ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 001-026   Cylinder Block

• Remove the engine and place it on an engine stand. Refer to Procedure 000-001 in Section 0.
• Disassemble the engine. See Section DS – Engine Disassembly.

Before cleaning or further disassembly of the block, perform an inspection to see if there is any damage (cracks, fretting, etc.) that would prohibit reuse. Give special attention to areas of the block that include:

• Main bearing caps and bores
• Camshaft bores
• Cylinder bores
• Tappet bores
• Cylinder block combustion deck
• Oil pan mounting surface
• Lubricating oil pump mounting area
• Water pump mounting area
• Front and rear of block sealing surfaces
• Lubricating oil cooler cavity.

Inspect all pipe plugs, expansion plugs, and straight thread plugs for signs damage or leaks.

If it is necessary to thoroughly clean the cylinder block for reuse, remove all pipe plugs, expansion plugs, and straight thread plugs, as necessary. This will make sure all oil and coolant passages can be cleaned out.

Refer to Procedure 017-002 in Section 17.

Refer to Procedure 017-007 in Section 17.

Refer to Procedure 017-011 in Section 17.

Use clean solvent and a non-metallic brush to clean the block oil drillings.

Thoroughly clean all gasket sealing surfaces of any remaining gasket residue.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Remove the block from the engine stand.

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.

CAUTION  If the camshaft bushings have not been removed, make sure to use a cleaning solution that will not damage the camshaft bushing(s).

Follow the manufacturer’s operating instructions for the cleaning tank.

Follow the solvent manufacturer’s instructions for using the solvent.

NOTE: Cummins Inc. does not recommend any specific cleaning solution. Experience has shown the best results are obtained by the use of a cleaning solution that can be heated from 80 to 95°C [176 to 203°F] and a cleaning tank that will mix and filter the cleaning solution.

Clean the cylinder block in the cleaning tank.

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.

CAUTION  To reduce the possibility of engine damage, make sure all debris is removed from the capscrew holes and oil passages.

Remove the block from the cleaning tank.

Use steam to clean the block thoroughly.

Use compressed air to dry the block.

With the cylinder block cleaned, inspect the cylinder block for signs of cracks, fretting, and discoloration that would prohibit reuse.

To help identify cracks in the cylinder block, use the crack detection kit, Part Number 3375432.

Give special attention to areas of the block that include:

• Main bearing caps and bores
• Camshaft bores
• Cylinder bores
• Tappet bores
• Cylinder block combustion deck
• Oil pan mounting surface
• Lubricating oil pump mounting area
• Water pump mounting area
• Front and rear of block sealing surfaces
• Lubricating oil cooler cavity.

Make sure to inspect the main bearing caps and main bearing saddle areas for cracks, fretting and signs of discoloration.

If any cracks are found, the block must be replaced.

Inspect all threaded capscrew holes for damaged threads. Coiled thread inserts may be used to repair any damaged threads.

Service tool thread repair kits are available:

1. Part Number 3377905 for standard threads.
2. Part Number 3377903 for metric threads.

NOTE: Coiled thread inserts should not be used to repair main bearing saddle threaded capscrew holes. If damaged, the block must be replaced.

Inspect the camshaft bores for scoring, scuffing, or excessive wear.

If the camshaft bore is damaged, the cylinder block must be replaced. Oversize cam bushings are not available.

Inspect the counterbore for extreme wear or cracks.

If surface C has signs of extreme wear, the counterbore will require machining and the installation of shims for the correct liner protrusion. See the Repair section of this procedure.

All measurements of the cylinder block must be made when the cylinder block is positioned on a flat surface with the main bearing caps installed.

If the cylinder block is mounted on the engine stand and/or the main bearing caps are not installed, the measurements can be incorrect because of distortion to the cylinder bores, main bearing bores, camshaft bores, etc.

Inspect the cylinder block head deck for damage.

Check the cylinder block head deck for flatness between each cylinder.

Inspect for any localized dips or imperfections. If any damage is detected, or the flatness is out of specification, the cylinder block must be replaced.

Measure the cylinder liner bore in the block.

Cylinder Liner Bore in Block (Press Fit Bore)

NOTE: If any of the cylinder liner bores are out of specification, the cylinder block must be replaced.

Measure the liner counterbore depth.

Cylinder Block Counterbore Depth from Cylinder Block Head Deck

NOTE: If any of the liner counterbore depths are out of specification, the counterbore can be machined and shims installed. See the Repair section of this procedure.

Measure the camshaft bores without the camshaft bushing installed.

Camshaft Bore Diameter (Without Bushing)

NOTE: If any of the camshaft bore diameters are out of specification, the cylinder block must be replaced.

Inspect the tappet bores for scoring or excessive wear.

Measure the tappet bores.

Tappet Bore Diameter

NOTE: If any of the tappet bores are out of specification, the cylinder block must be replaced.

Install the main bearing caps without the main bearings. Refer to Procedure 001-006 in Section 1.

Tighten the main bearing cap capscrews.

Measure the main bearing bore with the bearings removed.

Main Bearing Bore Diameter

NOTE: The maximum bore misalignment is 0.0127 mm [0.005 in].

If the counterbores require machining, use counterbore cutter, Part Number 3163785, to machine the counterbore to the proper depth.

Cylinder liner shims are available in the following thicknesses.

If the cylinder block is not to be used right away, coat all machined surfaces with a rust preventative solvent.

Make sure to cover the cylinder block to prevent dust and debris from collecting on and in the cylinder block.

New Cylinder Block

If replacing the cylinder block or using a previously stored cylinder block, make sure to clean any oil/rust preventative solvent from the cylinder bores, gasket sealing areas, and main bearing bores prior to use.

• Assemble the engine. See Section AS – Engine Assembly.
• Remove the engine from the engine stand and install the engine. Refer to Procedure 000-002 in Section 0.