Kubota D1803-CR-E4 Workshop Manual Download Page 258

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1. Install the DPF bracket (1).

(1) DPF bracket

2. Install the muffler full assembly (2).
3. Loosely tighten the muffler full assembly mounting

screws (3).

(2) Muffler full assembly

(3) Muffler full assembly mount-

ing screws

4. Loosely tighten the muffler flange nut (4).
5. Tighten the muffler full assembly mounting screws

(3) and muffler flange nut (4) to the specified torque.

6. Clamp the cord of exhausts gas temperature sensor

with clamp (5).

7. Attach the exhaust gas temperature sensor

connector (6), (7), (8) to the bracket.

Tightening tor-
que

DPF bracket
mounting screw

60.8 to 70.8 N

⋅

6.20 to 7.21 kgf

⋅

44.9 to 52.2 lbf

⋅

Muffler full assem-
bly mounting
screw (M10) (3)

49.0 to 55.9 N

⋅

5.00 to 5.70 kgf

⋅

36.2 to 41.2 lbf

⋅

Muffler full assem-
bly mounting
screw (M8) (3)

23.5 to 27.5 N

⋅

2.40 to 2.80 kgf

⋅

17.4 to 20.2 lbf

⋅

Muffler flange nut
(4)

23.5 to 27.5 N

⋅

2.40 to 2.80 kgf

⋅

17.4 to 20.2 lbf

⋅

(4) Muffler flange nut
(5) Clamp
(6) Exhaust gas temperature

sensor connector (T

)

(7) Exhaust gas temperature

sensor connector (T

)

(8) Exhaust gas temperature

sensor connector (T

)

4. ENGINE

SERVICING

6. Assembling

4-158

D1803-CR-E4,D1803-CR-TE4,D1803-CR-TIE4,V2403-CR-E4,V2403-CR-TE4,V2403-CR-TE4BG,V2403-CR-TIE4

KiSC issued 12, 2018 A

Summary of Contents for D1803-CR-E4

Page 1: ...WORKSHOP MANUAL DIESEL ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 2: ...ions and service limits are defined as followings Service specifications Specification which corresponds to new machine s ex factory It is based on quality standard drawings or actual measurements conducted by Kubota This value is used to determine whether there is a problem with the machine in the event of a troubleshooting However it is necessary to consider degradation due to wear based on the ...

Page 3: ...leaning contractor Checking DPF differential pressure pipes and hoses Thermostat Rail Function of diesel particulate filter DPF TROUBLESHOOTING Adjusting valve clearance Disassembling and assembling Air cleaner and others Filter comp DPF If necessary Crankshaft position sensor Fuel camshaft Pistons Flywheel Main bearing case assembly 2 10 3 16 3 23 4 87 3 2014 06 Oil separator Positive crankcase v...

Page 4: ...n control valve SCV Checking sensors Adjusting air gap between crank camshaft position sensor and flywheel pulsar gear Separate disassembling and assembling Added follow servicing information Replacing injector Replacing engine ECU Replacing DPF Change notification about fan drive pulley mounting nut tightening torque 4 96 4 107 4 107 4 114 4 115 4 191 4 193 4 196 ii D1803 CR E4 D1803 CR TE4 D1803...

Page 5: ...on 2 9 2 1 Part number and serial number DPF 2 9 3 Specifications 2 10 3 1 Specification for D1803 CR E4 TE4 2 10 3 2 Specification for V2403 CR E4 TE4 2 11 3 3 Specification for D1803 CR TIE4 V2403 CR TIE4 2 12 3 4 Specification for V2403 CR TE4BG 2 13 4 Performance curves 2 14 4 1 Performance curve for D1803 CR E4 2 14 4 2 Performance curve for D1803 CR TE4 2 15 4 3 Performance curve for D1803 C...

Page 6: ...heck points of every 400 hours 3 11 5 1 Changing engine oil 3 11 5 2 Replacing oil filter cartridge 3 12 6 Check points of every 500 hours 3 12 6 1 Replacing fuel filter cartridge 3 12 6 2 Cleaning water separator Type 1 3 13 6 3 Replacing water separator filter Type 2 3 13 6 4 Cleaning water jacket and radiator interior 3 13 6 5 Replacing fan belt 3 15 7 Check point of every 1000 hours 3 16 7 1 C...

Page 7: ...4 2 3 1 Outline of crankcase 4 4 2 3 2 Structure of crankcase 4 4 2 3 3 Function of crankcase 4 4 2 3 4 Specification of crankcase 4 4 2 4 Cylinder head 4 4 2 4 1 Outline of cylinder head 4 4 2 4 2 Structure of cylinder head 4 4 2 4 3 Function of cylinder head 4 4 2 5 Cylinder head cover 4 5 2 5 1 Outline of cylinder head cover 4 5 2 5 2 Structure of cylinder head cover 4 5 2 5 3 Function of cylin...

Page 8: ...6 4 Specification of valve 4 10 2 17 Tappet 4 11 2 17 1 Outline of tappet 4 11 2 17 2 Structure of tappet 4 11 2 17 3 Function of tappet 4 11 2 18 Push rod 4 11 2 18 1 Outline of push rod 4 11 2 18 2 Structure of push rod 4 11 2 18 3 Function of push rod 4 12 2 19 Timing gears 4 12 2 19 1 Outline of timing gears 4 12 2 19 2 Structure of timing gears 4 12 2 19 3 Function of timing gears 4 12 3 Fuel...

Page 9: ...nction of rail assembly 4 24 3 12 4 Specification of rail assembly 4 25 3 13 Injector 4 26 3 13 1 Outline of injector 4 26 3 13 2 Structure of injector 4 26 3 13 3 Function of injector 4 27 3 13 4 Specification of injector 4 29 3 14 Overflow pipe 4 29 3 14 1 Outline of overflow pipe 4 29 3 14 2 Structure of overflow pipe 4 29 3 14 3 Function of overflow pipe 4 29 3 15 Check valve 4 29 3 15 1 Outli...

Page 10: ...ture of intake and exhaust system 4 37 4 3 Flow of intake and exhaust system 4 38 4 4 Control of intake and exhaust system 4 40 4 5 Pre cleaner 4 40 4 5 1 Outline of pre cleaner 4 40 4 5 2 Structure of pre cleaner 4 40 4 5 3 Function of pre cleaner 4 40 4 5 4 Specification of pre cleaner 4 40 4 6 Air cleaner 4 40 4 6 1 Outline of air cleaner 4 40 4 6 2 Structure of air cleaner 4 40 4 6 3 Function ...

Page 11: ...3 Function of oil pan 4 55 6 4 4 Specification of oil pan 4 55 6 5 Oil strainer 4 55 6 5 1 Outline of oil strainer 4 55 6 5 2 Structure of oil strainer 4 55 6 5 3 Function of oil strainer 4 55 6 5 4 Specification of oil strainer 4 55 6 6 Oil pump 4 56 6 6 1 Outline of oil pump 4 56 6 6 2 Structure of oil pump 4 56 6 6 3 Function of oil pump 4 56 6 6 4 Specification of oil pump 4 56 6 7 Relief valv...

Page 12: ...7 9 4 Specification of cooling fan 4 64 7 10 Reserve tank 4 65 7 10 1 Outline of reserve tank 4 65 7 10 2 Structure of reserve tank 4 65 7 10 3 Function of reserve tank 4 65 7 11 Fan belt 4 65 7 11 1 Outline of fan belt 4 65 7 11 2 Structure of fan belt 4 65 7 11 3 Function of fan belt 4 65 8 Electrical system 4 66 8 1 Structure of electrical system 4 66 8 2 Feature of electrical system 4 67 8 3 F...

Page 13: ...81 9 11 2 Structure of exhaust gas temperature sensor 4 81 9 11 3 Function of exhaust gas temperature sensor 4 82 9 11 4 Specification of exhaust gas temperature sensor 4 82 9 12 Differential pressure sensor 4 83 9 12 1 Outline of differential pressure sensor 4 83 9 12 2 Structure of differential pressure sensor 4 83 9 12 3 Function of differential pressure sensor 4 83 9 12 4 Specification of diff...

Page 14: ... Adjusting air gap between camshaft position sensor and pulsar gear 4 115 5 Disassembling 4 115 5 1 Draining engine oil 4 115 5 2 Draining coolant 4 115 5 3 Removing CRS intermediate harness 4 116 5 4 Removing external components 4 116 5 5 Removing muffler full assembly 4 117 5 6 Disassembling DPF assembly 4 118 5 7 Removing EGR cooler 4 119 5 8 Removing turbocharger 4 119 5 9 Removing intake thro...

Page 15: ... 144 6 16 Installing fuel camshaft with supply pump gear 4 145 6 17 Installing idle gear 4 145 6 18 Installing crankshaft oil slinger 4 146 6 19 Installing gear case cover 4 146 6 20 Installing fan drive pulley 4 146 6 21 Installing water pump 4 147 6 22 Installing oil cooler 4 147 6 23 Installing supply pump 4 148 6 24 Installing suction control valve SCV 4 148 6 25 Installing thermostat assembly...

Page 16: ...earance between piston ring and ring groove 4 176 7 30 Checking side clearance of crankshaft 4 177 7 31 Checking crankshaft alignment 4 178 7 32 Checking oil clearance between crankpin and crankpin bearing 4 179 7 33 Checking oil clearance between crankshaft journal and crankshaft bearing 1 4 179 7 34 Replacing crankshaft sleeve 4 180 7 35 Replacing crankshaft bearing 1 4 181 7 36 Checking oil cle...

Page 17: ...1 SAFETY KiSC issued 12 2018 A ...

Page 18: ...mage could result if instructions are not followed NOTE Gives helpful information 1 Working precautions Understand all safety instructions and safety labels in this manual Park the machine on a stable and level ground then lower the attachment to check the machine safely Stop the engine and remove the key when leaving the operator s seat for cleaning maintenance and servicing Hang a DO NOT OPERATE...

Page 19: ...hine Make sure you have the support of the 3 points with both hands holding the handle and one foot at the step when getting on and off the machine Confirm the coolant temperature and release pressure when opening the radiator cap Release residual pressure in the hydraulic circuit before removing the hydraulic components Pay attention when releasing pressure in hydraulic circuit the machine or att...

Page 20: ...nting fires Keep fire welding sparks grinding sparks cigarettes away from the fuel Wipe the fuel off when spilled Keep fire welding sparks grinding sparks cigarettes away from the battery The battery produces oxygen and hydrogen gas that are flammable Make sure to disconnect the negative terminal first when disconnecting the battery cable Make sure to connect the positive terminal first when conne...

Page 21: ...es Get a medical aid immediately if the accident occurs 8 Avoiding hot exhaust Avoid skin exposure and contact with hot exhaust gas or components Exhaust gas and components are extremely hot during operation Do not work immediately after stopping the engine The engine muffler radiator and hydraulic components are extremely hot Do not remove caps and plugs soon after stopping the engine The tempera...

Page 22: ...s or components Exhaust gas and components are extremely hot during regeneration of diesel particulate filter DPF SAFETY FIRST 1 SAFETY D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 1 5 KiSC issued 12 2018 A ...

Page 23: ...1 SAFETY SAFETY FIRST 1 6 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 24: ...2 GENERAL KiSC issued 12 2018 A ...

Page 25: ...side Tighten the bolts and nuts with their specified torque NOTE Tighten the bolts and nuts alternately from top to bottom and left to right so the torque is distributed evenly Gradually tighten the bolts and nuts two or three times 2 Applying thread locking fluid 1 Clean and dry the location where a thread locking fluid will be applied with a solvent to remove moisture oil and dirt 2 Apply the th...

Page 26: ...kage apply it on the outer side Reassemble within 15 minutes after applying wait for 30 minutes or more then fill with oil 5 Replacing O rings 1 O ring groove 2 O ring 3 Burr 1 Remove the burr and clean the O ring groove 2 Lubricate the O ring Do not apply any grease to the floating seal 3 Put the O ring in the groove NOTE Do not twist the O ring Remove the burr to avoid damage on the O ring cause...

Page 27: ... the battery terminal posts to prevent corrosion 8 Handling electrical wiring CAUTION Do not put an unprotected electrical wiring to come in contact with other components Do not clamp the electrical wiring to fuel hoses If the electrical wiring is damaged repair it with an insulating tape or rat proof tape or replace the wiring with a new one Do not alter the electrical device and wiring Tighten t...

Page 28: ...locations make sure to clamp the electrical wiring loosely 12 Electrical wiring 13 Clamp A Correct B Incorrect Do not pinch the electrical wiring when installing parts 14 Electrical wiring B Incorrect 9 Handling fuses Always use fuses of the specified capacity Do not use steel or copper wiring instead of fuse Do not install work light or radio without auxiliary power line Do not install auxiliarie...

Page 29: ...bent rusty and so on If the terminal is rusted remove rust with sandpaper 1 Missing terminal 2 Bent terminal 3 Sandpaper 4 Rust Cover the female bullet terminals and male bullet terminals securely with the waterproof plastic covers Make sure that the bullet terminals are secure and connected securely to the tip B Correct C Incorrect Cover the female connectors and male connectors securely with the...

Page 30: ...b White W Yellow Y An example W R Red stripe on white color 12 Dispose fluids correctly Do not dispose fluids on the ground down the drain into a stream pond or lake Obey related environmental protection regulations when you dispose of oil fuel coolant electrolyte and other dangerous materials 2 GENERAL GENERAL WORKING PRECAUTIONS 11 Wiring color 2 6 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR...

Page 31: ...anufacture as below Engine series Number or alphabet Series 1 05 include WG 2 V3 include WG 3 08 4 SM include WG 5 Air cooled gasoline 6 GZ OC AC EA E 7 03 include WG 8 07 A EA RK B 03 KET production C V3 07 KEW production Production year Alphabet or number Year 1 2001 2 2002 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 A 2010 B 2011 C 2012 D 2013 E 2014 F 2015 G 2016 H 2017 J 2018 K 2019 L 20...

Page 32: ...th EF at the end of the Model designation on the US EPA label E4B designates some In terim Tier 4 Tier 4 models depending on engine output classification Category 1 Engine output classification EU regulation K From 19 to 37 kW STAGE IIIB P From 37 to less than 56 kW STAGE IIIB N From 56 to less than 75 kW STAGE IIIB M From 75 to less than 130 kW STAGE IIIB Category 2 Engine output classification E...

Page 33: ...ver to identify Output classification and Emission Control Information E4B engines are identified with EF at the end of the Model designation on the US EPA label Please note E4B is not marked on the engine Example Engine model name D1803 CR E4 XXXX or D1803 CR TE4 XXXX 1 3 Cylinder number You can see the cylinder numbers of Kubota diesel engine in the figure The sequence of cylinder numbers is No ...

Page 34: ... trochoid pump Oil pressure indicating Electrical type switch Lubricating filter Full flow paper filter Cartridge type Cooling system Pressurized radiator forced circulation with water pump Starting system Electric starting with starter Starter motor 12 V 1 4 kW Starting support device By glow plug in combustion chamber EGR External EGR EGR cooler Electric EGR valve Reed valve Battery 12 V 88 AH 1...

