D1105 - E2B & D1105 - E3B CT3-69 - TV (26 - 60002) : Diesel Engine

R Diesel Engine
WORKSHOP MANUAL
for
D1105--E2B & D1105--E3B
CT3-69--TV (26--60002)
Beginning With Serial Number 5A0001
62--11167 Rev A
WORKSHOP MANUAL
DIESEL ENGINE
D1105--E2B & D1105--E3B

CT3--69--TV (26--60002)
Beginning With Serial Number 5A0001
TABLE OF CONTENTS
PARAGRAPH NUMBER Page

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1.1 Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1.2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
1.2.1 E2B Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
1.2.2 Cylinder Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
1.3 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
1.4 Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
1.6 Servicing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
1.6.1 Engine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
1.6.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.6.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
1.6.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.6.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7 Check and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7.1 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7.2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7.3 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7.4 Checking Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
1.7.5 Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.7.6 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
1.8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.1 Diesel Engine Compression Tester (Glow Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.2 Adapter, Kubota 10 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.3 Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.4 Replacement Bowl, Tester Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.5 Adapter, Injector Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
1.8.6 Oil Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.7 Auxiliary Socket For Fixing Crankshaft Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.8 Gauge, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.9 Tester, Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.10 Rubber Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
1.8.11 Valve Guide Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.8.12 Bushing Replacing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.8.13 Flywheel Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--16
1.8.14 Crankshaft Bearing 1 Replacing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--17
i 62--11167
TABLE OF CONTENTS - Continued

ENGINE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1 Checking and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1.1 Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1.2 Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.2 Disassembling And Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.2.1 Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.2.2 Draining and Refilling Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.2.3 External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.2.4 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2.2.5 Oil Pan and Oil Pick--up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--6
2.2.6 Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--7
2.2.7 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--10
2.2.8 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--12
2.3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--14
2.3.1 Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--14
2.3.2 Timing Gears, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--20
2.3.3 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--23
2.3.4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--25
2.3.5 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--29
LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1.1 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1.2 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1.3 Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.1.4 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.1.5 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.2.1 Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.2.2 Rotor to Cover Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.1 V--Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.2 Fan Belt Damage and Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.3 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.4 Draining Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1.5 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.6 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.1.7 Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
4.2.1 Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
4.2.2 Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
62--11167 ii
TABLE OF CONTENTS - Continued

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1.1 Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1.2 Shim Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1.3 Pump Element Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
5.1.4 Delivery Valve Fuel Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
5.2 Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.2.1 Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.2.2 Nozzle Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.2.3 Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5.2.4 Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1 Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1.1 Lead Terminal Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1.2 Glow Plug Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.2.1 Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.2.2 Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6.3 Starter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.1 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.2 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.3 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.4 Housing, Idle Gear and Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.3.5 Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
6.4 Starter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.1 Overrunning Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.2 Armature Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.3 Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.4 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.5 Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6.4.6 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
6.4.7 Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--6
LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Table 1--1. Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Table 1--2 Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Table 1--3. Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
iii 62--11167
SAFETY
SAFETY PRECAUTIONS
Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, all
moving parts are fully enclosed to help prevent injury. During all 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.
Engine Coolant
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not
remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure
without spray.
Battery
This unit is equipped with a lead--acid type battery. The battery normally vents small amounts of flammable hydrogen
gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or blindness.
SPECIFIC WARNING AND CAUTION STATEMENTS

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 on the next page are specifically applicable to this unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equip-
ment covered herein.
62--11161 iv
SPECIFIC WARNING AND CAUTION STATEMENTS (Continued)
WARNING
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may discharge from the radiator, scalding anyone nearby.
WARNING
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.
CAUTION
Stop the engine when attempting to check and change the fuel line.
CAUTION
Stop the engine when preparing to change the engine oil.
CAUTION
Stop the engine when preparing to change the engine oil filter.
CAUTION
Secure the starter to prevent it from moving when power is applied to it.
v 62--11161
SECTION 1
General
1.1 ENGINE IDENTIFICATION When contacting Carrier Transicold, always specify
your engine model number and serial number.
4 The engine model and its serial number need to be
3 identified before the engine can be serviced or parts
replaced.
Engine Serial Number (S/N)

1 2
The engine serial number is an identified number for the
engine. It is marked after the engine model number.
It indicates month and year of manufacture as follows:
1. Engine Model
2. Serial Number
3. Emission Label
4. Engine Label
Serial Number:
D1105-- 7 W 4321
Lower 4 digits in numerals or alphabetical letter (A to Z) and numerals (start at 0001 to maximum Z999)
7th Digit Alpahbetical Letter (Month of Manufacture).

Alphabetical letter A,B C,D E,F G,H J,K L,M N,P Q,R S,T U,V W,X Y,Z
Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
6th Digit Alpabetical Letter or Numerals (Year of Manufacture).

Alphabetical letter or numerals 1 2 3 4 5 6 7 8 9 A B C
Year 01 02 03 04 05 06 07 08 09 10 11 12
Table 1-1. Model Chart

KUBOTA CARRIER NEW ENGINE
MODEL NO. PART NO. PRIMARY USE REPLACES
MODEL NO.
D1105--E2B CT3--69--TV 26--60002--05* SUPRA 922, 944, 950 26--60002--03
D1105--E3B CT3--69--TV 26--60002--07** GENESIS R90 26--60002--05
* Beginning with Serial Number 5A0001
** Beginning with Serial Number 7Q5583
Table 1-2 Additional Support Manuals

MANUAL/FORM NUMBER EQUIPMENT COVERED TYPE OF MANUAL
62--11088 CT3--69--TV (D1105--E2B) (Tier 2) Service Parts List
62--11370 CT3--69--TV (D1105--E3B) (Tier 4) Service Parts List
62--03213 Tools Service Tool Catalog
1--1 62--11167
1.2 ENGINE SPECIFICATIONS
Table 1-3. Specification Chart
MODEL NUMBER (Carrier / Kubota) CT3--69--TV / D1105--E2B CT3--69--TV / D1105--E3B
TYPE Vertical, Water--cooled, 4 cycle IDI diesel engine
NUMBER OF CYLINDERS 3
BORE X STROKE mm X mm (in. X in.) 78 X 78.4 (3.07 X 3.09)
TOTAL DISPLACEMENT cm3 (cu.in.) 1123 (68.53)
BRAKE SAE Intermittent H.P.
14.2 (19.0) / 2250
HORSEPOWER kW (HP) / RPM
MAXIMUM BARE SPEED RPM 2600
COMBUSTION CHAMBER Spherical Type (E--TVCS)
FUEL INJECTION PUMP Bosch MD Type Mini Pump
GOVERNOR Centrifugal Mechanical Governor
INJECTION NOZZLE Mini Nozzle (DNOPD)
INJECTION TIMING (before T.D.C.) 18°
FIRING ORDER 1--2--3
INJECTION PRESSURE
13.73 MPa (140 kgf/cm2, 1991 psi.)
(Valve Opening Pressure)
COMPRESSION RATIO 24 : 1
LUBRICATING SYSTEM Forced Lubrication by Pump
COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump
STARTING SYSTEM Electric Starter (With Glow Plug)
STARTING MOTOR 12V, 1.0 kW
RECOMMENDED BATTERY CAPACITY
12V, 65AH, equivalent
(5 Hour Capacity)
CHARGING GENERATOR 12V, 360 W
FUEL Diesel Fuel No.2--D (ASTM D975)
LUBRICATING OIL *Quality Better Than CF Class (API), SAE 10W--30 or 15W--40
LUBRICATING OIL CAPACITY 9.0 L (9.5 U.S. Quarts)
Weight (DRY) kg (lbs.) 93.0 (205.0)
62--11167 1--2
1.2.1 E2B ENGINE 1.3 GENERAL PRECAUTIONS
Carrier/Kubota supply diesel engines conforming to During disassembly, carefully arrange removed parts in
federal emission regulations. The emission controls that a clean area to prevent confusion latter. Screws, bolts
have been put into effect have been stepped up to the and nuts should be replaced in their original position to
second stage. Carrier/Kubota has executed the prevent reassembly errors.
improvement in the engines to conform to this
regulation. When special tools are required, use Carrier Transicold
genuine special tools. Special tools which are not
In order to discriminate between engines conforming to frequently used should be made according to the
Tier 1 / Phase 1 requirements and those conforming to drawings provided.
Tier 2 / Phase 2 requirements, we have adapted E2B as
a model name for the engines conforming to Tier2 / Before disassembling or servicing electrical wires,
Phase 2 regulations. make sure to always disconnect the grounding cable
from the battery first.
In the after--sale services for Tier 2 / Phase 2 engines,
only use the dedicated parts for E2B models and carry Remove oil and dirt from parts before taking any
out the maintenance services accordingly. measurements.
Use only Carrier Transicold genuine parts for parts
replacements to maintain engine performance and to
ensure safety.
Gaskets and o--rings must be replaced during
reassembly. Apply grease to new o--rings or oil seals
before assembling.
1.2.2 CYLINDER NUMBER
The cylinder numbers of diesel engines are designated 2

as shown above. The sequence of cylinder numbers is
given as No.1, No. 2, and No. 3 starting from the gear 2
case end of the engine.
2
3 3
1. Grease A. External Snap Ring

2. Force B. Internal Snap Ring
3. Place the Sharp Edge
against the Direction of Force
When reassembling external or internal snap rings,

position them so that the sharp edge faces against the
direction from which force is applied.
A newly serviced or reassembled engine should be
run--in with no load for 15 minutes. Serious damage to
the engine may result otherwise.
1--3 62--11167
1.4 TORQUE SPECIFICATION
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench. Several screws, bolts and
nuts such as those used on the cylinder head must be tightened in the proper sequence and at the proper torque.
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts
In removing and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar tool, if employed,
must be used with care. Failure to do so may result in stripped or seized screws, bolts and nuts.
When replacing “*” marked screws, bolt and nuts, apply engine oil to their threads and seats before reassembly.
The letter “M” in size and pitch means that the screw, bolt or nut dimension is metric. The size is the nominal outside
diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.
Item Size x Pitch N.m kgf.m ft--lbs

