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Rae 9-76789
TABLE OF CONTENTS
1270 - 1370 - 1570 TRACTORS
SECTION DESCRIPION FORM
10 - GENERAL
1010 General Specifications - 1370 Tractors ................................ .
NUMBER
9-76386
9-79586
9-76966
9-76396
9-79645
9-76975
9-45991
9-76955
9-76115
9-77936
9-76516
9-76525
9-76536
9-76545
1010 General Specifications - 1570 Tractors ................................ .
1011 General Specifications - 1270 Tractors ................................ .
1012 Lubrication - 1370 Tractors ........................................... .
1012 Lubrication - 1570 Tractors ........................................... .
1013 Lubrication - 1270 Tractors ........................................... .
1020 Engine - 504 BOT .................................................... .
1021 Engine - 451 BOT .................................................... .
1030 Fuel System ......................................................... .
1130 Fuel System ......................................................... .
1040 Hydraulic System .................................................... .
1050 Steering System ..................................................... .
1060 Power Train ......................................................... .
1070 Brake System ........................................................ .
2001
2002
2010
2011
2015
2020
2025
2030
2031
2032
2035
2040
2045
2050
2055
2060
2065
2165
2565
2075
2290
3010
3012
3013
3113
3015
4005
4009
4010
4011
4012
4013
4014
4015
4016
4017
4019
20 - ENGINES
Engine Diagnosis ..................................................... 9-76365
Engine Tune-Up ...................................................... 9-76379
Parts Removal to Gain Access to Cylinder Heads........................ 9-79445
Parts Removal to Gain Access to Camshaft ............................. 9-79485
Cylinder Head, Valve Train and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-76166
Parts Removal to Gain Access to Cyl. Block, Sleeves, Pistons and Rods... 9-79465
Cylinder Block, Sleeves, Pistons and Rods.............................. 9-76176
Parts Removal to Gain Access to Crankshaft ............................ 9-79505
Parts Removal to Gain Access to Front Oil Seal ......................... 9-79495
Splitting Tractor between Engine and Torque Tube...................... 9-76726
Crankshaft, Main Bearings, Flywheel and Oil Seal ....................... 9-76187
Parts Removal to Gain Access to Oil Pump ............................. 9-79455
Lubrication System, Oil Pump, Heat Exchanger and Oil Flow Diagrams ... 9-76325
Parts Removal to Gain Access to Cooling System ....................... 9-79475
Cooling System ....................................................... 9-76337
Parts Removal to Gain Access to Turbocharger ......................... 9-79425
Turbocharger - T04B .................................................. 9-78026
Turbocharger - T04 ................................................... 9-78435
Turbocharger Failure Analysis ......................................... 9-78235
Self Cleaning Air Induction System..................................... 9-76256
Reconditioning Engine Cylinder Block ................................. 8-21170
30 - FUEL SYSTEM
Fuel System .......................................................... 9-75297
Robert Bosch Fuel Injection Pumps .................................... 9-74937
Roosa Master Fuel Injectors ........................................... 9-74959
American Bosch Fuel Injectors......................................... 9-77756
Repairing Polyethylene Fuel Tank...................................... 9-76305
40 - HYDRAULICS
Testing Tractor Hydraulic System ...................................... 9-45851
Removal and Installation - Dual, Single and Charging Pumps ............ 9-77385
Hydraulic Oil Filters ................................................... 9-76275
Hydraulic Charging Pump ............................................. 9-76285
Hydraulic 4 Gear Dual Pump........................................... 9-76345
Hydraulic 2 Gear Single Pump ......................................... 9-76355
Remote Hydraulic Valves .................•............................ 9-76636
Variable Volume Flow Divider Valve .................................... 9-76405
Flow Divider and PTa Control Valve.................................... 9-77145
Draft-O-Matic Hydraulic System ....................................... 9-74277
Break-Away Couplings and Portable Cylinder........................... 9-74197
Printed in U.S.A.
