[SERVICE MANUAL ' Engines t ! 6T-830 ' ' 6TA-830 ' ' ' ' ' ' ' ' I 76544 1. Trim along dashed line. 2, Slide into pocket on Binder Spine. r SERVICE MANUAL _ | Engines 6T-830 6TA-830 oa 19 dast ide into pocket on Binder Spine, SERVICE MANUAL En, 6T-830 6TA-830 765441 ooo 1. Trim along dashed line. 2, Slide into pocket on Binder Spine. 6T-830 6TA-830 im along dashed line. ‘Slide into pocket on Binder Spin6T-830 and 6TA-830 Engine Service Manual 7-65441 Table of Contents Description ‘Section No. Form No. Tab 1 Loctite Product Chart 8-98900 Tab 2 Specification Details 2403 8-28426 ‘Cylinder Block Crankshaft, Pistons, Rod, Sleeves, ‘Camshaft, Bearings, Seals and Flywheel 2425 8-28444 Cooling System Thermostat, Water Pump, Fan Pulley and Belt Tensioner 2455 8.28466 HXAQW Turbocharger 2470 7-65590 Tab 3 SS eee injection Pump Pump Drive Gear, Timing Pin, Fuel Shutoff Solenoid, Primer Pump and Pump Timing 3412 8.28404 Fuel njectors ee 3413 8-28503 ‘CASE CORPORATION 700 Stale Soot Racin, WI 53408. USA on CORPORATION © 1996 Case Corporatior 3350 South Service Road ” Burlington, ON L7N M6 CANADA Panta US Fac 7-66600 arch, 1908Section 1001 STANDARD TORQUE SPECIFICATIONS ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA, CASE CANADA CORPORATION th Burlington, ON L7N 3M5_ CANADA Rac 6-716011001-2 TABLE OF CONTENTS ‘TORQUE SPECIFICATIONS - DECIMAL HARDWARE TORQUE SPECIFICATIONS - METRIC HARDWARE TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and Grade 8 Bolts, Nuts, and Studs UNF threads as received from suppliers dry, or when Weald ects, oar enone posure hat oO ® aroused Pound Newion ——— es Se Inches metres Grade 5 Bolts, Nuts, and Studs Tian Tas to 180 761020 5/16 inch 288 10 348 331089 QGO® [sein somee [ia Pound Newion | Pound- Newton Size | inches meres | Size Feet metres Ti nch Toei 132 Roe TAB inch 7010 i014 Caibinon 20410 252 Bowe 2 inch T1010 182 14910 179 Singh Woe Boar ‘SFBinch Teoi0 182 217 10260 Poune | Newton 3/8 inch 22010 264 208 10368 Size Feet meres ‘Siainch 38010 466 Biser | THB inch Se cd TiBinch 60010 720 81410976 Winch 801096 1090 190 Tong 900% 1080 | 120010 1485 | S716 inch TOTO 182 1810179 T-iBinch 128010 1440 | 173610 1053 SB inch 18010 180, 20310 244 Tiling | fee010 2000 | aabaTo DTI ainch 27010324 366 10 89 +38 inch 2380102720 | 3207 103688 7 inch 400 0 480 542 10651 TARinch ‘3160103660 | 4285104807 TOinch 58010 696 Tero | [NOTE: Use thick nuts with Grade 8 bolts 18 inch 800 10 880 1085 0 1788 inch Fai 1240 | 161970 1681 388 inch 1460 %0 1680 | 198010 2078 inch Tei0i0 2200 | 288110 2568 Retype Novenbe, 1094 ec 871601 Issued 1191 PrinesinUSATORQUE SPECIFICATIONS - METRIC HARDWARE 1001-3 Use the following torques when specifications are not given — Grade 10.9 Bolts, Nuts, and Studs These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated wih engine ol These vues oot apply I rapie o ) Molycisulfide grease or ois used Pound Newion Size Inches metres Grade 8.8 Bolts, Nuts, and Studs wa Beto 48 ai0S M5 841096 i011 16 ee [ee MB 3241 384 371043 Pound Newion Size Inches metres _ coe Neon ua i036 soa wo aoe 73087 Ms S107 708 m2 9810112 12510 150 Me %i0 108 Toe mig 910 179 20070245 MB 228 10 276 261051 i Le on Mio 61050 se m0 A010 540 1010790 Pounds ‘Newton Size Feet imetes M24 780 1 940 1050 0 1275 ie Sane ETT 80 Ya7o1o 1770 | 2000102400 Mt MOS 1oT AaDiTe 36 2580103090 | 3500t0 4200, wie 16010200 Briar w20 22010 380 $3410 515 Grade 12.9 Bolts, Nuts, and Studs wes 50010 600 BHI MoO 92010 1100 | 12500 1500 & M6 Teoo10 1950 [2176102600 Rece-71601 Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners. Issued 1191 PriesinuSA1001-4 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS TubeOD | Thread | Pound- Newton | [Tube OD Thread Pound- Newton Hose ID | Size Inches —_|_metres Hose ID | Size Inches | metres 37 Degree Flare Fitting Straight Threads with O-ring Tisinch | 720 | Taw IM | BITS Winch | 7620 | 144t0e28 | 161026 6.4mm 64mm 5/t6inch | 12-20 9610192 | 111022 ‘BAB inch | 172-20 9210300 | 221034 7.9 mm | 7.9mm Weinch | W648 | 12010800 | T4094 Binh | O61 | 80010480 | Bhto se 9.5mm | 95mm | Weinch | 314-16 18010504 | 201087 Winch | 314-16 54010804 | 671091 127 mm 127 mm Bench | 7644 | 90010696 | 41078 [Tube 00| Thread | Pound- | Newton | 159mm HoseID | Size Inches | metres TubeOD | Thread | Pound- | Newion Seinch | 710-14 Bet082 | 7910 126 HoseID | Size Inches | metres 169 mm | Gainch” | HAN612 | 40108 | SATO 108 Biainch | 1416-12 | @0to 128 | 108t0 174 190mm 1.0mm Tiginch | 311612 | 8010100 | 8110195 Tench | aera | 100% 160 | 1610216 22.2 mm 222mm (inch | T5612 | Welly | 10210158 ‘inch | 151612 | 11710187 | 18910253 254 mm 2.4mm Tia inch | +5842 | 12510165 | 16910220 [etieineh” | 1-51-12 165t0 264 | 22410957 31.8 mm 318mm Fiainch | 17-12 | 21010250 | 28510598 THinch | 1-718-12 | 25010400 | 99910542 38.1 mm 38.1 mm | Split Flange Mounting Bolts Pound Newton Sze Inches meres 56-18 Taio 20 201077 316 240 10 300 27034 THe R005 ae Pound- Newton Size Feet metres R18 Bs Tao 88 S811 14010 160, 19010203 | ac 8.71601 Iseved 1181 Presi USA1001-5 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Nom | SAE Dash Tweed Pound- Newton Thread Pound. Newton Size Tune 00 | Sze Inches metres Size Inches metres O-ring Boss End O-ring Face Seal End Fitting or Lock Nut 4 “ein 6-18 wow | iwi | mea 2HoR | wT 64mm 4 3B inch ‘e16 —| 2i6t0240 | 24ioa7 | ae-t8 30010360 | S4to4t 25mm Ey inch Tete | Setoweo | wioss” | aate HOI080 | TOE 127mm Thread Pound- Newton See Inches metres 0) SB inch ie seer | wire | Tete wes | 0 } 159mm Nom. ‘i612 | 851090 | 11510128, SAE Dash Thread Pound- Newton Tae ai wr Size TubeoD | Size Inches mets See aaah et 2 “Sine Wie | SwoO | BNO) 15112 | 11510125 15610169 180mm “4 78 inch TaH612 | 651080 | S0t0110 | EBEATN | t0to160 | DOS TeaTT 222mm 46 finch Tee | Mw p smo en) 178-12 | 19010200 | 2880271 2am | Q : 20 ‘inch | HH16-12 | 12510140 | 170%0 190 — 318mm | eine “e010 180 | Dow se pes 38.1 mm 4 ie eooee ac a.71601 NOTE: Case Corporation reser ihe ght to make improvements in design o changes in specications at anytime witheticuring any obigaton to stl them on Uns previously sal, Issued 11-91 Printedin USAS008 a so e069 294 yo. 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All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting parts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA eee CANADA CORE OEATION) (© 1906 Case Corporation 3950 South Service Road Pined RUS BButington, ON L7N 36 CANADA ac 8.91703 January, 1991 (Revised March 1096)2011-2 TABLE OF CONTENTS SPECIAL TOOLS .... SPECIAL TORQUES ... SERVICING THE AFTERCOOLER ..... Removal — instalation ... SPECIAL TOOLS aonise ‘THREAD SEALANT WITH TEFLON - 817509 6m! TUBE SILVER ‘Three Bond RTV Sil ‘Adhesive/Se: SPECIAL TORQUES Atercooler Mounting Bolts Crossover Tube Clamps. NOTE: Case Corporation reserves the right fo make improvements in dsign or changes specication at any tne whet incuring any sbigaton to instal thm on uns previously sel ac .91708, 85108 THREE BONO SILVER RTV SEALER 48234943 02 TUBE. 21 1027Nm 4t06Nm Revised 2.06, Prntadia USA20113 SERVICING THE AFTERCOOLER Removal STEP 4 Case 6TA 830 engine. Remove the bolts and aftercooler. Discard the gasket. Clean the gasket surfaces. Inspect the housing and core for de STEP 2 amet STEP 5 Drain the coolant trom the engine. Open the air vent valve on the aftercooler to help drain the coolant Remove the air vent valve from the aftercooler. STEP 6 STEP 3 mor 94006 Install a plug inthe air vent valve and put a cap on one of the Remove al fuel lines and water hoses from the aftercooler. aftercooler water hose tube. Attach regulated air pressure to the other water hose tube. Pressurize the core to 206 KPa (2 bar) (30 PSI) and submerge the aftercooler in water. Inspect for any air leaks. If there leaks or damage, the aftercooler must be replaced ac 8.91708, Revised 2.06 Pinesin USA201-4 Installation ens 1. Altercooler 3. Turbocharger 2. Crossover Tube 4 Water Line STEP 7 STEP 8 Apply teflon thread sealant to threads of air vent valve and. Apply a thin layer of Three Bond RTV Silver Sealer to both instal in the aftercooler. sides of a new gasket, Install the gasket and aftercooler on the cylinder head, ac .91708, Revised 2.06, PrntesinUSA.2011-5 STEP 9 STEP 11 ES Apply Loctite liquid teflon thread sealer on the injector line Install the crossover tube, injector tubes and water hoses on mounting bracket bolts. Install the injector line mounting the aftercooler and turbocharger. Tighten the water hose brackets on the aftercooler. clamps to a torque of 4 to 6 Nm STEP 12 STEP 10 aver Fill the cooling system with coolant. Open the air vent valve to remove trapped ar. Close the valve when coolant appears. T9409, Apply Loctite liquid teflon thread sealer to the remaining aftercooler bolts, Install the aftercooler mounting bolts and tighten to a torque of 21 to 27 Nm following the torque ‘sequence shown above, ac 8.91708, Revised 2.06 Pinesin USA2011-6 Induction System Leak Check NOTE: The induction system must be checked for air leaks anytime that there has been service work done on the system. STEP 1 . af Remove both air cleaner fiter elements. Completely wrap the mesh area of @ used secondary element with duct tape. No air should be able to pass through this element during the test. Install the wrapped element into the air cleaner housing ‘and install the cover STEP 15 THREE (a PLUGS IN (CYLINDER HEAD 1. Make @ solution of liquid soap and water. STEP 14 184 Remove the restrictor indicator and instal a fiting to connect a source for compressed air. Regulate the air source to a maximum of 20 to 30 kPa (3 1 5 PSI IMPORTANT: Do not exceed a maximum pressure of 20 to 30 kPa (3 to 5 PSI) or damage 10 induction components could result NOTE: The restrictor indicator is designed to see a vacume and not pressure and therefor must not be in the system when the leak check is performed. (OUTLET TUBE SEAM ‘OUTLET TUE SEAM ATELBOM ‘TUBE CONNECTION TURBOCHARGER INLET TURBOCHARGEA OUTLET 150196 2, With the induction system pressurized, apply the solution to the complete air induction system as shown above. 3, There must not be any signs of alr leakage except forthe turbocharger center housing ends. 4, Correct any leaks and test the system again. 5. When the testis done, instal the restrictor indicator and a new secondary fiter element ac .91708, Revised 2.06, PrntesinUSA.Section 2403 SPECIFICATION DETAILS 6-830 Diesel Engines IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting perts, CASE CORPORATION 700 Stale Stoo! Racine, WI 53408 USA ‘CASE CANADA CORPORATION One ee $350 Soh Sere Ron Printed NU SA. Burngton, ONL7N 8M CANADA Fac 6-28426 January, 1987 (Revised March, 1996)2408-2 TABLE OF CONTENTS RUN-IN INSTRUCTIONS Engine Lubrication .. un-in Procedure for Rebuilt Engine un-in Procedure for Rebuilt Engines (with a Dynamometer) un-in Procedure for Rebuilt Engines (without a Dynamometer) .. un-in Procedure (Agricuture Equipment) un-in Procedure (Construction Equipment) ENGINE SPECIFICATION DETAILS ... Cylinder Block Prior to Engine Serial Number 44487890 .. Cylinder Block Engine Serial Number 44487890 and After Cylinder Sleeve Prior to Engine Serial Number 44487830 yiinder Sleeve Engine Serial Number 44487890 and After .. Piston Pin Piston Piston Rings... ylinder Head Litters... Connecting Rod .. Crankshaft... Camshaft Turbocharger Gear Train... Rocker Arm Assembly Intake Valve... Exhaust Valve Valve Springs Oil Pressure Regulator Spring ‘SPECIAL TORQUES ... ac 8.20026 Revised 2.06, Prntadia USA2408-3 RUN-IN INSTRUCTIONS Engine Lubrication Fill the 6-880 engine crankcase with CCISF, CDISF, CEISF or CF-4 service classification oil. Use the correct viscosity rating for the ambient air temperature. Install new ol fiters after the engine is rebul. Fill the 6T 830 and the 6TA 830 engine crankcase with CE/SF or CF-4 service classification oll. Use the correct viscosity rating for the ambient air temperature. Install new ol fiters after the engine is rebul. Run-In Procedure for Rebuilt Engine Step 1 Disconnect the wire to the electric shut-off on the irjection pump so thatthe engine will not stat. Crank the engine for 30 seconds until there is ol pressure, then reconnect the wire, Step 2 Make sure the coolant level is correct. Step 3 Run the engine at 1000 APM minimum load for 5 minutes and check fr oi leaks, Step 4 Continue to check the oil pressure, coolant level anc coolant temperature during run-in, Run-In Procedure for Rebuilt Engines (with a Dynamometer) ‘The following procedure must be followed when using a PTO dynamometer to Run-In the engine. The dynamometer will control the engine load at each speed and will move stress on new paits during Run-n. Continue to check the oil pressure, coolant level and coolant ‘emperature. STEP. TIME ENGINE SPEED DYNAMOMETER SCALE LOAD 1 5 Minutes 1000 RPM 50 2 5 Minutes 1100 APM 12 3 5 Minutes 2200 RPM Full Run-In Procedure for Rebuilt Engines (without a Dynamometer) STEP. TIME ENGINE SPEED LOAD 1 5 Minutes 1000 RPM No Load 2 5 Minutes 1100 APM Light Load 3 5 Minutes 2000 RPM Full Run-In Procedure (Agriculture Equipment) Use one gear lower than normal forthe first 8 hours of field operation. DO NOT lug the engine for the next 12 hours. Move the lever to-a lower gear to prevent lugging the engine. Do not lug the engine below the rated engine RPM during early hours of lite Run-In Procedure (Construction Equipment) Operate the engine at fll throttle with a normal load for the fist 8 hours. Do not stall the converter or the hydraulics. Do not lug the engine below the Rated Engine RPM (Do not stall the engine more than 10 seconds). ac 8.20426 Revised 2.06 Printed in USA,2403-4 ENGINE SPECIFICATION DETAILS. Cylinder Block Prior to Engine Serial Number 44487830 Metric Value Type a ee : : sonsneWet Sleeved Material. sos Cast Ion Main Bearing Bore. 404,987 to 105.013 mm ‘Camshaft Bore. 163.987 to 64.013 mm Litter Bore .. 16.000 to 16.030 mm Maximum Service Limit Cylinder Sleeve Bore Cylinder Sleeve Counterbore .... . 16.085 mm 132,900 to 192,950 mm «132,938 to 192,958 mm Warpage at Cylinder Head Mounting Suriace (TOTAL)... 0.075 mm Within any 25 mm Diameter Area (Maximum) 0.02 mm Cylinder Block Engine Serial Number 44487830 and After Type Wet Sleeved Material nnn nnn sn Cast Iron Main Bearing Bore “104.987 to 105.013 mm ‘Camshaft Bore £63,987 to 64.013 mm Liter Bore -». 16.000 to 16.080 mm Maximum Service Limit 16.050 mm Cylinder Sleeve Bore Cylinder Sleeve Counterbore ... "190,900 to 180.950 mm 130.998 to 190.958 mm Warpage at Cylinder Head Mounting Surface (TOTAL).. 0.075 mm Within any 25 mm Diameter Area (Maximum) 0.02 mm Cylinder Sleeve Prior to Engine Serial Number 44487830 Type Wet, Can Be Replaced Material Cast Iron ‘0D of Cylinder Sleeve (At Top of Piston). 192,947 to 132.949 mm 1D of Cylinder Sieeve 114.000 to 114.040 mm Maximum Service Limit 114.117 mm Maximum Out of Round (Installed in Bloc). 0.04 mm Maximum Taper (installed in Block) 0.04 mm Sleeve Protrusion Above Block 0.015 t0 0.109 mm Cylinder Sleeve Engine Serial Number 44487830 and After ype Wet, Can Be Replaced Material sn sn Cast Iron OD of Cylinder Sleeve (Al Top of Piston, "192.947 to 132.049 mm 1D of Cylinder Sleeve 114.000 to 114.040 mm Maximum Service Limit . se ann snnnnee M847 mM Maximum Out of Round (Installed in Sock). 0.04 mm Maximum Taper (installed in Block) 0.04 mm Sleeve Protrusion Above Block "0,025 10 0.122 mm Piston Pin Type «Full Float OD af Pin 144,97 to 45.002 mm Maximum Service Limit. 44,993 mm Pinto Piston Clearance (0.008 to 0.015 mm Pin to Rod Bushing Clearance 002 t 0.088 mm ac 8.20026 Revised 2.06, Prntadia USAPiston Type. Material OD at 12 mm trom the Bottom, Degrees from Piston Pin Standard Size Piston Minimum Service Limit 1D of Piston Pin Bore Maximum Service Limit Width of st Ring Groove (Top). Width of 2nd Ring Groove (Intermediate). Width of 3 Ring Groove (Oil Ring) Prottusion Above Cylinder Block (Maximum) Prottusion Above Cylinder Block (Minimum) Piston Rings No. 1 Compression 67830 and 6TABGO End Gap in 114.020 1D No. t Compression 6-830 Engine End Gap in 11.4020 1D Side Clearance. No. 2 Compression, End Gap in 114.020 1D Side Clearance. No. 2 Compression, End Gap in 114.020 1D Side Clearance. No.3 Oil Cantrol Fings End Gap in 11.4020 1D Side Clearance. NOTE: Add 0.09 mm gap for every 0.03 mm of bore wear up to maximum worn limit. Cylinder Head Cyiinder Head Height (New). ‘Warpage (Maximum) Side to Side ‘Warpage (Maximum) Total Across Head Maximum Material Removal Minimum Head Height Now Head Thickness. Valve Guide Bore. Insert Bore (Intake) Insert Bore Depth (Intake) Insert Bore (Exhaust) Insert Bore Depth (Exhaust) Local Flatness (Maximum) 81 mm Area Lifters Material OD of Litter Minimum Service Limit ac 8.20426 2408-5 (Cam Ground ‘Aluminum Alloy 118.814 to 119.886 113.776 mm 45.006 to 45.012 mm 45.025 mm 3.50. mm 3.08 10 3.10 mm 4.040 to 4.060 mm 0.380 mm 0.018 mm Keystone Type (Bartel Face) (0.35 to 0.65 mm (See Note) Keystone Type (Bartel Face) (0.35 to 0.65 mm (See Note) Use Keystone Gauge Rectangular Type (Taper Face) (0.35 to 0.65 mm (See Note) 0.70 0 0.125 mm Keystone Type (Barrel Face) (0.35 to 0.65 mm (See Note) Use Keystone Gauge “Two Piece (0.30 to 0.60 mm (See Note) 0,020 to 0.088 mm 118.75 to 116.25 mm 0.076 mm 0.20 mm 4.00 mm 114.75 mm 118.75 to 116.25 mm 16.931 to 15.971 mm 53897 to §3.927 mm 12,00 to 12.20 mm 46,997 to 47.027 mm 9,63 to 9.83 mm 0.0254 mm Hardened Iron 18,929 to 15.980 mm 15,925 mm Revised 2.06 Pontadin USA2408-6 Connecting Rod Bushing Bushing ID Installed (Ream to Size). Bearing Liners. Journal 1D Without Bearing Liners Bearing Oil Clearance Side Clearance Maximum Service Limit Connecting Rod Bend (Maximum) Without Bushing With Bushing ‘Connecting Rod Twist (Maximum) Without Bushing With Bushing Crankshaft Type Main Bearing Liners. Crankshaft End Clearance Maximum Service Limit Genter Main Bearing Thrust Surface Thickness. Connecting Rod Journal OD Standard Maximum Service Limit 0.25 mm OD Undersize, Grind to Maximum Servic Limit 0.50 mm OD Undersize, Grind to Maximum Servic Limit 0.75 mm OD Undersize, Grind to Maximum Service Limit 1.00 mm OD Undersize, Grind to Maximum Service Limit Connecting Rod Journal Maximum Taper. Journals Out of Round Maximum Undersize Main Bearing Liners for Service. Main Bearing Oil Clearance Main Bearing Journal 0D, Standard. Maximum Service Limit 0.25 mm OD Undersize, Grind to Maximum Service Limit 0.50 mm OD Undersize, Grind to Maximum Service Limit 0.75 mm OD Undersize, Grind to Maximum Service Limit 1.00 mm OD Undersize, Grind to Maximum Service Limit Main Bearing Thrust Surfaces Standard 0.25 mm Oversize. 0.50 mm Oversize. Main Bearing Journal Bore ID No Liners Main Journal With ‘st, 2nd, Sd, Sth and 6th ath Connecting lod Journals Wicth ac 8.20026 Steel Backed Leaded Bronze 45.028 to 45.035 mm Replaceable {80.987 to 81.013 mm 0.093 100.117 mm (0.100 to 0.900 mm 0.330 mm 0.200 mm 0.150 mm 0.500 mm 0.300 mm Hardened Steel, Balanced Replaceable (0.187 to 0.384 mm 0.381 mm 3.447 to 3.580 mm 75,987 to 76,013 mm 75,962 mm (See Note) 75,737 to 75.763 mm 75.712 mm 75.487 to 75.513 mm 75.462 mm 75.237 to 75,263 mm 75.212 mm 74,987 to 75.013 mm 74,962 mm 0.013 mm 0.050 mm (0.25, 0.50, 0.75 and 1.00 mm 0.66 to 0.134 mm 97,987 to 98.013 mm 97.962 mm (97.737 to 97.763 mm 97.712 mm (97.487 to 97.513 mm 97.462 mm {97.237 to 97.263 mm 97.212 mm 196.987 to 97.013 mm 96.972 mm 42.975 to 43,076 43.225 to 43, 926 43.475 to 43.576 404,987 to 105,013 mm 42,924 to 43.078 mm 42.975 to 43.025 mm 145.950 to 46.050 mm Revised 2.06, Prntadia USA2408-7 Camshaft Type. Chilled Iron Bushings. 7, Replaceable Bushing Lubrication Bushing Lubrication Pressure Lubricated Oil clearance 0.045 to 0.123 mm 1D of Bushings (Installed) 60.058 to 60.110 mm Maximum Service Limit 60.122 mm Width of Bushing 24,75 t0 25.25 mm Camshaft Journal OD 59.987 to 60.013 mm Minimum Service Limit 58.962 mm Camshaft Bore Diameter in Block Bushing Bore 68.987 to 64.013 mm Camshaft Thrust Thickness. 9.42 10 9.58 mm Minimum Service Limit 9.34 mm Camshaft Thrust Clearance 0.420 t0 0.340 mm Maximum Service Limit 0.470 mm Turbocharger Horizontal Travel of Turbine Shat 0.038 to 0.093 mm Rial Travel of impel. 0.326 to 0.496 mm Gear Train Backlash Crankshaft Gear to Camshaft Gear 0.182 to 0.254 mm CGrankshat Gear to Idler Gear 0.08 0 0.38 mm Camshaft to Fuel Pump Gear. (0.182 to 0.254 mm Maximum Service Limit (Fuel Pump Gear) 0.38 mm Idler Gear to Oil Pump. (0.182 to 0.254 mm Camshaft to Auxiliary 0.152 to 0.254 mm Maximum Service Limit (All Gears Except as Noted) 0.45 mm Rocker Arm Assembly 0D to Shatt 22.219 to 22.281 mm Minimum Service Limit 22.199 mm ID of Arm Bore... 22,256 to 22,282 mm Maximum Service Limit 22.301 mm Lubrication Pressure trom Oil Gallery ac 8.20426 Revised 2.06 Pontadin USA2403-8 Intake Valve ‘Tappet Clearance (Cold) Face Angle Face Run-Out Valve Head Edge Thickness, Minimum Length (0D of Stem: Minimum Service Limit. (00 of Head. Seat Angle Seat Contact Width Seat Run-Out Insert Height. 0D of Valve insert ID of Valve Insert Valve Recession Below Head Surface ID of Valve Guide Bore (Installed in Head) Valve Guide Installed Height Exhaust Valve “Tappet Clearance (Cold) Face Angle Face Run-Out Valve Head Eidge Thickness, Minimum OD of Head 0D af Stem Minimum Service Limit Length Insert Seat Angle Seat Contact Width Seat Rur-Out Insert Height 0D of Insert 1D of Inset Valve Recession Below Head Surface. 1D of Valve Guide Bore (Installed in Head) Valve Guide Installed Height Valve Springs Standard Spring Free Length ‘Compressed to 37.90 mm Maximum Service Limit Valve Rotator Spring Free Length ‘Compressed to 35.89 mm Oil Pressure Regulator Spring: Free Length ‘Compressed to 60.3 mm ac 8.20026 0.30 mm 30 Degrees 0.038 mm 4.50 mm 180.65 to 151.21 mm 9.48 t0 9.50 mm 9.46 mm 59.897 to 63.927 mm 30 Degrees 4.98 to 1.98 mm 0.05 mm 8.06 to 8.32 mm 533.992 to 64.008 mm 44,37 to 44.63 mm 4.09 to 1.62 mm 9.539 to 9.559 mm 20.85 t0 21.16 mm 0.60 mm 4 Degrees 0.038 mm 4.50 mm 45.87 to 46.13 mm 9.48 to 9.50 mm 9.48 mm 180.60 to 151.16 mm 45 Degrees 1.92 to 2.68 mm 0.038 mm 6.20 10 6.48 mm ‘47.092 to 47.108 mm 39.87 to 40.13 mm 1,09 to 1.62 mm 9.539 to 9.559 mm 22.50 to 23.01 mm 65.86 mm 959.5 to 1060.5 N 940N 62.05mm 995 to 1095 N 86.61 mm 1726N Revised 2.06, Prntadia USASPECIAL TORQUES Alter Cooler Botts Alternator Bracket Bolts (Lower) Alternator Bracket Bolts (Upper) Alternator Retaining Bolt Belt Tensioner Bracket Bolts Belt Tensioner Retaining Bot. Camshaft Thrust Plate Connecting Rod Bolts ‘Torque Plus Angle Method (Lubricate Threads with Engine Oil) Standard Torque Step Method Exhaust Manifold Bolts Fan Pulley Bracket Bolts Fan Pulley Bolts Grade 88 Size M8 Grade 10.9 Size MB Grade 8.8 Size M10 Grade 10.9 Size M10. Flywheel Housing Bolts Flywhee! Retaining Bolts Flywheel Housing Cover Bolts Fuel Filter inlet Bolt Fuel Air Removal Bolt Fuel Filter inlet Nut Fuel Line Fiting (High Pressure) Fuel Line Fiting (Low Pressure) Front Cover Bolts Crankshaft Dampener Pulley Cylinder Head Bolts - Prior to Engine Serial Number 44487820 (Lubricate the Threads with Engine Oil). 2408-9 Metric Valve 211027 Nm 2110.27 Nm 2110.27 Nm 2110.27 Nm 210.27 Nm 390 47 Nm 21 10.27 Nm 70 Nm Plus 60 Degrees ‘sl. 40Nm 2nd. 80 Nm 3rd. 120 Nm 39 t0 47 Nm 21 1027 Nm 261031 Nm 37 to 43Nm 51 to 62.Nm 51 to 62. Nm 54 to 66 Nm 190 to 144 Nm 21 to 27 Nm 29 to 95 Nm 710 9Nm 13t0 17 Nm 21 to 27 Nm 181017 Nm 21 1027 Nm 188 to 212 Nm 200.Nm Cylinder Head Bolts Engine Serial Number 44487830 and Altar (Lubricate Threads with Engine Ol) ‘Short Bolts Long Bolts Injection Pump Drive Gear Nut Model A Model MW Model P Model EP-9 Nippondenzo Injection Pump Retaining Nuts. Injection Pump Timing Pin Cover Model A Model MW Model P Model EP-9 Nippondenzo Injector Leak Off Bot. Injector Retaining Bolt Intake Manifold Bolts Engine Lift Bracket Bolts Main Beating Bolts ‘Torque Plus Angle Method (Lubricate the Threads with Engine Oil) Standard Torque Step Method ac 8.20426 70 Nm Plus 90 Degrees 142 Nm Plus 90 Degrees 92Nm 404Nm 195 Nm 4104Nm 39 t0 47 Nm 30Nm 30 Nm 30 Nm 70 Nm 81010 Nm 21 t0.27 Nm 21 t0 27 Nm 71 to 88. Nm 95 Nm Plus 60 Degrees ‘st. 50.Nm 2nd. 119 Nm 3rd. 176 Nm Revised 2.06 Pontadin USA2408-10 il Pan Drain Plug. 76 to 84 Nm il Pan Heater Plug 76 to 84 Nm il Pan Retaining Bot... 21 to 27 Nm Ci Pump Retaining Bots 24 to 27 Nm il inlet Tube Bott... .