In the article, we will consider checking and replacing parts and assemblies of the oil system of the Cummins ISF3.8 engine

Checking the oil pressure

Unscrew the oil pressure service port plug located in the oil filter cover.

Install a pressure gauge.

Проверка и замена элементов масляной системы ISF3.8

Warm up the engine to operating temperature.

Check oil pressure at minimum speed.

At a minimum speed of 69 kPa

Increase the engine speed to the rated speed and let it run in this mode for 30 seconds. Check oil pressure.

At a rated speed of 207 kPa

Remove the pressure gauge and adapter and install the plug, first applying sealant to 2 - 3 threads.

Проверка и замена элементов масляной системы ISF3.8

Start the engine and check for oil leaks.

Check the oil level.

Note: maximum oil temperature 133 ° C.

Removal and installation of the oil pan

Disconnect the negative cable from the storage battery.

Drain the coolant.

Drain the oil from the lubrication system.

Remove the ancillary drive belt (article - Replacing the ancillary drive belt Cummins ISF3.8)

Unscrew the bolt and remove the ancillary unit wire belt tensioner.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Remove the six mounting bolts and remove the crankshaft speed sensor rotor.

Remove the four mounting bolts and remove the fan and fan pulley

Проверка и замена элементов масляной системы ISF3.8

Loosen the clamp and remove the crankcase ventilation hose (if using an open crankcase ventilation system).

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Loosen the clamps and disconnect the inlet and outlet ventilation hoses (if using a closed crankcase ventilation system).

Remove the inlet hose

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Removing the outlet hose

Loosen the clamp and disconnect the drain hose (if using a closed crankcase ventilation system).

Unscrew the two bolts and remove the camshaft trim

Remove the front crankshaft oil seal.

Disconnect the connector, remove the bolt and remove the CMP sensor.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Disconnect the connector, remove the bolt and remove the crankshaft position sensor

Remove the dipstick guide.

Проверка и замена элементов масляной системы ISF3.8

a) Clean the area around the dipstick guide.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

b) Remove the dipstick, unscrew the mounting bolts and remove the dipstick guide.

Disconnect the connector and remove the oil heater

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Unscrew the mounting bolts and remove the oil pan and gasket

Remove the front timing gear cover.

a) Unscrew the 14 mounting bolts and remove the cover of the front timing gears.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

b) Using a wooden spacer and a hammer, knock out the camshaft oil seal.

Install the front timing gear cover.

a) Clean the old seal from the cylinder block.

b) Lubricate the place on the front camshaft gear cover under the camshaft oil seal.

Проверка и замена элементов масляной системы ISF3.8

c) Install the oil seal into the front gear cover using a mandrel, tapping the mandrel with a hammer at points 90 degrees apart. Approximate gland installation depth 12 mm

d) Lubricate the toe of the camshaft with engine oil

Note: Do not damage the rubber seal when installing.

e) Lubricate the seal with adhesive sealant before installing the cover.

Sealant 3164070 or equivalent

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

f) Install the front timing gear cover and tighten the 14 bolts in the order shown in the figure. Tightening torque 24 Nm

Install the oil pan.

a) Install a new gasket on the oil pan.

b) Apply a thin coat of sealant in the areas shown in the figure.

Проверка и замена элементов масляной системы ISF3.8

c) Install the oil pan and tighten the 16 bolts in the sequence shown in the figure. Tightening torque 24 Nm

Install the oil heater and connect the connector. Tightening torque 24 Nm

Install the dipstick guide and tighten the mounting bolts. Tightening torque 5 Nm

Install and tighten the drain plug. Tightening torque 24 Nm

Install the crankshaft position sensor.

a) Install a new O-ring on the sensor, lubricated with engine oil.

b) Install the camshaft position sensor and tighten the mounting bolt. Tightening torque 25 Nm

c) Connect the connector.

Install the camshaft position sensor.

a) Install a new O-ring on the sensor, lubricated with engine oil.

b) Install the camshaft position sensor and tighten the mounting bolt. Tightening torque 10 Nm

c) Connect the connector.

Install the front crankshaft oil seal (article - Replacing the front crankshaft oil seal Cummins ISF3.8)

Install the camshaft trim.

a) Install a new O-ring and coat with adhesive sealant.

Sealant 3164070 or equivalent

b) Install the camshaft trim and tighten the 2 mounting bolts. Tightening torque 7.5 Nm

Connect the drain hose and tighten the clamp (if using a closed crankcase ventilation system). Tightening torque 7.5 Nm

Install the inlet and outlet ventilation hoses and tighten the clamps (if using a closed crankcase ventilation system). Tightening torque 7.5 Nm

Install the oil pan breather hose and tighten the clamp (if using an open crankcase ventilation system).

Install the fan pulley, fan and tighten the mounting bolts. Torque:

- M6 - 10 Nm;

- M10 - 43 Nm;

- M12 - 77 Nm.

Install a new crankshaft speed sensor and tighten the six mounting bolts cross-to-cross. Tightening torque 55 Nm

Install the ancillary wire belt tensioner and tighten the bolt. Tightening torque 43 Nm

Install the ancillary drive belt (article - Replacing the Cummins ISF3.8 ancillary drive belt).

