Workshop Manual

Diesel Engine - V2403-CR-E4B

(26-00159)
X4 7700, Vector 8700, 8800MT,
8811MT, Genset RG, Genset UG

62-12258 Rev. A
 Workshop Manual

V2403-CR-E4B
(26-00159)
Tier 4 Engine

© Carrier Corporation, 2024 Printed in U. S. A. January 2024

 Manual Revision History - 62-12258

Rev Date Reason for Release

10/19/2023 New product – new manual
A 1/5/2024 Added Appendix A (Engine P Codes); Section 2 – Added note to reference
Appendix A and updated Table 2-1
1.1 SAFETY PRECAUTIONS ...................................................... 1–1
1.2 ENGINE COOLANT ........................................................... 1–1
1.3 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.4 SPECIFIC WARNING AND CAUTION STATEMENTS ................................ 1–1
2.1 ENGINE IDENTIFICATION ..................................................... 2–1
2.1.1 Engine Serial Number ..................................................... 2–1
2.2 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.1 Diesel Engine Compression Tester (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.2 Adapter, Kubota 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.3 Oil Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.4 Auxiliary Socket For Fixing Crankshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.4.5 Gauge, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.6 Tester, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.7 Rubber Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.8 Main Bearing Install Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.9 Main Bearing Extract Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.4.10 Valve Guide Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.4.11 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.12 Flywheel Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.4.13 Crankshaft Bearing 1 Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.4.14 Crankshaft Sleeve Auxiliary Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.4.15 Injection Top Injection Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
2.4.16 Bearing Case Cover Oil Seal Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
3.1 ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1.1 Engine Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1.2 Engine Body Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.2 DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2.1 Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2.2 Draining and Refilling Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2.3 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2.4 Checking Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.2.5 Selecting Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.2.6 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.2.7 Measuring Angular Deviation Between Crankshaft T.D.C. and Crankshaft Position Sensor Detect-
ed T.D.C. 3–5
3.2.8 Adjusting Air Gap Between Crankshaft Position Sensor and Flywheel . . . . . . . . . . . . . . . . 3–7
3.2.9 Adjusting Air Gap Between Camshaft Position Sensor and Pulsar Gear . . . . . . . . . . . . . . 3–7
3.2.10 Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10

1–1 62-12258
 3.3 COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.3.1 Draining Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.3.2 Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.3.3 Removing Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
3.3.4 Removing Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
3.3.5 Removing Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
3.3.6 Removing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
3.3.7 Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
3.3.8 Removing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
3.3.9 Removing Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.3.10 Removing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.3.11 Removing Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
3.3.12 Removing Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
3.3.13 Removing Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.3.14 Removing Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
3.3.15 Removing Fan Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
3.3.16 Removing Gear Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.3.17 Removing Crankshaft Oil Slinger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.3.18 Removing Idle Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.3.19 Removing Fuel Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.3.20 Removing camshaft with Cam Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.3.21 Removing Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.3.22 Removing Crank Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
3.3.23 Removing Oil Pan and Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
3.3.24 Removing Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
3.3.25 Removing Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
3.3.26 Disassembling Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.3.27 Removing Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.3.28 Removing Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
3.3.29 Removing Bearing Case Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
3.3.30 Removing Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
3.3.31 Removing Main Bearing Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32

62-12258 1–2
3.4 COMPONENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33
3.4.1 Main Bearing Case Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33
3.4.2 Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35
3.4.3 Bearing Case Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36
3.4.4 Flywheel Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
3.4.5 Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
3.4.6 Assembly the Piston Assmbly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39
3.4.7 Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–40
3.4.8 Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41
3.4.9 Oil Strainer and Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43
3.4.10 Crank Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–44
3.4.11 Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–45
3.4.12 Camshaft with Cam Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–45
3.4.13 Fuel Camshaft with Supply Pump Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–47
3.4.14 Idle Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–48
3.4.15 Crankshaft Oil Slinger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–49
3.4.16 Gear Case Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–49
3.4.17 Fan Drive Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–50
3.4.18 Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–50
3.4.19 Supply Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–51
3.4.20 Suction Control Valve (SCV) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–52
3.4.21 Thermostat Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–52
3.4.22 Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–53
3.4.23 Tappet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–53
3.4.24 Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–54
3.4.25 Rocker Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–56
3.4.26 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–57
3.4.27 Glow Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–59
3.4.28 Cylinder Head Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–59
3.4.29 Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–60
3.4.30 Common Rail Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–62
3.4.31 CRS Intermediate Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–63
3.4.32 External Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–65
3.4.33 Filling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–67
3.4.34 Filling Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–67
3.5 SERVICING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–68
3.5.1 Checking Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–68
3.5.2 Checking Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–69
3.5.3 Checking Cylinder Head Flaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–70
3.5.4 Checking Valve Recessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–71
3.5.5 Adjusting Valve Lapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–72
3.5.6 Checking Clearance Between Valve Stem and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . 3–73
3.5.7 Replacing Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–74

1–3 62-12258
 4.1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.1 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.1.3 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
4.1.4 Replacing Oil Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.1.5 Replacing Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.1.6 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
5.1 CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.1.1 Checking Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.1.2 Checking Fuel Hoses and Clamp Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.1.3 Checking and Draining Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.1.4 Cleaning Air Cleaner Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5.1.5 Adjusting Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
5.1.6 Checking Radiator Hose and Clamp Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
5.1.7 Checking Air Intake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
5.1.8 Cleaning Water Separator Filter (Type 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
5.1.9 Anti-Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.1.10 Replacing Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
5.1.11 Checking Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
5.1.12 Checking Injector with Diagmaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
5.1.13 Checking Positive Crankcase Ventilation (PCV) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.1.14 Checking Intake Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
5.1.15 Checking Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
5.1.16 Replacing Water Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
6.1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.1 Checking Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.1.2 Checking and Draining Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.3 Checking Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
6.1.4 Checking Injector with Diagmaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.1.5 Checking Intake Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.1.6 Checking Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
6.1.7 Replacing Water Separator Filter (Type 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
7.1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.2 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.2.1 Checking Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3 GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.3.1 Checking Glow Plug Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.3.2 Glow Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.4 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.4.1 Checking Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
7.4.2 Checking Magnetic Switch of Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.4.3 Checking Magnetic Switch Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.4.4 Checking Overrunning Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.5 STARTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.6 STARTER SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9

62-12258 1–4
7.7 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.7.1 Checking Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.7.2 Checking Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
7.7.3 Checking Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
7.7.4 Checking Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
7.7.5 Checking Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
APPENDIX A - ENGINE P CODES

1–5 62-12258
62-12258 1–6
 SECTION 1
Safety Summary
1.1 Safety Precautions
Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, all
moving parts are fully enclosed to help prevent injury. During all 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.

1.2 Engine Coolant

The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do
not remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pres-
sure without spray.

1.3 Battery
This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydro-
gen gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or
blindness.

1.4 Specific Warning and Caution Statements

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is
given with the appropriate consequences:

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

! WARNING
WARNING – warns against hazards or unsafe conditions which COULD result in severe
personal 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.

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

1–1 62-12258
 • Beware of moving V-belt and belt driven components. When working with belts, beware of pinch
points.
• 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.
• 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.
• Secure the starter to prevent it from moving when power is applied to it.

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

62-12258 1–2
 SECTION 2
General

For a complete listing of Power Train (P) codes, refer to Appendix A at the end of this manual.

2.1 Engine Identification

When contacting Carrier Transicold, always specify your engine model number and serial number.
The engine’s model and serial number need to be identified before the engine can be serviced or parts replaced.

Figure 2.1 Serial Number Location

2.1.1 Engine Serial Number

The engine serial number is an identified number for the engine. It is marked after the engine model number and
indicates month and year of manufacture.

Table 2–1 Model Chart

Model Number Engine Type Service Engine Primary Use
Part Number
CT4-134-DI
V2403-CR-E4B-CTD-5 26-00159-00 Vector 8700, 8800MT, 8811MT
(1700 RPM)
CT4-134-DI
V2403-CR-E4B-CTD-2 26-00159-01 X4 7700
(1700 RPM)

2–1 62-12258
2.2 Engine Specifications
The specification described below is of the standard engine of each model.
Conversion formula: HP = 0.746 kW, PS = 0.7355 kW.
Model V2403-CR-E4B-CTD
Number of cylinder 4
Engine type Vertical, water-cooled, 4-cycle diesel
Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.)
Total displacement 2434 cm3 (148.5 cu.in.)

SAE gross continuous 32.4 kW / 2700 min-1 (rpm)

SAE gross intermittent 37.4 kW / 2700 min-1 (rpm)

Maximum bare speed 2900 min-1 (rpm)
Minimum bare 800 min-1 (rpm)
idlingspeed
Combustion chamber Reentrant type (Direct injection)
Fuel supply pump
Governor system
Injector
Fuel supply timing BOSCH common rail system
Fuel injection
pressure
Direction of rotation Counter-clockwise (Viewed from flywheel side)
Firing order 1-3-4-2
Compression ratio 18.1
Lubricating system Forced lubrication by trochoid pump
Oil pressure indicating Electrical type switch
Lubricating filter Full flow paper filter (Cartridge type)
Cooling system Pressurized radiator, forced circulation with
water pump
Starting system Electric starting with starter
Starter motor 12 V, 2.5 kW
Starting support By glow plug in combustion chamber
device
Charging alternator 12 V, 480 W
Fuel Diesel Fuel No.2- D (ASTM D975)
Lubricating oil (API
Quality Better Than CF Class (API),
classification)
SAE 10W-30 or 15W-40.
.
Lubricating oil
15 quarts (14.2 liters)
capacity
Weight (Dry) 487 lbs. (221 kg)

62-12258 2–2
2.3 Dimensions

V2403-CR-E4

A 23.46 inches (596.0 mm)

B 20.4 inches (517 mm)
C 26.49 inches (596.0 mm)

2–3 62-12258
 Figure 2.2 System Wiring Diagram

36 - Injector
37 - Shield cable

1 Main relay 13 Injector 1 25 Rail pressure sensor

2 Fuel feed pump 14 Injector 2 26 Boost pressure sensor
3 CAN1 connector (for service) 15 Injector 3 27 Stop switch
4 CAN2 connector (for vehicle) 16 Injector 4 28 Parked regeneration switch
5 Not Used 17 Crankshaft position sensor 29 Parking switch
6 Starter 18 Camshaft position sensor 30 Regeneration inhibit switch
7 Air flow sensor 19 Accel sensor 1 31 Neutral switch
8 Intake throttle valve 20 Accel sensor 2 32 Oil switch
9 Starter relay 21 Vehicle speed sensor 33 Exhaust gas temperature sen-
sor (T0)
10 Battery 22 Differential pressure sensor 34 Exhaust gas temperature sen-
(ΔP) sor (T1)
11 Glow relay 23 Suction control valve (SCV) 35 Exhaust gas temperature sen-
12 Glow heater 24 Coolant temperature sensor sor (T2)

62-12258 2–4
2.4 Special Tools
Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog (62-12253).

2.4.1 Diesel Engine Compression Tester Figure 2.3 Diesel Engine Compression Tester
(Glow Plug)

Part No. 07-00179-01 (Assembly)

Application: Use to measure diesel engine

compression and diagnosis for
major overhaul.

2.4.2 Adapter, Kubota 10 mm Figure 2.4 Adapter, Kubota 10mm

Part No. 07-00484-00

Application: Accessory for 07-00179-01

2.4.3 Oil Pressure Tester Figure 2.5 Oil Pressure Tester

Code No. 07916-32032

Application: Use to measure lubricating oil

pressure.

1. Guage 5. Threaded Joint

2. Adapter 2 6. Adapter 4
3. Cable 7. Adaptor 1
4. Adapter 3 8. Adaptor 3

2.4.4 Auxiliary Socket For Fixing Crank- Figure 2.6 Auxiliary Socket For Fixing Crankshaft Sleeve
shaft Sleeve

Code No. 07916-32091

Application: Use to fix the crankshaft sleeve

of the diesel engine.

2–5 62-12258
2.4.5 Gauge, Belt Tension Figure 2.7 Gauge, Belt Tension

Part No. 07-00203-00

Application: Used to adjust belt tension of all

cogged V-belts.

2.4.6 Tester, Belt Tension Figure 2.8 Tester, Belt Tension

Part No. 07-00253-00

Application: Used to test belt tension.

2.4.7 Rubber Band Figure 2.9 Rubber Band

Part No. 07-00253-01

Application: Replacement part for belt

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

2.4.8 Main Bearing Install Tool Figure 2.10 Main Bearing Install Tool

Part No. 07-00472-00

Application: Used on engines starting with

S/N 3S0001

2.4.9 Main Bearing Extract Tool Figure 2.11 Main Bearing Extract Tool

Part No. 07-00473-00

Application: Used on engines starting with

S/N 3S0001

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

62-12258 2–6
2.4.10 Valve Guide Replacing Tool Figure 2.12 Valve Guide Replacing Tool

Application: Use to press out and press fit

the valve guide.

A 20 mm dia. (0.79 in. dia.)

11.7 to 11.9 mm dia.

B
(0.460 to 0.468 in. dia.)

6.5 to 6.6 mm dia.

C
(0.256 to 0.259 in. dia.)

D 225 mm (8.86 in.)

E 70 mm (2.76 in.)

F 45 mm (1.77 in.)

G 25 mm (0.98 in.)

H 5 mm (0.197 in.)

6.7 to 7.0 mm dia.

I
(0.263 to 0.275 in. dia.)

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

12.5 to 12.8 mm dia. (0.492 to

K
0.504 in. dia.)

L 8.9 to 9.1 mm (0.350 to 0.358 in.)

C1 Chamfer 1.0 mm (0.039in.)

C2 Chamfer 2.0 mm (0.079in.)

C0.3 Chamfer 0.3 mm (0.012in.)

2–7 62-12258
2.4.11 Bushing Replacing Tools Figure 2.13 Brushing Replacing Tool

Application: Use to press out and press fit the

bushing

1. For small end bushing.

A 162 mm (6.38 in.)

B 35 mm (1.38 in.)

C 27 mm (1.06 in.)

D 35 mm dia. (1.38 in. dia.)

27.90 to 27.95 mm dia.

E
(1.098 to 1.100 in. dia.)

25.00 to 25.01 mm dia.

F
(0984 to 0.985 in. dia.)

2. For idle gear bushing

A 175 mm (6.89 in.)

B 40 mm (1.57 in.)

C 38 mm (1.49 in.)

D 45 mm (1.77 in.)

E 41.90 to 41.95 mm dia.

(1.650 to 1.652 in. dia.)

F 37.95 to 37.97 mm dia.

