Carrier CT2-29-TV Instruction manual

Diesel Engine
62--11161 Rev A
WORKSHOP MANUAL
for
CT2-29-TV (Z482-E2B)
Truck / ComfortPro
CT3-44-TV (D722-E2B)
Truck
Beginning With Serial Number 5A0001
R

WORKSHOP MANUAL
DIESEL ENGINE
CT2-29-TV (Z482-E2B)
Truck / ComfortPro
CT3-44-TV (D722-E2B)
Truck
Beginning With Serial Number 5A0001

i62--11161
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
TABLE OF CONTENTS i........................................................................
SAFETY PRECAUTIONS i...................................................................
SPECIFIC WARNING AND CAUTION STATEMENTS i...........................................
General 1--1......................................................................................
1.1 ENGINE IDENTIFICATION 1--1............................................................
1.2 ENGINE SPECIFICATIONS 1--2............................................................
1.2.1 E2B Engine 1--3......................................................................
1.2.2 Cylinder Number 1--3..................................................................
1.3 GENERAL PRECAUTIONS 1--3............................................................
1.4 TORQUE SPECIFICATION 1--4............................................................
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts 1--4..........................
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts 1--4..........................
1.5 TROUBLESHOOTING 1--5................................................................
1.6 SERVICING SPECIFICATIONS 1--8........................................................
1.6.1 Engine Body 1--8......................................................................
1.6.2 Lubricating System 1--11................................................................
1.6.3 Cooling System 1--11...................................................................
1.6.4 Fuel System 1--11......................................................................
1.6.5 Electrical System 1--12..................................................................
1.7 CHECK AND MAINTENANCE 1--12..........................................................
1.7.1 Checking Engine Oil Level 1--12..........................................................
1.7.2 Changing Engine Oil 1--12...............................................................
1.7.3 Checking Coolant Level 1--12............................................................
1.7.4 Checking Fuel Hose 1--12...............................................................
1.7.5 Bleeding Fuel System 1--12..............................................................
1.7.6 Valve Clearance 1--13..................................................................
1.8 SPECIAL TOOLS 1--14.....................................................................
1.8.1 Diesel Engine Compression Tester (Glow Plug) 1--14.......................................
1.8.2 Adapter, Kubota 10 mm 1--14............................................................
1.8.3 Tester Injector Nozzle 1--14..............................................................
1.8.4 Replacement Bowl, Tester Injector Nozzle 1--14............................................
1.8.5 Adapter, Injector Line 1--14..............................................................
1.8.6 Oil Pressure Tester 1--15................................................................
1.8.7 Auxiliary Socket For Fixing Crankshaft Sleeve 1--15........................................
1.8.8 Guage, Belt Tension 1--15...............................................................
1.8.9 Tester, Belt Tension 1--15................................................................
1.8.10 Rubber Band 1--15.....................................................................
1.8.11 Valve Guide Replacing Tool 1--16.........................................................
1.8.12 Bushing Replacing Tools 1--16
...........................................................
1.8.13 Flywheel Stopper 1--16..................................................................
1.8.14 Crankshaft Bearing 1 Replacing Tool 1--17.................................................

ii
62-11161
PARAGRAPH NUMBER Page
ENGINE BODY 2--1...............................................................................
2.1 CHECKING AND ADJUSTING 2--1.........................................................
2.1.1 Compression Pressure 2--1.............................................................
2.1.2 Top Clearance 2--1....................................................................
2.2 DISASSEMBLING AND ASSEMBLING 2--2..................................................
2.2.1 Draining Coolant 2--2..................................................................
2.2.2 Draining and Refilling Engine Oil 2--2....................................................
2.2.3 External Components 2--2..............................................................
2.2.4 Cylinder Head And Valves 2--3..........................................................
2.2.5 Oil Pan and Oil Pick--up Screen 2--6......................................................
2.2.6 Timing Gear, Camshaft and Fuel Camshaft 2--7...........................................
2.2.7 Piston and Connecting Rod 2--13.........................................................
2.2.8 Crankshaft 2--16.......................................................................
2.3 SERVICING 2--19.........................................................................
2.3.1 Cylinder Head And Valves 2--19..........................................................
2.3.2 Timing Gears, Camshaft and Fuel Camshaft 2--25..........................................
2.3.3 Piston and Connecting Rod 2--28.........................................................
2.3.4 Crankshaft 2--30.......................................................................
2.3.5 Cylinder 2--36..........................................................................
LUBRICATING SYSTEM 3--1.......................................................................
3.1 CHECKING AND ADJUSTING 3--1.........................................................
3.1.1 Checking Engine Oil Level 3--1..........................................................
3.1.2 Changing Engine Oil 3--1...............................................................
3.1.3 Changing Oil Filter 3--2................................................................
3.1.4 Engine Oil Pressure 3--2...............................................................
3.1.5 Relief Valve 3--3......................................................................
3.2 OIL PUMP SERVICE 3--3..................................................................
3.2.1 Rotor Lobe Clearance 3--3.............................................................
3.2.2 Rotor to Cover Clearance 3--3..........................................................
COOLING SYSTEM 4--1...........................................................................
4.1 CHECKING AND ADJUSTING 4--1.........................................................
4.1.1 V--Belt Tension 4--1....................................................................
4.1.2 Fan Belt Damage and Wear 4--1........................................................
4.1.3 Checking Coolant Level 4--1............................................................
4.1.4 Draining Coolant 4--1..................................................................
4.1.5 Radiator Cap 4--2.....................................................................
4.1.6 Radiator 4--2.........................................................................
4.1.7 Thermostat Opening Temperature 4--2...................................................
4.2 SERVICING 4--3.........................................................................
4.2.1 Thermostat Assembly 4--3..............................................................
4.2.2 Water Pump Assembly 4--3.............................................................

