Kubota D1803-CR-E4 Workshop Manual
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Kubota D1803-CR-E4 Workshop Manual

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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

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Summary of Contents for Kubota 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 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 operating time of the machine, application or maintenance condition.
  • Page 3 Added the information of V2403-CR-TE4BG 2014.11 D1803-CR-TIE4 Added the model about D1803-CR-TIE4 and V2403-CR-TIE4 － V2403-CR-TIE4 These models are equipped DOC only instead of DPF. 2017.04 Added the information about disassembling and assembling. 4-124 4-148 (Continued) 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 4 4-191 and flywheel/pulsar gear 4-193 Separate disassembling and assembling 4-196 Added follow servicing information. • Replacing injector • Replacing engine ECU • Replacing DPF Change notification about fan drive pulley mounting nut tightening torque 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 5: Table Of Contents

    6.1 Engine intermediate harness (Engine side harness) ..............2-21 6.2 Injector intermediate harness (Engine side harness) ..............2-23 6.3 Engine ECU intermediate harness (OEM side harness) ..............2-24 6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG ..........................2-29 6.5 System wiring diagram for D1803-CR-TIE4, V2403-CR-TIE4 ............2-31...
  • Page 6 10. Check points of every 1 year ........................ 3-25 10.1 Replacing air cleaner element....................... 3-25 10.2 Checking DPF differential pressure pipes and hoses ..............3-25 10.3 Checking EGR piping ........................3-26 10.4 Checking intake air line ......................... 3-26 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 7 2.9.1 Outline of piston ring ......................... 4-7 2.9.2 Structure of piston ring......................4-7 2.9.3 Function of piston ring ......................4-7 2.9.4 Specification of piston ring ......................4-7 2.10 Connecting rod ..........................4-7 2.10.1 Outline of connecting rod ......................4-7 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 8 3.6.1 Outline of water separator ...................... 4-17 3.6.2 Structure of water separator (Type1) ..................4-17 3.6.3 Structure of water separator (Type2) ..................4-17 3.6.4 Function of water separator ....................4-18 3.6.5 Specification of water separator (Type2) ................4-18 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 9 3.18.1 Outline of crankshaft position sensor..................4-31 3.18.2 Structure of crankshaft position sensor ................4-31 3.18.3 Function of crankshaft position sensor ................. 4-31 3.18.4 Specification of crankshaft position sensor................4-31 3.19 Camshaft position sensor......................4-32 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 10 4.10 Intake manifold ..........................4-42 4.10.1 Outline of intake manifold ..................... 4-42 4.10.2 Structure of intake manifold ....................4-42 4.10.3 Function of intake manifold ....................4-42 4.11 Exhaust manifold ........................... 4-42 4.11.1 Outline of exhaust manifold....................4-42 viii 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 11 6.9.4 Specification of oil cooler ......................4-58 6.10 Oil pressure switch ........................4-58 6.10.1 Outline of oil pressure switch ....................4-58 6.10.2 Structure of oil pressure switch..................... 4-58 6.10.3 Function of oil pressure switch ..................... 4-58 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 12 8.7.1 Outline of starter (planetary gear reduction type) ..............4-71 8.7.2 Structure of starter (planetary gear reduction type) ..............4-71 8.7.3 Function of starter (planetary gear reduction type) ..............4-71 8.7.4 Specification of starter (planetary gear reduction type) ............4-72 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 13 4.4 Checking fan belt tension ......................4-100 4.5 Checking fan belt damage and wear..................... 4-100 4.6 Checking radiator cap air leakage....................4-100 4.7 Checking radiator water leakage....................4-101 4.8 Checking opening temperature of thermostat valve..............4-101 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 14 5.27 Removing crankshaft oil slinger ....................4-126 5.28 Removing idle gear ........................4-127 5.29 Removing fuel camshaft assembly ..................... 4-127 5.30 Removing camshaft with cam gear ..................... 4-128 5.31 Removing oil pump ........................4-128 5.32 Removing crank gear ........................4-128 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 15 6.39 Assembling DPF assembly ......................4-156 6.40 Installing muffler full assembly ....................4-157 6.41 Installing CRS intermediate harness ................... 4-159 6.42 Installing external components....................4-161 6.43 Filling coolant ..........................4-162 6.44 Filling engine oil .......................... 4-162 7. Servicing ...............................4-162 xiii 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 16 7.52 Checking slip ring of alternator....................4-189 7.53 Checking brush wear of alternator ....................4-190 7.54 Checking rectifier ........................4-190 7.55 Checking IC regulator ......................... 4-190 7.56 Replacing injector........................4-191 7.57 Replacing engine ECU ........................ 4-193 7.58 Replacing DPF ..........................4-196 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 17: Safety

    SAFETY KiSC issued 12, 2018 A...

  • Page 18: Safety First

    • Keep emergency numbers near your telephone at all times. • 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. 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 19: Working Cautions

    • When using a garage jack, always use with a rigid • Do not allow third parties to come near the rack to prevent the machine from falling. machine. • Keep the machine clean. Remove dirt, debris, and oil attached to the machine. 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 20: Starting The Machine Safely

    • Keep away from rotating and moving objects. (DPF). • Keep tools and waste cloth away from rotating and • Do not make a short-circuit. moving objects. • Do not splash the hydraulic oil on the exhaust components. 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 21: Preventing Acid Burns

    The fluid can penetrate your skin and cause serious injuries. 9. Cleaning exhaust filter • Get a medical aid immediately if the accident occurs. 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 22 SAFETY FIRST 1. SAFETY • Avoid skin exposure and contact with hot exhaust gas or components. Exhaust gas and components are extremely hot during regeneration of diesel particulate filter (DPF). 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 23 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 KiSC issued 12, 2018 A...

  • Page 24: General

    GENERAL KiSC issued 12, 2018 A...

  • Page 25: General Working Precautions

    • Whenever a special tool is required, use the special tool that Kubota recommends. Or, craft the special tools according to the illustrations in this manual. • Use genuine Kubota parts to ensure safety and machine performance. 1. Tightening bolts and nuts...

  • Page 26: Handling Liquid Gasket

    • In cases when installing an oil seal without a for 30 minutes or more then fill with oil. press, place a wooden board on the seal and gently tap the board with a hammer; install the oil seal straightly and evenly. 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 27: Handling The Battery

    • If the electrical wiring is damaged, repair it with an insulating tape or rat-proof tape, or replace • Repair replace damaged wiring the wiring with a new one. immediately. • Do not alter the electrical device and wiring. 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 28: Handling Fuses

    (10) Clamp • Clamp the electrical wiring correctly. Do not slack, twist, and pull. • In cases of connecting the electrical wiring to moving or vibrating locations, make sure to clamp the electrical wiring loosely. 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 29: Handling Connectors

    • Do not pull the wire harness to separate. (5) Cover (C) Incorrect (B) Correct (C) Incorrect (B) Correct • Make sure the terminal condition of the connectors is not bent, rusty, and so on. 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 30: Wiring Color

    Brown BR, Br Green Gray GY, GR Blue Light green LG, Lg Orange OR, O Pink Purple PU, V, Pu Sky blue SB, Sb White Yellow (An example) W/R: Red stripe on white color 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 31: General Machine Information

    SM (include: WG) 2026 Air cooled gasoline 2027 GZ, OC, AC, EA, E * Alphabetical letters "I" and "O" are not used. 03 (include: WG) EA, RK 03 (KET production) V3, 07 (KEW production) 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 32: E4B Engine

    75 kW From 75 to less Interim Tier 4 than 130 kW The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Nonroad Emission Standards continue to 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 33: Cylinder Number

    E4B Kubota DPF for cleaning. Parts List and perform all maintenance services listed in the appropriate Kubota Operator's Manual or in the appropriate E4B Kubota Workshop Manual. Use of incorrect replacement parts or replacement parts from...

  • Page 34: Specifications

    GENERAL MACHINE INFORMATION 2. GENERAL 3. Specifications 3. Specifications 3.1 Specification for D1803-CR-E4, TE4 Model D1803-CR-E4 D1803-CR-TE4 Number of cylinder Engine type Vertical, water-cooled, 4-cycle diesel Bore × Stroke 87 × 102.4 mm (3.43 × 4.031 in.) Total displacement 1826 cm (111.4 cu.in.)

  • Page 35: Specification For V2403-Cr-E4, Te4

    221 kg (487 lbs) 233 kg (514 lbs) NOTE • The specification described above is of the standard engine of each model. • Conversion formula: HP = 0.746 kW, PS = 0.7355 kW. 2-11 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 36: Specification For D1803-Cr-Tie4, V2403-Cr-Tie4

    195 kg (430 lbs) 232 kg (511 lbs) NOTE • The specification described above is of the standard engine of each model. • Conversion formula: HP = 0.746 kW, PS = 0.7355 kW. 2-12 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 37: Specification For V2403-Cr-Te4Bg

    9.5 L (2.5 U.S.gals, 2.1 Imp.gals) Weight (Dry) 230 kg (507 lbs) NOTE • The specification described above is of the standard engine of each model. • Conversion formula: HP = 0.746 kW, PS = 0.7355 kW. 2-13 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 38: Performance Curves

    GENERAL MACHINE INFORMATION 2. GENERAL 4. Performance curves 4. Performance curves 4.1 Performance curve for D1803-CR-E4 D1803-CR-E4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C.

