Kubota V2203 Workshop Manual

WORKSHOP MANUAL
DIESEL ENGINE
03-E2B SERIES
KiSC issued 06, 2006 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of 03-E2B series. It is divided
into three parts, “General”, “Mechanism” and “Servicing”.
■ General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
■ 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. 9Y021-01870) for
the one which has not been described to this workshop manual.
■ 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.
Do to covering many models of this manual, information or picture being used have
not been specified as one model.
May 2004
© KUBOTA Corporation 2004

03-E2B SERIES, 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.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■ 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
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.

2
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.

3
03-E2B SERIES, WSM SPECIFICATIONS
SPECIFICATIONS
Model D1403-E2B D1503-E2B D1703-E2B
Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle diesel engine
Bore × Stroke 80 × 92.4 mm (3.15 × 3.64 in.) 83 × 92.4 mm (3.27 × 3.64 in.) 87 × 92.4 mm (3.43 × 3.64 in.)
Total Displacement 1393 cm3 (85.01 cu.in.) 1499 cm3 (91.47 cu.in.) 1647 cm3 (100.51 cu.in.)
ISO Net Continuous 18.8 kW / 2800 min-1 (rpm) 20.4 kW / 2800 min-1 (rpm) 22.4 kW / 2800 min-1 (rpm)
(25.5 HP / 2800 min-1 (rpm)) (27.3 HP / 2800 min-1 (rpm)) (30.0 HP / 2800 min-1 (rpm))
ISO/SAE Net Intermittent 21.6 kW / 2800 min-1 (rpm) 23.5 kW / 2800 min-1 (rpm) 25.7 kW / 2800 min-1 (rpm)
SAE Gross Intermittent 23.1 kW / 2800 min-1 (rpm) 24.9 kW / 2800 min-1 (rpm) 27.5 kW / 2800 min-1 (rpm)
Maximum Bare Speed 3000 min-1 (rpm)
Minimum Bare Idling Speed 700 to 750 min-1 (rpm)
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch throttle type
Injection Timing 0.314 rad (18 °) before T.D.C.
Firing Order 1-2-3
Injection Pressure 13.73 MPa (140 kgf/cm2, 1991 psi)
Compression Ratio 23 : 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, 1.4 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, 8.
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 (326.3 lbs)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10329950

4
Model V1903-E2B V2003-TE2B

Number of Cylinders 4
Bore × Stroke 80 × 92.4 mm (3.15 × 3.64 in.) 83 × 92.4 mm (3.27 × 3.64 in.)
3
Total Displacement 1857 cm (113.32 cu.in.) 1999 cm3 (121.99 cu.in.)
-1
ISO Net Continuous 25.4 kW / 2800 min (rpm) 36.3 kW / 2800 min-1 (rpm)
(34.0 HP / 2800 min-1 (rpm)) (48.7 HP / 2800 min-1 (rpm))
ISO/SAE Net Intermittent 29.1 kW / 2800 min-1 (rpm) 41.8 kW / 2800 min-1 (rpm)
SAE Gross Intermittent 31.0 kW / 2800 min-1 (rpm) 44.5 kW / 2800 min-1 (rpm)
-1
Minimum Bare Idling Speed 700 to 750 min (rpm) 750 to 850 min-1 (rpm)
Injection Timing 0.314 rad (18 °) before T.D.C.
Firing Order 1-3-4-2
Charging Alternator 12 V, 360 W 12 V, 480 W
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.)
Weight (Dry) 180 kg (397 lbs) 186 kg (410 lbs)
W10307730

5
Model V2203-E2B F2803-E2B

Number of Cylinders 4 5
Bore × Stroke 87 × 92.4 mm (3.43 × 3.64 in.)
3
Total Displacement 2197 cm (134.07 cu.in.) 2746 cm3 (167.57 cu.in.)
-1
ISO Net Continuous 29.8 kW / 2800 min (rpm) 37.3 kW / 2800 min-1 (rpm)
ISO/SAE Net Intermittent 34.3 kW / 2800 min-1 (rpm) 42.9 kW / 2800 min-1 (rpm)
SAE Gross Intermittent 36.4 kW / 2800 min-1 (rpm) 46.2 kW / 2800 min-1 (rpm)
Minimum Bare Idling Speed 700 to 750 min-1 (rpm)
Injection Timing 0.314 rad (18 °) before T.D.C. 0.332 rad (19 °) before T.D.C.
Firing Order 1-3-4-2 1-3-5-4-2
Charging Alternator 12 V, 420 W
7.6 L (2.01 U.S.gals) –
Oil Pan Depth
9.5 L (2.51 U.S.gals) 12.0 L (3.17 U.S.gals)
124 mm (4.88 in.)
Weight (Dry) 180 kg (397 lbs) 223 kg (492 lbs)
W10327090

6
03-E2B SERIES, WSM DIMENSIONS
DIMENSIONS
D1403-E2B D1503-E2B D1703-E2B

A 560.1 mm (22.05 in.) 560.1 mm (22.05 in.) 560.1 mm (22.05 in.)
B 502.5 mm (19.78 in.) 502.5 mm (19.78 in.) 502.5 mm (19.78 in.)
C 678.2 mm (26.70 in.) 678.2 mm (26.70 in.) 678.2 mm (26.70 in.)
W1028881

7
V1903-E2B V2003-TE2B V2003-E2B

A 652.1 mm (25.67 in.) 667.1 mm (26.26 in.) 652.1 mm (25.67 in.)
B 502.5 mm (19.78 in.) 520.0 mm (20.47 in.) 502.5 mm (19.78 in.)
C 678.2 mm (26.70 in.) 678.0 mm (26.69 in.) 678.2 mm (26.70 in.)
W1033724

8
F2803-E2B
A 779.2 mm (30.68 in.)
B 502.5 mm (19.78 in.)
C 739.2 mm (29.10 in.)
W1033845

9
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 POINT OF EVERY 50 HOURS ............................................. G-10
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-11
[9] CHECK POINTS OF EVERY 1 OR 2 MONTHS ............................... G-20
[10]CHECK POINT OF EVERY YEAR....................................................... G-21
[11]CHECK POINT OF EVERY 800 HOURS ........................................... G-22
[12]CHECK POINTS OF EVERY 1500 HOURS ....................................... G-23
[13]CHECK POINTS OF EVERY 3000 HOURS ....................................... G-25
[14]CHECK POINTS OF EVERY 2 YEARS.............................................. G-28
5. SPECIAL TOOLS .......................................................................................... G-32

03-E2B SERIES, 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.
■ 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
• 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. D1703-4A0001
“4” indicates 2004 and “A” indicates January.
So, 4A indicates that the engine was manufactured in January,
2004.
W1011076
[2] E2B ENGINE

[ex. Model Name D1703-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-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

G-2
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

G-3
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
50 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs 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 ✩
Cleaning water jacket and radiator interior ✩
Replacing fan belt ✩
Recharging battery ✩
* Replacing air cleaner element ✩
Checking valve clearance ✩
* Checking injection nozzle pressure ✩
* Checking turbocharger ✩
* Checking injection timing ✩
* 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

G-4
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
■ 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 ❍ ❍ TBN ≥ 10
CF-4 ❍ X
CG-4 ❍ X
❍ : Recommendable X : Not recommendable
W1035555

