Cummins ISX11.9 CM2250 – Service Manual 001-010   Camshaft Bushings

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Several components weigh 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift these components.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the air piping from the intake manifold and the turbocharger. Refer to the OEM service manual.
• Remove the cylinder head. Refer to Procedure 002-004 in Section 2.
• Remove the cam follower assemblies. Refer to Procedure 004-001 in Section 4.
• Remove the front gear cover. Refer to Procedure 001-031 in Section 1.
• Remove the rear camshaft cover plate. Refer to Procedure 001-011 in Section 1.
• Remove the rear camshaft gear from the camshaft. Refer to Procedure 001-085 from Section 1.
• Remove the camshaft. Refer to Procedure 001-008 in Section 8.

There are two service tools and methods available to remove camshaft bushings. This procedure describes the process for each method.

Slide Hammer Method

• Use slide hammer assembly, Part Number 3376637, and camshaft bushing replacer kit, Part Number 4919265.

Hydraulic Pump Method

• Use hydraulic pump kit, Part Number 3823621, and camshaft bushing replacer kit, Part Number 4919258.

NOTE: The next two stepblocks describe the slide hammer method for removing the camshaft bushings.

Use Slide hammer assembly, Part Number 3376637, and camshaft bushing replacer kit, Part Number 4919265.

Install the bushing remover onto the slide hammer assembly.

Remove bushing Number 1 first.

Remove the next three or four bushings in order from front to rear.

Place the centering guide into the appropriate camshaft bores to keep the slide hammer assembly in line with the bushings being removed.

After removing the first three or four bushings, move to the other end of the cylinder block and remove the remaining bushings, following the above steps.

NOTE: The next group of stepblocks describe the hydraulic pump method for removing the camshaft bushings.

Use camshaft bushing replacer kit, Part Number 4919258, for camshaft bushing removal.

• For inner camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10.
• For rear camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 11, 12, and 13.
• For front camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 14, 15, and 16.

CAUTION  Make sure to select the proper size centering guides. This kit contains different-size centering guides for journals both with and without bushings installed. Selection of the incorrect centering guides can result in damage to the journal and/or guides.

Step 1

Install the centering guides in two of the camshaft bore ends.

NOTE: The centering guide can be installed in any of the holes, but keeping the wider distance is preferred.

Step 2

Install the drive bar through both of the installed centering guides.

Step 3

Position the spacer, Part Number 3823646, onto the drive bar with the open end facing the cylinder block.

Step 4

Slide the hydraulic cylinder onto the drive bar until it contacts the spacer.

Step 5

Install the stop collar onto the groove of the drive bar closest to the hydraulic cylinder.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing and tool.

Step 6

Install the camshaft bushing replacer onto the drive bar beside the bushing to be removed, with the smaller end facing toward the hydraulic cylinder.

Slide the camshaft bushing replacer into the camshaft bushing until the flange contacts the camshaft bushing.

Step 7 (for inner bushings only)

Install the stop collar into the groove onto the drive bar closest to the flange side of the camshaft bushing replacer.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 8 (for inner bushings only)

Depress the hydraulic pump pedal on the side labeled PRESS, and hold it until the cam bushing is removed from the camshaft bore.

Step 9 (for inner bushings only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing from the camshaft bushing replacer.

Remove the camshaft bushing replacer and stop collar from the drive bar.

Step 10 (for inner bushings only)

Position the drive bar back into position for removal of the next camshaft bushing.

Remove the remaining inner bushings using the same procedure.

Remove the service tool assembly and centering guides from the engine.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing and tool equipment.

CAUTION  Make sure to select the proper size centering guides. This kit contains different-size centering guides for journals both with and without bushings installed. Selection of the incorrect centering guides can result in damage to the journal and/or guides.

Step 11 (for rear bushing only)

Install the camshaft bore centering guides into bores Number 2 and Number 6 in order to keep the drive bar positioned while removing the remaining camshaft bushings.

Install the camshaft bushing replacer onto the drive bar behind the rear bushing with the smaller end facing toward the hydraulic cylinder.

Slide the camshaft bushing replacer into the camshaft bushing until the flange contacts the camshaft bushing.

Install the stop collar into the groove onto the drive bar closest to the flange of the camshaft bushing replacer.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 12 (for rear bushing only)

Depress the hydraulic pump pedal on the side labeled PRESS and hold the pedal until the cam bushing is removed from the camshaft bore.

Step 13 (for rear bushing only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing from the camshaft bushing replacer.

Remove the camshaft bushing replacer and stop collar from the drive bar.

Step 14 (for front bushing only)

Install the camshaft bushing replacer onto the drive bar behind the front bushing with the smaller end facing toward the hydraulic cylinder.

Slide the camshaft bushing replacer into the camshaft bushing until the flange contacts the camshaft bushing.

