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ALTERNATOR (J08E: REMY 12V-130A,135A,180A)

EN11–4

OVERHAUL

EN0110611H200001

IMPORTANT POINTS - DISMOUNTING

1.

REMOVE THE ALTERNATOR.

(1)

Remove the drive belt.

(2)

Remove the through bolt and the fixing belt.

NOTICE
To remove the belt, turn the nut of the tension pulley with a wrench in
counterclockwise direction to turn the tension pulley in arrow direc-
tion. Then the belt becomes loose and can be removed.

! CAUTION

•

As the belt is under tension, take care not to get your hand
caught at the time of removal.

•

Remove the following parts because your hand might be stuck
when replacing the belt.

.

a.

Engine side cover

b.

Suction hose

c.

Fun shroud bracket (Engine side)

d.

Radiator stay

e.

Radiator stay bracket

Failure to disconnect negative battery cable at battery before remov-
ing or attaching alternator "BAT" terminal lead may result in an injury.
If a tool is shorted at alternator "BAT" terminal, the tool can quickly
heat enough to cause a skin burn.

NOTICE
Always reinstall fasteners at original location. If necessary to replace
fasteners, use only correct part number or equivalent.

•

If correct part number is not available, use only equal size and
strength. For alternator internal fasteners, refer to Delco Remy
America Standard Hardware Fasteners section in Service Parts
Catalog.

•

Fasteners that are not to be reused will be noted in procedure.

•

Fasteners requiring thread locking compound will be noted in
procedure.

•

Use specified torque values when shown.

Using or replacing fasteners in any other manner could result in part
or system damage.
If diagnosis determines that alternator repair is needed, remove alter-
nator from engine according to manufacturer's instructions.

Idler pulley

Alternator

Auto tensioner

Crankshaft pulley

Fun pulley

SHTS011061100002

Radiator
stay (right)

Radiator
stay (left)

Radiator

SHTS011061100003

Alternator

Wrench

SHTS011061100004

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Summary of Contents for J08E-VC

Page 1: ...irs on your vehicle be careful not to be injured through improper procedures As for maintenance items refer to the Driver s Owner s Manual All information and specifications in this manual are based upon the latest product information available at the time of printing Hino Motors Sales U S A Inc reserves the right to make changes at any time without prior notice MENU ...

Page 2: ... CJ08E10A CANADA MODEL J08E VB VC GENERAL INTRODUCTION GN01 001 ENGINE INTRODUCTION EN01 001 ENGINE MECHANICAL EN02 001 AIR INTAKE SYSTEM EN03 001 EXHAUST SYSTEM EN04 001 LUBRICATING SYSTEM EN05 001 COOLING SYSTEM EN06 001 FUEL SYSTEM EN07 001 TURBOCHARGER EN08 001 EMISSION CONTROL EN10 001 ALTERNATOR EN11 001 STARTER EN12 001 AIR COMPRESSOR EN13 001 ENGINE CONTROL EN16 001 ...

Page 3: ...HAUST SYSTEM LUBRICATING SYSTEM COOLING SYSTEM FUEL SYSTEM TURBOCHARGER FUEL INJECTION PUMP ALTERNATOR STARTER AIR COMPRESSOR INDEX ENGINE GROUP 1 2 EMISSION CONTROL WORKSHOP MANUAL ENGINE PTO POWER TAKE OFF ENGINE RETARDER ENGINE CONTROL GENERAL INTRODUCTION ...

Page 4: ...VEHICLE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS INDEX ENGINE GROUP 2 2 ...

Page 5: ...UCTION ENGINE GN01 2 GENERAL PRECAUTIONS GN01 2 HOW TO USE THIS WORKSHOP MANUAL GN01 5 IDENTIFICATION INFORMATION GN01 7 PRECAUTIONS GN01 8 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS GN01 11 DISMOUNTING AND MOUNTING GN01 12 SYMPTOM SIMULATION GN01 15 GLOSSARY OF SAE AND HINO TERMS GN01 17 ...

Page 6: ...ake utmost care when working on the battery It contains corrosive sulfuric acid Large electric current flows through the battery cable and starter cable Be careful not to cause a short which can result in personal injury and or property damage Read carefully and observe the instructions placed on the jack before using it Use safety stands to support the vehicle whenever you need to work under it I...

Page 7: ...sition 6 Make sure that the engine of the towed vehicle is kept running If the engine is off no compressed air no vacuum will be available for the brake This is dangerous as the brake system does not function if the engine is not running In addition the power steering system will not function The steering wheel therefore will become unusually hard to turn making it impossible to control the vehicl...

Page 8: ... or reset with out diagnosing and responding appropriately to the diagnostic codes regardless of whether the systems are installed to satisfy requirements in 86 004 25 or for other reasons and regardless of form or interface Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service Such signals may not be rendered inoperative during the rebuilding process 4 W...

Page 9: ...OOTING section for a guide to appropriate diagnoses SPECIAL TOOLS are dealt with in each chapter When ordering a special tool confirm the part number with the applicable parts catalog REPAIR PROCEDURES Repair procedures when self explanatory such as simple installation and removal of parts have been omitted Illustrations such as the one below have been provided to make such simple procedures clear...

Page 10: ...less of such nonessential differences DEFINITION OF TERMS This engine rotates counterclockwise viewed from the flywheel side 3 4 1 2 5 6 7 5 8 5 11 10 A 14 5 14 13 13 13 B 14 A 14 A 12 9 C D SHTS001060100007 1 Gasket 8 Main idle gear 2 Rear end plate 9 Crankshaft gear 3 Camshaft gear 10 Power steering pump drive gear 4 Cam idle gear 11 Air compressor drive gear 5 Idle gear thrust plate 12 Air comp...

Page 11: ...INFORMATION EN00106010200002 ENGINE SERIAL NUMBERS Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention The engine serial number is engraved on the engine cylinder block SHTS001060100008 ...

Page 12: ...cable from the minus termi nal of the battery in order to avoid burning caused by short circuiting 2 To remove the battery cable fully release the nut to avoid damage to the battery terminal Never twist the terminal 2 HANDLING OF ELECTRONIC PARTS 1 Never give an impact to electronic parts of a computer or relay 2 Keep electronic parts away from high temperatures and humidity 3 Never splash water o...

Page 13: ...nspection 5 INSTALLATION OF BATTERY DISCONNECT SWITCH WARNING Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF SCR DCU may dam age or result in the malfunction of DEF SCR system Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the battery discon nect switch 6 HANDLING OF BATTERY...

Page 14: ...e pipes or fuel pipes and leaf spring etc a Turn the starter switch off b Disconnect the battery s negative terminal of the battery c Earth welding equipment securely near to the area to be welded d Put back battery negative ground as original condition e Finally check the functioning of all instruments 2 In order to prevent damage to ancillary equipment components from sparks during welding take ...

Page 15: ...0 5 M12 x 1 75 97 990 71 6 125 1 280 92 6 M14 x 1 5 171 5 1 750 126 6 216 2 210 159 8 M14 x 2 154 1 570 113 6 199 2 030 146 8 7 q Class 4T 7T 9T Representation Diameter x Pitch M6 x 1 6 60 4 3 10 100 7 2 13 130 9 4 M8 x 1 25 14 140 10 1 25 250 18 1 31 320 23 1 M10 x 1 25 29 300 21 7 51 520 37 6 64 650 47 0 M10 x 1 5 26 270 19 5 47 480 34 7 59 600 43 4 M12 x 1 25 54 550 39 8 93 950 68 7 118 1 200 8...

Page 16: ... Gasket seal type aluminum rubber asbestos or copper Tightening torque chart Location of gasket seal Clamping screw size Diameter mm in Tightening torque N m kgf cm lbf ft 8 0 315 13 130 9 10 0 394 20 200 14 12 0 472 25 250 18 14 0 551 25 250 18 16 0 630 29 300 22 18 0 709 39 400 29 20 0 787 39 400 29 24 0 945 69 700 51 28 1 102 127 1 300 94 ...

Page 17: ... seal type Flare connector type Tightening torque chart Location of metal seal Clamping screw size Diameter mm in Tightening torque N m kgf cm lbf ft 12 0 472 20 200 14 14 0 551 31 320 23 16 0 630 39 400 29 18 0 709 59 600 43 20 0 787 64 650 47 ...

Page 18: ... no leakage from them When tightening two pipes together be very careful that they do not rotate together After installing the pipes apply the correct pressure to each pipe joint and ensure that there is no leakage Ensure that the various tightening torques conform to the above table If a soft washer 4840 FR N aluminum rubber and carbon press fit part is loosened or removed subsequent to being ins...

Page 19: ... be confirmed First narrow down the possible problem circuits according to the symp toms Then connect the tester and carry out the symptom simulation test judging whether the circuit being tested is defective or normal Also confirm the problem symptoms at the same time Refer to the problem symptoms table for each system to narrow down the possi ble causes 1 VIBRATION METHOD When malfunction seems ...

Page 20: ...ater onto the front of the radiator Never apply water directly onto the electronic components HINT If the vehicle has or had a water leakage problem the leakage may have damaged the ECU or connections Look for evidence of corro sion or short circuits Proceed with caution during water tests 4 HIGH ELECTRICAL LOAD METHOD When a malfunction seems to occur when electrical load is excessive 1 Turn on t...

Page 21: ...ATION CATALYST Oxidation catalyst AFTDOC AFTERTREATMENT DIESEL OXIDATION CATALYST Oxidation Catalytic Converter AFTDOCDP AFTERTREATMENT DIESEL OXIDATION CATALYST DIFFERENTIAL PRESSURE Differential pressure AFTDOS AFTERTREATMENT DOSER AFTDOS Dosing AFTDPF AFTERTREATMENT DIESEL PARTICULATE FILTER DPR filter AFTDPFDP Aftertreatment Diesel Particulate Filter Differ ential Pressure DPR differential pre...

Page 22: ...T GAS RECIRCULATION TEMPER ATURE EGR temperature EGRT Sensor EXHAUST GAS RECIRCULATION TEMPER ATURE Sensor EGR exit temperature sensor EGT EXHAUST GAS TEMPERATURE Exhaust Temperature EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature EI ELECTRONIC IGNITION Ignition coil EOP ENGINE OIL PRESSURE Oil Pressure EOT ENGINE OIL TEMPERATURE Oil Temperature FP FUEL PUMP Fuel pump FUEL PRESSURE Sensor FUEL...

Page 23: ...SE VENT Valve PCV Valve PNP PARK NEUTRAL POSITION Neutral position PNP Switch PARK NEUTRAL POSITION Switch Neutral switch RFP RAIL FUEL PRESSURE Common rail Pressure RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor SPARK PLUG SPARK PLUG Spark plug SRI SERVICE REMINDER INDICATOR Check engine ST SCAN TOOL Diagnostic tool TC TURBOCHARGER Turbocharger TCC TORQUE CONVERTER CLUTCH Torque...

Page 24: ...01 ENGINE ASSEMBLY EN01 2 DATA AND SPECIFICATIONS EN01 2 TROUBLESHOOTING EN01 4 TROUBLESHOOTING COMMON RAIL SYSTEM EN01 11 ENGINE TUNEUP EN01 12 SPECIAL TOOL EN01 18 OVERHAUL CRITERIA EN01 19 DISMOUNTING AND MOUNTING EN01 20 LIQUID GASKET AND APPLICATION POINTS EN01 22 ...

Page 25: ...l load 2 600 r min Idling revolution 750 r min Dry weight Approximately 640 kg 1 411 lb Valve seat angle Intake 30 Exhaust 45 Valve face angle Intake 30 Exhaust 45 Valve timing flywheel travel Intake opens 14 before top dead center Intake closes 30 after bottom dead center Exhaust opens 54 before bottom dead center Exhaust closes 13 after top dead center Valve clearance when cold Intake 0 30 mm 0 ...

Page 26: ...olution 750 r min Dry weight Approximately 645 kg 1 422 lb Valve seat angle Intake 30 Exhaust 45 Valve face angle Intake 30 Exhaust 45 Valve timing flywheel travel Intake opens 14 before top dead center Intake closes 30 after bottom dead center Exhaust opens 54 before bottom dead center Exhaust closes 13 after top dead center Valve clearance when cold Intake 0 30 mm 0 0118 in Exhaust 0 45 mm 0 017...

Page 27: ...oded vane Replace vane Engine overheating Radiator Clogged with rust or scale Clean radiator Clogged with iron oxide due to leakage of exhaust into cooling system Clean coolant passage and correct exhaust leakage Coolant leakage Repair or replace radiator Damaged cooling fan Replace cooling fan Clogged radiator core due to mud or other debris Clean radiator Defective radiator cap pressure valve Re...

Page 28: ...oo low Change oil as required and replace piston rings and cylinder liners Incorrectly fitted piston rings upside down Replace piston rings Gaps of piston rings in cell with each other Reassemble piston rings Excessive oil consumption Valve and valve guides Worn valve stem Replace valve and valve guide Worn valve guide Replace valve guide Incorrectly fitted valve stem seal Replace the stem seal Ex...

Page 29: ...eplace the coolant pump Leakage of coolant Repair Insufficient coolant Add coolant Dirty coolant Clean and replace coolant Defective radiator coolant leakage clogging Repair or replace the radiator Defective rubber hose leakage Replace rubber hose Defective thermostat Replace the thermostat Leakage of exhaust into cooling sys tem Repair Piston seizure Operation Abrupt stoppage of engine after run ...

Page 30: ...liner Replace piston rings piston and liner Lack of power Other problems Exhaust brake butterfly valve stuck in half open position Replace or repair exhaust brake Connecting rod bent Replace or repair connecting rod Exhaust pipe or muffler crushed increased back pressure Replace exhaust pipe or muffler Breakage of turbine or blower Replace turbocharger Symptom Possible cause Remedy Prevention Leak...

Page 31: ...er viscosity oil or install an oil immersion heater and warm up oil Difficulty starting engine Other problems Seized piston Replace piston piston rings and liner Seized bearing Replace bearing and or crankshaft Reduced compression pressure Overhaul engine Ring gear damaged or worn Replace the ring gear and or starter pinion Improperly adjusted or broken Adjust Symptom Possible cause Remedy Prevent...

Page 32: ... or worn piston pin bushing Replace piston pin bushing Worn pistons or cylinder liners Replace piston or cylinder liner Damaged or seized piston Replace piston and cylinder liner Foreign matter on top surface of the piston Remove foreign matter and repair or replace piston cylinder liner and or cylinder head Unusual engine noise Valve mecha nism Incorrect valve clearance Adjust valve clearance Val...

Page 33: ...ntake manifold flange gasket Retighten or replace Intake valve seating is not concentric Replace or correct the valve and valve seat Intake gas leakage Retighten Unusual engine noise Other prob lems Loose cooling fan mounting bolts or fan pulley nut Tighten the fan and crankshaft pulley Lack of lubricating oil coolant pump valves etc Lubricate Worn timing gear Replace the timing gear Breakage of t...

Page 34: ... Injector broken Replace the injector Engine does not start Electrical system Defective sensors or circuits Refer to the chapter FUEL CON TROL Engine starts and stops Fuel lines clogged Clean or replace fuel lines Air in fuel caused by damaged fuel lines or improper connection of fuel lines Repair fuel lines or replace fuel lines and gaskets Engine has low power Injector faulty Injector broken Rep...

Page 35: ...e compression stroke b Turn the crankshaft clockwise in the engine direction and align the damper timing mark 1 6 to the pointer NOTICE When matching the pulley mark 1 6 of the crankshaft pulley attach the 3 pins on the special tool to any of the 6 corresponding holes on the crankpulley Then turn the torque wrench in a clockwise direction SST Cranking Tool S0940 91200 2 Among three drill holes on ...

Page 36: ...n No 1 or No 6 piston is at the Top Dead Center of the compression stroke by the following chart 1 View from rear side of camshaft housing Mark Possible to check valve clearance Firing order 1 4 2 6 3 5 T D C Top Dead Center 2 Before checking the valve clearance make sure that the roller is on the base circle of the camshaft Correct Incorrect Click SHTS011060100005 Cylinder 1 2 3 4 5 6 Valve IN EX...

Page 37: ...ned to the specified torque 1 Loosen the adjusting screw lock nut A D of the rocker arm and cross head fully 2 The cross head adjusting screw must protrude 10 mm 0 394 in or more from the cross head upper face NOTICE Unless the adjusting screw is completely loose to the valve stem head the following adjustments may be adversely affected 3 Insert a feeler gauge of the specified thickness shown belo...

Page 38: ... torque when the feeler gauge feels correct Tightening Torque 25 N m 250 kgf cm 18 lbf ft NOTICE Do not over loosen the adjusting screw Over loosening of the adjusting screw C will cause the same condition as in step 3 again The feeler gauge may feel correct but there may be excessive clearance between the adjusting screw C of the cross head and the valve stem head E This does not allow for correc...