G-5
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.
■ IMPORTANT
• When using an oil of different maker or viscosity from the
previous, drain old oil. Never mix two different types of oil.
■ 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

G-6
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.
■ 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

G-7
[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).
■ 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.)
D1403-E2B
7.0 L 5.6 L
D1503-E2B
1.85 U.S.gals 1.48 U.S.gals
D1703-E2B
V1903-E2B 9.5 L 7.6 L
V2203-E2B 2.51 U.S.gals 2.01 U.S.gals
9.8 L 7.9 L
V2003-TE2B
12.0 L
F2803-E2B –
3.17 U.S.gals
*90 mm (3.54 in.) oil pan depth is optional.
(1) Drain Plug (2) Dipstick
W1016604

G-8
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.
■ 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

G-9
[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.
■ 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

G-10

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.
■ 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.
■ 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 lbs).
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

G-11
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

G-12

Changing Engine Oil (for 90 mm (3.54 in.) Depth Oil Pan)
CAUTION
■ 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.)
D1403-E2B
7.0 L 5.6 L
D1503-E2B
D1703-E2B
V1903-E2B 9.5 L 7.6 L
9.8 L 7.9 L
V2003-TE2B
12.0 L
F2803-E2B –
3.17 U.S.gals
W1016063

G-13
Replacing Oil Filter Cartridge (for 90 mm (3.54 in.) Depth Oil

Pan)
CAUTION
■ IMPORTANT
W1016338

G-14

Changing Engine Oil (for 124 mm (4.88 in.) Depth Oil Pan)
CAUTION
■ 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.)
D1403-E2B
7.0 L 5.6 L
D1503-E2B
D1703-E2B
V1903-E2B 9.5 L 7.6 L
9.8 L 7.9 L
V2003-TE2B
12.0 L
F2803-E2B –
3.17 U.S.gals
W1016525

G-15
Replacing Oil Filter Cartridge (for 124 mm (4.88 in.) Depth Oil
Pan)
CAUTION
■ IMPORTANT
W1016800
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) and the breather hose (3)
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) and the breather hose are made of rubber
and tends to age. It must be changed every two years. Also
change the clamp and tighten it securely.
■ IMPORTANT
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (3) Breather Hose
(2) Clamp
W1029631

G-16

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

G-17

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.
■ 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

G-18
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.
■ 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 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
■ 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 lbs)
(1) Fan Belt (A) Deflection

W1052220

G-19
[9] 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, charging 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.
■ Precaution for Operating a Quick Charger
• Operating with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
W1052658

G-20
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.
■ 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
[10] CHECK POINTS OF EVERY YEAR

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

G-21

Valve Clearance
■ 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.
■ 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 D1403-E2B V1903-E2B
arrangement D1503-E2B V2203-E2B F2803-E2B
Adjustable D1703-E2B V2003-TE2B
cylinder
location of piston IN. EX. IN. EX. IN. EX.
No. 1 ✩ ✩ ✩ ✩ ✩ ✩
When No. 1 piston No. 2 ✩ ✩ ✩
comes to
No. 3 ✩ ✩ ✩
compression top
dead center No. 4 – –
No. 5 – – – –
No. 1
No. 2 ✩ ✩ ✩
When No. 1 piston
comes to overlap No. 3 ✩ ✩ ✩
position
No. 4 – – ✩ ✩ ✩ ✩
No. 5 – – – – ✩ ✩
(1) Valve Clearance (3) TC Mark Line

(2) Projection
W10113200

G-22

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 nozzle piece.
(a) Good (b) Bad
W10411400
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 adjusting washer (1) in the nozzle holder to adjust it.
(Reference)
• Pressure variation with 0.025 mm (0.0010 in.) difference of
adjusting washer thickness.
Approx. 588 kPa (6.0 kgf/cm2, 85 psi)
13.73 to 14.71 MPa
Fuel injection pressure Factory spec. 140 to 150 kgf/cm2
1991 to 2134 psi
(1) Adjusting Washer

W10182100
Valve Seat Tightness

2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm2,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec.
130 kgf/cm2
1849 psi
W10412730

G-23
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• Assemble the nozzle in clean fuel oil.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
34.3 to 39.2 N·m
Nozzle holder 3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
19.6 to 24.5 N·m
Tightening torque Overflow pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
49.0 to 68.6 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
36.2 to 50.6 ft-lbs
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
W1018491

G-24

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

G-25
Injection Timing
1. Remove the injection pipes and nozzle.
2. Set the speed control lever to maximum fuel discharge position.
(Reference)
• Turn the flywheel with screwdriver.
3. Turn the flywheel counterclockwise (facing the flywheel) until the
fuel fills up to the hole of the delivery valve holder for 1st cylinder.
4. Turn the flywheel further and stop turning when the fuel begins to
flow over, to get the present injection timing.
5. (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.
[D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
0.297 to 0.331 rad (17 to
Injection timing Factory spec.
19 °) before T.D.C.
[F2803-E2B]
0.314 to 0.349 rad (18 to
■ 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 0.20 mm, 0.25 mm and
0.30 mm. Combine these shims for adjustments.
• 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 (4) 2-holes : 0.20 mm (Shim)
(2) Timing Mark (5) 1-hole : 0.25 mm (Shim)
(3) Shim (Soft Metal Gasket Shim) (6) Without hole : 0.30 mm (Shim)
W1023147

G-26
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 hand and raise the pressure to approx.
13.73 MPa (140 kgf/cm2, 1991 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 13.73 to 12.75 MPa (from 140
to 130 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (from 140 to 130 kgf/cm2, from 1991 to 1849 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.
13.73 MPa
Fuel tightness of pump
Allowable limit 140 kgf/cm2
element
1991 psi
10 seconds
13.73 → 12.75 MPa
Factory spec.
140 → 130 kgf/cm2
Fuel tightness of 1991 → 1849 psi
delivery valve 5 seconds
13.73 → 12.75 MPa
Allowable limit
140 → 130 kgf/cm2
1991 → 1849 psi
■ 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

G-27
[14] 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).
■ 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

G-28
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.
■ 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

G-29
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 (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.
■ 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) Drain Cock
(4) Recovery Tank
W1024599

G-30
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.
■ 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 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
■ 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

G-31
5. SPECIAL TOOLS
Diesel Engine Compression Tester
Code No: 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F) 07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and
diagnosis of need for major overhaul.
(1) Gauge (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
W1024200
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

G-32
■ 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

G-33
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 (F2803-E2B)
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 56.8 to 56.9 mm dia. (2.236 to 2.240 in. dia.)
2. Inserting tool
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
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 51.8 to 51.9 mm dia. (2.039 to 2.043 in. dia.)
J 56.8 to 56.9 mm dia. (2.236 to 2.240 in. dia.)
W1026139
G-34
Crankshaft Bearing 1 Replacing Tool

(D1403/D1503/D1703/V1903/V2003-T/V2203-E2B)
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.)
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.)
2. Inserting tool
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
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.)
W1025644
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