-Bto 10 Nm Oil inlet Tube Brace Bott. .-Bt0 10 Nm il Filter Housing Bott... 21 to 27 Nm Rear Seal Retaining Botts.. .-Bto 10 Nm Rocker Arm Bal... 40 t0 45 Nm Starter Retaining Bott... 730 82 Nm ‘Thermostat Housing Bots.. 24 to 27 Nm Timing Pin Retaining Bolts 4t06Nm Fuel Shutoft Solenoid Botts 810 12Nm “Turbocharger Mounting Nuts 29 to 35. Nm Turbocharger Mounting Nuts (HX40W), ABN ‘Turbocharger Drain Tube Bots. 24 to 27 Nm ‘Turbocharger Oil Supply (Both Ends)... 24 to 27 Nm Turbine Housing Bots - .-9t0 13 Nm “Turbine Housing Botts (HX40W).. 20Nm Genter Housing to Back Plate Bott, 5107Nm ‘Compressor Housing Bots. 5107Nm ‘Compressor Lock Nut 430 15Nm. ‘Thrust Bearing Sorews (Torx Head) sos 19 6 Nm Water Pump Mounting Bots 24 to 27 Nm Coolant Outlet Bots 24 to 27 Nm Valve Cover Bot... 24 to 27 Nm Primer Pump Botts 24 to 27 Nm Oil Pressure Plug, 76 to 84 Nm NOTE: Case Corporation reserves he right fo make improvements in dsign or changes specication a any tne without incuring any sbigaton to instal tam on uns previously sel, ac 8.20026 Revised 2.06, Prntadia USASection 2415 CYLINDER HEAD AND VALVE TRAIN 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting perts, ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA EASE CANADA CORRORATION) (© 1906 Case Corporation 3950 South Service Road Pined RUS Burlington, ON L7N 3M6_ CANADA Rac 8.2844 January, 1987 (Revised March, 1996)2415-2 TABLE OF CONTENTS ‘SPECIFICATIONS .... ‘SPECIAL TORQUES ... SPECIAL TOOLS... ‘SERVICE THE CYLINDER HEAD AND VALVE TRAIN Cylinder Head Removal... Cylinder Head Disassembly and Inspection .. EXPANSION PLUG REMOVAL AND INSTALLATION ... 18 mm Expansion Plugs .. ‘58 mm Expansion Plugs .. INSPECTION OF THE VALVES AND VALVE SEATS ... VALVE SEAT REMOVAL AND INSTALLATION ... REFACING INTAKE VALVES, EXHAUST VALVES AND VALVE SEATS .. DIAGNOSIS OF DIFFERENT DYE PATTERNS 45 Degree Exhaust Valve. 30 Degree intake Valve Only Valve Installation ... Rocker Arm Disassembly and inspection Rocker Arm Assembly Cylinder Head Installation CYLINDER HEAD TORQUE .. Prior to Engine Serial No. 44487890 .... Engine Service No, 44487890 and After CYLINDER HEAD ASSEMBLY .. LOCATING TOP CENTER .. ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE ... ac e.20404 Revised 2.06, Prntadia USA2416-3 SPECIFICATIONS Intake Valve Guide installation Spectications: Valve Guide Diameter 16,988 to 16.000 mm Diameter of Bore 16,931 to 15.971 mm Installed Height vs 20,65 t0 0.089 mm Press Fit v~: 0,017 t0 0.069 mm Exhaust Valve Guide Installation Specifications Valve Guide Diameter 16,988 to 16.000 mm Diameter of Bore 16,931 to 15.971 mm Installed Height vs 22.50 t0 23.01 mm Press Fit v 0,017 to 0,089 mm Exhaust Valve Insert Specifications: Diameter of insert Diameter of Bore Depth of Bore Press Fit 47,092 to 47.108 mm 46,997 to 47.027 mm 9.630 0.111 mm 0.088 to 0.111 mm Intake Valve Insert Specifications: Diameter of insert 53,992 to 64,008 mm Diameter of Bore 53,907 to 63.927 mm Depth of Bore vos 12,00 0 12.20 mm, Press Fit 0.088 to 0.111 mm Valve Spring Specifications: For Non Rotating Valves Free Length... 65.66 mm Outside Diameter 35.33 mm Number of Coils sonnei TS ‘Compress to 50.80 mm 1 465 10 514N For Rotating Valves Free Length 62.05 mm Outside Diamet 35.33 mm Number of Coils 72 Compress to 48.79 mm 464,80 to 513.80 N Cylinder Head Specifications: New Cylinder Head Height 118.75 10 116.25 mm Maximum Amount of Material That Can Be Removed During Resurfacing 4.0 mm Minimum Head Height. 114,75 mm Injector Tip Protrusion 3.0 to 40mm ac -204a4 Revised 2.06 Pinesin USA2415-4 SPECIAL TORQUES Metric Value Exhaust Manifold Bots 8047 Nm Fuel Fier inet iting 21t027Nm Fuel Fier Ott Fiting 21t027Nm Injection Pump ine iting 131017 Nm Injection Punp Leek Of Fiting 131017 Nm Fuel Line Leak Of iting 710 98m Fuel Fier Adapter Nut 2910 35 Nm Injctor Retaining Bot 21027 Nm Cylinder Head Bots Prior to Engine Serial Number 44487890 200 Nm Cylinder Head Bots Engin Serial Number 44487890 and After ShOrt BOMS ...ccerssseen “ soso oe : “ : oe 70 Nm Plus 90 Degrees Long BOIS ss . sn 7 sonssnnes 42 Nm Pas 90 Dogrees Intake Manifold Bots. . sn 7 son sous 211027 Nn Rooker Arm BOS ss . sons . sons soe 211027 Nn Valve Cover Bolts : : : : ~ : 21 to 27 Nm SPECIAL TOOLS er ‘©AS-1815, INJECTOR PULLER. (CAS-10564 ADAPTER NUT, (CAS-10828 VALVE GUIDE TOOL CCAS-1057 VALVE GUIDE REAMER. ‘OAS-1069 VALVE SEAT PULLER, (CAS-2162 TORQUE ANGLE GAUGE ac e.20404 Revised 2.06, PrntesinUSA.2418-5 SERVICE THE CYLINDER HEAD AND VALVE TRAIN Cylinder Head Removal STEP 1 STEP 4 ‘See Section 2466 to remove the turbocharger. STEP 2 | Remove the fitings, gaskets and the leak off ne STEP 3 Disconnect the injection lines from the injectors and the injection pump. Remove the injection lines. ac -204a4 Remove the injector retaining bolts and the injector holders. STEP 5 [ADAPTER Install the injection puller adapter. Install a slide hammer in the adapter and remove the injector. NOTE: Make sure the injector seal is removed from the cylinder head. STEP 6 Remove the fitings and the fuel inlet line. Revised 2.06 Pinesin USA2415-6 STEP 7 STEP 10 Remove the return line, fing and gaskets. NOTE: There are two gaskets on the return fitting, one (on each side of the return line. STEP 8 Disconnect and remove the fuel line. STEP 9 Use a strap wrench to remove the fuel fiters. ac e.20404 Remove the nut that holds the fuel fiter housing and remove the fiter housing, STEP 11 Remove the fuel fite inlet fiting, STEP 12 Remove the hose clamp, clamp batt andthe breather tube from the engine. Revised 2.06, PrntesinUSA.2816-7 STEP 13 STEP 16 Remove the valve cover bolts and the valve cover. Remove the exhaust manifold bolts and the exhaust manifold STEP 14 STEP 17 Remove the intake manifold cover bolts and the intake manifold cover. Disconnect and remove the coolant bypass tube. STEP 15 STEP 18 ‘Clean the intake manifold mounting surtaces of all foreign Remove the rocker arm bolts andthe rocker arm assembly. material ac -204a4 Revised 2.06 Pinesin USA2815-8 STEP 19 Be ia Remove the rocker arm oll supply tube and the push rods. IMPORTANT: If the rocker arm oil supply tube is made ‘of nylon material the supply tube must be replaced. STEP 20 Remove the cylinder head bolts and the cylinder head. Cylinder Head Disassembly and Inspect STEP 22 Put the cylinder head on a clean work surace. ac e.20404 STEP 21 REE Cover the cylinder bores and pistons. Clean all foreign ‘material from the cylinder head mounting surface. NOTE: The cylinders and pistons must be covered to prevent damage to the pistons and cylinder walls. STEP 23 Ela e Mie 01080 Using paint, make a mark on the valves, keepers and retainers, This will make sure the parts are installed in their original locations, Revised 2.06, PrntesinUSA.STEP 24 Push the valve springs down with a valve spring compressor and remove the valve keepers STEP 25 Remove the valve spring retainers and the valve springs. NOTE: Certain engines are equipped with valve rotators in place of retainers, STEP 26 Remove the valve and valve guide seals from the cylinder head. Discard the valve guide seals ac -204a4 2415-9 Remove and discard the valve spring seat from the cylinder head (i Equipped), STEP 28 Clean the cylinder head completely, removing carbon and ‘other deposits. Check for cracks and any sign of damage in the area of the fre ring contact. STEP 29 Prat0608 Install an injector with a standard injector seal into each injector bore in the cylinder head. Revised 2.06 Printed in USA,2415-10 STEP 30 STEP 32 Install the injector retaining bolt and tighten to a torque of 24 Nm. STEP 31 2181088, Turn the cylinder head over and use a gauge block to measure the injector tip protrusion. Tip protrusion must be 3.0 to 4.0 mm. If tip practoring is nat within specifications, the injector bore seal band area may need to be machined and ‘an oversize injector seal installed ac 8.20434 Check the cylinder head surface for warpage. Use a straight ‘edge and feeler gauge. Clean the machined surface of the head. Use a heavy, accurate straight edge to check for warpage at each side and between all cylinders. Also, check for end-to-end warpage in six positions or more, IMPORTANT: If the measurement is more than 0.020 ‘mm, the cylinder head must be machined or replaced, Replace the cylinder head if the head height is less than 115.75 mm, after the head is machined. STEP 33 sat Check the valve guides in three positions with a bore gauge. Revised 2.06, PrntesinUSA.STEP 34 -To1048, Check the bore gauge with a micrometer. If the diameter is more than 9.559 mm a new valve guide must be installed. STEP 35 Use the valve guide tool and a hydraulic press to remove the valve guides. Press on the bottom of the valve guides. STEP 36 Use the valve guide tool and a hydraulic press to install the valve guides Press onthe top surface of the valve guides, ac -204a4 2816-11 STEP 37 2066 10 21.16mm INTAKE sono ‘Check the installed height of the intake valve guides. Use a depth micrometer. The distance from the top of the valve {Quide to the bottom ofthe recess must be 20.65 to 21.16 mm. Revised 2.06 Printed in USA,2815-12 STEP 38 STEP 39 erro Use an 9 mm dri bit to drill the guides to size, Ream the valve guides toa diameter of 9.539 to 9.559 mm, 225070 2201 mm EXHAUST ono ‘Check the installed height ofthe exhaust valve guides. Use a depth micrometer. The distance from the top of the valve {Quide to the bottom of the recess must be 22.60 to 23.01 mm. ac e.20404 Revised 2.06, PrntesinUSA.2816-18 EXPANSION PLUG REMOVAL AND INSTALLATION 18 mm Expansion Plugs STEP 40 Remove the expansion plug from the cylinder head, STEP 41 eS, Clean the sealing surface of al foreign material STEP 42 Apply Loctite 277 to the sealing surface of the expansion plug, ac -204a4 STEP 43 cHAMFER EDGE EXPANSION PLUG 9010 Install the expansion plug into the cylinder head until the top ‘edge of the expansion plug is even with the bottom edge of the chamfer. Revised 2.06 Pinesin USA2815-14 58 mm Expansion Plugs STEP 44 STEP 47 Remove the expansion plug from the cylinder head, STEP 45 Clean the sealing surface of al foreign material STEP 46 Apply Loctite 277 to the sealing surface of the expansion plug. ac e.20404 EXPANSION PLUG ‘CHAMFER EDGE a0ato Install the expansion plug into the cylinder head until the top edge of the expansion plug is even with the bottom edge of the chamfer. Revised 2.06, PrntesinUSA.2816-15 INSPECTION OF THE VALVES AND VALVE SEATS. STEP 48 Clean the valves with a power driven wire brush. Do not scratch the valve stems, STEP 49 Check the valves forthe following conditions. VALVE STEM WITH A NARROW NECK oo 58918 NOTE: REPLACE THE VALVE IF THE CONDITION occurs. ‘This Condition Can be Caused by: 1. Valve does not have lubrication, 2, Restriction in the water passages. 3. Operating the engine under continued overload at too ‘much engine APM. GROOVE IN VALVE FACE oD sos NOTE: GRIND OR REPLACE VALVE IF THIS CONDITION OccuRS. This condition can be caused by foreign material entering the engine through the intake system or not giving service to the air intake system. ac .20434 STEP 49 (Cont'd) FINE PITTING sone NOTE: THIS IS A NORMAL CONDITION. Small amounts of very fine pitting can be found on the surfaces of the valve face or seat after the valves are leaned. These are normal and will not change the engine performance. This fine pitting is caused by normal oxidation procedure and can occur on any engine during the run-in- period. HEAVY CARBON AND VARNISH DEPOSITS. sot. NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDITION OccuRS. This condition is generally caused by worn valve guides or bad seals on the valves, permitting oil to go by the valves, Low operating temperature is a secondary cause. Worn piston rings and cylinder walls will also permit too much oil to reach the combustion chamber. RUST OR PITTING ON VALVE STEM. NOTE: REPLACE VALVE IF THIS CONDITION occurs. ‘This condition can be caused by using bad quality engine cil ‘or fuel and by not correctly Keeping the engine in storage, Revised 2.06 Printed in USA,2415-16 STEP 49 (Cont'd) RUST OR PITTING IN VALVE FACE ese.0 NOTE: THIS CONDITION CAN BE CAUSED BY USING BAD QUALITY ENGINE OIL OR FUEL. DEEP BURNED VALVE FACE 5708 CONCAVE VALVE HEAD NOTE: IF EITHER OF THESE CONDITIONS OCCUR, REPLACE THE VALVES. ‘These conditions are generally caused by running the engine at very high engine temperatures, grinding the valve face too thin or valve grinding that is not correct. WORN RETAINER GROOVE some WORN STEM TIP NOTE: IF EITHER OF THESE CONDITIONS OCCUR, REPLACE THE VALVE. ac 8.20434 STEP 50 INTAKE VALVES 946 70.9500 mm 1246 T0 9.500 mm 24670 9500mm aomo Check the intake valve stem diameter at three points along the stem. Ifthe stem diameter is less than 9.46 mm, the valve must be replaced, EXHAUST VALVES, 246 T0 9.500 mm aa7o Check the exhaust valve stem diameter at three points as shown, Ifthe stem diameter is less than 9.46 mm or the stem tip diameter is less than 9.46 mm, the valve must be replaced. Revised 2.06, PrntesinUSA.STEP 51 EXHAUST VALVE WITH REPLACEABLE SEATS 1.52 mm MAX. e981 ac .20434 2816-17 INTAKE VALVES WITH REPLACEABLE SEATS 1.52 mm MAX \\ Put the valves in the cylinder head and check to see if the valve heads are recessed in the cylinder head. If the valve head is recessed more than 1.62 mm below the cylinder head surface, the valve must be replaced or a valve insert must be installed to make sure that there is equal compression ratios between cylinders, Revised 2.06 Printed in USA,2815-18 VALVE SEAT REMOVAL AND INSTALLATION STEP 52 VALVE | ‘CYLINDER HEAD. VALVE sear PULLER onto Pot the valve seat puller into the valve cavity and tighten the adjusting nut so thatthe puller is located against the bottom of the valve seat. NOTE: Never try to remove the valve seats with a center punch, cold chisel, prybar, etc. STEP 53 ‘SET SCREW ‘Side the collar over the valve seat puller and tighten the set ‘screw. Place the small OD end ofthe collar against the valve sseat when removing the exhaust valve seat and place the large OD end of the collar when removing the intake valve seal, ac 8.20434 STEP 54 ae Install the adapter nut and puller on the valve seat puller and remove the valve seat STEP 55 Clean the recessed area in the cylinder head, Put new valve seats in dry ice to shrink the valve seats for easy installation, Use a driver and install the valve seats. Revised 2.06, PrntesinUSA.2816-19 REFACING INTAKE VALVES, EXHAUST VALVES AND VALVE SEATS STEP 56 STEP 57 ‘The 45 degree exhaust valves are smaller in diameter than VALVE AND SEAT GRINDING ANGLES the intake valves. ‘The 90 degree intake valves are larger in diameter than the wee exhaust valves. 30 DEGREE VALVE ‘aa pEGREE ANGLE Z| 45 DEGREE VALVE secre \S—— sp oecree S<— ANGLE SINGLE. 7 oto Ii dimension A and B is less than 1.5 mm, the valve must be replaced. NOTE: Use a precision seat grinder. Take very light cuts with the grinding stones so just enough metal is removed, to end up with a good smooth seat finish. ac .20434 Revised 2.06 Printed in USA,2815-20, STEP 58 VALVE BLUE OYE. Put a small amount of blue dye on the valve face. Install the valve in the head and rotate the valve on the seat. STEP 59 ss CHECK OVE PATTERN Remove the valve and look at the contact area on the a valve face and seat. The blue dye will be gone from the valve \where the valve made contact withthe seat ac e.20404 STEP 60 30 DEGREE VALVES em6L0 45 DEGREE VALVES srs Correct refacing of valves and seats will give a dye pattern as shown, NOTE: if the dye pattern is other than the patterns shown, check the diagnosis of the different dye patterns (nthe following pages. Revised 2.06, PrntesinUSA.2815-21 DIAGNOSIS OF DIFFERENT DYE PATTERNS. 45 Degree Exhaust Valve ‘SEAT CONTACT AREA ON THE VALVE TO LOW a, ‘CONTACT AREA gore I THE CONTACT AREA OF THE VALVE ON THE VALVE SEAT LOOKS LIKE THI. \ USE A 45 DEGREE STONE To LIFT THE CONTACT AREA, bots | USE A 60 DEGREE STONE To LIFT AND NARROW THE LOWER CONTACT AREA. cs Aq 80.04 | seaLoec | MAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.52 mm BELOW "THE CYLINDER HEAD SURFACE, s68L040 N | IF THE VALVE HEAD IS RECESSED MORE THAN 1.52 mm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. ac -204a4 a |F THE CONTACT AREA OF THE VALVE ON VALVE SEAT LOOKS LIKE THIS (A SEAT THAT HAS BEEN GROUND), | asnea USE A 45 DEGREE STONE TO LIFT AND \WIDEN THE CONTACT AREA Y serio USE A 60 DEGREE STONE TO NARROW THE LOWER CONTACT AREA WHICH WAS INCREASED BY THE 45 DEGREE STONE. serie ‘MAKE SURE THAT THE VALVE HEAD Is NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE. Y; s6r.40 IF THE VALVE HEAD Is RECESSED MORE THAN 4152 mm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. Revised 2.06 Printed in USA,2815-22 45 Degree Exhaust Valve SEAT CONTACT AREA ON THE VALVE TO HIGH a ‘CONTACT AREA 89194 |THE CONTACT AREA OF THE VALVE ON IF THE CONTACT AREA OF THE VALVE ON THE VALVE SEAT LOOKS LIKE THIS (A SEAT TH YALE SEAT L0G LE Ts ao masses 8944 40.944 ‘THE VALVE MUST BE REPLACED AND A VALVE SEAT MUST BE INSTALLED BECAUSE MORE t USE A 45 DEGREE STONE TO LOWER AND GRIING WR NOT CHANGE THE LOWER YSEA45 OEOREE STONE TC S80.080, N | USE A 30 DEGREE STONE To NARROW THE UUBPER CONTACT AREA VIKICH WAS INCREASED BY THE 45 DEGREE STONE, S MAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE Ce \N | IF THE VALVE HEAD IS RECESSED MORE THAN {uszmm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. 3891940 ac 8.20434 Revised 2.06, PrntesinUSA.2415-23 45 Degree Exhaust Valve Contact Point ‘SEAT CONTACT AREA ON THE VALVE TO NARROW em (CONTACT AREA svo.oee IF THE CONTACT AREA OF THE VALVE ON IF THE CONTACT AREA OF THE VALVE ON THE VALVE SEAT LOOKS LIKE THIS, THE VALVE SEAT LOOKS LIKE THIS (A SEAT THAT HAS BEEN GROUND). A | sra.s4a THE VALVE MUST BE REPLACED AND A VALVE ‘SEAT MUST BE INSTALLED BECAUSE NORE USE A 45 DEGREE STONE TO INCREASE THE GRINDING WILL NOT CHANGE THE LOWER CONTACT AREA Contacr POINT, 570.988 MAKE SURE THAT THE VALVE HEAD I NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE. N 12mm arose | THE VALVE HEAD IS RECESSED MORE THAN. 1152 mm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. ac .20434 Revised 2.06 Printed in USA,2815-24 45 Degree Exhaust Valve ‘SEAT CONTACT AREA ON THE VALVE TO WIDE JA So AREA arise IF THE CONTACT AREA OF THE VALVE ON IF THE CONTACT AREA OF THE VALVE ON ‘THE VALVE SEAT LOOKS LIKE THIS. ‘THE VALVE SEAT LOOKS LIKE THIS (A SEAT S ‘THAT HAS BEEN GROUND). Y Stee USE A 30 DEGREE STONE TO LOWER THE \ smite! UPPER CONTACT AREA, STiL9AB LSE A 60 DEGREE STONE To LIFT THE LOWER, ‘CONTACT AREA, USE A 30 DEGREE STONE TO LOWER THE UPPER CONTACT AREA, aTiLa4 USE A 60 DEGREE STONE To LIFT THE LOWER, CONTACT AREA. Anus ariLse STiL9AD MAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.52 mm BELOW THE CYLINDER HEAD SURFACE, IF THE VALVE HEAD Is RECESSED MORE THAN | ruses RRA PLAGE Te VALVE AND METAL A FE VALVE HEAD 1 RECESSED MORE THAN {mn neeLAGe TE VASE AND RETA waatear paced vend 396 PrntesinUSA.2415-25 45 Degree Exhaust Valve THIS IS THE CORRECT VALVE SEAT CONTACT [AREA ON THE VALVE & ‘CONTACT AREA | THE CORRECT EXHAUST VALVE CONTACT [AREA ON THE SEAT WILL GIVE A SEAT WIDTH OF 147 10.207 we, amma | amaec ‘CORRECT REFAGING OF THE EXHAUST VALVE AND VALVE SEAT WILL GIVE A' DEGREE INTERFER ENCE ANGLE WHICH I IMPORTANT FOR CARBON CCUTTING ANO VALVE SEATING. IF THE VALVE HEAD IS RECESSED MORE THAN {is2mm, REPLACE THE VALVE AND INSTALL A Valve SEAT. ac -204a4 Revised 2.06 Printed in USA,2415.26 30 Degree Intake Valve Only SEAT CONTACT AREA ON THE VALVE TO LOW Se ‘AREA ora I Conacr AREA OF THe VALVE On i cover AREA oF TH VALEON Th ace a RSE ‘er ac aba CORSE Sear y Tartan caotnn — ss Use Asnoeonee stone To LET THe | \WIDEN THE CONTACT AREA USE A 4s DEGREE OR 60 DEGREE STONE TO NARROW THE LONER CONTACT AREA. USE Ads DEGREE OF 60 DEGREE STONE TO NARROW THE LOWER CONTACT AREA INCREASED BY THE 30 DEGREE STONE. sree ‘MAKE SURE THAT THE VALVE HEAD Is NOT RECESSED MORE THAN 1.52 mm BELOW | ‘THE CYLINDER HERD SURFACE. 7a. 088 WAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.82 mm BELOW ‘THE CYLINDER HEAD SURFACE. 152mm \ == Ss | pase N IF THE VALVE HEAD Is RECESSED MORE THAN Lrauo4> 41.52 mm, REPLACE THE VALVE AND INSTALL A { VaLve SEAT \F THE VALVE HEAD Is RECESSED MORE THAN 4152'mm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. ac e.20404 Revised 2.06, PrntesinUSA.2416-27 30 Degree Intake Valve ‘SEAT CONTACT AREA ON THE VALVE TO HIGH “Ze ‘CONTACT AREA soar IF THE CONTACT AREA OF THE VALVE ON IF THE CONTACT AREA OF THE VALVE ON ‘THE VALVE SEAT LOOKS LIKE THIS. THE VALVE SEAT LOOKS LIKE THIS (A SEAT THAT HAS BEEN GROUND), ig ane wysrae peptcen a avave | SEAT MUST BE INSTALLED BECAUSE MORE USE A 30 DEGREE STONE To WIDEN GRINDING WILL NOT CHANGE THE LOWER AND LOWER THE CONTACT AREA. Contact Pom, | THE VALVE HEAD IS RECESSED MORE THAN 1152 mm, REPLACE THE VALVE AND INSTALL R VALVE SEAT. sraose USE A 15 DEGREE STONE TO LOWER THE UPPER CONTACT AREA, sraLoc MAKE SURE THAT THE VALVE HEAD Is NOT RECESSED MORE THAN 1.52 mm BELOW THE CYLINDER HEAD SURFACE, basso | IF THE VALVE HEAD IS RECESSED MORE THAN {is2mm, REPLACE THE VALVE AND INSTALL A Valve SEAT. ac -204a4 Revised 2.06 Printed in USA,2415.28 30 Degree Intake Valve ‘SEAT CONTACT AREA ON THE VALVE TO NARROW. IF THE CONTACT AREA OF THE VALVE ON ‘THE VALVE SEAT LOOKS LIKE THIS, s781940 THE VALVE MUST BE REPLACED AND A VALVE. ‘SEAT MUST BE INSTALLED BECAUSE MORE GGRINDING WILL NOT CHANGE THE LOWER Contact Pom, ac 8.20434 a ‘CONTACT AREA arse \F THE CONTACT AREA OF THE VALVE ON THE VALVE SEAT LOOKS LIKE THIS (SEAT THAT HAS BEEN GROUND), USE A 30 DEGREE STONE To WIDEN THE ‘CONTACT AREA, N MAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE, s7sL94a ‘751048 152mm aTeL94 SN \ | THE VALVE HEAD Is RECESSED MORE THAN 11521mm, REPLACE THE VALVE AND INSTALL A VALVE SEAT. Revised 2.06, PrntesinUSA.30 Degree Intake Valve SEAT CONTACT AREA ON THE VALVE TO WIDE Ca IF THE CONTACT AREA OF THE VALVE ON ‘THE VALVE SEAT LOOKS LIKE THIS, USE A 18 DEGREE STONE TO LOWER THE UPPER CONTACT AREA, svaLsaF USE A 45 DEGREE OR 60 DEGREE STONE TO LIFT THE LOWER CONTACT AREA. s7a.986 WAKE SURE THAT THE VALVE HEAD IS NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE. srOL98H \ IF THE VALVE HEAD Is RECESSED MORE THAN 452mm, REPLACE THE VALVE AND INSTALL A Valve SEAT. ac -204a4 2816-29 | THE CONTACT AREA OF THE VALVE ON ‘THE VALVE SEAT LOOKS LIKE THIS (A SEAT HAS BEEN GROUND). \ STOLOHA, \ USE A 15 DEGREE STONE TO LOWER THE UPPER CONTACT AREA. sve.see | USE A 4 DEGREE OR 60 DEGREE STONE TO eT THE LOWER CONTACT AREA, sra.s4e ‘MAKE SURE THAT THE VALVE HEAD Is NOT RECESSED MORE THAN 1.52 mm BELOW ‘THE CYLINDER HEAD SURFACE. 