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Hino S5-LJ05E04A, Workshop Manual

The Hino S5-LJ05E04A Workshop Manual is a comprehensive guide designed to assist in the proper maintenance and repair of your vehicle. This manual is available for free download, ensuring easy access and convenience. Enhance your product knowledge and optimize performance by downloading the manual from manualshive.com.

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Summary of Contents for S5-LJ05E04A

Page 1: ...be careful not to be injured through improper procedures As for maintenance items refer to the 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 FOREWORD fm 1 ページ ２０１２年１１月２８日 水曜日 午後３時３５分 MENU ...

Page 2: ...5 LJ05E05A CANADA MODEL J05E GENERAL INTRODUCTION 1 001 STANDARD VALUE 2 001 REQUIRED ITEMS 3 001 MOUNTING AND DISMOUNTING THE ENGINE 5 001 ENGINE CONTROL 6 001 FUEL SYSTEM 7 001 EMISSION CONTROL 8 001 INTAKE 9 001 ENGINE MECHANICAL 10 001 EXHAUST 11 001 COOLING 12 001 LUBRICATION 13 001 STARTING CHARGING 16 001 TURBOCHARGER 17 001 FOREWORD fm 2 ページ ２０１２年１１月２８日 水曜日 午後３時３５分 ...

Page 3: ...td INDEX ENGINE GROUP 1 2 STANDARD VALUE REQUIRED ITEMS TROUBLESHOOTING MOUNTING AND DISMOUNTING THE ENGINE ENGINE CONTROL FUEL SYSTEM EMISSION CONTROL INTAKE ENGINE MECHANICAL COOLING LUBRICATION SPEED CONTROL SYSTEM EXHAUST IGNITION STARTING CHARGING TURBOCHARGER AIR COMPRESSOR GENERAL INTRODUCTION INDEX_EN fm 1 ページ ２０１２年１１月１９日 月曜日 午前９時４６分 ...

Page 4: ...INDEX ENGINE GROUP 2 2 ENGINE PTO POWER TAKE OFF INDEX_EN fm 3 ページ ２０１２年１１月１９日 月曜日 午前９時４６分 ...

Page 5: ... VEHICLE 1 4 APPEARANCE OF VEHICLE 1 4 SAFETY INSTRUCTIONS AND READINESS TO WORK 1 5 WARNING 1 5 IDENTIFICATION INFORMATION 1 9 SAFETY INSTRUCTIONS FOR WORK 1 12 INTRODUCTION TO WORKSHOP MANUAL 1 15 TIGHTENING OF BOLTS AND NUTS 1 19 HANDLING OF LIQUID GASKET 1 29 GLOSSARY 1 30 DEFINITION OF ABBREVIATION IN THIS MANUAL 1 30 LUBRICANTS 1 36 RECOMMENDED LUBRICANTS 1 36 ...

Page 6: ... mm 114 in 3 500 mm 138 in 3 800 mm 150 in 4 400 mm 173 in ԝ 0 㧦TYPE OF SUSPENSION FRONT RIGID REAR RIGID Ԡ CAB FORM BRAKE TYPE 㧦CAB FORM BRAKE TYPE ԟ㧦STEERING WHEEL POSITION L LEFT HAND DRIVE H Q SINGLE CAB VACUUM CREW CAB VACUUM C D SINGLE CAB HYDRAULIC CREW CAB HYDRAULIC K L SINGLE CAB VACUUM SINGLE CAB HYDRAULIC ԡ㧦DECK HEIGHT K HIGH FLOOR Ԣ㧦TRANSMISSION T 6AT Ԧ㧦DECK FORM 3 CHASSIS WITH CAB Ԥ㧦E...

Page 7: ...140 8 850 kg 17 950 19 500 lbs CODE CLASS MODEL R S T PRODUCTION CODE CAB TYPE WHEEL BASE BRAKE SYSTEM U V W X Y P H K L HINO 195h HINO 195 HINO 195 HINO 195 HINO 155 HINO 155 HINO 155 HINO 155 HINO 195 HINO 195 HINO 155 HINO 155 5 5 5 5 4 4 5 5 4 4 4 4 XFC710 HINO 155h XFC720 HINO 155h XFC740 HINO 195h XFC720 HINO 195h XFC740 HINO 155h XFC710 HINO 195h XFC720 HINO 195h XFC740 HINO 155h XFC740 HIN...

Page 8: ...GENERAL INTRODUCTION 1 4 APPEARANCE OF VEHICLE APPEARANCE OF VEHICLE EN01F01ZZZ000102002001 SHTS01ZZZ0000003 ...

Page 9: ...the key from the switch is recommended To avoid serious burns keep yourself away from hot metal parts such as the engine exhaust manifold radiator muffler exhaust pipe and tail pipe Do not smoke while working on the vehicle since fuel and gas from battery are flammable Take utmost care when working on the battery It contains corrosive sulfuric acid Large electric current flows through the battery ...

Page 10: ...cab only by yourself if your cab is equipped with heavy component such as a roof rack Never put your body under the cab while raising or lowering the cab Make sure the cab stopper stay is securely locked by the catch E and raise the stopper F to lock the catch E completely after raising the cab Before lowering the cab make sure that any object such as hand tools gloves or cloth are not left under ...

Page 11: ...r the entry of dirt or foreign matter The above mentioned precautions should be observed for vehicles equipped with either manual or automatic transmission and for even short distance towing After being towed check and refill the rear axle housing with lubricant if necessary 2 Rear end towing When being towed with the rear wheels raised off the ground fasten and secure the steering wheel in a stra...

Page 12: ...ated control components including a listing of parts and components used engine parame ter adjustments emissions related codes or signals responded to and reset and work performed under paragraph 4 of this section a Parties may keep records in whatever format or system they choose as long as the records are understandable to an EPA enforcement officer or can be otherwise provided to an EPA enforce...

Page 13: ...TION NUMBER VIN STRUCTURE on the following page 3 PRODUCTION CODE AND VEHICLE COMPONENTS A B SHTS01ZZZ0000010 MODEL CLASS HINO 155h 4 HINO 155 4 HINO 195h 5 HINO 195 5 PRODUCTION CODE XFC710 XFC720 XFC740 XJC700 XJC710 XJC720 XJC740 XFC710 XFC720 XFC740 XJC700 XJC710 XJC720 XJC740 TRANSMISSION SERIES A465 TRANSMISSION RATIO 1st 3 742 2nd 2 003 3rd 1 343 4th 1 000 5th 0 773 6th 0 634 REAR AXLE SERI...

Page 14: ...ation A J05E 4 TRANSMISSION SERIAL NUMBER 1 The transmission serial number is stamped on the transmission as shown in the illustration A A465 5 CLEAN IDLE CERTIFIED LABEL FOR U S Make sure that the following clean engine idling certified label is affixed to the outside of the left door By the CARB below the label must be affixed there to prove that the new vehicle with die sel engine manufactured ...

Page 15: ...DUCTION 1 11 6 EXEMPTION LABEL FOR US GHG REGULATION HINT Exemption label fuel economy comes in paste right side of the front passenger seat However this label is limited to one year EXEMPTION LABEL SHTS01ZZZ0000015 ...

Page 16: ... LOCK position In this case use HINO DX to clear the DTC P204F and P068A to turn off the MIL and to conduct DPR regeneration manually a Before electrical system work remove the cable from the minus terminal of the battery in order to avoid burning caused by short circuiting b To remove the battery cable fully release the nut to avoid damage to the battery terminal Never twist the termi nal 2 Handl...

Page 17: ... connector hold a connector area shown in an arrow in the figure and then pull it off Do not pull wire harnesses b Pull off a lockable connector after unlocking c When connecting a lockable connector make sure to insert a lockable connector until it makes a click sound d When inserting a test lead insert it from the back of a connector e If it is difficult to insert a test lead from the back of a ...

Page 18: ...lectrical components etc Consequently the following precautions are always to be taken during welding 1 Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the frame itself Do not fit the welding equipment earth to such things as the tire rims brake pipes or fuel pipes and leaf spring etc a Turn the starter switch off b Disconnect the batte...

Page 19: ...nd lifting b Cleaning and washing of removed parts as required c Visual check 2 STANDARD VALUE 1 Standard values limits required actions and tightening torques are tabulated in this document 3 REQUIRED ITEMS 1 Special tools tools instruments oil and grease and other items to be prepared before starting work are listed in the section titled REQUIRED ITEMS Note that general tools jacks rigid racks a...

Page 20: ...paring electronic data and is not needed in repair work Alphabetical mark indicating the tightening torque in the following tightening torque table Numerical order indicating the part name in the following part name table Numerical order Part name Part name table Tightening torque table Tightening torque Alphabetical mark SHTS01ZZZ0000021 ...

Page 21: ...NERAL INTRODUCTION 1 17 2 WORK STEPS Indicating the work sequence Descriptive text Indicating the work method which is gone into detail Indicating the part number of SST required for work SHTS01ZZZ0000022 ...

Page 22: ...t side and the output side of motive power are defined as a front side and a rear side respectively 2 Rotational direction a The clockwise direction and the counterclockwise direction viewed from the back side are defined as right handed and left handed respectively 3 Vertical direction a The upward direction and the downward direction of a device in its installed position in a vehicle chassis are...

Page 23: ...Unique tightening torque may be specified for some parts Tighten with the tightening torque specified in the service manual HINT Check the tightening torque list for general torques CAUTIONS TO PREVENT LOOSENESS When tightening pay attention to the followings to prevent looseness after tightening Insufficient tightening torque Inclusion of foreign matters burrs and coatings in the tightening surfa...

Page 24: ... w o flange Bolts nuts without flange 2 With old flange w grooves Flange is small and has grooves on its back 3 With new flange w o grooves Flange is big and does not have grooves on its back SHTS01ZZZ0000023 SHTS01ZZZ0000024 FLANGE OUTER DIAMETER GROOVES GROOVES SHTS01ZZZ0000025 FLANGE OUTER DIAMETER ...

Page 25: ...h old flange w grooves With new flange w o grooves With old flange w grooves With new flange w o grooves Strength class Flange outer diameter Strength class Flange outer diameter Strength class Flange outer diameter Strength class Flange outer diameter M8 7T 9T 15 5 8 8 10 9 17 7N 15 5 8 17 M10 7T 9T 18 5 8 8 20 7N 18 5 8 21 5 10 9 21 5 M12 7T 9T 21 5 8 8 24 7N 21 5 8 26 10 9 26 M14 10 9 30 5 12 3...

Page 26: ...YMBOLS 1 With old flange w grooves 2 With new flange w o grooves Bolt Nut Strength class Symbols Strength class Symbols Carbon steel Boron steel 4T 7N 7T 9T Bolt Nut Strength class Symbols Strength class Symbols Carbon steel Boron steel 8 8 8 10 9 12 ...

Page 27: ...10 7T SH111 Plating 8N SL113 01008 Plating 9T SH112 Plating M12 7T SH111 Plating 8N SL113 01210 Plating 9T SH112 Plating M14 9T SH112 Plating 8N SL113 01411 Plating Thread diameter Bolt Nut Strength class Part No Surface treatment Strength class Part No Surface treatment M8 7T SH562 Plating 7N SL151 00809 Plating 9T SH562 Plating M10 7T SH562 Torquer 7N SL151 01011 Plating 9T SH562 Torquer M12 7T ...

Page 28: ... not conform to it due to their tightening conditions strength classes and surface treatments 1 Standard w o flange Unit N m kgf cm lbf ft Thread diameter Bolt Nut Strength class Part No Surface treatment Strength class Part No Surface treatment M8 8 8 91551 808 Plating 8 94151 80800 Plating 10 9 91551 008 Plating M10 8 8 91552 E10 Neotorquer 8 94151 81001 Neotorquer 10 9 91552 F10 Neotorquer M12 ...

Page 29: ...6 56 23 1 4 0 M10 7T 51 5 10 0 525 101 37 9 7 3 9T 68 5 13 5 698 137 50 5 9 9 M12 7T 91 0 18 0 927 183 67 0 13 2 9T 120 0 24 0 1 223 224 88 4 17 6 Thread diameter Strength classes Tightening Torque M8 8 8 31 0 9 3 316 94 22 8 6 8 10 9 39 0 11 7 397 119 28 7 8 6 M10 8 8 35 0 10 5 356 107 25 8 7 7 10 9 46 5 13 8 474 140 34 2 10 1 M12 8 8 63 0 18 9 642 192 46 4 13 9 10 9 82 0 24 6 836 250 60 4 18 1 M...

Page 30: ...th a numerical character 7 indicated on the head Bolt with a numerical character 9 indicated on the head Thread diameter X pitch 4T 7T 9T M6 X 1 coarse thread 6 60 4 3 10 100 7 2 13 130 9 4 M8 X 1 25 coarse thread 14 140 10 25 250 18 31 320 23 M10 X 1 25 fine thread 29 300 22 51 520 38 64 650 47 M10 X 1 5 coarse thread 26 270 20 47 480 35 59 600 43 M12 X 1 25 fine thread 54 550 40 93 950 69 118 1 ...

Page 31: ...ne parts employ the plastic region tightening method Said tightening method is different from the conventional tightening method Follow the instructions described in this document for tightening 1 Applicable parts Cylinder head bolt crankshaft main bearing cap bolt connecting rod bearing cap bolt and etc NOTICE Prior to installation measure a total length of a bolt If a measurement reading of a to...

Page 32: ... 8 Except brake 15 0 5 153 5 1 11 0 37 Except clutch 21 1 214 10 15 0 7 Types Material quality and shape Flare configuration Identification Tightening torque Feed pipe high pressure Copper Outer diame ter 10 Wall thick ness t 1 4 Single flare Red 44 5 449 51 32 3 7 Return pipe low pressure Copper Outer diame ter 10 Wall thick ness t 1 Single flare 44 5 449 51 32 3 7 Outer diameter of hose 13 fitti...

Page 33: ...gasket 4 Wait at least 15 minutes after assembling parts and then start the engine 2 REMOVAL OF PARTS 1 When removing individual parts alternately winkle two or more portions in a gap or a collar of a flange Avoid one point winkling When removing a gasket use care to avoid entry of gasket fragments into the engine 3 OTHERS 1 If liquid gasket is contained in a tube use a supplied squeezer If liquid...

Page 34: ...ead Only Memory CPU Central Processing Unit dB Decibel DC Direct Current D CAT Diesel Clean Advanced Technology System DC motor Direct Current Motor DCU Dosing Control Unit DEF Diesel Exhaust Fluid DPR Diesel Particulate active Reduction system DSS Driving Support System ECU Electronic Control Unit EEPROM Electronically Erasable and Programmable Read Only Memory EGR Exhaust Gas Recirculation ELR E...

Page 35: ...IS Idle Stop ISO International Organization for Standardization JIS Japanese Industrial Standards LED Light Emitting Diode LEV Low Emission Vehicle LH Left Hand LLC Long Life Coolant Lo Low MAX Maximum MIN Minimum MS evaporator Multi tank and Super slim structure evaporator MT Manual Transmission No Number NOx Nitrogen Oxide NMR No load Maximum Revolution OHC Over Head Camshaft PC Personal Compute...

Page 36: ...e ppm Parts Per Million PS pump Power Steering Pump PTO Power Take Off PVD Physical Vapor Deposit PWR Power QR code Quick Response Code R A Rear Axle RH Right Hand SCR Selective Catalytic Reduction SST Special Service Tool SW Switch T M Transmission Abbreviations Meaning or Official Name ...

Page 37: ...t AFTDOS AFTERTREATMENT DOSER AFTDOS Dosing AFTDPF AFTERTREATMENT DIESEL PARTICU LATE FILTER DPR filter AFTDPFDP AFTERTREATMENT DIESEL PARTICU LATE FILTER DIFFERENTIAL PRESSURE DPR differential pressure AFTEGT AFTERTREATMENT EXHAUST GAS TEM PERATURE Exhaust gas temperature AP ACCELERATOR PEDAL Accelerator pedal AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor APP ACCELERATOR PE...

Page 38: ...plug GND GROUND GROUND IA INTAKE AIR Air Intake IA System INTAKE AIR System Air Intake System IAT INTAKE AIR TEMPERATURE Intake temperature IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor IDLE IDLE Idle IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor INJ INJECTOR Injector MAF Sensor M...

Page 39: ...plug SRI SERVICE REMINDER INDICATOR Check engine ST SCAN TOOL Diagnostic tool TC TURBOCHARGER Turbocharger TCC TORQUE CONVERTER CLUTCH Torque Converter TP Sensor THROTTLE POSITION Sensor Throttle Sensor TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit VSS VEHICLE SPEED SENSOR Vehicle Sp...

Page 40: ...CANTS 4 Integral power steering gear HINO GENUINE SERIES Power steering fluid or ATF DEXRON 5 Brake HINO GENUINE SERIES Brake and clutch fluid or Brake fluid DOT 3 6 Wheel bearing Propeller shaft HINO GENUINE SERIES Bearing grease or Bearing grease NLGI No 2 LITHIUM SOAP 7 Front and rear suspension spring bracket pins and shackle pins HINO GENUINE SERIES Multipurpose grease NLGI No 2 LITHIUM SOAP ...

Page 41: ...IL SEAL RETAINER 2 17 FLYWHEEL ASSEMBLY 2 17 FLYWHEEL HOUSING 2 17 TIMING GEAR CAM IDLE GEAR 2 18 PISTON CONNECTING ROD 2 19 CRANKSHAFT 2 20 CYLINDER LINER 2 21 CYLINDER BLOCK 2 21 ENGINE MOUNTING AND BRACKET 2 21 GLOW PLUG 2 21 EXHAUST 2 23 EXHAUST MANIFOLD 2 23 EXHAUST PIPE 2 23 EXHAUST PIPE ATC 2 23 DEF SCR 2 24 DPR CLEANER 2 24 FUEL ADDITION VALVE 2 25 FUEL CUTOFF VALVE 2 25 DEF PUMP 2 25 DEF ...

Page 42: ...STANDARD VALUE J05E 2 2 STARTING CHARGING 2 35 STARTER 2 35 V BELT 2 35 ALTERNATOR 130 A 2 36 TURBOCHARGER 2 37 TURBOCHARGER ASSEMBLY 2 37 ...

Page 43: ... 0 MPa 31 kgf cm2 435 lbf in 2 2 7 MPa 28 kgf cm2 392 lbf in 2 Overhaul Valve clearance when cold Intake 0 30 mm 0 012 in Adjustment Exhaust 0 45 mm 0 018 in Tightening part Tightening torque Remarks Rocker arm lock nut 25 255 18 Crosshead lock nut 25 255 18 Oil pan drain plug 41 418 30 Engine hanger mounting bolt front 125 1 275 92 Engine hanger mounting bolt rear 85 867 63 Engine mounting nut 96...

Page 44: ...ING TORQUE Unit N m kgf cm lbf ft IDLE SET VOLUME EN01F02127010701002004 STANDARD VALUE LIMIT AND ACTION Tightening part Tightening torque Remarks Engine ECU mounting bolt 28 5 290 21 Tightening part Tightening torque Remarks Engine speed main sensor mounting bolt 10 102 7 Tightening part Tightening torque Remarks Engine speed sub sensor mounting bolt 4 6 41 61 3 0 4 4 Inspection item Standard val...

Page 45: ...alue Action Accelerator sensor 1 output volt age Accelerator fully closed 0 6 1 0 V Replace Accelerator fully open 2 8 3 6 V Replace Accelerator sensor 2 output volt age Accelerator fully closed 1 4 1 8 V Replace Accelerator fully open 3 6 4 4 V Replace Tightening part Tightening torque Remarks Accelerator pedal assembly mounting nut 5 5 56 4 Tightening part Tightening torque Remarks Block heater ...

Page 46: ...ft Tightening part Tightening torque Remarks Fuel tank drain plug 24 5 34 3 250 349 19 26 Fuel tank bracket mounting bolt 96 144 979 1 468 71 106 For 30 gallon Fuel tank band 10 2 15 0 105 152 8 11 For 33 gallon Inspection item Standard value Action Resistance between terminals Float height E 107 5 112 5 Replace F 3 5 Replace Tightening part Tightening torque Remarks Fuel sender gauge mounting bol...

Page 47: ...el filter mounting bolt 55 561 41 Fuel feed pipe No 3 mounting union bolt Fuel filter side 30 306 22 Supply pump side 14 8 19 6 151 199 11 14 Fuel shutoff valve side 19 6 200 14 Fuel feed pipe No 1 mounting union bolt Supply pump side 25 255 18 Fuel filter side 30 306 22 Fuel feed pipe No 2 mounting union bolt Supply pump side 25 255 18 Fuel filter side 30 306 22 Return pipe No 2 mounting union bo...

Page 48: ...176 F 0 310 0 326 k Replace 110 C 230 F 0 1399 0 1435 k Replace Tightening part Tightening torque Remarks Fuel filter drain plug 5 9 51 91 3 7 6 6 Bearing holder case mounting bolt 28 5 291 21 Coupling flange mounting nut 64 653 47 Coupling and supply pump mounting bolts 28 5 291 21 Pressure feed pipe 44 449 32 Inspection item Standard value Action Insulation resistance of injector Between one sid...

Page 49: ...on Resistance between terminals of common rail pressure sensor 1 2 1 05 3 55 k Replace 5 6 Replace 2 3 6 7 18 7 k Replace 4 5 Replace Tightening part Tightening torque Remarks Common rail mounting bolt 28 5 291 21 Injection pipe 44 449 32 Refer to this docu ment Return pipe No 1 Pressure limiter side 20 204 15 Cluster con nector side 20 204 15 Cylinderhead side 13 133 10 Tightening part Tightening...

Page 50: ...04002 TIGHTENING TORQUE Unit N m kgf cm lbf ft Tightening part Tightening torque Remarks EGR cooler mounting bolt 68 5 699 51 Bracket mounting bolt 28 5 291 21 EGR pipe mounting bolt 55 561 41 Bracket mounting bolt and nut 28 5 291 21 Tightening part Tightening torque Remarks Closed ventilator mounting bolt 31 316 23 Ventilator hose A mounting bolt 31 316 23 ...

Page 51: ...art Tightening torque Remarks Intake manifold mounting bolt and nut 28 5 291 21 Tightening part Tightening torque Remarks Diesel throttle mounting bolt and nut 28 5 291 21 Tightening part Tightening torque Remarks Primary intake pipe mounting clamp 6 25 64 4 6 Turbocharger side 2 4 5 0 25 50 1 8 3 6 Air cleaner side Secondary intake pipe mounting bolt 28 5 291 21 Tightening part Tightening torque ...

Page 52: ...t AIR FLOW SENSOR EN01F02127010701005008 TIGHTENING TORQUE Unit N m kgf cm lbf ft Tightening part Tightening torque Remarks Air cleaner housing mounting nut 19 5 199 14 Intake hose clamp 2 4 5 0 25 50 1 8 3 6 Tightening part Tightening torque Remarks Intake temperature sensor 19 6 200 14 Tightening part Tightening torque Remarks Boost pressure sensor mounting bolt 5 51 3 7 Tightening part Tighteni...

Page 53: ...value Permissible limit Action Rocker arm shaft outer diameter 22 0 866 21 92 0 863 Replace Rocker arm bushing inner diameter 22 0 866 22 08 0 869 Replace Oil clearance between rocker arm shaft outer diameter and rocker arm bushing inner diam eter 0 030 0 101 0 0012 0 0040 0 15 0 0059 Replace Valve clearance Intake 0 30 0 0118 Adjustment Exhaust 0 45 0 0177 Adjustment Tightening part Tightening to...

Page 54: ...7 0 3144 Replace Exhaust 10 104 0 398 10 024 0 395 Replace Outer diameter of camshaft journal 40 1 575 39 85 1 569 Replace Inner diameter of camshaft bearing 40 1 575 40 15 1 581 Replace Camshaft bearing oil clearance 0 020 0 063 0 0008 0 0025 Replace Runout of camshaft 0 04 0 0016 0 1 0 0039 Replace Under head length of camshaft gear mounting bolt 30 0 1 181 30 5 1 201 Replace Tightening part Tig...

Page 55: ...M12 126 0 4 961 126 5 4 980 Replace 156 0 6 142 156 5 6 161 Replace 187 0 7 362 187 5 7 382 Replace Strain of the bottom surface of the cylinder head Longitudinal direction 0 06 0 0024 0 20 0 0079 Replace Right angle direction 0 03 0 0012 0 20 0 0079 Replace Tightening part Tightening torque Remarks Cylinder head mounting head bolt M12 59 602 44 Refer to this document Cylinder head mounting head b...

Page 56: ... 2165 C 1 0 0 0393 Squareness of valve spring Inner 2 0 0 0787 Replace Outer 2 0 0 0787 Replace Valve spring Referential val ues in brackets Inner Set length 44 8 1 764 Replace Set load 128 5 N 13 1 kgf 118 2 N 12 kgf Replace Free length 64 6 2 543 61 6 2 425 Replace Outer Set length 46 8 1 843 Replace Set load 313 8 N 32 kgf 288 7 N 29 4 kgf Replace Free length 75 7 2 980 72 7 2 862 Replace Valve...

Page 57: ...6009 TIGHTENING TORQUE Unit N m kgf cm lbf ft Tightening part Tightening torque Remarks Crankshaft pulley mounting bolt 118 1 203 87 Tightening part Tightening torque Remarks Front oil seal retainer mounting bolt 30 306 22 Tightening part Tightening torque Remarks Flywheel assembly mounting bolt 186 1 897 137 Refer to this document Tightening part Tightening torque Remarks Flywheel housing mountin...

Page 58: ...outer diameter 34 1 339 Bushing inner diameter 34 1 339 Oil clearance 0 025 0 057 0 0010 0 0022 0 10 0 0039 Replace Camshaft end play 0 100 0178 0 0039 0 0070 Replace Idle gear backlash Between camshaft drive gear and cam idle gear 0 084 0 175 0 0033 0 0069 0 30 0 0118 Replace Between main idle gear and injection pump drive idle gear 0 030 0 218 0 0012 0 0086 0 30 0 0118 Replace Between main idle ...

Page 59: ...999 0 1181 2 899 0 1141 Replace Second 2 0 0 0787 1 9 0 0748 Replace Oil 4 0 0 1575 3 9 0 1535 Replace Piston ring groove width Top Taper Replace Second 2 0 0 0787 2 2 0 0866 Replace Oil 4 0 0 1575 4 1 0 1614 Replace Piston ring closed gap clearance Top 0 30 0 40 0 0118 0 0157 1 5 0 0590 Replace Second 0 75 0 90 0 0295 0 0354 1 5 0 0590 Replace Oil 0 15 0 30 0 0059 0 0118 1 2 0 0472 Replace Outer ...

Page 60: ...ing rod bolt 67 0 2 638 68 0 2 677 Replace Connecting rod end play 0 20 0 52 0 0079 0 0205 1 0 0 0394 Tightening part Tightening torque Remarks Connecting rod bolt 69 704 51 90 45 Refer to this docu ment Inspection item Standard value Repair limit Permissible limit Action Crankshaft end play 0 050 0 270 0 0020 0 0106 0 500 0 0197 1 270 0 05 Replace Rotational runout of crankshaft 0 0 1 0 0 0039 0 ...

Page 61: ...69 704 51 90 45 Refer to this document Inspection item Standard value Action Cylinder liner collar projection 0 01 0 08 0 0004 0 0032 Inspection item Standard value Repair limit Permissible limit Action Strain of upper surface of cylinder block 0 05 0 0020 0 20 0 0079 Replace Tightening part Tightening torque Remarks Cooling jet mounting bolt 22 224 16 Tightening part Tightening torque Remarks Rea...

Page 62: ...STANDARD VALUE J05E 2 22 TIGHTENING TORQUE Unit N m kgf cm lbf ft Tightening part Tightening torque Remarks Glow plug 20 25 204 254 15 18 Glow plug wire mounting nut 1 0 1 5 11 15 0 8 1 1 ...

Page 63: ...nifold mounting nut 29 600 43 5 Tightening part Tightening torque Remarks Exhaust pipe ATC to front exhaust pipe mounting bolt 43 438 31 7 Front exhaust pipe to muffler mounting bolt and nut 64 653 47 2 Muffler mounting nut 82 836 60 5 Water pipe mounting nut 31 316 22 9 DEF Injector mounting nut 6 10 61 102 4 4 7 4 Hose protector mounting bolt 43 59 438 602 31 7 43 5 Tightening part Tightening to...

Page 64: ...306 14 7 22 1 DEF SCR to tail pipe mounting bolt and nut 20 30 204 306 14 7 22 1 DEF SCR to support bracket mounting bolt and nut 43 59 438 602 438 602 Exhaust pipe protector mounting bolt 31 316 22 9 Tightening part Tightening torque Remarks Central pipe No 1 to DPR cleaner mounting bolt and nut 20 30 204 306 14 7 22 1 DPR cleaner to support bracket mounting bolt and nut 43 59 438 602 438 602 Dif...

Page 65: ...s Folder mounting nut 36 367 26 5 Nozzle clamp mounting bolt 28 5 290 21 0 Fuel delivery mounting bolt 28 5 290 21 0 Coolant pipe E mounting union bolt 24 5 250 18 1 Coolant pipe D mounting union bolt 24 5 250 18 1 Fuel feed pipe No 5 mounting union bolt 19 6 200 14 5 Fuel pressure sensor 19 6 200 14 5 Tightening part Tightening torque Remarks Fuel cutoff valve mounting bolt 28 5 290 21 0 Fuel fee...

Page 66: ...10 61 102 4 4 7 4 Hose protector mounting nut 31 316 22 9 Inspection item Concentration Standard value Action DEF analyzer 32 5 32 5 Replace pH test paper 32 5 number 9 Replace Refractive index measure ment 32 5 1 3817 1 384 Replace Tightening part Tightening torque Remarks Tank band mounting nut 23 5 36 5 240 372 17 3 26 9 DEF tank assembly mounting nut 38 4 57 6 392 587 28 3 42 5 Tightening part...

Page 67: ...lue Action Resistance between termi nals A B 15 k Replace B C 15 k Replace Tightening part Tightening torque Remarks DPR differential pressure sensor mounting nut 31 316 22 9 Tightening part Tightening torque Remarks SCR upstream NOx sensor 40 60 408 612 29 5 44 2 Clip mounting nut 31 316 22 9 SCR upstream NOx controller mounting nut 5 5 56 4 1 Tightening part Tightening torque Remarks SCR downstr...

Page 68: ...f cm lbf ft Inspection item Standard value Action Resistance between termi nals 50 C 122 F 8 0 17 2 k Replace Tightening part Tightening torque Remarks DOC upstream temperature sensor 25 35 255 357 18 4 25 8 Inspection item Standard value Action Resistance between termi nals 50 C 122 F 8 0 17 2 k Replace Tightening part Tightening torque Remarks DPR upstream temperature sensor 25 35 255 357 18 4 2...

Page 69: ...cm lbf ft Inspection item Standard value Action Resistance between termi nals 50 C 122 F 235 244 Replace Tightening part Tightening torque Remarks SCR upstream temperature sensor 32 5 331 24 0 Inspection item Minimum clearance Valve clearance Standard value Action Clearance between valve and body 0 2 0 0079 0 2 0 3 0 0079 0 0118 Angle between valve and body 90 Inspection item Standard value Action...

Page 70: ...ck for blockage 2 942 4 903 30 50 427 711 300mm 11 811 in Replace 4 903 7 845 50 80 711 1 138 500mm 19 685 in Replace Tightening part Tightening torque Remarks Radiator to radiator mounting bracket mounting bolt 19 5 199 14 Heater pipe mounting bolt 21 7 40 3 222 410 17 29 Reserve pipe mounting bolt 19 5 199 14 Inspection item Standard value Action Radiator cap opening relief valve pressure 93 1 1...

Page 71: ...tening part Tightening torque Remarks Radiator to intercooler mounting bolt 14 20 143 203 11 14 Clamp mounting bolt 6 25 64 4 6 Inspection item Standard value Action Thermostat injection valve opening temperature 76 5 C 169 7 F Replace Thermostat valve lift amount 90 C 194 F 10 mm 0 393 in or more Replace Tightening part Tightening torque Remarks Thermostat case mounting bolt 28 5 291 21 Water out...

Page 72: ...0 276 in Adjustment Tightening part Tightening torque Remarks Cooling fan to fan clutch mounting bolt 11 112 8 Fan clutch to coolant pump pulley mounting nut 28 5 291 21 Bracket mounting nut 28 5 291 21 Bracket to fan shroud ring mounting bolt 31 316 23 Inspection item Standard value Action Resistance between terminals A C 20 C 4 F 13 84 16 33 k Replace 20 C 68 F 2 32 2 59 k Replace 80 C 176 F 0 3...

Page 73: ...0 709 Replace Inner diameter of cylinder block side bush 18 0 0 709 Replace Difference between drive gear shaft outer diameter and cylinder block side bush inner diameter 0 040 0 099 0 0016 0 0039 Replace Drive gear outer diameter 54 0 2 126 Replace Inner diameter of cylinder block side pump housing 54 0 2 126 Replace Difference between drive gear outer diameter and cylinder block pump housing inn...

Page 74: ...n gear 0 073 0 207 0 0029 0 0082 0 30 0 012 Replace Backlash between oil pump drive gear and sub idle gear 0 030 0 131 0 0012 0 0052 0 30 0 012 Adjustment Tightening part Tightening torque Remarks Oil pump mounting bolt 28 5 291 21 Tightening part Tightening torque Remarks Oil pan mounting bolt 30 306 22 Refer to this docu ment Tightening part Tightening torque Remarks Oil strainer mounting bolt 3...

