Part of the Case Repair Manuals.
All 206 pages of this Case G 4.0 / G 4.0T Service Manual (OEM #Bur 7-15480) zero in on one engine family: the four-cylinder diesel in naturally aspirated and turbocharged form. Inside you get step-by-step rebuild procedures covering every major assembly, from cylinder head and piston work to crankshaft, timing Case, and fuel injection pump service. Open to any chapter and you'll find exploded views, clearance tables, torque specifications, and a full set of system diagrams spanning lubrication, cooling, aspiration, and fuel delivery. Compression ratio holds at 17.25:1, stroke measures 127 mm, and the dry installed engine weight is 500 kg. Your engine is apart. Get the clearance tolerance off a chart, not a forum post. Bookmarked chapters let you jump straight to the section you need; search any spec by keyword and keep wrenching.
What's Inside This Case G4.0/G4.0T Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 5-10 | Introduction, Engine Identification, Safety Precautions, Engine Lifting Equipment, Viton Seals |
| Specifications | 11-24 | Basic Engine Data, Recommended Torques, Compression Test Data |
| Cylinder Head Assembly | 25-30 | Rocker Cover, Valve Springs, Valve Guides, Cylinder Head Inspection, Data and Dimensions |
| Piston and Connecting Rod Assembly | 31-40 | Connecting Rod Bearing, Piston Rings, Piston Cooling Jets, Piston Height, Data and Dimensions |
| Crankshaft Assembly | 41-54 | Crankshaft Pulley, Rear Oil Seal Assembly, Main Bearings, Balancer Unit, Data and Dimensions |
| Timing Case and Drive Assembly | 55-64 | Timing Case Cover, Front Oil Seal, Idler Gear and Hub, Fuel Pump Gear, Camshaft and Tappets, Data and Dimensions |
| Cylinder Block Assembly | 65-78 | Cylinder Block, Cylinder Liner, Cylinder Bore, Data and Dimensions |
| Engine Timing | 79-86 | General Description, Set Piston to TDC, Check Valve Timing, Check Fuel Injection Pump Timing, Data and Dimensions |
| Aspiration System | 87-94 | Turbocharger, Turbocharger Faults, Engine Breather, Data and Dimensions |
| Lubrication System | 95-99 | Oil Filter, Sump, Oil Strainer and Suction Tube, Lubricating Oil Pump, Relief Valve, Data and Dimensions |
| Fuel System | 101-108 | Fuel Filters, Fuel Injectors, Fuel Lift Pump, Lucas DP200 Series Fuel Injection Pump, Data and Dimensions |
| Cooling System | 109-115 | Thermostats, Coolant Pump, Fan and Fan Drive, Lubricating Oil Cooler, Data and Dimensions |
| Flywheel and Flywheel Housing | 117-120 | Flywheel, Ring Gear, Flywheel Housing, Data and Dimensions |
| List of Special and Shop Equipment Tools | 121-126 | Special Tools, Shop Equipment Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cubic capacity | 4 litres (243 in³) | p. 14 |
| Compression ratio | 17.25:1 | p. 14 |
| Stroke | 127 mm (5.00 in) | p. 14 |
| Typical dry installed engine weight | 500 kg (1100 lb) | p. 14 |
Case G4.0/G4.0T Common Problems This Manual Covers
Case G 4.0 diesel engine runs rough and lacks power with low cylinder compression p. 14
Perform a cylinder compression test. Verify the compression ratio meets the 17.25:1 factory specification listed on page 14. Inspect the cylinder head and valve seating if readings fall below normal operating limits. Replace worn piston rings or damaged valves to restore proper cylinder sealing.
Manual Section: SpecificationsEngine produces a heavy bottom end knocking noise under load and loses oil pressure p. 14
Measure the crankshaft stroke to ensure it matches the 127 mm (5.00 in) standard dimension found on page 14. Inspect the main bearings and connecting rod journals for excessive wear. Replace the scored bearings and torque the caps accurately to prevent catastrophic failure.
Manual Section: SpecificationsEngine block requires complete removal due to seized pistons and massive internal metal contamination p. 14
Attach a certified heavy duty hoist to the lifting eyes. Verify your shop crane safely supports the typical dry installed engine weight of 500 kg (1100 lb) referenced on page 14. Disconnect all aspiration plumbing, coolant hoses, and fuel lines before unbolting the primary mounts.
Manual Section: SpecificationsFrequently Asked Questions
What torque specifications are listed?
The manual provides extensive torque specifications for various components. For instance, standard torques for M6 x 1,00 setscrews and nuts are 9 Nm (7 lbf ft) or 0,9 kgf m. Special torques are also listed for components like cylinder head assembly, fasteners, piston and connecting rod assembly, crankshaft assembly, timing case and drive assembly, fuel system, lubrication system, cooling system, flywheel and housing, and aspiration system.
How do you fix diesel engine runs rough and lacks power with low cylinder compression?
Perform a cylinder compression test. Verify the compression ratio meets the 17.25:1 factory specification listed on page 14. Inspect the cylinder head and valve seating if readings fall below normal operating limits. Replace worn piston rings or damaged valves to restore proper cylinder sealing.
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