Kubota D1803-CR / V2403-CR E5 Engines Workshop Manual

About this manual

Kubota published this Workshop Manual for the D1803-CR / V2403-CR E5 series engine models. It brings the documented service and technical-reference material for those named engines into a single publication.

Its documented technical value includes torque settings, wear limits, fluid and system capacities, dimensions, speed ratings, and emission data for service checks and specification lookup. Use the values and conditions stated in the PDF for the applicable model and procedure.

Use the Manual Contents below to check that the exact repair, inspection, or maintenance procedure you need is included in this publication.

Manual details

Manufacturer

Kubota

Manual type

Workshop Manual

Equipment type

Engine

Models

D1803-CR-E5, D1803-CR-TE5, D1803-CR-TIE5, D1803-CR-TE5LM, V2403-CR-E5, V2403-CR-TE5, V2403-CR-TIE5, V2403-CR-E5LM, V2403-CR-TE5LM, and V2403-CR-TE5BG

Document number

9Y311-00022

Publication year

2019

Publication date

March 2019

KiSC issue / revision

August 2020 (A)

Language

English

Page count

350

Product highlights

Electrical systems

The manual includes wiring diagrams and connector views.

Specifications and settings

The manual includes reference information for torque specifications, wear limits, clearances, capacities, dimensions, and speed ratings.

Special tools

A special-tools section is included.

Maintenance

The manual includes a maintenance schedule.

Manual contents

Use these source headings to locate the task or system you need in the PDF.