Page 35: ...id pump Oil pressure indicating Electrical type switch Lubricating filter Full flow paper filter Cartridge type Cooling system Pressurized radiator forced circulation with water pump Starting system Electric starting with starter Starter motor 12 V 2 0 kW Starting support device By glow plug in combustion chamber EGR External EGR EGR cooler Electric EGR valve Reed valve Battery 12 V 92 AH 130E41R ...

Page 36: ...p Oil pressure indicating Electrical type switch Lubricating filter Full flow paper filter Cartridge type Cooling system Pressurized radiator forced circulation with water pump Starting system Electric starting with starter Starter motor 12 V 1 4 kW 12 V 2 0 kW Starting support device By glow plug in combustion chamber EGR External EGR EGR cooler Electric EGR valve Reed valve Battery 12 V 88 AH 10...

Page 37: ...ype switch Lubricating filter Full flow paper filter Cartridge type Cooling system Pressurized radiator forced circulation with water pump Starting system Electric starting with starter Starter motor 12 V 2 0 kW Starting support device By glow plug in combustion chamber EGR External EGR EGR cooler Electric EGR valve Reed valve Battery 12 V 92 AH 130E41R equivalent Charging alternator 12 V 720 W Fu...

Page 38: ... B S F C 3 Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C 2 GENERAL GENERAL MACHINE INFORMATION 4 Performance curves 2 14 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 39: ... Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C GENERAL MACHINE INFORMATION 4 Performance curves 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 15 KiSC issued 12 2018 A ...

Page 40: ...3 Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C 2 GENERAL GENERAL MACHINE INFORMATION 4 Performance curves 2 16 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 41: ...Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C GENERAL MACHINE INFORMATION 4 Performance curves 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 17 KiSC issued 12 2018 A ...

Page 42: ... Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C 2 GENERAL GENERAL MACHINE INFORMATION 4 Performance curves 2 18 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 43: ...3 Engine speed 4 Brake horsepower 5 Gross intermittent torque 6 Gross intermittent brake horsepower 7 Gross intermittent B S F C GENERAL MACHINE INFORMATION 4 Performance curves 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 19 KiSC issued 12 2018 A ...

Page 44: ...8 9 in 744 mm 29 3 in V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 A 869 mm 34 2 in 869 mm 34 2 in 854 mm 33 6 in B 517 mm 20 4 in 517 mm 20 4 in 517 mm 20 4 in C 721 mm 28 4 in 735 mm 28 9 in 744 mm 29 3 in 2 GENERAL GENERAL MACHINE INFORMATION 5 Dimensions 2 20 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 45: ...6 CN207 Oil pressure switch 7 CN208 Boost pressure sensor 8 CN209 Suction control valve SCV 9 CN210 Intake throttle valve 10 Shield cable NOTE The figure shows the pin arrangement of the connector housing viewed from wire side not mating side GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 21 KiSC...

Page 46: ... 15 Shield cable NOTE The figure shows the pin arrangement of the connector housing viewed from wire side not mating side 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 22 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 47: ...jector 3 6 CN304 Injector 2 Injector 4 is equipped only V2403 model NOTE The figure shows the pin arrangement of the connector housing viewed from wire side not mating side GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 23 KiSC issued 12 2018 A ...

Page 48: ...03 Engine ECU joint connector 1 4 Power unit 5 Diesel Particulate Filter Hereinafter referred to as the DPF 6 Engine 7 Injector 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 24 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 49: ...3 CN404 Connector 14 CN405 Connector 15 CN413 Main relay 16 Glow 17 CN416 Glow relay 18 CN414 Connector 19 CN415 Connector 20 Fuel feed pump 21 Battery unit 22 Battery 23 Key switch 24 Speed sensor 25 CAN for vehicle Continued GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 25 KiSC issued 12 2018 ...

Page 50: ... CN102 Exhaust gas temperature sensor T1 31 CN103 Exhaust gas temperature sensor T0 32 CN104 Differential pressure sensor ΔP 33 CN105 Air flow sensor NOTE The figure shows the pin arrangement of the connector housing viewed from wire side not mating side 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 26 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 ...

Page 51: ... pin arrangement of the connector housing viewed from wire side not mating side GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 27 KiSC issued 12 2018 A ...

Page 52: ...e pin arrangement of the connector housing viewed from wire side not mating side 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 28 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 53: ...sure sensor 3 CAN1 connector for service 15 Injector 3 27 Stop switch 4 CAN2 connector for vehicle 16 Injector 2 28 Parked regeneration switch 5 EGR valve 17 Crankshaft position sensor 29 Parking switch 6 Starter 18 Camshaft position sensor 30 Regeneration inhibit switch Continued GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4...

Page 54: ...ure sensor T1 10 Battery 22 Differential pressure sensor ΔP 34 Exhaust gas temperature sensor T2 11 Glow relay 23 Suction control valve SCV 12 Glow heater 24 Coolant temperature sensor Injector 4 is equipped only V2403 model 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 30 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 55: ... sensor 4 CAN2 connector for vehicle 13 Injector 4 22 Rail pressure sensor 5 EGR valve 14 Injector 3 23 Boost pressure sensor 6 Starter 15 Injector 2 24 Stop switch 7 Air flow sensor 16 Crankshaft position sensor 25 Neutral switch 8 Starter relay 17 Camshaft position sensor Continued GENERAL MACHINE INFORMATION 6 Wiring diagram 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR ...

Page 56: ...ensor 1 Injector 4 is equipped only V2403 model 2 GENERAL GENERAL MACHINE INFORMATION 6 Wiring diagram 2 32 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 57: ...r measuring the diesel engine compression Code No 07909 30208 Assembly 1 Gauge SPECIAL TOOLS 1 Diesel engine compression tester 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 33 KiSC issued 12 2018 A ...

Page 58: ... 20 mm dia 0 315 to 0 322 in dia E 118 to 120 2 06 to 2 09 rad F 4 8 to 5 2 mm dia 0 19 to 0 20 in dia G 17 mm 0 67 in H 10 mm 0 39 in I 41 mm 1 6 in J 15 mm 0 59 in K 49 mm 1 9 in L 10 mm 0 39 in M 15 mm 0 59 in N 10 mm 0 39 in O 100 mm 3 94 in P 125 mm 4 92 in C0 3 Chamfer 0 3 mm Chamfer 0 01 in Material SS400 2 GENERAL SPECIAL TOOLS 2 Compression tester adapter K 2 34 D1803 CR E4 D1803 CR TE4 D...

Page 59: ... to 7 60 mm dia 0 296 to 0 299 in dia G 25 mm dia 0 98 in dia H 7 70 to 8 00 mm dia 0 304 to 0 314 in dia I 5 mm 0 2 in J 20 mm dia 0 79 in dia K 13 5 to 13 8 mm dia 0 532 to 0 543 in dia L 8 90 to 9 10 mm 0 351 to 0 358 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C0 3 Chamfer 0 3 mm 0 01 in Material SS400 5 Bushing replacing tools Use for press out and press fit the bushing NOTE This...

Page 60: ...nd tightening the flywheel screw NOTE This special tool is not provided therefore make it by referring to the figure A 140 mm 5 51 in B 80 mm 3 1 in C 49 3 mm 1 94 in D 49 3 mm 1 94 in E 23 8 mm 0 937 in F 23 8 mm 0 937 in G 11 mm dia 0 43 in dia H 56 5 mm 2 22 in I 56 5 mm 2 22 in J 8 mm 0 3 in Material SS400 7 Crankshaft bearing 1 replacing tool Use for press out and press fit the crankshaft bea...

Page 61: ...m 0 79 in G 20 mm dia 0 79 in dia H 68 mm dia 2 68 in dia I 59 80 to 59 90 mm dia 2 355 to 2 358 in dia J 64 80 to 64 90 mm dia 2 552 to 2 555 in dia Material SS400 8 Auxiliary socket for fixing crankshaft sleeve Use for fixing the crankshaft sleeve of the diesel engine NOTE The special tools are not provided so make them referring to the figure SPECIAL TOOLS 8 Auxiliary socket for fixing cranksha...

Page 62: ...ia X 140 mm 5 51 in Y 120 mm 4 72 in Continued Z 110 mm 4 33 in a 50 0 mm 1 97 in b 39 90 to 40 00 mm 1 571 to 1 574 in c 25 0 mm 0 984 in d 90 0 mm dia 3 54 in dia e 81 0 mm dia 3 19 in dia f 80 10 to 80 15 mm dia 3 154 to 3 155 in dia g 30 0 mm dia 1 18 in dia h 5 0 mm dia 0 20 in dia i 70 0 mm 2 76 in j 50 0 mm 1 97 in k 40 0 mm dia 1 57 in dia C1 Chamfer 1 0 mm 0 039 in C5 Chamfer 5 0 mm 0 20 ...

Page 63: ...7 in dia F 10 mm dia 0 39 in dia G 20 34 to 20 50 mm dia 0 8008 to 0 8070 in dia H 1 0 rad 60 C1 Chamfer 1 0 mm 0 039 in Material SS400 SPECIAL TOOLS 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 39 KiSC issued 12 2018 A ...

Page 64: ...a 1 7 in dia B 32 000 to 32 025 mm dia 1 2599 to 1 2608 in dia C 116 mm dia 4 57 in dia D 3 mm dia 0 1 in dia E 88 mm 3 5 in F 12 mm 0 47 in G 88 mm 3 5 in H 92 mm 3 6 in Continued 2 GENERAL SPECIAL TOOLS 10 Bearing case cover oil seal replacing tool 2 40 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 65: ... 0 87 in dia O 145 mm dia 5 71 in dia P 90 mm 3 5 in Q 12 mm 0 47 in C0 3 Chamfer 0 3 mm 0 01 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in C4 Chamfer 4 0 mm 0 16 in Material SS400 SPECIAL TOOLS 2 GENERAL D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 2 41 KiSC issued 12 2018 A ...

Page 66: ...2 GENERAL SPECIAL TOOLS 2 42 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 67: ...3 MAINTENANCE KiSC issued 12 2018 A ...

Page 68: ...t tension 3 10 Checking radiator hose and clamp bands 3 10 Checking intake air line 3 11 Replacing fuel filter cartridge 3 12 Cleaning water separator Type 1 3 13 Cleaning fuel tank interior Cleaning water jacket and radiator interior 3 13 Replacing fan belt 3 15 Replacing water separator filter Type2 3 13 Checking valve clearance 3 16 1 Checking injector with Diagmas ter 3 17 1 Checking EGR coole...

Page 69: ...ssion regulation As the engine owner you are responsible for the performance of the required maintenance on the engine according to the above instruction Please see the warranty statement in detail The items listed above other than 1 marked are not necessary to keep the emission related warranty valid 2 Only for D1803 E4 TE4 V2403 E4 TE4 Failure to perform the maintenance will cause problems that ...

Page 70: ...e use of ultra low sulfur fuel is mandatory for these engines when operated in US EPA regulated areas Therefore please use No 2 D S15 diesel fuel as an alternative to No 2 D and use No 1 D S15 diesel fuel as an alternative to No 1 D for ambient temperature below 10 14 SAE Society of Automotive Engineers EN European Norm ASTM American Society of Testing and Materials US EPA United States Environmen...

Page 71: ...l system replace the fuel hose with new ones and take other necessary measures It is advisable to replace the fuel filter fuel hose and clamp bands with new ones after half the specified replacement intervals Compared with the use of mineral oil diesel fuels the filtration performance of fuel filters gets degraded earlier than expected Biodiesel fuels easily induce the growth of microorganisms and...

Page 72: ...il can decrease the output or cause too much blow by gas On the closed breather type engine the port absorbs the mist and too much oil can cause oil hammer But if the oil level is not sufficient the moving parts of engine can get a seizure Above 25 77 SAE 30 or SAE 10W 30 SAE 15W 40 0 to 25 32 to 77 SAE 20 or SAE 10W 30 SAE 15W 40 Below 0 32 SAE10W or SAE 10W 30 SAE 15W 40 1 Make the engine level ...

Page 73: ... 3 Checking coolant level CAUTION Do not remove the radiator cap when the engine is hot Then loosen the cap slightly to release unwanted pressure before you remove the cap fully IMPORTANT When you add the coolant release the air from the engine coolant channels The engine releases the air when it shakes the radiator upper and lower hoses Make sure that you close the radiator cap correctly If the c...

Page 74: ... oil of different brand or viscosity from the previous drain the remaining oil Do not mix 2 different types of oil Engine oil must have the properties of API classification CJ 4 Use the correct SAE Engine Oil by reference to the ambient temperature Above 25 77 SAE 30 or SAE 10W 30 SAE 15W 40 0 to 25 32 to 77 SAE 20 or SAE 10W 30 SAE 15W 40 Below 0 32 SAE10W or SAE 10W 30 SAE 15W 40 1 Start and war...

Page 75: ...Oil filter cartridge 2 Apply a thin layer of oil on the new cartridge gasket 3 Install the new cartridge by hand NOTE Do not tighten too much because it can cause deformation of the rubber gasket 4 Make sure that the engine oil does not flow through the seal and read the oil level on the dipstick 5 Fill the engine oil until the specified level NOTE After you replace the cartridge the engine oil us...

Page 76: ...stem IMPORTANT As water is accumulated the red float 6 goes up When the float 6 has reached the specified line 2 immediately drain the water separator In reattaching the water separator be careful to keep off dust and dirt Be sure to air bleed the fuel system before operating engine 1 Water separator handle 2 Specified line 3 Bottom valve 4 Top screw 5 Cup 6 Float A Close 4 Check points of every 2...

Page 77: ... fan drive pulley and alternator pulley at a specified force to measure the deflection 1 Deflection 1 Service specifi cation 10 0 to 12 0 mm 0 394 to 0 472 in in under load of 98 N 10 kgf 22 1 lbf 1 Deflection NOTE If the measurement is out of the service specifications loosen the alternator mounting screws and adjust its position 4 3 Checking radiator hose and clamp bands 1 Check that the radiato...

Page 78: ...2 years Also replace the clamp 2 every 2 years and tighten it correctly 1 Intake air hose 2 Clamp 5 Check points of every 400 hours 5 1 Changing engine oil CAUTION Make sure that you stop the engine before you change the engine oil IMPORTANT When you use an oil of different brand or viscosity from the previous drain the remaining oil Do not mix 2 different types of oil Engine oil must have the pro...

Page 79: ...nt Use only a Kubota genuine filter or its equivalent Tools required Filter wrench 1 Remove the oil filter cartridge 1 with the filter wrench 1 Oil filter cartridge 2 Apply a thin layer of oil on the new cartridge gasket 3 Install the new cartridge by hand NOTE Do not tighten too much because it can cause deformation of the rubber gasket 4 Make sure that the engine oil does not flow through the se...

Page 80: ...o dirt in the fuel NOTE Replace the water separator filter with a new one every 500 hours or 1 year Tools required Filter wrench 1 Remove the old water separator filter 1 with a filter wrench 1 Water separator filter 2 Apply a thin layer of oil on the new water separator filter 3 Tighten the new water separator filter by hand 4 Operate the engine for a while and check if there is not the fuel leak...

Page 81: ...se 3 5 Fill with clean water and cooling system cleaner 6 Obey the directions of the cleaner instruction 7 After you flush fill with clean water and anti freeze until the coolant level is immediately below the port 8 Install the radiator cap 1 correctly 9 Fill with the coolant until the FULL A mark on the reserve tank 4 4 Reserve tank A FULL B LOW 10 Start and operate the engine for a few minutes ...