  • Page 39: Performance Curve For D1803-Cr-Te4

    4.2 Performance curve for D1803-CR-TE4 D1803-CR-TE4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C. 2-15 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 40: Performance Curve For D1803-Cr-Tie4

    4.3 Performance curve for D1803-CR-TIE4 D1803-CR-TIE4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C. 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: Performance Curve For V2403-Cr-E4

    4.4 Performance curve for V2403-CR-E4 V2403-CR-E4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C. 2-17 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 42: Performance Curve For V2403-Cr-Te4

    4.5 Performance curve for V2403-CR-TE4 V2403-CR-TE4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C. 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: Performance Curve For V2403-Cr-Tie4

    4.6 Performance curve for V2403-CR-TIE4 V2403-CR-TIE4 (1) Torque (3) Engine speed (6) Gross intermittent brake (2) Brake specific fuel consump- (4) Brake horsepower horsepower tion (B.S.F.C.) (5) Gross intermittent torque (7) Gross intermittent B.S.F.C. 2-19 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 44: Dimensions

    GENERAL MACHINE INFORMATION 2. GENERAL 5. Dimensions 5. Dimensions 5.1 Dimensions D1803-CR-E4 D1803-CR-TE4 D1803-CR-TIE4 744 mm (29.3 in.) 744 mm (29.3 in.) 758 mm (29.8 in.) 507 mm (20.0 in.) 513 mm (20.2 in.) 513 mm (20.2 in.) 721 mm (28.4 in.) 735 mm (28.9 in.)

  • Page 45: Wiring Diagram

    Boost pressure sensor CN209 Suction control valve (SCV) 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. 2-21 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 46 CN224 / CN225 CAN tool (14) CN226 Resistance connector (120 Ω) (15) Shield cable － NOTE • The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side. 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: Injector Intermediate Harness (Engine Side Harness)

    Injector 4 CN303 Injector 3 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. 2-23 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 48: Engine Ecu Intermediate Harness (Oem Side Harness)

    6.3 Engine ECU intermediate harness (OEM side harness) CN501 Engine ECU (1) CN502 Engine ECU (2) CN503 Engine ECU joint connector 1 Power unit － Diesel Particulate Filter (Hereinafter referred － to as the "DPF") Engine － Injector － 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 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) 2-25 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 50 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. 2-26 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 51 GENERAL MACHINE INFORMATION 6. Wiring diagram 2. GENERAL (34) Engine － (35) Shield cable － NOTE • The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side. 2-27 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 52 GENERAL MACHINE INFORMATION 2. GENERAL 6. Wiring diagram (36) － Injector (37) － Shield cable NOTE • The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side. 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: System Wiring Diagram For D1803-Cr-E4, D1803-Cr-Te4, V2403-Cr-E4, V2403-Cr-Te4, V2403-Cr-Te4Bg

    GENERAL MACHINE INFORMATION 6. Wiring diagram 2. GENERAL 6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG Main relay (13) Injector 1 (25) Rail pressure sensor Fuel feed pump (14) Injector 4 (26) Boost pressure sensor...
  • Page 54 Exhaust gas temperature sensor (10) Battery (22) Differential pressure sensor (ΔP) (34) (11) Glow relay (23) Suction control valve (SCV) (12) Glow heater (24) Coolant temperature sensor Injector 4 is equipped only V2403 model. 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: System Wiring Diagram For D1803-Cr-Tie4, V2403-Cr-Tie4

    EGR valve (14) Injector 3 (23) Boost pressure sensor Starter (15) Injector 2 (24) Stop switch Air flow sensor (16) Crankshaft position sensor (25) Neutral switch Starter relay (17) Camshaft position sensor (Continued) 2-31 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 56 GENERAL MACHINE INFORMATION 2. GENERAL 6. Wiring diagram Battery (18) Accel sensor 1 Injector 4 is equipped only V2403 model. 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: Special Tools

    SPECIAL TOOLS 1. Diesel engine compression tester 2. GENERAL SPECIAL TOOLS 1. Diesel engine compression tester Use for measuring the diesel engine compression. Code No. 07909-30208 (Assembly) (1) Gauge 2-33 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 58: Compression Tester Adapter K

    49 mm (1.9 in.) 10 mm (0.39 in.) 15 mm (0.59 in.) 10 mm (0.39 in.) 100 mm (3.94 in.) 125 mm (4.92 in.) C0.3 Chamfer 0.3 mm (Chamfer 0.01 in.) Material SS400 2-34 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 59: Oil Pressure Tester

    • This special tool is not provided, so make it referring to the figure. 5. Bushing replacing tools Use for press out and press fit the bushing. NOTE • This special tool is not provided, so make it referring to the figure. 2-35 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 60: Flywheel Stopper

    Material SS400 6. Flywheel stopper Use for loosening and tightening the flywheel screw. NOTE • This special tool is not provided, therefore make it by referring to the figure. 2-36 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 61: Auxiliary Socket For Fixing Crankshaft Sleeve

    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. 2-37 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 62: Injection Top Correction Jig

    60.0 mm dia. (2.36 in. dia.) 79.80 to 79.85 mm dia. (3.142 to 3.143 in. dia.) 10.0 mm (0.394 in.) 0.04 mm dia. (0.002 in. dia.) 140 mm (5.51 in.) 120 mm (4.72 in.) (Continued) 2-38 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 63 35 mm (1.4 in.) 12 mm dia. (0.47 in. dia.) 10 mm dia. (0.39 in. dia.) 20.34 to 20.50 mm dia. (0.8008 to 0.8070 in. dia.) 1.0 rad (60°) Chamfer 1.0 mm (0.039 in.) Material SS400 2-39 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 64: Bearing Case Cover Oil Seal Replacing Tool

    32.000 to 32.025 mm dia. (1.2599 to 1.2608 in. dia.) 116 mm dia. (4.57 in. dia.) 3 mm dia. (0.1 in. dia.) 88 mm (3.5 in.) 12 mm (0.47 in.) 88 mm (3.5 in.) 92 mm (3.6 in.) (Continued) 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 65 145 mm dia. (5.71 in. dia.) 90 mm (3.5 in.) 12 mm (0.47 in.) C0.3 Chamfer 0.3 mm (0.01 in.) Chamfer 1.0 mm (0.039 in.) Chamfer 2.0 mm (0.079 in.) Chamfer 4.0 mm (0.16 in.) Material SS400 2-41 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 66 SPECIAL TOOLS 2. GENERAL 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: Maintenance

    MAINTENANCE KiSC issued 12, 2018 A...

  • Page 68: Maintenance Check List

    3-20 Cleaning DPF ○ 3-20 Checking EGR system (with Diag- ○ 3-24 master) Replacing air cleaner element ○ 3-25 Checking DPF differential pressure ○ 3-25 pipes and hoses Checking EGR piping ○ 3-26 (Continued) 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 69: Inspection Item

    • When the battery is used for less than 100 hours in a year, check its electrolyte yearly (for refillable battery's only). • The items above (*1 marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA nonroad emission regulation.
  • Page 70 3. MAINTENANCE Engine oil classification (API classification) Fuel type D1803-CR-E4, -TE4, -TIE4, V2403-CR-E4, -TE4, -TIE4, TE4BG Ultra low sulfur fuel CJ-4 Sulfur content <0.0015% (15 ppm) • Engine oil should be API classification CJ-4. • Change the type of engine oil according to the ambient temperature.
  • Page 71 4. Bear it in mind that Biodiesel fuels have the characteristics below. Referring to the servicing intervals specified in the Kubota products' Operator's Manuals, be sure to maintain and clean up the fuel system, replace the fuel hose with new ones and take other necessary measures.

  • Page 72: Check And Maintenance

    3. Make sure that the oil level is between the upper viscosity from the previous, drain the remaining line (a) and lower line (b). oil. Do not mix 2 different types of oil. D1803-CR-E4 7.0 L D1803-CR-TE4 NOTE 1.8 U.S.gals D1803-CR- 1.5 Imp.gals...

  • Page 73: Checking Fuel Level

    • Do not use an anti-freeze and scale inhibitor at the same time. • Do not mix the different type or brand of L.L.C. 1. Remove the radiator cap (1). 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 74: Checking Fan Belt

    (Under load of 98 N (10 kgf, 22.1 lbf)) (1) Drain plug 4. Tighten the drain plug (1). 32.4 to 37.2 N⋅m Tightening tor- (1) Deflection Drain plug (1) 3.31 to 3.79 kgf⋅m 23.9 to 27.4 lbf⋅ft 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 75: Replacing Oil Filter Cartridge

    • To prevent serious damage to the engine, 2. If the fuel hose (1) or clamp (2) is damaged, replace replacement element must be highly efficient. Use only a Kubota genuine filter or its equivalent. Tools required • Filter wrench 1.

