8.3L Cummins Engine SM

Rac 7-88631 Released 11-98 (Revised 7-99) Printed in U.S.A.

TABLE OF CONTENTS

Introduction........................................................................................................................................................... i 7-89330

Engine Identification........................................................................................................................................... E 7-89340

Troubleshooting Symptoms ............................................................................................................................ TS 7-89351

Cylinder Block - Group 01...................................................................................................................................1 7-89370

Cylinder Head - Group 02....................................................................................................................................2 7-89380

Rocker Levers - Group 03 ...................................................................................................................................3 7-89390

Cam Followers/Tappets - Group 04....................................................................................................................4 7-89400

Fuel System - Group 05.......................................................................................................................................5 7-89411

Injectors and Fuel Lines - Group 06...................................................................................................................6 7-89421

Lubricating Oil System - Group 07.....................................................................................................................7 7-89430

Cooling System - Group 08.................................................................................................................................8 7-89440

Drive Units - Group 09.........................................................................................................................................9 7-89450

Air Intake System - Group 10............................................................................................................................10 7-89460

Exhaust System - Group 11 ..............................................................................................................................11 7-89470

Miscellaneous - Group 017 ...............................................................................................................................17 7-89510

Specifications...................................................................................................................................................... V 7-89520

NOTE: Portions reproduced by permission of Cummins Engine Company, Inc.

Section Form Number

24 Valve, 8.3 Liter EngineSection i - Introduction Page i-a

Rac 7-89330 Released 11-98 Printed in U.S.A.

Section i - Introduction

Section Contents

About the Manual ........................................................................................................................................................................................... 1

General Cleaning Instructions ...................................................................................................................................................................... 5Solvent and Acid Cleaning ............................................................................................................................................................... 5Steam Cleaning ................................................................................................................................................................................ 5Glass or Plastic Bead Cleaning ........................................................................................................................................................ 5

General Repair Instructions .......................................................................................................................................................................... 4

General Safety Instructions .......................................................................................................................................................................... 3Important Safety Notice .................................................................................................................................................................... 3

How to Use the Manual .................................................................................................................................................................................. 1

Illustrations ..................................................................................................................................................................................................... 2

24 Valve, 8.3 Liter EnginePage i-b Section i - Introduction


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24 Valve, 8.3 Liter EngineSection i - Introduction Page i-1


About the ManualThis manual contains information needed to correctly operate and maintain your engine as recommended by Case Corporation.

This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle service manual for specific maintenance rec-ommendations.

Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary in brackets.

Each section is preceded by a Section Contents to aid in locating information more quickly.

How to Use the ManualThe manual is organized to provide an easy flow from problem identification to problem correction. A list of troubleshooting symptoms con-taining most common engine problems begins on Page TS-a in Section TS - Troubleshooting Symptoms. Complete the following steps tolocate and correct the problem.

Refer to Section TS for a guide to troubleshooting your engine. Follow the directions given on Page TS-1 to locate and correct engine prob-lems.

The Troubleshooting Symptoms Charts are based on the following assumption:

• The engine has been installed according to specifications.

• The easiest repairs are done first.

• Generic solutions to cover problems with the most common applications.

Refer to Section V for specifications recommended by Case Corporation for your engine. Specifications and torque values for each enginesystem are given in that section.

24 Valve, 8.3 Liter EnginePage i-2 Section i - Introduction


Illustrations

Some of the illustrations throughout this manual are generic and willnot look exactly like the engine or parts used in your application. Theillustrations can contain symbols to indicate an action required and anacceptable or not acceptable condition.

The illustrations are intended to show repair or replacement proce-dures. The procedure will be the same for all applications, althoughthe illustration can differ.



General Safety Instructions

Important Safety Notice∆ WARNING ∆

Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death.

Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precau-tions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply.

• Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and haz-ardous substances. Be aware of hazardous conditions that can exist.

• Always wear protective glasses and protective shoes when working. • Rotating parts can cause cuts, mutilation or strangulation. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air start-

ing motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the con-trols.

• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure.

• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system.

• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work.

• Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel and liquid refrigerant (freon) lines in a well ven-tilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant.

• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded.

• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.

• To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY

Case approved replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replace-

ments are necessary. • Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can

cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.



General Repair InstructionsThis engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair prac-tices performed to quality standards.

Case Corporation does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Ser-vice Information. In particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listingof components classified as safety-related:

• Follow all safety instructions noted in the procedures

-- Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of the engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, injes-tion and contact with such substances. Always use good safety practices with tools and equipment.

• Provide a clean environment and follow the cleaning instructions specified in the procedures

-- The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause prema-ture wear.

• Perform the inspections specified in the procedures

• Replace all components or assemblies which are damaged or worn beyond the specifications

• Use Case approved service parts and assemblies

-- The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure is based on the use of new Case approved components.

• Follow the specified disassembly and assembly procedures to avoid damage to the components

Air Compressor Flywheel Mounting CapscrewsAir Controls Fuel Shutoff AssembliesAir Shutoff Assemblies Fuel Supply TubesBalance Weights Lifting BracketsCooling Fan Throttle ControlsFan Hub Assembly Turbocharger Compressor CasingFan Mounting Bracket(s) Turbocharger Oil Drain Line(s)Fan Mounting Capscrews Turbocharger Oil Supply Line(s)Fan Hub Spindle Turbocharger Turbine CasingFlywheel Vibration Damper Mounting CapscrewsFlywheel Crankshaft Adapter



General Cleaning Instructions

Solvent and Acid CleaningSeveral solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can be obtainedusing a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit]. A cleaning tank that provides a constantmixing and filtering of the cleaning solution will give the best results. Case Corporation does not recommend any specific cleaners.Always follow the cleaner manufacturer's instructions.

Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the parts in acleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaningtank.

∆ WARNING ∆Acid is extremely dangerous and can damage the machinery. Always provide a tank of strong soda water as a neutralizing agent.

Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the capscrew holes andthe oil drillings.

If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The rustproofing compound mustbe removed from the parts before installation on the engine.

Steam CleaningSteam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way to clean the oil drillings.

∆ WARNING ∆Wear protective clothing to prevent personal injury from the high pressure and extreme heat.

Do not steam clean the following parts:

Glass or Plastic Bead CleaningGlass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled bythe size of the glass or plastic beads, the operating pressure, and the cleaning time.

∆ CAUTION ∆Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning on aluminum ring grooves.Small particles of glass or plastic will embed in the aluminum and result in premature wear. Valves, turbocharger shafts, etc., canalso be damaged. Follow the cleaning directions listed in the procedures.

NOTE: Plastic bead blasting media can be used to clean aluminum ring grooves. Do not use any bead blasting media on pin bores or alumi-num skirts.

Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manufacturer's instructions:

1. Bead size:-Use U.S. size No. 16-20 for piston cleaning with plastic bead media.-Use U.S. size No. 70 for piston domes with glass media.-Use U.S. size No. 60 for general purpose cleaning with glass media.

2. Operating Pressure:-Glass: Use 620 kPa [90 psi] for general purpose cleaning.-Plastic: Use 270 kPa [40 psi] for piston cleaning.

3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after cleaning. Rinse with hot water. Dry with compressed air.

4. Do not contaminate the wash tanks with glass or plastic beads.

1. Electrical Components 4. Fuel Pump2. Wiring 5. Belts and Hoses 3. Injectors 6. Bearings



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24 Valve, 8.3 Liter EngineSection E - Engine Identification Page E-a


Section E - Engine Identification

Section Contents

Engine Identification ...................................................................................................................................................................................... 1Engine Dataplate .............................................................................................................................................................................. 1Fuel Injection Pump Dataplate ......................................................................................................................................................... 2ECM Dataplate ................................................................................................................................................................................. 2

Engine Views .................................................................................................................................................................................................. 5

Specifications ................................................................................................................................................................................................. 3Air Intake System ............................................................................................................................................................................. 3Cooling System ................................................................................................................................................................................ 3Electrical System .............................................................................................................................................................................. 4Exhaust System ............................................................................................................................................................................... 3Fuel System ..................................................................................................................................................................................... 4General Specifications ..................................................................................................................................................................... 3Lubricating Oil System ..................................................................................................................................................................... 3

Section E - Engine Identification 24 Valve, 8.3 Liter EnginePage E-b Section E - System Identification



24 Valve, 8.3 Liter Engine Engine IdentificationSection E - System Identification Page E-1


Engine Identification

Engine Dataplate

The engine dataplate shows specific information about your engine.The engine serial number (ESN) and Vehicle Parts List provide infor-mation for ordering parts and service needs. The engine dataplatemust not be changed unless approved by Case Corporation.

The dataplate is located on the top side of the gear housing. The information on the dataplate is mandatory when sourcing service parts.1. Engine Serial Number (ESN)2. Vehicle Parts List3. Model4. Horsepower and rpm rating

NOTE: If the engine dataplate (1) is not readable, the engine serial number(ESN) (2) can be identified on the engine block on top of the lubricating oil cool-er housing. Additional engine information is available by reading the ElectronicControl Module (ECM) dataplate.

Engine Identification 24 Valve, 8.3 Liter EnginePage E-2 Section E - System Identification


Fuel Injection Pump Dataplate

The CAPS fuel injection pump dataplate is located on the side of theinjection pump. The dataplate contains the following information:

A. Part Number

B. Pump Serial Number

C. Factory Code

ECM Dataplate

The Electronic Control Module (ECM) dataplate shows informationabout your ECM, and how the ECM was programmed. The dataplateis located on the ECM above the ECM connectors.

The following information is available on the ECM dataplate:

• ECM Part Number (PN)

• ECM Serial Number (SN)

• ECM Date Code (DC)

• Engine Serial Number (ESN)

• ECM Code identifying the Software Number indicating how the ECM is programmed.

24 Valve, 8.3 Liter Engine SpecificationsSection E - System Identification Page E-3


Specifications

General SpecificationsHorsepower...............................................................................................................................................................(Refer to engine dataplate)

Engine speed @ Maximum Power Output: Standard Rating (rpm) ........................................................................................................................................................................... 2000

Bore and Stroke .........................................................................................................................................114 mm [4.49 in] x 135 mm [5.32 in]

Displacement ......................................................................................................................................................................8.3 liters [505 C.I.D.]

Compression Ratio ...................................................................................................................................................................................... 17:1

Firing Order....................................................................................................................................................................................... 1-5-3-6-2-4

Approximate Engine Weight (with standard accessories):.........................................................................................................680 kg [1500 lb]

Crankshaft Rotation (viewed from the front of the engine).................................................................................................................. Clockwise

Valve Clearance:Intake ................................................................................................................................................................................ 0.3048 mm [0.012 in]Exhaust ............................................................................................................................................................................. 0.5588 mm [0.022 in]

NOTE: Refer to the vehicle operators manual for the valve lash adjustment interval for the Case 24 valve 8.3 liter engine. The valve trainoperates acceptably within the limits of 0.152 to 0.559 mm [0.006 to 0.022 in] intake valve lash and 0.381 to 0.813 mm [0.015 to 0.032 in]exhaust valve lash.

Air Intake SystemMaximum Intake Restriction (Clean Air Filter Element) ........................................................................................... 254 mm H2O [10.0 in H2O]

Maximum Intake Restriction (Dirty Air Filter Element) ............................................................................................. 635 mm H2O [25.0 in H2O]

Lubricating Oil SystemOil Pressure: at Low Idle (Minimum Allowable) ..........................................................................................................................................69 kPa [10 psig] at Rated Speed (Minimum Allowable).................................................................................................................................207 kPa [30 psig]

Regulated Pressure ...................................................................................................................................................................517 kPa [75 psi]

Oil Capacity Of Standard Engine: Standard Oil Pan Pan Only .........................................................................................................................................................................18.9 liters [20 qts]

Total System Capacity ...............................................................................................................................................................21 liters [22 qts]

NOTE: Some applications may use a slightly different oil pan capacity. Refer to the machine operators manual.

Cooling SystemCoolant Capacity (Engine Only).............................................................................................................................................10.9 liters [11.5 qt]

Standard Modulating Thermostat- Range................................................................................................................84° to 91°C [180° to 195°F]

Maximum Allowable Operating Temperature ................................................................................................................................100°C [212°F]

Minimum Recommended Operating Temperature ..........................................................................................................................70°C [158°F]

Minimum Recommended Pressure Cap ....................................................................................................................................103 kPa [15 psi]

Exhaust SystemMaximum Exhaust Back Pressure ....................................................................................................................................... 76 mm Hg [3 in Hg]

Specifications 24 Valve, 8.3 Liter EnginePage E-4 Section E - System Identification


Fuel SystemEngine Idle Speed ...................................................................................................................................................................... 850 to 950 rpm

Minimum Lift Pump Inlet Pressure at Rated (vacuum) ...................................................................................................... 102 mm Hg [4 in Hg]

Maximum Fuel Filter Outlet Pressure at Rated (vacuum)................................................................................................ 254 mm Hg [10 in Hg]

Minimum Fuel Filter Inlet Pressure during Cranking........................................................................................................ 508 mm Hg [20 in Hg]

Fuel Drain Line Maximum Pressure ................................................................................................................................ 254 mm Hg [10 in Hg]

Fuel Inlet Maximum Temperature ................................................................................................................................................... 71ºC [160ºF]

Engine Minimum Cranking Speed ......................................................................................................................................................... 150 rpm

Electrical SystemFor electrical specifications, refer to the Case 24 Valve, 8.3 Liter Engine Fuel Systems Troubleshooting and Repair Manual, Rac 7-88620.

24 Valve, 8.3 Liter Engine Engine ViewsSection E - System Identification Page E-5


Engine Views

Front View

1. Fan Pulley2. Top Dead Center Mark3. Front Gear Cover4. Vibration Damper5. Engine Oil Pan Drain Plug6. Automatic Belt Tensioner7. Water Inlet8. Water Pump9. Alternator10. Water Outlet11. Turbocharger Air Outlet12. Turbocharger Air Inlet13. Engine Rocker Housing Oil Fill

Engine Views 24 Valve, 8.3 Liter EnginePage E-6 Section E - System Identification


Rear View

1. Rear Engine Lifting Bracket 2. Turbocharger Exhaust Outlet 3. Clutch Mounting Holes 4. Flywheel Housing 5. Flywheel

24 Valve, 8.3 Liter Engine Engine ViewsSection E - System Identification Page E-7


Fuel Pump Side View

1. Engine Air Inlet2. Intake Manifold Pressure Sensor3. Intake Manifold Temperature Sensor 4. M10 (STOR) Fuel Pressure After Lift Pump 5. M10 (STOR) Fuel Pressure Before Lift Pump 6. Magnetic Pickup Location 3/4-16 UNF 7. Fuel Return Connection 8. Fuel Inlet Connection 9. Fuel Lift Pump 10. Starter 11. Engine Oil Pressure Sensor12. Fuel Filter/Water Separator13. Electronic Control Module (ECM)14. Dipstick Location 15. M10 (STOR) Oil Pressure Port 16. Engine Position Sensor (EPS) 17. Engine Speed Sensor (ESS)18. Engine Dataplate19. High Pressure Fuel Lines 20. CAPS Injection Pump 21. Intake Air Preheater

Engine Views 24 Valve, 8.3 Liter EnginePage E-8 Section E - System Identification


Exhaust Side View

1. 1/2 inch (NPTF) Coolant Taps2. Turbocharger Wastegate Actuator 3. Oil Fill4. Water Outlet5. Front Engine Lifting Bracket 6. Coolant Temperature Sensor 7. Provision for Coolant Heater8. Water Inlet9. Lubricating Oil Cooler 10. Engine Oil Pan Drain Plug11. Lubricating Oil Filter 12. Dipstick Location 13. Water Filter 14. Injector Drain Fuel Outlet

24 Valve, 8.3 Liter EngineSection TS - Troubleshooting Symptoms Page TS-a


Section TS - Troubleshooting Symptoms

Section Contents

Troubleshooting Procedures and Techniques ........................................................................................................................................... 1

Troubleshooting Symptoms Charts ............................................................................................................................................................. 1Communication Error Electronic Service Tool or Control Device ..................................................................................................... 2Coolant Loss External ...................................................................................................................................................................... 4Coolant Loss Internal ....................................................................................................................................................................... 5Coolant Temperature Above Normal Gradual Overheat .................................................................................................................. 6Coolant Temperature Above Normal Gradual Overheat .................................................................................................................. 7Coolant Temperature Above Normal Gradual Overheat .................................................................................................................. 8Coolant Temperature is Above Normal -- Sudden Overheat ........................................................................................................... 9Coolant Temperature is Below Normal .......................................................................................................................................... 11Coolant in the Lubricating Oil ......................................................................................................................................................... 12Crankcase Gases (Blowby) Excessive .......................................................................................................................................... 13Cranking Fuel Pressure is Low ...................................................................................................................................................... 14Engine Acceleration or Response Poor ......................................................................................................................................... 15Engine Decelerates Slowly ............................................................................................................................................................ 20Engine Difficult to Start or Will Not Start (Exhaust Smoke) ............................................................................................................ 21Engine Difficult to Start or Will Not Start (No Exhaust Smoke) ...................................................................................................... 26Engine Noise Excessive ................................................................................................................................................................. 30Engine Noise Excessive Combustion Knocks ................................................................................................................................ 33Engine Noise Excessive Connecting Rod ...................................................................................................................................... 34Engine Noise Excessive Main Bearing .......................................................................................................................................... 35Engine Noise Excessive Piston ...................................................................................................................................................... 36Engine Noise Excessive Turbocharger .......................................................................................................................................... 37Engine Power Output Low ............................................................................................................................................................. 38Engine Runs Rough at Idle ............................................................................................................................................................ 45Engine Runs Rough or Misfires ..................................................................................................................................................... 49Engine Shuts Off Unexpectedly or Dies During Deceleration ........................................................................................................ 53Engine Speed Surges at Low or High Idle ..................................................................................................................................... 55Engine Speed Surges Under Load or in Operating Range ............................................................................................................ 59Engine Speed Surges in PTO ........................................................................................................................................................ 64Engine Starts But Will Not Keep Running ...................................................................................................................................... 65Engine Vibration Excessive ............................................................................................................................................................ 67Engine Will Not Crank or Cranks Slowly (Electric Starter) ............................................................................................................. 69Engine Will Not Reach Rated Speed (RPM) .................................................................................................................................. 71Engine Will Not Shut Off ................................................................................................................................................................ 74Fault Code Warning Lamps Do Not Illuminate ............................................................................................................................... 75Fuel Consumption Excessive ......................................................................................................................................................... 76Fuel in Coolant ............................................................................................................................................................................... 80Fuel in the Lubricating Oil .............................................................................................................................................................. 81Intake Manifold Air Temperature Above Specification ................................................................................................................... 82Low Idle Adjust Switch Does Not Work .......................................................................................................................................... 84Intake Manifold Pressure (Boost) is Below Normal ........................................................................................................................ 85Lubricating Oil Consumption Excessive ......................................................................................................................................... 86Lubricating Oil Contaminated ......................................................................................................................................................... 88Lubricating Oil Pressure High ........................................................................................................................................................ 89Lubricating Oil Pressure Low ......................................................................................................................................................... 90Lubricating Oil Sludge in the Crankcase Excessive ....................................................................................................................... 92Lubricating Oil Temperature Above Specification .......................................................................................................................... 93

Section TS - Troubleshooting Symptoms 24 Valve, 8.3 Liter EnginePage TS-b Section TS - Troubleshooting Symptoms


Lubricating or Transmission Oil in the Coolant .............................................................................................................................. 94Smoke, White Excessive ............................................................................................................................................................... 95Smoke, Black Excessive ................................................................................................................................................................ 99Turbocharger Leaks Engine Oil or Fuel ....................................................................................................................................... 103

Engine Noise Diagnostic Procedures General Information ................................................................................................................... 104Main Bearing Noise ...................................................................................................................................................................... 104Connecting Rod Bearing Noise .................................................................................................................................................... 104Piston Noise ................................................................................................................................................................................. 104

24 Valve, 8.3 Liter Engine Troubleshooting Procedures and TechniquesSection TS - Troubleshooting Symptoms Page TS-1


Troubleshooting Procedures and TechniquesA thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved.

The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.

It is not possible to include all the solutions to problems that can occur; however, these charts are designed to stimulate a thought process that will lead to the cause and correction of the problem.

Follow these basic troubleshooting steps:

• Get all the facts concerning the complaint

• Analyze the problem thoroughly

• Relate the symptoms to the basic engine systems and components

• Consider any recent maintenance or repair action that can relate to the complaint

• Double-check before beginning any disassembly

• Solve the problem by using the symptom charts and doing the easiest things first

• Determine the cause of the problem and make a thorough repair

• After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected

Troubleshooting Symptoms ChartsUse the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row of blocks from top to bottom. Fol-low through the chart to identify the corrective action.

∆ WARNING ∆Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be performed by trained experi-enced technicians.

Communication Error Electronic Service Tool or Control Device 24 Valve, 8.3 Liter EnginePage TS-2 Section TS - Troubleshooting Symptoms


Communication Error Electronic Service Tool or Control Device

This is symptom tree T016

(Continued)

Cause Correction

Key switch is in the OFF position · · · · · · · · Turn on the key switch.

OK

Key switch circuit is malfunctioning · · · · · · · ·

Check the vehicle key switch circuit. Refer toProcedure 019-064 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Data bus cable is not connected correctly · · · · · · · · Check the cable connections. Refer to the electronicservice tool user's manual.

OK

Inline adapter (data bus adapter) is not connected to the battery voltage supply · · · · · · · ·

Check the power light on the inline adapter. If the lightis not illuminated, connect the battery voltage to theinline adapter. Refer to the appropriate electronicservice tool user's manual.

OK

Electronic service tool is addressing the wrong communication port · · · · · · · ·

Select System Menu/User Options and change thecommunication port setting. Refer to CommunicationMessages in the electronic service tool Help menuand the appropriate electronic service tool user'smanual.

OK

Verify that the electronic service tool is working and that the correct software or cartridge is being used · · · · · · · · Refer to the appropriate electronic service tool and

software or cartridge manuals.

OK

Fuse(s) malfunctioning · · · · · · · · Replace the fuse(s) in the interface harness.

OK

24 Valve, 8.3 Liter Engine Communication Error -- Electronic Service Tool or Control Device (Continued)Section TS - Troubleshooting Symptoms Page TS-3


Communication Error -- Electronic Service Tool or Control Device (Continued)

Cause Correction

Battery voltage supply to the electronic control (ECM) is low, interrupted, or open · · · · · · · ·

Check the battery connections. Refer to Procedure 019-087 in the Fuel Systems Troubleshooting and RepairManual for Case 24 Valve, 8.3 Liter Engines.

OK

Data bus circuit is malfunctioning · · · · · · · ·Check the data bus circuit. Refer to Procedure 019-028 in the Fuel Systems Troubleshooting and RepairManual for Case 24 Valve, 8.3 Liter Engines.

OK

Electronic fault codes active or high counts of inactive fault codes · · · · · · · · Refer to Section TF for fault code troubleshooting.

OK

Electronic Control Module (ECM) is not calibrated · · · · · · · · Calibrate the ECM.

OK

J1939 control devices are interfering with the engine controls · · · · · · · ·

Alternately disconnect all other J1939 control devicesfrom the data bus circuit until communications orfunctionality is restored. Refer to the vehicle servicemanual to locate and repair J1939 control devices.

OK

Electronic service tool COM PORT has been interrupted or is malfunctioning · · · · · · · · Refer to the appropriate electronic service tool and

personal computer user's manuals.

OK

Moisture in the wiring harness connectors · · · · · · · · Dry the connectors with an electronic connectorcleaner.

OK

J1939 data bus shield is not grounded correctly · · · · · · · ·Repair the electrical ground for the data bus shield.Refer to the vehicle wiring diagram and servicemanual.

OK

Electronic Control Module (ECM) is malfunctioning · · · · · · · ·Replace the ECM. Refer to Procedure 019-031 in theFuel Systems Troubleshooting and Repair Manual forCase 24 Valve, 8.3 Liter Engines.

Coolant Loss External 24 Valve, 8.3 Liter EnginePage TS-4 Section TS - Troubleshooting Symptoms


Coolant Loss External


Cause Correction

Coolant level is above specification · · · · · · · · Check the coolant level. Refer to the vehicle servicemanual.

OK

External coolant leak · · · · · · · ·

Visually inspect the engine for coolant leaking fromhoses, drain cocks, water manifold, jumper tubes,expansion and pipe plugs, fittings, radiator core, aircompressor and cylinder head gaskets, lubricating oilcooler, water pump seal, and vehicle mountedcomponents that have coolant flow. If necessary,pressure test the cooling system. Refer to Procedure008-018.

OK

Radiator cap is not correct, is malfunctioning, or has low pressure rating · · · · · · · · Check the radiator pressure cap. Refer to Procedure

008-047.

OK

Aftercooler is leaking (aftercooled engines only) · · · · · · · · Check the aftercooler and connections for leaks.

OK

Radiator hose is collapsed, restricted, or leaking · · · · · · · · Inspect the radiator hoses. Refer to Procedure 008-045.

OK

Coolant fill line is restricted or obstructed · · · · · · · · Check the coolant fill line for restrictions orobstructions.

OK

Vent lines or fill line are restricted, obstructed, or not routed correctly · · · · · · · ·

Check the vent lines and the fill line for correct routingand for restriction. Refer to the vehicle servicemanual.

OK

Engine is overheating · · · · · · · · Refer to the Coolant Temperature Above Normalsymptom trees.

24 Valve, 8.3 Liter Engine Coolant Loss InternalSection TS - Troubleshooting Symptoms Page TS-5


Coolant Loss Internal


Cause Correction

Lubricating oil cooler is leaking · · · · · · · · Check the lubricating oil cooler for coolant leaks. Referto Procedure 007-003.

OK

Cylinder block is cracked or porous · · · · · · · · Remove the oil pan. Pressure test the cooling systemto check for leaks. Refer to Procedure 001-027.

OK

Jacket water aftercooler is damaged or leaking · · · · · · · · Inspect the jacket water aftercooler. Refer to thevehicle service manual.

Coolant Temperature Above Normal Gradual Overheat 24 Valve, 8.3 Liter EnginePage TS-6 Section TS - Troubleshooting Symptoms


Coolant Temperature Above Normal Gradual Overheat

This is symptom tree T022.

(Continued)

Cause Correction

Charge air cooler (CAC) fins, radiator fins, or air conditioner condenser fins are damaged or obstructed with debris · · · · · · · ·

Inspect the CAC, air conditioner condenser, andradiator fins. Clean if necessary. Refer to Procedures008-042 and 010-027 and the vehicle service manual.

OK

Coolant level is below specification · · · · · · · ·Inspect the engine and radiator for external coolantleaks. Repair if necessary. Add coolant. Refer toProcedure 008-018.

OK

Coolant mixture of antifreeze and water is not correct · · · · · · · ·Verify the concentration of antifreeze in the coolant.Add antifreeze or water to correct the concentration.Refer to Section 8.

OK

Thermostat is not correct or is malfunctioning · · · · · · · · Check the thermostat for the correct part number andfor correct operation. Refer to Procedure 008-013.

OK


008-047.

OK

Fan shroud is damaged or missing, or the air recirculation baffles are damaged or missing · · · · · · · ·

Inspect the shroud and the recirculation baffles.Repair, replace, or install if necessary. Refer toProcedure 008-038 and the vehicle service manual.

OK

24 Valve, 8.3 Liter Engine Coolant Temperature Above Normal Gradual OverheatSection TS - Troubleshooting Symptoms Page TS-7



(Continued)

Cause Correction

Fan drive belt is broken · · · · · · · ·Check the fan drive belt. Replace the belt if necessary.Replace the belt if necessary. Refer to Procedure 008-002.

OK


OK


OK

Coolant temperature gauge is malfunctioning · · · · · · · · Test the temperature gauge. Repair or replace thegauge if necessary. Refer to Procedure 008-004.

OK

Intake manifold air temperature is above specification · · · · · · · · Refer to the Intake Manifold Air Temperature AboveSpecification symptom tree.

OK

Fan drive or fan controls are malfunctioning · · · · · · · · Check the fan drive and controls. Refer to Procedure008-027.

OK

Lubricating oil level is above or below specification · · · · · · · ·Check the oil level. Add or drain oil if necessary. Referto Procedure 007-025. Check the dipstick calibration.Refer to Procedure 007-009.

OK

Vent lines or fill line are restricted, obstructed, or not routed correctly · · · · · · · · Check the vent lines and the fill line for correct routing

and for restriction. Refer to the vehicle specifications.

OK

Coolant Temperature Above Normal Gradual Overheat 24 Valve, 8.3 Liter EnginePage TS-8 Section TS - Troubleshooting Symptoms



Cause Correction

Lubricating oil is contaminated with coolant or fuel · · · · · · · · Refer to the Lubricating Oil Contaminated symptomtree.

OK

Water pump is malfunctioning · · · · · · · ·Check the water pump using the diagnostic test inProcedure 008-020. Replace the water pump ifnecessary. Refer to Procedure 008-062.

OK

Radiator core is internally obstructed or damaged, or the check valve or J-tube is malfunctioning · · · · · · · · Inspect the radiator and clean if necessary.

OK

Torque converter is malfunctioning · · · · · · · · Check the torque converter. Refer to the vehicleservice manual.

OK

Vehicle cooling system is not adequate · · · · · · · ·Verify that the engine and vehicle cooling systems areusing the correct components. Refer to the vehiclespecifications.

OK

Engine is overfueled · · · · · · · · Check the engine fuel rate. Refer to Engine Testing -General Information in Section 14.

OK

Lubricating oil thermostat is malfunctioning · · · · · · · · Check the oil thermostat. Refer to Procedure 007-039.

OK

Cylinder head gasket is leaking · · · · · · · · Check the cylinder head gasket. Refer to Procedure002-004 or 002-021.

24 Valve, 8.3 Liter Engine Coolant Temperature is Above Normal -- Sudden OverheatSection TS - Troubleshooting Symptoms Page TS-9


Coolant Temperature is Above Normal -- Sudden Overheat


(Continued)

Cause Correction

Coolant level is below specification · · · · · · · ·Inspect the engine and radiator for external coolantleaks. Repair if necessary. Add coolant. Refer to thevehicle specifications.

OK

Electronic fault codes active or high counts of inactive fault codes · · · · · · · ·

Refer to Section TF in the Fuel SystemTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK

Fan drive belt is broken · · · · · · · · Check the fan drive belt. Replace the belt if necessary.Refer to Procedure 008-002.

OK

Coolant temperature gauge is malfunctioning · · · · · · · ·Test the temperature gauge. Repair or replace thegauge if necessary. Refer to Procedure 008-004 andthe vehicle service manual.

OK


008-047.

OK


OK


OK

Coolant Temperature is Above Normal -- Sudden Overheat (Continued) 24 Valve, 8.3 Liter EnginePage TS-10 Section TS - Troubleshooting Symptoms


Coolant Temperature is Above Normal -- Sudden Overheat (Continued)

Cause Correction

Water pump is malfunctioning · · · · · · · ·Check the water pump using the diagnostic test inProcedure 008-020. Replace the water pump ifnecessary. Refer to Procedure 008-062.

OK



OK

Cooling system component is malfunctioning · · · · · · · · Perform the Cooling System Diagnostics Test. Refer toProcedure 008-020.

OK


OK

Torque converter cooler or hydraulic oil cooler is malfunctioning · · · · · · · · Remove and inspect the cooler cores and o-rings.

Refer to the vehicle service manual.

OK

Vent lines or fill line are restricted, obstructed, or not routed correctly · · · · · · · · Check the vent lines and the fill line for correct routing

and for restriction. Refer to vehicle specifications.

24 Valve, 8.3 Liter Engine Coolant Temperature is Below NormalSection TS - Troubleshooting Symptoms Page TS-11


Coolant Temperature is Below Normal


Cause Correction

Coolant temperature gauge or sensor is malfunctioning · · · · · · · · Test the gauge and the sensor. Repair or replace ifnecessary.

OK


Refer to Section TF in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK


OK

Coolant flow through the radiator is not correct · · · · · · · · Check for correct coolant flow through the radiator.Refer to Procedure 008-042.

OK


Coolant in the Lubricating Oil 24 Valve, 8.3 Liter EnginePage TS-12 Section TS - Troubleshooting Symptoms


Coolant in the Lubricating Oil


Cause Correction

Lubricating oil cooler is malfunctioning · · · · · · · · Check the oil cooler. Refer to Procedure 007-003.

OK

Air compressor cylinder head is cracked or porous, or has a leaking gasket · · · · · · · · Inspect the air compressor cylinder head and gasket.

Refer to Procedure 007-003.

OK

Aftercooler is leaking (aftercooled engines only) · · · · · · · · Remove and pressure test the aftercooler. Refer toProcedure 010-027.

OK

Cylinder head core and expansion plugs leaking or misassembled · · · · · · · · Check cylinder head. Refer to Procedure 002-004

OK

Cylinder block is cracked or porous · · · · · · · · Inspect the cylinder block. Refer to Procedure 001-026.

OK

Cylinder liner is corroded or cracked · · · · · · · · Check the cylinder liners for corrosion or cracks. Referto Procedure 001-028.

24 Valve, 8.3 Liter Engine Crankcase Gases (Blowby) ExcessiveSection TS - Troubleshooting Symptoms Page TS-13


Crankcase Gases (Blowby) Excessive


Cause Correction

Cylinder head valve guides are excessively worn · · · · · · · · Check the valve guides for wear. Replace the cylinderhead if necessary. Refer to Procedure 002-004.

OK

Pistons or piston rings are worn, damaged, or not correct · · · · · · · ·Check the pistons for correct part numbers. Check thepistons and rings for wear and damage. Refer toProcedures 001-043 and 001-047.

OK

Turbocharger oil seal is leaking · · · · · · · · Check the turbocharger compressor and turbine seals.Refer to Procedure 010-040 or 010-049.

Cranking Fuel Pressure is Low 24 Valve, 8.3 Liter EnginePage TS-14 Section TS - Troubleshooting Symptoms


Cranking Fuel Pressure is Low


Cause Correction

Fuel level low in the tank · · · · · · · · Fill the supply tank.

OK

Fuel filter is plugged · · · · · · · · Measure before and after the fuel filter. Refer toProcedure 005-011.

OK

Fuel connections on the suction side of the pump are loose · · · · · · · · Tighten all fuel fittings and connections between thefuel tanks and fuel pump.

OK

Fuel suction stand pipe in the fuel tank is broken · · · · · · · · To check and repair the stand pipe, refer to the vehicleservice manual.

OK

Fuel lift pump is malfunctioning · · · · · · · ·Check the fuel lift pump for correct operation. Checkthe pump output pressure. Replace the fuel lift pump ifnecessary. Refer to Procedure 005-045.

24 Valve, 8.3 Liter Engine Engine Acceleration or Response PoorSection TS - Troubleshooting Symptoms Page TS-15


Engine Acceleration or Response Poor


(Continued)

Cause Correction

Engine duty cycle has changed · · · · · · · ·Verify the engine duty cycle with an electronic servicetool. Refer to the appropriate electronic service tooluser's manual.

OK

Operator technique is not correct · · · · · · · ·Explain the correct engine operation to the operator.Refer to the vehicle operation and maintenancemanual.

OK


OK

Fuel leak · · · · · · · ·

Check the fuel lines, fuel connections, and fuel filtersfor leaks. Refer to Procedure 006-024. Check thefuel lines to the supply tanks. Refer to vehicle servicemanual.

OK

Fuel inlet restriction · · · · · · · · Check for fuel inlet restriction. Refer to Procedure 006-020.

OK

Vehicle parasitics are excessive · · · · · · · ·

Check the vehicle brakes for dragging, transmissionmalfunction, cooling fan operation cycle time, andengine driven units. Refer to the vehicle servicemanual.

OK

Charge air cooler (CAC) is restricted or leaking · · · · · · · · Inspect the CAC for air restriction or leaks. Refer toProcedure 010-027.

OK

Clutch is malfunctioning or is not correct · · · · · · · ·Compare the drive train specifications to Caserecommendations. Check the clutch for correctoperation. Refer to the vehicle service manual.

OK

Engine Acceleration or Response Poor (Continued) 24 Valve, 8.3 Liter EnginePage TS-16 Section TS - Troubleshooting Symptoms


Engine Acceleration or Response Poor (Continued)

(Continued)

Cause Correction

Drive train is not correctly matched to the engine · · · · · · · · Check for correct gearing and drive train components.Refer to the vehicle specifications.

OK


Refer to Section TF in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK

Programmable parameters or selected features are not correct · · · · · · · ·

Check the programmable parameters and the selectedfeatures with an electronic service tool. Set theparameters and features again if necessary. Refer tothe appropriate electronic service tool Manual.

OK

Electronic Control Module (ECM) calibration is not correct · · · · · · · · Compare the calibration stored in the ECM with theengine rating. If necessary, calibrate the ECM.

OK

Accelerator pedal is restricted or malfunctioning · · · · · · · ·

Check the percent throttle reading on an electronicservice tool. Verify that it reads 100 percent with theaccelerator pedal depressed. Calibrate the acceleratorif possible. Replace the accelerator pedal if necessary.Refer to the vehicle service manual.

OK

Intake manifold pressure (boost) sensor or circuit is malfunctioning · · · · · · · ·

Check the boost sensor and circuit. Refer toProcedures 019-061 and 019-062 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

24 Valve, 8.3 Liter Engine Engine Acceleration or Response Poor (Continued)Section TS - Troubleshooting Symptoms Page TS-17



(Continued)

Cause Correction

Engine speed sensor (ESS) or circuit is malfunctioning · · · · · · · ·

Check the ESS for correct adjustment and for debrison the sensor. Check the ESS circuit. Refer toProcedure 019-042 and 019-106 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Ambient air pressure sensor is malfunctioning (if equipped) · · · · · · · ·

Check the ambient air pressure sensor. Refer toProcedure 019-004 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Air in the fuel system · · · · · · · · Check for air in the fuel system. Refer to Procedure006-003.

OK

Fuel supply line restriction between the fuel pump and the injectors · · · · · · · ·

Check the fuel supply line from the fuel pump to thecylinder head for sharp bends which can causerestrictions.

OK

Fuel connector is leaking fuel · · · · · · · ·

Perform the Automated Cylinder Performance Test toisolate the cylinder with the leaking fuel connector.Inspect the fuel connector and injector for nicks ordamage that may cause fuel leaks. Refer to Procedure006-026, or 014-008.

OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedures006-026 or 014-008.

OK

Air intake or exhaust leaks · · · · · · · · Inspect the air intake and exhaust systems for airleaks. Refer to Procedure 010-024.

OK

Engine Acceleration or Response Poor (Continued) 24 Valve, 8.3 Liter EnginePage TS-18 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction

Air intake system restriction is above specification · · · · · · · ·Check the air intake system for restriction. Clean orreplace the air filter and inlet piping as necessary.Refer to Procedure 010-031.

OK

Exhaust system restriction is above specification · · · · · · · · Check the exhaust system for restrictions. Refer toProcedure 011-009.

OK



OK

Turbocharger is not correct · · · · · · · ·Check the turbocharger part number and compare it tothe Vehicle Parts List. Replace the turbocharger ifnecessary. Refer to Procedure 010-033.

OK

Turbocharger wastegate is malfunctioning (if equipped) · · · · · · · · Check the wastegate for correct operation. Refer toProcedure 010-050.

OK

Turbocharger wheel clearance is out of specification · · · · · · · ·

Check the radial bearing clearance and axialclearance. Inspect the turbocharger. Repair or replacethe turbocharger if necessary. Refer to Procedures010-038 and 010-047.

OK

Turbocharger is malfunctioning · · · · · · · ·

Monitor the turbocharger boost pressure with anelectronic service tool. Refer to the appropriateelectronic service tool user's manual. Replace theturbocharger if necessary. Refer to Procedure 010-033or 010-037.

OK

24 Valve, 8.3 Liter Engine Engine Acceleration or Response Poor (Continued)Section TS - Troubleshooting Symptoms Page TS-19



Cause Correction

Fuel inlet temperature to pump is above specification · · · · · · · ·Fill the fuel tank, turn off or bypass the fuel heaters,and check the fuel cooler. Refer to the vehicle servicemanual.

OK

Fuel grade is not correct for the application or the fuel quality is poor · · · · · · · ·

Operate the engine from a tank of good fuel. Refer toFuel Recommendations and Specifications in thevehicle operation and maintenance manual.

OK

Overhead adjustments are not correct · · · · · · · · Measure and adjust the overhead settings. Refer toProcedure 003-004.

OK

Injectors are not correct · · · · · · · ·Remove the injectors and compare the part numbersto the Vehicle Parts List. Replace the injectors ifnecessary. Refer to Procedure 006-026.

OK

Fuel injection pump is malfunctioning · · · · · · · · Check CAPS gear pump output pressure. Refer toProcedure 005-025.

OK

Fuel injection pump is malfunctioning · · · · · · · · Check CAPS accumulator pressure. Refer toProcedure 005-077.

OK

Fuel injection pump is malfunctioning · · · · · · · · Remove and inspect the rate shape snubber valve.Refer to Procedure 006-056.

OK

Fuel injection pump is malfunctioning · · · · · · · · Remove and inspect the distributor snubber valve.Refer to Procedure 005-020.

OK

Fuel injection pump is malfunctioning · · · · · · · · Replace the fuel injection pump. Refer to Procedure005-012 or 005-014.

OK

Internal engine damage · · · · · · · · Analyze the oil and inspect the filters to locate an areaof probable damage. Refer to Procedure 007-002.

Engine Decelerates Slowly 24 Valve, 8.3 Liter EnginePage TS-20 Section TS - Troubleshooting Symptoms


Engine Decelerates Slowly


Cause Correction

Fuel drain line restriction · · · · · · · ·Check the fuel drain lines for restriction. Clear orreplace the fuel lines, check valves, or tank vents asnecessary. Refer to Procedure 006-012.

OK



OK


OK



OK


OK


24 Valve, 8.3 Liter Engine Engine Difficult to Start or Will Not Start (Exhaust Smoke)Section TS - Troubleshooting Symptoms Page TS-21


Engine Difficult to Start or Will Not Start (Exhaust Smoke)


(Continued)

Cause Correction


OK



OK

Battery voltage is low · · · · · · · ·

Check the batteries and the unswitched battery supplycircuit. Refer to Procedure 013-009, Procedure 019-087 in the Fuel Systems Troubleshooting and RepairManual for Case 24 Valve, 8.3 Liter Engines, or thevehicle service manual.

OK


OK

Starting aid is necessary for cold weather or starting aid is malfunctioning · · · · · · · ·

Check for correct operation of the starting aid. Refer tothe manufacturer's instructions. Refer to Cold WeatherStarting Aids in the vehicle operation and maintenancemanual.

OK

Fuel filter is plugged · · · · · · · · Measure the fuel pressure before and after the fuelfilter. Refer to Procedure 005-011.

OK

Engine block heater is malfunctioning (if equipped) · · · · · · · ·Check the electrical sources and wiring to the cylinderblock heater. Replace the block heater if necessary.Refer to the vehicle service manual.

OK

Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued) 24 Valve, 8.3 Liter EnginePage TS-22 Section TS - Troubleshooting Symptoms


Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)

(Continued)

Cause Correction

Fuel heater is malfunctioning (if equipped) · · · · · · · · Check the fuel heater and replace if necessary. Referto the manufacturer's instructions.

OK

Engine cranking speed is too low · · · · · · · ·

Check the engine cranking speed with a hand heldtachometer or electronic service tool. If the crankingspeed is lower than 150 rpm, refer to the Engine WillNot Crank or Cranks Slowly symptom tree.

OK



OK

Fuel leak · · · · · · · ·


OK


OK

Injector shim thickness is not correct · · · · · · · · Remove the injectors and verify the injector shimthickness. Refer to Procedure 006-026.

OK

24 Valve, 8.3 Liter Engine Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)Section TS - Troubleshooting Symptoms Page TS-23



(Continued)

Cause Correction


OK



OK



OK


OK


OK


OK



OK

Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued) 24 Valve, 8.3 Liter EnginePage TS-24 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction


OK



OK

Static injection timing is not correct · · · · · · · · Check the static injection timing. Refer to Procedure006-025 or 005-037.

OK


OK


OK

Fuel injection pump is malfunctioning · · · · · · · · Perform ICV solenoid click test. Refer to Procedure005-078.

OK

Fuel injection pump is malfunctioning · · · · · · · · Perform CAPS plunger cut out test. Refer to Procedure005-079.

OK

Fuel injection pump is malfunctioning · · · · · · · · Check for seized distributor rotor. Refer to Procedure005-072.

OK

24 Valve, 8.3 Liter Engine Engine Difficult to Start or Will Not Start (Exhaust Smoke) (Continued)Section TS - Troubleshooting Symptoms Page TS-25



Cause Correction

Fuel injection pump is malfunctioning · · · · · · · · Replace the fuel injection pump. Refer to Procedure005-012 or 005-014.

OK

Camshaft gear tonewheel loose · · · · · · · · Check the camshaft tonewheel for tightness. Refer toProcedure 001-008.

OK


Engine Difficult to Start or Will Not Start (No Exhaust Smoke) 24 Valve, 8.3 Liter EnginePage TS-26 Section TS - Troubleshooting Symptoms


Engine Difficult to Start or Will Not Start (No Exhaust Smoke)


(Continued)

Cause Correction


OK


OK


Check the batteries and the unswitched battery supplycircuit. Refer to Procedure 019-087 in the FuelSystems Troubleshooting and Repair Manual for Case24 Valve, 8.3 Liter Engines and the vehicle servicemanual.

OK



OK


OK

Electronic Control Module (ECM) is not calibrated or has incorrect calibration · · · · · · · ·

Compare the calibration stored in the ECM with theengine rating and the Vehicle Parts List. If necessary,calibrate the ECM.

OK



OK

24 Valve, 8.3 Liter Engine Engine Difficult to Start or Will Not Start (No Exhaust Smoke) (Continued)Section TS - Troubleshooting Symptoms Page TS-27


Engine Difficult to Start or Will Not Start (No Exhaust Smoke) (Continued)

(Continued)

Cause Correction

Vehicle engine protection system is malfunctioning · · · · · · · · Isolate the engine protection system. Follow thevehicle service manual to check for a malfunction.

OK


OK

Moisture in the wiring harness connectors · · · · · · · · Dry the connectors with an electronic contact cleaner.

OK



OK


OK


OK


OK


OK

Engine Difficult to Start or Will Not Start (No Exhaust Smoke) (Continued) 24 Valve, 8.3 Liter EnginePage TS-28 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction


OK


OK

Fuel injection pump is malfunctioning · · · · · · · · Perform CAPS plunger cut out test. Refer to Procedure005-079.

OK


OK

Fuel injection pump is malfunctioning · · · · · · · · Check pump to engine timing. Refer to Procedure 005-037.

OK

Fuel injection pump is malfunctioning · · · · · · · · Check the CAPS coupling for wear or failure. Refer toProcedure 005-072.

OK

Fuel injection pump is malfunctioning · · · · · · · · Replace the fuel injection pump. Refer to Procedure005-012 or 005-014 or 005-016.

OK


OK

24 Valve, 8.3 Liter Engine Engine Difficult to Start or Will Not Start (No Exhaust Smoke) (Continued)Section TS - Troubleshooting Symptoms Page TS-29



Cause Correction

Electronic Control Module (ECM) is locked up · · · · · · · · Disconnect the battery cables for 30 seconds. Connectthe battery cables and start the engine.

OK


OK


Engine Noise Excessive 24 Valve, 8.3 Liter EnginePage TS-30 Section TS - Troubleshooting Symptoms


Engine Noise Excessive

This is symptom tree T047.NOTE: When troubleshooting engine noise complaints, make sure the engine accessories (air compressor, fan clutch, freon compressor, or hydraulic pump) are not the cause of the noise. refer to Engine Noise Diagnostic Procedures - General Information at the end of Section TS before using this symptom tree.

(Continued)

Cause Correction

Fan drive belt is loose · · · · · · · · Check the belt tension and tighten if necessary.

OK

Fan is loose, damaged, or not balanced · · · · · · · · Check the fan. Refer to Procedure 008-040.

OK

Air intake or exhaust leaks · · · · · · · · Inspect the air intake and exhaust systems for airleaks. Refer to Procedure 010-024.

