manual servicio case 580 super k construction king

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2

SECTION INDEX - GENERAL

Section Title

Loctite Product Chart

Torque Specifications .

Fluids and Lubricants .

CASE CORPORATIONRae 8-17141

Section Number

1001

..1002

Copyright 1992 J I Case CompanyPrinted in U.SA

August. 1992

1001

STANDARD TORQUE SPECIFICATIONS

TABLE OF CONTENTS

Torque Specifications - DecimalHardware 1001-2

Torque Specifications - Steel HydraullcFittings 1001-4

Torque Specifications - Metric Hardware ...1001-3 Torque Specifications - O-ring FaceSeal Fittings..... ....................1001-5

CASE CORPORATION Bur 8-71600 Printed in U.S.A.Issued May 1988

1001-2

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special tor-ques are not given. These torques apply to fasten-ars with both UNC and UNF threads as receivedfrom suppliers. dry. or when lubricated with engineoil Not applicable if special graphites, rnotydisul-fide greases. or other extreme pressure lubricantsare used.

8113608

1001-3

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following toques when special torquesare not given.

These values apply to fasteners with coarsethreads as received from supplier. plated or un-plated. or when lubricated with engine oil. Thesevalues do not apply if graphite or molydisulfidegrease or oil if used.

811359A

1001-4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- NewtonHose ID Size Feet metres

37 Degree Flare Fittings

1/4 in 7/16-20 6-12 8-166.4 mm

5/16 in 1/2-20 8-16 11-217.9 mm

3/8 in 9/16-18 10-25 14-339.5 mm

1/2 in 3/4-16 15-42 20-5612.7 mm

5/8 in 7/8-14 25-58 34-7815.9 mm

3/4 in 1-1/16-12 40-80 54-10819.0 mm

l/8.in 1-3/16-12 60-100 81-13522.2 mm

1.0 in 1-5/16-12 75-117 102-15825.4 mm

1-1/4 in 1-5/8-12 125-165 169-22331.8 mm

1-1/2 in 1-7/8-12 210-250 285-33838.1 mm

Split Flange Mounting Bolts

Pound- NewtonSize Feet metres

5/16-18 15-20 20-27

3/8-16 20-25 26-33

7/16-14 35-45 47-61

1/2-13 55-65 74-88

5/8-11 140-150 190-203

Tube OD Thread Pound- NewtonHose ID Size Feet metres

Straight Threads with O-ring

1/4 in 7/16-20 12-19 16-256.4 mm

5/16 in 1/2-20 16-25 22-237.9 mm

3/8 in 9/16-18 25-40 34-549.5 mm

1/2 in 3/4-16 42-67 57-9012.7 mm

5/8 in 7/8-14 58-92 79-12415.9 mm

3/4 in 1-1/16-12 80-128 108-17419.0 mm

7/8 in 1-3/16-12 100-160 136-21622.2 mm

1.0 in 1-5/16-12 117-187 159-25325.4 mm

1-1/4 in 1-5/8-12 165-264 224-35731.8 mm

1-1/2 in 1-7/8-12 250-400 339-54238.1 mm

8113618

1001-5

TORQUE SPECIFICATIONS - O-RING FACE SEAL FITTING

Nom.SAEDash Thread Pound- Newton Thread Pound- NewtonSize Tube 00 Size Feet Metres Size Feet Metres

O-ring Face Seal End O-ring Boss EndFitting or Locknut

-4 1/4 In 9/16-18 10-12 14-16 7/16-20 17-20 23-276.4 mm

-6 3/8 in 11/16-16 18-20 24-27 9/16-18 25-30 33-4095 mm

-8 1/2 in 13/16-16 32-40 43-54 3/4-16 45-50 61-6812.7 mm

-10 5/8 in 1-14 46-56 60-75 7/8-14 60-65 81-88I 15.9 mmI

-12 3/4 in 1-3/16-12 65-80 90-110 1-1/16-12 85-90 115-12219.0 mm

I

-14 7/8 inI

1-3/16-12 65-80 90-110 1-3/16-12 95-100 129-13622.2 mm

-16 1.0 in 1-7/16-12 92-105 125-140 1-5/16-12 115-125 156-16925.4 mm

-20 1-1/4 in 1-11/16-12 125-140 170-190 1-5/8-12 150-160 203-21731.8 mm

-24 1-1/2 in 2-12 150-180 200-254 1-7/8-12 190-200 258-27138.1 mm

8871553

CASE CORPORATION

Section

1002

FLUIDS AND LUBRICANTS

Bur 8-12271 Printed in U.S.A.Issued March 1991

1002-2

TABLE OF CONTENTS

CAPACITIES AND LUBRICANTS ... .......................................2

ENGINE OIL RECOMMENDATIONS . . 3

DIESEL FUEL . .. .4

CAPACITIES AND LUBRICANTS

Engine OilCapacity with Filter Change 11.6 U.S. quarts (11 litres)Type of oil. See Engine Oil Recommendations on page 3

Engine Cooling SystemCapacity without heater 17.2 U.S. quarts (16.3 litres)Capacity with heater.. ... 17.9 U.S quarts (16.9 litres)Type of coolant. Ethylene glycol and water mixed for lowest ambient temperature

At least SO/50 mix

Fuel TankCapacity 25 U.S. gallons (94.6 litres)Capacity with auxiliary tank.................................. . 33 U.S. gallons (124.9 litres)Type of fuel See Diesel fuel specifications on page 4

Hydraulic SystemHydraulic reservoir refill capacity 21.5 US. gallons (81.4 litres)Type of oil Case TCH Fluid

TransmissionCapacity 47.6 U.S. quarts (45 litres)Total System Capacity 57.1 U.S. quarts (54 litres)Type of oiL............. Case Hy-Trans Plus (MS 1207)

Front Axle - Four Wheel DriveCapacity of center bowl 7.4 quarts (7 Iitres)Capacity of planetary (each) 1.1 U.S. quarts (1 litre)Type of oil..... .. CaselH 135-H EP gear lube

Brake ReservoirType of fluid Case TCH Fluid

Conversion Formulas

Imperial quart = litres x 0.879877Imperial gallon = litres x 0.219969

Bur 8-12271 Issued 3-91 Printed in U.S.A.

1002-3

ENGINE OIL RECOMMENDATIONSCase IH No.1 Engine Oil is recommended for use in your Case IH Engine. Case IHEngine Oil will lubricate your engine correctly under all operating conditions. If CaseIH No.1 Multi-Viscosity Engine Oil is not available, Case IH No.1 Single Grade EngineOil can be used

If Case IH No.1 Multi-Viscosity or SingleGrade Engine Oil is not available, useonly oil meeting API engine oil service ca-tergory CE.

654L9

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put Performance Additives or other oil additive products in the enginecrankcase. The oil intervals given in this manual are according to tests with Case IHlubricants.

AMBIENT AIR TEMPERATURE RANGESTemperature Fahrenheit

, I I

I I I I I I I I

MUL TI-GRADE OILI I. I I I I I I I I.

I

SINGLE GRADE OIL

. I I

I

I I I I I I I I I I I I

737L9

-34' _29' -23' -18' -12' -7" _1' 4' 10' 16" 21' 27" 32' 38' 43' -49'

Temperature Celsius


1002-4

DIESEL FUEL

Use NO.2 diesel fuel in the engine ofthis machine. The use of other fuels cancause the loss of engine power and highfuel consumption.

Invery cold temperatures, a mixture ofNO.1and NO.2 diesel fuels is tempora-rily permitted. See the following Note.

NOTE: See your fuel dealer forwinter fuel requirements in your area. Ifthe temperature of the fuel is below thecloud point (wax appearance point), waxcrystals in the fuel will cause the engineto lose power or not start.

The diesel fuel used in this machinemust meet the specifications in the chartbelow or Specification 0975-81 of theAmerican Society for Testing and Mate-rials.

Fuel Storage

If you keep fuel in storage for a periodof time, you can get foreign material orwater in the fuel storage tank. Manyengine problems are caused by water inthe fuel.

Keep the fuel storage tank outsideand keep the fuel as cool as possible.Remove water from the storage con-tainer at regular periods of time.

Specifications for Acceptable NO.2 Diesel Fuel

API gravity, minimum .. 34

Flash point, minimum. .. 140F (60C)

Cloud point (wax appearance point), maximum .. -5F (-20C) See Note abovePour point. maximum -15F (-26C) See Note above

Distillation temperature. 90% point... 540 to 640F (282 to 338C)

Viscosity, at 100F (88C)

Centistokes . 2.0 to 43

Saybolt Seconds Universal................. .. 32 to 40

Cetane number, minimum 43 (45 to 55 for winter or high altitudes)Water and sediment, by volume, maximum........................... .. 0.05 of 1%

Sulfur, by weight, maximum............... .. 0.5 of 1%

Copper strips corrosion, maximum .. No. 2

Ash, by weight, maximum................. .. 0.01 of 1%


Section

1024

SPECIFICATION DETAILS

IMPORTANT: This engine was made using the metric measurement system. Allmeasurements and checks must be made with metric tools to make sure of anaccurate reading when inspecting parts.

CASE CORPORATION Rae 8-24162Copyright 1991 J I Case Company

Printed in U.S.A.June, 1983 (Revised January, 1991)

1024-2

TABLE OF CONTENTS

RUN-IN INSTRUCTIONS. . 3

IDENTIFICATION MARKSCrankshaft 4Cylinder Block.... .. .4Cylinder Head..... . ..4

ENGINE SPECIFICATION DETAILSCylinder Block... . .4

Service Cylinder Sleeve..... . 5

Piston....... . 5

Piston Pin 5

Piston Rings 6

Cylinder Head. .. ...................6

Lifters .. ... 6

Connecting Rod . 7

Crankshaft. 8

Camshaft 9

Turbocharger 9

Gear Train 9

Rocker Arm Assembly. ..............10

Intake Valve... .. 10

Exhaust Valve 10

Valve Springs.......... . 11

Valve Seat Installation Dimensions 11

SPECIAL TORQUES .. , 11-13

Rae 8-24162 Revised 1-91 Printed in U.S.A.

1024-3

RUN-IN INSTRUCTIONS

Engine Lubrication

Fill the engine crankcase with CO or CE service classification oil that has the correct viscosity rating for the ambient airtemperature. Install new oil filters, after the engine has been rebuilt.

Run-In Procedure for Rebuilt Engine

Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start Crank theengine for 30 seconds until there is oil pressure, then reconnect the wire.

Step 2 Remove the air from the cooling system at the temperature sending unit.

Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks

Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.

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 willcontrol the engine load at each speed and will remove stress on new parts during Run-In.

During the Run-In, continue to check the oil pressure, coolant level and coolant temperature.

STEP123

TIME5 Minutes5 Minutes5 Minutes

ENGINE SPEED1000 RPM1100 RPM2200 RPM

DYNAMOMETER SCALE LOAD501/2Full

Run-In Procedure for Rebuilt Engines (Without a Dynamometer)

STEP123



LOADNo LoadLight LoadLight Load

Run-In Procedure (Agriculture Tractors)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours 00 NOT "lug" the engine.Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPMduring early hours of life.

