Carrier CT2-29-TV, CT3-44-TV, Z482-E2B, D722-E2B Workshop Manual

R

Diesel Engine

CT2-29-TV (Z482-E2B)

CT3-44-TV (D722-E2B)

Beginning With Serial Number 5A0001

62--11161 Rev A

WORKSHOP MANUAL

for

Truck / ComfortPro

Truck

WORKSHOP MANUAL

DIESEL ENGINE

CT2-29-TV (Z482-E2B)

Truck / ComfortPro

CT3-44-TV (D722-E2B)

Truck

Beginning With Serial Number 5A0001

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

TABLE OF CONTENTS i........................................................................

SAFETY PRECAUTIONS i...................................................................

SPECIFIC WARNING AND CAUTION STATEMENTS i...........................................

General 1--1......................................................................................

1.1 ENGINE IDENTIFICATION 1--1............................................................

1.2 ENGINE SPECIFICATIONS 1--2............................................................

1.2.1 E2B Engine 1--3......................................................................

1.2.2 Cylinder Number 1--3..................................................................

1.3 GENERAL PRECAUTIONS 1--3............................................................

1.4 TORQUE SPECIFICATION 1--4............................................................

1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts 1--4..........................

1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts 1--4..........................

1.5 TROUBLESHOOTING 1--5................................................................

1.6 SERVICING SPECIFICATIONS 1--8........................................................

1.6.1 Engine Body 1--8......................................................................

1.6.2 Lubricating System 1--11................................................................

1.6.3 Cooling System 1--11...................................................................

1.6.4 Fuel System 1--11......................................................................

1.6.5 Electrical System 1--12..................................................................

1.7 CHECK AND MAINTENANCE 1--12..........................................................

1.7.1 Checking Engine Oil Level 1--12..........................................................

1.7.2 Changing Engine Oil 1--12...............................................................

1.7.3 Checking Coolant Level 1--12............................................................

1.7.4 Checking Fuel Hose 1--12...............................................................

1.7.5 Bleeding Fuel System 1--12..............................................................

1.7.6 Valve Clearance 1--13..................................................................

1.8 SPECIAL TOOLS 1--14.....................................................................

1.8.1 Diesel Engine Compression Tester (Glow Plug) 1--14.......................................

1.8.2 Adapter, Kubota 10 mm 1--14............................................................

1.8.3 Tester Injector Nozzle 1--14..............................................................

1.8.4 Replacement Bowl, Tester Injector Nozzle 1--14............................................

1.8.5 Adapter, Injector Line 1--14..............................................................

1.8.6 Oil Pressure Tester 1--15................................................................

1.8.7 Auxiliary Socket For Fixing Crankshaft Sleeve 1--15........................................

1.8.8 Guage, Belt Tension 1--15...............................................................

1.8.9 Tester, Belt Tension 1--15................................................................

1.8.10 Rubber Band 1--15.....................................................................

1.8.11 Valve Guide Replacing Tool 1--16.........................................................

1.8.12 Bushing Replacing Tools 1--16

1.8.13 Flywheel Stopper 1-- 16..................................................................

1.8.14 Crankshaft Bearing 1 Replacing Tool 1--17.................................................

...........................................................

i

62--11161

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 DISASSEMBLING AND ASSEMBLING 2--2..................................................

2.2.1 Draining Coolant 2--2..................................................................

2.2.2 Draining and Refilling Engine Oil 2--2....................................................

2.2.3 External Components 2--2..............................................................

2.2.4 Cylinder Head And Valves 2--3..........................................................

2.2.5 Oil Pan and Oil Pick--up Screen 2--6......................................................

2.2.6 Timing Gear, Camshaft and Fuel Camshaft 2--7...........................................

2.2.7 Piston and Connecting Rod 2--13.........................................................

2.2.8 Crankshaft 2--16.......................................................................

2.3 SERVICING 2--19.........................................................................

2.3.1 Cylinder Head And Valves 2--19..........................................................

2.3.2 Timing Gears, Camshaft and Fuel Camshaft 2--25..........................................

2.3.3 Piston and Connecting Rod 2--28.........................................................

2.3.4 Crankshaft 2--30.......................................................................

2.3.5 Cylinder 2--36..........................................................................

LUBRICATING SYSTEM 3--1.......................................................................

3.1 CHECKING AND ADJUSTING 3--1.........................................................

3.1.1 Checking Engine Oil Level 3--1..........................................................

3.1.2 Changing Engine Oil 3--1...............................................................

3.1.3 Changing Oil Filter 3--2................................................................

3.1.4 Engine Oil Pressure 3--2...............................................................

3.1.5 Relief Valve 3-- 3......................................................................

3.2 OIL PUMP SERVICE 3--3..................................................................

3.2.1 Rotor Lobe Clearance 3--3.............................................................

3.2.2 Rotor to Cover Clearance 3--3..........................................................

COOLING SYSTEM 4--1...........................................................................

4.1 CHECKING AND ADJUSTING 4--1.........................................................

4.1.1 V--Belt Tension 4--1....................................................................

4.1.2 Fan Belt Damage and Wear 4--1........................................................

4.1.3 Checking Coolant Level 4--1............................................................

4.1.4 Draining Coolant 4--1..................................................................

4.1.5 Radiator Cap 4--2.....................................................................

4.1.6 Radiator 4--2.........................................................................

4.1.7 Thermostat Opening Temperature 4--2...................................................

4.2 SERVICING 4--3.........................................................................

4.2.1 Thermostat Assembly 4-- 3..............................................................

4.2.2 Water Pump Assembly 4--3.............................................................

Page

62-11161

ii

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 Element Fuel Seal 5--2...........................................................

5.1.4 Delivery Valve Fuel Seal 5--2...........................................................

5.2 INJECTION NOZZLE 5--3.................................................................

5.2.1 Nozzle Spraying Condition 5--3..........................................................

5.2.2 Nozzle Injection Pressure 5--3..........................................................

5.2.3 Valve Seat Tightness 5--4..............................................................

5.2.4 Nozzle Holder 5--4....................................................................

ELECTRICAL SYSTEM 6--1........................................................................

6.1 GLOW PLUG 6--1........................................................................

6.1.1 Lead Terminal Voltage 6--1.............................................................

6.1.2 Glow Plug Continuity 6--1..............................................................

6.2 STARTER (CT2--29--TV) 6--2...............................................................

6.2.1 Motor Test 6--2........................................................................

6.2.2 Magnetic Switch Test 6--2..............................................................

6.2.3 Assembly 6--3.........................................................................

6.3 STARTER (CT3--44--TV) 6--4...............................................................

6.3.1 Motor Test 6--4........................................................................

6.3.2 Magnetic Switch Test 6--4..............................................................

6.4 STARTER SERVICING 6--6................................................................

6.4.1 Overrunning Clutch 6-- 6................................................................

6.4.2 Armature Bearing 6--6.................................................................

6.4.3 Brush Wear 6--6......................................................................

6.4.4 Solenoid 6--6.........................................................................

6.4.5 Brush Holder 6--6.....................................................................

6.4.6 Armature 6--7.........................................................................

6.4.7 Field Coil 6--8.........................................................................

Page

iii

62--11161

SAFETY

SAFETY PRECAUTIONS

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 pretrip 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.

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 cap must be removed, do so very slowly in order to release the pressure
without spray.

Battery

This unit is equipped with a leadacid type battery.The battery normally vents small amounts of flammable hydrogen
gas. Do not smokewhen checking thebattery.Abattery explosioncan causeserious physical harmand/or blindness.

SPECIFIC WARNING AND CAUTION STATEMENTS

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.

The statements listed on the next page 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.

i

62-11161

SPECIFIC WARNING AND CAUTION STATEMENTS (Continued)

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

Checkthe injectionnozzle only after confirming that nobody is near the spray. If the spray fromthe
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.

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

Stop the engine when preparing to change the engine oil filter.

CAUTION

Secure the starter to prevent it from moving when power is applied to it.

62-11161

ii

SECTION 1

Serial

Numb

General

1.1 ENGINE IDENTIFICATION

S/N

er

Z482--

7 K A

176

Last 3 Digits in Numerals (1 to 999 Units in Sequence)
7th Digit Sequential Numeral or Letter (Units Manufactured)

Alphabetical Numeral or Letter
Unit Number Sequence

6th Digit Alpabetical Letter (Month of Manufacture -- 1st Letter 1--9999 Units, 2nd Letter 10,000--19,998 Units)

Alphabetical letter
Month

When contacting Carrier Transicold, always specify
your engine model number and serial number.

The engine model and its serial number need to be
identified before the engine can be serviced or parts
replaced.

Engine Serial Number (S/N)

Theengine serialnumber is an identified number forthe
engine. It is marked after the engine model number.

It indicates basic model, month, year and sequence of
manufacture as follows:

0to9

to 19,998

A,B C,DE,FG,HJ,K L,M N,P Q,R S,T U,V W,X Y,Z

Jan Feb Mar May Jun Jul Aug Sep OctApr Nov Dec

A

19,999--20997 20,998--21,996

BC

21,997--22,995

5th Digit Alpabetical Letter or Numerals (Year of Manufacture)
Alphabetical letter or numerals W XY
Year 98 99 00 01 02 03 04 05 06 07 08 09

Basic model number

1234 56789

Table 1-1. Model Chart

KUBOTA

MODEL NO.

Z482--E2B CT2--29--TV
Z482--E2B CT2--29--TV

Z4 82 -- E 2B -- AT C-- 1 CT2--29--TV 96-- 101--05K

CARRIER

MODEL NO.

NEW ENGINE

PART NO.

26--60001--03*
26--60001--04*

PRIMARY USE REPLACES

SOLARA Units 26--60001--01

SUPRA Units 26--60001--02

ProHeat / ComfortPro PC5000

Units

NEW

Z482--E2B--TFX--1 CT2--29--TV 96-- 101--20K ComfortPro PC6000 Units NEW

D722--E2B CT3--44--TV

26--60000--05*

GENESIS Units 26--60000--00

* Beginning with Serial Number 5A0001

1--1

62--11161

1.2 ENGINE SPECIFICATIONS

Table 1-2. Specification Chart

MODEL NUMBER (Carrier / Kubota) CT2--29-- TV / Z482--E2B CT3--44-- TV / D722--E2B
TYPE Vertical, Water--cooled, 4 cycle IDI diesel engine
NUMBER OF CYLINDERS 2 3
BOREXSTROKE mmXmm(in.Xin.) 67 X 68 (2.64 X 2.68)
TOTAL DISPLACEMENT cm3(cu.in.) 479 (29.23) 719 (43.88)
BRAKE

HORSEPOWER
MAXIMUM BARE SPEED RPM 3800
IDLING SPEED RPM 900 To 1000
COMBUSTION CHAMBER Spherical Type (E--TVCS)
FUEL INJECTION PUMP BoschMD TypeMini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
INJECTION NOZZLE Bosch Throttle--Type
INJECTION TIMING (before T.D.C.) 19 to 21°
FIRING ORDER 1-- 2 1-- 2--3
INJECTION PRESSURE

(Valve Opening Pressure)
COMPRESSION RATIO 23.5 : 1
LUBRICATING SYSTEM Forced Lubrication by Pump
COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump
STARTING SYSTEM Cell Starter (With Glow Plug)
STARTING MOTOR 12V,0.8 kW
RECOMMENDED BATTERY CAPACITY

(5 Hour Capacity)
CHARGING GENERATOR 12V,150 W 12V, 150 W
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

Weight (DRY) kg (lbs.) 53.1 (117.1) 63.1 (139.1)

SAE Intermittent H.P.
kW (HP) / RPM

9.3 (12.5) / 3600 14.0 (18.0) / 3600

13.73 MPa (140 kgf/cm2, 1991 psi.)

12V,28AH, equivalent 12V,36AH, equivalent

2.5 L (2.64 U.S. Quarts)

3.3 L (3.5 U.S. Quarts) (TFX--1 Only)

3.8 L (4.02 U.S. Quarts)

*See paragraph 1.7.2.

62--11161

1--2

1.2.1 E2B ENGINE

Carrier/Kubota supply diesel engines conforming to
federalemission regulations.The emissioncontrols that
have been put into effect have been stepped up to the
second stage. Carrier/Kubota has executed the
improvement in the engines to conform to this
regulation.

In order to discriminate between engines conforming to
Tier 1 / Phase 1 requirements and those conforming to
Tier2/ Phase 2requirements, wehave adapted E2Bas
a new model namefor theengines conforming to Tier2/
Phase 2 regulations.

In the after--sale services for Tier 2 / Phase 2 engines,
only use the dedicated parts for E2B models and carry
out the maintenance services accordingly.

1.2.2 CYLINDER NUMBER

1.3 GENERAL PRECAUTIONS

During disassembly,carefully arrange removed parts in
a clean area to prevent confusion latter. Screws, bolts
and nuts should be replaced in their original position to
prevent reassembly errors.

When special tools are required, use Carrier Transicold
genuine special tools. Special tools which are not
frequently used should be made according to the
drawings provided.

Before disassembling or servicing electrical 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.

The cylinder numbers of diesel engines are designated
as shown above. The sequence of cylinder numbers is
given as No.1, No. 2, and No. 3 starting from the gear
case end of the engine.

1

2

2

1. Grease

2. Force

3. Place the Sharp Edge
against the Direction of Force

3

A External Snap Ring
B Internal Snap Ring

3

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--11161

1.4 TORQUE SPECIFICATION

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.