iii 62--11161
PARAGRAPH NUMBER Page
FUEL SYSTEM 5--1...............................................................................
5.1 CHECKING AND ADJUSTING 5--1.........................................................
5.1.1 Injection Timing 5--1...................................................................
5.1.2 Shim Identification 5--1.................................................................
5.1.3 Pump Element Fuel Seal 5--2...........................................................
5.1.4 Delivery Valve Fuel Seal 5--2...........................................................
5.2 INJECTION NOZZLE 5--3.................................................................
5.2.1 Nozzle Spraying Condition 5--3..........................................................
5.2.2 Nozzle Injection Pressure 5--3..........................................................
5.2.3 Valve Seat Tightness 5--4..............................................................
5.2.4 Nozzle Holder 5--4....................................................................
ELECTRICAL SYSTEM 6--1........................................................................
6.1 GLOW PLUG 6--1........................................................................
6.1.1 Lead Terminal Voltage 6--1.............................................................
6.1.2 Glow Plug Continuity 6--1..............................................................
6.2 STARTER (CT2--29--TV) 6--2...............................................................
6.2.1 Motor Test 6--2........................................................................
6.2.2 Magnetic Switch Test 6--2..............................................................
6.2.3 Assembly 6--3.........................................................................
6.3 STARTER (CT3--44--TV) 6--4...............................................................
6.3.1 Motor Test 6--4........................................................................
6.3.2 Magnetic Switch Test 6--4..............................................................
6.4 STARTER SERVICING 6--6................................................................
6.4.1 Overrunning Clutch 6--6................................................................
6.4.2 Armature Bearing 6--6.................................................................
6.4.3 Brush Wear 6--6......................................................................
6.4.4 Solenoid 6--6.........................................................................
6.4.5 Brush Holder 6--6.....................................................................
6.4.6 Armature 6--7.........................................................................
6.4.7 Field Coil 6--8.........................................................................

i62-11161
SAFETY
SAFETY PRECAUTIONS
Your Carrier Transicold unit has been designed with the safety of the operator in mind. During normal operation, all
moving parts are fully enclosed to help prevent injury. During all pretrip inspections, daily inspections, and problem
troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts when the unit is in
operation and when the unit main power switch is in the START/RUN position.
Engine Coolant
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not
remove the cap from a hot radiator. If the cap must be removed, do so very slowly in order to release the pressure
without spray.
Battery
This unit is equipped with a leadacid type battery. The battery normally vents small amounts of flammable hydrogen
gas. Donotsmokewhencheckingthebattery.Abatteryexplosioncancauseserious physicalharm and/orblindness.
SPECIFIC WARNING AND CAUTION STATEMENTS
To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is
given with the appropriate consequences:
DANGER
DANGER -- warnsagainst an immediate hazard which WILL result in severe personal injury or death.
WARNING
WARNING -- warns against hazards or unsafe conditions which COULD result in severe personal in-
jury or death.
CAUTION
CAUTION -- warns against potential hazard or unsafe practice which could result in minor personal
injury, or product or property damage.
NOTE
NOTE -- gives helpful information that may help and avoid equipment and property damage.
The statements listed on the next page are specifically applicable to this unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equip-
ment covered herein.

ii
62-11161
SPECIFIC WARNING AND CAUTION STATEMENTS (Continued)
WARNING
When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water may discharge from the radiator, scalding anyone nearby.
WARNING
Check the injection nozzle only after confirming that nobody is near the spray. If the spray from the
nozzle contacts the human body, cells may be destroyed and blood poisoning may result.
CAUTION
Stop the engine when attempting to check and change the fuel line.
CAUTION
Stop the engine when preparing to change the engine oil.
CAUTION
Stop the engine when preparing to change the engine oil filter.
CAUTION
Secure the starter to prevent it from moving when power is applied to it.