Run-In Procedure (Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. Theengine must not be "lugged" below the Rated Engine RPM (00 not stall the engine more than 10 seconds).

Rae 8-24162 Revised 1-91 Printed in USA

1024-4

IDENTIFICATION MARKSCrankshaftLetter N = Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time

the crankshaft has been reconditioned.

Cylinder BlockLetter X = The cylinder block has been retaced and up to 0.25 mm has been removed. Use a thicker head gasket (DNa

notches).Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed Use a thicker head gasket

(three notches).

Cylinder HeadLetter G = Thermostat passage in cylinder did not need to be machinedLetter M = Thermostat passage in cylinder head was machined.

Letter V = Valve seats have been machined.Letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes

(one notch)Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (DNa

notches) .Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket

(three notches).Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.

ENGINE SPECIFICATION DETAILSCylinder Block

Metric ValueType.. . Non-SleevedMaterial Cast Iron10 of Cylinder... . 102.00 to 102.04 mm

Maximum Service Limit . 102.116 mmCylinder Out of Round (Maximum) 0.038 mm

Cylinder Taper (Maximum) 0.076 mm0.5 mm Oversize Piston

Machine Cylinder Bore to 102.40 to 102.44 mm

Hone to (Finished Diameter) 102.50 to 102.54 mm1.00 mm Oversize PistonMachine Cylinder Bore to 102.90 to 102.94 mmHone to (Finished Diameter) 103.00 to 103.04 mm

Warpage (Maximum).................................................................. 0.075 mmMaximum Material Removal 0.50 mm

Rae 8-24162 Revised 1-91 Printed in U.SA

1024-5

Service Cylinder SleeveType Dry, Can Be ReplacedMaterial Cast IronMachine Cylinder Block Bore to 104485 to 104.515 mm

Installation.................. . . Press FitMachine Sleeve Bore to:

Standard Size Piston (Finished Diameter) ................................10200 to 102.04 mm0.5 mm Oversize Piston

Machine Cylinder Bore to 10240 to 10244 mmHone to (Finished Diameter) 102.50 to 102.54 mm

1.0 mm Oversize Piston

Machine Cylinder Bore to.. .. 102.90 to 102.94 mmHone to (Finished Diameter) .. 103.00 to 103.04 mm

PistonType Cam GroundMaterial................... ...Aluminum alloyOD at 12 mm From the Bottom, 90 Degrees Piston Pin

Standard Size Piston 101.873 to 101.887 mmMinimum Service Limit. 101.823 mm

0.5 mm Oversize Piston 102.373 to 102.387 mmMinimum Service Limit. 101.323 mm

1.0 mm Oversize Piston 102.873 to 102.887 mmMinimum Service Limit 102.823 mm

ID of Piston Pin Bore 40.006 to 40.012 mmMaximum Service Limit 40.025 mm

Width of 1st Ring Groove (Top) .2465 to 2.485 mmWidth of 2nd Ring Groove (Intermediate) 2.425 to 2445 mm

Width of 3rd Ring Groove (Oil Ring) 4.040 to 4.060 mmProtrusion Above Cylinder Block (Maximum) 0.660 mm

Piston PinType Full FloatOD of Pin 39.997 to 40.003 mm

Minimum Service Limit 39.990 mm


1024-6

Piston RingsNO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)

End Gap in 102.02 10.... .. 0.4 to 0.70 mm

No.1. Compression 4-390 Engine Rectangular Type (Barrel Face)End Gap in 102.02 10.................. . 0.25 to 0.55 mm

Maximum Service l.irnit.. 0.806 mmSide Clearance 0.075 to 0.120 mm

Maximum Service Limit... 0.15 mmNO.2 Compression. Rectangular Type (Tapper Face)

End Gap in 102.02 10. ................0.25 to 0.55 mmMaximum Service Limit 0.806 mm

Side Clearance 0.075 to 0.120 mm

Maximum Service Limit . 0.15 mm

NO.3 Oil Control Rings.. Two PieceEnd Gap in 102.02 10 0.25 to 0.55 mmMaximum Service Limit............................................... . 0.806 mm

Side Clearance. . 0 130 mm

Cylinder HeadWarpage (Maximum) 0.20 mm

Maximum Material Removal.......................... . 1.00 mmMinimum Head Height .. 9375 mm

Engines Manufactured in U.S.A.:

Prior to Engine Serial Number 45511034 Injectior Nozzle 9 mmEngine Serial Number 45511034 and After Injectior Nozzle 7 mm

Engines Manufactured in Darlington England:Prior to Engine Serial Number 21092870 Injectior Nozzle 9 mmEngine Serial Number 21092870 and After . Injector Nozzle 7 mm

Engines Manufactured in Neuss Germany:Prior to Engine Serial Number 52107489 Injector Nozzle 9 mmEngine Serial Number 52107489 and After Injector Nozzle 7 mm

LiftersMaterial Hardened Iron00 of Lifter 15.961 to 15.977 mm

Minimum Service Limit. . .. 15.960 mmBore Diameter in Block 16.000 to 16.030 mmMaximum Service Limit. 16.055 mm

Rae 8-24162 Revised 1-91 Printed in USA.

1024-7

Connecting RodBushing . Steel Backed Leaded BronzeBushing 10 Installed (Ream to Size)........................................................... ..40.053 to 40.067 mm

Maximum Service Limit 40.092 mmBearing Liners...................... . Replaceable

Journal 10 Without Bearing Liners 72.987 to 73.013 mmBearing Oil Clearance ..............0.038 to 0.116 mm

Maximum Service Limit..... . 0129 mmSide Clearance...................................... . 0.100 to 0.300 mm

Maximum Service Limit ... 0330 mm

Connecting Rod Bend (Maximum)Without Bushing. . .

With Bushing .

Connecting Rod Twist (Maximum)Without Bushing. . ,..With Bushing .

. 0.200 mm

0150 mm

. 0.500 mm. 0.300 mm

Rae 8-24162 Revised 1-91 Printed in U.SA

1024-8

CrankshaftType Hardened Steel, Balanced

Main Bearing Liners...... .. . Replaceable

End Clearance, Center Main Bearing Cap 0.13 to 0.25 mm

Center Main Bearing Thrust Surface Thickness......... .. 2.50 mm

Connecting Rod Journal00, Standard . 68.987 to 69.013 mm

Maximum Service Lirnit.. . 68.962 mm

0.25 mm 00 Undersize, Grind to 68.737 to 68.763 mmMaximum Service Limi!........................................................... .. 68.712 mm

0.50 mm 00 Undersize, Grind to...................................... . 68.487 to 68.513 mmMaximum Service Limit.. 68.462 mm

0.75 mm 00 Undersize, Grind to 68.237 to 68.263 mmMaximum Service Limi!............ . . 68.212 mm

1.00 mm 00 Undersize, Grind to..........................67.987 to 68.013 mmMaximum Service Limi!..................................... . 67.962 mm

Connecting Rod Journal Maximum Taper 0.013 mm

Journals Out of Round Maximum....................................... . 0050 mm

Undersize Main Bearing Liners For Service . 0.25,0.50,0.75 and 1.00 mm

Main Bearing Oil Clearance 0.041 to 0.119 mm

Maximum Service Limit 0 140 mm

Main Bearing Journal00, Standard 82.987 to 83.013 mm

Maximum Service. Limi!..... . 82.962 mm

0.25 mm 00 Undersize, Grind to . 82.737 to 82.763 mmMaximum Service Limit. 82.712 mm

0.50 mm 00 Undersize, Grind to 82.487 to 82.513 mmMaximum Service Limit 82.462 mm

0.75 mm 00 Undersize, Grind to .......................................................................82.237 to 82.263 mmMaximum Service Limit. 82.212 mm

1.00 mm 00 Undersize, Grind to 81.987 to 82.013 mmMaximum Service Limit.. 81.962 mm

Main Bearing Journal Bore 10 No Liners 87.982 to 88.018 mmMaximum Service Limit . 88.031 mm

Main Journal Width:1st, 2nd, 3rd, 5th .. 37.424 to 37.576 mm

4th 37.475 to 37.525 mmConnect Rod Journals Width 38.950 to 39.050 mm


1024-9

CamshaftType Hardened Iron

Bushing (Front Only) 1, Replaceable

Bushing Lubrication:Front Bushing Pressure Lubricated

Intermediate. Pressure Lubricated

Rear Pressure Lubricated

Oil Clearance 0.076 to 0.152 mm

ID of NO.1 Bushing, Installed 54.107 to 54.133 mm

Maximum Service Limit .. 54.146 mm

ID of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm

Maximum Service Limit 54.146 mm

10 of NO.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm


Width of No 1 Bushing 25.15 to 25.65 mm

Width of No.2, 3, 4 and 5 Service Bushing 1775 to 18.25 mm

Camshaft Bushing Journal OD 53.987 to 54.013 mm

Camshaft Bore Diameter in BlockNO.1 Bushing 57.222 to 57.258 mm

NO.1. Oversize Bushing, Machine to 57. 722 to 57.758 mm

No.2, 3,4 and 5, Less Bushings 54.089 to 54139 mm

NO.2, 3,4 and 5 Oversize for Bushings, Machine to 57.222 to 57.258 mm

Camshaft Thrust Thickness 9.42 to 9.58 mm


Camshaft Thrust Clearance 0.130 to 0.340 mm


Camshaft Lobes:Minimum Diameter at Peak Intake 47.265 mm

Minimum Diameter at Peak Exhaust 46.994 mm

TurbochargerHorizontal Travel of Turbine Shaft 0.10 to 0.16 mm

Gear TrainBacklash:

Crankshaft Gear to Camshaft Gear 0.08 to 0.33 mmCrankshaft Gear to Idler Gear 0.08 to 0.33 mm

Camshaft to Fuel Pump Gear 0.08 to 0.33 mm

Idler Gear to Oil Pump 0.08 to 0.33 mm

Camshaft to Auxiliary 0.08 to 0.33 mm

Maximum Service Limit (All Gears) 0.45 mm


1024-10

Rocker Arm AssemblyOD of Shaft . . 18.963 to 18.975 mm

Minimum Service Limit.............. . 18.938 mmID of Arm Bore.............................. .. 19.000 to 19.026 mm

Maximum Service Limit 19.051 mmLubrication.. . Pressure From Oil Gallery

Shaft Oil Holes . Down

Intake ValveTappet Clearance (Cold) 0.254 mmFace Angle 29 DegreesFace Run-Out................. .. 0.038 mmValve Head Edge Thickness, Minimum........................... . 1.50 mmLength 128.84 to 129.46 mmOD of Stem . 7.960 to 7.980 mm

Minimum Service Limit . 7.940 mmOD of Head 44870 to 45.130 mm

Seat Angle................................ . 30 DegreesSeat Contact Width 1.32 to 1.92 mmSeat Run-Out....... . 0.10 mmInsert Height..................... .. 6.84 to 6.96 mmOD of Insert......................... .. .47.063 to 47.089 mmID of Insert..................... Tapered

Valve Recession Below Head Surface 0.99 to 1.52 mm

Maximum Service Limit. .. 1.52 mm

ID of Valve Guide Bore 8.019 to 8.039 mmMaximum Service Limit 8.089 mm

Exhaust ValveTappet Clearance (Cold) 0.508 mmFace Angle 44 DegreesFace Run-Out. 0.038 mm

Valve Head Edge Thickness, Minimum......................................................................................................150 mmOD of Head .41.870 to 42.130 mmOD of Stem .. 7.960 to 7.980 mm

Minimum Service Limit 7.940 mmLength 128.74 to 129.36 mmInsert Seat Angle.... .45 DegreesSeat Contact Width .. 1.47 to 2.07 mmSeat Run-Out. 0.10 mmInsert Heigh!...... . 6.65 to 6.77 mm

OD of Insert........ . 43713 to 43.739 mmID of Insert... . TaperedValve Recession Below Head Surface 0.99 to 1.52 mm

Maximum Service Limit 1.52 mmID of Valve Guide Bore 8.019 to 8.039 mm

Maximum Service Limit 8.089 mmRae 824162 Revised 1-91 Printed in U.S.A.

