Diesel Engine: Workshop Manual For

Diesel Engine
WORKSHOP MANUAL
for
V2203-DI (26-00119)
Beginning With Serial Number 3Y0015
62--10865 Rev --
WORKSHOP MANUAL
DIESEL ENGINE
V2203-DI (26-001190)
Beginning With Serial Number 3Y0015
TABLE OF CONTENTS
TO THE READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
1.1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Cylinder Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Servicing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.1 Engine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7 Check and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7.1 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7.2 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7.3 Checking Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7.4 Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7.5 Checking V--Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7.6 Checking V--Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7.7 Checking V--Belt Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7.8 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.7.9 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.7.10 Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.8.1 Diesel Engine Compression Tester (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.8.2 Oil Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.8.3 Auxiliary Socket For Fixing Crankshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.8.4 Valve Guide Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.8.5 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.8.6 Flywheel Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.8.7 Crankshaft Bearing 1 Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
i 62--10865
ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Disassembling And Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Draining Coolant And Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.3 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.4 Cylinder Head And Valves (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.5 Injection Pump and Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.6 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.2.7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.3.1 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.3.2 Timing Gears, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.3.3 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.3.4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.3.5 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3.1 Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3.1.1 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3.1.2 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3.2.1 Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3.2.2 Rotor to Cover Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 V--Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Fan Belt Damage and Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.3 Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
5.1.1 Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
5.1.2 Shim Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
5.1.3 Delivery Valves Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
5.2 Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
5.2.1 Nozzle Injection Presssure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
5.2.2 Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
5.2.3 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
62-10865 ii
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Lead Terminal Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Glow Plug Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Starter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Starter Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Disassembling Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Disassembling The Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.3 Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Starter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.1 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.2 Armature Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.4 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.5 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.6 Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.7 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.8 Commutator and Mica . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.9 26-00119-00 / 26-00119-02 Starter
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
iii 62--10865
SAFETY
1.1 SAFETY PRECAUTIONS
NOTE
Your Carrier Transicold unit has been designed with the
safety of the operator in mind. During normal operation, NOTE -- gives helpful information that may help
all moving parts are fully enclosed to help prevent injury.
During all pre-trip inspections, daily inspections, and and avoid equipment and property damage.
problem troubleshooting, you may be exposed to
moving parts. Please stay clear of all moving parts when The statements listed below are specifically applicable
the unit is in operation and when the unit main power to this unit and appear elsewhere in this manual. These
switch is in the START/RUN position. recommended precautions must be understood and ap-
plied during operation and maintenance of the equip-
Engine Coolant ment covered herein.
The engine is equipped with a pressurized cooling
system. Under normal operating conditions, the coolant
in the engine and radiator is under high pressure and is WARNING
very hot. Contact with hot coolant can cause severe
burns. Do not remove the cap from a hot radiator. If the Check the injection nozzle only after con-
cap must be removed, do so very slowly in order to firming that nobody is near the spray. If the
release the pressure without spray. spray from the nozzle contacts the human
Battery body, cells may be destroyed and blood
This unit is equipped with a lead-acid type battery. The poisoning may result.
battery normally vents small amounts of flammable
hydrogen gas. Do not smoke when checking the battery.
A battery explosion can cause serious physical harm
and/or blindness.
WARNING
1.2 SPECIFIC WARNING AND CAUTION When removing the radiator cap, wait at
STATEMENTS least ten minutes after the engine has
stopped and cooled down. Otherwize, hot
To help identify the label hazards on the unit and explain water may discharge from the radiator,
the level of awareness each one carries, an explanation
is given with the appropriate consequences: scalding anyone nearby.
DANGER WARNING
DANGER -- warns against an immediate Check the injection nozzle only after con-
hazard which WILL result in severe person- firming that nobody is near the spray. If the
al injury or death. spray from the nozzle contacts the human
body, cells may be destroyed and blood
poisoning may result.
WARNING
WARNING -- warns against hazards or un-
safe conditions which COULD result in se-
WARNING
vere personal injury or death. Secure the starter to prevent it from moving
when power is applied to it.
CAUTION
CAUTION -- warns against potential hazard
or unsafe practice which could result in mi-
nor personal injury, or product or property
damage.
i 62-10865
CAUTION CAUTION
Do not remove the radiator cap until the Stop the engine when preparing to change
coolant temperature is below its boiling the engine oil.
point. Loosen the cap slightly to relieve ex-
cess pressure before removing the cap
completely. CAUTION
Never remove the radiator cap until coolant
CAUTION temperatue is below its boiling point. Loos-
en the cap slightly to the first stop to relieve
Stop the engine when attempting to check any excess pressure before removing the
and change the fuel line. cap completely.
62-10865 ii
SECTION 1
General
1.1 ENGINE IDENTIFICATION When contacting Carrier Transicold, always specify
your engine model number and serial number.
The engine model and its serial number need to be
identified before the engine can be serviced or parts
replaced.
Engine Serial Number
The engine serial number is an identified number for the
engine. It is marked after the engine model number.
It indicates month and year of manufacture as follows:
Figure 1-1.
Year of Manufacture Month of Manufacture
Engine Serial Number

Alphabet or Alphabet or Month
Year Year
Number Number 0001~9999 10000~
1 2001 F 2015 January A0001~A9999 B0001~
2 2002 G 2016 February C0001~C9999 D0001~
3 2003 H 2017 March E0001~E9999 F0001~
4 2004 J 2018 April G0001~G9999 H0001~
5 2005 K 2019 May J0001~J9999 K0001~
6 2006 L 2020 June L0001~L9999 M0001~
7 2007 M 2021 July N0001~N9999 P0001~
8 2008 N 2022 August Q0001~Q9999 R0001~
9 2009 P 2023 September S0001~S9999 T0001~
A 2010 R 2024 October U0001~U9999 V0001~
B 2011 S 2025 November W0001~W9999 X0001~
C 2012 T 2026 December Y0001~Y9999 Z0001~
D 2013 Y 2027
e.g. V2203--3W001
E 2014 “3” indicates 2003 and “W” indicates November.
So, 3W indicates that the engine was manufactured in
November, 2003
Table 1-1. Model Chart

NEW ENGINE
MODEL NUMBER ENGINE TYPE PRIMARY USE REPLACES
PART NUMBER
V2203-DI-E2B- CT4-134-DI Extra XT, Ultra XT, Ultra XTC,
26-00119-00 26-00115-03SV
CTD-7 (1700 RPM) Multi-Temp, & Smart Air
V2203-DI-E2BG- CT4-134-DI
26-00119-01 GENSET 26-00115-01
CTD-6 (1800 RPM)
V2203-DI-E2B- CT4-134-DI
26-00119-02 Ultima 53 & Ultima XTC 26-00115-03SV
CTD-4 (2200 RPM)
1-1 62--10865
1.2 ENGINE SPECIFICATIONS
Table 1-2. Specification Chart
MODEL NUMBER 26-00119-00 26-00119-01 26-00119-02
TYPE Vertical, Water-cooled, 4 cycle diesel engine
NUMBER OF CYLINDERS 4
BORE X STROKE mm X mm (in. X in.) 87 X 92.4 (3.43 X 3.64)
TOTAL DISPLACEMENT cm3 (cu.in.) 2197 (134.1)
BRAKE HORSE- SAE Intermittent H.P.
23.7 (31.8) / 1700 24.9 (33.4) / 1800 28.2 (37.8) / 2200
POWER kW (HP) / RPM
MAXIMUM SPEED RPM Below 1920 Below 2000 Below 2420
IDLING SPEED RPM 900 To 1000 -
COMBUSTION CHAMBER Direct Injection
INJECTION PUMP Bosk “K” Type Mini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
INJECTION NOZZLE Bosch “P” Type Hole Nozzle
INJECTION TIMING (INPRESSURIZED) 5.0 Before T.D.C. 3.5 Before T.D.C. 5.5 Before T.D.C.
FIRING ORDER 1-3-4-2
INJECTION 1st. STAGE 1.86 to 20.1 MPa (190 to 205 kgf/cm2, 2702.3 to 2915.7 psi.)
PRESSURE (Valve
O
Opening
i Pressure)
P ) 2 d STAGE
2nd. 22 6 to
22.6 t 24.5
24 5 MPa
MP (230 to k f/ 2, 3271
t 250 kgf/cm 3271.2
2 to
t 3555.7
3555 7 psi.)
i)
COMPRESSION RATIO 20.5 : 1
LUBRICATION SYSTEM Forced Lubrication by Pump
OIL PRESSURE INDICATION Electrical Type Switch
LUBRICATION FILTER Full Flow Paper Filter (Cartridge Type)
COOLING SYSTEM Pressurized Radiation, Forced Circulation With Water Pump
Electric Starting With Starting Motor
STARTING SYSTEM
12V, 2.0 kW 12V, 1.4 kW 12V, 2.0 kW
STARTING SUPPORT DEVICE By Glow Plug In Combustion Chamber
FUEL Diesel Fuel No.2-D (ASTM D975)
*Quality Better Than CF Class (API), SAE 10W-40
LUBRICATING OIL
If this class of lubricating oil is not available, use class CD or CE lubricating oil.
LUBRICATING OIL CAPACITY 16.3 L (17.2 U.S. Quarts
Weight (DRY) kg (lbs.) 191.4 (422.0) 190.3 (419.6) 191.4 (422.0)
*See paragraph 1.8.8
62--10865 1-2
1.3 CYLINDER NUMBER 1.4 GENERAL PRECAUTIONS
The cylinder numbers of V2203--DI (26-00119) series

engine are designated as shown above. The sequence 2
of cylinder numbers is given as No.1, No. 2, No. 3, and
No. 4 starting from the gear case end of the engine.
2
3 3
1. Grease A External Snap Ring

2. Force B Internal Snap Ring
3. Place the Sharp Edge
against the Direction of Force
During disassembly, carefully arrange removed parts in

a clean area to prevent confusion latter. Screws, bolts
and nuts should be replaced in their original position to
prevent reassembly errors.
When special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently
used should be made according to the drawings
provided.
Before disassembling or servicing live wires, make sure
to always disconnect the grounding cable from the
battery first.
Remove oil and dirt from parts before taking any
measurements.
Use only Carrier Transicold genuine parts for parts
replacements to maintain engine performance and to
ensure safety.
Gaskets and O--rings must be replaced during
reassembly. Apply grease to new o--rings or oil seals
before assembling.
When reassembling external or internal snap rings,
position them so that the sharp edge faces against the
direction from which force is applied.
A newly serviced or reassembled engine should be
run--in with no load. Serious damage to the engine may
result otherwise.
1-3 62--10865
1.5 TORQUE SPECIFICATIONS
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench. Several screws, bolts and
nuts such as those used on the cylinder head must be tightened in the proper sequence and at the proper torque.
1.5.1 Torque Specifications For Special Use Screws, Bolts and Nuts
In removing and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar tool, if employed,
must be used with care. Failure to do so may result in stripped or seized screws, bolts and nuts.
When replacing “*” marked screws, bolt and nuts, apply engine oil to their threads and seats before reassembly.
The letter “M” in size and pitch means that the screw, bolt or nut dimension is metric. The size is the nominal outside
diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.
Item Size x Pitch N.m kgf.m ft--lbs