OK

Air intake or exhaust piping is contacting the chassis or cab · · · · · · · · Inspect the air piping, chassis, and cab for contactpoints.

OK


OK

Lubricating oil is thin or diluted · · · · · · · ·Refer to Lubricating Oil System General Information inSection 7. Refer to the Lubricating Oil Contaminatedsymptom tree.

OK

Lubricating oil pressure is below specification · · · · · · · ·Check the oil pressure. Refer to Procedure 007-052. Ifthe pressure is low, refer to the Lubricating OilPressure Low symptom tree.

OK

24 Valve, 8.3 Liter Engine Engine Noise Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-31


Engine Noise Excessive (Continued)

(Continued)

Cause Correction

Vibration damper is damaged · · · · · · · · Check the vibration damper. Refer to Procedure 001-051 or 001-052.

OK

Accessory drive is worn (axial end play is out of specification) · · · · · · · ·Check the accessory drive axial end play. Visuallyinspect the shaft for wear. Refer to Procedure 009-016.

OK

Coolant temperature is above specification · · · · · · · ·Refer to the Coolant Temperature is Above Normal -Sudden Overheat or the Coolant Temperature isAbove Normal - Gradual Overheat symptom tree.

OK

Drive train noise is excessive · · · · · · · · Disconnect the drive train. Check for engine noise.Refer to the vehicle service manual.

OK

Engine mounts are worn, damaged, or not correct · · · · · · · · Check the engine mounts. Refer to the vehicle servicemanual and Procedure 016-003.

OK


OK

Overhead components are damaged · · · · · · · ·Inspect the rocker levers, rocker shafts, and valves fordamage or excessive wear. Refer to Procedure 003-008.

OK

Engine Noise Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-32 Section TS - Troubleshooting Symptoms


Engine Noise Excessive (Continued)

Cause Correction

Injector is malfunctioning · · · · · · · ·Perform the single cylinder cut out test. Replace theinjectors as necessary. Refer to Procedure 006-026 or014-008.

OK

Flywheel or flexplate capscrews are loose or broken · · · · · · · · Check the flywheel or flexplate and the mountingcapscrews. Refer to Procedure 016-005.

OK

Torque converter is loose · · · · · · · · Check the torque converter. Refer to the vehicleservice manual.

OK

Main bearing or connecting rod bearing noise · · · · · · · · Refer to the Engine Noise Excessive - Main Bearingsymptom tree.

OK

Piston or piston rings are worn or damaged · · · · · · · ·

Check for air intake system leaks. Refer to Procedure010-024. Check the pistons and piston rings for wearor damage. Refer to Procedures 001-043 and 001-047.

OK

Turbocharger noise · · · · · · · · Refer to the Engine Noise Excessive - Turbochargersymptom tree.

OK

Combustion noise excessive · · · · · · · · Refer to Engine Noise Excessive (combustion knock)symptom tree.

24 Valve, 8.3 Liter Engine Engine Noise Excessive Combustion KnocksSection TS - Troubleshooting Symptoms Page TS-33


Engine Noise Excessive Combustion Knocks

This is symptom tree T048NOTE: Refer to Engine Noise Diagnostic Procedures - General Information at the end of Section TS before using this symptom tree.

Cause Correction

Ether starting aid is malfunctioning · · · · · · · · Repair or replace the ether starting aids. Refer to themanufacturer's instructions.

OK


Operate the engine from a tank of good fuel. Refer toFuel Recommendations and Specifications in thevehicle service manual.

OK

Air in the fuel system · · · · · · · · Check for air in the fuel system. Bleed air from thesystem. Refer to Procedure 006-003.

OK

Coolant temperature is above specification · · · · · · · · Check the coolant level. Refer to Procedure 008-018.

OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedure006-026 or 014-008.

OK


Engine Noise Excessive Connecting Rod 24 Valve, 8.3 Liter EnginePage TS-34 Section TS - Troubleshooting Symptoms


Engine Noise Excessive Connecting Rod

This is symptom tree T049.NOTE: Refer to Engine Noise Diagnostic Procedures - General Information at the end of Section TS before using this symptom tree.

Cause Correction

Lubricating oil level is below specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andthe oil pan capacity. Fill the system to the specifiedlevel. Refer to Procedures 007-009 and 007-025.

OK


OK


OK

Crankshaft journals are damaged or out-of-round · · · · · · · · Inspect the crankshaft journals. Refer to Procedure001-016.

OK

Connecting rod is bent or out of alignment · · · · · · · · Remove and inspect the connecting rods. Refer toProcedure 001-014.

OK

Connecting rod capscrews are loose or not tightened correctly · · · · · · · · Check the torque on the connecting rod capscrews.

Refer to Procedure 001-014.

OK

Connecting rod bearings are damaged or worn, are not assembled correctly, or are the wrong bearings · · · · · · · · Inspect the connecting rod bearings. Refer to

Procedure 001-005.

24 Valve, 8.3 Liter Engine Engine Noise Excessive Main BearingSection TS - Troubleshooting Symptoms Page TS-35


Engine Noise Excessive Main Bearing


Cause Correction


OK

Lubricating oil level is below specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andthe oil pan capacity. Fill the system to the specifiedlevel. Refer to Procedures 007-009 and 007-025.

OK


OK

Main bearing capscrews are loose, worn, or not tightened correctly · · · · · · · ·

Check the torque on the main bearing capscrews.Inspect the capscrews for wear. Refer to Procedure001-006.

OK

Main bearings are damaged or worn, or the wrong bearings are installed · · · · · · · ·

Inspect the main bearings for damage, excessivewear, and the correct part number. Refer to Procedure001-006.

OK

Crankshaft journals are damaged or out-of-round · · · · · · · · Inspect the crankshaft journals. Refer to Procedure001-016.

Engine Noise Excessive Piston 24 Valve, 8.3 Liter EnginePage TS-36 Section TS - Troubleshooting Symptoms


Engine Noise Excessive Piston


Cause Correction


Operate the engine from a tank of good fuel. Refer toFuel Recommendations and Specifications in thevehicle users manual.

OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedure006-026.

OK


OK

Connecting rod is bent or out of alignment · · · · · · · · Remove and inspect the connecting rods. Refer toProcedure 001-014.

OK



OK

Piston pin or bushing is loose, worn or not installed correctly · · · · · · · ·Remove the pistons and inspect the piston pin andbushing for damage, wear, and correct installation.Refer to Procedure 001-043.

24 Valve, 8.3 Liter Engine Engine Noise Excessive TurbochargerSection TS - Troubleshooting Symptoms Page TS-37


Engine Noise Excessive Turbocharger

This is symptom Tree T052.NOTE: Refer to Engine Noise Diagnostic Procedures - General Information at the end of Section TS before using this symptom tree.

Cause Correction


OK

Air intake or exhaust piping is contacting the chassis or cab · · · · · · · · Inspect the air piping, chassis, and cab for contactpoints.

OK


OK

Turbocharger is not correct · · · · · · · ·Check the turbocharger part number. Replace theturbocharger if necessary. Refer to Procedure 010-033.

OK

Turbocharger is worn or damaged · · · · · · · ·Check the turbocharger for damage. Measure theturbine and compressor wheel clearances. Refer toProcedure 010-038.

Engine Power Output Low 24 Valve, 8.3 Liter EnginePage TS-38 Section TS - Troubleshooting Symptoms


Engine Power Output Low


(Continued)

Cause Correction



OK

Engine protection fault code(s) resulted in power and engine speed derate · · · · · · · ·

View the fault codes and the engine protection datawith an electronic service tool. Refer to theappropriate electronic service tool user's manual. Refer to the corresponding fault code in Section TF in theFuel Systems Troubleshooting and Repair Manual forCase 24 valve, 8.3 Liter Engines.

OK


OK


OK

Fuel leak · · · · · · · ·


OK

Fuel lift pump is malfunctioning · · · · · · · ·Check the fuel lift pump for correct operation. Checkthe pump output pressure. Replace the fuel lift pump ifnecessary. Refer to Procedure 005-045

OK

24 Valve, 8.3 Liter Engine Engine Power Output Low (Continued)Section TS - Troubleshooting Symptoms Page TS-39


Engine Power Output Low (Continued)

(Continued)

Cause Correction


OK

Engine is operating above recommended altitude · · · · · · · ·Engine power decreases above recommendedaltitude. Refer to the Engine Data Sheet forspecifications.

OK


OK


Check the programmable parameters and the selectedfeatures with an electronic service tool. Set theparameters and features again if necessary. Refer tothe appropriate electronic service tool user's manual.

OK

Electronic Control Module (ECM) calibration is not correct · · · · · · · ·Compare the calibration stored in the ECM with theengine rating and the Vehicle Parts List. If necessary,calibrate the ECM.

OK



OK



OK

Engine Power Output Low (Continued) 24 Valve, 8.3 Liter EnginePage TS-40 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction


OK

Air intake or exhaust leaks · · · · · · · · Visually inspect the air intake and exhaust systems forair leaks. Refer to Procedure 010-024.

OK


Check the boost sensor and circuit. Refer toProcedures 019-061 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 valve,8.3 Liter Engines.

OK

Vehicle speed sensor (VSS) or circuit is malfunctioning · · · · · · · ·

Use an electronic service tool to monitor the vehiclespeed while the vehicle is not moving. Refer to theappropriate electronic service tool user's manual. If themonitor shows speed, check the sensor and circuit.Refer to Procedures 019-090, 019-091, and 019-093 inthe Fuel Systems Troubleshooting and Repair Manualfor Case 24 valve, 8.3 Liter Engines.

OK

Tachometer or speedometer is not calibrated or is malfunctioning · · · · · · · ·

Compare the vehicle tachometer and speedometerreadings with an electronic service tool reading.Check the calibration values for the flywheel teeth, rearaxle ratio, and tire revolutions. Adjust the values ifnecessary. Refer to the appropriate electronic servicetool user's manual. Calibrate or replace the tachometeror speedometer as necessary. Refer to the vehicleservice manual.

OK


OK




(Continued)

Cause Correction

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedures006-005, 006-026, or 014-008.

OK


OK



OK


OK



OK


OK




(Continued)

Cause Correction



OK

Turbocharger is not correct · · · · · · · ·Check the turbocharger part number and compare it tothe Vehicle Parts List. Replace the turbocharger ifnecessary. Refer to Procedure 010-033 or 010-037.

OK

Intake manifold air temperature is above specification · · · · · · · · Refer to the Intake Manifold Air Temperature AboveSpecification symptom tree.

OK


OK



OK


OK


OK




(Continued)

Cause Correction

Lubricating oil level is above specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andoil pan capacity. Fill the system to the specified level.Refer to the vehicle specifications.

OK


OK


OK


OK

Fuel injection pump is malfunctioning · · · · · · · · Perform a cylinder performance test. Refer toProcedure 014-008.

OK


OK


OK


OK




Cause Correction


OK


OK

Fuel injection pump is malfunctioning · · · · · · · ·Replace the CAPS sensor. Refer to Procedure 019-164 in the Fuel Systems Troubleshooting and RepairManual for Case 24 valve, 8.3 Liter Engines.

OK


OK


OK


24 Valve, 8.3 Liter Engine Engine Runs Rough at IdleSection TS - Troubleshooting Symptoms Page TS-45


Engine Runs Rough at Idle


(Continued)

Cause Correction

Engine is cold · · · · · · · ·

Allow the engine to warm to operating temperature. Ifthe engine will not reach operating temperature, referto the Coolant Temperature Below Normal symptomtree.

OK



OK



OK

Engine idle speed is set too low (electronic controlled fuel systems) · · · · · · · ·

Verify the correct idle speed setting. Increase the idlespeed with the idle increment switch or an electronicservice tool.

OK


OK


OK


OK

Engine Runs Rough at Idle (Continued) 24 Valve, 8.3 Liter EnginePage TS-46 Section TS - Troubleshooting Symptoms


Engine Runs Rough at Idle (Continued)

(Continued)

Cause Correction


OK


OK


OK


Perform the Automated Cylinder Performance Test toisolate the cylinder with the leaking fuel connector.Inspect the fuel connector and injector for nicks ordamage that may cause fuel leaks. Refer to Procedure006-005, 006-026, or 014-008.

OK



OK

Engine mounts are worn, damaged, or not correct · · · · · · · · Check the engine mounts. Refer to the service manualand Procedure 016-003 or 016-010.

OK


OK

24 Valve, 8.3 Liter Engine Engine Runs Rough at Idle (Continued)Section TS - Troubleshooting Symptoms Page TS-47



(Continued)

Cause Correction


Check the ESS for correct adjustment and for debrison the sensor. Check the ESS circuit. Refer toProcedure 019-042 and 019-106 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK

Idling with excessive load · · · · · · · ·Use the PTO feature for loaded conditions at lowengine speeds. Refer to the vehicle operation andmaintenance manual.

OK



OK


OK


OK


OK


OK


OK

Engine Runs Rough at Idle (Continued) 24 Valve, 8.3 Liter EnginePage TS-48 Section TS - Troubleshooting Symptoms



Cause Correction


OK


OK


OK


OK


24 Valve, 8.3 Liter Engine Engine Runs Rough or MisfiresSection TS - Troubleshooting Symptoms Page TS-49


Engine Runs Rough or Misfires


(Continued)

Cause Correction



OK



OK



OK


OK


OK


OK


OK

Engine Runs Rough or Misfires (Continued) 24 Valve, 8.3 Liter EnginePage TS-50 Section TS - Troubleshooting Symptoms


Engine Runs Rough or Misfires (Continued)

(Continued)

Cause Correction


OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedures006-026.

OK


Perform the Automated Cylinder Performance Test toisolate the cylinder with the leaking fuel connector.Inspect the fuel connector and injector for nicks ordamage that may cause fuel leaks. Refer to Procedure006-026.

OK



OK

Engine mounts are worn, damaged, or not correct · · · · · · · · Check the engine mounts.

OK


OK



OK

24 Valve, 8.3 Liter Engine Engine Runs Rough or Misfires (Continued)Section TS - Troubleshooting Symptoms Page TS-51



(Continued)

Cause Correction



OK


OK


OK


OK


OK


OK


OK

Engine Runs Rough or Misfires (Continued) 24 Valve, 8.3 Liter EnginePage TS-52 Section TS - Troubleshooting Symptoms



Cause Correction

Fuel injection pump is malfunctioning · · · · · · · · Check pump to engine timing.

OK


OK


OK


24 Valve, 8.3 Liter Engine Engine Shuts Off Unexpectedly or Dies During DecelerationSection TS - Troubleshooting Symptoms Page TS-53


Engine Shuts Off Unexpectedly or Dies During Deceleration


(Continued)

Cause Condition

If engine will not restart · · · · · · · · Refer to the Engine Difficult to Start or Will Not Startsymptom tree.

OK


OK



OK

Engine protection fault code(s) resulted in power and engine speed derate · · · · · · · ·

View the fault codes and the engine protection datawith an electronic service tool. Refer to theappropriate electronic service tool user's manual. Refer to the corresponding fault code in Section TF in theFuel Systems Troubleshooting and Repair Manual forCase 24 Valve, 8.3 Liter Engines.

OK

Idle shutdown or PTO shutdown features are activated · · · · · · · ·Check the time limit on idle and PTO shutdown with anelectronic service tool. Refer to the appropriateelectronic service tool user's manual.

OK



OK


OK

Engine protection system is malfunctioning · · · · · · · · Isolate the engine protection system. Follow thevehicle service manual to check for a malfunction.

OK

Engine Shuts Off Unexpectedly or Dies During Deceleration (Continued) 24 Valve, 8.3 Liter EnginePage TS-54 Section TS - Troubleshooting Symptoms


Engine Shuts Off Unexpectedly or Dies During Deceleration (Continued)

Cause Condition



OK


OK


OK


OK


OK


24 Valve, 8.3 Liter Engine Engine Speed Surges at Low or High IdleSection TS - Troubleshooting Symptoms Page TS-55


Engine Speed Surges at Low or High Idle


(Continued)

Cause Correction


OK



OK

Electronic Control Module (ECM) calibration is outdated · · · · · · · ·Compare the calibration stored in the ECM with themost recent calibration version available. If necessary,calibrate the ECM.

OK


OK


Alternately disconnect all other J1939 control devicesfrom the data bus circuit until communications orfunctionality is restored. Refer to the service manual tolocate and repair J1939 control devices.

OK



OK



OK

Engine Speed Surges at Low or High Idle (Continued) 24 Valve, 8.3 Liter EnginePage TS-56 Section TS - Troubleshooting Symptoms


Engine Speed Surges at Low or High Idle (Continued)

(Continued)

Cause Correction


Check the ESS for correct adjustment and for debrison the sensor. Check the ESS circuit. Refer toProcedure 019-042 and 019-106 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


Check the vehicle speed sensor and circuit. Refer toProcedures 019-090 and 019-091in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


OK


OK


OK


OK


OK

24 Valve, 8.3 Liter Engine Engine Speed Surges at Low or High Idle (Continued)Section TS - Troubleshooting Symptoms Page TS-57



(Continued)

Cause Correction


OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedures006-026.

OK


Perform the Automated Cylinder Performance Test toisolate the cylinder with the leaking fuel connector.Inspect the fuel connector and injector for nicks ordamage that may cause fuel leaks. Refer to Procedure006-026.

OK

Idling with excessive load · · · · · · · ·Use the PTO feature for loaded conditions at lowengine speeds. Refer to the vehicle operation andmaintenance manual.

OK



OK

Vibration damper is damaged · · · · · · · · Check the vibration damper. Refer to Procedure 001-052.

OK


OK

Engine Speed Surges at Low or High Idle (Continued) 24 Valve, 8.3 Liter EnginePage TS-58 Section TS - Troubleshooting Symptoms



Cause Correction


OK



OK


OK


OK


OK


OK


24 Valve, 8.3 Liter Engine Engine Speed Surges Under Load or in Operating RangeSection TS - Troubleshooting Symptoms Page TS-59


Engine Speed Surges Under Load or in Operating Range


(Continued)

Cause Correction


OK


Refer to Section TF in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting for faultcode troubleshooting.

OK


OK


OK


OK



OK



OK

Engine Speed Surges Under Load or in Operating Range (Continued) 24 Valve, 8.3 Liter EnginePage TS-60 Section TS - Troubleshooting Symptoms


Engine Speed Surges Under Load or in Operating Range (Continued)

(Continued)

Cause Correction


Check the ESS for correct adjustment and for debrison the sensor. Check the ESS circuit. Refer toProcedure 019-042 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


Check the vehicle speed sensor and circuit. Refer toProcedures 019-090 and 019-091 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


OK


OK


OK


OK


OK

24 Valve, 8.3 Liter Engine Engine Speed Surges Under Load or in Operating Range (Continued)Section TS - Troubleshooting Symptoms Page TS-61



(Continued)

Cause Correction


OK


OK



OK



OK


OK


OK

Engine Speed Surges Under Load or in Operating Range (Continued) 24 Valve, 8.3 Liter EnginePage TS-62 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction



OK


OK


OK



OK


OK


OK


OK

24 Valve, 8.3 Liter Engine Engine Speed Surges Under Load or in Operating Range (Continued)Section TS - Troubleshooting Symptoms Page TS-63



Cause Correction


OK


Engine Speed Surges in PTO 24 Valve, 8.3 Liter EnginePage TS-64 Section TS - Troubleshooting Symptoms


Engine Speed Surges in PTO


Cause Correction

Engine speed also surges at idle · · · · · · · ·

Refer to the Engine Speed Surges at Low or High Idlesymptom tree in the Fuel Systems Troubleshootingand Repair Manual for Case 24 Valve, 8.3 LiterEngines for fault code troubleshooting.

OK

Engine speed surges while in the normal operating range and not in PTO · · · · · · · ·

Refer to the Engine Speed Surges Under Load or inOperating Range symptom tree in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK

Electronic fault codes active or high counts of inactive fault codes


OK


OK


OK


OK


Check the vehicle speed sensor and circuit. Refer toProcedures 019-090 and 019-091 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


24 Valve, 8.3 Liter Engine Engine Starts But Will Not Keep RunningSection TS - Troubleshooting Symptoms Page TS-65


Engine Starts But Will Not Keep Running


(Continued)

Cause Correction


OK

Battery voltage supply to the electronic control (ECM) is low, interrupted, or open · · · · · · · · Check the battery connections. Refer to Procedure 019-

087. Refer to Procedure 013-009.

OK

Electronic fault codes active or high counts or inactive fault codes · · · · · · · ·


OK


Check the vehicle key switch circuit. Refer toProcedure 019-064 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines for fault code troubleshooting.

OK


OK



OK

Fuel leak · · · · · · · ·

Check the fuel lines, fuel connections, and fuel filtersfor leaks. Refer to Procedure 006-024. Check the fuellines to the supply tanks. Refer to the vehicle servicemanual.

OK

Engine Starts But Will Not Keep Running 24 Valve, 8.3 Liter EnginePage TS-66 Section TS - Troubleshooting Symptoms


Engine Starts But Will Not Keep Running

Cause Correction

Fuel filter or fuel suction line is restricted · · · · · · · · Replace the fuel filter. Refer to Procedure 005-015.Check the fuel suction line for restriction.

OK


OK


OK


OK


OK



24 Valve, 8.3 Liter Engine Engine Vibration ExcessiveSection TS - Troubleshooting Symptoms Page TS-67


Engine Vibration Excessive


(Continued)

Cause Correction

If engine is misfiring · · · · · · · · Refer to the Engine Runs Rough or Misfires symptomtree

OK

Belt driven accessories are malfunctioning · · · · · · · ·Check the fan hub, alternator, freon compressor, andhydraulic pump for interference. Isolate belt drivenaccessories and check for vibration.

OK



OK

Engine mounts are worn, damaged, or not correct · · · · · · · · Check the engine mounts. Refer to the vehicle servicemanual and Procedure 016-003.

OK

Fan is loose, damaged, or not balanced · · · · · · · · Check the fan. Refer to Procedure 008-040.

OK

Drive train components are malfunctioning or are not correct · · · · · · · ·

Compare the drive train components to the engine andequipment specifications. Isolate the drive traincomponents and check for vibrations. Refer to thevehicle specifications.

OK

Flywheel housing is not aligned correctly · · · · · · · · Check the flywheel housing alignment.

OK

Flywheel or flexplate capscrews are loose or broken · · · · · · · · Check the flywheel or flexplate and the mountingcapscrews.

OK

Engine Vibration Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-68 Section TS - Troubleshooting Symptoms


Engine Vibration Excessive (Continued)

Cause Correction

Gear driven accessories are malfunctioning · · · · · · · · Check the hydraulic pump and air compressor. Isolategear driven accessories and check for vibration.

OK

Power Take-Off (PTO) is damaged · · · · · · · · Check the PTO for damage and correct installation.Refer to the manufacturer's instructions.

OK

Vibration damper is damaged · · · · · · · · Check the vibration damper. Refer to Procedure 001-051 or 001-052.

24 Valve, 8.3 Liter Engine Engine Will Not Crank or Cranks Slowly (Electric Starter)Section TS - Troubleshooting Symptoms Page TS-69


Engine Will Not Crank or Cranks Slowly (Electric Starter)


(Continued)

Cause Correction

Batteries are cold · · · · · · · · Check the battery heater. Refer to the manufacturer'sinstructions.

OK

Battery cables or connections are loose, broken, or corroded (excessive resistance) · · · · · · · · Check the battery cables and connections.

OK

Battery capacity is below specification · · · · · · · · Refer to Electrical System Specifications.

OK

Vehicle starter interlock devices engaged · · · · · · · · Check the starter interlock devices. Refer to thevehicle service manual.

OK


Check the batteries and the unswitched battery supplycircuit. Refer to Procedure 019-087 in the FuelSystems Troubleshooting and Repair Manual for Case24 Valve, 8.3 Liter Engines.

OK

Engine driven units are engaged · · · · · · · · Disengage engine driven units.

OK

Engine Will Not Crank or Cranks Slowly (Electric Starter) (Continued) 24 Valve, 8.3 Liter EnginePage TS-70 Section TS - Troubleshooting Symptoms


Engine Will Not Crank or Cranks Slowly (Electric Starter) (Continued)

Cause Correction

Starting circuit component is malfunctioning · · · · · · · · Check the starting circuit components. Refer to thevehicle service manual.

OK

Starting motor pinion or ring gear is damaged · · · · · · · · Remove the starting motor and inspect the gear.

OK

Lubricating oil does not meet specifications for operating conditions · · · · · · · ·

Change the oil and filters. Refer to Procedure 007-013. Use the oil type recommended in the vehicleoperation and maintenance manual.

OK

Lubricating oil temperature is below specification · · · · · · · · Install an oil pan heater or drain the oil and fill thesystem with warm oil.

OK

Hydraulic lock in a cylinder · · · · · · · ·Remove the injectors and rotate the crankshaft. Lookfor the source of fluid in the cylinder. Refer toProcedures 006-026 and 001-016.

OK

Lubricating oil level is above specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andoil pan capacity. Fill the system to the specified level.Refer to Procedure 007-009 or 007-025.

OK

Lubricating oil pressure switch, gauge, or sensor is malfunctioning or is not in the correct location. · · · · · · · ·

Check the oil pressure switch, gauge, or sensor forcorrect operation and location. Refer to Procedure 007-052.

OK

Lubricating oil temperature switch, gauge, or sensor malfunctioning or not in the correct location · · · · · · · · Check the oil temperature switch, gauge, or sensor for

correct operation and location.

OK

Internal engine damage · · · · · · · · Analyze the oil and inspect the filter to locate an areaof probable damage. Refer to Procedure 007-002.

24 Valve, 8.3 Liter Engine Engine Will Not Reach Rated Speed (RPM)Section TS - Troubleshooting Symptoms Page TS-71


Engine Will Not Reach Rated Speed (RPM)


(Continued)

Cause Correction



OK


OK



OK



OK

Tachometer is not calibrated or is malfunctioning · · · · · · · ·

Compare the tachometer reading with a handtachometer or an electronic service tool reading.Calibrate or replace the tachometer as necessary.Refer to the vehicle service manual.

OK



OK

Engine Will Not Reach Rated Speed (RPM) (Continued) 24 Valve, 8.3 Liter EnginePage TS-72 Section TS - Troubleshooting Symptoms


Engine Will Not Reach Rated Speed (RPM) (Continued)

(Continued)

Cause Correction


Check the vehicle speed sensor and circuit. Refer toProcedures 019-090 and 019-091 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK


OK


OK



OK

Fuel injection pump is malfunctioning · · · · · · · · Perform a cylinder performance test.

OK


OK

24 Valve, 8.3 Liter Engine Engine Will Not Reach Rated Speed (RPM) (Continued)Section TS - Troubleshooting Symptoms Page TS-73


Engine Will Not Reach Rated Speed (RPM) (Continued)

Cause Correction


OK


OK


OK

Engine power output is low · · · · · · · · Refer to the Engine Power Output Low symptom tree.

Engine Will Not Shut Off 24 Valve, 8.3 Liter EnginePage TS-74 Section TS - Troubleshooting Symptoms


Engine Will Not Shut Off


Cause Correction



OK

Key switch circuit is malfunctioning · · · · · · · ·Check the vehicle key switch circuit. Refer to 019-064in the Fuel Systems Troubleshooting and RepairManual for Case 24 Valve, 8.3 Liter Engines.

OK

Engine is running on fumes drawn into the air intake · · · · · · · ·Check the air intake ducts. Locate and isolate thesource of the fumes. Repair as necessary. Refer to thevehicle service manual.

OK


OK


OK


24 Valve, 8.3 Liter Engine Fault Code Warning Lamps Do Not IlluminateSection TS - Troubleshooting Symptoms Page TS-75


Fault Code Warning Lamps Do Not Illuminate


Cause Correction

Key switch is in the OFF position · · · · · · · · Turn on the key switch.

OK

Fault code warning lamps are burned out · · · · · · · ·

Check the warning lamps for voltage. Replace thebulbs if necessary. Refer to Procedure 019-046 in theFuel Systems Troubleshooting and Repair Manual forCase 24 Valve, 8.3 Liter Engines.

OK



OK

Fault code warning lamp circuit is malfunctioning · · · · · · · ·

Check the fault code warning lamp circuit. Refer toProcedure 019-047 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK


OK



Fuel Consumption Excessive 24 Valve, 8.3 Liter EnginePage TS-76 Section TS - Troubleshooting Symptoms


Fuel Consumption Excessive


(Continued)

Cause Correction


OK

Operator technique is not correct · · · · · · · ·Explain the correct engine operation to the operator.Refer to the vehicle operation and maintenancemanual.

OK



OK



OK



OK

24 Valve, 8.3 Liter Engine Fuel Consumption Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-77


Fuel Consumption Excessive (Continued)

(Continued)

Cause Correction

Intake manifold pressure (boost) sensor or circuit is malfunctioning

Check the boost sensor and circuit. Refer toProcedures 019-061 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Engine idle or PTO time is excessiveCheck the idle or PTO time with an electronic servicetool. Low oil and coolant temperatures can be causedby long idle time (greater than 10 minutes).

OK


Check the vehicle speed sensor and circuit. Refer toProcedures 019-090 and 019-091 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Vehicle speed sensor (VSS) has been tampered with · · · · · · · ·

Check the vehicle speed sensor and circuit fortampering. Check for Fault Code 242. Repair thecircuit as necessary. Refer to Procedures 019-090and 019-091 in the Fuel Systems Troubleshooting andRepair Manual for Case 24 Valve, 8.3 Liter Engines.

OK

Fuel leak · · · · · · · ·

Check the fuel lines, fuel connections, and fuel filtersfor leaks. Refer to Procedure 006-024. Check the fuellines to the supply tanks. Refer to vehicle servicemanual.

OK


OK


OK

Fuel Consumption Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-78 Section TS - Troubleshooting Symptoms



(Continued)

Cause Correction


OK



OK

Fuel grade is not correct for the application or the fuel quality is poor. · · · · · · · ·


OK


OK

Lubricating oil level is above specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andoil pan capacity. Fill the system to the specified level.Refer to the vehicle specifications.

OK


OK

24 Valve, 8.3 Liter Engine Fuel Consumption Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-79



Cause Correction


OK


OK


OK


Fuel in Coolant 24 Valve, 8.3 Liter EnginePage TS-80 Section TS - Troubleshooting Symptoms


Fuel in Coolant


Cause Correction

Cylinder head is cracked or porous · · · · · · · · Pressure test the cylinder head. Refer to Procedure002-004.

OK

Bulk coolant supply is contaminated · · · · · · · ·Check the bulk coolant supply. Drain the coolant andreplace with non-contaminated coolant. Replace thecoolant filters. Refer to Procedure 008-018.

24 Valve, 8.3 Liter Engine Fuel in the Lubricating OilSection TS - Troubleshooting Symptoms Page TS-81


Fuel in the Lubricating Oil


Cause Correction

Engine idle time is excessive · · · · · · · ·

Low oil and coolant temperatures can be caused bylong idle time (greater than 10 minutes). Shut off theengine rather than idle for long periods. If idle time isnecessary, raise the idle speed.

OK

Injector o-rings are damaged or missing · · · · · · · · Remove and check the injectors. Replace the injectoro-rings. Refer to Procedure 006-026.

OK

Injector is malfunctioning · · · · · · · ·Perform the automated cylinder performance test.Replace injectors as necessary. Refer to Procedure006-005 or 006-026.

OK


OK

Bulk oil supply is contaminated · · · · · · · ·Check the bulk oil supply. Drain the oil and replacewith non-contaminated oil. Replace the oil filters. Referto the vehicle specifications.

OK

Fuel injection pump is malfunctioning · · · · · · · ·Inspect the cam housing for cracks and damage.Replace cam module if necessary. refer to Procedure005-088.

OK


Intake Manifold Air Temperature Above Specification 24 Valve, 8.3 Liter EnginePage TS-82 Section TS - Troubleshooting Symptoms


Intake Manifold Air Temperature Above Specification


(Continued)

Cause Correction



OK

Fan drive belt is loose · · · · · · · · Check the belt tension and tighten if necessary. Referto Procedure 008-002.

OK

Fan drive belt is broken · · · · · · · · Check the fan drive belt. Replace the belt if necessary.Refer to Procedure 008-002.

OK

Fan shroud is damaged or missing, or the air recirculation baffles are damaged or missing · · · · · · · ·

Inspect the shroud and the recirculation baffles.Repair, replace, or install if necessary. Refer toProcedure 008-038 and the vehicle service manual.

OK

Exhaust system leaking hot air into engine compartment · · · · · · · · Check the exhaust plumbing for leaks or brokencomponents.

OK

24 Valve, 8.3 Liter Engine Intake Manifold Air Temperature Above Specification (Continued)Section TS - Troubleshooting Symptoms Page TS-83


Intake Manifold Air Temperature Above Specification (Continued)

Cause Correction


OK

Intake manifold pressure sensor is malfunctioning · · · · · · · ·

Check the intake manifold pressure sensor. Refer toProcedure 019-061 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Vehicle cooling system is not adequate · · · · · · · · Verify that the engine and vehicle cooling systems areusing the correct components.

OK

Fan is not an adequate size for the application · · · · · · · · Verify that the fan is the correct size.

OK

Intake manifold temperature gauge is malfunctioning, if equipped · · · · · · · · Test the temperature gauge. Refer to the vehicle

service manual.

Low Idle Adjust Switch Does Not Work 24 Valve, 8.3 Liter EnginePage TS-84 Section TS - Troubleshooting Symptoms


Low Idle Adjust Switch Does Not Work


Cause Correction



OK

Engine idle speed is set at either the minimum or the maximum allowable value · · · · · · · ·

The idle adjust switch will not adjust the idle speedoutside of the allowable range. Refer to Section 1,Operating Instructions.

OK

Low idle adjust switch and circuit is malfunctioning · · · · · · · ·

Check the idle adjust switch and circuit. Refer toProcedures 019-052 and 019-053 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Low idle adjust switch feature is not enabled · · · · · · · ·Check the low idle adjust switch feature with anelectronic service tool. Refer to the appropriateelectronic service tool user's manual.

24 Valve, 8.3 Liter Engine Intake Manifold Pressure (Boost) is Below NormalSection TS - Troubleshooting Symptoms Page TS-85


Intake Manifold Pressure (Boost) is Below Normal


Cause Correction

Air intake or exhaust leaks · · · · · · · · Inspect the air intake and exhaust systems for airleaks. Refer to Procedure 010-024

OK


OK


OK


Refer to Section TF in the Fuel SystemsTroubleshooting and Repair Manual for fault codetroubleshooting.

OK

Air compressor connection is loose or damaged · · · · · · · · Check the connection between the manifold and the aircompressor. Repair or replace if necessary.

OK


OK

Turbocharger is not correct · · · · · · · ·Check the turbocharger part number and compare it tothe Vehicle Parts List. Replace the turbocharger ifnecessary. Refer to Procedure 010-033.

OK

Turbocharger is worn or damaged · · · · · · · ·Check the turbocharger for damage. Measure theturbine and compressor wheel clearances. Refer toProcedure 010-038.

OK

Engine power output is low · · · · · · · · Refer to the Engine Power Output Low symptom tree.

Lubricating Oil Consumption Excessive 24 Valve, 8.3 Liter EnginePage TS-86 Section TS - Troubleshooting Symptoms


Lubricating Oil Consumption Excessive


(Continued)

Cause Correction



OK

Lubricating oil drain interval is excessive · · · · · · · · Verify the correct lubricating oil drain interval. Refer tothe vehicle operation and maintenance manual.

OK

Lubricating oil leak (external) · · · · · · · ·

Inspect the engine for external oil leaks. Tighten thecapscrews, pipe plugs, and fittings. Replace gaskets ifnecessary. Refer to the vehicle operation andmaintenance manual.

OK

Verify the oil consumption rate · · · · · · · · Check the amount of oil added versus the mileage.

OK

Air compressor is pumping lubricating oil into the air system · · · · · · · ·Check the air lines for carbon buildup and lubricatingoil. Refer to the Air Compressor is Pumping ExcessiveLubricating Oil into the Air System symptom tree.

OK

Lubricating oil cooler is leaking · · · · · · · · Check the lubricating oil cooler for coolant leaks. Referto Procedure 007-003.

OK

Lubricating oil level is above specification · · · · · · · ·Check the oil level. Verify the dipstick calibration andoil pan capacity. Fill the system to the specified level.Refer to Procedures 007-009 or 007-025.

OK


OK

24 Valve, 8.3 Liter Engine Lubricating Oil Consumption Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-87


Lubricating Oil Consumption Excessive (Continued)

Cause Correction

Piston rings are not seated correctly (after an engine rebuild or piston installation) · · · · · · · ·

Check blowby. Refer to Section 14. If blowby isexcessive, check the piston rings for correct seating.Refer to Procedures 001-043 and 001-047.

OK



OK


OK


Lubricating Oil Contaminated 24 Valve, 8.3 Liter EnginePage TS-88 Section TS - Troubleshooting Symptoms


Lubricating Oil Contaminated


Cause Correction

Bulk oil supply is contaminated · · · · · · · ·Check the bulk oil supply. Drain the oil and replacewith non-contaminated oil. Replace the oil filters. Referto Procedure 007-025 or 007-013.

OK

Fuel in the lubricating oil · · · · · · · · Refer to the Fuel in the Lubricating Oil symptom tree.

OK

Internal coolant leaks · · · · · · · · Refer to the Coolant Loss - Internal symptom tree.

OK

Lubricating oil sludge is excessive · · · · · · · · Refer to the Lubricating Oil Sludge in the Crankcase isExcessive symptom tree.

OK

Identify lubricating oil contamination · · · · · · · · Perform an oil analysis to determine the contaminants.

24 Valve, 8.3 Liter Engine Lubricating Oil Pressure HighSection TS - Troubleshooting Symptoms Page TS-89


Lubricating Oil Pressure High


Cause Correction



OK

Coolant temperature is below specification · · · · · · · · Refer to the Coolant Temperature Below Normalsymptom tree.

OK



OK

Lubricating oil pressure switch, gauge, or sensor is malfunctioning or is not in the correct location · · · · · · · ·


OK

Lubricating oil pressure sensor or circuit is malfunctioning (electronic controlled fuel system) · · · · · · · ·

Check the lubricating oil pressure sensor and circuit.Refer to Procedure 019-066 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Main oil pressure regulator is malfunctioning · · · · · · · · Check the main oil pressure regulator assembly. Referto Procedure 007-029.

Lubricating Oil Pressure Low 24 Valve, 8.3 Liter EnginePage TS-90 Section TS - Troubleshooting Symptoms


Lubricating Oil Pressure Low


(Continued)

Cause Correction



OK


OK

Lubricating oil leak (external) · · · · · · · ·

Inspect the engine for external oil leaks. Tighten thecapscrews, pipe plugs, and fittings. Replace gaskets ifnecessary. Refer to the vehicle operation andmaintenance manual for specifications.

OK



OK

Lubricating oil filter is plugged · · · · · · · ·Change the oil and filter. Refer to Procedures 007-025and 007-013. Review the oil change interval. Refer tothe vehicle operation and maintenance manual.

OK


OK

Lubricating oil pressure switch, gauge, or sensor is malfunctioning or is not in the correct location · · · · · · · ·


OK

Engine angularity during operation exceeds specification · · · · · · · · Refer to the vehicle specification sheet.

OK

24 Valve, 8.3 Liter Engine Lubricating Oil Pressure Low (Continued)Section TS - Troubleshooting Symptoms Page TS-91


Lubricating Oil Pressure Low (Continued)

Cause Correction

Lubricating oil pressure sensor or circuit is malfunctioning (electronic controlled fuel system) · · · · · · · ·

Check the lubricating oil pressure sensor and circuit.Refer to Procedure 019-066 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Main oil pressure regulator is malfunctioning · · · · · · · · Check the main oil pressure regulator assembly. Referto Procedure 007-029.

OK

Lubricating oil cooler is plugged · · · · · · · · Check the oil cooler. Refer to Procedure 007-003.

OK

Lubricating oil suction or transfer tube is loose or broken, or the gasket or o-rings are leaking · · · · · · · · Remove and inspect the oil pan or suction tube. Refer

to Procedure 007-025.

OK

Lubricating oil pump is malfunctioning · · · · · · · · Inspect the lubricating oil pump. Refer to Procedure007-031.

OK

Internal engine damage or internal lubricating oil leak · · · · · · · ·

Analyze the lubricating oil. Inspect the oil filter. Refer toProcedure 007-002. Check the main bearings, rodbearings, cam bushings, and rocker lever bushings forexcessive wear. Refer to Section 1.

Lubricating Oil Sludge in the Crankcase Excessive 24 Valve, 8.3 Liter EnginePage TS-92 Section TS - Troubleshooting Symptoms


Lubricating Oil Sludge in the Crankcase Excessive


Cause Correction

Bulk oil supply is contaminated · · · · · · · ·Check the bulk oil supply. Drain the oil and replacewith non-contaminated oil. Replace the oil filters. Referto Procedure 007-025 or 007-013.

OK

Coolant temperature is below specification · · · · · · · · Refer to the Coolant Temperature Below Normalsymptom tree.

OK



OK



OK

Lubricating oil drain interval is excessive · · · · · · · · Verify the correct lubricating oil drain interval. Refer tothe vehicle operation and maintenance manual.

OK

Lubricating oil is contaminated with coolant or fuel · · · · · · · · Refer to the Lubricating Oil Contaminated symptomtree

OK

Crankcase pressure is excessive · · · · · · · · Check for excessive blowby. Refer to the CrankcaseGases (Blowby) Excessive symptom tree.

24 Valve, 8.3 Liter Engine Lubricating Oil Temperature Above SpecificationSection TS - Troubleshooting Symptoms Page TS-93


Lubricating Oil Temperature Above Specification


Cause Correction



OK

Coolant temperature is above specification · · · · · · · · Refer to the Coolant Temperature Above Normalsymptom tree.

OK


OK

Lubricating oil temperature switch, gauge, or sensor malfunctioning or not in the correct location · · · · · · · · Check the oil temperature switch, gauge, or sensor for

correct operation and location.

OK


OK

Vehicle components cooled with engine lubricating oil are malfunctioning · · · · · · · · Check the components. Refer to the vehicle service

manual.

Lubricating or Transmission Oil in the Coolant 24 Valve, 8.3 Liter EnginePage TS-94 Section TS - Troubleshooting Symptoms


Lubricating or Transmission Oil in the Coolant


Cause Correction

Bulk oil supply is contaminated · · · · · · · ·Check the bulk oil supply. Drain the oil and replacewith non-contaminated oil. Replace the oil filters. Referto Procedure 007-025.

OK


OK

Cylinder liner is corroded or cracked · · · · · · · · Check the cylinder liners for corrosion or cracks. Referto Procedure 001-028.

OK

Cylinder head gasket is leaking · · · · · · · · Check the cyliunder head gasket. Refer to Procedure002-004 or 002-021.

OK


OK

Torque converter cooler or hydraulic oil cooler is malfunctioning · · · · · · · · Remove and inspect the cooler cores and o-rings.


24 Valve, 8.3 Liter Engine Smoke, White ExcessiveSection TS - Troubleshooting Symptoms Page TS-95


Smoke, White Excessive


(Continued)

Cause Correction



OK



OK



OK

Engine is operating at low ambient temperature · · · · · · · ·Check the winterfront, shutters, and under hood air.Refer to the vehicle operation and maintenancemanual.

OK

Starting aid is necessary for cold weather or starting aid is malfunctioning · · · · · · · ·

Check for correct operation of the starting aid. Refer tothe manufacturer's instructions. Refer to Cold WeatherStarting Aids in the vehicle operation and maintenancemanual.

OK

Engine block heater is malfunctioning (if equipped) · · · · · · · ·Check the electrical sources and wiring to the cylinderblock heater. Replace the block heater if necessary.Refer to the vehicle service manual.

OK

Coolant temperature sensor is malfunctioning · · · · · · · ·

Check the coolant temperature sensor. Refer toProcedure 019-019 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK

Smoke, White -- Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-96 Section TS - Troubleshooting Symptoms


Smoke, White -- Excessive (Continued)

(Continued)

Cause Correction

Intake manifold temperature sensor is malfunctioning · · · · · · · ·

Check the intake manifold temperature sensor. Referto Procedure 019-059 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK


OK


OK

Fuel grade is not correct for application or the fuel quality is poor · · · · · · · ·


OK


OK


OK


OK

24 Valve, 8.3 Liter Engine Smoke, White -- Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-97



(Continued)

Cause Correction


OK


OK


OK

Raw fuel in the intake manifold · · · · · · · ·Check the intake manifold for fuel. Refer to Procedure010-023. Locate the fuel source and repair asnecessary.

OK


OK


OK


OK

Smoke, White -- Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-98 Section TS - Troubleshooting Symptoms



Cause Correction


OK


OK

Coolant is leaking into the combustion chamber · · · · · · · · Refer to the Coolant Loss - Internal symptom tree

OK

Injector protrusion is not correct · · · · · · · · Check the injector protrusion. Refer to Procedure 002-022 or 006-028.

OK


24 Valve, 8.3 Liter Engine Smoke, Black ExcessiveSection TS - Troubleshooting Symptoms Page TS-99


Smoke, Black Excessive


(Continued)

Cause Correction



OK



OK


Check the boost sensor and circuit. Refer toProcedures 019-061 in the Fuel SystemsTroubleshooting and Repair Manual for Case 24 Valve,8.3 Liter Engines.

OK


OK


OK


OK


OK

Smoke, Black Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-100 Section TS - Troubleshooting Symptoms


Smoke, Black Excessive (Continued)

(Continued)

Cause Correction


OK


OK


OK

Turbocharger oil seal is leaking · · · · · · · · Check the turbocharger compressor and turbine seals.Refer to Procedures 010-040 or 010-049.

OK



OK


OK

24 Valve, 8.3 Liter Engine Smoke, Black Excessive (Continued)Section TS - Troubleshooting Symptoms Page TS-101



(Continued)

Cause Correction


OK

Crankcase ventilation system is plugged · · · · · · · ·Check and clean the crankcase breather and venttube. Refer to Procedure 003-001, 003-002, or 003-018.

OK



OK


OK


OK


OK


OK

Smoke, Black Excessive (Continued) 24 Valve, 8.3 Liter EnginePage TS-102 Section TS - Troubleshooting Symptoms



Cause Correction


OK

Raw fuel in the intake manifold · · · · · · · ·Check the intake manifold for fuel. Refer to Procedure010-023. Locate the fuel source and repair asnecessary.

OK


24 Valve, 8.3 Liter Engine Turbocharger Leaks Engine Oil or FuelSection TS - Troubleshooting Symptoms Page TS-103


Turbocharger Leaks Engine Oil or Fuel


Cause CorrectionEngine is operating for extended periods under light or no

load conditions (slobbering) · · · · · · · · Review the engine operating instructions in the vehicleoperation and maintenance manual.

OK

Lubricating oil or fuel is entering the turbocharger · · · · · · · · Remove the intake and exhaust piping and check foroil or fuel.

OK

Turbocharger drain line is restricted · · · · · · · · Remove the turbocharger drain line and check forrestriction. Clean or replace the drain line.

OK

Crankcase pressure is excessive · · · · · · · · Check for excessive blowby. Refer to the CrankcaseGases (Blowby) Excessive symptom tree.

OK

Turbocharger is not correct · · · · · · · ·Check the turbocharger part number and compare it tothe Control Parts List (CPL). Replace the turbochargerif necessary. Refer to Procedure 010-033.

OK


OK

Valve stem clearance is excessive or the valve stem seals are damaged · · · · · · · · Check the valve stems and seals. Refer to Procedure

002-020.

OK

White smoke is present · · · · · · · · Excessive symptom tree.

Engine Noise Diagnostic Procedures General Information 24 Valve, 8.3 Liter EnginePage TS-104 Section TS - Troubleshooting Symptoms


Engine Noise Diagnostic Procedures General InformationNOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise caused by these units. Noise will also travel to other metal parts not related to the problem. The use of a stethoscope can help locate an engine noise.

Engine noises heard at the crankshaft speed, engine rpm, are noises related to the crankshaft, rods, pistons, and piston pins. Noises heard at the camshaft speed, one-half of the engine rpm, are related to the valve train. A hand-held digital tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft speed.

Engine noise can sometimes be isolated by performing a cylinder cutout test. If the volume of the noise decreases or the noise disappears, it is related to that particular engine cylinder.

There is not a definite rule or test that will positively determine the source of a noise complaint.