152mm Y 'sa.940 | IF THE VALVE HEAD Is RECESSED MORE THAN 452mm, REPLACE THE VALVE AND INSTALL A Valve SEAT. Revised 2.06 Printed in USA,2415-30 30 Degree Intake Valve ‘THiS I THE CORRECT VALVE SEAT CONTACT [AREA ON THE VALVE. ‘CONTACT AREA \ ‘THE CORRECT INTAKE VALVE CONTACT [AREA ON THE SEAT WILL GUE-A SEAT WIDTH OF 14770 207 mm. — sa0laec 001948 1 DEGREE INTERFERENCE ANGLE. AS, ? seo.sns | ‘CORRECT REFACING OF INTAKE VALVES AND ‘VALVE SEATS WILL GIVE A 1 DEGREE INTERFER. ENCE ANGLE WHICH Is IMPORTANT FOR CARBON ‘CUTTING AND VALVE SEATING, \ IF THE VALVE HEAD IS RECESSED MORE THAN 1152 mm, REPLACE THE VALTE AND INSTALL A VALVE SEAT. ac 8.20434 Revised 2.06, PrntesinUSA.2816-31 Valve Installation STEP 61 Se ory ct t uenéay soo It you grind the valve seats, mark the cylinder head with the letter "V STEP 62 I All abe wari somo It the cylinder head has been machined, mark the amount Femoved on the RH rear ofthe cylinder head. IMPORTANT: Do not machine more than 1.00 mm from the cylinder head. The head height must not be less than 115.75 mm, STEP 63 VALVE GUIDE] SEAL Install the valve guide seal ac -204a4 STEP 64 = Apply lubrication to the valves. Install the valves in the cylinder head, STEP 65 Check the valve springs with a valve spring tester. The springs must have these specifications: Non Rotating Valves Free Length 65.66 mm ‘Compress to 50.80 mm 465 10 514 N For Rotating Valves Free Length 62.05 mm ‘Compress to 48.79 mm 464,80 to 513.80 N STEP 66 Install the valve spring retainer or if equipped, the valve rotator Revised 2.06 Printed in USA,2815-32 STEP 67 Push down the valve springs witha spring compressor. Install the valve keepers. NOTE: Always install new valve keepers when new valves are installed, STEP 68 Remove the spring compressor and hit the end of the valve stems with a soft hammer to seat the valve keepers. Rocker Arm Disassembly and Inspection STEP 69 ne a Disassemble the rocker arm assembly. STEP 70 Use a micrometer and measure the rocker arm shaft for out of round, Measure three different locations around the shaft. If the rocker arm shaft is less than 22.199 mm in diameter, the rocker arm shaft assembly must be replaced, ac e.20404 STEP 71 Measure the rocker arm with a bore gauge in three different locations around the bore. STEP 72 Use a micrometer to measure the bore gauge. Ifthe diameter of the bore is more than 22.301 mm, the rocker arm must be replaced. Revised 2.06, PrntesinUSA.2818-33 Rocker Arm Assembly STEP 73 S iow ges won ‘Assemble the rocker atm components, Cylinder Head Installation STEP 74 STEP 75 Use the correct tap and clean all head bolt holes of foreign material below. sos. HEAD GASKET APPLICATION Replacement Gasket, 0.27 mm oversize thickness 0.48 mm oversize thickness IMPORTANT: Oversize thickness head gaskets are used only when the cylinder block has been machined, ac -204a4 Revised 2.06 Pinesin USA2815-34 STEP 76 Install the cylinder head. STEP 77 UST OR PITTING NARROWING CORROSION sratst Check and replace all head bolts that have rust, pitting, narrowing and corrasion. ac e.20404 STEP 78 ‘CORRECT LENGTH ost Use the bolt length gauge to check the length of the head bolt. Use the correct slot to check the bolt length, i the bolt length is maximum the bolt must be replaced. IMPORTANT: Each bolt length must be checked before installation. STEP 79 Put a small amount of clean engine oil on the head bolt threads, Prior to Engine Serial Number 4487830 use 150 mm and 70, mm length head bott, Engine Serial Number 4487830 and after use 160 mm and 80 mm length head botts, Revised 2.06, PrntesinUSA.2816-35 CYLINDER HEAD TORQUE Prior to Engine Serial No. 44487830 STEP 80 ‘BOLT TORQUE SEQUENCE Engine Service No. 44487830 and After STEP 81 BOLT TORAUE SEQUENCE snato oe Tighten the oylinder head bolts to the correct torque, following the torque sequence shown above. Use the folowing steps to get the circuit torque. Step 1 - Torque to 50 Nm Step 2 - Torque to 149 Nm Step 3 - Torque to 200 Nm ac -204a4 snato Tighten the oylinder head bolts to the correct torque, following the torque sequence shown above Use the following steps to get the correct torque. Step 1 - Torque all bolts to 70 Nm Step 2 - Torque the long bolts to 142 Nm STEP 82 HOLDING ROD. Install the torque angle gauge. Position and lock the holding Tod. Move the pointer to 90 degrees. Tighten the bolt until the pointer is a 0 degrees. Revised 2.06 Pinesin USA2815-38 CYLINDER HEAD ASSEMBLY STEP 83 STEP 85 BOLT TORQUE SEQUENCE BOLT TORQUE SEQUENCE. orto 90310 Install the gasket and the intake manifold. Tighten the bolts to Install the manifold on the cylinder head. Ti 4 torque of 21 to 27 Nm, following the torque sequence ‘a torque of 39 to 47 Nm, fallow the torque sequence shown shown above. above. STEP 84 STEP 86 PUSH ROD ‘Connect and tighten the coolant bypass tube. Install the push rods and the oll supply tube for the rocker arm assemblies. ac e.20404 Revised 2.06, PrntesinUSA.2818-37 STEP 87 STEP 90 Install the rocker arm assembly and the rocker arm bolts Install the fiter housing nut and tighten toa torque of 29 t0 35, Tighten the bolts toa torque of 40 to 46 Nm, Nm. STEP 88 STEP 91 INLET FLTER. BE Install the inlet iter tube and a new o-ring onthe inlet tube. Install the gaskets and the inlet fing, Tighten the filter inlet fiting and tighten to a torque of 21 10 27 Nm. STEP 89 STEP 92 Install a new o-ring on the iter housing and install the filter housing Connect and tighten the outlet tube tothe lit pump, ac -204a4 Revised 2.06 Pinesin USA2815-38 STEP 93 [CHECK VALVE OR ORIFICE. Install the injection pump return line gasket and fiting. Install ‘a gasket on each side of the return line IMPORTANT: The fuel return line fitting can have either a check valve or an orifice in the fitting, this fitting ‘must be installed in the return fuel return line. STEP 94 Tighten the return in fiting to a torque of 18 to 17 Nm. STEP 95 ne) Install the injection pump inlet ine. ac e.20404 STEP 96 SMOOTH SURFACE Install the gaskets and inet fitting. Install a gasket on each side on the tube IMPORTANT: The injection pump inlet fitting must not hhave a check valve. STEP 97 Tighten the inlet fiting to a torque of 13 to 17 Nm. STEP 98 Install the gaskets and the fiting, Tighten the fuel outlet iting toa torque of 24 to 27 Nm Revised 2.06, PrntesinUSA.2816-39 STEP 99 For correct fuel filter instalation, see section 3410 in the service manual LOCATING TOP CENTER STEP 100 STEP 101 Remove the plug and install the engine tur over too into the While tuning the engine wit the turn over tool, push te lock flywheel housing. Turn the engine over four revolutions to pin in. When the lock pin moves into the camshaft gear the make sure the push rods are seated correctly (If Equipped). ‘engine will be at top center. ac -204a4 Revised 2.06 Pinesin USA2815-40 ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE Cold Setting STEP 102 Check and adjust the intake and exhaust valves as the arrows show below. mast Number one cylinder top center compression stroke Valve Clearance, Cold - Intake Valves - 0.30 mm Exhaust Valves - 0.60 mm ac e.20404 STEP 103 Install the engine turn over tool (If Equipped). Move the engine a small amount in each direction, Pull the lock pin out Install the flywheel housing plug, Revised 2.06, PrntesinUSA.STEP 104 Tum the engine one complete revolution Check and adjust the intake and exhaust valves as the arrows show below, rast Number six cylinder top center compression stroke Valve Clearance, Cold - Intake Valves - 0.30 mm Exhaust Valves - 0.60 mm STEP 105 Put new seals on the injectors and install the injectors. ac -204a4 2816-41 STEP 106 Install the injector holder. Make sure the side marked TOP is forward the top of the engine, STEP 107 Install the injector retaining bolt and tighten toa torque of 21 10.27 Nm, STEP 108 ‘Connect the tighten the injection lines to the injection pump and te injectors. Revised 2.06 Pinesin USA2815-42 STEP 109 eS rs Install the leak off ine gasket and fitings. Tighten the fitings toa torque of 7 to 9 Nm. STEP 110 To install the turbocharger, see section 2465 in the service manuel, STEP 111 Sart and operate the engine, Check the engine oll pressure indicator to make sure of correct engine oil pressure. Check the rocker arms to make sure that the arms are receiving ol STEP 112 Install anew gasket on the valve cover. STEP 113 Install the valve cover and the valve cover bolts. Tighten the bolts to a torque of 21 to 27 Nm, STEP 114 Install the breather tube clamps and botts, NOTE: Case Company eserves the right to nake improvements in design or changes in specications a any ime wiht incuring any sbigaton to instal tern unis previously sel ac e.20404 Revised 2.06, PrntesinUSA.Section 2425 CYLINDER BLOCK Crankshaft, Pistons, Rods, Sleeves, Camshaft, Bearings, Seals and Flywheel 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting perts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA EASE CANADA CORRORATION) (© 1906 Case Corporation 3950 South Service Road Pined RUS Burlington, ON L7N 3M6_ CANADA Rac 8.28444 January, 1987 (Revised March, 1996)2425-2 TABLE OF CONTENTS ‘SPECIFICATIONS .... ‘SPECIAL TORQUES ... SPECIAL TOOLS... ‘SERVICING THE ENGINE BLOCK Front Oil Seal Replacement... Rear Oil Seal Replacement ... Front Oi Seal and Wear Sleeve Replacement. Rear Oil Seal and Wear Sleeve Replacement Removal of Pistons and Rods. Cylinder Sleeve Inspection (with Sleeve Inside Block) . Removing the Cylinder Sleeves... Cleaning and Inspecting the Cynder Sleeve Countrbor ylinder Sleeve Installation .. Piston and Connecting Rod Disassembly and Inspection Piston Assembly REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT .. Removal. Installation .. (CRANKSHAFT AND MAIN BEARINGS Removal .. Crankshaft Gear Removal Crankshaft Inspection Crankshaft Gear Installation .. Valve Litter Inspection (Oil Pan Removed) Crankshaft Installation ‘CAMSHAFT Removal . Camshaft Bushing Femoval and Instalation Valve Litter Inspection (Oil Pan installed) Camshaft Disassembly and inspection ... Camshaft Gear Installation Camshatt Installation FLYWHEEL Removal. Ring Gear Removal and instalation EXPANSION PLUG REMOVAL AND INSTALLATION ... 60 mm Expansion Plug, Camshatt.. 58 mm Expansion Plugs. 22.5 mm Expansion Plug. 10 mm Expansion lugs. CRANKCASE PRESSURE CHECK (LOW BY) Manometer Installation... Testing .. Manometer Removal ac. 20644 Revised 2.06, Prntadia USASPECIFICATIONS CYLINDER SLEEVE PRIOR TO ENGINE SERIAL NUMBER 44487890 20 Cynder Seve (Topo Sleeve. ID of Cylinder Sleeve. Maximum Service Limit... Maximum Gyiinder Sleeve Out of Round. Maximum Cylinder Sleeve Taper. Cylinder Sleeve Protrusion CYLINDER SLEEVE ENGINE SERIAL NUMBER 44487890 AND AFTER 0 0 Cyinder Steer (At Top of Sees) ID of Cylinder Sleeve. Maximum Service Limit Maximum Out of Round (Installed in Block) Maximum Taper (Installed in Block) Sleeve Protrusion Above Block. PISTON ‘0D 12mm From the Bottom, 90 Degrees from Piston Pin. Minimum Service Limit “ - 1D of Piston Pin Bore Maximum Service Limit PISTONS RINGS No. 1 Compression End Gap in 114.020 ID Cylinder. Maximum Service Limit No. 2 Compression End Gap in 114.20 1D Cylinder. Maximum Service Limit Side Clearance. Maximum Service Limit No. 3 Oil Control Ring End Gap in 114.20 ID Cylinder. Maximum Service Limit Side Clearance. Pratrusion Above Cylinder Sock (Maximum). PISTON PIN OD of Pin Minimum Service Limit. ‘CONNECTING ROD |D Without Bushing Installed Bushing 1D installed Maximum Service Limit Journal iD Without Beating Liner. Maximum Service Limit Journal iO With Bearing Liners Maximum Service Limit Bearing Oil Clearance. Maximum Service Limit Side Clearance. Maximum Service Limit ac .20444| 2428-3 132,947 to 192.949 mm 114,000 to 114,040 mm 114.417 mm 0.04 mm nnn 0.04 MM (0,013 to 0.109 mm 130,947 to 130.949 mm 114,000 to 114,040 mm 114.117 mm 0.04 mm sone 0,04 MM, (0,013 to 0.109 mm 119.899 to 113,847 mm soo 113,776 mm 48,006 to 45,012 mm 45,025 mm (0.40 to 0.70 mm 070mm (0.40 to 0.70 mm 0.70 mm (0.07 to 0.125 mm 0.125 mm (0.30 to 0.60 mm 0.60. mm 0,020 to 0.085 mm 0.680 mm 44,997 to 45,003 mm 44,993 mm 48,988 to 49,012 mm 48,023 to 45,085 mm 45,035 mm 80,887 to 81,013 mm 81.013 mm 76,046 to 76.104 mm 76.104 mm oo 0.098 100.117 mm 0.117 mm vn0.100 t0 0,300 mm, 0.330 mm Revised 2.06 Pinesin USA2425-4 (CRANKSHAFT. Crankshaft End Clearance Maximum Service Limit... Center Main Bearing Thrust Surface Thickness. ‘Connecting Rod Journal Standard OD. Maximum Service Limit (0.25 mm OD Undersize, Grind to. (0.50 mm OD Undersize, Grind to. (0.75 mm OD Undersize, Grind to. 4.00 mm OD Undersize, Grind to, ‘Connecting Rod Journal Maximum Taper ‘Connecting Rod Journal Maximum Out of Round Main Bearing Oil Clearance. “ Maximum Service Limit... Main Bearing Journal Standard OD Maximum Service Limit (0.25 mm OD Undersize, Grind to. (0.50 mm OD Undersize, Grind to. (0.75 mm OD Undersize, Grind to. 4.00 mm OD Undersize, Grind to Main Bearing Joumal (Thrust Surface) Width Standard Size (0.25 mm Oversize... - sn 0.50 mm Oversize... Main Bearing Joural Maximum Taper. Main Bearing Joural Maximum Out of Round... Maximum Service Limit Main Bearing Journal Bore 1D No Liners, Main Bearing Oil Clearance. Maximum Service Limit CAMSHAFT ID of Camshaft Bore... ID of Camshatt Bore Bushing Installed Maximum Service Limit... ‘00 of Each Camshaft Bearing Surface, Maximum Service Limit ‘Camshaft Thrust Plate Thickness... Minimum Service Limit ‘Camshaft Thrust Clearance Maximum Service Limit ‘CAMSHAFT LOBES Intake . Minimum Service Limit. Exhaust Minimum Service Limit. Litt Pump Lobe. Minimum Service Limit. GEAR TRAIN BACKLASH ‘Crankshaft Gear to Camshaft Gear Maximum Service Limit (All Gears). ac. 20644 0.187 to 0.994 mm voo0.981 mm 3.487 to 3,50 mm 75.987 to 76.013 mm 75.982 mm 75.137 to 75.763 mm 75.487 to 75.513 mm 75.273 to 75.263 mm ‘74,987 to 75.013 mm uo0,013 mm 0,050 mm (0,068 to 0.134 mm 0.134 mm, {97,962 to 98.013 mm 97.982 mm 97.712 to 97.763 mm 97,462 to 97.513 mm 97.212 to 97.263 mm 196.962 to 97.013 mm 42.975 to 43,078 mm 43,225 to 43,326 mm 43.475 to 43,576 mm u0,013 mm 0,050 mm 405.013 mm 404,987 to 105.013 mm (0,066 to 0.134 mm 0.134 mm 63.987 to 64.013 mm 60.058 to 60.110 mm 60,122 mm 59,987 to 60.013 mm 59,982 mm v9.42 to 9,58 mm 9.34 mm 0.120 t0 0.34 mm 0.47 mm 52,026 to 62.251 mm 51,774 mm 51.848 to 62.073 mm 51,896 mm 41,83 t0 41.57 mm v1 31 mm, 0,08 to 0.33 mm soo 45 MM Revised 2.06, PrntesinUSA.VALVE LIFTERS 0D of Litter Minimum Service Limi. Bore Diameter... Maximum Service Limit... ROCKER ARM ASSEMBLY ‘0D of Shaft Minimum Service Limi. ID of Arm Bore... Maximum Service Limit... Shaft Oil Holes... ac .20444| Revised 2.06 2428-5 18.929 to 18.980 mm 15,925 mm 16.000 to 16.080 mm 16.055 mm 22.219 to 22.231 mm 22.199 mm 22.256 to 22,282 mm 22.301 mm Downward Pinesin USA2425-6 SPECIAL TORQUES Metric Valve Belt Tensioner Bolt... . so os ssn sven 3940 47 Nm Camshaft Plate Bolts 211027 Nm ‘Connecting Rod Bolts ‘Torque Plus Angle Method (Lubricate Threads with Engine Oil). ..70.Nm Plus 60 Degrees ‘Standard Torque Step Method. ‘st. 40 Nm 2nd. 80 Nm 81d, 120 Nm Crankshaft Pulley and Viscous Damper Bolts. 200 Nm Fan Pulley Bracket Bats... - ssn a sn se 24 1027 NE Fan Pulley Bolts Grade 8.8 Size MB 211031. Nm Grade 10.9 Size NB.... - ssn a sn se 7 1048 N Grade 8.8 Size M10 51 to.62Nm Grade 10.9 Size M10. - ssn a sn sn 81 10 62.N Fuel Filter Housing Nut 291095 Nm Injection Pump Mounting NUtS..... ssn a sn sn 9 1047 Ne Front Gear Cover to Housing Bolts- Engine S/N 45075652 and Prior 24Nm Front Gear Cover to Housing Bolts-Engine SIN 45075652 and After... ssn svn AO NEM Front Housing to Block Bolts 40Nm Cylinder Head Botts Prior to Engine SIN 44487890... . smn sn 200 NEM Cylinder Head Bolts Engine SIN 44487890 and Alter Short Bots, TONm Plus 90 Degrees Long BOIS sess . sn “ swnsonnssnnsnsnsonnon'2 NM Plus 90 Degrees Main Bearing Bolts Torque Plus Angle Method (Lubricate Threads with Engine Oi). 95 Nm Plus 60 Degrees ‘Standard Torque Step Method... sn “ sono sn 18t,50.NM 2nd. 119 Nm 31d, 176 Nm il Suction Tube Bott... - ssn a sn se 24 1027 NE Seal Carrier Bots, 810 10Nm Injection Pump Inet Fitting. - ssn a sn se 1810.17 NM Injection Pump Return Fitting 431017 Nm Fuel Fitter Outlet Fiting... . sn “ sono sone 24 1027 NM Fuel Fitter Inet Fitting 2110.27 Nm Front Engine Support Bolts . sn “ sono sn $02t0 122 Nm Injection Pump Drive Gear Nut Model A Pump 92Nm Model MW PUM... . sn “ sono snes 104.NM Model P 495 Nm Model EP-9 Nippondenso. . sn “ sono - 404 Nm ac. 20644 Revised 2.06, PrntesinUSA.Injection Pump Mounting Nut Flywheel Housing Bolts Flywheel Bots... Starter Motor Mounting Bolts Lift Pump Mounting Bots. Rocker Arm Bolts Valve Cover Bots. Leak Of Fitting ac .20444| Revised 2.06 2425-7 vo 890 47 Nm 77Nm 190 to 137 Nm 77Nm 21 1027 Nm 4010.46 Nm 21 1027 Nm 7t0.9Nm Pinesin USA2425-8 SPECIAL TOOLS Cylinder Block and Cylinder Sp ‘CAS-1068 SLEEVE PULLER PLATE ‘CAS-1049A SLEEVE PROTRUSION TOOL KIT ‘0E1-65296528 WET CYLINDER SLEEVE PULLER ‘CAS-10900 CONNECTING ROD BUSHING REMOVAL AND INSTALLATION TOOL ‘CAS-2490 FRONT COVER SEAL INSTALLER. r96 ‘THREE BOND SILVER ATV SEALER 3623494-8 OZ TUBE 495104 CCAS-2855 REAR CRANKSHAFT SEAL INSTALLATION TOOL, ac. 20644 Revised 2.06, PrntesinUSA.® So 5 (cAS.2167 FRONT WEAR SLEEVE INSTALLATION TOOL (048-2162 TORQUE ANGLE GAUGE Crankcase Pressure Check (Blow By) ‘oAS-ti02 MANOMETER ac .20444| Revised 2.06 Printed in USA,2425-10 SERVICING THE ENGINE BLOCK Front Oil Seal Replacement STEP 1 Make sure the upper and lower mark on the crankshatt pulley are in align. if the mark is notin align the crankshaft pulley must be replaced STEP 2 Lift the belt tensioner and remove the fan belt. STEP 3 Remove the fan pulley bots and remove the fan pulley. ac. 20644 STEP 4 Remove the bolts and the crankshaft puley. STEP 5 i Remove the timing gear housing cover. STEP 6 Clean the crankshatt oil seal surface with Loctite safety solvent IMPORTANT: The seal surface on the crankshaft must be free of all oil and grease to prevent damage to the oil seal. Revised 2.06, PrntesinUSA.STEP 7 Remove the oil seal and clean the seal surface with Loctite safety solvent, STEP 8 sza.980 Leave the plastic pilot installation tool in the oil seal Position the seal on special tool CAS 2430 Front Seal Installer Too! with the oil seal dust lp facing outward STEP 9 ‘a.96a Use the cover support part of CAS 2430 and support the oil sseal cover flange from the front. Press the oll seal into the {ont cover from the back side of the cover. Press the ol seal Until the special tool contacts the front cover. ac .20444| 2425-11 STEP 10 Engine S/N 45075642 and Prior Apply a thin layer of Three Bond Silver ATV Sealer to both sides of a new cover gasket and install the gasket over the alignment dowels. STEP 11 Install the front cover and cover bolts. Tighten the bolts to a torque of 24 Nm. STEP 12 Engine S/N 45075642 and After ssL96 Apply Three Bond Silver Sealer in an even size bead of 3 to 4 mm diameter, tothe gutter onthe inside ofthe cover. NOTE: Assembly must be completed within 10 to 15 minutes after the sealer is applied. Revised 2.06 Pinesin USA2405-12 STEP 13 STEP 15 renee Insta alignment dowels and install the cover onto the engine i the ol seal was installed without using CAS 2430, be sure Insal hecapscrens, to measure the distance from the crankshaft end tothe oil seal in four postions, The measurement must be the same in all postions STEP 14 , STEP 16 125.968 Tighten the cover bolts to @ torque of 40 Nm. Remove the \ ‘eal plot tool from the crankshaft Install the crankshaft dust seal if equipped. Be sure that the part number is facing away from the engine and that the dust shield makes contact with the oll seal ac .204e Revised 2.06, PrntesinUSA.2426-18 STEP 17 STEP 18 Install the crankshaft pulley and it equipped, the viscous Install the fan pulley and bolts. Tighten the bolts to a torque ‘damper, Install the bolts and tighten to a torque of 200 Nm of Grade 8.8 Size MB 211031 Nm Grade 10.9 Size MB 37t0 43 Nm Grade 8.8 Size M10 sn 51 to 62Nm Grade 10.9 $i2€ M10...snnnsnnnnanon 51 40 62 NM STEP 19 Lift the belt tensioner and install the fan belt, ac .20444| Revised 2.06 Pinesin USA2425-14 Rear Oil Seal Replacement STEP 20 Remove the starter from the fynheel housing. STEP 21 Remove the flywheel bolts and the wheel from the flywheel housing STEP 22 Connect a chain and hoist tothe flywheel housing. Remove the bolts from the flywheel housing and remove the housing If equipped, remove the O-ring seal and fywheel spacer. ac. 20644 STEP 23 —— 4 (25820 Dril two small holes in the oll seal. Install screws or a slide hammer and carefully remove the seal. Use Loctite Safety Solvent and completely clean all foreign material from the ‘crankshaft flange surface and seal carrier ID. IMPORTANT: Do not damage the seal carrier housing or the crankshaft flange surface when removing the oil seal. IMPORTANT: The crankshaft sealing surface must be free of all oll and grease to prevent damage to the oll seal. The crankshaft surface and seal must be dry for proper seal break in STEP 24 Install the protective sleeve over the crankshaft, Revised 2.06, PrntesinUSA.STEP 25 Install the inner haif of special tool CAS-2355 on the end of the crankshaft Pull the protective sleeve over the tool STEP 26 Install a new seal in the outer half of special tool CAS-2955, ‘The open side of the seal must be visible when the seal is correctly placed in the special tool STEP 27 28825 Install the outer half ofthe too! onto the inner half of the tool Install the nut and tighten until the outer half of the tool makes contact with the seal carier, The seal will be corectly seated Remove the seal installation tool and the protective sleeve {rom the crankshatt ac .20444| 2428-15 STEP 28 If equipped, install a new O-ring seal andthe flywheel spacer. STEP 29 Apply Loctite 515 tothe aling surface ofthe engine block. STEP 30 Install two guide bolts in the engine block. Revised 2.06 Pinesin USA2425-16 STEP 31 STEP 33 Ac Install the starter and the starter retaining bolts, Tighten the bolts toa torque of 77 Nm, Install the flywheel housing and the housing bolts, Tighten the bolts to a torque of 77 Nm. STEP 32 Install the flywheel and flywheel retaining bolts. Tighten the bolts to a torque of 140 Nm, ac. 20644 Revised 2.06, PrntesinUSA.2425-17 Front Oil Seal and Wear Sleeve Replacement Used when crankshaft flange is wern and standard seal does not stop allow. STEP 34 STEP 37 Make sure the upper and lower mar onthe crarkshat pulley ‘Remove the crankshaft puley bolts and the crankshatt uly. are in align. If the mark snot in align the crankshatt pulley must be replaced, " STEP 38 STEP 35 Remove the front cover bolts and the front cover. Lift the belt tensioner and remove the fan belt. STEP 39 STEP 36 Clean the front cover mounting surfaces of all foreign material. Remove the fan pulley bolts and the fan pully. ac .20444| Revised 2.06 Pinesin USA2425-18 STEP 40 Remove the oil seal and clean the seal surface with Loctite Satety solvent STEP 41 ea.sec Leave the plastic pilot installation tool in the oil seal, Position the seal on special tool CAS 2430 Front Seal Installation Tool wth the oll seal dust lip facing outward, STEP 42 ‘24.96 Use the cover support part of CAS 2430 and support the oil seal cover flange from the front. Press the oil seal into the front cover from the back side of the cover. Press the ol seal Until the special tool contacts the front cover. ac .204e Clean the crankshatt oil seal surface with Loctite safety solvent STEP 44 Install the wear sleeve installation tol on the crankshaft STEP 45 Install the puller stud into the installation tool. Revised 2.06, PrntesinUSA.STEP 46 CHAMFER, Install the wear sleeve with the chamfer toward the crankshaft STEP 47 Install the cup and push the sleeve on the crankshaft STEP 48 Remove the sleeve installation too from the crankshaft ac .204ea 2426-19 STEP 49 Engine S/N 45075642 and Prior Apply a thin layer of Three Bond Silver RTV Sealer to both sides of a new cover gasket and install the gasket over the alignment dowels. STEP 50 Install the front cover and cover bolts. Tighten the bolts to a torque of 24 Nm. STEP 51 Engine S/N 45075642 and After 195196 ‘Apply Three Bond Sitver Sealer in an even size bead of 3 to 4 1mm diameter, tothe gutter on the inside ofthe cover. NOTE: Assembly must be completed within 10 to 15 ‘minutes after the sealer is applied. Revised 2.06 Printed in USA,2425-20, STEP 52 STEP 54 renee Insta alignment dowels and install the cover onto the engine if the ol seal was installed without using CAS 2430, be sue Insal hecapscrens, to measure the distance from the crankshaft end tothe oil seal in four postions, The measurement must be the same in all postions STEP 53 , STEP 55 125.968 Tighten the cover bolts to @ torque of 40 Nm. Remove the \ ‘eal plot tool from the crankshaft 125.968 Install the crankshaft dust seal if equipped. Be sure that the part number is facing away from the engine and that the dust seal makes contact with the oil seal ac .204e Revised 2.06, PrntesinUSA.2425-21 STEP 56 STEP 58 Install the crankshaft pulley and if equipped, the viscous Lift the belt tensioner and install the fan belt ‘damper, Install the bolts and tighten toa torque of 200 Nm STEP 57 Install the fan pulley and tighten the fan pulley bolts to a torque of Grade 8.8 Size MB 21 to 31 Nm Grade 10.9 Size M8. 37 to 43Nm Grade 8.8 Size M10. 