Cylinder Head Cover Nut M7 x 1.0 6.9 to 8.8 0.7 to 0.9 5.1 to 6.5
Injection Pipe Retaining Nut M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Overflow Pipe Retaining Nut M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Nozzle Holder Assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
Glow Plug M8 x 1.0 7.8 to 14.7 0.8 to 1.5 5.8 to 10.8
*Rocker Arm Bracket Nut M7 x 1.0 21.6 to 26.5 2.2 to 2.7 15.9 to 19.5
*Cylinder Head Bolt M10 x 1.25 63.7 to 68.6 6.5 to 7.0 47.0 to 50.6
*Fan Drive Pulley Bolt M14 x 1.5 235.4 to 245.2 24.0 to 25.0 173.6 to 180.8
*Idle Gear Shaft Mounting Bolt M6 x 1.0 9.8 to 11.3 1.0 to 1.15 7.2 to 8.3
*Connecting Rod Bolt M8 x 1.0 41.2 to 46.1 4.2 to 4.7 30.4 to 34.0
*Flywheel Bolt M10 x 1.25 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4
*Bearing Case Cover Mounting Bolt M6 x 1.0 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Main Bearing Case Bolt 2 M9 x 1.25 49.0 to 53.9 5.0 to 5.5 36.2 to 39.8
*Main Bearing Case Bolt 1 M8 x 1.25 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3
Oil Pressure Switch PT1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
Starter (B Terminal Nut) M8 8.8 to 11.8 0.9 to 1.2 6.5 to 8.7
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Special Screw and Bolt
Grade 4 Grade 7
N.m kgf.m ft--lbs N.m kgf.m ft--lbs
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be
sure to check out the numbers as shown below
Punched Number Screw And Bolt Material Grade
None or 4 Standard Screw And Bolt SS41, S20C
7 Special Screw And Bolt S43C, S48C (Refined)
62--11167 1--4
1.5 TROUBLESHOOTING
Symptom Probable Cause Solution Reference
No fuel Replenish fuel
Air in the fuel system Bleed fuel system 1.7.5
Change fuel and
Water in the fuel system repair or replace fuel --
system
Fuel pipe clogged Clean 1.7.5
Fuel filter clogged Clean or change --
Excessively high viscosity of fuel or engine oil Use specified fuel or
1.2
at low temperature engine oil
Fuel with low cetane number Use specified fuel 1.2
Incorrect injection timing Adjust 5.1.1
Engine Does Not Injection nozzle clogged Replace 5.2.1/5.2.2
Start
Injection pump malfunctioning Replace 2.2.6.d
Seizure of crankshaft, camshaft, piston, 2.2.6/2.2.7/
Repair or Replace
cylinder or bearing 2.2.8
Replace head
gasket, tighten
Compression leak from cylinder cylinder head screw, 2.2.4
glow plug and nozzle
holder
Correct or replace
Improper valve timing 2.2.6.e
timing gear
Piston ring and cylinder worn Replace 2.3.3.d
Excessive valve clearance Adjust 1.7.6
Battery discharged Charge --
(Starter Does Not Starter malfunctioning Repair or replace 6.2
Run)
Wiring disconnected Connect --
Fuel filter clogged or dirty Clean or change 1.7.5
Air cleaner clogged or dirty Clean or change --
Fuel leak due to loose injection pipe retaining
Tighten retaining nut --
nut
Engine Revolution Injection pump malfunctioning Replace 2.2.6.d
Is Not Smooth
Incorrect nozzle injection pressure Replace 5.2.2
Injection nozzle stuck or clogged Replace 5.2.2
2.2.6.c/
Governor malfunctioning Repair
2.2.6.d
Reduce to specified
Blue Exhaust Gas Excessive engine oil 1.7.1
level
Is Observed
Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1
White Exhaust Gas Check the cylinder
Is Observed Deficient compression compression pressure 2.1.1
and top clearance
1--5 62--11167
1.5 TROUBLESHOOTING (Continued)
Overload Lighten load --
Either Black or Dark Low grade fuel used Use specified fuel 1.2
Exhaust Gas Is Fuel filter clogged Clean or change 1.7.5
Observed Air cleaner clogged Clean or change --
Deficient nozzle injection Replace nozzle 5.2.4
Engine’s moving parts seem to be seizing Repair or replace 2
Replace injection
Uneven fuel injection 2.2.6.d
pump
Deficient Output Repair or replace
Deficient nozzle injection 5.2.4
nozzle
Check the
Compression leak compression 2.1.1
pressure and repair
Shift ring gap
Piston ring’s gap facing the same direction 2.2.7.b
direction
Excessive Lubricant Oil ring worn or stuck Replace 2.3.3.d
Oil Consumption Piston ring groove worn Replace worn piston 2.3.3.e
Valve stem and valve guide worn Replace 2.3.1.d
Oil leaking due to defective seals or packing Replace 2.2.4.g
Replace Injection
Injection pump’s plunger worn 2.2.6.d
Fuel Mixed into pump
Lubricant Oil Deficient nozzle injection Replace nozzle 5.2.4
Injection pump broken Replace 2.2.6.d
Water Mixed into Head gasket defective Replace 2.2.4.e
Lubricant Oil Cylinder block or cylinder head flawed Replace --
Engine oil level low Replenish 1.7.1
Oil strainer clogged Clean --
Oil filter cartridge clogged Replace --
Relief valve stuck with dirt Clean 3.1.5
Relief valve spring weak or broken Replace 3.1.5
Excessive clearance of crankshaft bearing Replace 2.3.4.d
Low Oil Pressure
Excessive clearance of crankpin bearing Replace 2.3.4.c
Excessive clearance of rocker arm Replace 2.3.1.k
Oil passage clogged Clean --
Use specified type of
Incorrect oil type 1.2
oil
Oil pump defective Repair or replace 3.2
Use specified type of
Incorrect oil type 1.2
High Oil Pressure oil
Relief valve defective Replace 3.1.5
62--11167 1--6
1.5 TROUBLESHOOTING (Continued)
Engine oil level low Replenish 1.7.1
Fan belt broken or improperly tensioned Replace or adjust --
Coolant level low Replenish --
Radiator net and radiator fin clogged with dust Clean --
Inside of radiator corroded Clean or replace --
Coolant flow route corroded Clean or replace --
Engine Overheated
Radiator cap defective Replace --
Radiator hose defective Replace --
Running overloaded Reduce load --
Head gasket defective Replace 2.2.4.e
Unsuitable fuel used Use specified fuel 1.2
Replenish distilled
Battery electrolyte level low --
water and charge
Adjust belt tension or
Fan belt slips --
change belt
Low Battery Charge Wiring disconnected Connect --
Rectifier defective Replace --
Alternator defective Replace --
Battery defective Change --
1--7 62--11167
1.6 SERVICING SPECIFICATIONS
1.6.1 Engine Body
Item Factory Specification Allowable Limit
0.145 to 0.185 mm
Valve Clearance (Cold) --
0.00571 to 0.00728 in.
2.84 to 3.24 MPa 2.26 MPa
D1105--E2B 29.0 to 33.0 kgf/cm2 23.0kgf/cm2
412 to 469 psi 327 psi
Compression Pressure
3.73 to 4.11 MPa 2.26 MPa
D1105--E3B 38.0 to 42.0 kgf/cm2 23.0kgf/cm2
541 to 597 psi 327 psi
Difference Between Cylinders -- 10% or less
0.55 to 0.70 mm
D1105--E2B --
0.022 to 0.0276 in.
Top Clearance
0.55 to 0.75 mm
D1105--E3B --
0.022 to 0.029 in.
0.05 mm
Cylinder Head Surface Flatness
0.0020 in.
--0.05 to 0.25 mm 0.40 mm
Valve Recessing (Intake and Exhaust)
--0.0020 to 0.0098 in. 0.0157 in.
0.035 to 0.065mm 0.10 mm
Clearance
0.0014 to 0.0025 in. 0.0039 in.
Valve Stem 6.960 to 6.975 mm
Valve Stem to Valve Guide --
O.D. 0.2741 to 0.2746 in.
Valve Guide 7.010 to 7.025 mm.
--
I.D. 0.2760 to 0.2765 in.
1.047 rad.
Angle (IN.) --
60°
Valve Face
0.785 rad.
Angle (EX.) --
45°
1.047 rad.
Angle (IN.) --
60°
0.785 rad.
Valve Seat Angle (EX.) --
45°
2.12 mm
Width --
0.0835 in.
37.0 to 37.5 mm 36.5 mm
Free Length
1.457 to 1.476 in. 1.437 in.
1.0 mm
Tilt --
Valve Spring 0.039 in.
117.4 N / 31.0 mm 100.0N / 31.0 mm
Setting Load/
11.97 kgf / 31.0 mm 10.2kgf / 31.0 mm
Setting Length
26.4 lbs. / 1.22 in. 22.5lbs /1.22 in.
0.016 to 0.045 mm 0.10 mm
Clearance
0.00063 to 0.00177 in. 0.0039 in.
Rocker Arm 11.973 to 11.984 mm
Rocker Arm Shaft to Rocker Arm --
Shaft (O.D.) 0.4714 to 0.4718 in.
12.000 to 12.018 mm
Rocker Arm (I.D.) --
0.4724 to 0.4731 in.
-- 0.25mm
Push Rod Alignment
0.0098 in.
62--11167 1--8
1.6.1 Engine Body (Continued)
0.020 to 0.062 mm 0.07 mm
Clearance
0.0008 to 0.0024 in. 0.0028 in.
19.959 to 19.980 mm
Tappet to Tappet Guide Tappet (O.D.) --
0.7858 to 0.7866 in.
Tappet Guide 20.000 to 20.021 mm
--
(I.D.) 0.7874 to 0.7882 in.
Crank Gear to
0.032 to 0.115 mm 0.15 mm
Idle Gear 1
0.0013 to 0.0045 in. 0.0059 in.
(Backlash)
Idle Gear 1 to 0.036 to 0.1114 mm 0.15 mm
Cam Gear 0.0014 to 0.0045 in. 0.0059 in.
(Backlash)
Idle Gear 1 to
0.034 to 0.116 mm 0.15 mm
Idle Gear Injection Pump
0.0013 to 0.0046 in. 0.0059 in.
Gear (Backlash)
Idle Gear 1 to
0.033 to 0.117 mm 0.15 mm
Idle Gear 2
0.0013 to 0.0046 in. 0.0059 in.
(Backlash)
Idle Gear 2 to
0.030 to 0.117 mm 0.15 mm
Governor Gear
0.0012 to 0.0046 in. 0.0059 in.
(Backlash)
Idle Gear 1 0.020 to 0.054 mm 0.10 mm
(Clearance) 0.0008 to 0.0021 in. 0.0039 in.
Idle Gear Bushing 26.000 to 26.021 mm
--
I.D. (Clearance) 1.0236 to 1.0244 in.
Idle Gear Shaft 1 25.967 to 25.980 mm
--
O.D. (Clearance) 1.0223 to 1.0228 in.
Idle Gear Shaft to Idle Gear Bushing
Idle Gear 2 0.020 to 0.054 mm 0.10 mm
Idle Gear Bushing 26.000 to 26.021 mm
--
I.D. (Clearance) 1.0236 to 1.0244 in.
Idle Gear Shaft 2 25.967 to 25.980 mm
--
O.D. (Clearance) 1.0223 to 1.0228 in.
Idle Gear 1 0.20 to 0.51 mm 0.80 mm
(Side Clearance) 0.0079 to 0.0201 in. 0.0315 in.
Idle Gear
Idle Gear 2 0.20 to 0.51 mm 0.80 mm
(Side Clearance) 0.0079 to 0.0201 in. 0.0315 in.
0.07 to 0.22 mm 0.30 mm
Side Clearance
0.0028 to 0.0087 in. 0.0118 In.
0.01 mm
Alignment --
0.0004 In.
Camshaft
Height 28.80 mm 28.75 mm
(Intake) 1.1339 in. 1.1319 In.
Height 29.0 mm 28.95 mm
(Exhaust) 1.1417 in. 1.1398 In.
0.050 to 0.091 mm 0.15 mm
Clearance
0.00197 to 0.00358 in. 0.00059 in.
Camshaft 35.934 to 35.950 mm
Camshaft Journal to Cylinder Block Bore --
Journal (O.D.) 1.4147 to 1.4153 in
Cylinder Block 36.000 to 36.025 mm
--
Bore (I.D.) 1.4173 to 1.4183
1--9 62--11167
22.000 to 22.013 mm 22.03 mm
Piston Pin Bore I.D.
0.8661 to 0.8667 in. 0.8673 in.
0.014 to 0.038 mm 0.15 mm
Clearance
0.00055 to 0.00150 in. 0.0059 in.
22.002 to 22.011 mm
Piston Pin to Small End Bushing Piston Pin (O.D.) --
0.8662 to 0.8666 in.
Small End 22.025 to 22.040 mm
--
Bushing (I.D.) 0.8671 to 0.8677 in.
0.30 to 0.45 mm 1.25 mm
Top Ring
0.0118 to 0.0177 in. 0.0492 in.
0.30 to 0.45 mm 1.25 mm
D1105--E2B Second Ring
0.0118 to 0.0177 in. 0.0492 in.
0.25 to 0.40 mm 1.25 mm
Oil Rng
0.0098 to 0.0157 in. 0.0492 in.
Piston Ring Gap
0.20 to 0.35 mm 1.20 mm
Top Ring
0.0079 to 0.013 in. 0.0472 in.
0.40 to 0.55 mm 1.20 mm
D1105--E3B Second Ring
0.016 to 0.021 in. 0.0472 in.
0.30 to 0.55 mm 1.25 mm
Oil Rng
0.012 to 0.021 in. 0.0492 in.
Second Ring 0.085 to 0.115 mm 0.2 mm
(Clearance) 0.0033 to 0.0045 in. 0.0079 in
D1105--E2B
Oil Ring 0.020 to 0.055 mm 0.15 mm
Piston Ring to Piston (Clearance) 0.0008 to 0.0021 in. 0.0059 in.
Ring Groove Second Ring 0.095 to 0.122 mm 0.2 mm
(Clearance) 0.0037 to 0.0048 in. 0.0079 in
D1105--E3B
Oil Ring 0.020 to 0.06 mm 0.15 mm
0.05 mm
Connecting Rod Alignment --
0.0020 in.
0.15 to 0.31 mm 0.5 mm
Side Clearance
0.0059 to 0.0122 in. 0.0197 in.
Crankshaft
0.02 mm
Alignment --
0.0008 in.
0.029 to 0.091 mm 0.20 mm
Oil Clearance
0.0011 to 0.0036 in. 0.0079 in.
39.959 to 39.975 mm
Crankpin to Crankpin Bearing Crankpin (O.D.) --
1.5732 to 1.5738 in.
Crankpin Bearing 40.004 to 40.050 mm
--
(I.D.) 1.5750 to 1.5768 in.
0.034 to 0.114 mm 0.2 mm
Oil Clearance
0.0013 to 0.0045 in. 0.0079 in.
Crankshaft 47.934 to 47.950 mm
Crankshaft Journal to Crankshaft Bearing1 --
Journal (O.D.) 1.8872 to 1.8878 in.
--
Bearing1 (I.D.) 1.8891 to 1.8916 in.
62--11167 1--10
0.034 to 0.095 mm 0.20 mm
Oil Clearance
0.0013 to 0.0037 in. 0.0079 in.
Crankshaft Journal to Crankshaft Bearing2 Crankshaft 47.934 to 47.950 mm
--
(Flywheel Side) Journal (O.D.) 1.8872 to 1.8878 in.
--
Bearing2 (I.D.) 1.8891 to 1.8909 in.
0.034 to 0.098 mm 0.20 mm
Oil Clearance
0.0013 to 0.0039 in. 0.0079 in.
Crankshaft Journal to Crankshaft Bearing3 Crankshaft 51.921 to 51.940 mm
--
(Intermediate) Journal (O.D.) 2.0441 to 2.00449 in.
--
Bearing3 (I.D.) 2.0462 to 2.0480 in.
78.000 to 78.019mm +0.15 mm
I.D. (Standard)
3.0709 to 3.0716 in. +0.0059 in.
Cylinder I.D.
+0.5 mm +0.15 mm
I.D. (Oversize)
+0.0197 in. +0.0059 in.
1.6.2 Lubricating System