1--1 62--11161
SECTION 1
General
1.1 ENGINE IDENTIFICATION
S/N
When contacting Carrier Transicold, always specify
your engine model number 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 (S/N)
The engineserialnumber is an identified number forthe
engine. It is marked after the engine model number.
It indicates basic model, month, year and sequence of
manufacture as follows:
S
er
i
a
l
N
um
b
er
7 K A
Last 3 Digits in Numerals (1 to 999 Units in Sequence)
6th Digit Alpabetical Letter (Month of Manufacture -- 1st Letter 1--9999 Units, 2nd Letter 10,000--19,998 Units)
Alphabetical letter A,B C,DE,FG,HJ,K L,M N,P Q,R S,T U,V W,X Y,Z
Month
5th Digit Alpabetical Letter or Numerals (Year of Manufacture)
Alphabetical letter or numerals W XY
Year 98 99 00 01 02 03 04 05 06 07 08 09
Jan Feb Mar May Jun Jul Aug Sep OctApr Nov Dec
1234 56789
Z482--
Basic model number
176
7th Digit Sequential Numeral or Letter (Units Manufactured)
Alphabetical Numeral or Letter
Unit Number Sequence A
to 19,998 19,999--20997 20,998--21,996
BC
21,997--22,995
0to9
Table 1-1. Model Chart
KUBOTA
MODEL NO. CARRIER
MODEL NO. NEW ENGINE PART NO. PRIMARY USE REPLACES
Z482--E2B CT2--29--TV 26--60001--03*SOLARA Units 26--60001--01
Z482--E2B CT2--29--TV 26--60001--04*SUPRA Units 26--60001--02
Z482 -- E2B-- AT C-- 1 CT2--29--TV 96-- 101--05K ProHeat / ComfortPro PC5000
Units NEW
Z482--E2B--TFX--1 CT2--29--TV 96-- 101--20K ComfortPro PC6000 Units NEW
D722--E2B CT3--44--TV 26--60000--05*GENESIS Units 26--60000--00
*Beginning with Serial Number 5A0001

1--2
62--11161
1.2 ENGINE SPECIFICATIONS
Table 1-2. Specification Chart
MODEL NUMBER (Carrier / Kubota) CT2--29--TV / Z482--E2B CT3--44--TV / D722--E2B
TYPE Vertical, Water--cooled, 4 cycle IDI diesel engine
NUMBER OF CYLINDERS 2 3
BOREXSTROKE mmXmm(in.Xin.) 67 X 68 (2.64 X 2.68)
TOTAL DISPLACEMENT cm3(cu.in.) 479 (29.23) 719 (43.88)
BRAKE
HORSEPOWER SAE Intermittent H.P. kW (HP) / RPM 9.3 (12.5) / 3600 14.0 (18.0) / 3600
MAXIMUM BARE SPEED RPM 3800
IDLING SPEED RPM 900 To 1000
COMBUSTION CHAMBER Spherical Type (E--TVCS)
FUEL INJECTION PUMP Bosch MD Type Mini Pump
GOVERNOR Centrifugal Ball Mechanical Governor
INJECTION NOZZLE Bosch Throttle--Type
INJECTION TIMING (before T.D.C.) 19 to 21°
FIRING ORDER 1--2 1--2--3
INJECTION PRESSURE
(Valve Opening Pressure) 13.73 MPa (140 kgf/cm2, 1991 psi.)
COMPRESSION RATIO 23.5 : 1
LUBRICATING SYSTEM Forced Lubrication by Pump
COOLING SYSTEM Pressurized Radiator, Forced Circulation With Water Pump
STARTING SYSTEM Cell Starter (With Glow Plug)
STARTING MOTOR 12V, 0.8 kW
RECOMMENDED BATTERY CAPACITY
(5 Hour Capacity) 12V, 28AH, equivalent 12V, 36AH, equivalent
CHARGING GENERATOR 12V, 150 W 12V, 150 W
FUEL Diesel Fuel No.2--D (ASTM D975)
LUBRICATING OIL *Quality Better Than CF Class (API), SAE 10W--30 or 15W--40
LUBRICATING OIL CAPACITY 2.5 L (2.64 U.S. Quarts) 3.8 L (4.02 U.S. Quarts)
3.3 L (3.5 U.S. Quarts) (TFX--1 Only)
Weight (DRY) kg (lbs.) 53.1 (117.1) 63.1 (139.1)
*See paragraph 1.7.2.

1--3 62--11161
1.2.1 E2B ENGINE
Carrier/Kubota supply diesel engines conforming to
federalemissionregulations.Theemissioncontrolsthat
have been put into effect have been stepped up to the
second stage. Carrier/Kubota has executed the
improvement in the engines to conform to this
regulation.
In order to discriminate between engines conforming to
Tier 1 / Phase 1 requirements and those conforming to
Tier 2/ Phase 2 requirements, we have adapted E2B as
a new model name for theengines conforming to Tier2/
Phase 2 regulations.
In the after--sale services for Tier 2 / Phase 2 engines,
only use the dedicated parts for E2B models and carry
out the maintenance services accordingly.
1.2.2 CYLINDER NUMBER
The cylinder numbers of diesel engines are designated
as shown above. The sequence of cylinder numbers is
given as No.1, No. 2, and No. 3 starting from the gear
case end of the engine.
1.3 GENERAL PRECAUTIONS
During disassembly, carefully arrange removed parts in
a clean area to prevent confusion latter. Screws, bolts
and nuts should be replaced in their original position to
prevent reassembly errors.
When special toolsare required, use Carrier Transicold
genuine special tools. Special tools which are not
frequently used should be made according to the
drawings provided.
Before disassembling or servicing electrical wires,
make sure to always disconnect the grounding cable
from the battery first.
Remove oil and dirt from parts before taking any
measurements.
Use only Carrier Transicold genuine parts for parts
replacements 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.
1
2
3
23
1. Grease
2. Force
3. Place the Sharp Edge
against the Direction of Force
A External Snap Ring
B Internal Snap Ring
When reassembling external or internal snap rings,
position them so that the sharp edge faces against the
direction from which force is applied.
A newly serviced or reassembled engine should be
run--in with no load for 15 minutes. Serious damage to
the engine may result otherwise.

