Service Bulletin

Subject
VTA-903 Big Cam Engine

Bulletin No. 3810471-00 Date:

March, 1991
VTA903-T600
WARNING
THIS DOCUMENT, AS WELL AS THE EN­
G IN E^) AND SOME PART(S) REFERRED TO
IN THIS DOCUMENT, ARE ON THE U.S. MU­
NITIONS LIST. EXPORTATION FROM THE
U.S. REQUIRES AN EXPORT LICENSE FROM
THE U.S. STATE DEPARTMENT. UNCLAIMED
EXPORTATION IS PUNISHABLE BY CRIMINAL
AND CIVIL SANCTION. REFER TO THE IN­
TERNATIONAL TRAFFIC IN ARMS REGULA­
TIONS, TITLE 22, CODE OF FEDERAL REG­
ULATIONS, PARTS 121 - 128 AND/OR
CUMMINS ENGINEERING STANDARD 10,047.

ew300gc

VTA903-T660

Cummins Engine Company, Inc., Columbus, Indiana 47202-3005

Cummins Engine Company Ltd., Daventry, Northerns, England NN11 SNU
Registered Office: 46-50 Coombe Road, New Malden, Surrey KT3 4QL
Registered No. 573951 England
Copyright © 1991
Cummins Engine Company Inc.
All rights reserved.
 VTA-903 Big Cam Engine
Page 3

Table of Contents

Section і - Introduction ............................................................................................................................................... i-1

Capscrew Markings and Torque Values - U.S. Customary ............................................................................ i-5
Definitions of Terms ............................................................................................................................................... i-4
General Safety Instructions .................................................................................................................................. i-3
How to Use the Bulletin ........................................................................................................................................ i-1
Symbols ................................................................................................................................................................... i-2
Section E - Engine Identification ............................................................................................................................. E-1
Engine Diagrams ................... ,............................................................................................................................. E-1
Engine Specifications .......................................................................................................................................... E-9
Engine Disassembly and Assembly - Group 00 .................................................................................................... 0-1
Aftercooler ........................................................................................................................................................... 0-15
Installation ........................................................................................................................................................ 0-20
Removal ........................................................................................................................................................... 0-15
Exhaust System and Turbocharger - Installation ............................................................................................. 0-9
Exhaust Collector Connection ....................................................................................................................... 0-10
Exhaust Manifolds ............................................................................................................................................. 0-9
Exhaust Outlet Tubes ..................................................................................................................................... 0-11
Radiator Support To Cylinder Block ............................................................................................................. 0-10
Turbocharger ................................................................................................................................................... 0-12
Injector .................................................................................................................................................................. 0-30
Installation ........................................................................................................................................................ 0-33
Removal ........................................................................................................................................................... 0-30
Intake Manifold ................................................................................................................................................... 0-26
Installation ........................................................................................................................................................ 0-28
Removal ........................................................................................................................................................... 0-26
Oil Cooler ................................................................................................................................................................ 0-3
Installation .......................................................................................................................................................... 0-4
Removal .................................................................................................................................................. 0-3
Oil Cooler Supports ................................................................................................................. 0-5
Installation .......................................................................................................................................................... 0-6
Removal .............................................................................................................................................................. 0-5
Pistons ......................................................................................................................................................... 0-1
Installation on Connecting Rod .................................................................................. 0-2
Removal From Connecting Rod ...................................................................................................................... 0-1
Radiator Support To Cylinder Head .................................................................................................................... 0-8
Installation .......................................................................................................................................................... 0-8
Removal ....................................................................................................... 0-8
Starting Aid Nozzle ............................................................................................................................................. 0-13
General Information ......................................................................................................................................... 0-13
Installation ........................................................................................................................................................ 0-14
Removal ........................................................................................................................................................... 0-13
Resistance Check ............................................................................................................................................ 0-15
Valve and Injector Adjustment .......................................................................................................................... 0-37
Adjustment After Major Repair or Rebuild ................................................................................................... 0-41
Adjustment During Routine Maintenance .................................................................................................... 0-39
General Information ............................................................. 0-37
Injector Preload Adjustment .......................................................................................................................... 0-43
Valve Adjustment ............................................. 0-46
VTA-903 Big Cam Engine
Page 4

Cylinder Block - Group 01 ...................................................................................................................................... 01-1

Camshaft .............................................................................................................................................................. 01-3
Camshaft Bushings ............................................................................................................................................. 01-6
Installation ...................................................................................................................................................... 01-13
Removal ........................................................................................................................................................... 01-7
Cylinder Block ...................................................................................................................................................... 01-2
General Information ........................................................................................................................................ 01-2
Gear Housing Plate .......................................................................................................................................... 01-5
Gear Housing PlateGasket ................................................................................................................................ 01-5
Parts Commonalty .......................................................................................................................................... 01-1
Piston .................................................................................................................................................................... 01-3
Piston Cooling ...................................................................................................................................................... 01-4
Piston Cooling Nozzle ........................................................................................................................................ 01-4
Rear Oil Crossover Passage ............................................................................................................................. 01-5
Vibration Damper ................................................................................................................................................ 01-2
Water Header ....................................................................................................................................................... 01-1
Front ................................................................................................................................................................. 01-1
Right and Left Bank ....................................................................................................................................... 01-2
Cylinder Head - Group 02 ...................................................................................................................................... 02-1
Parts Commonalty .......................................................................................................................................... 02-1
Rocker Lever - Group 03 ....................................................................................................................................... 03-1
Oil Filler Cap ........................................................................................................................................................ 03-2
Parts Commonalty ............................................................................................................................................... 03-1
Rocker Lever - Injector ....................................................................................................................................... 03-1
Rocker Lever Housing ........................................................................................................................................ 03-1
Cam Follower - Group 04 ....................................................................................................................................... 04-1
Parts Commonalty ............................................................................................................................................... 04-1
Valve Push Rods - Intake and Exhaust ............................................................................................................ 04-1
Fuel System - Group 05 ......................................................................................................................................... 05-1
Fuel Pump - Identification ................................................................................................................................. 05-1
Parts Commonalty ............................................................................................................................................... 05-1
Injectors - Group 06 ............................................................................................ 06-1
Fuel Tubing ........................................................................................................................................................ 06-11
Fuel, STC, and Cold Start Lines - VTA-903 T600 Horsepower Engine .......................................... 06-11
Fuel, STC, and Cold Start Lines - VTA-903 T660 Horsepower Engine .......................................... 06-11
Fuel Tubing System Engine Diagrams ........................................................................................................... 06-12
Injectors - General Information ......................................................................................................................... 06-1
Calibration ........................................................................................................................................................ 06-2
Identification ..................................................................................................................................................... 06-2
PT (Type D) Step Timing Control (STC) ...................................................................................................... 06-1
Rebuild .............................................................................................................................................................. 06-2
STC Electrical ...................................................................................................................................................... 06-3
Control System Diagnostic Tool Operation ................................................................................................ 06-3
Control System Diagnostics ........................................................................................................................... 06-5
Fuel Rail Pressure Switch Operation ........................................................................................................... 06-3
Oil Control Solenoid Operation ..................................................................................................................... 06-3
Time Delay Relay Operation ......................................................................................................................... 06-3
STC Electrical Control System Troubleshooting Chart ............................................................................... 06-11
STC Injector Operation ....................................................................................................................................... 06-2
STC System Functional Check ......................................................................................................................... 06-7
STC Solenoid Resistance Check ...................................................................................................................... 06-8
STC System Functional Check Troubleshooting Chart ............................................................................... 06-10
STC System Wiring Diagrams ........................................................................................................................ 06-19
Leece-Neville Starter .................................................................................................................................... 06-19
Delco-Remy Starter ...................................................................................................................................... 06-20
 VTA-903 Big Cam Engine
Page 5

Lubricating Oil System - Group 07 ................................................. . 07-1

. 07-4
Lubricating Oil Cooler Core - Pressure Testing ........................
Lubricating Oil Pressure Regulator (External) .......................... . 07-3
Lubricating Oil Pump (High Speed - Double Pump) ................ 07-18
07-18
Inspect for Reuse .....................................................................
07-19
Rebuild .......................................................................................
Lubricating Oil Pump (High Speed - Single Pump) ................. . 07-5
Inspect for Reuse ................................ ..................................... . 07-5
Rebuild ........................................................................................ . 07-7
Lubricating Oil Pump Body and Cover Bushing (Single Pump) 07-31
Replacement ............................................................................. 07-31
Lubricating Oil Pump Drive Gear Bushing ................................ 07-40
Replacement ............................................................................. 07-40
Lubricating Oil Pump Drive Gear or Shaft ................................ 07-44
Replacement ........................................ ..................................... 07-44
Lubricating Oil Pump Driven Shaft ............................................ 07-47
Replacement ............................................................................. 07-47
Lubricating Oil Pump Idler Gear Bushing ................................. 07-41
Replacement ............................................................................. 07-41
Lubricating Oil Pump Idler Shaft ................................................. 07-42
Replacement ............................................................................. 07-42
Lubricating Oil Scavenge Pump ................................................. 07-37
Body Bushing - Replacement ................................................. 07-37
Body Driven Shaft - Replacement .......................................... 07-48
Drive Gear or Shaft - Replacement ........................................ 07-45
Lubricating Oil System Flow ........................................................ . 07-1
Lubricating Oil System - General Information .......................... . 07-2
Drive Shaft Bushing Replacement ......................................... . 07-2
Installation of Oil Suction Tube .............................................. . 07-3
Lubricating Oil Pump Configurations .................................... . 07-2
Main Drive Gear Plate Mounting Capscrews ........................ . 07-2
Cooling System - Group 08 .................................................................................................................................... 08-1
Transmission Oil Cooler ..................................................................................................................................... 08-1
General Information ........................................................................................................................................ 08-1
Identification .............................................................................................................................. 08-2
Pressure Test ................................................................................................................................................... 08-2
Water Pump ......................................................................................................................................................... 08-1
General Information ...................................................................................................................................... 08-1
Identification ..................................................................................................................................................... 08-1
Drive Units - Group 09 ............................................................................................................................................ 09-1
Fuel Pump Drive - VTA-903 T660 Horsepower Engine Only ........................................................................ 09-1
General Information ........................................................................................................................................ 09-1
Installation ........................................................................................................................................................ 09-1
Intake System - Group 10 ...................................................................................................................................... 10-1
Aftercooler Core .................................................................................................................................................. 10-2
Pressure Test ................................................................................................................................................... 10-2
Cold Start System .................... 10-2
General Information ............................................................................................................... 10-2
Big Cam 600 Horsepower Engine ............................................................................................................ 10-2
Big Cam 660 Horsepower Engine ............................................................................................................ 10-2
Turbocharger ....................................................................................................................................................... 10-1
General Information ........................................................................................................................................ 10-1
Turbocharger Air Discharge Hose and Clamps .............................................................................................. 10-1
General Information ........................................................................................................................................ 10-1
VTA-903 Big Cam Engine
Page 6

Exhaust System - Group 11 ................... 11-1

General Information ................................... 11-1
Exhaust Manifold ................................ 11-1
Identification ............................ 11-1
Exhaust Manifold Mounting Capscrew 11-1
Identification ........................ . n-i
Engine Testing - Group 14 ................ 14-1
Cooling System Venting ................ 14-1
General Information ................... 14-1
Lubricating System ........................ 14-5
Priming ......................................... 14-5
Lubricating System Full Flow Filter 14-3
General Information ................... 14-3
Plumbing ..................................... 14-3
Thermostat Water Bypass ............ 14-3
General Information ................... 14-3
Plumbing ..................................... 14-3
Mounting Adaptations - Group 16 ......................................................................................................................... 16-1
Flexible Coupling ................................................................................................................................................ 16-1
General Information ........................................................................................................................................ 16-1
Identification .................................................................................................................................................... 16-1
Specifications - Group 18 ....................................................................................................................................... 18-1
Specifications ....................................................................................................................................................... 18-2
Cylinder Block ................................................................................................................................................. 18-7
Drive Units ....................................................................................................................................................... 18-8
Engine Assembly ............................................................................................................................................. 18-2
Engine Testing ................................................................................................................................................ 18-9
Lubricating Oil System .................................................................................................................................. 18-7
Section і - Introduction Introduction
V903 Page i-1

Introduction
The Cummins VTA903 Big Cam engine has been developed for the military combat vehicle market. Cummins
Engine Co., Inc. has combined proven concepts with new technology in the VTA-903 Big Cam engines to provide
new standards of performance and durability.
The major design improvements include a 3 inch diameter camshaft, new turbocharger, upgraded fuel system with
Step Timing Control (STC), new exhaust and intake system, new oil cooler and aftercooler, increased oil pan
capacity and new piston and piston cooling.
How To Use The Bulletin
This bulletin contains only information for the design changes between the V/VT903 Small Cam and
V/VT903 Big Cam engines. If further information is required, refer to the V/VT903 and VTB903 C.I.D. Engine
Shop Manual, Bulletin No. 3379057-04.
This bulletin is divided in the same group system used for previous manuals and the Cummins’ filmcard system.
Refer to the Table of Contents at the front of the bulletin to determine the groUp and section that details the desired
information.
Symbols Section і - Introduction
Page i-2 V903

Symbols
The following group of symbols have been used in this manual to help communicate the intent Of the instructions.
When 0ПЄ Of the symbols appears, it conveys the meaning defined below.

WARNING - Provides a warning to take precaution to avoid bodily injury from electrical shock or
A electrocution. There is in the vicinity uninsulated high A.C. voltage.

WARNING - Serious personal injury or extensive property damage can result if the warning
A instructions are not followed.

CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged
A if the caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

The main circuit breaker is closed and normal power is being supplied to the equipment.

The main circuit breaker must be open so that normal power is not being supplied to the
equipment.

The generator set is on and supplying power to the equipment.

The generator set must be off and not supplying power to the equipment.

The wiring harness disconnect plug must be disconnected.

The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get
assistance to lift the component.
Section і - Introduction General Safety Instructions
V903 Page i-3

General Safety Instructions

Important Safety Notice

A WARNING Д
Read and understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed to provide personal safety. Special safety precautions are
included in the procedures when they apply.
• Make sure the work area surrounding the product is safe. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery and discharge any capacitors before beginning any repair work. Disconnect the air
starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator’s
compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate
the engine by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
• Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (freon)
lines in a well ventilated area.
• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct
capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact
with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case
of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
• To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines, tubes,
and compartments.
• Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins Recon® replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lessor quality if replacements are necessary.
Definition of Terms Section і - Introduction
Page i-4 V903

Definition of Terms

AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is suf­
ficient intake manifold pressure to allow for complete combustion.

CPL: Control Parts List; this listing identifies the specific parts that must be installed on the
engine to meet agency certification.

Cummins® Sealant: This is a one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive and
sealant material having high heat and oil resistance, and low compression set.

End Clearance: An assembly measurement that is determined by pushing a shaft in an axial direction
ONE direction and then pushing the shaft in the opposite direction.

E.S.N.: Engine Serial Number

HP Horse power

I.D. Inside diameter.

Mallet: A hand tool consisting of a soft head; either wood, plastic, lead, brass, or rawhide on a
handle.

MAX: Maximum allowed.

MIN: Minimum allowed.

No.: Number

O.D. Outside diameter.

Protrusion: The difference in the height between two parts in the assembled state.

RDF: Reduced Drain Flow Injectors

STC: Step Timing Control; previously referred to as Hydraulic Variable Timing (HVT).

T.I.R.: Total Indicator Reading; referred to when measuring the concentricity or the run out.
The TIR refers to the total movement of the needle on a dial indicator, from the most
negative reading to the most positive reading.
Section і - introduction Capscrew Markings and Torque Values • U.S. Customary
V903 Page i-5

Capscrew Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
Capscrew Head Markings
These are all SAE Grade 5 (3) line

Cap>screw Torque - Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew

Capscrew Body Size ------- test Iron Aluminum 6 ast Iron Aluminum
N*m ft-lb N«m ft-lb N*m ft-lb N«m ft-lb
1/4 - 20 9 7 8 6 15 11 12 9
- 28 12 9 9 7 18 13 14 10
5/16 - 18 20 15 16 12 30 22 24 18
- 24 23 17 19 14 33 24 25 19
3/8 - 16 40 30 25 20 55 40 40 30
- 24 40 30 35 25 60 45 45 35
7/16 - 14 60 45 45 35 90 65 65 50
- 20 65 50 55 40 95 70 75 55
1/2 - 13 95 70 75 55 130 95 100 75
- 20 100 75 80 60 150 110 120 90
9/16 - 12 135 100 110 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
5/8 - 11 180 135 150 110 255 190 205 150
- 18 210 155 160 120 290 215 230 170
3/4 - 10 325 240 255 190 460 340 365 270
- 16 365 270 285 210 515 380 410 300
7/8 - 9 490 360 380 280 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1 - 8 720 530 570 420 1100 820 890 660
- 14 800 590 650 480 1200 890 960 710
Engine identification Engine Diagram - VTA-9013 T600 Engine
V903 Page E-1

Engine identification
Engine Diagram - VTA-903 T600 Big Cam

Radiator Support
Bracket (Center of
Vee)

Left Bank Exhaust Oil Cooler Wate

Outlet Tube Outlet Tube

External Oil Pressure

Regulator (Not Shown)

Oil Cooler Water

Inlet Tube

Oil Cooler
Coolant Drain

Oil Pressure
Engine Oil
Regulator Bypass
Cooler
Hose Oil Cooler Rear
Support
Oil Cooler
Front Support
Left Bank Exhaust twaciOgv
Manifold
Engine Diagram - VTA-903 T600 Engine E n g in e Identification
Page E-2 V903

Engine Diagram - VTA-903 T600 Big Cam

STC Time Delay Relay and

STC Oil Control Solenoid
Cold Start Fuel Solenoid and (Not Shown)
Engine Identification Engine Diagram - VTA-903 T600 Engine
V903 Page E-3

Engine Diagram - VTA-903 T600 Big Cam

Turbocharger
Engine Diagram - VTA-903 T600 Engine Engine Identification
Page E-4 V903

Engine Diagram - VTA-903 T600 Big Cam

STC Fuel Pressure

Engine Identification Engine Diagram - VTA-903 T660 EEngine
V903 Page E-5

Engine Diagram - VTA-903 T660 Big Cam

Hose ew300gs
Engine Diagram - VTA-903 T660 Engine Engine Identification
Page E-6 V903

Engine Diagram - VTA-903 T660 Big Cam

Engine Identification Engine Diagram - VTA-903 T660 Engine
V903 Page E-7

Engine Diagram - VTA-903 T660 Big Cam

Turbocharger Turbocharger
Oil Supply (Insulated)

Turbocharger
Oil Drain Tube

Exhaust Collector XC
(Insulated)

Aftercooler
Water Pump Coolant Drain

Left Bank Exhaust

Outlet Tube (Insulated)

Right Bank
Turbocharger
Exhaust Outlet
Oil Drain Tube
Tube (Insulated)

Oil Pressure
Engine Water Inlet Regulator Bypass
Hose

Oil Pan
Vibration Damper ewSOOgt
Engine Diagram - VTA-903 T660 Engine Engine Identification
Page E-8 V903

Engine Diagram - VTA-903 T660 Big Cam

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Engine Specifications GENERAL ENGINE DATA
V903 Page E-9

Engine Specifications
GENERAL ENGINE DATA
_______________________Engine Model_____

VTA-903 T600 Big Cam VTA-903 T660 Big Cam

Maximum Rating 600 HP at 2600 RPM 660 HP at 2800 RPM
447 kw at 2600 RPM 492 kw at 2800 RPM
Configuration Number D173061TX02 DX173068TX02
Fuel Pump Code E236 (Restricted) E254 (Restricted)
CPL Number 1191 1360
Type 4 Cycle, 90 Degree Vee, 8 Cylinder 4 Cycle, 90 Degree Vee, 8 Cylinder
Aspiration Single-Stage Turbocharged and Aftercooled Single-Stage Turbocharged and Aftercooled
Displacement 14.8 Litre |903 Cubic Inch] 14.8 Litre [903 Cubic Inch]
Dry Weight (Engine Only) 1200 kg [2650 lb] 1145 kg [2525 lb]
Firing Order 1-5-4-8-6-3-7-2 1-5-4-8-6-3-7-2
Compression Ratio 14.5:1 14.5:1
Injection Timing [0.110 inch + 0.003 inch] at [0.2032 inch] [0.110 inch + 0.003 inch] at [0.2032 inch]
BTDC BTDC
Timing Code HD HD

FUEL SYSTEM
VTA-903 T600 Big Cam VTA-903 T660 Big Cam
PT (Type G) dual spring AFC Fuel Pump with
RDF Full Top Stop (STC) Injectors
Minimum Fuel Supply line size normally
acceptable up to 7.6 m [25 ft] No. 12 No. 12
Fuel Drain Line size length normally
acceptable up to 7.6 m [25 ft] No. 8 No. 8
Maximum Allowable Restriction to PT Fuel Pump
With clean filter 100 mm Hg 4.0 in Hg] 100 mm Hg [4.0 in Hg
With dirty filter 200 mm Hg 8.0 in Hg] 200 mm Hg [8.0 in Hg
Maximum Allowable Injector Return Line Restriction
With check valves 165 mm Hg [6.5 in Hg] 165 mm Hg [6.5 in Hg]
Without check valves 64 mm Hg [2.5 in Hg] 64 mm Hg [2.5 in Hg]
Voltage required to operate STC oil control valve MIN MAX MIN MAX
18DC 31 DC 18DC 31 DC

EXHAUST SYSTEM
Maximum allowable back pressure 76 mm Hg [3.0 in Hg] 76 mm Hg [3.0 in Hg]
Exhaust pipe minimum diameter normally ac­ 152 mm [6 inch] 152 mm [6 inch]
ceptable
GENERAL ENGINE DATA Engine Specifications
Page E-10 V903

AIR INDUCTION SYSTEM

Engine Model
VTA-903 T600 Big Cam VTA-903 T660 Big Cam

Maximum Allowable Intake Restriction with Heavy Duty Air Cleaner

Clean Element 380 mm H20 [15 in H20] 380 mm H20 [15 in H20]
Dirty Element 635 mm H20 [25 in H20] 635 mm H20 [25 in H20]
Minimum Allowable Dirt Holding Capacity
with Heavy Duty Air Cleaner 11.8 grams/liters/sec 11.8 grams/liters/sec
[25 grams cfm] [25 grams cfm]
Intake Pipe minimum diameter normally ac­ 203 mm [8.0 inch] 203 mm [8.0 inch]
ceptable

COOLING SYSTEM
Coolant Capacity - Engine Only 34 Litre [36 U.S. Quart] 34 Litre [36 U.S. Quart]
Standard Thermostat (modulating) Range 82°C to 93°C 82°C to 93°C
[180°F to 200°F] [180°F to 200°F]
Minimum Recommended Top Tank 70°C [160°F] 70°C [160°F]
Temperature
Maximum Allowable Top Tank Temperature 110°C [230°F] 110°C [230°F]

LUBRICATION SYSTEM
Minimum Oil Pressure - Idle 103 kPa [15 psi] 103 kPa [15 psi]
Oil Pressure with 15W-40 Oil at 170°C
[225° F] (Main Oil Rifle):
• Minimum at Rated RPM: 275 kPa [40 psi] 275 kPa [40 psi]
• Maximum at Rated RPM: 414 kPa [60 psi] 414 kPa [60 psij
Rocker Lever Housing - STC Drilling:
• Minimum Oil Pressure - Idle RPM 103 kPa Minimum 103 kPa Minimum
(Advanced Mode): [15 psi] [15 psi]
• Maximum Oil Pressure - Rated RPM 55 kPa Maximum [8 psi] 55 kPa Maximum [8 psi]
(Retarded Mode):
Maximum Allowable Oil Temperature 138°C [280°F] 132°C [270° F]
Oil Pan Capacity
Part No. 3060069 3625258
• High: 26.5 Litre [7 U.S. Gal] 28.4 Litre [7.5 Gal]
• Low: 22.7 Litre [6 U.S. Gal] 24.6 Litre [6.5 Gal]
Engine Specifications GENERAL ENGINE DATA
V903 Page E- l 1

PERFORMANCE DATA
VTA903-T600 Big Cam

Low Idle Speed - RPM 800 RPM ± 25 RPM

Maximum No-load Governed Speed - RPM 2970 RPM ± 70 RPM

Maximum Overspeed Capacity - RPM 3200 RPM

\

Full Power
Minimum Maximum

Engine Speed RPM 2600 2600

Gross Power Output 439 KW 457 KW

[588 BHP] [612 BHP]

Torque 1610.7 N*m 1675 N»m

[1188 ft-lb] [1236 ft-lb]
Intake Manifold Pressure 1194 mm Hg 1448 mm Hg
[47 in Hg] [57 in Hg]
Fuel Pressure at Cylinder Heads 986 kPa 1082 kPa
[143 psi] [157 psi]

Blow-by with one 7.67 mm [0.302 inch] orifice 254 mm H20

(New or Rebuilt Engine During Initial Run-in Only) [10 inch H20]

VTA903-T660 Big Cam

Low Idle Speed - RPM 800 RPM ± 25 RPM
Maximum No-load Governed Speed - RPM 3075 RPM ± 75 RPM
Maximum Overspeed Capacity - RPM 3200 RPM

Full Power
Minimum Maximum
Engine Speed RPM 2800 2800
Gross Power Output 482 KW 502 KW
[647 BHP] [673 BHP]
Torque 1645 N»m 1710 N*m
[1214 ft-lb] [1262 ft-lb]
Intake Manifold Pressure 1194 mm Hg 1448 mm Hg
[48 in Hg] [57 in Hg]
Fuel Pressure at Cylinder Heads 1241 kPa 1379 kPa
[180 psi] [200 psi]
Blow-by with one 7.67 mm [0.302 inch] orifice 254 mm H20
(New or Rebuilt Engine During Initial Run-in Only) {10 inch H20]
DISASSEMBLY AND ASSEMBLY - Group 00 Pistons
V903 Page 0-1

DISASSEMBLY AND ASSEMBLY - Group 00

Pistons
Removal From Connecting Rod
NOTE: To prevent increased wear, if the piston and con­
necting rod assembly is to be reused, the piston must be
installed in the same cylinder number from which it was
removed. If the piston was not previously marked, mark the
piston with the cylinder number before removing the con­
necting rod from the piston.

