Carrier V2203-DI User Manual

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Page 1

Diesel Engine

V2203-DI (26--00128)

62--11362 Rev --

WORKSHOP MANUAL

for

Tier 4i

Page 2

WORKSHOP MANUAL

DIESEL ENGINE

V2203-DI (26-00118)

Tier 4i

Page 3

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

SAFETY PRECAUTIONS iv...................................................................

SPECIFIC WARNING AND CAUTION STATEMENTS iv..........................................

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

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

Engine Serial Number 1--1.......................................................................

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

1.3 CYLINDER NUMBER 1--3.................................................................

1.4 GENERAL PRECAUTIONS 1--3............................................................

1.5 TORQUE SPECIFICATIONS 1--4...........................................................

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

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

1.6 TROUBLESHOOTING 1--5................................................................

1.7 SERVICING SPECIFICATIONS 1--7........................................................

1.7.1 Engine Body 1--7......................................................................

1.7.2 Lubricating System 1--11................................................................

1.7.3 Cooling System 1--11...................................................................

1.7.4 Fuel System 1--11......................................................................

1.7.5 Electrical System 1--12..................................................................

1.8 CHECK AND MAINTENANCE 1--13..........................................................

1.8.1 Checking Engine Oil Level 1--13..........................................................

1.8.2 Checking Coolant Level 1--13............................................................

1.8.3 Checking Fuel Hose 1--13...............................................................

1.8.4 Bleeding Fuel System 1--14..............................................................

1.8.5 Checking V--Belt 1--14..................................................................

1.8.6 Changing Engine Oil 1--14...............................................................

1.8.7 Valve Clearance 1--15..................................................................

1.8.8 Fuel Injection 1--15.....................................................................

1.9 SPECIAL TOOLS 1--16.....................................................................

1.9.1 Diesel Engine Compression Tester (Glow Plug) 1--16.......................................

1.9.2 Adapter, Injector T o Tester Hose 1--16....................................................

1.9.3 Tester Injector Nozzle 1--16..............................................................

1.9.4 Replacement Bowl, Tester Injector Nozzle 1--16............................................

1.9.5 Adapter, Injector Line 1--16..............................................................

1.9.6 Oil Pressure Tester 1--17................................................................

1.9.7 Auxiliary Socket For Fixing Crankshaft Sleeve 1--17........................................

1.9.8 Gauge, Belt Tension 1--17...............................................................

1.9.9 Tester, Belt Tension 1--17................................................................

1.9.10 Rubber Band 1--17.....................................................................

1.9.11 Main Bearing Install Tool 1--17...........................................................

1.9.12 Main Bearing Extract Tool 1--17..........................................................

1.9.13 Valve Guide Replacing Tool 1--18.........................................................

1.9.14 Bushing Replacing T ools 1--18...........................................................

1.9.15 Flywheel Stopper 1--18..................................................................

1.9.16 Crankshaft Bearing 1 Replacing Tool 1--19.................................................

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PARAGRAPH NUMBER

ENGINE BODY 2--1...............................................................................

2.1 CHECKING AND ADJUSTING 2--1.........................................................

2.1.1 Compression Pressure 2--1.............................................................

2.1.2 Top Clearance 2-- 1....................................................................

2.2 DISASSEMBLY AND REASSEMBLY 2--2....................................................

2.2.1 Draining Coolant And Engine Oil 2--2....................................................

2.2.2 External Components 2--2..............................................................

2.2.3 Cylinder Head And V alves 2--3..........................................................

2.2.4 Injection Pump and Gear Case 2--6......................................................

2.2.5 Oil Pan and Oil Strainer 2--12............................................................

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

2.2.7 Crankshaft 2--15.......................................................................

2.3 SERVICING 2--18.........................................................................

2.3.1 Cylinder Head And V alves 2--18..........................................................

2.3.2 Timing Gears, Camshaft and Fuel Camshaft 2--23..........................................

2.3.3 Piston and Connecting Rod 2--26.........................................................

2.3.4 Crankshaft 2--28.......................................................................

2.3.5 Cylinder 2--33..........................................................................

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

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

3.1.1 Engine Oil Pressure 3--1...............................................................

3.2 SERVICING 3--2.........................................................................

3.2.1 Rotor Lobe Clearance 3--2.............................................................

3.2.2 Rotor to Cover Clearance 3--2..........................................................

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

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

4.1.1 Notched V--Belt Service 4--1............................................................

4.1.1a Poly V--Belt Service 4--1...............................................................

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

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

4.1.4 Radiator Cap 4--2.....................................................................

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

4.1.6 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

62-11362

Page 5

PARAGRAPH NUMBER

FUEL SYSTEM 5--1...............................................................................

5.1 CHECKING AND ADJUSTING 5--1.........................................................

5.1.1 Injection Timing 5--1...................................................................

5.1.2 Shim Identification 5--1.................................................................

5.1.3 Pump Pressure Test 5--2...............................................................

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

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

5.2.1 Nozzle Injection Pressure 5--3..........................................................

5.2.2 Nozzle Spraying Condition 5--3..........................................................

5.2.3 Valve Seat Tightness 5--3..............................................................

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

6.1 STARTER TEST 6--1......................................................................

6.1.1 Motor Test 6--1........................................................................

6.1.2 Magnetic Switch Test 6--1..............................................................

6.2 FUEL SPEED SOLENOID 6-- 2.............................................................

6.2.1 Solenoid Test 6-- 2.....................................................................

6.3 INTAKE AIR HEATER 6--3.................................................................

6.3.1 Intake Air Heater Test 6--3..............................................................

Page

iii

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SAFETY

SAFETY PRECAUTIONS

Your Carrier Transicoldunit has been designed with the safety of the operator inmind. During normal operation, allmovingparts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspections, and problem troubleshooting, you may be exposed to movingparts.Pleasestayclearofallmovingpartswhen 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 lead-acid type battery. The battery normally vents small amounts of flammable hydrogengas.Donotsmokewhencheckingthebattery. A battery explosion can cause serious physical harm and/or blindness.

SPECIFIC WARNING AND CAUTION

STATEMENTS

Tohelpidentifythe labelhazards on the unit andexplain thelevelof awareness each onecarries, an explanation is given with the appropriate consequences:

DANGER

DANGER -- warns against an immediate hazard which WILL result in severe personal injury ordeath.

WARNING

WARNING -- warns against hazards or unsafe conditions which COULD res ult 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.

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The statements listed below are specifically applicable to this unit and appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.

WARNING

Beware of moving V--belt and belt driven components

WARNING

When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may discharge from the radiator, scalding anyone nearby.

WARNING

Checktheinjectionnozzleonly afterconfirming that nobody is near the spray. If the spray fromthe nozzle contacts the human body, cells may be destroyed and blood poisoning may result.

WARNING

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

CAUTION

Do not removethe radiator cap until the coolant temperatureis below its boiling point. Loosen the cap slightly to relieve excess pressure before removing the cap completely.

CAUTION

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

CAUTION

Stop the engine when preparing to change the engine oil.

CAUTION

Never remove the radiator cap until coolant temperature is below its boiling point. Loosen the cap slightly to the first stop to relieve any excess pressure before removing the cap completely.

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SECTION 1

Serial

Numb

General

1.1 ENGINE IDENTIFICATION

S/N

V2203--

Y A 4321

Lower 4 digits in numerals 7th Digit Alpabetical Letter (Month of Manufacture)

Alphabetical letter Month

6th 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

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

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

It indicates month and year of manufacture as follows:

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

Jan Feb Mar May Jun Jul Aug Sep OctApr Nov Dec

1234 56789

MODEL NUMBER ENGINE TYPE

V2203L--DI--E3B--CTD--2

V2203L--DI--E3B--CTD--3

V2203L--DI--E3B--CTD--1

V2203L--DI--E3B--CTD--6

V2203L--DI--E3B--CTD--4

CT4--134--DI

(1700 RPM)

CT4--134--DI

(1800 RPM)

CT4--134--DI

(2200 RPM)

CT4--134--DI

(1800 RPM)

CT4--134--DI

(1700 RPM)

Table 1-1. Model Chart

SERVICE ENGINE

PARTNUMBER

26--00128--00

26--00128--01 RG Genset New

26--00128--02

26--00128--04 UG Genset New

26--00128--05 TM Ultra XL New

Ultra XT, Ultra XTC, X2 1800 (2.2),

PRIMARY USE REPLACES

X2 2100, X2 2100A, X2 2100R

UltimaXTC,ExtraXT(2.2),

X2 2500 A, X2 2500 R

New

1--1 62--11362

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1.2 ENGINE SPECIFICATIONS Table 1-2. Specification Chart

MODEL NUMBER 26--00128--00 26--00128--01 26--00128--02 26--00128--04 26--00128--05 TYPE Vertical, Water--cooled, 4 cycledieselengine NUMBER OF CYLINDERS 4 BOREXSTROKE mmXmm(in.Xin.) 83 X 102.4 (3.27 X 4.03) TOTAL DISPLACEMENT cm3(cu.in.) 2216 (135.2) BRAKE HORSEPOWER

SAE Intermittent HP kW (HP) / RPM MAXIMUM SPEED RPM Below 2470 IDLING SPEED RPM 900 COMBUSTION CHAMBER DirectInjection INJECTION PUMP Bosch “K” Type Mini Pump GOVERNOR Mechanical Governor + Electronic Governor INJECTION NOZZLE Bosch “P” Type Hole Nozzle

INJECTION TIMING (UNPRESSURIZED) 2.5° BeforeT.D.C.

FIRING ORDER 1-- 3--4--2 INJECTION PRESSURE

(Valve Opening Pressure) COMPRESSION RATIO 21.5 : 1 LUBRICATION SYSTEM Forced Lubrication by Pump OIL PRESSURE INDICATION Electrical Type Switch LUBRICATION FILTER Full Flow Synthetic Media Filter (Cartridge Type) COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump

STARTING SYSTEM

STARTING SUPPORT DEVICE Intake Air Heater in Intake Manifold FUEL Diesel Fuel No.2--D (ASTM D975) LUBRICATING OIL *Quality Better Than CF Class (API), SAE 10W--30 or 15W--40 LUBRICATING OIL CAPACITY 14.2 L (15.0 U.S. Quarts) Weight (DRY) kg (lbs.) 199 (439)

23.65 (31.7) / 1700

23.87 (32.0) / 1800

19.35 MPa (197.5 kgf/cm2, 2809 psi.)

Electric Starting With Starting Motor

26.85 (36.0) / 2200

4.0° Before T.D.C.

12V,2.5 kW

23.87 (32.0) / 1800

2.5° BeforeT.D.C.

23.65 (31.7) / 1700

*See paragraph 1.8.6

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1--2

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1.3 CYLINDER NUMBER

1.4 GENERAL PRECAUTIONS

The cylinder numbers of V2203--DI series engine are designated as shown above. The sequence of cylinder numbers is given as No.1, No. 2, No. 3, and No. 4 starting from the gear case end of the engine.

1. Grease

2. Force

3. Place the Sharp Edge against the Direction of Force

A External Snap Ring B Internal Snap Ring

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

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

Before disassembling orservicing live wires, makesure to always disconnect the grounding cable from the battery first.

Remove oil and dirt from parts before taking any measurements.

Use only Carrier Transicold genuine parts for parts replacements to maintain engine performance and to ensure safety.

Gaskets and O--rings must be replaced during reassembly. Apply grease to new O--rings or oil seals before assembling.

When reassembling external or internal snap rings, position them so that the sharp edge faces against the direction from which force is applied.

A newly serviced or reassembled engine should be run--in with no load for 15 minutes. Serious damage to the engine may result otherwise.

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1.5 TORQUE SPECIFICATIONS

Screws, bolts and nuts must be tightened to the specified torque using a torque wrench. Several screws, bolts and nuts such as those used on the cylinder head must be tightened in the proper sequence and at the proper torque.