(1.494 to 1.495 in. dia.)

2.4.12 Flywheel Stopper Figure 2.14 Flywheel Stopper

Application: Use to loosen and tighten the

flywheel screw.

A 200 mm (7.87 in.)

B 20 mm (0.79 in.)

C 30 mm (1.18 in.)

D 8 mm (0.31 in.)

E 10mm (0.39 in.)

62-12258 2–8
2.4.13 Crankshaft Bearing 1 Replacing Tool Figure 2.15 Crankshaft Bearing 1 Replacing Tool

Application: Use to press out and press fit the

crankshaft bearing No. 1

1. Extracting Tool

A 130 mm (5.31 in.)

B 72 mm (2.83 in.)

C R40 mm (R1.57 in.)

D 10mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.)

64.8 to 64.9 mm dia.

G
(2.551 to 2.555 in. dia.)

59.8 to 59.9 mm dia.

H
(2.354 to 2.358 in. dia.)

2. Extracting Tool

A 130 mm (5.31 in.)

B 72 mm (2.83 in.)

C R40 mm (R1.57 in.)

D 10mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)

H 68 mm dia. (2.68 in. dia.)

59.8 to 59.9 mm dia.

I
(2.354 to 2.358 in. dia.)

64.8 to 64.9 mm dia.

J
(2.551 to 2.555 in. dia.)

2–9 62-12258
2.4.14 Crankshaft Sleeve Auxiliary Socket Figure 2.16 Crankshaft Sleeve Auxiliary Socket Stopper /
Application: Use to fix diesel engine Sleeve Guide
crankshaft sleeve
Stopper
A 80.0 mm (3.15 in.)
60.10 to 60.30 mm (2.367 to 2.374
B
in.)
C 80.0 mm dia. (3.15 in. dia.)
D 85.0 mm dia. (3.35 in. dia.)

E 60.10 to 60.30 mm dia. (2.367 to

2.374 in. dia.)
26.30 to 26.40 mm (1.036 to 1.039
F
in.)
25.85 to 25.90 mm (1.018 to 1.019
G
in.)
H 15.0 mm (0.591 in.)
Sleeve Guide
J 42.0 mm (1.65 in.)
30.50 to 30.60 mm (1.201 to 1.204
K
in.)
L 23.0 mm (0.906 in.)
M 20.0 mm (0.787 in.)
N 2.0 mm (0.079 in.)
31.911 to 31.950 mm dia. (1.2564
O to
1.2578 in. dia.)
P 30.0 mm dia. (1.18 in. dia.)
Q 5.0 mm dia. (0.20 in. dia.)
R 0.09 rad (5°)

S 25.0 mm dia. (0.984 in. dia.)

T 60.0 mm dia. (2.36 in. dia.)

U 79.80 to 79.85 mm dia. (3.142 to 3.143 in.dia.)
V 10.0 mm (0.394 in.)
W 0.04 mm dia. (0.002 in. dia.)
X 140 mm (5.51 in.)
Y 120 mm (4.72 in.)
Z 110 mm (4.33 in.)

62-12258 2–10
 Auxiliary Socket Figure 2.17 Auxiliary Socket
a 120 mm (4.72 in.)
b 110 mm (4.33 in.)
c 25.0 mm (0.984 in.)
d 90.0 mm dia. (3.54 in. dia.)
e 81.0 mm dia. (3.19 in. dia.)
80.10 to 80.15 mm dia. (3.154 to
f
3.155 in.dia.)
g 30.0 mm dia. (1.18 in. dia.)
h 5.0 mm dia. (0.20 in. dia.)
i 70.0 mm (2.76 in.)
j 50.0 mm (1.97 in.)
k 40.0 mm dia. (1.57 in. dia.)
C1 Chamfer 1.0 mm (0.039 in.)
C5 Chamfer 5.0 mm (0.20 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
R1 1.0 mm radius (0.039 in. radius)
R2 2.0 mm radius (0.079 in. radius)
R10 10.0 mm radius (0.394 in. radius)

Material S43C

2.4.15 Injection Top Injection Jig Figure 2.18 Injection Top Injection Jig

Application: Use to detect and position the

sensor in top dead center
position.
A 60 mm (2.4 in.)

B 45 mm (1.8 in.)

C 37.3 mm (1.47 in.)

D 35 mm (1.4 in.)

E 12 mm dia. (0.47 in. dia.)

F 10 mm dia. (0.39 in. dia.)

G 20.34 to 20.50 mm dia. (0.8008 to

0.8070 in. dia.)

H 1.0 rad (60°)

C1 Chamfer 1.0 mm (0.039 in.)

Material
SS400

2–11 62-12258
2.4.16 Bearing Case Cover Oil Seal Replacing Tool

Figure 2.19 Bearing Case Cover Oil Seal Replacing Tool

A 42 mm dia. (1.7 in. dia.) K 0.70 rad (40°)

B 32.000 to 32.025 mm dia. (1.2599 to 1.2608 L 129 mm dia. (5.08 in. dia.)
in. dia.)
C 116 mm dia. (4.57 in. dia.) M 31.950 to 31.975 mm dia. (1.2579 to 1.2588
in. dia.)
D 3 mm dia. (0.1 in. dia.) N 22 mm dia. (0.87 in. dia.)
E 88 mm (3.5 in.) O 145 mm dia. (5.71 in. dia.)
F 12 mm (0.47 in.) P 90 mm (3.5 in.)
G 88 mm (3.5 in.) Q 12 mm (0.47 in.)
H 92 mm (3.6 in.) C0.3 Chamfer 0.3 mm (0.01 in.)
I 100 mm (3.94 in.) C1 Chamfer 1.0 mm (0.039 in.)
I 100 mm (3.94 in.) C2 Chamfer 2.0 mm (0.079 in.)
J M8 × Pitch 1.25 C4 Chamfer 4.0 mm (0.16 in.)

62-12258 2–12
 SECTION 3
Engine Body
3.1 Engine Body

3.1.1 Engine Body Structure

The engine body consists of cylinder related components, primary motion and valve train mechanisms.

Figure 3.1 Engine Body Structure

1. Cylinder head cover 5. Flywheel housing 9. Main bearing case 13. Camshaft with cam gear
2. Rocker Arm 6. Flywheel 10. Gear case 14. Connecting rod
3. Cylinder head 7. Crankcase 11. Crankshaft 15. Breather
4. Piston 8. Oil pan 12. Idle gear

3.1.2 Engine Body Features

The engine body is the main part of the engine. It consists of cylinder related components, primary motion and
valve train mechanisms.Each of the parts are designed and assembled with passages for lubricating oil and cool-
ant for circulating within the engine.

3–1 62-12258
3.2 Disassembling and Assembling

3.2.1 Draining Coolant

Refer to Section 3.

3.2.2 Draining and Refilling Engine Oil

Refer to Section 4.2.1 and Section 4.2.2

3.2.3 External Components

3.2.3.1 Alternator, Starter and others

1. Remove the air cleaner and muffler.

2. Remove the engine stop solenoid.

3. Remove the fan and fan belt.

4. Remove the alternator

5. Remove the starter

3.2.3.2 When Reassembling

1. Replace the starter

2. Replace the alternator

3. Replace the fan and fan belt.

NOTE
• When reinstalling the fan, ensure it is sealed correctly.
• Check to see that there are no cracks in the fan belt

NOTE
After reinstalling the fan belt, be sure to adjust the fan belt tension (refer to Section 5.8)

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away form the battery at all times. Hydrogen gas mixed with oxy-
gen becomes very explosive.

NOTICE
Do not disconnect or remove the battery when engine is in operation

62-12258 3–2
 NOTE
• B Terminal: Terminal that connects the cable from the battery to the starter
• C Terminal: Terminal that connects the cable from the motor to the magnet switch.

Tools Required: Circuit tester and Jumper lead

1. Disconnect the negative cable from the battery.
2. Disconnect the positive cable from 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 C termi-
nal (1) to the battery positive terminal (2).
6. Connect a jumper lead momentarily between the
starter body and the battery negative terminal (3)

(1) C terminal
(2) Positive terminal
(3) Negative terminal
NOTE
If the motor does not operate, starter is dam-
aged. Repair or replace the starter.

3–3 62-12258
 3.2.4 Checking Suction Control Valve (SCV)
Tools Required: Circuit tester
1. Place the START/RUN-OFF switch (SROS) in
the OFF position.
2. Disconnect the SCV wiring harness connector.
3. Measure the resistance between SCV terminals
(1) and (2)
Service Specifications
Resistance = 2.6 to 3.5 Ω at 20°C / 68F
NOTE
If measurement is out of the service specifi-
cations, replace the SCV.

(1) Terminal SCV+

(2) Terminal SCV
(a) Suction control valve (SCV)

3.2.5 Selecting Cylinder Head Gasket 3.2.6 Cylinder Head Gasket

When you replace any of the items listed below, the cyl-
inder head gasket must also be replaced:
• Piston
• Piston pin
• Small end bushings
• Connecting rod
• Crankpin bearings

Tools Required: Dial Gauge

3.2.5.1 Replacing Cylinder Head Gasket

1. Note the mark (A) of cylinder head gasket in

advance.
2. Replace the same mark (A) as the original (1) Cylinder Head
cylinder head gasket. (A) Mark

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3.2.7 Measuring Angular Deviation Between Crankshaft T.D.C. and Crankshaft Position Sensor
Detected T.D.C.
Gasket Model
mark and
V2403-CR-E4
code
number
15 1G790-03600

20 1G790-03310

25 1G790-03610

30 1G790-03620

35 1G790-03630

NOTICE
If the crankshaft, flywheel housing and/or flywheel are replaced, it is necessary to calibrate the
injection timing with the diagnosis tool.

Tools Required:
• Dial gauge
• Tri-Square
• Injection top correction jig
1. Remove the cylinder head cover, injectors and rocker arm (1).
2. Bring the piston of cylinder 4 to T.D.C. for 4-cylinder or piston of cylinder 1 to T.D.C. for 3-cylinder.
3. Remove the exhaust side valve spring of #4 cylinder (2) or #1 cylinder.

(1) Rocker Arm

(2) Exhaust side valve spring of#4 cylinder

4. Insert a small o-ring (4) to prevent the exhaust valve (5) from falling into the cylinder.
5. Set a dial gauge (3) on the tip of the valve.

3–5 62-12258
 IMPORTANT

Do not drop the valve (5) into the cylinder

(3) Dial gauge

(4) O-ring
(5) Valve
6. Turn the flywheel counterclockwise and measure the position where the tip of the valve (5) is the highest.
NOTE
When measuring the highest position of the tip of the valve (5), do not rotate the flywheelclockwise. If
you go past the highest point of the valve (5), back the flywheel up slightly and measure the highest
point of the valve (5).

7. Stop the flywheel at the position where the tip of the valve (5) is the highest.
8. Put a tri-square (6) on the flywheel housing and flywheel, and draw a mark for top dead center (7) and a ref-
erence line (8).

(6) Tri-Square
(7) Mark for top dead center
(8) Reference line

9. Remove the crankshaft position sensor.

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3.2.8 Adjusting Air Gap Between Crankshaft
Position Sensor and Flywheel
Tools Required:
• Vernier caliper
• Depth gauge
1. Measure the crankshaft position sensor length
between the sensor tip and sensor flange (1)
face with vernier caliper.
2. Measure the depth from sensor attaching face of
flywheel housing to flywheel side (2) surface with
depth gauge.
3. Calculate the air gap (A) from two values.
Service Specifications:
Air Gap (A) = 0.012 to 0.059” (0.30 to 1.5mm)

(1) Crankshaft position sensor length between the sen-

sortip and sensor flange
(2) Depth from sensor attaching face of flywheel hous-
ing to flywheel side
(A) Air gap
3.2.9 Adjusting Air Gap Between Camshaft Posi-
tion Sensor and Pulsar Gear
Tools Required:
• Vernier caliper
• Depth gauge
1. Measure the camshaft position sensor length
between the sensor tip and sensor flange (1)
face with vernier caliper.
2. Measure the depth from sensor attaching face of
gear case cover to pulsar gear side surface (2)
with depth gauge.
3. Calculate the air gap (A) from two values.
Service Specifications:
Air Gap (A) = 0.0079 to 0.051” (0.20 to 1.3mm)

(1) Camshaft position sensor length between the sensor

tip and sensor flange
(2) Depth from sensor attaching face of gear case cover
to pulsar gear side surface
(3) Set the reference pulsar hole (12) hole (12) to crank-
shaftposition sensor mounting hole (11) by rotating fly-
wheel (10) counterclockwise.
(A) Air gap

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 NOTE
Reference pulsar hole (12) is the 17th hold for 3-cylinder models or 20th hole for 4-cylinder models by
rotating counterclockwise from the area where there is no pulsar hole (9).

(9) Area where there is no pulsar hole

(10) Flywheel
(11) Crankshaft position sensor mounting hole
(12) Reference pulsar hold (17th 3-cylinder models/20th 4-cylinder models)

4. Insert a special tool that injection top correction jig (13) intro the crankshaft position sensor mounting hole
and align the center of the handle and pulsar.

(13) Injection top correction jig

5. This position is the crank position sensor top dead center detection position so position the tri-square on
the reference line (15) set in the previous item and make a crank position sensor top dead center detection
position mark (16) on the flywheel.

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 (14) Tri-square
(15) Reference line
(16) Mark of crankshaft position sensor top dead center detection position
6. Measure the difference (A0 between the top dead center mark (17) and the crankshaft position sensor top
dead center detection position mark (18).

(17) Mark for top dead center

(18) Mark of crankshaft position sensor top dead center detection position
(19) Difference (mm)
7. Calculate the fuel injection timing correction by difference (A)
IMPORTANT
• 1 MM = 360° / (Flywheel Diameter × π)
• If the crankshaft position sensor top dead center detection position is in front of top dead center,
enter a negative value.
• If the crankshaft position sensor top dead center detection position is in the back of top dead center,
enter a positive value

NOTE
Corrected angle = (360 / (flywheel diameter ×π)) × difference (A)

8. Overwrite the injection timing correction value in the engine ECU.

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3.2.10 Adjusting Valve Clearance

NOTICE
You must check and adjust the valve clearance when the engine is cold

Tools Required: Feeler gauge

1. Remove the air cleaner and muffler.
2. Remove the cylinder head cover.
3. Align the [1TC] mark (2) line on the flywheel and projection on the housing.

