Workshop Manual N4.50 PDF

WORK SHOP MANUAL
ENGINE BASE
N4.50
(Before serial number KTH08040183)
NANNI INDUSTRIES S.A.S – Zone Industrielle

11 avenue MARIOTTE
B.P.107 – 33260 LA TESTE - FRANCE
60300164
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of 03-M-DI-E2B series. It is
divided into three parts, “General”, “Mechanism” and “Servicing”.
Q General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
Q Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 9Y021-01874) for
the one which has not been described to this workshop manual.
Q Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
February 2004
© KUBOTA Corporation 2004
KiSC issued 09, 2008 A

03-M-DI-E2B, WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Q IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
Q NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
1 KiSC issued 09, 2008 A

SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.

VENTILATE WORK AREA

• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.

03-M-DI-E2B, WSM SPECIFICATIONS
SPECIFICATIONS
Model D1503-M-DI D1503-M-DI-T
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 83 × 92.4 mm (3.27 × 3.64 in.)
Total Displacement 1499 cm3 (91.47 cu.in.)
ISO Net Continuous 20.6 kW / 2800 min-1 (rpm) 27.0 kW / 2800 min-1 (rpm)
(27.6 HP / 2800 min-1 (rpm)) (36.2 HP / 2800 min-1 (rpm))
ISO/SAE Net Intermittent 23.7 kW / 2800 min-1 (rpm) 31.1 kW / 2800 min-1 (rpm)
SAE Gross Intermittent 24.9 kW / 2800 min-1 (rpm) 32.4 kW / 2800 min-1 (rpm)
Maximum Bare Speed 3000 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min-1 (rpm)
Combustion Chamber Reentrant Type (Direct Injection)
Fuel Injection Pump Bosch “K” Type Mini Pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “P” Type Hole Nozzle
Injection Timing 0.127 rad (7.25 °) before T.D.C. 0.135 rad (7.75 °) before T.D.C.
Firing Order 1-2-3
Injection 1st Stage 18.6 MPa (190 kgf/cm2, 2702 psi)
Pressure
2nd Stage 22.6 MPa (230 kgf/cm2, 3271 psi)
Compression Ratio 20 : 1
Lubricating System Forced Lubrication by Trochoid Pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starting Motor 12 V, 1.2 kW
Starting Support Device By glow plug in combustion chamber
Battery 12 V, 60 AH equivalent
Charging Alternator 12 V, 360 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page G-5, 13.
Lubricating Oil Oil Pan Depth
5.6 L (1.48 U.S.gals)
Capacity 90 mm (3.54 in.)
Oil Pan Depth
7.0 L (1.85 U.S.gals)
124 mm (4.88 in.)
Weight (Dry) 148 kg (326 lbs) 152 kg (335 lbs)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10275180

Model D1703-M-DI D1803-M-DI

Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 87 × 102.4 mm (3.43 × 4.03 in.)
3
Total Displacement 1647 cm (100.51 cu.in.) 1826 cm3 (111.43 cu.in.)
ISO Net Continuous 22.7 kW / 2800 min-1
(rpm) 23.9 kW / 2600 min-1 (rpm)
Maximum Bare Speed 3000 min-1 (rpm) 2800 min-1 (rpm)
-1
Minimum Bare Idling Speed 850 to 950 min (rpm)
Firing Order 1-2-3
Pressure
Starting Motor 12 V, 1.2 kW 12 V, 1.4 kW
Battery 12 V, 60 AH equivalent 12 V, 88 AH equivalent
5.6 L (1.48 U.S.gals)
Oil Pan Depth
7.0 L (1.85 U.S.gals)
124 mm (4.88 in.)
W10314320

Model V2203-M-DI V2003-M-DI-T

Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.) 83 × 92.4 mm (3.27 × 3.64 in.)
3
Total Displacement 2197 cm (134.07 cu.in.) 1999 cm3 (121.99 cu.in.)
(rpm) 35.6 kW / 2800 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min-1 (rpm)
Firing Order 1-3-4-2
Pressure
Starting Motor 12 V, 1.4 kW
Battery 12 V, 88 AH equivalent
7.6 L (2.01 U.S.gals) 7.9 L (2.09 U.S.gals)
Oil Pan Depth
9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals)
124 mm (4.88 in.)
W10329950

Model V2403-M-DI V2403-M-DI-T

Bore × Stroke 87 × 102.4 mm (3.43 × 4.03 in.)
Total Displacement 2434 cm3 (148.53 cu.in.)
(rpm) 37.9 kW / 2550 min-1 (rpm)
-1 1550 to 1650 min-1 (rpm)
Minimum Bare Idling Speed 850 to 950 min (rpm)
Firing Order 1-3-4-2
Pressure
Starting Motor 12 V, 2.0 kW 12 V, 2.5 kW
Battery 12 V, 92 AH equivalent 12 V, 88 AH equivalent
7.6 L (2.01 U.S.gals) –
Oil Pan Depth
9.5 L (2.51 U.S.gals) 9.8 L (2.59 U.S.gals)
124 mm (4.88 in.)
W10373510

03-M-DI-E2B, WSM DIMENSIONS
DIMENSIONS
D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI

A 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 572.1 mm (22.52 in.) 575.9 mm (22.67 in.)
B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.)
C 660.0 mm (25.98 in.) 680.8 mm (26.80 in.) 660.0 mm (25.98 in.) 665.0 mm (26.18 in.)
W1031045

03-M-DI-E2B, WSM DIMENSIONS
V2203-M-DI V2003-M-DI-T V2403-M-DI V2403-M-DI-T

A 667.1 mm (26.26 in.) 667.1 mm (26.26 in.) 670.9 mm (26.41 in.) 688.4 mm (27.10 in.)
B 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 499.0 mm (19.65 in.) 520.4 mm (20.49 in.)
C 659.5 mm (25.96 in.) 683.9 mm (26.93 in.) 664.5 mm (26.16 in.) 719.4 mm (28.32 in.)
W1028881

GENERAL
CONTENTS
1. ENGINE IDENTIFICATION ............................................................................. G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1
[2] E2B ENGINE............................................................................................. G-2
[3] CYLINDER NUMBER ............................................................................... G-2
2. GENERAL PRECAUTIONS ............................................................................ G-3
3. MAINTENANCE CHECK LIST ....................................................................... G-4
4. CHECK AND MAINTENANCE ....................................................................... G-6
[1] DAILY CHECK POINTS........................................................................... G-6
[2] CHECK POINTS OF INITIAL 50 HOURS ............................................. G-8
[3] CHECK POINTS OF EVERY 50 HOURS ........................................... G-10
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-11
[8] CHECK POINTS OF EVERY 1 OR 2 MONTHS ............................... G-19
[9] CHECK POINTS OF EVERY YEAR .................................................... G-20
[10]CHECK POINTS OF EVERY 800 HOURS ......................................... G-21
[11]CHECK POINTS OF EVERY 1500 HOURS ....................................... G-22
[12]CHECK POINTS OF EVERY 3000 HOURS ....................................... G-23
[13]CHECK POINTS OF EVERY 2 YEARS.............................................. G-25
5. SPECIAL TOOLS .......................................................................................... G-29

03-M-DI-E2B, WSM G GENERAL
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
Q Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial

Number
W1010477
G-1 KiSC issued 09, 2008 A

• Month of manufacture
Engine Serial Number
Month
0001 ~ 9999 10000 ~
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
e.g. D1803-3A0001
“3” indicates 2003 and “A” indicates January.
So, 3A indicates that the engine was manufactured in January,
2003.
W1011076
[2] E2B ENGINE

[ex. Model Name D1803-M-DI-E2B-XXXX]
The emission controls that have been put into effect in various countries to prevent air pollution will be stepped up.
The time to enforce the regulations differs depending on the engine output classifications.
Kubota has been supplying the diesel engines conforming to the emission regulations in respective countries.
Exhaust emissions regulations shift to the second stage. Kubota executed the improvement of the engine according
to this regulation.
In order to discriminate the engines conforming to Tier 1 / Phase 1 requirements and those conforming to Tier 2 /
Phase 2 requirements, we have adopted E2B as a new model name for the engines conforming Tier 2 / Phase 2
regulations.
In the after-sale services for 03-M-DI-E2B series engines, only use the dedicated parts for E2B models and carry
out the maintenance services accordingly.
[3] CYLINDER NUMBER

The cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2, No.3
and No.4 starting from the gear case side.
W1011077

2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
replaced in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from which
force is applied.
• Be sure to perform run-in the serviced or reassembled engine.
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Place the Sharp Edge against the
Direction of Force
W1011734

3. MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
Service Interval
Item Every
50 100 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs months year hrs hrs hrs years
* Checking fuel hoses and clamp bands ,
(1) Oil pan depth
+ ,
Changing engine oil (90 mm, 3.54 in.)
(depending on the oil pan) (2) Oil pan depth
+ ,
(124 mm, 4.88 in.)
*Cleaning air cleaner element
,
(replace the element after 6-times cleanings)
*Cleaning fuel filter (Element type) ,
Checking battery electrolyte level ,
Checking fan belt tension and damage ,
(1) Oil pan depth
+ ,
(90 mm, 3.54 in.)
Replacing oil filter cartridge
(2) Oil pan depth
+ ,
(124 mm, 4.88 in.)
Checking radiator hoses and clamp bands ,
* Checking intake air line ,
Replacing fuel filter cartridge ,
Cleaning water jacket and radiator interior ,
Replacing fan belt ,
Recharging battery ,
* Replacing air cleaner element ,
Checking valve clearance ,
* Checking injection nozzle condition ,
* Checking turbocharger ,
* Checking injection pump ,
* Replacing intake air line ,
Replacing battery ,
Replacing radiator hoses and clamp bands ,
* Replacing fuel hoses and clamps ,
Changing radiator coolant (L.L.C.) ,
+ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
W1029462

CAUTION
• When changing or inspecting, be sure to level and stop the engine.
Q NOTE
• Lubricating Oil
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-
sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to
employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with
a high-sulfur fuel, change the lubricating oil at shorter intervals.
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Low sulfur
High sulfur Remarks
Lubricating (0.5 % ≥)
oil class
CF P P TBN ≥ 10
CF-4 P X
CG-4 P X
P : Recommendable X : Not recommendable
W1035555

4. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
Q IMPORTANT
• When using an oil of different maker or viscosity from the
previous one, drain old oil. Never mix two different types of
oil.
Q NOTE
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradients, accurately, oil quantity may
not be measured.
• Be sure to keep the oil level between upper and lower limits
of the dipstick. Too much oil may cause a drop in output or
excessive blow-by gas. On the closed breather type engine
in which mist is sucked through port, too much oil may
caused oil hammer. While too little oil, may seize the
engine’s rotating and sliding parts.
(1) Dipstick (a) Maximum
(b) Minimum
W1016222

Checking and Replenish Coolant

1. Without recovery tank :
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) :
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh, soft
water.
(Case 2)
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft
water and L.L.C.). If the coolant brand cannot be identified, drain
out all of the remaining coolant and refill with a totally new brand
of coolant mix.
CAUTION
• Do not remove the radiator cap until coolant temperature is
below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
Q IMPORTANT
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• Be sure to close the radiator cap securely. If the cap is loose
or improperly closed, coolant may leak out and the engine
could overheat.
• Do not use an antifreeze and scale inhibitor at the same time.
• Never mix the different type or brand of L.L.C..
(1) Radiator Cap A: FULL
(2) Recovery Tank B: LOW
W1035779

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil
CAUTION
• Be sure to stop engine before changing engine oil.
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
Q IMPORTANT
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CD/
CE/CF/CF-4/CG-4.
• Use the proper SAE Engine Oil according to ambient
temperature.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40
Oil pan depth

Models
124 mm (4.88 in.) *90 mm (3.54 in.)
D1503-M-DI
D1503-M-DI-T 7.0 L 5.6 L
D1703-M-DI 1.85 U.S.gals 1.48 U.S.gals
D1803-M-DI
V2203-M-DI 9.5 L 7.6 L
V2403-M-DI 2.51 U.S.gals 2.01 U.S.gals
9.8 L 7.9 L
V2003-M-DI-T
2.59 U.S.gals 2.09 U.S.gals
9.8 L
V2403-M-DI-T –
2.59 U.S.gals
*90 mm (3.54 in.) oil pan depth is optional.
(1) Drain Plug (2) Dipstick
W1016604

Replacing Oil Filter Cartridge
CAUTION
• Be sure to stop the engine before replacing filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over tightening
may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does not
leak through the seal and be sure to read the oil level on the
dipstick. Then, replenish the engine oil up to the specified level.
Q IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge
W1013487

[3] CHECK POINTS OF EVERY 50 HOURS

Checking Fuel Hoses and Clamp Bands
1. If the clamp (2) is loose, apply oil to the threads and securely
retighten it.
2. The fuel hose (1) is made of rubber and ages regardless of the
period service.
Change the fuel hose together with the clamp every two years.
3. However, if the fuel hose and clamp are found to be damaged or
deteriorate earlier than two years, then change or remedy.
4. After the fuel hose and the clamp have been changed, bleed the
fuel system.
CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)

1. Fill the tank with fuel and open the fuel cock (4). ([B] only)
2. Loosen the air vent plug (3) of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up any more.
4. Open the air vent cock (5) on top of the fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key to AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock after air bleeding.
Q NOTE
• Always keep the air vent cock on the fuel injection pump
closed except when air is vented, or it may cause the engine
to stop.
(1) Fuel Hose [A] Cartridge Type
(2) Clamp [B] Element Type
(3) Air Vent Plug
(4) Fuel Cock
(5) Air Vent Cock
W1035921


Cleaning Air Cleaner Element
1. Remove the air cleaner element.
2. Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,
30 psi).
Maintain reasonable distance between the nozzle and the filter.
Q NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th cleaning.
W1045746
Cleaning Fuel Filter (Element Type only)
1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter cup (5), and
rinse the inside with kerosene.
3. Take out the element (4) and dip it in the kerosene to rinse.
4. After cleaning, reassemble the fuel filter, keeping out dust and
dirt.
5. Bleed the fuel system.
Q IMPORTANT
• If dust and dirt enter the fuel, the fuel injection pump and
injection nozzle will wear quickly. To prevent this, be sure
to clean the fuel filter cup (5) periodically.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
W1046058
Checking Battery Electrolyte Level
1. Check the battery electrolyte level.
2. If the level is below than lower level line (2), and the distilled water
to pour level of each cell.
(1) Upper Level Line (2) Lower Level Line
W1047154
Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
W1208957

Fan Belt Damage and Wear

1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good (B) Bad
W1057475


Changing Engine Oil (for 90 mm (3.54 in.) Depth Oil Pan)
CAUTION
Q IMPORTANT
CE/CF/CF-4/CG-4.
temperature.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
Oil pan depth

Models
124 mm (4.88 in.) *90 mm (3.54 in.)
D1503-M-DI
D1503-M-DI-T 7.0 L 5.6 L
D1803-M-DI
V2203-M-DI 9.5 L 7.6 L
9.8 L 7.9 L
V2003-M-DI-T
9.8 L
V2403-M-DI-T –
2.59 U.S.gals
W1022029

Replacing Oil Filter Cartridge (for 90 mm (3.54 in.) Depth Oil

Pan)
CAUTION
Q IMPORTANT
W1022423
Checking Radiator Hoses and Clamp Bands
1. Check to see if the radiator hoses are properly fixed every 200
hours of operation or every six months, whichever comes first.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The water hose is made of rubber and tends to age. It must be
replaced every two years. Also replace the clamp and tighten it
securely.
(1) Upper Hose (2) Lower Hose
W1029518
Checking Intake Air Line

1. Check to see if the intake air hose(s) are properly fixed every 200
hours of operation.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) is made of rubber and tends to age. It must
be changed every two years. Also change the clamp and tighten
it securely.
Q IMPORTANT
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp
W1029631


Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan)
CAUTION
Q IMPORTANT
CE/CF/CF-4/CG-4.
temperature.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
Oil pan depth

Models
124 mm (4.88 in.) *90 mm (3.54 in.)
D1503-M-DI
D1503-M-DI-T 7.0 L 5.6 L
D1803-M-DI
V2203-M-DI 9.5 L 7.6 L
9.8 L 7.9 L
V2003-M-DI-T
9.8 L
V2403-M-DI-T –
2.59 U.S.gals
W1022765

Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil
Pan)
CAUTION
Q IMPORTANT
W1023046
Replacing Fuel Filter Cartridge (Cartridge Type)
Water and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 400 hours service.
1. Remove the used filter cartridge with filter wrench.
2. Apply a thin film of fuel to the surface of new filter cartridge gasket
before screwing on.
3. Then tighten enough by hand.
4. Loosen the air vent plug to let the air out.
5. Start engine and check for fuel leakage.
(1) Fuel Filter Cartridge
W1050548
Replacing Fuel Filter Element (Element Type)
1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter cup (5), and
rinse the inside with kerosene.
3. Replace the filter element (4).
4. Reassemble the fuel filter, keeping out dust and dirt.
5. Bleed the fuel system.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
W1050583


Cleaning Water Jacket and Radiator Interior
CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock (3).
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (4).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (4) and add coolant if necessary.
Q IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Drain Cock
(4) Recovery Tank
W1038102

Anti-Freeze
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
Q IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11.2 106 222.8
50 –37 –34.6 108 226.4
* At 1.013 × 100000 Pa (760 mm Hg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
Q NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1039218
Replacing Fan Belt
1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
7.0 to 9.0 mm / 98 N
Deflection (A) Factory spec. 0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
(1) Fan Belt (A) Deflection

W1052220

[8] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
Use a voltmeter or hydrometer.
1) Slow Charging
1. Add distilled water if the electrolyte level is low. When charging,
the amount of electrolyte should be slightly lower than the
specified level to prevent overflow.
2. Connect the battery to the charging unit, following the
manufacture’s instructions.
3. As the electrolyte generates gas while charging, remove all port
caps.
4. The electrolyte temperature must not exceed 40 °C (104 °F)
during charging.
If it exceed 40 °C (104 °F), decrease the charging amperage or
stop charging for a while.
5. When charging several batteries in series, charge at the rate of
the smallest battery in the line.
2) Quick Charging
1. Determine the proper charging current and charging time with the
tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery
capacity. If the battery capacity exceeds 50 Ah, consider 50 A as
the maximum.
Q Precaution for Operating a Quick Charger
• Operate with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
W1052658

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
Q NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1012763
[9] CHECK POINTS OF EVERY YEAR

Replacing Air Cleaner Element
1. Remove used air cleaner element.
2. Replace new air cleaner element.
Q NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
W1020554


Valve Clearance
Q IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the head cover.
2. Align the “1TC” mark line (3) on the flywheel and projection (2)
on the housing so that the No.1 piston comes to the compression
or overlap top dead center.
3. Check the following valve clearance (1) marked with “,” using a
feeler gauge.
4. If the clearance is not within the factory specifications, adjust with
the adjusting screw.
0.18 to 0.22 mm
Valve clearance Factory spec.
0.0071 to 0.0087 in.
Q NOTE
• The “TC” marking line on the flywheel is just for No. 1
cylinder. There is no “TC” marking for the other cylinders.
• No. 1 piston comes to the top dead center position when the
“TC” marking is aligned with the projection (2) in the window
on flywheel-housing. Turn the flywheel 0.26 rad (15°)
clockwise and counterclockwise to see if the piston is at the
compression top dead center or the overlap position. Now
referring to the table below, readjust the valve clearance (1).
(The piston is at the top dead center when both the IN. and
EX. valves do not move; it is at the overlap position when
both the valves move.)
• Finally turn the flywheel 6.28 rad (360°) and align the “TC”
marking and the projection (2) perfectly. Adjust all the other
valve clearance as required.
• After turning the flywheel counterclockwise twice or three
times, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly tighten the lock
nut of the adjusting screw.
Valve D1503-M-DI V2203-M-DI
arrangement D1503-M-DI-T V2003-M-DI-T
Adjustable D1703-M-DI V2403-M-DI
cylinder D1803-M-DI V2403-M-DI-T
location of piston IN. EX. IN. EX.
No. 1 , , , ,
When No. 1 piston
comes to No. 2 , ,
compression top No. 3 , ,
dead center
No. 4 – –
No. 1
When No. 1 piston No. 2 , ,
comes to overlap
position No. 3 , ,
No. 4 – – , ,
(1) Valve Clearance (3) TC Mark Line

(2) Projection
W10113200


CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly.
18.6 to 20.1 MPa
Fuel injection pressure
Factory spec. 190 to 205 kgf/cm2
(1st stage)
2702 to 2916 psi
W10408820
Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly.
(a) Good (b) Bad
W10411400
Valve Seat Tightness

2. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170 kgf/cm2
2418 psi
W10412730


Checking Turbocharger
(Turbine Side)
1. Check the exhaust port (2) and inlet port (3) side of turbine
housing (1) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket with new one.
(Compressor Side)
1. Check the inlet hose (4) of the compressor cover (5) to see if
there is no air leak.
2. Check for loose connections or cracks in the suction side of the
intake hose.
3. If any air leak is found, change the clamp (6) and / or inlet hoses.
(Radial Clearance)
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
(1) Turbine Housing (4) Inlet Hose
(2) Exhaust Port (5) Compressor Cover
(3) Inlet Port (6) Clamp
W1022082

Checking Injection Pump

(Fuel Tightness of Pump Element)
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
(Fuel Tightness of Delivery Valve)
3. Set a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from 190
to 180 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190 to 180 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
18.63 MPa
Fuel tightness of pump
Allowable limit 190 kgf/cm2
element
2702 psi
10 seconds
18.63 → 17.65 MPa
Factory spec.
190 → 180 kgf/cm2
Fuel tightness of 2702 → 2560 psi
delivery valve 5 seconds
18.63 → 17.65 MPa
Allowable limit
190 → 180 kgf/cm2
2702 → 2560 psi
Q NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
W1022357

[13] CHECK POINTS OF EVERY 2 YEARS

Replacing Intake Air Line
1. Loosen the clamp (2).
2. Remove the intake air hose (1) and clamp (2).
3. Replace new intake air hose (1) and new clamp (2).
4. Tighten the clamp (2).
Q NOTE
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp
W1023867
Replacing Battery
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
1. Disconnect the negative terminal and positive terminal.
2. Remove the battery holder.
3. Remove the used battery.
4. Replace the new battery.
5. Tighten the battery holder.
6. Connect the positive terminal.
7. Connect the negative terminal.
W1023996
Replacing Radiator Hoses and Clamp Bands
CAUTION
1. Drain the coolant.
2. Loosen the clamp bands.
3. Remove the upper hose (1) and lower hose (2).
4. Replace new upper / lower hose (1), (2) and clamp bands.
5. Tighten the clamp bands.
6. Fill with clean water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.
(1) Upper Hose (2) Lower Hose
W1024178

Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).
2. Replace new fuel hose (1) and new clamp (2).
3. Tighten the clamp (2).
CAUTION
• Stop the engine when attempting the check and change
prescribed above.
(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4).
2. Loosen the air vent plug (3) of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up any more.
4. Open the air vent cock on top of the fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key to AC position
and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on stop
position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock after air bleeding.
Q NOTE
• Always keep the air vent cock on the fuel injection pump
closed except when air is vented, or it may cause the engine
to stop.
(1) Fuel Hose [A] Cartridge Type
(2) Clamp [B] Element Type
(3) Air Vent Plug
(4) Fuel Cock
W1024305

Changing Radiator Coolant (L.L.C.)
CAUTION
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and remove
the radiator cap (1). Then radiator cap (1) must be removed to
completely drain the coolant. And open the drain cock of engine
body.
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port. Install the radiator cap (1) securely.
7. Fill with coolant up to “FULL” (A) mark on the recovery tank (3).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator and
recovery tank (3) and add coolant if necessary.
Q IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A : Full
(2) Drain Plug B : Low
(3) Recovery Tank
W1024599

Changing Radiator Coolant (L.L.C.) (Continued)

(Anti-freeze)
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the make of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
Q IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11.2 106 222.8
50 –37 –34.6 108 226.4
* At 1.013 × 100000 Pa (760 mm Hg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
Q NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1024852

5. SPECIAL TOOLS
Diesel Engine Compression Tester (for Glow Plug)
Code No.: 07909-39081 (Assembly)
07909-31291 (K)
07909-31301 (L)
07909-31311 (M)
Application: Use to measure diesel engine compression and
diagnosis of need for major overhaul.
Adaptor: The adaptor K is required for 03-M-DI-E2B.
(1) Gauge (4) Adaptor K
(2) Hose Assembly (5) Adaptor L
(3) L Joint (6) Adaptor M
W1206183
Oil Pressure Tester
Code No: 07916-32032
Application: Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
W1024318

Q NOTE
• The following special tools are not provided, so make them referring to the figure.
Injection Pump Pressure Tester
Application: Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa
A
(300 kgf/cm2, 4267 psi)
B PF 1/2
C Copper gasket
D Flange (Material : Steel)
E Hex. nut 27 mm (1.06 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8 mm dia. (0.31 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in. dia.)
N 8 mm (0.31 in.)
O 4 mm (0.16 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4 mm (0.16 in.)
U 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5 mm (0.20 in.)
W10252400
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A 225 mm (8.86 in.)
B 70 mm (2.76 in.)
C 45 mm (1.77 in.)
D 20 mm dia. (0.79 in. dia.)
E 12.7 to 12.9 mm dia. (0.500 to 0.508 in. dia.)
F 7.5 to 7.6 mm dia. (0.295 to 0.299 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 7.7 to 8.0 mm dia. (0.303 to 0.315 in. dia.)
I 5 mm (0.197 in.)
J 20 mm dia. (0.787 in. dia.)
K 13.5 to 13.8 mm dia. (0.531 to 0.543 in. dia.)
L 8.9 to 9.1 mm (0.350 to 0.358 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
W1025017

Bushing Replacing Tools

Application: Use to press out and to press fit the bushing.
1. For small end bushing
A 162 mm (6.38 in.)
B 35 mm (1.38 in.)
C 27 mm (1.06 in.)
D 35 mm dia. (1.38 in. dia.)
2. For idle gear bushing
A 175 mm (6.89 in.)
B 40 mm (1.57 in.)
C 38 mm (1.50 in.)
D 45 mm dia. (1.77 in. dia.)
W1025500
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
A 20 mm (0.79 in.)
B 15 mm (0.59 in.)
C 10 mm dia. (0.39 in. dia.)
D 30 mm (1.18 in.)
E 8 mm (0.31 in.)
F 200 mm (7.87 in.)
W10259480
Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft bearing 1.
1. Extracting tool
A 135 mm (5.31 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)
E 20 mm (0.79 in.)
F 20 mm dia. (0.79 in. dia.)
G 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
H 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
2. Inserting tool
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 9 mm (0.35 in.)
E 4 mm (0.16 in.)
F 20 mm (0.79 in.)
G 20 mm dia. (0.79 in. dia.)
H 68 mm dia. (2.68 in. dia.)
I 59.8 to 59.9 mm dia. (2.354 to 2.358 in. dia.)
J 64.8 to 64.9 mm dia. (2.551 to 2.555 in. dia.)
W1026139

Socket Wrench for Crank Pulley Nut (46 mm Deep Socket

Wrench)
Application: Use to loosen and tighten the fan drive pulley mounting
nut.
A 100 mm (3.94 in.)
B 25.0 mm (0.98 in.)
C 27.0 mm (1.06 in.)
D 45.0 mm dia. (1.77 in. dia.)
E 35.0 mm dia. (1.38 in. dia.)
F 62.5 mm dia. (2.46 in. dia.)
G 46.0 mm (1.81 in.)
W1044361
Auxiliary Socket for Fixing Crankshaft Sleeve
Application: Use to fix the crankshaft sleeve of the diesel engine.
A 80.0 mm (3.1496 in.)
B 60.1 to 60.3 mm (2.3661 to 2.3740 in.)
C 80.0 mm dia. (3.1496 in. dia.)
D 85.0 mm dia. (3.3465 in. dia.)
F 26.3 to 26.4 mm (1.0354 to 1.0394 in.)
G 25.85 to 25.90 mm (1.0177 to 1.0197 in.)
H 15.0 mm (0.5906 in.)
I 5.0 mm (0.1969 in.)
(1) Stopper (3) Auxiliary Socket for Pushing

(2) Sleeve Guide
W1027695

Auxiliary Socket for Fixing Crankshaft Sleeve (Continued)

Application: Use to fix the crankshaft sleeve of the diesel engine.
J 42.0 mm (1.6535 in.)
K 30.5 to 30.6 mm (1.2008 to 1.2047 in.)
L 23.0 mm (0.9055 in.)
M 20.0 mm (0.7874 in.)
N 2.0 mm (0.0787 in.)
O 31.911 to 31.950 mm dia. (1.2563 to 1.2579 in. dia.)
P 30.0 mm dia. (1.1811 in. dia.)
Q 5.0 mm dia. (0.1969 in. dia.)
R 0.087 rad (5 °)
S 25.0 mm dia. (0.9843 in. dia.)
T 60.0 mm dia. (2.3622 in. dia.)
U 79.80 to 79.85 mm dia. (3.1417 to 3.1437 in. dia.)
V 10.0 mm (0.3937 in.)
W 0.04 mm dia. (0.0016 in. dia.)
X 140 mm (5.5118 in.)
Y 120 mm (4.7244 in.)
Z 110 mm (4.3307 in.)
a 50.0 mm (1.9685 in.)
b 39.9 to 40.0 mm (1.5709 to 1.5748 in.)
c 25.0 mm (0.9843 in.)
d 90.0 mm dia. (3.5433 in. dia.)
e 81.0 mm dia. (3.1890 in. dia.)
f 80.10 to 80.15 mm dia. (3.1535 to 3.1555 in. dia.)
g 30.0 mm dia. (1.1811 in. dia.)
h 5.0 mm dia. (0.1969 in. dia.)
i 70.0 mm (2.7559 in.)
j 50.0 mm (1.9685 in.)
k 40.0 mm dia. (1.5748 in. dia.)
C0.3 Chamfer 0.3 mm (0.012 in.)
R1 1.0 mm radius (0.0394 in. radius)
(2) Sleeve Guide (3) Auxiliary Socket for Pushing

W1027898

Balancer Metal Replacing Tool (for Removing)

Application: Use to remove the metal bearing.
A 41 mm (1.61 in.) L 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)

B 32.5 mm (1.28 in.) M 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.)
C Chamfer 0.3 mm (0.01 in.) N 21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.)
D 25 mm dia. (0.98 in. dia.) O 36 mm (1.42 in.)
E 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.) P 5 mm (0.20 in.)
F 0.52 rad (30 °) Q 29 mm (1.14 in.)
G 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.) R 28 mm (1.10 in.)
H 148.5 mm (5.85 in.) S 195.25 to 195.75 mm (7.687 to 7.707 in.)
I 10 mm (0.39 in.) T 145 mm (5.71 in.)
J 46.50 to 46.75 mm dia. (1.831 to 1.841 in. dia.) U 384.75 to 385.25 mm (15.148 to 15.167 in.)
K 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)

Balancer Metal Replacing Tool (for Fitting)

Application: Use to press fit the metal bearing.
A 182 mm (7.17 in.) O 60 mm dia. (2.36 in. dia.)

B 140 mm (5.51in.) P 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)
C 37 mm (1.46 in.) Q 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.)
D 35 mm dia. (1.38 in dia.) R 140 mm (5.51 in.)
E 60 mm dia. (2.36 in dia.) S 36 mm (1.42 in.)
F 10 mm (0.39 in.) T 60 mm dia. (2.36 in. dia.)
G 0.52 rad (30 °) U 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)
H 21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.) V 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)
I 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.) W 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)
J Chamfer 0.3 mm (0.01 in.) X 145 mm (5.71 in.)
K 8.8 to 9.2 mm (0.346 to 0.362 in.) Y 195.25 to 195.75 mm (7.687 to 7.707 in.)
L 5 mm (0.20 in.) Z 29 mm (1.14 in.)
M 3.3 to 3.7 mm (0.130 to 0.146 in.) a 36 mm (1.42 in.)
N 25 mm dia. (0.98 in. dia.)