1--4
62--11161
1.4 TORQUE SPECIFICATION
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 the proper sequence and at the proper torque.
1.4.1 Torque Specifications For Special Use Screws, Bolts and Nuts
In removing and applying the screws, bolts and nuts marked with “*”, a pneumatic wrench or similar tool, if employed,
must be used with care. Failure to do so may result in stripped or seized screws, bolts and nuts.
When replacing “*” marked screws, bolt and nuts, apply engine oil to their threads and seats before reassembly.
The letter “M” in size and pitch means that the screw, bolt or nut dimension is 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 SizexPitch N.m kgf.m ft--lbs
Cylinder Head Cover Bolt M6 x 1.0 6.9to11.3 0.7to1.15 5.1to8.3
Injection Pipe Retaining Nut M12 x 1.5 24.5 to 34.3 2.5to3.5 18.1 to 25.3
Overflow Pipe Retaining Bolt M12 x 1.5 19.6 to 24.5 2.0to2.5 14.5 to 18.1
Nozzle Holder Assembly M20 x 1.5 49.0 to 68.6 5.0to7.0 36.2 to 50.6
Glow Plug M8 x 1 7.85 to 14.7 0.8to1.5 5.8 to 10.8
*Rocker Arm Bracket Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
*Cylinder Head Bolt M8 x 1.25 37.3 to 42.2 3.8to4.3 27.5 to 31.1
*Fan Drive Pulley Bolt M12 x 1.5 117.7 to 127.5 12.0 to 13.0 86.8 to 94.0
*Idle Gear Shaft Mounting Bolt M6 x 1 9.8to11.3 1.0to1.15 7.2to8.3
Oil Pump Mounting Bolt M8 x 1.25 17.7 to 21.6 1.8to2.2 13.0 to 15.9
*Connecting Rod Bolt M7 x 0.75 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Flywheel Bolt M10 x 1.25 53.9 to 58.8 5.5to6.0 39.8 to 43.4
*Bearing Case Cover Mounting Bolt M6 x 1 9.8to11.3 1.00 to 1.15 7.2to8.3
*Main Bearing Case Bolt 2 M7 x 1 26.5 to 30.4 2.7to3.1 19.5 to 22.4
*Main Bearing Case Bolt 1 M6 x 1 12.7 to 15.7 1.3to1.6 9.4to11.6
Nozzle Holder -- 34.3 to 39.2 3.5to4.0 25.3 to 28.9
Overflow Pipe -- 19.6 to 24.5 2.0to2.5 14.5 to 18.1
Nozzle Holder Assembly -- 49.0 to 68.6 5.0to7.0 36.2 to 50.6
Oil Pressure Switch PT1/8 14.7 to 19.6 1.5to2.0 10.8 to 14.5
Starter (C Terminal Nut) (CT2--29--TV) M8 7.8to9.8 0.8to1.0 5.8to7.2
Starter (B Terminal Nut) (CT3--44--TV) M8 8.8to11.8 0.9to1.2 6.5to8.7
Starter (C Terminal Nut) (CT3--44--TV) M8 5.9to11.8 0.6to1.2 4.3to8.7
Drain Plug W/ Copper Gasket M12 x 1.25 32.4 to 37.3 3.3to3.8 23.9 to 27.5
Drain Plug W/ Copper Gasket M22 x 1.5 63.7 to 73.5 6.5to7.5 47.0 to 54.2
Drain Plug W/ Rubber Coated Gasket M12 x 1.25 44.1 to 53.9 4.5to5.5 32.5 to 39.8
1.4.2 Torque Specifications For General Use Screws, Bolts and Nuts
Standard Screw and Bolt Grade 4 Special Screw and Bolt Grade 7
N.m kgf.m ft--lbs N.m kgf.m ft--lbs
M6 7.9to9.3 0.80 to 0.95 5.8to6.9 9.8to11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8to2.1 13.0 to 15.2 23.5 to 27.5 2.4to2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0to4.6 28.9 to 33.3 48.1 to 55.9 4.9to5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4to7.4 46.3 to 53.5 77.5 to 90.2 7.9to9.2 57.1 to 66.5
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
7Special Screw And Bolt S43C, S48C (Refined)