Revised March, 1981
2. o 0 0
I'-- I'-- I'--
CI ('t) It)
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Rac 9-76789
SECTION DESCRIPION FORM
50 - STEERING
5005 Testing Tractor Steering and Brake System ............................ .
NUMBER
9-45911
9-74269
9-74037
5010 Steering Column and Pump Valve ..................................... .
5011 Steering Axle and Cylinders .......................................... .
6001
6005
6010
6011
6111
6012
6013
6014
6019
6020
6025
6030
6230
6035
6040
6045
6145
7010
7011
7012
7015
8010
8010
8110
8011
8012
8013
8014
8114
8115
8020
9005
9015
9025
9035
9050
14001
14014
14015
14016
14017
15010
16011
16030
10019
16145
17010
19010
60 - POWER TRAIN
Trouble Shooting RPS-34 Power Shift .................................. 9-76037
Testing RPS-34 Power Shift and PTO ................................... 9-45841
Power Shift and Four Speed Transmission (Prior to P.I.N. 8736001) ....... 9-74117
Differential Lock, Parking Brake, Brake Cylinders, Planetaries and Axles.. 9-74107
Differential Lock, Brake Cylinders, Planetaries and Axles ................ 9-79715
Hydraulic Pump Drive (Prior to P.I.N. 8736001) .......................... 9-74337
Hydraulic PTO (Prior to P.I.N. 8736001) ................................ 9-74086
Torque Limiter - 12" and 14" (Prior to P.I.N. 8736001) ................... 9-74347
Splitting Tractor between Torque Tube and Transmission
(P.I.N. 8736001 and After) ............................................. 9-79555
Torque Limiter (P.I.N. 8736001 and After) ............................... 9-77045
Hydraulic Pump Drives (P.I.N. 8736001 and After) ....................... 9-77306
RPS-34 Power Shift (P.I.N. 8736001 and After) .......................... 9-77246
RPS-34 Power Shift ................................................... 9-79575
RPS-34 Control Valve and Linkage ..................................... 9-77316
Four Speed Transmission (P.I.N. 8736001 and After) ..................... 9-77327
Hydraulic PTO (P.I.N. 8736001 and After) ............................... 9-76985
Hydraulic PTO ........................................................ 9-79405
70 - BRAKES
Power Assist Unit and Pedals .......................................... 9-74096
Parking Brake (Prior to P.I. N. 8797501) ................................ 9-74297
Power Assist Brake Valve W/Adjustable Relief Valve..................... 9-45871
Park Lock System (P.I.N. 8797501 and After) ............................ 9-79626
80 - ELECTRICAL
Tractor Electrical Wiring Diagram (Prior to SN8753831) .................. 9-77106
Tractor Electrical Wiring Diagram (SN8753831 thru SN8797500) .......... 9-79995
Tractor Electrical Wiring Diagram (Starting W/SN8797501) .............. 9-79255
Tractor Cab Wiring Diagram ........................................... 9-77698
Starting or Cranking Motors ........................................... 9-75366
Battery Service and Testing................... ......................... 9-75377
Prestolite Alternator System ........................................... 9-75399
Delco-Remy Alternator System ........................................ 9-78976
Delco-Remy Alternator System ........................................ 9-45901
Neutral Start Switch Adjustment and Correct
Starting Procedure Using Booster Batteries ............................. 9-79745
90 - ACCESSORIES
Trouble Shooting - Air Conditioning System ............................ 9-78895
Gauging and Testing - Air Conditioning System ......................... 9-78995
Compressor Isolation, Removal, Insta"ation and Evacuation System
Discharging, Evacuation and Charging ................................. 9-79015
Servicing Air Conditioning Components................................ 9-78705
Seat Adjustments (Swivel and Non Swivel) .............................. 9-79755
100 - HOW IT WORKS - TROUBLE SHOOTING
Hydraulic System Oil Flows............................................ 9-76606
Remote Hydraulic Valve ............................................... 9-76556
Variable Volume Flow Divider Valve .................................... 9-79615
Flow Divider/PTO Control Valve, R.H. Dual & L.H. Single Pumps ....... 9-76466
Draft-O-Matic Hydraulic System ....................................... 9-76476
Steering Hand Pump-Valve ............................................ 9-76566
Differential Lock ...................................................... 9-76486
Power Shift ........................................................... 9-76496
Hydraulic Power Take-Off ............................................. 9-76595
Hydraulic Power Take-Off ............................................. 9-79405
Power Brakes......................................................... 9-76506
Air Conditioning System............................................... 9-78615
Printed in U.S.A.
