Module 9 - Compr&i

QSV Diesel Engines
Module 9 - Component R & I
Cummins Corporate Training
QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

Component Removal & Installation Module
Learning Objectives
In this module you will be guided through the ‘key’ steps in removal
and installation of a number of service components. You will apply
this knowledge in a practical exercise to give complete understanding
of the theory and practice involved.
Agenda
☛ Key Steps to;
Cylinder Head,
Valve & Injection Timing Check,
Piston, Rod & Cylinder Liner,
V16 & V18 Flywheel Assembly,
Turbo Axial / Radial Clearances,
Fitters Notebook - Tips and upgrades.

D / R & I / BMG / 01-01 / Rev. 03

2
Cylinder Head Removal (1)
KE
Y
ST
EP
S
☛ Lockout engine as isolation
procedure, drain coolant. Warning:
Ensure Temp < 50º C (122º F).
☛ Dismantle any interfering exhaust
insulation covers for access.
☛ Rotate to TDC combustion,
remove rocker lever assembly, lift
off intake & exhaust crossheads
and push rods.
☛ Unscrew 2x27mm fittings and
remove injector supply line, then
transfer tube from injector.
☛ Draw push rod tubes vertically
through head openings, remove
O-rings from openings.

D / R & I / BMG / 01-01 / Rev. 03

3
KE
Y
ST
EP
☛ Using tool (SPC 837001) remove
S
injector.
☛ Dismantle coolant vent lines for
access, then remove (6) 8mm
multi-duct screws and spacers.
Note: One is located at bottom
between intake & exhaust
passages.
☛ Remove rocker assembly oil
supply line and injector drain line
from pump.
☛ Fit hydraulic sleeves and cylinders
to head bolts in line with bolt
tensioning procedure, pressurise to
890Bar (13083 psi) and remove (4)
head nuts.

D / R & I / BMG / 01-01 / Rev. 03

4
KE
Y
ST
EP
S
☛ Attach head lifting tool
(SPC 832004) to rocker fixing holes.
☛ Attach sling to top eyebolt to
maintain head angle and lift head
from block.
☛ Note: Remove copper head gasket.
Cover the cylinder to prevent ingress
of dirt.

D / R & I / BMG / 01-01 / Rev. 03

5
Cylinder Head Installation (1)
KE
Y
ST
EP
☛ Install new copper head gasket, new
S
water O-ring and new multi-duct
gasket. Clean head and liner mating
surfaces.
☛ Replace head in reverse order to
removal paying particular attention to
the following;
☛ a) Fit hydraulic sleeves, cylinders and
tension following the tensioning
procedure: 1st stage 785Bar
(11540psi), 2nd stage 870Bar
(12789psi).
☛ b) Lubricate multi-duct capscrews with
anti-seize lubricant, torque to 64Nm
(47ft.lbs.).
☛ c) Fit new O-ring to injector transfer
tube, torque to 60Nm (45ft.lbs.).

D / R & I / BMG / 01-01 / Rev. 03

6
Cylinder Head Installation (2)
KE
Y
ST
EP
S
☛ d) Fit injector supply line to procedure,
torque to 50Nm (38ft.lbs.).
☛ e) Install new push rod O-rings to head.
Externally lubricate push rod tubes,
install through head to multi-housing.
☛ f) Adjust valves to procedure.
☛ g) Replace all covers and head stud
protecting caps (if fitted).

D / R & I / BMG / 01-01 / Rev. 03

7
Determination of TDC
KE
Y
ST
EP
S
☛ To check flywheel pointer is set correctly
(two fixing positions on ‘V’ engine).
☛ Install TDC indicator tool (SPC 848004)
in place of B1 injector.
(Tool tracks from approximately 45º
BTDC).
☛ Engage barring mechanism and turn
in direction of rotation (A/C) to
approximately 15º BTDC. Mark position of
indicator on tool, note flywheel reading.
☛ Rotate engine A/C over TDC to line tool
pointer with mark. Take flywheel reading.
☛ 0º TDC is centre of two flywheel readings,
i.e. 345 - 0 - 15.