1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts

In removing andapplying the screws, bolts and nuts marked with “*”, apneumatic wrenchor similar tool, ifemployed,
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

SizexPitch N.m kgf.m ft--lbs

Cylinder Head Cover Bolt M6 x 1.0 6.9to11.3 0.7to1.15 5.1to8.3
Injection Pipe Retaining Nut M12 x 1.5 24.5 to 34.3 2.5to3.5 18.1 to 25.3
Overflow Pipe Retaining Bolt M12 x 1.5 19.6 to 24.5 2.0to2.5 14.5 to 18.1
Nozzle Holder Assembly M20 x 1.5 49.0 to 68.6 5.0to7.0 36.2 to 50.6

Glow Plug M8 x 1 7.85 to 14.7 0.8to1.5 5.8 to 10.8
*Rocker Arm Bracket Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
*Cylinder Head Bolt M8 x 1.25 37.3 to 42.2 3.8to4.3 27.5 to 31.1
*Fan Drive Pulley Bolt M12 x 1.5 1 17.7 to 127.5 12.0 to 13.0 86.8 to 94.0
*Idle Gear Shaft Mounting Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
Oil Pump Mounting Bolt M8 x 1.25 17.7 to 21.6 1.8to2.2 13.0 to 15.9
*Connecting Rod Bolt M7 x 0.75 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Flywheel Bolt M10 x 1.25 53.9 to 58.8 5.5to6.0 39.8 to 43.4
*Bearing Case Cover Mounting Bolt M6 x 1 9.8to11.3 1.00 to 1.15 7.2to8.3
*Main Bearing Case Bolt 2 M7 x 1 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Main Bearing Case Bolt 1 M6 x 1 12.7 to 15.7 1.3to1.6 9.4to11.6

Nozzle Holder -- 34.3 to 39.2 3.5to4.0 25.3 to 28.9

Overflow Pipe -- 19.6 to 24.5 2.0to2.5 14.5 to 18.1

Nozzle Holder Assembly -- 49.0 to 68.6 5.0to7.0 36.2 to 50.6

Oil Pressure Switch PT1/8 14.7 to 19.6 1.5to2.0 10.8 to 14.5

Starter (C Terminal Nut) (CT2--29--TV) M8 7.8to9.8 0.8to1.0 5.8to7.2

Starter (B Terminal Nut) (CT3--44--TV) M8 8.8to11.8 0.9to1.2 6.5to8.7

Starter (C Terminal Nut) (CT3--44--TV) M8 5.9to11.8 0.6to1.2 4.3to8.7
Drain Plug W/ Copper Gasket M12 x 1.25 32.4 to 37.3 3.3to3.8 23.9 to 27.5
Drain Plug W/ Copper Gasket M22 x 1.5 63.7 to 73.5 6.5to7.5 47.0 to 54.2
Drain Plug W/ Rubber Coated Gasket M12 x 1.25 44.1 to 53.9 4.5to5.5 32.5 to 39.8

1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Grade 4 Special Screw and Bolt Grade 7

N.m kgf.m ft--lbs N.m kgf.m ft--lbs

M6 7.9to9.3 0.80 to 0.95 5.8to6.9 9.8to11.3 1.00 to 1.15 7.23 to 8.32

M8 17.7 to 20.6 1.8to2.1 13.0 to 15.2 23.5 to 27.5 2.4to2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0to4.6 28.9 to 33.3 48.1 to 55.9 4.9to5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4to7.4 46.3 to 53.5 77.5 to 90.2 7.9to9.2 57.1 to 66.5

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be
sure to check out the numbers as shown below

Punched Number

Screw And Bolt Material Grade

None or 4 Standard Screw And Bolt SS41, S20C

7 Special Screw And Bolt S43C, S48C (Refined)

62--11161

1--4

1.5 TROUBLESHOOTING
Symptom

Engine Does Not
Start

(Starter Does Not
Run)

Engine Revolution
Is Not Smooth

Either White or Blue
Exhaust Gas Is
Observed

Probable Cause Solution Reference

No fuel Replenish fuel
Air in the fuel system Vent Air 1.7.5

Change fuel and

Water in the fuel system

repair or replace fuel

1.7.5

system
Fuel pipe clogged Clean 1.7.5
Fuel filter clogged Clean or change -­Excessively high viscosity of fuel or engine oil

at low temperature

Use specified fuel or

engine oil

--

Fuel with low cetane number Use specified fuel -­Fuel leak due to loose injection pipe retaining

nut

Tighten retaining nut 2.2.4.b

Incorrect injection timing Adjust 5.1.1
Fuel camshaft worn Replace 2.2.6.g
Injection nozzle clogged Replace 5.2.1/5.2.2
Injection pump malfunctioning Replace -­Seizure of crankshaft, camshaft, piston,

cylinder or bearing

Repair or Replace -­Replace head

gasket, tighten
Compression leak from cylinder

cylinder head screw,

--

glow plug and nozzle

holder
Improper valve timing

Correct or replace

timing gear

2.2.6.e

Piston ring and cylinder worn Replace 2.3.3.d
Excessive valve clearance Adjust 1.7.6
Battery discharged Charge
Starter malfunctioning Repair or replace 6.2/6.3
Wiring disconnected Connect -­Fuel filter clogged or dirty Clean or change 1.7.5
Air cleaner clogged or dirty Clean or change -­Fuel leak due to loose injection pipe retaining

nut

Tighten retaining nut --

Injection pump malfunctioning Replace 2.2.6.a
Incorrect nozzle injection pressure Replace 5.2.2
Injection nozzle stuck or clogged Replace 5.2.2
Governor malfunctioning Repair 2.2.6.g

Excessive engine oil

Reduce to specified

level

1.7.1

Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1

Check the cylinder

Deficient compression

compression

pressure and top

2.1.1

clearance

1--5

62--11161

1.5 TROUBLESHOOTING (Continued)
Symptom

Either Black or Dark
Exhaust Gas Is
Observed

Deficient Output

Excessive Lubricant
Oil Consumption

Fuel Mixed into
Lubricant Oil

Water Mixed into
Lubricant Oil

Low Oil Pressure

High Oil Pressure

Probable Cause Solution Reference

Overload Lesson load -­Low grade fuel used Use specified fuel -­Fuel filter clogged Clean or change -­Air cleaner clogged Clean or change -­Deficient nozzle injection Replace nozzle 5.2.4
Incorrect injection timing Adjust 5.1.1
Engine’s moving parts seem to be seizing Repair or replace --

Uneven fuel injection

Deficient nozzle injection

Replace injection
pump

Repair or replace
nozzle

2.2.6.a

5.2.4

Check the

Compression leak

compression

2.1.1

pressure and repair

Piston ring’s gap facing the same direction

Shift ring gap

direction

2.2.7.b

Oilringwornorstuck Replace 2.3.3.d
Piston ring groove worn Replace worn piston 2.3.3.e
Valve stem and valve guide worn Replace 2.3.1.d
Oil leaking due to defective seals or packing Replace --

Injection pump’s plunger worn

Replace Injection

pump

5.1

Deficient nozzle injection Replace nozzle 5.2.4
Injection pump broken Replace 5.1
Head gasket defective Replace 2.2.4.e
Cylinder block or cylinder head flawed Replace -­Engine oil level low Replenish -­Oil filter cartridge clogged Replace -­Relief valve stuck with dirt Clean 3.1.5
Relief valve spring weak or broken Replace 3.1.5
Excessive clearance of crankshaft bearing Replace 2.3.4.d
Excessive clearance of crankpin bearing Replace 2.3.4.c
Excessive clearance of rocker arm Replace 2.3.1.k
Oil passage clogged Clean --

Incorrect oil type

Use specified type of

oil

--

Oil pump defective Repair or replace 2.2.6.h/3.2
Incorrect oil type

Use specified type of

oil

--

Relief valve defective Replace 3.1.5

62--11161

1--6

1.5 TROUBLESHOOTING (Continued)
Symptom

Engine Overheated

Low Battery Charge

Probable Cause Solution Reference

Engine oil level low Replenish -­Fan belt broken or improperly tensioned Replace or adjust -­Coolant insufficient Replenish -­Radiator net and radiator fin clogged with dust Clean -­Inside of radiator corroded Clean or replace -­Coolant flow route corroded Clean or replace -­Radiator cap defective Replace -­Radiator hose defective Replace -­Running overloaded Reduce load -­Head gasket defective Replace 2.2.4.e
Incorrect injection timing Adjust -­Unsuitable fuel used Use specified fuel --

Battery electrolyte level low

Fan belt slips

Replenish distilled

water and charge

Adjust belt tension or

change belt

--

--

Wiring disconnected Connect -­Rectifier defective Replace -­Alternator defective Replace -­Battery defective Change --

1--7

62--11161

1.6 SERVICING SPECIFICATIONS

1.6.1 Engine Body
Item

Valve Clearance (Cold)

Compression Pressure

Factory Specification Allowable Limit

0.145 to 0.185 mm

0.00571 to 0.00728 in.

2.84 to 3.24 MPa

29.0to33kgf/cm

2

412 to 469 psi

--

2.26 MPa

23.0kgf/cm
327 psi

Difference Between Cylinders -- 10% or less
Top Clearance

Cylinder Head Surface Flatness

Valve Recessing (Intake and Exhaust)

Clearance

ValveStemtoValveGuide

Valve Stem
O.D.

Valve Guide
I.D.

Valve Face Angle

Angle

Valve Seat

Width

Free Length

Valve Spring

Tilt --

Setting Load/
Setting Length

Clearance

Rocker Arm Shaft to Rocker Arm

Rocker Arm
Shaft (O.D.)

Rocker Arm (I.D.)

Push Rod Alignment

Clearance

Tappet to Tappet Guide

Tappet (O.D.)
Tappet Guide

(I.D.)

0.50 to 0.70 mm

0.0197 to 0.0276 in.

--0.10 to 0.10 mm

--0.0039 to 0.0039 in.

0.030 to 0.057 mm

0.00118 to 0.00224 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm.

0.23661 to 0.23720 in.

0.785 rad.
45°

0.785 rad.
45°

2.12 mm

0.0835 in.

31.3 to 31.8 mm

1.232 to 1.252 in.

64.7 N / 27.0 mm

6.6 kgf / 27.0 mm

14.6 lbs. / 1.063 in.

0.016 to 0.045 mm

0.00063 to 0.00177 in.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

-- 0.25mm

0.016 to 0.052 mm

0.00063 to 0.00205 in.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in.

--

0.05 mm

0.0020 in.

0.30 mm

0.0118 in.

0.10 mm

0.0039 in.

--

--

--

--

--

28.4 mm

1.118 in.

1.2 mm

0.047 in.

54.9N / 27.0 mm

5.6kgf / 27.0 mm

12.3lbs /1.063 in.

0.15 mm

0.0059 in.

--

--

0.0098 in.

0.10 mm

0.0039 in.

--

--

2

62--11161

1--8

1.6.1 Engine Body (Continued)
Item

Crank Gear to
Idle Gear
(Backlash)

Idle Gear to Cam
Gear (Backlash)

Timing Gear

Idle Gear to Injec­tion Pump Gear
(Backlash)

Crank Gear to Oil
Pump Gear
(Backlash)

Idle Gear Side Clearance

Side Clearance

Camshaft

Alignment -­Height

(Intake / Exhaust)
Clearance 0.050 to 0.091 mm

Camshaft Journal to Cylinder Block Bore

Camshaft
Journal (O.D.)

Cylinder Block
Bore (I.D.)

Clearance 0.020 to 0.084 mm

Idle Gear Shaft to Idle Gear Bushing

Idle Gear Shaft
(O.D.)

Idle Gear Bushing
(I.D.)

Piston Pin Bore I.D.

Clearance

Piston Pin to Small End Bushing

Piston Pin (O.D.)
Small End

Bushing (I.D.)

Piston Pin to Small End Bushing
(Spare Parts)

Clearance
Small End

Bushing (I.D.)
Top Ring

Piston Ring Gap

Second Ring

Oil Rng

Factory Specification Allowable Limit

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.046 to 0.124 mm

0.00181 to 0.00488 in.

0.041 to 0.123 mm

0.00161 to 0.00484 in.

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.80 mm

0.0315 in.

0.50 mm

0.0197 In.

0.01 mm

0.0004 In.

26.88 mm

1.0583 in.

26.83 mm

1.0563 In.

0.15 mm

0.00197 to 0.00358 in.

32.934 to 32.950 mm

1.29661 to 1.29724 in

33.000 to 33.025 mm

1.29921 to 1.30020

0.00059 in.

--

--

0.1 mm

0.00079 to 0.00331 in.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78791 in.

20.000 to 20.013 mm

0.78740 to 0.78941 in.

0.014 to 0.038 mm

0.00055 to 0.00150 in.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

0.015 to 0.075 mm

0.00059 to 0.00295 in.

20.026 to 20.077 mm

0.78845 to 0.79043 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.0039 in.

--

--

20.05 mm

0.7894 in.

0.10 mm

0.0039 in.

--

--

0.15 mm

0.0059 in.

--

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1.20 mm

0.0472 in.

1--9

62--11161

1.6.1 Engine Body (Continued)
Item

Piston Ring to Piston Ring Groove

Second Ring
Clearance

Oil Ring
Clearance

Factory Specification Allowable Limit

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.040 to 0.080 mm

0.0016 to 0.0031 in.

Connecting Rod Alignment --

Side Clearance

0.15 to 0.31 mm

0.0059 to 0.0122 in.

Crankshaft

Alignment --

0.020 to 0.051 mm

0.00079 to 0.00201 in.

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

0.034 to 0.106 mm

0.00134 to 0.00417 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57148 to 1.57638 in.

0.028 to 0.051 mm

0.00110 to 0.00201 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.984 to 44.026 mm

1.73165 to 1.73331 in.

0.028 to 0.051 mm

0.00110 to 0.00201 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.026 mm

1.57417 to 1.57583 in.

67.000 to 67.019mm

2.63779 to 2.63854 in.

67.250 to 67.269mm

2.64764 to 2.64839 in.

Crankpin to Crankpin Bearing

Crankshaft Journal to Crankshaft Bearing1

Crankshaft Journal to Crankshaft Bearing2
(Flywheel Side)

Crankshaft Journal to Crankshaft Bearing3
(Intermediate)

Cylinder Liner

Oil Clearance

Crankpin (O.D.)
Crankpin Bearing

(I.D.)
Oil Clearance
Crankshaft

Journal (O.D.)
Crankshaft

Bearing1 (I.D.)
Oil Clearance
Crankshaft

Journal (O.D.)
Crankshaft

Bearing2 (I.D.)
Oil Clearance
Crankshaft

Journal (O.D.)
Crankshaft

Bearing3 (I.D.)
I.D. (Standard)
I.D. (Oversize) :

0.25mm

0.0098in.

