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wsm 03-CR-E4 Workshop Manual

wsm 03-CR-E4 Workshop Manual

Diesel engine
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WORKSHOP MANUAL
DIESEL ENGINE
03-CR-E4,
03-CR-TE4BG
KiSC issued 02, 2021 A

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Summary of Contents for wsm 03-CR-E4

  • Page 1 WORKSHOP MANUAL DIESEL ENGINE 03-CR-E4, 03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 2 Servicing part contains information and procedures for maintenance, troubleshooting and repair works. The reader should follow these instructions in order to satisfy any servicing work safely, correctly and quickly. In this WSM, service specifications and service limits are defined as followings. Service specifications: Specification which corresponds to new machine's ex-factory.
  • 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. 4-125 4-149 (Continued) 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 4 2020.04 Correction the value of SCV resistance 4-107 Mechanism Correction errors 9Y311-0067 2020.07 General The code number of this WSM has been changed from － Mechanism 9Y111-07829 to 9Y311-00670 Added the following information about D1803-CR-TIE4BG and 2-14 V2403-CR-TIE4BG. 4-23 •...

  • Page 5: Table Of Contents

    6.1 Engine intermediate harness (Engine side harness) ..............2-22 6.2 Injector intermediate harness (Engine side harness) ..............2-24 6.3 Engine ECU intermediate harness (OEM side harness) ..............2-25 6.4 System wiring diagram for D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4, V2403-CR-TE4BG..........................2-30 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 6 9.4 Judging reuse of DPF filter comp after cleaning (Cleaning contractor)........... 3-23 9.5 Checking EGR system (with Diagmaster) ..................3-24 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 7 2.8.4 Specification of piston ....................... 4-6 2.9 Piston ring ............................4-7 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 8 3.5.4 Specification of fuel tank ......................4-17 3.6 Water separator..........................4-17 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 9 3.17.4 Specification of engine ECU ....................4-30 3.18 Crankshaft position sensor......................4-31 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 10 4.9.3 Function of glow plug ......................4-42 4.9.4 Specification of glow plug ....................... 4-42 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 viii 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 11 6.9.2 Structure of oil cooler ......................4-58 6.9.3 Function of oil cooler....................... 4-58 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 12 8.6.4 Specification of key switch ...................... 4-71 8.7 Starter (Planetary gear reduction type) ................... 4-71 8.7.1 Outline of starter (planetary gear reduction type) ..............4-71 8.7.2 Structure of starter (planetary gear reduction type) ..............4-71 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 13 4.2 Adjusting valve clearance ....................... 4-98 4.3 Checking engine oil pressure ......................4-99 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 14 5.26 Removing gear case cover ......................4-127 5.27 Removing crankshaft oil slinger ....................4-127 5.28 Removing idle gear ........................4-127 5.29 Removing fuel camshaft assembly ..................... 4-128 5.30 Removing camshaft with cam gear ..................... 4-128 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 15 6.38 Installing EGR cooler ........................4-157 6.39 Assembling DPF assembly ......................4-157 6.40 Installing muffler full assembly ....................4-158 6.41 Installing CRS intermediate harness ................... 4-160 6.42 Installing external components....................4-162 6.43 Filling coolant ..........................4-163 xiii 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 16 7.51 Checking rotor of alternator......................4-190 7.52 Checking slip ring of alternator....................4-190 7.53 Checking brush wear of alternator ....................4-191 7.54 Checking rectifier ........................4-191 7.55 Checking IC regulator ......................... 4-192 7.56 Replacing injector........................4-192 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 17 7.57 Replacing engine ECU ........................ 4-194 7.58 Replacing DPF ..........................4-197 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 18 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 19: Safety

    SAFETY KiSC issued 02, 2021 A...

  • Page 20: Safety First

    • Keep a first aid kit and fire extinguisher ready at all times. • Keep emergency numbers near your telephone at all times. • Understand all safety instructions and safety labels in this manual. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 21: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 22: Starting 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 23: Preventing Acid Burns

    The fluid can penetrate your skin and cause serious injuries. 9. Cleaning exhaust filter • Get a medical aid immediately if an accident occurs. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 24  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 the diesel particulate filter (DPF). 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 25  SAFETY FIRST 1. SAFETY   03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 26: General

    GENERAL KiSC issued 02, 2021 A...