1024-11

Valve SpringsFree Length 55.63 mm

Total Coils. .. 7.25Wire Diameter.......... .. . 4.830 to 4.930 mm

Compressed to 38.53 mm (Valve Open) 785 to 839 N

Maximum Service Limit . 765 N

Compressed to 49.25 mm (Valve Closed) 285 to 321 N

Minimum Service Limit 270 N

Valve Seat Installation DimensionsExhaust Seat

Diameter of Insert .43. 713 to 43.73 mm

Machine Insert Bore to...... . .. .....43.647 to 43663 mm

Depth of Bore. ..........1010 to .092 mm

Press FiL... ..0.05 to 0 102 mm

Intake Seat

Diameter of Insert 47.063 to 47.089 mm

Machine Bore to ..46.987 to 47.013 mm

Depth of Bore .. 10.30 to 10.50 mm

Press Fit....................... '''_ 0.05 to 0.102 mm

14 mm Valve Guide Installation Dimensions

Guide Diameter 14.026 to 14.038 mm

Machine Guide Bore to 13.987 to 14013 mm

Press Fit.. 013 to .051 mm

Installed Height (above top of valve guide boss on head) 11.25 to 11.75 mm

Guide Installed ID 819 to 8.39 mm

SPECIAL TORQUESMetric Value

Aftercooler Bolts...... 21 to 27 Nm

Alternator Bracket Bolts (Lower) 21 to 27 Nm

Alternator Bracket Bolts (Upper) 21 to 27 Nm

Alternator Retaining Bolt 21 to 27 Nm

Balancer Counter Weight Bolts.................... .. 21 to 27 Nm

Balancer Mounting Bolts 167 to 183 Nm

Balancer Idler Gear .. 52 to 62 Nm

Belt Tensioner Bracket Bolts 21 to 27 Nm

Belt Tensioner Retaining Bolt. 39 to 47 Nm

Block Heater 11 to 13 Nm


1024-12

SPECIAL TORQUES (Cont'd)

Metric ValveCamshaft Retaining Bolts 21 to 27 Nm

Coolant Inlet Bolts 39 to 47 Nm

Connecting Rod Bolts..................... 95 to 100 Nm(Lubricate Threads with Engine Oil)

Cylinder Head Bolts 120 to 132 Nm

Engine Lift Bracket Bolts (Rear) 71 to 83 Nm

Exhaust Manifold Bolts 39 to 47 Nm

Fan Pulley Bracket Bolts .. __ .. 23 to 26 Nm

Fan Pulley Bolts 8.8..... ...__ __ __ 37 to 43 Nm

Fan Pulley Bolts 10.9.. " .__ 52 to 62 Nm

Flywheel Housing Bolts . 54 to 66 Nm

Flywheel Retaining Bolts 130 to 144 Nm

Flywheel Housing Cover Bolts __ 21 to 27 Nm

Fuel Filter Inlet Bolt 29 to 35 Nm

Fuel Air Removal Bolt........ .. 5 to 7 Nm

Fuel Filter Inlet NuL....... 29 to 35 Nm

Fuel Line Fitting (High Pressure) 22 to 28 Nm

Fuel Line Fitting (Low Pressure) 22 to 28 Nm

Fuel Shutoff Solenoid.. .. 15 Nm

Front Cover Bolts.... 21 to 27 Nm

Front Housing Bolts 21 to 27 Nm

Injection Pump Drive Gear Nut 59 to 71 Nm

Injection Pump Lock Bolt (Lock Position) 8 Nm

Injection Pump Lock Bolt (Unlock Position) 20 Nm

Injection Pump Retaining Nuts 21 to 27 Nm

Injection Pump Bracket Bolts 21 to 27 Nm

Injector Leak Off Bolt. . __.. .. 5 to 7 Nm

Injector Retaining NuL... .. 55 to 65 Nm

Rae 8-24162 Revised 1-91 Printed in U.S.A

1024-13

SPECIAL TORQUES (Cont'd)

Metric ValveIntake Manifold Bolts.. __ 21 to 27 Nm

Intake Manifold Plug __ __ 115 to 135 Nm

Lifter Cover Bolts.................. .. .. __ -- __ 21 to 27 Nm

Main Bearing Bolts............. ..__. __ __ __ __ __.__ 165 to 180 Nm(Lubricate the Thread with Engine Oil)

Oil Fill Tube Bolts __ __ __ __ __ 39 to 47 Nm

Oil Pan Drain Plug..... __ ......68 to 82 Nm

Oil Pan Heater Plug 108 to 132 Nm

Oil Pan Retaining Bolts __ __ 21 to 27 Nm

Oil Pump Retaining Bolts. .. __.. ........21 to 27 Nm

Oil Inlet Tube Bolts __ .18 to 30 Nm

Oil Inlet Tube Brace.. ..21 to 27 Nm

Oil Filter Housing Bolts __ __ 21 to 27 Nm

Oil Relief Valve Plug __ __ __ __ __ __..__ __ __.__ __ __108 to 132 Nm

Primer Pump 21 to 27 Nm

Rear Seal Retaining Bolts __ 8 to 10 Nm

Rocker Arm Bolts __ __ __.21 to 27 Nm

Starter Retaining Bolts __ __ __ __ 39 to 47 Nm

Tachometer Drive Retaining Bolts .. __ __ 2 to 4 Nm

Thermostat Housing Bolts __..__ __ 21 to 27 Nm

Timing Pin Retaining Bolts __ ..__.__ __ 4 to 6 Nm

Thrust Bearing Screws (Torx Head) __ __ __ __ __ __ __...4 to 6 Nm

Turbocharger Mounting Bolts __ __ 30 to 34 Nm

Turbocharger Drain Tube Bolts 21 to 27 Nm

Turbine Housing Bolts 9 to 13 Nm

Center Housing to Back Plate Bolts __ __ 5 to 7 Nm

Compressor Housing Bolts __ 5 to 7 Nm

Compressor Lock Nut... 13 to 1.5Nm

Water Pump Mounting Bolts 21 to 27 Nm

Valve Cover Bolts.......................... 21 to 27 Nm


1024-14

NOTE: The J I Case Company reserves the right to make improvements in design orchanges in specifications at any time without incurring any obligation to install themon units previously sold.

Rac 8-24162 Revised 1-91 Printed in U.S.A.

SECTION INDEX - ENGINE

Section Title Section Number

Engine Removal and Installation................................................. . 2001

Stall Tests. .. 2002

Detailed Engine Specifications. . 2402

Cylinder Head and Valve Train..... . 2415

Cylinder Block. . 2425

Lubrication System... .. 2445

Cooling System .. 2455

Turbocharger............. . ,..... ..2465

Turbocharger Failure Analysis 2565


Printed in U.S.AAugust. 1992

RADIATOR REMOVAL

2001-3

Put identification tags on all disconnected hosesand wires. Close disconnected hoses and fittings withcaps and plugs.

NOTE: Cal/outs on the photographs are in the orderof the procedure.

STEP 1

Park the machine on a level surface. Raise the loaderand lock the support strut (1) to hold the loader.

STEP 2

Disconnect the overflow hose (2) from the radiatorneck.

Remove the coolant reservoir (3). (bolts, flat washers,and self-locking nuts).

Disconnect the hood cable (4) from each side of theshroud. (flatwashers, spacers, lock washers, and nuts)

Remove the hardware from the hood hinges (5). (bolts,flatwashers, and lock washers).

Have another person help you remove the hood. Theweight of the hood is approximately 75 pounds (34 kg).

Bur 8-17560

NOTE: During instal/ation the hood must be adjusted.Put the hood in position. Install the hardware in the hoodhinges. Do not tighten the hardware. Close the hoodand remove the plastic plugs for access to the hingehardware. Push the top of the hood to the rear as far aspossible and tighten the hinge hardware.

STEP 3

Slowly remove the radiator cap (6).

Install a hose on the drain valve (7) and drain the ra-diator.

Disconnect the upper and lower radiator hoses (8).

Remove the hardware from the fan shroud (9). (bolts,lock washers, and flat washers)

NOTE: During installation fill the radiator completely andthe coolant reservoir with apprOXimately 18 U.S. quarts(17 litres) of coolant. See Section 1002 for coolantspecifications. Start and run the engine until the coolantis at operating temperature. Stop the engine and checkfor leakage. When the coolant is cold, check the coolantreservoir level.

Issued 3-91 Printed in U.S.A.

2001-4

STEP 4

Remove the strap (10) from the top of the radiatorshroud. (bolt, lock washer, and flat washer).

Remove the top cover (11). (bolts, lock washers, andflat washers).

Remove the upper and lower foam baffles (12).

STEP 5

Disconnect the radiator brackets (13) from each side ofthe radiator. (bolts, lock washers, and nuts)

Bur 8-17560

STEP 6

Remove the hardware (14) from each side of theradiator shroud. (bolts, flat washers, and nuts).

Remove the radiator shroud. The weight of the radiatorshroud is approximately 50 pounds (23 kg).

NOTE: During installation, push the top of the shroudtoward the rear of the machine and tighten the bolts forthe radiator shroud to 270 to 324 pound-feet (366 to 439Nm).

STEP 7

Remove the hardware that fastens the condenser andoil cooler (15) to the radiator. (bolts, lock washers, andflat washers).

Lift the radiator straight up and remove the radiator.

NOTE: Installation of the radiator is the reverse ofremoval.


ENGINE REMOVAL2001-5

Do steps 1 through 6 of radiator removal.

STEP 8

The hydraulic reservoir holds approximately 25 U.S.gallons (95 litres) of oil. Drain the oil from the hydraulicreservoir (16).

NOTE: During installation make sure the hydraulic re-servoir is filled with oil. See Section 1002 for specifica-tions.