Page 39: ... of the bearing holder case for installation of the supply pump SST Guide bolt SZ105 08067 a If the guide bolt is fully inserted the No 1 cylinder is at Top Dead Center of compression stroke and the timing is correct b If the guide bolt cannot be fully inserted turn the crankshaft 1 more turn to obtain the 1 6 mark 4 Insert the guide bolt again and confirm the correct timing START THE ENGINE WARNI...

Page 40: ...Remove the head cover 2 Set the engine revolution to the specified idling revolution 3 After the engine starts check that oil is supplied to the following loca tions of all rocker arms within approximately 10 seconds a Roller and cam face A b Cross head top C and spring upper seat top face D through adjusting screw B NOTICE If the supply of oil is delayed or not happening hydraulic pressure may be...

Page 41: ...Tool name Remarks S0955 21110 COMPRESSION GAUGE ADAPTER A For Overhaul criteria S0955 21030 COMPRESSION GAUGE ADAPTER B For 3 4 16UNF thread size Select accord ing to the thread size of air gauge S0955 21060 COMPRESSION GAUGE ADAPTER B For W16 threads 18 thread size S0940 91200 CRANKING TOOL SZ105 08067 GUIDE BOLT S1228 11901 ENGINE HANGER SH782 41235 BOLT Use 2 pieces ...

Page 42: ...re the compression pressure NOTICE Do not operate the starter for more than 15 seconds c Measure the compression pressure of each cylinder NOTICE Do not allow gas leakage from the seal face 3 Reassemble the removed parts 2 ENGINE OIL PRESSURE 1 Check the oil pressure warning lamp when the oil and coolant temper ature is hot about 80 C 176 F a If the warning lamp lightens check the oil level b Chec...

Page 43: ...efer to CHAPTER POWER STEERING for details 6 Disconnect the electric lines fuel lines and air lines NOTICE Disconnect the battery cable from the negative terminal of the battery and disconnect the electric lines Cover open ends of the pipes hoses and pumps to prevent entry of dirt 7 Disconnect the hoses coolant heater and air intake and remove the radiator with the intercooler NOTICE Do not damage...

Page 44: ... remove the rear hanger bracket and install it on the front of the flywheel housing as shown in the figure 14 Remove the engine mounting fitting nuts front and rear both sides 15 Lift the engine hanger so that the cables are fully tightened then after checking that the cables are securely lift gently and remove the engine from the vehicle NOTICE When the transmission is attached to the engine atta...

Page 45: ... of misalignment when assembling parts with liquid gasket If they are misaligned reapply the liquid gasket 4 Assemble parts within 20 minutes of application If more than 20 minutes have passed remove and reapply the liquid gasket 5 Wait for at least 15 minutes or more after assembly of parts before starting the engine 2 REMOVE PARTS 1 When removing parts do not use a tool for removal at one locati...

Page 46: ...in SHTS011060100033 1 Approximately 2 mm wide when cut at the first step 2 Approximately 5 mm wide when cut at the second step No Part name Application position and pattern Application width Gasket to be used Remarks 1 Oil seal retainer Matching flange face with the block 1 5 2 5 0 0591 0 0984 Black 2 Coolant pump Matching flange face with the block 1 5 2 5 0 0591 0 0984 Black 3 Oil cooler Matchin...

Page 47: ...rts of block upper face rear end gas ket rear end plate flywheel housing cylinder head gasket White Matching parts of oil seal retainer and block lower face front end 1 5 2 5 0 0591 0 0984 Black Matching parts of block lower front end gasket rear end plate and flywheel housing 1 5 2 5 0 0591 0 0984 Silver No Part name Application position and pattern Application width Gasket to be used Remarks Mat...

Page 48: ...rear end plate gasket with a craft knife flush with the block upper face 9 Flywheel housing Matching face of rear end plate 1 5 2 5 0 0591 0 0984 Silver No Part name Application position and pattern Application width Gasket to be used Remarks Liquid gasket Liquid gasket Matching face of rear end plate ...

Page 49: ...essive gasket completely When the cylinder head cover is assembled reapply the liquid gasket Assembly must be done within 20 minutes 1 5 2 5 0 0591 0 0984 Black 2 locations at front and rear ends NOTICE Figure on the right shows application pattern of the liquid gasket Apply the liquid gasket to the center of seal flange inside whenever possible No Part name Application position and pattern Applic...

Page 50: ...N02 21 SPECIAL TOOL EN02 22 OVERHAUL EN02 23 FLYWHEEL AND FLYWHEEL HOUSINGEN02 25 COMPONENT LOCATOR EN02 25 SPECIAL TOOL EN02 26 OVERHAUL EN02 26 INSPECTION AND REPAIR EN02 32 TIMING GEAR EN02 33 COMPONENT LOCATOR EN02 33 SPECIAL TOOL EN02 34 OVERHAUL EN02 35 INSPECTION AND REPAIR EN02 37 MAIN MOVING PARTS AND CYLINDER BLOCK EN02 39 COMPONENT LOCATOR EN02 39 SPECIAL TOOL EN02 42 OVERHAUL EN02 44 I...

Page 51: ...ECHANICAL J08E EN02 2 CYLINDER HEAD COMPONENT LOCATOR EN0110602D100001 12 J 15 13 18 17 14 11 22 23 24 I 31 32 28 27 26 25 30 11 10 F G 6 7 8 G B C 20 21 19 D 29 4 E 9 33 L K E 7 16 H 5 A 3 1 2 SHTS011060200001 ...

Page 52: ...4 Injection pipe oil seal 8 Leakage pipe 25 Injector 9 Injector clamp bolt 26 O ring 10 Rocker arm support bolt 27 Camshaft housing 11 Rocker arm assembly 28 Camshaft housing gasket 12 Lock nut 29 Camshaft bearing 13 Adjust screw 30 Plug 14 Rocker arm support 31 Cylinder head assembly 15 Rocker arm 32 Cylinder head gasket 16 Injector clamp 33 Harness assy 17 Collar A 28 5 290 21 G 12 3 126 9 B 31 ...

Page 53: ... Idle gear shaft 11 Valve spring seat lower 3 Camshaft idle gear 12 Valve stem guide 4 Idle gear thrust plate 13 Valve seat 5 Cross head 14 Valve 6 Valve spring retainer 15 Nozzle seat 7 Valve spring seat upper 16 O ring 8 Valve spring outer 17 Cylinder head block 9 Valve spring inner A 108 1 100 79 6 1 A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 SHTS011060200002 ...

Page 54: ...essary to have these special tools Illustration Part number Tool name Remarks S0943 31070 EYE BOLT S0949 11010 WIRE S0947 01170 VALVE SPRING PRESS S0943 11020 VALVE LAPPING TOOL S0947 22100 VALVE STEM SEAL PRESS S0947 21210 BAR For Nozzle sleeve SN441 00610 STEEL BALL Used with S0947 21210 S0947 11520 GUIDE ...

Page 55: ...e end of the rocker arm and turn the adjusting screw counterclockwise completely NOTICE Not untightening the adjusting screw may result in a bent rocker shaft b Loosen the injector clamp bolt c Loosen the rocker arm support bolt as shown in the figure NOTICE If the cross head is removed from the valve during disassembly of the rocker arm assembly reassemble the cross head as it was 5 Remove the ca...

Page 56: ...ASSEMBLE THE VALVE SYSTEM 1 Remove the valve spring retainer using the special tool SST Valve spring press S0947 01170 2 Remove the intake and exhaust valve NOTICE Attaching tags to the valves giving corresponding cylinder Nos will eliminate time required for lapping the valve seats on reassembly 3 CLEAN THE CYLINDER HEAD 1 Clean the cylinder head and remove carbon deposits or foreign parti cles N...

Page 57: ...cylinder head from welding spatter be sure to apply grease before welding 2 Place a brass back plate at the top of the valve system and strike it with a hammer to remove the valve seat WARNING Be sure to wear protective goggles Striking the valve seat for removal of valve seat may cause metal chips to fly up 3 Machine the valve according to the valve seat dimensions Unit mm in 4 Heat the cylinder ...

Page 58: ...to the valve guide using the special tool SST Valve stem seal press S0947 22100 WARNING Be sure to wear protective goggles Striking the valve stem seal for installing of valve stem seal may cause metal chips to fly up NOTICE After assembly of the stem seal check for deformation or cracking of the rubber or incline 2 After punching the valve stem seal measure the height A Height A 22 5 23 0 mm 0 88...

Page 59: ...emble it onto the cyl inder head NOTICE Be sure to replace the O ring with a new one Reuse of the O ring may cause water or gas leakage resulting in overheating or cracking of the cylinder head 3 Caulk the nozzle seat with the special tools SST Bar S0947 21210 Steel ball SN441 00610 IMPORTANT POINTS ASSEMBLY 1 ASSEMBLE THE VALVE AND VALVE SPRING 1 Install the valve spring retainer at the valve spr...

Page 60: ... silicon material is used for the gear case print seal make sure that there is no peeling before assembly 1 Install the cylinder head gasket on the cylinder block and flywheel housing 2 Fill the hole at the back of the cylinder head gasket with liquid gasket NOTICE Make sure that the liquid gasket surface will be in a convex shape above the head gasket upper surface 3 INSTALL THE CYLINDER HEAD 1 U...

Page 61: ...ctions as shown in the figure 6 Turn No 1 No 26 M12 bolts 90 1 4 turn in the same order as in 4 7 Retighten them 90 1 4 turn as step 6 8 Make sure that all paint marks face the same direction NOTICE When adding torque never untighten the bolts even if they have been overtightened 9 Tighten No 27 No 29 M10 bolts in the order shown in the figure to the specified torque below Tightening Torque 59 N m...

Page 62: ...lace with new bolts 2 Make sure that there is neither damage to the camshaft gear or cam shaft nor dirt on them 3 Apply clean engine oil to the bolt surface and bolt threads and tighten them to the specified torque below Tightening Torque 59 N m 600 kgf cm 43 4 lbf ft 4 Turn bolts an additional 90 1 4 turn NOTICE When adding torque never untighten the bolt even if it has been overtightened Idle ge...

Page 63: ...e front Tightening Torque 31 N m 320 kgf cm 23 lbf ft 9 INSTALL THE ROCKER ARM ASSEMBLY 1 Make sure that the cross head is on each valve NOTICE If the cross head is assembled whilst off the valve the upper seat will be pressed resulting in a loose valve 2 Make sure that the adjusting screw at the end of the rocker arm is completely screwed in NOTICE Make sure the oil hole is placed below 3 Tighten...

Page 64: ...amshaft housing plug to camshaft housing with torx bolt Tightening Torque 6 N m 60 kgf cm 4 3 lbf ft NOTICE Make sure that the camshaft housing plug is installed with no tilt 5 Install the head cover gasket into the gasket groove at the head cover lower surface NOTICE Make sure that there are no foreign particles including liquid gasket or oil on the gasket grooves of the head cover gasket or cam ...

Page 65: ...sert the silent block from the head cover upper surface 8 Tighten the bolt through the silent block to the specified torque below and fix the head cover on the cam housing Tightening Torque 28 5 N m 290 kgf cm 21 lbf ft SHTS011060200047 ...

Page 66: ...0008 0 0024 Replace camshaft and or cam bearing Camshaft end play 0 100 0 178 0 0040 0 0070 Replace camshaft Measure Cam height IN 50 046 1 9703 49 966 1 9672 Replace camshaft Measure EX 52 739 2 0763 52 659 2 0732 Camshaft deflection 0 04 0 0016 0 1 0 0039 Replace camshaft Measure Rocker arm bushing inside diameter 22 0 866 22 08 0 8693 Replace rocker arm Measure Rocker shaft outside diam eter 22...

Page 67: ... valve Guide inside diameter 7 0 2756 7 04 0 2772 Replace the valve guide Clearance 0 050 0 083 0 0020 0 0032 0 15 0 0059 Replace the valve and or valve guide Valve sink IN 0 55 0 85 0 0217 0 0334 1 1 0 0433 Replace the valve and valve seat Measure EX 1 15 1 45 0 0453 0 0570 1 7 0 0669 Replace the valve and valve seat Valve seat angle IN 30 30 30 35 Resurface the valve and or valve seat Measure EX...

Page 68: ... kgf 26 9 lbf at 44 8 1 764 Replace Free length reference value 64 6 2 543 61 6 2 425 Replace Squareness 2 0 0 0787 Replace Wear and damage of valve spring seat upper and lower Replace Visual check Nozzle protrusion 2 45 2 95 0 0965 0 1161 Replace nozzle seat Measure Cylinder head lower sur face flatness 0 06 or less 0 0024 or less for longitudinal direction 0 20 0 0078 Replace NOTICE Do not grind...

Page 69: ...ery of valve head evenly in contact Matches valve Visual check Cam idle gear shaft outside diameter 34 1 3386 Measure Cam idle gear shaft bush ing inside diameter 34 1 3386 Clearance between cam idle gear shaft and cam idle gear bushing 0 025 0 075 0 0010 0 0029 0 2 0 0078 Replace idle gear shaft and or idle gear Inspection item Standard Limit Remedy Inspection procedure ...

Page 70: ...ATOR EN0110602D100002 Tightening torque Unit N m kgf cm lbf ft Apply oil to the threads and seat surfaces before tightening 1 Crankshaft pulley 3 Oil seal retainer 2 Torsional damper 4 Crankshaft oil seal A 118 1 200 86 8 B 108 1 100 79 6 A B 1 2 3 4 SHTS011060200063 ...

Page 71: ...08E EN02 22 SPECIAL TOOL EN0110602K100002 Prior to starting an engine overhaul it is necessary to have these special tools Illustration Part number Tool name Remarks S0942 01731 OIL SEAL PULLER S0940 71030 OIL SEAL PRESS ...

Page 72: ... plate at the crankshaft end using the crankshaft pulley bolts 2 Engage the hook with the oil seal notch and install the hook using the bolt supplied 3 Remove the installed bolt in step 1 4 Install the center bolt and tighten it to remove the oil seal Plate SHTS011060200066 Notch Hook Remove this after installing the hook SHTS011060200067 Center bolt SHTS011060200068 ...

Page 73: ...e of the cylinder block 3 Apply a little engine oil to the seal portion of the crankshaft oil seal 4 Attach the oil seal press guide with the new crankshaft oil seal onto the crankshaft using the attached guide bolt 5 Insert the oil seal press by adjusting the oil seal press hole to the guide bolt 6 Press the crankshaft oil seal inside by attaching the accompanying center bolt onto the oil seal pr...

Page 74: ...en the bolt to the specified torque then loosen it Tighten to the specified torque again 1 Flywheel housing 5 Ring gear 2 Dust cover 6 Flywheel 3 Crankshaft oil seal 7 Pilot bearing 4 Hanger bracket 8 Stay A 186 1 900 137 4 D M8 28 5 290 21 B 97 990 71 6 D M8 Torx bolt 36 370 26 8 C 171 5 1 750 126 6 D M10 55 560 40 5 D M16 196 2 000 145 Example 1 4 3 2 5 6 A B C 8 2 D D 7 D torx bolt SHTS01106020...

Page 75: ...MOVE THE FLYWHEEL ASSY 1 Remove the main engine speed sensor from the flywheel housing NOTICE When dismounting and remounting the flywheel Remove the main engine speed sensor If not removed it will result in damage of the sensor Illustration Part number Tool name Remarks S0942 01742 REAR OIL SEAL PULLER S0940 71040 OIL SEAL PRESS S0948 11340 GUIDE BAR O ring Main engine speed sensor SHTS0110602000...

Page 76: ...PLACEMENT 1 REMOVE THE CRANKSHAFT REAR OIL SEAL SST Oil seal puller S0942 01742 1 Place the plate at the crankshaft end using the flywheel bolts NOTICE Match the plate hole to the crankshaft collar knock part 2 Engage the hook with the oil seal notch and install the hook using the bolt supplied 3 Remove the installed flywheel bolts in step 1 Example SHTS011060200079 Example SST SHTS011060200080 Co...

Page 77: ... into the guide of the oil seal press NOTICE Pay attention to the orientation of the crankshaft oil seal The felt side should face the outside of the cylinder block 3 Apply a little engine oil to the seal portion of the crankshaft oil seal 4 Attach the oil seal press guide with the new crankshaft oil seal onto the crankshaft using the attached guide bolt Center bolt Example SHTS011060200083 SHTS01...

Page 78: ... bar to remove the gear WARNING Never touch the heated ring gear or flywheel with your bare hand This can result in personal injury 2 Heat the ring gear evenly to about 200 C 392 F with a torch Insert the ring gear into the flywheel so that the chamfered side is upward WARNING Never touch the heated ring gear or flywheel with your bare hand This can result in personal injury 4 REPLACE THE FLYWHEEL...

Page 79: ... 2 5 mm width Mount the case within 20 minutes after applying the liquid gas ket c Mount the rear engine mounting to the flywheel housing with bolts Tightening torque 196 N m 2 000 kgf cm 145 lbf ft A 36 N m 370 kgf cm 26 8 lbf ft B 55 N m 560 kgf cm 40 5 lbf ft C 55 N m 560 kgf cm 40 5 lbf ft D d Mount the flywheel housing stay Tightening torque 97 N m 990 kgf cm 71 6 lbf ft M12 171 5 N m 1 750 k...