Engine driven components and accessories, such as gear-driven fan clutches, hydraulic pumps, belt-driven alternators, air-conditioning compressors, and turbochargers can contribute to engine noise. Use the following information as a guide to diagnosing engine noise.

Main Bearing Noise(Refer to Engine Noise Excessive Main Bearing symptom tree)

The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main bearings are loose, a loud clatter will be heard. The knock is heard regularly every other revolution. The noise is the loudest when the engine is lugging or under heavy load. The knock is duller than a connecting rod noise. Low oil pressure can also accompany this condition.

If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there is no oil at the bearing.

An irregular noise can indicate worn crankshaft thrust bearings.

An intermittent sharp knock indicates excessive crankshaft end clearance. Repeated clutch disengagements can cause a change in the noise.

Connecting Rod Bearing Noise(Refer to Engine Noise Excessive Connecting Rod symptom tree)

Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When the bearings begin to become loose, the noise can be confused with piston slap or loose piston pins. The noise increases in volume with engine speed. Low oil pressure can also accompany this condition.

Piston Noise(Refer to Engine Noise Excessive Piston symptom tree)

It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a loud double knock which is usually heard when the engine is idling. When the injector to this cylinder is cut out, a noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes more noticeable when the vehicle is operated on the road at steady speed condition.

24 Valve, 8.3 Liter Engine Section 01 - Cylinder Block - Group 01Section 1 - Cylinder Block - Group 01 Page 1-a


Section 01 - Cylinder Block - Group 01

Section Contents

Bearings, Connecting Rod (001-005) ........................................................................................................................................................ 1-3Clean (001-005-006) ..................................................................................................................................................................... 1-5Inspect for Reuse (001-005-007) .................................................................................................................................................. 1-5Install (001-005-026) ..................................................................................................................................................................... 1-6Remove (001-005-002) ................................................................................................................................................................. 1-3

Bearings, Main (001-006) ............................................................................................................................................................................ 1-9Clean (001-006-006) ................................................................................................................................................................... 1-11Initial Check (001-006-001) ........................................................................................................................................................... 1-9Inspect for Reuse (001-006-007) ................................................................................................................................................ 1-12Install (001-006-026) ................................................................................................................................................................... 1-12Remove (001-006-002) ............................................................................................................................................................... 1-10

Camshaft (001-008) ................................................................................................................................................................................... 1-15Inspect for Reuse (001-008-007) ................................................................................................................................................ 1-16Install (001-008-026) ................................................................................................................................................................... 1-19Remove (001-008-002) ............................................................................................................................................................... 1-15

Camshaft Bushings (001-010) .................................................................................................................................................................. 1-21Initial Check (001-010-001) ......................................................................................................................................................... 1-21Install (001-010-026) ................................................................................................................................................................... 1-22Measure (001-010-010) .............................................................................................................................................................. 1-22Remove (001-010-002) ............................................................................................................................................................... 1-22

Camshaft Gear (Camshaft Removed) (001-013) ..................................................................................................................................... 1-23Inspect for Reuse (001-013-007) ................................................................................................................................................ 1-24Install (001-013-026) ................................................................................................................................................................... 1-25Remove (001-013-002) ............................................................................................................................................................... 1-23

Connecting Rod (001-014) ........................................................................................................................................................................ 1-26Clean (001-014-006) ................................................................................................................................................................... 1-27Inspect for Reuse (001-014-007) ................................................................................................................................................ 1-27Install (001-014-026) ................................................................................................................................................................... 1-29Remove (001-014-002) ............................................................................................................................................................... 1-26

Crankshaft (001-016) ................................................................................................................................................................................. 1-30Rotation Check (001-016-052) .................................................................................................................................................... 1-30

Crankshaft Gear, Front (Crankshaft Installed) (001-018) ..................................................................................................................... 1-30General Information .................................................................................................................................................................... 1-30

Crankshaft Seal, Front (001-023) ............................................................................................................................................................. 1-30Clean (001-023-006) ................................................................................................................................................................... 1-31Inspect for Reuse (001-023-007) ................................................................................................................................................ 1-31Install (001-023-026) ................................................................................................................................................................... 1-32Remove (001-023-002) ............................................................................................................................................................... 1-30

Section 01 - Cylinder Block - Group 01 24 Valve, 8.3 Liter EnginePage 1-b Section 1 - Cylinder Block - Group 01


Crankshaft Seal, Rear (001-024) .............................................................................................................................................................. 1-33Clean (001-024-006) ................................................................................................................................................................... 1-34Inspect for Reuse (001-024-007) ................................................................................................................................................ 1-34Install (001-024-026) ................................................................................................................................................................... 1-34Remove (001-024-002) ............................................................................................................................................................... 1-33

Crankshaft Wear Sleeve, Front (001-025) ............................................................................................................................................... 1-35Clean (001-025-006) ................................................................................................................................................................... 1-36Inspect for Reuse (001-025-007) ................................................................................................................................................ 1-36Install (001-025-026) ................................................................................................................................................................... 1-36Remove (001-025-002) ............................................................................................................................................................... 1-35

Cylinder Liner (001-028) ........................................................................................................................................................................... 1-39Clean (001-028-006) ................................................................................................................................................................... 1-43Inspect for Reuse (001-028-007) ................................................................................................................................................ 1-43Install (001-028-026) ................................................................................................................................................................... 1-46Preparatory (001-028-000) ......................................................................................................................................................... 1-39Remove (001-028-002) ............................................................................................................................................................... 1-39

Gear Cover, Front (001-031) ..................................................................................................................................................................... 1-52Clean (001-031-006) ................................................................................................................................................................... 1-53Inspect for Reuse (001-031-007) ................................................................................................................................................ 1-53Install (001-031-026) ................................................................................................................................................................... 1-53Remove (001-031-002) ............................................................................................................................................................... 1-52

Gear Housing, Front (001-033) ................................................................................................................................................................ 1-55Clean (001-033-006) ................................................................................................................................................................... 1-56Inspect for Reuse (001-033-007) ................................................................................................................................................ 1-56Install (001-033-026) ................................................................................................................................................................... 1-57Remove (001-033-002) ............................................................................................................................................................... 1-55

Piston (001-043) ........................................................................................................................................................................................ 1-59Assemble (001-043-025) ............................................................................................................................................................ 1-63Clean (001-043-006) ................................................................................................................................................................... 1-61Disassemble (001-043-003) ........................................................................................................................................................ 1-60General Information .................................................................................................................................................................... 1-59Inspect for Reuse (001-043-007) ................................................................................................................................................ 1-62Install (001-043-026) ................................................................................................................................................................... 1-63Remove (001-043-002) ............................................................................................................................................................... 1-60

Piston and Connecting Rod Assembly (001-054) .................................................................................................................................. 1-70Assemble (001-054-025) ............................................................................................................................................................ 1-74Clean (001-054-006) ................................................................................................................................................................... 1-74Disassemble (001-054-003) ........................................................................................................................................................ 1-73Inspect for Reuse (001-054-007) ................................................................................................................................................ 1-74Install (001-054-026) ................................................................................................................................................................... 1-75Remove (001-054-002) ............................................................................................................................................................... 1-70

Piston Rings (001-047) ............................................................................................................................................................................. 1-64Inspect for Reuse (001-047-007) ................................................................................................................................................ 1-64Install (001-047-026) ................................................................................................................................................................... 1-65

24 Valve, 8.3 Liter EngineSection 1 - Cylinder Block - Group 01 Page 1-c


Service Tools................................................................................................................................................................................................ 1-1Cylinder Block ................................................................................................................................................................................ 1-1

Vibration Damper (001-052) ..................................................................................................................................................................... 1-68Remove (001-025-002) ............................................................................................................................................................... 1-68Inspect for Reuse (001-052-007) ................................................................................................................................................ 1-68Install (001-052-026) ................................................................................................................................................................... 1-69

Vibration Damper, Rubber (001-051) ....................................................................................................................................................... 1-66Inspect for Reuse (001-051-007) ................................................................................................................................................ 1-67Install (001-051-026) ................................................................................................................................................................... 1-67Remove (001-051-002) ............................................................................................................................................................... 1-66

Section 01 - Cylinder Block - Group 01 24 Valve, 8.3 Liter EnginePage 1-d Section 1 - Cylinder Block - Group 01



24 Valve, 8.3 Liter Engine Service ToolsSection 1 - Cylinder Block - Group 01 Page 1-1


Service Tools

Cylinder Block

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate pro-cedure.

Tool No. Tool Description Tool Illustration

OEM 6529 Universal Cylinder Liner Puller

Used to remove cylinder liners from the cylinder block. Requires Tool No. 1234 Cylinder Liner Puller Plate.

CAS-1049A Cylinder Liner Clamp Set

Used to clamp the liner into the bore of the cylinder block. Requires two cylinder head capscrews not included in clamp set.

OEM 6266 Piston Ring Expander

Used to install piston rings onto pistons without damaging or distorting the rings.

3823290 Piston Ring Compressor

Used to compress the piston rings while installing the pistons into the cylinder bores.

OEM 6459 Gauge Block

Used to measure cylinder liner protrusion, cylinder block counterbore depths, and valve intrusion and/or protrusion.

CAS-1412A Camshaft Bushing Tool

Used to remove and install camshaft bushings.

CAS 10904 Cylinder Liner Counterbore Tool

Used for machining the liner counterbore ledge.

OEM6529

CAS1049a

CAS1412

Service Tools 24 Valve, 8.3 Liter EnginePage 1-2 Section 01 - Cylinder Block - Group 01

Rac 7-89370 Released 11-98 Printed in U.S.A

CAS 10904-1 Cutter Plate

Used with Tool No. CAS 10904, cylinder liner counterbore tool.

CAS 10904-2 Cutter Bit

Used with Tool No. CAS 10904-1, cutter plate, to machine the cylinder liner counterbore ledge.

J823921 Capscrew Length Gauge

Used to measure capscrew free length.

CAS-2430 Lubricating Oil Seal Installation Tool

Used to install the front crankshaft lubricating oil seal in the front cover seal carrier.

CAS-2167 Front Wear Sleeve Installation Tool

Used to install front wear sleeves.

CAS-1690 Engine Barring Gear

Used to engage the flywheel ring gear to rotate the crankshaft.

OEM 4083and

OEM 6527used with

OTC plate 1234

Cylinder Liner Driver

Used to install cylinder liners into the cylinder block.

ST-647 Standard Puller

Used to remove drive pulleys, impellers, air compressor counterweights, etc.


CAS2167

24 Valve, 8.3 Liter Engine Bearings, Connecting Rod (001-005)Section 1 - Cylinder Block - Group 01 Page 1-3


Bearings, Connecting Rod (001-005)

Remove (001-005-002)

∆ WARNING ∆Some state and federal agencies in the United States of Americahave determined that used engine oil can be carcinogenic andcan cause reproductive toxicity. Avoid inhalation of vapors, in-gestion, and prolonged contact with used engine oil.

∆ WARNING ∆Avoid direct contact of hot oil with your skin. Hot oil can causepersonal injury.

Drain the lubricating oil. Refer to Procedure 007-025.

Remove the lubricating oil pan and gasket. Refer to Procedure 007-025.

Barring Tool, Tool No. CAS 1690

The barring tool inserts into the flywheel housing and engages the fly-wheel ring gear. The engine can then be rotated by hand using a 1/2-inch ratchet or breaker bar.

Using the barring tool, rotate the crankshaft to the bottom dead center(BDC) position of the connecting rod.

Bearings, Connecting Rod (001-005) 24 Valve, 8.3 Liter EnginePage 1-4 Section 1 - Cylinder Block - Group 01


Remove the connecting rod nuts and connecting rod caps.

Remove the lower bearing shell from the connecting rod cap and markit with the letter L (lower) and the cylinder number from which it was re-moved.

Push the connecting rod away from the crankshaft to allow the upperbearing shell to be removed.

Remove the upper bearing shell and mark it with the letter "U" (upper)and the cylinder number from which it was removed.



Clean (001-005-006)

Wash the bearing and connecting rod caps with an approved cleaningsolution.

Dry with compressed air.

Inspect for Reuse (001-005-007)

Inspect the connecting rod caps, connecting rod bearing saddles, andcapscrews for nicks, cracks, burrs, scratches, or fretting.

Inspect the bearings for damage.

Replace any bearings with the following damage:• Pitting• Flaking• Corrosion• Lock tang damage• Scratches.

Inspect the bearing shell seating surface for nicks or burrs.

If nicks or burrs can not be removed with Scotch-Brite™ 7448, orequivalent, the bearings must be replaced.

NOTE: If bearings are damaged they must be replaced as a set.



Measure the rod bearing shell thickness with an outside micrometerthat has a ball tip.

Discard a bearing shell if its thickness is below the minimum specifica-tion.

NOTE: Connecting rod bearings are identified with a part number andsize stamped on the back side.

Determine the size of the removed rod bearing and obtain a set of thesame size.

Over size service rod bearings are available for use with crankshaftsthat have been machined undersized. Refer to the appropriate partscatalog.

Install (001-005-026)

NOTE: Used bearings must be installed in the same location fromwhich they were removed.

Use Lubriplate 105, or equivalent, to coat the inside diameter of thebearing shell.

Install the upper bearing shell into the connecting rod with the tang ofthe bearing in the slot of the connecting rod.

Install the bearing shell in the connecting rod cap with the tang of thebearing in the slot of the connecting rod cap.

Connecting Rod Bearing Dimensionsmm in

Standard 2.454 MIN 0.09662.471 MAX 0.0973



Use clean 15W-40 oil to lubricate the threads of the connecting rodcapscrews.

The number stamped on the connecting rod and connecting rod cap atthe parting line must match and be installed on the lubricating oil coolerside of the engine.

Install the connecting rod cap and nuts to the connecting rod.

Alternately, tighten the two capscrews.

Torque Value:Step 1 35 N•m [26 ft-lb]

2 70 N•m [52 ft-lb]3 60 degrees

Measure the side clearance between the connecting rod and crank-shaft.

Do not measure the clearance between the connecting rod cap andcrankshaft.

Connecting Rod Side Clearance Limitsmm in0.10 MIN 0.0040.33 MAX 0.013



The crankshaft must rotate freely.

Check for freedom of rotation as the connecting rod caps are installed.If the crankshaft does not rotate freely, check the installation of theconnecting rod bearings and bearing size.

Install the lubricating oil pan, gasket, and suction tube. Refer to Proce-dure 007-025.

Fill the lubricating oil pan. Refer to Procedure 007-025, Lubricating OilSystem - General Information, for the correct lubricating oil specifica-tion.

NOTE: Refer to vehicle operations manual for correct amount of oil.

Operate the engine to normal operating temperature and check forleaks.

24 Valve, 8.3 Liter Engine Bearings, Main (001-006)Section 1 - Cylinder Block - Group 01 Page 1-9


Bearings, Main (001-006)

Initial Check (001-006-001)

∆ WARNING ∆Some state and local agencies in the United States of Americahave determined that used engine oil can be carcinogenic andcan cause reproductive toxicity. Avoid inhalation of vapors, in-gestion, and prolonged contact with used engine oil.




NOTE: Before removing the main bearing caps, make certain that thecaps are clearly marked for their location on the lubricating oil coolerside of the main bearing cap.

NOTE: The dimensions of the thrust bearing and crankshaft journaldetermine end play.

Measure the crankshaft end play with a Dial Indicator.

Perform a inspection of the main bearings and crankshaft journals. Re-move the No. 2 and 3 caps and check the crankshaft journals for signsof overheat, deep scratches, or other damage.

If there is no damage, there is no need to pull the other main bearingcaps at this time, unless the crankshaft end play is excessive.

Dimension A End Play Limitsmm in

0.127 MIN 0.0050.330 MAX 0.013

Bearings, Main (001-006) 24 Valve, 8.3 Liter EnginePage 1-10 Section 1 - Cylinder Block - Group 01


Inspect the main bearing caps for dents, cracks, and other damage.

NOTE: If the crankshaft journals or main caps are damaged, the en-gine will need to be removed to complete the overhaul.

Remove (001-006-002)





NOTE: Before removing the main bearing caps, make certain that thecaps are clearly marked for their location on the lubricating oil coolerside of the main bearing cap.

Remove all main bearing caps except the No. 1 and 7 main bearingcaps.

NOTE: When replacing bearings in chassis, replace Nos. 2 through 6while the No. 1 and 7 caps support the crankshaft. After replacing Nos.2 through 6, replace Nos. 1 and 7.



∆ CAUTION ∆Use care so the tool does not damage crankshaft or cylinderblock.

Use a pin to roll out the upper bearings from between the crankshaftand cylinder block.

To make a pin, grind a 6 mm capscrew to the dimensions shown.

Install the pin or tool into the lubricating oil hole in the crankshaft. Ro-tate the crankshaft so the pin or tool pushes against the end of themain bearing opposite the tang. Remove the main bearing.

Follow this procedure to remove the other main bearings except for No.1 front main bearing.

∆ CAUTION ∆Use care so the screwdriver does not damage the crankshaft orcylinder block.

NOTE: The front main bearing, No. 1, does not have a hole in the jour-nal so the tool can not be used to replace the bearing.

Using a flat blade screwdriver, gently bump the end of the bearing toloosen it from the cylinder block. Then, use finger pressure against themain bearing shell and rotate the crankshaft to roll the main bearingout.

Clean (001-006-006)

∆ WARNING ∆When using a steam cleaner, wear protective clothing and safetyglasses or a face shield. Hot steam can cause serious personal in-jury

Steam clean main bearing caps.





Inspect all main bearing caps and main bearing crankshaft journals fordeep scoring, overheating, etc.

Install (001-006-026)

∆ CAUTION ∆Do not lubricate the side that is against the cylinder block.

NOTE: Make sure the main bearing being installed is same size as themain bearing removed. The size is engraved on the back of the mainbearing.

Apply a coat of Lubriplate 105, or equivalent, to the new upper mainbearings.

Position the new main bearing on the crankshaft and install as far aspossible by hand.

Using the pin or tool, finish pushing the main bearing in slowly beingsure it is aligned with the cylinder block. Make sure the tang on themain bearing sets into the notch.



∆ CAUTION ∆Make sure the pin does not slide under the bearing.

Finish pushing the main bearing into position.

Install the lower main bearings into the main bearing caps. Apply a coatof Lubriplate 105, or equivalent, to the crankshaft side of the mainbearings.

∆ CAUTION ∆Make sure the caps are correctly installed with the number to-wards the oil cooler side of the engine.

Install a main bearing cap after each upper main bearing is installed tokeep the main bearing in place while the other uppers are installed.

Tighten capscrews.

Torque Value: 50 N•m [37 ft-lb]

Do not tighten to the final torque value at this time.

Repeat this procedure to install the remaining bearing and caps withthe exception of main bearing No. 1.

The thrust bearing should be installed in the No. 4 journal.



∆ CAUTION ∆Use care so the screwdriver does not damage the crankshaft orcylinder block.

The front main, No. 1, does not have a hole in the journal so the pincan not be used to replace the bearing.

Lubricate and install the No. 1 main bearing.

Use the screwdriver to push the main bearing into position as you ro-tate the crankshaft.

∆ CAUTION ∆The crankshaft must rotate freely.

Tighten the main bearing capscrews evenly and in sequence.

Torque Value:Step 1 50 N•m [37 ft-lb]

2 95 N•m [70 ft-lb]3 90 degrees

Check the main bearing installation and the size of the main bearingsif the crankshaft does not rotate freely.

NOTE: The dimensions of the thrust bearing and crankshaft journaldetermine end play.

Measure the crankshaft end play.

Install the lubricating oil pan and gasket. Refer to Procedure 007-025.

Fill the lubricating oil pan. Refer to Procedure 007-025, General Infor-mation, for the correct lubricating oil specification.

Refer to the vehicle operation and maintenance manual for the correctamount of oil.

Dimension (A) End Play Limitsmm in

0.127 MIN 0.0050.330 MAX 0.013

24 Valve, 8.3 Liter Engine Camshaft (001-008)Section 1 - Cylinder Block - Group 01 Page 1-15


Operate the engine at idle for 5 to 10 minutes. Check for loose partsand leaks.

Camshaft (001-008)

Remove (001-008-002)

1. Remove the rocker lever cover. Refer to Procedure 003-011.2. Remove the rocker levers. Refer to Procedure 003-008. 3. Remove the push rods. Refer to Procedure 004-014.4. Remove the drive belt. Refer to Procedure 008-039. 5. Remove the vibration damper. Refer to Procedure 001-052.6. Remove the gear cover. Refer to Procedure 001-031.7. Raise the tappets. Refer to Procedure 004-015.

Rotate the crankshaft to align the crankshaft to camshaft timing marks.

Remove the capscrews from the thrust plate.

NOTE: Because the thrust plate extends more than 180 degreesaround the camshaft, the thrust plate can only be removed from thecamshaft after removing the cam gear from the camshaft.

Camshaft (001-008) 24 Valve, 8.3 Liter EnginePage 1-16 Section 1 - Cylinder Block - Group 01


Remove the camshaft and thrust plate together.


Inspect the valve lobes and bearing journals for cracking, pitting andscoring.

Inspect the camshaft gear teeth for pitting. Look for cracks at the rootof the teeth.

Measure the valve lobes.

Diameter of Peak of Lobemm in

Intake 51.774 MIN 2.038Exhaust 51.596 MAX 2.031



Measure the bearing journals.

NOTE: Replace the camshaft if the outside diameter of any bearingsurface is less than 59.962 mm [2.3607 in].

Pitting Reuse Criteria

A single pit should not be greater than the area of a 2 mm [0.079 in]diameter circle.

Interconnection of pits is not allowable and is treated as one pit.

The total pits, when added together, should not exceed a circle of 6mm [0.236 in].

Journal Diametermm in

59.962 MIN 2.360760.013 MAX 2.3627



Only one pit is allowed within 20 degrees of the nose of the cam lobe.

Edge Deterioration (Breakdown) Criteria

The area of edge deterioration should not be greater than the equiva-lent area of a 2 mm [0.079 in] circle within 20 degrees of the nose ofthe cam lobe.

Outside of the 20 degrees of the nose of the cam lobe, the areas ofedge deterioration should not be greater than the equivalent area of a6 mm [0.236 in] circle.

NOTE: If the camshaft shows any pitting or wear, remove and inspectthe tappets before installing the camshaft. Refer to Procedure 004-015. If a new camshaft is installed, new tappets also should be in-stalled.

Measure the camshaft bore.

Camshaft Bore Inside Diametermm in

With Bushing 60.12 MAX 2.367



Measure camshaft thrust plate thickness.

Install (001-008-026)

Apply a coat of Lubriplate 105, or equivalent, to the front camshaftbore.

Lubricate the camshaft lobes, journals and thrust plate with Lubriplate105, or equivalent.

∆ CAUTION ∆Do not try to force the camshaft into the camshaft bore as damageto the camshaft bushing can result.

Install the camshaft. While pushing in slightly, rotate the camshaft andcarefully work the camshaft through the camshaft bushings. As eachcamshaft journal passes through a bushing, the camshaft will dropslightly and the camshaft lobes will catch on the bushings. Rotating thecamshaft will free the lobe from the bushing and allow the camshaft tobe installed.

Camshaft Thrust Platemm in9.34 MIN 0.3689.58 MAX 0.377



Before the camshaft gear engages the crankshaft gear, check the cam-shaft for ease of rotation. When installed properly, the camshaft shouldrotate freely.

Align the timing marks as illustrated and finish installing the camshaft.

Install the thrust plate capscrews.


Verify the camshaft has proper backlash and end play.

Camshaft End Play (A)mm in0.12 MIN 0.0470.46 MAX 0.018

Camshaft Gear Backlash Limits (B)mm in0.08 MIN 0.0030.33 MAX 0.013

24 Valve, 8.3 Liter Engine Camshaft Bushings (001-010)Section 1 - Cylinder Block - Group 01 Page 1-21


Complete the installation of the removed parts.

• Install the gear cover. Refer to Procedure 001-031.• Install the vibration damper. Refer to Procedure 001-051.• Install the drive belt. Refer to Procedure 008-003.• Release the tappets. Refer to Procedure 004-015.• Install the push rods. Refer to Procedure 004-014.• Install the rocker levers. Refer to Procedure 003-004.• Adjust the valve lash. Refer to Procedure 003-004.• Install the rocker lever cover. Refer to Procedure 003-004.

Operate the engine at idle for 5 to 10 minutes and check for leaks andloose parts.

Camshaft Bushings (001-010)


Inspect the camshaft bore for damage and excessive wear.

Measure the camshaft bore.

Camshaft Bore Inside Diametermm in

Without Bushing 64.01 MAX 2.520With Bushing 60.12 MAX 2.367

Camshaft Bushings (001-010) 24 Valve, 8.3 Liter EnginePage 1-22 Section 1 - Cylinder Block - Group 01


Remove (001-010-002)

Camshaft Bushing Tool, Tool No. CAS-1412A

Remove the camshaft from the cylinder block. Refer to Procedure 001-008.

Drive the camshaft bushing from the appropriate bore.

Measure (001-010-010)

Measure the installed camshaft bushing.

Install (001-010-026)

Mark the camshaft bushing and cylinder block so you can align the lu-bricating oil hole in the cylinder block with the large lubricating oil holein the bushing.

Camshaft Bore (Bushing Installed)mm in

60.058 MIN 2.3645

24 Valve, 8.3 Liter Engine Camshaft Gear (Camshaft Removed) (001-013)Section 1 - Cylinder Block - Group 01 Page 1-23


Camshaft Bushing Tool, Tool No. CAS-1412A

Install the camshaft bushings.

∆ CAUTION ∆The small hole in the bushing must be installed on the upper side.

Be sure the large lubricating oil hole is aligned.

A 3.2 mm [0.128 in] diameter rod must be able to pass through the lu-bricating oil hole.

Be sure the lubricating oil small hole is aligned with the appropriatehole.

Install camshaft. Refer to Procedure 001-008.

Camshaft Gear (Camshaft Removed) (001-013)

Remove (001-013-002)

Remove the gear.

Remove the thrust plate.

Camshaft Gear (Camshaft Removed) (001-013) 24 Valve, 8.3 Liter EnginePage 1-24 Section 1 - Cylinder Block - Group 01


Remove the camshaft key.


Inspect the camshaft gear for cracked, chipped, or broken teeth.

Inspect the camshaft bore for fretting or burrs.

NOTE: If the fretting, burrs, or raised material can not be removed withScotch-Brite™ 7448, or equivalent, replace the camshaft gear.

Inspect the camshaft gear keyway for burrs.

Remove burrs with Scotch-Brite™ 7448, or equivalent.

NOTE: If the keyway is damaged or the burrs can not be removed, thecamshaft gear must be replaced.

Inspect cam gear and timing plate for damage.

Inspect flathead capscrews to make sure they are tight.

If more than one capscrew is loose, replace cam gear.

If only one capscrew is loose, tighten all capscrews.

Torque Value: 7 N•m [60 in-lb]

24 Valve, 8.3 Liter Engine Camshaft Gear (Camshaft Removed) (001-013)Section 1 - Cylinder Block - Group 01 Page 1-25


Inspect the camshaft nose for fretting or burrs.

NOTE: If fretting or burrs can not be removed with Scotch-Brite™7448, or equivalent, replace the camshaft.

Install (001-013-026)

Lubricate the camshaft surface with Lubriplate 105, or equivalent.

Install the key.

Install the thrust plate.

NOTE: Because the thrust plate extends more than 180 degreesaround the camshaft, the thrust plate must be installed before install-ing the cam gear on the camshaft.

The camshaft gear will be permanently distorted if overheated. Theoven temperature should never exceed 177°C [350°F].

Heat the camshaft gear for 45 minutes.

Temperature: 149°C [300°F]

Connecting Rod (001-014) 24 Valve, 8.3 Liter EnginePage 1-26 Section 1 - Cylinder Block - Group 01


∆ WARNING ∆Wear protective gloves to prevent personal injury when handlingparts that have been heated.

Install the camshaft gear with the timing marks away from the cam-shaft.

NOTE: Be sure the gear is seated against camshaft shoulder.

Using a 0.001 inch feeler gauge, check to see if the feeler gauge canbe inserted between the camshaft gear and the shoulder on the cam-shaft. If the feeler gauge can be inserted, the camshaft gear is notproperly seated.

Connecting Rod (001-014)

Remove (001-014-002)

∆ WARNING ∆Coolant can be toxic. Keep away from pets and children. If not re-used, dispose of in accordance with local environmental regula-tions.

∆ WARNING ∆Wait until the temperature is below 50°C [120°F] to avoid personalinjury from hot coolant.

Drain the coolant. Refer to Procedure 008-018.

Remove the cylinder head. Refer to Procedure 002-004.





24 Valve, 8.3 Liter Engine Connecting Rod (001-014)Section 1 - Cylinder Block - Group 01 Page 1-27


Remove the piston and connecting rod assemblies from the engine.Refer to Procedure 001-054.

Remove the pistons from the connecting rods. Refer to Procedure 001-043.

Clean (001-014-006)

∆ WARNING ∆When using a steam cleaner, wear protective clothing and safetyglasses or a face shield. Hot steam can cause serious personal in-jury.

Use a nylon bristle brush to clean the oil drillings.

Use steam or solvent to clean the connecting rods.



Inspect the connecting rods and connecting rod caps for damage.

Replace the connecting rod if the I-beam is nicked or damaged.

Inspect the piston pin bore for damage or misalignment of the oil pas-sage and bushing.

Connecting Rod (001-014) 24 Valve, 8.3 Liter EnginePage 1-28 Section 1 - Cylinder Block - Group 01


Measure the connecting rod piston pin bushing inside diameter.

Measure the connecting rod crankshaft bore with the bearing shells re-moved and caps tightened.


Measure the diameter of the rod journal on the crankshaft.

Out-of-Roundness: 0.050 mm [0.002 in]

Taper: 0.013 mm [0.0005 in]

NOTE: If crankshaft rod journals are not within the given specifica-tions, the crankshaft must be replaced.

Bearing clearance: rod inside diameter (with bearing) minus crank-shaft journal diameter.

Connecting Rod Piston Bushing Diametermm in

45.023 MIN 1.772645.035 MAX 1.7730

Connecting Rod Crank Bore Diametermm in

80.987 MIN 3.188581.013 MAX 3.1895

Connecting Rod Journal Diametermm in

75.962 MIN 2.990676.013 MAX 2.9926

Bearing Clearancemm in

0.038 MIN 0.00150.116 MAX 0.0045

24 Valve, 8.3 Liter Engine Connecting Rod (001-014)Section 1 - Cylinder Block - Group 01 Page 1-29


Bearing clearance can also be determined with plastigauge during en-gine assembly.

Install (001-014-026)

Install the pistons on the connecting rods. Refer to Procedure 001-054.

Install the pistons and connecting rod assemblies. Refer to Procedure001-054.

Install lubricating oil pan and gasket. Refer to Procedure 007-025.

Install the cylinder head. Refer to Procedure 002-004.

Fill the lubricating oil pan. Refer to Procedure 007-025, General Infor-mation, for the correct lubrication oil specification.

Fill the cooling system.

Refer to vehicle operations manual for fluid amounts.

Crankshaft (001-016) 24 Valve, 8.3 Liter EnginePage 1-30 Section 1 - Cylinder Block - Group 01



Crankshaft (001-016)

Rotation Check (001-016-052)


The barring tool inserts into the flywheel housing and engages the fly-wheel ring gear. The crankshaft can then be rotated by hand using a 1/2-inch ratchet or breaker bar.

Crankshaft Gear, Front (Crankshaft Installed) (001-018)

General Information

The crankshaft gear can not be removed in chassis. To remove crank-shaft gear, refer to the vehicle user’s manual.

Crankshaft Seal, Front (001-023)

Remove (001-023-002)

Remove the drive belt. Refer to Procedure 008-002.

Remove the vibration damper. Refer to Procedure 001-052.

24 Valve, 8.3 Liter Engine Crankshaft Seal, Front (001-023)Section 1 - Cylinder Block - Group 01 Page 1-31


Remove the crank seal carrier. Refer to Procedure 001-023.

Remove the oil seal from the carrier. Drive the oil seal from the backside of the carrier toward the front side of the carrier, while supportingthe carrier.

Clean (001-023-006)

Clean the gear cover seal bore and the crankshaft surface of all oil andseal residue.


Inspect the crankshaft for excessive wear.

NOTE: If the crankshaft has excessive wear, a service wear sleeve isavailable.

Crankshaft Seal, Front (001-023) 24 Valve, 8.3 Liter EnginePage 1-32 Section 1 - Cylinder Block - Group 01


Install (001-023-026)

Apply a bead of Loctite™ 277, or equivalent, to the outside diameter ofthe seal.

Oil Seal Installation Tool, Tool No. CAS-2430

Leave the plastic pilot installation tool in the lubricating oil seal.

Position the seal on the service tool, Tool No. CAS-2430, with the lubri-cating oil seal dust lip facing outward.

NOTE: Properly support the carrier lubricating oil seal flange to pre-vent damage to the lubricating oil seal and carrier.

Press the lubricating oil seal into the carrier from the back side of thecarrier toward the front side of the carrier.

Press the lubricating oil seal until the seal is flush on front of the carrier.

Apply bead of sealant to the inside of the carrier to make sure thatthere is sealant inside of all through holes. Install seal carrier on frontcover. Refer to Procedure 001-031.

24 Valve, 8.3 Liter Engine Crankshaft Seal, Rear (001-024)Section 1 - Cylinder Block - Group 01 Page 1-33


Install the carrier on the front cover.

Tighten the carrier mounting nuts.


Install the vibration damper. Refer to Procedure 001-052.

Install the drive belt. Refer to Procedure 008-002.


Crankshaft Seal, Rear (001-024)

Remove (001-024-002)

Remove the clutch, transmission, and starter.

Remove the flywheel. Refer to Procedure 016-005.

Drill two holes 180 degrees apart into the seal carrier.

Crankshaft Seal, Rear (001-024) 24 Valve, 8.3 Liter EnginePage 1-34 Section 1 - Cylinder Block - Group 01


Remove the rear seal using a screwdriver to pry it loose.

Clean (001-024-006)

∆ CAUTION ∆The seal lip and the sealing surface on the crankshaft must befree from all oil residue to prevent seal leaks.

Clean and dry the rear crankshaft sealing surface.


Inspect the crankshaft for excessive wear.

If the crankshaft has excessive wear, a service wear sleeve is available.

Install (001-024-026)

Rear Camshaft Installation Tool, Tool No. CAS-2355

Install the seal pilot, provided in the replacement kit, onto the crank-shaft. Push the seal onto the pilot and crankshaft.

Remove the seal pilot.

NOTE: For installation, the lubricating oil seal requires a mild soap onthe outside diameter of the seal case.

24 Valve, 8.3 Liter Engine Crankshaft Wear Sleeve, Front (001-025)Section 1 - Cylinder Block - Group 01 Page 1-35


Use the alignment tool and installation tool, Tool No. CAS-2355, to in-stall the seal to the correct depth in the housing.

Install the flywheel. Tighten the capscrews in sequence as shown inthe illustration.


Install the clutch, transmission, and starter. Operate the engine andcheck for leaks.

Crankshaft Wear Sleeve, Front (001-025)

Remove (001-025-002)



Remove the front cover. Refer to Procedure 001-031.

Crankshaft Wear Sleeve, Front (001-025) 24 Valve, 8.3 Liter EnginePage 1-36 Section 1 - Cylinder Block - Group 01


∆ CAUTION ∆Do not nick or gouge the crankshaft with the chisel. If the crank-shaft is damaged, it must be replaced.

Use a hammer and a chisel that is only as wide as the wear sleeve.Make one or two chisel marks across the wear sleeve. This will expandthe wear sleeve allowing the sleeve to be removed.

Clean (001-025-006)

Use a crocus cloth to remove any rust or other deposits from the crank-shaft flange.

Use a clean cloth to clean the crankshaft flange.


Inspect the seal contact area of the crankshaft for a wear groove. If theseal has worn a groove deep enough to be felt with a sharp object orfingernail, it will be necessary to install a wear sleeve to prevent an oilleak.

The oil seal used with the wear sleeve has a larger inside diameterthan the standard seal. The two seals are not interchangeable. Referto the appropriate Case 24 Valve 8.3 Liter Engine Parts Catalog for thecorrect part number.

Install (001-025-026)

Crankshaft Front Wear Sleeve Installation Tool, Tool No. CAS-2167

Use the driver to install the wear sleeve to the correct position on thecrankshaft.

Ref. No. Description Qty.

1 Driver 12 Spacer 23 Capscrew

M14x1.5x60 mm2

4 Hai Pin Cotter 2

24 Valve, 8.3 Liter Engine Crankshaft Wear Sleeve, Front (001-025)Section 1 - Cylinder Block - Group 01 Page 1-37


Apply a thin coat of clean 15W-40 lubricating oil to the inside diameterand capscrew threads.

Apply a thin coat of clean 15W-40 lubricating oil to the crankshaftflange.

Position the chamfered end of the wear sleeve onto the end of thecrankshaft.

Install the wear sleeve installation tool on the crankshaft.

Install the puller stud into the installation tool.

Crankshaft Wear Sleeve, Front (001-025) 24 Valve, 8.3 Liter EnginePage 1-38 Section 1 - Cylinder Block - Group 01


Install the wear sleeve with the chamfer toward the crankshaft.

Install the cup and push the sleeve on the crankshaft.

Remove the sleeve installation tool from the crankshaft.

Install a new seal into the seal carrier. Refer to Procedure 001-023.

Install the gear cover. Refer to Procedure 001-023.

Install the seal carrier. Refer to Procedure 001-023.

Install vibration damper. Refer to Procedure 001-052.

Install drive belts. Refer to Procedure 008-002.

Operate the engine and check for leaks.

24 Valve, 8.3 Liter Engine Cylinder Liner (001-028)Section 1 - Cylinder Block - Group 01 Page 1-39


Cylinder Liner (001-028)

Preparatory (001-028-000)

The cylinder block has a replaceable cylinder liner. A mid-stop designis used to locate the liner in the block. A press fit between the liner andthe block provides coolant sealing at the top of the liner. A rectangularring seal (liner seal) is used for sealing at the mid-stop portion of theliner.

NOTE: Case Corporation does not recommend removing the cylinderliners to repair an oil consumption problem if the inside diameters ofthe liners are within the inspection limits included in this procedure.

Careful analysis of the condition of the liner bores, piston rings, andpistons can result in the restoration of cylinder sealing with a minimumreplacement of parts.

Remove (001-028-002)

Drain the cooling system. Refer to Procedure 008-018.

Remove valve cover. Refer to Procedure 003-011.



Remove the lubricating oil pan and oil suction tube. Refer to Procedure007-025.

Cylinder Liner (001-028) 24 Valve, 8.3 Liter EnginePage 1-40 Section 1 - Cylinder Block - Group 01


Remove the pistons and the connecting rods. Refer to Procedure 001-054.

Preliminary Liner Inspection

Before removing the cylinder liners, inspect the condition to determinereuse.

Inspect the inside diameters of the liners for cracks, scuffing, and scor-ing.

Inspect the inside diameters for vertical scratches deep enough to befelt with a fingernail.

NOTE: If a fingernail catches in the scratch, the liner must be re-placed.

Inspect the inside diameter for liner bore polishing.

A moderate polish produces a bright mirror finish in the worn area withtraces of the original hone marks or an indication of an etch pattern.

A heavy polish produces a bright mirror finish in the worn area with notraces of hone marks or an etch pattern.

Do not reuse liners exhibiting heavy polish or any indications of parti-cle embedment from a failure. Severely worn liners will have a ridgenear the top of the liner bore.

If the wear pattern indicates the liner bore is not straight or not round,use a dial bore gauge to measure the liner inside diameter in four plac-es 90 degrees apart at the top and bottom of the piston travel area.

Cylinder Liner DimensionsMaximum Out of Round 0.04 mm [0.0016 in]Maximum Taper 0.04 mm [0.0016 in]Maximum Bore Diameter

114.04 mm [4.4897 in]



NOTE: If a liner bore is not acceptable for reuse, it must be replaced.Damaged liners can not be honed or deglazed. This would destroy thecross-hatch pattern needed for oil control.

NOTE: Do not remove or disturb the liner seals for liners which passthe inspection criteria.

Liner Protrusion Gauge, Tool No. OEM6459

Liner protrusion is the distance the liner protrudes above the blockface. Before removing the liners, check the protrusion in the unclampedstage.

If the liner was installed correctly and the liner protrusion is out of limits,it will be necessary to machine the counterbore and add shims to re-store to the original specifications.

Use clean shop rags to cover the crankshaft to prevent debris from fall-ing into the main journal area or into the connecting rod journal oil drill-ing.

Cylinder Liner Puller, Tool No. OEM4083 and OTC Plate No. 1234

∆ CAUTION ∆The liner puller must be installed and used as described to avoiddamage to the cylinder block. The puller must not contact theblock casting at points (1), (2), (3), and (4).

Insert the liner puller into the top of the cylinder block.

Cylinder Liner Dimensionsmm in

0.025 MIN 0.0010.122 MAX 0.0048



NOTE: The liner puller must be centered on the top of the cylinderblock.

Turn the puller jackscrew clockwise to loosen the liner from the cylinderblock.

Use both hands to remove the liner.

Universal Liner Puller, Tool No. OEM-6529

∆ CAUTION ∆The liner puller must be installed and used as described to avoiddamage to the cylinder block. The puller plate must be parallel tothe main bearing saddles and must not overlap the liner outsidediameter.

Insert the liner puller into the top of the cylinder block.

NOTE: The liner puller must be centered on the top of the cylinderblock.

Turn the puller jackscrews clockwise to loosen the liner from the cylin-der block.

Use both hands to remove the liner.

Use Dykem®, or equivalent, to mark the cylinder number on each liner.



Clean (001-028-006)

∆ CAUTION ∆Do not use any abrasives in the ring travel area of the liner. Theliner can be damaged.

Use a soft wire brush or a fine fibrous abrasive pad such as Scotch-Brite™ 7448, or equivalent, to clean the flange seating area.

∆ WARNING ∆When using a steam cleaner, wear protective clothing and safetyglasses or a face shield. Hot steam can cause serious personal in-jury.

Use solvent or steam clean the liners and dry with compressed air.

Use clean 15W-40 oil to lubricate the inside diameter of the liners.

Allow the oil to soak in the liner for 5 to 10 minutes.

NOTE: Use lint-free paper towels to wipe the oil from the inside of theliners.

Continue to lubricate the inside of the liners and wipe clean until the pa-per towel shows no gray or black residue.


Inspect the liners for cracks on the inside and outside diameters.



Inspect for cracks under the flange.

Inspect the outside diameter and seat area for excessive corrosion orpitting.

NOTE: Pits must not be more than 1.6 mm [0.06 in] deep.

Replace the liner if the pits are too deep or if the corrosion can not beremoved with fine emery cloth.

Inspect the inside diameters for vertical scratches deep enough to befelt with a fingernail.

NOTE: If a fingernail catches in the scratch, the liner must be re-placed.

Inspect the inside diameter for scuffing or scoring.

Inspect the inside diameter for liner bore polishing.

A moderate polish produces a bright mirror finish in the worn area withtraces of the original hone marks or an indication of an etch pattern.

A heavy polish produces a bright mirror finish in the worn area with notraces of hone marks or an etch pattern.



Replace the liner if:• A heavy polish is present over 20 percent of the piston ring travel

area.• Both moderate and heavy polish over 30 percent of the piston

ring travel area and one half (15 percent) is heavy polish.

Dial Bore Gauge

Measure the liner inside diameter in four places 90 degrees apart atthe top and bottom of the piston travel area.

Measure the outside diameter of the liner top press fit area.

Measure the cylinder liner bore in the block.

Cylinder Liner I.D.mm in

114.000 MIN 4.4882114.040 MAX 4.4898

Cylinder Liner O.D. (Top Press Fit)mm in

130.938 MIN 5.1550130.958 MAX 5.1558

Cylinder Liner Bore in Block (Press Fit Bore)mm in

130.900 MIN 5.1535130.950 MAX 5.1570



Install (001-028-026)

∆ CAUTION ∆Clean all deposits and debris from sealing surfaces A, B, and C.Use Scotch-Brite™ 7448, or equivalent, and cleaning solvent topolish the surfaces. Due to the critical machined tolerances, careshould be taken not to remove any additional material.

If surface C has cracks or signs of extreme wear, the counterbore willrequire machining and the installation of shims for the correct liner pro-trusion.

Cylinder liner shims are available as follows:

Cylinder Liner Shim Thickness0.25 mm [0.010 in]0.38 mm [0.015 in]0.51 mm [0.020 in]0.76 mm [0.030 in]1.00 mm [0.040 in]

Clean the combustion deck with a gasket scraper or Scotch-Brite™7448, or equivalent, and diesel fuel or solvent.

Thoroughly flush the block with mineral spirits or cleaning solvent.

Remove the shop rags and clean the crankshaft with a cleaning sol-vent.

Blow the cylinder bores and crankshaft dry and wipe them clean witha lint-free cloth.



Lubricate surfaces A and B with clean 15W-40 engine oil.

Use clean 15W-40 oil to coat the liner o-ring seals.

Install new o-ring seals on the liners.

When reusing liners, install them in the same cylinder from which theywere removed and rotate them 45 degrees (1/8 turn) from their originalposition. When correctly installed, any liner pitting should be positionedas illustrated so the pitted surface is rotated away from the locationwhere pitting occurs.

Install the liner into the bore of the cylinder block.



Clamps, Tool No. CAS-1049A

Using two cylinder head capscrews, clamp the liner in position.

Turn the capscrews.


Remove the clamps and repeat this procedure until all liners have beenclamped and released.

Liner Protrusion Gauge, Tool No. OEM6459

Liner protrusion is the distance the liner protrudes above the blockface.Measure the liner protrusion at four points 90 degrees apart.

NOTE: If the liner protrusion varies more than 0.025 mm [0.0010 in]for 180 degrees:

Install and tighten the liner clamps again.


Inspect the liner protrusion again.

Cylinder Liner Protrusionmm in

0.025 MIN 0.0010.122 MAX 0.0048



If the protrusion still varies more than 0.025 mm [0.0010 in]:

• Remove the liner

Inspect the liner sealing edge for burrs, dirt, or damage.

Replace the liner if it is damaged.

Install the liner again.

Inspect the liner protrusion.

Service Tip:If the out-of-limit condition is minimal, tolerance stack-up may allow theprotrusion limits to be obtained by installing other new liners in the out-of-limit bore.

If the liner protrusion still does not meet the specifications, machine thecylinder block liner bore for shims.



Use a feeler gauge to inspect the liner to block clearance at the fourblock casting points.

NOTE: If the clearance is less than 0.229 mm [0.009 in]:

Remove the liner.

Inspect the liner and cylinder block for dirt or damage.

Replace the liner if it is damaged.

Install the liner again.

Cylinder Liner to Block Clearancemm in

0.229 MIN 0.009



Measure the liner bore for out-of-roundness at points C, D, E, F, and G.Measure each point in the direction AA and BB. The bore must not bemore than 0.04 mm [0.002 in] out-of-round.

NOTE: If the liner bore is more than 0.04 mm [0.002 in] out-of-round:

Remove the liner so the cylinder block liner bore can be measured.

Install the pistons and connecting rods. Refer to Procedures 001-054.

NOTE: Do not interchange pistons from the original cylinder location.

Install the lubricating oil pan and suction tube. Refer to Procedure 007-025.

Install the cylinder head. Refer to Procedure 002-004.

Gear Cover, Front (001-031) 24 Valve, 8.3 Liter EnginePage 1-52 Section 1 - Cylinder Block - Group 01


Fill and vent the cooling system. Refer to Procedure 008-018.

Fill lubricating system with oil. Refer to Procedure 007-025.

Operate the engine until the coolant temperature reaches 82ºC [180ºF]and check for leaks and proper operation.

Gear Cover, Front (001-031)

Remove (001-031-002)



If required, remove the fan hub pulley. Refer to Procedure 008-039.

Remove the front gear cover.

24 Valve, 8.3 Liter Engine Gear Cover, Front (001-031)Section 1 - Cylinder Block - Group 01 Page 1-53


Clean (001-031-006)

Clean sealant from the gear cover and gear housing gasket surface.


Inspect the gear cover for cracks or damage.

Install (001-031-026)

Install a new seal in the carrier. Refer to Procedure 001-023.