  • Page 27: General Working Precautions

    (A) Bolt hole (bolts, nuts) (B) Screw hole 3. Installing circlips • When installing the circlip, assemble the circlip's angular side (3) toward the side that receives force (4) as shown in the figure. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 28: Handling Liquid Gasket

    2. Use a press to install the oil seal until firmly fixed to the boss. NOTE • In cases when installing an oil seal without a press, place a wooden board on the seal 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 29: Handling The Battery

    • Do not allow dirt and dust to collect on the battery. • Connect the battery terminals after removing dust, old grease, blue rust and others. • Apply conductive grease thinly to the battery terminal posts to prevent corrosion. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 30: Handling Fuses

    • Install the grommet securely. • Always use fuses of the specified capacity. • Do not use steel or copper wiring instead of fuse. • Do not install work light or radio without auxiliary power line. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 31: Handling Connectors

    • Make sure that the bullet terminals are secure and connected securely to the tip. • Hold tightly connectors when disconnecting them. • Do not pull wire harness itself. (D) Good (F) Bad: poor connection (E) Bad: damaged cover 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 32: Wiring Color

    • Do not dispose fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you dispose of oil, fuel, coolant, electrolyte, and other dangerous materials. (1) Wire color (2) Stripe 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 33: 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) 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 34: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 35: Cylinder Number

    1.3 Cylinder number You can see the cylinder numbers of Kubota diesel engine in the figure. The sequence of cylinder numbers is No.1, No.2, No.3 and No.4 and it starts from the gear case cover side. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 36: Specifications

    185 kg (408 lbs) 196 kg (432 lbs) NOTE • The specification described above is of the standard engine of each model. • Conversion formula: HP = 0.746 kW, PS = 0.7355 kW. 2-10 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 37: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 38: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 39: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 40: Specification For D1803-Cr-Tie4Bg, V2403-Cr-Tie4Bg

    195 kg (430 lbs) 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. 2-14 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 41: 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. 2-15 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 42: 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. 2-16 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 43: 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. 2-17 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 44: 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. 2-18 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 45: 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. 2-19 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 46: 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. 2-20 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 47: Dimensions

    869 mm (34.2 in.) 869 mm (34.2 in.) 854 mm (33.6 in.) 517 mm (20.4 in.) 517 mm (20.4 in.) 517 mm (20.4 in.) 721 mm (28.4 in.) 735 mm (28.9 in.) 744 mm (29.3 in.) 2-21 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 48: 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. 2-22 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 49 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. 2-23 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 50: 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. 2-24 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 51: 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 － 2-25 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 52 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) 2-26 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 53 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. 2-27 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 54  GENERAL MACHINE INFORMATION 2. GENERAL 6. Wiring diagram (34) － Engine (35) Shield cable － NOTE • The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side. 2-28 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 55  GENERAL MACHINE INFORMATION 6. Wiring diagram 2. GENERAL (36) Injector － (37) Shield cable － NOTE • The figure shows the pin arrangement of the connector housing viewed from wire side, not mating side. 2-29 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 56: System Wiring Diagram For D1803-Cr-E4, D1803-Cr-Te4, V2403-Cr-E4, V2403-Cr-Te4, V2403-Cr-Te4Bg

    (27) Stop switch CAN2 connector (for vehicle) (16) Injector 4 (28) Parked regeneration switch EGR valve (17) Crankshaft position sensor (29) Parking switch Starter (18) Camshaft position sensor (30) Regeneration inhibit switch (Continued) 2-30 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 57 (22) Differential pressure sensor (ΔP) (34) Exhaust gas temperature sensor (11) Glow relay (23) Suction control valve (SCV) (35) (12) Glow heater (24) Coolant temperature sensor Injector 4 is equipped only V2403 model. 2-31 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 58: System Wiring Diagram For D1803-Cr-Tie4, D1803-Cr-Tie4Bg, V2403-Cr-Tie4, V2403-Cr- Tie4Bg

    Injector 1 (21) Coolant temperature sensor CAN2 connector (for vehicle) (13) Injector 2 (22) Rail pressure sensor EGR valve (14) Injector 3 (23) Boost pressure sensor Starter (15) Injector 4 (24) Stop switch (Continued) 2-32 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 59 6. Wiring diagram 2. GENERAL Air flow sensor (16) Crankshaft position sensor (25) Neutral switch Starter relay (17) Camshaft position sensor (26) Oil switch Battery (18) Accel sensor 1 Injector 4 is equipped only V2403 model. 2-33 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 60  GENERAL MACHINE INFORMATION 2. GENERAL 6. Wiring diagram 2-34 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 61: 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 2-35 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 62: 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 2-36 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 63: 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. 2-37 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 64: Flywheel Stopper

    1.4948 in. dia.) referring to the figure. Material SS400 6. Flywheel stopper Use for fixing the flywheel. NOTE • This special tool is not provided, therefore make it by referring to the figure below. 2-38 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 65: Auxiliary Socket For Fixing Crankshaft Sleeve

    Material SS400 8. Auxiliary socket for fixing crankshaft sleeve Use for fixing the crankshaft sleeve of the diesel engine. NOTE • This special tool is not provided. Make it referring to the figure. 2-39 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 66: Injection Top Correction Jig

    25.0 mm dia. (0.984 in. dia.) 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.) (Continued) 2-40 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 67 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 2-41 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 68: 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) 2-42 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 69 145 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 2-43 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 70  SPECIAL TOOLS 2. GENERAL   2-44 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 71: Maintenance

    MAINTENANCE KiSC issued 02, 2021 A...