Cylinder Head Cover Screw M6 x 1.0 6.9 to 11.3 0.7 to 1.15 5.1 to 8.32
*Cylinder Head Screw M11 x 1.25 93.1 to 98.0 9.5 to 10.0 68.7 to 72.3
*Main Bearing Case Screw 1 M9 x 1.25 46.1 to 50.9 4.7 to 5.2 34.0 to 37.6
*Main Bearing Case Screw 2 M10 x 1.25 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2
*Flywheel Screw M12 x 1.25 98.09 to 107.8 10.0 to 11.0 72.3 to 79.5
*Connecting Rod Screw M8 x 1.0 44.1 to 49.0 4.5 to 5.0 32.5 to 36.2
*Rocker Arm Bracket Screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Idle Gear Shaft Screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Crank Pulley Mounting Nut -- 137.3 to 156.9 14.0 to 16.0 101.3 to 115.7
*Bearing Case Cover Screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Glow Plug M10 x 1.25 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Nozzle Holder Clamp Screw -- 25.5 to 29.4 2.6 to 3.0 18.8 to 21.7
Oil Switch Taper Screw PT1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
Injection Pipe Retaining Nut M12 x 1.5 14.7 to 24.5 1.5 to 2.5 10.8 to 18.1
Overflow Pipe Assembly Retaining Screw -- 9.8 to 11.3 1.0 to 1.15 7.2 to 8.3
Camshaft Set Screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Hi--idling Body -- 44.1 to 49.0 4.5 to 5.0 32.6 to 36.3
1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Special Screw and Bolt
Grade 4 Grade 7
N.m kgf.m ft--lbs N.m kgf.m ft--lbs
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be
sure to check out the numbers as shown below
Punched Number Screw And Bolt Material Grade
None or 4 Standard Screw And Bolt SS400, S20C
7 Special Screw And Bolt S43C, S48C (Refined)
62--10865 1-4
1.6 TROUBLESHOOTING
Symptom Probable Cause Solution Reference
Engine Does Not --
No Fuel Replenish fuel
Start --
Air in the fuel system Vent Air
1.8.4
Water in the fuel system Change fuel and
1.8.4
repair or replace fuel
system
Fuel Pipe clogged Clean
1.8.4
Fuel filter clogged Clean or change
--
Excessively high viscosity fo fuel or engine oil Use specified fuel or
--
at low temperature engine oil
Fuel with low cetane number Use specified fuel
--
Incorrect injection timing Adjust
5.1.1
Injection nozzle clogged Replace
1.8.10
Injection pump malfunctioning Replace
--
Seizure of crankshaft, camshaft, piston, Repair or Replace
--
cylinder or bearing
Compression leak from cylinder Replace head
--
gasket, tighten
--
cylinder head screw,
--
glow plug and nozzle
--
holder
Improper valve timing Correct or replace
2.2.5.f
timing gear
Piston ring and cylinder worn Replace
2.3.3.d
Excessive valve clearance Adjust
1.8.9
(Starter Does Not
Battery discharged Charge
Run)
Starter malfunctioning Repair or replace
6.2
Key switch malfunctioning Repair or replace
--
Wiring disconnected Connect
--
Engine Revolution Fuel filter clogged or dirty Clean or change 1.8.4
Is Not Smooth Air cleaner clogged or dirty Clean or change --
Fuel leak due to loose injection pipe retaining Tighten retaining nut --
nut
Injection pump malfunctioning Replace 5.1
Incorrect nozzle injection pressure Replace 1.8.10.a
Injection nozzle stuck or clogged Replace 1.8.10.c
Either White or Blue Excessive engine oil Reduce to specified 1.8.1
Exhaust Gas Is level
Observed Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1
Deficient compression Check the cylinder 2.1.1
compression
pressure and top
clearance
Either Black or Dark Overload Lesson load --
Exhaust Gas Is Low grade fuel used Use specified fuel --
Observed Fuel filter clogged Clean or change --
Air cleaner clogged Clean or change --
Deficient nozzle injection Replace nozzle 1.8.10
Deficient Output Incorrect injection timing Adjust 5.1.1
Engine’s moving parts seem to be seizing Repair or replace --
Injection pump malfunctioning Replace 5.1
Deficient nozzle injection Replace nozzle 1.8.10.b
Compression leak Check the 2.1.1
compression
pressure and repair
Gas leak from exhaust system Repair or replace --
Air cleaner dirty or clogged Clean or replace --
1-5 62--10865
1.6 TROUBLESHOOTING (Continued)
Symptom Probable Cause Solution Reference
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap 2.2.6.b
Oil Consumption direction
Oil ring worn or stuck Replace 2.3.3.d
Piston ring groove worn Replace worn piston 2.3.3.e
Valve stem and valve guide worn Replace 2.3.1.d
Crankshaft bearing, and crank pin bearing Replace 2.3.4
worn
Oil leaking due to defective seals or packing Replace --
Fuel Mixed into Injection pump’s plunger worn Replace Injection 5.1
Lubricant Oil pump
Deficient nozzle injection Replace nozzle 1.8.10.c
Injection pump broken Replace 5.1
Water Mixed into Head gasket defective Replace 2.2.4.d
Lubricant Oil Cylinder block or cylinder head flawed Replace --
Low Oil Pressure Engine oil level low Replenish --
Oil strainer clogged Clean --
Relief valve stuck with dirt Clean 3.1.2
Relief valve spring weak or broken Replace 3.1.2
Excessive oil clearance of crankshaft bearing Replace 2.3.4.d
Excessive oil clearance of crankpin bearing Replace 2.3.4.c
Excessive oil clearance of rocker arm Replace 2.3.1.k

Oil passage clogged Clean --
Incorrect oil type Use specified type of --
oil
Oil pump defective Repair or replace 3.2
High Oil Pressure Incorrect oil type Use specified type of --
oil
Relief valve defective Replace 3.1.2
Engine Overheated Engine oil level low Replenish --
Fan belt broken or elongated Replace or adjust --
Coolant insufficient Replenish --
Radiator net and radiator fin clogged with dust Clean --
Inside of radiator corroded Clean or replace --
Coolant flow route corroded Clean or replace --
Radiator cap defective Replace --
Overload running Loosen load --
Head gasket defective Replace 2.2.4.d
Incorrect injection timing Adjust --
Unsuitable fuel used Use specified fuel --
Low Battery Charge Battery electrolyte level low Replenish distilled --
water and charge
Fan belt slips Adjust belt tension or --
change belt
Wiring disconnected Connect --
Rectifier defective Replace --
Alternator defective Replace --
Battery defective Change --
62--10865 1-6
1.7 SERVICING SPECIFICATIONS
1.7.1 Engine Body
Item Factory Specification Allowable Limit
Cylinder Head Surface Flatness --
D
Compression Pressure 2.94 to 3.24 MPa/ 2.35 MPa/
290 rpm 290 rpm
30 to 33 kgf/cm2 24kgf/cm2
290 rpm 290 rpm
427 to 469 psi/ 341 psi/
290 rpm 290 rpm
Difference among cylinders -- 10% or less

Top Clearance 0.60 to 0.70 mm --
0.0236 to 0.0276 in.
Valve Clearance (When Cold) 0.18 to 0.22 mm --
0.0071 to 0.0087 in.
Valve Seat Width (Intake) 2.12 mm --
0.0835 in.
Width (Exhaust) 2.12 mm --

0.0835 in.
Valve Seat Angle 0.785 rad. --
(Intake / Exhaust) 45
Valve Face Angle 0.785 rad. --
(Intake / Exhaust) 45
Valve Stem to Valve Guide Clearance 0.040 to 0.070 mm 0.1 mm
0.0016 to 0.0028 in. 0.0039 in.
Valve Stem O.D. 7.960 to 7.975 mm --

0.31339 to 0.31398 in.
Valve Guide I.D. 8.015 to 8.030 mm --

0.31555 to 0.31614 in.
Valve Recessing Protrusion 0.05 mm --
0.0020 in.
to
Recessing 0.15 mm --
0.0059 in.
Valve Timing (Intake Valve) Open 0.14 rad. (8) --
before T.D.C.
Close 0.35 rad. (20) --

before T.D.C
Valve Timing (Exhaust Valve) Open 0.87 rad. (50) --
before B.D.C.
Close 0.21 rad. (12) --

before B.D.C
1-7 62--10865
1.7.1 Engine Body (Continued)
Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm
1.6417 to 1.6614 in. 1.6220 in.
Setting Load/ 117.6 N / 35.0 mm 100.0N / 35.0 mm

Setting Length 12.0 kgf / 35.0 mm 10.2kgf / 35.0 mm
26.4 lbs. / 1.3780 in. 22.5lbs /1.3780 in
Tilt -- 1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 1.0 mm
0.00063 to 0.00177 in. 0.039 in.
Rocker Shaft O.D. 13.973 to 13.984 mm --

0.55012 to 0.55055 in.
Rocker Arm I.D. 14.000 to 14.018 mm --

0.55118 to 0.55189 in.
Push Rod Alignment -- 0.25mm
0.0098 in.
Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm
0.00079 to 0.00244 in. 0.0028 in.
O.D. 23.959 to 23.980 mm --

0.94327 to 0.94410 in.
I.D. 24.000 to 24.021 mm _

0.94488 to 0.94571 in.
Timing Gear
Crank Gear to Idle Gear Backlash 0.0415 to 0.2211 mm 0.15 mm
0.00163 to 0.00442 in. 0.0059 in.
Idle Gear to Cam Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

0.00163 to 0.00454 in. 0.0059 in.
Idle Gear to Injection Pump Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

0.00163 to 0.00454 in. 0.0059 in.
Crank Gear to Oil Pump Gear Backlash 0.0415 to 0.1090 mm 0.15 mm

0.00163 to 0.00429 in. 0.0059 in.
Idle Gear Side Clearance 0.12 to 0.48 mm 0.9 mm
0.0047 to 0.0189 in. 0.0039 in.
Idle Gear Shaft to Idle Gear Bushing Clearance 0.025 to 0.066 mm 0.1 mm
0.00098 to 0.00260 in. 0.0039 in.
Idle Gear Shaft O.D. 37.959 to 37.975 mm --

1.49445 to 1.49508 in.
Idle Gear Bushing I.D. 38.000 to 38.025 mm --

1.49606 to 1.49704 in.
62--10865 1-8
Camshaft Side Clearance 0.07 to 0.22 mm 0.3 mm
0.0028 to 0.0087 in. 0.0118 In.
Camshaft Alignment -- 0.01 mm
0.0004 in.
Cam (Lobe) Height (Intake) 33.27 mm 33.22 mm
1.3098 in. 1.3709 in.
Height (Exhaust) 33.47 mm 33.42

1.3177 in. 1.3158 in.
Camshaft Journal to Cylinder Block Bore Clearance 0.050 to 0.091 mm 0.15 mm
0.0020 to 0.0036 in. 0.00059 in.
Camshaft Journal O.D. 39.934 to 39.950 mm --

1.57221 to 1.57284 in.
Cylinder Block Bore I.D. 40.000 to 40.025 mm --

1.57480 to 1.57579
Piston Pin Bore I.D. 25.000 to 25.013 mm 25.05 mm
0.98425 to 0.98476 in. 0.9862 in.
Second Ring to Ring Groove Clearance 0.093 to 0.128 mm 0.2 mm
0.0037 to 0.0050 in. 0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.052 mm 0.15 mm
0.0008 to 0.0020 in. 0.0059 in.
Top Ring Ring Gap 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Second Ring Ring Gap 0.40 to 0.55 mm 1.25 mm
0.0157 to 0.0217 in. 0.0492 in.
Oil Rng Ring Gap 0.20 to 0.40 mm 1.25 mm
0.0079 to 0.0157 in. 0.0492 in.
Connecting Rod Alignment -- 0.05 mm
0.0020 in.
Piston Pin to Small End Bushing Clearance 0.014 to 0.038 mm 0.15 mm
0.00055 to 0.00150 in. 0.0059 in.
Piston Pin O.D. 25.002 to 25.011 mm --

0.98433 to 0.98468 in.
Small End Bushing I.D. 25.025 to 25.040 mm --

0.98523 to 0.98582 in.
Crankshaft Alignment -- 0.02 mm
0.00059 in.
Crankshaft Journal to Crankshaft Bearing1 Oil Clearance 0.040 to 0.118 mm 0.2 mm
0.00157 to 0.00465 in. 0.0079 in.
Crankshaft Journal O.D. 59.921 to 59.940 mm --

2.35909 to 2.35984 in.
Crankshaft Bearing1 I.D. 59.980 to 60.039 mm --

2.36142 to 2.36374 in.
1-9 62--10865
Crankshaft Journal to Crankshaft Bearing2 Oil Clearance 0.040 to 0.104 mm 0.2 mm
0.00157 to 0.00409 in. 0.0079 in.
Crankshaft Journal O.D. 59.921 to 59.940 mm --

2.35909 to 2.35984 in.
Crankshaft Bearing2 I.D. 59.980 to 60.025 mm --

2.36142 to 2.36318 in.
Crankpin to Crankpin Bearing Oil Clearance 0.025 to 0.087 mm 0.2 mm
0.00098 to 0.00343 in. 0.0079 in.
Crankpin O.D. 46.959 to 46.975 mm --

1.84878 to 1.84941 in.
Crankpin Bearing I.D. 47.000 to 47.046 mm --

1.85039 to 1.85220 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.5 mm
0.0059 to 0.0122 in. 0.0197 in.
Crankshaft Sleeve Wear -- 0.1mm
0.0039 in.
Cylinder Bore
(Standard) I.D. 87.00 to 87.022mm 0.15mm
3.42519 to 3.42606 in. 0.0059 in.
(Oversize) O.D. 87.250 to 87.272 mm 0.15mm