Revised March, 1981
4. 1010-2
E ,
TRACTOR MODEL AND
SERIAL NUMBER
General
SERIAL NUMBERS
ENGINE SERIAL NUMBER TRANSMISSION SERIAL NUMBER
DIESEL ENGINE
Type .................................................. 6 Cylinder, 4 Stroke Cycle, Valve-in-Head Turbo-charged
Firing Order ................................................................................................................ 1-5-3-6-2-4
Bore ....................................................................................................... 4-5/8 Inches (117.5mm)
Stroke ............................................................................................................ 5 Inches (127mm)
Piiton Displacement ....................................................................... 504 Cubic Inches (8 259cm3)
Compression Ratio ........................................................................................................ 15.8 to 1
Cylinder Sleeves ......................................................................................... Removable Wet Type
No Load Governed Speed ............................................................................... 2340 to 2380 RPM
Rated Engine Speed ................................................................................................... 2200 RPM
Engine Idling Speed .......................................................................................... 700 to 750 RPM
·Valve Tappet Clearance (Exhaust) ............................l ..................... (Hot) .020 Inch (0.508mm)
(Cold) .025 Inch (0.635mm)
(Intake) ....................................... (Hot and Cold) .015 Inch (0.381mm)
·Hot settings are made after the engine has operated at, thermostat controlled temperature for
at least fifteen minutes.
Piston and Connecting Rods
Rings per Piston ...................................................................................................................... 3
Number of Compression Rings ................................................................................................. 2
Number of Oil Rings ................................................................................................................ 1
Type of Pins .......................................................................................................... Full Floating
Type of Bearings ..... Replaceable Precision, Steel Back, Aluminum or Copper-lead Alloy Liners
5. 1010-3
DIESEL ENGINE
Main Bearings
Number of Bearings ................................................................................................................. 7
Type of Bearings ..... Replaceable Precision, Steel Back, Aluminum or Copper-lead Alloy Liners
Engine Lubricating System
Oil Pressure ............................................................. 45 to 60 PSI (310 to 414 kPa) with Engine
Warm and Operating at Rated Speed.
Type of System ................................................................... Pressureand Spray Circulation with
Piston Oil Cooling
Oil Pump ................................................................................................................... Gear Type
Oil Filter (2) ........................................................................................ Full Flow Spin-on Type,
Pleated with Bypass Valve in Filter Base
Oil Capacity ............................................................... With Filters, 22 U.S. Quarts (20.8 Litres)
Without Filters, 18 U.S. Quarts (17.1 Litres)
Oil Cooler .................................................................................................................. Engine Oil
Fuel System
Fuel Injection Pump ............................................ Robert Bosch, Type PES (Multiple Plunger)
Pump Timing ............................................. 30 Degrees Before Top Dead Center (Port Closing)
Fuel Injectors ...................................... Pencil Type (Opening Pressure 3200 PSI) (22 063 kPa)
Fuel Transfer Pump ........................................ Plunger Type, Integral Part of Injection Pump
Governor ............................................................. Variable Speed, Fly-Weight Centrifugal Type,
Integral Part of Injection Pump.
1st Stage Fuel Filter ............................................................................. Full Flow Spin-on Type
2nd Stage Fuel Filter ............................................................................ Full Flow Spin-on Type
Fuel Tank Water Trap and Drain .............................................. Located in Base of Fuel Tank
Fuel Tank Capacity ..................................................................... 80 U.S. Gallons (302.8 Litres)
Fuel Level Gauge .......................................................... Electric, Located ·on Instrument Panel
Hand Primer Pump ..................................................... Located on Top of Fuel Transfer Pump
Preliminary Fuel Filter .............................. Located at the Bottom of the Fuel Transfer Pump
6. 1010-4
GENERAL SPECIFICATIONS
Cooling System
Capacity .......................................................................................... 42 U.S. Quarts (39.7 Litres)
Type of System .................................................................... Pressurized Thermostat Controlled
By-pass Type, Impeller Type Pump
Thermostat (2) ............................... Starts to Open at Approximately 1750F. (790C.) Fully Open
at 202oF. (94°C.)
Pressure Cap Required ..........................................................................14 PSI Vented (97 kPa)
or 10PSI Non-Vented (69 kPa)
Electrical System
Type of System - Diesel ...................................................................... 12 Volt Negative Ground
Batteries ................................................................. (2) 12 Volt Batteries Connected in Parallel
Group Size 30H, Rated at 1.255 to 1.265 Specific Gravity. Discharge
Rate 300 Amps. at OOF. Voltage Drops to 9.2 After 10 Seconds.
Voltage Drops 1.0 Volt Per Cell After 4 Minutes.
!lternator ................................................................. 12 Volt 55 Amp. Output, Negative Ground
Voltage Regulator .................................... 12 Volt, Solid State, Internal Component of Alternator
Starter Motor ................................................................................. 12 Volt with Solenoid Switch
Head Lights (2) ...................................................................... 12 Volt 40/40 Watt, Sealed Beam
Flood Light (2) (Optional) .......................................................... 12 Volt 35 Watt, Sealed Beam
R. Rear Flood Light (1) (Optional) ............................................ 12 Volt 60 Watt, Sealed Beam
Flasher Lights with Directional Turn Signals (2) ...................................... 12 Volt, Amber Lens
L. Rear Flood&Tail Light(l) .. 12 Volt, 60 Watt Sealed Beam Combination Tail and Flood Lamp
Circuit Breaker System Overload Check .............................. 12 Volt Twin 40 Amp. Breakers
Connected in Parallel, 80 Amp. Rating - 60 Amp.