Page 80: ...ot when removing it because it is very heavy NOTICE Align the O mark on the flywheel and crankshaft collar knock pin 3 Apply clean engine oil to the threads of the flywheel bolt and the fly wheel bolt seat Be sure to tighten the flywheel bolts 6 pieces with a low torque impact wrench 4 Pull out the guide bar and tighten the remaining two flywheel bolts provisionally as in step 3 5 Tighten the flyw...

Page 81: ...item Standard Limit Remedy Inspection procedure Flywheel surface deflec tion 0 15 0 0059 Repair Measure Flywheel thickness Dimen sion A EATON SAS1401 SAS1402 MD DM series Diameter 350 mm 14 in 43 5 1 7126 42 5 1 6732 Repair Measure Flywheel surface crank on heat spot Repair Visual check DIM A ...

Page 82: ...d plate 9 Crankshaft gear 3 Camshaft gear 10 Power steering pump drive gear 4 Cam idle gear 11 Air compressor drive gear 5 Idle gear thrust plate 12 Air compressor idle gear 6 Sub idle gear 13 Idle gear bushing 7 Oil pump gear 14 Idle gear shaft A 108 1 100 79 6 C 55 560 41 Application of lock sealant B 172 1 750 127 D 59 600 43 90 3 4 1 2 5 6 7 5 8 5 11 10 A 14 5 14 13 13 13 B 14 A 14 A 12 9 C D ...

Page 83: ...Prior to starting an engine overhaul it is necessary to have these special tools Illustration Part number Tool name Remarks S0942 01100 SLIDING HAMMER For MAIN IDLE GEAR S0942 01442 SLIDING HAMMER For SUB AND CAM IDLE GEAR S0941 11300 SOCKET WRENCH For TORX BOLT ...

Page 84: ... bolts in the side of bearing holder case fitting 2 places and tighten to the specified torque using the special tool SST Socket wrench S0941 11300 Tightening Torque 55 N m 560 kgf cm 41 lbf ft 2 INSTALL THE CRANKSHAFT GEAR 1 Heat the crankshaft gear in oil heated to 100 C 150 C 212 F 302 F WARNING Never touch the heated gear with your bare hand This can result in personal injury 2 Align the crank...

Page 85: ...djust the timing of the main idle gear to align with the air com pressor gear as shown in the figure 4 MEASUREMENT OF GEAR BACKLASH 1 Measure the backlash between the gears with a dial gauge Refer to the table of INSPECTION AND REPAIR NOTICE Measure the backlash with the drive side gear fixed After measurement of the backlash apply engine oil to each gear surface SHTS011060200109 SHTS011060200110 ...

Page 86: ...ain idle Air compressor idle 0 020 0 096 0 0008 0 0038 0 10 0 0039 Air compres sor idle Air compressor gear 0 020 0 083 0 0008 0 0033 0 10 0 0039 Air compres sor Power steering pump 0 030 0 134 0 0012 0 0052 0 30 0 0118 Main idle Sub idle 0 030 0 113 0 0012 0 0044 0 30 0 0118 Sub idle Oil pump 0 030 0 131 0 0012 0 0052 0 30 0 0118 Sub idle Cam idle 0 050 0 218 0 0020 0 0085 0 30 0 0118 Cam idle Ca...

Page 87: ...gth 22 0 866 End play 0 040 0 120 0 0016 0 0047 0 30 0 0118 Replace gear and or shaft Cam idle shaft Shaft outside diameter 34 1 339 Bushing inside diame ter 34 1 339 Clearance 0 025 0 075 0 0010 0 0029 0 20 0 0079 Replace gear and or shaft Gear width 22 0 866 Shaft length 22 0 866 End play 0 040 0 120 0 0016 0 0047 0 30 0 0118 Replace gear and or shaft Air com pressor idle Shaft outside diameter ...

Page 88: ...necting rod bearing 2 Cylinder block 11 Crankshaft 3 Piston cooling jet 12 Crankshaft thrust bearing 4 Piston ring 13 Crankshaft main bearing 5 Piston 14 Crankshaft gear 6 Piston pin 15 Collar knock 7 Retainer ring 16 Main bearing cap 8 Connecting rod 17 Block heater assy 9 Connecting rod bushing 18 Dowel pin SHTS011060200113 ...

Page 89: ... surfaces before tightening Tighten the bolt to the specified torque then loosen it Tighten to the specified torque again A 22 220 15 9 C 69 700 51 90 45 B 69 700 51 90 45 1 Engine mounting bracket front 3 Engine mounting front 2 Engine mounting bracket rear 4 Engine mounting rear 1 2 4 3 SHTS011060200114 ...

Page 90: ...ENGINE MECHANICAL J08E EN02 41 Tightening torque Unit N m kgf cm lbf ft 1 Gasket 3 Soft washer 2 Oil pan 4 Drain plug A 41 420 30 B 30 310 22 4 3 4 2 1 B A A SHTS011060200115 ...

Page 91: ...ve these special tools Illustration Part number Tool name Remarks S0944 21011 PISTON RING EXPANDER For Piston ring S0942 02100 PULLER For Cylinder liner SZ910 24098 CONNECTOR BOLT For Piston cooling jet S0947 11490 GUIDE S0940 21540 SPINDLE S0948 11540 GUIDE SH691 20825 BOLT S0948 11130 GUIDE For Connecting rod bushing ...

Page 92: ...ENGINE MECHANICAL J08E EN02 43 S0940 21530 PRESS SUB ASSEMBLY SL271 01036 WING NUT S0944 11370 PISTON RING HOLDER 09219 E4010 GAGE Illustration Part number Tool name Remarks ...

Page 93: ...eful not to change the combi nation of the connecting rod and cap 2 REMOVE THE PISTON RINGS 1 Remove the piston ring using the special tool SST Piston ring expander S0944 21011 NOTICE Handle the piston rings carefully because they are made of a special casting which is easily broken Keep the piston rings for each cylinder separately 3 REMOVE THE CYLINDER LINER 1 Before removing the cylinder liner ...

Page 94: ... installation hole otherwise water will leak Do not reuse the V lock IMPORTANT POINT ON VEHICLE INSPECTION 1 INSPECT THE BLOCK HEATER 1 Measure the resistance between terminals If not standard value replace block heater assembly 2 Measure the resistance of insulation between terminals and heater insulation If not standard value replace block heater assembly IMPORTANT POINTS ASSEMBLY 1 INSPECT AND ...

Page 95: ... piston cooling jet nozzle at a hydraulic pres sure of 245 kPa 2 5 kgf cm2 35 lbf in2 5 If the center of the jet flow is within the two target circles 8 mm 0 3150 in and 15 mm 0 5906 in diameter Red the test is accept able WARNING Engine oil is flammable Never use an open flame or a naked bulb Carry out the following inspection only in a well ventilated area 6 If the center of the jet flow is out ...

Page 96: ...er liner having the same symbol 1 Apply engine oil to the inner surface of the block bore and insert the cylinder liner using the special tool SST Guide S0947 11490 NOTICE Handle the cylinder liner carefully because it is thin If it falls on the floor it cannot be used 3 MEASURE THE PROTRUSION AT THE CYLINDER LINER FLANGE SST Puller S0942 02100 Tightening Torque 9 8 N m 100 kgf cm 7 lbf ft SHTS011...

Page 97: ...groove side front toward the crank arm and with the part No stamp back toward the main bearing cap or cylinder block HINT Apply engine oil or grease to the back of the bearing to prevent loos ening during installation 3 Install the crankshaft onto the cylinder block Bearing size Outside diameter Crank pin Journal Standard 64 94 64 96 mm 2 5567 2 5574 in 79 94 79 96 mm 3 1473 3 1480 in 0 25US 64 69...

Page 98: ... the bolts 45 1 8 turn as in step 8 10 Make sure that all paint marks face the same direction NOTICE When adding torque never untighten the bolts even if they have been overtightened 11 After tightening tap the front and back ends of the crankshaft using a plastic hammer to allow complete fit 7 REPLACE THE CONNECTING ROD BUSHING 1 Prepare the special tools a Assembly the guide and press sub assemb...

Page 99: ...he groove of the press sub assembly c Using a hydraulic press remove the bushing NOTICE Always operate the press slowly and smoothly 3 Chamfer one edge of the bushing hole at the small end of the con necting rod uniformly by 0 5 1 0 mm 0 0197 0 0393 in NOTICE Irregular chamfering can cause out of roundness of the pressed bushing which may result in jamming during insertion Remove dust from the inn...

Page 100: ...fer side of the small end to the bushing side Apply the fresh engine oil to the bore of the connecting rod 6 Using a press install the bushing in the connecting rod 7 Inspect the bushing positioning after installation a Make sure that the oil hole of the bushing and the oil path of the connecting rod are suitably aligned allowing a 6 mm 0 2362 in diameter rod to penetrate NOTICE Misalignment can l...

Page 101: ...nside the piston ring Assemble the ring with the joint 180 opposite to the matching point 3 Position the matching points of the piston ring at an even distance as shown in the figure 10 CHECK THE PISTON Before assembling the piston with the connecting rod check whether the piston us specified for this engine NOTICE Check using the engine compatible identification code on the top of the piston Engi...

Page 102: ...p 3 Tighten the connecting rod bolt to the specified torque Tightening Torque 69 N m 700 kgf cm 51 lbf ft 4 Mark the bolt heads in the same direction with paint 5 Tighten the connecting rod bolt 90 1 4 turn 6 Tighten the connecting rod bolt 45 1 8 turn 7 Make sure that the paint marks face the same direction NOTICE When retightening the bolts never adjust them by turning counter clockwise even if ...

Page 103: ...ting bolts in the order 1 2 3 4 with an impact wrench Tightening Torque 19 7 24 5 N m 200 250 kgf cm 15 18 lbf ft 5 Finish tightening the bolts with a torque wrench to the specified torque Tighten the bolts according to the arrow in the figure NOTICE Make sure that the washer is not on the flange 14 INSTALL THE BLOCK HEATER 1 Apply silicone spray to O ring LPS Laboratories Parts No 01516 or equiva...

Page 104: ...ystem damage 4 Install the harness by tightening the cord nut fully by hand only 5 Handling precaution NOTICE Before using it remove all the rust and dirt Any rust and water attached to the terminal can trip the breaker First put the harness in the socket of the chassis side and turn on power 120 V CAUTION Make sure to disconnect the power source plug outlet before starting the engine Starting the...

Page 105: ...cording to the following table the engine will overheat and block heater coil will melt NOTICE Do not mix more than 60 or less than 50 LLC Concentrations more than 63 result in a loss of freezing protection Concentrations below 50 result in a loss of corrosion protection LLC Water Mixing Table Freezing protec tion Freezing temper ature LLC Water F C F C US Qt Liter US Qt Liter J08E engine 27 33 36...

Page 106: ...9 4 6071 Liner out side diam eter A 116 982 116 990 4 6056 4 6058 Reference only B 116 990 116 996 4 6059 4 6061 C 116 996 117 004 4 6062 4 6064 Clearance between block and liner A 0 010 0 026 0 0004 0 0010 Reference only B 0 012 0 024 0 0005 0 0009 C 0 010 0 026 0 0004 0 0010 Piston outside diameter at A 17 0 6693 111 927 111 943 4 40657 4 40720 Replace piston and or liner Measure Liner inside di...

Page 107: ... piston ring Top 0 30 0 40 0 0119 0 0157 1 5 0 0591 Replace piston ring Measure Second 0 75 0 90 0 0296 0 0354 1 2 0 0472 Oil 0 15 0 30 0 0059 0 0118 1 2 0 0472 Piston pin outside diam eter 37 1 4567 36 96 1 4551 Replace piston pin Measure Piston pin bore inside diameter 37 1 4567 37 05 1 4586 Replace piston Clearance between pis ton pin and piston pin bore 0 011 0 032 0 00043 0 00126 0 05 0 0020 ...

Page 108: ...en con necting rod bearing and crankpin 0 031 0 082 0 0013 0 0032 0 2 0 0079 Replace connecting rod bearing Connecting rod large end width 34 1 339 33 2 1 3071 Replace connecting rod Measure Crankpin width 34 1 339 34 8 1 371 Replace crankshaft Connecting rod end play 0 20 0 52 0 0079 0 0204 1 0 0 0394 Replace connecting rod and or crank shaft Crank journal outside diameter 80 3 150 More than 0 2 ...

Page 109: ...Service Replace crankshaft Crankshaft deflection 0 15 0 0059 Regrind under size Measure Clogging of crankshaft oil hole Clean Visual check Crack and wear of crank shaft Dye penetrant check Color check Replace Visual check Cylinder block upper surface flatness Longitudinal direc tion 0 06 0 0024 Right angle direc tion 0 03 0 0012 or less 0 20 0 0078 Replace NOTICE Do not grind for repair Measure In...

Page 110: ...DISMOUNTING AND MOUNTING EN03 3 AIR INTAKE EN03 4 COMPONENT LOCATOR EN03 4 AIR CLEANER EN03 5 DESCRIPTION EN03 5 OVERHAUL EN03 6 AIR HOSE EN03 7 COMPONENT LOCATOR EN03 7 OVERHAUL EN03 8 AIR FLOW SENSOR EN03 9 COMPONENT LOCATOR EN03 9 REPLACEMENT EN03 10 BOOST PRESSURE SENSOR EN03 11 COMPONENT LOCATOR EN03 11 REPLACEMENT EN03 12 ...

Page 111: ...E MANIFOLD AND PIPE COMPONENT LOCATOR EN0110603D100001 Tightening torque Unit N m kgf cm lbf ft 1 Intake manifold gasket 4 Intake throttle valve 2 Intake manifold 5 Bracket 3 Intake pipe 6 Gasket A 28 5 290 21 1 2 A 4 6 5 3 SHTS011060300001 ...

Page 112: ...TING AND MOUNTING EN0110603H100001 IMPORTANT POINT MOUNTING 1 INSTALL THE INTAKE MANIFOLD GASKET 1 Install the intake manifold gasket so that the protrusion is positioned at the stud bolt side of the cylinder head rear end SHTS011060300002 ...

Page 113: ...OMPONENT LOCATOR EN0110603D100002 1 Hood 5 Air flow sensor 2 Air intake grille 6 Air hose 3 Air cleaner 7 Air cleaner bracket 4 Air hose 8 Intake pipe 6 5 4 7 3 To Turbocharger Vehicle s right side Vehicle s front Example 2 1 8 SHTS011060300003 ...

Page 114: ...AIR INTAKE SYSTEM J08E EN03 5 AIR CLEANER DESCRIPTION EN0110603D100003 5 1 2 3 4 SHTS011060300004 1 Body assembly 4 Unloader valve 2 Cover 5 Adapter 3 Thumb screw ...

Page 115: ...INSTALL THE AIR CLEANER ELEMENT 1 Install in the reverse order of removing NOTICE Ensure the cover over the thumb screw is properly affixed IMPORTANT POINTS INSPECTION 1 INSPECTING 1 If on inspection the dust indicator is red replace it 2 If the cover case or unloader valve is damaged replace the part 3 Check the element to see if it is flattened or deformed or whether the filter paper of the elem...

Page 116: ...acket 8 Clamp B 2 Air cleaner 9 Dust indicator 3 Air hose 10 Intake throttle valve 4 Clamp A 11 Separator 5 Intake pipe 12 Air hose 6 Air hose 13 Air hose Separator 7 Air hose Intercooler 14 Cover If so equipped A 4 5 5 5 46 56 3 326 4 049 B 5 4 6 6 55 67 3 976 4 844 9 10 11 5 4 A 7 8 B 3 13 12 2 1 4 A 14 8 B 6 4 A SHTS011060300008 ...

Page 117: ... Torque 4 5 5 5 N m 46 56 kgf cm 3 326 4 049 lbf ft 2 INSTALL THE AIR HOSE INTER COOLER 1 Install the air hose against the stopper as shown in the figure 2 Match the straight line mark of the air hose and match mark stopper center of the intercooler 3 Tighten the clamp as shown in the figure Tightening Torque 5 4 6 6 N m 55 67 kgf cm 3 976 4 844 lbf ft SHTS011060300009 12 12 10 Stopper Clamp Strai...

Page 118: ...EN03 9 AIR FLOW SENSOR COMPONENT LOCATOR EN0110603D100005 Tightening torque Unit N m kgf cm lbf ft 1 Air flow sensor 4 Clamp 2 Air cleaner 5 Dust indicator 3 Air hose A 1 17 1 77 12 17 0 9 1 3 2 1 3 3 4 4 5 A SHTS011060300011 ...

Page 119: ... 1 Install the air flow sensor and tighten a bolt Tightening Torque 1 17 1 77 N m 12 18 kgf cm 0 9 1 3 lbf ft NOTICE Do not apply an excessive torque in tightening the mounting bolt M4 for air flow sensor The connector of the air flow sensor must be positioned in the frontward direction of the vehicle 2 Connect the connector of the air flow sensor Air flow sensor SHTS011060300012 Air flow sensor S...