Idle Gear 2 Puller

Application: Use for remove the idle gear 2 from the shaft.
A 24 mm (0.94 in.)
B 10 mm dia. (0.39 in. dia.)
C 0.5 mm radius (0.02 in. radius)
D M20 x Pitch 2.0
E 10 mm (0.39 in.)
F 20 mm (0.79 in.)
G 5 mm (0.20 in.)
H 95 mm (3.74 in.)
I 125 mm (4.92 in.)
J 0.89 rad (50 °)
K 5 mm (0.20 in.)
L 60 mm radius (2.36 in. radius)
M M20 x Pitch 2.0
N 30 mm (1.18 in.)
O 10 mm (0.39 in.)
P 10 mm (0.39 in.)
Q 10 mm (0.39 in.)
R 35.5 mm (1.40 in.)
S 4.5 mm radius (0.18 in. radius)
T 40 mm (1.57 in.)
U 40 mm (1.57 in.)
V 12 mm (0.47 in.)
W 120 mm (4.72 in.)
W1028521

MECHANISM
CONTENTS
1. ENGINE BODY ............................................................................................... M-1

[1] PISTON...................................................................................................... M-1
[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY).......... M-1
[3] HALF-FLOATING HEAD COVER ............................................................ M-2
2. COOLING SYSTEM ........................................................................................ M-3
[1] BOTTOM BYPASS SYSTEM................................................................... M-3
3. FUEL SYSTEM ............................................................................................... M-4
[1] GOVERNOR .............................................................................................. M-4
4. TURBOCHARGER SYSTEM .......................................................................... M-5
[1] BOOST COMPENSATOR ........................................................................ M-5

03-M-DI-E2B, WSM DIESEL ENGINE
1. ENGINE BODY
[1] PISTON
Piston’s skirt is coated with molybdenum
disulfide+, which reduces the piston slap noise and
thus the entire operating noise.
+Molybdenum disulfide (MoS2)

The molybdenum disulfide (1) serves as a solid
lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.
(1) Molybdenum Disulfide
W1013114
[2] BUILT-IN DYNAMIC BALANCER (BALANCER MODEL ONLY)

Engine are sure to vibrate by piston’s reciprocation.
Theoretically, three-cylinder engines are much less
prone to cause vibration than four-cylinder ones (second
inertia, etc.). However, any engine has many moving
parts in addition to its pistons and cannot be completely
free from vibration.
The four cylinders engine can be fitted with balance
weight on crankcase to absorb the second inertia
mentioned above and reduce vibration.
This engine is internally provide with two balancers
(1), one at the suction side and the other at the exhaust
side.
(1) Balancer
W1013221
M-1 KiSC issued 09, 2008 A

[3] HALF-FLOATING HEAD COVER

The rubber packing is fitted in to maintain the cylinder
head cover 0.5 mm (0.02 in.) or so off the cylinder head.
This arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
W1013327

2. COOLING SYSTEM
[1] BOTTOM BYPASS SYSTEM
Bottom bypass system is introduced in 03-M Series
for improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
the thermostat is held closed and the coolant is allowed
to flow through the bypass pipe and to circulate in the
engine.
When the temperature exceeds the thermostat valve
opening level, the thermostat fully opens itself to prevent
the hot coolant from flowing through the bypass into the
engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat (A) Bypass Opened
(B) Bypass Closed
W1013406

3. FUEL SYSTEM
[1] GOVERNOR
The governor serves to keep engine speed constant
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. This engine
employs an all-speed governor which controls the
centrifugal force of the steel ball (1) weight, produced by
rotation of the fuel camshaft (5), and the tension of the
governor spring 1 (7) and 2 (8) are balanced.
(1) Steel Ball (7) Governor Spring 1
(2) Governor Sleeve (8) Governor Spring 2
(3) Steel Ball (9) Fork Lever 2
(4) Governor Ball Case (10) Fork Lever 1
(5) Fuel Camshaft (11) Fork Lever Shaft
(6) Governor Lever (12) Fork Lever Holder
W1017186

4. TURBOCHARGER SYSTEM
[1] BOOST COMPENSATOR
(1) Injection Pump Assembly
(2) Boost Compensator
Assembly
(3) Actuator
(4) Stop Solenoid
(5) Plunger
(6) Stop Solenoid Guide
(7) Hi-Idling Body
W1014318
The higher the boost pressure rises, the more fuel is

fed. In this way, the turbocharger proves itself for high-
power performance.
W1014402
When the boost pressure drops, excess fuel is cut

down, allowing much less black emission.
The system is tremendously efficient in cutting down
on the emission; under low boost pressures at quick
speed-up or start-up, in particular.
W1014432

SERVICING
CONTENTS
1. TROUBLESHOOTING ......................................................................................S-1
2. SERVICING SPECIFICATIONS ......................................................................S-5
3. TIGHTENING TORQUES ..............................................................................S-14
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-14
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-15
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-16
[1] CHECKING AND ADJUSTING ...............................................................S-16
(1) Engine Body........................................................................................S-16
(2) Lubricating System .............................................................................S-18
(3) Cooling System ...................................................................................S-19
(4) Fuel System ........................................................................................S-21
(5) Electrical System ................................................................................S-24
(6) Turbocharger ......................................................................................S-28
[2] DISASSEMBLING AND ASSEMBLING..................................................S-29
(1) Draining Oil and Coolant.....................................................................S-29
(2) External Components .........................................................................S-29
(3) Cylinder Head and Valves ..................................................................S-31
(4) Gear Case and Timing Gears .............................................................S-36
(5) Piston and Connecting Rod ................................................................S-46
(6) Flywheel and Crankshaft ....................................................................S-49
(7) Starter .................................................................................................S-52
(8) Alternator ............................................................................................S-53
[3] SERVICING ..............................................................................................S-54
(1) Cylinder Head and Valves ..................................................................S-54
(2) Timing Gears ......................................................................................S-60
(3) Piston and Connecting Rod ................................................................S-65
(4) Crankshaft...........................................................................................S-69
(5) Cylinder...............................................................................................S-73
(6) Oil Pump .............................................................................................S-74
(7) Starter .................................................................................................S-75
(8) Alternator ............................................................................................S-78

1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not No fuel Replenish fuel G-10
Start Air in the fuel system Vent air G-10
Water in the fuel system Change fuel and –
repair or replace fuel
system
Fuel hose clogged Clean or replace G-10
Fuel filter clogged Replace G-16
Excessively high viscosity of fuel or engine oil at Use specified fuel or 4, 5, 6, 7,
low temperature engine oil G-8
Fuel with low cetane number Use specified fuel 4, 5, 6, 7
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31
Incorrect injection timing Adjust S-21
Fuel camshaft worn Replace S-45
Injection nozzle clogged Repair or replace S-23, 32
Injection pump malfunctioning Repair or replace S-22, 36,
37, 38
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace S-44 to 48
or bearing S-69 to 74
Compression leak from cylinder Replace head S-32, 33,
gasket, tighten 34
cylinder head screw,
glow plug and nozzle
holder
Improper valve timing Correct or replace S-43, 44
timing gear
Piston ring and cylinder worn Replace S-16, 47,
48, 67, 68,
73
Excessive valve clearance Adjust S-17
Stop solenoid malfunctioning Replace S-28, 37
(Starter Does Not Battery discharged Charge G-19, 20
Run) Starter malfunctioning Repair or replace S-26, 29,
52, 75
Key switch malfunctioning Replace –
Wiring disconnected Connect –
W1014322
S-1 KiSC issued 09, 2008 A

Reference
Page
Engine Revolution Is Fuel filter clogged or dirty Replace G-16
Not Smooth Air cleaner clogged Clean or replace G-11, 14,
20
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31
37, 38
Incorrect nozzle opening pressure Repair or replace S-23, 32
Injection nozzle stuck or clogged Repair or replace S-23, 32
Governor malfunctioning Repair S-39, 40,
45
Turbocharger bearing worn out Replace the S-30
turbocharger
assembly
Turbocharger shaft bent Replace the S-30
turbocharger
assembly
Turbocharger fin or other part damaged due to Replace the S-30
foreign matters turbocharger
assembly
Either White or Blue Excessive engine oil Reduce to specified G-6
Exhaust Gas Is level
Observed Piston ring and cylinder worn or stuck Repair or replace S-16, 47,
48, 67, 68,
73
Oil Leak into Exhaust Oil pipe clogged or deformed Repair or replace S-30
Pipe or Suction Pipe Turbocharger’s piston ring seal faulty Replace the S-30
turbocharger
assembly
Either Black or Dark Overload Reduce the load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel 4, 5, 6, 7
Observed
Fuel filter clogged Replace G-16
Air cleaner clogged Clean or replace G-11, 14,
20
Deficient nozzle injection Repair or replace S-23, 32
nozzle
W1011567

Reference
Page
Deficient Output Incorrect injection timing Adjust S-21
Engine’s moving parts seem to be seizing Repair or replace –
37, 38
nozzle
Compression leak Check the S-16
compression
pressure and repair
Gas leak from exhaust system Repair or replace S-28, 30
Air leak from compressor discharge side Repair or replace S-28, 30
Air cleaner dirty or clogged Clean or replace G-11, 14,
20
Turbocharger compressor wheel turning heavily Replace the S-30
turbocharger
assembly
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap S-47
Oil Consumption direction
Oil ring worn or stuck Replace S-48, 67,
68
Piston ring groove worn Replace piston S-48, 67,
68
Valve stem and valve guide worn Replace S-34, 55,
56
Crankshaft bearing, and crank pin bearing worn Replace S-47, 51,
70, 71, 72
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Repair or replace S-22, 36,
Lubricant Oil 37 ,38
nozzle
Injection pump broken Replace S-36, 37,
38
Water Mixed into Head gasket defective Replace S-33, 34
Lubricant Oil Cylinder block or cylinder head flawed Replace S-33, 54
W1012032

Reference
Page
Low Oil Pressure Engine oil insufficient Replenish G-6
Oil strainer clogged Clean S-46
Relief valve stuck with dirt Clean –
Relief valve spring weaken or broken Replace –
Excessive oil clearance of crankshaft bearing Replace S-51, 71,
72
Excessive oil clearance of crankpin bearing Replace S-47, 70
Excessive oil clearance of rocker arm Replace S-32, 58
Oil passage clogged Clean –
Different type of oil Use specified type of 4, 5, 6, 7,
oil G-8
Oil pump defective Replace S-18, 45,
74
High Oil Pressure Different type of oil Use specified type of 4, 5, 6, 7,
oil G-8
Relief valve defective Replace –
Engine overheated Engine oil insufficient Replenish G-8
Fan belt broken or elongated Replace or adjust G-12, 18
Coolant insufficient Replenish G-7
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace G-17
Coolant flow route corroded Clean or replace G-17, 18
Radiator cap defective Replace S-20
Overload running Reduce the load –
Head gasket defective Replace S-33, 34
Unsuitable fuel used Use specified fuel 4, 5, 6, 7
Battery Quickly Battery electrolyte insufficient Replenish distilled G-11, 19
Discharged water and charge
Fan belt slips Adjust belt tension or G-11, 12,
replace 18
Wiring disconnected Connect –
Rectifier defective Replace S-53, 79
Alternator defective Replace S-53, 78
Battery defective Replace –
W1012501

2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Valve Clearance (When Cold) 0.18 to 0.22 mm –
0.0071 to 0.0087 in.
Compression Pressure 2.94 to 3.24 MPa / 2.35 MPa /
(When Cranking with Starting Motor) 290 min-1 (rpm) 290 min-1 (rpm)
30 to 33 kgf/cm2 / 24 kgf/cm2 /
290 min-1 (rpm) 290 min-1 (rpm)
427 to 469 psi / 341 psi /
290 min-1 (rpm) 290 min-1 (rpm)
Difference among Cylinders – 10 % or less

Top Clearance 0.60 to 0.70 mm –
0.0236 to 0.0276 in.
Cylinder Head Surface Flatness – 0.05 mm / 500 mm
0.0020 in. /
19.69 in.
Valve Recessing Recessing 0.65 to 0.85 mm 1.20 mm
0.026 to 0.033 in. 0.0472 in.
Valve Stem to Valve Guide Clearance 0.040 to 0.070 mm 0.10 mm
0.00157 to 0.00276 in. 0.0039 in.
Valve Stem O.D. 7.960 to 7.975 mm –

0.31339 to 0.31398 in.
Valve Guide I.D. 8.015 to 8.030 mm –

0.31555 to 0.31614 in.
Valve Face Angle (Intake) 0.785 rad –
45 °
Angle (Exhaust) 0.785 rad –

45 °
Valve Seat Width (Intake) 2.12 mm –
0.0835 in.
Width (Exhaust) 2.12 mm –

0.0835 in.
Valve Seat Angle (Intake) 0.785 rad –
45 °
Angle (Exhaust) 0.785 rad –

45 °
Valve Timing (Intake Valve) Open 0.16 rad (9 °) –
before T.D.C.
Close 0.79 rad (45 °) –

after B.D.C.
W1013874

ENGINE BODY (Continued)

Valve Timing (Exhaust Valve) Open 0.87 rad (50 °) –
before B.D.C.
Close 0.21 rad (12 °) –

after T.D.C.
Valve Spring Free Length 41.7 to 42.2 mm 41.2 mm
1.6417 to 1.6614 in. 1.6220 in.
Setting Load / 117.6 N / 35.0 mm 100.0 N / 35.0 mm

Setting Length 12.0 kgf / 35.0 mm 10.2 kgf / 35.0 mm
26.4 lbf / 1.3780 in. 22.5 lbf /1.3780 in.
Tilt – 1.0 mm
0.039 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.10 mm
0.00063 to 0.00177 in. 0.0039 in.
Rocker Arm Shaft O.D. 13.973 to 13.984 mm –

0.55012 to 0.55055 in.
Rocker Arm I.D. 14.000 to 14.018 mm –

0.55118 to 0.55189 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Guide Oil Clearance 0.020 to 0.062 mm 0.07 mm
0.00079 to 0.00244 in. 0.0028 in.
Tappet O.D. 23.959 to 23.980 mm –

0.94327 to 0.94410 in.
Tappet Guide I.D. 24.000 to 24.021 mm –

0.94488 to 0.94571 in.
W1014004


Timing Gear
Crank Gear to Idle Gear Backlash 0.0415 to 0.1122 mm 0.15 mm
0.00163 to 0.00442 in. 0.0059 in.
Idle Gear to Cam Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

0.00163 to 0.00454 in. 0.0059 in.
Idle Gear to Injection Pump Gear Backlash 0.0415 to 0.1154 mm 0.15 mm

0.00163 to 0.00454 in. 0.0059 in.
Crank Gear to Oil Pump Gear Backlash 0.0415 to 0.1090 mm 0.15 mm

0.00163 to 0.00429 in. 0.0059 in.
Idle Gear to Balancer Gear Backlash 0.0350 to 0.1160 mm 0.15 mm

(Balancer Model Only) 0.00138 to 0.00457 in. 0.0059 in.
Cam Gear to Balancer Gear Backlash 0.0350 to 0.1160 mm 0.15 mm

Crank Gear to Idle Gear 2 Backlash 0.0415 to 0.1154 mm 0.15 mm

(Side PTO Model Only) 0.00163 to 0.00454 in. 0.0059 in.
Idle Gear 2 to Hydraulic Pump Drive Gear Backlash 0.0308 to 0.1062 mm 0.15 mm
(Side PTO Model Only) 0.00121 to 0.00418 in. 0.0059 in.
Idle Gear Side Clearance 0.12 to 0.48 mm 0.9 mm
0.0047 to 0.0189 in. 0.0354 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.025 to 0.066 mm 0.10 mm
0.00098 to 0.00260 in. 0.0039 in.
Idle Gear Shaft O.D. 37.959 to 37.975 mm –

1.49445 to 1.49508 in.
Idle Gear Bushing I.D. 38.000 to 38.025 mm –

1.49606 to 1.49705 in.
Camshaft Side Clearance 0.07 to 0.22 mm 0.30 mm
0.0028 to 0.0087 in. 0.0118 in.
Camshaft Alignment – 0.01 mm
0.0004 in.
Cam Height (Intake) 33.27 mm 33.22 mm
[D1503-M-DI] 1.3098 in. 1.3079 in.
Height (Exhaust) 33.47 mm 33.42 mm

1.3177 in. 1.3157 in.
Cam Height (Intake) 33.90 mm 33.85 mm

[D1503-M-DI-T] 1.3346 in. 1.3327 in.
[D1703-M-DI]
[D1803-M-DI] Height (Exhaust) 33.47 mm 33.42 mm
[V2003-M-DI-T] 1.3177 in. 1.3157 in.
[V2203-M-DI]
[V2403-M-DI]
[V2403-M-DI-T]
W1014959


Camshaft Journal to Cylinder Block Bore Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.00197 to 0.00358 in. 0.0059 in.
Camshaft Journal O.D. 39.934 to 39.950 mm –

1.57221 to 1.57284 in.
Cylinder Block Bore I.D. 40.000 to 40.025 mm –

1.57480 to 1.57579 in.
Balancer Shaft Side Clearance 0.07 to 0.22 mm 0.30 mm
Balancer Shaft Alignment – 0.02 mm
(Balancer Model Only) 0.0008 in.
Balancer Shaft Journal 1 to Balancer Shaft Oil Clearance 0.030 to 0.111 mm 0.20 mm
Bearing 1 (Balancer Model Only) 0.00118 to 0.00437 in. 0.0079 in.
Balancer Shaft Journal 1 O.D. 43.934 to 43.950 mm –

1.72969 to 1.73032 in.
Balancer Shaft Bearing 1 I.D. 43.980 to 44.045 mm –

1.73150 to 1.73406 in.

