bent or broken pins
• Pushed back or expanded pins Repair the damaged harness, connector, or
• Moisture in or on the connector pins if possible.
• Dirt or debris in or on the connector pins
• Missing or damaged connector seals Dirty or damaged pins? 3D
• Wire insulation damage
NO
• Connector shell broken
• Damaged locking tab connector.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-19

STEP 3D: Check for a pin-to-pin short circuit at the fuel control module.
Condition:
• Turn keyswitch OFF.
• Disconnect the fuel control module actuator connector from the fuel control module.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check for a pin to pin short circuit. Greater than 100k ohms? 3E
• Measure the resistance between the fuel YES
shutoff valve SIGNAL pin of the fuel control
module actuator connector, and all other pins
in the connector. Greater than 100k ohms? Repair
NO complete

STEP 3E: Check for a short circuit to ground in the engine harness.
Condition:
• Turn keyswitch OFF.
• Disconnect the fuel control module actuator connector from the fuel control module.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check for a short circuit to ground. Greater than 100k ohms? 3F

• Measure the resistance between the fuel YES
shutoff valve SIGNAL pin of the engine
harness fuel control module actuator
connector and engine block ground. Greater than 100k ohms? Repair
NO complete

Repair:
Repair or replace the engine harness.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-043. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-043 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-043.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-21

STEP 3F: Check for a pin-to-pin short circuit in the engine harness.
Condition:
• Turn keyswitch OFF.
• Disconnect the fuel control module actuator connector from the fuel control module.
• Disconnect the engine harness from the ECM.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check for a pin to pin short circuit. Greater than 100k ohms? 3G
• Measure the resistance between the fuel YES
shutoff valve SIGNAL pin of the engine
harness fuel control module actuator
connector and all pins in the engine harness Greater than 100k ohms? Repair
engine control module connector. NO complete

STEP 3G: Check ground connections.

Condition:
• Connect all components.

Action Specification/Repair Next Step

Check conditions of grounds. Check for loose, Ground connections clean and tight? Repair
missing, or dirty ground connections at the YES complete
following locations:
• Engine harness ground at block stud Repair:
• Starter to block ground strap and battery Replace the fuel control module.
negative
• Chassis to engine block or battery negative. Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-031. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-031 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-031.

Ground connections clean and tight? Repair

NO complete

Repair:
Tighten and clean ground connections as
needed.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-23

STEP 3H: Check the fuel shutoff valve resistance.

Condition:
• Turn keyswitch OFF.
• Remove the engine harness ring terminal from the fuel shutoff valve.

Action Specification/Repair Next Step

Check the shutoff valve resistance. Is the fuel shutoff solenoid resistance: 3I
• Measure the resistance between the fuel • 1 to 5 ohms for 6-VDC solenoids
shutoff valve ring terminal stud and engine • 6 to 15 ohms for 12-VDC solenoids
block ground. • 24 to 50 ohms for 24-VDC solenoids
• 42 to 80 ohms for 32-VDC solenoids
• 46 to 87 ohms for 36-VDC solenoids
• 92 to 145 ohms for 48-VDC solenoids
• 315 to 375 ohms for 74-VDC solenoids
• 645 to 735 ohms for 115-VAC solenoids?
YES

Is the fuel shutoff solenoid resistance: Repair

• 1 to 5 ohms for 6-VDC solenoids complete
• 6 to 15 ohms for 12-VDC solenoids
• 24 to 50 ohms for 24-VDC solenoids
• 42 to 80 ohms for 32-VDC solenoids
• 46 to 87 ohms for 36-VDC solenoids
• 92 to 145 ohms for 48-VDC solenoids
• 315 to 375 ohms for 74-VDC solenoids
• 645 to 735 ohms for 115-VAC solenoids?
NO
Repair:
Replace the fuel shutoff valve.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-050. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-050 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-050.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-24 Section TT - Engine Performance Features

STEP 3I: Check the engine position sensor installation.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Check the engine position sensor for proper Is the engine position sensor installed 3J
installation. Excessive air gap between the correctly?
sensor and camshaft can cause incorrect speed YES
sensor readings.
Is the engine position sensor installed Repair
correctly? complete
NO
Repair:
Install the engine position sensor correctly.
Replace the engine position sensor, if
necessary.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-038 or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-038 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-038.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-25

STEP 3J: Determine if engine is equipped with a exhaust gas recirculation (EGR).
Condition:
• Connect all components.

Action Specification/Repair Next Step

Determine if the engine is equipped with EGR. Is the engine equipped with EGR? 3K
YES

Is the engine equipped with EGR? Perform next

NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 3K: Check for coolant in the EGR transfer tube.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Remove the EGR transfer hose from the EGR Is coolant present in the crossover tube? Repair
cooler outlet. YES complete

Repair:
See the Coolant Loss - Internal symptom
tree.

Is coolant present in the crossover tube? Perform next

NO troubleshooti
ng procedure
as outlined in
Step 2
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-26 Section TT - Engine Performance Features

STEP 4: Fuel system checks.

STEP 4A: Check for air in the fuel.
Condition:
• Engine running at low idle (engine cranking if troubleshooting No-Start).

Action Specification/Repair Next Step

Connect the equipment to the fuel pump as Air bubbles visible in the sight glass? Repair
shown. YES complete

Repair:
Locate and correct cause of air ingestion in
OEM fuel supply system or damaged fuel
filter sealing ring.

Air bubbles visible in the sight glass? 4B

NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-27

STEP 4B: Check fuel inlet restriction.

Condition:
• Connect a manometer, Part Number ST-1111-3, to the fuel pump supply hose.
• Turn keyswitch ON.
• Engine running at rated speed.

Action Specification/Repair Next Step

Check the fuel inlet restriction. Is fuel inlet restriction less than the 4C
Refer to Procedure 006-020. specifications listed below?
Dirty - 254 mm Hg [10 in Hg];
New - 152 mm Hg [6 in Hg]
YES

Is fuel inlet restriction less than the Repair

specifications listed below? complete
Dirty - 254 mm Hg [10 in Hg];
New - 152 mm Hg [6 in Hg]
NO
Repair:
Locate the cause of high fuel inlet restriction.
Check the prefilter and fuel supply lines.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-28 Section TT - Engine Performance Features

STEP 4C: Check drain line restriction.

Condition:
• Connect a manometer, Part Number ST-1111-3, to the fuel drain line.
• Turn keyswitch ON.
• Engine running at rated speed.

Action Specification/Repair Next Step

Observe the reading on the pressure gauge. Is fuel drain line restriction less than 89 mm 4D
Hg [3.5 in Hg]?
YES

Is fuel drain line restriction less than 89 mm Repair

Hg [3.5 in Hg]? complete
NO
Repair:
Locate cause of high fuel drain line restriction
in OEM fuel return line.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-29

STEP 4D: Check pump output pressure.

Condition:
• Connect pressure gauge on the Compuchek® fitting of the fuel pump.
• Turn keyswitch ON.
• Engine running at 1200 rpm (engine cranking if troubleshooting No-Start).

Action Specification/Repair Next Step

Observe the reading on the pressure gauge. Does the fuel pressure meet the Perform next
Read the fuel pressure while cranking if the specification? troubleshooti
YES ng procedure
engine will not start.
as outlined in
• Cranking: minimum of 172 kPa [25 psi] Step 2
• Engine running at 1200 rpm: minimum of 827
kPa [120 psi]
Does the fuel pressure meet the 4E
specification?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-30 Section TT - Engine Performance Features

STEP 4E: Check fuel gear pump check valve.

Condition:
• Disconnect fuel drain line from fuel gear pump housing.

Action Specification/Repair Next Step

Inspect the fuel gear pump check valve for Is check valve installed and operating 4F
correct installation and operation. correctly?
Refer to Procedure 005-026. YES

Is check valve installed and operating Repair

correctly? complete
NO
Repair:
Install the check valve correctly or replace
the fuel gear pump check valve, if necessary.
Refer to Procedure 005-026.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-31

STEP 4F: Check fuel supply line for restrictions.

Condition:
• Connect all components.

Action Specification/Repair Next Step

Check the fuel line between the fuel pump and Are fuel lines free from restrictions? 4G
cylinder head for obstructions. Check the fuel YES
line for sharp bends or kinks that could cause a
restriction.
Are fuel lines free from restrictions? Repair
NO complete

Repair:
Remove obstructions from fuel lines.
Replace kinked or restricted lines as
necessary.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-32 Section TT - Engine Performance Features

STEP 4G: Check for plugged fuel drillings in the cylinder head.
Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

If a ReCon® cylinder head was installed, check Has plastic insert been removed from the fuel Perform the
that the plastic insert has been removed from the supply passage in the cylinder head? next
fuel supply inlet passage in the cylinder head. YES troubleshooti
ng procedure
as outlined in
Step 2

Has plastic insert been removed from the fuel Repair

supply passage in the cylinder head? complete
NO
Repair:
Remove the plastic insert from the fuel
supply passage in the cylinder head.
Refer to Procedure 002-004.

STEP 5: Injector diagnostics.

STEP 5A: Perform the the INSITE™ electronic service tool cylinder cutout test.
Condition:
• Connect the INSITE™ electronic service tool
• Engine running at low idle

Action Specification/Repair Next Step

Perform the INSITE™ cylinder cutout test. Do all cylinders pass the cylinder cutout test? Perform next
YES troubleshooti
ng procedure
as outlined in
Step 2

Do all cylinders pass the cylinder cutout test? Repair

NO complete

Repair:
Replace the injectors as needed.
Refer to Procedure 006-026.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-33

STEP 6: Air handling diagnostic checks.

STEP 6A: Start engine and read fault codes.
Condition:
• Connect the INSITE™ electronic service tool.
• Engine running at low idle.

Action Specification/Repair Next Step

Check the fault codes with the engine running. Active fault codes? Go to
• Use the INSITE™ electronic service tool to read YES appropriate
the fault codes. fault code
troubleshooti
ng tree

Active fault codes? 6B

STEP 6B: Inspect the turbocharger blades for damage.

Condition:
• Engine OFF.
• Remove intake and exhaust connections for turbocharger.

Action Specification/Repair Next Step

Inspect the compressor and turbine fins for Damage found on turbocharger fins? Repair
damage or wear. YES complete

Repair:
Replace the turbocharger.
Refer to Procedure 010-033.

Damage found on turbocharger fins? 6C

STEP 6C: Determination of turbocharger type.

Condition:
None.

Action Specification/Repair Next Step

Determine if the turbocharger is variable Is the turbocharger a variable geometry 6D

geometry turbocharger turbocharger?
YES

Is the turbocharger a variable geometry 6F

turbocharger?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-34 Section TT - Engine Performance Features

STEP 6D: Check the variable geometry actuator rod for correct travel.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Start the Turbocharger Actuator Test using Does the turbocharger actuator rod extend 6E
INSITE™ electronic service tool. between 7 and 9 mm [0.276 and 0.354 in]?
• Adjust the delay timer in the Turbocharger YES
Actuator Test so that the rod movement can be
observed.
• Select the Retract Actuator position with Does the turbocharger actuator rod extend 6D-1
INSITE™ electronic service tool. between 7 and 9 mm [0.276 and 0.354 in]?
• Mark or scribe the variable geometry actuator NO
rod at the base of the actuator.
• Select the Extend Actuator position with
INSITE™ electronic service tool..
• Measure the rod travel by measuring the
distance from the base of the turbocharger
actuator to the scribe mark.
NOTE: The turbocharger actuator moves quickly
and crisply. If the actuator rod movement is slow,
there could be a problem with the air supply, a
faulty ground connection on the engine or
chassis, or mechanical problems with the
variable geometry turbocharger assembly.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-35

STEP 6D-1: Check for air leaks and inspect air lines.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Use INSITE™ electronic service tool to perform Air leaks found in the system? Repair
the Turbocharger Actuator Test. YES complete
Select the Extend Actuator position. Listen for air Repair:
leaks at the following components:
Repair air leaks.
• Turbocharger control valve
• Turbocharger control shutoff valve inlet
connection (if equipped) Air leaks found in the system? 6D-2
• Turbocharger control shutoff valve outlet NO
connection (if equipped)
• Turbocharger control valve inlet connection
• Turbocharger control valve outlet connection
• Turbocharger actuator inlet connection
• Turbocharger actuator
• All air lines including the OEM supply line to
turbocharger control shutoff valve,
turbocharger control shutoff valve to
turbocharger control valve, and turbocharger
control valve to turbocharger actuator.
Note A small amount of air could possibly be
heard escaping from the turbocharger control
valve during th:e turbocharger actuator test. This
is a normal condition for the valve to achieve
output regulation pressure. Do not replace the
turbocharger control valve for this condition.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-36 Section TT - Engine Performance Features

STEP 6D-2: Check the engine and vehicle grounds.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Check for loose or corroded engine, chassis, or Connections tight and corrosion free? 6D-3
battery ground connections. YES
• Check the engine ground connection.
• Check the chassis ground connections.
• Check the battery terminal connections. Connections tight and corrosion free? Repair
NO complete

Repair:
Tighten the connections.
Tighten the loose connections, and clean the
terminals.
See the OEM troubleshooting and repair
manual.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-37

STEP 6D-3: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Perform the Turbocharger Actuator Test using Is vehicle air tank pressure present at the 6D-4
INSITE™ electronic service tool. Select Retract turbocharger control valve outlet?
Actuator position. YES
Remove the air line connection at the outlet of the
turbocharger control valve. Is vehicle air tank pressure present at the 6D-6
Install an M12 Compuchek® fitting at the outlet of turbocharger control valve outlet?
the turbocharger control valve. NO
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi].
Use the INSITE™ electronic service tool to
perform the Turbocharger Actuator Test. Select
the Extend Actuator position.

STEP 6D-4: Check for air pressure at the turbocharger control valve outlet.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Perform the Turbocharger Actuator Test using Does the pressure gauge read more than 103 Repair
INSITE™ electronic service tool. Select the kPa [15 psi] after five minutes? complete
Retract Actuator position. YES
• Remove the air line connection at the outlet of
the turbocharger control valve. Repair:
• Install an M12 Compuchek® fitting at the outlet Replace the turbocharger control valve.
of the turbocharger control valve.
• Install an air pressure gauge capable of Refer to CM870 and CM570 Electronic
reading at least 1034 kPa [150 psi]. Control System ISM Engine Troubleshooting
& Repair Manual, Bulletin 4021381,
Procedure 019-388 or ISM CM875 Electronic
Control System Troubleshooting and Repair
Manual, Bullletin 4021477, Procedure 019-
388.

Does the pressure gauge read more than 103 6D-5

kPa [15 psi] after five minutes?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-38 Section TT - Engine Performance Features

STEP 6D-5: Check for correct turbocharger actuator travel.

Condition:
• Engine OFF.
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

NOTE: Damage to the turbochager can result if Does the turbocharger actuator rod travel at Repair
the proper removal procedure is not followed. least 12 mm [0.472 in]? complete
• Remove the variable geometry actuator from YES
the turbocharger. Refer to Procedure 010-033.
Use the INSITE™ electronic service tool to Repair:
perform the Turbocharger Actuator Test. Replace the turbocharger assembly.
Select the Extend Actuator position.
Refer to Procedure 010-033.

Does the turbocharger actuator rod travel at Repair

least 12 mm [0.472 in]? complete
NO
Repair:
Replace the turbocharger actuator.
Refer to Procedure 010-113.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-39

STEP 6D-6: Determine if the engine is equipped with a turbocharger control shutoff valve.
Condition:
None.

Action Specification/Repair Next Step

Determine if the engine is equipped with a Is the engine equipped with a turbocharger 6D-7
turbocharger control shutoff valve. air control shutoff valve?
YES

Is the engine equipped with a turbocharger 6D-10

air control shutoff valve?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-40 Section TT - Engine Performance Features

STEP 6D-7: Check for air pressure at the turbocharger control shutoff valve outlet.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
• Connect the INSITE™ electronic service tool.

Action Specification/Repair Next Step

Perform the Turbocharger Actuator Test using Can air be heard escaping from the Repair
the INISTE™ electronic service tool. turbocharger control shutoff valve outlet? complete
• Select the Extend Actuator position. YES
• Loosen the air line connection at the
turbocharger control shutoff valve outlet. Repair:
Replace the turbocharger control valve.
Refer to CM870 and CM570 Electronic
Control System ISM Engine Troubleshooting
& Repair Manual, Bulletin 4021381,
Procedure 019-388 or ISM CM875 Electronic
Control System Troubleshooting and Repair
Manual, Bullletin 4021477, Procedure 019-
388.

Can air be heard escaping from the 6D-8

turbocharger control shutoff valve outlet?
NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-41

STEP 6D-8: Check for air pressure at the turbocharger control shutoff valve inlet.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Verify the OEM air supply line is connected to the Can air be heard escaping from the 6D-9
correct port on the turbocharger control shutoff turbocharger control shutoff valve inlet?
valve. YES
• Loosen the air line connection at the
turbocharger control shutoff valve inlet.
Can air be heard escaping from the Repair
turbocharger control shutoff valve inlet? complete
NO
Repair:
Repair the air supply from the OEM air tanks.

STEP 6D-9: Check for plugged turbocharger control shutoff valve filter.
Condition:
• Remove the turbocharger control shutoff valve filter.
• Turn keyswitch ON.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
• Connect the INSITE™ electronic service tool.

Action Specification/Repair Next Step

Perform the Turbocharger Actuator Test using Is an air leak present at the turbocharger Repair
the INSITE™ electronic service tool. control shutoff valve filter head? complete
• Select the Extend Actuator position. YES
• Listen for an air leak at the turbocharger
control shutoff valve filter head. Repair:
Replace the turbocharger control shutoff
valve filter.
Refer to Procedure 010-114.

Is an air leak present at the turbocharger Repair

control shutoff valve filter head? complete
NO
Repair:
Replace the turbocharger control shutoff
valve.
Refer to CM870 and CM570 Electronic
Control System ISM Engine Troubleshooting
& Repair Manual, Bulletin 4021381,
Procedure 019-386.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-42 Section TT - Engine Performance Features

STEP 6D-10: Verify the OEM air supply line is connected to the correct port on the turbocharger control
valve.
Condition:
• Engine OFF.
• Turn keyswitch ON.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.

Action Specification/Repair Next Step

Verify the OEM air supply line is connected to the Can air be heard escaping form the Repair
correct port on the turbocharger control valve. turbocharger control valve inlet? Complete
Loosen the air line connection at the YES
turbocharger control valve inlet. Repair:
Replace the turbocharger control valve.
Refer to CM870 and CM570 Electronic
Control System ISM Engine Troubleshooting
& Repair Manual, Bulletin 4021381,
Procedure 019-388 or ISM CM875 Electronic
Control System Troubleshooting and Repair
Manual, Bullletin 4021477, Procedure 019-
388.

Can air be heard escaping form the Repair

turbocharger control valve inlet? Complete
NO
Repair:
Repair the air supply from the OEM air tanks.

STEP 6E: Perform the INSITE™ electronic service tool EGR Valve/Turbocharger Operational Test.
Condition:
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
• Start the engine and run at low idle.

Action Specification/Repair Next Step

Select the EGR/Variable Geometry Does the Turbocharger Operational Test Perform next
Turbocharger Operational Test using the pass? troubleshooti
INSITE™ electronic service tool. YES ng procedure
• Choose the Turbocharger actuator option as outlined in
under Test Choices. Step 2

Does the Turbocharger Operational Test 6E-1

pass?
NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-43

STEP 6E-1: Check the engine and vehicle grounds.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Check for loose or corroded engine, chassis, or Connections tight and corrosion free? Repair
battery ground connections. YES complete
• Check the engine ground connection.
• Check the chassis ground connections. Repair:
• Check the battery terminal connections. Replace the variable geometry turbocharger.
Refer to Procedure 010-033.

Connections tight and corrosion free? Verify fix

NO Repair
Repair: complete

Tighten the connections.

Tighten the loose connections, and clean the
terminals.
See the OEM troubleshooting and repair
manual.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-44 Section TT - Engine Performance Features

STEP 6F: Inspect the wastegate actuator hose.

Condition:
• Engine OFF.
• Remove turbocharger if wastegate actuator is inaccessible.

Action Specification/Repair Next Step

Inspect the integral wastegate actuator hose for Holes or cracks found in the wastegate Repair
cracks or holes. actuator hose? complete
YES
Repair:
Replace wastegate actuator hose.

Holes or cracks found in the wastegate 6G

actuator hose?
NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-45

STEP 6G: Inspect the wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the wastegate actuator hose from the wastegate actuator.

Action Specification/Repair Next Step

Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? 6H
to the actuator and check for actuator movement. YES

Does the wastegate actuator rod move? 6G-1

NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-46 Section TT - Engine Performance Features

STEP 6G-1: Inspect wastegate actuator rod for travel.

Condition:
• Engine OFF.
• Remove the e-clip from the wastegate pin and disconnect the actuator rod.

Action Specification/Repair Next Step

Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? Repair
to the actuator and check for actuator movement. YES complete

Repair:
Move the wastegate lever on the
turbocharger back and forth and check for
smooth operation. Replace turbocharger
assembly if wastegate is seized.
Refer to Procedure 010-033.

Does the wastegate actuator rod move? Repair

NO complete

Repair:
Replace the wastegate actuator.
Refer to Procedure 010-050.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-47

STEP 6H: Measure resistance of the four-stage wastegate controllers, if equipped.

Condition:
• Engine OFF.
• Disconnect the ring terminals from the four-stage wastegate controllers, if equipped.

Action Specification/Repair Next Step

Measure the resistance from the wastegate Are the wastegate controller solenoid 6I
controller post to engine block ground. resistances between 7.0 and 8.0 ohms?
NOTE: The wastegate controller solenoids YES
must be between 20°C and 26°C [68°F and 78°
F] before using the resistance specifications Are the wastegate controller solenoid Repair
listed. resistances between 7.0 and 8.0 ohms? complete
NO
Repair:
Replace the failed wastegate controller.
Refer to Procedure 010-109 .
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-48 Section TT - Engine Performance Features

STEP 6I: Inspect four-stage wastegate controller, if equipped.

Condition:
• Engine OFF.
• Remove the four-stage wastegate controllers.

Action Specification/Repair Next Step

Check the valve disc, valve seat, and actuator Damage or debris found on the valve disc, Repair
disc for dirt, metal parts, bonding separation, valve seat, or actuator disc? complete
corrosion, cracks, or wear. YES
Repair:
Replace or clean failed components.

Damage or debris found on the valve disc, Perform next

valve seat, or actuator disc? troubleshooti
NO ng procedure
as outlined in
Step 2
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-49

STEP 7: Check EGR valve for proper operation.

STEP 7A: Check for air leaks in the EGR system.
Condition:
None.

Action Specification/Repair Next Step

Check for leaks in the EGR connection tubing Air leaks found in the EGR connection Repair
and connections. tubing? complete
Soot streaks can be noticeable where leaks are YES
present. Repair:
Repair any leaks in the EGR system.

Air leaks found in the EGR connection 7B

tubing?
NO

STEP 7B: Perform the EGR Valve Test.

Condition:
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.

Action Specification/Repair Next Step

Perform the INSITE™ electronic service tool EGR Does the EGR Valve Test pass? Perform next
Valve Test. YES troubleshooti
• Check for complete travel of the EGR valve by ng procedure
selecting Open Valve and verifying the EGR as outlined in
Valve opens 100 percent. Step 2

Does the EGR Valve Test pass? Repair

NO complete

Repair:
Replace the EGR valve.
Refer to Procedure 011-022.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-50 Section TT - Engine Performance Features

STEP 8: Verify electronic features are operating correctly.

STEP 8A: Verify accelerator pedal travel.
Condition:
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.

Action Specification/Repair Next Step

With INSITE™ electronic service tool, monitor Does the Percent Accelerator read 0 when 8B
Percent Accelerator while fully depressing and the accelerator is released and 100 percent
releasing the accelerator pedal. when the accelerator is depressed?
YES

Does the Throttle Position read 0 when the Repair

accelerator is released and 100 percent when complete
the accelerator is depressed?
NO
Repair:
Determine and correct cause of accelerator
pedal restriction.

STEP 8B: Monitor vehicle speed.

Condition:
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.
• Start the engine.

Action Specification/Repair Next Step

With INSITE™ electronic service tool, monitor Does the vehicle speed read 0 when the 8C
Vehicle Speed while the vehicle is not moving. vehicle is not moving?
YES

Does the vehicle speed read 0 when the Repair

vehicle is not moving? complete
NO
Repair:
Check the vehicle speed sensor and circuit
or locate the cause of the vehicle speed
interference.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-51

STEP 8C: Verify electronic feature settings are correct.

Condition:
• Turn keyswitch ON.
• Connect the INSITE™ electronic service tool.

Action Specification/Repair Next Step

With INSITE™ electronic service tool, verify the Are the electronic features set correctly? Perform next
following adjustable parameters are correctly YES troubleshooti
set: ng procedure
• Maximum vehicle speed as outlined in
• Powertrain protection Step 2
• Rear axle ratio
• Number of transmission tailshaft gear teeth Are the electronic features set correctly? Repair
• Tire revolutions per mile complete
• Gear-down protection NO
• Cruise control droop settings Repair:
• Cruise control maximum vehicle speed.
Correct programmable features.

STEP 8D: Check barometric pressure sensor reading.

Condition:
• Connect all components.
• Connect the INSITE electronic service tool.
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check for correct barometric pressure sensor Is the barometric pressure sensor reading in Perform next
reading. the INSITE™ electronic service tool within 5 troubleshooti
Compare the barometric pressure sensor percent of the wiring diagram specification or ng procedure
current local barometric pressure reading? as outlined in
reading on the INSITE™ electronic service tool
data monitor/logger to the specification listed on YES Step 2
the wiring diagram or the current local barometric
pressure. Is the barometric pressure sensor reading in Repair
INSITE™ electronic service tool within 5 complete
percent of the wiring diagram specification or
current local barometric pressure reading?
NO
Repair:
Replace the barometric pressure sensor.
Refer to ISM and QSM11 Electronic Control
System Troubleshooting and Repair Manual,
Bulletin 3666266, Procedure 019-004. or
CM870 and CM570 Electronic Control
System ISM Engine Troubleshooting &
Repair Manual, Bulletin 4021381, Procedure
019-004 or ISM CM875 Electronic Control
System Troubleshooting and Repair Manual,
Bullletin 4021477, Procedure 019-004.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-52 Section TT - Engine Performance Features

STEP 9: Perform base engine mechanical checks.

STEP 9A: Verify overhead adjustments are correct.
Condition:
• Turn keyswitch OFF.
• Remove valve cover.

Action Specification/Repair Next Step

Measure the overhead settings. Are the overhead settings within the reset 9B
• Refer to Procedure 003-004. limits?
YES

Are the overhead settings within the reset Repair

limits? complete
NO
Repair:
Adjust the overhead settings.
Refer to Procedure 003-004.

STEP 9B: Check air intake restriction.

Condition:
• Turn keyswitch ON.
• Run engine at advertised horsepower and rpm.

Action Specification/Repair Next Step

Check the intake system restriction by installing Is air intake restriction greater than 635 mm Repair
a manometer gauge into the air intake system. H2O [25 in H2O]? complete
Refer to Procedure 010-031. YES
Repair:
Correct the cause of high intake air
restriction.
Check for plugged air filter or restricted air
intake piping.

Is air intake restriction greater than 635 mm 9C

H2O [25 in H2O]?
NO
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-53

STEP 9C: Check exhaust restriction.

Condition:
• Install a pressure gauge into the exhaust system.
• Turn keyswitch ON.
• Run engine at advertised horsepower and rpm.

Action Specification/Repair Next Step

Check exhaust restriction by installing a pressure Is exhaust restriction between 1016 mm H2O 9D
gauge into the exhaust system just past the [40 in H2O] or 75 mm Hg [3.0 in Hg] and 2082
turbocharger outlet. mm H2O [82 in H2O] or 152 mm Hg [6.0 in
Refer to Procedure 011-009. Hg]?
YES

Is exhaust restriction between 1016 mm H2O Repair

[40 in H2O] or 75 mm Hg [3.0 in Hg] and 2082 complete
mm H2O [82 in H2O] or 152 mm Hg [6.0 in
Hg]?
NO
Repair:
Repair exhaust for source of high restriction.
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-54 Section TT - Engine Performance Features

STEP 9D: Inspect the charge air cooler.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Pressure test the charge air cooler. Is the pressure drop 34 kPa [5 psi] or less in 9E
• Refer to Procedure 010-027. 15 seconds?
YES

Is the pressure drop 34 kPa [5 psi] or less in Repair

15 seconds? complete
NO
Repair:
Repair the charge air cooler.

STEP 9E: Verify engine brake adjustment.

Condition:
• Turn keyswitch OFF.
• Remove valve cover.

Action Specification/Repair Next Step

Verify the engine brakes are operating correctly. Are the engine brake settings within the reset 9F
• Measure the engine brake settings. Refer to limits?
Procedure 003-004. YES

Are the engine brake settings within the reset Repair

limits? complete
NO
Repair:
Adjust the engine brakes settings.
Refer to Procedure 020-024.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-55

STEP 9F: Measure turbocharger axial and radial clearance.

Condition:
• Engine OFF.
• Disconnect exhaust and intake connections from the turbocharger.

Action Specification/Repair Next Step

Measure the axial and radial clearance of the Are the axial and radial clearances within 9G
turbocharger. specification?
Refer to Procedure 010-033. YES

Are the axial and radial clearances within Repair

specification? complete
NO
Repair:
Replace the turbocharger assembly.
Refer to Procedure 010-033.

STEP 9G: Verify engine blowby is within specification.

Condition:
• Turn keyswitch OFF.
• Connect the appropriate orifice to the end of the blowby draft tube.
• Start engine.

Action Specification/Repair Next Step

Load engine to rated rpm on a chassis Are the engine blowby measurements within 9H
dynamometer. specification?
Measure the engine blowby. YES
Refer to Procedure 014-002.
Are the engine blowby measurements within 9G-1
specification?
NO
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-56 Section TT - Engine Performance Features

STEP 9G-1: Verify turbocharger contribution to engine blowby.

WARNING
Do not run the engine for more than one minute. Severe engine damage can occur if the engine is run too
long with the turbocharger oil drain line disconnected from the block.

Condition:
• Turn keyswitch OFF.
• Verify oil level is full.
• Connect the appropriate orifice to the end of the blowby draft tube.
• Remove turbocharger oil drain line from the block and drain into a bucket.
• Ensure the turbocharger oil drain port in the block is plugged so no crankcase gases escape.
• Start engine.

Action Specification/Repair Next Step

Load engine to rated rpm on a chassis Did the total engine blowby drop more than Repair
dynamometer. 30 percent? complete
Measure the engine blowby. YES
Refer to Procedure 014-002. Repair:
Replace the turbocharger assembly.
Refer to Procedure 010-033.

Did the total engine blowby drop more than Repair

30 percent? complete
NO
Repair:
Engine may need to be rebuilt.
See engine rebuild specifications.

STEP 9H: Check the static injection timing.

Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Check for the correct static injection timing. Is the static injection timing correct? Perform the
YES next
Refer to Procedure 006-025.
troubleshooti
ng procedure
as outlined in
Step 2

Is the static injection timing correct? Repair

NO complete

Repair:
Set the static injection timing to specification.
Refer to Procedure 006-025.
ISM, ISMe, and QSM11 Engine Performance Troubleshooting Tree
Section TT - Engine Performance Features Page TT-57

STEP 10: Check the EGR differential pressure sensor and exhaust gas pressure sensor
STEP 10A: Check the EGR differential pressure tubes for cracks, restrictions, or leaks.
Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Inspect the EGR differential pressure tubes for Are cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the EGR differential
pressure tubes.
Refer to Procedure 011-026.

Are cracks, restrictions, or leaks present? Repair

NO complete

STEP 10B: Check the exhaust gas pressure tubes for cracks, restrictions, or leaks.
Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Inspect the exhaust gas pressure tubes for Are cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the exhaust gas pressure
tubes.
Refer to Procedure 011-027.

