Carrier 50ZH024-060 Air Conditioner User Manual

R
Diesel Engine
WORKSHOP MANUAL
for
V2203-DI (26--00128)
Tier 4i
62--11362 Rev --
WORKSHOP MANUAL
DIESEL ENGINE
V2203-DI (26-00118)
Tier 4i
TABLE OF CONTENTS
PARAGRAPH NUMBER
Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.1 ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--1
1.2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--2
1.3 CYLINDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--3
1.4 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--3
1.5 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--4
1.5.1 Torque Specifications For Special Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . .
1--4
1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . .
1--4
1.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--5
1.7 SERVICING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--7
1.7.1 Engine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1--7
1.7.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.7.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.7.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.7.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.8 CHECK AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.8.1 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.8.2 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.8.3 Checking Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.8.4 Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.5 Checking V--Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.6 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.7 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.8 Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.9 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.1 Diesel Engine Compression Tester (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.2 Adapter, Injector To Tester Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.3 Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.4 Replacement Bowl, Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.5 Adapter, Injector Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.9.6 Oil Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.7 Auxiliary Socket For Fixing Crankshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.8 Gauge, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.9 Tester, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.10 Rubber Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.11 Main Bearing Install Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.12 Main Bearing Extract Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
1.9.13 Valve Guide Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--18
1.9.14 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--18
1.9.15 Flywheel Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--18
1.9.16 Crankshaft Bearing 1 Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--19
i
62--11362
Page
PARAGRAPH NUMBER
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 DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.4 Injection Pump and Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.5 Oil Pan and Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.6 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.7 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2 Timing Gears, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Rotor to Cover Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Notched V--Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1a Poly V--Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Fan Belt Damage and Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.3 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.4 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.6 Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62-11362
ii
2--3
2--6
2--12
2--13
2--15
2--18
2--18
2--23
2--26
2--28
2--33
3--1
3--1
3--1
3--2
3--2
3--2
4--1
4--1
4--1
4--1
4--1
4--1
4--2
4--2
4--2
4--3
4--3
4--3
Page
PARAGRAPH NUMBER
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1.1 Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1.2 Shim Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--1
5.1.3 Pump Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--2
5.1.4 Delivery Valve Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--2
5.2 INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5--3
5.2.1 Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 STARTER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 FUEL SPEED SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Intake Air Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
62--11362
5--3
5--3
5--3
6--1
6--1
6--1
6--1
6--2
6--2
6--3
6--3
SAFETY
SAFETY PRECAUTIONS
cap must be removed, do so very slowly in order to
release the pressure without spray.
Your Carrier Transicold unit has been designed with the
safety of the operator in mind. During normal operation,
all moving parts are fully enclosed to help prevent injury.
During all pre-trip inspections, daily inspections, and
problem troubleshooting, you may be exposed to
moving parts. Please stay clear of all moving parts when
the unit is in operation and when the unit main power
switch is in the START/RUN position.
Battery
This unit is equipped with a lead-acid type battery. The
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.
SPECIFIC WARNING AND CAUTION
STATEMENTS
Engine Coolant
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
very hot. Contact with hot coolant can cause severe
burns. Do not remove the cap from a hot radiator. If the
To help identify the label hazards on the unit and explain
the level of awareness each one carries, an explanation
is given with the appropriate consequences:
DANGER
DANGER -- warns against an immediate hazard which WILL result in severe personal injury or death.
WARNING
WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal injury or death.
CAUTION
CAUTION -- warns against potential hazard or unsafe practice which could result in minor personal
injury, or product or property damage.
NOTE
NOTE -- gives helpful information that may help and avoid equipment and property damage.
iv
62-11362
The statements listed below are specifically applicable to this unit and appear elsewhere in this manual. These
recommended precautions must be understood and applied during operation and maintenance of the equipment
covered herein.
WARNING
Beware of moving V--belt and belt driven components
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.
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.
WARNING
Secure the starter to prevent it from moving when power is applied to it.
CAUTION
Do not remove the radiator cap until the coolant temperature is below its boiling point. Loosen the
cap slightly to relieve excess pressure before removing the cap completely.
CAUTION
Stop the engine when attempting to check and change the fuel line.
CAUTION
Stop the engine when preparing to change the engine oil.
CAUTION
Never remove the radiator cap until coolant temperature is below its boiling point. Loosen the cap
slightly to the first stop to relieve any excess pressure before removing the cap completely.
v
62-11362
SECTION 1
General
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.
1.1 ENGINE IDENTIFICATION
S/N
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:
Serial Number
V2203-- Y A
4321
Lower 4 digits in numerals
7th Digit Alpabetical Letter (Month of Manufacture)
Alphabetical letter
A,B C,D E,F G,H
Jan Feb Mar Apr
Month
J,K L,M
May Jun
6th Digit Alpabetical Letter or Numerals (Year of Manufacture).
1
2
Alphabetical letter or numerals
W
X
Y
Year
98
99
00
01
02
3
03
N,P Q,R S,T U,V W,X Y,Z
Jul Aug Sep Oct Nov Dec
4
04
5
05
6
06
7
07
8
08
9
09
Table 1-1. Model Chart
MODEL NUMBER
ENGINE TYPE
SERVICE ENGINE
PART NUMBER
PRIMARY USE
REPLACES
V2203L--DI--E3B--CTD--2
CT4--134--DI
(1700 RPM)
26--00128--00
Ultra XT, Ultra XTC, X2 1800 (2.2),
X2 2100, X2 2100A, X2 2100R
New
V2203L--DI--E3B--CTD--3
CT4--134--DI
(1800 RPM)
26--00128--01
RG Genset
New
V2203L--DI--E3B--CTD--1
CT4--134--DI
(2200 RPM)
26--00128--02
Ultima XTC, Extra XT (2.2),
X2 2500 A, X2 2500 R
New
V2203L--DI--E3B--CTD--6
CT4--134--DI
(1800 RPM)
26--00128--04
UG Genset
New
V2203L--DI--E3B--CTD--4
CT4--134--DI
(1700 RPM)
26--00128--05
TM Ultra XL
New
1--1
62--11362
1.2 ENGINE SPECIFICATIONS
Table 1-2. Specification Chart
MODEL NUMBER
26--00128--00
TYPE
26--00128--01
26--00128--02
26--00128--04
NUMBER OF CYLINDERS
BORE X STROKE
4
mm X mm (in. X in.)
TOTAL DISPLACEMENT
MAXIMUM SPEED
RPM
IDLING SPEED
RPM
83 X 102.4 (3.27 X 4.03)
cm3 (cu.in.)
BRAKE HORSEPOWER
SAE Intermittent HP kW (HP) / RPM
2216 (135.2)
23.65 (31.7) /
1700
23.87 (32.0) /
1800
26.85 (36.0) /
2200
23.87 (32.0) /
1800
900
Direct Injection
INJECTION PUMP
Bosch “K” Type Mini Pump
GOVERNOR
Mechanical Governor + Electronic Governor
INJECTION NOZZLE
INJECTION TIMING (UNPRESSURIZED)
Bosch “P” Type Hole Nozzle
2.5° Before T.D.C.
FIRING ORDER
4.0° Before
T.D.C.
2.5° Before T.D.C.
1--3--4--2
INJECTION PRESSURE
(Valve Opening Pressure)
19.35 MPa (197.5 kgf/cm2, 2809 psi.)
COMPRESSION RATIO
21.5 : 1
LUBRICATION SYSTEM
Forced Lubrication by Pump
OIL PRESSURE INDICATION
LUBRICATION FILTER
COOLING SYSTEM
Electrical Type Switch
Full Flow Synthetic Media Filter (Cartridge Type)
Pressurized Radiator, Forced Circulation With Water Pump
Electric Starting With Starting Motor
STARTING SYSTEM
12V, 2.5 kW
STARTING SUPPORT DEVICE
Intake Air Heater in Intake Manifold
FUEL
Diesel Fuel No.2--D (ASTM D975)
LUBRICATING OIL
*Quality Better Than CF Class (API), SAE 10W--30 or 15W--40
LUBRICATING OIL CAPACITY
14.2 L (15.0 U.S. Quarts)
kg (lbs.)
199 (439)
*See paragraph 1.8.6
62--11632
23.65 (31.7) /
1700
Below 2470
COMBUSTION CHAMBER
Weight (DRY)
26--00128--05
Vertical, Water--cooled, 4 cycle diesel engine
1--2
1.3 CYLINDER NUMBER
1.4 GENERAL PRECAUTIONS
1
The cylinder numbers of V2203--DI series engine are
designated as shown above. The sequence 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
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 later. 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 for 15 minutes. Serious damage to
the engine may result otherwise.