4. Ensure that the No. 1 piston comes to the compression or overlap top dead center.
5. Check the subsequent valve clearance (5) at the mark [1TC] with the feeler gauge.
NOTE
If the clearance is out of the service specifications, adjust with the adjusting screw (3). Tighten the lock
nut (4) of the adjusting screw.

Valve Clearance (cold) Service Specifications =

0.0071 to 0.0086 in (0.18 to 0.22 mm)

(3) Adjusting screw

(4) Lock nut
(5) Valve clearance

62-12258 3–10
 Table 3–1 Valve Clearance

6. Install the removed parts.

Table 3–2 Tightening Torque - Cylinder Head Cove
6.86 to 11.3 N:m
Tightening Cylinder head 0.700 to 1.15 kgf:m
torque cover screw 5.06 to 8.33 lbf ⋅ ft

3–11 62-12258
3.3 Component Disassembly

3.3.1 Draining Engine Oil

1. Warm up the engine and then stop it by placing the START/RUN-OFF switch in the OFF position.
2. Ensure the unit will not start automatically by disabling the starter.
3. If available, install oil drain tool (CTD part number 68-15763-01) (Figure 8.10.)The oil drain tool not only
directs the oil over the door latch pin bracket and bottom panel on units so equipped, but also holds a typical
drain bucket in place while the oil is draining from the engine.
4. Remove drain plug, drain engine oil. Replace plug and refill engine with oil.

(1) Drain plug

Table 3–3 Drain Plug Torque Specifications

32.4 to 37.2 N ⋅ m
Tightening 3.31 to 3.79 kgf ⋅ m
Drain plug (1)
torque 23.9 to 27.4 lbf ⋅ ft

3.3.2 Draining Coolant

! CAUTION
Do not remove the radiator cap while the engine is in operation or immediately after you stop
the engine as hot water can flow out from the radiator possibly causing injury. Allow a mini-
mum of ten minutes to pass allowing for the radiator temperature to cool.

1. Drain coolant completely by removing radiator cap and then the lower radiator hose or drain plug located at
the opposite end of the radiator.

(1) Radiator cap

62-12258 3–12
1. Install hose or drain plug, and fill the system with clean, untreated water.

(2) Drain Plug

NOTE
NEVER POUR COLD WATER INTO A HOT ENGINE. However, hot water can be added to a cold
engine.

2. Start the engine and drain system while warm. Rinse system three times after it has cooled down. Refill sys-
tem with water.
3. Run engine to operating temperature. Drain system again and fill with 50/50 water/anti-freeze mixture.
4. Reinstall the negative battery cable, start unit and check for leaks.

3–13 62-12258
3.3.3 Removing Common Rail

! CAUTION
Do not loosen the injection pipe (1) when fuel is under high pressure (within five minutes of
stopping the engine).

NOTE
• Replace the rail assembly if the exchange of the pressure limiter (3) or the rail pressure sensor (5) if nec-
essary.
• DO not remove the pressure limiter (3) and rail pressure sensor (5) from the common rail (4).
• When removing the common rail (4), do not hold it by the pressure limiter (3) and rail pressure sensor (5).
1. Remove the injection pipe (1).
2. Remove the overflow pipe and hose (2). To remove the overflow hose, push the retainer (3) in the direction
(A) of the arrow.
IMPORTANT
• Store the injection pipe (1) so that dust cannot get into it.
• Do not apply strong impact or excessive load to the connector of the overflow pipe and hose (2).
• Before starting the engine, ensure the overflow pipe and hose (2) are not damaged.

(1) Injection pipe (2) Overflow pipe and hose

(3) Retainer (A) Direction

Important
Store the common rail in such a way that no dust can get into it.

62-12258 3–14
 (4) Pressure limiter
(5) Common rail
(6) Rail pressure sensor
3.3.4 Removing Sensors
1. Remove the coolant temperature sensor (1).

(1) Coolant temperature sensor

2. Remove the crankshaft position sensor mounting screw.

3. Remove the camshaft position sensor (2).

(2) Camshaft position sensor

(3) Camshaft position sensor mounting screw

4. Remove the crankshaft position sensor mounting screw (5).

5. Remove the crankshaft position sensor

3–15 62-12258
 (4) Crankshaft Position Sensor
(5) Crankshaft position sensor mounting screw
IMPORTANT
If you drop the sensor, do not use it.

6. Remove the boost pressure sensor mounting screw (7).

(7) Boost pressure sensor mounting screw.

3.3.5 Removing Cylinder Head Cover
1. Remove the cylinder head cover (1).

(1) Cylinder head cover

62-12258 3–16
3.3.6 Removing Injector
1. Remove the injector clamp (2).
2. Remove the injector (1) and its gasket (4)
IMPORTANT
• Do not disassemble the injector (1).
• Do not damage the injector ID code (6).
• Do not get the injectors out of order.
• If the injector become out of order, injector code correction must be performed (writing injector codes (6) to
the engine ECU).
• Store injectors so they don’t get dust in them.

(1) Injector
(2) Injector clamp
(3) O-ring
(4) Gasket
(5) Injector clamp mounting screw
(6) Injector ID code

3–17 62-12258
3.3.7 Removing Rocker Arm Assembly

1. Remove the rocker arm assembly (1).

(1) Rocker arm assembly

2. Remove the push rods (2).

(2) Push rods

3.3.8 Removing Cylinder Head

1. Remove the intake manifold (1).

(1) Intake manifold

2. Remove the exhaust manifold (2).

62-12258 3–18
 (2) Exhaust manifold
3. Remove the cylinder head mounting screw in the sequence of (n or r) to (a).

(A) Gear case side

(B) Flywheel side

4. Remove the cylinder head (3) and cylinder head gasket (4).

3–19 62-12258
3.3.9 Removing Tappet

NOTE
Mark the cylinder number to the tappets to prevent interchanging.

1. Remove the tappets (1) from the crankcase (2).

(1) Tappet
(2) Crankcase
3.3.10 Removing Valve

NOTE
Mark the cylinder number to the valves to prevent interchanging.

Tools required: Valve spring compressor

1. Remove valve cap (6).
2. Push the valve spring (3) with the valve spring retainer (4) by valve spring compressor and remover valve
spring collets (5).
3. Remove valve spring (3), valve spring retainer (4) and valve (3).
4. Remove the valve stem seal (1).

(1) Valve stem seal

(2) Valve
(3) Valve spring
(4) Valve spring retainer
(5) Valve spring collet
(6) Valve cap

62-12258 3–20
3.3.11 Removing Thermostat Assembly
1. Remove thermostat cover mounting screws and thermostat cover.

(1) Thermostat cover

2. Remove thermostat assembly (2).

(2) Thermostat assembly

3.3.12 Removing Suction Control Valve (SCV)

IMPORTANT
• To determine whether or not it is necessary to replace the SCV, refer to related DTC decision flow (P0089,
P0628 and P0629) of diagnosis manual (DM).
• Perform this procedure without taking a break and leaving work during replacement. Keep kit parts
unopened until just before replacement.
• Replacement parts should not be dropped or subjected to impact. Do not use the parts if they have been
dropped.

Tools Required: Hexagon wrench (4 mm square)

1. Remove the SCV mounting screws (2) with hexagon wrench.
2. Remove SCV (1), carefully from the supply pump housing.

NOTE
• Ensure that no foreign materials get into the supply pump or on the SCV mounting surface during SCV
replacement.
• After removal, keep the removed part of the supply pump side without wipe with waste cloth
• DO not work with slanted and insufficient installation of hexagon wrench. Do not crush the hexagon socket.

3–21 62-12258
 • Confirm that no O-ring remains at the supply pump body side. Remove if necessary.

(1) SCV
(2) SCV mounting screw
3.3.13 Removing Supply Pump
1. Remove the fuel feed pump (1).

(1) Fuel feed pump

2. Remove the supply pump (2).

(2) Supply pump

62-12258 3–22
3.3.14 Removing Water Pump
1. Remove the water pump (1).

(1) Water pump

3.3.15 Removing Fan Drive Pulley

Tools Required:
• Flywheel stopper
• Gear puller
• 46 mm(1.8 inch) deep socket wrench
1. Mount a flywheel stopper (1) on the flywheel.

(1) Flywheel stopper

2. Remove the fan drive pulley mounting nut (2) with the deep wrench socket (3).
3. Remove the fan drive pulley (4) with gear puller.

3–23 62-12258
 (2) Fan drive pulley mounting nut

(3) 46 mm (1.8 in) deep socket wrench

(4) Fan drive pulley
4. Remove feather key.

3.3.16 Removing Gear Case Cover

1. Remove the hour meter gear case cover (if attached).
2. Remove gear case cover (1).

(1) Gear case cover

3.3.17 Removing Crankshaft Oil Slinger

1. Remove crankshaft collar (3).
2. Remove the O-ring (2).
3. Remove the crankshaft oil slinger (1).

62-12258 3–24
 (1) Crankshaft oil slinger
(2) O-ring
(3) Crankshaft collar
3.3.18 Removing Idle Gear
Tools Required:
• Gear puller
• Flywheel stopper
1. Mount a flywheel stopper (1) on the flywheel.

(1) Flywheel stopper

2. Loosen the oil pump drive gear 1 mounting nut (5).
3. Remove the oil pump drive gear 2 (4) with gear puller.
4. Remove the idle gear collar (2).
5. Remove the idle gear (3).

(2) Idle gear collar

(3) Idle gear

3–25 62-12258
 (4) Oil pump drive gear 2
(5) Oil pump drive gear 1 mounting nut
3.3.19 Removing Fuel Camshaft Assembly
1. Remove the fuel camshaft stopper (1).
2. Pull out the fuel camshaft assembly (2).

(1) Fuel camshaft stopper (2) Fuel camshaft assembly

3.3.20 Removing camshaft with Cam Gear

Remove the camshaft set screws and draw out the camshaft (1) with cam gear (2).

(1) Camshaft (2) Cam gear

3.3.21 Removing Oil Pump

Tools Required: Gear Puller
1. Remove the oil pump drive gear 1 mounting nut (1).

(1) Oil pump drive gear 1 mounting nut

62-12258 3–26
 2. Pull out the oil pump drive gear 1 (2) with gear puller (3).

(2) Oil pump drive gear 1 (3) Gear puller

3. Remove the oil pump (4)

(4) Oil pump

3.3.22 Removing Crank Gear

Tools Required: Gear puller
1. Remove the crank gear (2) with gear puller (1).
2. Remove the feather key.
3. Remove the idle gear shaft (3).

(1) Gear puller

(2) Crank gear
(3) Idle gear shaft

3–27 62-12258
3.3.23 Removing Oil Pan and Oil Strainer
1. Remove the oil pan (1).

(1) Oil pan

2. Remove the oil strainer (2).
NOTE
Be careful not to damage the O-ring.

3.3.24 Removing Piston

1. Turn the flywheel and move piston to bottom dead center.
2. Remove connecting rod screws (1).
3. Remove connecting rod cap (2).

(1) Connecting rod screw

(2) Connecting rod cap.

4. Thoroughly clean carbon in the cylinders.

5. Turn the flywheel and move the piston (3) to top dead center.

62-12258 3–28
 6. Pull the piston (3) out by lightly tapping the large end bore of the connecting rod from the bottom of the
crankcase using the grip of a handle.
IMPORTANT
Do not change the combination of cylinder and piston. Align the position of each piston by its mark. For example,
mark “1” on the No. 1 piston.

(3) Piston

3.3.25 Removing Piston Ring

Tools Required: Piston ring pliers
1. Remove the top ring (1) and second ring (2) with piston ring pliers.

(1) Top ring (2) Second ring

2. Remove oil ring (3) with piston ring pliers and expander (4).

(3) Oil ring (4) Expander

3–29 62-12258
3.3.26 Disassembling Piston Assembly

1. Remove the pin snap ring (1) from piston (2).

2. Remove the piston pin (4) to disconnect the connecting rod (3) from the piston.
IMPORTANT
Put a mark on the connecting rod (3) and piston (2) with the same number to retain the same combination.
NOTE
If you cannot easily remove the piston pin (4), put the entire piston in 176°F (80°C) oil for 10 to 15 min-
utes.

(1) Piston pin snap ring

(2) Piston
(3) Connecting rod
(4) Piston pin

3.3.27 Removing Flywheel

IMPORTANT
The flywheel is very heavy, so be sure to hold it carefully when removing.
NOTE
Do not use an impact wrench as serious damage will occur.

Tools Required:
• Flywheel stopper
• Flywheel guide screw
1. Attach the flywheel stopper (1) to the flywheel.
2. Remove the flywheel screws (2).

(1) Flywheel stopper (2) Flywheel screw

3. Set the flywheel guide screw (4).

62-12258 3–30
 4. Remove the flywheel (3).

(3) Flywheel (4) Flywheel guide screw

3.3.28 Removing Flywheel Housing

1. Remove the flywheel housing (1).

(1) Flywheel housing

3.3.29 Removing Bearing Case Cover

NOTE
Before disassembling, check the side clearance of the crankshaft. Be sure to check this during reassem-
bly as well.

1. Remove the inner mounting screws of the bearing case cover (1).
2. Remove the external mounting screws of the bearing case cover (2).
NOTE
The length of the inner mounting screws (1) and the external mounting screws of the bearing case
cover are different.

3–31 62-12258
 (1) Inner mounting screw
(2) External mounting screw

3. Remove bearing case cover (3).

(3) Bearing case cover

3.3.30 Removing Crankshaft

NOTE
Before disassembling, check the side clearance of the crankshaft. Be sure to check this during reassem-
bly as well.

1. Remove the main bearing case mounting screw 2 (1).

(1) Main bearing case mounting screw 2

2. Turn the crankshaft to set the crankpin of the fourth cylinder to the horizontal directions (right or left).
3. Hold the crankpins to the horizontal directions (right or left) and pull out the crankshaft completely.

3.3.31 Removing Main Bearing Case

1. Remove the main bearing case screw 1 (2) and then remove the main bearing case (1).

62-12258 3–32
 ! CAUTION
DO NOT change the combination of the main bearing case.

(1) Main bearing case

(2) Main bearing case screw 1

2. Remove other main bearing cases using above procedure.

3.4 Component Installation

3.4.1 Main Bearing Case Installation

1. Install the main bearing case (7).
IMPORTANT
• Clean the oil channel in the main bearing case.
• Align the numbers (1) on the main bearing case.
• When you install the main bearing case, point the [FLYWHEEL] mark (2) to the flywheel.
NOTE
• Apply oilk to the crankshaft bearing.
• When you install the thrust bearing, point the oil groove (8) externally.

