How to disassemble the Cummins M11 series engine exhaust manifold and intake manifold

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① The exhaust manifold assembly consists of three sections. To disassemble, remove one bolt from the end of each section, then install two guide pins (part number 3376488). Remove the remaining bolts, then remove the exhaust manifold itself. See Figure 2-25. 

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 ② Remove the intake manifold pressure sensor and temperature sensor wiring connectors from the intake manifold. See Figure 2-26.

 

  ③ Remove the intake manifold connector and gasket from the top of the intake manifold. Remove two mounting bolts, install two guide pins (part number 3376488), remove the remaining bolts, and use four M10x25 bolts to install the lift bracket onto the rocker arm housing. Tighten to a torque of 47 N·m. See Figure 2-27.

 

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How to disassemble the Cummins M11 series engine turbocharger and oil return pipe

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 Removal of the Turbocharger and Oil Return Pipe of the Cummins M11 Series Engine 4. Removal of the Turbocharger and Oil Return Pipe 

 

 

 

  ① Remove the oil supply pipe and gasket from the top of the turbocharger. Remove the other end of the oil supply pipe from the oil filter housing. Then remove the oil return pipe and gasket from the bottom of the turbocharger. See Figure 2-22. 

② Remove the V-clamp, exhaust elbow, and O-ring from the turbocharger compressor exhaust port. Remove the four mounting nuts. Remove the turbocharger and gasket. Block the turbocharger's oil supply and return ports. See Figure 2-23.

 

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③ Remove the turbocharger oil return pipe connector. See Figure 2-24.

 

  

Cummins DD13/15/16 Engine Drive Belt Replacement

This article describes the Cummins DD13/15/16 engine drive belt replacement

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NOTICE

Never rotate the automatic belt tensioners clock

wise. To do so may damage them, and require 

replacement of the entire assembly. To prevent

damage to the belt tensioners, always rotate

them counterclockwise. Never use more force

than 66 to 73 lbf (90 to 100 N), or you could dam

age the tensioner.

IMPORTANT: When releasing the automatic belt

tensioners and removing the drive belts, always

work on the front tensioner and belt (fan drive)

first, then the rear tensioner and belt (alternator,

A/C compressor, and water pump). When you

unlock the belt tensioners, reverse the proce

dure; unlock the rear belt tensioner first, then

front one.

5. Insert a 1/2-inch breaker bar, or 1/2-inch ratchet

into the square hole in the idler arm of the front

belt tensioner (grooved pulley), then smoothly

rotate it downward (counterclockwise) until you

feel resistance. See Fig. 3.

 

 

 

 

       

Fig. 3, Releasing the Front Tensioner

 

6. Insert a 10 mm diameter x 80 mm long bolt into the round hole on the idler arm of the tensioneras shown in Fig. 4, then push it all the way in.After the bolt is pushed all the way in, the tensioner will be locked in the released position. Remove the socket wrench from the square hole. 

 

7. Insert a 1/2-inch breaker bar, or 1/2-inch ratchet,into the square hole in the idler arm of the rear

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Fig. 4, Releasing the Rear Tensioner (smooth pulley)

 

belt tensioner (smooth pulley), then smoothly ro tate it downward (counterclockwise) until you feel resistance. See Fig. 4. 

 

8. Insert a second 10 mm diameter x 80 mm longbolt into the round hole on the idler arm of the rear tensioner as shown in Fig. 5, then push it all  the way in. After the bolt is pushed all the way in, the tensioner will be locked in the released posi tion. Remove the wrench from the square hole. 

 

9. Replace the drive belts, making sure the new belts are correctly installed on all the pulleys. 

 

10. Using the 1/2-inch breaker bar, or 1/2-inch ratchet, rotate the idler arm on the rear (smooth

pulley) tensioner downward (counterclockwise), until you can remove the locking bolt. Smoothly release the idler arm all the way up, being care ful not to jerk it. 

 

11. In the same manner as the previous step, re move the locking bolt from the front tensioner. 

 

12. Do a final check to make sure both drive belts are configured correctly, and correctly installed on all the pulleys. 

 

13. Close the hood, connect the batteries, then remove the chocks.

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Cummins M11 Series Engine oil Pan and Oil Pipe Removal Guide

 This short article introduces how to disassemble the oil pan and oil pipe of Cummins M11 series engine

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① Rotate the engine on the engine overhaul stand so that its side faces upward. Remove the two screws at positions 1 and 2 in Figure 2-88. 3 bolts, install the guide pin, and then remove the remaining 32 oil pan bolts.

② Remove the oil delivery pipe on the rear oil sump type oil pan, see Figure 2-89, and discard the two O-rings.

③ If the engine is equipped with a front oil collection tank suction pipe, remove it from the cylinder block, see Figure 2-90, and discard the O-ring.  

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How to Remove the Fuel Cummins Engine Suction Pipe Using the Sight Glass Method

 This article introduces the sight glass method for removing the fuel Cummins engine suction pipe

 Install a sight glass, Part Number 3375362, in the line.

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Operate the engine.

A small air leak will have a milky appearance. A large air leak will look like bubbles in the fuel.

If an air leak is found, inspect the fuel lines, o-rings, and fittings for damage. Check for loose connections.
Replace the damaged lines or tighten the loose

  

  Operate the engine at high idle with no load, and check the sight glass.

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  Tighten the hose connections and the fuel filter.
Check the drop tube in the fuel tank for damage.

 Replace any defective parts as required.
Remove the sight glass, and install the suction hose.
Test the engine again for other air leaks.

 Gear Pump Drain Method Remove the gear pump cooling drain line from the check valve, and install a plug in the line.
Install a hose on the check valve and place the other end of the hose in a container.

  Operate the engine at high idle with no load.

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 If air is entering the fuel pump suction line, bubbles will be visible in the container of fuel.