1--3
62--11362
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
Cylinder Head Cover Bolt
*Cylinder Head Bolt
*Main Bearing Case Bolt 1
*Main Bearing Case Bolt 2
*Flywheel Bolt
*Connecting Rod Bolt
*Rocker Arm Bracket Bolt
*Idle Gear Shaft Bolt
Crank Pulley Mounting Nut
*Bearing Case Cover Bolt
Nozzle Holder Clamp Bolt
Injection Pipe Retaining Nut
Overflow Pipe Assembly Retaining Bolt
Camshaft Retaining Bolt
Hi--idling Body
Starter’s Terminal B Mounting Nut
Size x Pitch
M6 x 1.0
M11 x 1.25
M9 x 1.25
M10 x 1.25
M12 x 1.25
M8 x 1.0
M8 x 1.25
M8 x 1.25
M30 x 1.5
M8 x 1.25
M10 x 1.25
M12 x 1.5
M6 x 1.0
M8 x 1.25
M14 x 1.0
M8
N.m
6.87 to 11.2
93.2 to 98.0
46 to 50
69 to 73
98.1 to 107
45 to 49
24 to 27
24 to 27
138 to 156
24 to 27
26 to 29
15 to 24
9.81 to 11.2
24 to 27
45 to 49
9.8 to 11
kgf.m
0.7 to 1.15
9.5 to 10.0
4.7 to 5.2
7.0 to 7.5
10.0 to 11.0
4.5 to 5.0
2.4 to 2.8
2.4 to 2.8
14.0 to 16.0
2.4 to 2.8
2.6 to 3.0
1.5 to 2.5
1.0 to 1.15
2.4 to 2.8
4.5 to 5.0
1.0 to 1.2
ft--lbs
5.07 to 8.31
68.8 to 72.3
34.0 to 37
51 to 54
72.4 to 79.5
33 to 36
18 to 20
18 to 20
102 to 115
18 to 20
19 to 21
11 to 18
7.24 to 8.31
18 to 20
33 to 36
7.3 to 8.6
1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt
Grade 4
M6
M8
M10
M12
N.m
7.9 to 9.3
18 to 20
40 to 45
63 to 72
kgf.m
0.80 to 0.95
1.8 to 2.1
4.0 to 4.6
6.4 to 7.4
Special Screw and Bolt
Grade 7
ft--lbs
5.8 to 6.8
13 to 15
29 to 33
47 to 53
N.m
9.81 to 11.2
24 to 27
49 to 55
78 to 90
kgf.m
1.00 to 1.15
2.4 to 2.8
5.0 to 5.7
7.9 to 9.2
ft--lbs
7.24 to 8.31
18 to 20
37 to 41
58 to 66
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
None or 4
7
62--11632
Screw And Bolt Material Grade
Standard Screw And Bolt SS41, S20C
Special Screw And Bolt S43C, S48C (Refined)
1--4
1.6 TROUBLESHOOTING
Symptom
Engine Does Not
Start
Probable Cause
Solution
Replenish fuel
Vent Air
Change fuel and
repair or replace fuel
system
Clean
Clean or change
Use specified fuel or
engine oil
Use specified fuel
Adjust
Replace
Replace
Repair or Replace
Reference
-1.8.4
1.8.4
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
Correct or replace
timing gear
Replace
Adjust
-----
2.3.3.d
1.8.7
Battery discharged
Starter malfunctioning
Key switch malfunctioning
Wiring disconnected
Fuel filter clogged or dirty
Air cleaner clogged or dirty
Fuel leak due to loose injection pipe retaining
nut
Injection pump malfunctioning
Incorrect nozzle injection pressure
Injection nozzle stuck or clogged
Charge
Repair or replace
Repair or replace
Connect
Clean or change
Clean or change
Tighten retaining nut
6.1
--1.8.4
---
Replace
Replace
Replace
5.1
5.2.1
5.2.3
Either White or Blue
Exhaust Gas Is
Observed
Excessive engine oil
1.8.1
Either Black or Dark
Exhaust Gas Is
Observed
Overload
Low grade fuel used
Fuel filter clogged
Air cleaner clogged
Deficient nozzle injection
Reduce to specified
level
Repair or replace
Adjust
Check the cylinder
compression
pressure and top
clearance
Lesson load
Use specified fuel
Clean or change
Clean or change
Replace nozzle
Deficient Output
Incorrect injection timing
Engine’s moving parts seem to be seizing
Injection pump malfunctioning
Deficient nozzle injection
Compression leak
No fuel
Air in the fuel system
Water in the fuel system
Fuel pipe clogged
Fuel filter clogged
Excessively high viscosity fo fuel or engine oil
at low temperature
Fuel with low cetane number
Incorrect injection timing
Injection nozzle clogged
Injection pump malfunctioning
Seizure of crankshaft, camshaft, piston,
cylinder or bearing
Compression leak from cylinder
Improper valve timing
Piston ring and cylinder worn
Excessive valve clearance
(Starter Does Not
Run)
Engine Revolution
Is Not Smooth
Piston ring and liner worn or ring stuck
Incorrect Injection timing
Deficient compression
Gas leak from exhaust system
Air cleaner dirty or clogged
1--5
Adjust
Repair or replace
Replace
Replace nozzle
Check the
compression
pressure and repair
Repair or replace
Clean or replace
1.8.4
---5.1.1
1.8.8
---
2.2.4.f
2.3.3.d
5.1.1
2.1.1
----1.8.8
5.1.1
-5.1
5.2.2
2.1.1
---
62--11362
1.6 TROUBLESHOOTING (Continued)
Symptom
Excessive Lubricant
Oil Consumption
Fuel Mixed into
Lubricant Oil
Water Mixed into
Lubricant Oil
Low Oil Pressure
High Oil Pressure
Engine Overheated
Low Battery Charge
Probable Cause
Piston ring’s gap facing the same direction
Oil ring worn or stuck
Piston ring groove worn
Valve stem and valve guide worn
Crankshaft bearing, and crank pin bearing
worn
Oil leaking due to defective seals or packing
Injection pump’s plunger worn
Reference
2.2.6.a
2.3.3.d
2.3.3.e
2.3.1.d
2.3.4
Deficient nozzle injection
Injection pump broken
Head gasket defective
Cylinder block or cylinder head flawed
Replace
Replace Injection
pump
Replace nozzle
Replace
Replace
Replace
5.2.3
5.1
2.2.3.e
--
Engine oil level low
Oil strainer clogged
Relief valve stuck with dirt
Relief valve spring weak or broken
Excessive oil clearance of crankshaft bearing
Replenish
Clean
Clean
Replace
Replace
--3.1.1
3.1.1
2.3.4.d
Excessive oil clearance of crankpin bearing
Replace
2.3.4.c
Excessive oil clearance of rocker arm
Oil passage clogged
Incorrect oil type
Replace
Clean
Use specified type of
oil
Repair or replace
Use specified type of
oil
Replace
Replenish
Replace or adjust
Replenish
Clean
Clean or replace
Clean or replace
Replace
Loosen load
Replace
Adjust
Use specified fuel
Replenish distilled
water and charge
Adjust belt tension or
change belt
Connect
Replace
Replace
Change
2.3.1.k
---
Oil pump defective
Incorrect oil type
Relief valve defective
Engine oil level low
Fan belt broken or elongated
Coolant insufficient
Radiator net and radiator fin clogged with dust
Inside of radiator corroded
Coolant flow route corroded
Radiator cap defective
Overload running
Head gasket defective
Incorrect injection timing
Unsuitable fuel used
Battery electrolyte level low
Fan belt slips
Wiring disconnected
Rectifier defective
Alternator defective
Battery defective
62--11632
Solution
Shift ring gap
direction
Replace
Replace worn piston
Replace
Replace
1--6
-5.1
3.2
-3.1.1
--------2.2.3.e
---------
1.7 SERVICING SPECIFICATIONS
1.7.1 Engine Body
Item
Cylinder Head Surface
Factory Specification
--
Flatness
Compression Pressure
2.95 to 3.23 MPa/
290 rpm
30 to 33 kgf/cm2
290 rpm
427 to 469 psi/
290 rpm
Allowable Limit
0.05 mm/500mm
0.0020 in./
19.69 in.
2.35 MPa/
290 rpm
24kgf/cm2
290 rpm
341 psi/
290 rpm
-0.60 to 0.70 mm
0.0236 to 0.0276 in.
0.18 to 0.22 mm
0.0071 to 0.0086 in.
2.12 mm
0.0835 in.
10% or less
--
2.12 mm
0.0835 in.
--
Angle
(Intake / Exhaust)
Angle
(Intake / Exhaust)
Clearance
0.79 rad.
45°
0.79 rad.
45°
0.040 to 0.070 mm
0.0016 to 0.0027 in.
--
Valve Stem
O.D.
7.960 to 7.975 mm
0.3134 to 0.3139 in.
--
Valve Guide
I.D.
8.015 to 8.030 mm
0.3156 to 0.3161 in.
0.65 mm
0.026 in.
to
0.85 mm
0.033 in.
--
Difference Among Cylinders
Top Clearance
Valve Clearance (When Cold)
Valve Seat
Width (Intake)
Width (Exhaust)
Valve Seat
Valve Face
Valve Stem to Valve Guide
Valve Recessing
Protrusion
Recessing
Valve Timing (Intake Valve)
Valve Timing (Exhaust Valve)
---
-0.1 mm
0.0039 in.
---
Open
0.1 rad. (8°)
before T.D.C.
--
Close
0.35 rad. (20°)
before T.D.C
--
Open
0.87 rad. (50°)
before B.D.C.
--
Close
0.21 rad. (12°)
before B.D.C
--
1--7
62--11362
1.7.1 Engine Body (Continued)
Item
Valve Spring
Free Length
Setting Load/
Setting Length
Tilt
Rocker Arm Shaft to Rocker Arm
Factory Specification
41.7 to 42.2 mm
1.65 to 1.66 in.
Allowable Limit
41.2 mm
1.62 in.
118 N / 35.0 mm
12.0 kgf / 35.0 mm
26.5 lbs. / 1.38 in.
100.0N / 35.0 mm
10.2kgf / 35.0 mm
22.5lbs /1.38 in
--
1.0 mm
0.039 in.
1.0 mm
0.039 in.
Clearance
0.016 to 0.045 mm
0.00063 to 0.0017 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
0.55119 to 0.55188 in.
--
--
Push Rod
Alignment
0.25mm
0.0098 in.
0.07 mm
0.003 in.
Tappet to Tappet Guide
Clearance
0.020 to 0.062 mm
0.00079 to 0.0024 in.
O.D.
23.959 to 23.980 mm
0.94327 to 0.94409 in.
--
I.D.
24.000 to 24.021 mm
0.94489 to 0.94570 in.
_
Timing Gear
Crank Gear to Idle Gear
Backlash
0.0415 to 0.1122 mm
0.001634 to 0.004417 in.
0.15 mm
0.0059 in.
Idle Gear to Cam Gear
Backlash
0.0415 to 0.1154 mm
0.00163 to 0.004543 in.
0.15 mm
0.0059 in.
Idle Gear to Injection Pump Gear
Backlash
0.0415 to 0.1154 mm
0.001634 to 0.004543 in.
0.15 mm
0.0059 in.
Crank Gear to Oil Pump Gear
Backlash
0.0415 to 0.1090 mm
0.001634 to 0.004291 in.
0.15 mm
0.0059 in.
Idle Gear
Side Clearance
Idle Gear Shaft to Idle Gear Bushing
Clearance
0.12 to 0.48 mm
0.0048 to 0.018 in.
0.025 to 0.066 mm
0.00099 to 0.0025 in.
0.9 mm
0.04 in.
0.1 mm
0.0039 in.
Idle Gear Shaft
O.D.
37.959 to 37.975 mm
1.4945 to 1.4950 in.
--
Idle Gear Bushing
I.D.
38.000 to 38.025 mm
1.4961 to 1.4970 in.
--
62--11632
1--8
1.7.1 Engine Body (Continued)
Item
Camshaft
Side Clearance
Camshaft
Alignment
Cam (Lobe)
Height (Intake)
33.27 mm
1.310 in.
Allowable Limit
0.3 mm
0.012 In.
0.01 mm
0.0004 in.
33.22 mm
1.308 in.
Height (Exhaust)
33.47 mm
1.318 in.
33.42
1.316 in.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
0.15 mm
0.00059 in.
Camshaft Journal to Cylinder Block Bore
Clearance
Factory Specification
0.07 to 0.22 mm
0.0028 to 0.0086 in.
--
Camshaft Journal
O.D.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
--
Cylinder Block Bore
I.D.
40.000 to 40.025 mm
1.5748 to 1.5757
25.000 to 25.013 mm
0.98425 to 0.98476 in.
0.093 to 0.128 mm
0.00367 to 0.00503 in.
0.020 to 0.060 mm
0.00079 to 0.0023 in.
0.20 to 0.35 mm
0.0079 to 0.013 in.
--
Piston Pin Bore
I.D.
