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 |
