Anda di halaman 1dari 36

Audio Only

B Engine Series Mechanicals


Scene Number: 0016 999
Audio
All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

Scene Number: 0016 1000


Audio
At the conclusion of this course you should be able to:
Recognize the B series engine mechanical components,
Identify B series mechanical design features and
Describe unique assembly and disassembly procedures related to the mechanical components of B series engines.
Scene Number: 0016 1010
Audio
B Series cylinder blocks are sculpted and stiffened for noise reduction.
Scene Number: 0016 1020
Audio
The sculpted engine block reduces the weight of the engine by only providing additional thickness where it is needed.
Scene Number: 0016 1030
Audio
B series engines utilize drillings that accommodate straight thread o-ring fittings in many locations. Depending on the date of
manufacturer, the threads may be metric or SAE standard. Be sure the fitting with the correct thread type is used.

Scene Number: 0016 1040


Audio
Front gear train versions of the B series engines use only a front camshaft bushing. This provides for additional support for the
camshaft at the front gear train.
For a rear gear train B series engine, there will also be a camshaft bushing at the rear of the cylinder block as well as at the front.
Scene Number: 0016 1050
Audio
Some versions of the B series engines utilize an internal stiffener plate fitted to the block and bolted into the area adjacent to the
main bearing caps. This improves the rigidity and reduces engine noise.

Scene Number: 0016 1060


Audio
The cylinder block has full thrust bearing capability, with both the lower and upper main bearing shells having a thrust face. This
gives improved clutch release intermittent load capability.

Scene Number: 0016 1065


Audio
The main bearing caps are numbered to ensure that they are installed in the correct saddle position. The main caps should be
installed with the numbers toward the oil cooler side of the engine.
B Engine Series Mechanicals
Scene Number: 0016 1070
Audio
The B series engines incorporate a forged steel induction hardened crankshaft. Adapters for the front of the crankshaft utilize a
six hole bolt mounting pattern.

Scene Number: 0016 1082


Audio
Most B series engines utilize a fracture split connecting rod design. With this manufacturing technique, the rod and cap are
manufactured as a unit and then separated by a controlled fracture. This provides the rod and cap with a matched mating face that
has virtually no gap. For this reason the rod and cap must be assembled as matched pairs.
The fracturing process makes the rod to cap mating surface vulnerable to damage and care must be taken when handling the
connecting rod or cap during service.

Scene Number: 0016 1090


Audio
Lets take a brief look at the fracture split connecting rod manufacturing process. First a rough casting of the rod is produced.
Scene Number: 0016 1200
Audio
The rough casting is then machined to a semi-finished state on the thrust faces, rough and semi-finish on both the large and small
end bores.

Scene Number: 0016 1210


Audio
Next the bolt seat faces are milled, and the holes are drilled and tapped.
Scene Number: 0016 1220
Audio
The rod is then laser etched at the intended fracture line.
Scene Number: 0016 1230
Audio
The joint is then fractured.
Scene Number: 0016 1240
Audio
The rod is then machined to its final specifications.
Scene Number: 0016 1250
Audio
The rod features a replaceable small end bushing and utilizes a slip fit piston pin.
Scene Number: 0016 1255
Audio
The piston rings are assembled onto the piston making sure that the chromed keystone groove compression ring and the plain
rectangular intermediate ring are installed with the correct side up. Both of these rings are labeled to indicate the correct
orientation. The oil ring can be installed either way.
B Engine Series Mechanicals
Scene Number: 0016 1270
Audio
The cast aluminum piston utilizes a combustion bowl design that produces swirl.
The single ni- resist insert provides good wear characteristics in the top ring land area.
Scene Number: 0016 1590
Audio
Assemble the piston to the connecting rod with the short side of the connecting rod toward the J-jet notch side of the piston.

It is important to orient the pistons correctly during installation since the piston pin is slightly offset to reduce noise.

Scene Number: 0016 1600


Audio
The upper and lower connecting rod bearings are made from different materials. Make certain that the correct part number rod
bearings are used in their respective location.

Scene Number: 0016 1610


Audio
Lubricate the cylinder and piston skirt. The position of the rods is flipped as compared with previous engines. Install the pistons
into the cylinders making sure that the notch aligns with the piston cooling nozzle and the "front" marking on the piston is
toward the front of the engine.

Scene Number: 0016 1620


Audio
Lubricate the piston rings and the top ring lands of the piston.
Position the ring gaps so that the gaps do not align, are not over the thrust or anti-thrust face, or over the pin.
Scene Number: 0016 1630
Audio
Install the ring compressor and insert the piston into the bore.
Scene Number: 0016 1640
Audio
Seat the connecting rod journal on the crankshaft. Lubricate and install the cap on the rod. Torque the connecting rod cap screws
to specification.

Scene Number: 0016 1650


Audio
Check the rod to make certain that the side play is within specification.
Scene Number: 0016 1660
Audio
When the engine is equipped with J-jet piston cooling nozzles, the nozzles should not be installed until after the piston and
connecting rod assemblies. The tube on the J-jet piston cooling nozzles can easily be bent.

Scene Number: 0016 1670


Audio
When installing the J-jet piston cooling nozzles, use a 10M fluted screw. This allows the oil to pass from the J-jet oil rifle to the
J-jet. No sealing washers are used to seal the joint.
B Engine Series Mechanicals
Scene Number: 0016 1680
Audio
If a stiffener plate is used, it is installed on the bottom of the block. The mounting location for this plate prevents interference
between the plate and the oil pan rail or gasket area.

Scene Number: 0016 1690


Audio
Install the stiffener plate to the block making sure that the relief notch for the oil suction tube is aligned with the oil suction
drilling in the block.

Scene Number: 0016 1700


Audio
Install the stiffener plate cap screws. Starting at the center of the plate, torque the cap screws to specification.
Scene Number: 0016 1710
Audio
Install the oil pan.
Scene Number: 0016 1721
Audio
The cylinder head can either be a 2 valve or 4 valve per cylinder design. The 2 valve design will have one intake and one exhaust
valve while the 4 valve design will have two exhaust valves and two intake valves per cylinder.

Scene Number: 0016 1730


Audio
The intake and exhaust valves look very similar but are machined at different seat angles. The easiest way to distinguish the
intake from the exhaust valves is to look for the dimple on the exhaust valve face.

Scene Number: 0016 1740


Audio
The cylinder head also includes an integral intake manifold, ... and integral thermostat housing.
Scene Number: 0016 1760
Audio
Some engines depending on horsepower rating will have hardened valve seat inserts installed in both intake and exhaust valve
ports.
Scene Number: 0016 1770
Audio
Replaceable valve seats and valve guides are available for service.
Scene Number: 0016 1775
Audio
Some heads have additional tapped holes to accommodate the mounting of the EGR air handling components.
Scene Number: 0016 1800
Audio
The procedure for setting the overhead is the same as for most versions of the B series engine, with the exception of how to
determine TDC. Refer to service information for the procedure applicable to the engine thats being serviced.
B Engine Series Mechanicals
Scene Number: 0016 1820
Audio
With the engine at TDC, check to be sure that the rocker levers are loose for cylinder number one. If they are not loose, bar the
engine 360 degrees. In this position the intake valves for cylinders 1, 2, and 4 and the exhaust valves for cylinders 1, 3, and 5 are
in a position to be checked.