Second Ring to Ring Groove
Clearance
Oil Ring to Ring Groove
Clearance
Top Ring
Ring Gap
Second Ring
Ring Gap
Oil Rng
Ring Gap
Connecting Rod
Alignment
Piston Pin to Small End Bushing
Clearance
0.014 to 0.036 mm
0.00056 to 0.0014 in.
Piston Pin
O.D.
25.004 to 25.011 mm
0.98441 to 0.98468 in.
--
Small End Bushing
I.D.
25.025 to 25.040 mm
0.98524 to 0.98582 in.
--
--
Crankshaft
Alignment
Crankshaft Journal to Crankshaft Bearing1 Oil Clearance
0.40 to 0.55 mm
0.016 to 0.021 in.
0.25 to 0.45 mm
0.0099 to 0.017 in.
--
0.040 to 0.118 mm
0.00158 to 0.00464 in.
25.05 mm
0.9862 in.
0.2 mm
0.0079 in.
0.15 mm
0.0059 in.
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
0.05 mm
0.002 in.
0.15 mm
0.0059 in.
0.02 mm
0.0008 in.
0.2 mm
0.0079 in.
Crankshaft Journal
O.D.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
--
Crankshaft Bearing1
I.D.
59.980 to 60.039 mm
2.3615 to 2.3637 in.
--
1--9
62--11362
1.7.1 Engine Body (Continued)
Item
Crankshaft Journal to Crankshaft Bearing2 Oil Clearance
Factory Specification
0.040 to 0.104 mm
0.00158 to 0.00409 in.
Allowable Limit
0.2 mm
0.0079 in.
Crankshaft Journal
O.D.
59.921 to 59.940 mm
2.3591 to 2.3598 in.
--
Crankshaft Bearing2
I.D.
59.980 to 60.025 mm
2.3615 to 2.3631 in.
0.025 to 0.087 mm
0.00099 to 0.0034 in.
--
Crankpin to Crankpin Bearing
Oil Clearance
0.2 mm
0.0079 in.
Crankpin
O.D.
46.959 to 46.975 mm
1.8488 to 1.8494 in.
--
Crankpin Bearing
I.D.
47.000 to 47.046 mm
1.8504 to 1.8522 in.
0.15 to 0.31 mm
0.0059 to 0.012 in.
--
--
Crankshaft
Side Clearance
Crankshaft Sleeve
Wear
Cylinder Bore
(Standard)
I.D.
83.00 to 83.022mm
3.2678 to 3.2685 in.
83.170 mm
3.2744 in.
(Oversize)
I.D.
83.250 to 83.272 mm
3.2776 to 3.2784 in.
83.420 mm
3.2843 in.
62--11632
1--10
0.5 mm
0.02 in.
0.1mm
0.0059 in.
1.7.2 Lubricating System
Item
Engine Oil Pressure
At Idle Speed
At Rated Speed
Engine Oil Pressure Switch
Working
Pressure
Inner Rotor to Outer Rotor
Clearance
Outer Rotor to Pump Body
Clearance
Inner Rotor to Cover
Clearance
Factory Specification
More Than 98 kPa
1.0 kgf/cm2
14 psi
Allowable Limit
50 kPa
0.5 kgf/cm2
7 psi
300 to 440 kPa
3.0 to 4.5kgf/cm2
43 to 64 psi
50 kPa
0.5kgf/cm2
7 psi
0.03 to 0.14 mm
0.0012 to 0.0055 in.
0.11 to 0.19 mm
0.0044 to 0.0074 in.
0.105 to 0.150 mm
0.00414 to 0.00590 in.
250 kPa
2.5 kgf/cm2
36 psi
--
Factory Specification
7.0 to 9.0 mm (0.28 to
0.35 in.) deflection at
98N(10kgf, 22 lbs.)
of force
80.5 to 83.5°C
176.9 to 182.3°F
Allowable Limit
--
95°C
203°F
--
0.2 mm
0.008 in.
0.25 mm
0.0098 in.
0.2 mm
0.008 in.
1.7.3 Cooling System
Item
V--Belt
Tension
Thermostat
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
--
1.7.4 Fuel System
Item
Factory Specification
0.0568 to 0.0829 rad.
(3.25 to 4.75°) before
T.D.C.
--
Injection Pump
Injection Timing
Pump Element
Fuel Tightness
Delivery Valve
Fuel Tightness
Injection Nozzle
Injection Pressure
(1st stage)
Injection Nozzle Valve Seat
Valve Seat
Tightness
10 seconds
18.62 to 17.76 Mpa
190.0 to 180.0 kgf/cm2
2702 to 2560 psi
18.64 to 20.10 Mpa
190.0 to 205.0 kgf/cm2
2703 to 2915 psi
When the pressure is
16.67 Mpa (170.0 kgf/cm2
2418 psi) the valve seat
must not leak.
1--11
Allowable Limit
--
18.63 Mpa
190.0 kgf/cm2
2702 psi
5 seconds
18.63 to 17.65 Mpa
190.0 to 180.0kgf/cm2
2702 psi to 2560 psi
--
--
62--11362
1.7.5 Electrical System
Item
Factory Specification
Allowable Limit
Starter
Commutator
O.D.
32.0 mm
1.26 in.
31.4 mm
1.24 in.
Mica
Undercut
0.50 mm
0.020 in.
0.20 mm
0.0079 in.
Brush
Length
0.18 mm
0.709 in.
11.0 mm
0.433 in.
Infinity
Approx. 0.3 ohm
---
Brush Holder and Holder Support
Intake Air Heater
62--11632
Resistance
Resistance (cold)
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.
Venting air can be accomplished 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.
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it
clean, reinsert it, and draw it out again. Check to see
that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified
level.
1.8.3 Checking Fuel Hose
1. If the clamp is loose, apply oil to the threads and
securely retighten it.
2. The fuel hose is made of rubber and ages regardless
of the service period. Change the hose and clamps
together every two years.
3. Change the fuel hose and clamps whenever any deterioration or damage is detected.
4. After the fuel hose and clamps have been changed,
bleed air out of the fuel system.
NOTE
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
mix two different types of oil. Never over fill a
crankcase.
CAUTION
Stop the engine when attempting to check
and change the fuel line.
1.8.2 Checking Coolant Level
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.
a. If coolant loss is due to evaporation, add only clean
soft water.
b. If coolant loss is due to a leak, repair the leak, then
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.
CAUTION
Do not remove the radiator cap until the
coolant temperature is below its boiling
point. Loosen the cap slightly to relieve excess pressure before removing the cap
completely.
1--13
62--11362
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 API classification CG--4 or better oils.
Use the proper SAE engine oil according to the
ambient temperatures.
Above 25°C (77°F).............SAE 30 or 10W--30
10W--40
0° to 25°C (32° to 77°F)......SAE 20 or 10W--30
10W--40
Below 0°C (32°F)............SAE 10W or 10W--30
1.8.4 Bleeding Fuel System
1. Open the air vent cock (1) on top of the fuel injection
pump.
2. Loosen the priming pump handle (2), and pump the
handle until bleeding is completed.
3. Depress and twist the priming pump handle clockwise to lock into place.
4. Close the air vent cock (1).
NOTE
With emission controls now in effect, the CG--4
or CH--4 / CI lubricating oils have been developed for use of a low--sulfur fuel on--road vehicles engines. When an off--road vehicle engine 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 lubricating oil at shorter intervals.
NOTE
Always keep the air vent cock on the fuel injection pump closed except when bleeding the fuel
system, or the engine may not run.
1.8.5 Checking V--Belt
Refer to Section 4.1
1.8.6 Changing Engine Oil
Lubricating oil recommended when a low--sulfur or
high--sulfur fuel is employed.
Fuel
Lubricating Oil Class
CAUTION
Low--sulfur
O
O
CH--4 or CI
O
X
O : Recommended X : Not Recommended
CG--4
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
completely.
4. Inspect the drain plug gasket. Replace if necessary.
5. Reinstall the drain plug.
6. Replace the oil filter with a new oil filter.
7. Fill the crankcase with new oil.
8. Check for the correct oil level. (Refer to Section 1.8.1)
62--11632
High--sulfur
1--14
1.8.7 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 projection (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.
Valve Clearance
Factory
Specification
0.18 to 0.22 mm
0.0071 to 0.0086 in.
4. If the clearance is not within the factory specifications, adjust with the adjusting screw.
Valve
Arrangement
Piston Location in Cylinder
No. 1
No. 2
When No. 1 piston is at TDC
IN.
EX.
*
*
*
*
No. 3
No. 4
No. 1
*
No. 2
When No. 1 piston is at past TDC
No. 3
No. 4
*
*
*
1.8.8 Fuel Injection
Refer to Section 5.2
1--15
62--11362
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, Injector To Tester Hose
Part No.
07--00484--00
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
Application:
Accessory for 07--00140--00
1.9.5 Adapter, Injector Line
Part No.
07--00036--00
Application:
Accessory for 07--00140--00
62--11632
1--16
1.9 SPECIAL TOOLS (Continued)
1.9.6 Oil Pressure Tester
Code No.
07916--32032
Application:
Use to measure lubricating oil
pressure.
1.
2.
3.
4.
Guage
Adapter 2
Cable
Adapter 3
5.
6.
7.
8.
Threaded Joint
Adapter 4
Adaptor 1
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.
1.9.8 Gauge, Belt Tension
Part No.
07--00203--00
Application:
Used to adjust belt tension of all
cogged V--belts.
1.9.9 Tester, Belt Tension
Part No.
07--00253--00
Application:
Used to test belt tension.
1.9.10 Rubber Band
Part No.
07--00253--01
Application:
Replacement part for belt tension
tester (Part No. 07--00253--00)
1.9.11 Main Bearing Install Tool
Part No.
Application:
07--00472--00
Used on engines starting with
S/N 3S0001
1.9.12 Main Bearing Extract Tool
Part No.
07--00473--00
Application:
Used on engines starting with
S/N 3S0001
1--17
62--11362
1.9 SPECIAL TOOLS (Continued)
The following are drawings for special tools that may need to be fabricated.
1.9.13 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.)
1.9.14 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.)
1.9.15 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.)
62--11632
1--18
1.9 SPECIAL TOOLS (Continued)
1.9.16 Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft
bearing No. 1
1. Extracting tool
130 mm (5.31 in.)
A
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.)
1--19
62--11362
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 to prevent fuel delivery to the
engine.
3. Remove the the air cleaner, the muffler and all the injection nozzles.
4. Install a compression tester with the adapter in one of
the nozzle hole.
5. While cranking the engine with the starter measure
the compression pressure.
6. Repeat steps 4 and 5 for each cylinder.
7. If the measurement is below the allowable limit, add a
small amount of oil to the cylinder thru the nozzle hole
and measure the compression again.