3–33 62-12258
 • Install the main bearing case assemblies in the initial positions. Since the diameters of the main bearing
cases are different, install them in the sequence of their marks (A, B, C) from the gear case cover side.

62-12258 3–34
 2. Tighten the main bearing case screw 1 to the specified torque.
NOTE
• Apply engine oil to the main bearing case screws 1.
• After you tighten the main bearing case screw 1 to the specified torque, make sure that the main bearing
case moves smoothly.

3.4.2 Crankshaft Installation

NOTE
Measure the side clearance of the crankshaft when reassembling.

1. Hold the crankpins to the horizontal directions (right or left) and install the crankshaft completely intocrank-
case.

3–35 62-12258
 2. Turn the crankshaft to set the crankpin of the fourth cylinder to the horizontal directions (right or left).
3. Align the screw hole of the main bearing case with the screw hole of the crankcase.
4. Install the main bearing case screw 2 (1) by hand.

NOTE
• Apply oil to the main bearing case screw 2.
• If you cannot turn the screw 2 smoothly, align the screw holes correctly between the crankcase and main
bearing case.

(1) Main bearing case screw 2

5. Tighten the main bearing case screw 2 (1) to specified torque.

Refer to Section 3.2.7

3.4.3 Bearing Case Cover Installation

IMPORTANT
• If replacement of the oil seal is required, the seal should be flush with the cover not tilted.
• Before installing the bearing case cover / oil seal, lube the seal and install in such a way as to not dam-
age the seal.

NOTE
Check the side clearance of the crankshaft after assembly.

1. Attach the bearing case gasket (1) and the bearing case cover gasket (2) in the correct position of the
upside mark (a).

(1) Bearing case gasket

(2) Bearing case cover gasket

62-12258 3–36
 (a) Upside mark

2. Put the casting mark [UP} (A) of the bearing case cover (6) upward and then install the bearing case cover
(6).
IMPORTANT
The length of inner mounting screws of the bearing case cover (4) and external mounting screws of bearing case
cover (3) are different. Make sure you use the correct screws at the correct position.
NOTE
Apply a thin layer of engine oil to the oil seal (5) and then install the oil seal so that it does not come off
the lip.

(3) External mounting screw

(4) Internal mounting screw
(5) Oil seal
(6) Bearing case cover
(A) Casting mark [UP]

3. Tighten the inner mounting screws of bearing case cover (4) and external mounting screws of bearing case
cover (3) to the specified tightening torque with even force on the diagonal line.

3–37 62-12258
3.4.4 Flywheel Housing Installation
1. Install the flywheel housing (1).

(1) Flywheel housing

NOTE
Tighten the flywheel housing mounting screws with even force on the diagonal line.

Refer to Section 3.2.7

3.4.5 Flywheel Installation

IMPORTANT
The flywheel is very heavy so be sure to hold it securely when installing.
NOTE
Do not use an impact wrench. Serious damage will occur.

Tools Required:
• Flywheel stopper
• Flywheel guide screw
1. Set the flywheel guide screw3 (2).
2. Install the flywheel (1).
3. Attach the flywheel stopper and tighten to the specified torque.
NOTE
• Apply engine oil to the flywheel screws.
• Check that there are no metal particles remaining on the flywheel mounting surfaces.
• The flywheel and crankshaft fit together in just on position. Make sure they fit securely and tighten the
screws.

62-12258 3–38
 (1) Flywheel (2) Flywheel guide screw

Refer to Section 3.2.7

3.4.6 Assembly the Piston Assmbly

! CAUTION
The end faces of the oil ring are plated withhard chrome. When you install the piston into
the cylinder, do not give a damage to the cylinder by the oil ring. If the ring's planting is
scratched, it may get stuck on the cylinder wall, causing serious damage.

IMPORTANT
Put a mark on the connecting rod and piston with the same number to keep the same combination.
1. Put the piston fully in 80 ℃ (176 ℉) oil for 10 to 15 minutes.
2. Install the piston pin (4) and the connecting rod (2) to the piston (1).
NOTE
• Apply engine oil to the piston pin.
• Align the mark [FW] (5) on the piston to the flywheel side and the connection rod mark (3) to the supply
pump side.

(1) Piston
(2) Connecting rod
(3) Mark
(4) Piston pin
(5) Mark [FW]

3–39 62-12258
 3. Install the piston pin snap ring (6)

(6) Piston pin snap ring

3.4.7 Piston Ring Installation

Tools Required: Piston ring pliers

4. Install the oil ring (3) to the piston with the piston ring pliers.

(1) Expander joint

(2) Oil ring gap
(3) Oil ring

5. Install the second ring (6) and top ring (5) to the piston with the piston ring pliers.
NOTE
Set the manufacturer mark (4) upward.

62-12258 3–40
 (4) Manufacturer mark
(5) Top ring
(6) Second ring

3.4.8 Piston Installation

IMPORTANT
• Do not change the combination of cylinder number and piston.
• Align the position of each piston with its mark. For example, mark “1” on the No.1 piston.
Tools Required: Piston ring compressor

1. Clean the carbon in the cylinders.

2. Turn the flywheel and move the crankshaft to top dead center.
3. Place the gap of each piston ring as shown in the figure below.

(A) Top ring gap

(B) Second ring gap
(C) Oil ring gap
(D) Piston pin hole
(a) 2.09 rad (120°)

4. Set the piston ring compressor (1) to the piston.

5. Install the piston to the cylinder.

3–41 62-12258
 IMPORTANT
Carefully set the piston ring compressor. If care is not taken, the chrome-plated section of the piston rings may be
scratched, causing trouble inside the liner.
NOTE
• Apply sufficient engine oil to the piston.
• Align the mark [FW] (2) on the piston face to the flywheel side.
• Align the marks (3) with each other.

(1) Piston ring compressor

(2) Mark [FW]
(3) Mark

6. Turn the flywheel and move the piston to button dead center.
7. Install the connection rod cap (5) and loosely tighten the connecting rod screw (4) by hand.

62-12258 3–42
 NOTE
• Apply engine oil to the connecting rod screws.
• If the connecting rod screw does not screw in smoothly, clean the threads. If it is still difficult to insert, replace
it.
• When reusing the existing crankpin bearing, put tally marks on the crankpin bearing and connecting rod to
retain their positioning.

(4) Connecting rod screw (5) Connecting rod cap

3.4.9 Oil Strainer and Oil Pan Installation

NOTE
Clean the oil pan and crankcase surface that are attached to each other.

Tools Required: Liquid gasket

1. Install the oil strainer.

NOTE
• Use care not to damage the O-ring
• Clean the oil strainer (1) before installing it

(1) Oil strainer

NOTE
• Confirm that the liquid gasket (2) coating surface is free of water, dust and oil in order to keep sealing effect.
• Make sure the surfaces align when mounting parts with a liquid gasket (2) applied.

3–43 62-12258
 • Carefully and evenly apply the liquid gasket (2).

(2) Liquid gasket

2. Install the oil pan (3)

NOTE
• Mount parts with a liquid gasket within ten minutes of application.
• Tighten oil pan mounting screws (3) in diagonal sequence from the center to tighten equally.
• Install the oil pan (3) with its central drain plug facing towards the air suction side.

(3) Oil pan

3.4.10 Crank Gear Installation

1. Install the crank gear (1).

(1) Crank gear

2. Install the idle gear shaft.

62-12258 3–44
3.4.11 Oil Pump Installation
1. Install the oil pump (1).

(1) Oil pump

2. Install the oil pump drive gear 1 (2).
NOTE
After the oil pump drive gear 1 (2) is installed, loosely tighten the oil pump drive gear 1 mounting nut (3). Tighten
the oil pump drive gear 1 mounting nut (3) completely to the specified torque after installing oil pump drive gear 2.

(2) Oil pump drive gear 1

(3) Oil pump drive gear 1 mounting nut
3.4.12 Camshaft with Cam Gear Installation
1. Install the camshaft (1) with cam gear (2).
2. Tighten the camshaft set screw to the specified torque.

3–45 62-12258
 (1) Camshaft
(2) Cam gear

62-12258 3–46
3.4.13 Fuel Camshaft with Supply Pump Gear Installation
1. Install the fuel camshaft with supply pump gear (2).
2. Install the fuel camshaft stopper (1).
NOTE
After installing the fuel camshaft, store oil in the pump room as shown in drawing Recommended oil
amount: More than 50 ml(cc)

(1) Fuel camshaft stopper

(2) Fuel camshaft with supply pump gear
(3) Oil

3–47 62-12258
3.4.14 Idle Gear Installation

1. Install the idle gear (2) and idle gear collar.

IMPORTANT
• Apply the engine oil inside the idle gear (2)
• When mounting the idle gear (2), bring the piston of cylinder 1 to T.D.C (refer to Section 3.2.7) and mount
the gears with their marks aligned to the respective gears.
a. Idle gear (2) and cam gear (3)
b. Idle gear (2) and crank gear (4)
c. Idle gear (2) and supply pump gear (1)

(1) Supply pump gear

(2) Idle gear
(3) Cam gear
(4) Crank gear
(5) Oil pump drive gear 1

2. Tighten the idle gear mounting screw to thespecified torque.

3. Install the oil pump drive gear 2 (6).

(6) Oil pump drive gear (2)

62-12258 3–48
 4. Tighten the oil pump drive gear 1 (5) mounting nut completely to the specified torque after installing oil pump
drive gear 2 (6).

3.4.15 Crankshaft Oil Slinger Installation

1. Install the crankshaft oil slinger (1).
2. Install the O-ring (2).
NOTE
Attach the crankshaft collar (3) after installing the gear case cover to the crankcase.

(1) Crankshaft oil slinger

(2) O-ring
(3) Crankshaft collar
3.4.16 Gear Case Cover Installation
1. Install the gear case cover gasket.
2. Install the gear case cover (1).
3. Apply oil to the lip of the oil seal.

(1) Gear case cover

3–49 62-12258
3.4.17 Fan Drive Pulley Installation
Tools Required:
• Flywheel stopper
• 46mm (1.8”) deep socket wrench
1. Mount the flywheel stopper (1) on the flywheel.

(1) Flywheel stopper

2. Install the feather key.
3. Install the fan drive pulley (2).
4. Install the fan drive pulley mounting nut (4) and tighten to specified torque with the 46mm (1.8”) deep socket
wrench (3).
NOTE
Apply grease to the splines of coupling.

(2) Fan drive pulley

(3) 46mm deep socket wrench
(4) Fan drive pulley mounting nut

3.4.18 Water Pump Installation

1. Install the water pump (1).
NOTE
Do not forget to mount the O-ring and to keep it in position.

62-12258 3–50
 (1) Water pump

3.4.19 Supply Pump Installation

NOTE
• Do not disassemble the supply pump.
• When attaching the supply pump to crankcase, do not apply force on the SCV and overflow sections of the
part.
• Do not remove the dust protection cap until immediately before you attach the part.
1. Install the supply pump (1) and tighten the supply pump mounting nut / screw to the specified torque.

(1) Supply pump

2. Install the fuel feed pump (2).

(2) Fuel feed pump

3–51 62-12258
3.4.20 Suction Control Valve (SCV) Installation

NOTE
Replace the SCV O-ring with a new one.

Tools Required:
• Silicone grease
• Hexagon wrench (4mm square)

1. Install the SCV O-ring (1).

NOTE
Apply clean silicone grease to the tip of the SCV O-ring.

2. Install the SCV until it hits the supply pump housing and tighten to the specified torque with the hexagon
wrench.
NOTE
Turn the SCV (1) carefully and prevent the SCV from jamming the O-ring.

(1) SCV (2) SCV mounting screw

3.4.21 Thermostat Assembly Installation

NOTE
Replace the gasket with a new one

1. Install the thermostat assembly (1).

NOTICE
Make sure that the direction of the jiggle valve is oriented to the coolant temperature sensor.

(1) Thermostat assembly

62-12258 3–52
 2. Install the thermostat cover (2).

(2) Thermostat cover

3.4.22 Valve Installation

NOTE
Clean the valve stem and valve guide hole.

Tools Required: Valve spring compressor

1. Install the valve stem seal (1).
NOTE
Install a sufficient amount of engine oil.

2. Install the valve (2).

3. Set the valve spring (3) and valve spring retainer (4).
4. Compress the valve spring with valve spring compressor and install the valve spring collet (5).

(1) Valve stem seal

(2) Valve
(3) Valve spring
(4) Valve spring retainer
(5) Valve spring collet
(6) Valve cap

5. Remove the valve spring compressor.

6. After installing the valve spring collets (5), lightly tapthe stem tip to attach it correctly with the plastic ham-
mer.
7. Install the valve cap (6).

3.4.23 Tappet Installation

IMPORTANT
Do not change the combination of cylinder number and tappet.
NOTE
Apply engine oil thinly around tappets.

3–53 62-12258
 1. Install the tappets (1) to the crankcase (2).

(1) Tappet (2) Crankcase

3.4.24 Cylinder Head Installation

IMPORTANT
• When replacing the piston, piston pin bushing, connecting rod or crankpin bearing, select the cylinder head
gasket (2) thickness to meet the top clearance. Refer to Section 3.2.5 (Selecting Cylinder Head Gasket).
• Before replacing the cylinder head gasket (2), record the mark on the cylinder head gasket on the engine
and then replace a cylinder head gasket with the same mark.
NOTE
• Replace the cylinder head gasket (2) with a new one.
• The cylinder head (1) should be free of scratches and dust.
1. Install the cylinder head gasket (2).
NOTE
• When installing the gasket, set it to the knock pin hole. Take care not to mount it in reverse.
• Take care handling the gasket so as not to damage it.
2. Install the cylinder head (1) and tighten to specified torque.
NOTE
• If you are reusing the cylinder head mounting screw, apply engine oil. You do not need engine oil if you are
using a new cylinder head mounting screw.
• Tighten the cylinder head mounting screw gradually in the sequence of (a) to (n or r).

62-12258 3–54
 (1) Cylinder head
(2) Cylinder head gasket
(A) Gear case side
(B) Flywheel side
3. Install the exhaust manifold (3) and tighten to the specified torque.
NOTE
Replace the exhaust manifold with new one.

(3) Exhaust manifold

4. Install the intake manifold (4) and tighten to the specified torque.
NOTE
Replace the intake manifold gasket with a new one.