Page 82: ...n the cooling system to get a higher boiling point NOTE The above data is the industrial standards that shows the minimum glycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep the anti freeze mixing ratio less than 50 If there is a leakage add anti freeze and clean soft water in the specified mixing ratio ...

Page 83: ...eck point of every 1000 hours 7 1 Checking valve clearance IMPORTANT You must check and adjust the valve clearance when the engine is cold Tools required Feeler gauge 1 Remove the air cleaner and muffler 2 Remove the cylinder head cover 3 Align the 1TC mark 2 line on the flywheel and projection 1 on the housing 4 Make sure that the No 1 piston comes to the compression or overlap top dead center 3 ...

Page 84: ...ts of every 1500 hours 8 1 Checking injector with Diagmaster Tools required Laptop computer Diagmaster software installed Interface DST i 1 Connect the diagnosis tool 2 Start Diagmaster then click the Active Test button 1 from the project window 3 Select the 1 2 3 and 4 Cylinder Injector Injection Stop item 2 then click the proceed button 3 1 Active Test button 2 1 2 3 and 4 Cylinder Injec tor Inj...

Page 85: ...a water tank 3 Check that the coolant passage is full of water 4 Apply the specified amount of air pressure a to the air hose side EGR cooler leakage test pressure Service speci fication Exhaust gas passage 290 kPa 3 0 kgf cm2 43 psi 1 Exhaust gas inlet 2 Exhaust gas outlet a Air pressure 5 Check that there are no air leaks in any of the EGR cooler parts NOTE If there are air leaks replace the EGR...

Page 86: ...w one 8 4 Checking positive crankcase ventilation PCV valve 1 Remove the cover 1 and element 3 1 Cover 2 O ring 3 Element 4 Body 2 Look into the hole leading to the PCV valve of the oil separator body 4 inside and then check if there is no crack break or abnormal sediment in the PCV valve 3 Check the oil separator assembly for crack oil leakage and loose connections NOTE If you find a crack or oil...

Page 87: ... or given a shock cannot be reused even if there is no damage outwardly replace it with a new one Be sure to loosen the exhaust gas temperature sensor tightening nut or the differential pressure pipe tightening nut with crowfoot wrench to prevent the damage of the sensor or pipe If it is still hard to loosen apply the lubricant spray to threaded portion and soak it with lubricant NOTE Always work ...

Page 88: ...lamp 5 4 Remove the tube 11 12 from the differential pressure pipe 1 4 5 Remove the differential sensor 3 6 Remove the differential sensor bracket 2 7 Remove the 4 screws of muffler flange 6 1 Differential pressure pipe 2 Differential pressure sensor bracket 3 Differential pressure sensor 4 Differential pressure pipe 5 Clamp 6 Muffler flange 7 Connector of exhaust gas temperature sensor T2 8 Conne...

Page 89: ...d make sure that there are no gas leaks Reassemble the filter comp DPF 16 in the correct direction Tightening tor que Filter comp DPF bracket 15 17 16 to 20 N m 1 7 to 2 0 kgf m 12 to 14 lbf ft Exhaust gas tem perature sensor 22 23 24 25 0 to 35 0 N m 2 55 to 3 56 kgf m 18 5 to 25 8 lbf ft Differential pres sure pipe 1 4 16 0 to 23 0 N m 1 64 to 2 34 kgf m 11 8 to 16 9 lbf ft 1 Differential pressu...

Page 90: ...f remaining ash in the following procedure and evaluate the reusability 1 After having cleaned the filter comp DPF 2 measure the actual cell depth D with a pin gauge 1 in the each block shown in the figure NOTE One cell The measurement point is not specified is measured in each block Model Measurement total D1803 V2403 16 blocks a Serial number NOTE If the actual cell depth D is less than the serv...

Page 91: ...required Laptop computer Diagmaster software installed Interface DST i 1 Connect the diagnosis tool 2 Start Diagmaster then click the Active Test button 1 from the project window 3 Select the Exhaust Gas Recirculation EGR Valve ON OFF Function item 2 then click the proceed button 3 1 Active Test button 2 Exhaust Gas Recirculation EGR Valve ON OFF Func tion item 3 Proceed button 4 Select the EGR Va...

Page 92: ...ent 2 NOTE The air cleaner uses a dry element Never apply oil to it Do not operate the engine with filter element removed 4 Install the removed parts 10 2 Checking DPF differential pressure pipes and hoses IMPORTANT Be sure to loosen the differential pressure pipe tightening nut with crowfoot wrench to prevent the damage of the sensor or pipe If it is still hard to loosen apply the lubricant spray...

Page 93: ... the EGR cooler 2 or EGR pipe 1 which has cracked If you find a gas leakage tighten the mounting screw again or replace the gasket with a new one If you find a loose mounting screw tighten the mounting screw again 1 EGR pipe 2 EGR cooler 10 4 Checking intake air line IMPORTANT To prevent serious damage to the engine keep out dust in the intake air line 1 Make sure that the intake air hose s 1 are ...

Page 94: ...w water separator filter by hand 4 Operate the engine for a while and check if there is not the fuel leakage from the filter 11 Check points of every 2 years 11 1 Replacing fan belt 1 Remove the alternator 1 2 Remove the fan belt 2 1 Alternator 2 Fan belt 3 Replace the fan belt 2 with a new one 4 Install the alternator 1 5 Adjust the tension of belt halfway between the fan drive pulley and alterna...

Page 95: ...sen the clamp and remove the hose 2 Replace the hose with new ones 3 Tighten the clamp correctly 11 7 Replacing lubricant hose 1 Loosen the clamp and remove the hose 2 Replace the hose with new ones 3 Tighten the clamp correctly 11 8 Changing radiator coolant CAUTION Do not remove the radiator cap when the engine is hot Then loosen the cap slightly to release unwanted pressure before you remove th...

Page 96: ...ctions of the cleaner instruction 7 After you flush fill with clean water and anti freeze until the coolant level is immediately below the port 8 Install the radiator cap 1 correctly 9 Fill with the coolant until the FULL A mark on the reserve tank 4 4 Reserve tank A FULL B LOW 10 Start and operate the engine for a few minutes 11 Stop the engine and let the coolant temperature decreases CHECK AND ...

Page 97: ...lycol content necessary in the concentrated anti freeze When the coolant level decreases because of evaporation add clean soft water only to keep the anti freeze mixing ratio less than 50 If there is a leakage add anti freeze and clean soft water in the specified mixing ratio The anti freeze absorbs moisture Keep new anti freeze in a tightly sealed container Do not use the radiator cleaning agents...

Page 98: ...ng intake air line IMPORTANT To prevent serious damage to the engine keep out dust in the intake air line 1 Loosen the clamp 2 2 Remove the intake air hose 1 and clamp 2 1 Intake air hose 2 Clamp 3 Replace the intake air hose 1 and clamp 2 with new ones 4 Tighten the clamp 2 correctly CHECK AND MAINTENANCE 11 Check points of every 2 years 3 MAINTENANCE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 ...

Page 99: ...3 MAINTENANCE CHECK AND MAINTENANCE 11 Check points of every 2 years 3 32 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 100: ...4 ENGINE KiSC issued 12 2018 A ...

Page 101: ...n delay period The ignition delay period is the period from when fuel is injected into the cylinder as a mist until start of combustion is attempted Fuel that injected into the cylinder at the high temperature high pressure compressed air through several degrees before compression top dead center is vaporized by heat of air Thereafter the fuel mixes with air nearing ignition point B point and igni...

Page 102: ...ction volume control fuel injection timing control fuel injection rate control and fuel pressure control See the CRS section for details RELATED PAGE 3 4 Control of common rail system CRS engine on page 4 17 4 ENGINE MECHANISM 1 General Introduction 4 2 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 103: ...nder head cover 2 Rocker arm 3 Cylinder head 4 Piston 5 Flywheel housing 6 Flywheel 7 Crankcase 8 Oil pan 9 Main bearing case 10 Gear case 11 Crankshaft 12 Idle gear 13 Camshaft with cam gear 14 Connecting rod 15 Breather MECHANISM 2 Engine body 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 3 KiSC issued 12 2018 A ...

Page 104: ...l camshaft 2 Idle gear 3 Camshaft 4 Crankshaft 2 3 4 Specification of crankcase Cylinder liner diameter D 87 000 to 87 022 mm 3 4252 to 3 4260 in Finish machining Honing 1 4 to 2 2 μmRz Oversize 0 25 mm 0 0098 in 2 4 Cylinder head 2 4 1 Outline of cylinder head Along with the crankcase the cylinder head is the most fundamental part that makes up the engine 2 4 2 Structure of cylinder head The cyli...

Page 105: ...function is to suppress noise emissions Furthermore the interior side of the cylinder head cover is provided with a structure in the passage blow by gas flows in for liquifying oil enabling the oil to stay within the head cover The half float type cylinder head cover reduces noise from the cylinder head 2 6 Breather 2 6 1 Outline of breather The breather is a component that releases blow by gases ...

Page 106: ...t 8 Ring groove 9 Piston profile re entrant shape 2 8 3 Function of piston Along with the cylinder and cylinder head the piston forms the combustion chamber In addition it reciprocates in the cylinder during each of the intake compression combustion and exhaust strokes The first and primary role is to receive explosive energy during combustion and transfer this to the crankshaft via the connecting...

Page 107: ...2 9 4 Specification of piston ring Service speci fication of pis ton ring gap Top ring 0 20 to 0 35 mm 0 0079 to 0 013 in Second ring D1803 CR E4 V2403 CR E4 0 30 to 0 45 mm 0 012 to 0 017 in D1803 CR TE4 TIE4 V2403 CR TE4 TE4BG TIE4 0 40 to 0 55 mm 0 016 to 0 021 in Oil ring D1803 CR E4 V2403 CR E4 0 20 to 0 40 mm 0 0079 to 0 015 in D1803 CR TE4 TIE4 V2403 CR TE4 TE4BG TIE4 0 25 to 0 45 mm 0 0099...

Page 108: ...ring case and that rotates is called the crank journal the part connected to the connecting rod is called a crankpin and the part that connects both of these is called the crank arm While conducting continuous power to outside the engine this also causes each of the intake compression combustion and exhaust strokes to be performed 2 11 4 Specification of crankshaft Crankpin Undersize 0 20 mm 0 007...

Page 109: ...ia the flywheel causes the engine to rotate smoothly during strokes other than the combustion stroke 2 13 4 Specification of flywheel Reference value Flywheel diameter 300 mm 11 8 in This value is for STD engine so that it may be different depending on the product used 2 14 Rocker arm 2 14 1 Outline of rocker arm Rocker arms transfer camshaft movement to valves via push rods 2 14 2 Structure of ro...

Page 110: ...41 before B D C Close angle 0 20 rad 9 after T D C 2 16 Valve 2 16 1 Outline of valve Valves open and close passages ports that conducted to the combustion chamber 2 16 2 Structure of valve Intake and exhaust valves are mounted to the cylinder head via valve springs valve retainers and collets 1 Exhaust valve 2 Intake valve 3 Valve stem 4 Valve face 5 Valve head 2 16 3 Function of valve In general...

Page 111: ...e cam and tappet are set with centers slightly offset and the tappet rotates while the engine is running so uneven wear does not readily occur 2 18 Push rod 2 18 1 Outline of push rod The push rod transfers tappet movement to the rocker arm 2 18 2 Structure of push rod The push rod is mounted so as to contact the tappet and rocker arm 1 Tappet side 2 Push rod 3 Rocker arm side MECHANISM 2 Engine b...

Page 112: ...dle gear 3 Cam gear 4 Crank gear 5 Oil pump drive gear 2 19 3 Function of timing gears The timing gears transfer power from the crankshaft to each gears The timing gears determine movement timing of each of the parts in conjunction with movement of the piston Timing gears synchronize timing for rotation of the crankshaft and opening and closing of valves Therefore when assembling each of the marks...

Page 113: ...gnetic fuel feed pump 4 Check valve 5 Fuel filter 6 Fuel pump 7 Supply pump 8 Rail 9 Injector 10 Check valve 11 Overflow pipe 12 Engine ECU 13 Fuel cooler 14 Check valve a High pressure fuel flow b Low pressure fuel flow MECHANISM 3 Fuel system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 13 KiSC issued 12 2018 A ...

Page 114: ...re transmitted from various sensors to the engine ECU as a signal This information and command signals from the engine ECU and between various control units are communicated via CAN communication The fuel system of a common rail engine is controlled by the engine ECU As a result fuel is injected at ideal conditions at all times suppressing the weak point of diesel engines of black smoke when start...

Page 115: ...3 3 Flow of common rail system CRS engine MECHANISM 3 Fuel system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 15 KiSC issued 12 2018 A ...

Page 116: ...sed through a water separator and fuel filter by an electromagnetic fuel feed pump and is supplied to the supply pump 2 Fuel is pressurized by the supply pump and fed to the rail and injectors 3 The injectors inject fuel based on instructions from the engine ECU 4 After injection surplus fuel passes through overflow pipe and fuel cooler and is returned to the fuel tank 4 ENGINE MECHANISM 3 Fuel sy...

Page 117: ...y the supply pump as well as the fuel pressure in the rail 3 5 Fuel tank 3 5 1 Outline of fuel tank The fuel tank stores fuel 3 5 2 Structure of fuel tank The fuel tank is made up of a tank body and fuel inlet opening 3 5 3 Function of fuel tank The fuel tank stores fuel A float is generally provided in the tank to show the amount of fuel remaining This float detects float liquid surface position ...

Page 118: ...agnetic fuel feed pump The electromagnetic fuel feed pump supplies fuel to the engine 3 7 2 Structure of electromagnetic fuel feed pump The electromagnetic fuel feed pump is made up of a pump filter and connector and the like 1 Fuel inlet 2 Fuel outlet 3 7 3 Function of electromagnetic fuel feed pump The electromagnetic fuel feed pump feeds fuel to supply the fuel to the supply pump Voltage is sup...

Page 119: ...e stroke During the up stroke the piston 3 is pushed up by the fuel cam 6 via the tappet 5 and push rod 11 As a result the pressure in the inner chamber 7 rises the check valve suction side 1 closes and the check valve discharge side 8 opens On the other hand the pressure in the outer chamber 10 is lowered so the check valve suction side 4 opens and check valve discharge side 9 closes During the d...

Page 120: ...ion accuracy 99 or higher 5 μor larger 3 10 Supply pump 3 10 1 Outline of supply pump The supply pump pressurizes and supplies fuel to the rail 3 10 2 Structure of supply pump The supply pump is made up of a SCV overflow valve IO valve and zero delivery drain and the like 1 Suction control valve SCV 2 Eye bolt Inlet 3 Eye bolt Outlet 4 Zero delivery drain 5 Overflow valve 6 IO valve A From fuel fi...

Page 121: ...sure of fuel fed by the electromagnetic fuel feed pump and delivers it to the rail The supply pump corresponds to conventional injection pumps but pressurizes the fuel to more than 2 times that of conventional pumps for delivery to the rail Suction control valve SCV MECHANISM 3 Fuel system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 21 Ki...