1. Piston
2 Plastic gauge
a. If the compression pressure is still less than the allowable limit, check the top clearance, valves and
cylinder head.
1. Remove the valve cover. (Refer to Section 2.2.3.a)
b. If the compression pressure increases after applying
oil, check the cylinder wall and piston rings.
3. Move the piston (1) up and stick a strip of plastic
gauge (2) on the piston head at three positions shown
on the illustration.
NOTE
4. Lower the piston and install the cylinder head. (Use a
new cylinder head gasket and tighten the cylinder
head bolts to the proper torque.
2. Remove the cylinder head.
Check the compression pressure with the specified valve clearance
5. Turn the flywheel until the piston (1) passes through
top dead center.
Always use a fully charged battery for performing this test.
6. Remove the cylinder head and measure the plastic
gauge.
Variances in cylinder compression values
should be under 10%.
Factory
Specification
2.95 to 3.23 MPa
30 to 33 kgt/cm2
427 to 469 psi
Allowable Limit
2.35 MPa
24 kgt/cm2
341 psi
Compression Pressure
7. If the measurement is not within the factory specifications, check the clearances between the crank pin
and bearing and between the piston pin and bushing.
2--1
Top Clearance
Factory
Specification
0.60 to 0.70 mm
0.024 to 0.027 in.
Tightening
Torque
Cylinder Head
Bolts
93.2 to 98.0 N.m
9.5 to 10.0 kgf.m
68.8 to 72.3 ft--lbs
62--11362
2.2 DISASSEMBLE AND REASSEMBLY
2.2.1 Draining Coolant And Engine Oil
2.2.2 External Components
Air Cleaner, Muffler and Others
1. Remove the air cleaner and muffler.
2. Remove the fan, fan belt, alternator and starter.
When Reassembling
CAUTION
Never remove the radiator cap until coolant
temperature is below its boiling point.
Loosen the cap slightly to the first stop to
relieve any excess pressure before removing the cap completely.
NOTE
Check to see that there are no cracks on the belt
surface.
1. Open the coolant drain cock or remove the coolant
drain plug and drain the coolant into a proper receptacle/bucket.
After reinstaling the fan belt, be sure to adjust
the fan belt tension.
2. Remove the oil drain plug and drain the engine oil into
a proper receptacle/bucket.
When reinstalling the fan, make sure that it is
put on correctly.
62--11362
2--2
2.2.3 Cylinder Head And Valves
2.2.3.a Valve Cover
1. Remove the breather hose (2).
2. Remove the valve cover bolts (1).
3. Remove the valve cover (3).
When Reassembling
Check to see that the valve cover gasket (4) is in good
condition and in place.
Tightening
Torque
Valve Cover
Bolts
1. Valve Cover Bolt
2. Breather Hose
3. Valve Cover
6.87 to 11.2 N.m
0.7 to 1.15 kgf.m
5.07 to 8.31 ft--lbs
4. Valve Cover Gasket
5. Breather Valve
6. Plate
2.2.3.b Injection Pipes
1. Loosen the bolts on the pipe clamps (1).
2. Detach the injection pipes (2).
When Reassembling
Blow out any debris that may be in the pipes.
Tightening
Torque
2--3
Injection Pipe
Retaining
Nut
15 to 24 N.m
1.5 to 2.5 kgf.m
11 to 18 ft--lbs
62--11362
2.2.3 Cylinder Head And Valves (Continued)
2.2.3.c Nozzle Holder Assembly
1. Remove the overflow pipe assembly.
2. Remove the nozzle holder assemblies (1).
When Reassembling
Replace the copper gasket with a new one.
Tightening
Torque
Nozzle Holder
Assembly
26 to 29 N.m
2.6 to 3.0 kgf.m
19 to 21 ft--lbs
Overflow Pipe
Assembly
Retaining Bolt
9.81 to 11.2 N.m
1.00 to 1.15 kgf.m
7.24 to 8.31 ft--lbs
2.2.3.d Rocker Arm and Push Rod
1. Remove the rocker arm bracket mounting bolts (1).
2. Detach the rocker arm assembly (2).
3. Remove the push rods (3).
When Reassembling
When putting the push rods (3) onto the tappets (4),
check to see if the push rod end is properly seated in the
tappet dimples.
3
4
NOTE
After instaling the rocker arm, be sure to adjust
the valve clearance. (Refer to Section 1.8.7)
1. Rocker Arm Bracket
Mounting Bolt
2. Rocker Arm Assembly
62--11362
3. Push Rod
4. Tappet
Tightening
Torque
2--4
Rocker Arm
Bracket Mounting
Bolt
24 to 27 N.m
2.4 to 2.8 kgf.m
18 to 20 ft--lbs
2.2.3 Cylinder Head And Valves (Continued)
14
6
18
10
17
9
13
2
3
5
11
7
1
15
8
4
2.2.3.e Cylinder Head
1. Loosen the hose clamp (1), and remove the water return pipe (2).
2. Remove the cylinder head bolts in the order of (18) to
(1).
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.
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 (1) to (18).
Tighten the head bolts uniformly or head warpage may
occur.
Tightening
Torque
16
Cylinder Head
Bolt
93.1 to 98.0 N.m
9.5 to 10.0 kgf.m
68.7 to 72.3 ft--lbs
12
NOTE
1.
2.
A:
B:
When replacing the cylinder head gasket (3), be
sure you are using a new gasket that matches
the original gasket.
Hose Clamp
Filter--Drier Inlet
Gear Case Side
Flywheel Side
2.2.3.f Tappets
1. Remove the tappets (1) from the crankcase.
When Reassembling
Visually check the contact between the tappets (1) and
individual cam lobes.
Coat the tappets with engine oil before installing them.
NOTE
When re--installing tappets into the engine,
make sure that they are re--installed in their original location.
2.2.3.g Valves
1. Remove the valve caps (3).
2. Remove the valve spring collet (4), pushing the valve
spring retainer (5) by the valve spring compressor (1).
3. Remove the valve spring retainer (5), valve spring (6)
and valve stem seal (2).
4. Remove the valve (7).
When Reassembling
Clean the valve stem and the valve guide. Apply engine
oil to the valve stem when reassembling.
After installing the valve spring collets (4), lightly tap the
stem with a plastic hammer to assure the collets have
seated on the valve stem.
NOTE
When re--installing valves into the engine,
make sure that they are re--installed in their
original location.
2--5
62--11362
2.2.4 Injection Pump and Gear Case
2.2.4.a Injection Pump
1. Remove the fuel speed solenoid (2) and hi--idling
body (3).
2. Remove the engine stop lever (5) and stop solenoid
guide (6).
3. Remove the fuel injection pump assembly (7).
NOTE
Remove the injection pump assembly (7) after
removing the fuel speed solenoid (2) and hi--idling body (3), engine stop lever (5) and stop
solenoid guide (6).
When Reassembling
Install the fuel speed solenoid (2), the hi--idling body (3)
and the stop solenoid guide (6) after Installing the
injection pump (7).
Replace the hi--idling body gasket (4) with a new one.
Install the fuel speed solenoid guide (6) and then the
stop lever (5) into the gear case. Cycle the stop lever to
insure that it functions.
NOTE
When installing the fuel speed solenoid (2), use
care to keep the O--ring (1) in place.
Be sure to insert the push rod of the stop solenoid into
the hole at the center of the solenoid guide (6).
Tightening
Torque
1.
2.
3.
4.
62--11362
2--6
Hi--idling Body
O--ring
Fuel Speed Solenoid
Hi--Idling Body
Hi--Idling Body Gasket
45.0 to 49.0 N.m
4.5 to 5.0 kgf.m
33 to 36 ft--lbs
5. Stop Lever
6. Stop Solenoid Guide
7. Injection Pump Assembly
2.2.4 Injection Pump and Gear Case (Continued)
2.2.4.b Governor Springs and Speed Control Plate
NOTE
Specific Tool (1): A 1.2mm (.050 inch) diameter
wire with a total length of 200mm (8 inch) with
the tip bent into a hook as depicted in the
illustration is required to hang the governor
springs.
1. Remove the injection pump cover.
2. Remove the speed control plate (7) mounting nuts (3)
and bolts (4).
3. Using the Specific Tool (1), undo the the large
governor spring (5) from the fork lever (2).
4. Set the speed control lever (6) as shown in the figure.
5. Remove the speed control plate (7), using care not to
let the governor spring (5) disengage from the plate
and fall into the gear case.
1. Specific Tool
2. Fork Lever
3. Speed Control Plate
Mounting Nut
4. Speed Control Plate
Mounting Bolt
2--7
5. Large Governor Spring
6. Speed Control Lever
7. Speed Control Plate
62--11362
2.2.4 Injection Pump and Gear Case (Continued)
2.2.4.b Governor Springs and Speed Control Plate
(Continued)
When Reassembling
NOTE
A length of string passed thru the governor
spring can be used to retrieve the spring if it unhooks from both the specific tool and the speed
control plate.
Begin reassembly by inserting the specific tool (1) thru
the injection pump cover opening thru to the speed
control plate opening.
1. Using the specific tool (1), capture the governor
spring (5) and speed control plate (7) assembly.
2. Pull the governor spring (5) / speed control plate (7)
assembly thru and secure it to the fork lever (2).
3. Seat and assemble the speed control (5) plate with
two bolts and two nuts to the gear case.
4. Check the movement of the speed control lever (4).
NOTE
The speed control lever (6) must be free to
move from low idle position to maximum speed
position and should always return to the high
idle position.
5. Finally, install the injection pump cover to the gear
case.
1. Specific Tool
2. Fork Lever
3. Speed Control Plate
Mounting Nut
4. Speed Control Plate
Mounting Bolt
62--11362
2--8
5. Large Governor Spring
6. Speed Control Lever
7. Speed Control Plate
2.2.4 Injection Pump and Gear Case (Continued)
2.2.4.c Fan Drive Pulley
1. Lock the flywheel using the flywheel stopper
2. Remove the fan drive pulley mounting nut (1) using
the 46 mm deep socket wrench (3).
3. Remove the fan drive pulley (2) with a gear puller (4).
4. Remove the feather key.
When Reassembling
Apply grease to the splines of the coupling.
Tightening
Torque
1. Nut
2. Fan Drive Pulley
3. 46 mm Deep Socket wrench
4. Gear Puller
Drive Pulley
Mounting Nut
138 to 156 N.m
14.0 to 16.0 kgf.m
102 to 115 ft--lbs
2.2.4.d Gear Case
1. Remove the gear case (1).
2. Remove the O--rings (3)(4).
When Reassembling
Replace the gear case gasket and O--rings (3)(4).
Apply gasket sealant to both sides of the gear case
gasket (2).
1. Gear Case
2. Gear Case Gasket
3. O--ring
Check/insure that the four O--rings (3)(4) are in place on
the gear case (1).