Scene Number: 0016 1830


Audio
Check the lash by inserting a feeler gauge between the crosshead and rocker lever socket.
Scene Number: 0016 1840
Audio
If valve adjustment is necessary, use a wrench to loosen the lock nut and adjust the setting by turning the set screw.
Scene Number: 0016 1850
Audio
Tighten the lock nut and re-check the valve lash.
Scene Number: 0016 1890
Audio
The sandwiched steel construction head gasket has an identification tab on the side of the engine. The ID tab contains the gasket
part number. The tab also has physical features that indicate the gasket thickness.

Scene Number: 0016 1900


Audio
On some versions of the B series engines, if the block, crankshaft, piston or rod have been replaced, the piston protrusion
measurement procedure must be followed to determine which of the two available gaskets should be used.

Scene Number: 0016 1910


Audio
After zeroing the dial indicator take a piston protrusion measurement along the pin bore axis for each piston.
Scene Number: 0016 1920
Audio
Average the piston protrusion readings as shown here. Determine the proper head gasket using the head gasket selection chart
found in the latest version of the Troubleshooting and Repair manual.

Scene Number: 0016 2480


Audio
You are about to leave the Virtual Classroom and take the assessment.

If you are in review mode selecting Next will return you to the Main Menu.

Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon
to view the program guide.

Scene Number: 0016 2490


Audio
What is the primary purpose of the sculpted engine block?
B Engine Series Mechanicals
Scene Number: 0016 2500
Audio
Which of the following is true concerning the thrust bearing?
Scene Number: 0016 2510
Audio
How is the alignment of the tone wheel assured on the front of the engine?
Scene Number: 0016 2520
Audio
Which of the following is a feature of the connecting rod?
Scene Number: 0016 2530
Audio
Which of the following is true concerning the camshaft bushings for rear gear train equipped B series engines?
Scene Number: 0016 2560
Audio
What is the advantage of the fracture split rod cap design?
Scene Number: 0016 2570
Audio
When installing the piston and rod assembly which of the following is TRUE?
Scene Number: 0016 2590
Audio
Which of the following is integral to the cylinder head?

Scene Number: 0016 2620


Audio
Which of the following is the easiest way to tell the intake and exhaust valves apart?
Scene Number: 0016 2630
Audio
Which of the following is used on some B series engines to determine head gasket selection?
Audio Only
B Series Engine Air Systems
Scene Number: 0017 999
Audio
All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

Scene Number: 0017 1000


Audio
At the conclusion of this course you should be able to:
Recognize the B Series engine air system configurations,
Identify the common B Series engine air system components and
Describe general and unique air system test procedures related to B Series engines.
Scene Number: 0017 1010
Audio
The intake manifold is integrated into the cylinder head on B series engines.
Scene Number: 0017 1020
Audio
A grid heater is required for most applications. It is installed on the intake manifold cover and is designed to heat intake air in
cold ambient conditions.
The ECM controls the pre and post heat cycles dependant on the cold start temperature.
Scene Number: 0017 1040
Audio
Depending on rated horsepower and application, B series engines use either a Holset wastegated turbocharger or a variable
geometry turbocharger, also know as a VGT.

Scene Number: 0017 1042


Audio
Wastegated turbochargers gate a portion of the exhaust gas around the turbocharger turbine wheel and the exhaust energy is
wasted. That is, the exhaust energy is not used by the turbocharger compressor wheel to pump intake air into the engine. A
wastegated turbocharger is used for better low engine speed performance and control of high engine speed boost.

Scene Number: 0017 1043


Audio
The wastegated turbocharger's actuator is mounted on the compressor housing. This means the turbine housing to compressor
housing angular relationship is fixed.

Scene Number: 0017 1045


Audio
The Variable Geometry Turbocharger's primary function is to build boost pressure more quickly to improve transient response.
The variable geometry turbos found on B series engines use an electrical actuator to move a sliding nozzle ring.
With the nozzle ring fully closed, the turbine volute exit area is at its minimum. This creates the maximum exhaust manifold
turbocharger shaft speed and boost pressure.
B Series Engine Air Systems
Scene Number: 0017 1047
Audio
With the nozzle ring in the fully open position the turbine volute exit area is at its maximum. This creates the minimum exhaust
manifold pressure.
Turbocharger shaft speed and boost are at their lowest.
Scene Number: 0017 1050
Audio
A turbocharger speed sensor and compressor inlet temperature sensor are mounted on the VG turbocharger.
Also, a VG actuator position sensor is mounted on the VG actuator.
Scene Number: 0017 1065
Audio
The charge air cooler mounted in front of the radiator reduces the temperature of the intake air.
Scene Number: 0017 1120
Audio
On EGR equipped engines, the intake air is drawn through the air cleaner into the compressor side of the turbocharger. After
leaving the turbocharger, the hot intake air flows to the charge air cooler by means of a large pipe. Once inside the charge air
cooler, heat from the intake air is transferred to the outside air flowing around the fins of the cooler, thus decreasing the
temperature of the intake air. The cooled intake air leaves the charge air cooler and enters another large pipe which allows the
air to flow to the intake air mixer where it is mixed with the EGR gas flow. From there the mixture of fresh intake air and EGR
gas flows to the intake manifold.

Scene Number: 0017 1140


Audio
Air flow continues through the inlet ports creating a swirl pattern into the combustion chambers. After combustion, the exhaust
gases flow from the combustion chambers to the opposite side of the cylinder head.

Scene Number: 0017 1145


Audio
A two-piece manifold is available for the low mount front out and rear out turbocharger options.
Scene Number: 0017 1150
Audio
On EGR equipped engines, after combustion exhaust gases flow through the exhaust manifold to the turbo housing of the
turbocharger. From here the gases exit the exhaust system.

Scene Number: 0017 1210


Audio
A portion of the exhaust gas is forced through the EGR valve to mix with the fresh intake air. The ECM also commands the EGR
valve to adjust according to the needed EGR gas flow.

Scene Number: 0017 1220


Audio
>From the EGR valve the recirculated exhaust gas passes through the water cooled EGR cooler. The EGR cooler is mounted just
above the exhaust manifold. This assembly is constructed of stainless steel to withstand the corrosive nature of exhaust gases.
The EGR gas travels the length of the cooler in tubes. Coolant surrounds these tubes and flows in parallel with the EGR gas, thus
reducing its overall gas temperature.
B Series Engine Air Systems
Scene Number: 0017 1222
Audio
The EGR Connection tubes are used to connect the EGR valve to the EGR cooler and to connect the EGR cooler to the air
intake mixer.
Scene Number: 0017 1230
Audio
The cooled EGR gas flows through the connection tubing to the intake air mixer inlet. B series engines use a fluted style mixer.
Here, the fresh intake air is combined with the recirculated gas to form the charge air used for combustion. From the EGR mixer
the charge air enters the intake manifold.

Scene Number: 0017 1241


Audio
In this section we will look at troubleshooting the Air System on non-EGR equipped B series engines.

Nearly all engine symptoms concerning the air system are related to Low Power complaints, Black Smoke, or both. In this
section we will briefly review the air system checks performed for either of these complaints. Refer to the available service
information for more detailed procedures.

Scene Number: 0017 1242


Audio
For many of the air system tests that we will discuss, the engine must be operated at rated speed and load using either a
dynamometer or performing a road test.

Scene Number: 0017 1243


Audio
One possible source of a low power or black smoke symptom is a restriction in the air cleaner.
Scene Number: 0017 1244
Audio
A filter minder, installed at the air cleaner, indicates the condition of the filter and whether the restriction is excessive.
Scene Number: 0017 1245
Audio
If a filter minder is not installed, install a manometer in the intake piping and check the vacuum pressure with the engine
operating at rated speed.

The restriction at the filter cannot exceed specifications.