D / R & I / BMG / 01-01 / Rev. 03

8
Injection & Valve Timing
KE
Y
ST
EP
S
☛ Remove the camshaft cover - flywheel-end.
☛ Remove B1 multi-housing by disconnecting
oil, air and fuel return lines. Remove fuel rail
circlips and slide aside rail collars, then
unscrew the four M10 fixing bolts.
☛ Install timing tool (SPC 848008) to block in
place of multi-housing. Fit DTI to clock tool
plunger position using magnetic base .
☛ Zero DTI, with cam on base circle (off cam).
☛ Rotate engine in direction of rotation (A/C)
to 4.0 mm (0.157 in) lift on DTI.
☛ Check cam gear does not move, may need
to break cam gear bolts before setting
camshaft position.
Torque cam drive/intermediate
gear 1st -76Nm, 2nd - 650Nm.

D / R & I / BMG / 01-01 / Rev. 03

9
Injection & Valve Timing
KE
Y
ST
EP
☛ Loosen the 6 cam gear bolts, rotate
S
engine to 16.0º BTDC (B1 firing), lock cam
gear bolts.
☛ CHECK - For cam lift, 8.28mm @ TDC.
☛ Always repeat complete procedure above
on the last (free-end) cylinder if the
camshaft has been removed or
dismantled.
☛ For ‘V’ engines repeat on A-bank. Cylinder
A1 fires immediately after B1.
☛ ABOVE SETTINGS FOR 1740 & 1800
RPM ENGINES.
☛ FOR 1500 / 1600 / 1650 RPM ENGINES Note: Both the timing procedure
SET; 4.0mm lift @ 14.0º BTDC and settings are different on Gas
engines. Refer to QSV Gas.
☛ CHECK- for cam lift 7.68mm @ TDC
☛ Refer to Data & Specification Section

D / R & I / BMG / 01-01 / Rev. 03

10
QSV Series - Connecting Rod
KE
Y
ST
EP
Features (End view of fasteners in rod)
S
* 4 Bolt cap fixing. • 50Nm / 120Nm / 220Nm
* Straight split design.

* No removal through liner, remove
piston, rod and liner as one assembly.
* Fully balanced, steel one-piece
casting with pressure lubricated piston 1 3
pin bush, crank feed directly to rod 4 2
( NOT via Cap).
☛ Installation - Clean and lubricate all parts with E.P. oil (NOT back of
bearing)
☛ Bar engine over to give access through hand hole cover.
☛ Lubricate bolt head (SAE 140 EP) & thread (SAE30W), torque cross
pattern 50Nm /120Nm/ 220Nm. Check Tight at 220Nm.

D / R & I / BMG / 01-01 / Rev. 03

11
Piston Rod and Liner - Removal
KE
Y
ST
EP
S
☛ Lockout engine as isolation procedure,
drain coolant & oil. Warning: Ensure
Temp < 50º C (122º F).
☛ Remove cylinder head to procedure.
☛ Remove crankshaft inspection cover.
☛ Cover piston with lint free cloth and
remove anti-polishing ring using slide
hammer with 3 external legs to locate
on machined groves.
☛ Clean any remaining carbon with nylon
pad, carefully remove lint cloth.
☛ Use solvent to clean piston lifting holes
(2 x M8) in piston crown as necessary.
☛ Engage barring gear and rotate engine
to give access to connecting rod cap
screws with wrench. 6-34/2

D / R & I / BMG / 01-01 / Rev. 03

12
KE
Y
ST
EP
☛ Loosen the four 19mm star headed cap
S
screws from the connecting rod cap.
Now bar engine to just before T.D.C.
☛ Install piston / liner assembly lifting tool
(SPC 836100) to piston and clamp to
liner rim. Tighten threaded ring to lock
assembly in place.
☛ Engage barring gear and slowly rotate
engine to TDC position to lift piston, rod
& liner assembly from block.
Warning! Never try to break the liner to
block seal using the lifting tool and hoist.
☛ Support rod cap from both sides,
remove the four cap screws, lift cap out
through hand hole cover.
☛ Mark cylinder No on bearing cap &
bearing tang for identification.

D / R & I / BMG / 01-01 / Rev. 03

13
KE EPS
ST
Y
☛ Attach sling to lifting tool and lift assembly
clear of block.
☛ Remove piston / liner tool.
Caution !
☛ Take care that the piston crown does NOT
go past the top edge of the piston liner
otherwise the fire ring will catch in the liner
seat for the anti-polishing ring, locking the
piston in the liner.

