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9 Service Manual

(/qs3/pubsys2/xml/en/manual/3666087/3666087-titlepage.html)

General Information
The cylinder block uses bored cylinders as opposed to liners.
In the event of damage or wear out, the cylinders may be able
to be repaired.
For B3.9, B4.5, and B5.9 engines, the cylinders can be bored
oversize twice for the use of over size pistons and rings (0.5
mm [0.020 in]) and 1 mm [0.040 in] oversize). A repair sleeve
can also be installed if the cylinder bore must be bored more
than 1 mm [0.040 in] oversize. See the Overbore and/or Repair
Sleeve section of this procedure.
For B4.5 RGT engines, the cylinders can only be bored
oversize once for the use of oversize pistons and rings (0.5
mm [0.020 in] over size). A repair sleeve can be installed if the
cylinder bore must be bored more than 0.5 mm [0.020 in]
oversize. See the Overbore section in this procedure.

Initial Check
Prior to removing the piston and connecting rod assemblies,
measure and record piston protrusion. Refer to Procedure 001-
054 in Section 1. (/qs3/pubsys2/xml/en/procedures/40/40-001-
054-tr.html)
Measuring piston protrusion prior to disassembly will aid in
determining if the cylinder block, if required, can be resurfaced.

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Preparatory Steps
Remove the engine and place on an engine stand. Refer
to Procedure 000-001 in Section 0.
(/qs3/pubsys2/xml/en/procedures/40/40-000-001.html)
Disassemble the engine. See Section DS - Engine
Disassembly.

Initial Check:
Before cleaning or further disassembly of the block, perform a
visual inspection to see if there is any damage (cracks, fretting,
etc.) that would prohibit reuse. Paying close 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.

Clean and Inspect for Reuse

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

If it is necessary to thoroughly clean the cylinder block for

reuse due to excessive debris or contamination, remove all
pipe plugs, expansion plugs and straight thread plugs as
necessary. Make sure all oil and coolant passages are cleaned
out.

Use the following procedures for removal and installation of

plugs. Refer to Procedure 017-002
(/qs3/pubsys2/xml/en/procedures/40/40-017-002.html). Refer

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to Procedure 017-007 (/qs3/pubsys2/xml/en/procedures/40/40-

017-007.html). Refer to Procedure 017-011
(/qs3/pubsys2/xml/en/procedures/100/100-017-011.html).

 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.

Use clean solvent and a nonmetallic 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 serious 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 

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Use a cleaning solution that will not damage the camshaft

bushings.

Follow the equipment manufacturer operating instructions for

the cleaning tank.

Follow the solvent equipment manufacturer instructions for

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

 WARNING 
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause 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 cylinder block thoroughly.

Use compressed air to dry the block.
Note : If the cylinder block is not going to be used
immediately, apply a coating of preservative oil to
prevent rust. Cover the block to prevent dirt from
sticking to the oil.

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With the cylinder block cleaned, inspect the cylinder block

again for signs of cracks, fretting, and discoloration that will
prohibit reuse.

To help identify cracks in the cylinder block, use the Crack

Detection Kit, Part Number 3375432.

Pay close 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 cylinder 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 threaded insert kits are available:

1. Part Number 3377905 for standard threads

2. Part Number 3377903 for metric threads.
Note : Coiled thread inserts must not be used to repair
main bearing saddle threaded capscrew holes. If
damaged, the block must be replaced.

Inspect the cylinder bores for glazing.

A surface without glaze will have a crosshatched appearance
with the lines at 25- to 30-degree angles with the top of the
cylinder bore.

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If deglazing is required, see the Deglazing section, located

later in this section.

Inspect the camshaft bores for scoring, scuffing or excessive

wear.

If damage to the camshaft bores is found and a camshaft

bushing was not previously installed, machine the camshaft
bores over size to install standard camshaft bushings. See the
Measure step of this procedure for specifications.

If the damage to the bore(s) is beyond machining, or if a

camshaft bushing was previously installed, the block must be
replaced. Oversize cam bushings are not available.

Measure
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, and torque plate 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. (Cylinder bores, main bearing
bores, camshaft bores, etc).

Inspect the camshaft bores without the camshaft bushing

installed.
Use the following procedure for specifications. Refer to
Procedure 001-010 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-001-010-tr.html)

Inspect the tappet bores for scores or excessive wear.

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Measure the tappet bores.

Tappet Bore Diameter

mm in
16.000 MIN 0.630
16.055 MAX 0.632

Note : If the tappet bores are out of specification, the

block must be replaced.

Install the main bearing caps without the main bearings. Use
the following procedure for main bearing installation. Refer to
Procedure 001-006 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-001-006.html)
Tighten the main bearing cap capscrews.
Torque Value: 176 n•m [ 130 ft-lb ]
Measure the main bearing bore with the bearings removed.