END OF SEGMENT

Scene Number: 0017 1246


Audio
If a problem is suspected with the air system, a boost pressure check verifies the problem since most air system problems reduce
the boost pressure.

Scene Number: 0017 1247


Audio
The engine is operated at rated speed and load and the turbocharger boost pressure is checked.

Refer to the service information for the correct boost pressure for your engine.

END OF SEGMENT
B Series Engine Air Systems
Scene Number: 0017 1248
Audio
A leak test measures how well the Charge Air Cooler retains pressure in the cooler core. This is accomplished by plugging the
inlet side of the cooler and pressurizing the core from a regulated air supply connection on the outlet side of the cooler.

END OF SEGMENT

Scene Number: 0017 1249


Audio
Remove the intake and exhaust piping and inspect the turbocharger for contact with the housing and excessive end play.

END OF SEGMENT

Scene Number: 0017 1250


Audio
If the boost pressure is out of range, whether too high or too low, the wastegate may be malfunctioning and should be checked for
proper operation. For this check a specific air pressure is applied to the wastegate actuator and the resulting movement on the
wastegate control rod is measured.

In some applications the turbocharger must be removed from the engine in order to conduct the actuator test or to replace the
wastegate actuator if necessary.

END OF SEGMENT

Scene Number: 0017 1251


Audio
Back pressure in the exhaust system can also cause air system related problems.

The exhaust back pressure specification is typically 3 inches of mercury. However, since this value is application dependant you
should check OEM specifications for your vehicle.

END OF SEGMENT

Scene Number: 0017 1252


Audio
To check the pressure drop across the Charge Air Cooler, compare the pressure at the elbow on the turbocharger compressor
outlet and the pressure in the intake manifold. Compare this value to specifications.

Typically, the pressure drop at the intake manifold should be no greater than 6 inches of mercury.

Scene Number: 0017 1253


Audio
Confirm the efficiency of the Charge Air Cooler by measuring the difference between ambient air temperature and intake air
temperature in the intake manifold.

Scene Number: 0017 1254


Audio
If the temperature differential is greater than the specifications, check the charge air cooler for dirt and debris on the fins and
clean them as necessary. Then, check between the charge air cooler and radiator for debris.

END OF SEGMENT
B Series Engine Air Systems
Scene Number: 0017 1259
Audio
This program will now cover air handling system service procedures unique to EGR equipped engines.
Scene Number: 0017 1260
Audio
If there is coolant in the oil the coolant leak test kit is used to check the turbocharger housing for coolant leaks.
Scene Number: 0017 1270
Audio
The coolant lines to the turbocharger are disconnected and the test kit is then connected. The bottom, coolant supply fitting is
capped while the regulated air supply is connected to the top, coolant return fitting.

Scene Number: 0017 1280


Audio
The specified pressure is applied, then the housing is observed for any pressure decrease.
Scene Number: 0017 1290
Audio
If the pressure falls less than 7 psi in one minute the turbocharger is acceptable for use. If the pressure drops more than 7 psi check the test kit
connections for air leaks. If there is no sign of leakage at the test hose connections, the turbocharger must be replaced.

Scene Number: 0017 1300


Audio
To check the EGR cooler for leaks one of the coolant ports must first be blocked off. A regulated supply of shop air with a
pressure gauge and a shutoff valve is then connected to the other coolant port. The cooler is then placed in a container of heated

Scene Number: 0017 1310


Audio
45psi of air pressure is slowly applied to the cooler. The shutoff valve will need to be closed and the gauge observed. A cooler
with no leaks should maintain the pressure for a minimum of 2 minutes.

Scene Number: 0017 1320


Audio
If the connections are not leaking and the cooler can not maintain pressure for the required length of time, the cooler is leaking
and must be replaced.

Scene Number: 0017 1330


Audio
To test for an exhaust restriction, a pressure gauge will need to be installed to the pressure tap in the exhaust pipe.
Scene Number: 0017 1340
Audio
The engine is then operated at rated speed and load. If the restriction exceeds the maximum pressure the exhaust pipe will need
to be inspected for damage.

Scene Number: 0017 1350


Audio
When removing the Air Intake Connection, the tubing to the Air Intake Connection adapter will need to be removed.
B Series Engine Air Systems
Scene Number: 0017 1360
Audio
The air compressor intake line from the air intake connection adapter is then removed.
Scene Number: 0017 1370
Audio
The air intake connection adapter will now need to be removed.
Scene Number: 0017 1380
Audio
The intake mixer from the air intake connection in then removed.
Scene Number: 0017 1390
Audio
The EGR transfer connection is now removed.
Scene Number: 0017 1400
Audio
The electrical connections to the Recirculated Exhaust Gas temperature sensor and the differential pressure sensor are then disconnected.
Scene Number: 0017 1410
Audio
The intake air connection is removed and the gasket discarded.
Scene Number: 0017 1420
Audio
The air intake connection and the EGR inlet mixer are cleaned and all components are inspected for reuse.
Scene Number: 0017 1430
Audio
When reinstalling the air intake connection a new gasket must be used. The four mounting capscrews are installed loose at this
time to aid in the alignment of the exhaust connection tube.

Scene Number: 0017 1440


Audio
The exhaust connection tube is reinstalled and the intake manifold mounting capscrews are torqued. Finally, the V-band clamp is torqued.
Scene Number: 0017 1450
Audio
The EGR mixer is installed into the intake connection and the air intake connection adapter is then installed.
Scene Number: 0017 1460
Audio
The air compressor intake tube is reinstalled and the sensors are connected to the harness.
Scene Number: 0017 1470
Audio
The charge air piping is reinstalled.
B Series Engine Air Systems
Scene Number: 0017 1480
Audio
The engine is operated and checked for leaks.
Scene Number: 0017 1485
Audio
We will now review the service procedures for removing the variable geometry turbocharger.
Scene Number: 0017 1490
Audio
The air inlet connection and compressor outlet connection are removed.
Scene Number: 0017 1500
Audio
The coolant is drained.
Scene Number: 0017 1510
Audio
All electrical connections to the turbo from the engine harness must be disconnected, including:
Turbocharger speed sensor
Turbocharger Compressor inlet air temperature sensor
VG actuator position sensor and
VG actuator motor connector

Scene Number: 0017 1520


Audio
The VGT coolant plumbing lines are disconnected, including:
The block to turbocharger inlet line.
The turbocharger outlet to cylinder head line.
The block to VG Actuator line.
And the VG Actuator to EGR valve line.
The VG actuator-to-EGR valve coolant line must be completely removed. If this is not done, the line and threads in the EGR
valve could accidentally be damaged during turbo removal.

Scene Number: 0017 1530


Audio
The turbo oil supply line is now disconnected.
Scene Number: 0017 1540
Audio
Next, the turbocharger drain line is disconnected.
Scene Number: 0017 1550
Audio
Removing the two mounting capscrews and the two nuts that secure the turbo to the exhaust manifold allows the turbo to now be removed.
Scene Number: 0017 1560
Audio
The VG turbocharger is reinstalled using a new mounting gasket and the mounting capscrews and nuts are torqued to specification.
All previously removed plumbing and wiring harness connectors are then reinstalled.
B Series Engine Air Systems
Scene Number: 0017 1570
Audio
To remove the EGR valve, begin by draining the engine coolant.
Scene Number: 0017 1580
Audio
The V-band clamp that connects the exhaust connection tube to the EGR valve must be removed and the flange gasket is discarded.
Scene Number: 0017 1581
Audio
The tubes are inspected for cracks, restrictions, plugging, or any other damage.
Scene Number: 0017 1590
Audio
The EGR valve position sensor connector and the EGR valve actuator motor connector are removed.
Then the harness attaching hardware will need to be removed.
Scene Number: 0017 1600
Audio
The EGR valve actuator coolant supply and return lines are removed and the banjo fitting seals are discarded.
Scene Number: 0017 1610
Audio
Next, the exhaust pressure sensing line is removed.
Scene Number: 0017 1620
Audio
The four capscrews that mount the EGR valve to the exhaust manifold are removed and then the EGR valve itself. The mounting
gasket is discarded.