Are cracks, restrictions, or leaks present? Perform the

NO next
troubleshooti
ng procedure
as outlined in
Step 2
Engine Performance Troubleshooting Tree ISM, ISMe, and QSM11
Page TT-58 Section TT - Engine Performance Features

Notes
ISM, ISMe, and QSM11
Section 0 - Complete Engine - Group 00 Page 0-a

Section 0 - Complete Engine - Group 00

Section Contents
Page
Engine Installation ............................................................................................................................................0-5
Install................................................................................................................................................................0-5
Engine Removal ................................................................................................................................................0-2
Remove............................................................................................................................................................0-2
ISM................................................................................................................................................................0-2
Service Tools ....................................................................................................................................................0-1
.........................................................................................................................................................................0-1
ISM, ISMe, and QSM11
Page 0-b Section 0 - Complete Engine - Group 00

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 0 - Complete Engine - Group 00 Page 0-1

Service Tools

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 your local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration

Engine Lifting Fixture
Used to remove and install the engine.
3162871
Engine Removal ISM, ISMe, and QSM11
Page 0-2 Section 0 - Complete Engine - Group 00

Engine Removal (000-001)

Remove
ISM

WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and connect the negative (-)
battery cable last.

WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Disconnect the battery cables.
Drain the engine coolant. Refer to Procedure 008-018.

Place a tag on all hoses, lines, linkage, and electrical

connections as they are removed, to identify their
locations.

Disconnect the OEM wiring harness from the ECM. Refer

to Procedure 019-031 in the Troubleshooting and Repair
Manual, Electronic Control System, ISM and QSM11
Engines, Bulletin 3666266.
ISM, ISMe, and QSM11 Engine Removal
Section 0 - Complete Engine - Group 00 Page 0-3

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

Disconnect the intake and exhaust air pipes.

Disconnect all chassis-mounted engine-driven
accessories.

WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection, and wrap a cloth around
the fittings before removing. Liquid refrigerant can
cause serious eye and skin injuries.

WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.

Remove all chassis components necessary to remove the

engine from the equipment.
Engine Removal ISM, ISMe, and QSM11
Page 0-4 Section 0 - Complete Engine - Group 00

WARNING
The engine lifting equipment must be designed to lift
the engine and the transmission as an assembly
without causing personal injury.
The dry weight of the engine is approximately 940 kg
[2070 lb]. Refer to the equipment manufacturer's
specifications for the transmission weight.
On applications in which the rear engine mounts are
attached to the transmission, it will be necessary to
remove the engine and transmission as an assembly.

Use a properly rated hoist and engine lifting fixture, Part

Number 3162871, attached 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.
Remove the engine.

Cover all engine openings to prevent dirt and debris from

entering the engine.
Place the engine on suitable engine support stands.

Remove all remaining accessories and brackets that will

be used with the replacement engine.
ISM, ISMe, and QSM11 Engine Installation
Section 0 - Complete Engine - Group 00 Page 0-5

Engine Installation (000-002)

Install
Install all accessories and brackets that were removed
from the previous engine.

WARNING
The engine lifting equipment must be designed to lift
the engine and the transmission as an assembly
without causing personal injury.
The dry weight of the engine is approximately 940 kg
[2070 lb]. See the equipment manufacturer's
specifications for the transmission weight.
On applications in which the rear engine mounts are
attached to the transmission, it will be necessary to install
the engine and transmission as an assembly.

Use a properly rated hoist and engine lifting bracket, Part

Number 3162871, attached to the engine-mounted lifting
brackets, to install the engine.

Inspect all of the rubber isolators to be sure they are in

good condition.
Align the engine in the chassis and tighten the engine
mounting capscrews. See the equipment manufacturer's
torque specifications.
Connect all engine- and chassis-mounted accessories
that were removed.
NOTE: Be sure all lines, hoses, and tubes are properly
routed and fastened to prevent damage.
Engine Installation ISM, ISMe, and QSM11
Page 0-6 Section 0 - Complete Engine - Group 00

Fill the engine with clean 15W-40 lubricating oil. Refer to

Procedure 007-025. Refer to Procedure 018-017 for the
correct oil capacity.
NOTE: The engine lubricating oil system must be
pressurized before the engine is operated. Refer to
Procedure 007-037.

Fill the cooling system with fully formulated coolant or a

50/50 mixture of fully formulated antifreeze and good-
quality water. Refer to Procedure008-018.
See the equipment manufacturer's specifications for
radiator and system capacity.

Connect the OEM wiring harness to the ECM. Refer to

Procedure 019-031 in the Troubleshooting and Repair
Manual, Electronic Control System, ISM and QSM11
Engines, Bulletin 3666266.

Perform a final inspection to make sure that all hoses,

wires, linkages, and components have been properly
installed and tightened.
ISM, ISMe, and QSM11 Engine Installation
Section 0 - Complete Engine - Group 00 Page 0-7

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 or spray can cause personal injury.
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, and check the oil and coolant levels again.

Fill the engine to the correct coolant and oil levels, if

necessary. Refer to Procedures 008-018 and 007-025.

Operate the engine for 8 to 10 minutes to check for proper

operation, unusual noises, and coolant, fuel, or lubricating
oil leaks.
Repair all leaks and component problems. See the
appropriate procedures.
Engine Installation ISM, ISMe, and QSM11
Page 0-8 Section 0 - Complete Engine - Group 00

Notes
ISM, ISMe, and QSM11
Section 1 - Cylinder Block - Group 01 Page 1-a

Section 1 - Cylinder Block - Group 01

Section Contents
Page
Accessory Drive Seal ........................................................................................................................................1-5
Clean................................................................................................................................................................1-6
Install................................................................................................................................................................1-6
Remove............................................................................................................................................................1-5
Alternator Drive Seal .........................................................................................................................................1-4
Clean................................................................................................................................................................1-4
Install................................................................................................................................................................1-4
Remove............................................................................................................................................................1-4
Bearings, Connecting Rod ................................................................................................................................1-7
Clean and Inspect for Reuse.............................................................................................................................1-8
Center Sump Pan...........................................................................................................................................1-8
Install..............................................................................................................................................................1-10
Remove............................................................................................................................................................1-7
Bearings, Main .................................................................................................................................................1-11
Clean and Inspect for Reuse...........................................................................................................................1-13
Finishing Steps...............................................................................................................................................1-18
Install..............................................................................................................................................................1-14
Preparatory Steps...........................................................................................................................................1-11
Remove..........................................................................................................................................................1-12
Bearings, Thrust ..............................................................................................................................................1-19
Install..............................................................................................................................................................1-20
ISM Engines.................................................................................................................................................1-20
Remove..........................................................................................................................................................1-19
Block Stiffener Plate .....................................................................................................................................1-130
Clean and Inspect for Reuse.........................................................................................................................1-130
Finishing Steps.............................................................................................................................................1-134
Install............................................................................................................................................................1-133
Machine........................................................................................................................................................1-131
Preparatory Steps.........................................................................................................................................1-130
Remove.........................................................................................................................................................1-130
Camshaft ..........................................................................................................................................................1-23
Clean..............................................................................................................................................................1-25
Inspect for Reuse............................................................................................................................................1-26
Install..............................................................................................................................................................1-27
Remove..........................................................................................................................................................1-23
Camshaft Bushings .........................................................................................................................................1-31
Clean..............................................................................................................................................................1-32
Inspect for Reuse............................................................................................................................................1-32
Install..............................................................................................................................................................1-32
Remove..........................................................................................................................................................1-31
Camshaft End Clearance ...............................................................................................................................1-127
Measure........................................................................................................................................................1-127
Camshaft Gear (Camshaft Installed) ...............................................................................................................1-35
Inspect for Reuse............................................................................................................................................1-37
Install..............................................................................................................................................................1-38
Remove..........................................................................................................................................................1-35
Camshaft Gear (Camshaft Removed) ..............................................................................................................1-41
Install..............................................................................................................................................................1-42
Remove..........................................................................................................................................................1-41
Connecting Rod ...............................................................................................................................................1-44
Clean..............................................................................................................................................................1-44
Inspect for Reuse............................................................................................................................................1-44
Install..............................................................................................................................................................1-46
Remove..........................................................................................................................................................1-44
Crankshaft .......................................................................................................................................................1-46
Rotation Check...............................................................................................................................................1-46
Crankshaft Gear, Front (Crankshaft Installed) ................................................................................................1-46
ISM, ISMe, and QSM11
Page 1-b Section 1 - Cylinder Block - Group 01

Clean..............................................................................................................................................................1-47
Inspect for Reuse............................................................................................................................................1-47
Install..............................................................................................................................................................1-48
Remove..........................................................................................................................................................1-46
Crankshaft Pulley ............................................................................................................................................1-50
Inspect for Reuse............................................................................................................................................1-50
Install..............................................................................................................................................................1-50
Remove..........................................................................................................................................................1-50
Crankshaft Seal, Front ....................................................................................................................................1-51
Clean..............................................................................................................................................................1-52
Install..............................................................................................................................................................1-52
Remove..........................................................................................................................................................1-51
Crankshaft Seal, Rear .....................................................................................................................................1-54
Clean and Inspect for Reuse...........................................................................................................................1-56
Finishing Steps...............................................................................................................................................1-58
Install..............................................................................................................................................................1-56
Non-REPTO Dry Unitized Seal.....................................................................................................................1-56
REPTO Dry Seal..........................................................................................................................................1-58
Preparatory Steps...........................................................................................................................................1-54
Remove..........................................................................................................................................................1-54
Non-REPTO Dry Lip Seal.............................................................................................................................1-54
Non-REPTO Dry Unitized Seal.....................................................................................................................1-54
REPTO Dry Seal..........................................................................................................................................1-55
Cylinder Block .................................................................................................................................................1-59
Basic Description............................................................................................................................................1-59
Inspect for Reuse............................................................................................................................................1-59
Cylinder Block and Liner Seats ......................................................................................................................1-64
Leak Test........................................................................................................................................................1-64
Cylinder Liner ..................................................................................................................................................1-65
Clean and Inspect for Reuse...........................................................................................................................1-69
Center Sump Pan.........................................................................................................................................1-69
Initial Check....................................................................................................................................................1-65
Install..............................................................................................................................................................1-73
Measure..........................................................................................................................................................1-72
Remove..........................................................................................................................................................1-68
Gear Cover, Front ............................................................................................................................................1-75
Remove..........................................................................................................................................................1-75
Gear Housing, Front ........................................................................................................................................1-77
Clean..............................................................................................................................................................1-79
Inspect for Reuse............................................................................................................................................1-80
Install..............................................................................................................................................................1-81
ISM..............................................................................................................................................................1-81
Remove..........................................................................................................................................................1-77
Idler Gear, Camshaft .......................................................................................................................................1-85
Clean..............................................................................................................................................................1-86
Inspect for Reuse............................................................................................................................................1-87
Install..............................................................................................................................................................1-88
Remove..........................................................................................................................................................1-85
Idler Gear, Hydraulic Pump .............................................................................................................................1-90
Clean..............................................................................................................................................................1-91
Inspect for Reuse............................................................................................................................................1-92
Install..............................................................................................................................................................1-93
Remove..........................................................................................................................................................1-90
Idler Gear, Water Pump ...................................................................................................................................1-95
Clean..............................................................................................................................................................1-96
Inspect for Reuse............................................................................................................................................1-97
Install..............................................................................................................................................................1-99
Remove..........................................................................................................................................................1-95
Piston .............................................................................................................................................................1-101
Assemble......................................................................................................................................................1-104
Articulated Piston.......................................................................................................................................1-104
Clean............................................................................................................................................................1-102
Articulated Piston.......................................................................................................................................1-102
ISM, ISMe, and QSM11
Section 1 - Cylinder Block - Group 01 Page 1-c

Disassemble..................................................................................................................................................1-101
Articulated Piston.......................................................................................................................................1-101
General Information.......................................................................................................................................1-101
Inspect for Reuse..........................................................................................................................................1-103
Articulated Piston.......................................................................................................................................1-103
Install............................................................................................................................................................1-104
Remove.........................................................................................................................................................1-101
Piston and Connecting Rod Assembly .........................................................................................................1-115
Assemble......................................................................................................................................................1-121
Articulated Piston.......................................................................................................................................1-121
Clean and Inspect for Reuse.........................................................................................................................1-119
Articulated Piston.......................................................................................................................................1-119
Disassemble..................................................................................................................................................1-118
Articulated Piston.......................................................................................................................................1-118
Finishing Steps.............................................................................................................................................1-127
Install............................................................................................................................................................1-122
Preparatory Steps.........................................................................................................................................1-115
Remove.........................................................................................................................................................1-116
Piston Cooling Nozzle ...................................................................................................................................1-105
Inspect for Reuse..........................................................................................................................................1-105
Install............................................................................................................................................................1-106
Remove.........................................................................................................................................................1-105
Piston Rings ..................................................................................................................................................1-107
Failure Analysis Inspection............................................................................................................................1-107
Service Tools .................................................................................................................................................... 1-1
Cylinder Block...................................................................................................................................................1-1
Vibration Damper, Viscous ...........................................................................................................................1-107
Clean............................................................................................................................................................1-107
Eccentricity Check.........................................................................................................................................1-108
Install............................................................................................................................................................1-108
Maintenance Check.......................................................................................................................................1-108
Remove.........................................................................................................................................................1-107
Wobble Check...............................................................................................................................................1-109
Water Header Plate, Cylinder Block .............................................................................................................1-109
Clean............................................................................................................................................................1-111
With EGR...................................................................................................................................................1-111
Without EGR..............................................................................................................................................1-111
Finishing Steps.............................................................................................................................................1-113
With EGR...................................................................................................................................................1-113
Without EGR..............................................................................................................................................1-114
Inspect for Reuse..........................................................................................................................................1-111
With EGR...................................................................................................................................................1-111
Without EGR..............................................................................................................................................1-111
Install............................................................................................................................................................1-112
With EGR...................................................................................................................................................1-112
Without EGR..............................................................................................................................................1-112
Preparatory Steps.........................................................................................................................................1-109
With EGR...................................................................................................................................................1-109
Without EGR..............................................................................................................................................1-110
Remove.........................................................................................................................................................1-110
With EGR...................................................................................................................................................1-110
Without EGR..............................................................................................................................................1-110
ISM, ISMe, and QSM11
Page 1-d Section 1 - Cylinder Block - Group 01

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 1 - Cylinder Block - Group 01 Page 1-1

Service Tools
Cylinder Block

Tool No. Tool Description Tool Illustration

Standard Puller
Remove alternator drive pulley. Use with two 5/16 x 18 x 2 inch
capscrews.
ST-647

Piston Ring Expander

Remove and install piston rings on pistons.
ST-821

Main Bearing Cap Puller

Remove main bearing caps.
ST-1178

Belt Tension Gauge

Measure drive v-ribbed belt tension.
ST-1293

Universal Cylinder Liner Puller

Remove cylinder liners from cylinder block. Requires cylinder liner
3162873 puller plate, Part Number 3376049.

Crankshaft Gear Puller Kit

Remove the crankshaft gear. Requires puller, Part Number 3375834,
and jaw, Part Number 3375839, to be used.
3375840
Service Tools ISM, ISMe, and QSM11
Page 1-2 Section 1 - Cylinder Block - Group 01

Tool No. Tool Description Tool Illustration

Connecting Rod Guide Pins
Guide connecting rods over crankshaft during removal or installation
of connecting rods.
3376038

Pulley Installation Tool

Install drive pulleys. Use pulley pusher adapter, Part Number
3377401, to install the alternator drive pulley.
3376326

Camshaft Guide Pilot

Aid in removal and installation of the camshaft cylinder block.
3376388

Guide Pin
Two guide pins are used to install the water header plate.
3376488

Hydraulic Actuator Kit

Used with installation/removal kit.
3823621

Installation/Removal Kit
Used to install/remove camshaft bushings.
3823642

Guide Pin Kit

Aid during installation of vibration damper. The kit consists of two
each guide pins, Part Number's 3376488, 3376638, 3376696,
3376695
3376697, and 3376698.

Piston Ring Compressor

Compress piston rings on pistons during installation of pistons in the
cylinder block.
3823309
ISM, ISMe, and QSM11 Service Tools
Section 1 - Cylinder Block - Group 01 Page 1-3

Tool No. Tool Description Tool Illustration

Gauge Block
Measure cylinder protrusion on the cylinder block and gear housing
3823495 protrusion below the cylinder block.

Needle Bearing Kit

Used to remove and install needle bearings in the gear housing and
hydraulic pump adapter. Use mandrel, Part Number 3823776, to
3823774
install hydraulic pump needle bearings.

Cam Gear Puller Kit

Used to remove the camshaft gear from the camshaft without
3162895 removing the camshaft from the engine.

Needle Bearing Installation Tool

Used to remove and install the water pump drive needle bearing in
the gear housing.
3824117

Engine Barring Tool

Used to bar the engine by hand.
3824270

Liner/Installation Tool
Used to seat and hold the liner while liner protrusion is measured.
3824272
Alternator Drive Seal ISM, ISMe, and QSM11
Page 1-4 Section 1 - Cylinder Block - Group 01

Alternator Drive Seal (001-001)

Remove
Remove the alternator drive belt. Refer to Procedure 013-
005.
Remove the alternator drive pulley. Refer to Procedure
009-010.

Remove the five capscrews and clamping ring.

Remove the dust seal and oil seal together.

Clean
Clean the gasket surface of the gear cover.

Install
Do not use lubricant to install the seal. The oil seal
must be installed with the lip of the seal and the shaft
clean and dry. The yellow dust lip of the seal must be
facing out.
Use the installation sleeve provided with the new seal to
install the new seal and gasket.
Apply sealant, Part Number 3375066 or equivalent, to the
threads of the capscrews.
Install the clamping ring with five (M8-1.25 x 20)
capscrews. Tighten the capscrews in a star pattern.
Torque Value: Step1 7 N•m [ 60 in-lb ]
Step2 20 N•m [ 175 in-lb ]
ISM, ISMe, and QSM11 Accessory Drive Seal
Section 1 - Cylinder Block - Group 01 Page 1-5

Place a light film of oil or antifreeze on the inside diameter

of a new oil seal dust seal.
Install the dust seal onto the shaft with the larger outside
diameter facing toward the engine.
Push the dust seal back by hand on the shaft until the
entire dust seal contacts the oil seal case.

Install the alternator drive pulley. Refer to Procedure 009-

010.
Install and adjust the alternator drive belt. Refer to
Procedure 013-005.

Accessory Drive Seal (001-003)

Remove
If equipped with an automatic belt tensioner, remove the
alternator drive belt. Refer to Procedure 013-001.

Remove the accessory drive pulley. Refer to Procedure

009-004.
Remove the five capscrews, clamping ring, seal, and
gasket.
Accessory Drive Seal ISM, ISMe, and QSM11
Page 1-6 Section 1 - Cylinder Block - Group 01

Clean
Clean the gasket surface of the gear cover.

Apply a coating of thread sealant, Part Number 3823494,

to the mounting capscrews.
Install the clamping ring and five capscrews.
Tighten the capscrews in a star pattern in two steps.
Torque Value: Step1 7 N•m [ 60 in-lb ]
Step2 20 N•m [ 175 in-lb ]
NOTE: The accessory drive pulley has a dust seal on the
engine side of the pulley.
Install the accessory drive pulley. Refer to Procedure 009-
004.
ISM, ISMe, and QSM11 Bearings, Connecting Rod
Section 1 - Cylinder Block - Group 01 Page 1-7

Bearings, Connecting Rod (001-005)

Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

Use the accessory drive pulley to rotate the crankshaft so

the connecting rod to be removed is at bottom dead
center.

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 dowel rings.
Bearings, Connecting Rod ISM, ISMe, and QSM11
Page 1-8 Section 1 - Cylinder Block - Group 01

Remove the capscrews and rod caps.

Remove the lower bearing shell from the rod cap. Mark it
with the letter "L" ( for lower) and the cylinder number it
was removed from.

Install two connecting rod guide pins, Part Number

3376038.
Use a t-handle piston pusher to push the rod away from
the crankshaft to allow the upper bearing shell to be
removed.
Remove the upper bearing shell. Mark it with the letter "U"
(upper) and the cylinder number it was removed from.

Clean and Inspect for Reuse

Center Sump Pan

WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause personal injury.

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.

Inspect the rod caps, connecting rod bearing saddles and

capscrews for nicks, cracks, burrs, scratches or frets.
ISM, ISMe, and QSM11 Bearings, Connecting Rod
Section 1 - Cylinder Block - Group 01 Page 1-9

Inspect the bearings for damage.

Replace any bearings with the following damage:
• Pits
• Flakes
• Corrosion
• Lock tang damage
• Scratches (deep enough to be felt with a fingernail).

Normal bearing wear produces a smooth finish that will

wear into the copper lining. Exposed copper does not
always indicate worn bearings. Refer to the Parts Reuse
Guidelines, Bulletin 3810303.
If large areas of copper lining are visible in the bearings
before the engine has accumulated 241,000 km [150,000
mi] or 3750 hours, inspect the engine for contamination
from fine dirt particles and correct the problem.

Inspect the bearing shell seating surface for nicks or burrs.

If nicks or burrs can not be removed with Scotch-Brite®
7448 or equivalent, the bearings must be replaced.
For more detailed information on bearing damage, refer
to the Analysis and Prevention of Bearing Failures
Manual, Bulletin 3810387.

Use an outside diameter ball-tipped micrometer to

measure the rod bearing thickness.

Standard Connecting Rod Bearing Thickness

mm in
2.430 MIN 0.0957
2.473 MAX 0.0974
Bearings, Connecting Rod ISM, ISMe, and QSM11
Page 1-10 Section 1 - Cylinder Block - Group 01

Install
Used bearings must be installed in the same location from
which they were removed.
Use Lubriplate™ 105, or equivalent, to coat the inside
diameter of the bearing shell.
Install the upper bearing shell in the connecting rod with
the tang (1) of the bearing in the slot (2) of the rod.
Remove the two connecting rod guide pins, Part Number
3376038.

Install the bearing shell in the connecting rod cap with the
tang (2) of the bearing in the slot (1) of the cap.
Use Lubriplate™ 105, or equivalent, to coat the inside
diameter of the bearing shell.
Use clean 15W-40 oil to lubricate under the head and the
threads of the connecting rod capscrews.

The connecting rod and cap must be matched with the

same number. The tang must be toward the camshaft side
of the engine.
Install the connecting rod caps and capscrews.

Tighten the capscrews in alternating sequence to the

following torque values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 142 N•m [ 105 ft-lb ]
Step3 210 N•m [ 155 ft-lb ]
Step4 Loosen completely
Step5 Repeat steps 1 through 3
Measure the connecting rod side clearance. Refer to
Procedure 001-054.
ISM, ISMe, and QSM11 Bearings, Main
Section 1 - Cylinder Block - Group 01 Page 1-11

Install the piston cooling nozzles. Refer to Procedure 001-

046.
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill the lubricating oil pan. Refer to Procedure 007-025.

Operate the engine to normal operating temperature and

check for leaks.
NOTE: The engine must have adequate oil pressure
within 15 seconds after starting. If the warning light
indicating low oil pressure has not gone out or there is no
oil pressure indicated on a gauge within 15 seconds, shut
off the engine immediately to avoid engine damage.
Confirm the correct oil level in the oil pan.

Bearings, Main (001-006)

Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

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.
Cummins Inc. recommends replacing the thrust bearings
when the main bearings are replaced. Refer to Procedure
001-007 in the ISM, ISMe, and QSM11 Troubleshooting
and Repair Manual or Procedure 001-007 in the M11
Series Engines (STC, CELECT™, CELECT™ Plus Models)
Base Engine Troubleshooting and Repair Manual for
thrust bearing replacement.
Drain the lubricating oil. Refer to Procedure 007-025.
Remove the lubricating oil pan. Refer to Procedure 007-
025.
Bearings, Main ISM, ISMe, and QSM11
Page 1-12 Section 1 - Cylinder Block - Group 01

Remove
Replace the main bearings one at a time.
Remove the main bearing capscrews.
Use main bearing cap puller, Part Number ST-1178, to
remove the cap.
The tool must be centered on the cap. Pull straight down
to remove the cap.

The number 4 main bearing cap has thrust bearings. The

cap is located with two dowel pins.

Remove the lower main bearing shell from the cap.

Mark the bearing shell with the letter L (lower) and the
journal number from which it was removed.

To remove the upper main bearing shell, install bearing

rollout tool, Part Number 3823818, in the oil hole of the
main bearing journal.
Remove the tang side (1) of the main bearing shell first.
Rotate the crankshaft with the accessory drive pulley to
remove the upper main bearing shell (2).
ISM, ISMe, and QSM11 Bearings, Main
Section 1 - Cylinder Block - Group 01 Page 1-13

Clean and Inspect for Reuse

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
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

CAUTION
Prevent oil seepage down onto the mating faces of the
block mains, cleaning of the block main capscrew
threaded holes is critical. (Use cotton swabs, or
equivalent, to absorb as much oil as possible prior to
installing main caps.) Loctite® 518 thread sealant
will not seal to an oily surface.
NOTE: Loctite® 518 thread sealant is available at local
automotive parts stores. There is no Cummins part
number available.

Clean all main bearing cap mounting surfaces on the

cylinder block with a solvent-based degreaser.
Dry the main bearing cap mounting surfaces on the
cylinder block with a clean, lint-free cloth.
The main bearing cap surfaces must be free of grease and
oily residue.
Use solvent and a soft bristle brush to clean the bearing
cap, capscrews, washers, and bearings.
Dry the parts with compressed air.

Clean the mounting surfaces of the main bearing caps

with a solvent-based degreaser. Dry the mounting
surfaces of the main bearing caps with a clean, lint-free
cloth.
The mounting surfaces of the main bearing caps must be
free of grease and oily residue.
Bearings, Main ISM, ISMe, and QSM11
Page 1-14 Section 1 - Cylinder Block - Group 01

Inspect the main cap, capscrews, and washers for

damage.
Inspect the bearing shells for nicks, scratches, or damage.
If the main bearings are damaged, see Shop Manual, M11
Series Engine, Bulletin 3666075, to inspect the crankshaft
main bearing journals. If the crankshaft is damaged, the
engine must be removed for repair.
Refer to Procedure 000-001 in the ISM, ISMe, and QSM11
Troubleshooting and Repair Manual, Bulletin 3666322 or
Procedure 000-001 in the M11 Series Engines (STC,
CELECT™, CELECT™ Plus Models) Base Engine
Troubleshooting and Repair Manual, Bulletin 3666139.

Use an outside diameter ball-tipped micrometer to

measure the main bearing shell thickness.

Standard Main Bearing Shell Thickness

mm in
3.894 MIN 0.1533
3.945 MAX 0.1553
For more detailed information on bearing damage, consult
the Analysis and Prevention of Bearing Failures Manual,
Bulletin 3810387.

Install

CAUTION
To reduce the possibility of engine damage, the upper
and lower bearings must be installed in the correct
location. The upper bearing has an oil groove. The
bearing shells are marked with the words "upper" and
"lower" for identification.

CAUTION
To correctly position the bearing and prevent engine
damage, the bearing tang (1) must be in the slot (2) of
the bearing saddle.

CAUTION
Only use Loctite® 518 thread sealant on the main cap
joint mating surface. Other sealants can become hard,
brittle, and allow oil and debris into the main bearing/
block joint.

CAUTION
The bead must be 3 to 5 mm [0.12 to 0.2 in] wide and
must not enter the main bearing shell inside diameter.
Sealant in the main bearing can cause engine damage.
ISM, ISMe, and QSM11 Bearings, Main
Section 1 - Cylinder Block - Group 01 Page 1-15

Used bearings must be installed in the same location from

which they were removed.
Use Lubriplate™ 105 multi-purpose lubricant, or
equivalent, to coat the inside diameter of the upper main
bearing shell.
Install the upper main bearing shells (2) using the same
method used to remove them.
The tang side (1) of the bearing must go into place last.

Install the lower main bearing shells with the bearing tang
(1) in the slot (2) of the main bearing cap.
Use Lubriplate™ 105 multi-purpose lubricant, or
equivalent, to coat the inside diameter of the bearing
shells.

Apply Loctite® 518 thread sealant to four locations on each

main bearing cap.
Apply a bead of Loctite® 518 thread sealant to the main
bearing cap mounting surface, as shown.
Repeat this procedure on the opposite side of the main
bearing cap.

CAUTION
The bead must be 3 to 5 mm [0.12 to 0.2 in] wide and
must not enter the main bearing shell inside diameter.
Sealant in the main bearing can cause engine damage.
Locate the leading edge of the main bearing cap
clearance chamfer.
Apply a bead of Loctite®518 thread sealant to the leading
edge of the main bearing cap clearance chamfer (as
shown).
Repeat this procedure on the opposite side of the main
bearing cap.
Bearings, Main ISM, ISMe, and QSM11
Page 1-16 Section 1 - Cylinder Block - Group 01

To reduce the possibility of bore size issues, clearance

issues, or both, the main bearing capscrews must be
tightened within 15 minutes of the Loctite® 518 thread
sealant application.

Use Lubriplate™ 105 multi-purpose lubricant, or

equivalent, to coat the lower thrust bearings.
Install the lower thrust bearings in the number 4 main
bearing cap, as shown.
The grooves of the thrust bearing must be toward the
crankshaft.
The locating dowels must not protrude above the thrust
bearing surface.

Use clean 15W-40 oil to coat the capscrew threads and

both sides of the washers.
Drain the excess oil from the capscrews before installing
them in the cylinder block.

The number 4 main bearing cap must be aligned with the

dowel pins in the bearing saddle when the capscrews are
tightened.
ISM, ISMe, and QSM11 Bearings, Main
Section 1 - Cylinder Block - Group 01 Page 1-17

The main bearing caps are numbered 1 through 7 from

front to rear in the cylinder block. The caps must be
installed so the number on the cap matches the bearing
saddle in the block. The lock tangs in the main bearing
saddle and bearing cap must be on the same side.
Install the main bearing caps.

Do not hit the main bearing cap with a hammer.

Make sure the proper main cap capscrew torque

procedure is used when torquing main bearings. The use
of the improper torque procedure will damage the engine.
Tighten all older blocks (prior to Engine Serial Number
(ESN) 35011095) main bearing capscrews in alternating
sequence to the following torque values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 Loosen completely
Step3 68 N•m [ 50 ft-lb ]
Step4 Rotate 180 degrees
All torque-to-yield blocks (ESN first 35011095) or blocks
with TTY stamped on the rear engine serial number stamp
pad must be tightened in alternating sequence to the
following torque values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 Loosen completely
Step3 135 N•m [ 100 ft-lb ]
Step4 Rotate 180 degrees
Bearings, Main ISM, ISMe, and QSM11
Page 1-18 Section 1 - Cylinder Block - Group 01

Use a dial indicator to measure the crankshaft end

clearance.

Crankshaft End Clearance

mm in
0.10 MIN 0.004
0.56 MAX 0.022
If the end clearance is not within the specifications, refer
to the M11 Shop Manual, Bulletin Number 3666075, to
inspect the main bearing cap and thrust bearing surfaces
in the cylinder block.

CAUTION
Low oil pressure faults can occur if more than one set
undersized main bearings are installed in the same
engine.
NOTE: Both upper and lower undersized main bearing
shells must be installed as a set in the same block
location.
Undersized main bearing installation procedures are the
same as standard main bearings procedures. Both upper
and lower undersized main bearing shells must be
installed as a set in the same block location.
For undersized main bearing installation, mark the outside
back of the main cap X -0.003 X with a permanent white
Dykem® marker to identify bearing location for future
repairs. Allow the Dykem® to dry before oil is added.

Finishing Steps

CAUTION
The engine must have adequate oil pressure within 15
seconds after starting. If the warning light indicating
low oil pressure has not gone out or there is no oil
pressure indicated on a gauge within 15 seconds,
shut off the engine immediately to avoid engine
damage. Confirm the correct oil level is in the oil pan.
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill the engine with lubricating oil. Refer to Procedure 007-
025.
Operate the engine to normal operating temperature and
check for leaks.
ISM, ISMe, and QSM11 Bearings, Thrust
Section 1 - Cylinder Block - Group 01 Page 1-19

Bearings, Thrust (001-007)

Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin

The number four main bearing cap has thrust bearings.

The cap is located with two dowel pins.

Remove the thrust bearings from the number four main

bearing cap.
Mark the thrust bearings in the oil passage groove as
being front or rear bearings.
Bearings, Thrust ISM, ISMe, and QSM11
Page 1-20 Section 1 - Cylinder Block - Group 01

CAUTION
Do not damage the crankshaft when removing the
upper thrust bearings.
Use a blunt tool to remove the upper thrust bearings.

Install
ISM Engines
Use Lubriplate™ 105 Part Number 3163086 or 3163087,
or equivalent, to coat the upper thrust bearings.

Push the crankshaft toward the rear of the engine to install

the rear thrust bearing, and to the front of the engine to
install the front thrust bearing.
Install the upper thrust bearings in the number four main
bearing saddle.
The grooves must be toward the crankshaft.