∆ CAUTION ∆The crankshaft must be clean, dry and oil free before installingthe gear cover. Failure to properly clean the sealing surface willresult in an oil leak.

Gear Cover, Front (001-031) 24 Valve, 8.3 Liter EnginePage 1-54 Section 1 - Cylinder Block - Group 01


Apply a thin bead of Three-Bond™, J823494, to the cover side of thefront cover only.

Install the front cover on the engine within 10 minutes.

Apply Three-Bond™, J823494, to inside of the bolt holes.

Tighten front cover capscrews.


Apply a bead of sealant to the inside of the carrier making sure thatthere is sealant inside all of the through holes.

Install seal carrier on front cover. Refer to Procedure 001-023.

Install the vibration damper. Refer to Procedure 001-051 or 001-052.



24 Valve, 8.3 Liter Engine Gear Housing, Front (001-033)Section 1 - Cylinder Block - Group 01 Page 1-55


Gear Housing, Front (001-033)

Remove (001-033-002)

Remove the valve cover, rocker levers, and push rods. Refer to Proce-dures 003-009 and 004-014.


Remove the gear cover. Refer to Procedure 001-032.

Remove the fuel pump. Refer to Procedure 005-016.

Remove the camshaft. Refer to Procedure 001-008.

Remove or disconnect gear driven accessories.

Remove the four front oil pan capscrews.

Remove the gear housing capscrews.

Using a feeler gauge, separate the lubricating oil pan gasket from thegear housing.

Gear Housing, Front (001-033) 24 Valve, 8.3 Liter EnginePage 1-56 Section 1 - Cylinder Block - Group 01


Remove the gear housing.

Clean (001-033-006)

Clean the gasket material from the cylinder block.


Inspect the lubricating oil pan gasket. If it is not torn, coat with Three-Bond™, J823494.

Inspect fuel pump mounting studs for damage. To install or remove thefuel pump studs, use two nuts locked together on the stud.

24 Valve, 8.3 Liter Engine Gear Housing, Front (001-033)Section 1 - Cylinder Block - Group 01 Page 1-57


Inspect gear housing for cracks or damaged sealing surfaces.

Install (001-033-026)

Pan Gasket - Repair

If the pan gasket is torn, it may be repaired. Cut the torn gasket off evenwith the front of the cylinder block.

Using the old gasket as a pattern, cut the front section of a new gasketto the same size.

Clean the sealing surfaces and coat the new gasket on both sides withThree-Bond™, J823494.

Gear Housing, Front (001-033) 24 Valve, 8.3 Liter EnginePage 1-58 Section 1 - Cylinder Block - Group 01


Use common thread or a very fine wire to hold the new gasket splicein position as illustrated.

Position the gear housing gasket on the alignment dowels.

Use guide pins (M8 x 1.25 x 50) to assist in aligning the gasket andgear housing. Be sure to remove the guide pins after alignment.

Carefully install the gear housing, making sure both gaskets are inplace.


Start the oil pan capscrews in the holes not being used to tie the gas-ket in place.

24 Valve, 8.3 Liter Engine Piston (001-043)Section 1 - Cylinder Block - Group 01 Page 1-59


Remove the thread or wire holding the gasket in place.

Install the remaining two capscrews and tighten.


Install the camshaft. Refer to Procedure 001-008.

Install the fuel pump. Refer to Procedure 005-016.

Install the gear cover. Refer to Procedure 001-032.

Install the vibration damper. Refer to Procedure 001-052.

Install the push rods, rocker levers, and rocker lever cover. Refer to Pro-cedures 003-009 and 004-014.

Install or connect gear driven or accessories if equipped. Refer to thevehicle service manual.

Piston (001-043)

General Information

Remove the dipstick bayonet.

Piston (001-043) 24 Valve, 8.3 Liter EnginePage 1-60 Section 1 - Cylinder Block - Group 01





∆ WARNING ∆Some state and federal agencies in the United States of Americahave determined that used oil can be carcinogenic and can causereproductive toxicity. Avoid inhalation of vapors, ingestion, andprolonged contact with used engine oil.



Remove the lubricating oil pan. Refer to Procedure 007-025.


Remove (001-043-002)

The piston and connecting rod must be removed as an assembly. Toremove the piston and connecting rod, Refer to Procedure 001-014.

Disassemble (001-043-003)

Piston Ring Expander, Tool No. OEM6266

Refer to Procedure 001-054 to disassemble the piston and connectingrod assembly.

Use Piston Ring Expander to remove the piston rings.

Place a tag on the rings and record the cylinder number of the pistonon the tag.

NOTE: Refer to Procedure 001-047 for piston ring inspection.



Clean (001-043-006)

∆ CAUTION ∆Do not use the bead blast method to clean the piston. The pistonwill be damaged by blast material embedded in the aluminum.

∆ CAUTION ∆Do not clean the pistons and rods in an acid tank.

Soak the pistons in cold parts cleaner.

Soaking the pistons overnight will usually loosen the carbon deposits.

Wash the pistons and rods in a strong solution of laundry detergent inhot water. Use a non-metallic brush to remove carbon deposits.

∆ CAUTION ∆Do not use a metal brush. A metal brush will damage the pistonring grooves.

∆ CAUTION ∆Do not use a ring groove cleaner and be sure not to scratch thering sealing surface in the piston groove.

Clean the remaining deposits from the ring grooves with the squareend of a broken piston ring.

Wash the pistons again in a detergent solution or solvent.

After rinsing, use compressed air to dry.

Piston (001-043) 24 Valve, 8.3 Liter EnginePage 1-62 Section 1 - Cylinder Block - Group 01



Inspect the piston for damage and excessive wear. Check the top, ringgrooves, skirt and pin bore for cracks or damage.

NOTE: If severe piston damage has occurred, check the turbochargerand other exhaust components for damage from debris.

Measure the piston skirt diameter as illustrated.

Use a new piston ring to measure the clearance in the oil control ringgroove.

Measure the pin bore when the piston temperature is at 20°C [68°F].

NOTE: Add 0.013 mm [0.0005 in] to the bore diameter per 5°C [10°F]temperature rise up to 32°C [90°F].

Piston Skirt Diametermm in

113.863 MIN 4.4828113.877 MAX 4.4833

Ring Clearancemm in

Oil Control Ring 0.040 MIN 0.00160.095 MAX 0.0037

Piston Pin Bore Diametermm in

45.006 MIN 1.771945.012 MAX 1.7721



Piston Pin - Inspection

Inspect the piston pin for nicks, gouges and excessive wear.

Measure the pin diameter.

Discard the piston pin if it is more than 0.003 mm [0.001 in] out-of-round.

Assemble (001-043-025)

Refer to Procedure 001-054 for piston and connecting rod assembly in-structions.

Install (001-043-026)

The piston and connecting rod must be installed as an assembly. Referto Procedure 001-054.

Pin Diametermm in

44.997 MIN 1.771545.003 MAX 1.7718

Piston Rings (001-047) 24 Valve, 8.3 Liter EnginePage 1-64 Section 1 - Cylinder Block - Group 01


Piston Rings (001-047)


Piston Ring - Inspection

Check the cylinder liner for wear, for those cylinders with no obviousdamage, check the following conditions which can cause loss of seal-ing:

• Rings installed incorrectly.

NOTE: There are two different design intermediate rings used (A) rect-angular (B) reverse twist.

Refer to piston rings installation in this section.

• Condition of ring is worn.

• Abrasive wear is indicated by the concentrated vertical scratches (B). The chromium plate is worn through and the face of the ring has a brighter finish compared to the dull satin finish of a new ring (A).

• This type of wear can be caused by ingested abrasive material. Inadequate cleaning during a previous repair or particles embed-ded in the liner can cause the condition.

Scuffing and scoring is indicated by the heavy scratches, metal discol-oration and voids (B).

This damage indicates a break down of the oil film on the liner wallcausing transfer of material from the ring face to the liner. The conditioncan be caused by:

• Engine is overheating.• Oil dilution or improper maintenance of the lubrication system.• Piston cooling nozzle malfunction.

Oil ring plugging is indicated by the deposits in the oil ring grooves (B).Plugging of the ring drains restricts oil drain back which floods the ringbelt area resulting in a loss of oil control. The condition can be causedby:

• Low engine operating temperatures - long periods of idling or a cooling system malfunction.

• Extended oil change intervals, the wrong grade of oil or poor quality oil.

24 Valve, 8.3 Liter Engine Piston Rings (001-047)Section 1 - Cylinder Block - Group 01 Page 1-65


Position each ring in the wear area of the cylinder liner in which theywill be used and use a piston to square it with the bore.

A = 89 mm [3.5 in].

Use a feeler gauge to measure the piston ring gap. Replace the ring ifit does not meet the following specifications.

NOTE: Add 0.09 mm [0.004 in] for every 0.03 mm [0.001 in] of cylinderliner bore wear up to the maximum worn limit.

Install (001-047-026)

The top surface of the upper and intermediate rings are identified ei-ther with the word TOP or a supplier identification mark, such as a dot.Assemble with the word TOP or the supplier mark facing upward.

The bottom or oil control ring can be installed with either side up.

NOTE: The two piece oil control ring must be installed with the ex-pander ring gap 180 degrees from the gap of the oil ring.

Ring Gapmm in

Top Ring: 0.35 MIN 0.0140.60 MAX 0.024

Intermediate Ring: 0.35 MIN 0.0140.60 MAX 0.024

Oil Control Ring: 0.30 MIN 0.0120.60 MAX 0.024

Vibration Damper, Rubber (001-051) 24 Valve, 8.3 Liter EnginePage 1-66 Section 1 - Cylinder Block - Group 01



Install the rings on the piston.

Position the oil ring expander in the oil control ring groove.

Vibration Damper, Rubber (001-051)

Remove (001-051-002)


Loosen the vibration damper capscrews.

Remove vibration damper.

24 Valve, 8.3 Liter Engine Vibration Damper, Rubber (001-051)Section 1 - Cylinder Block - Group 01 Page 1-67



Check the index lines (A) on the damper hub (B) and the inertia mem-ber (C). If the lines are more than 1.59 mm [1/16 inch] out of alignment,replace the damper.

Inspect the vibration damper hub (B) for cracks. Replace the damper ifthe hub is cracked.

Inspect the rubber member for deterioration. If pieces of rubber aremissing or if the elastic member is more than 3.18 mm [1/8 inch] belowthe metal surface, replace the damper.

NOTE: Also look for forward movement of the damper ring on the hub.Replace the damper if any movement is detected.

Install (001-051-026)

Install the vibration damper. Do not tighten the capscrews to the cor-rect torque value at this time.



Service Tip:If difficulty is experienced installing the drive belt (the belt seems tooshort), position the belt over the grooved pulleys first and then whileholding the tensioner up, slide the belt over the water pump pulley.

Vibration Damper (001-052) 24 Valve, 8.3 Liter EnginePage 1-68 Section 1 - Cylinder Block - Group 01


Tighten vibration damper capscrews.


Vibration Damper (001-052)

Remove (001-025-002)

Loosen the vibration damper capscrews.


Remove vibration damper.


Check the mounting web for cracks. Check the housing for dents orraised surfaces. Replace the damper if any of these defects are identi-fied.

24 Valve, 8.3 Liter Engine Vibration Damper (001-052)Section 1 - Cylinder Block - Group 01 Page 1-69


The viscous damper is filled with a silicone fluid. After many hours ofuse, the silicone fluid may become thicker and expand.

To determine if the damper thickness is correct, remove the paint fromthe damper in four locations on either side of the damper. Measure andrecord the thickness of the damper in four places.

Measure the thickness 3.175 mm [0.125 in] from the outside of thedamper.

Replace the damper if its thickness varies by more than 0.25 mm[0.010 in].

Spray the damper with spot check developer, Type SKD-NF, or equiva-lent. Heat the damper in an oven (rolled lip side down) for 2 hours.

Temperature: 93°C [200°F]

∆ CAUTION ∆Wear protective gloves to prevent personal injury when handlingparts that have been heated.

Remove the damper from the oven and check for fluid leakage. If thereis leakage, replace the damper.

Install (001-052-026)

Install the vibration damper. Do not tighten the capscrews to the correcttorque value at this time.


Piston and Connecting Rod Assembly (001-054) 24 Valve, 8.3 Liter EnginePage 1-70 Section 1 - Cylinder Block - Group 01



Service Tip: If difficulty is experienced installing the drive belt (the beltseems too short), position the belt over the grooved pulleys first andthen while holding the tensioner up, slide the belt over the water pumppulley.

Tighten vibration damper capscrews.

Torque Value: 200 N•m [147.5 ft-lb]

Piston and Connecting Rod Assembly (001-054)

Remove (001-054-002)

∆ WARNING ∆Some state and local agencies in the United States of Americahave determined that used engine oil can be carcinogenic andcan cause reproductive toxicity. Avoid inhalation of vapors, in-gestion, and prolonged contact with used engine oil.


Drain the lubricating oil. Refer to procedure 007-025.


24 Valve, 8.3 Liter Engine Piston and Connecting Rod Assembly (001-054)Section 1 - Cylinder Block - Group 01 Page 1-71


∆ WARNING ∆Coolant can be toxic. Keep away from children and pets. If not re-used, dispose of in accordance with local environmental regula-tions.




Mark each connecting rod cap according to the cylinder.

Rotate the crankshaft until the pistons are below the carbon depositswhich are found above the ring travel area.

Use a scraper or a blunt edged instrument to loosen the carbon depos-its. Do not damage the cylinder with the scraper.



Remove the remaining carbon with a Scotch-Brite™,or equivalent.

∆ WARNING ∆To prevent serious eye damage wear eye protection during thisoperation.

An alternative method to remove the carbon ridge is to use a high qual-ity steel wire wheel installed in a drill or die grinder.

NOTE: An inferior quality wire wheel will lose steel bristles during op-eration, thus causing additional contamination.

Do not use the steel wire wheel in the piston travel area. Operate thewheel in a circular motion to remove the deposits.

Mark each piston according to the cylinder.

NOTE: On pistons with anodized coatings, do not stamp on the anod-ized coating or on the outer rim.

Remove the nuts, connecting rod cap and connecting rod bearings.



Push the connecting rod and piston assembly out of the cylinder bore.Care must be taken not to mutilate the connecting rod or bearing.


Remove the retaining rings.

Remove the piston pin.

NOTE: Heating the piston is not required.


Remove the piston rings. Refer to Procedure 001-047.



Clean (001-054-006)

Clean the pistons. Refer to Procedure 001-043.


Refer to Procedure 001-043 for inspection specifications for the pis-tons.

Refer to Procedure 001-014 for inspection specifications for the con-necting rod.

Assemble (001-054-025)

Install the retaining ring in the pin groove on one side of the piston.



Lubricate the pin and pin bores with engine lubricating oil.

Install the pin through the piston and connecting rod.

NOTE: Pistons do not require heating to install the pin, however, thepistons do need to be at room temperature or above.

Install the second retaining ring.

Install (001-054-026)

Install the bearing shells into both the connecting rod and the connect-ing rod cap. Make sure the tang on the bearing shells is in the slot ofthe connecting rod cap and connecting rod.



Lubricate the connecting rod bearings with a light film of Lubriplate™105, or equivalent.

Install the piston rings. Refer to Procedure 001-047.

Lubricate the rings and piston skirts with clean engine lubricating oil.

Position the rings so that the ring gaps are 120 degrees apart.

Piston Ring Compressor, Tool No. OEM6268

∆ CAUTION ∆If using a strap type ring compressor, make sure the inside end ofthe strap does not hook on a ring gap and break the ring.

Compress the rings.



Lubricate the cylinder bore with clean 15W-40 engine oil.

Position the connecting rod journal for the piston to be installed to bot-tom dead center (BDC).

Take care not to damage the cylinder wall when inserting the connect-ing rod.

Carefully push the piston into the bore while guiding the connecting rodto the crankshaft journal.



Lubricate the threads of the connecting rod capscrews with clean 15W-40 engine oil.

∆ CAUTION ∆The number stamped on the rod and cap at the parting line mustmatch and be installed on the oil cooler side of the engine.

Install the connecting rod cap and capscrews to the connecting rod.

Alternately, tighten the two capscrews.

Torque Value: Step 1 35 N•m [26 ft-lb]2 70 N•m [52 ft-lb]3 60 degrees

NOTE: Do not measure the clearance between the rod cap and crank-shaft.

Measure the side clearance between the connecting rod and crank-shaft.

Connecting Rod and Crankshaft Side Clearancemm in0.10 MIN 0.0040.33 MAX 0.013



∆ CAUTION ∆The crankshaft must rotate freely.

Check for freedom of rotation as the connecting rod caps are installed.If the crankshaft does not rotate freely, check the installation of theconnecting rod bearings and the bearing size.

NOTE: If the connecting rod is not properly oriented (tang oppositethe camshaft), it will contact the camshaft and lock the engine.

24 Valve, 8.3 Liter Engine Section 2 - Cylinder Head - Group 02Section 2 - Cylinder Head - Group 02 Page 2-a


Section 2 - Cylinder Head - Group 02

Section Contents

Crosshead (002-001) ................................................................................................................................................................................... 2-2Remove (002-001-002) ................................................................................................................................................................. 2-2Inspect for Reuse (002-001-007) .................................................................................................................................................. 2-2Install (002-001-026) ..................................................................................................................................................................... 2-2

Cylinder Head (002-004) ............................................................................................................................................................................. 2-2Preparatory (002-004-000) ............................................................................................................................................................ 2-2Remove (002-004-002) ................................................................................................................................................................. 2-3Clean (002-004-006) ..................................................................................................................................................................... 2-4Inspect for Reuse (002-004-007) .................................................................................................................................................. 2-6Install (002-004-026) ..................................................................................................................................................................... 2-8

Injector Protrusion (002-022) ................................................................................................................................................................... 2-19Measure (002-022-010) .............................................................................................................................................................. 2-19

Service Tools................................................................................................................................................................................................ 2-1Cylinder Head ................................................................................................................................................................................ 2-1

Valve, Cylinder Head (002-020) ................................................................................................................................................................ 2-12Preparatory (002-020-000) .......................................................................................................................................................... 2-12Disassemble (002-020-003) ........................................................................................................................................................ 2-13Clean (002-020-006) ................................................................................................................................................................... 2-14Inspect for Reuse (002-020-007) ................................................................................................................................................ 2-14Assemble (002-020-025) ............................................................................................................................................................. 2-17Install (002-020-026) ................................................................................................................................................................... 2-18

Section 2 - Cylinder Head - Group 02 24 Valve, 8.3 Liter EnginePage2-b Section 2 - Cylinder Head - Group 02


THIS PAGE INTENTIONALLY LEFT BLANK

24 Valve, 8.3 Liter Engine Service ToolsSection 2 - Cylinder Head - Group 02 Page 2-1


Service Tools

Cylinder Head

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate pro-ceudre.


OEM 6414 Valve Spring CompressorUsed to remove and install valve collets.

J823921 Capscrew Length GaugeUsed to measure capscrew free length.

OEM 6459 Gauge BlockUsed to measure the injector protrusion and valve recess in the cylinder head.

CAS 1690 Engine Barring GearUsed to engage the flywheel ring gear to rotate the crankshaft.

Crosshead (002-001) 24 Valve, 8.3 Liter EnginePage 2-2 Section 2 - Cylinder Head - Group 02


Crosshead (002-001)

Remove (002-001-002)

Remove rocker lever cover and rocker levers. Refer to Procedures 003-011 and 003-008.


Check crossheads for cracks and/or excessive wear on rocker leverand valve tip mating surfaces.

Install (002-001-026)

Install rocker lever assembly. Refer to Procedure 003-008.

Install the rocker lever cover. Refer to Procedure 003-011.

Cylinder Head (002-004)


∆ WARNING ∆Coolant can be toxic. Keep away from children and pets. If not re-used, dispose of in accordance with local environmental regula-tions.


24 Valve, 8.3 Liter Engine Cylinder Head (002-004)Section 2 - Cylinder Head - Group 02 Page 2-3


• Drain the coolant. Refer to Procedure 008-018.

• Remove all water and heater hoses. Remove the intake manifold cover and intake heater (if equipped). Refer to Procedure 010-023.

• Remove the injector supply. Refer to Procedure 006-051.

• Remove the fuel connection tubes. Refer to Procedure 006-052.

• Remove the valve cover. Refer to Procedure 002-020.

• Remove the rocker levers. Refer to Procedure 003-008.

• Remove the injectors. Refer to Procedure 006-026.

• Remove the pushtubes. Refer to Procedure 003-008.

• Remove the fuel drain line. Refer to Procedure 006-013.

• Remove the turbocharger. Refer to Procedure 010-033.

• Remove the exhaust manifold. Refer to Procedure 011-007.

Remove (002-004-002)

Remove drive belt. Refer to Procedure 008-002.

Remove the fan hub assembly.

Omit this step if the fan hub assembly is not attached to the cylinderhead.

Remove the cylinder head capscrews in the order shown.

Cylinder Head (002-004) 24 Valve, 8.3 Liter EnginePage 2-4 Section 2 - Cylinder Head - Group 02


∆ WARNING ∆The component weighs 23 kg [50 lb] or more. To avoid personalinjury, use a hoist or get assistance to lift the component.

Cylinder Head Weight 71.2 kg [165 lb]

Remove the cylinder head and gasket from the cylinder block.

Clean (002-004-006)

Clean the carbon from the injector nozzle seat.

Remove the valves and springs. Refer to Procedure 002-020.

Scrape the gasket material from all gasket surfaces on the block andhead.

Clean the build-up of deposits from the coolant passages. Excessivedeposits may be cleaned in an acid tank but the expansion plugs mustfirst be removed.



Clean the cylinder head combustion deck with a Scotch-Brite™, orequivalent, and diesel fuel or solvent.

∆ WARNING ∆Wear protective eye covering while cleaning carbon deposits toprevent injury.

Clean carbon deposits from the valve pockets with a high quality steelwire wheel installed in a drill or a die grinder.

An inferior quality wire wheel will lose steel bristles during operation,thus causing additional contamination.

Wash the cylinder head in hot soapy water solution.


∆ CAUTION ∆Do not use caustic or acid solutions to clean the cylinder headcapscrews.

Use a petroleum-based solvent to clean the capscrews.

Clean the capscrew thoroughly with a wire brush, a soft wire wheel, oruse a non-abrasive bead blast to remove deposits from the shank andthe threads.




Straight Edge and Feeler Gauge

Cylinder Block Combustion Deck Inspect

Use a straight edge and feeler gauge to measure the overall flatnessof the cylinder block.

The overall flatness, end to end and side to side, must not exceed0.075 mm [0.003 in].

Inspect the combustion deck for any localized dips or imperfections. Ifpresent, the cylinder block head deck must be ground.

Cylinder Head Cracks - Reuse Guidelines

The reuse guidelines for a cylinder head with a crack extending fromthe injector bore to the intake valve seat are as follows:

If the crack does not extend into the valve seat, the cylinder head is re-usable.

If a crack extends into or through the valve seat, the cylinder headmust be repaired by replacing the valve seat insert.

Use a straight edge and a feeler gauge to inspect the cylinder headcombustion surface for flatness.

Cylinder Head Flatnessmm in

End to End 0.075 MAX 0.003Side to Side 0.075 MAX 0.003



Inspect the cylinder head capscrews for damaged threads, corrodedsurfaces, or a reduced diameter (due to capscrew stretching).

Do not reuse cylinder head capscrews under the following conditions:

• Visible corrosion or pitting exceeds 1 sq cm [0.155 sq in] in area. Example:

• acceptable is 9.525 x 9.525 mm [3/8 x 3/8 in]• unacceptable is 12.700 x 12.700 mm [1/2 x 1/2 in]• Visible corrosion or pitting exceeds 0.12 mm [0.005 in] in depth.

• Visible corrosion or pitting is located within 3.2 mm [1/8 in] of the fillet or threads.

• Stretched beyond free length maximum. Refer to the measure-ment procedure below:

Capscrew Length Gauge, Tool No. J823921

Free Length Measurement

NOTE: If the capscrews are not damaged, they can be reusedthroughout the life of the engine unless the specified free length is ex-ceeded.

To check the capscrew free length, place the head of the capscrew inthe appropriate slot with the flange against the base of the slot.



If the end of the capscrew touches the foot of the gauge, the capscrewis too long and must be discarded. The maximum capscrew freelength is 162.6 mm [6.4 in].

Install (002-004-026)

Position the new cylinder head gasket over the dowels.

NOTE: Do not attempt to reuse cylinder head gasket.


Carefully put the cylinder head on the cylinder block and seat it ontothe dowels.

Clyinder Head Weight: 75 kg [165 lb]

Lubricate the threads and under the heads on the head capscrews withclean 15W-40 engine lubricating oil.

NOTE: If new capscrews are used, capscrews threads are to be bur-nished.



Use the illustrated sequence to tighten the cylinder head capscrews.

14 mm

Torque Value:

All Capscrews Step 1 148 N•m [108 ft-lb]

Recheck All Step 2 148 N•m [108 ft-lb]

All Capscrews Step 3 90 degrees

Push Rods - Installation

Position the push tubes into the valve tappets.

Lubricate the push tube sockets with engine lubricating oil.



Rocker Levers - Installation

Lubricate the valve stems with engine lubricating oil.

Install the crossheads and rocker levers. Refer to Procedure 003-008.

Lubricate the pedestal capscrew threads and under the capscrewheads with engine lubricating oil.

Install the capscrews and tighten.


Valve Clearance - Adjustment

Set the valve clearance. Refer to Procedure 003-004.



• Install injectors. Refer to Procedure 006-026.

• Install fuel connection tubes. Refer to Procedure 006-052.

• Install intake manifold cover and intake heater (if equipped). Refer to Procedure 010-023.

• Install rocker lever cover. Refer to Procedure 003-011.

• Install injector supply lines. Refer to Procedure 006-051.

• Install fuel drain line. Refer to Procedure 006-013.

• Install turbocharger. Refer to Procedure 010-033.

• Install exhaust manifold. Refer to Procedure 011-007.

Install the fan hub.


Install the fan hub pulley.

Torque Value:8 mmCapscrew 24 N•m [18 ft-lb]10 mmCapscrew 43 N•m [32 ft-lb]

Valve, Cylinder Head (002-020) 24 Valve, 8.3 Liter EnginePage 2-12 Section 2 - Cylinder Head - Group 02


Drive Belt - Installation

3/8-Inch Square Drive

Lift the tensioner and install the belt. Refer to Procedure 008-002.

Service Tip: If difficulty is experienced installing the drive belt (the beltseems too short), position the belt over the grooved pulleys first andthen while holding the tensioner up, slide the belt over the water pumppulley.


Valve, Cylinder Head (002-020)



∆ WARNING ∆Wait until the temperature is below 50°C [120°F] to avoid personalinjury from not coolant.

• Drain the coolant. Refer to Procedure 008-018.

• Remove all water and heater hose. Refer to Procedure 008-045.

• Remove the cylinder head. Refer to Procedure 002-004.

24 Valve, 8.3 Liter Engine Valve, Cylinder Head (002-020)Section 2 - Cylinder Head - Group 02 Page 2-13



The following disassembly and assembly procedures are provided forinspection purposes only.

Mark the valves to identify their location.

Valve Spring Compressor, Tool No. OEM-6414

Compress the valve spring and remove the valve stem collets. UseService Tool, Tool No. OEM-6414.

Release valve spring and remove the spring retainer and spring.

Remove the remaining collets, retainers, springs and valves.

Keep the valves in a labeled rack for a correct match with companionseats while making measurements.



Remove the valve stem seals.

Clean (002-020-006)

∆ WARNING ∆Wear protective eye covering when cleaning the valves.

Clean the valve heads with a soft wire wheel.

NOTE: Keep the valves in a labeled rack to prevent mixing prior tomaking measurements.

Polish the valve stem with a Scotch-Brite™ pad, or equivalent, and die-sel fuel or solvent.


Valve Guide Inspection

Inspect the valve guides for scuffing or scoring.

Measure the valve guide bore.

Valve Guide Bore Diametermm in

8.019 MIN 0.31578.071 MAX 0.3185



Valve Seat Inspection

Inspect the valve seats for cracks or burned spots.

Service valve seats are available for seats with burned spots that willrequire more than 0.254 mm [0.010 in] grinding to clean up.

Inspect for abnormal wear on the heads and stems.

Measure the valve stem diameter.

Valve Seat Angle• Intake 30 degrees• Exhaust 45 degrees

Valve Stem Diametermm in7.94 MIN 0.31267.98 MAX 0.3142

Valve Depth (Installed)mm in

0.859 MIN 0.0341.21 MAX 0.048



Check the valve stem tip for flatness.

Inspect for bent valves.

Measure the rim thickness to determine if there is enough stock togrind the valve.

Inspect the valve springs.

Measure the valve spring.

Approx. Free Length (L):J944711 59 mm [2.34 in]

Maximum Inclination:J944711 1.5 mm [0.059 in]

Valve Rim Thickness Limitmm in0.79 MIN 0.031



A load of 906 to 1007 N [203.5 to 226.516 lb] is required to compressthe spring to a height of 30.6 mm [1.20 in].

Assemble (002-020-025)

NOTE: Clean all cylinder head components before assembling.

Install new valve guides, if damaged.

Install new valve stem seals.

Lubricate the stems with SAE 90W or 15W-40 engine oil before install-ing the valves.

Valve Spring Compressor

Compress the valve spring after assembling the spring and retainer.



Install new valve collets and release the spring tension.

Plastic Hammer

∆ CAUTION ∆Wear eye protection. If the collets are not correctly installed, theycan fly out when the stems are hit with a hammer.

After assembly, hit the valve stems with a plastic hammer to make surethat the collets are seated.

Install (002-020-026)


Install the cylinder head and gasket. Refer to Procedure 002-004.

Install the rocker levers. Refer to Procedure 003-008.

24 Valve, 8.3 Liter Engine Injector Protrusion (002-022)Section 2 - Cylinder Head - Group 02 Page 2-19


Adjust the valve lash. Refer to Procedure 003-004.

Install the rocker lever cover and gasket. Refer to Procedure 003-011.


Operate engine and check for leaks.

Injector Protrusion (002-022)

Measure (002-022-010)

∆ CAUTION ∆Improper injector protrusion can cause performance problemsand high pressure fuel leaks due to misalignment of the fuel con-nector tube.


Injector Protrusion (002-022) 24 Valve, 8.3 Liter EnginePage 2-20 Section 2 - Cylinder Head - Group 02


Gauge Block, Tool No. OEM6459

Place the injection protrusion tool on the flat surface of the head. Mea-sure the injector protrusion to the highest point on the injector. The pro-trusion should be within the following specifications:

3.0 mm +/- 0.4 mm [1.18 in +/- 0.16 in]

If the injector protrusion is out of specification, check the thickness ofthe injector sealing washer. Refer to Procedure 006-026.

If the sealing washer is the correct thickness, check to make sure theinjector bore is clean and free of debris.

If dirt is present, clean the injector bore using a injector bore brush.

In addition to a single sealing washer (A) on the injector, the thickness(B) of the head gasket controls injector protrusion.

If the head has been milled then the injector protrusion will be in-creased.

24 Valve, 8.3 Liter Engine Injector Protrusion (002-022)Section 2 - Cylinder Head - Group 02 Page 2-21


Make sure the proper thickness head gasket is being used for theamount the head that has been milled. Also when measuring the pro-trusion, the head gasket is not in place, so any increase in head gasketthickness over the standard head gasket must be subtracted from theinjector protrusion measurement.

NOTE: Measured protrusion - (new head gasket thickness - standardthickness) = protrusion. Protrusion must be within specification formu-la.

24 Valve, 8.3 Liter EngineSection 3 - Rocker Levers - Group 03 Page 3-a


Section 3 - Rocker Levers - Group 03

Section Contents

Overhead Set (003-004) .............................................................................................................................................................................. 3-1Adjust (003-004-029) .................................................................................................................................................................... 3-1

Rocker Lever (003-008) ............................................................................................................................................................................... 3-3Assemble (003-008-025) ............................................................................................................................................................... 3-6Clean (003-008-006) ..................................................................................................................................................................... 3-4Disassemble (003-008-003) .......................................................................................................................................................... 3-3Inspect for Reuse (003-008-007) .................................................................................................................................................. 3-5Install (003-008-026) ..................................................................................................................................................................... 3-7Remove (003-008-002) ................................................................................................................................................................. 3-3

Rocker Lever Cover (003-011) ................................................................................................................................................................... 3-8Inspect for Reuse (003-011-007) .................................................................................................................................................. 3-8Install (003-011-026) ..................................................................................................................................................................... 3-8Remove (003-011-002) ................................................................................................................................................................. 3-8

24 Valve, 8.3 Liter EnginePage 3-b Section 3 - Rocker Levers - Group 03


THIS PAGE LEFT BLANK

24 Valve, 8.3 Liter Engine Overhead Set (003-004)Section 3 - Rocker Levers - Group 03 Page 3-1


Overhead Set (003-004)

Adjust (003-004-029)

∆ CAUTION ∆Engine coolant temperature should be less than 60ºC [140ºF].

Remove the plastic fuel pump drive cover located on the front of the en-gine.

Rotate the crankshaft to align the top dead center (TDC) marks on thegear cover and the fuel pump gear.

Remove the rocker lever cover and gasket. Refer to Procedure 003-011.

With the engine in this position, lash can be checked on the followingrocker arms: 1l, 1E, 2l, 3E, 4l, and 5E.

Lash checks are usually performed as part of a troubleshooting proce-dure, and resetting is not required during checks as long as the lashmeasurements are within the above limits.

Lash Check Limitsmm in

Intake 0.152 MIN 0.006 0.559 MAX 0.022

Exhaust 0.381 MAX 0.015Side to Side 0.075 MAX 0.003Side to Side 0.075 MAX 0.003

Overhead Set (003-004) 24 Valve, 8.3 Liter EnginePage 3-2 Section 3 - Rocker Levers - Group 03


Measure lash by inserting a feeler gauge between the crosshead andthe rocker lever ball insert and socket while lifting up on the end of therocker arm. If the lash measurement is out of specifications, loosen thelocknut and adjust the lash to nominal specifications.

Lash resets are only required at the interval specified in the vehicle op-eration and maintenance manual when the lash is measured and foundout of specification, or when engine repairs cause removal of the rock-er arms and/or loosening of the adjusted screws.

Tighten the locknut and measure.


Using the barring tool, Tool No. CAS 1690, rotate the crankshaft 360degrees and measure lash for rocker arms 2E, 3l, 4E, 5l, 6l, and 6E.Reset if out of specification.

15 mmInstall the gasket and rocker lever cover. Refer to Procedure 003-011.


Lash Check Limitsmm in

Intake 0.254 NOMINAL 0.012Exhaust 0.508 NOMINAL 0.022

24 Valve, 8.3 Liter Engine Rocker Lever (003-008)Section 3 - Rocker Levers - Group 03 Page 3-3


Install the fuel pump drive cover.

Rocker Lever (003-008)

Remove (003-008-002)

15 mmRemove the rocker lever cover and gasket. Refer to Procedure 003-011.

13 mm, 18 mm

Remove the capscrews from the rocker lever pedestals.

Remove and mark the pedestals and rocker lever assemblies one at atime as to mark their location and position.

Remove and mark the crossheads one at a time as to their location andposition. The crossheads and rocker assemblies must be installed intheir original location and position.


If the rocker levers are to be inspected for reuse, follow these steps.

Remove the rocker levers.

Rocker Lever (003-008) 24 Valve, 8.3 Liter EnginePage 3-4 Section 3 - Rocker Levers - Group 03


Remove the rocker lever shafts from the rocker levers.

Remove the locknut and adjusting screw.

Remove the socket.

Clean (003-008-006)

Clean all parts in a strong solution of laundry detergent in hot water.



∆ WARNING ∆Wear gloves and eye protection when using compressed air todry engine parts. It can cause personal injury.

Use compressed air to dry the parts after rinsing in clean hot water.

The pedestals are made from powdered metal and will continue toshow wetness after they have been cleaned and dried.

Be sure that oil drillings in the rocker arms and shafts are unobstruct-ed.


Inspect for cracks and excessive wear in the bore.

Inspect the wear surfaces of the ball insert and socket as well as theretainer.

Measure the rocker lever bore.

Inspect the rocker lever pedestal and rocker lever shaft.

Measure the rocker lever shaft diameter.

Rocker Lever Boremm in

22.027 MIN 0.867

Rocker Lever Shaftmm in

21.967 MIN 0.865

Rocker Lever (003-008) 24 Valve, 8.3 Liter EnginePage 3-6 Section 3 - Rocker Levers - Group 03


Assemble (003-008-025)

Install the retaining clip and socket.

Install the adjusting screw and lock nut.

Lubricate the rocker lever shafts with engine lubricating oil.

Install the rocker lever shafts into the rocker levers.

Position the rocker levers on the rocker pedestal.



∆ CAUTION ∆Be sure to assemble the intake and exhaust rocker levers on thecorrect valves.

Install (003-008-026)

Install the crossheads in their original location and position.

Install the rocker lever assemblies and pedestals in their original loca-tions.

10 mm

Tighten the 10 mm pedestal capscrews.


15 mm

Install the gasket and rocker lever cover. Refer to Procedure 003-011.


Rocker Lever Cover (003-011) 24 Valve, 8.3 Liter EnginePage 3-8 Section 3 - Rocker Levers - Group 03


Rocker Lever Cover (003-011)

Remove (003-011-002)

Remove the capscrews.

Remove the rocker lever cover and gasket.


Check the isolators for cracks, tears, or brittleness.

Replace the capscrew assembly if isolators are damaged.

Check the gasket for cracks in the silicone covering.

Replace the gasket if cracks are present.

Install (003-011-026)

Place the gasket on the cylinder head. Be sure the gasket is properlyaligned around the cylinder head capscrews.

24 Valve, 8.3 Liter Engine Rocker Lever Cover (003-011)Section 3 - Rocker Levers - Group 03 Page 3-9


15 mm

Install the rocker lever cover and capscrews.

Tighten the capscrews.


Rocker Lever Cover (003-011) 24 Valve, 8.3 Liter EnginePage 3-10 Section 3 - Rocker Levers - Group 03


24 Valve, 8.3 Liter EngineSection 4 - Cam Followers/Tappets - Group 04 Page 4-a


Section 4 - Cam Followers/Tappets - Group 04

Section ContentsPush Rods or Tubes (004-014) .............................................................................................................................................. 4-1

Clean (004-014-006) ................................................................................................................................................. 4-1Inspect for Reuse (004-014-007) .............................................................................................................................. 4-1Install (004-014-026) ................................................................................................................................................. 4-2Preparatory (004-014-000) ........................................................................................................................................ 4-1Remove (004-014-002) ............................................................................................................................................. 4-1

Tappet (004-015) ...................................................................................................................................................................... 4-3Inspect for Reuse (004-015-007) .............................................................................................................................. 4-5Install (004-015-026) ................................................................................................................................................. 4-6Preparatory (004-015-000) ........................................................................................................................................ 4-3Remove (004-015-002) ............................................................................................................................................. 4-3

24 Valve, 8.3 Liter EnginePage 4-b Section 4 - Cam Followers/Tappets - Group 04



24 Valve, 8.3 Liter Engine Push Rods or Tubes (004-014)Section 4 - Cam Followers/Tappets - Group 04 Page 4-1


Push Rods or Tubes (004-014)


Remove the rocker lever cover. Refer to Procedure 003-011.

Remove the rocker levers. Refer to Procedure 003-008.

Remove (004-014-002)

Mark the push tubes to identify their location.

Remove the push tubes.

Clean (004-014-006)

Clean the push tubes in hot soapy water.



Inspect the push tube ball and socket for signs of scoring. Check forcracks where the ball and the socket are welded into the tube.

Push Rods or Tubes (004-014) 24 Valve, 8.3 Liter EnginePage 4-2 Section 4 - Cam Followers/Tappets - Group 04


Check the push tubes for straightness.

Push tubes must be straight, with no curve.

Install (004-014-026)

Install push tubes in their original location.

Install the push tubes into the sockets of the valve tappets.

Lubricate the push tube sockets with clean 15W-40 engine oil.

10 mm

Install the crossheads and rocker levers. Refer to Procedure 003-008.


Adjust the valve lash. Refer to Procedure 003-004.

24 Valve, 8.3 Liter Engine Tappet (004-015)Section 4 - Cam Followers/Tappets - Group 04 Page 4-3


15 mm

Install gasket and rocker lever cover. Refer to Procedure 003-011.



Tappet (004-015)


• Remove the rocker lever cover. Refer to Procedure 003-011. • Remove the rocker levers. Refer to Procedure 003-008. • Remove the push tubes. Refer to Procedure 004-014. • Remove the vibration damper. Refer to Procedure 001-050. • Remove the gear cover. Refer to Procedure 001-031. • Remove the camshaft. Refer to Procedure 001-008.

Remove (004-015-002)

Insert the trough to the full length of the cam bore. Refer to page 2425-70, step 290, of the 8.3 Liter Engine Service Manual.

Tappet (004-015) 24 Valve, 8.3 Liter EnginePage 4-4 Section 4 - Cam Followers/Tappets - Group 04


Make sure the trough is positioned so it will catch the tappet when thewooden dowel is removed.

Only remove one tappet at time. Remove the rubber band from the twocompanion tappets, securing the tappet not to be removed with therubber band.

Pull the wooden dowel from the tappet bore allowing the tappet to fallinto the trough.

When the tappet is dropped into the trough, most of the time it will fallover. However, if it doesn't, gently shake the trough just enough to allowthe tappet to fall over before removing.



When removing the No. 6 cylinder tappets, special care should be tak-en not to knock or shake the tappet over the end of the trough.

Carefully pull the trough and tappet from the cam bore and remove thetappet. Repeat the process until all tappets are removed.


Inspect the socket, stem, and face for excessive wear, cracks, and oth-er damage.

Pit marks on the tappet face are acceptable.

The following criteria defines the size of the pits allowed.

1. A single pit can not be greater than 2 mm [0.078 inch].2. Interconnection of pits is not allowed.3. Total pits when added together should not exceed 6 mm [0.236

inch] diameter or a total of 4 percent of the tappet face. 4. No pitting is allowed on the edges of the wear face of the tappet.

Visual Limits(A) - Normal Contact (exaggerated)(B) and (C) - Irregular Contact: Do not reuse.



Measure the valve tappet stem.

Install (004-015-026)

Insert the trough the full length of the cam bore.

Lower the tappet installation tool down the push tube hole, through thetappet bore, and into the trough. Refer to page 2425-71, step 296, ofthe 8.3 Liter Engine Service Manual.

Feed the installation tool through the cam bores by carefully pulling theplastic trough/installation tool out the front. The barrier at the rear of thetrough will pull the tool out most of the time.

Valve Tappet Stem Diametermm in

15.936 MIN 0.62715.977 MAX 0.629



Lubricate the tappets with Lubriplate™ 105, or equivalent.

Insert the installation tool into the tappet.

To aid in removing the installation tool after the tappet is installed, workthe tool in and out of the tappet several times before installing the tap-pets.

Slide the trough into the cam bore.

Pull the tool and tappet through the cam bore and up into the tappetbore.



If difficulty is experienced in getting the tappet to make the bend fromthe trough up to the tappet bore, pull the trough out enough to allow thetappet to drop down and align itself, then pull the tappet up into thebore.

After the tappet has been pulled up into position, slide the trough backinto the cam bore and rotate it one-half turn. This will position the roundside of the trough up, which will hold the tappet in place.

Remove the installation tool from the tappet.

Install a wooden dowel into the top of the tappet. Wrap rubber bandsaround the wooden dowels to secure the tappets.

Repeat this process until all tappets have been installed.

NOTE: Refer to page 2425-68, step 279, of the 8.3 Liter Engine Ser-vice Manual for specifications on the wooden dowel.



Complete the installation of the removed parts and adjustments as re-quired.

• Install the camshaft. Refer to Procedure 001-008. • Install the gear cover. Refer to Procedure 001-031. • Install the vibration damper. Refer to Procedure 001-050. • Install the push tubes. Refer to Procedure 004-014. • Install the rocker levers. Refer to Procedure 003-008. • Adjust the valves. Refer to Procedure 003-004. • Install the rocker lever cover. Refer to Procedure 003-008.


24 Valve, 8.3 Liter EngineSection 5 - Fuel System - Group 05 Page 5-a


Section 5 - Fuel System - Group 05

Section Contents

Engine Fuel Heater, Electric (005-008) ...................................................................................................................................................... 5-7Initial Check (005-008-001) ........................................................................................................................................................... 5-7Remove (005-008-002) ................................................................................................................................................................. 5-7

Flow Diagram, Fuel System ....................................................................................................................................................................... 5-4

Fuel Flow (005-011) ..................................................................................................................................................................................... 5-9Pressure Test (005-011-013) ........................................................................................................................................................ 5-9

Fuel Lift Pump (005-045) .......................................................................................................................................................................... 5-19Initial Check (005-045-001) ......................................................................................................................................................... 5-19Install (005-045-026) ................................................................................................................................................................... 5-21Remove (005-045-002) ............................................................................................................................................................... 5-20Test (005-045-012) ..................................................................................................................................................................... 5-20

Fuel Pump (005-016) ................................................................................................................................................................................. 5-10Install (005-016-026) ................................................................................................................................................................... 5-11Remove (005-016-002) ............................................................................................................................................................... 5-10

Fuel Pump Accumulator (005-077) .......................................................................................................................................................... 5-23Pressure Test (005-077-013) ...................................................................................................................................................... 5-23

Fuel Pump Accumulator Module (005-085) ............................................................................................................................................. 5-32Remove (005-085-002) ................................................................................................................................................................ 5-32Install (005-085-026) .................................................................................................................................................................... 5-35

Fuel Pump Cam Housing (005-080) ......................................................................................................................................................... 5-25Inspect for Reuse (005-080-007) ................................................................................................................................................ 5-25

Fuel Pump Cam Housing Module (005-088) ............................................................................................................................................ 5-43Remove (005-088-002) ................................................................................................................................................................ 5-43Install (005-088-026) .................................................................................................................................................................... 5-45

Fuel Pump Delivery Valve (005-020) ........................................................................................................................................................ 5-14Leak Test (005-020-014) ............................................................................................................................................................. 5-16Inspect for Reuse (005-020-007) ................................................................................................................................................ 5-14Install (005-020-026) ................................................................................................................................................................... 5-15Preparatory (005-020-000) .......................................................................................................................................................... 5-14Remove (005-020-002) ............................................................................................................................................................... 5-14

Fuel Pump Distributor Inlet Fitting (005-084) .......................................................................................................................................... 5-29Remove (005-084-002) ................................................................................................................................................................ 5-29Install (005-084-026) .................................................................................................................................................................... 5-30

Fuel Pump Distributor Module (005-086) ................................................................................................................................................. 5-37Remove (005-086-002) ................................................................................................................................................................ 5-37Install (005-086-026) .................................................................................................................................................................... 5-38

Section 5 - Fuel System - Group 05 24 Valve, 8.3 Liter EnginePage 5-b Section 5 - Fuel System - Group 05


Fuel Pump Gear Pump (005-025) ............................................................................................................................................................. 5-16Measure (005-025-010) .............................................................................................................................................................. 5-16Preparatory (005-025-000) ......................................................................................................................................................... 5-16

Fuel Pump Gear Pump Module (005-089) ................................................................................................................................................ 5-47Remove (005-089-002)................................................................................................................................................................ 5-47Install (005-089-026).................................................................................................................................................................... 5-48

Fuel Pump Injection Control Valve (005-087).......................................................................................................................................... 5-42

Fuel Pump Rate Shape Tube (005-090).................................................................................................................................................... 5-50Remove (005-090-002)................................................................................................................................................................ 5-50Install (005-090-026).................................................................................................................................................................... 5-51

Fuel Pump Timing (005-037) .................................................................................................................................................................... 5-17Inspect for Reuse (005-037-007) ................................................................................................................................................ 5-18Install (005-037-026) ................................................................................................................................................................... 5-18Remove (005-037-002) ............................................................................................................................................................... 5-17

Fuel System - General Information ........................................................................................................................................................... 5-1General Information ...................................................................................................................................................................... 5-1

Injection Control Valve (005-078) ............................................................................................................................................................ 5-23Click Test (005-078-072) ............................................................................................................................................................ 5-23

Pumping Control Valve (005-079) ............................................................................................................................................................ 5-24Click Test (005-079-072) ............................................................................................................................................................ 5-24Cutout Test (005-079-073) .......................................................................................................................................................... 5-24

Rotor, CAPS Fuel Injection Pump (005-072) .......................................................................................................................................... 5-22Inspect for Reuse ........................................................................................................................................................................ 5-22Install (005-072-026) ................................................................................................................................................................... 5-23Leak Test (005-072-014) ............................................................................................................................................................ 5-23Preparatory (005-072-000) ......................................................................................................................................................... 5-22Remove (005-072-002) ............................................................................................................................................................... 5-22

Service Tools .............................................................................................................................................................................................. 5-6Fuel System .................................................................................................................................................................................. 5-6

Snubber, Rate Shape (005-081) ............................................................................................................................................................... 5-25Inspect for Reuse (005-081-007) ................................................................................................................................................ 5-26Install (005-081-026) ................................................................................................................................................................... 5-27Leak Test (005-081-014) ............................................................................................................................................................ 5-26Preparatory (005-081-000) ......................................................................................................................................................... 5-25Remove (005-081-002) ............................................................................................................................................................... 5-26

Specifications ............................................................................................................................................................................................. 5-5Fuel System .................................................................................................................................................................................. 5-5

24 Valve, 8.3 Liter Engine Fuel System - General InformationSection 5 - Fuel System - Group 05 Page 5-1


Fuel System - General Information

General Information

CAPS Fuel Pump Familiarization

The CAPS fuel system is a distributor type injection system. CAPSstands for Cummins Accumulator Pump System. An accumulator isused to store pressurized fuel for the injection event. There are fourcomponents that provide or receive input to the electronic control mod-ule (ECM). There are two pumping control valves (1) which are con-trolled by the ECM. These valves control the pressure in theaccumulator. The accumulator fuel pressure/temperature (2) sensor islocated on the accumulator and provides the ECM with pressure andtemperature information. The Injection Control Valve (3) is also con-trolled by the ECM and regulates fueling and timing.