G-35
Auxiliary Socket for Fixing Crankshaft Sleeve

Application: Use to fix the crankshaft sleeve of the diesel engine.
A 80.0 mm (3.1496 in.)
F2803-E2B 52.1 to 52.3 mm (2.0512 to 2.0591 in.)
D1403-E2B
D1503-E2B
B D1703-E2B
60.1 to 60.3 mm (2.3661 to 2.3740 in.)
V1903-E2B
V2003-TE2B
V2203-E2B
C 80.0 mm dia. (3.1496 in. dia.)
D 85.0 mm dia. (3.3465 in. dia.)
F2803-E2B 52.1 to 52.3 mm dia. (2.0512 to 2.0591 in. dia.)
D1403-E2B
D1503-E2B
E D1703-E2B
60.1 to 60.3 mm dia. (2.3661 to 2.3740 in. dia.)
V1903-E2B
V2003-TE2B
V2203-E2B
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

G-36
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

G-37
MECHANISM
CONTENTS
1. ENGINE BODY ............................................................................................... M-1

[1] HALF-FLOATING HEAD COVER ............................................................ M-1
[2] CLOSED BREATHER (D1403 / D1503 / D1703 / V1903 / V2203-E2B) .. M-1
2. FUEL SYSTEM ............................................................................................... M-1
[1] GOVERNOR .............................................................................................. M-1

03-E2B SERIES, WSM DIESEL ENGINE
1. ENGINE BODY
[1] 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
[2] CLOSED BREATHER (D1403 / D1503 / D1703 / V1903 / V2203-E2B)

Closed breather system has been adopted to prevent
the release of blow-by gas into the atmosphere.
After its oil content is filtered by oil shield (4), the blow-
by gas is fed back to the intake manifold through breather
valve (3) to be used for re-combustion.
(1) Breather Hose (4) Oil Shield
(2) Cylinder Head Cover (5) Rubber Packing
(3) Breather Valve

M-1
2. 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

M-2
SERVICING
CONTENTS
1. TROUBLESHOOTING ......................................................................................S-1
2. SERVICING SPECIFICATIONS ......................................................................S-1
3. TIGHTENING TORQUES ..............................................................................S-13
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-13
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-14
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-15
[1] CHECKING AND ADJUSTING ...............................................................S-15
(1) Engine Body........................................................................................S-15
(2) Lubricating System .............................................................................S-17
(3) Cooling System...................................................................................S-17
(4) Fuel System ........................................................................................S-20
(5) Electrical System ................................................................................S-23
(6) Turbocharger ......................................................................................S-27
[2] DISASSEMBLING AND ASSEMBLING..................................................S-28
(1) Draining Oil and Coolant .....................................................................S-28
(2) External Components .........................................................................S-28
(3) Cylinder Head and Valves ..................................................................S-30
(4) Gear Case and Timing Gears .............................................................S-35
(5) Piston and Connecting Rod ................................................................S-40
(6) Flywheel and Crankshaft ....................................................................S-44
(7) Starter .................................................................................................S-47
(8) Alternator ............................................................................................S-48
[3] SERVICING ..............................................................................................S-49
(1) Cylinder Head and Valves ..................................................................S-49
(2) Timing Gears ......................................................................................S-54
(3) Piston and Connecting Rod ................................................................S-57
(4) Crankshaft...........................................................................................S-60
(5) Cylinder ...............................................................................................S-66
(6) Oil Pump .............................................................................................S-67
(7) Starter .................................................................................................S-68
(8) Alternator ............................................................................................S-70

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-10, 17
Excessively high viscosity of fuel or engine oil at Use specified fuel or 4, 5, 6, G-8
low temperature engine oil
Fuel with low cetane number Use specified fuel 4, 5, 6
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31
Incorrect injection timing Adjust S-20
Fuel camshaft worn Replace S-39
Injection nozzle clogged Repair or replace S-22, 23
Injection pump malfunctioning Repair or replace S-21, 35
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace S-38 to 43
or bearing S-60 to 67
Compression leak from cylinder Replace head S-31, 32,
gasket, tighten 33
cylinder head screw,
glow plug and nozzle
holder
Improper valve timing Correct or replace S-38
timing gear
Piston ring and cylinder worn Replace S-41, 42,
43, 59
Excessive valve clearance Adjust S-16
Stop solenoid malfunctioning Replace –
Starter Does Not Run Battery discharged Charge G-20
Starter malfunctioning Repair or replace S-28, 68,
69, 70
Key switch malfunctioning Replace –
Wiring disconnected Connect –
W1014322

S-1
Reference
Page
Engine Revolution Is Fuel filter clogged or dirty Replace G-10, 17
Not Smooth Air cleaner clogged Clean or replace G-11, 16,
21
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-31
Incorrect nozzle opening pressure Repair or replace S-22
Injection nozzle stuck or clogged Repair or replace S-22, 23
Governor malfunctioning Repair S-35, 36,
39
Turbocharger bearing worn out Replace the S-27
turbocharger
assembly
Turbocharger shaft bent Replace the S-27
turbocharger
assembly
Turbocharger fin or other part damaged due to Replace the S-27
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-41, 42,
43, 59
Oil Leak into Exhaust Oil pipe clogged or deformed Repair or replace S-27
Pipe or Suction Pipe Turbocharger’s piston ring seal faulty Replace the S-27
turbocharger
assembly
Either Black or Dark Overload Reduce the load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel 4, 5, 6
Observed
Fuel filter clogged Replace G-10, 17
Air cleaner clogged Clean or replace G-11, 16,
21
Deficient nozzle injection Repair or replace S-22, 23
nozzle
W1011567

S-2
Reference
Page
Deficient Output Incorrect injection timing Adjust S-20
Engine’s moving parts seem to be seizing Repair or replace –
Deficient nozzle injection Repair or replace S-22, 23
nozzle
Compression leak Check the S-15
compression
pressure and repair
Gas leak from exhaust system Repair or replace S-27, 29
Air leak from compressor discharge side Repair or replace S-27, 29
Air cleaner dirty or clogged Clean or replace G-11, 16,
21
Turbocharger compressor wheel turning heavily Replace the S-27
turbocharger
assembly
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap S-42
OIl Consumption direction
Oil ring worn or stuck Replace S-41, 42,
43
Piston ring groove worn Replace piston S-41, 42,
43
Valve stem and valve guide worn Replace S-34, 50,
51
Crankshaft bearing and crank pin bearing worn Replace S-46, 61 to
64
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Repair or replace S-21, 35
Lubricant Oil Deficient nozzle injection Repair or replace S-22, 23
nozzle
Injection pump broken Replace S-35
Water Mixed into Head gasket defective Replace S-33
Lubricant Oil Cylinder block or cylinder head flawed Replace S-33
Low Oil Pressure Engine oil insufficient Replenish G-6
Oil strainer clogged Clean S-40
Relief valve stuck with dirt Clean –
Relief valve spring weaken or broken Replace –
Excessive oil clearance of crankshaft bearing Replace S-45
Excessive oil clearance of crankpin bearing Replace S-41, 42,
43
Excessive oil clearance of rocker arm Replace S-32
Oil passage clogged Clean –
Different type of oil Use specified type of G-8
oil
Oil pump defective Replace S-39
W1012032
S-3
Reference
Page
High Oil Pressure Different type of oil Use specified type of G-8
oil
Relief valve defective Replace –
Engine overheated Engine oil insufficient Replenish G-6
Fan belt broken or elongated Replace or adjust G-11, 12
Coolant insufficient Replenish G-7
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace G-18
Coolant flow route corroded Clean or replace G-18, 19
Radiator cap defective Replace S-18
Overload running Reduce the load –
Head gasket defective Replace S-33
Unsuitable fuel used Use specified fuel 4, 5, 6
Battery Quickly Battery electrolyte insufficient Replenish distilled G-11
Discharged water and charge
Fan belt slips Adjust belt tension or G-11, 12
replace
Wiring disconnected Connect –
Rectifier defective Replace S-71
Alternator defective Replace S-26
Battery defective Replace G-28
W1012501