0.15 mm

0.0059 in

0.15 mm

0.0059 in.

0.05 mm

0.0020 in.

0.50 mm

0.0197 in.

0.02 mm

0.0008 in.

0.15 mm

0.0059 in.

--

--

0.20 mm

0.0079 in.

--

--

0.20 mm

0.0079 in.

--

--

0.20 mm

0.0079 in.

--

--

67.150 mm

2.64370 in.

67.400mm

2.65354 in.

62--11161

1--10

1.6.2 Lubricating System
Item

At Idle Speed

Engine Oil Pressure*

At Rated Speed

Inner Rotor to Outer Rotor Clearance

Outer Rotor to Pump Body Clearance

Inner Rotor to Cover Clearance

*Engines installed in Genesis, Solara and Supra units use an oil pressure safety switch which opens at
105 kPa / 1.06 kgf/cm

2

/ 15 psi.

Factory Specification Allowable Limit

More than 49kPa

0.5 kgf/cm
196 to 441 kPa

2.0 to 4.5kgf/cm

2

/7psi

2

/28to64psi

147kPa

1.5kgf/cm

0.03 to 0.14 mm

0.0012 to 0.0055 in.

0.07 to 0.15 mm

0.0028 to 0.0059 in.

0.075 to 0.135 mm

0.00295 to 0.00531 in.

--

2

/21psi

--

--

--

1.6.3 Cooling System
Item

Factory Specification Allowable Limit

7.0 to 9.0 mm at 98N

V--Belt Tension

0.28 to 0.35 in. at 98N

--

(10kgf, 22 lbs.)

Thermostat

Valve Opening
Temperature
(At Beginning)

Valve Opening
Temperature
(Opened Completely)

69.5 to 72.5°C
157 to 162.5°F

85°C

185°F

--

--

10 seconds or more

Radiator Cap Pressure Falling Time

88 to 59kPa

0.9 to 0.6 kgf/cm

2

--

13to9psi

No leaks at specified

Radiator

Leakage Test
Pressure

pressure

157 kPa / 1.6 kgf/cm

2

--

23 psi

1.6.4 Fuel System

Injection Pump

Item

Injection Timing
(3600 min

-- 1

rpm)

Factory Specification Allowable Limit

0.33 to 0.37 rad. (19° to
21°) before T.D.C

Pump Element Fuel Tightness --

10 seconds

Delivery Valve Fuel Tightness

13.73 to12.75 MPa
140 to130 kgf/cm

1991 to 1849 psi

13.73 to 14.71 MPa

Injection Pressure

140 to 150 kgf/cm

1991 to 2134 psi

Fuel Injection Nozzle

Valve Seat
Tightness

When the pressure is

12.75 MPa

(130 kgf/cm

valve must not pass fuel

1--11

2

2

2,1849 psi) the

--

13.73 MPa

140 kgf/cm

2

1991 psi

5 seconds

13.73 to12.75
MPa

140 to130 kgf/cm

1991 to 1849 psi

--

--

62--11161

2

1.6.5 Electrical System
Item

Glow Plug Resistance Approximately 0.9 OHM --

CT2--29--TV

Commutator O.D.

CT3--44--TV

CT2--29--TV

Difference of O.D.

Starter

Mica Undercut

Brush Length

1.7 CHECK AND MAINTENANCE

1.7.1 Checking Engine Oil Level

1. Refer to Section 3.1

1.7.2 Changing Engine Oil

1. Refer to Section 3.1

1.7.3 Checking Coolant Level

1. Refer to Section 4.1.3

1.7.4 Checking Fuel Hose

1. If the clamp is loose, apply oil to the threads and

securely retighten it.

2. The fuel hoseis 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 de-

terioration or damage is detected.

4. After the fuel hose and clamps have been changed,

bleed air out of the fuel system.

CT3--44--TV

CT2--29--TV

CT3--44--TV

1.7.5 Bleeding Fuel System

1. Open the air vent cock (1) on top of the fuel injection

2. Energizethe electricfuel pumpfor aperiodof 10to15

3. Close the air vent cock (1).

Factory Specification Allowable Limit

28.0 mm

1.1.102 in.

30.0 mm

1.181 in.

Less than 0.05 mm

0.0002 in.

Less than 0.02 mm

0.0008 in.

0.50 to 0.80 mm

0.0197 to 0.0315 in.

0.16 mm

0.630 in.

0.14 mm

0.551 in.

1

pump. (Availableon Solara, Supraand Genesis units
only.)

seconds, orjust longenough toexpel fuelthroughthe
air vent cock.

27.0 mm

1.063 in.

29.0 mm

1.142 in.

0.4 mm

0.016 in.

0.05 mm

0.0020 in.

0.20 mm

0.0079 in.

10.5 mm

0.413 in.

9.0 mm

0.354 in.

CAUTION

Stop the engine when attempting to check
and change the fuel line.

62--11161

NOTE

Always keep the air vent cock on the fuel injec­tionpump closed except when bleedingthe fuel
system, or the engine may not run.

1--12

1.7.6 Valve Clearance

NOTE

Valveclearance must bechecked andadjusted
when the engine is cold.

1. Remove the valve cover (1).

2. Align the “1TC” mark line (2) on the flywheel and pro­jection (3)on thehousing sothat the Number 1 piston
comes to compression top dead center (TDC).

3. Check the following valve clearance marked with “*”
(at TDC) using a feeler guage.

4. If the clearance is not within the factory specifica­tions, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360°), and align the
“1TC” mark (2) on the flywheel and alignment mark
(3)on therear endplateso that theNo. 1pistoncome
to the overlap position.

6. Check the following valve clearance marked with “*”
(past TDC) using a feeler guage.

CT2--29--TV

Piston Location in Cylinder IN. EX.

When No. 1 piston is at TDC

When No. 1 piston is past TDC

No. 1 * *
No. 2 *
No. 1
No. 2 *

Valve

Arrangement

1. Cylinder Head Cover

2. “1TC” Mark

3. Alignment Mark

A. Gear Case End
a. CT2--29--TV

b. CT3--44--TV

CT3--44--TV

Piston Location in Cylinder IN. EX.

When No. 1 piston is at TDC

When No. 1 piston is past TDC

No. 1 * *
No. 2 *
No. 3 *
No. 1
No. 2 *
No. 3 *

Valve

Arrangement

7. If the clearance is not within the factory specifica­tions, adjust with the adjusting screw.

NOTE

The sequence of cylinder numbers is given as
No.1,No.2 andNo.3startingfrom thegearcase
end.

After adjusting the valve clearance, secure the
adjusting screw with the lock nut.

1--13

62--11161

1.8 SPECIAL TOOLS

Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number
62--03213.

1.8.1 Diesel Engine Compression Tester (Glow
Plug)

Part No. 07--00179--01 (Assembly)
Application: Use to measure diesel engine

compression and diagnosis for
major overhaul.

1.8.2 Adapter, Kubota 10 mm

Part No. 07--00179--05
Application: Accessory for 07--00179--01

1.8.3 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.

1.8.4 Replacement Bowl, Tester Injector Nozzle

Part No. 07--00140--10
Application: Accessory for 07--00140--00

1.8.5 Adapter, Injector Line

Part No. 07--00036--00
Application: Accessory for 07--00140--00

62--11161

1--14

1.8 SPECIAL TOOLS (Continued)

Adapte

3

8.Adapto

3

1.8.6 Oil Pressure Tester

Code No. 07916--32032
Application: Use to measure lubricating oil
pressure.

1. Guage

2. Adapter 2

3. Cable

4.

r

5. Threaded Joint

6. Adapter 4

7. Adaptor 1
r

1.8.7 Auxiliary Socket For Fixing Crankshaft
Sleeve

Code No. 07916--32091
Application: Use to fix the crankshaft sleeve of the

diesel engine.

1.8.8 Guage, Belt Tension

Part No. 07--00203--00
Application: Used to adjust belt tension of all
cogged V--belts.

1.8.9 Tester , Belt Tension

Part No. 07--00253--00
Application: Used to test belt tension.

1.8.10 Rubber Band

Part No. 07--00253--01
Application: Replacement part for belt tension
tester (Part No. 07--00253--00)

1--15

62--11161

1.8 SPECIAL TOOLS (Continued)

The following are drawings for special tools that may need to be fabricated.

1.8.11 Valve Guide Replacing Tool

Application: Use to press out and press fit the valve

A
B 11.7to 11.9mm 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 6.7to 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.)

1.8.12 Bushing Replacing Tools

Application: Use to press out and press fit the bushing.

1. For small end bushing.
A

B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm (0.7835 to 0.7854 in.) dia.
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25.00 mm (098 in.) dia.

a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)

2. For idle gear bushing.
A

B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95.95 mm (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25 mm (0.98 in.)

a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)

1.8.13 Flywheel Stopper

Application: Use to loosen and tighten the flywheel

A
B 20 mm (0.79 in.)
C 30 mm (1.18 in.)
D 8 mm (0.31 in.)
E 10 mm (0.39 in.)

guide.

20 mm dia. (0.79 in. dia.)

145 mm (5.71 in.)

150 mm (5.91 in.)

screw.

200 mm (7.87 in.)

62--11161

1--16

1.8 SPECIAL TOOLS (Continued)

1.8.14 Crankshaft Bearing 1 Replacing Tool

Application: Usetopress outandpressfit thecrankshaft

bearing No. 1

1. Extracting tool

135 mm (5.31 in.)

A

B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)

E 22 mm (0.87 in.)

F 20 mm dia. (0.79 in. dia.)
G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

2. Installing tool
A

130 mm (5.12 in.)

B 72 mm (2.83 in.)

C 40 mm radius (1.57 in. radius)
D 9 mm (0.35 in.)

E 24 mm (0.95 in.)
F 20 mm dia. (0.79 in.dia.)

G 68 mm dia. (2.68 in. dia.)
H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)

1--17

62--11161

SECTION 2

ENGINE BODY

2.1 CHECKING AND ADJUSTING

2.1.1 Compression Pressure

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
glow plugs.

4. Install acompressiontester withthe adapter inone of
the glow plug holes.

5. While cranking the engine with the starter measure
the compression pressure.

6. Repeat steps 1 thru 5 for each cylinder.

2.1.2 Top Clearance

7. If themeasurementis belowthe allowablelimit,add a
small amount of oil to the cylinder thru the glow plug
hole and measure the compression again.

a. If the compression pressure is still less than the al-

lowable limit, check the top clearance, valves and
cylinder head.

b. If thecompression pressureincreasesafterapplying

oil, check the cylinder wall and piston rings.

NOTE

Check the compression pressure with the spe­cified valve clearance

Always use a fully charged battery for perform­ing this test.

Variances in cylinder compression values
should be under 10%.

2.84 to 3.24 MPa
29 to 33 kgt/cm

412 to 469 psi

2.26 MPa

23 kgt/cm

2

327 psi

2

Compression

Pressure

Factory

Specification

Allowable Limit

1. Piston 2. Plastigage

1. Remove the valve cover. Refer to 2.2.4.a.

2. Remove the cylinder head.

3. Move the piston (1) up and stick a strip of plastigage
(2)on thepistonhead atthreepositions shown on the
illustration.

4. Lower the piston andinstall the cylinder head. (Use a
new cylinder head gasket and tighten the cylinder
head bolts to the proper torque.

5. Turn the flywheel until the piston (1) passes through
top dead center.

6. Remove the cylinder head and measure the plasti­gage .

7. If the measurement is not within the factory specifica­tions, check the clearances between the crank pin
and bearing and between the piston pinand bushing.

Top Clearance

Tightening

Torque

Factory

Specification

Cylinder Head

Bolts

0.50 to 0.70 mm

0.0197 to 0.0276 in.

37.3 to 42.2 N.m

3.8to4.3kgf

27.5 to 31.1 ft--lbs

.

m

2--1

62--11161

2.2 DISASSEMBLING AND ASSEMBLING

2.2.1 Draining Coolant

Refer to Section 4.

2.2.2 Draining and Refilling Engine Oil

Refer to Section 3.

2.2.3 External Components
Alternator, Starter and Others

1. Remove the air cleaner and muffler.

2. Removethe enginestopsolenoid (1)(if soequipped).

3. Remove the fan(2), fan belt(3), alternator and start­er.

4. Remove the alternator.

5. Remove the starter.

When Reassembling

Replace the starter.
Replace the alternator.
Replace the fan, fan belt, alternator and starter.

NOTE

When reinstalling the fan, make sure that it is
seated correctly.

Check to see that there areno cracks in the fan
belt.

After reinstaling the fan belt, be sure to adjust
the fan belt tension. (Refer to Section 4.1.1.)

Replace the engine stop solenoid (1) (if so equipped)
andadjust the linkageso that engine stop lever (5)rests
against thestopper(4) whenthe engine stop solenoidis
not energized. There should be no tension on the
plunger arm (7) when the engine stop solenoid is not
energized. Adjustment is accomplished by loosening
the engine stop mounting screws and moving the
engine stop solenoid (1).

62--11161

2--2

2.2.4 Cylinder Head And Valves

2.2.4.a Valve Cover

1. Remove the breather tube (1).

2. Remove the valve cover bolts (2).

3. Remove the valve cover (3).

When Reassembling

Check to see that the valve cover gasket is in good
condition and in place.

Tightening

Torque

Valve Cover

Bolts

6.86 to 11.3 N.m

0.7to1.15kgf

5.1to8.32ft--lbs

.

m

2.2.4.b Injection Pipes

1. Loosen the screws on the pipe clamps (1).

2. Detach the injection pipes (2).

When Reassembling

Blow out any debris that may be in the pipes with
compressed air, then reassemble pipes.

Tightening

Torque

Injection Pipe

Retaining

Nut

24.5 to 34.3 N.m

2.5to3.5kgf

18.1 to 25.3 ft--lbs

.

m

2.2.4.c Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly (1).

