Engine J08E-UN
Engine J08E-UN
Engine J08E-UN
WORKSHOP MANUAL
J08E-UN
KSS-SMJ8-E102E
2007.6
GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE ASSEMBLY/DISASSEMBLY 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17
ENGINE
1
1 GENERAL
General information
Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts ...................... 1-11
Tightening of flare nuts and hoses........................ 1-13
Taper thread sealant for piping ............................. 1-14
Assembly of joints and gaskets for piping ............. 1-15
Handling of liquid gasket....................................... 1-17
Failure diagnosis table for each problem .............. 1-18
Failure diagnosis procedures ................................ 1-19
Failure diagnosis using HinoDX ............................ 1-21
Connection method of HinoDX ............................. 1-24
Chassis number and engine number ................... 1-24
1–2 GENERAL
Warning
JP31002010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
GENERAL 1–3
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.
! CAUTION The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in June, 2007. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
1–4 GENERAL
(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.
Check if failure occurs again after repair. If it is difficult to
(6) Confirmation test "Step 4" reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.
(2) Pre-inspection
Example
SAPH041170900182
SAPH310020100001
✩ It is the ID number for parts to prepare electronic data. It is not required for repair work.
1–6 GENERAL
7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction
a. Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
Vertical direction
With a unit mounted on the machine main unit, the upward direction is upper and the downward direction is
lower.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined
(3) Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Operation limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.
GENERAL 1–7
8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Spring 1kgf/mm=980665N/
Force N kgf 1kgf=9.80665N N/mm kgf/mm
constant mm
1kgf⋅cm=0.0980665
Torque*2 N⋅m kgf⋅cm Volume L cc 1cc=1mL
N⋅m
1kgf/
2 cm2
kgf/cm =98.0665kPa Efficiency W PS 1PS=0.735499kW
Pressure Pa =0.0980665MPa
1mmHg=0.133322k Calorific
mmHg W⋅h cal 1kcal=1.13279W⋅h
Pa value
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items :
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the
area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure machine, refer to “Towing” in the "Operation manual" of the machine.
1–8 GENERAL
SAPH310020100002
SAPH310020100003
GENERAL 1–9
SAPH310020100004
SAPH310020100005
1–10 GENERAL
Remark Bolt with number “7” on the head Bolt with number “9” on the head
SAPH310020100006
1–12 GENERAL
2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.
SAPH310020100008
SAPH310020100010
GENERAL 1–13
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
Packing
Brake hose — —
51.5±7.5{525±75}
Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
1–14 GENERAL
The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant ( # Loctite 575) has strong sealing feature.
Frame Air pipe (Flare joint) The return torque of the taper joint is increased about 1.5
(No application of sealant) times the initial tightening torque. When the joint is
Since sealant is
disconnected, use a long wrench for disconnection
applied to this (2) When a joint at a poorly accessible area is replaced,
area, remove
accessories with remove accessories first and disconnect the joint.
the joint attached
Air hose
SAPH310020100011
2. For connection
Screw
diameter 1/4 3/8 1/2
Material
Aluminu
m, 25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
M8 13{130}
M24 69{700}
M28 *127{1300}
Sealing surface
: 4 places
Flare connector
One piece eye joint Gasket
Gasket
with sleeve
Gasket Sealing surface Sealing surface: 5 places
Gasket
: 5 places
Sealing surface
: 8 places Connector nipple
Joint pipe
Bracket
Sealing surface
: 3 places
Joint bolt
Joint bolt
Joint pipe
2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.
Winding tool
Application gun
For a tube, desired application width may be obtained from the cut position at the nozzle end.
Nozzle of tube
General information
Description of function
1–18 GENERAL
Engine mechanical Causes and actions are described for each item.
JP03Z01020601001
SAPH310020100027
SAPH310020100028
Failure of main speed sensor (DTC code P0335/diagnosis monitor code 13)
JP03Z01030601004
1. Set the starter key to "LOCK" and connect the signal check
B6 B B7 harness.
OK
Standard : Normal
SAPH03Z010300011
OK
Normal
OK
Check the harness of the relevant circuit and repair the faulty area.
SAPH310020100030
GENERAL 1–21
1. HinoDX
Part name Part No. External shape General description and function
Unit harness ! CAUTION • Do not break the locking tab of the connector.
Signal check harness
b. Connect the signal check harness to the machine
harness and the ECU.
Test lead Signal check harness
(for common rail fuel injection system)
Part No.
09049-1080
SAPH310020100035
GENERAL 1–23
ECU unit
Signal check
harness
SAPH310020100037
1–24 GENERAL
SAPH310020100038
2. Connection of HinoDX
Engine ECU (1) Connect the engine failure diagnosis connector to the PC
which installed HinoDX through the interface box.
SAPH310020100039
Hino-Bowie
Setup layout
Layout
Stamp position
SAPH310020100041
STANDARD VALUE 2–1
ENGINE
2 STANDARD VALUE 2
Specification
System drawing
(performance)
Engine Body
Standard value
JP31002020205001
3.4-3.7MPa 2.7MPa
Compression pressure {35-38kgf/cm2, {28kgf/
—
(Engine revolution per cylinder: 150 r/min) 493-237lbf/ cm2,392lbf/
in.2} in.2}
Tightening torque
JP31002020205002
Unit:N⋅m{kgf⋅cm, lbf⋅ft}
7.8 - 8.8
Starter B terminal
{80 - 110, 5.8 - 6.5}
3.3 - 4.4
Alternator B terminal
{33 - 45, 2.4 - 3.2}
Fuel System
Tightening torque
JP31002020205003
Fuel filter air bleeding bolt 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}
Supply pump drive - flywheel housing 28.5 {290, 21}
STANDARD VALUE 2–3
Electrical
Standard value
JP31002020205004
Tightening torque
JP31002020205005
Intake
Tightening torque
JP31002020205006
Engine Mechanical
Standard value
JP31002020205007
Unit : mm {in.}
Inspection item Standard value Repair limit Service limit Action
IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —
0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.003}
117.008 - 117.014
Cylinder block inner diameter B — —
{4.6066 - 4.6068}
117.014 - 117.022
C — —
{4.6068 - 4.6072}
116.982 - 116.99
A — —
{4.6056 - 4.6059}
116.99 - 116.996
Cylinder liner outer diameter B — —
{4.6059 - 4.6061}
116.996 - 117.004
C — —
{4.6061 - 4.6064}
Cylinder
112.15
Cylinder liner inner diameter 112 {4.4094} — Replace
{4.4154}
liner
Approx. 11.5
Top — —
{0.4528}
Free joint clearance
Approx. 14
Second — —
{0.4921}
0.3 - 0.40
Top — 1.5 {0.0591}
{0.0118 - 0.0157}
Cylinder liner
0.75 - 0.90 Replace
Joint for assembly Second — 1.2 {0.0472}
Piston {0.0295 - 0.0354} piston ring
Clearance
ring 0.15 - 0.3
Oil — 1.2 {0.0472}
{0.0059 - 0.1181}
–0.1
Top 2.5 {0.0984} —
{–0.0039}
–0.1
Oil 4 {0.1574} —
{–0.0039}
+0.2
Top 2.5 {0.0984} —
{+0.0079}
+0.2 Replace
Piston ring groove Second 2 {0.0787} —
{+0.0079} piston
+0.1
Oil 4 {0.1574} —
{+0.0039}
0.09 - 0.13
Top — —
{0.0035 - 0.0051}
Clearance between Replace
0.04 - 0.08
piston ring and Second — — piston ring
{0.00016 - 0.0031}
Piston piston ring groove or piston.
0.02 - 0.06
Oil — —
{0.0008 - 0.0024}
–0.04 Replace
Piston pin outer diameter 37 {1.4567} —
{–0.0015} piston pin
+0.05 Replace
Piston boss inner diameter 37 {1.4567} —
{+0.0020} piston
–0.002T - 0.025L
{0.0000 - 0.0010} Replace
Clearance between piston pin 0.05
(T : Tightening — piston pin
and piston boss {0.0020}
allowance, or piston
L : Clearance)
Replace
+0.1
Connecting rod bushing inner diameter 37 {1.4567} — connecting
{0.0039}
rod bushing
2–6 STANDARD VALUE
Replace
0.015 - 0.036 0.08 piston pin or
Connecting rod bushing oil clearance —
{0.0006 - 0.0014} {0.0031} connecting
rod bushing
Replace the
63.8
Crank pin outer diameter 65 {2.5590} — crankshaft.
{2.5118}
(Note 1)
Replace
bearing for
0.031 - 0.082 clearance
Connecting rod oil clearance 0.2 {0.0079} —
{0.0012 - 0.0032} of 0.3 or
more (Note
2)
Crank
78.8 Replace
Crank journal outer diameter 80 {3.1496} —
{3.1024} shaft (Note
1)
Crank
Thickness of main bearing 2.5 {0.2342} — —
shaft
Replace
0.051 - 0.102
Crankshaft oil clearance 0.2 {0.0079} — bearing
{0.0020 - 0.0040}
(Note 2)
+1.00 Replace
Center journal width 36 {1.4173} —
{+0.039} crankshaft.