Page 75: ...Inspection item Standard value Action Perform no load performance test 220A or less Tightening part Tightening torque Remarks Starter mounting bolt and nut 154 1 570 113 5 C terminal mounting bolt 4 5 46 3 3 B terminal mounting nut 21 214 15 4 Harness clamp mounting bolt 18 184 13 2 Inspection item Standard value Action V belt front slack 8 10 0 31 0 39 Tightening part Tightening torque Remarks Al...

Page 76: ... 1 3 6 Pulley mounting nut 117 6 137 2 1 199 1 399 87 101 Field mounting screw 2 9 4 9 30 50 2 1 3 6 I terminal mounting nut 1 6 2 0 16 20 1 2 1 4 Rectifier mounting screw 2 9 4 9 30 50 2 1 3 6 Rectifier s terminal mounting nut 2 9 4 9 30 50 2 1 3 6 B terminal mounting nut 7 8 10 8 80 110 5 8 7 9 Regulator mounting screws 2 9 4 9 30 50 2 1 3 6 Rectifier and field coil outlet terminal mounting scre...

Page 77: ...ightening torque Unit N m kgf cm lbf ft Inspection item Permissible limit Action Turbocharger assembly Play in axle thrust direction 0 040 0 085 0 0016 0 0033 or less Replace Inspecting the boost pressure 22 1 kPa 0 23 kgf cm2 3 2 lbf ft in 2 Replace Tightening part Tightening torque Remarks Turbocharger mounting nut 70 714 52 ...

Page 78: ... SEAL 3 20 FLYWHEEL HOUSING 3 20 TIMING GEAR AND CAM IDLE GEAR 3 21 PISTON AND CONNECTING ROD 3 22 CRANKSHAFT 3 24 CYLINDER LINER 3 25 CYLINDER BLOCK 3 26 GLOW PLUG 3 26 EXHAUST 3 27 EXHAUST MANIFOLD 3 27 DPR 3 28 FUEL ADDITION VALVE 3 29 DEF PUMP 3 29 DEF INJECTOR 3 29 DEF TANK 3 30 DPR DIFFERENTIAL PRESSURE SENSOR 3 30 SCR UPSTREAM NOx SENSOR 3 30 SCR DOWNSTREAM NOx SENSOR 3 30 ATC DOWNSTREAM TE...

Page 79: ... For3 4 16UNF thread size Select according to the thread size of air gauge S0955 21060 Compression gauge adapter For W16 threads18 thread size 12081 E0090 Engine hanger Mounting on the engine front side SZ105 12024 Bolt Mounting two pcs on the engine front side S1228 11901 Engine hanger Mounting on the engine rear side SH782 41230 Bolt Mounting two pcs on the engine rear side S0949 11010 Wire rope...

Page 80: ...DST i after HINO DX Ver 3 0 5 Name Remarks Misting Used by putting water Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicl...

Page 81: ...HINO DX Ver 3 0 5 Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box C...

Page 82: ...TS Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer interfa...

Page 83: ...ER GAUGE EN01F02127020702003001 INSTRUMENTS WATER LEVEL WARNING SWITCH EN01F02127020702003002 INSTRUMENTS Name Remarks Circuit tester For measuring resistance across terminals Name Remarks Circuit tester For measuring continuity between terminals ...

Page 84: ...lt For positioning the supply pump Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer in...

Page 85: ...sVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer interface Without Bluetooth 95171 01020 With Bluetooth 95171 01040 DENSO DST i Set without LCD Without Blueto...

Page 86: ...emarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer interface Without Bluetooth 95...

Page 87: ...S J05E 3 10 FUEL FILTER AND CASE VEHICLE SIDE EN01F02127020702003006 COMMON TOOLS INSTRUMENTS Name Remarks Mityvac For inspecting the fuel heater Name Remarks Cylinder gauge For measuring resistance across terminals ...

Page 88: ...fter HINO DX Ver 3 0 5 Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface ...

Page 89: ...lashed detergent Rubber gloves For protecting skin from splashed detergent Protective garment For protecting cloth from splashed detergent Detergent PK 5300YP For cleaning the EGR cooler Reservoir metallic For cleaning the EGR cooler General purpose heater For cleaning the EGR cooler Shape Part No Name Remarks S0920 E0010 Vent pipe tool ...

Page 90: ...O DX Ver 3 0 5 Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Comp...

Page 91: ...O DX Ver 3 0 5 Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Comp...

Page 92: ...X Ver 3 0 5 Shape Part No Name Remarks Computer DOS V standard Operating system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Compute...

Page 93: ...or measuring the outer diameter of the rocker arm shaft Cylinder gauge For measuring the inner diameter of the rocker arm bush Thickness gauge For measuring valve clearance Name Remarks Flexible wire of approximately 0 8 mm 0 0315 in in diam eter For mounting the rocker arm Name Remarks Micrometer For measuring the camshaft cam height and journal outer diameter Cylinder gauge For measuring the inn...

Page 94: ...r measuring the under head length of the head bolt Straightedge Measuring the strain of bottom surface of cylinder head and manifold mounting surface Thickness gauge Measuring the strain of bottom surface of cylinder head and manifold mounting surface Name Remarks Liquid gasket ThreeBond TB1211 White or equivalent Apply to the cylinder block upper surface back end head gasket mating area of the fl...

Page 95: ...he valve stem seal Name Remarks Dolly block brass bar For removing the valve seat Magnet bar For removing the valve spring retainer Name Remarks Straightedge For measuring valve sink Thickness gauge For measuring valve sink and squareness of valve spring Squareness gauge For measuring squareness of valve spring Spring tester For measuring the valve spring set load Vernier calipers For measuring va...

Page 96: ... Shape Part No Name Remarks S0942 01731 Oil seal puller For pulling off a crankshaft front oil seal S0940 71030 Oil seal press For press fitting the crank shaft front oil seal Name Remarks Liquid gasket ThreeBond TB1207B Black or equivalent or ThreeBond TB1217G Gray or equivalent Apply to the front oil seal retainer mounting surface Shape Part No Name Remarks S0948 11340 Guide For attaching and de...

Page 97: ...ching the ring gear Shape Part No Name Remarks S0942 01742 Oil seal puller For pulling off a crankshaft rear oil seal S0940 71040 Oil seal press For mounting crankshaft rear oil seal Name Remarks Scraper For removing liquid gasket Name Remarks Liquid gasket ThreeBond TB1207D Silver or equivalent or ThreeBond TB1217G Gray or equivalent Apply to the joint surface of the rear end plate of the fly whe...

Page 98: ...or attaching and detaching the Torx bolt Name Remarks Scraper For removing liquid gasket Name Remarks Micrometer For measuring the outer diameter of each idle gear shaft Cylinder gauge For measuring the inner diameter of each idle gear bush Thickness gauge For measuring idle gear end play Dial gauge For measuring each gear backlash and camshaft end play Name Remarks Sealant Thread Lock Super 5M or...

Page 99: ...taching and detaching the connecting rod small end bush SL271 01036 Wing nut For attaching and detaching the connecting rod small end bush combined use with S0940 21530 S0940 21540 Spindle For attaching and detaching the connecting rod small end bush S0948 11540 Guide For attaching and detaching the connecting rod small end bush combined use with S0940 21540 SH691 20825 Bolt For attaching and deta...

Page 100: ...hick ness piston pin outer diameter and crank pin outer diame ter Thickness gauge For measuring the piston ring groove and piston ring end gap clearance Vernier calipers For measuring the under head length of the connecting rod bolt Dial gauge For measuring connecting rod end play Name Remarks Sandpaper about No 150 For removing the carbon adhered to the upper side of inner surface of the cylinder...

Page 101: ...ing the outer diameters of the crankshaft jour nal and crank pin Vernier calipers For measuring the width of the crankshaft center journal and the under head length of the main bearing cap bolt Cylinder gauge For measuring the crankshaft bearing inner diameter Name Remarks Dye penetrant red check For checking the crankshaft for cracks and damage THICKNESS ABOUT 10mm 0 394 in ARBITRARY M12X1 5 ABOU...

Page 102: ...42 02100 Cylinder liner puller For removing the cylinder liner S0947 11490 Guide For inserting the cylinder liner Name Remarks Bearing scraper Removing rust from the cylinder liner Name Remarks Dial gauge For measuring cylinder liner collar projection Name Remarks Dye penetrant red check For checking the cylinder liner for cracks and damage ...

Page 103: ...cooling jet 09211 E4020 Plug A tapping tool 09211 E4030 Plug B tapping tool Name Remarks Straightedge For measuring strain of upper surface of cylinder block Thickness gauge For measuring strain of upper surface of cylinder block Name Remarks Dye penetrant red check For checking the cylinder block for cracks and damage Sealant Loctite 962T or ThreeBond 1211 or 1215 For checking the cylinder block ...

Page 104: ...TEMS J05E 3 27 EXHAUST EXHAUST MANIFOLD EN01F02127020702007001 COMMON TOOLS Name Remarks Torque socket For attaching and detaching the stud bolt Stud bolt remover commercially available For removing the stud bolt ...

Page 105: ...ng system OS Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer interface Without Bluetooth 95171 01020 With Bluetooth 95171 01040 D...

Page 106: ... hose and using together Name Remarks 500 V megohmmeter For measuring parts Circuit tester For measuring resistance across terminals Name Remarks Glasses For protection of eyes by carbon cleaning agent scattering Rubber gloves For protection of skin by carbon cleaning agent scattering Protective garment For protection of clothes by carbon cleaning agent scatter ing Name Remarks Mobil velocite oil ...

Page 107: ...For DEF measurement Name Remarks pH test paper For DEF measurement Name Remarks Circuit tester For measuring resistance across terminals Name Remarks Circuit tester For measuring resistance across terminals Name Remarks Anti seizure lubricant Weicom Anti Seize ASW High Tech Assembly Paste or equivalent Apply to the threaded portion of SCR upstream NOx sen sor Name Remarks Circuit tester For measur...

Page 108: ...NEVER SEEZ Heavy Metal Free manufactured by Bostic Inc Apply to the threaded portion of ATC downstream tempera ture sensor Name Remarks Circuit tester For measuring resistance across terminals Name Remarks Anti seizure lubricant equivalent to NEVER SEEZ Heavy Metal Free manufactured by Bostic Inc Apply to the threaded portion of DOC upstream tempera ture sensor Name Remarks Circuit tester For meas...

Page 109: ...tance across terminals Name Remarks Anti seizure lubricant equivalent to NEVER SEEZ Heavy Metal Free manufactured by Bostic Inc Apply to the threaded portion of DPR downstream temper ature sensor Name Remarks Circuit tester For measuring resistance across terminals Name Remarks Anti seizure lubricant equivalent to NEVER SEEZ Pure Nickel Special Grade manufactured by Bostic Inc Apply to the threade...

Page 110: ...RUMENTS Configuration Part Number Name Remarks 09240 00020 Wire gauge set For measuring clearance between the valve and body 09242 00020 Wire gauge 0 2 mm content For measuring clearance between the valve and body Name Remarks Mityvac For inspecting the exhaust brake Name Remarks Circuit tester For measuring resistance across terminals ...

Page 111: ...OMMON TOOLS GREASE AND OTHERS Name Remarks Radiator cap tester commercially available For measuring valve opening pressure Name Remarks Vernier calipers For measuring valve lift amount Name Remarks Scraper For removing liquid gasket Name Remarks Liquid gasket ThreeBond TB1207B Black or equivalent Apply to the joining surface of the thermostat case ...

Page 112: ...HERS COOLANT TEMPERATURE SENSOR EN01F02127020702008004 INSTRUMENTS Name Remarks Scraper For removing liquid gasket Name Remarks Liquid gasket ThreeBond TB1207B Black or equivalent Apply to the coolant pump joint surface Name Remarks Circuit tester For measuring resistance across terminals ...

Page 113: ...hing the oil filter Name Remarks Scraper For removing liquid gasket Name Remarks Kerosene or detergent For washing the water oil groove well of the oil cooler ele ment Dye penetrant red check For checking the oil cooler element for cracks Liquid gasket ThreeBond TB1211 White or equivalent Apply to the gasket seal surface Liquid gasket ThreeBond TB1207B Black or equivalent Apply to the oil cooler a...

Page 114: ...ner diameter driven gear bush inner diameter cylinder block side pump housing inner diameter and cylinder block hole diameter Vernier calipers For measuring the drive gear outer diameter Dial gauge For measuring the backlashes between the drive gear and driven gear and between the oil pump drive gear and sub idle gear Name Remarks Scraper For removing liquid gasket Name Remarks Liquid gasket Three...

Page 115: ...RNATOR 130A EN01F02127020702012003 INSTRUMENTS Name Remarks Ammeter For measuring parts Circuit tester For measuring parts Dial gauge For measuring parts Thickness gauge For measuring parts Shape Part No Name Remarks S0944 41210 Compression gauge Name Remarks Circuit tester For measuring parts Micrometer For measuring parts ...

Page 116: ...S Windows2000 WindowsXP WindowsVista 2 Windows7 2 CPU and memory To guarantee proper operations of the oper ating systems listed above Display 800 x 600 pixel 256 or more col ors 09993 E9070 1 The main body and cables for RS 232C and USB Cable between vehicle and Hino Bowie S0904 21220 Hino Bowie Interface box Computer interface Without Bluetooth 95171 01020 With Bluetooth 95171 01040 DENSO DST i ...

Page 117: ...REQUIRED ITEMS J05E 3 40 COMMON TOOLS INSTRUMENTS Name Remarks Stud bolt remover For removing the stud bolt Name Remarks Dial gauge For measuring play in the axle thrust direction of the tur bine shaft ...

Page 118: ...THE ENGINE J05E 5 1 MOUNTING AND DISMOUNTING THE ENGINE J05E 5 001 5 ENGINE ASSEMBLY 5 2 PRECAUTIONS IN TILTING AND LOWERING THE CAB 5 2 MEASUREMENT OF COMPRESSION PRESSURE 5 2 ADJUSTING THE VALVE CLEARANCE 5 5 REPLACEMENT 5 7 ...

Page 119: ...t pipe can be very hot while your vehicle is operated Be sure to confirm they have been cooled down before you start working under the cab Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack Never put your body under the cab while raising or lowering the cab Make sure the cab stopper stay is securely locked by the catch E and raise the sto...

Page 120: ...ce INTAKE J05E AIR CLEANER REPLACEMENT MOUNTING THE AIR CLEANER ELEMENT AND BODY ASSEMBLY Page 9 23 5 Remove the all glow plugs Reference ENGINE MECHANICAL J05E GLOW PLUG REPLACEMENT REMOVING THE GLOW PLUG Page 10 129 6 Remove the 4 bolts from the glow plug hole 7 Disconnect the all connectors of each injector Reference FUEL SYSTEM J05E INJECTOR REPLACE MENT REMOVING THE INJECTOR Page 7 37 8 Conne...

Page 121: ...re the compression pressure of each cylinder continuously Engine speed 190 r min 4 Overhaul the engine if the compression pressure is at or below the permissible limit 5 Put back the removed parts in place after measurement 6 Use the HINO DX to delete the past malfunctions Refer to the HINO DX user s manual SST TO ENGINE SHTS021270400002 Part No Applicable parts S0955 21110 Insert to the injector ...

Page 122: ...r is at the compression stroke top dead center the valve clearance with mark in the table can be adjusted If the No 4 cylinder is at the compression stroke top dead center the cylinder with Δ mark can be adjusted 2 Fully loosen the adjust screw and lock nut of the crosshead CAUTION Make the adjust screw projecting beyond the upper surface of the crosshead by at least 10 mm 0 394 in Correct adjustm...

Page 123: ... becomes proper Tightening Torque 25 N m 255 kgf cm 18 lbf ft CAUTION Do not loosen the adjust screw too much If the adjust screw is made too loose the former state will be restored Although you may get proper feel with the thickness gauge a gap will be pro duced between the adjust screw of the crosshead and the valve and you cannot make correct adjustment NOTICE It is deemed appropriate if the th...

Page 124: ...revent burning Dispose the engine oil in accordance with the specified pro cedures industrial waste disposal or other environment friendly practices 2 Replace with a new gasket and mount the drain plug to the oil pan Tightening Torque 41 N m 418 kgf cm 30 lbf ft 5 DRAINING THE COOLANT Reference COOLING J05E RADIATOR REPLACEMENT REMOVING THE RADIATOR Page 12 5 6 DRAINING POWER STEERING FLUID Refere...

Page 125: ... the rear cab mounting bracket sub assembly from the frame 15 REMOVING THE RADIATOR Reference COOLING J05E RADIATOR REPLACEMENT REMOVING THE RADIATOR Page 12 5 16 REMOVING THE ALTERNATOR Reference STARTING CHARGING J05E ALTERNATOR 130A OVERHAUL OVERHAUL Page 16 13 17 DISCONNECTING THE STARTER HARNESS Reference STARTING CHARGING J05E STARTER REPLACEMENT REMOVING THE STARTER Page 16 3 18 DISCONNECTI...

Page 126: ...n bolt and detach the power steering oil pipe and gaskets 2 pcs from the power steering pump NOTICE Power steering oil will spill when disconnecting the pipe Prepare a reservoir and clean clothes 23 REMOVING THE CLOSED VENTILATOR Reference EMISSION CONTROL J05E CLOSED VENTILA TOR REPLACEMENT REMOVING THE CLOSED VENTILA TOR Page 8 14 24 REMOVING THE TRANSMISSION 1 Remove the transmission Reference ...

Page 127: ...engine 90 to the right and thrust it out from the vehicle CAUTION Do not allow the engine to contact with the frame and cab during work Handle it with care because it is a heavy load Do not allow the engine hoist wire rope to contact with the engine or transmission SST S0949 11010 Wire rope NOTICE For the 3 point hoist mount the eye bolt to the EGR pipe flange and then hook the wire rope NUT NUT L...

Page 128: ...le mount the engine while adjusting the engine mounting posi tion by using the tire lever 3 Tighten the 2 mounting nuts of the engine mounting Tightening Torque 98 N m 999 kgf cm 72 lbf ft 4 Remove the SST from the engine 2 MOUNTING THE TRANSMISSION ASSEMBLY Reference CHASSIS S1 LXJE03A TRANSMISSION Reference CHASSIS S1 LXJE04A TRANSMISSION 3 MOUNTING THE CLOSED VENTILATOR Reference EMISSION CONTR...

Page 129: ...n 5 CONNECTING THE FUEL HOSE 1 Connect the fuel hose return side and fuel hose feed side to fuel feed pipe No 4 and return pipe No 3 at the left rear of the fly wheel housing with 2 clamps CAUTION Align the marks on the pipe and hose to connect the hoses If the chassis side is disconnected to connect the hoses align the marks to connect them 6 CONNECTING OIL RESERVOIR OIL HOSE 1 Connect the oil re...

Page 130: ...G BLOCK HEATER Reference ENGINE CONTROL J05E BLOCK HEATER REPLACEMENT MOUNTING BLOCK HEATER Page 6 21 14 MOUNTING THE AIR CLEANER BODY ASSEMBLY Reference INTAKE J05E AIR CLEANER REPLACEMENT MOUNTING THE AIR CLEANER ELEMENT AND BODY ASSEMBLY Page 9 23 15 MOUNTING RELAY BLOCK 1 Mount the relay block to the cab mounting bracket 16 MOUNTING VACUUM RESERVOIR Reference CHASSIS S1 LXJE03A BRAKE Reference...

Page 131: ...el with the oil level gauge at the left of the engine Engine oil level L gal US CAUTION The engine is equipped with DPR exhaust gas purification unit Use a specified recommended brand engine oil to maintain the functions of the unit for a long time FILLER CAP SHTS021270400023 OIL LEVEL GAUGE SHTS021270400024 In oil pan Oil filter Approximately 8 0 2 1 Approximately 1 4 0 4 OIL LEVEL GAUGE NORMAL M...

Page 132: ... for fuel leakage 8 AIR BLEEDING OF POWER STEERING Reference CHASSIS S1 LXJE03A STEERING Reference CHASSIS S1 LXJE04A STEERING 9 INSPECTION FOR POWER STEERING FLUID LEAKAGE 1 Inspect for power steering fluid leakage 10 FILLING REFRIGERANT Reference CHASSIS S1 LXJE03A HEATER AIR CONDI TIONER Reference CHASSIS S1 LXJE04A HEATER AIR CONDI TIONER 11 INSPECTION FOR REFRIGERANT GAS LEAKAGE Reference CHA...

Page 133: ...AUGE 6 22 REPLACEMENT 6 22 INTAKE TEMPERATURE SENSOR 6 22 REPLACEMENT 6 22 DIESEL THROTTLE 6 22 REPLACEMENT 6 22 BOOST PRESSURE SENSOR 6 23 REPLACEMENT 6 23 AIR FLOW SENSOR 6 23 REPLACEMENT 6 23 DPR DIFFERENTIAL PRESSURE SENSOR 6 24 REPLACEMENT 6 24 SCR UPSTREAM NOx SENSOR 6 24 REPLACEMENT 6 24 SCR DOWNSTREAM NOx SENSOR 6 24 REPLACEMENT 6 24 ATC DOWNSTREAM TEMPERATURE SENSOR 6 25 REPLACEMENT 6 25 ...

Page 134: ...TO ACCELERATOR SENSOR KEY SWITCH BARMETRIC PRESSURE SENSOR ECU BUILT IN EXHAUST TEMPERATURE SENSOR DPF OUTLET EXHAUST TEMPERATURE SENSOR DPF INLET DPR DIFFERENTIAL PRESSURE SENSOR EXHAUST TEMPERATURE SENSOR DOC2 INLET EXHAUST TEMPERATURE SENSOR DOC1 INLET INTAKE TEMPERATURE SENSOR INTERCOOLER OUTLET INTAKE TEMPERATURE SENSOR INTAKE MANIFOLD EGR TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR 1 COOLA...

Page 135: ...ENGINE CONTROL J05E 6 3 COMPOSITION DIAGRAM ENGINE ECU COMPONENT LOCATOR EN01F02127050402007001 Tightening torque Unit N m kgf cm lbf ft 1 Engine ECU 2 ECU bracket A 28 5 290 21 A A 1 2 SHTS021270500002 ...

Page 136: ...ely connected to the engine ECU 2 Directly spray water around the engine ECU connector by using a spray bottle CAUTION While working do not disconnect the connectors NOTICE 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 sur face to remove dirt and foreign matter CAUTION While working do not disconnec...

Page 137: ... 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 detach the connector c Pull out the connector straight CAUTION Do not insert and remove the connector more than neces sary Do not give shocks to the engine ECU Never detach the harness by holding and pulling or prying as it may result in wire or terminal d...

Page 138: ...e engine ECU side connector is found dirty wipe off its side with a moistened waste cloth CAUTION Use the thoroughly wrung waste cloth Do not wipe off the terminal opening Do not directly spray water 10 Blow the air on the terminal part inside the engine ECU side con nector to remove dirt and foreign matter HARNESS SIDE CONNECTOR PORTIONS TO BE WIPE CLEAN DO NOT WIPE OFF THE TERMINAL SHTS021270500...

Page 139: ...gine ECU to the ECU bracket with the 4 bolts For the tightening order tighten them diagonally Tightening Torque 28 5 N m 290 kgf cm 21 lbf ft CAUTION 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 dis assemblable Do not paint o...

Page 140: ...raight on the engine ECU side connector CAUTION At this time check that the lever is fully open NOTICE Check that it is inserted along the wrong fitting prevention key way 2 Press the upper part of the harness side connector and insert the connector uniformly LEVER Rr Up SHTS021270500014 Rr Up WRONG FITTING PREVENTION KEYWAY SHTS021270500015 LEVER Rr Up SHTS021270500016 ...

Page 141: ...nector CAUTION 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 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 Rr Up SLIDING PORTION LEVER SHTS021270500017 Rr Up HOOK SHTS021270500018 ...

Page 142: ...ASSIS S1 LXJE04A ELECTRICAL 3 REMOVING THE VEHICLE CONTROL ECU Reference CHASSIS S1 LXJE03A ELECTRICAL Reference CHASSIS S1 LXJE04A ELECTRICAL MOUNTING THE VEHICLE CONTROL ECU 1 MOUNTING THE VEHICLE CONTROL ECU Reference CHASSIS S1 LXJE03A ELECTRICAL Reference CHASSIS S1 LXJE04A ELECTRICAL 2 CONNECTING THE HARNESS Reference CHASSIS S1 LXJE03A ELECTRICAL Reference CHASSIS S1 LXJE04A ELECTRICAL 3 MO...

Page 143: ...E CONTROL J05E 6 11 ENGINE SPEED MAIN SENSOR COMPONENT LOCATOR EN01F02127050402009001 Tightening torque Unit N m kgf cm lbf ft 1 Engine speed main sensor 2 Flywheel housing A 10 102 7 A 1 2 SHTS021270500019 ...

Page 144: ...eel housing MOUNTING THE ENGINE SPEED MAIN SENSOR 1 MOUNTING THE ENGINE SPEED MAIN SENSOR 1 Check that the O ring is attached to the engine speed main sen sor Mount the engine speed main sensor to the flywheel housing with bolts Tightening Torque 10 N m 102 kgf cm 7 lbf ft CAUTION Before reusing the O ring check the O ring for damage deforma tion and foreign matter NOTICE Gap adjustment is not nec...

Page 145: ...CONTROL J05E 6 13 ENGINE SPEED SUB SENSOR COMPONENT LOCATOR EN01F02127050402010001 Tightening torque Unit N m kgf cm lbf ft 1 Engine speed sub sensor 2 Cylinder head A 4 6 41 61 3 0 4 4 1 A 2 SHTS021270500023 ...

Page 146: ...er head MOUNTING THE ENGINE SPEED SUB SENSOR 1 MOUNTING THE ENGINE SPEED SUB SENSOR 1 Check that the O ring is attached to the engine speed sub sensor and mount the engine speed sub sensor to the cylinder head with the bolt Tightening Torque 4 6 N m 41 61 kgf cm 3 0 4 4 lbf ft CAUTION Before reusing the O ring check the O ring for damage deforma tion and foreign matter NOTICE Gap adjustment is not...

Page 147: ...ENGINE CONTROL J05E 6 15 IDLE SET VOLUME COMPONENT LOCATOR EN01F02127050402023001 1 Idle set volume 3 Idle set button 2 Ring nut 1 2 3 SHTS021270500027 ...

Page 148: ...ET VOLUME 1 Using the circuit tester measure resistance between the 1st and 3rd terminals of the connector parts side with the idle set volume shaft fully turned counterclockwise If the measured value exceeds the standard value replace the volume 2 While turning the idle set volume shaft measure resistance between the 2nd and 3rd terminals Check that the resistance value smoothly changes as the sh...

Page 149: ...l and fix it with the ring nut CAUTION Do not break the idle set volume Check the idle set volume for looseness 2 Fit the idle set button in the direction of the idle set volume claw Pull the idle set button to make sure that it is fixed and then con nect the harness connector CAUTION After mounting pull the button to make sure that it is securely fixed SHTS021270500031 ...

Page 150: ...ENGINE CONTROL J05E 6 18 ACCELERATOR PEDAL COMPONENT LOCATOR EN01F02127050402003001 Tightening torque Unit N m kgf cm lbf ft 1 Accelerator pedal assembly A 5 5 56 4 1 A SHTS021270500032 ...

Page 151: ...the output voltage does not meet the standard replace the accelerator pedal assembly MOUNTING THE ACCELERATOR PEDAL ASSEMBLY 1 MOUNTING THE ACCELERATOR PEDAL ASSEMBLY 1 Mount the accelerator pedal assembly with 2 nuts Tightening Torque 5 5 N m 56 kgf cm 4 lbf ft 2 Connect the connector of the accelerator pedal assembly ACCELERATOR PEDAL ASSEMBLY SHTS021270500033 Measured item Standard value V Acce...

Page 152: ...ENGINE CONTROL J05E 6 20 BLOCK HEATER COMPONENT LOCATOR EN01F02127050402086001 Tightening torque Unit N m kgf cm lbf ft 1 Bracket 2 Socket A 1 4 1 7 14 17 1 0 1 3 1 A 2 SHTS021270500035 ...

Page 153: ...socket to the bracket with the bolt Tightening Torque 1 4 1 7 N m 14 17 kgf cm 1 0 1 3 lbf ft 2 Mount the socket side connector to the socket 3 Fasten the harness with the clamp 4 Mount the block heater harness to the block heater or the cylinder block REMOVING BLOCK HEATER 1 REMOVING THE BLOCK HEATER 1 Disconnect the harness from the block heater 2 Pullout the block heater from the cylinder block...

Page 154: ...27050402055001 1 REMOVING THE INTAKE TEMPERATURE SENSOR Reference INTAKE J05E INTAKE TEMPERATURE SEN SOR REPLACEMENT REMOVING THE INTAKE TEMPERA TURE SENSOR Page 9 28 2 MOUNTING THE INTAKE TEMPERATURE SENSOR Reference INTAKE J05E INTAKE TEMPERATURE SEN SOR REPLACEMENT MOUNTING THE INTAKE TEMPERA TURE SENSOR Page 9 28 DIESEL THROTTLE REPLACEMENT EN01F02127050402038001 1 REMOVING THE DIESEL THROTTLE...

Page 155: ...UNTING THE BOOST PRESSURE SENSOR Reference INTAKE J05E BOOST PRESSURE SENSOR REPLACEMENT MOUNTING THE BOOST PRESSURE SEN SOR Page 9 31 AIR FLOW SENSOR REPLACEMENT EN01F02127050402006001 1 REMOVING THE AIR FLOW SENSOR Reference INTAKE J05E AIR FLOW SENSOR REPLACE MENT REMOVING THE AIR FLOW SENSOR Page 9 35 2 SINGLE UNIT INSPECTION 1 Use the HINO DX for inspection Refer to the HINO DX user s manual ...

Page 156: ...TIAL PRESSURE SENSOR Page 11 97 SCR UPSTREAM NOx SENSOR REPLACEMENT EN01F02127050402030001 1 REMOVING THE UPSTREAM NOx SENSOR Reference EXHAUST J05E SCR UPSTREAM NOx SEN SOR REPLACEMENT REMOVING THE SCR UPSTREAM NOx SENSOR Page 11 99 2 MOUNTING THE UPSTREAM NOx SENSOR Reference EXHAUST J05E SCR UPSTREAM NOx SEN SOR REPLACEMENT MOUNTING THE SCR UPSTREAM NOx SENSOR Page 11 100 SCR DOWNSTREAM NOx SEN...

Page 157: ... Reference EXHAUST J05E ATC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING THE ATC UPSTREAM TEMPERATURE SENSOR Page 11 106 DOC UPSTREAM TEMPERATURE SENSOR REPLACEMENT EN01F02127050402033001 1 REMOVING DOC UPSTREAM TEMPERATURE SENSOR Reference EXHAUST J05E DOC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING DOC UPSTREAM TEMPERATURE SENSOR Page 11 108 2 SINGLE UNIT INSPECTION Reference EXHAUST ...

Page 158: ...E DPR UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING THE DPR UPSTREAM TEMPERATURE SENSOR Page 11 111 DPR DOWNSTREAM TEMPERATURE SENSOR REPLACEMENT EN01F02127050402035001 1 REMOVING THE DPR DOWNSTREAM TEMPERATURE SEN SOR Reference EXHAUST J05E DPR DOWNSTREAM TEMPER ATURE SENSOR REPLACEMENT REMOVING THE DPR DOWNSTREAM TEMPERATURE SENSOR Page 11 113 2 SINGLE UNIT INSPECTION Reference EXHAUST J05E ...

Page 159: ...NSPECTION Page 11 117 3 MOUNTING THE SCR UPSTREAM TEMPERATURE SENSOR Reference EXHAUST J05E SCR UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING THE SCR UPSTREAM TEMPERATURE SENSOR Page 11 117 OUTSIDE TEMPERATURE SENSOR REPLACEMENT EN01F02127050402054001 1 REMOVING THE OUTSIDE TEMPERATURE SENSOR Reference EXHAUST J05E OUTSIDE TEMPERATURE SEN SOR REPLACEMENT REMOVING THE OUTSIDE TEMPERA TURE SENSO...

Page 160: ...ANT TEMPERATURE SENSOR Reference COOLING J05E COOLANT TEMPERATURE SENSOR REPLACEMENT MOUNTING THE COOLANT TEM PERATURE SENSOR Page 12 39 OIL PRESSURE SWITCH REPLACEMENT EN01F02127050402044001 1 REMOVING THE OIL PRESSURE SWITCH Reference LUBRICATION J05E OIL PRESSURE SWITCH REPLACEMENT REMOVING THE OIL PRESSURE SWITCH Page 13 31 2 SINGLE UNIT INSPECTION Reference LUBRICATION J05E OIL PRESSURE SWITC...

Page 161: ... CASE ENGINE SIDE 7 14 COMPONENT LOCATOR 7 14 REPLACEMENT 7 15 WATER LEVEL WARNING SWITCH 7 24 COMPONENT LOCATOR 7 24 REPLACEMENT 7 25 SUPPLY PUMP 7 27 COMPONENT LOCATOR 7 27 REPLACEMENT 7 28 INJECTOR 7 36 COMPONENT LOCATOR 7 36 REPLACEMENT 7 37 COMMON RAIL 7 46 COMPONENT LOCATOR 7 46 INSPECTION 7 47 REPLACEMENT 7 48 FUEL FILTER AND CASE VEHICLE SIDE 7 53 COMPONENT LOCATOR 7 53 REPLACEMENT 7 54 FU...