2. Remove the nozzle holder assemblies (2).

3. Remove the copper gasket (5) and heat seal (6).

1. Overflow Pipe

2. Nozzle Holder Assembly

3. Glow Plug Bus Bar

4. Glow Plug

5. Copper Gasket

6. Heat Seal

4. Remove the glow plug buss bar (3) from the glow
plugs (4).

5. Remove the glow plugs (4).

When Reassembling

Replace the copper gasket(s) and heat seal(s) with a
new one(s).

49.0 to 68.6 N.m

5.0to7.0kgf

36.2 to 50.6 ft--lbs

19.6 to 24.5 N.m

2.0to2.5kgf

14.5 to 18.1 ft--lbs

7.85 to 14.7 N.m

0.8to1.5kgf

5.8 to 10.8 ft--lbs

Tightening

Torque

Nozzle Holder

Assembly

Overflow Pipe

Assembly

Retaining Nut

Glow Plug

2--3

.

m

.

m

.

m

62--11161

2.2.4 Cylinder Head And Valves (Continued)

ArmA

y

1. RockerArmBracketBolts

2. Rocker

ssembl

2.2.4.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 end are properly engaged with the
dimples.

NOTE

After instaling the rocker arm, be sure to adjust
the valve clearance (Refer to Section 1.7.6).

Tightening

Torque

Rocker Arm

Bracket Mounting

Bolt

9.8 to11.3 N.m

1.00 to 1.15 kgf

7.2to8.3ft--lbs

.

m

2.2.4.e Cylinder Head

1. Loosen the hose clamps (1), and remove the water
return hose (2).

2. Remove the cylinder head bolts in the order of a: (10
to 1) or b: (14 to 1).

3. Lift up the cylinder head and remove.

4. Remove the cylinder head gasket and O--ring (3).

When Reassembling

Replace the cylinder head gasket with a new one.
Install the cylinder head, taking care not to damage the

O--ring (3).

a

6

10

9

5

3

2

1

7

8

4

B

b

10

14

13

1. Hose Clamp

2. Water Return Hose
3O--ring
a. CT2--29--TV

9

2

6

5

1

7

3

4

b. CT3--44--TV
A: Gear Case Side
B: Flywheel Side

11

12

8

62--11161

Apply oil to, then re--install the cylinder head bolts.
Tighten the cylinder head bolts in sequence starting

fromthe centerinthe orderofa: (1 to 10)o r b:(1 to 14)..
Retighten the head bolts after running the engine for 30

minutes.

Tightening

Torque

Cylinder Head

Bolt

37.3 to 42.2 N.m

3.8to4.3kgf

27.5 to 31.1 ft--lbs

2--4

.

m

2.2.4 Cylinder Head And Valves (Continued)

2.2.4.f Tappets

1. Remove the tappets (1) from the crankcase.

2. Visuallycheck thetappets forany abnormalcamshaft
contact wear pattern. If unusual wear/damage has
occurred, replace the tappet.

3. Coat the tappets with engine oil before reinstalling
them back into the crankcase.

NOTE

The tappets must always be reinstalled in their
original bores.

2.2.4.g Valves

1. Remove the valve caps (2).

2. Remove the valvespring collet (3), pushing the valve
springretainer (4)bythe valvespring compressor(1).

3. Remove thevalve spring retainer (4), valve spring(5)
and valve stem seal (6).

4. Remove the valve (7).

When Reassembling

Clean the valvestem andthe valve guide. Apply engine
oil to the valve stem when reassembling.

After installing the valve springcollets (3), lightly tapthe
stem with a plastic hammer to assure the collets have
seated on the valve stem.

NOTE

When re--installing valves into the cylinder
head, make sure that they are re--installed in
their original location.

2--5

62--11161

2.2.5 Oil Pan and Oil Pick--up Screen
CT2--29--TV

(1)

(2)

CT3--44--TV

(3)

(4)

(3)

(2)

(1)

1. Remove the oil pan mounting bolts.

2. Remove the oil pan by lightly tapping the side of the
pan with a soft hammer.

3. Scrape off theold adhesive from the mating surfaces
of the oil pan and the engine block completely.

4. Remove the oil pick--up screen (1).

5. Clean and Inspect the oil pick--up screen (1) for dam­age.

6. Visually inspect the oil pick--up screen O--ring (4) for
damage, oil it and reinstall.

7. CT2--29--TV engine, use holelabeled 2, CT3--44--TV
engine, use hole labeled 3 to install the pick--up
screen mounting bolt.

8. Apply gasket cement (sealer) so that the sealer is
about 3 to 5 mm (0.12 to 0.20 in.) thick around the
flange of the oilpan. Apply the sealer onthe center of
the flange as well as on the inner wall of each bolt
hole.

9. Within 20 minutes after the application of the sealer,
replace the oil pan and mounting bolts.

NOTE

Refer toSection1.4 for propertorque valueson
all fasteners.

Sealer Location

62--11161

2--6

2.2.6 Timing Gear, Camshaft and Fuel Camshaft

2.2.6.a Injection Pump, Fuel Feed Pump and Speed
Control Plate (Solara, Supra, Genesis and
PC5000 Units Only.)

1. Remove the socket head screws and nuts, and re-

move the injection pump (1).

2. Remove the screws and separate the speed control

plate (2), taking care not to damage the governor
spring (4).

3. Disconnect the governor spring (4) and remove the

speed control plate (2).

4. Remove the fuel feed pump (3).

When Reassembling

Hook the governor spring (4) to the governor lever (5)
first and install the speed control plate (2).

Be sure to replace the copper gaskets underneath two
screws (6) in the speed control plate (2).

Position the slot (7) on the fork lever just under the slot
(8) on the crankcase.

Insert the injection pump (1) so that the control rod (10)
should bepushed by the idlingadjusting spring (9) at its
end and the pin (11) onthe rod engages with the slot (7)
on the fork lever.

1. Injection Pump

2. Speed Control Plate

3. Fuel Feed Pump

4. Governor Spring

5. Governor Lever

6. Screw and Copper Washer

7. Slot (Fork Lever Side)

8. Slot (Crankcase Side)

9. Idling Adjusting Spring

10.Control Rod

11. Pin

NOTE

Sealant is applied to both sides of the shims,
gasket cement is not required for assembly .

When replacing the old gasket shims with new,
always replace with the same thickness and
number of gasket shims.

Addition or reduction ofshim (0.05 mm / 0.0020
in.) delays or advances the injection timing by
approximately 0.5°.

2--7

62--11161

2.2.6 Timing Gear, Camshaft and Fuel Camshaft (Continued)

2.2.6.b Injection Pump, Fuel Feed Pump andSpeed
Control Plate (Z482--E2b-- TFX--1 Only)

SpecificTool(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.

A length of string passed thru the governor
spring (6) can be used to retrieve the spring if it
unhooks from both the specific tool (1) and the
speed control plate

1. Remove the socket head screws (2) and remove the

engine stop solenoid (4).

2. Remove the screws and separate the speed control

plate (5), taking care not to damage the governor
spring (6).

3. Disconnect the governor spring (6) and remove the

speed control plate (5) using the specific tool (1).

4. Remove the fuel feed pump (3).

5. Disconnect the start spring (8) from the bracket (9)

using the specific tool (1).

6. Remove the socket head screws and nuts, then re-

move the injection pump (7).

1. Specific Tool

2. Socket Head Screw

3. Fuel Feed Pump

4. Engine Stop Solenoid

5. Speed Control Plate

NOTE

6. Governor Spring

7. Injection Pump

8. Start Spring

9. Bracket

62--11161

2--8

2.2.6 Timing Gear, Camshaft and Fuel Camshaft (Continued)

2.2.6.b Injection Pump, Fuel Feed Pump andSpeed
Control Plate (Z482--E2b-- TFX--1 Only)
(Continued)

When Reassembling

1. Move the fork lever (1) to the gear case side.

2. Hook the start spring (7) to the injection pumpcontrol

rack pin (5).

3. Put the specific tool (8) through the fork lever hole of

the cylinder block (9) and hook the start spring (7).

4. Slightly extended the start spring (7) andinstall the in-

jection pump (4).

Make sure the control rod (6) makes contact
with the idling adjusting spring (2).

Make sure the injection pump control rack pin
(5) engages the fork lever (1).

A length of string passed thru the governor
spring(14) canbeused toretrieve thespring ifit
unhooks from both the specific tool and the
speed control plate

5. Hook the start spring (7) to the bracket (3) using the

specific tool (8).

6. Hook the governor springs (small and large) (14) to

the governor lever (13) using the specific tool and in­stallthe speedcontrolplate (11).Use copperwashers
with the two screws (12) when securing the speed
control plate.

7. Install theengine stopsolenoid rod(15) into theguide

of the cylinder block (10) and secure the engine stop
solenoid (16) with hex head bolts.

NOTE

NOTE

Be careful not to stretch the start spring (7) too
far or you risk permanently deforming it.

Be sure the start spring (7) is attached to the
bracket (3).

Sealant is applied to both sides of the shims,
gasket cement is not required for assembly .

When replacing the old gasket shims with new,
always replace with the same thickness and
number of gasket shims.

Addition or reduction ofshim (0.05 mm / 0.0020
in.) delays or advances the injection timing by
approximately 0.5°.

1. Fork Lever

2. Idling Adjusting Spring

3. Bracket

4. Injection Pump

5. Injection Pump Control
Rack Pin

6. Injection Pump Control Rod

7. Start Spring

8. Specific Tool

9. Fork Lever Hole

10. Guide Hole

11. Speed Control Plate

12. Screw and Copper Washer

13. Governor Lever

14. Governor Spring

15. Engine Stop Solenoid Rod

16. Engine Stop Solenoid

2--9

62--11161

2.2.6 Timing Gear, Camshaft and Fuel Camshaft (Continued)

2.2.6.c Fan Drive Pulley

1. Secure the flywheel to keep it from turning.

2. Remove the fan drive pulley bolt.

3. Remove the fan drive pulley with a puller.

When Reassembling

Install the pulley to thecrankshaft, aligning the mark (1)
on them.

Apply engine oil to the fan drive pulley retaining bolts
and tighten them.

Tightening

Torque

Fan Drive Pulley

Screw

117.7 to 127.5 N.m

12.0 to 13.0 kgf

86.8 to 94.0 ft--lbs

.

m

2.2.6.d Gear Case

1. Disconnect the start spring (2) from the fork lever 1
(3).

2. Remove the bolt (1) inside the gear case.

3. Remove the remaining bolts securing the gear case
to the engine block.

4. Remove the gear case.

When Reassembling

Apply a gasket sealer to both sides of the gear case
gasket.

Be sure the three O--rings in the gear case are inplace.

1. Bolt (Inside)

2. Start Spring

3. Fork Lever 1
4 Gear Case

62--11161

2--10

2.2.6 Timing Gear, Camshaft and Fuel Camshaft (Continued)

2.2.6.e Idle Gear

1. Remove the external snap ring (3), the collar (2) and
the idle gear (1).

2. Remove the idle gear shaft mounting bolts (4).

3. Remove the idle gear shaft (5).

When Reassembling

Apply engine oil to the idle gear shaft mounting bolt (4)
and tighten them.

Install the idlegear, aligning the marks (6)on thegears.
Refer to the illustration.

Tightening

Torque

1. Idle Gear

2. Idle Gear Collar

3. External Snap Ring

Idle Gear Shaft

Mounting Bolt

4. Idle Gear Shaft Mounting

5.Idle Gear Shaft

6.Alignment Mark

9.8to11.3N.m

1.00 to 1.15 kgf

7.2to8.3ft--lbs

Bolt

.

m

2.2.6.f Camshaft

1. Remove the camshaft mounting screws (1) and draw
out the camshaft with the gear (2) on it.

When Reassembling

Apply engine oil to the camshaft journals before
installing it.

Apply engine oil to the camshaft mounting screws and
tighten them.

1. Camshaft Mounting Screw 2. Camshaft Gear

2--11

62--11161

2.2.6 Timing Gear, Camshaft and Fuel Camshaft (Continued)

2.2.6.g Fuel Camshaft

1. Remove the retaining plate (1).

2. Remove theforklever holdermountingbolts (8), then
draw out the injection pump gear (3) and fuel cam­shaft (2) with the governor fork assembly.

When Reassembling

Hook the governor spring (7) to the fork lever 2 (6) as
shown in the figure before installing the fork lever
assembly to the crankcase.

1. Retaining Plate

2. Fuel Camshaft

3. Injection Pump Gear

4. Governor Sleeve

5. Fork Lever 1

2.2.6.h Oil Pump and Crankshaft Gears

1. Remove the oil pump gear (6).

2. Remove the oil pump mounting bolts, then the oil
pump (5).

3. Remove the collar (4), O--ring (3) and crankshaft oil
slinger (2).

4. Remove the crankshaft gear (1) with a puller.

When Reassembling

Begin reassembly byinstalling thecrankshaft gear first.
Install the collar (4) after aligning the markson the gear.

(See 2.2.6.e)
Replace the oil pump.

6. Fork Lever 2

7. Governor Spring

8. Fork Lever Holder Mounting
Bolt

Tightening

Torque

1. Crankshaft Gear

2. Crankshaft Oil Slinger

3. O--ring

Mounting Bolt

Oil Pump

17.7 to 21.6 N.m

1.8to2.2kgf

13.0 to 15.9 ft--lbs

4. Crankshaft Collar

5. Oil Pump

6. Oil Pump Gear

.

m

62--11161

2--12

2.2.7 Piston and Connecting Rod

2.2.7.a Connecting Rod

1. Remove the connecting rod caps (1) using a bihexa­gonal 8 mm socket.

When Reassembling

Align the marks (a) with each other. Face the marks
toward the injection pump.

Apply engine oil to the connecting rod bolts and lightly
screw them in by hand, then tighten to the specified
torque.

If the connecting rod bolt does not screw in smoothly,
clean the connecting rod and bolt threads.