Scene Number: 0017 1630


Audio
The EGR valve marrmon flange, the mounting surfaces of the EGR valve and exhaust manifold are cleaned with a scotchbrite pad.
Scene Number: 0017 1640
Audio
The EGR valve is visually inspected for cracks, leaks, corrosion, restrictions, and debris.
The resistance of the EGR valve actuator motor is checked.
Scene Number: 0017 1650
Audio
The EGR valve is reinstalled using a new mounting gasket. The four mounting capscrews are installed but not torqued at this time.
Scene Number: 0017 1660
Audio
The V-band clamp is positioned on the exhaust connection tube and a new gasket is used.
B Series Engine Air Systems
Scene Number: 0017 1670
Audio
The V-band connection to the EGR valve is fit but not torqued at this time.
Scene Number: 0017 1680
Audio
The proper toque sequence must be followed when tightening the EGR valve mounting capscrews. The three lower vertical
mounting capscrews are first torqed to specification. Next, the upper horizontal mounting capscrews are torqued to specification.
Finally, the V-band clamp is torqued.

Scene Number: 0017 1690


Audio
The coolant lines will need to be inspected to be sure they are not clogged or pinched. The lines are installed using new banjo seals
and the fittings are torqued to specification.

Scene Number: 0017 1695


Audio
When reinstalling the EGR connection tube to the cooler inlet, it may be necessary to loosen the EGR valve so as to properly
align the tube.

Scene Number: 0017 1696


Audio
Note that when aligning the EGR connection tube to the intake air adapter, for installation, it may be necessary to loosen the
four capscrews that hold the air intake connection to the intake manifold cover.

Scene Number: 0017 1700


Audio
The exhaust pressure sensing line is now installed.
Scene Number: 0017 1710
Audio
The coolant plumbing and the electrical connectors are reconnected, then the engine is filled with coolant.
Scene Number: 0017 1720
Audio
The engine is operated and the system is checked for leaks.
Scene Number: 0017 1780
Audio
The EGR valve must be open during the check. The EGR valve position is monitored using INSITE in order to determine if the
EGR valve is open.

Scene Number: 0017 1785


Audio
If the EGR cooler fails a leak test or its performance is unacceptable, the cooler must be replaced. New coolers come with
preassembled brackets on the cooler.

Scene Number: 0017 1790


Audio
When removing the EGR cooler, the engine coolant must be drained.
B Series Engine Air Systems
Scene Number: 0017 1800
Audio
Following the proper procedure, the EGR connection tubes are removed from the EGR cooler inlet and outlet.
Scene Number: 0017 1810
Audio
The harness connector to the exhaust pressure sensor is disconnected and the harness clamp's attaching capscrews are removed.
Scene Number: 0017 1820
Audio
The EGR cooler coolant return line is removed and then the EGR coolant supply hose can be removed.
Scene Number: 0017 1830
Audio
The exhaust pressure sensing line is now removed.
Scene Number: 0017 1840
Audio
After removing the 2 capscrews which hold the cooler and bracket assembly to the enigne the EGR cooler assembly can be removed.
Scene Number: 0017 1850
Audio
The cooler is inspected for debris or plugging and the appropriate leak test should be performed at this time. Any brackets or
clamping straps that are damaged should be replaced.

Scene Number: 0017 1870


Audio
If an EGR cooler bracket or strap is defective, but the cooler's performance is acceptable, the following procedure should be used.
With the EGR cooler on a bench, the 2 clamping straps which hold the upper and lower bracket to the cooler are removed. The
brackets are then removed.

Scene Number: 0017 1880


Audio
The front bracket assembly is loosely installed. Measure 175 mm from the front flange of the cooler. This is the mounting hole
centerline for the front lower bracket. The mounting hole centerline measurement is 415 mm from the front flange of the cooler
for the rear lower bracket. The clamping straps are then torqued to specification. Overtorquing will likely lead to cooler damage.

Scene Number: 0017 1890


Audio
The cooler/bracket assembly is reinstalled to the engine along with the 2 capscrews, which are torqued to specification.
Scene Number: 0017 1900
Audio
All of the plumbing that had been removed from the EGR cooler will now need to be reconnected using the appropriate procedures.
Scene Number: 0017 1910
Audio
The engine is operated and the exhaust is checked for leaks. The EGR valve must be open during the check.
B Series Engine Air Systems
Scene Number: 0017 1920
Audio
To replace a defective clamping strap with the EGR cooler installed to the engine, any component that interferes with the
procedure should be removed along with the clamping strap capscrew.

Scene Number: 0017 1930


Audio
The clamping strap is expanded and removed from the cooler.
Scene Number: 0017 1940
Audio
The new clamping strap on the upper and lower bracket is placed into position and the clamp is compressed to align the capscrew
for installation.

Scene Number: 0017 1950


Audio
To complete the procedure, the clamping strap capscrews need to be torqued to specification with care taken not to overtorque.
Scene Number: 0017 1960
Audio
You are about to leave the Virtual Classroom and take the assessment.

Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon
to view the program guide.

Note: If you are in Review Mode selecting Next will either return you to the Main Menu if you have completed all of the
modules in your Play List, or it will take you to the next module in your Play List.

Scene Number: 0017 1970


Audio
Which of the following is true concerning the air system?
Scene Number: 0017 1980
Audio
Which of the following is true concerning the variable geometry turbochargers on the B series engine?
Scene Number: 0017 1990
Audio
Where is the grid heater installed on the B series engine?
Scene Number: 0017 2000
Audio
The EGR valve is opened and closed for what reason?
Scene Number: 0017 2010
Audio
Where is the fresh intake air combined with the recirculated gas?
B Series Engine Air Systems
Scene Number: 0017 2020
Audio
Which of the following controls the operation of the grid heater?
Scene Number: 0017 2040
Audio
With the VG turbocharger nozzle ring in the fully closed position, which of the following is TRUE?
Scene Number: 0017 2050
Audio
The Variable Geometry Turbocharger leak test identifies excessive ______________.
Scene Number: 0017 2060
Audio
Which of the following components needs to be removed to remove the air intake connection?
Scene Number: 0017 2070
Audio
For EGR Valve installation what is the proper torque sequence?
Scene Number: 0017 2080
Audio
Which of the following components should be installed loose, so as to aid in the installation of the EGR connection tubes?
Scene Number: 0017 2090
Audio
What component comes preassembled on a new EGR cooler?
Scene Number: 0017 2100
Audio
A wategated turbocharger controls low engine speed performance and high engine speed boost by _________.
Audio Only
B Series Engine Lube Systems
Scene Number: 0018 999
Audio
All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

Scene Number: 0018 1000


Audio
Welcome to the B series engine lubrication course.
Scene Number: 0018 1002
Audio
After completing this course you should be able to:
Trace the flow through various versions of the B series engine
Identify major lube system components
Identify B series lubrication system unique service procedures
Scene Number: 0018 1005
Audio
On B series engines the oil fill is through the top of the rocker lever cover.
Alternative fill locations are in a low position on the front gear cover. This provides access for fill tubes at convenient vehicle
And also there is an additional oil fill access hole on the left side of the block.
Scene Number: 0018 1010
Audio
The stamped steel oil pan is symmetrical and is used in both front or rear sump applications. Some B series engines will have a
suspended pan design. The oil pan capacity is typically 14 liters. (15 U.S. quarts)
Depending on application and vintage of engine, the pans are sealed by either a paper gasket, rubber flange gasket, or RTV.

