Part of the Case Repair Manuals.
All 570 pages of this Case 5.9 Liter Engine Troubleshooting and Repair Manual (OEM #Rac 6-11400) focus on one thing: getting your 5.9L diesel diagnosed and back in spec. You get a full troubleshooting symptoms section that walks air compressor cycling, blowby, fuel consumption, injection knock, turbocharger noise, and dozens of failure modes through step-by-step diagnostic charts. Back that up with exploded views, clearance tables, test value charts, system flow diagrams for fuel, lube, cooling, and air intake, plus a torque reference covering every fastener in the assembly. Set injector protrusion to 3.817–4.353 mm; torque the fuel pump drive shaft nut to 170 N•m before you button it up. Engine's apart and time is money. Jump to any section by keyword or bookmark, pull the factory number, and get back to wrenching.
What's Inside This Case 5.9 Liter Engine, Case 5.9 Liter Engine Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 1-8 | About the Manual, General Cleaning Instructions, General Safety Instructions, General Repair Instructions, How to Use the Manual, Illustrations |
| Engine Identification | 9-20 | Ecm Dataplate, Engine Dataplate, Fuel Injection Pump Dataplate |
| Trou Trouble Shooting Symptoms | 21-144 | Troubleshooting Procedures and Techniques, Troubleshooting Symptoms Charts, Air Compressor, Coolant Temperature, Engine Noise, Fuel Consumption |
| Cylinder Block | 145-242 | Bearings, Connecting Rod, Main, Camshaft, Camshaft Bushings, Camshaft Gear (Camshaft Removed) |
| Cylinder Head | 243-276 | Crosshead, Cylinder Head Gasket, Injector Protrusion, Valve, Valve Guide |
| Rocker Levers | 277-290 | Crankcase Breather Tube, Overhead Set, Rocker Lever, Rocker Lever Cover |
| Cam Followers/Tappets | 291-302 | Service Tools, Push Rods or Tubes, Tappet |
| Fuel System | 303-344 | Engine Fuel Heater, Electric, Flow Diagram, Fuel Consumption, Fuel Flow, Fuel Injection Pump, Rotary |
| Injectors and Fuel Lines | 345-370 | Air in Fuel, Fuel Connector (Head Mounted), Fuel Drain Line Restriction, Fuel Drain Lines, Fuel Filter (Canister Type), Fuel Filter Head Bracket |
| Lubricating Oil System | 371-412 | Engine Oil Heater, Flow Diagram, Lubricating Oil Cooler, Lubricating Oil Dipstick, Lubricating Oil Pan, Lubricating Oil Pump |
| Cooling System | 413-452 | Coolant Heater, Coolant Temperature Gauge, Coolant Thermostat, Cooling System Diagnostics, Drive Belt, Cooling Fan, Water Pump |
| Drive Units | 453-458 | Hydraulic Pump Drive, Hydraulic Pump Drive Gear and Shaft |
| Air Intake System | 459-508 | Air Crossover, Air Inlet Connection, Air Intake Manifold, Air Intake Restriction, Charge Air Cooler (Cac), Turbocharger |
| Exhaust | 509-518 | Exhaust Manifold, Dry, Exhaust Restriction, Flow Diagram, Exhaust System, Service Tools, Specifications |
| Miscellaneous | 519-526 | Cup Plug, Pipe Plug, Service Tools, Straight Thread Plug |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel Pump Drive Shaft Nut Torque | 170 N•m [125 ft-lb] | p. 545 |
| Injector Protrusion | 3.817 mm MIN, 4.353 mm MAX [0.150 in MIN, 0.171 in MAX] | p. 539 |
| Injector Sealing Washer Thickness | 1.5 mm [0.06 in] | p. 364 |
| Pressure Drop Across the Fuel Filter | 34 kPa MAX [5 psi MAX] | p. 544 |
| Lift Pump Pressure - Cranking | 41 kPa MIN [6 psi MIN] | p. 544 |
| Cylinder Head Flatness - End-to-End | 0.305 mm MAX [0.012 in MAX] | p. 538 |
| Cylinder Head Flatness - Side-to-Side | 0.076 mm MAX [0.003 in MAX] | p. 538 |
| Exhaust Manifold Flatness | 0.20 mm MAX [0.008 in MAX] | p. 557 |
| Exhaust Manifold Mounting Capscrews Torque | 43 N•m [32 ft-lb] | p. 516 |
| Turbocharger Axial Clearance | 0.038 mm MIN, 0.093 mm MAX [0.0015 in MIN, 0.0037 in MAX] | p. 554 |
| Turbocharger Radial Bearing Clearance | 0.326 mm MIN, 0.496 mm MAX [0.0128 in MIN, 0.0195 in MAX] | p. 554 |
| Cooling System Pressure Test | 140 kPa [20 psi] | p. 377 |