3–55 62-12258
 (4) Intake manifold
Refer to Section 3.2.5 (Selecting Cylinder Head Gasket)

3.4.25 Rocker Arm Assembly Installation

1. Install the push rod (1).
NOTE
When installing the push rod (1), mount it securely in the groove of the tappet (2).

(1) Push rod

(2) Tappet

2. Install the rocker arm assembly (3) and tighten the rocker arm bracket screw to the specified torque.

62-12258 3–56
 IMPORTANT
After installing the rocker arm assembly, adjust the valve clearance.

(3) Rocker arm assembly

Refer to Section 3.2.10 (Adjusting Valve Clearance).

3.4.26 Injector Installation

IMPORTANT
• Do not disassemble the injector
• Do not damage the injector ID code (1)
• Do not get the injector our of order. In the injectors get out of order, it will be necessary to perform injector
correction (writing injector codes (1) to the engine ECU).
• Store the injectors so they do not get dust in them.
• If you are replacing the injectors, you must perform injector correction (writing injector ID codes to the engine
ID to the engine ECU).

(1) Injector ID code

1. Install the injector (2) and gasket (4).
NOTE
Replace the injectors’ gaskets (4) with new ones.

2. Install the injector clamp (3) and tighten to the specified torque.

3–57 62-12258
 NOTE
When installing injector clamps (3), set them correctly as show in the drawing.

(2) Injector
(3) Injector clamp
(4) Gasket
(5) Injector clamp screw

Refer to Replacing Injector section.

62-12258 3–58
3.4.27 Glow Plug Installation
1. Install the glow plugs (1).
NOTE
• Adjust the direction of the ditch to the terminal side when the seal (2) is installed in the glow plug (1).
• After installing the glow plug (1), make sure that the seal (2) was set to the specified position.

(1) Glow plug

(2) Seal
(A) Good
(B) Bad

2. Install the glow lead (3).

(1) Glow plug (3) Glow lead

3.4.28 Cylinder Head Cover Installation

NOTE
Replace the gasket with a new one.

3–59 62-12258
 1. Install the cylinder head cover (1) and tighten to the specified torque.

(1) Cylinder head cover

3.4.29 Sensor Installation

IMPORTANT
Do not reuse the sensor if you drop it.
NOTE
• Replace the gasket with a new one.
• Replace the O-ring with a new one.
1. Install the coolant temperature sensor (1) and tighten to the specified torque.

(1) Coolant temperature sensor

2. Install the camshaft position sensor (2)
3. Tighten the camshaft position sensor mounting screw (3) to the specified torque.
NOTE
If you are replacing the camshaft position sensor, measure the air gap between camshaft position sen-
sor and pulsar gear.

62-12258 3–60
 (2) Camshaft position sensor
(3) Camshaft position sensor mounting screw
4. Install the crankshaft position sensor (4).
5. Tighten the crankshaft position sensor mounting screw (5) to the specified torque.
NOTE
If you are replacing the crankshaft position sensor, measure the air gap between the crankshaft posi-
tion sensor and flywheel.

(4) Crankshaft position sensor

(5) Crankshaft position sensor mounting screw

3–61 62-12258
3.4.30 Common Rail Installation
IMPORTANT
If the exchange of the pressure limiter (1) or the rail pressure sensor (3) is necessary, replace the rail assembly.
NOTE
• Do not remove the pressure limiter (1) and rail pressure sensor (3) from the common rail (2).
• When installing the common rail (2), do not hold it by the pressure limiter (1) and rail pressure sensor (3).
1. Install the common rail (2).

(1) Pressure limiter

(2) Common rail
(3) Rail pressure sensor

2. Connect the overflow pipe and hose (4).

3. Tighten the overflow pipe joint screw to the specified torque.
4. Install the injection pipes (5).
5. Tighten the injection pipe retaining nut to the specified torque.
IMPORTANT
• Do not apply strong impact or excessive load to the connector of the overflow pipe and hose (4).
• Before starting the engine, make sure that the overflow pipe and hose (4) is not damaged.

(4) Overflow pipe and hose

(5) Injection pipe

62-12258 3–62
3.4.31 CRS Intermediate Harness Installation
1. Connect the engine intermediate harness (engine side).

2. Connect the injector intermediate har-

ness (engine side)

(4) Name plate

(22) Injector connector (10P)
(23) Injector intermediate connector
(12P)
(k) Clamp

3. Connect the air flow sensor intermediate

harness (engine side)

(24) Air flow sensor intermediate con-

nector (6P)
(25) Air flow sensor connector (5P)

3–63 62-12258
 4. Connect engine ECU intermediate har-
ness

(31) Injector intermediate harness

(32) Engine intermediate harness
(33) Not used

62-12258 3–64
3.4.32 External Component Installation

NOTE
Check for cranks on the fan belt surface.

1. Install the fan pulley (2) and loosely tighten the cooling fan mounting screw.
IMPORTANT
• Do not put the cooling fan (1) in the incorrect direction.
• Install the cooling fan so that the parts number (3) of the cooling fan is toward the front side (radiator side).

(3) Part number

(2) Fan Pulley
2. Install the alternator (4).
3. Install the fan belt (6).
4. Tighten the cooling fan mounting screw (5)

3–65 62-12258
 IMPORTANT
After installing the fan belt, adjust the fan belt tension

10.0 to 12.0 mm
Service specification 0.394 to 0.472 in.
Deflection (A) (under load of 98 N
(10 kg, 22.1 lbf))

9.81 to 11.3 N ⋅ m
1.00 to 1.15 kgf ⋅ m
Cooling fan mounting
Tightening Torque 7.24 to 8.33 lbf ⋅ ft
screw (5)

5. Install the oil separator (7).

(4) Alternator (6) Fan belt

(7) Oil Separator

62-12258 3–66
 3.4.34 Filling Engine Oil
IMPORTANT
6. Install the starter (8) • Do not mix different types of oil
• Use the correct SAE engine oil by reference to the ambi-
ent temperature.

NOTE
Make sure the drain plug is tightened.

1. Fill the engine oil until the upper line (a) on the dipstick
from filling port.

3.4.33 Filling Coolant

IMPORTANT
• Do not mix the different type or brand of
L.L.C
• Do not use an anti-freeze and scale
inhibitor at this time.

NOTE
Make sure the drain valve is closed

1. Fill the coolant until below the port from

filling port. (a) Upper line
IMPORTANT (b) Lower line
• Make sure that you close the radiator
cap correctly.
• When you add the coolant, release
the air from the engine coolant channels.
• The engine releases the air when it
shakes the radiator upper and lower
hoses.

3–67 62-12258
3.5 Servicing Components

3.5.1 Checking Cylinder Head Top Clearance

Tools Required: Plastigauge
1. Remove the cylinder head.
2. With the piston at T.D.C., use grease to affix three or four plastigauges (1) to the crown of the piston; keep
the gauges away from the intake valve and combustion chamber fillings.

(1) Plastigauge
3. Take the piston to an intermediate position, install the cylinder head and tighten the cylinder head mounting
screw to the specified torque.
NOTE
• The polished cylinder head mounting screw with no marking on the screw head has possibly used.
• In this case, tighten this screw to the same torque as normal one.

4. Turn the crankshaft so the piston goes through T.D.C.

5. Remove the cylinder head and compare the width of the crushed plastigauges (2) with the scale (3).
NOTE
• Top clearance = Width of the crushed plastigauge (2)
• If they are out of service specification, check the oil clearance of the crank pin, journal and piston pins.

62-12258 3–68
 (2) Crushed plastigauge
(3) Scale
3.5.2 Checking Cylinder Head Flatness
Tools Required:
• Straight edge
• Feeler gauge
1. Clean the cylinder head surface.
2. Place a straight edge on the four sides of the cylinder head (A, B, C, and D) and two diagonal (E and F) as
shown in the following figure.

3. Measure the clearance with a feeler gauge.

NOTE
If the measurement exceeds the service limit, straighten it with a surface grinder.

IMPORTANT
• Top clearance = Width of the crushed plastigauge (2).
• If the top clearance is out of service specification, check the oil clearance of the crankpin, journal and piston
pins.

3–69 62-12258
3.5.3 Checking Cylinder Head Flaw
Tools Required:
• Red permeative liquid
• Detergent
• White developer
1. Clean the surface of the cylinder head withdetergent (2).
2. Apply some red permeative liquid (1) on thecylinder head surface.
3. After you apply, do not touch it for 5 to 10 minutes.
4. Clean away the red permeative liquid on thecylinder head surface with detergent (2).
5. Apply the white developer (3) on the cylinder head surface.
NOTE
If you find red flaw, replace the cylinder head.

(1) Red permeative liquid

(2) Detergent
(3) White developer

62-12258 3–70
3.5.4 Checking Valve Recessing
Tools Required: Depth gauge
1. Clean the cylinder head surface (1), valve face and valve seat.
2. Set the valve into the valve guide.
3. Measure the valve recessing wht the depth gauge.
NOTE
• If the measurement exceeds the service limit, replace the valve.
• If, after replacing the valve, the measurement remains more than the service limit, replace the cylinder
head.

(1) Cylinder head surface

(A) Recessing
(B) Protrusion

3–71 62-12258
3.5.5 Adjusting Valve Lapping
Tools Required:
• Compound
• Valve lapping tool
• Prussian Blue
1. Apply the compound equally to the valve lapping surface.
2. Put the valve into the valve guide. Lap the valve on its seat with the valve lapping tool.
3. After lapping the valve, clean away the compound and apply oil, then lap the valve again with oil.

4. Apply Prussian Blue to the contact surface to measure the seated rate.
NOTE
If the seated rate is less than 70-%, lap the valve again.

IMPORTANT
After you complete the valve lapping and assemble the valve, check the valve recessing and adjust the valve clear-
ance.

(1) Good
(2) Bad
(3) Bad

Refer to Section 3.5.4 (Checking Valve Lapping) and Section 3.2.10 (Adjusting Valve Clearance) for additional
information.

62-12258 3–72
3.5.6 Checking Clearance Between Valve Stem and Valve Guide
Tools Required:
• Outside micrometer
• Inside micrometer
1. Remove carbon from the valve guide section.
2. Measure the valve stem OD with an outside micrometer.

3. Measure the valve guide ID with an inside micrometer.

4. Calculate the clearance.

NOTE
• If the clearance exceeds the service limit, replace the valves.
• If, after replacing the valve, the clearance remains more than the service limit, replace the cylinder head.

Refer to Section 3.5.7 (Replacing Valve Guide) for additional information.

3–73 62-12258
3.5.7 Replacing Valve Guide
IMPORTANT
Do not hit the valve guide with a hammer during replacement.

Tools Required:
• Press tool
• Valve guide replacing tool

3.5.7.1 Removing Valve Guide

1. Press out the used valve guide with the valve guide replacing tool.

Removing direction

3.5.7.2 Installing New Valve Guide

1. Clean the new valve guide and valve guide bore,and apply engine oil to them.
2. Press fit the new valve guide with the valve guidereplacing tool.

Installing Direction

62-12258 3–74
 SECTION 4
Lubricating System
4.1 Maintenance
Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit.
NOTES
• As the engine owner, you are responsible for the performance of the required maintenance on the engine
according to unit-specific maintenance schedule.
• Please see the warranty statement in detail.
• Failure to perform the maintenance will cause problems that will significantly degrade the engine perfor-
mance.

4.2 Engine Oil

4.2.1 Checking Engine Oil

! CAUTION
When changing or inspecting, be sure to level and stop the engine.

NOTICE
Initial oil change at 50 hours, then change oil every 3,000 hours

NOTE
Refer to the following table for the suitable American Petroleum Institute (API) classification of engine
oil according to the engine type and the Fuel Type.

Table 4–1 Engine Oil Classification

Fuel Type Engine Oil Classification (API classification)

Ultra low sulfur fuel

Sulfur content CK-4
<0.0015% (15 ppm)

• Engine oil should be API classification CK-4.

• Change the type of engine oil according to the ambient temperature.
• When using oil of different brands from the previous one, be sure to drain all the previous oil before
adding the new engine oil.
• If the oil rises above the oil level gauge upper limit, it means the oil has been diluted too much, resulting
in a trouble.
• In such case, immediately change the oil for new one.

4–3 62-12258
 Figure 4.1 Oil Dipstick

1. Level the engine.

2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see
that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.

NOTE
When adding oil to the crankcase, be sure that the fresh oil is the same type and viscosity as the oil
that is already in the crankcase. Never mix two different types of oil. Never over fill a crankcase.
4.2.2 Changing Engine Oil

! CAUTION
Stop the engine when preparing to change the engine oil.
• When you use an oil of different brand or viscosity from the previous, drain the remainingoil.
• Do not mix two different types of oil.
• Engine oil must have the properties of API classification CK-4. Use the correct SAE Engine Oil by refer-
ence to the ambient temperature.

1. Start engine and warm up for five minutes. • Use only API classification CG-4 or better oils.
2. Place an oil pan underneath the engine. • Use the proper SAE Engine oil according to the
ambient temperatures.
3. Remove the drain plug, drain the engine oil com-
pletely. • Above 25°C (77°F)..............SAE 30 or 10W-30,
10W-40
4. Inspect the drain plug gasket. Replace if neces-
sary. • 0° to 25°C (32° to 77°F)......SAE 20 or 10W-30,
10W-40
5. Reinstall the drain plug.
• Below 0°C (32°F)............SAE 10W or 10W- 30
6. Replace the oil filter with a new oil filter. • Lubricating oil recommended when a low-sulfur
7. Fill the crankcase with new oil. or high-sulfur fuel is employed

8. Check for the correct oil level.

62-12258 4–4
 NOTE
When changing to a different oil manufacturer or viscosity, be sure to remove all of the old oil com-
pletely. Never mix different types of oil.

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

Table 4–2 Lubricating Oil Class

Lubricating Oil Class Fuel

Low- sulfur High- sulfur

CH- 4 or CI O X

O: Recommended X: Not Recommended

Table 4–3 Drain Plug Torque

32.4 to 37.2 N ⋅ m
Tightening Torque 3.31 to 3.79 kgf ⋅ m
23.9 to 27.4 lbf⋅ft

Table 4–4 Engine Oil Capacity

9.5 liters
V2403-CR-E4 2.5 U.S. gallons
2.1 Imperial gallons

4–5 62-12258
4.2.3 Engine Oil Pressure

4.2.3.1 Checking Engine Oil Pressure

Tools Required: Oil pressure tester
1. Remove the engine oil pressure switch.
2. Set the oil pressure tester.
3. Start the engine to warm up.
4. Measure the oil pressure at idle speed and rated
speed.
NOTE
If the oil pressure is less than the service
limit, check engine oil level, oil pump, oil
strainer, oil filter cartridge, oil passage, oil
clearance, and relief valve

5. After checking the engine oil pressure, tighten

the oil pressure switch to specified torque.

