CASE 1450B Crawler Dozer Service Repair Manual Instant Download

1
1450B AND 1455B CRAWLER TABLE OF CONTENTS AND
SERVICE MANUAL INTRODUCTION Table of
Contents DIVISION/SECTION SECTION NO.
FORM NO.
10 SERIES - GENERAL
General Engine Specifications - 504BDT ............................................................................ 1010 8-27710
Decals and Repainting......................................................................................................... 1012 9-67891
Detailed Engine Specifications - 504BDT............................................................................ 1020 8-27760
Maintenance and Lubrication .............................................................................................. 1050 9-67891
Torque Charts ...................................................................................................................... 1051 9-67890
Noise Control ....................................................................................................................... 1052 9-67890
20 SERIES - ENGINE
Engine Diagnosis ................................................................................................................. 2001 9-76365
Engine Tune-up.................................................................................................................... 2002 9-76379
Cylinder Head, Valve Train and Camshaft .......................................................................... 2015 9-76166
Cylinder Block, Sleeves, Pistons and Rods ........................................................................ 2025 9-76176
Crankshaft, Main Bearings, Flywheel and Oil Seals ........................................................... 2035 9-76187
Lubrication System............................................................................................................... 2046 8-22780
General Engine Information and Radiator........................................................................... 2050 9-67890
Air Cleaner............................................................................................................................ 2051 9-67891
Ether Injection ...................................................................................................................... 2053 9-67891
Cooling System ................................t................................................................................... 2055 9-76337
Turbocharger Removal and Installation...............................................................................2065 9-67890
Reconditioning Engine Cylinder Block.................................................................................2290 8-21170
Turbocharger Failure Analysis ............................................................................................. 2565 9-78235
30 SERIES - FUEL SYSTEM Fuel System and Filter ......................................................................................................... 3010 9-75297
Robert Bosch Fuel Injection Pumps .................................................................................... 3012 9-74937
Roosa Master Fuel lnjectors ................................................................................................ 3013 9-74959
Fuel Lines and Fuel Tank .................................................................................................... 3052 9-67890
40 SERIES - ELECTRICAL SYSTEM Electrical System Specifications and Troubleshooting ....................................................... 4002 9-67891
Wiring Diagram .................................................................................................................... 4003 9-67890
Gauges................................................................................................................................. 4004 9-67890
Batteries ...........................t................................................................................................... 4005 9-67891
Starter and Starter Solenoid................................................................................................. 4006 9-67891
Alternator.............................................................................................................................. 4007 9-67891
Electrical Accessories .......................................................................................................... 4015 9-67890
50 SERIES - TRACK SYSTEM Case Lubricated Track.........................................................................................................5504 8-42190
Track and Track Frame........................................................................................................ 5506 9-67891
Idler, Track Adjuster and Recoil Housing............................................................................ 5508 9-67891
Sprocket ............................................................................................................................... 5509 9-67890
Carrier Roller ........................................................................................................................ 5510 9-67891
Track Rollers ........................................................................................................................ 5511 9-67891
Printed in U.S.A. Issued September 1980 Revised
September 1984 Revised September 1986 Revised
March 1990
9-67890-R3
CASE CORPORATION
2
DIVISION/SECTION
SECTION NO.
FORM NO.