Use Lubriplate™ 105, or equivalent, to coat the lower thrust

bearings.
Install the lower thrust bearings in the number four main
bearing cap as shown.
The grooves of the thrust bearing must be toward the
crankshaft.
ISM, ISMe, and QSM11 Bearings, Thrust
Section 1 - Cylinder Block - Group 01 Page 1-21

Use clean 15W-40 oil to coat the capscrew threads and on

both sides of the washers.
Drain the excess oil from the capscrews before installing
them in the cylinder block.

CAUTION
To prevent damage to the cylinder block and main
bearing cap, the number four main bearing cap must
be aligned with the dowel pins in the bearing saddle
when the capscrews are tightened.

The main bearing caps are numbered one through seven

from front to rear in the cylinder block. The caps must be
installed so the number on the cap matches the bearing
saddle in the block. The lock tangs in the main bearing
saddle and bearing cap must be on the same side.
Install the main bearing caps.

CAUTION
To prevent damage to the main bearing cap and
bearings, do not hit the main bearing cap with a
hammer.
Bearings, Thrust ISM, ISMe, and QSM11
Page 1-22 Section 1 - Cylinder Block - Group 01

Tighten the main bearing capscrews in alternating

sequence to the following torque values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 142 N•m [ 105 ft-lb ]
Step3 210 N•m [ 155 ft-lb ]
Step4 Loosen completely
Step5 Repeat steps 1 through 3

Use a dial indicator to measure the crankshaft end

clearance.

Crankshaft End Clearance

mm in
0.10 MIN 0.004
0.56 MAX 0.022
If the end clearance is not within the specifications,
inspect the main bearing cap and thrust bearing surfaces
in the cylinder block. Refer to the Shop Manual, M11
Series Engines, Bulletin 3666075.

Install the lubricating oil pan. Refer to Procedure 007-025.

Fill the engine with lubricating oil. Refer to Procedure 007-

025.
Operate the engine to normal operating temperature and
check for leaks.
NOTE: The engine must have adequate oil pressure
within 15 seconds after starting. If the warning light
indicating low oil pressure has not gone out or there is no
oil pressure indicated on a gauge within 15 seconds, shut
off the engine immediately to avoid engine damage.
Confirm the correct oil level is in the oil pan.
ISM, ISMe, and QSM11 Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-23

Camshaft (001-008)
Remove
Remove the air piping from the intake manifold.
Remove the rocker lever cover. Refer to Procedure 003-
011.

Remove the engine brakes, if equipped. Refer to

Procedure 020-024.

Remove the push tubes and push rods. Refer to

Procedure 004-014.

Remove the gear cover. Refer to Procedure 001-031.

NOTE: It is possible to remove the camshaft without
removing the cylinder head. The cam followers can be tied
up and away from the camshaft with wire.
Camshaft ISM, ISMe, and QSM11
Page 1-24 Section 1 - Cylinder Block - Group 01

Remove the camshaft idler gear. Refer to Procedure 001-

036.

Raise the cam follower assemblies, and use a wire to tie

the cam followers up away from the camshaft.
Rotate the camshaft to align the holes in the camshaft
gear with the thrust plate capscrews.
Remove the thrust plate capscrews.

Remove the three capscrews and the camshaft rear cover

plate.

Install camshaft installation pilot, Part Number 3376388,

as follows:
• Install the expander (1), Part Number 3376923, in the
camshaft through the rear cover plate opening.
• Turn the screw inside the expander clockwise to
expand the swell plug.
ISM, ISMe, and QSM11 Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-25

• Install the arbor sleeve (2) over the expander.

• Install the locating pilot extensions (3) to the
expander.

Use one hand to rotate slowly and pull the camshaft from
the cylinder block and the other hand to balance the
camshaft as it is removed.
Remove the camshaft pilot tool.

Clean
Clean the camshaft rear cover plate and the cylinder block
mating surface.

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.
Clean the camshaft with steam or solvent. Dry with
compressed air.
Camshaft ISM, ISMe, and QSM11
Page 1-26 Section 1 - Cylinder Block - Group 01

CAUTION
After the camshaft has been steam cleaned, do not
touch the machined surfaces with bare hands. This
will cause rust to form, which will damage the
camshaft. Lubricate the camshaft with clean 15W-40
oil before handling.

Inspect for Reuse

Measure the clearance between the gear hub and the
thrust plate.

Camshaft Thrust Plate Clearance

mm in
0.13 MIN 0.005
0.33 MAX 0.013

Measure the outside diameter of the seven camshaft

bushing journals.

Camshaft Bushing Journal Outside Diameter

mm in
71.960 MIN 2.8331
72.013 MAX 2.8352

Inspect the camshaft lobes for cracks, scratches, or other

damage.
Refer to Camshaft Reuse Guidelines for engines with
crowned rollers, Bulletin 3666052.
ISM, ISMe, and QSM11 Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-27

Remove the camshaft gear, and measure the camshaft

nose (1), thrust plate (2), and gear (3). Refer to Procedure
001-013.

Install
Install the camshaft gear on the camshaft. Refer to
Procedure 001-013.

Use Lubriplate™ 105, or equivalent, to coat the camshaft

bushings and camshaft.

Install camshaft installation pilot, Part Number 3376388,

as follows:
• Install expander (1), Part Number 3376923,
• Turn the screw inside the expander clockwise to
expand the swell plug.
Camshaft ISM, ISMe, and QSM11
Page 1-28 Section 1 - Cylinder Block - Group 01

• Install the arbor sleeve (2) over the expander.

• Install the locating pilot extensions (3) to the
expander.

Rotate the camshaft slowly as it is being installed in the

cylinder block.

The camshaft installation pilot must be disassembled as

it clears the number seven camshaft bushing to prevent
interference with the rib across the top of die-cast flywheel
housings.
Remove the camshaft pilot.

Rotate the camshaft to align the holes in the camshaft

gear with the thrust plate capscrew holes in the cylinder
block.
Align the capscrew holes in the thrust plate with the
cylinder block capscrew holes.
Install the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
ISM, ISMe, and QSM11 Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-29

Use a new gasket to install the camshaft rear cover plate.

Tighten the three capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Measure the camshaft end clearance.

Camshaft End Clearance

mm in
0.13 MIN 0.005
0.33 MAX 0.013

Do not drop the cam follower levers on the camshaft

lobes.
Carefully lower the cam followers onto the camshaft.

Install the camshaft idler gear. Refer to Procedure 001-

036.
Check the engine timing. Refer to Procedure 006-025.

Install the gear cover. Refer to Procedure 001-031.

Camshaft ISM, ISMe, and QSM11
Page 1-30 Section 1 - Cylinder Block - Group 01

Install the push tubes and push rods. Refer to Procedure

004-014.

Adjust the valves and injectors. Refer to Procedure 003-

004.

Install the engine brakes, if equipped. Refer to Procedure

020-024.

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

ISM, ISMe, and QSM11 Camshaft Bushings
Section 1 - Cylinder Block - Group 01 Page 1-31

Operate the engine to normal operating temperature and

check for leaks.

Camshaft Bushings (001-010)

Remove
Remove the gear cover. Refer to Procedure 001-031.
Remove the cylinder head. Refer to Procedure 002-004.
Remove the cam followers. Refer to Procedure 004-001.

Remove the camshaft. Refer to Procedure 001-008.

Use Part Number 3376637, camshaft bushing driver and
Part Number 3367636 Driver, or Part Number 3823642,
hydraulic cam bushing tool, and Part Number 3823621
hydraulic actuator kit to remove the camshaft bushings.
Remove bushing number one first.

Remove the remaining six bushings in order from front to

rear.
Camshaft Bushings ISM, ISMe, and QSM11
Page 1-32 Section 1 - Cylinder Block - Group 01

Clean
Use Scotch-Brite® 7448, Part Number 3823258; or
equivalent, to remove burrs and clean the bushing bores.

Inspect for Reuse

Measure the cylinder block camshaft bore inside
diameter.

Cylinder Block Camshaft Bore I.D.

mm in
76.987 MIN 3.0310
77.040 MAX 3.0331

Install
Starting with number seven bushing, install the camshaft
bushings in order from rear to front.
NOTE: The oil hole (1) in the bushing must be at the three
o'clock location when viewed from the front of the engine.

Number Seven Bushing - Installation

Install guide (2), Part Number 3376069, between the
number six and number five bores.
Install a new bushing (3) on driver, Part Number 3376070,
with the oil hole (4) at the 3 o'clock location when viewed
from the front of the engine.
Drive the bushing into the bore.
ISM, ISMe, and QSM11 Camshaft Bushings
Section 1 - Cylinder Block - Group 01 Page 1-33

CAUTION
The bushing oil groove must be visible in both
cylinder block oil drillings (5 and 6) to prevent engine
damage. The oil drillings are not in alignment with
each other.
Inspect the bushing oil groove alignment with the two oil
drillings in the block as the bushing is installed.

Number Six Through Number Two Bushings - Installation

Use the same procedure to install the number six through
number two bushings.
Install the guide (2) in the correct location.
Install the bushing on the driver with the oil hole at the 3
o'clock location when viewed from the front of the engine.
Drive in the bushing.

CAUTION
The oil groove must be visible through the cam
follower stud holes (7). If the oil groove is not aligned,
engine damage will occur.
Remove the cam follower studs. Refer to Procedure 004-
001.
Inspect the location of the camshaft bushing oil groove.

Number One Bushing - Installation

Install a new bushing on driver, Part Number 3376070,
with the oil hole (1) at the 3 o'clock location when viewed
from the front of the engine.
NOTE: The guide is not used to install this bushing.
Drive the bushing into the bore.
Camshaft Bushings ISM, ISMe, and QSM11
Page 1-34 Section 1 - Cylinder Block - Group 01

CAUTION
The bushing oil groove must be visible in both block
oil drillings (8 and 9) to prevent engine damage. The
block oil drillings are not in alignment with each other.

Measure the camshaft bushing-installed inside diameter.

Camshaft Bushing I.D. Installed

mm in
72.078 MIN 2.8377
72.142 MAX 2.8402

Install the camshaft. Refer to Procedure 001-008.

Install the cam follower studs and cam followers. Refer to
Procedure 004-001.
Install the cylinder head. Refer to Procedure 002-004.

Install the gear cover. Refer to Procedure 001-031.

ISM, ISMe, and QSM11 Camshaft Gear (Camshaft Installed)
Section 1 - Cylinder Block - Group 01 Page 1-35

Operate the engine to normal operating temperature and

check for leaks.

Camshaft Gear (Camshaft Installed)

(001-012)
Remove
Remove the gear cover. Refer to Procedure 001-031.

Remove the camshaft idler gear. Refer to Procedure 001-

036.

Place two puller adapter assemblies (1) in opposite

lightening holes in cam gear.
Camshaft Gear (Camshaft Installed) ISM, ISMe, and QSM11
Page 1-36 Section 1 - Cylinder Block - Group 01

Install lifting plate (11) on the holder plate (2) with one
screw (8). Tighten screw securely.

Attach a lifting device to the lifting plate (11).

WARNING
The puller assembly is heavy. Use a lifting device
when securing it to the cam gear.
Make sure the forcing screw pilot is engaged with the
center of the camshaft and the puller adapter assembly
studs are properly seated in the holder plate assembly.
Using the lifting device, position the holder plate (2)
against the cam gear and install two screws (7) through
the holder plate (2) into the puller adapters (1).
Tighten screws securely.

WARNING
Cam gear and puller assembly may fall when released
and cause serious personal injury.
Do not attempt to alter the puller assembly for use with
any kind of impact wrench. The threads on the puller
assembly may gall and seize.
Use the lever bar (4), extension bar (5), and torque
reaction lever (6), to turn the forcing screw (3) clockwise,
pulling the cam gear from the camshaft.
ISM, ISMe, and QSM11 Camshaft Gear (Camshaft Installed)
Section 1 - Cylinder Block - Group 01 Page 1-37

Inspect for Reuse

Inspect the camshaft gear for cracks and chipped or
broken teeth.
Inspect the bore of the gear for frets or burrs.
Remove any burrs with Scotch-Brite™ 7448, Part Number
3823258; a fine honing stone, or equivalent.
If the frets, burrs, or raised material can not be removed,
replace the gear.

Inspect the gear keyway for burrs.

Remove burrs with Scotch-Brite™ 7448, Part Number
3823258; a fine honing stone, or equivalent.
If the keyway is damaged or the burrs can not be removed,
the gear must be replaced.

Measure the camshaft gear bore inside diameter.

Camshaft Gear Bore I.D.

mm in
46.912 MIN 1.8469
46.938 MAX 1.8479

Inspect the camshaft nose for frets or burrs.

Remove any burrs with Scotch-Brite™ 7448, Part Number
3823258; a fine honing stone, or equivalent.
If frets or burrs can not be removed, replace the camshaft.
Inspect the thrust surface of the camshaft for grooves or
heavy wear.
Camshaft Gear (Camshaft Installed) ISM, ISMe, and QSM11
Page 1-38 Section 1 - Cylinder Block - Group 01

Measure the camshaft gear journal outside diameter.

Camshaft Gear Journal O.D.

mm in
46.987 MIN 1.8499
47.013 MAX 1.8509

Measure the camshaft thrust plate thickness.

Camshaft Thrust Plate Thickness

mm in
8.96 MIN 0.353
9.04 MAX 0.356

Install
Install the thrust plate on the camshaft.
Install the capscrews and tighten.
Torque Value: 47 N•m [ 35 ft-lb ]

Gear housing clearance makes key installation more

difficult. Use care in seating the key.
Be sure the gear mounting surface is clean and free of oil,
dirt, or debris.
If the camshaft gear is used again, use the same part
number key as the one that was removed. Be sure the
arrow on the key is pointing in the same direction as when
it was removed.
Use a leather hammer to install the camshaft gear key.
ISM, ISMe, and QSM11 Camshaft Gear (Camshaft Installed)
Section 1 - Cylinder Block - Group 01 Page 1-39

It can be necessary to remove the camshaft rear cover

plate and apply pressure to the end of the camshaft to hold
it in the forward position while the gear is being installed.
Refer to Procedure 001-008.

Heat the gear in an oven for a minimum of 1 hour, but

not longer than 6 hours.
Temperature: 235 °C [ 450 °F ]

WARNING
Use insulated gloves, Part Number 3823730, and/or
hot clamp pliers, Part Number 3823732, when
handling heated parts. Hot parts can cause serious
personal injury.

CAUTION
The timing marks and gear part number must be
facing away from the camshaft when the gear is
installed to prevent engine damage.
Use Lubriplate™ 105, or equivalent, to coat the camshaft
nose before installing the camshaft gear.
Remove the gear from the oven. Install the gear on the
camshaft within 30 seconds after removing from the oven.
Align the gear keyway with the key in the camshaft, and
install the gear on the camshaft.
Camshaft Gear (Camshaft Installed) ISM, ISMe, and QSM11
Page 1-40 Section 1 - Cylinder Block - Group 01

Install a C-clamp around the gear housing and the

camshaft gear to hold the gear in position as it cools.
Remove the C-clamp after the gear has cooled to room
temperature (approximately 10 minutes).

Use a dial indicator to check the end clearance of the gear.

Push the camshaft to the rear and set the gauge at zero.
Pull the gear out and measure the end clearance.

Camshaft Gear End Clearance

mm in
0.13 MIN 0.005
0.41 MAX 0.016

Install the camshaft idler gear. Refer to Procedure 001-

036.

CAUTION
Failure to check the engine timing can cause severe
engine damage.
Check the engine timing. Refer to Procedure 006-025.
ISM, ISMe, and QSM11 Camshaft Gear (Camshaft Removed)
Section 1 - Cylinder Block - Group 01 Page 1-41

Install the gear cover. Refer to Procedure 001-031.

Operate the engine to normal operating temperature and
check for leaks.

Camshaft Gear (Camshaft Removed)

(001-013)
Remove

CAUTION
Support the camshaft gear on the center hub when
pressing it off the camshaft. Failure to do so can result
in damage to the gear.
Remove the camshaft. Refer to Procedure 001-008.
Install the camshaft and gear assembly in a hydraulic
press.

Press the camshaft from the gear.

NOTE: If the camshaft key is marked with an arrow, record
the direction the arrow is pointed.

Remove the camshaft key.

Remove the thrust plate.
Camshaft Gear (Camshaft Removed) ISM, ISMe, and QSM11
Page 1-42 Section 1 - Cylinder Block - Group 01

Install
The accompanying chart lists different camshaft key part
numbers, the degree of offset, and the approximate
injector timing change from nominal.

Install the thrust plate on the camshaft.

Be sure the gear mounting surface is clean and free of oil,

dirt, or debris.
Use a leather hammer 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.
Be sure the arrow on the key is pointing in the same
direction as when it was removed. If a different camshaft
and gear are used, install a straight key.

WARNING
Use insulated gloves, Part Number 3823730, and/or
hot clamp pliers, Part Number 3823732, when
handling heated parts. Hot parts can cause serious
personal injury.
Heat the gear in an oven for a minimum of 1 hour, but no
longer than 6 hours.
Temperature 235 °C [ 450 °F ]
Use Lubriplate™ 105, or equivalent, to coat the camshaft
nose before installing the camshaft gear.
ISM, ISMe, and QSM11 Camshaft Gear (Camshaft Removed)
Section 1 - Cylinder Block - Group 01 Page 1-43

CAUTION
The timing marks and gear part number must be
facing away from the camshaft when the gear is
installed to prevent engine damage.
The gear must be installed within 30 seconds after being
removed from the oven.
Remove the gear from the oven. Align the keyway in the
gear with the key in the camshaft, and install the gear on
the camshaft.
Keep the camshaft in a vertical position with the gear up
until the gear has cooled.

Measure the clearance between the gear hub and the

thrust plate.

Thrust Plate Clearance

mm in
0.13 MIN 0.005
0.33 MAX 0.013

Install the camshaft. Refer to Procedure 001-008.

Install the camshaft idler gear. Refer to Procedure 001-
036.

CAUTION
Failure to check engine timing can cause severe
engine damage.
Check the engine timing. Refer to Procedure 006-025.
Connecting Rod ISM, ISMe, and QSM11
Page 1-44 Section 1 - Cylinder Block - Group 01

Install the gear cover. Refer to Procedure 001-031.

Operate the engine to normal operating temperature and
check for leaks.

Connecting Rod (001-014)

Remove
The piston and connecting rod must be removed as an
assembly on M Series engines. Refer to Procedure 001-
054 for removal instructions.

Clean

WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause personal injury.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use steam or solvent to clean the connecting rods. Dry
with compressed air.

Inspect for Reuse

Inspect the connecting rods and caps for damage.
Replace the connecting rod if the "l-beam" is nicked or
damaged.
ISM, ISMe, and QSM11 Connecting Rod
Section 1 - Cylinder Block - Group 01 Page 1-45

Inspect the connecting rod pin bore bushing for damage.

Install the connecting rod caps and capscrews.

NOTE: The connecting rod cap number must match the
number on the connecting rod and be installed with the
numbers aligned.
Tighten the capscrews in alternating sequence to the
following torque values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 142 N•m [ 105 ft-lb ]
Step3 210 N•m [ 155 ft-lb ]
Step4 Loosen completely
Step5 Repeat steps 1 through 3

Measure the connecting rod crankshaft bore inside

diameter.

Connecting Rod Crankshaft Bore I.D.

mm in
83.975 MIN 3.3061
84.025 MAX 3.3080

Measure the piston pin bushing inside diameter.

Piston Pin Bushing I.D.

mm in
54.054 MIN 2.1281
54.099 MAX 2.1299
Refer to the Shop Manual, M11 Series Engine, Bulletin
3666075, to measure the bend and twist of the connecting
rods.
Crankshaft Gear, Front (Crankshaft Installed) ISM, ISMe, and QSM11
Page 1-46 Section 1 - Cylinder Block - Group 01

Remove the capscrews and rod caps.

Measure the connecting rod capscrew outside diameter.

Connecting Rod Capscrew O.D.

mm in
12.60 MIN 0.496
12.80 MAX 0.504

Install
The piston and connecting rod must be installed as an
assembly on M Series engines. Refer to Procedure 001-
054 for installation instructions.

Crankshaft (001-016)
Rotation Check
Use only the accessory driveshaft 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. Refer to the
correct procedure for inspection and replacement of
internal engine components.

Crankshaft Gear, Front (Crankshaft

Installed) (001-018)
Remove
Remove the gear housing. Refer to Procedure 001-033.
ISM, ISMe, and QSM11 Crankshaft Gear, Front (Crankshaft Installed)
Section 1 - Cylinder Block - Group 01 Page 1-47

Install crankshaft gear puller, Part Number 3375834, and

jaw, Part Number 3375839, on the gear.
Turn the pressure screw clockwise to remove the gear.
Remove the crankshaft gear key.
Do not damage the crankshaft when removing the key.

Clean
Clean the gear with solvent. Dry with compressed air.

Inspect for Reuse

Inspect the crankshaft gear for cracks and broken or
chipped teeth.

Remove any burrs with Scotch-Brite™ 7448, Part Number

3823258, or equivalent.
Crankshaft Gear, Front (Crankshaft Installed) ISM, ISMe, and QSM11
Page 1-48 Section 1 - Cylinder Block - Group 01

Inspect the crankshaft gear journal for burrs or damage.

Remove any burrs with Scotch-Brite™ 7448, Part Number
3823258, or equivalent.

Measure the crankshaft gear bore inside diameter.

Crankshaft Gear Bore Inside Diameter

mm in
85.910 MIN 3.3823
85.935 MAX 3.3833

Measure the crankshaft gear journal outside diameter.

Crankshaft Gear Journal Outside Diameter

mm in
85.975 MIN 3.3848
86.000 MAX 3.3858

Install

CAUTION
Do not exceed the specified time or temperature when
heating the crankshaft gear. The gear and teeth can
be damaged.
Use a leather hammer to install a new key in the
crankshaft keyway.
Heat the gear in an oven for a minimum of 1.5 hours, but
not more than 6 hours.
Temperature: 177 °C [ 350 °F ]
ISM, ISMe, and QSM11 Crankshaft Gear, Front (Crankshaft Installed)
Section 1 - Cylinder Block - Group 01 Page 1-49

WARNING
Use insulated gloves, Part Number 3823730, and/or
hot clamp pliers, Part Number 3823732, when
handling heated parts. Hot parts can cause serious
personal injury.

CAUTION
The timing mark (1) and part number (2) on the gear
must be facing away from the crankshaft after the
gear is installed. Engine damage can result if the gear
is installed backwards.
Use Lubriplate™ 105, or equivalent, to lubricate the
outside diameter of the crankshaft gear journal.
Remove the gear from the oven. Align the keyway of the
gear with the key in the crankshaft, and install the gear
within 30 seconds.

Install the gear housing. Refer to Procedure 001-033.

Operate the engine to normal operating temperature and

check for leaks.
Crankshaft Pulley ISM, ISMe, and QSM11
Page 1-50 Section 1 - Cylinder Block - Group 01

Crankshaft Pulley (001-022)

Remove
Remove the fan drive belt. Refer to Procedure 008-002.

CAUTION
Do not use a hammer or a screwdriver to remove the
viscous damper. These tools can damage the damper.
Remove two of the vibration damper and crankshaft pulley
retaining capscrews.
Install two guide studs, Part Number 3376696, in the
holes.
Remove the remaining three capscrews, clamping plate,
pulley, and damper.

Inspect for Reuse

Inspect the pulley for cracks, excessive wear in the belt
grooves, or other damage.

Install
Make sure the mounting surfaces of the crankshaft nose,
the vibration damper, and the pulley are clean, dry, and
free of burrs.
Install two guide studs, Part Number 3376696, in the
crankshaft nose.
Install the vibration damper, pulley, and clamping plate on
the guide studs.
ISM, ISMe, and QSM11 Crankshaft Seal, Front
Section 1 - Cylinder Block - Group 01 Page 1-51

Use clean 15W-40 oil to lubricate the capscrew threads.

Install three of the five capscrews.
Remove the two guide studs, and install the two remaining
capscrews.
Tighten the capscrews in a star pattern.
Torque Value: 203 N•m [ 150 ft-lb ]

Install and adjust the fan drive belt. Refer to Procedure

008-002.

Crankshaft Seal, Front (001-023)

Remove
Remove the fan drive belt. Refer to Procedure 008-002.

Remove the clamping plate, crankshaft pulley, and

vibration damper. Refer to Procedure 001-022.
Crankshaft Seal, Front ISM, ISMe, and QSM11
Page 1-52 Section 1 - Cylinder Block - Group 01

Remove the six capscrews, the clamping ring (1), the oil
seal (3), and dust seal (2) together.
Remove the gasket (4).

Clean
Clean the front crankshaft oil seal gasket surface of the
gear cover.

Install
The capscrew hole spacing on the oil seal is not
symmetrical.
The gear cover, oil seal, and carrier gasket are each
marked with an arrow located at approximately the three-
o'clock location.
The clamping ring is marked with four punch marks, which
can be found at approximately the eleven-thirty location.

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.
The yellow dust lip of the seal must be facing out.
Align the arrow markings on the seal and gasket to the
arrow markings on the gear cover.
Use the installation sleeve provided with the new seal kit
to install the new seal and gasket.
ISM, ISMe, and QSM11 Crankshaft Seal, Front
Section 1 - Cylinder Block - Group 01 Page 1-53

Orientate the four punch marks on the clamping ring at

the 11:30 o'clock location.
Apply a coating of thread sealant, Part Number 3823494,
to the six mounting capscrews.
Install the six seal capscrews (M8-1.25 x 20) and washers.
Tighten the capscrews in a star pattern in two steps.
Torque Value: Step1 7 N•m [ 60 in-lb ]
Step2 20 N•m [ 180 in-lb ]

Place a light film of oil or antifreeze on the inside diameter

of a new dust seal.
Install the dust seal with the larger outside diameter facing
toward the engine. Push the dust seal back on the shaft
until the entire seal contacts the oil seal case.

Install the vibration damper, crankshaft pulley, and

clamping plate. Refer to Procedure 001-022.
Install and adjust the fan drive belt. Refer to Procedure
008-002.
Crankshaft Seal, Rear ISM, ISMe, and QSM11
Page 1-54 Section 1 - Cylinder Block - Group 01

Crankshaft Seal, Rear (001-024)

Preparatory Steps

WARNING
This component weighs 23kg [50lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Disconnect the driveline and remove the transmission and
clutch. Refer to the manufacturer's instructions.
Remove the flywheel. if equipped.
• For L10 engines, refer to Procedure 7-32 in the
Troubleshooting and Repair Manual L10 COMMAND
STC and CELECT™ Models, Bulletin 3810439.
• For M11 engines, refer to Procedure 016-005 in the
Troubleshooting and Repair M11 Series Engines
(STC, CELECT™, CELECT™ Plus Models), Manual,
Bulletin 3666139.
• For L10G engines, refer to Procedure 016-005 in the
Troubleshooting and Repair L10 (Natural Gas)
Engines, Manual, Bulletin 3666207.
• For ISM, ISMe, and QSM11 engines, refer to
Procedure 016-005 in the Troubleshooting and
Repair ISM, ISMe, and QSM11 Engines, Manual,
Bulletin 3666322.

Remove
Non-REPTO Dry Lip Seal
NOTE: Only the unitized seal can be used as the service
replacement for Non-REPTO Dry Seal application.
Remove the 12 mounting capscrews from the rear
crankshaft oil seal.
The lip style seal can be easily removed by hand or light
prying bars.
Discard the oil seal.

Non-REPTO Dry Unitized Seal

The unitized seal requires the rear crankshaft seal
replacer kit, Part Number 3164302, for the removal
process.
1. Installer plate
2. Crankshaft seal guide
3. Guide screw
4. Washer
5. Installer screw
6. Sheet metal screw
7. Button head socket screw
8. Drill bit
9. Remover screw adapter
10. Remover screw.
ISM, ISMe, and QSM11 Crankshaft Seal, Rear
Section 1 - Cylinder Block - Group 01 Page 1-55

Place the remover screw adapter (9) on the back side of

the installer plate.
Install the three button head socket screws (7) through the
installer plate, into the adapter, and hand tighten.
Position the installer plate on the rear crankshaft oil seal.

Apply grease to the drill to catch the chips.

Drill one hole through the oil seal casing, using the
installer plate as a location guide.
Install a sheet metal screw and hand tighten.
Repeat the process of drilling and installing the sheet
metal screws.
At least three sheet metal screws equally spaced, must
be used. It can be necessary to use more sheet metal
screws on some engines.

Lubricate the threads and tip of the remover screw with

Lubriplate™ multi-purpose lubricant, Part Number
3163086, Part Number 3163087, or a suitable grease.
Install and turn the remover screw clockwise until the rear
crankshaft oil seal is removed.
Discard the rear crankshaft oil seal.

REPTO Dry Seal

Remove the crankshaft gear mounting capscrews.
Remove the 12 capscrews fastening the oil seal to the
flywheel housing.
Use a heel bar to remove the oil seal (2) and dust seal (1)
together.
Remove the gasket (3) and discard.
Crankshaft Seal, Rear ISM, ISMe, and QSM11
Page 1-56 Section 1 - Cylinder Block - Group 01

Clean and Inspect for Reuse

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Clean and inspect the crankshaft sealing surface area and
flywheel housing sealing surface. Use a crocus cloth to
remove any rust or deposits on the crankshaft sealing
surface.
Use a lint-free cloth to remove oil from the crankshaft
sealing surface and flywheel housing sealing surface.
Check the crankshaft sealing surface and flywheel
housing sealing surface for nicks, burrs, or grooves.
If nicks, burrs, or grooves are present, refer to the
Alternative Repair Manual, L10 and M11 Series Engines,
Bulletin 3810310.

Install
Non-REPTO Dry Unitized Seal
Place the crankshaft seal guide (2) with the counterbore
holes facing outward, away from the crankshaft.
Install the two guide screws (3) in opposite counterbore
holes and finger tighten.
Tighten the guide screws (3).
Torque Value: 7 N•m [ 62 in-lb ]

Do not separate the two parts of the oil seal assembly.

Make certain the raised section of the rear crankshaft oil
seal capscrew flange is facing outward, away from the
flywheel housing, and the gray rubber sealing bead is
facing toward the flywheel housing, as illustrated.
ISM, ISMe, and QSM11 Crankshaft Seal, Rear
Section 1 - Cylinder Block - Group 01 Page 1-57

Do not push on the oil seal capscrew flange.

Push on the black inside oil seal area while placing the oil
seal assembly onto the crankshaft seal guide.

Make certain that the remover screw adapter is removed

before the installation process.
Lubricate the threads of the installer screw (5) with
Lubriplate™ multi-purpose lubricant, Part Number
3163086, Part Number 3163087, or a suitable grease.
Position the installer plate (1) onto the rear crankshaft oil
seal and the crankshaft seal guide.
Install the installer screw (5) through the washer (4) and
the installer plate (1). Turn the installer screw clockwise
until the installer plate (1) positions the rear crankshaft oil
seal against the flywheel housing. Tighten the installer
screw.
Torque Value: 34 N•m [ 25 ft-lb ]

Remove the installer screw (5), washer (4), and the

installer plate (1).
Remove the two guide screws (3) and the crankshaft seal
guide.

Rotate the oil seal capscrew flange to align the bolt holes
and install the 12 capscrews.
Tighten three capscrews 120 degrees apart.
Torque Value: 6 N•m [ 50 in-lb ]
Tighten all capscrews, starting with the three previously
tightened, in a crisscrossing pattern.
Torque Value: 34 N•m [ 25 ft-lb ]
Crankshaft Seal, Rear ISM, ISMe, and QSM11
Page 1-58 Section 1 - Cylinder Block - Group 01

REPTO Dry Seal

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 gear clean and dry.
Use the installation sleeve provided with the new oil seal
to install the oil seal on the crankshaft gear.
Install the captive washer capscrews and tighten.
Tighten three capscrews in a crisscrossing pattern.
Torque Value: 6 N•m [ 50 in-lb ]
Tighten all capscrews, starting with the three previously
tightened, in a crisscrossing pattern.
Torque Value: 34 N•m [ 25 ft-lb ]

Place a light film of oil or antifreeze on the inside diameter

of the dust seal.
Install the dust seal on the crankshaft gear with the larger
outside diameter facing toward the engine. Push the dust
seal back by hand on the crankshaft gear until the entire
dust seal contacts the oil seal case.