Table 4–5 Engine Oil Pressure

More than98 kPa
Service 1.0 kgf/cm2
specification 14 psi
At idle speed
50 kPa
Service limit 0.5 kgf/cm27 psi

300 to
Engine oilpressure 450 kPa
Service
3.0 to
At ratedspeed specification 4.5 kgf/cm243 to 64
psi
250 kPa
Service limit 2.5 kgf/cm236 psi

When reassembling, after checking the engine oil pressure, tighten the engine oil pressure switch to the
specified torque.
Table 4–6 Tightening Torque - Oil Pressure Switch

Tightening Oil pressure 14.7 to 19.6 N:m

torque switch 1.50 to 1.99 kgf:m
10.9 to 14.4 lbf:ft

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 cool-
ants.

62-12258 4–6
4.3 Replacing Oil Separator Element

! CAUTION
Be sure to stop the engine before replacing the oil separator element.

1. Remove the cover (1)

2. Remove the oil separator element (3) and O-ring

(2).

3. Replace the oil separator element (3) and O-ring

(2) with a new one.

4–7 62-12258
4.4 Replacing Oil Filter Cartridge

! CAUTION
Ensure that you stop the engine before replacing the oil filter cartridge

NOTICE
To prevent serious damage to the engine, replacement element must be highly efficient. Use
only a Carrier Transicold genuine filter or its equivalent,

1. Using a filter wrench, remove the oil filter car-

NOTE
tridge (1).
Do not tighten too much because it can
cause deformation of the rubber gaskets.

4. Make sure that the engine oil does not flow

through the seal and read the oil level on the dip-
stick.

5. Fill the engine oil to the specified level.

NOTE
After the cartridge is replaced, the engine oil
usually decreases slightly.

2. Apply a thin layer of oil on the new cartridge gas-

ket.

3. Install the new cartridge by hand.

62-12258 4–8
 SECTION 5
Cooling System
Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit.
NOTES
• As the engine owner, you are responsible for the performance of the required maintenance on the engine
according to unit-specific maintenance schedule.
• Please see the warranty statement in detail.
• Failure to perform the maintenance will cause problems that will significantly degrade the engine perfor-
mance.

5.1 Checking and Draining Water Separator

1. Check that the fan belt is worn out and sunken 2. Push the belt halfway between the fan drive pul-
into the pulley groove. If it is, replace it. ley and alternator pulley at specified force to
measure the deflection (1).

1. Check if water and dirt contained in fuel precipi-

tate inside the water separator.

2. When such foreign substances are precipitated,

set the water separator handle (1) to the close
(A) position.

3. Loosen the top screw (4) first and then the bot-
tom valve (3) to let the foreign substances out of
the separator.

4. Loosen and remove the cup (5) properly, and

clean its inside with diesel fuel.

5. Tighten up the cup (5) properly.

6. Finally, be sure to air-bleed the fuel system

5–3 62-12258
 • As water is accumulated, the red float (6) goes up.
• When the float (6) has reached the specified line (2), immediately drain the water separator.
• When reattaching the water separator, be careful to keep off dust and dirt.

5.2 Cleaning Air Cleaner Primary Element

• Replace the primary element once a year or every sixth cleaning.
• The air cleaner uses a dry element. Never use oil.
• Do not operate the engine with filter element removed.
• Do not touch the secondary element except in cases where replacement is necessary.

1. Remove the dust cup (4).

2. Remove the primary element (3).

3. Clean the inner side of the primary element (3)

by clean, dry, compressed air.

NOTE
Compressed air pressure should be less than
205 kPa, 2.1 kgf/cm2, 30 psi

5.3 Adjusting Fan Belt

1. Check that the fan belt is worn out and sunken 2. Push the belt halfway between the fan drive pul-
into the pulley groove. If it is, replace it. ley and alternator pulley at specified force to
measure the deflection (1).

62-12258 5–4
5.4 Checking Radiator Hose and Clamp Bands

1. Check that the radiator hoses (1 & 2) are con-

nected correctly.

2. Check for radiator hose (1&2) or clamp damage.

Replace damaged hoses or clamp if necessary.

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

tighten again correctly.

NOTE
Radiator hoses must be replaced every two
years.

NOTE
Clamp must be replaced and tightened cor-
rectly every two years.

1. Intake Air Hose

2. Clamp

5.5 Checking Air Intake Line

! CAUTION
To prevent serious danger to the engine, keep dust out of the intake air line.

1. Make sure that the intake air hose(s) (1) are

connected correctly or not.

2. Visually check for cracks gas leak and anything

else that is unusual.

3. If the clamp (2) is loose, apply oil to the threads

andtighten it again correctly.

NOTE
Intake air hose (s) and clamp must be
replaced every two years. Clamp must be
tightened correctly.

5–5 62-12258
5.6 Cleaning Water Separator Filter (Type 2)

NOTICE
Replace the water separator filter periodically toprevent wear of the supply pump or the injec-
tor, due to dirt in the fuel.

NOTE
Replace the water separator filter with a new one every 500 hours or one year.

1. Turn the water separator handle (1) to the

closeposition (A).

2. Drain fuel and water from bottom valve (3).

3. Remove and flush the cup (5) if the float (6)

goesup with water, or the cup (5) has the dust.

1. Water separator handle

2. Specified line
3. Bottom valve
4. Top screw
5. Cup
6. Float
(A) Close

62-12258 5–6
5.7 Anti-Freeze
• There are two types of anti-freeze available. Use the permanent type (PT) for this engine.
• When you add anti-freeze for the first time, flush the water jacket and radiator interior with clean, soft
water several times.
• The brand of the anti-freeze and the ambient temperature have an effect on the procedureto mix water
and anti-freeze.
• Refer to the SAE J1034 standard, especially to the SAE J814c.
• Mix the anti-freeze with clean, soft water, and then fill into the radiator.

NOTICE
Make sure that when you mix the anti-freeze and water, the ratio of anti-freeze is less than 50%.

Anti- Freezing point Boiling point<XREF>*

freeze °C °F °C °F
volume
40% -24 -11 106 223
50% -37 -35 108 226

*At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Usea radiator pressure cap that lets the pressure col-
lect in the cooling system to get a higher boiling point.

NOTE
The above data is the industrial standards that shows the minimum glycol content necessary
in the concentrated anti-freeze.

• When the coolant level decreases because of evaporator, add clean, soft water only to keep the anti-
freeze mixing ratio less than 50%.
• If there is a leakage, add anti-freeze and clean, soft water in the specified mixing ratio.
• The anti-freeze absorbs moisture. Keep new anti-freeze in a tightly sealed container.
• Do not use the radiator cleaning agents afteryou add anti-freeze to the coolant.
• Anti-freeze contains an anti-corrosive agent,which reacts with the radiator cleaning agent to make
sludge and cause damages to the engine parts.

5–7 62-12258
5.8 Replacing Fan Belt

1. Remove the alternator (1).

2. Remove the fan belt (2).

3. Replace the fan belt (2) with the new one.

4. Reinstall the alternator (1).

5. Adjust the tension of belt halfway between the fan drive pulley and alternator pulley at a specified force to
measure the deflection (3).

62-12258 5–8
5.9 Checking Valve Clearance

Figure 5.1 Valve Clearance

NOTE
Valve clearance must be checked and
adjusted when the engine is cold.

1. Remove the air cleaner and muffler.

2. Remove the cylinder head cover.

3. Align the [1TC] mark (2) line on the fly-

wheel andprojection (1) on the housing.

4. Make sure that the No.1 piston comes to the

compression or overlap top dead center.

5. Check the subsequent valve clearance (5) at the

mark [1TC] with a feeler gauge.

6. Install removed parts.

Valve clearance: 0.0071 to 0.0086 inches (0.18 to

0.22 mm)

(3) Adjusting screw

(4) Lock nut
(5) Valve clearance

Table 5–1 Cylinder Head Tightening Torque

6.86 to 11.3 N ⋅ m
Tightening torque Cylinder head cover screw 0.700 to 1.15 kgf ⋅ m
5.06 to 8.33 lbf ⋅ ft

5–9 62-12258
5.10 Checking Positive Crankcase Ventilation (PCV) Valve
1. Remove cover (1) and element (3).

2. Look into the hole leading to the PCV valve of

the oil separator body (4) inside, and then check
if there is no crack, break or abnormal sediment
in the PCV valve.

3. Check the oil separator assembly for crack, oil

leakage and loose connections.

NOTE
If you find a crack or oil leakage, replace the
oil separator assembly with a new one.

NOTE
If you find loose connections, tighten the
clamp or replace the hoses.

62-12258 5–10
5.11 Checking Intake Air Line

NOTICE
To prevent serious damage to the engine, keep dust out of the intake air line.

1. Make sure that the intake air hose(s) (1) are

connected correctly or not.

2. Visually check for cracks gas leak and anything

else that is unusual.

3. If the clamp (2) is loose, apply oil to the threads

andtighten it again correct.

NOTE
The intake air hose(s) and clamp must be
replaced every two years. Make sure the
clamp is tightened correctly.

5.12 Checking Exhaust Manifold

Check the exhaust manifold for cracks, exhaust gas leakage and loose mounting screw.
• If you find a crack, change the exhaust manifold.
• If you find a gas leakage, tighten the mounting screw again or replace the gasket with a new one.
• If you find a loose mounting screw, tighten the mounting screw again.

5.13 Replacing Water Hose

1. Loosen the clamp and remove the hose.

2. Replace the hose with a new one.

3. Tighten the clamp correctly.

5–11 62-12258
62-12258 5–12
 SECTION 6
Fuel System
6.1 Maintenance Schedule
Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit.
NOTES
• As the engine owner, you are responsible for the performance of the required maintenance on the engine
according to unit-specific maintenance schedule.
• Please see the warranty statement in detail.
• Failure to perform the maintenance will cause problems that will significantly degrade the engine perfor-
mance.

6.2 Checking Fuel Filter

1. Using a filter wrench, remove the fuel filter car- Figure 6.1 Fuel Filter
tridge (1).

2. Apply a thin layer of fuel to the surface of the

new filter cartridge gasket.

3. Tighten the new cartridge by hand.

4. Open the fuel valve and bleed the fuel system.

5. Operate the engine for a while and check if there

is not the fuel leakage from the filter.

6–3 62-12258
6.3 Checking Fuel Hoses and Clamp Bands

1. Check fuel hose (1) and clamp

(2) for damage.

2. If the fuel hose (1) or clamp (2)

is damaged, replace it.

3. If the clamp (2) is loose, apply oil

to the threads and tighten it
again correctly

NOTE
Replace the fuel hose (1) and clamp (2) every two years.

NOTE
After replacing the fuel hose (1) and the clamp (2), bleed the fuel system.

62-12258 6–4
6.4 Checking Injector with Diagmaster
6.86 to 11.3 N ⋅ m
Tightening torque Cylinder head cover screw 0.700 to 1.15 kgf ⋅ m
5.06 to 8.33 lbf ⋅ ft
Tools Required:
• Laptop computer with Diagmaster software installed
• Interface (DST-i)

1. Connect the diagnosis tool.

2. Start "Diagmaster", then click the [Active Test] button (1) from the project window.

3. Select the "#1, 2, 3 and 4 Cylinder Injector InjectionStop" item (2), then click the [Proceed] button (3).

4. Select the "#Cylinder Injector Injection Stop" (7)from the "select signal group" (8).

5. Select the "number of graph" (6).

6. Click the [Start Active Test] button (4), then clickthe [OK] button (5).

6–5 62-12258
 7. Click the [Send Specified Active Test Value] button (9).

NOTE
Confirm that each of the injectors are injecting normally. If so, the engine vibration and noise will
increase and engine speed will fluctuate when the injector is stopped.

8. Click the [Finish Active Test] button (10).

62-12258 6–6
 SECTION 7
Electrical System
7.1 Maintenance
Refer to Table 8-1 in your unit’s operation and service manual for the maintenance schedule specific to that unit.
NOTES
• As the engine owner, you are responsible for the performance of the required maintenance on the engine
according to unit-specific maintenance schedule.
• Please see the warranty statement in detail.
• Failure to perform the maintenance will cause problems that will significantly degrade the engine perfor-
mance.
• Interface (DST-i)

7.2 Battery

7.2.1 Checking Battery Voltage

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxy-
gen becomes explosive.

NOTICE
Do not disconnect or remove the battery when you operate the engine.

Tools Required: Circuit Tester

1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery terminals.

Battery Voltage = More than 12V

7–3 62-12258
 (1) Positive terminal
(2) Negative terminal

NOTE
If the battery voltage is less than the service specification, check the battery specific gravity and
charge the battery.

7.3 Glow Plug

7.3.1 Checking Glow Plug Continuity

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away form the battery at all times. Hydrogen gas mixed with oxy-
gen becomes very explosive.

62-12258 7–4
Tools Required: Circuit tester
1. Remove glow plug (2).
2. Measure the resistance with circuit tester
between glow plug terminal and glow plug hous-
ing.
NOTE
If the measurement does not show the ser-
vice specification, the glow plug is damaged.

NOTE
Adjust direction of the ditch to the terminal
side when seal (1) is installed in the glow
plug (2).
(1) Seal
Service Specifications (2) Glow plug
Resistance = Approximately 0.8 Ω
3. Install glow plug to specified tightening torque.

7–5 62-12258
7.3.2 Glow Plug Installation
1. Install the glow plugs (1).
NOTE
• Adjust the direction of the ditch to the terminal side when the seal (2) is installed in the glow plug (1).
• After installing the glow plug (1), make sure that the seal (2) was set to the specified position.

(1) Glow plug

(2) Seal
(A) Good
(B) Bad

2. Install the glow lead (3).

62-12258 7–6
7.4 Starter

7.4.1 Checking Starter Motor

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away form the battery at all times. Hydrogen gas mixed with oxy-
gen becomes very explosive.

NOTICE
Do not disconnect or remove the battery when engine is in operation

NOTE
• B Terminal: Terminal that connects the cable from the battery to the starter
• C Terminal: Terminal that connects the cable from the motor to the magnet switch.

