Cummins ISX11.9 CM2250 – Service Manual 003-013   Rocker Lever Housing

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 animals. If not reused, dispose of in accordance with local environmental regulations.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the EGR crossover tube. Refer to Procedure 011-070 in Section 11.
• Remove the crankcase breather hoses. Refer to Procedure 003-018 in Section 3.
• Remove the crankcase breather. Refer to Procedure 003-001 in Section 3.
• Remove the crankcase breather bracket. Refer to Procedure 003-027 in Section 3.
• Disconnect the wiring harness from the EGR valve mounting bracket attachment points.
• Remove the EGR valve. Refer to Procedure 011-022 in Section 11.
• Remove the EGR hose. Refer to Procedure 011-034 in Section 11.
• Remove the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.
• Remove the EGR mass measurement flow assembly. Refer to Procedure 011-066 in Section 11.
• If necessary, remove the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the EGR cooler. Refer to Procedure 011-019 in Section 11.
• Remove the EGR valve mounting bracket. Refer to Procedure 011-044 in Section 11.
• Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Remove the air compressor coolant lines. Refer to Procedure 012-004 in Section 12.
• Remove the coolant thermostat. Refer to Procedure 008-013 in Section 8.
• Remove the internal wiring harness pass through connector. Refer to Procedure 019-063 in Section 19.

Remove the rocker housing mounting capscrews.

Remove the rocker housing.

Discard the gasket and five grommet seals.

WARNING  When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Hot steam can cause serious personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use steam to clean the rocker lever housing.

Dry with compressed air.

Clean the rocker housing gasket surface on the cylinder head.

Inspect the housing for cracks or other damage.

If the housing is cracked or otherwise damaged, it must be replaced.

Replace the rocker housing if the sealing flange surface or groove is damaged or bent, creating a leak path.

Inspect the cup plugs for leaks or other damage.

Use the following procedure for removal and installation of the cup plugs if leaks or other damage is found. Refer to Procedure 017-002 in Section 17.

Install a new gasket and grommet seals into the bottom of the rocker lever housing.

Install the new seal into the groove on the bottom of the rocker lever housing. Orientate the formed shape of the seal to match the groove in the housing and press in place. Make sure the locating tabs mate with the notches in the groove to prevent damage to the gasket.

Install the rocker lever housing.

While installing the rocker lever housing, make sure the gasket has not fallen out of place.

Hand-tighten the capscrews.

Tighten the capscrews in the sequence illustrated.

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

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.

• Install the internal wiring harness pass through connector. Refer to Procedure 019-063 in Section 19.
• Install the coolant thermostat. Refer to Procedure 008-013 in Section 8.
• Install the air compressor coolant lines. Refer to Procedure 012-004 in Section 12.
• Install the rocker lever cover. Refer to Procedure 003-011 in Section 3.
• Install the EGR valve mounting bracket. Refer to Procedure 011-044 in Section 11.
• Install the EGR cooler. Refer to Procedure 011-019 in Section 11.
• If removed, install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Install the EGR mass measurement flow assembly. Refer to Procedure 011-066 in Section 11.
• Install the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.
• Install the EGR hose. Refer to Procedure 011-034 in Section 11.
• Install the EGR valve. Refer to Procedure 011-022 in Section 11.
• Attach the wiring harness to the EGR valve mounting bracket attachment points.
• Install the crankcase breather bracket. Refer to Procedure 003-027 in Section 3.
• Install the crankcase breather. Refer to Procedure 003-001 in Section 3.
• Install the crankcase breather hoses. Refer to Procedure 003-018 in Section 3.
• Install the EGR crossover tube. Refer to Procedure 011-070 in Section 11.
• 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.