  • Page 72: Maintenance Check List

    3-19 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) 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 73: Inspection Item

    Every 400 Hrs or 1 year whichever comes first D1803-CR-TE4 D1803-CR-TIE4 D1803-CR-TIE4BG V2403-CR-E4 Initial 50 Hrs V2403-CR-TE4 V2403-CR-TIE4 V2403-CR-TE4BG V2403-CR-TIE4BG API service classification: CJ-4 or CK-4 grade Ambient temperature: below 35 ℃ (95 ℉) 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 74 When the finally blended Biodiesel fuel is B7, make sure it conforms to the updated EN590 (European) standard. Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN590 (European) standard and that the B100 blend conforms to the updated EN14214 (European) standard. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 75 In cold season in particular, this may clog the fuel filter. 6. If Biodiesel fuels are spilt on a coated surface, the coating may get damaged. Immediately wipe the spill off the surface. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 76: Check And Maintenance

    2. Pull out the dipstick (1) and clean it. Put in and pull it out again. (a) Upper line (b) Lower line NOTE • If the level is too low, add new oil to the upper line (a). 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 77: 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). 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 78: Checking Fan Belt

    10.0 to 12.0 mm engine and drain the oil fully. Service specifi- 0.394 to 0.472 in. in. Deflection (1) cation (Under load of 98 N (10 kgf, 22 lbf)) (1) Drain plug (1) Deflection 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 79: Replacing Oil Filter Cartridge

    • 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 80: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 81: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 82: Checking Intake Air Line

    1. Start and warm-up the engine for approximately 5 every 2 years. minutes. Also replace the clamp (2) every 2 years and 2. Put an oil pan below the engine. tighten it correctly. 3-11 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 83: Replacing Oil Filter Cartridge

    • After you replace the cartridge, the engine oil usually decrease by a small level. 6. Check points of every 500 hours 6.1 Replacing fuel filter cartridge (2) Dipstick Tools required • Filter wrench 3-12 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 84: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 85 (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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 86: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 87: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 88: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 89: 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 4-192 3-18 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 90: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 91: Cleaning Dpf

    DPF cleaning order form. • Since the engine operating time is recorded in the engine ECU, check the operating time by connecting the service tool (Diagmaster). 3-20 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 92 (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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 93: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 94: Judging Reuse Of Dpf Filter Comp After Cleaning (Cleaning Contractor)

    (D) with a pin gauge (1) in the each block shown in the figure. NOTE • One cell (The measurement point is not specified) is measured in each block. 3-23 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 95: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 96: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 97: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 98: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 99: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 100 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 101: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 102: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 103  CHECK AND MAINTENANCE 3. MAINTENANCE 11. Check points of every 2 years 3-32 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 104: Engine

    ENGINE KiSC issued 02, 2021 A...

  • Page 105: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 106: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 107: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 108: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 109: Cylinder Head Cover

    The half float type cylinder head cover reduces noise from the cylinder head. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 110: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 111: Piston Ring

    2. Wipe down oil on the cylinder wall. Also prevent oil getting into combustion chamber. 3. Transfer piston heat to the cylinder wall. (1) Small end (4) Small end bushing 4. Support piston posture. (2) Big end (5) Bearing metal (3) Connecting rod cap 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 112: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 113: 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. 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 114: Camshaft

    Close angle 0.20 rad (9°) after T.D.C. 37.5 mm Intake valve head diameter 1.48 in. 32.0 mm Exhaust valve head diameter 1.26 in. 0.18 to 0.22 mm Valve clearance 0.0071 to 0.0086 in. 4-10 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 115: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 116: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 117: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 118: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 119: Flow Of Common Rail System (Crs) Engine

     MECHANISM 3. Fuel system 4. ENGINE 3.3 Flow of common rail system (CRS) engine 4-15 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 120 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 121: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 122: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 123: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 124: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 125: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 126 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 127: Specification Of Supply Pump

    • *1: BG model is kept a rated speed operation the valve body and returns to the fuel tank. only. Therefore, the pressure in the suction control valve is stabilized and fuel flow is accurately adjusted. 4-23 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 128: Injection Pipe