Replace
0.050 - 0.219 0.50 1.219 thrust
Crankshaft end play
{0.0020 - 0.0086} {0.0020} {0.0086} bearing or
crankshaft
0.15 Ground to
Crankshaft runout — —
{0.0059} under-size
+0.8 Replace
Crank pin width 34 {13.386} —
{+0.0315} crankshaft
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or
more. Replace crankshaft for wear of 1.20 or more.
Note 2 : Under-size bearing values are 0.25, 0.50, 0.75 and 1.00.
Replace
–0.8
Connecting rod large end width 34 {1.3386} — connecting
{–0.0315}
rod
STANDARD VALUE 2–7
Replace
0.20 - 0.52 connecting
Connecting rod end play — 1.0 {0.0394}
{0.0079 - 0.0205} rod or
crankshaft
Replace
Camshaft bearing oil 0.020 - 0.063
Cam — — camshaft
Clearance {0.0008 - 0.0025}
shaft or bearing
0.04 Replace
Camshaft runout — 0.1 {0.039}
{0.0016} camshaft
–0.08 Replace
Rocker shaft outer diameter 22 {0.8661} —
{–0.0031} rocker shaft
Replace
+0.08
Rocker arm bushing inner diameter 22 {0.8661} — rocker arm
{+0.0031}
bushing
IN 7 {0.2756} — — Replace
Valve stem outer diameter
EX 7 {0.2756} — — valve
IN 7 {0.2756} — — Replace
Valve guide inner diameter
EX 7 {0.2756} — — valve guide
0.023 - 0.058
IN — — Replace
Oil clearance between valve guide {0.0009 - 0.0020}
valve or
and valve stem 0.050 - 0.083
EX — — valve guide
{0.0020 - 0.0033}
0.55 - 0.85
IN — 1.1 {0.0433} Replace
{0.0217 - 0.0335}
Valve sink valve and
1.15 - 1.45
EX — 1.7 {0.0669} valve seat
{0.0453 - 0.0571}
2–8 STANDARD VALUE
129N
Set load — —
{13.1kgf}
Inner 64.6 –3.0 Replace
Free length —
{2.5433} {–0.3543} spring
2.0 Replace
Squareness — —
{0.0787} spring
Valve
46.8
spring Set length — —
{1.8252}
314N
Set load — —
{32.0kgf}
Outer
75.7 –3.0 Replace
Free length —
{2.9803} {–0.3543} spring
2.0 Replace
Squareness — —
{0.0787} spring
STANDARD VALUE 2–9
Bushing inner
57{2.2441} — —
diameter
Timing Replace
Clearance between 0.030 - 0.090 0.20
gear — shaft or
Main shaft and bushing {0.0012 - 0.0084} {0.0079}
bushing
idle
Gear width 44 {1.7322} — —
Replace
0.114 - 0.160 0.30
End play — shaft or
{0.0045 - 0.0063} {0.0012}
gear
Replace
Clearance between 0.025 - 0.075 0.20
— shaft or
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {0.8661} — —
Replace
0.040 - 0.120 0.30
End play — shaft or
{0.0016 - 0.0047} {0.0012}
gear
2–10 STANDARD VALUE
Bushing inner
34 {1.3386} — —
diameter
Grinding is
inhibited
Longitudinal because
direction 0.06 backlash
Flatness under cylinder head 0.2
{0.0024} — between
Flatness above cylinder block {0.0079}
Square direction cam idle –
0.03 {0.0012} sub-idle
gears is
changed.
0.15
Surface runout of flywheel — —
{0.0060}
126.5
Head bolt — — Replacement
{49.8031}
Valve timing
Tightening torque
JP31002020205008
Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.
36 {370, 27} M8
Flywheel housing stay - Flywheel housing 171.5 {1, 750, 126} M14
Rear end plate torx bolt 55 {560, 41}
Pump drive idle gear shaft mounting bolt 108 {1,100, 80}
2–12 STANDARD VALUE
Exhaust
Tightening torque
JP31002020205009
Cooling
Standard value
JP31002020205010
74.5 - 78.5°C
Thermostat valve open temperature {166.1 - — — Replacement
173.3°F}
Lubrication
Standard value
JP31002020205011
Unit : mm {in.}
Repair Service
Inspection item Standard value Action
limit limit
39kPa
Hydraulic alarm switch operation pressure {0.4kgf/cm2, — —
5.66lbf/in.2}
Clearance between drive gear and cylinder 0.100 - 0.202 0.30 Replace drive
—
block {0.0039 - 0.0080} {0.0118} gear or oil pump
Clearance between driven gear shaft outer 0.030 - 0.075 Replace oil
— —
diameter and cylinder block hole diameter {0.0012 - 0.0030} pump
Clearance between driven gear shaft outer 0.040 - 0.083 0.15 Replace oil
—
diameter and gear bushing inner diameter {0.016 - 0.0033} {0.059} pump or bushing
Backlash between drive gear and driven 0.072 - 0.277 0.30 Replace oil
—
gear {0.0028 - 0.0109} {0.0118} pump
Tightening torque
JP31002020205012
Standard Service
Inspection item Repair limit Action
value limit
1MΩor
Resistance between stator coil core and coil — — Replacement
more
1MΩor
Resistance between feed coil core and coil — — Replacement
more
Forward Approx.
— —
Resistance between resistance value 10Ω
Replacement
diode and rectifier holder Reverse
Infinite — —
resistance value
Forward Approx.
Resistance between — —
resistance value 10Ω
regulator terminals F — Replacement
Reverse
E Infinite — —
resistance value
Heat sink mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Screw lock is
Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} used
Front side - Rear side mounting bolt 7.8 - 9.8 {80 - 99, 6 - 7}
Unit : mm {in.}
Standard
Inspection item Service limit Action
value
Resistance between
1MΩ or more 1kΩ or less
commutator and core
Replace armature
Commutator outer diameter 36 {1.4173} 34 {1.1458} or less
Armature assembly
Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
assembly
Shaft outer diameter B 9 {0.3643} 8.98 {0.3535} or less
0.5 - 0.8
Undercut depth 0.2 {0.0079} or less Correction
{0.0197}
Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush
Replace
Bearing housing inner diameter of rear
28 {1.1024} 28.1 {1.1063} or more commutator end
bracket
frame
2–16 STANDARD VALUE
Standard
Inspection item Service limit Action
value
Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}
Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}
Turbocharger
Standard value
JP31002020205017
Unit : mm {in.}
Standard
Inspection item Repair limit Service limit Action
value
Tightening torque
JP31002020205018
ENGINE
3 PARTS TO BE PREPARED
Special tool (SST)
3
Engine Body................................................................ 3-2
Special tool ............................................................. 3-2
Fuel System ................................................................ 3-2
Lubricant, etc. ........................................................ 3-2
Electrical...................................................................... 3-2
Special tool ............................................................. 3-2
Engine Mechanical ..................................................... 3-3
Special tool ............................................................. 3-3
Instruments ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Cooling ........................................................................ 3-6
Special tool ............................................................. 3-6
Lubrication .................................................................. 3-7
Special tool ............................................................. 3-7
Lubricant, etc. ........................................................ 3-7
Starting and Charging................................................ 3-7
Jig (reference dimensional drawing for manufacture)
............................................................................... 3-7
Instruments ............................................................. 3-8
Lubricant, etc. ........................................................ 3-8
Turbocharger............................................................... 3-8
Special tool ............................................................. 3-8
Engine Failure Diagnosis........................................... 3-9
Special tool ............................................................. 3-9
3–2 PARTS TO BE PREPARED
Engine Body
Special tool
JP31002030901001
Fuel System
Lubricant, etc.
JP31002030901002
Name Remark
Guide bolt (9069-08180) For supply pump positioning
Electrical
Special tool
JP31002030901003
Engine Mechanical
Special tool
JP31002030901004
For assembly/disassembly
09433–1070 Eye bolt
of cylinder head
For assembly/disassembly
09470–1170 Valve spring press
of valve spring retainer
For assembly/disassembly
09442–1011 Piston ring expander
of piston ring
For assembly/disassembly
09402–1530 Press sub-assembly of connecting rod small end
bushing
For assembly/disassembly
of connecting rod small end
9233–10360 Wing nut
bushing (together with
09402–1530)
For assembly/disassembly
of connecting rod small end
09481–1130 Guide
bushing (together with
09402–1530)
For assembly/disassembly
09402–1540 Spindle of connecting rod small end
bushing
For assembly/disassembly
09481–1340 Guide
of flywheel
09420–1100
For main/sub idle gear
Sliding hammer assembly and cam idle gear
09420–1442
shaft removal
For assembly/disassembly
09411–1300 Socket wrench
of Torx bolt
Instruments
JP31002030901005
Name Remark
Micrometer For measurement of part outer diameter
Lubricant, etc.
JP31002030901006
Name Remark
Liquid gasket (Threebond TB1207B or equivalent :
For sealing of parts
Black)
Cooling
Special tool
JP31002030901007
Lubrication
Special tool
JP31002030901008
Lubricant, etc.