Page 120: ...N03 11 BOOST PRESSURE SENSOR COMPONENT LOCATOR EN0110603D100006 Tightening torque Unit N m kgf cm lbf ft 1 Boost pressure sensor 3 Intake manifold 2 Intake pipe 4 Intake manifold gasket A 10 102 7 3 4 3 2 1 A SHTS011060300014 ...

Page 121: ...ressure sen sor 3 Remove two bolts to remove the boost pressure sensor from the intake pipe 2 INSTALL THE BOOST PRESSURE SENSOR 1 Install the boost pressure sensor to the intake pipe and tighten two bolts Tightening Torque 10 N m 102 kgf cm 7 3 lbf ft 2 Insert a hose into the boost pressure sensor and fasten two clamps 3 Connect the connector of the boost pressure sensor SHTS011060300015 SHTS01106...

Page 122: ...ION EN04 24 INSPECTION PROCEDURE FOLLOWED WHEN DPR MAINTENANCE IS DISPLAYED ON THE INFORMATION DISPLAY EN04 25 INSPECTION BY WAY OF HINO DX EN04 26 INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES ABNORMAL EN04 30 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX EN04 33 CHECKING THE DPR STATE EN04 33 REPLACEMENT OF DPR FILTER EN04 34 OVERALL OPERATION FLOW EN04 3...

Page 123: ...04 2 EXHAUST MANIFOLD AND PIPE COMPONENT LOCATOR EN0110604D100001 Tightening torque Unit N m kgf cm lbf ft 1 Exhaust manifold sub assembly 4 Heat insulator 2 Gasket 5 Spacer 3 Bracket A 65 660 48 4 3 2 1 5 A SAPH011060400001 ...

Page 124: ...ST MANIFOLD 1 Install the exhaust manifold onto the cylinder head and tighten the mounting nut in the order shown in the figure to the specified torque Tightening Torque 65 N m 660 kgf cm 48 lbf ft 2 Retighten the same nuts according to the same procedure again NOTICE Be sure to carry out the procedure SAPH011060400002 8 7 18 17 16 15 14 13 12 11 10 9 1 2 6 5 4 3 Tightening order New manifold Tigh...

Page 125: ... EXHAUST PIPE AND MUFFLER UNIT DESCRIPTION EN0110604H200001 Example 3 6 6 1 2 1 4 5 SAPH011060400004 1 Exhaust pipe 4 Muffler unit with burner 2 Exhaust control cylinder Exhaust brake 5 Tail pipe 3 Bracket 6 Bracket sub assembly ...

Page 126: ...UST PIPE Tightening torque Unit N m kgf cm lbf ft 1 Exhaust pipe No 1 4 Gasket 2 Exhaust pipe No 2 5 Exhaust control cylinder Exhaust brake 3 Gasket 6 Bracket A 56 84 571 856 42 62 C 41 61 418 622 30 45 B 49 61 500 622 36 50 5 3 B C 3 1 A 2 3 3 A A 4 SAPH011060400005 ...

Page 127: ...ket 9 Flange 3 Particulate filter assembly 10 Support Front 4 Chamber sub assembly Rear 11 Support Rear 5 Gasket 12 Bracket Front 6 Chamber sub assembly Front 13 Bracket Rear 7 Monolithic converter assembly 14 Pipe sub assembly A 64 653 47 M8 18 26 184 265 14 19 10 10 14 6 A A A A A 2 5 2 8 9 13 A A A 4 2 3 2 1 12 11 A 7 SAPH011060400006 ...

Page 128: ...sub assembly Rear 7 Clamp sub assembly 3 Support sub assembly Front lower 8 Lifting clamp 4 Support sub assembly Rear lower 9 Muffler unit 5 Bracket 10 Protector A 80 120 816 1 223 59 88 D 69 103 704 1 050 51 76 B 34 44 347 448 25 32 M8 18 26 184 265 14 19 C 41 61 418 622 30 45 6 2 A A A C D 3 5 1 4 A 7 C 8 9 D B D 10 SAPH011060400007 ...

Page 129: ...EXHAUST SYSTEM J08E EN04 8 TAIL PIPE SHORT TAIL TYPE Tightening torque Unit N m kgf cm lbf ft 1 Tail pipe 2 Muffler unit A 108 132 1 101 1 346 80 97 2 1 A SAPH011060400008 ...

Page 130: ...EXHAUST SYSTEM J08E EN04 9 TAIL PIPE STACK TYPE 11 6 G 13 2 3 F 12 8 E 8 4 B 10 A 1 9 5 7 C C E D 13 G SAPH011060400009 ...

Page 131: ...cket 9 Exhaust flexible pipe 3 Bracket 10 Muffler unit 4 Tail pipe sub assembly 11 Clamp 5 Tail pipe sub assembly 12 Clamp 6 Tail pipe 13 U bolt 7 Insulator A 104 126 1 060 1 284 77 92 E 60 80 612 815 45 59 B 108 132 1 102 1 346 80 97 F 20 4 30 4 208 310 15 22 C 130 158 1 326 1 611 96 116 G 36 44 367 448 27 32 D 37 50 378 509 28 36 M8 18 26 184 265 14 19 ...

Page 132: ...r use the battery disconnect switch when it is necessary to break the supply of electric ity completely Otherwise electricity may remain supplied from the battery by the circuit that bypasses the battery disconnect switch and you may get burns or injury from the electricity 2 Dismount the steps top and bottom and the insulator on the right side of the vehicle 3 Remove the bolts and nuts on the fla...

Page 133: ... Remove the front ignition cable of the combustion chamber 8 Remove the front atomized fuel pipe of the combustion chamber NOTICE After removal do not allow foreign objects to get into the pipe and nozzle Connector Example Exhaust gas temperature sensor SAPH011060400013 Connector Exhaust gas temperature sensor SAPH011060400014 Ignition cable SAPH011060400015 Fuel pipe SAPH011060400016 ...

Page 134: ...do not allow foreign objects to get into the pipe 11 Disconnect the SCR catalyst front exhaust gas temperature sensor connector 12 Remove the coolant hose connecting to the injector NOTICE When removed coolant will flow out Drain coolant beforehand or plug the end of the pipe Connector Burner flame temperature sensor SAPH011060400017 Swivel SAPH011060400018 Harness connector SAPH011060400019 Clamp...

Page 135: ... HINT Remove it by pushing inward the 2 white knobs of the connector 14 Remove the clamp of the harness connecting to the injector and the injector connector 15 Disconnect the DOC rear exhaust gas temperature sensor connector and remove the clip Clip Connector SAPH011060400021 Clamp Connector SAPH011060400022 Clip Harness connector SAPH011060400023 ...

Page 136: ...Ox sensor controller 17 Disconnect the NOx sensor 2 connector and remove the NOx sensor controller 18 Remove the differential pressure hose NOx sensor controller Harness connector SAPH011060400024 Connector NOx sensor controller SAPH011060400025 Difference pressure hose SAPH011060400026 ...

Page 137: ...ly heavy load or impact to the muffler unit when mounting and dismounting NOTICE Be extremely careful when handing the heavy muffler unit HINT The jack can be operated easily by placing a base as shown in the fig ure at left Rear view Nut Nut Bolt Nut Bolt Muffler unit Muffler unit Nut Front view SAPH011060400027 Muffler unit Base Transmission Jack SAPH011060400028 ...

Page 138: ...e muffler unit when mounting and dismounting 2 Mount the tail pipe 3 Connect the combustion chamber and the exhaust pipe NOTICE If the exhaust pipe is removed make sure to mount the bellows tube of the exhaust pipe as in the figure to secure durability Nut Nut Bolt Muffler unit SAPH011060400029 Tail pipe SAPH011060400030 SAPH011060400031 SAPH011060400032 ...

Page 139: ...ightening Torque 3 9 7 1 N m 40 72 kgf cm 2 9 5 2 lbf ft 6 Install the NOx sensor 1 and connect the harness connector Tightening Torque 3 9 7 1 N m 40 72 kgf cm 2 9 5 2 lbf ft Difference pressure hose SAPH011060400033 Correct Incorrect SAPH011060400034 NOx sensor controller Harness connector SAPH011060400035 Clip NOx sensor controller Harness connector SAPH011060400036 ...

Page 140: ...cting to the injector and the injector connector 9 Install the DEF hose connecting to the injector NOTICE Before reassembling wash away crystallized DEF on the connector with water 10 Install the coolant hose connecting to the injector Connector Clip SAPH011060400037 Clamp Connector SAPH011060400038 Clip Connector SAPH011060400039 Clamp SAPH011060400040 ...

Page 141: ...ch Before reassembling remove the combustion air valves 2 places without bending the hose so that the valves will be free 13 Connect the burner flame temperature sensor connector 14 Install the front atomized fuel pipe Harness connector SAPH011060400041 Swivel Hexagonal part SAPH011060400042 Connector Burner flame temperature sensor SAPH011060400043 Fuel pipe SAPH011060400016 ...

Page 142: ...rear exhaust gas temperature sensor connector 18 Mount the steps top and bottom and the insulator on the right side of the vehicle Tightening Torque 18 26 N m 184 265 kgf cm 14 19 lbf ft 19 Connect the battery ground terminal Ignition cable SAPH011060400044 Connector Exhaust gas temperature sensor SAPH011060400045 Connector Exhaust gas temperature sensor Example SAPH011060400046 SAPH011060400047 ...

Page 143: ...110604D100003 1 Engine 7 Differential pressure sensor 2 Engine ECU 8 DPR manual regeneration switch 3 Exhaust pipe 9 DPR indicator light 4 Exhaust control valve 10 Check engine light 5 Catalyst coated filter 11 Burner control unit 6 Oxidation catalyst 12 Combustion chamber 12 SAPH011060400048 ...

Page 144: ...EN0110604D100004 1 Combustion chamber 6 Chamber sub assembly Front 2 Gasket 7 Monolithic converter assembly 3 Particulate filter assembly 8 Outlet chamber sub assembly 4 Chamber sub assembly Rear 9 Flange 5 Gasket 7 2 5 2 9 10 4 2 3 2 1 8 SAPH011060400049 ...

Page 145: ...ROUTINE INSPECTION ITEMS 1 Check the exhaust system tightening portions exhaust pipe main unit flange for looseness or exhaust leakage 2 Check external appearance of the harness of the exhaust tempera ture sensor for trouble cracks in coating or missing clip 3 Inspect the hose of the backpressure sensor and check the hose for deterioration or cracks Replace a hose which has been used for three yea...

Page 146: ...ION 3 FORCED REGENERATION Forced regeneration by way of HINO DX Execution of manual regeneration Confirm the combustible doesn t exist near the exhaust pipe 4 FORCED REGENERATION COMPLETION COMPLETION 5 DIAGNOSIS 6 MEASUREMENT OF BACKPRESSURE 7 DIAGNOSIS FILTER CLEANING FILTER CLEANING Regeneration is not complete and the check engine lamp comes on Check the backpressure sensor value while raising...

Page 147: ...e DPR status display display monitor if the value for all the items are OFF DPR functions normally Then Manual forced regeneration and DPR differential pressure check can be done 3 In case ON is displayed in Data view of the DPR status display dis play monitor check according to the procedure on page EN04 32 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX SAPH011060400052 ...

Page 148: ...Confirm safety of the surrounding area then press DPR regener ation switch inside the cabin to execute the regeneration Confirm the PTO switch is OFF 2 When the Regeneration switch ON identification value is ON inspection of burner system and wash or replace the filter When the value is OFF DPR functions normally SAPH011060400053 ...

Page 149: ...differential pressure check Specific value 5 When the differential pressure is unchanged check the following If the following are normal the differential pressure sensor should be replaced a Check differential pressure hose for cracks or hole openings b Check that the hose clamp is neither loose nor disconnected c Check whether there is clogging in the differential pressure pipe DPR cleaner side U...

Page 150: ...EXHAUST SYSTEM J08E EN04 29 SAPH011060400054 ...

Page 151: ...perature is detected by the rear temperature sensor Clogging of DPR is detected by the backpressure sensor DPR backpressure of the backpressure sensor has dropped abnormally Abnormally high temperature is detected by the front DPR exhaust temperature sensor CHECK ENGINE LIGHTS ILLUMINATES PAST FAULT CHECK determination of sensor system trouble Front DPR exhaust temperature sensor trouble DTC code ...

Page 152: ...ck Load L c Click System Fix W after the DTC code has been put out d Enter Work memorandum information Customer Name License Plate and Mileage information at the pop up screen e Click the OK button f Click the Close Work C button of the pull down menu File F for Close Work g Click Past work information O of the File F pull down menu h Select the files when System Fix was performed in items d and e...

Page 153: ...tity of oil adheres to the filter body as seen from the gas flow inlet side 3 Cleaning is not possible when the filter or the catalyst shows cracks or damage seen from any side When cleaning has been completed and the filter has been installed again perform the following inspections 4 Use the HINO DX to perform DPR forced regeneration then confirm normal completion 5 In this condition wait for the...

Page 154: ...gain In case a code indicating a sensor system trouble is displayed inspect and replace the sensor circuit 3 Check past faults In case DPR trouble DTC code P141F P200C P2459 P244A P244B P2463 is displayed check the DPR state monitor CHECKING THE DPR STATE EN0110604H200007 1 CHECK THE DPR STATE MONITOR 1 Refer to INSPECTION BY WAY OF HINO DX and check the DPR state monitor Perform inspection as per...

Page 155: ...ed fuel pipe of the combustion chamber NOTICE After removal do not allow foreign objects to get into the pipe and nozzle 3 Disconnect the burner flame temperature sensor connector 4 Remove the burner burning air hose NOTICE When removing be sure to remove the swivel on the vehicle upper side After removal do not allow foreign objects to get into the pipe SAPH011060400056 Fuel pipe SAPH011060400057...

Page 156: ...en the DPR filter 10 Remove the DPR filter 2 INSTALL THE DPR FILTER 1 Install the DPR filter to the chamber subassembly NOTICE Before installing check if the DPR filter has the 14 mark on it Replace with a new gasket Tighten the fastening bolts in the diagonal order 2 Install the combustion chamber to the DPR filter NOTICE Replace with a new gasket Tighten the fastening bolts in the diagonal order...

Page 157: ...e lubricant NEVER SEEZ Pure Nickel Special Bostic inc Tightening Torque 25 35 N m 255 356 kgf cm 19 25 lbf ft Flare nut 5 Install the burner burning air hose NOTICE When tightening fix the hexagonal part under the swivel with the wrench Before reassembling remove the combustion air valves 2 places without bending the hose so that the valves will be free 6 Connect the burner flame temperature senso...

Page 158: ...8E EN04 37 7 Install the front atomized fuel pipe of the combustion chamber 8 Install the exhaust pipe to the flanges on the exhaust brake side and the combustion chamber side Fuel pipe SAPH011060400067 SAPH011060400068 ...

Page 159: ...ION 1 After a manual regeneration check the differential pressure with the Hino DX Standard value Refer to LIST OF STANDARD VALUES FOR DIFFERENTIAL PRESSURE INSPECTION on page EN04 40 NO YES SAPH011060400069 4 For P141F P200C P244B P244A P2459 P2463 5 For others than above 2 MANUAL REGENERATION Exhaust gas purification switch SAPH011060400070 3 INSPECT THE DPR FILTER No clean up necessary Vehicle ...

Page 160: ...400071 Replace with a new DPR filter and install it on the vehicle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE Recheck the differential pressure after the installation Make sure it is within the standard value and deliver the vehicle Perform ash cleaning to the DPR filter and then install it on the vehi cle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE Recheck the different...

Page 161: ...DPR filter and install it on the vehicle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE After the installation regenerate the DPR filter manually and recheck the differential pressure Make sure it is within the standard value and deliver the vehicle Perform soot cleaning to the DPR filter and then install it on the vehicle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE After th...

Page 162: ...vehicle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE After the installation regenerate the DPR cleaner manually and recheck the differential pressure Make sure it is within the standard value and deliver the vehicle Perform soot cleaning to the DPR filter and then install it on the vehicle Refer to 2 INSTALL THE DPR FILTER on page EN04 35 NOTICE After the installation regenerate the DP...

Page 163: ...R SURFACE 1 Visually inspect the filter rear surface to detect soot escapes black part Standard value No soot escape NO YES 3 INSPECT THE DPR FILTER WITH THE DEDI CATED CHECK PROBE Catalyst coated filter Oxidation catalyst Combustion chamber Ammonia slip catalyst DEF SCR catalyst DOC DPR DOC SCR catalyst SAPH011060400073 2 VISUALLY INSPECT THE CASE EDGE ...

Page 164: ... to detect soot escapes black part Standard value No soot escape NO YES DOC SCR catalyst DOC DPR Oxidation catalyst Catalyst coated filter Ammonia slip catalyst DEF SCR catalyst Combustion chamber SAPH011060400074 3 INSPECT THE DPR FILTER WITH THE DEDI CATED CHECK PROBE The DPR filter is normal ...