S-4
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 3.53 to 3.72 MPa / 2.55 MPa /
(When Cranking with Starting Motor) 290 min-1 (rpm) 290 min-1 (rpm)
36 to 38 kgf/cm2 / 26 kgf/cm2 /
290 min-1 (rpm) 290 min-1 (rpm)
512 to 540 psi / 370 psi /
290 min-1 (rpm) 290 min-1 (rpm)
Difference among Cylinders – 10 % or less

Top Clearance 0.55 to 0.70 mm –
0.0217 to 0.0276 in.
Cylinder Head Surface Flatness – 0.05 mm
0.0020 in.
Valve Recessing Protrusion 0.05 mm –
0.0020 in.
Recessing 0.15 mm 0.40 mm

0.0059 in. 0.0157 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) 1.047 rad –
60 °
Angle (Exhaust) 0.785 rad –

45 °
Valve Seat Angle (Intake) 1.047 rad –
60 °
Angle (Exhaust) 0.785 rad –

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

0.0835 in.
W1013874

S-5
ENGINE BODY (Continued)

Valve Timing (Intake Valve) Open 0.14 rad (8 °) –
[D1403-E2B] before T.D.C.
[D1503-E2B]
Close 0.35 rad (20 °) –
after B.D.C.
[D1703-E2B] before T.D.C.
[V1903-E2B]
[V2203-E2B] Close 0.63 rad (36 °) –
[F2803-E2B] after B.D.C.
[V2003-TE2B] before T.D.C.
Close 0.79 rad (45 °) –

after B.D.C.
Valve Timing (Exhaust Valve) Open 1.05 rad (60 °) –
[D1403-E2B] before B.D.C.
[D1503-E2B]
Close 0.21 rad (12 °) –
after T.D.C.
[D1703-E2B] before B.D.C.
[V1903-E2B]
[V2203-E2B] Close 0.21 rad (12 °) –
[F2803-E2B] after T.D.C.
[V2003-TE2B] before B.D.C.
Close 0.24 rad (14 °) –

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 lbs / 1.3780 in. 22.5 lbs /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.
W1013874

S-6

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.
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 Side Clearance 0.12 to 0.48 mm 0.90 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) 33.263 to 33.283 mm 33.22 mm
[D1403-E2B] 1.3096 to 1.3104 in. 1.3079 in.
[D1503-E2B]
[F2803-E2B] Height (Exhaust) 33.463 to 33.483 mm 33.42 mm
1.3174 to 1.3182 in. 1.3157 in.
[D1703-E2B] 1.3174 to 1.3182 in. 1.3157 in.
[V1903-E2B]
[V2203-E2B] Height (Exhaust) 33.463 to 33.483 mm 33.42 mm
1.3174 to 1.3182 in. 1.3157 in.
[V2003-TE2B] 1.3343 to 1.3350 in. 1.3327 in.
Height (Exhaust) 33.463 to 33.483 mm 33.42 mm

1.3174 to 1.3182 in. 1.3157 in.
W1013874

S-7

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.
Piston Pin Bore I.D. 25.000 to 25.013 mm 25.05 mm
0.98425 to 0.98476 in. 0.9862 in.
Second Ring to Ring Groove Clearance 0.093 to 0.120 mm 0.20 mm
[D1403/D1503/D1703/V1903/V2203/ 0.0037 to 0.0047 in. 0.0079 in.
F2803-E2B]
Second Ring to Ring Groove Clearance 0.093 to 0.123 mm 0.20 mm
[V2003-TE2B] 0.0037 to 0.0048 in. 0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.052 mm 0.15 mm
0.0008 to 0.0020 in. 0.0059 in.
Top Ring Ring Gap 0.30 to 0.45 mm 1.25 mm
0.0118 to 0.0177 in. 0.0492 in.
Second Ring Ring Gap 0.30 to 0.45 mm 1.25 mm
0.0118 to 0.0177 in. 0.0492 in.
Oil Ring Ring Gap 0.25 to 0.45 mm 1.25 mm
0.0098 to 0.0177 in. 0.0492 in.
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

S-8

Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.040 to 0.118 mm 0.20 mm
[D1403/D1503/D1703/V1903/V2003-T/ 0.00157 to 0.00465 in. 0.0079 in.
V2203-E2B]
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.
[F2803-E2B] 0.00157 to 0.00465 in. 0.0079 in.

2.04413 to 2.04488 in.

2.04646 to 2.04878 in.
[D1403/D1503/D1703/V1903/V2003-T/ 0.00157 to 0.00409 in. 0.0079 in.
V2203-E2B]
59.921 to 59.940 mm –
Crankshaft Journal O.D. 2.35910 to 2.35984 in.
59.980 to 60.025 mm –
Crankshaft Bearing 2 I.D. 2.36142 to 2.36319 in.
[F2803-E2B] 0.00157 to 0.00409 in. 0.0079 in.

2.04413 to 2.04488 in.

2.04646 to 2.04823 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.
W1013874

S-9

Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
[D1403/D1503/D1703/V1903/V2003-T/ 0.0059 to 0.0122 in. 0.0197 in.
V2203-E2B]
Crankshaft Side Clearance 0.15 to 0.35 mm 0.50 mm
[F2803-E2B] 0.0059 to 0.0138 in. 0.0197 in.
Cylinder Bore (Standard) I.D. 80.000 to 80.022 mm 80.150 mm
[D1403-E2B] 3.14961 to 3.15047 in. 3.15551 in.
[V1903-E2B]
[D1503-E2B] 3.26772 to 3.26858 in. 3.27362 in.
[V2003-TE2B]
[D1703-E2B] 3.42520 to 3.42606 in. 3.43110 in.
[V2203-E2B]
[F2803-E2B]
Cylinder Bore (Oversize) I.D. 80.500 to 80.522 mm 80.650 mm
[D1403-E2B] 3.16929 to 3.17016 in. 3.17520 in.
[V1903-E2B]
[D1503-E2B] 3.28740 to 3.28827 in. 3.29331 in.
[V2003-TE2B]
[D1703-E2B] 3.44488 to 3.44575 in. 3.45079 in.
[V2203-E2B]
[F2803-E2B]
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 0.20 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