JP31002030901009
Name Remark
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}
Jig C Jig D
φ34{1.339} φ41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}
SAPH310020300034
3–8 PARTS TO BE PREPARED
Instruments
JP31002030901011
Alternator
Name Remark
Starter
Name Remark
Circuit tester For measurement of parts
Lubricant, etc.
JP31002030901012
Name Remark
Turbocharger
Special tool
JP31002030901013
This is installed as
interruption between vehicle
09049–1080 Signal check harness harness and the ECU.
Tester inspection is allowed
in energized status.
ENGINE ASSEMBLY/DISASSEMBLY 4–1
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
Service procedure
Overhaul item
2. Measurement
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Difference between
0.3{3, 44} or less
cylinders
Engine Body
Removal
JP31002040702002
(2) Drain engine oil from the oil pan drain plug as required.
Drain cock
SAPH310020400004
SAPH310020400005
ENGINE ASSEMBLY/DISASSEMBLY 4–5
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.
SAPH310020400006
(1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter hose.
(4) Disconnect the fuel filter hose.
(3) When the wire is completely tense, make sure that the
Image wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
SAPH310020400008
4–6 ENGINE ASSEMBLY/DISASSEMBLY
Installation
JP31002040702003
SAPH310020400009
! CAUTION • Please use Hino genuine engine oil
ENGINE
5 FUEL SYSTEM
Setup layout
Layout
Fuel System
Fuel system diagram
JP31002050402001
Common rail
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Supply pump
Fuel tank
Fuel filter
SAPH310020500001
FUEL SYSTEM 5–3
Part layout
JP31002050402002
SAPH310020500002
4. Start the priming pump and bleed air from the system.
! CAUTION • Make sure that the fuel filter air bleeding bolt
is loose.
! CAUTION • The frequency for water draining and replacement of the fuel filter element differs
according to the fuel situation in the use region.
Replace the fuel filter element every 500 hours or when the engine output decreases,
whichever occurs first.
• Inspection of the fuel filter element and draining of water should be performed before each
start of operation.
• Always use an original fuel filter element.
! CAUTION • Completely remove any dust around the fuel filter head and especially around the air vent
bolt.
• Since the filter contains diesel oil, prepare a tray.
5–6 FUEL SYSTEM
(1) The soiling and the foreign material of the clamp face are removed.
(2) Install the fuel filter element with according to tightening angle in the table below of a turn after the O-ring
of the fuel filter element comes into contact with the fuel filter head.
NOTICE • The cross-section shape of the O-ring on the side of the fuel filter element has been
changed.
! CAUTION • Tighten after confirming whether the O-ring is a new or an old one.
• As the O-ring is included in the element kit, do not use an O-ring again after it has been
removed once.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not use a tool, but tighten by hand.
Old New
Old New
3/4
11/2 1/2
SAPH310020500004
عTightening angleع
(Image with the fuel filter seen from below)
O-ring
SAPH310020500007
(1) Install the fuel filter element with 1/2 to 3/4 of a turn after the O-ring of the water cup comes into contact
with the fuel filter element.
(2) Tighten the fuel filter drain valve.
! CAUTION • Make sure that the fuel filter air bleeding bolt is loose.
! CAUTION • After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel
leak.
5–8 FUEL SYSTEM
1
Flywheel housing
SAPH310020500008
SAPH310020500009
Pipe B
SAPH310020500010
(2) Remove the supply pump together with the supply pump
drive.
O-ring
(3) Remove the supply pump at the bearing holder case from
the supply pump drive.
SAPH310020500011
FUEL SYSTEM 5–9
(4) Fix the coupling flange with a vice to prevent turning and
Bearing holder case
remove the coupling flange.
Shaft (5) Remove the bearing holder case from the supply pump.
Nut
Coupling flange
SAPH310020500012
SAPH310020500013
(2) Fix the supply pump and install the coupling flange to the
Bearing holder case shaft. Tighten nuts while fixing with a vice to prevent
turning.
Shaft
Tightening torque : 63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}
SAPH310020500014
Casting mark
SAPH310020500015
5–10 FUEL SYSTEM
(2) Put the guide bolt 9069-08180 into the bearing holder
Bearing holder case case to come in contact with the stopper key hole of the
coupling flange.
Shaft
(3) Replace the O-ring of the supply pump drive and the
Bearing holder case supply pump with new O-rings and attach couplings for
Coupling
assembly. Then, tighten bolts.
Supply pump
(4) Replace the O-ring with a new one. Install the supply
pump drive assembled with the supply pump on the
O-ring
flywheel housing.
Replacement of injector
JP31002050704005
1. Removal of injector
(1) Remove the fixing bolt and remove the plate and the
injection pipe oil seal.
(2) Remove the nozzle clamp holder and remove the injector.
2. Installation of injector
(1) Attach a new O-ring to the groove of the cylinder head and
insert the injector.
Fixing bolt
Injector ! CAUTION • Apply engine oil to the O-ring and be careful
to prevent pinching of the O-ring.
Injection pipe (2) Install the nozzle clamp holder and tack weld the injector
temporarily.
Nozzle clamp ! CAUTION • Do not fix the nozzle holder until the injection
holder pipe is tack welded.
(3) Put a new injection pipe oil seal on the injector and install
the plate.
Injection pipe
oil seal
! CAUTION • Install the injection pipe oil seal to prevent
O-ring undue force to the injection nozzle. (Offset
position between the injection pipe oil seal
and the injection nozzle may cause oil leak or
poor assembly of the injection pipe.)
SAPH310020500020
5–12 FUEL SYSTEM
PC
QR code reader
Hino-Bowie
(Special interface)
Connector
New injector
ECU
SAPH310020500022
FUEL SYSTEM 5–13
Inspection of injector
JP31002050704006
(4) If the resistance value in (2) and (3) exceeds the standard
value, replace the injector assembly.
2. Cleaning of injector
Upper body
(1) Remove sludge at or around the terminal, if any.
Pressure limiter
SAPH310020500024
SAPH310020500025
5–14 FUEL SYSTEM
ENGINE
7 ELECTRICAL
Setup layout
Layout
7
7–2 ELECTRICAL
Electrical System
Part layout
JP31ZZZ070402001
SAPH310020700001
SAPH310020700002
Tightening torque
9011-64401 83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft} 9241-10107 51 N⋅m {520 kgf⋅cm, 37 lbf⋅ft}
9069D 154 N⋅m {1, 570 kgf⋅cm, 114 lbf⋅ft} 9241-14147 154 N⋅m {1,570 kgf⋅cm, 114 lbf⋅ft}
7–4 ELECTRICAL
Layout of components
JP31ZZZ070402002
Upper view
SAPH310020700005
Service procedure
Overhaul item
ELECTRICAL 7–7
Inspection of components
JP31ZZZ070702001
39.2 - 58.8kPa
2 2
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase
SAPH310020700007
Connector color: Dark (1) Heat the coolant temperature sender gauge using hot
water.
A (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
Between A and C
C
B Temperat
-20 20 80 110
SAPH310020700008
ure
{-68} {68} {176} {230}
(°C{°F})
Resistanc
13.84 - 2.32 - 0.31 - 0.1399 -
e value
16.33 2.59 0.326 0.1435
(Ω)
Temperat
75 100
ure
{167} {212}
(°C,°F)
Resistanc
35.5 -
e value 79 - 92
42.5
(Ω)
7–8 ELECTRICAL
Standard value
Resistance value : Ω
(Normal temperature 2.59 - 3.29
20°C{68°F})
SAPH310020700009
SAPH310020700010
SAPH310020700011
6. Inspection of injector
(1) For inspection and replacement of the injector, refer to
the chapter of "J08EFuel".
ELECTRICAL 7–9
Installation of component
JP31ZZZ070702002
Sub-revolution sensor
O-ring
SAPH310020700012
Installation of starter
JP31ZZZ070702003
SAPH310020700013
7–10 ELECTRICAL
1. Removal of alternator.
Fixing nut(s) on the Adjustment bolt Brace
side of the brace (1) Remove the adjustment bolt.
(2) Remove the fixing nut(s) on the side of the brace.
(3) Remove the through bolt while supporting the alternator,
and remove the alternator.
2. Installation of alternator.
When installing a
Item At the time of inspection
new belt
#
22 - 23mm 24 - 25mm
Deflection
{0.8661 - 0.9055in.} {0.9449 - 0.9843in.}
100 - 120 N
70 - 80 N
Tension {10 - 12 kgf, 22 - 27
{7 - 8 kgf, 16 - 18 lbf}
Alternator lbf}
Pulley
Crankshaft
Special tool : 09444-1210 Compression gauge (used
Pulley at the time of measuring the deflection
amount) [Reference push force 98N
{10kgf, 22lbf}]
SAPH310020700015
95506-00090 (Denso part No.) Belt
tension gauge (used at the time of
measuring the tension force)
(3) After the adjustment, tighten all nuts and bolts securely.
Tightening torque :
83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft} (Through bolt)
51 N⋅m {520 kgf⋅cm, 38 lbf⋅ft} (Fixing nuts at brace)
5.9 N⋅m {60 kgf⋅cm, 4 lbf⋅ft} (Adjustment bolt)
Alternator
SAPH310020700016
INTAKE 8–1
ENGINE
8 INTAKE
Setup layout
Layout
8
8–2 INTAKE
Intake Manifold
Part layout
JP31002080402001
SAPH310020800001
Replacement
JP31002080704001
Protrusion
SAPH310020800002
(3) Install the intake manifold and tighten it with bolts and
nuts.