    This greatly improves the ability to raise the pressure at low speed and enables high-pressure injection from low speed ranges. 4-24 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 129: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 130: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 131: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 132 (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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 133: Specification Of Injector

    3.16 Fuel cooler 3.16.1 Outline of fuel cooler The fuel cooler cools fuel returning from the engine. Cooling fuel returning to the fuel tank prevents temperature increase of the fuel in the fuel tank. 4-29 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 134: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 135: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 136: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 137: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 138: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 139: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 140: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 141: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 142: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 143 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 144: Control Of Intake And Exhaust System

    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 power. 4-40 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 145: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 146: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 147: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 148: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 149: Feature Of Egr System

    This reduces the amount of available oxygen, lowers combustion temperatures and reduces NOx emissions. The amount of exhaust gas returned to the combustion chamber is controlled using the amount the EGR valve is opened. 4-45 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 150: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 151: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 152: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 153 (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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 154: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 155: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 156: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 157: Flow Of Lubricating System

     MECHANISM 6. Lubricating system 4. ENGINE 6.3 Flow of lubricating system 4-53 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 158 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 159: Oil Pan

    TE4, -TIE4, - 1.8 U.S.gals 0.079 × 0.098 in. TIE4BG 1.5 Imp.gals Amount of oil V2403-CR-E4, - 9.0 L TE4, -TE4BG, - 2.4 U.S.gals TIE4, -TIE4BG 2.0 Imp.gals Three Bond 1217H Liquid gasket or equivalent 4-55 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 160: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 161: Function Of Relief Valve

    6.8.3 Function of oil filter [Normal State] (1) Element (b) Unfiltered oil (a) Filtered oil The engine oil enters through the outer surface of the element and is filtered through to the inside. 4-57 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 162: Oil Cooler

    6.9.4 Specification of oil cooler Cooling method Water cooled (6) Oil pressure switch (9) Mounting screw part (7) Pressurization (10) Terminal (8) Atmospheric pressure (11) IG 4-58 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 163: Function 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 164: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 165: Feature Of Cooling System

    (B) When thermostat opens pump device (coolant temperature 65 ℃ (149 ℉) or (A) When thermostat closes higher). 3. Conditions for regeneration of the DPF (coolant temperature 65 ℃ (149 ℉) or higher). 4-61 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 166: Water Pump

    Here, the bypass valve closes the bypass part. Depending in the specification, the jiggle valve is equipped. The jiggle valve assists in bleeding air at the thermostat so that the coolant is easily filled. 4-62 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 167: Specification Of Thermostat

    (5), core (1) and the like. 4.0 L Radiator capacity 1.1 U.S.gals 0.88 Imp.gals 137 kPa Test pressure 1.40 kgf/cm 19.9 psi *These values may be different depending on the product used 4-63 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 168: Radiator Cap

    When the pressure in the radiator is below atmospheric The cooling fan causes outdoor air to pass through the pressure, the vacuum valve opens suctioning coolant radiator core for cooling. 4-64 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 169: Specification Of Cooling Fan

    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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 170: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 171: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 172: Flow Of Electrical System

    2. Upon receiving current, the starter motor rotates and a pinion gear engages and starts to rotate. 3. The pinion gear that engages meshes with the ring gear (flywheel) and causes the flywheel to rotate. 4. The crankshaft that is connected to the flywheel rotates, and the engine starts. 4-68 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 173 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 174: Control Of Electrical System

    (1) Key cylinder (3) Key (2) Harness 8.5.4 Specification of battery D1803-CR-E4 D1803-CR-TE4 12 V, 88 AH D1803-CR-TIE4 D1803-CR-TIE4BG Battery capacity V2403-CR-E4 V2403-CR-TE4 V2403-CR-TIE4 12 V, 92 AH V2403-CR-TE4BG V2403-CR-TIE4BG 4-70 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 175: Function Of Key Switch

    3. The pinion gear meshes with the ring gear (flywheel) and causes the flywheel to rotate. 4. The crankshaft that is connected to the flywheel rotates, and the engine starts. 4-71 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 176: Specification Of Starter (Planetary Gear Reduction Type)

    The alternator generates 3 phase current by means of a fixed coil and rotation of a rotor. The current generated is rectified using a rectifier made up of diodes. The rectified current charges the battery. 4-72 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 177 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 178: 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 V2403-CR-TE4 Capacity V2403-CR-TIE4 D1803-CR-TIE4BG V2403-CR-TE4BG 12 V, 720 W V2403-CR-TIE4BG Battery voltage 12 V 4-74 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 179: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 180: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 181 ○ 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 182: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 183: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 184: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 185: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 186: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 187: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 188: Intake Throttle Valve