51 to 62Nm Grade 10.9 Size M10 51 to 62Nm ac .20444| Revised 2.06 Pinesin USA2425-22 Rear Oil Seal and Wear Sleeve Replacement Used when the crankshatt ange is wom and standard seal does not stp ol fw. STEP 59 Remove the starter from the fyheel housing. STEP 60 Remove the bolts and the flywh STEP 61 ‘Connect a chain and a hoist to the flywheel housing. Remove the bolts from the flywheel housing and remove the housing If equipped, remove the O-ring seal and the flywheel spacer. ac. 20644 STEP 62 = A25820R oe Drill two small holes in the oil seal. Install screws or a slide hammer and carefully remove the seal. Use Loctite Safety Solvent and completely clean all foreign material from the crankshaft flange surface and seal carer ID. IMPORTANT: Do not damage the seal carrier housing or the crankshaft flange surface when removing the oil seal. IMPORTANT: The crankshaft sealing surface must be free of all oil and grease to prevent damage to the oil seal. The crankshaft surface and seal must be dry for proper seal break in STEP 63 - = Ea Install the inner half of special tool CAS-2355 onthe end of the erankshat Revised 2.06, PrntesinUSA.STEP 64 Remove any oll from the wear sleeve. Carefully instal the ‘wear sleeve in a new seal. Install the wear sleeve and seal assembly in the outer half of special tool CAS-2356. The wear sleeve flange and the open side of the seal will be toward the engine when correctly placed inthe special tool. STEP 65 Install the outer half ofthe too! onto the inner half of the tool Install the nut and tighten until the outer half of the tool makes contact with the seal carier, The seal wll be corectly ‘seated. Remove the installation tool from the crankshatt STEP 66 I¥ equipped, install the flywheel spacer and anew O-ring seal ac .20444| 2426-28 STEP 67 = A25821 ‘Apply Loctite 515 tothe sealing surface of the engine block. STEP 68 Install two guide bolts in the engine block. STEP 69 Install the flywheel housing and the housing bolts, Tighten the botts to a torque of 77 Nm. Revised 2.06 Pinesin USA2425-24 STEP 70 STEP 71 cecal Install the starter and the starter retaining bolts, Tighten the bolts toa torque of 77 Nm, Install the flywheel and flywheet retaining bolts. Tighten the bolts to a torque of 140 Nm. Removal of Pistons and Rods STEP 74 Remove the manifolds and cylinder head from the engine. heck the side clearance of the piston connecting rods. See Section 2415 of the service manual for removal. Replace the connecting rods ifthe side clearance is more ‘han 0.390 mm. STEP 73 a Remove the engine oil pan and inlet tube. See Section 2445 of the service manual for removal, ac. 20644 Revised 2.06, PrntesinUSA.STEP 75 sais Remove the carbon from the top ofthe cylinder walls, Check the cylinder walls fora ridge atthe top ofthe ring movement zone, A ridge will cause damage to the piston when the piston is removed. A ridge will have to be removed with a ridge reamer. STEP 76 Install a ridge reamer into the cylinder and remove the ridge from the cylinder walls. Number each rod and rod cap on the ol cooler side ofthe engine for cylinder identification ac .204ea 2426-05 STEP 78 Put a cylinder identification number on each piston for assembly. STEP 79 Remove the rod nuts and the rod cap. STEP 80 Remove the pistons from the top ofthe engine block Revised 2.06 Printed in USA,2425-26 Cylinder Sleeve Inspection (wi STEP 81 Inspect the cylinder sleeves for the following conditions, Normal Wear ‘A smooth surface with some of the crosshatch pattern showing between the upper and lower limits of the ring movement area shows normal wear. There will always be a ‘small amount of wear present because of combustion pressure moving the lop ring against the cylinder wall. Clean the cylinder wall witha clean cloth and clean engine ol Normal wear shows acceptable cylinder wall conditions. See ‘Steps 80 and 81 to measure the cylinder bore for taper and ‘out-f-round. ac. 20644 th Sleeve Inside Block) Worn Cylinder Wall ‘A smooth surface between the upper and lower limits of the ring movement area shows a wor cylinder wall. Measure the sylinder bore for out-of round and taper as shown under this heading NOTE: Clean the cylinder walls with hot soapy water until a clean white cloth stays completely clean. One leaning operation will not be enough. IMPORTANT: Do not use gasoline diesel fuel or kerosene to clean cylinders because these materials will ‘not clean the sleeve surface. Revised 2.06, PrntesinUSA.2425-27 Scoring on Cylinder Walls Scoring on cylinder walls is caused by metal moving from one location to a different location. This is shown by heavy vertical lines. The vertical lines are caused by metal coming in contact with the piston. The scoring can be in one specific area or it can occur the complete length of the piston movement. If this condition is present, the cylinder sleeve and the piston and rings must be replaced, ac .20444| Dusted Cylinder 91269 ‘Too much area in the piston ring movement area shows @ dusting failure, ‘A dusting failure will cause the folowing: 1. Lower area of piston wall will how wear. 2, Too much piston ring groove wear. 3, Too much piston ring side clearance. 4, Washed away areas of the piston ring lands where the aluminum will be gone. 5. Piston rings will have too much face contact and wear which can be seen as a reduction in radial width and increase in end gap. 6. Chrome piston rings wil show wear through the face. The chrome will be worn off the face and base iron can be seen, 7. The oylinder heads can have smooth intake ports and worn valve guides. Alf these conditions are caused by dit which is mixed with the intake air. Revised 2.06 Printed in USA,2425-28, STEP 82 Measure the cylinder sleeve bore for taper as follows: 41. Measure the bore parallel to the orankshatt atthe top end ofthe ring travel zone, 2, Measure the bore in the same position atthe bottom end ofthe ring travel zone, 3, Measure the bore at right angles tothe crankshaft at the top end of the ring travel zone. 4, Measure the bore in the same position atthe bottom end of the travel zone ‘Compare the results of the measurements (1) and (3) with (2) and (4), to find out if the bore has taper. To measure use a inside miorometer, bore gauge or taper gauge. Ifthe taper is mare than 0.04 mm, the cylinder sleeve must be replaced. ac .204e STEP 83 Measure the cylinder sleeve bores for out-of-round as follows: 41. Measure the bore parallel to the crankshaft atthe top end ofthe rng travel. 2, Measure the bore in the same position atthe bottom end ofthe rng travel. 3, Measure the bore at right angles tothe crankshaft atthe top end of the ring travel 4, Measure the bore in the same position atthe bottom end ofthe rng travel. Compare the measurements (1) and (3) to find the out- of round wear atthe top end ofthe bore. Compare the measurements (2) and (4) to find the out- of round wear atthe bottom of the bore If out-of-round is more than 0.04 mm, the cylinder sleeve must be replaced. Revised 2.06, PrntesinUSA.2426-29 Removing the Cylinder Sleeves IMPORTANT: Cover the crankshaft journals with a clean cloth, Foreign material from the cylinder sleeve or the cylinder block will cause damage to the crankshaft Install a sleeve puller to remove the cylinder sleeve. Postion the puller in the sleeve. Make sure thatthe jaws of the puller do not contact the four block lugs. Tighten the lock bar against the cylinder sleeve IMPORTANT: Make sure that the jaws of the sleeve puller do not contact the block lugs. ac .20444| STEP 85 Carefully turn the bearing nut until the cylinder sleeve is loose {rom the cylinder block. STEP 86 Remove the cylinder sleeve from the cylinder block. Remove the o-ing from the cylinder sleeve. Revised 2.06 Printed in USA,2425-30 — @ : CClean and flush the lower sleeve area in the crankcase. Inspect the lower sleeve bore for erosion. Check the four block lugs in each oynder for damage, If the upper and lower sleeve area or any ofthe lugs are damaged the cyinder block must be replaced STEP 88 i ‘COUNTERBORE FOR | SLEEVE FLANGE | °@ Inspect the crankcase counterbore forthe cylinder sleeve ange contact area. Ths area Is mela fo motel sea, THe sleeve Range andthe coulerbore ust be good condition forthe conect sleeve pettus, ac .204e ig the Cylinder Sleeve Counterbore STEP 89 Clean the counterbore flange and the upper bore surface of all foreign material STEP 90 Use a clean clath to clean the upper and lower sleeve contact area, STEP 91 Measure the upper sleeve contact area before cylinder sleeve installation. Prior to Engine Serial Number 44487830, 482,900 to 192.950 mm Engine Serial Number 144487830 and AVter. 130.900 to 130.950 mm Revised 206, PrinesinUSA.2425-31 Cylinder Sleeve Installation Lubricate the upper and lower sleeve contact area with clean engine ol STEP 93 Install a new o-ring inta the groove on the cylinder sleeve, Lubricate the cylinder sleeve o-ring with clean engine oil ac .204ea Install the cylinder sleeve into the cylinder block, IMPORTANT: Make sure that the correct sleeve is installed. The sleeve for prior to engine serial number 44487830 and the sleeve for engine serial number 44487830 can not be interchanged. STEP 96 Push the sleeves into the cylinder block bore. Make sure the sleeve is firmly seated in the cylinder block counterbore, The cylinder sleeves are a press fit STEP 97 The cylinder sleeve must not contact the block lugs. If the cylinder sleeve makes contact with the block lugs the cylinder block must be replaced, Revised 2.06 Printed in USA,2425-32 STEP 98 Use a dial indicator and check the sleeve protrusion above Lubricate the cylinder sleeve with clean engine oil the cylinder block surface. Measure the distance from the top ‘outer surface of the sleeve to the top surface ofthe cylinder black. Measure the protrusion at four positions, The correct sleeve protrusion is 0.013 to 0.109 mm. If the protrusion is not correct remove the sleeve and install a different sleeve Until the sleeve protrusion is 0,013 to 0.109 mm. ifthe sleeve protrusion specs cannot be met, see your local block machine shop. Piston and Connecting Rod Disassembly and Inspection STEP 100 STEP 101 ‘CONNECTING Roo, Put the piston assembly on a clean work surface, Remove the piston pin retaining ring, piston pin and the connecting rad from the piston, ac. 20644 Revised 2.06, PrntesinUSA.2428-38 STEP 102 STEP 104 Kwock our FING aye oF } unvpn, DAWER ING wan Pin + 18L964 Remove the compression rings and the oll ring from the Use CAS-10900 connecting rod bushing removal and Piston, installation tool to remove and install the rod bushing. NOTE: The oil two pie 1 oll rng is a two piece ring, STEP 105 STEP 103 ret068 Place the pin bore end of the connecting rod on the mandrel, Measure the inside diameter of the connecting rod for wear ~ ‘eLsec And out-o-round. Ifthe inside diameter is more than 45.035, Place the knack out ring (hin) on the mandrel ontop ofthe mmm the connecting rod bushing mus be replaced. connecting rod gin bre, Match up the angle surfaces ac .20444| Revised 2.06 Pinesin USA2425-34 STEP 107 19.964 Install the cap on the mandrel and secure with the hair pin cotter. STEP 108 19.9662 Install the mandrel in the anvil, Put the connecting rod so the angle on the connecting rod matches with the angle on the anvil, The connecting rad willbe in the horizontal position. STEP 109 aLs6c Press the connecting rod bushing out ofthe connecting rod bore by applying force on the top of the cup. ac .204e STEP 110 =F = —— A O06, Remove the hair pin, Remove the cup and slide the ‘onnecting rd from the mandrel STEP 111 | l<— SF 7 \ —| Le || vu Measure the connecting rod bushing pin bore with the bushing removed. The bore diameter must be 48.988 to 49,012 mm. If the rod pin bore is not within specifications, the connecting rad and cap must be replaced. STEP 112 20.g6c Put the connecting rod pin end and new bushing in clean 15W - 40 engine oil Revised 2.06, PrntesinUSA.STEP 113 ‘nL96a Place the connecting rod bushing on the mandrel STEP 114 C 1211968 Place the knock out ring thin) inside the driver ring. Match the angles and place the angle side down. Align the notch of the knack out ring (thin) to the pin inthe driver ring and slide onto the mandrel STEP 115 rai.gsc Install the cap and secure with the hair pin. ac .20444| 2425-35 STEP 116 raiLs60) Insert the mandrel assembly into the chamfered side of the ‘connecting rod. STEP 117 122.968 Align the oil hole in the connecting rod bushing and ‘connecting rod (use the groove in the mandrel) and push the mandrel assembly into the pin bore ofthe rod until contact is made. This contact helps maintain the alignment of the oil holes. STEP 118 i= A 0.968 Place the rod and mandrel assembly on the anvil, Position the rod so thatthe angle on the rod matches the angle on the anwil. The rod wil be in the horizontal postion. Revised 2.06 Printed in USA,2425-38, STEP 119 sa.s6c Use either an arbor or hydraulic press and press the bushing into the connecting rod. Push through in a continuous motion Until the driver ring makes contact withthe connecting ro. STEP 120 120L96A Check the alignment of the oil holes. A 3mm (1/8 inch} diameter rod must move freely through the rod and bushing cil holes (A). Check for clearance between the rod and bushing. Use a 0.025 mm (0.001 inch) feeler gauge to make sure the busing is propery seated. The feeler gauge must not ‘enter between the bushing and connecting rod (8). ac. 20644 STEP 121 e988, ‘The inside diameter of new connecting rod bushings must be machined with a connecting rod baring machine NOTE: Do not use a “floating connecting rod” type honing machine. STEP 122 IMPORTANT: The connecting rod bearing bore must be ‘measured for out-of-round if the contact surface between the rod and the cap shows any sign of wear. The bearing liners must be removed from the rod and the cap for this check. The connecting rod nut must be tightened to a torque of 70 to Nm plus 60 degrees. Measure the diameter of the connecting rod bore in three positions. The diameter must be 80.987 to 81.013 mm. Ifthe tiameter is more than 81.013 mm the connecting rod must be replaced. Revised 2.06, PrntesinUSA.STEP 123 2425-37 STEP 125 Measure the diameter ofthe piston pin. If the diameter is less than 44,999 mm the piston pin must be replaced. STEP 124 Measure the piston pin bore. If the piston pin bore is more than 45,025 mm the piston must be replaced. ac .20444| Measure the diameter of the piston across the thrust face 12 mm from the bottom of the piston, at right angles ofthe piston pin holes. Replace the piston if the diameter is less than 113.776 mm, STEP 126 Break an old piston ring in half and use the broken ring half to Clean the piston ring grooves. Too much deposit in the ring ‘grooves can force the rings out and will cause scoring, STEP 127 ‘Check the side clearance of the oil ring inthe piston. Insert a {eeler gauge between the upper surface of a new ring and the piston lands to check the clearance. Replace the piston if side clearance is more than 0.085 mm. Revised 2.06 Pinesin USA2425-38 STEP 128 STEP 129 ‘Check the side clearance of the second compression ring Clean the piston holes with a small dil or fine wie Replace the piston ifthe side clearance is more than 0.125 mm. ac. 20644 Revised 2.06, PrntesinUSA.2426-39 Piston Assembly STEP 132 STEP 130 Put the piston rings in the cylinder sleeve and check the end ‘gap. Replace the piston rings i the end gap is more than: Number 1 Compression Ring 070 Number 2 Compressing Ring enn O.70 Number 3 il Control Rng cnn 060 STEP 131 OIL ANG ‘SPRING Install the ol ring. Install the spring first and the cil ring second NOTE: The spring must be between the oll ring and the piston ac .20444| Install the second compression ring. The piston ring must be installed with the side marked TOP toward the top of the piston to give good cil control Revised 2.06 Pinesin USA2425-40 STEP 133 Install the first compression ring on the piston. The piston ring ‘must be installed withthe side marked TOP toward the top of the piston to give good oil contol ume ING NuMBER 2 ING vUNDER, ine SPRING 2495 STEP 134 Rotate the piston rings so thatthe ring ends ae separated by 120 degrees. ac. 20644 STEP 135 reais Install the connecting rod in the piston, Make sure the mark FRONT on the piston and the number on the rod are in the correct position shown above. STEP 136 PISTON PIN Install the piston pin and the piston pin retaining rings. Revised 2.06, PrntesinUSA.STEP 137 Apply lubrication to the pistons, piston rings and cylinder walls, using clean engine ol NOTE: Install the pistons in the correct bore. STEP 138 Install a ring compressor on the piston and carefully install the piston inthe cylinder. IMPORTANT: Make sure that the mark FRONT on top of the piston is toward the front of the engine and the connecting rod numbers are toward the oil cooler side of the engine, STEP 139 ss . ie] Measure the connecting rod journals on the crankshaft, Measure the front and rear of each journal, checking for taper. Ifthe taper is more than 0.013 mm, reconditioning of the journals must be done. ac .204ea 2425-41 STEP 140 ‘The connecting rod journals must be checked again, 90 degrees from the first measurements for out-ofround. If out- ‘of-round is more than 0.050 mm, reconditioning of the journals must be done. STEP 141 Install the liners. The liner locks must be in alignment NOTE: When installing the liners, make sure that the liner locks are in alignment. Use a sliding type movement when instaling the liners. Never push on the center of the liner locks. Revised 2.06 Printed in USA,2425-42 STEP 142 a OLD STYLE — stem -~ Measure the length of the connecting rod bolts. Ifthe bolt length is more than the maximum shown for your style bot, the bolt must be replaced, 2.05 IMPORTANT: Each bolt length must be measured before installation. IMPORTANT: Do not mix old and new style bolts on any one connecting rod. STEP 143 PLASTIGAGE ‘Clean the connecting rod journals and the rod bearing liners. Put a piece of plastigage on the bearing cap journal or the journal on the crankshaft. ac .204e STEP 144 Install the bearing caps. NOTE: Make sure that the number on the rod cap is the same as the number on the connecting rod. STEP 145 Lubricate the connecting rod bolts with clean engine oil and torque the bolts. See below. Torque Sequence: Step 1 - Torque to 40 Nm Step 2 - Torque to 70 Nm STEP 146 PONTER HOLDING ROD. Install the torque angle gauge. Position and lock the holding Tod. Turn the pointer to 60 degrees. Tighten the nut until the pointer is at 0 degrees. evi 298 PrntesinUSA.STEP 147 Remove the bearing caps and check the clearance. The clearance must be between 0.033 to 0.117 mm. If the clearance is more than 0.117 mm, undersize bearing liners must be installed and reconditioning ofthe bearing journals must be done by grinding, NOTE: A clearance of 0.033 to 0.117 mm is required when installing new bearing liners. Direct Measure Method STEP 148 ‘7.964 Use a micrometer to measure the rod journals. The journals ‘must meet the following specifications Standard - 75.987 Machined 0.25 mm - 78.737 Machined 0.50 mm - 75.487 Machined 0.75 mm - 75.237 Machined 1.00 mm - 74.987 ac .204ea 2426-49 STEP 149 1731968 Standard Oversize 0.25 mm (.010 in) (0.50 mm (.020 In.) 0.75 mm (.030 in) 4.00 mm (040 In.) sva.sec Measure the rod bearing shell thickness with an outside micrometer with a ball tip. Used standard rod bearing thickness must be 2.43 to 2.471 mm, NOTE: fod bearings are identified with a part number and size stamped on the back side, Determine the size of the removed rod bearing and obtain a set of the same size Over size service rod bearings are available for use with crankshafts that have been machined undersize. Refer to the appropriate parts catalog, Revised 2.06 Printed in USA,2405-44 STEP 150 ion Apply lubrication to the beating liners before installation, using clean engine oil. Lubricate the crankshaft journal mating surface of the bearing shells with Lubrplate 105, STEP 151 Lubricate the connecting rod bolts with clean engine oll and torque the bolts. See below, ‘Torque Sequence: Step 1 - Torque to 40 Nm Step 2 - Torque to 70 Nm STEP 152 PONTER HOLDING ROD; Install the torque angle gauge. Position and lock the holding fod. Turn the pointer to 60 degrees. Tighten the nut until the pointer is at 0 degrees. ac -204ea STEP 153 i at Install the engine oil inlet tube. See Section 2445 of the service manual forthe inlet tube and the oil pan installation, STEP 154 Use a dial indicator to check piston prottusion. The piston protrusion must not be more than 0.380 mm above the sylinder block. Install the cylinder head and manifold. See Section 2415 of the service manual, Revised 2.06, PrntesinUSA.2426-45 REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT Removal STEP 156 an Remove the engine oil pan and gasket. See Section 2445 of the service manual STEP 157 a Remove the bolts from the oil inlet tube. See Section 2445 of the service manual forthe oil inlet tube removal STEP 158 Remove the bolts from the main bearing cap. NOTE: Remove only one cap at a time to prevent the Crankshaft from moving. ac .20444| STEP 159 Remove the main bearing cap. STEP 160 ‘To remove the front main bearing liner, use a thin piece of plastic to push the bearing liner out Revised 2.06 Printed in USA,2425-48 Installation STEP 161 Put a new bearing liner on the crankshatl Use a thin piece of plastic to push the bearing liner in position STEP 162 STEP 163 Put a new bearing liner in the bearing cap. NOTE: Make sure the bearing liner locks are aligned when installing the liners. Slide the liner in position Never push on the center of the liners. ac .204e STEP 164 1. MAxmMUM LENGTH esa >| use Measure the length of the main bearing bolt. If the length is more than 128.75 mm the main bearing bolt must be replaced. IMPORTANT: Each bolt length must be measured before installation. STEP 165 ane c rd Install the bearing cap and torque the mounting bolts. See below. Torque Sequence Step 1 - Torque to 50 Nm Step 2 - Torque to 95 Nm STEP 166 Install the torque angle gauge. Position and lock the holding Tod. Turn the pointer to 60 degrees. Tighten the bolt until the pointer is at 0 degrees. Revised 2.06, PrntesinUSA.STEP 167 Remove the bearing cap and check the clearance. Clearance must be 0.066 to 0.134 mm. New liners must be installed if the clearance is more than 0.140 mm. NOTE: The crankshaft must be machined if the clearance is more than 0.134 mm with the new liners. STEP 168 {Add lubrication to the bearing liners and install the bearing cap. STEP 169 ‘Add lubrication to the cap bolts. Install the cap bolts and torque. See below. ‘Torque Sequence: Step 1 - Torque to 50 Nm Step 2 - Torque to 95 Nm ac .ze4ea 2426-47 STEP 170 Install the torque angle gauge. Position and lock the holding rod. Turn the pointer to 60 degrees, Tighten the bolt until the pointer is at 0 degrees. STEP 171 90594 Install @ new oll inlet tube gasket, See Section 2446 of the service manual forthe installation of the oll inlet tube. STEP 172 | Install the ol pan. See Section 2445 ofthe service manual Revised 2.06 Printed in USA,2425-48 CRANKSHAFT AND MAIN BEARINGS Removal STEP 173 Remove the cylinder head. See Section 2416 in the service manwal or cylinder head removal STEP 174 Make sure the upper and lower mark on the crankshatt pulley are in align. If the mark isnot in align replace the crankshaft pulley. STEP 175 Remove the crankshaft pulley bolts and the crankshaft pulley. ac. 20644 STEP 176 Remove the ol pan. See Section 2445 in the service manual for oil pan removal STEP 177 Remove the oil inlet tube bolts, See Section 2445 in the service manual for ol inlet tube removal. STEP 178 Remove the timing cover bolts and cover, Revised 2.06, PrntesinUSA.STEP 179 Remove the engine mounting plate bolts and the mounting plate, STEP 180 Remove the lft pump bolts and the lit pump. STEP 181 Remove the shutoff solenoid bolts and the shutoff solenoid ac .20444| 2426-49 STEP 182 Remove the nut and washer from the injection pump drive gear. STEP 183 Install the puller on the injection pump drive gear. Carefully tighten the bolts unt the gear is loose on the injection pump shaft and remove the gear from the injection pump. STEP 184 Remove te injection pump bolts andthe injection pump from the front housing Revised 2.06 Printed in USA,2425-50 STEP 185 Make twelve dowels, 1/2 x 18 inches long, Cut a slat in each dowel 9 mm deep. STEP 