SAPH310020800003
ENGINE
9 ENGINE MECHANICAL
Setup layout
Layout
Cylinder Head
Part layout
JP31002090402001
SAPH310020900001
SAPH310020900002
SAPH310020900003
(2) Remove the cylinder head using a special tool and hoist.
Figure is an Special tool : 09433–1070 Eye bolt
example of work.
SAPH310020900005
Too small
Clearance Clearance
SAPH310020900007
(4) Tighten head bolts M12 only in the order from the center
to outside.
Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
(5) After tightening M12 bolt, tighten the bolts again from the
center to outside.
Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
(6) Mark the heads of the head bolts (M12 only) using paint.
No. 1 to No. 26: M12 bolt (7) Retighten the 90 deg head bolts (M12 only) in the same
No. 27 to No. 29: M10 bolt
order in (5).
SAPH310020900008
(8) Retighten the 90 deg head bolts (M12 only) in the same
order.
(9) Make sure that all marks face the same direction.
Paint mark
! CAUTION • If a bolt is turned excessively in retightening,
do not loosen it.
SAPH310020900009
SAPH310020900010
SAPH310020900011
ENGINE MECHANICAL 9–7
SAPH310020900012
SAPH310020900013
SAPH310020900014
SAPH310020900015
9–8 ENGINE MECHANICAL
(1) Remove liquid gasket near the side of the cylinder plug at
the front/rear ends of the camshaft housing, using a
scraper.
SAPH310020900016
(2) Wipe dirt (including liquid gasket) and oil on the joint
surfaces of the head cover and the camshaft housing.
Install a new gasket on the head cover.
SAPH310020900017
(4) Put the head cover on the camshaft housing and tighten
Head cover Bolt bolts.
Silent block
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
surface
Camshaft housing
SAPH310020900019
ENGINE MECHANICAL 9–9
SAPH310020900020
Backing Valve seat ! CAUTION • The valve seat replacement procedure below
metal
may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.
Electric welding
Valve
(1) If the valve seat is replaced, use an out-of-use valve.
Cut three areas
from here. After cutting three pieces from the valve circumference,
weld them to the valve seat.
SAPH310020900022
(2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
(3) Remove welding spatter or dirt on the valve seat surface.
9–10 ENGINE MECHANICAL
SAPH310020900023
(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : 09431–1020 Valve lapping tool
SAPH310020900024
(1) Tap the nozzle seat from the cylinder head lower part.
Then, put an appropriate bolt inside.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.
(4) After attaching a new O-ring into the nozzle seat hole of
Cylinder head the cylinder head, apply the liquid gasket [Threebond
O-ring
TB1211 (white) or equivalent] at the lower part of a new
nozzle seat and assemble it on the cylinder head.
Nozzle sheet ! CAUTION • Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
head.
SAPH310020900026
ENGINE MECHANICAL 9–11
Cylinder
Head
Steel ball
SAPH310020900028
9–12 ENGINE MECHANICAL
Cylinder Block
Part layout
JP31002090402002
SAPH310020900029
Tightening torque
11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 22N ⋅m{220kgf⋅cm, 16lbf⋅ft}
Service procedure
Overhaul item
ENGINE MECHANICAL 9–13
Overhaul
JP31002090702002
SAPH310020900030
(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.
(3) Apply engine oil to the inner bore of the cylinder block.
(4) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
Special tool : 09471–1490 Guide
SAPH310020900032
Front of engine
SAPH310020900033
9–14 ENGINE MECHANICAL
Cylinder liner
A, B and C marking
position
SAPH310020900034
0.01 - 0.08
Standard value (mm{in.})
{0.0004 - 0.0031}
SAPH310020900035
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : 9001–24262 Check bolt
Check bolt
SAPH310020900036
(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.
Check bolt
Oil hose
SAPH310020900037
ENGINE MECHANICAL 9–15
Cylinder liner
Cooling jet
SAPH310020900038
(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Oil injection unit (example)
Pressure pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Regulator
Oil
Hose NOTICE • Refer to the drawing for the oil injection unit.
Air tank
(Oil tank) Compressed
Air gauge air
Air hose
SAPH310020900039
(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.
(7) If injection does not hit the target circle, correct it with a
special tool.
SAPH310020900042
ENGINE MECHANICAL 9–17
SAPH310020900043
SAPH310020900044
SAPH310020900047
ENGINE MECHANICAL 9–19
Flywheel housing
SAPH310020900048
SAPH310020900049
(2) Hook the special tool oil seal puller with the tab of the
crankshaft front oil seal and install the hook on the plate of
the special tool oil seal puller with accompanying bolts.
SAPH310020900050
9–20 ENGINE MECHANICAL
(3) Remove two bolts which installed the plate of the special
tool oil seal puller on the crankshaft.
(4) Attach the accompanying center bolt to the special tool oil
seal puller and tighten it. Pull out the crankshaft front oil
seal.
SAPH310020900051
SAPH310020900052
(3) Apply small amount of engine oil to the seal area of the
crankshaft front oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
front oil seal with accompanying guide bolts on the
crankshaft.
SAPH310020900053
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft front oil
seal.
SAPH310020900054
ENGINE MECHANICAL 9–21
(1) Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
Special tool : 09420–1742 Oil seal puller
! CAUTION • Align the large hole of the plate with the collar
dowel of the crankshaft.
SAPH310020900055
(2) Hook the oil seal puller with the tab of the crankshaft rear
oil seal and install the hook on the plate of the oil seal
puller with accompanying bolts.
(3) Remove two bolts which installed the plate of the oil seal
puller on the crankshaft.
SAPH310020900056
(4) Attach the accompanying center bolt to the oil seal puller
and tighten it. Pull out the crankshaft rear oil seal.
SAPH310020900057
Guide of oil seal press (1) Insert a new crankshaft rear oil seal into the guide of the
oil seal press.
Special tool : 09407–1040 Oil seal press
SAPH310020900058
9–22 ENGINE MECHANICAL
(3) Apply small amount of engine oil to the seal area of the
crankshaft rear oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
rear oil seal with accompanying guide bolts on the
crankshaft.
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
SAPH310020900060
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft rear oil
seal.
Setup layout
Layout
SAPH310020900061
ENGINE MECHANICAL 9–23
SAPH310020900062
1. Removal of piston
Figure is an
example of work. (1) Remove bolts and remove the connecting rod cap.
SAPH310020900064
(4) Hit the connecting rod from underneath the engine using
a handle of a hammer. Remove the piston together with
the connecting rod.
SAPH310020900065
SAPH310020900066
ENGINE MECHANICAL 9–25
SAPH310020900067
SAPH310020900069
9–26 ENGINE MECHANICAL
(3) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.
(4) Connect the joint of the coil expander and fit the oil ring
Lower surface
inside the ring. Offset the coil expander joint with the ring
Oil ring joint Clearance
joint by 180 deg for installation.
(5) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Coil expander Ring
Second ring
SAPH310020900070
SAPH310020900072
ENGINE MECHANICAL 9–27
(4) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.
Bearing
SAPH310020900074
(6) Align the match mark of the connecting rod cap with that
of the connecting rod and fix it with a dowel pin.
Match mark
Stamp ! CAUTION • Do not change the combination between the
connecting rod and the connecting rod cap.
1234 1234
SAPH310020900075
SAPH310020900076
9–28 ENGINE MECHANICAL
(9) Tighten the connecting rod bolt and mark the bolt head in
Paint mark the same direction with paint.
112{4.4095} 112.15{4.4153}
SAPH310020900078
SAPH310020900079
cylinder liner and the outer diameter of the piston. If it is beyond
the standard value, replace the cylinder liner and the piston.
Service limit
Standard value (mm{in.})
(mm{in.})
SAPH310020900082
Top ring 0.3 - 0.40 {0.0118 - 0.0157} 1.5{0.0591}
37 {1.4567} 36.96{1.4551}
SAPH310020900083
(2) Measure the piston boss inner diameter using a cylinder gauge.
–0.002T-0.025L 0.05{0.0020}
SAPH310020900086
Groove
Spindle
Special tool : 09402–1540 Spindle
Connecting rod ! CAUTION • Align the press sub-assembly groove with the
special tool spindle groove for installation.
Press
Sub-assembly
SAPH310020900087
SAPH310020900088
ENGINE MECHANICAL 9–31
SAPH310020900089
(2) Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
Groove
Oil hole ! CAUTION • Place the connecting rod so that the chamfer
side of the connecting rod small end inner
diameter may be the bushing side
• Apply engine oil to the inner diameter surface
SAPH310020900091 of the connecting rod.
SAPH310020900092
9–32 ENGINE MECHANICAL
Replacement of crankshaft
JP31002090704008
1. Removal of crankshaft
(1) Remove the main bearing cap and the crankshaft bearing.
Remove the crankshaft using a hoist.