Use a piston ring expander, Part No. 3823871, to remove

the piston rings.
Put a tag on the rings, and record the cylinder number of
the piston on the tag for future reference (if required).

NOTE: Do not heat the piston to remove the piston pin.

Use internal snap ring pliers to remove the snap rings
from both sides of the piston.
Use your fingers to push the piston pin from the piston
and rod assembly.

I
Pistons DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-2 V903

Installation On Connecting Rod

Do not heat the piston to install the piston pin. If the piston
pin will not fit into the bore freely with both parts at the
same temperature, check for burrs or dirt in the pin bore.
Install a new retaining ring in the pin bore closest to the
piston cooling nozzle notch in the piston skirt.
NOTE: Make sure the retaining ring is seated in the groove.

Check to make sure any new connecting rods are marked

so the rod and cap remain together. New rods have a
common number stamped on the cap and rod OPPOSITE
the bearing tang side of the rod. Mark the rod and cap on
the bearing tang side with the engine cylinder in which
they will be installed.

Use clean 15W-40 oil to lubricate the connecting rod pin

bore and the piston pin.

NOTE: If the pistons are being reused, the cylinder number

on the piston and connecting rod must be the same.
Position the piston cooling nozzle notch (1) in the skirt
away from the bearing tang (2) side of the connecting rod.
When properly installed the OUTSIDE OF VEE marking
on top of the piston will be closer to the outside of the
cylinder block (farthest from the tappet bores).

11
DISASSEMBLY AND ASSEMBLY - Group 00 Oil Cooler
V903 Page 0-3

Align the pin bore in the rod with the pin bore in the piston.
Install the piston pin. Do not use force to install the piston
pin. If the pin will not slip into the bore freely, check for
burrs in the pin bore.

Install a new retaining ring in the second pin bore retain­

ing ring groove.
Check to make sure both retaining rings are seated com­
pletely in the grooves. If the retaining rings are not in­
stalled correctly, the rings will fall out during engine op­
eration and cause severe damage.

Oil Cooler
Removal
NOTE: The cooling system must be drained prior to remov­
ing the oil cooler assembly.
Loosen the two hose clamps and slide the hose onto the
water outlet transfer tube.

Loosen the two hose clamps on the water inlet transfer

tube. Remove the tube clamp capscrew, clamp, and the
transfer tube. Discard the o-ring.

\
Oil Cooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-4 V903

Support the oil cooler assembly while removing the two

capscrews from each of the mounting flanges.
Remove the oil cooler assembly. Remove and discard the
two rectangular seal rings.

Installation
Apply a small amount of gasket adhesive to the rectan­
gular seal ring grooves in the oil cooler supports to hold
the seal rings in place.
Install new rectangular seal rings in the seal ring grooves.

Put the oil cooler assembly on the cooler supports, and

align the mounting holes in the flanges with the capscrew
holes in the cooler supports.
Install two captive washer capscrews in each of the mount­
ing flanges. Tighten the capscrews.
Torque Value: 50 N»m [35 ft-lb]

Install a new o-ring on the water inlet transfer tube.

Use clean vegetable oil to lubricate the o-ring.
DISASSEMBLY AND ASSEMBLY - Group 00 Oil Cooler Supports
V903 Page 0-5

Slide the hose down over the oil cooler water inlet con­
nection.

screw. Tighten the capscrew.

Torque Value: 30 N»m [20 ft-lb]

Center the hose between the transfer tube and the oil
cooler water inlet connection on the oil cooler. Tighten the
hose clamps.
Torque Value: 5 N»m [40 in-lb]

Center the hose on the water outlet transfer tube between

the tube and the oil cooler outlet connection. Tighten the
hose clamps.
Torque Value: 5 N*m [40 in-lb]

Oil Cooler Supports

Removal
Remove the oil cooler. Refer
this section.

1
Oil Cooler Supports DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-6 V903

Front Support
Remove the oil pressure regulator bypass hose (1).
Remove the main oil supply hose from the cooler support
to the remote oil filter (2).

Remove the six captive washer capscrews and the cooler

support.
Discard the rectangular seal ring.

Rear Support
Remove the seven captive washer capscrews and the
cooler support.
Discard the rectangular seal ring.

Installation
Front Support
Apply a small amount of gasket adhesive to the rectan­
gular seal ring groove in the support to hold the seal ring
in place.
Install a new rectangular seal ring in the sea! ring groove.
DISASSEMBLY AND ASSEMBLY - Group 00 Oil Cooler Supports
V903 Page 0-7

Position the front cooler support on the water header

cover. Align the capscrew holes in the support with the
capscrew holes in the water header cover plate.
Install the six captive washer capscrews. Tighten the
capscrews.
Torque Value: 50 N«m [35 ft-lb]

Install the oil pressure regulator bypass hose (1). Tighten

the hose nut.
Torque Value: 75 N»m [55 ft-lb]
Install the main oil supply hose (2) from the cooler support
to the remote oil filter. Tighten the hose nut.
Torque Value: 135 N*m [100 ft-lb]

Rear Support
Apply a small amount of gasket adhesive to the rectan­
gular seal ring groove in the support to hold the seal ring
in place.
Install a new rectangular seal ring in the seal ring groove.

Position the rear cooler support on the water header

cover. Align the capscrew holes in the support with cap­
screw holes in the water header cover plate.
Install the seven captive washer capscrews. Tighten the
capscrews.
Torque Value: 50 N«m [35 ft-lb]

I
Radiator Support To Cylinder Head DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-8 V903

Install the oil cooler. Refer to Oil Cooler - Installation in

this section.

Radiator Support To Cylinder Head

Removal
NOTE: Special capscrews and washer are used to mount
the radiator supports to the cylinder heads. Tag or mark the
capscrews and washers to identify their location on the
engine.
Remove the four capscrews, washers, and the support.

Installation
NOTE: Special SAE Grade 8 head locking capscrews and
special washers must be used to mount the radiator sup­
ports. The special capscrews can be identified by the slots
in the capscrew head. The special washers can be identified
by the material thickness of 3.17 mm [0.125 inch].

NOTE: Do not use a gasket between the radiator support

and cylinder head. The gasket will fail resulting in a coolant
leak.
Apply a 1/8 inch bead of silicone sealant, Part No.
3823494, or equivalent around the mounting capscrew
holes and along the sealing surface. The support must
be installed within five minutes after the sealant is applied.
 49
DISASSEMBLY AND ASSEMBLY - Group 00 Exhaust System and Turbocharger - Installation
V903 Page 0-9

Position the support on the cylinder head. Align the holes

in the radiator support with the capscrew holes in the
cylinder head. Install the four special capscrews and
washers. Tighten the capscrews.
Torque Value: 60 N«m [45 ft-lb]

Exhaust System and Turbocharger -

Installation
Exhaust Manifolds
NOTE: The gaskets must be installed with the OUT side
facing the exhaust manifold.
Install two guide studs.
Use an adhesive to hold the gaskets in place on the
cylinder head.

NOTE: Special SAE Grade 8 hex flange head capscrews

designed to withstand high temperatures must be used to
mount the exhaust manifolds.
Do not use standard capscrews to mount the exhaust
manifolds. Lock washers and lock plates are not used.

NOTE: To aid in future capscrew removal, apply a film of

anti-seize compound on the capscrew threads.
Install the exhaust manifold and six capscrews.
Remove the guide studs and install the two remaining
capscrews.
Exhaust System and Turbocharger • Installation DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-10 V903

Tighten the capscrews in the sequence shown to the (a)

torque values and again to the (b) torque value.
(a) Torque Value: 50 N»m [35 ft-lb]
(b) Torque Value: 80 N*m [60 ft-lb]

Radiator Support To Cylinder Block

Put the bracket in the VEE of the cylinder block.
Align the slots in the bracket with the capscrew holes in
the cylinder block.
NOTE: Do not tighten the capscrews at this time.
Install the six mounting capscrews. Use your fingers to
tighten the capscrews.

Exhaust Collector Connection

NOTE: Special SAE Grade 8 hex flange head capscrews
and special washers designed to withstand high tempera­
tures must be used to mount the exhaust collector.
Do not use standard capscrews to mount the exhaust
collector connection.

xs3cswa

Install two guide studs in the collector.

NOTE: To aid in future capscrew removal, apply a film of
anti-seize compound to the capscrew threads.
DISASSEMBLY AND ASSEMBLY - Group 00 Exhaust System and Turbocharger - Installation
V903 Page 0-11

Install the collector, two capscrews, and washers.

Remove the two guide studs and install the two remaining
capscrews and washers. Use your fingers to tighten the
capscrews.

Exhaust Outlet Tubes

Install the exhaust outlet tubes between the collector and
right and left bank exhaust manifolds.
Hold the outlet tubes in place and slide the radiator sup­
port bracket to the front or rear until the flares on the
tubes seat squarely on the tapered flanges on the col­
lector and exhaust manifolds.
NOTE: The right and left bank exhaust outlet tubes are not
interchangeable. The right bank uses exhaust outlet tube,
Part No. 3066141, and the left bank uses exhaust outlet
tube, Part No. 3066140.

Install the V-band clamps and nuts at the collector and

exhaust manifolds.
Tighten the clamp nuts.
Torque Value: 9 N»m [75 in-lb]
Use a mallet. Tap around the clamp to be sure it is seated.
Torque the clamp nut to the same torque value.
Torque Value: 9 N«m [75 in-lb]
Continue tapping and tightening the clamp until the nut
does not turn at the specified torque after tapping.

Tighten the radiator support mounting capscrews.

Torque Value: 75 N»m [55 ft-lb]
Exhaust System and Turbocharger - Installation DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-12 V903

Tighten the collector mounting capscrews to the (a) torque

value and again to the (b) torque value.
(a) Torque Value: 50 N»m [35 ft-lb]
(b) Torque Value: 100 N«m [75 ft-lb]

Turbocharger
NOTE: The gasket must be installed with the OUT side
facing the turbocharger.
Install a new gasket on the turbocharger mounting flange.
Apply a film of high temperature anti-seize compound to
the turbocharger mounting studs.

NOTE: Special nuts manufactured from high strength, heat

resistant material must be used to mount the turbocharger.
Do not use standard nuts to mount the turbocharger.
Install the turbocharger and the four mounting nuts.
Tighten the mounting nuts.
Torque Value: 100 N»m [75 ft-lb]

Install the oil drain tube and a new gasket on the turbo­
charger.
Install and tighten the mounting capscrews.
Torque Value: 50 N«m [35 ft-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Starting Aid Nozzle
V903 Page 0-13

Put 50 cc to 60 cc [2 to 3 ounces] of clean engine oil into

the turbocharger oil supply tube fitting.

Install the oil supply hose. Tighten the swivel nut.

Torque Value: 35 N*m [25 ft-lb]

Starting Aid Nozzle

General Information
Warning: The cold start system produces a flame in the
intake manifold when energized. NEVER use starting
fluid in conjunction with the cold start system. This com­
bination can cause an explosion.
Caution: NEVER energize the cold start system or apply
voltage to the starting aid nozzles if fuel flow is NOT
available to the nozzles. Operating the starting aid noz­
zles without adequate fuel flow will damage the nozzles.
Four starting aid nozzles are installed in the intake man­
ifold in the locations shown to aid in starting the engine
in cold ambient temperatures.
Removal
NOTE: The right bank starting aid nozzles are shown for
illustration purposes only. The information applies to both
the right and left bank starting aid nozzles.
Remove the fuel supply tube nut (1) at the tee fitting.
Remove the capscrews (2) that attach the support clips
to the brackets.
Remove the fuel supply tube nuts (3) at both starting aid
nozzles. Remove the tube assembly.
Starting Aiid Nozzle DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-14 V903

Use starting aid nozzle socket, Part No. 3823488, and

wobble drive extension, Part No. 3823489, to remove the
nozzle.
Remove and discard the sealing washer.

Installation
Install a new sealing washer on the nozzle. Install the
washer with the smaller outside diameter toward the noz­
zle fuel inlet connection.
Apply a light film of silicone sealant, Part No. 3823494,
or equivalent to the threads of the nozzle.

Use your fingers to install the nozzle in the manifold.

Caution: Do not overtighten the nozzle. Overtightening
will damage the threads in the manifold.
Use starting aid nozzle socket, Part No 3823488, and
wobble drive extension, Part No. 3823489, to tighten the
nozzle.
Torque Value: 30 N»m [20 ft-lb]

Install the fuel supply tube between the two starting aid
nozzles. Tighten the tube nuts (3).
Torque Value: 10 N«m [90 in-lb]
Connect the fuel supply tube to the tee fitting. Tighten the
tubing nut (1).
Torque Value: 10 N»m [90 in-lb]
Install the support clips, lock washers, and capscrews.
Tighten the capscrews (2).
Torque Value: 40 N«m [30 ft-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-15

Resistance Check
Use a digital multimeter, Part No. 3377161, or equivalent.
Set the multimeter to measure resistance (OHMS).
Disconnect the electrical wire from the nozzle before
measuring the resistance.

Connect one of the multimeter leads to the electrical

terminal on the nozzle and the other lead to the fuel inlet
connection.
The multimeter m ust indicate between 2.0 and 3.0 OHMS
resistance. If the resistance is not within this range, the
starting aid nozzle m ust be replaced.

Aftercooler
Removal
Drain the coolant from the engine.
Loosen the two clamps (1) on the aftercooler water inlet
hose.
Remove the two nuts and the aftercooler water inlet con­
nection. Remove and discard the o-ring.

Loosen the two clamps on the aftercooler water outlet

hose at the transmission cooler.
Remove the capscrew that attaches the water transfer
tube support to the transmission oil cooler.
Aftercooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-16 V903

Remove the two nuts and the water outlet connection.

Remove and discard the o-ring.

Loosen the two hose clamps (1) on the turbocharger air

outlet hose.
Slide the hose onto the turbocharger compressor hous­
ing as far as possible.

Remove the electrical wires (1 and 2) from the Step Tim­

ing Control (STC) solenoid.
Disconnect the electrical connector (3) from the STC time
delay relay.

Remove the cold start fuel supply tube (1) from the tee on
the cold start solenoid and the tee on the right bank.
 і?
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-17

Remove the cold start fuel supply tube from the tee fitting
on the cold start solenoid.

Remove the smoke generator fuel inlet hose nut from the
fitting on the smoke generator solenoid.
Remove the smoke generator fuel outlet tube nut from the
fitting on the smoke generator solenoid.

Remove the STC oil supply tube nut (1) from the fitting on
the STC solenoid.
Remove the left bank STC oil supply tube nut (2) from the
fitting on the STC solenoid.

Remove the STC oil supply tube (1) from the STC sole­
noid to the fitting on the right bank rocker housing.
bl
Aftercooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-18 V903

Remove the wire ties that secure the STC wiring harness
to the STC oil supply tubes.

Remove the STC oil supply tube nut (1) from the fitting on
the left bank rocker housing.
Remove the STC oil supply tube nut (2) from the fitting on
the gear cover.

Remove the capscrews, washers, and the spacers that

attach the smoke generator tube support clips to the
intake manifold.

Remove the smoke generator fuel tube (1), left bank STC
oil supply tube (2), and STC oil supply tube (3) from the
gear cover to the solenoid as an assembly.
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-19

Remove the left bank cold start fuel tube nut (1) at the tee.
Remove the capscrews (2), washers, and spacer that
attaches the cold start fuel tube support clips to the intake
manifold.
Remove the cold start fuel supply tube.

Remove the capscrews that attach the solenoid mounting

plate to the rocker housing and intake manifold.
Remove the solenoid mounting plate.

NOTE: Attempting to remove the aftercooler before remov­

ing the aftercooler drain tube can damage the aftercooler
beyond use.
Remove the tube nut (1) from the aftercooler drain fitting.
Remove the two capscrews and washers that attach the
drain tube support clips to the cylinder block. Remove the
drain tube.

Remove the remaining aftercooler mounting capscrews.

Aftercooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-20 V903

Caution: This assembly weighs more than 23 kg [50 lb].

Two people or a hoist are required to lift the aftercooler.
NOTE: Raise the rear of the manifold approximately three
inches higher than the front of the manifold during removal
or installation to avoid damage to the drain fitting.
Lift the aftercooler from the intake manifold.

Remove the gasket from the intake manifold. Discard the

gasket.

Installation
Install a new seal on the aftercooler drain tube.

Install a new gasket on the intake manifold. Use a small

amount of gasket adhesive to hold the gasket in place.
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-21

Caution: This assembly weighs more than 23 kg [50 lb]. A

Two people or a hoist are required to lift the aftercooler. iu A
NOTE: Raise the rear of the manifold approximately three
inches higher than the front of the manifold during removal
or installation to avoid damage to the drain fitting.
Carefully install the aftercooler on the intake manifold to
prevent damage to the gasket and aftercooler drain fitting.

Check the alignment between the capscrew holes in the

gasket and the holes in the aftercooler and intake man­
ifold before installing any of the capscrews.

Install 13 capscrews in the locations shown.

NOTE: The capscrew used in location 7 is approximately 3/8
inch shorter than the other 12 capscrews being installed at
this time.
Wire clips are mounted on capscrews location 2 and 10.
Install the clips with the eye or open end toward the
aftercooler.

Position the solenoid mounting plate on the intake man­

ifold and rocker housing.
Install the two capscrews that attach the plate to the
intake manifold and the one capscrew that attaches the
plate to the rocker housing.
 41
Aftercooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-22 V903

Position the smoke generator fuel tube and the STC oil
supply tube assembly.
Position the left bank cold start fuel supply line.
Install the capscrews and spacers as shown.
NOTE: Do not install the tube nuts on the fittings at this time.

Tighten the aftercooler mounting capscrews in the se­

quence shown to the torque values listed below.
Torque Value: 20 N»m [15 ft-lb]
Torque Value: 40 N»m [30 ft-lb]
Allow 15 minutes for the gasket to compress. Torque the
capscrew again.
Torque Value: 40 N«m [30 ft-lb]

Tighten the capscrew that attaches the solenoid mount­

ing plate to the rocker housing.
Torque Value: 50 N»m [35 ft-lb]

Connect the left bank cold start fuel supply tube to the tee
fitting on the left bank and on the cold start solenoid.
Tighten the tube nut.
Torque Value: 10 N«m [90 in-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-23

Connect the right bank cold start fuel supply tube (1) to
the tee fitting on the right bank and on the cold start
solenoid. Tighten the tube nut.
Torque Value: 10 N«m [90 in-lb]

Connect the smoke generator hose (1) to the fitting on the

smoke generator solenoid. Tighten the hose.
Torque Value: 15 N»m [120 in-lb]
Connect the smoke generator fuel outlet tube (2) to the
fitting on the smoke generator solenoid. Tighten the tube
nut.
Torque Value: 30 N*m [20 ft-lb]
Connect the STC oil supply tube nut (3) to the fitting on
the STC solenoid.
Torque Value: 30 N»m [20 ft-lb]

Connect the left bank STC oil supply tube (1) to the tee
on the STC solenoid and the fitting on the rocker housing.
Connect the STC oil supply tube nut (2) to the fitting on
the gear cover. Tighten the tube nuts.
Torque Value: 30 N»m [20 ft-lb]

Connect the right bank STC oil supply tube to the tee on
the STC solenoid and the fitting on the rocker housing.
Tighten the tube nuts.
Torque Value: 30 N*m [20 ft-lb]
Aftercooler DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-24 V903

Install a new o-ring in the groove of the aftercooler water

inlet connection.
Push the hose over the inlet coupling until the holes in the
mounting flange align with the studs on the aftercooler.
Position the flange on the aftercooler. Install and tighten
the nuts.
Torque Value: 20 N*m [15 ft-lb]

Center the hose between the inlet connection and the

coupling. Tighten the hose clamps.
Torque Value: 5 N*m [40 in-lb]

Install a new o-ring in the groove in the aftercooler water

outlet connection.
Push the hose over the inlet connection on the transmis­
sion cooler.
Position the flange on the aftercooler. Install and tighten
the nuts.
Torque Value: 20 N*m [15 ft-lb]

Install the capscrew that attaches the water transfer tube

support to the transmission cooler. Tighten the capscrew.
Torque Value: 50 N*m [35 ft-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Aftercooler
V903 Page 0-25

Center the hose between the transfer tube and the inlet
connection on the transmission cooler. Tighten the hose
clamps.
Torque Value: 5 N*m [40 in-lb]

Install the white wire (1) and black wire (2) on the STC
solenoid in the location shown.
Connect the electrical connector to the STC time delay
relay.