Minimum Continuous Capacity
Lights Circuit Breaker ........................................................... 40 Amp. Located on Light Switch
Parking Brake Warning Light .......................................................... 12 Volt, Red Flasher Type
Parking Brake
Type ..................... Rod Actuated by Orscheln Type Handle - Adjustable From Operator's Seat
Double Wrap Steel Band on Differential
Hydraulic Power Assist Brake
Type ................................................... Hydraulic, Power Assisted, Self-adjusting Multiple Plate
Wet Type Differential Brakes.
7. 1010-5
Power Shift Transmission
Type ................................................. 3 Speed Compound Planetary with Hydraulically Actuated
Clutches and a 4 Speed Gear Range Section.
Gear Selection ................................................................ 12 Speeds Forward - 3 Speeds Reverse
Shifting ............................................................ Hydraulic Power Shifting Controlled by a Lever
on Operator's Console. 4 Speed Range Controlled
by a Mechanical Shifter from a Lever on
Operator's Console.
Oil Cooler ....................................................... Transmission, Hydraulic, Steering and Brake Oil
Differential Lock
Type .................................................................................. Hydraulically Actuated, Operated by
Operator's Foot Pedal.
Hydrostatic Power Steering
Dual Pump Type (8 gal. section) .......................................... Gear Type, Driven by the Engine
Pump Capacity at 2000 Engine RPM ............................................................ 8 GPM (30.3 limn)
HGA Hydrostatic Type ......................................................... Integral and Bi-directional Gerotor
Metering Section, Actuated by the
Steering Wheel.
Steering Cylinders ......................................................................... Two Double Acting Cylinders
Remote Hydraulic System
Dual Pump (20 gal. section) ................................................................. Direct Drive Gear Type
Type Remote Valve (R.H. side) ................................ Dual Valve-individual Hand Lever Control
R.H. Portable CylinderCoupling ...................................................... ASAE R3GG Standard Quick
Detachable Break-away Type
Pump Capacity at 2000 Engine RPM ........................................................... 20 GPM (75.7 limn)
Relief Valve Pressure ................................................... 1900 to 2050 PSI (13 100 to 14 134 kPa)
Portable Cylinders ........................................................................................................ Available
Variable Flow Remote Hydraulic System
Single Pump ......................................................................................... Gear Type, Direct Drive
Type Remote Valve (L.H. side) ............................................................. Dual Valve - Individual
Hand Lever Control
Pump Capacity at 2000 Engine RPM ........................................................... 20 GPM (75.7 limn)
Relief Valve Prp.ssure ........................................................................................ 1900 to 2050 PSI
(13 100 to 14 134 kPa)
Variable Flow Control Valve ..................................................................... Hand Operated From
Console - Minimum 2.7 GPM (10.21/mn)
to Maximum 20 GPM (75.7 limn)
8. 1010-6
Variable Flow Remote Hydraulic System (Continued)
Portable Cylinder Couplings (L.H. side) ............•........... ASAE R366 Standard Quick Detachable
Break-away Type
Portable Cylinders ........................................................................................................ Avallable
Power Take-Off
'I'ype Clutch ............................................................................................ Hydraulically Operated
Rotation ....................................................................................................................... Clockwise
Spline Size ................................................................................. 21 Splines, 1·3/8in~34.9mm) Dia.
Engine Speed 2000 RPM .......................................................................... 1000 RPM Shaft Speed
Draft-O-Matic System
'I'ype of Sensing ........................................................................................................ Lower Link
'I'ype Control ............................................................................................................. Hand Lever
'I'ype Valve ............................................................................ 3 Positions - Raise - Hold - Lower
'I'ype Draft Arms ........................................................ Swinging, with Manual Float Adjustment
'I'ype Hitch .................................................................................................. 3 Point Category III
Convertible Hitch Coupler (Available) ............................................................. Category III - II
Drawbars
Standard or Yoke 'I'ype ............................................................... Full Swinging Roller Mounted
W1ll Accommodate a 1-1/2 Inch,(38.1mm), Dia. Pin.