Tightening

Torque

1. Connecting Rod Cap a. Mark

Connecting Rod

Bolt

26.5 to 30.4 N.m

2.7to3.1kgf

19.5 to 22.4 ft--lbs

.

m

2--13

62--11161

2.2.7 Piston and Connecting Rod (Continued)

3

2.2.7.b Pistons

1. Completely remove the carbon ridge at the top of the
cylinder walls.

2. Remove the the connecting rod cap.

3. Turn the flywheel and bring the piston to top dead
center.

4. Push the piston out by lightly tapping the connecting
rodfromthe bottom of thecrankcasewith thegrip ofa
hammer.

5. Repeat the procedure for the other cylinder(s).

When Reassembling

Liberally coat thepiston and piston ringswith 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
intotheengine besure that they arereturnedto
their original cylinder.

When installing the piston into the cylinder,
placethegaps ofallthepistonrings asshownin
the figure.

Carefully insert the pistons into the cylinders
using the piston ring compressor (1).

Wheninserting thepistonintothecylinderavoid
damagingthe molybdenum disulfidecoating 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 (d) is on top of the piston.

1. Piston Ring Compressor
(A) Top Ring Gap
(B) Second Ring Gap
(C)OilRingGap
(D) Piston Pin Hole

(a) 0.785 rad. (45°)
(b) 0.785 rad. (45°)
(c) 1.57 rad. (90°)
(d)Mark

62--11161

2--14

2.2.7 Piston and Connecting Rod (Continued)

2.2.7.c Piston Ring and Connecting Rod

1. Remove the piston rings (1), (2), (3).

2. Remove thepistonpin (7)and then seperate thecon­necting rod (6) from the piston (5).

NOTE

Mark boththe connecting rodand pistonso that
if they are to be re--used that the original com­bination of parts will go backtogether.Do notin­terchange used parts.

When Reassembling

When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near the gap faces the top of
the piston (5).

Wheninstalling theoilcontrol ring(3) ontothe piston(5),
place theexpander joint (10) on the opposite sideof the
oil ring gap (1 1).

Apply engine oil to the piston pin (7).
When assembling the connecting rod (6) to the piston

(5),immersethepiston(5)in hotoil(80°C /176°F)for10
to15 minutes, thenassemblethe piston, piston pin,and
connecting rod.

When installing the connecting rod to the piston, align
the mark (8) on the connecting rod to the fan--shaped
concave (9).

1. TopRing

2. Second Ring

3. Oil Control Ring

4. Piston Snap Ring

5. Piston

6. Connecting Rod

7. Piston Pin

8. Mark

9. Fan Shaped Concave

10. Expander Joint

11. Oil Ring Gap

12. Manufacturer’s Mark

2--15

62--11161

2.2.8 Crankshaft

2.2.8.a Flywheel

1. Position theflywheel (2) sothat the “1TC”mark(a) on
the outer surface of the flywheel aligns horizontally
with the alignment mark (b) on the rear end plate.

2. Prevent the flywheel (2) from rotating.

3. Remove all of the flywheel screws (1).

4. Remove the flywheel (2).

When Reassembling

Check to see that the mating surfaces of the crankshaft
and flywheel are clean.

Align the “1TC” mark (a) on the outer surface of the
flywheel horizontally with the alignment mark (b) on the
rear end plate and install the flywheel

Apply engine oil to the flywheel bolts and install.

Tightening

Torque

1. Flywheel Bolt

2. Flywheel

Flywheel Bolts

a1TCMark
b Alignment Mark

53.9 to 58.8 N.m

5.5to6.0kgf

39.8 to 43.4 ft--lbs

.

m

2.2.8.b Bearing Case Cover

1. Removethe bearingcasecover mountingbolts. First,
remove the inside bolts (1) and then the outside
screws (2).

2. Screw two of the removed bolts into the bolt hole of
the bearing case cover (6) to remove it.

NOTE

The length of the inside and the outside bolts
are different. When reassembling reinstall the
appropriate bolt in the correct location.

When Reassembling

Fit the bearing case gasket (3) and the bearing case
cover gasket (4) to the bearing case cover (6). Orient
them correctly.

Install the bearing case cover (6), again orienting it
correctly, using the “UP” mark (a).

Apply oil to the oilseal, and take care that it is not rolled
while being installed.

Tighten the bearing case cover bolts diagonally and
evenly.

62--11161

Tightening

Torque

1. Bearing Case Cover
Mounting Bolt (Inside)

2. Bearing Case Cover
Mounting Bolt (Outside)

3. Bearing Case Gasket

4. Bearing Case Cover Gasket

2--16

Bearing Case

Cover Mounting

Screw

5. Oil Seal

6. Bearing Case Cover
(a).Top Mark “UP”
(b)Upside

9.8to11.3N.m

1.00 to 1.15 kgf

7.2to8.3ft--lbs

.

m

2.2.8 Crankshaft (Continued)

2.2.8.c Crankshaft Assembly

NOTE

Before disassembling, check the side clear­ance of the crankshaft. Check it during reas­sembly.

1. Remove the two main bearing case bolts (1).

2. Pull out the crankshaft, being careful not to damage
the crankshaft bearing.

When Reassembling

Clean the oil passages of the crankshaft with
compressed air.

Install the crankshaft assembly,aligning the bolt hole of
the main bearing case screw 2 with the bolt hole of the
crankcase.

Whentightening themainbearingcase2,apply oiltothe
main bearing case bolt 2 (1) and tighten by handbefore
tightening to the specific torque. If any resistance is
encountered while tightening, re--align the bolt holes.

Tightening

Torque

Main Bearing

Case

Bolt2

26.5 to 30.4 N.m

2.7to3.1kgf

19.5 to 22.4 ft--lbs

.

m

1. Main Bearing Case
Bolt 2r

(a).Z482--E2B
(b).D722--E2B

2--17

62--11161

2.2.8 Crankshaft (Continued)

2.2.8.d Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (7) and
remove the main bearing case assembly 1 (1) being
careful with crankshaft bearing 3 (4).

2. Remove the main bearing case assembly 2 (2) and
the main bearing case assembly (3) as above. Keep
in mind that the thrust bearing (6) is installed in the
main bearing case assembly (3).

When Reassembling

Clean the oil passages in the main bearing cases.
Apply clean engine oil on the bearings.
Reinstall the main bearing case assemblies into their

original positions. Since diameters of main bearing
cases vary, install them in order by marking (b in the
illustration) (1for Z482 and1, 2for D722), from thegear
case side.

The diameters of the main bearing cases vary. Install
them in order from the gear case end according to their
markings

Match the alignment numbers (a) on the main bearing
case assembly 1.

Do the same for the main bearing case assembly 2 (2),
and face the mark ’FLYWHEEL’ to the flywheel.

Install the thrust bearing (6) with its oil groove facing
outward.

Confirm that the main bearing case moves smoothly
after tightening the main case bolt 1 to the specified
torque.

Tightening

Torque

1. Main Bearing Case
Assembly 1

2. Main Bearing Case
Assembly 2

3. Main Bearing Case
Assembly

4. Crankshaft Bearing 3

Case Screw 1

Main Bearing

12.7 to 15.7 N.m

1.3to1.6kgf

9.4to11.6ft--lbs

5. Crankshaft Bearing 2

6. Thrust Bearing 2

7. Main Bearing Case
Screw 1

(a) Alignment Number
(b) Marking (1 or 2)

.

m

62--11161

2--18

2.3 SERVICING

g

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

1. Red Dye

2. Deter

ent

1

5

Do not measure the combustion chamber.
Check the valve recessing after after resurfac-

3

4

ing the head.

6

2

Cylinder Head

Surface Flatness

Allowable

Limit

0.05mm

0.0020 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. Washthe dyeofftheheadusing thedetergent (2)and
dry the head.

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.

2--19

62--11161

2.3.1 Cylinder Head And Valves (Continued)

(B)

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 recession (A) with a depth gauge.

4. If the measurement exceeds the allowable limit, re­place the valve.

5. If the measurement still exceeds the allowable limit,
replace the cylinder head.

0.10 (protrusion) mm to

0.10 (recessing) mm

0.0039(protrusion) in. to

0.0039 (recessing) in.

0.30 (recessing) mm

0.0118 (recessing) in.

Valve

Recessing

Factory

Specification

Allowable Limit

1. Cylinder Head
Surface

(A) Recess

Protrusion

2.3.1.d Clearance Between Valve Stem And Valve
Guide

1. Remove carbon from the valve guide section.

2. Measure the valve stem O.D. with a micrometer.

3. Measure thevalve guidewith a smallhole gauge,and

calculate the clearance.

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

place the valves. If the clearance still exceeds the al­lowable limit, replace the valve guide.

Clearance

Between

Valve Stem

and Guide

Valve Stem

O.D.

Valve Guide

I.D.

Factory

Specification

Allowable Limit

Factory

Specification

Factory

Specification

0.030 to 0.057 mm

0.00118 to 0.00224 in.

0.10 mm

0.0039 in.

5.968 to 5.980 mm

0.23496 to 0.23543 in.

6.010 to 6.025 mm

0.23661 to 0.23720 in.

62--11161

2--20

2.3.1 Cylinder Head And Valves (Continued)

2.3.1.e Replacing Valve Guide
(A) (When removing)

1. Pressout theusedvalve guideusing a valveguidere­placing tool.

(B) (When installing)

1. Clean a new valve guide and valve guide bore, then
apply oil to them.

2. Press ina newvalve guideusing a valveguide replac­ing tool.

3. Ream the I.D. of the valve guide to the specified di­mension (precisely).

(A) When Removing (B) When Installing

Valve Guide I.D.

Intake & Exhaust

Factory

Specification

6.010 to 6.025 mm

0.2366 to 0.2372 in.

NOTE

Donot hitthevalve guidewitha hammer during
replacement.

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 thevalve does notseat all the wayaround thevalve
seat,or thecontact islessthan 70%,correct thevalve
seating as outlined in 2.3.1.g.

3. If the valve contact does not comply with the refer­encevalue, replace thevalve orcorrectthe contactof
valve seating.

Valve Seat

Width

Factory

Specification

2.12 mm

0.0835 in.

1. Correct

2. Incorrect

3 Incorrect

2--21

62--11161

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 thevalve andvalve guideare within factory
specifications.

After correcting thevalve seat, be sureto check
the valve recession.

(A) Correcting the Valve

1. Correct the valve with a valve grinder.

Valve Face Angle

Factory

Specification

0.785 rad.
45°

(B) Correcting the Valve Seat

1. Slightly correct the valve seat surface with a 0.785
rad. (45°) valve seat cutter.

2. Reinsert the valve, check the contact pattern with
prussian blue. A valveseat widthshould beapproxi­mately 70% of the total valve contact area. See(A)in
the illustration

3. Resurface the seat surface with a 0.262 rad. (15°)
valve seat cutter to the valve seat so that (a) equals
(b) in the illustration.

4. Grind theseat witha 0.785 rad(45°)valve seatcutter
again, and visually recheck the contact between the
valve and the seat.

5. Repeat steps 3 and 4 until the correct contact is
achieved.

6. Continue lapping until the seated width becomes
more than 70% of the total contact area.

Valve Seat Angle

1. Valve Seat Cutter

A. Check Contact
B. Correct Seat Width
C. Correct Seat Surface
D. Check Contact

Specification

Factory

a. Identical Dimensions
b. Valve Seat Width
c. 0.262 rad (15°)
d 0.785 rad (45°)

0.785 rad.
45°

62--11161

2.3.1.h Valve Lapping

1. Apply compound evenly to the valve lappingsurface.

2. Insert the valve into the valve guide. Lap the valve
onto its seat with a valve lapper.

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
thecontact pattern. Ifit islessthan 70%,repeatvalve
lapping again.

NOTE

When valve lapping is performed, be sure to
check the valve recession and adjust the valve
clearance after assembling the valve.

2--22

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 andmeasure for maximum
tilt(B). Checkthe entiresurfaceof thevalve springfor
defects. If any are found, replace it.

Factory

Specification

Free Length (A)

Allowable Limit

Tilt (B) Allowable Limit

31.3 to 31.8 mm

1.232 to 1.252 in.

28.4 mm

1.118 in.

1.2 mm

0.047 in.

2.3.1.j Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to
the same length it’s actually compressed in the en­gine.

2. Read the compression load on the gauge.

3. Ifthemeasurement isless thanthe allowablelimit, re­place it.

64.7 N / 27.0 mm

6.6 kgf / 27.0 mm.

14.6 lbs. / 1.063 in.

54.9 N / 27.0 mm

5.6 kgf / 27.0 mm.

12.3 lbs. / 1.063 in.

Setting Load /

Setting Length

Factory

Specification

Allowable

Limit

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. Measurethe rockerarm I.D.withainside 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.

2--23

Oil Clearance

Rocker Arm/

Shaft

Rocker Arm

Shaft O.D.

RockerArm I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.016 to 0.045 mm

0.00063 to 0.00177 in.

0.15 mm

0.0059 in.

10.473 to 10.484 mm

0.41232 to 0.41276 in.

10.500 to 10.518 mm

0.41339 to 0.41410 in.

62--11161

2.3.1 Cylinder Head And Valves (Continued)

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

Allowable

Limit

0.25 mm

0.0098 in.

2.3.1.m Oil Clearance Between Tappet and Tappet

Guide Bore

1. Measure the tappet O.D. with a micrometer.

2. Measure theI.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.

Oil Clearance

Tappet/

Tappet Guide

Bore

Tappet O.D.

Tappet Guide I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.016 to 0.052 mm

0.00063 to 0.00205 in.

0.10 mm

0.0039 in.

17.966 to 17.984 mm

0.70732 to 0.70803 in.

18.000 to 18.018 mm

0.70866 to 0.70937 in.

62--11161

2--24

2.3.2 Timing Gears, Camshaft and Fuel Camshaft

2.3.2.a Timing Gear Backlash

1. Set a dialindicator (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
bearing clearance of the shafts and the gear.

4. If the bearing 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

Allowable

Limit

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

0.043 to 0.124 mm

0.00169 to 0.00488 in.

0.15 mm

0.0059 in.