Use new wire ties to secure the STC wiring harness to the
STC oil supply tubes in the locations shown.

NOTE: The turbocharger air discharge hose used on the Big

Cam engine is a special 5 ply hose. Do not use a substitute
hose in this location.
Push the turbocharger air discharge hose over the af­
tercooler air inlet connection. Center the hose between
the turbocharger compressor housing and the aftercooler
inlet connection. Tighten the t-bolt clamps.
Torque Value: 8 N»m [75 in-lb]
Intake Manifold DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-26 V903

Intake Manifold
Removal
Remove the aftercooler. Refer to Aftercooler Removal in
this bulletin.

Remove the capscrews that attach the starting aid fuel

tube clips to the support brackets on the left bank of the
engine.

Remove the capscrew that attaches the starting aid fuel

tube clip to the support bracket on the right bank of the
engine.

Remove the Air Fuel Control (AFC) manifold pressure

tube.
DISASSEMBLY AND ASSEMBLY - Group 00 Intake Manifold
V903 Page 0-27

Caution: Cover the intake ports in the manifold BEFORE

removing the intake manifold mounting capscrews. The
washers can fall off the mounting capscrews into the
cylinders causing severe damage to the engine.

A flat and lock washer were used on the intake manifold

mounting capscrews (1) on engines built prior to Octo­
ber, 1989. The washers can fall off the capscrews during
capscrew removal or installation.
A captive washer capscrew (2), Part No. 3067337, is used
to mount the intake manifold on engines built after Oc­
tober, 1989.

Remove the two outside capscrews that are located at the

left bank front (1) and right bank rear (2) of the manifold.
Remove the 14 capscrews that are located inside the
manifold.

Remove the intake manifold. Remove and discard the

gaskets.
Intake Manifold DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-28 V903

Installation
Position the intake manifold with the mounting surface
facing up. Apply a small amount of gasket adhesive to the
gasket surfaces to hold the gaskets in place.
Install new intake manifold gaskets on the mounting
surface.

Position the intake manifold in the VEE and align the

mounting holes with the capscrew holes in the cylinder
heads.

Caution: Cover the intake ports to eliminate the possi­

bility of the washers falling off the capscrews and drop­
ping into the cylinders.

NOTE: If captive capscrews are not used, install the 14

capscrews, lock washers, and flat washers located inside
the manifold.
Caution: Do not allow the parts to fall into the engine.
Engine damage will result.
Install the 14 capscrews with captive washers, lock wash­
ers, and flat washers located inside the manifold.
Install the two remaining outside capscrews, lock wash­
ers, and flat washers located at the left bank front (1) and
the right bank rear (2) of the manifold.
DISASSEMBLY AND ASSEMBLY - Group 00 Intake Manifold
V903 Page 0-29

Tighten the intake manifold capscrews in the sequence

shown to the torque values listed below.
Torque Value: 30 N*m [20 ft-lb]
Torque Value: 60 N*m [45 ft-lb]
Allow 15 minutes for the gaskets to compress. Torque the
capscrews again.
Torque Value: 60 N»m [45 ft-lb]

Install the capscrews that attach the starting aid fuel tube
clips to the support brackets on the left bank of the en­
gine. Tighten the capscrew.
Torque Value: 40 N»m [30 ft-lb]

Install the capscrew that attaches the starting aid fuel

tube clip to the support bracket on the right bank of the
engine. Tighten the capscrew.
Torque Value: 40 N«m [30 ft-lb]

Install the AFC manifold pressure tube. Tighten the tube

nut.
Torque Value: 25 N*m [20 ft-lb]
 50
Injector DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-30 V903

Caution: If the covers are not removed, severe engine

damage can result.
Remove the cover from the intake ports.

Install the aftercooler. Refer to Aftercooler Installation in

this bulletin.

Injector
Removal
Remove the nine captive washer capscrews.

Tap the cover lightly with a mallet to break the seal be­
tween the cover and gasket.
DISASSEMBLY AND ASSEMBLY - Group 00 Injector
V903 Page 0-31

Remove the cover.

Remove the STC oil supply tube from the STC plug on
cylinders No. 2 and No. 8.
Remove the four STC plugs and springs from the rocker
housing.
Remove and discard the o-ring.

Use the STC oil transfer tube pliers, Part No. 3823296, to
remove the oil transfer tube.
Injector DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-32 V903

Remove and discard the oil transfer tube o-rings.

Loosen the adjusting screw lock nut on the injector rocker

lever.
Remove the injector adjusting screw and lock nut from
the rocker lever.

NOTE: Push the rocker lever down (seat the injector plunger
in the cup) if necessary to remove the push rod from under
the rocker lever.
Move the injector push rod to the side.
Push the rocker lever up.

Remove the capscrew, washer, and the injector hold

down clamp.
Caution: Use care when handling the injector to prevent
damage to the injector cup.
Use injector puller, Part No. 3376872, to remove the
injector.
DISASSEMBLY AND ASSEMBLY - Group 00 Injector
V903 Page 0-33

Installation
Caution: Do NOT use metal to scrape the injector
sleeves.
Use a clean cloth wrapped around the end of a clean
wooden stick to remove all the carbon from the injector
sleeves in the cylinder head.
Use the chip removing tool, Part No. 3823461, if neces­
sary to remove the carbon from the top of the piston.

Install three new o-rings on the injector.

Lubricate the o-rings with vegetable oil before installation.

Install the injector in the cylinder head with the tappet oil
supply hole facing the oil transfer tube hole in the rocker
housing.
Center the top stop tappet locknut between the valve
springs.

Put a 32 mm [1 1/4 inch] deep well-socket on top of the

injector. Center the socket on the tappet top stop cap to
prevent damage to the cap.
Use a blunt instrument to seat the injector in the bore.
Caution: Do NOT use a smaller socket on the tappet top
stop cap to seat the injector. Using a smaller socket, or
NOT centering the socket on the cap will damage the
cap, causing engine performance degradation and pos­
sible progressive damage to the engine.
Injector DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-34 V903

A snap will be heard and felt when the injector is seated.

NOTE: If the injector fails to seat properly, remove the in­
jector and check for cut o-rings.

Install a new o-ring on one end of the oil transfer tube.

Insert the end of the tube without the o-ring through the
drilling in the rocker housing.
Install a new o-ring on the end of the tube after the tube
is through the drilling.

Lubricate the o-rings with vegetable oil.

Align the oil transfer tube with the oil supply hole in the
tappet top stop lock nut.
NOTE: It can be necessary to rotate the injector to the right
or left to align the transfer tube with the oil supply hole in the
tappet top stop lock nut.
 ss
DISASSEMBLY AND ASSEMBLY - Group 00 Injector
V903 Page 0-35

Use a 10 mm [13/32 inch] dowel rod to seat the transfer

tube in the injector.
NOTE: The top of the oil transfer tube will be approximately
25 mm [1 inch] below the bottom of the counterbore in the
rocker housing when the tube is properly seated in the
injector.

Install a new o-ring on the STC plug.

Use vegetable oil to lubricate the o-ring.
Install the spring and plug in the rocker housing. Tighten
the plug.
Torque Value: 20 N«m [15 ft-lb]
Install the STC oil supply tube on the STC plug on cyl­
inders No. 2 and No. 8. Tighten the tube nut.
Torque Value: 30 N«m [20 ft-lb]

Install the injector hold down clamp, washer, and cap­

screw. Push the clamp up tight against the injector to
obtain maximum clearance between the clamp and the
valve springs. Tighten the capscrew.
Torque Value: 50 N*m [35 ft-lb]

Push the injector rocker lever down until it contacts the

injector link.
Injector DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-36 V903

Align the injector push rod with the adjusting screw hole
in the injector rocker lever.
NOTE: Push the rocker lever down (seat the injector plunger
in the cup) if necessary to install the push rod under the
rocker lever.
Install the adjusting screw. Tighten the adjusting screw
until it is properly seated in the push rod socket.

Adjust the injector. Refer to Valve and Injector Adjust­

ment in this bulletin.

Install two guide studs in the rocker housing.

Install a new valve cover gasket on the rocker housing.

Install the valve cover and seven captive washer cap­

screws. Remove the two guide studs and install the two
remaining captive washer capscrews. Tighten the cap­
screws.
Torque Value: 50 N»m [35 ft-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
Page 0-37
V903

Valve and Injector Adjustment

General Information
.NOTE: Injector and valve adjustment on the Big Cam engine
is significantly different than on the Small Cam engine. Read
and understand this complete section before attempting to
perform injector and valve adjustments.

The valve adjustment marks are located on the vibration

damper. The marks must be aligned with a pointer
mounted on the front cover.

Caution: Because of the camshaft design, alignment

between the pointer and VS marks on the damper is
critical on the Big Cam series engine. Look directly at the
pointer and center line of the crankshaft when aligning
the VS marks on the damper with the pointer. The VS
mark MUST be aligned with the top edge of the point. If
the alignment is incorrect, engine performance will be
degraded and the push rods can be bent.

The crankshaft rotation is clockwise when viewed from

the front of the engine.
Use the vibration damper mounting capscrews to rotate
the crankshaft.
Valve and Injector Adjustment DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-38 V903

The cylinders are numbered from the front to the rear of

the engine. Cylinder Nos. 1 through 4 are located on the
right bank of the engine. Cylinder Nos. 5 through 8 are
located on the left bank of the engine when viewed from
the rear (flywheel end) of the engine.
The engine firing order is 1-5-4-8-6-3-7-2.

Each cylinder has three rocker levers. The rocker lever on

the left (1) is the intake lever. The rocker lever in the
center (2) is the injector rocker lever. The rocker lever on
the right (3) is the exhaust rocker lever.

In je c to r a n d V a lv e A d ju s tm e n t S e q u e n c e The valves and injectors on the same cylinder are not

IF AND
adjusted at the same index mark on the vibration damper.
Intake V alves Exhaust V alves Set In jec to r Set V alves
Index M a rk “ O P E N " on “ O P E N " on on on One pair of valves and one injector are adjusted at each
1— 6 5 6 5 2
index mark before rotating the vibration damper to the
3— 5 4 3 4 1 next index mark.
4 -7 8 7 8 5
2 -8 6 2 6 4 Two crankshaft revolutions are required to adjust all valves
1— 6 3 1 3 8 and injectors.
3— 5 7 5 7 6
4— 7 2 4 2 3
2— 8 1 8 1 7

Firing Order: 1 —5— 4—8—6— 3— 7— 2

fi300wa

Intake and exhaust valve adjustment must be performed

on the Big Cam engine with the injector plunger seated
in the injector cup. The mechanical loading required to
seat the injector plunger causes deflection in the rocker
lever shaft and supports.

fi3 pgu a
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
V903 Page 0-39

The injector must be adjusted on each cylinder before

the valves on the same cylinder are adjusted. If the valves
are adjusted before the injector, the valve lash will change
when the injector preload is set.

After an engine rebuild or any major repair where the Injector and Valve Adjustment Sequence
injector adjustments have been disturbed, adjust only the IF AND
injectors at the first two set points. Follow the Valve and Intake Valves Exhaust V alves Set In je c to r Set V alves
Index M ark “ O PEN” on “ O PEN” on on on
Injector Adjustment Chart until all injectors and valves
5
have been adjusted. 1— 6 5

4
6

3 4
3 — 5

4 — 7 8 7 8 5

2 — 8 6 2 6 4

1— 6 3 1 3 8

3 — 5 7 5 7 6

4 — 7 2 4 2 3

2 - 8 1 8 1 7

1— 6 5 6 2

3 — 5 4 3 1

О-

04
ГО
F ir in g O rd e r: 1 — 5 — 4 — 8 — 6- f i3 0 0 w b

I
I
Adjustment During Routine Maintenance
Rotate the vibration damper clockwise until VS 1-6 mark
aligns with the pointer on the front cover.

When the VS 1-6 mark is aligned with the pointer, adjust

the injector on either cylinder No. 5 and the valves on
cylinder No. 2, or the injector on cylinder No. 3 and the
valves on cylinder No. 8 depending on the position of the
camshaft.
Valve and Injector Adjustment DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-40 V903

The valves are ready to be adjusted on the cylinder that

has all of the valves closed. Check the valves on cylinder
No. 2 to see if they are closed.
NOTE: Both the intake and exhaust valves are closed when
both rocker levers are loose and can be moved from side to
side.

If both the intake and exhaust valves appear to be closed

on cylinder No. 2, check the intake valves on cylinder No.
5 and the exhaust valves on cylinder No. 6.

If the intake valves are open on cylinder No. 5 and the

exhaust valves are open on cylinder No. 6, adjust the
injector on cylinder No. 5 and the valves on cylinder No.
2.

If the intake valves are not open on cylinder No. 5 and the
exhaust valves are not open on cylinder No. 6, rotate the
vibration damper one complete revolution and align the
VS 1-6 mark with the pointer. The injector on cylinder No.
5 and the valves on cylinder No. 2 are now ready to be
adjusted.
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
V903 Page 0-41

Follow the Injector and Valve Adjustment Chart until all In je c t o r a n d V a lv e A d ju s t m e n t S e q u e n c e

injectors and valves are adjusted. IF AND
Intake Valves Exhaust Valves Set Injector Set Valves
Index Mark “ OPEN” on “ OPEN” on on on

1 —6 5 6 5 2
3— 5 4 3 4 1
4— 7 8 7 8 5
2—8 6 2 6 4
1 -6 3 1 3 8
3— 5 7 5 7 6
4— 7 2 4 2 3
2—8 1 8 1 7

Firing Order: 1 _5 __4_g__g. _ 3 _7__2

fi300wa

Adjustment After Major Repair or Rebuild

Special attention is required to determine which cylinders
are ready for injector and valve adjustment after any
major repair or rebuild, where all of the valve and injector
adjusting screws have been removed or loosened several
turns.

To identify which cylinder is ready for injector and valve

adjustment after major repair or rebuild, rotate the vibra­
tion damper clockwise until the VS 1-6 mark is aligned
with the pointer on the front cover.

Hold the intake and exhaust rocker levers down against

the crossheads on cylinder No. 2. Turn the adjusting
screws down until they touch the push rods.
Valve and Injector Adjustment DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-42 V903

Turn the lock nuts down on the adjusting screws until they
touch the rocker levers.
Compare the height of the adjusting screws above the
lock nuts on both the intake and exhaust rocker levers on
cylinder No.2
If the height of the adjusting screws are equal, both the
intake and the exhaust valves are in the closed position.

If both the intake and exhaust valves appear to be closed

on cylinder No.2, check the intake valves on cylinder No.
5 and the exhaust valves on cylinder No. 6.
Turn the adjusting screws down until they touch the push
rods on cylinder Nos. 5 and 6.

Turn the lock nuts down on the adjusting screws until they
touch the rocker levers.
Compare the height of the adjusting screws above the
lock nuts on both the intake and exhaust rocker levers on
cylinder Nos. 5 and 6.

If the adjusting screw height is the same above the lock

nuts on cylinder No. 2 and the intake valve adjusting
screw is higher than the exhaust on cylinder No. 5 and the
exhaust higher than the intake on cylinder No. 6, the
injector is ready for adjustment on cylinder No. 5.
Refer to Injector Preload Adjustment section in this
bulletin.
 63
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
V903 Page 0r43

If the height of the adjusting screw is not as described

above, rotate the vibration damper one complete revo­
lution and align the VS 1-6 mark with the pointer again.
The injector is now ready to be adjusted on cylinder No.
5.
Refer to Injector Preload Adjustment section in this
bulletin.

After adjusting the injector on cylinder No. 5, rotate the

vibration damper to the VS 3-5 mark and align the mark
with the pointer. Adjust the injector on cylinder No. 4.

Follow the Injector and Valve Adjustment Chart until all Injector and Valve Adjustment Sequence
the injectors and valves are adjusted. IF AND
Inta ke V alves Exhaust V alves Set Injec tor Set V alves
Index M a rk “ O P E N ” on “ O PEN” on on on

1— 6 5 6 5
3— 5 4 3 4
4— 7 8 7 8 5
2— 8 6 2 6 4
1— 6 3 1 3 8
3— 5 7 5 7 6
4— 7 2 4 2 3
2— 8 1 8 1 7
1— 6 5 6 2
3— 5 4 3 1

Firing O rd e r; - 1 - 5 — 4 — 8 — 6-- 3 — 7 — 2 fi300wb

Injector Preload Adjustment

When the VS 1-6 mark is aligned with the pointer and the
injector on cylinder No. 5 is ready for adjustment, tighten
the adjusting screw until all the clearance is removed
from the injector train.
Tighten the adjusting screw one additional turn to cor­
rectly seat the link.
Valve and Injector Adjustment DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-44 V9Q3

Loosen the injector adjusting screw until the STC tappet

touches the top-cap of the injector.

Put STC tappet adjusting tool, Part No. 3823348, on the

upper surface of the STC injector top-cap. Rotate the tool
around the tappet until the tool’s locating pin is inserted
into one of the four holes in the top of the tappet.

Apply light thumb pressure to the tool handle to hold the

tappet in the maximum upward position.

Caution: Allowing the tappet to move downward while

torquing the injector adjusting screw will produce in­
creased stress on the injector train and the camshaft
injector lobe which can result in engine damage.
While holding the tappet up with the tool, use torque
wrench, Part No. 3376592, to tighten the adjusting screw.
Torque Value: 0.56 to 0.68 N»m [5 to 6 in-lb]
NOTE: Apply only enough pressure on the tool handle so the
tappet does not move downward when the torque is applied.
Applying too much pressure on the tool will break the tappet
or tool.
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
V903 Page 0-45

Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened.
Tighten the lock nut.
Torque Value:
With Torque Wrench Adapter 50 N«m [35 ft-lb]
Part No. ST-669
Without Adapter 60 N*m [45 ft-lb]

Remove the tappet adjusting tool.

Caution: The tappet tool MUST be removed BEFORE
rotating the crankshaft to prevent damage to the tappet.
If the crankshaft is rotated with the tool in place, a piece
of the tappet or tool will break off and drop into the
engine.

If the injector on cylinder No. 2 has been adjusted, adjust

the valves on cylinder No. 2 before rotating the vibration
damper to the next VS mark. Refer to Adjust After Major
Repair or Rebuild in this bulletin for the exception.

Follow the Injector and Valve Adjustment Chart until all Injector and Valve Adjustment Sequence
injectors and valves are adjusted. IF AND
Intake V alves Exhaust Valves Set In jec to r Set V alves
Index M ark “ O P E N ” on “ O PEN” on on on

1— 6 5 6 5 2
3— 5 4 3 4 1
4— 7 8 7 8 5
2— 8 6 2 6 4
1— 6 3 1 3 8
3— 5 7 5 7 6
4— 7 2 4 2 3
2 -8 1 8 1 7

Firing Order: 1 — 5 — 4— 8 — 6-- 3 - 7 — 2

fi300wa
Valve and Injector Adjustment DISASSEMBLY AND ASSEMBLY - Group 00
Page 0-46 V903

Valve Adjustment
With the VS 1-6 mark aligned with the pointer, and both
valves closed on cylinder No. 2, and the injector already
adjusted on No. 2 cylinder, loosen the lock nuts on the
intake and exhaust adjusting screw on cylinder No.2.

Select a feeler gauge for the correct valve lash

specification.*•

Valve Lash Specification

_________ Intake_________________ Exhaust________
0.64 mm 0.64 mm
______ [0.025 inch]______________ [0.025 in ch ]____
Insert the feeler gauge between the top of the crosshead
and the rocker lever pad.

Two different methods for establishing valve lash clear­

ance are described below. Either method can be used.
The torque wrench method has proven to be the most
consistent by eliminating the need to feel the drag on the
feeler gauge.
• Torque Wrench Method: Use the inch pound torque
wrench, Part No. 3376592, (normally used to set
preload on top stop injectors) and tighten the ad­
justing screw.
Torque Value: 0.68 N»m [6 in-lb]
• Feel Method: Tighten the adjusting screw until a
slight drag is felt on the feeler gauge.

Hold the adjusting screw in this position. The adjusting

screw must not turn when the lock nut is tightened.
Tighten the lock nut.
Torque Values:
W ith torque wrench adapter 50 N»m [35 ft-lb]
Part No. ST-669
Without adapter 60 N»m [45 ft-lb]
DISASSEMBLY AND ASSEMBLY - Group 00 Valve and Injector Adjustment
V903 Page 0-47

After tightening the lock nut to the correct torque value,

check to make sure the feeler gauge will slide backward
between the crosshead and the rocker lever with only a
slight drag.

if using the feel method, insert a feeler gauge that is 0.03

mm [0.001 inch] thicker between the crosshead and the
rocker lever pad. The valve lash is not correct when a
thicker feeler gauge will fit.

After adjusting the injector on cylinder No. 5 and the

valves on cylinder No. 2, rotate the vibration damper and
align the next VS mark with the pointer.

Adjust the appropriate injector and valves following the In je c to r a n d V a lv e A d ju s tm e n t S e q u e n c e

injector and Valve Sequence Chart. IF AND
Intake Valves Exhaust V alves Set In je c to r Set Valves
Repeat the process until all injectors and valves are Index M a rk “ O PEN” on “ O PEN” on on on
adjusted. 1 -6 5 6 5 2
3 -5 4 3 4 1
4— 7 8 7 8 5
2 -8 6 2 6 4
1— 6 3 1 3 8
3— 5 7 5 7 6
4— 7 2 4 2 3
2— 8 1 8 1 7

F irin g O r d e r 1 — 5 — 4 — 8 — 6- 3 7 2
fi300wa
Cylinder Block - Group 01 Parts Commonalty
V903 Page 1-1

Cylinder Block - Group 01

Parts Commonalty
The following parts in the cylinder block group are common in both the Big Cam and Small Cam series engines:
Cylinder Liners Piston Pins Piston Pin Retaining Rings
Piston Rings Connecting Rods Connecting Rod Bearings
Main Bearings Crankshaft Crankshaft Gear
Crankshaft Pulley Crankshaft Pulley Adapter Camshaft Gear
Camshaft Thrust Plate ‘ Camshaft Front Cover Gear Cover
Flywheel Adapter ‘ Flywheel Housing Front Cover
‘ Note: The camshaft front cover and flywheel housing for the VTA-903 T660 are different from the Big Cam
VTA-903 T600 and small cam engines.
The remainder of this group contains information on parts in the cylinder block group that are not common between
the E3ig Cam and Small Cam series engines.