Page 162: ...P FEED PUMP SUCTION CONTROL VALVE ELEMENT OVER FLOW VALVE NEGATIVE PRESSURE SIDE NEGATIVE PRESSURE RETURN POSITIVE PRESSURE SIDE POSITIVE PRESSURE PRIMING PUMP VEHICLE SIDE FUEL FILTER ENGINE SIDE FUEL FILTER ENGINE SIDE CHASSIS SIDE FUEL COOLER FUEL TANK WATER LEVEL WARNING SWITCH FUEL QUANTITY VALVE FUEL SHUT VALVE SHTS021270600001 ...

Page 163: ...TATIVE EXAMPLE Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Fuel sender gauge 6 Clamp 2 Drain plug 7 Fixed bracket 3 Gasket 8 Fuel tank 4 Fuel hose 9 Fuel tank band 5 Breather hose 10 Fuel tank support A 24 5 34 3 250 349 19 26 B 96 144 979 1 468 71 106 1 4 9 10 7 8 3 2 A B 6 6 5 SHTS021270600002 ...

Page 164: ...akage and the ingress of dirt 5 Remove the drain plug and the gasket to drain the fuel CAUTION Dispose of the drained fuel in accordance with the regulation of disposal specified in each region 6 Unfasten 2 clamps then put alignment marks on the fuel hose and breather hose and disconnect them from the fuel tank 7 Remove the bolt 1 and lift the fuel tank to a position where the fixed bracket can be...

Page 165: ...rain plug and replace with a new gasket before mounting the drain plug Tightening Torque 24 5 34 3 N m 250 349 kgf cm 19 26 lbf ft 2 Place the fuel tank into the frame from the lower side and lift it to a position where space to accommodate the fixed bracket is avail able by using a jack or the like CAUTION When lifting be careful not to let the fuel tank touch the upper deck 3 Attach the fixed br...

Page 166: ... Fasten each hose with the clamp 7 Connect the connector of the fuel sender gauge then connect the 2 harness clamps 3 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 BREATHER HOSE FUEL HOSE SHTS021270600008 SHTS021270600009 ...

Page 167: ...3 Loosen the clamp of the feed hose and that of the return hose 4 Put the alignment marks on the feed hose and the return hose and disconnect them NOTICE After the fuel hoses are disconnected stop up both ends to pre vent fuel leakage and the ingress of dirt 5 Remove the drain plug and the gasket to drain the fuel CAUTION Dispose of the drained fuel in accordance with the regulation of disposal sp...

Page 168: ...FUEL SYSTEM J05E 7 8 6 Unfasten the double nut to remove the fuel tank band 7 Remove the fuel tank from the fuel tank support FUEL TANK FUEL TANK BAND DOUBLE NUT FUEL TANK SUPPORT SHTS021270600013 ...

Page 169: ...ing the fuel tank align the guide at the lower part of the fuel tank with the stay hole Assemble the fuel tank band so as to cover the seal on the top surface of the fuel tank 3 Mount the fuel tank band with the double nuts Tightening Torque 10 2 15 0 N m 105 152 kgf cm 8 11 lbf ft 4 After fastening the fuel tank band make sure to check that the fuel tank and fuel tank support are in close contact...

Page 170: ... make sure of the correct insert direction of bolt 6 Fasten the feed hose and the return hose with the clamps 7 Connect the harness clamp 8 Connect the connector of the fuel sender gauge 3 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 SHTS021270600017 SHTS021270600018 ...

Page 171: ...J05E 7 11 FUEL SENDER GAUGE COMPONENT LOCATOR EN01F02127060402010001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Fuel sender gauge 3 Fuel tank 2 Gasket A 1 5 2 5 16 25 1 2 1 8 1 2 3 SHTS021270600019 ...

Page 172: ... gauge and the gasket from the fuel tank NOTICE Prepare a reservoir and a waste cloth because the fuel spills when the fuel sender gauge is removed SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Make sure that the float of the fuel sender gauge smoothly moves 2 Use the circuit tester to measure the resistance between termi nals when changing the float position between Point E and F If the me...

Page 173: ... CAUTION Note the mounting direction to avoid interference with the buffer plate of the tank interior wall After assembly start the engine for testing and check for fuel leakage from around the fuel sender gauge While working be careful not to make dirt and water enter parts Before mounting parts make sure that there is no dirt on the connection between them 2 CONNECTING THE HARNESS 1 Connect the ...

Page 174: ...ENGINE SIDE COMPONENT LOCATOR EN01F02127060402042001 Tightening torque Unit N m kgf cm lbf ft 1 Fuel filter 3 Priming pump 2 Drain plug 4 Air bleeding plug A 5 9 51 91 3 7 6 6 C 55 561 41 B 23 1 32 9 236 335 18 24 A 1 B 4 3 2 C SHTS021270600023 ...

Page 175: ...ied in each region Do not fail to drain water because the ingress of water into the fuel causes not only poor driving but also damage to the engine 3 Tighten the drain plug of the fuel filter Tightening Torque 5 9 N m 51 91 kgf cm 3 7 6 6 lbf ft 4 Connect the hose to the air bleeding plug 5 Turn the priming pump to the left to lift it up and then move it up and down 6 Operate the priming pump up a...

Page 176: ...the left to lift it up and then move it up and down 4 Operate the priming pump up and down continuously to pump the fuel so that no air is bled from the air bleeding hose CAUTION Check that the air bleeding plug of the fuel filter is loosened Check that the air bleeding plug of the vehicle side fuel filter is tightened Keep the cover free from brake fluid or other substances containing organic sol...

Page 177: ...he reservoir under the drain plug to receive the drained fuel 2 Loosen the drain plug and then the air bleeding plug of the fuel fil ter and drain the fuel from the drain plug Check that the fuel is no longer drained from the drain plug and then tighten the drain plug Tightening Torque 5 9 N m 51 91 kgf cm 3 7 6 6 lbf ft CAUTION Drain the fuel in accordance with the regulation of disposal specifie...

Page 178: ... CAUTION Do not reuse the element Replace the O ring with a new one included in the element kit 5 Set the cap on the fuel filter case with the alignment marks aligned with each other and tighten the center bolt Tightening Torque 23 1 32 9 N m 236 335 kgf cm 18 24 lbf ft CAUTION Be careful not to damage the O ring by twisting it Check that the O ring is in correct contact with the sealing surface A...

Page 179: ... then tighten the drain plug with a new O ring Tightening Torque 5 9 N m 51 91 kgf cm 3 7 6 6 lbf ft CAUTION Drain the fuel in accordance with the regulation of disposal speci fied in each region 3 DISCONNECTING THE HARNESS 1 Disconnect the connector connected to the water level warning switch 4 REMOVING THE FUEL PIPE 1 Unfasten 2 union bolts to disconnect return pipe No 2 from the fuel filter cas...

Page 180: ...ste cloth because fuel spills when disconnecting the fuel pipe 6 Unfasten 3 union bolts to remove fuel feed pipe No 3 and the gas ket from the fuel filter case and supply pump NOTICE Prepare a reservoir and a waste cloth because fuel spills when disconnecting the fuel pipe 7 Unfasten the clamp to disconnect the hose from the fuel filter case RETURN PIPE No 2 CLIP SHTS021270600038 CLIP HOSE CLAMP F...

Page 181: ...n the clip 5 REMOVING THE FUEL FILTER 1 Remove the bolts 2 pcs and remove the fuel filter CAUTION Be careful not to spill the residual fuel in the fuel filter case INTERCEPTION VALVE FUEL FEED PIPE No 3 SHTS021270600041 FUEL FILTER SHTS021270600042 ...

Page 182: ... lbf ft 3 MOUNTING THE FUEL PIPE 1 Attach the clip with the nut and fix fuel feed pipe No 3 2 Connect the hose to the fuel filter with the clamp 3 Connect fuel feed pipe No 3 to the fuel filter supply pump and fuel shutoff valve with a new gasket and 3 union bolts Tightening Torque 30 N m 306 kgf cm 22 lbf ft Fuel filter side 14 8 19 6 N m 151 199 kgf cm 11 14 lbf ft Supply pump side 19 6 N m 200 ...

Page 183: ...w gasket and 2 union bolts Tightening Torque 30 N m 306 kgf cm 22 lbf ft Fuel filter side 24 5 N m 250 kgf cm 18 lbf ft Intake manifold side 4 CONNECTING THE HARNESS 1 Connect the connector to the water level warning switch CAUTION Before connecting the connectors make sure that the terminals are free of a spark mark 5 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENG...

Page 184: ...TCH COMPONENT LOCATOR EN01F02127060402022001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Air bleeding plug 3 Drain plug 2 Water level warning switch 4 O ring A 5 9 51 91 3 7 6 6 B 2 3 21 30 1 5 2 2 1 4 3 2 4 A B 4 SHTS021270600050 ...

Page 185: ...ghtening Torque 5 9 N m 51 91 kgf cm 3 7 6 6 lbf ft CAUTION Drain the fuel in accordance with the regulation of disposal speci fied in each region 2 DISCONNECTING THE HARNESS 1 Disconnect the connector connected to the water level warning switch 3 REMOVING THE WATER LEVEL WARNING SWITCH 1 Remove the water level warning switch from the fuel filter case NOTICE Prepare a reservoir and a waste cloth b...

Page 186: ...f cm 1 5 2 2 lbf ft CAUTION After the water level warning switch is attached start the engine for a trial run to check for fuel leakage from around the switch 2 CONNECTING THE HARNESS 1 Connect the connector to the water level warning switch CAUTION Before connecting the connectors make sure that the terminals are free of a spark mark 3 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL F...

Page 187: ...J05E 7 27 SUPPLY PUMP COMPONENT LOCATOR EN01F02127060402007001 Nonreusable part 1 Pipe A 5 O ring 2 Pipe B 6 Cup ring flange 3 Supply pump 7 Bearing holder case 4 Cut ring 8 O ring 8 1 2 3 7 6 4 5 SHTS021270600057 ...

Page 188: ...in the fuel from the drain plug Check that the fuel is no longer drained from the drain plug and then tighten the drain plug with a new O ring Tightening Torque 5 9 N m 51 91 kgf cm 3 7 6 6 lbf ft CAUTION Drain the fuel in accordance with the regulation of disposal speci fied in each region 3 REMOVING THE FUEL FILTER CASE 1 Remove the fuel filter case and the fuel pipe Reference FUEL SYSTEM J05E F...

Page 189: ...ssure feed pipe 6 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 flywheel hous ing 2 Turn the crankshaft in the running direction of the engine coun terclockwise viewed from the flywheel side to align the timing mark put on the periphery of the flywheel with 1 through the ...

Page 190: ...t at the compression stroke top dead center In this case detach the SST turn the crankshaft and attach the SST again to see if it is seated Before turning the crankshaft do not fail to pull out the SST Do not perform cranking with the SST inserted 7 REMOVING THE SUPPLY PUMP CAUTION While working be careful not to make dirt or water enter the parts Do not remove pipe A or B Hold the pipe not to app...

Page 191: ... Unfasten the nut with the coupling flange locked with a vise and remove the coupling flange 3 Unfasten 2 bolts to remove the bearing holder case and O ring from the supply pump SUPPLY PUMP COUPLING FLANGE O RING BEARING HOLDER CASE SHTS021270600068 COUPLING FLANGE SHAFT BEARING HOLDER CASE NUT SHTS021270600069 BEARING HOLDER CASE O RING BOLT SUPPLY PUMP SHTS021270600070 ...

Page 192: ...istance between the ter minals If the measured value is in excess of the standard value replace the supply pump 3 INSPECTING THE RESISTANCE OF THE FUEL TEMPERA TURE SENSOR 1 Using the circuit tester measure the resistance between the ter minals If the measured value is in excess of the standard value replace the supply pump FUEL TEMPERATURE SENSOR SUCTION CONTROL VALVE SHTS021270600071 SUCTION CON...

Page 193: ...iewed from the flywheel side to align the timing mark put on the periphery of the flywheel with 1 through the check window of the flywheel housing 3 MOUNTING THE SUPPLY PUMP 1 Mount the bearing holder case to the supply pump with a new O ring and 2 bolts Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 2 Mount the coupling flange to the shaft 3 Fix the supply pump and tighten the nuts while prevent...

Page 194: ... pump with the No 1 cylinder set at the compression stroke top dead center and the cast mark and 0 mark stamped on the front face of the coupling aligned with each other 6 Make sure that the No 1 cylinder is set at the compression stroke top dead center and then remove the SST and attach the timing checking window plug CAUTION After all parts are assembled do not fail to remove the SST and mount t...

Page 195: ...ER AND CASE ENGINE SIDE REPLACEMENT MOUNTING THE FUEL FIL TER ENGINE SIDE Page 7 22 7 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 8 UPDATING THE SUPPLY PUMP LEARNED VALUE 1 When replacing the supply pump update the learned value recorded in the engine ECU by using HINO DX Refer to the HINO DX user s manua...

Page 196: ... COMPONENT LOCATOR EN01F02127060402004001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Leakage pipe 4 Injector 2 Gasket 5 Injector clamp 3 Injection pipe oil seal 6 O ring A 25 255 18 1 2 2 4 5 A 6 3 SHTS021270600083 ...

Page 197: ...ge pipe and 5 gaskets CAUTION The leakage pipe can be twisted easily Use care in handling 3 REMOVING THE INJECTOR HARNESS 1 Disconnect each connector connected to the injector 2 Unfasten 5 nuts to remove the injector harness together with the injector harness bracket CAUTION The injector harness bracket can be twisted easily Use care in handling NOTICE For easy removal detach the connector of the ...

Page 198: ...UTION Do not reuse the injection pipes Be careful when handling the pipe because the fuel pipe may be deformed NOTICE Prepare the reservoir and a waste cloth because fuel spills when removing the injection pipes 5 REMOVING THE INJECTOR 1 Remove the 4 injection pipe oil seals from the cylinder head SHTS021270600087 SHTS021270600088 HEAVY GOODS INCORRECT INCORRECT SHTS021270600089 SHTS021270600090 ...

Page 199: ...r will be dam aged 2 Use the circuit tester measure the resistance between terminals 3 The resistance values of 1 and 2 exceed the standard value replace the injector 2 CLEANING THE INJECTOR 1 Use the clean clothes to remove sludge adhered to the terminal part and its perimeter CAUTION Use the clean clothes to wipe off sludge without using any detergent Use of detergent causes it to penetrate whic...

Page 200: ...e 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 and a detergent It is advisable to perform a contact check using red lead 2 Make sure that the inside of the nozzle seat is free of sludge or foreign matters CYLINDER HEAD NOZZLE SEAT SHTS021270600094 ...

Page 201: ...r clamp and injector at the same time CAUTION Apply engine oil to the O ring Use care not to get the O ring jammed when inserting it Note that if the O ring is damaged fuel will leak out and the engine will fail to start to run Do not fix the injector clamp until the injection pipe is fit tem porarily 2 Set the new injection pipe oil seal to the injector CAUTION Mount the injection pipe oil seal s...

Page 202: ...jection pipes will be arranged in the order of the numbers engraved on the nuts shown in the figure below 4 Tighten the injector clamp mounting bolt Tightening Torque 25 N m 255 kgf cm 18 lbf ft CAUTION 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 wre...

Page 203: ...d write an injector compensation value QR code indicated on a new injector in the engine ECU Write the incorrect compensation value may cause engine troubles NOTICE Injector compensation value can be written by means of a combined use of the PC tool and QR code reader The work flow is indicated below For the detailed procedure see the HINO DX instruction manual SHTS021270600100 INJECTOR QR CODE SH...

Page 204: ...et with 5 bolts 2 Connect each connector of the injector harness CAUTION Before connecting the connectors make sure that the terminals are free of a spark mark NOTICE For easy installation attach the connector of the cylinder head first HINO BOWIE DST i OR QR CODE READER NEW INJECTOR ENGINE SPECIFICATION CODE QR CODE COMPUTER CONNECTOR ENGINE ECU SHTS021270600102 NUT CONNECTOR INJECTOR HARNESS BRA...

Page 205: ...ew pitch is different between 4 injector union bolts and the cylinder head union bolt An X mark is put on the cylinder head union bolt 6 MOUNTING THE HEAD COVER Reference ENGINE MECHANICAL J05E HEAD COVER REPLACEMENT MOUNTING THE HEAD COVER Page 10 4 7 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 UNION BOL...

Page 206: ...PONENT LOCATOR EN01F02127060402005001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Common rail 4 Injection pipe 2 Common rail pressure sensor 5 Clip 3 Bracket A 28 5 291 21 B 44 449 32 1 A 2 3 5 5 5 5 4 B 5 SHTS021270600108 ...

Page 207: ...er parts 3 Attach the union to the pressure limiter and connect a vinyl hose to the end of the union 4 Place the fuel reservoir under the free end of the vinyl hose 5 Start the engine If the fuel continuously flows out replace the pressure limiter with a common rail assembly WARNING When the pressure limiter is working fuel flow out at a high tem perature and pressure serious injury like scalding ...

Page 208: ...ECTING THE FUEL PIPE 1 Unfasten 3 union bolts to remove 3 gaskets Then disconnect return pipe No 1 from the pressure limiter and cylinder head NOTICE Prepare a reservoir and a waste cloth because fuel spills when disconnecting the fuel pipe 3 REMOVING THE INJECTION PIPE Reference FUEL SYSTEM J05E INJECTOR REPLACE MENT REMOVING THE INJECTOR Page 7 37 4 REMOVING THE PRESSURE FEED PIPE Reference FUEL...

Page 209: ...void entry of dirt into the com mon rail Remove dirt from around each part and detach the common rail Remove the common rail together with the flow damper the common rail pressure sensor and the pressure limiter NOTICE Prepare the reservoir and a waste cloth because fuel spills when removing the common rail PRESSURE LIMITTER COMMON RAIL PRESSURE SENSOR FLOW DUMPER BRACKET BOLT COMMON RAIL SHTS0212...

Page 210: ...ting the pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 MOUNTING THE COMMON RAIL 1 Mount the common rail and bracket to the intake manifold with 2 bolts Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 3 MOUNTING THE PRESSURE FEED PIPE Reference FUEL SYSTEM J05E COMMON RAIL REPLACEMENT MOUNTING THE COMMON RAIL Page 7 50 PRESSURE LIMITTER COMMON RAIL PRESS...

Page 211: ...TICE Mount the injection pipes so that the flare tightening nuts of the injection pipes will be arranged in the order of the numbers engraved on the nuts shown in the figure below 2 Mount the 5 clips with 5 nuts and fix the injection pipe 5 MOUNTING THE FUEL PIPE 1 Mount the return pipe No 1 to the pressure limiter and cylinder head with 3 new gaskets and 3 union bolts Tightening Torque 20 N m 204...

Page 212: ...spring lock clicks and returns Before connecting the connectors make sure that the termi nals are free of a spark mark 7 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 COMMON RAIL SHTS021270600121 COMMON RAIL SIDE SPRING LOCK HARNESS SIDE MALE CONNECTOR FEMALE CONNECTOR SHTS021270600122 ...

Page 213: ... FILTER AND CASE VEHICLE SIDE COMPONENT LOCATOR EN01F02127060402041001 Tightening torque Unit N m kgf cm lbf ft 1 Drain plug 4 O ring 2 Air bleeding plug 5 Clamp 3 Cover 6 Fuel filter A 17 5 178 13 A 6 5 2 4 3 1 SHTS021270600123 ...

Page 214: ...el pipe Use Hino s genuine fuel filter element 1 FUEL DISCHARGE 1 Prepare reservoir under the drain plug to receive the drained fuel 2 Loosen the drain plug and then the air bleeding plug of the fuel fil ter and drain the fuel from the drain plug Check that the fuel is no longer drained from the drain plug and then tighten the drain plug CAUTION Do not use a tool to tighten it Drain the fuel in ac...

Page 215: ...G THE ELEMENT 1 Clean the element setting faces inside the fuel filter cover and inside the fuel filter body 2 Replace the element with a new one and insert it into the fuel filter cover 3 Apply fuel to the new O ring and mount it into the groove of the fuel filter cover CAUTION Do not reuse the element Replace the O ring with a new one included in the element kit DIRECTION OF ROTATION COVER CLAW ...

Page 216: ... to damage the O ring by twisting it Check that the O ring is in correct contact with the sealing surface Do not use a tool to tighten it 4 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 O RING COVER CLAW DIRECTION OF ROTATION SHTS021270600128 ...

Page 217: ...nnection between them Air enters the fuel pipe in the process of mounting the pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 FUEL DISCHARGE 1 Prepare reservoir under the drain plug to receive the drained fuel 2 Loosen the drain plug and then the air bleeding plug of the fuel fil ter and drain the fuel from the drain plug DRAIN PLUG AIR BLEEDING PLUG SHTS...

Page 218: ...n of disposal specified in each region 3 DISCONNECTING THE HARNESS 1 Disconnect the connector connected to the fuel heater Vehicle with fuel heater 4 REMOVING THE FUEL HOSES 1 Unfasten 2 clamps to disconnect 2 fuel hoses from the fuel filter body NOTICE Prepare the reservoir and a waste cloth because fuel spills when disconnecting the fuel hoses DRAIN PLUG AIR BLEEDING PLUG SHTS021270600130 SHTS02...

Page 219: ...SINGLE UNIT INSPECTION 1 INSPECTION OF FUEL HEATER VEHICLE WITH FUEL HEATER 1 Seal the fuel IN side Using a mityvac apply a vacuum of 30 8 31 8 kPa 231 238 mmHg to the fuel out side 2 Using the circuit tester measure the resistance between the ter minals CAUTION Note that the value may vary according to the temperature or mea surement method NOTICE Measure the resistance with the fuel filter insta...

Page 220: ...nection between them Air enters the fuel pipe in the process of mounting the pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 MOUNTING FUEL FILTER ASSEMBLY 1 Mount the fuel filter assembly with 2 bolts Tightening Torque 17 5 N m 178 kgf cm 13 lbf ft 3 MOUNTING THE FUEL HOSE 1 Connect the 2 fuel hoses to the fuel filter body with 2 clamps SHTS021270600135 S...

Page 221: ... heater Vehicle with fuel heater CAUTION Before connecting the connectors make sure that the terminals are free of a spark mark 5 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM Page 7 16 SHTS021270600137 ...

Page 222: ...FUEL SYSTEM J05E 7 62 FUEL COOLER COMPONENT LOCATOR EN01F02127060402027001 Tightening torque Unit N m kgf cm lbf ft 1 Clamp 3 Fuel cooler 2 Fuel hose 4 Bracket A 25 255 18 A 3 4 1 1 2 2 SHTS021270600138 ...

Page 223: ...he pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 REMOVING THE FUEL HOSES 1 Unfasten 2 clamps to disconnect 2 fuel hoses from the fuel cooler NOTICE Prepare the reservoir and a waste cloth because fuel spills when disconnecting the fuel hoses For easy disconnection slightly twist the fuel hose when pulling it out 3 REMOVING FUEL COOLER 1 Unfasten 4 bolts...

Page 224: ...ir enters the fuel pipe in the process of mounting the pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 MOUNTING THE FUEL COOLER 1 Mount the fuel cooler to the bracket with 4 bolts Tightening Torque 25 N m 255 kgf cm 18 lbf ft 3 CONNECTING THE FUEL HOSE 1 Connect the 2 fuel hoses to the fuel cooler with 2 clamps FUEL COOLER SHTS021270600141 FUEL COOLER SHT...

Page 225: ...EMISSION CONTROL J05E 8 1 EMISSION CONTROL J05E 8 001 8 EGR VALVE COOLER 8 2 COMPONENT LOCATOR 8 2 INSPECTION 8 3 REPLACEMENT 8 3 CLOSED VENTILATOR 8 10 COMPONENT LOCATOR 8 10 REPLACEMENT 8 12 ...

Page 226: ...OLER COMPONENT LOCATOR EN01F02114070402016001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 EGR pipe 5 EGR cooler 2 Gasket 6 EGR valve 3 Coolant hose 7 Gasket 4 Clamp A 68 5 699 51 B 55 561 41 4 3 A 4 3 2 B 1 8 B B 2 6 2 3 4 5 A SHTS021270700001 ...

Page 227: ...er cooling to prevent burns Turn the starter key to the LOCK position and leave it for more than 30 minutes to cool 2 DRAINING THE COOLANT Reference COOLING J05E RADIATOR REPLACEMENT REMOVING THE RADIATOR Page 12 5 3 REMOVING THE EGR PIPE 1 Remove the engine harness from 2 brackets 2 Unfasten the 3 bolts and nut to remove 2 brackets from the EGR pipe CAUTION Do not touch the EGR pipe with bare han...

Page 228: ...ase 5 REMOVING THE EGR COOLER 1 Unfasten the 2 bolts to remove the bracket from the EGR cooler 2 Unfasten the 3 bolts to remove the EGR cooler and gasket from the exhaust manifold CAUTION Do not hold the pipe and shell while working to avoid defects such as dent and water leakage Do not touch the EGR cooler with bare hands while it is hot immediately after running COOLANT HOSE COOLANT HOSE PIPE PA...

Page 229: ...e EGR valve If any of these components is removed or loosened the EGR valve will deteriorate in performance If the bolts nuts and snap rings are removed and the EGR valve is disassembled do not reassemble the EGR valve Replace it with a new one Do not hold the link when replacing the EGR valve assembly If the link is held it may bend and cause a malfunction EGR VALVE GASKET LINK INTAKE MANIFOLD SH...

Page 230: ... the MSDS Material Safety Data Sheet before use 2 JUDGMENT OF CLEANING 1 If the EGR valve is found stuck check soot accumulation in the EGR cooler If it is 2 mm 0 079 in or more clean the EGR cooler CAUTION Remove the coolant hose in advance to avoid possible damage due to immersion in the detergent 3 CLEANING THE EGR COOLER 1 Prepare the reservoir metallic that is deep enough to immerse the EGR c...

Page 231: ...ut Repeat this 2 3 times NOTICE Dissolved carbon inside the EGR cooler flows out If carbon stain cannot be removed easily use a nylon brush 5 DRYING THE EGR COOLER 1 After all carbon stains are removed by rinsing blow off water inside the EGR cooler with an air blower Dry it for about 10 min utes Shake the body 2 3 times to check if no carbon lump comes out and reuse it EGR COOLER DISSOLVED CARBON...

Page 232: ...68 5 N m 699 kgf cm 51 lbf ft CAUTION Do not hold the pipe and shell while working to avoid defects such as dent and water leakage 2 Mount the bracket to the EGR cooler with 2 bolts Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 3 CONNECTING THE COOLANT HOSE 1 Connect the coolant hose to the EGR cooler and thermostat case with 2 clamps 2 Connect the coolant hose to the EGR cooler and coolant pipe...

Page 233: ... N m 561 kgf cm 41 lbf ft 2 Mount the 2 brackets to the EGR pipe with 3 bolts and a nut Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 3 Mount the engine harness to 2 brackets 5 ADDING THE COOLANT Reference COOLING J05E RADIATOR REPLACEMENT MOUNTING THE RADIATOR Page 12 9 EGR PIPE SHTS021270700013 BRACKET BRACKET ENGINE HARNESS SHTS021270700014 ...

Page 234: ...TILATOR COMPONENT LOCATOR EN01F02114070402011001 Tightening torque Unit N m kgf cm lbf ft 1 Cap 5 Clamp 2 Closed ventilator 6 Oil pipe 3 Ventilator hose A 7 Bracket 4 Ventilator hose B A 31 316 23 5 3 1 A A 5 4 7 A 2 5 6 5 SHTS021270700015 ...

Page 235: ...EMISSION CONTROL J05E 8 11 1 Closed ventilator 3 Element 2 Cap 4 Body 1 2 3 4 SHTS021270700016 ...

Page 236: ...EMENT 1 Remove the 2 bolts and remove the closed ventilator cover 2 Remove the cap while pressing and turning it counterclockwise 3 Remove the element from the body 4 Remove the O ring from the cap COVER SHTS021270700017 CAP CLOSED VENTILATOR SHTS021270700018 CAP O RING BODY ELEMENT SHTS021270700019 ...

Page 237: ... ring is nonreusable Remove the dirt or foreign matter on the O ring mounting surface NOTICE It is recommended that the element of the closed ventilator be replaced once after replacing the oil filter twice Reference LUBRICATION J05E OIL FILTER REPLACEMENT REMOVING THE OIL FILTER Page 13 4 4 Mount the closed ventilator cover from the 2 bolts Tightening Torque 31 N m 316 kgf cm 23 lbf ft CENTER BOS...

Page 238: ...ide break SST S0920 E0010 Vent pipe tool HINT For non reusable clamp the clamp break when you remove them 4 Using the SST remove the clamp on the vehicle side break SST S0920 E0010 Vent pipe tool HINT For non reusable clamp the clamp break when you remove them 5 Using the flat blade screwdriver etc break out of the clamp closed ventilator under body HINT For non reusable clamp the clamp break when...

Page 239: ...emove the closed ventilator from the bracket 3 Using the SST remove the clamp on the flywheel housing side break SST S0920 E0010 Vent pipe tool NOTICE Prepare the reservoir and clean clothes to collect dripping engine oil when disconnecting the oil hose COVER SHTS021270700027 CAP CLOSED VENTILATOR SHTS021270700028 Rh Fr SST CLAMP SHTS021270700029 ...

Page 240: ...0 E0010 Vemt pipe tool NOTICE Installed so that the clamp claw in the direction of A Install the new clamp 2 Mount the closed ventilator to the bracket with the 4 bolts Tightening Torque 31 N m 316 kgf cm 23 lbf ft 3 Mount the closed ventilator cover from the 2 bolts Tightening Torque 31 N m 316 kgf cm 23 lbf ft Rh Fr SST CLAMP Rh A Fr A X SHTS021270700030 CAP CLOSED VENTILATOR SHTS021270700031 CO...

Page 241: ...dard value X 6 mm 0 236 in or less SST S0920 E0010 Vent pipe tool 6 Attach the hose on the engine side attach the clamp is crimped using a SST Standard value X 6 mm 0 236 in or less SST S0920 E0010 Vent pipe tool 7 Connect the ventilator hose B to the closed ventilator and cylinder head with 2 clamps and the bolt Tightening Torque 31 N m 316 kgf cm 23 lbf ft NOTICE Do not twist the ventilator hose...

Page 242: ...COOLER 9 14 OVERHAUL 9 14 STACK DUCT 9 15 COMPONENT LOCATOR 9 15 CLEANING THE PRECLEANER HOUSING 9 16 REPLACEMENT 9 17 AIR CLEANER 9 19 COMPONENT LOCATOR 9 19 REPLACEMENT 9 21 CLEANING THE AIR CLEANER ELEMENT 9 25 INTAKE TEMPERATURE SENSOR 9 26 COMPONENT LOCATOR 9 26 REPLACEMENT 9 28 BOOST PRESSURE SENSOR 9 29 COMPONENT LOCATOR 9 29 INSPECTION 9 30 REPLACEMENT 9 30 AIR FLOW SENSOR 9 32 COMPONENT L...

Page 243: ...INTAKE J05E 9 2 COMPOSITION DIAGRAM INTAKE MANIFOLD COMPONENT LOCATOR EN01F02114080402004001 Nonreusable part 1 Intake manifold 2 Gasket 1 2 SHTS021270800001 ...

Page 244: ...E EGR VALVE COOLER Page 8 3 3 REMOVING THE CLOSED VENTILATOR Reference EMISSION CONTROL J05E CLOSED VENTILA TOR REPLACEMENT REMOVING THE CLOSED VENTILA TOR Page 8 14 4 REMOVING THE FUEL FILTER CASE Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT REMOVING THE FUEL FIL TER Page 7 19 5 DISCONNECTING THE RETURN PIPE No 3 1 Remove the nut and then the clip 2 Unfasten the bolts a...

Page 245: ... when replacing the EGR valve assembly If the link is held it may bend and cause a malfunction 7 REMOVING THE COMMON RAIL Reference FUEL SYSTEM J05E COMMON RAIL REPLACEMENT REMOVING THE COMMON RAIL Page 7 48 8 REMOVING THE GLOW PLUG VEHICLE EQUIPPED WITH A GLOW PLUG Reference ENGINE MECHANICAL J05E GLOW PLUG REPLACEMENT REMOVING THE GLOW PLUG Page 10 129 9 REMOVING THE INTAKE MANIFOLD 1 Unfasten t...

Page 246: ...he 8 bolts and 2 nuts to remove the intake manifold and gasket from the cylinder head NOTICE Block the openings of the intake manifold with gummed tape to prevent the ingress of dirt into it GASKET INTAKE MANIFOLD SHTS021270800006 ...

Page 247: ... pump and com mon rail 4 Mount the 2 clips with 2 nuts and fix the pressure feed pipe 2 MOUNTING THE GLOW PLUG Reference ENGINE MECHANICAL J05E GLOW PLUG REPLACEMENT MOUNTING THE GLOW PLUGS Page 10 130 3 MOUNTING THE COMMON RAIL Reference FUEL SYSTEM J05E COMMON RAIL REPLACEMENT MOUNTING THE COMMON RAIL Page 7 50 4 MOUNTING THE EGR VALVE 1 Replace the gasket with a new one and temporarily attach t...

Page 248: ...REPLACEMENT MOUNTING THE FUEL FIL TER ENGINE SIDE Page 7 22 7 MOUNTING THE CLOSED VENTILATOR Reference EMISSION CONTROL J05E CLOSED VENTILA TOR REPLACEMENT MOUNTING THE CLOSED VENTILA TOR Page 8 16 8 MOUNTING THE EGR PIPE Reference EMISSION CONTROL J05E EGR VALVE COOLER REPLACEMENT MOUNTING THE EGR VALVE COOLER Page 8 8 9 CONNECTING THE HARNESS 1 Mount the engine harness around the intake manifold...

