Part of the Case Repair Manuals.
Aftercooler through turbocharger, cylinder block through both CAV and Bosch Model A injection pumps: the Case 4-390, 4T-390, 4TA-390 Service Manual PDF, OEM number 7-91612, walks all 342 pages of those systems end to end on a rebuild of the 390 diesel family. Front and rear oil seal replacement, piston and rod removal, and two gear and three gear balancer work take up the largest block of the book, with procedures running through pulling, inspecting, and reinstalling each assembly. Injection pump timing gets its own treatment for both pump makes, so your fuel side matches what is actually bolted to the engine. Hold connecting rod journal taper to 0.013 mm maximum, and pull 3/8 inch Grade 5 fasteners to 420 to 504 pound-inches. Bookmarks and searchable text put you on the clearance or torque sequence you want in seconds.
What's Inside This Case 4-390, 4T-390, 4TA-390 Manual
| System | Pages | Key Topics |
|---|---|---|
| Loctite Product Chart | 3-4 | Gasket Eliminator, Threadlocker, Instant Adhesive, Retaining Compound, Hydraulic Sealant, Pipe Sealant |
| Standard Torque Specifications | 5-10 | Decimal Hardware, Metric Hardware, Steel Hydraulic Fittings |
| Specification Details | 11-26 | Run-In Instructions, Identification Marks, Engine Specification Details |
| Aftercooler | 27-80 | Removing the Aftercooler, Inspecting the Aftercooler, Installing the Aftercooler |
| Cylinder Block | 81-180 | Front Oil Seal Replacement, Rear Oil Seal Replacement, Removal of Pistons and Rods |
| Balancer | 181-212 | Two Gear Balancer, Three Gear Balancer |
| Turbocharger | 213-266 | Servicing the Turbocharger, Inspection After Disassembly |
| Fuel System and Filters | 267-298 | Filter Replacement, Bleeding Air From the Fuel System, Lift Pump Service |
| CAV Fuel Injection Pump | 299-334 | Injection Pump Removal, Injection Pump Gear, Injection Pump Timing |
| Bosch Model a Fuel Injection Pump | 335-342 | Injection Pump Removal, Injection Pump Gear, Injection Pump Timing |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Grade 5 Bolts, Nuts, and Studs (1/4 inch) | 108 to 132 Pound-Inches | p. 7 |
| Grade 5 Bolts, Nuts, and Studs (5/16 inch) | 204 to 252 Pound-Inches | p. 7 |
| Grade 8.8 Bolts, Nuts, and Studs (M4) | 24 to 36 Pound-Inches | p. 8 |
| Grade 8.8 Bolts, Nuts, and Studs (M5) | 60 to 72 Pound-Inches | p. 8 |
| Connecting Rod Journal Maximum Taper | 0.013 mm | p. 19 |
| Journals Out of Round Maximum | 0.050 mm | p. 19 |
| Cylinder Head Height (New) | 94.75 to 95.25 mm | p. 17 |
| Warpage (Maximum) | 0.20 mm | p. 17 |
| Cylinder Out of Round (Maximum) | 0.038 mm | p. 84 |
| Cylinder Taper (Maximum) | 0.076 mm | p. 84 |
| Aftercooler mounting bolts torque | 21 to 27 Nm | p. 28 |
| Fuel injector lines torque | 22 to 28 Nm | p. 28 |
Case 4-390, 4T-390, 4TA-390 Common Problems This Manual Covers
Case 4-390 knocking under load with heavy smoke and oil pushed out of the dipstick tube
Pull the pan and measure crankshaft endplay before condemning anything. Endplay past the 0.13 to 0.25 mm listed on page 86 means thrust washer and main bearing wear. Check rod journals for taper over 0.013 mm, then bore taper against the 0.076 mm limit on page 106.
Manual Section: Cylinder Block p. 86Coolant in the oil, white exhaust, and pressure in the cooling system after a head gasket job
Deck the head flat and measure it. Warpage over 0.020 mm in any 51 mm area, or 0.076 mm side to side, means resurfacing per the limits on page 45. Never cut past 1.0 mm total or below 93.75 mm overall height. Finish the surface to 1.5 to 3.2 micrometers.
Manual Section: Specification Details p. 45Head gasket blowing again shortly after reassembly, compression low on two adjacent cylinders
Clean the bolt threads and blind holes dry, then follow the four step sequence on page 69: 90 Nm, 120 Nm, 90 Nm, then 90 degrees of turn. Skipping the final angle pull is what loses clamp load. Torque the rocker shaft brackets to 21 to 27 Nm afterward and set valve lash.
Manual Section: Specification Details p. 69Blue exhaust smoke, high oil consumption, and a whining or cyclic sound from the turbocharger
Check shaft endplay and radial play by hand before you buy a cartridge, and inspect the oil drain tube for restriction. Reusing a coked drain line kills the new unit. Torque the turbine housing bolts to 11 Nm and the compressor housing bolts to 6 Nm per page 215, and the drain tube bolts to 24 Nm.
Manual Section: Turbocharger p. 215Hard starting, rough idle, surging, and low power with fog-like exhaust at the stack
Bleed the fuel system and confirm the lift pump holds pressure before touching pump timing. Work the injection pump chart on page 301 for surge and no-shutoff complaints, then crack lines one at a time to find the dead injector. Torque injector lines to 22 to 28 Nm.
Manual Section: CAV Fuel Injection Pump Troubleshooting p. 301Piston slap and low compression on a high hour engine being measured for a rebuild
Bore gauge each cylinder at three depths and two axes. Taper over 0.076 mm or out of round over 0.038 mm means boring oversize, and anything past 102.116 mm diameter is done as listed on page 107. Hone to a 0.4 to 0.8 micrometer finish, then torque rod bolts to 60 Nm plus 60 degrees.
Manual Section: Cylinder Block p. 107Frequently Asked Questions
What are the torque specifications for the cylinder head bolts on a Case 4T-390 engine?
The cylinder head bolts for the 4T-390 engine require a multi-step tightening process. First, tighten all bolts to 90 Nm and recheck. Then, tighten the four long bolts to 120 Nm. Finally, loosen each short and medium bolt in sequence and re-tighten to 90 Nm, followed by a final turn of 90 degrees as indicated on the bolt head. p. 69
What is the correct valve clearance for the intake and exhaust valves on a 4-390 engine?
For a cold engine, the intake valve clearance is 0.254 mm and the exhaust valve clearance is 0.508 mm. p. 74
What is the procedure for bleeding air from the fuel system on a 4-390 engine?
To bleed the fuel system, ensure there is fuel in the tank, then loosen the bleed screw on the fuel injection pump. Actuate the primer pump until clear fuel without air bubbles flows from the bleed screw, then tighten it. If the primer pump cannot be actuated, rotate the engine until the pump can be actuated. p. 72
What is the oil pan drain plug torque spec on a Case 4-390, 4T-390, 4TA-390 diesel engine?
The oil pan drain plug should be tightened to a torque of 68 to 82 Nm. p. 179
What is the minimum oil pressure for a used 4-390 engine at low idle?
For a used engine, the minimum oil pressure at low idle is 0.7 Bar (10 PSI). p. 170
What do I get after purchasing this Case 4-390 manual?
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