9. STEP 5
REMOVEVALVE ROTATORS OR SPRING RETAINERS,
SPRINGS, SPRING SEATS AND VALVES.
STEP 6
CLEAN CYLINDER HEAD COMPLETELY, REMOVING
ALL TRACES OF CARBON AND OTHER DEPOSITS.
STEP 7
CLEAN VALVES WITH A FINE POWER DRIVEN WIRE
BRUSH, REMOVING ALLCARBON AND VARNISH DE-
POSITS. BE CAREFUL NOT TO SCRATCH VALVE
STEMS.
2001-25
STEP 8
MINIMUM 1/16" WIDE FLAT
~/
CHECK VALVE GUIDE TOP SURFACE, THERE
MUST BE A MINIMUM OF A 1116" WIDE FLAT
AROUND ENTIRE TOP SURFACE.
STEP 9
USE M20617 TOOL IN A ELECTRIC DRILL (IF RE-
QUIRED) TO PROVIDE NECESSARY FLAT AREA ON
VALVE GUIDE. IMPORTANT: DO NOT EXCEED 450
RPM WHEN DRILLING
10. 2001-26
STEP 10
LUBRICATE VALVES WITH CLEAN ENGINE OIL BE-
FORE REINSTALLING INTO CYLINDER HEAD.
STEP 11
PLACE PLASTIC INSTALLATION CAP, PROVIDED IN
KIT, ON THE END OF THE VALVE STEM. NOTE: CAP
PREVENTS SHARP EDGES ON VALVE STEM GRO-
OVES FROM CUTTING VALVE SEAL.
STEP 12
STEP 13
I
USE M20624 TOOL AND PRESS SEAL DOWN OVER
VALVE GUIDE UNTIL SEAL IS FLUSH WITH TOP OF
GUIDE.
STEP 14
INSET A
CLOSE COIL END
INSTALL THE VALVE SPRING. IMPORTANT: THE
CLOSE COIL END OF THE SPRING MUST BE IN-
STALLED TOWARDS THE CYLINDER HEAD, SEE
INSET A.
11. STEP 15
INSTALL VALVE ROTATORS OR SPRING RETAINERS.
IMPORTANT: ASSEMBLE VALVE ROTATORS WITH
THEIR ORIGINAL VALVES SINCE THEY TEND TO
WEAR IN AS A MATCHED SET.
STEP 16
INSTALL VALVE SPRING COMPRESSOR.
STEP 17
INSTALL STEM SEAL IN LOWER VALVE STEM
GROOVE.
2001-27
STEP 18
INSTALL VALVE KEEPERS IN OUTER VALVE STEM
GROOVE.
STEP 19
REMOVE SPRING COMPRESSOR AND TAP VALVE
STEM END TO SEAT KEEPERS.
STEP 20
INSTALL TEFLON SEALS ON THE OTHER INTAKE
AND EXHAUST VALVES, FOLLOWING THE PRECED-
ING PROCEDURE.
12. 2001-28
STEP 21
REINSTALL CYLINDER HEAD ON ENGINE FOLLOW-
ING PROCEDURE OUTLINED IN SECTION 2015.
NOTE: The CASE CORPORAliON reserves the right to make improvements
in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
14. 2002-2
ENGINE TUNEUp·
A COMPLETE ENGINE TUNEUP INCLUDES THE PERFORMING OF THE FOLLOWING ITEMS:
Air Intake System - Cleaning ........................................................................................... Page 19
Compression Check ..........;.......................;.......... -...................;................................ Pages 14-17
Crankshaft Damper Pulley - .Check .........................,..........;.................~ ............................ Page 4
Fan Belts - Adjusting .............................................;........................................................ Page 20
Fuel Line Screen and Filters - Cleaning .....;.........;................................~ ......................... Page 17
Injection Pump - Retiming ............................................:..................................................Page 18
Nozzle Removal ...............................................................~ ................................................. Page 14
Nozzle Spray Pattern - Checking ..............................:.................................................... Page' 14
Speed Adjusting - Governed ..........................................................................................'. Page 19
Tappets - Adjusting ................................................................................................... Pages 9-13
Co.ld Setting ....................................................................,....................................... Pages 9,10
Hot Setting With Engine Stopped ........................................................................ Pages 11, 12
Tools Required For Tuneup ................................................................................................ Page 3
Top Dead Center - Checking ........................................................................................ Pages 5-8
Valve Timing - Check .................................................................................................... Page 21
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 POSSI-
BILITY OF PERSONAL INJURY.