SERIES - POWER TRAIN General Transmission Information....................................... .,..................................... ....... 6002 9-67891
Transm ssion Diagrams and Operation....,.......,................................... .... ................. ....... 6003 9-67891
Charging Pump ..,.......................,...........,........,...,.......,.,.......,.,. ... .......,............. . .,... 6005 9-67891
Transmisston Control Valve ........................... ..................................... ...... ......... .......... ... 6007 9-67891
Torque Converter .,..... ..... ............. ..... ............,.....,.,....,...... ... .. ... .........,....,...,.. ... .. 6010 9-67891
Transmission .............. ....... ......... ............................... .... .. . . ....... ............. ... ......... .. 6016 9-67891
Final Drive for 1450B Loader................. ...... ..... . .. . .. ... . . . .. . ............ 6017 Final Drive Planetary ..,.... .........................,.......,...................,......,....,................. . 6018 Transmission Controls .....,...................................,...,....... ...,...,.................................. ... 6019 9-67891 8-1S510 8-67890
Drive Shaft...,......,. .......................,...,......................... ..................................... ... .. .. ...... 6021 9-67890
70 SERIES - BRAKES Brakes ................,..........................,.......,................................ ...........,..... ...........................7001 9-g7891
80 SERIES - HYDRAULIC SYSTEM General Hydraulic System Information .. . . ..,. ... . ............... ........... ...... ..,. .. ....... .. . . 8002 9-67891
Hydraulic Pump..,.,.....................................,..,.. ...,... ,.. ....... ..... ....... ... . . . 8005 9-67891
Equipment Control Valve .. .............. ................. .........,....................... ..,..................... .... 8007 9-67891
Selector Valve, ,.....,......,............................. .......,..............................,.....,.., .,.,.... .......... . 8021 9-67890
Cylinders....,........................,...................,..,...... ....... ...........,...................... .... . . ... . . . . 8090 9-67891
SERIES - MOUNTED EQUIPMENT Air Conditioning Troubleshooting and System ChgCks................ ........................ .... ...... 9002 8-41280
Air Conditioning System................................ .............,........... .................................,....,.... 9003 9-67890
Loader ....,............................,......... ........ . . . . . . . ............,................ 9010 9-67891
Blade ....,...,......,............ .... ......,.............,......,.,...,.............................,...,.........,...... ......... 9020 9-67891
Ripper......... ... . . .. .... .. .. . . ..... . ... ............. . ..... 9031 9-67891
ROPS Canopy,..,......,.................,....................,...,.. ......................................,.. ... ............ 906a 9-67891
Wtnch...........,.....................,................................................,....,..,.,.,................................ .... 9300 9-67891
Bur 67890-R3
Printed n U.S.A.
Issued 3-90
3
Section
1010
GENERAL ENGINE SPECIFICATIONS 1450B CRAWLER
LOADER AND DOZER 504 BDT DIESEL ENGINES
Written In C/ear And English
Printed in U.S.A. Issued April, 1980
Rac 8-22710
CASE CORPORATION
4
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General Type .. . .. .. . .. . . ... .. 6
Cylinder, 4 Stroke Cycle, Valve-in-head,
Turbo-Charged Firing Order ......................
..................................................
..... 1-5-3-6-2-4 Bore ...........................
...........................................
4-5/8 Inches (117.48 mm) Stroke . .. .. . . .
. .... . . .. .. .. . Slnches(127.0 mm) Piston
Displacement . .. . .. .. . .. . . . . . 504
Cubic Inches(8 259cm3) Compression Ratio
..................................................
....................... 15.8 to 1 No Load
Governed Speed ...................................
......................... 2230-2270 RPM Rated
Engine Speed .....................................
................................. 2100 RPM Engine
Idling Speed . . . ... . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 725
to 775 RPM Exhaust Valve Rotators
..................................................
.............. Positive Type Valve Tappet
Clearance (Exhaust) ..............................
........ (COLD) 0.025 Inch (0.635 mm) (Intake)
....................................... (COLD)
0.015 Inch (0.381 mm) Piston and Connecting
Rods Rings per Piston ...........................
..................................................
..... 3 Number of Compression Rings
..................................................
................... 2 Number of Oil Rings
..................................................
............................. 1 Type Pins
..................................................
....................... Full Floating Type Type
Bearing ..................................
Replaceable Precision, Steel Back, Copper-Lead
Liners Main Bearings Number of Bearings
..................................................
............................. 7 Type Bearings
.................................. Replaceable
Precision Steel Back, Copper-Lead Liners Engine
Lubricating System Crankcase (without filter
change) ..........................................
..... 14 Quarts 13.25 '!'res) (with filter
change) ..........................................
....... 17 Quarts (16.09 litres) Oil pressure
............................................ 45
to 60 PSI (310 to 414 kPa)(3.10 to 4.14 bar) with
Engine Warm and Operating at Rated Engine Speed
Type System ......................................
................... Pressure and Spray
Circulation oii Pump ............................
..................................................
.. Gear Type Oil Filter ..........................
........................................... Full
Flow Turn-on Type Fuel System Fuel Injection
Pump ........................................