Main Bearing Bore Diameter with Bearings Removed

mm in
87.983 MIN 3.4639
88.019 MAX 3.4653

Note : If the main bearing bore diameters are not within

specification, check if the main bearing caps where
installed in the proper location and orientation. If main
caps are installed properly, the block must be replaced.

Main Bearing Capscrew Reuse Measurement

 CAUTION 
This step must be completed on B4.5 RGT engines.
Failure to check the main bearing capscrew against reuse
guidelines can result in severe engine damage.

To check if a main bearing capscrew can be reused, the length

must be measured by performing the following:

For each main bearing capscrew that has been removed,

measure the length from underneath the head of the capscrew
to the tip of the capscrew, as illustrated, use one of two
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methods:

1. A depth micrometer (preferred method for accuracy)

2. A machinist's rule.
If the measurement is above the maximum specification, the
main bearing capscrew must be replaced.

Main Bearing Underhead Capscrew Length

mm in
120.00 MAX 4.724

Measure the cylinder block's overall flatness.

Cylinder Block Flatness

mm in
End-to-
0.076 MAX 0.003
End
Side-to-
0.051 MAX 0.002
Side

Inspect for any localized dips or imperfections. If present, the

deck must be resurfaced.

For B3.9, B4.5, and B5.9 series engines, oversize head

gaskets are available for resurfacing of the cylinder head and
cylinder block combustion decks.

oversize head gaskets must be used to make sure the correct

piston to cylinder head clearance can be maintained.

Use a dial bore gauge accurate to within .001 mm [0.0001 in],

calibrated with an appropriately sized master ring, to measure
the cylinder bore in four places, 90 degrees apart, at the top
and bottom of the piston travel area.
When measuring, deglazing, or boring, a cylinder block, make
sure all of the main bearing caps, Cummins® cylinder head
torque plate, and cylinder head gasket, are in place and
properly torqued. Use the following procedures for proper
torque values. Refer to Procedure 001-006
(/qs3/pubsys2/xml/en/procedures/40/40-001-006.html)in

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Section 1. Refer to Procedure 002-004

(/qs3/pubsys2/xml/en/procedures/40/40-002-004-tr.html) in
Section 2.
After machining, the cylinder block is stamped at the upper
rear right corner surface of the cylinder block as follows:
A. Standard none
B. 0.25 mm [0.010 in] machined for the first over size gasket
X
C. 0.50 mm [0.020 in] total for the second over size gasket
XX.

For B4.5 RGT series engines, the combustion deck of the

block can only be resurfaced if, after the resurface, the correct
piston protrusion can be achieved.
A specific head gasket with an increased thickness is not
available for combustion deck resurfacing. If the combustion
deck can not be resurfaced such that the correct piston
protrusion can be achieved, the cylinder block must be
replaced.

B3.9, B4.5, and B5.9 Series Engines

 CAUTION 
Do not measure the bore diameter within 50 mm (1.97 in)
of the block combustion deck. Inaccurate measurements
will result.

Use a dial bore gauge accurate to within .001 mm [0.0001 in],

calibrated using an appropriately sized master ring, to
measure the cylinder bore in four places, 90 degrees apart, at
the top and bottom of the piston travel area.

When measuring, deglazing, or boring a cylinder block, make

sure all of the main bearing caps, Cummins® cylinder head
torque plate, and cylinder head gasket are in place and
properly torqued. Use the following procedures for proper
torque values:
Refer to Procedure 001-006
(/qs3/pubsys2/xml/en/procedures/40/40-001-006.html)in
Section 1.

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Refer to Procedure 002-004

(/qs3/pubsys2/xml/en/procedures/40/40-002-004-tr.html) in
Section 2.

Inspect the cylinder bores for damage or excessive wear.

Cylinder Bore Diameter - B3.9, B4.5, and B5.9 Series

Engines Only (New Cylinder Block)
mm in
101.995 MIN 4.0155
102.045 MAX 4.0175

Cylinder Bore Diameter - B3.9, B4.5, and B5.9 Series

Engines Only (Used Cylinder Block)
mm in
101.995 MIN 4.0155
102.070 MAX 4.0185

Out-of-Roundness
mm in
0.038 MAX 0.0015

Taper
mm in
0.076 MAX 0.003

Note : For B3.9, B4.5, and B5.9 Series Engines, the

cylinders can be bored oversize twice for the use of
oversize pistons and rings (0.5 mm [0.020 in] and 1 mm
[0.040 in] over size). A repair sleeve can also be
installed if the cylinder bore must be bored more than 1
mm [0.040 in] oversize. See the Overbore and/or Repair
Sleeve section in this procedure.

B4.5 RGT Series Engines

 CAUTION 
Do not measure the bore diameter within 50 mm (1.97 in)
of the block combustion deck. Inaccurate measurements
will result.

