Case IH D155 to DT402 Diesel Engine Service Manual – Basic Engine Section 2000 PDF

Description

Case IH D-155 to DT-402 Diesel Engine Service Manual — Basic Engine Section 2000

This is the complete Basic Engine Service Manual (Section 2000) for the Neuss-built Case IH direct injection diesel engine family, covering naturally aspirated and turbocharged versions from the D-155 through the DT-402. Every major engine assembly is addressed in its own chapter — from the valve lever assembly and camshaft through the crankcase, crankshaft, pistons, cylinder sleeves, connecting rods, balancer, flywheel, lubricating system, cooling system and injection pump timing. Whether you are rebuilding a D-206 in a tractor or diagnosing low oil pressure on a DT-358, this Case IH D-155 to DT-402 diesel engine service manual gives you the procedures, clearances, torque figures and illustrations required to do the job correctly.

File Details

• Manual type: Basic Engine Service Manual — Section 2000
• Brand: Case IH
• Document number: 8-59030
• Engine family: D-155, D-179, D-206, D-239, D-246, D-268, D-310, D-358, DT-239, DT-358, DT-402
• Language: English
• Page count: 108
• File format: PDF

Chapters Covered

• 1. Introduction
• 2. Service Diagnosis
• 3. Specifications
• 4. Longitudinal and Cross Section
• 5. Valve Lever Assy
• 6. Camshaft and Idler Gear
• 7. Cylinder Head Valves and Valve Guides
• 8. Manifolds
• 9. Fan – V-Belts
• 10. Crankshaft Pulley and Vibration Damper
• 11. Crankcase Front Cover and Plate
• 12. Crankcase
• 13. Crankshaft
• 14. Pistons Cylinder Sleeves – Connecting Rods
• 15. Balancer (4-cyl. only)
• 16. Flywheel
• 17. Lubricating System
• 18. Oil Pump
• 19. Water Pump
• 20. Thermostat and Coolant Manifold
• 21. Injection Pump EP/VA-VE
• 22. Injection Nozzle Holder
• 23. Timing Gear Train
• 24. Valve Lash Adjustment
• 25. Engine Testing

Introduction and Service Diagnosis

The manual opens with the safety rules and lubrication notes you need before touching the engine, followed by a diagnostic chapter organised by symptom. Engine will not start, does not develop full power, poor compression, overheating, excessive oil consumption, rough idle, misfire, excessive smoke, bearing failure, piston and sleeve wear, improper fuel pressure, low RPM, vibration and other complaints are each broken down into probable cause and corrective action. This is the chapter you reach for when the engine is telling you something is wrong but you are not yet sure where to look.

Specifications and Engine Data

Bore, stroke and piston displacement for every engine in the family, compression ratio, firing order, valve clearance (engine hot), cooling system operating temperature, minimum oil pressure at the main gallery, air cleaner restriction limits, blow-by values, and special nut and bolt torque data. The torque tables alone cover main bearing caps, connecting rod nuts, cylinder head nuts, studs, capscrews and bolts, flywheel bolts, injection pump gear bolts, nozzle holder studs and much more, with first-step, second-step and final torque values in both daNm and lbf-ft.

Engine Sectional Views

Longitudinal and cross-section illustrations of the engine with every major component numbered and identified. These give you a clear picture of how the valve train, crankshaft, balancer, oil pump, turbocharger and injection equipment sit relative to one another before you start dismantling.

Valve Lever Assembly, Camshaft and Timing Gears

Removal, disassembly, cleaning, inspection and reassembly of the valve lever shaft assembly, including bushing replacement and reaming, lever regrinding, spring and cover inspection. The camshaft chapter covers gear backlash, cam lobe lift, journal wear, thrust plate condition, line boring of camshaft bushings, and camshaft gear replacement with heat-fit instructions. The idler gear carrier, needle bearings, spacer ring and the LH-thread idler gear bolt are all addressed with torque and end-float values.

Cylinder Head, Valves and Valve Guides

Cylinder head removal and installation with the correct bolt torque sequence for 3, 4 and 6-cylinder engines, warpage limits, valve removal, valve seat insert replacement with oversize counterbore charts, valve guide replacement and reaming, valve refacing, lapping, valve stem seal and Rotocap installation, and the nozzle holder sleeve replacement procedure. Valve timing figures and the valve dimensional chart are included so you can verify every critical measurement.

Manifolds, Fan and V-Belts

Intake and exhaust manifold inspection, distortion limits and installation, plus the turbocharger mounting notes. Fan inspection, blade alignment and run-out limits, V-belt tensioning and pulley installation are covered with the torque values you need.