0.047 to 0.123 mm

0.00185 to 0.00484 in.

0.15 mm

0.0059 in.

0.046 to 0.124 mm

0.00181 to 0.00488 in.

0.15 mm

0.0059 in.

0.041 to 0.123 mm

0.00161 to 0.00484 in.

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 thegear frontto rearto measurethe sideclear­ance.

3. If the measurement exceeds the allowable limit, re­place the idle gear collar.

Idle Gear

Side

Clearance

Factory

Specification

Allowable

Limit

0.20 to 0.51 mm

0.0079 to 0.0201 in.

0.80 mm

0.0315 in.

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

Allowable

Limit

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

2--25

62--11161

2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)

2.3.2.d Camshaft Run--Out

1. Supportthecamshaft withVblocks ona surfaceplate
at both end journals.

2. Setadialindicatorwithitstipontheintermediatejour­nal.

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.e Cam Height

1. Measure the cam lobeat its largest O.D. with anout­side micrometer.

2. Ifthemeasurement isless thanthe allowablelimit, re­place the camshaft.

Cam Height

Intake/Exhaust

Factory

Specification

Allowable

Limit

26.88 mm

1.0583 in.

26.83 mm

1.0563 in.

2.3.2.f Camshaft Bearing 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.

Camshaft Journal

Clearance

Camshaft Journal

O.D

.

Camshaft Bore

I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.050 to 0.091 mm

0.00197 to 0.00358 in.

0.15 mm

0.0059 in.

32.934 to 32.950 mm

1.29661 to 1.29724 in.

33.000 to 33.025 mm

1.29921 to 1.30020 in.

62--11161

2--26

2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)

2.3.2.g Idle Gear Shaft and Idle Gear Bushing
Clearance

1. Measure the idle gear shaft O.D. with an outside mi­crometer.

2. Measure the idle gear shaft bore I.D. with a cylinder
gauge, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, re­place the bushing.

Idle Gear Journal

Clearance

Idle Gear Journal

O.D

.

Idle Gear Bore

I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.020 to 0.084 mm

0.00079 to 0.00331 in.

0.10 mm

0.0039 in.

19.967 to 19.980 mm

0.78610 to 0.78661 in.

20.000 to 20.051 mm

0.78740 to 0.78941 in.

2.3.2.h Replacing Idle Gear Bushing
(A) When Removing

1. Pressout thebushingusing anIdleGear BushingRe­placing Tool.

(B) When Installing

1. Clean anew idle gearbushing and theidle gear bore,
and apply engine oil to both.

2. Using the idle gear replacing tool, press in the new
bushing to the specified dimension (see B)

2--27

62--11161

2.3.3 Piston and Connecting Rod

2.3.3.a Piston Pin Bore I.D.

1. Measure thepiston pinbore I.D. inboththehorizontal
and vertical directions with a cylinder gauge.

2. If the measurement exceeds the allowable limit, re­place the piston.

A. When Removing B. Correct Seat Width

Piston Pin Bore

I.D.

Factory

Specification

Allowable

Limit

20.000 to 20.013 mm

0.78740 to 0.78791 in.

20.05 mm

0.7894 in.

2.3.3.b Piston Pin and Bushing Clearance

1. Measure thepiston pinO.D.withan 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
thebushing. Iftheclearanceisstillexcessive,replace
the piston pin.

Piston Pin to

Small End Bush-

ing Clearance

Piston Pin O.D.

Small End

Bushing I.D

.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.014 to 0.038 mm

0.00055 to 0.00150 in.

0.10 mm

0.0039 in.

20.002 to 20.011 mm

0.78748 to 0.78783 in.

20.025 to 20.040 mm

0.78839 to 0.78897 in.

2.3.3.c Replacing Connecting Rod Small End Bu-

shing

(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

1. Seam

2. Oil Hole

a. 0.785 rad (45°)

62--11161

2--28

Be sure to align the bushing so that the oil hole
in the bushingaligns with the oilport in the con­necting rod.

Piston Pin to

Small End Bush-

ing Clearance
(Replacement

Parts)

Small End
Bushing I.D
placement Parts)

.(Re-

Factory

Specification

Allowable

Limit

Factory

Specification

0.015 to 0.075 mm

0.00059 to 0.00295 in.

0.15 mm

0.0059 in.

20.026 to 20.77 mm

0.78845 to 0.79043 in.

2.3.3 Piston and Connecting Rod (Continued)

2.3.3.d Piston Ring Gap

1. Insert thepistonring intothelower partof the cylinder
(the least wornsection). Use the piston to square the
ring in the cylinder.

2. Measure the ring gap with a feeler gauge.

3. If the gapexceeds theallowable limit, replace the pis­ton ring.

Top Ring

Second Ring

OilControlRing

Factory

Specification

Allowable Limit 1.20 mm / 0.0472 in.

Factory

Specification

Allowable Limit 1.20 mm / 0.0472 in.

Factory

Specification

Allowable Limit 1.20 mm / 0.0472 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

0.30 to 0.45 mm

0.0118 to 0.0177 in.

0.15 to 0.30 mm

0.0059 to 0.0118 in.

2.3.3.e Piston Ring to Groove Clearance

1. Clean therings and the ring grooves, andinstall each
ring in its groove.

2. Measure the clearance between the ring and its
groove 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

OilControlRing

Factory

Specification

Allowable Limit 0.15 mm / 0.0059 in.

Factory

Specification

Allowable Limit 0.15 mm / 0.0059 in.

0.090 to 0.120 mm

0.00354 to 0.00472 in.

0.040 to 0.080 mm

0.0016 to 0.0031 in.

2.3.3.f Connecting Rod Alignment

NOTE

Since the I.D. of the connecting rod small end
bushingisthe basisofthisprocedure,checkthe
bushing for wear before proceeding.

1. Install the piston pin into the connecting rod.

2. Installtheconnectingrodontheconnectingrodalign­ment tool.

3. Put a gauge over the piston pin and move it against
thefaceplate.

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

Allowable Limit 0.05 mm / 0.0020 in.

2--29

62--11161

2.3.4 Crankshaft

2.3.4.a Crankshaft End Clearance

1. Push on theend ofthe crankshaft toseat ittoward the
flywheel end of the engine block.

2. Attach, thenzeroa dialindicatorontheforward endof
the crankshaft.

3. Measure the end play by pulling the crankshaft for­ward.

4. If the measurement exceeds the allowable limit re­place the thrust bearings.

5. If the new thrust bearings do not correct the exces­sive end clearance condition, over size thrust bea­rings may be necessary.

Crankshaft Side

Clearance

Factory

Specification

Allowable

Limit

0.15 to 0.31 mm

0.0059 to 0.0122 in.

0.50 mm

0.0197 in.

(Reference)

Oversize dimensions of thrust bearing.

Oversize Bearing Part Number Marking

0.2 mm

0.008 in.

Thrust Bearing 1 02
Thrust Bearing 2 02 020 OS

25--36430--01

020 OS

(Reference)

Oversize dimensions of crankshaft journal.

Oversize 0.2mm/ 0.0008 in. 0.4mm / 0.0016 in.

Dimension A

Dimension B

Dimension C

The crankshaft journal must be fine--finished to higher than

23.40 to 23.45 mm

0.9134 to 0.9154 in.

46.1 to 46.3 mm

1.815 to 1.823 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in.
radius

0.8--S.

23.80 to 23.85 mm

0.9213 to 0.9232 in.

46.3 to 46.5 mm

1.823 to 1.831 in.

1.8 to 2.2 mm radius

0.071 to 0.087 in.
radius

62--11161

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

Allowable

Limit

0.02 mm

0.0008 in.

2--30

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 Section 2.2.7.b)

4. Remove the cap again.

5. Measure theamount oftheflatteningwiththe scaleto

get the clearance.

6. If the measurement exceeds the allowable limit re-

place the connecting rod bearing.

7. If the allowable limit is not attainable with a standard

size bearing, install anundersize bearing byreferring
to the table below.

Crankpin/

Connecting Rod

Clearance

Factory

Specification

Allowable

Limit

0.020 to 0.051 mm

0.00079 to 0.00201 in.

0.15 mm

0.0059 in.

Crankpin O.D.

Connecting Rod

Bearing I.D.

Factory

Specification

Factory

Specification

33.959 to 33.975 mm

1.33697 to 1.33760 in.

33.995 to 34.010 mm

1.33893 to 1.33898 in.

(Reference)

Undersize dimensions of connecting rod bearing.

Undersize Bearing Part Number Marking

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Connecting Rod

Bearing

Connecting Rod

Bearing

25--34386--02 020US

25--34386--04 040US

(Reference)

Undersize dimensions of crankpin journal.

Oversize 0.2mm/ 0.008 in. 0.4mm / 0.016 in.

Dimension A

Dimension B

Dimension C

The crankshaft journal must be fine--finished to higher than

2.3to2.7mm

0.091 to 0.106 in.

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia.

33.759 to 33.775
mm dia.

1.32910 to 1.32973
in. dia.

0.8--S.

2.3to2.7mm

0.091 to 0.106 in.

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia.

33.559 to 33.575
mm dia.

1.32112 to 1.32185
in. dia.

2--31

62--11161

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 in-

side 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 anundersize bearing byreferring
to the table below.

Crankshaft

Journal to #1

Bearing

Clearance

Crankshaft

Journal O.D.

Crankshaft

Bearing Bearing

I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.034 to 0.106 mm

0.00134 to 0.00417 in.

0.20 mm

0.0079 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.040 mm

1.57148 to 1.57638 in.

(Reference) Bearing clearance between crankshaft

journal and crankshaft bearing 1.

Undersize Bearing Code Number Marking

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Crankshaft Bearing 1

02

Crankshaft Bearing 1

04

25--34389--02 020US

25--34389--04 040US

(Reference) Undersize dimensions of crankshaft

journal.

62--11161

2--32

Undersize 0.2mm / 0.008 in. 0.4mm / 0.016 in.

1.8 to 2.2 mm radius

Dimension A

Dimension B

Dimension C

The crankshaft journal must be fine--finished to higher than

0.071 to 0.087 in.
radius

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia

39.734 to 39.750
mm dia.

1.56433 to 1.56496
in. dia.

0.8--S.

1.8 to 2.2 mm radius

0.071 to 0.087 in.
radius

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia

39.534 to 39.550
mm

1.55646 to 1.55709
in. dia.

2.3.4 Crankshaft (Continued)

1. Seam

2. Crankshaft Bearing#1

3. Cylinder Block

A Dimension

2.3.4.e Replacing Crankshaft Bearing #1
(A) When Removing

1. Pressout thecrankshaftbearing#1(2) usingacrank-

shaft bearing replacing tool (Refer to Special T ools

1.8.14).

(B) When Installing

1. Cleananewcrankshaft bearing#1(2) andcrankshaft

journal bore, and apply engine oil to both.

2. Using the crankshaft bearing replacing tool, press in

the new bearing #1 (2) so that its seam (1) is toward
the exhaust manifold side.

NOTE

Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port.

Dimension A

Factory

Specification

0.0to0.3mm

0.0to0.118in.

2--33

62--11161

2.3.4 Crankshaft (Continued)

2.3.4.f Crankshaft Journal to Crankshaft Bearing
Clearance

1. Put a strip of plastigage on the center of the crank-

shaft journal.

2. Install thebearing caseand tighten thebolts to speci-

fication.

3. Remove the bearing case again.

4. Measure theamount offlattening withthe scaleto get

the clearance.

5. If the measurement exceeds the allowable limit re-

place crankshaft bearing.

6. If the allowable limit is not attainable with a standard

size bearing, install anundersize bearing byreferring
to the table below.

NOTE

Be sure not to move the crankshaft while the
bearing bolts are tightened.

Clearance-­Crankshaft

Journal to Bearing

Crankshaft

Journal O.D

(Flywheel Side)

Crankshaft

Bearing #2 I.D.

Crankshaft

Journal O.D

(Intermediate)

Crankshaft

Bearing #3 I.D.

.

.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

Factory

Specification

Factory

Specification

0.028 to 0.051 mm

0.00110 to 0.00201 in.

0.20 mm

0.0079 in.

43.934 to 43.950 mm

1.72968 to 1.73031 in.

43.984 to 44.026 mm

1.73165 to 1.73331 in.

39.934 to 39.950 mm

1.57221 to 1.57284 in.

39.984 to 40.026 mm

1.57417 to 1.57583 in.

(Reference)

Oversize dimensions of crankshaft bearing 2 and3 (0.2
mm / 0.008 in.) and (0.4 mm / 0.016 in.).

Oversize Bearing Part Number Marking

0.2 mm

0.008 in.

0.4 mm

0.016 in.

Crankshaft Bearing 2 25--36428--01 020 US
Crankshaft Bearing 3 25--34390--02 020 US
Crankshaft Bearing 2 25--34391--04 040 US
Crankshaft Bearing 3 25--34390--04 040 US

(Reference)

Undersize dimensions of crankshaft journal.

Oversize 0.2mm / 0.008 in. 0.4mm / 0.016 in.

DimensionA1.8 to 2.2 mm radius

0.071 to 0.087 in. radius

*Dimension

B

Dimension

C

Dimension

D

The crankpin must be fine--finished to higher than 0.8--S.

*Holes to be de--burred and edges rounded with relief.

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia.

39.734 to 39.750 mm
dia.

1.56433 to 1.56496 in.
dia.

43.734 to 43.750 mm
dia.

1.72181 to 1.72244 in.
dia.

1.8 to 2.2 mm radius

0.071 to 0.087 radius

1.0 to 1.5 mm dia.

0.0394 to 0.0591 in.
dia.

39.534 to 39.550 mm
dia.

1.55646 to 1.55709 in.
dia.

43.534 to 43.550 mm
dia.

1.71394 to 1.71470 in.
dia.

62--11161

2--34

2.3.4 Crankshaft (Continued)

2.3.4.g Crankshaft Sleeve Wear

1. Check the wear on the crankshaft sleeve (1).

2. If thewear exceeds the allowable limit orif the engine
oil leaks, replace the crankshaft sleeve (1).

Sleeve Wear

Allowable

Limit

0.1 mm

0.004 in.