Install the stop collar into the groove onto the drive bar closest to the flange of the camshaft bushing replacer.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 15 (for front bushing only)

Depress the hydraulic pump pedal on the side labeled PRESS, and hold until the cam bushing is removed from the camshaft bore.

Step 16 (for front bushing only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing from the camshaft bushing replacer.

Remove the service tool assembly and camshaft bore centering guides from the engine.

NOTE: This step is for inspecting camshaft bushings when they are installed in the engine.

NOTE: The two outer camshaft bushings, Number 1 and Number 7, are wider than the inner bushings, Numbers 2 through 6.

Inspect the entire inside diameter of the bushing for damage, both visually and by feel. A mirror may be needed to see portions of the bushing.

Replace the bushings that have any of the following damage:

• Debris
• Pitting
• Flaking
• Corrosion
• Heavy wear
• Scratches.

Scratches originating from the oil passage hole are not acceptable. Replace the bushing.

NOTE: Scratches that can not be felt with your fingernail are acceptable.

Use a fine grade abrasive pad, such as Scotch-Brite™ 7448 or equivalent, to remove burrs and clean the bushing bores.

Measure the cylinder block camshaft bore inside diameter.

Cylinder Block Camshaft Bore Inside Diameter

If the camshaft bore inside diameter is larger than the acceptable limits, clean the bores and take a second measurement.

If the camshaft bore inside diameter is larger than the acceptable limits, the cylinder block must be replaced.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing and tool equipment.

NOTE: This section contains the instructions for using a slide hammer to install the camshaft bushings.

Install the centering guide into the appropriate camshaft bore.

Starting with Number 7 bushing, install the camshaft bushings in order, from rear to front.

NOTE: The oil hole (1) in the bushing must be at the 12 o’clock location when viewed from the front of the engine.

Number 7 Bushing – Installation

Install a new wide bushing (3) on the camshaft bushing replacer, Part Number 4919266, with the oil hole (4) at the 12 o’clock location.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

Install the camshaft bushing into the camshaft bore.

Center the camshaft bushings in the journals so that the oil groove in the bushing lines up with the oil supply hole in the block.

Number 6 Through Number 2 Bushings – Installation

Use the same procedure to install the Number 6 through Number 2 bushings.

Install the centering guide (2) in the appropriate camshaft bore.

Install a new narrow camshaft bushing onto the camshaft bushing replacer with the oil hole at the 12 o’clock location.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

Install the camshaft bushing into the camshaft bore.

Number 1 Bushing – Installation

Install a new wide bushing onto the camshaft bushing replacer, Part Number 4919266, with the oil hole (1) at the 12 o’clock location.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

NOTE: The guide is not used to install this bushing.

Install the camshaft bushing into the camshaft bore.

Measure the camshaft bushing installed inside diameter.

Camshaft Bushing InsideDiameter Installed

If the camshaft bushing installed inside diameter does not meet the specifications, remove the bushing and use a fine grade abrasive pad, such as Scotch-Brite™ 7448 or equivalent, to remove burrs and clean the bushing bores.

Measure the camshaft bore inside diameter and be sure the measurement meets the specifications.

Install a new camshaft bushing onto the camshaft bushing replacer with the oil hole at the 12 o’clock location.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

Install the camshaft bushing into the camshaft bore. 

Measure the camshaft bushing installed inside diameter.

NOTE: The next group of step blocks describes the hydraulic pump method for installing the camshaft bushings.

Use camshaft bushing replacer kit, Part number 4919258, for camshaft bushing removal.

• For inner camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 below.
• For rear camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 11, 12, and 13 below.
• For front camshaft bushing removal, follow Steps 1, 2, 3, 4, 5, 6, 14, 15, and 16 below.

CAUTION  Make sure to select the proper size centering guides. This kit contains different size centering guides for journals both with and without bushings installed. Selection of the incorrect centering guides can result in damage to the journal and/or guides.

Step 1

Install the camshaft bore centering guides, Part Number 4919261, into both camshaft bore ends.

Step 2 (for inner bushing only)

Slide the drive bar through the camshaft bore centering guide and into the Number 2 journal. Place a camshaft bushing, if desired, over the end of the puller shaft.

Move the puller shaft through the Number 3 journal and repeat the same above.

Continue through each inner journal until the drive bar is completely through the opposite end of the camshaft bore centering guide.

Step 3

Position the spacer onto the drive bar with the open end facing the cylinder block.

Step 4

Slide the hydraulic cylinder onto the drive bar until it contacts the spacer.

Step 5

Install the stop collar into the groove of the drive bar closest to the hydraulic cylinder.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing, journal, and tool equipment.

Step 6 (for inner bushings only)

Install the camshaft bushing replacer onto the drive bar next to the bushing to be installed, with the smaller end facing toward the hydraulic cylinder.

Slide the camshaft bushing over the camshaft bushing replacer.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

CAUTION  It is very important that the oil ports on the camshaft bushings being installed be aligned with the oil ports in the journal. Misalignment of cam bushing oil port to journal oil port can result in damage to the engine.

