Carrier Automobile Parts V2203 DI 26 00128 User Manual

Diesel Engine

WORKSHOP MANUAL

for

V2203-DI (26--00128)

Tier 4i

62--11362 Rev --

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TABLE OF CONTENTS

PARAGRAPH NUMBER

Page

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 CYLINDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

1.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 SERVICING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.1 Engine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--1

1--2

1--3

1--4

1--5

1--7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1.9.2 Adapter, Injector To Tester Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16

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

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

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

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

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

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

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

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

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

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

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

1.9.14 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--18

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

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

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PARAGRAPH NUMBER

Page

2--1

2--2

2--3

2--6

ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 Draining Coolant And Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 Injection Pump and Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Rotor to Cover Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Notched V--Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

4.1.2 Fan Belt Damage and Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.6 Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3--1

3--2

4--1

4--2

4--3

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PARAGRAPH NUMBER

Page

5--1

5--2

5--3

6--1

6--2

6--3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Shim Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Pump Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Delivery Valve Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 INJECTION NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 STARTER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 FUEL SPEED SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Intake Air Heater Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

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SAFETY

SAFETY PRECAUTIONS

cap must be removed, do so very slowly in order to

release the pressure without spray.

Your Carrier Transicold unit has been designed with the

safety of the operator in mind. During normal operation,

all moving parts are fully enclosed to help prevent injury.

During all pre-trip inspections, daily inspections, and

problem troubleshooting, you may be exposed to

moving parts. Please stay clear of all moving parts when

the unit is in operation and when the unit main power

switch is in the START/RUN position.

Battery

This unit is equipped with a lead-acid type battery. The

battery normally vents small amounts of flammable

hydrogen gas. Do not smoke when checking the battery.

A battery explosion can cause serious physical harm

and/or blindness.

SPECIFIC WARNING AND CAUTION

STATEMENTS

Engine Coolant

The engine is equipped with a pressurized cooling

system. Under normal operating conditions, the coolant

in the engine and radiator is under high pressure and is

very hot. Contact with hot coolant can cause severe

burns. Do not remove the cap from a hot radiator. If the

To help identify the label hazards on the unit and explain

the level of awareness each one carries, an explanation

is given with the appropriate consequences:

DANGER

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

WARNING

WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal in-

jury 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

Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the

nozzle contacts the human body, cells may be destroyed and blood poisoning may result.

WARNING

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

CAUTION

Do not remove the radiator cap until the coolant temperature is below its boiling point. Loosen the

cap slightly to relieve excess pressure before removing the cap completely.

CAUTION

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

CAUTION

Stop the engine when preparing to change the engine oil.

CAUTION

Never remove the radiator cap until coolant temperature is below its boiling point. Loosen the cap

slightly to the first stop to relieve any excess pressure before removing the cap completely.

62-11362

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SECTION 1

General

1.1 ENGINE IDENTIFICATION

When contacting Carrier Transicold, always specify

your engine model number and serial number.

The engine model and its serial number need to be

identified before the engine can be serviced or parts

replaced.

S/N

Engine Serial Number

The engine serial number is an identified number for the

engine. It is marked after the engine model number.

It indicates month and year of manufacture as follows:

Serial Number

4321

V2203--

Lower 4 digits in numerals

7th Digit Alpabetical Letter (Month of Manufacture)

Alphabetical letter

Month

A,B C,D E,F G,H J,K L,M N,P Q,R S,T U,V W,X

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Y,Z

6th Digit Alpabetical Letter or Numerals (Year of Manufacture).

Alphabetical letter or numerals

Year

Table 1-1. Model Chart

SERVICE ENGINE

PART NUMBER

MODEL NUMBER

ENGINE TYPE

PRIMARY USE

REPLACES

New

CT4--134--DI

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

X2 2100, X2 2100A, X2 2100R

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

26--00128--00

26--00128--01

26--00128--02

26--00128--04

26--00128--05

(1700 RPM)

CT4--134--DI

RG Genset

New

(1800 RPM)

CT4--134--DI

Ultima XTC, Extra XT (2.2),

X2 2500 A, X2 2500 R

New

(2200 RPM)

CT4--134--DI

UG Genset

TM Ultra XL

New

(1800 RPM)

CT4--134--DI

New

(1700 RPM)

1--1

62--11362

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1.2 ENGINE SPECIFICATIONS

Table 1-2. Specification Chart

MODEL NUMBER

TYPE

26--00128--00

26--00128--01

26--00128--02

26--00128--04

26--00128--05

Vertical, Water--cooled, 4 cycle diesel engine

NUMBER OF CYLINDERS

BORE X STROKE

mm X mm (in. X in.)

83 X 102.4 (3.27 X 4.03)

2216 (135.2)

TOTAL DISPLACEMENT

cm (cu.in.)

BRAKE HORSEPOWER

23.65 (31.7) /

1700

23.87 (32.0) /

1800

26.85 (36.0) /

2200

23.87 (32.0) /

1800

23.65 (31.7) /

1700

SAE Intermittent HP kW (HP) / RPM

MAXIMUM SPEED

IDLING SPEED

RPM

Below 2470

900

COMBUSTION CHAMBER

INJECTION PUMP

GOVERNOR

Direct Injection

Bosch “K” Type Mini Pump

Mechanical Governor + Electronic Governor

Bosch “P” Type Hole Nozzle

4.0° Before

INJECTION NOZZLE

INJECTION TIMING (UNPRESSURIZED)

FIRING ORDER

2.5° Before T.D.C.

T.D.C.

1--3--4--2

INJECTION PRESSURE

(Valve Opening Pressure)

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

COMPRESSION RATIO

LUBRICATION SYSTEM

OIL PRESSURE INDICATION

LUBRICATION FILTER

COOLING SYSTEM

21.5 : 1

Forced Lubrication by Pump

Electrical Type Switch

Full Flow Synthetic Media Filter (Cartridge Type)

Pressurized Radiator, Forced Circulation With Water Pump

Electric Starting With Starting Motor

12V, 2.5 kW

STARTING SYSTEM

STARTING SUPPORT DEVICE

FUEL

Intake Air Heater in Intake Manifold

Diesel Fuel No.2--D (ASTM D975)

*Quality Better Than CF Class (API), SAE 10W--30 or 15W--40

14.2 L (15.0 U.S. Quarts)

LUBRICATING OIL

LUBRICATING OIL CAPACITY

Weight (DRY)

kg (lbs.)

199 (439)

*See paragraph 1.8.6

62--11632

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 KUBOTA genuine

special tools. Special tools which are not frequently

used should be made according to the drawings

provided.

Before disassembling or servicing live wires, make sure

to always disconnect the grounding cable from the

battery first.

Remove oil and dirt from parts before taking any

measurements.

Use only Carrier Transicold genuine parts for parts

replacements to maintain engine performance and to

ensure safety.

Gaskets and O--rings must be replaced during

reassembly. Apply grease to new O--rings or oil seals

before assembling.

When reassembling external or internal snap rings,

position them so that the sharp edge faces against the

direction from which force is applied.

A newly serviced or reassembled engine should be

run--in with no load for 15 minutes. Serious damage to

the engine may result otherwise.

1--3

62--11362

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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 and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar tool, if employed,

must be used with care. Failure to do so may result in stripped or seized screws, bolts and nuts.

When replacing “*” marked screws, bolt and nuts, apply engine oil to their threads and seats before reassembly.

The letter “M” in size and pitch means that the screw, bolt or nut dimension is metric. The size is the nominal outside

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

Item

Cylinder Head Cover Bolt

*Cylinder Head Bolt

Size x Pitch

M6 x 1.0

N.m

kgf.m

ft--lbs

5.07 to 8.31

68.8 to 72.3

34.0 to 37

51 to 54

6.87 to 11.2

93.2 to 98.0

46 to 50

0.7 to 1.15

9.5 to 10.0

4.7 to 5.2

7.0 to 7.5

10.0 to 11.0

4.5 to 5.0

2.4 to 2.8

14.0 to 16.0

2.4 to 2.8

2.6 to 3.0

1.5 to 2.5

1.0 to 1.15

2.4 to 2.8

4.5 to 5.0

1.0 to 1.2

M11 x 1.25

M9 x 1.25

M10 x 1.25

M12 x 1.25

M8 x 1.0

*Main Bearing Case Bolt 1

*Main Bearing Case Bolt 2

*Flywheel Bolt

69 to 73

98.1 to 107

45 to 49

72.4 to 79.5

33 to 36

*Connecting Rod Bolt

*Rocker Arm Bracket Bolt

*Idle Gear Shaft Bolt

M8 x 1.25

M30 x 1.5

M8 x 1.25

M10 x 1.25

M12 x 1.5

M6 x 1.0

24 to 27

18 to 20

24 to 27

18 to 20

Crank Pulley Mounting Nut

*Bearing Case Cover Bolt

Nozzle Holder Clamp Bolt

Injection Pipe Retaining Nut

Overflow Pipe Assembly Retaining Bolt

Camshaft Retaining Bolt

Hi--idling Body

138 to 156

24 to 27

102 to 115

18 to 20

26 to 29

19 to 21

15 to 24

11 to 18

9.81 to 11.2

24 to 27

7.24 to 8.31

18 to 20

M8 x 1.25

M14 x 1.0

45 to 49

33 to 36

Starter’s Terminal B Mounting Nut

9.8 to 11

7.3 to 8.6

1.5.2 Torque Specifications For General Use Screws, Bolts and Nuts

Standard Screw and Bolt

Grade 4

Special Screw and Bolt

Grade 7

N.m

kgf.m

0.80 to 0.95

1.8 to 2.1

4.0 to 4.6

6.4 to 7.4

ft--lbs

5.8 to 6.8

13 to 15

29 to 33

47 to 53

N.m

kgf.m

ft--lbs

7.24 to 8.31

18 to 20

7.9 to 9.3

18 to 20

40 to 45

63 to 72

9.81 to 11.2

24 to 27

1.00 to 1.15

2.4 to 2.8

5.0 to 5.7

7.9 to 9.2

M10

M12

49 to 55

37 to 41

78 to 90

58 to 66

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

sure to check out the numbers as shown below

Punched Number

Screw And Bolt Material Grade

Standard Screw And Bolt SS41, S20C

Special Screw And Bolt S43C, S48C (Refined)

None or 4

62--11632

1--4

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1.6 TROUBLESHOOTING

Symptom

Probable Cause

Solution

Reference

Engine Does Not

Start

No fuel

Air in the fuel system

Water in the fuel system

Replenish fuel

Vent Air

Change fuel and

repair or replace fuel

system

1.8.4

Fuel pipe clogged

Fuel filter clogged

Excessively high viscosity fo fuel or engine oil Use specified fuel or

Clean

Clean or change

1.8.4

at low temperature

Fuel with low cetane number

Incorrect injection timing

engine oil

Use specified fuel

Adjust

Replace

5.1.1

1.8.8

Injection nozzle clogged

Injection pump malfunctioning

Seizure of crankshaft, camshaft, piston,

cylinder or bearing

Repair or Replace

Compression leak from cylinder

Replace head

gasket, tighten

cylinder head screw,

glow plug and nozzle

holder

Improper valve timing

Correct or replace

timing gear

2.2.4.f

Piston ring and cylinder worn

Excessive valve clearance

Replace

Adjust

2.3.3.d

1.8.7

(Starter Does Not

Run)