3.43503 to 3.43590 in. 0.0059 in.
62--10865 1-10
1.7.2 Lubricating System
Engine Oil Pressure At Idle Speed -- 49kPa
0.5 kgf/cm2
7 psi
At Rated Speed 294 to 441 kPa 245kPa

3.0 to 4.5kgf/cm2 2.5kgf/cm2
43 to 64 psi 36 psi
Engine Oil Pressure Switch Working 49 kPa --
Pressure 0.5kgf/cm2
7 psi
Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm 0.2 mm
0.0012 to 0.0055 in. 0.0079 in.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm 0.25 mm
0.0043 to 0.0075 in. 0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm 0.2 mm
0.00413 to 0.00591 in. 0.0079 in.
1.7.3 Cooling System

V--Belt Tension 7.0 to 9.0 mm (0.28 to --
0.35 in.) deflection at
98N(10kgf, 22 lbs.)
of force
Thermostat Valve Opening 80.5 to 83.5C --
Temperature 176.9 to 182.3F
(At Beginning)
Valve Opening 95C --

Temperature 203F
(Opened
Completely)
1.7.4 Fuel System

Injection Pump V2203--DI-- Injection Timing 0.07 to 0.10 rad. (4.25 to --
E2B--CTD--7 5.75) before T.D.C.
V2203--DI-- 0.05 to 0.07 rad. (2.75 to

V2203--DI 0.08 to 0.11 rad. (4.75 to

1-11 62--10865
1.7.5 Electrical System
Starter
Commutator V2203--DI-- O.D. 30.0 mm 29.0 mm
E2B--CTD--6 1.181 in. 1.142 in.
V2203--DI--
E2B--CTD--4 & --7
Mica V2203--DI-- Undercut 0.50 to 0.80 mm 0.20 mm

E2B--CTD--6 0.0197 to 0.0315 in. 0.0079 in.
V2203--DI-- 0.50 to 0.90 mm 0.20 mm

E2B--CTD--4 & --7 0.0197 to 0.0354 in. 0.0079 in.
Brush Length 0.15 mm 11.0 mm

0.591 in. 0.433 in.
Brush Holder and Resistance Infinity _

Holder Support
Glow Plug Resistance Approximately 1 OHM --
62--10865 1-12
1.8 CHECK AND MAINTENANCE
NOTE
1.8.1 Checking Engine Oil Level
When adding coolant to the system, air must be
vented from the engine coolant passages. The
air vents by jiggling the upper and lower radiator
hoses.
Be sure to close the radiator cap securely. If the
cap is loose or improperly closed, coolant may
leak out and the engine could overheat.
Do not use an antifreeze and scale inhibitor at
the same time.
Never mix different types or brands of coolants.
Figure 1-2. .
1. Level the engine. 1.8.3 Checking Fuel Hose
2. to check the oil level, draw out the dipstick (1), wipe it 1. If the clamp is loose, apply oil to the threads and
clean, reinsert it, and draw it out again. Check to see securely retighten it.
that the oil level lies between the two notches. 2. The fuel hose is made of rubber and ages regardless
3. If the level is too low, add new oil to the specified of the service period. Change the hose and clamps
level. together every two years.
3. Change the fuel hose and clamps whenever any de-
terioration or damage is detected.
NOTE 4. After the fuel hose and clamps have been changed,
bleed air out of the fuel system.
When adding oil to the crankcase, be sure that
the fresh oil is the same type and viscosity as
the oil that is already in the crankcase. Never CAUTION
mix two different types of oil.
Stop the engine when attempting to check
1.8.2 Checking Coolant Level and change the fuel line.
1. Remove the radiator cap and check to see that the
coolant level is just below the port.
With the recovery tank: Check to see that the coolant
level lies between FULL and LOW.
2. If the coolant level is too low, check the reason for the
lost coolant.
1. If coolant loss is due to evaporation, add only clean
soft water.
2. If coolant loss is due to a leak, add a coolant mixture
of the same type and specification that is in the
system. If the coolant brand cannot be identified,
drain out all of the remaining coolant and refill with a
totally new mix. 1.8.4 Bleeding Fuel System
1. Open the air vent cock (1) on top of the fuel injection
CAUTION pump.
2. Loosen the priming pump handle (2), and pump the
Do not remove the radiator cap until the handle until bleeding is completed.
coolant temperature is below its boiling 3. Depress and twist the priming pump handle clock-
point. Loosen the cap slightly to relieve ex- wise to lock into place.
cess pressure before removing the cap 4. Close the air vent cock (1).
completely.
NOTE
Always keep the air vent cock on the fuel injec-
tion pump closed except when bleeding the fuel
system, or the engine may not run.
1-13 62--10865
1.8.5 Checking V--Belt Tension 1.8.8 Changing Engine Oil
CAUTION
Stop the engine when preparing to change
the engine oil.
1. After warming up the engine, shut it off.

2. Place a pan underneath the engine.
3. Remove the drain plug, drain the engine oil complete-
ly.
4. Inspect the drain plug gasket. Replace if necessary.
1. Press the V--belt mid--way between the fan pulley and
pulley with a force of 98N (10kgf, 22lbs). 5. Reinstall the drain plug.
2. If the deflection is not within the factory specifications, 6. Fill the crankcase with new oil.
adjust with the tension pulley adjusting bolts
1.8.6 Checking V--Belt Wear NOTE
When changing to a different oil manufacturer
or viscosity, be sure to remove all of the old oil
completely. Never mix different types of oil.
Use only MIL--L--46152 / MIL--L--2104C or API
classification CG--4 or CH--4 / CI oils.
Use the proper SAE Engine oil according to the
ambient temperatures.
Above 25C (77F).............SAE 30 or 10W--30
0 to 25C (32 to 77F)......SAE 20 or 10W--30
1. Check the V--belt for wear. Below 0C (32F)............SAE 10W or 10W--30
2. It should ride in the pulleys at the right depth (A).
3. If the belt is worn enough to bottom in the pulley (B) NOTE
replace the belt.
1.8.7 Checking V--Belt Damage With emission controls now in effect, the CG--4
or CH--4 / CI lubricating oils have been devel-
oped for use of a low--sulfur fuel on--road ve-
hicles engines. When an off--road vehicle en-
gine runs on a high--sulfur fuel, it is advisable to
employ the CH--4 / CI lubricating oil with a high
total base number. If the CG--4 lubricating oil is
used with a high sulfur fuel, change the lubricat-
ing oil at shorter intervals.
Lubricating oil recommended when a low--sulfur or

high--sulfur fuel is employed.
Fuel
1. Check the V--belt for damage.
Low-- High-- Remarks
2. If the belt shows signs of chaffing or damage (see sulfur sulfur
above), replace the belt. Lubricating
Oil Class
CG--4
O X
CH--4 or CI
O X
O : Recommended X : Not Recommended
62--10865 1-14
1.8.9 Valve Clearance
NOTE
Valve clearance must be checked and adjusted
when the engine is cold.
1. Remove the valve cover.

2. Align the “1TC” mark line (3) on the flywheel and pro-
jection (2) on the housing so that the Number 1 piston
comes to compression or overlap top dead center
(TDC).
3. Check the following valve clearance (1) marked with
“*” using a feeler guage.
4. If the clearance is not within the factory specifica-
tions, adjust with the adjusting screw.
Valve
Arrangement
Piston Location in Cylinder IN. EX.
No. 1 * *
When No. 1 piston is at TDC No. 2 *
No. 3 *
No. 4
No. 1
No. 2 *
When No.
No 1 piston is at past TDC
No. 3 *
No. 4 * *
1-15 62--10865
1.8.10 Fuel Injection
WARNING
Check the injection nozzle only after con-
firming that nobody is near the spray. If the
spray from the nozzle contacts the human
body, cells may be destroyed and blood
poisoning may result.
1.8.10.a Fuel Injection Pressure

1. Set the injection nozzle in a nozzle tester.
2. Slowly move the tester handle to measure the pres-
sure at which fuel begins jetting out from the nozzle.
3. If the measurement is not within factory specifica-
tions, replace the nozzle assembly.
Fuel Injection 18.6 to 20.1 MPa

Factory
Pressure 190 to 205 kgt/cm2
Specification
1st Stage 2702 to 2916 psi
1.8.10.b Nozzle Spraying Condition

1. Set the injection nozzle in a nozzle tester and check
the nozzle spraying condition.
2. If the spraying condition is defective, replace the
injection nozzle assembly.
(a) Good (b) Bad
1.8.10.c Valve Seat Tightness

2. Raise the fuel pressure, and maintain 12.7MPa (130
kgf/cm2, 1850 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle
assembly.
No fuel leak at
Valve Seat Factory 16.67MPa
Tightness Specification 170 kgf/cm2
2418 psi
62--10865 1-16
1.9 SPECIAL TOOLS
Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number
62--03213.
1.9.1 Diesel Engine Compression Tester (Glow
Plug)
Part No. 07-00179-01 (Assembly)
Application: Use to measure diesel engine
compression and diagnosis for
major overhaul.
1.9.2 Adapter, Kubota 10 mm

Part No. 07-00179-05
Application: Accessory for 07-00179-01
1.9.3 Tester Injector Nozzle

Part No. 07-00140-00
Application: Injector nozzle tester kit used for
checking and adjusting of the fuel injectors in diesel
engines.
1.9.4 Replacement Bowl, Tester Injector Nozzle

Part No. 07-00140-10
1.9.5 Adapter, Injector Line

Part No. 07-00036-00
1-17 62--10865
1.9 SPECIAL TOOLS (Continued)
1.9.6 Oil Pressure Tester
Code No. 07916--32032
Application: Use to measure lubricating oil
pressure.
1. Guage 5. threaded Joint

2. Adapter 2 6. Adapter 4
3. Cable 7. Adaptor 1
4. Adapter 3 8. Adaptor 3
1.9.7 Auxiliary Socket For Fixing Crankshaft

Sleeve
Code No. 07916--32091
Application: Use to fix the crankshaft sleeve of the
diesel engine.
62--10865 1-18
The following are drawings for special tools that may need to be fabricated.
1.9.8 Valve Guide Replacing Tool
Application: Use to press out and press fit the valve
guide.
A 20 mm dia. (0.79 in. dia.)
B 11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)
C 6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
D 225 mm (8.86 in.)
E 70 mm (2.76 in.)
F 45 mm (1.77 in.)
G 25 mm (0.98 in.)
H 5 mm (0.197 in.)
I 6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)
J 20 mm dia. (0.787 in. dia.)
K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L 8.9 to 9.1 mm (0.350 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039in.)
C2 Chamfer 2.0 mm (0.079in.)
C0.3 Chamfer 0.3 mm (0.012in.)
1.9.9 Bushing Replacing Tools
Application: Use to press out and press fit the bushing.
1. For small end bushing.
A 162 mm (6.38 in.)
B 35 mm (1.38 in.)
C 27 mm (1.06 in.)
D 35 mm dia. (1.38 in. dia.)
E 27.90 to 27.95 mm dia. (1.098 to 1.100 in. dia.)
F 25.00 to 25.01 mm dia. (0984 to 0.985 in. dia.)
2. For idle gear bushing.