4. O--ring
5. Oil seal
Apply a thin film of oil to the crankshaft oil seal lip (5) and
take care not to roll the lip when installing the gear case.
2--9
62--11362
2.2.4 Injection Pump and Gear Case (Continued)
2.2.4.e Crankshaft Oil Slinger
1. Remove the crankshaft collar (1).
2. Remove the O--ring (2).
3. Remove the crankshaft oil slinger (3).
When Reassembling
Insert the crankshaft collar (1) after installing the gear
case to the crankcase.
1. Crankshaft Collar
2. O--ring
3. Crankshaft Oil Slinger
2.2.4.f Idle Gear
1. Detach the external snap ring.
2. Remove the idle gear collar.
3. Remove 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
2. Idle Gear
3. Cam Gear
4. Crank Gear
5. Oil Pump Drive Gear
Idle gear (2) and cam gear (3)
Idle gear (2) and injection pump gear (1)
2.2.4.g Camshaft
1. Remove the camshaft retaining bolt (1) and pull the
camshaft (2) out.
When Reassembling
Refer to installation of Idle Gear (Refer to Section
2.2.4.f).
Tightening
Torque
1. Camshaft Set Screw
Camshaft
retaining bolt
2. Camshaft
24 to 27 N.m
2.4 to 2.8 kgf.m
18 to 20 ft--lbs
2.2.4.h Fuel Feed Pump Holder
1. Disconnect the oil pipe (1).
2. Remove the fuel feed pump (2).
3. Remove the fuel feed pump holder (4).
When Reassembling
Replace the O--rings (3) with new O--rings.
1. Oil Pipe
2. Fuel Feed Pump
62--11362
3. O--ring
4. Fuel Feed Pump Holder
2--10
2.2.4 Injection Pump and Gear Case (Continued)
2.2.4.i Fuel Camshaft And Fork Lever Assembly
1. Detach the fuel camshaft stopper (1).
2. Remove the three fork lever holder mounting screws
(2).
3. Remove the fuel camshaft assembly (5), (6) and fork
lever assembly (3), (4), and (7) at the same time.
When Reassembling
After installation, check to see that the fork levers 1 (3)
and 2 (4) are fixed to the fork lever shaft, and that they
can turn smoothly in the holder (7).
1. Fuel Camshaft Stopper
2. Fork Lever Holder Mounting
Screws
3. Fork Lever 1
4. Fork Lever 2
5. Injection Pump Gear
6. Fuel Camshaft
7. Fork Lever Holder
2.2.4.j Oil Pump
1. Remove the nut.
2. Draw out the oil pump drive gear (2) with a gear puller
(3).
3. Remove the four oil pump mounting bolts. Detach the
oil pump (1).
1. Oil Pump
2. Oil Pump Drive Gear
3 Gear Puller
2--11
62--11362
2.2.5 Oil Pan and Oil Strainer
2.2.5.a Oil Pan and Oil Strainer
1. Remove the oil pan cover (4).
2. Remove the oil pan mounting bolts (1).
3. Remove the oil pan (2) by lightly tapping the rim of the
pan with a wooden hammer.
4. Remove the old gaskets (3) and (7).
5. Remove the oil strainer (6) and O--ring (5).
When Reassembling
Check to see that the oil filter strainer (6) is clean.
Visually check the O--ring (5), apply engine oil and install
it to the pick--up tube.
(7)
Install the strainer (6) and O--ring (5).
Apply gasket sealant to the oil pan side of the oil pan
gasket (7) and fit the gasket to the oil pan (2).
Install the oil pan (2) to the engine, and tighten the oil pan
mounting bolts (1) diagonally. Avoid uneven tightening
of the oil pan mounting bolts. (Refer to Section 1.5.2
Torque Specifications)
1.
2.
3.
4.
Oil Pan Mounting Screw
Oil Pan
Oil Pan Cover Gasket
Oil Pan Cover
62--11362
Apply gasket sealant to the oil pan cover side of the oil
pan cover gasket (3) and fit the gasket to the oil pan
cover (4).
5. O--ring
6. Oil Strainer
7. Oil Pan Gasket
Install the oil pan cover (4) to the oil pan (2).
Install and tighten the oil pan cover bolts diagonally.
Avoid uneven tightening of the oil pan cover mounting
bolts. (Refer to Section 1.5.2 Torque Specifications)
2--12
2.2.6 Piston and Connecting Rod
2.2.6.a Pistons
1. Completely remove the carbon ridge (1) at the top of
the cylinder walls.
2. Remove 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 (7).
When inserting the piston into the cylinder avoid
damaging the molybdenum disulfide coating on
the piston skirt. This coating is useful in minimizing the clearance between the piston and
cylinder.
When replacing a piston, use a replacement
piston with the same code number. The piston
ID mark (6) is on top of the piston.
6
1.
2.
3.
4.
5.
Carbon
Connecting Rod Bolt
Connecting Rod Cap
Connecting Rod
Molybdenum Disulfide
Coating on Piston Skirt
6. Piston ID Mark
Tightening
Torque
2--13
7.
(A)
(B)
(C)
(D)
Piston Ring Compressor
Top Ring Gap
Second Ring Gap
Oil Ring Gap
Piston Pin Hole
(a)
2.09 rad. (120°)
Connecting
Rod Bolt
45 to 49 N.m
4.5 to 5.0 kgf.m
33 to 36 ft--lbs
62--11362
2.2.6 Piston and Connecting Rod (Continued)
2.2.6.b Piston Ring and Connecting Rod
1. Remove the piston rings (1), (2), (3).
2. Remove the piston pin (8) and then seperate the connecting rod (6) from the piston (5).
7
NOTE
8
Mark both the connecting rod and piston so that
if they are to be re--used that the original combination of parts will go back together. Do not interchange used parts.
When Reassembling
When installing the rings, assemble 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 (8).
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 (7) facing the
injection pump side.
7
1.
2.
3.
4.
5.
6.
62--11362
2--14
Top Ring
Second Ring
Oil Control Ring
Piston Pin Snap Ring
Piston
Connecting Rod
7.
8.
9.
10.
11.
12.
Mark
Piston Pin
FW Mark
Expander Joint
Oil Ring Gap
Manufacturer’s Mark
2.2.7 Crankshaft
2.2.7.a Flywheel
1. Prevent the flywheel (1) from rotating.
2. Remove two flywheel bolts (2).
NOTE
The use of air tools to remove the flywheel bolts
may damage the threads in the crankshaft.
1. Flywheel
2. Flywheel Bolt
3. Install two flywheel guide bolts (3).
4. Remove all of the flywheel bolts (2).
5. Remove the flywheel (1) slowly along the flywheel
guide bolts (3).
When Reassembling
Install two flywheel guide bolts (3).
Check to see that the mating surfaces of the crankshaft
and flywheel are clean.
Apply engine oil to the flywheel bolts and install.
3. Flywheel Guide Bolts
Tightening
Torque
Flywheel Bolts
98.0 to 107.8 N.m
10.0 to 11.0 kgf.m
72.3 to 79.5 ft--lbs
2.2.7.b Bearing Case Cover
1. Remove the bearing case cover mounting bolts. First,
remove the inside bolts (2) and then the outside bolts
(1).
2. Screw two of the removed bolts into the bolt hole of
the bearing case cover (3) to remove it.
NOTE
The length of the inside (2) and the outside (1)
bolts is different. When reassembling reinstall
the appropriate bolt in the correct location.
When Reassembling
Fit the bearing case gasket (5) and the bearing case
cover gasket (6) to the bearing case cover (3). Orient
them correctly.
Install the bearing case cover (3), again orienting it
correctly, using the “UP” mark (a).
Apply oil to the oil seal (4), and take care not to roll the
seal when installed.
Tighten the bearing case cover bolts diagonally and
evenly.
Tightening
Torque
1. Bearing Case Cover
Mounting Bolt
2. Bearing Case Cover
Mounting bolt
3. Bearing Case Cover
4. Oil Seal
Bearing Case
Cover Mounting
bolt
24 to 27 N.m
2.4 to 2.8 kgf.m
18 to 20 ft--lbs
5. Bearing Case Gasket
6. Bearing Case Cover
Gasket
(a). Top
2--15
62--11362
2.2.7 Crankshaft (Continued)
2.2.7.c Crankshaft Assembly Removal
NOTE
Before disassembling, check the side
clearance of the crankshaft. Check it
during reassembly.
1. Remove the three main bearing case bolts (1).
2. Pull out the crankshaft assembly (2), being careful not
to damage the crankcase bearings (3).
3. While pulling the crankshaft assembly (2) out, use
care to align each of the crank pins (5) (left or right) to
clear the crankcase relief (a).
When Reassembling
When installing the main bearing case assembly, align
the bolt holes of the crankshaft assembly (2) with the
holes of the crankcase.
Apply oil to the threads of the main bearing case bolts (1)
before re--insertion.
Tightening
Torque
1.
2.
3.
4.
62--11362
2--16
Main Bearing
Case Bolt
69 to 73 N.m
7.0 to 7.5 kgf.m
51 to 54 ft--lbs
Main Bearing Case Screw 2 5. Cylinder 4 Crank Pin
(a).Main Bearing Case Relief
Main Bearing Case 2
Crankshaft Bearing 1
Crankshaft Assembly
2.2.7 Crankshaft (Continued)
2.2.7.d Main Bearing Case Assembly
1. Remove the two main bearing case bolts (7), and remove the main bearing case assembly being careful
with the thrust bearing and crankshaft bearing.
2. Remove the remaining main bearing cases 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, face the mark
“FLYWHEEL” to the flywheel.
Install the thrust bearing with its oil groove facing (8)
outward.
Confirm that main bearing case moves smoothly after
torquing the main bearing case bolt to specification.
Tightening
Torque
1.
2.
3.
4.
Alignment Number
Alignment Mark
No Mark
C
Main Bearing
Case bolt
5.
6.
7.
8.
46 to 50 N.m
4.7 to 5.2 kgf.m
34 to 37 ft--lbs
B
A
Main bearing Case Bolt
Oil Groove
7
8
8
2--17
62--11362
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 gauge.
4. If the measurement exceeds the allowable limit,
resurface or replace the head.
NOTE
Check the valve recessing after after resurfacing the head.
Cylinder Head
Surface Flatness
Factory
Specification
0.05mm over a span of
500mm
0.002 in. over a span of
20 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/penetrant 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
2. Detergent
3. White Developer
5. Spray the white developer (3) on to the head.
6. Red marks will bleed through the developer identifying cracks in the head if they are present.
62--11362
2--18
2.3.1 Cylinder Head And Valves (Continued)
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 gauge.
4. If the measurement exceeds the allowable limit, replace the valve.
1. Cylinder Head
Surface
(A) Recess
(B) Protrusion
5. If the measurement still exceeds the allowable limit,
replace the cylinder head.