1--5 62--11161
1.5 TROUBLESHOOTING
Symptom Probable Cause Solution Reference
Engine Does Not
Start
No fuel Replenish fuel
Air in the fuel system Vent Air 1.7.5
Water in the fuel system Change fuel and
repair or replace fuel
system 1.7.5
Fuel pipe clogged Clean 1.7.5
Fuel filter clogged Clean or change --
Excessively high viscosity of fuel or engine oil
at low temperature Use specified fuel or engine oil --
Fuel with low cetane number Use specified fuel --
Fuel leak due to loose injection pipe retaining
nut Tighten retaining nut 2.2.4.b
Incorrect injection timing Adjust 5.1.1
Fuel camshaft worn Replace 2.2.6.g
Injection nozzle clogged Replace 5.2.1/5.2.2
Injection pump malfunctioning Replace --
Seizure of crankshaft, camshaft, piston,
cylinder or bearing Repair or Replace --
Compression leak from cylinder
Replace head
gasket, tighten
cylinder head screw,
glow plug and nozzle
holder
--
Improper valve timing Correct or replace
timing gear 2.2.6.e
Piston ring and cylinder worn Replace 2.3.3.d
Excessive valve clearance Adjust 1.7.6
(Starter Does Not
Run)
Battery discharged Charge
Starter malfunctioning Repair or replace 6.2/6.3
Wiring disconnected Connect --
Engine Revolution
Is Not Smooth
Fuel filter clogged or dirty Clean or change 1.7.5
Air cleaner clogged or dirty Clean or change --
Fuel leak due to loose injection pipe retaining
nut Tighten retaining nut --
Injection pump malfunctioning Replace 2.2.6.a
Incorrect nozzle injection pressure Replace 5.2.2
Injection nozzle stuck or clogged Replace 5.2.2
Governor malfunctioning Repair 2.2.6.g
Either White or Blue
Exhaust Gas Is
Observed
Excessive engine oil Reduce to specified
level 1.7.1
Piston ring and liner worn or ring stuck Repair or replace 2.3.3.d
Incorrect Injection timing Adjust 5.1.1
Deficient compression Check the cylinder
compression
pressure and top
clearance 2.1.1

1--6
62--11161
1.5 TROUBLESHOOTING (Continued)
Symptom Probable Cause Solution Reference
Either Black or Dark
Exhaust Gas Is
Observed
Overload Lesson load --
Low grade fuel used Use specified fuel --
Fuel filter clogged Clean or change --
Air cleaner clogged Clean or change --
Deficient nozzle injection Replace nozzle 5.2.4
Deficient Output
Incorrect injection timing Adjust 5.1.1
Engine’s moving parts seem to be seizing Repair or replace --
Uneven fuel injection Replace injection
pump 2.2.6.a
Deficient nozzle injection Repair or replace
nozzle 5.2.4
Compression leak Check the
compression
pressure and repair 2.1.1
Excessive Lubricant
Oil Consumption
Piston ring’s gap facing the same direction Shift ring gap
direction 2.2.7.b
Oilringwornorstuck Replace 2.3.3.d
Piston ring groove worn Replace worn piston 2.3.3.e
Valve stem and valve guide worn Replace 2.3.1.d
Oil leaking due to defective seals or packing Replace --
Fuel Mixed into
Lubricant Oil
Injection pump’s plunger worn Replace Injection
pump 5.1
Deficient nozzle injection Replace nozzle 5.2.4
Injection pump broken Replace 5.1
Water Mixed into
Lubricant Oil Head gasket defective Replace 2.2.4.e
Cylinder block or cylinder head flawed Replace --
Low Oil Pressure
Engine oil level low Replenish --
Oil filter cartridge clogged Replace --
Relief valve stuck with dirt Clean 3.1.5
Relief valve spring weak or broken Replace 3.1.5
Excessive clearance of crankshaft bearing Replace 2.3.4.d
Excessive clearance of crankpin bearing Replace 2.3.4.c
Excessive clearance of rocker arm Replace 2.3.1.k
Oil passage clogged Clean --
Incorrect oil type Use specified type of
oil --
Oil pump defective Repair or replace 2.2.6.h/3.2
High Oil Pressure Incorrect oil type Use specified type of
oil --
Relief valve defective Replace 3.1.5

1--7 62--11161
1.5 TROUBLESHOOTING (Continued)
Symptom Probable Cause Solution Reference
Engine Overheated
Engine oil level low Replenish --
Fan belt broken or improperly tensioned Replace or adjust --
Coolant insufficient Replenish --
Radiator net and radiator fin clogged with dust Clean --
Inside of radiator corroded Clean or replace --
Coolant flow route corroded Clean or replace --
Radiator cap defective Replace --
Radiator hose defective Replace --
Running overloaded Reduce load --
Head gasket defective Replace 2.2.4.e
Incorrect injection timing Adjust --
Unsuitable fuel used Use specified fuel --
Low Battery Charge
Battery electrolyte level low Replenish distilled
water and charge --
Fan belt slips Adjust belt tension or
change belt --
Wiring disconnected Connect --
Rectifier defective Replace --
Alternator defective Replace --
Battery defective Change --