15. SPEC·IAL TOOLS
. . ,
. INCH POUND AND FOOT POUND
TORQUE WRENCH
A43277 INJECTOR .~.
BORE CLEANER
(CLAMP TYPE INJECTO~)
6050
COMPRESSION
GAUGE ADAPTER
SERVICE KIT 2205
A43278 .INJECTOR
REMOVAL TOOL,
(CLAMP TYPE INJE<;:TOR)
6062
INJECTOR BORE
CLEANER
NUDAY CO.• 14615 WYOMING AVE.
DETROIT. MICHIGAN. 48238
(SCREW-IN TYPE INJECTOR) DIAL INDICATOR
2002-3
COMPRESSION GAUGE
ADAPTER
BACHARACH 70-314
(0-558)
(CLAMP TYPE INJECTOR)
TAPPET ADJUSTMENT TOOL
SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE
Valve Spring Compressor T·oo.
S.7S!· . . -: 1-1.125
-1== === = = = =====~-;:;==::f1,-=3=.=88=_=i111-4 :
1_14.25 -1- 7.50 ._i .81
1+111
~+J
.56_ t1;125- -
(2) HOLES ;812 011•..
STOCK SIZE '.25 X 2.00 .
NOTE: ALL DIMENSIONS IN INCHES 1.00
,.
16. 2002-4
ENGINE TUNEUP PROCEDURE
Checking Crankshaft Damper Pulley
STEP 1
THE RECOMMENDED CHANGE INTERVAL FOR THE
CRANKSHAFT DAMPER PULLEY IS 2000 HOURS
MAXIMUM. AT ANY TIME OVER 1500 HOURS.
CONSIDER CHANGING PULLEY .AT ANY MAJOR
ENGINE OVERHAUL OR TUNE UP.
EVERY 500 HOURS AND AT ENGINE TUNEUP.
VISUALLY INSPECT RUBBER ELEMENT FOR PEEL
AREAS OR RUBBER MISSING. CHECK ALIGNMENT
OF THE "V" MARKS BETWEEN THE INNER AND
OUTER MEMBERS. IF "V" MARKS SHIFT. ENGINE
TIMING WILL BE OFF AND DAMPER PULLEY
MUST BE REPLACED.
DETERIORATED RUBBER
~~~~--ALIGNMENT MARKS
(LOCATED ON TIMING
GEAR COVER SIDE
OF PULLEY)
USE BOLT ON TYPE PULLER TO REMOVE PULLEY.
REMOVE VISCOUS DAMPER FROM PULLEY (IF SO
EQUIPPED). DO NOT pulL OR HAMMER ON OUT-
SIDE OF PULLEY OR VISCOUS DAMPER; SERIOUS
DAMAGE TO PULLEY. DAMPER. AND RUBBER
SLEEVE COULD RESULT.
INSET B
VISCOUS DAMPER-
TORQUE DAMPER-TO-PULLEY MOUNTING BOLTS
35 TO 42 FT. LBS. FOR 3/8" MOUNTING BOLTS
AND 110 TO 132 FT. LBS. FOR 1/2" GRADE 8
MOUNTING BOLTS.
17. 2002-5
Checking Top Dead Center
STEP 2
CRANK ENGINE UNTIL 100 BTDC MARK ON CRANK-
SHAFT PULLEY IS ALIGNED WITH TIMING POINTER.
STEP 3
STEP 4
r
REMOVE VALVE COVER AND GASKET FROM NO.1
AND NO.2 CYLINDERS.
STEP 5
REMOVE ROCKER ARM ASSEMBLY.
STEP 6
COMPRESS EXHAUST VALVE SPRING ON NO. 1
CYLINDER USING FABRICATED TOOL (SEE PAGE
3).
STEP 7
REMOVE VALVE KEEPERS
18. 2002-6
STEP 8
------
I
" ,,"-"VALVE ROTATOR
I
REMOVE VALVE ROTATOR, SPRING AND SEAT.
STEP 9
I
KEEP VALVE SEAL IN PLACE TO PREVENT VALVE
FROM FALLING THROUGH VALVE GUIDE IF PISTON
IS MOVED TOO FAR
---------------------------
STEP 10
INSTALL DIAL INDICATOR ON END OF VALVE
STEM WITH VALVE RESTING ON TOP OF PISTON.
I
CRANK ENGINE CLOCKWISE UNTIL DIAL INDICATOR
HAND STOPS MOVING. RESET INDICATOR TO ZERO.
CRANK ENGINE CLOCKWISE UNTIL .01 0" SHOWS ON
DIAL. SCRIBE A MARK ON CRANKSHAFT PULLEY IN
LINE WITH TIMING POINTER.