  • Page 76: Checking And Draining Water Separator (Type 1)

    When the float (6) has reached the specified line (2), immediately drain 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. 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 77: Adjusting Fan Belt Tension

    • If the measurement is out of the service specifications, loosen alternator mounting screws and adjust its position. 4.3 Checking radiator hose and clamp bands 1. Check that the radiator hoses (1), (2) are connected correctly or not. 3-10 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 78: Checking Intake Air Line

    1. Start and warm-up the engine for approximately 5 • You must replace the intake air hose(s) minutes. every 2 years. 2. Put an oil pan below the engine. Also replace the clamp (2) every 2 years and tighten it correctly. 3-11 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 79: Replacing Oil Filter Cartridge

    IMPORTANT engine and drain the oil fully. • To prevent serious damage to the engine, replacement element must be highly efficient. Use only a Kubota genuine filter or its equivalent. Tools required • Filter wrench 1. Remove the oil filter cartridge (1) with the filter wrench.

  • Page 80: Cleaning Water Separator (Type 1)

    • Use clean and soft water with anti-freeze to fill the radiator and reserve tank. • Make sure that when you mix the anti-freeze and water, the ratio of anti-freeze is less than 50%. 3-13 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 81 (2) Drain valve (3) EGR cooler hose 4. After you drained all coolant, close the drain valve (2) and install the EGR cooler hose (3). 5. Fill with clean water and cooling system cleaner. 3-14 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 82: Replacing Fan Belt

    • Do not use the radiator cleaning agents after you add anti-freeze to the coolant. Anti-freeze contains an anti-corrosive agent, which reacts with the radiator cleaning agent to make sludge and cause damages to the engine parts. 3-15 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 83: Check Point Of Every 1000 Hours

    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. 3-16 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 84: Check Points Of Every 1500 Hours

    Cylinder head cov- 0.700 to 1.15 kgf⋅m er screw 5.06 to 8.33 lbf⋅ft (4) Start Active Test button (8) Select signal group (5) OK button (6) Number of graph (7) #Cylinder Injector Injection Stop 3-17 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 85: Checking Egr Cooler

    3. Apply the specified amount of air pressure (a) to the air hose side. EGR cooler 250 kPa Service speci- Coolant pas- leakage test 2.5 kgf/cm fication sage pressure 36 psi (10) Finish Active Test button RELATED PAGE 7.56 Replacing injector on page 4-191 3-18 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 86: Replacing Oil Separator Element

    (2) O-ring (3) Element 3. Replace the oil separator element (3) and O-ring (2) with a new one. 8.4 Checking positive crankcase ventilation (PCV) valve 1. Remove the cover (1) and element (3). 3-19 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 87: Check Points Of Every 3000 Hours

    2. Replace the inlet hose and check the suction side • Before removing the DPF muffler full assembly of the intake hose for loose connections or crack. from a product (engine), connect the diagnosis 3-20 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 88 (6) Muffler flange (11) Tube (7) Connector of exhaust gas (12) Tube temperature sensor (T 8. Remove the muffler full assembly (DPF) mounting screws (13). 9. Remove the muffler full assembly (DPF) (14). 3-21 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 89: Judging Reuse Of Dpf Filter Comp Before Cleaning (Service Dealer)

    Tightening tor- perature sensor 2.55 to 3.56 kgf⋅m (22), (23), (24) 18.5 to 25.8 lbf⋅ft 16.0 to 23.0 N⋅m Differential pres- 1.64 to 2.34 kgf⋅m sure pipe (1), (4) 11.8 to 16.9 lbf⋅ft 3-22 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 90: Judging Reuse Of Dpf Filter Comp After Cleaning (Cleaning Contractor)

    • If there are any cracks or losses of the ceramics element, the filter comp (DPF) Less than cannot be reused even if it is cleaned. D1803-CR-E4 85 mm 3.3 in. • If it is judged that the filter comp (DPF) is not...

  • Page 91: Checking Egr System (With Diagmaster)

    (7) #EGR Valve ON/OFF Func- tion 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 [proceed] button (3). 3-24 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 92: Check Points Of Every 1 Year

    10. Check points of every 1 year • If you find a gas leakage, remove the DPF differential pressure pipe and wipe off the 10.1 Replacing air cleaner element anti-seize & lubricating compound. 1. Remove the dust cup (4). 3-25 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 93: Checking Egr Piping

    • 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) Intake air hose (2) Clamp 3-26 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 94: Checking Exhaust Manifold

    1. Loosen the clamp (1), (2), (4) and remove the 11. Check points of every 2 rubber hose (3), (5). years 11.1 Replacing fan belt 1. Remove the alternator (1). 3-27 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 95: Replacing Rubber Hose Of Differential Pressure Sensor

    • Make sure that you close the radiator cap 2. Replace the hose and clamp with new ones. correctly. 3. Tighten the clamp correctly. If the cap is loose or incorrectly closed, coolant can flow out and the engine can overheat. 3-28 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 96 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. 3-29 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 97: Replacing Radiator Hose And Clamp Bands

    5. Tighten the clamp bands correctly. Anti-freeze contains an anti-corrosive agent, which reacts with the radiator cleaning agent to make sludge and cause damages to the engine parts. 3-30 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 98: Replacing Fuel Hose And Clamps

    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. 3-31 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 99 CHECK AND MAINTENANCE 3. 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: Engine

    ENGINE KiSC issued 12, 2018 A...

  • Page 101: Mechanism

    4. Late combustion period After fuel injection stops, combustion continues for a short period burning the remaining fuel. This period is called late combustion period and this period should be as short as possible. 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 102: Control Of Combustion (E-Cdis)

    Combustion control consists of fuel injection 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 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: Engine Body

    (9) Main bearing case (13) Camshaft with cam gear (2) Rocker arm (6) Flywheel (10) Gear case (14) Connecting rod (3) Cylinder head (7) Crankcase (11) Crankshaft (15) Breather (4) Piston (8) Oil pan (12) Idle gear 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 104: Feature Of Engine Body

    1. Along with the crankcase, the cylinder head is the (1) Fuel camshaft (3) Camshaft most fundamental part that makes up the engine (2) Idle gear (4) Crankshaft forming the combustion chamber along with the crankcase and piston. 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 105: Cylinder Head Cover

    The half float type cylinder head cover reduces noise from the cylinder head. 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 106: Structure Of Oil Separator

    2.8.2 Structure of piston The piston is a re-entrant shape. 2.8.4 Specification of piston The piston skirt has a molybdenum coating. 87.0 mm Piston diameter (D) 3.43 in. +0.25 mm Oversize +0.0098 in. 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 107: Piston Ring

    V2403-CR-TE4, TE4BG, (4) Expander -TIE4 model) (5) Plane (barrel face) type (for (7) Inner bevel (taper face) type D1803-CR-E4, and V2403- (8) Bevel cutter type CR-E4 model) 2.9.3 Function of piston ring 1. Maintain airtightness of the combustion chamber during the compression stroke and combustion stroke.

  • Page 108: Function Of Connecting Rod

    While conducting continuous power to outside the engine, this also causes each intake, compression, combustion, and exhaust strokes to be performed. 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 109: Flywheel

    2.13.4 Specification of flywheel (Reference value) 300 mm Flywheel diameter 11.8 in. *This value is for STD engine so that it may be different depending on the product used 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 110: Function Of Rocker Arm

    0.72 rad (41°) before B.D.C. Exhaust valve 32.0 mm Exhaust valve head diameter timing Close angle 0.20 rad (9°) after T.D.C. 1.26 in. 0.18 to 0.22 mm Valve clearance 0.0071 to 0.0086 in. 4-10 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 111: Tappet

    Receives cam force on the surface. Further, the 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. 4-11 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 112: Function Of Push Rod

    Timing gears synchronize timing for rotation of the crankshaft and opening and closing of valves. Therefore, when assembling each of the marks has to be aligned. 4-12 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 113: Fuel System

    (6) Fuel pump (11) Overflow pipe (b) Low pressure fuel flow (3) Electromagnetic fuel feed (7) Supply pump (12) Engine ECU pump (8) Rail (13) Fuel cooler (4) Check valve (9) Injector (14) Check valve 4-13 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 114: Feature Of Common Rail System (Crs) Engine

    As a result fuel is injected at ideal conditions at all times suppressing the weak point of diesel engines of black smoke when starting and when accelerating and achieves reduction of exhaust gas cleanup as well as high power output. 4-14 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 115: Flow Of Common Rail System (Crs) Engine

    MECHANISM 3. Fuel system 4. ENGINE 3.3 Flow of common rail system (CRS) engine 4-15 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 116 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. 4-16 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 117: Control Of Common Rail System (Crs) Engine

    3.5.4 Specification of fuel tank Tank volume is different depending on the model equipped on. Check the specifications of the model equipped on for details. 4-17 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 118: Function Of Water Separator

    3.7.4 Specification of electromagnetic fuel 3.6.5 Specification of water separator feed pump (Type2) Rated voltage 12 V 15 cm / stroke Hand pump discharge volume 0.92 cu.in. / stroke 4-18 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 119: Fuel Feed Pump

    The fuel feed pump supplies fuel to supply pump by mechanical. The fuel feed pump is provided with a priming pump. This is for air removal through manual operation of the priming pump. 4-19 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 120: Fuel Filter

    (1) Suction control valve (SCV) (6) IO valve (2) Eye bolt (Inlet) (A) From fuel filter (3) Eye bolt (Outlet) (B) To rail (4) Zero delivery drain (C) To fuel tank (5) Overflow valve 4-20 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 121: Function Of Supply Pump

    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. 4-21 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 122 IO valve and into the plunger chamber (11). Rotation continues and during the lift stroke of the cam the plunger rises, pressurizes the fuel, and supplies it through the IO valve to the rail. 4-22 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 123: Specification Of Supply Pump

    Bosch PF49 Rail pressure reference values Engine model At rated speed (No At idling load) 55 to 60 MPa D1803-CR-E4 560 to 610 kgf/cm 8000 to 8700 psi 75 to 80 MPa D1803-CR-TE4 765 to 815 kgf/cm 10900 to 11600 psi...

