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ISBe4 Engine Introduction

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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.
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Upon completion of this course the learner will be capable of:
Describing the source of the engine name.
Describing the reason for the engine's introduction.
Demonstrating knowledge of the available service information.
Demonstrating knowledge of the base engine specifications.
Identifying the engines.
Identifying dataplate locations.
Demonstrating knowledge of engine features or components.
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The ISBe4 engine name is derived from many sources:
The IS portion of the name represents the Interact System. The Interact System is Cummins
automotive/on-highway full-authority electronic engine control system.
The B portion of the name represents the engine family. The ISBe4 is part of the B series mid-
range engine family.
The e4 portion of the name represents the specific market and emissions regulation stage
within that market. The ISBe4 is designed for the European stage 4 market.
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The ISBe4 engines have been designed for the European market and are certified to meet the
requirements of Euro 4 European on-highway emissions legislation. Euro 4 legislation applies to
new vehicle type approvals from Oct 2005 and all registrations by Oct 2006.
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The ISBe4 engines are supported by:
The ISBe4 4.5L and 6.7L (Common Rail Fuel System) Operation and Maintenance Manual
ISBe4, ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual The Service
Manual replaces the traditional Troubleshooting and Repair Manual, a Shop Manual, and the
Alternative Repair Manual.
ISBe4 CM850 Electronic Control System Troubleshooting and Repair Manual.
ISBe4 with CM850 Electronic Control Module Wiring Diagram
This service information is available electronically on QuickServe Online and Intercept and
also in hard copy. For more information contact your local Cummins Distributor.
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The ISBe4 is available as a 4.5 liter displacement inline 4 or a 6.7 liter displacement inline 6
cylinder engine.
The four and six cylinder engines have a common bore and stroke.
The inline six cylinder engines have a firing order of 1-5-3-6-2-4
The inline four cylinder engines have a firing order of 1-3-4-2
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The engine dataplate shows specific facts about the engine. The dataplate is typically located
on the engine rocker cover, but may be located on the side of the gear housing. The engine serial
number and CPL provide data for ordering parts and service.
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The ISBe4 engines may be produced at different factories for different markets. The data plates
used on engines may differ in appearance and location of information.
The dataplate contains the following information:
Engine serial number,
Control parts list (CPL),
Model, and
Horsepower and rpm rating.
If the engine dataplate is not readable, the engine serial number can be identified on the engine
block on top of the lubricating oil cooler housing.
Additional engine information is available by reading the ECM dataplate.
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The Bosch fuel injection pump dataplate is located on the fuel pump. The dataplate contains
the following information:
Pump serial number,
Cummins part number,
Factory code,
Bosch part number,
Date code.
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The electronic control module (ECM) dataplate shows information about the ECM and how the
ECM was programmed. The dataplate is located on the ECM.
The following information is available on the ECM dataplate:
ECM part number (PN)
ECM serial number (SN)
ECM date code (DC)
Engine serial number (ESN)
ECM code: Identifies the software in the ECM.
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The ISBe4 engines can quickly be distinguished from ISBe engines by:
The CM850 ECM with three connectors:
A sixty pin engine harness connector.
A fifty pin OEM harness connector.
A four pin OEM power connector.
A high pressure common rail fuel system.
An After Treatment Interface Connection in the wiring harness.
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The following sections will cover the systems and components of the ISBe4 including:
The Fuel system,
Air system,
Cooling system,
Lubrication system,
Electronic components,
and Mechanicals.
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The fuel system contains the following components:
The Gear Pump,
High Pressure Pump,
Fuel Control Valve,
Pre Filter,
Main Filter,
Low Pressure Fuel Lines,
High Pressure Fuel Lines,
Quick Disconnect Fittings,
Fuel Return Line,
Return Manifold,
Fuel Rail,
and the Fuel Rail Pressure Relief Valve.
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The fuel is pressurized to 6-9 bar in the gear pump.
The fuel supplied from the gear pump first flows to the Fuel Return Overflow Valve.
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The high pressure fuel pump assembly on the ISBe4 is similar to the high pressure fuel pump
assembly used on previous common rail equipped B series engines. The assembly contains a gear
pump, an EFC valve with associated wiring and external plumbing.
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At engine shutdown, the ECM causes the electronic fuel control valve to shut off the flow of
fuel to the fuel rail.
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Due to the closer tolerances of a High Pressure Common Rail fuel system, an additional 25
micron pre-filter is required to be mounted by the OEM between the fuel tank and the gear
pump, which is mounted on the high pressure fuel pump assembly.
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Filtering is provided by a 3 micron primary fuel filter mounted on the pressure side of the gear
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A new style quick disconnect low pressure fuel line connector is used at several locations on
the low pressure side of the fuel system.
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The quick disconnect is removed by pressing the two tabs inward that are located on the
connector. This allows the internal white clip ring to expand around the shoulder on the fuel line
fitting. The fuel line quick disconnect can then be pulled from the shouldered fuel line fitting.

