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In this video Diesel Pro Power customer Imperial Diesel Service, LLC overhauls a Cummins 6BT. This video is part 1 of 2 for this complete rebuild. Note that not every part is shown and when rebuilding a Cummins 6BT it is best to refer to the OEM service manual.

Parts To Rebuild Your 6BT Engine Can Be Found At The Link Below: https://dieselpro.com/cummins-6bt-parts.

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️ Breakdown of What’s Shown in the Video:

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0:11 Assembling The Piston Kits & Connecting Rods

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9:49 Preparing The Crankshaft

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12:40 Installing The Main Bearings

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17:51 Torquing The Main Cap Bearing Bolts

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22:05 Cleaning The Connecting Rods

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22:26 Installing The Gear Housing

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23:02 Polishing The Camshaft

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25:17 Installing The Camshaft

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28:17 Installing The Piston Kits

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39:32 Checking Piston Deck Height

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40:22 Installing The Cylinder Head

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Why a Cummins 6BT Might Need a Rebuild

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The Cummins 6BT — also known as the 5.9L — has earned a reputation for durability in trucks, industrial equipment, and marine applications. Many engines easily surpass 300,000 miles or 10,000 hours with proper care. Still, like any mechanical system, the 6BT will eventually show signs of wear that may call for a complete rebuild.

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1. High Operating Hours or Mileage

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After thousands of hours of heavy use, internal components such as pistons, rings, and bearings begin to wear. This leads to loss of compression, lower power output, and increased oil consumption.

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2. Oil Pressure Problems

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Declining oil pressure at idle or under load often points to worn bearings, oil pump issues, or internal clearances that have grown beyond spec. If oil analysis shows excessive metal particles, a rebuild may be necessary.

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3. Excessive Smoke or Blow-By

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Blue or white smoke from the exhaust, along with heavy crankcase blow-by, indicates worn piston rings, scored cylinder walls, or failing valve guides and seals — common signs that the engine’s bottom end and cylinder head need attention.

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4. Cooling System Failures

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Overheating can warp the cylinder head or compromise head gasket sealing. Repeated overheating events often shorten the life of the engine and make a rebuild more cost-effective than piecemeal repairs.

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5. Fuel System Wear

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Injectors and injection pumps gradually lose efficiency, but if wear extends into pistons, valves, and compression rings, rebuilding the engine ensures reliable fuel delivery and combustion.

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6. Preventive Maintenance for Long-Term Value

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Owners often choose to rebuild before catastrophic failure to avoid more costly damage. A proactive rebuild restores factory compression, extends service life, and maintains reliability for demanding applications.

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See The Second Half Of The Rebuild Here

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0:02 Setting The Valve Lash

12:59 Installing The Injectors

17:08 Installing The Intake Manifold Elbow

17:53 Installing The Valve Covers

18:42 Installing The Tappet Cover

19:23 Installing The Injection Pump

24:24 Installing Rear Main Seal Housing Adaptor Plate

25:02 Installing The Oil Pan

27:05 Installing The Lubricating Oil Pump

27:33 Engine Post Paint Job

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Parts Catalog For The Cummins 6BT

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Buy Cummins 6BT Parts Online – Fast, Global & Accurate

Explore Our Extensive Cummins 6BT Inventory

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We maintain one of the internet’s largest Cummins 6BT parts inventories, carefully curated to support marine propulsion systems, industrial gensets, stationary diesel pumps, and hydraulic units. All components are rated for continuous-duty applications and selected for corrosion resistance and long-term reliability.

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Cylinder Heads for Cummins 6BT

Our 6BT cylinder heads are precision-machined and fully assembled for quick installation.

Each head includes:

• New valves and valve springs

• Injector tubes

• Valve seals and guides

• Pressure-tested casting

Optional accessories:

• Cylinder head bolts

• Push rods

• Rocker arms

• Valve cover gaskets

These heads are ideal for engines suffering from overheating, blow-by, or compromised compression in marine or industrial systems.

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Fresh Water Pumps for Cummins 6BT

Designed for closed-loop cooling systems, our fresh water pumps keep coolant flowing through heat exchangers or keel coolers.

Pump features include:

• Heavy-duty cast housings

• Reinforced impellers

• Sealed, high-temp bearings

• Direct bolt-on replacement

Also available:

• Fan and tension belts

• Thermostat housings

• Marine-grade antifreeze and coolant treatments

• Pulley kits

Perfect for marine vessels or remote stationary engines operating in dusty, hot, or salt-laden conditions.