STEP 9

Disconnect the hose (17) from the bottom of the torqueconverter to drain the oil from the torque converter.

Bur 8-17560

STEP 10

Remove the battery cover (18) from the left step. (capscrews and lock washers).

STEP 11

Disconnect the ground cable(s) (19) from the batt-ery(s) .

STEP 12

~7Remove the bottom cover (20). (bolts, lock washers,and flat washers).


2002-4

CHECK SHEET

1. _ (22301

SECTION INDEX - ENGINE

Section Title Section Number

Engine Removal and Installation . ................. 2001

Stall Tests 2002

Detailed Engine Specifications........ ...2402

Cylinder Head and Valve Train . ...... 2415

Cylinder Block . ..2425

Lubrication System . ... ............ ...... ......... .... .... ........................ .... ...................................................... ............ ....2445

Cooling System ..... .. ..... 2455

Turbocharger . ....... ....2465

Turbocharger Failure Analysis.. . . .. 2565


Printed in U.S.A.August. 1992

Section2001

ENGINE REMOVAL AND INSTALLATION

CASE CORPORATION Bur 8-17560 Printed in U.S.A.Issued March 1991

2001-2

TABLE OF CONTENTS

SPECIAL TOOLS 2

RADIATOR REMOVAL 3

ENGINE REMOVAL 5

REMOVING AND INSTALLING THE TORQUE CONVERTER 11

INSTALLING THE FRONT ENGINE SUPPORT.. 14

SPECIAL TOOLS

In Europe:

Order special tools from one of the following ad-dresses:

In the U.S.A. and Canada:

Service ToolsP.O. Box 314Owatonna, Minnesota 55060

VL Churchill Ltd.P.O. Box 3, DaventryNorthants, NN11 4NFEngland

CAS-1690 Rotation ToolThis tool is first used on page 12.

CAS-2081 Alignment ToolThis tool is first used on page 11.


RADIATOR REMOVAL

2001-3

Put identification tags on all disconnected hosesand wires. Close disconnected hoses and fittings withcaps and plugs.

NOTE: Cal/outs on the photographs are in the orderof the procedure.

STEP 1

Park the machine on a level surface. Raise the loaderand lock the support strut (1) to hold the loader.

STEP 2

Disconnect the overflow hose (2) from the radiatorneck.

Remove the coolant reservoir (3). (bolts, flat washers,and self-locking nuts).

Disconnect the hood cable (4) from each side of theshroud. (flatwashers, spacers, lock washers, and nuts)

Remove the hardware from the hood hinges (5). (bolts,flatwashers, and lock washers).

Have another person help you remove the hood. Theweight of the hood is approximately 75 pounds (34 kg).

Bur 8-17560

NOTE: During installation the hood must be adjusted.Put the hood in position. Install the hardware in the hoodhinges. Do not tighten the hardware. Close the hoodand remove the plastic plugs for access to the hingehardware. Push the top of the hood to the rear as far aspossible and tighten the hinge hardware.

STEP 3

Slowly remove the radiator cap (6).

Install a hose on the drain valve (7) and drain the ra-diator.

Disconnect the upper and lower radiator hoses (8).

Remove the hardware from the fan shroud (9). (bolts,lock washers, and flat washers)

NOTE: During installation fill the radiator completely andthe coolant reservoir with approximately 18 U.S. quarts(17 litres) of coolant. See Section 1002 for coolantspecifications. Start and run the engine until the coolantis at operating temperature. Stop the engine and checkfor leakage. When the coolant is cold, check the coolantreservoir level.

Issued 3-91 Printedin U.S.A.

2001-4

STEP 4

Remove the strap (10) from the top of the radiatorshroud. (bolt, lock washer, and flat washer).

Remove the top cover (11). (bolts, lock washers, andflat washers).

Remove the upper and lower foam baffles (12).

STEP 5

Disconnect the radiator brackets (13) from each side ofthe radiator. (bolts, lock washers, and nuts)

Bur 6-17560

STEP 6

Remove the hardware (14) from each side of theradiator shroud. (bolts, flat washers, and nuts).

Remove the radiator shroud. The weight of the radiatorshroud is approximately 50 pounds (23 kg).

NOTE: During installation, push the top of the shroudtoward the rear of the machine and tighten the bolts forthe radiator shroud to 270 to 324 pound-feet (366 to 439Nm).

STEP 7

Remove the hardware that fastens the condenser andoil cooler (15) to the radiator. (bolts, lock washers, andflat washers).

Lift the radiator straight up and remove the radiator.

NOTE: Installation of the radiator is the reverse ofremoval.


ENGINE REMOVAL

2001-5

Do steps 1 through 6 of radiator removal.

STEP 8

The hydraulic reservoir holds approximately 25 U.S.gallons (95 litres) of oil. Drain the oil from the hydraulicreservoir (16).

NOTE: During installation make sure the hydraulic re-servoir is filled with oil. See Section 1002 for specifica-tions.

STEP 9

Disconnect the hose (17) from the bottom of the torqueconverter to drain the oil from the torque converter.

Bur 8-17560

STEP 10

Remove the battery cover (18) from the left step. (capscrews and lock washers).

STEP 11

Disconnect the ground cable(s) (19) from the batt-ery(s).

STEP 12

Remove the bottom cover (20). (bolts, lock washers,and flat washers).


2001-6

STEP 13

Disconnect the two hoses (21) from the RH side of theoil cooler.

Disconnect the two tubes (22) from the LH side of the oilcooler.

STEP 14

Remove the hardware (23) that fastens the condenserto the oil cooler and radiator. (bolts, lock washers, andflat washers - bottom three on each side).

Move the condenser (24) to the LH side out of the way.Have another person help you remove the oil coolerand radiator (25). The weight of the oil cooler andradiator is approximately 50 pounds (23 kg).

Remove the fan shroud (26).

Bur 8-17560

STEP 15

Disconnect the two hoses (27) from the LH side of thepump. Remove the bolts and lock washers that fastenthe flange (28) on the RH side of the pump.

Remove the pump (29). (Bolts, lock washers, andhardened washers on the lower two bolts).

NOTE: During installation, remove and clean thesuction screen for the pump. Apply Molykote Type G tothe splines of the pump.

STEP 16

Disconnect the two connectors (30).

Remove the hardware (31) from the adjusting straps.(bolts, lock washers, flat washers, and nut - fronthardware has a weld nut).

Cut tie strap (32).

Issued3-91 Printedin U.S.A.

STEP 17

Remove the hardware (33) that fastens the compressorto the bracket. (long bolt, flat washer, lock washer, andnut). Remove the belt (34) and lay the compressor overthe side of the frame.

NOTE: During installation, adjust the drive belt ac-cording to instructions in Section 9003.

STEP 18

Close the fuel shut off valve (35).

Bur 8-17560

2001-7

STEP 19

Disconnect throttle rod (36).

Disconnect the wiring clamp (37).

Disconnect the wire from the oil pressure sender (38).

Disconnect the fuel shutoff wire (39).

If the machine has ether injection, disconnect the tube(40) and the wire (41).

Disconnect the fuel lines (42).

STEP 20

Remove the hardware from the muffler (43). (bolts, lockwashers, flat washers, and nuts)

Loosen the nuts on the muffler clamp (44). Remove themuffler.

Disconnect the wires from the air restriction switch (45).Then cut the tie straps which fasten the wire to the fuellines and put the wire out of the way.

Loosen the clamp (46) and remove the hose from theturbocharger.

Remove the hardware that fastens the firewall (47).(cap screws and flat washers). Remove the firewall (47)and the air cleaner assembly. If the machine has etherinjection, disconnect the wire from the harness.


2001-8

STEP 21

Remove harness clamp (48).

Disconnect the wire (49) from the temperature sender.Cut the tie straps that fasten the harness to the fuellines.

STEP 22



Disconnect the wires from the alternator (52).

Loosen the clamp (53) and disconnect the heater hose.

Bur 8-17560

STEP 23

Disconnect the wires (54) from the starter.

Disconnect the ground strap (55). (bolt and lockwasher).

Remove the hardware (56) for the engine mount. (bolt,flat washer, and nut).

NOTE: During installation, tighten the nut to 135 to 165pound-feet (183 to 224 Nm).

STEP 24

Connect the lifting eye (57) to the rear of the enginehead.

NOTE: During installation, remove the lifting eye and putin tool box.

Loosen the clamp (58) and disconnect the heater hose.

Remove the clamp (59).

Remove the hardware (60) for the engine mount. (bolt,flat washer, and nut)

NOTE: During installation, tighten the nut to 135 to 165pound-feet (183 to 224 Nm).


STEP 25

Remove the clamp (61).

STEP 26

Disconnect the tube (62) from the top of the filter head.

Disconnect the wire (63) from the sender on the filterhead.

Bur 8-17560

2001-9

STEP 27

Disconnect the hose (64) from the torque converter.

Disconnect the drive shaft (65) from the torque con-verter. (bolts and straps)

NOTE: During installation, tighten the bolts to 288 to348 pound-inches (33 to 40 Nm).

Loosen the clamps (66) on the hose.

STEP 28

Remove the hardware (67) for the front engine mount.(bolts, flat washers, and self-locking nuts)

NOTE: During installation, tighten self-locking nuts to360 to 420 pound-inches (41 to 47 Nm).


2001-10

STEP 29

Connect lifting equipment to the lifting eyes on theengine. Carefully lift the engine slightly and move theengine toward the front. Disconnect the hose (66)shown in step 27. Make sure all hoses and wires are outof the way. Remove the engine from the machine.

Bur 8-17560

NOTE: Installation of the engine is the reverse ofremoval. Before starting the engine, do the following:

a. The turbocharger must be filled with oil. Discon-nect the wire from the fuel shutoff solenoid. Actuatethe starter for 10 to 20 seconds to fill the turboch-arger with oil. Connect the wire to the fuel shutoffsolenoid.

b. Check the oil level in the transaxle.

c. On machines with PTO, the torque converterhousing is filled with oil. To prevent leakage, thestarter and torque converter housing must besealed. Use Loctite 504 on the torque converterhousing and form-in-place gasket material on thestarter.

d. With PTO fill the torque converter housing withapproximately one U.S. quart (0.95 litres) of oil.See Section 1002 for specifications.

Issued3-91 Printedin U.S.A.

2001-11

REMOVING AND INSTALLING THE TORQUE CONVERTER

NOTE: On machines with PTO, drain the oil from thetorque converter housing.

STEP 30

Remove the cap screws and lock washers that fastenthe torque converter housing to the engine. Remove thetorque converter housing.

STEP 31

Remove the cap screws and hardened washers thatfasten the drive ring to the flywheel.

STEP 32

Remove the torque converter.

NOTE: If the torque converter or the drive ring is beingreplaced, do the following steps.Bur 8-17560

STEP 33

Install the drive ring and the CAS-2018 alignmenttool.Install the drive ring to get the least amount ofmovement between the alignment tool and the drivering.

STEP 34

Install four cap screws and hardened washers.