A 175 mm (6.89 in.)
B 40 mm (1.57 in.)
C 38 mm (1.49 in.)
D 45 mm (1.77 in.)
E 41.90 to 41.95 mm dia. (1.650 to 1.652 in. dia.)
F 37.95 to 37.97 mm dia. (1.494 to 1.495 in. dia.)
1.9.10 Flywheel Stopper

Application: Use to loosen and tighten the flywheel
screw.
A 200 mm (7.87 in.)
B 20 mm (0.79 in.)
C 30 mm (1.18 in.)
D 8 mm (0.31 in.)
E 10 mm (0.39 in.)
1-19 62--10865
1.9.11 Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft
bearing No. 1
1. Extracting tool
A 130 mm (5.31 in.)
B 72 mm (2.83 in.)
C R40 mm (R1.57 in.)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
H 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
2. Extracting tool
A 130 mm (5.31 in.)
B 72 mm (2.83 in.)
C R40 mm (R1.57 in.)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.68 in. dia.)
I 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
J 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
62--10865 1-20
SECTION 2
ENGINE BODY
2.1 Checking and Adjusting

2.1.1 Compression Pressure 2.1.2 Top Clearance
1 Run the engine until it is warmed up.

2 Stop the engine and disconnect the 2P connector
from the stop solenoid prevent fuel delivery to the
engine.
3 Remove the the air cleaner, the muffler and all the
glow plugs.
4 Install a compression tester with the adapter in one of
the glow plug holes.
5 While cranking the engine with the starter measure
the compression pressure.
6 Repeat steps 1 thru 5 for each cylinder.
7 If the measurement is below the allowable limit, add a 1. Piston 2 Plastic gauge
small amount of oil to the cylinder thru the glow plug
hole and measure the compression again.
8 If the compression pressure is still less than the allow-
able limit, check the top clearance, valves and cylin-
der head. 1 Remove the cylinder head.
9 If the compression pressure increases after applying 2 Move the piston (1) up and stick a strip of plastic
oil, check the cylinder wall and piston rings. gauge (2) on the piston head at three positions shown
on the illustration.
NOTE 3 Lower the piston and install the cylinder head. (Use a
new cylinder head gasket and tighten the cylinder
Check the compression pressure with the spe- head bolts to the proper torque.
cified valve clearance 4 Turn the flywheel until the piston (1) passes through
top dead center.
Always use a fully charged battery for perform-
ing this test. 5 Remove the cylinder head and measure the plastic
guage.
Variances in cylinder compression values
should be under 10%. 6 If the measurement is not within the factory specifica-
tions, check the clearances between the crank pin
and bearing and between the piston pin and bushing.
2.94 to 3.24 MPa
Factory
30 to 33 kgt/cm2 Factory 0.60 to 0.70 mm
Specification Top Clearance
Compression Pres- 427 to 469 psi Specification 0.0236 to 0.0276 in.
sure 2.35 MPa 93.1 to 98.0 N.m
Tightening Cylinder Head
Allowable Limit 24 kgt/cm2 9.5 to 10.0 kgf.m
Torque Screws
341 psi 68.7 to 72.3 ft--lbs
2-1 62--10865
2.2 Disassembling And Assembling
2.2.1 Draining Coolant And Engine Oil 2.2.2 External Components
Air Cleaner, Muffler and Others
CAUTION 1 Remove the air cleaner and muffler.

2 Remove the fan, fan belt, alternator and starter.
Never remove the radiator cap until coolant When Reassembling
temperature is below its boiling point.
Loosen the cap slightly to the first stop to
relieve any excess pressure before remov- NOTE
ing the cap completely.
Check to see that there are no cracks on the belt
surface.
1 Open the coolant drain cock or remove the coolant After reinstaling the fan belt, be sure to adjust
drain plug and drain the coolant into a proper recep-
tacle/bucket. the fan belt tension.
2 Remove the oil drain plug and drain the engine oil into When reinstalling the fan, make sure that it is
a proper receptacle/bucket. put on correctly.
62--10865 2-2
2.2.3 Cylinder Head And Valves
2.2.3.a Valve Cover
1 Remove the head (1).
2 Remove the breather hose (2).
3 Remove the valve cover screws (3).
4 Remove the valve cover (4).
When Reassembling
Check to see that the valve cover gasket (5) is in good
condition and in place.
6.9 to 11.3 N.m
Tightening Valve Cover
0.7 to 1.15 kgf.m
Torque Screws
5.1 to 8.32 ft--lbs
1. Head 5. Valve Cover Gasket

2. Breather Hose 6. Breather Valve
2.2.3.b Injection Pipes
3 Valve Cover Screw 7. Plate 1 Loosen the screws on the pipe clamps.
4. Valve Cover 2 Detach the injection pipes.
When Reassembling
Blow out any debris that may be in the pipes.
Injection Pipe 14.7 to 24.5 N.m
Tightening
Retaining 1.5 to 2.5 kgf.m
Torque
Nut 10.8 to 18.1 ft--lbs
2-3 62--10865
2.2.4 Cylinder Head And Valves (Continued)
2.2.4.a Nozzle Holder Assembly and Glow Plug
1 Remove the overflow pipe assembly.
2 Remove the glow plugs (1).
3 Remove the nozzle holder assemblies (2).
When Reassembling
Replace the copper gasket with a new one.
25.5 to 29.4 N.m

Nozzle Holder
2.6 to 3.0 kgf.m
Clamp Screw
18.8 to 21.7 ft--lbs
Overflow Pipe 9.8 to 11.3 N.m
Assembly 1.00 to 1.15 kgf.m
Retaining Screw 7.2 to 8.3 ft--lbs
19.6 to 24.5 N.m
Tightening
Glow Plug 2.0 to 2.5 kgf.m
Torque
14.5 to 18.1 ft--lbs
25.5 to 29.4 N.m
Injection Nozzle
2.6 to 3.0 kgf.m
Mounting Bolt
18.8 to 21.7 ft--lbs
0.98 to 1.77 N.m
Glow Plug
0.10 to 0.18 kgf.m
1. Glow Plug 4. Nozzle Clamp Terminal
0.72 to 1.30 ft--lbs
2. Injection Nozzle Assembly 5. O-Ring
3 Nozzle Mounting Bolt 6. Copper Gasket
2.2.4.b Rocker Arm and Push Rod
1 Remove the rocker arm bracket mounting bolts (1).
2 Detach the rocker arm assembly (2).
1 Remove the push rods (3).
When Reassembling
When putting the push rods (3) onto the tappets (4),
check to see if the end are properly engaged with the
dimples.
NOTE
After instaling the rocker arm, be sure to adjust

the valve clearance. See S--17??
Factory 0.18 to 0.22 mm

Valve Clearance
Specification 0.0071 to 0.0086 in.
1. Glow Plug 3. Nozzle Clamp
2. Injection Nozzle Assembly 4. O-Ring Rocker Arm 25.5 to 29.4 N.m
Tightening
Bracket Mounting 2.6 to 3.0 kgf.m
Torque
Bolt 18.8 to 21.7 ft--lbs
62--10865 2-4
2.2.4.c Cylinder Head
1 Loosen the hose clamp (1), and remove the water re-
turn pipe (2).
2 Remove the cylinder head bolts in the order of (r) to
(a).
3 Lift up the cylinder head and remove.
4 Remove the cylinder head gasket (3).
When Reassembling
Replace the cylinder head gasket (3) with a new one.
Note the marking (4) on the original gasket and replace
with a new one with the same marking.
Apply oil to, then re--install the cylinder head bolts.
Tighten the cylinder head bolts in sequence starting
from the center in the order of (a) to (r).
Tighten the head bolts uniformly or head warpage may
occur.
93.1 to 98.0 N.m

Tightening Cylinder Head
9.5 to 10.0 kgf.m
Torque Bolt
68.7 to 72.3 ft--lbs
NOTE
When replacing the cylinder head gasket (3), be
sure you are using a new gasket that matches
the original gasket.
When replacing any part of the reciprocating

assembly, measure the piston deck height for
each cylinder and average the results, then se-
lect the correct head gasket based on the chart
below.
2.2.4.d Selecting the Cylinder Head Gasket

Select the correct cylinder head gasket thickness:
1 Measure the piston deck height at four places on
each piston, then the four pistons by using a dial indi-
cator as shown. Average the results.
2 Select the suitable cylinder gasket using the chart.
Gasket Size Piston Protrusion

Part Number
(Marking) (deck height)
0.475 to 0.525 mm
15 1G790--03600
0.0187 to 0.0207
0.525 to 0.575 mm
20 1G790--03310
0.0207 to 0.0226
3EEADAB1P012B 0.575 to 0.625 mm
25 25-39355-00
0.0226 to 0.0246
1. Hose Clamp 5. Measuring Points 0.625 to 0.675 mm
30 1G790--03620
2. Filter-Drier Inlet A: Gear Case Side 0.0246 to 0.0266
3 Cylinder Head Gasket B: Flywheel Side 0.675 to 0.725 mm
4. Marking 35 1G790--03630
0.0266 to 0.0285
2-5 62--10865
2.2.4.e Tappets 2.2.4.f Valves
1 Remove the valve caps (2).

2 Remove the valve spring collet (3), pushing the valve
spring retainer (4) by the valve spring compressor (1).
1 Remove the tappets (1) from the crankcase. 3 Remove the valve spring retainer (4), valve spring (5)
and valve stem seal (6).
When Reassembling 4 Remove the valve.
Visually check the contact between the tappets (1) and When Reassembling
individual cam lobes. Clean the valve stem and the valve guide. Apply engine
oil to the valve stem when reassembling.
Coat the tappets with engine oil before installing them. After installing the valve spring collets (3), lightly tap the
stem with a plastic hammer to assure the collets have
seated on the valve stem.
NOTE NOTE
When re--installing tappets into the engine, When re--installing valves into the engine,
make sure that they are re--installed in their make sure that they are re--installed in their
original location. original location.
62--10865 2-6
2.2.5 Injection Pump and Gear Case
2.2.5.a Injection Pump
1 Remove the stop solenoid (1) and hi--idling body (2).
2 Remove the injection pump cover (3) with the engine
stop lever (4).
3 Disconnect the fuel hose.
4 Remove the injection pump (5).
NOTE
It is necessary to remove the injection pump (5)
after removing the stop solenoid (1) and hi--id-
ling body (2).
When Reassembling
Apply gasket sealer to both sides of the injection pump
cover gasket and install the cover and cover gasket.
Install the stop solenoid (1) and the hi--idling body (2)
after attaching the injection pump.
Replace the stop solenoid gasket and hi--idling body
gasket (6) with a new one.
Replace the injection pump, being careful to orient the
injection pump mounting bolts as shown in figure
3EEADAB1PO51A.
44.1 to 49.0 N.m
Tightening
Hi--idling Body 4.5 to 5.0 kgf.m
Torque
32.6 to 36.3 ft--lbs
1. Stop Solenoid 6. Hi--Idling Body Gasket

2. Hi--idling Body 7. Flanged Bolt
3 Injection Pump Cover 8. Hexagon Socket
4. Engine Stop Lever Headed Bolt
5. Injection Pump 2.2.5.b Speed Control Plate
1 Remove the mounting bolt/nut and lift up the speed
control plate (1).
2 Disconnect the governor spring (2).
3 Remove the control plate.
When Reassembling
Apply gasket sealer to both sides of the speed control
plate gasket.
Check that the speed control lever (3) positions low idle,
after assembling the governor spring.
Check that the speed control lever (3) returns to the high
idle position rather than the low idle position, after
1. Speed Control Plate 3 Speed Control Lever moving the lever to the maximum speed position.
2. Governor Spring
After assembling the engine, check the idling speed.
2-7 62--10865
2.2.5.c Fan Drive Pulley
1 Lock the flywheel using the flywheel stopper
2 Remove the fan drive pulley mounting nut.
3 Remove the fan drive pulley with a gear puller.
4 Remove the feather key.
When Reassembling
Apply grease to the splines of the coupling.
137.3 to 156.9 N.m

Tightening Drive Pulley
14.0 to 16.0 kgf.m
Torque Mounting Nut
101.3 to 115.7 ft--lbs
2.2.5.d Gear Case

1 Remove the gear case.
When Reassembling
Apply grease to the crankshaft oil seal lip and take car
not to roll the lip when installing the gear case.
1. Gear Case 3 Oil Seal
2. O--ring Apply gasket sealant to both sides of the gear case
gasket.
2.2.5.e Crankshaft Oil Slinger

1 Remove the crankshaft collar (3).
2 Remove the O--ring (2).
3 Detach the crankshaft oil slinger (1)
When Reassembling
1. Crankshaft Oil Slinger 3 Crankshaft Collar
2. O--ring Insert the crankshaft collar (3) after installing the gear
case to the crankcase.
2.2.5.f Idle Gear
1 Remove the external snap ring.
2 Detach the idle gear collar.
3 Detach the idle gear (2).
When Reassembling
Check to see each gear is aligned with its aligning mark.
Idle gear (2) and crank gear (4)
1. Injection pump gear 4 Crank gear
2. Idle gear 5 Oil pump drive gear Idle gear (2) and cam gear (3)
3 Cam gear
Idle gear (2) and injection pump gear
62--10865 2-8
2.2.5.g Camshaft
1 Remove the camshaft retaining bolt (2) and pull the
camshaft (1) out.
When Reassembling
Refer to installation of Idle Gear (above).
23.5 to 27.5 N.m
Tightening Camshaft
2.4 to 2.8 kgf.m
Torque retaining bolt
17.4 to 20.3 ft--lbs
1. Camshaft 2 Camshaft retaining bolt
2.2.5.h Fuel Feed Pump Holder

1 Disconnect the oil pipe (1) and fuel pipe .
2 Remove the fuel feed pump (2).
3 Remove the fuel feed pump holder (3).
When Reassembling
Replace the O--rings with new O--rings.
1. Oil Pipe 3 Fuel Feed Pump