Battery discharged

Charge

Starter malfunctioning

Key switch malfunctioning

Wiring disconnected

Repair or replace

Connect

6.1

Engine Revolution

Is Not Smooth

Fuel filter clogged or dirty

Clean or change

Tighten retaining nut

1.8.4

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

Replace

5.1

5.2.1

5.2.3

Either White or Blue Excessive engine oil

Exhaust Gas Is

Reduce to specified

level

1.8.1

Observed

Piston ring and liner worn or ring stuck

Incorrect Injection timing

Deficient compression

Repair or replace

Adjust

Check the cylinder

compression

pressure and top

clearance

2.3.3.d

5.1.1

2.1.1

Either Black or Dark Overload

Lesson load

Exhaust Gas Is

Observed

Low grade fuel used

Fuel filter clogged

Air cleaner clogged

Deficient nozzle injection

Use specified fuel

Clean or change

Replace nozzle

1.8.8

Deficient Output

Incorrect injection timing

Adjust

Repair or replace

Replace

Replace nozzle

Check the

5.1.1

5.1

5.2.2

2.1.1

Engine’s moving parts seem to be seizing

Injection pump malfunctioning

Deficient nozzle injection

Compression leak

compression

pressure and repair

Repair or replace

Clean or replace

Gas leak from exhaust system

Air cleaner dirty or clogged

1--5

62--11362

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1.6 TROUBLESHOOTING (Continued)

Symptom

Probable Cause

Solution

Shift ring gap

direction

Reference

2.2.6.a

Exces s ive Lubricant Piston ring’s gap facing the same direction

Oil Cons umption

Oil ring worn or stuck

Piston ring groove worn

Valve stem and valve guide worn

Crankshaft bearing, and crank pin bearing

worn

Replace

Replace worn piston

Replace

2.3.3.d

2.3.3.e

2.3.1.d

2.3.4

Replace

Oil leaking due to defective seals or packing

Replace

Fuel Mixed into

Lubricant Oil

Injection pump’s plunger worn

Replace Injection

pump

Replace nozzle

Replace

5.1

Deficient nozzle injection

Injection pump broken

5.2.3

5.1

Water Mixed into

Lubricant Oil

Head gasket defective

Cylinder block or cylinder head flawed

Replace

2.2.3.e

Low Oil Pressure

Engine oil level low

Oil strainer clogged

Replenish

Clean

Relief valve stuck with dirt

Relief valve spring weak or broken

Excessive oil clearance of crankshaft bearing

Clean

Replace

3.1.1

2.3.4.d

Excessive oil clearance of crankpin bearing

Replace

2.3.4.c

Excessive oil clearance of rocker arm

Oil passage clogged

Incorrect oil type

Replace

Clean

Use specified type of

oil

2.3.1.k

Oil pump defective

Incorrect oil type

Repair or replace

3.2

High Oil Pressure

Engine Overheated

Use specified type of

oil

Replace

Relief valve defective

3.1.1

Engine oil level low

Replenish

Fan belt broken or elongated

Coolant insufficient

Radiator net and radiator fin clogged with dust Clean

Replace or adjust

Replenish

Inside of radiator corroded

Coolant flow route corroded

Radiator cap defective

Overload running

Head gasket defective

Incorrect injection timing

Unsuitable fuel used

Clean or replace

Replace

Loosen load

Replace

Adjust

2.2.3.e

Use specified fuel

Low Battery Charge Battery electrolyte level low

Replenish distilled

water and charge

Adjust belt tension or

change belt

Connect

Replace

Fan belt slips

Wiring disconnected

Rectifier defective

Alternator defective

Battery defective

Change

62--11632

1--6

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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

2.95 to 3.23 MPa/

290 rpm

2.35 MPa/

290 rpm

24kgf/cm²

290 rpm

341 psi/

30 to 33 kgf/cm²

290 rpm

427 to 469 psi/

290 rpm

Difference Among Cylinders

Top Clearance

10% or less

0.60 to 0.70 mm

0.0236 to 0.0276 in.

Valve Clearance (When Cold)

Valve Seat

0.18 to 0.22 mm

0.0071 to 0.0086 in.

Width (Intake)

2.12 mm

0.0835 in.

Width (Exhaust)

2.12 mm

0.0835 in.

Valve Seat

Angle

(Intake / Exhaust)

0.79 rad.

45°

Valve Face

Angle

0.79 rad.

(Intake / Exhaust)

45°

Valve Stem to Valve Guide

Clearance

0.040 to 0.070 mm

0.0016 to 0.0027 in.

0.1 mm

0.0039 in.

Valve Stem

O.D.

7.960 to 7.975 mm

0.3134 to 0.3139 in.

Valve Guide

I.D.

8.015 to 8.030 mm

0.3156 to 0.3161 in.

Valve Recessing

Protrusion

0.65 mm

0.026 in.

Recessing

Open

0.85 mm

0.033 in.

Valve Timing (Intake Valve)

Valve Timing (Exhaust Valve)

0.1 rad. (8°)

before T.D.C.

Open

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

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1.7.1 Engine Body (Continued)

Item

Factory Specification

Allowable Limit

Valve Spring

Free Length

41.7 to 42.2 mm

1.65 to 1.66 in.

41.2 mm

1.62 in.

Setting Load/

Setting Length

118 N / 35.0 mm

12.0 kgf / 35.0 mm

26.5 lbs. / 1.38 in.

100.0N / 35.0 mm

10.2kgf / 35.0 mm

22.5lbs /1.38 in

Tilt

1.0 mm

0.039 in.

Rocker Arm Shaft to Rocker Arm

Rocker Shaft

Clearance

0.016 to 0.045 mm

0.00063 to 0.0017 in.

1.0 mm

0.039 in.

O.D.

13.973 to 13.984 mm

0.55012 to 0.55055 in.

Rocker Arm

Push Rod

I.D.

14.000 to 14.018 mm

0.55119 to 0.55188 in.

Alignment

Clearance

0.25mm

0.0098 in.

Tappet to Tappet Guide

0.020 to 0.062 mm

0.00079 to 0.0024 in.

0.07 mm

0.003 in.

O.D.

I.D.

23.959 to 23.980 mm

0.94327 to 0.94409 in.

24.000 to 24.021 mm

0.94489 to 0.94570 in.

Timing Gear

Crank Gear to Idle Gear

Backlash

0.0415 to 0.1122 mm

0.001634 to 0.004417 in.

0.15 mm

0.0059 in.

Idle Gear to Cam Gear

0.0415 to 0.1154 mm

0.00163 to 0.004543 in.

0.15 mm

0.0059 in.

Idle Gear to Injection Pump Gear

0.0415 to 0.1154 mm

0.15 mm

0.001634 to 0.004543 in.

0.0059 in.

Crank Gear to Oil Pump Gear

Idle Gear

Backlash

0.0415 to 0.1090 mm

0.001634 to 0.004291 in.

0.15 mm

0.0059 in.

Side Clearance

Clearance

0.12 to 0.48 mm

0.0048 to 0.018 in.

0.9 mm

0.04 in.

Idle Gear Shaft to Idle Gear Bushing

0.025 to 0.066 mm

0.1 mm

0.00099 to 0.0025 in.

0.0039 in.

Idle Gear Shaft

O.D.

I.D.

37.959 to 37.975 mm

1.4945 to 1.4950 in.

Idle Gear Bushing

38.000 to 38.025 mm

1.4961 to 1.4970 in.

62--11632

1--8

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1.7.1 Engine Body (Continued)

Item

Factory Specification

Allowable Limit

Camshaft

Side Clearance

Alignment

0.07 to 0.22 mm

0.0028 to 0.0086 in.

0.3 mm

0.012 In.

Camshaft

0.01 mm

0.0004 in.

Cam (Lobe)

Height (Intake)

33.27 mm

1.310 in.

33.22 mm

1.308 in.

Height (Exhaust)

Clearance

33.47 mm

1.318 in.

33.42

1.316 in.

Camshaft Journal to Cylinder Block Bore

Camshaft Journal

0.050 to 0.091 mm

0.0020 to 0.0035 in.

0.15 mm

0.00059 in.

O.D.

39.934 to 39.950 mm

1.5722 to 1.5728 in.

Cylinder Block Bore

Piston Pin Bore

I.D.

40.000 to 40.025 mm

1.5748 to 1.5757

I.D.

25.000 to 25.013 mm

0.98425 to 0.98476 in.

25.05 mm

0.9862 in.

Second Ring to Ring Groove

Oil Ring to Ring Groove

Top Ring

Clearance

Ring Gap

Alignment

Clearance

0.093 to 0.128 mm

0.00367 to 0.00503 in.

0.2 mm

0.0079 in.

0.020 to 0.060 mm

0.00079 to 0.0023 in.

0.15 mm

0.0059 in.

0.20 to 0.35 mm

0.0079 to 0.013 in.

1.25 mm

0.0492 in.

Second Ring

0.40 to 0.55 mm

0.016 to 0.021 in.

1.25 mm

0.0492 in.

Oil Rng

0.25 to 0.45 mm

0.0099 to 0.017 in.

1.25 mm

0.0492 in.

Connecting Rod

0.05 mm

0.002 in.

Piston Pin to Small End Bushing

0.014 to 0.036 mm

0.15 mm

0.00056 to 0.0014 in.

0.0059 in.

Piston Pin

O.D.

25.004 to 25.011 mm

0.98441 to 0.98468 in.

Small End Bushing

Crankshaft

I.D.

25.025 to 25.040 mm

0.98524 to 0.98582 in.

Alignment

0.02 mm

0.0008 in.

Crankshaft Journal to Crankshaft Bearing1 Oil Clearance

0.040 to 0.118 mm

0.00158 to 0.00464 in.

0.2 mm

0.0079 in.

Crankshaft Journal

Crankshaft Bearing1

O.D.

I.D.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

59.980 to 60.039 mm

2.3615 to 2.3637 in.

1--9

62--11362

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1.7.1 Engine Body (Continued)

Item

Factory Specification

Allowable Limit

Crankshaft Journal to Crankshaft Bearing2 Oil Clearance

0.040 to 0.104 mm

0.00158 to 0.00409 in.

0.2 mm

0.0079 in.

Crankshaft Journal

O.D.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

Crankshaft Bearing2

I.D.

59.980 to 60.025 mm

2.3615 to 2.3631 in.

Crankpin to Crankpin Bearing

Oil Clearance

0.025 to 0.087 mm

0.00099 to 0.0034 in.

0.2 mm

0.0079 in.

Crankpin

O.D.

46.959 to 46.975 mm

1.8488 to 1.8494 in.

Crankpin Bearing

Crankshaft

I.D.

47.000 to 47.046 mm

1.8504 to 1.8522 in.

Side Clearance

Wear

0.15 to 0.31 mm

0.0059 to 0.012 in.

0.5 mm

0.02 in.

Crankshaft Sleeve

0.1mm

0.0059 in.

Cylinder Bore

(Standard)

I.D.

83.00 to 83.022mm

3.2678 to 3.2685 in.

83.170 mm

3.2744 in.

(Oversize)

83.250 to 83.272 mm

3.2776 to 3.2784 in.

83.420 mm

3.2843 in.

62--11632

1--10

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1.7.2 Lubricating System

Item

Factory Specification

Allowable Limit

Engine Oil Pressure

At Idle Speed

More Than 98 kPa

1.0 kgf/cm²

14 psi

50 kPa

0.5 kgf/cm²

7 psi

At Rated Speed

300 to 440 kPa

3.0 to 4.5kgf/cm²

43 to 64 psi

250 kPa

2.5 kgf/cm²

36 psi

Engine Oil Pressure Switch

Working

Pressure

50 kPa

0.5kgf/cm²

7 psi

Inner Rotor to Outer Rotor

Outer Rotor to Pump Body

Inner Rotor to Cover

Clearance

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.