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Note : When measuring, deglazing, or boring a cylinder

block, make sure all of the main bearing caps are in
place and properly torqued. Refer to Procedure 001-006
(Bearings, Main) in Section 1 for proper torque values.
(/qs3/pubsys2/xml/en/procedures/40/40-001-006.html)
Inspect the cylinder bores for damage or excessive wear.
Use a dial bore gauge to measure the cylinder bore in four
places, 90 degrees apart, at the top and bottom of the piston
travel area.

Cylinder Bore Diameter - B4.5 RGT Series Engines

Only (New Cylinder Block)
mm in
106.990 MIN 4.2122
107.010 MAX 4.2130

Cylinder Bore Diameter - B4.5 RGT Series Engines

Only (Used Cylinder Block)
mm in
106.990 MIN 4.2122
107.030 MAX 4.2138

Out-of-Roundness
mm in
0.038 MAX 0.0015

Taper
mm in
0.076 MAX 0.003

Note : For B4.5 RGT Series Engines, the cylinders can

only be bored oversize once for the use of oversize
pistons and rings (0.5 mm [0.020 in] oversize). A repair
sleeve can be installed if the cylinder bore must be
bored more than 1.5 mm [0.020 in] oversize. See the
Overbore and/or Repair Sleeve section of this
procedure.

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Repair
 CAUTION 
Precautions must be taken to prevent debris from any
reconditioning operation from entering the lubricating oil
passages of the engine. Engine damage will result.

Prior to any reconditioning of the cylinder bores, make sure to

cover the lubricating holes and tappet holes in the top of the
cylinder block with waterproof tape.

Deglaze:

Deglazing gives the cylinder bore the correct surface finish

required to seat the piston rings. Deglazing must only be
performed if the cylinder bores are still in specification.
Note : New piston rings will not seat in glazed cylinder
bores.

Use ball type hone and a rotational speed of 300 to 400 RPM
with a stroke frequency of one stroke up and down per second.
Make sure to use a good grade of honing oil or a mixture of
equal parts SAE 30W engine oil and diesel fuel for a honing
lubricant.
Note : Vertical strokes must be smooth, continuous
passes along the full length of the cylinder bore.
Inspect the cylinder bore after 10 strokes.
Note : The crosshatch angle is a function of drill speed
and how fast the hone is moved vertically. Moving too
fast or too slow will give an incorrect crosshatch angle.
A correctly deglazed surface will have a crosshatched
appearance with the lines at 25- to 30-degree angles with the
top of the cylinder block.

Overbore:
If the cylinder bore was found out of specification or damaged,
the cylinder bore can be refinished for oversize pistons and
piston rings.

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Boring must be done by qualified personnel on a suitable

boring machine. Care must be taken to make sure the
cylinders are perpendicular to the combustion deck and within
taper and out-of-round specifications for the cylinder bore.

Follow the boring machine manufacturer's recommendations

for machine setup to achieve the best quality bore.

Note : The boring diameters given below are not the

finished cylinder bore dimensions. The finished cylinder
bore diameter will be reached through the final honing
operation.
The boring diameter dimensions are as follows:
Note : Maximum cutting depth must be limited to 0.228
mm [0.009 in] per cut.
B3.9, B4.5, and B5.9 Series Engines Boring Diameter
mm in
First
102.469 NOM 4.0342
Rebore
Second
102.969 NOM 4.0539
Rebore

B4.5 RGT Series Engines Boring Diameter

mm in
Rebore 107.45 NOM 4.2303

After boring, use a honing stone to break the edge of the bore
to approximately 1.25 mm [0.049 in] at 15 degrees.

Repair Sleeve:
If more than 0.50 mm [0.020 in] in diameter oversize bore is
required, the cylinder block must be rebored and a repair
sleeve installed. The installation of a repair sleeve will allow for

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the use of standard size pistons and piston rings.

Note : Main bearing caps must be in place and
properly torqued prior to any boring or measuring
operations.

 CAUTION 
Boring must be done by qualified personnel on a suitable
boring machine. Care must be taken to make sure that
cylinders are perpendicular to the combustion deck and
within taper and out-of-round specifications for the
cylinder bore.

To prepare for repair sleeve installation, bore the cylinder(s)

requiring a repair sleeve to:

Cylinder Bore Diameter (A)

mm in
109.700 MIN 4.3189
109.715 MAX 4.3195

To a depth of:

Cylinder Bore Depth (B)

mm in
192.65 MAX 7.5846

This will result in a step at the bottom of the cylinder,

approximately 6.35 mm [0.25 in] thick (C), against which the
repair sleeve will sit.

After boring, thoroughly clean the bore of all metal chips,

debris and oil before installing the repair sleeve(s).

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Apply a coat of Loctite 620 to the top of the cylinder bore, one
at a time as the sleeve is installed.