Tools Required: Circuit tester and Jumper lead

1. Disconnect the negative cable from the battery.
2. Disconnect the positive cable from 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 C termi-
nal (1) to the battery positive terminal (2).
6. Connect a jumper lead momentarily between the
starter body and the battery negative terminal (3)

(1) C terminal
(2) Positive terminal
(3) Negative terminal
NOTE
If the motor does not operate, starter is dam-
aged. Repair or replace the starter.

7–7 62-12258
7.4.2 Checking Starter Magnetic Switch

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away form the battery at all times. Hydrogen gas mixed with oxy-
gen becomes very explosive.

NOTICE
Do not disconnect or remove the battery when engine is in operation

NOTE
• B Terminal: Terminal that connects the cable from the battery to the starter
• C Terminal: Terminal that connects the cable from the motor to the magnet switch.

Tools Required: Circuit tester and Jumper lead

1. Disconnect the negative cable from the battery.
2. Disconnect the positive cable from 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 C termi-
nal (1) to the battery positive terminal (2).
6. Connect a jumper lead momentarily between the
starter body and the battery negative terminal (3)

(1) S terminal
(2) Positive terminal
(3) Negative terminal

NOTE
If pinion gear does not come out, the magnetic switch is damaged. Repair or
replace the starter.

62-12258 7–8
7.4.3 Checking Magnetic Switch Continuity

! CAUTION
To prevent an accidental short circuit, attach the positive cable to the positive terminal before
the negative cable is attached to the negative terminal. Do not remove the battery cap while the
engine is in operation.

Keep electrolyte away from eyes, hands and clothes. If you are splattered with electrolyte, clean
with water immediately.
Keep open sparks and flames away form the battery at all times. Hydrogen gas mixed with oxy-
gen becomes very explosive.

Tools Required: Circuit tester

1. Push in the plunger.
2. Check continuity across the C terminal (1) and B
terminal (2) with a circuit tester.
Resistance between C terminal and B terminal = Conti-
nuity

7.4.4 Checking Overrunning Starter

1. Check the pinion for wear or damage. If there is any damage, replace the starter.
2. Check that the pinion turns freely and smoothly in the direction that it overruns. If there is any damage,
replace the starter.

Service 15.0 mm
specification 0.591 in
Brush Length (A) 9.0 mm
Service limit 0.35 in.

7–9 62-12258
7.5 Starter Assembly

7.6 Starter Servicing

7.7 Sensors

7.7.1 Checking Rail Pressure Sensor

Tools Required: Diagnosis tool
1. Place the SROS in the ON position.
2. Check the “Actual Rail Pressure” and “Rail Pressure Sensor Output Voltage” on the diagnosis tool data
monitor.
3. Start the engine.
4. Change the depressed amount of the accelerator pedal and check same items again.
Rail Pressure Service Specifications

62-12258 7–10
7.7.2 Checking Boost Pressure Sensor
Tools Required: Circuit tester
1. Place the SROS in the ON position.
2. Measure the voltage between the boost pressure sensor terminal (1) and (4) connector from the wiring
harness side.
3. Start the engine, change the depressed amount of the accelerator pedal and check the same items again.
Service Specifications:
SROS ON = Output voltage = Approx. 1.0V
After engine startup - Output voltage = Approx. 1.0 to 2.2V

(1) Terminal pressure signal

(2) Terminal 5V
(3) Terminal temperature signal
(4) Terminal ground
(a) Pin assignment

4. Set the SROS to the OFF position.

5. Disconnect the boost pressure sensor connector from the socket.
6. Place the SROS in the ON positions.
7. Measure the voltage between boost pressure sensor terminal (2) and (4) connector (from the wiring har-
ness side).
Service Specifications
Terminal 5V (2) and terminal ground (4) = Approx. 5V
NOTE
If the measurement is out of the service specification, replace the boost pressure sensor.

7–11 62-12258
7.7.3 Checking Crankshaft Position Sensor 7.7.4 Checking Camshaft Position Sensor
1. Disconnect the sensor and check the following 1. Disconnect the sensor and check the following
items. items.
• Check to determine whether or not there is a • Check to determine whether or not there is a
large amount of magnetic foreign material large amount of magnetic foreign material
adhering to the sensor surface. adhering to the sensor surface.
• Check to determine whether or not there are • Check to determine whether or not there are
interference marks of the pulsar and the sen- interference marks of the pulsar and the sen-
sor. sor.
• Check to determine whether or not there are • Check to determine whether or not there are
any pulsar gear abnormalities. any pulsar gear abnormalities.

(1) Crankshaft position sensor (1) Camshaft position sensor

NOTE NOTE
If the crankshaft position sensor is faulty, If the camshaft position sensor is faulty,
replace it. replace it.

Refer to Section XXX for instructions on adjusting air Refer to Section XXX for instructions on adjusting air
gap between crankshaft position sensor and flywheel. gap between camshaft position sensor and flywheel.

62-12258 7–12
7.7.5 Checking Coolant Temperature Sensor
Tools Required: Circuit Tester
1. Turn the SROS OFF.
2. Remove the connector from the sensor side.
3. Measure the resistance between the terminals on the sensor side.

Table 7–1 Coolant Temperature Sensor Service Specifications

Service specification

Temperature Resistance

20 ℃
68 ℉ Approx. 2.5 kΩ

40 ℃
104 ℉ Approx. 1.2 kΩ

60 ℃
140 ℉ Approx. 0.58 kΩ

80 ℃
176 ℉ Approx. 0.32 kΩ
100 ℃
212 ℉ Approx. 0.18 kΩ

NOTE
If the measurement is out of the service specifications, replace the coolant temperature sensor.

(1) Coolant temperature sensor

Table 7–2 Air Flow Sensor Service Specifications

Service specification

Temperature Resistance

20 ℃
68 ℉ Approx. 2.43 kΩ

40 ℃
104 ℉ Approx. 1.15 kΩ
60 ℃
140 ℉ Approx. 0.587 kΩ
80 ℃
176 ℉ Approx. 0.321 kΩ

7–13 62-12258
62-12258 7–14
 Appendix A - Engine P Codes

03 series NA-DOC (for Carrier TRU) model DTC Code LIST

(Recommendation)

(Recommendation)

Engine stop
HMI behavior

HMI behavior

Warning

Caution
Engine
ISO Time to action or Limp home action Behavior
J1939-73 SPN name warnin Delay time for
DTC 14229 Detection item DTC set preconditions DTC set parameter number by engine ECU Remark during Recovery from error
SAE J1939 g recovery
P-Code of error detection (system action) malfunction
light

SPN FMI
- Battery voltage is normal
NE-G phase shift - Sensor supply voltage VCC# is
normal (Approximately) (Invalid G signal) Diagnostic counter =
Large phase shift
NE: Crankshaft Engine Position - NE signal is normal Phase difference between NE Output limitation: Approximately 75% of - Engine zero
P0016 636 7 between NE pulse and G 2 times or more ON immediately
position sensor Sensor - G signal is normal pulse and G pulse is within +30 normal condition hesitates at start- or
pulse
G: Camshaft - Engine speed is 350 rpm or more and -20 degree up Key switch turn OFF
position sensor - Coolant temperature is 10 deg. C
(50 deg. F) or more
- Insufficient
Output limitation: To minimize PM emission
output
Pressure limiter Engine Fuel Actuator Pressure limiter - Sensor supply voltage VCC# is Pressure limiter emergency open Approximately 50% of normal condition Engine speed may go down due
P0087 633 7 one time or more ON - Worsening Key switch turn OFF ―
emergency open 1 Control Command emergency open normal Engine speed is more than 10 rpm Speed limitation (Accelerator limitation: to lack of fuel pressure,
exhaust gas
50%) regardless limp home de-rating
emissions

- Insufficient
Output limitation:
Engine Injector - Rail pressure sensor is normal output
Actual pressure exceeds Actual pressure is more than 179 Approximately 50% of normal condition
High rail pressure P0088 157 0 Metering Rail 1 - Sensor supply voltage VCC# is 3 sec or more To minimize PM emission ON - Worsening Key switch turn OFF ―
the command pressure MPa (1830 kg/cm2, 26000 psi) Speed limitation (Accelerator limitation:
Pressure normal exhaust gas
50%)
emissions

- Engine is operating (Q: 3 mm3/st - Insufficient

Discharge request of supply pump
SCV stuck at open or more) output
goes Output limitation:
Engine Fuel Pump position - Injector is normal - Worsening
-1800 mm3/st or less and the Approximately 50% of normal condition
SCV (MPROP) stuck P0089 1347 7 Pressurizing (Actual rail pressure - Battery voltage is normal 5 sec or more To minimize PM emission ON exhaust gas Key switch turn OFF ―
actual rail pressure is 20 MPa Speed limitation (Accelerator limitation:
Assembly #1 continuously exceeds the- Sensor supply voltage VCC# is emissions
(200 kg/cm2, 2900 psi) higher than 50%)
command rail pressure) normal - Engine stops in
command pressure
- Rail pressure sensor is normal some cases
Fuel leak from high - Battery voltage is normal
pressured fuel system - Sensor supply voltage VCC# is
- Insufficient
(Fuel consumption is normal
Pump supplies fuel fully output
calculated from the - Rail pressure sensor is normal Output limitation:
The deviation between actual rail - Worsening
Fuel leak (in high Engine Fuel Leakage difference of fuel - Supply pump (SCV) is normal Approximately 50% of normal condition
P0093 1239 1 pressure and desired one is more 60 sec or more To minimize PM emission ON exhaust gas Key switch turn OFF ―
pressured fuel system) 1 pressure of before and - Injector and injector drive circuit Speed limitation (Accelerator limitation:
than 20 MPa (200 kg/cm2, 2900 emissions
after the injection, and are normal 50%)
psi) - Engine stops in
the error will be detected - NE signal is active [Engine is
some cases
when excess fuel operating (700 rpm or more)]
consumption is found) - No DTC of P0087, P0088, P0089
- White smoke
During start-up = -25 deg. C (-13 deg. F)
increases at low
[default value]
temperature
Under other conditions = 80 deg. C (176
Coolant temperature Engine Coolant Ground short circuit of Voltage of coolant temperature - Insufficient
P0117 110 4 - Battery voltage is normal 3 sec or more deg. F) [default value] ON Key switch turn OFF ―
sensor: Low Temperature sensor or harness sensor is 0.176 V or less output
- Worsening
Output limitation:
exhaust gas
Approximately 75% of normal condition
emissions

- White smoke
During start-up = -25 deg. C (-13 deg. F)
increases at low
[default value]
temperature
Open circuit or +B short Under other conditions = 80 deg. C (176
Coolant temperature Engine Coolant Voltage of coolant temperature - Insufficient
P0118 110 3 circuit of sensor or - Battery voltage is normal 3 sec or more deg. F) [default value] ON Key switch turn OFF ―
sensor: High Temperature sensor is 4.870 V or more output
harness
- Worsening
Output limitation:
exhaust gas
Approximately 75% of normal condition
emissions

- Insufficient
output
Output limitation: - Worsening
Approximately 50% of normal condition exhaust gas
Engine Injector Ground short circuit of - Battery voltage is normal
Rail pressure sensor: Voltage of rail pressure sensor is Speed limitation (Accelerator limitation: emissions
P0192 157 4 Metering Rail 1 sensor or harness - Sensor supply voltage VCC# is transient To minimize PM emission ON Key switch turn OFF ―
Low 0.065 V or less 50%) - Engine running
Pressure Failure of sensor normal
noise increases
Engine forcibly stopped 60 sec later - White smoke
increases
- Engine stops
- Insufficient
output
Output limitation: - Worsening
Open circuit or +B short Approximately 50% of normal condition exhaust gas
Engine Injector - Battery voltage is normal
Rail pressure sensor: circuit of sensor or Voltage of rail pressure sensor is Speed limitation (Accelerator limitation: emissions
P0193 157 3 Metering Rail 1 - Sensor supply voltage VCC# is transient To minimize PM emission ON Key switch turn OFF ―
High harness 3.235 V or more 50%) - Engine running
Pressure normal
Failure of sensor noise increases
Engine forcibly stopped 60 sec later - White smoke
increases
- Engine stops