0.105 to 0.150 mm

0.00414 to 0.00590 in.

0.2 mm

0.008 in.

1.7.3 Cooling System

Item

Factory Specification

Allowable Limit

V--Belt

Tension

7.0 to 9.0 mm (0.28 to

0.35 in.) deflection at

98N(10kgf, 22 lbs.)

of force

Thermostat

Valve Opening

Temperature

(At Beginning)

80.5 to 83.5°C

176.9 to 182.3°F

Valve Opening

Temperature

(Opened

95°C

203°F

Completely)

1.7.4 Fuel System

Item

Factory Specification

Allowable Limit

Injection Pump

Pump Element

Delivery Valve

Injection Timing

Fuel Tightness

0.0568 to 0.0829 rad.

(3.25 to 4.75°) before

T.D.C.

18.63 Mpa

190.0 kgf/cm²

2702 psi

10 seconds

5 seconds

18.62 to 17.76 Mpa

190.0 to 180.0 kgf/cm²

2702 to 2560 psi

18.63 to 17.65 Mpa

190.0 to 180.0kgf/cm²

2702 psi to 2560 psi

Injection Nozzle

Injection Pressure

(1st stage)

18.64 to 20.10 Mpa

190.0 to 205.0 kgf/cm²

2703 to 2915 psi

Injection Nozzle Valve Seat

Valve Seat

Tightness

When the pressure is

16.67 Mpa (170.0 kgf/cm²

2418 psi) the valve seat

must not leak.

1--11

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1.7.5 Electrical System

Item

Factory Specification

Allowable Limit

Starter

Commutator

O.D.

32.0 mm

1.26 in.

31.4 mm

1.24 in.

Mica

Undercut

Length

0.50 mm

0.020 in.

0.20 mm

0.0079 in.

Brush

0.18 mm

0.709 in.

11.0 mm

0.433 in.

Brush Holder and Holder Support Resistance

Intake Air Heater Resistance (cold)

Infinity

Approx. 0.3 ohm

62--11632

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1.8 CHECK AND MAINTENANCE

1.8.1 Checking Engine Oil Level

NOTE

When adding coolant to the system, air must be

vented from the engine coolant passages.

Venting air can be accomplished by jiggling the

upper and lower radiator hoses.

Be sure to close the radiator cap securely. If the

cap is loose or improperly closed, coolant may

leak out and the engine could overheat.

Do not use an antifreeze and scale inhibitor at

the same time.

Never mix different types or brands of coolants.

1. Level the engine.

1.8.3 Checking Fuel Hose

2. To check the oil level, draw out the dipstick (1), wipe it

clean, reinsert it, and draw it out again. Check to see

that the oil level lies between the two notches.

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

securely retighten it.

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

level.

2. The fuel hose is made of rubber and ages regardless

of the service period. Change the hose and clamps

together every two years.

3. Change the fuel hose and clamps whenever any de-

terioration or damage is detected.

NOTE

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

bleed air out of the fuel system.

When adding oil to the crankcase, be sure that

the fresh oil is the same type and viscosity as

the oil that is already in the crankcase. Never

mix two different types of oil. Never over fill a

crankcase.

CAUTION

Stop the engine when attempting to check

and change the fuel line.

1.8.2 Checking Coolant Level

1. Remove the radiator cap and check to see that the

coolant level is just below the port.

With the recovery tank: Check to see that the coolant

level lies between FULL and LOW.

2. If the coolant level is too low, check the reason for the

lost coolant.

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

soft water.

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

add a coolant mixture of the same type and specifi-

cation that is in the system. If the coolant brand can-

not be identified, drain out all of the remaining cool-

ant and refill with a totally new mix.

CAUTION

Do not remove the radiator cap until the

coolant temperature is below its boiling

point. Loosen the cap slightly to relieve ex-

cess pressure before removing the cap

completely.

1--13

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NOTE

When changing to a different oil manufacturer

or viscosity, be sure to remove all of the old oil

completely. Never mix different types of oil.

Use only API classification CG--4 or better oils.

Use the proper SAE engine oil according to the

ambient temperatures.

Above 25°C (77°F).............SAE 30 or 10W--30

10W--40

0° to 25°C (32° to 77°F)......SAE 20 or 10W--30

10W--40

1.8.4 Bleeding Fuel System

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

pump.

Below 0°C (32°F)............SAE 10W or 10W--30

2. Loosen the priming pump handle (2), and pump the

handle until bleeding is completed.

3. Depress and twist the priming pump handle clock-

wise to lock into place.

NOTE

4. Close the air vent cock (1).

With emission controls now in effect, the CG--4

or CH--4 / CI lubricating oils have been devel-

oped for use of a low--sulfur fuel on--road ve-

hicles engines. When an off--road vehicle en-

gine runs on a high--sulfur fuel, it is advisable to

employ the CH--4 / CI lubricating oil with a high

total base number. If the CG--4 lubricating oil is

used with a high sulfur fuel, change the lubricat-

ing oil at shorter intervals.

NOTE

Always keep the air vent cock on the fuel injec-

tion pump closed except when bleeding the fuel

system, or the engine may not run.

1.8.5 Checking V--Belt

Refer to Section 4.1

Lubricating oil recommended when a low--sulfur or

high--sulfur fuel is employed.

1.8.6 Changing Engine Oil

Lubricating Oil Class

Fuel

CAUTION

Low--sulfur

High--sulfur

CG--4

Stop the engine when preparing to change

the engine oil.

CH--4 or CI

O : Recommended X : Not Recommended

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

2. Place a pan underneath the engine.

3. Remove the drain plug, drain the engine oil

completely.

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

5. Reinstall the drain plug.

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

7. Fill the crankcase with new oil.

8. Check for the correct oil level. (Refer to Section 1.8.1)

62--11632

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1.8.7 Valve Clearance

NOTE

Valve clearance must be checked and adjusted

when the engine is cold.

1. Remove the valve cover.

2. Align the “1TC” mark line (3) on the flywheel and pro-

jection (2) on the housing so that the Number 1 piston

comes to compression or overlap top dead center

(TDC).

3. Check the following valve clearance (1) marked with

“*” using a feeler guage.

Factory

Specification

0.18 to 0.22 mm

0.0071 to 0.0086 in.

Valve Clearance

4. If the clearance is not within the factory specifica-

tions, adjust with the adjusting screw.

Valve

Arrangement

Piston Location in Cylinder

When No. 1 piston is at TDC

IN.

EX.

No. 1

No. 2

No. 3

No. 4

No. 1

No. 2

No. 3

No. 4

When No. 1 piston is at past TDC

1.8.8 Fuel Injection

Refer to Section 5.2

1--15

62--11362

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1.9 SPECIAL TOOLS

Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number

62--03213.

1.9.1 Diesel Engine Compression Tester (Glow

Plug)

Part No.

07--00179--01 (Assembly)

Application:

Use to measure diesel engine

compression and diagnosis for

major overhaul.

1.9.2 Adapter, Injector To Tester Hose

Part No.

Application:

07--00484--00

Accessory for 07--00179--01

1.9.3 Tester Injector Nozzle

Part No.

07--00140--00

Application:

Injector nozzle tester kit used for

checking and adjusting of the fuel injectors in diesel

engines.

1.9.4 Replacement Bowl, Tester Injector Nozzle

Part No.

Application:

07--00140--10

Accessory for 07--00140--00

1.9.5 Adapter, Injector Line

Part No.

Application:

07--00036--00

Accessory for 07--00140--00

62--11632

1--16

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1.9 SPECIAL TOOLS (Continued)

1.9.6 Oil Pressure Tester

Code No.

Application:

07916--32032

Use to measure lubricating oil

pressure.

1. Guage

5. Threaded Joint

6. Adapter 4

7. Adaptor 1

8. Adaptor 3

2. Adapter 2

3. Cable

4. Adapter 3

1.9.7 Auxiliary Socket For Fixing Crankshaft

Sleeve

Code No.

Application:

07916--32091

Use to fix the crankshaft sleeve of the

diesel engine.

1.9.8 Gauge, Belt Tension

Part No.

Application:

07--00203--00

Used to adjust belt tension of all

cogged V--belts.

1.9.9 Tester, Belt Tension

Part No.

Application:

07--00253--00

Used to test belt tension.

1.9.10 Rubber Band

Part No.

Application:

07--00253--01

Replacement part for belt tension

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

1.9.11 Main Bearing Install Tool

Part No.

Application:

07--00472--00

Used on engines starting with

S/N 3S0001

1.9.12 Main Bearing Extract Tool

Part No.

Application:

07--00473--00

Used on engines starting with

S/N 3S0001

1--17

62--11362

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1.9 SPECIAL TOOLS (Continued)

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

1.9.13 Valve Guide Replacing Tool

Application: Use to press out and press fit the valve

guide.

20 mm dia. (0.79 in. dia.)

11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)

6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)

225 mm (8.86 in.)

70 mm (2.76 in.)

45 mm (1.77 in.)

25 mm (0.98 in.)

5 mm (0.197 in.)

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

20 mm dia. (0.787 in. dia.)

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

8.9 to 9.1 mm (0.350 to 0.358 in.)

Chamfer 1.0 mm (0.039in.)

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.

162 mm (6.38 in.)

35 mm (1.38 in.)

27 mm (1.06 in.)

35 mm dia. (1.38 in. dia.)

27.90 to 27.95 mm dia. (1.098 to 1.100 in. dia.)

25.00 to 25.01 mm dia. (0984 to 0.985 in. dia.)

2. For idle gear bushing.

175 mm (6.89 in.)

40 mm (1.57 in.)

38 mm (1.49 in.)

45 mm (1.77 in.)

41.90 to 41.95 mm dia. (1.650 to 1.652 in. dia.)

37.95 to 37.97 mm dia. (1.494 to 1.495 in. dia.)

1.9.15 Flywheel Stopper

Application: Use to loosen and tighten the flywheel

screw.

200 mm (7.87 in.)

20 mm (0.79 in.)

30 mm (1.18 in.)

8 mm (0.31 in.)

10 mm (0.39 in.)

62--11632

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1.9 SPECIAL TOOLS (Continued)

1.9.16 Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit thecrankshaft

bearing No. 1

1. Extracting tool

130 mm (5.31 in.)

72 mm (2.83 in.)

R40 mm (R1.57 in.)

10 mm (0.39 in.)

20 mm (0.79 in.)

20 mm dia. (0.79 in. dia.)

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

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

2. Extracting tool

130 mm (5.31 in.)

72 mm (2.83 in.)

R40 mm (R1.57 in.)

10 mm (0.39 in.)

20 mm (0.79 in.)

20 mm dia. (0.79 in. dia.)

68 mm dia. (2.68 in. dia.)

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

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

1--19

62--11362

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SECTION 2

ENGINE BODY

2.1 CHECKING AND ADJUSTING

2.1.1 Compression Pressure

2.1.2 Top Clearance

1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2P connector

from the stop solenoid to prevent fuel delivery to the

engine.

3. Remove the the air cleaner, the muffler and all the in-

jection nozzles.

4. Install a compression tester with the adapter in one of

the nozzle hole.

5. While cranking the engine with the starter measure

the compression pressure.