More than 103 kPa
At Idle Speed 1.05 kgf/cm2 --
15 psi
Engine Oil Pressure
196 to 441 kPa 147kPa
At Rated Speed 2.0 to 4.5 kgf/cm2 1.5kgf/cm2
28 to 64 psi 21 psi
0.06 to 0.18 mm
Inner Rotor to Outer Rotor Clearance --
0.0024 to 0.0071 in.
0.100 to 0.180 mm
Outer Rotor to Pump Body Clearance --
0.0039 to 0.0071 in.
0.025 to 0.075 mm
Inner Rotor to Cover Clearance --
0.0010 to 0.0030 in.
1.6.3 Cooling System

7.0 to 9.0 mm at 98N
V--Belt Tension 0.28 to 0.35 in. at 98N --
(10kgf, 22 lbs.)
Valve Opening
69.5 to 72.5°C
Temperature --
157.1 to 162.5°F
(At Beginning)
Thermostat Valve Opening
Temperature 85°C
--
(Opened 185°F
Completely)
10 seconds or more
Pressure Falling 88 to 59kPa
Radiator Cap --
Time 0.9 to 0.6 kgf/cm2
13 to 9 psi
No leaks at specified
pressure
Leakage Test
Radiator 137 kPa --
Pressure
1.4 kgf/cm2
20 psi
1--11 62--11167
1.6.4 Fuel System
Injection Timing 0.24 to 0.28 rad.
D1105--E2B --
(2250 rpm) (14° to 16°) B.T.D.C
Injection Pump
D1105--E3B --
(2250 rpm) (14.25° to 15.75°) B.T.D.C
13.73 MPa
Pump Element Fuel Tightness -- 140 kgf/cm2
1991 psi
10 seconds 5 seconds
13.73 to12.75 MPa 3.73 to12.75 MPa
Delivery Valve Fuel Tightness
140 to130 kgf/cm2 140 to130 kgf/cm2
1991 to 1849 psi 1991 to 1849 psi
13.73 to 14.71 MPa
Injection Pressure 140 to 150 kgf/cm2 --
1991 to 2134 psi
Fuel Injection Nozzle When the pressure is
12.75 MPa
Valve Seat
(130 kgf/cm2, 1849 psi) --
Tightness
the valve must not pass
fuel
1.6.5 Electrical System

Glow Plug Resistance Approximately 0.9 OHM --
Commutator 30.0 mm 29.0 mm
(O.D.) 1.181 in. 1.142 in.
Less than 0.02 mm 0.05 mm
Difference of O.D.
0.0008 in. 0.0020 in.
Starter
0.50 to 0.80 mm 0.20 mm
Mica Undercut
0.0197 to 0.0315 in. 0.0079 in.
13.0 mm 8.5 mm
Brush Length
0.5118 in. 0.3346 in.
1.7 CHECK AND MAINTENANCE

1.7.1 Checking Engine Oil Level
1. Refer to Section 3.1 CAUTION
1.7.2 Changing Engine Oil Stop the engine when attempting to check
1. Refer to Section 3.1 and/or change the fuel line.
1.7.3 Checking Coolant Level
1.7.4 Checking Fuel Hose
1. Refer to Section 4.1.3
1. If the clamp is loose, apply oil to the threads and
securely retighten it.
2. The fuel hose is made of rubber and ages regardless
of the service period. Change the hose and clamps
together every two years.
3. Change the fuel hose and clamps whenever any de-
terioration or damage is detected.
4. After the fuel hose and clamps have been changed,
bleed air out of the fuel system.
62--11167 1--12
1.7.5 Bleeding Fuel System
1. Open the air vent cock (1) on top of the fuel injection
pump.
1
2. Energize the electric fuel pump for a period of 10 to 15
seconds, or just long enough to expel fuel through the
air vent cock.
3. Close the air vent cock (1).
NOTE
Always keep the air vent cock on the fuel injec-
tion pump closed except when bleeding the fuel
system, or the engine may not run.
1.7.6 Valve Clearance
NOTE
Valve clearance must be checked and adjusted
when the engine is cold.
1. Remove the valve cover (1) and the glow plugs.

2. Align the “1TC” mark line (2) on the flywheel and pro-
jection (3) on the housing so that the Number 1 piston
comes to compression top dead center (TDC).
3. Check the following valve clearance marked with “*”
(at TDC) using a feeler guage.
4. If the clearance is not within the factory specifica-
tions, adjust with the rocker arm adjusting screw.
5. Then turn the flywheel 6.28 rad (360°), and align the
“1TC” mark (2) on the flywheel and alignment mark
(3) on the rear end plate so that the No. 1 piston come
to the overlap position.
6. Check the following valve clearance marked with “*”
(past TDC) using a feeler guage.
Valve
CT3--69--TV Arrangement
Piston Location in Cylinder IN. EX.
No. 1 * *
When No. 1 piston is at TDC
No. 2 *
No. 3 *
No. 1
When No. 1 piston is past TDC No. 2 *
No. 3 *
NOTE
The sequence of cylinder numbers is given as
No.1, No.2 and No.3 starting from the gear case
end.
After adjusting the valve clearance, secure the
adjusting screw with the lock nut. 1. Cylinder Head Cover A. Gear Case End
2. “1TC” Mark
3. Alignment Mark
1--13 62--11167
1.8 SPECIAL TOOLS
Additional tools may be found in the Carrier Transicold Performance Parts Service Tool Catalog Number
62--03213.
1.8.1 Diesel Engine Compression Tester (Glow
Plug)
Part No. 07--00179--01 (Assembly)
Application: Use to measure diesel engine
compression and diagnosis for
major overhaul.
1.8.2 Adapter, Kubota 10 mm

Part No. 07--00179--05
Application: Accessory for 07--00179--01
1.8.3 Tester Injector Nozzle

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

Part No. 07--00140--10
1.8.5 Adapter, Injector Line

Part No. 07--00036--00
62--11167 1--14
1.8 SPECIAL TOOLS (Continued)
1.8.6 Oil Pressure Tester
Code No. 07916--32032
Application: Use to measure lubricating oil
pressure.
1. Gauge 5. Threaded Joint

2. Adapter 2 6. Adapter 4
3. Cable 7. Adaptor 1
4. Adapter 3 8. Adaptor 3
1.8.7 Auxiliary Socket For Fixing Crankshaft

Sleeve
Code No. 07916--32091
Application: Use to fix the crankshaft sleeve of the
diesel engine.
1.8.8 Gauge, Belt Tension

Part No. 07--00203--00
Application: Used to adjust belt tension of all
cogged V--belts.
1.8.9 Tester, Belt Tension

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

Part No. 07--00253--01
Application: Replacement part for belt tension
tester (Part No. 07--00253--00)
1--15 62--11167
The following are drawings for special tools that may need to be fabricated.
1.8.11 Valve Guide Replacing Tool
Application: Use to press out and press fit the valve
guide.
A 20 mm dia. (0.79 in. dia.)
B 11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)
C 6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
D 225 mm (8.86 in.)
E 70 mm (2.76 in.)
F 45 mm (1.77 in.)
G 25 mm (0.98 in.)
H 5 mm (0.197 in.)
I 6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)
J 20 mm dia. (0.787 in. dia.)
K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L 8.9 to 9.1 mm (0.350 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039in.)
C2 Chamfer 2.0 mm (0.079in.)
C0.3 Chamfer 0.3 mm (0.012in.)
1.8.12 Bushing Replacing Tools
Application: Use to press out and press fit the bushing.
1. For small end bushing.
A 145 mm (5.71 in.)
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm (0.7835 to 0.7854 in.) dia.
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25.00 mm (098 in.) dia.
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
2. For idle gear bushing.

A 150 mm (5.91 in.)
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95.95 mm (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm (0.8622 to 0.8642 in.) dia.
F 25 mm (0.98 in.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
1.8.13 Flywheel Stopper

Application: Use to loosen and tighten the flywheel
screw.
A 200 mm (7.87 in.)
B 20 mm (0.79 in.)
C 30 mm (1.18 in.)
D 8 mm (0.31 in.)
E 10 mm (0.39 in.)
62--11167 1--16
1.8.14 Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft
bearing No. 1
1. Extracting tool
A 135 mm (5.31 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)
E 22 mm (0.87 in.)
F 20 mm dia. (0.79 in. dia.)
G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
2. Installing tool
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 9 mm (0.35 in.)
E 24 mm (0.95 in.)
F 20 mm dia. (0.79 in.dia.)
G 68 mm dia. (2.68 in. dia.)
H 39.90 to 39.95 mm dia. (1.5709 to 1.5728 in. dia.)
1--17 62--11167
SECTION 2
ENGINE BODY
2.1 CHECKING AND ADJUSTING

2.1.1 Compression Pressure 2.1.2 Top Clearance
1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2 pin connector
from the stop solenoid to prevent fuel delivery to the
engine.
3. Remove the the air cleaner, the muffler and all the
glow plugs.
4. Install a compression tester with the adapter in one of
the glow plug holes.
5. While cranking the engine with the starter measure
the compression pressure.
6. Repeat steps 4 thru 5 for each cylinder.
1. Piston 2. Plastigage
7. If the measurement is below the allowable limit, add a
small amount of oil to the cylinder thru the glow plug 1. Drain oil and coolant. Refer to Sections 3 and 4.
hole and measure the compression again. 2. Remove external components. Refer to 2.2.3
a. If the compression pressure is still less than the al- 3. Remove the valve cover. Refer to 2.2.4.a.
lowable limit, check the top clearance, valves and 4. Remove the cylinder head. Refer to 2.2.4.e.
cylinder head. 5. Move the piston (1) up and stick a strip of plastigage
b. If the compression pressure increases after applying (2) on the piston head at three positions shown on the
oil, check the cylinder wall and piston rings. illustration.
6. Lower the piston and install the cylinder head. (Use a
new cylinder head gasket and tighten the cylinder
NOTE head bolts to the proper torque.
7. Turn the flywheel until the piston (1) passes through
Check the compression pressure with the spe- top dead center.
cified valve clearance.
8. Remove the cylinder head and measure the plasti-
Always use a fully charged battery for perform- gage .
ing this test. 9. If the measurement is not within the factory specifica-
tions, check the clearances between the crank pin
Variances in cylinder compression values and bearing and between the piston pin and bushing.
should be under 10%.
Factory 0.55 to 0.70 mm
Top Clearance
Specification 0.0217 to 0.0276 in.
Factory 2.84 to 3.23 MPa
Specification 29 to 33 kgt/cm2 63.7 to 68.6 N.m
Tightening Cylinder Head
D1105--E2B 412 to 469 psi 6.5 to 7.0 kgf.m
Torque Bolts
47.0 to 50.6 ft--lbs
Factory 3.73 to 4.11 MPa
Compression
Specification 38 to 42 kgt/cm2
Pressure
D1105--E3B 541 to 597 psi
NOTE
2.25 MPa
Allowable Limit 23 kgt/cm2 Always use a new head gasket when replacing
327 psi the cylinder head.
2--1 62--11167
2.2 DISASSEMBLING AND ASSEMBLING
2.2.1 Draining Coolant
Refer to Section 4.1.4.
2.2.2 Draining and Refilling Engine Oil
Refer to Section 3.1.
2.2.3 External Components
Refer to Section 4. Alternator, Starter and Others
1. Remove the air cleaner and muffler.
2. Remove the engine stop solenoid (1).
3. Remove the fan (2), fan belt (3), alternator and
starter.
4. Remove the alternator.
5. Remove the starter.
When Reassembling
Replace the starter.
Replace the alternator.
Replace the fan, fan belt, alternator and starter.
NOTE
When reinstalling the fan, make sure that it is
put on correctly.
Check to see that there are no cracks in the fan
belt.
After reinstaling the fan belt, be sure to adjust
the fan belt tension. (Refer to Section 4.1.1.)
62--11167 2--2
2.2.4 Cylinder Head And Valves
2.2.4.a Valve Cover
1. Remove the breather tube (1).
2. Remove the valve cover bolts (2).
3. Remove the valve cover (3).
When Reassembling
Check to see that the valve cover gasket is in good
condition and in place.
6.9 to 8.8 N.m
Tightening Valve Cover
0.7 to 0.9 kgf.m
Torque Bolts
5.1 to 6.5 ft--lbs
2.2.4.b Injection Pipes