Valve
Recessing
Factory
Specification
0.065 (protrusion) mm to
0.085 (recessing) mm
0.026 (protrusion) in. to
0.033 (recessing) in.
Allowable Limit
--
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 gauge, and
calculate the clearance.
4. If the clearance exceeds the the allowable limit, replace the valves. If the clearance still exceeds the allowable limit, replace the valve guide.
Clearance
Between
Valve Stem
and Guide
2--19
Factory
Specification
Allowable Limit
0.040 to 0.070 mm
0.0016 to 0.0027 in.
0.1 mm
0.0039 in.
Valve Stem
O.D.
Factory
Specification
7.960 to 7.975 mm
0.3134 to 0.3139 in.
Valve Guide
I.D.
Factory
Specification
8.015 to 8.030 mm
0.3156 to 0.3161 in.
62--11362
2.3.1 Cylinder Head And Valves (Continued)
2.3.1.e Replacing Valve Guide
(A) (When removing)
1. Press out the used valve guide using a valve guide replacing 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 replacing tool.
3. Ream the I.D. of the valve guide to the specified dimension (precisely).
Valve Guide I.D.
Intake & Exhaust
(A) When Removing
Factory
Specification
8.015 to 8.030 mm
0.3156 to 0.3161 in.
(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 outlined in paragraph 2.3.1.g.
3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of
valve seating.
1. Correct
2. Incorrect
62--11362
3. Incorrect
2--20
2.3.1 Cylinder Head And Valves (Continued)
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.
Valve Face Angle
a
Factory
Specification
IN.
0.79 rad / 45°
EX.
0.79 rad / 45°
b
(B) Correcting the Valve Seat
1. Slightly correct the valve seat surface with a 1.0 rad.
(60°) (intake valve) or 0.79 rad. (45°) (exhaust valve)
seat cutter.
2. Resurface the seat surface with a 0.52 rad. (30°)
valve seat cutter to the Intake valve seat and with a
0.26 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.).
(1)
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.
(2)
4. Check the valve seating with prussian blue. The valve
seating should show good contact all the way around.
a.
b.
c.
0.26 rad.(15°) or
0.52 rad.(30°)
0.79 rad.(45°) or
1.0 rad.(60°)
0.52 rad.(30°) or
0.26 rad.(15°)
A.
B.
C
1.
2.
Check Contact
Correct Seat Width
Check Contact
Valve Seat Width
Identical Dimensions
Valve Face Angle
Factory
Specification
IN.
0.79 rad / 45°
EX.
0.79 rad / 45°
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 bolt driver.
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.
2--21
62--11362
2.3.1 Cylinder Head And Valves (Continued)
2.3.1.i Free Length and Tilt of Valve Spring
1. Measure the free length A of the valve spring with vernier calipers. If the measurement is less than the allowable 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.
Factory
Specification
41.7 to 42.2 mm
1.65 to 1.66 in.
Allowable Limit
41.2 mm
1.62 in.
Allowable Limit
1.0 mm
0.039 in.
Free Length A
Tilt B
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 engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Setting Load /
Setting Length
Factory
Specification
118 N / 35 mm
12.0 kgf / 35 mm.
26.5 lbs. / 1.38 in.
Allowable
Limit
100 N / 35 mm
10.2 kgf / 35 mm.
22.5 lbs. / 1.38 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, replace the rocker arm then measure the oil clearance
again. If the clearance is still out of specification, replace the rocker arm shaft.
Factory
Specification
0.016 to 0.045 mm
0.0063 to 0.0017 in.
Allowable
Limit
0.10 mm
0.0039 in.
Rocker Arm
Shaft O.D.
Factory
Specification
13.973 to 13.984 mm
0.55012 to 0.55055 in.
Rocker Arm I.D.
Factory
Specification
14.000 to 14.018 mm
0.55119 to 0.55188 in.
Oil Clearance
Rocker Arm/
Shaft
2.3.1.l Push Rod Alignment
1. Place the push rod on V blocks
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push rod.
Push Rod
Alignment
62--11362
2--22
Allowable
Limit
0.25 mm
0.0098 in.
2.3.1 Cylinder Head And Valves (Continued)
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 cylinder gauge and calculate the clearance.
3. If the measurement exceeds the allowable limit, or
the tappet is damaged, replace the tappet.
Factory
Specification
0.020 to 0.062 mm
0.00079 to 0.00244 in.
Allowable
Limit
0.07 mm
0.003 in.
Tappet O.D.
Factory
Specification
23.959 to 23.980 mm
0.94327 to 0.94409 in.
Tappet Guide I.D.
Factory
Specification
24.000 to 24.021 mm
0.94489 to 0.94570 in.
Oil Clearance
Tappet/
Tappet Guide
Bore
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/
Idle Gear/
Crank Gear
Backlash/
Idle Gear/
Cam Gear
Backlash/
Idle Gear/
Injection Pump
Gear
Backlash/
Crank Gear/
Oil Pump Gear
Factory
Specification
0.0415 to 0.1122 mm
0.00163 to 0.00442 in.
Allowable
Limit
0.15 mm
0.0059 in.
Factory
Specification
0.0415 to 0.1154 mm
0.00163 to 0.00454 in.
Allowable
Limit
0.15 mm
0.0059 in.
Factory
Specification
0.0415 to 0.1154 mm
0.00163 to 0.00454 in.
Allowable
Limit
0.15 mm
0.0059 in.
Factory
Specification
0.0415 to 0.1090 mm
0.00163 to 0.00429 in.
Allowable
Limit
0.15 mm
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 clearance.
3. If the measurement exceeds the allowable limit, replace the idle gear collar.
Idle Gear
Side
Clearance
2--23
Factory
Specification
0.12 to 0.48 mm
0.0047 to 0.018 in.
Allowable
Limit
0.9 mm
0.04 in.
62--11362
2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)
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.
3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
Camshaft
Side
Clearance
Factory
Specification
0.07 to 0.22 mm
0.0028 to 0.0087 in.
Allowable
Limit
0.30 mm
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 micrometer, and calculate the the clearance.
3. If the measurement exceeds the allowable limit, replace the bushing.
Factory
Specification
0.025 to 0.066 mm
0.00099 to 0.00260 in.
Allowable
Limit
0.1 mm
0.0039 in.
Idle Gear Shaft
O.D.
Factory
Specification
23.959 to 23.980 mm
0.94327 to 0.94410 in.
Idle Gear Shaft
I.D.
Factory
Specification
24.000 to 24.021 mm
0.94488 to 0.94571 in.
Idle Gear Shaft/
Bushing
Clearance
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 Replacing 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)
62--11362
2--24
2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)
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 journal.
3. Rotate the camshaft and measure for run--out.
4. If the measurement exceeds the allowable limit, replace the camshaft.
Camshaft
Run--out
Allowable
Limit
0.1 mm
0.0004 in.
2.3.2.g Cam Height
1. Measure the cam lobe at its largest O.D. with an outside micrometer.
2. If the measurement is less than the allowable limit, replace the camshaft.
Cam Height
Intake
Cam Height
Exhaust
Factory
Specification
33.27 mm
1.310 in.
Allowable
Limit
33.22 mm
1.308 in.
Factory
Specification
33.47 mm
1.318 in.
Allowable
Limit
33.42 mm
1.316 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 gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the camshaft
Factory
Specification
0.050 to 0.091 mm
0.0020 to 0.0035 in.
Allowable
Limit
0.15 mm
0.0059 in.
Camshaft Journal
O.D.
Factory
Specification
39.934 to 39.950 mm
1.5722 to 1.5728 in.
Camshaft Bore
I.D.
Factory
Specification
40.000 to 40.025 mm
1.5748 to 1.5757 in.
Camshaft Journal
Clearance
2--25
62--11362
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 gauge.
2. If the measurement exceeds the allowable limit, replace the piston.
Piston Pin Bore
I.D.
Factory
Specification
25.000 to 25.013 mm
0.98426 to 0.98476 in.
Allowable
Limit
25.05 mm
0.9862 in.
2.3.3.b Piston Pin and Bushing Clearance
1. Measure the piston pin O.D. with an outside micrometer.
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, replace
the piston pin.
Factory
Specification
0.014 to 0.038 mm
0.00055 to 0.00150 in.
Allowable
Limit
0.15 mm
0.0059 in.
Piston Pin O.D.
Factory
Specification
25.002 to 25.011 mm
0.98433 to 0.98468 in.
Small End
Bushing I.D.
Factory
Specification
25.025 to 25.040 mm
0.98523 to 0.98582 in.
Piston Pin to
Small End Bushing Clearance
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 connecting rod.
62--11362
2--26
2.3.3 Piston and Connecting Rod (Continued)
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 gauge.
3. If the gap exceeds the allowable limit, replace the
ring.
Top Ring
(Keystone Type)
Second Ring
Oil Control Ring
Factory
Specification
0.20 to 0.35 mm
0.0079 to 0.013 in.
Allowable Limit
1.25 mm / 0.0492 in.
Factory
Specification
0.40 to 0.55 mm
0.016 to 0.021 in.
Allowable Limit
1.25 mm / 0.0492 in.
Factory
Specification
0.25 to 0.45 mm
0.0099 to 0.017 in.
Allowable Limit
1.25 mm / 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 gauge (with the exception of the
top ring, Keystone Type, which cannot be accurately
measured with a feeler gauge).
3. If the clearance exceeds the allowable limit, replace
the ring.
4. If the clearance still exceeds the allowable limit after
replacing the ring, replace the piston.
Second Ring
Oil Control Ring
Factory
Specification
0.093 to .128 mm
0.00367 to 0.00503 in.
Allowable Limit
0.20 mm / 0.0079 in.
Factory
Specification
0.020 to 0.060 mm
0.00079 to 0.0023 in.
Allowable Limit
0.15 mm / 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 procedure, 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 alignment tool.
3. Put a gauge over the piston pin and move it against
the face plate.
4. If the gauge does not fit squarely against the face
plate, measure the space between the pin of the
gauge and the face plate.
5. If the measurement exceeds the allowable limit, replace the connecting rod.
Connecting Rod
Alignment
2--27
Allowable Limit
0.05 mm / 0.002 in.
62--11362
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 forward.
4. If the measurement exceeds the allowable limit replace the thrustwashers.
Crankshaft Side
Clearance
A
B
Factory
Specification
0.15 to 0.31 mm
0.0059 to 0.012 in.
Allowable
Limit
0.5 mm
0.02 in.
(Reference)
Oversize dimensions of crankshaft journal.
Oversize
0.2mm / 0.008 in.
0.4mm / 0.02 in.
Dimension A
54.5 to 54.7 mm
2.146 to 2.153 in.
54.6 to 54.8 mm
2.150 to 2.157 in.