1.5.1 Torque Specifications For Special Use Screws, Bolts and Nuts

In removing andapplyingthe screws, bolts andnuts marked with“*”, a pneumatic wrench or similartool, if employed, must be used with care. Failure to do so may result in stripped or seized screws, bolts and nuts.

When replacing “*” marked screws, bolt and nuts, apply engine oil to their threads and seats before reassembly. The letter “M” in size and pitch means that the screw, bolt or nut dimension is metric. The size isthe nominal outside

diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.

Item

Cylinder Head Cover Bolt M6 x 1.0 6.87 to 11.2 0.7to1.15 5.07 to 8.31 *Cylinder Head Bolt M11 x 1.25 93.2 to 98.0 9.5 to 10.0 68.8 to 72.3 *Main Bearing Case Bolt 1 M9 x 1.25 46 to 50 4.7to5.2 34.0to37 *Main Bearing Case Bolt 2 M10 x 1.25 69 to 73 7.0to7.5 51 to 54 *Flywheel Bolt M12 x 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5 *Connecting Rod Bolt M8 x 1.0 45 to 49 4.5to5.0 33 to 36 *Rocker Arm Bracket Bolt M8 x 1.25 24 to 27 2.4to2.8 18 to 20 *Idle Gear Shaft Bolt M8 x 1.25 24 to 27 2.4to2.8 18 to 20 Crank Pulley Mounting Nut M30 x 1.5 138 to 156 14.0 to 16.0 102 to 115 *Bearing Case Cover Bolt M8 x 1.25 24 to 27 2.4to2.8 18 to 20

Nozzle Holder Clamp Bolt M10 x 1.25 26 to 29 2.6to3.0 19 to 21

Injection Pipe Retaining Nut M12 x 1.5 15 to 24 1.5to2.5 11 to 18

Overflow Pipe Assembly Retaining Bolt M6 x 1.0 9.81 to 11.2 1.0to1.15 7.24 to 8.31

Camshaft Retaining Bolt M8 x 1.25 24 to 27 2.4to2.8 18 to 20

Hi--idling Body M14 x 1.0 45 to 49 4.5to5.0 33 to 36

Starter’s Terminal B Mounting Nut M8 9.8to11 1.0to1.2 7.3to8.6

1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts Standard Screw and Bolt

Grade 4

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

M6 7.9to9.3 0.80 to 0.95 5.8to6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31

M8 18 to 20 1.8to2.1 13 to 15 24 to 27 2.4to2.8 18 to 20 M10 40 to 45 4.0to4.6 29 to 33 49 to 55 5.0to5.7 37 to 41 M12 63 to 72 6.4to7.4 47 to 53 78 to 90 7.9to9.2 58 to 66

SizexPitch N.m kgf.m ft--lbs

Special Screw and Bolt

Grade 7

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

Punched Number

None or 4 Standard Screw And Bolt SS41, S20C

7 Special Screw And Bolt S43C, S48C (Refined)

62--11632

Screw And Bolt Material Grade

1--4

Page 12

1.6 TROUBLESHOOTING Symptom

Engine Does Not Start

Probable Cause Solution Reference

No fuel Air in the fuel system Water in the fuel system

Fuel pipe clogged Fuel filter clogged Excessively high viscosity fo fuel or engine oil

at low temperature Fuel with low cetane number Incorrect injection timing Injection nozzle clogged Injection pump malfunctioning Seizure of crankshaft, camshaft, piston,

cylinder or bearing Compression leak from cylinder

Improper valve timing Piston ring and cylinder worn

Excessive valve clearance

Replenish fuel Vent Air Change fuel and repair or replace fuel system Clean Clean or change Use specified fuel or

engine oil Use specified fuel Adjust Replace Replace Repair or Replace

Replace head

gasket, tighten

cylinder head screw,

glow plug and nozzle

holder Correct or replace

timing gear Replace Adjust

1.8.4

5.1.1

1.8.8

2.2.4.f

2.3.3.d

1.8.7

(Starter Does Not Run)

Battery discharged Starter malfunctioning Key switch malfunctioning Wiring disconnected

Engine Revolution Is Not Smooth

Fuel filter clogged or dirty Air cleaner clogged or dirty Fuel leak due to loose injection pipe retaining

nut Injection pump malfunctioning Incorrect nozzle injection pressure Injection nozzle stuck or clogged

Either White or Blue

Excessive engine oil

Exhaust Gas Is Observed

Piston ring and liner worn or ring stuck Incorrect Injection timing Deficient compression

Either Black or Dark Exhaust Gas Is Observed

Overload Low grade fuel used Fuel filter clogged Air cleaner clogged Deficient nozzle injection

Deficient Output Incorrect injection timing

Engine’s moving parts seem to be seizing Injection pump malfunctioning Deficient nozzle injection Compression leak

Gas leak from exhaust system Air cleaner dirty or clogged

Charge Repair or replace Repair or replace Connect

Clean or change Clean or change Tighten retaining nut

Replace Replace Replace

Reduce to specified

level Repair or replace Adjust Check the cylinder

compression

pressure and top

clearance Lesson load

Use specified fuel Clean or change Clean or change Replace nozzle

Adjust Repair or replace Replace Replace nozzle Check the compression pressure and repair Repair or replace Clean or replace

6.1

1.8.4

5.1

5.2.1

5.2.3

1.8.1

2.3.3.d

5.1.1

2.1.1

1.8.8

5.1.1

5.1

5.2.2

2.1.1

1--5 62--11362

Page 13

1.6 TROUBLESHOOTING (Continued) Symptom

Excessive Lubricant

Piston ring’s gap facing the same direction

Probable Cause Solution Reference

Oil Consumption

Oilringwornorstuck Piston ring groove worn Valve stem and valve guide worn Crankshaft bearing, and crank pin bearing

worn

Oil leaking due to defective seals or packing

Fuel Mixed into

Injection pump’s plunger worn

Lubricant Oil

Deficient nozzle injection Injection pump broken

Water Mixed into Lubricant Oil

Head gasket defective Cylinder block or cylinder head flawed

Low Oil Pressure Engine oil level low

Oil strainer clogged Relief valve stuck with dirt Relief valve spring weak or broken Excessive oil clearance of crankshaft bearing

Excessive oil clearance of crankpin bearing Excessive oil clearance of rocker arm

Oil passage clogged Incorrect oil type

Oil pump defective

High Oil Pressure Incorrect oil type

Relief valve defective

Engine Overheated Engine oil level low

Fan belt broken or elongated Coolant insufficient Radiator net and radiator fin clogged with dust Inside of radiator corroded Coolant flow route corroded Radiator cap defective Overload running Head gasket defective Incorrect injection timing Unsuitable fuel used

Low Battery Charge Battery electrolyte level low

Fan belt slips Wiring disconnected

Rectifier defective Alternator defective Battery defective

Shift ring gap

direction Replace Replace worn piston Replace Replace

Replace Replace Injection

pump Replace nozzle Replace

Replace Replace

Replenish Clean Clean Replace Replace

Replace Replace

Clean Use specified type of

oil Repair or replace

Use specified type of

oil Replace

Replenish Replace or adjust Replenish Clean Clean or replace Clean or replace Replace Loosen load Replace Adjust Use specified fuel

Replenish distilled

water and charge Adjust belt tension or

change belt Connect Replace Replace Change

2.2.6.a

2.3.3.d

2.3.3.e

2.3.1.d

2.3.4

5.1

5.2.3

5.1

2.2.3.e

3.1.1

2.3.4.d

2.3.4.c

2.3.1.k

3.2

3.1.1

2.2.3.e

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1--6

Page 14

1.7 SERVICING SPECIFICATIONS

1.7.1 Engine Body Item

Factory Specification Allowable Limit

Cylinder Head Surface Flatness -- 0.05 mm/500mm

0.0020 in./

19.69 in.

Compression Pressure

Difference Among Cylinders Top Clearance 0.60 to 0.70 mm

2.95 to 3.23 MPa/ 290 rpm

30 to 33 kgf/cm

290 rpm

427 to 469 psi/

290 rpm

2.35 MPa/

290 rpm

24kgf/cm

290 rpm

341 psi/

290 rpm

10% or less

0.0236 to 0.0276 in.

Valve Clearance (When Cold) 0.18 to 0.22 mm

0.0071 to 0.0086 in.

Valve Seat Width (Intake)

2.12 mm

0.0835 in.

Width (Exhaust)

2.12 mm

0.0835 in.

Valve Seat Angle

(Intake / Exhaust)

Valve Face Angle

(Intake / Exhaust)

ValveStemtoValveGuide

Clearance

0.79 rad. 45°

0.040 to 0.070 mm

0.0016 to 0.0027 in.

0.1 mm

0.0039 in.

Valve Stem

Valve Guide

O.D.

I.D.

Valve Recessing Protrusion

Recessing

Valve Timing (Intake Valve) Open

Valve Timing (Exhaust Valve) Open

7.960 to 7.975 mm

0.3134 to 0.3139 in.

8.015 to 8.030 mm

0.3156 to 0.3161 in.

0.65 mm

0.026 in. to

0.85 mm

0.033 in.

0.1 rad. (8°)

before T.D.C.

0.35 rad. (20°) before T.D.C

0.87 rad. (50°)

before B.D.C.

0.21 rad. (12°)

before B.D.C

1--7 62--11362

Page 15

1.7.1 Engine Body (Continued) Item

Valve Spring Free Length

Setting Load/ Setting Length

Tilt

Factory Specification Allowable Limit

41.7 to 42.2 mm

1.65 to 1.66 in.

118N/35.0mm

12.0 kgf / 35.0 mm

26.5 lbs. / 1.38 in.

41.2 mm

1.62 in.

100.0N / 35.0 mm

10.2kgf / 35.0 mm

22.5lbs /1.38 in

1.0 mm

0.039 in.

Rocker Arm Shaft to Rocker Arm

Rocker Shaft

Clearance

O.D.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

13.973 to 13.984 mm

1.0 mm

0.039 in.

0.55012 to 0.55055 in.

Rocker Arm

I.D.

14.000 to 14.018 mm

0.55119 to 0.55188 in.

Push Rod Alignment -- 0.25mm

0.0098 in.

Tappet to Tappet Guide Clearance

O.D.

0.020 to 0.062 mm

0.00079 to 0.0024 in.

23.959 to 23.980 mm

0.07 mm

0.003 in.

0.94327 to 0.94409 in.

I.D.

24.000 to 24.021 mm

0.94489 to 0.94570 in.

Timing Gear Crank Gear to Idle Gear

Backlash

0.0415 to 0.1122 mm

0.001634 to 0.004417 in.

Idle Gear to Cam Gear

Backlash

0.0415 to 0.1154 mm

0.00163 to 0.004543 in.

Idle Gear to Injection Pump Gear

Backlash

0.0415 to 0.1154 mm

0.001634 to 0.004543 in.

Crank Gear to Oil Pump Gear

Backlash

0.0415 to 0.1090 mm

0.001634 to 0.004291 in.

Idle Gear Side Clearance 0.12 to 0.48 mm

0.0048 to 0.018 in.

Idle Gear Shaft to Idle Gear Bushing

Clearance

0.025 to 0.066 mm

0.00099 to 0.0025 in.

Idle Gear Shaft

O.D.

37.959 to 37.975 mm

1.4945 to 1.4950 in.

Idle Gear Bushing

I.D.

38.000 to 38.025 mm

1.4961 to 1.4970 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.9 mm

0.04 in.

0.1 mm

0.0039 in.

62--11632

1--8

Page 16

1.7.1 Engine Body (Continued) Item

Camshaft Side Clearance 0.07 to 0.22 mm

Factory Specification Allowable Limit

0.3 mm

0.0028 to 0.0086 in.