Water Header
Front
The front water header is located on the left bank front of
the cylinder block opposite the water pump.
On Small Cam engines a water transfer tube is welded to
the front v/ater header to supply coolant to the aftercooler.

On Big Cam engines the coolant for the aftercooler is

supplied from a fitting in the cylinder block which is lo­
cated directly above the water pump cavity. A blank plate
is used to cover the front water header on the Big Cam
engine.
Vibration Damper Cylinder Block - Group 01
Page 1-2 V903

Right and Left Bank

The water header cover plates and gaskets used on both
the right (1) and left bank (2) water headers are unique to
the Big Cam engine because of the oil cooler design and
location.

Vibration Damper
The vibration damper used on both the Big Cam 600
horsepower and Small Cam engines are similar in ap­
pearance. The damper used on the Big Cam VTA-903
600 horsepower engine, however, contains a special
elastomer (1) designed to withstand the higher operating
temperatures. The Big Cam VTA-903 600 horsepower
damper can be used on both the Big Cam VTA-903 600
horsepower and Small Cam engines.
NOTE: Do not use the Small Cam damper on the Big Cam
engine.

The vibration damper used on the Big Cam VTA-903 660

horsepower engine (1) is unique to this engine. The
damper is smaller in diameter and greater in thickness
than the damper used in the Small Cam engines and the
Big Cam 600 horsepower engine (2). A special high tem­
perature elastomer is also used in this damper.
NOTE: Do not use the Big Cam VTA-903 T660 HP damper
on either the Small Cam engine or Big Cam VTA-903 T600
HP engine.

Cylinder Block
General Information
The Big Cam cylinder block (1) incorporates a 76 mm [3
inch] diameter camshaft, piston cooling, and a rear oil
crossover passage.
All cylinder block dimensions except the camshaft bore
are the same as the Small Cam cylinder block (2).
 3c?
Cylinder Block - Group 01 Camshaft
V903 Page 1-3

Camshaft
The 76 mm [3 inch] camshaft was released with the
introduction of the Big Cam engine to reduce Hertz stress
loading on the injector lobes and also reduce injection
duration.

The outside diameter of all five bearing journals (A) on the

Small Cam is 63 mm [2.5 inch].
The outside diameter of journal (A) No. 1 on the Big Cam
is 63 mm [2.5 inch]. The outside diameter of journals (B)
No. 2, 3, 4, and 5 are 76 mm [3 inch].

Piston
The Big Cam piston is designed to withstand higher ther­
mal and mechanical loads. The design improvements
include high strength material, anodized crown and bowl
(1), graphite coated skirt (2), and shaped pin bore (3). The
compression ratio is 14.5:1.

The piston skirt contains a single notch to provide clear­

ance for the piston cooling nozzle. The pistons must be
installed with the notch toward the inside of the vee
(opposite the bearing tang side of the connecting rod).
NOTE: Incorrect installation will cause the piston cooling
nozzle to break causing piston scoring or scuffing.
Piston Cooling Cylinder Block - Group 01
Page 1-4 V903

The piston design includes a full floating piston pin. Heat­

ing the piston for piston pin removal or installation is not
necessary.

Piston Cooling
Piston cooling was designed in the Big Cam cylinder
block to reduce piston crown and pin bore temperatures.
The piston cooling nozzles are located in the cylinder
block cavity directly below the vee area and adjacent to
the tappets.

The piston cooling design allows continuous piston cool­

ing oil flow at all engine operating oil pressures. The
piston cooling oil is supplied by the main engine oil rifles
located on each side of the vee.
NOTE: A separate piston cooling oil pressure regulator is
not used with this design. Piston cooling oil pressure is
controlled by the main oil pressure regulator located in the
oil cooler support.

Piston Cooling Nozzle

The piston cooling nozzle consists of a nonmetallic ma­
terial formed around a steel spray nozzle. Eight nozzles
are required per engine. Each nozzle is attached to the
cylinder block by a Nylock®, capscrew and flat washer.
NOTE: New Nylock®, capscrews must be installed any time
the piston cooling nozzles are removed.
Do not install a lock washer on the piston cooling nozzle
capscrew. If a lock washer is used, there is not enough
clearance between the capscrew head and crankshaft
counterweights.
Cylinder Block - Group 01 Rear Oil Crossover Passage
V903 Page 1-5

For the removal and installation of the piston cooling

nozzles without removing the connecting rods and pis­
tons, use the following Service Tools.

_____________Service Tools Available_____________

No. Tool No. Description________________ Quantity
1 3823297 Pick-Up, Flexible 4 Jaw 1
2 3823298 Wrench, Flexible 1
3 3823299 Socket, MagneticAdjusting 1

Rear Oil Crossover Passage

The Big Cam cylinder block design includes a rear oil
crossover passage. The oil crossover transfers oil from
the lubricating oil pump to the oil cooler.
The Small Cam cylinder block design does not include
the rear oil crossover passage.

Gear Housing Plate

The gear housing plate for the Big Cam engine (1) con­
tains a sealing area below the camshaft bore and addi­
tional mounting capscrew holes which are not used on
the Small Cam plate (2). The plate forms part of the rear
oil crossover passage from the lubricating oil pump to the
oil cooler.

Gear Housing Plate Gasket

NOTE: Do not use the Small Cam engine gasket (2) on the
Big Cam engine.
The gasket used between the plate and cylinder block on
the Big Cam engine (1) also forms part of the rear oil
crossover passage. The gasket is made from high
strength, steel reinforced material to withstand the high
oil pressure in the rear oil crossover passage.
 13
Camshaft Bushings Cylinder Block - Group 01
Page 1-6 V903

To mount the plate to the cylinder block, capscrews with

captive conical hardened washers are used inside the
gear housing at the locations shown. Tighten the cap­
screws in the sequence shown.
Torque Value: 50 N»m [35 ft-lb]

Camshaft Bushings
Three different camshaft bushings are used in the Big
Cam engine. The bushing, Part No. 200780, used in the
No. 1 position is the same as the bushing that is used
in the Small Cam engine. With the cylinder block in the
upright position, the bushing has an oil slot at 12:00
o’clock and an oil hole at the 6:00 o’clock position. The
installed inside diameter is 63.477 to 63.551 mm [2.4990
to 2.5020 inch],
NOTE: The cam bushings are numbered starting from the
front of the cylinder block.

The bushing, Part No. 3037368, used in the Nos. 2, 3,

and 4 position is unique to the Big Cam engine. The
bushing has a continuous oil groove around the inside
diameter. The bushing has an oil slot at the 6:00 o’clock
position. The installed inside diameter is 76.200 to 76.280
mm [3.0000 to 3.0030 inch].

cg 3 bsw b

The bushing, Part No. 3037367, used in the No. 5 po­

sition is also unique to the Big Cam engine. With the
cylinder block in the upright position, the bushing has an
oil slot at 12:00 o’clock and an oil hole at the 6:00 o’clock
position. The installed inside diameter is 76.200 to 76.280
mm [3.000 to 3.0030].

c g 3 b sw c
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-7

Removal
Use the air or hydraulic actuator kit, Part No. 3823621, in
conjunction with the camshaft bushing installation and
removal kit, Part No. 3823671, to remove and install the
camshaft bushings.

The air or hydraulic actuator kit consists of the following

components:

3823621 Hydraulic Actuator Kit

No. Tool No. Description Quantity
1 3823622 Pump, Hydraulic 1
2 3823623 Ram, Center Hole 1
3 3823624 Hose, Hydraulic 1
4 3823625 Shaft, Puller 1
5 3823626 Collar, Stop 2

The camshaft bushing installation and removal kit, Part

No. 3823671, consists of the following components:

3823671 600HP V903 Cam Bushing

Installation/Removal Kit
No. Tool No. Description Quantity
1 3823629 Bushing, Driver No. 1 1
2 3823648 Driver 1
3 3823631 Guide, Centering 1
4 3823632 Guide, Centering 1
5 3823650 Guide, Centering 1
6 3823651 Guide, Centering 1
7 3823646 Spacer, Receiver 1

Camshaft Bushing Nos. 4, 3, and 2 • Removal

In the following sequence, remove bushing Nos. 4,3, and
2.
Install the centering guide, Part No. 3823631, in the No.
1 bushing with the flange toward the front of the block.
Install the centering guide, Part No. 3823650, in the No.
5 bushing with the flange toward the front of the block.
Camshaft IE3ushiirtgs Cylinder Block - Group 01
Page 1-8 V903

Slide the puller shaft, Part No. 3823625, through the

centering guides.

Put the open end of the receiving spacer, Part No.

3823646, on the end of the puller shaft that extends
through the No. 1 bushing.

Install the hydraulic center hole ram, Part No. 3823623,

on the puller shaft with the hydraulic quick disconnect
end facing the receiving spacer. Slide the ram against
the receiving spacer.

Put the stop collar, Part No. 3823626, in the groove in the
puller shaft that is nearest to the end of the hydraulic
center hole ram.

cg3shwc
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-9

Put the bushing driver, Part No. 3823648, on the puller

shaft next to the No. 4 bushing with the small end of the
driver toward the center hole ram. Slide the driver into
the bushing bore until the flange on the driver contacts
the bushing.
NOTE: The following illustrations show part of the cylinder
block removed for clarity.

Put the stop collar, Part No. 3823626, into the groove of
the puller shaft nearest to the end of the bushing driver.

Push down on the PRESS side of the pedal on the air/

hydraulic actuator pump, Part No. 3823622, to expand
the hydraulic center hole ram. Hold the pedal down until
the bushing clears the camshaft bushing bore.

Slide the camshaft bushing from the bushing driver. Re­

move the driver and the stop collar from the puller shaft.
Camshaft Bushings Cylinder Block - Group 01
Page 1-10 V903
Push down on the RELEASE side of the pedal on the
air/hydraulic actuator pump to retract the hydraulic cen­
ter hole ram. Push the puller shaft back through the
center ram until the stop collar contacts the end'of the
ram.

Repeat the above procedure to remove bushing Nos. 3

and 2 in that order.

Camshaft Bushing No. 5 - Removal

Put the bushing driver, Part No. 3823648, on the puller
shaft next to bushing No. 5 with the small end of the driver
toward the center hole ram. Slide the driver into the
bushing bore until the flange on the driver contacts the
bushing.

Put the stop collar into the groove of the puller shaft
nearest to the end of the bushing driver.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-11

Push down on the PRESS side of the pedal on the aiir/

hydraulic actuator pump. Hold the pedal down until the
bushing clears the bushing bore. The centering guide will
come out with the bushing.

Slide the camshaft bushing from the bushing driver. Re­

move the driver and the stop collar.

Push down on the RELEASE side of the pedal on the

air/hydraulic actuator pump to retract the hydraulic cen­
ter hole ram. Push the puller shaft back through the
center ram until the stop collar contacts the end of the
ram.

Camshaft Bushing No. 1 - Removal

Put the centering guide, Part No. 3823651, on the end of
the puller shaft that extends through bushing bore No. 5.
Slide the guide into the camshaft bushing bore until the
flange on the guide contacts the cylinder block.
Camshaft Eiushings Cylinder Block - Group 01
Page 1-12 V903

Put the bushing driver, Part No. 3823629, on the puller

shaft with the large end of the driver toward the center
hole ram. Slide the driver against the bushing.

Put the stop collar, Part No. 3823626, into the groove in
the puller shaft nearest to the end of the bushing driver.

Push down on the PRESS side of the pedal on the air/

hydraulic actuator pump. Hold the pedal down until the
bushing clears the bushing bore. The centering guide will
come out with the bushing.

Remove the stop collar, hydraulic center hole ram, re­

ceiving spacer, centering guide, bushing and bushing
driver.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-13

Remove the puller shaft from the camshaft bore. Remove

the centering guide form the No. 5 bushing bore.

Clean and Inspect

Use a fine fibrous abrasive pad such as Scotch-Brite 7448
or equivalent to clean and remove any burrs from the
bushing bores.

Measure the cylinder block camshaft bore inside diam­

eter.

Camshaft Bore I.D.

No. 1 Bushing Bore
mm in
68.237 MIN 2.6865
68.263 MAX 2.6875

Camshaft Bore I.D.

Nos. 2, 3, 4, and 5 Bushing Bore
mm in
80.963 MIN 3.1875
80.988 MAX 3.1885

Installation
Caution: Incorrect installation of the camshaft bushing
will block oil flow to the rocker levers, fuel pump drive,
and STC injectors, resulting in severe damage to the
engine. The oil holes or slots in the bushings MUST be
aligned with the oil drillings in the camshaft bushing
bores.
Install the centering guide, Part No. 3823632, in the No.
1 bushing bore with the flange toward the front of the
cylinder block.
Camshaft I3ushings Cylinder Block - Group 01
Page 1-14 V903

Install the centering guide, Part No. 3823651, in the No.

5 bushing bore with the flange toward the front of the
cylinder block.
NOTE: The following illustrations show part of the cylinder
block removed for clarity.

Slide the puller shaft, Part No. 3823625, through the

centering guide in the No. 1 bushing bore. Place the No.
1 bushing over the puller shaft with the two locating
notches toward the front of the cylinder block.

Slide the puller shaft through the No. 2 bushing bore.

Place the No. 2 bushing over the puller shaft with the
locating notch toward the rear of the cylinder block.

Slide the puller shaft through the No. 3 bushing bore.

Place the No. 3 bushing over the puller shaft with the
locating notch toward the rear of the cylinder block.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-15

Slide the puller shaft through the No. 4 bushing bore.

Place the No. 4 bushing over the puller shaft with the
locating notch toward the rear of the cylinder block.

Slide the puller shaft through the centering guide in the

No. 5 bushing bore until the shaft extends approximately
100 mm [4 inch] beyond the centering guide. Place the
No. 5 bushing over the puller shaft with the two locating
notches toward the rear of the cylinder block.

Camshaft Bushing No. 5 - Installation

Put the bushing driver, Part No. 3823648, on the puller
shaft with the small end toward the cylinder block and the
slot facing down. Slide the driver into the bushing, then
push the driver on the shaft until the bushing contacts the
cylinder block.

Put the stop collar, Part No. 3823626, into the groove in
the puller shaft that is nearest to the end of the bushing
driver. Rotate the bushing until the oil hole in the bushing
is aligned with the oil drilling to the main bearing saddle.
With the oil hole properly aligned, the oil slot in the bush­
ing will be aligned with the oil drilling to the cylinder head
deck surface.
Camshaft Eiushings Cylinder Block - Group 01
Page 1-16 V903

Put the open end of the receiving spacer. Part No.

3823646, on the end of the puller shaft that extends
through the centering guide in the No. 1 bushing bore.

Install the hydraulic center hole ram, Part No. 3823623,

on the puller shaft with the hydraulic quick disconnect
end facing the receiving spacer. Slide the ram against the
receiving spacer.

Slide the puller shaft through the centering guides until

the stop collar that is installed behind the bushing driver
in bushing No. 5 contacts the bushing driver.

Put the remaining stop collar, Part No. 3823626, into the
groove in the puller shaft that is nearest to the hydraulic
center hole ram.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-17

NOTE: Check the alignment between the oil hole in the

bushing and oil drilling in the bushing bore before pulling
the bushing into the bore.
Push down on the PRESS side of the pedal on the air/
hydraulic actuator pump to pull the bushing into the bore.
As the oil hole in the bushing nears the oil drilling in the
bore, reduce the amount of downward pressure being
applied to the pedal.

Apply light periodic downward pressure to the pedal to

pull the bushing into the correct position to center the oil
hole in the bushing with the oil drilling in the bushing bore.
The centering guide installed in the No. 5 bushing bore
will be pushed into the cavity between the No. 4 and No.
5 bushing bores.

Push down on the RELEASE side of the pedal on the

air/hydraulic actuator pump to retract the hydraulic cen­
ter hole ram. Push the puller shaft back through the
center hole ram until the stop collar contacts the end of
the ram. Remove the stop collar and driver from the puller
shaft.

Camshaft Bushings No. 4, 3, and 2 - Installation

Put the centering guide, Part No. 3823650, on the end of
the puller shaft that extends through bushing No. 5. Slide
the guide into the bushing until the flange on the guide
contacts the bushing.
Camshaft Bushings Cylinder Block - Group 01
Page 1-18 V903

Put the bushing driver, Part No. 3823648, on the puller

shaft with the small end toward the center hole ram and
the slot facing down. Slide the driver into the bushing then
push the driver on the shaft until the bushing contacts the
camshaft bushing bore in the cylinder block.

Put the stop collar, Part No. 3823626, into the groove in
the puller shaft that is nearest to the end of the bushing
driver. Rotate the bushing until the oil slot in the bushing
is aligned with the oil drilling to the main bearing saddle.

NOTE: Check the alignment between the oil hole in the

(<ф;) bushing and oil drilling in the bushing bore before pulling
4—' the bushing into the bore.
Push down on the PRESS side of the pedal on the air/
hydraulic actuator pump to pull the bushing into the bore.
As the oil hole in the bushing nears the oil drilling in the
bore, reduce the amount of downward pressure being
applied to the pedal.

Apply light periodic downward pressure to the pedal to

pull the bushing into the correct position to center the oil
hole in the bushing with the oil drilling in the bushing bore.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-19

Push down on the RELEASE side of the pedal on the

air/hydraulic actuator pump to retract the hydraulic cen­
ter hole ram. Push the puller shaft back through the
center hole ram until the stop collar contacts the end of
the ram. Remove the driver and stop collar from the puller
shaft.

Repeat the above procedure to install bushing Nos. 3 and

No. 2 respectively.

Camshaft Bushing No. 1 - installation

Put the bushing driver, Part No. 3823629, on the puller
shaft with the small end toward the center hole ram and
the slot facing down. Slide the driver into the bushing then
push the driver on the shaft until the bushing contacts the
camshaft bushing bore in the cylinder block.

Put the stop collar, Part No. 3823626, into the groove in
the puller shaft that is nearest the end of the bushing
driver. Rotate the bushing until the oil hole in the bushing
is aligned with the oil drilling to the main bearing saddle.
With the oil hole properly aligned, the oil slot in the bush­
ing will be aligned with the oil drilling to the cylinder head
deck surface.
Camshaft ESushings Cylinder Block - Group 01
Page 1-20 V903

NOTE: Check the alignment between the oil hole in the

bushing and oil drilling in the bushing bore before pulling
the bushing into the bore.
Push down on the PRESS side of the pedal on the air/
hydraulic actuator pump to pull the bushing into the bore.
As the oil hole in the bushing nears the oil drilling in the
bore, reduce the amount of downward pressure being
applied to the pedal.

Apply light periodic downward pressure to the pedal to

pull the bushing into the correct position to center the oil
hole in the bushing with the oil drilling in the bushing bore.
The centering guide installed in the No. 1 bushing bore
will be pushed into the receiving spacer.

Push down on the RELEASE side of the pedal on the

air/hydraulic actuator pump to retract the hydraulic cen­
ter hole ram. Push the puller shaft back through the
center hole ram until the stop collar contacts the end of
the ram. Remove the stop collar and driver from the puller
shaft.

Remove the stop collar, hydraulic center hole ram, re­

ceiving spacer, and centering guide from the puller shaft.
Cylinder Block - Group 01 Camshaft Bushings
V903 Page 1-21

Remove the puller shaft from the camshaft bushing in­

side diameter. Remove the centering guide from the No.
5 bushing bore.

Meeisure the camshaft bushing installed inside diameter.

Camshaft Bushing I.D. Installed

No. 1 Bushing Bore
mm_____________________________in___
63.475 MIN 2.4990
65.551 MAX 2.5020

Camshaft Bushing I.D. Installed

Nos. 2, 3, 4, and 5 Bushing Bore
m m ___________ ___________in
76.200 MIN 3.0000
76.276 MAX 3.0030
 №
Cylinder Head - Group 02 Parts Commonalty
V903 Page 2-1

Cylinder Head - Group 02

Parts Commonalty
The Big Cam and Small Cam engines all use the same cylinder heads. The rebuild procedures and specifications
contained in the V/VT903 Shop Manual, Bulletin No. 3379057-04, are applicable.
Rocker Lever - Group 03 Parts Commonalty
V903 Page 3-1

Rocker Lever - Group 03

Parts Commonalty
The Big Cam and Small Cam series engines use the same parts within the rocker lever group with exception to
the injector rocker lever, rocker lever housing, oil filler tube, and oil filler cap.

Rocker Lever - injector

The injector rocker levers are not interchangeable be­
tween the Big and Small Cam engines. The Small Cam
engine injector rocker lever (1), Part No. 211399, has a
1:1 ratio. The Big Cam injector rocker lever (2), Part No.
196571, has a 1.2:1 ratio.

Do not use Small Cam injector rocker levers on Big Cam

engines. Intermixing Small Cam injector rocker levers on
Big Cam engines will result in poor performance, exces­
sive smoke and fuel dilution of the lubricating oil.

Rocker Lever Housing

The rocker lever housings are not interchangeable be­
tween the Big and Small Cam engines. The rocker lever
housing used on the Big Cam engine contains oil drillings
which provide for oil transfer from the STC oil supply tube
to the STC tappets.

rh3hsga
Oil Filler Cap Rocker Lever - Group 03
Page 3-2 V903

Oil Filler Cap

The oil filler cap is not interchangeable between the Big
Cam and Small Cam engines. The Small Cam engine oil
filler cap (1) is an expandable rubber plug type design.
The Big Cam engine oil filler cap and tube combination
(2) is a twist type positive lock design.
Cam Follower - Group 04 Parts Commonalty
V903 Page 4-1

Cam Follower - Group 04

Parts Commonalty
The Big Cam and Small Cam series engines use the same parts within the cam follower group with exception to
the intake and exhaust valve push rods.

Valve Push Rods - Intake and Exhaust

The intake and exhaust valve push rods are not inter­
changeable between the Big and Small Cam engines. %
The Small Cam engine (1) intake and exhaust valve push
rods, Part No. 169351, are approximately 6 mm [1/4 inch]
longer than push rods used on the Big Cam engine (2), 370 mm 333 mm
Part No. 3041013. [13-1/8 In.] [12-7/8 In.]

pfSvaga

Do not use Small Cam intake and exhaust valve push

rods on the Big Cam engine. The increased length will
cause the rocker lever adjusting screw to contact the
valve cover resulting in damage to the push rod and valve
cover and possible damage to the valve tappet.
Fuel System - Group 05 Parts Commonalty
V903 Page 5-1

Fuel System - Group 05

Parts Commonalty
The fuel pump used on the Big Cam and Small Cam engines are not interchangeable. The Small Cam engine
fuel pump is a PT (Type G) single spring AFC design. The Big Cam engine fuel pump is a PT (Type G) dual spring
AFC design. The fuel pump calibration values for both the Big and Small Cam fuel pumps are Munitions Controlled,
and therefore are not published in the Fuel Pump Calibration Values, Bulletin No. 3810396. If calibration values
are required, contact the Government Business Service Department, Phone No. 812-377-3957, Fax No. 812-
377-3082.