Use a sleeve driver, Part Number 3823230 for 102 mm [4.02

in], and Part Number 2892407 for 107 mm [4.21 in], to press or
drive the repair sleeve into the cylinder bore until it contacts the
step in the bottom of the bore.

Bore the installed sleeve to 106.880 mm [4.2079 in].

Machine the top of the sleeve to less than 0.050 mm [0.0019

in] protrusion above the combustion deck.

After boring, use a honing stone to break the edge of the bore
to approximately 1.25 mm [0.049 in] at 15 degrees.

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After boring a cylinder oversize or boring a repair sleeve, the

cylinder requires a two stage honing process to finish the
cylinder bores. It is recommended that quality equipment
intended for honing engine cylinder bores be used.
Note : Use of a ball-type hone is only recommended for
refinishing cylinder walls that do need reboring and/or
the installation of a repair sleeve.

A correctly finished cylinder bore surface will have a

crosshatched appearance with the lines at 25- to 30-degree
angles with the top of the cylinder block.

After Deglazing/Finishing Honing, use a strong solution of hot

water and laundry detergent to clean the cylinder bores.

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

 CAUTION 
Clean the cylinder bores immediately after
deglazing/finish honing. Failure to do so can result in
engine damage.

Rinse the cylinder bores until the detergent is removed.

Dry the cylinder block with compressed air.

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

 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 
Be sure to remove the tape covering the tappet holes after
the cleaning process is completed. Failure to do so can
result in engine damage.

Check the cylinder bore cleanliness by wiping with a white, lint-

free, lightly oiled cloth. If grit residue is still present, repeat the
cleaning process until all residue is removed.
Wash the cylinder bores with solvent. Dry the cylinder block
with compressed air.

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.

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.

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After boring a cylinder oversize, the cylinder requires a two

stage honing process to finish the cylinder bores. It is
recommended that quality equipment intended for honing
engine cylinder bores be used.
Note : Use of a ball-type hone is only recommended for
refinishing cylinder walls that do need reboring and/or
the installation of a repair sleeve.

Honing Process for B3.9, B4.5, and B5.9 Engines

Use a honing rotational speed of 300 to 400 RPM with a stroke
frequency of 1 stroke up and down per second. Make sure to
use a good grade of honing oil. For the first stage honing, or
rough honing, use a soft (fast cutting) 80 grit silicone carbide
stone. Hone the cylinders to their final size during this stage of
honing.
For the second stage honing, or finish honing, use a medium
hardness 285 grit silicone carbide stone. Hone the cylinder(s)
for 15 to 20 strokes to apply the appropriate crosshatch.

Honing Diameter Dimensions B3.9, B4.5, and B5.9

Series Engines
mm in
Standard
Bore/Repai 102.000 MIN 4.0157
r Sleeve
102.040 MAX 4.0173
First
102.500 MIN 4.0354
Rebore
102.540 MAX 4.0370
Second
103.000 MIN 4.0551
Rebore
103.040 MAX 4.0567

Honing Diameter Dimensions B4.5 RGT and B6.7

Series Engines
mm in
Standard
Bore/Repai 106.990 MIN 4.2122
r Sleeve
107.010 MAX 4.2130
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Rebore 107.490 MIN 4.2319

107.510 MAX 4.2327

Honing Process for B6.7 and B4.5 RGT Engines

For the first stage honing, or rough honing, use a 160 grit diamond honing stone. Hone the
cylinders to 106.9873 maximum.
For the second stage honing, or finish honing, use a 280 grit silicon carbide stone. Hone the
cylinders to 106.990 minimum 107.000 maximum. Use a Plateau Honing Tools (PHT) brush for
10 to 12 strokes.

A correctly finished cylinder bore surface will have a

crosshatched appearance with the lines at 25- to 30-degree
angles with the top of the cylinder block.

After Deglazing/Finishing Honing, use a strong solution of hot

water and laundry detergent to clean the cylinder bores.

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

 CAUTION 
Clean the cylinder bores immediately after
deglazing/finish honing. Failure to do so can result in
engine damage.

Rinse the cylinder bores until the detergent is removed.

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Dry the cylinder block with compressed air.

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

 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 
Be sure to remove the tape covering the tappet holes after
the cleaning process is completed. Failure to do so can
result in engine damage.

Check the cylinder bore cleanliness by wiping with a white, lint-

free, lightly oiled cloth. If grit residue is still present, repeat the
cleaning process until all residue is removed.
Wash the cylinder bores with solvent. Dry the cylinder block
with compressed air.

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.

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.

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Finishing Steps
Assemble the engine. See Section AS - Engine Assembly
Remove the engine from the stand and install the engine.
Refer to Procedure 000-002 (Engine Installation) in
Section 0. (/qs3/pubsys2/xml/en/procedures/40/40-000-
002.html)

Last Modified: 28-Jun-2019

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