S-10
COOLING SYSTEM
Fan Belt Tension 7.0 to 9.0 mm (0.28 to –
0.35 in.) deflection at
98 N (10 kgf, 22 lbs) of
force
Thermostat Valve Opening 69.5 to 72.5 °C –
Temperature 157.1 to 162.5 °F
(At Beginning)
Valve Opening 85 °C –
Temperature 185 °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 0.297 to 0.331 rad –
[D1403/D1503/D1703/V1903/V2003-T/ (17 to 19 °)
V2203-E2B] before T.D.C.
Injection Pump Injection Timing 0.314 to 0.349 rad –
[F2803-E2B] (18 to 20 °) before T.D.C.
Pump Element Fuel Tightness – 13.73 MPa
140 kgf/cm2
1991 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.73 → 12.75 MPa 13.73 → 12.75 MPa
140 → 130 kgf/cm2 140 → 130 kgf/cm2
1991 → 1849 psi 1991 → 1849 psi
Injection Nozzle Injection Pressure 13.73 to 14.71 MPa –
140 to 150 kgf/cm2
1991 to 2134 psi
Injection Nozzle Valve Seat Valve Seat When the pressure is –
Tightness 12.75 MPa
(130 kgf/cm2, 1849 psi),
the valve seat must be
fuel tightness.
W1013973

S-11
ELECTRICAL SYSTEM
Starter
Commutator O.D. 30.0 mm 29.0 mm
1.181 in. 1.142 in.
Mica Under Cut 0.45 to 0.75 mm 0.20 mm

0.0177 to 0.0295 in. 0.0079 in.
Brush Length 15.0 mm 11.0 mm

0.591 in. 0.433 in.
Alternator No-load voltage More than 13.5 V –
Stator Resistance Less than 1.0 Ω –
Rotor Resistance 2.9 Ω –
Slip Ring O.D. 14.4 mm 14.0 mm

0.567 in. 0.551 in.
Brush Length 10.5 mm 8.4 mm

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

S-12
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 ft-lbs N·m kgf·m ft-lbs
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

S-13
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS
■ 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 ft-lbs
*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 cover cap nut M8 x 1.25 6.9 to 8.8 0.7 to 0.9 5.1 to 6.5
Injection pipe retaining nut M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Nozzle holder assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
Overflow pipe assembly retaining nut M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Glow plug M10 x 1.25 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
*Rocker arm bracket screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Rocker arm bracket nut M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Cylinder head screw M11 x 1.25 93.2 to 98.1 9.5 to 10.0 68.7 to 72.3
Fan drive pulley mounting nut M30 x 1.5 137.3 to 156.9 14.0 to 16.0 101.3 to 115.7
Fan drive pulley screw M16 x 1.5 313.8 to 333.4 32.0 to 34.0 231.5 to 245.9
Camshaft set screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Connecting rod screw M8 x 1.0 44.1 to 49.0 4.5 to 5.0 32.5 to 36.2
*Flywheel screw M12 x 1.25 98.1 to 107.9 10.0 to 11.0 72.3 to 79.6
*Bearing case cover screw M8 x 1.25 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
*Main bearing case screw 2 M10 x 1.25 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2
*Main bearing case screw 1 M9 x 1.25 46.1 to 51.0 4.7 to 5.2 34.0 to 37.6
Oil pressure switch R 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
Nozzle holder – 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9
Starter’s terminal B mounting nut M8 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7
Alternator’s pulley nut – 58.3 to 78.9 5.95 to 8.05 43.0 to 58.2
W1013236

S-14
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 injection nozzles.
4. Set a compression tester (Code No. 07909-30208) with the
adaptor to the nozzle hole.
5. Keep the engine stop lever at “Stop Position”.
6. While cranking the engine with the starter, measure the
compression pressure.
7. Repeat steps 4 through 6 for each cylinder.
8. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the nozzle hole and
measure the compression pressure again.
9. If the compression pressure is still less than the allowable limit,
check the top clearance, valve and cylinder head.
10.If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
■ 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 %.
3.53 to 3.72 MPa
Factory spec. 36 to 38 kgf/cm2
512 to 540 psi
Compression pressure
2.55 MPa
370 psi
W1018639

S-15
Valve Clearance
■ 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.
■ 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 D1403-E2B V1903-E2B
arrangement D1503-E2B V2203-E2B F2803-E2B
Adjustable D1703-E2B V2003-TE2B
cylinder
location of piston IN. EX. IN. EX. IN. EX.
No. 1 ✩ ✩ ✩ ✩ ✩ ✩
When No. 1 piston No. 2 ✩ ✩ ✩
comes to
No. 3 ✩ ✩ ✩
compression top
dead center No. 4 – –
No. 5 – – – –
No. 1
No. 2 ✩ ✩ ✩
When No. 1 piston
comes to overlap No. 3 ✩ ✩ ✩
position
No. 4 – – ✩ ✩ ✩ ✩
No. 5 – – – – ✩ ✩
(1) Valve Clearance (3) TC Mark Line

(2) Projection
W10161700

S-16
(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 ft-lbs
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 lbs).
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

S-17
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

S-18
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 69.5 to 72.5 °C
Factory spec.
opening temperature 157.1 to 162.5 °F
Temperature at which
85 °C
thermostat completely Factory spec.
185 °F
opens
W1035849

S-19
(4) Fuel System

Injection Timing
1. Remove the injection pipes and nozzle.
2. Set the speed control lever to maximum fuel discharge position.
(Reference)
• Turn the flywheel with screwdriver.
3. Turn the flywheel counterclockwise (facing the flywheel) until the
fuel fills up to the hole of the delivery valve holder for 1st cylinder.
4. Turn the flywheel further and stop turning when the fuel begins to
flow over, to get the present injection timing.
5. (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.
[D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
0.279 to 0.331 rad (17 to
[F2803-E2B]
0.314 to 0.349 rad (18 to
■ 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 0.20 mm, 0.25 mm and
0.30 mm. Combine these shims for adjustments.
• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or
• In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Delivery Valve Holder (4) 2-holes : 0.20 mm (Shim)
(2) Timing Mark (5) 1-hole : 0.25 mm (Shim)
(3) Shim (Soft Metal Gasket Shim) (6) Without hole : 0.30 mm (Shim)
W1045339

S-20
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.
13.73 MPa
Fuel tightness of pump
element
1991 psi
■ 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 hands and raise the pressure to
approx. 13.73 MPa (140 kgf/cm2, 1991 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 13.73 to 12.75 MPa (from 140
to 130 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (140 to 130 kgf/cm2, 1991 to 1849 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
13.73 → 12.75 MPa
Factory spec.
140 → 130 kgf/cm2
Fuel tightness of 1991 → 1849 psi
delivery valve 5 seconds
13.73 → 12.75 MPa
Allowable limit
140 → 130 kgf/cm2
1991 → 1849 psi
■ NOTE
W1017786

S-21
CAUTION
• Check the nozzle 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 nozzle piece.
(a) Good (b) Bad
W10181310
Fuel Injection Pressure

2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
replace the adjusting washer (1) in the nozzle holder to adjust it.
(Reference)
• Pressure variation with 0.025 mm (0.0010 in.) difference of
adjusting washer thickness.
Approx. 588 kPa (6.0 kgf/cm2, 85 psi)
13.73 to 14.71 MPa
Fuel injection pressure Factory spec. 140 to 150 kgf/cm2
1991 to 2134 psi
(1) Adjusting Washer

W10182100
Valve Seat Tightness

2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm2,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec.
130 kgf/cm2
1849 psi
W10183690