Finishing Steps

WARNING
This component weighs 23kg [50lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Install the flywheel, if equipped.
• For L10 engines, refer to Procedure 7-32 in the
Troubleshooting and Repair Manual L10 COMMAND
STC and CELECT™ Models, Bulletin 3810439.
• For M11 engines, refer to Procedure 016-005 in the
Troubleshooting and Repair M11 Series Engines
(STC, CELECT™, CELECT™ Plus Models), Manual,
Bulletin 3666139.
• For L10G engines, refer to Procedure 016-005 in the
Troubleshooting and Repair L10 (Natural Gas)
Engines, Manual, Bulletin 3666207.
• For ISM, ISMe, and QSM11 engines, refer to
Procedure 016-005 in the Troubleshooting and
Repair ISM, ISMe, and QSM11 Engines, Manual,
Bulletin 3666322.
Install the clutch, transmission, and driveline. Refer to the
manufacturer's instructions.
Operate the engine and check for leaks.
ISM, ISMe, and QSM11 Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-59

Cylinder Block (001-026)

Basic Description
Fretting, typically occurs on main bearing caps number 2 and number 6. However, main bearing caps numbers 3, 4,
and 5 are also at risk of fretting; therefore, inspection of main bearing caps number 2 through number 6 can be
necessary. An inspection is conducted to determine which main bearing cap requires the Plastigage® procedure.
Side-to-side press fit of a main bearing cap is the fit between the block joint and the main cap sides. The intent of
machining a press fit into the joint is to establish the correct position of the lower main bearing for assembly. During
disassembly, it is possible to encounter a main cap with a slip fit. This is acceptable and the main cap can be reused.
Some engines have been previously inspected for main bearing cap fretting. These engines were upfitted with a
stiffener plate or Service Block Kit and returned to service. These main caps must also be inspected prior to main
bearing replacement or overhaul.
To determine if a stiffener plate has previously been installed, inspect the joint between the oil pan and the engine
block. The stiffener plate is approximately 6.35 mm [0.25 in] thick and will be visible between the oil pan and engine
block. Removal of the oil pan is not necessary to determine if a stiffener plate has been installed.
Service Block Kit incorporates the Torque-To-Yield block. These blocks were introduced into production June 28,
2000. Engine serial number (ESN) first is 35011095. These blocks require a higher main cap capscrew torque
procedure than earlier production blocks.
To determine if a Service Block Kit has been previously installed, inspect the engine case history. If the engine case
history is not available, inspect the rear engine serial number stamp pad located on the camshaft side of the block.
If the block had previously been replaced with a Torque-To-Yield Block, the letters TTY will be stamped in the rear
engine serial number stamp pad.
NOTE: Do not destroy evidence-go slowly and observe all conditions.
Inspect for Reuse

CAUTION
Make sure the proper main cap capscrew torque
procedure is used when tightening the main bearings
on M11 and ISM engines. Using the incorrect torque
procedure will damage the engine.

CAUTION
Two evenly spaced main bearing caps must be left in
place to support the engine crankshaft. This prevents
the crankshaft from dropping.

CAUTION
Do not mark the backside of the bearing shell. Marking
on the backside of the bearing shell can give a false
Plasitgage® reading.

The block type must be identified to determine which main

cap capscrew torque method must be used.
Torque-to-yield block
The torque-to-yield block was introduced into production
June 28, 2000. ESN first is 35011095.
To determine if an older block has been replaced with a
torque-to-yield block perform the following:
Review the engine case history.
Inspect the rear ESN stamp pad. A torque-to-yield service
block will have the letters TTY stamped in the rear serial
number stamp pad on the camshaft side of the block.
Cylinder Block ISM, ISMe, and QSM11
Page 1-60 Section 1 - Cylinder Block - Group 01

Remove main caps 2 through 6 and arrange all parts as

they are located in the engine.
Use 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.
Observe respective part conditions-amount and condition
of lubricant present, burrs, cuts or particles in evidence,
condition of journals, fillets, and so forth.

Remove the lower main bearing shell from the cap.

Mark the bearing shell with the letter L (lower) and the
journal number from which it was removed.

Wipe oil from all main bearing cap mounting surfaces on

the cylinder block with a clean, lint-free cloth.
The main bearing cap surfaces must be free of grease and
oily residue to perform a proper inspection.

Inspect the lower bearing shells for type and extent of

damage, unusual wear patterns, uneven wear, or copper
exposure.
An uneven wear pattern on the lower bearing shell is an
indication of fretting.
If a lower bearing shell exhibits an uneven wear pattern or
copper exposure, as shown here, the bearing must be
Plastigaged®.
ISM, ISMe, and QSM11 Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-61

Inspect both main cap mating surfaces for condition and

unusual circumstances.
Inspect the exhaust side of the main cap and block for
fretting.
Fretting appears as a frosted surface or orange peal
texture on the exhaust side of the main cap.

Inspect the block mating surfaces for condition and

unusual circumstances.
Fretting appears as a frosted surface texture on the
exhaust side of the block joint.
The main cap capscrew hole is larger in diameter than the
mating block capscrew hole. If fretting is present, the
block mating surface wears leaving the original surface
material around the capscrew hole. This lip can be felt with
a fingernail.

The number 7 lower main bearing shell typically wears at

the 6 o'clock position towards the rear half of the bearing
surface. This wear pattern is caused by the weight of the
flywheel/clutch assembly and is considered normal wear.
Inspection procedures outlined in this topic only pertain
to the number 2 through 6 main bearing caps and
respective lower bearing shells.

Shims push the crankshaft up against the adjoining upper

bearings, so an accurate clearance measurement can be
made on the lower bearing.
The shims can be manufactured easily 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 in].
Cut the pipe in half. The shims must be fabricated to the
above-specified dimensions and be less the 180 degrees
in circumference.
Cylinder Block ISM, ISMe, and QSM11
Page 1-62 Section 1 - Cylinder Block - Group 01

NOTE: 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.
To Plastigage® a main bearing journal clearance on an in-
chassis engine, shims must be inserted into 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.

NOTE: Two fabricated shims are required for this

procedure.
Remove the lower bearing shells and install the shims in
the main bearing caps on both sides of the bearing being
plastigaged.
For example, to check the number four main bearing cap,
install the shims on the number 3 and number 5 main
bearing caps. To check the number 6 main bearing cap,
install the shims on the number 5 and number 7 main
bearing caps.
Install the caps.
Torque Value: 34 N•m [ 25 ft-lb ]

Remove the main bearing cap to be Plastigaged®.

Wipe the oil from the bearing and crankshaft journal.
Cut or tear a piece of Plastigage® as long as the full
bearing width. (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.
NOTE: Do not squeeze the gauge material. Squeezing
the gauge material can result in a false reading.
With the envelope open, lift out the Plastigage® by one
end. (Roll out with the 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® the full length of the
bearing. Insert approximately about 6 mm [0.24 in] off
center. See illustration.
NOTE: The Plastigage® clearance check procedure must
be performed with the original bearings. New bearings
can result in a false reading.
ISM, ISMe, and QSM11 Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-63

To install the main bearing cap for the M11 engines. Refer
to Procedure 001-006 in the Troubleshooting and Repair
Manual, M11 STC, CELECT™ and CELECT™ Plus
Engines, Bulletin 3666139 or Shop Manual, M11 Series
Engines, Bulletin 3666075.
To install the main bearing cap for the ISM/QSM11
engines. Refer to Procedure 001-006 in the ISM/QSM11
Troubleshooting and Repair Manual Base Engine, Bulletin
3666322.

NOTE: Do not disturb the Plastigage® before reading the

measurement. Disturbing the Plastigage® will result in an
incorrect measurement.
Remove the main bearing cap. 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 millimeters or inches, 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.

The only correct in-chassis method to only Plastigage®

the number 7 main bearing is to insert a shim in the
number 6 main cap and use a bottle jack to support the
clutch/flywheel assembly (there is an access hole in the
flywheel housing). This is why the number 7 main bearing
is not recommended to be Plastigage® in-chassis.
Cylinder Block and Liner Seats ISM, ISMe, and QSM11
Page 1-64 Section 1 - Cylinder Block - Group 01

Cylinder Block and Liner Seats (001-

027)
Leak Test

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

Pressurize the engine cooling system. Refer to Procedure

008-018.
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 ]

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.
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 Shop Manual, M11 Series
Engines, Bulletin 3666075. If fretting or wear is
found, the cylinder block liner counterbore can be
repaired. Refer to the Alternate Repair Manual, L10
Series Engines, Bulletin 3810310.
ISM, ISMe, and QSM11 Cylinder Liner
Section 1 - Cylinder Block - Group 01 Page 1-65

Install a new gasket and the lubricating oil pan. Refer to

Procedure 007-025. Tighten the oil pan drain plug.
Torque Value: 88 N•m [ 65 ft-lb ]
Fill the engine with clean 15W-40 oil. Refer to Procedure
007-025.
Operate engine until it reaches a temperature of 80°C
[180°F] and check for coolant or lubricating oil leaks.

Cylinder Liner (001-028)

Initial Check

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot engine oil with your skin.

WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
NOTE: Cummins Inc. does not recommend removing the
cylinder liners to repair an oil consumption problem unless
the cylinder liners are damaged and must be replaced.
Drain the coolant. Refer to Procedure 008-018.
Remove the cylinder head. Refer to Procedure 002-004.
Drain the lubricating oil. Refer to Procedure 007-025.
Cylinder Liner ISM, ISMe, and QSM11
Page 1-66 Section 1 - Cylinder Block - Group 01

Remove the lubricating oil pan. Refer to Procedure 007-

025.
Remove the piston cooling nozzles. Refer to Procedure
001-046.

Remove the pistons and connecting rods. Refer to

Procedure 001-054.

Use cylinder liner clamping tool, Part Number 3824272, to

seat the liner in the cylinder block.
Place the force plate (3) across the top of the liner with the
step inside the liner bore.

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.
ISM, ISMe, and QSM11 Cylinder Liner
Section 1 - Cylinder Block - Group 01 Page 1-67

CAUTION
Do not use an impact wrench to tighten the liner force
plate screw. Excessive torque will cause damage to
the liner installation tool.
Tighten the forcing screw (2).
Torque Value: 136 N•m [ 100 ft-lb ]

Use a depth gauge, Part Number 3823495, to measure the

liner protrusion at four points 90 degrees apart.

Cylinder Liner Protrusion

mm in
0.00 MIN 0.0000
0.12 MAX 0.0047

Measure the liner bore for out of roundness at points "C,

" "D," "E," "F," and "G." Measure each point in the
direction "AA" and "BB". The bore must not be more than
0.10 mm [0.004 in] out-of-round.

If the liner bore is more than 0.10 mm [0.004 in] out-of-

round, remove the liner so the cylinder block liner bore can
be measured.
The block counterbore diameters above and below the
cylinder block counterbore area are not critical
dimensions and do not need to be measured.
Cylinder Liner ISM, ISMe, and QSM11
Page 1-68 Section 1 - Cylinder Block - Group 01

If the clearance is less than 0.25 mm [0.010 in].

Replace the liner.

Remove
The cylinder liners can be removed by using universal
liner puller, Part Number 3375629.

CAUTION
The liner puller must be installed and used as
described to avoid damage to the cylinder block. The
puller plate must be parallel to the main bearing
saddles and must not overlap the liner outside
diameter.
Insert the liner puller on the top of the cylinder block.

The liner puller must be centered on the top of the cylinder

block.
Turn the puller jackscrew clockwise to loosen the liner
from the cylinder block.
Use both hands to remove the liner.
ISM, ISMe, and QSM11 Cylinder Liner
Section 1 - Cylinder Block - Group 01 Page 1-69

When the liner is removed from the cylinder block, use

Dykem®, or equivalent, to place a mark on the camshaft
side of the liner to show liner orientation.

Use Dykem®, or equivalent, to mark the cylinder number

on each liner.

Clean and Inspect for Reuse

Center Sump Pan

CAUTION
Do not use any abrasives in the ring travel area of the
liner. The liner can be damaged.
Use a soft wire brush to clean the flange seating area.
Use a fine fibrous abrasive pad such as Scotch-Brite™
7448, or equivalent, to remove the remaining scale and
rust.

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.
Use solvent or steam to clean the liners, and dry with
compressed air.
Use clean 15W-40 oil to lubricate the inside diameter of
the liners.
Allow the oil to soak in the liner for 5 to 10 minutes.
Cylinder Liner ISM, ISMe, and QSM11
Page 1-70 Section 1 - Cylinder Block - Group 01

Use lint-free paper towels to wipe the oil from the inside
of the liners.
Continue to lubricate the inside of the liners and wipe
clean until the paper towel shows no gray or black residue.

Inspect the liner and cylinder block for dirt or damage.

Inspect the liners for cracks on the inside and outside

diameters.

Inspect for cracks under the liner flange.

Cracks can also be detected using either magnetic
inspection or the dye method.
ISM, ISMe, and QSM11 Cylinder Liner
Section 1 - Cylinder Block - Group 01 Page 1-71

Inspect the outside diameter for excessive corrosion or

pitting. Liners with pitting generally can not be reused.
However, if the pitting is light and can be removed with
fine emery cloth, the liner can be reused.
Pits must not be more than 1.60 mm [0.060 in] deep.

Inspect the inside diameter 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.

NOTE: M Series cylinder liners are not lubricated.
A moderate polish (A) produces a bright mirror finish in the
worn area with traces of the original hone marks or an
indication of an etch pattern.
A heavy polish (B) produces a bright mirror finish in the
worn area with no traces of hone marks or an etch pattern.

Replace the liner if:

• A heavy polish is present over 20 percent of the
piston ring travel area.
• 30 percent of the piston ring travel area has both
moderate and heavy polish and one-half (15 percent)
is heavy polish.
Cylinder Liner ISM, ISMe, and QSM11
Page 1-72 Section 1 - Cylinder Block - Group 01

Measure
Use a dial bore gauge to measure the liner's inside
diameter in four places 90-degrees apart at the top and
bottom of the piston travel area.

Cylinder Liner Inside Diameter

mm in
125.000 MIN 4.9213
125.095 MAX 4.9250

Measure the liner top press fit area outside diameter.

Cylinder Liner Top Press Fit Outside Diameter

mm in
145.938 MIN 5.7456
145.976 MAX 5.7471

Measure the cylinder block upper liner bore (A).

Cylinder Block Upper Liner Bore Inside Diameter (A)

mm in
145.900 MIN 5.7441
145.950 MAX 5.7460
Measure the cylinder block liner seal seat bore (B) 8.0 to
13.5 mm [0.32 to 0.53 in] below the counterbore.

Cylinder Block Liner Seal Seat Bore Inside Diameter

(B)
mm in
138.063 MIN 5.4355
138.113 MAX 5.4375

Measure the liner outside diameter (A).

Cylinder Liner Top Press Fit Outside Diameter (A)

mm in
145.938 MIN 5.7456
145.976 MAX 5.7471
The cylinder block liner counterbore flange diameter is
not a critical dimension and does not need to be
measured.
ISM, ISMe, and QSM11 Cylinder Liner
Section 1 - Cylinder Block - Group 01 Page 1-73

Measure the cylinder liner seal seat outside diameter (C).

Cylinder Liner Seal Seat Outside Diameter (C)

mm in
137.937 MIN 5.4306
138.013 MAX 5.4336

Install
The current o-ring has been produced by two distinctly
different manufacturing processes. Following are those
two methods and the installation procedures:
The molded o-ring has a symmetrical cross section. The
edges are rounded. It does not require specific care in
orientation of the o-ring other than normal prevention of
rolling the o-ring.

The lathe-cut o-ring has a straight outside with sharp

corners. The inside has two 45-degree chamfers (1), so
there are no sharp corners next to the liner. This o-ring
must be installed with the straight side (2) facing the
block, and the chamfered side next to the liner. If the o-
ring is not installed this way, liner bore distortion can
occur.

CAUTION
The liners must be installed within 30 seconds after
being lubricated with oil. If the liners are not installed
within this time limit, the o-rings will swell and be
damaged when the liner is installed.
Make sure the cylinder block and all parts are clean before
assembly.
Use clean 15W-40 oil to coat the liner o-ring seals.
Install the o-ring seal on the liner.
Cylinder Liner ISM, ISMe, and QSM11
Page 1-74 Section 1 - Cylinder Block - Group 01

Install the liner into the cylinder block.

When acceptable reused liners are installed, rotate the
liner 90 degrees from their original position in the engine.
The thrust and anti-thrust surfaces must face the front and
back of the cylinder block.
Use cylinder liner driver, Part Number 3824272, and a
leather mallet to drive the liner into the cylinder block bore.
If the liner does not seat properly, remove the liner.
Inspect the counterbore seat and liner for nicks, burrs, or
dirt. Install the liner again.

The cylinder liner protrusion must be checked before

installing the pistons and connecting rods.

Use a feeler gauge to measure the liner-to-block clearance

at the four-block casting points.

Cylinder Liner-to-Block Clearance

mm in
0.25 MIN 0.010

Install the pistons and connecting rods. Refer to

Procedure 001-054.
Install the piston cooling nozzles. Refer to Procedure 001-
046.
ISM, ISMe, and QSM11 Gear Cover, Front
Section 1 - Cylinder Block - Group 01 Page 1-75

Install the lubricating oil pan. Refer to Procedure 007-025.

Install the cylinder head. Refer to Procedure 002-004.

Fill the cooling system with coolant. Refer to Procedure

008-018.
Fill the engine with lubricating oil. Refer to Procedure 007-
025.
Operate the engine to normal operating temperature and
check for leaks.

Gear Cover, Front (001-031)

Remove
Remove the fan drive belt. Refer to Procedure 008-002.
Remove the alternator drive belt. Refer to Procedure 013-
005.
Remove the fan and fan hub support. Refer to Procedure
008-036.

If the engine is equipped with an automatic belt tensioner,

remove the belt tensioner arm from the tensioner bracket.
Remove the four mounting capscrews and the tensioner
bracket from the gear cover.
Gear Cover, Front ISM, ISMe, and QSM11
Page 1-76 Section 1 - Cylinder Block - Group 01

Remove the accessory drive pulley. Refer to Procedure

009-004.
Remove the alternator drive pulley. Refer to Procedure
009-010.

Remove the clamping plate, crankshaft pulley, and

vibration damper. Refer to Procedure 001-052.

WARNING
The engine lifting equipment must be designed to lift
the engine and transmission as an assembly without
causing personal injury.
Use an overhead hoist or hydraulic arm to support the
engine.
Remove the capscrews that hold the front engine support
to the cross member of the equipment.

Remove the capscrews and the front engine support.

ISM, ISMe, and QSM11 Gear Housing, Front
Section 1 - Cylinder Block - Group 01 Page 1-77

Remove the oil seals from the gear cover. Refer to

Procedures 001-001, 001-003, and 001-023.
Remove the remaining capscrews and the gear cover.

Gear Housing, Front (001-033)

Remove
Remove the alternator and alternator bracket. Refer to
Procedure 013-001.

Remove the gear cover. Refer to Procedure 001-031.

Remove the accessory drive. Refer to Procedure 009-001.

Remove the hydraulic pump, if equipped. Refer to
Procedures 009-016.
Gear Housing, Front ISM, ISMe, and QSM11
Page 1-78 Section 1 - Cylinder Block - Group 01

Disconnect the engine position wire connector, and

remove the engine position sensor from the backside of
the housing.

Remove the water pump. Refer to Procedure 008-062.

Remove the idler gears. Refer Procedures 001-036, 001-

039, and 001-040.

Remove the camshaft gear or the camshaft and gear

assembly. Refer Procedure 001-012 or 001-008.
ISM, ISMe, and QSM11 Gear Housing, Front
Section 1 - Cylinder Block - Group 01 Page 1-79

Remove the four oil pan-to-gear housing capscrews.

Remove the capscrews that secure the gear housing to

the cylinder block.
NOTE: Be careful not to damage the oil pan gasket when
removing the gear housing. If the gasket is damaged, the
oil pan must be removed and the gasket replaced.
Remove the gear housing from the cylinder block.

Use bearing driver kit, Part Number 3824117, to remove

the water pump drive needle bearing.
Use bearing puller kit, Part Number 3823774, to remove
the hydraulic drive needle bearing.

Clean
Remove the RTV sealant from the rear surface of the gear
housing.
Remove the seal in the grooves on the front surface of the
gear housing.
Use a wire brush, rounded blade or screwdriver, to clean
the grooves on both sides.
Gear Housing, Front ISM, ISMe, and QSM11
Page 1-80 Section 1 - Cylinder Block - Group 01

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.
Use steam or solvent to clean the gear housing and dry
with compressed air.

Inspect for Reuse

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Inspect the gear housing for cracks or other damage.
Inspect the seal grooves on both sides of the housing for
debris or damage.
Inspect the o-ring groove at the accessory drive oil jumper
gallery for cracks or damage.
Use compressed air to make sure the oil jumper gallery to
the accessory drive is free of any obstructions.

Measure the inside diameter of the bearing bores at the

accessory drive, water pump drive, and hydraulic drive.

Gear Housing Bearing Bore I.D.

mm in
Hydraulic Drive 41.967 MIN 1.6522
41.992 MAX 1.6532
Water Pump 36.967 MIN 1.4553
36.992 MAX 1.4564
Accessory Drive 45.100 MIN 1.7756
45.125 MAX 1.7766
ISM, ISMe, and QSM11 Gear Housing, Front
Section 1 - Cylinder Block - Group 01 Page 1-81

Install
ISM

CAUTION
Avoid the use of excessive amounts of sealant, which
could result in blocked oil passages in the engine and
cause engine damage.
Install a new o-ring, Part Number 3883150, into the rear
of the gear housing at the oil jumper gallery (1) for the
accessory drive support. Be sure to keep sealant from the
hole.
NOTE: Sealant requires assembly in 10 minutes or less.
It is best to apply the sealant and then immediately
assemble the parts.
Apply a bead of sealant, Part Number 3823494, to the
groove in the rear of the gear housing. Completely fill the
groove so that approximately 1/16 to 1/8 inch of the bead
is raised above the block mounting surface of the gear
housing.

Apply a 2-mm [1/6-in] bead of sealant, Part Number

3823494, to the oil pan and cylinder block gear housing
joint.

Apply additional sealant in the area by the camshaft

opening as shown in the graphic.
Gear Housing, Front ISM, ISMe, and QSM11
Page 1-82 Section 1 - Cylinder Block - Group 01

Install two guide pins, Part Number 3376488, in the gear

housing end of the cylinder block.
Use care not to damage the oil pan gasket while installing
the gear housing.
Install the gear housing and ten capscrews (M10-1.50 x
25) in the inner part of the gear housing.
Install five capscrews (M10-1.50 x 50) on the outer surface
of the housing.
Remove the guide pins, and install the two remaining
capscrews (M10-1.50 x 25).

Tighten the capscrews in the sequence shown.

Torque Value: Step1 20 N•m [ 15 ft-lb ]
Step2 68 N•m [ 50 ft-lb ]

Install the four oil pan to gear housing capscrews.

Torque Value: 47 N•m [ 35 ft-lb ]

Install the camshaft gear, or camshaft and gear assembly.

Refer Procedure 001-012 or 001-008.
ISM, ISMe, and QSM11 Gear Housing, Front
Section 1 - Cylinder Block - Group 01 Page 1-83

CAUTION
The bearing must be installed with the part number
side of the bearing against the installation tool to
prevent damage to the bearing during the installation.
Use bearing driver kit, Part Number 3824117, to install a
new needle bearing in the water pump drive bore of the
gear housing.
Install the bearing from the front side of the gear housing
until the bearing is flush with the front edge of the housing
bore.

Use bearing installation tool, Part Number 3823776,

included in bearing puller kit, Part Number 3823774, to
install a new needle bearing in the hydraulic drive bore of
the gear housing.
Tap the bearing gently until it comes in contact with the
shoulder in the housing.
The bearing must be 0.25 to 0.76 mm [0.010 to 0.030 in]
past the outside edge of the gear housing bore surface.

Install the idler gears. Refer to Procedures 001-036, 001-

039, and 001-040.

Install the water pump. Refer to Procedure 008-062.

Gear Housing, Front ISM, ISMe, and QSM11
Page 1-84 Section 1 - Cylinder Block - Group 01

Install the engine position sensor in the backside of the

gear housing.
Torque Value: 34 N•m [ 25 ft-lb ]
Connect the sensor to the engine wiring harness.

Install the accessory drive. Refer to Procedure 009-001.

Install the hydraulic drive, if equipped. Refer to Procedure
009-016.

Install the alternator bracket with two M10-1.50 x 30

capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Install the alternator. Refer to Procedure 013-001.

Install the gear cover. Refer to Procedure 001-031.

ISM, ISMe, and QSM11 Idler Gear, Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-85

Operate the engine to normal operating temperature and

check for leaks.

Idler Gear, Camshaft (001-036)

Remove
Remove the gear cover. Refer to Procedure 001-031.

Before removing the idler gear, use the accessory

driveshaft to rotate the crankshaft until the timing marks
on the crankshaft gear (1), camshaft gear (2), and
accessory drive gear (3) are completely engaged in the
camshaft idler gear.
NOTE: Due to the camshaft idler gear having more gear
teeth than the crankshaft gear, the camshaft idler gear
timing marks will not align with the crankshaft, camshaft,
and accessory drive gears timing marks on every engine
revolution.

Three idler gear assemblies are used:

• Water pump idler gear (1)
• Camshaft idler gear (2)
• Hydraulic pump idler gear (3).
Idler Gear, Camshaft ISM, ISMe, and QSM11
Page 1-86 Section 1 - Cylinder Block - Group 01

To remove the camshaft idler gear assembly, remove:

• The three capscrews
• Cover plate (4)
• Front thrust bearing (5)
• Idler gear (6)
• Rear thrust bearing (7)
• Idler gear shaft (8)
• Wear plate (9).

Mark or tag the individual pieces of the idler gear

assembly and attach them together.

Clean

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the parts with solvent. Dry with compressed air.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a bristle brush to clean the oil drillings in the idler gear
shaft.
Blow out the oil drillings with compressed air.
ISM, ISMe, and QSM11 Idler Gear, Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-87

Inspect for Reuse

Use a straightedge to inspect the retaining capscrews for
necking. If necking is observed, do not reuse the
capscrews. They must be replaced.

Inspect the idler gear for chipped, broken, or cracked

teeth.

Measure the inside diameter of the idler gear bushing

bore.

Camshaft Idler Gear Bushing Bore Inside Diameter

mm in
60.045 MIN 2.3640
60.100 MAX 2.3661

Measure the outside diameter of the idler gear shaft.

Camshaft Idler Gear Shaft Outside Diameter

mm in
59.975 MIN 2.3612
60.008 MAX 2.3625
Idler Gear, Camshaft ISM, ISMe, and QSM11
Page 1-88 Section 1 - Cylinder Block - Group 01

Measure the outside diameter of the camshaft idler shaft

ring dowel.

Camshaft Idler Ring Dowel Outside Diameter

mm in
19.217 MIN 0.7566
19.243 MAX 0.7576

Measure the thrust washer thickness in three places 120-

degrees apart.

Camshaft Idler Thrust Washer Thickness

mm in
2.400 MIN 0.0945
2.470 MAX 0.0972

Flex the thrust washers approximately 3 to 6 mm [1/8 to

1/4 in], and inspect the surfaces for cracks.

Install
When installing the camshaft idler gear (1), make certain
the timing mark “0”on the crankshaft gear (2), timing mark
“X” on the camshaft gear (3), and timing mark “V” on the
accessory drive gear (4) are aligned as shown.
The marks on the idler gears must match the same mark
on each of the other gears.
ISM, ISMe, and QSM11 Idler Gear, Camshaft
Section 1 - Cylinder Block - Group 01 Page 1-89

CAUTION
The grooved side of the rear thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
NOTE: Only the camshaft idler gear has a wear plate.
Use Lubriplate™ 105, or equivalent, to lubricate the wear
plate, thrust bearing, and idler gear.
Install the camshaft idler gear wear plate (9).
Install the idler gear shaft (8) and rear thrust bearing (7).

CAUTION
The grooved side of the front thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
Align the timing marks and install the idler gear (6), front
thrust bearing (5), and gear retainer (4).
Install the retaining capscrews and tighten.
Torque Value: Step1 61 N•m [ 45 ft-lb ]
Step2 Rotate 60 degrees

The following idler gear end clearance and backlash

checks apply to all three idler gears. The same
MINIMUM and MAXIMUM values apply, also.
Use a dial indicator gauge with a magnetic base to
measure the idler gear end clearance.
Place the contact tip of the gauge against the face of the
idler gear.

Idler Gear End Clearance

mm in
0.30 MIN 0.012
0.53 MAX 0.021

Use a dial indicator gauge with a magnetic base to

measure the idler gear backlash.
Place the contact tip of the gauge against a tooth on the
idler gear.
NOTE: Do not allow the mating gears to move while
measuring the backlash.

Idler Gear Backlash

mm in
0.08 MIN 0.003
0.38 MAX 0.015
Idler Gear, Hydraulic Pump ISM, ISMe, and QSM11
Page 1-90 Section 1 - Cylinder Block - Group 01

Install the gear cover. Refer to Procedure 001-031.

Operate the engine to normal operating temperature and
check for leaks.

Idler Gear, Hydraulic Pump (001-039)

Remove
Remove the gear cover. Refer to Procedure 001-031.

Three idler gear assemblies are used:

• Water pump idler gear (1)
• Camshaft idler gear (2)
• Hydraulic pump idler gear (3).

SAE 'A' and SAE 'B' Removal

To remove the hydraulic drive idler gear assembly,
remove:
• Mounting spacer (1)
• Rectangular seal (2)
• The three twelve-point capscrews
• Gear retainer (3)
• Rectangular seal (4)
• Front thrust bearing (5)
• Idler gear (6)
• Rear thrust bearing (7)
• Idler gear shaft (8).
NOTE: SAE "A" drives do not use a rectangular seal (4)
on the rear surface of the gear retainer.
ISM, ISMe, and QSM11 Idler Gear, Hydraulic Pump
Section 1 - Cylinder Block - Group 01 Page 1-91

SAE 'B-B' Removal

To remove SAE B-B hydraulic drive idler gear assembly,
remove:
• Mounting Spacer (1)
• Tapered Roller Bearing (2)
• Gear Drive (3)
• Tapered Roller Bearing (4)
• Shim(s) (5)
• Idler Gear Shaft (6)
• Mounting Spacer (7)
• Rectangular Seal (8).

Mark or tag the individual pieces of the idler gear

assembly and attach them together.

Clean

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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the parts with solvent. Dry with compressed air.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a bristle brush to clean the oil drillings in the idler gear
shaft.
Blow out the oil drillings with compressed air.
Idler Gear, Hydraulic Pump ISM, ISMe, and QSM11
Page 1-92 Section 1 - Cylinder Block - Group 01

Inspect for Reuse

Use a straightedge to inspect the retaining capscrews for
necking. If necking is observed, do not reuse the
capscrews. They must be replaced.

Inspect the idler gear for chipped, broken, or cracked

teeth.

NOTE: Measurements do not apply to SAE 'B-B' hydraulic

drive idler gear. Visually inspect the inside diameter of the
gear for reuse.
Measure the inside diameter of the idler gear bushing
bore.

SAE 'A' and 'B' Hydraulic Drive Idler Gear Bushing

Bore Inside Diameter
mm in
60.045 MIN 2.3640
60.100 MAX 2.3661

Measure the outside diameter of the idler gear shaft.

SAE 'A' and 'B' Hydraulic Drive Idler Gear shaft

Outside Diameter
mm in
59.975 MIN 2.3612
60.008 MAX 2.3625

SAE 'B-B' Hydraulic Drive Idler Gear Shafts Outside

Diameter
mm in
63.455 MIN 2.4982
63.486 MAX 2.4994
ISM, ISMe, and QSM11 Idler Gear, Hydraulic Pump
Section 1 - Cylinder Block - Group 01 Page 1-93

Measure the outside diameter of the ring dowel.

Hydraulic Drive Idler Ring Dowel Outside Diameter

mm in
19.217 MIN 0.7566
19.243 MAX 0.7576

NOTE: SAE 'B-B' hydraulic drive gear assembly does

not use thrust washers.
Measure the thrust washer thickness in three places 120-
degrees apart.

Hydraulic Drive Idler Thrust Washer Thickness

mm in
2.400 MIN 0.0945
2.470 MAX 0.0972

NOTE: SAE 'B-B' hydraulic drive gear assembly does

not use thrust washers.
Flex the thrust washers approximately 3 to 6 mm [1/8 to
1/4 in], and inspect the surfaces for cracks.

