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 engines displacing 3.9L and 5.9L, 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] 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, Note : For 5.9L engines with exhaust gas recirculation (EGR) and Marine applications, if boring the cylinder bores oversize or installing repair sleeves, a service specific head gasket must be used to make sure of proper sealing of the combustion seal. For engines displacing 4.5 L and 6.7 L, 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 0.5 mm [0.020 in] oversize. See the Overbore section of 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/44/44-001-054-tr htm!) Measuring piston protrusion prior to disassembly will aid in determining if the cylinder block, if required, can be resurfaced Preparatory Steps+ Remove the engine and place it on an engine stand. Refer to Procedure 000-001 in Section 0. (/qs3/pubsys2/xmi/en/procedures/44/44-000-001 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. 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. (Clean and Inspect for Reuse Inspect all pipe plugs, expansion plugs, and straight thread plugs for signs of damage or leaks. Ifit 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 Refer to Procedure 017-002 in Section 17, ('qs3/pubsys2/xml/en/procedures/44/44-017-002.html) Refer to Procedure 017-007 in Section 17. (/qs3/pubsys2/xml/en/procedures/44/44-017-007 html) Refer to Procedure 017-011 in Section 17. (/qs3/pubsys2/xmi/en/procedures/44/44-017-011.html)AXWARNING A 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 drilings. Thoroughly clean all gasket sealing surfaces of any remaining gasket residue. AXWARNING A This component or assembly weighs greater than 23 kg [50 Ib]. 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. AXWARNING AL 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. AXCAUTION A Use a cleaning solution that will not damage the camshaft bushings. 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 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. AXWARNING AL #3 GRAPHIC NOT FOUND When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. AXWARNING AV Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. AXCAUTION A 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 used immediately, apply a coating of preservative oil to prevent rust. Cover the block to prevent dirt from sticking to the oil 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. 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: + Part Number 3377905 for standard threads * 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. If deglazing is required, see the Deglazing information in the Repair section of this procedure. 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 oversize to install standard camshaft bushings. See the Measure section 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 the torque plate installed. If the cylinder block is mounted on the engine stand andlor 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 Camshaft Bore Diameter without Camshaft Installed (Maximum) Camshaft Bore (Camshaft Bushing Previously Installed) 59.248 MAX 2.3326 Camshaft Bore (Camshaft Bushing not. Previously Installed) 54.164 MAX 2.1324 Ifa camshaft bushing was previously installed and the camshaft bore is out of specification, the block must be replaced. Oversize cam bushings are not available. Ifa camshaft bore in which a camshaft bushing was not previously installed is damaged or out of specification, the camshaft bore can be machined oversize to install a standard camshaft bushing Machine the damaged bore to a maximum of 59.248 mm (2.3326 in) to accept a standard bushing. Nia ? foun Inspect the tappet bores for scores or excessive wear. Measure the tappet bores. Tappet Bore Diameter mm in‘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. Refer to Procedure 001-006 in Section 1 (/qs3/pubsys2/xmi/en/procedures/44/44-001-006.html) Tighten the main bearing cap capscrews, [Torque Value: 176 nem [130 ft1b] 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 were installed in the proper location and orientation. If main caps are installed properly, the block must be replaced Main Bearing Capscrew Reuse Measurement AXCAUTION A This step must be completed on 4.5L and 6.7L 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 methods: 1. A depth micrometer (preferred method for accuracy) 2. Amachinist's rule. Contact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 Endeto- 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. Note : The combustion deck of the block can only be resurfaced if one of the two following criteria are met 1. After the resurface, the correct piston protrusion can be achieved. 2. For engines that use graded head gaskets, the next thickness head gasket can be used to achieve the correct piston protrusion. 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 reached, the cylinder block must be replaced. 3.9L and 5.9L Engines AXCAUTION A Do not measure the bore diameter within 50 mm [1,97 in] of the block combustion deck. Inaccurate measurements will result. Inspect the cylinder bores for damage or excessive wear. 