Page 122: ...nd fuel flow changes based on position of the cylinder enabling suitable fuel flow Pump Body Pressurizing Part 8 IO valve 9 Outlet valve 10 Inlet valve 11 Plunger chamber 12 Plunger 13 Plunger barrel 14 Spring 15 Tappet 16 Fuel camshaft C From SCV D To rail E Suction stroke F Compression stroke The pump body pressurizing part applies pressure to the fuel supplied from the suction control valve has...

Page 123: ...provided in the valve body and returns to the fuel tank Therefore the pressure in the suction control valve is stabilized and fuel flow is accurately adjusted 3 10 4 Specification of supply pump Pump type Bosch PF49 Engine model Rail pressure reference values At idling At rated speed No load D1803 CR E4 25 to 30 MPa 260 to 300 kgf cm2 3700 to 4300 psi 55 to 60 MPa 560 to 610 kgf cm2 8000 to 8700 p...

Page 124: ...al ground 7 5 V 8 Engine ECU a Rail pressure sensor con nector 3 12 3 Function of rail assembly The rail assembly stores high pressure fuel fed from the supply pump and while retaining the pressure delivers fuel to the injectors for each cylinder The pressure of the fuel in the rail is detected by the rail pressure sensor and optimal feedback control is provided for the engine speed and load This ...

Page 125: ...rt so replacement requires replacing the rail assembly Pressure limiter The pressure limiter operates when the pressure inside the rail becomes excessively high valve opens and then once the pressure drops to a certain pressure it acts to keep the pressure valve closes Fuel discharged by the pressure limiter returns to the fuel tank Please note that the pressure limiter is not treated as a part so...

Page 126: ... chamber 4 Valve body 5 Command piston 6 Nozzle body 7 Needle valve 8 Valve spring 9 Solenoid 10 Two way valve TWV 11 Suction orifice 12 Nozzle spring 13 Nozzle nut A To fuel tank B From rail 14 ID code Wiring diagram 15 Injector 16 Rated amperage circuit 17 High voltage generating cir cuit 18 Control circuit 19 Engine ECU 4 ENGINE MECHANISM 3 Fuel system 4 26 D1803 CR E4 D1803 CR TE4 D1803 CR TIE...

Page 127: ...e ID codes are used to correct for these differences information for correcting is input to the engine ECU Part Function Two way electromag netic valve Electromagnetic valve that is operated through turning current to a solenoid ON and OFF controlling flowing in and flow ing out of fuel from the rail to the control chamber Suction discharge orifice This sets the raise and lower speed of the needle...

Page 128: ... is electrified by the drive circuit 14 the two way electromagnetic valve 7 is lifted by an electromagnetic force and the valve ball 8 is lifted by fuel pressure opening the discharge orifice 15 Here fuel inside the control chamber 9 passes through the discharge orifice and flows to the fuel tank As a result the needle valve 12 is pushed up based on fuel pressure and fuel injection starts Note lon...

Page 129: ... valve There are two types of check valves with or without a regulator A No regulator B Regulator included 3 15 3 Function of check valve The check valve prevents reverse flow of fuel inside the fuel piping The check valve is being used as a no return valve A check valve without a regulator is used in the return path from the fuel filter This path is used as a return path for excess fuel and for a...

Page 130: ...t devices 3 17 2 Structure of engine ECU The engine ECU is made up of a case and electronics part mounting board Furthermore it has a program called software installed 1 Engine ECU 3 17 3 Function of engine ECU The engine ECU controls the injection amount injection timing injection rate and injection pressure during fuel injection Control based on the engine ECU is performed by sending instruction...

Page 131: ...ywheel has some pulsar hole missing The engine ECU calculates the piston position and engine speed based on the signal detected The crankshaft position sensor is a magnetic resistance element type sensor When the flywheel passes by the sensor part the internal magnetic field changes AC voltage is generated by the change in magnetic field and this is rectified and output to the engine ECU 1 Pulsar ...

Page 132: ...r gear has teeth at non equal intervals The engine ECU calculates the piston position based on the signal detected The camshaft position sensor is a magnetic resistance element type sensor When the pulsar gear passes by the sensor part the internal magnetic field changes AC voltage is generated by the change in magnetic field and this is rectified and output to the engine ECU 1 Pulsar gear cam 3 1...

Page 133: ...t inside the engine When the engine coolant temperature changes the resistance of the thermistor at the tip of the sensor changes Then the resistance of the thermistor changes the sensor output voltage changes The output voltage signal of the sensor is sent to the engine ECU 3 20 4 Specification of coolant temperature sensor Operating voltage 5 V Output characteristics 1 Voltage 2 Resistance A Vol...

Page 134: ...re sensor A silicon element in the sensor changes with pressure fluctuations and converts pressure detected using the piezo resistance effect to voltage The output voltage signal of the sensor is sent to the engine ECU 3 21 4 Specification of boost pressure sensor Operating voltage 5 V Pressure characteristics 3 22 Atmosphere pressure sensor 3 22 1 Outline of atmosphere pressure sensor The atmosph...

Page 135: ...push the tappet roller of supply pump to compress the fuel The shape of fuel cam is rounded square and fuel cam push the tappet roller of supply pump four times per one rotation The rotation of the gear at the end of the crankshaft is transferred to the supply pump gear and the fuel camshaft rotates synchronized with the crankshaft The fuel camshaft rotates once for every two rotations of the cran...

Page 136: ... DPF 7 Intercooler 8 Glow plug 9 Intake manifold 10 Combustion chamber A Intake air flow B Exhaust gas flow a Exhaust gas NOTE The parts marked with is called aftertreatment unit DOC for D1803 CR TIE4 and V2403 CR TIE4 The parts marked with are equipped only for D1803 CR TIE4 and V2403 CR TIE4 4 ENGINE MECHANISM 4 Intake and exhaust system 4 36 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2...

Page 137: ...ercooler enables increasing the amount of intake air The exhaust system aggregates exhaust gases after combustion and discharges them to the atmosphere after aftertreatment MECHANISM 4 Intake and exhaust system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 37 KiSC issued 12 2018 A ...

Page 138: ...system This shows the flow of the intake system and exhaust system 4 ENGINE MECHANISM 4 Intake and exhaust system 4 38 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 139: ...is cooled increasing the intake air density NOTE This flow is only for D1803 CR TIE4 and V2403 CR TIE4 4 This is distributed from the intake manifold to each of the cylinders B Exhaust air flow 1 Post combustion gases discharged from the combustion chamber in each cylinder are collected by the exhaust manifold 2 Pass through the turbocharger rotating the turbine and pressurizing the intake air 3 H...

Page 140: ...cleaner The air cleaner is made up of an air cleaner housing element and dust cup Clean air is essential to satisfactory performance and long engine life The air cleaner must be able to remove fine materials such as dust and blown sand as well as chaff or lawn from the air 1 Air cleaner housing 2 Secondary element 3 Primary element 4 Dust cup 5 Evacuator valve 4 6 3 Function of air cleaner The air...

Page 141: ...air pressure is kept constant 4 7 4 Specification of turbocharger Actuator set pres sure 2 mm point 88 9 kPa 0 907 kgf cm2 12 9 psi 4 8 Intercooler 4 8 1 Outline of intercooler The intercooler uses outdoor air temperature to cool air compressed in the turbocharger whose temperature has risen 4 8 2 Structure of intercooler The intercooler is made up of a core inner fins and heat dissipating fins 1 ...

Page 142: ...manifold 4 10 1 Outline of intake manifold The intake manifold efficiently distributes intake air to each cylinder 4 10 2 Structure of intake manifold The intake manifold is mounted on the intake air side of the cylinder head 1 Intake manifold 4 10 3 Function of intake manifold The intake manifold efficiently distributes intake air to each cylinder 4 11 Exhaust manifold 4 11 1 Outline of exhaust m...

Page 143: ...ects exhaust gases combusted in each of the cylinders and feeds this to the aftertreatment units MECHANISM 4 Intake and exhaust system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 43 KiSC issued 12 2018 A ...

Page 144: ...f the EGR valve cooler and pipe 1 EGR valve 2 Reed valve 3 EGR pipe 4 EGR cooler A Exhaust gas flow B Intake air flow 4 ENGINE MECHANISM 5 Exhaust gas recirculation EGR system 4 44 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 145: ...ude components with high thermal capacity Returning a part of the exhaust gases to the combustion chamber enables reducing the combustion chamber temperature The amount of exhaust gas returned to the combustion chamber is controlled using the amount the EGR valve is opened MECHANISM 5 Exhaust gas recirculation EGR system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V240...

Page 146: ...are cooled in the EGR cooler 5 2 Thereafter the gases pass through the EGR pipe 4 EGR valve 1 reed valve 2 and are returned to the intake manifold 3 3 Intake air and exhaust gases are mixed in the intake manifold 3 and are fed to the combustion chamber 4 ENGINE MECHANISM 5 Exhaust gas recirculation EGR system 4 46 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403...

Page 147: ...r and tubes 1 EGR cooler A Exhaust gas inlet B Exhaust gas outlet a Coolant inlet b Coolant outlet 5 5 3 Function of EGR cooler The EGR cooler cools the exhaust gas Exhaust gas passes through narrow tubes provided in the cooler and cools the area around these with engine coolant to lower the temperature of the exhaust gas This enables preventing rise in intake air temperature As a result this supp...

Page 148: ... 6 Rotor 7 Bearing 8 Magnet 9 Washer 10 Boss 11 Shaft 12 Assist Spring 13 Spring holder 14 Spring holder 15 Spring 16 Housing 17 Bush 18 Filter 19 Valve assembly 20 Valve seat 4 ENGINE MECHANISM 5 Exhaust gas recirculation EGR system 4 48 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 149: ...rcuit unit 26 Overcurrent detection circuit unit 27 Hall IC I F circuit unit 28 Brush less motor 29 Hall IC A Power B GND C CAN L D CAN H MECHANISM 5 Exhaust gas recirculation EGR system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 49 KiSC issued 12 2018 A ...

Page 150: ...osition specified by the engine ECU Built in microcomputer in the EGR valve input output signals from each of the hall switches and detect the valve position The microcomputers drive the rotor by turning energization on off of coils arranged on the outer circumference at set timing 5 6 4 Specification of EGR valve Cooling method Water cooled 5 7 Reed valve 5 7 1 Outline of reed valve The reed valv...

Page 151: ...n oil pump and oil filter and the like 1 Oil pressure switch 2 Oil pump 3 Oil pan 4 Relief valve 5 Oil cooler 6 Oil strainer 7 Oil filter MECHANISM 6 Lubricating system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 51 KiSC issued 12 2018 A ...

Page 152: ... the important role of enabling full exhibiting of engine function through the effects of oil on lubricated parts The method for supplying oil to various parts of the engine uses pressurized supply of supplying oil to each of the parts using a pump 4 ENGINE MECHANISM 6 Lubricating system 4 52 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 1...

Page 153: ...6 3 Flow of lubricating system MECHANISM 6 Lubricating system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 53 KiSC issued 12 2018 A ...

Page 154: ...from the oil pan by the oil pump 2 Suctioned oil is pumped to sliding parts of various components by the oil pump through oil passages 3 After lubricating various parts the oil returns to the oil pan 4 ENGINE MECHANISM 6 Lubricating system 4 54 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 155: ... 2 0 Imp gals Liquid gasket Three Bond 1217H or equivalent 6 5 Oil strainer 6 5 1 Outline of oil strainer The oil strainer removes foreign material from the oil 6 5 2 Structure of oil strainer The oil strainer has a structure of having a mesh entrance at the tip 1 Oil strainer 2 Mesh 6 5 3 Function of oil strainer The oil strainer removes foreign material contained in the oil circulating in the en...

Page 156: ...from the pump outlet port 2 to the sliding parts of various components 6 6 4 Specification of oil pump Item Specification Pump type Trochoid Number of teeth Inner rotor 4 Outer rotor 5 Theoretical discharge volume Conditions are that oil temperature is 80 176 and used oil is SAE 10W 30 10 L min or more at 1000 min 1 24 3 L min or more at 2000 min 1 6 7 Relief valve 6 7 1 Outline of relief valve Th...

Page 157: ...gh to the inside When element is clogged 1 Element 2 Bypass valve b Unfiltered oil If the oil pressure flowing to the filter reaches the bypass valve open pressure the bypass valve opens Engine oil passes through the bypass valve and is pumped without being filtered 6 8 4 Specification of oil filter Bypass valve open pressure Approximately 98 kPa 1 0 kgf cm2 14 psi 6 9 Oil cooler 6 9 1 Outline of ...

Page 158: ...ulator 5 Terminal Circuit diagram and connection table 6 Oil pressure switch 7 Pressurization 8 Atmospheric pressure 9 Mounting screw part 10 Terminal 11 IG 6 10 3 Function of oil pressure switch 1 Oil lamp Off 2 Battery 3 Diaphragm 4 Oil pressure 5 Oil lamp On A Specified oil pressure B Less than specified oil pres sure The oil pressure switch determines if the oil pressure is within specified ra...

Page 159: ... 2 to 58 8 kPa 0 400 to 0 599 kgf cm2 5 69 to 8 52 psi Rated oil pressure 241 to 441 kPa 2 46 to 4 49 kgf cm2 35 0 to 63 9 psi MECHANISM 6 Lubricating system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 59 KiSC issued 12 2018 A ...

Page 160: ...ing fan and the like 1 Radiator 2 Radiator cap 3 Cooling fan 4 Fan belt 5 Water pump 6 Thermostat 7 Coolant temperature sensor 8 Cylinder head 9 Crankcase 4 ENGINE MECHANISM 7 Cooling system 4 60 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 161: ...re reaches the thermostat valve open temperature the valve closes the bypass 2 As the bypass is closed warmed coolant flows to the radiator and is cooled 3 Coolant that has been cooled in the radiator is returned to the engine by the water pump 7 4 Control of cooling system Bottom by pass system The cooling system includes a coolant temperature sensor that fulfills the following roles 1 Suppressin...

Page 162: ...thermostat A When coolant temperature is low valve is closed B When coolant temperature is high valve is open The thermostat opens and closes the coolant path based on the engine coolant temperature to maintain suitable temperature A When coolant temperature is low valve is closed The wax inside the pellet is solidified so that the valve of the thermostat is closed by the spring Also the bypass pa...

Page 163: ...the radiator core passage coolant is cooled by heat dissipation from the core to air 7 7 4 Specification of radiator Reference values Radiator capacity 4 0 L 1 1 U S gals 0 88 Imp gals Test pressure 137 kPa 1 40 kgf cm2 19 9 psi These values may be different depending on the product used 7 8 Radiator cap 7 8 1 Outline of radiator cap The radiator cap maintains the pressure in the cooling system at...

Page 164: ...uctioning coolant from the reserve tank and preventing deformation of the radiator 7 8 4 Specification of radiator cap Pressure valve open pressure 88 kPa 0 90 kgf cm2 13 psi 7 9 Cooling fan 7 9 1 Outline of cooling fan The cooling fan draws in outdoor air or allows air to pass causing air to pass through the radiator 7 9 2 Structure of cooling fan Cooling fans are classified as suction type or bl...

Page 165: ...ospheric pressure When the engine cools the coolant in the reserve tank returns to the radiator based on lower than atmospheric pressure 7 11 Fan belt 7 11 1 Outline of fan belt The fan belt drives the cooling fan and alternator 7 11 2 Structure of fan belt The fan belt is made up of rubber and synthetic fibers 1 Top fabric 2 Cord 3 Rib rubber 7 11 3 Function of fan belt The fan belt transfers rot...