Install

CAUTION
The grooved side of the rear thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
SAE 'A' and SAE 'B' Install
Use Lubriplate™ 105, or equivalent, to lubricate the thrust
bearings and idler gear.
Install the idler gear shaft (8) and rear thrust bearing (7).
NOTE: When an SAE B drive is used, a special hydraulic
drive idler shaft with two oil holes is used. With the engine
in the upright position, orientate the shaft so that one oil
hole is at twelve- o'clock and the other at four-o'clock.
Idler Gear, Hydraulic Pump ISM, ISMe, and QSM11
Page 1-94 Section 1 - Cylinder Block - Group 01

CAUTION
The grooved side of the front thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
Install the idler gear (6) and front thrust bearing (5).

NOTE: On SAE "B" drives, install a new rectangular seal

on the rear surface of the gear retainer (4) before installing
the retainer.
Install the gear retainer (4).
Install the three retaining capscrews and tighten.
Torque Value: Step1 61 N•m [ 45 ft-lb ]
Step2 Rotate 60 degrees

SAE 'B-B' Install

NOTE: Use shim(s) as necessary for proper idler gear end
clearance.
Use Lubriplate™ 105, or equivalent to lubricate the roller
bearings and gear.
To install SAE B-B hydraulic drive idler gear assembly,
install
• Mounting Spacer (1)
• Tapered Roller Bearing (2)
• Gear Drive (3)
• Tapered Roller Bearing (4)
• Shim (s) (5)
• Idler Gear Shaft (6)
• Mounting Spacer (7)
• Rectangular Seal (8).
Torque Value: Step1 61 N•m [ 45 ft-lb ]
Step2 Rotate 60 degrees
ISM, ISMe, and QSM11 Idler Gear, Water Pump
Section 1 - Cylinder Block - Group 01 Page 1-95

The following idler gear end clearance and backlash

Idler Gear End Clearance

mm in
0.30 MIN 0.012
0.53 MAX 0.021

Use a dial indicator gauge with a magnetic base to

measure the idler gear backlash.
Place the contact tip of the gauge against a tooth on the
idler gear.
Do not allow the mating gears to move while measuring
the backlash.

Idler Gear Backlash

mm in
0.08 MIN 0.003
0.38 MAX 0.015

Install the gear cover. Refer to Procedure 001-031.

Operate the engine to normal operating temperature and
check for leaks.

Idler Gear, Water Pump (001-040)

Remove
Remove the gear cover. Refer to Procedure 001-031.
Idler Gear, Water Pump ISM, ISMe, and QSM11
Page 1-96 Section 1 - Cylinder Block - Group 01

Three idler gear assemblies are used:

• Water pump idler gear (1)
• Camshaft idler gear (2)
• Hydraulic pump idler gear (3).
The water pump must be removed before the water pump
idler gear (1) can be removed. Refer to Procedure 008-
062.

To remove the water pump idler gear assembly, remove:

• The three capscrews
• Cover plate (4)
• Front thrust bearing (5)
• Idler gear (6)
• Rear thrust bearing (7)
• Idler gear shaft (8).

Mark or tag the individual pieces of the idler gear

assembly and attach them together.

Clean

WARNING
When using solvents 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
Wear appropriate eye and face protection when using
compressed air. Flying dirt and debris can cause
personal injury.
Clean the parts with solvent. Dry with compressed air.
ISM, ISMe, and QSM11 Idler Gear, Water Pump
Section 1 - Cylinder Block - Group 01 Page 1-97

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying dirt and debris can cause
personal injury.
Use a bristle brush to clean the oil drilling in the idler gear
shaft.
Blow out the oil drilling with compressed air.

Inspect for Reuse

Use a straightedge to inspect the retaining capscrews for
necking. If necking is observed, do not reuse the
capscrews. They must be replaced.

Inspect the idler gear for chipped, broken, or cracked

teeth.

Measure the inside diameter of the idler gear bushing

bore.

Water Pump Idler Gear Bushing Bore Inside Diameter

mm in
60.045 MIN 2.3640
60.100 MAX 2.3661
Idler Gear, Water Pump ISM, ISMe, and QSM11
Page 1-98 Section 1 - Cylinder Block - Group 01

Measure the outside diameter of the idler gear shaft.

Water Pump Idler Gear Shaft Outside Diameter

mm in
59.975 MIN 2.3612
60.008 MAX 2.3625

Measure the outside diameter of the ring dowel.

Water Pump Idler Ring Dowel Outside Diameter

mm in
19.217 MIN 0.7566
19.243 MAX 0.7576

Measure the thrust washer thickness in three places 120-

degrees apart.

Water Pump Idler Thrust Washer Thickness

mm in
2.400 MIN 0.0945
2.470 MAX 0.0972

Flex the thrust washers approximately 3 to 6 mm [1/8 to

1/4 in], and inspect the surfaces for cracks.
ISM, ISMe, and QSM11 Idler Gear, Water Pump
Section 1 - Cylinder Block - Group 01 Page 1-99

Install

CAUTION
The grooved side of the rear thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
Use Lubriplate™ 105, or equivalent, to lubricate the thrust
bearings and idler gear shaft.
Install the rear thrust bearing.
Install the idler gear without the shaft.

Align the inside diameter of the rear thrust bearing with

the inside diameter of the idler gear.

The shaft must pass through the gear and pilot into the
rear thrust bearing. After installation, the shaft must
protrude only slightly more than the thickness of the front
thrust bearing. Excessive shaft protrusion beyond the
thickness of the front thrust bearing indicates the shaft
is not properly piloted into the rear thrust bearing.
Install the shaft into the gear bore.

CAUTION
The grooved side of the front thrust bearing must be
facing toward the gear to prevent damage to the gear
and engine during engine operation.
Install the front thrust bearing.
Install the gear retainer.
Install the capscrews and tighten.
Torque Value: Step1 61 N•m [ 45 ft-lb ]
Step2 Rotate 60 degrees
Idler Gear, Water Pump ISM, ISMe, and QSM11
Page 1-100 Section 1 - Cylinder Block - Group 01

Install the water pump. Refer to Procedure 008-062.

The following idler gear end clearance and backlash

Idler Gear End Clearance

mm in
0.30 MIN 0.012
0.53 MAX 0.021

Use a dial indicator gauge with a magnetic base to

measure the idler gear backlash.
Place the contact tip of the gauge against a tooth on the
idler gear.
Do not allow the mating gears to move while measuring
the backlash.

Idler Gear Backlash

mm in
0.08 MIN 0.003
0.38 MAX 0.015

Install the gear cover. Refer to Procedure 001-031.

Operate the engine to normal operating temperature and
check for leaks.
ISM, ISMe, and QSM11 Piston
Section 1 - Cylinder Block - Group 01 Page 1-101

Piston (001-043)
General Information
All M Series engines are equipped with articulated
pistons.
The articulated piston is a two-piece piston consisting of
a forged-steel crown and an aluminum skirt.
A closed chamber oil gallery is located on the underside
of the crown of the piston to provide more oil contact with
the piston and give better piston cooling. Piston cooling
nozzle targeting is critical because of the closed chamber
oil gallery.

Remove
The piston and connecting rod must be removed as an
assembly. To remove the piston and connecting rod, refer
to Procedure 001-054.

Disassemble
Articulated Piston
Refer to Procedure 001-054 to disassemble the piston and
connecting rod assembly.
Refer to Procedure 001-047 for piston ring inspection.
Piston ISM, ISMe, and QSM11
Page 1-102 Section 1 - Cylinder Block - Group 01

Clean
Articulated Piston

CAUTION
Be sure the cleaning solvent is approved for
aluminum. Damage to the pistons can result if the
wrong solution is used.
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 nonmetallic brush to
remove carbon deposits.

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 or plastic bead, Part
Number 3822735, blasting can be used on ring
grooves 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.
The recommended blast pressure for plastic bead
blasting is 276 kPa [40 psi]. Do not use glass beads or
walnut shell blasting on the aluminum piston pin
bores or articulated piston skirts. This can cause
piston pin bore damage.

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.
Use steam to clean the pistons.
Dry with compressed air.
ISM, ISMe, and QSM11 Piston
Section 1 - Cylinder Block - Group 01 Page 1-103

Inspect for Reuse

Articulated Piston
Inspect the piston bowl (1) and crown piston pin bore (2)
for cracks or damage.
Do not use pistons with cracks. If the crown is cracked, it
must be replaced.

Inspect the piston gallery cover plate in the piston crown

for cracks or looseness.
If the gallery is cracked or loose, the piston crown must
be replaced.

Inspect the piston skirt pin bore (1) and sides (2) for cracks
or damage.
Do not use pistons with cracks. If the skirt is cracked, it
must be replaced.

The ring groove can be inspected with a new ring and a

feeler gauge.
Hold a new ring in the groove even with the outside
diameter of the piston. Install a 0.15-mm [0.006-in] feeler
gauge. If the feeler gauge enters the groove without
resistance, there is too much wear. Replace the piston.
Piston ISM, ISMe, and QSM11
Page 1-104 Section 1 - Cylinder Block - Group 01

Measure the piston pin bore inside diameter.

Articulated Piston Pin Bore Inside Diameter (Crown)

mm in
54.040 MIN 2.1276
54.055 MAX 2.1281

Articulated Piston Pin Bore Inside Diameter (Skirt)

mm in
54.007 MIN 2.1263
54.015 MAX 2.1266

Measure the piston pin outside diameter and length.

Piston Pin Outside Diameter

mm in
53.997 MIN 2.1259
54.003 MAX 2.1261

Piston Pin Length

mm in
101.70 MIN 4.0039
102.00 MAX 4.0157

Assemble
Articulated Piston
Refer to Procedure 001-054 for piston and connecting rod
assembly instructions.

Install
The piston and connecting rod must be installed as an
assembly on M series engines. Refer to Procedure 001-
054 for installation instructions.
ISM, ISMe, and QSM11 Piston Cooling Nozzle
Section 1 - Cylinder Block - Group 01 Page 1-105

Piston Cooling Nozzle (001-046)

Remove

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

The crankshaft must be rotated to allow access to remove

all the nozzles.
Remove the piston cooling nozzles.

Inspect for Reuse

Measure the piston cooling nozzle length.

Piston Cooling Nozzle Length

mm in
44.5 NOM 1.752
Piston Cooling Nozzle ISM, ISMe, and QSM11
Page 1-106 Section 1 - Cylinder Block - Group 01

Inspect the capscrews, washers, and piston cooling

nozzles for damage.

Install
Install the nozzles, washers, and capscrews.
Tighten the capscrews.
Torque Value: 28 N•m [ 21 ft-lb ]
NOTE: The crankshaft must be rotated to allow access to
install all the nozzles.

Install the lubricating oil pan. Refer to Procedure 007-025.

Fill the engine with lubricating oil. Refer to Procedure 007-

025.
Operate the engine to normal operating temperature and
check for oil leaks.
ISM, ISMe, and QSM11 Vibration Damper, Viscous
Section 1 - Cylinder Block - Group 01 Page 1-107

Piston Rings (001-047)

Failure Analysis Inspection
To check the ring gap, install the piston rings into the
cylinder liner in which they were used, below the ring
reversal area.
Use the top part of the piston to position the ring in the
liner.
Use a feeler gauge to inspect the ring end gap.

Piston Ring Gap

mm in
Top 0.35 MIN 0.014
0.60 MAX 0.024
Intermediate 0.76 MIN 0.030
1.14 MAX 0.045
Oil 0.26 MIN 0.010
0.64 MAX 0.025

Vibration Damper, Viscous (001-052)

Remove
Remove the fan drive belt. Refer to Procedure 008-002.
Remove the clamping plate, crankshaft pulley, and
vibration damper. Refer to Procedure 001-022.

Clean

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.
Use steam or solvent to clean the vibration damper. Dry
with compressed air.
Vibration Damper, Viscous ISM, ISMe, and QSM11
Page 1-108 Section 1 - Cylinder Block - Group 01

Maintenance Check

CAUTION
The silicone fluid in the vibration damper will become
solid after extended service, which makes the
vibration damper inoperative. An inoperative vibration
damper can cause major engine or driveline failures.
Check the vibration damper for evidence of fluid loss,
dents, and wobble. Inspect the vibration damper thickness
for any deformation or raising of the damper front cover
plate.

Install
Install the vibration damper, crankshaft pulley, and
clamping plate. Refer to Procedure 001-022.

Install the fan drive belt. Refer to Procedure 008-002.

Eccentricity Check
Clean the outside surface of the vibration damper.
To measure damper eccentricity (out of round), install the
dial indicator gauge, Part Number 3376050, and
extension Part Number ST-537-4, on the gear cover as
indicated.
Rotate the crankshaft with the accessory driveshaft one
complete revolution (360 degrees), and record the total
indicator movement.
Replace the vibration damper if the eccentricity exceeds
0.28 mm [0.011 in].
ISM, ISMe, and QSM11 Water Header Plate, Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-109

Wobble Check
To measure wobble (face alignment), install the dial
indicator as shown.
Push the crankshaft to the front or rear of the engine and
“0” (zero) the indicator.

Rotate the crankshaft with the accessory driveshaft one

complete revolution (360 degrees) while maintaining the
position of the crankshaft either toward the front or the
rear of the engine.
Record the total indicator movement.
Replace the damper if wobble exceeds 0.28 mm [0.011
in].

Water Header Plate, Cylinder Block

(001-053)
Preparatory Steps
With EGR
• Drain the cooling system. Refer to Procedure 008-
018.
• Remove the air intake piping.
• Remove the alternator belt. Refer to Procedure 013-
005.
• Remove the alternator. Refer to Procedure 013-001.
• Remove the lubricating oil cooler. Refer to
Procedure 007-003.
• Remove the coolant filter and filter head. Refer to
Procedure 008-007.
• Remove the coolant heater housing. Refer to
Procedure 008-011.
• Remove the turbocharger. Refer to Procedure 010-
033.
• Remove the coolant thermostat housing. Refer to
Procedure 008-014.
• Remove the coolant thermostat housing support.
Refer to Procedure 008-015.
• Remove the EGR cooler coolant return line. Refer to
Procedure 011-031.
• Remove the water pump. Refer to Procedure 008-
062.
Water Header Plate, Cylinder Block ISM, ISMe, and QSM11
Page 1-110 Section 1 - Cylinder Block - Group 01

Without EGR
• Drain the cooling system. Refer to Procedure 008-
018.
• Remove the intake air piping.
• Remove the alternator belt. Refer to Procedure 013-
005.
• Remove the alternator. Refer to Procedure 013-001.
• Remove the lubricating oil cooler. Refer to
Procedure 007-003.
• Remove the coolant filter and filter head. Refer to
Procedure 008-007.
• Remove the coolant heater housing. Refer to
Procedure 008-011.
• Remove the turbocharger. Refer to Procedure 010-
033.
• Remove the coolant thermostat housing. Refer to
Procedure 008-014.
• Remove the coolant thermostat housing support.
Refer to Procedure 008-015.

Remove
With EGR
Remove the water header plate and gasket.

Without EGR
Remove the water header plate (7) and gasket (8).
ISM, ISMe, and QSM11 Water Header Plate, Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-111

Clean
With EGR
Use a wire brush and a gasket scraper to clean the water
header plate and the cylinder block gasket surface.

Without EGR
Use a wire brush and a gasket scraper to clean the water
header plate and the cylinder block gasket surface.

Inspect for Reuse

With EGR
Inspect the water header plate and the cylinder block
gasket surface for cracks or other damage.

Without EGR
Inspect the water header plate and the cylinder block
gasket surface for cracks or other damage.
Water Header Plate, Cylinder Block ISM, ISMe, and QSM11
Page 1-112 Section 1 - Cylinder Block - Group 01

Install
With EGR
Install two guide pins, Part Number 3376488, in the top
row of the water header plate mounting capscrew holes.
Install the water header plate and capscrews. Use a new
gasket
Remove the two guide pins and install the other two
capscrews.
The capscrews are not tightened to their final value until
all related components are installed.
Install the coolant heater housing (3). Refer to Procedure
008-011.
Install the coolant filter head and filter (2). Refer to
Procedure 008-007.
Install the coolant thermostat housing support and gasket
(6). Refer to Procedure 008-015.

Tighten all capscrews in the sequence shown.

Torque Value: 54 N•m [ 40 ft-lb ]

Without EGR
Install two guide pins, Part Number 3376488, in the top
row of the water header plate mounting capscrew holes.
Install the water header plate and capscrews. Use a new
gasket.
Remove the two guide pins, and install the other two
capscrews.
The capscrews are not tightened to their final value until
all related components are installed.
ISM, ISMe, and QSM11 Water Header Plate, Cylinder Block
Section 1 - Cylinder Block - Group 01 Page 1-113

Install the coolant heater housing (3). Refer to Procedure

008-011.
Install the coolant filter head and filter (2). Refer to
Procedure 008-007.
Install the coolant thermostat housing support and gasket
(6). Refer to Procedure 008-015.

Tighten all capscrews in the sequence shown.

Torque Value: 54 N•m [ 40 ft-lb ]

Finishing Steps
With EGR
• Install the water pump. Refer to Procedure 008-062.
• Install the EGR cooler coolant return line. Refer to
Procedure 011-031.
• Install the coolant thermostat housing support. Refer
to Procedure 008-015.
• Install the coolant thermostat housing. Refer to
Procedure 008-014.
• Install the turbocharger. Refer to Procedure 010-033.
• Install the coolant heater housing. Refer to
Procedure 008-011.
• Install the coolant filter and filter head. Refer to
Procedure 008-007.
• Install the lubricating oil cooler. Refer to Procedure
007-003.
• Install the alternator. Refer to Procedure 007-003.
• Install the alternator belt. Refer to Procedure 013-
005.
• Install the air intake piping.
• Fill the cooling system. Refer to Procedure 013-001.
• Operate the engine until it reaches a temperature of
80°C [180°F] and check for coolant leaks.
Water Header Plate, Cylinder Block ISM, ISMe, and QSM11
Page 1-114 Section 1 - Cylinder Block - Group 01

Without EGR
• Install the coolant thermostat housing support. Refer
to Procedure 008-015.
• Install the coolant thermostat housing. Refer to
Procedure 008-014.
• Install the turbocharger. Refer to Procedure 010-033.
• Install the coolant heater housing. Refer to
Procedure 008-011.
• Install the coolant filter and filter head. Refer to
Procedure 008-007.
• Install the lubricating oil cooler. Refer to Procedure
007-003.
• Install the alternator. Refer to Procedure 007-003.
• Install the alternator belt. Refer to Procedure 013-
005.
• Install the air intake piping.
• Fill the cooling system. Refer to Procedure 013-001.
• Operate the engine until it reaches a temperature of
80°C [180°F] and check for coolant leaks.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-115

Piston and Connecting Rod Assembly

(001-054)
Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
Drain the lubricating oil. Refer to Procedure 007-025 in
Troubleshooting and Repair Manual, ISM and QSM11
Engines, Bulletin 3666322 for ISM and QSM11 engines,
or Procedure 007-025 in Troubleshooting and Repair
Manual, M11 STC, CELECT™, and CELECT™ Plus
Engines, Bulletin 3666139 for M11 engines, or Procedure
007-025 in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207.
Remove the lubricating oil pan. Refer to Procedure 007-
025 in Troubleshooting and Repair Manual, ISM and
QSM11 Engines, Bulletin 3666322 for ISM and QSM11
engines, or Procedure 007-025 in Troubleshooting and
Repair Manual, M11 STC, CELECT™, and CELECT™ Plus
Engines, Bulletin 3666139 for M11 engines, or Procedure
007-025 in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207.
Remove the cylinder head. Refer to Procedure 002-004 in
Troubleshooting and Repair Manual, ISM and QSM11
Engines, Bulletin 3666322 for ISM and QSM11 engines,
or Procedure 002-004 in Troubleshooting and Repair
Manual, M11 STC, CELECT™, and CELECT™ Plus
Engines, Bulletin 3666139 for M11 engines, or Procedure
002-004 in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207.
Remove the piston cooling nozzles. Refer to Procedure
001-046 in Troubleshooting and Repair Manual, ISM and
QSM11 Engines, Bulletin 3666322 for ISM and QSM11
engines, or Procedure 001-046 in Troubleshooting and
Repair Manual, M11 STC, CELECT™, and CELECT™ Plus
Engines, Bulletin 3666139 for M11 engines, or Procedure
001-046 in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207.
Piston and Connecting Rod Assembly ISM, ISMe, and QSM11
Page 1-116 Section 1 - Cylinder Block - Group 01

Remove

CAUTION
Do not use emery cloth or sandpaper to remove
carbon from the cylinder liners. Aluminum oxide or
silicon particles from emery cloth or sandpaper can
cause serious engine damage. Do not use any
abrasives in the ring travel area. The cylinder liner can
be damaged.
Use a fine fibrous abrasive pad such as Scotch-Brite™
7448, Part Number 3823258, or equivalent, and solvent to
remove the carbon.

Rotate the crankshaft to position the rod caps at bottom

dead center for removal.
Loosen the connecting rod capscrews.
NOTE: Do not remove the capscrews from the rods at this
time.
Use a rubber hammer to hit the connecting rod capscrews
to loosen the caps from the dowel rings.

Remove the connecting rod capscrews.

Remove the rod caps.
Remove the lower rod bearings.
Mark the cylinder number and the letter "L" (lower) in the
flat surface of the bearing tangs.
NOTE: Some M Series engines were built without drilled
connecting rods and without bearings with an oil hole in
the upper bearing shell. Beginning in the fall of 1995, all
M series engines are built with drilled connecting rods and
bearings with an oil hole in the upper bearing shell.

Install two connecting rod guide pins, Part Number

3376038.
Use a "t-handle" piston pusher to push the rod away from
the crankshaft.
Push the rod until the piston rings are outside of the top
of the cylinder liner.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-117

Use both hands to remove the piston and connecting rod

assembly.
If parts are reused, the piston and connecting rod
assemblies must be installed in the same cylinder number
from which they were removed, to make sure of proper fit
of worn mating surfaces,
Mark and attach a tag showing the cylinder number from
which the piston and connecting rod assembly was
removed.

Place the rod and piston assemblies in a container to

protect them from damage.

A unique number (not cylinder number) is stamped on the

connecting rod and matching cap. When the rods and
caps are installed in the engine, the numbers on the rods
and caps must match and be installed on the same side
of the engine.

Remove the upper rod bearing.

Mark the cylinder number and the letter "U" (upper) in the
flat surface of the bearing tang.
Piston and Connecting Rod Assembly ISM, ISMe, and QSM11
Page 1-118 Section 1 - Cylinder Block - Group 01

Disassemble
Articulated Piston
Use piston ring expander, Part Number ST-821, to remove
the piston rings.
Place a tag on the rings, and record the cylinder number
of the piston on the tag.
NOTE: Refer to Procedure 001-047 in Troubleshooting
and Repair Manual, ISM and QSM11 Engines, Bulletin
3666322 for piston ring inspection on ISM and QSM11
engines, or Procedure 001-047 in Troubleshooting and
Repair Manual, M11 STC, CELECT™, and CELECT™ Plus
Engines, Bulletin 3666139 for piston ring inspection on
M11 engines, or Procedure 001-047 for piston ring
inspection in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207.

Use internal snap ring pliers to remove the snap rings from
both sides of the piston.

CAUTION
Do not use a hammer to remove the piston pins. The
piston can distort, causing it to seize in the liner.
If the piston pin can not be easily removed by hand:
• Install the piston and rod assembly in a container of
water.
• Heat the piston in boiling water for 15 minutes.
• Use a blunt tool to push the piston pin from the piston
and rod assembly.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-119

NOTE: When the piston pin is removed from an articulated

piston, the skirt will separate from the crown. Use care to
reduce the possibility of damage to the piston.
Mark the cylinder number the piston, crown, skirt, and pin
was removed from on the parts to make sure they are
installed in the correct cylinder if they are used again.

Clean and Inspect for Reuse

Articulated Piston

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

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.
Use steam to clean the pistons.
Dry with compressed air.

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
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

Refer to Procedure 001-043 for inspection specifications

for M series pistons. Refer to Procedure 001-043 for
inspection specifications for L10G series pistons in
Troubleshooting and Repair Manual, L10G Natural Gas
Base Engine, Bulletin 3666207.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-121

Refer to Procedure 001-014 in Troubleshooting and

Repair Manual, ISM and QSM11 Engines, Bulletin
3666322 for inspection specifications for ISM/QSM11
series connecting rods, or Procedure 001-014 in
Troubleshooting and Repair Manual, M11 STC, CELECT™
and CELECT™ Plus engines, Bulletin 3666139 for
inspection specifications for M series engines, or
Procedure 001-014 in Troubleshooting and Repair
Manual, L10G Natural Gas Base Engine, Bulletin 3666207
for inspection specifications for L10G engines.

Assemble
Articulated Piston

CAUTION
The retainer snap ring must be seated completely in
the piston pin groove to reduce the possibility of
engine damage during engine operation.
Install a new snap ring in one piston pin bore of each
piston skirt.
NOTE: If the pistons are being reused, the crown, skirt,
and pin must be matched as they were when they were
removed.

NOTE: All pistons (bushed and nonbushed) must be

properly lubricated prior to assembly.
For all pistons, use a clean, lint free cloth to apply a heavy
film of 80W-140 gear oil with EP additive to the following
locations:
• Piston pin bore inside diameter in the piston crown
• Piston pin bore inside diameter in the piston skirt
• Rod bushing inside diameter
• Piston pin
Assemble the piston crown into the piston skirt.
NOTE: It is not necessary to heat the articulated pistons
before assembly. The piston pin is slip fitted.

CAUTION
Do not use a hammer to install the piston pin. The
piston can distort, causing it to seize in the liner.
Align the pin bore of the rod with the pin bore of the piston
skirt and crown, and install the piston pin.
Piston and Connecting Rod Assembly ISM, ISMe, and QSM11
Page 1-122 Section 1 - Cylinder Block - Group 01

CAUTION
The snap ring must be seated completely in the piston
groove to reduce the possibility of engine damage
during engine operation.
Install a new snap ring in the piston pin bore.

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.
Do not overlap the ends of the expander ring.

Use piston ring expander, Part Number ST-821, to install

the rings on the piston.
The top piston ring (1) is a positive twist design that has a
cutback notch (2) on the topside of the ring.
The intermediate ring (3) is a negative twist design with a
cutback notch (4) on the bottom side and a two-degree
taper face. It also has a black phosphate coating (5), which
helps to readily distinguish it from the top ring.
The oil control ring (6) is the bottom piston ring.

Install
The cylinder block and all parts must be clean before
assembly. Refer to Procedure 001-028 in Troubleshooting
and Repair Manual, ISM and QSM11 Engines, Bulletin
3666322 for ISM and QSM11 engines, Procedure 001-028
in Troubleshooting and Repair Manual, M11 STC,
CELECT and CELECT Plus Engines, Bulletin 3666139 for
M11 engines, or Procedure 001-028 in Troubleshooting
and Repair Manual, L10G Natural Gas Base Engine,
Bulletin 3666207 for L10G engines to inspect the cylinder
liners for reuse.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-123

Use a clean, lint free cloth to clean the connecting rods

and bearing shells.
Do not lubricate the backside of the bearing shells. The
operating clearance of the bearing will be reduced and the
bearing can be damaged during engine operation.

If new bearings are not used, the used bearings must be

installed on the same connecting rod from which they
were removed.
Install the upper bearing shell into the connecting rod.
The tang of the bearing shell (1) must be in the slot of the
rod (2). The end of the bearing shell must be even with
the cap mounting surface.

Use Lubriplate™ 105, or equivalent, to coat the inside

diameter of the bearing shell.
Apply a heavy film of clean 15W-40 oil to the liner.

Install the piston and ring assembly in a container of clean

15W-40 oil.
Remove the piston and ring assembly from the container,
and let the excess oil drain from the piston.
Piston and Connecting Rod Assembly ISM, ISMe, and QSM11
Page 1-124 Section 1 - Cylinder Block - Group 01

Rotate the rings to position the ring gaps as shown.

NOTE: The ring gap of each ring must not be aligned with
the piston pin or with any other ring. If the ring gaps are
not aligned correctly, the rings will not seal properly.

Install connecting rod guide pins, Part Number 3376038.

Use piston ring compressor, Part Number 3823309, to
compress the rings.

Use the accessory drive pulley to rotate the crankshaft so

the connecting rod journal of the connecting rod being
installed is at bottom dead center.

Insert the connecting rod through the cylinder liner with

the bearing tang (1) toward the camshaft side of the
engine until the ring compressor contacts the top of the
liner.
ISM, ISMe, and QSM11 Piston and Connecting Rod Assembly
Section 1 - Cylinder Block - Group 01 Page 1-125

CAUTION
Do not use a metal drift to push the piston into the
cylinder liner. The piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the
cylinder liner. Push the piston until the top ring is
completely in the cylinder liner.
NOTE: If the piston does not move freely, remove the
piston and inspect for broken or damaged rings.

Use the nylon guide pins to align the connecting rod with
the crankshaft while pushing the piston and rod assembly
in place.
Remove the nylon guide pins.

NOTE: If new bearings are not used, the used bearings

must be installed on the same connecting rod cap from
which they were removed.
Install the bearing in the connecting rod cap.
The tang of the bearing (2) must be in the slot of the cap
(1).
Use Lubriplate™ 105, or equivalent, to coat the inside
diameter of the bearing shell.
Use clean 15W-40 oil to lubricate the connecting rod
capscrew threads.

The connecting rod and cap must have the same number
and must be installed in the proper cylinder. The
connecting rod cap number and rod number must be on
the same side of the connecting rod to reduce the
possibility of engine damage during engine operation.
Install the connecting rod caps and capscrews.
Piston and Connecting Rod Assembly ISM, ISMe, and QSM11
Page 1-126 Section 1 - Cylinder Block - Group 01

Complete the following steps to tighten the rod capscrews

in alternating sequence:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 142 N•m [ 105 ft-lb ]
Step3 210 N•m [ 155 ft-lb ]
Step4 Loosen completely
Step5 Repeat steps 1 through 3

Measure the connecting rod side clearance.

Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.30 MAX 0.012
ISM, ISMe, and QSM11 Camshaft End Clearance
Section 1 - Cylinder Block - Group 01 Page 1-127

Finishing Steps
Install the piston cooling nozzles. Refer to Procedure 001-
046 in Troubleshooting and Repair Manual, ISM and
QSM11 Engines, Bulletin 3666322 for ISM and QSM11
engines, Procedure 001-046 in Troubleshooting and
Repair Manual, M11 STC, CELECT and CELECT Plus
Engines, Bulletin 3666139 for M11 engines, or Procedure
001-046 in Troubleshooting and Repair Manual, L10G
Natural Gas Base Engine, Bulletin 3666207 for L10G
engines.
Install the lubricating oil pan. Refer to Procedure 001-025
in Troubleshooting and Repair Manual, ISM and QSM11
Engines, Bulletin 3666322 for ISM and QSM11 engines,
Procedure 001-025 in Troubleshooting and Repair
Manual, M11 STC, CELECT and CELECT Plus Engines,
Bulletin 3666139 for M11 engines, or Procedure 001-025
in Troubleshooting and Repair Manual, L10G Natural Gas
Base Engine, Bulletin 3666207 for L10G engines.
Install the cylinder head. Refer to Procedure 002-004 in
Troubleshooting and Repair Manual, ISM and QSM11
Engines, Bulletin 3666322 for ISM and QSM11 engines,
Procedure 002-004 in Troubleshooting and Repair
Manual, M11 STC, CELECT and CELECT Plus Engines,
Bulletin 3666139 for M11 engines, or Procedure 002-004
in Troubleshooting and Repair Manual, L10G Natural Gas
Base Engine, Bulletin 3666207 for L10G engines.
Fill the lubricating oil pan. Refer to Procedure 001-025 in
Troubleshooting and Repair Manual, ISM and QSM11
Engines, Bulletin 3666322 for ISM and QSM11 engines,
Procedure 001-025 in Troubleshooting and Repair
Manual, M11 STC, CELECT and CELECT Plus Engines,
Bulletin 3666139 for M11 engines, or Procedure 001-025
in Troubleshooting and Repair Manual, L10G Natural Gas
Base Engine, Bulletin 3666207 for L10G engines.
Operate the engine to normal operating temperature and
check for leaks.

Camshaft End Clearance (001-065)

Measure
A condition on M series 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 M series
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.
Camshaft End Clearance ISM, ISMe, and QSM11
Page 1-128 Section 1 - Cylinder Block - Group 01

To measure the camshaft end clearance without removing

the front gear cover, first remove the rocker lever cover.
Refer to Procedure 003-011.