Add oil to the lubrication system.

Fill with coolant.

Connect a wire to the negative plug of the storage battery.

Start the engine and check for leaks.

Disassembly and assembly of the oil pump

Place the front timing gear cover on a flat surface with the front end facing down.

Remove the 8 bolts securing the oil pump cover and remove the cover.

Проверка и замена элементов масляной системы ISF3.8

Remove the male and female rotors.

Install the gate rotor, beveled towards the front timing gear cover.

Install the main rotor by aligning the tab on the rotor with the tab in the front timing gear cover.

If both rotors are flat against a common plane, then the rotors are installed correctly.

Проверка и замена элементов масляной системы ISF3.8

Install the oil pump cover, apply adhesive sealant to the threads of the bolts, and tighten the 8 mounting bolts.

Loctite 243 Sealant or Equivalent

Tightening torque 8.5 Nm

Cleaning and checks

Check the front timing gear cover.

a) Remove the oil with thinner and dry the crankshaft pulley with compressed air.

b) Check for damage and cracks.

Проверка и замена элементов масляной системы ISF3.8

Check the installation location of the front crankshaft oil seal.

a) Remove oil and sealant residues from the crankshaft surface with thinner. Dry with compressed air.

Проверка и замена элементов масляной системы ISF3.8

b) Check the crankshaft nose for damage and remove minor damage with fine-grained emery paper.

If the contact surface of the crankshaft nose is damaged, it is impossible to install the repair sleeve on it.

Проверка и замена элементов масляной системы ISF3.8

Check the installation location of the front camshaft oil seal.

a) Remove oil and sealant residues from the camshaft surface with thinner. Dry with compressed air.

Проверка и замена элементов масляной системы ISF3.8

b) Check the camshaft nose for damage and remove minor damage with fine sandpaper.

If the contact surface of the camshaft nose is damaged, it is impossible to install the repair sleeve on it.

Проверка и замена элементов масляной системы ISF3.8

Check oil heater.

a) Clean the heating element with a dry towel.

b) Check the heating element for damage.

c) Check the resistance of the heating element. Nominal impedance 91 - 101 Ohm

Проверка и замена элементов масляной системы ISF3.8

Check the oil pump.

a) Clean the oil pump with solvent and dry with compressed air.

b) Check the rotors and cover for damage. If damaged, replace the front timing gear cover.

Проверка и замена элементов масляной системы ISF3.8

Removal and installation of the oil cooler

Drain the coolant.

Remove the ancillary drive belt (article - Replacing the ancillary drive belt Cummins ISF3.8).

Disconnect the radiator hose from the coolant pump.

Disconnect the cooling system bypass pipe.

Remove the oil cooler.

a) Unscrew the fastening bolts, remove the coolant pump housing with oil cooler and the seal.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

Remove the four mounting bolts and remove the oil cooler

Remove the lubrication pressure relief valve.

a) Remove any dirt around the spring seat of the pressure reducing valve

b) Remove the relief valve by removing the spring seat, o-ring, spring and plug.

Проверка и замена элементов масляной системы ISF3.8

Install a pressure reducing valve.

a) Install a new O-ring on the spring seat and lubricate the parts with engine oil.

b) Install the relief valve by installing the plug, spring and spring seat. Tightening torque 80 Nm

Install the oil cooler.

a) Install the oil cooler and tighten the 4 bolts. Tightening torque 15 Nm

b) Install the coolant pump housing, gasket and tighten the mounting bolts in the order shown in the figure. Tightening torque 27 Nm

Проверка и замена элементов масляной системы ISF3.8

Connect the cooling system bypass pipe.

Connect the radiator hose to the coolant pump.

Install the ancillary drive belt.

Fill with coolant.

Start the engine and check for leaks.

Cleaning and checks

Check the pressure relief valve.

a) Clean the plug, spring and spring seat with solvent and dry the parts with compressed air.

Note: If it is necessary to clean the plug bore, remove the body.

b) Check the plunger for damage.

Проверка и замена элементов масляной системы ISF3.8

Ensure free movement of the plunger in the relief valve body

Проверка и замена элементов масляной системы ISF3.8

d) With a valve spring tester, measure the pressure of the pressure reducing valve spring at the following heights:

Spring force of the pressure reducing valve

Height

An effort

42,6 mm

155 - 165 Nm

30,7 mm

311 - 339 Nm

Check the oil cooler.

Проверка и замена элементов масляной системы ISF3.8

a) Use a solvent to clean the oil cooler body and cover and dry with compressed air.

Проверка и замена элементов масляной системы ISF3.8

Проверка и замена элементов масляной системы ISF3.8

b) Clean the sealing surfaces.

d) Check the tightness of the oil cooler using a pressure test kit.

Проверка и замена элементов масляной системы ISF3.8

Oil cooler crimping kit No. 4918868

Air pressure testing:

- minimum pressure 449 kPa

- maximum pressure 518 kPa.