2.3.4.h Replacing Crankshaft Sleeve

1. Remove the crankshaft sleeve using a special--use
puller set.

2. Set the sleeve guide (4) to the crankshaft (2).

3. Heat thenew sleeveto atemperaturebetween 150to
200°C(302to 392°F), and fixthesleeve on thecrank­shaft (2) as shown in the figure.

4. Press fit the sleeve using the auxiliary socket for
pushing (3).

NOTE

Install the sleeve with the largest chamfered
surface facing outward.

1. Crankshaft Sleeve

2. Crankshaft

3. Auxiliary Socket For
Pushing

4. Sleeve Guide

2--35

62--11161

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 thewear exceedstheallowablelimit,bore andhone
to the oversize dimension. (Refer to Section 2.3.5.b)

4. Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder walls should be
bored. (Refer to Section 2.3.5.b)

0. Top
A. Middle
B. Bottom (skirt)

a. Right--angled to

Piston Pin

b. Piston Pin Direction

Cylinder Wear

Factory

Specification

Allowable

Limit

67.000 to 67.019 mm

2.63779 to 2.63854 in.

67.169 mm

2.64445 in.

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.

67.250 to 67.269 mm

2.647644 to 2.64839
in.

67.400 mm

2.65354 in.

Cylinder I.D.

Maximum Wear

Finishing

Factory

Specification

Allowable

Limit

Hone to 2.2 to 3.0 mm μRmax.

(0.000087 to 0.00012 in. μRmax.)

1. Cylinder I.D.
(before correction)

2. Oversize Cylinder I.D.

62--11161

2. Replace the piston and piston rings with oversize
ones: (0.25 mm / 0.0098 in.)

Oversize Part Name Code Number Marking

0.25 mm

0.0098 in.

0.25 mm

0.0098 in.

Piston 16851--21900 025

Piston Ring Assembly 16851--21090 025

2--36

3.1 CHECKING AND ADJUSTING

SECTION 3

LUBRICA TING SYSTEM

4. Remove the oil drain plug (1) and drain the engine oil
into a proper receptacle/bucket.

5. Removethe usedoilfilter andreplace witha new one.
(Refer to Section3.1.3)

6. After draining all of the oil in the engine, replace the
drain plug (1).

7. Removethe oilfillcap(3) andaddthe correctoil tothe
engine.

8. Add oil until the engine oil level is up tothe upper line
on the dipstick (2).

NOTE

Replace the engine oil filter with every oil
change.

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.

3.1.1 Checking Engine Oil Level

1. Level the engine.

2. Tocheck the oil level, draw outthe dipstick (2), wipeit
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.

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.

3.1.2 Changing Engine Oil

CAUTION

Stop the engine when preparing to change
the engine oil.

1. Start and warm up the engine for approximately for 5
minutes.

2. Turn the engine off.

3. Place a proper receptacle/bucket under the engine
drain plug.

Use only MIL--L--46152 / MIL--L--2104C or API
classification CG--4 or CH--4 / CI oils.

Use theproper SAE Engine oil according tothe
ambient temperatures.

Above 25°C(77°F).............SAE30 or15W--40

0° to 25°C(32° to 77°F)......SAE20 or10W--30

......................................................or 10W--40

Below0°C(32°F)............SAE 10Wor10W-- 30

NOTE

With emission controls now ineffect, 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 ona high--sulfur fuel, itis advisable to
employtheCH--4or CIlubricating oilwith ahigh
total base number. If the CG--4 lubricating oil is
usedwith ahigh sulfurfuel,change the lubricat­ing oil at shorter intervals.

Lubricating oil recommended when a low--sulfur or
high--sulfur fuel is employed.

ubricating Oil Class Fuel

L

Low--sulfur High--sulfur

CG--4 O X

CH--4 or CI O X

O : Recommended X : Not Recommended

62--111613--1

3.1 CHECKING AND ADJUSTING (Continued)

3.1.3 Changing Oil Filter

CAUTION

Stop the engine when preparing to change
the engine oil filter.

1. Remove the oil filter cartridge (1) with a filter wrench.

2. Applyaslight coatof oil ontothe newoilfilter cartridge
gasket.

3. Install the new oil filter cartridge, screwing it on by
hand.Over tighteningit maycausedeformationof the
rubber gasket.

4. After the new oil filter cartridge has been installed
start theengine andcheck for a leak aroundthe oilfil­ter cartridge gasket. Recheck the crankcase oil level
(Refer to section3.1.1) andadjust the engineoil level
as necessary.

3.1.4 Engine Oil Pressure

1. Remove theengine oilpressure switch, and installan
oil pressure guage.

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

103 kPa

1.0 kgf/cm

196 to 441 kPa

2.0 to 4.5 kgf/cm
28 to 64 psi

147 kPa

1.5 kgf/cm

2

15 psi

2

21 psi

2

At Idle Speed

At Rated Speed

Allowable

Limit

Factory

Specification

Allowable

Limit

62--11161

(When Reassembling)

After checking the engine oil pressure, tighten the
engine oil pressure switch to the specified torque.

14.7 to 19.6 N.m

1.5to2.0kgf

10.8 to 14.5 ft--lbs.

Tightening Torque

Oil Pressure

Switch

3--2

.

m

3.1 CHECKING AND ADJUSTING (Continued)

3.2 OIL PUMP SERVICE

3.1.5 Relief Valve

1. Remove the oil filter cartridge and the oil filter base
(2).

2. Check therelief valve(1) fordirt,and theseat andball
for damage.

3. If damaged, replace.

4. Check the free length of the spring.

5. If it is less than the allowable limit, replace.

Spring Free

Length

Oil Filter Base

Tightening Torque

Factory

Specification

Allowable

Limit

Joint

32 mm

1.26 in.
28 mm

1.10 in.

39.2 to 49.0 N.m

4.0to5.0kgf

29.0 to 36.3 ft--lbs.

.

m

3.2.1 Rotor Lobe Clearance

1. Measure the clearance between lobes of the inner ro­tor and the outer rotor with a feeler guage.

2. Measure the clearance between the outer rotor and
the pump body with a feeler guage.

3. If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.

Inner/Outer

Rotor Clearance

Outer Rotor/

Pump Body

Clearance

Factory

Specification

Factory

Specification

0.03 to 0.14 mm

0.0012 to 0.0055 in.

0.07 to 0.15 mm

0.0028 to 0.0059 in.

3.2.2 Rotor to Cover Clearance

1. Put a strip of plastigage onto the rotor face (use a
small dab of grease to hold the plastigage in place).

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

Factory

Specification

0.075 to 0.135 mm

0.00295 to 0.00531 in.

62--111613--3

4.1 CHECKING AND ADJUSTING

SECTION 4

COOLING SYSTEM

4.1.3 Checking Coolant Level

NOTE

When the engine is installed in an APU, follow
OEMvehicle instructionsas tochecking/adjust­ing engine coolant levels.

1. Turn the engine off.

WARNING

4.1.1 V--Belt Tension

1. Measure the deflection (A), by depressing the belt
halfway between the fan drive pulley and alternator
pulley at the specified force (Refer to1.6.3).

2. If the tension is not within the factory specifications,
loosen the tensioner mounting bolts and adjust the
belt tension.

Use of a belt tension gauge (Carrier Part #
07--00203--00) or a belt tension tester (Carrier Part #
07--00253--00) is advised.

(A)

(B)

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.

2. Remove the radiator cap and check to see that the
coolant level is just below the port.

With the recovery tank: Check to seethat thecoolant
level lies between FULL and LOW.

FULL

LOW

3. If the coolantlevel is too low, check thereasonforthe
lost coolant.

a. If coolant loss is due to evaporation, add only clean

soft water.

b. If coolantlossis duetoaleak, repairtheleak andadd

a coolant mixture of the same type andspecification
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.

4.1.2 Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the belt is damage in any way, replace it.

3. Checkif thebeltis wornandsunkin thepulleygroove.

4. If the fan belt is worn and deeply sunk in the pulley
groove, replace it.

A. Good B. Bad

4--1

NOTE

Whenadding coolanttothe system,air must be
ventedfrom theenginecoolant passagesbyjig­gling the upper and lower radiator hoses.

When the engine is installed in an APU, An air
bleed screw is provided in the thermostat hous­ing.

Besure to closethe radiator capsecurely.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
thesametime.

Nevermix different types orbrands of coolants.

62--11161

4.1.4 Draining Coolant

1. Turn the engine off.

2. Remove the radiator cap.

4.1 CHECKING AND ADJUSTING (Continued)

3. Open the coolant drain cock or remove the coolant
drain plug and drain the coolant into a proper recep­tacle/bucket.

4.1.5 Radiator Cap

1. Attach the radiator cap to a pressure tester.

2. Apply pressure and observe thetimefor the pressure
to fall.

3. If the measurement is less than the factory specifica­tion, replace the cap.

More than 10 seconds

Pressure Falling

Time

Factory

Specification

for pressure fall from

88 to to 59kPa

0.9 to 0.6 kgf/cm
13to9psi

2

4.1.6 Radiator

1. Fill the radiator with water.

2. Attach the pressure tester to the radiator.

3. Apply pressure and look for leaks.

4. Repair/replace as necessarytoassurethat thespeci­fied pressure will hold.

Radiator Leakage

Test

Factory

Specification

157 kPa

1.6 kgf/cm
23 psi

2

62--11161

4.1.7 Thermostat Opening Temperature

1. Suspend the thermostat in water by a string with one
end of the string inserted between the valve and its
seat.

2. Immerse the thermostat in water and raise the 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).

5. If the measurement is not within the factory specifica­tions, replace the thermostat.

Thermostat

Opening

Temperature

Thermostat

Full Open

Temperature

Factory

Specification

Factory

Specification

69.5 to 72.5°C

157.1 to 162.5

85°C

185

°F

4--2

°F

4.2 SERVICING

4.2.1 Thermostat Assembly

1. Removethethermostatcovermountingbolts,andre­move the thermostat cover (1).

2. Remove the thermostat assembly (3).

(When Reassembling)

Applyaliquid gasketonly atthe thermostat coverside of
the thermostat cover gasket (2).

1. Thermostat Cover

2. Thermostat Cover Gasket

1. Water Pump Flange

2. Water Pump Shaft
3 Water Pump Body

3. Thermostat Assembly

4. Water Pump Gasket

5. Mechanical Seal

6. Impeller

4.2.2 Water Pump Assembly

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).

4--3

62--11161

5.1 CHECKING AND ADJUSTING

SECTION 5

FUEL SYSTEM

5.1.1 Injection Timing

1. Remove the injection lines.

2. Remove the engine stop solenoid (when applicable).

3. Turn the flywheel counterclockwise (facing the fly­wheel) until fuel flows from the delivery valve holder.

4. Turn the flywheel further and stop turning when the
fuel level at the tip of the delivery valve holder begins
to increase.

5. Check tosee whichof thetiming anglelines(1) onthe
flywheel is aligned with the alignment mark (2).

Injection Timing

Factory

Specification

0.33 to 0.37 rad.

19

° to 21° B.T.D.C.

NOTE

Injection timing adjustment is accomplished by
adding or removing shims under the injection
pump.

Thetiming advancesbyremoving oneshimand
retards by adding the same shim.

The addition or removal of 0.05 mm (0.002 in.)
of shim, changes the injection timing by approx­imately 0.087 rad. (0.5°).

Sealant should be applied to both sides of the
soft metal gasket shim.

Rated Speed

Specification

0.30 to 0.33 rad.

17

° to 19° B.T.D.C.

0.26 to 0.30 rad.

15

° to 17° B.T.D.C.

0.23 to 0.26 rad.

13

° to 15° B.T.D.C.

Injection Timing

Map

Rated Speed

3000 to 2501

2500 to 2001

Under 2000

234

1

5.1.2 Shim Identification

NOTE

Shims are available in thicknesses of 0.20 mm,

0.25 mm, 0.30 mm, and 0.35mm. Combine
shims for adjustments.

Referto thefigurebelow tocheck thethickness ofshims

1. Shim (soft metal)

2. 2--Holes: 0.20 mm shim

5--1

3. 1--Hole: 0.25 mm shim

4. 0--Holes: 0.30 mm shim

62--11161

5.1 CHECKING AND ADJUSTING (Continued)

5.1.3 Pump Element Fuel Seal

1. Remove the engine stop solenoid (when applicable).

2. Remove the injection lines and glow plugs.

3. Install the injection pump pressure tester to the injec­tion pump.

4. Install the injection nozzle (1) jetted withthe proper in­jection pressure tothe injection pumppressuretester
(2).

5. Set the speed control lever to the maximum speed
position.

6. Engage the starter.

7. If the pressure does not build up, replace the pump
element with a new one and test again.

Fuel pump ele-

ment seal

Allowable

Limit

13.73 MPa

140 kgf/cm

1991 psi

2

5.1.4 Delivery Valve Fuel Seal

1. Remove the engine stop solenoid (when applicable).

2. Remove the injection lines and glow plugs.

3. Install the injection pump pressure tester to the injec­tion pump.

4. Install the injection nozzle (1) jetted withthe proper in­jection pressure tothe injection pumppressuretester
(2).

5. Engage the starter.

6. Stop the starter when fuel jets from the injection
nozzle. Continue turning the flywheel by hand and
raise the pressure to approximately 13.73 MPa (140
kgf/cm

2

, 1991 psi.)

7. Now turn the flywheel about half a turn backward by
hand to keep the plunger free. Leave the flywheel in
this position while recording the time taken for the
pressure to drop from 13.73 MPa(140 kgf/cm

2

, 1991

psi.) to 12.75 MPa (130 kgf/cm2, 1849 psi.)