1. Loosen the screws on the pipe clamps (1).
2. Detach the injection pipes (2).
When Reassembling
Blow out any debris that may be in the pipes with
compressed air, then reassemble pipes.
Injection Pipe 24.5 to 34.3 N.m
Tightening
Retaining 2.5 to 3.5 kgf.m
Torque
Nut 18.1 to 25.3 ft--lbs
2.2.4.c Nozzle Heat Seal Removal Procedure
NOTE
Use a No. 2 Pt. (phillips head) screw driver that
has a diameter which is larger than the heat
seal hole. (approximately 6mm/0.25 inch)
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat
seal out together with the injection nozzle gasket.
If the heat seal drops, repeat the above procedure.
When Reassembling
The heat seal and injection nozzle gasket must be
1. #2 Phillips Screwdriver 3. Injection Nozzle Packing
changed when the injection nozzle is removed for
2. Injection Nozzle 4. Heat Seal
cleaning or for service.
2--3 62--11167
2.2.4 Cylinder Head And Valves (Continued)
2.2.4.d Rocker Arm and Push Rod
1. Remove the rocker arm bracket mounting nuts.
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2).
When Reassembling
When putting the push rods (2) onto the tappets (3),
check to see if the end are properly engaged with the
dimples.
1. Rocker Arm Assembly
2 Push Rod
3 Tappet
NOTE
After instaling the rocker arm, be sure to adjust

the valve clearance (Refer to Section 1.7.6).
Rocker Arm 21.6 to26.5 N.m

Tightening
Bracket Mounting 2.2 to 2.7 kgf.m
Torque
nut 15.9 to 19.5 ft--lbs
2.2.4.e Cylinder Head
1. Loosen the hose clamps (1), and remove the water

return hose (2).
2. Remove the cylinder head bolts in the order of (14 to

1).
3. Lift up the cylinder head and remove.
4. Remove the cylinder head gasket and O--ring (3).
When Reassembling
Replace the cylinder head gasket with a new one.
Install the cylinder head, taking care not to damage the

O--ring (3).
Apply oil to, then re--install the cylinder head bolts.
Tighten the cylinder head bolts in sequence starting

from the center in the order of (1 to 14)..
Retighten the head bolts after running the engine for 30

B minutes.
1. Hose Clamp
10 2 7 2. Water Return Hose A: Gear Case Side
14 6 3 11 3 O--ring B: Flywheel Side
5 4 12
13 9 1 8 63.7 to 68.6 N.m
Tightening Cylinder Head
6.5 to 7.0 kgf.m
Torque Bolt
47 to 50.6 ft--lbs
62--11167 2--4
2.2.4.f Tappets
1. Remove the tappets (1) from the crankcase.
2. Visually check the tappets for any abnormal camshaft
contact wear pattern. If unusual wear/damage has
occurred, replace the tappet.
3. Coat the tappets with engine oil before reinstalling
them back into the crankcase.
NOTE
The tappets must always be reinstalled in their
original bores.
2.2.4.g Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve
spring retainer (4) by the valve spring compressor (1).
3. Remove the valve spring retainer (4), valve spring (5)
and valve stem seal (6).
4. Remove the valve (7).
When Reassembling
Clean the valve stem and the valve guide. Apply engine
oil to the valve stem when reassembling.
After installing the valve spring collets (3), lightly tap the
stem with a plastic hammer to assure the collets have
seated on the valve stem.
NOTE
1. Valve Spring Compressor 5. Valve Spring
2. Valve Cap 6. Valve Stem Seal When re--installing valves into the cylinder
3. Valve Spring Collet 7. Valve head, make sure that they are re--installed in
4. Valve Spring Retainer their original locations.
2--5 62--11167
2.2.5 Oil Pan and Oil Pick--up Screen
1. Remove the oil pan mounting bolts (5).
2. Remove the oil pan (4). Lightly tapping the side of the
6
pan with a soft hammer may be necessary to break
gasket seal.
3. Scrape off the old adhesive from the mating surfaces

1 of the oil pan and the engine block completely.
3 4. Remove the oil pick--up screen (3).
2 4 5. Clean and Inspect the oil pick--up screen for damage.
5
6. Visually inspect the oil pick--up screen O--ring (1) for

1. O--ring 4. Oil Pan damage, oil it and reinstall.
2. Bolt 5. Oil Pan Mounting Bolts
3. Oil Strainer 6. Oil Pan Gasket 7. Apply gasket cement (sealer) so that the sealer is
about 3 to 5 mm (0.12 to 0.20 in.) thick around the
flange of the oil pan. Apply the sealer on the center of
the flange as well as on the inner wall of each bolt
hole.
8. Within 20 minutes after the application of the sealer,

replace the oil pan and mounting bolts.
NOTE
Sealer Location Refer to Section 1.4 for proper torque values on

all fasteners.
62--11167 2--6
2.2.6 Gear Case
2.2.6.a Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley bolt.
3. Using a puller, remove the fan drive pulley.
When Reassembling
Install the pulley to the crankshaft, aligning the marks (1)
on both.
Apply engine oil to the fan drive pulley retaining bolt and
tighten to specifications.
235.4 to 245.2 N.m
Tightening Fan Drive Pulley
24.0 to 25.0 kgf.m
Torque Screw
173.6 to 180.8 ft--lbs
2.2.6.b Gear Case

1. Remove the gear case.
When Reassembling
Apply engine oil to the oil seal, and install it insuring the
lip does not come off.
Measure the length of the mounting bolts (L). Insure that

they are reinstalled in the gear case in the correct
locations.
A: L= 18 mm (0.71 in.) (Pipe Pin Position)

B: L= 13 mm (0.51 in.) (Water Pipe Mounting)
C: L= 10 mm (0.39 in.)
D: Nut
2--7 62--11167
2.2.6 Gear Case (Continued)
2.2.6.c Engine Stop Solenoid And Speed Control
Plate
1. Remove the engine stop solenoid (1).
2. Remove the speed control plate.
When Reassembling
Apply a liquid gasket to both sides of the solenoid cover
gasket and control plate.
Do not drop the governor springs (2) into the crankcase.
1. Governor Lever
2. Governor Spring
2.2.6.d Injection Pump

1. Disconnect the starter spring (4) on the thrust lever
side (5).
2. Align the control rack pin (2) with the notch (1) on the
crankcase, and remove the injection pump (3).
3. Remove the injection pump shims.
When Reassembling
When installing the injection pump, insert the control
rack pin (2) firmly into the groove (6) of the thrust lever of
the fork lever.
NOTE
Sealant is applied to both sides of the shims,

gasket cement is not required for assembly.
When replacing the old gasket shims with new,

always replace with the same thickness and
number of gasket shims.
Addition or reduction of shim (0.05 mm / 0.0020

in.) delays or advances the injection timing by
approximately 0.5 degrees.
1. Notch 4. Start Spring

2. Control Rack Pin 5. Thrust Lever
3. Injection Pump 6. Groove
62--11167 2--8
2.2.6 Gear Case (Continued)
2.2.6.e Cam Gear and Idle Gear
5
1. Remove the idle gear (4).
2. Remove the fuel camshaft stopper (6).
3. Draw out the fuel cam gear (1) with the fuel camshaft
4
(7).
2 4. Remove the camshaft stopper bolt.

3
5. Remove the cam gear (5) with the camshaft.
6. Remove the external snap ring (8) from the governor

10 shaft (9).
7
6
7.Remove the governor gear (2) with the governor shaft
(9).
1
When Reassembling
Apply engine oil to the idle gear shaft mounting bolts (4)
and tighten them.
Install the idle gear, aligning the marks (6) on the gears.
Refer to the illustration.
10 9
1. Fuel Cam Gear 7. Fuel Camshaft
8
2. Governor Gear 8. External Snap Ring
3. Crank Gear 9. Governor Shaft
4. Idle Gear 10. Ball Bearing
5. Cam Gear 11. Set Screw
6. Fuel Camshaft Stopper
11
2--9 62--11167
2.2.7 Piston and Connecting Rod
2.2.7.a Connecting Rod
1. Remove the connecting rod caps (1).
When Reassembling
Align the marks (a) with each other. Face the marks
toward the injection pump.
Apply engine oil to the connecting rod bolts and lightly
screw them in by hand, then tighten to the specified
torque.
If a connecting rod bolt does not screw in smoothly,
clean the connecting rod and bolt threads or replace the
bolt.
41.2 to 46.1 N.m
Tightening Connecting Rod
4.2 to 4.7 kgf.m
Torque Bolt
30.4 to 34.0 ft--lbs
1. Connecting Rod Cap a. Mark
1
2.2.7.b Pistons
1. Completely remove the carbon ridge at the top of the
cylinder walls.
2. Remove the the connecting rod cap.
3. Turn the flywheel and bring the piston to top dead
center.
4. Push the piston out by lightly tapping the connecting
rod from the bottom of the crankcase with the grip of a
hammer.
5. Repeat the procedure for the other cylinder(s).
When Reassembling
Liberally coat the piston and piston rings with engine oil.
When inserting the piston into the cylinder, face the
mark on the connecting rod to the injection pump.
NOTE
If re--installing the original piston assemblies
into the engine be sure that they are returned to
their original cylinder.
When installing the piston into the cylinder,
place the gaps of all the piston rings as shown in
the figure.
Carefully insert the pistons into the cylinders
using the piston ring compressor (1).
When inserting the piston into the cylinder avoid
damaging the molybdenum disulfide coating on
the piston skirt. This coating is useful in mini-
mizing the clearance between the piston and
cylinder.
1. Piston Ring Compressor (a) 0.785 rad. (45°)

(A) Top Ring Gap (b) 0.785 rad. (45°)
(B) Second Ring Gap (c) 1.57 rad. (90°)
(C) Oil Ring Gap
(D) Piston Pin Hole Center Line
62--11167 2--10
2.2.7 Piston and Connecting Rod (Continued)
2.2.7.c Piston Ring and Connecting Rod
1. Remove the piston rings (1), (2), (3).
2. Remove the piston pin (7) and then seperate the con-
necting rod (6) from the piston (5).
NOTE
Mark both the connecting rod and piston so that

if they are to be re--used that the original com-
bination of parts will go back together. Do not in-
terchange used parts.
When Reassembling
When installing the ring, assemble the rings so that the

manufacturer’s mark (12) near the gap faces the top of
the piston (5).
When installing the oil control ring (3) onto the piston (5),
place the expander joint (10) on the opposite side of the
oil ring gap (11).
Apply engine oil to the piston pin (7).
When assembling the connecting rod (6) to the piston

(5), immerse the piston (5) in hot oil (80°C / 176°F) for 10
to 15 minutes, then assemble the piston, piston pin, and
connecting rod.
When installing the connecting rod to the piston, align

the mark (8) on the connecting rod to the fan--shaped
concave (9).
1. Top Ring 8. Mark

2. Second Ring 9. Fan Shaped Concave
3. Oil Control Ring 10. Expander Joint
4. Piston Cir--Clip 11. Oil Ring Gap
5. Piston 12. Manufacturer’s Mark
6. Connecting Rod
7. Piston Pin
2--11 62--11167
2.2.8 Crankshaft
2.2.8.a Flywheel
1. Position the flywheel (2) so that the “1TC” mark (a) on
the outer surface of the flywheel aligns horizontally
with the alignment mark (b) on the rear end plate.
2. Prevent the flywheel (2) from rotating.
3. Remove all of the flywheel screws (1).
4. Remove the flywheel (2).
When Reassembling
Check to see that the mating surfaces of the crankshaft
and flywheel are clean.
Align the “1TC” mark (a) on the outer surface of the
flywheel horizontally with the alignment mark (b) on the
rear end plate and install the flywheel
Apply engine oil to the flywheel bolts and install.
53.9 to 58.8 N.m
Tightening
Flywheel Bolts 5.5 to 6.0 kgf.m
Torque
39.8 to 43.4 ft--lbs
1. Flywheel Bolt a: 1TC Mark

2. Flywheel b: Alignment Mark
2.2.8.b Bearing Case Cover

1. Remove the bearing case cover mounting bolts. First,
remove the inside bolts (1) and then the outside
screws (2).
2. Screw two of the removed bolts into the bolt hole of
the bearing case cover (6) to remove it.
NOTE
The length of the inside and the outside bolts
are different. When reassembling reinstall the
appropriate bolt in the correct location.
When Reassembling
Fit the bearing case gasket (3) and the bearing case
cover gasket (4) to the bearing case cover (6). Orient
them correctly.
Install the bearing case cover (6), again orienting it
correctly, using the “UP” mark (a).
Apply oil to the oil seal, and take care that it is not rolled
while being installed.
Tighten the bearing case cover bolts diagonally and
evenly.
Bearing Case 9.8 to 11.3 N.m
Tightening
Cover Mounting 1.00 to 1.15 kgf.m
Torque
Screw 7.2 to 8.3 ft--lbs
1. Bearing Case Cover 5. Oil Seal

Mounting Bolt (Inside) 6. Bearing Case Cover
2. Bearing Case Cover (a). Top Mark “UP”
Mounting Bolt (Outside) (b). Upside
3. Bearing Case Gasket
3 4 4. Bearing Case Cover Gasket
62--11167 2--12
2.2.8 Crankshaft (Continued)
2.2.8.c Crankshaft Assembly
NOTE
Before disassembling, check the side clear-
1 ance of the crankshaft. Check it during reas-
sembly.
1. Remove the two main bearing case bolts (1).