STEP 35

Tighten the four cap screws evenly to 456 to 504pound-inches (52 to 57 Nm). Remove the CAS-2018tool and install the remaining hardened washers andcap screws. Tighten the cap screws to the same torquevalue.


2001-12

STEP 36

Hold the torque converter in place and install the capscrews and lock washers.

STEP 37

Use a dial indicator to check the position of the torqueconverter.

STEP 38

Remove the plastic plug at the left front of the flywheelhousing.

Bur 8-17560

STEP 39

Install the CAS-1690 tool to rotate the flywheel.

STEP 40

Rotate the flywheel and read the dial indicator. Thetorque converter must be centered within 0.004 inch(0.1 mm) so that the full indicated movement of the dialindicator is 0.008 inch (0.2 mm) or less.

STEP 41

When the torque converter is centered, tighten the capscrews to 156 to 180 pound-inches (18 to 20 Nm).


STEP 42

Remove the CAS-1690 tool and install the plastic plug.

NOTE: On machines with PTa, Apply Loctite 504 to theedge of the flywheel housing.

STEP 43

Install the torque converter housing so that the filterhead is horizontal.

IMPORTANT: DO NOT use extra force to push thetorque converter housing into place. Rotate the driveyoke to align the shafts with the torque converter andslide the torque converter housing against the engine.

Bur 8-17560

2001-13

STEP 44

Install the cap screws and lock washers. Tighten thecap screws to 456 to 540 pound-inches (52 to 61 Nm).


2001-14

INSTALLING THE FRONT ENGINE SUPPORT

NOTE: If the front engine support was removed forany reason, the front engine support must be alignedwith the crankshaft of the engine. If the front enginesupport is not aligned with the crankshaft of the engine,the pump can be damaged.

STEP 45

FRONT ENGINE SUPPORT

B892300J

Install a bushing in each top hole in the front enginesupport. Install the front engine support with thehardware shown.

STEP 46

Use a dial indicator to check the alignment of the frontengine support.

Bur 8-17560

STEP 47

Remove the plastic plug at the left front of the flywheelhousing.

STEP 48

Install the CAS-1690 tool to rotate the flywheel.

STEP 49

Rotate the flywheel and read the dial indicator. The frontengine support must be centered with the crankshaftwithin 0.010 inch (0.25 mm).


STEP 50

When the front engine support is centered, tighten thecap screws to 66 to 79 pound-feet (89 to 107 Nm).

Bur 8-17560

2001-15

STEP 51

Remove the CAS-1690 tool and install the plastic plug.


2002STALL TEST

TABLE OF CONTENTS

Specifications 2002-2 Procedure to Heat Hydraulic andTorque Converter Oil 2002-3

General Information 2002-2Test Procedure .2002-3

Preparing the Machine for the Stall Test.. 2002-2Check Sheet 2002-4

CASE CORPORATION Bur 8-12301 Printed in U.S.A.Issued March 1991

2002-2

SPECIFICATIONS

The specifications are the same for the naturally aspirated and turbocharged engines.

Low idle 850 to 900 rpm (r/rnin)

Full throttle (no load) 2330 to 2380 rpm (r/rnin)

Hydraulic stall speed (loader only) 2230 to 2280 rpm (r/rnin)

Torque converter stall speed 2200 to 2300 rpm (r/rnin)

Combined stall speed 1550 to 1750 rpm (r/min)

GENERAL INFORMATION

Do the stall test to find the cause of poor perfor-mance.

The engine is run at full throttle and the transmissionand hydraulic systems are engaged separately, andthen together.

Comparing the engine speeds from the stall testwith the check sheet on page 2002-4 will help to find thecause of the problem. It can be necessary to check aseparate system to find the exact cause of the problem.

Use a photo tachometer or other tachometer ofequal accuracy to get accurate results from the stalltest.

The engine, transmission and hydraulic systemmust be at operating temperature before doing the stalltest. Heat the oil according to instructions in thissection.

PREPARING THE MACHINE FOR THE STALL TEST

1. See Section 9001 and check the full throttle and lowidle speeds.

2. Apply the parking brake.

3. With the engine running at low idle move the trans-mission control lever to fourth gear and the directioncontrol lever to FORWARD.

Bur 8-12301

4. Slowly increase the engine speed to full throttle.

5. If the machine begins to move at any time,decrease the engine speed to low idle and stop theengine.

6. Adjust or repair the parking brake as required. SeeSection 7002 or 9001 as required.


PROCEDURE TO HEAT TORQUE CONVERTER AND HYDRAULIC OIL

2002-3

1. Apply the parking brake.

2. Start and run the engine at low idle.

3. With the engine running at full throttle, hold theloader control lever in ROLLBACK for 15 seconds.

4. Return the loader control lever to NEUTRAL for 15seconds.

5. Repeat steps 3 and 4 until the temperature of the oilis 125F (52C). The side of the reservoir will be verywarm at this temperature.

6. With the engine running at low idle, move the trans-mission control to fourth gear and the direction controllever to FORWARD.

7. Run the engine at full throttle for 15 seconds.

8. Decrease the engine speed to low idle and movethe direction control lever to NEUTRAL for 15 seconds

9. Repeat steps 6 through 8 until the pointer in thegauge for transmission oil temperature is in the centerof the green zone or the lamps in the optional instru-ment cluster are illuminated to the center of the greenzone of the gauge for transmission oil temperature.

TEST PROCEDURE

1. Prepare the machine for the stall test according toinstructions in this section.

2. Heat the oil according to instructions in this section.

3. Apply the parking brake and start the engine.

4. With the engine running at full throttle, hold theloader control lever in ROLLBACK and read the tachom-eter. Write the reading on line 1 on the check sheet.

5. Decrease the engine speed to low idle.

6. Move the transmission control lever to fourth gearand the direction control lever to FORWARD.

Bur 8-12301

7. Slow!y increase the engine speed to full throttle andread the tachometer. Write the reading on line 2 on thecheck sheet.

8. With the transmission control lever in fourth gear,the direction control lever in FORWARD, and the enginerunning at full throttle. hold the loader control lever inROLLBACK and read the tachometer. Write the readingon line 3 on the check sheet.

9. Decrease the engine speed to low idle (twominutes with turbocharger) and stop the engine.

10. See the check sheet to understand the results ofthe stall test.


2002-4

CHECK SHEET1. _ (2230 to 2280 specified) rpm (r/min) hydraulic stall speed

2. _ (2200 to 2300 specified) rpm (r/min) torque converter stall speed

3. _ (1550 to 1750 specified) rpm (r/min) hydraulic and torque converter stall speed

rpm (r/min)

1. 2230 to 2280 Torque converter, transmission, hydraulic system and engine are probably good.2. 2200 to 23003. 1550 to 1750

1. Above 2280 Engine problem. Check engine speeds. See specifications in Section 9001. Check the2. Above 2300 timing of the fuel injection pump according to instructions in Section 3412.3. Above 1750

1. Below 2230 Engine problem. Check engine speeds according to instructions in Section 9001. Check2. Below 2200 the timing of the fuel injection pump according to instructions in Section 3412. Replace3. Below 1550 the fuel and air filters.

1. Below 2230 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief2. 2200 to 2300 valve. Check the output of the pumps.3. Below 1550

1. Above 2280 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief2. 2200 to 2300 valve. Check the output of the hydraulic pumps. Check for leakage in the loader3. Above 1750 control valve.

1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check the2. Above 2300 transmission and torque converter.3. Above 1750

1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check2. Below 2200 the transmission and torque converter.3. Below 1550


Section

2402

4-390 Diesel Engine

SPECIFICATION DETAILS

IMPORTANT: This engine was made using the metric measurement system. Allmeasurements and checks must be made with metric tools to make sure of anaccurate reading when inspecting parts.

CASE CORPORATIONRae 8-24163

Copyright 1992 J I Case CompanyPrinted in U.S.A.

June, 1983 (Revised February, 1992)

2402-2

TABLE OF CONTENTS

RUN-IN INSTRUCTIONS 3

IDENTIFICATION MARKSCrankshaft 4Cylinder Block 4Cylinder Head .4

ENGINE SPECIFICATION DETAILSCylinder Block .4

Service Cylinder Sleeve 5

Piston 5

Piston Pin 5

Piston Rings 6

Cylinder Head 6

Lifters 6

Connecting Rod 7

Crankshaft 8

Camshaft 9

Gear Train 9

Rocker Arm Assembly 10

Intake Valve 10

Exhaust Valve 10

Valve Springs 11

Valve Seat Installation Dimensions 11

SPECIAL TORQUES 11-13

Rae 8-24163

Turbocharger 9

Revised 2-92 Printed in U.S.A.

2402-3

RUN-IN INSTRUCTIONS

Engine Lubrication

Fill the 4-390 engine crankcase with CC/SF, CD/SF, CE/SF or CF-4 service classification oil. Use the correct viscosityrating for the ambient air temperature. Install new oil filters after the engine is rebuilt.

Fill the 4T390 and the 4TA 390 engine crankcase with CE/SF or CF-4 service classification oil. Use the correct viscosityrating for the ambient air temperature. Install new oil filters after the engine is rebuilt.

Run-In Procedure for Rebuilt Engine

Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start. Crank theengine for 30 seconds until there is oil pressure, then reconnect the wire.

Step 2 Remove the air from the cooling system at the temperature sending unit.

Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks.

Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.

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 willcontrol the engine load at each speed and will remove stress on new parts during Run-In.

During the Run-In, continue to check the oil pressure, coolant level and coolant temperature

STEP123



DYNAMOMETER SCALE LOAD501/2Full

Run-In Procedure for Rebuilt Engines (without a Dynamometer)

STEP123



LOADNo LoadLight LoadLight Load

Run-In Procedure (Agriculture Equipment)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours DO NOT "lug" the engine.Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPMduring early hours of life.

Run-In Procedure (Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. Theengine must not be "lugged" below the Rated Engine RPM (Do not stall the engine more than 10 seconds).


2402-4

IDENTIFICATION MARKSCrankshaftLetter N = Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time

the crankshaft has been reconditioned.

Cylinder BlockLetter X = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker head gasket (two

notches).Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket

(three notches).

Cylinder HeadLetter G = Thermostat passage in cylinder did not need to be machined.Letter M = Thermostat passage in cylinder head was machined.Letter V = Valve seats have been machined.LetterX = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes

(one notch). This gasket is used for standard replacement, 0.5 mm oversize and 1.0 mm oversize bore.Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (two

notches).Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket

(three notches).Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.

