Case 1450 b crawler dozer service repair manual

the best repair workshop manual

1. 1450B AND 1455B CRAWLER TABLE OF CONTENTS
AND SERVICE MANUAL INTRODUCTION
Table of Contents
DIVISION/SECTION SECTION NO.
10 SERIES -GENERAL
General Engine Specifications -504BDT ................. , .......................................................... 1010
Decals and Repainting ......................................................................................................... 1012
Detailed Engine Specifications -504BDT. ........................................................................... 1020
Maintenance and Lubrication .............................................................................................. 1050
Torque Charts ...................................................................................................................... 1051
Noise Control ....................................................................................................................... 1052
20 SERIES -ENGINE
Engine Diagnosis ................................................................................................................. 2001
Engine Tune-up .................................................................................................................... 2002
Cylinder Head, Valve Train and Camshaft .......................................................................... 2015
Cylinder Block, Sleeves, Pistons and Rods ........................................................................ 2025
Crankshaft, Main Bearings, Flywheel and Oil Seals ........................................................... 2035
Lubrication System ............................................................................................................... 2046
General Engine Information and Radiator ........................................................................... 2050
Air Cleaner ............................................................................................................................ 2051
Ether Injection ...................................................................................................................... 2053
Cooling System .................................................................................................................... 2055
Turbocharger Removal and Installation ............................................................................... 2065
Reconditioning Engine Cylinder Block ................................................................................. 2290
Turbocharger Failure Analysis ............................................................................................. 2565
30 SERIES -FUEL SYSTEM
Fuel System and Filter ......................................................................................................... 3010
Robert Bosch Fuel Injection Pumps .................................................................................... 3012
Roosa Master Fuel Injectors ................................................................................................ 3013
Fuel Lines and Fuel Tank .................................................................................................... 3052
40 SERIES -ELECTRICAL SYSTEM
Electrical System Specifications and Troubleshooting ....................................................... 4002
Wiring Diagram .................................................................................................................... 4003
Gauges ................................................................................................................................. 4004
Batteries ............................................................................................................................... 4005
Starter and Starter Solenoid ................................................................................................. 4006
Alternator .............................................................................................................................. 4007
Electrical Accessories .......................................................................................................... 4015
50 SERIES -TRACK SYSTEM
Case Lubricated Track ......................................................................................................... 5504
Track and Track Frame ........................................................................................................ 5506
Idler, Track Adjuster and Recoil Housing ............................................................................ 5508
Sprocket ............................................................................................................................... 5509
Carrier Roller ........................................................................................................................ 5510
Track Rollers ........................................................................................................................ 5511
9-67890-R3
FORM NO.
8-27710
9-67891
8-27760
9-67891
9-67890
9-67890
9-76365
9-76379
9-76166
9-76176
9-76187
8-22780
9-67890
9-67891
9-67891
9-76337
9-67890
8-21170
9-78235
9-75297
9-74937
9-74959
9-67890
9-67891
9-67890
9-67890
9-67891
9-67891
9-67891
9-67890
8-42190
9-67891
9-67891
9-67890
9-67891
9-67891
Printed in U.S.A.
CASE CORPORATION
Issued September 1980
Revised September 1984
Revised September 1986
Revised March 1990

2. DIVISION/SECTION SECTION NO
60 SERIES -POWER TRAIN
General Transmission Information ....... , ........ ..... " ............................................. ................... 6002
Transmission Diagrams and Operation .................................. " ........................................... 6003
Charging Pump ........................ < •••••••••••••••••••••••••••••••••••••••• < < ••••••••••••••••••••••••••••••••••• < ••• < •••• < •••• 6005
Transmission Control Valve ......................................................................................... «.«.6007
Torque Converter ........................... «." ...................................................... « ......................... 6010
Transmission ................ « ......... « ....... « ..... , .............. , ..... , ................ " ..................................... 6016
Fina! Drive for 1450B Loader ........................ , .......................................... , ........................... 6017
Final Drive Planetary ................................................. " .................. « .............. « ............. " ...... 6018
Transmission Controls .................................... , ......................... , .......................................... 6019
Drive Shaft ....................................... , ............................... , .......... , ....................... , ........ ,., .. , ... 6021
70 SERIES -BRAKES
Brakes .... , ... ' ........................................................................ ............ ..................... ... , ........ " .. 7001
80 SERIES -HYDRAULIC SYSTEM
General Hydraulic System Information ......... ..................................................................... 8002
Hydraulic Pump .......................................................................... .................... , ... ,., ............... 8005
Equipment Control Valve" .......... ..... , ................... ,.,., ... , .................. , ...... , ... " ........ ,., ... , ......... 8007
Selector Valve, ...... , ....... , ......... " ............. , ............ , ... , ....... , , ........... , ... , ... " ........................ ,., ... , 8021
Cylinders .... , ... , .... , ... ", , .... , ..... , , ... , ... , .... , ........ , ...... , ............. " ... , ... ,., ..... , ........ , .............. ..... , ..... 8090
90 SERIES -MOUNTED EQUIPMENT
Air Conditioning Troubleshooting and System Checks ...................................................... 9002
Air Conditioning System ........ , ........ , ......... , ............. , .. , ......... , ... , ................ , ................... , ....... 9003
Loader .................................. , ... , ............................... , ......... , ... , ... , .................... , ... , ....... " ... " .. 9010
Blade ... , ' .. ' ........ , ....... , ........ , . ..... , ........ , .... ' ... , ..................................... , , ......... , ..... , ................ ,.9020
Ripper, .................................. , ..... , ......... , ...... , .................... ,., .. " ............ , .... , ..................... , ..... 9031
ROPS Canopy, ..... , ..................... , .... , ............ , ...... , ............ , .. ,.", .. , ... , ... , ..... " ............. , .... ,." .... 9061
......... " .. 9300
FORM NO.
9-67891
9-67891
9-67891
9-67891
9-67891
9-67891
9-67891
8-15510
8-67890
9-67890
9-67891
9-67891
9-67891
9-67891
9-67890
9-67891
8-41280
9-67890
9-67891
9-67891
9-67891
9-67891
9-67891
Bur 8-67Sgo.R3 Issued 3-90 Printed in U.SA