2. Pull out the crankshaft, being careful not to damage
the crankshaft bearing.
1. Main Bearing Case Bolt
When Reassembling
Clean the oil passages of the crankcase with
compressed air.
While installing the crankshaft assembly, align the bolt
holes of the main bearing case bolts with the bolt holes
of the crankcase.
Apply oil to the two main bearing case bolts.
Tighten the two main bearing case bolts by hand before
tightening to the specific torque. If any resistance is
encountered while tightening, re--align the bolt holes.
49.0 to 53.9 N.m

Tightening Main Bearing
5.0 to 5.5 kgf.m
Torque Case Bolt 1
36.2 to 39.8 ft--lbs
2.2.8.d Main Bearing Case Assembly

4 1. Remove the two main bearing case bolts (4) from
2 each of the main bearing cases (2).
(c) 2. Remove the main bearing case (2) from the crank-
shaft.
When Reassembling
Clean the oil passages in the main bearing cases (2) and
the crankshaft.
Apply clean engine oil to the bearings.
Match the alignment numbers (a) on the main bearing
case assembly (2).
Install the main bearing case assemblies (2) into their
4
original positions. Since diameters of main bearing
cases vary, install them in order by marking (c) (A, B, C)
3 from the gear case side.
When installing the main bearing case 1 and 2, face the
2 mark “FLYWHEEL” to the flywheel.
Install the thrust bearing (3) with its oil groove facing
outward.
Confirm that the main bearing case moves smoothly
2. Main Bearing Case (a). Alignment Number
after tightening the main case bolt to the specified
torque.
Assembly (c). Marking (A, B, C)
3. Thrust Bearing
29.4 to 34.3 N.m
4. Main Bearing Case Bolt Tightening Main Bearing
3.0 to 3.5 kgf.m
Torque Case Bolt 4
21.7 to 25.3 ft--lbs
2--13 62--11167
2.3 SERVICING
2.3.1 Cylinder Head And Valves
2.3.1.a Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head surface, in
six locations as depicted in the drawing.
3. Measure any clearance between the straightedge
and cylinder head with a feeler gauge.
4. If the measurement exceeds the allowable limit,
resurface or replace the head.
NOTE
Do not measure the combustion chamber.
Check the valve recessing after after resurfac-
ing the head.
Cylinder Head Allowable 0.05mm

Surface Flatness Limit 0.0020 in.
2.3.1.b Cylinder Head Cracks

1. Cylinder head crack(s) can be found with using a
non--destructive test procedure using a dye/pene-
trant kit.
2. Clean the cylinder head surface using a good quality
degreaser and detergent (2).
3. Spray the cylinder head surface with the red liquid or
dye (1). Let it sit on the surface for ten minutes.
4. Wash the dye off the head using the detergent (2) and
dry the head.
5. Spray the white developer (3) on to the head.
1. Red Dye 3. White Developer 6. Red marks will bleed through the developer identify-
2. Detergent ing cracks in the head if they are present.
62--11167 2--14
2.3.1.c Valve Recessing
1. Clean the cylinder head surface, valve face and valve
seat.
2. Insert the valve into the head, making certain that the
valve is fully seated.
3. Measure the valve recession (A) with a depth gauge.
4. If the measurement exceeds the allowable limit, re-

place the valve.
5. If the measurement still exceeds the allowable limit,

replace the head.
0.05 (protrusion) mm to
Factory 0.25 (recessing) mm
Valve Specification 0.0020(protrusion) in. to
Recessing 0.0098 (recessing) in.
0.40 (recessing) mm
Allowable Limit
0.0157 (recessing) in.
1. Cylinder Head (A). Recess

Surface (B). Protrusion
2.3.1.d Clearance Between Valve Stem And Valve

Guide
1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with a micrometer.
3. Measure the valve guide with a small hole gauge, and

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

place the valves. If the clearance still exceeds the al-
lowable limit, replace the valve guide.
Clearance Factory 0.035 to 0.065 mm

Between Specification 0.0014 to 0.0025 in.
Valve Stem 0.10 mm
Allowable Limit
and Guide 0.0039 in.
Valve Stem Factory 6.960 to 6.975 mm

O.D. Specification 0.2741 to 0.2746 in.
Valve Guide Factory 7.010 to 7.025 mm
I.D. Specification 0.2760 to 0.2765 in.
2--15 62--11167
2.3.1.e Replacing Valve Guide
(A) (When removing)
1. Press out the used valve guide using a valve guide re-
placing tool.
(B) (When installing)
1. Clean a new valve guide and valve guide bore, then

apply oil to them.
2. Press in a new valve guide using a valve guide replac-

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

mension precisely.
Valve Guide I.D. Factory 7.010 to 7.025 mm

(A) When Removing (B) When Installing Intake & Exhaust Specification 0.2760 to 0.2765 in.
(C)
NOTE
Do not hit the valve guide with a hammer during

replacement.
(D)
2.3.1.f Valve Seating
1. Coat the valve face lightly with prussian blue and put
the valve on its seat to check the contact pattern (Re-
fer to drawings C and D).
1. Correct 3 Incorrect
2. Incorrect
2. If the valve does not seat all the way around the valve
seat, or the contact is less than 70% (Refer to drawing
D), correct the valve seating as outlined in 2.3.1.g.
3. If the valve contact does not comply with the refer-

ence value, replace the valve or correct the valve
seat.
Valve Seat Factory 2.12 mm

Width Specification 0.0835 in.
62--11167 2--16
2.3.1.g Correcting Valve and Valve Seat
NOTE
Before correcting the valve seat, make certain
that the valve and valve guide are within factory
specifications.
After correcting the valve seat, be sure to check
valve recession.
(A) Correcting the Valve

1. Correct the valve with a valve grinder.
1.047 rad.
Intake
Factory 60°
Valve Face Angle
Specification 0.785 rad.
Exhaust
45°
(B) Correcting the Valve Seat

1. Slightly correct the valve seat surface with a 0.785
rad. (45°) valve seat cutter.
2. Reinsert the valve, check the contact pattern with
prussian blue. A valve seat width should be approxi-
mately 70% of the total valve contact area. See (A) in
the illustration
3. Resurface the seat surface with a 0.262 rad. (15°)
valve seat cutter to the valve seat so that (a) equals
(b) in the illustration.
4. Grind the seat with a 0.785 rad (45°) valve seat cutter
again, and visually recheck the contact between the
valve and the seat.
5. Repeat steps 3 and 4 until the correct contact is
achieved.
6. Continue lapping until the seated width becomes
more than 70% of the total contact area.
1.047 rad.
Intake
Factory 60°
Valve Seat Angle
Specification 0.785 rad.
Exhaust
45°
1. Valve Seat Cutter a. Identical Dimensions

A. Check Contact b. Valve Seat Width
B. Correct Seat Width c. 0.262 rad (15°)
C. Correct Seat Surface d 0.785 rad (45°)
D. Check Contact
2.3.1.h Valve Lapping

1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve
onto its seat with a valve lapper.
NOTE 3. After lapping the valve, wash the compound away
and apply oil, then repeat valve lapping with oil.
When valve lapping is performed, be sure to 4. Apply prussian blue to the contact surface to check
check the valve recession and adjust the valve the contact pattern. If it is less than 70%, repeat valve
clearance after assembling the valve. lapping again.
2--17 62--11167
2.3.1.i Free Length and Tilt of Valve Spring
1. Measure the free length (A) of the valve spring with
vernier calipers. If the measurement is less than the
allowable limit, replace the spring.
2. Put the valve spring on a surface plate, place a
square on the side of the valve spring.
3. Check to see if the entire side is in contact with the
square. Rotate the spring and measure for maximum
tilt (B). Check the entire surface of the valve spring for
defects. If any are found, replace it.
Free Length (A)
36.5 mm
Allowable Limit
1.437 in.
1.0 mm
Tilt (B) Allowable Limit
0.039 in.
2.3.1.j Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to
the same length it’s actually compressed in the en-
gine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, re-
place it.
117.4 N / 31.0 mm
Factory
11.97 kgf / 31.0 mm.
Specification
Setting Load / 26.4 lbs. / 1.22 in.
Setting Length 100.0 N / 31.0 mm
Allowable
10.2 kgf / 31.0 mm.
Limit
22.5 lbs. / 1.22 in.
2.3.1.k Oil Clearance Between Rocker Arm and

Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside
micrometer.
2. Measure the rocker arm I.D. with a inside micrometer,
then calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, re-
place the rocker arm then measure the oil clearance
again. If the clearance is still out of specification, re-
place the rocker arm shaft.
Oil Clearance Specification 0.00063 to 0.00177 in.
Rocker Arm/
Allowable 0.10 mm
Shaft
Limit 0.0039 in.
Rocker Arm Factory 10.973 to 10.984 mm

Shaft O.D. Specification 0.4714 to 0.4718 in.
Rocker Arm I.D.
62--11167 2--18
2.3.1.l Push Rod Alignment
1. Place the push rod on V blocks
2. Measure the push rod alignment.

place the push rod.
Push Rod Allowable 0.25 mm

Alignment Limit 0.0098 in.
2.3.1.m Oil Clearance Between Tappet and Tappet

Guide Bore
1. Measure the tappet O.D. with a micrometer.
2. Measure the I.D. of the tappet guide bore with a cylin-

der gauge and calculate the clearance.
3. If the measurement exceeds the allowable limit, or

the tappet is damaged, replace the tappet.
Oil Clearance Factory 0.020 to 0.062 mm

Tappet/ Specification 0.0008 to 0.0024 in.
Tappet Guide Allowable 0.07 mm
Bore Limit 0.0028 in.
Tappet O.D.
Tappet Guide I.D.
2--19 62--11167
2.3.2 Timing Gears, Camshaft and Fuel Camshaft
2.3.2.a Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear
tooth.
2. Move the gear to measure the backlash, holding its
mating gear.
3. If the backlash exceeds the allowable limit, check the
bearing clearance of the shafts and the gear.
4. If the bearing clearance is proper, replace the gear.

Backlash/ Specification 0.0013 to 0.0045 in.
Idle Gear/
Allowable 0.15 mm
Crank Gear
Limit 0.0059 in.
Backlash/ Specification 0.0014 to 0.0045 in.
Idle Gear/
Allowable 0.15 mm
Cam Gear
Limit 0.0059 in.
Backlash/ Factory 0.034 to 0.116 mm

Idle Gear/ Specification 0.0013 to 0.0046 in.
Injection Pump Allowable 0.15 mm
Gear Limit 0.0059 in.
Backlash/ Factory 0.030 to 0.117 mm

Injection Pump Specification 0.0012 to 0.0046 in.
Gear/ Allowable 0.15 mm
Governor Gear Limit 0.0059 in.
2.3.2.b Idle Gear Side Clearance

1. Set a dial indicator with its tip on the idle gear.
2. Move the gear front to rear to measure the side clear-
ance.
place the idle gear collar.

Idle Gear Specification 0.0079 to 0.0201 in.
Side
Allowable 0.80 mm
Clearance
Limit 0.0315 in.
2.3.2.c Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.
2. Move the camshaft gear front to rear to measure the
side clearance.
place the camshaft stopper.

Camshaft Specification 0.0028 to 0.0087 in.
Side
Allowable 0.30 mm
Clearance
Limit 0.0118 in.
62--11167 2--20
2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)
2.3.2.d Camshaft Run--Out
1. Support the camshaft with V blocks on a surface plate
at both end journals.
2. Set a dial indicator with its tip on the intermediate jour-
nal.
3. Rotate the camshaft and measure for run--out.
place the camshaft.
Camshaft Allowable 0.1 mm

Run--out Limit 0.0004 in.
2.3.2.e Cam Height

1. Measure the cam lobe at its largest O.D. with an out-
side micrometer.
place the camshaft.
Factory 28.80 mm
Cam Height Specification 1.1339 in.
Intake Allowable 28.75 mm
Limit 1.1319 in.
Factory 29.00 mm
Cam Height Specification 1.1417 in.
Exhaust Allowable 28.95 mm
Limit 1.1398 in.
2.3.2.f Camshaft Bearing Clearance

1. Measure the camshaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block camshaft bore I.D. with a
cylinder gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, re-
place the camshaft.

Camshaft Journal Specification 0.00197 to 0.00358 in.
Clearance Allowable 0.15 mm
Limit 0.0059 in.
Camshaft Journal Factory 35.934 to 35.950 mm
Camshaft Bore Factory 36.000 to 36.025 mm
2--21 62--11167
2.3.2 Timing Gears, Camshaft and Fuel Camshaft (Continued)
2.3.2.g Idle Gear Shaft and Idle Gear Bushing
Clearance
1. Measure the idle gear shaft O.D. with an outside mi-

crometer.
2. Measure the idle gear shaft bore I.D. with a cylinder

gauge, and calculate the idle gear bearing clearance.
3. If the idle gear bearing clearance exceeds the allow-

able limit, replace the bushing.