SAPH310020900093
2. Installation of crankshaft
(1) Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.
(2) Install the main bearing on the cylinder block and each
bearing cap.
SAPH310020900094
(4) Align the main bearing cap which has the thrust bearing
Stamp number and the main bearing with the cylinder block.
Front of engine
SAPH310020900076
(6) Apply engine oil to the bolt seat and the bolt thread of the
bearing cap bolt.
Paint mark (14) Make sure that all paint marks are in the same direction.
45ࠑ (15) After tightening, hit the front/rear ends of the crankshaft
90ࠑ
gently with a plastic hammer for initial fit.
Inspection of crankshaft
JP31002090703002
0.050 - 0.219
0.50{0.0197} 1.219{0.0480}
{0.020 - 0.0086}
SAPH310020900099
Measure two (1) Measure the outer diameter of the crankshaft journal
places. using a micrometer. If it is faulty, grind or replace the
90ࠑ
crankshaft. When the crankshaft is ground, use the
undersize bearing.
SAPH310020900100
Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
Wear of 1.20{0.0472} Replace the crankshaft.
ENGINE MECHANICAL 9–35
36{1.4173} 37.0{1.4567}
SAPH310020900101
80{3.1496} 78.8{3.1024}
SAPH310020900102
SAPH310020900103
Standard value (mm{in.}) Repair limit (mm{in.})
0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}
Crank pin
Radius is
incomplete. Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.}
small. Step Step
R
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor
SAPH310020900104
SAPH310020900105
SAPH310020900106
SAPH310020900107
Wear value (mm{in.}) Action
Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
SAPH310020900108
(1) Apply engine oil to the bolt seat and the bolt thread of the
1 crankshaft pulley mounting bolt.
6 3 (2) Install the crankshaft pulley on the crankshaft and tighten
it according to the figure.
4 5 Tightening torque : 118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}
2
NOTICE • Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
SAPH310020900109 inspection hole to prevent turning of the
crankshaft.
Replacement of flywheel
JP31002090704010
1. Removal of flywheel
Engine revolution sensor
Flywheel
(1) Remove the engine revolution sensor.
Mounting bolt (2) Remove bolts fixing the flywheel.
SAPH310020900110
(3) Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).
SAPH310020900112
SAPH310020900113
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).
SAPH310020900114
(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.
SAPH310020900115
ENGINE MECHANICAL 9–39
4. Installation of flywheel
(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Install the special tool into the bolt hole of the crankshaft.
Special tool : 09481–1340 Guide
(3) Insert the flywheel until it comes in contact with the collar
dowel of the crankshaft and adjust the position.
(5) Apply engine oil to the bolt seat and the bolt thread of the
flywheel mounting bolt.
SAPH310020900117
SAPH310020900118
SAPH310020900120
Tightening torque
900124 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90° 900125 172N⋅m {1, 750 kgf⋅cm, 127lbf⋅ft}
900124A 108N⋅m {1, 100 kgf⋅cm, 80lbf⋅ft}
Service procedure
Overhaul item
ENGINE MECHANICAL 9–41
Removal of camshaft
JP31002090702006
(1) Loosen the lock nut and turn the adjusting screw
completely.
Rock nut
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
SAPH310020900121
Disassembly of camshaft
JP31002090702007
1. Disassembly of camshaft
(1) Fix the camshaft gear using a vice to disassemble the
camshaft.
SAPH310020900122
9–42 ENGINE MECHANICAL
0.04{0.0016} 0.1{0.0039}
SAPH310020900124
40{1.5748} 39.85{1.5689}
40{1.5748} 40.15{1.5807}
0.020 - 0.063
Standard value (mm{in.})
{0.0008 - 0.0025}
ENGINE MECHANICAL 9–43
Assembly of camshaft
JP31002090702009
Underhead length
SAPH310020900126
2. Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
bolt.
3. Set the dowel pin to the camshaft and the camshaft gear
and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
Installation of camshaft
JP31002090702010
2. Installation of camshaft
Timing decision
drill hole (1) Place the camshaft so that two holes at 180 degrees from
the three drilled holes of the camshaft gear may be
horizontal to the upper surface of the camshaft housing.
(2) Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the three-sided mark
on the cap points forward.
1
(6) Apply engine oil to the cam threads and set the rocker
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
tightening them each time.
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
Camshaft gear
Sub-idle gear
Crankshaft gear
Air compressor
drive gear
(supply pump
drive gear)
SAPH310020900130
Service procedure
Overhaul item
SAPH310020900131
9–46 ENGINE MECHANICAL
Standard value
(mm{in.})
Lubricating
hole
Cylinder block
SAPH310020900134
(4) Install the idle gear thrust plate on the idle gear shaft.
(5) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.
(6) Install the idle gear shaft mounting bolt.
Tightening torque : 108 N⋅m {1,100 kgf⋅cm, 80 lbf⋅ft}
SAPH310020900135
Lubricating
hole
Cylinder
Block
SAPH310020900136
9–48 ENGINE MECHANICAL
(3) Face the lubricating hole of the idle gear shaft toward the
oil pan (downward). Install A in the figure by adjusting the
Sub-idle gear timing of the crankshaft gear and the main idle gear as in
the detailed drawing.
Oil pump
gear
A
Main idle gear
Crankshaft gear
SAPH310020900137
(4) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.
SAPH310020900138
ENGINE MECHANICAL 9–49
SAPH310020900139
SAPH310020900140
(4) Remove the sub-idle gear shaft mounting bolt and pull out
the idle gear shaft using a sliding hammer.
SAPH310020900141
SAPH310020900142
9–50 ENGINE MECHANICAL
SAPH310020900143
0.025 - 0.075
Standard value (mm{in.})
{0.0010 - 0.030}
SAPH310020900144
SAPH310020900145
(5) Align two pins of the bearing case assembly with the
concave area of the flywheel housing for installation.
SAPH310020900146
ENGINE MECHANICAL 9–51
(1) Insert a large flat tip screwdriver into the cam idle gear
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.
SAPH310020900147
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}
SAPH310020900148
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
SAPH310020900149
SAPH310020900150
9–52 ENGINE MECHANICAL
(3) Measure backlash between the main idle gear and the
pump drive idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
(4) Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH310020900152
(1) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
SAPH310020900153
(2) Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.
SAPH310020900154
ENGINE MECHANICAL 9–53
(1) Insert a large flat tip screwdriver into the sub-idle gear to
prevent turning of the sub-idle gear.
SAPH310020900155
(2) Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.
SAPH310020900156
0.114 - 0.160
Main idle gear {0.0045 - 0.30{0.0118}
SAPH310020900157
0.0063}
0.040 - 0.095
Sub-idle gear {0.0016 - 0.30{0.0118}
0.0037}
SAPH310020900158
9–54 ENGINE MECHANICAL
(2) Measure backlash between the cam idle gear and the
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.
Setup layout
Layout
SAPH310020900159
ENGINE MECHANICAL 9–55
Valve System
Part layout
JP31002090402007
SAPH310020900160
(1) Loosen the lock nut and turn the adjusting screw
completely.
Lock nut
! CAUTION • Removal without turning the adjusting screw
may bend the rocker arm shaft.
SAPH310020900161
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
ԝ ԛ ԙ Ԙ Ԛ Ԝ Ԟ
SAPH310020900162
(2) Make sure that the rocker arm is correctly assembled into
the rocker arm shaft.
(3) Turn the adjusting screw at the end of the rocker arm
Rocker arm
completely.
Rubber band
SAPH310020900164
ENGINE MECHANICAL 9–57
(4) Place the rocker arm and the rocker arm shaft on the
camshaft housing and make sure that the rocker arm is
correctly on the crosshead. Tighten the rocker arm
support bolts gradually several times.
22{0.8661} 21.92{0.8630}
22{0.8661} 20.08{0.7905}
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
SAPH310020900167
9–58 ENGINE MECHANICAL
SAPH310020900168
SAPH310020900169
22.5 - 23.0
Standard value (mm{in.})
+0.1{0.0039in.}
{0.8858 - 0.9055}
22.9mm{0.9022in.}
-0.4{0.0157in.}
SAPH310020900170
ENGINE MECHANICAL 9–59
(1) Install the valve spring upper seat on the valve spring.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : 09470–1170 Valve spring press
SAPH310020900171
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for
assembly.
• Check for scratch on the valve stem seal
when the valve is reused.
SAPH310020900172
(2) Measure the free length of the valve spring using a vernier
calipers. If it is out of the service limit, replace the valve
spring.
Standard
Service limit
value
(mm{in.})
(mm{in.})
Standard value
(mm{in.})
Intake valve stem 7{0.2756}
Standard value
(mm{in.})
Standard value
(mm{in.})
0.023 - 0.058
Intake valve oil clearance
{0.0009 - 0.0023}
(3) Loosen the adjusting screw and the lock nut of the
Adjusting screw of rocker arm
Roller crosshead completely.
Cam base
circle Lock nut
Adjusting screw of
crosshead ! CAUTION • Provide the adjusting screw protrusion of 10
10 mm or more
mm or more from the top surface of the
crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
Close contact
Nut
SAPH310020900176
(4) Insert a thickness gauge between the rocker arm and the
Rocker arm Thickness gauge crosshead and adjust the clearance with the adjusting
screw of the rocker arm. Tighten the lock nut.