Dimension B
26.20 to 26.25 mm
1.032 to 1.033 in.
26.40 to 26.45 mm
1.040 to 1.041 in.
Dimension C
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
The crankshaft journal must be fine--finished to higher than
0.4--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, replace the crankshaft.
Crankshaft
Alignment
62--11362
2--28
Allowable
Limit
0.02 mm
0.0008 in.
2.3.4 Crankshaft (Continued)
2.3.4.c Crankpin to Connecting Rod Bearing Clearance
1. Clean the crankpin and the connecting rod bearing.
2. Put a strip of plastigage on the center of the crankpin
in each direction as shown in the figure.
3. Install the connecting rod cap and tighten the bolts to
the specification. (Refer to 2.2.6.a)
4. Remove the cap again
5. Measure the amount of the flattening with the scale to
get the clearance.
6. If the measurement exceeds the allowable limit replace 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.
Factory
Specification
0.025 to 0.087 mm
0.00099 to 0.0034 in.
Allowable
Limit
0.2 mm
0.0079 in.
Crankpin O.D.
Factory
Specification
46.959 to 46.975 mm
1.8488 to 1.8494 in.
Connecting Rod
Bearing I.D.
Factory
Specification
47.000 to 47.046 mm
1.8504 to 1.8522 in.
Crankpin/
Connecting Rod
Clearance
(Reference)
Undersize dimensions of crankpin journal.
Undersize
0.2mm / 0.008 in.
0.4mm / 0.02 in.
Dimension A
3.3 to 3.7 mm
0.13 to 0.14 in.
3.3 to 3.7 mm
0.13 to 0.14 in.
Dimension B
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
Dimension C
46.759 to 46.775
mm
1.8409 to 1.8415 in.
radius
46.559 to 46.575
mm
1.8331 to 1.8336 in.
radius
The crankshaft journal must be fine--finished to higher than
0.8--S.
*Holes to be de--- burred and edges rounded with 1.0 to 1.5
mm
(0.040 to 0.059 in. relief.
2--29
62--11362
2.3.4 Crankshaft (Continued)
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 inside micrometer and calculate clearance.
3. If the clearance exceeds the allowable limit, replace
crankshaft bearing #1.
4. If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
Crankshaft
Journal to #1
Bearing
Clearance
Factory
Specification
0.040 to 0.118 mm
0.00158 to 0.00464 in.
Allowable
Limit
0.2 mm
0.0079 in.
Crankshaft
Journal O.D.
Factory
Specification
59.921 to 59.940 mm
2.3591 to 2.3598 in.
Crankshaft
Bearing Bearing
I.D.
Factory
Specification
59.980 to 60.039 mm
2.3615 to 2.3637 in.
(Reference) Undersize dimensions of crankshaft
journal.
Oversize
0.2mm / 0.0008 in.
0.4mm / 0.0016 in.
Dimension A
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
Dimension B
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
Dimension C
59.721 to 59.740
mm
2.3513 to 2.3519 in.
59.521 to 59.540
mm
2.3434 to 2.3440 in.
The crankshaft journal must be fine--finished to higher than
0.4--S.
*Holes to be de--burred and edges rounded with 1.0 to 1.5 mm
(0.040 0.059 in.) relief.
1. Seam
2. Crankshaft Bearing #1
2.3.4.e Replacing Crankshaft Bearing #1
(A) When Removing
1. Press out the crankshaft bearing #1 (2) using a crankshaft 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.
3. Cylinder Block
A Dimension
NOTE
Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port in the connecting rod.
Dimension A
62--11362
2--30
Factory
Specification
4.2 to 4.5 mm
0.166 to 0.177 in.
2.3.4 Crankshaft (Continued)
2.3.4.f Crankshaft Journal to Crankshaft Bearing
#2 Clearance
1. Put a strip of plastigage on the center of the crankshaft journal.
2. Install the bearing case and tighten the bolts to specification.
3. Remove the bearing case again.
4. Measure the amount of the flattening with the scale to
get the clearance.
5. If the measurement exceeds the allowable limit replace crankshaft bearing #2.
6. If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
NOTE
Be sure not to move the crankshaft while the
bearing bolts are tightened.
Crankshaft
Journal to #2
Bearing
Clearance
Factory
Specification
0.040 to 0.104 mm
0.00158 to 0.00409 in.
Allowable
Limit
0.2 mm
0.0079 in.
Crankshaft
Journal O.D.
Factory
Specification
59.921 to 59.940 mm
2.3591 to 2.3598 in.
Crankshaft
Bearing Bearing
I.D.
Factory
Specification
59.980 to 60.025 mm
2.3615 to 2.3631 in.
(Reference)
Undersize dimensions of crankshaft journal.
Oversize
0.2mm / 0.008 in.
0.4mm / 0.016 in.
Dimension A
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
2.8 to 3.2 mm radius
0.11 to 0.12 in.
radius
Dimension B
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
1.0 to 1.5 mm radius
0.040 to 0.059 in.
radius
Dimension C
59.721 to 59.740
mm
2.3513 to 2.3519 in.
59.521 to 59.540
mm
2.3433 to 2.3440 in.
The crankshaft journal must be fine--finished to higher than
0.4--S.
*Holes to be de--burred and edges rounded with 1.0 to 1.5 mm
(0.040 0.059 in.) relief.
2--31
62--11362
2.3.4 Crankshaft (Continued)
2.3.4.g 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 in
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 crankshaft (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
2. Sleeve Guide
3. Crankshaft Sleeve
62--11362
4. Auxiliary Socket For
Pushing
5. Crankshaft
2--32
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 gauge to find 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)
a. Top
b. Middle
c. Bottom (skirt)
Cylinder I.D.
Factory
Specification
83.000 to 83.022 mm
3.2678 to 3.2685 in.
Maximum Wear
Allowable
Limit
83.170 mm
3.2744 in.
a. Right--angled to
Piston Pin
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.
Factory
Specification
83.250 to 83.272 mm
3.2776 to 3.2784 in.
Maximum Wear
Allowable
Limit
83.420 mm
3.2843 in.
Finishing
1. Cylinder I.D.
(before correction)
Hone to 2.2 to 3.0 mm μR max.
(0.00087 to 0.00118 in. μR max.)
2. Oversize Cylinder I.D.
2. Replace the piston and piston rings with oversize
(+0.25 mm) ones.
2--33
62--11362
SECTION 3
LUBRICATING SYSTEM
3.1 CHECKING AND ADJUSTING
3.1.1 Engine Oil Pressure
1. Remove the engine oil pressure switch, and install an
oil pressure gauge.
2. Start the engine. After warming up, read the oil pressure 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
Factory
Specification
More than 98 kPa
1.0 kgf/cm2
14 psi
Allowable
Limit
50 kPa
0.5 kgf/cm2
7 psi
Factory
Specification
300 to 440 kPa
3.0 to 4.5 kgf/cm2
43 to 64 psi
Allowable
Limit
250 kPa
2.5 kgf/cm2
36 psi
At Idle Speed
At Rated Speed
(When Reassembling)
After checking the engine oil pressure, tighten the
engine oil pressure switch to the specified torque.
3--1
62--11362
3.2 SERVICING
3.2.1 Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge.
2. Measure the clearance between the outer rotor and
the pump body with a feeler gauge.
3. If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Inner/Outer
Rotor Clearance
Outer Rotor/
Pump Body
Clearance
Factory
Specification
0.03 to 0.14 mm
0.0012 to 0.0055 in.
Allowable
Limit
0.2 mm
0.008 in.
Factory
Specification
0.11 to 0.19 mm
0.0044 to 0.0074 in.
Allowable
Limit
0.25 mm
0.0098 in.
3.2.2 Rotor to Cover Clearance
1. Put a strip of plastigage onto the rotor face with
grease.
2. Install the cover and tighten the bolts.
3. Remove the cover carefully, and read the plastigage.
4. If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Rotor/Cover
Clearance
62--11362
3--2
Factory
Specification
0.105 to 0.150 mm
0.00414 to 0.00590 in.
Allowable
Limit
0.20 mm
0.008 in.
SECTION 4
COOLING SYSTEM
4.1 CHECKING AND ADJUSTING
2. Replace the Poly--V--Belt by positioning the belt on
the water pump pulley, and while rotating the engine
(as in step 1), use a flat, blunt object to guide the belt
onto the crank pulley. Be careful not to damage
grooves on the pulley or belt.
WARNING
Beware of moving V--belt and belt driven
components
4.1.2 Fan Belt Damage and Wear
4.1.1 Notched V--Belt Service
1. Check the fan belt for damage.
2. If the belt is damage in any way, replace it.
NOTE
A frayed, cracked or worn V--belt must be replaced. After installing a new belt, it is advisable
to check the adjustment after running the unit
for three or four hours. This will allow for the initial stretch, which is common on new belts.
Once this initial stretch has taken place, the belt
should be checked at regular intervals.
(A)
(B)
To replace or adjust the notched V--belt, do the
following:
a. Replacing the V--Belt
1. Loosen the idler pivot bolt.
A. Good
B. Bad
2. Replace the belt and adjust tension in accordance
with the following steps.
3. Check if the belt is worn and sunk in the pulley groove.
b. Adjusting Tension
4. If the fan belt is worn and deeply sunk in the pulley
groove, replace it.
1. Measure the deflection (A), by depressing the belt
halfway between the fan drive pulley and alternator
pulley at the specified force (Refer to1.7.3).
A. Good
B. Bad
4.1.3 Checking Coolant Level
2. Use hand force only on the idler pulley to tighten belt.
Do not use a pry bar or excessive force as it may
cause damage to the engine.
WARNING
Use of a belt tension gauge (Carrier Part #
07--00203--00) or a belt tension tester (Carrier Part #
07--00253--00) is advised.
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.
3. When belt is at correct tension, tighten pivot bolt.
4.1.1a Poly V--Belt Service
a. Replacing the Poly--V--Belt
1. Apply the proper size socket to the crank pulley nut,
then slowly rotate the crank. At the same time, use a
flat, blunt object to guide the belt off the crank pulley
towards radiator. Be careful not to damage grooves
on the pulley.
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.
4--1
62--11362
4.1.5 Radiator
FULL
LOW
2. If the coolant level is too low, check the reason for the
lost coolant.
a. If coolant loss is due to evaporation, add only clean
soft water.
1. Fill the radiator with water.
b. If coolant loss is due to a leak, repair the leak, then
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.
2. Attach the pressure tester to the radiator.
3. Apply pressure and look for leaks.
4. Repair/replace as necessary to assure that the specified pressure will hold.
NOTE
Radiator Leakage
Test
When adding coolant to the system, air must be
vented from the engine coolant passages by jiggling the upper and lower radiator hoses.
Factory
Specification
157 kPa
1.6 kgf/cm2
23 psi
4.1.6 Thermostat Opening Temperature
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.