CRANK ENGlNE COUNTERCLOCKWISE PAST ZERO
MARK ON INDICATOR UNTIL .010" SHOWS ON DIAL.
AGAIN, SCRIBE MARK ON CRANKSHAFT PULLEY.
19. STEP 11
HALF THE DISTANCE BETWEEN THESE TWO SCRIBE
MARKS ON CRANKSHAFT PULLEY WILL BE THE
TOP DEAD CENTER (TDC) MARK. IF THE SCRIBE
MARKS ARE NOT THE SAME AS ORIGINAL MARKS
ON PULLEY CHECK DAMPER.
STEP 12
INSET A
CLOSE COIL END
INSTALL SPRING SEAT AND VALVE SPRING.
NOTE: IF EQUIPPED WITH VALVE SPRING
HAVING ONLY ONE CLOSE.COIL END. PLACE
THIS END TOWARD CYLINDER HEAD. SEE INSET
A.
2002-7
STEP 13
COMPRESS VALVE SPRING USING FABRICATED
TOOL. INSTALL SEAL IN LOWER VALVE STEM
GROOVE. INSTALL VALVE KEEPERS IN OUTER
VALVE STEM GROOVE.
STEP 14
REMOVE SPRING COMPRESSING TOOL. TAP END
OF VALVE STEM TO SEAT KEEPERS.
STEP 15
INSTALL ROCKER ARM ASSEMBLY ONTO CYLINDER
HEAD.
20. 2002-8
STEP 16
TORQUE ROCKER ARM ASSEMBLY RETAINING NUTS
40 TO 45 FT. LBS.
STEP 17
;yl
.'.'/~,/ ~_~_ _o ~
ADJUST VALVE TAPPETS. REFER TO STEP 26
FOR COLD SETTING OR TO STEP 33 FOR HOT
SETTING.
STEP 18
INSTALL VALVE COVERS AND GASKETS.
TORQUE VALVE COVER NUTS 60 TO 70 IN. LBS.
STEP 20
21. 2002-9
Adjusting Tappets
STEP 21
Cold Setting
STEP 24
~
~~/:/
I
REMOVE TURBOCHARGER INTAKE elBOW (IF SO
EQUIPPED).
---------------------
STEP 22
REMOVE BREATHER TUBE.
STEP 23
~
REMOVE VALVE COVERS AND GASKETS FROM ALL
CYLINDERS.
!) J,I-~"""
TIM1~~iOINTr ~~:::::
CRANK ENGINE UNTIL TIMING POINTER IS ALIGNED
WITH TDC TIMING MARK ON CRANKSHAFT PULLEY.
STEP 25
CHECK PUSH RODS ON NO.1 CYLINDER FOR LOOSE~
NESS. IF PUSH RODS ARE LOOSE, NO.1 CYLINDER
IS ATTDC ON THE COMPRESSION STROKE. IF PUSH
RODS ARE TIGHT, CRANK ENGINE ONE COMPLETE
REVOLUTION AND ALIGN TIMING POINTER WITH
TDC MARK ON PULLEY.
22. 2002-10
STEP 26
CHECK AND ADJUST THE INTAKE AND EXHAUST
VALVES AS POINTED OUT BY THE ARROWS BELOW.
TAPPET CLEARANCE COLD - INTAKE VALVES .015"
EXHAUST VALVES - .025"
FOUR CYLINDER ENGINES
4 3 2 1
E I lEE I I E
~~ FANt
. ~ ..NO.1 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
FANt
6 5 4 3 2 1
EI IE EI IE EI IE
~~~
~~~
•• ••••
NO. 1 TDC COMPRESSION STROKE
STEP 27
CRANK THE ENGINE Or,JE COMPLETE REVOLU-
TION AND ALIGN THE TIMING POINTER WITH THE
TDC MARK ON CRANKSHAFT PULLEY.
CHECK AND ADJUST THE INTAKE AND EXHAUST
VALVES AS POINTED OUT BY THE ARROWS BELOW.
TAPPET CLEARANCE COLD - INTAKE VALVES .015"
EXHAUST VALVES .025"
FOUR CYLINDER ENGINES
FANt
4 3 2 1
E. l E E E
);LJ"LJW~ J/W'U'LcJ.
tf-~
••••
NO.4 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
FANt
NO.6 TDC COMPRESSION STROKE
NOTE: AFTER COMPLETING COLD SETTING
VALVE TAPPET ADJUSTMENT PROCEED TO STEP
35.
23. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
24. STEP 28
STEP 29
STEP 30
2002-11
Adjusting Tappets
Hot Setting with Engine Stopped
STEP 31
REMOVE BREATHE~ TUBE
/""-
CRANK ENGINE UNTIL TIMING POINTER IS ALIG-
NED WITH TDC TIMING MARK ON CRANKSHAFT
PULLEY.
STEP 32
~
CHECK PUSH RODS ON NO. 1 G¥L1NDER FOR
LOOSENESS. IF PUSH RODS ARE LOOSE. NO.1 CYL-
INDER IS AT TDC ON THE COMPRESSION STROKE.
IF PUSH RODS ARE TIGHT. CRANK ENGINE ONE
COMPLETE REVOLUTION AND ALIGN TIMING
POINTER WITH TDC MARK ON PULLEY.
REMOVE VALVE COVERS AND GASKETS FROM ALL
CYLINDERS.
25. 2002-12
STEP 33
) "_~ 0 ;'
CHECK AND ADJUST THE INTAKE AND EXHAUST
VALVES AS POINTED OUT BY THE ARROWS BELOW.
TAPPET CLEARANCE HOT - INTAKE VALVES .015"
EXHAUST VALVES .020"
FOUR CYLINDER ENGINES
4 3 2 1
E I lEE I I E
lWL.jO~ jWOU0~
W-~~~
.....NO. 1 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
FANt
6 5 4 3 2 1
~Elo ~~~E!!~~~.!!~o 0 0 0 0 0
o 0 0 0 a 0
.. .....NO.1 TDC COMPRESSION STROKE
STEP 34
CRANK THE ENGINE ONE COMPLETE REVOLU-
TION AND ALIGN THE TIMING POINTER WITH THE
TDC MARK ON CRANKSHAFT PULLEY.
CHECK AND ADJUST THE INTAKE AND EXHAUST
VALVES AS POINTED OUT BY THE ARROWS BELOW.
TAPPET CLEARANCE HOT - INTAKE VALVES .015"
EXHAUST VALVES .020"
6
E I
FOUR CYLINDER ENGINES
FANt
4 3 2 1
E l E E E
JjkJ'UtJ,.j/~kU"lcJ.
Vf~I~VI~I~
• •••NO.4 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
FANt
5 4 3 2
lEE I lEE I
1
I E
JJLJUkJ.~JLJUkJ.
~~~~
••••••NO. 6 TDC COMPRESSION STROKE
STEP 35
AFTER TAPPET ADJUSTMENT. INSTALL VALVE
COVERS AND GASKETS.
26. 2002-13
STEP 36 STEP 38
INSTALL TURBOCHARGER INTAKE ELBOW
T(JRQUE VALVE COVER NUTS 60 TO 70 IN. LBS.
STEP 37
INSTALL BREATHER TUBE AND GASKETS.
27. 2002-14
Checking Nozzle Spray Pattern and Engine Compression
Nozzle Removal
STEP 39 (CLAMP TYPE INJECTOR)
NOZZLE PULLER A43278
! .
REMOVE AND TEST EACH FUEL INJECTOR. RE-
FER TO SECTION 3013. PERFORM A COMPRESS-
ION TEST ON EACH CYLINDER BEFORE INSTAL-
LING FUEL INJECTOR
STEP 40 (SCREW-IN TYPE INJECTOR)
REMOVE AND TEST EACH FUEL INJECTOR. REFER
TO SECTION 3113. PERFORM A COMPRESSION TEST
ON EACH CYLINDER BEFORE INSTALLING FUEL
INJECTOR.
Compression Check
STEP 41
. THERE ARE TWO METHODS OF CHECKING COM-
PRESSION PRESSURE - THE CRANKING METHOD
AND THE ENGINE RUNNING METHOD. THE EN-
GINE MUST BE AT OPERATING TEMPERATURE
FOR EITHER METHOD USED.
A. CRANKING METHOD - REMOVE ALL INJEC-
TORS.
B. RUNNING METHOD - DISCONNECT HIGH
PRESSURE FUEL LINE AND LEAKOFF LINE
FROM NO. 1 INJECTOR. ROUTE FUEL FROM
THESE LINES BACK TO FUEL TANK OR
CLEAN CONTAINER. REPEAT FOR EACH
CYLINDER.
CAUTION Before cranking engine
make sure all operating controls are
in neutral, brakes are set and wheels
are securely blocked.
STEP 42 (CLAMP TYPE INJECTOR)
CLEAN CYLINDER HEAD INJECTOR BORE USING
BORE CLEANING TOOL A43277.