Fuel Pump - Identification

The fuel pumps can be identified by the AFC cover. The
single spring AFC used on the Small Cam engine does
not have an adjusting screw in the AFC cover (1). The
dual spring AFC used on the Big Cam engine has two
adjusting screws in the AFC cover (2).

The fuel pumps can also be identified by the fuel pump

body. The body used on the Small Cam pump (1) has a
no-air adjusting screw. The body used on the Big Cam
pump (2) does not contain a no-air adjusting screw.
Injectors - Group 06 Injectors - General Information
V903 Page 6-1

Injectors - Group 06
Injectors - General Information
The injectors used on the Big Cam and Small Cam engines are not interchangeable.
The Small Cam engine uses PT (Type D) non STC style injectors. The Big Cam engine uses PT (Type D) STC
full top-stop style injectors.
PT (Type D) Step Timing Control (STC)
The step timing control (STC) system allows an engine to operate with advanced injection timing under light load
conditions. STC allows the engine to operate with normal injection timing under heavy load conditions.
The injector top-stop plunger travel and total travel must be adjusted with a top-stop injector setting fixture before
installing into the engine.
To adjust the injector overhead setting on STC engines after injector installation, use the 0.56 to 0.68 N»m [5 to
6 in-lb] torque wrench method to preload the injector adjusting screw while holding the STC tappet up with the
STC tappet lifting tool. Refer to Valve and Injector Adjustment in Group 00 of this bulletin.
NOTE: Use the tappet lifting tool to hold the tappet up while applying the preload.
The STC tappet assembly contains a plunger and a sleeve that are machined to a very precise tolerance. The
plunger and the sleeve are then class fit. Never exchange or combine the plungers and the sleeves.
The tappet assembly and the injector are not class fit. The tappet assembly can be used in any STC injector,
provided the tappet part number is correct for the injector assembly part number. After the tappet is replaced or
reinstalled, the total travel must be reset on the top-stop injector setting fixture before installing the injector into
the engine.
STC Injector - Operation Injectors - Group 06
Page 6-2 V903

Identification
The injectors used on the Small Cam engine (1) are
standard PT (Type D) injectors. The injectors used on the
Big Cam engine (2) are PT (Type D) STC injectors. The
STC injectors can be identified by the top-stop feature
and the oil inlet port.

Rebuild
The disassembly, inspection, repair, and calibration pro­
cedures for the injectors are covered in Shop Manual PT
(Type D) Step Timing Control Injector, Bulletin No.
3810313.

Calibration
The injector calibration specifications and parts informa,-
tion are provided in Injector Specifications, Bulletin No.
3379664.

It800gs

STC Injector - Operation

The STC injector used in the Big Cam VTA903 engine has
the same design and function as the STC injectors used
in other Cummins engine families. Refer to Step Timing
Control Familiarization, Bulletin No. 3387380, and Step
Timing Control System Troubleshooting and Repair Man­
ual, Bulletin No. 3810385, for additional information.
Injectors - Group 06 STC Electrical
V903 Page 6-3

STC Electrical
Time Delay Relay Operation
The STC time delay relay (1) is used to prevent the in­
jection timing from switching to the advance mode during
the cranking operation. The relay timer starts when the
starter button is released. Twenty seconds later the relay
closes, completing the electrical circuit to the fuel pres­
sure switch and STC oil control solenoid. The solenoid
then opens allowing oil flow to the STC tappets. The
injection timing then switches to the advance mode.

Fuel Rail Pressure Switch Operation

The fuel rail pressure switch is normally closed which
allows electrical current to flow to the STC oil control
solenoid when the twenty second time delay relay is
closed and the fuel rail pressure is between 0 to 241 kPa
[35 psij. When the fuel rail pressure exceeds 241 kPa [35
psi], the fuel rail pressure switch opens, which stops the
flow of electrical current to the STC oil control solenoid.
The solenoid then closes, shutting off the oil flow to the
STC tappets. The timing then switches to the normal
mode.

Oil Control Solenoid Operation

The STC oil control solenoid (1) is normally closed. When
the twenty second time delay relay closes and the fuel rail
pressure is between 0 to 241 kPa [35 psi], electrical
current from the vehicle electrical system flows to the
solenoid causing the solenoid to open. Oil from the en­
gine lubricating system then flows through the solenoid
to the STC tappets, causing the injection timing to switch
to the advance mode. When the fuel rail pressure ex­
ceeds 241 kPa [35 psi], the fuel rail pressure switch
opens, stopping the flow of electrical current to the STC
oil control solenoid. The solenoid then closes, shutting off fs3cnw a
the oil flow to the STC tappets. The timing then switches
to the normal mode.

Control System Diagnostic Tool Operation

The STC Electrical System Diagnostic Tool, Part No.
3823880, has an ON/OFF switch and three indicator lights.
The ON/OFF switch is used to functionally check the STC
system during engine operation.
The lights are used to indicate if the electrical control
system is operating properly with the engine off and dur­
ing engine operation.

ee3tova
STC Electrical Injectors - Group 06
Page 6-4 V903

When the ON/OFF switch is turned off with the engine

operating at low idle, the timinq will switch from advance
to normal. The RELAY OUT and PRESSURE SWITCH
indicator lights on the diagnostic tool will also go out when
the switch is turned off.

When the ON/OFF switch is turned on with the engine

20 Seconds operating at low idle, the timing will switch from normal
to advance after a 20 second delay. The RELAY OUT and
щ
— --------
BAJTERY
Щ PRESSURE SWITCH indicator lights will also illuminate
ON 20 seconds after the switch is turned off.
Ж
RELAY O U T

P R E S S U R E S W ITC H

OFF
' - r |
_________ e
// Т/ ee3tovc

The top indicator light is labelled BATTERY. The light

when illuminated indicates that a minimum of 18 volts are
available at the time delay relay.
The light will not illuminate if less than 18 volts are
available.

The middle light is labelled RELAY OUT. The light when

illuminated indicates that the time delay relay has closed
and voltage is available to the fuel rail pressure switch.
The light will illuminate approximately 20 seconds after
the battery light illuminates if the relay is operating
correctly.
Injectors - Group 06 STC Electrical
V903 Page 6-5

The bottom light is labelled PRESSURE SWITCH. The

light when illuminated indicates that the pressure switch
is closed and voltage is available at the STC oil control
solenoid.
The light will be illuminated anytime the BATTERY, and
RELAY OUT lights are illuminated and the fuel rail pres­
sure is below 170 kPa [25 psi]. When the fuel rail pressure
exceeds 170 kPa [25 psi], the fuel rail pressure switch
opens causing the timing to switch to normal. The PRES­
SURE SWITCH indicator light will go off when the pres­
sure switch opens.

Control System Diagnostics

Use the Electrical System Diagnostic Tool, Part No.
3823880, to diagnose STC electrical problems.
NOTE: The diagnostic tool is designed specifically for the
STC electrical control system used on the Big Cam VTA903
series engine. The tool can not be used to diagnose STC
electrical problems on other Cummins Engine Company,
Inc. engine families.

Turn the vehicle master power switch OFF.

Disconnect the electrical connector from the time delay
relay.

Connect the female connector on the diagnostic tool to

the male connector on the time delay relay.
Connect the male connector on the diagnostic tool to the
female connector on the STC wiring harness.
STC Electrical Injectors - Group 06
Page 6-6 V903

Connect the small alligator clip on the diagnostic tool to

the terminal with the black wire at the STC solenoid.
Connect the large alligator clip to the vehicle ground, at
any convenient location such as the negative terminal on
the starter.

With the vehicle MASTEER POWER switch and the EN­

GINE ACCESSORY switch in the OFF position, all three
lights on the diagnostic tool will be off.

Turn the MASTER POWER and ENGINE ACCESSORY

switch ON, but do not start the engine.
NOTE: The ON/OFF switch on the diagnostic tool must be
in the ON position.

If there are 18 volts available at the time delay relay, the

top indicator light on the diagnostic tool labelled BAT­
TERY will illuminate immediately upon turning on the
vehicle MASTER POWER and ENGINE ACCESSORY
switch.
Injectors - Group 06 STC System Functional Check
V903 Page 6-7

The middle indicator light labelled RELAY OUT, and bot­

tom indicator light labelled PRESSURE SWITCH will il­
luminate 20 seconds after the battery light illuminates.

If all lights are operating as described, the STC wiring

harness, time delay relay, and pressure switch are op­
erating properly.
If the lights do not operate as described, refer to the
accompanying troubleshooting chart.

STC System Functional Check

With the STC diagnostic tool connected into the STC
electrical system as described under STC Electrical Con­
trol System - Diagnostics, start the engine.
Operate the engine at low idle during this check.

With the ON/OFF switch on the diagnostic tool in the ON

position, the three indicator lights will all be illuminated 20
seconds after the vehicle starter button is released, and
the engine will then be operating in the advanced injec­
tion timing mode.
 m
STC Solenoid Resistance Check Injectors - Group 06
Page 6-8 V903

Move the diagnostic tool ON/OFF switch to the OFF po­

sition. The RELAY OUT and PRESSURE SWITCH light
will go off. The STC will switch from the advance to the
normal injection timing mode.

A distinct change in the engine noise level will be audible

when the timing switches from the advance to normal
mode. A significant increase in the white smoke level will
also be visable if the engine coolant temperature is below
60°C [140°F].

If the STC electrical control system diagnostic tool indi­

cates that the electrical system is operating properly and
the timing will not switch from normal to advance, or
advance to normal when the switch on the diagnostic tool
is turned ON and OFF, check the STC oil control valve for
electrical or mechanical problems.

STC Solenoid Resistance Check

Remove the two electrical wires from the solenoid.
Injectors - Group 06 STC Solenoid Resistance Check
V903 Page 6-9

Use a volt-ohm meter to check the resistance between

the two terminals on the solenoid.
Replace the solenoid if the resistance is not within spec­
ifications.

Coil Resistance (Ohms)

MIN MAX
28' 32
STC System Functional Check Troubleshooting Chart Injectors - Group 06
Page 6-10 V903

STC SYSTEM FUNCTIONAL CHECK TROUBLESHOOTING CHART

(FOR USE WITH STC ELECTRICAL SYSTEM DIAGNOSTIC TOOL,
PART NO. 3823880 WITH ENGINE RUNNING AT LOW IDLE)
M A S TE R P O W ER D IA G N O S TIC B A TTER Y TIM E SINCE RELAY P R ESSU RE A U D IB LE FA U LT (C O R R E C TIV E A C TIO N )
AMD ENGINE T O O L O N /O F F LIG H T S TA R TER S W ITC H OUT S W ITC H C HANG E IN
A C C ES S O R Y S W ITC H SW ITC H RELEASED LIG H T LIG H T ENGINE N O ISE

ON ON ON MORE THAN 15 ON ON YES NO NE - S Y S TE M NO R M A L

S EC O N D S

ON ON M O R E THAN 25 O FF O FF NO D IA G N O S TIC TO O L O N /O FF
SEC O N D S SW ITCH IN O FF PO SITIO N (TURN
S W ITC H ON)

ON ON ON M O RE THAN 25 ON ON NO E N G IN E STA R TIN G IN ADVANCE

SEC O N D S TIM IN G - W IR IN G H ARNESS
C O N N E C T E D W R O N G AT
S TARTER (C H E C K HARNESS
FO R PR O PE R INSTALLATION)
S EE NOTE BELOW

ON ON ON M O R E THAN 25 ON ON NO STC S O LE N O ID D EFEC TIVE

SECO NDS (C HECK C O IL RESISTANCE)

OK

STC OIL C O N TR O L VALVE DE­

FE C TIVE (REPAIR/REPLACE
VALVE)

OK

LESS THAN 103 KPA [15 PSI] OIL

P R ES S U RE TO TA PPETS (CHECK
FOR BLOCKED O IL SUPPLY
LINES, BROKEN OIL TR A N SFER
TU B E S , OR M ISSIN G O-RINGS)

OK

S TC TA P P ETS D E FE C TIV E (R E ­
M O V E IN JE C TO R S AND R EPA IR /
REPLACE TA P P ETS )

ON ON M O R E THAN 25 O FF O FF NO STC S O LE N O ID D EFEC TIVE

SEC O N D S (C H EC K C O IL RESISTANCE)

OK

T IM E DELAY RELAY D EFEC TIVE

(REPLACE RELAY)

OK

STC W IR IN G HA R N ESS D E FE C ­
TIV E (REPAIR/REPLA C E W IR IN G
HARNESS)

ON S W ITC H ED O F F ON N O T APPLICABLE O FF O FF Y ES N O NE- S Y S T E M NORM AL

W H ILE E N G IN E
IN ADVA N C ED
TIM IN G

NOTE: If the STC wiring harness is connected wrong at the starter solenoid the engine will start in the advance timing
mode, However the lights on the diagnostic tool will indicate that the system is operating normally. If the engine noise
level does not change 20 seconds ( + /- 5 seconds) after the starter switch is released, shut the engine off. Restart the
engine and 10 seconds after the starter switch is released turn the ON/OFF switch on the diagnostic tool to OFF. If the
engine noise level changes the STC wiring harness is connected wrong at the starter solenoid.
 ■Spi/
Injectors - Group 06 STC Electrical Control System Troubleshooting Chart
V903 Page 6-11

STC ELECTRICAL CONTROL SYSTEM TROUE3LESHOOTING CHART

(FOR USE WITH STC ELECTRICAL SYSTEM DIAGNOSTIC TOOL,
PART NO. 3823880 WITH ENGINE NOT RUNNING)
M A S TE R PO W ER B A TT ER Y T IM E SIN C E R E LA Y O U T P R ESSURE S W ITC H F A U L T (C O R R E C TIV E A C TIO N )
A N D EN G IN E LIG H T EN G IN E A C C ESSO R Y L IG H T LIG H T
A C C ESSO R Y S W ITC H SW ITC H TU R N E D ON

ON ON M O R E TH A N 15 ON ON NONE
S EC O N D S

ON ON LESS THAN 15 ON ON TIM E DELAY RELAY D E TE C TIV E

S EC O N D S (REPLACE RELAY)
?
ON OFF M O R E TH A N 25 OFF O FF IM P R O P E R D IA G N O S TIC TO O L
S EC O N D S G R O U N D (C HECK G R O U N D
C O N N E C T IO N )

OK

IN S U FFIC IE N T V E H IC L E BAT­
T E R Y P O W ER (C H E C K B A T rE R Y
C H A R G E)

OK

STC W IR IN G HA R N ES S D E FE C ­
TIVE (RE P AIR/RE P LA C E W IRING
H A R N ESS)

ON ON M O R E TH A N 25 OFF O FF STC S O LE N O ID D E FE C TIV E

S EC O N D S (C H E C K CO IL RESISTAN C E)

OK

TIM E DELAY RELAY D E FE C TIV E

(REPLACE RELAY)

OK

S TC W IR IN G H A R N ES S DEFEC­
T IV E (R E P AIR/RE P LA C E W IR IN G
H A R N ES S )

ON ON M O R E TH A N 25 ON O FF P R E S S U R E S W ITC H D E FE C TIV E
S EC O N D S (R EPLA C E P R E S S U R E SW ITC H )

S TC W IR IN G H A R N ES S DEFEC­
TIV E (REPLACE W IR IN G HAR­
NESS)

Fuel Tubing
Fuel, STC, and Cold Start Lines - VTA903-T 600 Horsepower Engine
Due to the complexity of the Big Cam 600 HP engine, use extreme care when installing the fuel, STC or cold start
lines to prevent the lines from chafing against each other, or against an engine component. A plumbing diagram
for the 600 HP engine is included in this section.
Fuel, STC, and Cold Start Lines - VTA903-T 660 Horsepower Engine
The plumbing arrangement for the VTA903 660 HP engine has not been finalized at this time. Additional
information will be provided when the design is finalized.
Fuel Tubing System Diagrams Injectors - CSroup 06
Page 6-12 Fuel Tubing

Fuel Tubing System Diagrams

Injectors - Group 06 Fuel Tubing System Diagrams
Fuel Tubing Page 6-13

Fuel Tubing System Diagrams

Ref. Part Ref. Part

Part Name Part Name
No. Number No. Number
1 3033023 Elbow 22 3033412 Tee
2 3 02 83 2 4 Check Valve 23 6 8139 Elbow
3 68139 Elbow 24 3028325 Check Valve
4 170460 Clip 25 1 07460 Clip
5 101467 Bracket 26 3006182 Capscrew
6 3021470 Capscrew 27 1 18347 Elbow
7 3 02 14 7 3 Capscrew 28 3 06 8 7 3 2 Tube
8 S- 602 Washer, Flat 29 S-1040-A Elbow
9 3 06 46 6 6 Tee 30 3064672 Tube
10 3 06 4 6 6 8 Tube 31 180371 Clip
11 144372 Elbow 32 1 01476 Bracket
12 187368 Adapt er 33 S-181-B Capscrew
13 3 03 95 5 8 Elbow 34 3012470 Capscrew
14 3 02 5 4 5 8 Elbow 35 S-6 04 Washer, Lock
15 3064671 Tube 36 3 0 6 46 7 2 Tube
16 3 04 0 8 3 8 Capscrew 37 144372 Elbow
17 180371 Clip 38 3 0 2 54 5 8 Plug
18 63385 Spacer 39 3 03 9 5 5 8 Elbow
19 180372 Clip 40 1 87368 Adapt er
20 S- 223 Nut 41 3 0 6 37 5 3 Tube
21 3063712 Tube 42 3 0 3 37 4 0 Check Valve
ftJOOgl
Fuel Tubing System Diagrams Injectors - Group 06
Page 6-14 Fuel Tubing

Fuel Tubing System Diagrams

Ref. Ref.
Part Number Part Name Part Number Part Name
No. No.
1 3 0 6 37 0 7 Tube 11 S- 223 Nut
2 3 0 3 30 3 8 C ap screw, Capt i ve 12 196421 Bracket
3 180371 Clip 13 3006183 Capscrew
4 633 85 Spacer 14 180371 Clip
5 3063756 Tube 15 3063751 Tube
6 112 10 5 Elbow 16 A K 0 4 01 80 0S S Hose
7 3056346 Switch 17 6 8139 Elbow
8 681 43 Clip 18 3007025 Clamp
9 S -1 0 9 Capscrew 19 S-251 Nut
10 1 27362 Washer, Flat 20 S - 131 5 Capscrew

fttOOej
Injectors - Group 06 Fuel Tubing System Diagrams
Fuel Tubing Page 6-15

Fuel Tubing System Diagrams

Ref. Part
Part Name
No. Number
1 3 03 30 3 8 Capscrew
2 180371 Clip
3 63.385 Spacer
4 3 06 46 6 9 Tube
5 3 06 57 2 7 Fitting
6 3 0 6 57 26 Cap
7 112105 Elbow

Ref. Part
Part Name
No. Number
1 68139 Elbow
2 3063714 T ube
3 68139 Elbow
 m
Fuel Tubing System Diagrams Injectors - Group 06
Page 6-16 Fuel Tubing

Fuel Tubing System Diagrams

Ref. Part Ref. Part

Part Name Part Name
No. Number No. Number
1 S-181-B Capscrew 5 S-181-B Capscrew
2 S-604 Washer, Lock 6 S-604 Washer, Lock
3 180371 Clip 7 180371 Clip
4 68190 Bracket 8 681 90 Bracket

Ref. Part
Part Name
No. Number
1 3065725 Tee
2 3 063708 T ube
3 3065724 Tee
4 30637 57 Tube
5 3 063235 Bracket
6 3065731 Tube
7 112105 Elbow
8 306 37 09 Tube

lOOgl
Injectors - Group 06 Fuel Tubing System Diagrams
Fuel Tubing Page 6-17

Fuel Tubing System Diagrams

Ref. Par t Part Name

No. N u mb e r
1 3068929 Air M anifold
3063704 &
2 Nozzle & Washer
3 0 6 3 7 7 2 (4)
3 3068713 Tube
4 3 0 6 5731 Tube
5 3068714 Tube
є 3068715 Tube
7 3065724 Tee
30 6 4 7 2 1 &
8 Nut & Ferrule
3 9 0 3 5 9 7 (4)
9 1 5 4 3 9 6 (2) Gasket, Intake (2)
10 3067337 Capscrew, Captive (16) ftSOOgnn
Fuel Tubing System Diagrams Injectors - Group 06
Page 6-18 Fuel Tubing

Fuel Tubing System Diagrams

Ref. Part Ref. Part

No. Part Name Part Name
Number No. Number
1 112105 Elbow 10 30685 62 Bracket
2 3 008466 Plug, Smoke Generator 11 3 01 87 92 Capscrew (4)
3 3 067299 T ee 12 3 06 57 30 Spacer
4 3 06 6145 Capscrew 13 3 06 46 70 T ee
5 S-607 Washer, Lock 14 187368 Fitting
6 S-603-A Washer, Flat 15 S-955 Reducer
7 145345 Capscrew 16 306 57 25 Tee
8 138764 Capscrew 17 112105 Elbow
9 30661 59 Harness 18 3 06 61 58 Relay
19 3063761 Solenoid, Cold Start
Solenoid,
20 3063761
Smoke Generator
ft300gn
 W Z
Fuel Tubing System Diagrams
Injectors - Group 06 Page 6-19
Leece-Neville Starter

ЗТЕР TIMING CONTROL SYSTEM WIRING DIAGRAM - LEECE - NEVILLE STARTER

FUEL PRESSURE
SWITCH

TIME DELAY
RELAY

CtdE
FROM FUEL
f
H
PUMP

STEP TIMING
CONTROL DIODE
ASSEMBLY (STC)
1— c ® © ® © y -j

WH 001
BLK 002
WH 004
WH 003

BATTERY
TERMINAL
* STC WIRE
NO. 003
AND 004
/

\^ .G R O U N ID
<y>-fk TERMINAL
/ • STC WIRE
LEECE O ) / NO. 007A
NEVILLE \ /
STARTER
\ STARTER
/ GROUND
\
/
/ LEECE - NEVILLE / \
STARTHR ^ \
+24VDC FROM
MASTER RELAY

ft300g;r
 //з
Fuel Tubing System Diagrams Injectors - Group 06
Page 6-20 Delco-Remy Starter

STEP TIMING CONTROL SYSTEM WIRING DIAGRAM - DE1LCO REMY STARTER

FUEL PRESSURE
SWITCH (N.C.)
TIME DELAY
RELAY
H
tft
FROM FUEL §
PUMP X
5
49

Ss
m§
<

i-------
і ґЛ
STEP TIMING DIODE
CONTROL
ASSEMBLY (STC) I
~ “ C ® © __ ® _

WH 001
BLK 002

WH 003

+24 VOLT DC

ft3 0 0 g y
Lubricating Oil System Lubricating Oil Siystem Flow
V903 Page 7-1

Lubricating Oil System Flow

VTA 903-T600 HP
Lubricating System
Lubricating Oil System - General Information Lubricating Oil System
Page 7-2 V903

Lubricating Oil System - General

Information
Lubricating Oil Pump Configurations
Two different lubricating oil pump configurations are used
on the VTA903 Big Cam series engine. These include a
high speed single lubricating oil pump used on the VTA-
903T600 HP engine and a high speed double lubricating
oil pump used on the VTA-903 T660 HP engine. The high
speed pumps have a driving ratio of 1.25:1 in relation to
engine speed.
The single and double lubricating oil pumps used on the
Small Cam V/VT/VTA-903 series engines are the slow
speed design with a drive ratio of 0.83:1.