• 1. SAFETY — p. 19
  • SAFETY FIRST — p. 20
    • 1. Working precautions — p. 20
    • 2. Preparing for emergencies — p. 20
    • 3. Working cautions — p. 21
    • 4. Starting machine safely — p. 22
    • 5. Preventing fires — p. 22
    • 6. Preventing acid burns — p. 23
    • 7. Avoiding high pressure fluid — p. 23
    • 8. Avoiding hot exhaust — p. 23
    • 9. Cleaning exhaust filter — p. 23
• 2. GENERAL — p. 26
  • GENERAL WORKING PRECAUTIONS — p. 27
    • 1. Tightening bolts and nuts — p. 27
    • 2. Applying thread-locking fluid — p. 27
    • 3. Installing circlips — p. 27
    • 4. Handling liquid gasket — p. 28
    • 5. Replacing O-rings — p. 28
    • 6. Replacing oil seals — p. 28
    • 7. Handling the battery — p. 29
    • 8. Handling wire harness — p. 29
    • 9. Handling fuses — p. 30
    • 10. Handling connectors — p. 31
    • 11. Wiring color — p. 32
    • 12. Dispose fluids correctly — p. 32
  • GENERAL MACHINE INFORMATION — p. 33
    • 1. Engine identification — p. 33
      • 1.1 Engine model name and engine serial number — p. 33
      • 1.2 E5B engine — p. 34
      • 1.3 Cylinder number — p. 35
    • 2. Muffler full assembly identification — p. 35
      • 2.1 Part number and serial number (DPF) — p. 35
    • 3. Specifications — p. 37
      • 3.1 Specification for D1803-CR-E5, TE5, TIE5, TE5LM — p. 37
      • 3.2 Specification for V2403-CR-E5, TE5, TIE5, E5LM, TE5LM — p. 39
      • 3.3 Specification for V2403-CR-TE5BG — p. 41
    • 4. Performance curves — p. 42
      • 4.1 Performance curve for D1803-CR-E5 — p. 42
      • 4.2 Performance curve for D1803-CR-TE5 — p. 43
      • 4.3 Performance curve for D1803-CR-TIE5 — p. 44
      • 4.4 Performance curve for D1803-CR-TE5LM — p. 45
      • 4.5 Performance curve for V2403-CR-E5 — p. 46
      • 4.6 Performance curve for V2403-CR-TE5 — p. 47
      • 4.7 Performance curve for V2403-CR-TIE5 — p. 48
      • 4.8 Performance curve for V2403-CR-E5LM — p. 49
      • 4.9 Performance curve for V2403-CR-TE5LM — p. 50
    • 5. Dimensions — p. 51
      • 5.1 Dimensions — p. 51
    • 6. Wiring diagram — p. 55
      • 6.1 Engine intermediate harness (Engine side harness) — p. 55
      • 6.2 Injector intermediate harness (Engine side harness) — p. 57
      • 6.3 Engine ECU intermediate harness (OEM side harness) — p. 58
      • 6.4 System wiring diagram — p. 63
      • 6.5 System wiring diagram for V2403-CR-TE5BG — p. 65
  • SPECIAL TOOLS — p. 67
    • 1. Diesel engine compression tester — p. 67
    • 2. Compression tester adapter K — p. 68
    • 3. Oil pressure tester — p. 69
    • 4. Valve guide replacing tool — p. 69
    • 5. Bushing replacing tools — p. 69
    • 6. Flywheel stopper — p. 70
    • 7. Crankshaft bearing 1 replacing tool — p. 70
    • 8. Auxiliary socket for fixing crankshaft sleeve — p. 71
    • 9. Injection top correction jig — p. 72
    • 10. Bearing case cover oil seal replacing tool — p. 74
    • 11. HLA air vent tool — p. 76
• 3. MAINTENANCE — p. 79
  • MAINTENANCE CHECK LIST — p. 80
  • CHECK AND MAINTENANCE — p. 84
    • 1. Daily check points — p. 84
      • 1.1 Checking engine oil level — p. 84
      • 1.2 Checking fuel level — p. 85
      • 1.3 Checking coolant level — p. 85
      • 1.4 Checking fan belt (for standard model) — p. 85
    • 2. Check points of initial 50 hours — p. 86
      • 2.1 Changing engine oil — p. 86
      • 2.2 Replacing oil filter cartridge — p. 87
    • 3. Check point of every 50 hours — p. 87
      • 3.1 Checking fuel hoses and clamp bands — p. 87
      • 3.2 Checking and draining water separator (Type 1) — p. 88
    • 4. Check points of every 250 hours — p. 88
      • 4.1 Cleaning air cleaner primary element — p. 88
      • 4.2 Adjusting fan belt tension (for standard model) — p. 89
      • 4.3 Checking radiator hose and clamp bands — p. 89
      • 4.4 Checking intake air line — p. 90
    • 5. Check points of every 500 hours — p. 90
      • 5.1 Changing engine oil — p. 90
      • 5.2 Replacing oil filter cartridge — p. 91
      • 5.3 Replacing fuel filter cartridge — p. 91
      • 5.4 Cleaning water separator (Type 1) — p. 92
      • 5.5 Replacing water separator filter (Type 2) — p. 92
      • 5.6 Cleaning water jacket and radiator interior — p. 92
      • 5.7 Replacing fan belt (for standard model) — p. 94
    • 6. Check point of every 1000 hours — p. 95
      • 6.1 Checking valve clearance — p. 95
    • 7. Check points of every 1500 hours — p. 96
      • 7.1 Checking injector (with Diagmaster) — p. 96
      • 7.2 Checking EGR cooler — p. 97
      • 7.3 Replacing oil separator element — p. 98
      • 7.4 Checking positive crankcase ventilation (PCV) valve — p. 98
    • 8. Check points of every 3000 hours — p. 98
      • 8.1 Checking turbocharger — p. 98
      • 8.2 Checking EGR system (with Diagmaster) — p. 99
      • 8.3 Replacing fan belt (for LM model) — p. 100
    • 9. Check points of every 3000 to 6000 hours — p. 101
      • 9.1 Cleaning DPF (except V2403-CR-TIE5 and V2403-CR-TE5BG) — p. 101
      • 9.2 Cleaning DPF (V2403-CR-TIE5) — p. 103
      • 9.3 Cleaning DPF (V2403-CR-TE5BG) — p. 105
      • 9.4 Judging reuse of DPF filter comp before cleaning (Service dealer) — p. 107
      • 9.5 Judging reuse of DPF filter comp after cleaning (Cleaning contractor) — p. 108
    • 10. Check points of every 1 year — p. 109
      • 10.1 Replacing air cleaner element — p. 109
      • 10.2 Checking DPF differential pressure pipes and hoses — p. 110
      • 10.3 Checking EGR piping — p. 111
      • 10.4 Checking intake air line — p. 111