6. Repeat steps 4 and 5 for each cylinder.

7. If the measurement is below the allowable limit, add a

small amount of oil to the cylinder thru the nozzle hole

and measure the compression again.

1. Piston

Plastic gauge

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

2. Remove the cylinder head.

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 pressure increases after applying

oil, check the cylinder wall and piston rings.

3. Move the piston (1) up and stick a strip of plastic

gauge (2) on the piston head at three positions shown

on the illustration.

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.

NOTE

Check the compression pressure with the spe-

cified valve clearance

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

top dead center.

Always use a fully charged battery for perform-

ing this test.

6. Remove the cylinder head and measure the plastic

gauge.

Variances in cylinder compression values

should be under 10%.

7. If the measurement is not within the factory specifica-

tions, check the clearances between the crank pin

and bearing and between the piston pin and bushing.

2.95 to 3.23 MPa

Factory

0.60 to 0.70 mm

0.024 to 0.027 in.

30 to 33 kgt/cm

Specification

Top Clearance

Specification

427 to 469 psi

Compression Pres-

sure

2.35 MPa

93.2 to 98.0 N m

Tightening

Torque

Cylinder Head

Bolts

Allowable Limit

24 kgt/cm

9.5 to 10.0 kgf m

341 psi

68.8 to 72.3 ft--lbs

62--11362

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2.2 DISASSEMBLE AND REASSEMBLY

2.2.1 Draining Coolant And Engine Oil

2.2.2 External Components

Air Cleaner, Muffler and Others

1. Remove the air cleaner and muffler.

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

When Reassembling

CAUTION

Never remove the radiator cap until coolant

temperature is below its boiling point.

Loosen the cap slightly to the first stop to

relieve any excess pressure before remov-

ing the cap completely.

NOTE

Check to see that there are no cracks on the belt

surface.

1. Open the coolant drain cock or remove the coolant

drain plug and drain the coolant into a proper recep-

tacle/bucket.

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.

2. Remove the oil drain plug and drain the engine oil into

a proper receptacle/bucket.

62--11362

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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.

6.87 to 11.2 N m

Tightening

Torque

Valve Cover

Bolts

0.7 to 1.15 kgf m

5.07 to 8.31 ft--lbs

1. Valve Cover Bolt

2. Breather Hose

3. Valve Cover

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.

Injection Pipe

Retaining

Nut

15 to 24 N m

Tightening

Torque

1.5 to 2.5 kgf m

11 to 18 ft--lbs

62--11362

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2.2.3 Cylinder Head And Valves (Continued)

2.2.3.c Nozzle Holder Assembly

1. Remove the overflow pipe assembly.

2. Remove the nozzle holder assemblies (1).

When Reassembling

Replace the copper gasket with a new one.

26 to 29 N m

Nozzle Holder

Assembly

2.6 to 3.0 kgf m

19 to 21 ft--lbs

Tightening

Torque

Overflow Pipe

Assembly

9.81 to 11.2 N m

1.00 to 1.15 kgf m

Retaining Bolt

7.24 to 8.31 ft--lbs

2.2.3.d Rocker Arm and Push Rod

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

2. Detach the rocker arm assembly (2).

3. Remove the push rods (3).

When Reassembling

When putting the push rods (3) onto the tappets (4),

check to see if the push rod end is properly seated in the

tappet dimples.

NOTE

After instaling the rocker arm, be sure to adjust

the valve clearance. (Refer to Section 1.8.7)

1. Rocker Arm Bracket

Mounting Bolt

3. Push Rod

4. Tappet

Rocker Arm

Bracket Mounting

Bolt

24 to 27 N m

Tightening

Torque

2.4 to 2.8 kgf m

2. Rocker Arm Assembly

18 to 20 ft--lbs

62--11362

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2.2.3 Cylinder Head And Valves (Continued)

2.2.3.e Cylinder Head

1. Loosen the hose clamp (1), and remove the water re-

turn pipe (2).

2. Remove the cylinder head bolts in the order of (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.

93.1 to 98.0 N m

Tightening

Torque

Cylinder Head

Bolt

9.5 to 10.0 kgf m

68.7 to 72.3 ft--lbs

NOTE

When replacing the cylinder head gasket (3), be

sure you are using a new gasket that matches

the original gasket.

1. Hose Clamp

2. Filter--Drier Inlet

A: Gear Case Side

B: Flywheel Side

2.2.3.f Tappets

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

When Reassembling

Visually check the contact between the tappets (1) and

individual cam lobes.

Coat the tappets with engine oil before installing them.

NOTE

When re--installing tappets into the engine,

make sure that they are re--installed in their ori-

ginal location.

2.2.3.g Valves

1. Remove the valve caps (3).

2. Remove the valve spring collet (4), pushing the valve

spring retainer (5) by the valve spring compressor (1).

3. Remove the valve spring retainer (5), valve spring (6)

and valve stem seal (2).

4. Remove the valve (7).

When Reassembling

Clean the valve stem and the valve guide. Apply engine

oil to the valve stem when reassembling.

After installing the valve spring collets (4), lightly tap the

stem with a plastic hammer to assure the collets have

seated on the valve stem.

NOTE

When re--installing valves into the engine,

make sure that they are re--installed in their

original location.

62--11362

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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--id-

ling body (3), engine stop lever (5) and stop

solenoid guide (6).

When Reassembling

Install the fuel speed solenoid (2), the hi--idling body (3)

and the stop solenoid guide (6) after Installing the

injection pump (7).

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

Install the fuel speed solenoid guide (6) and then the

stop lever (5) into the gear case. Cycle the stop lever to

insure that it functions.

NOTE

When installing the fuel speed solenoid (2), use

care to keep the O--ring (1) in place.

Be sure to insert the push rod of the stop solenoid into

the hole at the center of the solenoid guide (6).

45.0 to 49.0 N m

Tightening

Torque

Hi--idling Body

4.5 to 5.0 kgf m

33 to 36 ft--lbs

1. O--ring

5. Stop Lever

2. Fuel Speed Solenoid

3. Hi--Idling Body

6. Stop Solenoid Guide

7. Injection Pump Assembly

4. Hi--Idling Body Gasket

62--11362

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2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.b Governor Springs and Speed Control Plate

NOTE

Specific Tool (1): A 1.2mm (.050 inch) diameter

wire with a total length of 200mm (8 inch) with

the tip bent into a hook as depicted in the

illustration is required to hang the governor

springs.

1. Remove the injection pump cover.

2. Remove the speed control plate (7) mounting nuts (3)

and bolts (4).

3. Using the Specific Tool (1), undo the the large

governor spring (5) from the fork lever (2).

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

5. Remove the speed control plate (7), using care not to

let the governor spring (5) disengage from the plate

and fall into the gear case.

1. Specific Tool

2. Fork Lever

5. Large Governor Spring

6. Speed Control Lever

7. Speed Control Plate

3. Speed Control Plate

Mounting Nut

4. Speed Control Plate

Mounting Bolt

62--11362

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2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.b Governor Springs and Speed Control Plate

(Continued)

When Reassembling

NOTE

A length of string passed thru the governor

spring can be used to retrieve the spring if it un-

hooks from both the specific tool and the speed

control plate.

Begin reassembly by inserting the specific tool (1) thru

the injection pump cover opening thru to the speed

control plate opening.

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

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

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

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

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

two bolts and two nuts to the gear case.

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

NOTE

The speed control lever (6) must be free to

move from low idle position to maximum speed

position and should always return to the high

idle position.

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

case.

1. Specific Tool

2. Fork Lever

5. Large Governor Spring

6. Speed Control Lever

7. Speed Control Plate

3. Speed Control Plate

Mounting Nut

4. Speed Control Plate

Mounting Bolt

62--11362

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2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.c Fan Drive Pulley

1. Lock the flywheel using the flywheel stopper

2. Remove the fan drive pulley mounting nut (1) using

the 46 mm deep socket wrench (3).

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

4. Remove the feather key.

When Reassembling

Apply grease to the splines of the coupling.

138 to 156 N m

Tightening

Torque

Drive Pulley

14.0 to 16.0 kgf m

Mounting Nut

102 to 115 ft--lbs

1. Nut

3. 46 mm Deep Socket wrench

4. Gear Puller

2.2.4.d Gear Case

2. Fan Drive Pulley

1. Remove the gear case (1).

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

When Reassembling

Replace the gear case gasket and O--rings (3)(4).

Apply gasket sealant to both sides of the gear case

gasket (2).

Check/insure that the four O--rings (3)(4) are in place on

the gear case (1).

1. Gear Case

2. Gear Case Gasket

3. O--ring

4. O--ring

5. Oil seal

Apply a thin film of oil to the crankshaft oil seal lip (5) and

take care not to roll the lip when installing the gear case.

62--11362

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2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.e Crankshaft Oil Slinger

1. Remove the crankshaft collar (1).

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

3. Remove the crankshaft oil slinger (3).

When Reassembling

Insert the crankshaft collar (1) after installing the gear

case to the crankcase.

1. Crankshaft Collar

2. O--ring

3. Crankshaft Oil Slinger

2.2.4.f Idle Gear

1. Detach the external snap ring.

2. Remove the idle gear collar.

3. Remove the idle gear (2).

When Reassembling

Check to see each gear is aligned with its aligning mark.

Idle gear (2) and crank gear (4)

Idle gear (2) and cam gear (3)

Idle gear (2) and injection pump gear (1)

1. Injection Pump Gear

2. Idle Gear

4. Crank Gear

5. Oil Pump Drive Gear

3. Cam Gear

2.2.4.g Camshaft

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

camshaft (2) out.

When Reassembling

Refer to installation of Idle Gear (Refer to Section

2.2.4.f).

24 to 27 N m

Tightening

Torque

Camshaft

2.4 to 2.8 kgf m

retaining bolt

18 to 20 ft--lbs

1. Camshaft Set Screw

2. Camshaft

2.2.4.h Fuel Feed Pump Holder

1. Disconnect the oil pipe (1).

2. Remove the fuel feed pump (2).

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

When Reassembling

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

1. Oil Pipe

3. O--ring

2. Fuel Feed Pump

4. Fuel Feed Pump Holder

62--11362

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2.2.4 Injection Pump and Gear Case (Continued)

2.2.4.i Fuel Camshaft And Fork Lever Assembly

1. Detach the fuel camshaft stopper (1).

2. Remove the three fork lever holder mounting screws

(2).

3. Remove the fuel camshaft assembly (5), (6) and fork

lever assembly (3), (4), and (7) at the same time.

When Reassembling

After installation, check to see that the fork levers 1 (3)

and 2 (4) are fixed to the fork lever shaft, and that they

can turn smoothly in the holder (7).

1. Fuel Camshaft Stopper

5. Injection Pump Gear

2. Fork Lever Holder Mounting 6. Fuel Camshaft

Screws

7. Fork Lever Holder

3. Fork Lever 1

4. Fork Lever 2

2.2.4.j Oil Pump

1. Remove the nut.

2. Draw out the oil pump drive gear (2) with a gear puller

(3).

3. Remove the four oil pump mounting bolts. Detach the

oil pump (1).

1. Oil Pump

Gear Puller

2. Oil Pump Drive Gear

62--11362

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2.2.5 Oil Pan and Oil Strainer

2.2.5.a Oil Pan and Oil Strainer

1. Remove the oil pan cover (4).

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

3. Remove the oil pan (2) by lightly tapping the rim of the

pan with a wooden hammer.

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

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

When Reassembling

Check to see that the oil filter strainer (6) is clean.