  • Page 124: Function Of Injection Pipe

    This greatly improves the ability to raise the pressure at low speed and enables high-pressure injection from low speed ranges. (1) Rail pressure sensor (3) Pressure limiter (2) Rail body 4-24 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 125: Specification Of Rail Assembly

    (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 replacement requires replacing the rail assembly. 4-25 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 126: Injector

    (11) Suction orifice (4) Valve body (12) Nozzle spring (5) Command piston (13) Nozzle nut (6) Nozzle body (A) To fuel tank (7) Needle valve (B) From rail (8) Valve spring (14) ID code 4-26 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 127: Function Of Injector

    The needle valve is raised and lowered based on change to pressure in the control chamber, opens and closes the fuel injection port, and while the valve is open, atomizes and injects fuel from the rail. 4-27 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 128 (5) and the discharge orifice (15) is closed by the valve ball (8). As a result, fuel pressure in the control chamber (9) rises and the needle valve (12) is pushed by the valve piston (10). 4-28 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 129: Specification Of Injector

    30.0 to 160 MPa 3.15 Check valve Operating pressure range 306 to 1630 kgf/cm 4360 to 23200 psi 3.15.1 Outline of check valve D1803-CR-E4, TE4, V2403-CR-E4, TE4, The check valve prevents reverse flow of fuel inside the Number of injection TE4BG fuel piping.

  • Page 130: Structure Of Fuel Cooler

    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 4-30 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 131: Crankshaft Position Sensor

    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. 4-31 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 132: Camshaft Position 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. 4-32 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 133: Coolant Temperature Sensor

    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. 4-33 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 134: Boost Pressure Sensor

    The output signal of the sensor is sent to the engine The output voltage signal of the sensor is sent to the ECU. engine ECU. 4-34 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 135: Fuel Camshaft

    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 crankshaft. 4-35 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 136: Intake And Exhaust System

    (B) Exhaust gas flow 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. 4-36 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 137: Feature Of Intake And Exhaust System

    The air intake system supplies clean air to the engine. Also, installing of a turbocharger and intercooler enables increasing the amount of intake air. The exhaust system aggregates exhaust gases after combustion and discharges them to the atmosphere after aftertreatment. 4-37 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 138: Flow Of Intake And Exhaust System

    MECHANISM 4. ENGINE 4. Intake and exhaust system 4.3 Flow of intake and exhaust system This shows the flow of the intake system 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 2. Pass through the turbocharger rotating the turbine and pressurizing the intake air. 3. Hazardous components in the exhaust gas are cleaned in aftertreatment unit and the exhaust is gas discharged to the atmosphere 4-39 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 140: Control Of Intake And Exhaust System

    -22 to 176 ℉ 4.7 Turbocharger 4.5.4 Specification of pre-cleaner 4.7.1 Outline of turbocharger Airflow range Max. 2.5 m /min. The turbocharger uses the engine exhaust gas to compress intake air. The turbocharger increases engine output. 4-40 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 141: Structure Of Turbocharger

    4.7.4 Specification of turbocharger 4.8.4 Specification of intercooler 88.9 kPa Actuator set pres- 2 mm point 0.907 kgf/cm sure 12.9 psi Cooling method Air cooled 4-41 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 142: Glow Plug

    4.11.2 Structure of exhaust manifold Voltage at rated operation DC 11 V Approx. 0.8 Ω The exhaust manifold is mounted on the exhaust side Resistance (at normal temperature) of the cylinder head. (1) Exhaust manifold 4-42 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 143: Function Of Exhaust Manifold

    MECHANISM 4. Intake and exhaust system 4. ENGINE 4.11.3 Function of exhaust manifold exhaust manifold collects exhaust gases combusted in each of the cylinders and feeds this to the aftertreatment units. 4-43 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 144: Exhaust Gas Recirculation (Egr) System

    The EGR system is made up of the EGR valve, cooler, and pipe. (1) EGR valve (3) EGR pipe (A) Exhaust gas flow (2) Reed valve (4) EGR cooler (B) Intake air flow 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: Feature Of Egr System

    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. 4-45 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 146: Flow Of Egr System

    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. 4-46 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 147: Control Of Egr System

    5.5.2 Structure of EGR cooler The EGR cooler is made up of the cooler and tubes. (1) EGR cooler (a) Coolant inlet (A) Exhaust gas inlet (b) Coolant outlet (B) Exhaust gas outlet 4-47 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 148: Structure Of Egr Valve

    (12) Assist Spring (17) Bush (3) Magnet (8) Magnet (13) Spring holder (18) Filter (4) Motor exterior (9) Washer (14) Spring holder (19) Valve assembly (5) Bent core (10) Boss (15) Spring (20) Valve seat 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 (28) Brush less motor (C) CAN L (22) CAN I/F circuit unit (26) Overcurrent detection circuit (29) Hall-IC (D) CAN H (23) EEPROM unit (A) Power (24) Micro computer (27) Hall-IC I/F circuit unit (B) GND 4-49 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 150: Function Of Egr Valve

    The reed valve prevents backflow of intake air into the Cooling method Water cooled EGR cooler while supercharging. The valve is designed to close during the intake stroke and open during the exhaust stroke. 4-50 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 151: Lubricating System

    The lubrication system is made up of an oil pump and oil filter and the like. (1) Oil pressure switch (3) Oil pan (5) Oil cooler (7) Oil filter (2) Oil pump (4) Relief valve (6) Oil strainer 4-51 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 152: Feature Of Lubricating System

    In addition, the lubricating system has 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. 4-52 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 153: Flow Of Lubricating System

    MECHANISM 6. Lubricating system 4. ENGINE 6.3 Flow of lubricating system 4-53 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 154 1. Oil is suctioned 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. 4-54 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: Oil Pan

    6.4.4 Specification of oil pan 6.5.4 Specification of oil strainer 7.0 L 2.0 × 2.5 mm D1803-CR-E4, - Mesh pore size 1.8 U.S.gals 0.079 × 0.098 in. TE4, -TIE4 1.5 Imp.gals...

  • Page 156: Oil Pump

    The relief valve is made up of a spring and ball etc. (1) Body (4) Inlet port (2) Inner rotor (5) Outlet port (3) Outer rotor 6.6.3 Function of oil pump (1) Valve seat (3) Spring (2) Ball (1) Inlet port (2) Outlet port 4-56 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 157: Function Of Relief Valve

    The engine oil enters through the outer surface of the element and is filtered through to the inside. (1) Cooling plates (a) Coolant outlet (A) Oil inlet (b) Coolant inlet (B) Oil outlet 4-57 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 158: Function Of Oil Cooler

    When abnormal (Oil pressure is less than specified range) • The oil pressure is weaker than the spring force so circuit remains closed. Therefore the oil lamp turns “ON” to provide notification that oil pressure is abnormal. 4-58 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 159: Specification Of Oil Pressure Switch

    Rated voltage 12 V 39.2 to 58.8 kPa Operating pressure 0.400 to 0.599 kgf/cm 5.69 to 8.52 psi 241 to 441 kPa Rated oil pressure 2.46 to 4.49 kgf/cm 35.0 to 63.9 psi 4-59 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 160: Cooling System

    The cooling system is made up of a radiator, water pump, cooling fan and the like. (1) Radiator (4) Fan belt (7) Coolant temperature sensor (2) Radiator cap (5) Water pump (8) Cylinder head (3) Cooling fan (6) Thermostat (9) Crankcase 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: Feature Of Cooling System

    The cooling system prevents overheating while the engine is running and maintains coolant temperature at a suitable temperature during operation. KUBOTA engines use a cooling system with forced circulation using a water pump. This series of engines use a bottom bypass system.

