CUMMINS NTC400 NTC 400 DIESEL WORKSHOP SERVICE MANUAL 

ENGINE, DIESEL, 6 CYLINDER 
INLINE, TURBOCHARGED, 
CUMMINS MODEL NTC-400 BC2 

CHAPTER 1 INTRODUCTION .......................................................................................................... 1-1 
Section I General Information .................................................................................................. 1-1 
Section II Equipment Description and Data................................................................................. 1-3 
CHAPTER 2 DIRECT SUPPORT AND GENERAL SUPPORT 
MAINTENANCE INSTRUCTIONS.................................................................................. 2-1 
Section I Repair Parts, Special Tools, TMDE, and...................................................................... 
Support Equipment . 
Section II Troubleshooting......................................................................................................... 2-1 
Section III General Maintenance ................................................................................................ 2-1 
CHAPTER 3 REPAIR OF ENGINE ASSEMBLY ................................................................................. 3-1 
Section I General ..................................................................................................................... 3-1 
Section II Engine Disassembly................................................................................................... 3-28 
Section III Cylinder Block Repair................................................................................................. 3-57 
Section IV Cylinder Liners Inspection........................................................................................... 3-115 
Section V Crankshaft Assembly Repair....................................................................................... 3-117 
Section VI Bearing Halves Inspection .......................................................................................... 3-126 
Section VII Connecting Rod Repair.............................................................................................. 3-127 
Section VIII Piston Assembly Repair ............................................................................................. 3-140 
Section IX Camshaft Repair........................................................................................................ 3-146 
Change 
Gear Case Cover Repair............................................................................................ 3-150 
Section XI Cylinder Head Assembly Repair.................................................................................. 3-156 
Section XII Rocker Lever Housing Assembly Repair...................................................................... 3-198 
Section XIII Push Tubes Repair ................................................................................................... 3-210 
Section XIV Cam Follower Housing Assembly Repair ..................................................................... 3-212 
Section XV Vibration Damper Repair ........................................................................................... 3-224 
Section XVI Flex Disk and Ring Gear Assembly Repair .................................................................. 3-226 
VOLUME 2 OF 2 
Section XVII Flywheel Housing Repair............................................................................................ 3-229 
Section XVIII Rear Cover Repair .................................................................................................... 3-230 
Section XIX Rocker Lever Covers Repair....................................................................................... 3-231 
Section XX Oil Pump Assembly Repair ......................................................................................... 3-234 
Section XXI Oil Pan Repair .......................................................................................................... 3-240 
Section XXII Oil Cooler Assembly Repair........................................................................................ 3-244 
Section XXIII Aftercooler Repair...................................................................................................... 3-250 
Section XXIV Exhaust Manifold Repair............................................................................................. 3-253 
Section XXV Accessory Drive Assembly ......................................................................................... 3-254 
Section XXVI Engine Brake Assembly Repair................................................................................... 3-257 
Section XXVII Fuel Injector Repair.................................................................................................... 3-262 
Section XXVIII Fuel Pump Repair ..................................................................................................... 3-287 
Section XXIX Turbocharger Repair ................................................................................................. 3-374 
Section XXX Water Pump and Idler Pulley Assembly Repair ............................................................ 3-390 
Section XXXI Engine Reassembly ................................................................................................... 3-398 
Section XXXII Engine Testing .......................................................................................................... 3-462 
Section XXXIII Preparation for Storage or Shipment ........................................................................... 3-472 
APPENDIX A REFERENCES............................................................................................................. A-1 
APPENDIX B EXPENDABLE SUPPLIES AND MATERIALS LIST......................................................... B-1 
APPENDIX C TORQUE LIMITS .......................................................................................................... C-1 
INDEX .........................................................................................................................INDEX-1 
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