Each of the lubricating oil pump configurations can con­

tain several different combinations of oil pressure regu­
lator plungers (5), springs (4), spacers (3), washers (2)
and caps (1), depending on the engine configuration.
Label or tag all oil pressure regulator parts as they are
removed from the pump. Intermixing oil pressure regu­
lator components from one pump to another can result in
high or low oil pressure problems.

Drive Shaft Bushing - Replacement

Do not remove the drive shaft bushings from the main
pump body, scavenge pump body, or cover unless the
bushings are worn beyond specifications. The bushings
must be precision machined after they are installed in the
bores. If the bushings require replacement, refer to Lu­
bricating Oil Pump Body And Cover Bushing - Replace­
ment in this bulletin for the service tools required to re­
move, install, and machine the bushings.

Main Drive Gear Cover Plate Mounting

Capscrews
The capscrews which secure the main drive gear cover
plate to the lube pump rear cover are self-locking cap­
screws. Install new self locking capscrews each time the
cover plate is removed.
Lubricating Oil System Lubricating Oil Pressure Regulator (External)
V903 Page 7-3

Installation Of Oil Suction Tube

The oil suction tube must be mounted on the lubricating
oil pump after the pump is mounted on the engine. In­
stallation of the suction tube prior to mounting the pump
on the engine will result in suction tube failure due to
assembly stress resulting from misalignment between
the pump and suction tube.
NOTE: Do not use Small Cam oil suction tube gasket, Part
No. 144667, on the Big Cam engine. The hole for oil flow
through the gasket has a smaller ID and will cause excessive
restriction if used on the Big Cam engine in place of oil
suction tube gasket, Part No. 3063668. Oil suction tube
gasket, Part No. 3063668, must be used on the Big Cam
engine and can also be used on the Small Cam engine.

Lubricating Oil Pressure Regulator

(External)
Disassembly
Caution: The parts are under spring tension. The spring
can move with enough force to cause personal injury.
Use a tool that will control the parts firmly.
This regulator controls the pressure in the main oil rifle.
Remove the regulator cap (1), and copper washer (2).
Discard the copper washer. Remove the two washers (3)
from the bore in the cap, the spring (4) and plunger (5)
from the boring in the oil cooler support (6).

Inspection
Visually inspect the oil pressure regulator plunger for
scratches or scoring.
If scratches are deep enough to be felt with a fingernail,
the plunger must be replaced.
Visually inspect the spring for damaged or broken coils.

Use a valve spring tester, Part No. 3375182, to determine

if the spring is defective.
Compress the spring to a height of 53.98 mm [2.125 in].
The force required must be:•
• Minimum 200 N [45 Ibf]
• Maximum 222 N [50 Ibf]
If the force required to compress the spring is not within
the specifications given, the spring must be replaced.
Lubricating Oil Cooler Core - Pressure Testing Lubricating Oil System
Page 7-4 V903

Assembly
Caution: The parts are under spring tension. The spring
can move with enough force to cause personal injury.
Use a tool that will control the parts firmly.
Install the spring (4) in the bore in the oil pressure reg­
ulator plunger (5). Install the plunger in the bore in the oil
cooler support (6), the two washers (3) in the bore in the
cap, the copper washer (2) on the cap (1), and the cap in
the oil cooler support.

Use your fingers to tighten the pressure regulator cap.

Tighten the cap to the specified torque value.
Torque Value: 60 N»m [45 ft-lb]

Lubricating Oil Cooler Core - Pressure

Testing
Install and clamp a short section of hose over either the
inlet or outlet of the oil cooler. Install a plug into the
opposite end of the section of hose and install the clamp.

Attach a regulated air pressure hose to the other end of

the oil cooler. Use an air pressure regulator, Part No.
3823799, or equivalent.
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-5

Submerge the oil cooler in a tank of water heated to 82°C

[180°F] for three to five minutes. Slowly apply 415 kPa
[60 psi] air pressure to the oil cooler core and inspect for
leaks.
If leaks are found, replace the oil cooler core.

Release the air pressure from the cooler core before

removing it from the water tank. Remove the oil cooler
core from the water tank and the hoses and clamps from
the oil cooler. Dry the oil cooler with compressed air.

Lubricating Oil Pump (High Speed -

Single Pump)
Inspect For Reuse
Cleaning
Use a gasket scraper to remove the gasket material from
the gasket mating surfaces.
Use solvent to clean the lubricating oil pump. Dry with
compressed air.

Inspection
Turn the main drive gear by hand to inspect the internal
gears for freedom of rotation.
Visually inspect the gears for cracked or broken teeth.
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-6 V903

Visually inspect the bushings for excessive wear or dis­

coloration due to overheating or seizure of the shafts.

Measure the drive shaft end clearance.

Drive Shaft End Clearance

mm_____________________________in
0.05 MIN 0.002
0.13 MAX 0.005
If the main drive gear does not turn freely by hand,
cracked or broken teeth are found, or the shaft end clear­
ance is not within the specifications given, the oil pump
must be replaced or rebuilt. Refer to Lubricating Oil Pump
- Rebuild in this bulletin.

Measure the idler gear end clearance.

Idler Gear End Clearance

____ mm_____________________________in_________
0.08 MIN 0.003
0.38 MAX 0.015
If the end clearance is not within specifications, the oil
pump must be replaced or rebuilt. Refer to Lubricating
Oil Pump - Rebuild in this bulletin.

Use a dial indicator to measure the [Link] the

main drive gear and idler gear.
NOTE: Hold the main drive gear while performing this check.

Backlash Between Main Drive and Idler Gear

mm_____________________________in__
0.13 MIN 0.005
0.38 MAX 0.015
If the backlash is not within the specifications given, the
oil pump must be replaced or rebuilt. Refer to Lubricating
Oil Pump - Rebuild in this bulletin.
Lubricating Oil System Lubricatinq Oil Pump (High Speed - Single Pump)
V903 Page 7-7

Rebuild
Disassembly
Caution: The parts are under spring tension. The spring
can move with enough force to cause personal injury.
Use a tool that will control the parts firmly.
Remove the main oil pressure regulator as follows:
Bend the tab on the lockplate away from the regulator
cap.

Remove the regulator cap (1) and lockplate (2). Discard

the lockplate.
Remove the spacer (3), spring (4), and the plunger (6)
from the pump body (7).
Remove the washer (5) from the plunger (6).

Remove the four self-locking capscrews and the cover

plate. Discard the capscrews.

Measure the backlash between the main drive gear and

the idler gear.

Backlash Between Main Drive and idler Gear

mm______________________________ [n_________
0.13 MIN 0.005
0.38 MAX 0.015
If backlash is not within specifications, mark the gears for
replacement.
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-8 V903

Remove the snap ring (1), thrust washer (2), and the idler
gear (3).

NOTE: The capscrews are different lengths. Tag the cap­

screws as they are removed so they can be installed in their
original location.
Caution: Installing the capscrews in the wrong location
will lock or damage the main drive or idler gear.
Remove the two capscrews, spring washers, and cover
from the pressure regulator secondary dump port.

NOTE: The capscrews are different lengths. Tag the cap­

screws as they are removed so they can be installed in their
original location.
Caution: Installing the capscrews in the wrong location
will lock or damge the main drive or idler gear.
Remove the two capscrews and spring washers from the
pump body.
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-9

Remove the pump body from the cover. Remove and

discard the gasket.
Remove the driven gear from the cover.

Caution: The drive shaft and gear can drop free from the
cover during removal of the main drive gear.
Install the cover in an arbor press with the gasket surface
of the cover facing down.
Use the mandrel, Part No. 3823795, to push the drive
shaft from the main drive gear.

Remove the main drive gear from the cover.

Remove the cover, drive shaft, and drive gear from the
arbor press.
Remove the drive shaft and gear from the cover.
NOTE: Do not remove the drive gear from the shaft. Refer
to the Inspection procedures listed in Lubricating Oil Pump
(High Speed - Single Pump) - Rebuild.
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-10 V903

Cleaning
Clean the gasket material from the lubricating oil pump
body and the cover.
Use solvent to clean the lubricating oil pump parts. Dry
with compressed air.

Inspection
Visually inspect the cover and gear pockets in the body
for scratches or other damage.
If the marks on the cover or in the body can be felt with
your fingernail, the part must be replaced.

Visually inspect the oil pump body and cover for cracks
or damage.
Visually inspect the oil pump gears for worn or damaged
teeth.
Cracked, worn, or damaged oil pump parts must be
replaced.

Visually inspect the bushings in the oil pump body and

the cover for damage.
Measure the inside diameter of the bushings in the oil
pump body and cover.

Bushing I.D.
mm_________________________________in_____
22.28 MIN 0.877
22.33 MAX 0.879
If the bushings are worn larger than the maximum given,
the bushings must be replaced.
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-11

Visually inspect the bushings in the driven gear for dam­

age.
Measure the inside diameter of the bushings in the oil
pump driven gear.

Bushing I.D.
mm_____________________________ in_________
22.263 MIN 0.8765
22.33 MAX 0.879
If the bushings are worn larger than the maximum given,
the bushings must be replaced.

Visually inspect the drive shaft and the driven shaft for
damage.

Measure the outside diameter of the drive and the driven

shafts in the bushing contact area.

Shaft O.D.
mm____________________________ in_________
22.20 MIN 0.874
22.23 MAX 0.875
If the shaft is damaged or worn smaller than the minimum
given, the shaft must be replaced. Refer to Lubricating
Oil Pump Drive Gear or Shaft - Replacement in this
bulletin.

Visually inspect the idler gear for worn or damaged teeth.

Measure the inside diameter of the bushing in the idler
gear.

Bushing I.D.
mm____________________________ in_________
25.20 MIN 0.992
25.25 MAX 0.994
If the bushing is worn larger than the maximum given, the
bushing must be replaced. Refer to the Lubricating Oil
Pump Idler Gear Bushing - Replacement in this bulletin.
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-12 V903

Visually inspect the idler gear shaft for damage.

Measure the outside diameter of the idler gear shaft in the
bushing contact area.

Shaft O.D.
mm____________________________ in__
25.15 MIN “ 0.990
25.17 MAX 0.991
If the shaft is damaged or worn smaller than the minimum
given, the shaft m ust be replaced. Refer to Lubricating
Oil Pump Idler Shaft - Replacement in this bulletin.

Visually inspect the main drive gear for cracks, chipped,

or broken teeth.
Inspect the bore of the gear for scoring or other damage.

Measure the inside diameter of the main drive gear bore.

Maim Drive Gear bore I.D.

mm____________________________ jn_________
22.161 MIN 0.8725
22.187 MAX 0.8735
If the main drive gear bore is worn beyond the maximum
limit, the drive gear must be replaced.

Visually inspect the oil regulator plunger for scratches or

scoring.
If scratches are deep enough to be felt with a fingernail,
the plunger must be replaced.
Visually inspect the spring for damaged or broken coils.
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-13

Use a valve spring tester, Part No. 3375182, to determine

if the spring is defective.
Compress the spring to a height of 45.21 mm [1.780 in].
The force required must be:
• Minimum: 351 N [79 Ibf]
• Maximum: 405 N [91 Ibf]
If the force required to compress the spring is not within
the specifications given, the spring must be replaced.

Assembly
Position the mandrel, Part No. 3823793, on an arbor
press with the 13.97 mm [0.550 in] deep counterbore
facing up.
Position the short end of the drive shaft in the counterbore.

Use clean 15W-40 oil to lubricate the drive shaft.

Use clean 15W-40 oil to lubricate the bushing in the
cover.

Install the cover on the drive shaft.

Position the main drive gear on the drive shaft with the
center flange (1) facing up.
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-14 V903

Use the mandrel, Part No. 3823794, to push the main

drive gear onto the drive shaft.
Position the mandrel on the drive gear with the 4.70 mm
[0.185 in] counterbore facing the center flange on the
gear.
Push the gear on the shaft until the shaft contacts the
bottom of the counterbore in the mandrel.

Lubricate the inside diameter of the bushings in the driven

gear with clean 15W-40 oil.
Install the driven gear on the shaft.

Install a new gasket on the pump body. Position the dowel

holes in the gasket over the locating dowels in the cover.
Install the cover on the pump body.

Tap the cover lightly with a mallet to push the cover over
the locating dowels.
Install the cover mounting capscrew and spring washer.
Use your fingers to tighten the capscrew.
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-15

NOTE: The cover mounting capscrews are different lengths.

Install the capscrews in their original location.
Caution: Installing the capscrews in the wrong location
will lock or damage the main drive or idler gear.
Install the two capscrews and spring washers. Use your
fingers to tighten the capscrews.

NOTE: The cover mounting capscrews are different lengths.

Install the capscrews in their original location.
Caution: Installing the capscrews in the wrong location
will lock or damage the main drive or idler gear.
Install the pressure regulator dump port cover, the two
mounting capscrews, and spring washers. Use your fin­
gers to tighten the capscrews.

Tighten the four capscrews on the suction side of the

pump.
Tighten the capscrew on the drive gear side of the pump.
Torque Value: 50 N*m [35 ft-lb]
Lubricating Oil Pump (High Speed - Single Pump) Lubricating Oil System
Page 7-16 V903

Install the idler gear (1) on the idler shaft with the center
flange facing up. Install the thrust washer (2) and snap
ring (3) on the shaft.

Turn the idler gear by hand to inspect the internal gears

for freedom of rotation. If the pump does not turn freely,
disassemble the pump and check for burrs, nicks, or
foreign material between the gears and pump body or
cover.

Measure the drive shaft end clearance.

Drive Shaft End Clearance

mm_____________________________[n_________
0.05 MIN 0.002
0.13 MAX 0.005
If the shaft end clearance is not within the specifications
given, disassemble the pump and check for nicks, burrs,
or foreign material between gears and pump body or
cover, or a missing gasket between the body and cover.

NOTE: If the idler gear, shaft, or thrust washer were re­

placed during pump rebuild, check the idler gear end
clearance.

Idler Gear End Clearance

mm_____________________________ in_
0.08 MIN ' 0.003"
0.38 MAX 0.015
Lubricating Oil System Lubricating Oil Pump (High Speed - Single Pump)
V903 Page 7-17

If either the idler gear or main drive gear were replaced

during pump rebuild, check backlash between the idler
and main drive gears.

Backlash Between Main Drive and Idler Gear

mm_____________________________ in
0.13 MIN 0.005
0.38 MAX 0.015

Install the cover plate on the cover using four new self
locking screws.
Tighten the screws.
Torque Value: 10 N«m [96 in-lb]

Caution: The parts are under spring tension. The spring

can move with enough force to cause personal injury.
Use a tool that will control the parts firmly.
Install the washer (5) and spring (4) in the bore of the oil
pressure regulator plunger.
Install the plunger (6) in the regulator bore in the pump
body (7).
Install a new lockplate (2) on the pressure regulator cap.
Install the spacer (3) in the regulator cap.
Install the regulator cap (1) in the pump body.

Use your fingers to tighten the pressure regulator cap.

Tighten the cap to the specified torque.
Torque Value: 75 N*m [55 ft-lb]
Bend one side of the lockplate down against the boss on
the drive gear side of the pump body.
Bend the other side of the lockplate against the pressure
regulator cap.

Ip3lpfb
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-18 V903

Lubricating Oil Pump (High Speed -

Double Pump)
Inspect For Reuse
Cleaning
Use a gasket scraper to remove the gasket material from
the gasket mating surfaces.
Use solvent to clean the lubricating oil pump. Dry with
compressed air.

Inspection
Turn the main drive gear by hand to inspect the internal
gears for freedom of rotation.
Visually inspect the gears for cracked or broken teeth.

Visually inspect the bushings for excessive wear or dis­

coloration due to overheating or seizure of the shafts.

Measure the drive shaft end clearance.

Drive Shaft End Clearance

mm____________________________ jn_________
0.05 MIN ' 0.002
0.13 MAX 0.005
If the main drive gear does not turn freely by hand,
cracked or broken teeth are found, or the shaft end clear­
ance is not within the specifications given, the oil pump
must be replaced or rebuilt. Referto Lubricating Oil Pump
. Rebuild in this bulletin.
 -* 32 .
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-19

Measure the idler gear end clearance.

Idler Gear End Clearance

mm_____________________________ in_________
0.08 MIN 0.003
0.38 MAX 0.015
If the end clearance is not within specifications, the oil
pump must be replaced or rebuilt. Refer to Lubricating
Oil Pump - Rebuild in this bulletin.

Use a dial indicator to measure the backlash between the

main drive gear and idler gear.

Backlash Between Main Drive and Idler Gear

mm_____________________________ in_________
0.13 MIN 0.005
0.38 MAX 0.015
If the backlash is not within the specifications given, the
oil pump must be replaced or rebuilt. Refer to Lubricating
Oil Pump - Rebuild.

Rebuild
Disassembly
Remove the main oil pressure regulator as follows:
Bend the tab on the lockplate away from the regulator
cap.

Caution: The parts are under spring tension. The spring

can move with enough force to cause personal injury.
Use a tool that will control the parts firmly.
Remove the regulator cap (1) and lockplate (2). Discard
the lockplate.
Remove the spacer (3), spring (4) and plunger (6) from the
pump body (7). Remove the washer (5) from the plunger
( 6).
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-20' V903

Remove the four self-locking capscrews and the cover

plate. Discard the capscrews.

Measure the backlash between the main drive gear and

the idler gear.

Backlash Between Main Drive and Idler Gear

mm_____________________________in_________
0.13 MIN 0.005
0.38 MAX 0.015
If backlash is not within specifications, mark the gears for
replacement.

Remove the snap ring (1), thrust washer (2), and the idler
gear (3).

Remove the two capscrews and spring washers from the

scavenge body.
Remove the scavenge body from the pump body. Re­
move and discard the gasket.
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-21

Remove the driven gear from the scavenge body.

Install the pump in an arbor press with the scavenge body

gasket surface facing down.
Use the mandrel, Part No. 3823795, to push the drive
shaft from the main drive gear.

Remove the main drive gear from the cover.

Remove the six cover mounting capscrews and spring

washers.
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-22 V903

Remove the cover from the pump body. Remove and

discard the gasket.
Remove the driven gear from the pump body.

Install the pump body in an arbor press with the scavange

pump drive gear facing down.
Use the mandrel, Part No. 3823795, to push the drive
shaft through the drive gear.

Cleaning
Clean the gasket material from the lubricating oil pump
body and the cover.
Use solvent to clean the lubricating oil pump parts. Dry
with compressed air.

Inspection
Visually inspect the cover and gear pockets in the body
for scratches or other damage.
If the marks on the cover or in the body can be felt with
your fingernail, the part m ust be replaced.
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-23

Visually inspect the surface of the main pump body, and

the pockets in the scavange body for scratches or other
damage.
If the marks on the main pump body or scavange body
can be felt with a fingernail, the part must be replaced.

Visually inspect the main pump body, scavange pump

body, and the pump cover for cracks or damage.
Visually inspect the oil pump gears for worn or damaged
teeth.
Cracked, worn or damaged parts must be replaced.

Visually inspect the bushings in the cover and the

scavange body for damage.
Measure the inside diameter of the bushings in the cover
and in the scavange body.

Bushing I.D.
____ mm_________________________________ [n_____
22.28 MIN 0.877
22.33 MAX 0.879
If the bushings are worn larger than the maximum given,
the bushings must be replaced.

Visually inspect the bushings in the driven gears for dam-

age. 1<СИ
Measure the inside diameter of the bushings in the oil
pump driven gears.

Bushing I.D.
mm_____________________________in________
22.263 MIN 0.8765
22.33 MAX 0.879
If the bushings are worn larger than the maximum given,
the bushings must be replaced.
Ip3bstb
 ф
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-24 V903

Visually inspect the drive and driven shafts for damage.

Measure the outside diameter of the drive and the driven

shafts in the bushing contact area.

Shaft O.D.
____ mm____________________________jn________
22.20 MIN 0.874
22.23 MAX 0.875
Shafts that are damaged or worn smaller than the min-
imum given must be replaced. Refer to Lubricating Oil
Pump Drive Gear or Shaft - Replacement in this bulletin.

Visually inspect the idler gear for worn or damaged teeth.

Measure the inside diameter of the bushing in the idler
gear.

Bushing I.D.
mm____________________________ in
25.20 MIN 0.992
25.25 MAX 0.994
If the bushing is worn larger than the maximum given, the
bushing must be replaced. Refer to Lubricating Oil Pump
Idler Gear Bushing - Replacement in this bulletin.

Visually inspect the idler gear shaft for damage.

Measure the outside diameter of the idler gear shaft in the
bushing contact area.

Shaft O.D.
mm____________________________ in
25.15 MIN 0.990
25.17 MAX 0.991
If the shaft is damaged or worn smaller than the minimum
given, the shaft must be replaced. Refer to Lubricating
Oil Pump Idler Shaft - Replacement in this bulletin.
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-25

Visually inspect the main drive gear for cracks, chipped,

or broken teeth.
Inspect the bore of the gear for scoring or other damage.

Measure the inside diameter of the main drive gear bore.

Main Drive Gear Bore I.D.

mm_____________________________ in_________
22.162 ' MIN 0.8725
22.187 MAX 0.8735
NOTE: If the main drive gear bore is worn beyond the max­
imum limit, the drive gear must be replaced.

Visually inspect the oil regulator plunger for scratches or

scoring.
If scratches are deep enough to be felt with a fingernail,
the plunger must be replaced.
Visually inspect the spring for damaged or broken coils.

Use valve spring tester, Part No. 3375182, to determine

if the spring is defective.
Compress the spring to a height of 53.97 mm [2.125
inches]. The force required must be:
• Minimum: 200 Newtons [45 Ibf]
• Maximum: 222 Newtons [50 Ibf]
If the force required to compress the spring is not within
the specifications given, the spring must be replaced.
Lubricating Oil Pump (High Sneed - Double Pump) Lubricating Oil System
Page 7-26 V903

Assembly
Position mandrel, Part No. 3823792, in an arbor press
with the counterbore facing up.
Position the main drive shaft and scavenger pump drive
gear assembly in the counterbore.

Install the pump body on the drive shaft.

Use clean 15W-40 oil to lubricate the drive shaft.

Caution: The oil pump drive gear has an oil hole that
aligns with a groove in the drive shaft to supply oil to the
bushing in the scavange pump and the scavenge pump
driven gear. DO NOT intermix the oil pump and scavenge
pump drive gears.
Position the oil pump drive gear on the drive shaft.