Visually check the O--ring (5), apply engine oil and install

it to the pick--up tube.

(7)

Install the strainer (6) and O--ring (5).

Apply gasket sealant to the oil pan side of the oil pan

gasket (7) and fit the gasket to the oil pan (2).

Install the oil pan (2) to the engine, and tightenthe oilpan

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).

1. Oil Pan Mounting Screw

2. Oil Pan

5. O--ring

6. Oil Strainer

7. Oil Pan Gasket

Install the oil pan cover (4) to the oil pan (2).

3. Oil Pan Cover Gasket

4. Oil Pan Cover

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

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2.2.6 Piston and Connecting Rod

2.2.6.a Pistons

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

the cylinder walls.

2. Remove the connecting rod cap (3).

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

center.

4. Push the piston out by lightly tapping the connecting

rod from the bottom of the crankcase with the grip of a

hammer.

5. Repeat the procedure for the other three cylinders.

When Reassembling

Liberally coat the piston and piston rings with engine oil.

When inserting the piston into the cylinder, face the

mark on the connecting rod to the injection pump.

NOTE

If re--installing the original piston assemblies

into the engine be sure that they are returned to

their original cylinder.

Place the piston rings with their gaps at 2.09

rad. (120°) from the piston pin’s direction as

shown.

Carefully insert the pistons into the cylinders

using the piston ring compressor (7).

When inserting the piston into the cylinder avoid

damaging the molybdenum disulfide coating on

the piston skirt. This coating is useful in mini-

mizing 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

7. Piston Ring Compressor

(A) Top Ring Gap

2. Connecting Rod Bolt

3. Connecting Rod Cap

4. Connecting Rod

5. Molybdenum Disulfide

Coating on Piston Skirt

6. Piston ID Mark

(B) Second Ring Gap

(D) Piston Pin Hole

(a) 2.09 rad. (120°)

45 to 49 N m

Tightening

Torque

Connecting

Rod Bolt

4.5 to 5.0 kgf m

33 to 36 ft--lbs

62--11362

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2.2.6 Piston and Connecting Rod (Continued)

2.2.6.b Piston Ring and Connecting Rod

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

2. Remove the piston pin (8) and then seperate the con-

necting rod (6) from the piston (5).

NOTE

Mark both the connecting rod and piston so that

if they are to be re--used that the original com-

bination of parts will go back together. Do not in-

terchange used parts.

When Reassembling

When installing the rings, assemble so that the

manufacturer’s mark (12) near the gap faces the top of

the piston (5).

When installing the oil control ring (3) onto the piston (5),

place the expander joint (10) on the opposite side of the

oil ring gap (11).

Apply engine oil to the piston pin (8).

When assembling the connecting rod (6) to the piston

(5), immerse the piston (5) in hot oil (80°C / 176°F) for 10

to 15 minutes, then assemble the piston, piston pin, and

connecting rod.

NOTE

Assemble the piston (5) on to the connecting

rod (6) with the FW mark (9) facing the flywheel

end and the connecting rod mark (7) facing the

injection pump side.

1. Top Ring

7. Mark

2. Second Ring

3. Oil Control Ring

4. Piston Pin Snap Ring

5. Piston

8. Piston Pin

9. FW Mark

10. Expander Joint

11. Oil Ring Gap

12. Manufacturer’s Mark

6. Connecting Rod

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2.2.7 Crankshaft

2.2.7.a Flywheel

1. Prevent the flywheel (1) from rotating.

2. Remove two flywheel bolts (2).

NOTE

The use of air tools to remove the flywheel bolts

may damage the threads in the crankshaft.

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

1. Flywheel

3. Flywheel Guide Bolts

Install two flywheel guide bolts (3).

2. Flywheel Bolt

Check to see that the mating surfaces of the crankshaft

and flywheel are clean.

Apply engine oil to the flywheel bolts and install.

98.0 to 107.8 N m

Tightening

Torque

Flywheel Bolts

10.0 to 11.0 kgf m

72.3 to 79.5 ft--lbs

2.2.7.b Bearing Case Cover

1. Remove the bearing case cover mounting bolts. First,

remove the inside bolts (2) and then the outside bolts

(1).

2. Screw two of the removed bolts into the bolt hole of

the bearing case cover (3) to remove it.

NOTE

The length of the inside (2) and the outside (1)

bolts is different. When reassembling reinstall

the appropriate bolt in the correct location.

When Reassembling

Fit the bearing case gasket (5) and the bearing case

cover gasket (6) to the bearing case cover (3). Orient

them correctly.

Install the bearing case cover (3), again orienting it

correctly, using the “UP” mark (a).

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

seal when installed.

Tighten the bearing case cover bolts diagonally and

evenly.

Bearing Case

Cover Mounting

bolt

24 to 27 N m

Tightening

Torque

2.4 to 2.8 kgf m

18 to 20 ft--lbs

1. Bearing Case Cover

Mounting Bolt

5. Bearing Case Gasket

6. Bearing Case Cover

Gasket

2. Bearing Case Cover

Mounting bolt

(a). Top

3. Bearing Case Cover

4. Oil Seal

62--11362

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2.2.7 Crankshaft (Continued)

2.2.7.c Crankshaft Assembly Removal

NOTE

Before disassembling, check the side

clearance of the crankshaft. Check it

during reassembly.

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

2. Pull out the crankshaft assembly (2), being carefulnot

to damage the crankcase bearings (3).

3. While pulling the crankshaft assembly (2) out, use

care to align each of the crank pins (5) (left or right) to

clear the crankcase relief (a).

When Reassembling

When installing the main bearing case assembly, align

the bolt holes of the crankshaft assembly (2) with the

holes of the crankcase.

Apply oil to the threads of the main bearingcase bolts (1)

before re--insertion.

69 to 73 N m

Tightening

Torque

Main Bearing

Case Bolt

7.0 to 7.5 kgf m

51 to 54 ft--lbs

1. Main Bearing Case Screw 2 5. Cylinder 4 Crank Pin

2. Main Bearing Case 2

3. Crankshaft Bearing 1

4. Crankshaft Assembly

(a).Main Bearing Case Relief

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2.2.7 Crankshaft (Continued)

2.2.7.d Main Bearing Case Assembly

1. Remove the two main bearing case bolts (7), and re-

move the main bearing case assembly being careful

with the thrust bearing and crankshaft bearing.

2. Remove the remaining main bearing cases as above.

When Reassembling

Clean the oil passages in the main bearing case.

Apply clean engine oil to the bearings.

Install the main bearing case assemblies in their original

locations. The diameters of the main bearing cases

vary. Install them in order from the gear case end

according to their markings (A,B,C).

Match the alignment numbers (1) and mark (2) on the

main bearing case.

When installing the main bearing case, face the mark

“FLYWHEEL” to the flywheel.

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

outward.

Confirm that main bearing case moves smoothly after

torquing the main bearing case bolt to specification.

46 to 50 N m

Tightening

Torque

Main Bearing

Case bolt

4.7 to 5.2 kgf m

34 to 37 ft--lbs

1. Alignment Number

2. Alignment Mark

3. No Mark

7. Main bearing Case Bolt

8. Oil Groove

62--11362

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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 resurfac-

ing the head.

0.05mm over a span of

Cylinder Head

Factory

500mm

0.002 in. over a span of

20 in.

Surface Flatness

Specification

2.3.1.b Cylinder Head Cracks

1. Cylinder head crack(s) can be found with using a

non--destructive test procedure using a dye/pene-

trant kit.

2. Clean the cylinder head surface using a good quality

degreaser and detergent (2).

3. Spray the cylinder head surface with the red liquid or

dye (1). Let it sit on the surface for ten minutes.

4. Wash the dye off the head using the detergent (2) and

dry the head.

1. Red Dye

2. Detergent

3. White Developer

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

6. Red marks will bleed through the developer identify-

ing cracks in the head if they are present.

62--11362

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2.3.1 Cylinder Head And Valves (Continued)

2.3.1.c Valve Recessing

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

valve seat.

2. Insert the valve into the head, making certain that the

valve is fully seated.

3. Measure the valve recessing with a depth gauge.

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

place the valve.

1. Cylinder Head

Surface

(A) Recess

5. If the measurement still exceeds the allowable limit,

replace the cylinder head.

(B) Protrusion

0.065 (protrusion) mm to

Factory

0.085 (recessing) mm

0.026 (protrusion) in. to

0.033 (recessing) in.

Valve

Specification

Recessing

Allowable Limit

2.3.1.d Clearance Between Valve Stem And Valve

Guide

1. Remove carbon from the valve guide section.

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

3. Measure the valve guide with a small hole gauge, and

calculate the clearance.

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

place the valves. If the clearance still exceeds the al-

lowable limit, replace the valve guide.

Factory

0.040 to 0.070 mm

0.0016 to 0.0027 in.

Clearance

Between

Specification

Valve Stem

and Guide

0.1 mm

Allowable Limit

0.0039 in.

Valve Stem

O.D.

Factory

7.960 to 7.975 mm

0.3134 to 0.3139 in.

Specification

Valve Guide

I.D.

Factory

8.015 to 8.030 mm

0.3156 to 0.3161 in.

Specification

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2.3.1 Cylinder Head And Valves (Continued)

2.3.1.e Replacing Valve Guide

(A) (When removing)

1. Press out the used valve guide using a valve guide re-

placing tool.

(B) (When installing)

1. Clean a new valve guide and valve guide bore, then

apply oil to them.

2. Press in a new valve guide using a valve guide replac-

ing tool.

3. Ream the I.D. of the valve guide to the specified di-

mension (precisely).

Valve Guide I.D.

Intake & Exhaust

Factory

8.015 to 8.030 mm

0.3156 to 0.3161 in.

Specification

(A) When Removing

(B) When Installing

2.3.1.f Valve Seating

1. Coat the valve face lightly with prussian blue and put

the valve on its seat to check the contact pattern

2. If the valve does not seat all the way around the valve

seat, or the contact is less than 70%, correct the valve

seating as outlined in paragraph 2.3.1.g.

3. If the valve contact does not comply with the refer-

ence value, replace the valve or correct the contact of

valve seating.

1. Correct

3. Incorrect

2. Incorrect

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2.3.1 Cylinder Head And Valves (Continued)

2.3.1.g Correcting Valve and Valve Seat

NOTE

Before correcting the valve seat, make certain

that the valve and valve guide are within factory

specifications.

After correcting the valve seat, be sure to check

the valve recessing.

(A) Correcting the Valve

1. Correct the valve with a valve grinder.

IN.

0.79 rad / 45°

Factory

Valve Face Angle

Specification

EX.

(B) Correcting the Valve Seat

1. Slightly correct the valve seat surface with a 1.0 rad.

(60°) (intake valve) or 0.79 rad. (45°) (exhaust valve)

seat cutter.

2. Resurface the seat surface with a 0.52 rad. (30°)

valve seat cutter to the Intake valve seat and with a

0.26 rad. (15°) valve seat cutter to the exhaust valve

seat so that the width is close to the specified valve

seat width (2.12 mm, 0.0835 in.).

3. After resurfacing the seat, apply a thin film of valve

lapping compound between the valve and the seat,

then use a valve lapping tool to seat the valve to the

valve seat.

(2)

(1)

4. Check the valve seating with prussian blue. The valve

seating should show good contact all the way around.

a. 0.26 rad.(15°) or

0.52 rad.(30°)

A. Check Contact

IN.