The CAPS injection pump can be divided into six distinct units/mod-ules. They are the gear pump, cam and housing, accumulator/pumpingplunger, rate shape tube, injection control valve (ICV), and distributor.Fuel flows through the modules in the following order;

1. gear pump2. cam and housing3. accumulator4. rate shape tube 5. injector control valve (ICV)6. distributor

A lift pump is used for priming the pump at start up. The lift pump runsfor approximately 30 seconds after key-on. Once the engine is started,the gear pump is able to maintain prime without any assistance fromthe lift pump.

1. fuel filter2. lift pump3. fuel tank

The gear pump supplies fuel to the pumping plungers through internaldrillings in the cam housing. The gear pump also supplies fuel to thedistributor for lubrication and injection line refill purposes. The gearpump is regulated to approximately 180 psi at 2400 engine rpm. Thegear pump has an internal filter to catch any debris generated down-stream of the main, external fuel filter. The pump camshaft is driven offthe engine camshaft (just like the Bosch pump), therefore pump rpm isone-half engine rpm. The gear pump is driven by the pump camshaftvia an internal coupling. The gear pump shaft drives the distributor ro-tor.

Fuel System - General Information 24 Valve, 8.3 Liter EnginePage 5-2 Section 5 - Fuel System - Group 05


Each pumping plunger is driven by a two lobed camshaft with three liftprofiles per lobe. The camshaft pump is located in the cam housingmodule. The bearings that support the camshaft as well as the tappets,rollers, and camshaft itself are lubricated with engine oil. These are theonly components in the pump lubricated with engine oil.

The volume above each pumping plunger is filled, by the gear pump,as the plungers travel downwards. A pumping control valve (PCV) is lo-cated above each pumping plunger. The supply fuel from the gearpump flows around the plunger of this normally open valve into thechamber above the plunger. As the plunger starts to move upwards thefuel is pushed backwards into the gear pump. The time at which thepumping control valve is energized (closed) is based on engine speed,accumulator pressure, and throttle position. When the pumping controlvalve closes, the fuel is pushed into the accumulator and then held bycheck valves. A zero to 24000 psi pressure sensor is located in the ac-cumulator. The pressure sensor provides direct feed back to the ECM,so the desired accumulator pressure is maintained. This pressure sen-sor also has temperature sensing capabilities built into it. Fuel movesfrom the accumulator to the distributor via the rate shape tube.

Fuel is delivered to the injection control valve (ICV) by the rate shapetube through a drilling in the distributor. The ICV controls both fuelingand timing. The injection control valve contains an inner pin and outervalve. The outer valve is fastened to an armature which is driven by themagnetic force of an ECM controlled stator. The inner pin is driven bytwo methods, spring force and fuel pressure. When the two pins are inthe closed position no fuel flows through the control valve. When thestator is energized the outer valve is drawn towards the stator. The in-ner pin is forced to travel with the outer pin by a spring. The inner pinonly travels about half the distance the outer pin does and comes torest against a stop. Once the two pins separate fuel can flow to drainor to the injectors. The pressure of this fuel forces the inner pin to moveback to the starting position. When the outer pin seats against its seatthe flow path to the drain is closed and fuel is directed to the injectorthrough the distributor. The injection control valve goes through thisprocess once for each injection event.

24 Valve, 8.3 Liter Engine Fuel System - General InformationSection 5 - Fuel System - Group 05 Page 5-3


The distributor directs the fuel to the correct injector. The drain fuelfrom the ICV is routed through the ICV pressure regulator and is re-turned to the tank.

Flow Diagram, Fuel System 24 Valve, 8.3 Liter EnginePage 5-4 Section 5 - Fuel System - Group 05


Flow Diagram, Fuel System

1. Fuel from Supply Tank2. Electronic Lift Pump3. Fuel Filter and Water Separator4. Fuel Drain Line 5. CAPS Injection Pump6. Distributor Outlet Fitting7. High Pressure Supply Lines 8. Fuel Connector 9. Injectors 10. Fuel Return to Supply Tank

24 Valve, 8.3 Liter Engine SpecificationsSection 5 - Fuel System - Group 05 Page 5-5


Specifications

Fuel System

Engine Idle Speed ......................................................................................................................................................................850 to 950 rpm

Minimum Lift Pump Inlet Pressure at Rated (vacuum) ...................................................................................................... 102 mm Hg [4 in Hg]

Maximum Fuel Filter Outlet Pressure at Rated (vacuum) ................................................................................................. 102 mm Hg [4 in Hg]

Minimum Fuel Filter inlet Pressure during Cranking ......................................................................................................... 102 mm Hg [4 in Hg]

Fuel Drain Line Maximum Pressure................................................................................................................................ 254 mm Hg [10 in Hg]

Fuel Inlet Maximum Temperature................................................................................................................................................... 71°C [160°F]

Engine Minimum Cranking Speed ........................................................................................................................................................ 150 rpm

Service Tools 24 Valve, 8.3 Liter EnginePage 5-6 Section 5 - Fuel System - Group 05


Service Tools

Fuel System

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate pro-cedure. These tools can be purchased from your local Case Corp. Repair Location.


CAS-1691A Fuel Pump Gear Puller

Used to pull the fuel pump gear.

24 Valve, 8.3 Liter Engine Engine Fuel Heater, Electric (005-008)Section 5 - Fuel System - Group 05 Page 5-7


Engine Fuel Heater, Electric (005-008)


NOTE: The fuel heater is not controlled by the electronic control mod-ule (ECM). A bimetallic strip on the filter head acts as a thermostat.The fuel heater will turn on at approximately 1°C [34°F] and turn off atapproximately 18°C [65°F].

Remove the 2-pin connector from the fuel heater.

Check for proper voltage to the fuel heater.

NOTE: Minimum voltage is 12 volts.

If the voltage is not within specifications, refer to the vehicle trouble-shooting and repair manual.

Remove (005-008-002)

Disconnect the connector from the fuel heater.

Disconnect the connector from the water-in-fuel (WIF) sensor ifequipped.

Turn the fuel drain valve for approximately 5 seconds to reduce fuelspillage during filter removal.

Engine Fuel Heater, Electric (005-008) 24 Valve, 8.3 Liter EnginePage 5-8 Section 5 - Fuel System - Group 05


Remove the fuel filter.

Remove the fuel filter stud.

Remove the fuel heater from the filter head. The heater should be ableto be pulled off the filter head.

If the maximum fuel pressure drop across the fuel filter is greater than0.725 kPa [5 psi], replace the fuel filter. Refer to Procedure 006-015.

Install (005-008-026)

Install gasket on fuel heater.

Place the fuel heater, gasket side facing up, against the filter head.

Apply Loctite® to the filter stud.

Install the fuel filter stud.


24 Valve, 8.3 Liter Engine Fuel Flow (005-011)Section 5 - Fuel System - Group 05 Page 5-9


Install the fuel filter.

Connect fuel heater.

Connect water-in-fuel (WIF) sensor if equipped.

Fuel Flow (005-011)

Pressure Test (005-011-013)

Remove the plug from the inlet and outlet side of the fuel filter head.

Install two 10 mm [0.39 in] Compucheck fittings and a pressure gaugethat has a range of at least zero to 2.90 kPa [zero to 20 psi].

Run the engine loaded at rated conditions. Fuel supply restrictionshould read as follows:

Pressure drop across the fuel filter should equal 0.725 kPa [5 psi] max-imum. Outlet side of the filter should equal 2.96 kPa [10 psi] minimumwith the keyswitch in the ON position.

Fuel Pump (005-016) 24 Valve, 8.3 Liter EnginePage 5-10 Section 5 - Fuel System - Group 05


If the maximum fuel pressure drop across the fuel filter is greater than0.725 kPa [5 psi], replace the fuel filter. Refer to Procedure 006-015.

If the restriction is too high, the supply lines from the fuel supply tankneed to be checked. Refer to Procedure 006-020.

Fuel Pump (005-016)

Remove (005-016-002)

• Disconnect the injection pump supply line. Refer to Procedure 006-024.

• Remove the injector supply lines. Refer to Procedure 006-051. • Disconnect the tank return line. Refer to Procedure 006-013. • Disconnect the pumping control valve 4-pin Deutsch connector.• Disconnect the injection control valve 4-pin Deutsch connector. • Disconnect the accumulator pressure/temperature sensor.

Remove the injection pump upper support bracket.

Remove the injection pump tail support bracket.

Remove the access cap and gear retaining nut and washer.

24 Valve, 8.3 Liter Engine Fuel Pump (005-016)Section 5 - Fuel System - Group 05 Page 5-11


Locate TDC for cylinder No. 1 by barring engine slowly until the line onthe pump gear lines up with the line on the gear cover.

Use Tool No. CAS-1691A, and pull the fuel injection pump drive gearloose from the pump drive shaft.

Remove the four mounting nuts. Remove the fuel injection pump.

Install (005-016-026)

Make sure the engine has No. 1 cylinder at TDC.

Fuel Pump (005-016) 24 Valve, 8.3 Liter EnginePage 5-12 Section 5 - Fuel System - Group 05


Make sure the fuel injection pump is at its TDC position.

The fuel injection pump is at No. 1 cylinder TDC when the dowel pin inthe shaft (A) is perpendicular to the top of the accumulator.

Make sure the o-ring seals for the fill orifice (A) and pilot (B) are cor-rectly installed and are not damaged.

Lubricate the mounting flange with cleaner.

The fuel pump drive gear inside diameter and the shaft outside diam-eter must be clean and dry before installing the gear.

Slide the fuel injection pump shaft through the drive gear and positionthe fuel injection pump flange onto the mounting studs.

Make sure the dowel pin lines up with the keyway in the fuel injectionpump gear.

Make sure the dowel pin in the fuel injection pump flange lines up withthe hole in the gear housing.

Install the mounting nuts.

Install the fuel injection pump upper support bracket.

Install the fuel injection pump tail support bracket.

Torque Value:

Fuel Pump Mounting Nuts 44 N•m [32 ft-lb]Fuel Pump Support Brackets 44 N•m [32 ft-lb]

24 Valve, 8.3 Liter Engine Fuel Pump (005-016)Section 5 - Fuel System - Group 05 Page 5-13


30 mm

Tighten the fuel injection pump drive gear nut.

Torque Value:

Fuel Injection Pump 165 N•m [122 ft-lb]

Install the gear cover access cap hand tight.

• Connect the injection pump supply line. Refer to Procedure 006-024.

• Connect the injector supply lines. Refer to Procedure 006-051.

• Connect the tank return line. Refer to Procedure 006-013.

• Connect the pumping control valve 4-pin Deutsch connector.

• Connect the injection control valve 4-pin Deutsch connector.

• Connect the accumulator pressure/temperature sensor connec-tor.

Perform the control valve click test to verify pump is connected to ECM.Refer to Procedure 005-078.


Fuel Pump Delivery Valve (005-020) 24 Valve, 8.3 Liter EnginePage 5-14 Section 5 - Fuel System - Group 05


Fuel Pump Delivery Valve (005-020)


Thoroughly steam clean the distributor snubber and fuel pump area.


Remove (005-020-002)

Remove the high pressure fuel supply lines. Refer to Procedure 006-051.

Remove the distributor snubber and the seal disk.

The snubber valve and seat are a matched set; do not mix and matchvalves and seats with other snubber assemblies.

If either the snubber valve or seat is damaged, the entire snubber as-sembly must be replaced. Also, the seal washers must always be re-placed.


Check for broken parts, debris, or sticking of the snubber valve. Re-place the snubber assembly if any parts are damaged. Always replacethe seal washer.

24 Valve, 8.3 Liter Engine Fuel Pump Delivery Valve (005-020)Section 5 - Fuel System - Group 05 Page 5-15


Install (005-020-026)

Install a new seal washer into the distributor outlet fitting hole. Makesure the washer is fully seated in the bottom of the hole.

Install the snubber assembly hand tight.

Tighten the snubber assemblies.


Install the high pressure fuel supply lines. Refer to Procedure 006-051.

Fuel Pump Gear Pump (005-025) 24 Valve, 8.3 Liter EnginePage 5-16 Section 5 - Fuel System - Group 05


Leak Test (005-020-014)

Run the engine and check for fuel leaks at the distributor snubbers andhigh pressure fuel supply lines.

Fuel Pump Gear Pump (005-025)


Perform fuel inlet restriction test. Refer to Procedure 006-020.

Measure (005-025-010)

Measure outlet pressure at the diagnostic fitting on the CAPS pumpand compare to the following chart.

If pressure is below the minimum values listed and the fuel inlet restric-tion is satisfactory, inspect the gear pump outlet screen.

Engine Speed (rpm) Gear Pump Pressure (psi)200 2700 20

1300 552200 120

24 Valve, 8.3 Liter Engine Fuel Pump Timing (005-037)Section 5 - Fuel System - Group 05 Page 5-17


Recheck gear pump outlet pressure. If the pressure is still low, the gearpump or the fuel pump gear pump module must be replaced. Refer toProcedure 005-089.


Fuel Pump Timing (005-037)

Remove (005-037-002)

Remove the gear cover. Refer to Procedure 001-031.

Remove the injection pump camshaft nut.

Fuel Pump Timing (005-037) 24 Valve, 8.3 Liter EnginePage 5-18 Section 5 - Fuel System - Group 05



Check that the fuel pump camshaft alignment dowel is present in thefuel pump drive gear keyway. If the alignment dowel is not visible, re-move the injection pump, determine the cause of misalignment, and re-pair or replace any damaged components.

If this inspection is being performed due to a performance complaint,and the problem surfaced after gear train removal and replacement,then check the timing of the camshaft gear to the crankshaft gear andthe camshaft gear to the fuel pump drive gear. Refer to Procedure 001-012.

Install (005-037-026)

Install and tighten the injection pump camshaft nut.


Install the front gear cover. Refer to Procedure 001-031.

24 Valve, 8.3 Liter Engine Fuel Lift Pump (005-045)Section 5 - Fuel System - Group 05 Page 5-19


Fuel Lift Pump (005-045)


A malfunctioning electric fuel lift pump can cause low power or roughrunning from the engine. The fuel lift pump can be cleaned and re-paired to a limited extent.

∆ CAUTION ∆Do not operate the fuel system with a suction restriction of morethan 4 in Hg.

Maximum pressure drop across the filter is 34 kPa [5 psi] or 258 mmHg [10 in Hg].

The pressure drop will increase as the filter removes contaminationfrom the fuel.

NOTE: The Case 24 Valve, 8.3 Liter Engine lift pump is used for initialprime only.

Check for fuel lift pump operation by turning the vehicle key switch tothe ON position and listening or feeling for operation.

NOTE: Lift pump runs for only 30 seconds at key ON then shuts off.

If the fuel lift pump is not working, check for voltage at the lift pump en-gine harness connector (9 to 12 volts) after keyswitch is on.

If the voltage does not meet the specifications, check for a good powersupply.

Fuel Lift Pump (005-045) 24 Valve, 8.3 Liter EnginePage 5-20 Section 5 - Fuel System - Group 05


Remove (005-045-002)

Disconnect the battery, negative (-) cable first.

NOTE: Thoroughly clean fittings and components before removal.Make sure that the debris, water, steam, or cleaning solution does notreach inside of the fuel system.

Remove the fuel lift pump inlet and outlet fuel lines. Refer to Procedure006-024.

Disconnect the fuel pump power lead.

10 mm

Remove three capscrews and lift pump from engine block.

Test (005-045-012)

The output of the fuel lift pump can be checked through the followingtest.

24 Valve, 8.3 Liter Engine Fuel Lift Pump (005-045)Section 5 - Fuel System - Group 05 Page 5-21


Test

Turn the key switch on, measure the output pressure of the fuel liftpump using pressure gauge at the tap on the outlet port of the lift pumphead.

At initial key-on, the lift pump will run for 30 seconds and then stop.

Measure the fuel inlet restriction before the fuel lift pump.

Measurable restriction is another possible cause for low lift pump pres-sure. Refer to Procedure 006-020.

Install (005-045-026)

10 mm

Install the fuel lift pump to block using three capscrews.


Connect the power lead to the fuel lift pump.

Install all removed fuel lines. Refer to Procedure 006-024.

Valid Pressuremm Hg in Hg

508 MIN 20

Rotor, CAPS Fuel Injection Pump (005-072) 24 Valve, 8.3 Liter EnginePage 5-22 Section 5 - Fuel System - Group 05


Rotor, CAPS Fuel Injection Pump (005-072)


Steam clean the fuel injection pump and the engine in the vicinity of thefuel pump.

Dry with compressed air. Pay special attention to the distributor area.

Bar the engine to TDC using the marks on the gear cover and the fuelpump drive gear as a guide.

Remove the ignition keys from the ignition or otherwise disable the en-gine starting system.

Remove (005-072-002)

Remove the distributor plug (1).

NOTE: Do not attempt to start the engine with the distributor plug re-moved. Doing so could cause the rotor to be ejected from the distribu-tor, causing damage to the rotor.

Inspect for Reuse

Check the position of the notch on the rotor. It should line-up with thealignment mark (A) on the outside of the distributor. If the alignment iscorrect, the rotor is properly timed to the engine. If a mechanical prob-lem exists, as indicated by misalignment of the rotor, check fuel pump-to-engine timing, refer to Procedure 005-037 If pump-to-engine timingis okay, the distributor module or whole pump will have to be replaced.

Check the o-ring on the distributor plug for damage. Replace if re-quired.

24 Valve, 8.3 Liter Engine Fuel Pump Accumulator (005-077)Section 5 - Fuel System - Group 05 Page 5-23


Install (005-072-026)

Install the distributor plug and torque.


Be sure the rotor is fully engaged before replacing the plug.

Enable the engine starting system.

Leak Test (005-072-014)

Run the engine and check for fuel leaks.

Fuel Pump Accumulator (005-077)

Pressure Test (005-077-013)

Using the electronic service tool, monitor the accumulator pressurewith the engine at idle and under load.

With the engine at an idle, minimum accumulator pressure should be5000 ± 200 psi.

Under full load the maximum accumulator pressure the pump will de-velop is 15000 ± 200 psi. If the accumulator pressure is low, replacethe fuel pump accumulator module. Refer to Procedure 005-085.

Injection Control Valve (005-078)

Click Test (005-078-072)

Use an electronic service tool, with the keyswitch in the ON position, torun the Control Valve Click Test.

Pumping Control Valve (005-079) 24 Valve, 8.3 Liter EnginePage 5-24 Section 5 - Fuel System - Group 05


Select Injection Control Valve to initiate the test.

An audible click will be heard until none is selected on the Control ValveClick Test screen.

If no click is heard troubleshoot any active fault codes.

Pumping Control Valve (005-079)

Click Test (005-079-072)

Use an electronic service tool, with the keyswitch in the ON position, torun the Control Valve Click Test.

Select the Pumping Control Valve to be tested to initiate the test. Selecteither front control valve or rear control valve.

An audible click will be heard until the other pumping control valve isselected, or none is selected on the control valve click test screen.

If no click is heard trouble shoot any active fault codes.

Cutout Test (005-079-073)

The plunger cutout test can be used to check performance of the frontand rear pumping plungers.

NOTE: When performing this test the engine load must be the samewhen each pumping plunger is cutout.

Use an electronic service tool, with the engine running at idle, to per-form this test.

24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing (005-080)Section 5 - Fuel System - Group 05 Page 5-25


Select the pumping control valve to be cutout.

Select the monitor button and monitor valve close angle (VCA), enginespeed, and accumulator pressure while the selected plunger is cutout.

Record VCA, engine speed, and accumulator pressure after the en-gine stabilizes.

Cutout the other pumping control valve and record VCA engine speed,and accumulator pressure after the engine stabilizes.

Compare the results when the rear pumping control valve is cutout,against the results when the front pumping control valve is cutout.

The VCA should not vary more than 15 degrees crank angle (dca).

If the engine dies when one of the pumping control valves is cutout, re-place the fuel fuel pump accumulator module. Refer to Procedure 005-085.

Troubleshoot any active fault codes before replacing the accumulatormodule.

Fuel Pump Cam Housing (005-080)


Inspect the cam housing for any signs of cracks or fuel leakage. Re-place cam module if necessary, refer to procedure 005-088.

Snubber, Rate Shape (005-081)


Thoroughly steam clean the rate shape tube and fuel pump area.


Snubber, Rate Shape (005-081) 24 Valve, 8.3 Liter EnginePage 5-26 Section 5 - Fuel System - Group 05


Remove (005-081-002)

Remove the rate shape tube (4) assembly.

Remove the rate shape snubber assembly (2).


Check for broken parts, debris, or sticking of the snubber valve. Re-place the snubber assembly if any parts are damaged. Always replacethe seal disk.

1. Snubber Valve Seat2. Spring3. Rate Shape Snubber Body4. Seal Disc5. Snubber Valve6. Spring Post.

Leak Test (005-081-014)

Run the engine and check for fuel leaks at the rate shape snubber (2)and rate shape tube (4).

24 Valve, 8.3 Liter Engine Snubber, Rate Shape (005-081)Section 5 - Fuel System - Group 05 Page 5-27


Install (005-081-026)

Install a new seal disk into the accumulator.

Apply lube oil to the face of the snubber seat, and to the face andthreads of the snubber fitting.

Install the snubber assembly.

Torque Value: Step 1 14 N•m [10 ft-lb]Step 2 120 degrees

Install the rate shape tube assembly. Tighten both rate shape tubenuts.


NOTE: Make sure that the rate shape tube bracket capscrews areloose. This allows the bracket to align with the rate shape tube.

Snubber, Rate Shape (005-081) 24 Valve, 8.3 Liter EnginePage 5-28 Section 5 - Fuel System - Group 05


Verify rate shape tube isolator capscrew torque.

Torque Value: 8.5 N•m [75 in-lb]

Tighten the rate shape bracket mounting capscrews (1).



24 Valve, 8.3 Liter Engine Fuel Pump Distributor Inlet Fitting (005-084)Section 5 - Fuel System - Group 05 Page 5-29


Fuel Pump Distributor Inlet Fitting (005-084)

Remove (005-084-002)

Remove the rate shape tube assembly; refer to Procedure 005-090.

17 mm

Remove the distributor inlet fitting.

There are two types of inlet fittings and sealing washers. The new de-sign is identified by the notches (1) in the flats of the fitting and has asealing washer with a raised center (2) and a smaller internal diameter.

Use the appropriate removal steps below, for the type of fitting beingremoved.

No. 4 Spiral Easy Out

New Style Fitting and Washer

Using a plastic hammer, tap the spiral easy out into the center hole ofthe sealing washer. Turn the easy out counterclockwise to dislodgethe washer.

Fuel Pump Distributor Inlet Fitting (005-084) 24 Valve, 8.3 Liter EnginePage 5-30 Section 5 - Fuel System - Group 05


3/16 or 1/8-inch Allen Wrench

Old Style Fitting and Washer

The old sealing washer is swagged into the inlet fitting bore during in-stallation. A special tool can be made to aid in its removal by grindingthe short leg of an Allen wrench so that wrench is no longer than 13mm [1/2-in] long (measured from the outside of the long leg). This toolacts as a miniheal bar to pry out the sealing washer without damagingthe back of the hole.

3/16 or 1/8-inch Allen Wrench

Old Style Fitting and Washer

Pry out the old sealing washer using the modified Allen wrench.

Quite a bit of force is required to remove the sealing washer.

Clean (005-084-006)

∆ WARNING ∆Any debris left in this fitting during assembly will run through thefuel pump and damage the fuel pump.

Using QD contact cleaner, Part No. 3824510, clean the inlet fitting borefrom the bottom of the bore outward.

Install (005-084-026)

∆ WARNING ∆Any dirt trapped in this fitting during assembly will run throughthe fuel pump and damage the fuel pump.

Use very clean grease to retain the sealing washer to the inlet fittingwhile it is being installed into the bore. Use Lubriplate� 105, or equiv-alent.

Install sealing washer into counterbore in the inlet fitting.

24 Valve, 8.3 Liter Engine Fuel Pump Distributor Inlet Fitting (005-084)Section 5 - Fuel System - Group 05 Page 5-31


17 mm

Install new inlet fitting and tighten after sealing washer is seated cor-rectly.

Torque Value:

Step 1 5.7 N�m [50 in-lb]Step 2 Rotate 120 degrees clockwise

Install the rate shape tube assembly; refer to Procedure 005-090.

Start the engine and check for fuel leaks at the rate shape tube con-nections.

Road-test the vehicle for at least 1 mile. Recheck for fuel leaks or activefault codes.

Fuel Pump Accumulator Module (005-085) 24 Valve, 8.3 Liter EnginePage 5-32 Section 5 - Fuel System - Group 05


Fuel Pump Accumulator Module (005-085)

Preparatory (005-085-000)∆ CAUTION ∆

Make sure that steam does not spray directly on the electricalconnections on the top of the accumulator block; or fault codeswill possibly occur.

Thoroughly steam-clean the entire fuel pump.

Dry the fuel pump with compressed air.

Remove (005-085-002)

Remove the fuel pump drive gear cover.

Locate top dead center for cylinder No. 1 by barring the engine slowlyuntil the line on the pump gear lines up with the line on the gear cover.


Remove the air bleed line; refer to Procedure 006-056.

Remove the fuel pump upper support bracket.

24 Valve, 8.3 Liter Engine Fuel Pump Accumulator Module (005-085)Section 5 - Fuel System - Group 05 Page 5-33


Disconnect the 4-pin Deutsch connector for the pumping controlvalves.

Disconnect the 4-pin connector from the fuel pressure/temperaturesensor.

13 mm

Remove two of the four capscrews that are located diagonally from oneanother.

13 mm∆ WARNING ∆

Accumulator module weighs 11 kg [25 lb] and is free to moveonce the capscrews are removed.

∆ CAUTION ∆Do not use air tools. The use of air tools will possibly damage thefuel pump.

Remove the last two capscrews. Alternately loosen the capscrew toavoid binding. Loosen each capscrew about on turn at a time.

∆ WARNING ∆Accumulator module weighs 11 kg [25 lb] and is free to moveonce the capscrews are removed.

Remove accumulator module.

Use as much care as possible to avoid dislodging the springs from thebottom of the accumulator.



If the springs are dislodged, the ceramic plungers can fall out. Theplungers are matched to each bore. Reseat springs fully onto plungerbarrels.

Do not interchange the plungers.

NOTE: Before replacing a ceramic plunger, special care needs to betaken to clean it.

Use QD contact cleaner, Part No. 3824510, to clean the plunger.

Remove the two o-rings, and discard them.

Clean (005-085-006)

Clean the small fuel passage using the plastic tube provided with thecontact cleaner.

Use QD contact cleaner, Part No. 3824510.

Clean the o-ring groove and mounting surface on the cam housing andthe accumulator.

Make sure the top of the tappets in the cam housing are clean. Wipeout debris with a clean towel.

24 Valve, 8.3 Liter Engine Fuel Pump Accumulator Module (005-085)Section 5 - Fuel System - Group 05 Page 5-35



Check the tappets for proper alignment.

The tappets have a slot on the side that engages a pin on the engineside of the cam housing. The pin keeps the roller aligned with the cam-shaft. Make sure the tappet assembly is properly aligned.

Install (005-085-026)

Install new o-rings.

Apply Lubriplate� 105, or equivalent, to the o-ring grooves to hold theo-rings in place.

∆ WARNING ∆The ceramic plungers can fall out when removing the plastic capsor old springs. Do not interchange the plungers. If thy fall out, useQD contact cleaner, Part No. 3824510, to thoroughly clean theplungers before replacing them.

If replacing the accumulator module with a new one, remove springsfrom the old accumulator module.

Fully install the springs on the plunger barrels of the new accumulatormodule.

NOTE: Use of two 10 mm x 80 mm studs will aid in the installation.

Install the accumulator module. Use care to avoid dislodging thesprings on the accumulator and the o-rings on the cam housing.



∆ CAUTION ∆Do not use air tools. The use of air tools will possibly damage thefuel pump.

Install two of the four capscrews.

Draw the accumulator module down evenly.Only turn each capscrew about one turn at a time.

Make sure the o-rings are still in their grooves before the accumulatoris fully tightened to the cam housing. Use a mirror if necessary.

13 mm

Install remaining two capscrews.

Tighten the four capscrews.

Torque Value: 68 N�m [50 ft-lb]

Connect the 4-pin pumping control valve connector.

Connect the 4-pin fuel pressure/temperature sensor.

Install the upper support bracket.



Install rate shape tube assembly (1); refer to Procedure 005-090.

Install the air bleed line (2); refer to Procedure 006-056.

Install the drive gear cover.

Start the engine and check for fuel leaks or active fault codes.


24 Valve, 8.3 Liter Engine Fuel Pump Distributor Module (005-086)Section 5 - Fuel System - Group 05 Page 5-37


Fuel Pump Distributor Module (005-086)





Remove (005-086-002)

CAPS vise ring, Part No. 3162897

Remove the air bleed line (1); refer to Procedure 006-056.

Remove the fuel pump from the engine; refer to Procedure 005-016 inthe Troubleshooting and Repair Manual, ISC Engines, Bulletin No.3666245.

Mount the fuel pump in the vise ring. Orient the pump with the distrib-utor facing upward to aid in disassembly.


8 mm Allen Wrench, or T45 Torx

∆ CAUTION ∆The capscrews also fasten the gear pump module. The gear pumpis free to move after the capscrews are removed.

Loosen but do not remove the distributor plug.

Remove the four capscrews on the distributor.

Fuel Pump Distributor Module (005-086) 24 Valve, 8.3 Liter EnginePage 5-38 Section 5 - Fuel System - Group 05


Remove the distributor module.

Remove the drive coupling.

Discard the two o-rings.


Inspect coupling and shaft ends for excessive wear. Wear is typicallyfound on the inside corners of the coupling groove.

A polished surface is acceptable.

Replace coupling if wear is visible.

Clean (005-086-006)

Clean the mounting surfaces of the distributor and gear pump.


Install (005-086-026)

Install the drive coupling.

Center the coupling on the gear pump shaft.

Apply Lubricate� 105, or equivalent, to the coupling to keep it fromsliding in the shaft groove during reassembly.




Apply Lubriplate� 105, or equivalent to o-rings to keep them from fall-ing out during reassembly.

Make sure the dowel pin is facing up toward the top of the pump.

If the shaft needs to be rotated, install the fuel pump drive nut onto theshaft to provide a means for rotating the shaft.

∆ CAUTION ∆The rotor can slide out once the distributor plug is removed.

∆ CAUTION ∆Do not drop the rotor. The entire distributor module will be ruinedand the rotor damage.

Remove the large plug from the end of the distributor.

Do not remove the rotor.

Install the distributor module.

Lightly rotate the rotor with finger-pressure until it drops into the slot inthe drive coupling.

When properly engaged, the notch in the rotor will align with the holein the distributor.

If the rotor will not engage, remove the distributor, and reposition thedrive coupling in the center of the shaft.

Fuel Pump Distributor Module (005-086) 24 Valve, 8.3 Liter EnginePage 5-40 Section 5 - Fuel System - Group 05


∆ CAUTION ∆The rotor must be properly timed to the fuel pump camshaft. Im-proper assembly will cause the rotor to be 180 degrees out oftime.

If not properly timed, remove the distributor housing, and repeat theprevious step. Make sure the fuel pump camshaft dowel pin is pointingtoward the top of the pump before reinstalling.

T45 Torx

Make sure the o-rings are not pinched.

Install the four distributor capscrews.



8 mm Allen Wrench

Install a new o-ring on the distributor plug.

Install the large plug at the end of the distributor.

Tighten the distributor plug.

Torque Value: 14 N�m [120 in-lb]


Install the fuel pump on the engine; refer to Procedure 005-016.




Run the injection control valve click test using INSITE�; refer to Pro-cedure 005-078.



Fuel Pump Injection Control Valve (005-087) 24 Valve, 8.3 Liter EnginePage 5-42 Section 5 - Fuel System - Group 05


Fuel Pump Injection Control Valve (005-087)This module is not able to be replaced as a separate unit at this time.The distributor and injection control valve modules must be replacedtogether. Refer to the procedure for the fuel pump removal and instal-lation, Procedure 005-086.

24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing Module (005-088)Section 5 - Fuel System - Group 05 Page 5-43


Fuel Pump Cam Housing Module (005-088)


∆ CAUTION ∆Make sure that steam does not spray directly on the electricalconnections on the top of the accumulator block; or fault codeswill possibly occur.


Dry the pump with compressed air.

Remove (005-088-002)





Remove the accumulator module; refer to Procedure 005-085.

Remove the distributor module; refer to Procedure 005-086.

Remove the gear pump module; refer to Procedure 005-089.


Remove the roller tappets from the cam housing bores.

Inspect the roller surfaces for pitting and wear.

Make sure the roller rotates freely and smoothly.

Replace the cam housing module if the rollers are worn.

Fuel Pump Cam Housing Module (005-088) 24 Valve, 8.3 Liter EnginePage 5-44 Section 5 - Fuel System - Group 05


Inspect the camshaft lobes for pitting and wear.

Replace the cam housing if there is any pitting or wear.

Inspect the tappet bores for scuffing or wear to the housing.

Polishing will occur in vertical bands at many places around the insideof the bores.

Polish of the bores is acceptable.

Replace the cam housing if there is any scuffing or wear on the bores,or damage to the guide pins.

Using fingers, make sure the camshaft turns freely. The bearings mustturn smoothly and free during rotation.

Replace the cam housing if the bearings are tight or rough.

Check the camshaft for end play. If any end play can be felt, use a dialindicator to check it.

If there is more than 0.05 mm [0.002 in] of end play, replace the camhousing assembly.

Clean (005-088-006)

Clean the mounting surfaces of the cam housing.


24 Valve, 8.3 Liter Engine Fuel Pump Cam Housing Module (005-088)Section 5 - Fuel System - Group 05 Page 5-45


Install (005-088-026)

Make sure the timing dowel pin in the camshaft points toward the topof the fuel pump.

∆ WARNING ∆The ceramic plungers will possibly fall out when removing thesprings. Do not interchange the plungers. If the plungers fall out,use QD contact cleaner, Part No. 3824510, to thoroughly cleanthem before replacing.

Lubricate the tappets and camshaft lobes with clean 15W-40 engineoil.

Install the roller tappets into the cam housing.

Install the new springs onto the plunger barrels of the accumulatormodule.

Check the tappets for proper alignment.

The tappets have a slot on the side that engages a pin on the engineside of the cam housing. The pin keeps the roller aligned with the cam-shaft. Make sure the tappet is properly aligned.

Install the gear pump module; refer to Procedure 005-089.

Install the distributor module; refer to Procedure 005-086.


Install the accumulator module; refer to Procedure 005-085.


Install the fuel pump onto the engine; refer to Procedure 005-016.

Install the air bleed line; refer to Procedure 005-056.

Fuel Pump Cam Housing Module (005-088) 24 Valve, 8.3 Liter EnginePage 5-46 Section 5 - Fuel System - Group 05



Road-test the vehicle for at least 1 mile. Recheck for fuel leaks and ac-tive fault codes.

24 Valve, 8.3 Liter Engine Fuel Pump Gear Pump Module (005-089)Section 5 - Fuel System - Group 05 Page 5-47


Fuel Pump Gear Pump Module (005-089)


∆ CAUTION ∆Make sure that steam does not spray directly on the electricalconnections on the top of the accumulator block; or fault codeswill possibly occur.



Remove (005-089-002)




Remove the rate shape tube; refer to Procedure 005-090.

Remove the distributor module; refer to Procedure 005-086.

Remove the gear pump module.

NOTE: Do not remove the two capscrews. The gear pump will slide offof the dowel pins once the distributor is removed.


Inspect the drive coupling and shaft ends for excessive wear.

A polished surface is acceptable.

Replace the coupling if wear is visible.

Fuel Pump Gear Pump Module (005-089) 24 Valve, 8.3 Liter EnginePage 5-48 Section 5 - Fuel System - Group 05


Clean (005-089-006)

Clean the mounting surfaces of the gear pump and cam housing.


Install (005-089-026)

∆ CAUTION ∆The larger o-rings on either end of the gear pump differ in size.The longer o-ring goes to the side facing the cam housing.


Apply Lubricate� 105, or equivalent, to the o-rings to keep them fromfalling out during assembly.

Install the drive coupling.

Center the coupling in the shaft.

Align the gear pump shaft with the drive coupling.

24 Valve, 8.3 Liter Engine Fuel Pump Gear Pump Module (005-089)Section 5 - Fuel System - Group 05 Page 5-49


Install the gear pump module.

Make sure the o-rings are not pinched.

Make sure the timing dowel pin is facing toward the top of the fuelpump.


Install the rate shape tube; refer to Procedure 005-090.

Install the fuel pump on the engine; refer to Procedure 005-016.




Fuel Pump Rate Shape Tube (005-090) 24 Valve, 8.3 Liter EnginePage 5-50 Section 5 - Fuel System - Group 05


Fuel Pump Rate Shape Tube (005-090)


∆ CAUTION ∆Make sure that direct steam spray stream does not contact theelectrical connections on the top of the accumulator block; faultcodes will possibly occur.


Dry the fuel pump with compressed air

Remove (005-090-002)

10 mm, 19 mm

Loosen the two rate shape tube nuts (1).

Remove the two bracket capscrews (2).

Remove the rate shape tube assembly.

Do not loosen or remove the isolator capscrews (3).


Inspect isolators for signs of wear or cracks.

Replace rate shape tube assembly if any isolator is worn, cracked, ormissing.

Inspect the ends of the rate shape tube for damage.

Clean (005-090-006)

Clean the ends of the rate shape tube.

Clean out the rate shape tube with contact cleaner if debris is suspect-ed of entering the tube.

Flush any dirt from the snubber fitting and distributor inlet fitting.

Use QD contact cleaner, Part no,. 3824510.

24 Valve, 8.3 Liter Engine Fuel Pump Rate Shape Tube (005-090)Section 5 - Fuel System - Group 05 Page 5-51


Install (005-090-026)

8 mm, 19 mm

Install the rate shape tube assembly using the following steps:

Tighten the rate shape tube nuts (1).Torque Value: 46 N�m [34 ft-lb]

NOTE: IF any force is required to flex the rate shape tube in order tostart the tube nuts, the rate shape tube must be replaced with a newtube.

8 mm, 10 mm

Install the two bracket capscrews.

Tighten the bracket capscrews (2).


NOTE: Isolator capscrew torque is 12 N�m [110 in-lb] if loosened.

Start the engine and check for fuel leaks at the rate shape tube con-nections.

24 Valve, 8.3 Liter EngineSection 6 - Injectors and Fuel Lines - Group 06 Page 6-a


Section 6 - Injectors and Fuel Lines - Group 06

Section Contents

Air in Fuel (006-003) 3Measure (006-003-010) ................................................................................................................................................................ 6-3Test (006-003-012) ....................................................................................................................................................................... 6-3

Fuel Connector (Head Mounted) (006-052) ............................................................................................................................................. 6-22Inspect for Reuse (006-051-007) ................................................................................................................................................ 6-22Install (006-052-026) ................................................................................................................................................................... 6-22Remove (006-052-002) ............................................................................................................................................................... 6-22

Fuel Drain Line Restriction (006-012) ........................................................................................................................................................ 6-5Measure (006-012) ........................................................................................................................................................................ 6-5

Fuel Drain Lines (006-013) ......................................................................................................................................................................... 6-6Remove (006-013-002) ................................................................................................................................................................. 6-6Initial Check (006-013-001) ........................................................................................................................................................... 6-6Inspect for Reuse (006-013-007) .................................................................................................................................................. 6-7Install (006-013-026) ..................................................................................................................................................................... 6-7

Fuel Filter (Spin-On Type) (006-015) ......................................................................................................................................................... 6-8Remove (006-015-002) ................................................................................................................................................................. 6-8Install (006-015-026) ..................................................................................................................................................................... 6-8

Fuel Filter Head Bracket (006-018) .......................................................................................................................................................... 6-10Assemble (006-018-025) ............................................................................................................................................................. 6-11Disassemble (006-018-003) ........................................................................................................................................................ 6-10Inspect for Reuse (006-018-007) ................................................................................................................................................ 6-11Install (006-018-026) ................................................................................................................................................................... 6-11Remove (006-018-002) ............................................................................................................................................................... 6-10

Fuel Inlet Restriction (006-020) ................................................................................................................................................................ 6-12Initial Check (006-024-001) ......................................................................................................................................................... 6-12

Fuel Pump Air Bleed Line (006-056)......................................................................................................................................................... 6-23Remove (006-056-002) ................................................................................................................................................................ 6-23Install (006-056-026) .................................................................................................................................................................... 6-24

Fuel Supply Lines (006-024) ..................................................................................................................................................................... 6-12Initial Check (006-024-001) ......................................................................................................................................................... 6-12Inspect for Reuse (006-024-007) ................................................................................................................................................ 6-13Install (006-024-026) ................................................................................................................................................................... 6-13Remove (006-024-002) ............................................................................................................................................................... 6-13

Section 6 - Injectors and Fuel Lines - Group 06 24 Valve, 8.3 Liter EnginePage 6-b Section 6 - Injectors and Fuel Lines - Group 06


Injector (006-026) ...................................................................................................................................................................................... 6-13Assemble (006-026-025) ............................................................................................................................................................ 6-17Clean (006-026-006) ................................................................................................................................................................... 6-15Disassemble (006-026-003) ........................................................................................................................................................ 6-14Inspect (006-026-062) ................................................................................................................................................................. 6-17Inspect for Reuse (006-026-007) ................................................................................................................................................ 6-15Install (006-026-026) ................................................................................................................................................................... 6-18Measure (006-026-010) .............................................................................................................................................................. 6-15Remove (006-026-002) ............................................................................................................................................................... 6-13Test (006-026-012) ..................................................................................................................................................................... 6-15

Injectors and Fuel Lines - General Information ....................................................................................................................................... 6-1General Information ...................................................................................................................................................................... 6-1

Injector Supply Lines (High Pressure) (006-051) ................................................................................................................................... 6-19Initial Check (006-051-001) ......................................................................................................................................................... 6-19Inspect for Reuse (006-051-007) ................................................................................................................................................ 6-20Install (006-051-026) ................................................................................................................................................................... 6-21Remove (006-051-002) ............................................................................................................................................................... 6-20

24 Valve, 8.3 Liter Engine Injectors and Fuel Lines - General InformationSection 6 - Injectors and Fuel Lines - Group 06 Page 6-1


Injectors and Fuel Lines - General Information

General Information

∆ WARNING ∆Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcingequipment, and switches out of the work area and areas sharingventilation to avoid severe personal injury or death when workingon the fuel system.

Injectors used in the Case 24 Valve, 8.3 Liter engines have hole typenozzles. High pressure fuel flows into the side of the injector and caus-es the needle to lift and fuel to be injected. The clearances in the noz-zle bore are extremely small and any sort of dirt or contaminants willcause the injector needle valve to stick. This is why it is important toclean around any fuel connection before servicing it. Also, cap or coverany open fuel connections before a fuel system repair is performed.

High pressure fuel is supplied to the injector (1) from the fuel pump viaan injector supply line (2) and a fuel connector (3). The end ferrule onthe injector supply line pushes against the fuel connector when the fuelline nut is torqued in the cylinder head. This force provides the sealingpressure between both the injector supply line to the fuel connectorand the connector to the injector.

The torque on this line is critical. If the nut is under torqued, the sur-faces will not seal and a high pressure fuel leak will result. If the nut isover torqued, the connector and injector will deform and also cause ahigh pressure leak. The leak may result in an injector misfire and lowpower.

Always lubricate the threads of the high pressure line nuts with engineoil before tightening. Always make sure the proper torque is used onthe high pressure line nuts.

The fuel connector contains an edge filter that breaks up small contam-inants that enter the fuel system. The edge filter uses the pulsatinghigh pressure to break up most particles so they are small enough topass through the injector.

NOTE: The edge filters are not a substitute for cleaning and coveringall fuel system connections during repair. Edge filters are not a substi-tute for maintaining the recommended engine mounted fuel filter.

24 Valve, 8.3 Liter Engine Injectors and Fuel Lines - General InformationSection 6 - Injectors and Fuel Lines - Group 06 Page 6-2


The fuel filter is a spin-on type.

Fuel flows around the outside of the filter and back up through the mid-dle. The filtering media is a 10 micron Stratapore design for efficientdebris removal. The filter also strips the water and collects it at the bot-tom of the filter to be drained daily.

The Case 24 Valve, 8.3 Liter Engine lift pump will run for approximately30 seconds after the key is switched on to assist with fuel priming. Thelift pump will run during cranking and while the engine is running untilthe 30 seconds has lapsed. The lift pump will shut off anytime the keyis switched off. The 30 second timer is reset after each key switch cycleand ECM power down.

Once the engine is started, additional fuel is drawn through the liftpump head via the gear pump. A valve in the head opens when thegear pump requires more flow than the lift pump can provide or whenthe lift pump is shut off.

24 Valve, 8.3 Liter Engine Air in Fuel (006-003)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-3


Air in Fuel (006-003)

Measure (006-003-010)

∆ CAUTION ∆The pressure of the fuel line is sufficient to penetrate the skin andcause serious bodily harm.

To check for air in the high pressure lines, loosen the fittings at thehead. Crank the engine to allow entrapped air to bleed from the line.Tighten the fittings.


High pressure line tube nuts should be lubricated with fuel or oil beforetorquing.

∆ CAUTION ∆Do not bleed a hot engine as this could cause fuel to spill onto thehot exhaust manifold creating a danger of fire.

Operate the engine and vent one line at a time until the engine runssmoothly.

Test (006-003-012)

The air bleed fitting on the CAPS fuel system creates a self-bleedingsystem during replacement of the supply side components.

High pressure fuel line removal and replacement will not require exter-nal bleeding to start the engine. The CAPS fuel pump will create highfuel pressure during cranking and purge the air in the high pressureside through the injectors.

Generally, most of the air that enters the low pressure system duringcomponent replacement can be bled out by turning the fuel lift pumpon for 30 seconds.

NOTE: To run the fuel lift pump for an additional 30 seconds, cycle thekey switch to off, pause for 30 seconds then turn the key switch to theON position.

24 Valve, 8.3 Liter Engine Air in Fuel (006-003)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-4


NOTE: If an excessive amount of air has entered the system, the sys-tem will need to be bled.

Loosen the fuel supply line at the CAPS pump. Run the fuel lift pumpuntil the air has been bled. When all the air has been bled, retightenthe fitting.