2. Fuel Feed Pump Holder
2.2.5.i Fuel Camshaft
1 Remove the fuel camshaft stopper (1).
2 Remove the fork lever holder bolt and remove the fuel
camshaft (2) with the fork lever 1 (3) and 2 (4).
When Reassembling
Lubricate the fuel camshaft before installation.
1. Fuel camshaft stopper 3 Fork Lever 1

2. Fuel camshaft 4 Fork Lever 2
2-9 62--10865
2.2.5.j Oil Pump
1 Remove the nut.
2 Draw out the oil pump drive gear (1) with a gear puller
(2).
3 Remove the four oil pump mounting screws. Detach
the oil pump (3).
1. Oil Pump Drive Gear 3 Oil Pump

2. Gear Puller
2.2.6 Piston and Connecting Rod

2.2.6.a Oil Pan and Oil Strainer
1 Remove the oil pan mounting screws.
2 Remove the oil pan by lightly tapping the rim of the
pan with a soft hammer.
3 Remove the oil pan gasket.
4 Remove the oil strainer (1) and O--ring (2).
When Reassembling
Check to see that the oil filter strainer (1) is clean.
Visually check the O--ring (2), apply engine oil and install
it to the pick--up tube.
1. Oil Strainer
Install the strainer (1) and O--ring (2).
2. O--ring
Apply gasket sealant to the oil pan side of the oil pan
gasket and fit the gasket to the oil pan.
Install the oil pan to the engine, and tighten the oil pan
screws diagonally. Avoid uneven tightening of the oil
pan mounting screws.
2.2.6.b Pistons
62--10865 2-10
2.2.6.b Pistons (Continued)
1 Completely remove the carbon ridge (1) at the top of

the cylinder walls.
2 Remove the the connecting rod cap (3).
3 Turn the flywheel and bring the piston to top dead

center.
4 Push the piston out by lightly tapping the connecting

rod from the bottom of the crankcase with the grip of a
hammer.
5 Repeat the procedure for the other three cylinders.
When Reassembling
Liberally coat the piston and piston rings with engine oil.
When inserting the piston into the cylinder, face the

mark on the connecting rod to the injection pump.
NOTE
If re--installing the original piston assemblies

into the engine be sure that they are returned to
their original cylinder.
Place the piston rings with their gaps at 2.09

rad. (120) from the piston pin’s direction as
shown.
Carefully insert the pistons into the cylinders

using the piston ring compressor (6).
When inserting the piston into the cylinder avoid

damaging the molybdenum disulfide coating on
the piston skirt. This coating is useful in mini-
mizing the clearance between the piston and
cylinder. Cool the piston assembly before at-
tempting to insert the assembly into the cylin-
der.
When replacing a piston, use a replacement

1. Carbon 7. Piston ID Mark
piston with the same code number. The piston
2. Connecting Rod Bolt (A) Top Ring Gap
ID mark (7) is on top of the piston.
3. Connecting Rod Cap (B) Second Ring Gap
4. Connecting Rod (C) Oil Ring Gap
5. Molybdenum Disulfide (D) Piston Pin Hole
Coating on Piston Skirt 44.1 to 49.0 N.m
Tightening Connecting
6. Piston Ring Compressor (a) 2.09 rad. (120) 4.5 to 5.0 kgf.m
Torque Rod Bolt
32.5 to 36.2 ft--lbs
2-11 62--10865
2.2.6.c Piston Ring and Connecting Rod
1 Remove the piston rings (1), (2), (3).
2 Remove the piston pin (7) and then seperate the con-
necting rod (6) from the piston (5).
NOTE
Mark both the connecting rod and piston so that

if they are to be re--used that the original com-
bination of parts will go back together. Do not in-
terchange used parts.
When Reassembling
When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near the gap faces the top of
the piston (5).
When installing the oil control ring (3) onto the piston (5),
place the expander joint (10) on the opposite side of the
oil ring gap (11).
Apply engine oil to the piston pin (7).
When assembling the connecting rod (6) to the piston
(5), immerse the piston (5) in hot oil (80C / 176F) for 10
to 15 minutes, then assemble the piston, piston pin, and
connecting rod.
NOTE
Assemble the piston (5) on to the connecting

rod (6) with the FW mark (9) facing the flywheel
end and the connecting rod mark (8) facing the
injection pump side.
1. Top Ring 8. Mark

2. Second Ring 9. FW Mark
3. Oil Control Ring 10. Expander Joint
4. Piston Snap Ring 11. Oil Ring Gap
5. Piston 12. Manufacturer’s Mark
6. Connecting Rod 13. Piston ID Mark
7. Piston Pin
62--10865 2-12
2.2.7 Crankshaft
2.2.7.a Flywheel
1 Fit the flywheel stopper to the flywheel (1).
2 Remove two flywheel bolts (2).
3 Install two flywheel guide screws (3).
4 Remove all of the flywheel screws (2).
5 Remove the flywheel (1) slowly along the flywheel
guide screws (3).
When Reassembling
Install two flywheel guide screws (3).
1. Flywheel 3 Flywheel Guide Screws Check to see that the mating surfaces of the crankshaft
2. Flywheel Bolt
and flywheel are clean.
Apply engine oil to the flywheel bolts and install.
98.0 to 107.8 N.m
Tightening
Flywheel Bolts 10.0 to 11.0 kgf.m
Torque
72.3 to 79.5 ft--lbs
2.2.7.b Bearing Case Cover

1 Remove the bearing case cover mounting screws.
First, remove the inside screws (6) and then the out-
side screws (3).
2 Screw two of the removed screws into the screw hole
of the bearing case cover (5) to remove it.
NOTE
The length of the inside and the outside screws
is different. When reassembling reinstall the
appropriate screw in the correct location.
When Reassembling
Fit the bearing case gasket (1) and the bearing case
cover gasket (2) to the bearing case cover (5). Orient
them correctly.
Install the bearing case cover (5), again orienting it
correctly, using the “UP” mark.
1. Bearing Case Gasket 5. Bearing Case Cover Apply oil to the oil seal, and take care that it is not rolled
2. Bearing Case Cover 6. Bearing Case Cover
when installed.
Gasket Mounting Screw Tighten the bearing case cover screws diagonally and
3. Bearing Case Cover (a). Top evenly.
Mounting Screw
Bearing Case 23.5 to 27.5 N.m
4. Oil Seal Tightening
Cover Mounting 2.4 to 2.8 kgf.m
Torque
Screw 17.4 to 20.3 ft--lbs
2-13 62--10865
2.2.7.c Bearing Case Cover
NOTE
Before disassembling, check the side clear-
ance of the crankshaft. Check it during reas-
sembly.
1 Remove the two main bearing case screws (1).

2 Pull out the crankshaft, being careful not to damage
the crankshaft bearing (2).
1. Main Bearing Case 2 Main Bearing Case
Screw 68.6 to 73.5 N.m
Tightening Main Bearing
7.0 to 7.5 kgf.m
Torque Case Screw
50.6 to 54.2 ft--lbs
2.2.7.d Main Bearing Case Assembly

1 Remove the two main bearing case screws 1(8), and
remove the main bearing case assembly being care-
ful with the thrust bearing and crankshaft bearing.
2 Remove the main bearing case 1, 2 as above.
When Reassembling
Clean the oil passages in the main bearing case.
Apply clean engine oil to the bearings.
Install the main bearing case assemblies in their original
locations. The diameters of the main bearing cases
vary. Install them in order from the gear case end
according to their markings (A,B,C).
Match the alignment numbers (1) and mark (2) on the
main bearing case.
When installing the main bearing case 1 and 2, face the
mark “FLYWHEEL” to the flywheel.
Install the thrust bearing with its oil groove facing (7)
outward.
Confirm that main bearing case moves smoothly after
torquing the main bearing case screw to specification.
46.1 to 50.9 N.m
Tightening Main Bearing
4.7 to 5.2 kgf.m
Torque Case Screw
34.0 to 37.6 ft--lbs
1. Alignment Number 5. C
2. Alignment Mark 6. No Mark
3. A 7. Oil Groove
4. B 8. Main bearing Case Screw
62--10865 2-14
2.3 Servicing
2.3.1 Cylinder Head And Valves
2.3.1.a Cylinder Head Surface Flatness
1 Clean the cylinder head surface.
2 Place a straightedge on the cylinder head surface, in
six locations as depicted in the drawing.
3 Measure any clearance between the straightedge
and cylinder head with a feeler guage.
4 If the measurement exceeds the allowable limit,
resurface or replace the head.
NOTE
Check the valve recessing after after resurfac-
ing the head.
Cylinder Head Factory 0.05mm / 500mm

Surface Flatness Specification 0.0020 in. / 19.69 in.
2.3.1.b Cylinder Head Cracks

1 Cylinder head crack(s) can be found with using a
non--destructive test procedure using a dye/pene-
trant kit.
2 Clean the cylinder head surface using a good quality
degreaser and detergent (2).
3 Spray the cylinder head surface with the red liquid or
dye (1). Let it sit on the surface for ten minutes.
4 Wash the dye off the head using the detergent (2) and
dry the head.
1. Red Dye 3 White Developer
5 Spray the white developer (3) on to the head.
2. Detergent
6 Red marks will bleed through the developer identify-
ing cracks in the head if they are present.
2-15 62--10865
2.3.1.c Valve Recessing
1 Clean the cylinder head surface (1), valve face and

valve seat.
2 Insert the valve into the head, making certain that the
valve is fully seated.
3 Measure the valve recessing with a depth guage.
4 If the measurement exceeds the allowable limit, re-

place the valve.
5 If the measurement still exceeds the allowable limit,

replace the cylinder head.
0.05 (protrusion) mm to
Factory 0.15 (recessing) mm
Valve Specification 0.0020 (protrusion) in. to
Recessing 0.0059 (recessing) in.
0.04 (recessing) mm
Allowable Limit
0.0157 (recessing) in.
1. Cylinder Head (A) Recess

Surface (B) Protrusion
2.3.1.d Clearance Between Valve Stem And Valve

Guide
1 Remove carbon from the valve guide section.
2 Measure the valve stem O.D. with a micrometer.
3 Measure the valve guide with a small hole guage, and

calculate the clearance.
4 If the clearance exceeds the the allowable limit, re-

place the valves. If the clearance still exceeds the al-
lowable limit, replace the valve guide.
Clearance Factory 0.050 to 0.070 mm

Between Specification 0.0020 to 0.0028 in.
Valve Stem 0.1 mm
Allowable Limit
and Guide 0.0039 in.
Valve Stem Factory 7.960 to 7.975 mm

O.D. Specification 0.31339 to 0.314398 in.
Valve Guide Factory 8.015 to 8.030 mm
I.D. Specification 0.31555 to 0.31614 in.
62--10865 2-16
2.3.1.e Replacing Valve Guide
(A) (When removing)
1 Press out the used valve guide using a valve guide re-
placing tool.
(B) (When installing)
1 Clean a new valve guide and valve guide bore. then
apply oil to them.
2 Press in a new valve guide using a valve guide replac-
ing tool.
3 Ream the I.D. of the valve guide to the specified di-
mension (precisely).
Valve Guide I.D. Factory 8.015 to 8.030 mm
Intake & Exhaust Specification 0.31555 to 0.31614 in.
(A) When Removing (B) When Installing
2.3.1.f Valve Seating