Page 166: ...parated into the starting system and charging system 1 Alternator 2 Regulator 3 Battery 4 Key switch 5 Charge lamp 6 Starter 4 ENGINE MECHANISM 8 Electrical system 4 66 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 167: ...The starting circuit starts up the starter by means of the key switch and starts the engine by turning the flywheel The charge circuit generates electricity in the alternator utilizing power when the engine is running and this is used to charge the battery MECHANISM 8 Electrical system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 67 KiSC i...

Page 168: ...witch is rotated to the start position current flows from the battery to the starter 2 Upon receiving current the starter motor rotates and a pinion gear engages and starts to rotate 3 The pinion gear that engages meshes with the ring gear flywheel and causes the flywheel to rotate 4 The crankshaft that is connected to the flywheel rotates initial combustion occurs in the engine and the engine sta...

Page 169: ... of the alternator pulley causes the alternator to rotate generating power 4 The generated electricity is supplied to and charges the battery via the B terminal of the alternator MECHANISM 8 Electrical system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 69 KiSC issued 12 2018 A ...

Page 170: ...ngine The battery is charged by the alternator during operation and stores electrical energy During operation the battery is used as a power supply along with the alternator 8 5 4 Specification of battery Battery capacity D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 12 V 88 AH V2403 CR E4 V2403 CR TE4 V2403 CR TIE4 V2403 CR TE4BG 12 V 92 AH NOTE Battery capacity can be different depending on the OEM spe...

Page 171: ...arter uses electric power from the battery to start the engine 8 7 2 Structure of starter planetary gear reduction type The starter is made up of a magnet switch various gears and shaft and the like 1 Front bracket 2 Drive lever 3 Magnetic switch 4 Pinion gear 5 Overrunning clutch 6 Gear shaft 7 Internal gear 8 Pinion gear 9 Armature shaft 8 7 3 Function of starter planetary gear reduction type Th...

Page 172: ...Pulley 2 Drive end frame 3 Rear end frame 4 Stator 5 Terminal 6 Connector 7 IC regulator 8 Spring 9 Brush 10 Rectifier 11 Rear end cover 12 Rotor 13 Bearing 8 8 3 Function of alternator The alternator generates 3 phase current by means of a fixed coil and rotation of a rotor The current generated is rectified using a rectifier made up of diodes The rectified current charges the battery Operation o...

Page 173: ...stor When Engine Starts When the engine starts and the alternator 7 rotates M IC circuit makes current pour continuously to the Tr1 instead of the uncontinuous in pulse current Therefore a sufficient exciting current flows and a generated voltage rises rapidly As a result the current to the Tr2 is shut and lights off the charge lamp 4 When terminal B voltage rises over the battery voltage a charge...

Page 174: ...D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TIE4 12 V 480 W V2403 CR TE4BG 12 V 720 W Battery voltage 12 V 4 ENGINE MECHANISM 8 Electrical system 4 74 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 175: ...d is combusted in a regeneration process and separated into carbon dioxide and ash The carbon dioxide is released to the atmosphere and ash accumulated in the DPF 9 3 Flow of diesel particulate filter DPF system 1 Exhaust manifold 2 Exhaust gas temperature sensor T0 3 Exhaust gas temperature sensor T1 4 Differential pressure sensor 5 Exhaust gas temperature sensor T2 6 Outside 7 Catalyst DOC 8 Fil...

Page 176: ... for regeneration first the intake throttle valve is operated reducing the amount of intake air raising the exhaust gas temperature Further engine speed is raised and adjusted so that the DOC temperature rises to 250 482 or higher After the DOC reaches 250 482 or higher control is performed the same as for auto regeneration When regeneration is finished the operation state is returned what it was ...

Page 177: ...rature 3 Engine speed is raised and adjusted so that the DOC temperature rises to 250 482 or higher 4 After the DOC reaches 250 482 or high er control is performed the same as for auto regeneration 5 When regeneration is finished the operation state is returned what it was prior to auto regen eration idle speed 3 Parked active re generation with output limitation Automatic active regenera tion sto...

Page 178: ...by chemical reaction The carbon dioxide is released to the atmosphere 9 7 Flow of diesel oxidation catalyst DOC system 1 Exhaust manifold 2 Catalyst DOC 3 Catalyst DOC 4 Body DOC outlet 5 Outside A DOC assembly 1 Exhaust gas that passes through the exhaust manifold flows into the catalyst DOC 1 2 Exhaust gas that passes through the catalyst DOC 1 flows into the next catalyst DOC 2 3 PM is combuste...

Page 179: ... places the post injection fuel into contact with the core thereof and raises the exhaust gas temperature to a temperature where regeneration is feasible 9 9 Diesel particulate filter DPF 9 9 1 Outline of diesel particulate filter DPF The DPF captures PM soot 9 9 2 Structure of diesel particulate filter DPF The DPF is constructed with a single core and has an closed end structure 1 Diesel particul...

Page 180: ...unction of air flow sensor The air flow sensor uses the hot wire and cold wire to measure the intake air flow amount Also the air flow sensor is an intake air temperature sensor and measures the temperature of the intake air The wire and intake air temperature sensor have power supplied from the engine ECU The wire is maintained at a specified temperature by the power supplied The wire part change...

Page 181: ...erature sensor 9 11 1 Outline of exhaust gas temperature sensor The exhaust gas temperature sensor detects the exhaust gas temperature of the DPF system 9 11 2 Structure of exhaust gas temperature sensor The exhaust gas temperature sensor is made up of a thermistor and connector and the like 1 Exhaust gas temperature sensor T0 2 Exhaust gas temperature sensor T1 3 Exhaust gas temperature sensor T2...

Page 182: ...s temperature sensors are sensors that utilize resistance changes based on an NTC thermistor When the exhaust gas temperature changes the resistance of the thermistor at the tip of the sensor changes Then the resistance of the thermistor changes the sensor output voltage changes The output voltage signal of the sensor is sent to the engine ECU 1 Resistance Ω 2 Temperature 9 11 4 Specification of e...

Page 183: ...The differential pressure sensor measures the pressure difference between the inlet and outlet of the DPF and sends this information to the engine ECU The engine ECU calculates the amount of PM accumulated in the DPF based on the differential pressure sensor information The differential pressure sensor has an internal silicon diaphragm and the output changes based on diaphragm displacement due to ...

Page 184: ...lve The intake throttle valve adjusts the intake air flow amount Wide open throttle state is maintained during normal operation The engine ECU changes the amount the intake throttle valve is open during DPF regeneration control raising the exhaust gas temperature 9 13 4 Specification of intake throttle valve Motor rated voltage 12 V Voltage applied polarity and valve rotating direction Shaft rotat...

Page 185: ...put V 2 Sensor operating angle de gree A Fully closed 0 B Fully open 81 4 MECHANISM 9 Aftertreatment system 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 85 KiSC issued 12 2018 A ...

Page 186: ...4 ENGINE MECHANISM 9 Aftertreatment system 4 86 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 187: ...e the specified fuel 3 1 Fuel leakage because of loose injection pipe retaining nut Tighten the retaining nut 4 154 The injector is clogged Replace 4 191 The supply pump is damaged Replace 4 125 4 148 Seizure of the crankshaft cam shaft piston or bearing Repair or replace Compression leakage from the cylinder Replace the head gasket Tighten the cylinder head screw 4 111 4 149 Incorrect valve timin...

Page 188: ...specified level 3 5 The piston ring piston and cylin der is worn out Replace the piston ring or piston or repair the cylinder 4 175 4 176 4 183 There is oil leakage into the ex haust pipe or suction pipe The oil pipe is clogged or has a damage Check replace or clean the oil pipe 4 106 4 106 4 119 4 155 The piston ring seal of the turbo charger is damaged Replace the turbocharger as sembly 4 106 4 ...

Page 189: ...place the piston and piston ring 4 175 4 176 4 141 The valve stem and valve guide are worn out Replace 4 165 4 165 The crankshaft bearing and the crankpin bearing is worn out Replace 4 179 The fuel is mixed into the lubri cant oil The injector is damaged Replace 4 191 Oil dilution due to regeneration Change the engine oil 3 7 Water is mixed into the lubricant oil The head gasket is damaged Replace...

Page 190: ... fan belt tension is too loose Replace or adjust 3 15 The coolant is not sufficient Replenish to the specified amount The radiator net and the radiator fin are clogged with dust Clean There is corrosion in the inner side of the radiator Clean or replace There is clogged in the coolant flow route Clean or replace The radiator or radiator cap is damaged Replace 4 100 The load is too much Reduce the ...

Page 191: ... to 0 85 mm 0 026 to 0 033 in 1 20 mm 0 0472 in Exhaust 0 65 to 0 85 mm 0 026 to 0 033 in 1 20 mm 0 0472 in Valve stem to valve guide Clearance 0 040 to 0 070 mm 0 0016 to 0 0027 in 0 10 mm 0 0039 in Valve stem O D 7 960 to 7 975 mm 0 3134 to 0 3139 in Valve guide I D 8 015 to 8 030 mm 0 3156 to 0 3161 in Valve clearance Cold 0 18 to 0 22 mm 0 0071 to 0 0086 in Intake valve timing Open 0 2 rad 9 b...

Page 192: ...3 in Exhaust 33 90 mm 1 335 in 33 85 mm 1 333 in Cam height V2403 CR E4 TE4 TE4BG TIE4 Intake 33 47 mm 1 318 in 33 42 mm 1 316 in Exhaust 33 00 mm 1 299 in 32 95 mm 1 297 in Camshaft journal to crankcase bore Oil clearance 0 050 to 0 091 mm 0 0020 to 0 0035 in 0 15 mm 0 0059 in Camshaft journal O D 39 934 to39 950 mm 1 5722 to 1 5728 in Crankcase bore I D 40 000 to 40 025 mm 1 5748 to 1 5757 in Ti...

Page 193: ...13 in 1 25 mm 0 0492 in Second ring D1803 CR E4 V2403 CR E4 0 30 to 0 45 mm 0 012 to 0 017 in 1 25 mm 0 0492 in Second ring D1803 CR TE4 TIE4 V2403 CR TE4 TE4BG TIE4 0 40 to 0 55 mm 0 016 to 0 021 in 1 25 mm 0 0492 in Oil ring D1803 CR E4 V2403 CR E4 0 20 to 0 40 mm 0 0079 to 0 015 in 1 25 mm 0 0492 in Oil ring D1803 CR TE4 TIE4 V2403 CR TE4 TE4BG TIE4 0 25 to 0 45 mm 0 0099 to 0 017 in 1 25 mm 0 ...

Page 194: ...Pa 1 0 kgf cm2 14 psi 50 kPa 0 5 kgf cm2 7 psi At rated speed 300 to 440 kPa 3 0 to 4 5 kgf cm2 43 to 64 psi 250 kPa 2 5 kgf cm2 36 psi Oil pressure switch Working pressure 50 kPa 0 5 kgf cm2 7 psi Inner rotor to outer rotor Clearance 0 030 to 0 14 mm 0 0012 to 0 0055 in 0 2 mm 0 008 in Outer rotor to pump body Clearance 0 11 to 0 19 mm 0 0044 to 0 0074 in 0 25 mm 0 0098 in Inner rotor to cover Cl...

Page 195: ...15 0 mm 0 591 in 11 0 mm 0 433 in Brush V2403 CR E4 TE4 TE4BG TIE4 Length 15 0 mm 0 591 in 9 0 mm 0 35 in Alternator No load voltage More than 13 5 V Stator Resistance Less than 1 0 Ω Rotor Resistance 2 9 Ω Slip ring O D 14 4 mm 0 567 in 14 0 mm 0 551 in Brush Length 10 5 mm 0 413 in 8 4 mm 0 33 in Glow plug Resistance Approx 0 8 Ω SERVICING 2 Service specifications 4 ENGINE D1803 CR E4 D1803 CR T...

Page 196: ...etric system The dimension is the nominal external diameter in mm of the threads The pitch is the nominal distance in mm between 2 threads Disassembling and assembling Item Dimension Pitch N m kgf m lbf ft Drain plug M12 1 25 32 4 to 37 2 3 31 to 3 79 23 9 to 27 4 Alternator pulley nut 58 4 to 78 9 5 95 to 8 05 43 1 to 58 2 Main bearing case screw 1 M9 1 25 46 1 to 51 0 4 70 to 5 20 34 0 to 37 6 M...

Page 197: ...1 0 9 81 to 11 3 1 00 to 1 15 7 24 to 8 33 Injection pipe retaining nut M14 1 5 M12 1 5 24 5 to 29 4 2 50 to 2 99 18 1 to 21 6 Overflow pipe joint screw M12 1 25 20 0 to 29 0 2 04 to 2 95 14 8 to 21 3 Turbocharger assembly mounting nut M8 1 25 29 4 to 34 3 3 00 to 3 49 21 7 to 25 2 Oil pipe joint screw M8 1 25 M10 1 5 15 7 to 19 6 1 60 to 1 99 11 6 to 14 4 Filter comp DPF bracket M8 1 25 16 to 20 ...

Page 198: ...ssion pres sure Service specifi cation 2 95 to 3 23 MPa 30 1 to 32 9 kgf cm2 428 to 468 psi Service limit 2 35 MPa 24 0 kgf cm2 341 psi 8 Do the same steps twice for each cylinder 9 Install the removed parts Tightening tor que Glow plug 14 7 to 19 6 N m 1 50 to 1 99 kgf m 10 9 to 14 4 lbf ft Glow lead mount ing nut 0 980 to 1 77 N m 0 100 to 0 180 kgf m 0 723 to 1 30 lbf ft 4 2 Adjusting valve cle...

Page 199: ...ester 1 Remove the engine oil pressure switch 2 Set the oil pressure tester 3 Operate the engine for warming up 4 Measure the oil pressure at the idle speed and rated speed Engine oil pressure At idle speed Service speci fication More than 98 kPa 1 0 kgf cm2 14 psi Service limit 50 kPa 0 5 kgf cm2 7 psi At rated speed Service speci fication 300 to 450 kPa 3 0 to 4 5 kgf cm2 43 to 64 psi Service li...

Page 200: ...fan belt has a damage replace it 2 Check if the fan belt is worn out and sunk in the pulley groove A Good B Bad NOTE If it is Bad B replace it 4 6 Checking radiator cap air leakage CAUTION Remove the radiator cap only after you stop the engine for a minimum of 10 minutes to decrease its temperature If not hot water can gush out and cause injury Tools required Radiator cap tester and an adapter 1 S...

Page 201: ...ator for water leakage Radiator water leakage test Service specifi cation No leak at specified pres sure NOTE For water leakages from the pinhole replace the radiator or repair with the radiator cement When water leak is too much replace the radiator 4 8 Checking opening temperature of thermostat valve Tools required Thermometer 1 Push down the thermostat valve and put the thread between the valve...

Page 202: ... battery specific gravity and charge the battery 4 10 Checking battery specific gravity CAUTION To prevent an accidental short circuit attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal Do not remove the battery cap while the engine operates Keep electrolyte away from eyes hands and clothes If you are spattered with it clean with water...