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The high-pressure fuel lines connect the fuel rail to the individual fuel connectors.
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An all-in-one drain line from the fuel rail, the injector drain and the fuel pump drain is used to
route the drain fuel to the fuel return manifold and onto the tank.
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The fuel rail stores fuel and prevents pressure fluctuations by utilizing the elasticity of the
volume of fuel contained in the rail to dampen pressure spikes.

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The high pressure fuel rail is a laser welded forging equipped with a pressure relief valve
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The air system contains the following components:
Wastegate Controller,
Intake Manifold,
Intake Air Inlet,
Exhaust Manifold,
Charge Air Cooler,
Charge Air tubing.
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The ISBe4 utilizes a Holset wastegated turbocharger.
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The wastegated turbocharger's actuator is mounted on the compressor housing. This means the
turbine housing to compressor housing angular relationship is fixed.
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The intake manifold is a two-piece design with a captive capscrew. The intake manifold also
provides a mounting location for the Intake Temperature Manifold Pressure (TMAP) Sensor.
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The air intake manifold uses a circular inlet with a circular grid heater element, as well as a
rotating elbow.
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Turbocharging causes an increase in the temperature of the intake air. The charge air cooler
mounted in front of the radiator reduces the temperature of the intake air.
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Hot intake air flows to the charge air cooler from the turbocharger compressor outlet, through
the charge air cooler, and to the intake manifold.

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The cooling system contains the following components:
Water Pump,
Integral Thermostat Housing,
Water Inlet,
Water Outlet.
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The water pump is belt driven and installs in the integral volute in the engine block.
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The integral thermostat housing, located in the cylinder head, provides a location for mounting
the thermostat vertically in the cooling system. This orientation of the thermostat provides for
better de-aeration of the cooling system.
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Various style water inlets are available. One water inlet has a provision for an alternator,
tensioner, and idler pulley mounting.
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The water outlet installs over the thermostat.
Alternative water outlet connections are available.
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The lubrication system contains the following components:
Lube Oil Fill Locations,
Turbocharger Feed Line,
Turbocharger Drain Line,
Crankcase Breather,
Crankcase Breather Drain line,
Oil Pan,
Lube Oil Filter,
Lube Oil Filter Head,
Lube Oil Cooler,
Piston Cooling Nozzles,
Lube Oil Pump.
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The oil fill is through the top of the valve cover.
An alternative fill location is in a low position on the front gear cover. This provides access for
fill tubes at convenient vehicle locations.
The six cylinder engine has an additional oil fill access hole on the left side of the block.
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Optional dipstick mounting locations are available to provide access in various installations.
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Once the oil is cooled and filtered, oil flow is divided, with a portion of the oil flowing through
the Turbocharger oil supply line to the turbocharger.