      • 10.5 Checking exhaust manifold — p. 111
      • 10.6 Checking exhaust heating catalyst (EHC) and exhaust throttle valve (for BG model) — p. 111
      • 10.7 Replacing water separator filter (Type 2) — p. 112
    • 11. Check points of every 2 years — p. 112
      • 11.1 Replacing fan belt (for standard model) — p. 112
      • 11.2 Replacing fan belt (for LM model) — p. 112
      • 11.3 Replacing oil separator rubber hose — p. 113
      • 11.4 Replacing rubber hose of differential pressure sensor — p. 113
      • 11.5 Replacing intake hose (after air flow sensor) and intercooler hose — p. 113
      • 11.6 Replacing EGR cooler hose — p. 113
      • 11.7 Replacing water hose — p. 114
      • 11.8 Replacing exhaust throttle valve hose (for BG model) — p. 114
      • 11.9 Replacing lubricant hose — p. 114
      • 11.10 Changing radiator coolant — p. 114
      • 11.11 Replacing radiator hose and clamp bands — p. 116
      • 11.12 Replacing fuel hose and clamps — p. 117
      • 11.13 Replacing intake air line — p. 117
• 4. ENGINE — p. 118
  • MECHANISM — p. 119
    • 1. General (Introduction) — p. 119
      • 1.1 Feature of combustion (E-CDIS) — p. 119
      • 1.2 Structure of combustion (Center direct injection system (E-CDIS)) — p. 119
      • 1.3 Flow of combustion (E-CDIS) — p. 119
      • 1.4 Control of combustion (E-CDIS) — p. 120
    • 2. Engine body — p. 121
      • 2.1 Structure of engine body — p. 121
      • 2.2 Feature of engine body — p. 122
      • 2.3 Crankcase — p. 122
        • 2.3.1 Outline of crankcase — p. 122
        • 2.3.2 Structure of crankcase — p. 122
        • 2.3.3 Function of crankcase — p. 122
        • 2.3.4 Specification of crankcase — p. 122
      • 2.4 Cylinder head — p. 122
        • 2.4.1 Outline of cylinder head — p. 122
        • 2.4.2 Structure of cylinder head — p. 122
        • 2.4.3 Function of cylinder head — p. 122
      • 2.5 Cylinder head cover — p. 123
        • 2.5.1 Outline of cylinder head cover — p. 123
        • 2.5.2 Structure of cylinder head cover — p. 123
        • 2.5.3 Function of cylinder head cover — p. 123
      • 2.6 Breather — p. 123
        • 2.6.1 Outline of breather — p. 123
        • 2.6.2 Structure of breather — p. 123
        • 2.6.3 Function of breather — p. 123
      • 2.7 Oil separator — p. 123
        • 2.7.1 Outline of oil separator — p. 123
        • 2.7.2 Structure of oil separator — p. 124
        • 2.7.3 Function of oil separator — p. 124
      • 2.8 Piston — p. 124
        • 2.8.1 Outline of piston — p. 124
        • 2.8.2 Structure of piston — p. 124
        • 2.8.3 Function of piston — p. 124
        • 2.8.4 Specification of piston — p. 124
      • 2.9 Piston ring — p. 125
        • 2.9.1 Outline of piston ring — p. 125
        • 2.9.2 Structure of piston ring — p. 125
        • 2.9.3 Function of piston ring — p. 125
        • 2.9.4 Specification of piston ring — p. 125
      • 2.10 Connecting rod — p. 125
        • 2.10.1 Outline of connecting rod — p. 125
        • 2.10.2 Structure of connecting rod — p. 126
        • 2.10.3 Function of connecting rod — p. 126
      • 2.11 Crankshaft — p. 126
        • 2.11.1 Outline of crankshaft — p. 126
        • 2.11.2 Structure of crankshaft — p. 126
        • 2.11.3 Function of crankshaft — p. 126
        • 2.11.4 Specification of crankshaft — p. 126
      • 2.12 Main bearing case — p. 127
        • 2.12.1 Outline of main bearing case — p. 127
        • 2.12.2 Structure of main bearing case — p. 127
        • 2.12.3 Function of main bearing case — p. 127
      • 2.13 Flywheel — p. 127
        • 2.13.1 Outline of flywheel — p. 127
        • 2.13.2 Structure of flywheel — p. 127
        • 2.13.3 Function of flywheel — p. 127
        • 2.13.4 Specification of flywheel — p. 127
      • 2.14 Rocker arm assembly — p. 128
        • 2.14.1 Outline of rocker arm assembly — p. 128
        • 2.14.2 Structure of rocker arm assembly — p. 128
        • 2.14.3 Function of rocker arm assembly — p. 128
      • 2.15 Camshaft — p. 128
        • 2.15.1 Outline of camshaft — p. 128
        • 2.15.2 Structure of camshaft — p. 128
        • 2.15.3 Function of camshaft — p. 128
        • 2.15.4 Specification of camshaft — p. 128
      • 2.16 Valve — p. 129
        • 2.16.1 Outline of valve — p. 129
        • 2.16.2 Structure of valve — p. 129
        • 2.16.3 Function of valve — p. 129
        • 2.16.4 Specification of valve — p. 129
      • 2.17 Tappet — p. 129
        • 2.17.1 Outline of tappet — p. 129
        • 2.17.2 Structure of tappet — p. 129
        • 2.17.3 Function of tappet — p. 129
      • 2.18 Tappet assembly (for LM models) — p. 130
        • 2.18.1 Outline of tappet assembly — p. 130
        • 2.18.2 Structure of tappet assembly — p. 130
        • 2.18.3 Function of tappet assembly — p. 130
      • 2.19 Push rod — p. 131
        • 2.19.1 Outline of push rod — p. 131
        • 2.19.2 Structure of push rod — p. 131
        • 2.19.3 Function of push rod — p. 131
      • 2.20 Timing gears — p. 131
        • 2.20.1 Outline of timing gears — p. 131
        • 2.20.2 Structure of timing gears — p. 131
        • 2.20.3 Function of timing gears — p. 131
    • 3. Fuel system — p. 132
      • 3.1 Structure of common rail system (CRS) engine — p. 132
      • 3.2 Feature of common rail system (CRS) engine — p. 133
      • 3.3 Flow of common rail system (CRS) engine — p. 134
      • 3.4 Control of common rail system (CRS) engine — p. 136
      • 3.5 Fuel tank — p. 136
        • 3.5.1 Outline of fuel tank — p. 136
        • 3.5.2 Structure of fuel tank — p. 136