Page 165: ... 8mm 0 0315 in Grip for depth check Tighten a screw and am fixed Gas flow DOC DPR Filter Judgement Rear side The probe is inserted to the end The probe is stuck in the middle Taget part of insertion inspection Part with Inspect only black parts when the filter is partially black Correct Incorrect J08E SAPH011060400075 Replace with a new DPR filter and install it on the vehicle Refer to 2 INSTALL T...

Page 166: ...EXHAUST SYSTEM J08E EN04 45 AIR CLEANING FLOW SOOT SUCTION SOOT CLEANING SOOT AIR BLOW DISPOSE OF THE WASTE AND THE POWDER AS INDUSTRIAL WASTES SAPH011060400076 ...

Page 167: ...TEM J08E EN04 46 DIFFERENTIAL PRESSURE SENSOR COMPONENT LOCATOR EN0110604D100005 Tightening torque Unit N m kgf cm lbf ft 1 Differential pressure sensor 3 Muffler unit 2 Hose A 18 26 183 265 13 19 SAPH011060400077 ...

Page 168: ...e clamps and disconnect the hose from the differential pressure sensor NOTICE Do not allow foreign objects to get into the differential pressure pipe and hose 3 REMOVE THE DPR DIFFERENTIAL PRESSURE SENSOR 1 Remove the nut and the differential pressure sensor from the bracket Differential pressure sensor Connector SAPH011060400078 Differential pressure sensor Clamp Hose SAPH011060400079 Differentia...

Page 169: ...alue replace it INSTALL THE DIFFERENTIAL PRESSURE SENSOR 1 INSTALL THE DIFFERENTIAL PRESSURE SENSOR 1 Install the differential pressure sensor to the bracket with a nut Tightening Torque 18 26 N m 183 265 kgf cm 13 19 lbf ft Differential Pressure sensor A B C SAPH011060400081 Measurement item Standard value k A B 15 B C 15 Differential pressure sensor Bracket SAPH011060400082 ...

Page 170: ...ll not operate properly CAUTION Connect the white marks of the sensor and the pipe Insert the hoses certainly against the sensor body Insert the hoses certainly against the sensor spool 3 INSTALL THE HARNESS 1 Connect the connector to the differential pressure sensor Differential pressure sensor Clamp Clamp Hose SAPH011060400083 SAPH011060400084 Differential pressure sensor Connector SAPH011060400...

Page 171: ...t relay 9 Accelerator sensor 2 Exhaust relay 10 Engine ECU 3 Magnetic valve 11 Combination meter ECU 4 Exhaust control cylinder Exhaust brake 12 Exhaust brake light 5 Air tank 13 Exhaust brake switch 6 Exhaust pipe 1 To actuator power relay 7 Butterfly valve 2 To ABS ECU 8 Accelerator pedal SAPH011060400086 ...

Page 172: ...of foreign matter or water into the fuel tank Use of bad fuel Air filter element dirty clogged etc Damage to air cleaner body or air intake stack Damaged or bent air hose Damaged inter cooler body or hose Most recent program No Following characteris tic at the time of inspec tion Error within 5 YES NO YES NO YES NO YES NO Handling in case of NO judg ment Element replace ment Fuel sampling Investig...

Page 173: ...n oper ation Exhaust control valve operation No clinging or air leakage etc At the time of exhaust con trol valve opening adjust ment refer to the standard value table shown blow left Confirm the injection quan tity at the time of exhaust control valve is operating when the exhaust tempera ture has stabilized To be performed with all auxiliary equipment load off Gas leakage at the time of regenera...

Page 174: ...standard value table value with all auxiliary equipment loads off Idling normal Speed rpm 750 Injection quantity q 7 16 At the time of manual regeneration guide value Speed rpm 980 Backpressure standard Speed rpm 2 800 Backpressure kPa kgf cm2 lbf in 2 5 0 0 05 0 7 ...

Page 175: ...TING SYSTEM EN05 2 DIAGRAM EN05 2 OIL PUMP AND OIL STRAINER EN05 4 COMPONENT LOCATOR EN05 4 OVERHAUL EN05 5 INSPECTION AND REPAIR EN05 6 OIL FILTER AND OIL COOLER EN05 8 COMPONENT LOCATOR EN05 8 SPECIAL TOOL EN05 9 DISMOUNTING AND MOUNTING EN05 10 INSPECTION AND REPAIR EN05 11 ...

Page 176: ...LUBRICATING SYSTEM J08E EN05 2 LUBRICATING SYSTEM DIAGRAM EN0110605J100001 SHTS011060500001 ...

Page 177: ...ross head 6 Oil cooler safety valve 21 Supply pump 352 432 3 6 4 4 52 62 22 Air compressor 7 Oil filter full flow 23 Main idle gear 8 Oil filter by pass 24 Cam idle gear 9 Pressure switch 25 Sub idle gear 10 Oil filter safety valve 26 Check valve 137 157 1 3 1 6 20 23 245 2 5 36 11 Regulator valve 27 Check valve for turbocharger 490 570 5 0 5 8 72 82 28 Turbocharger 12 Main oil hole 29 Idle gear 1...

Page 178: ... COMPONENT LOCATOR EN0110605D100001 Tightening torque Unit N m kgf cm lbf ft 1 Gasket 6 Safety valve 2 Oil pump 7 Relief spring 3 Driven gear 8 Spring seat 4 Oil strainer 9 Cotter pin 5 O ring A 28 5 291 21 B 30 306 22 5 3 1 2 A 6 7 9 8 B 4 SHTS011060500002 ...

Page 179: ... If you change with the gasket misaligned the seal will be defective and cause all the oil in the oil pump to flow out when the engine is stopped The defective seal may also result in an insufficient oil suc tion quantity in the initial rotation when restarting the engine and cause seizure or abnormal wear 3 Tighten the oil pump mounting bolts provisionally in the order as shown in the figure Tigh...

Page 180: ... inside depth 43 1 693 End play With gasket 0 047 0 150 0 0019 0 0059 0 15 0 0059 Replace oil pump Without gasket 0 013 0 050 0 0005 0 0020 Drive gear Shaft out side diame ter 18 0 709 Measure Block side bushing inside diameter 18 0 709 Clearance 0 040 0 099 0 0016 0 0039 Replace oil pump Driven gear Shaft out side diame ter 18 0 709 Measure Block hole diameter 18 0 709 Clearance 0 030 0 075 0 001...

Page 181: ...LUBRICATING SYSTEM J08E EN05 7 Gear backlash 0 073 0 207 0 0029 0 0082 0 30 0 0118 Replace pump Measure Inspection item Standard Limit Remedy Inspection procedure ...

Page 182: ...LUBRICATING SYSTEM J08E EN05 8 OIL FILTER AND OIL COOLER COMPONENT LOCATOR EN0110605D100002 3 E 6 A 5 4 11 M 10 L I J F 9 C D B K 7 8 H 2 1 G SHTS011060500009 ...

Page 183: ...oler safety valve 4 Gasket 10 Oil filter element 5 Oil cooler case 11 Insert 6 Regulator valve A 29 4 39 2 300 400 22 28 H 29 4 39 2 300 400 22 28 B 24 5 34 3 250 350 19 25 I 19 6 29 4 200 300 15 21 C 39 2 49 400 500 29 36 J 29 4 39 2 300 400 22 28 D 19 6 29 4 200 300 15 21 K 19 6 29 4 200 300 15 21 E 19 6 29 4 200 300 15 21 L 39 2 49 400 500 29 36 F 24 5 34 3 250 350 19 25 M 98 1 117 7 1 000 1 20...

Page 184: ... side IMPORTANT POINT MOUNTING 1 INSTALL THE OIL FILTER 1 Remove the dust on installation surface of oil cooler case side 2 Apply the engine oil to the O ring on new oil filter 3 Install the oil filter by turning it lightly to the right by hand until it comes in contact with the surface of the oil cooler Then using the special tool tighten the oil filter about 270 360 3 4 1 turn SST Oil filter wre...

Page 185: ...onto the cylinder block then tighten the bolt to the specified torque Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft INSPECTION AND REPAIR EN0110605H300002 SHTS011060500014 Inspection item Standard Limit Remedy Inspection procedure Oil cooler air leakage Air pressure 588 kPa 6 kgf cm2 85 lbf in 2 0 mL Replace if neces sary Visual check Wear or damage to valve spring of oil cooler and oil filter R...

Page 186: ...OCATOR EN06 3 THERMOSTAT EN06 4 COMPONENT LOCATOR EN06 4 OVERHAUL EN06 5 RADIATOR AND INTERCOOLER EN06 7 COMPONENT LOCATOR EN06 7 OVERHAUL EN06 7 RADIATOR EN06 9 COMPONENT LOCATOR EN06 9 SPECIAL TOOL EN06 10 OVERHAUL EN06 10 INSPECTION AND REPAIR EN06 14 COOLING FAN EN06 15 COMPONENT LOCATOR EN06 15 INSPECTION AND REPAIR EN06 16 ...

Page 187: ...linder head 4 Coolant temperature gauge 13 Cylinder block 5 Thermostat case cover Outlet 14 Oil cooler 6 Thermostat case 15 Drain plug 7 Thermostat 16 Turbocharger 8 Thermostat case cover Inlet 17 Car heater 9 Air compressor 1 11 16 15 15 12 13 14 10 9 6 7 4 8 3 2 17 5 For cooling engine For cooling Auxiliary units Air bleeding SHTS011060600001 ...

Page 188: ...COOLING SYSTEM J08E EN06 3 COOLANT PUMP COMPONENT LOCATOR EN0110606D100001 1 Coolant pump assembly 3 O ring 2 Pulley 1 2 3 SHTS011060600002 ...

Page 189: ...COOLING SYSTEM J08E EN06 4 THERMOSTAT COMPONENT LOCATOR EN0110606D100002 1 Thermostat case 4 Water inlet 2 Water outlet 5 O ring 3 Thermostat 2 5 1 3 5 4 SHTS011060600003 ...

Page 190: ... is defective and must be replaced IMPORTANT POINTS ASSEMBLY 1 ASSEMBLE THE THERMOSTAT CASE NOTICE Remove water or dirt adhering to the thermostat case Be sure to replace the gasket if it is corroded damaged or flat tened Before installing the hose apply liquid gasket to the hose instal lation part of the thermostat case cover To prevent clogging of the radiator do not use a large amount of liquid...

Page 191: ... 1 Apply liquid gasket to the thermostat case 2 Install the o ring into the groove of the coolant pump 3 Temporarily tighten the bolts 1 and bolts 2 in that order and securely contact the fitting surface 4 Tighten the bolts in numeral order Liquid gasket SHTS011060600007 2 1 SHTS011060600008 ...

Page 192: ...RADIATOR WARNING Do not drain the coolant while the engine and radiator are still hot to avoid burns and scalds NOTICE When dismounting and mounting the radiator do not damage the radiator core 1 Radiator 6 Inter cooler 2 Inlet hose 7 Radiator stay RH 3 Reservoir tank 8 Radiator stay LH 4 Hose 9 Baffle plate 5 Outlet hose 4 6 2 8 9 3 7 5 1 SHTS011060600009 ...

Page 193: ...ortion of the radia tor Match the red mark of the radiator hose and match mark convex portion of the radiator 2 INSTALL THE RADIATOR OUTLET HOSE NOTICE Install the radiator hose against the convex portion of the radia tor Match the red mark of the radiator hose and match mark convex portion of the radiator SHTS011060600010 SHTS011060600011 ...

Page 194: ...SYSTEM J08E EN06 9 RADIATOR COMPONENT LOCATOR EN0110606D100004 1 Radiator assy 6 Sensor 2 Intercooler assy 7 Packing 3 Fan shroud 8 Drain plug 4 Radiator cap 9 Seal 5 Bracket 4 1 6 7 9 3 2 5 8 SHTS011060600012 ...

Page 195: ...re still hot to avoid burns and scalds NOTICE When dismounting and mounting the radiator do not damage the radiator core IMPORTANT POINTS DISASSEMBLY NOTICE Recaulking should be limited to twice 1 DISASSEMBLE THE UPPER TANK LOWER TANK AND RADIA TOR CORE 1 Remove the left support and right support Illustration Part number Tool name Remarks S0976 01030 RADIATOR TOOL TOOL FOR UNCAULKING S0976 01040 R...

Page 196: ...t NOTICE Do not lift up tangs more than 90 4 Remove the upper tank and lower tank from the radiator core by tap ping lightly with plastic hammer NOTICE Do not remove the tank by forcing or prying IMPORTANT POINTS ASSEMBLY 1 ASSEMBLE THE UPPER TANK LOWER TANK AND RADIATOR CORE 1 Exchange the crow of the radiator tool S0976 01030 for the radiator tool S0976 01040 as shown in the figure SST Radiator ...

Page 197: ...y rub the inside portion of the groove with the emery paper 4 Install the upper tank and lower tank into the groove of the radiator core 5 Tap the tangs to obtain a tight contact with the upper tank and lower tank 6 Press the radiator tool caulking tool against the side portion Tempo rarily caulk the tangs several times then proceed to the final caulking by gripping the handle until it hits the st...

Page 198: ...to the sequence as shown in the fig ure 7 Check the dimension C Assembly standard 8 2 8 8 mm 0 323 0 346 in If the dimension is out of the standard value adjust the stopper bolt of the handle once again and perform the caulking again SHTS011060600024 SHTS011060600025 ...

Page 199: ... damage of the engine When carrying out high pressure washing to remove fin clogging do not apply excessive pressure to the fins which may cause deformation and consequent performance deterioration Inspection item Standard Limit Remedy Inspection procedure Air leakage When the air pressure of 100 1 14 is applied Replace radiator Visual check Clogging of the fins Clean Radiator cap valve open ing p...

Page 200: ...of overheating or conversely is replaced with one of a smaller capacity due to overcooling the performance may in fact be reduced and durability may be jeopardized Other items Check the bimetal to see if there is any mud or dust on it If the bimetal is covered with mud or dust the fan per formance will be erratic and may result in overheating or overcooling In such case carefully remove mud and du...

Page 201: ...ING SYSTEM J08E EN06 16 INSPECTION AND REPAIR EN0110606H300002 Inspection item Standard Limit Remedy Inspection procedure Cooling fan and fan clutch deformation and damage Replace if neces sary Visual check ...

Page 202: ...PTION EN07 4 COMPONENT LOCATOR EN07 5 SPECIAL TOOL EN07 5 OVERHAUL EN07 6 COMMON RAIL EN07 15 DESCRIPTION EN07 15 REPLACEMENT EN07 17 INJECTOR EN07 21 DESCRIPTION EN07 21 REPLACEMENT EN07 22 FUEL FILTER EN07 30 DESCRIPTION EN07 30 AIR BLEEDING EN07 31 BUBBLE SEPARATOR EN07 33 DESCRIPTION EN07 33 FUEL TANK EN07 34 COMPONENT LOCATOR EN07 34 ...

Page 203: ...1 1 Injector 8 Fuel filter 2 Injection pipe 9 Fuel tank 3 Flow damper 10 Through feed pipe 4 Common rail 11 Overflow pipe 5 Pressure feeding pipe 12 Leakage pipe 6 Pressure limiter 13 Bubble separator 7 Supply pump 7 3 2 4 5 6 13 11 1 10 12 8 9 SAPH011060700001 ...

Page 204: ... COMPONENT LOCATOR EN0110607C100001 Tightening torque Unit N m kgf cm lbf ft 1 Injector 3 Common rail 2 Supply pump 4 Bubble separator A 12 3 126 9 C 25 250 18 B 44 450 32 5 1 2 4 3 C A B A Y Y Z f e e B e f SAPH011060700002 ...

Page 205: ...FUEL SYSTEM J08E EN07 4 SUPPLY PUMP DESCRIPTION EN0110607J100002 1 SAPH011060700003 1 Supply pump assembly ...

Page 206: ...rior to starting an engine overhaul it is necessary to have this special tool 1 Supply pump assembly 5 Bracket 2 Bearing holder case 6 Coupling assembly 3 O ring 7 Plug 4 Coupling flange A 63 7 650 47 C 28 5 290 21 B 28 5 290 21 Illustration Part number Tool name Remarks SZ105 08067 GUIDE BOLT B 3 2 7 3 5 4 A 6 C 1 SAPH011060700004 ...

Page 207: ... no more fuel comes out 5 Tighten the drain plug and the bleeder plug of the bubble separator Tightening Torque Drain plug 5 9 7 9 N m 60 2 80 5 kgf cm 4 4 5 8 lbf ft Bleeder plug 5 8 8 N m 51 89 7 kgf cm 3 7 6 5 lbf ft CAUTION Drain the fuel in accordance with the regulation of disposal specified in each region 3 REMOVING THE FUEL FILTER 1 Remove the fuel filter and the fuel pipe Refer to the cha...