If air continues to appear in the system for several minutes, an air leakis present. A source, which is often overlooked, for air to enter the fuelsystem is between the inlet of the pre-filter and the suction tube in thetank. Fuel tanks that have the outlet fitting at the top will have a suctiontube at the bottom of the tank. Cracks or pin holes in the weld that joinsthe tube to the fitting can let air enter the fuel system.

Check to make sure that all fittings from the fuel supply line on the tankto the inlet of the fuel lift pump are tight.

Supply line leaks from the lift pump to the CAPS fuel pump may be lo-cated by operating the lift pump via an electronic servoce tool or keyswitch cycling, to build pressure in the fuel lines. Inspect all lines, con-nections, and filter assembly for an external fuel leak.

19 mm

A stuck open injector can also blow combustion gas back into the pumpand cause air to be present in the overflow. If the engine seems to bemisfiring or running rough, break all the injector supply lines loose atthe pump end. Crank the engine and observe the lines. If combustiongas seems to be blowing back through the line, the injector is stuckopen. Remove and test the injector, refer to Procedure 006-026.


NOTE: Use two wrenches when loosening the lines at the fuel pump,one to hold the delivery valve and one to loosen the line.

24 Valve, 8.3 Liter Engine Fuel Drain Line Restriction (006-012)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-5


Fuel Drain Line Restriction (006-012)

Measure (006-012)

Remove the fuel drain line from the fitting at the rear of the lift pumphead.

Install a test fitting.

Install the zero to 762 mm Hg [zero to 30 in Hg] pressure gauge.

Operate the engine at rated speed and no load.

Observe the reading on the gauge.

If the drain line pressure is out of specification, check for bends or kinksin the drain lines or plugged fuel tank vent valves.

Fuel Drain Line Pressuremm Hg in Hg254.0 MAX 10.0

24 Valve, 8.3 Liter Engine Fuel Drain Lines (006-013)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-6


Fuel Drain Lines (006-013)


Inspect the drain lines for any signs of leaks, cracks, chafing, loose, orbroken brackets.

Remove (006-013-002)

10 mm

Remove the capscrew from the fuel line brace.

Clean all fittings before disassembly. Dirt or contaminants can damagethe fuel system.

19 mm, 15 mm

Remove the banjo fitting at the fuel pump return line. Use two wrench-es to prevent the fuel line from being bent.

Remove drain line fittings at CAPS pump.

17 mm

Remove drain line from the banjo connection at the rear of the head.

24 Valve, 8.3 Liter Engine Fuel Drain Lines (006-013)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-7


17 mm, 19 mm

Disconnect the drain lines from the lift pump.


Inspect lines for clogging or a damaged connector.

Install (006-013-026)

19 mm, 15 mm

Connect fuel drain line at fuel pump banjo, rear fitting at the cylinderhead, and lift pump. Use two wrenches when installing the drain line atthe fuel pump return. Use new sealing washers at pump banjo.


10 mm

Install and tighten the clamp capscrews.


24 Valve, 8.3 Liter Engine Fuel Filter (Spin-On Type) (006-015)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-8


Run the engine under a load and check for leaks.

Fuel Filter (Spin-On Type) (006-015)

Remove (006-015-002)

80 to 95 mm, Filter Wrench

Disconnect wiring harness from WIF, if equipped.

Disconnect wiring harness from fuel heater (if equipped).

Loosen the combination water separator/fuel filter.

Remove the combination water separator/fuel filter.

NOTE: Make sure o-ring does not stick to filter head. Remove o-ringwith screwdriver if necessary.

Install (006-015-026)

Install the water-in-fuel (WIF) sensor into the new fuel filter, if neces-sary.

24 Valve, 8.3 Liter Engine Fuel Filter (Spin-On Type) (006-015)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-9


The Case 24 Valve, 8.3 Liter Engine has a self-priming, low-pressuresystem that purges the air from the fuel system. There is no need topre-fill the new filter with fuel, but it is recommended.

Lubricate the o-ring with clean lubricating oil.

∆ CAUTION ∆Mechanical tightening may distort the threads as well as damagethe filter element seal or filter canister.

Install the filter as specified by the filter manufacturer.

Connect the water-in-fuel (WIF) sensor to the wiring harness (ifequipped).

Connect the wiring harness to the heater (if equipped).

Turn the key to the ON positon, but do not attempt to start the enginefor 30 seconds. The electric fuel transfer pump will run and purge airfrom the system for about 30 seconds.

After 30 seconds attempt to start the engine.


24 Valve, 8.3 Liter Engine Fuel Filter Head Bracket (006-018)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-10


Fuel Filter Head Bracket (006-018)

Remove (006-018-002)

Remove the fuel filter. Refer to Procedure 006-015.

1 Inch

Remove the fuel supply lines from the filter head.

13 mm, 9/16-Inch

Remove the four capscrews retaining the filter head.

Remove the filter head bracket from the engine bracket.


Remove the fuel heater (if equipped).

Remove the filter adapter stud.

24 Valve, 8.3 Liter Engine Fuel Filter Head Bracket (006-018)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-11



Inspect the filter head for cracks, passage blockage, material or debrison the sealing surfaces.

Assemble (006-018-025)

7/8-Inch

Apply Loctite™ 277, or equivalent, to the filter adapter threads that areengaging the filter head.

Assemble the filter head.

Install the filter adapter and fuel heater (if equipped).

Torque Value: 3.4 N•m [30 in-lb]

NOTE: Make sure there is an o-ring between the filter head and heat-er.

Install (006-018-026)

14 mm, 9/16-Inch

Install the bracket and filter head. Tighten the retaining capscrews.


1 Inch

Install fuel lines.


Install the fuel filter. Refer to Procedure 006-015.

24 Valve, 8.3 Liter Engine Fuel Inlet Restriction (006-020)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-12


Run the engine and check for leaks.

Fuel Inlet Restriction (006-020)


Install a fitting at the lift pump inlet.

Install a vacuum gauge that has a range of at least zero to 508 mm Hg[zero to 20 in Hg].

Measure the inlet restriction.

If the fuel inlet restriction is too high, check to make sure the lines fromthe tank are sized properly, there are no kinks or bends in the lines, andthe lines are not clogged. Also, make sure there are no clogged fuelstrainers or malfunctioning check valves.

Fuel Supply Lines (006-024)


Inspect all fuel supply line fittings and lines. Look for cracks in the linesor leaking fitting.

Fuel Inlet Restrictionmm Hg in Hg

8 MAX 4

24 Valve, 8.3 Liter Engine Injector (006-026)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-13


Remove (006-024-002)

1 Inch

Remove fuel supply lines.


Look for burrs or debris around the fittings that could cause a leak, alsolook for damaged or frayed flexible fuel hose.

Install (006-024-026)

1 inch

Install fuel supply lines.


Injector (006-026)

Remove (006-026-002)

Remove the rocker lever cover. Refer to Procedure 003-011.

Remove the injector supply lines. Refer to Procedure 006-051.

The fuel connector must be removed before removing the injector ordamage to the connector will result.



8 mm

Remove the injector hold-down.

Injector Puller, Tool No. 3825156

Using the injector puller, Tool No. 3825156, pull the injector out of thehead.


Place the injector in the injector clamp and remove the nozzle retainingnut.

NOTE: Injectors covered under warranty by the manufacturer shouldnot be repaired. Refer to the manufacturer's warranty instructions.

Remove the nozzle, intermediate plate, spring, and shims from the in-jector.



Clean (006-026-006)

∆ WARNING ∆Do not use a steel wire brush or glass beading to clean the injec-tors. This will damage the nozzle holes and cause performanceproblems.

Clean injector tip and body with safety solvent and soft clean rag.

If necessary use a brass brush to clean off carbon.


Inspect the injector. Inspect o-ring for damage. Look for burrs on the in-let to the injector. Check the nozzle holes for any signs of damage suchas hole erosion or hole plugging. Also check the nozzle color for signsof overheating. Overheating will cause the nozzle to turn dark yellow/tan or blue color depending on the temperature of overheat.

Measure (006-026-010)

Verify the injector sealing washer is the correct thickness. The incorrectsealing washer can cause high pressure fuel leaks, and/or perfor-mance problems due to incorrect injector protrusion.

Refer to the injector part number for correct sealing washer shim thick-ness.

NOTE: All 1998 emissions engines use 1.5 mm [0.06 in] injectorshims.

Test (006-026-012)

Injector Nozzle Tester, Tool No. 3162269

Install the injectors on an injector test stand. Open the bypass valve forthe pressure gauge so the spray pattern can be checked.



Operate the test stand lever quickly several times to check the spraypattern of the injectors. Verify that the correct number of plumes arepresent for the number of holes in the injector. Also pay close attentionto the size and shape of each plume. If possible, compare the spraypattern to that of a new injector with the same assembly number.

NOTE: The injector spray pattern is an excellent indicator of the nozzlehole condition. Check each plume carefully because it is possible thatonly a single hole has been damaged, yet significant performance is-sues may result.

Close the bypass valve for the pressure gauge and operate the teststand lever to check the nozzle opening pressure. There should be agood crisp pop when the nozzle opens and the pressure should bewithin specification for the assembly number.

If the nozzle opening pressure is excessively low and/or the nozzlesprays excessive fuel, the injector needle may be sticking. The needlemay be stuck due to poor lubrication or debris.

Sometimes it is possible to unstick an injector needle by using the in-jector test stand. Open the bypass valve for the pressure gauge andoperate the test stand lever rapidly for 10 to 20 strokes.

Recheck the nozzle opening pressure and spray pattern to see if theinjector has returned to normal operation.

If the injector is still out of specification, replace the injector.



Check the injector for drip and/or excessive leak down. Close the by-pass valve for the pressure gauge and build pressure to within 10 barsof the opening pressure of the nozzle.

A drop of fuel should not form within 15 seconds.

Inspect (006-026-062)

Remove the needle from the nozzle tip and inspect the color. Look forsigns of excessive carbon or overheating (dark yellow/tan or blue colorof needle). Also look for scuffing marks on the needle.

NOTE: Do not touch needle with finger tips. Oil from fingers will dam-age the needle. Hold the needle by the stem. If needle is touched wipeclean with soft cloth and dip in diesel fuel.

Dip the needle in clean diesel fuel and insert the nozzle. Hold the noz-zle at a 45 degree angle and pull the needle 2/3 the way out. Under itsown weight the needle should slide smoothly back onto the nozzle.

Assemble (006-026-025)

Clean injector internal components with clean diesel fuel and cleanrag. Make sure there is no debris in the internal parts of the injector.



Install shims necessary to modify the nozzle opening pressure. Moreshims raise the nozzle opening pressure, less shims lower the nozzleopening pressure.

Install the spring, button, intermediate plate, and nozzle/needle.

Make sure that the intermediate plate is in the correct orientation withthe supply hole on the plate lining up with the supply hole on the holder.

Install the retaining nut finger tight. Place the injector in the injectorclamp and tighten the retaining nut. Install the sealing washer and bodyo-ring.


Install (006-026-026)

8 mm

Place the injector in the head in the proper orientation. Install the injec-tor hold-down and tighten.


24 Valve, 8.3 Liter Engine Injector Supply Lines (High Pressure) (006-051)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-19


Install the fuel connector. Refer to Procedure 006-052.

Install the rocker lever cover. Refer to Procedure 003-011.

Install the high pressure fuel lines. Refer to Procedure 006-051.


Injector Supply Lines (High Pressure) (006-051)


17 mm, 19 mm

Inspect the lines for cracks, chafing, or leaks. Make sure that the linesare tightened to the proper specification.

17 mm

Check the fuel pump connection.


19 mm

Check the cylinder head connection.




Remove (006-051-002)

19 mm, 17 mm

Remove the fuel line from the injection pump.

NOTE: Use two wrenches to prevent the outlet fitting from turning.

10 mm

Remove the fuel line clamp capscrews from the intake cover.

Fuel line clamp capscrews must be removed from the intake cover be-fore injection line can be pulled loose from head.

19 mm

Remove the fuel line from the cylinder head.

NOTE: Use two wrenches to prevent the outlet fitting from turning.


Check the ferrules of the lines for any signs of burrs or foreign material.

Check for cracks and deformation.



Install (006-051-026)

Before installing the injector supply lines, make sure that the fuel con-nector is fully and properly seated against the injector.

19 mm, 17 mm

Install the fuel lines in the reverse order of removal.

17 mm

Check the fuel pump connection.


19 mm

Check the cylinder head connection.


∆ WARNING ∆Do not bleed a hot engine as this could cause fuel to spill onto ahot exhaust manifold creating a danger of fire.

Operate the engine and vent one line at a time until the engine runssmoothly.

24 Valve, 8.3 Liter Engine Fuel Connector (Head Mounted) (006-052)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-22


Fuel Connector (Head Mounted) (006-052)

Remove (006-052-002)

Fuel Connector Puller, Tool No. 3825157

Remove injector supply line. Refer to Procedure 006-051.

Install a fuel connector puller, Part No. 3825157.

Remove the fuel connector out of the cylinder head.

NOTE: When removing the fuel connector from the cylinder head,care must be taken to make sure that the connector o-ring is not dam-aged.


Inspect the fuel connector. Look for burrs or deformation around the in-let and outlet sides of the connector.

Check the edge filter for signs of plugging or material contamination.

Check the o-ring for tearing or deterioration.

NOTE: It is recommended that the o-ring on the high pressure connec-tor is replaced.

Install (006-052-026)

Carefully push the fuel connector into the head until it stops against theinjector. Be sure not to tear the o-ring as the connector is being in-stalled.

NOTE: Lubricate the o-ring prior to installation with the engine or veg-etable oil.

Install high pressure fuel lines. Refer to Procedure 006-051.


24 Valve, 8.3 Liter Engine Fuel Pump Air Bleed Line (006-056)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-23


Fuel Pump Air Bleed Line (006-056)




Dry the fuel pump with compressed air

Remove (006-056-002)15 mm, 19 mm

Remove banjo capscrew at the distributor drain fitting of th fuel pump.

Use two wrenches to prevent the line from being bent.

15 mm, 19 mm

Remove the banjo capscrew at the air bleed fitting on top of the fuelpump. It is located on the accumulator module next to the two pumpingcontrol valves.

Use two wrenches to prevent the air bleed fitting from turning.


Inspect line for pinches, bends, or damaged connectors.

24 Valve, 8.3 Liter Engine Fuel Pump Air Bleed Line (006-056)Section 6 - Injectors and Fuel Lines - Group 06 Page 6-24


Install (006-056-026)

15 mm, 19 mm

Install the banjo capscrew at the air bleed fitting on top of the fuelpump. Use two wrenches to prevent the air bleed fitting from turning.


Use new sealing washers.

15 mm, 19 mm

Install banjo capscrew drain fitting on the fuel pump at the distributor.Use two wrenches to prevent the line from being bent.


Use new sealing washers.

Start the engine and check for fuel leaks at the air bleed line connec-tions.

24 Valve, 8.3 Liter Engine Section 7 - Lubricating Oil System - Group 07Section 7 - Lubricating Oil System - Group 07 Page 7-a


Section 7 - Lubricating Oil System - Group 07

Section Contents

Engine Oil Heater (007-001) ........................................................................................................................................................................ 13Install (007-001-026) ...................................................................................................................................................................... 13Preparatory (007-001-000) ............................................................................................................................................................. 13Remove (007-001-002) .................................................................................................................................................................. 13

Flow Diagram, Lubricating Oil System ........................................................................................................................................................ 8Lubrication for the Turbocharger ...................................................................................................................................................... 9Lubrication for the Power Components .......................................................................................................................................... 10

Lubricating Oil System - General Information ............................................................................................................................................ 1

Lubricating Oil and Filters (007-002) .......................................................................................................................................................... 13Inspect (007-002-062) .................................................................................................................................................................... 13

Lubricating Oil Cooler (007-003) ................................................................................................................................................................. 14Clean (007-003-006) ...................................................................................................................................................................... 16Install (007-003-026) ...................................................................................................................................................................... 17Leak Test (007-003-014) ................................................................................................................................................................ 16Preparatory (007-003-000) ............................................................................................................................................................. 14Remove (007-003-002) .................................................................................................................................................................. 15

Lubricating Oil Dipstick (007-009) 18Calibrate (007-009-030) ................................................................................................................................................................. 18

Lubricating Oil Dipstick Tube (007-011) .................................................................................................................................................... 19Install (007-011-026) ...................................................................................................................................................................... 20Preparatory (007-011-000) ............................................................................................................................................................. 19Remove (007-011-002) .................................................................................................................................................................. 20

Lubricating Oil Filter (Spin-On) (007-013) .................................................................................................................................................. 21Install (007-013-026) ...................................................................................................................................................................... 21Remove (007-013-026) .................................................................................................................................................................. 21

Lubricating Oil Pan (007-025) ..................................................................................................................................................................... 22Clean (007-025-006) ...................................................................................................................................................................... 22Drain (007-025-005) ....................................................................................................................................................................... 22Fill (007-025-028) ........................................................................................................................................................................... 24Inspect for Reuse (007-025-007) ................................................................................................................................................... 23Install (007-025-026) ...................................................................................................................................................................... 23Remove (007-025-002) .................................................................................................................................................................. 22

Lubricating Oil Pressure Regulator (Main Rifle) (007-029) ...................................................................................................................... 25Clean (007-029-006) ...................................................................................................................................................................... 25Inspect for Reuse (007-029-007) ................................................................................................................................................... 26Install (007-029-026) ...................................................................................................................................................................... 26Remove (007-029-002) .................................................................................................................................................................. 25

Section 7 - Lubricating Oil System - Group 07 24 Valve, 8.3 Liter EnginePage 7-b Section 7 - Lubricating Oil System - Group 07


Lubricating Oil Pump (007-031) .................................................................................................................................................................. 26Inspect for Reuse (007-031-007) ................................................................................................................................................... 27Install (007-031-026) ...................................................................................................................................................................... 30Measure (007-031-010) ................................................................................................................................................................. 29Preparatory (007-031-000) ............................................................................................................................................................ 26Remove (007-031-002) .................................................................................................................................................................. 27

Lubricating Oil Suction Tube (Block-Mounted) (007-035) ........................................................................................................................ 33Clean (007-035-006) ...................................................................................................................................................................... 33Fill (007-035-028) ........................................................................................................................................................................... 35Inspect for Reuse (007-035-007) ................................................................................................................................................... 34Install (007-035-026) ...................................................................................................................................................................... 34Preparatory (007-035-000) ............................................................................................................................................................ 33Remove (007-035-002) .................................................................................................................................................................. 33

Lubricating Oil Thermostat (007-039) ........................................................................................................................................................ 35Inspect for Reuse (007-039-007) ................................................................................................................................................... 35Install (007-039-026) ...................................................................................................................................................................... 36Remove (007-039-002) .................................................................................................................................................................. 35

Lubricating Oil Pressure Sensor (007-052) ............................................................................................................................................... 37Inspect for Reuse (007-052-007) ................................................................................................................................................... 37Install (007-052-026) ...................................................................................................................................................................... 37Remove (007-052-002) .................................................................................................................................................................. 37

Specifications .............................................................................................................................................................................................. 12Lubricating Oil System ................................................................................................................................................................... 12

24 Valve, 8.3 Liter Engine Lubricating Oil System - General InformationSection 7 - Lubricating Oil System - Group 07 Page 7-1


Lubricating Oil System - General Information

∆ WARNING ∆Some state and federal agencies in the United Statesof America have determined that used engine oil canbe carcinogenic and can cause reproductive toxicity.Avoid inhalation of vapors, ingestion, and prolongedcontact with used engine oil.

∆ WARNING ∆Avoid direct contact of hot oil with your skin. Hot oilcan cause personal injury.

Case Corporation recommends the use of a high qualitySAE 15W-40 heavy duty engine oil which meets theAmerican Petroleum Institute (API) performance classifi-cation CE/SG.

APi grade CG-4/CF-4 engine oils can be used in areaswhere CE oil is not yet available, but the lubricating oilchange interval must be reduced to 1/2 of the interval giv-en in the maintenance schedule.

∆ CAUTION ∆Limited use of low viscosity lubricating oils, such as10W-30, can aid in starting the engine and providingsufficient lubricating oil flow at ambient temperaturesbelow -5°C [23°F]. However, the continuous use of lowviscosity lubricating oils can decrease engine life. Re-fer to the accompanying chart.

Diagnosing Lubricating System Malfunctions

When diagnosing lubrication system malfunctions, checkall obvious items related to oil pressure, such as gauges;high and low oil level; excessive oil contamination; and oilviscosity.

Lubricating Oil System - General Information 24 Valve, 8.3 Liter EnginePage 7-2 Section 7 - Lubricating Oil System - Group 07


High Lubricating Oil Pressure

High oil pressure usually occurs after the engine is firststarted in cold weather. Cold start oil pressure typicallywill be approximately 827 to 1034 kPa [120 to 150 psi]. Ifthe pressure regulator plunger is operating properly, thenthe oil pressure should drop back to approximately 449kPa [65 psi] when normal operating temperature isreached.

Lubricating Oil Pressure Regulating Valve

The engine will have high oil pressure at the normal oper-ating temperature if the regulator sticks in the closed po-sition. Check the regulator for freedom of movement.Refer to Procedure 007-029.

Low Lubricating Oil Pressure

Low lubricating oil pressure (or no oil pressure) can becaused by several lubrication system related malfunc-tions. To begin the investigation, determine the engine op-erating conditions when the low pressure was firstobserved; for example, following a service interval, at idleonly, while operating on a steep grade.

Lubricating Oil Level

High oil level can cause low oil pressure. If the oil level ishigh enough for the connecting rods to dip into during op-eration, the oil can become aerated. This will result in lowoil pressure and high engine temperature.



Low lubricating oil level will not normally appear as low oilpressure. Typically, it will appear as an intermittent loss ofoil pressure when rounding a corner or operating on asteep grade. This condition exists when the oil level is ex-tremely low and the suction tube can not pick up oil duringall modes of operation.

Lubricating Oil Filter

A plugged filter will cause a gradual loss of oil pressure byapproximately 69 kPa [10 psi]. The pressure will return tonormal when the filter bypass valve opens. If not correct-ed, this will result in severe engine wear, as the engine isrunning on unfiltered oil when the bypass valve is open.

Lubricating Oil Gauge

Check the lubricating oil gauge and sending unit to makesure they are operating correctly by verifying the pressurewith a manual gauge.

Lubricating Oil Suction Tube

A loose suction tube, damaged gasket, or crack in the suc-tion tube can cause a temporary loss of prime for the oilpump. The engine will have low pressure or no oil pres-sure at starting, followed by normal oil pressure.



Bearings and Lubricating Oil Pump

A steady decrease in oil pressure over a long period oftime can be an indication of worn bearings or excessive oilpump wear.

Lubricating Oil Dilution

∆ CAUTION ∆Diluted oil can cause severe engine damage.

Check the condition of the lubricating oil.

• Thin, black lubricating oil is an indication of fuel in the oil.

• Milky discoloration is an indication of coolant in the lubricating oil.

Coolant in the oil can be caused by:

• Expansion plugs that are leaking• Lubricating oil cooler element that is leaking• Damaged cylinder head or gasket• Cracked engine block • Casting porosity.

•

Coolant Diluted Lubricating Oil

Since the lubricating oil cooler design does not requiregaskets or seals to maintain the separation of oil and cool-ant, the element itself must leak to allow mixing of the flu-ids. Refer to Procedure 007-003.



During operation, the lubricating oil pressure will be higherthan coolant pressure. A leak in the lubricating oil coolerwill appear as lubricating oil in the coolant.

However, following an engine shutdown, the residualpressure in the coolant system can cause coolant to seepthrough the leak path into the lubricating oil.

To check for leaks, pressurize the cooling system to 140kPa [20 psi]. With the system pressurized, remove the fol-lowing components and inspect for leaks:

• Valve covers (leaks indicate cracked head).• Lubricating oil drain plug (leaks indicate defective

lubricating oil cooler, head gasket, cracked head, or block).

Coolant in the lubricating oil can be caused by a damagedcylinder head gasket or cracked cylinder head or block.

Remove the cylinder head and gasket, and inspect forcracks or damage. Refer to Procedure 002-004.

Fuel Diluted Lubricating Oil

Use the following logic to determine the source of the oildilution with fuel.

Fuel dilution is limited to three sources:

• Injection pump cam housing• Fuel leaking by the rings• Injector leakage.

A cracked cam housing can cause fuel to leak into thegear housing and then into the lubrication oil pan.



Incomplete combustion in the cylinders can result in un-burned fuel draining into the oil pan.

This condition can be caused by a leaking injector or re-duced compression caused by inadequate piston ringsealing.

An increase in white exhaust smoke during the first startof the day is a symptom that an injector is leaking.

An injector leak will also cause the engine to run roughand have low power.Remove, repair, or replace leaking injectors. Refer to Pro-cedure 006-026, for test and repair instructions.

Lubricating Oil Leaks

Various gaskets, seals, and plugs are used to contain thelubricating oil. Most leaks can be identified during routineinspection of the engine and vehicle.

A blown expansion plug can allow a relatively large quan-tity of lubricating oil to escape, resulting in a sudden dropin the lubricating oil pressure.

When checking for such a leak, be sure to check all ex-pansion plugs that may be obscured by chassis parts.

Lubricating oil blowing out of the breather is a sign of ablown expansion plug.



If the lubricating oil cooler element ruptures, the lubricat-ing oil pressure may force lubricating oil into the coolingsystem. Lubricating oil in the coolant should be visiblewhen the radiator cap is removed. Refer to Procedure007-003.

Worn or damaged seals in the turbocharger can also allowlubricating oil to leak into the air crossover pipe and beburned in the engine.

The condition can be verified by removing the air cross-over tube or charge air cooler tubing and looking for oil.

Inadequate sealing of the piston rings will result in lubri-cating oil being blown out the breather tube and/or con-sumed by the engine. Refer to Procedure 014-002.

Lubricating oil can also be lost through a worn or malfunc-tioning air compressor. Look for carbon build-up in the airline from the compressor to the air tank. Also, a failed aircompressor head or head gasket can allow oil to leak intothe coolant, or coolant to leak into the oil, during hot shut-down.

Flow Diagram, Lubricating Oil System 24 Valve, 8.3 Liter EnginePage 7-8 Section 7 - Lubricating Oil System - Group 07


Flow Diagram, Lubricating Oil System

1. Gerotor Lubricating Oil Pump2. Pressure Regulating Valve Closed3. Pressure Regulating Valve Open4. From Lubricating Oil Pump 5. To Lubricating Oil Cooler6. To Lubricating Oil Pump7. Lubricating Oil Cooler8. Filter Bypass Valve9. Filter Bypass Valve Closed10. Filter Bypass Valve Open11. To Lubricating Oil Filter12. Full Flow Lubricating Oil Filter13. From Lubricating Oil Filter14. Main Lubricating Oil Rifle

24 Valve, 8.3 Liter Engine Flow Diagram, Lubricating Oil SystemSection 7 - Lubricating Oil System - Group 07 Page 7-9


Lubrication for the Turbocharger

1. Lubricating Oil Filter2. Turbocharger Lubricating Oil Supply3. Turbocharger Lubricating Oil Drain4. To Main Lubricating Oil Rifle

Flow Diagram, Lubricating Oil System 24 Valve, 8.3 Liter EnginePage 7-10 Section 7 - Lubricating Oil System - Group 07


Lubrication for the Power Components

1. From Lubricating Oil Cooler2. Main Lubricating Oil Rifle3. To Camshaft4. From Main Lubricating Oil Rifle5. To Piston Cooling Nozzle6. To Connecting Rod Bearing

24 Valve, 8.3 Liter Engine Flow Diagram, Lubricating Oil SystemSection 7 - Lubricating Oil System - Group 07 Page 7-11


Lubrication for the Overhead

1. From Cam Bushings2. Transfer Slot3. Rocker Lever Support4. Rocker Lever Shaft5. Rocker Lever Bore6. Rocker Lever

Specifications 24 Valve, 8.3 Liter EnginePage 7-12 Section 7 - Lubricating Oil System - Group 07


Specifications

Lubricating Oil SystemOil Pressure:

at Low Idle (Minimum Allowable)................................................................................................ 69 kPa [10 psig]at Rated Speed (Minimum Allowable) ...................................................................................... 207 kPa [30 psig]

Regulated Pressure .......................................................................................................................... 517 kPa [75 psi]

Oil Capacity Of Standard Engine:Standard Oil Pan

Pan Only ................................................................................................................................. 18.9 liters [20 qts] Total System Capacity with Filter ...................................................................................................... 21 liters [22 qts]

Some applications may use a slightly different oil pan capacity. Refer to the Machine Operators Manual.

24 Valve, 8.3 Liter Engine Engine Oil Heater (007-001)Section 7 - Lubricating Oil System - Group 07 Page 7-13


Engine Oil Heater (007-001)

Preparatory (007-001-000)∆ WARNING ∆

Some state and federal agencies in the United Statesof America have determined that used engine oil canbe carcinogenic and can cause reproductive toxicity.Avoid inhalation of vapors, ingestion, and prolongedcontact with used engine oil.



Remove (007-001-002)

Disconnect the oil heater electrical cord and remove theheater element.

Remove the heater element

Install (007-001-026)

Ratchet, 1-Inch Deep Well Socket, Torque Wrench

Replace the heater element.


Refill the engine to the correct oil level. Refer to the Ve-hicle Operators Manual.

Connect oil heater electrical cord.

Lubricating Oil and Filters (007-002)

Inspect (007-002-062)

An analysis of used oil can help diagnose internal enginedamage and determine if it was caused by one of the fol-lowing:

• Intake air filter malfunction• Coolant leaks• Oil diluted with fuel• Metal particles causing wear.

Lubricating Oil Cooler (007-003) 24 Valve, 8.3 Liter EnginePage 7-14 Section 7 - Lubricating Oil System - Group 07


NOTE: Do not take apart an engine for repair based sole-ly on the results of an oil analysis. Inspect the oil filters. Ifthe oil filter shows evidence of internal damage, find thesource of the problem and repair the damage. Refer to theappropriate procedure(s) based on the following oil filterinspection.

∆ CAUTION ∆Restrain the full flow lubricating oil filter and carefullycut the filter (upper section of combo filter) open. Thefilter element spring is under compression and cancause personal injury.

Inspect the filter element for evidence of moisture or metalparticles.

Lubricating Oil Cooler (007-003)


∆ WARNING ∆Coolant is toxic. Keep away from pets and children. Ifnot reused, dispose of in accordance with local envi-ronmental regulations.

∆ WARNING ∆Wait until the temperature is below 50°C [120°F] toavoid personal injury from hot coolant.


Metal Possible SourceCopper Bearings and BushingsChromium Piston RingsIron Cylinder LinersLead Bearing Overlay MaterialAluminum Piston Wear or Scuffing

24 Valve, 8.3 Liter Engine Lubricating Oil Cooler (007-003)Section 7 - Lubricating Oil System - Group 07 Page 7-15


Remove (007-003-002)

Clean around the lubricating oil cooler cover.

Remove the lubricating oil filter.

16 mm, 19 mm

Disconnect the turbocharger lubricating oil supply line.

10 mm

Remove the lubricating oil cooler cover, gaskets and cool-er element.

Lubricating Oil Cooler (007-003) 24 Valve, 8.3 Liter EnginePage 7-16 Section 7 - Lubricating Oil System - Group 07


Clean (007-003-006)

Clean the sealing surfaces.

Leak Test (007-003-014)

Pressure test the element to check for leaks. If leaks aredetected, replace the element.

Assemble the lubricating oil cooler gaskets, element andcover.


NOTE: Be sure to remove the shipping plugs from the el-ement.

Connect the turbocharger lubricating oil supply line.


Air Pressure TestkPa psi449 MIN 65518 MAX 75

24 Valve, 8.3 Liter Engine Lubricating Oil Cooler (007-003)Section 7 - Lubricating Oil System - Group 07 Page 7-17


Fill the filter with clean lubricating oil and apply a thin coatof oil to the sealing gasket. Refer to the operators manualfor lubricating oil recommendation.

Install the lubricating oil filter. Refer to Procedure 007-013.

Fill the coolant system and operate the engine to check forleaks.

Stop the engine and check the coolant and lubricating oillevel.

Install (007-003-026)10 mm

Assemble the lubricating oil cooler gaskets, element andcover.


NOTE: Be sure to remove the shipping plugs from the el-ement.

16 mm, 19 mm

Connect the turbocharger lubricating oil supply line.

Lubricating Oil Dipstick (007-009) 24 Valve, 8.3 Liter EnginePage 7-18 Section 7 - Lubricating Oil System - Group 07


Fill the filter with clean lubricating oil and apply a thin coatof clean oil to the sealing gasket. Refer to the operatorsmanual for lubricating oil recommendation.

Install the lubricating oil filter. Refer to Procedure 007-013.

Fill the coolant system and operate the engine to check forleaks.

Stop the engine and check the coolant and lubricating oillevel.

Lubricating Oil Dipstick (007-009)

Calibrate (007-009-030)

∆ WARNING ∆Some state and federal agencies in the United Statesof America have determined that used engine oil canbe carcinogenic and can cause reproductive toxicity.Avoid inhalation of vapors, ingestion, and prolongedcontact with used engine oil.



Install the dipstick in the dipstick tube housing.

Use clean 15W-40 oil to fill the oil pan to the specified"LOW" oil level. Refer to the operators manual for the cor-rect engine oil capacity.

24 Valve, 8.3 Liter Engine Lubricating Oil Dipstick Tube (007-011)Section 7 - Lubricating Oil System - Group 07 Page 7-19


∆ CAUTION ∆Use care when marking the dipstick. The dipstick willbreak if the scribe mark is too deep.

Remove the dipstick and scribe a mark across the stick atthe oil level. Label the mark with an "L" to indicate the"LOW" oil level.

NOTE: If a new blank dipstick is being used, cut the dip-stick off approximately 38 mm [1.5 in] below the "LOW" oillevel mark.

Wipe off the dipstick and install it in the dipstick tube hous-ing.

Fill the oil pan to the specified "HIGH" oil level. Refer to theoperators manual for engine oil capacity.

Remove the dipstick and scribe a mark across the stick atthe oil level. Label the mark with a "H" to indicate the"HIGH" oil level.

Lubricating Oil Dipstick Tube (007-011)


Clean the area around the dipstick tube before removingto prevent debris from entering the oil system.

Lubricating Oil Dipstick Tube (007-011) 24 Valve, 8.3 Liter EnginePage 7-20 Section 7 - Lubricating Oil System - Group 07


Remove (007-011-002)

Remove dipstick from the dipstick tube.

Remove dipstick tube from the cylinder block.

Service Tip: Use a dent puller and a M8 x 1.25 x 21 mmself-tapping capscrew. Thread the capscrew into the dip-stick tube and remove the tube.

Install (007-011-026)

Apply a thin bead of Loctite™ 277, or equivalent, aroundthe bottom of the knurled end of the tube.

Place knurled end of tube into the dipstick tube bore in thecylinder block.

Use a flat washer and hex head capscrew to drive the tubeinto the cylinder block.

Lightly drive the dipstick tube until it seats against theblock casting.

Install dipstick into the dipstick tube.

24 Valve, 8.3 Liter Engine Lubricating Oil Filter (Spin-On) (007-013)Section 7 - Lubricating Oil System - Group 07 Page 7-21


Lubricating Oil Filter (Spin-On) (007-013)

Remove (007-013-026)

Clean the area around the lubricating oil filter head.

Remove the filter.

Clean the gasket surface of the filter head.

Install (007-013-026)

Use clean 15W-40 oil to coat the gasket surface of the fil-ter.

∆ CAUTION ∆Lubrication oil filter should be full of oil at startup toprevent engine damage.

Fill the filter with clean 15W-40 oil.

∆ CAUTION ∆Mechanical overtightening of the filter can distort thethreads or damage the filter element seal.

Install the filter on the oil filter head. Tighten the filter untilthe gasket contacts the filter head surface.

Tighten the filter. Refer to the instructions supplied withthe filter.


NOTE: Engine oil pressure must be indicated on thegauge within 15 seconds after starting. If oil pressure isnot registered within 15 seconds, shut off the engine im-mediately to avoid engine damage. Confirm that the oilpan has the correct oil level.

Lubricating Oil Pan (007-025) 24 Valve, 8.3 Liter EnginePage 7-22 Section 7 - Lubricating Oil System - Group 07


Lubricating Oil Pan (007-025)

Drain (007-025-005)

17 mm∆ WARNING ∆

Some state and federal agencies in the United Statesof America have determined that used engine oil canbe carcinogenic and can cause reproductive toxicity.Avoid inhalation of vapor, ingestion, and prolongedcontact with used engine oil.

∆ WARNING ∆Hot oil can cause serious personal injury.

Use a container that can hold at least 20.1 liters [22 U.S.qts] of lubricating oil.

Operate the engine until the coolant temperature reaches60°C [140°F]. Shut off the engine. Remove the oil drainplug. Drain the oil immediately to make sure all the oil andsuspended contaminants are removed from the engine.

Remove (007-025-002)

10 mm

Remove the lubricating oil pan and gasket.

If suction tube must be removed, Refer to Procedure 007-035.

Clean (007-025-006)

Remove all gasket material from the cylinder block and oilpan surface.

Steam clean the oil pan.


24 Valve, 8.3 Liter Engine Lubricating Oil Pan (007-025)Section 7 - Lubricating Oil System - Group 07 Page 7-23



Inspect the oil pan, suction tube, and tube braces for dam-age.

NOTE: If cracks are found, replace the damaged part. Donot attempt to repair the oil pan by welding.

If the suction tube must be replaced, Refer to Procedure007-035.

Install (007-025-026)

Use Three Bond™ RTV sealant, or equivalent, to fill thejoints between the lubricating oil pan rail, gear housing,and rear seal housing.

If the suction tube has been removed, Refer to Procedure007-035 for installation instructions.

10 mm

Apply a 2 mm [1/16 in] bead of Three Bond™ Sealant toboth sides of the new lubricating pan gasket.

Install the gasket and lubricating oil pan.

10 mm

Assemble the washers and capscrews to secure the lubri-cating oil pan as illustrated.

Tighten all capscrews in the sequence shown in the ac-companying chart.


Lubricating Oil Pan (007-025) 24 Valve, 8.3 Liter EnginePage 7-24 Section 7 - Lubricating Oil System - Group 07


17 mm

Clean and check the lubricating oil drain plug threads andsealing surface.

Install the lubricating oil pan drain plug.


Fill (007-025-028)

Use a high quality 15W-40 multiviscosity oil in Case en-gines. Choose the correct oil for your operating climate asoutlined in the Vehicle Operation and Maintenance Manu-al.

Fill the engine with clean lubricating oil to the proper level.

When filling the oil pan, use the fill tube on the side of theengine rather than on top of the rocker lever cover.

Idle the engine to inspect for leaks at the drain plug.

NOTE: Engine oil pressure must be indicated on thegauge within 15 seconds after starting. If oil pressure isnot registered within 15 seconds, shut off the engine im-mediately to avoid engine damage. Confirm that oil hasbeen filled to the correct level in the oil pan.

24 Valve, 8.3 Liter Engine Lubricating Oil Pressure Regulator (Main Rifle) (007-029)Section 7 - Lubricating Oil System - Group 07 Page 7-25


Shut off the engine. Wait approximately 10 minutes to letthe oil drain from the upper parts of the engine. Check thelevel again.

Add oil as necessary to bring the oil level to the H (high)mark on the dipstick.

Lubricating Oil Pressure Regulator (Main Rifle)(007-029)

Remove (007-029-002)

Thoroughly clean the area around the pressure regulatorplug with clean solvent to prevent debris from falling intothe plunger bore when the plug is removed.

19 mm

Remove the threaded plug, spring, and plunger.

Service Tip: The plunger normally can be removed by in-serting one finger into the plunger bore until snug and pull-ing up. If the plunger can not be removed in this manner,the plunger is probably stuck and will require removal ofthe housing for cleaning the plunger.

Clean (007-029-006)

∆ CAUTION ∆Compressed air used for cleaning should not exceed207 kPa [30 psi]. Use only with personal protectiveequipment (goggles/shield, gloves, etc.).

Thoroughly clean all components with clean solvent.


If the plunger bore requires cleaning, remove the housingto avoid flushing debris into the engine.

Lubricating Oil Pump (007-031) 24 Valve, 8.3 Liter EnginePage 7-26 Section 7 - Lubricating Oil System - Group 07



Inspect the plunger and plunger bore. Polished areas onthe plunger and bore are acceptable.

Verify that the plunger moves freely in the bore.

Install (007-029-026)

19 mm

Install a new sealing o-ring on the threaded plug and lubri-cate with clean engine oil. Install the pressure regulatorassembly.


Lubricating Oil Pump (007-031)



24 Valve, 8.3 Liter Engine Lubricating Oil Pump (007-031)Section 7 - Lubricating Oil System - Group 07 Page 7-27


Remove (007-031-002)

15 mm

Remove the vibration damper. Refer to Procedure 001-051 or 001-052.

10 mm

Remove the front cover. Refer to Procedure 001-031.

13 mm

Remove the four mounting capscrews.

Remove the pump from the bore in the cylinder block.


If the lubricating oil pump is to be inspected for reuse, fol-low these steps.

Inspect the lubricating oil pump gears for chips, cracks, orexcessive wear.



Remove the back plate.

NOTE: The Case 24 Valve 8.3 Liter Engine lube oil pumpuses a large diameter 5/6 rotor set. The graphics in thismanual illustrates a 4/5 rotor set.

Mark "TOP" on the gerotor planetary.

Remove the gerotor planetary.

Inspect for excessive wear or damage.

Clean all parts in solvent.




Inspect the lubricating oil pump housing and gerotor drivefor damage and excessive wear.

∆ CAUTION ∆Make sure that the gerotor planetary is installed in theoriginal position.

Install the gerotor planetary.

Measure (007-031-010)

Measure the tip clearance.

Measure the clearance of the gerotor drive/gerotor plane-tary to port plate.

Tip Clearancemm in

0.025 MIN 0.0010.1778 MAX 0.007

Gerotor Clearancemm in

0.025 MIN 0.0010.127 MAX 0.005



Measure the clearance of the gerotor planetary to thebody bore.

Measure the backlash.

Install (007-031-026)

Install the back plate.

∆ CAUTION ∆Failure to fill the pump with oil during installation canresult in a failure of the lube oil pump to prime at ini-tial engine start-up, resulting in severe engine dam-age.

Lubricate the lubricating oil pump with clean 15W-40 en-gine oil.

Limitmm in

0.1778 MIN 0.0070.381 MAX 0.015

Limits (Used Pump)mm in

0.076 MIN 0.0030.330 MAX 0.013



∆ CAUTION ∆Make sure the idler gear pin is installed in the locatingbore in the cylinder block.

Install the lubricating oil pump.

13 mm

Tighten capscrews in an X pattern starting with the upperright capscrew.


NOTE: Be sure the gear backlash is correct if installing anew lubricating oil pump.

Measure the gear backlash.

If the adjoining gear moves when you measure the back-lash, the reading will be incorrect.

Lubricate the front gear train with clean 15W-40 engineoil.

Backlash Limits mm in

A 0.076 MIN 0.0030.330 MAX 0.013

B 0.076 MIN 0.0030.330 MAX 0.013



∆ CAUTION ∆The seal lip and the sealing surface on the crankshaftmust be free from all oil residue to prevent seal leaks.

Thoroughly clean the front seal area of the crankshaft.

Always replace the front seal when removing and install-ing the gear cover. Refer to Procedure 001-031.

10 mm

Install the front cover on the engine. Refer to Procedure001-031.

15 mm

Install the vibration damper. Do not tighten the capscrewsto the correct torque value at this time. Refer to Proce-dures 001-051 or 001-052.


Raise the belt tensioner to install the belt. Refer to Proce-dure 008-002.

24 Valve, 8.3 Liter Engine Lubricating Oil Suction Tube (Block-Mounted) (007-035)Section 7 - Lubricating Oil System - Group 07 Page 7-33


15 mm

Tighten the vibration damper. Refer to Procedure 001-051or 001-052.


Lubricating Oil Suction Tube (Block-Mounted) (007-035)



Remove the lubricating oil pan and gasket. Refer to Pro-cedure 007-025.

Remove (007-035-002)

10 mm

Remove the lubricating oil suction tube.

Clean (007-035-006)

Clean the gasket surfaces.

Lubricating Oil Suction Tube (Block-Mounted) (007-035) 24 Valve, 8.3 Liter EnginePage 7-34 Section 7 - Lubricating Oil System - Group 07



Inspect the suction tube for cracks.

Install (007-035-026)

10 mm

Install the lubricating oil suction tube and new gasket.


Use Three-Bond™ 1207-C, or equivalent, to fill the jointsbetween the lubricating oil pan rail, gear housing, and rearseal housing.

10 mm

Install the lubricating oil pan and gasket.


24 Valve, 8.3 Liter Engine Lubricating Oil Thermostat (007-039)Section 7 - Lubricating Oil System - Group 07 Page 7-35


17 mm

Install the lubricating oil pan drain plug.


Fill (007-035-028)

Fill the engine with lubricating oil. Refer to the operatorsmanual for lubricating oil specification.


Stop the engine and check the lubricating oil level with thedipstick.

Lubricating Oil Thermostat (007-039)

Remove (007-039-002)

32 mm

Remove the oil temperature thermostat.


Inspect for a damaged o-ring, broken spring or other dam-age.

Lubricating Oil Thermostat (007-039) 24 Valve, 8.3 Liter EnginePage 7-36 Section 7 - Lubricating Oil System - Group 07


∆ CAUTION ∆The flash point of new lubricating oil is approximately221°C [430°F]. Do not allow oil temperature in the con-tainer to exceed 150°C [300°F]. Do not allow waterdroplets to enter the container of hot oil. Water drop-lets will cause a violent reaction which can cause per-sonal injury.

Suspend the thermostat and a 116°C [240°F] thermome-ter in a container of new lubricating oil. Do not allow thethermostat or the thermometer to touch the sides of thecontainer.

Heat the lubricating oil.

NOTE: Write down the temperature at which the thermo-stat is fully extended. The thermostat must be fully ex-tended at least 45.9 mm [1.80 in] when the temperaturereaches 104°C [220°F] or 116°C [240°F] depending onwhat temperature the thermostat is rated.

Replace the thermostat if it does not operate as de-scribed.

Install (007-039-026)

Install the oil temperature thermostat.


24 Valve, 8.3 Liter Engine Lubricating Oil Pressure Sensor (007-052)Section 7 - Lubricating Oil System - Group 07 Page 7-37


Lubricating Oil Pressure Sensor (007-052)

Remove (007-052-002)

Disconnect the wire from the sending unit.


Remove the oil pressure sensor and install a pressuregauge.

Start the engine and measure the lubricating oil pressure.Minimum lubricating oil pressure:

Low Idle (675 to 725 rpm): 69 kPa [10 psi]

High Idle: 207 kPa [30 psi]

The oil pressure sensor switch is set to actuate when oilpressure drops to 55 kPa [8 psi].

Install (007-052-026)

Install the sending unit.

Connect the wire to the sending unit.