Page 249: ...J05E 9 8 DIESEL THROTTLE COMPONENT LOCATOR EN01F02114080402017001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Intake manifold 3 Gasket 2 Diesel throttle A 28 5 291 21 1 3 2 A A SHTS021270800011 ...

Page 250: ...OVING THE INTERCOOLER HOSE OUTLET HOSE Reference COOLING J05E INTERCOOLER OVERHAUL REMOVING THE INTERCOOLER Page 12 21 2 REMOVING THE DIESEL THROTTLE 1 Unfasten the 2 bolts and 2 nuts and remove the diesel throttle and gasket from the intake manifold 3 DISCONNECTING THE HARNESS 1 Disconnect the connector from the diesel throttle DIESEL THROTTLE INTAKE MANIFOLD SHTS021270800012 CONNECTOR DIESEL THR...

Page 251: ...e 28 5 N m 291 kgf cm 21 lbf ft CAUTION When assembling the diesel throttle exercise care not to impose an impact on the valve Do not use the diesel throttle if an impact is imposed on the valve If any portion of the gasket remains on the diesel throttle set ting face of the intake pipe remove it before attaching the diesel throttle 3 MOUNTING THE INTERCOOLER HOSE OUTLET HOSE Reference COOLING J05...

Page 252: ...INTAKE J05E 9 11 INTAKE PIPE EXHAUST SIDE COMPONENT LOCATOR EN01F02114080402020001 1 Primary intake hose 3 Clamp 2 Turbocharger 1 3 2 SHTS021270800016 ...

Page 253: ...eference COOLING J05E INTERCOOLER OVERHAUL REMOVING THE INTERCOOLER Page 12 21 3 REMOVING THE INTAKE PIPE EXHAUST SIDE 1 Unfasten the 4 bolts to remove the secondary intake pipe and gasket from the turbocharger assembly 2 Loosen the clamp of the primary intake hose and ventilator hose to remove the primary intake hose NOTICE Block the opening of the turbocharger with gummed tape to pre vent the in...

Page 254: ...0 kgf cm 1 8 3 6 lbf ft CAUTION No sealing agent must be used at the air inlet and outlet to prevent defects such as breakage due to clogging or looseness in the tightening area 5 Replace with a new gasket and mount the secondary intake pipe to the turbocharger assembly with 4 bolts Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 2 MOUNTING THE INTERCOOLER HOSE INLET HOSE Reference COOLING J05E IN...

Page 255: ...erence COOLING J05E INTERCOOLER REMOVING THE INTERCOOLER Page 12 21 2 INSPECTING THE INTERCOOLER 1 Inspect the radiator core for dirt or crushing If found defective clean or adjust or replace it 3 MOUNTING THE INTERCOOLER Reference COOLING J05E INTERCOOLER MOUNTING THE INTERCOOLER Page 12 22 ...

Page 256: ...INTAKE J05E 9 15 STACK DUCT COMPONENT LOCATOR EN01F02114080402011001 Tightening torque Unit N m kgf cm lbf ft 1 Stack duct 3 Duct mount 2 Intake hose A 19 5 199 14 B 13 133 10 2 1 3 A B SHTS021270800019 ...

Page 257: ...ECLEANER HOUSING 1 Clean the inside of the precleaner housing with a cloth CAUTION When cleaning the precleaner housing exercise care not to allow water to enter the air cleaner 3 MOUNTING THE WING 1 Mount the plate and the wing to the stack duct with 8 screws STACK DUCT PLATE WING SHTS021270800020 STACK DUCT PRECLEANER HOUSING SHTS021270800021 STACK DUCT PLATE WING SHTS021270800022 ...

Page 258: ...the duct mount 2 Loosen the clamp and disconnect the intake hose from the bot tom of the stack duct 2 REMOVING THE DUCT MOUNT 1 Unfasten the bolt to remove the duct mount from the cab 2 Unfasten the 2 bolts to remove 2 duct mounts from the bracket CLAMP INTAKE HOSE STACK DUCT SHTS021270800023 BRACKET CAB DUCT MOUNT DUCT MOUNT DUCT MOUNT SHTS021270800024 ...

Page 259: ...ightening Torque 19 5 N m 199 kgf cm 14 lbf ft 2 MOUNTING THE STACK DUCT 1 Insert the intake hose to the lower part of the stack duct and tighten the clamp Tightening Torque 2 4 5 0 N m 25 50 kgf cm 1 8 3 6 lbf ft 2 Mount the stack duct to the duct mount with 3 nuts Tightening Torque 13 N m 133 kgf cm 10 lbf ft BRACKET CAB DUCT MOUNT DUCT MOUNT DUCT MOUNT SHTS021270800025 CLAMP INTAKE HOSE STACK D...

Page 260: ...NT LOCATOR EN01F02114080402008001 WIDE CAB SINGLE CAB Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Air cleaner body assembly 3 Air cleaner element 2 Cover 4 Air flow sensor A 2 4 5 0 25 50 1 8 3 6 1 2 3 4 A SHTS021270800027 ...

Page 261: ...5E 9 20 WIDE CAB CREW CAB Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Air cleaner body assembly 3 Air cleaner element 2 Cover 4 Air flow sensor A 2 4 5 0 25 50 1 8 3 6 A 4 1 3 2 SHTS021270800028 ...

Page 262: ...e cover to the inboard side 2 Hold the grip at the center of the air cleaner element and remove the air cleaner element from the air cleaner body assembly NOTICE To remove the air cleaner element of the crew cab model draw it out to the vehicle rear side rotate it 90 to the right side of the vehicle and pull it off toward the vehicle lower side SINGLE CAB COVER COVER AIR CLEANER CASE AIR CLEANER C...

Page 263: ...ference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT REMOVING THE ENGINE ASSEMBLY Page 5 7 4 Unfasten the 4 nuts securing the air cleaner body assembly and remove the air cleaner body assembly from the air cleaner bracket AIR FLOW SENSOR CONNECTOR CLAMP INTAKE HOSE No 1 SHTS021270800031 SINGLE CAB AIR CLEANER BRACKET AIR CLEANER BRACKET AIR CLEANER BODY ASSEMBLY AIR CLEANER...

Page 264: ...nt the fender side apron right Reference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT MOUNTING THE ENGINE ASSEMBLY Page 5 11 4 Match the alignment marks before connecting the intake hose No 1 to the air cleaner body assembly Tightening Torque 2 4 5 0 N m 25 50 kgf cm 1 8 3 6 lbf ft 5 Connect the connector to the air flow sensor SINGLE CAB AIR CLEANER BRACKET AIR CLEANER BRA...

Page 265: ...rom the vehicle lower side rotate it 90 to the left of the vehicle around the air cleaner body assembly and insert it to the case 2 Mount the cover on the air cleaner body assembly with the clamps 3 pcs that secured the cover SINGLE CAB AIR CLEANER ELEMENT AIR CLEANER ELEMENT SEAL RUBBER AIR CLEANER BODY ASSEMBLY AIR CLEANER BODY ASSEMBLY CREW CAB AIR CLEANER ELEMENT SHTS021270800035 SINGLE CAB CO...

Page 266: ...replace the air cleaner element 2 If dry dust is adhered blow compressed air 690 kPa 7 0 kgf cm2 100 lbf in 2 or less from the upper flow side of the air cleaner ele ment to remove dust CAUTION Do not hit the air cleaner element or throw it down to the floor when removing dust AIR CLEANER ELEMENT SEAL RUBBER SHTS021270800037 AIR CLEANER ELEMENT SHTS021270800038 ...

Page 267: ...6 INTAKE TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02114080402026001 INTAKE MANIFOLD Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Intake temperature sensor 2 Washer A 19 6 200 14 1 A 2 SHTS021270800039 ...

Page 268: ...INTAKE J05E 9 27 INTERCOOLER Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Intake temperature sensor 2 Washer A 19 6 200 14 1 2 A SHTS021270800040 ...

Page 269: ... and washer from the intake manifold and intercooler MOUNTING THE INTAKE TEMPERATURE SENSOR 1 MOUNTING THE INTAKE TEMPERATURE SENSOR 1 Replace with a new washer and attach the intake temperature sensor to the intake manifold and intercooler Tightening Torque 19 6 N m 200 kgf cm 14 lbf ft 2 CONNECTING THE HARNESS 1 Mount the clip to the bracket 2 Connect the connector to the intake temperature sens...

Page 270: ...INTAKE J05E 9 29 BOOST PRESSURE SENSOR COMPONENT LOCATOR EN01F02114080402021001 1 Boost pressure sensor 3 Hose 2 Clamp 2 3 2 1 SHTS021270800043 ...

Page 271: ...ENSOR 1 DISCONNECTING THE HARNESS 1 Disconnect the connector connected to the boost pressure sen sor 2 REMOVING THE BOOST PRESSURE SENSOR 1 Unfasten the 2 bolts to remove the boost pressure sensor from the intake manifold 2 Unfasten the clamps 2 pcs securing the hose and remove the hose from the boost pressure sensor CONNECTOR BOOST PRESSURE SENSOR SHTS021270800044 CLAMP HOSE BOOST PRESSURE SENSOR...

Page 272: ...e clamps 2 pcs that secured the hose 2 Mount the boost pressure sensor on the intake manifold with 2 bolts Tightening Torque 5 N m 51 kgf cm 3 7 lbf ft 2 CONNECTING THE HARNESS 1 Connect the connector to the boost pressure sensor CLAMP HOSE BOOST PRESSURE SENSOR INTAKE MANIFOLD SHTS021270800046 CONNECTOR BOOST PRESSURE SENSOR SHTS021270800047 ...

Page 273: ...INTAKE J05E 9 32 AIR FLOW SENSOR COMPONENT LOCATOR EN01F02114080402009001 Tightening torque Unit N m kgf cm lbf ft 1 Air flow sensor A 0 56 0 82 5 8 8 3 0 42 0 60 1 A SHTS021270800048 ...

Page 274: ... air flow sensor aside from the one mounted to the vehicle 2 Mount the HINO DX 3 Measure the intake air volume at NMR see the following by using the air flow sensor mounted to the vehicle in accordance with measurement of intake air volume of the HINO DX A NOTICE NMR No Load Maximum Revolution 4 Warm up the engine fully first After confirming the safety of sur roundings depress the accelerator ful...

Page 275: ...ounted before finishing the inspection Calculation formula B A B 100 10 b If the both air flow sensors show an equal flow rate the air flow sensor mounted to the vehicle functions normally Mount the original air flow sensor again before finishing the inspec tion Tightening Torque 0 56 0 82 N m 5 8 8 3 kgf cm 0 42 0 60 lbf ft CAUTION The flow rate detecting element wire is processed with extreme in...

Page 276: ...HE AIR FLOW SENSOR 1 MOUNTING THE AIR FLOW SENSOR 1 Make sure that the O ring is attached to the air flow sensor and mount the air flow sensor with screws 2 pcs Tightening Torque 0 56 0 82 N m 5 8 8 3 kgf cm 0 42 0 60 lbf ft CAUTION Do not apply excessive torque to the air flow sensor mounting screw M 3 5 when tightening it 2 CONNECTING THE HARNESS 1 Connect the connector to the air flow sensor CO...

Page 277: ... 53 REPLACEMENT 10 54 FLYWHEEL ASSEMBLY 10 56 COMPONENT LOCATOR 10 56 OVERHAUL 10 57 CRANKSHAFT REAR OIL SEAL 10 61 COMPONENT LOCATOR 10 61 REPLACEMENT 10 62 FLYWHEEL HOUSING 10 65 COMPONENT LOCATOR 10 65 REPLACEMENT 10 66 TIMING GEAR CAM IDLE GEAR 10 70 COMPONENT LOCATOR 10 70 CONFIGURATION DIAGRAM 10 71 OVERHAUL 10 71 PISTON AND CONNECTING ROD 10 84 COMPONENT LOCATOR 10 84 OVERHAUL 10 85 CRANKSH...

Page 278: ...SITION DIAGRAM HEAD COVER COMPONENT LOCATOR EN01F02127090402013001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Half round plugs 3 Head cover 2 Head cover gasket 4 Silent block A 28 5 291 21 1 1 2 3 4 A SHTS021270900001 ...

Page 279: ...nnector then detach the harness from top of the cylinder head 3 REMOVING THE HEAD COVER 1 Unfasten the 13 bolts to remove 13 silent blocks and a head cover 2 Remove the head cover gasket from the head cover 3 If oil leak is found from the half round plug remove the half round plugs at the cylinder head front and rear ends 2 pcs CAUTION Do not remove the half round plugs unless oil leak is found BO...

Page 280: ...0590 0 0984 in width Apply the liquid gasket seamlessly Mount the case within 20 minutes after applying the liquid gasket 3 Mount the new half round plug to the upper side of the cylinder head parallel and ensure that the plug comes in contact with the head at the bottom 4 After mounting the half round plug wipe out the liquid gasket that swells out of the upper surface of the cylinder head immedi...

Page 281: ...tact with harnesses harness brackets and other cylinder head inner parts carefully mount the head cover without applying excessive force Wait at least 15 minutes after assembly before start of driv ing 4 Remove the swollen liquid gasket completely NOTICE Rubber spacers are attached to the silent block 3 CONNECTING THE HARNESS 1 Mount the harness to the cylinder head then connect the connec tor 4 M...

Page 282: ...EN01F02127090402014001 Tightening torque Unit N m kgf cm lbf ft 1 Crosshead 5 Spacer 2 Rocker arm intake 6 Adjust screw 3 Rocker arm shaft 7 Rocker arm exhaust 4 Rocker support A 25 255 18 B 36 367 27 3 1 6 4 4 4 4 4 B 2 B B B 5 7 2 5 7 A 2 5 7 2 5 7 SHTS021270900009 ...

Page 283: ...INJECTOR Page 7 37 3 REMOVING THE ROCKER ARM ASSEMBLY 1 Loosen the lock nut to wind up the adjust screw completely CAUTION Remove the adjust screw without winding may cause the rocker arm shaft to bend 2 Gradually loosen the rocker arm support bolts and camshaft bear ing cap mounting bolts from the center to remove the rocker arm and camshaft NOTICE The camshaft bearing caps and rocker arm support...

Page 284: ...to measure the inner diameter of the rocker arm bush 3 Calculate the gap between the outer diameter of the rocker arm shaft and the inner diameter of the rocker arm bush If a calcu lated value exceeds the permissible limit replace the rocker arm shaft or rocker arm bush SPACER ROCKER SUPPORT ROCKER ARM EXHAUST ROCKER ARM INTAKE ROCKER ARM SHAFT SHTS021270900012 SHTS021270900013 Standard value mm i...

Page 285: ...r individual valves CAUTION Off position of the crossheads on individual valves will cause the upper seat to lift resulting in valve dislodgement NOTICE To check whether the crossheads are properly seated in place manually move each crosshead to right and left to aurally check a clicking sound 2 Check that the rocker arms are properly assembled to the rocker arm shaft CAUTION Apply engine oil to t...

Page 286: ... diameter to bind rocker arms together for intake and exhaust respectively 2 MOUNTING THE ROCKER ARM ASSEMBLY 1 Apply engine oil to the cam ridge and set the rocker arm and rocker arm shaft on the crosshead properly Gradually tighten the bolts in the order as shown in the figure Tightening Torque 36 N m 367 kgf cm 27 lbf ft CAUTION After tightening check that the rocker arms move smoothly LOCK NUT...

Page 287: ...NICAL J05E ROCKER ARM ASSEMBLY OVERHAUL ADJUSTING THE VALVE CLEAR ANCE Page 10 12 3 MOUNTING THE INJECTOR HARNESS Reference FUEL SYSTEM J05E INJECTOR REPLACE MENT MOUNTING THE INJECTOR Page 7 41 4 MOUNTING THE HEAD COVER Reference ENGINE MECHANICAL J05E HEAD COVER REPLACEMENT MOUNTING THE HEAD COVER Page 10 4 CROSSHEADS SHTS021270900021 ...

Page 288: ...compression stroke top dead center you can adjust the valve clearance with a mark on the table If the No 4 cylinder is at the compression stroke top dead center the cylinder with mark can be adjusted 2 Fully loosen the adjust screw and lock nut of the crosshead CAUTION Make the adjust screw projecting beyond the upper surface of the crosshead by at least 10mm 0 394 in Correct adjustment cannot be ...

Page 289: ...nut of the crosshead at a position where your feel of the thickness gauge becomes proper Tightening Torque 25 N m 255 kgf cm 18 lbf ft CAUTION Do not loosen the adjust screw too much Excessive loosening of the adjust screw will set the condition back to the original state Sensory detection with the thickness gauge may be proper but there will be an excessive gap between the crosshead adjust screw ...

Page 290: ...ENGINE MECHANICAL J05E 10 14 CAMSHAFT ASSEMBLY COMPONENT LOCATOR EN01F02127090402015001 1 Cylinder head 2 Camshaft bearings 1 2 SHTS021270900027 ...

Page 291: ...ENGINE MECHANICAL J05E 10 15 Tightening torque Unit N m kgf cm lbf ft 1 Camshaft drive gear 2 Camshaft A 59 602 44 2 1 A SHTS021270900028 ...

Page 292: ...ECTOR Page 7 37 3 REMOVING THE ROCKER ARM ASSEMBLY 1 Loosen the lock nut and wind up the adjust screw completely to remove the rocker arm assembly Reference ENGINE MECHANICAL J05E ROCKER ARM ASSEMBLY OVERHAUL REMOVING THE ROCKER ARM ASSEMBLY Page 10 7 4 REMOVING THE 1 Remove the camshaft bearing from the camshaft bearing cap and cylinder head NOTICE Push either of camshaft bearing halves with a fi...

Page 293: ...ometer to measure the cam height If the value exceeds the permissible limit replace the camshaft 2 INSPECTING THE CAMSHAFT BEARING OIL CLEARANCE 1 Use the micrometer to measure the outer diameter of the cam shaft journal CAMSHAFT CAMSHAFT GEAR SHTS021270900030 SHTS021270900031 Measured item Standard value mm in Permissible limit mm in Cam height Intake 50 067 1 971 49 987 1 968 Exhaust 52 104 2 05...

Page 294: ...camshaft Reference ENGINE MECHANICAL J05E CAMSHAFT ASSEMBLY OVERHAUL INSPECTING THE COMPONENTS Page 10 17 5 INSPECTING FOR BACKLASH BETWEEN THE CAMSHAFT DRIVE GEAR AND CAM IDLE GEAR 1 Use the dial gauge to measure the backlash between the cam shaft drive gear and cam idle gear Reference ENGINE MECHANICAL J05E TIMING GEAR CAM IDLE GEAR OVERHAUL INSPECTING THE COMPO NENTS Page 10 73 6 INSPECTING CAM...

Page 295: ...tighten the bolt by another 90 1 4 turns CAUTION Do not loosen the bolt even if it is overtightened Be careful that the gear is free from deformation dent or damage during work MOUNTING THE CAMSHAFT ASSEMBLY 1 SETTING THE COMPRESSION STROKE TOP DEAD CENTER OF No 1 CYLINDER 1 Set the No 1 cylinder at the compression stroke top dead center Reference FUEL SYSTEM J05E SUPPLY PUMP REPLACE MENT MOUNTING...

Page 296: ...of 1 5 from front to back Tightening Torque 36 N m 367 kgf cm 27 lbf ft 3 Check that the end play of the camshaft is within the standard value Reference ENGINE MECHANICAL J05E TIMING GEAR CAM IDLE GEAR OVERHAUL INSPECTING INSTALLATION OF EACH GEAR Page 10 80 4 MOUNTING THE ROCKER ARM ASSEMBLY 1 Loosen the lock nut and wind up the adjust screw completely mounting the rocker arm assembly Reference E...

Page 297: ...E MECHANICAL J05E 10 21 CYLINDER HEAD ASSEMBLY COMPONENT LOCATOR EN01F02127090402016001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Cylinder head 2 Gasket A 59 602 44 1 A A 2 SHTS021270900042 ...

Page 298: ...HARGER ASSEMBLY Reference TURBOCHARGER J05E TURBOCHARGER ASSEMBLY REPLACEMENT REMOVING THE TURBO CHARGER ASSEMBLY Page 17 5 6 REMOVING THE EXHAUST MANIFOLD Reference EXHAUST J05E EXHAUST MANIFOLD REPLACEMENT REMOVING THE EXHAUST MANIFOLD Page 11 4 7 REMOVING THE EGR VALVE AND COOLER Reference EMISSION CONTROL J05E EGR VALVE COOLER REPLACEMENT REMOVING THE EGR VALVE COOLER Page 8 3 8 REMOVING THERM...

Page 299: ...AL J05E HEAD COVER REPLACEMENT REMOVING THE HEAD COVER Page 10 3 2 REMOVING THE INJECTOR HARNESS Reference FUEL SYSTEM J05E INJECTOR REPLACE MENT REMOVING THE INJECTOR Page 7 37 3 REMOVING THE ROCKER ARM ASSEMBLY Reference ENGINE MECHANICAL J05E ROCKER ARM ASSEMBLY OVERHAUL REMOVING THE ROCKER ARM ASSEMBLY Page 10 7 4 REMOVING THE CAMSHAFT ASSEMBLY Reference ENGINE MECHANICAL J05E CAMSHAFT ASSEMBL...

Page 300: ...bench to pro tect peripheral parts against any load CAUTION If the injector is mounted be careful not to damage the nozzle end 6 Remove the head gasket from the cylinder head or cylinder block INSPECTING THE COMPONENTS 1 INSPECTING LENGTH OF HEAD BOLTS 1 Use the vernier calipers to measure the head bolt under head M12 only If the measurement reading exceeds the permissible limit replace the head b...

Page 301: ... for the rear end plate so that the gasket will be flush with the upper surface of the cylinder block 2 Clean the upper surface of cylinder block CAUTION Before working remove dirt water or oil on the cylinder head and cylinder block CYLINDER BLOCK FLYWHEEL HOUSING CUT OFF HERE WITH SCRAPER GASKET REAR END PLATE SHTS021270900047 CYLINDER BLOCK UPPER SHTS021270900048 ...

Page 302: ...block upper surface rear end and head gasket mating area of the flywheel housing 2 places NOTICE When applying liquid gasket use care not to allow the sur face of liquid gasket to go over the upper surface of the head gasket Install the case within 20 minutes after applying the liquid gasket GASKET DOWEL PIN SHTS021270900049 SHTS021270900050 APPLY LIQUID GASKET HERE A LIQUID GASKET HEAD GASKET CYL...

Page 303: ...th a sub idle gear Forced engagement of gear teeth may cause dent or chip ping resulting in troubles such as abnormal noise or chipped teeth NOTICE When setting the cylinder head in place use of guide bolts can prevent off position of liquid gasket 4 Apply engine oil to the bolt seat surface and threaded part of head bolts 5 Tighten the 18 head bolts M12 only cylinder head to cylinder block in the...

Page 304: ...TOR Reference FUEL SYSTEM J05E INJECTOR REPLACE MENT MOUNTING THE INJECTOR Page 7 41 4 MOUNTING THE CAMSHAFT ASSEMBLY Reference ENGINE MECHANICAL J05E CAMSHAFT ASSEMBLY OVERHAUL MOUNTING THE CAMSHAFT ASSEMBLY Page 10 19 5 MOUNTING THE ROCKER ARM ASSEMBLY Reference ENGINE MECHANICAL J05E ROCKER ARM ASSEMBLY OVERHAUL MOUNTING THE ROCKER ARM ASSEMBLY Page 10 9 6 MOUNTING THE INJECTOR HARNESS Referenc...

Page 305: ...ING J05E THERMOSTAT CASE AND THERMOSTAT OVERHAUL MOUNTING THERMOSTAT CASE AND THERMOSTAT Page 12 27 7 MOUNTING THE EGR VALVE AND COOLER Reference EMISSION CONTROL J05E EGR VALVE COOLER REPLACEMENT MOUNTING THE EGR VALVE COOLER Page 8 8 8 MOUNTING THE EXHAUST MANIFOLD Reference INTAKE J05E INTAKE PIPE EXHAUST SIDE REPLACEMENT MOUNTING THE INTAKE PIPE EXHAUST SIDE Page 9 13 9 MOUNTING THE TURBOCHARG...

Page 306: ...CYLINDER HEAD 1 Use the scraper to remove carbon and other adherents 2 Wash the cylinder head CAUTION When removing carbon and other adherents do not damage the bottom surface of the cylinder head 3 REMOVING THE HALF ROUND PLUG 1 If oil leak is found from the half round plug remove the half round plugs at the cylinder head front and rear ends 2 pcs CAUTION Do not remove the half round plugs unless...

Page 307: ...EMBLING THE VALVE SYSTEM Page 10 37 8 REMOVING THE VALVE SEAT Reference ENGINE MECHANICAL J05E VALVE SYSTEM OVERHAUL DISASSEMBLING THE VALVE SYSTEM Page 10 37 9 REMOVING THE CAM IDLE GEAR Reference ENGINE MECHANICAL J05E TIMING GEAR CAM IDLE GEAR OVERHAUL REMOVING THE CAMSHAFT DRIVE GEAR AND CAM IDLE GEAR Page 10 71 10 REMOVING NOZZLE SEATS 1 Tap nozzle seats from the lower side of the cylinder he...

Page 308: ...late to prevent the deformation in the head Do not adjust the bottom surface by grinding or the timing gear backlash will be changed 2 Use the dye penetrant testing red check to inspect for crack and damage on the cylinder head If found defective replace the cylin der head STRAIGHTEDGE RIGHT ANGLE DIRECTION LONGITUDINAL DIRECTION SICKNESS GAUGE LOCATION OF MEASUREMENT SHTS021270900064 Measurement ...

Page 309: ...Ball 2 MOUNTING THE CAM IDLE GEAR Reference ENGINE MECHANICAL J05E TIMING GEAR CAM IDLE GEAR OVERHAUL MOUNTING THE CAMSHAFT DRIVE GEAR AND CAM IDLE GEAR Page 10 77 3 MOUNTING THE VALVE SEAT Reference ENGINE MECHANICAL J05E VALVE SYSTEM OVERHAUL ASSEMBLING THE VALVE SYSTEM Page 10 42 4 MOUNTING THE VALVE GUIDE Reference ENGINE MECHANICAL J05E VALVE SYSTEM OVERHAUL ASSEMBLING THE VALVE SYSTEM Page 1...

Page 310: ...at the cylinder head front and rear ends as shown in the figure CAUTION Apply the liquid gasket seamlessly Mount the case within 20 minutes after applying the liquid gasket 3 Mount the new half round plug to the upper side of the cylinder head parallel and ensure that the plug comes in contact with the head at the bottom 4 After mounting the half round plug wipe out the liquid gasket that swells o...

Page 311: ... INJECTOR HARNESS CONNECTOR 1 Replace with the new O ring and fit it to the injector harness con nector 2 Mount the injector harness connector to the cylinder head with 2 bolts O RING SHTS021270900071 INJECTOR HARNESS CONNECTOR SHTS021270900072 ...

Page 312: ...VALVE SYSTEM COMPONENT LOCATOR EN01F02127090402009001 1 Crosshead 5 Valve spring retainer 2 Intake valve 6 Exhaust valve 3 Spring 7 Valve stem seal 4 Spring seat lower 8 Spring seat upper 1 8 8 5 5 3 3 4 4 7 6 2 7 SHTS021270900073 ...

Page 313: ...valves NOTICE For storage sort by cylinder number and by intake and exhaust 4 REMOVING THE VALVE AND VALVE SPRING 1 Use the SST to remove the valve spring retainer while compress ing the valve spring removing the spring seat upper and valve spring SST S0947 01170 Valve spring press CAUTION If eye bolts are used fasten them via washers and use care not to cause a potential risk of damaging the uppe...

Page 314: ... with care because it is a heavy load Put tags with relevant cylinder numbers to the valves and valve springs so that the combination of the valve and cylin der head will not be changed 5 REMOVING THE VALVE STEM SEAL 1 Use the pliers to pull off the valve stem seal while shaking it right to left NOTICE Pull out the seal with a bar shaped tool by using leverage will facilitate the work VALVE SHTS02...

Page 315: ...e unnecessary valve to replace the valve seat After cutting out three parts from the valve periphery weld to the valve seat CAUTION Before welding apply grease to the bottom surface of the cylinder head to protect from spatter 2 Place the dolly block such as a brass bar to the valve stem head and pull off the valve seat by using the press VALVE GUIDE DOLLY BLOCK USE A PRESS TO PULL OFF THE VALVE G...

Page 316: ...rmissible limit replace the valve spring VALVE SEAT VALVE INTAKE EXHAUST CYLINDER HEAD AMOUNT OF VALVE SINKING SHTS021270900082 Measured item Standard value mm in Permissible limit mm in Intake 0 55 0 85 0 0217 0 0335 1 1 0 0433 Exhaust 1 15 1 45 0 0452 0 0571 1 7 0 0669 INTAKE VALVE VALVE SEAT 30 45 EXHAUST SHTS021270900083 Measured item Stan dard value Permissible angle Valve seat Intake 30 30 3...

Page 317: ...RANCE OF THE VALVE GUIDE AND VALVE STEM 1 Use the micrometer to measure the outside diameter of the valve stem SHTS021270900086 Measured item Standard value Permissi ble limit Inner spring Set length mm in 44 8 1 764 Set load N kgf 128 5 13 1 118 2 12 Outer spring Set length mm in 46 8 1 843 Set load N kgf 313 8 32 288 7 29 4 SHTS021270900087 Measured item Standard value mm in Permissible limit mm...

Page 318: ...ooled valve seat to the cylinder head mount ing area using the dolly block and hammer CAUTION Make sure of orientation face side and back side of a valve seat Be careful not to break the valve seat because it is sintered part NOTICE The valve seat with an outer diameter of 41 mm 1 614 in is for intake and 39 mm 1 535 in for exhaust SHTS021270900089 Measured item Standard value mm in Intake valve g...

Page 319: ... guide end when press fitting 3 MOUNTING THE VALVE STEM SEAL 1 Mount the spring seat lower before the valve stem seal 2 Apply engine oil to the lip and inner surface of the valve stem seal Use the SST to tap in the valve stem seal until the SST comes in contact with the spring seat lower SST S0947 22100 Bar CAUTION After assembling the valve stem seal check for deformation crack and inclination of...

Page 320: ...assembly can be faced sideways by using manpower However handle it with care because it is a heavy load When reusing the valve check that the valve stem is free from damage NOTICE There is an engraving of I intake or E exhaust at the center of the valve bottom 2 Check that the spring seat lower is mounted and place the valve spring and then spring seat upper on the cylinder head 3 Insert the valve...

Page 321: ... the valve spring retainer vertically to the SST will facilitate the work Constant pitch valve springs do not require vertical orienta tion top and bottom prior to mount 5 MOUNTING THE CROSSHEAD 1 Apply engine oil to crosshead guide pins and install the cross heads 2 Check that crossheads are properly seated on or over individual valves and apply engine oil to the heads of the crossheads 6 MOUNTIN...

Page 322: ...ENGINE MECHANICAL J05E 10 46 CRANKSHAFT PULLEY COMPONENT LOCATOR EN01F02127090402048001 Tightening torque Unit N m kgf cm lbf ft 1 Crankshaft pulley A 118 1 203 87 1 A SHTS021270900102 ...

Page 323: ...rt a large flat blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft 2 Unfasten the remaining bolts while supporting the crankshaft pul ley and remove the crankshaft pulley CAUTION Handle it with care because it is a heavy load Do not reuse the dropped crankshaft pulley which is out of balance NOTICE To prevent the co rot...

Page 324: ...f the crankshaft insert a large flat blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft 2 MOUNTING THE V BELT Reference STARTING CHARGING J05E V BELT REPLACEMENT MOUNTING THE V BELT Page 16 9 3 MOUNTING THE COOLING FAN ASSEMBLY AND FAN SHROUD RING Reference COOLING J05E COOLING FAN AND FAN CLUTCH OVERHAUL MOUNTING THE C...

Page 325: ...ENGINE MECHANICAL J05E 10 49 CRANKSHAFT FRONT OIL SEAL COMPONENT LOCATOR EN01F02127090402018001 1 Cylinder block 2 Crankshaft front oil seal 2 1 SHTS021270900105 ...

Page 326: ...RONT OIL SEAL 1 Mount the SST plate to the crankshaft with 2 crankshaft pulley mounting bolts SST S0942 01731 Oil seal puller NOTICE SST kit 2 Hook the SST hooks 2 pcs on the chuck of the crankshaft front oil seal and fasten SST bolts to secure the hooks onto the SST plate 3 From the crankshaft remove 2 crankshaft pulley mounting bolts securing the SST plate PLATE SHTS021270900106 PLATE BOLT x 4 C...

Page 327: ...2 Remove dirt from the SST SST S0940 71030 Oil seal press NOTICE SST kit 3 Apply the small amount of engine oil to the interference and cir cumference surfaces of a new crankshaft front oil seal 4 Note the direction of the oil seal and insert it to the oil seal guide of the SST CAUTION Use care to have correct longitudinal orientation of the crankshaft front oil seal The felted side must face to t...

Page 328: ...rcumference 7 Align holes in the oil seal press with the guide bolts and insert the oil seal press 8 Fit the SST center bolt into the oil seal press and tighten it until it stops Then press fit the crankshaft front oil seal CAUTION Press fit evenly around the circumference 9 Tighten the center bolt until the press comes in contact and check that the oil seal is press fit evenly around the circumfe...