    Voltage applied polarity and valve rotating direction Valve rotating direction: clockwise viewed from the motor side (1) Intake throttle valve (3) Valve Voltage applied polarity (2) Motor (4) Gear Shaft rotating direction Valve opening direction Valve closing direction 4-84 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 189  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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 190  MECHANISM 4. ENGINE 9. Aftertreatment system 4-86 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 191: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 192 The air cleaner is clogged Clean or replace the element 3-25 The injector is damaged Replace 4-192 The output is deficient The moving parts of engine have Repair or replace － a seizure (Continued) 4-88 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 193 The relief valve does not operate Repair or replace － with dirt The oil clearance of the bearings Replace the metal, bushing or 4-180 are too much shaft 4-180 4-182 The oil passage is clogged Clean － (Continued) 4-89 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 194 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 195: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 196 0.15 to 0.25 mm 0.90 mm 0.0059 to 0.0098 in. 0.035 in. Idle gear shaft to idle gear bush- 0.025 to 0.066 mm 0.10 mm Oil clearance 0.00099 to 0.0025 in. 0.0039 in. (Continued) 4-92 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 197 25.025 to 25.040 mm • Small end bushing I.D. － 0.98524 to 0.98582 in. 0.15 to 0.31 mm 0.50 mm Side clearance 0.0059 to 0.012 in. 0.020 in. Crankshaft 0.03 mm Alignment － 0.001 in. (Continued) 4-93 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 198 0.11 to 0.19 mm 0.25 mm Outer rotor to pump body Clearance 0.0044 to 0.0074 in. 0.0098 in. 0.105 to 0.150 mm 0.20 mm Inner rotor to cover Clearance 0.00414 to 0.00590 in. 0.008 in. 4-94 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 199 Resistance 2.9 Ω 14.4 mm 14.0 mm • Slip ring O.D. 0.567 in. 0.551 in. 10.5 mm 8.4 mm • Brush Length 0.413 in. 0.33 in. Glow plug Resistance Approx. 0.8 Ω － 4-95 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 200: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 201 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 202: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 203: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 204: Checking Fan Belt Tension

    0.90 kgf/cm 13 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 205: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 206: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 207: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 208: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 209: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 210: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 211: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 212: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 213: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 214: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 215: Checking Exhaust Gas Temperature Sensor

    2. Replace the same mark (A) as the original cylinder 2. Remove the connector from the sensor side. head gasket (1). 3. Measure the resistance between the terminal (1) and terminal A-GND3 (2) on the sensor side. 4-111 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 216: Measuring Angular Deviation Between Crankshaft T.d.c. And Crankshaft Position Sensor Detected T.d.c

    3. Use the below table to select an applicable cylinder head gasket. (1) Rocker arm (2) Exhaust side valve spring of #4 cylinder 4. Insert a small O-ring (4) to prevent the exhaust valve (5) from falling into the cylinder. 4-112 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 217 (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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 218: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 219: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 220: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 221: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 222: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 223: 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 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 224: Removing Intake Throttle Valve

    (1) Air cleaner flange (2) 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 • Do disassemble valve assembly. 4-120 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 225: Removing Sensors

    • Store the common rail (5) so it does not get any dust in it. (2) Camshaft position sensor (3) Camshaft position sensor mounting screw 4. Remove the crankshaft position sensor mounting screw (5). 4-121 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 226: Removing Cylinder Head Cover

    (2) Glow plug 5.15 Removing injector (6) Boost pressure sensor (7) Boost pressure sensor mounting screw 1. Remove the injector clamp (2). 5.13 Removing cylinder head cover 1. Remove the cylinder head cover (1). 4-122 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 227: Removing Rocker Arm Assembly

    (2) Push rod 5.17 Removing cylinder head 1. Remove the intake manifold (1). (1) Intake manifold (1) Injector (5) Injector clamp mounting (2) Injector clamp screw (3) O-ring (6) Injector ID code (4) Gasket 4-123 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 228: Removing Tappet

    4. Remove the cylinder head (3) and cylinder head gasket (4). (1) Valve stem seal (5) Valve spring collet (2) Valve (6) Valve cap (3) Valve spring (4) Valve spring retainer (3) Cylinder head (4) Cylinder head gasket 4-124 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 229: Removing Thermostat Assembly

    Do not use the parts if dropped. Tools required • Hexagon wrench (4 mm-square) 1. Remove the SCV mounting screws (2) with hexagon wrench. 2. Remove the SCV (1) carefully from the supply pump housing. 4-125 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 230: Removing Oil Cooler

    2. Remove the oil cooler joint screw (5). • Flywheel stopper 3. Remove the water hoses (2) (3). • Gear puller 4. Remove the oil cooler (4). • 46 mm (1.8 in.) deep socket wrench 4-126 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 231: Removing Gear Case Cover