Scene Number: 0018 1020


Audio
The B series engine can utilize different breather arrangements depending on date of manufacture and gear train configuration.
Scene Number: 0018 1030
Audio
The crankcase breather on rear gear train equipped engines contains a metal baffle inside the rocker lever cover. The large tube
connects the area on top of the baffle to the open cavity in the gear housing. The top of the cavity is open to provide relief of
the crankcase pressure. A second tube drains the oil from the baffle area to the gear housing and then back to the oil pan.

Scene Number: 0018 1040


Audio
All B series engines with a rear gear train use an open crankcase breather. A breather tube is installed in the flywheel housing,
above the left rear motor mount pad.

Scene Number: 0018 1120


Audio
The lubricating oil flow begins as oil is drawn from the oil pan through the suction tube. Various suction tube designs and
mounting arrangements have been used on B series engines.
B Series Engine Lube Systems
Scene Number: 0018 1130
Audio
The suction tube delivers oil to the gerotor type lubricating oil pump.
The gerotor type lubricating oil pump is mounted at the front of the cylinder block and gear driven from the front of the
crankshaft. The oil pump is driven through a straight cut spur gear.

Scene Number: 0018 1140


Audio
The pump then delivers the lubricating oil through an internal drilling to the oil cooler cover and the pressure regulator.
Scene Number: 0018 1150
Audio
When the oil pressure from the pump exceeds the pressure regulator valve opening pressure the valve opens, uncovering the
dump port and allowing some oil to drain back through the cover to the oil sump, this is also known as dump to sump.
On some B series engines the oil pressure regulator opens a passage in the cover leading to the inlet side of the pump, this is often
referred to as dump to pump.

Scene Number: 0018 1160


Audio
Oil also is directed to a cast-in passage in the oil cooler cover leading to the oil cooler element.
Scene Number: 0018 1170
Audio
The oil is cooled as it moves through the oil cooler element plates as coolant is circulated around the outside of the plates. The
actual number of plates will vary depending on application and horsepower.

The oil then continues through another cast passage in the oil cooler cover to the oil filter.

Scene Number: 0018 1175


Audio
The oil filter is a full flow spin-on element.
Scene Number: 0018 1180
Audio
The Fleetguard StrataPore oil filter reduces the restriction of oil flow and extends the oil drain interval. The oil flows up the
center of the filter and into the filter head.

Scene Number: 0018 1190


Audio
In the event of a plugged filter, the cooler cover incorporates a bypass valve to maintain oil flow. If the pressure drop across the
oil filter exceeds specification, the bypass valve opens, allowing unfiltered oil to lubricate the engine.

Scene Number: 0018 1200


Audio
Once the oil is cooled and filtered, oil flow is divided, with a portion of the oil flowing to the turbocharger and the rest passing
through the cooler cover down a cast passage to a cross drilling in the block.
B Series Engine Lube Systems
Scene Number: 0018 1210
Audio
One cross drilling between cylinder number one and cylinder number two carries the oil across the block to an angle drilling that
intersects the main oil rifle. The main oil rifle runs the length of the block and carries oil to the overhead and main bearings
through individual transfer drillings.

Scene Number: 0018 1220


Audio
The transfer drillings connected to the main oil rifle supplies oil to a groove in the upper main bearing shells. Oil is then supplied
to the cam bores through short radial drillings.

Scene Number: 0018 1230


Audio
From the main bearings, oil enters the crankshaft and lubricates the connecting rod bearings through internal cross drillings.
Scene Number: 0018 1235
Audio
Piston cooling on B series engines is accomplished by the use of either a saddle jet or j-jet piston cooling arrangement.
Scene Number: 0018 1240
Audio
If the engine utilizes saddle-jet piston cooling nozzles, oil from the main bearings is directed to the nozzles and then sprayed onto
the pistons.

Scene Number: 0018 1250


Audio
Oil for the J-jet piston cooling nozzles, is delivered through a second cross drilling connected to the piston cooling rifle.
Scene Number: 0018 1252
Audio
If functional saddle mounted piston cooling nozzles are installed, a bolt is installed in each of the oil feed drillings to plug the
passages feeding to the J-jet piston cooling nozzle mounting locations.

Scene Number: 0018 1253


Audio
If J-jet piston cooling nozzles are installed, a red piston cooling plug is installed in the saddle to seal off the hole where the saddle
mounted piston cooling nozzle would be installed.

Scene Number: 0018 1260


Audio
The piston pins are splash lubricated by the piston cooling nozzle spray.
Scene Number: 0018 1270
Audio
Oil to the overhead is carried to the cylinder head deck by individual vertical drillings - one per cylinder - intersecting the main
oil rifle. The oil then continues to flow vertically through drillings in the cylinder head.
B Series Engine Lube Systems
Scene Number: 0018 1280
Audio
>From the drillings in the cylinder head, oil flows through a groove in the bottom of the pedestal plate. The oil then flows around
the rocker lever mounting capscrews to the rocker shafts.

Oil flows through angle drillings in the capscrew bore in the shaft.

At each end of the shaft, a drilling allows oil to flow from the inside
diameter of the shaft to the rocker lever bore.

A lubrication groove in each end of the shaft directs oil to two drillings providing a path for oil flow; one drilling directs oil flow
to the foot pad that contacts the crosshead. Oil from this drilling then travels down the crosshead and lubricates the valve stems.

The second drilling in the rocker lever directs oil to the adjusting screw. Oil flow around the adjusting screw lubricates the push
rod sockets.
Scene Number: 0018 1290
Audio
For a front gear train equipped engine, lubrication is received from oil splash and oil carryover. The oil pump idler gear is
pressure-lubricated.

From here the oil drains back to the pan for recirculation.

Scene Number: 0018 1300


Audio
For a rear gear train, the main oil rifle s oil to the rear housing. A channel in the block side of the housing feeds the oil to
internal drillings in the housing to supply oil to the air compressor.

Scene Number: 0018 1310


Audio
Details for the following lubrication system service level procedures are covered in the service literature:
Oil cooler leak test
Dipstick calibration
Oil pressure regulator valve free movement
Pressure regulator valve spring pressure
Scene Number: 0018 1360
Audio
You are about to leave the Virtual Classroom and take the assessment.

Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon
to view the program guide.

Note: If you are in Review Mode selecting Next will either return you to the Main Menu if you have completed all of the
modules in your Play List, or it will take you to the next module in your Play List.

Scene Number: 0018 1410


Audio
How are the oil pans sealed on B series engines?
Scene Number: 0018 1420
Audio
Which of the following is true concerning the piston cooling nozzles?
B Series Engine Lube Systems
Scene Number: 0018 1440
Audio
Which of the following drives the geroter type lubricating oil pump?
Scene Number: 0018 1450
Audio
Excess oil from the pressure relief valve is directed to which of the following?
Scene Number: 0018 1460
Audio
What is the purpose of the oil bypass valve?
Scene Number: 0018 1470
Audio
Which of the following components is supplied oil from a source other than the main oil rifle?
Scene Number: 0018 1480
Audio
Which of the following directs oil for lubrication to the large end connecting rod bearings?
Scene Number: 0018 1490
Audio
Which of the following carries oil to the cylinder head deck?
Scene Number: 0018 1500
Audio
Now, see if you can correctly identify the correct piston cooling nozzle application using the component labels provided.