0.79 rad / 45°

Factory

Valve Face Angle

B. Correct Seat Width

Specification

EX.

b. 0.79 rad.(45°) or

1.0 rad.(60°)

Check Contact

1. Valve Seat Width

c. 0.52 rad.(30°) or

0.26 rad.(15°)

2 . Identical Dimensions

2.3.1.h Valve Lapping

1. Apply compound evenly to the valve lapping surface.

2. Insert the valve into the valve guide. Lap the valve

onto its seat with a valve lapper or bolt driver.

3. After lapping the valve, wash the compound away

and apply oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check

the contact pattern, if it is less than 70%, repeat valve

lapping again.

NOTE

When valve lapping is performed, be sure to

check the valve recessing and adjust the valve

clearance after assembling the valve.

62--11362

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2.3.1 Cylinder Head And Valves (Continued)

2.3.1.i Free Length and Tilt of Valve Spring

1. Measure the free length A of the valve spring with ver-

nier calipers. If the measurement is less than the al-

lowable limit, replace the spring.

2. Put the valve spring on a surface plate, place a

square on the side of the valve spring.

3. Check to see if the entire side is in contact with the

square. Rotate the spring and measure for maximum

tilt B. Check the entire surface of the valve spring for

defects. If any are found, replace it.

Factory

41.7 to 42.2 mm

1.65 to 1.66 in.

Specification

Free Length A

Tilt B

41.2 mm

1.62 in.

Allowable Limit

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 en-

gine.

2. Read the compression load on the gauge.

3. If the measurement is less than the allowable limit, re-

place it.

118 N / 35 mm

Factory

12.0 kgf / 35 mm.

Specification

26.5 lbs. / 1.38 in.

Setting Load /

Setting Length

100 N / 35 mm

10.2 kgf / 35 mm.

22.5 lbs. / 1.38 in.

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. Measure the rocker arm I.D. with a inside micrometer,

then calculate the oil clearance.

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

place the rocker arm then measure the oil clearance

again. If the clearance is still out of specification, re-

place the rocker arm shaft.

Factory

0.016 to 0.045 mm

0.0063 to 0.0017 in.

Oil Clearance

Rocker Arm/

Shaft

Specification

Allowable

Limit

0.10 mm

0.0039 in.

Rocker Arm

Shaft O.D.

Factory

13.973 to 13.984 mm

0.55012 to 0.55055 in.

Specification

Factory

14.000 to 14.018 mm

0.55119 to 0.55188 in.

Rocker Arm I.D.

Specification

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.

62--11362

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2.3.1 Cylinder Head And Valves (Continued)

2.3.1.m Oil Clearance Between Tappet and Tappet

Guide Bore

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

2. Measure the I.D. of the tappet guide bore with a cylin-

der gauge and calculate the clearance.

3. If the measurement exceeds the allowable limit, or

the tappet is damaged, replace the tappet.

Factory

0.020 to 0.062 mm

Oil Clearance

Tappet/

Specification

0.00079 to 0.00244 in.

Tappet Guide

Bore

Allowable

Limit

0.07 mm

0.003 in.

Factory

23.959 to 23.980 mm

0.94327 to 0.94409 in.

Tappet O.D.

Specification

Factory

24.000 to 24.021 mm

0.94489 to 0.94570 in.

Tappet Guide I.D.

Specification

2.3.2 Timing Gears, Camshaft and Fuel Camshaft

2.3.2.a Timing Gear Backlash

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

tooth.

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

mating gear.

3. If the backlash exceeds the allowable limit, check the

oil clearance of the shafts and the gear.

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

Factory

0.0415 to 0.1122 mm

0.00163 to 0.00442 in.

Backlash/

Idle Gear/

Crank Gear

Specification

Allowable

Limit

0.15 mm

0.0059 in.

Factory

0.0415 to 0.1154 mm

0.00163 to 0.00454 in.

Backlash/

Idle Gear/

Cam Gear

Specification

Allowable

Limit

0.15 mm

0.0059 in.

Factory

0.0415 to 0.1154 mm

0.00163 to 0.00454 in.

Backlash/

Idle Gear/

Injection Pump

Gear

Specification

Allowable

Limit

0.15 mm

0.0059 in.

Factory

0.0415 to 0.1090 mm

0.00163 to 0.00429 in.

Backlash/

Crank Gear/

Oil Pump Gear

Specification

Allowable

Limit

0.15 mm

0.0059 in.

2.3.2.b Idle Gear Side Clearance

1. Set a dial indicator with its tip on the idle gear.

2. Move the gear front to rear to measure the side clear-

ance.

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

place the idle gear collar.

Factory

0.12 to 0.48 mm

Idle Gear

Side

Specification

0.0047 to 0.018 in.

Allowable

Limit

0.9 mm

0.04 in.

Clearance

62--11362

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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, re-

place the camshaft stopper.

Factory

0.07 to 0.22 mm

Camshaft

Side

Specification

0.0028 to 0.0087 in.

Allowable

Limit

0.30 mm

Clearance

0.0118 in.

2.3.2.d Idle Gear Shaft and Idle Gear Bushing

Clearance

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

2. Measure the idle gear bushing I.D. with an inside mi-

crometer, and calculate the the clearance.

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

place the bushing.

Factory

0.025 to 0.066 mm

Idle Gear Shaft/

Bushing

Specification

0.00099 to 0.00260 in.

Allowable

Limit

0.1 mm

Clearance

0.0039 in.

Idle Gear Shaft

O.D.

Factory

23.959 to 23.980 mm

0.94327 to 0.94410 in.

Specification

Idle Gear Shaft

I.D.

Factory

24.000 to 24.021 mm

0.94488 to 0.94571 in.

Specification

2.3.2.e Idle Gear Shaft and Idle Gear Bushing

Clearance

(A) When Removing

1. Press out the bushing using an Idle Gear Bushing Re-

placing Tool.

(B) When Installing

1. Clean a new idle gear bushing and the idle gear bore,

and apply engine oil to both.

2. Using the idle gear replacing tool, press in the new

bushing to the specified dimension (see B)

62--11362

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2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)

2.3.2.f Camshaft Alignment

1. Support the camshaft with V blocks on a surface plate

at both end journals.

2. Set a dial indicator with its tip on the intermediate jour-

nal.

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

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

place 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 out-

side micrometer.

2. If the measurement is less than the allowable limit, re-

place the camshaft.

Factory

33.27 mm

1.310 in.

Specification

Cam Height

Intake

Allowable

Limit

33.22 mm

1.308 in.

Factory

33.47 mm

1.318 in.

Specification

Cam Height

Exhaust

Allowable

Limit

33.42 mm

1.316 in.

2.3.2.h Camshaft Oil Clearance

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

micrometer.

2. Measure the cylinder block camshaft bore I.D. with a

cylinder gauge, and calculate the oil clearance.

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

place the camshaft

Factory

0.050 to 0.091 mm

0.0020 to 0.0035 in.

Specification

Camshaft Journal

Clearance

Allowable

Limit

0.15 mm

0.0059 in.

Camshaft Journal

O.D.

Factory

39.934 to 39.950 mm

1.5722 to 1.5728 in.

Specification

Camshaft Bore

I.D.

Factory

40.000 to 40.025 mm

1.5748 to 1.5757 in.

Specification

62--11362

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2.3.3 Piston and Connecting Rod

2.3.3.a Piston Pin Bore I.D.

1. Measure the piston pin bore I.D. in both the horizontal

and vertical directions with a cylinder gauge.

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

place the piston.

Factory

25.000 to 25.013 mm

0.98426 to 0.98476 in.

Specification

Piston Pin Bore

I.D.

Allowable

Limit

25.05 mm

0.9862 in.

2.3.3.b Piston Pin and Bushing Clearance

1. Measure the piston pin O.D. withan outsidemicrome-

ter.

2. Measure the connecting rod small end bushing I.D.

with an inside micrometer.

3. If the clearance exceeds the allowable limit, replace

the bushing. If the clearance is still excessive, replace

the piston pin.

Factory

0.014 to 0.038 mm

Piston Pin to

Small End Bush-

ing Clearance

Specification

0.00055 to 0.00150 in.

Allowable

Limit

0.15 mm

0.0059 in.

Factory

25.002 to 25.011 mm

0.98433 to 0.98468 in.

Piston Pin O.D.

Specification

Small End

Factory

25.025 to 25.040 mm

0.98523 to 0.98582 in.

Bushing I.D.

Specification

2.3.3.c Replacing Connecting Rod Small End Bu-

shing

(A) When Removing

1. Press out the small end bushing using a Small End

Bushing Replacing Tool.

(B) When Installing

1. Clean a new small end bushing and bore, and apply

engine oil to both.

2. Using the small end bushing replacing tool, press in

the new bushing to the specified dimension (see B).

NOTE

Be sure to align the bushing so that the oil hole

in the bushing aligns with the oil port in the con-

necting rod.

62--11362

2--26

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2.3.3 Piston and Connecting Rod (Continued)

2.3.3.d Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder

(the least worn section). Use the piston to square the

ring in the cylinder.

2. Measure the ring gap with a feeler gauge.

3. If the gap exceeds the allowable limit, replace the

ring.

Factory

0.20 to 0.35 mm

Top Ring

Specification

0.0079 to 0.013 in.

(Keystone Type)

Allowable Limit

1.25 mm / 0.0492 in.

Factory

0.40 to 0.55 mm

0.016 to 0.021 in.

Specification

Second Ring

Allowable Limit

1.25 mm / 0.0492 in.

Factory

0.25 to 0.45 mm

Specification

0.0099 to 0.017 in.

Oil Control Ring

Allowable Limit

1.25 mm / 0.0492 in.

2.3.3.e Piston Ring to Groove Clearance

1. Clean the rings and the ring grooves, and install each

ring in its groove.

2. Measure the clearance between the ring and its

groove with a feeler gauge (with the exception of the

top ring, Keystone Type, which cannot be accurately

measured with a feeler gauge).

3. If the clearance exceeds the allowable limit, replace

the ring.

4. If the clearance still exceeds the allowable limit after

replacing the ring, replace the piston.

Factory

0.093 to .128 mm

Specification

0.00367 to 0.00503 in.

Second Ring

Allowable Limit

0.20 mm / 0.0079 in.

Factory

0.020 to 0.060 mm

Specification

0.00079 to 0.0023 in.

Oil Control Ring

Allowable Limit

0.15 mm / 0.0059 in.

2.3.3.f Connecting Rod Alignment

NOTE

Since the I.D. of the connecting rod small end

bushing is the basis of this procedure, check the

bushing for wear before proceeding.

1. Install the piston pin into the connecting rod.

2. Install the connecting rod on the connecting rod align-

ment tool.

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

the face plate.

4. If the gauge does not fit squarely against the face

plate, measure the space between the pin of the

gauge and the face plate.

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

place the connecting rod.

Connecting Rod

Allowable Limit

0.05 mm / 0.002 in.

Alignment

62--11362

2--27

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2.3.4 Crankshaft

2.3.4.a Crankshaft End Clearance

1. Push on the end of the crankshaft to seat it toward the

flywheel end of the engine block.

2. Attach, then zero a dial indicator on the forward end of

the crankshaft.

3. Measure the end play by pulling the crankshaft for-

ward.

4. If the measurement exceeds the allowable limit re-

place the thrustwashers.

Factory

0.15 to 0.31 mm

Specification

0.0059 to 0.012 in.

Crankshaft Side

Clearance

Allowable

Limit

0.5 mm

0.02 in.

(Reference)

Oversize dimensions of crankshaft journal.