Page 208: ...Prepare a reservoir and a waste cloth because fuel spills when remov ing the pressure feeding pipe CAUTION The pressure feeding pipes are nonreusable Be careful when numbering the pipe because the fuel pipe may be deformed 8 SETTING THE COMPRESSION STROKE TOP DEAD CENTER OF No 1 CYLINDER 1 Unfasten the bolts 2 pcs securing the flywheel housing cover and remove the flywheel housing cover from the f...

Page 209: ...er In this case remove the special tool turn the crankshaft and install the special tool again to see if it is seated Before turning the crankshaft do not fail to pull out the special tool Do not perform cranking with the special tool inserted 9 REMOVING THE SUPPLY PUMP CAUTION While working be careful not to make dirt and water enter parts Do not remove pipe A and pipe B Be careful not to apply e...

Page 210: ...ing holder case and the O ring from the supply pump INSPECTING THE COMPONENT PARTS 1 INSPECTING THE SUCTION CONTROL VALVE AND THE FUEL TEMPERATURE SENSOR 1 Using Hino DX inspect the suction control valve and the fuel temper ature sensor If some abnormalities are found replace the supply pump Air compressor Bearing holder case Supply pump Coupling Bolt O ring SAPH011060700015 Bearing holder case Sh...

Page 211: ...e sure that there is no dirt on the connection between them Air enters the fuel pipe in the process of mounting the pre fuel fil ter case After mounting is completed thoroughly purge air from the fuel pipe 1 COMPRESSION UPPER DEAD CENTER SETTING OF NO 1 CYL INDER 1 Turn the flywheel clockwise in the engine direction and align the No 1 cylinder mark to the pointer in the flywheel housing inspection...

Page 212: ...l tool to lock the shaft 4 Insert the special tool specified below into the bearing holder case and bring it into close contact with the detent of the coupling flange SST Guide bolt SZ105 08067 CAUTION Do not tighten the special tool by applying it to a part other than the detent of the coupling or do not use a tool other than the special tool for locking The special tool is not designed to allow ...

Page 213: ...d mount the timing checking window plug Before turning the crankshaft do not fail to pull out the special tool Do not perform cranking with the special tool inserted 7 Mount the flywheel housing cover to the flywheel housing with the bolts 2 pcs 4 MOUNTING THE PRESSURE FEEDING PIPE 1 Mount the pressure feeding pipe Tightening torque Supply pump side 44 N m 450 kgf cm 32 5 lbf ft Common rail side 4...

Page 214: ... lbf ft Inlet manifold side 30 N m 305 kgf cm 22 lbf ft Pressure limiter side 20 N m 205 kgf cm 15 lbf ft 2 Mount the clips 2 pcs with the nuts 2 pcs and fix the return pipe 6 CONNECTING THE HARNESS 1 Connect the connector to the fuel temperature sensor and suction control valve of the supply pump CAUTION Before connecting the connectors make sure that the terminals are free of a spark mark Return...

Page 215: ...0 RESET THE ECU DEFAULT VALUE NOTICE It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service replacement In addition the ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service replacement so ensure sufficient time several minutes is available Diagnosis tool refer to chapter FUEL CONTROL ECU default va...

Page 216: ...g to full throttle Use Hino DX to check the diagnosis code of the flow damper operation 2 If the diagnosis code of the flow damper operation is detected replace the relevant injector and inspect it again 3 If the same phenomenon occurs even after the injector is replaced replace the flow damper with a common rail assembly 2 3 4 1 SAPH011060700034 1 Common rail 3 Flow damper 2 Pressure limiter 4 Pr...

Page 217: ... common rail assembly WARNING When the pressure limiter is working fuel flows out at a high tempera ture and pressure Serious injury like scalding could result from this hot fuel being blown out under pressure 3 INSPECTING THE COMMON RAIL PRESSURE SENSOR 1 Using a circuit tester measure the resistance between the terminals If the measured value is in excess of the standard value replace the common...

Page 218: ...ctor from the male connector 2 DISCONNECTING THE FUEL PIPE 1 Unfasten the union bolt securing return pipe No 1 and disconnect the return pipe No 1 from the pressure limiter NOTICE Prepare a reservoir and a waste cloth because fuel spills when dis connecting the fuel pipe 3 REMOVING THE INJECTION PIPE 1 Remove the injection pipe from the common rail 4 REMOVING THE PRESSURE FEEDING PIPE 1 Remove the...

Page 219: ...ASSY 1 Install the common rail with 2 bolts Tightening Torque 28 5 N m 290 kgf cm 21 lbf ft CAUTION While working be careful not to make dirt and water enter parts Before mounting a part check that there is no dirt on the con nection between the parts 2 Connect the connector CAUTION Before inserting the connector check that there are no spark traces on the terminals NOTICE Be careful to prevent du...

Page 220: ...ipe 5 Tighten the pressure feeding pipe nuts to the specified torque 6 Fit the clips 2 pcs and fix the pressure feeding pipe Tightening Torque 44 N m 450 kgf cm 32 5 lbf ft CAUTION While working be careful not to make dirt and water enter parts Before mounting a part check that there is no dirt on the con nection between the parts Air enters the fuel pipe while working After working be sure to pur...

Page 221: ...fied value it may cause a fuel leak If the tightening torque of the nuts is greater than the specified value it may have a negative influ ence on the engine function As a result always perform torque management After mounting is completed fuel leak check using check func tions menu of Hino DX ...

Page 222: ...FUEL SYSTEM J08E EN07 21 INJECTOR DESCRIPTION EN0110607C100003 1 2 3 SAPH011060700047 1 Return joint bolt 3 Injector assembly 2 Gasket ...

Page 223: ...pe can be twisted easily Use care in handling 3 REMOVING THE INJECTOR HARNESS 1 Disconnect each connector connected to the injector 2 Unfasten the nuts 7 pcs securing the injector harness and remove the injector harness together with the injector harness bracket CAUTION The injector harness bracket can be twisted easily Use care in han dling NOTICE It is easy to disconnect the connectors by last d...

Page 224: ... a waste cloth because fuel spills when remov ing the injection pipes 5 REMOVING THE INJECTOR 1 Unfasten the bolts 2 pcs to remove the injection pipe oil seals 6 pcs and plates 6 pcs from the cylinder head 2 Unfasten the injector clamp mounting bolts to remove the injector and injector clamp 3 Remove the O ring NOTICE Replace the O ring with new one SAPH011060700045 SAPH011060700043 Plate Injectio...

Page 225: ... clothes to wipe off sludge without using any deter gent Use of detergent causes it to penetrate which may lead to elec tric failure 3 CLEANING THE INSIDE OF THE NOZZLE SEAT 1 If sludge sticks to the inside of the nozzle seat spray a detergent over it wipe it off with a waste cloth and wash it out with the detergent NOTICE If sludge sticks hard to the inside of the nozzle seat remove it with brush...

Page 226: ... Do not fix the injector clamp until the injection pipe is fit tempo rarily 2 Slip a new injection pipe oil seal on the injector and mount the plate with the bolts 2 pcs that secured it CAUTION Mount the injection pipe oil seal so that excessive force will not be applied to the injection nozzle If the injection pipe oil seal and the injection nozzle are out of position oil leakage or improper asse...

Page 227: ...Insufficient tightening will cause gas leakage which will result in the seizure of the nozzle Before reusing the injector clamp bolt be sure to apply oil to its washer and thread Use the torque wrench to tighten the bolt with the specified torque 5 Tighten the injection pipe to the specified torque Tightening Torque 44 N m 450 kgf cm 32 5 lbf ft Injection pipe Injector clamp Injector SAPH011060700...

Page 228: ...ncorrect compensation value may cause engine trou bles NOTICE Injector compensation value can be written by means of a combined use of the PC tool and QR code reader 1 Read the QR code of the injector by using the scanner of the QR code reader to create a compensation data file 2 Write the injector compensation value in the engine ECU from a com puter SAPH011060700045 QR code Injector SAPH01106070...

Page 229: ...face 2 Replace the gasket with a new one and mount the leakage pipe on the injector and the camshaft housing with the union bolts 7 pcs that fastened them Tightening Torque 12 3 N m 126 kgf cm 9 lbf ft CAUTION Do not reuse the old gasket The leakage pipe can be twisted easily Use care in handling Note that the thread pitch is different between the union bolts 6 pcs for the injector and the union b...

Page 230: ... bolt for the camshaft housing 5 MOUNTING THE HEAD COVER 1 Mount the head cover Refer to the chapter ENGINE MECHANICAL 6 AIR BLEEDING OF FUEL SYSTEM 1 Perform air bleeding Refer to the chapter AIR BLEEDING Camshaft housing side union bolt SAPH011060700066 ...

Page 231: ...FUEL FILTER DESCRIPTION EN0110607J100004 4 2 3 1 6 9 13 11 5 10 7 8 12 SAPH011060700068 1 Body 8 Stud 2 Cover 9 Drain valve 3 Collar 10 Filter 4 Vent cap 11 Label 5 Spring 12 Heater 6 Fuel pipe Out 13 Water level sensor 7 Seal ...

Page 232: ...death Do not smoke when performing maintenance on the fuel system Keep flame and heat away from the fuel system since the fuel is flammable and can cause a fire resulting in serious personal injury or death Any of these can result in personal injury and or property dam age due to fire Use the designated special tool and fuel filter wrench to tighten the fuel filter Use of an ordinary tool for exam...

Page 233: ...ut then close the drain valve and vent cap Drain minimum amount of fuel possible 5 Remove the drain plug of the bubble separator 6 Loosen the bleeder plug of the bubble separator 7 Drain until no more water comes out 8 Tighten the drain plug and the bleeder plug of the bubble separator Tightening Torque Drain plug 5 9 7 9 N m 60 2 80 5 kgf cm 4 4 5 8 lbf ft Bleeder plug 5 8 8 N m 51 89 7 kgf cm 3 ...

Page 234: ...SYSTEM J08E EN07 33 BUBBLE SEPARATOR DESCRIPTION EN0110607J100005 3 1 4 C A A C 2 5 9 6 7 8 SEC A A 1 1 SEC C C 1 1 SAPH011060700072 1 Body 6 Valve 2 Insert 7 Spring 3 Plug 8 Plug 4 Pipe 9 O ring 5 Cartridge ...

Page 235: ...FUEL SYSTEM J08E EN07 34 FUEL TANK COMPONENT LOCATOR EN0110607J100006 5 6 50GAL 50GAL C B 1 8 2 4 10 A 3 7 1 LH side LH side 90GAL 50GAL UP FR LH UP RH FR UP RH FR SAPH011060700073 ...

Page 236: ...gf cm lbf ft Nonreusable Be sure to use new parts 1 Fuel tank 6 Gasket 2 Fuel tank band 7 Plug 3 Pin 8 Joint 4 Fuel tank support 9 Hose 5 Fuel sender 10 Plate fuel tank set A 91 2 136 8 930 1 396 67 100 C 0 5 0 7 5 7 0 362 0 506 B 23 29 234 5 296 17 21 4 ...

Page 237: ...TURBOCHARGER J08E EN08 1 EN08TURBOCHARGER J08E EN08 001 TURBOCHARGER EN08 2 DESCRIPTION EN08 2 TROUBLESHOOTING EN08 3 OVERHAUL CRITERIA EN08 19 ...

Page 238: ...608C100001 NOTICE This turbocharger should not be disassembled unless by turbocharger manufacture The turbocharger parts cannot be replaced 4 2 3 1 SHTS011060800001 1 Turbine housing 3 Center housing and rotating assy 2 Compressor housing 4 Actuator assembly ...

Page 239: ...See Note H Leakage at turbocharger mounting flange Turbocharger rotating assembly binding or dragging Restricted duct between air cleaner and turbocharger Restricted duct between compressor and engine intake Check condition of gasket at turbocharger mounting flange and tighten loose bolts Perform troubleshooting procedures outlined in table 1 7 Remove restriction or replace turbocharger as necessa...

Page 240: ...e tween air cleaner and turbocharger compressor NO NO NO Seal leakage at compressor end of turbocharger Engine malfunction rings pistons valves etc Remove restriction or replace damaged parts as necessary Perform troubleshooting procedures outlined in Table 1 6 Refer to engine manufacturer s service manual YES Seal leakage at turbine end of turbocharger Perform troubleshooting procedures outlined ...

Page 241: ...on wheel Seal leakage at turbine end of turbocharger indicated by oil in housing or on wheel Oil in engine exhaust manifold indicating malfunction of rings pistons valves etc Service engine lube system in accordancewith engine service manual manufacturer s Perform troubleshoot ing procedures out lined in Table 1 6 Perform troubleshooting procedures outlined in Table 1 9 Refer to engine manufacture...

Page 242: ... foreign object Repair air intake system and replace turbocharger as necessary Remove foreign object Repair air intake system and replace turbocharger as necessary Remove foreign object Repair exhaust system and replace turbocharger as necessary Symptom or trouble NO NO NO YES YES YES YES Carbon build up in turbine housing Turbocharger rotating assembly binding or dragging Clean housing or replace...

Page 243: ...using or wheel Clean and repair air intake system as necessary Replace turbocharger Clean and repair engine exhaust system as necessary Replace turbocharger Worn bearings shaft journals or bearing bores Replace turbocharger Clean and repair air intake system as necessary Clean compressor or replace turbocharger Symptom or trouble NO NO NO YES YES YES YES Excessive carbon build up behind turbine wh...

Page 244: ...l Restricted turbo charger oil drain line NO Plugged engine crankcase NO Worn or damaged compressor wheel NO Turbocharger bearings bearing bores or shaft journals worn NO YES YES YES YES Clean and remove restriction or replace oil drain line as required Refer to engine manufacturer s service manual Clean and repair air intake system as necessary Replace turbocharger Perform troubleshooting procedu...

Page 245: ...facturer s service manual Clean and remove restriction or replace oil drain line as required Service engines lubrication system Replace turbocharger Turbocharger bearings bearing bores or shaft journals worn NO Engine malfunction excessive piston blow by or high internal crankcase pressure YES YES Perform troubleshooting procedures out lined in Table 1 8 Refer to engine manufacturer s service manu...

Page 246: ... YES YES YES Follow pre oiling instructions Service engine lube system in accordance with engine manufacturer s service manual Follow proper engine operating procedures Remove restriction or replace turbocharger as necessary Plugged engine oil filter NO Abrasive wear due to flaking of particles from center housing internal surfaces NO Insufficient lube oil supplied to turbocharger due to engine oi...

Page 247: ...amage With the engine stopped check the turbocharger shaft wheel assembly for damage as outlined Note I below F With engine running a change in the noise level to a higher pitch can indicate air leakage between the air cleaner and the engine or a gas leak between the engine block and the turbocharger inlet G Exhaust gas leakage may be indicated by hat discoloration in the area of the leak H With t...

Page 248: ...DARAINING THE COOLANT 1 Drain the coolant Reference COOLING SYSTEM J08E 2 DISCONNECTING THE HARNESS 1 Disconnect the electric actuator connector 3 REMOVING THE INTAKE PIPE EXHAUST SIDE 1 Remove the intake pipe exhaust side Reference AIR INTAKE SYSTEM J08E 4 REMOVING THE TURBOCHARGER INSULATOR 1 Unfasten the bolts to remove a turbocharger insulator upper from a turbocharger assembly 2 Unfasten the ...

Page 249: ...disconnecting the coolant pipe 3 Block water holes of the turbocharger assembly to prevent entry of foreign matters CAUTION Use special care to prevent the entry of foreign matter into the turbo charger assembly 6 REMOVING THE EXHAUST PIPE 1 Inspect the turbine shaft play on the exhaust side Reference EXHAUST SYSTEM J08E 7 DISCONNECTING THE OIL PIPE 1 Unfasten the bolt and union bolts to remove th...

Page 250: ... REMOVING THE TURBOCHARGER ASSEMBLY 1 Unfasten the nuts to remove the turbocharger assembly and gasket from the exhaust manifold CAUTION The electric actuator is plastic and easily damaged Use care to place it in an appropriate direction for storage after removal Heat resisting steel is used for bolts and nuts Do not mix them with ordinary bolts and nuts when mounting 2 After removing the turbocha...

Page 251: ...used for bolts and nuts Do not mix them with ordinary bolts and nuts when mounting Mount the turbocharger securely so that there is no gas leakage from the connections of the exhaust pipe NOTICE If the stud bolt of the exhaust flange is stuck use a commercially available stud bolt remover to remove and replace the stuck stud bolt 2 MOUNTING THE OIL PIPE 1 Replace with new gaskets and connect the o...

Page 252: ...e to avoid defects such as damage by clogging or loosening at the tightening portion 2 Replace with new gaskets and connect the coolant pipe E to the tur bocharger assembly with union bolts NOTICE Clean the oil pipe and check the pipe for collapse and dirt and foreign matters inside Do not use any sealant on the oil pipe installation surface to avoid defects such as damage by clogging or loosening...

Page 253: ...T SIDE 1 Mount the intake pipe exhaust side Reference INTAKE SYSTEM J08E 7 CONNECTING THE HARNESS 1 Connect the connector to the electric actuator 8 FEEDING ENGINE OIL 1 Inspect the engine oil level if insufficient add engine oil Reference ENGINE INTRODUCTION J08E 9 ADDING THE COOLANT 1 Add the coolant Reference COOLING SYSTEM and ENGINE MAECHANI CAL J08E Turbocharger insulator lower SAPH01Z080800...