Click and hold down on the label at the bottom, drag it to the correct component's title line and release it. You may clear your
choices by selecting "Reset." Submit your choices by selecting the "Next" button.

Scene Number: 0018 1510


Audio
If saddle-jet cooling nozzles are installed, how are the j-jet cooling nozzle passages accommodated?
Audio Only
B Series Engine Cooling Systems
Scene Number: 0019 999
Audio
All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

Scene Number: 0019 1000


Audio
Welcome to the B series engine cooling system training course.
Scene Number: 0019 1001
Audio
At the conclusion of this course you should be able to:
Recognize the B series engine cooling system components.
Describe the coolant flow through the B series engine.
Understand the initial coolant fill procedure and the operation of the positive deaeration coolant system and,
Perform unique cooling system test procedures on the B series engine.
Scene Number: 0019 1003
Audio
Cummins recommends the use of a positive flow dearating cooling system, containing a top tank with expansion area, fill line,
vent line, and vent tube. This system aids in purging air from the cooling system during initial coolant fill and during operation.

Scene Number: 0019 1005


Audio
Although the deaerating cooling system is used on most automotive applications, some light duty applications, such as the pickup
truck market, may utilize an "open top tank" cooling system.

Scene Number: 0019 1007


Audio
One of the features of the positive flow deaerating cooling system is in the way the system fills with coolant.
Coolant is added to the reserve volume tank at a rate of approximately 5 gallons per minute or less. This rate allows the coolant
to flow through the fill tube and fill the cooling system.

Scene Number: 0019 1009


Audio
Coolant flows out of the reserve tank through the fill line to the engine and radiator. Flow from the fill line allows the engine and
radiator to fill with coolant from the bottom of the system.

Scene Number: 0019 1011


Audio
As the system fills the coolant pushes the air out of the system through the engine vent line and the radiator core vent tube.
Scene Number: 0019 1013
Audio
After filling the engine and radiator, coolant fills the reserve tank until the coolant level reaches the bottom of the fill neck. The
position of the fill neck limits the amount of coolant in the reserve tank. This room in the tank not only leaves room for
expansion but also ensures that the radiator core vent tube remains open.
The size and location of the vent line and radiator core vent are important to ensure proper venting of the cooling system.
B Series Engine Cooling Systems
Scene Number: 0019 1015
Audio
During initial coolant fill of EGR equipped engines, a quarter inch pipe plug in the line from the EGR cooler to the cylinder head
should be removed. This will allow air to be purged from the system. Reinstall the plug once the system has been filled.

Scene Number: 0019 1017


Audio
Coolant is circulated by the integrally- mounted water pump. The pump is belt driven and has been designed to function without
the use of a water pump shroud. The pump installs in the integral volute in the engine block.

Scene Number: 0019 1020


Audio
Alternative water outlet connections are available.
Scene Number: 0019 1030
Audio
The integral thermostat housing, located in the cylinder head, provides a location for mounting the vented thermostat vertically
in the cooling system. Depending on engine application and date of manufacturer the thermostat can be found in either a vertical
or horizontal position.

Scene Number: 0019 1040


Audio
Various style water inlets are available. One water inlet has a provision for an alternator, tensioner, and idler pulley mounting.
Scene Number: 0019 1050
Audio
Depending on turbocharger mounting location, two optional block heater mounting locations are available. The heater provides
for improved engine starting and operation during cold climate conditions.

Scene Number: 0019 1070


Audio
Coolant flow begins at the water pump.
Scene Number: 0019 1080
Audio
The output from the water pump empties into the side of the oil cooler cavity of the cylinder block. This provides the oil cooler
with coolant at the lowest possible temperature. A small passage from the bottom of the oil cooler cavity allows some coolant to
return to the suction side of the water pump to ensure constant coolant flow around all areas of the oil cooler core.

Scene Number: 0019 1090


Audio
The coolant then exits the oil cooler cavity through the large inboard opening and circulates into the block to cool the cylinders.
Scene Number: 0019 1100
Audio
The head gasket is orificed to control coolant flow into the cylinder head. Orifacing the gasket creates larger openings for the
coolant to flow the further downstream the hole location is in the flow path. This provides that coolant flow is sufficient to
provide nearly equal cooling along the head rather than diminishing cooling capabilities along the flow path.
B Series Engine Cooling Systems
Scene Number: 0019 1110
Audio
Coolant flowing through the single passage per cylinder in the left side of the cylinder head gasket flows to the lower water cavity
through drillings in the cylinder head. The coolant flows over the valve seats and bridges to cool the valve seat and injector
areas. This applies to both the 2 valve and 4 valve heads.

Scene Number: 0019 1120


Audio
Coolant flowing through the passages on the right side of the cylinder head gasket flows to the upper water cavity in the cylinder
head.

The coolant in the lower water jacket in the cylinder head connects to the upper water jacket through a series of passages in the
cylinder head.

Scene Number: 0019 1130


Audio
When the engine is below operating temperature, the thermostat is closed, allowing the coolant to pass the radiator and flow back
to the water pump inlet through internal drillings in the cylinder head and block.

Scene Number: 0019 1140


Audio
When operating temperature is reached, the thermostat opens, blocking the bypass passage to the water pump and opening the
outlet to the radiator. The engine must never by operated without a thermostat. Without a thermostat, the coolant recirculates,
by-passing the radiator, causing the engine to overheat.

Scene Number: 0019 1150


Audio
When the thermostat is closed, the pressure in the block circuit causes the supply to the water pump to flow from the bypass
tube. When the engine reaches operating temperature and the thermostat opens, the pressure in that part of the circuit causes the
flow to come from the radiator.

Scene Number: 0019 1155


Audio
Additional coolant plumbing has been added to accommodate the use of EGR and VGT air handling components.
Scene Number: 0019 1160
Audio
The coolest water flows from a drilling in the block just above the water pump volute to the EGR cooler inlet.
Scene Number: 0019 1170
Audio
The coolant flows through the stainless steel tubes in the EGR cooler. The coolant then returns to the cylinder head and
continues on to the thermostat housing.

Scene Number: 0019 1180


Audio
Coolant flow to the VG actuator comes from a drilling in the block, behind to the oil cooler.
The Variable Geometry turbocharger picks up its coolant from the block cavity at the rear of the block. After cooling the turbo
the coolant returns to the rear end of the cylinder head.
B Series Engine Cooling Systems
Scene Number: 0019 1190
Audio
After cooling the turbocharger actuator the coolant flows to the EGR valve actuator housing.
Scene Number: 0019 1200
Audio
The coolant then exits the top of the EGR valve actuator housing and flows to a fitting in the top of the head.
Scene Number: 0019 1220
Audio
The routing of coolant flow to the air compressor is dependant on whether the engine is a front or rear gear train configuration.
After cooling the air compressor the coolant returns to the engine by way of connection at the rear of the cylinder head.

Scene Number: 0019 1260


Audio
The unique cooling system related tests for EGR equipped engines, the EGR Cooler Leak Test, the Turbocharger Leak Test, are
covered in the B Series engine Air System course.

Scene Number: 0019 1270


Audio
You are about to leave the Virtual Classroom and take the assessment.

Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon
to view the program guide.

Note: If you are in Review Mode selecting Next will either return you to the Main Menu if you have completed all of the
modules in your Play List, or it will take you to the next module in your Play List.

