Category Archives: Cummins 4BT

Inspect for abnormal wear on the heads and stems. Check the valve stem tip for flatness. Visually inspect for bent valves. Measure the rim thickness to determine if there is enough stock to grind the valve.  

Injector Bore Brush 3822509 Clean the carbon from the injector nozzle seat. Scrape the gasket material from all gasket surfaces. Clean the build-up of deposits from the coolant passages. Excessive deposits may be cleaned in an acid tank but the expansion plugs must first be removed. Clean the cylinder head combustion deck with a Scotch-Brite®… Read More »

The following disassembly and assembly procedures are provided for inspection purposes only. Refer to the Shop Manual, Bulletin No. 3810206, for complete rebuild in­ structions. Mark the valves to identify their location. Compress the valve spring and remove the valve stem collets. Remove the collets. Release valve spring and remove the retainer spring. Remove the… Read More »

Clean the cylinder head with solvent. Visually inspect the cylinder head for obvious damage that would prohibit reuse. Check for cracks and damage to the deck surface that would result in loss of sealing.  

Removal Preparatory Step: • Drain the coolant. • Remove all water and heater hoses. Remove the turbocharger and exhaust manifold. Refer to Procedures (7-05) and (7-06). Remove the injectors and fuel lines. 10 mm Remove the intake manifold cover and intake heater (if equipped). Note the manifold cover orientation for proper direction during installation. 3/8… Read More »

Removal Preparatory Steps: • Remove the turbocharger. Refer to Procedure (7-05). 13 mm Remove the mounting capscrews, exhaust manifold and gaskets. Cleaning Clean the gasket sealing surfaces. Installation “ Package” the exhaust manifold capscrews and gaskets on the manifold. Apply anti-seize compound to the cap­ screws. The bead on the exhaust manifold gasket can be… Read More »

Install the turbocharger gasket and apply anti-seize com­pound to the mounting studs. 15 mm Install the turbocharger. Torque Value: 45 N®m [33 ft-lb] 13 mm, 7/16 inch If required, loosen the turbine housing capscrews and the compressor housing clamp to position the bearing hous­ing for installation of the turbocharger drain tube. 10 mm Install the… Read More »

Remove the exhaust and intake air piping. 16 m m and 19 m m Remove the turbocharger lubricating oil supply line from the turbocharger and oil filter head. Screwdriver or 7/16 in Remove the air crossover tube or charge air cooler piping from the turbocharger. 10 mm Disconnect the lubricating oil drain tube from the… Read More »

Check/adjust the valves as indicated in the illustration (I = Intake, E = Exhaust). Tighten the locknut and measure the valve lash again. Torque Value: 24 N«m [18 ft-lb] Mark the pulley and rotate the crankshaft 360 degrees. Caution: To prevent engine or pin damage, be sure tim­ing pin is disengaged. Adjust the valves as… Read More »

14 mm, Flat Blade Screwdriver Locate Top Dead Center (TDC) for Cylinder Number 1. Check/adjust the valves as indicated in the illustration (I = Intake, E = Exhaust). Tighten the locknut and measure the valve lash again. Torque Value: 24 N»m [18 ft-lb] Mark the vibration damper and rotate the crankshaft 360 degrees. Caution: To… Read More »