ENGINE SPECIFICATION DETAILSCylinder Block

Metric ValueType Non-Sleeved

Material Cast Iron

10 of Cylinder 102.00 to 102.04 mmMaximum Service Limit 102.116 mm

Cylinder Out of Round (Maximum) 0.038 mmCylinder Taper (Maximum) 0.076 mm0.5 mm Oversize Piston

Machine Cylinder Bore to 102.40 to 102.44 mm

Hone to (Finished Diameter) 102.50 to 102.54 mm

1.00 mm Oversize PistonMachine Cylinder Bore to... .. 102.90 to 102.94 mmHone to (Finished Diameter) 103.00 to 103.04 mm

Warpage (Maximum) 0.075 mmMaximum Material Removal. 0.50 mm


2402-5

Service Cylinder SleeveType , Dry, Can Be ReplacedMaterial .. , , , Cast IronMachine Cylinder Block Bore to ,104.485 to 104.515 mm

Installation Press FitMachine Sleeve Bore to:

Standard Size Piston (Finished Diameter) 102.00 to 102,04 mm0.5 mm Oversize Piston

Machine Cylinder Bore to 102.40 to 102.44 mmHone to (Finished Diameter) 102.50 to 10254 mm

1.0 mm Oversize PistonMachine Cylinder Bore to 102.90 to 102.94 mm

Hone to (Finished Diameter) 103,00 to 103.04 mm

PistonType : Cam GroundMaterial Aluminum Alloy00 at 12 mm From the Bottom, 90 Degrees Piston PinStandard Size Piston ,101.873 to 101.887 mm

Minimum Service Limit. , , 101.823 mm

0.5 mm Oversize Piston 102.373 to 102.387 mm

Minimum Service Limit. 101.323 mm

1.0 mm Oversize Piston 102.873 to 102.887 mm

Minimum Service Limit. , 102.823 mm10 of Piston Pin Bore .40.006 to 40.012 mmMaximum Service Limit 40.025 mm

Width of 1st Ring Groove (Top) 2.465 to 2.485 mmWidth of 2nd Ring Groove (Intermediate) 2.425 to 2.445 mmWidth of 3rd Ring Groove (Oil Ring) , 4.040 to 4.060 mm

Protrusion Above Cylinder Block (Maximum) 0.660 mm

Protrusion Above Cylinder Block (Minimum) 0.280 mm

Piston PinType Full Float00 of Pin , 39.997 to 40.003 mm


Rae 8-24163 Revised292 Printedin U.S.A.

2402-6

Piston RingsNO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)

End Gap in 102.02 ID 0.4 to 0.70 mmNO.1 Compression 4-390 Engine Rectangular Type (Barrel Face)

End Gap in 102.02 ID 0.25 to 0.55 mmMaximum Service Limit....... .. 0.806 mm

Side Clearance.................... . 0.075 to 0.120 mmMaximum Service Limit. 0.15 mm

NO.2 Compression Rectangular Type (Tapper Face)End Gap in 102.021D 0.25 to 0.55 mm

Maximum Service Limit. 0.806 mm


Maximum Service Limit.. 015 mm

NO.3 Oil Control Rings Two PieceEnd Gap in 102.02 ID 0.25 to 0.55 mm

Maximum Service Limit. . 0806 mm

Side Clearance 0.130 mm

Cylinder HeadWarpage (Maximum) . 0.20 mm

Maximum Material Removal.................. 1.00 mm

Minimum Head Height 93.75 mmEngines Manufactured in U.S.A.:

Prior to Engine Serial Number 45511034 Injector Nozzle 9 mmEngine Serial Number 45511034 and After Injector Nozzle 7 mm

Engines Manufactured in Darlington England:Prior to Engine Serial Number 21092870 Injector Nozzle 9 mmEngine Serial Number 21092870 and After Injector Nozzle 7 mm

Engines Manufactured in Neuss Germany:Prior to Engine Serial Number 52107489 Injector Nozzle 9 mm

Engine Serial Number 52107489 and After Injector Nozzle 7 mm

LiftersMaterial Hardened Iron

OD of Lifter 15.961 to 15.977 mmMinimum Service Limit. 15.960 mm

Bore Diameter in Block 16.000 to 16.030 mm

Maximum Service Limit... 16.055 mm


2402-7

Connecting RodBushing Steel Backed Leaded BronzeBushing ID Installed (Ream to Size) 40.053 to 40.067 mm

Maximum Service Limit 40.092 mmBearing Liners Replaceable

Journal 10 Without Bearing Liners 72.987 to 73.013 mmBearing Oil Clearance 0.038 to 0.116 mmMaximum Service Limit 0.129 mm



Connecting Rod Bend (Maximum)Without Bushing 0200 mm

With Bushing 0150 mm

Connecting Rod Twist (Maximum)Without Bushing 0500 mm

With Bushing 0.300 mm .

Connecting Rod Bolt Maximum 59.25


2402-8

CrankshaftType............................. . Hardened Steel, Balanced

Main Bearing Liners...... . Replaceable

End Clearance, Center Main Bearing Cap . 013 to 0.25 mm

Center Main Bearing Thrust Surface Thickness.. . 2.50 mm

Connecting Rod JournalOD, Standard 68.987 to 69.013 mm

Maximum Service Limit.. . 68.962 mm

0.25 mm OD Undersize, Grind to......................................................... ..68.737 to 68.763 mm

Maximum Service Limit.... . 68.712 mm

0.50 mm OD Undersize, Grind to 68.487 to 68.513 mm

Maximum Service Limit........ .. 68.462 mm


Maximum Service Limit.. 68.212 mm

1.00 mm OD Undersize, Grind to. .. . 67.987 to 68.013 mm

Maximum Service Limit.............................................. .. 67962 mm

Connecting Rod Journal Maximum Taper.................................................. .. 0.013 mm

Journals Out of Round Maximum 0.050 mm

Undersize Main Bearing Liners For Service 0.25,0.50, 0.75 and 1.00 mm

Main Bearing Oil Clearance 0.041 to 0.119 mm


Main Bearing JournalOD, Standard 82.987 to 83.013 mm










Main Bearing Journal Bore 10 No Liners 87.982 to 88.018 mmMaximum Service Limit 88.031 mm

Main Journal Width:tst, 2nd, 3rd, 5th.......................... . 37.424 to 37.576 mm

4th................................................... . 37.475 to 37.525 mmConnect Rod Journals Width 38.950 to 39.050 mm

Main Bearing Bolt Maximum Length 119.25 mm


2402-9

CamshaftType................ . Hardened Iron

Bushing (Front Only) 1, Replaceable

Bushing Lubrication:Front Bushing Pressure Lubricated

Intermediate Pressure Lubricated

Rear Pressure Lubricated

Oil Clearance 0.076 to 0.152 mm

10 of NO.1 Bushing, Installed 54.107 to 54.133 mm


10of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm


10 of No.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm


Width of No. 1 Bushing 25.15 to 25.65 mm

Width of No.2, 3, 4 and 5 Service Bushing 17.75 to 18.25 mm

Camshaft Bushing Journal 00 53.987 to 54.013 mmCamshaft Bore Diameter in Block

NO.1 Bushing 57.222 to 57.258 mm

NO.1 Oversize Bushing, Machine to 57.722 to 57.758 mm

No.2, 3, 4 and 5, Less Bushings 54.089 to 54.139 mm

No.2, 3, 4 and 5 Oversize for Bushings, Machine to 57.222 to 57.258 mm

Camshaft Thrust Thickness 9.42 to 9.58 mm


Camshaft Thrust Clearance 0.130 to 0.340 mm


Camshaft Lobes:Minimum Diameter at Peak Intake 47.265 mm

Minimum Diameter at Peak Exhaust... 46.994 mm

TurbochargerHorizontal Travel of Turbine Shaft 0.10 to 0.16 mm

Gear TrainBacklash:

Crankshaft Gear to Camshaft Gear 0.08 to 0.33 mm

Crankshaft Gear to Idler Gear 0.08 to 0.33 mm

Camshaft to Fuel Pump Gear 0.08 to 0.33 mm

Idler Gear to Oil Pump 0.08 to 0.33 mm

Camshaft to Auxiliary 0.08 to 0.33 mm

Maximum Service Limit (All Gears) 0.45 mm

Rae 8-24163 Revised2-92 Printedin U.S.A.

2402-10

Rocker Arm Assembly00 of Shaft . 18.963 to 18.975 mm

Minimum Service Limit .. 18.938 mm

10 of Arm Bore 19.000 to 19.026 mmMaximum Service Limit 19.051 mm

Lubrication Pressure From Oil Gallery

Shaft Oil Holes Down

Intake ValveTappet Clearance (Cold) 0.254 mmFace Angle..................... . 29 DegreesFace Run-Out.. 0.038 mm

Valve Head Edge Thickness, Minimum 1.50 mm

Length 128.84 to 129.46 mm

00 of Stem 7.960 to 7.980 mmMinimum Service Limit.. 7.940 mm

00 of Head .44.870 to 45.130 mmSeat Angle 30 DegreesSeat Contact Width 1.32 to 1.92 mmSeat Run-Out... 0.10 mm

Insert Height 6.84 to 6.96 mm00 of Insert .47.063 to 47.089 mm10 of Insert Tapered

Valve Recession Below Head Surface 0.99 to 1.52 mmMaximum Service Limit . 1.52 mm

10 of Valve Guide Bore 8.019 to 8.039 mmMaximum Service Limit 8.089 mm

Exhaust ValveTappet Clearance (Cold) 0.508 mm

Face Angle 44 DegreesFace Run-Out 0.038 mmValve Head Edge Thickness, Minimum 1.50 mm00 of Head 41.870 to 42.130 mm00 of Stem 7.960 to 7.980 mm

Minimum Service Limit 7.940 mmLength 128.74 to 129.36 mmInsert Seat Angle 45 DegreesSeat Contact Width 1.47 to 2.07 mmSeat Run-Out. 0.10 mmInsert Height 6.65 to 6.77 mm00 of Insert .43.713 to 43.739 mm10 of Insert TaperedValve Recession Below Head Surface 0.99 to 1.52 mm

Maximum Service Limit : 1.52 mm10 of Valve Guide Bore 8.019 to 8.039 mm



2402-11

Valve SpringsFree Length , , ,' , ,.,.., , , , 55.63 mm

Total Coils ' ,' ' , ,' , , , 7.25

Wire Diameter, , , '.. , , , , , , . , .4.830 to 4.930 mmCompressed to 38.53 mm , (Valve Open) 785 to 839 N

Maximum Service Limit , , , , 765 N

Compressed to 49.25 mm , (Valve Closed) 285 to 321 NMinimum Service Limit , , ' 270 N

Valve Seat Installation DimensionsExhaust SeatDiameter of Insert .' ,..43.713 to 43.73 mm

Machine Insert Bore to , , .43.647 to 43,663 mm

Depth of Bore , , 10.10 to .092 mm

Press Fit.. 0.05 to 0.102 mm

Intake Seat

Diameter of Insert .47.063 to 47.089 mm

Machine Bore to .46.987 to 47.013 mm

Depth of Bore . 10.30 to 10.50 mm

Press Fit................. 0.05 to 0.102 mm

Valve Guide Installation Dimensions11 mm Valve Guide Installation DimensionsValve Guide 00 , , 11.150 to 11.163 mm

Machine Guide Bore to 11.112 to 11.138 mm

Press Fit... 0.012 to 0.051 mm

Installed Height (above top of valve guide boss on head) "'"'''''''''''' """"'"'''''''''''''''' """ " " " " 11.25 to 11.75 mm