  • Page 162: Function Of Water Pump

    (A) Coolant temperature (C) Overshoot (B) Time (min) 7.6.4 Specification of thermostat 85 to 95 ℃ (1) Valve (4) Bypass valve Coolant suitable temperature 185 to 203 ℉ (2) Spring (5) Jiggle valve (3) Pellet 4-62 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 163: Radiator

    (3) Vacuum valve pressure (A) When radiator internal pres- sure is high (1) Core (5) Lower tank (2) Overflow pipe (6) Cooling air (3) Radiator cap (7) Tube (4) Upper tank (8) Fin 4-63 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 164: Function Of Radiator Cap

    Cooling performance changes depending on the number of blades, angle of the blades, outer diameter, and rotation speed. 7.9.4 Specification of cooling fan (Reference values) Number of blades 380 mm Outer diameter 15.0 in. 4-64 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 165: Reserve Tank

    When radiator internal pressure below atmospheric pressure When the engine cools, the coolant in the reserve tank returns to the radiator based on lower than atmospheric pressure. 4-65 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 166: Electrical System

    8. Electrical system 8.1 Structure of electrical system The electrical system is separated into the starting system and charging system. (1) Alternator (3) Battery (5) Charge lamp (2) Regulator (4) Key switch (6) Starter 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: Feature Of Electrical System

    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. 4-67 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 168: Flow Of Electrical System

    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 starts. 4-68 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 169 2. Power is transferred to the alternator via the fan belt. 3. Rotation 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. 4-69 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 170: Control Of Electrical System

    During operation the battery is used as a power supply (1) Key cylinder (3) Key along with the alternator. (2) Harness 8.5.4 Specification of battery D1803-CR-E4 D1803-CR-TE4 12 V, 88 AH D1803-CR-TIE4 Battery capacity V2403-CR-E4 V2403-CR-TE4...

  • Page 171: Function Of Key Switch

    8.6.4 Specification of key switch Specification is different depending on the OEM installed so reference the installed OEM specification for details. A standard contact connections table for Kubota is given below. Contact connections table (1) Front bracket (6) Gear shaft...

  • Page 172: Specification Of Starter (Planetary Gear Reduction Type)

    MECHANISM 4. ENGINE 8. Electrical system Operation of charging system 8.7.4 Specification of starter (planetary gear reduction type) D1803-CR-E4, - 12 V, 1.4 kW TE4, -TIE4 Nominal output V2403-CR-E4, - TE4, -TE4BG, - 12 V, 2.0 kW TIE4 Pinion gear teeth 8.8 Alternator...
  • Page 173 Therefore the current to the rotor coil (2) is shut, resulting to decrease the terminal B voltage. When the terminal B voltage lowers below the regulated voltage, the Tr1 turns on again and makes current pour to the rotor coil(2). 4-73 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 174: Specification Of Alternator

    MECHANISM 4. ENGINE 8. Electrical system 8.8.4 Specification of alternator D1803-CR-E4 D1803-CR-TE4 D1803-CR-TIE4 12 V, 480 W V2403-CR-E4 Capacity V2403-CR-TE4 V2403-CR-TIE4 V2403-CR-TE4BG 12 V, 720 W Battery voltage 12 V 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: Aftertreatment System

    The PM captured 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 4-75 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 176: Control Of Diesel Particulate Filter (Dpf) System

    250 ℃ (482 ℉), the fuel will not burn even if a post in- jection is performed so post injection is not per- formed. Therefore, re- generation is also not performed. (Continued) 4-76 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 177 ○ Need to use Diagmaster for tool (Diagmaster). output limitation） regeneration. Regeneration with Diagmas- Cleaning DPF ter becomes impossible. （with output limi- × × × － Need to change or clean tation） DPF. 4-77 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 178: Structure Of Diesel Oxidation Catalyst (Doc) System

    The PM is combusted and changed into carbon dioxide and water by chemical reaction. The carbon dioxide is released to the atmosphere. 9.7 Flow of diesel oxidation catalyst (DOC) system 4-78 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 179: Diesel Oxidation Catalyst (Doc)

    (DPF), the DOC places the post injection fuel into contact with the core thereof and raises the exhaust (1) Diesel particulate filter (DPF) (A) Honeycomb structure (2) Exhaust gas flow (B) Closed-end structure 4-79 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 180: Function Of Diesel Particulate Filter (Dpf)

    The resistance value changes based on intake air temperature and the intake air temperature sensor measures the temperature based on this change in resistance. 4-80 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 181: Specification Of Air Flow Sensor

    • Standard conditions: voltage 14 V, temperature 25 ℃ (77 ℉), humidity 65%, air pressure 101.3 kPa (1) Exhaust gas temperature (3) Exhaust gas temperature sensor (T sensor (T (2) Exhaust gas temperature (4) Thermistor sensor (T 4-81 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 182: Function Of Exhaust Gas Temperature Sensor

    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. 4-82 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 183: Differential Pressure Sensor

    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. 4-83 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 184: Intake Throttle Valve

    12 V Voltage applied polarity and valve rotating direction Voltage applied polarity Shaft rotating direction (1) Intake throttle valve (3) Valve (2) Motor (4) Gear Valve opening direction － Valve closing direction － 4-84 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 185 MECHANISM 9. Aftertreatment system 4. ENGINE Output characteristics (1) Sensor output (V) (A) Fully closed (0°) (2) Sensor operating angle (de- (B) Fully open (81.4°) gree) 4-85 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 186 MECHANISM 4. ENGINE 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: Servicing

    Discharged battery Charge or replace 4-102 Starter is damaged Repair or replace － The key switch is damaged Replace － The connection of the wires is in- Check or correct － correct (Continued) 4-87 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 188 The air cleaner is clogged Clean or replace the element 3-25 The injector is damaged Replace 4-191 The output is deficient The moving parts of engine have Repair or replace － a seizure (Continued) 4-88 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 189 The relief valve does not operate Repair or replace － with dirt The oil clearance of the bearings Replace the metal, bushing or 4-179 are too much shaft 4-179 4-181 The oil passage is clogged Clean － (Continued) 4-89 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 190 The radiator or radiator cap is Replace 4-100 damaged The load is too much Reduce the load － The head gasket is damaged Replace 4-111 The fuel used is incorrect Replace the specified fuel 4-90 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 191: Service Specifications

    Free length (Intake) 1.65 to 1.66 in. 1.62 in. 41.7 to 42.2 mm 41.2 mm Valve spring Free length (Exhaust) 1.65 to 1.66 in. 1.62 in. 1.0 mm Tilt － 0.039 in. (Continued) 4-91 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 192 0.01 mm Alignment － 0.0004 in. 33.90 mm 33.85 mm Intake 1.335 in. 1.333 in. Cam height [D1803-CR-E4, -TE4, -TIE4] 33.90 mm 33.85 mm Exhaust 1.335 in. 1.333 in. Cam height Intake 33.47 mm 33.42 mm [V2403-CR-E4, -TE4, -TE4BG, - 1.318 in.
  • Page 193 Piston pin bore I.D. 0.98426 to 0.98476 in. 0.9862 in. Top ring to ring groove 0.050 to 0.090 mm 0.20 mm Clearance [D1803-CR-E4, V2403-CR-E4] 0.0020 to 0.0035 in. 0.0079 in. Top ring to ring groove Clearance － － [D1803-CR-TE4, -TIE4, V2403-...
  • Page 194 0.89 → 0.61 kgf/cm 12 → 8.6 psi 10.0 to 12.0 mm 0.394 to 0.427 in. Fan belt Tension － (under load of 59 to 68 N (6.0 to 7.0 kgf, 14 to 15 lbf)) 4-94 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 195 2. Service specifications 4. ENGINE Electrical system Item Service Service limit Starter • Commutator 30.0 mm 29.0 mm O.D. [D1803-CR-E4, -TE4, -TIE4] 1.18 in. 1.14 in. • Commutator O.D. 35.0 mm 34.0 mm [V2403-CR-E4, -TE4, 1.38 in. 1.34 in. TE4BG, -TIE4] 0.45 to 0.75 mm...

  • Page 196: Tightening Torques

    Oil cooler joint screw M18 × 1.5 39.2 to 49.0 4.00 to 4.99 29.0 to 36.1 Supply pump mounting nut / screw M8 × 1.25 23.5 to 27.5 2.40 to 2.80 17.4 to 20.2 (Continued) 4-96 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 197 M6 × 1.0 9.81 to 11.3 1.00 to 1.15 7.24 to 8.33 Servicing Dimension Item N⋅m kgf⋅m lbf⋅ft × Pitch Oil pressure switch R 1/8 14.7 to 19.6 1.50 to 1.99 10.9 to 14.4 4-97 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 198: Checking And Adjusting

    30.1 to 32.9 kgf/cm cation 428 to 468 psi Compression pres- sure 2.35 MPa Service limit 24.0 kgf/cm 341 psi 8. Do the same steps twice for each cylinder. 9. Install the removed parts. 4-98 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 199: Checking Engine Oil Pressure

    10.9 to 14.4 lbf⋅ft er screw 5.06 to 8.33 lbf⋅ft 4.3 Checking engine oil pressure Tools required • Oil pressure tester 1. Remove the engine oil pressure switch. 2. Set the oil pressure tester. 4-99 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 200: Checking Fan Belt Tension

    0.90 kgf/cm 12 psi (A) Good (B) Bad NOTE • If the fan belt has a damage, replace it. 2. Check if the fan belt is worn out and sunk in the pulley groove. 4-100 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 201: Checking Radiator Water Leakage

    176.9 to 182.3 ℉ pressure with the radiator tester and an adapter. ture 4. Check the radiator for water leakage. Radiator water Service specifi- No leak at specified pres- leakage test cation sure 4-101 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 202: Checking Battery Voltage