0.012 In.

Camshaft Alignment -- 0.01 mm

0.0004 in.

Cam (Lobe) Height (Intake)

Height (Exhaust)

Camshaft Journal to Cylinder Block Bore

Camshaft Journal

Clearance

O.D.

33.27 mm

1.310 in.

33.47 mm

1.318 in.

0.050 to 0.091 mm

0.0020 to 0.0035 in.

39.934 to 39.950 mm

33.22 mm

1.308 in.

33.42

1.316 in.

0.15 mm

0.00059 in.

1.5722 to 1.5728 in.

Cylinder Block Bore

I.D.

40.000 to 40.025 mm

1.5748 to 1.5757

Piston Pin Bore I.D. 25.000 to 25.013 mm

0.98425 to 0.98476 in.

Second Ring to Ring Groove Clearance 0.093 to 0.128 mm

0.00367 to 0.00503 in.

Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm

0.00079 to 0.0023 in.

Top Ring Ring Gap 0.20 to 0.35 mm

0.0079 to 0.013 in.

Second Ring Ring Gap 0.40 to 0.55 mm

0.016 to 0.021 in.

Oil Rng Ring Gap 0.25 to 0.45 mm

0.0099 to 0.017 in.

25.05 mm

0.9862 in.

0.2 mm

0.0079 in.

0.15 mm

0.0059 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

Connecting Rod Alignment -- 0.05 mm

0.002 in.

Piston Pin to Small End Bushing

Clearance

0.014 to 0.036 mm

0.00056 to 0.0014 in.

0.15 mm

0.0059 in.

Piston Pin

O.D.

25.004 to 25.011 mm

0.98441 to 0.98468 in.

Small End Bushing

I.D.

25.025 to 25.040 mm

0.98524 to 0.98582 in.

Crankshaft Alignment -- 0.02 mm

0.0008 in.

Crankshaft Journal to Crankshaft Bearing1

Crankshaft Journal

Oil Clearance

O.D.

0.040 to 0.118 mm

0.00158 to 0.00464 in.

59.921 to 59.940 mm

0.2 mm

0.0079 in.

2.3591 to 2.3598 in.

Crankshaft Bearing1

I.D.

59.980 to 60.039 mm

2.3615 to 2.3637 in.

1--9 62--11362

Page 17

1.7.1 Engine Body (Continued) Item

Crankshaft Journal to Crankshaft Bearing2

Crankshaft Journal

Crankshaft Bearing2

Crankpin to Crankpin Bearing

Crankpin

Crankpin Bearing

Crankshaft Side Clearance 0.15 to 0.31 mm

Crankshaft Sleeve Wear -- 0.1mm

Cylinder Bore (Standard)

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Factory Specification Allowable Limit

0.040 to 0.104 mm

0.00158 to 0.00409 in.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

59.980 to 60.025 mm

2.3615 to 2.3631 in.

0.025 to 0.087 mm

0.00099 to 0.0034 in.

46.959 to 46.975 mm

1.8488 to 1.8494 in.

47.000 to 47.046 mm

1.8504 to 1.8522 in.

0.0059 to 0.012 in.

83.00 to 83.022mm

3.2678 to 3.2685 in.

0.2 mm

0.0079 in.

0.2 mm

0.0079 in.

0.5 mm

0.02 in.

0.0059 in.

83.170 mm

3.2744 in.

(Oversize)

I.D.

83.250 to 83.272 mm

3.2776 to 3.2784 in.

83.420 mm

3.2843 in.

62--11632

1--10

Page 18

1.7.2 Lubricating System Item

Engine Oil Pressure At Idle Speed

Factory Specification Allowable Limit

More Than 98 kPa

1.0 kgf/cm

14 psi

At Rated Speed

300 to 440 kPa

3.0 to 4.5kgf/cm

43 to 64 psi

Engine Oil Pressure Switch Working

Pressure

50 kPa

0.5kgf/cm

7psi

Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm

0.0044 to 0.0074 in.

Inner Rotor to Cover Clearance 0.105 to 0.150 mm

0.00414 to 0.00590 in.

1.7.3 Cooling System Item

Factory Specification Allowable Limit

V--Belt Tension 7.0to9.0mm(0.28to

0.35 in.) deflection at 98N(10kgf, 22 lbs.)

of force

Thermostat Valve Opening

Temperature

80.5 to 83.5°C

176.9 to 182.3°F

(At Beginning)

50 kPa

0.5 kgf/cm 7psi

250 kPa

2.5 kgf/cm

36 psi

0.2 mm

0.008 in.

0.25 mm

0.0098 in.

0.2 mm

0.008 in.

Valve Opening Temperature

95°C

203°F (Opened Completely)

1.7.4 Fuel System Item

Injection Pump Injection Timing 0.0568 to 0.0829 rad.

Factory Specification Allowable Limit

(3.25to4.75°) before

T.D.C.

Pump Element Fuel Tightness -- 18.63 Mpa

190.0 kgf/cm 2702 psi

Delivery Valve Fuel Tightness 10 seconds

18.62 to 17.76 Mpa

190.0 to 180.0 kgf/cm 2702 to 2560 psi

Injection Nozzle Injection Pressure

(1st stage)

18.64 to 20.10 Mpa

190.0 to 205.0 kgf/cm

5 seconds

18.63 to 17.65 Mpa

190.0 to 180.0kgf/cm 2702 psi to 2560 psi

2703 to 2915 psi

Injection Nozzle Valve Seat Valve Seat

Tightness

When the pressure is

16.67 Mpa (170.0 kgf/cm

2418 psi) the valve seat

must not leak.

1--11 62--11362

Page 19

1.7.5 Electrical System Item

Starter

Commutator

Mica

Brush

Brush Holder and Holder Support

Intake Air Heater Resistance (cold) Approx. 0.3 ohm --

O.D.

Undercut

Length

Resistance

Factory Specification Allowable Limit

32.0 mm

1.26 in.

0.50 mm

0.020 in.

0.18 mm

0.709 in. Infinity

31.4 mm

1.24 in.

0.20 mm

0.0079 in.

11.0 mm

0.433 in.

62--11632

1--12

Page 20

1.8 CHECK AND MAINTENANCE

1.8.1 Checking Engine Oil Level

1. Level the engine.

2. Tochecktheoillevel,draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches.

3. If the level is too low, add new oil to the specified level.

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.

1.8.2 Checking Coolant Level

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

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

2. Ifthe coolant level istoolow,checkthe reason for the lost coolant.

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

soft water.

b. If coolant loss is due to a leak, repair the leak, then

add a coolant mixture of the same type and specificationthatisinthesystem. If thecoolantbrandcannot be identified, drain out all of the remaining coolant and refill with a totally new mix.

NOTE

Whenaddingcoolanttothe system,airmustbe vented from the engine coolant passages. Venting air can be accomplished by jigglingthe upper and lower radiator hoses.

Besureto close the radiator capsecurely.Ifthe 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.

1.8.3 Checking Fuel Hose

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

2. The fuel hose is made of rubber and agesregardless of the service period. Change the hose and clamps together every two years.

3. Change the fuel hose and clamps whenever any deterioration or damage is detected.

4. After the fuel hose and clamps have been changed, bleed air out of the fuel system.

CAUTION

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

CAUTION

Do not remove the radiator cap until the coolant temperature is below its boiling point. Loosen the cap slightly to relieve excess pressure before removing the cap completely.

1--13 62--11362

Page 21

1.8.4 Bleeding Fuel System

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

2. Loosen the priming pump handle (2), and pump the handle until bleeding is completed.

3. Depress and twist the priming pump handle clockwisetolockintoplace.

4. Close the air vent cock (1).

NOTE

Always keep the air vent cock on the fuelinjectionpumpclosed except when bleeding the fuel system, or the engine may not run.

1.8.5 Checking V--Belt

Refer to Section 4.1

1.8.6 Changing Engine Oil

CAUTION

Stop the engine when preparing to change the engine oil.

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

2. Place a pan underneath the engine.

3. Remove the drain plug, drain the engine oil completely.

4. Inspect the drain plug gasket. Replace if necessary.

5. Reinstall the drain plug.

6. Replace the oil filter with a new oil filter.

7. Fill the crankcase with new oil.

8. Check for thecorrectoillevel.(RefertoSection1.8.1)

NOTE

When changing to a different oil manufacturer or viscosity, be sure to remove all of the old oil completely. Never mix different types of oil.

Use only API classification CG--4 or better oils. Use the proper SAE engine oil according to the

ambient temperatures.

Above 25°C(77°F).............SAE 30 or10W--30

10W--40

0° to25°C(32° to77°F)......SAE20 or 10W--30

10W--40

Below0°C(32°F)............SAE10Wor10W--30

NOTE

With emission controls now in effect, theCG--4 or CH--4 / CI lubricating oils have been developed for use of a low--sulfur fuel on--road vehicles engines. When an off--road vehicle engine runs on a high--sulfur fuel, it is advisableto employ the CH--4 / CI lubricating oil with a high total base number. If the CG--4 lubricating oil is usedwithahighsulfurfuel,changethelubricating oil at shorter intervals.

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

ubricating Oil Class Fuel

Low--sulfur High--sulfur

CG--4 O O

CH--4 or CI O X

O : Recommended X : Not Recommended

62--11632

1--14

Page 22

1.8.7 Valve Clearance

NOTE

Valveclearancemust be checked and adjusted when the engine is cold.

1. Remove the valve cover.

2. Align the“1TC” mark line (3)on the flywheel and projection (2) on the housing so that the Number 1piston comes to compression or overlap top dead center (TDC).

3. Check the following valve clearance (1) marked with “*” using a feeler guage.

Valve Clearance

Factory

Specification

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

Piston Location in Cylinder IN. EX.

When No. 1 piston is at TDC

When No. 1 piston is at past TDC

0.18 to 0.22 mm

0.0071 to 0.0086 in.

Valve

Arrangement

No. 1 * * No. 2 * No. 3 * No. 4 No. 1 No. 2 * No. 3 * No. 4 * *

1.8.8 Fuel Injection

Refer to Section 5.2

1--15 62--11362

Page 23

1.9 SPECIAL TOOLS

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

1.9.1 Diesel Engine Compression Tester (Glow

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

1.9.2 Adapter, Injector To Tester Hose

Part No. 07--00484--00 Application: Accessory for 07--00179--01

1.9.3 Tester Injector Nozzle

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

Plug)

compression and diagnosis for major overhaul.

62--11632

1.9.4 Replacement Bowl, Tester Injector Nozzle

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

1.9.5 Adapter, Injector Line

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

1--16

Page 24

1.9 SPECIAL TOOLS (Continued)

Adapte

8.Adapto

1.9.6 Oil Pressure Tester

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

pressure.

1. Guage

2. Adapter 2

3. Cable

5. Threaded Joint

6. Adapter 4

7. Adaptor 1 r

1.9.7 Auxiliary Socket For Fixing Crankshaft Sleeve

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

diesel engine.

1.9.8 Gauge, Belt Tension

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

cogged V--belts.

1.9.9 Tester, Belt Tension

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

1.9.10 Rubber Band

Part No. 07--00253--01 Application: Replacement part for belt tension

tester (Part No. 07--00253--00)

1.9.11 Main Bearing Install Tool

Part No. 07--00472--00 Application: Used on engines starting with

S/N 3S0001

1.9.12 Main Bearing Extract Tool

Part No. 07--00473--00 Application: Used on engines starting with

S/N 3S0001

1--17 62--11362

Page 25

1.9 SPECIAL TOOLS (Continued)

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

1.9.13 Valve Guide Replacing Tool

Application: Use to press out and press fit the valve

B 11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.) C 6.5to 6.6 mm dia. (0.256 to 0.259 in. dia.) D 225mm(8.86 in.)