Page 254: ... Do not run engine at idle or at a high speed immediately after starting the engine If the turbocharger is operated without suffi cient lubrication at the beginning of engine start it may cause bearing seizure If the engine is stopped suddenly the turbocharger keeps rotat ing with no oil pressure applied which may result in a worn bear ing due to absence of oil film NOTICE Run the engine at idle f...

Page 255: ...auled after completion of the remainder of this trouble shooting procedure WARNING Operation of the turbocharger without the intake pipe and air cleaner connected can result in personal injury and damage to equipment from foreign objects entering the turbocharger 3 INSPECTION TURBINE WHEEL AND HOUSING Remove the duct from the turbine outlet Using a flash light check the turbine for wheel to housin...

Page 256: ...stricted air intake system c Oil leakage into the compressor can be caused by frequent use of the engine as a brake In this case nothing is wrong with either the engine or the turbocharger but frequent compressor wheel and housing clean up is recommended 3 Foreign object damage If the compressor wheel has been damaged by a foreign object the turbocharger must be overhauled 5 SIMPLE INSPECTION OF T...

Page 257: ...LATOR EN10 7 DESCRIPTION EN10 7 REPLACEMENT OF CLOSED VENTILATOR EN10 7 SELECTIVE CATALYTIC REDUCTION SCR EN10 8 GENERAL DESCRIPTION EN10 8 COMPONENT LOCATOR EN10 10 INSPECTION EN10 11 DISMOUNTING AND MOUNTING EN10 12 INSPECTION AND REPAIR EN10 27 BURNER SYSTEM EN10 28 COMPONENT LOCATOR EN10 28 BURNER SYSTEM WARNING AND CAUTION EN10 29 DISMOUNTING AND MOUNTING EN10 30 INSPECTION AND REPAIR EN10 39...

Page 258: ...MPONENT LOCATOR EN0110610J100001 Tightening torque Unit N m kgf cm lbf ft 1 EGR cooler sub assembly 6 Water pipe sub assembly 2 Gasket 7 Water pipe sub assembly 3 EGR pipe assembly 8 Water pipe 4 Gasket 9 Water hose 5 EGR valve A 55 560 40 SHTS011061000001 ...

Page 259: ...EMISSION CONTROL J08E EN10 3 EGR VALVE DESCRIPTION EN0110610J100002 SHTS011061000002 1 EGR valve assembly 3 Butterfly valve 2 DC Motor ...

Page 260: ...f the engine 1 Disconnect the harness coupler 2 Drain the coolant out of the drain plug of oil cooler situated on the right side of the engine 3 Disconnect and remove all pipes connected to the EGR pipe as well as coolant hose and related parts 4 Remove EGR pipe 5 Remove EGR cooler sub assembly 6 Remove EGR valve from intake pipe EGR pipe EGR valve Coupler Front of vehicle SHTS011061000003 SHTS011...

Page 261: ...not to hit the EGR valve lever with a tool when you are removing or installing the valve 2 INSPECT THE EGR COOLER 1 Visually inspect cracks or clogging in the main body gas passage and sub coolant piping In case a trouble is found replace the EGR cooler with a new one IMPORTANT POINTS MOUNTING 1 INSTALL THE EGR VALVE 1 Install the EGR valve to the intake pipe with new gaskets 2 Install the EGR coo...

Page 262: ...plug of the oil cooler situated on the right side of the engine NOTICE Fit the exhaust manifold gasket with the claw of the gasket facing down 6 Connect the harness coupler SHTS011061000009 EGR pipe EGR valve Coupler Front of vehicle SHTS011061000010 ...

Page 263: ...LOSED VENTILATOR EN0110610H200002 1 REMOVE THE CLOSED VENTILATOR 1 Remove the hoses and then the closed ventilator 2 INSTALL THE CLOSED VENTILATOR 1 Connect the hoses and install the closed ventilator 5 4 2 1 3 SHTS011061000011 1 Body 4 Cap 2 Filter 5 Safety valve 3 PCV valve SHTS011061000012 ...

Page 264: ... DEF it will be separated it to harmless water and nitrogen It is an extremely effective dependable efficient and economical selection What is DEF DEF is an abbreviation for Diesel Exhaust Fluid a solution made from 67 5 purified water and 32 5 automotive grade urea that serves as a carrying agent for the ammonia needed to reduce nitro gen oxide NOx emissions from diesel engines When DEF is inject...

Page 265: ...tomization module Burner control unit BCU Fuel tank Air tank DEF indicator MIL DPR switch Battery Reverting valve Filter Motor Pressure sensor DEF pump Combustion air Exhaust brake valve Feed Backflow Suction Feed Return Pressure Pressure sensors Turbocharger Feed Return Exhaust gas Feed Ambient air temperature sensor Coolant cut off valve Combustion air valve Air drier Coolant line DEF line with ...

Page 266: ...F tank 6 Exhaust gas temperature sensor 2 DEF level sensor 7 NOx sensor 3 DCU Dosing control unit 8 SCR catalyst inlet temperature sensor 4 DEF pump 9 Ambient temperature sensor 5 DEF injector 10 Burner flame temperature sensor 6 9 4 3 5 7 6 7 2 10 8 1 1 SHTS011061000014 ...

Page 267: ...tration 31 8 33 2 2 PH TEST PAPER INSPECTION 1 Extract DEF put few drops on the pH test paper to measure the color change and replace the DEF if the value is outside the standard value HINT When the digital type tester is used standard value is 9 0 to 9 5 3 REFRACTIVE INDEX MEASUREMENT INSPECTION 1 Extract DEF put few drops on the refractometer to measure the refractive index and replace the DEF i...

Page 268: ...pped hot coolant may spout and you may get burned Before performing work be sure that engine coolant is thor oughly cooled Formed tubes are used for DEF plumbing Do not apply an excessive force to tubes when working If a tube is bent must to be replaced Do not directly touch an DEF or coolant flowing out from the plumbing If you have touched it thoroughly rinse it out After removal place a plastic...

Page 269: ...battery disconnect switch when it is necessary to break the supply of electricity completely Otherwise electricity may remain supplied from the battery by the circuit that bypasses the battery disconnect switch and you may get burns or injury from the electricity 2 Dismount the steps top and bottom and insulator on the right side of the vehicle 3 Dismount the front fender SHTS011061000015 SHTS0110...

Page 270: ...TICE Pull the tab on the connector side surface to remove the connec tor Do not touch the connector pin with bare hand Do not have an impact on DCU If dropping the DCU do not reuse it because of concern that inside of DCU is damaged Protect the removed connectors from dirt and dust c Remove the DCU bracket mounting nut Dismount the DCU along with the bracket d Remove the nut and then dismount the ...

Page 271: ... 82 122 kgf cm 6 8 lbf ft DCU Tightening Torque 18 26 N m 184 265 kgf cm 14 19 lbf ft DCU bracket b Connect the harness connectors 53 pin and 86 pin to the DCU NOTICE Press the tab on the connector side surface until a click is heard c Mount the DCU cover Tightening Torque 18 26 N m 184 265 kgf cm 14 19 lbf ft SHTS011061000020 SHTS011061000021 SHTS011061000022 ...

Page 272: ...e from entering the DEF tank via the DEF hose connection when removing it HINT Coolant will spout if the coolant hose is removed Drain coolant beforehand or block the hose with the vice grip plier If you use the vice grip at the area as shown in the figure below you can minimize leakage of coolant e Disconnect the harness connector and then remove the DEF tank NOTICE Remove the harness connector l...

Page 273: ...hoses c Connect the harness connector NOTICE Tighten clockwise the connector connecting to the DEF sensor until a click is heard d Fix the DEF tank with the rod stay and nut Tightening Torque 21 7 30 3 N m 222 308 kgf cm 16 22 3 lbf ft e Mount the drain plug to the DEF tank Pour the DEF SHTS011061000026 SHTS011061000027 ...

Page 274: ... pipe When taking out the sensor from inside the tank be careful not to damage the sensor by hitting the tank edge c Check if the DEF sensor float moves smoothly d Insert the DEF sensor to the DEF tank Rotate it to mount NOTICE Replace the O ring between the tank and sensor with a new one Thoroughly wipe off crystals of DEF precipitating on the mount ing surface with a clean cloth Check that the t...

Page 275: ...harness wire connector Disconnect it from the DEF pump NOTICE Be careful to prevent the coolant and DEF residues in the cool ant and DEF hoses from wetting the harness connector terminal Protect the removed connector from dirt and dust e Remove the mounting bolt of the DEF pump f Remove the coolant and DEF hoses connected to the DEF pump HINT Lower the DEF pump to secure working space g Dismount t...

Page 276: ...3 REPLACE THE COOLANT CONNECTOR OF THE DEF PUMP a When the connector is exchanged the O ring must not be used two times NOTICE All sealing surface must be clean contamination or particles are not acceptable Mounting torque for connector 5 0 6 0 N m 51 61 kgf cm 3 7 4 4 lbf ft Wrench size 15 mm 0 59 in For the mounting process oil the O ring with Mobile velocite oil No 61 DEF pump Connector Band cl...

Page 277: ... cm 3 0 3 6 lbf ft Wrench size 17 mm 0 67 in For the mounting process oil the O ring with Mobile velocite oil No 61 6 REPLACE THE DEF BACKFLOW CONNECTOR OF THE DEF PUMP a When the connector is exchanged the O ring must not be used two times NOTICE All sealing surface must be clean Contamination or particles are not acceptable Mounting torque for connector 4 0 5 0 N m 41 51 kgf cm 3 0 3 6 lbf ft Wr...

Page 278: ...n or particles are not acceptable It must be checked if there are cracks around the area of the filter cover No cracks in the material are allowed If there are cracks in the housing the entire supply module must be exchanged If there are cracks in the filter cover the filter cover must be exchanged Wrench size 27 mm 1 06 in Mounting torque for connector 20 25 N m 204 255 kgf cm 15 18 lbf ft Equali...

Page 279: ...e area as shown in the figure below you can minimize leakage of coolant c Remove the nut and then dismount the DEF injector and gasket from the muffler unit 2 IMPORTANT POINT MOUNTING a When the DEF injector is reused must to replace with a new gas ket and attach the DEF injector to the muffler unit with the nut Tightening Torque 6 10 N m 61 102 kgf cm 4 4 7 4 lbf ft DEF hose Harness wire Coolant ...

Page 280: ...sealing surface on the cooling body if necessary NOTICE Take care when cleaning the sealing interfaces avoid scratches Do not touch the orifice plate c Mount new gasket NOTICE The sealing interfaces must be clean Place the gasket on the interface and press on Avoid any damages or scratches on the gasket Dosing module with fully mounted gasket see figure DEF hose Harness wire Coolant Connector Inje...

Page 281: ...bolt e Remove the hose 2 clamp and remove the hose 2 engine coolant valve side only NOTICE Coolant will spout if the coolant hose is removed Drain coolant beforehand or block the hose with the vice grip If you use the vice grip at the area as shown in the figure below you can minimize leakage of coolant 2 IMPORTANT POINT MOUNTING a Connect the hose 2 to the engine coolant valve and fix it with cla...

Page 282: ...e the clips b Disconnect the harness coupler c Remove the NOx sensor controller d Remove the sensor NOTICE After removing the sensor check that there is no entry of foreign mat ters inside the muffler 2 IMPORTANT POINT MOUNTING a Mount the sensor Tightening Torque 40 60 N m 407 611 kgf cm 29 44 lbf ft Sensor Tightening Torque 3 9 7 1 N m 40 72 kgf cm 2 9 5 2 lbf ft Controller b Mount the NOx senso...

Page 283: ...ghtening Torque 3 9 7 1 N m 40 72 kgf cm 2 9 5 2 lbf ft Controller b Mount the NOx sensor controller c Connect the harness coupler d Mount the clips NOTICE When reassembling apply anti seizure lubricant to the temperature sensor INSPECTION AND REPAIR EN0110610H300001 Inspect the SCR related components in accordance with the table below and perform a repair or replacement if necessary Clip Sensor C...

Page 284: ...OMPONENT LOCATOR EN0110610J100004 1 Fuel filter 6 Burner control unit 2 Fuel pump 7 Nozzle 3 Atomizer 8 Flame temperature sensor 4 Combustion air valve 9 Ignition plug 5 Ignition coil 10 Combination chamber 9 7 10 8 6 4 3 5 2 8 1 SHTS011061000063 ...

Page 285: ...ponents to prevent death or serious personal injury and damage to compo nents The burner system oxidizes and releases heat into the exhaust outlet Depending on the amount of soot exhaust outlet temperatures during regeneration can exceed 1 290 F 700 C Do not touch the exhaust outlet Do not park a vehicle under objects such as trees and awnings which can ignite from the extremely high exhaust outle...

Page 286: ... the battery in accordance with the procedures in this manual and never use the battery disconnect switch when it is necessary to break the supply of electricity completely Otherwise electricity may remain supplied from the battery by the circuit that bypasses the battery disconnect switch and you may get burns or injury from the electricity 2 Dismount the steps top and bottom and insulator on the...

Page 287: ... POINT DISMOUNTING a Disconnect the harness wire connector from the combustion air valve b Remove the air hose on the engine side c Remove the air hose on the combustion chamber side d Remove the bolts and then dismount the combustion air valve NOTICE When removing be sure to remove the swivel on the vehicle upper side After removal be careful to avoid entry of foreign matter into the pipe BCU Har...

Page 288: ...connectors 2 places d Disconnect the ignition coil harness connector e Remove the fuel pipe eye joint f Disconnect the fuel hose g Disconnect the air tube h Remove the atomized fuel line on the front of the combustion chamber i Detach the ignition cable on the front of the combustion chamber j Remove the fuel pipe joint bracket bolts 2 places k Remove the atomizer mounting bolt from the burner acc...

Page 289: ...UNTING a Remove the solenoid valve Refer to SOLENOID VALVE for details b Disconnect the ignition coil harness connector c Disconnect the ignition cable d Remove the ignition coil mounting bolt from the burner accessory module bracket 2 places and remove the ignition coil 2 IMPORTANT POINT MOUNTING a Installation is the reversal of the removal Tightening Torque 9 N m 92 kgf cm 6 6 lbf ft Ignition c...

Page 290: ...oval be careful to avoid entry of foreign matter into the removed pipe If rust is gathered around the nut on the front of the combustion chamber blow air before removal to avoid rust from getting into the combustion chamber 2 IMPORTANT POINT MOUNTING a Installation is the reversal of the removal Tightening Torque 6 N m 62 kgf cm 4 4 lbf ft Fuel pipe clip SHTS011061000073 SHTS011061000074 ...

Page 291: ...tion is the reversal of the removal NOTICE When reassembling apply anti seizure lubricant Ignition plug gap range 2 5 3 5mm 0 1 0 14in Use ignition plug gap checking tool to confirm gap 8 IGNITION CABLES 1 IMPORTANT POINT DISMOUNTING a Remove the clip b Disconnect the ignition cable by twisting pulling motion NOTICE After removal be careful to avoid entry of foreign matter into the removed ignitio...

Page 292: ...o avoid entry of foreign matter into the removed harness connector and combustion chamber If rust is gathered around the nut on the front of the combustion chamber blow air before removal to avoid rust from getting into the combustion chamber 2 IMPORTANT POINT MOUNTING a Mount the temperature sensor Tightening Torque 42 3 47 7 N m 432 486 kgf cm 32 35 lbf ft b Mount the clips c Connect the harness...

Page 293: ...getting into the combustion chamber 2 IMPORTANT POINT MOUNTING a Mount the temperature sensor Tightening Torque 5 3 5 9 N m 54 60 kgf cm 3 9 4 3 lbf ft b Connect the harness connector NOTICE When reassembling apply anti seizure lubricant 13 DIFFERENCE PRESSURE SENSOR 1 IMPORTANT POINT DISMOUNTING a Remove the clip Remove the hose between the pipe and differen tial pressure sensor b Remove the nut ...

Page 294: ...ine 15 FUEL FILTER 1 IMPORTANT POINT DISMOUNTING a Remove the clip and then the fuel hose b Dismount the fuel filter from the No 3 crossmember NOTICE After removal be careful to avoid entry of foreign matter into the removed filter and hose CAUTION While working be careful not to make dirt and water enter parts 2 IMPORTANT POINT MOUNTING a Mount the fuel filter to the No 3 crossmember b Connect th...

Page 295: ...replacement if necessary Item Content Action Travel distance DPR filter Ash deposition Clean up 200 000 mile Hose for difference pressure sensor Replacement Replacement 3 years Burner fuel injection nozzle Replacement Replacement 150 000 mile Burner flame temperature sensor Replacement Replacement 150 000 mile Fuel filter element for burner Replacement Replacement 2 years ...