    • Keep your body and face as far away from the battery when performing maintenance and inspection. • Do not allow people who do not know how to handle a battery or who do not sufficiently 4-102 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 203: Checking Starter Motor

    Use the following table as a reference. battery at all times. Hydrogen gas mixed with oxygen becomes very explosive. • Hold the starter to prevent its movement when you do a test on the motor. 4-103 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 204: Checking Magnetic Switch Of Starter

    • Do not remove the battery cap while the engine operates. • Keep electrolyte away from eyes, hands and clothes. 4-104 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 205: Checking Magnetic Switch Continuity

    (at 25 ℃ (77 ℉)) (1) C terminal (2) B terminal 4.14 Checking alternator on unit CAUTION • To prevent an accidental short circuit, attach the positive cable to the positive terminal before 4-105 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 206: Checking Glow Plug Continuity

    NOTE 14.7 to 19.6 N⋅m Tightening tor- • If you find an air leakage, change the clamps Glow plug 1.50 to 1.99 kgf⋅m and / or the inlet hose. 10.9 to 14.4 lbf⋅ft 4-106 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 207: Checking Radial Clearance Of Turbocharger

    SCV. • When replace the injector, write the ID code (3) of replaced injector in the engine ECU with the diagnosis tool. (1) Terminal SCV+ (a) Suction control valve (SCV) (2) Terminal SCV－ 4-107 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 208: Checking Rail Pressure Sensor

    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 Approx. 1.0 V Service specifi- After engine start- cation Approx. 1.0 to 2.2 V 4-108 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 209: Checking Crankshaft Position Sensor

    • Check that there are interference marks of the pulsar and the sensor or not. • Check that there pulsar gear abnormalities or not. 4-109 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 210: Checking Egr System

    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) Service specifi- and terminal 9 to 16 V cation ground (3) 4-110 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 211: Checking Exhaust Gas Temperature Sensor

    • Circuit tester 1. 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. 4-111 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 212: Measuring Angular Deviation Between Crankshaft T.d.c. And Crankshaft Position Sensor

    (1) Cylinder head gasket (A) Mark IMPORTANT • If the crankshaft, flywheel housing and/or Gasket Model mark and flywheel are replaced, it is necessary to D1803-CR-E4, -TE4, - V2403-CR-E4, -TE4, code calibrate the injection timing with the diagnosis TIE4 TE4BG, -TIE4 number tool.
  • Page 213 (8). (9) Area where there is no pul- (12) Reference pulsar hole (17th: sar hole 3 cylinder models / 20th: 4 (10) Flywheel cylinder models) (11) Crankshaft position sensor mounting hole 4-113 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 214: Adjusting Air Gap Between Crankshaft Position Sensor And Flywheel

    (15) Reference line sensor top dead center de- tection position 13. Measure the difference (A) between the top dead center mark (17) and the crankshaft position sensor top dead center detection position mark (18). 4-114 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 215: Adjusting Air Gap Between Camshaft Position Sensor And Pulsar Gear

    • Do not remove the radiator cap while you Air gap (A) cation 0.0079 to 0.051 in. operate or immediately after you stop the engine. • If not, hot water can flow out from the radiator. 4-115 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 216: Removing Crs Intermediate Harness

    5.4 Removing external components 1. Remove the air cleaner. 2. Remove the starter (1). (1) Starter (2) Drain valve (3) EGR cooler hose 4. After you drain, close the drain valve (2). 4-116 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 217: Removing Muffler Full Assembly

    Tools required (6) Cooling fan (7) Fan pulley • Crowfoot wrench 1. Remove the connectors of exhaust gas temperature sensor (3), (4), (5) from the bracket. 2. Remove the clamp (2). 4-117 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 218: Disassembling Dpf Assembly

    1. Remove the DPF mounting bracket (2). (6) Muffler full assembly mount- (7) Muffler full assembly ing screw 6. Remove the DPF bracket (8). 4-118 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 219: Removing Egr Cooler

    5.7 Removing EGR cooler 1. Remove the muffler flange (1). 2. Remove the EGR pipe (2). (1) Muffler flange (2) EGR pipe 3. Remove the EGR cooler hose (3). 4. Remove the EGR cooler (5). 4-119 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 220: Removing Intake Throttle Valve

    5.10 Removing EGR valve 1. Disconnect the cooler pipe (1), (3) of EGR valve (2). 2. Remove the EGR valve (2). NOTE (1) Injection pipe (2) Overflow pipe and hose • Do disassemble valve assembly. 4-120 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 221: Removing Sensors

    7. Remove the boost pressure sensor (6). 2. Remove the camshaft position sensor mounting screw (3). 3. Remove the camshaft position sensor (2). (6) Boost pressure sensor (7) Boost pressure sensor mounting screw 4-121 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 222: Removing Cylinder Head Cover

    • 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. 4-122 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 223: Removing Rocker Arm Assembly

    (A) Gear case side (B) Flywheel side 4. Remove the cylinder head (3) and cylinder head gasket (4). (1) Intake manifold 2. Remove the exhaust manifold (2). (3) Cylinder head (4) Cylinder head gasket 4-123 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 224: Removing Tappet

    • Hexagon wrench (4 mm-square) (1) Valve stem seal (5) Valve spring collet (2) Valve (6) Valve cap 1. Remove the SCV mounting screws (2) with (3) Valve spring hexagon wrench. (4) Valve spring retainer 4-124 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 225: Removing Supply Pump

    3. Remove the water hoses (2) (3). 4. Remove the oil cooler (4). (1) Fuel feed pump 2. Remove the supply pump (2). (2) Water hose (5) Oil cooler joint screw (3) Water hose (4) Oil cooler 4-125 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 226: Removing Water Pump

    46 mm (1.8 in.) deep socket wrench (3). 3. Remove the fan drive pulley (4) with gear puller. (1) Gear case cover 5.27 Removing crankshaft oil slinger 1. Remove the crankshaft collar (3). 4-126 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 227: Removing Idle Gear

    2. Loose the oil pump drive gear 1 mounting nut (5). 3. Remove the oil pump drive gear 2 (4) with gear puller. 4. Remove the idle gear collar (2). 5. Remove the idle gear (3). 4-127 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 228: Removing Camshaft With Cam Gear

    (1) Oil pump drive gear 1 mounting nut 2. Pull out the oil pump drive gear 1 (2) with a gear puller (3). (1) Gear puller (3) Idle gear shaft (2) Crank gear 4-128 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 229: Removing Oil Pan And Oil Strainer

    1. Turn the flywheel and move the piston to bottom (3) Piston dead center. 2. Remove the connecting rod screws (1). 3. Remove the connecting rod cap (2). 5.35 Removing piston ring Tools required • Piston ring pliers 4-129 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 230: Disassembling Piston Assembly

    (2) with the same number to keep the same combination. NOTE • If do not remove the piston pin (4) easily, put the piston fully in 80 ℃ (176 ℉) oil for 10 to 15 minutes. 4-130 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 231: Removing Flywheel Housing

    • Before disassembling, check the side clearance • This topic is used for only 3 cylinders engine of crankshaft. Also check it after reassembling. (D1803-CR-E4, -TE4, -TIE4). 1. Remove the inner mounting screws of bearing case cover (1). 2. Remove the external mounting screws of bearing case cover (2).

  • Page 232: Removing Crankshaft (For 4 Cylinders)

    2. Turn the crankshaft to set the crankpin of the fourth cylinder to the horizontal directions (right or left). 3. Hold the crankpins to the horizontal directions (right or left) and pull out the crankshaft completely. 4-132 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 233: Removing Main Bearing Case

    (2) Rear bracket 5. Remove also the ball (8) from the tip of the 3. Hold the rotor (base of the claw) in a vise. armature. 4-133 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 234: Assembling

    2. Install the bearing (2) to the slip ring side of rotor (1). (5) Rotor 8. When the rotor is detached, the 2 brushes are found to stretch out of the shaft hole. (1) Rotor (2) Bearing 4-134 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 235 58.4 to 78.9 N⋅m Tightening torque Pulley nut 5.95 to 8.05 kgf⋅m 43.1 to 58.2 lbf⋅ft 7. Fit the brush with its sliding face in the clockwise direction when viewed from front. 4-135 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 236: Assembling Starter

    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). 4-136 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 237: Installing Main Bearing Case

    1 to the specified torque, make sure that the main bearing case moves smoothly. 46.1 to 51.0 N⋅m Tightening tor- Main bearing case 4.70 to 5.20 kgf⋅m screw 1 34.0 to 37.6 lbf⋅ft 4-137 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 238: Installing Crankshaft (For 3 Cylinders)

    • This topic is used for only 3 cylinders engine • This topic is used for only 4 cylinders engine (D1803-CR-E4, -TE4, -TIE4). (V2403-CR-E4, -TE4, -TE4BG, -TIE4). 1. Install the crankshaft until the crankpin of the first 1.