Robert Bosch, Type PES Multiple Plunger Pump
Timing ...................................... 30
Degrees Before Top Dead Center (Port C!sing)
Fuel Injectors ..................................
......................................... Pencil
Type 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
NOTE The wsE CORPORATiON reserves the right to
make improvements in design or changes in
specifications at any time without incurring any
obliga- tion to install them on units previously
sola.
Rac 8-22710
Issued 4-80
Printed in U.S.A.
6
1012
DECALS AND PAINTING
TABLE OF CONTENTS General Information
.................... 1012-2 Common Decals
..................... 1012-4 Illustrations of
Decals .................. 1012-3 Loader Decals
....................... 1012-5 Common Decals
..................... 1012-3 Dozer Decals
........................ 1012-6
Written In Clear And Simple English
9-67891
Printed in U.S.A. Issued Sept 1980 Rev/Reprinted
Sept 1984
CASE CORPORATION
7
1012-2
GENERAL INFORMATION
The following pages show decals that are in-
stalled on the machine and machine attachments.
Part numbers for the decals are also shown. When
decals are needed, check the parts catalog to be
sure the part number is correct. Decals are
available separately or in a kit for this machine.
decal. Use enamel thinner to help remove the old
decal.
5. Remove all dirt, grease, and oil before
installing a new decal.
6. Use standard procedure to prepare the machine
or attachment for painting.
1. The condition of all decals about the
operation of the machine and/or attachments must
be easy to read.
a. Remove all dirt, grease, and oil from the
sur- face to painted.
2. The condition of all decals that start with
the words WARNING, CAUTION, or DANGER must be
easy to read.
b. Wash the area to be painted.
c. Use sandpaper to prepare the surface that is
to be painted.
3. Replace any decal that is damaged or is not
easy to read.
d. Cover all surfaces that are not to be
painted. 4. Remove the old decal before
installing a new e. Paint the machine or
attachment.
8
1012-3
DIESEL FUEL
10
HYDRAULIC FLUID 12

• 1. 321-5273
• 2. 321-4192
• 3. 321-6672 7.
• 321-3708 (UNDER COVER FOR RADIATOR CAP) 8.
• R52403 (UNDER COVER FOR AIR CLEANER) 9.

6.
321-6240 (UNDER COVER FOR 10. 321-3123 BLACK,
R48488 BROWN
AIR CLEANER) 11. 321-5974
321-5272 BLACK, R48491 BROWN 12. 321-6209
R49131 BROWN 13. 321-3596 (BOTH SIDES OF ENGINE)
321-229
Common Decals
9
Section 2001
ENGINE DIAGNOSIS
Rac. 9-76365
PRINTED IN U.S A
CASE CORPORATION
10
2001-2
GENERAL INFORMATION
Proper compression is affected by the air
cleaner condition, muffler restriction, valve
condition and operation including proper valve
adjustment, cylinder head gaskets condition of
sleeves, rings, pistons, camshaft, and cam- shaft
timing. 3. IGNITION. Ignition is the result of
adequate compression to develop enough heat in
the air charge on the compression stroke to fire
the fuel being injected into the engine
cylinders. Proper spray pattern and atomization
of the fuel by the injector is very important.
Timing the fuel injection pump to the engine to a
pre- cise degree BTDC is a vital requirement for
proper ignition. The engine diagnosis contained
in the fol- lowing pages covers many trouble
symptoms, the causes, and what will be necessary
to re- pair or eliminate the problem. Under each
symptom are listed the most common and re-
occuring problems progressively to the not so
common problems. Locate your problem sym- ptom in
the diagnosis chart and refer to the pages listed
for the probable causes and re- medies.

• Before making any repairs or adjustments on an
  engine, a mechanic or technician must properly
  diagnose the trouble.
• Locating the trouble and repairing it is only
• part of the job, a technician must find and
  eliminate the cause of the trouble as well. Too
  many repairs are made with no thought to removing
  the causes that made the repair necessary.
• For any engine to start or perform proper- ly,
  three main requirements must be present.
• FUEL
• COMPRESSION
• IGNITION
• When any of these requirements are not pre- sent
  or limited by qome mechanical reason the engine
  will not start or fails to operate properly
  throughout the power range.