Page 296: ...2V 130A 135A 180A EN11 1 EN11ALTERNATOR EN11 J08E REMY 12V 130A 135A 180A EN11 001 ALTERNATOR EN11 2 DATA AND SPECIFICATIONS EN11 2 TROUBLESHOOTING EN11 2 COMPONENT LOCATOR EN11 3 OVERHAUL EN11 4 INSPECTION AND REPAIR EN11 7 ...

Page 297: ... not light with starter switch ON and engine off Fuse blown Determine cause and replace fuse Light burned out Replace light Wiring connection loose Tighten loose connections IC regulator faulty Replace IC regulator Charge warning light does not go out with engine running Battery requires frequent recharging Drive belt loose or worn Adjust or replace drive belt Battery cables loose corroded or worn...

Page 298: ...OCATOR EN0110611D100001 Tightening torque Unit N m kgf cm lbf ft 1 Brace 4 Bracket 2 Tensioner pulley 5 V belt 3 Alternator 6 Idler pulley A 88 897 65 D 68 5 700 51 B 93 948 69 E 68 5 700 51 C 80 95 816 968 59 70 Example 2 5 E D B 1 4 3 6 C A SHTS011061100001 ...

Page 299: ... an injury If a tool is shorted at alternator BAT terminal the tool can quickly heat enough to cause a skin burn NOTICE Always reinstall fasteners at original location If necessary to replace fasteners use only correct part number or equivalent If correct part number is not available use only equal size and strength For alternator internal fasteners refer to Delco Remy America Standard Hardware Fa...

Page 300: ...TICE Turn the tension pulley in the same way as for the belt removal and install the belt NOTICE When installing the drive belt use the gauge on the belt tensioner 1 to confirm that the tensioner arm is correctly positioned View from A Alternator Idler pulley Fun pulley Crankshaft pulley Auto tensioner SHTS011061100005 Alternator Wrench SHTS011061100006 View A View A Belt usage limit line Belt usa...

Page 301: ... 136 and or 146 Tightening Torque 130A 135A 2 0 N m 20 kgf cm 17 7 lbf in 180A 4 0 N m 40 kgf cm 35 4 lbf in 2 Cap 138 to the R or Relay pin terminal stud 146A if necessary 3 Ground lead 110 to GRD hole in SRE housing 1 with screw assembly 159 Tightening Torque 6 N m 61 kgf cm 55 lbf in 4 BAT output lead 111 washer 122 and nut 121 to BAT terminal stud 125 Tightening Torque 130A 180A 11 N m 112 kgf...

Page 302: ...N AND REPAIR EN0110611H300001 Inspect the alternator related components in accordance with the table below and perform a repair or replacement if necessary View A View A Belt usage limit line Belt usable range New belt setting range Indicator Engraved line Alternator SHTS011061100010 Item Content Action Travel distance 130A 180A Alternator Replacement Replacement 250 000 mile 135A Alternator Repla...

Page 303: ...TARTER J08E EN12 1 EN12STARTER J08E EN12 001 STARTER EN12 2 DATA AND SPECIFICATIONS EN12 2 DESCRIPTION EN12 2 TROUBLESHOOTING EN12 3 COMPONENT LOCATOR EN12 4 OVERHAUL EN12 5 INSPECTION AND REPAIR EN12 9 ...

Page 304: ...ated output 12 V 4 8 kW Number of teeth of pinion 11 Module 3 Rotating direction Clockwise Seen from pinion side SHTS011061200001 1 Holder assembly 7 Pinion gear 2 Brush 8 Drive housing assembly 3 Yoke assembly 9 Armature assembly 4 Magnetic switch assembly 10 Field coil 5 Lever 11 Commutator end frame 6 Drive shaft 12 Clutch assembly ...

Page 305: ...ine does not crank or cranks slowly Starter Brush worn out Replace Commutator burnt out Replace the armature assembly Commutator worn out Field winding shorted or grounded Replace the yoke assembly Armature winding shorted or grounded Replace the armature assembly Insufficient brush spring tension Replace the brush spring Poor contact between magnetic switch and field windings Repair Armature cont...

Page 306: ...gear 9 Brush holder 2 Drive housing assembly 10 End frame 3 Main switch assembly 11 Through bolt 4 Clutch assembly 12 Lever assembly 5 Internal gear assembly 13 Terminal 6 O ring 14 Cover 7 Armature assembly 15 Plate 8 Yoke assembly A 17 173 12 5 C 139 169 1 418 1 723 103 124 B 21 214 15 5 SHTS011061200002 ...

Page 307: ...ring may spring out the groove at the time of removal 2 Remove the pinion stopper 3 Remove the pinion gear 4 Remove the return spring 2 REMOVE THE TERMINAL LEAD 1 Remove the nut disconnect the M terminal lead 3 REMOVE THE COMMUTATOR END FRAME 1 Remove the bolt SHTS011061200003 D Diameter 110 mm 4 331 in T Thickness 10 mm 0 394 in H Height 120 mm 4 724 in Pinion gear Pinion stopper Retainer ring Re...

Page 308: ...ing a long nose plier remove the brush of the yoke from the holder 2 Remove the holder assembly from the armature 5 REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEMBLY 1 Remove the yoke assembly and armature assembly from the center bracket assembly SHTS011061200007 SHTS011061200008 SHTS011061200009 SHTS011061200010 ...

Page 309: ...ve the planetary gear 3 Remove the internal gear 7 REMOVE THE DRIVE HOUSING ASSEMBLY 1 Remove the bolt remove the drive housing assembly 8 REMOVE THE CLUTCH ASSEMBLY 1 Remove the retainer ring 2 Pushing the clutch assembly toward yoke assembly 3 Remove the clutch assembly SHTS011061200011 SHTS011061200012 SHTS011061200013 SHTS011061200014 ...

Page 310: ...T POINTS INSPECTION NOTICE These tests must be performed within 3 to 5 seconds to avoid burning out the coil 1 PERFORM NO LOAD PERFORMANCE TEST 1 Connect battery and ammeter to the starter as shown 2 Check that the starter rotates smoothly and steadily with the pinion gear moving out Check the reading on the ammeter Standard amperage 220 A or less 11 V SHTS011061200015 SHTS011061200016 1 Front bea...

Page 311: ...ore 10 k or more 10 k Replace Measure Armature short circuit test Using a growler tester If the iron piece does not vibrate the armature is good Replace Measure Measure the circle run out 0 05 0 0020 Replace Measure Outside diameter of the commutator 34 0 1 338 33 0 1 299 Replace Measure Depth between the mica and the commutator Under cut depth 0 7 0 028 0 2 0 008 Replace or repair Measure Continu...

Page 312: ...33 Replace Measure Brush spring load 45 N 162 oz 17 N 61 20 oz Replace Measure Insulation between the brush and brush holder 10 k or more 10 k Replace Measure Rotating of pinion Replace Visual check Rotating of needle roller front bearing Sticks or does not rotate Replace Visual check Inspection item Standard Limit Remedy Inspection procedure Continuity Ohmmeter No continuity Ohmmete LENGTH No con...

Page 313: ...ce Visual check Continuity between ter minals 50 and C 1 or less 1 Replace Measure Continuity between ter minal 50 and the switch body 2 or less 2 Replace Measure Inspection item Standard Limit Remedy Inspection procedure Continuity Terminal C Terminal 50 Ohmme Continuity Terminal 50 Ohmmeter ...

Page 314: ...13 1 EN13AIR COMPRESSOR J08E 340 cm3 EN13 001 AIR COMPRESSOR EN13 2 DATA AND SPECIFICATIONS EN13 2 DESCRIPTION EN13 3 TROUBLESHOOTING EN13 4 COMPONENT LOCATOR EN13 5 SPECIAL TOOL EN13 6 OVERHAUL EN13 6 INSPECTION AND REPAIR EN13 14 ...

Page 315: ...ESSOR DATA AND SPECIFICATIONS EN0110613I200001 Type Reciprocating single cylinder Discharge amount 340 cm3 20 7 cu in Bore x stroke 85 mm x 60 mm 3 35 in x 2 36 in Lubrication system Forced feed lubrication Cooling system Forced water circulated ...

Page 316: ...0613C100001 Nonreusable part 2 1 4 5 6 7 9 3 11 10 6 8 A B SAPH011061300001 1 O ring 8 Bearing holder 2 Cylinder head assembly 9 Crankcase 3 Suction valve 10 Piston pin 4 Piston 11 Piston ring 5 Connecting rod A Suction 6 Bearing B Delivery 7 Crankshaft ...

Page 317: ...lement Noisy operation Piston Wear of piston pin boss or piston pin Replace Seized damaged or worn connecting rod small end Replace Worn piston or cylinder liner Replace Damaged or seized piston Replace Foreign particles on the top surface of piston Clean or replace Noisy operation Bearing Damaged or worn ball bearing and or connecting rod bearing Replace Excessive carbon or oil in the com pressor...

Page 318: ...AIR COMPRESSOR J08E 340 cm3 EN13 5 COMPONENT LOCATOR EN0110613D100001 E A 5 6 7 8 13 12 18 21 D 17 7 8 15 13 16 9 C 10 2 4 A B 14 11 20 19 1 3 E SAPH011061300002 ...

Page 319: ...OTICE Excessive force to the air compressor may damage the mounting spigot or may cause oil leakage due to flaking of liquid gasket between the flywheel housing and plate 1 Cylinder head assembly 14 Crankcase 2 Suction valve 15 Crankshaft 3 O ring 16 Woodruff key 4 Cylinder liner 17 Coupling 5 Piston ring 18 Coupling bolt 6 Piston 19 Pin 7 Connecting rod 20 Air compressor assembly 8 Connecting rod...

Page 320: ... the O ring in to the O ring groove of the air compressor of bear ing holder side 4 Place a guide stud bolt M8 x 1 25 length 50 mm 1 968 in or more in the flywheel housing as shown in the figure and insert the compres sor onto the stud bolt 5 Tighten the mounting bolts other than the stud bolt then remove the stud bolt Insert a bolt in the place of the stud bolt Tightening Torque 28 5 N m 290 kgf ...

Page 321: ... the chapter FUEL SYSTEM IMPORTANT POINTS DISASSEMBLY 1 REMOVE THE DRIVE GEAR 1 Remove the lock nut from the compressor drive gear NOTICE If the spread is insufficient the drive gear will be damaged when loos ing the nut 2 Pull the drive gear from the crankshaft then remove the woodruff key SST Bearing puller S0965 01101 Body Coupling flange 0 Mark Protrusion SAPH011061300008 SAPH011061300009 SAPH...

Page 322: ... Piston ring expander S0944 01060 NOTICE Handle the piston rings carefully because they are made of a special casting which is easily broken When reusing the piston rings first arrange them face up and in the correct installation sequence in order to prevent installing them incorrectly 5 REMOVE THE PISTON 1 Remove the retainer rings installed on both ends of the piston using retainer ring pliers W...

Page 323: ...not to damage the bearing holder 7 REMOVE THE BEARING HOLDER 1 Use the press to remove the bearing holder NOTICE Be careful not to damage the bearing holder 8 REMOVE THE BALL BEARING 1 Using the special tool remove the ball bearing from the end of the crankshaft SST Bearing puller S0965 01101 Crankshaft Bearing holder SAPH011061300015 Crankshaft Bearing holder SAPH011061300016 SAPH011061300017 ...

Page 324: ...nd bearing holder into the crankcase 3 Tighten the bearing holder fitting screw 3 INSTALL THE CONNECTING ROD AND MEASURE THE END PLAY NOTICE Be sure to align the aligning mark Apply engine oil to the connecting rod and cap 1 Apply engine oil to the thread before installing the connecting rod bolt 2 Measure the connecting rod end play Assembly standard 0 2 0 4 mm 0 008 0 015 in Limit 0 5 mm 0 02 in...

Page 325: ...n 5 ASSEMBLE THE PISTON NOTICE Assemble the various parts after applying engine oil to the sliding parts 1 When installing the piston rings on the piston ensure that the piston skirt is at the bottom and use the special tool SST Piston ring expander S0944 01060 NOTICE Install the piston rings in order shown in the figure SAPH011061300022 SAPH011061300023 SAPH011061300024 ...

Page 326: ...ear a pair of safety goggles during assembly 7 INSTALL THE CYLINDER LINER AND CYLINDER HEAD NOTICE Do not twist the O ring when installing it on the cylinder liner and cyl inder head assembly 1 Rotate the crankshaft to the top dead center position 2 Arrange the piston rings so that their gaps are equally spaced 3 Install the cylinder liner and cylinder head assembly 8 INSTALL THE DRIVE GEAR 1 Inst...

Page 327: ...e Measure Clearance between the piston pin and connecting rod 0 016 0 044 0 0007 0 0017 0 07 0 0028 Inside diameter of the connect ing rod Tighten the bearing cap to the specified torque 34 1 339 Replace Measure Outside diameter of the crank pin 34 1 339 Oil clearance between the con necting rod and the crank pin 0 025 0 075 0 0010 0 0029 0 1 0 0039 Connecting rod end play 0 2 0 4 0 0079 0 0157 0 ...

Page 328: ...32 B 0 09 0 155 0 0036 0 0061 0 195 0 0077 Clearance between the piston pin hole and the piston pin 0 0 028 0 0 0011 0 08 0 0031 Replace Measure Outer diameter of the piston pin 18 0 709 Piston ring thickness Compression ring 2 0 0 0787 Replace Measure Oil ring 4 0 0 1575 Piston ring groove Compression ring 2 0 0 0787 Oil ring 4 0 0 1575 Clearance between the ring groove and the compression ring 0...

Page 329: ...ction valve Replace valve seat Visual check Outside diam eter of the crankshaft journal Drive gear side 45 1 7716 44 995 1 7714 Replace Measure Opposite drive gear side 55 2 1654 54 995 2 1651 Inside diame ter of the bearing holder Cylinder block 100 3 9370 100 04 3 9385 Replace Measure Bearing holder 100 3 9370 100 04 3 9385 Crankshaft end play 0 0 6 0 0 0236 1 0 0 0394 Replace crank shaft and or...

Page 330: ...ENGINE CONTROL J08E EN16 1 EN16ENGINE CONTROL J08E EN16 001 ACCELERATOR PEDAL EN16 2 DESCRIPTION EN16 2 ENGINE ECU EN16 3 COMPONENT LOCATOR EN16 3 REPLACEMENT EN16 4 ...

Page 331: ...ENGINE CONTROL J08E EN16 2 ACCELERATOR PEDAL DESCRIPTION EN0110616F200001 140 5 150 5 mm 5 5315 5 9251 in 1 Floor board SAPH011061600001 1 Accelerator pedal assy ...

Page 332: ...ENGINE CONTROL J08E EN16 3 ENGINE ECU COMPONENT LOCATOR EN0110610J100004 Tightening torque Unit N m kgf cm lbf ft 1 Engine ECU A 28 5 291 21 1 A SAPH011061600002 ...

Page 333: ...ed to the engine ECU 2 Directly spray water around the engine ECU connector by using a spray bottle NOTICE While working do not disconnect the connectors HINT If it is much dirty squirt water at the connector sliding portion and connector surface 3 Blow air around the engine ECU connector and engine ECU surface to remove dirt and foreign matter NOTICE While working do not disconnect the connectors...

Page 334: ... b While pushing the primary latch of the connector move the lever in the direction of the arrow as shown in the figure until a click is heard and then disconnect the connector c Pull out the connector straight NOTICE Do not insert and remove the connector more than necessary Do not give shocks to the engine ECU Never disconnect the harness by holding and pulling or prying as it may result in wire...

Page 335: ...9 If the engine ECU side connector is found dirty wipe off its side with a moistened waste cloth NOTICE Use a thoroughly wrung waste cloth Do not wipe off the terminal opening Do not directly spray water 10 Blow air on the terminal part inside the engine ECU side connector to remove dirt and foreign matter Harness side connector Portions to be wiped clean Do not wipe off the terminal SAPH011061600...

Page 336: ...ine ECU the cylinder block with the bolts 4 pcs For the tightening order tighten them diagonally Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft NOTICE Check that there are no dirt and foreign matter in the engine ECU connectors Do not give shocks to the ECU Do not use the engine ECU if dropped Do not directly touch the connector terminals by hand The engine ECU is non disassemblable Do not paint ...

Page 337: ...the wrong fitting prevention keyway 2 Press the upper part of the harness side connector and insert the connector uniformly 3 Move the lever in the direction of the arrow as shown in the figure until a click is heard and connect the connector NOTICE If the lever cannot move smoothly repeat steps 1 and 2 Also drop a few drops of water to the sliding portion to make it smooth Lever SAPH011061600014 ...

Page 338: ...ENGINE CONTROL J08E EN16 9 4 Move the hook in the direction of the arrow as shown in the figure until a click is heard in order to lock the connector Hook SAPH011061600018 ...

Page 339: ...Pub No S5 UJ08E10A 12 11 Hino Motors Sales U S A Inc PRINTED IN JAPAN 41180 Bridge Street Novi MI 48375 Telephone 248 699 9300 ...

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