1--8
62--11161
1.6 SERVICING SPECIFICATIONS
1.6.1 Engine Body
Item Factory Specification Allowable Limit
Valve Clearance (Cold) 0.145 to 0.185 mm
0.00571 to 0.00728 in. --
Compression Pressure 2.84 to 3.24 MPa
29.0to33kgf/cm
2
412 to 469 psi
2.26 MPa
23.0kgf/cm2
327 psi
Difference Between Cylinders -- 10% or less
Top Clearance 0.50 to 0.70 mm
0.0197 to 0.0276 in. --
Cylinder Head Surface Flatness 0.05 mm
0.0020 in.
Valve Recessing (Intake and Exhaust) --0.10 to 0.10 mm
--0.0039 to 0.0039 in. 0.30 mm 0.0118 in.
ValveStemtoValveGuide
Clearance 0.030 to 0.057 mm
0.00118 to 0.00224 in. 0.10 mm 0.0039 in.
Valve Stem
O.D. 5.968 to 5.980 mm 0.23496 to 0.23543 in. --
Valve Guide
I.D. 6.010 to 6.025 mm. 0.23661 to 0.23720 in. --
Valve Face Angle 0.785 rad.
45°--
Valve Seat Angle 0.785 rad.
45°--
Width 2.12 mm
0.0835 in. --
Valve Spring
Free Length 31.3 to 31.8 mm
1.232 to 1.252 in. 28.4 mm 1.118 in.
Tilt -- 1.2 mm
0.047 in.
Setting Load/
Setting Length 64.7 N / 27.0 mm
6.6 kgf / 27.0 mm
14.6 lbs. / 1.063 in.
54.9N / 27.0 mm
5.6kgf / 27.0 mm
12.3lbs /1.063 in.
Rocker Arm Shaft to Rocker Arm
Clearance 0.016 to 0.045 mm
0.00063 to 0.00177 in. 0.15 mm 0.0059 in.
Rocker Arm
Shaft (O.D.) 10.473 to 10.484 mm 0.41232 to 0.41276 in. --
Rocker Arm (I.D.) 10.500 to 10.518 mm
0.41339 to 0.41410 in. --
Push Rod Alignment -- 0.25mm
0.0098 in.
Tappet to Tappet Guide
Clearance 0.016 to 0.052 mm
0.00063 to 0.00205 in. 0.10 mm 0.0039 in.
Tappet (O.D.) 17.966 to 17.984 mm
0.70732 to 0.70803 in. --
Tappet Guide
(I.D.) 18.000 to 18.018 mm 0.70866 to 0.70937 in. --

1--9 62--11161
1.6.1 Engine Body (Continued)
Item Factory Specification Allowable Limit
Timing Gear
Crank Gear to
Idle Gear
(Backlash) 0.043 to 0.124 mm
0.00169 to 0.00488 in. 0.15 mm 0.0059 in.
Idle Gear to Cam
Gear (Backlash) 0.047 to 0.123 mm 0.00185 to 0.00484 in. 0.15 mm 0.0059 in.
Idle Gear to Injec-
tion Pump Gear
(Backlash) 0.046 to 0.124 mm
0.00181 to 0.00488 in. 0.15 mm 0.0059 in.
Crank Gear to Oil
Pump Gear
(Backlash) 0.041 to 0.123 mm
0.00161 to 0.00484 in. 0.15 mm 0.0059 in.
Idle Gear Side Clearance 0.20 to 0.51 mm
0.0079 to 0.0201 in. 0.80 mm 0.0315 in.
Camshaft
Side Clearance 0.15 to 0.31 mm
0.0059 to 0.0122 in. 0.50 mm 0.0197 In.
Alignment -- 0.01 mm
0.0004 In.
Height
(Intake / Exhaust) 26.88 mm 1.0583 in. 26.83 mm 1.0563 In.
Camshaft Journal to Cylinder Block Bore
Clearance 0.050 to 0.091 mm
0.00197 to 0.00358 in. 0.15 mm 0.00059 in.
Camshaft
Journal (O.D.) 32.934 to 32.950 mm 1.29661 to 1.29724 in --
Cylinder Block
Bore (I.D.) 33.000 to 33.025 mm 1.29921 to 1.30020 --
Idle Gear Shaft to Idle Gear Bushing
Clearance 0.020 to 0.084 mm
0.00079 to 0.00331 in. 0.1 mm 0.0039 in.
Idle Gear Shaft
(O.D.) 19.967 to 19.980 mm 0.78610 to 0.78661 in. --
Idle Gear Bushing
(I.D.) 20.000 to 20.051 mm 0.78740 to 0.78791 in. --
Piston Pin Bore I.D. 20.000 to 20.013 mm
0.78740 to 0.78941 in. 20.05 mm 0.7894 in.
Piston Pin to Small End Bushing
Clearance 0.014 to 0.038 mm
0.00055 to 0.00150 in. 0.10 mm 0.0039 in.
Piston Pin (O.D.) 20.002 to 20.011 mm
0.78748 to 0.78783 in. --
Small End
Bushing (I.D.) 20.025 to 20.040 mm 0.78839 to 0.78897 in. --
Piston Pin to Small End Bushing
(Spare Parts)
Clearance 0.015 to 0.075 mm
0.00059 to 0.00295 in. 0.15 mm 0.0059 in.
Small End
Bushing (I.D.) 20.026 to 20.077 mm 0.78845 to 0.79043 in. --
Piston Ring Gap
Top Ring 0.15 to 0.30 mm
0.0059 to 0.0118 in. 1.20 mm 0.0472 in.
Second Ring 0.30 to 0.45 mm
0.0118 to 0.0177 in. 1.20 mm 0.0472 in.
Oil Rng 0.15 to 0.30 mm
0.0059 to 0.0118 in. 1.20 mm 0.0472 in.