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Sea Water Pumps for Cummins 6BT

If your Cummins 6BT relies on raw water (seawater) cooling, Diesel Pro Power offers rugged, saltwater-rated pumps.

Key features:

• Bronze marine housings

• Marine-grade impellers

• High-endurance seals and wear plates

• OEM-matched flanges

Related components:

• Thermostats

• Impellers

• Zinc anodes

• Raw water strainers

• Seal kits and impeller tools

Saltwater corrodes quickly—use our pump kits and accessories to stay ahead of failure and avoid overheating your engine at sea.

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Engine Overhaul Kits for Cummins 6BT

We carry complete 6BT engine rebuild kits for marine and industrial applications. Whether your vessel is due for scheduled maintenance or your pump station needs a fresh powerplant, these kits save time and ensure part compatibility.

Each kit includes:

• Pistons and piston rings

• Cylinder liners

• Main and rod bearings

• Upper and lower gasket sets

• Oil seals and valve train components

Choose from standard and oversized configurations based on your engine’s wear profile. Our rebuild kits are carefully matched to engine CPLs for drop-in compatibility.

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Gaskets and Seals for Cummins 6BT

We provide comprehensive gasket solutions for your 6BT, including:

• Upper gasket sets

• Lower gasket sets

• Full overhaul kits

• Thermostat housing gaskets

• Valve cover and oil pan gaskets

• Seal rings and o-rings

We only offer marine-grade, industrial-rated materials—no compromise. These gaskets are made to withstand prolonged exposure to vibration, heat, pressure, and corrosive fluids.

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Fuel System Parts for Cummins 6BT

Proper fuel delivery is essential in any high-demand application. Diesel Pro Power offers:

• Fuel injectors (mechanical)

• Injector seals and nozzles

• Injection pumps

• Lift pumps

• Fuel filters and filter bases

• Return lines and banjo fittings

These components are ideal for 6BT engines operating in:

• Standby and continuous industrial gensets

• Auxiliary pump systems on board vessels

• Heavy-duty marine propulsion engines

All fuel system parts are compatible with marine diesel and high-sulfur blends common in international locations.

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Oil System Components for Cummins 6BT

To protect your 6BT’s internal components, we carry an extensive selection of oil system parts:

• Oil pumps and oil pickup assemblies

• Oil coolers and oil filter bases

• Spin-on oil filters

• Pressure sensors and switches

• Oil pan gaskets and drain plugs

Built to handle extended oil change intervals in industrial and marine duty cycles.

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Starters, Alternators & Electrical System for Cummins 6BT

From cold starts in damp marinas to 24/7 generator operation, we offer:

• 12V and 24V starters

• High-output marine alternators

• Waterproof sensors

• Pre-heaters for cold environments

• Engine harnesses and electrical relays

All electrical components are waterproof, vibration-resistant, and marine-tested.

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Additional Cummins 6BT Parts We Offer

We also carry:

• Turbochargers and exhaust hardware

• Control cables and shift levers

• Air intake systems and filters

• Mounting brackets and isolators

• Belt tensioners and idlers

• Exhaust elbows and water-cooled manifolds

Every part is curated for non-automotive use—ensuring compatibility and durability for your work environment.

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Why Buy Your Cummins 6BT Parts From Diesel Pro Power?

Over 40,000 Satisfied Customers Worldwide

From independent marine operators to large-scale industrial power companies, we’ve built a customer base based on trust, speed, and support. With thousands of five-star reviews and repeat customers, we’ve earned our place as a global leader in diesel engine support.

Fast, Worldwide Shipping

We ship within 24 hours—often same-day. We can reach:

• Shipyards and marinas

• Offshore oil platforms

• Island power plants

• Agricultural irrigation stations

• Construction equipment hubs

Intuitive Online Ordering

Our site is:

• Accurate – Cross-referenced with OEM part numbers

• Simple – No diesel knowledge required to navigate

• Fast – Optimized for both desktop and mobile

Secure and Private

We implement the latest encryption and data protection standards. Order with confidence knowing your information is safe.

World-Class Customer Service

Our diesel parts team is standing by to help you:

• Identify the correct parts

• Confirm CPL compatibility

• Advise on installation and repair

• Track international shipments

Call, email, or chat with a real expert—not a call center.