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 in Section 1. Refer to Procedure 002-004 (Iqs3/pubsys2/xmi/en/procedures/44/44-002-004.himl) in Section 2. Cylinder Bore Diameter - 3.9L and 5.9L Engines Only (New Cylinder Block) mm in 101.995 MIN 4.0155 102.045 MAX 4.0175 Cylinder Bore Diameter - 3.9L and 5.9L 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 engines displacing 3.9L and 5.9L, 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] 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 sections of this procedure AXCAUTION A Some 5.9L engines require a service specific head gasket if boring the cylinder bores oversize or installing repair sleeves. Failure to use the correct head gasket will result in engine damage. AXCAUTION ALSome 5.9L engines, require a service specific head gasket if boring the cylinder bores oversize or installing repair sleeves, The service gasket must be used to ensure proper sealing of the combustion seal. To identify if a service specific head gasket is needed, visually check the previously removed head gasket. If the combustion seal has a non-circular shape, as illustrated, a service gasket must be used. 4.5L and 6.7L Engines AXCAUTION A Do not measure the bore diameter within 50 mm (1.97 in) of the block combustion deck. Inaccurate measurements will result. Note : When measuring, deglazing, or boring a cylinder block, make sure all of the main bearing caps and the torque plate are in place and properly tightened. Refer to Procedure 001- 006 in Section 1. (/qs3/pubsys2/xml/en/procedures/44/44-001- 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 - 4.5L and 6.7L Engines Only (New Cylinder Block) mm in 106,990 MIN 4.2122 107.010 MAX 4.2130 Cylinder Bore Diameter - 4.5L and 6.7L Engines (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 Taper in mm in 0.076 MAX 0.003 Note : For engines displacing 4.5L and 6.7L, 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 0.5 mm [0.020 in] oversize. See the Overbore and/or Repair Sleeve section of this procedure. Repair AXCAUTION A 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 a 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. 10 to 20) 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. Accorrectly 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. =——s By Boring must be done by qualified personnel on a suitable boring | machine. Care must be taken to make sure the cylinders are — |e) perpendicular to the combustion deck and within taper and out-of- a _ 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, 3.9L and 5.9L Bore Diameter mm in First Rebore | 102.469 NOM 4.0342 Second 102.969 Nom 4.0539 Rebore B4.5 and B6.7 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 1.00 mm [0.0394 in] in diameter oversize bore is required for 3.9L or 5.9L engines, or if more than 0.50 mm [0.0197 in] in diameter oversize bore is required for 4.5L ir 6.7L engines, the cylinder bore must be rebored and a repair sleeve installed. The installation of a repair sleeve will allow for the use of standard size pistons and piston rings. To prepare for repair sleeve installation, bore the cylinder(s) requiring a repair sleeve to: 3.9L and 5.9L Machined Bore Diameter (A) mm in 104.500 MIN 4.1140 104.515 MAX 4.1146 4.5L and 6.7L Machined 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).‘Apply a coat of Loctite 620 to the top of the cylinder bores, as the sleeves are installed. Use a sleeve driver, Part Number 3823230, for 102 mm [4.0157 in, and Part Number 2892407, for 107 mm [4.2126 in], to press or drive the repair sleeve into the cylinder bore unti it contacts the step in the bottom of the bore. 3.9L and 5.9L Series Engines ‘* Bore the installed sleeve to 101.956 mm [4.014 in]. 4.5L and 6.7L Series Engines * 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. 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 crosshached 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.AXWARNING A Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. AXCAUTION A 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. AXWARNING A Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. AXWARNING AV 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, AXCAUTION A 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. 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 300 to 400 good grade of honing oil. For the first stage honing, or rough honing, rem use a soft (fast cutting) 80 grit silicone carbide stone. Hone the S Sotie cylinders to their final size during this stage of honing (eh Per Second 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/Repair | 102.000 MIN 4.0187 Sleeve 102,040 MAX 4.0173 First Rebore | 102.500 MIN 4.0354 702.540 MAX 4.0370 secon 103.000 MIN 4.0551 103.040 MAX 4.0567 Honing Diameter Dimensions B4.5 RGT and B6.7 Series Enginesmm in Standard Bore/Repair 106.990 MIN 4.2122 Sleeve 107.010 MAX 4.2130 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 [4.2120 in] maximum diameter. For the second stage honing, or finish honing, use a 280 grt silicon carbide stone. Hone the cylinders to 106,990 mm [4.2122 in] minimum diameter (107.000 mm [4.2125 in] maximum diameter). 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. AXWARNING AV Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. AXCAUTION A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. AXWARNING AL Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. AXWARNING AV 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. AXCAUTION A 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.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 in Section 0. (/qs3/pubsys2/xml/en/procedures/44/44-000-002 html) Last Modified: 28-Jun-2019