Oversize

0.2mm / 0.008 in.

0.4mm / 0.02 in.

54.5 to 54.7 mm

2.146 to 2.153 in.

54.6 to 54.8 mm

2.150 to 2.157 in.

Dimension A

26.20 to 26.25 mm

1.032 to 1.033 in.

26.40 to 26.45 mm

1.040 to 1.041 in.

Dimension B

Dimension C

2.8 to 3.2 mm radius 2.8 to 3.2 mm radius

0.11 to 0.12 in.

radius

0.11 to 0.12 in.

radius

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

0.4--S.

2.3.4.b Crankshaft Alignment

1. Support the crankshaft with V blocks on a surface

plate at both end journals. Set a dial indicator with its

tip on the intermediate journal, perpendicular to the

journal.

2. Rotate the crankshaft on the V blocks and get the

misalignment (half of the measurement).

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

place the crankshaft.

Crankshaft

Alignment

Allowable

Limit

0.02 mm

0.0008 in.

62--11362

2--28

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2.3.4 Crankshaft (Continued)

2.3.4.c Crankpin to Connecting Rod Bearing Clear-

ance

1. Clean the crankpin and the connecting rod bearing.

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

in each direction as shown in the figure.

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

the specification. (Refer to 2.2.6.a)

4. Remove the cap again

5. Measure the amount of the flattening with the scale to

get the clearance.

6. If the measurement exceeds the allowable limit re-

place the connecting rod bearing.

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

size bearing, install an undersize bearing by referring

to the table below.

Factory

0.025 to 0.087 mm

Crankpin/

Connecting Rod

Clearance

Specification

0.00099 to 0.0034 in.

Allowable

Limit

0.2 mm

0.0079 in.

Factory

46.959 to 46.975 mm

1.8488 to 1.8494 in.

Crankpin O.D.

Specification

Connecting Rod

Bearing I.D.

Factory

47.000 to 47.046 mm

1.8504 to 1.8522 in.

Specification

(Reference)

Undersize dimensions of crankpin journal.

Undersize

0.2mm / 0.008 in.

0.4mm / 0.02 in.

3.3 to 3.7 mm

0.13 to 0.14 in.

3.3 to 3.7 mm

0.13 to 0.14 in.

Dimension A

1.0 to 1.5 mm radius 1.0 to 1.5 mm radius

Dimension B

Dimension C

0.040 to 0.059 in.

radius

0.040 to 0.059 in.

radius

46.759 to 46.775

46.559 to 46.575

1.8409 to 1.8415 in. 1.8331 to 1.8336 in.

radius radius

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

0.8--S.

*Holes to be de ---burred and edges rounded with 1.0 to 1.5

(0.040 to 0.059 in. relief.

62--11362

2--29

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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 bearing by referring

to the table below.

Factory

0.040 to 0.118 mm

Crankshaft

Journal to #1

Bearing

Specification

0.00158 to 0.00464 in.

Allowable

Limit

0.2 mm

Clearance

0.0079 in.

Crankshaft

Factory

59.921 to 59.940 mm

2.3591 to 2.3598 in.

Journal O.D.

Specification

Crankshaft

Bearing Bearing

I.D.

Factory

59.980 to 60.039 mm

2.3615 to 2.3637 in.

Specification

(Reference) Undersize dimensions of crankshaft

journal.

Oversize

0.2mm / 0.0008 in.

0.4mm / 0.0016 in.

2.8 to 3.2 mm radius 2.8 to 3.2 mm radius

Dimension A

0.11 to 0.12 in.

radius

0.11 to 0.12 in.

radius

1.0 to 1.5 mm radius 1.0 to 1.5 mm radius

Dimension B

Dimension C

0.040 to 0.059 in.

radius

0.040 to 0.059 in.

radius

59.721 to 59.740

59.521 to 59.540

2.3513 to 2.3519 in. 2.3434 to 2.3440 in.

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

0.4--S.

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

(0.040 0.059 in.) relief.

2.3.4.e Replacing Crankshaft Bearing #1

(A) When Removing

1. Press out the crankshaft bearing #1 (2) using a crank-

shaft bearing (1) replacing tool.

(B) When Installing

1. Clean a new crankshaft bearing #1 (2) and crankshaft

journal bore, and apply engine oil to both.

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

in the new bearing #1 (2) so that its seam (1) directs

toward the exhaust manifold side.

1. Seam

3. Cylinder Block

A Dimension

2. Crankshaft Bearing #1

NOTE

Be sure to align the bushing so that the oil hole

in the bushing aligns with the oil port in the con-

necting rod.

Factory

4.2 to 4.5 mm

Dimension A

Specification

0.166 to 0.177 in.

62--11362

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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. Measure the amount of the flattening with the scale to

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 bearing by referring

to the table below.

NOTE

Be sure not to move the crankshaft while the

bearing bolts are tightened.

Factory

0.040 to 0.104 mm

Crankshaft

Journal to #2

Bearing

Specification

0.00158 to 0.00409 in.

Allowable

Limit

0.2 mm

Clearance

0.0079 in.

Crankshaft

Factory

59.921 to 59.940 mm

2.3591 to 2.3598 in.

Journal O.D.

Specification

Crankshaft

Bearing Bearing

I.D.

Factory

59.980 to 60.025 mm

2.3615 to 2.3631 in.

Specification

(Reference)

Undersize dimensions of crankshaft journal.

Oversize

0.2mm / 0.008 in.

0.4mm / 0.016 in.

2.8 to 3.2 mm radius 2.8 to 3.2 mm radius

Dimension A

0.11 to 0.12 in.

radius

0.11 to 0.12 in.

radius

1.0 to 1.5 mm radius 1.0 to 1.5 mm radius

Dimension B

Dimension C

0.040 to 0.059 in.

radius

0.040 to 0.059 in.

radius

59.721 to 59.740

59.521 to 59.540

2.3513 to 2.3519 in. 2.3433 to 2.3440 in.

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

0.4--S.

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

(0.040 0.059 in.) relief.

62--11362

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2.3.4 Crankshaft (Continued)

2.3.4.g Replacing Crankshaft Sleeve

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

use puller set.

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

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

the figure.

4. Heat the new sleeve to a temperature between 150 to

200°C (302 to 392°F), and fix the sleeve on the crank-

shaft (5) as shown in the figure.

5. Press fit the sleeve using the auxiliary socket for

pushing (4).

NOTE

Install the sleeve with the largest chamfered

surface facing outward.

1. Stopper

4. Auxiliary Socket For

2. Sleeve Guide

3. Crankshaft Sleeve

Pushing

5. Crankshaft

62--11362

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2.3.5 Cylinder

2.3.5.a Cylinder Wear

1. Measure the I.D. of the cylinder at the six positions

(see figure with a cylinder gauge to find the maximum

and minimum I.D.’s.

2. Determine the difference (maximum wear) between

the maximum and minimum I.D.’s.

3. If the wear exceeds the allowable limit, bore and hone

to the oversize dimension. (refer to Correcting

Cylinder)

4. Visually check the cylinder wall for scratches. If deep

scratches are found, the cylinder walls should be

bored. (refer to Correcting Cylinder)

Factory

83.000 to 83.022 mm

3.2678 to 3.2685 in.

Cylinder I.D.

Specification

Allowable

Limit

83.170 mm

3.2744 in.

Maximum Wear

a. Top

a. Right--angled to

Piston Pin

b. Middle

c. Bottom (skirt)

b. Piston Pin Direction

2.3.5.b Correcting Cylinder (Oversize +0.25 mm)

1. When the cylinder is worn beyond the allowable limit,

bore and hone it to the specified dimension.

Factory

83.250 to 83.272 mm

3.2776 to 3.2784 in.

Cylinder I.D.

Specification

Allowable

Limit

83.420 mm

3.2843 in.

Maximum Wear

Hone to 2.2 to 3.0 mm μR max.

(0.00087 to 0.00118 in. μR max.)

Finishing

1. Cylinder I.D.

2. Oversize Cylinder I.D.

(before correction)

2. Replace the piston and piston rings with oversize

(+0.25 mm) ones.

62--11362

2--33

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SECTION 3

LUBRICATING SYSTEM

3.1 CHECKING AND ADJUSTING

3.1.1 Engine Oil Pressure

1. Remove the engine oil pressure switch, and install an

oil pressure gauge.

2. Start the engine. After warming up, read the oil pres-

sure at idling and at rated speeds.

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

check the following:

Engine oil sufficient

Oil pump defective

Oil strainer clogged

Oil filter cartridge clogged

Oil gallery clogged

Excessive oil clearance

Relief valve stuck

More than 98 kPa

Factory

1.0 kgf/cm

Specification

14 psi

At Idle Speed

50 kPa

Allowable

0.5 kgf/cm

Limit

7 psi

300 to 440 kPa

Factory

3.0 to 4.5 kgf/cm

Specification

43 to 64 psi

At Rated Speed

250 kPa

Allowable

2.5 kgf/cm

Limit

36 psi

(When Reassembling)

After checking the engine oil pressure, tighten the

engine oil pressure switch to the specified torque.

62--11362

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3.2 SERVICING

3.2.1 Rotor Lobe Clearance

1. Measure the clearance between lobes of the inner ro-

tor and the outer rotor with a feeler 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.

Factory

0.03 to 0.14 mm

Specification

0.0012 to 0.0055 in.

Inner/Outer

Rotor Clearance

Allowable

Limit

0.2 mm

0.008 in.

Factory

0.11 to 0.19 mm

Outer Rotor/

Pump Body

Clearance

Specification

0.0044 to 0.0074 in.

Allowable

Limit

0.25 mm

0.0098 in.

3.2.2 Rotor to Cover Clearance

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

grease.

2. Install the cover and tighten the bolts.

3. Remove the cover carefully, and read the plastigage.

4. If the clearance exceeds the factory specifications,

replace the oil pump rotor assembly.

Factory

0.105 to 0.150 mm

Specification

0.00414 to 0.00590 in.

Rotor/Cover

Clearance

Allowable

Limit

0.20 mm

0.008 in.

62--11362

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SECTION 4

COOLING SYSTEM

4.1 CHECKING AND ADJUSTING

2. Replace the Poly--V--Belt by positioning the belt on

the water pump pulley, and while rotating the engine

(as in step 1), use a flat, blunt object to guide the belt

onto the crank pulley. Be careful not to damage

grooves on the pulley or belt.

WARNING

Beware of moving V--belt and belt driven

components

4.1.2 Fan Belt Damage and Wear

1. Check the fan belt for damage.

4.1.1 Notched V--Belt Service

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

NOTE

A frayed, cracked or worn V--belt must be re-

placed. After installing a new belt, it is advisable

to check the adjustment after running the unit

for three or four hours. This will allow for the ini-

tial stretch, which is common on new belts.

Once this initial stretch has taken place, the belt

should be checked at regular intervals.

(A)

(B)

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

following:

a. Replacing the V--Belt

1. Loosen the idler pivot bolt.

A. Good

B. Bad

2. Replace the belt and adjust tension in accordance

with the following steps.

3. Check if the belt is worn and sunk in the pulley groove.

4. If the fan belt is worn and deeply sunk in the pulley

groove, replace it.

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).

A. Good

B. Bad

4.1.3 Checking Coolant Level

2. Use hand force only on the idler pulley to tighten belt.

Do not use a pry bar or excessive force as it may

cause damage to the engine.

WARNING

Use of

belt tension gauge (Carrier Part

07--00203--00) or a belt tension tester (Carrier Part #

07--00253--00) is advised.