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.
It is not necessary to remove the push rods or push tubes.

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 toward the rear of the engine.

Set up 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.
ISM, ISMe, and QSM11 Camshaft End Clearance
Section 1 - Cylinder Block - Group 01 Page 1-129

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.
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 in] 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
0.41 MAX 0.016
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.

Adjust the valve and injectors. Refer to Procedure 003-

004.
Install the camshaft inspection plug in the gear cover.
Install the engine position sensor.
Block Stiffener Plate ISM, ISMe, and QSM11
Page 1-130 Section 1 - Cylinder Block - Group 01

Block Stiffener Plate (001-089)

Preparatory Steps

WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.

Remove
Remove and discard the 18 Torx head capscrews.
Remove the block stiffener plate from the chassis.
Torx capscrews require a size 45 Torx socket.

Clean and Inspect for Reuse

Remove all sealant material and oil from the cylinder block
mating surface.
Thoroughly clean the block threaded capscrew holes.
Remove all gasket and sealant material from the stiffener
plate.
Thoroughly clean all oil from both surfaces of the stiffener
plate with solvent.
ISM, ISMe, and QSM11 Block Stiffener Plate
Section 1 - Cylinder Block - Group 01 Page 1-131

Inspect the stiffener plate for cracks or damage.

Take note of the following:
• The machined-out areas are for main cap and
capscrew clearance.
• Oil pump sump suction tube orientation.

Machine

WARNING
To reduce the possibility of personal injury, keep
hands, long hair, jewelry, and loose fitting or torn
clothing away from fans and other moving parts.
NOTE: This machine step applies only to cast aluminum
oil pan modification.
Non-EGR Aluminum Oil Pan Modification
These modifications to the cast aluminum oil pan must be
made prior to initial stiffener plate installation.

Orient the block stiffener plate onto the oil pan to the
correct upfit position on the oil pan mounting flange.

Align the stiffener plate capscrew holes to the oil pan

mounting flange holes.
Block Stiffener Plate ISM, ISMe, and QSM11
Page 1-132 Section 1 - Cylinder Block - Group 01

Locate and mark the 18 Torx head screw holes on the oil
pan mounting flange.

Using a round file, carefully remove enough material in the

oil pan mounting flange to accommodate the 2-mm Torx
head screw protrusion.

After completing all 18 notches, thoroughly clean the pan,

removing all aluminum debris.

Mate the oil pan mounting surface to the stiffener plate

and inspect for proper fit.
ISM, ISMe, and QSM11 Block Stiffener Plate
Section 1 - Cylinder Block - Group 01 Page 1-133

Install

CAUTION
Too much sealant applied to the stiffener plate can
drip into the lubrication pan assembly. This excess
sealant can become lodged in the oil suction tube
screen and cause engine damage.
Install four evenly spaced (1 and 2) 10 cm [4 in] long guide
pins in the block oil pan capscrew holes.
These guide pins aid in the stiffener plate and oil pan
assembly.

Apply a 2 mm [0.0625 in] bead of sealant on the block

contact area of the stiffener plate along the oil pan
capscrew holes.
NOTE: The recessed areas in the stiffener plate allow
main cap and capscrew clearance. This is the side that
faces the block.

Maneuver the stiffener plate into place under the engine

in the chassis.
Use the guide pins to align the stiffener plate into place
and install new Torx head capscrews.
Guide pins can be removed, or left in place to assist in oil
pan installation.

Tighten the Torx head capscrews in the sequence shown.

Torque Value: 47 N•m [ 35 ft-lb ]
Block Stiffener Plate ISM, ISMe, and QSM11
Page 1-134 Section 1 - Cylinder Block - Group 01

Finishing Steps

CAUTION
Make sure the oil transfer tube designed for the block
stiffener plate is used. Failure to install the correct oil
transfer tube will result in engine damage.
Replace the discarded oil transfer tubes with the correct
oil transfer tubes.
Install the oil transfer tubes. Refer to Procedure 007-040.

Install the oil pan. Refer to procedure 007-025.

Fill the engine with oil. Refer to Procedure 007-025.

Operate the engine and check for leaks.
ISM, ISMe, and QSM11
Section 2 - Cylinder Head - Group 02 Page 2-a

Section 2 - Cylinder Head - Group 02

Section Contents
Page
Cylinder Head ....................................................................................................................................................2-2
Assemble........................................................................................................................................................2-25
Clean................................................................................................................................................................2-7
Clean and Inspect for Reuse...........................................................................................................................2-11
Disassemble.....................................................................................................................................................2-8
Finishing Steps...............................................................................................................................................2-34
With EGR.....................................................................................................................................................2-34
Without EGR................................................................................................................................................2-35
Install..............................................................................................................................................................2-31
Leak Test..........................................................................................................................................................2-4
Magnetic Crack Inspect...................................................................................................................................2-22
Preparatory Steps.............................................................................................................................................2-2
With EGR.......................................................................................................................................................2-2
Without EGR..................................................................................................................................................2-3
Pressure Test..................................................................................................................................................2-19
Remove............................................................................................................................................................2-3
Vacuum Test.....................................................................................................................................................2-5
Service Tools ....................................................................................................................................................2-1
Cylinder Head...................................................................................................................................................2-1
ISM, ISMe, and QSM11
Page 2-b Section 2 - Cylinder Head - Group 02

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 2 - Cylinder Head - Group 02 Page 2-1

Service Tools
Cylinder Head

Tool No. Tool Description Tool Illustration

Cylinder Head Water Test Fixture
Used to pressure-test the cylinder head injector sleeves for leakage.
3376082

Cylinder Head Lifting Bracket

Used for lifting the cylinder head on and off the engine.
3822479

Cylinder Head Capscrew Length Gauge

Used to measure the length of the cylinder head mounting
capscrews.
3823546
Cylinder Head ISM, ISMe, and QSM11
Page 2-2 Section 2 - Cylinder Head - Group 02

Cylinder Head (002-004)

Preparatory Steps
With EGR
Remove or disconnect the following:
• Air piping from the intake manifold and the
turbocharger. Refer to Procedures 010-023 and 010-
033.
• Rocker lever cover. Refer to Procedure 003-011.
• Engine brakes, if applicable. Refer to Procedure 020-
024.
• Engine brake oil feed line, if equipped.
• Locking capscrew from the Metri-Pack 12-pin
connector at the front of the rocker lever housing, and
separate the connector.
• Internal engine wiring harness holding clamp
capscrews.
• Deutsch 2-pin connectors from the internal engine
wiring harness to the fuel injectors.
• Internal engine wiring harness from the engine.
• Push rods or push tubes. Refer to Procedure 004-014.
• Rocker lever assemblies. Refer to Procedure 003-009.
• Crossheads.
• Injectors. Refer to Procedure 006-026.
• Air compressor air supply tube from the EGR mixer.
Refer to Procedure 012-109.
• EGR differential pressure sensor harness and sensor.
Refer to Procedure 019-370 in the CM870 Electronic
Control System, ISM Engines Troubleshooting and
Repair Manual, Bulletin 4021381.
• Exhaust pressure sensor from the harness. Refer to
Procedure 019-376 in the CM870 Electronic Control
System, ISM Engines Troubleshooting and Repair
Manual, Bulletin 4021381.
• EGR differential pressure sensor and exhaust
pressure sensor tubes. Refer to Procedures 011-026
and 011-027.
• EGR mixer and air horn assembly. Refer to Procedure
011-021.
• EGR connection tube. Refer to Procedure 011-025.
• Water manifold. Refer to Procedure 008-061.
• EGR cooler vent lines. Refer to Procedure 011-031.
• EGR cooler coolant return and supply tubes. Refer to
Procedure 011-019.
• EGR valve. Refer to Procedure 011-022.
• EGR cooler. Refer to Procedure 011-019.
• Cylinder head vent lines.
• Rocker lever housing. Refer to Procedure 003-013.
• Turbocharger. Refer to Procedure 010-033.
• Exhaust manifold. Refer to Procedure 011-007.
• Fuel lines from the cylinder head. Refer to Procedure
006-024.
• Fan hub and fan. Refer to Procedures 008-036 and
008-040.
• ECM connectors from the ECM. Refer to Procedure
006-006.
• CM870 ECM mounting bracket. Refer to Procedure
019-031 in the CM870 Electronic Control System, ISM
Engines Troubleshooting and Repair Manual, Bulletin
4021381.
• Refrigerant compressor and mounting bracket.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-3

Without EGR
Remove or disconnect the following:
• Air piping from the intake manifold and the
turbocharger.
• Rocker lever cover. Refer to Procedure 003-011.
• Engine brakes, if applicable. Refer to Procedure 020-
024.
• Locking capscrew from the Metri-Pack 12-pin
connector at the rear end of the rocker lever housing,
and separate the connector.
• Internal engine wiring harness holding clamp
capscrews.
• Deutsch 2-pin connectors from the internal engine
wiring harness to the fuel injectors.
• Internal engine wiring harness from the engine.
• Push tubes and push rods. Refer to Procedure 004-
014.
• Rocker lever assemblies. Refer to Procedure 003-
009.
• Crossheads.
• Injectors. Refer to Procedure 006-026.
• Rocker lever housing. Refer to Procedure 003-013.
• Turbocharger. Refer to Procedure 010-033.
• Exhaust manifold. Refer to Procedure 011-007.
• Fuel lines and air compressor tube from the cylinder
head.
• Fan and fan hub. Refer to Procedure 008-036 and
008-040.
• All the necessary brackets and clamps.

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 component.
Remove the seven 12-point cylinder head capscrews on
the fuel pump side of the engine.

Remove the remaining 32 cylinder head capscrews in the

sequence shown.
Three capscrews are located inside the intake ports.
Cylinder Head ISM, ISMe, and QSM11
Page 2-4 Section 2 - Cylinder Head - Group 02

Install cylinder head lifting bracket, Part Number 3822479,

with two rocker lever support mounting capscrews and two
of the long rocker housing mounting capscrews.
Tighten the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]

WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.

CAUTION
Place the cylinder head on wood blocks to prevent
damage to the combustion face.
Use a hoist or hydraulic arm, and remove the cylinder
head.
Remove the cylinder head gasket.

Leak Test
Inspect the valves for indications of leaking or burning. If
indications of leaking or burning are found, the valves and
the seats must be resurfaced. Refer to the M11 Series
Shop Manual, Bulletin 3666075.
Test the cylinder head for damage. Set the head down
with the exhaust ports facing up. Pour fuel into one of the
exhaust ports until it is full. Set the container of fuel down,
and start a 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 M11 Series Shop
Manual, Bulletin 3666075.
If a drop of fuel has not run down the face of the head in
30 seconds, the exhaust valves are acceptable.
Repeat the process for all six cylinders.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-5

Pour fuel into one of the intake ports until it is full. Set the
container of fuel down, and start the timer.
Each intake port supplies four intake valves (two cylinders)
on M Series cylinder heads.

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 M11 Series Shop Manual,
Bulletin 3666075.
If a drop of fuel has not run down the face of the head in
30 seconds, the intake valves are acceptable.
Repeat the process for all six cylinders.
If any of the intake or exhaust valves fail the test, all the
valves and valve seats must be resurfaced.

Vacuum Test
Use the vacuum tester, Part Number ST-1257, to inspect
the seal between the valve and the valve seat.
The valve vacuum tester is not recommended for use on
used cylinder heads. See the Leak Test section of this
procedure for the recommended procedure to check used
heads.
The valve vacuum tester can be used to test all Cummins
engine models. The seal ring, Part Number ST-1257-35,
and vacuum cup, Part Number 3376100, are used on the
M11 cylinder heads.

Install the seal ring and vacuum cup to the vacuum line
hose.
Cylinder Head ISM, ISMe, and QSM11
Page 2-6 Section 2 - Cylinder Head - Group 02

The valves and valve seats must be clean and dry when
vacuum testing.
Cover the valve with the cup and seal.
The seal must make a tight contact on the cylinder head
around the valve.

Move the toggle switch (1) to the ON position.

Turn the vacuum control valve (2) to the OPEN position.
The vacuum control valve is in the OPEN position if the
vacuum gauge needle moves clockwise.

Operate the vacuum pump until the gauge indicates the

specified vacuum.

Valve to Valve Seat Vacuum

kPa psi
1724 MIN 250
2317 MAX 336
Turn the toggle switch to the OFF position.

Use a stopwatch and start timing when the needle on the

gauge indicates 457 mm Hg [18 in Hg].
Stop timing when the needle on the gauge indicates 203
mm Hg [8 in Hg].
The elapsed time for the needle to move between the
specified gauge readings must be 10 seconds or more.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-7

If the elapsed time is less than 10 seconds, perform the

following checks:
• Repeat the test to be sure the equipment is operating
properly.
• Use a mallet to hit the valve stem lightly to make sure
the valve is seated. Repeat the test.
• Apply a thin layer of grease on the outside diameters
of the insert and the valve head. Repeat the test. The
grease pattern will show the point of leakage.
A break in the grease seal pattern will indicate leakage
between the valves and valve seat or the valve seat insert
and the cylinder head.

Clean

CAUTION
If the oil passages are not plugged or covered before
cleaning, a crankshaft failure can occur.
Place clean, lint-free rags over the cam followers and
above the pistons to prevent dirt from falling into the
engine.
Plug or cover the coolant and oil passages in the cylinder
block deck.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a gasket scraper to clean the cylinder block deck
surface.
Use Scotch-Brite™ 7448 abrasive pad, Part Number
3823258, or equivalent, and solvent to remove any
residual gasket material from the cylinder block deck
surface.
Make sure the cylinder head capscrew holes are clean
and free of debris, oil, and coolant.
Cylinder Head ISM, ISMe, and QSM11
Page 2-8 Section 2 - Cylinder Head - Group 02

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.
Steam clean the cylinder head and dry with compressed
air.
Use compressed air to blow out all capscrew holes.

WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendation
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
Use Scotch-Brite™ 7448 abrasive pad, Part Number
3823258, or equivalent, and solvent to clean the cylinder
head combustion face.
Clean the exhaust manifold gasket surface.

Clean the rocker housing gasket surface.

Disassemble
Prior to disassembly, measure and record the valve
recess and valve tip height above the top deck of the
cylinder head. See Clean and Inspect for Reuse Section
in this procedure.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-9

Install the cylinder head in the head holding fixture, Part

Number ST-583, as shown.

Install a wood block between the valves and head holding

fixture to support the valves.
Use the valve spring compressor, Part Number ST-448,
the compressor threaded adapter, Part Number 3376850,
and the compressor adapter, Part Number 3376851, to
compress the valve springs.

Use a pencil magnet to remove the valve collets. Discard

the valve collets.
Slowly release the pressure on the valve spring.

Remove the valve spring retainer.

Remove the valve spring.
Remove the valve spring wear plate.
Cylinder Head ISM, ISMe, and QSM11
Page 2-10 Section 2 - Cylinder Head - Group 02

Remove the valve.

Mark the valves with an electric pencil (engraving tool) for
location as they are removed.
The intake and exhaust valves are manufactured from
different materials and are not interchangeable.
Repeat the procedure to remove the remaining valve
collets, retainers, springs, wear plates, and valves.

Remove the valve seals from the valve guides.

Prior to removing the valve guides, measure and record
the valve guide inside diameter and height. See Clean and
Inspect for Reuse in this procedure.

Use valve guide driver, Part Number 3376398, to remove

the old valve guides.

Prior to removing the valve seat inserts, see Leak Test and
Inspect for Reuse in this procedure. The condition of the
valve, the amount of recess, and the sealing of the valve
on the seat insert, all help determine whether or not a seat
insert needs to be replaced.
Use slide hammer assembly, Part Number 3376616, and
valve seat extractor, Part Number 3376146, to remove the
valve seat inserts from the cylinder head.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-11

Inspect the insert bore for cracks or damage.

If cracks or damage is found, it is possible to repair the
cylinder head by machining the insert bore for oversize
valve seat inserts. Refer to the Alternative Repair Manual,
Bulletin 3710310.

Perform the coolant passage and fuel passage pressure

test before removing the injector sleeves.
Use injector sleeve puller, Part Number 3377079, to
remove the injector sleeves from the cylinder head.
Follow the directions supplied with the tool to remove the
sleeves.
Remove the injector sleeve o-ring from the injector bore in
the cylinder head. Discard the o-ring.

Clean and Inspect for Reuse

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a wire brush and solvent to clean the deposits from
the valve seat insert bores.
Use solvent to clean the cylinder head.
Dry with compressed air.
Cylinder Head ISM, ISMe, and QSM11
Page 2-12 Section 2 - Cylinder Head - Group 02

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the injector bore.
Dry with compressed air.
Inspect the injector seat surface in the bottom of the
injector bore.
If the bead in the cylinder head is not smooth, the injector
bore must be repaired. Refer to the L10 Alternative Repair
Shop Manual, Bulletin 3810310.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a flexible brush and solvent to clean the valve guide
bores in the cylinder head. Dry with compressed air.

Inspect the fuel drillings and water passages for

restrictions or foreign material.
Remove any obstructions.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-13

Inspect the valves and valve springs for cracks, bent or

broken valve stems, broken valve spring collets, or other
damage.
Inspect the valves for indications of leaking or burning.
If cracked or damaged parts or indication of leaking or
burning is found, the cylinder head must be rebuilt. Refer
to the M11 Series Shop Manual, Bulletin 3666075.

Inspect the cylinder head and valves for cracks or

damage.
If a crack in the cylinder head is suspected, pressure-test
the cylinder head. See Pressure Test in this procedure.

Measure the flatness of the cylinder head combustion face

surface as follows:
• AA and BB (corner to corner)
• CC (across combustion face)
• DD (across entire head surface).
Dimensions CC and DD must be checked from front to
rear of cylinder head.

Cylinder Head Flatness

mm in
AA and BB 0.200 MAX 0.008
CC 0.076 MAX 0.003
DD 0.127 MAX 0.005
If the cylinder head is pitted, has grooves or wear greater
than the maximum specified, the cylinder head surface
must be machined or cut. Refer to the L10 Alternative
Repair Shop Manual, Bulletin 3810310.
Cylinder Head ISM, ISMe, and QSM11
Page 2-14 Section 2 - Cylinder Head - Group 02

CAUTION
Do not use caustic or acid solutions to clean the
cylinder head capscrews to avoid damage to cylinder
head capscrews.
Clean the cylinder head capscrews with a petroleum-
based solvent.
Clean the capscrews thoroughly with a wire brush, with a
wire wheel (soft), or use a nonabrasive bead blast to
remove deposits from the shank and threads.

Using flange head capscrews with the torque plus angle

method of installation places the capscrews beyond the
yield point and permanently stretches the capscrews.
These capscrews can be reused throughout the life of the
engine unless the capscrew exceeds the specified free
length. The free length must be checked to avoid
bottoming in the block during installation.
Cylinder head capscrew length gauge, Part Number
3823546, has been designed to check capscrew free
length.
NOTE: The new capscrews are coated with grey coating
and do not have the 90 degree markings on the capscrew.

To check the capscrew free length, place the head of the

capscrew in the appropriate slot, long or short, with the
flange against the base of the slot.
Use the slot marked for L10 cylinder head capscrews
when checking M11 cylinder head capscrews.

If the end of the capscrew touches the foot of the gauge,

the capscrew is too long and must be discarded.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-15

If there is clearance between the end of the capscrew and

the bottom base of the tool, the capscrew can be reused.

The capscrew can also be checked using a set of calipers.

The maximum allowable free length is measured from the
bottom of the flange to the end of the capscrew (dimension
X).

Cylinder Head Capscrew Free Length

mm in
3045849 Short Intake 74.5 MAX 2.933
Port Capscrews
3045850 Long Hex 139.5 MAX 5.492
Head Capscrews
4923187 Long Hex 139.5 MAX 5.492
Head Capscrews

Use valve spring tester, Part Number 3375182, to

measure the valve spring load at the valve spring working
height.

Valve Spring Load at 71.5 mm [2.814 in]

N lbf
1252 MIN 281
1584 MAX 356
If the valve spring load for the working height is less than
the minimum specified, the valve spring must be
replaced.

Inspect the valve spring retainers and valve spring guides

for damage or work areas.
Discard damaged and worn parts.
Cylinder Head ISM, ISMe, and QSM11
Page 2-16 Section 2 - Cylinder Head - Group 02

Inspect the valves for damage and the collet grooves for
wear.
Measure the outside diameter of the valve stem.

Valve Stem Outside Diameter (OD)

mm in
9.580 MIN 0.3772
9.633 MAX 0.3793
If the valves are damaged or the stems are worn smaller
than the minimum specified, the valves must be replaced.

Inspect the valve guides, if not removed in the

Disassemble step, for chips or cracks.
Measure the valve guide inside diameter.

New Valve Guide Inside Diameter (ID), Installed

mm in
9.670 MIN 0.3807
9.695 MAX 0.3817
If the valve guide is not within the specifications given, the
valve guide must be replaced.

Measure the valve guide installed height above the

cylinder head top deck surface.

Valve Guide Height (Installed)

mm in
27.15 MIN 1.069
27.65 MAX 1.089

Install a new or reconditioned valve in the valve guide.

Hold the valve firmly against the valve seat insert.
Use a depth gauge, Part Number 3823495, to measure the
valve recess in the cylinder head.

Valve Recession
mm in
0.76 MIN 0.030
1.17 MAX 0.046

Maximum Operational Recession

mm in
3.05 MAX 0.120
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-17

Maximum Valve Recession Variation Between Valves

on Same Cylinder
mm in
0.76 MAX 0.030

Maximum Valve Tip Height

mm in
99.6 MAX 3.921

Measure the inside diameter of the valve seat insert bore

in the cylinder head.

Insert Bore Inside Diameter (ID)

mm in
45.920 MIN 1.8079
45.935 MAX 1.8085
If the valve seat insert bore inside diameter does not meet
the specifications given, refer to the oversize valve
installation insert installation instructions in the L10
Alternative Repair Shop Manual, Bulletin 3810310.

Measure the inside diameter of the valve guide bore in the

cylinder head.

Valve Guide Bore Inside Diameter (ID)

mm in
16.480 MIN 0.6488
16.500 MAX 0.6496
If the valve guide bore is worn larger than the maximum
specified, the valve guide bore can be machined, and a
0.51 mm [0.02 in] oversize valve guide installed. Refer to
the L10 Alternative Repair Shop Manual, Bulletin
3810310.

Measure the valve seat insert bore depth in the cylinder

head.

Insert Bore Depth (Standard Insert)

mm in
9.40 MIN 0.370
9.50 MAX 0.374
If the valve seat insert bore depth does not meet the
specifications given, refer to Cylinder Head Oversize
Valve Seat Insert installation in the L10 Alternative Repair
Shop Manual, Bulletin 3810310.
Cylinder Head ISM, ISMe, and QSM11
Page 2-18 Section 2 - Cylinder Head - Group 02

Inspect the insert bore for cracks or damage.

If cracks or damage is found, it is possible to repair the
cylinder head by machining the insert bore for oversize
valve seat inserts. Refer to the L10 Alternative Repair
Shop Manual, Bulletin 3810310.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the parts.
Dry with compressed air.

Inspect the rocker lever contact pad for wear, cracks, or

damage.
Wear in the pad contact area must not exceed 7 mm
[0.276 in] width.
Dry with compressed air.

Measure the valve stem pocket depth from the valve stem
pocket to the rocker pad face (1).

Stem Pocket to Pad Face

mm in
12.05 MIN 0.474
12.55 MAX 0.494
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-19

Pressure Test

CAUTION
Do not pressure-test the cylinder head with the valves
and valve springs installed. Water entering the
cylinder head can not be dried thoroughly and will
damage the valve guides and valve stems.
Coolant Passage
Install cylinder head water test fixture, Part Number
3376082:
• Install gasket, Part Number 3376084 (1)
• Install test plate, Part Number 3376658 (2)
• Install the 32 cylinder head capscrews and 32 (M14
x 1.50) nuts.
Tighten the nuts.
Torque Value: 47 N•m [ 35 ft-lb ]

Use six injector sleeve holding tools, Part Number ST-

1179.
Install the capscrew (1), flat washer (2), anvil (3), Part
Number ST-179-4, and mandrel (4), Part Number ST-
1179-2 in each injector bore as shown.

Tighten the six injector sleeve holding tool capscrews.

Torque Value: 75 N•m [ 55 ft-lb ]
Cylinder Head ISM, ISMe, and QSM11
Page 2-20 Section 2 - Cylinder Head - Group 02

WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Connect a regulated air supply hose to the test fixture
plate. Apply air pressure.
Air Pressure 276 kPa [ 40 psi ]
Use a nylon lifting strap and a hoist to place the cylinder
head in a tank of heated water.
Completely submerge the cylinder head in the water.
Water Temperature 60 °C [ 140 °F ]

Inspect for air bubbles rising from the water.

If air bubbles are seen, replace or rebuild the cylinder
head. Refer to the M11 Series Shop Manual, Bulletin
3666075 for rebuild procedures.
If a crack is found in the cylinder head, preserve the
cylinder head with clean engine oil so that rust does not
develop.

Remove the test equipment.

Fuel Passage
Use clean 15W-40 oil to lubricate the injector o-rings.
Install a set of injectors with new o-rings in the cylinder
head.
See Section 0 for proper o-ring orientation.
Install the injector hold-down clamps and mounting
capscrews.
Torque Value: 75 N•m [ 55 psi ]
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-21

Install a 0-160 psi pressure gauge, Part Number 3375275,

to the fuel outlet fitting.
Install an air supply line to the fuel inlet fitting.
Apply air pressure to the cylinder head.

Air Pressure
kPa psi
552 MIN 80
689 MAX 100

Close the air supply valve and inspect the fuel passages
for leaks.
Record the air pressure on the gauge. The air pressure
must not decrease on the gauge for at least fifteen
seconds.
If the air pressure decreased, use a solution of soap and
water on the fuel passage areas and pipe plugs to find the
leaks.

Remove the injectors from the cylinder head.

Install the cylinder head and parts in a tank of cleaning

solution.
Be sure to follow the cleaning solution manufacturer's
instructions when cleaning the parts.
Cylinder Head ISM, ISMe, and QSM11
Page 2-22 Section 2 - Cylinder Head - Group 02

WARNING
This component weighs 23 km [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Remove the cylinder head and parts from the cleaning
tank.
Use fuel passage cleaning brush, Part Number ST-876, to
clean the fuel and oil passages with solvent. Dry with
compressed air.
Inspect the fuel and oil passages to make sure they are
clean.

Magnetic Crack Inspect

Use the magnetic particle residual method to inspect the
valves for cracks.
The exhaust valves contain two types of metal and must
be inspected by the coil shot method. There will be a
magnetic leakage apparent at the point where the two
metals are welded together. The leakage will appear as a
wide pattern of magnetic particles.
Magnetize the valves in a coil of 100 to 200 amperes.

Inspect the valves with residual Magnaglo™.

A broad fuzzy pattern will appear at the welded joint on
the exhaust valves. If there is a distinct line in the pattern,
the valve must be replaced.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-23

The intake valves contain only one type of metal and

must be magnetized and inspected in two directions. Use
the Magnaglo™ coil method and inspect with residual
Magnaglo™ the same as exhaust valves.
Magnetize the intake valves again with a headshot at 500
to 700 amperes.
Inspect the valves again with residual Magnaglo™.

Acceptance Criteria (Exhaust and Intake Valves)

A visible crack is one which can be seen through a three
power magnifying glass after the magnetic particle
suspension is removed.
Area 1, no indication longer than 12.70 mm [0.500 in].
There must be no more than five indications or no
indications closer together than 3.18 mm [0.125 in].
Areas 2, 3, 4, and 5 must not have any magnetic
indications or visible indications.
Remove all magnetism and clean the acceptable valves.

Remove the pipe plugs, fuel passage plugs, and fuel

fittings from the cylinder head.
Use a dent puller to remove the expansion plugs.

Magnetize the crosshead and inspect it with residual

Magnaglo™.
Cracks will be indicated by a bright line. The primary
location for cracks is the valve stem pocket area.
If cracks are found, the crosshead must be replaced.
Cylinder Head ISM, ISMe, and QSM11
Page 2-24 Section 2 - Cylinder Head - Group 02

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Remove all magnetism.
Use solvent to clean the crossheads.
Dry with compressed air.

Use magnetic crack detector, Part Number ST-1166, to

find cracks in the combustion face, in areas around the
valve ports and the injector bores.
Place the magnetizing head on the combustion face as
shown, to check for cracks that run across the cylinder
head.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Fill the powder spray bulb one-third full with metal powder.
Spray the powder lightly onto the combustion face.
Use compressed air to remove the excess metal powder.
Air Pressure: 276 kPa [40 psi]
The powder will remain in the cracks, if present, and show
as a white line.

Inspect the cylinder head for cracks in the combustion

face.
If any cracks around the injector bore are longer than 7
mm [0.250 in], the cylinder head must be replaced.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-25

Place the magnetizing head on the combustion face as

shown to check for cracks that run lengthwise of the
cylinder head.
Repeat the procedure as outlined above.

WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Remove all magnetism and use solvent to clean the
cylinder head. Dry with compressed air.
The cylinder head must be thoroughly cleaned after using
the magnetic crack detector to remove all of the iron
fragments.

Assemble
Install the base and swivel of the valve seat insert tool,
Part Number ST-275, on the cylinder head to guide the
valve seat driver. Install valve guide arbor, Part Number
ST-804-1.
The insert chamfer (1) must be installed toward the bottom
of the counterbore.
Use valve seat driver, Part Number 3376105, to drive the
valve seat insert into the counterbore.
Make sure the insert is at the bottom of the counterbore.
Cylinder Head ISM, ISMe, and QSM11
Page 2-26 Section 2 - Cylinder Head - Group 02

Use valve seat grinding machine, Part Number ST-685,

and valve guide arbor set, Part Number 804, to grind the
new valve seat inserts. Refer to Valve Seats - Grinding in
the M11 Series Shop Manual, Bulletin 3666075.

Use valve guide driver (1), Part Number 3823947, to install

the new valve guides.

Measure the valve guide installed height above the

cylinder head top deck surface.
See Clean and Inspect for Reuse in this procedure for
specifications.

Measure the valve guide inside diameter.

See Clean and Inspect for Reuse in this procedure for
specifications.
If the valve guide is not within the specifications given, the
valve guide must be replaced.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-27

Use vegetable oil to lubricate the injector sleeve o-rings.

Install the o-ring (1) in the groove of the injector sleeve.

Use injector sleeve driver, Part Number ST-1227, to install

the injector sleeve into the cylinder head. Remove the
sleeve driver.
Install injector sleeve holding tool, Part Number ST-1179,
in the injector sleeve.
Torque Value: 50 N•m [ 37 ft-lb ]

Install the injector sleeve driver.

Hit the driver with a mallet to seat the sleeve in the bore.
Remove the driver and tighten the injector sleeve holding
tool capscrew again.
Torque Value: 50 N•m [ 37 ft-lb ]

Use injector sleeve expander, Part Number ST-880, to

expand the upper section of the injector sleeve.
Adjust the expander roller edge (1) and collar (2) to the
clearance specified.
Clearance 27 mm [ 1.06 in ]
Cylinder Head ISM, ISMe, and QSM11
Page 2-28 Section 2 - Cylinder Head - Group 02

Install the expander into the injector sleeve and turn the
mandrel with a 1/2-in socket and an inch-pound torque
wrench.
Torque Value: 9 N•m [ 80 in-lb ]
Remove the expander and holding tool from the injector
sleeve.

Use pilot, Part Number ST-379-2, holder, Part Number ST-

884-1, and injector seat cutter, ST-844-3, to cut the
injector seat.
Install the injector sleeve cutter and the cylinder head in
a drill press.
Use a cutting oil to lubricate the cutter head.
Carefully machine the injector sleeve until the sealing area
is smooth.
Clean the metal particles from the injector sleeve bore and
fuel passages.

CAUTION
Support the cylinder head in the Part Number ST-583
head holding fixture to reduce the possibility of
damage to the injector tip that protrudes from the
combustion face.
Install the injector into the cylinder head without the o-
rings.
Torque Value: 75 N•m [ 55 ft-lb ]

Turn the cylinder head over and use depth gauge, Part
Number 3823495, to measure the injector tip protrusion.