186 Install a dowel in each liter, Pull each lifter up until it makes contact with the cylinder block. Use a rubber band to hold the dowel in place. STEP 187 Remove the bolts and the camshaft thrust plate ac. 20644 STEP 188 Remove the camshaft STEP 189 Remove the front housing bolts and the front housing, STEP 190 Remove the seal carrer bolts and the seal carrer Revised 2.06, PrntesinUSA.STEP 191 Remove the nuts and the connecting rod bearing caps, STEP 192 BE Remove the pistons and connecting rods. STEP 193 a Remove the bots trom the crankshaft main bearing caps. ac .204ea 2425-51 STEP 194 FLYWHEEL Each bearing cap has a number for assembly identification, STEP 195 Remove the crankshaft main bearing caps. STEP 196 Remove the crankshatt from the engine Revised 2.06 Printed in USA,2425-52 STEP 197 STEP 199 Remove the main bearing liners from the engine. STEP 198 Prior to Serial Number 44487830 SPRAY NOZZLE stetet Engine Serial Number 44487830 and After ‘SPRAY Nozze rater lean the oll spray nozzles with a small wire, if a nozzle is ‘damaged it must be replaced, ac .204e Revised 2.06, PrntesinUSA.2426-59 Crankshaft Gear Removal STEP 200 Pll the gear off the crankshaft, STEP 201 damaged. Crankshaft Inspection STEP 202 ‘Te9070 Measure the main bearing journals to see ifthe journals are worn. Measure the front and rear of each journal. If the diameter is less than 97.962 mm, grind the crankshaft journals NOTE: Grind the crankshaft journals undersize .025mm, 0.050 mm, 0.75 mm or 1.00 mm, if the crankshaft journals are worn more than 0.025 mm. ac .20444| STEP 203 Measure the main bearing journals, again, 90 degrees from the first measurements (Step 183) for out of round. If the out ‘of round is more than 0.050 mm, grind the journals and use undersize liners. Revised 2.06 Pinesin USA2425-54 STEP 204 69072 Measure the connecting rod journals for taper. Measure the {ont and rear of each journal. Grind the journals if the taper is more than 0.013 mm, STEP 205 iad MR Check the connecting rod journals again, 90 degrees from the frst measurements (Step 185) for out of round, Grind the journals if out of round is more than 0.050 mm. Crankshaft Gear Installation STEP 206 6.01 Install the crankshaft gear pin. The pin must be above the crankshaft surface, ac. 20644 STEP 207 Heat the crankshaft gear for a minimum of 45 minutes in a bearing heater oven tothe following temperatures: 300" F (149°C) 350" F (17°C) Austempered Gear Steel Gear Install the heated gear onto the crankshaft WARNING: Always wear heat protective gloves to prevent burming your hands when hrandling heated pars. swank Revised 2.06, PrntesinUSA.2426-55 Valve Lifter Inspection (Oil Pan Removed) STEP 211 STEP 208 Remove the dowels from the liters and remove the liters. © STEP 209 ror Measure the liter bores, Use an expandable bore gauge. STEP 210 Ifthe diameter of the liter bore is more than 16.055 mm the cylinder block must be replaced, ac .204ea Measure the outside diameter of the valve liter stem. Ifthe diameter ofthe lifter stem is less than 16.925 mm, the valve lifter must be replaced. STEP 212 Lubricate the valve lifters with Lubriplate No. 105 paste or Lubrplate No. 4 ol STEP 213 Install the valve iter into the cylinder block and install the dowels in the valve liter. Revised 2.06 Printed in USA,2425-56 Crankshaft Installation STEP 214 RIOR TO ENGINE ENGINE SERIAL NUMBER ‘SERIAL NUMBER 44487890, 14867690 AND AFTER Wire NozzLe / Reo hoz reais Install he oll spray nozzle on nozzles into the bearing cartier. STEP 215 Lubricate the beating liner with clean engine oil and install the bearing liners. ac .204e STEP 216 Install the crankshaft in the engine block. STEP 217 i ead Install the liners in the bearing caps. Make sure the liner locks are aligned. Use a sliding type movement when installing the liners. Never push on the center of the liner. STEP 218 PLASTIGAGE Clean the main bearing journals and put a piece of plastigage ‘on the journals to check main bearing il clearance. Revised 2.06, PrntesinUSA.STEP 219 FLYWHEEL FAN , 26.91 Make sure the number on main bearing cap is in the correct number sequence. STEP 220 BEARING CAP cap BOLT | sta.et The cap bolt and bearing cap on engine serial number 4487830 and after use a larger diameter cap bol STEP 221 Maxum encr# 128.79 mm use Measure the length of the main bearing bolts. If the bolt length is more than 128.75 mm the main bearing bolt must be replaced. IMPORTANT: Each bolt length must be measured before installation. ac .204ea 2426-57 STEP 222 & Install the main bearing cap bolts and torque. See below: ‘Torque Sequence: Step 1 - Torque to 50 Nm Step 2 Torque to 95 Nm STEP 223 a HOLONG ROD Install the torque angle gauge. Position and lock the holding fod. Turn the pointer to 60 degrees. Tighten the main bearing bolt unt the pointer is at 0 degrees. Remove the main bearing caps. Revised 2.06 Printed in USA,2425-58 STEP 225 Check the main bearing oil clearance. Clearance must be (0.066 to 0.134 mm. If the clearance is more than 0.140 mm, undersize bearing liners must be installed. Install new Uundersize liners which will give a clearance of 0.066 to 0.134 mm. NOTE: if the clearance is more than 0.134 mm, the crankshaft must be machined. Direct Measure Method STEP 226 174.964 Use a micrometer to measure the main bearing journals, The journals must meet the following specifications for minimum worn diameters Standard - 97.962 Machined 0.25 mm - 97.712 Machined 0.50 mm - 97.462 Machined 0.75 mm - 97.212 Machined 1.00 mm - 96.962 Bearing Clearance = Main bore diameter with bearing installed minus crankshaft main bearing journal diameter. Maximum Bearing Clearance - 0.134 mm, ac .204e STEP 227 1731968 svaLg60 Measure the main bearing shell thickness with an outside micrometer with a ball tip. Standard main bearing shell thickness must be 3.446 to 3.454 mm, Discard any shell i tis, thinner than the minimum specification, NOTE: The upper bearings contain two oil hole, lower bearings do not. Both bearings are marked on the back to indicate either standard (STO) or oversize (OS). Determine the size of the bearing being removed and obtain the same size for installation. STEP 228 Lubricate the crankshaft journal mating surface ofthe bearing shells with Lubriplate 105, Revised 2.06, PrntesinUSA.STEP 229 2s = f = Lubricate the main bearing cap bolts with clean engine ol. STEP 230 Install the cap bolts and torque. See torque sequence below, Torque Sequence: Step 1 - Torque to 50 Nm Step 2 - Torque to 95 Nm STEP 231 Install the torque angle gauge. Postion and lock the holding Tod. Turn the pointer to 60 degrees. Tighten the main bearing bolt unt the pointer is at 0 degrees. ac .204ea 2426-59 STEP 232 Put a dial indicator on the crankshaft gear. Check the crankshaft end clearance. The end clearance must be 0.157 100.334 mm. If the clearance is more than 0.981 mm, ater all the main bearing liners have been replaced, the crankshaft must be replaced. NOTE: To get an accurate reading, use a pry bar between the crankshaft and the number three and ‘number five main bearing caps as shown above. STEP 233 Install two guide bolts M x 1.25 x 75 mm, Revised 2.06 Printed in USA,2425-60, STEP 234 te Apply a thin layer of Three Bond Silver ATV Sealer to both sides of a new paper timing gear housing gasket. I a new steel gasket with rubber sealing edge is being used, no additonal sealant is required. Install the new gasket. STEP 235 (OIL PASSAGE | lean the oil passage for the injection pump of all foreign material STEP 236 Install the timing gear housing, ac. 20644 STEP 237 Install the housing bolts and remove the guide bolts. For housings that use the old style paper gasket, tighten the five 20 mm length bolts to a torque of 40 Nm. Tighten the remaining bolts to a torque of 24 Nm. Housings that use the new style steel gasket, tighten all the bolts to a torque of 40, Nm, STEP 238 ‘Add lubrication to the camshaft bearing journals. Use clean engine oil STEP 239 cy Make sure the timing marks onthe crankshaft and camshatt are aligned Revised 2.06, PrntesinUSA.STEP 240 Install the thrust plate and the bolts. Tighten the bolts to a torque of 21 to 27 Nm, STEP 241 Puta lal indicator on the camshaft gear. Check the backlash between the camshaft gear and the crankshaft gear. Backlash must be 0.152 to 0.254 mm. If backlash is more than 0.281 mm, the gears must be replaced, NOTE: Too much backlash can also be caused by worn camshaft bushings STEP 242 Remove the dowels from the liters. ac .20444| 2425-61 STEP 243 Install the injection pump, shutoff solenoid and the hand primer pump. See Section 3412 in the service manual. STEP 244 ‘Add lubrication to the cylinder walls and piston rings. Use clean engine oil STEP 245 Install the ring compressor onthe piston and carefully push te piston down into the cylinder IMPORTANT: Make sure that the mark FRONT is toward the front of the engine. Make sure the correct connecting rod is in the correct cylinder. Revised 2.06 Printed in USA,2425-62 STEP 246 LINER LOCKS] Install the bearing liners on the connecting rods and rod caps. IMPORTANT: Make sure the liner locks are aligned when installing the liners. Use a sliding type movement when installing the liners. Never push on the center of the liners. STEP 247 NEW STYLE 62005 Measure the length of the connecting rod bolts. If the bolt length is more than the maximum shown for your style bot, the bolt must be replaced. IMPORTANT: Each bolt length must be measured before installation. IMPORTANT: Do not mix old and new bolts on any one connecting rod. Both rod bolts must be the same part umber. ac .204e STEP 248 Clean the connecting rod journals and the bearing liners. Put ‘piece of plastigage on the rod cap liner or the rod journals STEP 249 Install the bearing caps. NOTE: Make sure the number on the bearing cap is equal to the number on the connecting rod. STEP 250 Torque the connecting rod bolts. See below. Step 1 - Torque to 40 Nm Step 2 - Torque to 70 Nm PrntesinUSA.STEP 251 Install the torque angle gauge. Position and lock the holding Tod. Turn the pointer to 60 degrees. Tighten the main bearing bolt until the pointer is at 0 degrees. STEP 252 Remove the bearing caps and check the clearance. The clearance must be 0.033 to 0.117 mm. If the clearance is more than 0.117 mm, undersize bearing liners must be installed and reconditioning of the bearing journals must be done. Install new bearing liners which will give a clearance of 0,038 to 0.117 mm, STEP 253 ‘Add lubrication to the bearing liners. Use clean engine ol ac .204ea 2428-6 STEP 254 Install the rod bearing caps. STEP 255 Lubricate the connecting rod bolts with clean engine oll STEP 256 ‘Torque the connecting rod bolts. See below. Step 1 - Torque to 40 Nm Step 2 - Torque to 70 Nm Revised 2.06 Printed in USA,2425-64 STEP 257 Install the torque angle gauge. Position and lock the holding Tod. Turn the pointer to 60 degrees. Tighten the main bearing bolt until the pointer is at 0 degrees. STEP 258 Install the support bracket and tighten the bolts toa torque of 402 10 122 Nm, STEP 259 ace Install the cylinder head. See Section 2416 for instaling the cylinder head. ac .204e STEP 260 Clean the front crankshaft seal surace of all foreign material, using Loctite safety solvent. See seal installation inthe this section for installing the front crankshatt seal and the orankshatt pulley. STEP 261 Clean the rear crankshalt seal surface ofall foreign material, using Loctite safety solvent STEP 262 ‘GUIDE BOLTS Install two guide bolts (MG x 1.00 x 50 mm). Apply a thin layer of Three Bond Silver RTV Sealer to both sides of a new seal carrier gasket and install the gasket. Revised 2.06, PrntesinUSA.2426-65 STEP 263 STEP 265 Install the seal carrier bolts finger tight. Center the carrier on Install the engine oil pan. See Section 2445 for oil pan the crankshaft. Tighten the bolts to a torque of 8 to 10 Nm. instalation, See seal installation in this section for installing the rear crankshaft seal STEP 264 Te Install @new oll inlet tbe gasket. See Section 2445 for ol inlet tube instalation, ac .20444| Revised 2.06 Pinesin USA2425-66, CAMSHAFT Removal STEP 266 STEP 269 Make sure the upper and lower mark onthe crankshaft pulley are in align. If the upper and lower mark are notin align, replace the crankshaft pulley. STEP 267 Lift the belt tensioner and remove the fan belt. STEP 268 Remove the fan pulley bolts and the fan pulley. ac. 20644 Remove the crankshaft pulley bolts and the crankshaft pulley. a STEP 270 Remove the front cover bolts and the front cover. STEP 271 Clean the front cover and the housing surface of all foreign material Revised 2.06, PrntesinUSA.STEP 272 Disconnect the fuel fiter init line from the lit pump, STEP 273 Remove the lit pump bolts and the lit pump from the cylinder bloc. STEP 274 Remove the breather from the valve cover. ac .20444| 2425-67 STEP 275 Remove the valve cover STEP 276 Remove the rocker arm bolts and the rocker arm assembly. STEP 277 Remove the rocker arm oll supply tube, IMPORTANT: 4 new oil supply tube must be installed if the supply tube is made of nylon material Revised 2.06 Printed in USA,2425-68 STEP 278 Remove the push rods. STEP 279 Make twelve wood dowels 1/2 x 18 inches. Cut to a slot in ‘each dowel 9 mm deep. STEP 280 Push a dowel nto each iter. It may be necessary o push the ‘dowel into the liter wih a soft face hammer ac. 20644 STEP 281 sylinder block. Put a rubber band around two dowels to hold the lifters off the camshaft, STEP 282 Remove the nut and washer from the injection pump drive gear. STEP 283 S. B a Install the puller on the drive gear. Tighten the bolts until the gear is loose on the injection pump shatt. Remove the gear from the injection pump. Revised 2.06, PrntesinUSA.2426-69 STEP 284 STEP 285 Remove the bolts and the camshaft thrust plate. Remove the camshaft from the engine block. Camshaft Bushing Removal and Installa STEP 286 STEP 287 If the bushing diameter is more than 60.122 mm, the ‘camshaft bushings must be replaced. STEP 288 Measure the camshaft bores. Use a bore gauge. The bores must be measured in two positions. Take a second measurement 90 degrees from the first measurement Put a bushing puller in the engine block and pull the busting ‘out ofthe cylinder block. ac .20444| Revised 2.06 Pinesin USA2425-70 STEP 289 Install the bushing on the puller. Align the oil holes, Pull the bushing into the cylinder block until it is even with the housing Valve Lifter Inspection (Oil Pan Installed) STEP 290 STEP 292 VALVE LIFTER TRAY Make a valve lifer tray from a piece of 50.8 mm plastic pipe. Remove the rubber band from one dowel ‘See dimensions above ania NOTE: Remove only one lifter ata time. STEP 291 Puta piece of tape on one end ofthe tray so thatthe liters do not falloff the tay. Install the tray into the camshaft bore. ac. 20644 Revised 2.06, PrntesinUSA.STEP 293 “4 90764 es.a1 Remove the dowel from the lifter, the lifter wil fall into the tray. STEP 294 Carefully remove the tray and iter from the bore, NOTE: You must be careful when removing the lifters from number 6 cylinder so that the litter does not fal off the tray. fa fitter does falloff the tray the oil pan must be removed. ac .20444| 2425-71 STEP 295 Use a micrometer to measure the outside diameter of the lifter. Replace the lifter ifthe outside diameter is less than 16,925 mm, STEP 296 Make a liter installation fol. Use the folowing: Wood dowel 1/2 x 1/2 inch Cotter pin 1/8 x1 inch Number 6 flat washer 7 feet of 200 pound test nylon cord STEP 297 Ee Put the installation tool down the lifter bore into the tray and pul the tray out of the camshaft bore. Revised 2.06 Printed in USA,2425-72 STEP 298 STEP 300 Push the installation tool into the litter bore, Tum the tray over in the camshaft bore so that the surface of the tray is against the face of the liter. STEP 299 a STEP 301 E Remove the installation tool from the bore and install the dowel inthe lifter. STEP 302 raat01 Push the tray into the camshaft bore and carefully pull the liter into te liter bore. Put a rubber band on the dowel to hold the ters up. Remove the tray trom the camshaft bore ac. 20644 Revised 2.06, PrntesinUSA.2426-73 Camshaft Disassembly and Inspection STEP 303 STEP 305 69065 Press the gear off the camshatt Measure the front and rear of each bearing surface on the ‘camshaft. Use a micrometer. STEP 304 STEP 306 Remove the shaft key. Each bearing surface must be measured in four positions. Measure the front and rear bearing surfaces again, 90 degrees from the frst measurement. NOTE: Replace the camshaft if the outside diameter of any bearing surface is less than 59.962 mm. ac .20444| Revised 2.06 Printed in USA,2425-74 Camshaft Gear Installation STEP 307 STEP 308 PINHOLE. Install the shat key. Heat the camshaft gear a minimum of 45 minutes ina bearing heater oven tothe folowing temperatures: Austempered Gear 00°F (149°0) Steel Gear 350°C (177°C) Install the gear on the camshaft withthe lock pin hole down. WARNING: Always wear heat protective gloves to prevent burning your hands when hanaling heated parts. sua Camshaft Installation STEP 310 STEP 309 Align the timing marks on the camshaft with the timing mark on the crankshaft Lubricate the camshaft bearing surface with clean engine oll ac. 20644 Revised 2.06, PrntesinUSA.STEP 311 Install the camshatt thrust plate, Tighten the bolts toa torque (of 21 to 27 Nm. STEP 312 ‘Check the camshaft end clearance with a dial indicator. If the clearance is more than 0.470 mm the camshaft thrust plate must be replaced ac .20444| 2426-75 STEP 313 Puta dial indicator on the camshaft gear and check the gear clearance between the camshaft gear and the crankshaft ‘gear. Gear clearance must be 0.182 to 0.251 mm. The gears must be replaced if the clearance is more than 0.251 mm, NOTE: Too much gear clearance can also be caused by worn camshaft bushings. STEP 314 Remove the dowels from the liters. STEP 315 Install the gasket and lit pump. Tighten the bolts to a torque (of 21 to 27 Nm. Revised 2.06 Pinesin USA2425-78 STEP 316 STEP 319 ‘Connect and tighten the fiter inlet line tothe ft pump. STEP 317 Install the gaskets one on each side of the inlet. Tighten the filter inlet fitting to a torque of 21 to 27 Nm STEP 318 Install the gasket and leak off bot. Tighten the leak off bot to a torque of 7 10 9 Nm. ac. 20644 Install the push rods, STEP 320 Install the oll supply tube forthe rocker arms, STEP 321 ROCK ARM. ASSEMBLY Install the rocker arm assembly and the rocker arm clamp. Revised 2.06, PrntesinUSA.2426-7 STEP 322 STEP 324 Install the rocker arm bolts and tighten to a torque of 40 to 46, Nm. : STEP 323 Install the engine turn over tool (if equipped) push in on the lock pin and turn the engine over until the lock pin engages into the camshaft gear. ‘Adjust the valve clearance. See Section 2415 in the service manual for valve adjustment, STEP 325 “TIMING IN Remove the timing pin cover and the timing pin. ac .20444| Revised 2.06 Pinesin USA2425-78 STEP 326 PUMP SHAFT Turn the injection pump shaft until the tab isin the center of, the timing pin hole, STEP 327 Install the timing pin into the injection pump. The timing pin slot must align with the tab inthe injection pump. ac. 20644 STEP 328 Install the timing pin cover and tighten a small amount STEP 329 Install the injection pump drive gear on the injection pump shatt NOTE: The injection pump drive gear does not have a key slot or a timing mark on the gear. STEP 330 Install the dive gear washer and nut, Tighten the nut a small amount Revised 2.06, PrntesinUSA.STEP 331 STEP 334 Remove the injection pump timing pin cover and pull the Pll the timing pin out ofthe camshaft timing pin out ofthe injection pump. STEP 332 ‘SHORT END Tighten the drive gear nut to a torque of ‘Tum the timing pin over and install the timing pin into the Bosch Model A 92Nm econ pump. The shot ae te tre pt eb ede Feet “cet nm Bosch Model P non 145 Nm Nippendenso EP-0... "104.Nm STEP 333 STEP 336 Install the timing pin cover and tighten tothe following Bosch Model A. 30 Nm Clean the crankshatt seal surface with Loctite safety solvent. Bosch Model MW 30 Nm See front seal instalation in ths section. Bosch Model P. 30 Nm Nippendenso injection Pump 70Nm ac .20444| Revised 2.06 Pinesin USA2425-80, STEP 337 STEP 338 Install the fan pulley and fan pulley bolts. Tighten the fan Lit the bet tensioner and instal the fan belt pulley bolts to a torque of: Grade 8.8 Size M8 21 t031 Nm Grade 10.9 Size MB 37 to 43 Nm Grade 8.8 Size M10 51 to 62 Nm Grade 10.9 Size M10 51 to 62 Nm FLYWHEEL Removal STEP 339 STEP 340 REMOVE BOLTS. Remove the botts from the flywheel Remove the flywheel from the flywheel housing ac. 20644 Revised 2.06, PrntesinUSA.Ring Gear Removal and Installation STEP 341 STEP 343 2425-81 Te0212 Remove the ring gear from the flywheel, using a drift and Install the flywheel. Tighten the retaining bolts to a torque of hammer. Work around the circumference of the ring gear. 490 to 141 Nm, STEP 342 eee 769213 Heat the new ring gear to 350°F (177°C), in a bearing heater ‘oven for a minimum of 30 minutes. Do not use a torch to heat the ring gear. Install the ring gear on the flywheel gloves to prevent burning your hands when WARNING: Always wear heat protective A hanaling heated parts. smi ac .20444| Revised 2.06 Pinesin USA2425-82 EXPANSION PLUG REMOVAL AND INSTALLATION 60 mm Expansion Plug, Camshaft NOTE: The flywheel and flywheel housing must be removed to replace the camshaft expansion plug. STEP 344 Remove the expansion plug from the cylinder block, STEP 345 Use Locite safety solvent to clean the sealing surface of all {foreign material ac .204e STEP 346 Install a new O-ring onto the plug. Apply Loctite 277 to the sealing surface of the expansion plug STEP 347 Install the expansion plug into the cylinder block. Hit the ‘expansion plug in the center to lock the expansion plug in position, Revised 2.06, PrntesinUSA.2426-83 58 mm Expansion Plugs STEP 348 Remove the expansion plug from the cylinder block. STEP 349 Clean the sealing surface of all foreign materia STEP 350 Apply Loctite 277 to the sealing surface of the expansion plug ac .204ea STEP 351 rt ete / ‘CHAMFER EXPANSION PLUG 2210 expansion plug into the cylinder block, until the top ‘edge of the expansion plug is even with the bottom edge of the chamfer. Revised 2.06 Printed in USA,2425-84 22.5 mm Expan: STEP 352 On FILTER Jooaess Remove the expansion plug from the cylinder block STEP 353 eT TB0E lean the expansion plug bore of all foreign material, use Loctite safety solvent. STEP 354 Apply Loctite 277 to the sealing surface of the expansion plug ac .204e n Plug STEP 355 oo ‘CHAMFER EXPANSION PLUG 03.0 Install the expansion plug into the bore, until the top edge of the expansion plug is even with the bottom edge of the chamfer PrntesinUSA.2425-85 10 mm Expansion Plugs STEP 356 STEP 359 Put a small amount of grease in the expansion plug STEP 357 Drill a small hole in the center of the expansion plug STEP 358 Install a screw in the expansion plug and pull the expansion Plug out of the cylinder black ac .204ea Use Loctite safety solvent to clean the sealing surface of all foreign material STEP 360 Apply Loctite 277 to the sealing surface of the expansion plug. Revised 2.06 Printed in USA,2425-86 STEP 361 ence CHAMFER \ EXPANSION PLUG 0010 Install the expansion plug into the cylinder block until the top ‘edge of the expansion plug is even to the bottom edge of the chamfer, ac .204e Revised 2.06, PrntesinUSA.2425-87 CRANKCASE PRESSURE CHECK (BLOW BY) Manometer Installation STEP 362 Remove the clamp and the breather hose, STEP 363 — Install the breather adapter with the six cylinder orifice, NOTE: Use the 7.67 mm (0.302 inch) orifice for six cylinder engines. STEP 364 = ’ L pence Install the manometer. ac 8.20444 STEP 365 Turn each connector on the manometer one turn counterclockwise. STEP 366 Connect the tube from the breather adapter to one of the ‘connectors on the manometer. STEP 367 LiQUD Push the button on the gauge and move the gauge up or ‘THERMOSTAT ais 3, Remove the plug from the housing to get access to the valve. Push the valve out ofthe housing, 4, Drive a new valve in until the valve bottoms against the step in the bore, 5. Install the filter adapter or the