• FUEL. Fuel system problems can be pre- sent
  anywhere from the fuel tank, through the filters
  and injection pump as well as the injec- tors.
  Correct injection pump timing is impor- tant in
  the overall fuel system performance.
• COMPRESSION. Compression on an en- gine is
  related to the breathing function.

11
2001-24 INSTALLATION lNSTRUCTious FoR u20614
TEFLON VALVE SEAL KIT Special Tools Required
M2O617 VALVE GUIDE CUTTING TOOL
M2O624 SEAL INSTALLATION TOOL
VALVE SPRING COMPRESSOR
STEP 3
NOTE FOUR CYLINDER ENGINES REQUIRE TWO M2O614
KITS AND SIX CYLINDER ENGINES REQUIR E THREE
M2O614 KITS.
VALVE KEEPERS
STEP 1
COMPRESS VALVE SPRING AND REMOVE VALVE
KEEPERS. IMPORTANT VALVES, VALVE RETAINERS OR
RO- TATORS AND VALVE KEEPERS SHOULD BE MARK- ED
WHEN REMOVED, TO INSURE THAT THEY WILL BE
REINSTALLED IN THEIR ORIGINAL LOCATION.
REMOVE THE CYLINDER HEADS FROM THE EN- GINE.
REFER TO SECTION 2015 FOR HEAD R EMOVAL.
STEP 2
STEP 4
VALVE STEM SEAL
INSTALL A VALVE SPRING COMPRESSOR.
REMOVE VALVE STEM SEAL.
12
2001-25
STEP 5
STEP 8
MINIMUM 1/16 WIDE FLAT
REMOVE VALVE ROTATORS OR SPRING RETAINERS.
SPRINGS, SPRING SEATS AND VALVES. STEP 6
CHECK VALVE GUIDE TOP SURFACE, THERE MUST BE A
MINIMUM OF A 1/16" WIDE FLAT AROUND ENTIRE TOP
SURFACE. STEP 9
CLEAN CYLINDER HEAD COMPLETELY, REMOVING ALL
TRACES OF CARBON AND OTHER DEPOSITS.
STEP 7
CLEAN VALVES WITH A FINE POWER DRIVEN WIRE BRUSH,
REMOVING ALL CARBON AND VARNISH DE- POSITS. BE
CAREFUL NOT TO SCRATCH VALVE STEMS. USE M2O617
TOOL IN A ELECTRIC DRILL (IF RE- QUIRED) TO
PROVIDE NECESSARY FLAT AREA ON VALVE GUIDE. IM
PORTANT DO NOT EXCEED 450 RPM WHEN DRILLING
13
2001-26
STEP 1O
STEP 13
LUBRICATE VALVES WITH CLEAN ENGINE OIL BE- FORE
REINSTALLING INTO CYLINDER HEAD.
USE M2O624 TOOL AND PRESS SEAL DOWN OVER VALVE
GUIDE UNTIL SEAL IS FLUSH WITH TOP OF GUIDE.
STEP 1 1 VALVE SPRING SEAT
STEP 14
INSET A CLOSE COIL END
PLASTIC CAP
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 TEFLON VALVE SEAL
INSTALL THE VALVE SPRING. IMPORTANT THE CLOSE
COIL END OF THE SPRING MUST BE IN- STALLED
TOWARDS THE CYLINDER HEAD, SEE INSET A.
CAREFULLY in SEAL ON CAP AND HOLD START
VALVE THUMBS AGAINST WHITE SEAL INSERT TO AVOID
DISLODGING IT, PUSH SEAL DOWN UNTIL SEALJAC- KET
TOUCHES TOP OF VALVE GUIDE. REMOVE IN- STALLATION
CAP AND SAVE, SINCE IT MUST BE REUSED.
14
2001-27
STEP 15
STEP 1 8
VALVE KEEPERS
INSTALL VALVE ROTATORS OR SPRING RETAINERS.
IMPORTANT ASSEMBLE VALVE ROTATORS WITH THEIR
ORIGINAL VALVES SINCE THEY TEND TO WEAR IN AS A
MATCHED SET.
INSTALL VALVE KEEPERS IN OUTER VALVE STEM GROOVE.
STEP 16
STEP 19
INSTALL VALVE SPRING COMPRESSOR.