Use the mandrel, Part No. ST-722, to push the drive gear
onto the drive shaft.
Push the drive gear on the shaft until the gear seats
against the bottom of the gear pocket.

Ip 3 g e ld
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-27

Use a feeler gauge to check the clearance between the

scavange pump drive gear and the pump body.

Clearance between scavange gear and body

mm_____________________________ jn_________
0.05 MIN 0.002
0.13 MAX 0.005
If the clearance is not within the required specifications,
press on the shaft until it is within specifications.

Use clean 15W-40 oil to lubricate the driven shaft.

Install the driven gear on the shaft.

Ip 3 b d e g

Install a new gasket on the pump body. Position the dowel

holes in the gasket over the locating dowels in the cover.
Install the cover on the pump body.

Tap the cover lightly with a mallet to push the cover over
the locating dowels.
Install the cover mounting capscrews and spring wash­
ers.
Tighten the capscrews.
Torque Value: 50 N«m [35 ft-lb]
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-28 V903

Position the mandrel, Part No. 3823792, in an arbor press

with the counterbore facing up.
Position the scavenger pump drive gear in the
counterbore.

Use clean 15W-40 oil to lubricate the drive shaft.

Install the main drive gear on the drive shaft with the
center flange (1) facing up.

Use a mandrel, Part No. 3823794, to push the main drive

gear onto the drive shaft.
Position the mandrel on the drive gear with the 4.70 mm
[0.185 in] counterbore facing the center flange on the
gear.
Push the gear on the shaft until the shaft contacts the
bottom of the counterbore in the mandrel.

Use clean 15W-40 oil to lubricate the bushing and driven

shaft in the scavenge pump body.
Install the driven gear on the shaft.

Ір З де Іе .
Lubricating Oil System Lubricating Oil Pump (High Speed - Double Pump)
V903 Page 7-29

Install a new gasket on the scavenge pump body. Posi­

tion the gasket over the locating dowels.
Install the scavenge pump body on the main pump body.
Tap the scavenge pump body lightly with a mallet to push
the locating dowels into the dowel holes in the main pump
body.

Install the two spring washers and capscrews. Tighten

the capscrews.
Torque Value: 50 N«m [35 ft-lb]

Use clean 15W-40 oil to lubricate the idler gear shaft..

Install the idler gear (1) on the idler shaft with the center
flange facing up. Install the thrust washer (2) and snap
ring (3) on the shaft.
Lubricating Oil Pump (High Speed - Double Pump) Lubricating Oil System
Page 7-30 V903

Turn the idler gear by hand to inspect the internal gears

for freedom of rotation. If the pump does not turn freely,
disassemble the pump and check for burrs, nicks, or
foreign material between the gears and pump body or
cover.

Measure the drive shaft end clearance.

Drive Shaft End Clearance

mm_____________________________ in_________
0.05 MIN 0.002
0.13 MAX 0.005
If the shaft end clearance is not within the specifications
given, disassemble the pump and check for nicks, burrs,
or foreign material between the gears and pump bodies
or cover, or a missing gasket between the body and
cover, or body and scavenge pump.

Measure the idler gear end clearance.

Idler Gear End Clearance

______mm__________________ __________ in_______
0.08 MIN 0.003
0.38 MAX 0.015
If the end clearance is not within specifications, the oil
pump must bereplaced or rebuilt. Refer to Lubricating Oil
Pump - Rebuild in this bulletin.

Use a dial indicator to measure the backlash between the

main drive gear and the idler gear.

Backlash Between Main Drive and Idler Gear

______mm_____________________________ in_______
0.13 MIN 0.005
0.38 MAX 0.015
If the backlash is not within specifications, the oil pump
must be replaced or rebuilt. Refer to Lubricating Oil Pump
- Rebuild.
 '/Щ
Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing (Single Pump)
V903 Page 7-31

Install the cover plate on the cover using four new self­
locking capscrews.
Tighten the capscrews.
Torque Value: 10 N»m [96 in-lb]

Caution: The parts are under spring tension. Use ap­

propriate tool(s) and eye protection to assemble.
Install the spacer (3), washer (5) and the spring (4) in the
bore of the oil pressure regulator plunger (6).
Install the plunger in the regulator bore in the pump body
(7).
Install a new lockplate (2), on the pressure regulator cap
( 1).
Install the regulator cap in the pump body.

Use your fingers to tighten the pressure regulator cap.

Tighten the cap to the specified torque.
Torque Value: 75 N*m [55 ft-lb]
Bend one of the tabs on the lockplate down against the
flat area on the regulator boss.
(jn $ \
Bend the other two tabs against the flats on the pressure
regulator cap.

zlJ
/ I Ip 3 lp fc

Lubricating Oil Pump Body and Cover

Bushing (Single Pump)
Replacement
Disassembly
Use the bushing mandrel, Part No. ST-1158, to remove
the worn or damaged bushings from the oil pump body
and the cover.
NOTE: The double oil pump does not require a bushing in
the oil pump body. The bushing is contained in the scavenge
pump body. Refer to Lubricating Oil Pump Scavenge Pump
Body Bushing - Replacement.
Lubricating Oil Pump Body and Cover Bushing (Single Pump) Lubricating Oil System
Page 7-32 V903

Inspection
Visually inspect the bushing bore in the oil pump body
and the cover for damage.
Measure the inside diameter of the bushing bore in the
oil pump body and cover.

Bushing Bore I.D.

mm____________________________ in_________
25.387 MIN 0.9995 '
25.413 MAX 1.0005
If the bushing bore is not within specifications, replace
the part.

Assembly
Use the bushing mandrel, Part No. ST-1158, to push the
new bushing into the pump cover.
NOTE: Do not install the new bushing in the pump body at
this time.
NOTE: The bushings must be installed level with or to a
maximum of 0.51 mm [0.020 inch] below the surface of the
oil pump cover.

Install guide bushings, Part No. 3823790, in the gear

pocket.
Tighten the guide capscrew against the driven shaft to
hold the guide bushing in position.

Install the cover on the pump body.

Tap the over lightly with a mallet to push the cover over
the locating dowels.
Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing (Single Pump)
V903 Page 7-33

Install the cover mounting capscrew (1) and spring

washer.
Install cover mounting capscrews (2) and (3) and the
spring washers.
Tighten the capscrews.
Torque Value: 30 N«m [20 ft-lb]

Use penetrating oil to lubricate the bore in the guide

bushing.

Use a hand reamer, Part No. 3823791, to ream the bore

in the cover.
Insert the reamer through the guide bushing. Apply light
downward pressure while rotating the reamer in the clock­
wise direction.

After the reaming operation is complete, remove the

reamer from the bore by applying light upward pressure
while rotating the reamer in the clockw ise direction.
Lubricating Oil Pump Body and Cover Bushing (Single Pump) Lubricating Oil System
Page 7-34 ' V903

Use solvent to clean the cover assembly. Dry with com­

pressed air.

Inspect the bushing bore for deep scratches. If a scratch

is deep enough to be felt with a finger nail, the bushing
must be replaced.

Measure the inside diameter of the bushing in the cover.

Bushing I.D. (New)

____ mm____________________________ jn_________
22.28 MIN 0.877 '
22.30 MAX 0.878
Bushings that do not meet the specifications given must
be replaced.
Lubricating Oil System Lubricating Oil Pump Body and Cover Bushing (Single Pump)
V903 Page 7-35

Remove the guide bushing from the gear pocket.

Use the bushing mandrel, Part No. ST-1158, to push the

new bushing into the pump body.
NOTE: The bushing must be installed level with or to a
maximum 0.51 mm [0.020 inch] below the surface of the oil
pump body.

Install guide bushing, Part No. 3823790, in the gear

pocket.
Tighten the guide capscrew against the driven shaft to
hold the guide bushing in position.

Use penetrating oil to lubricate the bore in the guide

bushing.
Lubricating Oil Pump Body and Cover Bushing (Single Pump) Lubricating Oil System
Page 7-36 V903

/Sirs. Use a hand reamer, Part No. 3823791, to ream the bush-
ing in the body. Insert the reamer through the guide
bushing. Apply light downward pressure while rotating
the reamer in the clockw ise direction.

After the reaming operation is complete, remove the

reamer from the bore by applying light upward pressure
while rotating the reamer in the clockwise direction.

Remove the guide bushing from the gear pocket.

Use solvent to clean the body assembly. Dry with com­

pressed air.
Lubricating Oil System Lubricating Oil Scavenge Pump Body Bushing
V903 Page 7-37

Inspect the bushing bore for deep scratches. If a scratch

is deep enough to be felt with a finger nail, the bushing
must be replaced.

Measure the inside diameter of the bushing in the body.

Bushing I.D. (New)

mm_____________________________[n_________
22.28 MIN 0.877
22.30 MAX 0.878
Bushings that do not meet the specifications given must
be replaced.

Lubricating Oil Scavenge Pump Body

Bushing
Replacement
Disassembly
Use a bushing mandrel, Part No. ST-1158, to remove the
worn or damaged bushing from the scavenge pump body.

Inspection
Visually inspect the bushing bore in the scavenge pump
body for damage.
Measure the inside diameter of the bushing bore in the
scavenge pump body.

Bushing Bore I.D.

mm_____________________________in_________
25.387 MIN 0.9995
25.413 MAX 1.0005
If the bushing bore is not within specifications, replace
the part.
Lubricating Oil Scavenge Pump Body Bushing Lubricating Oil System
Page 7-38 V903

Assembly
Use the bushing mandrel, Part No. St-1158, to push the
new bushing into the body.
NOTE: The bushing must be installed level with or to a
maximum of 0.51 mm [0.020 inch] below the surface of the
body.

Install guide bushing, Part No. 3823790, in the gear

pocket.
Tighten the guide capscrew against the driven shaft to
hold the guide bushing in position.

Use penetrating oil to lubricate the bore in the guide

bushing.

Use a hand reamer, Part No. 3823791, to ream the bush­

ing in the body. Insert the reamer through the guide
bushing. Apply light downward pressure while rotating
the reamer in the clockwise direction.
Lubricating Oil System Lubricating Oil Scavenge Pump Body Bushing
V903 Page 7-39

After the reaming operation is complete, remove the

reamer from the bore by applying light upward pressure
while rotating the reamer in the clockwise direction.

Remove the guide bushing from the gear pocket.

Use solvent to clean the body assembly. Dry with com­

pressed air.

Inspect the bushing bore for deep scratches. If a scratch

is deep enough to be felt with a finger nail, the bushing
must be replaced.
 ■fS3
Lubricating Oil Pump Drive Gear Bushing Lubricating Oil System
Page 7-40 V903

Measure the inside diameter of the bushing in the body.

Bushing I.D. (New)

____ mm_____________________________jn_________
22.28 MIN 0.877
22.30 MAX 0.878
Bushings that do not meet the specifications given must
be replaced.

Lubricating Oil Pump Drive Gear

Bushing
Replacement
Disassembly
Use a bushing mandrel, Part No. ST-1158, to remove the
worn or damaged bushings from the driven gear.

Inspection
Visually inspect the bushing bore in the driven gear for
damage.
Measure the inside diameter of the bushing bore in the
oil pump driven gear.

Bushing Bore I.D.

mm_____________________________in_________
25.387 MIN 0.9995
25.413 MAX 1.0005
If the bushing bore inside diameter is not within speci­
fications, the gear must be replaced.

Assembly
Use bushing mandrel, Part No. ST-1158, to push the new
bushings into the driven gear.
The bushings must be installed level with or to a maxi­
mum of 0.51 mm [0.020-inch] below the surface of the
driven gear.
Lubricating Oil System Lubricating Oil Pump Idler Gear Bushing
V903 Page 7-41

Measure the inside diameter of the new bushings in the

driven gear.

Bushing I.D. (New)

mm____________________________ in
22.263 MIN 0.8765
22.289 MAX 0.8775
The bushings used in the driven gear are finished bush­
ings and do not require cutting. If the bushing inside
diameter is not within the specifications given after in­
stallation, the bushing must be replaced.

Lubricating Oil Pump idler Gear

Bushing
Replacement
Disassembly
Use bushing mandrel, Part No. 3823795, to remove the
worn or damaged bushing from the idler gear.

Inspection
Visually inspect the bore in the idler gear for damage.
Measure the inside diameter of the bushing bore in the
idler gear.

Bushing Bore I.D.

mm_____________________________ in_______
28.562 MIN 1.1245
28.588 MAX 1.1255
If the bushing bore inside diameter is not within speci­
fications, the gear must be replaced.

Assembly
Use bushing mandrel, Part No. 3823795, to push the new
bushing into the idler gear.
The bushing must be installed level with or to a maximum
of 0.51 mm [0.020 inch] below the surface of the idler
gear.

Ip3bsmf
Lubricating Oil Pump Idler Shaft Lubricating Oil System
Page 7-42 V903

Measure the inside diameter of the new bushing in the

idler gear.

Bushing I.D. (New)

______ mm_____________________________ in_______
" 25.197 ~ MIN “ 0.992 "
25.222 MAX 0.993
NOTE: The bushing used in the idler gear is a finished
bushing and does not require cutting. If the bushing inside
diameter is not within the specifications given after instal­
lation, the bushing must be replaced.

Lubricating Oil Pump Idler Shaft

Replacement
Disassembly
Remove the pipe plug from the idler shaft.

Use spacer mandrel, Part No. 3823796, to support the

cover during removal of the idler shaft. Position the man­
drel over the idler shaft.

Install the cover in an arbor press with the spacer mandrel

and large diameter of the idler shaft facing down.
Use mandrel, Part No. 3823795, to push the idler shaft
from the cover.
Lubricating Oil System Lubricating Oil Pump Idler Shaft
V903 Page 7-43

Inspection
Visually inspect the bore in the cover for damage.
Measure the inside diameter of the bore in the cover.

Idler Shaft Bore I.D.

______ mm_____________________________in_______
22.263 MIN 0.8765
22.289 MAX 0.8775
If the bore inside diameter is not within specifications, the
cover must be replaced.

Visually inspect the idler shaft for damage.

Measure the outside diameter of the idler shaft.

Idler Shaft Bore O.D.

_______mm_____________________________in_______
22.301 MIN 0.8780
22.314 MAX 0.8785
If the shaft is damaged or the outside diameter is not
within specifications, the shaft must be replaced.

Assembly
Use clean 15W-40 to lubricate the idler shaft.

Align the oil hole in the idler shaft with the oil slot in the
cover idler shaft bore.
Rotate the idler shaft counterclockwise as far as pos­
sible while still maintaining alignment with the oil slot in
the shaft bore.

Ip3idua
Lubricating Oil Pump Drive Gear or Shaft Lubricating Oil System
Page 7-44 V903

Use mandrel, Part No. 3823795, to push the idler shaft

into the cover. Push the shaft until the shoulder on the
shaft seats against the cover.

Install the pipe plug in the idler shaft.

Torque Value: 20 N»m [15 ft-lb]

Lubricating Oil Pump Drive Gear or

Shaft
Replacement
Disassembly
To remove the drive shaft from the drive gear, do the
following:
Install the shaft and the gear assembly in an arbor press.
Use a mandrel to push the shaft from the gear.

inspection
Visually inspect the bore in the drive gear for damage.
Measure the inside diameter of the bore in the drive gear.

Drive Gear Bore I.D.

____ mm_____________________________m_________
22.187 MIN 0.8735
22.200 MAX 0.8740
If the bore inside diameter is not within specifications, the
gear must be replaced.
Lubricating Oil System Lubricating Oil Scavenge Pump Drive Gear or Shaft
V903 Page 7-45

Visually inspect the drive shaft for damage.

Measure the outside diameter of the drive shaft.

Drive Shaft O.D.

mm_____________________________in_________
22.20 MIN 0.874
22.23 MAX 0.875
Shafts that are damaged or worn smaller than the min­
imum given must be replaced.

Assembly
Position the mandrel, Part No. 3823793, on an arbor
press with the 13.97 mm [0.550 in] deep counterbore
facing up.
Position the oil pump drive gear on the mandrel.

Use clean 15W-40 oil to lubricate the drive shaft.

Push the shaft into the oil pump drive gear until the end
of the shaft contacts the bottom of the counterbore in the
mandrel.

Lubricating Oil Scavenge Pump Drive

Gear or Shaft
Replacement
Disassembly
To remove the drive shaft from the drive gear, do the
following:
Install the shaft and the gear assembly in an arbor press.
Use a mandrel to push the shaft from the gear.
Lubricating Oil Scavenge Pump Drive Gear or Shaft Lubricating Oil System
Page 7-46 V903

Inspection
Visually inspect the bore in the drive gear for damage.
Measure the inside diameter of the bore in the drive gear.

Drive Gear Bore I.D..

mm____________________________ in_________
22.187 MIN 0.8735
22.200 MAX 0.8740
If the bore inside diameter is not within specifications, the
gear must be replaced.

Visually inspect the drive shaft for damage.

Measure the outside diameter of the drive shaft.

Drive Shaft O.D.

____ mm____________________________ |n_________
22.20 MIN 0.874
22.23 MAX 0.875
Shafts that are damaged or worn smaller than the min­
imum given must be replaced.

Assembly
Caution: The main drive shaft used in the double oil
pump has a drilling which supplies oil from the main oil
pump to the bushings in the scavenge pump driven gear.
The groove in the shaft (1) aligns with the hole in the
main oil pump drive gear (2) when the pump is assem­
bled.
The end of the drive shaft without the groove must be
installed in the scavenge pump drive gear during shaft or
gear replacement.

Position the mandrel, Part No. 3823792, in an arbor press

with the counterbore facing up
Position the scavenge pump drive gear in the counterbore.
Lubricating Oil System Lubricating Oil Pump Driven Shaft
V903 Page 7-47

Use clean 15W-40 oil to lubricate the drive shaft.

Push the shaft into the scavenge pump drive gear until
the end of the shaft contacts the bottom of the small
counterbore in the mandrel.

Lubricating Oil Pump Driven Shaft

Replacement
Disassembly
Install the oil pump body in an arbor press with the cover
mounting surface of the body facing down.
Use a mandrel to push the driven shaft from the lubri­
cating oil pump body.

Inspection
Visually inspect the driven shaft bore in the lubricating oil
pump body for damage.
Measure the inside diameter of the driven shaft bore.

Driven Shaft Bore i.D.

mm____________________________ [n_________
22.263 MIN 0.8765
22.289 MAX 0.8775
If the shaft bore diameter is not within specifications, the
pump body must be replaced.

Measure the driven shaft outside diameter in the press fit

area.

Driven Shaft Press Fit Area O.D.

mm___________________________ J n _________
22.301 MIN 0.8780
22.314 MAX 0.8785
If the shaft outside diameter is not within specifications,
it must be replaced.

Ip3shtg
Lubricating Oil Scavenge Pump Body Driven Shaft Lubricating Oil System
Page 7-48 V903

Assembly
Use the gear and spacer mandrel, Part No. ST-722, to
install the driven shaft into the oil pump body as follows:
Lubricate the large outside diameter of the driven shaft
with clean 15W-40 oil.
Install the large outside diameter of the driven shaft into
the bore in the oil pump body.

Position the spacer mandrel, Part No. ST-722, over the

driven shaft. Press the shaft in the bore until the end of
the shaft is even with the top of the spacer mandrel.

Measure the amount of shaft protrusion above the bottom

of the gear pocket.

Driven Shaft Protrusion

mm_____________________________m_________
48.77 MIN 1.920
49.28 MAX 1.940
If the protrusion does not meet the specifications, press
on the shaft until the protrusion meets specifications.

Lubricating Oil Scavenge Pump Body

Driven Shaft
Replacement
Disassembly
Install the scavenge pump body in an arbor press with the
gear pockets facing down.
Use a suitable mandrel to push the driven shaft from the
scavenge pump body.

Ip3bdf-
Lubricating Oil System Lubricating Oil Scavenge Pump Body Driven Shaft
V903 Page 7-49

Inspection
Visually inspect the driven shaft bore in the scavenge
pump body for damage.
Measure the inside diameter of the driven shaft bore.

Driven Shaft Bore I.D.

mm_____________________________ in_________
22.263 MIN 0.8765
22.289 MAX 0.8775
If the shaft bore diameter is not within specifications the
body must be replaced.

Measure the driven shaft outside diameter in the press fit

area.

22.301
____ mm_____________________________ in_________
22.301 MIN 0.8780
22.314 MAX 0.8785
If the shaft outside diameter is not within specifications,
replace the part.

Assembly
1___________ 4 / • .......... .......... 4
Caution: The scavenge pump driven shaft (1) has an oil
________ u _________________

drilling which supplies oil to the bushing in the scavenge

pump driven gear. The driven shaft for the main oil pump
(2) does not have an oil drilling.
Do not intermix the main oil pump and scavenge pump
driven shafts.

і i
і i
і-------1-------1------- 1 _____
i____ :____:____ i L 1
Ip S s h w f

Use the gear and spacer mandrel, Part No. ST-722, to

install the driven shaft into the scavenge pump body as
follows:
Lubricate the large diameter of the driven shaft with clean
15W-40 oil.
Install the large diameter of the shaft into the bore in the
scavenge pump body.
Lubricating Oil Scavenge Pump Body Driven Shaft Lubricating Oil System
Page 7-50 V903

Position the spacer mandrel, Part No. ST-722, over the

driven shaft. Press the shaft in the bore until the end of
the shaft is even with the top of the spacer mandrel.

Measure the amount of shaft protrusion above the bottom

of the gear pocket.

Driven Shaft Protrusion

mm_____________________________in
48.77 MIN 1.920
49.28 MAX 1.940

Ip3shtj
Cooling System - Group 08 Water Pump
V903 Page 8-1

Cooling System - Group 08

Water Pump
General Information
NOTE: The Big Cam 600 horsepower water pump must not
be used on the Small Cam or Big Cam 660 horsepower
engine. Severe engine overheat and possible engine dam­
age will occur.
The same water pump is used on the Small Cam engine
and Big Cam 660 horsepower engine. The water pump
used on the Big Cam 600 horsepower engine contains
the same parts as the water pump used on the Small Cam
engine and the Big Cam 660 horsepower engine with the
exception of the water pump body. The Big Cam 600
horsepower water pump body is not drilled for the ther­
mostat water by-pass. The Small Cam and Big Cam 660
horsepower engine water pump body contains a thermo­
stat water by-pass drilling.
The Small Cam and Big Cam 660 horsepower engine
water pump can be used on the Big Cam 600 horsepower
engine in case of an emergency by plugging off the ther­
mostat water by-pass drilling.

Identification
The water pumps can be identified by the thermostat
water by-pass boss on the water pump body. The boss on
the water pump body used on the Small Cam and Big
Cam 660 horsepower engines (1) is drilled for the ther­
mostat water by-pass.
The boss on the water pump body used on the Big Cam
600 horsepower engine (2) is not drilled for the thermo­
stat water by-pass.