S-22
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
• Assemble the nozzle in clean fuel oil.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
34.3 to 39.2 N·m
Nozzle holder 3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
19.6 to 24.5 N·m
Tightening torque Overflow pipe retaining nut 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
49.0 to 68.6 N·m
36.2 to 50.6 ft-lbs
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
W1018491
(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.
■ 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

S-23
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.
■ 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

S-24
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.
■ 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.
■ 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

S-25
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.
■ 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 at 25 °C
Factory spec.
load (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

S-26
(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

S-27
[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).
■ 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 (2), alternator (3) and starter (4).
(When reassembling)
• Check to see that there are no cracks on the belt surface.
■ 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) Alternator
(2) Fan Belt (4) Starter
W1060302

S-28
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.
■ 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.
■ 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

S-29
(3) Cylinder Head and Valves

Cylinder Head Cover
1. Remove the lead (1).
2. Remove the breather hose (2).
3. [a] D1403/D1503/D1703/V1903/V2203-E2B
Remove the cylinder head cover screws (3).
[b] V2003-TE2B / [c] F2803-E2B
Remove the cylinder head cover cap nuts (8).
4. Remove the cylinder head cover (4).
(When reassembling)
• Check to see if the cylinder head cover gasket is not defective.
6.9 to 11.3 N·m
Cylinder head cover screw 0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
Tightening torque
6.9 to 8.8 N·m
Cylinder head cover cap
0.7 to 0.9 kgf·m
nut
5.1 to 6.5 ft-lbs
(1) Lead (8) Cylinder Head Cover Cap Nut

(2) Breather Hose
(3) Cylinder Head Cover Screw [a] D1403/D1503/D1703/V1903/V2203-
(4) Cylinder Head Cover E2B
(5) Cylinder Head Cover Gasket [b] V2003-TE2B
(6) Breather Valve [c] F2803-E2B
(7) Plate
W1060460

S-30
Injection Pipes
1. Loosen the screws on the pipe clamps (1).
2. Detach the injection pipes (2).
(When reassembling)
• Blow out dust inside the pipes.
24.5 to 34.3 N·m
Tightening torque Injection pipe retaining nut 2.5 to 3.5 kgf·m
18.1 to 25.3 ft-lbs
(1) Pipe Clamp (2) Injection Pipe

W1060970
Nozzle Holder Assembly and Glow Plug
1. Remove the overflow pipe assembly (3).
2. Remove the nozzle holder assemblies (4) using a 21 mm deep
socket wrench.
3. Remove the copper gasket and heat seal (5).
4. Remove the glow plugs (2).
(When reassembling)
• Replace the copper gasket and heat seal with new one.
49.0 to 68.6 N·m
36.2 to 50.6 ft-lbs
19.6 to 24.5 N·m
Overflow pipe assembly
Tightening torque 2.0 to 2.5 kgf·m
retaining screw
14.5 to 18.1 ft-lbs
19.6 to 24.5 N·m
Glow plug 2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
(1) Lead (4) Nozzle Holder Assembly

(2) Glow Plug (5) Heat Seal
(3) Overflow Pipe Assembly
W1020917
Nozzle Heat Seal Service Removal Procedure
■ IMPORTANT
• Use a plus (phillips head) screw driver (1) that has a
diameter which is bigger than the heat seal hole (Approx. 6
mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).
4. If the heat seal drops, repeat the above procedure.
(When reassembling)
• Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
(1) Plus Screw Driver (3) Injection Nozzle Gasket
(2) Injection Nozzle (4) Heat Seal
W1021255

S-31
Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws (D1403/D1503/D1703/
D1903/V2203-E2B) or nuts (V2203-T/F2803-E2B).
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.
■ IMPORTANT
• After installing the rocker arm, be sure to adjust the valve
clearance.
23.5 to 27.5 N·m
Rocker arm bracket screw 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
23.5 to 27.5 N·m
Rocker arm bracket nut 2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
(1) Rocker Arm Assembly (3) Tappet

(2) Push Rod
W1021437

S-32
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 (v or r or n) to (a).
3. Lift up the cylinder head (3) to detach.
4. Remove the cylinder head gasket (4) and O-ring (5).
(When reassembling)
• Replace the cylinder head gasket (4) with a new one.
• Securely fit the O-ring (5) to the pin pipe (6).
• 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 or v).
• Tighten them uniformly, or the head may deform in the long run.
• Retighten the cylinder head screws after running the engine for
30 minutes.
93.2 to 98.1 N·m
Tightening torque Cylinder head screw 9.5 to 10.0 kgf·m
68.7 to 72.3 ft-lbs
(1) Return Pipe (v or n or r) to (a): To Loosen

(2) Pipe Clamp (a) to (n or r or v): To Tighten
(3) Cylinder Head (A) Gear Case Side
(4) Cylinder Head Gasket (B) Flywheel Side
(5) O-ring
(6) Pin Pipe
W1021755

S-33
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).
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket
W10363950
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.
■ 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.
■ 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

S-34
(4) Gear Case and Timing Gears

Injection Pump
1. Remove the injection pump cover (3) with the engine stop lever
(2).
2. Remove the injection pump mounting screws and nuts.
3. Align the control rack pin (4) with the groove (5) on the
crankcase, then remove the injection pump.
4. Remove the injection pump timing shims (6).
5. In principle, the injection pump should not be disassemble.
(When reassembling)
• Install the injection pump so that its control rack pin (4) engages
with the groove (5) of fork lever 1 (1).
• Install the injection pump cover with the arm of engine stop lever
(2) at the right of the arm of fork lever 1 (1).
• The sealant is applied to both sides of the shim (soft metal gasket
shim). The liquid gasket is not required for assembling.
• Addition or reduction of shims (0.05 mm, 0.0020 in.) delays or
• In disassembling and replacing, be sure to use same number of
new shims with the same thickness.
• Refer to figure left to check the thickness of the shims.
(1) Fork Lever 1 (6) Shim
(2) Engine Stop Lever (7) 2-holes : 0.20 mm (0.0079 in.)
(3) Injection Pump Cover (8) 1-hole : 0.25 mm (0.0098 in.)
(4) Control Rack Pin (9) Without hole : 0.30 mm (0.0118 in.)
(5) Groove
W1023637
Governor Spring
■ 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. Disconnect the governor spring 1 (2) and 2 (3) from the fork lever
2 (4).
(When reassembling)
• Fix the governor spring to the speed control lever, and pull the
spring or wire through the window of the injection pump, and
spring will be able to be hooked on the governor fork with ease.
Bend the end of the governor spring to prevent if from falling off.
(1) Specific Tool (3) Governor Spring 2
(2) Governor Spring 1 (4) Fork Lever 2
W1024893

S-35
Speed Control Plate

1. Remove the speed control plate and governor spring 1 (2) and 2
(1).
(When reassembling)
• Be careful not to drop the governor spring in the gear case.
• Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the speed control plate gasket.
(1) Governor Spring 2 (2) Governor Spring 1
W1025063
Start Spring
1. Remove the start spring (1) from the gear case.
(When reassembling)
• Be careful not to drop the start spring into the gear case.
• Hook the start spring so that the longer hook is on the fork lever
side.
(1) Start Spring
W1025252