1.65095 to 1.65158 in.

1.65276 to 1.65532 in.

0.86406 to 0.86457 in.

0.86535 to 0.86776 in.
Piston Pin Bore I.D. 25.000 to 25.013 mm 25.05 mm
0.98425 to 0.98476 in. 0.9862 in.
Top Ring to Ring Groove Clearance 0.050 to 0.090 mm 0.20 mm
[D1703-M-DI] 0.0020 to 0.0035 in. 0.0079 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
Second Ring to Ring Groove Clearance 0.093 to 0.128 mm 0.20 mm
[D1503-M-DI] 0.0037 to 0.0050 in. 0.0079 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
[V2403-M-DI-T]
W1015276


Second Ring to Ring Groove Clearance 0.078 to 0.110 mm 0.20 mm
[D1703-M-DI] 0.0031 to 0.0043 in. 0.0079 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm 0.15 mm
[D1503-M-DI] 0.0008 to 0.0024 in. 0.0059 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
[V2403-M-DI-T]
Oil Ring to Ring Groove Clearance 0.030 to 0.070 mm 0.15 mm
[D1703-M-DI] 0.0012 to 0.0028 in. 0.0059 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
Top Ring Ring Gap 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Second Ring Ring Gap 0.40 to 0.55 mm 1.25 mm
[D1503-M-DI] 0.0157 to 0.0217 in. 0.0492 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
[V2403-M-DI-T]
Second Ring Ring Gap 0.30 to 0.45 mm 1.25 mm
[D1703-M-DI] 0.0118 to 0.0177 in. 0.0492 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
Oil Ring Ring Gap 0.25 to 0.45 mm 1.25 mm
[D1503-M-DI] 0.0098 to 0.0177 in. 0.0492 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
[V2403-M-DI-T]
Oil Ring Ring Gap 0.20 to 0.40 mm 1.25 mm
[D1703-M-DI] 0.0079 to 0.0157 in. 0.0492 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
Connecting Rod Alignment – 0.05 mm
0.0020 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.15 mm
0.00055 to 0.00150 in. 0.0059 in.
Piston Pin O.D. 25.002 to 25.011 mm –

0.98433 to 0.98469 in.
Small End Bushing I.D. 25.025 to 25.040 mm –

0.98524 to 0.98583 in.
Crankshaft Alignment – 0.02 mm
0.00079 in.
W1013874


Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.040 to 0.118 mm 0.20 mm
1 0.00157 to 0.00465 in. 0.0079 in.
Crankshaft Journal O.D. 59.921 to 59.940 mm –

2.35910 to 2.35984 in.
Crankshaft Bearing 1 I.D. 59.980 to 60.039 mm –

2.36142 to 2.36374 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.040 to 0.104 mm 0.20 mm
2 0.00157 to 0.00409 in. 0.0079 in.
Crankshaft Journal O.D. 59.921 to 59.940 mm –

2.35910 to 2.35984 in.
Crankshaft Bearing 2 I.D. 59.980 to 60.025 mm –

2.36142 to 2.36319 in.
Crankpin to Crankpin Bearing Oil Clearance 0.025 to 0.087 mm 0.20 mm
0.00098 to 0.00343 in. 0.0079 in.
Crankpin O.D. 46.959 to 46.975 mm –

1.84878 to 1.84941 in.
Crankpin Bearing I.D. 47.000 to 47.046 mm –

1.85039 to 1.85221 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.5 mm
0.0059 to 0.0122 in. 0.0197 in.
Cylinder Bore (Standard) I.D. 83.000 to 83.022 mm 83.150 mm
[D1503-M-DI] 3.26772 to 3.26858 in. 3.2736 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
Cylinder Bore (Standard) I.D. 87.000 to 87.022 mm 87.150 mm
[D1703-M-DI] 3.42520 to 3.42606 in. 3.4311 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
[V2403-M-DI-T]
Cylinder Bore (Oversize) I.D. 83.250 to 83.272 mm 83.400 mm
[D1503-M-DI] 3.27756 to 3.27843 in. 3.2835 in.
[D1503-M-DI-T]
[V2003-M-DI-T]
Cylinder Bore (Oversize) I.D. 87.250 to 87.272 mm 87.400 mm
[D1703-M-DI] 3.43504 to 3.43591 in. 3.4409 in.
[D1803-M-DI]
[V2203-M-DI]
[V2403-M-DI]
[V2403-M-DI-T]
W1013874

LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed More than 98 kPa 49 kPa
1.0 kgf/cm2 0.5 kgf/cm2
14 psi 7 psi
At Rated Speed 294 to 441 kPa 245 kPa

3.0 to 4.5 kgf/cm2 2.5 kgf/cm2
42.7 to 64.0 psi 35.6 psi
Engine Oil Pressure Switch Working 49 kPa –
Pressure 0.5 kgf/cm2
7 psi
Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm 0.2 mm
0.0012 to 0.0055 in. 0.0079 in.
Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm 0.25 mm
0.0043 to 0.0075 in. 0.0098 in.
Inner Rotor to Cover Clearance 0.105 to 0.150 mm 0.20 mm
0.00413 to 0.00591 in. 0.0079 in.
W1013973
COOLING SYSTEM
Fan Belt Tension 7.0 to 9.0 mm –
(0.28 to 0.35 in.)
deflection at
98 N (10 kgf, 22 lbf)
of force
Thermostat Valve Opening 80.5 to 83.5 °C –
Temperature 176.9 to 182.3 °F
(At Beginning)
Valve Opening 95 °C –
Temperature 203 °F
(Opened
Completely)
Radiator Water Tightness No leak at –
137 kPa
1.4 kgf/cm2
20 psi
Radiator Cap Pressure Falling More than 10 seconds –
Time for pressure fall
from 88 to 59 kPa
from 0.9 to 0.6 kgf/cm2
from 13 to 9 psi
W1013874

FUEL SYSTEM
Injection Pump
Injection Timing 0.113 to 0.140 rad (6.50 –
(D1503-M-DI) to 8.00 °) before T.D.C.

(D1503-M-DI-T) to 8.50 °) before T.D.C.


(V2403-M-DI-T)

(V2203-M-DI) to 8.95 °) before T.D.C.

(V2003-M-DI-T) to 10.00 °) before T.D.C.

(V2403-M-DI) to 7.25 °) before T.D.C.
Pump Element Fuel Tightness – 18.63 MPa
190 kgf/cm2
2702 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
18.63 → 17.65 MPa 18.63 → 17.65 MPa
190 → 180 kgf/cm2 190 → 180 kgf/cm2
2702 → 2560 psi 2702 → 2560 psi
Injection Nozzle Injection Pressure 18.6 to 20.1 MPa –
(1st stage) 190 to 205 kgf/cm2
2702 to 2916 psi
Injection Nozzle Valve Seat Valve Seat When the pressure is –
Tightness 16.67 MPa
(170 kgf/cm2, 2418 psi),
the valve seat must be
fuel tightness.
W1013973

ELECTRICAL SYSTEM
Starter
Commutator O.D. 30.0 mm 29.0 mm
[D1503-M-DI] 1.181 in. 1.142 in.
[D1503-M-DI-T]
[D1703-M-DI]
[D1803-M-DI]
[V2203-M-DI]
[V2003-M-DI-T]

[V2403-M-DI] 1.378 in. 1.339 in.

[V2403-M-DI-T] 1.417 in. 1.378 in.
Mica Under Cut 0.45 to 0.75 mm 0.20 mm

[D1503-M-DI] 0.0177 to 0.0295 in. 0.0079 in.
[D1503-M-DI-T]
[D1703-M-DI]
[D1803-M-DI]
[V2203-M-DI]
[V2003-M-DI-T]
[V2403-M-DI]
Mica Under Cut 0.70 to 0.90 mm 0.20 mm

[V2403-M-DI-T] 0.0276 to 0.0354 in. 0.0079 in.
Brush Length 15.0 mm 11.0 mm

[D1503-M-DI] 0.591 in. 0.433 in.
[D1503-M-DI-T]
[D1703-M-DI]
[D1803-M-DI]
[V2203-M-DI]
[V2003-M-DI-T]

[V2403-M-DI] 0.591 in. 0.354 in.

[V2403-M-DI-T] 0.807 in. 0.630 in.
Brush Holder and Holder Support Resistance Infinity –

Alternator No-load voltage More than 13.5 V –
Stator Resistance Less than 1.0 Ω –
Rotor Resistance 2.9 Ω –
Slip Ring O.D. 14.4 mm 14.0 mm

0.567 in. 0.551 in.

0.413 in. 0.331 in.
Glow Plug Resistance Approx. 0.9 Ω –
W1013874

3. TIGHTENING TORQUES
Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS AND

NUTS
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
Grade Standard Screw and Bolt Special Screw and Bolt
Nominal Unit
Diameter N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
W10371750
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to
tightening, be sure to check out the numbers as shown below.
Punched number Screw and bolt material grade
None or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)
W1012705

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS
Q NOTE
• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two
threads.
Item Size x Pitch N·m kgf·m lbf·ft
Cylinder head cover screw M6 x 1.0 6.9 to 11.3 0.7 to 1.15 5.1 to 8.32
*Cylinder head screw M11 x 1.25 93.2 to 98.1 9.5 to 10.0 68.7 to 72.3
*Main bearing case screw 1 M9 x 1.25 46.1 to 51.0 4.7 to 5.2 34.0 to 37.6
*Main bearing case screw 2 M10 x 1.25 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2
*Flywheel screw M12 x 1.25 98.1 to 107.9 10.0 to 11.0 72.3 to 79.6
*Connecting rod screw M8 x 1.0 44.1 to 49.0 4.5 to 5.0 32.5 to 36.2
*Rocker arm bracket screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Idle gear shaft screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Fan drive pulley mounting nut M30 x 1.5 137.3 to 156.9 14.0 to 16.0 101.3 to 115.7
*Bearing case cover mounting screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Glow plug M10 x 1.25 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Nozzle holder clamp screw M10 x 1.25 25.5 to 29.4 2.6 to 3.0 18.8 to 21.7
Oil pressure switch R 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
Injection pipe retaining nut M12 x 1.5 14.7 to 24.5 1.5 to 2.5 10.8 to 18.1
Overflow pipe assembly retaining screw M6 x 1.0 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
Camshaft set screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
Hi-idling body M14 x 1.0 44.1 to 49.0 4.5 to 5.0 32.5 to 36.2
Balancer shaft set bolt
M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
(Balancer model only)
Alternator’s pulley nut – 58.3 to 78.9 5.95 to 8.05 43.0 to 58.2
Idle gear 2 stopper set screw
– 49.0 to 55.9 5.0 to 5.7 36.2 to 41.2
(Side PTO model only)
Idle gear 2 shaft set screw
– 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
(Side PTO model only)
Starter’s terminal B mounting nut M8 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7
W1013236

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine and disconnect the 2P connector from the stop
solenoid in order not to inject fuel.
3. Remove the air cleaner, the muffler and all glow plugs.
4. Set a compression tester (07909-39081) with the adaptor K
(07909-31291) to the glow plug hole.
5. While cranking the engine with the starter, measure the
compression pressure.
6. Repeat steps 4 through 5 for each cylinder.
Q NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
2.94 to 3.24 MPa
427 to 469 psi
Compression pressure
2.35 MPa
341 psi
W1018639

Valve Clearance
Q IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the head cover.
2. Align the “1TC” mark line (3) on the flywheel and projection (2)
on the housing so that the No.1 piston comes to the compression
or overlap top dead center.
3. Check the following valve clearance (1) marked with “,” using a
feeler gauge.
4. If the clearance is not within the factory specifications, adjust with
the adjusting screw.
0.18 to 0.22 mm
Valve clearance Factory spec.
0.0071 to 0.0087 in.
Q NOTE
• The “TC” marking line on the flywheel is just for No. 1
cylinder. There is no “TC” marking for the other cylinders.
• No. 1 piston comes to the top dead center position when the
“TC” marking is aligned with the projection (2) in the window
on flywheel-housing. Turn the flywheel 0.26 rad (15°)
clockwise and counterclockwise to see if the piston is at the
compression top dead center or the overlap position. Now
referring to the table below, readjust the valve clearance (1).
(The piston is at the top dead center when both the IN. and
EX. valves do not move; it is at the overlap position when
both the valves move.)
• Finally turn the flywheel 6.28 rad (360°) and align the “TC”
marking and the projection (2) perfectly. Adjust all the other
valve clearance as required.
• After turning the flywheel counterclockwise twice or three
times, recheck the valve clearance (1).
• After adjusting the valve clearance (1), firmly tighten the lock
nut of the adjusting screw.
Valve D1503-M-DI V2203-M-DI
arrangement D1503-M-DI-T V2003-M-DI-T
Adjustable D1703-M-DI V2403-M-DI
cylinder D1803-M-DI V2403-M-DI-T
location of piston IN. EX. IN. EX.
No. 1 , , , ,
When No. 1 piston
comes to No. 2 , ,
compression top No. 3 , ,
dead center
No. 4 – –
No. 1
When No. 1 piston No. 2 , ,
comes to overlap
position No. 3 , ,
No. 4 – – , ,
(1) Valve Clearance (3) TC Mark Line

(2) Projection
W10249750

(2) Lubricating System

Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil pressure
tester (Code No.: 07916-32032). (Adaptor screw size : PT 1/8)
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient.
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
More than 98 kPa
Factory
1.0 kgf/cm2
spec.
At idle 14 psi
speed 49 kPa
Allowable
0.5 kgf/cm2
limit
7 psi
Engine oil pressure
294 to 441 kPa
Factory
3.0 to 4.5 kgf/cm2
spec.
At rated 42.7 to 64.0 psi
speed 245 kPa
Allowable
2.5 kgf/cm2
limit
35.6 psi
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
14.7 to 19.6 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
10.8 to 14.5 lbf·ft
W1034952

(3) Cooling System

Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosen
the alternator mounting screws and relocate the alternator to
adjust.
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
(A) Deflection
W10356670
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good (B) Bad
W1020602

CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester and an adaptor on the radiator cap.
2. Apply the specified pressure 88 kPa (0.9 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm2,
9 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
More than 10 seconds
for pressure fall from
Pressure falling time Factory spec. 88 to 59 kPa
(from 0.9 to 0.6 kgf/cm2,
from 13 to 9 psi)
W10387530
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester and an adaptor and raise the water pressure
to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, replace the radiator or repair with
the radiator cement. When water leak is excessive, replace the
radiator.
No leak at 137 kPa
Radiator water leakage
Factory spec. 1.4 kgf/cm2
test pressure
20 psi
W10389070
Thermostat Valve Opening Temperature
1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 6 mm (0.236 in.).
replace the thermostat.
Thermostat’s valve 80.5 to 83.5 °C
Factory spec.
opening temperature 176.9 to 182.3 °F
Temperature at which
95 °C
thermostat completely Factory spec.
203 °F
opens
W1035849