Injector Tip Protrusion (New Injector Sleeve)

mm in
2.28 MIN 0.090
2.54 MAX 0.100
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-29

Remove the injectors and apply a bluing compound to the

outside diameter of the injector at the injector seat area.
Install the injectors into the cylinder head without the o-
rings.
Torque Value: 75 N•m [ 55 ft-lb ]

The bluing pattern of the injector seating area (1) must be

approximately 13 mm [0.50 in] from the cylinder head
surface.
The injector bore seating width (2) must be a minimum of
1.52 mm [0.060 in].
Inspect the cylinder head for leaks after the new injector
sleeves have been installed. See Pressure Test in this
procedure.

Apply a coat of cup plug sealant, Part Number 3375068,

to the pipe plugs threads. Install the pipe plugs.
The pipe plugs (1) located in the front of the cylinder head
must be installed below the surface of the cylinder head.
Torque Value: 10 N•m [ 89 in-lb ]

Apply a coat of cup plug sealant, Part Number 3375068,

to the outside diameter of the expansion plugs.
Use expansion plug drivers, Part Numbers 3823372,
3376058, and 3376816, to install the expansion plugs in
the cylinder head.
The correct expansion plug driver will install the
expansion plugs to the correct depth in the cylinder head.
Cylinder Head ISM, ISMe, and QSM11
Page 2-30 Section 2 - Cylinder Head - Group 02

CAUTION
Do not use excessive force or the seal will be
damaged.
Use valve seal driver, Part Number 3823946, to install the
valve seals on the valve guides.
Position the seal on the tool arbor.
Insert the arbor into the top of the guide and tap the tool
with a plastic mallet to seat the bottom of the seal against
the machined step on the valve guide.

Use clean 80W, or higher, gear lube with EP additives to

lubricate the valve stems.
Install the valves in the valve guides.
After the valves are installed, place the cylinder head on
a flat surface that will not damage the cylinder head
surface.

Install the valve spring wear plates.

Install valve springs.
Install the valve spring retainers.

Use valve spring compressor, Part Number ST-448,

compressor thread adapter, Part Number 3376850, and
compressor adapter, Part Number 3376851, to compress
the valve springs.
Always use new collets when rebuilding the cylinder
head.
Install the new valve spring retainer collets.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-31

Use vacuum tester, Part Number ST-1257, with vacuum

cup, Part Number 3376100, to vacuum test the valve
seating. See Cylinder Head - Vacuum Test Valve Seating.

Install
A plastic insert is installed in all fuel inlet passages on new
and ReCon® cylinder heads.
The fuel inlet passages are the lower row of drillings.

Depending on the fuel plumbing option, one fuel inlet

passage insert must be removed to allow fuel to flow to
the injectors. If the insert is not removed, the engine
will not start.
Remove the pipe plug and use a sharp object to pull the
insert from the hole.

Install the cylinder head lifting bracket, Part Number

3822476, with two rocker lever support mounting
capscrews and two long rocker housing mounting
capscrews.
Tighten the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Cylinder Head ISM, ISMe, and QSM11
Page 2-32 Section 2 - Cylinder Head - Group 02

WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.

CAUTION
Do not drop the cylinder head on the cylinder head
gasket. The gasket material can be damaged.
Install the cylinder head gasket.
Use a hoist or hydraulic arm and install the cylinder head.
Use clean 15W-40 oil to lightly coat the cylinder head
capscrew threads and bottom of the flange.
Allow the excess oil to drain from the capscrew threads.

Remove cylinder head lifting bracket, Part Number

3822479.

Install the seven hex flange head capscrews with new

sealing washers on the fuel pump side of the engine.

Install the remaining 32 cylinder head capscrews in the

sequence shown.
Be sure to install the three short capscrews inside the
intake ports.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-33

All of the 32 capscrews, old and new, must be rotated 180

degrees after they have been tightened according to
torque step 2. Make a mark on the cylinder head as a
reference. Rotate the capscrew more than two flats and
but less than three flats.
After tightening according to torque step 2, mark the
cylinder head as a reference.
When using torque plus angle, the tolerance on the 180-
degree angle of rotation is between two and three flats. If
the capscrew is unintentionally rotated beyond three flats,
do not loosen the capscrew. The clamp load is still
acceptable. However, rotating the capscrew beyond three
flats reduces the number of potential reuses.
NOTE: This torque procedure is applicable to both old and
new capscrews.

Tighten all the capscrews in the sequence shown to the

specified values:
Torque Value: Step1 68 N•m [ 50 ft-lb ]
Step2 136 N•m [ 100 ft-lb ]
Step3 Rotate 180 degrees
NOTE: Rotate at least two flats, but not more than three
flats.

Tighten the seven capscrews in the fuel pump side of the

cylinder head in the sequence shown.
Torque Value: 68 N•m [ 50 ft-lb ]
Cylinder Head ISM, ISMe, and QSM11
Page 2-34 Section 2 - Cylinder Head - Group 02

Finishing Steps
With EGR
Install or connect the following:
• Refrigerant compressor and mounting bracket.
• CM870 ECM mounting bracket. Refer to Procedure
019-031 in the CM870 Electronic Control System, ISM
Engines Troubleshooting and Repair Manual, Bulletin
4021381.
• ECM connector from the ECM. Refer to Procedure
006-006.
• Fan hub and fan. Refer to Procedure 008-036 and
008-040.
• Fuel lines from the cylinder head. Refer to Procedure
006-024.
• Exhaust manifold. Refer to Procedure 011-007.
• Turbocharger. Refer to Procedure 010-033.
• Rocker lever housing. Refer to Procedure 003-013.
• Cylinder head vent lines.
• EGR cooler. Refer to Procedure 011-019.
• EGR valve. Refer to Procedure 011-022.
• EGR cooler coolant return and supply tubes. Refer to
Procedure 011-019.
• EGR cooler vent lines. Refer to Procedures 011-031.
• Water manifold. Refer to Procedure 008-061.
• EGR connection tube. Refer to Procedure 011-025.
• EGR mixer and air horn assembly. Refer to Procedure
011-021.
• EGR differential pressure sensor and exhaust
pressure sensor tubes. Refer to Procedures 011-026
and 011-027.
• Exhaust pressure sensor from the harness. Refer to
Procedure 019-376 in the CM870 Electronic Control
System, ISM Engines Troubleshooting and Repair
Manual, Bulletin 4021381.
• EGR differential pressure sensor harness and sensor.
Refer to Procedure 019-370 in the CM870 Electronic
Control System, ISM Engines Troubleshooting and
Repair Manual, Bulletin 4021381.
• Air compressor air supply tube from the EGR mixer.
Refer to Procedure 012-109.
• Injectors. Refer to Procedure 006-026.
• Crossheads.
• Rocker lever assemblies. Refer to Procedure 003-009.
• Push tubes or push rods. Refer to Procedure 004-014.
• Internal wiring harness from the engine.
• Deutsch 2-pin connectors to the internal engine wiring
harness to the fuel injectors.
• Internal engine wiring harness holding clamps
capscrews.
• Locking capscrew from the Metri-Pack 12-pin
connector at the front of rocker lever housing, and
connect the connector.
• Engine brake oil feed line, if equipped.
• Engine brakes, if applicable. Refer to Procedure 020-
024.
• Rocker lever cover. Refer to Procedure 003-011.
• Air piping to the intake manifold and turbocharger.
Refer to Procedures 010-023 and 010-033.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine to normal operating temperature
and check for leaks.
ISM, ISMe, and QSM11 Cylinder Head
Section 2 - Cylinder Head - Group 02 Page 2-35

Without EGR
Install or connect the following:
• Fan hub and fan. Refer to Procedure 008-036 and
008-040.
• Brackets and clamps that were removed.
• Fuel lines and air compressor tube to the cylinder
head.
• Exhaust manifold. Refer to Procedure 011-007.
• Rocker lever housing. Refer to Procedure 003-013.
• Injectors. Refer to Procedure 006-026.
• Rocker lever assemblies. Refer to Procedure 003-
009.
• Internal engine wiring harness on the engine.
• The 12-pin connector of the internal engine harness
to the 12-pin connector of the external engine
harness.
• Locking capscrew (Torx® size T-25). Tighten the
capscrew.
• Holding clamps for the internal engine harness.
• Deutsch 2-pin connectors from the internal engine
harness to the fuel injectors.
• Crossheads.
• Push tubes and push rods. Refer to Procedure 004-
014.
• Engine brakes, if equipped. Refer to Procedure 020-
024.
• Turbocharger. Refer to Procedure 010-033.
• Rocker lever cover. Refer to Procedure 003-011.
• Air piping to the turbocharger and the intake
manifold. See the manufacturer's specifications for
the correct torque value.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine to normal operating temperature
and check for leaks.
Cylinder Head ISM, ISMe, and QSM11
Page 2-36 Section 2 - Cylinder Head - Group 02

Notes
ISM, ISMe, and QSM11
Section 3 - Rocker Levers - Group 03 Page 3-a

Section 3 - Rocker Levers - Group 03

Section Contents
Page
Crankcase Breather (Internal) ...........................................................................................................................3-2
Clean................................................................................................................................................................3-3
Inspect for Reuse..............................................................................................................................................3-3
Install................................................................................................................................................................3-3
With EGR.......................................................................................................................................................3-3
Without EGR..................................................................................................................................................3-4
Remove............................................................................................................................................................3-2
With EGR.......................................................................................................................................................3-2
Without EGR..................................................................................................................................................3-2
Crankcase Ventilation Filter ............................................................................................................................3-19
Install..............................................................................................................................................................3-20
Remove..........................................................................................................................................................3-19
Overhead Set .....................................................................................................................................................3-4
Adjust...............................................................................................................................................................3-4
General Information........................................................................................................................................3-4
Injectors.........................................................................................................................................................3-8
Valves............................................................................................................................................................3-8
Rocker Lever Assembly ..................................................................................................................................3-11
Finishing Steps...............................................................................................................................................3-11
Preparatory Steps...........................................................................................................................................3-11
Rocker Lever Cover .........................................................................................................................................3-11
Clean..............................................................................................................................................................3-11
Inspect for Reuse............................................................................................................................................3-12
Install..............................................................................................................................................................3-12
Remove..........................................................................................................................................................3-11
Rocker Lever Housing .....................................................................................................................................3-13
Clean..............................................................................................................................................................3-15
Inspect for Reuse............................................................................................................................................3-16
Install..............................................................................................................................................................3-16
Remove..........................................................................................................................................................3-13
Service Tools ....................................................................................................................................................3-1
Rocker Levers...................................................................................................................................................3-1
ISM, ISMe, and QSM11
Page 3-b Section 3 - Rocker Levers - Group 03

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 3 - Rocker Levers - Group 03 Page 3-1

Service Tools
Rocker Levers

Tool No. Tool Description Tool Illustration

Torque Wrench Adapter
Used to tighten rocker lever adjusting screws.
3163196

Crack Detection Kit

Used to clean and inspect components for cracks.
3375432

Inch-Pound Torque Wrench

Can be used as an optional valve set. Screwdriver socket, Part
Number ST-669-13, must be used with this tool.
3376592

Injector Travel Measurement Kit

Used to measure injector travel lash.
3823610
Crankcase Breather (Internal) ISM, ISMe, and QSM11
Page 3-2 Section 3 - Rocker Levers - Group 03

Crankcase Breather (Internal) (003-

002)
Remove
With EGR
Remove the tube support bracket capscrew and bracket.
Remove the tube from the engine.

Remove the rocker lever housing cover. Refer to

Procedure 003-011.

Without EGR
Remove the tube support bracket capscrew and bracket.
Remove the tube from the engine.

Remove the rocker lever housing cover. Refer to

Procedure 003-011.
ISM, ISMe, and QSM11 Crankcase Breather (Internal)
Section 3 - Rocker Levers - Group 03 Page 3-3

Clean

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use solvent to clean the cover, breather cavity, and
breather tube. Dry with compressed air.

Inspect for Reuse

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use compressed air to blow through the breather cavity.
If the breather cavity is clogged and the restriction can
not be removed by cleaning, the cover must be replaced.
Use air pressure to blow through the tube.
Replace the tube if it is clogged.

Install
With EGR
Install the rocker lever housing cover. Refer to Procedure
003-011.

Install the breather tube, bracket, and capscrew on the

engine.
Tighten the bracket capscrew.
Torque Value: 27 N•m [ 20 ft-lb ]
Overhead Set ISM, ISMe, and QSM11
Page 3-4 Section 3 - Rocker Levers - Group 03

Without EGR
Install the rocker lever housing cover. Refer to Procedure
003-011.

Install the breather tube, bracket, and capscrew on the

engine.
Tighten the bracket capscrew.
Torque Value: 27 N•m [ 20 ft-lb ]

Overhead Set (003-004)

Adjust
General Information
Valves, injectors, and engine brakes must be correctly adjusted for the engine to operate efficiently. Valve, injector,
and engine brake adjustment must be performed using the values listed in this section. The accompanying table gives
the adjustment specifications.
If the valves and injectors have been adjusted during troubleshooting or before this scheduled interval, adjustment is
not required at this time.

Valve, Injector, and Engine Brake Adjustment Specifications

mm in
Intake Valve 0.36 0.014
Exhaust Valve 0.69 0.027
Engine Brake 0.38 0.015
ISM, ISMe, and QSM11 Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-5

All valve and injector adjustments must be made when the

engine is cold (any stabilized coolant temperature at 60°
C [140°F] or below).

Remove the rocker lever cover and gasket.

WARNING
Do not straighten a bent fan blade or continue to use
a damaged fan. A bent or damaged fan blade can fail
during operation and cause personal injury or
property damage.
The valve set marks are located on the accessory drive
pulley. The marks align with a pointer on the gear cover.
Use the accessory driveshaft to rotate the crankshaft.

The crankshaft rotation is clockwise when viewed from

the front of the engine.
The cylinders are numbered from the front gear housing
end of the engine.
The engine firing order is 1-5-3-6-2-4.
Overhead Set ISM, ISMe, and QSM11
Page 3-6 Section 3 - Rocker Levers - Group 03

Each cylinder has three rocker levers:

• The long rocker lever (E) is the exhaust lever.
• The center rocker lever is the injector lever.
• The short rocker lever (l) is the intake lever.
Refer to the accompanying graphic for valve rocker lever
locations.
ISM, ISMe, and QSM11 Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-7

The valves and injectors on the same cylinders 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 the valves and injectors.
NOTE: See the example before attempting to begin the adjusting procedure.
NOTE: Set the injector on the same cylinder before setting valves.
Adjust all of the injectors, valves, and brakes (if equipped) to the following injector and valve adjustment sequence
chart.

Injector and Valve Measurement Sequence

Set Cylinder
Bar Engine in Direction of Rotation Pulley Position
Injector Valve
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

The adjustment can begin on any valve set mark. In the

following example, the adjustment will begin on the "A"
valve set mark with cylinder Number 1 valves closed and
ready for adjustment.
Rotate the accessory drive clockwise until the "A" valve
set mark on the accessory drive pulley is aligned with the
pointer on the gear cover.

When the "A" mark is aligned with the pointer, the intake
and exhaust valves for cylinder Number 1 must be closed.
If these conditions are not correct, cylinder Number 6
injector and valves must be ready to set. Set the injector
and valves on the cylinder so that both the intake and
exhaust valve rocker lever arms are loose and can be
moved from side-to-side.
Both valves are closed when both rocker levers are loose
and can be moved from side-to-side.
Overhead Set ISM, ISMe, and QSM11
Page 3-8 Section 3 - Rocker Levers - Group 03

Injectors
Loosen the injector adjusting screw locknut. Using a
screwdriver (box end wrench if equipped with engine
brakes) and the adjusting screw, bottom the injector
plunger three or four times to remove the fuel.
Turn the adjusting screw in until you can feel it just bottom
the plunger.
NOTE: Do not use excessive force when bottoming the
plunger.
Back out the adjusting screw two flats, 120 degrees. Hold
the adjusting screw, and tighten the locknut.
Torque Value: 61 N•m [ 45 ft-lb ]

After setting the injector, set the valves on the same

cylinder.

Valves
With the "A" valve set mark aligned with the pointer on the
gear cover and both valves closed on the cylinder to be
adjusted, loosen the adjusting screw locknuts on the
intake and exhaust valves.

Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specification
mm in
Intake 0.36 0.014
Exhaust 0.69 0.027

Insert the feeler gauge between the top of the crosshead

and the rocker lever pad.
ISM, ISMe, and QSM11 Overhead Set
Section 3 - Rocker Levers - Group 03 Page 3-9

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. It eliminates the need to feel the
drag on the feeler gauge.
• Torque Wrench Method: Use the inch-pound torque
wrench, Part Number 3376592, normally used to set
preload on top-stop injectors, and tighten the
adjusting screw.
Torque Value: 0.7 N•m [ 6 in-lb ]
• Touch 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 locknut is tightened.
Torque Value:
Without torque 61 N•m [ 45 ft-lb ]
wrench adapter
With torque 47 N•m [ 35 ft-lb ]
wrench
adapter, Part
Number
3163196

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 touch 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 ISM, ISMe, and QSM11
Page 3-10 Section 3 - Rocker Levers - Group 03

If the engine is equipped with an engine brake, refer to

Engine Brake - Adjust following in this procedure.

After adjusting the injector, valves, and engine brakes (if

equipped) on the appropriate cylinder, rotate the
accessory drive pulley, and align the next valve set mark
with the pointer on the gear cover.

If the valve cover gasket was not damaged, it can be used

again. If the gasket was damaged, it must be discarded
and a new one used.
Install the gasket on the cover.

Install the cover on the rocker lever housing.

Install the 16 isolators, spacers, and capscrews in the
cover.
Tighten the capscrews in the sequence shown.
Torque Value: 15 N•m [ 130 in-lb ]
ISM, ISMe, and QSM11 Rocker Lever Cover
Section 3 - Rocker Levers - Group 03 Page 3-11

Rocker Lever Assembly (003-009)

Preparatory Steps
Remove the following:
• Air piping from the intake manifold.
• Rocker lever cover. Refer to Procedure 003-011.
• Engine brakes, if equipped. Refer to Procedure 020-
024.

Rocker Lever Cover (003-011)

Remove
Remove the air piping from the intake manifold.
Remove the hose from the crankcase breather.

Remove the 16 capscrews and the rocker lever cover.

Remove the 16 isolators from the cover.

Clean

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: The gasket can be reused if it is not damaged.
Remove the gasket and inspect for damage.
Steam clean and dry with compressed air.
Rocker Lever Cover ISM, ISMe, and QSM11
Page 3-12 Section 3 - Rocker Levers - Group 03

Inspect for Reuse

Inspect the cover for cracks or damage and replace if
necessary.

Install
If the gasket was not damaged, it can be used again. If
the gasket was damaged, it must be discarded and a new
one used.
Install the gasket on the cover.

Install the cover on the rocker lever housing.

Install the 16 isolators, spacers, and capscrews in the
cover.

Tighten the capscrews in the sequence shown.

Torque Value: 15 N•m [ 130 in-lb ]
ISM, ISMe, and QSM11 Rocker Lever Housing
Section 3 - Rocker Levers - Group 03 Page 3-13

Install the hose on the crankcase breather.

Install the air piping to the intake manifold. Refer to the
manufacturer's specifications for the correct torque
values.

Rocker Lever Housing (003-013)

Remove
Remove the air piping from the intake manifold.
Remove the rocker lever cover. Refer to Procedure 003-
011.

Remove the engine brakes, if applicable, from the engine.

Refer to Procedure 020-024.

Remove all valve push tubes and injector push rods from
the engine. Refer to Procedure 004-014.
Rotate the rocker levers up.
Mark the position of the crossheads as they are removed.
They must be installed in the same position as from which
they were removed.
Remove the crossheads to prevent them from falling into
the lower area of the engine.
Rocker Lever Housing ISM, ISMe, and QSM11
Page 3-14 Section 3 - Rocker Levers - Group 03

The internal engine harness is located inside the rocker

housing.
A pass through connector joins the internal and external
engine harness. This connector has two clips that can
manually be opened to allow separation of the two
harnesses. Engines with pass through connectors in the
front of the engine have clips on the outside, engines with
pass through connections in the rear of the engine have
clips on the inside of the rocker housing that require the
valve cover to be removed to access.

Remove the internal engine harness holding clamp

capscrews.

Separate the Deutsch 2-pin connectors from the internal

engine harness to the fuel injectors.

Remove the internal engine harness from the engine.

ISM, ISMe, and QSM11 Rocker Lever Housing
Section 3 - Rocker Levers - Group 03 Page 3-15

Remove the rocker lever assemblies. Refer to Procedure

003-009.

Remove the injectors. Refer to Procedure 006-026.

Remove the rocker housing mounting capscrews.

Remove the rocker housing and the intake manifold as a
complete unit.
NOTE: If high blowby is a symptom, the rocker housing
gasket must be inspected before it is removed from the
cylinder head.

Clean

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.
Use steam to clean the rocker lever housing. Dry with
compressed air.
Clean the cylinder head gasket surface.
Rocker Lever Housing ISM, ISMe, and QSM11
Page 3-16 Section 3 - Rocker Levers - Group 03

Inspect for Reuse

Inspect the rocker housing gasket for cuts or damage on
the portion of the gasket that seals around the intake
ports. Damage to the gasket can cause high blowby.
Inspect the housing for cracks or damage.
If the housing is cracked, it must be replaced.

Install
Use a new gasket, and install the rocker lever housing.

Step 1: Snug all bolts.

Step 2: Tighten the 24 capscrews in the sequence shown.
Torque Value: 34 N•m [ 25 ft-lb ]
Step 3: Tighten the 24 capscrews in the sequence shown.
Torque Value: 61 N•m [ 45 ft-lb ]

Install the injectors. Refer to Procedure 006-026.

ISM, ISMe, and QSM11 Rocker Lever Housing
Section 3 - Rocker Levers - Group 03 Page 3-17

Install the rocker lever assemblies. Refer to Procedure

003-009.

Install the internal engine wiring harness on the engine.

The harness and connectors must be clear of any moving
parts, so the wires will not be damaged during engine
operation.

Connect the 15-pin connector of the internal engine

harness to the 15-pin connector of the external engine
harness.
NOTE: The internal and external Metri-Pack connectors
are "keyed." Make sure both connectors are correctly
aligned when they are joined together.

Install the holding clamps for the internal engine harness.

Tighten the capscrews.
Torque Value: 20 N•m [ 15 ft-lb ]
Rocker Lever Housing ISM, ISMe, and QSM11
Page 3-18 Section 3 - Rocker Levers - Group 03

Lubricate the connector ends with lubricant, Part Number

3822934.
Connect the Deutsch 2-pin connectors from the internal
engine harness to the fuel injectors.

Install the crossheads in the same position they were

removed from, and rotate the rocker levers down.
Install the push rods and push tubes. Refer to Procedure
004-014.

Adjust the valves and injectors. Refer to Procedure 003-

004.

Install the engine brakes, if applicable. Refer to Procedure

020-024.
ISM, ISMe, and QSM11 Crankcase Ventilation Filter
Section 3 - Rocker Levers - Group 03 Page 3-19

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

Install the air piping to the intake manifold. Refer to the
manufacturer's specifications for the correct torque value.

Crankcase Ventilation Filter (003-021)

Remove

CAUTION
It is recommended that all service be performed with
the engine shut down.
Identify a place to set the canister without spilling any oil
remaining in it.
Use shop towels to clean up any oil that drips from the
canister or filter.
Hold onto the canister and release the four latches (2)
which hold the canister to the filter head assembly.
Pull the canister down, being careful not to spill any oil
remaining in the bottom of the canister.
Set the canister in the place identified earlier.
Pull down on the filter to remove it. Make sure the o-ring
(3) on the top of the end cap is removed with the filter.
Dispose of the filter.
Remove the o-ring from the bottom of the head assembly,
if a new o-ring is available.
Crankcase Ventilation Filter ISM, ISMe, and QSM11
Page 3-20 Section 3 - Rocker Levers - Group 03

Install
Make sure there is a new o-ring (3) on the end cap of the
new element (4).

Install a new o-ring (5) onto the bottom of the head

assembly (6), as needed.
Install the new element pushing the end cap into the hole
in the bottom of the head assembly (6).
Install the canister on the bottom of the head assembly.
Align the latches.
Hook the four latches and snap closed.
ISM, ISMe, and QSM11
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..........................................................................................................................................................4-5
Clean................................................................................................................................................................4-3
Disassemble.....................................................................................................................................................4-3
Inspect for Reuse..............................................................................................................................................4-4
Install................................................................................................................................................................4-6
Remove............................................................................................................................................................4-2
Push Rods or Tubes .........................................................................................................................................4-9
Inspect for Reuse..............................................................................................................................................4-9
Install..............................................................................................................................................................4-10
Remove............................................................................................................................................................4-9
Service Tools ....................................................................................................................................................4-1
Cam Followers/Tappets.....................................................................................................................................4-1
ISM, ISMe, and QSM11
Page 4-b Section 4 - Cam Followers/Tappets - Group 04

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 4 - Cam Followers/Tappets - Group 04 Page 4-1

Service Tools
Cam Followers/Tappets

Tool No. Tool Description Tool Illustration

Cam Follower Assembly Removal and Installation Tool
Used to remove and install the cam follower assemblies.
3824519
Cam Follower Assembly ISM, ISMe, and QSM11
Page 4-2 Section 4 - Cam Followers/Tappets - Group 04

Cam Follower Assembly (004-001)

Remove
NU
Remove the cylinder head. Refer to Procedure 002-004.
Remove the nuts and washers from the cam follower
assembly supports.

Install the cam follower assembly installation and removal

tool, Part Number 3824519. Slide the tool under the
assemblies with the supports located in the cutouts on the
bottom surface of the tool.
The cam follower assembly consists of two shaft
assemblies with a common center support.
Secure the tool to the assemblies by hand-tightening the
screws on top of the tool.

Lift both ends of the cam follower assemblies to remove

them from the engine.
Set the assemblies on a flat surface. Loosen the two
screws on top of the tool, and remove the tool from the
cam follower assemblies.

Install two M10 x 1.50 nuts on each stud.

Tighten the nuts together.
Turn the bottom nut counterclockwise to remove the
stud.
NOTE: The cam follower studs have an internal oil
passage to supply the cam followers with lubricating oil.
The studs must be removed and checked.
ISM, ISMe, and QSM11 Cam Follower Assembly
Section 4 - Cam Followers/Tappets - Group 04 Page 4-3

Disassemble
NU
Separate the two shafts from the center support.
The cam follower levers must be installed in the same
position they were removed from. Mark both of the end
supports, the center support, and all of the cam followers
to identify their location when they are removed. The end
supports are not interchangeable. The center support is
not interchangeable with any of the other inner supports.

Remove the end supports (1) from the shafts.

Remove the cam followers and supports from both shafts.
• Valve cam follower (2)
• Injector cam follower (3)
• Valve cam follower (4)
• Shaft support (5).

Clean
NU

WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the cam follower parts with solvent and dry with
compressed air.
Make sure the oil passages in the cam followers and the
cam follower studs are clean.
Cam Follower Assembly ISM, ISMe, and QSM11
Page 4-4 Section 4 - Cam Followers/Tappets - Group 04

Inspect for Reuse

NU
Inspect the cam followers for cracks or other damage.
Refer to Camshaft Reuse Guidelines, Bulletin 3666052,
for inspection criteria of cam follower rollers.

Inspect the cam follower sockets for excessive wear.

If excessive wear is found in the cam follower sockets, the
push rods must be inspected. Refer to Procedure 004-
014. Refer to the Overhead Reuse Guidelines, Bulletin
3810388, to identify wear patterns and excessive wear.
Replace all parts that do not meet the reuse guidelines.

Inspect the cam follower shafts for scores or damage.

Inspect the cam follower rollers for flat spots, freedom of

rotation, or other damage.
ISM, ISMe, and QSM11 Cam Follower Assembly
Section 4 - Cam Followers/Tappets - Group 04 Page 4-5

Measure the cam follower roller side clearance.

Cam Follower Roller Side Clearance

mm in
0.19 MIN 0.007
0.65 MAX 0.026

Use clean 15W-40 oil to check the oil flow through the cam
followers.

Use clean 15W-40 oil to check the oil flow through the cam
follower studs.

Assemble
NU
Use clean 15W-40 oil to lubricate the cam followers and
shafts.
Cam Follower Assembly ISM, ISMe, and QSM11
Page 4-6 Section 4 - Cam Followers/Tappets - Group 04

The cam followers, supports, and shafts must be installed

in the same position from which they were removed. The
shaft end supports are not interchangeable.
Install the end support (1) on the shaft.
Install the cam followers on the shaft in the following
sequence:
• Valve cam follower (2)
• Injector cam follower (3)
• Valve cam follower (4)
• Shaft support (5).

Install the two cam follower shaft assemblies in the

common center support (6).
NOTE: The common center support (6) has a locating
dowel hole. The other inner supports do not have this
hole.

Install
NU
Install the cam follower studs with two M10 x 1.50 nuts
tightened together.
Tighten the studs.
Torque Value: 34 N•m [ 25 ft-lb ]
Remove the two nuts.

Install cam follower assembly installation and removal

tool, Part Number 3824519, onto the cam follower
assemblies.
Before installing the cam follower assemblies, the cylinder
head deck must be cleaned. Refer to Procedure 002-004.
ISM, ISMe, and QSM11 Cam Follower Assembly
Section 4 - Cam Followers/Tappets - Group 04 Page 4-7

Supports one, four, and seven are doweled. The supports

must align with the dowel pins in the cylinder block.
Install the cam follower assemblies on the studs.
Remove the service tool.
Install the washers and nuts on each stud.
Tighten the nuts on supports one, four, and seven.
Torque Value: 47 N•m [ 35 ft-lb ]

Install a 0.76-mm [0.030 in] feeler gauge between the

number three support and the exhaust lever for cylinder
number three. Push the number three support toward the
No. four support.
Tighten the number three support nut.
Torque Value: 47 N•m [ 35 ft-lb ]

Install a 0.76-mm [0.030 in] feeler gauge between the

number two support and the intake lever for cylinder
number two. Push the number two support toward the
number three support.
Tighten the number two support nut.
Torque Value: 47 N•m [ 35 ft-lb ]

Measure side clearance between the number one and two

supports.

Cam Follower Side Clearance Between Supports

mm in
0.76 MIN 0.030
Cam Follower Assembly ISM, ISMe, and QSM11
Page 4-8 Section 4 - Cam Followers/Tappets - Group 04

Install the 0.76-mm [0.030 in] feeler gauge between the

number five support and the exhaust lever for cylinder
number four. Push the number five support toward the
number four support.
Tighten the number five support nut.
Torque Value: 47 N•m [ 35 ft-lb ]

Install the 0.76-mm [0.030 in] feeler gauge between the

number six support and the intake lever for cylinder
number five. Push the number six support toward the
number five support.
Tighten the number six support nut.
Torque Value: 47 N•m [ 35 ft-lb ]

Measure the side clearance between the number six and

seven supports.

Cam Follower Side Clearance Between Supports

mm in
0.76 MIN 0.030

Install the cylinder head. Refer to Procedure 002-004.

Operate the engine and check for leaks.
ISM, ISMe, and QSM11 Push Rods or Tubes
Section 4 - Cam Followers/Tappets - Group 04 Page 4-9

Push Rods or Tubes (004-014)

Remove
Remove the air piping from the intake manifold.
Remove the rocker lever cover. Refer to Procedure 003-
011.

Remove the engine brakes, if applicable. Refer to

Procedure 020-024.

Mark the position of the valve push tubes and injector

push rods as they are removed. The push tubes and push
rods must be installed in the same positions when the
engine is assembled.
Loosen the rocker lever adjusting screws, and remove the
valve push tubes and injector push rods.
Hold the push tubes and push rods while loosening the
adjusting screws. Do not let them fall into the engine while
rotating the accessory drive pulley.
NOTE: Some push tubes and rods are under compression
because the valves are open. Rotate the crankshaft
clockwise with the accessory drive pulley to relieve the
spring tension.

Inspect for Reuse

Inspect the straightness of the push tubes and push rods
by rolling them on a level bench. If any push tube or push
rod is bent, it must be replaced.
Push Rods or Tubes ISM, ISMe, and QSM11
Page 4-10 Section 4 - Cam Followers/Tappets - Group 04

Inspect the ball-and-socket ends for uneven wear or

scratches.
Check the push tubes for oil. If the push tubes are filled
with oil, they must be replaced.

Inspect the seating pattern in the socket for excessive

wear.
Inspect the ball end for excessive wear.
If excessive wear is found on the ball end, the cam follower
sockets must be inspected. Refer to Procedure 004-001.
Refer to the Overhead Reuse Guidelines, Bulletin
3810388, to identify wear patterns and excessive wear.
Replace all parts that do not meet the reuse guidelines.