Torque Value:Installed into Cast Iron

16 N•m [12 ft-lb]

Installed into Alumi-num

10 N•m [7 ft-lb]

Lubricating Oil Pressure Sensor (007-052) 24 Valve, 8.3 Liter EnginePage 7-38 Section 7 - Lubricating Oil System - Group 07


24 Valve, 8.3 Liter Engine Section 8 - Cooling System - Group 08Section 8 - Cooling System - Group 08 Page 8-a


Section 8 - Cooling System - Group 08

Section Contents

Coolant Filter (008-006) ................................................................................................................................................................................. 5Install (008-006-026) ........................................................................................................................................................................ 6Remove (008-006-002) .................................................................................................................................................................... 5

Coolant Filter Head (008-007) ....................................................................................................................................................................... 6Clean (008-007-006) ........................................................................................................................................................................ 7Install (008-007-006) ........................................................................................................................................................................ 7Remove (008-007-002) .................................................................................................................................................................... 6

Coolant Filter Valve (008-009) ....................................................................................................................................................................... 8Install (008-009-026) ........................................................................................................................................................................ 9Remove (008-009-002) .................................................................................................................................................................... 8

Coolant Heater (008-011) ............................................................................................................................................................................. 10Clean (008-011-006) ...................................................................................................................................................................... 10Install (008-011-026) ...................................................................................................................................................................... 11Preparatory (008-011-000) ............................................................................................................................................................. 10Remove (008-011-002) .................................................................................................................................................................. 10

Coolant Temperature Gauge (008-004) ........................................................................................................................................................ 5General Information ......................................................................................................................................................................... 5Initial Check (008-004-001).............................................................................................................................................................. 5

Coolant Thermostat (008-013) .................................................................................................................................................................... 12Clean (008-013-006) ...................................................................................................................................................................... 12General Information ....................................................................................................................................................................... 12Inspect for Reuse (008-013-007) ................................................................................................................................................... 13Install (008-013-026) ...................................................................................................................................................................... 15Leak Test (008-013-014) ................................................................................................................................................................ 13Remove (008-013-002) .................................................................................................................................................................. 12

Cooling System (008-018) ........................................................................................................................................................................... 16General Information ....................................................................................................................................................................... 16

Drive Belt, Cooling Fan (008-002) ................................................................................................................................................................. 4Inspect for Reuse (008-002-007) ..................................................................................................................................................... 4Install (008-002-026) ........................................................................................................................................................................ 4Remove (008-002-002) .................................................................................................................................................................... 4

Fan Clutch, On-Off (008-027) ...................................................................................................................................................................... 20General Information ....................................................................................................................................................................... 20

Fan Shroud Assembly (008-038) ................................................................................................................................................................ 20General Information ....................................................................................................................................................................... 20Initial Check (008-038-001) ............................................................................................................................................................ 21

Fan Spacer and Pulley (008-039) ................................................................................................................................................................ 21Remove (008-039-002) .................................................................................................................................................................. 21

Section 8 - Cooling System - Group 08 24 Valve, 8.3 Liter EnginePage 8-b Section 8 - Cooling System - Group 08


Fan, Cooling (008-040) ................................................................................................................................................................................ 22Inspect for Reuse (008-040-007) ................................................................................................................................................... 22Install (008-040-026) ...................................................................................................................................................................... 23Remove (008-040-002) .................................................................................................................................................................. 22

Flow Diagram, Cooling System .................................................................................................................................................................... 1

Radiator (008-042) ........................................................................................................................................................................................ 24General Information ....................................................................................................................................................................... 24Initial Check (008-042-001) ............................................................................................................................................................ 24

Radiator Hoses (008-045) ............................................................................................................................................................................ 25Inspect for Reuse (008-045-007) ................................................................................................................................................... 25

Radiator Pressure Cap (008-047) ............................................................................................................................................................... 25General Information ....................................................................................................................................................................... 25Inspect for Reuse (008-047-007) ................................................................................................................................................... 26

Specifications ................................................................................................................................................................................................ 3Cooling System ................................................................................................................................................................................ 3

Water Pump (008-062) ................................................................................................................................................................................. 26General Information ....................................................................................................................................................................... 26Inspect for Reuse (008-062-007) ................................................................................................................................................... 28Install (008-062-026) ...................................................................................................................................................................... 28Preparatory (008-062-000) ............................................................................................................................................................ 27Remove (008-062-002) .................................................................................................................................................................. 28

24 Valve, 8.3 Liter Engine Flow Diagram, Cooling SystemSection 8 - Cooling System - Group 08 Page 8-1


Flow Diagram, Cooling SystemThe following illustration identifies the significant features of the cooling system.

1. Coolant is drawn from the radiator by the integrally mounted water pump. The output from the water pump empties into the oil cooler cavity of the cylinder block.

2. The coolant then circulates around each cylinder and crosses the block to the fuel pump side of the engine.3. Coolant then flows up into the cylinder head, crosses over the valve bridges and down the exhaust manifold

side of the engine to the integral thermostat housing.4. As the coolant flows across the head toward the thermostat housing, it provides coolant for the injector. When

the engine is below operating temperature, the thermostat is closed, and the coolant flow bypasses the radiator and goes to the water pump inlet through internal drillings in the block.

When operating temperature is reached, the thermostat opens, blocking the bypass passage to the water pump andopening the outlet to the radiator.

∆ CAUTION ∆Never operate the engine without a thermostat. Without a thermostat, the coolant will not flow to the radiatorand the engine will overheat.

Flow Diagram, Cooling System 24 Valve, 8.3 Liter EnginePage 8-2 Section 8 - Cooling System - Group 08


1. Coolant Inlet from Radiator2. Water Pump Suction3. Coolant Flow through Lubricating Oil Cooler 4. Block Lower Water Manifold (to cylinders)5. Coolant Filter Inlet 6. Coolant Filter Outlet7. Coolant Supply To Cylinder Head8. Coolant Return from Cylinder Head9. Block Upper Water Manifold10. Thermostat Bypass11. Coolant Return to Radiator

24 Valve, 8.3 Liter Engine SpecificationsSection 8 - Cooling System - Group 08 Page 8-3


Specifications

Cooling System

Coolant Capacity (Engine Only) ............................................................................................. 10.9 liters [11.5 qt]

Standard Modulating Thermostat- Range ................................................................ 84° to 91°C [180° to 195°F]

Maximum Allowable Operating Temperature ................................................................................ 100°C [212°F]

Minimum Recommended Operating Temperature .......................................................................... 70°C [158°F]

Minimum Recommended Pressure Cap .................................................................................... 103 kPa [15 psi]

Drive Belt, Cooling Fan (008-002) 24 Valve, 8.3 Liter EnginePage 8-4 Section 8 - Cooling System - Group 08


Drive Belt, Cooling Fan (008-002)

Remove (008-002-002)


Lift the tensioner to remove the drive belt.

NOTE: The belt tensioner is spring loaded and must bepivoted away from the drive belt. Pivoting in the wrong di-rection can result in damage to the belt tensioner.


Inspect the belt for:

• Cracks• Glazing• Tears or cuts• Excessive wear.

Inspect the drive belt pulleys and idlers for cracked or bro-ken grooves. Refer to the following sections if a pulley oridler is damaged:

• Inspect fan pulley. Refer to Procedure 008-039.• Inspect crankshaft pulley. Refer to Procedure 001-

052.• Inspect alternator drive belt. Refer to Procedure 013-

005. • Inspect water pump idler. Refer to Procedure 008-

062.• Belt tensioner idler. Refer to Procedure 013-021.

Install (008-002-026)


Lift and hold the belt tensioner. Install the drive belt and re-lease the tensioner.


24 Valve, 8.3 Liter Engine Coolant Temperature Gauge (008-004)Section 8 - Cooling System - Group 08 Page 8-5


Coolant Temperature Gauge (008-004)

General Information

Gauges and sensors are used in the system to measurethe coolant temperature. These can malfunction and pro-vide an incorrect temperature reading.

The coolant temperature sensor used by the engine con-trol system is discussed in Procedure 019-019 of theCase 24 Valve, 8.3 Liter, Fuel System Troubleshootingand Repair Manual.


Check for a blown fuse.

Check the wiring from the gauge to the sending unit for abroken connection.


Use a temperature gauge of known accuracy to check theexisting gauge.

Replace a faulty gauge or sending unit.

Coolant Filter (008-006)

Remove (008-006-002)

Turn the shutoff valve to the OFF position.

Remove and discard the coolant filter.

Clean the gasket surface.

Coolant Filter Head (008-007) 24 Valve, 8.3 Liter EnginePage 8-6 Section 8 - Cooling System - Group 08


Install (008-006-026)∆ CAUTION ∆

Do not allow oil to get into the filter. Oil will damagethe DCA.

∆ CAUTION ∆Mechanical overtightening can distort the threads ordamage the filter head.

Apply a thin film of lubricating oil to the gasket sealing sur-face before installing the new coolant filter.

Install the coolant filter on the filter head. Tighten the filteruntil the gasket contacts the filter head surface.

Tighten the coolant filter an additional 1/2 to 3/4 of a turn,or as specified by the filter manufacturer.

∆ CAUTION ∆The valve must be in the ON position to prevent en-gine damage.

Open the shutoff valve and install the coolant systempressure cap.

Operate the engine and check for coolant leaks.

After the air has been purged from the system, check thecoolant level again.

Coolant Filter Head (008-007)

Remove (008-007-002)∆ WARNING ∆

Some coolants are toxic. Keep away from childrenand pets. Dispose in a accordance with local environ-mental regulations.

Drain at least three gallons of coolant from the coolingsystem. Refer to Procedure 008-018.

Remove the coolant filter. Refer to Procedure 008-006.

24 Valve, 8.3 Liter Engine Coolant Filter Head (008-007)Section 8 - Cooling System - Group 08 Page 8-7


Loosen the four filter head capscrews.

Remove the filter head and gasket.

Clean (008-007-006)

Clean the mating surfaces.

Install (008-007-006)

Install a new gasket and the filter head.

Tighten the four capscrews.

Install the coolant filter. Refer to Procedure 008-006.


Fill the cooling system with either a 50/50 mixture of goodquality water and fully formulated antifreeze or fully formu-lated coolant. The fully formulated antifreeze or coolantmust meet TMC RP329 or TMC RP330 specifications.

Coolant Filter Valve (008-009) 24 Valve, 8.3 Liter EnginePage 8-8 Section 8 - Cooling System - Group 08



Coolant Filter Valve (008-009)

Remove (008-009-002)

Remove the coolant filter head. Refer to Procedure 008-007.

Loosen the shutoff valve screw from the end of the valve.

Remove the two pieces of the shutoff valve from bothsides of the valve bore.

24 Valve, 8.3 Liter Engine Coolant Filter Valve (008-009)Section 8 - Cooling System - Group 08 Page 8-9


Install (008-009-026)

Replace the shutoff valve o-rings.

Lubricate the o-rings before installing the valve piecesback into the bore.

Tighten the shutoff valve screw to tighten the two piecesof the valve together.

Install the coolant filter head on the engine. Refer to Pro-cedure 008-007.

Install the coolant filter. Refer to Procedure 008-006.

Fill the cooling system with either a 50/50 mixture of goodquality water and fully formulated antifreeze or fully formu-lated coolant. The fully formulated antifreeze or coolantmust meet TMC RP329 or TMC RP330 specifications.

Coolant Heater (008-011) 24 Valve, 8.3 Liter EnginePage 8-10 Section 8 - Cooling System - Group 08



Coolant Heater (008-011)


Drain at least 19 liters [5 U.S. gal] of coolant. Refer to Pro-cedure 008-018.

Disconnect the block heater electrical cord.

Remove (008-011-002)

1-1/8 Inch

Loosen the block heater and remove it from the block.

Clean (008-011-006)

Clean the heater threads thoroughly.

24 Valve, 8.3 Liter Engine Coolant Heater (008-011)Section 8 - Cooling System - Group 08 Page 8-11


Install (008-011-026)

Lubricate the new heater with clean engine oil.

1-1/8 Inch

Install the heater.


Attach the heater electrical cord.


Coolant Thermostat (008-013) 24 Valve, 8.3 Liter EnginePage 8-12 Section 8 - Cooling System - Group 08


Coolant Thermostat (008-013)

General Information

The thermostat controls the coolant temperature. Whenthe coolant temperature is below operating temperature,coolant is bypassed to the inlet of the water pump. Whenthe coolant temperature reaches the operating range, thethermostat opens, sealing off the bypass, forcing coolantto flow to the radiator. The thermostat begins opening at82°C [180°F].

∆ CAUTION ∆Never operate the engine without a thermostat. With-out a thermostat, the path of least resistance for thecoolant is through the bypass to the pump inlet. Thiswill cause the engine to overheat.

An incorrect or malfunctioning thermostat can cause theengine to run too hot or too cold.

Remove (008-013-002)

10 mm

Remove the water outlet tube capscrews and water outlettube. Refer to Procedure 008-014.

Remove the thermostat.

Clean (008-013-006)

Clean all mating surfaces.

NOTE: Do not let any debris fall into the thermostat cavitywhen cleaning the surfaces.

24 Valve, 8.3 Liter Engine Coolant Thermostat (008-013)Section 8 - Cooling System - Group 08 Page 8-13



Inspect the thermostat for damage.

NOTE: Do not allow the thermostat or thermometer totouch the container.

Heat the water and check the thermostat as follows:

Suspend the thermostat and a 100°C [212°F] thermome-ter in a container of water.

The nominal operating temperature is stamped on thethermostat. The thermostat must meet the following crite-ria:

• The thermostat must begin to open within 1°C [2°F] of this nominal temperature.

• The thermostat must be fully open within 12°C [22°F] of this nominal temperature.

The fully open distance between the thermostat flangeand housing is 9.4 mm [0.370 in].

Leak Test (008-013-014)

The engine thermostat and thermostat seal must operateproperly in order for the engine to operate in the most ef-ficient heat range. Overheating or overcooling will shortenengine life.

Coolant Thermostat (008-013) 24 Valve, 8.3 Liter EnginePage 8-14 Section 8 - Cooling System - Group 08


∆ WARNING ∆Complete this test with the engine coolant tempera-ture below 49°C [120°F]. Hot steam can cause seriouspersonal injury.

Remove the radiator hose from the thermostat housing.

Use an electronic service tool to monitor the coolant tem-perature. Install a thermocouple or temperature gauge,which is known to be accurate, in the water heater plateon the engine side of the thermostat housing.

Install a hose of the same size on the thermostat housingoutlet long enough to reach a remote dry container usedto collect coolant.

Install and tighten a hose clamp on the housing outlet.

Place the other end of the hose in a dry container.

Operate the engine at rated speed for 1 minute.

Shut off the engine and measure the amount of coolantcollected in the container.

The amount of coolant collected must not be more than100 cc [3.3 fl. oz.].

24 Valve, 8.3 Liter Engine Coolant Thermostat (008-013)Section 8 - Cooling System - Group 08 Page 8-15


If more than 100 cc [3.3 fl. oz.] of coolant is collected, thethermostat is leaking and must be replaced.

Complete the following test in-chassis to determine thethermostat opening temperature.

Start the engine and monitor the water temperature withan electronic servoce tool or a gauge. Keep the enginespeed below 1500 rpm during the test.

Shut off the engine when the coolant starts to flow.

If coolant does not start flowing into the container duringthe initial opening temperature range, the thermostatmust be replaced. Refer to Procedure 008-013.

Install (008-013-026)

Install the new thermostat into the thermostat housing.Make sure the top and bottom o-rings are in place.

Thermostat Initial Opening Temperature°C °F81 MIN 17883 MAX 182

Cooling System (008-018) 24 Valve, 8.3 Liter EnginePage 8-16 Section 8 - Cooling System - Group 08


10 mm

Install the water outlet tube and capscrews.


∆ CAUTION ∆Be sure to vent the engine and aftercooler during fill-ing, to remove air from the coolant system or over-heating will result.

Fill the cooling system.


Cooling System (008-018)

General Information

The function of the cooling system is to maintain a speci-fied operating temperature for the engine. Some of theheat generated by the engine is absorbed by the coolantflowing through the passages in the cylinder block andhead. Then, heat is removed from the coolant as it flowsthrough the radiator.

The accompanying chart illustrates the coolant flowthrough the engine. For more detail, refer to the coolantflow diagrams.

1. Water pump2. Engine block, oil cooler, cylinder head, other acces-

sories (e.g., heater core)3. Thermostat4. Radiator

24 Valve, 8.3 Liter Engine Cooling System (008-018)Section 8 - Cooling System - Group 08 Page 8-17


Open the petcocks at the bottom of the radiator and at thebottom of the oil cooler housing. Remove the lower radia-tor hose. A 20 liter [4 U.S. gallons] drain pan will containthe coolant in most applications.

When you troubleshoot overheating, remember that toomuch oil in the oil pan can cause additional heat from fric-tion when the rod journals are submerged in oil. Overfillingwith oil raises the oil temperature that is transferred to thecooling system at the oil cooler.

The system is designed to use a specific quantity of cool-ant. If the coolant level is low, the engine will run hot.

NOTE: The engine or system has a leak if frequent addi-tion of coolant is necessary. Find and repair the leak.

∆ CAUTION ∆The engine coolant passages must be completelyfilled with coolant.

During operation, entrapped air mixes with the coolant,which results in cavitation corrosion and poor heat trans-fer. Highly aerated coolant can cause localized overheat-ing of the cylinder head and block that can result in acracked head, scored cylinder liner, or blown head gasket.

Cooling System (008-018) 24 Valve, 8.3 Liter EnginePage 8-18 Section 8 - Cooling System - Group 08


Obstructions in the coolant passages will reduce coolantflow, which can lead to overheating.

NOTE: The small holes in the head gasket are especiallysusceptible to plugging. Their size is critical. Do not en-large the size of the orifices. To do so will disturb the cool-ant flow and will not solve an overheating problem.

∆ CAUTION ∆Never use water alone for coolant. Damage from cor-rosion can result.

Water will cause rust formation, reducing the flow in thesmaller coolant passages.

Also, water used as a coolant for even a relatively shortperiod can result in the expansion plugs rusting through,which will allow the coolant to leak.

NOTE: A sudden loss of coolant from a heavily loadedengine can result in severe damage to the pistons and cyl-inder bore.

Overfueling and Loading

∆ CAUTION ∆Overfueling can cause the engine to overheat. Makesure that the correct engine electronic control module(ECM) calibration is being used.

∆ CAUTION ∆Constant overloading (lugging) can cause the engineto run hot.

24 Valve, 8.3 Liter Engine Cooling System (008-018)Section 8 - Cooling System - Group 08 Page 8-19


Fully Formulated Coolant/Antifreeze

Case Corporation recommends using either a 50/50 mix-ture of good quality water and fully formulated antifreeze,or fully formulated coolant when filling the cooling system.The fully formulated antifreeze or coolant must meet TMCRP329 or TMC RP330 specifications.

Good quality water is important for cooling system perfor-mance. Excessive levels of calcium and magnesium con-tribute to scaling problems, and excessive levels ofchlorides and sulfates cause cooling system corrosion.

Fully formulated antifreeze must be mixed with good qual-ity water at a 50/50 mix (40 to 60 percent working range).A 50/50 mixture of antifreeze and water gives a -36°C [-34°F] freezing point and a boiling point of 110°C [228°F],which is adequate for locations in North America. The ac-tual lowest freezing point of ethelyne glycol antifreeze is at68 percent. Using higher concentrations of antifreeze willraise the freezing point of the solution and increase thepossibility of a silicate gel problem.

Cooling System Sealing Additives

Do not use sealing additives in the cooling system. Theuse of sealing additives will:

• Build up in coolant low flow areas• Clog coolant filters• Plug radiator and oil cooler.

Fan Clutch, On-Off (008-027) 24 Valve, 8.3 Liter EnginePage 8-20 Section 8 - Cooling System - Group 08


Cooling System Soluble Oils

Do not use soluble oils in the cooling system. The use ofsoluble oils will:

• Corrode brass and copper• Damage heat transfer surfaces• Damage seals and hoses.

Fan Clutch, On-Off (008-027)

General Information

Many fan clutches can be controlled by the engine's elec-tronic control module (ECM). The ECM monitors coolanttemperature and intake manifold temperature to deter-mine when to engage the cooling fan. Some applicationshave additional sensors monitored by the ECM for fancontrol (for example, air conditioner pressure and trans-mission temperature). These are various fan clutch types,such as air engaged, air disengaged, electric, viscous,and ON/OFF. Refer to the equipment manufacturer's ser-vice manual to determine fan clutch type.

The ECM is capable of using either a zero VDC or 12 VDCsignal to engage the fan clutch. The enable logic is con-tained in the ECM calibration and can be programmed us-ing an electronic service tool.

Refer to the vehicle service manual for fan clutch trouble-shooting and repair information.

Fan Shroud Assembly (008-038)

General Information

The radiator or fan shroud is used to direct all air flowacross the radiator fins rather than around the edges ofthe radiator.

An incorrect fan shroud or obstructions can reduce air flowand cause the engine to run hot.

NOTE: Check to be sure air is not recirculating. Check formissing baffles.

24 Valve, 8.3 Liter Engine Fan Spacer and Pulley (008-039)Section 8 - Cooling System - Group 08 Page 8-21



∆ CAUTION ∆The fan shroud must be installed correctly, be in goodcondition, and the shroud to fan clearance must bewithin the manufacturer's specifications to ensureproper air flow through the radiator to provide ade-quate engine cooling.

Inspect the fan shroud for proper fan clearance, cracks, airleaks, and damage. Replace if necessary.

Case Corporation recommends that fan clearance be be-tween 5.08 to 10.16 cm [2 to 4 in] from the radiator core.

Fan Spacer and Pulley (008-039)

Remove (008-039-002)


Lift the tensioner to relieve tension in the belt. Remove thebelt. Refer to Procedure 008-002.


15 mm

Remove the fan capscrews, fan, and spacer.

Remove the fan pulley.

Fan, Cooling (008-040) 24 Valve, 8.3 Liter EnginePage 8-22 Section 8 - Cooling System - Group 08


Install (008-039-026)

15 mm

Install the fan pulley.

Install the spacer, fan, and fan capscrews.

Torque Value: 51 to 62 N•m [37 to 45 ft-lb]


Lift the tensioner and install the belt. Refer to Procedure008-002.

Service Tip: If difficulty is experienced installing the drivebelt (i.e., the belt seems too short), position the belt overthe grooved pulleys first and then, while holding the ten-sioner up, slide the belt over the water pump pulley.

Fan, Cooling (008-040)

Remove (008-040-002)

15 mm

Remove the fan capscrews, the fan, and spacer.


∆ WARNING ∆Do not rotate the engine by pulling or prying on thefan. The fan blade(s) can be damaged and cause thefan to fail and cause serious personal injury or prop-erty damage. Use the engine barring gear to rotate thecrankshaft.

24 Valve, 8.3 Liter Engine Fan, Cooling (008-040)Section 8 - Cooling System - Group 08 Page 8-23


Inspect the cooling fan daily. Check for cracks, loose riv-ets, and bent or loose blades. Check the fan to make sureit is securely mounted. Tighten the capscrews if neces-sary.

∆ WARNING ∆Do not straighten a bent fan blade or continue to usea damaged fan. A bent or damaged fan blade can failduring operation and cause serious personal injury orproperty damage.

Replace any fan that is damaged with a fan of the identicalpart number. Case Corporation must approve any otherfan changes.

Install (008-040-026)

15 mm

Install the spacer, fan, and fan capscrews.

Torque Value: 51 to 62 N•m [37 to 45 ft-lb]

Radiator (008-042) 24 Valve, 8.3 Liter EnginePage 8-24 Section 8 - Cooling System - Group 08


Radiator (008-042)

General Information

Air forced through the fins of the radiator by a fan cools thecoolant pumped through the radiator. Environmental de-bris (such as paper, straw, lint, and dust) can obstruct thefins and stop the flow of air that will reduce the cooling ef-fect of the radiator.


∆ CAUTION ∆Wear appropriate eye and face protection when usingcompressed air. Improper use can cause bodily injuryfrom flying debris and dirt.

Inspect for plugged radiator fins.

Use compressed air to blow out the dirt and debris.

Air Pressure: 552 kPa [80 psi]

Inspect for bent or broken fins.

Inspect for radiator core and gasket leaks.

If the radiator must be replaced, refer to the equipmentmanufacturer's replacement procedures.

∆ WARNING ∆If a liquid refrigerant system must be removed beforeremoving the radiator, wear eye and face protection.Wrap cloth around the fittings before removal. Liquidrefrigerant can cause serious eye and skin injury.

Recycle refrigerant according to accepted practices.

24 Valve, 8.3 Liter Engine Radiator Hoses (008-045)Section 8 - Cooling System - Group 08 Page 8-25


Radiator Hoses (008-045)


Inspect all hoses for cracks, cuts, or collapsing.

Radiator Pressure Cap (008-047)

General Information

The system is designed to use a pressure cap to preventboiling of the coolant.

An incorrect or malfunctioning cap can result in the loss ofcoolant and the engine running hot.

Air in the coolant can result in loss of coolant from theoverflow when the aerated coolant is hot. The heated airexpands, increasing the pressure in the system, causingthe cap to open.

Similarly, coolant can be displaced through the overflow ifthe head gasket leaks compression gases to the coolantsystem.

Radiator Cap Pressurre Test System Cap

A (Normal Duty) 104°C [220°F] 103 kPa [15 psi]

Water Pump (008-062) 24 Valve, 8.3 Liter EnginePage 8-26 Section 8 - Cooling System - Group 08


The operating pressure of the cooling system and the lu-bricating system can result in the mixing of the fluids ifthere is a leak between the systems such as the headgasket or oil cooler. Refer to Section 7, Lubricating OilSystem.

Transmission fluid can also leak into the coolant throughradiator bottom tank transmission oil coolers.


Be sure the correct radiator cap is being used. Refer toProcedure 008-047, General Information.

Inspect the rubber seal of the pressure cap for damage.

Inspect the radiator fill neck for cracks or other damage.

Refer to the equipment manufacturer's service manual forinstructions if the fill neck is damaged.

Pressure test the radiator cap.

The pressure cap must seal within 14 kPa [2 psi] of thevalue stated on the cap, or it must be replaced.

Refer to the vehicle service manual for radiator cap testprocedure.

Water Pump (008-062)

General Information

The water pump pulls coolant from the bottom of the radi-ator and pumps it through the engine back to the top of theradiator for cooling. Reduced or interrupted flow will resultin the engine running hot.

24 Valve, 8.3 Liter Engine Water Pump (008-062)Section 8 - Cooling System - Group 08 Page 8-27


The pump is belt driven from the crankshaft pulley. An au-tomatic belt tensioner is used to prevent the belt from slip-ping on the pump pulley. A malfunction of the tensionerwill cause the water pump impeller to rotate at a slowerspeed, reducing the amount of coolant flow.

The coolant flow can also be reduced if the inlet hose tothe water pump collapses. A hose will usually not collapsewhile the engine is running at low speed. Check the hosewhile the engine is running at rated speed.

NOTE: Be sure the engine is warm, a minimum of 90.6°C[195°F], so the thermostat is open.

A worn or malfunctioning water pump will not produce theflow required to prevent the engine from running hot. How-ever, be sure to check the other possibilities indicated inthe Coolant Temperature Above Normal symptom chart inSection TS, Troubleshooting Symptoms, before checkingthe flow or replacing the pump.






Remove (008-062-002)

13 mm

Remove the water pump capscrews and water pump.

Clean (008-062-002)

Clean the o-ring sealing surface on the water pump hous-ing.


Inspect the water pump housing and impeller for cracks ordamage.

Inspect the water pump weep hole for an indication of asteady leak.

NOTE: A streak or chemical buildup at the weep hole isnot justification for water pump replacement. If a steadyflow of coolant or oil is observed, replace the water pumpwith a new or rebuilt unit.

Install (008-062-026)

Install a new sealing ring into the pump groove.

24 Valve, 8.3 Liter Engine Water Pump (008-062)Section 8 - Cooling System - Group 08 Page 8-29


13 mm

Install the water pump.



Lift the tensioner and install the belt. Refer to Procedure008-002.

Service Tip: If difficulty is experienced installing the drivebelt (i.e., the belt seems too short), position the belt overthe grooved pulleys first and then, while holding the ten-sioner up, slide the belt over the water pump pulley.

Fill the cooling system. Refer to Procedure 008-018.

Close the drain valves. Install all hoses previously re-moved. Install the pressure cap. Operate the engine untilit reaches a temperature of 80°C [180°F], and check forcoolant leaks.

24 Valve, 8.3 Liter Engine Section 9 - Drive Units - Group 09Section 9 - Drive Units - Group 09 Page 9-a


Section 9 - Drive Units - Group 09

Section Contents

Hydraulic Pump Drive (009-016) ................................................................................................................................................................... 1Clean (009-016-006) ........................................................................................................................................................................ 1Inspect for Reuse ............................................................................................................................................................................. 2Install (009-016-026) ........................................................................................................................................................................ 2Remove (009-016-002) .................................................................................................................................................................... 1

24 Valve, 8.3 Liter EnginePage 9-b Section 9 - Drive Units - Group 09



24 Valve, 8.3 Liter Engine Hydraulic Pump Drive (009-016)Section 9 - Drive Units - Group 09 Page 9-1


Hydraulic Pump Drive (009-016)

Remove (009-016-002)

Disconnect all hydraulic lines from the pump.

Remove the hydraulic pump and gear assembly.

Refer to the vehicle service manual for removal proce-dures.

Clean (009-016-006)

Clean the gasket material from the hydraulic pump.

Clean the hydraulic pump gear with solvent.


Hydraulic Pump Drive (009-016) 24 Valve, 8.3 Liter EnginePage 9-2 Section 9 - Drive Units - Group 09


Inspect for Reuse

Inspect the hydraulic pump drive gear for damage.

Install (009-016-026)

Use a new gasket and install the hydraulic pump.

Connect all hydraulic lines to the pump.

Tighten mounting bolts.


24 Valve, 8.3 Liter Engine Section 10 - Air Intake System - Group 10Section 10 - Air Intake System - Group 10 Page 10-a


Section 10 - Air Intake System - Group 10

Section Contents

Air Crossover (010-019) ................................................................................................................................................................................. 7Inspect for Reuse (010-019-007) ..................................................................................................................................................... 7Install (010-019-026) ........................................................................................................................................................................ 7Remove (010-019-002) .................................................................................................................................................................... 7

Air Inlet Connection (010-022) ...................................................................................................................................................................... 7Install (010-019-026) ........................................................................................................................................................................ 8Remove (010-022-002) .................................................................................................................................................................... 7

Air Intake Manifold (010-023) ........................................................................................................................................................................ 8Clean (010-023-006) ........................................................................................................................................................................ 9Inspect for Reuse (010-023-007) ..................................................................................................................................................... 9Install (010-023-026) ........................................................................................................................................................................ 9Preparatory (010-023-000) ............................................................................................................................................................... 8Remove (010-023-002) .................................................................................................................................................................... 8

Air Intake Restriction (010-031) .................................................................................................................................................................. 17Measure (010-031-010) ................................................................................................................................................................. 17

Air Intake System - General Information ..................................................................................................................................................... 1

Air Leaks, Air Intake and Exhaust Systems (010-024) .............................................................................................................................. 10Initial Check (010-024-001) ............................................................................................................................................................ 10

Boost Pressure (010-057) ............................................................................................................................................................................ 31Measure (010-057-010) ................................................................................................................................................................. 31

Charge Air Cooler (CAC) (010-027) ............................................................................................................................................................ 15Clean (010-027-006) ...................................................................................................................................................................... 15Inspect for Reuse (010-027-007) ................................................................................................................................................... 16

Cold Starting Aid (010-029) ......................................................................................................................................................................... 16Clean (010-029-006) ...................................................................................................................................................................... 17Install (010-029-026) ...................................................................................................................................................................... 17Remove (010-029-002) .................................................................................................................................................................. 16

Flow Diagram, Air In take System ................................................................................................................................................................ 5

Specifications ................................................................................................................................................................................................. 6Air Intake System ............................................................................................................................................................................. 6

Turbocharger (010-033) ............................................................................................................................................................................... 19Clean (010-033-006) ...................................................................................................................................................................... 20Inspect for Reuse (010-033-007) ................................................................................................................................................... 20Install (010-033-026) ...................................................................................................................................................................... 22Remove (010-033-002) .................................................................................................................................................................. 19

Turbocharger Axial Clearance (010-038) ................................................................................................................................................... 23Measure (010-038-010) ................................................................................................................................................................. 23

Section 10 - Air Intake System - Group 10 24 Valve, 8.3 Liter EnginePage 10-b Section 10 - Air Intake System - Group 10


Turbocharger Blade Damage (010-039) ..................................................................................................................................................... 24Inspect for Reuse (010-039-007) ................................................................................................................................................... 24

Turbocharger Compressor Seal Leaks (010-040) ..................................................................................................................................... 25Leak Test (010-040-014) ............................................................................................................................................................... 25

Turbocharger Oil Drain Line (010-045) ...................................................................................................................................................... 25Clean (010-045-006) ...................................................................................................................................................................... 26Initial Check (010-045-001) ............................................................................................................................................................ 25Inspect for Reuse (010-045-007) ................................................................................................................................................... 26Install (010-045-026) ...................................................................................................................................................................... 26Remove (010-045-002) .................................................................................................................................................................. 26

Turbocharger Oil Supply Line (010-046) .................................................................................................................................................... 27Initial Check (010-046-001) ............................................................................................................................................................ 27Inspect for Reuse (010-046-007) ................................................................................................................................................... 27Install (010-046-026) ...................................................................................................................................................................... 27Remove (010-046-002) .................................................................................................................................................................. 27

Turbocharger Radial Bearing Clearance (010-047) .................................................................................................................................. 28Measure (010-047-010) ................................................................................................................................................................. 28

Turbocharger Wastegate Actuator (010-050) ............................................................................................................................................ 29Initial Check (010-050-001) ............................................................................................................................................................ 29Test (010-050-012) ........................................................................................................................................................................ 30

Turbocharger Wastegate Valve Body (010-055) ....................................................................................................................................... 31Maintenance Check (010-055-008) ............................................................................................................................................... 31

24 Valve, 8.3 Liter Engine Air Intake System - General InformationSection 10 - Air Intake System - Group 10 Page 10-1


Air Intake System - General Informa-tion

The combustion air system on the Case 24 Valve, 8.3 Literengine consists of an air cleaner, intake air piping, turbo-charger, charge air piping, charge air cooler (CAC), andintake air heater.

Air is drawn through the air cleaner into the compressorside of the turbocharger (1). It is then forced through theCAC piping (2) to the CAC (3), the intake air heater (if ap-plicable), and into the intake manifold (4). From the intakemanifold, air is forced into the cylinders (5) and used forcombustion.

The turbocharger uses exhaust gas energy to turn the tur-bine wheel. The turbine wheel drives the compressor im-peller which provides pressurized air to the engine forcombustion. The additional air provided by the turbo-charger allows more fuel to be injected to increase thepower output from the engine.

The turbine, compressor wheels, and the shaft are sup-ported by two rotating bearings in the bearing housing.Passages in the bearing housing direct filtered, pressur-ized engine oil to the shaft bearings and thrust bearings.The oil is used to lubricate and cool the rotating compo-nents. Oil then drains from the bearing housing to the en-gine sump through the oil drain line.

∆ CAUTION ∆A restricted oil drain line can cause the turbochargerbearing housing to be pressurized, causing oil to leakpast the seal rings.

NOTE: An adequate supply of good, filtered oil is very im-portant to the life of the turbocharger. Make sure that ahigh quality oil is used and that it and the oil filter arechanged according to maintenance recommendations.

Air Intake System - General Information 24 Valve, 8.3 Liter EnginePage 10-2 Section 10 - Air Intake System - Group 10


∆ CAUTION ∆The turbocharger is a performance part and must notbe tampered with. The wastegate bracket is an inte-gral part of the turbocharger. Tampering with thewastegate components can reduce durability by in-creasing cylinder pressure and thermal loading dueto incorrect inlet and exhaust manifold pressure.

∆ CAUTION ∆Poor fuel economy and failure to meet regulatoryemissions laws may result. Increasing the turbo-charger boost will not increase engine power.

Wastegated turbochargers are used to optimize perfor-mance. The wastegated design allows maximum boost tobe developed quickly while ensuring that the turbo doesnot overspeed at higher engine rpm's.

Wastegate operation is controlled by an actuator thatsenses compressor pressure and balances it against apreset spring load. The wastegate valve is located in theturbine inlet passage. When open, it diverts a portion ofthe exhaust gas away from the turbine wheel, therebycontrolling the shaft speed and boost.

Malfunctioning Turbocharger

Failure of the internal components of the turbocharger canreduce its effectiveness and also cause excessive smokeand low power. A bearing failure can produce frictionwhich will slow the speed of the rotor assembly. Failedbearings can also allow the blades of the rotor assemblyto rub the housings, thus reducing the rotor assemblyspeed.

Malfunctioning turbocharger wastegate failure or miscali-bration of the turbocharger wastegate can result in exces-sively high or low boost pressures. Low boost pressurescan cause excessive smoke and low power. High boostpressures can cause major engine damage.

Lubricating Oil Consumption and Leaks

Engine lubricating oil is used to lubricate the bearings andprovide some cooling for the turbocharger. The lubricatingoil supplied to the turbocharger through the supply line isat engine operating pressure. A return line connected tothe bottom of the turbocharger routes the lubricating oilback to the engine lubricating oil pan.

24 Valve, 8.3 Liter Engine Air Intake System - General InformationSection 10 - Air Intake System - Group 10 Page 10-3


Seal rings are used on each end of the rotor assembly.The primary function of the seals is to prevent exhaustgases and compressed air from entering the turbochargerhousing. Lubricating oil leakage from the seals is rare, butit can occur.

NOTE: Excessive crankcase pressure will not allow theoil to drain from the turbocharger. This will load the bear-ing housing and allow lubricating oil to leak past the com-pressor seals and into the engine.

A restricted or damaged lubricating oil return line willcause the turbocharger housing to be pressurized, caus-ing lubricating oil to migrate past the seals.

Additionally, high intake or exhaust restrictions can causea vacuum between the compressor and the turbochargerhousing resulting in oil leaking past the seals.

NOTE: If this occurs, it is necessary to flush the charge aircooler to clean oil from the intake system. Refer to Proce-dures 010-027 and 010-033.

Turbocharger Noise

It is normal for the turbocharger to emit a whine sound thatvaries in intensity depending on engine speed and load.The sound is caused by the very high rotational speed ofthe rotor assembly and the method used to balance therotor assembly during manufacturing. Consequently, thesound will be more audible at full speed.

If possible, operate the engine at full speed to verify thenoise level.

Air Intake System - General Information 24 Valve, 8.3 Liter EnginePage 10-4 Section 10 - Air Intake System - Group 10


Leaks in the air system intake and/or exhaust componentscan produce excessive engine noise. Leak noise is typi-cally a high pitched whine or sucking sound.

Check for leaks in the intake and exhaust system. Checkto make sure all hose clamps are tight. Refer to Procedure010-024.

Lower pitch sounds or rattles at lower engine speeds canindicate debris in the system or that the rotor assembly istouching the housings.

Remove the turbocharger inlet and check for foreign ob-jects.

If suspect, check for turbocharger blade damage andbearing clearance. Refer to Procedures 010-038, 010-039, and 010-047.

If leaks, blade damage, or improper clearances are found,replace the turbocharger. Refer to Procedure 010-033.

Engines can use a chassis-mounted charge air cooler toimprove engine performance and reduce emissions. Thissystem also uses large diameter piping to transfer the airfrom the engine turbocharger to the CAC, then returns theair from the CAC to the engine intake manifold.

24 Valve, 8.3 Liter Engine Flow Diagram, Air In take SystemSection 10 - Air Intake System - Group 10 Page 10-5


Flow Diagram, Air In take System

1. Intake Air Inlet to Turbocharger2. Turbocharger Air to Charge Air Cooler3. Charge Air Cooler4. Intake Manifold (Integral Part of Cylinder Head)5. Intake Valve

Specifications 24 Valve, 8.3 Liter EnginePage 10-6 Section 10 - Air Intake System - Group 10


Specifications

Air Intake System

Maximum Intake Restriction (Clean Air Filter Element) ............................................ 254 mm H2O [10.0 in H2O]

Maximum Intake Restriction (Dirty Air Filter Element) .............................................. 635 mm H2O [25.0 in H2O]

24 Valve, 8.3 Liter Engine Air Crossover (010-019)Section 10 - Air Intake System - Group 10 Page 10-7


Air Crossover (010-019)

Remove (010-019-002)

8 mm or Screwdriver

Loosen the hose clamps and position the crossover tubeso that it can be removed.

Remove the tube.


Check the crossover tube for cracks, holes, and worn sec-tions. Replace with a new hose and clamps if necessary.

Install (010-019-026)

8 mm or Screwdriver

Install the crossover tube and clamps in the reverse orderof removal.

Tighten the clamps.


Air Inlet Connection (010-022)

Remove (010-022-002)

8 mm

Loosen air inlet clamps.

Remove the air inlet connection.

Air Intake Manifold (010-023) 24 Valve, 8.3 Liter EnginePage 10-8 Section 10 - Air Intake System - Group 10


Install (010-019-026)

Install the air inlet connection.

Tighten air inlet clamps.

Run engine and check for leaks.

Air Intake Manifold (010-023)


Disconnect the cold starting aid, if used.

Remove the cooler air crossover tube, if used.

Disconnect the charged air cooler hose, if used.

Remove the air intake connection.

Remove (010-023-002)

Remove the injector supply lines. Refer to Procedure 006-051.

Remove the mounting capscrews and the intake cover.

Tape off the intake manifold opening to prevent debrisfrom entering the intake system.

NOTE: Be sure not to tape over the entire manifold edgesso that the surface can be cleaned.

24 Valve, 8.3 Liter Engine Air Intake Manifold (010-023)Section 10 - Air Intake System - Group 10 Page 10-9


Clean (010-023-006)


Keep the gasket material and any other material out of theair intake.


Remove the tape.

Inspect the intake manifold for cracks or other damage.

NOTE: When inspecting the intake manifold for oil or de-bris from an air system failure, also inspect the cylinderhead for oil and debris.

Install (010-023-026)

Install the cover with intake air heater (if equipped) and anew gasket.


NOTE: Some capscrews shared with fuel line braces.

Install the injector supply line. Refer to Procedure 006-051.

Air Leaks, Air Intake and Exhaust Systems (010-024) 24 Valve, 8.3 Liter EnginePage 10-10 Section 10 - Air Intake System - Group 10


Install the air intake connections, including new gaskets.

Connect the charge air cooler hose.

Install the air crossover tube.

Air Leaks, Air Intake and Exhaust Systems (010-024)


Leaks in the intake air system are most commonly identi-fied by:1. Inspection of piping for cracked or loose clamps.2. Applying a solution of soapy water in the suspected

area and inspecting for bubbles.3. Listening for high pitch whining or sucking sound in

the suspected area.

∆ CAUTION ∆Engine intake air must be filtered to prevent dirt anddebris from entering the engine. If intake air piping isdamaged or loose, unfiltered air will enter the engineand cause premature wear.

24 Valve, 8.3 Liter Engine Air Leaks, Air Intake and Exhaust Systems (010-024)Section 10 - Air Intake System - Group 10 Page 10-11


Inspect the inlet air piping for cracked hoses and damagedor loose clamps.

Operate the engine at high idle and use a solution ofsoapy water to spot intake air leaks.

If an air leak exists, the soap bubbles will be drawn in withthe air.

Replace damaged pipes and tighten loose clamps tomake sure the air inlet system does not leak.


Check for corrosion of the inlet system piping under theclamps and hoses. Corrosion can allow corrosive prod-ucts and dirt to enter the intake system.

Disassemble and clean as required.

Pressure Side Intake System

Leaks in the intake system will reduce the amount of air tothe cylinders during engine operation and decrease en-gine performance.

Operate the engine at full throttle and rated rpm with max-imum load.

Apply soapy water solution to sealing surfaces and in-spect for bubbles. Bubbles should be easy to detect.



Leaks may also be found at the turbo outlet connection.

Inspect for damage, replace sealing o-ring, and tightenloose clamps.

Leaks may also be found at the turbo outlet connection.

Inspect for damage, replace sealing o-ring, and tightenloose clamps.


Any Charge Air Cooler Tubing or Connecting Hoses

Inspect the hose and tubing for damage.

Tighten loose clamps.


Intake Manifold Connection

Inspect for damage.

Tighten loose clamps.

Replace the gasket. Refer to Procedure 010-023.

24 Valve, 8.3 Liter Engine Air Leaks, Air Intake and Exhaust Systems (010-024)Section 10 - Air Intake System - Group 10 Page 10-13


Intake Manifold

Inspect for damage.

Replace the gasket. Refer to Procedure 010-023.

Wastegate Capsule/Plumbing

Inspect for damage.

Compressor Housing Sealing Surface

Inspect for damage.

Clean surface.

Exhaust System

Leaks in the exhaust system will cause the turbo to oper-ate at a lower speed, reducing the amount of air going tothe cylinders during engine operation.




Leaks can be identified by noise, soapy water, or discolor-ation caused by the escaping hot gases.

Inspect the exhaust manifold gaskets for leaks.

Inspect the turbocharger mounting gaskets for leaks.

Inspect the turbine housing sealing surface for leaks.

24 Valve, 8.3 Liter Engine Charge Air Cooler (CAC) (010-027)Section 10 - Air Intake System - Group 10 Page 10-15



Listen and inspect again for leaks.

Charge Air Cooler (CAC) (010-027)

Clean (010-027-006)

If the engine experiences a turbocharger failure or anyother occasion where oil or debris is put into the chargeair cooler (CAC), the CAC must be cleaned.

Remove the CAC piping and CAC from the vehicle.

∆ CAUTION ∆Do not use caustic cleaners to clean the CAC. Dam-age to the CAC will result.

Flush the CAC internally with solvent in the opposite direc-tion of normal air flow. Shake the CAC and lightly tap onthe end tanks with a rubber mallet to dislodge trapped de-bris. Continue flushing until all debris or oil is removed(i.e., the water runs clear).

NOTE: Make sure that the tubes are in the vertical direc-tion when flushing.

If the debris can not be totally removed from the CAC, theCAC must be replaced.

After the CAC has been thoroughly cleaned of all oil anddebris with solvent, wash the CAC internally with hotsoapy water to remove the remaining solvent. Rinse thor-oughly with clean water.

∆ CAUTION ∆The CAC must be rinsed, dried, and free of solvent,oil, and debris, or engine damage will result.

Blow compressed air through the inside of the CAC in theopposite direction of normal air flow until the CAC is dryinternally.

Cold Starting Aid (010-029) 24 Valve, 8.3 Liter EnginePage 10-16 Section 10 - Air Intake System - Group 10



Inspect the CAC for cracks, holes, or damage.

Inspect the tubes, fins, and welds for tears, breaks, or oth-er damage. If any damage causes the CAC to fail the airleak check, the CAC must be replaced. Refer to Proce-dure 010-024.

Install the CAC and CAC piping on the vehicle.

Always clean and inspect the CAC piping and hoses priorto installation.

Cold Starting Aid (010-029)

Remove (010-029-002)

If equipped, remove charge air cooler (CAC) plumbing.

Disconnect grid heater wiring.

Remove the air intake connection.

Remove high pressure fuel lines. Refer to Procedure 006-051.

Remove intake air heater assembly. Refer to Procedure010-022.

If the grid heater is to be removed for any length of time,apply tape over the hole to keep debris out of the air in-take.

24 Valve, 8.3 Liter Engine Air Intake Restriction (010-031)Section 10 - Air Intake System - Group 10 Page 10-17


Clean (010-029-006)

Clean the grid heater sealing surfaces.

Clean the intake cover sealing surface.

Clean the air intake connection sealing surface.

Keep the gasket material and any other material out of thecylinder head intake manifold.

Install (010-029-026)

Install the grid heater, high pressure fuel lines, intake con-nection, and new gaskets. Refer to Procedures 010-022and 006-051.


Connect grid heater wiring.

Install CAC plumbing. Refer to Procedure 010-027.

Run the engine and check for leaks.

Air Intake Restriction (010-031)

Measure (010-031-010)

Install a vacuum gauge or water manometer in the intakeair piping.

The gauge adapter must be installed at a 90 degree angleto the air flow in a straight section of pipe, one pipe diam-eter before the turbocharger.

Air Intake Restriction (010-031) 24 Valve, 8.3 Liter EnginePage 10-18 Section 10 - Air Intake System - Group 10



Record the data on the gauge or manometer.

If restriction exceeds specifications:

Replace or clean the air filter element. Refer to the operators manual instructions.

Inspect the intake piping for damage.

Remove the test equipment.

Inlet Air Restrictionmm H2O in H2O

63.5 MAX 25.0

24 Valve, 8.3 Liter Engine Turbocharger (010-033)Section 10 - Air Intake System - Group 10 Page 10-19


Turbocharger (010-033)

Remove (010-033-002)

Remove the intake and exhaust pipes from the turbo-charger.

Remove the oil supply line from the turbocharger.

Remove the oil drain line from the turbocharger.

Remove the v-band clamp, discharge elbow and o-ringfrom the turbocharger compressor discharge outlet.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.

NOTE: If the turbocharger is not to be immediately re-placed, cover the opening to prevent any material fromfalling into the manifold.

Turbocharger (010-033) 24 Valve, 8.3 Liter EnginePage 10-20 Section 10 - Air Intake System - Group 10


Clean (010-033-006)

Clean the turbocharger and exhaust manifold gasket sur-faces.