S-36
Fan Drive Pulley

1. Lock the flywheel not to turn using the flywheel stopper.
2. [D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
Remove the fan drive pulley mounting nut (1) using 46 mm deep
socket wrench (5).
[F2803-E2B]
Remove the fan drive pulley screws.
3. Remove the fan drive pulley (2) with gear puller (3).
4. [D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
Remove the feather key.
(When reassembling)
• Apply grease to the splines of coupling.
• [F2803-E2B]
Install the pulley to the crankshaft, aligning the marks (4) on
them.
• Tighten the fan drive pulley mounting nut or the fan drive pulley
screw to the specified torque.
137.3 to 156.9 N·m
Fan drive pulley mounting
14.0 to 16.0 kgf·m
nut
101.3 to 115.7 ft-lbs
Tightening torque
313.8 to 333.4 N·m
Fan drive pulley screw 32.0 to 34.0 kgf·m
231.5 to 245.9 ft-lbs
(1) Nut (4) Mark

(2) Fan Drive Pulley (5) 46 mm Deep Socket Wrench
(3) Gear Puller
W1025370

S-37
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)
• 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
Camshaft
1. Remove the camshaft set screw (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 ft-lbs
(1) Camshaft Set Screw (2) Camshaft

W1025098

S-38
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 Screw (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 (1) with a puller (2).
2. Remove the feather key.
(1) Crank Gear (2) Gear Puller
W1025476

S-39
(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

S-40
Pistons (To be continued)

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.
(1) Carbon (3) Connecting Rod Cap
(2) Connecting Rod Screw (4) Connecting Rod
W1026909

S-41
Pistons (Continued)
(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.
■ 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 0.79 rad (45 °) from
the piston pin’s direction as shown in the figure.
• Carefully insert the pistons using a piston ring compressor
(1).
44.1 to 49.0 N·m
Tightening torque Connecting rod screw 4.5 to 5.0 kgf·m
32.5 to 36.2 ft-lbs
(1) Piston Ring Compressor (C) Oil Ring Gap

(D) Piston Pin Hole
(A) Top Ring Gap
(B) Second Ring Gap (a) 0.79 rad (45 °)
W1027404

S-42
Piston Ring and Connecting Rod

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

S-43
(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 ft-lbs
(1) Flywheel (3) Flywheel Guide Screw

(2) Flywheel Screw
W1026863
Bearing Case Cover
1. Remove the bearing case cover mounting screws. First, remove
inside screws (6) and then outside screws (3).
2. Screw two removed screws into the screw hole of bearing case
cover (5) to remove it.
■ IMPORTANT
• The length of inside screws (6) 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 (5) 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
Tightening torque 2.4 to 2.8 kgf·m
mounting screw
17.4 to 20.3 ft-lbs
(1) Bearing Case Gasket (5) Bearing Case Cover

(2) Bearing Case Cover Gasket (6) Bearing Case Cover Mounting Screw
(3) Bearing Case Cover Mounting Screw
(4) Oil Seal (a) Upside
W10292140

S-44
Crankshaft
■ NOTE
• Before disassembling, check the side clearance of
crankshaft. Also check it during reassembling.
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).
(When reassembling)
■ 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 ft-lbs
(1) Main Bearing Case Screw 2 (3) Crankshaft Bearing 1

(2) Main Bearing Case 2
W1066311

S-45
Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (8), 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, A, B, C for 4 cylinders and A, B,
C, D for 5 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 (9) facing outward.
• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 (8) 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 ft-lbs
(1) Alignment Number (6) D

(2) Alignment Mark (7) No Mark
(3) A (8) Main Bearing Case Screw 1
(4) B (9) Oil Groove
(5) C
W1027366

S-46
(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).
■ 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 ft-lbs
W1012736

S-47
(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 ft-lbs
W1224556

S-48
[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.
■ NOTE
• After checking the top clearance, be sure to assemble the
cylinder head with a new cylinder head gasket.
0.55 to 0.70 mm
Top clearance Factory spec.
0.0217 to 0.0276 in.
93.2 to 98.1 N·m

Tightening torque Cylinder head screw 9.5 to 10.0 kgf·m
68.7 to 72.3 ft-lbs
(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.
■ IMPORTANT
• Do not place the straightedge on the combustion chamber.
• Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.0020 in.
W1027737

S-49
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 read 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.
0.05 (protrusion) to
0.15 (recessing) mm
Factory spec.
0.0020 (protrusion) to
Valve recessing 0.0059 (recessing) in.
0.40 (recessing) mm
Allowable limit
0.0157 (recessing) 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

S-50
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.
■ 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

S-51
Correcting Valve and Valve Seat

■ 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.
1.047 rad
IN.
Factory 60 °
Valve face angle
spec. 0.785 rad
EX.
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.047 rad (60 °) (intake
valve) or 0.785 rad (45 °) (exhaust valve) valve seat cutter.
2. Resurface the seat surface with a 0.523 rad (30 °) valve seat
cutter to intake valve seat and with a 0.262 rad (15 °) valve seat
cutter to exhaust 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.
1.047 rad
IN.
Factory 60 °
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.
■ IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
W10288140

S-52
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.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
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.
(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 lbs / 1.3780 in.
Setting length 100.0 N / 35.0 mm
Allowable limit 10.2 kgf / 35.0 mm
22.5 lbs / 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

S-53
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.
W1029564

S-54
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
0.90 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

S-55
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.
[D1403/D1503/F2803-E2B]
33.263 to 33.283 mm
Factory spec.
1.3096 to 1.3104 in.
Cam height of intake
33.22 mm
Allowable limit
1.3079 in.
33.463 to 33.483 mm
Factory spec.
1.3174 to 1.3182 in.
Cam height of exhaust
33.42 mm
Allowable limit
1.3157 in.
[D1703/V1903/V2203-E2B]
33.463 to 33.483 mm
Factory spec.
1.3174 to 1.3182 in.
33.42 mm
Allowable limit
1.3157 in.
33.463 to 33.483 mm
Factory spec.
1.3174 to 1.3182 in.
33.42 mm
Allowable limit
1.3157 in.
[V2003-TE2B]
33.890 to 33.910 mm
Factory spec.
1.3343 to 1.3350 in.
33.85 mm
Allowable limit
1.3327 in.
33.463 to 33.483 mm
Factory spec.
1.3174 to 1.3182 in.
33.42 mm
Allowable limit
1.3157 in.
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.
W10299330

S-56
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
(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

S-57
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 position of the connecting rod oil
hole matches the bushing hole.
(A) When removing (B) When installing
W1032140
Connecting Rod Alignment

■ 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

S-58
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.
0.30 to 0.45 mm
Factory spec.
0.0118 to 0.0177 in.
Top ring
1.25 mm
Allowable limit
0.0492 in.
0.30 to 0.45 mm
Factory spec.
0.0118 to 0.0177 in.
Second ring
1.25 mm
Allowable limit
0.0492 in.
0.25 to 0.45 mm
Factory spec.
0.0098 to 0.0177 in.
Oil ring
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.
[D1403/D1503/D1703/V1903/V2203/F2803-E2B]
0.093 to 0.120 mm
Factory spec.
0.0037 to 0.0047 in.
Second ring
0.20 mm
Allowable limit
0.0079 in.
0.020 to 0.052 mm
Factory spec.
0.0008 to 0.0020 in.
Oil ring
0.15 mm
Allowable limit
0.0059 in.
[V2003-TE2B]
0.093 to 0.123 mm
Factory spec.
0.0037 to 0.0048 in.
Second ring
0.20 mm
Allowable limit
0.0079 in.
0.020 to 0.052 mm
Factory spec.
0.0008 to 0.0020 in.
Oil ring
0.15 mm
Allowable limit
0.0059 in.
W1032489