Page 329: ...E MECHANICAL J05E 10 53 FRONT OIL SEAL RETAINER COMPONENT LOCATOR EN01F02127090402025001 Tightening torque Unit N m kgf cm lbf ft 1 Front oil seal retainer 2 Cylinder block A 30 306 22 1 2 A SHTS021270900115 ...

Page 330: ...EY Reference ENGINE MECHANICAL J05E CRANKSHAFT PULLEY REPLACEMENT REMOVING THE CRANKSHAFT PULLEY Page 10 47 3 REMOVING THE CRANKSHAFT FRONT OIL SEAL Reference ENGINE MECHANICAL J05E CRANKSHAFT FRONT OIL SEAL REPLACEMENT REMOVING THE CRANK SHAFT FRONT OIL SEAL Page 10 50 4 REMOVING THE FRONT OIL SEAL RETAINER 1 Unfasten the 5 bolts to remove the front oil seal retainer from the cylinder block FRONT...

Page 331: ...linder block with 5 bolts Tightening Torque 30 N m 306 kgf cm 22 lbf ft 2 MOUNTING THE CRANKSHAFT FRONT OIL SEAL Reference ENGINE MECHANICAL J05E CRANKSHAFT FRONT OIL SEAL REPLACEMENT MOUNTING THE CRANK SHAFT FRONT OIL SEAL Page 10 51 3 MOUNTING THE CRANKSHAFT PULLEY Reference ENGINE MECHANICAL J05E CRANKSHAFT PULLEY REPLACEMENT MOUNTING THE CRANKSHAFT PULLEY Page 10 48 4 MOUNTING THE OIL PAN Refe...

Page 332: ...GINE MECHANICAL J05E 10 56 FLYWHEEL ASSEMBLY COMPONENT LOCATOR EN01F02127090402020001 Tightening torque Unit N m kgf cm lbf ft 1 Crankshaft 3 Flywheel 2 Ring gear A 186 1 897 137 2 3 A 1 SHTS021270900119 ...

Page 333: ...first and then fasten SST to prevent drop off SST S0948 11340 Guide NOTICE To prevent the co rotation of the crankshaft insert a large flat blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft 2 Mount the eyebolts at the clutch mounting threaded parts and remove the remaining bolts while lifting the flywheel assembly with...

Page 334: ...the flywheel CAUTION Do not touch with bare hands while the ring gear and flywheel are hot ASSEMBLING FLYWHEEL ASSEMBLY 1 MOUNTING THE RING GEAR 1 Use the burner to heat the periphery of a ring gear to approxi mately 200 C 392 F CAUTION Do not touch with bare hands while the ring gear and flywheel are hot 2 Quickly mount the ring gear to the flywheel with a chamfered face positioned to face the fl...

Page 335: ...se it is a heavy load Before removing SST temporarily tighten the bolt NOTICE Set the dowel pin to the mounting position while checking the dowel hole 4 Insert the flywheel assembly until it contacts with the crankshaft 5 Apply engine oil to the bolt seat surface and bolt threaded part of the flywheel assembly mounting bolt 6 Fit the six bolts into bolt holes not occupied by the SST and man ually ...

Page 336: ...sert a large flat blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft 10 Loosen the all the bolts once 11 Tighten the bolts again in order as shown in the figure Tightening Torque 186 N m 1 897 kgf cm 137 lbf ft 2 MOUNTING THE ENGINE MAIN REVOLUTION SENSOR Reference ENGINE CONTROL J05E ENGINE SPEED MAIN SENSOR REPLACEMEN...

Page 337: ...ENGINE MECHANICAL J05E 10 61 CRANKSHAFT REAR OIL SEAL COMPONENT LOCATOR EN01F02127090402021001 Nonreusable part 1 Crankshaft rear oil seal 1 SHTS021270900130 ...

Page 338: ...ing bolts 2 pcs to secure the SST plate on the crankshaft SST S0942 01742 Oil seal puller CAUTION Align the large hole of the plate with the collar knock of the crank shaft NOTICE SST kit 2 Hook the 2 SST hooks on the claw of the crankshaft rear oil seal and secure the hooks to the SST plate with the SST bolts 3 From the crankshaft remove the flywheel assembly mounting bolts 2 pcs securing the SST...

Page 339: ...part of the flywheel housing and crankshaft 2 Remove the dirt from the SST SST S0940 71040 Oil seal press NOTICE SST kit 3 Apply the small amount of engine oil to the interference and cir cumference surfaces of a new crankshaft rear oil seal 4 Note the direction of the oil seal and insert it to the oil seal guide of the SST CAUTION Note the front and rear direction of the crankshaft rear oil seal ...

Page 340: ...l seal press with the guide bolts and insert the oil seal press 7 Attach the accompanying center bolt to the oil seal press and tighten it until it stops to press fit the crankshaft rear oil seal CAUTION Press fit evenly around the circumference 8 Tighten the center bolt until the press comes in contact and check that the oil seal is press fit evenly around the circumference 9 Remove the SST 2 MOU...

Page 341: ... COMPONENT LOCATOR EN01F02127090402022001 Tightening torque Unit N m kgf cm lbf ft 1 Rear end plate 3 Flywheel housing 2 Housing stay A 55 561 41 D 196 1 999 145 B 28 291 21 E 171 5 1 749 126 C 97 989 72 1 1 3 D 2 E C 2 A A E C B SHTS021270900140 ...

Page 342: ...ence CHASSIS S1 LXJE03A BRAKE Reference CHASSIS S1 LXJE04A BRAKE 5 REMOVING THE HYDRAULIC PUMP Reference CHASSIS S1 LXJE03A BRAKE Reference CHASSIS S1 LXJE04A BRAKE 6 REMOVING THE OIL PAN Reference LUBRICATION J05E OIL PAN REPLACEMENT REMOVING THE OIL PAN Page 13 24 7 REMOVING THE FLYWHEEL ASSEMBLY Reference ENGINE MECHANICAL J05E FLYWHEEL ASSEMBLY OVERHAUL REMOVING THE FLYWHEEL ASSEMBLY Page 10 5...

Page 343: ... and place the cylinder block joint surface on the wooden workbench during work If the flywheel housing does not come off smoothly tempo rarily fasten one mounting nut in the center of the flywheel housing and use a plastic hammer to tap the back face to remove the flywheel housing 3 Unfasten the damping stud from the flywheel housing HV ONLY SHTS021270900142 VIBRATION CONTROL STUD SHTS02127090014...

Page 344: ...ssly Apply the liquid gasket with 1 5 2 5 mm 0 0590 0 0984 in width Mount the case within 20 minutes after applying the liquid gasket 4 Fasten 2 4 guide bolts and align the flywheel housing with the cyl inder block mounting position along the guide bolts 5 Tighten the bolts and nuts with the specified tightening torques to secure the flywheel housing Tightening Torque 196 N m 1 999 kgf cm 145 lbf ...

Page 345: ...YWHEEL ASSEMBLY Page 10 59 4 MOUNTING THE OIL PAN Reference LUBRICATION J05E OIL PAN REPLACEMENT MOUNTING THE OIL PAN Page 13 25 5 MOUNTING THE HYDRAULIC PUMP Reference CHASSIS S1 LXJE03A BRAKE Reference CHASSIS S1 LXJE04A BRAKE 6 MOUNTING THE VACUUM PUMP Reference CHASSIS S1 LXJE03A BRAKE Reference CHASSIS S1 LXJE04A BRAKE 7 MOUNTING THE POWER STEERING PUMP Reference CHASSIS S1 LXJE03A STEERING R...

Page 346: ...02024001 Tightening torque Unit N m kgf cm lbf ft 1 Sub idle gear 5 Thrust plate 2 Thrust plate 6 Sub idle gear shaft 3 Main idle gear shaft 7 Injection pump idle gear 4 Main idle gear 8 Injection pump idle gear shaft A 108 1 101 80 D 172 1 754 127 2 2 4 1 5 3 2 6 7 A B A SHTS021270900148 ...

Page 347: ...HEAD Reference ENGINE MECHANICAL J05E CYLINDER HEAD ASSEMBLY REPLACEMENT REMOVING THE CYLINDER HEAD ASSEMBLY Page 10 23 4 REMOVING THE CAM IDLE GEAR 1 Unbolt an idle gear shaft to remove a cam idle gear the idle gear shaft and a thrust plate from the cylinder head CAUTION Be careful not to drop the thrust plate in the flywheel housing NOTICE Turn over the engine vertically or turn it onto the side...

Page 348: ...E GEAR 1 Unfasten the bolt of the main idle gear shaft 2 Use the SST to pull off the main idle gear shaft and remove the main idle gear shaft a main idle gear and a thrust plate SST S0942 01100 Sliding hammer CAUTION Use care not to drop the main idle gear and thrust plate 3 Remove the main idle gear shaft and thrust plate from the main idle gear SST MAIN IDLE GEAR SHAFT MAIN IDLE GEAR SHAFT THRUS...

Page 349: ...nd thrust plate from the sub idle gear 4 REMOVING REAR END PLATE 1 Use the SST to unfasten Torque bolts on the rear end plate SST S0941 11300 Socket wrench 2 Unfasten the remaining bolts and remove the rear end plate INSPECTING THE COMPONENTS 1 INSPECTING IDLE GEAR OIL CLEARANCE 1 Use the micrometer to measure the idle gear shaft outer diameter SUB IDLE GEAR SHAFT SST SUB IDLE GEAR SHAFT THRUST PL...

Page 350: ...ing surface on the cylinder block 2 Apply the sealant Thread Lock Super 5M or equivalent to threads of the torque bolts 3 Use the SST mount the torque bolts SST S0941 11300 Socket wrench Tightening Torque 55 N m 561 kgf cm 41 lbf ft SHTS021270900155 Measured item Standard value mm in Main idle gear Shaft outer diameter 57 2 244 Bushing inner diameter 57 2 244 Sub idle gear Shaft outer diameter 50 ...

Page 351: ...reads of the sub idle gear shaft mounting bolt vertically orient oil holes in the sub idle gear shaft before installation to the cylinder block 4 Fasten the sub idle gear shaft mounting bolt to secure the sub idle gear on the cylinder block Tightening Torque 108 N m 1 101 kgf cm 80 lbf ft CYLINDER BLOCK REAR END PLATE FLY WHEEI HOUSING GASKET SHTS021270900157 SUB IDLE GEAR SUB IDLE GEAR SHAFT BOLT...

Page 352: ...rient an oil hole in the idle gear shaft to the oil pan downward direction and synchronize timing between the crankshaft gear and the main idle gear before instal lation MAIN IDLE GEAR MAIN IDLE GEAR SHAFT BOLT THRUST PLATE SHTS021270900161 THRUST PLATE MAIN IDLE GEAR MAIN IDLE GEAR SHAFT SYLINDER BLCOCK OIL HOLES SHTS021270900162 SUB IDLE GEAR MAIN IDLE GEAR CRANKSHAFT GEAR OIL PUMP GEAR DETAIL V...

Page 353: ...RIVE GEAR AND CAM IDLE GEAR 1 MOUNTING THE CAM IDLE GEAR 1 After applying engine oil to the thrust plate cam idle gear bush idle gear shaft and the seating surface and bolt threads of the idle gear shaft orient an oil hole in the idle gear shaft to the downward direction and assemble them as shown in the figure 2 MOUNTING THE CYLINDER HEAD Reference ENGINE MECHANICAL J05E CYLINDER HEAD ASSEMBLY RE...

Page 354: ...e gear shaft mounting bolt on the bearing case 3 Use the sliding hammer or other similar tools to pull off the idle gear shaft and remove the injection pump drive idle gear and thrust plate 3 INSPECTING INJECTION PUMP DRIVE IDLE GEAR CLEAR ANCE 1 Use the micrometer to measure the injection pump drive idle gear shaft outer diameter SHTS021270900166 BEARING CASE INJECTION PUMP IDLE GEAR SLIDING HAMM...

Page 355: ...p drive idle gear shaft to the downward direction before installation to the bearing case 3 Use the vise to hold the bearing case and fasten the injection pump drive idle gear shaft mounting bolt to secure the injection pump drive idle gear on the bearing case Tightening Torque 108 N m 1 101 kgf cm 80 lbf ft 5 MOUNTING BEARING CASE ASSEMBLY 1 Replace with the new O ring and set the pins 2 places o...

Page 356: ...amshaft 2 INSPECTING FOR BACKLASH BETWEEN THE CAMSHAFT DRIVE GEAR AND CAM IDLE GEAR 1 Set the camshaft assembly to the cylinder head Tighten the mounting bolt of the camshaft bearing cap with the specified torque Reference ENGINE MECHANICAL J05E CAMSHAFT ASSEMBLY OVERHAUL INSPECTING THE COMPONENTS Page 10 17 2 To prevent rotation of the cam idle gear insert a large flat blade screwdriver into the ...

Page 357: ...lize bolt holes in the cylinder block to temporarily mount a metal plate for measure ment 4 INSPECTING BACKLASH BETWEEN MAIN IDLE GEAR AND SUB IDLE GEAR 1 To prevent rotation of the main idle gear insert a large flat blade screwdriver into the main idle gear through the dust cover port on the timing gear side in the flywheel housing 2 Use the dial gauge to measure backlash between the main idle ge...

Page 358: ...idle gear and the oil pump 6 INSPECTING THE IDLE GEAR END PLAY 1 Use the thickness gauge to measure the end play of each idle gear If a measurement reading exceeds the permissible limit replace the gear and thrust plate SHTS021270900182 SHTS021270900183 Standard value mm in Permissible limit mm in 0 030 0 131 0 0012 0 0052 0 30 0 0118 SHTS021270900184 Measured item Standard value mm in Permissible...

Page 359: ...river into the sub idle gear through a gap around the cylin der head cam idle gear 2 Use the dial gauge to measure backlash between the cam idle gear and the sub idle gear If a measurement reading exceeds the permissible limit replace individual gears SHTS021270900185 SHTS021270900186 Standard value mm in Permissible limit mm in 0 084 0 235 0 0033 0 0093 0 30 0 0118 ...

Page 360: ...NT LOCATOR EN01F02127090402027001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Connecting rod bearing 5 Piston ring 2 Piston pin 6 Retainer ring 3 Piston 7 Connecting rod cap 4 Connecting rod cap A 69 704 51 90 45 2 3 6 4 7 A 1 5 6 SHTS021270900187 ...

Page 361: ...TRAINER Page 13 29 4 REMOVING THE PISTON AND CONNECTING ROD 1 To prevent the cylinder liner from coming off mount the cylinder liner disconnection preventing jig to the upper surface of cylinder block 2 Use the scraper or sandpaper No 150 or equivalent to scrape off carbon deposits on the inner upper surface of the cylinder liner along the circumferential direction CAUTION Make sure not to damage ...

Page 362: ...and stored in order of cylinder number NOTICE To prevent the crankshaft from rotating set the bar to the adjustment hole of the balance weight and attach it to the oil pan mounting flange When removing the piston set the crankshaft to the top dead center in the applicable cylinder 6 Use the wooden bar to push tap the connecting rod from the lower of the engine to pull off the piston and connecting...

Page 363: ... in order of cylinder number NOTICE When writing cylinder numbers on the piston and connecting rod use white paint to place markings at the positions indicated in the figure 2 REMOVING THE PISTON RING 1 Use the SST to remove the piston ring SST S0944 21011 Piston ring expander CAUTION Handle the piston ring with care because it can be easily damaged The piston rings must be identified and stored i...

Page 364: ...le the SST press subassembly and guide on the level bench and use the other SST wing nut to secure the assembly SST S0948 11130 Guide S0940 21530 Press subassembly SL271 01036 Wing nut CAUTION Orient the H mark engraved on the guide to the top before assembly Make sure that the lower ends of the guide and the press subassembly are level 2 With a bearing removed from a large end of a connecting rod...

Page 365: ...ng 4 Use the press to pull off the connecting rod bush CAUTION Carefully operate the press 5 Evenly chamfer one side of the small end of the connecting rod as shown in the figure CAUTION Remove all burrs After chamfering remove dirt from the oil hole and the inner surface of the small end CONNECTING ROD SPINDLE PRESS SUB ASSY GROOVE SHTS021270900203 PRESS BUSH SHTS021270900204 CHAMFER SHTS02127090...

Page 366: ...measurement reading exceeds the permissible limit replace the piston ring 3 INSPECTING THE PISTON RING GROOVE 1 Use the thickness gauge to measure the piston ring groove If a measurement reading exceeds the permissible limit replace the piston SHTS021270900206 Standard value mm in Permissible limit mm in 112 4 409 112 15 4 415 17mm 0 669 in PIN DIRECTION MEASURE DIRECTION SHTS021270900207 Standard...

Page 367: ...he piston boss inner diame ter If a measurement reading exceeds the permissible limit replace the piston 3 Calculate the gap between the outer diameter of the contact sur face of the piston pin with the piston boss and the piston boss inner diameter If a calculated value exceeds the permissible limit replace the piston pin CYLINDER LINER SICKNESS GAUGE PISTON RING SHTS021270900210 Measured item St...

Page 368: ...g red check to inspect the connect ing rod for crack and damage If found defective replace the con necting rod 2 Insert the bar of 4 mm 0 1575 in in diameter into an oil hole in the large end of the connecting rod and check if the bar goes through the oil hole to the small end If clogging in the oil hole pre vents the bar of 4 mm 0 1575 in in diameter from going through replace the connecting rod ...

Page 369: ...fter mounting the cap tighten the connecting rod bolt with the specified torque 3 Use the cylinder gauge to measure the bearing inner diameter of the connecting rod large end 4 Calculate the difference between the crank pin outer diameter of crankshaft and the connecting rod bearing inner diameter If a measurement reading exceeds the permissible limit replace the connecting rod bearing or cranksha...

Page 370: ...ECTING ROD BOLT 1 Use the vernier calipers to measure the connecting rod bolt under head If a measurement reading exceeds the permissible limit replace the head bolt SHANK LENGTH SHTS021270900220 Standard value mm in Permissible limit mm in 67 0 2 638 68 0 2 677 ...

Page 371: ...end of the connecting rod faces the bush Apply engine oil to the inner diameter surfaces of the con necting rods 3 Use the press to press fit the bush into the connecting rod 4 Insert the bar with a diameter of 4 mm 0 1575 in from the oil hole on the large end of the connecting rod and check that the bar passes through to the oil hole on the small end CAUTION Off position of the oil hole may cause...

Page 372: ...eck the retainer ring for play or looseness 2 Orient the 0 mark indicated on the piston to the opposite direc tion of the alignment mark indicated on the connecting rod when fitting the piston to the connecting rod 3 After applying engine oil to the piston pin align the alignment mark on the piston with the one on the piston pin before inserting the piston pin CONNECTING ROD BEARING CONNECTING ROD...

Page 373: ...and a top ring in this sequential order NOTICE The identification print is given only to the second ring while there is no vertical identification given to the top and oil rings SST S0944 21011 Piston ring expander 2 Connect the joint of the coil expander and then set it inside the oil ring Stagger the coil expander joint and ring closed gap 180 apart 3 Position the piston rings with the ring ends...

Page 374: ...to the cylinder liner SST S0944 11370 Piston ring holder CAUTION Assemble the pistons and connecting rods in the order of cylinder numbers as identified before removal Check the SST for deformation or scratches 4 Use care to avoid interference of the connecting rod with a cool ing jet when using the wooden rod or other similar tools to insert the piston CAUTION Before insertion orient a 0 mark ind...

Page 375: ...alignment mark directions and Nos of the connecting rod cap and connecting rod match 9 Tighten the connecting rod bolt Tightening Torque 69 N m 704 kgf cm 51 lbf ft 10 Use the paint to mark the bolt heads in the same direction 11 Tighten the bolts by 90 1 4 turns in the rotational direction and check that all the paint marks face to the same direction 12 Retighten the bolt by 45 1 8 turn in the ro...

Page 376: ...MENT MOUNTING THE OIL STRAINER Page 13 29 3 MOUNTING THE OIL PAN Reference LUBRICATION J05E OIL PAN REPLACEMENT MOUNTING THE OIL PAN Page 13 25 4 MOUNTING THE CYLINDER HEAD ASSEMBLY Reference ENGINE MECHANICAL J05E CYLINDER HEAD ASSEMBLY REPLACEMENT MOUNTING THE CYLINDER HEAD ASSEMBLY Page 10 25 SHTS021270900239 Standard value mm in Permissible limit mm in 0 20 0 52 0 0079 0 0205 1 0 0 0394 ...

Page 377: ...ENGINE MECHANICAL J05E 10 101 CRANKSHAFT COMPONENT LOCATOR EN01F02127090402028001 1 Crankshaft 1 SHTS021270900240 ...

Page 378: ...ENGINE MECHANICAL J05E 10 102 1 Thrust bearing 2 Crankshaft bearing 1 2 SHTS021270900241 ...

Page 379: ...REMOVING THE FLYWHEEL HOUSING Reference ENGINE MECHANICAL J05E FLYWHEEL HOUSING REPLACEMENT REMOVING THE FLYWHEEL HOUSING Page 10 66 5 INSPECTING THE END PLAY 1 Use the dial gauge to measure end play of the crankshaft If a measurement reading exceeds the repair limit replace the thrust bearings If a measurement reading exceeds the permissible limit replace the thrust bearings and crankshaft NOTICE...

Page 380: ...RING AND THRUST BEARING 1 Remove the crankshaft bearing mounted to the main bearing cap CAUTION The removed crankshaft bearings must be identified and stored in order of cylinder number NOTICE Press the one end of the crankshaft bearing at the opposite side of the concave with fingers to facilitate removal 2 Remove the thrust bearing mounted to the cylinder block and main bearing cap SHTS021270900...

Page 381: ... crankshaft bearing at the opposite side of the concave with fingers to facilitate removal INSPECTING THE COMPONENTS 1 INSPECTING THE ROTATION RUNOUT 1 Use the dial gauge to measure crankshaft revolution runout If a measurement reading exceeds the repair limit replace the crank shaft CONCAVE PART CRANKSHAFT BEARING PUSH SHTS021270900247 SHTS021270900248 Standard value mm in Repair limit mm in 0 0 ...

Page 382: ... adjust a fillet radius dimension as indicated below Journals 2 5 3 0 mm 0 0984 0 1181 in 2 Use the vernier calipers to measure a width of the crankshaft cen ter journal If a measurement reading exceeds the permissible limit replace the crankshaft 90 MEASUREMENT 2 PLACES SHTS021270900249 Standard value mm in Permissible limit mm in 80 0 3 150 79 3 3 122 Bearing size Outside diameter of journal Sta...

Page 383: ...l and the crankshaft bearing inner diameter If a mea surement reading exceeds the repair limit replace the crankshaft bearing or crankshaft 4 INSPECTING THE CRANKSHAFT FOR CRACK DAMAGE AND OIL HOLE 1 Use the dye penetrant testing red check to check the crankshaft for crack and damage If found defective replace the crankshaft 2 Check the crankshaft for clogged oil hole If found defective replace th...

Page 384: ... NOTICE When grinding the crankshaft adjust a fillet radius dimension as indicated below Crank pins 2 5 3 0 mm 0 0984 0 1181 in Journals 2 5 3 0 mm 0 0984 0 1181 in 6 INSPECTING THE LENGTH OF MAIN BEARING CAP BOLT 1 Use the vernier calipers to measure the under head of the main bearing cap bolt If a measurement reading exceeds the permissi ble limit replace the bolt 90 MEASUREMENT 2 PLACES SHTS021...

Page 385: ...l 3 Mount the thrust bearing to the main bearing cap with the groove side front side facing to the crank arm side and the part No side back side to the main bearing cap side before applying engine oil CAUTION Apply engine oil or grease to the back side of the thrust bearing to prevent it from falling off during assembly NOTICE Do not mount the thrust bearing on the cylinder block side now because ...

Page 386: ...ewdriver or other similar tools to keep an enough gap for inserting the thrust bearing Dur ing this step use care not to cause any scratches or damages 3 Set the main bearing cap mounted with the thrust bearing and main bearing to the cylinder block CAUTION Make sure that the pentagon shaped marks indicated on the main bearing caps face to the engine front side in the order of 1 5 from front to ba...

Page 387: ...completion of tightening tap the front and back ends of the crankshaft with the plastic hammer so that crankshaft fits the assembly CAUTION Check the crankshaft for smooth rotation Measure the crankshaft end play and check that a measure ment reading is within the standard value 3 MOUNTING THE FLYWHEEL HOUSING Reference ENGINE MECHANICAL J05E FLYWHEEL HOUSING REPLACEMENT MOUNTING THE FLYWHEEL HOUS...

Page 388: ...ENGINE MECHANICAL J05E 10 112 CYLINDER LINER COMPONENT LOCATOR EN01F02127090402029001 1 Cylinder block assembly 2 Cylinder liner 2 1 SHTS021270900268 ...

Page 389: ...o put alignment marks 2 Hold the cylinder liner end with both hands and pull it off over the cylinder block at a stroke CAUTION Use the particular care in handling the cylinder liner No dropped cylinder liners are reusable The removed cylinder liners must be identified and stored in order of cylinder number NOTICE Pull off the cylinder liner vertically at a stroke Otherwise it gets caught with the...

Page 390: ...ignment mark indicated on the cylinder liner and the one indicated on the cylinder block and use the SST to insert the cylinder liner in the vertical posture SST S0947 11490 Guide NOTICE Vertical insertion can be performed with or without using the SST CAUTION When mounting new cylinder liners select appropriate cylin der liners that have the same identification mark A B or C as the liner identifi...

Page 391: ... Use the dial gauge to measure the collar projection 3 MOUNTING THE PISTON AND CONNECTING ROD Reference ENGINE MECHANICAL J05E PISTON AND CON NECTING ROD OVERHAUL MOUNTING THE PISTON AND CONNECTING ROD Page 10 98 4 MOUNTING THE CYLINDER HEAD ASSEMBLY Reference ENGINE MECHANICAL J05E CYLINDER HEAD ASSEMBLY REPLACEMENT MOUNTING THE CYLINDER HEAD ASSEMBLY Page 10 25 INTAKE SIDE EXHAUST SIDE 0 MARK PO...

Page 392: ...E 10 116 CYLINDER BLOCK COMPONENT LOCATOR EN01F02127090402030001 Tightening torque Unit N m kgf cm lbf ft 1 Cylinder block assembly 4 Cooling jet 2 Plug A 5 Plug B 3 Dowel pins A 22 224 16 1 4 3 5 2 A 2 5 2 SHTS021270900280 ...

Page 393: ...E CRANKSHAFT PULLEY Page 10 47 6 REMOVING THE COOLANT PUMP Reference COOLING J05E COOLANT PUMP REPLACE MENT REMOVING THE COOLANT PUMP Page 12 31 7 REMOVING THE CRANKSHAFT FRONT OIL SEAL Reference ENGINE MECHANICAL J05E CRANKSHAFT FRONT OIL SEAL REPLACEMENT REMOVING THE CRANK SHAFT FRONT OIL SEAL Page 10 50 8 REMOVING THE OIL COOLER ASSEMBLY Reference LUBRICATION J05E OIL COOLER OVERHAUL DISASSEMBL...

Page 394: ...NGINE MECHANICAL J05E CYLINDER LINER REPLACEMENT REMOVING THE CYLINDER LINER Page 10 113 19 REMOVING THE FLYWHEEL ASSEMBLY Reference ENGINE MECHANICAL J05E FLYWHEEL ASSEMBLY OVERHAUL REMOVING THE FLYWHEEL ASSEMBLY Page 10 57 20 REMOVING THE CRANKSHAFT REAR OIL SEAL Reference ENGINE MECHANICAL J05E CRANKSHAFT REAR OIL SEAL REPLACEMENT REMOVING CRANK SHAFT REAR OIL SEAL Page 10 62 21 REMOVING THE FR...

Page 395: ...ECTING THE CYLINDER BLOCK 1 Use the straightedge and thickness gauge to measure the strain of the upper surface of cylinder block If a measurement reading exceeds the permissible limit replace it CAUTION Do not grind or blend the surface Otherwise backlash in timing gears may change COOLING JET SHTS021270900281 SICKNESS GAUGE STRAIGHTEDGE LOCATION OF MEASUREMENT RIGHT ANGLED DIRECTION LONGER DIREC...

Page 396: ... bolt and use the SST to mount the cooling jet to the cylinder block SST SZ910 24098 Bolt for checking 2 Connect the oil hose for injection test to the SST from under the cylinder block CAUTION Use new engine oil for injection 3 Set the SST to the upper surface of cylinder block SST 09219 E4030 Gauge SHTS021270900283 COOLING JET BOLT FOR CHECKING SHTS021270900284 OIL HOSE BOLT FOR CHECKING SHTS021...

Page 397: ...on bottom dead center MOUNTING THE CYLINDER BLOCK 1 MOUNTING THE COOLING JET 1 Mount the cooling jet to the cylinder block Tightening Torque 22 N m 224 kgf cm 16 lbf ft 2 After mounting the piston check that the cooling jet does not interfere with the piston at the piston bottom dead center 2 MOUNTING THE CRANKSHAFT Reference ENGINE MECHANICAL J05E CRANKSHAFT REPLACEMENT MOUNTING THE CRANKSHAFT Pa...

Page 398: ...DER LINER Page 10 114 10 MOUNTING THE PISTON AND CONNECTING ROD Reference ENGINE MECHANICAL J05E PISTON AND CON NECTING ROD OVERHAUL MOUNTING THE PISTON AND CONNECTING ROD Page 10 98 11 MOUNTING THE OIL STRAINER Reference LUBRICATION J05E OIL STRAINER REPLACE MENT MOUNTING THE OIL STRAINER Page 13 29 12 MOUNTING THE OIL PAN Reference LUBRICATION J05E OIL PAN REPLACEMENT MOUNTING THE OIL PAN Page 1...

Page 399: ...ANT PUMP Reference COOLING J05E COOLANT PUMP REPLACE MENT MOUNTING THE COOLANT PUMP Page 12 32 22 MOUNTING THE CRANKSHAFT PULLEY Reference ENGINE MECHANICAL J05E CRANKSHAFT PULLEY REPLACEMENT MOUNTING THE CRANKSHAFT PULLEY Page 10 48 23 MOUNTING THE AIR CONDITIONER COMPRESSOR Reference CHASSIS S1 LXJE03A HEATER AIR CONDI TIONER Reference CHASSIS S1 LXJE04A HEATER AIR CONDI TIONER 24 MOUNTING THE A...

Page 400: ... with 1 5 2 5 mm 0 0590 0 0984 in width Tap in the plugs to a depth of 0 5 1 0 mm 0 0197 0 0394 in from the cylinder block end When tapping do not allow the sealant to run over to the oil groove When tapping make sure not to crack the cylinder block by applying excessive impact CYLINDER BLOCK TOP FLYWHEEL SIDE CRANKSHAFT PULLEY SIDE 17mm 0 669 in PLUG A DOWEL PIN 22mm 0 866 in PLUG B PLUG B PLUG B...

Page 401: ...EN01F02127090402031001 Tightening torque Unit N m kgf cm lbf ft 1 Front engine mounting 3 Front engine mounting bracket 2 Rear engine mounting 4 Rear engine mounting bracket A 103 1 050 76 C 125 1 275 92 B 64 653 47 D 98 999 72 3 2 A 4 B 4 B A 1 1 D D D D 3 C C SHTS021270900292 ...

Page 402: ...NGINE J05E ENGINE ASSEMBLY REPLACEMENT REMOVING THE ENGINE ASSEMBLY Page 5 7 2 REMOVING THE ENGINE MOUNTING AND BRACKET 1 Unfasten the nut to remove a front engine mounting from a front engine mounting bracket 2 Unfasten the bolts 4 pcs to remove the front engine mounting bracket from the cylinder block 3 Unfasten the nut to remove the rear engine mounting from the rear engine mounting bracket 4 U...

Page 403: ...he rear engine mounting bracket with the nut Tightening Torque 64 N m 653 kgf cm 47 lbf ft 3 Mount the front engine mounting bracket to the cylinder block with 4 bolts Tightening Torque 125 N m 1 275 kgf cm 92 lbf ft 4 Fasten the nut to secure the front engine mounting on the front engine mounting bracket Tightening Torque 98 N m 999 kgf cm 72 lbf ft REAR ENGINE MOUNTING BRACKET REAR ENGINE MOUNTI...

Page 404: ...MECHANICAL J05E 10 128 GLOW PLUG COMPONENT LOCATOR EN01F02127090402037001 Tightening torque Unit N m kgf cm lbf ft 1 Glow harness 3 Nut 2 Glow plug 4 Connector A 20 25 204 254 15 18 3 4 1 2 A SHTS021270900297 ...

Page 405: ...ness connector from a glow plug 2 REMOVING THE GLOW PLUG 1 Unfasten the nuts 4 pcs from glow plugs 2 Unfasten the nuts 4 pcs to disconnect the glow plug wire and glow harness from the glow plugs 3 Remove the glow plugs from the cylinder head GLOW HARNESS SHTS021270900298 GLOW PLUG SHTS021270900299 GLOW HARNESS GLOW PLUG NUT SHTS021270900300 ...

Page 406: ...NG THE GLOW PLUGS 1 MOUNTING THE GLOW PLUGS 1 Mount the glow plugs to the cylinder block Tightening Torque 20 25 N m 204 254 kgf cm 15 18 lbf ft 2 Connect the glow plug wire and sub harness to the glow plugs and tighten the nuts 4 pcs Tightening Torque 1 0 1 5 N m 11 15 kgf cm 0 8 1 1 lbf ft SHTS021270900301 Standard value at 20 C 68 F 0 55 0 75 GLOW HARNESS GLOW PLUG NUT SHTS021270900302 ...

