Cummins 5.9 Shop Manual 1991+

Cummins 5.9, 3.9, 4.5 Shop Manual 1991+

Factory printed Cummins 5.9, 3.9, 4.5 Shop Manual 1991+.  This covers 1991 & newer engine mechanical parts.

No coverage for electronic diagnostics or fault codes.

B Series Engine Coverage:

• Cummins 5.9 liter
• Cummins 3.9 liter
• Cummins 4.5 liter

Cummins 5.9, 3.9, 4.5 Manual Contents:

• Introduction
• Familiarization

1. Air intake system overview & flow diagram
2. Complete engine overview & info
3. Compressed air system & flow diagram
4. Cooling system overview & flow diagram
5. Cylinder block overview & info
6. Engine electrical equipment overview
7. Engine testing overview including dyno testing
8. Flow diagram for exhaust system
9. Fuel system overview & flow diagram
10. Injectors & fuel line overview including operation theory for PT & STC fuel system
11. Lubrication system overview & flow diagram

• Troubleshooting Symptoms

1. Troubleshooting Procedures & Techniques
2. Air compressor problems
3. Alternator problems
4. Cooling system problems
5. Excessive crankcase blowby
6. Low fuel pressure
7. Engine brake problems
8. Hard starting
9. Engine noises
10. Low power
11. Misfire or runs rough
12. Engine dies
13. Speed surge
14. Starts but dies
15. Excessive vibration
16. Fuel consumption
17. Fuel in coolant
18. Fuel in oil
19. Low boost
20. Excessive oil consumption
21. Smoking
22. Governor problems
23. Troubleshooting overview
24. More

• Complete Engine

1. Removal & Installation

• Cylinder Block

1. Accessory drive seal
2. Con rod bearings
3. Main bearings
4. Thrust bearings
5. Camshaft, bushings, clearance & bearing supports
6. Crankshaft inspection & servicing
7. Crankshaft gears, pulley & seals
8. Cylinder block, servicing, liners, liner seats, counterbore
9. Gear cover accessory drive bushing
10. Pistons & rings
11. Con rods
12. Piston cooling pipes
13. Vibration damper

• Cylinder Head

1. Clean / inspect
2. Finishing / surfacing
3. Installation / removal
4. Leak / pressure test
5. Head gasket general info

• Rocker Arms

1. Crankcase breather
2. Overhead adjusting, finishing, general info
3. Rocker arm, clean, inspect & service
4. Rocker cover & housing
5. Special tools

• Cam Followers / Push Rods or Tubes

1. Remove, clean, inspect, disassemble, assemble & install

• Fuel System

1. Fuel Flow, inspect & test
2. Fuel pump, inspect & test
3. Check valve
4. High idle speed adjust
5. Idle speed adjust
6. Pressure regulator
7. Pulsation damper
8. Throttle lever & linkage
9. VS throttle shaft housing
10. Shut-off valve
11. Service tools
12. Stall speed test
13. VS governor adjusting screw sealing washers & idle spring

• Injectors & Fuel Lines

1. AFC no air check
2. Air in fuel
3. Cylinder misfire or smokes
4. ECM fuel plate, fuel cooled
5. Fuel drain line restriction
6. Fuel filter, spin on
7. Fuel inlet restriction
8. Fuel supply lines
9. Injector
10. Service tools
11. Static injector timing

• Lubrication System

1. Lube oil & filter analysis
2. Lube oil contamination
3. Lube oil cooler & transfer housing
4. Dipstick & housing
5. Lube oil filter, spin on
6. Lube oil by-pass valve
7. Lube oil filter head
8. Lube oil high pressure relief valve
9. Lube oil leaks
10. Lube oil pan
11. Lube oil pressure gauge
12. Lube oil pressure regulator
13. Lube oil pump
14. Lube oil pump signal tube & signal tube oriface
15. Lube oil system diagnostics
16. Lube oil temperature gauge
17. Lube oil thermostat
18. Lube oil transfer tube
19. Lube oil viscosity sensor

• Cooling System

1. Coolant filter, head & valve
2. Temperature gauge
3. Thermostat, housing & seal
4. Vent lines
5. Cooling system, servicing
6. Cooling system, air or combustion gas test
7. Cooling fan & water pump drive belt
8. Fan clutch, electric / on-off / viscous
9. Fan hub, belt driven
10. Fan shroud, spacer & pulley
11. Cooling fan
12. Radiator, hoses & cap
13. Radiator shutters
14. Heat exchanger
15. Sea water pump
16. Water pump & idler

• Drive Units

1. Accessory drive & pulley
2. Accessory drive pulley wear sleeve

• Air Intake System

1. Aftercooler
2. Intake manifold
3. Intake restriction
4. Air leaks, intake & exhaust system
5. Charge air cooler
6. Turbocharger
7. Turbocharger inspection

• Exhaust System

1. Exhaust manifold, dry
2. Exhaust restriction

• Compressed Air System

1. Air compressor
2. Carbon buil-up
3. Air compressor head
4. Pin bore wear
5. Unloader & valve assy.
6. Governor testing (compressor pumps continuously or will not pump
7. Air leaks

• Electrical Equipment

1. Alternator
2. Batteries, cables & connections
3. Alternator drive belt
4. Starter magnetic switch
5. Starter solenoid
6. Starter switch
7. Starter motor

• Engine Testing

1. Dyno worksheet
2. Engine run-in (dyno)
3. Engine run-in (without dyno)
4. Engine testing with dyno

• Mounting Adaptations

1. Engine lifting brackets
2. Engine mounts
3. Support brackets
4. Flywheel & ring gear
5. Flywheel housing

• Miscellaneous

1. Cup plugs
2. Pipe plugs
3. Straight thread fittings & plugs

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