- Insufficient
Output limitation: output
Injector charge Injector charge voltage: - Battery voltage is normal Approximately 75% of normal condition - Worsening
P0200 ##### 0 proprietary Injector charge voltage: High transient ON Key switch turn OFF ―
voltage: High High - CPU is normal exhaust gas
Engine forcibly stopped 60 sec later emission
- Engine stops
 - Insufficient
- Engine is operating To minimize PM emission output
Open circuit of Open circuit of harness
Engine Injector - Battery voltage is normal Open circuit of harness or Output limitation: - Engine vibration
harness or coil in 1st P0201 651 3 Open circuit of injector 3 times or more ON Key switch turn OFF ―
Cylinder #01 - During injection Open circuit of injector coil Approximately 75% of normal condition Injectors which have no error are increases
cylinder injector coil
- CPU is normal operated - Worsening
exhaust gas
- Insufficient
- Engine is operating To minimize PM emission output
Open circuit of Open circuit of harness
Engine Injector - Battery voltage is normal Open circuit of harness or Output limitation: - Engine vibration
harness or coil in 3rd P0202 653 3 Open circuit of injector 3 times or more ON Key switch turn OFF ―
Cylinder #03 - During injection Open circuit of injector coil Approximately 75% of normal condition Injectors which have no error are increases
cylinder injector coil
- CPU is normal operated - Worsening
exhaust gas
- Insufficient
- Engine is operating To minimize PM emission output
Open circuit of Open circuit of harness
Engine Injector - Battery voltage is normal Open circuit of harness or Output limitation: - Engine vibration
harness or coil in 4th P0203 654 3 Open circuit of injector 3 times or more ON Key switch turn OFF ―
Cylinder #04 - During injection Open circuit of injector coil Approximately 75% of normal condition Injectors which have no error are increases
cylinder injector coil
- CPU is normal operated - Worsening
exhaust gas
- Insufficient
- Engine is operating To minimize PM emission output
Open circuit of Open circuit of harness
Engine Injector - Battery voltage is normal Open circuit of harness or Output limitation: - Engine vibration
harness or coil in 2nd P0204 652 3 Open circuit of injector 3 times or more ON Key switch turn OFF ―
Cylinder #02 - During injection Open circuit of injector coil Approximately 75% of normal condition Injectors which have no error are increases
cylinder injector coil
- CPU is normal operated - Worsening
exhaust gas
Output limitation: Diagnostic counter =
- Insufficient
Engine Coolant Overheat of engine - Coolant temperature sensor is Engine coolant temperature is Approximately 75% of normal condition zero
Engine overheat P0217 110 0 5 sec or more ON output 30 sec
Temperature coolant temperature normal 120 deg. C (248 deg. F) or more (X4,Vector) or
- Overheat
Engine Stop (Genset) Key switch turn OFF
Diagnostic counter =
Engine speed exceeds zero
Engine overrun P0219 190 0 Engine Speed - Key switch is ON Engine speed is 3500 rpm or more 3 revolutions or more Stop injection (Q = 0 mm3/st) ON - Overrun immediately
threshold speed or
(Running only Key switch turn OFF
with G signal)
Open circuit or short - Battery voltage is normal
No input of NE sensor - Faulty starting
Engine Position circuit of sensor or - Sensor supply voltage VCC# is Output limitation:
(Crank position P0335 636 8 No recognition of NE sensor pulse 10 times or more ON - Engine vibration Key switch turn OFF ―
Sensor harness normal Approximately 75% of normal condition
sensor) pulse increases slightly
Failure of sensor - Engine is not stalled
- Insufficient
output
(Running only
with G signal)
Open circuit or short - Battery voltage is normal
NE sensor (Crank - Faulty starting
Engine Position circuit of sensor or - Sensor supply voltage VCC# is Pulse count per rotation is not 58 Output limitation:
position sensor) pulse P0336 636 2 10 times or more ON - Engine vibration Key switch turn OFF ―
Sensor harness normal teeth Approximately 75% of normal condition
number error increases slightly
Failure of sensor - Engine speed is 350 rpm or more
- Insufficient
output
Open circuit or short - Battery voltage is normal (Invalid G signal) Diagnostic counter =
No input of G sensor 1.1 rotations of
circuit of sensor or - Sensor supply voltage VCC# is 4.4 rotations of CRANK - Engine zero
(Camshaft position P0340 723 8 Engine Speed 2 No recognition of G sensor pulse None ON CRANK sensor
harness normal sensor pulse hesitates at start- or
sensor) pulse pulse
Failure of sensor - Engine is not stalled up Key switch turn OFF
Open circuit or short - Battery voltage is normal (Invalid G signal) Diagnostic counter =
G sensor (Camshaft 1.1 rotations of
circuit of sensor or - Sensor supply voltage VCC# is Pulse count per rotation is not 3 4.4 rotations of CRANK - Engine zero
position sensor) pulse P0341 723 2 Engine Speed 2 None ON CAM sensor
harness normal teeth sensor pulse hesitates at start- or
number error pulse
Failure of sensor - Engine speed is 350 rpm or more up Key switch turn OFF
(At low
Open circuit of starting - Battery voltage is normal temperature)
Engine Glow Plug Open circuit of starting Open circuit of harness or
aid relay driving circuit P0380 676 5 - Starting aid relay is being 3 sec or more None ON - Faulty starting Key switch turn OFF ―
Relay aid relay Open circuit of relay coil
(Genset Only) energized - White smoke
increases
(At low
+B short of starting aid - Battery voltage is normal temperature)
+B short of starting aid
relay driving circuit P0380 ##### 3 proprietary - Starting aid relay is being +B short circuit of harness 3 sec or more None ON - Faulty starting Key switch turn OFF ―
relay driving circuit
(Genset Only) energized - White smoke
increases
(At low
Ground short of
- Battery voltage is normal temperature)
starting aid relay Ground short of starting
P0380 ##### 4 proprietary - Starting aid relay is being Ground short circuit of harness 3 sec or more None ON - Faulty starting Key switch turn OFF ―
driving circuit aid relay driving circuit
energized - White smoke
(Genset Only)
increases
- Battery voltage is normal
- Key switch turn ON
- Starter switch signal is not Oil pressure switch ON: continues None (X4,Vector)
Oil pressure error P0524 100 1 Engine Oil Pressure Oil pressure switch transient ON - Engine stops Key switch turn OFF ―
activated one sec or more Engine Stop (Genset)
- 10 sec or more after engine start
[700 rpm or more] - Faulty starting
- Insufficient
output Diagnostic counter =
Open circuit, short circuit - Key switch is ON ECU recognition of battery voltage
Battery Potential / Output limitation: - Worsening zero
Battery voltage: Low P0562 168 4 or damage of harness - Starter switch signal is not is 8 V or less one sec or more ON 30 sec
Power Input 1 Approximately 75% of normal condition exhaust gas or
Failure of battery activated Not monitored during cranking
emissions Key switch turn OFF
- Engine stops in
-some cases
Faulty starting
- Insufficient
Open circuit, short circuit - Key switch is ON
Battery Potential / ECU recognition of battery voltage Output limitation: output
Battery voltage: High P0563 168 3 or damage of harness - Starter switch signal is not one sec or more ON Key switch turn OFF ―
Power Input 1 is 16 V or more Approximately 75% of normal condition - Worsening
Failure of battery activated
exhaust gas
emissions
Diagnostic counter =
Nozzle calibration is not executed
To cover each injector - Insufficient zero
QR (IQA) data error P0602 ##### 2 proprietary QR data read error - Key switch is ON QR data read error from EEPROM transient Output limitation: ON Immediately
dispersion output or
Approximately 75% of normal condition
Key switch turn OFF

Diagnostic counter =
Nozzle correction factor = 0 [default value]
Area of QR data on EEPROM is - Insufficient zero
No QR （IQA) data P0602 ##### 7 proprietary QR data is unwritten - Key switch is ON transient Output limitation: ON Immediately
vacant output or
Approximately 75% of normal condition
Key switch turn OFF
Check-sum error
ECU FLASH ROM Erase error
P0605 628 2 Program Memory FLASH ROM error - Key switch is ON one time or more Engine stop ON - Engine stops Key switch turn OFF ―
error Write error
Read error
 - Key switch is ON
ECU CPU (Main IC) Engine Fuel Injection - Battery voltage is 10 V or more
P0606 1077 2 Failure of CPU and/or IC CPU and/or IC fatal error one time or more Engine stop ON - Engine stops Key switch turn OFF ―
error Pump Controller - Starter switch signal is not
activated
- Key switch is ON
ECU CPU (Monitoring Failure of monitoring IC - Battery voltage is 10 V or more
P0606 ##### 2 proprietary Failure of monitoring IC of CPU one time or more Engine stop ON - Engine stops Key switch turn OFF ―
IC) error of CPU - Starter switch signal is not
activated - Insufficient
Injector charge voltage: output
Injector charge Low - Battery voltage is normal Injector charge voltage: Low Output limitation: - Worsening
P0611 ##### 1 proprietary transient ON Key switch turn OFF ―
voltage: Low Failure of charge circuit - CPU is normal Failure of charge circuit of ECU Approximately 75% of normal condition exhaust gas
of ECU emissions
- Engine stops

Output limitation: - Insufficient

- Battery voltage is normal Approximately 50% of normal condition output
Engine Fuel Pump
Open circuit of SCV Open circuit of SCV - Key switch is ON Speed limitation (Accelerator limitation: - Worsening
P0627 1347 5 Pressurizing Open circuit of SCV transient ON Key switch turn OFF ―
(MPROP) (MPROP) - Starter switch signal is not 50%) exhaust gas
Assembly #1
activated emissions
Engine forcibly stopped 60 sec later - Engine stops

- Insufficient
- Battery voltage is normal output
Engine Fuel Pump
SCV (MPROP) drive Ground short circuit of - Key switch is ON - Worsening
P0628 1347 4 Pressurizing Ground short of SCV transient Engine stop ON Key switch turn OFF ―
system error SCV (MPROP) - Starter switch signal is not exhaust gas
Assembly #1
activated emissions
- Engine stops

Output limitation: - Insufficient

- Battery voltage is normal Approximately 50% of normal condition output
Engine Fuel Pump
+B short circuit of SCV +B short circuit of SCV - Key switch is ON Speed limitation (Accelerator limitation: - Worsening
P0629 1347 3 Pressurizing +B short circuit of SCV transient ON Key switch turn OFF ―
(MPROP) (MPROP) - Starter switch signal is not 50%) exhaust gas
Assembly #1
activated emissions
Engine forcibly stopped 60 sec later - Engine stops

Injector drive IC error - Key switch is ON Injector drive IC error

Injector drive IC error Engine Fuel Injection or - Battery voltage is 10 V or more or
P062B 1077 12 one time or more Engine stop ON - Engine stops Key switch turn OFF ―
or open circuit Pump Controller Open circuit of No.1 & 2 - Starter switch signal is not Open circuit of No.1 & 2 & 3 & 4
& 3 & 4 cylinder injector activated cylinder injector

- Insufficient
output
- Engine
Injectors which have error stop injection
Vibration
Internal injector drive Short circuit in injector - Battery voltage is normal
P062D ##### 6 proprietary Injector IC report the error 3 times or more ON increases Key switch turn OFF ―
circuit short driver IC - Key switch is ON Output limitation:
- Worsening
Approximately 75% of normal condition
exhaust gas
emissions
- Engine stops in
- Faulty starting
- Insufficient
Voltage to sensor is more than
output
Sensor supply voltage Sensor supply voltage Sensor supply voltage 1 - Battery voltage is normal 5.25 V
P0643 3509 3 transient Engine Stop Emission related ON - Worsening Key switch turn OFF ―
1: failure 1 error or recognition error - Key switch turn ON or
exhaust gas
Voltage to sensor is below 4.75 V
emissions
- Engine stops
- Faulty starting
Voltage to sensor is more than - Insufficient
Sensor supply voltage Sensor supply voltage Sensor supply voltage 2 - Battery voltage is normal 5.25 V Output limitation: output
P0653 3510 3 transient Emission related ON Key switch turn OFF ―
2: failure 2 error or recognition error - Key switch turn ON or Approximately 75% of normal condition - Worsening
Voltage to sensor is below 4.75 V exhaust gas
emissions
Voltage to sensor is more than
Sensor supply voltage Sensor supply voltage Sensor supply voltage 3 - Battery voltage is normal 5.25 V Output limitation:
P0663 3511 3 transient ON - Faulty starting Key switch turn OFF ―
3: failure 3 error or recognition error - Key switch turn ON or Approximately 75% of normal condition
Voltage to sensor is below 4.75 V
Main relay is locked in - Key switch turn OFF Main relay stays active longer than - Battery goes
P0687 1485 2 ECM Main Relay Failure of main relay one times or more None OFF Key switch turn OFF ―
closed position - Engine stops 1 sec without command dead

Wiring harness short to

+B Wiring harness short to +B
All injectors short to +B - Engine is operating
P2148 ##### 3 proprietary or or 3 times or more All Injectors stop injection ON - Engine stops Key switch turn OFF ―
or GND - Battery voltage is normal
Wiring harness short to Wiring harness short to ground
ground

Diagnostic counter =
Default value is set in
Barometric pressure Sensor or ECU internal Barometric pressure sensor 65 kPa (0.663 kg/cm2, 9.43 psi) [default - Insufficient zero
P2228 108 4 Barometric Pressure - Battery voltage is normal 3 sec or more consideration with high altitude ON Immediately
sensor error (Low side) circuit short to ground voltage: 0.2 V or less value] output or
usage
Key switch counter
Diagnostic turn OFF=
Barometric pressure Default value is set in
Sensor or ECU internal Barometric pressure sensor 65 kPa (0.663 kg/cm2, 9.43 psi) [default - Insufficient zero
sensor error (High P2229 108 3 Barometric Pressure - Battery voltage is normal 3 sec or more consideration with high altitude ON Immediately
circuit short to +B voltage: 4.850 V or more value] output or
side) usage
Rail pressure value is Key switch turn OFF
sticking or too low - Battery voltage is normal After fault opening pressure limiter,
Pressure limiter not
P2293 679 7 Pressure relief valve engine power not to - Key switch is ON rail pressure is 160 MPa (1630 20 sec or more Engine stop ON - Engine stops Key switch turn OFF ―
open
open pressure limiter - after DTC P0088, P0089 kg/cm2, 23200 psi) or more
forcibility Pressure limiter open (the opening
Rail pressure value is too
response is detected)
Rail pressure failure high or low despite the
- Battery voltage is normal Rail pressure value is not within 50
after pressure limiter P2293 679 16 Pressure relief valve existence of response transient Engine stop ON - Engine stops Key switch turn OFF ―
- Key switch is ON MPa (510 kg/cm2, 7250 psi) and
open that the pressure limiter
120 MPa (1230 kg/cm2, 17400
opened
psi) - Insufficient
CAN2 +B or ground
- Battery voltage is normal Forced idle output
CAN2 Bus off U0075 ##### 2 proprietary short circuit or high traffic CAN2 bus off 2 sec or more ON Key switch turn OFF ―
- Key switch is ON (Accelerator = 0%) - Transmitted
error
CAN data are
 - Battery voltage is normal
CAN-Kubota frame
CAN-Kubota original - Key switch turn OFF to ON CAN2 Kubota Frame open circuit Forced idle - Insufficient
error U0081 ##### 2 proprietary 5 sec or more ON Key switch turn OFF ―
frame open circuit error - Starter switch signal is not error (Accelerator = 0%) output
(X4,Vector Only)
activated

DTC Code LIST

- Worsening Diagnostic counter =
Engine coolant temperature is 110 exhaust gas zero
Overheat pre-caution P3025 ##### 15 proprietary Coolant temp. - Coolant temp. sensor is normal transient None ON Immediately
deg. C (230 deg. F) or more emissions or
(NOx) Key switch turn OFF
 WARNING: Breathing diesel engine
exhaust exposes you to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.

 Always start and operate the engine in a

well-ventilated area.
 If in an enclosed area, vent the exhaust to
the outside.
 Do not modify or tamper with the exhaust
system.
 Do not idle the engine except as
necessary.

For more information, go to

www.P65warnings.ca.gov/diesel

Specifications are subject to change without notice.

Consult your Carrier Transicold representative for details on warranty coverage.

North America Central America and Mexico

Carrier Transicold Carrier Transicold
700 Olympic Drive Ejercito Nacional 253-A Piso 5
Athens, GA 30601 USA Colonia Anahuac
11320 Mexico D.F.
www.trucktrailer.carrier.com