(4) Fuel System

Injection Timing
1. Remove the stop solenoid.
2. Remove the injection pipes and nozzle.
3. Set the speed control lever to maximum fuel discharge position.
(Reference)
• Turn the flywheel with screwdriver.
4. Turn the flywheel counterclockwise (facing the flywheel) until the
fuel fills up to the hole of the delivery valve holder for 1st cylinder.
5. Turn the flywheel further and stop turning when the fuel begins to
flow over, to get the present injection timing.
6. (The flywheel has mark 1TC and four lines indicating every 0.087
rad (5 °) of crank angle from 0.175 rad (10 °) to 0.436 rad (25 °)
before mark 1TC) Calculate the angle which the center of the
window points out. If the calculation differs from specified
injection timing, add or remove the shim to adjust.
(Injection Timing)
Model Injection Timing
D1503-M-DI 0.113 to 0.140 rad (6.50 ° to 8.00 °) before T.D.C.
D1503-M-DI-T 0.122 to 0.148 rad (7.00 ° to 8.50 °) before T.D.C.
D1703-M-DI 0.121 to 0.147 rad (6.95 ° to 8.45 °) before T.D.C.
D1803-M-DI
0.083 to 0.109 rad (4.75 ° to 6.25 °) before T.D.C.
V2403-M-DI-T
V2203-M-DI 0.130 to 0.156 rad (7.45 ° to 8.95 °) before T.D.C.
V2003-M-DI-T 0.148 to 0.175 rad (8.50 ° to 10.00 °) before T.D.C.
V2403-M-DI 0.100 to 0.127 rad (5.75 ° to 7.25 °) before T.D.C.
Q NOTE
• The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.175 mm (7), 0.20 mm
(3), 0.25 mm (4), 0.30 mm (5) and 0.35 mm (6). Combine these
shims for adjustments.
• The 0.175 mm thick shim is coated only the lower face.
Therefore, do not use the 0.175 mm thick shim as the top
shim of the combination (injection pump side), because this
can cause oil leakage.
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
advances the injection timing by approx. 0.0087 rad (0.5 °).
• In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Delivery Valve Holder (A) 3 Cylinder
(2) Timing Mark (B) 4 Cylinder
(3) 2-Holes: 0.20 mm (Shim)
(4) 1-hole: 0.25 mm (Shim)
(5) Without hole: 0.30 mm (Shim)
(6) 3-Holes: 0.35 mm (Shim)
(7) 2-Holes: 0.175 mm (Shim)
W1036402

Fuel Tightness of Pump Element

3. Install the injection pump pressure tester to the injection pump.
pressure to the injection pump pressure tester (1). (Refer to the
figure.)
5. Set the speed control lever to the maximum speed position.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
18.63 MPa
Fuel tightness of pump
element
2702 psi
Q NOTE
W1017430
Fuel Tightness of Delivery Valve
3. Set a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by the hand and raise the pressure to
approx. 18.63 MPa (190 kgf/cm2, 2702 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger
free). Maintain the flywheel at this position and clock the time
taken for the pressure to drop from 18.63 to 17.65 MPa (from 190
to 180 kgf/cm2, from 2702 to 2560 psi).
8. Measure the time needed to decrease the pressure from 18.63 to
17.65 MPa (from 190 to 180 kgf/cm2, from 2702 to 2560 psi).
9. If the measurement is less than allowable limit, replace the pump
with new one or repair with a Kubota-authorized pump service
shop.
10 seconds
18.63 → 17.65 MPa
Factory spec.
190 → 180 kgf/cm2
Fuel tightness of 2702 → 2560 psi
delivery valve 5 seconds
18.63 → 17.65 MPa
Allowable limit
190 → 180 kgf/cm2
2702 → 2560 psi
Q NOTE
W1017786

CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly.
(a) Good (b) Bad
W10226470
Fuel Injection Pressure

2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
replace the injection nozzle assembly.
18.6 to 20.1 MPa
Fuel injection pressure
(1st stage)
2702 to 2916 psi
W10227280
Valve Seat Tightness

2. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly.
No fuel leak at
16.67 MPa
Valve seat tightness Factory spec.
170 kgf/cm2
2418 psi
W10228300

(5) Electrical System
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
Q IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal (2) Negative Terminal

W10125620

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
Q NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1019017

Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is failure.
Repair or replace the starter.
Q NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal (3) Negative Terminal
(2) Positive Terminal
W1019297
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.
Q NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• S terminal : It is the terminal which connects the cable from
the starter switch to the magnet switch.
(1) S Terminal (3) Negative Terminal
(2) Positive Terminal
0000010743E
Magnet Switch Continuity Test
1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.
2. If not continuous or if a certain value is indicated, replace the
magnet switch.
(1) C Terminal (2) B Terminal
0000010771E

Alternator on Unit Test

(Before testing)
• Before alternator on unit test, check the battery terminal
connections, circuit connection, fan belt tension, charging
indicator lamp, fuses on the circuit, and abnormal noise from the
alternator.
• Prepare full charged battery for the test.
Q NOTE
• Be careful not to touch the rotating engine parts while
engine is running.
Keep safety distance from the engine rotating parts.
1. Start the engine.
2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator is operating normally.
3. If the results of alternator on unit test are not within the
specifications, disassemble the alternator and check the each
component part for finding out the failure. See the
“DISASSEMBLING AND ASSEMBLING” and “SERVICING” for
alternator.
Regulating voltage at no 13.8 to 14.8 V
Factory spec.
load at 25 °C (77 °F)
0000010745E
Glow Plug Lead Terminal Voltage
1. Turn the key switch to the “GLOW (or PREHEAT)” position, and
measure the voltage with a circuit tester between the lead
terminal and the engine body.
2. If the voltage differs from the battery voltage, the wiring harness
or main switch is faulty.
Main switch key at
Voltage GLOW Approx. battery voltage
(or PREHEAT)
0000010725E
Glow Plug Continuity

1. Remove the glow plug.
2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.
3. If the factory specification is not indicated, glow plug is faulty.
Resistance Factory spec. Approx. 0.9 Ω
0000010726E

Engine Stop Solenoid

1. Remove the engine stop solenoid from the engine.
2. Connect the jumper leads from the pulling coil P terminal to the
switch (3), and from switch (3) to the battery positive terminal.
3. Connect the jumper leads from the holding coil H terminal to the
switch (4), and from switch (4) to the battery positive terminal.
4. Connect the jumper leads from the engine stop solenoid body to
the battery negative terminal.
5. When switch (4) is turn on, the plunger pull into the solenoid body
and then turn off the switch (4), the plunger comes out.
6. Turn on the switch (3) then turn on the switch (4), the plunger pull
into the solenoid body and it keep in holding position after turn off
the switch (4).
7. If the plunger is not attracted, the engine stop solenoid is faulty.
Q IMPORTANT
• Never apply the current for pulling coil more than two
seconds when inspecting.
(1) Connector P : Terminal for Pulling Coil
(2) Battery H : Terminal for Holding Coil
(3) Switch for Holding Coil
(4) Switch for Pulling Coil
W1020600
(6) Turbocharger
Turbine Side
1. Check the exhaust port (2) and inlet port (3) side of the turbine
housing (1) to see if there is no exhaust gas leak.
2. If any gas leak is found, retighten the bolts and nuts or replace
the gasket with new one.
(1) Turbine Housing (3) Inlet Port
(2) Exhaust Port
W1069824
Compressor Side
1. Check the inlet hose (1) of the compressor cover (2) to see if
there is no air leak.
2. Check for loose connections or cracks in the suction side of the
intake hose.
3. If any air leak is found, change the clamp (3) and / or inlet hoses.
(1) Inlet Hose (3) Clamp
(2) Compressor Cover
W1069939
Radial Clearance
1. If the wheel contact to the housing, replace the turbocharger
assembly with new one.
W1077353

[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Oil and Coolant
Draining Engine Oil
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug.
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (2).
Q IMPORTANT
temperature.
W1028998
Draining Coolant
CAUTION
• Never remove radiator cap while operating or immediately
after stopping. Otherwise, hot water will spout out from the
radiator. Wait for more than ten minutes to cool the radiator,
before opening the cap.
1. Prepare a bucket. Open the coolant drain cock.
(1) Coolant Drain Cock
W1029172
(2) External Components

Air Cleaner, Muffler and Others
1. Remove the air cleaner and muffler.
2. Remove the fan (1), fan belt (4), alternator (2) and starter (3).
(When reassembling)
• Check to see that there are no cracks on the belt surface.
Q IMPORTANT
• After reassembling the fan belt, be sure to adjust the fan belt
tension.
• Do not confuse the direction of the fan.
(1) Fan (3) Starter
(2) Alternator (4) Fan Belt
W1060302

Turbocharger (equipped with Turbocharger Model)
CAUTION
• While the engine is running and or just after it stops, the
turbocharger is hot, be careful not to touch the
turbocharger.
Q NOTE
• When detaching and attaching the turbocharger assembly,
be very careful not to allow dust, dirt and other foreign
matters in the oil pipes.
• When the turbocharger assembly has been replaced, pour
fresh engine oil through the oil filter port of the
turbocharger.
• Before starting the engine, make sure that the air cleaner is
in position.
1. Disconnect the inlet hose (1).
2. Remove the joint bolt (2), (7) and take off the oil pipe 1 (8).
3. Remove the bolts 1 (3) and release the clamp (5).
4. Disconnect the oil pipe 2 (4) and pipe 3 (6).
5. Remove the bolts 2 (10).
6. Take off the turbocharger assembly (9).
(When reassembling)
• Pour fresh engine oil through the oil filter port of the turbocharger.
• Replace the gaskets with new one.
• Be careful not to allow dust, dirt and other foreign matters in the
oil pipes.
Q NOTE
• Tape or plug all opening to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1) Inlet Hose (6) Oil Pipe 3
(2) Joint Bolt (7) Joint Bolt
(3) Bolt 1 (8) Oil Pipe 1
(4) Oil Pipe 2 (9) Turbocharger Assembly
(5) Clamp (10) Bolt 2
W1021474

(3) Cylinder Head and Valves

Cylinder Head Cover
1. Remove the lead (4).
2. Remove the breather hose (1).
3. Remove the head cover screws (3).
4. Remove the cylinder head cover (2).
(When reassembling)
• Check to see if the cylinder head cover gasket (5) is not
defective.
6.9 to 11.3 N·m
Tightening torque Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 lbf·ft
(1) Breather Hose (5) Cylinder Head Cover Gasket

(2) Cylinder Head Cover (6) Breather Valve
(3) Head Cover Screw (7) Plate
(4) Lead
W1060460
Injection Pipes
1. Loosen the screws on the pipe clamps (2).
2. Detach the injection pipes (1).
(When reassembling)
• Blow out dust inside the pipes.
14.7 to 24.5 N·m
Tightening torque Injection pipe retaining nut 1.5 to 2.5 kgf·m
10.8 to 18.1 lbf·ft
(1) Injection Pipe (2) Pipe Clamp

W1060970

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly.
2. Remove the nozzle holder assemblies (2).
3. Remove the glow plugs (1).
(When reassembling)
• Replace the copper gasket with new one.
25.5 to 29.4 N·m
Nozzle holder clamp screw 2.6 to 3.0 kgf·m
18.8 to 21.7 lbf·ft
9.8 to 11.3 N·m
Overflow pipe assembly
Tightening torque 1.00 to 1.15 kgf·m
retaining screw
7.23 to 8.32 lbf·ft
19.6 to 24.5 N·m
Glow plug 2.0 to 2.5 kgf·m
14.5 to 18.1 lbf·ft
(1) Glow Plug (2) Nozzle Holder Assembly

W1020917
Rocker Arm and Push Rod
1. Remove the rocker arm bracket screws.
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2).
(When reassembling)
• When putting the push rods (2) onto the tappets (3), check to see
if their ends are properly engaged with the grooves.
Q IMPORTANT
• After installing the rocker arm, be sure to adjust the valve
clearance.
23.5 to 27.5 N·m
Tightening torque Rocker arm bracket screw 2.4 to 2.8 kgf·m
17.4 to 20.3 lbf·ft
(1) Rocker Arm Assembly (3) Tappet

(2) Push Rod
W1021437

Cylinder Head
1. Loosen the pipe clamp (2), and remove the water return pipe (1).
2. Remove the cylinder head screw in the order of (n or r) to (a).
3. Lift up the cylinder head (3) to detach.
4. Remove the cylinder head gasket (4).
(When reassembling)
• Replace the cylinder head gasket (4) with a new one.
• Tighten the cylinder head screws after applying sufficient oil.
• Tighten the cylinder head screws in diagonal sequence starting
from the center in the order of (a) to (n or r).
• Tighten them uniformly, or the head may deform in the long run.
93.2 to 98.1 N·m
Tightening torque Cylinder head screw 9.5 to 10.0 kgf·m
68.7 to 72.3 lbf·ft
Q IMPORTANT
• To replace the cylinder head gasket (4), in advance make
sure the marking (5) of cylinder head gasket in the original
engine, and replace the same marking as the original
cylinder head gasket.
Gasket Model
Marking & V2203-M-DI
Code D1503-M-DI D1703-M-DI
V2003-M-DI-T V2403-M-DI
Number D1503-M-DI-T D1803-M-DI
V2403-M-DI-T
15 1G720-03600 1G750-03600 1G770-03600 1G790-03600
20 1G720-03310 1G750-03310 1G770-03310 1G790-03310
25 1G720-03610 1G750-03610 1G770-03610 1G790-03610
30 1G720-03620 1G750-03620 1G770-03620 1G790-03620
35 1G720-03630 1G750-03630 1G770-03630 1G790-03630
(1) Return Pipe (n or r) to (a): To Loosen

(2) Pipe Clamp (a) to (n or r): To Tighten
(3) Cylinder Head (A) Gear Case Side
(4) Cylinder Head Gasket (B) Flywheel Side
(5) Marking
W1021755

Cylinder Head (Continued)

Q IMPORTANT
• When replacing piston, piston pin, small end bushing,
connecting rod, or crankpin bearings, measure piston
head’s protrusion or recessing from the level of crankcase
cylinder face (average of 4 pistons) after installing the
pistons, and select the cylinder head gasket following the
below table.
Selecting the cylinder head gasket
1. Measure the piston head’s protrusion or recessing from the
crankcase cylinder face 4 spots per each piston (average of four
pistons) using the dial gauge.
2. Select the suitable cylinder need gasket refer to the table below.
Gasket Size (Number) Piston Protrusion
0.475 to 0.525 mm
15
0.0187 to 0.0207 in.
0.525 to 0.575 mm
20
0.0207 to 0.0226 in.
0.575 to 0.625 mm
25
0.0226 to 0.0246 in.
0.625 to 0.675 mm
30
0.0246 to 0.0266 in.
0.675 to 0.725 mm
35
0.0266 to 0.0285 in.
(6) Measuring Points

W1085632
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.
• Before installing the tappets, apply engine oil thinly around them.
Q IMPORTANT
• Do not change the combination of tappet and tappet guide.
(1) Tappet
W1022001
Valves
1. Remove the valve caps (3).
2. Remove the valve spring collet (4), pushing the valve spring
retainer (5) by valve spring replacer (1).
3. Remove the valve spring retainer (5), valve spring (6) and valve
stem seal (2).
4. Remove the valve (7).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets (4), lightly tap the stem to
assure proper fit with a plastic hammer.
Q IMPORTANT
• Do not change the combination of valve and valve guide.
(1) Valve Spring Replacer (5) Valve Spring Retainer
(2) Valve Stem Seal (6) Valve Spring
(3) Valve Cap (7) Valve
(4) Valve Spring Collet
W1022102

Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the thermostat cover gasket (2).
• Apply a liquid gasket (Three Bond 1215 or equivalent) to the
thermostat flange 1 (4) and flange 2 (5)
(1) Thermostat Cover (4) Water Flange 1
(2) Thermostat Cover Gasket (5) Water Flange 2
(3) Thermostat Assembly
W1105115

(4) Gear Case and Timing Gears

Injection Pump (for Non Turbocharger Model)
1. Remove the stop solenoid (4) and hi-idling body (1).
2. Remove the engine stop lever (3) and stop solenoid guide (6).
3. Remove the fuel injection pump assembly (2).
Q IMPORTANT
• Before removing the injection pump assembly (2), be sure to
remove the stop solenoid (4), hi-idling body (1), engine stop
lever (3) and stop solenoid guide (6).
(When reassembling)
• Before attaching the stop solenoid (4), hi-idling body (1) and stop
solenoid guide (6), install the injection pump first into position.
• Replace the hi-idling body gasket (5) with a new one.
• Before fitting the stop lever (3) to the gear case, install the stop
solenoid guide (6) first into position. Then attach the stop lever
and use it to see if it functions well.
• Before fitting the idling limiter in place, attach the stop solenoid
guide (6) and the engine stop lever (3) in their respective
positions.
• When installing the stop solenoid (4), be careful to keep the O-
ring in place.
• Be sure to insert the push rod of the stop solenoid into the hole
at the center of the solenoid guide (6).
44.1 to 49.0 N·m
Tightening torque Hi-idling body 4.5 to 5.0 kgf·m
32.5 to 36.2 lbf·ft
(1) Hi-idling Body (4) Stop Solenoid

(2) Injection Pump Assembly (5) Hi-idling Body Gasket
(3) Stop Lever (6) Stop Solenoid Guide
W1023686

Injection Pump (for Turbocharger Model)

1. Remove the stop solenoid (3).
2. Remove the hi-idling body (4).
Q NOTE
• Do not remove the boost compensator assembly (2) from
gear case.
3. Check to see if the stop solenoid guide (6) touches boost lever
(5). If not, push the control rack from the mounting hole of hi-
idling body to make the solenoid guide (6) touched boost lever
(5). (See figure.)
4. Remove the injection pump assembly (1).
Q IMPORTANT
• Before removing the injection pump assembly (1), be sure to
remove the stop solenoid (3) and hi-idling body (4). And
check to see if the stop solenoid guide (6) touches boost
lever (5).
(1) Injection Pump Assembly (4) Hi-idling Body
(2) Boost Compensator Assembly (5) Boost Lever
(3) Stop Solenoid (6) Stop Solenoid Guide
W1032355

Injection Pump (for Turbocharger Model) (Continued)

(When reassembling)
• Check to see if the stop solenoid guide (6) touches boost lever
(5). If not, push the solenoid guide (6) to make the solenoid guide
(6) touched boost lever (5). (See figure [A].)
• Install the injection pump assembly into position.
• Tighten the injection pump assembly mounting bolts and nuts
with specified torque.
1. Install the hi-idling body and new gasket, and tighten them with
specified torque.
2. Install the stop solenoid and tighten it with specified torque.
44.1 to 49.0 N·m
Tightening torque Hi-idling body 4.5 to 5.0 kgf·m
32.5 to 36.2 lbf·ft
(5) Boost Lever [A] Correct

(6) Stop Solenoid Guide [B] Incorrect
W1032914

Governor Springs and Speed Control Plate

Q NOTE
• Specific tool (1) :
1.2 mm diameter hard wire with its end hooked, overall
length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang governor
springs.
1. Remove the injection pump cover.
2. Remove the speed control plate (6) mounting nuts and bolts.
3. Using the specific tool (1), undo the large governor spring (3)
from the fork lever (2).
4. Using the specific tool (1), undo the small governor spring (4)
from the fork lever (2).
5. Set the speed control lever (5) as shown in the figure.
6. Take out the speed control plate (6) with care not to let the large
(3) and small (4) governor springs come off this plate and fall in
to the gear case.
(1) Specific Tool (4) Small Governor Spring

(2) Fork Lever (5) Speed Control Lever
(3) Large Governor Spring (6) Speed Control Plate
W1148604

Governor Springs and Speed Control Plate (Continued)

(When reassembling)
• Hook the small spring (4) first and then the large governor spring
(3) on the speed control plate (6).
• Put the specific tool (1) from the injection pump side to catch the
large governor spring (3). Keep this spring slightly extended and
place the speed control plate (6) in its specified position.
• Using the specific tool (1), hook the small governor spring (4)
onto the fork lever (2).
Q NOTE
• Be careful not to stretch the small governor spring (4) too
long because otherwise it may get deformed permanently.
• Using the specific tool (1), hook the large governor spring (3)
onto the fork lever (2).
• Make sure both the governor springs (3), (4) are tight on the
fork lever (2).
• Apply and tighten up the two bolts and two nuts on the
speed control plate (6).
• Check that the speed control lever (5) positions low idle,
after assembling governor springs.
• Check that the speed control lever (5) returns to the high idle
position rather than the low idle position, after moving the
lever to the maximum speed position.
• Finally attach the injection pump cover in position.
(1) Specific Tool (4) Small Governor Spring

(2) Fork Lever (5) Speed Control Lever
(3) Large Governor Spring (6) Speed Control Plate
W1152334

Fan Drive Pulley

1. Lock the flywheel not to turn using the flywheel stopper.
2. Remove the fan drive pulley mounting nut (1) using 46 mm deep
socket wrench (3).
3. Remove the fan drive pulley (2) with gear puller (4).
4. Remove the feather key.
(When reassembling)
• Apply grease to the splines of coupling.
137.3 to 156.9 N·m
Fan drive pulley mounting
nut
101.3 to 115.7 lbf·ft
(1) Nut (3) 46 mm Deep Socket Wrench

(2) Fan Drive Pulley (4) Gear Puller
W1024348

Idle Gear 2 and Hydraulic Pump Base Assembly

(for Side PTO Model)
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case cover (1).
3. Remove the hydraulic pump base assembly (2).
4. Remove the idle gear 2 stopper (3).
5. Remove the idle gear 2 (4) using the puller (5).
6. Remove the idle gear 2 shaft (7).
(When reassembling)
• Replace the washer (6) and gear case cover gasket.
• Apply liquid gasket (Three Bond 1215 or equivalent) to both side
of hour meter gear case gasket.
23.5 to 27.5 N·m
Idle gear 2 shaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 lbf·ft
Tightening torque
49.0 to 55.9 N·m
Idle gear 2 stopper set
5.0 to 5.7 kgf·m
screw
36.2 to 41.2 lbf·ft
(1) Gear Case Cover (6) Washer

(2) Hydraulic Pump Base Assembly (7) Idle Gear 2 Shaft
(3) Idle Gear 2 Stopper (8) Idle Gear 2 Stopper Set Screw
(4) Idle Gear 2 (9) Idle Gear 2 Shaft Set Screw
(5) Puller
W1034122

Gear Case (for Side PTO Model)

1. Remove the gear case (1).
2. Remove the O-rings (2).
(When reassembling)
• Replace the gear case gasket and O-rings.
• Check to see if there are four O-rings (2) inside the gear case (1).
• Apply a thin film of engine oil to the oil seal, and install it, noting
the lip come off.
• Before installing the gear case gasket, apply a non-drying
adhesive.
(1) Gear Case (2) O-rings
W1034671
Gear Case
1. Remove the hour meter gear case (if equipped).
2. Remove the gear case (1).
3. Remove the O-rings (2).
(When reassembling)
• Replace the gear case gasket and O-rings (2).
• Apply liquid gasket (Three Bond 1215 or equivalent) to both side
of hour meter gear case gasket.
• Check to see if there are four O-rings (2) inside the gear case (1).
• Apply a thin film of engine oil to the oil seal (3), and install it,
noting the lip come off.
• Before installing the gear case gasket, apply a non-drying
adhesive.
(1) Gear Case (3) Oil Seal
(2) O-ring
W1024531
Crankshaft Oil Slinger
1. Remove the crankshaft collar (3).
2. Remove the O-ring (2).
3. Detach the crankshaft oil slinger (1).
(When reassembling)
• Insert the crankshaft collar (3) after install the gear case to
cylinder body.
(1) Crankshaft Oil Slinger (3) Crankshaft Collar
(2) O-ring
W1024731
Idle Gear
1. Remove the external snap ring.
2. Detach the idle gear collar.
3. Detach the idle gear (2).
(When reassembling)
• Check to see each gear is aligned with its aligning mark
- Idle gear (2) and crank gear (4)
- Idle gear (2) and cam gear (3)
- Idle gear (2) and injection pump gear (1)
(1) Injection Pump Gear (4) Crank Gear
(2) Idle Gear (5) Oil Pump Drive Gear
(3) Cam Gear
W1024941

Idle Gear (For Balancer Model)

1. Remove the external snap ring.
2. Detach the idle gear collar.
3. Detach the idle gear (2).
(When reassembling)
• Check to see each gear is aligned with its aligning mark:
- Idle gear (2) and crank gear (6), cam gear (3) and balancer
gear (4)
- Cam gear (3) and idle gear (2)
- Idle gear (2) and injection pump gear (1)
- Idle gear (2) and balancer gear (7)
(1) Injection Pump Gear (5) Oil Pump Drive Gear
(2) Idle Gear (6) Crank Gear
(3) Cam Gear (7) Balancer Gear
(4) Balancer Gear
W1097988
Camshaft
1. Remove the camshaft set screws (1) and draw out the camshaft
(2).
(When reassembling)
• When installing the idle gear, be sure to align the alignment
marks on gears.
23.5 to 27.5 N·m
Tightening torque Camshaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 lbf·ft
(1) Camshaft Set Screw (2) Camshaft

W1025098
Camshaft and Balancer Shaft (For Balancer Model)
1. Remove the camshaft set screws and draw out the camshaft (1).
2. Remove the balancer shaft 1 (2) set bolts and draw out the
balancer shaft 1 (2).
3. Remove the balancer shaft 2 (3) set bolts and draw out the
balancer shaft 2 (3).
(When reassembling)
• When install the balancer shaft 1 (2) and 2 (3), be sure to place
the 1st. and 4th. cylinders piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the idle gear last.
23.5 to 27.5 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
17.4 to 20.3 lbf·ft
Tightening torque
23.5 to 27.5 N·m
Balancer shaft set bolt 2.4 to 2.8 kgf·m
17.4 to 20.3 lbf·ft
(1) Camshaft (3) Balancer Shaft 2

(2) Balancer Shaft 1
W1099079

Fuel Camshaft and Fork Lever Assembly

1. Remove the fuel feed pump.
2. Detach the fuel camshaft stopper (1).
3. Remove the three fork lever holder mounting screws (2).
4. Draw out the fuel camshaft assembly (5), (6) and fork lever
assembly (3), (4), (7) at the same time.
(When reassembling)
• After installation, check to see that the fork lever 1 (3) and lever
2 (4) are fixed to the fork lever shaft, and that they can turn
smoothly in the holder (7).
(1) Fuel Camshaft Stopper (5) Injection Pump Gear
(2) Fork Lever Holder Mounting Screws (6) Fuel Camshaft
(3) Fork Lever 1 (7) Fork Lever Holder
(4) Fork Lever 2
W1025309
Oil Pump
1. Remove the nut.
2. Draw out the oil pump drive gear (2) with gear puller (1).
3. Remove the four oil pump mounting screws. Detach the oil pump
(3).
(1) Gear Puller (3) Oil Pump
(2) Oil Pump Drive Gear
W1025581
Crank Gear
1. Draw out the crank gear (2) with a puller (1).
2. Remove the feather key.
(1) Gear Puller (2) Crank Gear
W1025476

(5) Piston and Connecting Rod

Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws.
2. Remove the oil pan (3) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil pan gasket (2).
4. Remove the oil strainer (1) and O-ring (4).
(When reassembling)
• After cleaning the oil strainer (1), check to see that the filter mesh
in clean, and install it.
• Visually check the O-ring (4), apply engine oil, and install it.
• Securely fit the O-ring (4) to the oil strainer (1).
• Apply a liquid gasket (Three Bond 1215 or equivalent) to the oil
pan side of the oil pan gasket (2).
• To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
(1) Oil Strainer (3) Oil Pan
(2) Oil Pan Gasket (4) O-ring
W1025687

Pistons
1. Completely clean carbon (1) in the cylinders.
2. Remove the connecting rod cap (3).
3. Turn the flywheel and bring the piston to top dead center.
4. Draw out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer.
5. Draw out the other piston in the same method as above.
(When reassembling)
• Before inserting piston into the cylinder, apply enough engine oil
to the piston.
• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
Q IMPORTANT
• Do not change the combination of cylinder and piston. Make
sure of the position of each piston by marking. For example,
mark “1” on the No. 1 piston.
• Place the piston rings with their gaps at 2.09 rad (120 °) from
the piston pin’s direction as shown in the figure.
• Carefully insert the pistons using a piston ring compressor
(7).
• When inserting the piston in place, be careful not to get the
molybdenum disulfide coating torn off its skirt. This coating
is useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been press-fitted, in particular,
the piston is still hot and the coating is easy to peel off. Wait
until the piston cools down.
• When replacing the piston, look at the code number (6)
marked on top of the piston. Use a replacement piston with
the same code number.
44.1 to 49.0 N·m

Tightening torque Connecting rod screw 4.5 to 5.0 kgf·m
32.5 to 36.2 lbf·ft
(1) Carbon (A) Top Ring Gap

(2) Connecting Rod Screw (B) Second Ring Gap
(3) Connecting Rod Cap (C) Oil Ring Gap
(4) Connecting Rod (D) Piston Pin Hole
(5) Molybdenum Disulfide Coating in
Piston Skirt (a) 2.09 rad (120 °)
(6) Code Number
(7) Piston Ring Compressor
W1026141

Piston Ring and Connecting Rod

1. Remove the piston rings (1), (2), (3) using a piston ring tool.
2. Remove the piston pin (8), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near the gap faces the top of the piston
(5).
• When installing the oil ring (3) onto the piston (5), place the
expander joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin (8).
• When installing the connecting rod (6) to the piston (5), immerse
the piston (5) in 80 °C (176 °F) oil for 10 to 15 minutes and insert
the piston pin (8) to the piston (5).
• Assemble the piston (5) to the connecting rod (6) with the FW
mark (9) facing the flywheel side and the connecting rod mark (7)
facing the injection pump side.
Q NOTE
• Mark the same number on the connecting rod (6) and the
piston (5) so as not to change the combination.
(1) Top Ring (7) Mark
(2) Second Ring (8) Piston Pin
(3) Oil Ring (9) FW Mark
(4) Piston Pin Snap Ring (10) Expander Joint
(5) Piston (11) Oil Ring Gap
(6) Connecting Rod (12) Manufacturer’s Mark
W1026376

(6) Flywheel and Crankshaft

Flywheel
1. Fit the stopper to the flywheel (1).
2. At first, remove two pieces of the flywheel screws (2).
3. Insert two pieces of the flywheel guide screws (3) in the holes.
4. Remove the all flywheel screws (2).
5. Remove the flywheel (1) slowly along the flywheel guide screws
(3).
(When reassembling)
• Insert two pieces of the flywheel guide screws (3).
• Check to see that there are no metal particles left on the flywheel
mounting surfaces.
• Apply engine oil to the threads and the undercut surface of the
flywheel bolt and fit the bolt.
98.1 to 107.9 N·m
Tightening torque Flywheel screw 10.0 to 11.0 kgf·m
72.3 to 79.6 lbf·ft
(1) Flywheel (3) Flywheel Guide Screws

(2) Flywheel Screw
W1026863
Bearing Case Cover
1. Remove the bearing case cover mounting screws. First, remove
inside screws (5) and then outside screws (3).
2. Screw two removed screws into the screw hole of bearing case
cover (6) to remove it.
Q IMPORTANT
• The length of inside screws (5) and outside screws (3) are
different. Do not take a mistake using inside screws and
outside screws.
(When reassembling)
• Fit the bearing case gasket (1) and the bearing case cover gasket
(2) with correct directions.
• Install the bearing case cover (6) to position the casting mark
“UP” on it upward.
• Apply engine oil to the oil seal lip and take care that it is not rolled
when installing.
• Tighten the bearing case cover mounting screws with even force
on the diagonal line.
23.5 to 27.5 N·m
Bearing case cover
mounting screw
17.4 to 20.3 lbf·ft
(1) Bearing Case Gasket (5) Bearing Case Cover Mounting Screw
(2) Bearing Case Cover Gasket (6) Bearing Case Cover
(3) Bearing Case Cover Mounting Screw
(4) Oil Seal (a) Upside
W10292140