Idle Gear Journal Specification 0.0008 to 0.0021 in.
Limit 0.0039 in.
Idle Gear Journal Factory 25.967 to 25.980 mm
Idle Gear Bore Factory 26.000 to 26.021 mm
2.3.2.h Replacing Idle Gear Bushing
(A) When Removing
1. Press out the bushing using an Idle Gear Bushing Re-

placing Tool. (see section 1.8.12)
(B) When Installing
1. Clean a new idle gear bushing and the idle gear bore,
and apply engine oil to both.
2. Using the idle gear replacing tool, press in the new

bushing to the specified dimension. (see B)
62--11167 2--22
2.3.3 Piston and Connecting Rod
2.3.3.a Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal
and vertical directions with a cylinder gauge.
place the piston.

Piston Pin Bore Specification 0.8661 to 0.8667 in.
I.D. Allowable 22.03 mm
Limit 0.8673 in.
2.3.3.b Piston Pin and Bushing Clearance

1. Measure the piston pin O.D. with an outside microme-
ter.
2. Measure the connecting rod small end bushing I.D.
with an inside micrometer.
3. If the clearance exceeds the allowable limit, replace
the bushing. If the clearance is still excessive, replace
the piston pin.

Piston Pin to Specification 0.00055 to 0.00150 in.
Small End Bush-
Allowable 0.15 mm
ing Clearance
Limit 0.0059 in.
Piston Pin O.D.
Small End Factory 20.025 to 20.040 mm
Bushing I.D. Specification 0.8671 to 0.8677 in.
2.3.3.c Replacing Connecting Rod Small End

Bushing
(A) When Removing
1. Press out the small end bushing using a Small End
Bushing Replacing Tool.
(B) When Installing
1. Clean a new small end bushing and bore, and apply
engine oil to both.
2. Using the small end bushing replacing tool, press in
the new bushing to the specified dimension (see B).
A. When Removing B. Correct Seat Width
NOTE
Be sure to align the bushing so that the oil hole
in the bushing aligns with the oil port in the con-
necting rod.
Piston Pin to Factory 0.015 to 0.075 mm

Small End Bush- Specification 0.00059 to 0.00295 in.
ing Clearance
(Replacement Allowable 0.15 mm
Parts) Limit 0.0059 in.
Small End
1. Seam a. 0.785 rad (45°) Factory 20.026 to 20.77 mm
Bushing I.D.(Re-
2. Oil Hole Specification 0.78845 to 0.79043 in.
placement Parts)
2--23 62--11167
2.3.3 Piston and Connecting Rod (Continued)
2.3.3.d Piston Ring Gap
1. Insert the piston ring into the lower part of the cylinder.
Use the piston to square the ring at the bottom of the
cylinder.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the pis-
ton ring.
Top Ring Gap Specification 0.0079 to 0.0138 in.
D1105--E3B
Allowable Limit 1.20 mm / 0.047 in.
Second Ring Gap Specification 0.0157 to 0.0217 in.
Factory 0.30 to 0.45 mm D1105--E3B
Top Ring Gap Specification 0.0118 to 0.0177 in. Allowable Limit 1.20 mm / 0.047 in.
D1105--E2B Factory 0.30 to 0.55 mm
Allowable Limit 1.25 mm / 0.0492 in. Oil Control Ring
Gap Specification 0.0118 to 0.0217 in.
Second Ring Gap Specification 0.0118 to 0.0177 in.
D1105--E3B Allowable Limit 1.25 mm / 0.0492 in.
D1105--E2B
Allowable Limit 1.25 mm / 0.0492 in. 2.3.3.e Piston Ring to Groove Clearance
Oil Control Ring Factory 0.25 to 0.40 mm 1. Clean the rings and the ring grooves, and install each
Gap Specification 0.0098 to 0.0157 in. ring in its groove.
D1105--E2B Allowable Limit 1.25 mm / 0.0492 in. 2. Measure the clearance between the ring and its
groove with a feeler gauge.
the ring.
4. If the clearance still exceeds the allowable limit after
replacing the ring, replace the piston.
Second Ring Factory 0.095 to 0.122 mm

Groove Clearance Specification 0.0037 to 0.0048 in.
Oil Control Ring Factory 0.020 to 0.060 mm

Groove Clearance Specification 0.0008 to 0.0023 in.
2.3.3.f Connecting Rod Alignment

Second Ring Factory 0.085 to 0.115 mm
Groove Clearance NOTE
Factory 0.020 to 0.055 mm Since the I.D. of the connecting rod small end
Oil Control Ring
Specification 0.0008 to 0.0021 in. bushing is the basis of this procedure, check the
Groove Clearance
D1105--E2B bushing for wear before proceeding.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod align-
ment tool.
3. Put a gauge over the piston pin and move it against
the face plate.
4. If the gauge does not fit squarely against the face
plate, measure the space between the pin of the
gauge and the face plate.
place the connecting rod.
Connecting Rod
Alignment
62--11167 2--24
2.3.4 Crankshaft
2.3.4.a Crankshaft End Clearance
1. Push on the end of the crankshaft to seat it toward the
flywheel end of the engine block.
2. Attach, then zero a dial indicator on the forward end of

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

ward.
4. If the measurement exceeds the allowable limit re-
place the thrust bearings.
5. If the new thrust bearings do not correct the exces-

sive end clearance condition, over size thrust bea-
rings may be necessary.

Crankshaft Side Specification 0.0059 to 0.0122 in.
Limit 0.0197 in.
(Reference)
Oversize dimensions of crankshaft journal.
Oversize 0.2mm / 0.0008 in. 0.4mm / 0.0016 in.

23.40 to 23.45 mm 23.80 to 23.85 mm
Dimension A
0.9134 to 0.9154 in. 0.9213 to 0.9232 in.
46.1 to 46.3 mm 46.3 to 46.5 mm
Dimension B
1.815 to 1.823 in. 1.823 to 1.831 in.
1.8 to 2.2 mm radius 1.8 to 2.2 mm radius
Dimension C 0.071 to 0.087 in. 0.071 to 0.087 in.
radius radius
The crankshaft journal must be fine--finished to higher than
0.8--S.
2.3.4.b Crankshaft Alignment

1. Support the crankshaft with V blocks on a surface
plate at both end journals. Set a dial indicator with its
tip on the intermediate journal, perpendicular to the
journal.
2. Rotate the crankshaft on the V blocks and get the

misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, re-

place the crankshaft.
Crankshaft Allowable 0.02 mm

Alignment Limit 0.0008 in.
2--25 62--11167
2.3.4.c Crankpin to Connecting Rod Bearing
Clearance
1. Clean the crankpin and the connecting rod bearing.
2. Put a strip of plastigage on the center of the crankpin
in each direction as shown in the figure.
3. Install the connecting rod cap and tighten the bolts to
the specification. (Refer to Section 2.2.7.b)
4. Remove the cap again.
5. Measure the amount of the flattening with the scale to
get the clearance.
place the connecting rod bearing.
7. If the allowable limit is not attainable with a standard
size bearing, install an undersize bearing by referring
to the table below.
Crankpin/ Specification 0.0011 to 0.0036 in.
Connecting Rod
Allowable 0.20 mm
Clearance
Limit 0.0079 in.

Crankpin O.D.
Connecting Rod Factory 40.004 to 40.050 mm
Bearing I.D. Specification 1.5750 to 1.5768 in.
(Reference)
Undersize dimensions of crankpin journal.
2.8 to 3.2 mm 2.8 to 3.2 mm
Dimension A
0.1102 to 0.1206 in. 0.1102 to 0.1206 in.
1.0 to 1.5 mm dia. 1.0 to 1.5 mm dia.
Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
dia. dia.
39.759 to 39.775 39.559 to 39.575
mm dia. mm dia.
Dimension C
1.5653 to 1.5659 in. 1.5574 to 1.5581 in.
dia. dia.
0.8--S.
62--11167 2--26
2.3.4.d Crankshaft Journal to Crankshaft Bearing
#1 Clearance
1. Measure the O.D. of the crankshaft journal with an
outside micrometer.
2. Measure the I.D. of crankshaft bearing #1 with an in-
side micrometer and calculate clearance.
crankshaft bearing #1.
to the table below.
Crankshaft Factory 0.034 to 0.114 mm

Journal to #1 Specification 0.0013 to 0.0045 in.
Bearing Allowable 0.20 mm
Clearance Limit 0.0079 in.
Journal O.D. Specification 1.8872 to 1.8878 in.
Crankshaft
Bearing Bearing
I.D.
(Reference) Undersize dimensions of crankshaft

journal.
Undersize 0.2mm / 0.0008 in. 0.4mm / 0.0016 in.
2.3 to 2.7 mm radius 2.3 to 2.7 mm radius
Dimension A 0.0906 to 0.1063 in. 0.0906 to 0.1063 in.
radius radius
1.0 to 1.5 mm dia. 1.0 to 1.5 mm dia.
Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
dia. dia.
47.734 to 47.750 47.534 to 47.550
mm dia. mm
Dimension C
1.8793 to 1.8799 in. 1.8714 to 1.8720 in.
dia. dia.
0.8--S.
2.3.4.e Replacing Crankshaft Bearing #1

(A) When Removing
1. Press out the crankshaft bearing #1 (2) using a crank-
shaft bearing replacing tool (Refer to Special Tools
1.8.14).
(B) When Installing
1. Clean a new crankshaft bearing #1 (2) and crankshaft
journal bore, and apply engine oil to both.
2. Using the crankshaft bearing replacing tool, press in
the new bearing #1 (2) so that its seam (1) is toward
the exhaust manifold side.
NOTE
Be sure to align the bushing so that the oil hole
1. Seam 3. Cylinder Block
in the bushing aligns with the oil port.
2. Crankshaft Bearing #1 A. Dimension
Dimension A
2--27 62--11167
2.3.4.f Crankshaft Journal to Crankshaft Bearing
Clearance
1. Put a strip of plastigage on the center of the crank-
shaft journal.
2. Install the bearing case and tighten the bolts to speci-
fication.
3. Remove the bearing case again.
4. Measure the amount of flattening with the scale to get
the clearance.
place crankshaft bearing.
to the table below.
NOTE
Be sure not to move the crankshaft while the
bearing case bolts are tightened.
Clearance-- Factory 0.034 to 0.095 mm

(Reference) Specification 0.0013 to 0.0037 in.
Crankshaft
Undersize dimensions of crankshaft journal. Journal to Bearing Allowable 0.20 mm
#2 Limit 0.0079 in.
Crankshaft
2.3 to 2.7 mm radius 2.3 to 2.7 mm radius Factory 47.934 to 47.950 mm
Dimension Journal O.D.
0.0906 to 0.1063 in. 0.0906 to 0.1063 in. Specification 1.8872 to 1.8878 in.
A (Intermediate)
radius radius
1.0 to 1.5 mm dia. 1.0 to 1.5 mm dia.
Dimension Bearing #2 I.D. Specification 1.8891 to 1.8909 in.
0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
B
dia. dia.
47.734 to 47.750 mm 47.534 to 47.550 mm Clearance-- Factory 0.034 to 0.098 mm
Dimension dia. dia. Crankshaft Specification 0.0013 to 0.0039 in.
C 1.8793 to 1.8799 in. 1.8714 to 1.8720 in. Journal to Bearing Allowable 0.20 mm
dia. dia. #3 Limit 0.0079 in.
43.734 to 43.750 mm 43.534 to 43.550 mm Crankshaft
Dimension dia. dia. Journal O.D.
D 1.72181 to 1.72244 in. 1.71394 to 1.71470 in. (Intermediate)
dia. dia. Crankshaft Factory 51.974 to 52.019 mm
The crankpin must be fine--finished to higher than 0.8--S. Bearing #3 I.D. Specification 2.0462 to 2.0480 in.
62--11167 2--28
2.3.5 CYLINDER
2.3.5.a Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions
(see figure) with a cylinder gauge to find the maxi-
mum and minimum I.D.’s.
2. Determine the difference (maximum wear) between
the maximum and minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone
to the oversize dimension. (Refer to Section 2.3.5.b)
4. Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder walls should be
bored. (Refer to Section 2.3.5.b)

Cylinder I.D.
Allowable 78.169 mm
Limit 3.0775 in.
A. Top a. Right--angled to
B. Middle Piston Pin
C. Bottom (skirt) b. Piston Pin Direction
2.3.5.b Correcting Cylinder

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

Cylinder I.D.
Allowable 78.669 mm
Maximum Wear
Limit 3.0972 in.
Hone to 1.2 to 2.0 mm μR max.
Finishing
(0.00047 to 0.00079 in. μR max.)
NOTE
1. Cylinder I.D. 2. Oversize Cylinder I.D.
(before correction)
When a cylinder is worn more than the maxi-
mum allowable limit, replace the cylinder block.
2--29 62--11167
SECTION 3
LUBRICATING SYSTEM