Scene Number: 0019 1280


Audio
Which of the following is TRUE pertaining to the cooling system of the B series engine?
Scene Number: 0019 1310
Audio
The optional block heater installs into which of the following components?
Scene Number: 0019 1330
Audio
Which of the following components receives coolant from the water pump first?
Scene Number: 0019 1340
Audio
In a positive flow deaerating cooling system, which of the following supplies coolant to the inlet side of the water pump?
Audio Only
B Series Engine Rear Gear Train
Scene Number: 0020 999
Audio
All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

Scene Number: 0020 1000


Audio
This training course will cover the rear gear train configuration used on some B series engines.
Scene Number: 0020 1005
Audio
At the conclusion of this course you should be able to:
Recognize the B series rear gear train components,
Understand the B series rear gear train operation
Describe unique service procedures related to the B series engine
Scene Number: 0020 1010
Audio
The die cast aluminum gear housing is at the rear of the engine, located between the block and the flywheel housing.
Scene Number: 0020 1020
Audio
The gear train utilizes straight cut spur gear design. There are no idler gears in the gear train. The crankshaft drives the camshaft,
which drives the fuel pump, and accessory gear. The accessory gear drives the air compressor / power steering pump assembly.

Scene Number: 0020 1030


Audio
The crankshaft gear has a chamfered tooth that is used to time the engine to top dead center.
Scene Number: 0020 1040
Audio
The standard flywheel housing is an aluminum SAE 2, gravity die casting with vertical side mounting pads. This housing has a
219.6 mm starter center distance which is compatible with a new 132 tooth ring gear.

Scene Number: 0020 1050


Audio
Various starter and ring gear options are available.
Scene Number: 0020 1060
Audio
The flywheel housing carries the rear crankshaft seal which is a cartridge type seal. With this type seal, the rotating sealing
surface is in the seal rather than between the seal and the crankshaft.

Scene Number: 0020 1070


Audio
The gear driven accessory location is on the rear left side of the engine. This drive is utilized for the air compressor which has
through drive provision for a power steering pump.
B Series Engine Rear Gear Train
Scene Number: 0020 1080
Audio
The drive runs at 1:1. The maximum torque capability of the drive is 240N-m.
Scene Number: 0020 1090
Audio
The front of the block has side and front mounting pad hole patterns similar to earlier ISB engines.
Scene Number: 0020 1100
Audio
The front gear cover provides a mounting location for the Crankshaft Speed Sensor and the Camshaft Position Sensor.
Scene Number: 0020 1110
Audio
The Camshaft Position Sensor and the Crankshaft Speed Sensor are the hall effect type. An o-ring is installed on the sensor in
both locations. However the camshaft position sensor o-ring seals against oil. Be sure to confirm that this o-ring is in good
condition prior to installation.

Scene Number: 0020 1120


Audio
The front gear cover carries the front crankshaft seal. This cartridge type seal is the same design as used on the rear of the engine.
Scene Number: 0020 1130
Audio
A front PTO option is available that has 475N-m of output capability.
Scene Number: 0020 1140
Audio
The front-end accommodates belt-driven fan arrangements. An 8-rib poly vee belt also drives the water pump, alternator, and air
conditioning compressor.

Scene Number: 0020 1150


Audio
To remove the rear crankshaft oil seal, begin by removing the transmission, clutch and the flywheel.
Scene Number: 0020 1160
Audio
Use two capscrews to secure the rear crankshaft seal tool to the crankshaft.
Scene Number: 0020 1170
Audio
Using an 1/8th inch drill bit, drill a hole through the seal casing using the holes in the tool as a guide.
Install a seal puller screw into the seal.
Scene Number: 0020 1180
Audio
Drill holes in the seal casing through the five remaining holes in the tool.

Install the five remaining seal puller screws through the rear crankshaft seal tool into the holes you just drilled in the seal casing.
B Series Engine Rear Gear Train
Scene Number: 0020 1190
Audio
Tighten the screw in the center of the rear crankshaft seal tool and remove the seal.
Scene Number: 0020 1200
Audio
Use a crocus cloth to polish and remove any deposits from the crankshaft flange. Any scratches that are visible can result in oil
seal leakage. Use a clean lint free cloth to clean the crankshaft flange making sure to remove all traces of oil film.

Scene Number: 0020 1210


Audio
Do not use any type of lubricant to install the new rear oil seal.
Guide the rear crankshaft oil seal and installation tool over the end of the crankshaft.
Scene Number: 0020 1220
Audio
Finger tighten the two installation capscrews against the installation tool. Make sure that the seal is pressed evenly into the bore.
Allowing the seal to "cock" in the bore can damage components.

Scene Number: 0020 1230


Audio
Turn the center jackscrew counterclockwise until the seal seats against the counterbore in the flywheel housing.
Scene Number: 0020 1240
Audio
Remove the installation tool.
Scene Number: 0020 1250
Audio
To remove the front crankshaft oil seal, begin by removing the drive belt, vibration damper, pulley, and tone wheel.
Scene Number: 0020 1260
Audio
Position the front crankshaft seal tool on the nose of the crankshaft so that the dowel pin in the end of the crankshaft does not
interfere with the tool. Using mounting capscrews supplied in the kit, secure the front crankshaft seal tool to the crankshaft.

Scene Number: 0020 1270


Audio
The remainder of the removal procedure and the installation procedure are the same as used for the rear crankshaft seal.
Scene Number: 0020 1280
Audio
To remove the Rear Gear Housing, begin by disconnecting the battery. Drain the coolant. Drain the oil. Support the rear of the
engine and remove the transmission.

Scene Number: 0020 1290


Audio
Remove the flywheel.
Remove the rear oil seal and then remove the flywheel housing.
B Series Engine Rear Gear Train
Scene Number: 0020 1300
Audio
Remove the fuel pump and air compressor.
Scene Number: 0020 1305
Audio
Rotate the engine to align the timing marks on the crankshaft and camshaft gears.
Scene Number: 0020 1320
Audio
Remove the camshaft gear bolts and the camshaft gear.
Scene Number: 0020 1330
Audio
Loosen the oil pan to provide needed clearance for rear gear housing removal. Remove the oil pan mounting bolts that attach to
the gear housing.

Scene Number: 0020 1340


Audio
Remove the breather tubes from the engine.
Scene Number: 0020 1350
Audio
Remove the gear housing mounting capscrews. Then remove the gear housing.
Scene Number: 0020 1360
Audio
Clean the sealing surfaces on the engine block and the gear housing.
Scene Number: 0020 1370
Audio
When installing the rear gear housing, place a bead of the proper sealant on the housing. A chart in the T&R manual shows the
proper path for applying the sealant. Marking the path on the housing may be helpful.

Scene Number: 0020 1380


Audio
When installing the rear gear housing to the engine, it is secured using three different size capscrews.
Install the housing and mounting bolts including the bolts that go through the oil pan and into the housing. The proper torque
procedure must be followed when mounting the rear gear housing.

Scene Number: 0020 1390


Audio
Align the camshaft gear marks with the crankshaft gear and install the camshaft gear.

Torque the gear bolts to specification.


Check the end play and backlash of the camshaft gear.
Scene Number: 0020 1400
Audio
Install the air compressor and install the fuel pump.
B Series Engine Rear Gear Train
Scene Number: 0020 1410
Audio
Apply Loctite sealant or equivalent to the flywheel housing. Install the flywheel housing and torque the capscrews to specification.
Scene Number: 0020 1420
Audio
Install the rear crankshaft seal.
Scene Number: 0020 1430
Audio
To complete the installation, re-install the breather assembly, the flywheel, and transmission.
Scene Number: 0020 1440
Audio
When removing the front gear cover from the engine, remove the necessary components to gain access to the front gear cover.