Crankshaft
Q NOTE
• Before disassembling, check the side clearance of
crankshaft. Also check it during reassembling.
For D1503-M-DI, D1503-M-DI-T, D1703-M-DI, V2003-M-DI-T and
V2203-M-DI
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly, taking care not to damage the
crankshaft bearing 1 (3).
For D1803-M-DI
2. Turn the crankshaft to set the crank pin of the third cylinder to the
bottom dead center. Then draw out the crankshaft until the crank
pin of the second cylinder comes to the center of the third
cylinder.
3. Turn the crankshaft by 2.09 rad (120 °) counterclockwise to set
the crank pin of the second cylinder to the bottom dead center.
Draw out the crankshaft until the crank pin of the first cylinder
comes to the center of the third cylinder
4. Repeat the above steps to draw out all the crankshaft.
For V2403-M-DI and V2403-M-DI-T
2. Turn the crankshaft to set the crank pin of the 4th cylinder to the
horizontal directions (Right or Left). Then draw out all the
crankshaft, holding the crank pins to the horizontal directions
(Right or Left).
(When reassembling)
Q IMPORTANT
• Install the crankshaft sub assembly, aligning the screw hole
of main bearing case 2 (2) with the screw hole of cylinder
block.
• When tightening the main bearing case screw 2 (1), apply oil
to the screw and screw by hand before tightening the
specific torque.
If not smooth to screw by hand, align the screw holes
between the cylinder block and the main bearing case.
68.6 to 73.5 N·m
Tightening torque Main bearing case screw 2 7.0 to 7.5 kgf·m
50.6 to 54.2 lbf·ft
(1) Main Bearing Case Screw 2 (a) Cut place for removing and
(2) Main Bearing Case 2 installing the crankshaft
(3) Crankshaft Bearing 1 [A] D1803-M-DI
W1066311

Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (7), and remove the
main bearing case assembly being careful with thrust bearing
and crankshaft bearing.
2. Remove the main bearing case 1, 2 as above.
(When reassembling)
• Clean the oil passage in the main bearing case.
• Apply clean engine oil on the bearings.
• Install the main bearing case assemblies in the original positions.
Since diameters of main bearing cases vary, install them in order
of makings (A, B for 3 cylinders and A, B, C for 4 cylinders) from
the gear case side.
• Match the alignment numbers (1) and mark (2) on the main
bearing case.
• When installing the main bearing case 1 and 2, face the mark
“FLYWHEEL” to the flywheel.
• Install the thrust bearing with its oil groove (8) facing outward.
• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 (7) to the specified
torque.
46.1 to 51.0 N·m
Tightening torque Main bearing case screw 1 4.7 to 5.2 kgf·m
34.0 to 37.6 lbf·ft
(1) Alignment Number (5) C

(2) Alignment Mark (6) No Mark
(3) A (7) Main Bearing Case Screw 1
(4) B (8) Oil Groove
W1027366

(7) Starter
(1) Through Bolt
(2) Brush
(3) C Terminal Nut
(4) Yoke
(5) Armature
(6) Overrunning Clutch
(7) Idle Gear
(8) End Frame
(9) Brush Holder
(10) Magnet Switch Cover
(11) Plunger
(12) B Terminal Nut
(13) Housing
W1222714
1. Unscrew the C terminal nut (3), and disconnect the connecting lead.
2. Remove the two through bolts (1).
3. Detach the motor.
4. Remove the end frame (8).
5. Remove the brush from the brush holder while holding the spring up.
6. Remove the brush holder (9).
7. Draw out the armature (5) from the yoke (4).
8. Remove the housing (13).
9. Remove the idle gear (7) and the overrunning clutch (6).
10.Remove the magnet switch cover (10).
11.Remove the plunger (11).
Q NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO No. 50 or equivalent) to the idle gear and overrunning clutch portions.
5.9 to 11.8 N·m
Tightening torque B terminal nut 0.6 to 1.2 kgf·m
4.3 to 8.7 lbf·ft
W1012736

(8) Alternator
(1) Pulley
(2) Drive End Frame
(3) Stator
(4) Bearing
(5) Retainer Plate
(6) Rotor
(7) Bearing
(8) Rear End Frame
(9) Rectifier
(10) IC Regulator
(11) Brush Holder
(12) Rear End Cover
W1224079
1. Remove the pulley (1).

2. Remove the rear end cover (12).
3. Remove the brush holder (11).
4. Remove the IC regulator (10).
5. Remove the four screws holding the stator lead wires.
6. Remove the rectifier (9).
7. Remove the rear end frame (8).
8. Press out the rotor (6) from drive end frame (2).
9. Remove the retainer plate (5).
10.Press out the bearing (4) from drive end frame (2) with a press and jig.
11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.
(When reassembling)
58.3 to 78.9 N·m
Tightening torque Pulley nut 5.95 to 8.05 kgf·m
43.0 to 58.2 lbf·ft
W1224556

[3] SERVICING
(1) Cylinder Head and Valves
Top Clearance
1. Remove the cylinder head.
2. Move the piston up and stick a strip of fuse on the piston head at
three position with grease.
3. Lower the piston and install the cylinder head. (Use a new
cylinder head gasket and tighten with a specified tightening
torque.)
4. Turn the flywheel until the piston exceeds top dead center.
5. Remove the cylinder head and measure the thickness of the
fuses.
6. If the measurement is not within the factory specifications, check
the oil clearances between the crankpin and bearing and
between the piston pin and bushing.
Q NOTE
• After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
0.60 to 0.70 mm
Top clearance Factory spec.
0.0236 to 0.0276 in.
93.2 to 98.1 N·m

Tightening torque Cylinder head screws 9.5 to 10.0 kgf·m
68.7 to 72.3 lbf·ft
(1) Piston (2) Fuse

W1020190
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.
3. Measure the clearance with a feeler gauge.
4. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
Q IMPORTANT
• Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.0020 in.
W1027737

Cylinder Head Flaw

1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent
W1076542
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
0.65 to 0.85 mm
Factory spec.
0.026 to 0.033 in.
Valve recessing
1.20 mm
Allowable limit
0.0472 in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
W10768800
Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
0.040 to 0.070 mm
Clearance between Factory spec.
0.00157 to 0.00276 in.
valve stem and valve
guide 0.10 mm
Allowable limit
0.0039 in.
7.960 to 7.975 mm
Valve stem O.D. Factory spec.
0.31339 to 0.31398 in.
8.015 to 8.030 mm
Valve guide I.D. Factory spec.
0.31555 to 0.31614 in.
W10774950

Replacing Valve Guide

(When removing)
1. Press out the used valve guide using a valve guide replacing tool.
(See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new valve guide and valve guide bore, and apply engine
oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
Valve guide I.D. 8.015 to 8.030 mm
Factory spec.
(Intake and exhaust) 0.31555 to 0.31614 in.
Q IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
(A) When Removing (B) When Installing
W10278890
Valve Seating
1. Coat the valve face lightly with prussian blue and put the valve on
its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or the
valve contact is less than 70 %, correct the valve seating as
follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seating.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
(1) Correct (3) Incorrect

(2) Incorrect
W10282190

Correcting Valve and Valve Seat

Q NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
0.785 rad
IN.
Factory 45 °
Valve face angle
spec. 0.785 rad
EX.
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 0.785 rad (45 °) valve seat
cutter.
2. Resurface the seat surface with a 0.262 rad (15 °) valve seat
cutter to valve seat so that the width is close to specified valve
seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of compound between the valve face and valve seat, and
fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
0.785 rad
IN.
Factory 45 °
Valve seat angle
spec. 0.785 rad
EX.
45 °
(1) Valve Seat Width (A) Check Contact

(2) Identical Dimensions (B) Correct Seat Width
(C) Check Contact
(a) 0.262 rad (15 °) or 0.523 rad (30 °)
(b) 0.785 rad (45 °) or 1.047 rad (60 °)
(c) 0.523 rad (30 °) or 0.262 rad (15 °)
W10283500
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
Q IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
W10288140

Free Length and Tilt of Valve Spring

1. Measure the free length (B) of valve spring with vernier calipers.
If the measurement is less than the allowable limit, replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (A).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
41.7 to 42.2 mm
Factory spec.
1.6417 to 1.6614 in.
Free length (B)
41.2 mm
Allowable limit
1.6220 in.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
(A) Tilt (B) Free Length

W10289350
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
117.6 N / 35.0 mm
Factory spec. 12.0 kgf / 35.0 mm
Setting load / 26.4 lbf / 1.3780 in.
Setting length 100.0 N / 35.0 mm
Allowable limit 10.2 kgf / 35.0 mm
22.5 lbf / 1.3780 in.
W10784360
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and then
calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
0.016 to 0.045 mm
Oil clearance between Factory spec.
0.00063 to 0.00177 in.
rocker arm and rocker
arm shaft 0.10 mm
Allowable limit
0.0039 in.
13.973 to 13.984 mm
Rocker arm shaft O.D. Factory spec.
0.55012 to 0.55055 in.
14.000 to 14.018 mm
Rocker arm I.D. Factory spec.
0.55118 to 0.55189 in.
W1029150

Push Rod Alignment

1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
0.25 mm
Push rod alignment Allowable limit
0.0098 in.
W10292900
Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
0.020 to 0.062 mm
Oil Clearance between Factory spec.
0.00079 to 0.00244 in.
tappet and tappet guide
bore 0.07 mm
Allowable limit
0.0028 in.
23.959 to 23.980 mm
Tappet O.D. Factory spec.
0.94327 to 0.94410 in.
24.000 to 24.021 mm
Tappet guide bore I.D. Factory spec.
0.94488 to 0.94571 in.
W1029366

(2) Timing Gears

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance is proper, replace the gear.
0.0415 to 0.1122 mm
Factory spec.
Backlash between idle 0.00163 to 0.00442 in.
gear and crank gear 0.15 mm
Allowable limit
0.0059 in.
0.0415 to 0.1154 mm
Factory spec.
Backlash between idle 0.00163 to 0.00454 in.
gear and cam gear 0.15 mm
Allowable limit
0.0059 in.
0.0415 to 0.1154 mm
Backlash between idle Factory spec.
0.00163 to 0.00454 in.
gear and injection pump
gear 0.15 mm
Allowable limit
0.0059 in.
0.0415 to 0.1090 mm
Factory spec.
Backlash between crank 0.00163 to 0.00429 in.
gear and oil pump gear 0.15 mm
Allowable limit
0.0059 in.
For Balancer Model Only

0.0350 to 0.1160 mm
0.00138 to 0.00457 in.
gear and balancer gear
(Intake side) 0.15 mm
Allowable limit
0.0059 in.
0.0350 to 0.1160 mm
Backlash between cam Factory spec.
0.00138 to 0.00457 in.
gear and balancer gear
(Exhaust side) 0.15 mm
Allowable limit
0.0059 in.
For Side PTO Model Only

0.0415 to 0.1154 mm
Factory spec.
Backlash between crank 0.00163 to 0.00454 in.
gear and idle gear 2 0.15 mm
Allowable limit
0.0059 in.
0.0308 to 0.1062 mm
0.00121 to 0.00418 in.
gear 2 and hydraulic
pump drive gear 0.15 mm
Allowable limit
0.0059 in.
W1029564
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
0.12 to 0.48 mm
Factory spec.
0.0047 to 0.0189 in.
Idle gear side clearance
0.9 mm
Allowable limit
0.0354 in.
W1029843

Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the front
to rear.
camshaft stopper.
0.07 to 0.22 mm
Factory spec.
Camshaft side 0.0028 to 0.0087 in.
clearance 0.30 mm
Allowable limit
0.0118 in.
W1030012
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
camshaft.
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
W1031413

Cam Height
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
33.27 mm
D1503-M-DI
1.3098 in.
D1503-M-DI-T
Factory D1703-M-DI
spec. D1803-M-DI
33.90 mm
V2003-M-DI-T
1.3346 in.
V2203-M-DI
V2403-M-DI
V2403-M-DI-T
Cam height of intake
33.22 mm
D1503-M-DI
1.3079 in.
D1503-M-DI-T
Allowable D1703-M-DI
limit D1803-M-DI
33.85 mm
V2003-M-DI-T
1.3327 in.
V2203-M-DI
V2403-M-DI
V2403-M-DI-T
33.47 mm
D1503-M-DI
1.3177 in.
D1503-M-DI-T
Factory D1703-M-DI
spec. D1803-M-DI
33.47 mm
V2003-M-DI-T
1.3177 in.
V2203-M-DI
V2403-M-DI
V2403-M-DI-T
Cam height of exhaust
33.42 mm
D1503-M-DI
1.3157 in.
D1503-M-DI-T
limit D1803-M-DI
33.42 mm
V2003-M-DI-T
1.3157 in.
V2203-M-DI
V2403-M-DI
V2403-M-DI-T
W1031532

Oil Clearance of Camshaft Journal

1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.00197 to 0.00358 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
39.934 to 39.950 mm
Camshaft journal O.D. Factory spec.
1.57221 to 1.57284 in.
40.000 to 40.025 mm
Cylinder block bore I.D. Factory spec.
1.57480 to 1.57579 in.
W1031662
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
bushing.
If it still exceeds the allowable limit, replace the idle gear shaft.
0.025 to 0.066 mm
0.00098 to 0.00260 in.
idle gear shaft and idle
gear bushing 0.10 mm
Allowable limit
0.0039 in.
37.959 to 37.975 mm
Idle gear shaft O.D. Factory spec.
1.49445 to 1.49508 in.
38.000 to 38.025 mm
Idle gear bushing I.D. Factory spec.
1.49606 to 1.49705 in.
W1030933
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing tool,
until it is flush with the end of the idle gear.
(A) When Removing (B) When Installing
W1031083

Balancer Shaft Side Clearance (for Balancer Model Only)

1. Set a dial indicator with tip on the balancer shaft.
2. Measure the side clearance by moving the balancer shaft to the
front and rear.
balancer shaft.
0.07 to 0.22 mm
Factory spec.
Balancer shaft side 0.0028 to 0.0087 in.
clearance 0.30 mm
Allowable limit
0.0118 in.
W1030111
Balancer Shaft Alignment
1. Support the balancer shaft with V blocks on the surface plate and
set a dial indicator with its tip on the intermediate journal at high
angle.
2. Rotate the balancer shaft on the V block and get the
misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
balancer shaft.
Balancer shaft 0.02 mm
Allowable limit
alignment 0.0008 in.
W1042630

Oil Clearance of Balancer Shaft Journal (for Balancer Model

Only)
1. Measure the balancer shaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. for balancer shaft with an
inside micrometer or cylinder gauge.
3. If the clearance exceeds the allowable limit, replace the balancer
shaft.
0.030 to 0.111 mm
Factory spec.
balancer shaft journal 1 0.20 mm
Allowable limit
0.0079 in.
Balancer shaft journal 1 43.934 to 43.950 mm

Factory spec.
O.D. 1.72969 to 1.73032 in.
Balancer shaft bearing 1 43.980 to 44.045 mm
Factory spec.
I.D. 1.73150 to 1.73406 in.
0.030 to 0.111 mm
Factory spec.
Allowable limit
0.0079 in.

Factory spec.
O.D. 1.65095 to 1.65158 in.
Factory spec.
I.D. 1.65276 to 1.65532 in.
0.020 to 0.094 mm
Factory spec.
Allowable limit
0.0079 in.