    (3) 46 mm (1.8 in.) deep socket wrench 4. Remove the feather key. 5.26 Removing gear case cover 1. Remove the hour meter gear case cover (if attached). 2. Remove the gear case cover (1). 4-127 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 232: Removing Fuel Camshaft Assembly

    (4) Oil pump drive gear 2 5.31 Removing oil pump Tools required 5.29 Removing fuel camshaft • Gear puller assembly 1. Remove the fuel camshaft stopper (1). 2. Pull out the fuel camshaft assembly (2). 4-128 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 233: Removing Crank Gear

    • Using care not to damage the O-ring (4) Oil pump 5.32 Removing crank gear Tools required • Gear puller 1. Remove the crank gear (2) with a gear puller (1). (2) Oil strainer 4-129 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 234: Removing Piston

    1. Remove the piston pin snap ring (1) from the piston (2). (3) Piston 5.35 Removing piston ring Tools required • Piston ring pliers 1. Remove the top ring (1) and second ring (2) with a piston ring pliers. 4-130 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 235: Removing Flywheel

    • Do not use an impact wrench. Serious damage will occur. Tools required • Flywheel stopper • Flywheel guide screw 1. Attach the flywheel stopper (1) to the flywheel. 2. Remove the flywheel screws (2). (1) Flywheel housing 4-131 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 236: Removing Bearing Case Cover

    3. Remove the bearing case cover (3). (3) Bearing case cover 5.40 Removing crankshaft (for 3 cylinders) NOTE • Before you disassemble, measure the side clearance of crankshaft. Measure it when you assemble again. 4-132 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 237 NOTE • Before you disassemble, measure the side clearance of crankshaft. Measure it when you assemble again. • This topic is used for only 4 cylinders engine (V2403-CR-E4, -TE4, -TE4BG, -TIE4, -TIE4BG). 4-133 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 238: 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. 4-134 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 239: 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 4-135 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 240 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. 4-136 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 241: 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). 4-137 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 242: 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 4-138 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 243: Installing Crankshaft (For 3 Cylinders)

    Main bearing case 7.00 to 7.49 kgf⋅m on page 4-112 screw 2 (1) 50.6 to 54.2 lbf⋅ft RELATED PAGE 4.30 Measuring angular deviation between crankshaft T.D.C. and crankshaft position sensor detected T.D.C. on page 4-112 4-139 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 244: 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. 4-140 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 245: 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. 4-141 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 246: 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 4-142 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 247 • 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. 4-143 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 248: 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. 4-144 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 249: 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). 4-145 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 250: 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 4-146 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 251: 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. 4-147 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 252: 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. 4-148 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 253: 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 4-149 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 254: 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 4-150 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 255 93.2 to 98.1 N⋅m Exhaust manifold Tightening tor- Cylinder head 3.00 to 3.49 kgf⋅m 9.51 to 10.0 kgf⋅m mounting screw mounting screw 21.7 to 25.2 lbf⋅ft 68.8 to 72.3 lbf⋅ft (3) Exhaust manifold 4-151 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 256: 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). 4-152 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 257: 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 4-153 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 258: 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. 4-154 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 259: 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 4-155 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 260: Installing Egr Valve

    3. Tighten the oil pipe joint screw (1) to the specified torque. 15.7 to 19.6 N⋅m Tightening tor- Oil pipe joint screw 1.60 to 1.99 kgf⋅m 11.6 to 14.4 lbf⋅ft (1) Cooler hose (3) Cooler hose (2) EGR valve 4-156 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 261: Installing Egr Cooler

    • After attaching the assembly, start the engine and make sure that there are no gas leaks. Tools required • Crowfoot wrench 4-157 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 262: 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 4-158 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 263 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 4-159 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 264: 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) 4-160 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 265 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 4-161 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 266: 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)) 4-162 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 267: Filling Coolant

    • Use the correct SAE engine oil by reference to the ambient temperature. NOTE • Make sure the drain plug is tightened. (1) Plastigauge 1. Fill the engine oil until the upper line (a) on the dipstick from filling port. 4-163 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 268: Checking Cylinder Head Surface Flatness

    4. Clean away the red permeative liquid on the 2. Place a straightedge on the cylinder head's four cylinder head surface with detergent (2). sides (A), (B), (C) and (D) and two diagonal (E) and (F) as shown in the figure. 4-164 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 269: 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. 4-165 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 270: 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 4-166 7.7 Replacing valve guide IMPORTANT • Do not hit the valve guide with a hammer during replacement. 4-166 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 271: 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°) 4-167 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 272: 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. 4-168 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 273: 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. 4-169 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 274: Checking Push Rod Alignment