1 Coat the valve face lightly with prussian blue and put
the valve on its seat to check the contact pattern
2 If the valve does not seat all the way around the valve
seat, or the contact is less than 70%, correct the valve
seating as follows.
3 If the valve contact does not comply with the refer-
ence value, replace the valve or correct the contact of
valve seating.
1. Correct 3 Incorrect
2. Incorrect
2-17 62--10865
2.3.1.g Correcting Valve and Valve Seat
NOTE
Before correcting the valve seat, make certain
that the valve and valve guide are within factory
specifications.
After correcting the valve seat, be sure to check

the valve recessing.
(A) Correcting the Valve

1 Correct the valve with a valve grinder.
(B) Correcting the Valve Seat
1 Slightly correct the valve seat surface with a 1.046
rad. (60)(intake valve) or 0.785 rad. (45)exhaust
valve seat cutter
2 Resurface the seat surface with a 0.523 rad. (30)
valve seat cutter to the Intake valve seat and with a
0.262 rad. (15) valve seat cutter to the exhaust valve
seat so that the width is close to the specified valve
seat width (2.12 mm, 0.0835 in.)
3 After resurfacing the seat, apply a thin film of valve
lapping compound between the valve and the seat,
then use a valve lapping tool to seat the valve to the
valve seat.
4 Check the valve seating with prussian blue. The
valve seating should show good contact all the way
around.
a. Identical Dimensions A. Check Correct

b. .Valve Seat Width B. Correct Seat Width
c. .0.523 rad.(30) or C Check Contact
0.262 rad.(15)
d. .0.262 rad.(15) or
0.523 rad.(30)
e. .0.785 rad.(45) or
1.047 rad.(60) 2.3.1.h Valve Lapping
1 Apply compound evenly to the valve lapping surface.
2 Insert the valve into the valve guide. Lap the valve
onto its seat with a valve lapper or screwdriver.
3 After lapping the valve, wash the compound away
and apply oil, then repeat valve lapping with oil.
4 Apply prussian blue to the contact surface to check
the contact pattern. if it is less than 70%, repeat valve
lapping again.
NOTE
When valve lapping is performed, be sure to
check the valve recessing and adjust the valve
clearance after assembling the valve.
62--10865 2-18
2.3.1.i Free Length and Tilt of Valve Spring
1 Measure the free length A of the valve spring with ver-
nier calipers. If the measurement is less than the al-
lowable limit, replace the spring.
2 Put the valve spring on a surface plate, place a
square on the side of the valve spring.
3 Check to see if the entire side is in contact with the
square. Rotate the spring and measure for maximum
tilt B. Check the entire surface of the valve spring for
defects. If any are found, replace it.
Free Length A
41.2 mm
Allowable Limit
1.6220 in.
1.0 mm
Tilt B Allowable Limit
0.039 in.
2.3.1.j Valve Spring Setting Load

1 Place the valve spring on a tester and compress it to
the same length it is actually compressed in the en-
gine.
2 Read the compression load on the guage.
3 If the measurement is less than the allowable limit, re-
place it.
117.6 N / 35 mm
Factory
12.0 kgf / 35 mm.
Specification
Setting Load / 26.4 lbs. / 1.3780 in.
Setting Length 100.0 N / 35 mm
Allowable
10.2 kgf / 35 mm.
Limit
22.5 lbs. / 1.3780 in.
2.3.1.k Oil Clearance Between Rocker Arm and

Rocker Arm Shaft
1 Measure the rocker arm shaft O.D. with an outside
micrometer.
2 Measure the rocker arm I.D. with a inside micrometer,
then calculate the oil clearance.
3 If the oil clearance exceeds the allowable limit, re-
place the rocker arm then measure the oil clearance
again. If the clearance is still out of specification, re-
place the rocker arm shaft.
Oil Clearance Specification 0.00063 to 0.00177 in.
R k Arm/
Rocker A /
Allowable 0.10 mm
Shaft
Limit 0.0039 in.
Rocker Arm Factory 13.973 to 13.984 mm
Shaft O.D. Specification 0.55012 to 0.55055 in.
Rocker Arm I.D.
2.3.1.l Push Rod Alignment

1 Place the push rod on V blocks
2 Measure the push rod alignment.
place the push rod.
Push Rod Allowable 0.25 mm
Alignment Limit 0.0098 in.
2-19 62--10865
2.3.1.m Oil Clearance Between Tappet and Tappet
Guide Bore
1 Measure the tappet O.D. with a micrometer.
2 Measure the I.D. of the tappet Guide bore with a cylin-
der guage and calculate the clearance.
3 If the measurement exceeds the allowable limit, or
the tappet is damaged, replace the tappet.
Oil Clearance Factory 0.020 to 0.062 mm
Tappet/ Specification 0.00079 to 0.00244 in.
Tappet Guide Allowable 0.07 mm
Bore Limit 0.0028 in.
Tappet O.D.
Tappet Guide I.D.
2.3.2 Timing Gears, Camshaft and Fuel Camshaft

2.3.2.a Timing Gear Backlash
1 Set a dial indicator (lever type) with its tip on the gear
tooth.
2 Move the gear to measure the backlash, holding its

mating gear.
3 If the backlash exceeds the allowable limit, check the
oil clearance of the shafts and the gear.
4 If the oil clearance is proper, replace the gear.

Backlash/ Specification 0.00163 to 0.00442 in.
Idl Gear/
Idle G /
Allowable 0.15 mm
Crank Gear
Limit 0.0059 in.
Idl Gear/
Idle G /
Allowable 0.15 mm
Cam Gear
Limit 0.0059 in.
Backlash/ Factory 0.0415 to 0.1154 mm

Idle Gear/ Specification 0.00163 to 0.00454 in.
Injection Pump Allowable 0.15 mm
Gear Limit 0.0059 in.
C k Gear/
Crank G /
Allowable 0.15 mm
Oil Pump Gear
Limit 0.0059 in.
2.3.2.b Idle Gear Side Clearance

1 Set a dial indicator with its tip on the idle gear.
2 Move the gear front to rear to measure the side clear-
ance.
place the idle gear collar.

Idle Gear Specification 0.0047 to 0.0189 in.
Sid
Side
Allowable 0.9 mm
Clearance
Limit 0.0354 in.
62--10865 2-20
2.3.2.c Camshaft Side Clearance
1 Set a dial indicator with its tip on the camshaft.
2 Move the camshaft gear front to rear to measure the
side clearance.
place the camshaft stopper.

Camshaft Specification 0.0028 to 0.0087 in.
Sid
Side
Allowable 0.30 mm
Clearance
Limit 0.0118 in.
2.3.2.d Idle Gear Shaft and Idle Gear Bushing

Clearance
1 Measure the idle gear shaft O.D. with a micrometer.
2 Measure the idle gear bushing I.D. with an inside mi-
crometer, and calculate the the clearance.
place the bushing.

Idle Gear Shaft/ Specification 0.00098 to 0.00260 in.
B hi
Bushing
Allowable 0.1 mm
Clearance
Limit 0.0039 in.
Idle Gear Shaft Factory 23.959 to 23.980 mm
Idle Gear Shaft Factory 24.000 to 24.021 mm
2.3.2.e Idle Gear Shaft and Idle Gear Bushing

Clearance
(A) When Removing
1 Press out the bushing using an Idle Gear Bushing Re-
placing Tool.
(B) When Installing
1 Clean a new idle gear bushing and the idle gear bore,
and apply engine oil to both.
2 Using the idle gear replacing tool, press in the new
bushing to the specified dimension (see B)
2-21 62--10865
2.3.2.f Camshaft Alignment
1 Support the camshaft with V blocks on a surface plate
at both end journals.
2 Set a dial indicator with its tip on the intermediate jour-
nal.
3 Rotate the camshaft and measure for run-out.
place the camshaft.
Camshaft Allowable 0.1 mm

Run--out Limit 0.0004 in.
2.3.2.g Cam Height

1 Measure the cam lobe at its largest O.D. with an out-
side micrometer.
2 If the measurement is less than the allowable limit, re-
place the camshaft.
Factory 33.27 mm
Cam Height Specification 1.3098 in.
Intake Allowable 33.22 mm
Limit 1.3079 in.
Factory 33.47 mm
Cam Height Specification 1.3177 in.
Exhaust Allowable 33.42 mm
Limit 1.3158 in.
2.3.2.h Camshaft Oil Clearance

1 Measure the camshaft journal O.D. with an outside
micrometer.
2 Measure the cylinder block camshaft bore I.D. with a
cylinder guage, and calculate the oil clearance.
3 If the oil clearance exceeds the allowable limit, re-
place the camshaft

Camshaft Journal Specification 0.0020 to 0.0036 in.
Clearance Allowable 0.15 mm
Limit 0.0059 in.
Camshaft Journal Factory 39.934 to 39.950 mm
Camshaft Journal Factory 40.000 to 40.025 mm
62--10865 2-22
2.3.3 Piston and Connecting Rod
2.3.3.a Piston Pin Bore I.D.
1 Measure the piston pin bore I.D. in both the horizontal
and vertical directions with a cylinder guage.
place the piston.
Piston Pin Bore Specification 0.98425 to 0.98476 in.
I.D. Allowable 25.05 mm
Limit 0.9862 in.
2.3.3.b Piston Pin and Bushing Clearance

1 Measure the piston pin O.D. with an outside microme-
ter.
2 Measure the connecting rod small end bushing I.D.
with an inside micrometer.
3 If the clearance exceeds the allowable limit, replace
the bushing. If the clearance is still excessive, re-
place the piston pin.
Piston Pin to Specification 0.00055 to 0.00150 in.
S ll End
Small E d Bush-
B h
Allowable 0.15 mm
ing Clearance
Limit 0.0059 in.
Piston Pin O.D.
Small End Factory 25.025 to 25.040 mm
Bushing I.D. Specification 0.98523 to 0.98582 in.
2.3.3.c Replacing Connecting Rod Small End

Bushing
(A) When Removing
1 Press out the small end bushing using a Small End
Bushing Replacing Tool.
(B) When Installing
1 Clean a new small end bushing and bore, and apply
engine oil to both.
2 Using the small end bushing replacing tool, press in
the new bushing to the specified dimension (see B).
NOTE
Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port in the con-
necting rod.
2-23 62--10865
2.3.3.d Piston Ring Gap
1 Insert the piston ring into the lower part of the cylinder
(the least worn section). Use the piston to square the
ring in the cylinder.
2 Measure the ring gap with a feeler guage.
3 If the gap exceeds the allowable limit, replace the
ring.
Top Ring
Allowable 1.25 mm
Limit 0.0492 in.
Second Ring
Allowable 1.25 mm
Limit 0.0492 in.
Oil Control Ring
Allowable 1.25 mm
Limit 0.0492 in.
2.3.3.e Piston Ring to Groove Clearance

1 Clean the rings and the ring grooves, and install each
ring in its groove.
2 Measure the clearance between the ring and its
groove with a feeler guage.
the ring.
4 If the clearance still exceeds the allowable limit after
replacing the ring, replace the piston.
Second Ring
Allowable 0.2 mm
Limit 0.0079 in.
Oil Control Ring
Allowable 0.15 mm
Limit 0.0059 in.
2.3.3.f Connecting Rod Alignment
NOTE
Since the I.D. of the connecting rod small end
bushing is the basis of this check, check the
bushing for wear before proceeding.
1 Install the piston pin into the connecting rod.
2 Install the connecting rod on the connecting rod align-
ment tool.
3 Put a guage over the piston pin and move it against
the face plate.
4 If the guage does not fit squarely against the face
plate, measure the space between the pin of the
guage and the face plate.
place the connecting rod.
Connecting Rod Allowable 0.05 mm
62--10865 2-24
2.3.4 Crankshaft
2.3.4.a Crankshaft End Clearance
1 Push on the end of the crankshaft to seat it toward the
flywheel end of the engine block.
2 Attach, then zero a dial indicator on the forward end of
the crankshaft.
3 Measure the end play by pulling the crankshaft for-
ward.
4 If the measurement exceeds the allowable limit re-
place the thrustwashers.
Crankshaft Side Specification 0.0059 to 0.0122 in.
Clearance Allowable 0.5 mm
Limit 0.0197 in.
(Reference)
Oversize dimensions of crankshaft journal.
Oversize 0.2mm / 0.0008 in. 0.4mm / 0.0016 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension A
1.0315 to 1.0335 in. 1.0394 to 1.0413 in.
54.5 to 54.7 mm 54.6 to 54.8 mm
Dimension B
2.1456 to 2.1535 in. 2.1496 to 2.1574 in.
2.8 to 3.2 mm ra- 2.8 to 3.2 mm ra-
dius dius
Dimension C
0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
The crankshaft journal must be fine-finished to higher than
0.8-S.
2.3.4.b Crankshaft Alignment

1 Support the crankshaft with V blocks on a surface
plate at both end journals, set a dial indicator with its
tip on the intermediate journal. perpendicular to the
journal.
2 Rotate the crankshaft on the V blocks and get the
misalignment (half of the measurement).
3 If the misalignment exceeds the allowable limit, re-
place the crankshaft.
Crankshaft Allowable 0.02 mm
2-25 62--10865
2.3.4.c Crankpin to Connecting Rod Bearing
Clearance
1 Clean the crankpin and the connecting rod bearing.
2 Put a strip of plastiguage on the center of the crankpin
in each direction as shown in the figure.
3 Install the connecting rod cap and tighten the screws
to the specification.
4 Remove the cap again
5 Measure the amount of the flattening with the scale to
get the clearance.
place the connecting rod bearing.
7 If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
Crankpin/ Specification 0.00098 to 0.00343 in.
C
Connecting
ti Rod
R d
Allowable 0.2 mm
Clearance
Limit 0.0079 in.