D / R & I / BMG / 01-01 / Rev. 03

14
Cylinder Liner Inspection
KE
Y
ST
EP
S
☛ Visually inspect internal walls for wear
or damage. Replace liner if bores are
worn or glazed.
☛ Inspect outer wall for corrosion wear
(cavitation damage). Brush off
deposits from outer surface.
☛ Check liner inside diameter for ovality,
at top, middle and bottom using dial
bore gauge. Two measurements at 90º
apart for each location.
☛ Install three new O-rings.
☛ NOTE: If more than one liner has been
removed check that liners are installed
in the same cylinders. Liners are
marked with cylinder numbers, if no
markings can be found mark on
removal.

D / R & I / BMG / 01-01 / Rev. 03

15
Piston Rod and Liner - Install
KE
Y
ST
EP
☛ Install piston assemblies into the same liners
S
from which they were removed, the rods and
caps have cylinder numbers stamped on the
side.
☛ CTR mark to multi-duct (cooling nozzle cut-out).
☛ Apply film of oil to liner face and apply silicone
grease to O-rings. Immerse the piston in oil.
☛ Check seating surface of block for cracks.
Spread a bead of ORASEAL (or Wellseal ) on the
seating surface. TOP
☛ Note ‘TOP’ mark. Rotate piston rings so gaps are
120º apart and gap in oil ring expander is
opposite gap in oil ring.
☛ Install ring compressor (SPC 843002) to piston
assembly.
☛ Caution! Close the tool carefully, do not force
piston rings.

D / R & I / BMG / 01-01 / Rev. 03

16
KE
Y
ST
EP
S
☛ Invert liner and fit ring compressor to liner
base, lock in place with clamps. Slide
assembly into liner, do NOT remove ring
compressor to prevent piston rings locking in
anti-polishing ring seat.
☛ Rotate the whole assembly and install piston /
liner lifting tool (SPC 836100), lock in place
with clamp ring. Remove ring compressor tool.
☛ Locate upper bearing shell (with oil hole) in
rod, check tang is located centrally in grove.
Lubricate. Rotate crank pin to TDC.
☛ Using hoist, position assembly over cylinder
with piston crown “CTR” marking to the multi-
duct side.
☛ Guide assembly into position on crank pin,
check shell remains located & connecting rod
does not hit piston cooling nozzles.

D / R & I / BMG / 01-01 / Rev. 03

17
KE
Y
ST
EP
S
☛ Install lower bearing shell to cap,
lubricate. Install hand tight, slowly rotate
engine to pull liner to block face.
☛ Remove piston / liner lifting tool.
☛ Torque connecting rod cap bolts to
procedure.
☛ Important. Check rod has axial clearance
by testing for sideways movement.
(no lateral movement on crank pin must
be investigated and geometry checked).
☛ Install new anti-polishing ring .
☛ Fit new head gasket, reinstall cylinder
head to procedure.
☛ Replace crankshaft Inspection covers.
Torque to 100Nm (75ft.lbs.).
☛ Refill engine with oil and coolant.

D / R & I / BMG / 01-01 / Rev. 03

18
Flywheel Flange Assembly
KE
(Diesel V16 & V18 Only)
Y
ST
EP
S
Locking
Assembly
Thrust Plate
Thrust Rings
F.W Flange
Dowel Pins
Fitted

D / R & I / BMG / 01-01 / Rev. 03

19
Flywheel Assembly Procedure
KE
Y
ST
EP
S
ASSEMBLY:
☛ Clean and lubricate all components with engine oil, except bore of thrust ring.
☛ Clean and grease bore of thrust ring with with Molykote BR2, assemble
locking assembly, thrust rings and flywheel flange with 20 x M16 Set Screws
hand tight.
☛ Push in the two dowel pins and assemble the thrust plate with its two screws.
☛ Fit dowel pin to flywheel flange (indicates first crank pin). Clean crankshaft
and locate assembly on crankshaft.
☛ Identify a first screw, starting with this screw tighten all screws to 40Nm in a
clockwise sequence (not diagonal) until no further movement occurs.