Crankshaft Pulley, Vibration Damper and Crankcase Front Cover

Removal and installation of the crankshaft pulley and vibration damper, wedge ring and clamping ring versions, timing slot and dowel pin alignment. The front cover and plate chapter covers seal replacement, timing pointer installation, and the correct procedure for installing the front oil seal with the cover in place.

Crankcase and Crankshaft

Crankcase inspection for warpage and cracks, cylinder sleeve protrusion measurement and shim selection, counterbore resurfacing with the cutting tool, and crankcase salvage dimensions. The crankshaft chapter is extensive: identification of nitrided, tufftried and induction hardened shafts, undersize grinding limits for first, second and third undersize, radii and surface finish requirements, straightening rules, rear seal flange reconditioning, crankshaft pinion and balancer drive gear replacement, main bearing fitting, running clearance checks with lead wire, and end play measurement.

Pistons, Cylinder Sleeves and Connecting Rods

Three and four-ring piston identification, piston clearance measurement with the ribbon gauge, piston ring gap and groove clearance, cylinder sleeve inspection and removal, piston pin and bushing replacement, connecting rod squareness and alignment, and the current angle-tightening procedure for connecting rod nuts (25 Nm pre-torque plus 120 degrees). Piston protrusion and connecting rod side clearance are also specified.

Balancer and Flywheel

Balancer removal, disassembly, inspection and reassembly with timing mark alignment for the drive and driven weights, backlash values, and the difference between old and new balancer designs. Flywheel removal with guide pins and lifting hook, friction surface inspection and refacing, ring gear replacement with shrink-fit temperatures, and flywheel installation torque.

Lubricating System and Oil Pump

Lubrication circuit diagrams, oil pump removal and disassembly, relief valve service, body gear replacement with heat-fit and feeler gauge clearance, idler gear and roller bearing installation, end play adjustment, and the self-locking nut procedure with the correct idler gear shaft.

Water Pump, Thermostat and Coolant Manifold

Water pump removal and disassembly, impeller removal with jack screw, bearing and packing replacement, clearance and hub flush specifications, thermostat testing and replacement, coolant manifold inspection, and temperature sender unit installation torque.

Injection Pump, Nozzle Holders and Timing

Static timing checks using both the dial indicator method and the timing window method, injection pump removal and installation, hub and drive gear alignment, injection pump timing to the engine with the 1.0 mm plunger stroke reference, and the complete timing gear train diagram with punch mark alignment for 3, 4 and 6-cylinder engines. Nozzle holder installation for flange-mounted and crab-mounted versions, fuel line routing, return valve and return line connection are also covered.

Valve Lash Adjustment and Engine Testing

Valve lash adjustment sequence for 3, 4 and 6-cylinder engines with the correct valves to adjust at TDC compression and TDC exhaust for each cylinder. Engine testing covers valve timing verification with a dial indicator, compression testing, lubricating oil pressure testing, air cleaner restriction, boost pressure on turbocharged engines, and crankcase pressure measurement with the orificed restrictor and water manometer.

Why This Case IH D-155 to DT-402 Service Manual Matters

These Neuss-built engines are long-lived, but only if they are rebuilt and adjusted to the correct specifications. The wrong main bearing clearance, an incorrectly timed injection pump, or a cylinder sleeve installed without the right protrusion will shorten the life of an otherwise sound engine. This Case IH basic engine service manual gives you the exact figures: torque values for every fastener, running clearances for every bearing, end play for the camshaft, idler gear and crankshaft, valve timing and injection pump timing data, cylinder sleeve protrusion and counterbore dimensions, piston clearance and ring gap limits, and the angle-tightening procedure for connecting rod nuts. It covers jobs from a top-end valve job to a complete engine overhaul, and it includes the diagnostic chapter that helps you find the fault before you start pulling the engine apart.

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Instant PDF Delivery — No Shipping, No Waiting

This Case IH D-155 to DT-402 diesel engine service manual is delivered as an instant PDF download immediately after checkout. There is no printed book to wait for, no shipping cost, and no risk of a damaged manual arriving in the post. The file works on any device — desktop, laptop, tablet or smartphone — and you can print the pages you need for the workshop, whether that is a single torque table or the whole cylinder head chapter. Keep it on the shop computer, take it to the machine on a tablet, or print it and mark it up. For anyone maintaining, repairing or overhauling a D-155, D-179, D-206, D-239, D-246, D-268, D-310, D-358, DT-239, DT-358 or DT-402 engine, this is the reference you want open on the bench.