STEP 17
REMOVE SPRING COMPRESSOR AND TAP VALVE STEM END
TO SEAT KEEPERS.
VALVE STEM SEAL
STEP 2O
INSTALL TEFLON SEALS ON THE OTHER INTAKE AND
EXHAUST VALVES, FOLLOWING THE PRECED- ING
PROCEDURE.
INSTALL GROOVE.
STEM SEAL IN LOWER VALVE STEM
15
2001-28 STEP 21
REINSTALL CYLINDER HEAD ON ENGINE FOLLOW- ING
PROCEDURE OUTLINED IN SECTION 2015.
NOE The CASE CORPORATioN reserves the
righf to make improvements in design or
changes in specifications at any time
without incurring any obligation to install
them on units previously sold.
16
2002-4
ENGINE TUNEUP PROCEDURE Checking Crardcshaft
Damper Pulley
STEP 1 THE RECOMMENDED CHANGE INTERVAL FOR THE
CRANKSHAFT DAMPER PULLEY IS 2OOO HOURS MAXIMUM.
AT ANY TIME OVER 1500 HOURS. CONSIDER CHANGING
PULLEY AT ANY MAJOR ENGINE OVERHAUL OR TUNE
UP. EVERY SOO 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.
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.
RUBBER SLEEVE INSET B VISCOUS
DAMPER TORQUE DAMPER-TO-PULLEY
MOUNTING BOLTS 35 TO 42 FT. LBS. FOR 3/8
MOUNTING BOLTS AND 11O TO 132 FT. LBS. FOR 1 /2
GRADE 8 MOUNTING BOLTS.
INSET A RUBBER ELEMENT, RANKSHAFT DAMPER
PULLEY DETERIORATED RUBBER ALIGNMENT MARKS
(LOCATED ON TIMING GEAR COVER SIDE OF PULLEY)
17
2002-5
Checking Top Dead Center STEP 5
STEP 2
CRANK ENGINE UNTIL 10 BTDC MARK ON CRANK- SHAFT
PULLEY IS ALIGNED WITH TIMING POINTER.
REMOVE ROCKER ARM ASSEM BLY.
STEP 3
STEP 6
REMOVE BREATHER TUBE.
COMPRESS EXHAUST VALVE SPRING ON NO. 1 CYLINDER
USING FABRICATED TOOL (SEE PAGE )-
STEP 4
STEP 7
t REMOVE VALVE COVER AND GASKET FROM NO. 1 AND
NO. 2 CYLINDERS.
REMOVE VALVE KEEPERS
18
2002-6 STEP 8
CRANK ENGINE CLOCKWISE UNTIL
DIAL INDICATOR HAND STOPS MOVING. RESET INDICATOR
TO ZERO.
VALVE ROTATOR
SPRING
REMOVE VALVE ROTATOR, SPRING AND SEAT.
STEP 9
VALVE SEAT
VALVE SEAL
CRANK ENGINE CLOCKWISE UNTIL .010 SHOWS ON DIAL.
SCRIBE A MARK ON CRANKSHAFT PULLEY IN LINE WITH
TIMING POINTER.
KEEP VALVE SEAL IN PLACE TO PREVENT VALVE FROM
FALLING THROUGH VALVE GUIDE IF PISTON IS MOVED
TOO FAR
CRANK ENGINE COUNTERCLOCKWISE PAST ZERO MARK ON
INDICATOR UNTIL .OIO SHOWS ON DIAL. AGAIN,
SCRIBE MARK ON CRANKSHAFT PULLEY.
STEP 1 O
EXHAUST VALVE STEM INSTALL DIAL INDICATOR ON
END OF VALVE STEM WITH VALVE RESTING ON TOP OF
PISTON.
19
2002-7
STEP 13
STEP 11
' \
.O1O
ii T'fCv1 .OIO
COMPRESS VALVE SPRING USING FABRICATED TOOL.
INSTALL SEAL IN LOWER VALVE STEM GROOVE. INSTALL
VALVE KEEPERS IN OUTER VALVE STEM GROOVE.