E 70 mm (2.76 in.)

F 45 mm (1.77 in.) G 25 mm (0.98 in.) H 5 mm (0.197 in.)

I 6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)

J 20 mm dia. (0.787 in. dia.)

K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)

L 8.9 to 9.1 mm (0.350 to 0.358 in.) C1 Chamfer 1.0 mm (0.039in.) C2 Chamfer 2.0 mm (0.079in.)

C0.3 Chamfer 0.3 mm (0.012in.)

1.9.14 Bushing Replacing Tools

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

1. For small end bushing. A

B 35 mm (1.38 in.)

C 27 mm (1.06 in.) D 35 mm dia. (1.38 in. dia.)

E 27.90 to 27.95 mm dia. (1.098 to 1.100 in. dia.) F 25.00 to 25.01 mm dia. (0984 to 0.985 in. dia.)

2. For idle gear bushing. A

B 40 mm (1.57 in.)

C 38 mm (1.49 in.) D 45 mm (1.77 in.)

E 41.90 to 41.95 mm dia. (1.650 to 1.652 in. dia.) F 37.95 to 37.97 mm dia. (1.494 to 1.495 in. dia.)

1.9.15 Flywheel Stopper

Application: Use to loosen and tighten the flywheel

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.)

162 mm (6.38 in.)

175 mm (6.89 in.)

screw.

200 mm (7.87 in.)

62--11632

1--18

Page 26

1.9 SPECIAL TOOLS (Continued)

1.9.16 Crankshaft Bearing 1 Replacing Tool

Application: Usetopressoutandpressfitthecrankshaft

bearing No. 1

1. Extracting tool

130 mm (5.31 in.)

A B 72 mm (2.83 in.) C R40 mm (R1.57 in.) D 10 mm (0.39 in.) E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.) G 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.) H 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)

2. Extracting tool A

130 mm (5.31 in.)

B 72 mm (2.83 in.) C R40 mm (R1.57 in.) D 10 mm (0.39 in.) E 20 mm (0.79 in.)

F 20 mm (0.79 in.) G 20 mm dia. (0.79 in. dia.) H 68 mm dia. (2.68 in. dia.)

I 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)

J 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)

1--19 62--11362

Page 27

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 aircleaner, the muffler and allthe injection nozzles.

4. Install acompression testerwith the adapter in one of the nozzle hole.

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

6. Repeat steps 4 and 5 for each cylinder.

2.1.2 Top Clearance

7. Ifthe measurement is below the allowable limit, adda smallamount of oil to the cylinder thruthenozzlehole 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 the compression 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%.

2.95 to 3.23 MPa 30 to 33 kgt/cm

427 to 469 psi

2.35 MPa

24 kgt/cm

341 psi

Compression Pres-

sure

Factory

Specification

Allowable Limit

1. Piston 2 Plastic gauge

1. Remove the valve cover. (Refer to Section 2.2.3.a)

2. Remove the cylinder head.

3. Move the piston (1) up and stick a strip of plastic gauge(2)onthepistonheadatthreepositionsshown on the illustration.

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

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

6. Remove the cylinder head and measure the plastic gauge.

7. Ifthe measurement is not withinthefactory specifications, check the clearances between the crank pin and bearing and betweenthe pistonpin and bushing.

Top Clearance

Tightening

Torque

Factory

Specification

Cylinder Head

Bolts

0.60 to 0.70 mm

0.024 to 0.027 in.

93.2 to 98.0 N.m

9.5 to 10.0 kgf

68.8 to 72.3 ft--lbs

2--1

62--11362

Page 28

2.2 DISASSEMBLE AND REASSEMBLY

2.2.1 Draining Coolant And Engine Oil

CAUTION

Never remove the radiator cap until coolant temperature is below its boiling point. Loosen the cap slightly to the first stop to relieve any excess pressure before removing the cap completely.

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

2. Removetheoildrainpluganddraintheengineoilinto a proper receptacle/bucket.

2.2.2 External Components Air Cleaner, Muffler and Others

1. Remove the air cleaner and muffler.

2. Remove the fan, fan belt, alternator and starter.

When Reassembling

NOTE

Check to see that there are no cracks on the belt surface.

After reinstaling the fan belt, be sure to adjust the fan belt tension.

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

62--11362

2--2

Page 29

2.2.3 Cylinder Head And Valves

2.2.3.a Valve Cover

1. Remove the breather hose (2).

2. Remove the valve cover bolts (1).

3. Remove the valve cover (3).

When Reassembling

Check to see that the valve cover gasket (4) is in good condition and in place.

Tightening

Torque

1. Valve Cover Bolt

2. Breather Hose

3. Valve Cover

Valve Cover

Bolts

6.87 to 11.2 N.m

0.7to1.15kgf

5.07 to 8.31 ft--lbs

4. Valve Cover Gasket

5. Breather Valve

6. Plate

2.2.3.b Injection Pipes

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

2. Detach the injection pipes (2).

When Reassembling

Blow out any debris that may be in the pipes.

Tightening

Torque

Injection Pipe

Retaining

Nut

2--3

15 to 24 N.m

1.5to2.5kgf 11to 18 ft--lbs

62--11362

Page 30

2.2.3 Cylinder Head And Valves (Continued)

ArmA

2.2.3.c Nozzle Holder Assembly

1. Remove the overflow pipe assembly.

2. Remove the nozzle holder assemblies (1).

When Reassembling

Replace the copper gasket with a new one.

26 to 29 N.m

2.6to3.0kgf 19 to 21 ft--lbs

9.81 to 11.2 N.m

1.00 to 1.15 kgf

7.24 to 8.31 ft--lbs

Tightening

Torque

Nozzle Holder

Assembly

Overflow Pipe

Assembly

Retaining Bolt

2.2.3.d Rocker Arm and Push Rod

1. Remove the rocker arm bracket mounting bolts (1).

2. Detach the rocker arm assembly (2).

3. Remove the push rods (3).

When Reassembling

When putting the push rods (3) onto the tappets (4), check to see if the push rod end is properly seated in the tappet dimples.

1. RockerArmBracket Mounting Bolt

2. Rocker

ssembl

62--11362

3. Push Rod

4. Tappet

2--4

NOTE

After instaling the rocker arm, besure to adjust the valve clearance. (Refer to Section 1.8.7)

Tightening

Torque

Rocker Arm

Bracket Mounting

Bolt

24 to 27 N.m

2.4to2.8kgf 18 to 20 ft--lbs

Page 31

2.2.3 Cylinder Head And Valves (Continued)

1. Hose Clamp

2. Filter--Drier Inlet A: Gear Case Side B: Flywheel Side

4513 12

157

1689

2.2.3.e Cylinder Head

1. Loosen the hose clamp (1),andremove the waterreturn pipe (2).

2. Remove the cylinder headbolts in the order of (18)to (1).

3. Lift up the cylinder head and remove.

4. Remove the cylinder head gasket (3).

When Reassembling

Replace the cylinder head gasket (3) with a new one. Apply oil to, then re--install the cylinder head bolts. Tighten the cylinder head bolts in sequence starting

from the center in the order of (1)to(18). Tighten the head bolts uniformly or head warpage may

occur.

Tightening

Torque

Cylinder Head

Bolt

93.1 to 98.0 N.m

9.5 to 10.0 kgf

68.7 to 72.3 ft--lbs

NOTE

Whenreplacingthecylinderheadgasket (3), be sure you are using a new gasket that matches the original gasket.

2.2.3.f Tappets

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

When Reassembling

Visually check the contact between the tappets (1) and individual cam lobes.

Coat the tappets with engine oil before installing them.

NOTE

When re--installing tappets into the engine, make sure that they arere--installed in their original location.

2.2.3.g Valves

1. Remove the valve caps (3).

2. Remove the valve springcollet (4), pushing thevalve springretainer(5)bythevalvespringcompressor(1).

3. Removethevalve spring retainer (5),valve spring (6) and valve stem seal (2).

4. Remove the valve (7).

When Reassembling

Clean the valve stem and the valveguide. Apply engine oil to the valve stem when reassembling.

After installing the valve spring collets (4), lightly tap the stem with a plastic hammer to assure the collets have seated on the valve stem.

NOTE

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

2--5

62--11362

Page 32

2.2.4 Injection Pump and Gear Case

2.2.4.a Injection Pump

1. Remove the fuel speed solenoid (2) and hi--idling body (3).

2. Remove the engine stop lever (5) and stop solenoid guide (6).

3. Remove the fuel injection pump assembly (7).

NOTE

Remove the injection pump assembly (7) after removing the fuel speed solenoid(2) and hi--idling body (3), engine stop lever (5) and stop solenoid guide (6).

When Reassembling

Install the fuel speed solenoid (2), the hi--idling body (3) and the stop solenoid guide (6) after Installing the injection pump (7).

Replace the hi--idling body gasket (4) with a new one.

Install the fuel speed solenoid guide (6) and then the stop lever (5) into the gear case. Cycle the stop leverto insure that it functions.

NOTE

Wheninstalling the fuel speedsolenoid(2), use care to keep the O--ring (1) in place.

Be sure to insert the push rod of the stop solenoid into the hole at the center of the solenoid guide (6).

Tightening

Torque

Hi--idling Body

45.0 to 49.0 N.m

4.5to5.0kgf 33 to 36 ft--lbs

62--11362

1. O--ring

2. Fuel Speed Solenoid

3. Hi--Idling Body

4. Hi--Idling Body Gasket

2--6

5. Stop Lever

6. Stop Solenoid Guide

7. Injection Pump Assembly

Page 33

2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.b Governor Springs and Speed Control Plate

NOTE

SpecificTool(1):A1.2mm(.050inch)diameter wire with a total length of 200mm (8 inch) with the tip bent into a hook as depicted in the illustration is required to hang the governor springs.

1. Remove the injection pump cover.

2. Removethespeedcontrol plate (7)mounting nuts (3) and bolts (4).

3. Using the Specific Tool (1), undo the the large governor spring (5) from the fork lever (2).

4. Set thespeed control lever (6)as shown in the figure.

5. Remove the speed control plate (7), usingcarenot to let the governor spring (5) disengage from the plate and fall into the gear case.

1. Specific Tool

2. Fork Lever

3. Speed Control Plate Mounting Nut

4. Speed Control Plate Mountin

Bolt

5. Large Governor Spring

6. Speed Control Lever

7. Speed Control Plate

2--7

62--11362

Page 34

2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.b Governor Springs and Speed Control Plate (Continued)

When Reassembling

NOTE

A length of string passed thru the governor spring can be usedto retrievethe spring if it unhooks from both the specific tool and thespeed control plate.

Begin reassembly by inserting the specific tool (1) thru the injection pump cover opening thru to the speed control plate opening.

1. Using the specific tool (1), capture the governor

spring (5) and speed control plate (7) assembly.

2. Pull the governor spring (5) / speed control plate (7)

assembly thru and secure it to the fork lever (2).

3. Seat and assemble the speed control (5) plate with

two bolts and two nuts to the gear case.

4. Check the movement of the speed control lever (4).

NOTE

The speed control lever (6) must be free to move from low idle position to maximum speed position and should always return to the high idle position.

5. Finally, install the injection pump cover to the gear

case.

1. Specific Tool

2. Fork Lever

3. Speed Control Plate Mounting Nut

4. Speed Control Plate Mountin

Bolt

5. Large Governor Spring

6. Speed Control Lever

7. Speed Control Plate

62--11362

2--8

Page 35

2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.c Fan Drive Pulley

1. Lock the flywheel using the flywheel stopper

2. Remove the fan drive pulley mounting nut (1) using the 46 mm deep socket wrench (3).

3. Remove the fan drivepulley (2) with a gear puller (4).

4. Remove the feather key.

When Reassembling

Apply grease to the splines of the coupling.