1--10
62--11161
1.6.1 Engine Body (Continued)
Item Factory Specification Allowable Limit
Piston Ring to Piston Ring Groove Second Ring
Clearance 0.090 to 0.120 mm 0.00354 to 0.00472 in. 0.15 mm 0.0059 in
Oil Ring
Clearance 0.040 to 0.080 mm 0.0016 to 0.0031 in. 0.15 mm 0.0059 in.
Connecting Rod Alignment -- 0.05 mm
0.0020 in.
Crankshaft Side Clearance 0.15 to 0.31 mm
0.0059 to 0.0122 in. 0.50 mm 0.0197 in.
Alignment -- 0.02 mm
0.0008 in.
Crankpin to Crankpin Bearing
Oil Clearance 0.020 to 0.051 mm
0.00079 to 0.00201 in. 0.15 mm 0.0059 in.
Crankpin (O.D.) 33.959 to 33.975 mm
1.33697 to 1.33760 in. --
Crankpin Bearing
(I.D.) 33.995 to 34.010 mm 1.33893 to 1.33898 in. --
Crankshaft Journal to Crankshaft Bearing1
Oil Clearance 0.034 to 0.106 mm
0.00134 to 0.00417 in. 0.20 mm 0.0079 in.
Crankshaft
Journal (O.D.) 39.934 to 39.950 mm 1.57221 to 1.57284 in. --
Crankshaft
Bearing1 (I.D.) 39.984 to 40.040 mm 1.57148 to 1.57638 in. --
Crankshaft Journal to Crankshaft Bearing2
(Flywheel Side)
Oil Clearance 0.028 to 0.051 mm
0.00110 to 0.00201 in. 0.20 mm 0.0079 in.
Crankshaft
Journal (O.D.) 43.934 to 43.950 mm 1.72968 to 1.73031 in. --
Crankshaft
Bearing2 (I.D.) 43.984 to 44.026 mm 1.73165 to 1.73331 in. --
Crankshaft Journal to Crankshaft Bearing3
(Intermediate)
Oil Clearance 0.028 to 0.051 mm
0.00110 to 0.00201 in. 0.20 mm 0.0079 in.
Crankshaft
Journal (O.D.) 39.934 to 39.950 mm 1.57221 to 1.57284 in. --
Crankshaft
Bearing3 (I.D.) 39.984 to 40.026 mm 1.57417 to 1.57583 in. --
Cylinder Liner
I.D. (Standard) 67.000 to 67.019mm
2.63779 to 2.63854 in. 67.150 mm 2.64370 in.
I.D. (Oversize) :
0.25mm
0.0098in. 67.250 to 67.269mm
2.64764 to 2.64839 in. 67.400mm 2.65354 in.

1--11 62--11161
1.6.2 Lubricating System
Item Factory Specification Allowable Limit
Engine Oil Pressure*At Idle Speed More than 49kPa
0.5 kgf/cm2/7psi --
At Rated Speed 196 to 441 kPa
2.0 to 4.5kgf/cm2/28to64psi 147kPa 1.5kgf/cm2/21psi
Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm
0.0012 to 0.0055 in. --
Outer Rotor to Pump Body Clearance 0.07 to 0.15 mm
0.0028 to 0.0059 in. --
Inner Rotor to Cover Clearance 0.075 to 0.135 mm
0.00295 to 0.00531 in. --
*Engines installed in Genesis, Solara and Supra units use an oil pressure safety switch which opens at
105 kPa / 1.06 kgf/cm2/ 15 psi.
1.6.3 Cooling System
Item Factory Specification Allowable Limit
V--Belt Tension 7.0 to 9.0 mm at 98N
0.28 to 0.35 in. at 98N
(10kgf, 22 lbs.) --
Thermostat
Valve Opening
Temperature
(At Beginning) 69.5 to 72.5°C
157 to 162.5°F--
Valve Opening
Temperature
(Opened Completely) 85°C
185°F--
Radiator Cap Pressure Falling Time 10 seconds or more
88 to 59kPa
0.9 to 0.6 kgf/cm2
13to9psi --
Radiator Leakage Test
Pressure
No leaks at specified
pressure
157 kPa / 1.6 kgf/cm2
23 psi --
1.6.4 Fuel System
Item Factory Specification Allowable Limit
Injection Pump Injection Timing
(3600 min-- 1 rpm) 0.33 to 0.37 rad. (19°to 21°) before T.D.C --
Pump Element Fuel Tightness -- 13.73 MPa
140 kgf/cm2
1991 psi
Delivery Valve Fuel Tightness 10 seconds
13.73 to12.75 MPa
140 to130 kgf/cm2
1991 to 1849 psi
5 seconds
13.73 to12.75
MPa
140 to130 kgf/cm2
1991 to 1849 psi
Fuel Injection Nozzle
Injection Pressure 13.73 to 14.71 MPa
140 to 150 kgf/cm2
1991 to 2134 psi --
Valve Seat
Tightness
When the pressure is
12.75 MPa
(130 kgf/cm2,1849 psi) the
valve must not pass fuel --