Factory spec.
O.D. 0.86406 to 0.86457 in.
Factory spec.
I.D. 0.86535 to 0.86776 in.
(1) Balancer Shaft Journal 3 (3) Balancer Shaft Journal 1

(2) Balancer Shaft Journal 2
W1030206
(3) Piston and Connecting Rod

Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
25.000 to 25.013 mm
Factory spec.
0.98425 to 0.98476 in.
Piston pin bore I.D.
25.05 mm
Allowable limit
0.9862 in.
W1031817

Oil Clearance between Piston Pin and Small End Bushing

1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
bushing. If it still exceeds the allowable limit, replace the piston
pin.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
piston pin and small end
bushing 0.15 mm
Allowable limit
0.0059 in.
25.002 to 25.011 mm
Piston pin O.D. Factory spec.
0.98433 to 0.98469 in.
25.025 to 25.040 mm
Small end bushing I.D. Factory spec.
0.98524 to 0.98583 in.
W1031982
Replacing Connecting Rod Small End Bushing
(When removing)
1. Press out the used small end bushing using a small end bushing
replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Using a small end bushing replacing tool, press in a new bushing
taking due care to see that the connecting rod oil hole matches
the bushing hole.
(A) When removing (B) When installing
W1032140
Connecting Rod Alignment

Q NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin, and move it against the face
plate.
4. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
connecting rod.
Connecting rod 0.05 mm
Allowable limit
alignment 0.0020 in.
W10314620

Piston Ring Gap

1. Insert the piston ring into the lower part of the liner (the least worn
out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the ring.
0.20 to 0.35 mm
Factory spec.
0.0079 to 0.0138 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.
D1503-M-DI
D1503-M-DI-T 0.40 to 0.55 mm
V2003-M-DI-T 0.0157 to 0.0217 in.
Factory V2403-M-DI-T
spec. D1703-M-DI
Second ring
D1803-M-DI 0.30 to 0.45 mm
V2203-M-DI 0.0118 to 0.0177 in.
V2403-M-DI
1.25 mm
Allowable limit
0.0492 in.
D1503-M-DI
D1503-M-DI-T 0.25 to 0.45 mm
V2003-M-DI-T 0.0098 to 0.0177 in.
spec. D1703-M-DI
Oil ring
D1803-M-DI 0.20 to 0.40 mm
V2203-M-DI 0.0079 to 0.0157 in.
V2403-M-DI
1.25 mm
Allowable limit
0.0492 in.
W1032246

Clearance between Piston Ring and Groove

1. Clean the rings and the ring grooves, and install each ring in its
groove.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
D1703-M-DI
Factory D1803-M-DI 0.050 to 0.090 mm
spec. V2203-M-DI 0.0020 to 0.0035 in.
Top Ring V2403-M-DI
0.20 mm
Allowable limit
0.0079 in.
D1503-M-DI
D1503-M-DI-T 0.093 to 0.128 mm
V2003-M-DI-T 0.0037 to 0.0050 in.
spec. D1703-M-DI
Second ring
D1803-M-DI 0.078 to 0.110 mm
V2203-M-DI 0.0031 to 0.0043 in.
V2403-M-DI
0.20 mm
Allowable limit
0.0079 in.
D1503-M-DI
D1503-M-DI-T 0.020 to 0.060 mm
V2003-M-DI-T 0.0008 to 0.0024 in.
spec. D1703-M-DI
Oil ring
D1803-M-DI 0.030 to 0.070 mm
V2203-M-DI 0.0012 to 0.0028 in.
V2403-M-DI
0.15 mm
Allowable limit
0.0059 in.
W1032489

(4) Crankshaft
Side Clearance of Crankshaft
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.5 mm
Allowable limit
0.0197 in.
(Reference)
• Oversize dimensions of crankshaft journal
0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
54.5 to 54.7 mm 54.6 to 54.8 mm
Dimension A
2.1457 to 2.1535 in. 2.1496 to 2.1575 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension B
1.0315 to 1.0335 in. 1.0394 to 1.0413 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.1102 to 0.1260 in. radius 0.1102 to 0.1260 in. radius
(0.4S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
W1032880
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at both
end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.00079 in.
W1033001

Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
crankpin bearing.
6. If the same size bearing is useless because of the crankpin wear,
replace it with an undersize one referring to the table and figure.
Q NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
0.025 to 0.087 mm
0.00098 to 0.00343 in.
crankpin and crankpin
bearing 0.20 mm
Allowable limit
0.0079 in.
46.959 to 46.975 mm
Crankpin O.D. Factory spec.
1.84878 to 1.84941 in.
47.000 to 47.046 mm
Crankpin bearing I.D. Factory spec.
1.85039 to 1.85221 in.
(Reference)
• Undersize dimensions of crankpin
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
Dimension A
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.0394 to 0.0591 in. relief 0.0394 to 0.0591 in. relief
46.759 to 46.775 mm dia. 46.559 to 46.575 mm dia.
Dimension C
1.84091 to 1.84154 in. dia. 1.83303 to 1.83366 in. dia.
(0.4S)
The crankpin must be fine-finished to higher than ∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
W1033106

Oil Clearance between Crankshaft Journal and Crankshaft

Bearing 1
1. Measure the O.D. of the crankshaft journal with an outside
micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate oil clearance.
3. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 1.
journal wear, replace it with an undersize one referring to the
table and figure.
0.040 to 0.118 mm
0.00157 to 0.00465 in.
crankshaft journal and
crankshaft bearing 1 0.2 mm
Allowable limit
0.0079 in.
59.921 to 59.940 mm
Crankshaft journal O.D. Factory spec.
2.35910 to 2.35984 in.
Crankshaft bearing 1 59.980 to 60.039 mm
Factory spec.
I.D. 2.36142 to 2.36374 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
Dimension A
*Dimension B
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C
2.35122 to 2.35197 in. dia. 2.34335 to 2.34410 in. dia.
(0.4S)
(0.0394 to 0.0591 in.) relief.
W1033717
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page “SPECIAL TOOLS”.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaust
manifold side. (See figure.)
4.2 to 4.5 mm
Dimension (A) Factory spec.
0.1654 to 0.1772 in.
(1) Seam (3) Cylinder Block

(2) Crankshaft Bearing 1 (A) Dimension
W1033946

Oil Clearance between Crankshaft Journal and Crankshaft

Bearing 2
1. Put a strip of plastigage on the center of the journal.
2. Install the bearing case and tighten the bearing case screws 1 to
the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale and get the
oil clearance.
4. If the clearance exceeds the allowable limit, replace the
crankshaft bearing 2.
journal wear, replace it with an undersize one referring to the
table and figure.
Q NOTE
• Be sure not to move the crankshaft while the bearing case
screws are tightened.
0.040 to 0.104 mm
0.00157 to 0.00409 in.
crankshaft and
crankshaft bearing 2 0.20 mm
Allowable limit
0.0079 in.
59.921 to 59.940 mm
Crankshaft journal O.D. Factory spec.
2.35910 to 2.35984 in.
Crankshaft bearing 2 59.980 to 60.025 mm
Factory spec.
I.D. 2.36142 to 2.36319 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
Dimension A
*Dimension B
59.721 to 59.740 mm dia. 59.521 to 59.540 mm dia.
Dimension C, D
2.35122 to 2.35197 in. dia. 2.34335 to 2.34410 in. dia.
(0.4S)
(0.0394 to 0.0591 in.) relief.
W1083821

Replacing Crankshaft Sleeve

1. Remove the used crankshaft sleeve (3).
2. Set the sleeve guide (2) to the crankshaft (5).
3. Set the stopper (1) to the crankshaft (5) as shown in figure.
4. Heat a new sleeve to a temperature between 150 and 200 °C
(302 and 392 °F), and fix the sleeve to the crankshaft (5) as
shown in figure.
5. Press fit the sleeve using the auxiliary socket for pushing (4).
(Refer to “SPECIAL TOOLS”.)
Q NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
• Should heating is not enough, a sleeve might stop halfway,
so careful.
(1) Stopper (4) Auxiliary Socket for Pushing
(2) Sleeve Guide (5) Crankshaft
(3) Crankshaft Sleeve
W1033503
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
D1503-M-DI
83.000 to 83.022 mm
D1503-M-DI-T
3.26772 to 3.26858 in.
V2003-M-DI-T
Factory D1703-M-DI
spec. D1803-M-DI
87.000 to 87.022 mm
V2203-M-DI
3.42520 to 3.42606 in.
V2403-M-DI
V2403-M-DI-T
Cylinder I.D.
D1503-M-DI
83.150 mm
D1503-M-DI-T
3.2736 in.
V2003-M-DI-T
limit D1803-M-DI
87.150 mm
V2203-M-DI
3.4311 in.
V2403-M-DI
V2403-M-DI-T
A: Top (a) Right-angled to Piston Pin

B: Middle (b) Piston Pin Direction
C: Bottom (Skirt)
W1034389

Correcting Cylinder (Oversize)

1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
D1503-M-DI
83.250 to 83.272 mm
D1503-M-DI-T
3.27756 to 3.27843 in.
V2003-M-DI-T
Factory D1703-M-DI
spec. D1803-M-DI
87.250 to 87.272 mm
V2203-M-DI
3.43504 to 3.43591 in.
V2403-M-DI
Oversize cylinder V2403-M-DI-T
I.D. D1503-M-DI
83.400 mm
D1503-M-DI-T
3.2835 in.
V2003-M-DI-T
limit D1803-M-DI
87.400 mm
V2203-M-DI
3.4409 in.
V2403-M-DI
V2403-M-DI-T
Hone to 2.2 to 3.0 μmRz
Finishing (0.000087 to 0.000118 in.Rz)
∇∇∇.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.25 mm (0.0098 in.)
Q NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
W1034448
(6) Oil Pump

Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
3. If the clearance exceeds the factory specifications, replace the oil
pump rotor assembly.
0.03 to 0.14 mm
0.0012 to 0.0055 in.
inner rotor and outer
rotor 0.2 mm
Allowable limit
0.0079 in.
0.11 to 0.19 mm
0.0043 to 0.0075 in.
outer rotor and pump
body 0.25 mm
Allowable limit
0.0098 in.
W1035296

Clearance between Rotor and Cover

1. Put a strip of plastigage onto the rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the width of the press
gauge with a sheet of gauge.
4. If the clearance exceeds the factory specifications, replace oil
pump rotor assembly.
0.105 to 0.150 mm
Factory spec.
Clearance between 0.00413 to 0.00591 in.
inner rotor and cover 0.20 mm
Allowable limit
0.0079 in.
W1035444
(7) Starter
Overrunning Clutch
1. Check the pinion and if worn or damage, replace the clutch
assembly.
2. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
3. If the pinion slips or does not turn in both directions, replace the
overrunning clutch assembly.
Q NOTE
• Do not wash off the grease in the overrunning clutch with
the chemicals or oils.
W1156799

Commutator and Mica

1. Check the contact of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
D1503-M-DI
D1503-M-DI-T
D1703-M-DI 30.0 mm
D1803-M-DI 1.181 in.
V2203-M-DI
Factory
V2003-M-DI-T
spec.
35.0 mm
V2403-M-DI
1.378 in.
36.0 mm
V2403-M-DI-T
1.417 in.
Commutator O.D.
D1503-M-DI
D1503-M-DI-T
D1703-M-DI 29.0 mm
D1803-M-DI 1.142 in.
V2203-M-DI
Allowable
V2003-M-DI-T
limit
34.0 mm
V2403-M-DI
1.339 in.
35.0 mm
V2403-M-DI-T
1.378 in.
Less than 0.02 mm

Factory spec.
0.0008 in.
Difference of O.D.’s
0.05 mm
Allowable limit
0.0020 in.
D1503-M-DI
D1503-M-DI-T
D1703-M-DI
0.45 to 0.75 mm
D1803-M-DI
Factory 0.0177 to 0.0295 in.
V2203-M-DI
spec. V2003-M-DI-T
V2403-M-DI
0.70 to 0.90 mm
V2403-M-DI-T
0.0276 to 0.0354 in.
Mica under cut
D1503-M-DI
D1503-M-DI-T
D1703-M-DI
0.20 mm
D1803-M-DI
Allowable 0.0079 in.
V2203-M-DI
limit V2003-M-DI-T
V2403-M-DI
0.20 mm
V2403-M-DI-T
0.0079 in.
(1) Segment (a) Correct

(2) Depth of Mica (b) Incorrect
(3) Mica
W1155802

Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.
2. Measure the brush length (A) with vernier caliper.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
D1503-M-DI
D1503-M-DI-T
D1703-M-DI 15.0 mm
D1803-M-DI 0.591 in.
V2203-M-DI
Factory
V2003-M-DI-T
spec.
15.0 mm
V2403-M-DI
0.591 in.
20.5 mm
V2403-M-DI-T
0.807 in.
Brush length (A)
D1503-M-DI
D1503-M-DI-T
D1703-M-DI 11.0 mm
D1803-M-DI 0.433 in.
V2203-M-DI
Allowable
V2003-M-DI-T
limit
9.0 mm
V2403-M-DI
0.354 in.
16.0 mm
V2403-M-DI-T
0.630 in.
W1156360
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If it conducts, replace the brush holder.
W1156895
Armature Coil
1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.
4. If it does not conduct, replace the armature.
W1156507

Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Bush
W1156968
(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1019790
Stator
1. Measure the resistance across each lead of the stator coil with
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with
4. If infinity is not indicated, replace it.
Resistance Factory spec. Less than 1.0 Ω
W1019964
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with resistance
range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec. 2.9 Ω
W1020094

Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.
W1020208
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
10.5 mm
Factory spec.
0.413 in.
Brush length
8.4 mm
Allowable limit
0.331 in.
W1020329
Rectifier
1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1020452
IC Regulator
1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
(1) F Terminal (2) B Terminal
W1020645

EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : [email protected]
Printed in Japan 2008. 09, S, EI, EI, e Code No.9Y011-02863

KUBOTA Corporation 2004. 02, S, EI, EI, e

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WORK SHOP MANUAL

NANNI INDUSTRIES S.A.S – Zone Industrielle

KiSC issued 09, 2008 A

Q NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

1 KiSC issued 09, 2008 A

2 KiSC issued 09, 2008 A

VENTILATE WORK AREA

DISPOSE OF FLUIDS PROPERLY

PREVENT ACID BURNS

PREPARE FOR EMERGENCIES

3 KiSC issued 09, 2008 A

4 KiSC issued 09, 2008 A

Model D1703-M-DI D1803-M-DI

5 KiSC issued 09, 2008 A

Model V2203-M-DI V2003-M-DI-T

6 KiSC issued 09, 2008 A

Model V2403-M-DI V2403-M-DI-T

7 KiSC issued 09, 2008 A

D1503-M-DI D1503-M-DI-T D1703-M-DI D1803-M-DI

8 KiSC issued 09, 2008 A

V2203-M-DI V2003-M-DI-T V2403-M-DI V2403-M-DI-T

9 KiSC issued 09, 2008 A

1. ENGINE IDENTIFICATION ............................................................................. G-1

KiSC issued 09, 2008 A

(1) Engine Model Name and Serial

G-1 KiSC issued 09, 2008 A

[2] E2B ENGINE

[3] CYLINDER NUMBER

G-2 KiSC issued 09, 2008 A

G-3 KiSC issued 09, 2008 A

3. MAINTENANCE CHECK LIST

G-4 KiSC issued 09, 2008 A

G-5 KiSC issued 09, 2008 A

4. CHECK AND MAINTENANCE

G-6 KiSC issued 09, 2008 A

Checking and Replenish Coolant

G-7 KiSC issued 09, 2008 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Oil pan depth

G-8 KiSC issued 09, 2008 A

Replacing Oil Filter Cartridge

G-9 KiSC issued 09, 2008 A

[3] CHECK POINTS OF EVERY 50 HOURS

(When bleeding fuel system)

G-10 KiSC issued 09, 2008 A

[4] CHECK POINTS OF EVERY 100 HOURS

Fan Belt Tension

G-11 KiSC issued 09, 2008 A

Fan Belt Damage and Wear

G-12 KiSC issued 09, 2008 A

[5] CHECK POINTS OF EVERY 200 HOURS

Oil pan depth

G-13 KiSC issued 09, 2008 A

Replacing Oil Filter Cartridge (for 90 mm (3.54 in.) Depth Oil

Checking Intake Air Line

G-14 KiSC issued 09, 2008 A

[6] CHECK POINTS OF EVERY 400 HOURS

Oil pan depth