If necessary, remove the fan drive.

Scene Number: 0020 1450


Audio
Remove the front crankshaft oil seal. It is easier to remove this seal while the front cover is still installed on the engine.
Scene Number: 0020 1460
Audio
Depending on front engine mount option, the front engine mount may need to be removed to remove the front gear cover.
Scene Number: 0020 1470
Audio
When removing the front gear cover from the engine, loosen the oil pan capscrews to allow the pan to drop down to clear the
gear cover lower face. Remove the two oil pan capscrews that install into the front gear cover.

Scene Number: 0020 1480


Audio
Remove the front cover.
Scene Number: 0020 1490
Audio
Clean the sealing surfaces of the cover and the front engine block.
Scene Number: 0020 1500
Audio
When installing the front gear cover to the engine, it is secured using two different length capscrews.
Scene Number: 0020 1510
Audio
To install the front gear cover, apply a small bead of Loctite sealant or equivalent to the front cover. The gear cover must be
installed to the block within 10 minutes of sealant being applied. Install the cover and torque the capscrews to specification.
B Series Engine Rear Gear Train
Scene Number: 0020 1520
Audio
Install a new crankshaft oil seal. Install the tone wheel, and pulley. Install the vibration damper.
Scene Number: 0020 3995
Audio
We will now look at the tappet removal and installation procedure for rear gear train equipped engines.
Scene Number: 0020 3999
Audio
A tappet removal and installation service tool is available or may be fabricated according to the instructions in the service
literature. This tool consists of a trough, slotted wooden dowels, and slotted plugs with strings.

Scene Number: 0020 4000


Audio
To remove the tappets begin by removing the rocker lever cover, rocker levers, and push rods.
Then remove the transmission, clutch, flywheel, and flywheel housing.
Scene Number: 0020 4001
Audio
For each tappet, insert the slotted wooden dowel down through the push rod bore until the end enters the top of the tappet.
Scene Number: 0020 4002
Audio
Lift each tappet in its bore and hold it in position by placing rubber bands around pairs of the dowel rods to hold them in place.
This holds the tappets off of the camshaft.

Scene Number: 0020 4003


Audio
With all of the tappets lifted off of the camshaft, remove the thrust plate and camshaft from the engine.
Scene Number: 0020 4005
Audio
Immediately after removing the camshaft, install the trough into the camshaft bore and position it so that it will catch the tappet.
Scene Number: 0020 4007
Audio
Only remove one tappet at a time. Remove the rubber band from two of the companion tappets and secure the tappet that is not
being removed to a neighboring tappet. Pull the rod from the tappet to be removed and allow it to drop into the trough.

Scene Number: 0020 4008


Audio
If the tappet does not fall over, carefully shake the trough just enough to cause it to fall over. Carefully slide the trough out of
the engine far enough to retrieve the tappet.

Scene Number: 0020 4009


Audio
Re-insert the tray and repeat the procedure for each of the tappets.
B Series Engine Rear Gear Train
Scene Number: 0020 4010
Audio
Inspect the tappets for reuse. Refer to the service information for reuse specifications for this style tappet. Mark each of the
tappets to indicate their position in the engine. Used tappets must be installed in their original position.

Scene Number: 0020 4011


Audio
Reverse the trough and slide it into the engine with the open end first. This will assist in installing the tappets in the engine.
Lower the tappet installation tool down through the tappet bore and into the trough.

Scene Number: 0020 4012


Audio
Carefully feed the installation tool through the camshaft bore, by gently pulling the trough out the rear of the engine. The hook
provided with the service tool can be used to pull the tool through the engine, if necessary.

Scene Number: 0020 4013


Audio
Lubricate the tappets with Lubriplate or equivalent. Insert the installation tool into the tappet.
Scene Number: 0020 4014
Audio
Slide the trough into the camshaft bore. Pull the tool and tappet through the camshaft bore and up into the tappet bore.
If it becomes difficult to align the tappet with its bore, pull the trough out enough to allow the tappet to drop down and align
itself. Then pull the tappet up into the bore.

Scene Number: 0020 4015


Audio
After the tappet has been pulled up into position, slide the trough back into the camshaft bore and rotate it one-half turn. This
positions the round side of the trough up. Which holds the tappet in place.

Scene Number: 0020 4016


Audio
Remove the installation tool from the tappet.
Scene Number: 0020 4017
Audio
Install a slotted wooden dowel into the top of the tappet.
Repeat the procedure until all of the tappets have been installed. The tappet tools can then be rubber banded together to hold
them in place.

Scene Number: 0020 4018


Audio
Immediately after removing the trough for the last time, lubricate the camshaft journals and lobes. Insert the camshaft into the block.
Scene Number: 0020 4019
Audio
Install the camshaft thrust plate to the block and torque the two mounting cap screws.
B Series Engine Rear Gear Train
Scene Number: 0020 4020
Audio
Using the two holes in the camshaft adapter, rotate the camshaft so that the dowel in the camshaft adapter is at the top of its travel.
Scene Number: 0020 4021
Audio
The camshaft gear is correctly located by a keyway in the camshaft gear.
Scene Number: 0020 4022
Audio
Make sure to properly align the timing marks.
Scene Number: 0020 4023
Audio
With the camshaft installed, pull the dowel rods from the tappets to lower the tappets onto the camshaft lobe surface.
Scene Number: 0020 4024
Audio
Install the push rods. Make certain that the push rods are correctly located in the tappets during installation. Install the
crossheads. Install and adjust the rocker levers.

Scene Number: 0020 4025


Audio
Complete the installation of the previously removed components.
Scene Number: 0020 4050
Audio
You are about to leave the Virtual Classroom and take the assessment.

If you are in review mode selecting Next will return you to the Main Menu.

Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon
to view the program guide.

Scene Number: 0020 5000


Audio
Which of the following is TRUE concerning the rear gear train?
Scene Number: 0020 5010
Audio
Which of the following components provides the mounting location for the camshaft position sensor?
Scene Number: 0020 5020
Audio
Which of the following is TRUE concerning the flywheel housing?
Scene Number: 0020 5030
Audio
Which of the following is TRUE concerning the gear driven accessory?
B Series Engine Rear Gear Train
Scene Number: 0020 5050
Audio
With the front and rear crankshaft seal design used on this engine, where is the rotating sealing surface?
Scene Number: 0020 5060
Audio
Which of the following is an aid in determining top dead center?
Scene Number: 0020 5070
Audio
Which of the following is a part of the procedure used to remove the rear crankshaft oil seal?
Scene Number: 0020 5080
Audio
Which of the following is recommended to polish and remove deposits from the crankshaft flange after removing the oil seal?
Scene Number: 0020 5090
Audio
Which of the following needs to be removed to gain access to the front crankshaft oil seal?
Scene Number: 0020 5100
Audio
Which of the following must be removed in order to access the camshaft gear?
Scene Number: 0020 5130
Audio
Which of the following gears have marks for alignment when installing?
Scene Number: 0020 5140
Audio
When should the front crankshaft seal be removed?
Scene Number: 0020 5150
Audio
How many different length capscrews are used for the front gear cover installation?
Scene Number: 0020 5160
Audio
After lifting the tappets in their bores using the service tool, what is used to hold the tappets out of the way for camshaft removal?
Scene Number: 0020 5170
Audio
What should be done immediately after removing the camshaft from the bore?