1--12
62--11161
1.6.5 Electrical System
Item Factory Specification Allowable Limit
Glow Plug Resistance Approximately 0.9 OHM --
Starter
Commutator O.D. CT2--29--TV 28.0 mm
1.1.102 in. 27.0 mm 1.063 in.
CT3--44--TV 30.0 mm
1.181 in. 29.0 mm 1.142 in.
Difference of O.D. CT2--29--TV Less than 0.05 mm
0.0002 in. 0.4 mm 0.016 in.
CT3--44--TV Less than 0.02 mm
0.0008 in. 0.05 mm 0.0020 in.
Mica Undercut 0.50 to 0.80 mm
0.0197 to 0.0315 in. 0.20 mm 0.0079 in.
Brush Length CT2--29--TV 0.16 mm
0.630 in. 10.5 mm 0.413 in.
CT3--44--TV 0.14 mm
0.551 in. 9.0 mm 0.354 in.
1.7 CHECK AND MAINTENANCE
1.7.1 Checking Engine Oil Level
1. Refer to Section 3.1
1.7.2 Changing Engine Oil
1. Refer to Section 3.1
1.7.3 Checking Coolant Level
1. Refer to Section 4.1.3
1.7.4 Checking Fuel Hose
1. If the clamp is loose, apply oil to the threads and
securely retighten it.
2. The fuel hose is made of rubber and ages regardless
of the service period. Change the hose and clamps
together every two years.
3. Change the fuel hose and clamps whenever any de-
terioration or damage is detected.
4. After the fuel hose and clamps have been changed,
bleed air out of the fuel system.
CAUTION
Stop the engine when attempting to check
and change the fuel line.
1.7.5 Bleeding Fuel System
1
1. Open the air vent cock (1) on top of the fuel injection
pump. (Available on Solara, Supraand Genesisunits
only.)
2. Energizetheelectricfuelpumpfor aperiodof10to15
seconds,or just longenoughtoexpelfuelthroughthe
air vent cock.
3. Close the air vent cock (1).
NOTE
Always keep the air vent cock on the fuel injec-
tionpumpclosedexcept whenbleedingthefuel
system, or the engine may not run.

1--13 62--11161
1.7.6 Valve Clearance
1. Cylinder Head Cover
2. “1TC” Mark
3. Alignment Mark
A. Gear Case End
a. CT2--29--TV
b. CT3--44--TV
NOTE
Valve clearancemust be checked and adjusted
when the engine is cold.
1. Remove the valve cover (1).
2. Align the “1TC” mark line (2) on the flywheel and pro-
jection (3) onthe housingsothat the Number 1piston
comes to compression top dead center (TDC).
3. Check the following valve clearance marked with “*”
(at TDC) using a feeler guage.
4. If the clearance is not within the factory specifica-
tions, adjust with the adjusting screw.
5. Then turn the flywheel 6.28 rad (360°), and align the
“1TC” mark (2) on the flywheel and alignment mark
(3)ontherearendplatesothat theNo.1pistoncome
to the overlap position.
6. Check the following valve clearance marked with “*”
(past TDC) using a feeler guage.
CT2--29--TV Valve
Arrangement
Piston Location in Cylinder IN. EX.
When No. 1 piston is at TDC No. 1 * *
No. 2 *
When No. 1 piston is past TDC No. 1
No. 2 *
CT3--44--TV Valve
Arrangement
Piston Location in Cylinder IN. EX.
When No. 1 piston is at TDC No. 1 * *
No. 2 *
No. 3 *
When No. 1 piston is past TDC
No. 1
No. 2 *
No. 3 *
7. If the clearance is not within the factory specifica-
tions, adjust with the adjusting screw.
NOTE
The sequence of cylinder numbers is given as
No.1,No.2andNo.3startingfromthegearcase
end.
After adjusting the valve clearance, secure the
adjusting screw with the lock nut.