Crankpin O.D.
Connecting Rod Factory 47.000 to 47.046 mm
Bearing I.D. Specification 1.85039 to 1.85220 in.
(Reference)
Undersize dimensions of crankpin journal.
3.3 to 3.7 mm 3.3 to 3.7 mm
Dimension A
0.1299 to 0.1457 in. 0.1299 to 0.1457 in.
1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
radius radius
46.759 to 46.775 46.559 to 46.575
mm mm
Dimension C
1.84091 to 1.84154 1.83303 to 1.83366
in. radius in. radius
0.8-S.
62--10865 2-26
2.3.4.d Crankshaft Journal to Crankshaft Bearing
#1 Clearance
1 Measure the O.D. of the crankshaft journal with an
outside micrometer.
2 Measure the I.D. of crankshaft bearing #1 with an in-
side micrometer and calculate clearance.
crankshaft bearing #1.
to the table below.
Crankshaft Factory 0.040 to 0.118 mm
Journal to #1 Specification 0.00157 to 0.00409 in.
Bearing Allowable 0.2 mm
Clearance Limit 0.0079 in.
Journal O.D. Specification 2.35909 to 2.35984 in.
Crankshaft
Bearing Bearing
I.D.
(Reference) Undersize dimensions of crankshaft

journal.
Dimension A 0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
radius radius
59.721 to 59.740 59.521 to 59.540
mm mm
Dimension C
2.35122 to 2.35197 2.34335 to 2.34409
in. in.
0.8-S.
2.3.4.e Replacing Crankshaft Bearing #1

(A) When Removing
1 Press out the crankshaft bearing #1 (2) using a crank-
shaft bearing (1) replacing tool.
(B) When Installing
1 Clean a new crankshaft bearing #1 (2) and crankshaft
Journal bore, and apply engine oil to both.
2 Using the crankshaft bearing (1) replacing tool, press
in the new bearing #1 (2) so that its seam (1) directs
toward the exhaust manifold side.
NOTE
Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port in the con-
necting rod.

Dimension A
1. Seam 3 Cylinder Block

2. Crankshaft Bearing#1
2-27 62--10865
2.3.4.f Crankshaft Journal to Crankshaft Bearing
#2 Clearance
1 Put a strip of plastiguage on the center of the crank-
shaft journal.
2 Install the bearing case and tighten the screws to
specification.
3 Remove the bearing case again.
4 Measure the amount of the flattening with the scale to
get the clearance.
place crankshaft bearing #2.
to the table below.
NOTE
Be sure not to move the crankshaft while the
bearing screws are tightened.

Journal to #2 Specification 0.00157 to 0.00409 in.
Bearing Allowable 0.2 mm
Clearance Limit 0.0079 in.
Journal O.D. Specification 2.35909 to 2.35984 in.
Crankshaft
Bearing Bearing
I.D.
(Reference)
Undersize dimensions of crankshaft journal.
Dimension A 0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
radius radius
59.721 to 59.740 59.521 to 59.540
mm mm
Dimension C
2.35122 to 2.35197 2.34335 to 2.34409
in. in.
0.8-S.
2.3.4.g Crankshaft Sleeve Wear

1 Check the wear on the crankshaft sleeve (1).
2 If the wear exceeds the allowable limit or if the engine
oil leaks, replace the crankshaft sleeve (1).
Allowable 0.1 mm
Sleeve Wear
Limit 0.004 in.
62--10865 2-28
2.3.4.h Replacing Crankshaft Sleeve
1 Remove the crankshaft sleeve (3) using a special--
use puller set..
2 Set the sleeve guide (2) to the crankshaft (5).
3 Set the stopper (1) to the crankshaft (5) as shown if
the figure.
4 Heat the new sleeve to a temperature between 150 to
200C (302 to 392F), and fix the sleeve on the crank-
shaft (5) as shown in the figure.
5 Press fit the sleeve using the auxiliary socket for
pushing (4).
NOTE
Install the sleeve with the largest chamfered
surface facing outward.
1. Stopper 4. Auxiliary Socket For

2. Sleeve Guide Pushing
3. Crankshaft Sleeve 5. Crankshaft
2-29 62--10865
2.3.5 Cylinder
2.3.5.a Cylinder Wear
1 Measure the I.D. of the cylinder at the six positions

(see figure with a cylinder guage to fin the maximum
and minimum I.D.’s.
2 Determine the difference (maximum wear) between

the maximum and minimum I.D.’s.
3 If the wear exceeds the allowable limit, bore and hone

to the oversize dimension. (refer to Correcting
Cylinder)
4 Visually check the cylinder wall for scratches. If deep

scratches are found, the cylinder walls should be
bored. (refer to Correcting Cylinder)

Cylinder I.D.
Allowable 0.15 mm
Maximum Wear
Limit 0.0059 in.
a. Top a. Right--angled to
b. Middle Piston Pin
c. Bottom (skirt) b. Piston Pin Direction
2.3.5.b Correcting Cylinder (Oversize +0.25 mm)
1 When the cylinder is worn beyond the allowable limit,

bore and hone it to the specified dimension.

Cylinder I.D.
Allowable 0.15 mm
Maximum Wear
Limit 0.0059 in.
Hone to 2.2 to 3.0 mm ←R max.
Finishing
(0.00087 to 0.00118 in. ←R max.)
1. Cylinder I.D. 2 Oversize Cylinder I.D.

(before correction)
2 Replace the piston and piston rings with oversize
(+0.25 mm) ones.
62--10865 2-30
SECTION 3
LUBRICATING SYSTEM

3.1.1 Engine Oil Pressure
1 Remove the engine oil pressure switch, and install an
oil pressure guage.
2 Start the engine. After warming up, read the oil pres-
sure at idling and at rated speeds.
3 If the oil pressure is less than the allowable limit,
check the following:
Engine oil sufficient
Oil pump defective
Oil strainer clogged
Oil filter cartridge clogged
Oil gallery clogged
Excessive oil clearance
Relief valve stuck.
49 kPa
Allowable
At Idle Speed 0.5 kgf/cm2
Limit
7 psi
294.2 to 441 kPa
Factory
3.0 to 4.5 kgf/cm2
Specification
42.7 to 64 psi
At Rated Speed
245 kPa
Allowable
2.5 kgf/cm2
Limit
36 psi
(When Reassembling)
After checking the engine oil pressure, tighten the
engine oil pressure switch to the specified torque.
3.1.2 Relief Valve

1 Remove the oil filter cartridge and the oil filter base.
2 Check the relief valve for dirt, and the seat and ball for
damage.
3 If damaged, replace.
4 Check the free length of the spring.
5 if it is less than the allowable limit, replace.
Factory 35 mm
Spring Free Specification 1.38 in.
Length Allowable 30 mm
Limit 1.18 in.
39.2 to 49.0 N.m
Tightening Torque Joint 4.0 to 5.0 kgf.m
29.0 to 36.3 ft-lbs.
3--1 62--10865
3.2 Servicing
3.2.1 Rotor Lobe Clearance
1 Measure the clearance between lobes of the inner ro-
tor and the outer rotor with a feeler guage.
2 Measure the clearance between the outer rotor and
the pump body with a feeler guage.
3 If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Inner/Outer Factory 0.03 to 0.14 mm

Rotor Clearance Specification 0.0012 to 0.0055 in.
Outer Rotor/
Pump Body
Clearance
3.2.2 Rotor to Cover Clearance

1 Put a strip of plastiguage onto the rotor face with
grease.
2 Install the cover and tighten the screws.
3 Remove the cover carefully, and read the plasti-
guage.
4 If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Rotor/Cover Factory 0.105 to 0.150 mm

Clearance Specification 0.00413 to 0.00591 in.
62--10865 3--2
SECTION 4
COOLING SYSTEM

4.1.1 V--Belt Tension
1 Measure the deflection (A), by depressing the belt
halfway between the fan drive pulley and alternator
pulley at the specified force (98N, 10kgf, 22lbs).
2 If the tension is not within the factory specifications,
loosen the alternator mounting screws and move the
alternator to adjust tension.
7.0 to 9.0 mm/
Factory 98 N or 10kgf
Deflection (A)
Specification 0.28 to 0.35 in./
98 n or 22lbs
4.1.2 Fan Belt Damage and Wear

1 Check the fan belt for damage.
2 If the belt is damage in any way, replace it.
3 Check if the belt is worn and sunk in the pulley groove.
4 If the fan belt is worn and deeply sunk in the pulley
groove, replace it.
4.1.3 Thermostat Opening Temperature

1 Suspend the thermostat in water by a string with one
end of the string inserted between the valve and its
seat.
2 Immerse the thermostat in water and raise the tem-
perature of the water gradually.
3 With a thermometer, read the temperature of the
water when the valve opens and leaves the string.
4 Continue heating the water, read the temperature of
the water when the valve has opened approximately
6mm (0.236 in.
5 If the measurement is not within the factory specifica-
tions, replace the thermostat.
Thermostat
Factory 80.5 to 83.5C
Opening
Specification 176.9 to 182.3F
Temperature
Thermostat
Factory 95C
Full Open
Specification 203F
Temperature
4-1 62--10865
4.2 Disassembling and Assembling
WARNING
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may discharge from the radiator, scalding anyone nearby.
4.2.1 Thermostat Assembly
1 Remove the thermostat cover mounting screws, and
remove the thermostat cover (1).
2 Remove the thermostat assembly (3).
(When Reassembling)
Apply a liquid gasket only at the thermostat cover side of
the thermostat cover gasket.
1. Thermostat Cover 3 Thermostat Assembly

2. Thermostat Cover Gasket
62--10865 4-2
SECTION 5
FUEL SYSTEM

5.1.2 Shim Identification
Shims are available in thicknesses of o.20 mm,
0.25 mm, 0.30 mm, and 0.35mm. Combine
shims for adjustments.
5.1.1 Injection Timing

1 Remove the injection pipes from the injection pump.
2 Move the speed control lever to the maximum speed
position.
3 Turn the flywheel counterclockwise (facing the fly-
wheel) until the fuel fills up the hole of the delivery
valve holder for #1 cylinder.
1. 2-Holes: 0.20 mm shim 3 0-Holes: 0.30 mm shim
4 Turn the flywheel further and stop turning when the 2. 1-Hole: 0.25 mm shim 4 3-Holes: 0.35 mm shim
fuel begins to flow over.
5 Open the view port on the flywheel bell housing and
read the number on the flywheel. The number indi-
cated is the timing value for the engine. (The flywheel 5.1.3 Delivery Valves Fuel Seal
has a mark ’1TC’ and marks every 5 of engine timing
to 25 total). 1 Remove the injection pipes, glow plugs, and the in-
take manifold, and install a compression guage.
NOTE 2 With the speed control lever set at the full throttle
Injection timing adjustment is accomplished by position, turn the crankshaft counterclockwise until
adding or removing shims under the Injection the fuel pressure is built up.
pump.
3 Release the pressure in the delivery chamber by ro-
The timing advances by removing one shim and tating the crankshaft to bottom dead center. (turn the
retards timing by adding the same shim. crankshaft 1.57 rad. (90) clockwise from fuel timing
set point)
The addition or removal of 0.05 mm (0.0020 in.)
of shim, changes the injection timing by approx- 4 If the pressure drop for 5 seconds exceeds the allow-
imately 0.0087 rad. (0.5). able limit, replace the delivery valve or pump assem-
bly.
The sealant is should be applied to both sides of
the soft metal gasket shim. 5 If the pressure does not build up, replace the pump
element with a new one and test again.
0.07 to 0.10 rad. less than 981 kPa(10

Timing Factory
4.25 to 5.75 kgf/cm2, 142 psi pres-
26-00119-00 Specification Factory
B.T.D.C. sure drop from injec-
Specification
0.05 to 0.07 rad. tion pressure for 10
Timing Factory Delivery Valve
2.75 to 4.25 seconds
26-00119-01 Specification Fuell Tightness
F Ti ht
B.T.D.C. 981 kPa(10 kgf/cm2,
0.08 to 0.11 rad. Allowable 142 psi pressure drop
Timing Factory
4.75 to 6.25 Limit from injection pres-
26-00119-02 Specification
sure for 5 seconds
B.T.D.C.
5--1 62--10865
5.2 Injection Nozzle
WARNING
Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.
5.2.1 Nozzle Injection Pressure
2. Slowly move the tester handle to measure the pres-
sure at which fuel begins jetting out from the nozzle.
3. If the measurement is not within factory specifica-
tions, replace the nozzle assembly.
Fuel Injection Factory 18.6 to 20.1 MPa