        • 3.5.3 Function of fuel tank — p. 136
        • 3.5.4 Specification of fuel tank — p. 136
      • 3.6 Water separator — p. 136
        • 3.6.1 Outline of water separator — p. 136
        • 3.6.2 Structure of water separator (Type1) — p. 136
        • 3.6.3 Structure of water separator (Type2) — p. 136
        • 3.6.4 Function of water separator — p. 137
        • 3.6.5 Specification of water separator (Type2) — p. 137
      • 3.7 Electromagnetic fuel feed pump — p. 137
        • 3.7.1 Outline of electromagnetic fuel feed pump — p. 137
        • 3.7.2 Structure of electromagnetic fuel feed pump — p. 137
        • 3.7.3 Function of electromagnetic fuel feed pump — p. 137
        • 3.7.4 Specification of electromagnetic fuel feed pump — p. 137
      • 3.8 Fuel feed pump — p. 138
        • 3.8.1 Outline of fuel feed pump — p. 138
        • 3.8.2 Structure of fuel feed pump — p. 138
        • 3.8.3 Function of fuel feed pump — p. 138
        • 3.8.4 Specification of fuel feed pump — p. 138
      • 3.9 Fuel filter — p. 139
        • 3.9.1 Outline of fuel filter — p. 139
        • 3.9.2 Structure of fuel filter — p. 139
        • 3.9.3 Function of fuel filter — p. 139
        • 3.9.4 Specification of fuel filter — p. 139
      • 3.10 Supply pump — p. 139
        • 3.10.1 Outline of supply pump — p. 139
        • 3.10.2 Structure of supply pump — p. 139
        • 3.10.3 Function of supply pump — p. 140
        • 3.10.4 Specification of supply pump — p. 142
      • 3.11 Injection pipe — p. 143
        • 3.11.1 Outline of injection pipe — p. 143
        • 3.11.2 Structure of injection pipe — p. 143
        • 3.11.3 Function of injection pipe — p. 143
      • 3.12 Rail assembly — p. 143
        • 3.12.1 Outline of rail assembly — p. 143
        • 3.12.2 Structure of rail assembly — p. 143
        • 3.12.3 Function of rail assembly — p. 143
        • 3.12.4 Specification of rail assembly — p. 144
      • 3.13 Injector — p. 145
        • 3.13.1 Outline of injector — p. 145
        • 3.13.2 Structure of injector — p. 145
        • 3.13.3 Function of injector — p. 146
        • 3.13.4 Specification of injector — p. 148
      • 3.14 Overflow pipe — p. 148
        • 3.14.1 Outline of overflow pipe — p. 148
        • 3.14.2 Structure of overflow pipe — p. 148
        • 3.14.3 Function of overflow pipe — p. 148
      • 3.15 Check valve — p. 148
        • 3.15.1 Outline of check valve — p. 148
        • 3.15.2 Structure of check valve — p. 148
        • 3.15.3 Function of check valve — p. 148
        • 3.15.4 Specification of check valve — p. 148
      • 3.16 Fuel cooler — p. 148
        • 3.16.1 Outline of fuel cooler — p. 148
        • 3.16.2 Structure of fuel cooler — p. 149
        • 3.16.3 Function of fuel cooler — p. 149
      • 3.17 Engine ECU — p. 149
        • 3.17.1 Outline of engine ECU — p. 149
        • 3.17.2 Structure of engine ECU — p. 149
        • 3.17.3 Function of engine ECU — p. 149
        • 3.17.4 Specification of engine ECU — p. 149
      • 3.18 Crankshaft position sensor — p. 150
        • 3.18.1 Outline of crankshaft position sensor — p. 150
        • 3.18.2 Structure of crankshaft position sensor — p. 150
        • 3.18.3 Function of crankshaft position sensor — p. 150
        • 3.18.4 Specification of crankshaft position sensor — p. 150
      • 3.19 Camshaft position sensor — p. 151
        • 3.19.1 Outline of camshaft position sensor — p. 151
        • 3.19.2 Structure of camshaft position sensor — p. 151
        • 3.19.3 Function of camshaft position sensor — p. 151
        • 3.19.4 Specification of camshaft position sensor — p. 151
      • 3.20 Coolant temperature sensor — p. 152
        • 3.20.1 Outline of coolant temperature sensor — p. 152
        • 3.20.2 Structure of coolant temperature sensor — p. 152
        • 3.20.3 Function of coolant temperature sensor — p. 152
        • 3.20.4 Specification of coolant temperature sensor — p. 152
      • 3.21 Boost pressure sensor — p. 153
        • 3.21.1 Outline of boost pressure sensor — p. 153
        • 3.21.2 Structure of boost pressure sensor — p. 153
        • 3.21.3 Function of boost pressure sensor — p. 153
        • 3.21.4 Specification of boost pressure sensor — p. 153
      • 3.22 Atmosphere pressure sensor — p. 153
        • 3.22.1 Outline of atmosphere pressure sensor — p. 153
        • 3.22.2 Structure of atmosphere pressure sensor — p. 153
        • 3.22.3 Function of atmosphere pressure sensor — p. 153
      • 3.23 Fuel camshaft — p. 154
        • 3.23.1 Outline of fuel camshaft — p. 154
        • 3.23.2 Structure of fuel camshaft — p. 154
        • 3.23.3 Function of fuel camshaft — p. 154
    • 4. Intake and exhaust system — p. 155
      • 4.1 Structure of intake and exhaust system — p. 155
      • 4.2 Structure of intake and exhaust system (for BG model) — p. 156
      • 4.3 Feature of intake and exhaust system — p. 157
      • 4.4 Flow of intake and exhaust system — p. 158
      • 4.5 Flow of intake and exhaust system (for BG model) — p. 160
      • 4.6 Control of intake and exhaust system — p. 162
      • 4.7 Pre-cleaner — p. 162
        • 4.7.1 Outline of pre-cleaner — p. 162
        • 4.7.2 Structure of pre-cleaner — p. 162
        • 4.7.3 Function of pre-cleaner — p. 162
        • 4.7.4 Specification of pre-cleaner — p. 162
      • 4.8 Air cleaner — p. 162
        • 4.8.1 Outline of air cleaner — p. 162
        • 4.8.2 Structure of air cleaner — p. 162
        • 4.8.3 Function of air cleaner — p. 162
        • 4.8.4 Specification of air cleaner — p. 162