gasket and filter head, as. equipped. Revised 2.06 Printed in USA,2445-10 Oil Cooler Service and Testing STEP 23 Install plugs in the cooler element ports and soak the cooler in a cleaning solution to remove coolant deposits. STEP 24 58.068 Remove the plugs and flush the cooler element with solvent ‘The cooler element can be cleaned in a hot tank. Back flush the oil passages with clean solvent and use compressed air to dry. IMPORTANT: If the oil passages are contaminated by foreign material, the oil cooler must be replaced. STEP 25 581964 Inspect the soldered joints for corrosion or cracks. Check the clement for flatness. There can be a maximum of 0.8 mm (0.031 inches) of element distortion. ac 8.20453, STEP 26 581960, Block one port and connect a regulated air line to the other port. Apply 483 kPa (70 psi) air pressure to the element and check for leaks. If leaks are found, the oll cooler must be replaced. STEP 27 ‘Submerge the cooler in a tank of water. Heat the water to 82" C (180°F) and check for leaks. If leaks are found, the oil ‘00ler must be replaced. STEP 28 ake = 8.064, Remove the oil cooler from the tank of water. Remove the pressure check equipment and use compressed ai to dry the oil cooler. Cover the parts with tape to prevent dirt from entering the ‘element unt the cooler i installed in the machine. Revised 2.06, PrntesinUSA.2845-11 Oil Temperature Thermostat Service STEP 29 THERMOSTAT A 11984 It not already done, remove the thermostat from the oil cooler. Clean the thermostat with solvent. Dry with ‘compressed ait STEP 30 1968 Visually inspect for a broken or damaged spring or other damage. ac 0.20453, STEP 31 411980 ‘Suspend the thermostat and a 150°C (300°F) thermometer in ‘a container of new engine ol. Do not alow the thermostat or thermometer to touch the sides or bottom of the container Heat the oil WARNING: The flash point of new lubricating oil is approximately 221°C (430°F). Do not allow oil temperature in the container to exceed 150°C (300'F). Do not allow water droplets to enter the container of hot oil. Water droplets will cause a violent reaction which can cause personal injury. Mus STEP 32 =—— 459mm (tan to) + anis6c \Write down the temperature at which the thermostat i fully extended. The thermostat must fully extend to at lease 45.9 mim (1.80 inch) when the oil reaches 116°C (240'F} Replace the thermostat if t does not operate as described. Revised 2.06 Printed in USA,2485-12 Installation Prior to Engine S/N44500595, Engine S/N44500595 and After ‘iL cooLER Breas. ‘THERMOSTAT ‘GASKET iL cooteR ‘o cooLER FILTER HEAD FILTER HEAD ans sos STEP 33 STEP 34 Install two guide bolts and a new oil cooler gasket. Install the oil cooler. ac 8.20453, Revised 2.06, PrntesinUSA.2446-19 STEP 35 STEP 37 6T-830 En: Install a new fiter head gasket. Install and tighten the fitting. Connect and tighten the turbocharger pressure tube, STEP 36 STEP 38 Install the ol fier head and tighten te bolts to a torque of 2t t0.27 Nm, See the operators manuel for servicing the oi fier. ac 0.20453, Revised 2.06 Pinesin USA2445-14 OIL PAN AND OIL INLET TUBE SERVICE Removal STEP 39 STEP 41 Remove the ol pan drain plug and remove the cil Remove the ol inlet tube retaining bolts. Remove the oll inlet lube. STEP 40 STEP 42 Remove the oil pan bolts and washers. Remove the oil pa. Clean all surfaces of foreign material ac 8.20453, Revised 2.06, PrntesinUSA.2445-15 Installation STEP 46 Install a new gasket Install the ol pan, STEP 44 STEP 47 ‘TUBE CLAMP SUPPORT RACKET Do the following to install the oil inlet tube: Tighten the pan bolts toa torque of 21 to 27 Nm. 1. Install the support bracket and inlet tube. The bolts must be finger tight. eucie 2, Tighten the inlet tube bots to a torque of 8 to 10 Nm. 3, Tighten the support bracket to block bolts toa torque of 8 to 10 Nm, 4, Tighten the inlet tube clamp. STEP 45 Install the oil pan drain plug and tighten to a torque of 76 to 84 Nm. Install a new oil pan gasket. ac .20453, Revised 2.06 Pinesin USASection 2455 COOLING SYSTEM Thermostat, Water Pump, Fan Pulley and Belt Tensioner 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measureme All measurements and checks must be made with metric tools to m an accurate reading when inspecting perts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA eee CANADA CORE OEATION) (© 1906 Case Corporation 3950 South Service Road tod ih Burlington, ON L7N 3M6_ CANADA Rac 8.28464 December, 1990 (Revised March, 109)2855-2 TABLE OF CONTENTS ‘SPECIFICATIONS .... ‘SPECIAL TORQUES ... HOW TO CLEAN THE COOLING SYSTEM WATER PUMP SERVICI Removal Installation ‘THERMOSTAT SERVICE ... Removal nner Thermostat inspection Check Valve Installation . Installation nnn FAN PULLEY SEAVICE Removal and Disassembly... ‘Assembly and Installation BELT TENSIONER SERVICE .. Belt Tensioner Check and Removal Belt Tensioner Installation... SPECIFICATIONS Bett Tension ‘Spring Tension at 35 degree angle (minimUm)....0no “ sonnannnnn son 241NM ac 8.20464 Revised 2.06, Prntadia USA2455-3 SPECIAL TORQUES Metric Value ‘eter Pump Housing Bolts 21 to.27 Nm ‘Thermostat Housing Bolts 24 t027Nm Coolant Outlet Bolts 24 t027Nm Fan Pulley Bracket Bolts 24 t027Nm Fan Pulley Bots Grade 8.8 Size M8 26 t0 31 Nm Grade 10.9 Size MB. 87 to 43 Nm Grade 8.8 Size M10. 51 to 62 Nm Grade 10.9 Size M10. 51 to 62 Nm Tensioner Bracket Bolts 241027 Nm Tensioner Bot 38 10 47 Nm WARNING: Add coolant fo the radiator only when the engine is stopped or slowly idling. To avoid being scalded when the pressure-type filer cap is being removed, turn the cap slowly to the frst stop position to relieve pressure before removing the cap. ots IMPORTANT: Never put coolant in a hot engine. The engine black or cylinder head can get cracks because 0! the difference in temperature between the metal and coolant, HOW TO CLEAN THE COOLING SYSTEM Clean the cooling system a minimum of one time each year. 3, Remove the radiator cleaner solution. Flush the system In areas where the water has minerals, clean the system with wih clean water. Fill the system with antifreeze and water more frequency. solution for operation. Check the hoses, radiator and water pump fo leaks. 1. When the coolant is hot, open the radiator drain valve and remove the engine black drain plug. Close the valve NOTE: After the cooling system is completely filed, run and instal the engine block drain plug after the system is the engine for approximately 20 minutes to remove all air empty. from the system. Check coolant level and add coolant as needed. 2. Add a radiator cleaner such as Fleetguard Restore | or Restore Il and fill the system with clean water, Follow the instructions given with the radiator cleaner ac -20404| Revised 2.06 Printed in USA,2455-4 WATER PUMP SERVICE Removal Installation STEP 1 STEP 4 Lift the bett tensioner pulley and remove te fan bel, Install a new O-ring inthe water pump housing STEP 2 STEP 5 Remove the water pump bolts. Remove the water pump. Install the water pump and bolts. Tighten the bolts to a torque Discard the O-ring of 21 to 27 Nm, STEP 3 STEP 6 lean all surfaces of foreign material Lift the belt tensioner pulley and install the fan bel ac 8.20464 Revised 2.06, PrntesinUSA.2485-5 THERMOSTAT SERVICE Removal NOTE: The engine shown is not equipped with a water fiter. Your engine may be equipped with a water fiter on the thermostats housing. STEP 7 Litt the belt tensioner pulley and remove the fan bet. STEP 8 Remove the belt tensioner bolt and the belt tensioner. STEP 9 Remove the tensioner bracket bolts and the tensioner bracket ac -20404| STEP 10 BRACKET} Remove the altemator and the alternator bracket. STEP 11 ‘Remove the coolant outlet pipe trom the thermostat housing, STEP 12 THERMOSTAT] ‘Remove the thermostat housing and the thermostats, Revised 2.06 Pinesin USA2455.6 Thermostat Inspection STEP 13 e.0 Check the two thermostats for correct operation. Put a thermostat in @ container of hot water (approximately 175°F (79°C) water). The thermostat should start to open at 178° to 182° F(81 to 83°C). The thermostat should be completely ‘open at 203°F (25°C). Replace the thermostat if it does not meet the above specifications. ac 8.20464 Check Valve Installation STEP 14 CHECK VALVE. TEE FITTING vent TUBE {ooo [CHECK VALVE. TEE FITTING VENT TUBE Check the vent tube and check valve for correct operation. The vent tube and check valve must be free of all foreign material. The check valve pin must have movement, i the pin ‘does not move freely, the check valve must be replaced. IMPORTANT: The check vaive pin must operate freely and the vent tube must be free of foreign material, to remove air from the cooling system. Revised 2.06, PrntesinUSA.2455-7 Installation IG/ ‘a! anh f ie 7 | | EZ J, come BRACKET WATER FILTER ALTERNATOR 7 BRACKET & » “& $$ °Gg. STEP 15 STEP 16 NeW THERMOSTAT HOUSING ENGAGES ‘THEENGINE BLOCK AT TWO POWTS NOTE: On blocks without alignment pins, uses a straight ‘edge to align housing and block face. Install the thermostats and gasket into the cylinder block. The thermostats must point up toward the outlet pipe. Install the thermostat housing and using a straight edge, align 0 the alternator pulley will be even with the fan pulley. Tighten thermostat batts to a torque of 21 to 27 Nm, ac -20404| Revised 2.06 Pinesin USA2455-8 STEP 17 Install the gasket, coolant pipe and bolts Tighten the bolts to torque of 21 to 27 Nm. STEP 18 Install the alternator bracket and bolts. Tighten the bolts to a torque of 21 to 27 Nm, STEP 19 Install the alternator and tighten the bolts. ac 8.20464 STEP 20 Install the tensioner bracket and bolts. Tighten the bolts to a torque of 21 t0 27 Nm. STEP 21 Install the belt tensioner and bolt. Tighten the bolt toa torque 0f 39 to 47 Nm, STEP 22 Lift the bett tensioner pulley and install the fan belt, Revised 2.06, PrntesinUSA.2455-9 FAN PULLEY SERVICE Removal and Disassembly STEP 23 STEP 26 Lift the belt tensioner and remove the fan belt Visually inspect the fan hub for any oll seal leakage. Inspect the fan hub for eracks or damage. STEP 24 STEP 27 soL968 ‘Tum the fan hub shaft by hand. The fan hub must spin freely without any wobble or excessive end clearance. Remove the fan pulley bots and the fan pulley. STEP 25 STEP 28 Remove the fan pulley bracket, anigec Measure the fan hub shaft end clearance. End clearance must not be more than 0.15 mm, ac -20404| Revised 2.06 Pinesin USA2455-10 STEP 29 STEP 31 | stL088 0.960 Put the fan hub in a vice and remove the center bolt and Support the hub housing/puller and press out the fan hub retainer. using a 3/4 inch dri ‘The fan hub must be replaced or rebuilt if there are damaged parts, the shaft does not rotate freely or the shaft end STEP 32 clearance is not within specifications. Ky STEP 30 v LL =e Support the hub housing and use a 2 inch pipe or equivalent ‘and press out the bearing. S1L96A Install a bearing puller as shown, NOTE: Do not overtighten the bearing puller as hub shaft damage may result when the hub is pressed out. ac 8.20464 Revised 2.06, PrntesinUSA.2855-11 Assembly and Installation STEP 36 STEP 33 dt eee) Press a new bearing into the fan hub housing even with the front ofthe housing I the installation force is less than 9000 NN (2028 I), the housing must be replaced. IMPORTANT: Do no! press on the inside diameter of the bearing as bearing damage could result. STEP 34 2.004, Support the bottom of the inner bearing race. Use a 1-1/2 inch 1D pipe and press the shatt in until seated. Check the assembled height. The assembled height must be 124.85 to 125.65 mm. Ifthe assembled height is incorrect, disassemble and assemble with a new bearing STEP 35 01960 Install the hub retainer and center bolt. Tighten the bolt toa torque of 77 Nm. ac -20404| Install the bracket and bolts. Tighten the bolts to a torque of 211027 Nm. STEP 37 Install the fan pulley and tighten the bolts to a torque of Grade 8.8 Size MB vw» 261031 Nm Grade 10.9 Size MB . vw 87 0.43. Nm Grade 8.8 Size M10 . vw 51 to 62Nm Grade 10.9 Size M10 vw 51 t0 62. Nm STEP 38 Lift the belt tensioner pulley and install the fan bet Revised 2.06 Pinesin USA2455-12 BELT TENSIONER SERVICE Belt Tensioner Check and Removal STEP 39 STEP 40 Litt the belt tensioner pulley and remove the fan bet. see.0 toer.o 66.0 NOTE: Your engine can be equipped with one of the belt tensioners shown above. The lift holes are as shown. Use a precision type torque wrench to it the belt tensioner to a 45 degree angle, Lower the belt tensioner to a 35 degree angle. The spring tension must not be less than 24 Nm, Ifthe spring tension is less than 24 Nm the belt tensioner must be replaced. NOTE: Do not use a clik type torque wrench to measure the spring tension. ac 8.20464 Revised 2.06, PrntesinUSA.2485-18 STEP 41 STEP 43 Remove the belt tensioner bolt and the belt tensioner. eae STEP 42 sHOULDER BOLT a BEARING DUST SEAL sites Remove the shoulder bolt, bearing and dust seal from the belt tensioner pulley. Belt Tensioner Installation STEP 44 STEP 45 sHouLDER BOLT BEARING a bust seaL. silt 'nstall the bracket and tighten the Allen head bolts to a torque Install a new bearing in the tensioner idler pulley. Tighten the of 21 to 27 Nm. shoulder bolt to a torque of 33 to 47 Nm. Install the new dust seal in the bearing ac -20404| Revised 2.06 Pinesin USA2855-14 STEP 47 Install the bet tensioner and tighten the bol o a torque of 39 Litt the belt tensioner pulley and install the fan bet to47 Nm, NOTE: Case Corporation reserves the right make improvements in sign or changes in specications al any tine witout incuring any abigaton o instal hem on units previously so ac 8.20464 Revised 2.06, PrntesinUSA.Section 2465 TURBOCHARGER 6T-830 and 6TA830 Diesel Engine IMPORTANT: This turbocharger was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting parts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA CASE CANADA CORPORATION © 1994 Case Corporation 3850 South Service Road Printed nUSA. BButington, ON L7N 36 CANADA Rac 8.28471 Decombes, 198 Revised2865-2 TABLE OF CONTENTS ‘SPECIFICATIONS .... ‘SPECIAL TORQUES ... SPECIAL TOOLS... ‘TROUBLESHOOTING GUIDE ..... ‘SERVICING THE TURBOCHARGER: REMOVAL snnnnnnnere Inspection nnn . Disassembly nn Inspection After Disassembly . ASSEMDIY ence . . 16 Installation anne . 24 WASTEGATE TURBOCHARGER ‘Actuator Calibration . 26 SPECIFICATIONS Turbine Whee! Horizontal Movement... son o ssn 10.10 t0 0.16 mm Turbine Wheel Vertical Movement... son . ssn v0.90 t0 0.46 mm ac .2047t Revised 12.04 Prntadia USATurbine Housing Bolts Center Housing to Back Plate Bolts «0. Compressor Lock Nut. ‘Thrust Bearing Screws (Torx Head)... Turbocharger Mounting Nuts Drain Tube Botts. SPECIAL TORQUES 96 Ib inch (11 Nm) ..48 Ib inch (6 Nm) 420 Ib inch (14 Nm) ..6 Ib inch (5 Nm) 24 Ib ft (82. Nm) so 18 Ib ft (24 Nm) SPECIAL TOOLS 2465-3 (CAS-10066-14 DIAL INDICATOR Rac 8.28471 542A 528 (CAS-10032 LB INCH TORQUE WRENCH (CAS-10039 LB FT TORQUE WRENCH Ravieed 12.94 Printed inUS.A,2865-4 ‘SYMPTOM : TROUBLESHOOTING GUIDE 4 2 FOR THE TURBOCHARGER gy a al el a 2 3} 3) 8] al al 3 2} 8] 3] a] EE } 3} gf gt as al 3 2 8] al a cee ee e Dirty air cleaner ee ee Restricted compressor intake duct Festcted air duct tom compressor to intake manifold esticted intake manifold ‘Air leak in food romalr cleaner to compressor ‘ir leak in food rom compressor to intake manifold ‘Air leak between intake manifold and engine Foreign objct in exhaust manifold from engine) Resticted exhaust gstem Exhaust manifold cracked, gaskets blown or missing OOOO) OO © crsicrscxsronen @1O/O1O/OO) COO or rxcomusrsuoxe ‘Gas leak at turbine nlevexhaust marifold joint ‘Gas leak in ducting aftr turbine outet, Resticted wrbocharger ol drain tine Restricted engine crankcase breather “Turbocharger bearing housing sludged or coked Fuel injection pump or uel injectors incorecly set Engine valve ting noorrect ‘Worn engine piston rings or ines ‘Burt valves andlor pistons Excessive dit build up on compressor wheel andr cituser vanes ‘Turbocharger damaged ac @-28471 eavieed 12.94 Printed in USA.2465-5 SERVICING THE TURBOCHARGER Removal STEP 1 STEP 4 ‘Turbocharger with the air cleaner and the exhaust pipe Disconnect and remove the oil supply tube. removed. STEP 5 STEP 2 Disconnect the oil drain tube. Loosen the air intake hose clamps. STEP 6 STEP 3 Clean the mounting surface on the turbocharger and the oil Remove the air intake hose. drain tube. NOTE: The oil drain tube must be removed and thoroughly cleaned before turbocharger installation. A plugged oil drain tube can cause a turbocharger failure. ac -20471 Revised 12.04 Prinesin USA2465-6 STEP 7 STEP 9 Remove the nuts that hold the turbocharger to the exhaust Remove the gasket. ‘manifold, STEP 10 STEP 8 Clean the mounting surface on the turbocharger and the Remove the turbocharger from the exhaust manifold ‘exhaust manifold ac .2047t Revised 12.04 PrntesinUSA.2465-7 Inspection STEP 11 STEP 12 Put the turbocharger on a clean work surface. Use a cal indicator to check the horizontal movement and the vertical movement of the turbine wheel assembly. The turbocharger must be rebuilt if the horizontal movement is ‘more than 0.16 mm or less than 0.10 mm, The turbocharger ‘must be rebuilt if he vertical movement is more than 0.46 mm ‘or less than 0.30 mm. ac -20471 Revised 12.04 Pinesin USA2465-8 Disassembly STEP 13 STEP 16 Put an identification mark on the compressor housing and Remove the compressor housing clamp. bback plate. Ths identification is to make sure the parts are in the correct positon at assembly STEPnT STEP 14 Put an identification mark on the turbine housing and each plate, This identification is to make sure the parts are in the Loosen the retaining clamp on the compressor housing, ‘correct position at assembly. STEP 15 STEP 18 Lift the assembly off the compressor housing Make the tabs straight on the lock plate. ac .2047t Revised 12.04 PrntesinUSA.STEP 19 2465-9 STEP 22 Remove the retaining botts trom the lock plate, STEP 20 Remove the lock plates and clamp plates from the turbine housing STEP 21 Lit the center housing assembly from the turbine housing ac -20471 Put the turbine end of the center housing assembly into the holding fixture, STEP 23 Use a double universal joint to remove the compressor whe lock nut. This procedure wil prevent the turbine shaft rom bending STEP 24 Remove the compressor whee! lock nut. NOTE: The compressor wheel locknut is left hand thread. Revised 12.04 Pinesin USA2465-10 STEP 25 STEP 28 SEALING. Remove the compressor whe STEP 26 Remove the seal ring ftom the turbine shaft Lift the center housing from the turbine shaft STEP 29 STEP 27 Turbocharger center housing, Remove the heat shield. ac .2047t Revised 12.04 PrntesinUSA.2465-11 STEP 30 STEP 33 Put an identification mark on the center housing end back Remove the lock plates from the center housing, plate, This identification is to make sure the parts are in the correct position at assembly. ETEPIaa STEP 31 Remove the center housing from the back plate. Make the tabs straight on the lock plate. STEP 35 STEP 32 Remove the oil batfe from the back plate. Remove the retaining bots from the center housing. ac -20471 Revised 12.04 Pinesin USA2465-12 STEP 36 STEP 39 Remove the seal from the back plate, Turbocharger center housing, STEP 37 STEP 40 Remove the oil slinger from the back plate. Remove the torx head screws from the center housing, STEP 38 STEP 41 Remove the seal ring from the oil singer. Remove the thrust bearing. ac .2047t Revised 12.04 PrntesinUSA.2468-13 STEP 42 STEP 45 Remove the thrust collar. Remove inner bearing retaining ring STEP 43 STEP 46 Remove the outer bearing retaining ring ‘Turn the center housing over and remove the outer bearing retaining rng, STEP 44 g STEP 47 Use a wire hook and pull the bearing from the center housing Use a wire hook and pull the bearing from the center housing ac -20471 Revised 12.04 Pinesin USA2465-14 STEP 48 STEP 49 Remove the inner bearing retaining ring. Inspection After STEP 50 Clean all parts in cleaning solvent. STEP 51 Replace the turbocharger if the outlet openings show warpage or cracks, STEP 52 Replace the turbocharger it the compressor housing shows damage caused by whee! friction. ac .2047t Center housing disassembled. assembly STEP 53 Replace the turbocharger if the turbine whee! is damaged or ifthe turbine shatt has grooves or scratches. STEP 54 Replace the turbocharger if the back plate has wheel tition wear. Revised 12.04 PrntesinUSA.2468-15 STEP 55 STEP 57 Inspect the compressor wheel for bent blades and scratches. Replace the turbocharger it the oil slinger shows damage, Replace the turbocharger if the wheel shows damage. STEP 58 STEP 56 Inspect the center housing bearing surfaces for scoring or Replace the turbocharger if the heat shield shows damage. scratches. Replace the turbocharger if there is damage. ac -20471 Revised 12.04 Pinesin USA2465-16 Assembly ‘COMPRESSOR HOUSING cuaue Lock Nur BACK PLATE RETAINING RING ‘ R SAL % 4 2 co sumoen vo a | i I ‘COMPRESSOR WHEEL a | Pa ‘THRUST BEARING L ‘ { 2 twrusrcouan | | ‘SEAL RING CENTER HOUSING | | U Beano | - Oe | go \ | MEAT SHEL Or | romesorew ETANNG RING ) | i SEALAING CLAMP PLATE. inane srt aj ene \ ‘) vole Ma ) 4 ccuame PLATE. A PLATE 21194 NOTE: Lubricate all bearings, seals and the turbine shaft with clean engine oil before assembly. ac .2047t Revised 12.04 PrntesinUSA.STEP 59 oe Install a new inner bearing retaining ring. The round edge of the retaining ring must be toward the top. STEP 60 Install a new center housing beating, STEP 61 Install a new outer bearing retaining ring with the round edge down. ac -20471 2468-17 ‘Tumn the center housing over and install a new inner bearing retaining ring, The round edge of the retaining ring must be toward the top. STEP 63 Install a new bearing in the center housing, STEP 64 Install a new outer bearing retaining ring with the round edge ‘own. Revised 12.04 Pinesin USA2465-18 STEP 65 STEP 68 Install the thrust collar with the large OD down, Tighten the thrust bearing screws to a torque of 36 lb inch (5 Nm), STEP 66 STEP 69 Install a new thrust bearing on the center housing Install a new seal rng on the oil singer. STEP 67 STEP 70 Install new torx head screws inthe center housing, Carefully install he ol singer inthe back plat. ac .2047t Revised 12.04 PrntesinUSA.2465-19 STEP 71 STEP 74 Install a new seal in the back plate. Install new lock plates and new mounting bolts. STEP 72 STEP 75 Install he ol bafle on the back plate with the cup side up. Tighten the back plate mounting bolts toa torque of 48 Ib inch (Nm), STEP 73 STEP 76 Install the center housing on the back plate. Make sure the mark on the back plate and the center housing are aligned, Bend the tabs onthe lock plate. ac -20471 Revised 12.04 Pinesin USA2465-20 STEP 77 Install a new seal ring in the groove ofthe turbine wheel. STEP 78 STEP 80 Install the compressor wheel on the turbine shaft STEP 81 Install the turbine wheel in the fixture and install the heat shield on the turbine wheel STEP 79 Install the center housing onthe turbine shaft. Be careful not to damage the seal ring ac .2047t Install a new compressor whee! lock nut The compressor wheel lock nut is left hand STEP 82 Use a double universal joint socket to tighten the lock nut on the compressor wheel. This procedure will stop the turbine shaft from bending. Revised 12.04 PrntesinUSA.2465-21 STEP 83 STEP 85 Tighten the lock nut toa torque of 120 Ib inch (14 Nm). STEP 84 Carefully install the center housing on the turbine housing. Make sure the mark on the turbine housing is in align with the ‘mark on the center housing Remove the center housing assembly from the fixture. STEP 86 Install the clamp plates and the new lock plates. ac -20471 Revised 12.04 Pinesin USA2465-22 STEP 87 Install the new turbine housing bolts and tighten to a torque of 96 Ib inch (11 Nm). STEP 88 Bend the tabs on the lock plates, STEP 89 Install the clamp on the turbine housing ac .2047t Install the turbine housing assembly on the compressor housing. Make sure the mark on the center housing isin align withthe mark on the compressor housing. STEP 91 Install and tighten the compressor housing clamp. STEP 92 Turbocharger completely assembled. Revised 12.04 PrntesinUSA.2465-282465-24 Installation STEP 93 Install a new gasket on the exhaust manifold STEP 94 Install the turbocharger on the exhaust manifold, STEP 95 Install the turbocharger mounting nuts and tighten to a torque ‘of 24 Ib ft (32 Nm) ac .2047t STEP 96 Install a new gasket on the oll drain tube NOTE: The oll drain tube must be removed and thoroughly cleaned before turbocharger installation. A plugged oil drain tube can cause a turbocharger failure. STEP 97 TORQUE HERE Install the ol drain tube bolts and tighten the bolts to a torque of 18 Ib ft (24 Nm), STEP 98 Pour two to three ounces of clean engine oil into supply liting. Rotate the turbine wheel to allow oil to enter the turbocharger. Revised 12.04 PrntesinUSA.STEP 99 ‘Connect and tighten the oil supply tube to the turbocharger, ‘and the filter housing. STEP 100 Install the air intake hose. ac -20471 2468-25 STEP 101 Install and tighten the air intake hose clamps. STEP 102 “Turbocharger installed on engine. Revised 12.04 Pinesin USA2465-26 WASTEGATE TURBOCHARGER Actuator Calibration 1, Remove the hose from the wastegate actuating canister, and ft a regulated air supply and gauge with a pressure range of 15 to 30 psi (1.0 to 2.0 bar). The gauge should bbe accurate to plus of minus 0.5 percent or beter 2, Mount a dial indicator so that its shaft is inline with the wastegate actuator rod. Ensure that the indicator shaft rests on the actuator rod end, not on the valve actuating arm directly beneath it, 3, With no pressure applied to the wastegate capsul the dial indicator to zero. sot 4, Apply 26.68 psi (1.84 bar) to the wastegate capsule and check the movement ofthe rad from its original position Travel on the rod should be between 0.015 to 0.097 inch (0.38 to 2.46 mm) haven 0015 TO 0.097 NCH (03870 246m) soniae 5. Ifthe travel of the actuator rod is less than 0.015 inch (0.38 mm) of more than 0.097 inch (2.46 mm) then loosen the rod locknut and remove the spring clip and remove the rod end from the pivot pin. Turn the rod end ‘one direction of the other to lengthen or shorten as required, NOTE: One half turn of the rod end will change the rod travel by approximately 0.021 inch (0.53 mm). 