Inspect the turbocharger and exhaust manifold gasketsurfaces, and mounting studs for cracks and damage.

Inspect the turbine and compressor housings.

If cracks that go all the way through the outer walls arefound, the housing must be replaced.

NOTE: A charge air cooler failure can cause progressivedamage to the turbine housing. If the turbine housing isdamaged, check the charge air cooler. Refer to Procedure010-027.

Cracks in the mounting flange longer than 15 mm [0.6 in]are not acceptable.

24 Valve, 8.3 Liter Engine Turbocharger (010-033)Section 10 - Air Intake System - Group 10 Page 10-21


Cracks of any length that reach mounting holes are notacceptable.

Two cracks must be separated by at least 6.4 mm [0.25in].

Cracks in the divider are acceptable only if they are sepa-rated by at least 12.5 mm [0.50 in].

NOTE: If the engine experiences a turbocharger failure orany other occasion where oil or debris is put into thecharge air system, the charge air system must be inspect-ed and cleaned. Refer to Procedures 010-027 and 010-023.

Turbocharger (010-033) 24 Valve, 8.3 Liter EnginePage 10-22 Section 10 - Air Intake System - Group 10


Install (010-033-026)

Apply a film of high temperature anti-seize compound tothe turbocharger mounting studs.

Use a new gasket and install the turbocharger.

Install and tighten the four mounting nuts.

The torque values given have been established using anti-seize compound as a lubricant.


Install the discharge elbow, v-band clamp, and new o-ringseal on the turbocharger compressor discharge outlet.

Tighten the clamp.


Install and tighten the turbocharger oil drain line.


Lubricate the bearings by pouring 50 to 60 cc [2.0 to 3.0oz] of clean 15W-40 engine oil into the turbocharger oilsupply line fitting.

Install and tighten the turbocharger oil supply line.


24 Valve, 8.3 Liter Engine Turbocharger Axial Clearance (010-038)Section 10 - Air Intake System - Group 10 Page 10-23


Rotate the compressor housing to fit intake pipes, if nec-essary. Use the snap ring to make necessary adjust-ments.

Install the intake pipe and tighten the clamp.

Install the exhaust pipe and tighten the clamp.


Operate the engine and check for air leaks.

Turbocharger Axial Clearance (010-038)

Measure (010-038-010)

Remove exhaust and intake piping.

Push the rotor assembly away from the gauge.

Set the gauge on zero (0).

Push the rotor assembly toward the gauge and record thereading.

Replace the turbocharger if the clearance does not meetthe specifications. Refer to Procedure 010-033.




Axial Clearancemm in

0.038 MIN 0.00150.089 MAX 0.0035

Turbocharger Blade Damage (010-039) 24 Valve, 8.3 Liter EnginePage 10-24 Section 10 - Air Intake System - Group 10


Turbocharger Blade Damage (010-039)


Remove the intake pipe from the turbocharger.

Inspect the turbocharger compressor impeller blades fordamage.

Replace the turbocharger if damage is found. Refer toProcedure 010-033.

If the compressor impeller is damaged, inspect the intakepiping and filter element for damage.

Repair any damage before operating the engine.

Remove the exhaust pipe from the turbocharger.

Inspect the turbine wheel for damage.

Replace the turbocharger if damage is found. Refer toProcedure 010-033.




24 Valve, 8.3 Liter Engine Turbocharger Compressor Seal Leaks (010-040)Section 10 - Air Intake System - Group 10 Page 10-25


Turbocharger Compressor Seal Leaks (010-040)

Leak Test (010-040-014)

Remove the air intake and CAC piping from the turbo-charger.

Inspect the compressor intake and discharge for oil.

If oil is present in the compressor intake as well as in thedischarge, check upstream in the turbocharger for thesource of the oil.

If oil is present only in the discharge side, install the air in-take and CAC piping.

Check for intake restriction. Refer to Procedure 010-031.

If no intake restriction is found, replace the turbocharger.Refer to Procedure 010-033.

NOTE: If the engine experiences a turbocharger failure orany other occasion where oil is put into the charge air sys-tem, the charge air system must be inspected andcleaned. Refer to Procedures 010-027 and 010-023.

Turbocharger Oil Drain Line (010-045)


Inspect the turbocharger oil drain line for oil leaks or dam-age.

Repair as necessary.

Turbocharger Oil Drain Line (010-045) 24 Valve, 8.3 Liter EnginePage 10-26 Section 10 - Air Intake System - Group 10


Remove (010-045-002)

Remove the capscrews from the oil drain tube.

Pull the drain line out of the drain line boss.

Clean (010-045-006)

Clean the gasket sealing surfaces (first frame).

Clean the o-ring seating bore and make sure it is free ofdirt and debris (second frame).


Inspect the line for cracks, wear, and damage.

Inspect the o-ring for fretting and cracking. Replace if nec-essary.

Check the rubber section of the drain line for deterioration.

Install (010-045-026)

Apply a thin film of oil to the drain line o-rings.

Push the drain line into the drain line boss. Be sure botho-rings are completely seated in the bore.

Install the drain line capscrews with a new gasket.


24 Valve, 8.3 Liter Engine Turbocharger Oil Supply Line (010-046)Section 10 - Air Intake System - Group 10 Page 10-27


Turbocharger Oil Supply Line (010-046)


Inspect the line for oil leaks or damage. Replace if neces-sary.

Remove (010-046-002)

Remove the oil supply line from the turbo bearing housing(1).

Remove the oil supply line from the oil filter head (2).


Inspect the line for cracks, wear, and damage.

Inspect o-rings for cracking and fretting. Replace if neces-sary.

Install (010-046-026)

Apply a thin film of oil to the o-ring seals.

Fill the turbo oil inlet with clean oil.

Install a line at both the filter head and the turbo bearinghousing, then hand tighten.

Tighten the line to final torque.


Turbocharger Radial Bearing Clearance (010-047) 24 Valve, 8.3 Liter EnginePage 10-28 Section 10 - Air Intake System - Group 10



Turbocharger Radial Bearing Clear-ance(010-047)

Measure (010-047-010)

Remove the intake and exhaust pipes from the turbo-charger.

Use a narrow blade or a wire type feeler gauge to mea-sure the clearance between the compressor wheel andhousing.

Gently push the compressor wheel toward the compres-sor housing and gauge.

Record this clearance.

With the feeler gauge in the same location, gently pushthe compressor wheel away from the compressor housingand measure the clearance between the compressorwheel and housing.

Record this clearance.

24 Valve, 8.3 Liter Engine Turbocharger Wastegate Actuator (010-050)Section 10 - Air Intake System - Group 10 Page 10-29


Subtract the smaller clearance from the larger clearance.This is the radial bearing clearance.

Replace the turbocharger if the radial bearing clearancedoes not meet the specifications. Refer to Procedure 010-033.





Turbocharger Wastegate Actuator (010-050)


Case 24 Valve, 8.3 Liter engines are equipped with waste-gated turbochargers to limit the peak boost level and in-crease engine response at low rpm.

The integral wastegate line takes boost from the turbocompressor outlet to the wastegate capsule.

Inspect the integral wastegate actuator hose for cracks orholes. Replace the hose if damaged.

Radial Bearing Clearancemm in 0.15 MIN 0.0060.64 MAX 0.025

Turbocharger Wastegate Actuator (010-050) 24 Valve, 8.3 Liter EnginePage 10-30 Section 10 - Air Intake System - Group 10


Inspect the wastegate mounting bracket, actuator rod,and lever for damage. A bent wastegate mounting brack-et, actuator rod, or lever can cause improper operation.

If the wastegate mounting bracket, actuator rod, or lever isbent, it must be replaced.

Test (010-050-012)

NOTE: In some applications the turbocharger must beremoved to test the wastegate actuator. Refer to Proce-dure 010-033.

Disconnect the integral boost line from the wastegate cap-sule.

Attach a dial indicator (1) as shown, so that its shaft is inline with the wastegate actuator rod. Set the indicator tozero.

Connect clean regulated air pressure and a pressuregauge to the capsule. Apply 200 kPa [29 psi] to make surethe wastegate is functioning properly.

The rod should move approximately 0.5 to 1.04 mm [0.20to 0.41 in] without any sticking or air leakage.

NOTE: No air should be heard such as leak noise througha functional wastegate capsule.

NOTE: A small amount of travel when air pressure is firstapplied is normal. The tolerance is being removed fromthe system.

Replace the turbocharger if no movement of the actuatorrod and lever is detected.

24 Valve, 8.3 Liter Engine Turbocharger Wastegate Valve Body (010-055)Section 10 - Air Intake System - Group 10 Page 10-31


Turbocharger Wastegate Valve Body (010-055)

Maintenance Check (010-055-008)

Inspect the lever pin.

Replace the turbine housing assembly if worn excessively.

Inspect the valve and valve seat for cracks or erosion.

Replace the turbine housing assembly if worn excessively.

Boost Pressure (010-057)

Measure (010-057-010)

Measure boost pressure at the intake manifold by usingan electronic service tool for hookup and monitoring pro-cedures.

Boost Pressure (010-057) 24 Valve, 8.3 Liter EnginePage 10-32 Section 10 - Air Intake System - Group 10


24 Valve, 8.3 Liter Engine Section 11 - Exhaust System - Group 11Section 11 - Exhaust System - Group 11 Page 11-a


Section 11 - Exhaust System - Group 11

Section Contents

Exhaust Manifold, Dry (011-007) ................................................................................................................................................................... 3Preparatory (001-007-000) ............................................................................................................................................................... 3Remove (011-007-002 ..................................................................................................................................................................... 3Clean (011-007-006) ........................................................................................................................................................................ 3Inspect for Reuse (011-007-007) ..................................................................................................................................................... 4Install (011-007-026) ........................................................................................................................................................................ 5

Exhaust Restriction (011-009) ....................................................................................................................................................................... 5Measure (011-009-010) ................................................................................................................................................................... 5

Flow Diagram, Exhaust System .................................................................................................................................................................... 1

Specifications ................................................................................................................................................................................................. 2Exhaust System ............................................................................................................................................................................... 2

24 Valve, 8.3 Liter EnginePage 11-b Section 11 - Exhaust System - Group 11



24 Valve, 8.3 Liter Engine Flow Diagram, Exhaust SystemSection 11 - Exhaust - Group 11 Page 11-1


Flow Diagram, Exhaust System

1. Exhaust Valve2. Exhaust Manifold (Pulse Type)3. Dual Entry Turbocharger 4. Turbocharger Exhaust Outlet.

Specifications 24 Valve, 8.3 Liter EnginePage 11-2 Section 11 - Exhaust System - Group 11


Specifications

Exhaust System

Maximum Exhaust Back Pressure ........................................................................................76 mm Hg [3 in Hg]

24 Valve, 8.3 Liter Engine Exhaust Manifold, Dry (011-007)Section 11 -Exhaust System - Group 11 Page 11-3


Exhaust Manifold, Dry (011-007)


Remove the air crossover tube, if used.

Disconnect the charge air cooler hose. Refer to Procedure010-019.

Disconnect the air intake and exhaust piping.

Remove the turbocharger, if used. Refer to Procedure010-033.

Remove (011-007-002

15 mm

Remove the exhaust manifold and gaskets.

NOTE: Apply a thin coating of nickel based high tempcompound grease to the coarse threads of the manifoldcapscrews.

Clean (011-007-006)


Clean the sealing surfaces of the head and exhaust man-ifold.

Use 240 grit inert cloth to remove carbon deposits fromthe sealing surfaces.

Multipiece Only

Clean the multipiece sealing joint.

Use 40 grit cloth to remove carbon deposits from the seal-ing surfaces.

Exhaust Manifold, Dry (011-007) 24 Valve, 8.3 Liter EnginePage 11-4 Section 11 - Exhaust System - Group 11


∆ WARNING ∆When using a steam cleaner, wear protective clothing,safety glasses, or a face shield. Hot steam can causeserious personal injury.

Use steam to clean the exhaust manifold.



Inspect the exhaust manifold for cracks, burnout, or dam-aged threads.

NOTE: If the exhaust manifold is damaged, check thecharge air cooler. A charge air cooler failure can causeprogressive damage to the exhaust manifold. Refer toProcedure 010-027.

Inspect the gasket surfaces for gouges, scratches, orburnout.

Measure the manifold surface for flatness. Place a straightedge over all exhaust ports in the manifold. Measure, witha feeler gauge, the gap between the port surface and thestraight edge.

If any port measures out of specifications, replace themanifold.

Exhaust Manifold Flatnessmm in 0.20 MAX 0.008

24 Valve, 8.3 Liter Engine Exhaust Restriction (011-009)Section 11 -Exhaust System - Group 11 Page 11-5


Install (011-007-026)

15 mm

Install the exhaust manifold and new gaskets.


Follow the tightening sequence shown in the illustration.

Install the turbocharger. Refer to Procedure 010-033.

Connect the air intake and exhaust pipe.

Connect the charge air cooler hose.

Connect the air crossover tube. Refer to Procedure 010-019.


Exhaust Restriction (011-009)

Measure (011-009-010)

Install pressure gauge to the pressure tap in the exhausthead pipe or at the inlet to the muffler assembly.

Operate the engine at rated speed and load. Record theexhaust restriction.

Exhaust Restriction (011-009) 24 Valve, 8.3 Liter EnginePage 11-6 Section 11 - Exhaust System - Group 11


If restriction exceeds specification, inspect the muffler andreplace as necessary.

If the exhaust pressure exceeds the specifications, in-spect the exhaust piping for damage.

Remove the test equipment.

Exhaust Restrictionmm Hg in Hg

Maximum Exhaust Restriction

76 MAX 3

24 Valve, 8.3 Liter Engine Section 17 - Miscellaneous - Group 17Section 17 - Miscellaneous - Group 17 Page 17-a


Section 17 - Miscellaneous - Group 17

Section Contents

Cup Plug (017-002) ......................................................................................................................................................................................... 1Clean (017-002-006) ........................................................................................................................................................................ 1Inspect for Reuse (017-002-007) ..................................................................................................................................................... 1Install (017-002-026) ........................................................................................................................................................................ 2Remove (017-002-002) .................................................................................................................................................................... 1

Pipe Plug (017-007) ........................................................................................................................................................................................ 2Clean (017-007-006) ........................................................................................................................................................................ 3Inspect for Reuse (017-007-007) ..................................................................................................................................................... 3Install (017-007-026) ........................................................................................................................................................................ 3Remove (017-007-002) .................................................................................................................................................................... 2

Straight Thread Plug (017-011) ..................................................................................................................................................................... 4Clean (017-011-006) ........................................................................................................................................................................ 4Inspect for Reuse (017-011-007) ..................................................................................................................................................... 4Install (017-011-026) ........................................................................................................................................................................ 4Remove (017-011-002) .................................................................................................................................................................... 4

24 Valve, 8.3 Liter EnginePage 17-b Section 17 - Miscellaneous - Group 17



24 Valve, 8.3 Liter Engine Cup Plug (017-002)Section 17 - Miscellaneous - Group 17 Page 17-1


Cup Plug (017-002)

Remove (017-002-002)

Use a center punch to mark the cup plug for drilling.

∆ CAUTION ∆Do not allow metal shavings to fall in the engine whendrilling a hole in the cup plug. Damage to engine com-ponents can occur.

Drill an 1/8-inch hole into the cup plug.

Use a dent puller to remove the plug.

Discard all used cup plugs. Do not use them again.

Clean (017-002-006)

Thoroughly clean the cup plug hole using Scotch-Brite, orequivalent. Use spray cleaner or equivalent, to perform afinal clean of the bore.


Inspect the cup plug bores for damage.

Pipe Plug (017-007) 24 Valve, 8.3 Liter EnginePage 17-2 Section 17 - Miscellaneous - Group 17


Install (017-002-026)

∆ CAUTION ∆Excessive sealant can run back into the engine andcause damage to other components. Allow the seal-ant to dry for a minimum of 2 hours before operatingthe engine. The plug can come out of the bore if thesealant is not dry.

Apply a 2 mm [1/16 in] bead of cup plug sealant to the out-side circumference of the cup plug and the inside diame-ter of cup plug bore.

NOTE: Do not install a used cup plug. Discard all plugsafter removal.

Install the cup plug with the appropriate cup plug driver.

∆ CAUTION ∆Do not install the cup plug too deeply. If the cup plugis not installed straight and flat, it must be replacedwith a new cup plug.

The cup plug must be installed with the edge of the cupplug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than theleading chamber of the bore.

Pipe Plug (017-007)

Remove (017-007-002)

Remove the pipe plug.

24 Valve, 8.3 Liter Engine Pipe Plug (017-007)Section 17 - Miscellaneous - Group 17 Page 17-3


Clean (017-007-006)

Use a spray cleaner to clean the threads of the pipe plugsand threaded bores.


Inspect the threads of the pipe plugs for mutilation or dam-age.

Inspect the threaded bores for damage.

Install (017-007-026)

Apply a film of pipe plug sealant to the threads.

Install and tighten the pipe plugs.

Refer to the following chart for torque values.

Tighten pipe plugs to the appropriate torque values.

Straight Thread Plug (017-011) 24 Valve, 8.3 Liter EnginePage 17-4 Section 17 - Miscellaneous - Group 17


Straight Thread Plug (017-011)

Remove (017-011-002)

Select the appropriate size Allen wrench or socket and re-move the plug.

Clean (017-011-006)

Use a spray cleaner to clean the threads of the straightthread plugs and threaded bores.


Inspect the threads of the pipe plugs for mutilation or dam-age.

Inspect the threaded bores for damage.

Repair the bores, if necessary. Replace the plugs, if dam-aged.

Install (017-011-026)

Install a new o-ring on the straight threaded plugs. Lubri-cate with clean 15W-40 oil.

Install the plugs.

24 Valve, 8.3 Liter Engine Straight Thread Plug (017-011)Section 17 - Miscellaneous - Group 17 Page 17-5


Tighten the straight threaded plugs. Refer to the adjoiningchart for the appropriate torque values.

Straight Thread Plug (017-011) 24 Valve, 8.3 Liter EnginePage 17-6 Section 17 - Miscellaneous - Group 17


24 Valve, 8.3 Liter EngineSection V - Specifications Page V-a


Section V - Specifications

Section Contents

Air Intake System - Specifications ..........................................................................................................................................................V-18Air Intake Restriction (010-003) ..................................................................................................................................................V-18Axial Clearance (010-038) ..........................................................................................................................................................V-18Radial Bearing Clearance (010-047) ...........................................................................................................................................V-18

Air Intake System - Torque Values ..........................................................................................................................................................V-18Air Crossover (010-019) ..............................................................................................................................................................V-18Air Leaks, Air Intake and Exhaust Systems (010-024) ................................................................................................................V-18Turbocharger (010-033) ..............................................................................................................................................................V-18Turbocharger Axial Clearance (010-038) ....................................................................................................................................V-19Turbocharger Blade Damage (010-039) .....................................................................................................................................V-19Turbocharger Radial Bearing Clearance (010-047) ....................................................................................................................V-19Turbocharger Turbine Seal Leaks (010-049) ..............................................................................................................................V-19

Cam Followers/Tappets ............................................................................................................................................................................V-10

Capscrew Markings and Torque Values .................................................................................................................................................V-25Capscrew Markings and Torque Values - Metric ........................................................................................................................V-26Capscrew Markings and Torque Values - U.S. Customary .........................................................................................................V-27

Cooling System - Specifications .............................................................................................................................................................V-17Coolant Thermostat (008-013) ....................................................................................................................................................V-17

Cooling System - Torque Values .............................................................................................................................................................V-17Coolant Filter Head (008-007) .....................................................................................................................................................V-17Coolant Heater (008-011) ...........................................................................................................................................................V-17Coolant Thermostat (008-013) ....................................................................................................................................................V-17Fan Spacer and Pulley (008-039) ...............................................................................................................................................V-17Water Pump (008-062) ................................................................................................................................................................V-17

Cylinder Block - Specifications .................................................................................................................................................................V-1Bearings, Connecting Rod (001-005) ............................................................................................................................................V-1Camshaft (001-008) ......................................................................................................................................................................V-1Camshaft Bushings (001-010) ......................................................................................................................................................V-2Camshaft Gear (Camshaft Removed) (001-013) ..........................................................................................................................V-2Conncecting Rod (001-014) ..........................................................................................................................................................V-2Cylinder Liner (001-028) ...............................................................................................................................................................V-3Measure (001-010) ........................................................................................................................................................................V-2Piston (001-043) ............................................................................................................................................................................V-4Piston and Connecting Rod Assembly (001-054) .........................................................................................................................V-4Piston Rings (001-047) .................................................................................................................................................................V-4

24 Valve, 8.3 Liter EnginePage V-b Section V - Specifications


Cylinder Block - Torque Values .................................................................................................................................................................V-5Bearings, Connecting Rod (001-005) ...........................................................................................................................................V-5Bearings, Main (001-006) .............................................................................................................................................................V-5Camshaft (001-008) ......................................................................................................................................................................V-5Connecting Rod (001-014) ............................................................................................................................................................V-5Crankshaft Wear Sleeve, Rear (001-067) .....................................................................................................................................V-6Cylinder Liner (001-028) ...............................................................................................................................................................V-5Gear Housing, Front (001-033) .....................................................................................................................................................V-5Piston and Conecting Rod Assembly (001-054) ...........................................................................................................................V-6Vibration Damper (001-052) .........................................................................................................................................................V-6Vibration Damper, Rubber (001-051) ............................................................................................................................................V-5

Cylinder Head - Specifications ..................................................................................................................................................................V-7Cylinder Head (002-004) ...............................................................................................................................................................V-7Valve, Cylinder Head (002-020) ....................................................................................................................................................V-7

Cylinder Head - Torque Values ..................................................................................................................................................................V-8Cylinder Head (002-004) ...............................................................................................................................................................V-8

Exhaust System - Specifications ............................................................................................................................................................V-20Exhaust Manifold, Dry (011-007) ................................................................................................................................................V-20Exhaust Restriction (011-009) ....................................................................................................................................................V-20

Exhaust System - Torque Values ............................................................................................................................................................V-20Exhaust Manifold Dry (011-007) .................................................................................................................................................V-20

Fraction, Decimal, Millimeter Conversions ............................................................................................................................................V-29

Fuel System - Torque Values ...................................................................................................................................................................V-11Fuel Pump (005-016) ..................................................................................................................................................................V-11Rotor, CAPS Fuel Injection Pump (005-072) ..............................................................................................................................V-11Snubber, Rate Shape (005-081) .................................................................................................................................................V-11

Injectors and Fuel Lines - Torque Values ...............................................................................................................................................V-12Air in Fuel (006-003) ...................................................................................................................................................................V-12Fuel Drain Line Restriction (006-012) .........................................................................................................................................V-12Fuel Drain Lines (006-013) .........................................................................................................................................................V-12Fuel Filter Head Bracket (006-018) .............................................................................................................................................V-12Fuel Supply Lines (006-024) .......................................................................................................................................................V-12Injector (006-026) ........................................................................................................................................................................V-13Injector Supply Lines (High Pressure) (006-051) ........................................................................................................................V-13

Lubricating Oil System - Specifications .................................................................................................................................................V-14Lubricating Oil Cooler (007-003) .................................................................................................................................................V-14Lubricating Oil Pump (007-031) ..................................................................................................................................................V-14

Lubricating Oil System - Torque Values .................................................................................................................................................V-14Engine Oil Heater (007-001) .......................................................................................................................................................V-14Lubricating Oil Cooler (007-003) .................................................................................................................................................V-15Lubricating Oil Pan (007-025) .....................................................................................................................................................V-15Lubricating Oil Pressure Regulator (Main Rifle) (007-029) .........................................................................................................V-15Lubricating Oil Pump (007-031) ..................................................................................................................................................V-15Lubricating Oil Suction Tube (Block-Mounted) (007-035) ...........................................................................................................V-16Lubricating Oil Thermostat (007-039) .........................................................................................................................................V-16

24 Valve, 8.3 Liter EngineSection V - Specifications Page V-c


Newton-Meter to Foot-Pound Conversion Chart ...................................................................................................................................V-28

Pipe Plug Torque Values ..........................................................................................................................................................................V-24

Rocker Levers - Specifications ..................................................................................................................................................................V-9Overhead Set (003-004) ...............................................................................................................................................................V-9Rocker Lever (003-008) ................................................................................................................................................................V-9

Rocker Levers - Torque Values .................................................................................................................................................................V-9Rocker Lever (003-008) ................................................................................................................................................................V-9Rocker Lever Cover (003-011) ......................................................................................................................................................V-9

Tap-Drill Chart - U.S. Customary and Metric ..........................................................................................................................................V-23

Weights and Measures - Conversion Factors ........................................................................................................................................V-22

24 Valve, 8.3 Liter EnginePage V-d Section V - Specifications



24 Valve, 8.3 Liter Engine Cylinder Block - SpecificationsSection V - Specifications Page V-1


Component or Assembly (Procedure) Ref. No./StepsMetric U.S.

Cylinder Block - Specifica-tions

Bearings, Connecting Rod (001-005)Connecting Rod Bearing Dimensions Standard

2.4542.471

mmmm

MINMAX

0.09660.0973

inin

Connecting Rod Side Clearance Limits 0.100.33

mmmm

MINMAX

0.0040.013

inin

Dimension A End Play Limits 0.1270.330

mmmm

MINMAX

0.0050.013

inin

Camshaft (001-008)Diameter of Peak of Lobe

IntakeExhaust

51.77451.596

mmmm

MINMAX

2.0382.031

inin

Journal Diameter 59.96260.013

mmmm

MINMAX

2.36072.3627

inin

Camshaft Thrust Plate 9.349.58

mmmm

MINMAX

0.3680.377

inin

Camshaft Bore Inside DiameterWith Bushing 60.12 mm MAX 2.367 in

24 Valve, 8.3 Liter EnginePage V-2 Section V - Specifications


Camshaft End Play (A)

Camshaft Gear Backlash Limits (B)

0.120.46

0.080.33

mmmm

mmmm

MINMAX

MINMAX

0.0050.018

0.0030.013

inin

inin

Camshaft Bushings (001-010)Camshaft Bore Diameter (Maximum)

without bushingwith bushing

64.0160.12

mmmm

MINMAX

2.5202.367

inin

Measure (001-010)Camshaft Bore (Bushing Installed)

60.058

mm

MIN

2.3645

in

Camshaft Gear (Camshaft Removed) (001-013)Camshaft GearTemperature

149

°C 300

°F

Connecting Rod Piston Pin BushingDiameter

45.02345.035

mmmm

MINMAX

1.77261.7730

inin

Conncecting Rod (001-014)Connecting Rod Crank Bore Diameter (Bearings Removed)

80.98781.013

mmmm

MINMAX

3.18853.1895

inin

Crankshaft Rod Journal Diameter 75.96276.013

mmmm

MINMAX

2.99062.9926

inin


24 Valve, 8.3 Liter EngineSection V - Specifications Page V-3


Bearing Clearance 0.0380.116

mmmm

MINMAX

0.00150.0045

inin

Cylinder Liner (001-028)Cylinder Liner Dimensions

Maximum Out Of Round Maximum Taper Maximum Bore Diameter

0.040.04

114.04

mmmmmm

0.00160.00164.4897

ininin

Cylinder Liner Protrusion 0.250.122

mmmm

MINMAX

0.00980.0048

inin

Cylinder Liner I.D. 114.000114.040

mmmm

MINMAX

4.48824.4897

inin

Cylinder Liner O.D. (Top Press Fit)130.838130.958

mmmm

MINMAX

5.15115.1558

inin

Cylinder Liner Bore in Block (Press Fit Bore) 130.900

130.950mmmm

MINMAX

5.15355.1555

inin

Cylinder Liner to Block Clearance 0.229 mm MIN 0.009 in




Cylinder Liner Shim ThicknessJ924445J924446J924447J924448J924449

0.250.380.510.761.00

mmmmmmmmmm

0.0100.0150.0200.0300.040

ininininin

Piston (001-043)Piston Skirt Diameter

113.863113.877

mmmm

MINMAX

4.48284.4833

inin

Ring ClearanceOil Control Ring 0.040

0.0995mmmm

MINMAX

0.00160.0037

inin

Piston Pin Bore Diameter45.00645.012

mmmm

MINMAX

1.77191.7721

inin

Pin Diameter44.99745.003

mmmm

MINMAX

1.77151.7718

inin

Piston Rings (001-047)Ring Gap

Top Ring:

Intermediate Ring:

Oil Control Ring:

0.350.60

0.350.60

0.300.60

mmmm

mmmm

mmmm

MINMAX

MINMAX

MINMAX

0.0140.024

0.0140.024

0.0120.024

inin

inin

inin

Piston and Connecting Rod Assembly (001-054)Connecting Rod and Crankshaft SideClearance

0.100.33

mmmm

MINMAX

0.0040.013

inin


24 Valve, 8.3 Liter Engine Cylinder Block - Torque ValuesSection V - Specifications Page V-5


Cylinder Block - Torque Val-ues

Bearings, Connecting Rod (001-005)Connecting Rod CapscrewTorque Value:

123

357060

degrees

N·mN·m

2652

ft-lbft-lb

Bearings, Main (001-006)Main Bearing CapscrewTorque Value:

123

509590

degrees

N·mN·m

3770

ft-lbft-lb

Camshaft (001-008)Thrust Plate Capscrew

24

N·m

18

ft-lb

Connecting Rod (001-014)120 N·m 89 ft-lb

Cylinder Liner (001-028)68 N·m 50 ft-lb

Gear Housing, Front (001-033)Capscrew Torque

24

N·m

18

ft-lb




Vibration Damper, Rubber (001-051) 125 N·m 92 ft-lb

Vibration Damper (001-052)Crankshaft Damper Capscrew Torque

125

N·m

92

ft-lb

Piston and Conecting Rod Assembly (001-054)Torque Value:

123

357060

degrees

N·mN·m

2652

ft-lbft-lb

Crankshaft Wear Sleeve, Rear (001-067)Rear Cover Capscrew Torque

9

N·m

80

in-lb


24 Valve, 8.3 Liter Engine Cylinder Head - SpecificationsSection V - Specifications Page V-7



Cylinder Head - Specifica-tions

Cylinder Head (002-004)Cylinder Head Weight

71.2

kg

165

lb

Cylinder Head FlatnessEnd to EndSide to Side

0.0750.075

mmmm

MINMAX

0.0030.003

inin

Valve, Cylinder Head (002-020)Approx. Free Length (L):

V942095Maximum Inclination:

V943161

55

1.5

mm

mm.

2.165

0.059

in

in

Valve Guide Bore Diameter 8.0188.071

mmmm

MINMAX

0.31570.3178

inin

Valve Depth (Installed) 0.8591.21

mmmm

MINMAX

0.03380.0476

inin

Valve Rim Thickness Limit0.79 mm MIN 0.031 in

Cylinder Head - Torque Values 24 Valve, 8.3 Liter EnginePage V-8 Section V - Specifications


Cylinder Head - Torque Val-ues

Cylinder Head (002-004)Torque Value:All Capscrews Step 1Recheck All Step 2All Capscrews Step 3

148148

90degrees

N·mN·m

108108

ft-lbft-lb

24 N·m 18 ft-lb

Fan Hub CapscrewTorque Value:8 mmCapscrew10 mmCapscrew

24

43

N·m

N·m

18

32

ft-lb

ft-lb


24 Valve, 8.3 Liter Engine Rocker Levers - SpecificationsSection V - Specifications Page V-9



Rocker Levers - Specifica-tions

Overhead Set (003-004)Lash Check Limits

Intake

Exhaust

0.1520.559

0.3810.813

mmmm

mmmm

MINMAX

MINMAX

0.0060.022

0.0150.032

inin

inin

Lash Reset SpecificationsIntakeExhaust

0.2540.508

mmmm

NominalNominal

0.0120.022

inin

Rocker Lever (003-008)Rocker Lever Bore

22.027

mm

MIN

0.867

in

Rocker Lever Shaft21.965 mm MIN 0.865 in

Rocker Levers - Torque Val-ues

Rocker Lever (003-008)Pedestal Capscrew

60

N·m

44

ft-lb

Rocker Lever Capscrew 24 N·m 18 ft-lb

Rocker Lever Cover (003-011)Rocker Lever Capscrew

24

N·m

18

ft-lb

Cam Followers/Tappets 24 Valve, 8.3 Liter EnginePage V-10 Section V - Specifications



Cam Followers/Tappets

Tappet (004-015) Valve Tappet Stem Diameter 15.936

15.977mmmm

MINMAX

0.6270.629

inin

24 Valve, 8.3 Liter Engine Fuel System - Torque ValuesSection V - Specifications Page V-11



Fuel System - Torque Values

Fuel Pump (005-016)Torque Value:Fuel Pump Mounting Nuts SupportBracket

Support BracketFuel Pump Support Brackets

4444

N·mN·m

3232

ft-lbft-lb

Torque Value:Fuel Injection Pump Drive Gear Nut 205 N·m 151 ft-lb

Rotor, CAPS Fuel Injection Pump (005-072)14 N·m 10 ft-lb

Snubber, Rate Shape (005-081)Snubber AssemblyTorque Value: Step 1

Step 2

14120

degrees

N·m

10

ft-lb

Rate Shape Tube Assembly 46 N·m 34 ft-lb

Rate Shape Tube Isolator Capscrew 6 N·m 55 in-lb

Injectors and Fuel Lines - Torque Values 24 Valve, 8.3 Liter EnginePage V-12 Section V - Specifications



Injectors and Fuel Lines - Torque Values

Air in Fuel (006-003)Fuel Line Fitting

24

N·m

18

ft-lb

Fuel Drain Line Restriction (006-012)Fuel Drain Line Pressure

254.0

mmHg

MAX

10.0

in Hg

Fuel Drain Lines (006-013)24 N·m 18 ft-lb

Fuel Filter Head Bracket (006-018)Fuel Heater

3.4

N·m

30

in-lb

Filter Head Bracket14 mm 43 N·m 32 ft-lb

Fuel Inlet Restriction 8 mmHg

MAX 4 in Hg

Fuel Supply Lines (006-024)37 N·m 27 ft-lb

24 Valve, 8.3 Liter Engine Injectors and Fuel Lines - Torque ValuesSection V - Specifications Page V-13


Injector (006-026)Retaining Nut

47 N·m 35 ft-lb

Injector Supply Lines (High Pressure) (006-051)Fuel Pump ConnectionCylinder Head Connection

2438

N·mN·m

1828

ft-lbft-lb

Fuel Pump ConnectionCylinder Head Connection

2438

N·mN·m

1828

ft-lbft-lb


Lubricating Oil System - Specifications 24 Valve, 8.3 Liter EnginePage V-14 Section V - Specifications



Lubricating Oil System - Specifications Lubricating Oil Pump (007-031)Backlash Limits

A

B

0.0760.330

0.0760.330

mmmm

mmmm

MINMAX

MINMAX

0.0030.013

0.0030.013

inin

inin

Lubricating Oil Cooler (007-003)Air Pressure Test

449518

kPakPa

MINMAX

6575

psipsi

Tip Clearance 0.0250.1778

mmmm

MINMAX

0.0010.007

inin

Gerotor Clearance 0.0250.127

mmmm

MINMAX

0.0010.005

inin

Limit 0.17780.381

mmmm

MINMAX

0.0070.015

inin

Limits (Used Pump) 0.0760.330

mmmm

MINMAX

0.0030.013

inin

Lubricating Oil System - Torque ValuesEngine Oil Heater (007-001)

120 N·m 88 ft-lb

24 Valve, 8.3 Liter Engine Lubricating Oil System - Torque ValuesSection V - Specifications Page V-15


Lubricating Oil Cooler (007-003)24 N·m 18 ft-lb

10 mm24 N·m 18 ft-lb

Lubricating Oil Pan (007-025)24 N·m 18 ft-lb

80 N·m 60 ft-lb

Lubricating Oil Pressure Regulator (Main Rifle) (007-029)80 N·m 60 ft-lb

Lubricating Oil Pump (007-031)24 N·m 18 ft-lb

125 N·m 92 ft-lb


Lubricating Oil System - Torque Values 24 Valve, 8.3 Liter EnginePage V-16 Section V - Specifications


Lubricating Oil Suction Tube (Block-Mounted) (007-035)

24 N·m 18 ft-lb

24 N·m 18 ft-lb

80 N·m 60 ft-lb

Lubricating Oil Thermostat (007-039) 50 N·m 37 ft-lb


24 Valve, 8.3 Liter Engine Cooling System - SpecificationsSection V - Specifications Page V-17



Cooling System - SpecificationsCoolant Thermostat (008-013)Thermostat Initial opening Temperature 81

83

°C°C

MINMAX

178182

°F°F

Radiator Cap Pressure Test

A (Normal Duty)

System

104[220

°C°F]

103[15

CapkPapsi]

Cooling System - Torque ValuesCoolant Filter Head (008-007)Filter Head

24 N·m 18 ft-lb

Coolant Heater (008-011)24 N·m 18 ft-lb

Coolant Thermostat (008-013)24 N·m 18 ft-lb

Fan Spacer and Pulley (008-039)Fan Capscrew 51 to 62 N·m 37 to 45 ft-lb

Water Pump (008-062)24 N·m 18 ft-lb

Air Intake System - Specifications 24 Valve, 8.3 Liter EnginePage V-18 Section V - Specifications


Component or Assembly (Procedure) Metric U.S.

Air Intake System - SpecificationsAir Intake Restriction (010-003)Inlet Air Restriction 63.5 mm

H2OMAX 25.0 in

H2O

Axial Clearance (010-038)Axial Clearance 0.038

0.089mmmm

MINMAX

0.00150.0035

inin

Radial Bearing Clearance (010-047)Radial Bearing Clearance 0.15

0.64mmmm

MINMAX

0.0060.025

inin

Air Intake System - Torque ValuesAir Crossover (010-019) 5 N·m 44 in-lb

Air Leaks, Air Intake and Exhaust Systems (010-024)8 N·m 71 in-lb

Turbocharger (010-033)45 N·m 33 ft-lb

Air Inlet Pipe Clamp 8 N·m 71 in-lb

24 Valve, 8.3 Liter EngineSection V - Specifications Page V-19


Turbocharger Oil Drain Line 27 N·m 20 ft-lb

Turbocharger Oil Supply Line 20 N·m 15 ft-lb

Exhaust Pipe Clamp 8 N·m 71 in-lb

Turbocharger Axial Clearance (010-038)

8 N·m 71 in-lb

Turbocharger Blade Damage (010-039)

8 N·m 71 in-lb

Turbocharger Radial Bearing Clearance (010-047)8 N·m 71 in-lb

Turbocharger Turbine Seal Leaks (010-049)8 N·m 71 in-lb

Component or Assembly (Procedure) Metric U.S.

Exhaust System - Specifications 24 Valve, 8.3 Liter EnginePage V-20 Section V - Specifications


Component or Assembly (Procedure) Ref.No./StepsMetric U.S.

Exhaust System - Specifications Exhaust Restriction (011-009)Exhaust Restriction

Maximum Exhaust Restriction 76 mmHg

MAX 3 in Hg

Exhaust Manifold, Dry (011-007)Exhaust manifold Flatness 0.20 mm MAX 0.008 in

Exhaust System - Torque ValuesExhaust Manifold Dry (011-007)Exhaust Manifold Capscrew Torque 43 N·m 32 ft-lb

24 Valve, 8.3 Liter Engine Weights and Measures - Conversion FactorsSection V - Specifications Page V-21


Weights and Measures - Conversion Factors

Quantity U.S. Customary Metric From U.S.CustomaryTo Metric

Multiply By

From MetricTo U.S.

CustomaryMultiply By

Unit Name Abbr. Unit Name Abbr.

Area sq. inch in2 sq. millimeters mm2 645.16 0.001550

sq. centimeters cm2 6.452 0.155

sq. foot ft2 sq. meter m2 0.0929 10.764

FuelConsumption

pounds perhorsepower hour

lb/hp-hr grams per kilowatt hour

g/kW-hr 608.277 0.001645

FuelPerformance

miles per gallon mpg kilometers per liter km/l 0.4251 2.352

gallons per mile gpm liters per kilometer l/km 2.352 0.4251

Force pounds force lbf Newton N 4.4482 0.224809

Length inch in millimeters mm 25.40 0.039370

foot ft millimeters mm 304.801 0.00328

Power horsepower hp kilowatt kW 0.746 1.341

Pressure pounds force persq. inch

psi kilopascal kPa 6.8948 0.145037

inches of mercury in Hg kilopascal kPa 3.3769 0.29613

inches of water in H2O kilopascal kPa 0.2488 4.019299

inches of mercury in Hg millimeters ofmercury

mm Hg 25.40 0.039370

inches of water in H2O millimeters of water mm H2O 25.40 0.039370

bars bars kilopascals kPa 100.001 0.00999

bars bars millimeters ofmercury

mm Hg 750.06 0.001333

Temperature fahrenheit °F centigrade °C (°F-32) 1.8 (1.8 x °C) +32

Torque pound force per foot ft-lb Newton-meter N·m 1.35582 0.737562

pound force per inch in-lb Newton-meter N·m 0.113 8.850756

Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214

Volume:liquiddisplacement

gallon (U.S.) gal. liter l 3.7853 0.264179

gallon (Imp*) gal. liter l 4.546 0.219976

cubic inch in3 liter l 0.01639 61.02545

cubic inch in3 cubic centimeter cm3 16.387 0.06102

Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623

Work British Thermal Unit BTU joules J 1054.5 0.000948

British Thermal Unit BTU kilowatt-hour kW-hr 0.000293 3414

horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341

Tap-Drill Chart - U.S. Customary and Metric 24 Valve, 8.3 Liter EnginePage V-22 Section V - Specifications


Tap-Drill Chart - U.S. Customary and Metric

24 Valve, 8.3 Liter Engine Pipe Plug Torque ValuesSection V - Specifications Page V-23


Pipe Plug Torque Values

Size Torque Torque

Thread Actual Thread O.D. In Aluminum ComponentsIn Cast Iron or

Steel Components

in in N·m ft-lb N·m ft-lb

1/16 0.32 5 45 in-lb 15 10

1/8 0.41 15 10 20 15

1/4 0.54 20 15 25 20

3/8 0.68 25 20 35 25

1/2 0.85 35 25 55 40

3/4 1.05 45 35 75 55

1 1.32 60 45 95 70

1-1/4 1.66 75 55 115 85

1-1/2 1.90 85 65 135 100

Capscrew Markings and Torque Values 24 Valve, 8.3 Liter EnginePage V-24 Section V - Specifications


Capscrew Markings and Torque Values

∆ CAUTION ∆When replacing capscrews, always use a capscrew of the same measurement and strength as the cap-screw being replaced. Using the wrong capscrews can result in engine damage.

Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the sur-face of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.

The following examples indicate how capscrews are identified:

NOTES:

Always use the torque values listed in the following tables when specific torque values are not available. Do not use the torque values in place of those specified in other sections of this manual. The torque values in the table are based on the use of lubricated threads. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torquewrench. Example: 6 ft-lb equals 72 in-lb.

24 Valve, 8.3 Liter Engine Capscrew Markings and Torque Values - MetricSection V - Specifications Page V-25


Capscrew Markings and Torque Values - Metric

BodySize Torque Torque Torque

Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum

mm N·m ft-lb N·m ft-lb N·m ft-lb N·m ft-lb N·m ft-lb N·m ft-lb

6 9 5 7 4 12 9 7 4 14 9 7 4

7 14 9 11 7 18 14 11 7 23 18 11 7

8 25 18 18 14 33 25 18 14 40 29 18 14

10 45 33 30 25 60 45 30 25 70 50 30 25

12 80 60 55 40 105 75 55 40 125 95 55 40

14 125 90 90 65 165 122 90 65 195 145 90 65

16 180 130 140 100 240 175 140 100 290 210 140 100

18 230 170 180 135 320 240 180 135 400 290 180 135

Capscrew Markings and Torque Values - U.S. Customary 24 Valve, 8.3 Liter EnginePage V-26 Section V - Specifications


Capscrew Markings and Torque Values - U.S. Customary

Capscrew Body Size

Cast Iron Aluminum Cast Iron Aluminum

N·m ft-lb N·m ft-lb N·m ft-lb N·m ft-lb

1/4 - 20- 28

912

79

89

67

1518

1113

89

67

5/16 - 18- 24

2023

1517

1619

1214

3033

2224

1619

1214

3/8 - 16- 24

4040

3030

2535

2025

5560

4045

2535

2025

7/16 - 14- 20

6065

4550

4555

3540

9095

6570

4555

3540

1/2 - 13- 20

95100

7075

7580

5560

130150

95110

7580

5560

9/16 - 12- 18

135150

100110

110115

8085

190210

140155

110115

8085

5/8 - 11- 18

180210

135155

150160

110120

255290

190215

150160

110120

3/4 - 10- 16

325365

240270

255285

190210

460515

340380

255285

190210

7/8 - 9- 14

490530

360390

380420

280310

745825

550610

380420

280310

1 - 8- 14

720800

530590

570650

420480

11001200

820890

570650

420480

24 Valve, 8.3 Liter Engine Newton-Meter to Foot-Pound Conversion ChartSection V - Specifications Page V-27


Newton-Meter to Foot-Pound Conversion Chart

N·m ft-lb N·m ft-lb N·m ft-lb

1 8.850756 in-lb 55 41 155 114

5 44 in-lb 60 44 160 118

6 53 in-lb 65 48 165 122

7 62 in-lb 70 52 170 125

8 71 in-lb 75 55 175 129

9 80 in-lb 80 59 180 133

10 89 in-lb 85 63 185 136

1 0.737562 ft-lb 90 66 190 140

12 9 95 70 195 144

14 10 100 74 200 148

15 11 105 77 205 151

16 12 110 81 210 155

18 13 115 85 215 159

20 15 120 89 220 162

25 18 125 92 225 165

30 22 130 96 230 170

35 26 135 100 235 173

40 30 140 103 240 177

45 33 145 107 245 180

50 37 150 111 250 184

NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.

Fraction, Decimal, Millimeter Conversions 24 Valve, 8.3 Liter EnginePage V-28 Section V - Specifications


Fraction, Decimal, Millimeter Conversions

Conversion Factor: 1 inch = 25.4 mm

Fraction inch mm Fraction inch mm

1/64 0.0156 0.397 33/64 0.5156 13.097

1/32 0.0313 0.794 17/32 0.5313 13.494

3/64 0.0469 1.191 35/64 0.5469 13.891

1/16 0.0625 1.588 9/16 0.5625 14.288

5/64 0.0781 1.984 37/64 0.5781 14.684

3/32 0.0938 2.381 19/32 0.5938 15.081

7/64 0.1094 2.778 39/64 0.6094 15.478

1/8 0.1250 3.175 5/8 0.6250 15.875

9/64 0.1406 3.572 41/64 0.6406 16.272

5/32 0.1563 3.969 21/32 0.6563 16.669

11/64 0.1719 4.366 43/64 0.6719 17.066

3/16 0.1875 4.763 11/16 0.6875 17.463

13/64 0.2031 5.159 45/64 0.7031 17.859

7/32 0.2188 5.556 23/32 0.7188 18.256

15/64 0.2344 5.953 47/64 0.7344 18.653

1/4 0.2500 6.350 3/4 0.7500 19.050

17/64 0.2656 6.747 49/64 0.7656 19.447

9/32 0.2813 7.144 25/32 0.7813 19.844

19/64 0.2969 7.541 51/64 0.7969 20.241

5/16 0.3125 7.938 13/16 0.8125 20.638

21/64 0.3281 8.334 53/64 0.8281 21.034

11/32 0.3438 8.731 27/32 0.8438 21.431

23/64 0.3594 9.128 55/64 0.8594 21.828

3/8 0.3750 9.525 7/8 0.8750 22.225

25/64 0.3906 9.922 57/64 0.8906 22.622

13/32 0.4063 10.319 29/32 0.9063 23.019

27/64 0.4219 10.716 59/64 0.9219 23.416

7/16 0.4375 11.113 15/16 0.9375 23.813

29/64 0.4531 11.509 61/64 0.9531 24.209

15/32 0.4688 11.906 31/32 0.9688 24.606

31/64 0.4844 12.303 63/64 0.9844 25.003

1/2 0.5000 12.700 1 1.0000 25.400

8.3L Cummins Engine SM

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