Page 407: ...NGINE MECHANICAL J05E 10 131 3 Mount the caps to the glow plugs 2 CONNECTING THE HARNESS 1 Connect the sub harness connector to the glow plug GLOW PLUG NUT SHTS021270900303 GLOW HARNESS SHTS021270900304 ...

Page 408: ... kgf cm lbf ft REPLACEMENT 1 REMOVING THE GCU 1 Disconnect the connector from the GCU 2 Unfasten the nut and remove the GCU 2 MOUNTING THE GCU 1 Mount the nut and remove the GCU 2 Connect the connector from the GCU 1 GCU 3 Bracket 2 Connector A 8 0 82 5 9 2 A 1 3 SHTS021270900305 SHTS021270900306 ...

Page 409: ...ENT LOCATOR 11 49 REPLACEMENT 11 50 FUEL CUTOFF VALVE 11 58 COMPONENT LOCATOR 11 58 REPLACEMENT 11 59 DEF PUMP 11 60 COMPONENT LOCATOR 11 60 REPLACEMENT 11 61 DEF INJECTOR 11 66 COMPONENT LOCATOR 11 66 REPLACEMENT 11 67 DEF TANK 11 72 COMPONENT LOCATOR 11 72 INSPECTION 11 73 REPLACEMENT 11 74 DEF SENSOR 11 83 COMPONENT LOCATOR 11 83 REPLACEMENT 11 84 COOLANT CUTOFF VALVE 11 86 COMPONENT LOCATOR 11...

Page 410: ...UTSIDE TEMPERATURE SENSOR 11 119 COMPONENT LOCATOR 11 119 REPLACEMENT 11 120 EXHAUST BRAKE 11 121 COMPONENT LOCATOR 11 121 REPLACEMENT 11 122 EXHAUST BRAKE MAGNETIC VALVE 11 125 COMPONENT LOCATOR 11 125 REPLACEMENT 11 126 ...

Page 411: ...HAUST MANIFOLD COMPONENT LOCATOR EN01F02127100402009001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Insulator 4 Stud bolt 2 Exhaust manifold 5 Gasket 3 Spacer A 30 305 22 1 B 59 600 43 5 1 2 5 3 3 4 A B B 4 A SHTS021271000001 ...

Page 412: ...OOLER REPLACEMENT REMOVING THE EGR VALVE COOLER Page 8 3 3 REMOVING THE TURBOCHARGER ASSEMBLY Reference TURBOCHARGER J05E TURBOCHARGER ASSEMBLY REPLACEMENT REMOVING THE TURBO CHARGER ASSEMBLY Page 17 5 4 REMOVING THE EXHAUST MANIFOLD 1 Unfasten the 3 bolts to remove the insulator from the exhaust manifold 2 Unfasten the 12 nuts to remove the exhaust manifold 4 gaskets and 12 spacers from the cylin...

Page 413: ...nd in the stud bolts 12 pcs unfasten them with a Torx socket or commercially available stud bolt remover 2 Remove dirt on the female threads on the cylinder head side including sealant and then clean the threads again with the tap M10 x 1 5 CYLINDER HEAD STUD BOLT SHTS021271000004 ...

Page 414: ...h excessive torque may cause cracks in the cylinder head 2 MOUNTING THE EXHAUST MANIFOLD 1 Replace with 4 new gaskets and fit the exhaust manifold to the cylinder head mounting position CAUTION Mount the gasket with the coating surface black surface facing to the exhaust manifold side CYLINDER HEAD STUD BOLT SHTS021271000005 CYLINDER HEAD EXHAUST MANIFOLD SHTS021271000006 GASKET BLACK SURFACE SHTS...

Page 415: ...orque 59 N m 600 kgf cm 43 5 lbf ft CAUTION Make sure to tighten twice 4 Fasten the 3 bolts to secure the insulator on the exhaust manifold 3 MOUNTING THE TURBOCHARGER ASSEMBLY Reference TURBOCHARGER J05E TURBOCHARGER ASSEMBLY REPLACEMENT MOUNTING THE TURBO CHARGER ASSEMBLY Page 17 9 4 MOUNTING THE EGR COOLER Reference EMISSION CONTROL J05E EGR VALVE COOLER REPLACEMENT MOUNTING THE EGR VALVE COOLE...

Page 416: ...tector 2 Gasket 8 Muffler bracket 3 Front exhaust pipe 9 Plate 4 Muffler 10 Cushion 5 Water pipe 11 Nut 6 Harness bracket A 43 438 31 7 D 31 316 22 9 B 64 653 47 2 E 43 59 438 602 31 7 43 5 C 82 836 60 5 F 6 10 61 102 4 4 7 4 C 11 C 1 2 3 x 3 x 4 x 4 x 2 x 3 2 6 5 D D E F 12 2 4 B 7 9 10 8 8 A 9 10 9 10 9 10 8 11 8 8 10 8 8 10 8 11 C 11 C 11 SHTS021271000010 ...

Page 417: ...THE HOSE PROTECTOR 1 Remove the hose clip from the hose protector 2 Unfasten the bolts 2 pcs to remove the hose protector from the muffler bracket 2 REMOVING THE DEF INJECTOR 1 Unfasten the 3 nuts to remove the DEF injector from the muffler HOSE PROTECTOR SHTS021271000011 DEF INJECTOR MUFFLER SHTS021271000012 ...

Page 418: ... DOC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING DOC UPSTREAM TEMPERATURE SENSOR Page 11 108 5 Disconnect the DPR upstream temperature sensor Reference EXHAUST J05E DPR UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR Page 11 111 6 Disconnect a DPR downstream temperature sensor Reference EXHAUST J05E DPR DOWNSTREAM TEMPER ATURE SENSOR REPLACEMENT REMOVING...

Page 419: ...fler CAUTION To hold and stabilize the muffler make sure to use a lashing belt to lash the muffler before installation or removal 2 Unfasten the 4 nuts to remove the muffler 4 plates and 7 cush ions from the muffler bracket CAUTION Handle the DPR cleaner and DEF SCR with particular care because they are heavy made of ceramic and can be easily bro ken 3 While holding the muffler to prevent it from ...

Page 420: ...nce 3 Temporarily tighten the muffler 4 plates and 7 cushions to the muffler bracket with 4 nuts CAUTION Handle the DPR cleaner and DEF SCR with particular care because they are heavy made of ceramic and can be easily broken Temporarily tighten to avoid play in vertical direction 2 TEMPORARY MOUNTING OF THE FRONT EXHAUST PIPE 1 Replace with 2 new gaskets 7 bolts and 4 nuts Align alignment marks an...

Page 421: ...aust pipe to muffler part B Tightening Torque 64 N m 653 kgf cm 47 2 lbf ft 2 Tighten the muffler fully a Muffler part C Tightening Torque 82 N m 836 kgf cm 60 5 lbf ft 4 INSPECTING THE EXHAUST FLEXIBLE AREA MOUNTING CONDITION 1 Check if the exhaust flexible area is mounted as shown in the fig ure EXHAUST PIPE ATC MUFFLER FRONT EXHAUST PIPE A B C C C C SHTS021271000019 177 191mm 6 97 7 52 in BELOW...

Page 422: ...EAM NOx SEN SOR REPLACEMENT MOUNTING THE SCR DOWNSTREAM NOx SENSOR Page 11 103 4 Connect the DOC upstream temperature sensor Reference EXHAUST J05E DOC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING DOC UPSTREAM TEMPERATURE SENSOR Page 11 109 5 Connect the DPR upstream temperature sensor Reference EXHAUST J05E DPR UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING THE DPR UPSTREAM TEMPERATURE SE...

Page 423: ...N m 61 102 kgf cm 4 4 7 4 lbf ft 3 Mount the DEF injector harness clip 9 MOUNTING THE HOSE PROTECTOR 1 Mount the hose protector to the muffler bracket with the bolts 2 pcs Tightening Torque 43 59 N m 438 602 kgf cm 31 7 43 5 lbf ft 2 Mount the hose clip to the hose protector 10 INSPECTING FOR EXHAUST GAS LEAKAGE 1 Start the engine and inspect for exhaust gas leakage DEF INJECTOR MUFFLER SHTS021271...

Page 424: ...OCATOR EN01F02127100402041001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Stud bolt 4 Exhaust pipe ATC 2 Gasket 5 Bracket 3 Spacer 6 Clamp A 70 714 51 6 C 25 4 259 18 7 B 55 560 40 6 4 C B 5 6 1 2 3 A x 3 x 3 x 3 x 2 SHTS021271000025 ...

Page 425: ...ference EXHAUST J05E FUEL ADDITION VALVE REPLACEMENT REMOVING THE FUEL ADDITION VALVE Page 11 50 4 REMOVING THE ATC UPSTREAM TEMPERATURE SENSOR Reference EXHAUST J05E ATC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING THE ATC UPSTREAM TEMPERATURE SENSOR Page 11 105 5 REMOVING THE EXHAUST PIPE ATC 1 Unfasten the bolts 3 pcs to remove the bracket and clamp from the exhaust pipe ATC 2 Unfasten the...

Page 426: ...cm 51 6 lbf ft 5 Tighten the clamp fully Tightening Torque 25 4 N m 259 kgf cm 18 7 lbf ft CAUTION When tightening the clamp do not allow clearance with the pipe 3 MOUNTING THE ATC UPSTREAM TEMPERATURE SENSOR Reference EXHAUST J05E ATC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING THE ATC UPSTREAM TEMPERATURE SENSOR Page 11 106 4 MOUNTING THE FUEL ADDITION VALVE Reference EXHAUST J05E FUEL ADD...

Page 427: ...e Wire Harness CAN Bus Interface Fuel Line DOC DPR COOLANT PIPING INJECTOR COOLING NH3 S DEF SCR CATALYST DEF COOLANT PIPING COOLANT PIPING AQUEOUS UREA SOLUTION DEFROSTS COOLANT PIPING RETURN FUEL TANK FUEL FUELADDITIVEVALVE ECU DPR SWITCH EXHAUST BRAKE TURBOCHARGER ENGINE DIESEL THROTTLE FCV INTER COOLER ATC DCU DEF PUMP OUTSIDE TEMPERATURE SENSOR TEMPERATURESENSOR NOx SENSOR DEF INJECTOR NOx SE...

Page 428: ...roughly rinse it out 6 After removal place a plastic cover to avoid entry of foreign matter into the pipe 7 Place the cover immediately after removing the joint to avoid entry of foreign matter into the DEF tank DEF pump and DEF injector 8 When covering use separate covers to avoid mixing of DEF and coolant 9 If removal is difficult do not apply an excessive force since it may damage the quick con...

Page 429: ...ft 1 Exhaust pipe protector 6 Tail pipe 2 Center pipe No 2 7 Stay 3 Gasket 8 Support bracket 4 Exhaust pipe protector stay 9 Washer 5 DEF SCR A 31 316 22 9 C 43 59 438 602 31 7 43 5 B 20 30 204 306 14 7 22 1 2 3 8 8 8 C 9 8 B C 9 A 1 4 4 B 7 6 3 5 x 4 x 3 x 3 x 5 x 5 x 4 x 4 x 4 x 4 x 4 x 4 x 5 x 3 x 3 x 5 SHTS021271000030 ...

Page 430: ...r the DEF SCR and lash with a lashing device CAUTION To hold and stabilize the DEF SCR make sure to lash it with a lashing device before installation or removal 2 Put alignment marks on the DEF SCR joining areas 3 Unfasten the 16 bolts and 14 nuts to remove the DEF SCR 2 gaskets and 2 exhaust pipe protector stays from the center pipe No 2 and tail pipe 4 Unfasten the 8 bolts and 8 nuts to remove 2...

Page 431: ...ng position while supporting it to prevent falling 3 Replace with new 2 gaskets 16 bolts and 14 nuts Align align ment marks and temporarily tighten the DEF SCR and 2 exhaust pipe protector stays to the center pipe No 2 and tail pipe CAUTION To prevent exhaust gas and DEF leakage make sure to replace with new gaskets bolts and nuts When mounting the DEF SCR note the longitudinal and ver tical direc...

Page 432: ... a Center pipe No 2 DEF SCR part A Tightening Torque 20 30 N m 204 306 kgf cm 14 7 22 1 lbf ft b DEF SCR tail pipe part B Tightening Torque 20 30 N m 204 306 kgf cm 14 7 22 1 lbf ft c DEF SCR support bracket part C Tightening Torque 43 59 N m 438 602 kgf cm 31 7 43 5 lbf ft SUPPORT BRACKET DEF SCR SHTS021271000036 DEF SCR A C B C TAIL PIPE SUPPORT BRACKET SUPPORT BRACKET CENTER PIPE No 2 SHTS02127...

Page 433: ...G THE EXHAUST PIPE PROTECTOR 1 Mount the exhaust pipe protector to the muffler with the bolts 4 pcs Tightening Torque 31 N m 316 kgf cm 22 9 lbf ft 6 INSPECTING FOR EXHAUST GAS LEAKAGE 1 Start the engine and inspect for exhaust gas leakage 177 191mm 6 97 7 52 in BELOW 7mm 0 28 in 233mm 9 17 in BELLOWS SHTS021271000038 EXHAUST PIPE PROTECTOR SHTS021271000039 ...

Page 434: ... m kgf cm lbf ft 1 Support bracket 5 Clip 2 DPR cleaner 6 Center pipe No 1 3 Gasket 7 Washer 4 Differential pressure pipe A 20 30 204 306 14 7 22 1 C 30 36 306 367 22 1 26 5 B 43 59 438 602 31 7 43 5 D 31 316 22 9 B 1 1 B 2 A 7 4 C 6 1 1 7 B B D 5 3 x 4 x 4 x 4 x 2 x 2 x 8 x 8 x 2 x 2 x 4 x 4 x 4 SHTS021271000040 ...

Page 435: ...1 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 temper ature sensor for trouble cracks in coating or missing clip 3 Inspect the hose of the back pressure sensor and check the hose for deterioration or cracks Replace a hose which has been used for three ...

Page 436: ...r the engine revolution Engine inspection found normal 1 CHECKING THE CURRENT CONDITION If normal manual regeneration is not complete check and clean the fuel addition valve Refer to Page 11 52 53 EXHAUST GAS AFTERTREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT LIGHT UP As a damage in the engine may degrade DPR performance first check condition of the engine Injection system inspection Fuel injecti...

Page 437: ...ntial pressure check can be done 3 In case ON is displayed in Data View of the DPR status display display monitor check according to the procedure on page Reference EXHAUST J05E DPR CLEANER DETERMINA TION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX Page 11 36 2 FORCED REGENERATION 1 Forced regeneration is done by the Manual forced regeneration screen CAUTION Confirm safety of the surround...

Page 438: ...aust gas temperature in and out is less than 200 C 392 F 3 Engine speed will rise automatically then record the indicated maximum DPR differential pressure 4 In case the central value of the recorded DPR differential pressure value exceeds the specific value clean or replace the filter Then Stop the DPR differential pressure check SHTS021271000044 Engine speed no load maximum revolution Differenti...

Page 439: ...aced a Check the differential pressure hose for cracks or hole open ings 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 Use the compressed air from one end of the pipe to check for clogging If the air passes to the other side easily it is clear SHTS021271000045 ...

Page 440: ...rature SHTS021271000046 Engine coolant temperature More than 82 C 180 F Exhaust brake valve to OFF Adjust the engine speed by idle set knob Engine speed 980 rpm Injection quantity B mm3 st Exhaust brake valve to ON Engine speed 980 rpm Injection quantity A mm3 st Difference of adjustable range of fuel injection A B Optimum injection quantity 8 12 mm3 st Adjustment target quantity 10 mm3 st ...

Page 441: ...perature is detected by the rear temperature sensor Clogging of DPR is detected by the back pressure sensor DPR back pressure of the back pressure sensor has dropped abnormally Abnormally high temperature is detected by the front DPR exhaust temperature sensor CHECK MALFUNCTION INDICATOR ILLUMINATES PAST FAULT CHECK determination of sensor system trouble Front DPR exhaust temperature sensor troubl...

Page 442: ...eneration has started wait until regeneration has been completed and confirm that the engine check light has gone out Confirmation method Use the HINO DX perform System Fix and then continue in the order of Check Function E DPR Reset Confir mation D Manual regeneration E Recording method for the HINO DX Report a Connect the HINO DX to the vehicle and execute System Fix b Click the Equipment DTC bu...

Page 443: ...ttachment for DPR filters made by Hino Motors In the following instances the filter cannot be cleaned In these cases the filter must be replaced 1 Cleaning is not possible for filters where soot has escaped and the surroundings have turned black when the filter body is seen from the gas flow outlet side 2 Cleaning is not possible when a large quantity of oil adheres to the filter body as seen from...

Page 444: ... again In case a code indicating a sensor system trouble is dis played inspect and replace the sensor circuit 3 Check past faults In case DPR trouble DTC code P200C P2459 P244A P244B P2463 is displayed check the DPR state monitor CHECKING THE DPR STATE EN01F02127100402002008 1 CHECK THE DPR STATE MONITOR 1 Refer to INSPECTION BY WAY OF HINO DX and check the DPR state monitor Perform inspection as ...

Page 445: ...m temperature sensor Reference EXHAUST J05E DOC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING DOC UPSTREAM TEMPERATURE SENSOR Page 11 108 3 Disconnect the DPR upstream temperature sensor Reference EXHAUST J05E DPR UPSTREAM TEMPERA TURE SENSOR REPLACEMENT REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR Page 11 111 4 Disconnect the DPR downstream temperature sensor Reference EXHAUST J05E DPR DOWNST...

Page 446: ... CLEANER 1 Set a transmission jack under the DPR cleaner and lash with a lashing device CAUTION To hold and stabilize the DPR cleaner make sure to lash it with a lashing device before installation or removal 2 Set the DPR cleaner to the mounting position while supporting it to prevent falling 3 Replace with a new gasket 8 bolts and 8 nuts and temporarily tighten the DPR cleaner to the center pipe ...

Page 447: ...N m 438 602 kgf cm 31 7 43 5 lbf ft 3 MOUNTING THE FRONT EXHAUST PIPE Reference EXHAUST J05E EXHAUST PIPE REPLACE MENT MOUNTING THE EXHAUST SYSTEM COMPONENT PARTS Page 11 12 4 INSPECTING THE EXHAUST FLEXIBLE AREA MOUNTING CONDITION 1 Check and confirm if the exhaust flexible area is mounted as shown in the figure DPR CLEANER A B B SUPPORT BRACKET SUPPORT BRACKET CENTER PIPE No 1 SHTS021271000053 1...

Page 448: ...PR differential pressure sensor Reference EXHAUST J05E DPR DIFFERENTIAL PRES SURE SENSOR REPLACEMENT MOUNTING THE DPR DIF FERENTIAL PRESSURE SENSOR Page 11 97 2 Connect the DOC downstream temperature sensor Reference EXHAUST J05E DOC UPSTREAM TEMPERA TURE SENSOR REPLACEMENT MOUNTING DOC UPSTREAM TEMPERATURE SENSOR Page 11 109 3 Connect the DPR upstream temperature sensor Reference EXHAUST J05E DPR...

Page 449: ...ssure with the HINO DX Standard value Reference EXHAUST J05E DPR CLEANER OVERALL OPERATION FLOW LIST OF STANDARD VALUES FOR DIF FERENTIAL PRESSURE INSPECTION Page 11 44 NO YES 1 VEHICLE RECEIPT FOR INSPECTION SHTS021271000056 4 For P200C P244B P244A P2459 P2463 5 For others than above 2 MANUAL REGENERATION 2 MANUAL REGENERATION SHTS021271000057 3 INSPECT THE DPR FILTER No clean up necessary Vehicl...

Page 450: ...271000058 Replace with a new DPR filter and install it on the vehicle Reference EXHAUST J05E DPR CLEANER REPLACEMENT MOUNTING DPR CLEANER Page 11 38 CAUTION Recheck the differential pressure after the instal lation 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 vehicle Reference EXHAUST J05E DPR CLEANER REPLACEMEN...

Page 451: ... filter and install it on the vehicle Reference EXHAUST J05E DPR CLEANER REPLACEMENT MOUNTING DPR CLEANER Page 11 38 CAUTION 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 Reference EXHAUST J05E DPR CLEANER REP...

Page 452: ... Reference EXHAUST J05E DPR CLEANER REPLACEMENT MOUNTING DPR CLEANER Page 11 38 CAUTION 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 Reference EXHAUST J05E DPR CLEANER REPLACEMENT MOUNTING DPR CLEANER Page 1...

Page 453: ...1 Visually inspect the filter rear surface to detect soot escapes black part Standard value No soot escape NO YES 1 VISUALLY INSPECT THE FILTER REAR SURFACE GAS FLOW GAS FLOW DOC DPR FILTER REAR SURFACE FILTER SHTS021271000061 3 INSPECT THE DPR FILTER WITH THE DEDI CATED CHECK PROBE 2 VISUALLY INSPECT THE CASE EDGE ...

Page 454: ...dge to detect soot escapes black part Standard value No soot escape NO YES 2 VISUALLY INSPECT THE CASE EDGE GAS FLOW GAS FLOW DOC DPR CASE EDGE FILTER SHTS021271000062 3 INSPECT THE DPR FILTER WITH THE DEDI CATED CHECK PROBE The DPR filter is normal ...

Page 455: ...TH 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 OK NG J08E SHTS021271000063 Replace with a new DPR filter and install it on the vehicle Reference EXHAUST J05E DPR CLEANER REPLACEMENT MOUNTING DPR...

Page 456: ...EXHAUST J05E 11 48 AIR CLEANING FLOW EN01F02127100402002011 SOOT CLEANING SOOT SUCTION SOOT AIR BLOW DISPOSE OF THE WASTE AND THE POWDER AS INDUSTRIAL WASTES SHTS021271000064 ...

Page 457: ...rque Unit N m kgf cm lbf ft 1 Coolant pipe D 6 Nozzle clamp 2 Coolant pipe E 7 Fuel addition valve 3 Gasket 8 O ring 4 Fuel feed pipe No 5 9 Folder 5 Fuel delivery 10 Stud Bolt A 36 367 26 5 C 19 6 200 14 5 B 24 5 250 18 1 D 28 5 290 21 0 4 C 3 D 1 2 x 2 5 D 9 C 6 3 B 3 9 10 x 3 x 3 A 3 7 8 3 B SHTS021271000065 ...

Page 458: ... to remove the fuel feed pipe No 5 and 2 gaskets from the fuel delivery NOTICE Prepare the reservoir and waste to collect dripping fuel when dis connecting the pipe 2 Remove the nut and then the clip 3 Unfasten the 2 union bolts to remove the coolant pipe D and 4 gaskets from the folder and turbocharger assembly NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when discon...

Page 459: ...fuel addition valve O ring If it did not come off it can be reused 2 Unfasten the bolt to remove the nozzle clamp from the folder 3 Remove the fuel addition valve O ring and gasket from the folder 4 Unfasten the 3 nuts to remove the folder and gasket from the exhaust pipe ATC FUEL DELIVERY FOLDER SHTS021271000069 NOZZLE CLAMP FOLDER SHTS021271000070 O RING FUEL ADDITION VALVE GASKET FOLDER SHTS021...

Page 460: ...backup ring closed gap for overriding and gaping as shown in the figure 2 CHECKING AFTER MOUNTING 1 After mounting the O ring backup ring and E ring to the fuel addition valve check the seal for damage collapse and protru sion from the seal groove CAUTION Check the O ring groove of the fuel addition valve for foreign mat ter or damage E RING O RING BACKUP RING No 3 BACKUP RING No 2 BACKUP RING No ...

Page 461: ...the standard value CAUTION Never measure between the terminals or the fuel addition valve will be damaged 2 RESISTANCE TEST BETWEEN TERMINALS 1 Using the circuit tester measure the resistance between the fuel addition valve terminals Replace if the measurement reading exceeds the standard value MEGOHMMETER SHTS021271000076 Standard value Room tempera ture 10M or more Using the 500 V megohmmeter SH...

Page 462: ...the resin parts terminals and O ring of the fuel addition valve If adhered immediately wipe it off 1 Spray the carbon cleaner to the fuel addition valve nozzle hole SST S0826 E3065 Carbon cleaner CAUTION Do not touch the nozzle hole with hands or wipe it with a waste Do not apply excessive force or weight to the connector to avoid the risk of breakage 2 Leave it for a while until carbon is dissolv...

Page 463: ...THE FUEL ADDITION VALVE 1 Replace with a new gasket and mount the folder to the exhaust pipe ATC with 3 nuts Tightening Torque 36 N m 367 kgf cm 26 5 lbf ft 2 Replace with a new O ring and gasket and mount the fuel addition valve to the folder CAUTION Apply engine oil to the O ring Use care not to get the O ring jammed when inserting Do not apply excessive force or weight to the connector to avoid...

Page 464: ...ng jammed when inserting the fuel delivery Check the O ring seal for dirt before mounting 3 CONNECTING PIPES 1 Replace with 4 new gaskets and connect the coolant pipe E to the folder and oil cooler assembly with 2 union bolts Tightening Torque 24 5 N m 250 kgf cm 18 1 lbf ft 2 Replace with 4 new gaskets and connect the coolant pipe D to the folder and turbocharger assembly with 2 union bolts Tight...

Page 465: ...k that there are no spark traces on the terminals When connecting do not apply excessive force to the con nector on the fuel addition valve side The connector may be damaged 5 ADDING THE COOLANT Reference COOLING J05E RADIATOR REPLACEMENT ADDING THE COOLANT Page 12 13 6 AIR BLEEDING OF FUEL SYSTEM Reference FUEL SYSTEM J05E FUEL FILTER AND CASE ENGINE SIDE REPLACEMENT AIR BLEEDING OF FUEL SYSTEM P...

Page 466: ...OMPONENT LOCATOR EN01F02127100402037001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Fuel feed pipe No 3 3 Fuel cutoff valve 2 Gasket 4 Fuel feed pipe No 5 A 19 6 200 14 5 B 28 5 290 21 0 B A 2 1 3 4 2 A x 2 SHTS021271000088 ...

Page 467: ...the process of mounting the pre fuel filter case After mounting is completed thoroughly purge air from the fuel pipe 2 MOUNTING THE FUEL CUTOFF VALVE 1 Mount the fuel cutoff valve to the flywheel housing with the bolts 2 pcs Tightening Torque 28 5 N m 290 kgf cm 21 0 lbf ft 3 CONNECTING PIPES 1 Replace with 2 new gaskets and connect the fuel feed pipe No 3 and fuel feed pipe No 5 to the fuel cutof...

Page 468: ...it N m kgf cm lbf ft 1 DEF pump assembly 6 DEF pump 2 Outlet connector 7 Filter 3 Backflow connector 8 Filter cover 4 Inlet connector 9 Tank bracket 5 Coolant connector A 15 2 22 8 155 232 11 2 16 8 C 5 6 51 61 3 7 4 4 B 4 5 41 51 2 9 3 7 D 15 25 153 255 11 1 18 4 9 1 A 7 6 5 C B 2 3 4 8 D SHTS021271000091 ...

Page 469: ...ing work wait for at least 10 minutes after turn ing the starter key to LOCK 2 REMOVING THE FILTER 1 Turn the filter cover counterclockwise using the 27 mm 1 06 in box dodecagon to remove it from the DEF pump CAUTION Prepare the reservoir and waste to collect dripping DEF when removing the fuel cover 2 Remove the filter and equalizer from the DEF pump DEF PUMP FILTER COVER SHTS021271000092 DEF PUM...

Page 470: ...F drawn back to the DEF tank is performed after the starter key is turned to LOCK and the muffler temperature drops Before starting work wait for at least 10 minutes after turn ing the starter key to LOCK 2 REMOVING THE DEF TANK ASSEMBLY Reference EXHAUST J05E DEF TANK REPLACEMENT REMOVING THE DEF TANK ASSEMBLY Page 11 79 3 REMOVING THE DEF PUMP 1 Unfasten the bolts 3 pcs to remove the DEF pump fr...

Page 471: ... 3 Disconnect the outlet connector from the DEF pump using a 17 mm 0 67 in spanner 4 Disconnect the backflow connector from the DEF pump using a 17 mm 0 67 in spanner DEF PUMP COOLANT CONNECTOR O RING 77 mm 18 mm SHTS021271000097 DEF PUMP INLET CONNECTOR O RING 88 mm 22 mm SHTS021271000098 DEF PUMP OUTLET CONNECTOR O RING 88 mm 20 mm SHTS021271000099 DEF PUMP BACKFLOW CONNECTOR O RING 81 mm 25 mm ...

Page 472: ...ful not to get crystallized DEF jammed 5 Apply Mobil Velocite Oil No 6 to the O ring of the inlet connector 6 Connect the inlet connector to the DEF pump using a 17 mm 0 67 in spanner Tightening Torque 4 5 N m 41 51 kgf cm 2 9 3 7 lbf ft CAUTION Be careful not to get crystallized DEF jammed 7 Apply Mobil Velocite Oil No 6 to the O ring of the coolant connec tor 8 Connect the coolant connector to t...

Page 473: ... m 155 232 kgf cm 11 2 16 8 lbf ft 3 MOUNTING THE DEF TANK ASSEMBLY Reference EXHAUST J05E DEF TANK REPLACEMENT MOUNTING THE DEF TANK ASSEMBLY Page 11 81 4 ADDING THE COOLANT 1 Inspect the coolant level and if insufficient pour coolant Reference COOLING J05E RADIATOR REPLACEMENT ADDING THE COOLANT Page 12 13 DEF PUMP SHTS021271000105 ...

Page 474: ...OR EN01F02127100402055001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Gasket 4 Hose bracket 2 DEF injector 5 Hose protector 3 Coolant connector A 31 316 22 9 C 5 6 51 61 3 7 4 4 B 6 10 61 102 4 4 7 4 A B C 4 2 1 3 5 SHTS021271000106 ...

Page 475: ...on DEF coolant piping attaching and detach ing Reference EXHAUST J05E DEF SCR DPR CAUTIONS ON DEF COOLANT PIPING ATTACHING AND DETACHING Page 11 20 1 Disconnect the coolant inlet hose and coolant outlet hose from the DEF injector NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when disconnecting the hose Block with vice clip to prevent coolant outflow from the hose Mount...

Page 476: ...liers and remove the gasket from the DEF injector CAUTION Do not use a pliers with sharp end 3 Clean the surface of the DEF injector sealing interface CAUTION Pay attention not to scratch the sealing interface surface Do not touch the orifice plate DEF INJECTOR MUFFLER CONNECTOR SHTS021271000110 DEF INJECTOR MUFFLER SHTS021271000111 GASKET DEF INJECTOR TAB SHTS021271000112 ORIFICE PLATE SEALING IN...

Page 477: ... 1 Replace with a new gasket and mount the gasket by placing and pressing on the sealing interface CAUTION The gasket is nonreusable because of the deformation of tabs Pay attention not to scratch the gasket Check that the tabs 3 places of the gasket are engaged with the tabs of the DEF injector 2 Mount the DEF injector to the muffler with 3 nuts Tightening Torque 6 10 N m 61 102 kgf cm 4 4 7 4 lb...

Page 478: ...EXHAUST J05E DEF SCR DPR CAUTIONS ON DEF COOLANT PIPING ATTACHING AND DETACHING Page 11 20 1 Connect the DEF inlet hose to the DEF injector 2 Connect the coolant inlet hose and coolant outlet hose to the DEF injector DEF INJECTOR MUFFLER CONNECTOR SHTS021271000118 DEF INJECTOR DEF INLET HOSE MUFFLER SHTS021271000119 DEF INJECTOR COOLANT INLET HOSE COOLANT OUTLET HOSE MUFFLER SHTS021271000120 ...

Page 479: ...ctor to the hose bracket with 2 nuts Tightening Torque 31 N m 316 kgf cm 22 9 lbf ft 6 ADDING THE COOLANT 1 Inspect the coolant level and if insufficient pour coolant Reference COOLING J05E RADIATOR REPLACEMENT ADDING THE COOLANT Page 12 13 HOSE PROTECTOR SHTS021271000121 ...

Page 480: ...Unit N m kgf cm lbf ft 1 Tank bracket 6 J bolt 2 DEF tank 7 Tank band 3 Drain plug 8 Filler cap 4 Water level gauge 9 DEF tank cover 5 Clamp A 38 4 57 6 392 587 28 3 42 5 C 32 326 23 6 B 23 5 36 5 240 372 17 3 26 9 A C SINGLE CAB CREW CAB C 1 3 4 5 2 8 6 B 7 9 9 5 x 4 x 2 SHTS021271000122 ...

Page 481: ...tandard value 3 PH TEST PAPER INSPECTION 1 Extract the DEF and put a few drops on the pH test paper to check color change Replace the DEF if the measurement reading exceeds the standard value 4 REFRACTIVE INDEX MEASUREMENT INSPECTION 1 Extract the DEF and put a few drops on the refractometer to mea sure refractive index Replace the DEF if the measurement read ing exceeds the standard value SHTS021...

Page 482: ...vel may burst when frozen Promptly wipe off DEF with a waste if it overflowed from the DEF tank or adhered to the tank or peripheral parts when adding Wipe it off while it is in liquid form since it will crys tallize and whiten when left unattended and become difficult to be removed Use a cloth soaked in warm water to wipe off crystallized urea Avoid entry of dust and foreign matter into the DEF t...