8. Ifthemeasurement isless thanthe allowablelimit, re­place the pump with a new one.

10 seconds

Delivery valve

fuel seal

Delivery valve

fuel seal

FactorySpecifi-

cation

Allowable

Limit

13.73 to 12.75 MPa
140 to 130 kgf/cm

1991 to 1849 psi

5 seconds

13.73 to 12.75 MPa
140 to 130 kgf/cm

1991 to 1849 psi

2

2

62--11161

5--2

5.2 INJECTION NOZZLE

WARNING

Checkthe injectionnozzle only after confirming that nobody is near the spray. If the spray fromthe
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.

5.2.1 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.

5.2.2 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 adjusting washer (1) in the nozzle
holder.

Fuel Injection

Pressure

1st Stage

Factory

Specification

(Reference)

A washerthickness of0.01 mm (0.0004 in.)will vary the
the nozzle injection pressure by approximately 235 kPa
(2.4kgf/cm

2

,34psi.)

13.73 to 14.71 MPa
140 to 150 kgt/cm

1991 to 2133 psi

2

(a) Good (b) Bad

5--3

62--11161

5.2 INJECTION NOZZLE (Continued)

5.2.3 Valve Seat Tightness

1. Set the injection nozzle in a nozzle tester.

2. Raise the fuel pressure, and maintain 12.7MPa (130
kgf/cm

2

, 1850 psi) for 10 seconds.

3. If any fuel leak is found or if there is any loss of pres­sure through the injection nozzle, replace the injec­tion nozzle assembly.

No fuel leak at

12.7MPa

130 kgf/cm

1850 psi

2

Valve Seat

Tightness

Factory

Specification

5.2.4 Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzleholder (1), and remove the parts.

3. If any fuel leak is found, replace the injection nozzle
assembly.

(When Reassembling)

Assemble the nozzle in clean fuel oil.
Install the push rod (4), noting its direction.
After assembling the nozzle, be sure to adjust the fuel

injection pressure.

34.3 to 39.2 N--m

Tightening Torque Nozzle Holder

Tightening Torque

Tightening Torque

1. Nozzle Holder

2. Adjusting Washer

3. Nozzle Spring

4. Push Rod

Overflow Pipe

Nut

Nozzle Holder

Assembly

3.5to4.0kgf--m

25.3 to 28.9 ft--lbs

19.6 to 24.5 N--m

2.0to2.5kgf--m

14.5 to 18.1 ft--lbs

49.0 to 68.6 N--m

5.0to7.0kgf--m

36.2 to 50.6 ft--lbs

5. Distance Piece

6. NozzlePiece

7. Nozzle Retaining Nut

62--11161

5--4

6.1 GLOW PLUG

1. Wiring Lead (Positive) 2 Glow Plug

SECTION 6

ELECTRICAL SYSTEM

6.1.1 Lead Terminal Voltage

1. Disconnect theglowplugwiring lead(1)from theglow
plug (2).

2. Connect a voltmeter between the glow plug wiring
lead (1) and a suitable ground on the engine.

3. Energize the glow plug lead and read the voltage.

4. Energize theglow pluglead, engagethe starter atthe
same time and read the voltage.

5. If the voltagediffers from the battery voltage in either
case, thewiring harnessor theswitchor switches are
faulty.

6.1.2 Glow Plug Continuity

1. Disconnect theglowplugwiring lead(1)from theglow
plug (2).

2. Measurethe resistancebetweentheglowplugtermi­nal and the engine body with an ohmmeter.

3. If 0 ohmis indicated, the glow plug may beshort--cir­cuited.

4. If the factory specification is not met the plug is also
faulty.

Glow Plug

Resistance

Factory

Specification

Approximately 0.9 ohm

6--1

62--11161

6.2 STARTER (CT2--29--TV)

(3)

1. C Terminal 2. Connecting Lead

3. S Terminal

6.2.1 Motor Test

CAUTION

Secure the starterto preventit from moving
when power is applied to it.

1. Disconnect the cable from the negative terminal on
the battery

2. Disconnect the the positive cable and leads from the
starter.

3. Remove the starter from the engine.

4. Disconnect thetheconnectinglead(2)fromthestart­er solenoid C terminal (1).

5. Connecta jumperleadfrom theconnectinglead(2) to
the positive post on the battery.

6. Connect a jumper lead momentarily between the
starter motor housing and the negative post on the
battery.

7. If the starter does not run, check the motor.

6.2.2 Magnetic Switch Test

6.2.2.a Pull--in Coil Test

1. Connect ajumper leadfrom the negative battery post
to the starter C terminal.

2. The plunger should be attracted strongly when a
jumperleadisconnectedfromthebatterypositiveter­minal to the S terminal.

6.2.2.b Holding Coil Test

1. Connect ajumper leadfrom the negative battery post
to the starter case and and another jumper from the
positive battery post to the starter S terminal.

2. Pushthe plungerinbyhandand releaseit. Theplung­er should stay in.

62--11161

6--2

6.2 STARTER (CT2--29--TV) (Continued)

6.2.3 Assembly

1. Solenoid Switch Mounting Nut

2. Starter Drive Housing

3. Drive Lever

4. Gasket

5. Solenoid Switch

6. C Terminal Nut

7. Snap Ring

8. Overrunning Clutch

9. Armature

10. Brush Spring

11. Connecting Lead

12. Rear End Frame

13. Gasket

14. Break Spring

15. Break Shoe

16. End Frame Cap

17. Screw

18. Yoke

19. Brush

20. Brush Holder

21. Through Bolt

1. Unscrew the C terminal nut (6), and disconnect the connecting lead (11).

2. Unscrew the solenoid switch mounting nuts (1), and remove the solenoid switch (5).

3. Remove the end frame cap (16).

4. Remove the break shoe (15), break spring (14) and gasket (13).

5. Unscrew the through bolts (21), and remove the rear end frame (12).

6. Unscrew the brush from the brush holder while holding the spring up.

7. Remove the brush holder (20).

8. Draw out the yoke (18) from the starter drive housing (2).

9. Draw out the armature (9) with the drive lever (3).

NOTE

Do not damage the brush and commutator.

When Reassembling

Apply grease (Carrier Part No. 07--00245--00) to the parts indicated in the figure.

-- Joint of solenoid switch (a)

-- B us hin g ( b)

-- Drive lever (c)

-- Collar (d)

-- Teeth of pinion gear (e)

-- Armature shaft (f)

Tightening

Torque

C Terminal Nut

7.8to9.8N.m

0.8to1.0kgf

5.8to7.2ft--lbs

.

m

6--3

62--11161

6.3 STARTER (CT3--44--TV)

6.3.1 Motor Test

CAUTION

Secure the starterto preventit from moving
when power is applied to it.

(3)

1. C Terminal 2. Connecting Lead

3. B Terminal

(3)

(4)

1. Disconnect the cable from the negative terminal on
the battery

2. Disconnect the the positive cable and leads from the
starter B terminal.

3. Remove the starter from the engine.

4. Disconnect thetheconnectinglead(2)fromthestart­er solenoid C terminal (1).

5. Connecta jumperleadfrom theconnectinglead(2) to
the positive post on the battery.

6. Connect a jumper lead momentarily between the
starter motor housing and the negative post on the
battery.

7. If the starter does not run, check the motor.

8.8to11.8N.m

0.9to1.2kgf

6.5to8.7ft--lbs.

.

m

Tightening Torque

B

Terminal Nut

6.3.2 Magnetic Switch Test

1. Disconnect the cable from the negative terminal on
the battery

2. Disconnect the positive cable and leads from the
starter B terminal.

3. Remove the starter from the engine.

4. Disconnect thetheconnectinglead(1)fromthestart­er solenoid C terminal (2).

5. Connect a jumper lead from the starter S terminal(3)
to the positive battery post.

6. Momentarily, connect a jumper lead between the
starter C terminal (2) and negative battery terminal.

7. If the pinion gear nose does not pop out, check the
magnetic switch.

1. Connecting Lead

2. C Terminal

3. S terminal

4. B terminal

62--11161

NOTE

This test should only be carried out for a 3 to 5
second time period and not longer.

6--4

6.3 STARTER (CT3--44--TV) (Continued)

6.3.3 Assembly

1. Magnetic Switch Mounting Nut

2. Housing

3. Magnetic Switch

4. C Terminal Nut

5. Shaft Assembly

6. Drive Lever

7. Overrunning Clutch

8. Connecting Lead

9. Mounting Screw

10. Armature

11. Yoke

12. Brush Holder

13. Rear End Frame

14. Through Bolt

1. Unscrew the C terminal nut (4), and disconnect the connecting lead (8).

2. Unscrew the magnetic switch mounting nuts (1), and remove the magnetic switch (3) from the housing (2).

3. Unscrew the through bolts (14) and mounting screw (9), and remove the rear end frame (13).

4. Remove the brush from the brush holder while holding the spring up.

5. Remove the brush holder.

6. Draw out the armature (10) and yoke (11) from the housing.

7. Draw out the shaft assembly (5) with the drive lever (6) and overrunning clutch (7) from the housing.

When Reassembling

Tightening

Torque

C Terminal Nut

5.9to11.8N.m

0.6to1.2kgf

4.3to8.7ft--lbs

.

m

6--5

62--11161

6.4 STARTER SERVICING

6.4.1 Overrunning Clutch

1. Inspect the pinion for wear or damage.

2. If there is any defect, replace the assembly.

3. Check that the pinionturnsfreely andsmoothly in the
overrunning direction and does not slip in the crank­ing direction.

4. If the pinion slips or does not rotate inboth directions,
replace the overrunning clutch assembly.

6.4.2 Armature Bearing

1. Check the bearing for smooth rotation.

2. If it does not rotate smoothly, replace it.

6.4.3 Brush Wear

1. Ifthecontact faceofthebrush isdirty ordusty,cleanit
with emery cloth.

2. Measure the brush length “A” with a vernier caliper.

3. If the length is less than the the allowable limit, re­place the yoke assembly and the brush holder.

Brush

Length

A

CT2--29-- TV

CT3--44-- TV

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

16.0 mm

0.630 in.

10.5 mm

0.413 in.

14.0 mm

0.551 in.

9.0 mm

0.354 in.

6.4.4 Solenoid

1. Check the continuity across the “C” terminal and the
“B” terminal by pushing the plunger, then measuring
resistance with an ohmmeter.

2. If there is no continuity, check the contacts.

6.4.5 Brush Holder

1. Check the continuity across the brush holder and
holder support with an ohmmeter.

2. If there is any continuity, replace the brush holder

62--11161

6--6

6.4 STARTER SERVICING (Continued)

6.4.6 Armature

6.4.6.a Continuity Check

1. Check the continuity across the commutator and the
armature with an ohmmeter.

2. If there is continuity, replace the armature.

3. Checkthe continuityacross thesegments ofthecom­mutator with an ohmmeter.

4. If there is no continuity, replace the armature.

6.4.6.b Commutator and Mica

1. Check the contact pattern of the commutator for
wear, and grind the commutator with emery cloth if it
is slightly worn.

2. Measure the commutator O.D. with an outside mi­crometer at several points.

3. If the minimum O.D. is less than the allowable limit,
replace the armature.

4. If the difference of the O.D.’s exceeds the allowable
limit,correctthecommutatorona latheto thefactory
specifications.

5. Measure the mica undercut.

6. If the undercut is lessthan the allowable limit, correct
it with a saw blade and chamfer the segment edges.

1. Segment

2. Depth of Mica

3. Mica

(a). Correct
(b). Incorrect

6--7

62--11161

6.4 STARTER SERVICING (Continued)

6.4.7 Field Coil

1. Checkthe continuityacross thelead(1) andthebrush
with an ohmmeter.

2. If there is no continuity, replace the yoke assembly.

3. Check the continuity across the brush (2) and the
yoke (3) with an ohmmeter.

4. If there is continuity, replace the yoke assembly.

1. Lead

2. Brush

3. Yoke

62--11161

6--8

INDEX

B

Battery, i
bearing case, 2--16, 2--18

C

camshaft, 2--11, 2--25, 2--26
camshaft -- fuel, 2--12
compression pressure, 2--1
connecting rod, 2--13, 2--15, 2--29
coolant, i, 2--2, 4--1
coolant level, 1--12
cooling system, 4--1
crankshaft, 2--30
crankshaft assembly, 2--17
crankshaft gear, 2--12
crankshaft sleeve, 2--35
cylinder, 2--36

I

Identification, 1--1
idle gear, 2--11
injection nozzle, 5--3, 5--4
injection timing, 5--1

L

lubricating system, 3--1

O

oil filter, 3--2
oil level, 1--12, 3--1
oil pressure, 3--2
oil pump gear, 2--12
oil pump service, 3--3

cylinder head, 2--3, 2--4, 2--19

D

delivery valve, 5--2
dye/penetrant, 2--19

E

electrical system, 6--1
engine oil, 1--12, 2--2, 3--1

F

Fan Drive Pulley, 2--10
flywheel, 2--16
fuel injection, 2--3
fuel system, 5--1
fuel system -- bleeding , 1--12

P

piston, 2--14, 2--28, 2--29
piston ring, 2--15
Pump element, 5--2
push rod, 2--24

R

radiator, 4--2
radiator cap, 4--2
reliefvalve,3--3
rocker arm, 2--23

S

Safety Precautions, i
Specific Warning and Cautions Statements, i, ii

G

Gear Case, 2--10
glow plug, 6--1

Index--1

specifications, 1--2
starter service, 6--6, 6--7, 6--8

starter -- 2 cylinder, 6--2, 6--3
starter -- 3 cylinder, 6--4, 6--5

62--11161

INDEX

T

tappets, 2--5, 2--24
thermostat, 4--2
timing gear, 2--25
timing gear, camshafts, 2--7, 2--8, 2--9, 2--10,

2--11, 2--12

Torque Specification, 1--4

V

v--belt, 4--1

valve clearance, 1--13
valve guide, 2--21
valve seat, 2--21
valve spring, 2--23
valves, 2--5, 2--6, 2--20, 2--22

W

water pump, 4--3
water pump assembly, 2--7, 2--8, 2--9

62--11161

Index--2

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©2007 Carrier Corporation D Printed in U. S. A. 0707

Carrier Transicold Division, Carrier Corporation
Truck/Trailer & Container Product Groups
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com