Page 203: ...cific gravity B Discharge C Good D Charging is necessary NOTE Temperature conversion of electrolyte specific gravity Battery electrolyte specific gravity changes based on temperature Insert the value identified on a specific gravity meter into the following conversion equation for temperature correction to learn an accurate specific gravity value Standard temperature assumed to be 20 68 D20 Dt 0 0...

Page 204: ...while the engine operates Keep electrolyte away from eyes hands and clothes If you are spattered with it clean with water immediately Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive IMPORTANT Do not disconnect or remove the battery when you operate engine NOTE B terminal It is the terminal that connects the cable from the battery...

Page 205: ... the battery cap while the engine operates Keep electrolyte away from eyes hands and clothes If you are spattered with it clean with water immediately Keep open sparks and flames away from the battery at all times Hydrogen gas mixed with oxygen becomes very explosive NOTE Before check alternator on unit do a check of the below list Battery terminal connections Circuit connection Fan belt tension C...

Page 206: ...low plug 2 Resistance Service specifi cation Approx 0 8 Ω 1 Seal 2 Glow plug 3 Install the glow plug to the specified tightening torque Tightening tor que Glow plug 14 7 to 19 6 N m 1 50 to 1 99 kgf m 10 9 to 14 4 lbf ft 4 16 Checking exhaust gas leakage of turbocharger turbine side 1 Check the exhaust port 3 and the inlet port 5 side of the turbine housing 1 for exhaust gas leakage 1 Turbine hous...

Page 207: ...laced injector in the engine ECU with the diagnosis tool 1 Terminal high 2 Terminal low 3 ID code a Injector RELATED PAGE 7 56 Replacing injector on page 4 191 4 20 Checking suction control valve SCV Tools required Circuit tester 1 Place the key switch in the OFF position 2 Disconnect the SCV wiring harness connector 3 Measure the resistance between SCV terminals 1 and 2 Resistance Service specifi...

Page 208: ...or from the wiring harness side 3 Start the engine change the depressed amount of the accelerator pedal and check the same items again Engine state Output voltage Key switch ON Service specifi cation Approx 1 0 V After engine start up Approx 1 0 to 2 2 V 1 Terminal pressure signal 2 Terminal 5V 3 Terminal temperature signal 4 Terminal ground a Pin assginment 4 Set the key switch to the OFF positio...

Page 209: ...ct the sensor and check the following items Check that there is a large amount of magnetic foreign material adhering to the sensor surface or not Check that there are interference marks of the pulsar and the sensor or not Check that there are any pulsar gear abnormalities or not 1 Camshaft position sensor NOTE If the sensor is faulty replace the camshaft position sensor RELATED PAGE 4 32 Adjusting...

Page 210: ...t the EGR valve connector 2 Check of battery line of motor in EGR valve 3 Measure the voltage between terminal power 4 and terminal ground 3 at key ON status Terminal power 4 and terminal ground 3 Service specifi cation 9 to 16 V 1 Terminal CAN1 H 2 Terminal CAN1 L 3 Terminal ground 4 Terminal power 12 V a Pin assignment 4 27 Checking air flow sensor Tools required Circuit tester 1 Turn the key sw...

Page 211: ... Turn the key switch OFF 2 Remove the connector from the sensor side 3 Measure the resistance between the terminal 1 and terminal A GND3 2 on the sensor side Service specification Temperature Resistance 100 212 Approx 18 3 kΩ 150 302 Approx 7 88 kΩ 200 392 Approx 4 00 kΩ 250 482 Approx 2 30 kΩ 1 Terminal T0 IDOC T1 ODOC T2 ODPF 2 Terminal A GND3 4 29 Selecting cylinder head gasket After you replac...

Page 212: ...5 mm 0 0207 to 0 0226 in 25 0 575 to 0 625 mm 0 0227 to 0 0246 in 30 0 625 to 0 675 mm 0 0246 to 0 0265 in 35 0 675 to 0 725 mm 0 0266 to 0 0285 in 4 30 Measuring angular deviation between crankshaft T D C and crankshaft position sensor detected T D C IMPORTANT If the crankshaft flywheel housing and or flywheel are replaced it is necessary to calibrate the injection timing with the diagnosis tool ...

Page 213: ...ywheel and draw a mark for top dead center 7 and a reference line 8 6 Tri square 7 Mark for top dead center 8 Reference line 9 Remove the crankshaft position sensor 10 Set the reference pulsar hole 12 to crankshaft position sensor mounting hole 11 by rotating flywheel 10 counterclockwise IMPORTANT Reference pulsar hole 12 is 17th hole for 3 cylinder models or 20th hole for 4 cylinder models by rot...

Page 214: ...fference mm 14 Calculate the fuel injection timing correction by difference A IMPORTANT 1 mm 360 Flywheel Diameter π If the crankshaft position sensor top dead center detection position is in front of top dead center enter a negative value If the crankshaft position sensor top dead center detection position is in back of top dead center enter a positive value NOTE Corrected angle 360 flywheel diam...

Page 215: ...m 0 0079 to 0 051 in 1 Camshaft position sensor length between the sensor tip and sensor flange face 2 Depth from sensor attaching face of gear case cover to pulsar gear side surface A Air gap 5 Disassembling 5 1 Draining engine oil 1 Start and increase the temperature of the engine for approximately 5 minutes 2 Put an oil pan below the engine 3 Remove the drain plug 1 to drain the engine oil 1 Dr...

Page 216: ...e ECU intermediate harness 2 Remove the DPF intermediate harness 3 from the bracket 3 Remove the injector intermediate harness 1 from the bracket 4 Remove the engine intermediate harness 2 from the bracket 1 Injector intermediate harness 2 Engine intermediate harness 3 DPF intermediate harness 5 Remove the connecters from each sensor and each device 5 4 Removing external components 1 Remove the ai...

Page 217: ...rking brake As the muffler full assembly is hot just after the engine shutdown make sure to start operation after it gets cool Make sure not to let any foreign substances enter the opening section during the operation Make sure not to damage the muffler full assembly by falling or impact as it contains a ceramic filter Before removing the muffler full assembly from a product engine connect the dia...

Page 218: ...es enter the opening section during the operation Make sure not to damage the DPF muffler full assembly by falling or impact as it contains a ceramic filter Before removing the DPF for cleaning keep the records of the engine serial number filter comp DPF part number filter comp DPF serial number catalyst DOC part number catalyst DOC serial number and engine operating time which are required in pre...

Page 219: ...ooler hose 3 4 Remove the EGR cooler 5 5 Remove the EGR cooler pipe 4 3 EGR cooler hose 4 EGR cooler pipe 5 EGR cooler 5 8 Removing turbocharger CAUTION While the engine operates or just after it stops do not touch the hot turbocharger assembly NOTE When you remove the turbocharger assembly do not let dust dirt and other unwanted materials in the oil pipes 1 Remove the inlet hose 3 4 2 Remove the ...

Page 220: ...2 EGR valve 3 Cooler pipe 5 11 Removing common rail CAUTION Do not loosen the injection pipe 1 when the fuel is under high pressure within five minutes of stopping the engine NOTE Replace the rail assembly if the exchange of the pressure limiter 3 or the rail pressure sensor 5 is necessary Do not remove the pressure limiter 3 and rail pressure sensor 5 from the common rail 4 When removing the comm...

Page 221: ... Camshaft position sensor mounting screw 4 Remove the crankshaft position sensor mounting screw 5 5 Remove the crankshaft position sensor 4 4 Crankshaft position sensor 5 Crankshaft position sensor mounting screw IMPORTANT If you drop the sensor do not reuse it 6 Remove the boost pressure sensor mounting screw 7 7 Remove the boost pressure sensor 6 6 Boost pressure sensor 7 Boost pressure sensor m...

Page 222: ...ector 1 Do not damage the injector ID code 6 Do not get the injectors out of order If the injectors get out of order it is necessary to perform injector correction writing the injector ID codes 6 to the engine ECU Store the injectors so they do not get any dust in them 1 Injector 2 Injector clamp 3 O ring 4 Gasket 5 Injector clamp mounting screw 6 Injector ID code 4 ENGINE SERVICING 5 Disassemblin...

Page 223: ... Remove the exhaust manifold 2 2 Exhaust manifold 3 Remove the cylinder head mounting screw in the sequence of n or r to a A Gear case side B Flywheel side 4 Remove the cylinder head 3 and cylinder head gasket 4 3 Cylinder head 4 Cylinder head gasket SERVICING 5 Disassembling 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 4 123 KiSC issued 12 ...

Page 224: ...stat assembly 1 Remove the thermostat cover mounting screws and remove the thermostat cover 1 1 Thermostat cover 2 Remove the thermostat assembly 2 2 Thermostat assembly 5 21 Removing suction control valve SCV IMPORTANT For necessary or not of replacement be sure to decide based on the suction control valve SCV related DTC decision flow P0089 P0628 and P0629 of diagnosis manual DM Do not take a br...

Page 225: ...ody side To be removed if remained 1 SCV 2 SCV mounting screw 5 22 Removing supply pump 1 Remove the fuel feed pump 1 1 Fuel feed pump 2 Remove the supply pump 2 1 Supply pump 5 23 Removing oil cooler Tools required Filter wrench 1 Remove the oil filter cartridge 1 with the filter wrench 1 Oil filter cartridge 2 Remove the oil cooler joint screw 5 3 Remove the water hoses 2 3 4 Remove the oil cool...

Page 226: ...h 3 3 Remove the fan drive pulley 4 with gear puller 2 Fan drive pulley mounting nut 3 46 mm 1 8 in deep socket wrench 4 Fan drive pulley 4 Remove the feather key 5 26 Removing gear case cover 1 Remove the hour meter gear case cover if attached 2 Remove the gear case cover 1 1 Gear case cover 5 27 Removing crankshaft oil slinger 1 Remove the crankshaft collar 3 4 ENGINE SERVICING 5 Disassembling 4...

Page 227: ... oil pump drive gear 2 4 with gear puller 4 Remove the idle gear collar 2 5 Remove the idle gear 3 2 Idle gear collar 3 Idle gear 4 Oil pump drive gear 2 5 Oil pump drive gear 1 mounting nut 5 29 Removing fuel camshaft assembly 1 Remove the fuel camshaft stopper 1 2 Pull out the fuel camshaft assembly 2 1 Fuel camshaft stopper 2 Fuel camshaft assembly SERVICING 5 Disassembling 4 ENGINE D1803 CR E4...

Page 228: ...out the oil pump drive gear 1 2 with a gear puller 3 2 Oil pump drive gear 1 3 Gear puller 3 Remove the oil pump 4 4 Oil pump 5 32 Removing crank gear Tools required Gear puller 1 Remove the crank gear 2 with a gear puller 1 2 Remove the feather key 3 Remove the idle gear shaft 3 1 Gear puller 2 Crank gear 3 Idle gear shaft 4 ENGINE SERVICING 5 Disassembling 4 128 D1803 CR E4 D1803 CR TE4 D1803 CR...

Page 229: ...n the cylinders 5 Turn the flywheel and move the piston 3 to top dead center 6 Lightly tap the connecting rod big end bore from the bottom of the crankcase with the grip of a hammer to pull the piston 3 out IMPORTANT Do not change the combination of cylinder and piston Align the position of each piston by the its mark For example mark 1 on the No 1 piston 3 Piston 5 35 Removing piston ring Tools r...

Page 230: ...not remove the piston pin 4 easily put the piston fully in 80 176 oil for 10 to 15 minutes 1 Piston pin snap ring 2 Piston 3 Connecting rod 4 Piston pin 5 37 Removing flywheel IMPORTANT The flywheel is very heavy so securely hold the flywheel when removing NOTE Do not use an impact wrench Serious damage will occur Tools required Flywheel stopper Flywheel guide screw 1 Attach the flywheel stopper 1...

Page 231: ...ounting screws of bearing case cover 1 and external mounting screws of bearing case cover 2 are different 1 Inner mounting screw of bearing case cover 2 External mounting screw of bearing case cover 3 Remove the bearing case cover 3 3 Bearing case cover 5 40 Removing crankshaft for 3 cylinders NOTE Before you disassemble measure the side clearance of crankshaft Measure it when you assemble again T...

Page 232: ...l the crankshaft 6 Do the above steps again to pull out the crankshaft completely 5 41 Removing crankshaft for 4 cylinders NOTE Before you disassemble measure the side clearance of crankshaft Measure it when you assemble again This topic is used for only 4 cylinders engine V2403 CR E4 TE4 TE4BG TIE4 1 Remove the main bearing case mounting screw 2 1 1 Main bearing case mounting screw 2 2 Turn the c...

Page 233: ...the set of packings 9 the 4 planetary gears and another packing IMPORTANT Take note of the positions of the set of packings and the setup bolt 7 Remove the gear 1 and shaft assembly 4 5 6 Take note of the position of the lever 1 Gear 2 Front bracket 3 Solenoid switch 4 Overrunning clutch 5 Internal gear 6 Shaft 7 Planetary gear 8 Ball 9 Set of packings 10 Through screws 11 Armature 12 Yoke 13 Brus...

Page 234: ...t hole 9 Lightly secure the rotor 5 with a vise to prevent damage 10 Remove the bearing 6 with a puller 7 5 Rotor 6 Bearing 7 Puller 6 Assembling 6 1 Assembling alternator 1 Lightly secure the rotor with a vise to prevent damage 2 Install the bearing 2 to the slip ring side of rotor 1 1 Rotor 2 Bearing 4 ENGINE SERVICING 6 Assembling 4 134 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 C...

Page 235: ...ith its sliding face in the clockwise direction when viewed from front IMPORTANT Be sure to keep the 2 brushes deep in the brush holder Otherwise the rotor and the rear section can not be fitted into the position 8 Push the brushes into place using a 4 mm hex wrench 9 Keep the brushes from popping out using a pin pointed punch 10 Align the mark line 5 of the front bracket with that of the rear bra...

Page 236: ...11 to the yoke 12 5 Install the ball 8 to the tip of the armature 11 6 Install the brush holder 13 and rear end frame 14 7 Install the 2 brush holder lock screws 8 Install the 2 through screws 10 9 Install the solenoid switch 3 1 Pinion gear 2 Front bracket 3 Solenoid switch 4 Overrunning clutch 5 Internal gear 6 Shaft 7 Planetary gear 8 Ball 9 Set of packings 10 Through screws 11 Armature 12 Yoke...

Page 237: ...all them in the sequence of their marks A B for 3 cylinders and A B C for 4 cylinders from the gear case cover side 1 Number 2 FLYWHEEL mark 3 A 4 B 5 C 6 No mark 7 Main bearing case 8 Oil groove 2 Tighten the main bearing case screw 1 to the specified torque NOTE Apply engine oil to the main bearing case screws 1 After you tighten the main bearing case screw 1 to the specified torque make sure th...

Page 238: ...54 2 lbf ft RELATED PAGE 4 30 Measuring angular deviation between crankshaft T D C and crankshaft position sensor detected T D C on page 4 112 6 5 Installing crankshaft for 4 cylinders NOTE Measure the side clearance of crankshaft when you assemble again This topic is used for only 4 cylinders engine V2403 CR E4 TE4 TE4BG TIE4 1 Hold the crankpins to the horizontal directions right or left and ins...