    Tools required • Outside 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 outside gear tooth. micrometer. 4-170 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 275: 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 4-171 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 276: 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. 4-172 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 277: 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. 4-173 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 278: Checking Oil Clearance Between Idle Gear Shaft And Idle Gear Bushing

    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. 4-174 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 279: Replacing Small End Bushing

    0.15 mm comes in contact with the connecting rod. Service limit bushing 0.0059 in. RELATED PAGE 7.26 Replacing small end bushing on page 4-175 4-175 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 280: 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. 4-176 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 281: Checking Clearance Between Piston Ring And Ring Groove

    0.015 in. D1803-CR- D1803-CR- TIE4 Service speci- D1803-CR- fication TIE4BG 0.25 to Oil ring V2403-CR- 0.45 mm 0.0099 to V2403-CR- 0.017 in. TE4BG V2403-CR- TIE4 V2403-CR- TIE4BG 1.25 mm Service limit 0.0492 in. 4-177 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 282: Checking Side Clearance Of Crankshaft

    0.0027 in. D1803-CR- D1803-CR- TIE4 Service speci- D1803-CR- fication TIE4BG 0.020 to Oil ring V2403-CR- 0.060 mm 0.00079 to V2403-CR- 0.0023 in. TE4BG V2403-CR- TIE4 V2403-CR- TIE4BG 0.15 mm Service limit 0.0059 in. 4-178 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 283: 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 4-179 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 284: Checking Oil Clearance Between Crankpin And Crankpin Bearing

    0.00099 to 0.0034 in. tween crankpin 7.33 Checking oil clearance between and crankpin bear- 0.20 mm Service limit crankshaft journal and crankshaft 0.0079 in. bearing 1 Tools required • Inside micrometer • Outside micrometer 4-180 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 285: Replacing Crankshaft Sleeve

    0.0079 in. in figure. NOTE (Reference) • Make sure that the large chamfer of the • Undersize dimensions of crankshaft journal sleeve points to outward. 3. Heat a new sleeve to the specified temperature. 4-181 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 286: Replacing Crankshaft Bearing 1

    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. 4-182 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 287: Replacing Bearing Case Cover Oil Seal

    4. Install the bearing case cover oil seal into the (0.040 to 0.059 in.) relief. bearing case cover by using the bearing case cover oil seal replacing tool 2 (4) as shown in the figure, 4-183 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 288: Checking Cylinder Wear

    87.000 to 87.022 mm maximum and minimum inner diameters. cation 3.4252 to 3.4260 in. Cylinder I.D. 87.170 mm Service limit 3.4319 in. Difference be- tween maximum 0.15 mm Service limit I.D. and minimum 0.0059 in. I.D. 4-184 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 289: 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 4-184 7.40 Checking clearance between inner rotor and outer rotor Tools required • Feeler gauge 4-185 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 290: 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. 4-186 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 291 V2403-CR- 34.0 mm lathe to the service specification. TE4BG 1.34 in. V2403-CR- TIE4 V2403-CR- TIE4BG Less than Service speci- 0.02 mm fication Difference of 0.0008 in. O.D.'s 0.05 mm Service limit 0.002 in. 4-187 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 292: Checking Brush Wear Of Starter

    D1803-CR- 0.433 in. TIE4 D1803-CR- Brush length TIE4BG V2403-CR-E4 Service limit V2403-CR- 7.47 Checking armature coil of starter V2403-CR- 9.0 mm TE4BG 0.35 in. Tools required V2403-CR- TIE4 • Circuit tester V2403-CR- TIE4BG 4-188 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 293: Checking Field Coil Of Starter

    (2) Brush (3) Yoke 7.48 Checking field coil of starter Tools required • Circuit tester 1. Check the continuity across the lead (1) and brush (2) with a resistance range of circuit tester. 4-189 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 294: Checking Bearing Of Alternator

    • If there is slight score, correct with an emery and core with the resistance range of circuit tester. paper (#500 to 600). NOTE • If it does not show infinity, replace the stator assembly. Service specifi- Resistance Infinity cation 4-190 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 295: Checking Brush Wear Of Alternator

    1. Measure the brush length (A) with a vernier calipers. NOTE • If the measurement is less than the service limit, replace it. Service specifi- 10.5 mm cation 0.413 in. Brush length (A) 8.4 mm Service limit 0.33 in. 4-191 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...