Pressure 190 to 205 kgt/cm2
1st Stage Specification 2702 to 2916 psi
5.2.2 Nozzle Spraying Condition

1. Set the injection nozzle in a nozzle tester and check
the nozzle spraying condition.
2. If the spraying condition is defective, replace the
injection nozzle assembly.
(a) GOOD (b) BAD
5.2.3 Valve Seat Tightness

2. Raise the fuel pressure, and maintain 12.7MPa (130
kgf/cm2, 1850 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle
assembly.
No fuel leak at
Valve Seat Tight- Factory 16.67MPa
ness Specification 170 kgf/cm2
2418 psi
62--10865 5--2
SECTION 6
ELECTRICAL SYSTEM
6.1 Glow Plug

6.1.1 Lead Terminal Voltage
1. Disconnect the glow plug wiring lead (1) from the glow
plug (2).
2. Connect a voltmeter between the glow plug wiring
lead (1) and a suitable ground on the engine.
3. Energize the glow plug lead and read the voltage.
4. Energize the glowplug lead, engage the starter at the
same time and read the voltage.
5. If the voltage differs from the battery voltage in either
case, the wiring harness or the swtche(s) are faulty.
1. Wiring Lead (Positive) 2 Glow Plug
6.1.2 Glow Plug Continuity

1. Disconnect the glow plug wiring lead (1) from the glow
plug (2).
2. Measure the resistance between the glow plug termi-
nal and the engine body with an ohmmeter.
3. If 0 ohm is indicated, the glow plug may be short--cir-
cuited.
4. If the factory specification is not met the plug is also
faulty.
Glow Plug Factory
Approximately 1.0 ohm
Resistance Specification
6-1 62--10865
6.2 Starter Test
6.2.1 Motor Test
WARNING
Secure the starter to prevent it from moving
when power is applied to it.
1. Disconnect the cable from the negative terminal on

the battery
2. Disconnect the the positive cable and leads from the
starter B terminal.
1. C Terminal 2 Connecting Lead 3. Remove the starter from the engine.
4. Disconnect the the connecting lead (2) from the start-
er solenoid C terminal (1).
5. Connect a jumper lead from the connecting lead (2) to
the positive post on the battery.
6. Connect a jumper lead momentarily between the
starter motor housing and the negative post on the
battery.
7. If the starter does not run, check the motor.
8.8 to 11.8 N.m
B
Tightening Torque 0.9 to 1.2 kgf.m
Terminal Nut
6.5 to 8.7 ft-lbs.
6.2.2 Magnetic Switch Test

1. Disconnect the cable from the negative terminal on
the battery
2. Disconnect the the positive cable and leads from the
starter B terminal.
3. Remove the starter from the engine.
4. Disconnect the the connecting lead (1) from the start-
er solenoid C terminal (2).
5. Connect a jumper lead from the starter S terminal (3)
to the positive battery post.
6. Momentarily, connect a jumper lead between the
starter C terminal (2) and negative battery terminal.
7. If the pinion gear nose does not pop out, check the
magnetic switch.
1. Connecting Lead 3 S terminal NOTE
2. C Terminal This test should only be carried out for a 3 to 5
second time period and not longer.
62--10865 6-2
6.3 Starter Disassembly And Assembly
6.3.1 Disassembling Motor
1. Disconnect the connecting lead (9) from the solenoid
(8).
2. Remove the screws (6), and then separate the end
frame (4), yoke (2) and armature (1).
3. Remove the two screws (5), and then take out the
brush holder (3) from the end frame (4).
When Reassembling
Apply grease to the spline teeth A of the armature (1).
5.9 to 11.8 N.m
Tightening Torque Nut (7) 0.6 to 1.2 kgf.m
1. Armature 6. Screw
4.3 to 8.7 ft-lbs.
2. Yoke 7. Nut
3 Brush Holder 8. Magnetic Switch
4. End Frame 9. Connecting Lead
5. Screw A Spline Teeth
6.3.2 Disassembling The Solenoid

1. Remove the drive end frame (1) mounting screws.
2. Take out the overrunning clutch (2), ball (3), spring
(4), gear (5), rollers (6) and retainer (7).
When Reassembling
Apply grease to the gear teeth of the gear (5),
overrunning clutch (2) and ball (3).
1. Drive End Frame 5. Gear

2. Overrunning Clutch 6. Roller
3 Ball 7. Retainer
4. Spring
6.3.3 Plunger
1. Remove the end cover (1).
2. Take out the plunger (2).
1. End Cover 2 Plunger
6-3 62--10865
6.4 Starter Servicing
6.4.1 Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the assembly.
3. Check tat the pinion turns freely and smoothly in the
overrunning direction and does not slip in the crank-
ing direction.
4. If the pinion slips or does not rotate in both directions,
replace the overrunning clutch assembly.
6.4.2 Armature Bearing

1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
6.4.3 Brush Wear

1. If the contact face of the brush is dirty or dusty, clean it
with emery cloth.
2. Measure the brush length “A” with a vernier caliper.
3. If the length is less than the the allowable limit, re-
place the yoke assembly and the brush holder.
Factory 15.0 mm
Specification 0.591 in.
Brush Length A
Allowable 11.0 mm
Limit 0.433 in.
6.4.4 Solenoid
1. Check the continuity across the “C” terminal and the
“B” terminal by pushing the plunger, then measuring
resistance with an ohmmeter.
2. If there is no continuity, check the contacts.
6.4.5 Brush Holder

1. Check the continuity across the brush holder and
holder support with an ohmmeter.
2. If there is any continuity, replace the brush holder
62--10865 6-4
6.4.6 Field Coil 6.4.7 Armature
1. Lead 3 Yoke
2 Brush
1. Check the continuity across the commutator and the

1. Check the continuity across the lead (1) and the brush armature with an ohmmeter.
with an ohmmeter.
2. If there is continuity, replace the armature.
2. If there is no continuity, replace the yoke assembly.
3. Check the continuity across the brush (2) and the 3. Check the continuity across the segments of the com-
yoke (3) with an ohmmeter. mutator with an ohmmeter.
4. If there is continuity, replace the yoke assembly. 4. If there is no continuity, replace the armature.
6-5 62--10865
6.4.8 Commutator and Mica
1. Check the contact pattern of the commutator for
wear, and grind the commutator with emery cloth if it
is slightly worn.
2. Measure the commutator O.D. with an outside mi-
crometer at several points.
3. If the minimum O.D. is less than the allowable limit,
replace the armature.
4. If the difference of the O.D.’s exceeds the allowable
limit, correct the commutator on a lathe to the factory
specifications.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct
it with a saw blade and chamfer the segment edges.
6.4.9 26-00119-00 / 26-00119-02 Starter
Specification
Factory 35.0 mm
Commutator O.D.
OD
Allowable 34.0 mm
Limit 1.339 in.
Factory Less Than 0.02 mm
Difference of O.D.
OD
Allowable 0.05 mm
Limit 0.0020 in.
Mica Under Cut
Allowable 0.20 mm
Limit 0.0079 in.
6.4.10 26-00119-01 Starter Specification

Factory 30.0 mm
1. Segment (a). Correct Commutator O.D.
OD
Allowable 29.0 mm
2. Depth of Mica (b). Incorrect
Limit 1.142 in.
3 Mica
Factory Less Than 0.02 mm
Difference of O.D.
OD
Allowable 0.05 mm
Limit 0.0020 in.
Mica Under Cut
Allowable 0.20 mm
Limit 0.0079 in.
62--10865 6-6
INDEX
B I
bearing case, 2-13, 2-14
Identification, 1-1
idle gear, 2-8
C injection nozzle, 2-2
camshaft, 2-9, 2-21, 2-22
injection timing, 2-1
camshaft -- fuel, 2-9
compression pressure, 2-1
connecting rod, 2-12, 2-24
coolant, 2-2 L
coolant level, 1-12
lubricating system, 2-1
cooling system, 4-1
crankshaft, 2-25
crankshaft oil slinger, 2-8
crankshaft sleeve, 2-28
O
cylinder, 2-30
oil level, 1-12
cylinder head, 2-3, 2-5, 2-15
oil pan, 2-10
oil pressure, 2-1
D
oil pump, 2-10, 2-2
dye/penetrant, 2-15
E P
electrical system, 6-1
engine oil, 1-13, 2-2 piston, 2-10, 2-23, 2-24
piston ring, 2-12
F push rod, 2-19
fan belt, 4-1

fan drive pulley, 2-8
flywheel, 2-13 R
fuel injection, 1-15, 2-3, 2-7
relief valve, 2-1
fuel system, 2-1
fuel system -- bleeding , 1-12 rocker arm, 2-19
G
S
gear case, 2-8
glow plug, 6-1 starter motor, 6-2
Index-1 62--10865
INDEX
T V
V--belt, 1-13
tappets, 2-6, 2-20 valve clearance, 1-14
thermostat, 4-1 valve guide, 2-17
valve seat, 2-17
timing gear, 2-20
valve spring, 2-19
Torque Specification, 1-3 valves, 2-6, 2-16, 2-18
62--10865 Index-2
Carrier Transicold Division,
Carrier Corporation
Truck/Trailer & Container
Product Groups
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
www.carrier.transicold.com
A member of the United Technologies Corporation family. Stock symbol UTX

2004 Carrier Corporation D Printed in U. S. A. 0404

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Diesel Engine

Engine Serial Number

Table 1-1. Model Chart

*See paragraph 1.8.8

The cylinder numbers of V2203--DI (26-00119) series

1. Grease A External Snap Ring

During disassembly, carefully arrange removed parts in

Item Size x Pitch N.m kgf.m ft--lbs

Excessive oil clearance of crankpin bearing Replace 2.3.4.c

Excessive oil clearance of rocker arm Replace 2.3.1.k

Difference among cylinders -- 10% or less

Width (Exhaust) 2.12 mm --

Valve Stem O.D. 7.960 to 7.975 mm --

Valve Guide I.D. 8.015 to 8.030 mm --

Close 0.35 rad. (20) --

Close 0.21 rad. (12) --

Setting Load/ 117.6 N / 35.0 mm 100.0N / 35.0 mm

Rocker Shaft O.D. 13.973 to 13.984 mm --

Rocker Arm I.D. 14.000 to 14.018 mm --

O.D. 23.959 to 23.980 mm --

I.D. 24.000 to 24.021 mm _

Idle Gear to Cam Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

Idle Gear to Injection Pump Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

Crank Gear to Oil Pump Gear Backlash 0.0415 to 0.1090 mm 0.15 mm

Idle Gear Shaft O.D. 37.959 to 37.975 mm --

Idle Gear Bushing I.D. 38.000 to 38.025 mm --

Height (Exhaust) 33.47 mm 33.42

Camshaft Journal O.D. 39.934 to 39.950 mm --

Cylinder Block Bore I.D. 40.000 to 40.025 mm --

Piston Pin O.D. 25.002 to 25.011 mm --

Small End Bushing I.D. 25.025 to 25.040 mm --

Crankshaft Journal O.D. 59.921 to 59.940 mm --

Crankshaft Bearing1 I.D. 59.980 to 60.039 mm --

Crankshaft Journal O.D. 59.921 to 59.940 mm --

Crankshaft Bearing2 I.D. 59.980 to 60.025 mm --

Crankpin O.D. 46.959 to 46.975 mm --

Crankpin Bearing I.D. 47.000 to 47.046 mm --

(Oversize) O.D. 87.250 to 87.272 mm 0.15mm

At Rated Speed 294 to 441 kPa 245kPa

1.7.3 Cooling System

Valve Opening 95C --

1.7.4 Fuel System

V2203--DI-- 0.05 to 0.07 rad. (2.75 to

V2203--DI 0.08 to 0.11 rad. (4.75 to

Mica V2203--DI-- Undercut 0.50 to 0.80 mm 0.20 mm

V2203--DI-- 0.50 to 0.90 mm 0.20 mm

Brush Length 0.15 mm 11.0 mm

Brush Holder and Resistance Infinity _

1. After warming up the engine, shut it off.

Lubricating oil recommended when a low--sulfur or

1. Remove the valve cover.

1.8.10.a Fuel Injection Pressure

Fuel Injection 18.6 to 20.1 MPa

1.8.10.b Nozzle Spraying Condition

(a) Good (b) Bad

1.8.10.c Valve Seat Tightness

1.9.2 Adapter, Kubota 10 mm

1.9.3 Tester Injector Nozzle

1.9.4 Replacement Bowl, Tester Injector Nozzle