Page 239: ...e correct position NOTE Apply a thin layer of engine oil to the oil seal 5 Then install the oil seal not to come off the lip 3 External mounting screw of bearing case cover 4 Inner mounting screw of bearing case cover 5 Oil seal 6 Bearing case cover A Casting mark UP 3 Tighten the inner mounting screws of bearing case cover 4 and external mounting screws of bearing case cover 3 to the specified ti...

Page 240: ...sor detected T D C on page 4 112 6 9 Assembling piston assembly CAUTION The end faces of the oil ring are plated with hard chrome When you install the piston into the cylinder do not give a damage to the cylinder by the oil ring If the ring s planting is scratched it may get stuck on the cylinder wall causing serious damage IMPORTANT Put a mark on the connecting rod and the piston with the same nu...

Page 241: ...ton ring pliers NOTE Set the manufacturer mark 4 upward 4 Manufacturer mark 5 Top ring 6 Second ring 6 11 Installing piston IMPORTANT Do not change the combination of cylinder number and piston Align the position of each piston by the its mark For example mark 1 on the No 1 piston Tools required Piston ring compressor 1 Clean the carbon in the cylinders 2 Turn the flywheel and move the crankshaft ...

Page 242: ...eir chrome plated section of piston rings may be scratched causing trouble inside the liner NOTE Apply sufficient engine oil to the piston Align the mark FW 2 on the piston face to flywheel side Align the marks 3 with each other 1 Piston ring compressor 2 Mark FW 3 Mark 6 Turn the flywheel and move the piston to bottom dead center 4 ENGINE SERVICING 6 Assembling 4 142 D1803 CR E4 D1803 CR TE4 D180...

Page 243: ...o 4 58 kgf m 29 5 to 33 1 lbf ft 6 12 Installing oil strainer and oil pan NOTE Clean the oil pan and crankcase surface that attached each other Tools required Liquid gasket Three Bond 1217H 1 Install the oil strainer 1 NOTE Using care not to damage the O ring After cleaning the oil strainer 1 install it 1 Oil strainer 2 Apply liquid gasket 2 to the oil pan as shown in the figure NOTE Confirm that ...

Page 244: ... the oil pump drive gear 1 2 NOTE After oil pump drive gear 1 2 installed loosely tighten the oil pump drive gear 1 mounting nut 3 Tighten the oil pump drive gear 1 mounting nut 3 completely to the specified torque after installing oil pump drive gear 2 Tightening tor que Oil pump drive gear 1 mounting nut 3 78 5 to 88 3 N m 8 01 to 9 00 kgf m 57 9 to 65 1 lbf ft 2 Oil pump drive gear 1 3 Oil pump...

Page 245: ...e gear 1 Install the idle gear 2 and idle gear collar IMPORTANT Apply the engine oil inside of idle gear 2 When mounting idle gear 2 bring the piston of cylinder 1 to T D C and mount the gears with their marks aligned to the respective gears a Idle gear 2 and cam gear 3 b Idle gear 2 and crank gear 4 c Idle gear 2 and supply pump gear 1 1 Supply pump gear 2 Idle gear 3 Cam gear 4 Crank gear 5 Oil ...

Page 246: ...the crankcase 1 Crankshaft oil slinger 2 O ring 3 Crankshaft collar 6 19 Installing gear case cover 1 Install the gear case cover gasket 2 Install the gear case cover 1 Apply oil to the lip of oil seal 1 Gear case cover 3 Install the hour meter gear case cover if attached 4 Install the crankshaft collar 6 20 Installing fan drive pulley Tools required Flywheel stopper 46 mm 1 8 in deep socket wrenc...

Page 247: ... the water pump 1 NOTE Take care not to forget mounting the O ring and not to let it out of position 1 Water pump 6 22 Installing oil cooler 1 Install the oil cooler 3 and water hose 1 2 2 Install the oil cooler joint screw 4 and tighten to the specified tightening torque Tightening tor que Oil cooler joint screw 4 39 2 to 49 0 N m 4 00 to 4 99 kgf m 29 0 to 36 1 lbf ft 1 Water hose 2 Water hose 3...

Page 248: ... 4 to 20 2 lbf ft 1 Supply pump 2 Install the fuel feed pump 2 2 Fuel feed pump 6 24 Installing suction control valve SCV NOTE Replace the O ring of SCV with a new one Tools required Silicon grease Hexagon wrench 4 mm square 1 Install the O ring to SCV 1 NOTE Apply clean silicon grease on the O ring of the SCV tip 2 Install the SCV until it hits the supply pump housing and tighten to the specified...

Page 249: ...d install the valve spring collet 5 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve retainer 5 Valve spring collet 6 Valve cap 5 Remove the valve spring compressor 6 After installing the valve spring collets 5 lightly tap the stem tip to attach it correctly with the plastic hammer 7 Install the valve cap 6 6 27 Installing tappet IMPORTANT Do not change the combination of cylinder number and tappe...

Page 250: ...mounting screw apply the engine oil If use new cylinder head mounting screw do not need to apply the engine oil Tighten the cylinder head mounting screw gradually in the sequence of a to n or r Tightening tor que Cylinder head mounting screw 93 2 to 98 1 N m 9 51 to 10 0 kgf m 68 8 to 72 3 lbf ft 1 Cylinder head 2 Cylinder head gasket A Gear case side B Flywheel side 3 Install the exhaust manifold...

Page 251: ... torque IMPORTANT After installing the rocker arm assembly adjust the valve clearance Tightening tor que Rocker arm brack et screw 23 5 to 27 5 N m 2 40 to 2 80 kgf m 17 4 to 20 2 lbf ft Valve clearance Cold Service specifi cation 0 18 to 0 22 mm 0 0071 to 0 0086 in 3 Rocker arm assembly RELATED PAGE 4 2 Adjusting valve clearance on page 4 98 6 30 Installing injector IMPORTANT Do not disassemble t...

Page 252: ...5 to 27 5 N m 2 40 to 2 80 kgf m 17 4 to 20 2 lbf ft 2 Injector 3 Injector clamp 4 Gasket 5 Injector clamp screw RELATED PAGE 7 56 Replacing injector on page 4 191 6 31 Installing glow plug 1 Install the glow plugs 1 NOTE Adjust the direction of the ditch to the terminal side when the seal 2 is installed in the glow plug 1 After installing the glow plug 1 make sure that the seal 2 was set to the s...

Page 253: ... specified torque Tightening tor que Coolant tempera ture sensor 1 15 7 to 19 6 N m 1 60 to 1 99 kgf m 11 6 to 14 4 lbf ft 1 Coolant temperature sensor 2 Install the camshaft position sensor 2 3 Tighten the camshaft position sensor mounting screw 3 to the specified torque NOTE If replace the camshaft position sensor measure the air gap between camshaft position sensor and pulsar gear Air gap Servi...

Page 254: ...re sensor mounting screw RELATED PAGE 4 31 Adjusting air gap between crankshaft position sensor and flywheel on page 4 114 4 32 Adjusting air gap between camshaft position sensor and pulsar gear on page 4 115 6 34 Installing common rail IMPORTANT Replace the rail assembly if the exchange of the pressure limiter 1 or the rail pressure sensor 3 is necessary NOTE Do not remove the pressure limiter 1 ...

Page 255: ...all the intake throttle valve 2 2 Install the air cleaner flange 1 1 Air cleaner flange 2 Intake throttle valve 6 37 Installing turbocharger assembly NOTE Before you start the engine make sure that the air cleaner is in the correct position Replace the gaskets with new ones 1 Install turbocharger assembly 5 NOTE Do not let dust dirt and other unwanted materials in the oil pipes Fill clean engine o...

Page 256: ...full assembly DPF make sure that the exhaust gas temperature sensor differential pressure sensor and differential pressure pipe do not make contact with surrounding parts Replace the gasket with a new one If the differential pressure tube is damaged or cracked replace it When replacing the differential pressure pipe apply a anti seize lubricating compound Bostik NEVER SEEZ Pure Nickel Special Grad...

Page 257: ...sembled by the same way of E4 and TE4 NOTE Put a product engine on a stable ground and set the parking brake Make sure not to let any foreign substances enter the opening section during the operation Make sure not to damage the muffler full assembly by falling or impact as it contains a ceramic filter When installing the muffler full assembly DPF make sure that the exhaust gas temperature sensor d...

Page 258: ...ightening tor que DPF bracket mounting screw 60 8 to 70 8 N m 6 20 to 7 21 kgf m 44 9 to 52 2 lbf ft Muffler full assem bly mounting screw M10 3 49 0 to 55 9 N m 5 00 to 5 70 kgf m 36 2 to 41 2 lbf ft Muffler full assem bly mounting screw M8 3 23 5 to 27 5 N m 2 40 to 2 80 kgf m 17 4 to 20 2 lbf ft Muffler flange nut 4 23 5 to 27 5 N m 2 40 to 2 80 kgf m 17 4 to 20 2 lbf ft 4 Muffler flange nut 5 ...

Page 259: ...re sensor con nector 3P 11 Intake air temperature sensor connector 2P 12 Resistor 120 Ω 2P 13 Resistor 1 1 kΩ 2P 14 EGR valve connector 3P 15 CAN connector 4P 16 CAN connector 4P 17 Engine intermediate connector 18 Engine joint connector 4 8P 19 Engine joint connector 3 8P 20 Engine joint connector 2 10P 21 Engine joint connector 1 6P a to j Clamp 2 Connect the injector intermediate harness engine...

Page 260: ... gas temperature sen sor T2 2P 28 Exhaust gas temperature sen sor T1 2P 29 Exhaust gas temperature sen sor T0 2P 30 Differential pressure sensor ΔP 3P l Clamp 5 Connect the engine ECU intermediate harness 31 Injector intermediate harness 32 Engine intermediate harness 33 DPF intermediate harness 4 ENGINE SERVICING 6 Assembling 4 160 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V...

Page 261: ...ternator 4 3 Install the fan belt 6 4 Tighten the cooling fan mounting screw 5 IMPORTANT After install the fan belt adjust the fan belt tension Deflection A Service specifi cation 10 0 to 12 0 mm 0 394 to 0 472 in under load of 98 N 10 kg 22 1 lbf A Deflection Tightening tor que Cooling fan mount ing screw 5 9 81 to 11 3 N m 1 00 to 1 15 kgf m 7 24 to 8 33 lbf ft 4 Alternator 5 Cooling fan mountin...

Page 262: ...per line a on the dipstick from filling port a Upper line b Lower line 7 Servicing 7 1 Checking cylinder head top clearance Tools required Plastigauge 1 Remove the cylinder head 2 With the piston at T D C use grease to affix three or four plastigauges 1 to the crown of the piston keep the gauges away from the intake valve and combustion chamber fittings Plastigauge 1 cut size Diameter 1 5 mm 0 059...

Page 263: ...in the figure 3 Measure the clearance with a feeler gauge NOTE If the measurement is more than the service limit make it straight with a surface grinder IMPORTANT Check the valve recessing after you correct Cylinder head sur face flatness Service limit 0 05 mm 0 002 in 7 3 Checking cylinder head flaw Tools required Red permeative liquid Detergent White developer 1 Clean the surface of the cylinder...

Page 264: ...fter you replace the valve replace the cylinder head Valve recessing Service specifi cation 0 65 to 0 85 mm 0 026 to 0 033 in Service limit 1 20 mm 0 0472 in 1 Cylinder head surface A Recessing B Protrusion 7 5 Adjusting valve lapping Tools required Compound Valve lapping tool Prussian Blue 1 Apply the compound equally to the valve lapping surface 2 Put the valve into the valve guide Lap the valve...

Page 265: ...rvice specifi cation 7 960 to 7 975 mm 0 3134 to 0 3139 in 3 Measure the valve guide I D with a small hole gauge Valve guide I D Service specifi cation 8 015 to 8 030 mm 0 3156 to 0 3161 in 4 Calculate the clearance NOTE If the clearance is more than the service limit replace the valves If the clearance stays more than the service limit replace the valve guide also Clearance be tween valve stem an...

Page 266: ... the valve guide section Repair them if necessary Tools required Valve refacer 1 Adjust the valve with a valve refacer Valve face angle Service specifi cation 0 79 rad 45 7 9 Adjusting valve seat NOTE Before you adjust the valve seat check the valve stem and measure the I D of the valve guide section Repair them if necessary After you adjust the valve seat be sure to check the valve recessing Tool...

Page 267: ...stem and valve guide on page 4 165 7 4 Checking valve recessing on page 4 164 7 10 Checking free length of valve spring Tools required Vernier caliper 1 Measure the free length 1 of valve spring with a vernier calipers NOTE If the measurement is less than the service limit replace it Free length 1 Service specifi cation 41 7 to 42 2 mm 1 65 to 1 66 in Service limit 41 2 mm 1 62 in 1 Free length 2 ...

Page 268: ...ce the valve spring Setting load Set ting length Service specifi cation 118 N 35 0 mm 12 0 kgf 35 0 mm 26 5 lbf 1 38 in Service limit 100 N 35 0 mm 10 2 kgf 35 0 mm 22 5 lbf 1 38 in 7 13 Checking oil clearance between rocker arm and rocker arm shaft Tools required Internal micrometer External micrometer 1 Measure the rocker arm I D with an internal micrometer Rocker arm I D Service specifi cation ...

Page 269: ...tappet guide bore Tools required External micrometer Cylinder gauge 1 Measure the tappet O D with an external micrometer Tappet O D Service specifi cation 23 959 to 23 980 mm 0 94327 to 0 94409 in 2 Measure the tappet guide bore I D with a cylinder gauge Tappet guide bore I D Service specifi cation 24 000 to 24 021 mm 0 94489 to 0 94570 in 3 Calculate the oil clearance NOTE If the oil clearance is...

Page 270: ...0059 in Backlash between crank gear and oil pump drive gear 2 Service specifi cation 0 04150 to 0 1090 mm 0 001634 to 0 004291 in Service limit 0 15 mm 0 0059 in RELATED PAGE 4 30 Measuring angular deviation between crankshaft T D C and crankshaft position sensor detected T D C on page 4 112 7 17 Checking side clearance of idle gear Tools required Dial gauge 1 Set a dial gauge with its point on th...

Page 271: ...indicator Half of the measurement NOTE If the measurement is more than the service limit replace the camshaft Camshaft align ment Service limit 0 01 mm 0 0004 in 7 20 Replacing idle gear bushing Tools required Press tool Idle gear bushing replacing tool Removing idle gear bushing 1 Press out the used idle gear bushing with the replacing tool A Removing direction Installing idle gear bushing 1 Clea...

Page 272: ...ournal and crankcase bore Tools required External micrometer Internal micrometer Cylinder gauge 1 Measure the camshaft journal O D with an external micrometer Camshaft journal O D Service specifi cation 39 934 to 39 950 mm 1 5722 to 1 5728 in 2 Measure the crankcase bore I D for the camshaft with an internal micrometer or cylinder gauge Crankcase bore I D Service specifi cation 40 000 to 40 025 mm...

Page 273: ...Replacing idle gear bushing on page 4 171 7 24 Checking piston pin bore I D Tools required Cylinder gauge 1 Measure the piston pin bore I D in the horizontal and vertical directions with a cylinder gauge NOTE If the measurement is more than the service limit replace the piston When replacing the piston select the cylinder head gasket thickness to meet with the top clearance Piston pin bore I D Ser...