When removing the radiator cap, wait at

least ten minutes after the engine has

stopped and cooled down. Otherwise, hot

water may discharge from the radiator,

scalding anyone nearby.

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

4.1.1a Poly V--Belt Service

a. Replacing the Poly--V--Belt

1. Apply the proper size socket to the crank pulley nut,

then slowly rotate the crank. At the same time, use a

flat, blunt object to guide the belt off the crank pulley

towards radiator. Be careful not to damage grooves

on the pulley.

1. Remove the radiator cap and check to see that the

coolant level is just below the port.

With the recovery tank: Check to see that the coolant

level lies between FULL and LOW.

62--11362

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4.1.5 Radiator

FULL

LOW

2. If the coolant level is too low, check the reason for the

lost coolant.

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

soft water.

1. Fill the radiator with water.

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

add a coolant mixture of the same type and specifi-

cation that is in the system. If the coolant brand can-

not be identified, drain out all of the remaining cool-

ant and refill with a totally new mix.

2. Attach the pressure tester to the radiator.

3. Apply pressure and look for leaks.

4. Repair/replace as necessary to assure that the speci-

fied pressure will hold.

NOTE

157 kPa

Radiator Leakage

Test

Factory

1.6 kgf/cm

23 psi

Specification

When adding coolant to the system, air must be

vented from the engine coolant passages by jig-

gling the upper and lower radiator hoses.

4.1.6 Thermostat Opening Temperature

Be sure to close the radiator cap securely. If the

cap is loose or improperly closed, coolant may

leak out and the engine could overheat.

Do not use an antifreeze and scale inhibitor at

the same time.

Never mix different types or brands of coolants.

4.1.4 Radiator Cap

1. Suspend the thermostat in water by a string with one

end of the string inserted between the valve and its

seat.

2. Immerse the thermostat in water and raise the tem-

perature of the water gradually.

3. With a thermometer, read the temperature of the

water when the valve opens and leaves the string.

4. Continue heating the water, read the temperature of

the water when the valve has opened approximately

6mm (0.236 in).

1. Attach the radiator cap to a pressure tester.

2. Apply pressure and observe the time for the pressure

to fall.

5. If the measurement is not within the factory specifica-

tions, replace the thermostat.

3. If the measurement is less than the factory specifica-

tion, replace the cap.

Thermostat

Factory

80.5 to 83.5.5°C

176.9 to 182.3°F

Opening

More than 10 seconds

for pressure fall from

Specification

Temperature

Pressure Falling

Time

Factory

88 to to 59kPa

0.9 to 0.6 kgf/cm

13 to 9 psi

Thermostat

Full Open

Specification

Factory

95°C

203°F

Specification

Temperature

62--11362

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4.2 SERVICING

4.2.1 Thermostat Assembly

4.2.2 Water Pump Assembly

1. Water Pump Flange

2. Water Pump Shaft

4. Water Pump Gasket

1. Thermostat Cover Bolt

2. Thermostat Cover

4. Thermostat Assembly

5. Thermostat Housing

5. Mechanical Seal

6. Impeller

Water Pump Body

3. Thermostat Cover Gasket

1. Remove the fan belt.

1. Remove the thermostat cover mounting bolts (1), and

remove the thermostat cover (2).

2. Remove the water pump pulley.

2. Remove the thermostat assembly (4).

3. Remove the water pump from the gear case assem-

bly.

(When Reassembling)

4. Remove the water pump flange (1).

Apply a liquid gasket only at the thermostat cover side of

the thermostat cover gasket (3).

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).

62--11362

4--3

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SECTION 5

FUEL SYSTEM

5.1 CHECKING AND ADJUSTING

5.1.1 Injection Timing

1. Remove the fuel speed solenoid.

2. Remove the injection pipes and nozzle.

3. Move the speed control lever to the maximum speed

position.

NOTE

Turn the flywheel with a screwdriver.

4. Turn the flywheel counterclockwise (facing the fly-

wheel) 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 indi-

cated is the timing value for the engine. (The flywheel

has a mark ’1TC’ and marks every 5° of engine timing

to 25° total).

0.0568 to 0.0829 rad.

Factory

Injection Timing

3.25° to 4.75°

Specification

B.T.D.C.

NOTE

Injection timing adjustment is accomplished by

adding or removing shims under the injection

pump.

The timing advances by removing one shim and

retards timing by adding the same shim.

The addition or removal of 0.05 mm (0.0020 in.)

of shim, changes the injection timing by approx-

imately 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 ap-

plied 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

5. 0--Holes: 0.30 mm shim

6. 3--Holes: 0.35 mm shim

7. 2--Holes: 0.175 mm shim

3. 2--Holes: 0.20 mm shim

4. 1--Hole: 0.25 mm shim

5--1

62--11362

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5.1 CHECKING AND ADJUSTING

18.63 MPa

Fuel Pump

Factory

190 kgf/cm

2702 psi

Pressure Test

Specification

5.1.4 Delivery Valve Fuel Seal

1. Remove the engine fuel speed solenoid.

2. Remove the injection pipes and nozzle.

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

4. Connect the injection nozzle (2) jetted with the proper

injection pressure to the injection pump pressuretest-

er (1).

5. Using the starter, rotate the crankshaft until the fuel

pressure is built up.

1. Injection Pump Pressure

Tester

2. Injection Nozzle

3. Protective Cover

6. Release the pressure in the delivery chamber by ro-

tating the crankshaft to bottom dead center. (turn the

crankshaft 1.57 rad. (90°) clockwise from fuel timing

set point)

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.

7. If the pressure drop for 5 seconds exceeds the allow-

able limit, replace the delivery valve or pump assem-

bly.

10 seconds

4. Connect the injection nozzle (2) jetted with the proper

injection pressure to the injection pump pressuretest-

er (1).

Factory

18.63 to 17.65 MPa

Specification

190 to 180 kgf/cm

2702 to 2560 psi

Delivery Valve

Fuel Seal

5. Using the starter, rotate the crankshaft until the fuel

pressure is built up.

5 seconds

Allowable

Limit

18.63 to 17.65 MPa

190 to 180 kgf/cm

6. If the pressure does not build up, replace the pump

element with a new one and test again.

2702 to 2560 psi

62--11362

5--2

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5.2 INJECTION NOZZLE

WARNING

Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the

nozzle contacts the human body, cells may be destroyed and blood poisoning may result.

5.2.1 Nozzle Injection Pressure

1. Set the injection nozzle in a nozzle tester.

2. Slowly move the tester handle to measure the pres-

sure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within factory specifica-

tions, replace the nozzle assembly.

Fuel Injection

Pressure

1st Stage

18.64 to 20.1 MPa

190 to 205 kgt/cm

2703 to 2915 psi

Factory

Specification

5.2.2 Nozzle Spraying Condition

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

the nozzle spraying condition.

2. If the spraying condition is defective, replace the

injection nozzle assembly.

(a) GOOD

(b) BAD

5.2.3 Valve Seat Tightness

1. Set the injection nozzle in a nozzle tester.

2. Raise the fuel pressure, and maintain 16.67 MPa

(170 kgf/cm², 2418 psi) for 10 seconds.

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

assembly.

No fuel leak at

Factory

16.67MPa

Valve Seat Tight-

ness

170 kgf/cm

2418 psi

Specification

5--3

62--11362

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SECTION 6

ELECTRICAL SYSTEM

6.1 STARTER TEST

6.1.1 Motor Test

WARNING

Secure the starter to prevent it from moving

when power is applied to it.

1. Disconnect the cable from the negative terminal on

the battery.

2. Disconnect the cable from the positive terminal on the

battery.

3. Disconnect the leads from the starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter solenoid C ter-

1. C Terminal

3. Negative Terminal

minal (1) to the positive battery terminal.

2. Positive Terminal

6. Connect a jumper lead momentarily between the

starter motor housing and the negative post on the

battery.

7. If the starter does not run, repair or replace thestarter.

8.8 to 11.8 N m

0.9 to 1.2 kgf m

6.5 to 8.7 ft--lbs.

Tightening Torque

Terminal Nut

6.1.2 Magnetic Switch Test

NOTE

This test should only be carried out for a 3 to 5

second time period and not longer.

1. Disconnect the cable from the negative terminal on

the battery.

2. Disconnect the cable from the positive terminal on the

battery.

3. Disconnect the the positive cable and leads from the

starter B terminal.

4. Remove the starter from the engine.

5. Connect a jumper lead from the starter S terminal (1)

to the positive battery post (2).

6. Momentarily, connect a jumper lead between the

starter housing and negative battery terminal (3).

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

starter.

NOTE

The B terminal is the terminal that connects the

cable from the battery to the starter.

1. S Terminal

3. Negative Terminal

The S terminal is the terminal that connects the

cable from the starter switch to the magnetic

switch.

2. Positive Terminal

62--11362

6--1

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6.2 FUEL SPEED SOLENOID

6.2.1 Solenoid Test

WARNING

The solenoid can become very warm to the

touch when energized for any length in

time.

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

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

3. Supply power (12VDC) to the solenoid thru terminals

(3) and (4).

4. If the rod in the solenoid (1) moves smoothly (approx-

imately 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 (--)

A. Actuator Rod (Power Off)

B. Actuator Rod (12VDC

applied)

4. Terminal 1 (+)

62--11362

6--2

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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

Factory

Specification

0.3 ohms

1. Positive Terminal

2. Heater Body

62--11362

6--3

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INDEX

Battery, iv

Identification, 1--1

bearing case, 2--15, 2--17

idle gear, 2--10

injection nozzle, 5--3

injection timing, 5--1

intake air heater, 6--3

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

lubricating system, 3--1

crankshaft, 2--28

crankshaft oil slinger, 2--10

cylinder, 2--33

Notched V--Belt, 4--1

cylinder head, 2--3, 2--5, 2--18

dye/penetrant, 2--18

oil level, 1--13

oil pan, 2--12

oil pressure, 3--1

oil pump, 2--11, 3--2

electrical system, 6--1

engine oil, 1--14, 2--2

piston, 2--13, 2--26, 2--27

piston ring, 2--14

Poly V--belt, 4--1

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

push rod, 2--22

fuel system -- bleeding , 1--14

radiator, 4--2

radiator cap, 4--2

rocker arm, 2--22

gear case, 2--9

governor , 2--7, 2--8

62--11362

Index--1

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INDEX

Safety Precautions, iv

V--belt, 1--14

specifications, 1--2

valve clearance, 1--15

valve guide, 2--20

valve seat, 2--20

speed control plate, 2--7, 2--8

starter motor, 6--1

valve spring, 2--22

valves, 2--5, 2--19, 2--21

tappets, 2--5, 2--23

thermostat, 4--2

timing gear, 2--23

Torque Specification, 1--4

water pump, 4--3

Index--2

62--11362

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Mexico and

Central America

North America

Carrier Transicold

Ejercito Nacional No. 418

Piso 9, Torre Yumal

Col. Chapultepec Morales

11570 Mexico, D.F.

Tel: (5255) 9126.0300

Fax: (5255) 9126.0373

700 Olympic Drive

Athens, GA 30601 USA

Tel: 1--706--357--7223

Fax: 1--706--355--5435

Carrier Transicold Division,

Carrier Corporation

Truck/Trailer Products Group

P.O. Box 4805

Syracuse, N.Y. 13221 U.S.A.

www.carrier.transicold.com

A member of the United Technologies Corporation family. Stock symbol UTX

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