      • 4.9 Turbocharger — p. 162
        • 4.9.1 Outline of turbocharger — p. 162
        • 4.9.2 Structure of turbocharger — p. 163
        • 4.9.3 Structure of turbocharger (for BG model) — p. 163
        • 4.9.4 Function of turbocharger — p. 163
        • 4.9.5 Specification of turbocharger — p. 163
      • 4.10 Intercooler — p. 163
        • 4.10.1 Outline of intercooler — p. 163
        • 4.10.2 Structure of intercooler — p. 163
        • 4.10.3 Function of intercooler — p. 163
        • 4.10.4 Specification of intercooler — p. 163
      • 4.11 Glow plug — p. 164
        • 4.11.1 Outline of glow plug — p. 164
        • 4.11.2 Structure of glow plug — p. 164
        • 4.11.3 Function of glow plug — p. 164
        • 4.11.4 Specification of glow plug — p. 164
      • 4.12 Intake manifold — p. 164
        • 4.12.1 Outline of intake manifold — p. 164
        • 4.12.2 Structure of intake manifold — p. 164
        • 4.12.3 Function of intake manifold — p. 164
      • 4.13 Exhaust manifold — p. 164
        • 4.13.1 Outline of exhaust manifold — p. 164
        • 4.13.2 Structure of exhaust manifold — p. 164
        • 4.13.3 Function of exhaust manifold — p. 165
    • 5. Exhaust gas recirculation (EGR) system — p. 166
      • 5.1 Structure of EGR system — p. 166
      • 5.2 Feature of EGR system — p. 167
      • 5.3 Flow of EGR system — p. 168
      • 5.4 Control of EGR system — p. 169
      • 5.5 EGR cooler — p. 169
        • 5.5.1 Outline of EGR cooler — p. 169
        • 5.5.2 Structure of EGR cooler — p. 169
        • 5.5.3 Function of EGR cooler — p. 169
        • 5.5.4 Specification of EGR cooler — p. 169
      • 5.6 EGR valve — p. 169
        • 5.6.1 Outline of EGR valve — p. 169
        • 5.6.2 Structure of EGR valve — p. 170
        • 5.6.3 Function of EGR valve — p. 172
        • 5.6.4 Specification of EGR valve — p. 172
      • 5.7 Reed valve — p. 172
        • 5.7.1 Outline of reed valve — p. 172
        • 5.7.2 Structure of reed valve — p. 172
        • 5.7.3 Function of reed valve — p. 172
    • 6. Lubricating system — p. 173
      • 6.1 Structure of lubricating system — p. 173
      • 6.2 Feature of lubricating system — p. 174
      • 6.3 Flow of lubricating system — p. 175
      • 6.4 Oil pan — p. 177
        • 6.4.1 Outline of oil pan — p. 177
        • 6.4.2 Structure of oil pan — p. 177
        • 6.4.3 Function of oil pan — p. 177
        • 6.4.4 Specification of oil pan — p. 177
      • 6.5 Oil strainer — p. 177
        • 6.5.1 Outline of oil strainer — p. 177
        • 6.5.2 Structure of oil strainer — p. 177
        • 6.5.3 Function of oil strainer — p. 177
        • 6.5.4 Specification of oil strainer — p. 177
      • 6.6 Oil pump — p. 178
        • 6.6.1 Outline of oil pump — p. 178
        • 6.6.2 Structure of oil pump — p. 178
        • 6.6.3 Function of oil pump — p. 178
        • 6.6.4 Specification of oil pump — p. 178
      • 6.7 Relief valve — p. 178
        • 6.7.1 Outline of relief valve — p. 178
        • 6.7.2 Structure of relief valve — p. 178
        • 6.7.3 Function of relief valve — p. 179
      • 6.8 Oil filter — p. 179
        • 6.8.1 Outline of oil filter — p. 179
        • 6.8.2 Structure of oil filter — p. 179
        • 6.8.3 Function of oil filter — p. 179
        • 6.8.4 Specification of oil filter — p. 179
      • 6.9 Oil cooler — p. 180
        • 6.9.1 Outline of oil cooler — p. 180
        • 6.9.2 Structure of oil cooler — p. 180
        • 6.9.3 Function of oil cooler — p. 180
        • 6.9.4 Specification of oil cooler — p. 180
      • 6.10 Oil pressure switch — p. 180
        • 6.10.1 Outline of oil pressure switch — p. 180
        • 6.10.2 Structure of oil pressure switch — p. 180
        • 6.10.3 Function of oil pressure switch — p. 181
        • 6.10.4 Specification of oil pressure switch — p. 181
    • 7. Cooling system — p. 182
      • 7.1 Structure of cooling system — p. 182
      • 7.2 Feature of cooling system — p. 183
      • 7.3 Flow of cooling system (Bottom by-pass system) — p. 183
      • 7.4 Control of cooling system (Bottom by-pass system) — p. 183
      • 7.5 Water pump — p. 184
        • 7.5.1 Outline of water pump — p. 184
        • 7.5.2 Structure of water pump — p. 184
        • 7.5.3 Function of water pump — p. 184
      • 7.6 Thermostat — p. 184
        • 7.6.1 Outline of thermostat — p. 184
        • 7.6.2 Structure of thermostat — p. 184
        • 7.6.3 Function of thermostat — p. 184
        • 7.6.4 Specification of thermostat — p. 185
      • 7.7 Radiator — p. 185
        • 7.7.1 Outline of radiator — p. 185
        • 7.7.2 Structure of radiator — p. 185
        • 7.7.3 Function of radiator — p. 185
        • 7.7.4 Specification of radiator — p. 185
      • 7.8 Radiator cap — p. 186
        • 7.8.1 Outline of radiator cap — p. 186
        • 7.8.2 Structure of radiator cap — p. 186
        • 7.8.3 Function of radiator cap — p. 186
        • 7.8.4 Specification of radiator cap — p. 186
      • 7.9 Cooling fan — p. 186
        • 7.9.1 Outline of cooling fan — p. 186
        • 7.9.2 Structure of cooling fan — p. 186
        • 7.9.3 Function of cooling fan — p. 186
        • 7.9.4 Specification of cooling fan — p. 187
      • 7.10 Reserve tank — p. 187
        • 7.10.1 Outline of reserve tank — p. 187
        • 7.10.2 Structure of reserve tank — p. 187
        • 7.10.3 Function of reserve tank — p. 187
      • 7.11 Fan belt — p. 187
        • 7.11.1 Outline of fan belt — p. 187
        • 7.11.2 Structure of fan belt — p. 187
        • 7.11.3 Function of fan belt — p. 187
