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 |
Case 5.9 Liter Engine, Case 5.9 Liter Engine Common Problems This Manual Covers
Case 5.9 Liter Engine VP44 injection pump hard starts, stalling, and no-load power loss p. 303
Check lift pump output before condemning the injection pump: running pressure must reach 69 kPa [10 psi MIN] (page 336) and cranking pressure at least 41 kPa [6 psi MIN] (page 544). Verify fuel inlet restriction stays under 20 kPa [6 in Hg]. If the pump needs replacement, torque the drive shaft nut to 170 N•m [125 ft-lb] on reinstall (page 545).
Manual Section: Fuel SystemFuel injectors clogged or worn, rough idle, excessive black smoke, and high fuel consumption p. 345
Remove and inspect each injector per the procedure starting on page 345. Always replace the sealing washer (1.5 mm [0.06 in], page 364) when pulling an injector. Verify protrusion measures 3.817 to 4.353 mm [0.150 to 0.171 in] (page 539). Torque injectors to 47 N•m [35 ft-lb] and high-pressure supply lines to 38 N•m [28 ft-lb] (page 547).
Manual Section: Injectors and Fuel LinesCoolant mixing with oil, white smoke at startup, and coolant temperature climbing past 100 degrees C p. 243
Pressure-test the cooling system to 140 kPa [20 psi] (page 377); a sustained drop confirms internal leakage. Pull the head and check flatness: 0.305 mm MAX end-to-end and 0.076 mm MAX side-to-side (page 538). Torque new head capscrews to 105 N•m [77 ft-lb] in the three-step sequence, then rotate each 90 degrees clockwise (page 540).
Manual Section: Cylinder HeadTurbocharger worn or oil-starved after high hours, excessive exhaust smoke, power drop, and bearing whine p. 459
Check axial clearance (0.038 to 0.093 mm [0.0015 to 0.0037 in]) and radial bearing clearance (0.326 to 0.496 mm [0.0128 to 0.0195 in]) per page 554 before ordering parts. Inspect the oil drain line for restriction first; a blocked drain starves bearings fast. Torque mounting nuts to 45 N•m [33 ft-lb] and the oil drain line to 24 N•m [18 ft-lb] (page 555).
Manual Section: Air Intake SystemExhaust manifold cracked from thermal cycling, ticking noise at startup, and power loss under load p. 509
Remove the manifold and check each seating surface with a straightedge. Any warpage beyond 0.20 mm [0.008 in MAX] requires replacement (page 557). Verify exhaust back pressure stays under 76 mm Hg [3 in Hg] per page 14. Torque new manifold capscrews to 43 N•m [32 ft-lb] in a crisscross pattern (page 516).
Manual Section: ExhaustFrequently Asked Questions
How do you reset the 5.9 Cummins engine error codes?
To reset the 5.9 Cummins engine error codes, use the appropriate CASE service tool to clear the fault code from the Electronic Control Module (ECM) after the VP44 fuel pump test has been completed. For example, after a VP44 fuel pump test, clear Fault Code 364 from the ECM.
What are the torque specs for 5.9 Cummins cylinder head bolts?
The torque specifications for the 5.9 Cummins cylinder head capscrews are a multi-step process: Step 1: 80 N•m [59 ft-lb], Step 2: 105 N•m [77 ft-lb], Step 3: Re-check All - 105 N•m [77 ft-lb], and Step 4: Rotate 90 degrees clockwise.
How to reset 5.9 Cummins ECU
To reset the 5.9 Cummins ECU (ECM), if it is locked up, disconnect the battery cables for 30 seconds, then reconnect them and start the engine. If the ECM is not calibrated or has an incorrect calibration, it must be calibrated using the appropriate electronic service tool, referring to Procedure 019-032 in the Troubleshooting and Repair Manual, Fuel System, 5.9 liter Engine.
How to reset 5.9 Cummins check engine light
The manual does not provide a direct procedure to 'reset' the check engine light. However, it indicates that fault codes can be cleared from the Electronic Control Module (ECM) using an appropriate CASE service tool, which would typically extinguish the check engine light if the underlying issue is resolved. For example, Fault Code 364 can be cleared from the ECM after a fuel pump test.
What are the replacement specifications for VP44 Injection Pump?
The manual does not list specific replacement part numbers or detailed specifications for the VP44 Injection Pump. However, it states that if the engine will not start after troubleshooting, the VP44 injection pump should be replaced. Refer to the Troubleshooting and Repair Manual, 5.9 L engine for appropriate troubleshooting procedures.
How will I receive this Case 5.9 Liter Engine Troubleshooting and Repair Manual?
This is a 570-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Am I able to print pages from this Case 5.9 Liter Engine manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Reviews
There are no reviews yet.