Install
Use clean 15W-40 oil to coat the ball end of the push tubes
and push rods.
NOTE: The injector push rods (l) are smaller in diameter
and longer than the valve push tubes (V).

Install the valve push tubes and injector push rods.

Position the push tubes and push rods under the rocker
lever adjusting screws.
Tighten the adjusting screws enough to hold the push
tubes and push rods in position.
ISM, ISMe, and QSM11 Push Rods or Tubes
Section 4 - Cam Followers/Tappets - Group 04 Page 4-11

Adjust the valves and injectors. Refer to Procedure 003-

004.

Install the engine brakes, if applicable. Refer to Procedure

020-024.

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

Install the air piping to the intake manifold. Refer to the
manufacturer's specifications for the correct torque.
Push Rods or Tubes ISM, ISMe, and QSM11
Page 4-12 Section 4 - Cam Followers/Tappets - Group 04

Notes
ISM, ISMe, and QSM11
Section 5 - Fuel System - Group 05 Page 5-a

Section 5 - Fuel System - Group 05

Section Contents
Page
Fuel Consumption .............................................................................................................................................5-3
Measure............................................................................................................................................................5-3
Fuel Flow ...........................................................................................................................................................5-6
Initial Check......................................................................................................................................................5-6
Leak Test..........................................................................................................................................................5-7
Pressure Test....................................................................................................................................................5-7
Minimum Cranking Pressure..........................................................................................................................5-7
Minimum Operating Pressure.........................................................................................................................5-7
Fuel Pump .........................................................................................................................................................5-8
Clean................................................................................................................................................................5-9
Inspect for Reuse..............................................................................................................................................5-9
Install..............................................................................................................................................................5-10
Prime..............................................................................................................................................................5-10
Remove............................................................................................................................................................5-8
Rotation Check...............................................................................................................................................5-12
Fuel Pump Gear Pump Check Valve ...............................................................................................................5-13
Install..............................................................................................................................................................5-13
Remove..........................................................................................................................................................5-13
Fuel Pump Pressure Regulator .......................................................................................................................5-20
Initial Check....................................................................................................................................................5-20
Fuel Pump Pulsation Damper .........................................................................................................................5-14
Inspect for Reuse............................................................................................................................................5-14
Fuel Shutoff Valve ...........................................................................................................................................5-15
Voltage Check.................................................................................................................................................5-15
Service Tools ....................................................................................................................................................5-1
Fuel System......................................................................................................................................................5-1
Stall Speed Test ..............................................................................................................................................5-15
Stall Speed Check...........................................................................................................................................5-15
ISM..............................................................................................................................................................5-15
Stall Speed Check List....................................................................................................................................5-19
Time Speed Check..........................................................................................................................................5-18
ISM..............................................................................................................................................................5-18
ISM, ISMe, and QSM11
Page 5-b Section 5 - Fuel System - Group 05

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 5 - Fuel System - Group 05 Page 5-1

Service Tools
Fuel System

Tool No. Tool Description Tool Illustration

Pressure Gauge (0 to 100 psi)
Used to measure fuel pressure during cranking.
3375388

Digital Tachometer Kit

Used to measure engine rpm.
3377462

Pressure Gauge and Hose (0 to 300 psi)

Used to measure oil pressure or measure fuel pump pressure.
Includes necessary hoses and hardware to attach to a fuel pump.
3375932
Part Number ST-435-1 is the hose and Part Number ST-435-6 is the
pressure gauge.

Fuel Measurement Device

Used to measure fuel rate on the engine.
3376375

Remote Starter Switch

Used to turn engine on and off from a remote location.
3376506

Digital Multimeter
Used to measure electrical circuits: voltage (volts), resistance (ohms),
and current (amps).
3377161
Service Tools ISM, ISMe, and QSM11
Page 5-2 Section 5 - Fuel System - Group 05

Tool No. Tool Description Tool Illustration

Safety Solvent
Used to clean parts and tools safely.
3824510
ISM, ISMe, and QSM11 Fuel Consumption
Section 5 - Fuel System - Group 05 Page 5-3

Fuel Consumption (005-010)

Measure
Refer to the fuel consumption check list sheets in the back
of Section TS.
The most accurate method to check the fuel consumption
is to weigh the fuel used. Use a scale capable of
measuring within 0.045 kg [0.1 lb] to weigh the fuel tank.
Use a remote mount tank with enough capacity to run 80
km [50 mi].
Fill the fuel tank. Weigh the tank with the fuel. The weight
on Number 2 diesel fuel is nominally 0.844 kg per liter
[7.03 lb 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
remaining fuel. Compute the fuel used in liters [gallons] as
required.
Fuel Consumption ISM, ISMe, and QSM11
Page 5-4 Section 5 - Fuel System - Group 05

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 in determining differences
in fuel consumption between two vehicles under the same
environmental, road, and test conditions.

Perform the test with the test vehicle and a control vehicle.
The control vehicle compensates for changes in traffic
conditions.
The vehicles must stay close together to experience the
same varying traffic and weather conditions, but not so
close as to affect each other's driving or headwind.

The test course must be 65 to 80 km [40 to 50 mi] long.

ISM, ISMe, and QSM11 Fuel Consumption
Section 5 - Fuel System - Group 05 Page 5-5

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 ca
n only be plus or minus 0.5 percent. This will be ±15
seconds on 80 km [50 mi] at 60 mph.

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.
Fuel Flow ISM, ISMe, and QSM11
Page 5-6 Section 5 - Fuel System - Group 05

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.

The vehicle speeds must be representative of a typical
operation.

During the test, record the following:

• Ambient temperature
• Humidity
• Barometric pressure
• Wind velocity
• Wind direction.
NOTE: Avoid testing under any extreme conditions.

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.
ISM, ISMe, and QSM11 Fuel Flow
Section 5 - Fuel System - Group 05 Page 5-7

Pressure Test
Minimum Cranking Pressure
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
172 MIN 25
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. Prime the fuel
pump if necessary. Refer to Procedure 005-016.

Minimum Operating Pressure

Connect a 0 to 611 kPa [0 to 300 psi] pressure gauge to
the quick disconnect fitting to the fuel pump.

Start the engine and operate it at 1200 rpm with no load

applied.
Record the fuel pressure.

Minimum Fuel Pressure at 1200 rpm

kPa psi
827 MIN 120

Leak Test
Install an 457 mm [18 in] 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.
Add the 457 mm [18 in] 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 in] piece of clear tubing.
Fuel Pump ISM, ISMe, and QSM11
Page 5-8 Section 5 - Fuel System - Group 05

Start the engine and allow the air to purge from the clear
tubing. Air bubbles can not appear.
Shut off the engine, and observe the clear tubing.
Generally, an air space will appear in the clear tubing that
is drawn from the top of the fuel filter.

Observe the fuel in the clear tubing. It will 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, then 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
drainback of the suction lines.
Remove the clear tubing, and connect the suction line
back to its original connection.

Fuel Pump (005-016)

Remove
Disconnect the battery cables. Disconnect negative (-)
cable first.
ISM, ISMe, and QSM11 Fuel Pump
Section 5 - Fuel System - Group 05 Page 5-9

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.

Clean
Clean the gasket surfaces of the fuel pump and the air
compressor or accessory drive.

Inspect for Reuse

Inspect the mounting surfaces for damage.

Inspect the jaw coupling spider and the jaw coupling hub
for damage or wear.
Fuel Pump ISM, ISMe, and QSM11
Page 5-10 Section 5 - Fuel System - Group 05

Install
Install the jaw coupling spider, mounting gasket, and fuel
pump.
Install the four mounting capscrews.

Install the two fuel pump support brackets to cylinder

block bracket capscrews.
Tighten the support bracket to engine mounting
capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Tighten the fuel pump mounting capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]

Connect the fuel plumbing.

Connect the electric wire to the shutoff solenoid.
Connect the battery cables.
Start the engine and check for leaks.

Prime
To reduce engine cranking time, prime the fuel supply
pump.
If the fuel supply pump is dirty, clean the outside of the
pump.
ISM, ISMe, and QSM11 Fuel Pump
Section 5 - Fuel System - Group 05 Page 5-11

Remove the filter cap from the top of the front support.
Fill the pump with clean fuel oil.

Install and tighten the filter cap.

Torque Value: 16 N•m [ 142 in-lb ]

If the filter cap opening can not be used, remove the fuel
supply hose to the gear pump.
Fill the pump with clean fuel.

Install the fuel supply hose to the gear pump.

Fuel Pump ISM, ISMe, and QSM11
Page 5-12 Section 5 - Fuel System - Group 05

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. Refer to Procedure 005-016.

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. Refer to the Shop Manual, M11
Series Engines, Bulletin 3666075, for rebuilding
instructions.
If the shaft does not turn, remove the air compressor and
check the accessory drive for rotation. If the accessory
derivations turns, the air compressor or air compressor
coupling is damaged and must be replaced.
ISM, ISMe, and QSM11 Fuel Pump Gear Pump Check Valve
Section 5 - Fuel System - Group 05 Page 5-13

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.

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-in] spotface in the valve area. A gear pump
that has a pipe tap thread will have a 16-mm [0.625-in]
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.
Torque Value: 6 N•m [ 50 in-lb ]
• If the check valve has a pipe thread, install the elbow
until it is tight and pointed toward the drain line.
Fuel Pump Pulsation Damper ISM, ISMe, and QSM11
Page 5-14 Section 5 - Fuel System - Group 05

Install the drain line.

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.

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.
Torque Value: 18 N•m [ 13 ft-lb ]
ISM, ISMe, and QSM11 Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-15

Remove the two damper mounting capscrews. Install the

damper assembly with a new o-ring on the gear pump.
Tighten the capscrews.
Torque Value: 18 N•m [ 13 ft-lb ]
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 Shutoff Valve (005-043)

Voltage Check

CAUTION
To avoid damage to the ECM, connect only one wire
to the fuel shut off solenoid.
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 key switch to the OFF position.

Stall Speed Test (005-054)

Stall Speed Check
ISM
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.
Stall Speed Test ISM, ISMe, and QSM11
Page 5-16 Section 5 - Fuel System - Group 05

CAUTION
Do not exceed 120°C [250°F] converter oil
temperature. Overheating 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.

The following equipment is needed for this check:

• Stopwatch
• Cummins electronic service tool
• Equipment manufacturer's stall speed and time to
stall specifications.

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.
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.
ISM, ISMe, and QSM11 Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-17

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.
Stall Speed Test ISM, ISMe, and QSM11
Page 5-18 Section 5 - Fuel System - Group 05

Check the speed (rpm) against the specifications for the

equipment, converter, or automatic transmission.
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.

Time Speed Check

ISM
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 stopwatch at the same time

• When the engine speed is 90 percent of the stall

speed rpm, stop the stopwatch
Example: Stall speed 2089 [2089 X 0.90 = 1880 rpm]
The type of unit and the stall speed rpm can make the stall
speed time a maximum of 10 seconds.
ISM, ISMe, and QSM11 Stall Speed Test
Section 5 - Fuel System - Group 05 Page 5-19

Check the equipment manufacturer's specifications for

the time to stall or the acceleration time.

Stall Speed Check List

If the stall speed is too low, Check the following:

Yes No
1. The vehicle 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 converter charging pressure is correct.
9. The tailshaft governor is interfering with and preventing a full-throttle opening.
Disconnect the tailshaft governor. Do not exceed the manufacturer's
maximum output speed.
10. The converter blading is interfering or in a stage of failure. Check the sump
or filter for particles.
11. The converter blading is interfering, or in a stage of failure. Check the sump
or filter for particles.
12. The engine is set for power other than that specified on the power curve.
13. The converter is wrong due to improper build or rebuild of the unit.
14. The converter is performing to the published absorption curve.
15. The engine and converter match is correct. Check the engine and converter
models for proper match.
16. The engine is matched to too large of a converter. If this condition is believed
to exist, report the engine-converter-accessory information to the factory.
17. The engine power is down. Refer to the Engine Power Output Low
performance tree.

If the stall speed is too high, check the following:

Yes No
1. The accessory power requirements are less than 10 percent of the gross
engine power.
2. 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. It is
accompanied by a noticeable loss of machine performance.
Fuel Pump Pressure Regulator ISM, ISMe, and QSM11
Page 5-20 Section 5 - Fuel System - Group 05

Yes No
3. The converter is benign 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.
4. The converter turbine element is beginning to fail and lose blades, or the
converter was originally built with the wrong size element.
5. The engine and converter match is correct, due to a revision in the engine
rating or the converter performance.
6. 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 into the
oil.
7. The converter is performing to the published absorption curve.
8. The converter charging pressure is correct.

The reasons for abnormal stall speeds listed above are some that have been encountered by Cummins representatives
and possibly do not include all causes. The correction of the problem is either covered in the vehicle service manual,
the converter service manual, or is self-explanatory.

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 can 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 Shop Manual, M11
Series Engines, Bulletin 3666075.
Index
Page X-1

About the Manual ..........................................................................................i-1 Cooling System - Overview .......................................................................F-21

General Information.....................................................................................i-1 General Information..................................................................................F-21
Accessory Drive Seal ...................................................................................1-5 Injection Cycle......................................................................................F-21
Clean..........................................................................................................1-6 Crankcase Breather (Internal) ......................................................................3-2
Install..........................................................................................................1-6 Clean..........................................................................................................3-3
Remove......................................................................................................1-5 Inspect for Reuse........................................................................................3-3
Acronyms and Abbreviations ......................................................................i-12 Install..........................................................................................................3-3
General Information...................................................................................i-12 With EGR...............................................................................................3-3
Air Compressor Air Pressure Rises Slowly ...............................................TS-3 Without EGR...........................................................................................3-4
Air Compressor Cycles Frequently............................................................TS-5 Remove......................................................................................................3-2
Air Compressor Noise is Excessive...........................................................TS-7 With EGR...............................................................................................3-2
Air Compressor Pumping Excess Lubricating Oil into the Air System .......TS-8 Without EGR...........................................................................................3-2
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Crankcase Gases (Blowby) Excessive.....................................................TS-26
Continuously)..............................................................................................TS-10 Crankcase Ventilation Filter .......................................................................3-19
Air Compressor Will Not Pump Air..........................................................TS-11 Install........................................................................................................3-20
Air Compressor Will Not Stop Pumping...................................................TS-12 Remove....................................................................................................3-19
Air Intake System - Overview ....................................................................F-36 Crankshaft ..................................................................................................1-46
General Information..................................................................................F-36 Rotation Check.........................................................................................1-46
Alternator Drive Seal ....................................................................................1-4 Crankshaft Gear, Front (Crankshaft Installed) ...........................................1-46
Clean..........................................................................................................1-4 Clean........................................................................................................1-47
Install..........................................................................................................1-4 Inspect for Reuse......................................................................................1-47
Remove......................................................................................................1-4 Install........................................................................................................1-48
Alternator Not Charging or Insufficient Charging.....................................TS-13 Remove....................................................................................................1-46
Alternator Overcharging..........................................................................TS-15 Crankshaft Pulley .......................................................................................1-50
Bearings, Connecting Rod ...........................................................................1-7 Inspect for Reuse......................................................................................1-50
Clean and Inspect for Reuse.......................................................................1-8 Install........................................................................................................1-50
Center Sump Pan...................................................................................1-8 Remove....................................................................................................1-50
Install........................................................................................................1-10 Crankshaft Seal, Front ...............................................................................1-51
Remove......................................................................................................1-7 Clean........................................................................................................1-52
Bearings, Main ............................................................................................1-11 Install........................................................................................................1-52
Clean and Inspect for Reuse.....................................................................1-13 Remove....................................................................................................1-51
Finishing Steps.........................................................................................1-18 Crankshaft Seal, Rear ................................................................................1-54
Install........................................................................................................1-14 Clean and Inspect for Reuse.....................................................................1-56
Preparatory Steps.....................................................................................1-11 Finishing Steps.........................................................................................1-58
Remove....................................................................................................1-12 Install........................................................................................................1-56
Bearings, Thrust .........................................................................................1-19 Non-REPTO Dry Unitized Seal..............................................................1-56
Install........................................................................................................1-20 REPTO Dry Seal...................................................................................1-58
ISM Engines.........................................................................................1-20 Preparatory Steps.....................................................................................1-54
Remove....................................................................................................1-19 Remove....................................................................................................1-54
Block Stiffener Plate ................................................................................1-130 Non-REPTO Dry Lip Seal......................................................................1-54
Clean and Inspect for Reuse...................................................................1-130 Non-REPTO Dry Unitized Seal..............................................................1-54
Finishing Steps.......................................................................................1-134 REPTO Dry Seal...................................................................................1-55
Install......................................................................................................1-133 Cylinder Block ............................................................................................1-59
Machine..................................................................................................1-131 Basic Description......................................................................................1-59
Preparatory Steps...................................................................................1-130 Inspect for Reuse......................................................................................1-59
Remove..................................................................................................1-130 Cylinder Block and Liner Seats .................................................................1-64
Cam Follower Assembly ..............................................................................4-2 Leak Test..................................................................................................1-64
Assemble....................................................................................................4-5 Cylinder Block - Overview ...........................................................................F-1
Clean..........................................................................................................4-3 General Information....................................................................................F-1
Disassemble...............................................................................................4-3 Cylinder Head ...............................................................................................2-2
Inspect for Reuse........................................................................................4-4 Assemble..................................................................................................2-25
Install..........................................................................................................4-6 Clean..........................................................................................................2-7
Remove......................................................................................................4-2 Clean and Inspect for Reuse.....................................................................2-11
Camshaft .....................................................................................................1-23 Disassemble...............................................................................................2-8
Clean........................................................................................................1-25 Finishing Steps.........................................................................................2-34
Inspect for Reuse......................................................................................1-26 With EGR.............................................................................................2-34
Install........................................................................................................1-27 Without EGR.........................................................................................2-35
Remove....................................................................................................1-23 Install........................................................................................................2-31
Camshaft Bushings ....................................................................................1-31 Leak Test....................................................................................................2-4
Clean........................................................................................................1-32 Magnetic Crack Inspect.............................................................................2-22
Inspect for Reuse......................................................................................1-32 Preparatory Steps.......................................................................................2-2
Install........................................................................................................1-32 With EGR...............................................................................................2-2
Remove....................................................................................................1-31 Without EGR...........................................................................................2-3
Camshaft End Clearance ..........................................................................1-127 Pressure Test...........................................................................................2-19
Measure..................................................................................................1-127 Remove......................................................................................................2-3
Camshaft Gear (Camshaft Installed) ..........................................................1-35 Vacuum Test..............................................................................................2-5
Inspect for Reuse......................................................................................1-37 Cylinder Liner .............................................................................................1-65
Install........................................................................................................1-38 Clean and Inspect for Reuse.....................................................................1-69
Remove....................................................................................................1-35 Center Sump Pan.................................................................................1-69
Camshaft Gear (Camshaft Removed) .........................................................1-41 Initial Check..............................................................................................1-65
Install........................................................................................................1-42 Install........................................................................................................1-73
Remove....................................................................................................1-41 Measure...................................................................................................1-72
Complete Engine - Overview .......................................................................F-1 Remove....................................................................................................1-68
General Information....................................................................................F-1 Electrical Equipment - Overview ...............................................................F-55
Compressed Air System - Overview ..........................................................F-51 General Information..................................................................................F-55
General Information..................................................................................F-51 Engine Brake - Low Retarding Power or Slow to Activate........................TS-29
Connecting Rod ..........................................................................................1-44 Engine Brake Does Not Operate.............................................................TS-27
Clean........................................................................................................1-44 Engine Brake — One or More Cylinders Braking with Power Switch Off. .TS-31
Inspect for Reuse......................................................................................1-44 Engine Decelerates Slowly.....................................................................TS-32
Install........................................................................................................1-46 Engine Diagrams ..........................................................................................E-4
Remove....................................................................................................1-44 Engine Views.............................................................................................E-4
Coolant in the Lubricating Oil..................................................................TS-25 With CM870...........................................................................................E-5
Coolant Loss - External...........................................................................TS-16 Without CM870.....................................................................................E-12
Coolant Loss - Internal............................................................................TS-17 Industrial and Generator Drive..............................................................E-14
Coolant Temperature Above Normal - Gradual Overheat.........................TS-18 Marine Applications..............................................................................E-16
Coolant Temperature Above Normal - Sudden Overheat.........................TS-21 Engine Identification ....................................................................................E-1
Coolant Temperature Below Normal.......................................................TS-23 Cummins Engine Nomenclature.................................................................E-3
Index
Page X-2

ECM Dataplate...........................................................................................E-2 Gear Cover, Front .......................................................................................1-75

With CM870 and CM570.........................................................................E-2 Remove....................................................................................................1-75
Without EGR..........................................................................................E-2 Gear Housing, Front ...................................................................................1-77
Engine Dataplate........................................................................................E-1 Clean........................................................................................................1-79
Engine Installation .......................................................................................0-5 Inspect for Reuse......................................................................................1-80
Install..........................................................................................................0-5 Install........................................................................................................1-81
Engine Noise Excessive.........................................................................TS-33 ISM.......................................................................................................1-81
Engine Noise Excessive — Combustion Knocks.....................................TS-36 Remove....................................................................................................1-77
Engine Noise Excessive — Connecting Rod...........................................TS-37 General Cleaning Instructions ......................................................................i-8
Engine Noise Excessive — Main Bearing................................................TS-38 Abrasive Pads and Abrasive Paper..............................................................i-8
Engine Noise Excessive — Piston..........................................................TS-39 Definition of Clean.......................................................................................i-8
Engine Noise Excessive — Turbocharger...............................................TS-40 Gasket Surfaces..........................................................................................i-9
Engine Performance Troubleshooting Tree ..............................................TT-1 Plastic Bead Cleaning................................................................................i-10
Engine Removal ...........................................................................................0-2 Solvent and Acid Cleaning...........................................................................i-9
Remove......................................................................................................0-2 Steam Cleaning.........................................................................................i-10
ISM.........................................................................................................0-2 General Repair Instructions ..........................................................................i-7
Engine Speed Surges in PTO or Cruise Control......................................TS-41 General Information.....................................................................................i-7
Engine Starts But Will Not Keep Running...............................................TS-43 Welding on a Vehicle with an Electronic Controlled Fuel System..................i-7
Engine Testing - Overview .........................................................................F-56 General Safety Instructions ..........................................................................i-5
Fuel Flow Measurement on Engine or Chassis Dynamometer...................F-59 Important Safety Notice................................................................................i-5
General Information..................................................................................F-56 How to Use the Manual .................................................................................i-2
Engine Vibration Excessive.....................................................................TS-45 General Information.....................................................................................i-2
Engine Will Not Crank or Cranks Slowly (Air Starter)...............................TS-47 Idler Gear, Camshaft ..................................................................................1-85
Engine Will Not Crank or Cranks Slowly (Electric Starter)........................TS-48 Clean........................................................................................................1-86
Engine Will Not Shut Off.........................................................................TS-50 Inspect for Reuse......................................................................................1-87
Exhaust System - Overview .......................................................................F-42 Install........................................................................................................1-88
General Information..................................................................................F-42 Remove....................................................................................................1-85
Flow Diagram, Air Intake System ..............................................................F-38 Idler Gear, Hydraulic Pump ........................................................................1-90
Flow Diagram...........................................................................................F-38 Clean........................................................................................................1-91
Automotive Applications with EGR........................................................F-38 Inspect for Reuse......................................................................................1-92
Automotive Applications Without EGR...................................................F-39 Install........................................................................................................1-93
Marine Applications..............................................................................F-40 Remove....................................................................................................1-90
Industrial and Generator Drive..............................................................F-41 Idler Gear, Water Pump ..............................................................................1-95
Flow Diagram, Compressed Air System ....................................................F-53 Clean........................................................................................................1-96
Compressed Air System............................................................................F-53 Inspect for Reuse......................................................................................1-97
Cummins..............................................................................................F-53 Install........................................................................................................1-99
Holset® Models.....................................................................................F-54 Remove....................................................................................................1-95
Flow Diagram, Cooling System .................................................................F-22 Illustrations ....................................................................................................i-4
Flow Diagram...........................................................................................F-22 General Information.....................................................................................i-4
Automotive Applications with EGR........................................................F-22 Injectors and Fuel Lines - Overview ............................................................F-5
Automotive Applications Without EGR...................................................F-24 Theory of Operation....................................................................................F-5
Marine Applications..............................................................................F-26 Hydromechanical Subsystem..................................................................F-5
Industrial and Generator Drive..............................................................F-34 Injection Cycle........................................................................................F-6
Flow Diagram, Exhaust System .................................................................F-44 ISM......................................................................................................F-10
Flow Diagram...........................................................................................F-44 Intake Manifold Air Temperature Above Specification.............................TS-57
Automotive Applications with EGR........................................................F-44 Intake Manifold Pressure (Boost) is Below Normal..................................TS-59
Automotive Applications Without EGR...................................................F-46 Low Idle Adjust Switch Does Not Work...................................................TS-61
Marine Applications..............................................................................F-48 Lubricating Oil Consumption Excessive..................................................TS-62
Industrial and Generator Drive..............................................................F-49 Lubricating Oil Contaminated..................................................................TS-64
Flow Diagram, Fuel System .......................................................................F-11 Lubricating Oil Degradation (Centinel)....................................................TS-65
Fuel System..............................................................................................F-11 Lubricating Oil Pressure High.................................................................TS-66
Automotive Applications........................................................................F-11 Lubricating Oil Pressure Low..................................................................TS-67
Marine Applications..............................................................................F-12 Lubricating Oil Sludge in the Crankcase Excessive.................................TS-70
Industrial and Generator Drive..............................................................F-13 Lubricating Oil System - Overview ............................................................F-14
Flow Diagram, Lubricating Oil System ......................................................F-19 General Information..................................................................................F-14
Flow Diagram...........................................................................................F-19 With EGR.............................................................................................F-14
Automotive, Industrial, and Generation-Drive Applications.....................F-19 Maximum Oil Drain Intervals.................................................................F-15
Fuel Consumption ........................................................................................5-3 Without EGR........................................................................................F-15
Measure.....................................................................................................5-3 Lubricating Oil Temperature Above Specification....................................TS-71
Fuel Consumption Excessive..................................................................TS-51 Lubricating or Transmission Oil in the Coolant........................................TS-72
Fuel Flow ......................................................................................................5-6 Oil Pan Level Incorrect - High (Centinel).................................................TS-74
Initial Check................................................................................................5-6 Oil Pan Level Incorrect - Low (Centinel)..................................................TS-73
Leak Test....................................................................................................5-7 Operating Fuel Pressure is Low..............................................................TS-75
Pressure Test.............................................................................................5-7 Overhead Set ................................................................................................3-4
Minimum Cranking Pressure...................................................................5-7 Adjust.........................................................................................................3-4
Minimum Operating Pressure..................................................................5-7 General Information................................................................................3-4
Fuel in Coolant.......................................................................................TS-55 Injectors..................................................................................................3-8
Fuel in the Lubricating Oil.......................................................................TS-56 Valves....................................................................................................3-8
Fuel Pump ....................................................................................................5-8 Piston ........................................................................................................1-101
Clean..........................................................................................................5-9 Assemble................................................................................................1-104
Inspect for Reuse........................................................................................5-9 Articulated Piston................................................................................1-104
Install........................................................................................................5-10 Clean......................................................................................................1-102
Prime........................................................................................................5-10 Articulated Piston................................................................................1-102
Remove......................................................................................................5-8 Disassemble...........................................................................................1-101
Rotation Check.........................................................................................5-12 Articulated Piston................................................................................1-101
Fuel Pump Gear Pump Check Valve ..........................................................5-13 General Information................................................................................1-101
Install........................................................................................................5-13 Inspect for Reuse....................................................................................1-103
Remove....................................................................................................5-13 Articulated Piston................................................................................1-103
Fuel Pump Pressure Regulator ..................................................................5-20 Install......................................................................................................1-104
Initial Check..............................................................................................5-20 Remove..................................................................................................1-101
Fuel Pump Pulsation Damper ....................................................................5-14 Piston and Connecting Rod Assembly ....................................................1-115
Inspect for Reuse......................................................................................5-14 Assemble................................................................................................1-121
Fuel Shutoff Valve ......................................................................................5-15 Articulated Piston................................................................................1-121
Voltage Check..........................................................................................5-15 Clean and Inspect for Reuse...................................................................1-119
Fuel System - Overview ...............................................................................F-2 Articulated Piston................................................................................1-119
Installation Recommendations....................................................................F-2 Disassemble...........................................................................................1-118
ISM........................................................................................................F-2 Articulated Piston................................................................................1-118
Index
Page X-3

Finishing Steps.......................................................................................1-127 Preparatory Steps...................................................................................1-109

Install......................................................................................................1-122 With EGR............................................................................................1-109
Preparatory Steps...................................................................................1-115 Without EGR.......................................................................................1-110
Remove..................................................................................................1-116 Remove..................................................................................................1-110
Piston Cooling Nozzle ..............................................................................1-105 With EGR............................................................................................1-110
Inspect for Reuse....................................................................................1-105 Without EGR.......................................................................................1-110
Install......................................................................................................1-106
Remove..................................................................................................1-105
Piston Rings .............................................................................................1-107
Failure Analysis Inspection......................................................................1-107
Push Rods or Tubes ....................................................................................4-9
Inspect for Reuse........................................................................................4-9
Install........................................................................................................4-10
Remove......................................................................................................4-9
Rocker Lever Assembly .............................................................................3-11
Finishing Steps.........................................................................................3-11
Preparatory Steps.....................................................................................3-11
Rocker Lever Cover ....................................................................................3-11
Clean........................................................................................................3-11
Inspect for Reuse......................................................................................3-12
Install........................................................................................................3-12
Remove....................................................................................................3-11
Rocker Lever Housing ................................................................................3-13
Clean........................................................................................................3-15
Inspect for Reuse......................................................................................3-16
Install........................................................................................................3-16
Remove....................................................................................................3-13
Service Tools ...............................................................................................0-1
...................................................................................................................0-1
Service Tools ...............................................................................................1-1
Cylinder Block............................................................................................1-1
Service Tools ...............................................................................................2-1
Cylinder Head.............................................................................................2-1
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
Stall Speed Test .........................................................................................5-15
Stall Speed Check....................................................................................5-15
ISM.......................................................................................................5-15
Stall Speed Check List..............................................................................5-19
Time Speed Check....................................................................................5-18
ISM.......................................................................................................5-18
Symbols .........................................................................................................i-3
General Information.....................................................................................i-3
Troubleshooting Overview ......................................................................TS-77
Connecting Rod Bearing Noise...............................................................TS-77
Driveability/Low Power - Customer Complaint Form................................TS-79
Driveability/Low Power/Excessive Fuel Consumption - Checklist.............TS-77
Driveability/Low Power/Excessive Fuel Consumption - Checklist.............TS-80
Engine Noise Diagnostic Procedures - General Information.....................TS-77
Fuel Consumption - Customer Complaint Form.......................................TS-82
Fuel Consumption - General Information.................................................TS-81
Main Bearing Noise................................................................................TS-77
Oil Consumption.....................................................................................TS-83
Piston Noise...........................................................................................TS-77
Response Test.......................................................................................TS-86
Troubleshooting Procedures and Techniques ..........................................TS-1
General Information..................................................................................TS-1
Troubleshooting Symptoms Charts ..........................................................TS-2
General Information..................................................................................TS-2
Turbocharger Leaks Engine Oil or Fuel...................................................TS-76
Vehicle Braking - Overview .......................................................................F-61
General Information..................................................................................F-61
Engine Brake Solenoid.........................................................................F-61
Vibration Damper, Viscous ......................................................................1-107
Clean......................................................................................................1-107
Eccentricity Check..................................................................................1-108
Install......................................................................................................1-108
Maintenance Check................................................................................1-108
Remove..................................................................................................1-107
Wobble Check.........................................................................................1-109
Water Header Plate, Cylinder Block ........................................................1-109
Clean......................................................................................................1-111
With EGR............................................................................................1-111
Without EGR.......................................................................................1-111
Finishing Steps.......................................................................................1-113
With EGR............................................................................................1-113
Without EGR.......................................................................................1-114
Inspect for Reuse....................................................................................1-111
With EGR............................................................................................1-111
Without EGR.......................................................................................1-111
Install......................................................................................................1-112
With EGR............................................................................................1-112
Without EGR.......................................................................................1-112
Troubleshooting and Repair Manual

ISM, ISMe, and QSM11 Engines Volume 1

Bulletin 3666322
Printed in U.S.A. 15-AUGUST-2005 p63

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