S-59
(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.
[D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
[F2803-E2B]
0.15 to 0.35 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 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 2.1574 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
(0.8S)
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

S-60
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.
■ 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
0.1299 to 0.1457 in. radius 0.1299 to 0.1457 in. radius
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.
(0.8S)
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

S-61
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 0.20 mm
Allowable limit
0.0079 in.
[D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
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.
[F2803-E2B]
51.921 to 51.940 mm
2.04413 to 2.04488 in.
Factory spec.
I.D. 2.04646 to 2.04878 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
Dimension A 0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
*Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
relief relief
D1403-E2B
D1503-E2B 59.721 to 59.740 mm 59.521 to 59.540 mm
D1703-E2B dia. dia.
V1903-E2B 2.35122 to 2.35197 in. 2.34335 to 2.34410 in.
V2003-TE2B dia. dia.
Dimension C V2203-E2B
51.721 to 51.740 mm 51.521 to 51.540 mm
dia. dia.
F2803-E2B
2.03626 to 2.03701 in. 2.02839 to 2.02913 in.
dia. dia.
(0.8S)
(0.0394 to 0.0591 in.) relief.
W1033717

S-62
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

S-63
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 baring 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.
■ 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.
[D1403/D1503/D1703/V1903/V2003-T/V2203-E2B]
59.921 to 59.940 mm
2.35910 to 2.35984 in.
Factory spec.
I.D. 2.36142 to 2.36319 in.
[F2803-E2B]
51.921 to 51.940 mm
2.04413 to 2.04488 in.
Factory spec.
I.D. 2.04646 to 2.04823 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
Dimension A 0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
*Dimension B 0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
relief relief
D1403-E2B
D1503-E2B 59.721 to 59.740 mm 59.521 to 59.540 mm
D1703-E2B dia. dia.
V1903-E2B 2.35122 to 2.35197 in. 2.34335 to 2.34410 in.
V2003-TE2B dia. dia.
Dimension C V2203-E2B
51.721 to 51.740 mm 51.521 to 51.540 mm
dia. dia.
F2803-E2B
2.03626 to 2.03701 in. 2.02839 to 2.02913 in.
dia. dia.
(0.8S)
(0.0394 to 0.0591 in.) relief.
W1083821

S-64
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”.)
■ 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

S-65
(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”.)
[D1403/V1903-E2B]
80.000 to 80.022 mm
Factory spec.
3.14961 to 3.15047 in.
Cylinder I.D.
80.150 mm
Allowable limit
3.15551 in.
[D1503/V2003-TE2B]
83.000 to 83.022 mm
Factory spec.
3.26772 to 3.26858 in.
Cylinder I.D.
83.150 mm
Allowable limit
3.2736 in.
[D1703/V2203/F2803-E2B]
87.000 to 87.022 mm
Factory spec.
3.42520 to 3.42606 in.
Cylinder I.D.
87.150 mm
Allowable limit
3.4311 in.
A: Top (a) Right-angled to Piston Pin

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

S-66
Correcting Cylinder (Oversize)

1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
[D1403/V1903-E2B]
80.500 to 80.522 mm
Factory spec.
3.16929 to 3.17016 in.
Oversize cylinder I.D.
80.650 mm
Allowable limit
3.17520 in.
[D1503/V2003-TE2B]
83.500 to 83.522 mm
Factory spec.
3.28740 to 3.28827 in.
83.650 mm
Allowable limit
3.29331 in.
[D1703/V2203/F2803-E2B]
87.500 to 87.522 mm
Factory spec.
3.44488 to 3.44575 in.
87.650 mm
Allowable limit
3.45079 in.
Hone to 2.2 to 3.0 μmRz

Finishing (0.000087 to 0.00012 in.Rz)
∇∇∇.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.50 mm (0.0197 in.)
■ 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 0.20 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

S-67
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.
■ 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.
30.0 mm
Factory spec.
1.181 in.
Commutator O.D.
29.0 mm
Allowable limit
1.142 in.
Less than 0.02 mm

Factory spec.
0.0008 in.
Difference of O.D.’s
0.05 mm
Allowable limit
0.0020 in.
0.45 to 0.75 mm
Factory spec.
0.0177 to 0.0295 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Correct

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

S-68
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.
15.0 mm
Factory spec.
0.591 in.
Brush length (A)
11.0 mm
Allowable limit
0.433 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 dose not conduct, replace the armature.
W1156507

S-69
Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it dose 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

S-70
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

S-71
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 : ksos-pub@kubota.co.jp
Printed in Japan 2006. 02, S, EI, EI, e Code No.9Y011-03091

KUBOTA Corporation 2004. 05, S, EI, EI, e

Kubota V2203 Workshop Manual

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WORKSHOP MANUAL

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

■ NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

VENTILATE WORK AREA

DISPOSE OF FLUIDS PROPERLY

PREVENT ACID BURNS

PREPARE FOR EMERGENCIES

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

Model V1903-E2B V2003-TE2B

KiSC issued 06, 2006 A

Model V2203-E2B F2803-E2B

KiSC issued 06, 2006 A

D1403-E2B D1503-E2B D1703-E2B

KiSC issued 06, 2006 A

V1903-E2B V2003-TE2B V2003-E2B

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

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

KiSC issued 06, 2006 A

(1) Engine Model Name and Serial

KiSC issued 06, 2006 A

[2] E2B ENGINE

[3] CYLINDER NUMBER

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

3. MAINTENANCE CHECK LIST

KiSC issued 06, 2006 A

KiSC issued 06, 2006 A

4. CHECK AND MAINTENANCE

KiSC issued 06, 2006 A

Checking and Replenish Coolant

KiSC issued 06, 2006 A

[2] CHECK POINTS OF INITIAL 50 HOURS

Oil pan depth

KiSC issued 06, 2006 A

Replacing Oil Filter Cartridge

KiSC issued 06, 2006 A

[3] CHECK POINTS OF EVERY 50 HOURS

(When bleeding fuel system)

KiSC issued 06, 2006 A

[4] CHECK POINTS OF EVERY 100 HOURS

Fan Belt Tension

KiSC issued 06, 2006 A

Fan Belt Damage and Wear

KiSC issued 06, 2006 A

[5] CHECK POINTS OF EVERY 150 HOURS

Oil pan depth

KiSC issued 06, 2006 A

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

KiSC issued 06, 2006 A

[6] CHECK POINTS OF EVERY 200 HOURS

Oil pan depth

KiSC issued 06, 2006 A

Checking Intake Air Line

KiSC issued 06, 2006 A

[7] CHECK POINTS OF EVERY 400 HOURS

KiSC issued 06, 2006 A

[8] CHECK POINTS OF EVERY 500 HOURS

KiSC issued 06, 2006 A