3.1.2 Changing Engine Oil
CAUTION
Stop the engine when preparing to change
the engine oil.
1. Start and warm up the engine for approximately for 5
minutes.
2. Turn the engine off.
3. Place a proper receptacle/bucket under the engine
drain plug.
4. Remove the oil drain plug (1) and drain the engine oil
into a proper receptacle/bucket.
5. Remove the used oil filter and replace with a new one.
(Refer to Section 3.1.3)
6. After draining all of the oil in the engine, replace the
drain plug (1).
7. Remove the oil fill cap (3) and add the correct oil to the
engine.
8. Add oil until the engine oil level is up to the upper line
on the dipstick (2).
3.1.1 Checking Engine Oil Level
NOTE
1. Level the engine.
2. To check the oil level, draw out the dipstick (2), wipe it Replace the engine oil filter with every oil
clean, reinsert it, and draw it out again. Check to see change.
that the oil level lies between the two notches. When changing to a different oil manufacturer
3. If the level is too low, add new oil to the specified or viscosity, be sure to remove all of the old oil
level. completely. Never mix different types of oil.
Use only MIL--L--46152 / MIL--L--2104C or API
classification CG--4 or CH--4 / CI oils.
NOTE
Use the proper SAE Engine oil according to the
Allow adequate time for all of the oil to return to ambient temperatures.
the crankcase to ensure an accurate deter- With emission controls now in effect, the CG--4
mination of oil level. or CH--4 / CI lubricating oils have been devel-
oped for use of a low--sulfur fuel on--road ve-
When adding oil to the crankcase, be sure that
hicles engines. When an off--road vehicle en-
the fresh oil is the same type and viscosity as
gine runs on a high--sulfur fuel, it is advisable to
the oil that is already in the crankcase. Never
employ the CH--4 or CI lubricating oil with a high
mix two different types of oil. Never over fill a
total base number. If the CG--4 lubricating oil is
crankcase.
used with a high sulfur fuel, change the lubricat-
ing oil at shorter intervals.
Lubricating oil recommended when a low--sulfur or Temperature Lubricating Oil Class
high--sulfur fuel is employed.
SAE 30, 10W--30 or
Lubricating Oil Class Fuel Above 25°C (77°F)
15W--40
Low--sulfur High--sulfur
SAE 20, 10W--30 or
0° to 25°C (32° to 77°F)
CG--4 O X 15W--40
CH--4 or CI O X SAE 10, 10W--30 or
Below 0°C (32°F)
O : Recommended X : Not Recommended 0W--30
3--1 62--11167
3.1 CHECKING AND ADJUSTING (Continued)
NOTE
3.1.3 Changing Oil Filter
CAUTION
Stop the engine when preparing to change
the engine oil filter.
1. Remove the oil filter cartridge (1) with a filter wrench.
2. Apply a slight coat of oil onto the new oil filter cartridge
gasket.
3. Install the new oil filter cartridge, screwing it on by
hand. Over tightening it may cause deformation of the
rubber gasket.
4. After the new oil filter cartridge has been installed
start the engine and check for a leak around the oil fil-
ter cartridge gasket. Recheck the crankcase oil level
(Refer to section 3.1.1) and adjust the engine oil level
as necessary.
3.1.4 Engine Oil Pressure
1. Remove the engine oil pressure switch, and install an
oil pressure guage.
2. Start the engine. After warming up, read the oil pres-
sure at idling and at rated speeds.
3. If the oil pressure is less than the allowable limit,
check the following:
Engine oil sufficient
Oil pump defective
Oil strainer clogged
Oil filter cartridge clogged
Oil gallery clogged
Excessive oil clearance
Relief valve stuck
103 kPa
Factory
At Idle Speed 1.1 kgf/cm2
Specification
15 psi
196 to 441 kPa
Factory
2.0 to 4.5 kgf/cm2
Specification
28 to 64 psi
At Rated Speed
147 kPa
Allowable
1.5 kgf/cm2
Limit
21 psi
(When Reassembling)
After checking the engine oil pressure, tighten the
engine oil pressure switch to the specified torque.
14.7 to 19.6 N.m
Oil Pressure
Tightening Torque 1.5 to 2.0 kgf.m
Switch
10.8 to 14.5 ft--lbs.
62--11167 3--2
3.1.5 Relief Valve
1. Remove the oil filter cartridge and the oil filter base
(2).
2. Check the relief valve (1) for dirt, and the seat and ball
for damage.
3. If damaged, replace.
4. Check the free length of the spring.
5. If it is less than the allowable limit, replace.
Factory 32 mm
Spring Free Specification 1.26 in.
Length Allowable 28 mm
Limit 1.10 in.
39.2 to 49.0 N.m
Oil Filter Base
Joint 4.0 to 5.0 kgf.m
Tightening Torque
29.0 to 36.3 ft--lbs.
3.2 SERVICING
3.2.1 Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner ro-
tor and the outer rotor with a feeler guage.
2. Measure the clearance between the outer rotor and
the pump body with a feeler guage.
3. If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Inner/Outer Factory 0.06 to 0.18 mm

Rotor Clearance Specification 0.0024 to 0.0071 in.
Outer Rotor/
Pump Body
Clearance
3.2.2 Rotor to Cover Clearance

1. Put a strip of plastigage onto the rotor face (use a
small dab of grease to hold the plastigage in place).
2. Install the cover and tighten the bolts.
3. Remove the cover carefully, and read the plastigage.
4. If the clearance exceeds the factory specifications,
replace the oil pump rotor assembly.
Rotor/Cover Factory 0.025 to 0.075 mm

Clearance Specification 0.0010 to 0.0030 in.
3--3 62--11167
SECTION 4
COOLING SYSTEM

4.1.3 Checking Coolant Level
1. Turn the engine off.
WARNING
When removing the radiator cap, wait at
least ten minutes after the engine has
stopped and cooled down. Otherwise, hot
water may discharge from the radiator,
scalding anyone nearby.
4.1.1 V--Belt Tension 2. Remove the radiator cap and check to see that the
coolant level is just below the port.
1. Measure the deflection (A), by depressing the belt
halfway between the fan drive pulley and alternator With the recovery tank: Check to see that the coolant
pulley at the specified force (Refer to1.6.3). level lies between FULL and LOW.
2. If the tension is not within the factory specifications,

loosen the tensioner mounting bolts and adjust the
belt tension. FULL
Use of a belt tension gauge (Carrier Part #
07--00203--00) or a belt tension tester (Carrier Part #
07--00253--00) is advised. LOW
3. If the coolant level is too low, check the reason for the
lost coolant.
(A)
a. If coolant loss is due to evaporation, add only clean
soft water.
b. If coolant loss is due to a leak, repair the leak and add
a coolant mixture of the same type and specification
(B) that is in the system. If the coolant brand cannot be
identified, drain out all of the remaining coolant and
refill with a totally new mix.
NOTE
When adding coolant to the system, air must be
vented from the engine coolant passages by jig-
gling the upper and lower radiator hoses.
Be sure to close the radiator cap securely. If the
cap is loose or improperly closed, coolant may
leak out and the engine could overheat.
Do not use an antifreeze and scale inhibitor at
the same time.
4.1.2 Fan Belt Damage and Wear
Never mix different types or brands of coolants.
1. Check the fan belt for damage.
2. If the belt is damage in any way, replace it. 4.1.4 Draining Coolant
3. Check if the belt is worn and sunk in the pulley groove. 1. Turn the engine off.
2. Remove the radiator cap.
4. If the fan belt is worn and deeply sunk in the pulley
groove, replace it. 3. Open the coolant drain cock or remove the coolant
drain plug and drain the coolant into a proper
A. Good B. Bad receptacle/bucket.
4--1 62--11167
4.1.5 Radiator Cap
1. Attach the radiator cap to a pressure tester.
2. Apply pressure and observe the time for the pressure
to fall.
3. If the measurement is less than the factory specifica-
tion, replace the cap.
More than 10 seconds
for pressure fall from
Pressure Falling Factory
88 to to 59kPa
Time Specification
0.9 to 0.6 kgf/cm2
13 to 9 psi
4.1.6 Radiator
1. Fill the radiator with water.
2. Attach the pressure tester to the radiator.
3. Apply pressure and look for leaks.
4. Repair/replace as necessary to assure that the speci-
fied pressure will hold.
137 kPa
Radiator Leakage Factory
1.4 kgf/cm2
Test Specification
20 psi
4.1.7 Thermostat Opening Temperature

1. Suspend the thermostat in water by a string with one
end of the string inserted between the valve and its
seat.
2. Immerse the thermostat in water and raise the tem-
perature of the water gradually.
3. With a thermometer, read the temperature of the
water when the valve opens and leaves the string.
4. Continue heating the water, read the temperature of
the water when the valve has opened approximately
8mm (0.315 in).
5. If the measurement is not within the factory specifica-
tions, replace the thermostat.
Thermostat
Factory 69.5 to 72.5°C
Opening
Specification 157.1 to 162.5°F
Temperature
Thermostat
Factory 85°C
Full Open
Specification 185°F
Temperature
62--11167 4--2
4.2 SERVICING
4.2.1 Thermostat Assembly
1. Remove the thermostat cover mounting bolts, and re-
move the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When Reassembling)
Apply a liquid gasket only at the thermostat cover side of
the thermostat cover gasket (2).
1. Thermostat Cover 3. Thermostat Assembly

2. Thermostat Cover Gasket
4.2.2 Water Pump Assembly
1. Remove the fan belt.
2. Remove the water pump pulley.
3. Remove the water pump from the gear case assem-
bly.
4. Remove the water pump flange (1).
5. Press out the water pump shaft (2) with the impeller
(6) on it.
6. Remove the impeller (6) from the water pump shaft
(2).
7. Remove the mechanical seal (5).
8. Carefully clean the old water pump gasket (4) from
the gear case assembly.
(When Reassembling)
1. Water Pump Flange 4. Water Pump Gasket
1. Apply a liquid gasket to both sides of the new
2. Water Pump Shaft 5. Mechanical Seal
gasket (4).
3 Water Pump Body 6. Impeller
2. Reassemble the water pump assembly.
4--3 62--11167
SECTION 5
FUEL SYSTEM

5.1.1 Injection Timing
1. Remove the injection lines.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (facing the fly-
wheel) until fuel flows from the delivery valve holder.
4. Turn the flywheel further and stop turning when the
fuel level at the tip of the delivery valve holder begins
to increase.
5. Check to see which of the timing angle lines (1) on the
flywheel is aligned with the alignment mark (2).
6. If the timing is out of adjustment, readjust the timing
by adding or removing shims.
Injection Timing
Factory 0.24 to 0.28 rad.
D1105--E2B
Specification 14° to 16° B.T.D.C.
(2250 RPM)
Factory
D1105--E3B 14.25° to 15.75°
Specification
(2250 RPM) B.T.D.C.
NOTE
Injection timing adjustment is accomplished by
adding or removing shims under the injection
pump.
The timing advances by removing one shim and
retards by adding the same shim.
The addition or removal of 0.05 mm (0.002 in.)
of shim, changes the injection timing by approx-
imately 0.087 rad. (0.5°).
Sealant should be applied to both sides of the
soft metal gasket shim.
1 5.1.2 Shim Identification

NOTE
Shims are available in thicknesses of 0.20 mm,
0.25 mm, 0.30 mm, and 0.35mm. Combine
shims for adjustments.
Refer to the figure below to check the thickness of shims

2 3 4
1. Shim (soft metal) 3. 1--Hole: 0.25 mm shim
2. 2--Holes: 0.20 mm shim 4. No Holes: 0.30 mm shim
5--1 62--11167
5.1.3 Pump Element Fuel Seal
2. Remove the injection lines and glow plugs.
3. Install the injection pump pressure tester to the injec-
tion pump.
4. Install the injection nozzle (1) jetted with the proper in-
jection pressure to the injection pump pressure tester
(2).
5. Set the speed control lever to the maximum speed
position.
6. Engage the starter.
7. If the pressure does not build up, replace the pump
element with a new one and test again.
13.73 MPa
Fuel pump Allowable
140 kgf/cm2
element seal Limit
1991 psi
5.1.4 Delivery Valve Fuel Seal

2. Remove the injection lines and glow plugs.
3. Install the injection pump pressure tester to the injec-
tion pump.
4. Install the injection nozzle (1) jetted with the proper in-
jection pressure to the injection pump pressure tester
(2).
5. Engage the starter.
6. Stop the starter when fuel jets from the injection
nozzle. Continue turning the flywheel by hand and
raise the pressure to approximately 13.73 MPa (140
kgf/cm2, 1991 psi.)
7. Now turn the flywheel about half a turn backward by
hand to keep the plunger free. Leave the flywheel in
this position while recording the time taken for the
pressure to drop from 13.73 MPa (140 kgf/cm2, 1991
psi.) to 12.75 MPa (130 kgf/cm2, 1849 psi.)
place the pump with a new one.
10 seconds
Delivery valve Factory 13.73 to 12.75 MPa
fuel seal Specification 140 to 130 kgf/cm2
1991 to 1849 psi
5 seconds
Delivery valve Allowable 13.73 to 12.75 MPa
fuel seal Limit 140 to 130 kgf/cm2
1991 to 1849 psi
NOTE
Never try to disassemble the injection pump as-
sembly.
62--11167 5--2
5.2 INJECTION NOZZLE
WARNING
Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.
5.2.1 Nozzle Spraying Condition
1. Set the injection nozzle in a nozzle tester and check