  • Page 239: Installing Bearing Case Cover

    • Then install the oil seal not to come off the T.D.C. and crankshaft position sensor detected T.D.C. lip. on page 4-112 6.8 Installing flywheel IMPORTANT • The flywheel is very heavy, so securely hold the flywheel when installing. 4-139 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 240: Assembling Piston Assembly

    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. 4-140 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 241: Installing Piston Ring

    • Piston ring compressor 1. Clean the carbon in the cylinders. 2. Turn the flywheel and move the crankshaft to top dead center. (1) Expander joint (3) Oil ring (2) Oil ring gap 4-141 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 242 • Align the mark [FW] (2) on the piston face to 6. Turn the flywheel and move the piston to bottom flywheel side. dead center. • Align the marks (3) with each other. 4-142 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 243: Installing Oil Strainer And Oil Pan

    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. 4-143 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 244: Installing Crank Gear

    (1) Crank gear 2. Install the idle gear shaft. 6.15 Installing camshaft with cam gear 6.14 Installing oil pump 1. Install the camshaft (1) with cam gear (2). 1. Install the oil pump (1). 4-144 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 245: Installing Fuel Camshaft With Supply Pump Gear

    (5) Oil pump drive gear 1 (3) Cam gear 2. Tighten the idle gear mounting screw to the specified torque. 23.5 to 27.5 N⋅m Tightening tor- Idle gear mounting 2.40 to 2.80 kgf⋅m screw 17.4 to 20.2 lbf⋅ft 4-145 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 246: Installing Crankshaft Oil Slinger

    (3) Crankshaft collar (2) O-ring 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. 4-146 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 247: Installing Water Pump

    (2) Water hose (3) Oil cooler 6.21 Installing water pump 1. Install the water pump (1). NOTE • Take care not to forget mounting the O-ring and not to let it out of position. 4-147 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 248: Installing Supply Pump

    5.0 to 7.0 N⋅m Tightening tor- SCV mounting 0.51 to 0.71 kgf⋅m screw (2) 3.7 to 5.1 lbf⋅ft (1) Supply pump 2. Install the fuel feed pump (2). (1) SCV (2) SCV mounting screw 4-148 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 249: Installing Thermostat Assembly

    6.28 Installing cylinder head 2. Install the valve (2). IMPORTANT 3. Set the valve spring (3) and valve spring retainer • When replacing the piston, piston pin bushing, (4). connecting rod or crankpin bearing, select the 4-149 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 250 Exhaust manifold 93.2 to 98.1 N⋅m 3.00 to 3.49 kgf⋅m Tightening tor- Cylinder head mounting screw 9.51 to 10.0 kgf⋅m 21.7 to 25.2 lbf⋅ft mounting screw 68.8 to 72.3 lbf⋅ft (3) Exhaust manifold 4-150 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 251: Installing Rocker Arm Assembly

    • 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 (1) to the engine ECU). 4-151 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 252: Installing Glow Plug

    14.7 to 19.6 N⋅m 2.40 to 2.80 kgf⋅m Tightening tor- screw (5) Glow plug 1.50 to 1.99 kgf⋅m 17.4 to 20.2 lbf⋅ft 10.9 to 14.4 lbf⋅ft (1) Glow plug (B) Bad (2) Seal (A) Good 4-152 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 253: Installing Cylinder Head Cover

    • If you drop the sensor, do not reuse it. 4. Install the crankshaft position sensor (4). NOTE • Replace the gasket with a new one. • Replace the O-ring with a new one. 4-153 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 254: Installing Common Rail

    3. Tighten the overflow pipe joint screw to the specified torque. 4. Install the injection pipes (5). (6) Boost pressure sensor (7) Boost pressure sensor mounting screw RELATED PAGE 4.31 Adjusting air gap between crankshaft position sensor and flywheel on page 4-114 4-154 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 255: Installing Egr Valve

    11.6 to 14.4 lbf⋅ft (1) Cooler hose (3) Cooler hose (2) EGR valve 6.36 Installing intake throttle valve NOTE • Do not disassemble the intake throttle valve (2). • Replace the gaskets with new ones. 4-155 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 256: Installing Egr Cooler

    • After attaching the assembly, start the engine and make sure that there are no gas leaks. Tools required • Crowfoot wrench 4-156 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 257: Installing Muffler Full Assembly

    25.0 to 35.0 N⋅m Tightening tor- perature sensor 2.55 to 3.56 kgf⋅m (6), (8), (9) 18.5 to 25.8 lbf⋅ft 16.0 to 23.0 N⋅m Differential pres- 1.64 to 2.34 kgf⋅m sure pipe (7) 11.8 to 16.9 lbf⋅ft 4-157 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 258 Muffler full assem- 23.5 to 27.5 N⋅m bly mounting 2.40 to 2.80 kgf⋅m screw (M8) (3) 17.4 to 20.2 lbf⋅ft 23.5 to 27.5 N⋅m Muffler flange nut 2.40 to 2.80 kgf⋅m 17.4 to 20.2 lbf⋅ft 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...

  • Page 259: Installing Crs Intermediate Harness

    (15) CAN connector (4P) connector (2P) (16) CAN connector (4P) 2. Connect the injector intermediate harness (engine side). (4) Name plate (23) Injector intermediate connec- (k) Clamp (22) Injector connector (10P) tor (12P) 4-159 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 260 Clamp (27) Exhaust gas temperature sen- sor (T ) (2P) sor (T ) (2P) 5. Connect the engine ECU intermediate harness. (31) Injector intermediate harness (32) Engine intermediate harness (33) DPF intermediate harness 4-160 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 261: Installing External Components

    • After install the fan belt, adjust the fan belt tension. (7) Oil separator 10.0 to 12.0 mm Service specifi- 0.394 to 0.472 in. Deflection (A) cation (under load of 98 N (10 kg, 22.1 lbf)) 4-161 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 262: Filling Coolant

    93.2 to 98.1 N⋅m Tightening tor- Cylinder head 9.51 to 10.0 kgf⋅m mounting screw 68.8 to 72.3 lbf⋅ft 4. Turn the crankshaft so the piston goes through T.D.C.. 4-162 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 263: Checking Cylinder Head Surface Flatness

    4. Clean away the red permeative liquid on the sides (A), (B), (C) and (D) and two diagonal (E) and cylinder head surface with detergent (2). (F) as shown in the figure. 3. Measure the clearance with a feeler gauge. 4-163 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 264: Checking Valve Recessing

    0.026 to 0.033 in. 3. After you lap the valve, clean away the compound Valve recessing and apply oil, then lap the valve again with oil. 1.20 mm Service limit 0.0472 in. 4-164 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 265: Checking Clearance Between Valve Stem And Valve Guide

    Valve stem O.D. cation 0.3134 to 0.3139 in. RELATED PAGE 7.7 Replacing valve guide on page 4-165 7.7 Replacing valve guide IMPORTANT • Do not hit the valve guide with a hammer during replacement. 4-165 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 266: Adjusting Valve Angle

    • Before you adjust the valve, check the valve stem and measure the I.D. of the valve guide section. Repair them if necessary. (a) 0.26 rad (15°) or 0.52 rad (b) 0.79 rad (45°) or 1.0 rad (30°) (60°) 4-166 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 267: Checking Free Length Of Valve Spring

    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. 4-167 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 268: Checking Set Load Of Valve Spring

    0.55012 to 0.55055 in. valve spring to the specified setting length. 2. Read the compression load on the gauge. NOTE • If the measurement is less than the service specification, replace the valve spring. 4-168 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 269: Checking Push Rod Alignment

    Tools required • External micrometer • Dial gauge (Lever type) • Cylinder gauge 1. Set a dial gauge (lever type) with its point on the 1. Measure tappet O.D. with external gear tooth. micrometer. 4-169 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 270: Checking Side Clearance Of Idle Gear

    1. Set a dial gauge with its point on the camshaft. 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 4-170 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 271: Checking Camshaft Alignment

    2. Press fit the new bushing with the replacing tool. Camshaft align- 0.01 mm NOTE Service limit ment 0.0004 in. • Make sure that the bushing end aligns the end of the idle gear. 4-171 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 272: Checking Cam Height

    • If the oil clearance is more than the service limit, replace the camshaft. Service specifi- 0.050 to 0.091 mm cation 0.0020 to 0.0035 in. Oil clearance of camshaft journal 0.15 mm Service limit 0.0059 in. 4-172 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 273: Checking Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing

    • Internal micrometer or cylinder gauge Service specifi- 0.025 to 0.066 mm Oil clearance be- cation 0.00099 to 0.0025 in. tween idle gear shaft and idle gear 0.10 mm Service limit bushing 0.0039 in. 4-173 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 274: Replacing Small End Bushing

    0.15 mm flash with the connecting rod. Service limit bushing 0.0059 in. RELATED PAGE 7.26 Replacing small end bushing on page 4-174 4-174 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 275: Checking Connecting Rod Alignment

    • 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 0.05 mm Service limit alignment 0.002 in. 4-175 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 276: Checking Clearance Between Piston Ring And Ring Groove

    Service speci- 0.20 to 0.35 mm each ring in its groove. fication 0.0079 to 0.013 in. Top ring 1.25 mm Service limit 0.0492 in. 0.30 to D1803-CR-E4 0.45 mm V2403-CR-E4 0.012 to 0.017 in. D1803-CR- Service speci- D1803-CR- fication TIE4 0.40 to...