Step 7 (for inner bushings only)

Move the camshaft bushing replacer over until the cam bushing just touches the camshaft bore.

Install the stop collar into the groove on the puller shaft closest to the end of the bushing driver.

Rotate the camshaft bushing until the oil port is aligned with the oil port of the bore.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 8 (for inner bushing only)

NOTE: Lightly tapping the PRESS side of the hydraulic pump pedal will provide control to stop the camshaft bushing in the desired position.

Install the camshft bushing.

Step 9 (for inner bushings only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing replacer from the camshaft bushing.

Remove the camshaft bushing replacer and stop collar from the drive bar.

Install the remaining inner bushings using the same procedure.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing, journal, and tool equipment.

Step 10 (for rear bushing only)

Remove the camshaft bore centering guides, Part Number 4919261, from journals Number 1 and 7.  Install centering guides, Part Number 4919260, into bores Number 2 and 6.  Install the drive bar through the centering guides.

Place the rear camshaft bushing over the end of the drive bar.

Install the camshaft bushing replacer onto the drive bar with the small end facing toward the hydraulic cylinder.

Install the camshaft bushing onto the camshaft bushing replacer.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

CAUTION  It is very important that the oil ports on the camshaft bushings being installed be aligned with the oil ports in the journal. Misalignment of cam bushing oil port to journal oil port can result in damage to the engine.

Step 11 (for rear bushing only)

Move the camshaft bushing replacer over until the cam bushing just touches the camshaft bore.

Install the stop collar into the groove onto the puller shaft closest to the end of the bushing driver.

Rotate the camshaft bushing until the oil port is aligned with the oil port of the bore.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 12 (for rear bushing only)

NOTE: Lightly tapping the PRESS side of the hydraulic pump pedal will provide control to stop the camshaft bushing in the desired position.

Install the rear camshaft bushing.

Step 13 (for rear bushing only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing replacer from the camshaft bushing.

Remove the camshaft bushing replacer and stop collar from the drive bar.

CAUTION  Make sure to install the proper size camshaft bushing replacer. Selection of the incorrect camshaft bushing replacer can result in damage to the camshaft bushing, journal, and tool equipment.

Step 14 (for front bushing only)

Position the camshaft bushing replacer onto the drive bar with the small end facing toward the hydraulic cylinder.

Slide the camshaft bushing over the camshaft bushing replacer.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

CAUTION  It is very important that the oil ports on the camshaft bushings being installed be aligned with the oil ports in the journal. Misalignment of cam bushing oil port to journal oil port can result in damage to the engine.

Step 15 (for front bushing only)

Move the camshaft bushing replacer over until the cam bushing just touches the camshaft bore.

Install the stop collar into the groove onto the puller shaft closest to the end of the bushing driver.

Rotate the camshaft bushing until the oil port is aligned with the oil port of the bore.

WARNING  Keep hands clear of the journal area when operating the pedal of the hydraulic pump. Serious injury can result if hands are caught between journal and bushing area when operating the hydraulic pump pedal.

Step 16 (for front bushing only)

NOTE: Lightly tapping the PRESS side of the hydraulic pump pedal will provide control to stop the camshaft bushing in the desired position.

Install the front camshaft bushing.

Step 19 (for front bushing only)

Release the pressure from the hydraulic pump by pressing the RELEASE side of the pedal.

Remove the camshaft bushing replacer from the camshaft bushing.

Remove the service tool assembly and centering guides from the cylinder block.

Measure the camshaft bushing installed inside diameter.

Camshaft Bushing Inside Diameter – Installed

If the camshaft bushing installed inside diameter does not meet the specifications, remove the bushing and use a fine grade abrasive pad, such as Scotch-Brite™ 7448 or equivalent, to remove burrs and clean the bushing bores.

Measure the camshaft bore inside diameter and be sure the measurement meets the specifications.

Install a new camshaft bushing onto the camshaft bushing replacer with the oil hole at the 12 o’clock location.

Be sure the camshaft bushing is fully installed onto the camshaft bushing replacer. Failure to do so can result in bushing damage.

Install the camshaft bushing into the camshaft bore. 

Measure the camshaft bushing installed inside diameter.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Several components weigh 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift these components.

• Install the camshaft. Refer to Procedure 001-008 in Section 8.
• Install the rear camshaft gear onto the camshaft. Refer to Procedure 001-085 from Section 1.
• Install the rear camshaft cover plate. Refer to Procedure 001-011 in Section 1.
• Install the front gear cover. Refer to Procedure 001-031 in Section 1.
• Install the cam follower assemblies. Refer to Procedure 004-001 in Section 4.
• Install the cylinder head. Refer to Procedure 002-004 in Section 2.
• Install the air piping onto the intake manifold and the turbocharger. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.