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

injection nozzle assembly.
(a) Good (b) Bad
5.2.2 Nozzle Injection Pressure
1. Set the injection nozzle in a nozzle tester.
2. Slowly move the tester handle to measure the pres-

sure at which fuel begins jetting out from the nozzle.
3. If the measurement is not within factory specifica-

tions, replace the adjusting washer (1) in the nozzle
holder.
Fuel Injection Factory 13.73 to 14.71 MPa
Pressure 140 to 150 kgt/cm2
1st Stage Specification 1991 to 2133 psi
(Reference)
A washer thickness of 0.01 mm (0.0004 in.) will vary the

the nozzle injection pressure by approximately 235 kPa
(2.4kgf/cm2, 34 psi.)
5--3 62--11167
5.2 INJECTION NOZZLE (Continued)
5.2.3 Valve Seat Tightness
1. Set the injection nozzle in a nozzle tester.
2. Raise the fuel pressure, and maintain 12.7MPa (130

kgf/cm2, 1850 psi) for 10 seconds.
3. If any fuel leak is found or if there is any loss of pres-

sure through the injection nozzle, replace the injec-
tion nozzle assembly.
No fuel leak at
Valve Seat Factory 12.7MPa
Tightness Specification 130 kgf/cm2
1850 psi
5.2.4 Nozzle Holder

1. Secure the nozzle retaining nut (7) in a vise.
2. Remove the nozzle holder (1), and remove the parts.
(When Reassembling)
Assemble the nozzle using clean fuel oil.
Install the push rod (4), noting its direction.
After assembling the nozzle, be sure to adjust the fuel

injection pressure.
34.3 to 39.2 N--m
Tightening Torque Nozzle Holder 3.5 to 4.0 kgf--m
25.3 to 28.9 ft--lbs
19.6 to 24.5 N--m
Overflow Pipe
Tightening Torque 2.0 to 2.5 kgf--m
1. Nozzle Holder 5. Distance Piece Nut
14.5 to 18.1 ft--lbs
2. Adjusting Washer 6. Nozzle Piece
49.0 to 68.6 N--m
3. Nozzle Spring 7. Nozzle Retaining Nut Nozzle Holder
Tightening Torque 5.0 to 7.0 kgf--m
Assembly
4. Push Rod 36.2 to 50.6 ft--lbs
62--11167 5--4
SECTION 6
ELECTRICAL SYSTEM
6.1 GLOW PLUG

6.1.1 Lead Terminal Voltage
1. Disconnect the glow plug wiring lead (1) from the glow
plug (2).
2. Connect a voltmeter between the glow plug wiring
lead (1) and a suitable ground on the engine.
3. Energize the glow plug lead and read the voltage.
4. Energize the glow plug lead, engage the starter at the
same time and read the voltage.
5. If the voltage differs from the battery voltage in either
case, the wiring harness or the switch or switches are
faulty.
1. Wiring Lead (Positive) 2 Glow Plug
6.1.2 Glow Plug Continuity

1. Disconnect the glow plug wiring lead (1) from the glow
plug (2).
2. Measure the resistance between the glow plug termi-
nal and the engine body with an ohmmeter.
3. If 0 ohm is indicated, the glow plug may be short--cir-
cuited.
4. If the factory specification is not met the plug is also
faulty.
Glow Plug Factory
Approximately 0.9 ohm
Resistance Specification
6--1 62--11167
6.2 STARTER
6.2.1 Motor Test
CAUTION
Secure the starter to prevent it from moving
when power is applied to it.
1. Disconnect the cable from the negative terminal on

the battery
2. Disconnect the the positive cable and leads from the
starter C terminal (1).
3. Remove the starter from the engine.
1. C Terminal 2. Connecting Lead
4. Disconnect the the connecting lead (2) from the start-
er C terminal (1).
5. Connect a jumper lead from the connecting lead (2) to
the positive post on the battery.
6. Connect a jumper lead momentarily between the
starter motor housing and the negative post on the
battery.
7. If the starter does not run, check the motor.
8.8 to 11.8 N.m
B
Tightening Torque 0.9 to 1.2 kgf.m
Terminal Nut
6.5 to 8.7 ft--lbs.
6.2.2 Magnetic Switch Test

1. Disconnect the cable from the negative terminal on
the battery.
2. Disconnect the positive cable and leads from the
starter C terminal (1).
3. Remove the starter from the engine.
3
4. Disconnect the the connecting lead (2) from the start-
er solenoid C terminal (1).
5. Connect a jumper lead from the starter S terminal (3)
to the positive battery post.
6. Momentarily, connect a jumper lead between the
2 starter C terminal (1) and negative battery terminal.
1
7. If the pinion gear nose does not pop out, check the
magnetic switch.
1. C 3. S Terminal NOTE
2. Connecting Lead
This test should only be carried out for a 3 to 5
second time period and not longer.
62--11167 6--2
6.3 STARTER ASSEMBLY
6.3.1 Starter Motor
1. Disconnect the connecting lead.
2. Remove the through bolts.
3. Remove the magnetic switch by sliding it out so that it
disconnects from the driver lead.
6.3.2 Brush Holder

1. Remove the brush from the holder while relieving the
spring pressure on the brush.
2. Remove the brush holder.
(When Reassembling)
Reverse the above procedure.
Use care not to damage the brush, commutator and
bearing during reassembly.
6.3.3 Armature
1. Remove the armature (1).
6.3.4 Housing, Idle Gear and Overrunning Clutch

1. Remove the housing (3).
2. Remove the idle gear (1) and the overrunning clutch
(2).
NOTE
Do not damage the clutch bearing and keep it
clean.
Do not lose the steel ball in the overrunning
clutch.
6.3.5 Plunger
1. Remove the end cover (1) of the solenoid switch (4).
2. Remove the plunger (2) and the spring (3).
6--3 62--11167
6.4 STARTER SERVICING
6.4.1 Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch
assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the crank-
ing direction.
4. If the pinion slips or does not rotate in both directions,
replace the overrunning clutch assembly.
6.4.2 Armature Bearing

1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
6.4.3 Brush Wear

1. If the contact face of the brush is dirty or dusty, clean it
with emery cloth.
2. Measure the brush length “A” with a vernier caliper.
3. If the length is less than the the allowable limit, re-
place the yoke assembly and the brush holder.
Factory 13.0 mm
Specification 0.5118 in.
Brush Length A
Allowable 8.5 mm
Limit 0.3346 in.
6.4.4 Solenoid
1. Check the continuity across the “C” terminal and the
“B” terminal by pushing the plunger, then measuring
resistance with an ohmmeter.
2. If there is no continuity, check the contacts.
6.4.5 Brush Holder

1. Check the continuity across the brush holder and
holder support with an ohmmeter.
2. If there is any continuity, replace the brush holder
62--11167 6--4
6.4 STARTER SERVICING (Continued)
6.4.6 Armature
6.4.6.a Continuity Check
1. Check the continuity across the commutator and the
armature with an ohmmeter.
2. If there is continuity, replace the armature.
3. Check the continuity across the segments of the com-
mutator with an ohmmeter.
4. If there is no continuity, replace the armature.
6.4.6.b Commutator and Mica

1. Check the contact pattern of the commutator for
wear, and grind the commutator with emery cloth if it
is slightly worn.
2. Measure the commutator O.D. with an outside mi-
crometer at several points.
3. If the minimum O.D. is less than the allowable limit,
replace the armature.
4. If the difference of the O.D.’s exceeds the allowable
limit, correct the commutator on a lathe to the factory
specifications.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct
it with a saw blade and chamfer the segment edges.
Factory 30.0 mm
Specification 1.181 in.
Commutator O.D.
Allowable 29.0 mm
Limit 1.142 in.
Factory Less Than 0.02 mm

Difference of Specification 0.0008 in.
O.D.’s Allowable 0.05 mm
Limit 0.0020 in.

Mica Undercut
Allowable 0.20 mm
Limit 0.0079 in.
1. Segment (a). Correct

2. Mica Undercut (b). Incorrect
3. Mica
6--5 62--11167
6.4 STARTER SERVICING (Continued)
6.4.7 Field Coil
1. Check the continuity across the lead (1) and the brush
with an ohmmeter.
2. If there is no continuity, replace the yoke assembly.
3. Check the continuity across the brush (2) and the
yoke (3) with an ohmmeter.
4. If there is continuity, replace the yoke assembly.
1. Lead 3. Yoke
2. Brush
62--11167 6--6
INDEX
B I
Battery, iv Identification, 1--1
bearing case, 2--12, 2--13
idle gear, 2--9
injection nozzle, 5--3, 5--4
C Injection Pump, 2--8
camshaft, 2--20, 2--21
injection timing, 5--1
compression pressure, 2--1
connecting rod, 2--10, 2--11, 2--24
coolant, iv, 2--2, 4--1
L
coolant level, 1--12
cooling system, 4--1 lubricating system, 3--1
crankshaft, 2--25
crankshaft assembly, 2--13
cylinder, 2--29 O
cylinder head, 2--3, 2--4, 2--14
oil filter, 3--2
oil level, 1--12, 3--1
D
oil pressure, 3--2
delivery valve, 5--2
oil pump, 3--3
dye/penetrant, 2--14
E P
electrical system, 6--1
piston, 2--10, 2--23, 2--24
engine oil, 1--12, 2--2, 3--1
piston ring, 2--11
Pump element, 5--2
F
push rod, 2--19
flywheel, 2--12
fuel injection, 2--3
fuel system, 5--1
fuel system -- bleeding , 1--13
R
radiator, 4--2
G radiator cap, 4--2
Gear Case, 2--7, 2--8, 2--9 relief valve, 3--3

glow plug, 6--1 rocker arm, 2--18
Index--1 62--11167
INDEX
S V
Safety Precautions, iv
v--belt, 4--1
Specific Warning and Cautions Statements, iv, v
valve clearance, 1--13
specifications, 1--2
starter, 6--2 valve guide, 2--16
starter -- assembly, 6--3 valve seat, 2--16
starter service, 6--4, 6--5, 6--6 valve spring, 2--18
Stop Solenoid / Speed Control Plate, 2--8
valves, 2--5, 2--6, 2--15, 2--17
T
tappets, 2--5, 2--19 W
thermostat, 4--2
timing gear, 2--20 water pump, 4--3
Torque Specification, 1--4 water pump assembly, 2--7
62--11167 Index--2
Carrier Transicold Division, Carrier Corporation
Truck/Trailer & Container Product Groups
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
www.carrier.transicold.com
A member of the United Technologies Corporation family. Stock symbol UTX

©2008 Carrier Corporation D Printed in U. S. A. 1108

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R Diesel Engine

D1105--E2B & D1105--E3B

PARAGRAPH NUMBER Page

PARAGRAPH NUMBER Page

PARAGRAPH NUMBER Page

SPECIFIC WARNING AND CAUTION STATEMENTS

Engine Serial Number (S/N)

7th Digit Alpahbetical Letter (Month of Manufacture).

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

Table 1-1. Model Chart

Table 1-2 Additional Support Manuals

The cylinder numbers of diesel engines are designated 2

1. Grease A. External Snap Ring

When reassembling external or internal snap rings,

Item Size x Pitch N.m kgf.m ft--lbs

1.6.2 Lubricating System

1.6.3 Cooling System

1.6.5 Electrical System

1.7 CHECK AND MAINTENANCE

1.7.6 Valve Clearance

1. Remove the valve cover (1) and the glow plugs.

1.8.2 Adapter, Kubota 10 mm

1.8.3 Tester Injector Nozzle

1.8.4 Replacement Bowl, Tester Injector Nozzle

1.8.5 Adapter, Injector Line

1. Gauge 5. Threaded Joint

1.8.7 Auxiliary Socket For Fixing Crankshaft

1.8.8 Gauge, Belt Tension

1.8.9 Tester, Belt Tension

1.8.10 Rubber Band

2. For idle gear bushing.

1.8.13 Flywheel Stopper

2.1 CHECKING AND ADJUSTING

1. Run the engine until it is warmed up.

2.2.4.b Injection Pipes

2.2.4.c Nozzle Heat Seal Removal Procedure

1. Remove the rocker arm bracket mounting nuts.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

After instaling the rocker arm, be sure to adjust

Rocker Arm 21.6 to26.5 N.m

2.2.4.e Cylinder Head

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

2. Remove the cylinder head bolts in the order of (14 to

3. Lift up the cylinder head and remove.

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

Replace the cylinder head gasket with a new one.

Install the cylinder head, taking care not to damage the

Apply oil to, then re--install the cylinder head bolts.

Tighten the cylinder head bolts in sequence starting

Retighten the head bolts after running the engine for 30

3. Scrape off the old adhesive from the mating surfaces

6. Visually inspect the oil pick--up screen O--ring (1) for

8. Within 20 minutes after the application of the sealer,

Sealer Location Refer to Section 1.4 for proper torque values on

2.2.6.b Gear Case

Measure the length of the mounting bolts (L). Insure that

A: L= 18 mm (0.71 in.) (Pipe Pin Position)

2. Remove the speed control plate.