      • 7.12 Auto tensioner assembly — p. 188
        • 7.12.1 Outline of auto tensioner assembly — p. 188
        • 7.12.2 Structure of auto tensioner assembly — p. 188
        • 7.12.3 Function of auto tensioner assembly — p. 188
    • 8. Electrical system — p. 189
      • 8.1 Structure of electrical system — p. 189
      • 8.2 Feature of electrical system — p. 190
      • 8.3 Flow of electrical system — p. 191
      • 8.4 Control of electrical system — p. 193
      • 8.5 Battery — p. 193
        • 8.5.1 Outline of battery — p. 193
        • 8.5.2 Structure of battery — p. 193
        • 8.5.3 Function of battery — p. 193
        • 8.5.4 Specification of battery — p. 193
      • 8.6 Key switch — p. 193
        • 8.6.1 Outline of key switch — p. 193
        • 8.6.2 Structure of key switch — p. 193
        • 8.6.3 Function of key switch — p. 194
        • 8.6.4 Specification of key switch — p. 194
      • 8.7 Starter (Planetary gear reduction type) — p. 194
        • 8.7.1 Outline of starter (planetary gear reduction type) — p. 194
        • 8.7.2 Structure of starter (planetary gear reduction type) — p. 194
        • 8.7.3 Function of starter (planetary gear reduction type) — p. 194
        • 8.7.4 Specification of starter (planetary gear reduction type) — p. 195
      • 8.8 Alternator — p. 195
        • 8.8.1 Outline of alternator — p. 195
        • 8.8.2 Structure of alternator — p. 195
        • 8.8.3 Function of alternator — p. 195
        • 8.8.4 Specification of alternator — p. 197
    • 9. Aftertreatment system — p. 198
      • 9.1 Structure of diesel particulate filter (DPF) system — p. 198
      • 9.2 Feature of diesel particulate filter (DPF) system — p. 198
      • 9.3 Flow of diesel particulate filter (DPF) system — p. 198
      • 9.4 Flow of diesel particulate filter (DPF) system (for BG model) — p. 199
      • 9.5 Control of diesel particulate filter (DPF) system — p. 200
      • 9.6 Control of exhaust heating catalyst (EHC) system (for BG model) — p. 202
        • 9.6.1 Control of exhaust gas heating — p. 202
        • 9.6.2 Control of automatic regeneration — p. 203
      • 9.7 Exhaust heating catalyst (EHC) (for BG model) — p. 205
        • 9.7.1 Outline of exhaust heating catalyst (EHC) — p. 205
        • 9.7.2 Structure of exhaust heating catalyst (EHC) — p. 205
        • 9.7.3 Function of exhaust heating catalyst (EHC) — p. 205
      • 9.8 Diesel oxidation catalyst (DOC) — p. 205
        • 9.8.1 Outline of diesel oxidation catalyst (DOC) — p. 205
        • 9.8.2 Structure of diesel oxidation catalyst (DOC) — p. 205
        • 9.8.3 Function of diesel oxidation catalyst (DOC) — p. 206
      • 9.9 Diesel particulate filter (DPF) — p. 206
        • 9.9.1 Outline of diesel particulate filter (DPF) — p. 206
        • 9.9.2 Structure of diesel particulate filter (DPF) — p. 206
        • 9.9.3 Function of diesel particulate filter (DPF) — p. 207
      • 9.10 Air flow sensor — p. 207
        • 9.10.1 Outline of air flow sensor — p. 207
        • 9.10.2 Structure of air flow sensor — p. 207
        • 9.10.3 Function of air flow sensor — p. 208
        • 9.10.4 Specification of air flow sensor — p. 208
      • 9.11 Exhaust gas temperature sensor — p. 209
        • 9.11.1 Outline of exhaust gas temperature sensor — p. 209
        • 9.11.2 Structure of exhaust gas temperature sensor — p. 209
        • 9.11.3 Function of exhaust gas temperature sensor — p. 209
        • 9.11.4 Specification of exhaust gas temperature sensor — p. 210
      • 9.12 Differential pressure sensor — p. 210
        • 9.12.1 Outline of differential pressure sensor — p. 210
        • 9.12.2 Structure of differential pressure sensor — p. 210
        • 9.12.3 Function of differential pressure sensor — p. 211
        • 9.12.4 Specification of differential pressure sensor — p. 211
      • 9.13 Intake throttle valve — p. 211
        • 9.13.1 Outline of intake throttle valve — p. 211
        • 9.13.2 Structure of intake throttle valve — p. 211
        • 9.13.3 Function of intake throttle valve — p. 212
        • 9.13.4 Specification of intake throttle valve — p. 212
      • 9.14 Exhaust throttle valve (for BG model) — p. 213
        • 9.14.1 Outline of exhaust throttle valve — p. 213
        • 9.14.2 Structure of exhaust throttle valve — p. 213
        • 9.14.3 Function of exhaust throttle valve — p. 213
        • 9.14.4 Specification of exhaust throttle valve — p. 213
  • SERVICING — p. 215
    • 1. Troubleshooting — p. 215
      • 1.1 Troubleshooting for 03 series engine — p. 215
    • 2. Service specifications — p. 219
      • 2.1 Service specifications for engine — p. 219
    • 3. Tightening torques — p. 224
      • 3.1 Tightening torques of screws, bolts and nuts for general use — p. 224
      • 3.2 Tightening torques of screws, bolts and nuts for special use — p. 224
    • 4. Checking and adjusting — p. 226
      • 4.1 Checking compression pressure of cylinder — p. 226
      • 4.2 Adjusting valve clearance — p. 227
      • 4.3 Checking engine oil pressure — p. 227
      • 4.4 Checking fan belt tension (for standard model) — p. 228
      • 4.5 Checking fan belt damage and wear — p. 229
      • 4.6 Checking tappet assembly — p. 229
      • 4.7 Checking radiator cap air leakage — p. 230
      • 4.8 Checking radiator water leakage — p. 230
      • 4.9 Checking opening temperature of thermostat valve — p. 230
      • 4.10 Checking battery voltage — p. 231
      • 4.11 Checking battery specific gravity — p. 231
      • 4.12 Checking starter motor — p. 232