HALF THE DISTANCE BETWEEN THESE TWO SCRIBE MARKS
ON CRANKSHAFT PULLEY WILL BE THE TOP DEAD CENTER
(TDC) MAR K. IF THE SCRIBE MARKS ARE NOT THE SAME
AS ORIGINAL MARKS ON PULLEY CHECK DAMPER.
STEP 14
STEP 1 2
INSET A CLOSE COIL END
REMOVE SPRING COMPRESSING TOOL. TAP END OF VALVE
STEM TO SEAT KEEPERS.
VALVE SPRING
STEP 15
INSTALL VALVE ROTATOR. VALVE SPRING SEAT
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
INST-ALL ROCKER ARM ASSEMBLY ONTO CYLINDER HEAD.
20
2002-8
STEP 16
STEP 1 8
TORQUE ROCKER ARM ASSEMBLY RETAINING NUTS 40 TO
45 FT. LBS.
INSTALL VALVE COVERS AND GASKETS.
STEP 19
TORQUE VALVE COVER NUTS 6O TO 7O IN. LBS.
ADJUST VALVE TAPPETS. REFER TO FOR COLD SETTING
OR TO STEP 33 SETTING.
STEP 26 FOR HOT
STEP 2O
INSTALL BREATHER TUBE AND GASKETS.
21
2002-9
Adjusting Tappets Cold Setting STEP 24
STEP 21
TIMING POINTER
REMOVE TURBOCHARGER INTAKE ELBOW (IF SO EQUIPPED).
CRANK ENGINE UNTIL TIMING POINTER IS ALIGNED WITH
TDC TIMING MARK ON CRANKSHAFT PULLEY.
STEP 22
STEP 25
REMOVE BREATHER TUBE.
NO. 1 PUSH RODS
STEP 23
CHECK PUSH RODS ON NO. 1 CYLINDER FOR LOOSE-
NESS. IF PUSH RODS ARE LOOSE, NO. 1 CYLINDER 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.
22
2002-10
STEP 26
STEP 27
CRANK THE ENGINE OFJE COMPLETE REVOLU- TION AND
ALIGN THE TIMING POINTER WITH THE TDC MARIA 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
2
1
CHECK AND ADJUST THE INTAKE ANo Ex AuST VALVES AS
POINTED OUT BY THE ARROWS BELOW.
NO. 4 TDC COMPRESSION STROKE
TAPPET CLEARANCE COLD - INTAKE VALVES .015 Ex
AuST VALVES - .025
SIX CYLINDER ENGINES
FOUR CYLINDER ENGINES
2
1
NO. 1 TDC COMPRESSION STROKE
NO. 6 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
NOTE AFTER COMPLETING COLD SETTING VALVE
TAPPET ADJUSTMENT PROCEED TO STEP 35.
NO. 1 TDC COMPRESSION STROKE
23
2002-11
Adjusting Tappets Hot Setting with Engine
Stopped STEP 31
STEP 2 8
TIMING POINTER
REMOVE TURBOCHARGER INTAKE ELBOW (IF SO EQUIPPED).
CRANK ENGINE UNTIL TIMING POINTER IS ALIG- NED
WITH TDC TIMING MARK ON CRANKSHAFT PULLEY.
STEP 29
STEP 32
!
REMOVE BREATHER TUBE
O. 1 PUSH RODS
STEP SO
CHECK PUSH RODS ON NO. 1 CYLINDER 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.
24
2002-12 STEP 33
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 FOUR CYLINDER ENGINES
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
NO. 4 TDC COMPRESSION STROKE
SIX CYLINDER ENGINES
NO. 1 TDC COMPRESSION STROKE
six cvLiNDER ENGINES
NO. 6 TDC COMPRESSION STROKE
6 5 4 3 E 2
E I I E E I
I
E I I Eo
STEP 35
a o o
NO. 1 TDC COMPRESSION STROKE
COVER GASKET AFTER TAPPET ADJUSTMENT, INSTALL
VALVE COVERS AND GASKETS.
25
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26
2002-13
STEP 3 8
STEP 36
INSTALL TURBOCHARGER INTAKE ELBOW
TORQUE VALVE COVER NUTS 60 TO 70 IN. LBS.
BREATHER TUBE GASKET
INSTALL BREATHER TUBE AND GASKETS.
27
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the link into your browser. The full manual is
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