D / R & I / BMG / 01-01 / Rev. 03

20
Flywheel Assembly Procedure
KE
Y
ST
EP
☛ Begin tightening the OPPOSITE screw to the first one by increasing torque
S
50Nm, continue clockwise as before until no further movement.
☛ Repeat above in 50Nm steps up to the final torque of 240Nm, verify flange
total run-out at 4 points is no greater than 0.15mm on 240mm diameter.
☛ Lift flywheel into position, ensure correct location of dowel pin. Fit set screws
20 x M20 with Loctite M243 and torque to 544Nm.
☛ DISMANTLING:
☛ Remove the flywheel first.
☛ Important!
☛ Loosen the screws in sequence and in several steps to avoid tilting of the
thrust rings which would cause the assembly to lock in place.
☛ Under NO circumstances should the locking screws be completely removed
from the threads, pre-tensioning of the assembly could cause it to spring
apart without warning resulting in flywheel flange falling from the shaft.
☛ Clean and lubricate all components ready for re-use.
Remember: The L6 and L8 Flywheels are fixed by bolts to a crankshaft flange!

D / R & I / BMG / 01-01 / Rev. 03

21
Engine Supports
KE
Y
ST
EP
S
O-rings fitted in foot
to isolate oil
leakage from lateral
bolts (2-off centre
fixings only).
X2
Torque engine feet bolts to 350Nm.
Torque side bolts to 100 / 350Nm in sequence 0, 1, 2, 3... B-Bank first as procedure.

D / R & I / BMG / 01-01 / Rev. 03

22
ABB & Holset Axial / Radial Clearances
KE
Y
ST
EP
Check every 2,000 hrs
S
CLEARANCE TPS 48 TPS 52
A min 0.08 0.10
A max 0.16 0.18
B min 0.54 0.62
B max 1.22 1.35

Maa
WITH DIFFUSER FITTED (mm)
CLEARANCE DIFFUSER
HX 82
A min 0.051
A max 0.125
B min 0.485
B max 0.746
Maa
WITH DIFFUSER FITTED (mm)

Compressor Turbine

D / R & I / BMG / 01-01 / Rev. 03

23
THE FITTERS
NOTEBOOK
Updates and points to be aware of

C / Training Info / BMG / 01-01 / Rev. 03

The Fitters Notebook
Things to watch out for When ....!
Some engines produced before May 1998 utilised pistons

Engine that gave a 16:1 compression ratio and used 8-hole fuel
Timing injectors. These engines require an engine timing of
4.0mm fuel cam lift at 12.5º BTDC. ALWAYS check timing
code on data plate before adjustment.
Remember: All QSV Diesel engines are now 15:1.

D / R & I / BMG / 01-01 / Rev. 03

25
‘V’ engines are fitted with an anti-drain oil valve in the top of
Lube Oil the flywheel housing (return channel from LOM). The valve
Module operates at approximately 0.5Bar preventing the housing /
Removal filters from draining and drying when engine not in use. Not
required on ‘L’ engines because of LOM fill / return positions.
When removing LOM remove the filters and apply low
pressure air to the housing in order to overcome the drain
valve and completely drain the module.
Oil supply to
LOM
Oil return from

LOM to block
Position of
2 x O-rings

D / R & I / BMG / 01-01 / Rev. 03

26
Fitting Water and Oil Pump Driving Gears: Tighten lightly and align
hub. Then, in three stages in diametrically opposed sequence, to value
shown. Check no further tightening at final value.
Oil Pump Ringfader shown here

Clamping force is dependant on
cleanliness of all components. A similar
assembly is used on the water pump
gear. Clean and lightly lubricated
before assembly:
Oil Pump - Torque to 17Nm
Water Pump - Torque to 25Nm

D / R & I / BMG / 01-01 / Rev. 03

27
Removal: Removing and Assembly:
Caution! Mark caps to Assembling Install top bearings with
bearing site on block - manufacturers stamp / site
they are paired together. QSV Diesel number on flywheel-side.
Loosen lateral A-bank Main Bearings. Lubricate bearing surfaces
screws. Flywheel-End only with Vaseline. Lubricate
under head and threads of
Loosen lateral B-bank
side bolts with engine oil.
screws (Screws tightened
to 350Nm). Assemble caps hand tight,
pre-tighten B-bank side
Hydraulically loosen and
screws only to 100Nm.
remove cap nuts.
Hydraulically Tension caps in
Remove side screws and A B order - 0, 1, 2,.......etc.
caps.
Tighten B-bank side screws
Mark bearing tag with site
to 350Nm.
number for re-assembly.
Cap Stepped Cap Straight Tighten A-bank side screws
Side Side
to 350Nm.
CLEAN & LUBRICATE ALL PARTS THREADS AND JOURNALS