SAPH310020900178
9–62 ENGINE MECHANICAL
Close contact
Close contact
SAPH310020900179
ENGINE
10 EXHAUST
Setup layout
Layout
10
10–2 EXHAUST
Exhaust Manifold
Part layout
JP31002100402001
SAPH310021000001
Replacement
JP31002100704001
Black side
SAPH310021000002
SAPH310021000003
COOLING 11–1
ENGINE
11 COOLING
System drawing
11
11–2 COOLING
Cooling System
Cooling system drawing
JP31ZZZ110803001
Reserve tank
Air bleeding
Radiator cap
Thermo cover
(Outlet) Heater
Coolant
temperature
Radiator
Cylinder block
Drain cock
Coolant pump
Oil cooler
Drain cock
SAPH310021100001
Setup layout
Layout
COOLING 11–3
Part layout
JP31ZZZ110402001
SAPH310021100002
(2) Remove the O-ring from the groove on the coolant pump.
SAPH310021100003
(3) Install the new O-ring on the groove of the coolant pump.
SAPH310021100005
COOLING 11–5
Inspection of thermostat
JP31ZZZ110703001
SAPH310021100006
13mm
Thermostat valve opening
{0.5122in.} 74.5 - 76.5
temperature standard value :
{166.1 - 173.3}
Valve lift
T1(°C{°F})
(1) Use the special tool and check the fan belt tension at the
measuring position (A).
(2) If the tension is not within the standard value, adjust with
the adjustment bolt (M8) or replace the fan belt.
SAPH310021100010
(3) Install the coolant pump to the dowel pin of the cylinder
block.
SAPH310021100010
LUBRICATION 12–1
ENGINE
12 LUBRICATION
System drawing
12
12–2 LUBRICATION
Roller pin
Cam Roller
Adjusting Rocker
Valve Crosshead Rocker arm arm
screw shaft
Camshaft
Oil pan
Cam idle
gear shaft
Sub-idle
gear shaft
Turbocharger
Strainer
Supply
pump
drive
Main idle
gear shaft
: Lubrication
: Return
SAPH310021200001
Setup layout
Layout
LUBRICATION 12–3
Part layout
JP31002120402001
SAPH310021200002
Part layout
JP31002120402002
SAPH310021200003
(1) Remove bolts and hose joint, and remove the oil cooler.
SAPH310021200004
SAPH310021200005
! CAUTION • Face the D-ring flat area toward the oil cooler.
Flat area
SAPH310021200006
(3) Insert the positioning stud into the screw hole of the
cylinder block and install the oil cooler.
Tightening torque :
44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4 lbf⋅ft}
SAPH310021200009
Overhaul item
SAPH310021200011
LUBRICATION 12–7
SAPH310021200012
SAPH310021200013
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} (M14, M20)
29.4±4.9 N⋅m {300±50 kgf⋅cm, 22±4 lbf⋅ft} (M22)
34.3±4.9 N⋅m {350±50 kgf⋅cm, 25±4 lbf⋅ft} (M24)
SAPH310021200011
(3) Install the soft washer in (2) and the hydraulic pressure
warning switch.
SAPH310021200012
12–8 LUBRICATION
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft}
SAPH310021200014
(2) To prevent bolt hole offset of the gasket, apply engine oil
to the cylinder block in advance and place and fix the
gasket.
(3) Tighten the oil pump according to the order in the figure.
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
SAPH310021200015
12–10 LUBRICATION
SAPH310021200016
SAPH310021200017
(1) Measure the outer diameter of the drive gear and the
inner diameter of the pump chamber at cylinder block.
Standard value
Measuring area
(mm{in.})
SAPH310021200019
LUBRICATION 12–11
(1) Measure the drive gear width and the pump chamber
depth at the cylinder block using a depth gauge.
Standard value
Measuring area
(mm{in.})
0.049 - 0.113{0.0020 -
0.15{0.0060}
0.0044} (reference)
SAPH310021200021
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the cylinder block hole
diameter using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
0.040 - 0.099
Standard value (mm{in.})
{0.0016 - 0.0039}
SAPH310021200023
12–12 LUBRICATION
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
0.030 - 0.075
Standard value (mm{in.})
{0.0012 - 0.0030}
SAPH310021200025
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
0.040 - 0.083
0.15{0.00059}
{0.0016 - 0.0033}
SAPH310021200026
LUBRICATION 12–13
SAPH310021200017
SAPH310021200016
SAPH310021200028
12–14 LUBRICATION
Oil Pan
Part layout
JP31002120402003
SAPH310021200029
Replacement
JP31002120704004
Bolt tightening direction (1) Cut the gasket of the rear end plate to be flush to the
cylinder block lower surface using a scraper.
(2) Make sure that there is no deformation, dirt or oil on the
joint surface between the cylinder block and the oil pan.
Apply liquid gasket [Threebond TB1207D (silver) or
equivalent] to the front rear end of the cylinder block lower
Rear surface.
(3) Insert several stud bolts (70 mm{2.7559 in.} or larger) for
Protrusion
positioning into the cylinder block screw hole.
Front (4) Position the gasket protrusion at the intake side and the
flywheel housing (printed seal surface at cylinder block).
Align the new gasket and oil pan to the cylinder block
lower surface and tighten bolts in the arrow order of the
figure.
Tightening torque :
19.6 - 24.5 N⋅m {200 - 250 kgf⋅cm, 14 - 18 lbf⋅ft}
Liquid gasket applying position (5) Remove positioning stud bolts and install the correct bolts.
(6) Tighten bolts in the arrow order of the figure.
SAPH310021200030
Tightening torque : 30 N⋅m {300 kgf⋅cm, 22 lbf⋅ft}
ENGINE
13
13–2 STARTING AND CHARGING
Starter
Part layout (typical example)
JP31002130402001
SAPH310021300001
Disassembly
JP31002130702001
SAPH310021300002
Commutator end
frame
SAPH310021300003
(2) Remove two set bolts and remove the commutator end
frame.
Set bolt
! CAUTION • Hold the M lead wire and remove the
commutator end frame by lifting.
SAPH310021300004
13–4 STARTING AND CHARGING
Brush lead
Clamp
SAPH310021300005
! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.
Center bracket
assembly
SAPH310021300006
5. Removal of packing
Yoke assembly (1) Remove the packing from the centering parts at both ends
of the yoke assembly.
Packing Packing
SAPH310021300007
STARTING AND CHARGING 13–5
SAPH310021300008
Puller
SAPH310021300009
8. Removal of cover
Packing Cover (1) Remove the cover from the center bracket assembly.
(2) Remove the packing.
SAPH310021300010
Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin
SAPH310021300011
13–6 STARTING AND CHARGING
Center bracket
SAPH310021300012
Shim
SAPH310021300013
SAPH310021300015
STARTING AND CHARGING 13–7
SAPH310021300016
Holder
Lever assembly
SAPH310021300017
(2) Turn and pull out the lever assembly using the clutch as
the axis.
Lever assembly
SAPH310021300018
SAPH310021300019
13–8 STARTING AND CHARGING
Brake plate
SAPH310021300020
SAPH310021300021
SAPH310021300022
Packing
SAPH310021300023
Inspection of components
JP31002130703001
SAPH310021300024
(3) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it.
Feed coil
Service limit 1kΩ or less
SAPH310021300025
SAPH310021300026
Growler tester
SAPH310021300027
13–10 STARTING AND CHARGING
SAPH310021300028
Commutator
Standard value Service limit
8.98{0.3535} or
Area 9{0.3543}
SAPH310021300032 less
Brush
SAPH310021300034
25.90{1.0197} or
Area 26{1.0236}
less
SAPH310021300035
12.04{0.4740} or
Area 12.1{0.4764}
less
13–12 STARTING AND CHARGING
SAPH310021300036
6. Inspection of bearing
(1) Measure the bearing metal inner diameter (1 in the figure)
of the pinion case using a cylinder gauge. If it is beyond
the service limit, replace the bushing.
1
Standard value (mm{in.}) Service limit (mm{in.})
SAPH310021300037
2 26{1.0236} 26.2{1.0315}
SAPH310021300038
9{0.3543} 9.2{3.6220}
SAPH310021300040
Body
Standard value( Ω ) 1.13 - 1.25
SAPH310021300041
B terminal
SAPH310021300042
(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.
SAPH310021300043
Overhaul item
13–14 STARTING AND CHARGING
Assembly
JP31002130702002
1. Installation of packing
(1) Install a new packing on the center bracket assembly.
Packing
SAPH310021300023
SAPH310021300044
Brake plate
SAPH310021300045
STARTING AND CHARGING 13–15
5. Installation of lever
(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list). Turn and install the lever assembly
using the clutch as the axis.
Lever assembly
SAPH310021300018
SAPH310021300016
7. Installation of pinion
(1) Lubricate parts (refer to the lubrication point drawing and
Pinion stopper the lubrication list) and install the pinion and the pinion
stopper.
Pinion
SAPH310021300015
(2) Install the retainer clip using a tool such as snap ring
pliers.