1. Nut

2. Fan Drive Pulle

3. 46 mm Deep Socket wrench

4. Gear Puller

Tightening

Torque

Drive Pulley

Mounting Nut

2.2.4.d Gear Case

1. Remove the gear case (1).

2. Remove the O--rings (3)(4).

138 to 156 N.m

14.0 to 16.0 kgf 102 to 115 ft--lbs

When Reassembling

Replace the gear case gasket and O--rings (3)(4). Apply gasket sealant to both sides of the gear case

gasket (2). Check/insure that thefour O--rings (3)(4) are in place on

1. Gear Case

2. Gear Case Gasket

3. O--ring

4. O--ring

5. Oil seal

the gear case (1). Applyathinfilm of oil to the crankshaftoilseallip(5)and

take care not to rollthe lipwhen installing the gearcase.

2--9

62--11362

Page 36

2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.e Crankshaft Oil Slinger

1. Remove the crankshaft collar (1).

2. Remove the O--ring (2).

3. Remove the crankshaft oil slinger (3).

When Reassembling

Insert the crankshaft collar (1) after installing the gear case to the crankcase.

1. Crankshaft Collar

2. O--rin

1. Injection Pump Gear

2. Idle Gear

3. Cam Gear

3. Crankshaft Oil Slinger

4. Crank Gear

5. Oil Pump Drive Gear

2.2.4.f Idle Gear

1. Detach the external snap ring.

2. Remove the idle gear collar.

3. Remove the idle gear (2).

When Reassembling

Checkto see eachgearisalignedwithits aligning mark.

Idle gear (2) and crank gear (4) Idle gear (2) and cam gear (3) Idle gear (2) and injection pump gear (1)

2.2.4.g Camshaft

1. Remove the camshaft retaining bolt (1) and pull the camshaft (2) out.

When Reassembling

1. Camshaft Set Screw 2. Camshaft

1. Oil Pipe

2. Fuel Feed Pump

3. O--ring

4. Fuel Feed Pump Holder

62--11362

Refer to installation of Idle Gear (Refer to Section

2.2.4.f).

Tightening

Torque

Camshaft

retaining bolt

24 to 27 N.m

2.4to2.8kgf 18 to 20 ft--lbs

2.2.4.h Fuel Feed Pump Holder

1. Disconnect the oil pipe (1).

2. Remove the fuel feed pump (2).

3. Remove the fuel feed pump holder (4).

When Reassembling

Replace the O--rings (3) with new O--rings.

2--10

Page 37

2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.i Fuel Camshaft And Fork Lever Assembly

1. Detach the fuel camshaft stopper (1).

2. Remove the three fork lever holder mounting screws (2).

3. Remove the fuel camshaft assembly(5),(6) andfork lever assembly (3), (4), and (7) at the same time.

When Reassembling

After installation, check to see that the fork levers 1 (3) and 2 (4) are fixed to the fork lever shaft, and that they can turn smoothly in the holder (7).

1. Fuel Camshaft Stopper

2. Fork Lever Holder Mounting Screws

3. Fork Lever 1

4. Fork Lever 2

1. Oil Pump

2. Oil Pump Drive Gear

5. Injection Pump Gear

6. Fuel Camshaft

7. Fork Lever Holder

2.2.4.j Oil Pump

1. Remove the nut.

2. Draw out theoilpumpdrive gear (2) withagearpuller (3).

3. Removethefour oilpumpmounting bolts. Detachthe oil pump (1).

3 Gear Puller

2--11

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Page 38

2.2.5 Oil Pan and Oil Strainer

1. Oil Pan Mounting Screw

2. Oil Pan

3. Oil Pan Cover Gasket

4. Oil Pan Cover

5. O--ring

6. Oil Strainer

7. Oil Pan Gasket

(7)

2.2.5.a Oil Pan and Oil Strainer

1. Remove the oil pan cover (4).

2. Remove the oil pan mounting bolts (1).

3. Removetheoilpan(2)bylightlytappingtherimofthe pan with a wooden hammer.

4. Remove the old gaskets (3) and (7).

5. Remove the oil strainer (6) and O--ring (5).

When Reassembling

Check to see that the oil filter strainer (6) is clean. VisuallychecktheO--ring(5),applyengineoil andinstall

it to the pick--up tube. Install the strainer (6) and O--ring (5). Apply gasket sealant to the oil pan side of the oil pan

gasket (7) and fit the gasket to the oil pan (2). Installtheoilpan(2) to theengine,andtightentheoilpan

mounting bolts (1) diagonally. Avoid uneven tightening of the oil pan mounting bolts. (Refer to Section 1.5.2 Torque Specifications)

Apply gasket sealant to the oil pan cover side of the oil pan cover gasket (3) and fit the gasket to the oil pan cover (4).

Install the oil pan cover (4) to the oil pan (2). Install and tighten the oil pan cover bolts diagonally .

Avoid uneven tightening of the oil pan cover mounting bolts. (Refer to Section 1.5.2 Torque Specifications)

62--11362

2--12

Page 39

2.2.6 Piston and Connecting Rod

(a)

)

2.2.6.a Pistons

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

2. Remove the connecting rod cap (3).

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

4. Push the piston out by lightly tapping the connecting rodfrom thebottom of the crankcasewiththegripofa hammer.

5. Repeat the procedure for the other three cylinders.

When Reassembling

Liberally coat thepiston andpiston rings with engineoil. 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 intothe enginebe sure that theyare returned to their original cylinder.

Place the piston rings with their gaps at 2.09 rad. (120°) from the piston pin’s direction as shown.

Carefully insert the pistons into the cylinders using the piston ring compressor (7).

Wheninsertingthepistonintothecylinderavoid damagingthemolybdenum disulfide coating on the piston skirt. This coating is useful in minimizing the clearance between the piston and cylinder.

When replacing a piston, use a replacement piston with the same code number. The piston ID mark (6) is on top of the piston.

1. Carbon

2. Connecting Rod Bolt

3. Connecting Rod Cap

4. Connecting Rod

5. Molybdenum Disulfide CoatingonPistonSkirt

6. Piston ID Mark

Tightening

Torque

2--13

Connecting

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

2.09 rad.(120°

Rod Bolt

45 to 49 N.m

4.5to5.0kgf 33 to 36 ft--lbs

62--11362

Page 40

2.2.6 Piston and Connecting Rod (Continued)

2.2.6.b Piston Ring and Connecting Rod

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

2. Removethepiston pin(8)and then seperate theconnecting rod (6) from the piston (5).

NOTE

Mark both the connecting rod and pistonsothat if they are to be re--used that the original combinationofpartswillgoback together.Donotinterchange used parts.

When Reassembling

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

Wheninstallingtheoilcontrolring(3)ontothepiston(5), place the expander joint (10) on the opposite side of the oil ring gap (11).

Apply engine oil to the piston pin (8). When assembling the connecting rod (6) to the piston

(5),immersethepiston(5)inhot oil(80°C /176°F)for10 to15minutes, then assemblethe piston, piston pin, and connecting rod.

NOTE

Assemble the piston (5) on to the connecting rod (6) with the FW mark (9) facing theflywheel end and the connecting rod mark (7) facing the injection pump side.

1. Top Ring

2. Second Ring

3. Oil Control Ring

4. Piston Pin Snap Ring

5. Piston

6. Connecting Rod

7. Mark

8. Piston Pin

9. FW Mark

10. Expander Joint

11. Oil Ring Gap

12. Manufacturer’s Mark

62--11362

2--14

Page 41

2.2.7 Crankshaft

1. Flywheel

2. Fl

wheel Bolt

3. Flywheel Guide Bolts

2.2.7.a Flywheel

1. Prevent the flywheel (1) from rotating.

2. Remove two flywheel bolts (2).

NOTE

Theuseof airtools to remove the flywheelbolts may damage the threads in the crankshaft.

3. Install two flywheel guide bolts (3).

4. Remove all of the flywheel bolts (2).

5. Remove the flywheel (1) slowly along the flywheel guide bolts (3).

When Reassembling

Install two flywheel guide bolts (3). Check to see that the mating surfaces of the crankshaft

and flywheel are clean. Apply engine oil to the flywheel bolts and install.

Tightening

Torque

Flywheel Bolts

2.2.7.b Bearing Case Cover

1. Removethebearingcasecovermountingbolts.First, remove the insidebolts (2) andthen the outside bolts (1).

2. Screw two of the removed bolts into the bolt hole of the bearing case cover (3) to remove it.

98.0 to 107.8 N.m

10.0 to 11.0 kgf

72.3 to 79.5 ft--lbs

1. Bearing Case Cover Mounting Bolt

2. Bearing Case Cover Mounting bolt

3. Bearing Case Cover

4. Oil Seal

5. Bearing Case Gasket

6. Bearing Case Cover Gasket

(a). Top

NOTE

The length of the inside (2) and the outside (1) bolts is different. When reassembling reinstall the appropriate bolt in the correct location.

When Reassembling

Fit the bearing case gasket (5) and the bearing case cover gasket (6) to the bearing case cover (3). Orient them correctly.

Install the bearing case cover (3), again orienting it correctly, using the “UP” mark (a).

Apply oil to the oil seal (4), and take care not to roll the seal when installed.

Tighten the bearing case cover bolts diagonally and evenly.

Tightening

Torque

Bearing Case

Cover Mounting

bolt

24 to 27 N.m

2.4to2.8kgf 18 to 20 ft--lbs

2--15

62--11362

Page 42

2.2.7 Crankshaft (Continued)

2.2.7.c Crankshaft Assembly Removal

NOTE

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

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

2. Pull out thecrankshaft assembly (2),beingcarefulnot to damage the crankcase bearings (3).

3. While pulling the crankshaft assembly (2) out, use care to align eachofthe crank pins (5) (left or right)to clear the crankcase relief (a).

When Reassembling

When installing the main bearing case assembly, align the bolt holes of the crankshaft assembly (2) with the holes of the crankcase.

Applyoiltothethreadsofthemainbearingcasebolts(1) before re--insertion.

Tightening

Torque

1. Main Bearing Case Screw 2

2. Main Bearing Case 2

3. Crankshaft Bearing 1

4. Crankshaft Assembly

Main Bearing

Case Bolt

69 to 73 N.m

7.0to7.5kgf 51 to 54 ft--lbs

5. Cylinder 4 Crank Pin (a).Main Bearing Case Relief

62--11362

2--16

Page 43

2.2.7 Crankshaft (Continued)

2.2.7.d Main Bearing Case Assembly

1. Remove the two main bearing case bolts (7), and remove the main bearing case assembly being careful with the thrust bearing and crankshaft bearing.

2. Removetheremainingmainbearingcasesasabove.

When Reassembling

Clean the oil passages in the main bearing case. Apply clean engine oil to the bearings. Install the main bearing case assembliesintheiroriginal

locations. The diameters of the main bearing cases vary. Install them in order from the gear case end according to their markings (A,B,C).

Match the alignment numbers (1) and mark (2) on the main bearing case.

When installing the main bearing case, face the mark “FLYWHEEL” to the flywheel.

Install the thrust bearing with its oil groove facing (8) outward.

Confirm that main bearing case moves smoothly after torquing the main bearing case bolt to specification.

Tightening

Torque

1. Alignment Number

2. Alignment Mark

3. No Mark

4. C

Main Bearing

Case bolt

5. B

6. A

7. Main bearing Case Bolt

8. Oil Groove

46 to 50 N.m

4.7to5.2kgf 34 to 37 ft--lbs

2--17

62--11362

Page 44

2.3 SERVICING

2.3.1 Cylinder Head And Valves

2.3.1.a Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straightedge on the cylinder head surface, in six locations as depicted in the drawing.