Guide Installed 10 8.19 to 8.39 mm

14 mm Valve Guide Installation DimensionsGuide Diameter 14.026 to 14.038 mm

Machine Guide Bore to 13.987 to 14.013 mm

Press Fit. , 013 to 051 mmInstalled Height (above top of valve guide boss on head) 11.25 to 11.75 mm

Guige Installed 10 , 8.19 to 8.39 mm

Metric ValueAftercooler Bolts , 21 to 27 Nm

SPECIAL TORQUES

Alternator Bracket Bolts (Lower) 21 to 27 Nm

Alternator Bracket Bolts (Upper) , , , 21 to 27 Nm

Alternator Retaining Bolt 21 to 27 Nm

Balancer Counter Weight Bolts 21 to 27 Nm

Balancer Mounting Bolts 167 to 183 Nm

Balancer Idler Gear 52 to 62 Nm

Belt Tensioner Bracket Bolts 21 to 27 Nm

Rae 8-24163 Revised 2-92 Printedin U.S.A,

2402-12

Metric ValveBelt Tensioner Retaining Bolt .39 to 47 NmBlock Heater 11 to 13 Nm

Camshaft Retaining Bolts...... 21 to 27 Nm

Coolant Inlet Bolts 39 to 47 Nm

Connecting Rod Bolts 60 Nm Plus 60 Degrees(Lubricate Threads with Engine Oil)

Cylinder Head TorqueShort Bolts 90 Nm Plus 90 Degrees

Long Bolts 120 Nm Plus 90 Degrees

Engine lift Bracket Bolts (Rear) 71 to 83 Nm

Exhaust Manifold Bolts 39 to 47 Nm

Fan Pulley Bracket Bolts 23 to 26 Nm

Fan Pulley BoltsGrade 8.8 Size M8 37 to 43 Nm

Grade 10.9 Size M8 52 to 62 Nm



Flywheel Housing Bolts 54 to 66 Nm

Flywheel Retaining Bolts................ 130 to 144 Nm

Flywheel Housing Cover Bolts 21 to 27 Nm

Fuel Filter Inlet Bolt 29 to 35 Nm

Fuel Air Removal Bolt 5 to 7 Nm

Fuel Filter Inlet Nut 29 to 35 Nm

Fuel Line Fitting (High Pressure) 22 to 28 Nm

Fuel line Fitting (Low Pressure) 22 to 28 Nm

Fuel Shutoff Solenoid 15 Nm

Front Cover Bolts 21 to 27 Nm

Front Housing Bolts 21 to 27 Nm

Injection Pump Drive Gear Nut.. 59 to 71 Nm

Injection Pump Lock Bolt (Lock Position) 8 Nm

Injection Pump Lock Bolt (Unlock Position) 20 Nm

Injection Pump Retaining Nuts 21 to 27 Nm

Injection Pump Bracket Bolts 21 to 27 Nm

Injector Leak Off Bolt 5 to 7 Nm

Injector Retaining Nut. 55 to 65 Nm


2402-13

Metric ValveIntake Manifold Bolts 21 to 27 Nm

Intake Manifold Plug 115 to 135 Nm

Lifter Cover Bolts 21 to 27 Nm

Main Bearing Bolts 80 Nm Plus 60 Degrees(Lubricate the Thread with Engine Oil)

Oil Fill Tube Bolts 39 to 47 Nm

Oil Pan Drain Plug 68 to 82 Nm

Oil Pan Heater Plug 108 to 132 Nm

Oil Pan Retaining Bolts 21 to 27 Nm

Oil Pump Retaining Bolts... . 21 to 27 Nm

Oil Inlet Tube Bolts 18 to 30 Nm

Oil Inlet Tube Brace 21 to 27 Nm

Oil Filter Housing Bolts 21 to 27 Nm

Oil Relief Valve Plug 108 to 132 Nm

Primer Pump 21 to 27 Nm

Rear Seal Retaining Bolts 8 to 10 Nm

Rocker Arm Bolts 21 to 27 Nm

Starter Retaining Bolts 39 to 47 Nm

Tachometer Drive Retaining Bolts 2 to 4 Nm

Thermostat Housing Bolts 21 to 27 Nm

Timing Pin Retaining Bolts 4 to 6 Nm

Thrust Bearing Screws (Torx Head) .4 to 6 Nm

Turbocharger Mounting Bolts 30 to 34 Nm

Turbocharger Drain Tube Bolts 21 to 27 Nm

Turbine Housing Bolts 9 to 13 Nm

Center Housing to Back Plate Bolts 5 to 7 Nm

Compressor Housing Bolts 5 to 7 Nm

Compressor Lock NuL 13 to 15 Nm

Water Pump Mounting Bolts 21 to 27 Nm

Valve Cover Bolts 21 to 27 Nm


2402-14

NOTE: The J I Case Company reserves the right to make improvements in design orchanges in specifications at any time without incurring any obligation to install themon units previously sold.


Section

2415

CYLINDER HEAD AND VALVE TRAIN

4-390 Diesel Engine

IMPORTANT: This engine was made using the metric measurement system. NImeasurements and checks must be made with metric tools to make sure of anaccurate reading when inspecting parts.


Printed in U.S.A.June, 1983 (Revised February. 1992)

2415-2

TABLE OF CONTENTS

IDENTIFICATION MARKS 2

SPECIFICATIONS 3

SPECIAL TORQUES 4

SPECIAL TOOLS 5

CHECKING AND RESURFACING THE CYLINDER HEAD 12,13

VALVE GUIDE REPLACEMENT14 mm Replacement Valve Guides 14

11 mm Replacement Valve Guides 15

INSPECTION OF THE VALVES AND VALVE SEATS 16-18

VALVE SEAT INSTALLATION.......................................... 19

REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS 20-26

CYLINDER HEAD ASSEMBLy 27,28

ROCKER ARM DiSASSEMBLy .28,29

ROCKER ARM ASSEMBLy 29

CYLINDER HEAD INSTALLATION 30-34

LOCATING TOP CENTER 35

ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE 35-39

THERMOSTAT SERViCE 39-40

IDENTIFICATION MARKS

letter G Thermostat passage in cylinder did not need to be machined.

letter M = Thermostat passage in cylinder head was machined.

Letter V = Valve seats have been machined.

CYLINDER HEAD REMOVAL 6-10

CYLINDER HEAD DiSASSEMBLy................. 11

letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes(one notch).

Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker head gasket (twonotches).

Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket(three notches).

Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.Rae 8-24173 Revised 2-92 Printed in U.SA

2415-3

SPECIFICATIONS

ENGINES MANUFACTURED IN USAPrior to Engine Serial Number 45511034 Injector Nozzle 9 mmEngine Serial Number 45511034 and After Injector Nozzle 7 mm

ENGINES MANUFACTURED IN DARLINGTON ENGLANDPrior to Engine Serial Number 21092870..................... Injector Nozzle 9 mmEngine Serial Number 21092870 and After Injectior Nozzle 7 mm

ENGINES MANUFACTURED IN NEUSS GERMANYPrior to Engine Number 52107489 Injector Nozzle 9 mmEngine Serial Number 52107489 and After Injector Nozzle 7 mm

CYLINDER HEADMaximum Warpage 0.010 mm in any 50 mm diameter area or more than

0.075 mm overall end to end or side to side.Maximum amount of material that can be removed during resurfacing 1.0 mmMinimum total height of cylinder head 93.75 to 94.25 mm

CYLINDER HEAD MACHINING IDENTIFICATION MARKSTotal thickness of cylinder head material removed See Page 12X on head indicates block resurfacing See Page 27Von head indicates valves have been ground See Page 27G on head indicates thermostat bore inspected See Page 40M on head indicates thermostat bore machined See Page 40

14 MM REPLACEMENT VALVE GUIDEValve guide 00 14.026 to 14.038 mmBore cylinder head to 13.987 to 14.013 mmPress fit 0.013 to 0.051 mmInstalled height above top of valve guide boss on cylinder head 11.25 to 11.75 mm

11 MM REPLACEMENT VALVE GUIDEValve guide 00 11.150 to 11.163 mmBore cylinder head to 11.112 to 11.138 mmPress fit 0.012 to 0.051 mmInstalled height above top of valve guide boss on cylinder head 11.25 to 11.75 mm

EXHAUST VALVE INSERTDiameter of insert .43.713 to 43.739 mmDiameter of bore 43.647 to 43.663 mmDepth of bore 10.10 to 10.30 mmPress fit 0.05 to 0.092 mm

INTAKE VALVE INSERTDiameter of insert .47.063 to 47.089 mmDiameter of bore .46.987 to 47.013 mmDepth of bore 10.30 to 10.50 mmPress fit 0.05 to 0.102 mm:


2415-4

SPECIAL TORQUES

Alternator bracket bolts 21 to 27 Nm

Belt tensioner bracket bolts (Allen head) 21 to 27 Nm

Belt tensioner bolt 39 to 47 Nm

Cylinder head bolts 120 to 132 Nm

Exhaust manifold bolts 39 to 47 Nm

Fan belt pulley bracket bolts 23 to 25 Nm

Fan belt pulley boltsGrade 8.8 Size M8 26 to 31

Grade 10.9 Size M8 37 to 43



Fuel filter housing nut 29 to 35 Nm

Injector leak off fitting 5 to 7 Nm

Injector cap nut 55 to 60 Nm

Intake manifold cover bolts 21 to 27 Nm

Lift bracket bolts (Rear) 71 to 83 Nm

Rocker arm bracket bolts 21 to 27 Nm

Thermostat housing bolts 21 to 27 Nm

Valve cover bolts 21 to 27 Nm


2415-5

SPECIAL TOOLS

B90288SJ

B9028B3J CAS-1066A Head Bolt WrenchThis tool is first used on Page 36.

CAS-1694 Injector Bore Cleaner (For 9 mm injectors)CAS-2155 Injector Bore Cleaner (For 7 mm injectors)This tool is first used on Page 28.

B902884JCAS-2162 Torque Angle GaugeThis tool first used on Page 31 .

CAS-1743 Valve Guide ReamerThis tool is first used on Page 14.


2415-6

STEP 1

CYLINDER HEAD REMOVALSTEP 4

Lift the belt tensioner and remove the fan belt.

STEP 2

Remove the belt tensioner bolt and the belt tensioner.

STEP 3

Mc,iQ,I6~94gRemove the fan hub bolts and the fan hub.

Rae 8-24173

'T68944Remove the belt tensioner bolts and the bracket.

STEP 5

i1Remove the fan hub bracket bolts and the bracket.

STEP 6

Remove the bolts that hold the alternator and removethe alternator.


STEP 7

Remove the alternator bracket bolts and the bracket.

STEP 8

Remove the thermostat bolts and the housing as-sembly.

STEP 9 4T-390 ENGiNE

To remove the turbocharger see section 2465 in theservice manual.

Rae 8-24173

2415-7

STEP 10

STEP 11

Disconnect and remove the fuel lines.

STEP 12

I,Install protective covers on the injection pump outletlines and the injection lines.