Retainer clip
Pinion stopper
Pinion
SAPH310021300014
13–16 STARTING AND CHARGING
SAPH310021300013
Internal gear
Center bracket
SAPH310021300012
SAPH310021300011
SAPH310021300010
SAPH310021300008
Packing Packing
SAPH310021300007
Center bracket
assembly
SAPH310021300006
13–18 STARTING AND CHARGING
Spring
Brush
Brush lead
Clamp
SAPH310021300005
Tightening torque :
15.7 - 17.6 N⋅m {160 - 179 kgf⋅cm, 12 - 13 lbf⋅ft}
Commutator end
frame
SAPH310021300003
SAPH310021300004
STARTING AND CHARGING 13–19
SAPH310021300002
19. Lubrication
Refer to the following figure and table for lubricant to be applied.
! CAUTION • There shall be no lubricant on the commutator surface, brush and contact.
SAPH310021300046
13–20 STARTING AND CHARGING
Table of lubricant
Amount Lubricant
Code Lubricating point Lubricant used Remark
(g{oz}) manufacturer
0.5 - 1
4 Armature front metal Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
Internal gear
7 -11
6 Armature gear Multemp AC-N Kyodo Yushi
{0.25 - 0.39}
Planetary gear
0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}
0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}
0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}
Setup layout
Layout
STARTING AND CHARGING 13–21
Alternator (60A)
Part layout (typical example of 60A)
JP31002130402002
SAPH310021300047
Tightening torque
27317 7.8-9.8 N m{80-99 kgf cm, 6-7lbf⋅ft} 27317C 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft}
27317A 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft} 27391 127 - 157 N⋅m{1, 300 - 1, 600 kgf⋅cm, 94-
116lbf⋅ft}
27317B 2.9 - 3.9 N⋅m{30 - 39 kgf⋅cm, 2-3lbf⋅ft} 27391A Internal nut : 4.9-5.9 N m{50-60 kgf cm,
3.6-4.3lbf⋅ft}
System drawing
13–22 STARTING AND CHARGING
Capacitor
Diode
Fuse Load
L Lamp 1.4 to 3W
R
Starter switch
P
Feed coil
N
Regulator
Battery 24V
Stator coil
Alternator
SAPH310021300048
Service procedure
Overhaul item
STARTING AND CHARGING 13–23
Disassembly (60A)
JP31002130702003
SAPH310021300050
(3) Remove three through bolts and disconnect the front from
the rear.
SAPH310021300051
2. Disassembly of front
(1) Remove nuts and remove the pulley, fan and collar.
SAPH310021300052
13–24 STARTING AND CHARGING
SAPH310021300053
SAPH310021300054
(4) Remove the ball bearing from the front bracket using a
press or jig C.
Jig C
! CAUTION • Place jig C at the inner race of the front
bearing.
• Removed bearing must not be reused.
SAPH310021300055
3. Disassembly of rear
(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device
SAPH310021300057
SAPH310021300058
Terminal
Lead wire
Regulator assembly
SAPH310021300059
SAPH310021300060
13–26 STARTING AND CHARGING
SAPH310021300061
SAPH310021300062
(8) Remove the roller bearing from the rear bracket using a
press, jig A and jig B.
SAPH310021300063
SAPH310021300064
STARTING AND CHARGING 13–27
(2) Measure the resistance between the stator coil core and
each terminal using a megger tester.
SAPH310021300065
(4) Measure the resistance between the core and the coil
using a megger tester.
SAPH310021300067
(1) Measure the outer diameter of the shaft at the ball bearing
insertion area of the rotor assembly using a micrometer.
SAPH310021300068
13–28 STARTING AND CHARGING
SAPH310021300069
Standard value
SAPH310021300070
SAPH310021300071
Standard value
Overhaul item
SAPH310021300072
STARTING AND CHARGING 13–29
Assembly (60A)
JP31002130702004
1. Assembly of front
(1) Press fit a new ball bearing into the front bracket using a
press and jig C.
SAPH310021300074
SAPH310021300075
(4) Install the space collar, fan and pulley on the shaft of the
rotor assembly.
Tightening torque :
127 - 157 N⋅m {1,300 - 1,600 kgf⋅cm, 94 - 116 lbf⋅ft}
SAPH310021300076
13–30 STARTING AND CHARGING
2. Assembly of rear
(1) Press fit a new roller bearing into the rear bracket using a
Jig A
press, jig A and jig B.
Jig B
SAPH310021300077
Tightening torque :
2.9 - 3.9 N⋅m {30 - 39 kgf⋅cm, 2 - 3 lbf⋅ft}
SAPH310021300078
SAPH310021300079
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH310021300080
STARTING AND CHARGING 13–31
(5) Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
soldering bit.
Terminal
Lead wire
Regulator assembly
SAPH310021300082
Tightening torque :
4.9 - 5.9 N⋅m {50 - 60 kgf⋅cm, 3.6 - 4.3 lbf⋅ft}
SAPH310021300083
SAPH310021300084
13–32 STARTING AND CHARGING
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH310021300085
(3) Align the tab and install the cover. Fix it with bolts.
Tightening torque :
3.3 - 4.4 N⋅m {34 - 44 kgf⋅cm, 2 - 3 lbf⋅ft}
SAPH310021300086
STARTING AND CHARGING 13–33
1. Inspection of rotation
(1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is smooth.
SAPH310021300087
B E Approx. 20 Ω
SAPH310021300088
E B Infinite
P E Approx.7 Ω
E P Infinite
R L
N P
E
Connector details
SAPH310021300089
TURBOCHARGER 14–1
ENGINE
14 TURBOCHARGER
Setup layout
Layout
14
14–2 TURBOCHARGER
Turbocharger Assembly
Part layout
JP31002140402001
SAPH310021400001
Inspection
JP31002140501001
SAPH310021400003
Bolt
SAPH310021400004
SAPH310021400005
14–4 TURBOCHARGER
(3) When the guide (key No. 9) is fixed, move the bar (key
No. 4) vertically and fix the guide (key No. 9) with the
stopper (key No. 10) so that the needle of the dial gauge
may come at the center.
SAPH310021400006
(4) Hold the puller (key No. 5) and press it toward the turbine
in the axial direction. Set the dial gauge reading to 0.
0 point adjustment
SAPH310021400007
SAPH310021400008
TURBOCHARGER 14–5
SAPH310021400009
Service procedure
Replacement procedure item
14–6 TURBOCHARGER
Replacement
JP31002140704001
1. Removal
(1) Remove the boost pipe and U-turn pipe.
(2) Disconnect all pipes connected to the turbocharger.
(3) Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger.
2. Installation
(1) Install the turbocharger in the reverse order of
disassembly. When the turbocharger is installed on the
engine or after installation, observe the following
precautions for work. Pay special attention to entry of
foreign matter inside the turbocharger.
Tightening torque :
56 N⋅m {570 kgf⋅cm, 41 lbf⋅ft}
(Turbocharger to exhaust manifold)
(2) Lubrication and cooling system
a. Before installation on the engine, pour new engine oil
from the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
b. Clean the oil pipe, oil hose, coolant pipe and hose.
Check for pipe deformation, hose crack or dirt or
foreign matter in the pipe or hose.
c. Do not use sealant at the installation surface of the oil
pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as
damage due to clogging or loosening of tightened
areas.
d. Be sure to use new soft washers, O-rings and gaskets.
e. Be sure to install the oil pipe, oil hose, coolant pipe and
coolant hose correctly to prevent leak of oil or water
from connections.
TURBOCHARGER 14–7
ENGINE
16
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft
Alternator
JP31002160601002
Starter
JP31002160601003
Turbocharger
JP31002160601004
ENGINE
17
ENGINE DIAGNOSIS CODE 17–3
Engine ECU
Precautions
JP31002170102001
ACT Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
Glow relay
INPUT
Common rail T
Engine
P
SAPH310021700002
Service procedure
Inspection procedure item
ENGINE DIAGNOSIS CODE 17–5
Inspection
JP31002170703001
1. Pre-inspection
SAPH310021700003
SAPH310021700004
SAPH310021700005
17–6 ENGINE DIAGNOSIS CODE
SAPH310021700006
2. Connection of HinoDX
Engine ECU (1) Connect the system to the engine failure diagnosis
connector through the interface box.
SAPH310021700007
Failure
List of failure
diagnosis
diagnosis
Hino-Bowie
NOTICE • For the system status by indication of failure code(DTC code) in the table, refer to "1. Pre-
inspection, Inspection, Engine ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
Diagnosis
[a] Failure diagnosis and DTC
monitor Estimated failure cause Page
[b] Alarm display (alarm status) code
code
a. Engine does not start P0335 13 Engine speed main sensor circuit
17-15
Engine stopped. malfunction
P0606 3 CPU malfunction (Hard detection)
17-49
b. Failure code(DTC code) (Detection of hardware)
indication. P0629 74 SCV out put short to BATT
17-45
(+B short-circuit)
Diagnosis
[a] Failure diagnosis and DTC
monitor Estimated failure cause Page
[b] Alarm display (alarm status) code
code
Diagnosis
[a] Failure diagnosis and DTC
monitor Estimated failure cause Page
[b] Alarm display (alarm status) code
code
Diagnosis
[a] Failure diagnosis and DTC
monitor Estimated failure cause Page
[b] Alarm display (alarm status) code
code
Function, movement
Description of function
and operation
ENGINE DIAGNOSIS CODE 17–11
SAPH310021700009
17–12 ENGINE DIAGNOSIS CODE
Unit harness
Signal check harness
Test lead
SAPH310021700010
ENGINE DIAGNOSIS CODE 17–13
SAPH310021700011
Failure diagnosis list
17–14 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
# 㧭 # & 㧰 ' 㧱 ' harness.
#
2. Turn the starter key "ON" and measure voltage between
terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
OK
Normal
1. Set the starter key to "OFF" and connect the signal check
D1 D E4 E E5 harness.