3. Section
1010
GENERAL ENGINE SPECIFICATIONS
1450B CRAWLER LOADER AND DOZER
CASE CORPORATION
504 BDT DIESEL ENGINES
Written I n Clear
. And
Simp..le
English
Rac 8-22710 Printed in U.S.A.
Issued April, 1980

4. 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
..•.....................................•......................•.......... 5
Inches (127.0 mm)
Piston Displacement
•.....•.............................................
504 Cubic Inches (8 259 cm3)
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 litres)
(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
Oil 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 Closing)
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
Rac 8-22710
NOTE: The CASE 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 sold.
Issued 4-80 Printed in U.S.A.

5. 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
CASE CORPORATION
Written I n Clear
And
Simple
English
9-67891
Printed in U.S.A.
Issued Sept 1980
Rev/Reprinted Sept 1984

6. 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.
1. The condition of all decals about the operation
of the machine and/or attachments must be
easy
to read.
2. The condition of
all decals that start with the
words WARNING, CAUTION, or DANGER must
be easy to read.
3. Replace any decal that is damaged or is not easy
to read.
4. Remove the old decal before installing a new
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.
a. Remove all dirt, grease, and oil from the sur­
face
to painted.
b. Wash the area to be painted.
c. Use sandpaper to prepare the surface that is
to be painted.
d. Cover
all surfaces that are not to be painted.
e. Paint the machine or attachment.

7. AWARNING
AWARNING
11
1. 321-5273
2. 321-4192
3. 321-6672
4. 321-3708 (UNDER COVER FOR RADIATOR CAP)
5. R52403 (UNDER COVER FOR AIR CLEANER)
6
1012-3
DIESEL FUEL
AWARNING
c,.,ell ."'0 .'.VIC. CaOUNG ""S"IIII &CeOIlDIIiIIIG TO ... "INUIiI.
AIilCI ~"'.UCTIOII.
NOT COOL .... T C .... "."Y OUT ., .... ol .. TO. c .. ~ '1 ••• OYIO
TO IIIMO"'" ."O.ATOII c .... LIT .,.,TIM COO", T",'UI TO fI.,T
"OTeN 1'lOI'" WA". ..,Nn .. ALL "" ••• 1,1"" 'S •• ~.O.
ICALOIMI CA" •• IULT UIO. , .. lIT ""IiIIIOVA&. Of IUII""'1'OII c .....
5
AWARNING
ROTATING FAN AND BELTS
CONTACT CAN INJURE
KEEP CLEAR
~'i:.=.=;r:r:..;.E.';:==.':.~,:,.:.:,'.::;::. _ .. __ ._-_ .... ----
HYDRAULIC
FLUID
==:J
I
i
6. 321-6240 (UNDER COVER FOR
AIR CLEANER)
7. 321-5272 BLACK, R48491 BROWN
8. R49131 BROWN
9. 321-229
Common Decals
ENGINE DATA CECAL NO 321 6209
MODEL. A504BOT
FUll LOAD RPM _ _ 2100
NO LOAD R.P.M ______ 2250
VALVE TAPPET _INTAKE __ 015 COLD
CLEARANCE _ EXHAUST __ 025 COLD
FUElPUMPTIMING ____ 27° BTC
NOZZLE OPENING PRESS _3200 PSI
AWARNING
ROTATING FAN AND BELTS
CONTACT CAN INJURE
K!:EP CLEAR
801049
A
10. 321-3123 BLACK, R48488 BROWN
11. 321-5974
12. 321-6209
13. 321-3596 (BOTH SIDES OF ENGINE)

8. CASE CORPORATION
Section
2001
ENGINE DIAGNOSIS
Rae. 9-76365 PRINTED IN u.s A

9. 2001-2
GENERAL INFORMATION
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.
1. FUEL
2.
COMPRESSION
3. IGNITION
When any of these requirements
are not pre­
sent or limite,d by
~ome mechanical reason the
engine will not
start or fails to operate properly
throughout the power range.
1. 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.
2.
COMPRESSION. Compression on an en­
gine is related
to the
"breathing function".
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 a tomiza tion 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.

10. 2001-24
INSTALLATION INSTRUCTIONS FOR M20614 TEFLON
VALVE SEAL KIT
Special Tools Required
M20617 VALVE GUIDE CUTTING TOOL
M20624 SEAL INSTALLATION TOOL
NOTE: FOUR CYLINDER ENGINES REQUIRE TWO
M20614 KITS AND SIX CYLINDER ENGINES REQUIRE
THREE M20614 KITS.
STEP 1
REMOVE THE CYLINDER HEADS FROM THE EN­
GINE, REFERTO SECTION 2015 FOR HEAD REMOVAL.
STEP 2
VALVE SPRING COMPRESSOR
STEP 3
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.
STEP 4
REMOVE VALVE STEM SEAL.

11. 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

12. 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.

13. 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.

14. 2001-28
STEP 21
REINSTALL CYLINDER HEAD ON ENGINE FOLLOW­
ING PROCEDURE OUTLINED IN SECTION 2015.
NOTE: The CASE CORPORA liON 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.

15. 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.

16. 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

17. 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.

18. 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.

19. 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

20. 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.

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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. lEE 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. 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.

24. 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 lEE 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.

25. 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.