2415-8

STEP 13 CAV INJECTION PUMP

Remove the leak off fitting and gasket.

STEP 14 BOSCH INJECTION PUMP

Remove the leak off fitting and gaskets.

STEP 15

15Remove the leak off fittings, gaskets and the leak offline.

Rae 8-24173

STEP 16

Loosen the nut on the injectors.

NOTE: The injector must not rotate in the bore of thecylinder head. This will damage the cylinder head.

STEP 17

Remove the injectors from the cylinder head.

NOTE: Make sure the injector seal is removed from thecylinder head.

STEP 18

Use a strap type wrench to remove the fuel filters.

NOTE: Some engines have a single fuel filter.


STEP 19

. " .w N

T68983

Remove the fuel line fittings and the fuel line.

STEP 20

STEP 21 CAY INJECTION PUMP

Remove the inlet line.

Rae 8-24173

2415-9

STEP 22 BOSCH INJECTION PUMP

Remove the inlet line.

STEP 23

:>.:,.;

T~8~9~jInstall a protective cover in the injection pump.

STEP 24

.~:..

. . ~~ .....-.:~..------ ':T68994

Remove the valve bolts and the valve covers.


2415-10

STEP 25

....".-- ..... ",...., .Remove the intake manifold cover bolts and the intakemanifold cover.

STEP 26

Remove the rocker arm bolts and the rocker arm as-semblies.

STEP 27

Remove the push rods from the cylinder head.

Rae 8-24173

STEP 28

Remove the lift bracket bolts and the lift bracket.

STEP 29

Remove the cylinder head bolts and the cylinder head.

STEP 30

~A#W T68~Cover the cylinder bores and pistons. Clean all foreignmaterial from the cylinder head mounting surface.

NOTE: The cylinders and pistons must be covered toprevent damage to the pistons and cylinder walls.


2415-11

STEP 31

CYLINDER HEAD DISASSEMBLYSTEP 34

687~8'Put the cylinder head on a clean work surface.

STEP 32

. ../-).~~,~ . -"(. 6~Q7':l()~ ...'.~:::w:..Use a valve spring compressor to push down the valvesprings. Remove the valve keepers.

STEP 33

{" -. "t-~ ~...&Remove the valve spring retainers and the valve spring.

Rae 8-24173

Remove the valve seals.

STEP 35;::

Remove the valves.


2415-12

STEP 36

CHECKING AND RESURFACING THE CYLINDER HEADSTEP 38

.:.:.:

....ppClean the cylinder head completely. Remove carbonand other deposits. Check for cracks and any otherdamage to the head.

STEP 37

Check the cylinder head surface with a straight edgeand feeler gauge. Resurface the cylinder head ifwarpage or erosion is more than 0.010 mm in any 50mm diameter area or if there is more than 0.075 mmoverall end to end or side to side

Rae 8-24173

B902888J

Resurface the cylinder head in increments necessary tostraighten the surface and maintain surface finish ac-cording to the following specifications:

A = 10 mm total amount of material removed.B = 93.75 mm minimum total height of the cylinderhead.C = Surface finish1.5 to 3.2 micrometers.D = Use this area to stamp the total thickness ofcylinder head material removed in rnrn.

"levised 2-92 Printed in U.S.A

STEP 39

B902889J

Measure the valve guide diameter at three depths with abore gauge.

Rae 8-24173

2415-13

STEP 40".

Measure the bore gauge with a micrometer. If thediameter of the valve guide at any depth is more than8.089 mm, install a new valve guide. See Page 14for 14mm valve guides and Page 15 for 11 mm valve guides.


2415-14

VALVE GUIDE REPLACEMENT14 mm Replacement Valve Guides

STEP 42There are two different diameters of replacement valveguides for your engine. You can get either 14 mm or 11mm 00 replacement valve guides. Measure the re-placement valve guides before you machine thecylinder head.

SpecificationsValve guide 00 14.026 to 14.038 mmBore cylinder head to 13.987 to 14.013 mmInstalled height above top of valve guide bosson cylinder head 11.25 to 11.75 mm

STEP 41

Drill the valve guide bores to 13.987 to 14.013 mmdiameter.

Rae 8-24173

B902891J

Make a bushing 16.038 mm 10 x 11.25 to 11.75 mmlong. Install the bushing over the new valve guide. Pressthe new valve guide into the cylinder head until thepress contacts the bushing.

STEP 43

Drill the new valve guides to a diameter of 8.0 mm.Ream the new valve guides to a finished diameter of8.019 to 8.039 rnrn.

Revised 2-92 Printed in U.SA

2415-15

11 mm Replacement Valve GuidesSpecifications STEP 45Valve guide 00 11.150to 11.163 mmBore cylinder head to 11.112 to 11.138 mmInstalled height above top of valve guide

boss on cylinder head 1125 to 11.75 mm

STEP 44

DIAMETER OF11.112 TO 11.138 mm

(\

Drill the valve guide bores to 11.112 to 11.138 mmdiameter.

Rae 8-24173

t11.25 TO 11.75 mm

t

B902891J

Make a bushing 16.038 mm 10 x 11.25 to 11.75 mmlong Install the bushing over the new valve guide. Pressthe new valve guide into the cylinder head until thepress contacts the bushing.

STEP 46

Drill the valve guides to a diameter of 8.0 mm. Ream thenew valve guides to a finished diameter of 8.019 to8.039 mm.


2415-16

STEP 47

INSPECTION OF THE VALVES AND VALVE SEATSSTEP 48 (Cont'd)

STEP 48

Check the valves for the following conditions.

VALVE STEM WITH A NARROW NECK

j8902893J

NOTE: REPLACE THE VALVE IF THIS 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 attoo much engine RPM.

._-- GROOVE IN VALVE FACE

8902894J

NOTE: GRIND OR REPLACE VALVE IF THIS CONDITIONOCCURS.

This condition can be caused by foreign materialentering the engine through the intake system or notgiving service to the air intake system.

Rae 8-24173

I FINE PiniNG

8902895J

NOTE: THIS IS A NORMAL CONDITION.

Small amounts of very fine pitting can be found on thesurfaces of the valve face or seat after the valves arecleaned. These are normal and will not change theengine performance. This fine pitting is caused bynormal oxidation procedure and can occur on anyengine during the run-in period. It is not necessary togrind valves or seats if this fine pitting is found. becausepitting will generally occur after the engine has run forseveral hours.

8902896J

NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDITIONOCCURS.

This condition is generally caused by worn valve guidesor bad seals on the valves. permitting oil to go by thevalves. Low operating temperature is a secondarycause. Worn piston rings and cylinder walls will alsopermit too much oil to reach the combustion chamber.

RUST OR PiniNG ON VALVE STEM

18902897J

NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.

This condition can be caused by using bad qualityengine oil or fuel and by not correctly keeping theengine in storage.


NOTE: THIS CONDITION CAN BE CAUSED BY USING BADQUALITY ENGINE OIL OR FUEL.

DEEP BURNED VALVE FACE

CONCAVE VALVE HEAD

These conditions are generally caused by running theengine at very high engine temperatures, grinding thevalve face too thin or valve grinding that is not correct.

B902900J

Rae 8-24173

2415-17

STEP 49INTAKE VALVES

7.960 TO 7.980 mm

7.960 TO 7.980 mm

B902901J

Check the intake valve stem diameter at three pointsalong the stem. If the stem diameter is less than 7.960mm, the valve must be replaced.

EXHAUST VALVES

7.960 TO 7.980 mm

B902902J

Check the exhaust valve stem diameter at two points asshown. If the stem diameter is less that 7.960 mm or thestem tip diameter is less than 7.960 mm, the valve mustbe replaced.


STEP 48 (Cont'd)/' 1. RUST OR PiniNG IN VALVE FACE

2425-18

STEP 50

VALVE WITHOUT REPLACEABLE SEATS1.52 mm MAX.

B902903J

Put the valves in the cylinder head and check to makesure that the valve heads are recessed in the cylinderhead. The valves must not protrude from the head. If thevalve head is recessed more than 1.52 mm below thecylinder head surface, the valve must be replaced or avalve insert must be installed to make sure that there isequal compression ratios between cylinders.


2415-19

STEP 51

VALVE SEAT INSTALLATIONSTEP 52

Machine the cylinder head to the following specifica-tions for valve seats.

Exhaust Valve Seat Specifications:

Diameter of Valve Seat 43.713 to 43739 mmDiameter of Bore 43.647 to 43.663 mmDepth of Bore 10.10 to 10.30 mmPress Fit 0.05 to 0.092 mm

Intake Valve Seat Specifications:

Diameter of Valve Seat 47.063 to 47.089 mmDiameter of Bore 46.987 to 47.013 mmDepth of Bore 10.30 to 10.50 mmPress Fit 0.05 to 0.102 mm

1. VALVE SEAT BORE

/

B902904J

Rae 8-24173

Clean the recessed area in the cylinder head. Put thenew valve seats in dry ice for a minimum of one hour toshrink the valve seats for easy installation. Use a driverand install the valve seats.

A Always wear gloves to prevent frostbite toyour hands when handling frozen parts.SM118A

STEP 53

Use a center punch and stake the valve seats in threepositions. Grind the valve seats to the correct angle.

Revised 2-92 Printed in U.S.A

2415-20

REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS

STEP 54

VALVE IDENTIFICATION

The 45 degree exhaust valves are smaller in diameterthan the intake valves.

The 30 degree intake valves are larger in diameter thanthe exhaust valves.

Rae 8-24173

STEP 55VALVE AND SEAT GRINDING ANGLES

44 DEGREEANGLE

30 DEGREE VALVE

45 DEGREE SEAT 30 DEGREE SEAT

B902905J

If dimension A and B is less than 1.5 mm the valve mustbe replaced.

NOTE: Use a precision seat grinder. Take very light cutswith the grinding stones so just enough metal isremoved to end up with a good smooth seat finish.


2415-22

IF THE VALVE CONTACT AREA ON THESEAT LOOKS LIKE THIS (A SEAT THATHAS BEEN GROUND).

SEAT CONTACT AREA ON THE VALVETO LOW

IF THE VALVE CONTACT AREA ON THESEAT LOOKS LIKE THIS.

_ USE A 45 DEGREE ST~TO MAKE WIDER, THE

- USE A 45 DEGREE STlCONTACT AREA.

SEAT CONTACT AREA ON THE VALVETOO HIGH

Rae 8-24173

IF THE VALVE CONTACT AREA ON THESEAT LOOKS LIKE THIS.

_ USE A 45 DEGREE 51AND TO MAKE WIDER

_ THE VALVE MUST BE fVALVE SEAT MUST SfCAUSE MORE GRIN[CHANGE THE LOWER l

Revised 2-92

DIAGNOSIS OF DIFFERENTDYE PATTERNS45 Degree Exhaust valves

INE TO LIFT THE - USE A 60 DEGREE STONE TO LIFT ANDNARROW THE LOWER CONTACT A

manual servicio case 580 super k construction king

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