OK
Normal
ENGINE DIAGNOSIS CODE 17–15
1. Set the starter key to "OFF" and connect the signal check
B6 B B7 harness.
OK
SAPH310021700015
OK
Normal
SAPH310021700016
OK
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the sub-speed sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
connector (at machine harness side).
OK
SAPH310021700018
OK
Harness failure
ENGINE DIAGNOSIS CODE 17–17
1. Set the starter key to "OFF" and connect the connector of the
D D19
sub-speed sensor.
D30
2. Start the engine and keep idling status.
OK
SAPH310021700020
NG Harness failure
OK
Engine speed main and sub sensor circuit malfunction (DTC code P0335/
diagnosis monitor code 13)
JP31002170601006
1. Inspection item
(1) Take actions of (DTC code P0335/diagnosis monitor code 13) and (DTC code P0340/diagnosis monitor
code 12).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335/diagnosis monitor code 13),
Engine ECU, Engine diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340/diagnosis monitor code 12),
Engine ECU, Engine diagnosis code"
17–18 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
D E harness.
E19
D34 2. Disconnect the ECU side connector of the signal check
harness and meausre the resistance between terminal B19
and terminal D34.
OK
OK
OK
1. This failure code is displayed when the engine speed of 2,700 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,600 r/min.,
fuel injection is resumed.
NOTICE • The objective of this failure code is not to detect overrun due to failure of this system, but
to memorize high revolution of the engine.
• Engine speed may be incorrectly recognized with noise on the speed sensor signal due to
harness failure or modification, resulting in detection of overrun.
17–20 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
D34 E27 harness.
OK
OK
1. Set the starter key to "OFF" and connect the signal check
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the boost pressure
sensor connector (at machine harness side).
OK
SAPH310021700026
OK
Harness failure
17–22 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the connector of the
D D27
boost pressure sensor.
2. Set the starter key to "ON" and measure the voltage between
terminal D27 and terminal D33 of the signal check harness.
D33
SAPH310021700027
OK
SAPH310021700028
OK
Harness failure
ENGINE DIAGNOSIS CODE 17–23
SAPH310021700004
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237/diagnosis monitor code 37).
DTC P0088 diagnosis monitor code 68 Excessive common rail pressure (1st step)
DTC P0088 diagnosis monitor code 69 Excessive common rail pressure (2nd step)
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
OK
Excessive common rail pressure, supply pump excess forced feed (DTC
code P0088/diagnosis monitor code 76)
JP31002170601014
1. Set the starter key to "OFF" and connect the signal check
㧰 D20 harness.
D31 2. Start and warm-up the engine until the coolant temperature
D33 gauge moves.
OK
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
tool (HinoDX) using PC.
ENGINE DIAGNOSIS CODE 17–25
1. Set the starter key to "OFF" and connect the signal check
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33.
OK
OK
1. Set the starter key to "OFF" and connect the signal check
D33 D D20
harness.
D31 2. Set the starter key to "ON" and measure the voltage between
terminals D20/D31 and terminal D33 of the signal check
harness.
OK
2. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at machine harness side).
OK
ENGINE DIAGNOSIS CODE 17–27
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
pressure sensor connector (at machine harness side).
SIG
Standard value : 2 Ω or less
NG Harness failure
SAPH310021700035
OK
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
SAPH310021700036
NG Harness failure
D33
SAPH310021700037
OK
1. Set the starter key to "OFF" and connect the signal check
harness.
2. Set the starter key to "ON" and measure the voltage between
terminal A21 and terminal B20 of the signal check harness.
B20
A21 Standard value : 0.7 - 1.5V (idle status)
OK
Standard value
B20 Engine
A21 Measuring item Voltage(V)
revolution(r/min)
Low idle 1,000 Approx. 1.4
High idle 2,100 Approx. 3.5
SAPH310021700038
OK
Harness failure
ENGINE DIAGNOSIS CODE 17–29
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B20 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.6 V or more
OK
1. Set the starter key to "OFF" and connect the signal check
㧭 㧮 harness.
A22
B21
2. Set the starter key to "ON" and measure the voltage between
terminal A22 and terminal B21 of the signal check harness.
OK
Engine
Measuring item Voltage(V)
revolution(r/min)
Low idle 1,000 Approx. 1.4
High idle 2,100 Approx. 3.5
SAPH310021700039
OK
Harness failure
ENGINE DIAGNOSIS CODE 17–31
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.6 V or more
OK
1 Inspection item
OK
SAPH310021700041
OK
Harness failure
17–34 ENGINE DIAGNOSIS CODE
$
# NG [4] Go to measurement of voltage between terminals.
SAPH310021700042
OK
OK
Harness failure
ENGINE DIAGNOSIS CODE 17–35
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229/diagnosis monitor code 15) is output.
Standard : Normal
SAPH310021700004
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
17–36 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
harness.
Standard value : ∞ Ω
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH310021700004
ENGINE DIAGNOSIS CODE 17–37
Terminal to measure
Failure code
resistance
SAPH310021700045
Diagnosis
DTC code monitor + side – side
code
7, 8, 9, 10, ECU case
P1211 57
11, 12 ground
5, 6, 1, 2, ECU case
P1214 58
3, 4 ground
Standard value : ∞ Ω
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
17–38 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
2. Disconnect the ECU side connector of the signal check
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
Terminal to measure
Failure code
voltage
Diagnosis
DTC code monitor + side – side
code
ECU case
P1212 57 D5, D6
ground
ECU case
P1215 58 E6, E7
ground
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH310021700004
ENGINE DIAGNOSIS CODE 17–39
Terminal to measure
Failure code
voltage
Diagnosis
DTC code monitor + side – side
code
ECU case
1212 57 8, 10, 12
ground
ECU case
1215 58 2, 4, 6
ground
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
17–40 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
harness.
OK
1. Set the starter key to "OFF" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
SAPH310021700004
ENGINE DIAGNOSIS CODE 17–41
OK
machine harness disconnection (Check the harness between the ECU and the injector clustered connector.)
SAPH310021700049
OK
SAPH310021700050
OK
SAPH310021700004
4. If the same failure code is displayed as the current failure after
deleting the past failure, check the flow damper of the cylinder
indicated by the failure code.
1. Remove the flow damper from the common rail and run air from
one side of the flow damper. Check if the damper is not blocked
by release of air to the opposite side.
SAPH310021700052
OK
17–44 ENGINE DIAGNOSIS CODE
SCV malfunction (DTC code P0628, P0629/diagnosis monitor code 74, 75)
JP31002170601026
SAPH310021700053
OK
1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
OK
17–46 ENGINE DIAGNOSIS CODE
E4
E E8
E9
2. Measure voltage between terminal E4 and terminals E8/E9 of
the signal check harness.
Standard value : Pulse waveform at 24V ↔ 0V
SAPH310021700055
OK
! CAUTION • After turning "ON" the starter key, take measurements within 40 seconds.
ENGINE DIAGNOSIS CODE 17–47
Supply pump SCV sticking (DTC code P2635/diagnosis monitor code 75),
Supply pump malfunction (DTC code P2635/diagnosis monitor code 77),
Supply pump abnormal pressure record (DTC code P2635/diagnosis monitor
code 79)
JP31002170601027
OK
2. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - Hino DX
SAPH310021700056 [Inspection Menu], using PC.
17–48 ENGINE DIAGNOSIS CODE
1. Set the starter key to "OFF" and connect the signal check
C2
C1 C D1 D E4 E E5
harness.
OK
SAPH310021700058
OK
1 Inspection of QR code
1. Read the QR code data with the failure diagnosis tool (HinoDX)
using PC.
SAPH310021700004
OK
ECU internal error (DTC code P0605, P0606, P0607/diagnosis monitor code 3)
JP31002170601030
2. After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607/diagnosis monitor code 3) is output
again.
Standard : Normal
SAPH310021700004
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
17–50 ENGINE DIAGNOSIS CODE
1 Check of ECU
2. After deleting the past failure, check if the same code (DTC
code P0611, P0200/diagnosis monitor code 59) is output
again.
Standard : Normal
SAPH310021700004
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
1. Set the starter key to "OFF" and connect the signal check
A6
A5 A A7 harness.
Standard value : 0 V
OK
1. Set the starter key to "OFF" and connect the signal check
B B14 C C4
harness.
Standard value
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
NG Harness failure
OK