4.1.4 Radiator Cap
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 temperature 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).
1. Attach the radiator cap to a pressure tester.
2. Apply pressure and observe the time for the pressure
to fall.
5. If the measurement is not within the factory specifications, replace the thermostat.
3. If the measurement is less than the factory specification, replace the cap.
Pressure Falling
Time
62--11362
Factory
Specification
More than 10 seconds
for pressure fall from
88 to to 59kPa
0.9 to 0.6 kgf/cm2
13 to 9 psi
4--2
Thermostat
Opening
Temperature
Factory
Specification
80.5 to 83.5.5°C
176.9 to 182.3°F
Thermostat
Full Open
Temperature
Factory
Specification
95°C
203°F
4.2 SERVICING
4.2.1 Thermostat Assembly
1. Thermostat Cover Bolt
2. Thermostat Cover
3. Thermostat Cover Gasket
4.2.2 Water Pump Assembly
1. Water Pump Flange
2. Water Pump Shaft
3 Water Pump Body
4. Thermostat Assembly
5. Thermostat Housing
4. Water Pump Gasket
5. Mechanical Seal
6. Impeller
1. Remove the fan belt.
2. Remove the water pump pulley.
3. Remove the water pump from the gear case assembly.
4. Remove the water pump flange (1).
5. Press out the water pump shaft (2) with the impeller
(6) on it.
6. Remove the impeller from the water pump shaft.
7. Remove the mechanical seal.
(When Reassembling)
Replace the mechanical seal with a new one.
Apply a liquid gasket to both sides of the gasket (4).
1. Remove the thermostat cover mounting bolts (1), and
remove the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When Reassembling)
Apply a liquid gasket only at the thermostat cover side of
the thermostat cover gasket (3).
4--3
62--11362
SECTION 5
FUEL SYSTEM
5.1 CHECKING AND ADJUSTING
5.1.1 Injection Timing
1. Remove the fuel speed solenoid.
2. Remove the injection pipes and nozzle.
3. Move the speed control lever to the maximum speed
position.
NOTE
Turn the flywheel with a screwdriver.
4. Turn the flywheel counterclockwise (facing the flywheel) until the fuel fills up the hole of the delivery
valve holder for #1 cylinder.
5. Turn the flywheel further and stop turning when the
fuel begins to flow over.
6. Open the view port on the flywheel bell housing and
read the number on the flywheel. The number indicated is the timing value for the engine. (The flywheel
has a mark ’1TC’ and marks every 5° of engine timing
to 25° total).
Injection Timing
Factory
Specification
0.0568 to 0.0829 rad.
3.25° to 4.75°
B.T.D.C.
NOTE
Injection timing adjustment is accomplished by
adding or removing shims under the injection
pump.
The timing advances by removing one shim and
retards timing by adding the same shim.
The addition or removal of 0.05 mm (0.0020 in.)
of shim, changes the injection timing by approximately 0.009 rad. (0.5°).
Sealant should be applied to both sides of soft
metal gasket shims except for the .0175mm
shim. A .0175mm shim should have sealant applied to one side only.
When replacing the injection pump be sure to
use the same number and size of new gasket
shims.
5.1.2 Shim Identification
Shims are available in thicknesses of 0.20 mm,
0.25 mm, 0.30 mm, and 0.35mm. Combine
shims for adjustments.
1.
2.
3.
4.
5--1
Delivery Valve Holder
Timing Mark
2--Holes: 0.20 mm shim
1--Hole: 0.25 mm shim
5. 0--Holes: 0.30 mm shim
6. 3--Holes: 0.35 mm shim
7. 2--Holes: 0.175 mm shim
62--11362
5.1 CHECKING AND ADJUSTING
Fuel Pump
Pressure Test
1. Injection Pump Pressure
Tester
Factory
Specification
18.63 MPa
190 kgf/cm2
2702 psi
5.1.4 Delivery Valve Fuel Seal
1. Remove the engine fuel speed solenoid.
2. Remove the injection pipes and nozzle.
3. Connect a pressure tester to the fuel injection pump.
4. Connect the injection nozzle (2) jetted with the proper
injection pressure to the injection pump pressure tester (1).
5. Using the starter, rotate the crankshaft until the fuel
pressure is built up.
6. Release the pressure in the delivery chamber by rotating the crankshaft to bottom dead center. (turn the
crankshaft 1.57 rad. (90°) clockwise from fuel timing
set point)
7. If the pressure drop for 5 seconds exceeds the allowable limit, replace the delivery valve or pump assembly.
2. Injection Nozzle
3. Protective Cover
5.1.3 Pump Pressure Test
1. Remove the engine fuel speed solenoid.
2. Remove the injection pipes and nozzle.
3. Connect a pressure tester to the fuel injection pump.
4. Connect the injection nozzle (2) jetted with the proper
injection pressure to the injection pump pressure tester (1).
10 seconds
18.63 to 17.65 MPa
190 to 180 kgf/cm2
2702 to 2560 psi
Allowable
Limit
5 seconds
18.63 to 17.65 MPa
190 to 180 kgf/cm2
2702 to 2560 psi
Delivery Valve
Fuel Seal
5. Using the starter, rotate the crankshaft until the fuel
pressure is built up.
6. If the pressure does not build up, replace the pump
element with a new one and test again.
62--11362
Factory
Specification
5--2
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
1. Set the injection nozzle in a nozzle tester.
2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.
3. If the measurement is not within factory specifications, replace the nozzle assembly.
Fuel Injection
Pressure
1st Stage
Factory
Specification
18.64 to 20.1 MPa
190 to 205 kgt/cm2
2703 to 2915 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
1. Set the injection nozzle in a nozzle tester.
2. Raise the fuel pressure, and maintain 16.67 MPa
(170 kgf/cm2, 2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle
assembly.
Valve Seat Tightness
5--3
Factory
Specification
No fuel leak at
16.67MPa
170 kgf/cm2
2418 psi
62--11362
SECTION 6
ELECTRICAL SYSTEM
6.1 STARTER TEST
6.1.1 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 cable from the positive terminal on the
battery.
3. Disconnect the leads from the starter B terminal.
1. C Terminal
2. Positive Terminal
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter solenoid C terminal (1) to the positive battery terminal.
6. Connect a jumper lead momentarily between the
starter motor housing and the negative post on the
battery.
3. Negative Terminal
7. If the starter does not run, repair or replace the starter.
Tightening Torque
B
Terminal Nut
8.8 to 11.8 N.m
0.9 to 1.2 kgf.m
6.5 to 8.7 ft--lbs.
6.1.2 Magnetic Switch Test
NOTE
This test should only be carried out for a 3 to 5
second time period and not longer.
1. Disconnect the cable from the negative terminal on
the battery.
2. Disconnect the cable from the positive terminal on the
battery.
3. Disconnect the the positive cable and leads from the
starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1)
to the positive battery post (2).
6. Momentarily, connect a jumper lead between the
starter housing and negative battery terminal (3).
7. If the pinion gear nose does not pop out, replace the
starter.
NOTE
The B terminal is the terminal that connects the
cable from the battery to the starter.
1. S Terminal
2. Positive Terminal
3. Negative Terminal
The S terminal is the terminal that connects the
cable from the starter switch to the magnetic
switch.
6--1
62--11362
6.2 FUEL SPEED SOLENOID
6.2.1 Solenoid Test
WARNING
The solenoid can become very warm to the
touch when energized for any length in
time.
1. Disconnect the plug from the solenoid connector (2).
2. Remove the solenoid (1) from the engine.
3. Supply power (12VDC) to the solenoid thru terminals
(3) and (4).
4. If the rod in the solenoid (1) moves smoothly (approximately 0.6”), the solenoid is normal, if the rod does
not move, or moves only a fraction of that distance,
replace it.
1.
2.
3.
4.
62--11362
6--2
Fuel Speed Solenoid
Solenoid Connector
Terminal 2 (--)
Terminal 1 (+)
A. Actuator Rod (Power Off)
B. Actuator Rod (12VDC
applied)
6.3 INTAKE AIR HEATER
6.3.1 Intake Air Heater Test
1. Disconnect the lead from the heater terminal (1).
2. Measure the resistance between the heater positive
terminal (1) and the heater body (2).
3. If the resistance is infinity or significantly different
than the specification, replace the heater.
Intake Air Heater
Resistance
1. Positive Terminal
6--3
Factory
Specification
0.3 ohms
2. Heater Body
62--11362
INDEX
B
Battery, iv
bearing case, 2--15, 2--17
C
camshaft, 2--10, 2--24, 2--25
I
Identification, 1--1
idle gear, 2--10
injection nozzle, 5--3
injection timing, 5--1
intake air heater, 6--3
compression pressure, 2--1
connecting rod, 2--14, 2--27
L
coolant, iv, 2--2
coolant level, 1--13, 4--1
lubricating system, 3--1
cooling system, 4--1
crankshaft, 2--28
N
crankshaft oil slinger, 2--10
cylinder, 2--33
cylinder head, 2--3, 2--5, 2--18
Notched V--Belt, 4--1
D
dye/penetrant, 2--18
E
electrical system, 6--1
O
oil level, 1--13
oil pan, 2--12
oil pressure, 3--1
oil pump, 2--11, 3--2
engine oil, 1--14, 2--2
P
F
fan drive pulley, 2--9
piston, 2--13, 2--26, 2--27
flywheel, 2--15
piston ring, 2--14
fuel injection, 1--15, 2--3, 2--6
Poly V--belt, 4--1
fuel speed solenoid, 6--2
push rod, 2--22
fuel system, 5--1
fuel system -- bleeding , 1--14
G
R
radiator, 4--2
gear case, 2--9
radiator cap, 4--2
governor , 2--7, 2--8
rocker arm, 2--22
Index--1
62--11362
INDEX
S
V
Safety Precautions, iv
V--belt, 1--14
specifications, 1--2
valve clearance, 1--15
speed control plate, 2--7, 2--8
valve guide, 2--20
starter motor, 6--1
T
valve seat, 2--20
valve spring, 2--22
valves, 2--5, 2--19, 2--21
tappets, 2--5, 2--23
thermostat, 4--2
W
timing gear, 2--23
Torque Specification, 1--4
62--11362
water pump, 4--3
Index--2
North America
Carrier Transicold
700 Olympic Drive
Athens, GA 30601 USA
Tel: 1--706--357--7223
Fax: 1--706--355--5435
Mexico and
Central America
Ejercito Nacional No. 418
Piso 9, Torre Yumal
Col. Chapultepec Morales
11570 Mexico, D.F.
Tel: (5255) 9126.0300
Fax: (5255) 9126.0373
Carrier Transicold Division,
Carrier Corporation
Truck/Trailer Products Group
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
©2008 Carrier Corporation D Printed in U. S. A. 0508