Page 483: ...e the DEF tank and DEF sensor In this case no other parts need to be replaced REMOVING THE DEF TANK 1 CAUTIONS CAUTION After run DEF drawn back to the DEF tank is performed after the starter key is turned to LOCK and the muffler temperature drops Before starting work wait for at least 10 minutes after turn ing the starter key to LOCK 2 REMOVING THE TANK BAND 1 Unfasten the 2 J bolts and 2 nuts to ...

Page 484: ... cap to the DEF sensor 2 Unfasten the 2 clamps to disconnect the coolant inlet hose and coolant outlet hose from the DEF sensor NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when disconnecting the hose Block with vice clip to prevent coolant outflow from the hose Mount the protection cap to the DEF sensor 5 DISCONNECTING THE HARNESS 1 Disconnect the connector from the ...

Page 485: ...ch ing Reference EXHAUST J05E DEF SCR DPR CAUTIONS ON DEF COOLANT PIPING ATTACHING AND DETACHING Page 11 20 1 Connect the coolant inlet hose and coolant outlet hose to the DEF sensor with 2 clamps 2 Connect the DEF backflow hose and DEF outlet hose to the DEF sensor TANK BRACKET DEF TANK SHTS021271000133 DEF SENSOR CONNECTOR DEF TANK SHTS021271000134 DEF TANK DEF SENSOR DEF OUTLET HOSE DEF BACKFLO...

Page 486: ...ket and DEF tank with 2 nuts At this time tighten the J bolts to make the protrusion amount of the screws even Tightening Torque 23 5 36 5 N m 240 372 kgf cm 17 3 26 9 lbf ft 6 ADDING THE COOLANT 1 Inspect the coolant level and if insufficient pour coolant Reference COOLING J05E RADIATOR REPLACEMENT ADDING THE COOLANT Page 12 13 DEF TANK DEF TANK COVER DEF TANK DEF TANK COVER CREW CAB SINGLE CAB S...

Page 487: ...tes after turn ing the starter key to LOCK 2 DISCONNECTING THE HARNESS 1 Disconnect the connector from the DCU Reference EXHAUST J05E DCU REPLACEMENT REMOV ING THE DCU Page 11 90 2 Disconnect the connector from the DEF sensor 3 Disconnect the connector from the outside temperature sensor 4 Disconnect the connector from the DEF pump 5 Remove the harness clip DCU OUTSIDE TEMPERATURE SENSOR DEF SENSO...

Page 488: ...t the coolant inlet hose and coolant outlet hose from the DEF pump NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when disconnecting the hose Block with vice clip to prevent coolant outflow from the hose Mount the protection cap to the DEF pump 4 REMOVING THE DEF TANK ASSEMBLY 1 Lash the transmission jack and DEF tank assembly with a lashing device CAUTION Pay attention...

Page 489: ...kgf cm 28 3 42 5 lbf ft 2 CONNECT THE HOSE CAUTION Refer to Cautions on DEF coolant piping attaching and detach ing Reference EXHAUST J05E DEF SCR DPR CAUTIONS ON DEF COOLANT PIPING ATTACHING AND DETACHING Page 11 20 1 Connect the coolant inlet hose and coolant outlet hose to the DEF pump 2 Connect the DEF inlet hose DEF outlet hose and DEF backflow hose to the DEF pump 3 Connect the hose to the D...

Page 490: ... Connect the connector to the outside temperature sensor 3 Connect the connector to the DEF sensor 4 Connect the connector to the DCU Reference EXHAUST J05E DCU REPLACEMENT MOUNT ING THE DCU Page 11 92 DEF PUMP SHTS021271000144 DCU OUTSIDE TEMPERATURE SENSOR DEF SENSOR SHTS021271000145 ...

Page 491: ...EXHAUST J05E 11 83 DEF SENSOR COMPONENT LOCATOR EN01F02127100402057001 Nonreusable part 1 O ring 2 DEF sensor 2 1 SHTS021271000146 ...

Page 492: ...erclockwise to remove it from the DEF tank CAUTION When removing be careful not to bend the water level sensor pipe When taking out the sensor from inside the tank be careful not to damage the sensor by hitting the tank edge 2 Remove the O ring from the DEF sensor SINGLE UNIT INSPECTION 1 INSPECTING A FLOAT 1 Check if the DEF sensor float moves smoothly DEF TANK O RING DEF SENSOR SHTS021271000147 ...

Page 493: ...DEF crystals precipitated on the mount ing surface with a clean waste When inserting the sensor inside the tank be careful not to damage the sensor by hitting the tank edge Check that the tank center and DEF sensor pipe are mounted in parallel position Do not tighten the DEF sensor excessively 2 MOUNTING THE DEF TANK Reference EXHAUST J05E DEF TANK REPLACEMENT MOUNTING THE DEF TANK Page 11 77 DEF ...

Page 494: ...OFF VALVE COMPONENT LOCATOR EN01F02127100402019001 Tightening torque Unit N m kgf cm lbf ft 1 Coolant cutoff valve 4 Clamp 2 Water valve bracket 5 Hose 3 Harness bracket A 31 316 22 9 2 A A 4 5 A x 2 x 2 x 2 1 3 4 5 SHTS021271000150 ...

Page 495: ...th vice clip to prevent coolant outflow from the hose Close the vice clip since the coolant flows out from the cool ant cutoff valve 2 DISCONNECTING THE HARNESS 1 Disconnect the connector connected to the coolant cutoff valve 3 REMOVING THE COOLANT CUTOFF VALVE 1 Remove the harness clamp 2 Unfasten the nuts 2 pcs and remove the coolant cutoff valve with the bracket 3 Unfasten the bolts 2 pcs to re...

Page 496: ... ft 4 Mount the harness clamp 2 CONNECTING THE HARNESS 1 Connect the connector to the coolant cutoff valve 3 CONNECTING THE HOSE CAUTION Refer to Cautions on DEF coolant piping attaching and detach ing Reference EXHAUST J05E DEF SCR DPR CAUTIONS ON DEF COOLANT PIPING ATTACHING AND DETACHING Page 11 20 1 Connect the 2 hoses to the coolant cutoff valve with 2 clamps 4 ADDING THE COOLANT 1 Inspect th...

Page 497: ...EXHAUST J05E 11 89 DCU COMPONENT LOCATOR EN01F02127100402021001 Tightening torque Unit N m kgf cm lbf ft 1 DCU 2 DCU bracket A 10 102 7 4 B 22 224 16 2 B 2 1 A x 3 x 4 SHTS021271000157 ...

Page 498: ...DE TEMPERA TURE SENSOR Page 11 120 2 DISCONNECTING THE DEF SENSOR CONNECTOR 1 Disconnect the connector from the DEF sensor 3 REMOVING THE DCU BRACKET 1 Unfasten the nuts 3 pcs and remove the DCU with the DCU bracket from the tank bracket 2 Remove the harness clamp from the DCU bracket DEF SENSOR SHTS021271000158 DCU DCU BRACKET TANK BRACKET SHTS021271000159 HARNESS DCU BRACKET SHTS021271000160 ...

Page 499: ...ary Never detach the harness by holding and pulling or prying as it may result in wire or terminal deformation Never insert a test lead from the rear of the connector Do not paint or apply grease or oil to the connector to main tain its function and durability NOTICE If it cannot be pulled out with a light force check if the slide is fully open 86 POLE CONNECTOR SLIDE SLIDE 53 POLE CONNECTOR SHTS0...

Page 500: ...1 Check that the harness side connector slide is fully open and place it straight on the DCU side connector CAUTION At this time check that the slide is fully open 2 Press the upper part of the harness side connector and insert the connector uniformly DCU BRACKET DCU SHTS021271000163 DCU BRACKET DCU SHTS021271000164 86 POLE CONNECTOR SLIDE SLIDE HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR DCU SI...

Page 501: ...is heard CAUTION If the slide cannot move smoothly repeat steps 1 and 2 Securely insert the slide part and the connector in parallel since the slide part may tilt causing a gap between the slide and the connector 86 POLE CONNECTOR 53 POLE CONNECTOR SLIDE SLIDE SHTS021271000166 SLIDE PART NORMAL INCLINED SLIDE PART SHTS021271000167 ...

Page 502: ...2 N m 224 kgf cm 16 2 lbf ft 4 CONNECTING THE DEF SENSOR CONNECTOR 1 Connect the connector to the DEF sensor 5 MOUNTING THE OUTSIDE TEMPERATURE SENSOR Reference EXHAUST J05E OUTSIDE TEMPERATURE SEN SOR REPLACEMENT MOUNTING THE OUTSIDE TEMPERA TURE SENSOR Page 11 120 HARNESS DCU BRACKET SHTS021271000168 TANK BRACKET DCU BRACKET DCU SHTS021271000169 DEF SENSOR SHTS021271000170 ...

Page 503: ...E 11 95 DPR DIFFERENTIAL PRESSURE SENSOR COMPONENT LOCATOR EN01F02127100402003001 Tightening torque Unit N m kgf cm lbf ft 1 DPR differential pressure sensor 3 Hose 2 Clamp A 31 316 22 9 A 1 2 2 3 SHTS021271000171 ...

Page 504: ...connect 2 hoses from the DPR differ ential pressure sensor and differential pressure pipe 3 REMOVE THE DPR DIFFERENTIAL PRESSURE SENSOR 1 Unfasten the 2 nuts to remove the DPR differential pressure sen sor from the bracket SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Measure the resistance of the DPR differential pressure sensor with a circuit tester If the value exceeds the standard value...

Page 505: ... and differential pressure pipe with 4 clamps CAUTION If the DPR differential pressure sensor hose is inserted incor rectly the DPR will not operate properly Use care to avoid twisting or kink of the hoses Insert the hoses to the end at which they come in contact with the DPR differential pressure sensor body Insert the hoses to the end at which they come in contact with the spools on the differen...

Page 506: ...CR UPSTREAM NOx SENSOR COMPONENT LOCATOR EN01F02127100402022001 Tightening torque Unit N m kgf cm lbf ft 1 SCR upstream NOx sensor 2 Clip A 5 5 56 4 1 C 40 60 408 612 29 5 44 2 B 31 316 22 9 A 2 B 1 C x 2 SHTS021271000175 ...

Page 507: ...PSTREAM NOx SENSOR 1 Unfasten the 2 nuts and remove SCR upstream NOx controller from the bracket 2 Remove the nut and then the clip 3 Remove the SCR upstream NOx sensor together with the har ness clamp from the muffler CAUTION If the harness clamp is damaged mount a new clamp to the origi nal place correctly and securely SCR UPSTREAM NOx SENSOR SHTS021271000176 SCR UPSTREAM NOx SENSOR MUFFLER SHTS...

Page 508: ...y Paste or equivalent to the thread area A new upstream NOx sensor has anti seizure lubricant applied Pay attention not to twist the harness of the SCR upstream NOx sensor Do not allow the harness to interfere with the bracket or bolt 2 Mount the clip with a nut Tightening Torque 31 N m 316 kgf cm 22 9 lbf ft 3 Mount the SCR upstream NOx controller to the bracket with 2 nuts Tightening Torque 5 5 ...

Page 509: ... 11 101 SCR DOWNSTREAM NOx SENSOR COMPONENT LOCATOR EN01F02127100402023001 Tightening torque Unit N m kgf cm lbf ft 1 SCR downstream NOx controller A 5 5 56 4 1 B 40 60 408 612 29 5 44 2 A 1 B x 2 SHTS021271000180 ...

Page 510: ...OVING THE SCR DOWNSTREAM NOx SENSOR 1 Unfasten the 2 nuts and remove SCR downstream NOx controller from the bracket 2 Remove the SCR downstream NOx sensor together with the har ness clamp from the muffler CAUTION If the harness clamp is damaged mount a new clamp to the origi nal place correctly and securely SCR DOWNSTREAM NOx SENSOR SHTS021271000181 SCR DOWNSTREAM NOx SENSOR MUFFLER SHTS0212710001...

Page 511: ...COM Anti Seize ASW High Tech Assembly Paste or equivalent to the thread area A new downstream NOx sensor has anti seizure lubricant applied Pay attention not to twist the harness of the SCR down stream NOx sensor Do not allow the harness to interfere with the bracket or bolt 2 Mount the SCR downstream NOx controller to the bracket with 2 nuts Tightening Torque 5 5 N m 56 kgf cm 4 1 lbf ft 2 CONNEC...

Page 512: ...T J05E 11 104 ATC UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402058001 Tightening torque Unit N m kgf cm lbf ft 1 ATC upstream temperature sensor A 25 35 255 357 18 4 25 8 1 A SHTS021271000185 ...

Page 513: ...pstream temperature sensor together with a harness clamp from the exhaust pipe ATC SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Use water and a circuit tester to measure resistance between ter minals Replace if a measurement reading exceeds the standard value ATC UPSTREAM TEMPERATURE SENSOR EXHAUST PIPE ATC SHTS021271000186 ATC UPSTREAM TEMPERATURE SENSOR THERMOMETER HEAT SOURCE A A B B SH...

Page 514: ...eam temperature sensor is reused wipe off old anti seizure lubricant and apply new anti seizure lubri cant equivalent to NEVER SEEZ Heavy Metal Free manufac tured by Bostic Inc to threads A new ATC upstream temperature sensor has anti seizure lubricant applied Use care to avoid twisting or kink of an ATC upstream tem perature sensor harness 2 CONNECTING THE HARNESS 1 Connect a connector to the ATC...

Page 515: ...T J05E 11 107 DOC UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402025001 Tightening torque Unit N m kgf cm lbf ft 1 DOC upstream temperature sensor A 25 35 255 357 18 4 25 8 1 A SHTS021271000189 ...

Page 516: ...OC upstream temperature sensor together with a harness clamp from the muffler SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Use water and a circuit tester to measure resistance between ter minals Replace if a measurement reading exceeds the standard value DOC UPSTREAM TEMPERATURE SENSOR MUFFLER SHTS021271000190 DOC UPSTREAM TEMPERATURE SENSOR A A B B THERMOMETER HEAT SOURCE SHTS021271000191...

Page 517: ...ld anti seizure lubricant on the DOC upstream temperature sensor and apply anti seizure lubricant equivalent to NEVER SEEZ Heavy Metal Free man ufactured by Bostic Inc to the thread area A new DOC upstream temperature sensor has anti seizure lubricant applied Use care to avoid twisting or kink of a DOC upstream temper ature sensor harness 2 CONNECTING THE HARNESS 1 Connect the connector to the DOC...

Page 518: ...T J05E 11 110 DPR UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402044001 Tightening torque Unit N m kgf cm lbf ft 1 DPR upstream temperature sensor A 25 35 255 357 18 4 25 8 1 A SHTS021271000193 ...

Page 519: ...onnect the DPR upstream temperature sensor to the muffler and then the harness clamp Tightening Torque 25 35 N m 255 357 kgf cm 18 4 25 8 lbf ft CAUTION When reusing clean the old anti seizure lubricant on the DPR upstream temperature sensor and apply anti seizure lubricant equivalent to NEVER SEEZ Heavy Metal Free man ufactured by Bostic Inc to the thread area A new DPR upstream temperature senso...

Page 520: ...J05E 11 112 DPR DOWNSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402027001 Tightening torque Unit N m kgf cm lbf ft 1 DPR downstream temperature sensor A 25 35 255 357 18 4 25 8 1 A SHTS021271000197 ...

Page 521: ...e DPR downstream temperature sensor together with a harness clamp from the muffler SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Use the water and a circuit tester to measure resistance between terminals Replace if a measurement reading exceeds the stan dard value DPR DOWNSTREAM TEMPERATURE SENSOR MUFFLER SHTS021271000198 DPR DOWNSTREAM TEMPERATURE SENSOR A A B B THERMOMETER HEAT SOURCE SHT...

Page 522: ... old anti seizure lubricant on the DPR downstream temperature sensor and apply anti seizure lubricant equivalent to NEVER SEEZ Heavy Metal Free man ufactured by Bostic Inc to the thread area A new DPR downstream temperature sensor has anti seizure lubricant applied Use care to avoid twisting or kink of a DPR downstream tem perature sensor harness 2 CONNECTING THE HARNESS 1 Connect a connector to t...

Page 523: ...E 11 115 SCR UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402028001 Tightening torque Unit N m kgf cm lbf ft 1 SCR upstream temperature sensor 2 Christmas tree A 32 5 331 24 0 1 1 A SHTS021271000201 ...

Page 524: ...ream tem perature sensor 2 REMOVING THE SCR UPSTREAM TEMPERATURE SENSOR 1 Remove the SCR upstream temperature sensor together with the harness clamp from the muffler 2 Remove the Christmas tree from the connector of the SCR upstream temperature sensor SCR UPSTREAM TEMPERATURE SENSOR SCR UPSTREAM TEMPERATURE SENSOR MUFFLER SHTS021271000202 CONNECTOR CHRISTMAS TREE SHTS021271000203 ...

Page 525: ...ading exceeds the stan dard value MOUNTING THE SCR UPSTREAM TEMPERATURE SENSOR 1 MOUNTING THE SCR UPSTREAM TEMPERATURE SENSOR 1 Mount the Christmas tree to the connector of the SCR upstream temperature sensor SCR UPSTREAM TEMPERATURE SENSOR B B A A THERMOMETER HEAT SOURCE SHTS021271000204 Temperature Standard value 50 C 122 F 235 244 CONNECTOR CHRISTMAS TREE SHTS021271000205 ...

Page 526: ...and apply anti seizure lubricant equivalent to NEVER SEEZ Pure Nickel Special Grade manufactured by Bostic Inc to the thread area A new SCR upstream temperature sensor has anti seizure lubricant applied Pay attention not to twist the harness of the SCR upstream temperature sensor 2 CONNECTING THE HARNESS 1 Connect the connector to the SCR upstream temperature sensor SCR UPSTREAM TEMPERATURE SENSOR...

Page 527: ...EXHAUST J05E 11 119 OUTSIDE TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402038001 1 Outside temperature sensor 1 SHTS021271000207 ...

Page 528: ...TEMPERATURE SENSOR 1 Unfasten the clamp to remove the outside temperature sensor from the bracket MOUNTING THE OUTSIDE TEMPERATURE SENSOR 1 MOUNTING THE OUTSIDE TEMPERATURE SENSOR 1 Mount the outside temperature sensor to the bracket with the clamp 2 CONNECTING THE HARNESS 1 Connect the connector to the outside temperature sensor OUTSIDE TEMPERATURE SENSOR SHTS021271000208 OUTSIDE TEMPERATURE SENS...

Page 529: ...EXHAUST J05E 11 121 EXHAUST BRAKE COMPONENT LOCATOR EN01F02127100402008001 Nonreusable part 1 Exhaust brake 2 Gasket 1 2 SHTS021271000210 ...

Page 530: ...r more than 30 minutes to cool 2 REMOVING THE EXHAUST PIPE ATC Reference EXHAUST J05E EXHAUST PIPE ATC REPLACEMENT REMOVING THE EXHAUST PIPE ATC Page 11 17 3 DISCONNECTING THE VACUUM HOSE 1 Disconnect the vacuum hose from the exhaust brake 4 REMOVING THE EXHAUST BRAKE 1 Remove the exhaust brake and gasket from the turbocharger assembly EXHAUST BRAKE VACUUM HOSE SHTS021271000211 EXHAUST BRAKE SHTS0...

Page 531: ...G THE VALVE BODY 1 Close the valve completely by applying a load of 80 kPa 600 mmHg 11 6 inHg using the Mityvac 2 Inspect the clearance between the valve and body using the SST SST 09240 00020 Wire gauge set 09242 00020 Wire gauge 0 2 mm contained in kit 3 Open the valve completely by applying atmospheric pressure to the exhaust brake and inspect the angle between the valve and body SHTS0212710002...

Page 532: ...CONNECTING THE VACUUM HOSE 1 Connect the vacuum hose to the exhaust brake 3 MOUNTING THE EXHAUST PIPE ATC Reference EXHAUST J05E EXHAUST PIPE ATC REPLACEMENT MOUNTING THE EXHAUST PIPE ATC Page 11 18 4 INSPECTING FOR EXHAUST GAS LEAKAGE 1 Start the engine and inspect for exhaust gas leakage EXHAUST BRAKE SHTS021271000216 EXHAUST BRAKE VACUUM HOSE SHTS021271000217 ...

Page 533: ...5E 11 125 EXHAUST BRAKE MAGNETIC VALVE COMPONENT LOCATOR EN01F02127100402045001 Tightening torque Unit N m kgf cm lbf ft 1 Exhaust brake magnetic valve 3 Hose 2 Clamp A 31 316 22 9 1 2 3 3 A x 2 SHTS021271000218 ...

Page 534: ...the bolts 2 pcs to remove the exhaust brake magnetic valve from the bracket SINGLE UNIT INSPECTION 1 RESISTANCE TEST BETWEEN TERMINALS 1 Use the circuit tester measure the resistance between the exhaust brake magnetic valve terminals Replace if the measure ment reading exceeds the standard value 2 VENTILATION TEST 1 Apply a battery voltage 12 V between the exhaust brake mag netic valve terminals a...

Page 535: ...t brake magnetic valve with the bolts 2 pcs Tightening Torque 31 N m 316 kgf cm 22 9 lbf ft 2 CONNECTING THE HARNESS 1 Connect the connector to the exhaust brake magnetic valve 3 CONNECT THE HOSE 1 Align the markings and connect the hoses 2 pcs to the exhaust brake magnetic valve ÅØÈÁÕÓÔ ÂÒÁËÅ ÍÁÇÎÅÔÉÃ ÖÁÌÖÅ SHTS021271000222 ...

Page 536: ...ENT 12 16 RESERVE TANK 12 18 COMPONENT LOCATOR 12 18 REPLACEMENT 12 19 INTERCOOLER 12 20 COMPONENT LOCATOR 12 20 OVERHAUL 12 21 THERMOSTAT CASE AND THERMOSTAT 12 23 COMPONENT LOCATOR 12 23 OVERHAUL 12 24 COOLANT PUMP 12 30 COMPONENT LOCATOR 12 30 REPLACEMENT 12 31 COOLING FAN AND FAN CLUTCH 12 33 COMPONENT LOCATOR 12 33 OVERHAUL 12 34 COOLANT TEMPERATURE SENSOR 12 37 COMPONENT LOCATOR 12 37 REPLAC...

Page 537: ...405009001 RESERVOIR EGR COOLER CYLINDER HEAD CYLINDER BLOCK OIL COOLER DRAIN COCK DRAIN COCK TURBO CHARGER COOLANT PUMP CAR HEATER COOLANT TEMPERATURE METER FUEL ADDITION VALVE THERMOSTAT THERMOSTAT CASE RADIATOR FOR ENGINE COOLING FOR ACCESSORY COOLING AIR PULLING OUT SHTS021271100001 ...

Page 538: ...NT LOCATOR EN01F02127110402019001 Tightening torque Unit N m kgf cm lbf ft 1 Radiator inlet hose 4 Radiator bracket No 3 2 Clamp 5 Radiator bracket No 4 3 Radiator outlet hose 6 Radiator support seal No 1 A 19 5 199 14 1 2 2 6 A 4 A 5 3 2 SHTS021271100002 ...

Page 539: ...CLEANING 1 CHECK FIN FOR BLOCKAGE 1 If the fins are clogged wash them with water or a steam cleaner then dry them with compressed air NOTICE If the steam cleaner is too close to the core there is a possi bility of damaging the fins so keep the following injection distances If the fins are bent straighten them with a screwdriver or pli ers Do not expose electronic components to water SHTS0212711000...

Page 540: ...drain plug on the oil pan lower surface to drain auto matic transmission oil CAUTION When draining automatic transmission oil check for oil quantity and quality and presence of metallic fragments Dispose the automatic transmission oil in accordance with the specified procedures industrial waste disposal or by other environment friendly methods For details refer to RZT 0010 Environment Manual NOTIC...

Page 541: ...servoir and clean clothes to collect dripping coolant when disconnecting the hose 1 Remove the resin clamp from the radiator inlet hose 2 Loosen the 2 clamps and disconnect the radiator inlet hose and radiator hose from the radiator 3 Remove the clamp and disconnect the radiator outlet hose from the radiator lower tank 6 REMOVING THE COOLING FAN AND FAN PULLEY Reference COOLING J05E COOLING FAN AN...

Page 542: ...n the bolt to remove the heater pipe and reserve pipe 2 Unfasten the 4 bolts and nuts to remove the radiator bracket No 3 from the radiator 3 Unfasten the 4 bolts and nuts to remove the radiator bracket No 4 from the radiator SHTS021271100008 SHTS021271100009 SHTS021271100010 ...

Page 543: ... the upper side from the vehicle CAUTION Be careful not to damage the fin of the radiator core during work 9 REMOVING THE RADIATOR SUPPORT SEAL No 1 1 Unfasten the 6 bolts to remove the radiator support seal No 1 from the radiator RADIATOR SUPPORT SEAL No 1 SHTS021271100011 ...

Page 544: ... position CAUTION Be careful not to damage the fin of the radiator core during work 3 MOUNTING THE HEATER PIPE AND RADIATOR BRACKET 1 Mount the radiator bracket No 4 to the radiator with 4 bolts and nuts Tightening Torque 19 5 N m 199 kgf cm 14 lbf ft 2 Mount the radiator bracket No 3 to the radiator with 4 bolts and nuts Tightening Torque 19 5 N m 199 kgf cm 14 lbf ft RADIATOR SUPPORT SEAL No 1 S...

Page 545: ...3 N m 222 410 kgf cm 17 29 lbf ft 4 Mount the reserve pipe with the bolt Tightening Torque 19 5 N m 199 kgf cm 14 lbf ft 4 MOUNTING THE COOLING FAN AND FAN PULLEY Reference COOLING J05E COOLING FAN AND FAN CLUTCH OVERHAUL MOUNTING THE COOLING FAN FAN CLUTCH Page 12 36 SHTS021271100015 ...

Page 546: ...rting area Do not reuse the clamp Be sure that the distance between the hose end and the clamp is 0 4 mm 0 0 157 in when mounting the clamp Insert the hose to the stopper Check that there is no bending of the clamp and landing upon the pipe spool If the clamp is installed at an unspecified location the clamp will land on the pipe spool resulting in coolant leakage RADIATOR OUTLET HOSE SHTS02127110...

Page 547: ...pipe spool If the clamp is installed at an unspecified location the clamp will land on the pipe spool resulting in coolant leakage 6 CONNECTING THE OIL COOLER HOSE 1 Connect the oil cooler outlet hose No 1 to the radiator lower tank with the clamp 2 Connect the oil cooler inlet hose No 1 to the radiator lower tank with the clamp 3 Add automatic transmission oil Reference CHASSIS S1 LXJE03A TRANSMI...

Page 548: ...a few times with hands If the coolant level of the radiator inlet decreases add coolant 4 Mount the radiator cap 5 Add the coolant into the reserve tank to FULL and tighten the cap 6 Warm up the engine until the thermostat injection valve opens NOTICE Bring pressure on the 2 radiator hoses for a few times during engine warming up 7 After stopping the engine check the water level If the water level...

Page 549: ...ure does not decrease NOTICE If the pressure decreases check the hose radiator or coolant pump for leakage If leakage to the outside is not found check the heater core cylinder block or cylinder head 10 FILLING REFRIGERANT Reference CHASSIS S1 LXJE03A HEATER AIR CONDI TIONER Reference CHASSIS S1 LXJE04A HEATER AIR CONDI TIONER 11 WARMING UP ENGINE 1 Warm up the engine 12 INSPECTION FOR REFRIGERANT...

Page 550: ...COOLING J05E 12 15 RADIATOR CAP COMPONENT LOCATOR EN01F02127110402020001 1 Radiator cap 1 SHTS021271100023 ...

Page 551: ...AUTION Do not remove the radiator cap with the needle of the coolant tem perature meter indicating above the center INSPECTING THE RADIATOR CAP 1 CAUTIONS CAUTION If the radiator cap is not clean make sure to wash it with water Before use of a radiator cap tester soak the relief valve and pressure valve with coolant or water 2 INSPECTING THE RADIATOR CAP 1 Use the commercially available radiator c...

Page 552: ... read by the tester as opening pressure If opening pressure falls below the limit replace the radiator cap MOUNTING THE RADIATOR CAP 1 MOUNTING THE RADIATOR CAP 1 Mounting the radiator cap by rotating it right to the second block CAUTION If the cap is not mounted securely high temperature coolant will spray out at the time of overheat Standard value Limit 93 1 122 9 kPa 0 95 1 25 kgf cm2 13 5 17 8...

Page 553: ...COOLING J05E 12 18 RESERVE TANK COMPONENT LOCATOR EN01F02127110402021001 Tightening torque Unit N m kgf cm lbf ft 1 Reserve tank 2 Hose A 3 5 6 5 36 66 2 6 4 7 2 1 A SHTS021271100027 ...

Page 554: ...to collect coolant dripping from the reserve tank when disconnecting the hose 2 Unfasten the 4 bolts to remove the reserve tank MOUNTING THE RESERVE TANK 1 MOUNTING THE RESERVE TANK 1 Mount the reserve tank with 4 bolts Tightening Torque 3 5 6 5 N m 36 66 kgf cm 2 6 4 7 lbf ft 2 Mount the hose to the reserve tank 2 ADDING THE COOLANT 1 Add the coolant Reference COOLING J05E RADIATOR REPLACEMENT MO...

Page 555: ...2 20 INTERCOOLER COMPONENT LOCATOR EN01F02127110402039001 Tightening torque Unit N m kgf cm lbf ft 1 Clamp 3 Intercooler 2 Intercooler hose A 14 20 143 203 11 14 B 6 25 64 4 6 A 1 2 2 1 3 B 1 B B 1 B SHTS021271100030 ...

Page 556: ...ooler core for dirt or crushing If found defective clean adjust or replace it 2 CHECK FIN FOR BLOCKAGE 1 If the fins are clogged wash them with water or a steam cleaner then dry them with compressed air NOTICE If the steam cleaner is too close to the core there is a possi bility of damaging the fins so keep the following injection distances If the fins are bent straighten them with a screwdriver o...

Page 557: ...ns of the radiator core and inter cooler core 2 CONNECTING THE INTERCOOLER 1 Connect the Intercooler hose to the Intercooler with the clamp Tightening Torque 6 25 N m 64 kgf cm 4 61 lbf ft 2 After 10 minutes re tighten the clamp Tightening Torque 6 25 N m 64 kgf cm 4 61 lbf ft NOTICE When assembling the intercooler hose it fully degreased inner hose the outer surface of the intercooler pipe INTERC...

Page 558: ...1F02127110402011001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Coolant pipe F 6 Gasket 2 Gasket 7 Thermostat 3 Coolant pipe A 8 Water outlet pipe 4 Heater pipe 9 O ring 5 Thermostat case A 285 291 21 B 24 5 250 18 1 B 2 8 9 A A 4 5 7 6 A 3 SHTS021271100034 ...

Page 559: ...G THE COOLANT TEMPERATURE SENSOR Reference COOLING J05E COOLANT TEMPERATURE SENSOR REPLACEMENT REMOVING THE COOLANT TEM PERATURE SENSOR Page 12 38 6 REMOVING THE THERMOSTAT 1 Unfasten the union bolt to remove the coolant pipe F and 2 gas kets from the thermostat case 2 Unfasten the bolt and clamp to disconnect the heater pipe from the coolant pipe A CAUTION Check the marking on hose and then disco...

Page 560: ... the reservoir and clean clothes to collect dripping coolant when removing the water outlet pipe 2 Unfasten the 6 bolts to remove the thermostat case and O ring from the cylinder head and coolant pump NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when removing the thermostat case COOLANT PIPE A THERMOSTAT GASKET THERMOSTAT CASE SHTS021271100037 WATER OUTLET PIPE SHTS02...

Page 561: ...he lift amount of the thermostat valve 4 Submerge the thermostat into water at ordinary temperature with the valve fully opened Check that the thermostat valve closes completely within five minutes 5 If found defective in inspection above replace the thermostat THERMO STAT VALVE LIFT AMOUNT SHTS021271100040 10 mm 0 393 in T1 T2 0 C F T1 C F T2 C F OPENING VALVE TEMPERATURE Beginning valve opening ...

Page 562: ...ve 4 Fit the thermostat case mounting bolts 1 4 pcs to the thermostat case in advance 5 Align the thermostat case with the mounting position and tempo rarily tighten the mounting bolts 1 4 pcs to the cylinder head 6 Temporarily tighten the mounting bolts 2 2 pcs to the coolant pump 7 Tighten the mounting bolts 1 4 pcs to the cylinder head and then the mounting bolts 2 2 pcs to the coolant pump Tig...

Page 563: ... mounting Assemble the thermostat with its jiggle valve facing up 2 Mount the coolant pipe A to the bracket with the bolt Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft 3 Connect the heater pipe to the heater hose left side with the bolt and clamp Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft COOLANT PIPE A THERMOSTAT GASKET THERMOSTAT CASE SHTS021271100047 THERMOSTAT GASKET FLANGE PART SHTS021...

Page 564: ... 4 CONNECTING THE RADIATOR HOSE Reference COOLING J05E RADIATOR REPLACEMENT MOUNTING THE RADIATOR Page 12 9 5 MOUNTING THE EGR COOLER Reference EMISSION CONTROL J05E EGR VALVE COOLER REPLACEMENT MOUNTING THE EGR VALVE COOLER Page 8 8 6 MOUNTING THE COOLING FAN FAN CLUTCH Reference COOLING J05E COOLING FAN AND FAN CLUTCH OVERHAUL MOUNTING THE COOLING FAN FAN CLUTCH Page 12 36 7 ADDING THE COOLANT R...