3. Measure any clearance between the straightedge and cylinder head with a feeler gauge.

4. If the measurement exceeds the allowable limit, resurface or replace the head.

NOTE

Check the valve recessing after after resurfacing the head.

0.05mm over a span of

Cylinder Head

Surface Flatness

Factory

Specification

500mm

0.002 in. over a span of 20 in.

1. Red Dye

2. Deter

ent

3. White Developer

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 headsurface using a good quality degreaser and detergent (2).

3. Spray the cylinder headsurface with the red liquid or dye (1). Let it sit on the surface for ten minutes.

4. Wash the dye offtheheadusingthedetergent(2)and dry the head.

5. Spray the white developer (3) on to the head.

6. Red marks will bleed through the developer identifying cracks in the head if they are present.

62--11362

2--18

Page 45

2.3.1 Cylinder Head And Valves (Continued)

(B)

1. Cylinder Head Surface

(A) Recess

Protrusion

2.3.1.c Valve Recessing

1. Clean the cylinder head surface (1), valve face and valve seat.

2. Insert the valve into the head,making certain that the valve is fully seated.

3. Measure the valve recessing with a depth gauge.

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

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

0.065 (protrusion) mm to

Valve

Recessing

Factory

Specification

Allowable Limit --

0.085 (recessing) mm

0.026 (protrusion) in. to

0.033 (recessing) in.

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. Measurethevalve guidewithasmallholegauge,and calculate the clearance.

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

Clearance

Between Valve Stem and Guide

Valve Stem

O.D.

Valve Guide

I.D.

Factory

Specification

Allowable Limit

Factory

Specification

Factory

Specification

0.040 to 0.070 mm

0.0016 to 0.0027 in.

0.1 mm

0.0039 in.

7.960 to 7.975 mm

0.3134 to 0.3139 in.

8.015 to 8.030 mm

0.3156 to 0.3161 in.

2--19

62--11362

Page 46

2.3.1 Cylinder Head And Valves (Continued)

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

1. Pressouttheusedvalveguideusingavalveguidereplacing tool.

(B) (When installing)

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

2. Pressinanew valveguideusingavalveguidereplacing 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

8.015 to 8.030 mm

0.3156 to 0.3161 in.

2.3.1.f Valve Seating

1. Coat the valve face lightly with prussian blue andput the valve on its seat to check the contact pattern

2. Ifthe valve does not seat allthe way around the valve seat,orthecontactislessthan70%, correctthevalve seating as outlined in paragraph 2.3.1.g.

3. If the valve contact does not comply with the referencevalue, replace the valve or correctthecontactof valve seating.

1. Correct

2. Incorrect

62--11362

3. Incorrect

2--20

Page 47

2.3.1 Cylinder Head And Valves (Continued)

2.3.1.g Correcting Valve and Valve Seat

NOTE

Before correcting the valve seat, make certain that the valve and valve guide are withinfactory specifications.

After correctingthe valveseat, besuretocheck the valve recessing.

(A) Correcting the Valve

1. Correct the valve with a valve grinder.

(1)

a. 0.26 rad.(15°)or

0.52 rad.(30°)

b. 0.79 rad.(45°)or

1.0 rad.(60°)

c. 0.52 rad.(30°)or

0.26 rad.(15°)

(2)

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

1. Valve Seat Width

2. Identical Dimensions

Valve Face Angle

Factory

Specification

IN. 0.79 rad / 45°

EX. 0.79 rad / 45°

(B) Correcting the Valve Seat

1. Slightly correct the valve seat surface with a 1.0 rad. (60°) (intake valve) or0.79 rad. (45°) (exhaust valve) seat cutter.

2. Resurface the seat surface with a 0.52 rad. (30°) valve seat cutter to the Intake valve seat and with a

0.26 rad. (15°) valve seat cutter to the exhaust valve seat so that the width is close to the specified valve seat width (2.12 mm, 0.0835 in.).

3. After resurfacing the seat, apply a thin film of valve lapping compound between the valve and the seat, then use a valve lapping tool to seat the valve to the valve seat.

4. Check the valveseatingwithprussianblue.Thevalve seating should show goodcontact allthewayaround.

Valve Face Angle

Factory

Specification

IN. 0.79 rad / 45°

EX. 0.79 rad / 45°

2.3.1.h Valve Lapping

1. Apply compound evenly to the valve lapping surface.

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

3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check thecontact pattern, if it is less than 70%, repeatvalve lapping again.

NOTE

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

2--21

62--11362

Page 48

2.3.1 Cylinder Head And Valves (Continued)

2.3.1.i Free Length and Tilt of Valve Spring

1. MeasurethefreelengthAofthevalvespringwithvernier 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. Check the entire surface of the valve spring for defects. If any are found, replace it.

Factory

Specification

Free Length A

Allowable Limit

Tilt B Allowable Limit

41.7 to 42.2 mm

1.65 to 1.66 in.

41.2 mm

1.62 in.

1.0 mm

0.039 in.

2.3.1.j Valve Spring Setting Load

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

2. Read the compression load on the gauge.

3. Ifthemeasurementislessthantheallowablelimit,replace it.

118N/35mm

12.0 kgf / 35 mm.

26.5 lbs. / 1.38 in. 100 N / 35 mm

10.2 kgf / 35 mm.

22.5 lbs. / 1.38 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. MeasuretherockerarmI.D.withainsidemicrometer,

then calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, re-

place the rocker arm then measure the oil clearance again. If the clearance is still out of specification, replace the rocker arm shaft.

62--11362

Oil Clearance

Rocker Arm/

Shaft

Rocker Arm

Shaft O.D.

Rocker Arm I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.016 to 0.045 mm

0.0063 to 0.0017 in.

0.10 mm

0.0039 in.

13.973 to 13.984 mm

0.55012 to 0.55055 in.

14.000 to 14.018 mm

0.55119 to 0.55188 in.

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, re-

place the push rod.

Push Rod Alignment

Allowable

Limit

0.25 mm

0.0098 in.

2--22

Page 49

2.3.1 Cylinder Head And Valves (Continued)

2.3.1.m Oil Clearance Between T appet and Tappet Guide Bore

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

2. MeasuretheI.D. of thetappet guide bore with a cylin-

der 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

0.020 to 0.062 mm

0.00079 to 0.00244 in.

0.07 mm

0.003 in.

23.959 to 23.980 mm

0.94327 to 0.94409 in.

24.000 to 24.021 mm

0.94489 to 0.94570 in.

2.3.2 Timing Gears, Camshaft and Fuel Camshaft

2.3.2.a Timing Gear Backlash

1. Set a dial indicator (lever type) with its tip on the gear

tooth.

2. Move the gear to measure the backlash, holding its

mating gear.

3. If the backlash exceeds theallowable limit, checkthe

oil clearance of the shafts and the gear.

4. If the oil clearance is proper, replace the gear.

Backlash/ Idle Gear/

Crank Gear

Backlash/ Idle Gear/

Cam Gear

Backlash/ Idle Gear/

Injection Pump

Gear

Backlash/

Crank Gear/

Oil Pump Gear

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

0.0415 to 0.1122 mm

0.00163 to 0.00442 in.

0.15 mm

0.0059 in.

0.0415 to 0.1154 mm

0.00163 to 0.00454 in.

0.15 mm

0.0059 in.

0.0415 to 0.1154 mm

0.00163 to 0.00454 in.

0.15 mm

0.0059 in.

0.0415 to 0.1090 mm

0.00163 to 0.00429 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. Movethegear front to rear to measurethe side clear-

ance.

3. If the measurement exceeds the allowable limit, re-

place the idle gear collar.

Idle Gear

Side

Clearance

Factory

Specification

Allowable

Limit

0.12 to 0.48 mm

0.0047 to 0.018 in.

0.9 mm

0.04 in.

2--23

62--11362

Page 50

2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)

2.3.2.c Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.

2. Move the camshaft gear front to rear to measure the side clearance.

3. If the measurement exceeds the allowable limit, replace the camshaft stopper.

Camshaft

Side

Clearance

Factory

Specification

Allowable

Limit

0.07 to 0.22 mm

0.0028 to 0.0087 in.

0.30 mm

0.0118 in.

2.3.2.d Idle Gear Shaft and Idle Gear Bushing

Clearance

1. Measure the idle gear shaft O.D. with a micrometer.

2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the the clearance.

3. If the measurement exceeds the allowable limit, replace the bushing.

Idle Gear Shaft/

Bushing

Clearance

Idle Gear Shaft

O.D.

Idle Gear Shaft

I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.025 to 0.066 mm

0.00099 to 0.00260 in.

0.1 mm

0.0039 in.

23.959 to 23.980 mm

0.94327 to 0.94410 in.

24.000 to 24.021 mm

0.94488 to 0.94571 in.

2.3.2.e Idle Gear Shaft and Idle Gear Bushing Clearance

(A) When Removing

1. Pressoutthebushingusing an IdleGear BushingReplacing Tool.

(B) When Installing

1. Clean anewidle gear bushing and theidlegearbore, and apply engine oil to both.

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

62--11362

2--24

Page 51

2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)

2.3.2.f Camshaft Alignment

1. SupportthecamshaftwithVblocksona surfaceplate at both end journals.

2. Set adialindicatorwithitstipontheintermediatejournal.

3. Rotate the camshaft and measure for run--out.

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

Camshaft

Run--out

Allowable

Limit

0.1 mm

0.0004 in.

2.3.2.g Cam Height

1. Measure the cam lobe at its largest O.D. with an outside micrometer.

2. Ifthemeasurementislessthantheallowablelimit,replace the camshaft.

Cam Height

Intake

Cam Height

Exhaust

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

33.27 mm

1.310 in.

33.22 mm

1.308 in.

33.47 mm

1.318 in.

33.42 mm

1.316 in.

2.3.2.h Camshaft Oil Clearance

1. Measure the camshaft journal O.D. with an outside micrometer.

2. Measure the cylinder block camshaft bore I.D. with a cylinder gauge, and calculate the oil clearance.

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

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

0.0020 to 0.0035 in.

0.15 mm

0.0059 in.

39.934 to 39.950 mm

1.5722 to 1.5728 in.

40.000 to 40.025 mm

1.5748 to 1.5757 in.

2--25

62--11362

Page 52

2.3.3 Piston and Connecting Rod

2.3.3.a Piston Pin Bore I.D.

1. Measurethepiston pin boreI.D. inboththehorizontal and vertical directions with a cylinder gauge.

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

Piston Pin Bore

I.D.

Factory

Specification

Allowable

Limit

25.000 to 25.013 mm

0.98426 to 0.98476 in.

25.05 mm

0.9862 in.

2.3.3.b Piston Pin and Bushing Clearance

1. MeasurethepistonpinO.D.withanoutsidemicrometer.

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.

0.15 mm

0.0059 in.

25.002 to 25.011 mm

0.98433 to 0.98468 in.

25.025 to 25.040 mm

0.98523 to 0.98582 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).

62--11362

NOTE

Be sure to align the bushing so that the oil hole in the bushing alignswith the oil port in theconnecting rod.

2--26

Page 53

2.3.3 Piston and Connecting Rod (Continued)

2.3.3.d Piston Ring Gap

1. Insert the piston ring into the lower part ofthecylinder (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 gap exceeds the allowable limit, replace the ring.

Top Ring

(Keystone Type)

Second Ring

OilControlRing

Factory

Specification

Allowable Limit 1.25 mm / 0.0492 in.

Factory

Specification

Allowable Limit 1.25 mm / 0.0492 in.

Factory

Specification

Allowable Limit 1.25 mm / 0.0492 in.

0.20 to 0.35 mm

0.0079 to 0.013 in.

0.40 to 0.55 mm

0.016 to 0.021 in.

0.25 to 0.45 mm

0.0099 to 0.017 in.