      • 4.13 Checking magnetic switch of starter — p. 233
      • 4.14 Checking magnetic switch continuity — p. 234
      • 4.15 Checking alternator on unit — p. 234
      • 4.16 Checking glow plug continuity — p. 235
      • 4.17 Checking exhaust gas leakage of turbocharger turbine side — p. 235
      • 4.18 Checking air leakage of turbocharger compressor side — p. 235
      • 4.19 Checking radial clearance of turbocharger — p. 236
      • 4.20 Checking injector — p. 236
      • 4.21 Checking suction control valve (SCV) — p. 236
      • 4.22 Checking rail pressure sensor — p. 237
      • 4.23 Checking boost pressure sensor — p. 237
      • 4.24 Checking crankshaft position sensor — p. 238
      • 4.25 Checking camshaft position sensor — p. 238
      • 4.26 Checking coolant temperature sensor — p. 238
      • 4.27 Checking EGR system — p. 239
      • 4.28 Checking exhaust heating catalyst (EHC) and exhaust throttle valve (for BG model) — p. 239
      • 4.29 Checking air flow sensor — p. 239
      • 4.30 Checking exhaust gas temperature sensor — p. 240
      • 4.31 Selecting cylinder head gasket — p. 240
      • 4.32 Measuring angular deviation between crankshaft T.D.C. and crankshaft position sensor detected T.D.C — p. 241
      • 4.33 Adjusting air gap between crankshaft position sensor and flywheel — p. 243
      • 4.34 Adjusting air gap between camshaft position sensor and pulsar gear — p. 244
    • 5. Disassembling — p. 244
      • 5.1 Draining engine oil — p. 244
      • 5.2 Draining coolant — p. 244
      • 5.3 Removing CRS intermediate harness — p. 245
      • 5.4 Removing external components (for standard model) — p. 245
      • 5.5 Removing external components (for LM model) — p. 246
      • 5.6 Removing DPF muffler full assembly (except V2403-CR-TIE5) — p. 247
      • 5.7 Removing DPF muffler full assembly (V2403-CR-TIE5) — p. 248
      • 5.8 Disassembling DPF muffler full assembly (except V2403-CR-TIE5) — p. 249
      • 5.9 Disassembling DPF muffler full assembly (V2403-CR-TIE5) — p. 250
      • 5.10 Removing exhaust throttle valve (for BG model) — p. 251
      • 5.11 Removing exhaust heating catalyst (EHC) (for BG model) — p. 251
      • 5.12 Removing EGR cooler — p. 251
      • 5.13 Removing turbocharger — p. 252
      • 5.14 Removing intake throttle valve — p. 252
      • 5.15 Removing EGR valve — p. 252
      • 5.16 Removing common rail — p. 252
      • 5.17 Removing sensors — p. 253
      • 5.18 Removing cylinder head cover — p. 254
      • 5.19 Removing glow plug — p. 254
      • 5.20 Removing injector — p. 254
      • 5.21 Removing rocker arm assembly — p. 255
      • 5.22 Removing cylinder head — p. 255
      • 5.23 Removing tappet / tappet assembly — p. 256
      • 5.24 Removing valve — p. 256
      • 5.25 Removing thermostat assembly — p. 257
      • 5.26 Removing suction control valve (SCV) — p. 257
      • 5.27 Removing supply pump — p. 258
      • 5.28 Removing oil cooler — p. 258
      • 5.29 Removing water pump — p. 259
      • 5.30 Removing fan drive pulley — p. 259
      • 5.31 Removing gear case cover — p. 259
      • 5.32 Removing crankshaft oil slinger — p. 259
      • 5.33 Removing idle gear — p. 260
      • 5.34 Removing fuel camshaft assembly — p. 260
      • 5.35 Removing camshaft with cam gear — p. 261
      • 5.36 Removing oil pump — p. 261
      • 5.37 Removing crank gear — p. 261
      • 5.38 Removing oil pan and oil strainer — p. 262
      • 5.39 Removing piston — p. 262
      • 5.40 Removing piston ring — p. 262
      • 5.41 Disassembling piston assembly — p. 263
      • 5.42 Removing flywheel — p. 263
      • 5.43 Removing flywheel housing — p. 264
      • 5.44 Removing bearing case cover — p. 264
      • 5.45 Removing crankshaft (for 3 cylinders) — p. 264
      • 5.46 Removing crankshaft (for 4 cylinders) — p. 265
      • 5.47 Removing main bearing case — p. 266
      • 5.48 Disassembling starter — p. 266
      • 5.49 Disassembling alternator — p. 266
    • 6. Assembling — p. 267
      • 6.1 Assembling alternator — p. 267
      • 6.2 Assembling starter — p. 269
      • 6.3 Installing main bearing case — p. 270
      • 6.4 Installing crankshaft (for 3 cylinders) — p. 271
      • 6.5 Installing crankshaft (for 4 cylinders) — p. 271
      • 6.6 Installing bearing case cover — p. 272
      • 6.7 Installing flywheel housing — p. 272
      • 6.8 Installing flywheel — p. 272
      • 6.9 Assembling piston assembly — p. 273
      • 6.10 Installing piston ring — p. 274
      • 6.11 Installing piston — p. 274
      • 6.12 Installing oil strainer and oil pan — p. 276
      • 6.13 Installing crank gear — p. 277
      • 6.14 Installing oil pump — p. 277
      • 6.15 Installing camshaft with cam gear — p. 277
      • 6.16 Installing fuel camshaft with supply pump gear — p. 278
      • 6.17 Installing idle gear — p. 278
      • 6.18 Installing crankshaft oil slinger — p. 279
      • 6.19 Installing gear case cover — p. 279
      • 6.20 Installing fan drive pulley — p. 279
      • 6.21 Installing water pump — p. 280
      • 6.22 Installing oil cooler — p. 280
      • 6.23 Installing supply pump — p. 281
      • 6.24 Installing suction control valve (SCV) — p. 281
      • 6.25 Installing thermostat assembly — p. 282
      • 6.26 Installing valve — p. 282
      • 6.27 Installing tappet / tappet assembly — p. 282
      • 6.28 Installing cylinder head — p. 283
      • 6.29 Installing rocker arm assembly (for standard model) — p. 285
      • 6.30 Installing rocker arm assembly (for LM model) — p. 285