Page 565: ...ING J05E 12 30 COOLANT PUMP COMPONENT LOCATOR EN01F02127110402008001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Coolant pipe B 3 Coolant pump 2 Gasket A 28 5 291 21 1 2 3 A SHTS021271100052 ...

Page 566: ...SHAFT PULLEY REPLACEMENT REMOVING THE CRANKSHAFT PULLEY Page 10 47 4 DISCONNECTING THE COOLANT PIPE 1 Unfasten the union bolt and the gasket to disconnect the coolant pipe B from the coolant pump NOTICE Prepare the reservoir and clean clothes to collect dripping coolant when disconnecting the pipe 5 REMOVING THE COOLANT PUMP 1 Unfasten the bolts 8 pcs to remove the coolant pump from the cylinder b...

Page 567: ... kgf cm 21 lbf ft NOTICE Mount the coolant pump using guide bolts to avoid misalignment of the liquid gasket 2 CONNECTING THE COOLANT PIPE 1 Replace with the new gasket and mount the coolant pipe B to the coolant pump with a union bolt 3 MOUNTING THE CRANKSHAFT PULLEY Reference ENGINE MECHANICAL J05E CRANKSHAFT PULLEY REPLACEMENT MOUNTING THE CRANKSHAFT PULLEY Page 10 48 4 MOUNTING THERMOSTAT CASE...

Page 568: ...COOLING J05E 12 33 COOLING FAN AND FAN CLUTCH COMPONENT LOCATOR EN01F02127110402031001 Tightening torque Unit N m kgf cm lbf ft 1 Cooling fan A 11 112 8 A 1 SHTS021271100058 ...

Page 569: ...2 21 2 Unfasten the 4 nuts to remove the cooling fan and fan clutch together from the coolant pump pulley NOTICE To prevent the co rotation of the crankshaft insert a large flat blade screwdriver into the flywheel gear from the inspec tion hole of the flywheel housing and stop the rotation of the crankshaft To prevent dislocation of the coolant pump pulley mounting the fan fastening bolts 2 places...

Page 570: ... INSPECTING FOR SILICONE OIL LEAKAGE 1 Inspect the fan clutch for adherence and bleeding of silicone oil If found defective replace the fan clutch CAUTION The fan clutch is not detachable So if found defective replace it as assembly 3 INSPECTING THE BIMETAL 1 Remove the dirt and dust on the bimetal if any CAUTION Do not apply excessive force to the bimetal to prevent deforma tion 2 If crack and da...

Page 571: ...l ley with 4 nuts Tightening Torque 28 5 N m 291 kgf cm 21 lbf ft NOTICE To prevent the co rotation of the crankshaft insert a large flat blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft 4 Mount the intercooler hose Reference COOLING J05E INTERCOOLER OVERHAUL MOUNTING THE INTERCOOLER Page 12 22 3 CONNECTING THE RADIAT...

Page 572: ... COOLANT TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127110402012001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Coolant temperature sensor 2 Gasket A 27 0 31 9 276 325 20 23 1 A 1 A 2 2 SHTS021271100068 ...

Page 573: ...e sensor SINGLE UNIT INSPECTION 1 INSPECTING THE RESISTANCE 1 Warm the coolant temperature sensor using water or coolant stock solution 2 Use the circuit tester to measure the resistance between the ter minals If the value exceeds the standard value replace it Between A terminal and C terminal THERMOSTAT CASE CONNECTOR SHTS021271100069 COOLANT TEMPERATURE SENSOR THERMOSTAT GASKET SHTS021271100070 ...

Page 574: ...perature sensor to the thermostat case Tightening Torque 27 0 31 9 N m 276 325 kgf cm 20 23 lbf ft 2 Connect the connector to the coolant temperature sensor 2 ADDING THE COOLANT Reference COOLING J05E RADIATOR REPLACEMENT MOUNTING THE RADIATOR Page 12 9 COOLANT TEMPERATURE SENSOR THERMOSTAT GASKET SHTS021271100072 THERMOSTAT CASE CONNECTOR SHTS021271100073 ...

Page 575: ...IL COOLER 13 6 COMPONENT LOCATOR 13 6 OVERHAUL 13 7 OIL PUMP 13 14 COMPONENT LOCATOR 13 14 OVERHAUL 13 15 OIL PAN 13 23 COMPONENT LOCATOR 13 23 REPLACEMENT 13 24 OIL STRAINER 13 28 COMPONENT LOCATOR 13 28 REPLACEMENT 13 29 OIL PRESSURE SWITCH 13 30 COMPONENT LOCATOR 13 30 REPLACEMENT 13 31 OIL LEVEL GAUGE AND GUIDE 13 33 COMPONENT LOCATOR 13 33 REPLACEMENT 13 34 ...

Page 576: ...FT COOLING JET CHECK VALVE SUB OIL HOLE LUBRICATION RETURN CONNECTING ROD CRANK SHAFT PISTON PIN PUMP DRIVE GEAR SHAFT CAM SHAFT CAM IDLE GEAR SHAFT SUB IDLE GEAR SHAFT ROLLER PIN ROLLER CAM CROSS HEAD ADJUST SCREW OIL PUMP OIL COOLER OIL FILTER MAIN OIL HOLE ROCKER ARM ROCKER ARM SHAFT VALVE OIL PAN TURBO CHARGER STRAINER SHTS021271200001 ...

Page 577: ...TION J05E 13 3 OIL FILTER COMPONENT LOCATOR EN01F02114120402006001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Oil filter 2 Oil cooler assembly A 39 2 49 0 400 499 29 36 2 1 A SHTS021271200002 ...

Page 578: ...es to collect dripping engine oil when removing the drain plug 2 Use the SST remove the oil filter and O rings 2 pcs from the oil cooler assembly SST S0950 31090 Oil filer wrench CAUTION Make sure that no O ring is left on the oil filter cap side Remove dirt on the O ring mounting surface The O ring is nonreusable NOTICE It is recommended that the element of the closed ventilator be replaced once ...

Page 579: ...l filter to the oil cooler assembly Tightening Torque 39 2 49 0 N m 400 499 kgf cm 29 36 lbf ft SST S0950 31090 Oil filer wrench CAUTION Be careful not to damage the O ring by twisting it 2 ADDING ENGINE OIL 1 Add engine oil through an oil filler Reference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT NEXT STEPS AFTER INSTALLATION Page 5 14 OIL COOLER ASSEMBLY O RING OIL FIL...

Page 580: ... 6 OIL COOLER COMPONENT LOCATOR EN01F02114120402002001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Oil cooler 3 Gasket 2 O ring 4 Oil cooler element A 19 6 29 4 200 299 15 21 1 A 2 2 3 3 4 SHTS021271200007 ...

Page 581: ...Page 13 4 4 REMOVING THE TURBOCHARGER ASSEMBLY 1 Remove the turbocharger assembly Reference TURBOCHARGER J05E TURBOCHARGER ASSEMBLY REPLACEMENT REMOVING THE TURBO CHARGER ASSEMBLY Page 17 5 5 DISCONNECTING THE HARNESS 1 Disconnect the connector from the oil pressure switch 2 Remove the harness around the oil cooler assembly 6 REMOVING THE COOLANT PIPE 1 Remove the nut and then the clip 2 Unfasten ...

Page 582: ...l cooler assembly CAUTION To avoid the oil cooler element from dropping off do not unfasten the oil cooler element mounting nuts NOTICE If the liquid gasket is stuck to the cylinder block and it is hard to remove the oil cooler assembly remove it by placing the flat blade screwdriver to the protrusion shown in the figure 3 Remove the O rings 3 pcs from the oil cooler assembly 4 Remove the guide bo...

Page 583: ...ng and safety valve from the oil cooler case CAUTION Note that residual pressure in the oil cooler may cause the engine oil to spew out when disassembling immediately after the engine stops 3 REMOVING THE OIL PRESSURE SWITCH 1 Remove the oil pressure switch and gasket from the oil cooler case OIL COOLER CASE OIL COOLER ELEMENT O RING GASKET SHTS021271200014 OIL COOLER CASE SAFETY VALVE PLUG VALVE ...

Page 584: ...IL PRESSURE SWITCH REPLACEMENT SINGLE UNIT INSPECTION Page 13 31 CLEANING THE OIL COOLER ELEMENT 1 CLEANING THE OIL COOLER ELEMENT 1 Wash the water oil groove well with kerosene or detergent 2 Check the stud bolt installation area and element for crack or deformation by using the dye penetrant testing red check and visual check 3 Pass the air of about 51 kPa 0 5 kgf cm2 7 4 lbf in 2 through the oi...

Page 585: ...d valve spring to the oil cooler case and mount each plug Tightening Torque 24 5 34 3 N m 250 349 kgf cm 19 25 lbf ft 3 MOUNTING THE OIL COOLER ELEMENT 1 Replace with the new gaskets 2 pcs and O rings 2 pcs and mount the oil cooler element to the oil cooler case with nuts 4 pcs Tightening Torque 19 6 29 4 N m 200 299 kgf cm 15 21 lbf ft CAUTION Use care not to damage the oil cooler element when ha...

Page 586: ...liquid gasket with 1 5 2 5 mm 0 059 0 098 in width Mount the case within 20 minutes after applying the liquid gasket 3 Mount the new D ring to the D ring mounting groove of the oil cooler assembly CAUTION Assemble the flat side of the D ring to the oil cooler assembly side 4 Mount the new O rings 3 pcs to the oil cooler assembly 5 Mount the 2 4 guide bolts to the cylinder block OIL COOLER ASSEMBLY...

Page 587: ...cooler assembly 2 Connect the connector to the oil pressure switch 4 MOUNTING THE TURBOCHARGER ASSEMBLY 1 Mount the turbocharger assembly Reference TURBOCHARGER J05E TURBOCHARGER ASSEMBLY REPLACEMENT MOUNTING THE TURBO CHARGER ASSEMBLY Page 17 9 5 MOUNTING THE OIL FILTER 1 Using the SST mount the oil filter to the oil cooler assembly Reference LUBRICATION J05E OIL FILTER REPLACE MENT MOUNTING THE ...

Page 588: ...E 13 14 OIL PUMP COMPONENT LOCATOR EN01F02114120402008001 Nonreusable part 1 Oil pump 6 Seat 1 2 Gasket 7 Seat 2 3 Drive gear 8 Valve spring 4 Driven gear 9 Safety valve 5 Cotter pin 1 4 3 2 9 8 7 6 5 SHTS021271200029 ...

Page 589: ... THE OIL PUMP 1 Unfasten the 2 bolts and mount 2 guide bolts to the oil pump to prevent dropping 2 Unfasten the remaining bolts 7 pcs to remove the oil pump from the cylinder block NOTICE To loosen the adherence and facilitate the removal tap the oil pump mounted with guide bolts using the plastic hammer in advance Prepare the reservoir and clean clothes to collect dripping engine oil when removin...

Page 590: ...ng the depth gauge measure the pump chamber depth on the cylinder block side 3 Calculate the difference between the drive gear width and pump chamber depth on the cylinder block side If exceeding the per missible limit replace the oil pump SEAT 2 SAFETY VALVE VALVE SPRING SEAT 1 COTTER PIN SHTS021271200032 OIL PUMP DRIVE GEAR SHTS021271200033 Standard value mm in 28 5 1 122 CYLINDER BLOCK SHTS0212...

Page 591: ...P CHAMBER INNER DIAMETER ON THE CYLINDER BLOCK SIDE 1 Using the vernier calipers measure the drive gear outer diameter 2 Using the cylinder gauge measure the pump chamber inner diameter on the cylinder block side 3 Calculate the difference between the drive gear outer diameter and pump chamber inner diameter on the cylinder block side If exceeding the permissible limit replace the oil pump OIL PUM...

Page 592: ...OLE DIAMETER 1 Using the micrometer measure the driven gear shaft outer diam eter 2 Using the cylinder gauge measure the cylinder block side hole diameter 3 Calculate the difference between the outer diameter of the driven gear shaft and the cylinder block side hole diameter If the value exceeds the standard value replace the oil pump OIL PUMP DRIVEN GEAR SHAFT SHTS021271200039 Standard value mm i...

Page 593: ...the oil pump 2 Using the dial gauge measure the backlash between the drive gear and driven gear If exceeding the permissible limit replace the oil pump DRIVE GEAR OIL PUMP DRIVEN GEAR DIAL GAUGE SHTS021271200043 Standard value mm in Permissible limit mm in 0 073 0 207 0 0029 0 0082 0 30 0 012 ...

Page 594: ...mp MOUNTING THE OIL PUMP 1 MOUNTING THE OIL PUMP 1 Apply engine oil to the pump case and bearing of the cylinder block CAUTION Without engine oil defective oil suction may occur when the engine is initially started which results in seizure and abnormal wear SEAT 2 SAFETY VALVE VALVE SPRING SEAT 1 COTTER PIN COTTER PIN SHTS021271200044 OIL PUMP DRIVE GEAR DRIVEN GEAR SHTS021271200045 CYLINDER BLOCK...

Page 595: ...ng which results in outflow of all engine oil in the oil pump when the engine is stopped Defective sealing may also result in an insufficient engine oil suction quantity in the initial rotation when the engine is restarted which leads to seizure or abnormal wear Unfasten the guide bolts 2 pcs after temporarily tightening the oil pump mounting bolts 7 pcs Note that failure to observe the tightening...

Page 596: ...il pump drive gear and sub idle gear When it exceeds the standard value mount the oil pump again NOTICE When mounting the oil pump the backlash may fluctuate due to the looseness of the oil pump mounting bolt hole 4 MOUNTING THE FLYWHEEL HOUSING 1 Mount the flywheel housing to the cylinder block Reference ENGINE MECHANICAL J05E FLYWHEEL ASSEMBLY OVERHAUL MOUNTING THE FLYWHEEL ASSEMBLY Page 10 59 O...

Page 597: ...LUBRICATION J05E 13 23 OIL PAN COMPONENT LOCATOR EN01F02114120402005001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Cylinder block 3 Gasket 2 Oil pan A 30 306 22 1 A 2 3 SHTS021271200050 ...

Page 598: ...E ASSEMBLY REPLACEMENT REMOVING THE ENGINE ASSEMBLY Page 5 7 2 REMOVING THE OIL PAN 1 Unfasten the 26 bolts to remove the oil pan and gasket from the cylinder block NOTICE If the gasket is stuck and hard to separate use a scraper to peel it off Prepare the reservoir and clean clothes oil pan because the engine oil will spill when removing the oil pan CYLINDER BLOCK GASKET OIL PAN FRONT OF ENGINE B...

Page 599: ...fter applying the liquid gasket 4 Then apply the small quantity of liquid gasket ThreeBond TB1207D Silver or equivalent or ThreeBond TB1217G Grey or equivalent to around the bolt mounting hole on the oil pan side 5 Mount the guide bolts 70 mm 2 756 in or more to the cylinder block Align the new gasket with the mounting position in a way that its protrusions are set on the intake and flywheel housi...

Page 600: ...guide bolt and tighten 26 bolts again Tightening Torque 30 N m 306 kgf cm 22 lbf ft CAUTION Handle the gasket of the oil pan with care because it can be easily broken Check that the washer does not run on the flange 2 ADDING ENGINE OIL 1 Add engine oil through an oil filler Reference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT NEXT STEPS AFTER INSTALLATION Page 5 14 DIRECT...

Page 601: ...camshaft is covered 2 Adjust the engine speed at the standard idling speed 750 r min 3 Check if oil is supplied to all rocker arm parts below within about 10 seconds after the engine start a The roller and cam surfaces b The crosshead head and spring upper seat upper surface via the adjust screw CAUTION If the duration before the oil supply is long or no oil is supplied dropped oil pressure or clo...

Page 602: ...LUBRICATION J05E 13 28 OIL STRAINER COMPONENT LOCATOR EN01F02114120402003001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Oil strainer 2 O ring A 30 306 22 1 A 2 SHTS021271200057 ...

Page 603: ...he cylinder block NOTICE Prepare the reservoir and clean clothes to collect dripping engine oil when removing the oil strainer MOUNTING THE OIL STRAINER 1 MOUNTING THE OIL STRAINER 1 Replace with the new O ring and mount the oil strainer to the cyl inder block with bolts 2 pcs Tightening Torque 30 N m 306 kgf cm 22 lbf ft 2 MOUNTING THE OIL PAN 1 Mount the oil pan to the cylinder block Reference L...

Page 604: ...ICATION J05E 13 30 OIL PRESSURE SWITCH COMPONENT LOCATOR EN01F02114120402016001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Oil pressure switch 2 Gasket A 24 5 250 18 2 1 A SHTS021271200060 ...

Page 605: ...oil pressure switch SINGLE UNIT INSPECTION 1 INSPECTING THE OIL PRESSURE SWITCH 1 Apply air or oil pressure to measure the continuity between the terminal and body using the circuit tester If found defective replace it OIL PRESSURE SWITCH OIL COOLER CASE HARNESS SHTS021271200061 GASKET OIL COOLER CASE OIL PRESSURE SWITCH SHTS021271200062 OIL PRESSURE SWITCH SHTS021271200063 Pressure Continuity Whe...

Page 606: ...e oil cooler case Tightening Torque 24 5 N m 250 kgf cm 18 lbf ft 3 Connect the connector to the oil pressure switch 2 ADDING ENGINE OIL 1 Inspect the engine oil level If insufficient add engine oil Reference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT NEXT STEPS AFTER INSTALLATION Page 5 14 GASKET OIL COOLER CASE OIL PRESSURE SWITCH SHTS021271200064 OIL PRESSURE SWITCH OI...

Page 607: ...UBRICATION J05E 13 33 OIL LEVEL GAUGE AND GUIDE COMPONENT LOCATOR EN01F02114120402017001 Nonreusable part 1 Oil level gauge and guide 3 O ring 2 Oil level gauge 4 Cylinder block 2 1 3 4 SHTS021271200066 ...

Page 608: ... receive dripping engine oil when pull ing out the oil level gauge 2 REMOVING THE OIL LEVEL GAUGE GUIDE 1 Remove the nut and then the clip 2 Remove the oil level gauge guide and O ring from the cylinder block NOTICE Prepare the reservoir and clean clothes to collect dripping engine oil when removing the oil level gauge guide OIL LEVEL GAUGE GUIDE OIL LEVEL GAUGE SHTS021271200067 OIL LEVEL GAUGE GU...

Page 609: ... O ring and mount the oil level gauge guide to the cylinder block 2 Mount the clip with the nut and secure the oil level gauge guide 2 MOUNTING THE OIL LEVEL GAUGE 1 Insert the oil level gauge to the oil level gauge guide OIL LEVEL GAUGE GUIDE O RING SHTS021271200069 OIL LEVEL GAUGE GUIDE OIL LEVEL GAUGE SHTS021271200070 ...

Page 610: ...RGING J05E 16 1 STARTING CHARGING J05E 16 001 16 STARTER 16 2 COMPONENT LOCATOR 16 2 REPLACEMENT 16 3 V BELT 16 8 COMPONENT LOCATOR 16 8 REPLACEMENT 16 9 ALTERNATOR 130A 16 12 COMPONENT LOCATOR 16 12 OVERHAUL 16 13 ...

Page 611: ... 2 MECHANICAL SYSTEM DRAWING STARTER COMPONENT LOCATOR EN01F02127150407006001 Tightening torque Unit N m kgf cm lbf ft 1 Starter assembly A 21 214 15 4 C 4 5 46 3 3 B 154 1 570 113 5 D 154 1 570 113 5 1 A D B C SHTS021271500001 ...

Page 612: ...ECTING THE HARNESS 1 Disconnect the 2 wire harness clamps 2 Remove the bolt and the wire harness clamp bracket 3 Pull off the terminal cap and remove the nut and disconnect the starter wire from terminal B 4 Pull off the terminal cap and remove the nut and disconnect the starter wire from terminal C 3 REMOVING THE STARTER 1 Remove the nut bolt and the starter assembly STARTER SHTS021271500002 ...

Page 613: ...ghtening Torque 21 N m 214 kgf cm 15 4 lbf ft 3 Install the wire harness clamp bracket with the bolt Tightening Torque 18 N m 184 kgf cm 13 2 lbf ft IMPORTANT POINTS INSPECTION 1 MATTER FOR REFERENCE NOTICE These tests must be performed within 3 to 5 seconds to avoid burning out the coil 2 PERFORM NO LOAD PERFORMANCE TEST 1 Connect battery and ammeter to the starter as shown 2 Check that the start...

Page 614: ...0 k or more 10 k Replace Measure Armature short circuit test Using the 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 com mutator Under cut depth 0 7 0 028 0 2 0 008 Replace or repair Measure CONTINUIT...

Page 615: ...Replace Measure Brush length 20 5 0 807 11 0 433 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 Inspection item Standard Limit Remedy Inspection procedure CONTINUITY OHMMETER NO CONTINUITY OHMMETER LENGTH NO CONTINUITY OHMMETER q w LOCK FREE ...

Page 616: ...r rear bearing Sticks or does not rotate Replace Visual check Continuity between terminals 50 and C 1 or less 1 Replace Measure Continuity between terminal 50 and the switch body 2 or less 2 Replace Measure Inspection item Standard Limit Remedy Inspection procedure CONTINUITY TERMINAL C TERMINAL 50 OHMMETER CONTINUITY TERMINAL 50 OHMMETER ...

Page 617: ...STARTING CHARGING J05E 16 8 V BELT COMPONENT LOCATOR EN01F02127150407001001 Tightening torque Unit N m kgf cm lbf ft 1 Alternator 2 V belt A 6 60 4 4 B 55 560 40 5 1 2 B A SHTS021271500021 ...

Page 618: ... 3 Press the belt center A in the figure with a finger at about 98 N 10 kgf Or adjust the belt deflection to the standard value using the SST compression gauge or adjust the belt tension to the standard value using the SST belt tension gauge SST S0944 41210 Compression gauge CAUTION Excessively stretching the V belt reduces its service life Exercise care not to stretch the V belt in excess of the ...

Page 619: ...een driving time and tension Driving time Tension Relationship between driving time and tension Driving time Tension High adjusting tension High initial tension Relationship between driving time and tension Driving time Excessive adjustment means that adjustment has been frequently performed without waiting for the legal inspection period In case of excessive adjustment In case adjusting tension i...

Page 620: ...N m 60 kgf cm 4 4 lbf ft Condition of the V belt Remaining life for reference Same distance as the travel distance from the time of a new vehicle or replacement to inspection or more Half of the travel distance from the time of a new vehicle or replacement to inspection One fourth of the travel distance from the time of a new vehicle or replacement to inspection Service life ...

Page 621: ...r 14 Drive frame 6 Through bolt 15 Collar 7 Insulator outer 16 Fan 8 Rear frame 17 Pulley 9 Field coil A 15 7 20 6 160 210 12 15 E 6 5 9 3 66 95 4 8 6 9 B 7 8 10 8 80 110 5 8 7 9 F 1 9 2 5 19 25 1 4 1 8 C 117 6 137 2 1 199 1 399 87 101 G 1 6 2 0 16 20 1 2 1 4 D 2 9 4 9 30 50 2 1 3 6 H 2 5 3 0 25 31 1 8 2 2 17 C 16 15 10 9 14 13 12 D 11 3 2 I K J 7 E G 5 4 1 F 6 8 H 11 D 12 13 14 15 H G 7 16 17 C 1...

Page 622: ...ENT MOUNTING THE V BELT Page 16 9 IMPORTANT POINTS DISASSEMBLY 1 REMOVING THE REAR COVER 1 Remove the 3 screws to remove the rear cover 2 SEPARATE THE FRONT AND REAR PORTIONS 1 Remove the 4 screws and separate the stator outlet terminal and the rectifier 2 Remove the 4 through bolts SCREW SHTS021271500030 SCREW SHTS021271500031 THROUGH BOLT SHTS021271500032 ...

Page 623: ... drive frame 4 Drive and rear frames separated 3 REMOVING THE PULLEY 1 Remove the pulley lock nut using an impact wrench 2 Remove the pulley from the shaft REAR FRAME STATOR DRIVE FRAME SHTS021271500033 REAR FRAME DRIVE FRAME SHTS021271500034 PULLEY IMPACT WRENCH SHTS021271500035 PULLEY FAN SHTS021271500036 ...

Page 624: ...e rotor 7 REMOVING THE FRONT BEARING 1 Remove the 3 screws to remove the bearing cover 2 Using the JIG C and press remove the front bearing from the drive frame NOTICE Do not drop the front bearing COLLAR FAN SHTS021271500037 ROTOR SHAFT PRESS DRIVE FRAME JIG A SHTS021271500038 BEARING COVER SHTS021271500039 JIG C FOR PRESS PRESS FRONT BEARING JIG C FOR SUPPORT SHTS021271500040 ...

Page 625: ... THE REGULATOR 1 Remove the 3 screws to separate the rectifier the exciting coil outlet terminal and the regulator 2 Remove the 2 screws to remove the regulator 3 Regulator removed 10 REMOVING THE RECTIFIER 1 Loosen the B terminal nut STATOR REAR FRAME SHTS021271500041 SCREW SHTS021271500042 REGULATOR SHTS021271500043 SHTS021271500044 ...

Page 626: ...e the 4 screws to remove the rectifier 4 Rectifier removed 11 REMOVING THE I TERMINAL 1 Loosen the I terminal nut to remove the I terminal 2 I terminal removed SCREW SHTS021271500045 RECTIFIER SHTS021271500046 I TERMINAL REAR FRAME SHTS021271500047 I TERMINAL REAR FRAME SHTS021271500048 ...

Page 627: ...d coil from the rear frame 2 Field coil removed 13 REMOVING THE REAR BEARING 1 Using the JIG E and press remove the rear bearing from the rear frame NOTICE Do not reuse the rear bearing REAR FRAME SHTS021271500049 FIELD COIL SHTS021271500050 JIG E FOR PRESS PRESS JIG E FOR SUPPORT SHTS021271500051 ...

Page 628: ...cure the pulley with belt using the vice as shown in the figure tighten the pulley lock nut with specified torque Tightening Torque 117 6 137 2 N m 1 199 1 399 kgf cm 87 101 lbf ft 4 INSTALL THE REAR BEARING 1 Using the JIG E and press press a new rear bearing into the rear frame NOTICE Once a bearing is removed do not reuse it 5 INSTALL THE FIELD COIL 1 Using the 3 screws install the field coil o...

Page 629: ...cm 2 1 3 6 lbf ft 2 Using the 3 screws install the rectifier and the field coil outlet ter minal to the regulator Tightening Torque 1 6 2 0 N m 16 20 kgf cm 1 2 1 4 lbf ft 9 INSTALLING THE STATOR AND THE REAR FRAME 1 Slow the insert the stator while maintaining it perpendicular to the rear frame 10 ASSEMBLING THE DRIVE AND REAR FRAME 1 Apply the thin coat of NSK EA5 grease on the rear bearing port...

Page 630: ...elow Note the battery polarity carefully so as not to make reverse connections If the connections are reversed the rectifier will short the cir cuit and allow a large current to flow through and damage the diodes and I C regulator as well as burning the wiring har ness Take care not to make wrong connections of terminals When charging the battery with a quick charge disconnect the battery terminal...

Page 631: ...ant 5 000 rpm 3 While observing the voltmeter regulate the load variable resis tance R so that a 12V system outputs 13 5V 4 At this time measure the output current it is normal if more than the rated output current is obtained 5 VERIFYING THE REGULATOR S REGULATED VOLTAGE 1 In the state in which the rated output was measured turn Switch 2 OFF NOTICE At this time reduce the current that flows to th...

Page 632: ...or to water 2 OTHER PRECAUTIONS Make sure to disconnect the battery terminal before inspecting the alternator Do not interchange the polarity of the battery cables when replac ing the battery Make sure to disconnect the cables and charge the battery sepa rately when using the quick charger Never perform a megohmmeter on the alternator assembly Make sure to disconnect the wiring to the alternator w...

Page 633: ...ce of stator coil 0 01 0 10 Replace Measure Insulation resistance of stator 1M min Replace Measure Resistance of rectifier between B terminal and heat sink When polarity is changed there is continuity in one direction but not in the opposite direction Replace Measure Resistance of rectifier between terminal and heat sink When polarity is changed there is continuity in one direction but not in the ...

Page 634: ...ing portion 25 00 25 01 0 9843 0 9846 24 99 0 9839 Replace Measure Rotor shaft outside diameter rear bearing portion 16 99 17 00 0 6689 0 6693 16 98 0 6685 Replace Measure Rotor shaft outside diameter pulley por tion 22 189 22 202 0 8739 0 8741 22 18 0 8732 Replace Measure Bearing wear or dam age Rotates smoothly with no abnormal noise Replace Also replace every 2 years Visual check Inspection ite...

Page 635: ...TURBOCHARGER J05E 17 1 TURBOCHARGER J05E 17 001 17 TURBOCHARGER ASSEMBLY 17 2 COMPONENT LOCATOR 17 2 INSPECTION 17 3 REPLACEMENT 17 5 ...

Page 636: ...RBOCHARGER ASSEMBLY COMPONENT LOCATOR EN01F02114160704005001 Nonreusable part Tightening torque Unit N m kgf cm lbf ft 1 Turbocharger assembly 4 Gasket 2 Turbocharger insulator 5 Oil pipe B 3 Oil pipe A A 70 714 52 1 3 4 4 5 4 2 4 4 A SHTS021271600001 ...

Page 637: ...on follow up Refer to the HINO DX user s manual CAUTION The adjusting screw for opening closing operation of the tur bocharger assembly has been adjusted Do not loosen it Do not remove the link plate of the turbocharger assembly 2 If the electric actuator does not operate inspect the wiring up to it for disconnection or short circuit If no defect is found in the wiring replace the electric actuato...

Page 638: ...cts with the blower case replace the tur bocharger assembly 2 INSPECTING THE TURBINE SHAFT PLAY IN THE AXLE THRUST DIRECTION 1 Inspect the turbine shaft play on the exhaust side 2 If a measurement reading exceeds the standard value replace the turbocharger assembly CAUTION Turbocharger is replaced as assembly Do not overhaul BLOWER IMPELLER RADIAL DIRECTION TURN THE TIP OF THE BLOWER IMPELLER SHTS...

Page 639: ...uch the link plate and adjusting screw dur ing work Do not remove the link plate of the turbocharger assembly The adjusting screw for opening closing operation of the tur bocharger assembly has been adjusted Do not loosen it TURBOCHARGER ASSEMBLY TURBOCHARGER LINK PLATE ELECTRIC ACTUATOR ACTUATOR DRIVE LEVER PART SHTS021271600005 ...

Page 640: ...oil pipe A and gaskets from the turbocharger assembly and oil cooler assembly CAUTION Use care not to splash the oil in the pipes and turbocharger assembly NOTICE When disconnecting the oil pipe engine oil will spill Prepare a reservoir and clean clothes 2 Unfasten the 4 bolts to remove the oil pipe B and gaskets from the turbocharger assembly and cylinder block CAUTION Use care not to splash the ...

Page 641: ...then the clip 4 Unfasten the 2 union bolts to remove the coolant pipe F and gas kets from the turbocharger assembly and thermostat case CAUTION Use care not to splash the coolant in the pipes and turbocharger assembly NOTICE Use the container and a waste cloth to avoid spillage of coolant when disconnecting the coolant pipe 5 Block water holes of the turbocharger assembly to prevent entry of forei...

Page 642: ...bracket from the turbocharger assembly and oil cooler assembly 2 Unfasten the nuts 4 pcs 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 mount...

Page 643: ...ace the stuck stud bolt Heat resisting steel is 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 leak age from the connections of the exhaust pipe 4 Tighten the 4 nuts in the order shown in the figure again Tightening Torque 70 N m 714 kgf cm 52 lbf ft CAUTION Make sure to tighten twice 5 Mount the bracket to...

Page 644: ...ghtening portion 4 Mount the clip with the nut and secure coolant pipe E 7 MOUNTING THE OIL PIPE 1 Replace with the new gaskets and connect the oil pipe B to the turbocharger assembly and cylinder block with 4 bolts CAUTION 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 dama...

Page 645: ...ST SIDE REPLACEMENT MOUNTING THE INTAKE PIPE EXHAUST SIDE Page 9 13 11 MOUNTING THE INTAKE HOSE Reference INTAKE J05E INTAKE PIPE EXHAUST SIDE REPLACEMENT MOUNTING THE INTAKE PIPE EXHAUST SIDE Page 9 13 12 ADDING ENGINE OIL Reference MOUNTING AND DISMOUNTING THE ENGINE J05E ENGINE ASSEMBLY REPLACEMENT NEXT STEPS AFTER INSTALLATION Page 5 14 13 ADDING THE COOLANT Reference COOLING J05E RADIATOR REP...

Page 646: ...e is added to the atmospheric pressure Check the pressure when engine is stopped 2 Remove the boost pressure sensor of the intake pipe and connect the SST boost pressure measuring hose SST S0944 41250 Gauge 09258 E1010 Boost pressure measuring hose 3 Pull in the SST gauge into the cab 4 After warming up the engine fully put the shift lever in neutral 5 Press down the accelerator pedal fully and me...

Page 647: ...Pub No S5 LJ05E04A 12 11 Hino Motors Sales PRINTED IN JAPAN 41180 Bridge Street Novi MI 48375 Telephone 248 699 9300 U S A Inc COLOPHON fm 1 ページ ２０１２年１１月２８日 水曜日 午後３時３２分 ...

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