2.3.3.e Piston Ring to Groove Clearance

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

2. Measure the clearance between the ring and its groove with a feeler gauge (with the exception of the top ring, Keystone Type, which cannot be accurately measured with a feeler gauge).

3. If the clearance exceeds the allowable limit, replace the ring.

4. If the clearance still exceeds the allowable limit after replacing the ring, replace the piston.

Second Ring

OilControlRing

Factory

Specification

Allowable Limit 0.20 mm / 0.0079 in.

Factory

Specification

Allowable Limit 0.15 mm / 0.0059 in.

0.093 to .128 mm

0.00367 to 0.00503 in.

0.020 to 0.060 mm

0.00079 to 0.0023 in.

2.3.3.f Connecting Rod Alignment

NOTE

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

1. Install the piston pin into the connecting rod.

2. Install the connecting rod on theconnecting rodalignment 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 / 0.002 in.

2--27

62--11362

Page 54

2.3.4 Crankshaft

2.3.4.a Crankshaft End Clearance

1. Pushontheendofthecrankshafttoseatittowardthe flywheel end of the engine block.

2. Attach, thenzeroadialindicatorontheforwardendof the crankshaft.

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

4. If the measurement exceeds the allowable limit replace the thrustwashers.

Factory

Crankshaft Side

Clearance

Specification

Allowable

Limit

0.15 to 0.31 mm

0.0059 to 0.012 in.

0.5 mm

0.02 in.

(Reference)

Oversize dimensions of crankshaft journal.

Oversize 0.2mm / 0.008 in. 0.4mm / 0.02 in.

Dimension A

Dimension B

Dimension C

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

54.5 to 54.7 mm

2.146 to 2.153 in.

26.20 to 26.25 mm

1.032 to 1.033 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

0.4--S.

54.6 to 54.8 mm

2.150 to 2.157 in.

26.40 to 26.45 mm

1.040 to 1.041 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

2.3.4.b Crankshaft Alignment

1. Support the crankshaft with V blocks on a surface plate at both endjournals. 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.

62--11362

2--28

Crankshaft

Alignment

Allowable

Limit

0.02 mm

0.0008 in.

Page 55

2.3.4 Crankshaft (Continued)

2.3.4.c Crankpin to Connecting Rod Bearing Clearance

1. Clean the crankpin and the connecting rod bearing.

2. Put a strip of plastigage on the center of the crankpin

in each direction as shown in the figure.

3. Install the connecting rod cap and tighten the bolts to

the specification. (Refer to 2.2.6.a)

4. Remove the cap again

5. Measuretheamount of the flatteningwiththescaleto

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 an undersize bearingbyreferring to the table below.

Crankpin/

Connecting Rod

Clearance

Factory

Specification

Allowable

Limit

0.025 to 0.087 mm

0.00099 to 0.0034 in.

0.2 mm

0.0079 in.

Crankpin O.D.

Connecting Rod

Bearing I.D.

Factory

Specification

Factory

Specification

46.959 to 46.975 mm

1.8488 to 1.8494 in.

47.000 to 47.046 mm

1.8504 to 1.8522 in.

(Reference)

Undersize dimensions of crankpin journal.

Undersize 0.2mm / 0.008 in. 0.4mm / 0.02 in.

Dimension A

Dimension B

Dimension C

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

0.8--S.

3.3to3.7mm

0.13 to 0.14 in.

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

46.759 to 46.775 mm

1.8409 to 1.8415 in. radius

3.3to3.7mm

0.13 to 0.14 in.

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

46.559 to 46.575 mm

1.8331 to 1.8336 in. radius

*Holestobede---burred and edges rounded with 1.0 to 1.5

mm (0.040 to 0.059 in. relief.

2--29

62--11362

Page 56

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 an undersize bearingbyreferring 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

0.040 to 0.118 mm

0.00158 to 0.00464 in.

0.2 mm

0.0079 in.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

59.980 to 60.039 mm

2.3615 to 2.3637 in.

(Reference) Undersize dimensions of crankshaft

journal.

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

2.8 to 3.2 mm radius

Dimension A

Dimension B

Dimension C

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

0.4--S. *Holes to be de--burred and edges rounded with 1.0 to 1.5 mm

(0.040 0.059 in.) relief.

0.11 to 0.12 in. radius

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

59.721 to 59.740 mm

2.3513 to 2.3519 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

59.521 to 59.540 mm

2.3434 to 2.3440 in.

1. Seam

2. Crankshaft Bearin

62--11362

3. Cylinder Block

A Dimension

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

1. Pressoutthecrankshaftbearing#1(2)usingacrank-

shaft bearing (1) replacing tool.

(B) When Installing

1. Clean anewcrankshaftbearing#1(2)andcrankshaft

journal bore, and apply engine oil to both.

2. Using the crankshaft bearing(1)replacing tool, press

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

NOTE

Be sure to align the bushing so that the oil hole in the bushing alignswith the oil port in theconnecting rod.

2--30

Dimension A

Factory

Specification

4.2to4.5mm

0.166 to 0.177 in.

Page 57

2.3.4 Crankshaft (Continued)

2.3.4.f Crankshaft Journal to Crankshaft Bearing #2 Clearance

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

shaft journal.

2. Install the bearing case and tighten the bolts to spe-

cification.

3. Remove the bearing case again.

4. Measuretheamount of the flatteningwiththescaleto

get the clearance.

5. If the measurement exceeds the allowable limit re-

place crankshaft bearing #2.

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

size bearing, install an undersize bearingbyreferring to the table below.

NOTE

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

Crankshaft

Journal to #2

Bearing

Clearance

Crankshaft

Journal O.D

Crankshaft

Bearing Bearing

I.D.

Factory

Specification

Allowable

Limit

Factory

Specification

Factory

Specification

0.040 to 0.104 mm

0.00158 to 0.00409 in.

0.2 mm

0.0079 in.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

59.980 to 60.025 mm

2.3615 to 2.3631 in.

(Reference)

Undersize dimensions of crankshaft journal.

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

2.8 to 3.2 mm radius

Dimension A

Dimension B

Dimension C

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

0.4--S. *Holes to be de--burred and edges rounded with 1.0 to 1.5 mm

(0.040 0.059 in.) relief.

0.11 to 0.12 in. radius

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

59.721 to 59.740 mm

2.3513 to 2.3519 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

1.0 to 1.5 mm radius

0.040 to 0.059 in. radius

59.521 to 59.540 mm

2.3433 to 2.3440 in.

2--31

62--11362

Page 58

2.3.4 Crankshaft (Continued)

2.3.4.g Replacing Crankshaft Sleeve

1. Remove the crankshaft sleeve (3) using a special-use puller set.

2. Set the sleeve guide (2) to the crankshaft (5).

3. Set the stopper (1) to the crankshaft (5) as shown in the figure.

4. Heat thenewsleevetoatemperaturebetween150to 200°C(302to392°F),andfixthesleeveonthecrankshaft (5) as shown in the figure.

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

NOTE

Install the sleeve with the largest chamfered surface facing outward.

1. Stopper

2. Sleeve Guide

3. Crankshaft Sleeve

4. Auxiliary Socket For Pushing

5. Crankshaft

62--11362

2--32

Page 59

2.3.5 Cylinder

2.3.5.a Cylinder Wear

1. Measure the I.D. of the cylinder at the six positions (seefigure 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. Ifthe wearexceedstheallowablelimit,boreandhone to the oversize dimension. (refer to Correcting

Cylinder)

4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder walls should be bored. (refer to Correcting Cylinder)

a. Top b. Middle c. Bottom (skirt)

a. Right--angled to

Piston Pin

b. Piston Pin Direction

Cylinder I.D.

Maximum Wear

Factory

Specification

Allowable

Limit

83.000 to 83.022 mm

3.2678 to 3.2685 in.

83.170 mm

3.2744 in.

2.3.5.b Correcting Cylinder (Oversize +0.25 mm)

1. When the cylinder isworn beyond the allowable limit, bore and hone it to the specified dimension.

Cylinder I.D.

Maximum Wear

Finishing

Factory

Specification

Allowable

Limit

Hone to 2.2 to 3.0 mm μRmax.

(0.00087 to 0.00118 in. μRmax.)

83.250 to 83.272 mm

3.2776 to 3.2784 in.

83.420 mm

3.2843 in.

1. Cylinder I.D. (before correction)

2. Oversize Cylinder I.D.

2. Replace the piston and piston rings with oversize (+0.25 mm) ones.

2--33

62--11362

Page 60

SECTION 3

LUBRICA TING SYSTEM

3.1 CHECKING AND ADJUSTING 3.1.1 Engine Oil Pressure

1. Removetheengineoilpressure switch, and installan oil pressure gauge.

2. Start the engine. After warming up, read the oil pressure at idling and at rated speeds.

3. If the oil pressure is less than the allowable limit, check the following:

Engine oil sufficient Oil pump defective Oil strainer clogged Oil filter cartridge clogged Oil gallery clogged Excessive oil clearance Relief valve stuck

Factory

Specification

At Idle Speed

Allowable

Limit

Factory

Specification

At Rated Speed

Allowable

Limit

(When Reassembling)

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

More than 98 kPa

1.0 kgf/cm

0.5 kgf/cm

300 to 440 kPa

3.0 to 4.5 kgf/cm 43 to 64 psi

250 kPa

2.5 kgf/cm

14 psi

50 kPa

7psi

36 psi

3--1

62--11362

Page 61

3.2 SERVICING

3.2.1 Rotor Lobe Clearance

1. Measuretheclearance between lobes of the inner rotor and the outer rotor with a feeler gauge.

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

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

Inner/Outer

Rotor Clearance

Outer Rotor/

Pump Body

Clearance

Factory

Specification

Allowable

Limit

Factory

Specification

Allowable

Limit

0.03 to 0.14 mm

0.0012 to 0.0055 in.

0.2 mm

0.008 in.

0.11 to 0.19 mm

0.0044 to 0.0074 in.

0.25 mm

0.0098 in.

3.2.2 Rotor to Cover Clearance

1. Put a strip of plastigage onto the rotor face with grease.

2. Install the cover and tighten the bolts.

3. Remove the cover carefully, and read theplastigage.

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

Rotor/Cover

Clearance

Factory

Specification

Allowable

Limit

0.105 to 0.150 mm

0.00414 to 0.00590 in.

0.20 mm

0.008 in.

62--11362

3--2

Page 62

4.1 CHECKING AND ADJUSTING

WARNING

Beware of moving V--belt and belt driven components

4.1.1 Notched V--Belt Service NOTE

A frayed, cracked or worn V--belt must be replaced. After installinganewbelt,itisadvisable to check the adjustment after running the unit for three orfour hours. This will allow for the initial stretch, which is common on new belts. Once thisinitial stretchhastakenplace,thebelt should be checked at regular intervals.

SECTION 4

COOLING SYSTEM

2. Replace the Poly--V--Belt by positioning the belt on the water pump pulley,and while rotating theengine (as in step 1),use a flat, bluntobject to guide thebelt onto the crank pulley. Be careful not to damage grooves on the pulley or belt.

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.

(A)

To replace or adjust the notched V--belt, do the following:

a. Replacing the V--Belt

1. Loosen the idler pivot bolt.

2. Replace the belt and adjust tension in accordance with the following steps.

b. Adjusting Tension

1. Measure the deflection (A), by depressing the belt halfway between the fan drive pulley and alternator pulley at the specified force (Refer to1.7.3).

2. Usehandforceonlyontheidlerpulleytotightenbelt.

Do not use a pry bar or excessive force as it may cause damage to the engine.

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

3. When belt is at correct tension, tighten pivot bolt.

4.1.1a Poly V--Belt Service

a. Replacing the Poly--V--Belt

1. Apply the proper size socket to the crank pulley nut, then slowly rotate the crank. At the same time, usea flat, blunt object to guide the belt offthe crank pulley towards radiator. Be careful not to damage grooves on the pulley .