  • Page 296: Checking Ic Regulator

    • The IC regulator is correct if it conducts electricity only in one direction. (1) Utility button 2. Select the "Injector Compensation" item (2), then Service specifi- Resistance Less than 1.0 Ω click the [Proceed] button (3). cation 4-192 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 297 5. Click the [OK] button (7) when rewriting is correctly completed. (4) Register button (5) Initial display 4. Click the [OK] button (6) if rewriting is OK. (7) OK button 6. Click the [Close] button (8) to exit function. 4-193 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 298 • Laptop computer (Diagmaster (software) installed) • Interface (DST-i) Download DPK file (from K-iSS) 1. Enter the base model name and serial number to the "Search with Engine Serial No." window (1), then click the [Search] button (2). 4-194 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 299 [Download] button (5). (4) Service engine ECU serial (5) Download button number 4. Click the [Save] button (6), then download the DPK file. (8) Browse button 3. Click the [Validate] button (9). 4-195 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 300 (10) Write button (13) Instruction (14) OK button 5. After the main program rewriting is complete, follow the "instruction" (11), then click the [OK] button 7. Click the [Close] button (15) to exit function. (12). 4-196 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 301 2. Select the "DPF Regeneration Interval Time Reset" item (2), then click the [Proceed] button (3). (17) Clear DTC button 4. Click the [Clear DTC] button (18) to clear DTC and exit function. 4-197 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 302 DPF soot load reset 4. Follow the instructions according to steps of 1. Start "Diagmaster", then click the [Utility] button (7) "Notes" screen (12), then click the [Start] button from the project window. (13). 4-198 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 303 2. Select the "DPF Manual Regeneration Request Function" item (16). 6. Confirm caution description, then click the [OK] 3. Follow the instructions according to steps of button (21). "Instruction" screen (17), then click the [Proceed] button (18). 4-199 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 304 2. Click the [Registration of Service Info.] button level / status (29). 10. Click the [Finish Active Test] button (24) to stop the data monitor, then click the [Save] button (25) to save monitor data. 4-200 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 305 Component" and enter the new service information to the "After Exchanged" window (32), then click the [Register] button (33). (32) After Exchanged window (33) Register button RELATED PAGE 5.5 Removing muffler full assembly on page 4-117 4-201 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 306  SERVICING 4. ENGINE 7. Servicing 4-202 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 307 3-31 removing............4-132 clamp band bearing case cover oil seal checking............3-8,3-10 replacing............4-183 replacing............3-30 bearing case cover oil seal replacing tool....2-42 combustion bolt and nut control..............4-2 tightening............. 2-1 feature..............4-1 flow...............4-1 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 308 4-163 crankcase function..............4-4 function..............4-4 installing............4-150 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........4-173 function..............4-5 installing............4-154 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 309 3-28 engine specification............4-83 service specifications......... 4-91 structure............. 4-83 engine body dispose fluids correctly..........2-6 feature..............4-4 structure............... 4-3 cleaning..............3-20 engine ECU replacing............4-197 function.............. 4-30 DPF assembly outline..............4-30 assembling............4-157 replacing............4-194 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 310 4-42 adjusting air gap..........4-114 removing............4-122 function..............4-9 specification............4-42 installing............4-140 structure............. 4-42 outline..............4-9 removing............4-131 specification............4-9 IC regulator structure............... 4-9 checking............4-192 flywheel housing idle gear installing............4-140 installing............4-146 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 311 4-41 function.............. 4-57 outline..............4-41 installing............4-148 specification............4-41 outline..............4-57 structure............. 4-41 specification............4-57 intercooler hose structure............. 4-57 replacing............3-28 oil filter cartridge replacing............3-8,3-12 oil pan function.............. 4-55 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 312 4-6 cleaning..............3-13 installing............4-142 rail assembly outline..............4-6 function.............. 4-24 removing............4-130 outline..............4-24 specification............4-6 specification............4-25 structure............... 4-6 structure............. 4-24 piston assembly rail pressure sensor assembling............4-141 checking............4-108 disassembling..........4-130 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 313 4-186 checking.............3-19 disassembling..........4-134 checking radial clearance........ 4-107 starter (planetary gear reduction type) function ............. 4-41 function.............. 4-71 outline..............4-40 outline..............4-71 removing............4-119 specification............4-72 specification............4-41 structure............. 4-71 structure............. 4-41 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 314 4-166 replacing............4-166 valve guide replacing tool........2-37 valve seat adjusting............4-167 valve spring checking free length.........4-168 checking set load..........4-169 checking tilt............4-168 valve stem checking clearance.......... 4-166 water hose replacing............3-28 VIII 03-CR-E4,03-CR-TE4BG KiSC issued 02, 2021 A...
  • Page 315 Editor : 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 2021. 02, S, EI, EI, engusa Code No. 9Y311-00671 KUBOTA Corporation 2013. 02, S, EI, EI, engusa...

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