6. Attach the actuator rod back on the pivot pin and check ‘new travel dimensions. New travel dimensions must be Within 0.041 to 0.089 inch (1.04 to 1.60 mm). 7. When new travel dimensions are obtained, remove air supply and attach hose back on the wastegate actuating canister NOTE: Case Corporation reserves he right make improvements in design or changes specications a any ie wiht incuring any sbigaton to istl ther on unis previously sel ac .2047t Revised 12.04 PrntesinUSA.Section 2470 HX40W TURBOCHARGER IMPORTANT: This turbocharger was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting parts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA ‘CASE CANADA CORPORATION 3950 South Service Road BButington, ON L7N 36 CANADA ac 7-65590 (© 1906 Case Corporation Printed in USA. March, 1996 24702870-2 TABLE OF CONTENTS ‘SPECIFICATIONS .. ‘SPECIAL TORQUES ... ‘TROUBLESHOOTING GUIDE FOR THE TURBOCHARGER ‘TURBOCHARGER SERVICE Removal . Disassembly. Cleaning and Inspection . Cleaning Component inspection. Assembly instalation... ‘TURBOCHARGER WASTGATE CALIBRATION General Information Calibration Pressures HX40W Turbocharger Cross Section NOTE: Case Corporation reserves the right fo make improvements in sign or changes specication at any te wiht incuring any sbigaton to instal thar on uns previously seh, ac 7.65500 letues 998 Prntadia USASPECIFICATIONS Turbine Whee! Horizontal Movement Turbine Wheel Vertical Movement ‘Actuator Rod Movement (With Correct Calibration Pressure Applied) SPECIAL TORQUES Actuator Braoket Bolts. ‘Actuator Canister Mounting Nuts. Turbine Housing Bolts Compressor Wheel Locknut (LH Thread) Adapter Connection Bolts. Turbocharger Mounting Nuts Drain Tube Bolts. Fac 7-65590 ‘sued 3-06 24703 0,326 to 0.496 mm 0,098 to 0.093 mm 0.390 to 1.27 mm -24 Nm (18 fof) 7 Nm (60 b inch) 20 Nm (180 Ib inch) 17/Nm (150 b inch) 20.5 Nm (18 ib inch) 45 Nm (33 lb ft) 24 Nm (18 tof) Printed in USA.2870-4 svuetou a TROUBLESHOOTING GUIDE FOR gl 3 THE TURBOCHARGER 3) 3] a 3} 3) 8} sl al 3 see a} 3) g| 3 & al {| 2] 8 a a caUSE ee e Diy air cleaner ee Ol) Restricted compressor intake duct Rstcted air duct om compressor to intake manifold Restcted intake manitold ‘Air leakin feed romair cleaner to compressor ‘Ar eakin feed from compressor to intake manifold ‘lr leak between intake manifold and engine Foreign object exhaust manifold (rom engine) esticted exhaust system Exhaust manifold cracked, gaskets blown or missing @@ OOOO, OO) © crcicrrcxs rower @O OOOO) COO @ rcxcomusr smoxe ‘Gas leak at turbine leVexhaust manifold joint Gas leak in ducting after turbine outet esticted turbocharger of drain line esticted engine crankcase breather “Turboctarger bearing housing ludged or coked Fuel injection pur 9 fuel injectors incorecly set Engine valve ting noorect ‘Worn engine piston rings or liners| ‘Burnt valves andlor pistons Excessive dit build up on compressor whee! andor diffuser vanes | “Turbocharger damaged Pac 7-65590 sued 3.06 Printed in USA.24705 TURBOCHARGER SERVICE Removal STEP 1 Remove the air cleaner and exhaust pipes from the turbocharger. STEP 2 Loosen and remove the air intake hose. Remove the hose from the wastegate actuating canister STEP 3 Disconnect and remove the oil supply ine. ac 7.65500, STEP 4 Disconnect the oil drain tube. STEP 5 CClean the mounting flange on the turbocharger and the ol! drain tube. STEP 6 Remove the four turbocharger mounting nuts and remove the turbocharger from the exhaust manifold lstuee 996 Printed in USA,2870-6 STEP 9 Remove the gasket and clean the mounting flange on the turbocharger and the exhaust manifold, Use a dial indicator to check the vertical movement of the turbine whee! assembly. Vertical movement must be 0.038 to 0.093 mm, If movement is not within this range, the turbocharger must be rebuilt. Secure the turbocharger in a vice. Use @ dial indicator to check the horizontal movement of the turbine wheel assembly. Horizontal movement must be 0.326 to 0.496 mm. | movement is not within this range, the turbocharger must be rebuilt, ac 7.65500 letues 998 PrntesinUSA.2470-7 Disassembly STEP 10 ACTUATOR ROD RETAINING RING Remove the retaining ring from the lever pin. Carefully remove the actuator rod from the pin, NOTE: The actuator rod is installed with spring tension, STEP 11 APOBAZ69 Remove the two lock nuts from the actuator canister and remove the actuator assembly from the mounting bracket, NOTE: if the mounting bracket is not damaged, do not remove the bracket from the turbine housing. Go to Step 13, ac 7.65500, STEP 12 Remove the bol, two nuts, spacers and the mounting bracket {rom the housing. STEP 13 : Make alignment marks on the compressor housing, turbine housing and the bearing housing to get correct alignment during assembly. STEP 14 ew AP96AZ72 Remove the compressor cover retaining ring, lstuee 996 Printed in USA,2870-8 STEP 15 STEP 18 besos ‘ | pp9eaz77 Carefully remove the compressor cover. Be sure not to Remove the five adapter plate bolts ‘damage the compressor whee! blades. STEP 19 STEP 16 Remove the adapter plate and gasket from the housing. Loosen and remove the six bolts and clamp plates. STEP 20 STEP 17 POBA282 \ FORTS tine cere aig ato 1 rm kt hts clnped Remove the center housing rotating assembly from the in avioe turbine housing, ac 7.65500 letues 998 PrntesinUSA.STEP 21 APOGAZB4 Remove the compressor wheel lock nut, NOTE: The lock nut isa left hand thread. STEP 22 APO6A28S Remove the compressor whee STEP 23 APOBA2B6 Remove the remaining center housing rotating assembly from the socket and carefully slide the shatt and turbine wheel from the bearing housing, ac 7.65500, 2470-9 STEP 24 AP96A287 Carefully remove and discard the piston ring sea NOTE: Do not scratch the turbine wheel shaft. STEP 25 P96A288 Remove the heat shield. STEP 26 AP96A289 Use a snap ring pliers to remove the insert retaining ring. lstuee 996 Printed in USA,2870-10 STEP 27 531084, Use two fiat nose pliers and gently remove the il seal plate, STEP 28 sas Remove the ol singer STEP 29 y \y ) ) ) ‘Se SY SJ aL 96C Remove and discard the spit rng seal ac 7.65500 STEP 30 Remove and discard the oil battle, STEP 31 Remove and discard the O-ring seal STEP 32 Remove the thrust bearing. letues 998 eAL96A 1.068 attase PrntesinUSA.STEP 33 5.084, Remove the thrust colar. STEP 34 25.088 Use snap ring pliers to remove the retaining ring, journal bearing and second retaining ring ac 7.65500, STEP 35 Sq) y 2870-11 astase ‘Tum the bearing housing over and repeat the process. lstuee 996 Printed in USA,2870-12 Cleaning and Inspection Cleaning With the turbocharger completely disassembled, soak al the ‘components in a non-caustic cleaner to loosen deposits. Bead blast the turbine housing only if chemicals do not clean sufficiently. A bristle brush can be used on aluminium parts, Never use a \ire brush or metal scraper on any turbocharger component. Use compressed air to dry all parts, especially any drilled passages and machined apertures, ‘The surfaces adjacent to the turbine and compressor wheels ‘on the stationary housings must be clean, smooth and free of deposits Component Inspection STEP 36 «© ~ a @ Sd ) wo | BrT96 Inspect the assembly turbine wheel forthe following 4) Inspect the piston ring groove walls for wear. b) Inspect the bearing journal area for excessive scratches ‘and wear. Minor light scratches can be accepted. 6) Inspect for cracked, tent or damaged blades. IMPORTANT: Do not attempt to straighten blades Inspect for any signs of rubbing Replace the assembly turbine wheel if any of the above are visible ac 7.65500 STEP 37 srmase Inspect the turbine housing for the following: Check the profile for damage caused by possible contact with the rotor. Check all threads for damage. Inspect the outer and internal walls for cracks or flaking caused by overheating, Check the mounting flanges for signs of distortion Replace the housing it any ofthe above are visible STEP 38 s7e.98e Inspect the compressor housing forthe following: Check the profile for damage due to possible contact with the rotor. Check that the retaining ring groove area is free of deposits, Replace the housing it any damage is visible. letues 998 PrntesinUSA.STEP 39 28198 Inspect the valve lever pin. Replace the turbine housing assembly if the pin is worn excessively STEP 40 ‘Actuate the valve lever by hand to be sure that the shaft rotates freely and is not seized. Check for excessive movement between the shaft and bushing Replace the turbine housing i the shaft or bushing are worn, damaged or seized, STEP 41 21198 Inspect the valve and valve seat for cracks or erosion, Replace the turbine housing assembly if worn excessively ac 7.65500, 2470-13 STEP 42 20196 (Check the actuator for cracks and dents. Also check for air leaks by pressurizing the actuator (see calbration pressures inthis section) and applying a soap and water solution tothe actuator around the rod hole, Replace as necessary STEP 43 ® 25196 Inspect the actuator rod for bends, cracks, stripped threads and excessive wear ofthe pin hole, Replace as necessary. STEP 44 erase Inspect the bearing housing for the following: ‘Check the bore for heavy wear or score marks on both the bearing and piston ring area. Also check that all tapped holes are clean and free of contamination. Replace the bearing housing it damage or heavy wear is found, lstuee 996 Printed in USA,2870-14 STEP 45 STEP 47 (4 (Lh, armgso eTeLO5A, Inspect the compressor wheel fo the following: Inspect the oil seal plate seal boar. Replace if scored or ‘Check for cracked, bent or damaged blades. damaged. 7 empt to straighten ble IMPORTANT: Do not attempt to straighten blades. ET EPIAG Replace the compressor wheel if any ofthe above is found. STEP 46 676.988 CCheck the heat shield and replace if the shield is distorted or if signs of rubbing or cracking are visible. srm988, Inspect the oil singer as follows: Check the piston ring seal groove walls for scoring or damage. Check for signs of rubbing on the flat surfaces Replace as required. ac 7.65500 letues 998 PrntesinUSA.2470-15 Assembly TANG RNG cowPRESs08 HOUSW ocx wr ona seat \ seu ‘upust Beanie on . ETAING RIG es: ese iiPeLLER BEARING HOUSING Naver 92 rerannc ave NiSy Ywrusreou.an f conga sur ate BEARING eg & 74.96 ac 7.65500, lstuee 996 Printed in USA,2870-16 STEP 49 STEP 51 JOURNAL BEARING Oo oN geveuzn ena araigse eine Install the outer retaining ring with the bevelled edge facing the bearing, Turn the housing over and install the remaining bearing and retaining rings, STEP 52 IMPORTANT: Premature failure will result if the retaining rings are installed incorrectly. Make sure that the retaining rings are always installed with the bevelled ledge facing the journal bearing. Put the bearing housing on a bench with the turbine end facing up. Install the inner retaining ring with the bevelled ‘edge facing up. Install the heat shield STEP 50 STEP 53 81088 g RP96A287 Lubricate the journal bearing with clean engine oil and install the bearing nto the housing Install a new piston ring seal to the turbine wheel assembly. ac 7.65500 letues 998 PrntesinUSA.STEP 54 er988, Lubricate the shaft using clean engine oil. Align the piston ring seal so the gap is positioned 180" from the oil drain hole in the housing. Gently press down on the turbine wheel with a slight rotation motion to properly locate the seal STEP 55 anasc Put the assembly turbine wheel in a suitable fixture, STEP 56 eaL00A, Align the balance mark on the thrust collar withthe mark on the shaft. Install he thrust collar on the shaft. ac 7.65500, 2870-17 STEP 57 eaL960 Lubricate the thrust bearing with clean engine cil. Install the thrust bearing onto the shatt. STEP 58 aataec Install anew piston ring seal onto the oll singer. STEP 59 e000, Lubricate the ol stinger with clean engine cil. Install the oil slinger into the oil seal plate, lstuee 996 Printed in USA,2870-18 STEP 60 e2.080 Install the oil battle into the oil seal plat. STEP 61 aataec Apply a thin coat of clean engine oil to the oil seal plate. Install the new O-ring seal onto the seal plate, STEP 62 ‘Align the balance marks on the ol stinger with the mark on the shaft. Install the ol seal plate int the bearing housing ac 7.65500 STEP 63 aL968 Gently tap the oil seal plate with a soft hammer to seat in position, STEP 64 sot9ec Install the seal retaining ring into the housing, STEP 65 sits Align the balance marks on the shaft and the compressor wheel and instal the wheel onto the shat. NOTE: Be sure that the balance mark on the shaft is aligned with the mark on the compressor wheel. letues 998 PrntesinUSA.AP96A283 Install the compressor wheel locknut and tighten to a torque of 17 Nm (150 Ib inch). NOTE: The locknut has LH threads, STEP 67 Carefully slide the retaining ring over the turbine whee! assembly. Install the center housing rotating assembly into the turbine housing. Align the marks on the housings and instal the two clamp plates and six bolts. Tighten the bolts to a torque of 20.3 Nm (180 Ib inch). STEP 68 Secure the turbine housing and check again the turbine clearance as shown in Step 8 and 9 ac 7.65500, 2470-19 STEP 69 Align the scribe marks on the compressor cover with the scribe marks on the turbine housing and carefully instal the ‘compressor cover. Install the retaining ring. STEP 70 Install a new gasket and adapter plate. Install the five bolts ‘and tighten the bolts to a torque of 20.5 Nm (181 Ip inch), STEP 71 It the actuator mounting bracket was removed, install the three spacers, mounting bracket, two nuts and bolt. Tighten the hardware to a torque of 24 Nm. lstuee 996 Printed in USA,2870-20 STEP 72 AP96A269 Install the actuatoritod assembly onto the mounting bracket. Install and tighten the mounting nuts to a torque of 7 Nm (60 tb inch). ac 7.65500 STEP 73 ‘ACTUATOR ROD RETAINING RING Carefully install the rod onto the lever pin. Install the retaining alip onthe lever pin letues 998 PrntesinUSA.2870-21 Installation STEP 74 Install a new gasket onto the exhaust manifold flange. STEP 75 Install the turbocharger and mounting nuts, Tighten the nuts to-a torque of 45 Nm (33 Ib ft), ac 7.65500, STEP 76 Install @ new oll drain tube gasket. Install the oll dain tube bolts and tighten the bolts to a torque of 24 Nm (18 Ib ft) NOTE: Be sure the oll drain tube is free of obstructions. A plugged drain tube can cause a turbocharger failure. STEP 77 Pour two to three ounces of clean engine oil into the oil ‘supply port. Rotate the turbine wheel to allow the ail to enter the turbocharger. lstuee 996 Printed in USA,2870-22 STEP 78 STEP 80 ‘Connect and tighten the oil supply line Install the air cleaner and exhaust pipes onto the turbocharger. STEP 79 Install the hose onto the wastegate actuating canister. Install and tighten the air intake hose. ac 7.65500 letues 998 PrntesinUSA.2470-28 TURBOCHARGER WASTGATE CALIBRATION General Information IMPORTANT: Improper wastegate calibration can result in major engine damage. ‘The turbocharger wastegate can be calibrated on the work bench or installed on a machine. When installed on a machine, the engine must not be running A precise air pressure regulator and an air pressure gauge accurate to plus or minus 1/2% (or better) across a range from 15 to 30 psi must be used when calibrating the wasigate, Use the calibration pressures table and apply the correct pressure for your machine to the actuating canister and observe rod movement, With the correct pressure applied, rod movement must be 0.330 to 1.27 mm (0.013 to 0.050 inch). The rod must be adjusted if rod movement isnot within this range. Calibration Pressures Model Pressure: kPa (psi) 2188 Combine 172 (28) 7250 Tractor 172 (25) 7240 Tractor 182 (26.4) 2155 Cotton Picker 172 (25) 6-890 TA Power Unit 182 (26.4) 2166 Combine 182 (26.4) 2166E Combine 182 (26.4) 9330 Tractor 182 (26.4) 7220 Tractor 155 (22.5) 7280 Tractor 155 (22.5) 9310 Tractor 155 (22.5) 6-830T Power Unit 155 (22.5) 8218 Loader 155 (22.5) ac 7.65500, STEP 81 Remove the hose from the actuating canister and attach the regulated alr supply STEP 82 Use a dial indicator witha fat shaft between 1/4 and 1/2 inch in diameter. Mount the dal indicator so thatthe indicator shaft isin line with the actuator rod. Be sure that the indicator shaft rests on the actuator rod end. Zero the dial indicator. ‘Apply the correct pressure for your machine and check the movement of the rod from the original position. Rod movement must be 0.330 to 1.27 mm (0.013 to 0.050 inches), lstuee 996 Printed in USA,2870-24 STEP 83 STEP 84 If rod movement is not within specified limits, adjust the rod as follows: 1, Loosen the rod locknut, remove the spring clip from the lever pivot pin. 2, Remove the rod from the pivot pin. f movement was less than.330 mm, rotate the rod counterclockwise, I movement was more than 1.27 mm, rotate the rod clockwise, NOTE: One half turn of the rod end will change the rod travel by approximately 0.533 mm (0.021 inch). 43, Install the rod end onto the lever pivot pin and apply the regulated pressure to the actuating canister and check movement. 4, fr0d movement is sill not within limits, repeat items 2 and in this step. 5. If the movement is correct, install the spring clip and tighten the lock nut ac 7.65500 Remave the regulated pressure line and connect the boost sensing hose to the actuating canister. STEP 85 PRESSURE LINE FROM MANIFOLD It there are any air leaks in the pressure lines to the turbo actuating canister or the injection pump android, the engine will not perform propery, Check the airline as follows: 1, Remove the pressure air ine from the intake manifold 2. Connect regulated pressure to the end of the line removed {rom the manifold and pressurize the system to 138 kPa (20 psi. 3. Apply a soap and water solution to all the lines, fitings and ‘connections in the system and look for bubbles. Correct ‘any leaks that are found. 4. Connect the pressure line to the manifold letues 998 PrntesinUSA.ac 7.65500, 2470-25 HX40W Turbocharger Cross Section ADAPTOR AcTyaToncANSTER | : FETAMNG ANG on comPaesson HoUsWs Shere _- ome sea seu sea ; i Jou suncen HEAT_} = — Seo | Lock wor Coupnesson eed —} ions “RUST a COLLAR RETAINING RING ‘ner Hea 4 i / Th on earns saan retane peranne Printed in USA,Section 3410 FUEL SYSTEMS AND FILTERS 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measurement system. AAll measurements and checks must be made with metric tools to make su an accurate reading when inspecting parts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA EASE CANADA CORRORATION) (© 1906 Case Corporation 3950 South Service Road Pined RUS Burlington, ON L7N 3M6_ CANADA Rac 8.28482 November, 1986 (Revised March, 1996)3410-2 SPECIFICATIONS Filter Replacement (Primary and Secondary) ‘See Operators Manual for recommended change interval or when loss of engine power ocours Primary Filter Full Flow, turn on type ‘Secondary Filter Full Flow, turn on type Maximum Pressure Drop Across Filters. 5 PSI (34 kPa) (3.4 Bar) Fuel System Operating Pressure at Rated Speed 20 to 25 PSI (140 to 172 kPa) (14,0 to 17.2 Bar) Fuel System Operating Pressure at Rated Speed (High Capacity Pump). 25 to OPS! (172 to 207 kPa) (17.2 to 20.7 Bar) Minimum Pressure at Fuel Pump Inlet.. = = os ssnsnneeines 10 PSL (68.9 kPa) (6.89 Bar) For Acceptable Number Two Diesel Fuel (ASTM D975 Grade 2D) API. Gravity (Min)... 30 Pour Point (Max) oss 10 6 below ambient operating temperature Distilation (90% Point)... “ .» 540 to 625'F (282 to 329°C) Flash Point (Min)... 425°F (62°C) or legal kinematic Viscosity Centstokes AE 100°F (88°C) rn = = 2.0 to 4.3 Seconds" Getane Number (Min) 40 (45 to 85 For Gold Temperature or High Altitude Use. Water and Sediment Volume (Max) son - 0.05% ‘Ash Weight (Max) 0.01% ‘Sulphur Weight (Max). 0.5% Carbon Residue or 10° Residuum (Max ream 02” Corrasion, Copper Strip, 3 hours at 212 F (100° C) ves Number 3 (32 to 40 Saybott Universal Seconds) FUEL SYSTEM Filter Replacement and Air Removal STEP 2 Install new gaskets on the primary and secondary mounting studs. Apply clean oil or grease to the gaskets on the new ‘Turn off the fuel supply to the filters. Clean the filter heads, filters and engine area next tothe filters. Remove the drain plug from the primary filter. Use a clamp wrench to remove fiers. the fiers. ac -20482 Revised 2.06, PrntesinUSA.We Install the new filters. Do not fil the new filters with fuel before installation, Turn the filters clockwise until the filter ‘gasket comes in contact wth te fter head, Hand tighten 1/2 ‘of a turn. To get the correct seal, loosen filters and again tighten 1/2 to 3/4 of a tur after the gasket comes in contact with te fiter head, Fitters that are to tight can cause damage to the gaskets and fiers. STEP 4 ‘Turn on the fuel supply tothe fers. Be sure there is fuel in the tank. Loosen the air removal screw on the fer housing. Operate the hand primer pump to fill the filters with fuel Tighten the air removal screw when clear fuel with no bubbles flows from the screw. NOTE: ifthe primer pump cannot be activated, turn the engine over a small amount. 34103 STEP 5 ‘To remove air from the injection pump, loosen the fuel return line fitting on the injection pump. Operate the hand primer ump. Tighten the fuel return line fiting when clear fuel with no bubbles flows from the fiting, NOTE: DO NOT overtighten the fitting as the seal washer will deform and a leak will result. STEP 6 Start the engine and check for leaks around the fiter, ines and fitings NOTE: Case Corporation reserves the igh o make inprovements in design o changes in specications at any tie wiht incuring any cbigatan to instal ham on unis previously ac -20482 Revised 2.06 Pinesin USASection 3412 INJECTION PUMP Pump Drive Gear,Timing Pin, Fuel Shutoff Solenoid, Primer Pump, Pump Timing and Android Check 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measurement system, All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting perts. ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA eee CANADA CORE OEATION) (© 1906 Case Corporation 3950 South Service Road tod ih BButington, ON L7N 36 CANADA Rac 8.2644 January, 1987 (Revised March, 109)34122 TABLE OF CONTENTS SPECIAL TOOLS .. FUEL SHUTOFF SOLENOID SPECIFICATIONS .. ‘SPECIAL TORQUES ... GENERAL INFORMATION .. ‘SERVICING THE FUEL SYSTEM ... Injection Pump Removal .. ‘Shutott Lever and Spring Replacement Injection Pump installation Injection Pump Gear Removal Injection Pump Gear Installation TIMING LOCK PIN . Removal. Installation .. FUEL SHUTOFF SOLENOID Removal. Installation ... Adjustment. Plunger Type Direct Link Type RQVK Governor Fuel Shutoff Solenoid Adjustment PRIMER PUMP . Removal and Disassembly Assembly and Installation. INJECTION PUMP TIMING .. LOW IDLE SPEED ADJUSTMENT .... INJECTION PUMP ANDROID LEAK CHECK ... NOTE: Caso Corporation resowes gh to makoimprovrants in dsign or changes in specication at any ie winutincuring any sbigaton to istl tar on unis previously sol, ac .20404 Revised 2.06, Prntadia USA3412-3 SPECIAL TOOLS ‘CAS-1691A GEAR PULLER. ac 8.20404 Pontadin USA34124 FUEL SHUTOFF SOLENOID SPECIFICATIONS Pull Current 12vDC. 24 VOC. Hold Current s2v0C. 24 voc. Resistance Pull Col 12V0C. 24 voc. Hold Coil 12V0C. 24 voc. Plunger Travel PlungeriLever Clearance. ROVK Governor Solenoids Solenoid Plunger Travel... Pull Current s2voc. Hold Current y2v0c. Resistance Pull Col Hold Coil ac .20404 Plunger Type 75.5 amps 37.5 amps 1 amp 0.5 amps 0.16 t0 0.18 ohms 0.64 to 0.72 ohms 12.78 to 14.42 ohms. 47 to 88 ohms 38 mm 1103 mm Revised 2.06, Direct Link Type 55 amps 29 amps 1.10 amps 0.60 amps 0.22 ohms 0.82 ohms 11.1 ohms 41.3 ohms 417 mm 162.05 to 154.60 mm 61.8 amps 0.85 amps. 0.194 ohms 14.17 ohms PrntesinUSA.3412-5 SPECIAL TORQUES Metric Value Injection Line Nut 211027 Nm Injection Pump Mounting Nut 39t0 47 Nm Injection Pump Gear Nut Bosch Model A. 92.Nm Bosch Model MW. 4104Nm Bosch Model P 4195 Nm Nippondenso Model EP-9 4104.Nm Fuel Inlet Fiting 211027 NM Filter Outlet Fiting 1810 17N Fuel Return Fiting 1810 17Nm Leak Of Fitting 710 9Nm Primer Pump Bolts 211027 Nm Fuel Shutoff Solenoid Bolts 10Nm Timing Pin Cover Bosch Model A 30Nm Bosch Model MW. 30Nm Bosch Model P 30Nm Nippondenzo Model EP 9 70Nm Fan Pulley Bolts Grade 8.8 Size MB 211031 Nm Grade 10.9 Size M8 370 43Nm Grade 8.8 Size M10 51 to 62Nm Grade 10.9 Size M10 51 to 62Nm Bracket Bolts 21 10.27 Nm GENERAL INFORMATION ‘The function of the injection pump is to supply the correct lis very important that you take extra care to prevent any amount of fuel under pressure to the injectors. The fuel must dust or foreign material for entering the fuel system when be pressurized with accurate timing tothe engine fring order. service is done on the system. ac -20404| Revised 2.06 Printed in USA,3412-6 s Troubleshooting guide e KS Ls iy for the diesel fuel injection system CY SSSI S “ifs its Se ELE/ NOTE: itis assumed that the engine is in good LSS) S81 5) 5/8 working order and properly tuned, and that the ky. Le DAILY Ly tiectrical system has beon checked and repaired fof ve Les Ze eke Efe as necessary. SSMS MII SM CAUSE + REMEDY Improper fuel inthe tank + Drain tank, flush system, fil with proper fuel Tank empiy or tank vent blocked + Fil tank/bleod system, chock lank vont (See Secticn 3410) Air in the fuel systom t Bleed fuel system, eliminate air leaks (See [Section 3410) - Voltage supply maliunction/stop solenoid detective t Correct electrical faulls/teplaces stop solenoid (See Section 3412) Fuel fiter blocked + Replace fuel fiter (See Section 3410) Fucl-supply lines biockediresiricied t Test all fuel supply lines -flush or replace - | Loose connections, injection lines leak or broken f Tighten the con nection, eliminale the leak Paratfin deposit in fuel fter | Replace liter, use Diesel Fuel No. 1 (See (Operators Manval) Pump-to-engine timing incorrect + Readiust timing (See Section 3412) Injection nozzte defective + Repair or replace (See Section 3413) [Engine air fiter blocked + Replace air fiter element injection sequence does not correspond to fring order f Install fuel in- lection lines in the correct order (See Section 3412) JOvertiow fiting nterchanged with inlet fiting t Install fitings in their lproper positions (See Section 3412) [Coid-start device malfunction (if equipped) + Check cold-start mech- anism (it equiped) Low or uneven engine compression t Repair as necessary (See [Section 2425) Fuel injection pump detective or cannot be adjusted f Replace (See [Section 3412) 40194 ac .20404 Revised 2.06, PrntesinUSA.3412-7 SERVICING THE FUEL SYSTEM Injection Pump Removal STEP 4 Clean the engine before any service works done on he fuel Remove the fuel shut solnoi, system, STEP 2 TEES Disconnect and remove the injection lines from the injection BUI aap UE IIE ATI pump and the injectors. Install dust covers on the injectors injection pump shat and the injection pump. STEP 3 Remove the leak off fitting and gaskets that the engine is equipped with. Install a plug in the leak off hole in the injection pump. ac -20404| Revised 2.06 Pinesin USA34128 STEP 6 STEP 8 Install the engine turn over tool, push in on the lock pin and turn the engine over until the lock pin engages into the camshaft gear. STEP 7 Remove the cover and the injection pump timing pin. ac .20404 Install the timing pin onthe tab in the injection pump. The slot ‘on the timing pin must align withthe tab inthe injection pump, STEP 9 Install the cover and finger tighten. STEP 10 Install CAS-1691A gear puller and tighten the botts until the gear is loose on the pump shaft NOTE: Make sure the gear is loose on the pump shaft. Revised 2.06, PrntesinUSA.3412-9 STEP 11 Remove the nuts and the injection pump from the front housing NOTE: There is not a key in the injection pump shatt The injection pump gear does not have a key slot. Shutoff Lever and Spring Replacement IMPORTANT: A return spring is not used on a shutoff STEP 14 lever equipped with the direct link solenoid. STEP 12 Install anew o-ring and if equipped, a new return spring Remove the lever returning screw and lever. STEP 15 STEP 13 ‘Align the hole in the housing with the spring end. Install the housing over the spring, Remove the housing, return spring if equipped and the o-ring ac -20404| Revised 2.06 Pinesin USA3412-10 STEP 16 STEP 18 ‘Tum the housing counterclockwise approximately 1/4 tun _Irstall and tighten the lever retaining bol. nd hold the housing inthis position, STEP 17 one o-ING a DING j HOUSING HousINa HOUSING ke RETURN SPAING PLUNGER DIRECT TYPE OMRECT UNK. TYPE SOCKET TYPE BALL TYPE Lever iever (even! 2ra.06 Install the shutoff lever on the housing. Be sure the spring ‘end is engaged in the hole in the lever. Injection Pump Installation STEP 19 STEP 20 Install a new o-ring inthe groove on the mounting flange. Install anew o-ring inthe ol supply port. ac .20404 Revised 2.06, PrntesinUSA.STEP 21 Install the injection pump into the housing, STEP 22 Install the nuts that hold the injection pump to the front housing. Tighten the nuts to a torque of 39 to 47 Nm. STEP 23 Install the washer and nut on the injection pump shaft and tighten a small amount ac -20404| 3a12-41 STEP 24 Remove the cover and pull the timing pin out ofthe injection pump. STEP 25 Install the timing pin into the injection pump. The long end of the timing pin must be toward the cover. STEP 26 Install the cover and tighten the covert a torque of: Bosch Model A 30 Nm Bosch Mose! MIW..nsnsnnsnnsnnnnnennnennnnn 0 NM Bosch Mosel P 30 Nm Nippondenzo Model EP 9 ......n.nureuenenesenennsneTO NM Revised 2.06 Pinesin USA3412-12 STEP 27 STEP 30 Pall the lock pin out of the camshaft gear. STEP 28 Tighten the nut to a torque of Bosch Model A, 92Nm Bosch Model MW 104Nm Bosch Model P. 195 Nm 104 Nm Nippondenso Model EP 9 Install the injection pump cover. STEP 29 Install the fuel shutoff solenoid. Install and tighten the solenoid retaining botts to a torque of 10 Nm. ac .20404 Install the fuel inlet iting and gaskets. Tighten the fiting to a torque of 21 t0 27 Nm. NOTE: There must be a gasket on each side of the fuel inlet line, STEP 31 Install the gaskets and iting, Tighten the fuel inlet fiting to a torque of 13 10 17 Nm. IMPORTANT: The pump inlet fitting must not have a check valve. Revised 2.06, PrntesinUSA.3412-18 STEP 32 STEP 34 Install the gaskets and return fiting, Tighten the fuel return ‘To remove the air from the fuel system see Section 3410 in line fitting to a torque of 13 to 17 Nm, the service manual IMPORTANT: The fuel return fitting and the fue! inlet fitting are not interchangeable, STEP 33 Connect the injector lines to the injection pump and the fuel injectors. Tighten the injector lines toa torque of 21 to 27 Nm. ac -20404| Revised 2.06 Printed in USA,aatat4 Injection Pump Gear Removal STEP 35 STEP 38 Lift the belt tensioner and remove the fan belt. Remove the front cover bolts and the front cover. STEP 36 STEP 39 Remove the pulley bolts and the fan pulley. Remove the nut and washer from the injection pump shaft STEP 37 Remove the crankshaft pulley bolts and the crankshatt pulley ac .20404 Revised 2.06, PrntesinUSA.STEP 40 3412-18 STEP 42 Install the engine turn over tool. Turn the engine over until the lock pin can be pushed into the camshatt gear. STEP 41 Remove the injection pump timing pin cover and timing pin {rom the injection, ac -20404| Install the timing pin into the injection pump. The slot on timing pin must align withthe tab in injection pump. NOTE: If the tab in the injection pump is not in align with the timing pin slot, see injection pump timing in this section. STEP 43 Install the timing pin cover and finger tighten. STEP 44 . Install the gear puller and remove the drive gear from the injection pump shatt Revised 2.06 Pinesin USA3412-16 Injection Pump Gear Installation STEP 45 Install the drive gear on the injection pump shaft. The drive ‘gear does nat have timing marks. NOTE: The ID of the drive gear is tapered to fit the injection pump shatt. There is not a key slot in the drive gear. STEP 46 Install the washer and nut on the injection pump shaft and tighten to a torque of approximately 20 Nm. STEP 47 Remove the cover and pull the timing pin out ofthe injection pump, ac .20404 STEP 48 SMALL END Install the timing pin into the injection pump. The small end ‘must be toward the tab in the injection pump. STEP 49 Install the timing pin cover and tighten to a torque of 13 to 17, Nm, STEP 50 Pulte lock pin out ofthe camshaft gear. Revised 2.06, PrntesinUSA.STEP 51 Tighten the pump drive gear to a torque of Bosch Model A. 92Nm Bosch Model MW 104Nm Bosch Model P| 195 Nm Nippondenso Model EP 9 104.Nm STEP 52 Clean the crankcase seal surface with Loctite Safety Solvent. See Section 2425 in the service manual to install the front ‘cover and oil seal ac -20404| 3412-17 STEP 53 Install the fan pulley and pulley bolts. Tighten the bolts to a torque of 39 to 47 Nm, STEP 54 Lift the belt tensioner and install the fan belt. Revised 2.06 Pinesin USA3412-18 TIMING LOCK PIN Removal STEP 55 STEP 56 Remove the retraining ring from the lock in housing, Remove the lock pin from the housing Installation STEP 58 1.L06K PIN 2.0-RING NX a) O° ~N 2. RETAINING RING aust STEP 57 Install the retaining fing inthe lock pin housing Install a new o-ring onthe lack pin. ac .20404 Revised 2.06, PrntesinUSA.3412-19 FUEL SHUTOFF SOLENOID Removal NOTE: Do not replace the fuel shutoff solenoid until the electrical circuit has been checked. See Electrical Troubleshooting in the service manual. STEP 59 It equipped with a direct link type solenoid, first disconnect the plunger from the fuel shutoff lever. For both type of solenoids, remove the fuel shutoff solenoid bolts. STEP 60 Remove the fuel shutoff solenoid from the mounting bracket. Installation STEP 61 VOLTAGE MARK’ Make sure the fuel shutoff solenoid has the correct voltage mark forthe electrical system, ac -20404| It equipped with a plunger type solenoid, install the fuel shutoff solenoid and bolts in the mounting bracket so thatthe plunger is centered on the shutoff lever, Tighten the mounting bolts to a torque of 10 Nm. if equipped with a direct link type, tighten the mounting bolts and connect the plunger tothe fuel shutof lever. NOTE: Make sure the solenoid electrical circuit has been checked. See Electrical Troubleshooting in the service manval. Revised 2.06 Pinesin USA3412-20 Adjustment STEP 63 PLUNGER TYPE SOLENOID sotoe DIRECT LINK SOCKET TYPE SOLENOID soiigy DIRECTLINK BALL TYPE SOLENOID 6106, Your engine can be equipped with either a plunger type or a direct link type solenoid. Use the steps that apply to your engine. Identify the part numbers for the shutoff valve lever and solenoid mounting bracket. The correct parts combination ‘must be forthe particular pump/governor combination. Do nat mi lever and bracket parts from any other pump. Plunger Type STEP 65 Check the lever for free movement from the run to stop position. Retract the solenoid plunger by hand and make ‘sure the lever moves freely. The lever will be returned to the run position by a spring located inside the metal cover under the lever ac 8.20404 STEP 66 ristae {the lever does not move freely, spray the spring with WD- 40 or an equivalent lubricant or replace the o-ring, spring and spring housing. See steps under Shutoff Lever and Spring Replacement in this section NOTE: If the lever does not move freely and is only partially activated, fuel flow will be reduced and low ower will result. Revised 2.06, PrntesinUSA.STEP 67 & Toa196 Measure distance A (solenoid mounting bracket to plunger end with solenoid deactivated). Activate the solenoid and measure distance B (mounting bracket to plunger end with solenoid activated). The difference (A - B or plunger stroke length) must be 38 mm, NOTE: Make sure that the engine will shut down completely when the solenoid is deactivated, and will start immediately when the solenoid is activated. 3412-21 ‘When the plunger is fll retracted, there must be a 1 to 8 mm clearance between the plunger end and shutoff lever Direct Link Type NOTE: Your engine can be equipped either the direct link socket type or the direct link ball type shut off solenoid and lever. The adjustment procedure and dimensions is the same for both. The direct link ball type is shown here, STEP 69 éacoi=anl O19 Bottom out the plunger in the run position. Check the distance from the mounting plate face to the centerline of the lever socket end. The distance must be 118.5 to 118.5 mm, ‘Adjust the socket as necessary as shown in Step 72. The plunger and lever assembly must move freely. ac -20404| STEP 70 It the plungeriiever assembly does not move freely or have {ull ravel, do the following: 1, Remove the plunger socket end from the lever. 2, Use steel wool or similar material to clean the lever ball and socket. Flush away any foreign material with safety solvent, 3, Lightly spray the ball and socket with WD-40 or an equivalent lubricant, Apply a thin layer of powder graphite to the ball and socket. 4, Assembly the ball and socket and check the assembly for {ull ravel and ease of movement NOTE: If the assembly still does not move freely, the shutoff valve lever and lever socket end must be replaced. See Step 71 thru 73. Revised 2.06 Printed in USA,9412-22 STEP 71 See Shutoff Lever and Spring Replacement in this section ‘and replace the shutoff lever IMPORTANT: 4 return to run spring is not used inside the cover under the shutoff lever with the direct link solenoid, STEP 72 Lever Locknut SOCKET ones Loosen the lock nut and remove the lever socket end. Install ‘a new lever socket end, Adjust the socket end so there is 115.5 to 118.5 mm of distance from the mounting plate to the socket center as shown in Step 69. Tighten the lock nut STEP 73 SX SHUTOEF LEVER Install the lever socket end onto the shutoff lever ball. Check ‘operation ofthe assembly again, ac 8.20404 RQVK Governor Fuel Shutoff Solenoid Adjustment STEP 74 / | | Lock nur BALL END o7.96 Tum the key switch to the ON position and check the fuel shutoff solenoid plunger travel. Travel must be 152.05 to 14.60 mm (A) measured from the center ine of the mounting bracket bolt hole tothe centerline ofthe ball end. Loosen the lock nut and turn the ball end until the correct dimension is obtained, Tighten the lock nut. Revised 2.06, PrntesinUSA.3412-2 PRIMER PUMP HIGH FLOW PUMP. 16.96 1, Outlet Fiting Check Valve 4. Spring 0: 2. Check Valve 5, O-Ring 3. Check Valve Gasket 6. Inlet Fitting ac 8.20404 Revised 2.06 Printed in USA,3412-24 Removal and Disassembly STEP 77 NOTE: Service of the low flow pump is shown. High flow pump is similar, STEP 75 Remove the fuel inlet line STEP 76 Remove the primer pump retaining bolts, Remove the pump {rom the engine block. ac .20404 Remove the internal components from the pump. Remove and discard the o-ings, NOTE: Do not remove the teflon seal. The teflon seal cannot be serviced. STEP 78 Completely flush the pump housing and the outlet fitting with ‘leaning solution to remove any foreign material Nort removed. The check valve in the outlet fiting cannot be Revised 2.06, PrntesinUSA.3412-25 Assembly and Installation STEP 79 STEP 82 Install new o-rings on the inlet and outlet fitings. Install new ‘o-tings in the hand prime button and fiting, STEP 80 FLAT SIDE Install a new check valve gasket and a check valve in the piston. Be sure the check valve is installed with the flat side up, STEP 81 Install the piston assembly into the pump body. ac -20404| i Install the spring, the other check valve and another new ‘check valve gasket into the pump body. Be sure the check valve is installed with the flat side up. STEP 83 Install the ile iting and finger tighten. STEP 84 Install the remaining spring, hand prime button and fiting into the pump body. Finger tighten the hand prime fiting. Revised 2.06 Pinesin USAInstall the outlet fiting into the pump body and finger tighten STEP 86 Put the primer pump in a soft jaw vise. Tighten the three fittings to torque of 30 Nm. Install the rubber boot over the hand prime button. STEP 87 Install the primer pump in the engine block. Install the primer pump bolts and tighten toa torque of 212 to 27 Nm. ac .20404 STEP 88 Connect and tighten the fuel inlet line to the primer pump STEP 89 Install new gaskets and the inlet fiting. Tighten the inlet fiting toa torque of 14 to 27 Nm, STEP 90 Install the leak off ine gasket and bolt Tighten the leak off bolt toa torque of 7 to 9 Nm Revised 2.06, PrntesinUSA.3412-27 INJECTION PUMP TIMING STEP 91 STEP 93 Remove the cover and the timing pin from the injection pump. Remove the cover. Remove the nut and washer from the injection pump shaft STEP 92 STEP 94 Install the timing point into the injection pump. The sot in the timing pin must align withthe tap in the injection pump. STEP 95 Install the engine turn over tool and turn over the engine unt the tabis inthe timing pin hole Install the timing pin cover and finger tighten, ac -20404| Revised 2.06 Pinesin USA3412-28, STEP 96 STEP 98 Install a gear puller and tighten the bolts until the gear is loose on the pump shatt IMPORTANT: Make sure the pump gear is loose on the pump shatt STEP 97 Install the engine tum over too}, push in on the lock pin and turn the engine over until the lock pin engages into the ‘camshaft gear. The injection pump will now be timed. ac .20404 Install the washer and nut on the injection pump shaft, Tighten the nut toa torque of approximately 20 Nm. IMPORTANT: Do not fully torque the drive gear nut until the camshaft timing pin has been pulled and the injection pump timing pin has been turned. STEP 99 Pill the timing pin out ofthe camshatt gear. STEP 100 Remove the covers and pull he timing pinout of the injection pump. Revised 2.06, PrntesinUSA.STEP 101 ISMALLEND Install the timing pin into the injection pump with the small ‘end toward the tab STEP 102 Install the timing cover and tighten to a torque of Bosch Model A... 30/Nm Bosch Model MW 30 Nm Bosch Model P... 30 Nm Nippondenzo Model EP 9 70 Nm ac -20404| 3412-29 STEP 103 Tighten the drive gear nut to a torque of: Bosch Model A 92Nm Bosch Model MW. 404Nm Bosch Model P| 195 Nm Nippondenso Model EP 9 4104Nm STEP 104 Install the injection pump nut cover. Revised 2.06 Pinesin USA3412-30 LOW IDLE SPEED ADJUSTMENT STEP 105 LOW OLE. SCREW Idle speed adjustment requires the setting of the low idle sorew and the bumper spring screw. STEP 106 Loosen the lock nut and turn the bumper spring screw counterclockwise until there is no change in engine speed. ac .20404 STEP 107 Loosen the lock nut and adjust the idle screw until engine speed Is 20 to 20 rpm below the desired idle speed. Turn the screw counterclockwise to decrease engine rpm and clockwise to increase engine rpm. Tighten the lock nut STEP 108 Tur the bumper spring screw clockwise unt the desired idle speed is reached, Tighten the lock nut. Revised 2.06, PrntesinUSA.3412-31 INJECTION PUMP ANDROID LEAK CHECK STEP 109 Sa JECTION pa PUMP ANDROID A 7 ae Md ot ee Gee If there are any air leaks in the pressure lines tothe injection ump android or the turbocharger actuating canister, the engine will not perform property. Check the airline for leaks as follows: 1. Remove the pressure airline from the intake manifold. 2, Connect regulated pressure to the end of the line removed from the manifold and pressurize the system to 138 kPa (20 psi). 3. Apply a soap and water solution to all the lines, fittings and connections in the system and look for bubbles. Correct any leaks that are found, 4, Connect the pressure line to the manifold. TURBOCHARGER ACTUATING CANISTER ‘0186 ac 8.20404 Revised 2.06 Printed in USA,Section 3413 FUEL INJECTORS 6-830 Diesel Engine IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting perts, ‘CASE CORPORATION 700 State Street Racine, WI 53408 USA EASE CANADA CORRORATION) (© 1906 Case Corporation 3950 South Service Road Pined RUS Burlington, ON L7N 3M6_ CANADA Rac 8-28503 November, 1986 (Revised March, 1996)3413-2 TABLE OF CONTENTS ‘SPECIFICATIONS .. ‘SPECIAL TORQUES ... SPECIAL TOOLS .. GENERAL INFORMATION .. OPERATING PROCEDURES .... LOCATING BAD INJECTORS .... Locating Bad Injactors at the Fuel Pump... 7 Locating Bad Injectors at the 7 7 Gylinder Head REMOVING INJECTORS FUEL INJECTOR TESTER .. Injector Tester Preparation TESTING INJECTORS Checking Opening Pressure. "1 Checking Seat Leakage .. Spray Pattern... INJECTOR SERVICE . 8 Disassembly. 3 16 Cleaning and Inspection. Assembly... INJECTOR ADJUSTMENTS .. ‘Adjusting the Opening Pressure INSTALLING INJECTORS NOTE: Case Corporation reserves the right fo make improvements in sign or changes specication at any te wiht incuring any sbigaton to instal thar on uns previously seh, ac -20509, Revised 2.06, Prntadia USA3413-3 THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT] SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE | THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT] FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. wire WARNING LX ret pray tom an injector hs sufcint velootyto penetrate the skin and Exiss sev tac or arta sasaki putea bil poratateat oe your doctor immediately. When testing or adjusting diesel fuel injectors, do not place your hands, arms, or any other pert of your body into the fuel injector spray sMta7a, WASH THE INJURED PART WITH BORIC ACID SOLUTION, SUPPORT THE INJURED FINGER OR HAND WITH A SPLINT AND SLING SO THE INJURED PART WILL REMAIN ABSOLUTELY AT REST UNTIL A PHYSICIAN CAN EXAMINE IT. Valve Leakage Rate Maximum Opening Pressure Variation Between Each Cylinder Injector Tip Protrusion ac -20508| SPECIFICATIONS Pari Number Spray Numer spray Robert Angle of orifices Bosch case Degrees ontcas Size New Uses ‘oaaeTovaos | 08505 155 7 ‘Uzamm | 26816 30B4 PSI | 27AP we GOeA PST (205 to 219 Bar) (188 10219 Bar) o«aerere12 | 008507 150 4 0.32 mm [Reset to 2069 to 2084 Pe (205 10219 Bar) Opening Pressure o«sere17a7 | sooest1 150 4 034 mm Fale Below 2722 PSI (188 Bar) o«aere1798 | sor9602 155 5 029 mm osssr7iier | se2rase 150 4 034 mm Production | 920526 150 4 0.325 mm Only oasaTorrea | 0857S 1 7 or oase191505 | sos0505 155 5 o.2ramm | s7rot0s8e7Psi | 3998103887 PSI (260 to 268 Bar) (234 1.268 Bar) oasTares2 | W008787 1 3 ‘astm | 435010 4467 PSI] S076 104467 PST (00 to 308 Bar) (270 1 308 Bar) Metric Value No Leakage Permissible Slight Moistening of Nozzle Tip Permissible 1034 kPa 3.0 to 4.0mm Revised 2.06 Printed in USA,