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Oil is sent back to the oil pan from the Turbocharger through the Turbocharger Drain Line.
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The crankcase breather has internal baffling under the rocker lever cover and exits the rear of
the cover. The baffling should not be removed for service.
A new breather connection tube from the rocker lever cover to the rear gear housing eliminates
the need for a separate drain.
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The standard oil pan is a suspended oil pan design that is isolated to reduce engine noise.
Typical capacities are 17 liters for the 6 cylinder and 11.4 liters for the 4 cylinder.
An optional 14.2 liter capacity oil pan can be utilized on the 6 cylinder engine.
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The oil filter is a full flow spin-on element.
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The oil flows up the center of the filter and into the filter head.
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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
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All ISBe4 engines have J Jet piston cooling nozzles. These engines also use a gallery cooled
piston design.
Oil from the J Jet piston cooling nozzles is directed into an oil gallery in the piston crown. This
design allows oil to absorb additional heat from the piston crown when compared to other piston
cooling methods.
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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.
The ISBe4 is a dump to sump, unlike the ISBe3, which was a dump to pump.
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The electronic components contain the following:
CM850 Engine Control Module
OEM Connector,
Engine Connector,
OEM Power Connector,
ECM Air-Cooling Plate,
Engine Wiring Harness,
Aftertreatment Interface Connection,
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The CM850 ECM contains three outboard facing ports for the individual wiring harness
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The OEM Connector is a 50 pin OEM harness connector.
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The Engine Connector is a 60 pin engine harness connector.
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The OEM Power Connector is a 4 pin power connector.
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The new style air cooled ECM cooling plate utilizes a three bolt mounting yoke. This yoke
contains soft shock mounting hardware.
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The wiring harness connects the ECM to the various electrical components.
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The Aftertreatment Interface Connection is a SCR 14-pin Connector.
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The electrical components contain the following sensors:
Fuel Rail Pressure Sensor,
Intake Manifold Pressure/Temperature Sensor,
Ambient Air Pressure Sensor,
Engine Speed Sensor (Camshaft),
Engine Speed Sensor (Crankshaft),
Coolant Temperature Sensor,
Oil Pressure Switch.
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The signal from the Fuel Rail Pressure Sensor is used by the ECM to determine the fuel
pressure in the rail.
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The Intake Manifold Pressure/Temperature Sensor is a combination sensor.
The Intake Manifold pressure input is used for air/fuel control.
The ECM uses the intake manifold temperature input for engine protection and for fan clutch
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Information from the Ambient Air Pressure Sensor allows the ECM to determine the
atmospheric pressure. This information is used for Air/Fuel control and altitude derate
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The Camshaft speed sensor is located on the front gear cover.
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Engine speed is sensed by the Engine Speed Sensor from a disc on the crankshaft pulley.

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The Coolant Temperature Sensor is located at the front right side of the cylinder head, near the
thermostat. The input from this sensor allows the ECM to determine the coolant temperature.
Coolant temperature input is used for:
Controlling the operation of the fan,
varying the fueling for starting,
controlling injection timing
and the engine protection system.
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The Engine Oil Pressure switch is installed on the top of the front gear cover above the
camshaft speed sensor. This sensor indicates the pressure of the oil as an input to the engine
protection system.
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The mechanical system contains the following components:
Air Compressor,
Cylinder Head,
Cylinder Block,
Flywheel Housing,
Rear Gear Housing,
Front Gear Cover,
Front Gear Housing,
Vibration Damper,
Tone Wheel,
Belt Tensioner,
Connecting Rods,
Main Bearings,
Rod Bearings,

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The ISBe4 utilizes a Knorr Bremse twin Reed single-cylinder air compressor. It is very
important that this compressor be timed to the engine at TDC

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The cylinder head is a one-piece, cross flow design.
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The new cylinder blocks for the four and six cylinder engines are sculpted and stiffened for
noise reduction.
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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. The flywheel housing also serves as the rear gear cover.
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The front gear cover provides a mounting location for the front crankshaft oil seal, the
Crankshaft Speed Sensor, the Camshaft Position Sensor and the Oil Pressure Switch.
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Six cylinder engines have a viscous damper and four cylinder engines may be equipped with a
rubber element damper or no damper device.

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The tone wheel sensor window is used to locate Top Dead Center for some service procedures.
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The crankshaft drives the camshaft, which drives the fuel pump, and accessory gear.
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The engine design incorporates a spring loaded automatic belt tensioner.
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The connecting rods utilize a fractured rod cap. 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.
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The block is machined to accept seven main bearings with thrust bearings located at the
number 6 main bearing location.
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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.
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The cast aluminum piston utilizes an improved swirl design combustion chamber and a piston
cooling gallery.
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The IS portion of the name ISBe4 represents what?
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Which of these is not listed on the engine dataplate?
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The CM850 ECM engine harness connector is
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What micron pre-filter is used on the ISBe4 engine?
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How is the thermostat mounted in the cooling system?
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What is the typical capacity of the 6 cylinder engine oil pan?
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The Gerotor type lubricating oil pump is mounted at the front of the cylinder block is?
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The Aftertreatment Interface Connection is a
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True or False: The 6 cylinder engines may be equipped with a rubber element damper or
without a damper device.
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Where are the thrust bearings located?