Page 274: ...i cation 0 014 to 0 036 mm 0 00056 to 0 0014 in Service limit 0 15 mm 0 0059 in RELATED PAGE 7 26 Replacing small end bushing on page 4 174 4 29 Selecting cylinder head gasket on page 4 111 7 1 Checking cylinder head top clearance on page 4 162 7 26 Replacing small end bushing Tools required Small end bushing replacing tool Removing small end bushing 1 Press out the used bushing with small end bus...

Page 275: ... plate NOTE If the gauge does not touch fully against the face plate measure the space between the gauge pin and face plate If the measurement is more than the service limit replace the connecting rod When replacing the connecting rod select the cylinder head gasket thickness to meet with the top clearance Connecting rod alignment Service limit 0 05 mm 0 002 in RELATED PAGE 7 25 Checking oil clear...

Page 276: ...0 016 to 0 021 in Service limit 1 25 mm 0 0492 in Oil ring Service speci fication D1803 CR E4 V2403 CR E4 0 20 to 0 40 mm 0 0079 to 0 015 in D1803 CR TE4 D1803 CR TIE4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 0 25 to 0 45 mm 0 0099 to 0 017 in Service limit 1 25 mm 0 0492 in 7 29 Checking clearance between piston ring and ring groove Tools required Feeler gauge 1 Clean the rings and the ring groo...

Page 277: ...R E4 0 0780 to 0 110 mm 0 00307 to 0 00433 in D1803 CR TE4 D1803 CR TIE4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 0 0930 to 0 128 mm 0 00367 to 0 00503 in Service limit 0 20 mm 0 0079 in Oil ring Service speci fication D1803 CR E4 V2403 CR E4 0 030 to 0 070 mm 0 0012 to 0 0027 in D1803 CR TE4 D1803 CR TIE4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 0 020 to 0 060 mm 0 00079 to 0 0023 in Service li...

Page 278: ...adi us 0 11 to 0 12 in radi us 2 8 to 3 2 mm radi us 0 11 to 0 12 in radi us The crankshaft journal must be fine finished to higher than Rmax 0 4 S A Dimension A B Dimension B C Dimension C 7 31 Checking crankshaft alignment Tools required V blocks Surface plate Dial gauge 1 Hold the two end journals of crankshaft with V blocks on the surface plate 2 Set a dial gauge with its point on the middle j...

Page 279: ... an undersize one Crankpin O D Service specifi cation 46 959 to 46 975 mm 1 8488 to 1 8494 in Crankpin bearing I D Service specifi cation 47 000 to 47 046 mm 1 8504 to 1 8522 in Oil clearance be tween crankpin and crankpin bear ing Service specifi cation 0 025 to 0 087 mm 0 00099 to 0 0034 in Service limit 0 20 mm 0 0079 in Reference Undersize dimensions of crankpin Undersize 0 2 mm 0 008 in 0 4 m...

Page 280: ...2 8 to 3 2 mm radi us 0 11 to 0 12 in radi us Dimension B 1 0 to 1 5 mm relief 0 040 to 0 059 in relief 1 0 to 1 5 mm relief 0 040 to 0 059 in relief Dimension C 59 721 to 59 740 mm dia 2 3513 to 2 3519 in dia 59 521 to 59 540 mm dia 2 3434 to 2 3440 in dia The crankshaft journal must be fine finished to higher than Rmax 0 4 S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 to 0 0...

Page 281: ...ure 3 Press fit the new crankshaft bearing 1 2 with the crankshaft bearing replacing tool Dimension A Service specifi cation 3 90 to 4 10 mm 0 154 to 0 161 in 1 Seam 2 Crankshaft bearing 1 3 Crankcase A Dimension 7 36 Checking oil clearance between crankshaft journal and crankshaft bearing 2 Tools required Plastigauge 1 Clean the crankshaft journal and crankshaft bearing 2 Put a strip of plastigau...

Page 282: ...9 740 mm dia 2 3513 to 2 3519 in dia 59 521 to 59 540 mm dia 2 3434 to 2 3440 in dia The crankshaft journal must be fine finished to higher than Rmax 0 4 S Holes to be de burred and edges rounded with 1 0 to 1 5 mm 0 040 to 0 059 in relief A Dimension A B Dimension B C Dimension C D Dimension D 7 37 Replacing bearing case cover oil seal Tools required Bearing case cover oil seal replacing tool Rem...

Page 283: ... 3 4252 to 3 4260 in Service limit 87 170 mm 3 4319 in Difference be tween maximum I D and minimum I D Service limit 0 15 mm 0 0059 in A Top B Middle C Bottom a Right angled to piston pin b Piston pin direction 3 Check the cylinder wall for scratches NOTE If you find deep scratches bore the cylinder RELATED PAGE 7 39 Adjusting cylinder correction over size on page 4 183 7 39 Adjusting cylinder cor...

Page 284: ...d piston rings with oversize ones Oversize piston and piston rings Service specifi cation 0 25 mm 0 0098 in RELATED PAGE 7 38 Checking cylinder wear on page 4 183 7 40 Checking clearance between inner rotor and outer rotor Tools required Feeler gauge 1 Measure the clearance between the lobes of the inner rotor and the outer rotor with a feeler gauge NOTE If the clearance more than the service limi...

Page 285: ...at with the scale to get the oil clearance NOTE If the clearance is more than the service limit replace oil pump rotor assembly and the cover Clearance be tween rotor and cover Service specifi cation 0 105 to 0 150 mm 0 00414 to 0 00590 in Service limit 0 20 mm 0 008 in 7 43 Checking overrunning clutch of starter 1 Check the pinion for wear or damage NOTE If there is any damage replace the overrun...

Page 286: ...1803 CR TE4 D1803 CR TIE4 29 0 mm 1 14 in V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 34 0 mm 1 34 in Difference of O D s Service speci fication Less than 0 02 mm 0 0008 in Service limit 0 05 mm 0 002 in 4 Measure the mica undercut NOTE If the undercut is less than the service limit correct it with a saw blade Chamfer the segment edges Mica undercut Service specifi cation 0 45 to 0 75 mm...

Page 287: ...ter 1 Check the continuity across the brush holder and the holder support with a circuit tester NOTE If electricity flows replace the brush holder assembly Resistance be tween brush hold er and holder sup port Service specifi cation Infinity 7 47 Checking armature coil of starter Tools required Circuit tester 1 Check the continuity across the commutator and armature coil core with the resistance r...

Page 288: ... the yoke assembly Resistance be tween lead and brush Service specifi cation 0 Ω 1 Lead 2 Brush 2 Check the continuity across the brush 2 and yoke 3 with a resistance range of circuit tester NOTE If electricity is out of service specification replace the yoke assembly Resistance be tween brush and yoke Service specifi cation Infinity 2 Brush 3 Yoke 7 49 Checking bearing of alternator 1 Check that ...

Page 289: ...cifi cation 2 9 Ω 2 Check the continuity across the slip ring and core with the resistance range of circuit tester NOTE If electricity is out of service specification replace the rotor Resistance be tween slip ring and rotor core Service specifi cation Infinity 7 52 Checking slip ring of alternator Tools required Emery paper 500 to 600 Vernier caliper 1 Check the slip ring for dirt or scratch NOTE...

Page 290: ...er with the resistance range of circuit tester NOTE The rectifier is correct if the diode in the rectifier conducts electricity only in one direction Resistance Service specifi cation Less than 1 0 Ω 7 55 Checking IC regulator Tools required Circuit tester 1 Check the continuity across the B terminal 2 and the F terminal 1 of IC regulator with the resistance range of circuit tester NOTE The IC reg...

Page 291: ...y button 1 from the project window 1 Utility button 2 Select the Injector Compensation item 2 then click the proceed button 3 2 Injector Compensation item 3 Proceed button 3 Enter the injector compensation value to the initial display 5 then click the Register button 4 4 Register button 5 Initial display 4 Click the OK button 6 if rewriting is OK 6 OK button 5 Click the OK button 7 when rewriting ...

Page 292: ...ndow 10 Search button 2 Click the Registration of Service Info button 11 11 Registration of Service Info button 3 Select the Injection Compensation and enter the new service information to the After Exchanged window 12 then click the Register button 13 12 After Exchanged window 13 Register button 4 ENGINE SERVICING 7 Servicing 4 192 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V...

Page 293: ... the Download Reprogram File button 3 3 Download Reprogram File button 3 Enter the service engine ECU serial number 4 then click the Download button 5 4 Service engine ECU serial number 5 Download button 4 Click the Save button 6 then download the DPK file 6 Save button ECU reprogram 1 Start Diagmaster and click the ECU Reprogram button 7 from the default window 7 ECU Reprogram button 2 Select the...

Page 294: ...main program rewriting is complete follow the instruction 11 then click the OK button 12 11 Instruction 12 OK button 6 After the engine ECU data rewriting is complete follow the instruction 13 then click the OK button 14 4 ENGINE SERVICING 7 Servicing 4 194 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 295: ...om the project window 16 DTC button 3 Click the Clear DTC button 17 17 Clear DTC button 4 Click the Clear DTC button 18 to clear DTC and exit function 18 Clear DTC button DPF manual regeneration 1 Perform the DPF manual regeneration RELATED PAGE 7 58 Replacing DPF on page 4 196 SERVICING 7 Servicing 4 ENGINE D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TI...

Page 296: ...e DPF Regeneration Interval Time Reset item 2 then click the proceed button 3 2 DPF Regeneration Interval Time Reset item 3 Proceed button 3 Follow the instructions according to steps of Notes screen 4 then click the Start button 5 4 Notes screen 5 Start button 4 Click the OK button to exit function 6 OK button DPF soot load reset 1 Start Diagmaster then click the Utility button 7 from the project...

Page 297: ...eneration 1 Start Diagmaster then click the Utility button 15 from the project window 15 Utility button 2 Select the DPF Manual Regeneration Request Function item 16 3 Follow the instructions according to steps of Instruction screen 17 then click the proceed button 18 16 DPF Manual Regeneration Request Function item 17 Instruction screen 18 Proceed button 4 Select the DPF Manual Regeneration Reque...

Page 298: ...ration button on the machine 9 Observe the data monitor until the DPF regeneration control level status 23 value becomes 0 23 DPF regeneration control level status 10 Click the Finish Active Test button 24 to stop the data monitor then click the Save button 25 to save monitor data 24 Finish Active Test button 25 Save button 11 Click the Back to Item Select button 26 to exit from active test 4 ENGI...

Page 299: ...k the Register button 31 30 After Exchanged window 31 Register button 4 If you replace DOC component select the DOC Component and enter the new service information to the After Exchanged window 32 then click the Register button 33 32 After Exchanged window 33 Register button RELATED PAGE 5 5 Removing muffler full assembly on page 4 117 5 6 Disassembling DPF assembly on page 4 118 6 40 Installing m...

Page 300: ...4 ENGINE SERVICING 7 Servicing 4 200 D1803 CR E4 D1803 CR TE4 D1803 CR TIE4 V2403 CR E4 V2403 CR TE4 V2403 CR TE4BG V2403 CR TIE4 KiSC issued 12 2018 A ...

Page 301: ...ing case cover oil seal replacing tool 2 40 bolt and nut tightening 2 1 bolts tightening torques 4 96 boost pressure sensor checking 4 108 function 4 34 outline 4 34 removing 4 121 specification 4 34 structure 4 34 breather function 4 5 outline 4 5 structure 4 5 bushing replacing tool 2 35 C cam checking height 4 172 camshaft checking alignment 4 171 checking side clearance 4 170 function 4 10 ins...

Page 302: ...e 4 177 function 4 8 installing 4 138 outline 4 8 removing for 3 cylinders 4 131 removing for 4 cylinders 4 132 specification 4 8 structure 4 8 crankshaft alignment checking 4 178 crankshaft bearing 1 checking oil clearance 4 179 replacing 4 181 crankshaft bearing 1 replacing tool 2 36 crankshaft bearing 2 checking oil clearance 4 181 crankshaft journal checking oil clearance 4 179 4 181 crankshaf...

Page 303: ...ssembly assembling 4 156 disassembling 4 118 DPF differential pressure hose checking 3 25 DPF differential pressure pipe checking 3 25 DPF filter comp judging reuse after cleaning cleaning contractor 3 23 judging reuse before cleaning service dealer 3 22 E E4B engine 2 8 EGR cooler checking 3 18 function 4 47 installing 4 156 outline 4 47 removing 4 119 specification 4 47 structure 4 47 EGR cooler...

Page 304: ...e 4 9 removing 4 130 specification 4 9 structure 4 9 flywheel housing installing 4 139 removing 4 131 flywheel stopper 2 36 fuel camshaft function 4 35 installing with supply pump gear 4 145 outline 4 35 structure 4 35 fuel camshaft assembly removing 4 127 fuel cooler function 4 30 outline 4 29 structure 4 30 fuel feed pump function 4 19 outline 4 19 specification 4 19 structure 4 19 fuel filter f...

Page 305: ...removing 4 120 specification 4 84 structure 4 84 intercooler function 4 41 outline 4 41 specification 4 41 structure 4 41 intercooler hose replacing 3 28 K key switch function 4 71 outline 4 70 specification 4 71 structure 4 70 L liquid gasket handling 2 2 lubricant hose replacing 3 28 lubricating system feature 4 52 flow 4 53 structure 4 51 M magnetic switch checking continuity 4 105 main bearing...

Page 306: ...sassembling 4 130 piston pin checking oil clearance 4 173 piston pin bore I D checking 4 173 piston ring checking clearance 4 176 checking gap 4 175 function 4 7 installing 4 141 outline 4 7 removing 4 129 specification 4 7 structure 4 7 positive crankcase ventilation valve checking 3 19 pre cleaner function 4 40 outline 4 40 specification 4 40 structure 4 40 pump body checking clearance 4 184 pus...

Page 307: ... specification 4 72 structure 4 71 starter motor checking 4 103 suction control valve SCV checking 4 107 supply pump function 4 21 installing 4 148 outline 4 20 removing 4 125 specification 4 23 structure 4 20 system wiring diagram D1803 CR E4 2 29 D1803 CR TE4 2 29 D1803 CR TIE4 2 31 V2403 CR E4 2 29 V2403 CR TE4 2 29 V2403 CR TE4BG 2 29 V2403 CR TIE4 2 31 T tappet checking oil clearance 4 169 fu...

Page 308: ...ication 4 10 structure 4 10 valve guide checking clearance 4 165 replacing 4 165 valve guide replacing tool 2 35 valve seat adjusting 4 166 valve spring checking free length 4 167 checking set load 4 168 checking tilt 4 167 valve stem checking clearance 4 165 W water hose replacing 3 28 water jacket cleaning 3 13 water pump function 4 62 installing 4 147 outline 4 61 removing 4 126 structure 4 61 ...

Page 309: ...ess 64 Ishizu Kitamachi Sakai Ku Sakai City Osaka 590 0823 Japan Phone 81 72 241 1531 Fax 81 72 245 2928 E mail kbt_g estg pub kubota com KUBOTA Corporation Printed in Japan 2018 12 S EI EI engusa 2013 02 S EI EI engusa Code No 9Y111 07827 ...

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Kubota D1803-CR-E4, Workshop Manual

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