(B)

A. Good B. Bad

3. Check if thebeltiswornandsunk inthepulleygroove.

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

A. Good B. Bad

4.1.3 Checking Coolant Level

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.

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

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

4--1

62--11362

Page 63

FULL

LOW

2. Ifthe coolant level istoolow,checkthe reason for the lost coolant.

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

soft water.

b. If coolant loss is due to a leak, repair the leak, then

add a coolant mixture of the same type and specificationthatisinthesystem. If thecoolantbrandcannot be identified, drain out all of the remaining coolant and refill with a totally new mix.

4.1.5 Radiator

1. Fill the radiator with water.

2. Attach the pressuretester to the radiator.

3. Apply pressure and look for leaks.

4. Repair/replaceasnecessarytoassurethat thespecified pressure will hold.

NOTE

Whenaddingcoolanttothe system,airmustbe ventedfromtheenginecoolantpassagesbyjiggling the upper and lower radiator hoses.

Besureto close the radiator capsecurely.Ifthe 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.

4.1.4 Radiator Cap

Radiator Leakage

Test

Factory

Specification

157 kPa

1.6 kgf/cm 23 psi

4.1.6 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.

1. Attach the radiator cap to a pressure tester.

2. Apply pressure andobserve the timefor 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

62--11362

4. Continue heating the water, read the temperature of the water when the valve has opened approximately 6mm (0.236 in).

5. Ifthe measurement is not withinthefactory specifications, replace the thermostat.

Thermostat

Opening

Temperature

Thermostat

Full Open

Temperature

Factory

Specification

Factory

Specification

80.5 to 83.5.5°C

176.9 to 182.3

95°C

203

°F

4--2

°F

Page 64

4.2 SERVICING

4.2.1 Thermostat Assembly

4.2.2 Water Pump Assembly

1. Thermostat Cover Bolt

2. Thermostat Cover

3. Thermostat Cover Gasket

4. Thermostat Assembly

5. Thermostat Housing

1. Removethethermostatcovermountingbolts (1), and remove the thermostat cover (2).

2. Remove the thermostat assembly (4).

(When Reassembling)

Applyaliquidgasketonlyatthethermostat cover side of the thermostat cover gasket (3).

1. Water Pump Flange

2. Water Pump Shaft 3 Water Pump Body

4. Water Pump Gasket

5. Mechanical Seal

6. Impeller

1. Remove the fan belt.

2. Remove the water pump pulley.

3. Remove the water pump from the gear case assembly.

4. Remove the water pump flange (1).

5. Press out the water pump shaft (2) with the impeller (6) on it.

6. Remove the impeller from the water pump shaft.

7. Remove the mechanical seal.

(When Reassembling)

Replace the mechanical seal with a new one. Apply a liquid gasket to both sides of the gasket (4).

4--3

62--11362

Page 65

5.1 CHECKING AND ADJUSTING

SECTION 5

FUEL SYSTEM

5.1.1 Injection Timing

1. Remove the fuel speed solenoid.

2. Remove the injection pipes and nozzle.

3. Move the speed control lever to the maximum speed position.

NOTE

Turn the flywheel with a screwdriver.

4. Turn the flywheel counterclockwise (facing the flywheel) until the fuel fills up the hole of the delivery valve holder for #1 cylinder.

5. Turn the flywheel further and stop turning when the fuel begins to flow over.

6. Open the view port on the flywheel bell housing and read the number on the flywheel. The number indicated is the timing value for theengine. (The flywheel hasamark’1TC’ andmarks every 5° of engine timing to 25° total).

0.0568 to 0.0829 rad.

3.25

° to 4.75°

B.T.D.C.

Injection Timing

Factory

Specification

NOTE

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

Thetimingadvancesbyremovingone shimand retards timing by adding the same shim.

Theaddition or removal of 0.05 mm (0.0020in.) ofshim,changestheinjectiontimingbyapproximately 0.009 rad. (0.5°).

Sealant should be applied to both sides of soft metal gasket shims except for the .0175mm shim. A .0175mm shim should have sealant applied to one side only.

When replacing the injection pump be sure to use the same number and size of new gasket shims.

5.1.2 Shim Identification

Shims are available in thicknesses of 0.20 mm,

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

1. Delivery Valve Holder

2. Timing Mark

3. 2--Holes: 0.20 mm shim

4. 1--Hole: 0.25 mm shim

5. 0--Holes: 0.30 mm shim

6. 3--Holes: 0.35 mm shim

7. 2--Holes: 0.175 mm shim

62--113625--1

Page 66

5.1 CHECKING AND ADJUSTING

1. InjectionPump Pressure Tester

2. InjectionNozzle

3. Protective Cover

5.1.3 Pump Pressure Test

1. Remove the engine fuel speed solenoid.

2. Remove the injection pipes and nozzle.

3. Connect a pressure tester to the fuel injection pump.

4. Connect theinjectionnozzle(2)jetted with theproper injectionpressuretotheinjectionpumppressuretester (1).

5. Using the starter, rotate the crankshaft until the fuel pressure is built up.

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

Fuel Pump

Pressure Test

Factory

Specification

18.63 MPa

190 kgf/cm

2702 psi

5.1.4 Delivery Valve Fuel Seal

1. Remove the engine fuel speed solenoid.

2. Remove the injection pipes and nozzle.

3. Connect a pressure tester to the fuel injection pump.

4. Connect theinjectionnozzle(2)jetted with theproper injectionpressuretotheinjectionpumppressuretester (1).

5. Using the starter, rotate the crankshaft until the fuel pressure is built up.

6. Release the pressure in the delivery chamber by rotating the crankshaft to bottom dead center. (turn the crankshaft 1.57 rad. (90°) clockwise from fuel timing set point)

7. If the pressure drop for 5 seconds exceeds the allowable limit, replace the delivery valve or pump assembly.

10 seconds

Factory

Specification

Delivery Valve

Fuel Seal

Allowable

Limit

18.63 to 17.65 MPa 190 to 180 kgf/cm

2702 to 2560 psi

5 seconds

18.63 to 17.65 MPa 190 to 180 kgf/cm

2702 to 2560 psi

62--11362 5--2

Page 67

5.2 INJECTION NOZZLE

WARNING

Checktheinjectionnozzleonly afterconfirming 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 Injection Pressure

1. Set the injection nozzle in a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within factory specifications, replace the nozzle assembly.

(a) GOOD (b)BAD

Fuel Injection

Pressure

1st Stage

Factory

Specification

18.64 to 20.1 MPa

190 to 205 kgt/cm

2703 to 2915 psi

5.2.2 Nozzle Spraying Condition

1. Set the injection nozzle in a nozzle tester and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the injection nozzle assembly.

5.2.3 Valve Seat Tightness

1. Set the injection nozzle in a nozzle tester.

2. Raise the fuel pressure, and maintain 16.67 MPa (170 kgf/cm

, 2418 psi) for 10 seconds.

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

No fuel leak at

16.67MPa

170 kgf/cm

2418 psi

Valve Seat Tight-

ness

Factory

Specification

62--113625--3

Page 68

6.1 STARTER TEST

1. C Terminal

2. Positive Terminal

ELECTRICAL SYSTEM

3. Negative Terminal

SECTION 6

6.1.1 Motor Test

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

2. Disconnectthecablefromthepositiveterminal onthe battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumperleadfromthestartersolenoidCterminal (1) to the positive battery terminal.

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

7. Ifthestarterdoesnotrun,repairorreplacethestarter.

Tightening Torque

WARNING

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

Terminal Nut

8.8to11.8N.m

0.9to1.2kgf

6.5to8.7ft--lbs.

1. S Terminal

2. Positive Terminal

3. Negative Terminal

6.1.2 Magnetic Switch Test

NOTE

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

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

2. Disconnectthecablefromthepositiveterminal onthe battery.

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

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter S terminal(1) to the positive battery post (2).

6. Momentarily, connect a jumper lead between the starter housing and negative battery terminal (3).

7. If the pinion gear nose does not pop out, replace the starter.

NOTE

TheBterminal is the terminal that connectsthe cable from the battery to the starter.

TheSterminal is theterminal that connects the cable from the starter switch to the magnetic switch.

6--1

62--11362

Page 69

6.2 FUEL SPEED SOLENOID

6.2.1 Solenoid Test

WARNING

The solenoid can become very warm to the touch when energized for any length in time.

1. Disconnect the plug from the solenoid connector (2).

2. Remove the solenoid (1) from the engine.

3. Supply power (12VDC) to the solenoid thruterminals (3) and (4).

4. Ifthe rod inthesolenoid(1) moves smoothly (approximately 0.6”), the solenoid is normal, if the rod does not move, or moves only a fraction of that distance, replace it.

1. Fuel Speed Solenoid

2. Solenoid Connector

3. Terminal 2 (--)

4. Terminal 1 (+)

A. Actuator Rod (Power Off) B. Actuator Rod (12VDC

applied)

62--11362

6--2

Page 70

6.3 INTAKE AIR HEATER

6.3.1 Intake Air Heater Test

1. Disconnect the lead from the heater terminal (1).

2. Measure the resistance between the heater positive terminal (1) and the heater body (2).

3. If the resistance is infinity or significantly different than the specification, replace the heater.

Intake Air Heater

Resistance

1. Positive Terminal 2. Heater Body

Factory

Specification

0.3 ohms

6--3

62--11362

Page 71

INDEX

Battery, iv bearing case, 2--15, 2--17

camshaft, 2--10, 2--24, 2--25 compression pressure, 2--1 connecting rod, 2--14, 2--27 coolant, iv, 2--2 coolant level, 1--13, 4--1 cooling system, 4--1 crankshaft, 2--28 crankshaft oil slinger, 2--10 cylinder, 2--33 cylinder head, 2--3, 2--5, 2--18

Identification, 1--1 idle gear, 2--10 injection nozzle, 5--3 injection timing, 5--1 intake air heater, 6--3

lubricating system, 3--1

Notched V--Belt, 4--1

dye/penetrant, 2--18

electrical system, 6--1 engine oil, 1--14, 2--2

fan drive pulley, 2--9 flywheel, 2--15 fuel injection, 1--15, 2--3, 2--6 fuel speed solenoid, 6--2 fuel system, 5--1 fuel system -- bleeding , 1--14

gear case, 2--9 governor , 2--7, 2--8

oil level, 1--13 oil pan, 2--12 oil pressure, 3--1 oil pump, 2--11, 3--2

piston, 2--13, 2--26, 2--27 piston ring, 2--14 Poly V--belt, 4--1 push rod, 2--22

radiator, 4--2 radiator cap, 4--2 rocker arm, 2--22

Index--1

62--11362

Page 72

INDEX

Safety Precautions, iv specifications, 1--2 speed control plate, 2--7, 2--8 starter motor, 6--1

tappets, 2--5, 2--23 thermostat, 4--2 timing gear, 2--23 Torque Specification, 1--4

V--belt, 1--14 valve clearance, 1--15 valve guide, 2--20 valve seat, 2--20 valve spring, 2--22 valves, 2--5, 2--19, 2--21

water pump, 4--3

62--11362

Index--2

Page 73

North America

Carrier Transicold 700 Olympic Drive Athens, GA 30601 USA Tel: 1--706--357--7223 Fax: 1--706--355--5435

Mexico and Central America

Ejercito Nacional No. 418 Piso 9, T orreYumal Col. Chapultepec Morales 11570 Mexico, D.F. Tel: (5255) 9126.0300 Fax: (5255) 9126.0373

Carrier Transicold Division, Carrier Corporation Truck/Trailer Products Group P.O. Box 4805 Syracuse, N.Y. 13221 U.S.A.

www.carrier.transicold.com

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