D / R & I / BMG / 01-01 / Rev. 03

28
Dowel
Installing Main pin hole
Bearing Shells
Tang position in the top half of

the shell is different to the tang
in the bottom half of the shell. In Tang
addition, one half (block) of the
shell has an oil groove around
the bearing surface, the other
half (cap) does not.
Cap has a single dowel pin
locating hole. Check alignment.
Upper bearing removal tool
available.

D / R & I / BMG / 01-01 / Rev. 03

29
The Fitter’s Notebook
i) On In-line engines the first standard bushing and on ‘V’
Fitting engines the first standard A-bank and last B-bank camshaft
bushings do NOT require an oil hole due to the ‘handing’ of
Camshaft the multi-housing (oil feed to head connection).
Bushings Note: Bushing kit has oil holes in all bushes.
ii) QSV Diesel bushings can be installed either way round, it
is good practice to install all with edge part number stamp
facing the same way, e.g. A-bank No’s to flywheel-end,
B-bank No’s to free-end.
iii) Use of liquid nitrogen eases installation. Immerse bushing
until nitrogen stops boiling, you have approximately 5
seconds to install. Important: Check oil hole alignment to
block with tapered pin.
Caution! Wear protective clothing and eye protection when
using liquid nitrogen to prevent direct contact.
Boiling Point: -196º C (-321º F).

D / R & I / BMG / 01-01 / Rev. 03

30
Piston skirt and crown is 4 View A
Piston and point fixing (with dowel). Rod oil
drilling
Rod Assembly Remember to assemble rod
correctly relative to the
piston. The lubricating hole
in the connecting rod must
be opposite the oil hole in
the underside of the piston
Crown
crown. View A oil hole
Remember to mark cylinder liners on disassembly

Liner and re-install in the same cylinder locations with the
Installation liner mark on the top edge opposite the multi-duct.
Important! Fit the bearing shell with the oil holes in

Connecting the rod not the cap (oil flow is directly into rod).
rod Cap Connecting rod caps are located using two dowel
Installation pins. Remember: Always check alignment and end
float after assembly.

D / R & I / BMG / 01-01 / Rev. 03

31
TEAM TASK
Practical Exercise

C / Training Info / BMG / 01-01 / Rev. 03

Practical Work Rules
☛ Use the barrier cream and protective clothing provided.

☛ Lifting and handling equipment provided for large and heavy items.
☛ When dismantling the engine always set out the work area first.
Working in an orderly manner will assist in re-assembly:
☛ 1) Spread clean paper on the ground to layout the parts as
removed.
☛ 2) Layout the components in sets, A1, A2, A3, etc. in the order of
removal, starting furthest away from the engine. Replacement is then
simplified by starting with the parts closest to the engine and working
outward.
☛ 3) Always replace bolts after parts have been removed, they are then
at hand for re-assembly!
☛ Make reference to the O & M manual for procedures and torque
values.

D / R & I / BMG / 01-01 / Rev. 03

33
QSV Diesel Engines MIDI Sequence
END

D / R & I / BMG / 01-01 / Rev. 03

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QSV Diesel Engines

Module 9 - Component R & I

Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

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D / R & I / BMG / 01-01 / Rev. 03

* Straight split design.

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

A max 0.16 0.18

B min 0.54 0.62

B max 1.22 1.35

WITH DIFFUSER FITTED (mm)

WITH DIFFUSER FITTED (mm)

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

QSV Diesel CUMMINS CORPORATION

C / Training Info / BMG / 01-01 / Rev. 03

Some engines produced before May 1998 utilised pistons

Remember: All QSV Diesel engines are now 15:1.

QSV Diesel CUMMINS CORPORATION

D / R & I / BMG / 01-01 / Rev. 03

Oil return from

QSV Diesel CUMMINS CORPORATION

Module 9 - Compr&i

Module 9 - Compr&i