Transmission Oil Cooler

General Information
The transmission oil cooler used on the Small and Big
Cam engines are not interchangeable. Both coolers have
the same external dimensions and appearance. How­
ever, the transmission cooler used on the Big Cam en­
gine has a high efficiency design which is required be­
cause of the increased demand on the transmission. The
transmission cooler used on the Small Cam engines con­
tains 276 internal tubes. The transmission cooler used on
the Big Cam engine contains 511 internal tubes.
NOTE: Do not use the Small Cam transmission cooler on
the Big Cam engine as severe transmission overheating and
possible transmission damage will occur.
The Big Cam engine transmission cooler can be used on
the Small Cam engine.
Transmission Oil Cooler Cooling System - Group 08
Page 8-2 V903

Identification
The oil cooler can be identified by the number of internal
tubes. The Small Cam engine oil cooler (1) has 276 tubes
while the Big Cam engine oil cooler (2) has 511 internal
tubes.

Pressure Test
Install a cover plate, gasket, and four capscrews on the
transmission oil inlet and outlet connections. Tighten the
capscrews.
Torque Value: 95 N»m [70 ft-lb]
NOTE: The cover plates must be fabricated locally. One of
the cover plates must be drilled and tapped for a fitting.

Use air pressure regulator, Part No. 3823799, or equiv­

alent.
Attach a regulated air pressure hose to the cover plate.

Submerge the oil cooler in a tank of water heated to 82°C

[180°F] for three to five minutes. Slowly apply 415 kPa
[60 psi] air pressure to the oil cooler and inspect for leaks.
If leaks are found, the oil cooler assembly must be
replaced.
Cooling System - Group 08 Transmission Oil Cooler
V903 Page 8-3

Release the air pressure from the oil cooler before re­
moving it from the water tank.
Remove the oil cooler from the water tank.
Remove the capscrews, cover plates, and gaskets from
the oil cooler.
Dry the oil cooler with compressed air.
Drive Units - Group 09 Fuel Pump Drive - VTA-903 T660 Engine Only
V903 Page 9-1

Drive Units - Group 09

Fuel Pump Drive - VTA-903 T660
Engine Only
General Information
A 90 degree angled drive transfer gearbox is used to drive
the fuel pump on the Big Cam 660 horsepower engine.
The gear box contains an integral lubricating oil reservoir
and dipstick.

Caution: Do not overfill the oil reservoir. Operating the

gearbox with the oil level above the high oil level mark
on the dipstick will result in gearbox damage.
The oil capacity of the oil reservoir is 90 cc [3 oz] low and
110 cc [4 oz] high. To check the oil level, screw the
dipstick (1) in hand tight against the top of the reservoir.
Remove the dipstick from the reservoir and check the
dipstick oil level.

A high quality SAE 15W-40 or OMD 80 heavy duty engine

oil is recommended for use in the gearbox. An oil change
is not required during the 600 hour design life of the
gearbox.

Installation
Install the fuel pump drive coupling on the fuel pump drive
shaft.
Install a new gasket on the fuel pump drive.
Install the fuel pump drive and the four mounting cap­
screws. Tighten the capscrews.
Torque Value: 65 N«m [50 ft-lb]
Fuel Pump Drive - VTA-903 T660 Engine Only Drive Units - Group 09
Page 9-2 V903

Install the fuel pump drive coupling on the angled drive

fuel pump drive shaft.
Install a new gasket on the fule pump.
Install the fuel pump and the four mounting capscrews.
Tighten the capscrews.
Torque Value: 65 N*m [50 ft-lb]

Install the fuel pump support bracket and support to fly­

wheel housing mounting capscrew. Finger tighten the
capscrews.
Install the two fuel pump cover mounting capscrews
through the fuel pump support. Check to be sure the
bracket is flat against the fuel pump cover and flywheel
housing. Tighten the capscrews.
Torque Value: 12 N«m [110 in-lb]

Tighten the fuel pump support to flywheel housing mount­

ing capscrew.
Torque Value: 60 N*m [45 ft-lb]

Connect the fuel rail pressure tube to the fitting on the fuel
pump solenoid (1). Tighten the tubing nut.
Torque Value: 27 N»m [20 ft-lb]
Connect the fuel by-pass tube to the fitting (2) on the gear
pump. Tighten the tube nut.
Torque Value: 20 N*m [15 ft-lb]
Connect the AFC manifold pressure tube to the fitting on
the AFC cover (3). Tighten the tube nut.
Torque Value: 12 N«m [110 in-lb]
Intake System - Group 10 Turbocharger
V903 Page 10-1

Intake System - Group 10

Turbocharger
General Information
The Small Cam and Big Cam engine turbochargers are
not interchangeable. The Big Cam 600 and 660 horse­
power engine turbochargers are also not interchange­
able. The Small Cam engine uses a ST50 series turbo­
charger. The Big Cam engine uses an HT80 series
turbocharger.
The HT80 turbocharger has left hand rotation (counter­
clockwise) when viewed from the compressor end. The
HX80 turbocharger has a right hand rotation when viewed
from the compressor end.

Special attention is required when rebuilding the HT80

and HX80 series turbochargers. The internal parts, es­
pecially the turbine shaft bearings, thrust bearings, and
oil slinger are similar in appearance between the two
turbochargers, but are not interchangeable. Intermixing
parts between the two turbochargers will result in turbo­
charger failure, and possible engine damage. Refer to
Turbocharger Shop Manual, Bulletin No. 3810243, for
rebuild procedures.

Turbocharger Air Discharge Hose and

Clamps
General Information
The turbocharger air discharge hose used on the Big
Cam engine is a four ply hose designed to withstand the
high operating pressure and temprature. Do not use a
substitute hose in this location.
Special clamps are used on the turbocharger air dis­
charge hose to prevent damage to the hose. Do not use
substitute clamps in this location. Tighten the hose clamps
to 8 N«m [75 in-lb] torque during installation.
 470
Cold Start System Intake System - Group 10
Page 10-2 V903

Cold Start System

General Information
Big Cam 600 Horsepower Engine
The cold start system used on the Big Cam 600 horse­
power engine consists of four starting aid nozzles (1), fuel
supply tubes (2), and electrical fuel solenoid (3), electrical
control module (not shown), and electrical wiring harness
(not shown). The starting aid nozzles, fuel solenoid, and
fuel supply tubes from the solenoid to the nozzles are
supplied by Cummins Engine Company, Inc.. The elec­
trical control module, wiring harness and fuel supply tube
to the fuel solenoid are supplied by FMC.
The starting aid nozzles are designed to operate on a fuel
inlet pressure of 9 kPa to 12 kPa [1.3 to 1.8 psi] (measured
at the cold start solenoid), and a voltage input of 20 to 24
volts DC. If the cold start system is not operating prop­
erly, refer to the Starting Aid Nozzle - Resistance Check,
that is included in this bulletin, before measuring the fuel
inlet pressure and voltage input to the nozzles.
Big Cam 660 Horsepower Engine
The cold start system for the Big Cam 660 horsepower
engine has not been finalized at this time. Additional
information will be provided when the design is finalized.

Aftercooler Core
Pressure Test
Install the hose (1), the hose clamps (2), and the solid pipe
plug (3) onto the water outlet connection.
Install the hose (4), the hose clamps (5), and the solid pipe
plug (6) onto the water inlet connection.
Torque Value: 5 N*m [40 in-lb]
Install the hose (7) and the air pressure gauge (8) on the
fitting on the aftercooler core.
at3co w a

Connect the air pressure gauge to a regulated air supply.

Submerge the aftercooler core into a tank of water heated
to 82°C [180°F] for three to five minutes. Slowly increase
air pressure to 276 kPa [40 psi] and check for leaks.
If bubbles appear, the core is damaged and must be
replaced.
Intake System - Group 10 Aftercooler Core
V903 Page 10-3

Release air pressure from the aftercooler core.

Remove the aftercooler core from the water tank.
Remove the test equipment.
Dry the aftercooler core with compressed air.

at3bdlb
 Уу72 .
Exhaust System - Group 11 Exhaust System
V903 Page 11-1

Exhaust System - Group 11

Exhaust System
General Information
The exhaust system components are not interchange­
able between the Small and Big Cam engines. The Big
Cam exhaust system includes aerodynamic exhaust man­
ifolds, insulated collector housing, redesigned bellows
connections, and special high strength exhaust manifold
mounting capscrews.
Special high temperature resistant capscrews are re­
quired to mount the exhaust manifolds. Use only the
special capscrews to attach the exhaust manifolds to the
cylinder heads. Do not use washers or lock plates with
the special exhaust manifold mounting capscrews.

Exhaust Manifold
Identification
The exhaust manifolds can be identified by the manifold
design. The manifolds, (left bank, Part No. 214193, and
right bank, Part No. 215898), used on the Small Cam
engine (1) have a log type design. The Big Cam engine
manifolds, (left bank, Part No. 3058793, and right bank,
Part No. 3058794), have the aerodynamic design (2).
NOTE: The VTA-903 T660 HP engine uses an insulated
version of manifolds, Part No. 3058793 and Part No.
3058794, used on the VTA-903 T600 HP engine.

Exhaust Manifold Mounting Capscrew

Identification
The exhaust manifold mounting capscrews, Part No.
3046283, used on the Big Cam engine are a special high
strength material, designed to withstand high operating
temperatures. The capscrews can be identified by the
markings on the capscrew head (1) and the capscrew
head design (2).

xm 3 csga
Engine Tessting - Group 14 Cooling System Venting
V903 Page 14-1

Engine Testing - Group 14

Cooling System Venting
General Information
Caution: The cooling system must be properly vented
during engine dynamometer testing to ensure that air is
not trapped in the cooling system. Air entrainment in the
cooing system can cause loss of water pump prime re­
sulting in piston scoring or seizure and major engine
damage.

Remove the 1/4 inch pipe plug or draincock from the

aftercooleir water outlet tube. Install a 9.52 mm [3/8 inch]
inside diameter hose or No. 6 hose fitting in the tube.

Remove the 1/2 inch pipe plug from the thermostat hous­
ing at the location shown. Install a 9.52 mm [3/8 inch]
inside diameter hose or a No. 6 hose fitting in the ther­
mostat housing.

Install a 9.52 mm [3/8 inch] inside diameter pipe hose

fitting from the engine water outlet connection on the
thermostat housing to the stand pipe or heat exchanger
water inlet.
Cooling System Venting Engine Testing - Group 14
Page 14-2 V903
Using a 3/4 inch pipe cross, install one straight 9.52 mm
[3/8 inch] inside diameter or No. 6 hose fitting and two 90
degree elbows at the locations shown.

Install one straight 12.70 mm [1/2 inch] inside diameter

hose fitting in the pipe cross at the location shown.

Select the appropriate length of hoses to connect be­

tween the fittings on the engine, the pipe cross, and the
stand pipe or surge tank.
The vent hoses must run up hill from the engine to the
stand pipe or surge tank. The hoses must not contain any
loops or sags.
NOTE: The engine vent connection in the stand pipe or
surge tank must be located in the expansion space above
the water level.
Engine Testing - Group 14 Thermostat Water Bypass
V903 Page 14-3

Thermostat Water Bypass

General Information
The thermostat water bypass circuit allows constant wa­
ter flow through the engine and transmission cooler dur­
ing closed or partially opened thermostat operation. The
bypass connection on the thermostat housing must be
connected to the inlet side of the water pump during
engine dynamometer testing to provide constant water
flow through the bypass circuit.

Plumbing
Using a 1 1/2 inch inside diameter hose, connect one end
of this hose to the thermostat housing connection. Con­
nect the other end of this 1 1/2 inch inside diameter hose
to either the water pump inlet hose or pipe (from the heat
exchanger to the water pump) or to one of the bosses on
the suction side of the water pump body.

Lubricating System Full Flow Filter

General Information
The Big Cam engine developed for the military combat
vehicle market is not equipped with an engine mounted
full flow lubricating oil filter. The full flow oil filter is remote
mounted to provide easy accessibility with the power
pack installed in the vehicle.

Plumbing
Use remote mount full flow filter, Part No. AR12518, or
equivalent to filter the engine oil during dynamometer
testing. Install the proper fittings in the filter head to
accept a No. 16 hose.
NOTE: Use a No. 16 hose such as Aeroquip FC 107 or
Stratoflex 213 to connect the filter to the engine.

If3ftwa
Lubricating System Full Flow Filter Engine Testing - Group 14
Page 14-4' V903

Install one end of the oil filter outlet hose on the filter head
at the location marked OUT. Install the other end of the
hose on the right bank front water header cover fitting
marked IN. Tighten the hose nuts.
Torque Value: 135N«m [100ft-lb]

Install one end of the oil filter inlet hose on the filter head
at the locations marked IN. Install the other end of the
hose on the front oil cooler support fitting marked OUT.
Tighten the hose nuts.
Torque Value: 135N»m [100ft-lb]

Clean the oil filter head surface.

Use clean vegetable oil to lubricate the gasket surface of
the filter(s).

Fill the filter(s) with clean 15W-40 oil.

Install the filter(s) on the oil filter head. Tighten the filter(s)
until the gasket contacts the filter head surface.
Caution: Mechanical overtightening can distort the
threads or damage the filter element seal.
Use oil filter wrench, art No. 3375049, to tighten the
filter(s) an additional three-fourths to one (3/4 to 1) turn,
or follow the instructions supplied with the filter(s).
Engine Testing - Group 14 Lubricating System
V903 Page 14-5

Lubricating System
Priming
Caution: The lubricating oil system must be primed be­
fore operating the engine after it has been rebuilt or
placed in service after temporary or long term storage to
prevent internal damage due to lack of lubrication during
engine start up.
Fill the crankcase to the low level mark on the dipstick
with 15W-40 oil.

Remove the pipe plug from the fitting on the STC oil
control valve.
Use a pump capable of supplying 210 kPa {30 psi] con­
tinuous pressure. Connect the pump discharge hose to
the fitting on the STC oil control valve.

Use clean 15W-40 oil to prime the system. Operate the

pump until the oil level is approximately 12.7 mm [1/2
inch] below the high oil level mark on the dipstick.

Shut the pump off and allow approximately five minutes

for the oil pressure to bleed off. Remove the pump dis­
charge hose from the fitting on the STC oil control valve.
Install the 1/8 inch pipe plug in the fitting. Tighten the pipe
plug.
Torque Value: 20N«m 15ft-lb
Lubricating System Engine Testing - Group 14
Page 14-6' V903

Make sure the lubricating oil has had time to drain to the
oil pan and measure the oil level with the dipstick.
Add oil as required to bring the oil level to the high level
mark on the dipstick.
Mounting Adaptations - Group 16 Flexible Coupling
V903 Page 16-1

Mounting Adaptations - Group 16

Flexible Coupling
General Information
The flexible coupling, Part No. 217079 (1), used on Small
Cam engines built prior to June, 1988, Engine First Serial
Number 37121114 must not be used on Big Cam en­
gines.
An improved design coupling, Part No. 3063485 (2), was
introduced at that time to provide increased dampening.
The improved design coupling can be used on either the
Small or Big Cam engine.

Identification
The flexible couplings can be identified by the outer di­
ameter of the hub and also by the method in which the
damper springs are mounted in the coupling.
The outside diameter of the coupling hub (B) used on
Small Cam engines built prior to June, 1988 (1) is ap­
proximately 305 mm [12 inches]. This design does not
incorporate formed spring guides (A).
The outside diameter of the coupling hub (B) used on
Small Cam and Big Cam engines built after June, 1988
(2), is approximately 343 mm [131/2 inches]. This design
incorporates formed spring guides (A).
Specifications - Group 18
V903 Page 18-1

Specifications - Group 18
The follov/ing Specifications section only includes the torque values that are unique for the Big Cam engine. For
torque values not listed in this bulletin, refer to V/VT-903 and VTB-903 C.I.D. Engine Shop Manual, Bulletin No.
3379057-04.
Specifications Specifications - Group 18
Page 18-2 V903

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Specifications
Engine Assembly
Oil Cooler Assembly to Cooler Supports
M ounting Capscrews 0-4 50 N *m 35 ft-lb

Oil Cooler Water Inlet Transfer Tube

Clam p and M ounting Capscrew 0-5 30 N *m 20 ft-lb

Oil Cooler Water Inlet Hose Clamps 0-5 5 N«m 40 in-lb

Oil Cooler Water Outlet Hose Clamps 0-5 5 N *m 40 in-lb

Front Cooler Support to Water Header

C over M ounting Capscrews 0-7 50 N #m 35 ft-lb

Oil Pressure Regulator Bypass Hose Nut 0-7 75 N *m 55 ft-lb

Main Oil Supply Hose Nut

From oil cooler support to filter and filter to
w ater header plate 0-7 135 N *m 100 ft-lb
Specifications -■Group 18 Engine Assembly
V903 Page 18-3

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Rear Cooler Support to Water Header

Cover
M ounting C apscrew s 0-7 50 N *m 35 ft-lb

Radiator Support to Cylinder Head

Capscrews 0-9 60 N *m 45 ft-lb

Exhaust Manifold Mounting Capscrews

(a) Torque Value: 0-10 50 N«m 35 ft-lb
(b) Torque Value: 0-10 80 N«m 60 ft-lb

Collector and Exhaust Manifolds

Clamps and Nuts
Torque Value: 0-11 9 N«m 75 in-lb
Use a m allet. Tap_ around the clam p to make
sure it is seated.. Torque the clam p nut
again.
Torque Value: 0-11 9 N *m 75 in-lb

Radiator Support Mounting Capscrew 0-11 75 N«m 55 ft-lb

Exhaust Collector Mounting Capscrews

(a) Torque Value: 0-12 50 N *m 35 ft-lb
(b) Torque Value: 0-12 100 N *m 75 ft-lb

Turbocharger Mounting Nuts 0 -1 2 100 N#m 75 ft-lb

 №
Engine Assembly Specifications - Group 18
Page 18-4 V903

Component or Assembly (Procedure) [Link]./Steps__ Metric_______________ U-S.

Turbocharger Oil Drain Tube

M ounting Capscrews 0-12 50 N *m 35 ft-lb

Turbocharger Oil Supply Hose

Swivel Nut 0-13 35 N«m 25 ft-lb

0-14 30 !N«m 20 ft-lb

Starting Aid Nozzle Fuel Supply Tube

Nuts 0-14 10 !N«m 90 in-lb

Starting Aid Nozzle Fuel Tube Support

Clip
M ounting Capscrews 0-14 40 N #m 30 ft-lb

Aftercooler Mounting Capscrews

(a) Torque Value: 0-22 20 N«m 15 ft-lb
(b) Torque Value: 0-22 40 N«m 30 ft-lb
Allow 15 m inutes for gasket to compress.
(c) Torque Value: 0-22 40 N»m 30 ft-lb

Solenoid Mounting Plate to Rocker

Housing
Mounting Capscrews 0-22 50 N®m 35 ft-lb
Specifications - Group 18 Engine Assembly
V903 Page 118-5

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Cold Start Fuel Supply Tube Nuts (All) 0-22 10 N*m 90 in-lb

Smoke Generator Hose Swivel Nuts (All) 0-23 15 N*m 120 in-lb

Smoke Generator Fuel Outlet Tube Nuts

(All) 0-23 30 N*m 20 ft-lb

STC Oil Supply Tube Nuts (All) 0-23 30 N»m

Aftercooler Water Inlet and Outlet

Connection
M ounting Nuts 0-24 20 N«m 15 ft-lb

Aftercooler Water Inlet and Outlet

Connection
Hose C lam ps 0-24 5 N *m 40 in-lb

Aftercooler Water Transfer Tube

Support Capscrew 0-24 50 N*m 35 ft-lb
Engine Assembly Specifications - Group 18
Page 18-6 V903

Component or Assembly (Procedure) [Link]./Steps Metric_________________ U.S.

Turbocharger Air Discharge Hose Clamps 0-25 8 N»m 75 in-lb

Intake Manifold Mounting Capscrews

(a) Torque Value: 0-29 30 N *m 20 ft-lb
(b) Torque Value: 0-29 60 N«m 45 ft-lb
Allow 15 m inutes fo r gaskets to compress,
(c) Torque Value: 0-29 60 N *m 45 ft-lb

AFC Manifold Pressure Tube Nut 0-29 25 N *m 20 ft-lb

Rocker Housing STC Plug 0-35 20 N *m 15 ft-lb

Hold Down Injector Clamp Capscrews 0-35 50 N tti 35 ft-lb

Valve Cover Mounting Capscrews 0-36 50 N *m 35 ft-lb

Injector Adjusting Screw 0-44 0.56 to 0.68 N«m 5 to 6 in-lb

Specifications - Group 18 Engine Assembly
V903 Page 18-7

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Injector Adjusting Screw Lock Nut

W ith A dapter Part No. ST-669 0-45 50 N«m
W ithout Adapter: 0-45 60 N«m

Valve Adjusting Screw Lock Nut

• W ith A dapter Part No. ST-669 0-46 50 N»m
• W ithout Adapter 0-46 60 N *m

Cylinder Block
Gear Housing Plate to Cylinder
Block Capscrews 1-6 50 N«m 35 ft-lb

Lubricating Oil System

Lubricating Oil Pressure Regulator Cap
(External Regulator) 7-5 60 N»m

Lubricating Oil Pump Cover to Body

Capscrews 7-16 50 N»m 35 ft-lb

Lubricating Oil Pump Cover Plate to Cover

Capscrew s 7-18 10 N»m

Lubricating Oil Pump Pressure Regulator

Cap 7-18 75 N»m 55 ft-lb
 4£1
Lngine Assembly Specifications - Group 18
Page 18-8 V903

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Scavenge Pump Body to Main Pump Body

Capscrews 7-30 50 N #m 35 ft-lb

Lubricating Oil Pump Idler Shaft Pipe Plug 7-45 20 N *m 15 ft-lb

Drive Units
Fuel Pump Angle Drive Mountng
Capscrews 9-1 65 N«m 50 ft-lb

Fuel Pump Mounting Capscrews 9-2 65 N«m 50 ft-lb

Fuel Pump Support to Fuel Pump

Mounting Capscrews 9-2 12 N«m 110 in-lb

Fuel Pump Support to Flywheel Housing

Mounting Capscrews 9-2 60 N *m 45 ft-lb

Rail Pressure Tube Nut to Fuel Pump

Solenoid Fitting 9-2 27 N #m 20 ft-lb
Specifications - Group 18 Engine Assembly
V903 Page 18-9

Component or Assembly (Procedure) [Link]./Steps Metric U.S.

Fuel By-Pass Tube Nut to Gear Pump

Fitting 9-2 20 N»m 15 ft-lb

AFC Manifold Pressure Tube Nut to AFC

Cover Fitting 9-2

Engine Testing
Oil Filter Out Hose to Right Bank Front
Water Header Cover Hose Nuts 14-4 135 N»m

Oil Filter Inlet Hose From Front Oil Cooler

Support to Filter Hose Nuts 14-4 135 N»m

STC Oil Control Valve Pipe Plug 14-5 20 N»m 15 ft-lb