  • Page 277: Checking Side Clearance Of Crankshaft

    • When replacing the piston, select the cylinder head gasket thickness to meet with the top clearance. 0.050 to Service speci- D1803-CR-E4 0.090 mm fication V2403-CR-E4 0.0020 to Top ring 0.035 in.

  • Page 278: Checking Crankshaft Alignment

    2.8 to 3.2 mm radi- 2.8 to 3.2 mm radi- Dimension C 0.11 to 0.12 in. radi- 0.11 to 0.12 in. radi- The crankshaft journal must be fine-finished to higher than Rmax = 0.4 S 4-178 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 279: Checking Oil Clearance Between Crankpin And Crankpin Bearing

    Oil clearance be- crankshaft journal and crankshaft cation 0.00099 to 0.0034 in. tween crankpin bearing 1 and crankpin bear- 0.20 mm Service limit 0.0079 in. Tools required • External micrometer • Internal micrometer 4-179 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 280: Replacing Crankshaft Sleeve

    0.0079 in. in figure. (Reference) NOTE • Undersize dimensions of crankshaft journal • Make sure that the large chamfer of the sleeve points to outward. 3. Heat a new sleeve to the specified temperature. 4-180 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 281: Checking Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 2

    4.70 to 5.20 kgf⋅m screw 1 34.0 to 37.6 lbf⋅ft Removing crankshaft bearing 1 1. Press out the used crankshaft bearing 1 with the 5. Remove the main bearing case again. crankshaft bearing 1 replacing tool. 4-181 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 282: Replacing Bearing Case Cover Oil Seal

    Holes to be de-burred and edges rounded with 1.0 to 1.5 mm 2 (4) as shown in the figure, until it is flash with the (0.040 to 0.059 in.) relief. bearing case cover. 4-182 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 283: Checking Cylinder Wear

    (see figure) with a cylinder gauge and find the 87.170 mm maximum and minimum inner diameters. Service limit 3.4319 in. Difference be- tween maximum 0.15 mm Service limit I.D. and minimum 0.0059 in. I.D. 4-183 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 284: Checking Clearance Between Inner Rotor And Outer Rotor

    Oversize piston Service specifi- 0.25 mm and piston rings cation 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 4-184 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 285: Checking Clearance Between Rotor And Cover

    Clearance be- cation 0.00414 to 0.00590 in. • Emery paper (#300) tween rotor and • External micrometer 0.20 mm cover Service limit 0.008 in. 1. Check the contact of the commutator for wear. 4-185 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 286: Checking Brush Wear Of Starter

    • If the difference of the O.D.'s more than the Mica undercut 0.20 mm service limit, correct the commutator on a Service limit 0.0079 in. lathe to the service specification. D1803-CR-E4 D1803-CR- 30.0 mm 1.18 in. D1803-CR- TIE4 Service speci-...

  • Page 287: Checking Brush Holder Of Starter

    1. Measure the brush length (A) with a vernier caliper. NOTE • If the length is less than the service limit, replace the yoke assembly and brush holder assembly. Service speci- 15.0 mm fication 0.591 in. D1803-CR-E4 D1803-CR- 11.0 mm 0.433 in. D1803-CR- Brush length TIE4 V2403-CR-E4 Service limit V2403-CR- 7.47 Checking armature coil of...

  • Page 288: Checking Field Coil Of Starter

    7.50 Checking stator of alternator Tools required • Circuit tester (1) Lead (2) Brush 2. Check the continuity across the brush (2) and yoke (3) with a resistance range of circuit tester. 4-188 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 289: Checking Rotor Of Alternator

    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- Service specifi- tween slip ring and Infinity cation rotor core 4-189 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 290: Checking Brush Wear Of Alternator

    NOTE • The rectifier is correct if the diode in the rectifier conducts electricity only in one direction. Service specifi- Resistance Less than 1.0 Ω cation (1) F terminal (2) B terminal 4-190 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 291: Replacing Injector

    5. Click the [OK] button (7) when rewriting is correctly completed. (2) Injector Compensation item (3) Proceed button 3. Enter the injector compensation value to the initial display (5), then click the [Register] button (4). 4-191 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 292 K-iSS registration 1. Enter the base model name and serial number to the "Search with Engine Serial No." window (9), then click the [Search] button (10). (12) After Exchanged window (13) Register button 4-192 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 293: Replacing Engine Ecu

    3. Enter the service engine ECU serial number (4), (7) ECU Reprogram button then click the [Download] button (5). 2. Select the download file (DPK file), then click the [browse] button (8). 4-193 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 294 4. If "Present ECU Information" is correct (green (11) Instruction (12) OK button color), click the [Write] button (10). 6. After the engine ECU data rewriting is complete, follow the "instruction" (13), then click the [OK] button (14). 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 2. Start "Diagmaster", then click the [DTC] button (16) from the project window. (18) Clear DTC button DPF manual regeneration 1. Perform the DPF manual regeneration. RELATED PAGE 7.58 Replacing DPF on page 4-196 4-195 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 296: Replacing Dpf

    3. Follow the instructions according to steps of (7) Utility button "Notes" screen (4), then click the [Start] button (5). 2. Select the "DPF Soot Load Reset" item (8), then click the [proceed] button (9). 4-196 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 297 5. Click the [OK] button to exit function. (16) DPF Manual Regeneration (18) Proceed button Request Function item (17) Instruction screen 4. Select the "#DPF Manual Regeneration Request Function" (19) from "Select Signal Group". 4-197 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 298 (21) OK button 7. Click the [Send Specified Active Test Value] button (22). (24) Finish Active Test button (25) Save button 11. Click the [Back to Item Select] button (26) to exit from active test. 4-198 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 299 6.39 Assembling DPF assembly on page 4-156 (29) Registration of Service Info. button 3. Select the "DPF Component" and enter the new service information to the "After Exchanged" window (30), then click the [Register] button (31). 4-199 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 300 SERVICING 4. ENGINE 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 3-31 removing............4-131 clamp band bearing case cover oil seal checking............3-8,3-10 replacing............4-182 replacing............3-30 bearing case cover oil seal replacing tool....2-40 combustion bolt and nut control..............4-2 tightening............. 2-1 feature..............4-1 flow...............4-1 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 302 4-162 crankcase function..............4-4 function..............4-4 installing............4-149 outline..............4-4 outline..............4-4 specification............4-4 removing............4-123 structure............... 4-4 structure............... 4-4 crankcase bore cylinder head cover checking oil clearance........4-172 function..............4-5 installing............4-153 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 303 E4B engine..............2-8 cylinder number............2-9 EGR cooler checking.............3-18 function.............. 4-47 D1803 installing............4-156 troubleshooting..........4-87 outline..............4-47 D1803-CR-E4 removing............4-119 dimension............2-20 specification............4-47 performance curve..........2-14 structure............. 4-47 specification............2-10 EGR cooler hose D1803-CR-TE4 replacing............3-28 dimension............2-20 EGR piping performance curve..........
  • Page 304 4-122 function..............4-9 specification............4-42 installing............4-139 structure............. 4-42 outline..............4-9 removing............4-130 specification............4-9 IC regulator structure............... 4-9 checking............4-190 flywheel housing idle gear installing............4-139 installing............4-145 removing............4-131 removing............4-127 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 305 4-57 function.............. 4-41 oil filter outline..............4-41 function.............. 4-57 specification............4-41 installing............4-147 structure............. 4-41 outline..............4-57 intercooler hose specification............4-57 replacing............3-28 structure............. 4-57 oil filter cartridge replacing............3-8,3-12 oil pan function.............. 4-55 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 306 4-6 cleaning..............3-13 installing............4-141 rail assembly outline..............4-6 function.............. 4-24 removing............4-129 outline..............4-24 specification............4-6 specification............4-25 structure............... 4-6 structure............. 4-24 piston assembly rail pressure sensor assembling............4-140 checking............4-108 disassembling..........4-130 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 307 4-56 removing............4-125 structure............. 4-56 specification............4-23 reserve tank structure............. 4-20 function.............. 4-65 system wiring diagram outline..............4-65 D1803-CR-E4............ 2-29 structure............. 4-65 D1803-CR-TE4..........2-29 ring groove D1803-CR-TIE4..........2-31 checking clearance.......... 4-176 V2403-CR-E4.............2-29 rocker arm V2403-CR-TE4..........2-29 checking oil clearance........4-168 V2403-CR-TE4BG..........
  • Page 308 4-168 checking tilt............4-167 valve stem checking clearance.......... 4-165 water hose replacing............3-28 water jacket cleaning..............3-13 water pump function.............. 4-62 installing............4-147 outline..............4-61 VIII 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 309 : Engine Service Department Address : 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone : +81-72-241-1531 : +81-72-245-2928 E-mail : kbt_g.estg-pub@kubota.com Printed in Japan 2018. 12, S, EI, EI, engusa Code No. 9Y111-07827 KUBOTA Corporation 2013. 02, S, EI, EI, engusa...

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