      • 6.31 Installing injector — p. 287
      • 6.32 Installing glow plug — p. 288
      • 6.33 Installing cylinder head cover — p. 288
      • 6.34 Installing sensors — p. 288
      • 6.35 Installing common rail — p. 289
      • 6.36 Installing EGR valve — p. 290
      • 6.37 Installing intake throttle valve — p. 290
      • 6.38 Installing turbocharger assembly — p. 290
      • 6.39 Installing EGR cooler — p. 291
      • 6.40 Installing exhaust heating catalyst (EHC) (for BG model) — p. 291
      • 6.41 Installing exhaust throttle valve (for BG model) — p. 292
      • 6.42 Assembling DPF muffler full assembly (except V2403-CR-TIE5) — p. 292
      • 6.43 Assembling DPF muffler full assembly (V2403-CR-TIE5) — p. 293
      • 6.44 Installing muffler full assembly (except V2403-CR-TIE5) — p. 294
      • 6.45 Installing DPF muffler full assembly (V2403-CR-TIE5) — p. 295
      • 6.46 Installing CRS intermediate harness — p. 297
      • 6.47 Installing CRS intermediate harness (for BG model) — p. 299
      • 6.48 Installing external components (for standard model) — p. 301
      • 6.49 Installing external components (for LM model) — p. 302
      • 6.50 Filling coolant — p. 303
      • 6.51 Filling engine oil — p. 303
    • 7. Servicing — p. 303
      • 7.1 Checking cylinder head top clearance — p. 303
      • 7.2 Checking cylinder head surface flatness — p. 304
      • 7.3 Checking cylinder head flaw — p. 304
      • 7.4 Checking valve recessing — p. 305
      • 7.5 Adjusting valve lapping — p. 305
      • 7.6 Checking clearance between valve stem and valve guide — p. 306
      • 7.7 Replacing valve guide — p. 306
      • 7.8 Adjusting valve angle — p. 307
      • 7.9 Adjusting valve seat — p. 307
      • 7.10 Checking free length of valve spring — p. 308
      • 7.11 Checking tilt of valve spring — p. 308
      • 7.12 Checking set load of valve spring — p. 309
      • 7.13 Checking oil clearance between rocker arm and rocker arm shaft — p. 309
      • 7.14 Checking push rod alignment — p. 310
      • 7.15 Checking oil clearance between tappet / tappet assembly and tappet guide bore — p. 310
      • 7.16 Checking timing gear backlash — p. 310
      • 7.17 Checking side clearance of idle gear — p. 311
      • 7.18 Checking side clearance of camshaft — p. 311
      • 7.19 Checking camshaft alignment — p. 312
      • 7.20 Replacing idle gear bushing — p. 312
      • 7.21 Checking cam height — p. 313
      • 7.22 Checking oil clearance between camshaft journal and crankcase bore — p. 313
      • 7.23 Checking oil clearance between idle gear shaft and idle gear bushing — p. 314
      • 7.24 Checking piston pin bore I.D — p. 314
      • 7.25 Checking oil clearance between piston pin and small end bushing — p. 314
      • 7.26 Replacing small end bushing — p. 315
      • 7.27 Checking connecting rod alignment — p. 316
      • 7.28 Checking piston ring gap — p. 316
      • 7.29 Checking clearance between piston ring and ring groove — p. 317
      • 7.30 Checking side clearance of crankshaft — p. 318
      • 7.31 Checking crankshaft alignment — p. 319
      • 7.32 Checking oil clearance between crankpin and crankpin bearing — p. 320
      • 7.33 Checking oil clearance between crankshaft journal and crankshaft bearing 1 — p. 320
      • 7.34 Replacing crankshaft sleeve — p. 321
      • 7.35 Replacing crankshaft bearing 1 — p. 322
      • 7.36 Checking oil clearance between crankshaft journal and crankshaft bearing 2 — p. 322
      • 7.37 Replacing bearing case cover oil seal — p. 323
      • 7.38 Checking cylinder wear — p. 324
      • 7.39 Adjusting cylinder correction (over size) — p. 324
      • 7.40 Checking clearance between inner rotor and outer rotor — p. 325
      • 7.41 Checking clearance between outer rotor and pump body — p. 325
      • 7.42 Checking clearance between rotor and cover — p. 326
      • 7.43 Checking overrunning clutch of starter — p. 326
      • 7.44 Checking commutator and mica of starter — p. 326
      • 7.45 Checking brush wear of starter — p. 327
      • 7.46 Checking brush holder of starter — p. 328
      • 7.47 Checking armature coil of starter — p. 328
      • 7.48 Checking field coil of starter — p. 329
      • 7.49 Checking bearing of alternator — p. 329
      • 7.50 Checking stator of alternator — p. 329
      • 7.51 Checking rotor of alternator — p. 330
      • 7.52 Checking slip ring of alternator — p. 330
      • 7.53 Checking brush wear of alternator — p. 331
      • 7.54 Checking rectifier — p. 331
      • 7.55 Checking IC regulator — p. 331
      • 7.56 Replacing injector — p. 332
      • 7.57 Replacing engine ECU — p. 334
      • 7.58 Replacing DPF — p. 337

Capabilities

The source outline separates mechanism explanations from servicing instructions for 4. Engine. Use these indexed headings to locate the applicable system in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service work.

Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.

Technical reference

Reference tables include torque settings, wear limits, fluid and system capacities, dimensions, and speed ratings for service checks, adjustment work, and specification lookup. Use the values and conditions in the PDF for the applicable model and procedure.

• Service limits and settings: torque settings and wear limits.
• Fluid reference: fluid and system capacities.
• Machine specifications: dimensions and speed ratings.

Delivery

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Workshop Manual for Engine, document code 9Y311-00022, PDF edition.