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Hino J05E-TH, Workshop Manual

The Hino J05E-TH Workshop Manual is a comprehensive guide for maintaining and repairing this powerful engine. Designed for easy understanding, this manual provides step-by-step instructions and detailed diagrams. Download this essential resource for free from manualshive.com to ensure optimal performance and longevity of your Hino J05E-TH engine.

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HINO DIESEL ENGINE

WORKSHOP MANUAL

J05E-TH

(HS ENGINE for 25t)

2007.6

KSS-SMJ5-E111E

Summary of Contents for J05E-TH

Page 1: ...HINO DIESEL ENGINE WORKSHOP MANUAL J05E TH HS ENGINE for 25t 2007 6 KSS SMJ5 E111E ...

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Page 3: ...AL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING AND CHARGING TURBOCHARGER FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ENGINE DIAGNOSIS CODE PARTS TO BE PREPARED AIR COMPRESSOR For your information This documentation does not contain any descriptions in regard to the hatched part 6 Emission Control 15 Air Compressors ...

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Page 5: ...uts 1 10 Tightening of chassis bolts and nuts 1 12 Tightening of flare nuts and hoses 1 14 Taper thread sealant for piping 1 15 Assembly of joints and gaskets for piping 1 16 Handling of liquid gasket 1 18 Failure diagnosis table for each problem 1 19 Failure diagnosis using HinoDX 1 20 Connection method of HinoDX 1 23 Chassis number and engine number 1 23 ...

Page 6: ... Be sure to use Hino genuine parts for replacement of parts Do not use deteriorated parts in quality Items described in this manual are the procedures to be observed in service and repair For service and repair according to this procedure be sure to use the special tools designed for each purpose If a method or a tool not recommended is used safety of service engineers and safety and reliability o...

Page 7: ...and lubricant etc These are listed in the list section of items to be prepared Items such as general tools jack rigid rack etc that are usually equipped in general service shop are omitted 4 How to read sections and titles 1 Sections are classified according to J2008 SAE standard 2 For areas that show system names like Engine control system Inspection Adjustment Replacement Overhaul etc of compone...

Page 8: ...ation test Step 4 Check if failure occurs again after repair If it is difficult to reproduce a failure perform the confirmation test under the conditions and environment of the failure Pre inspection Pre inspection is performed in the following steps Diagnosis inspection Diagnosis deletion Failure status check Use the reproduction method if not reproduced Diagnosis reconfirmation Estimate the fail...

Page 9: ...Parts not to be reused Tightening torque Service procedure Overhaul item 11308 Flywheel housing 11390 End plate 11309 Oil seal retainer 9828A Front oil seal 11357 Gasket 9828B Rear oil seal 11357A Gasket 9069H M14 171 5N m 1 750kgf cm 9419A M16 196N m 2 000kgf cm 9069J M12 97N m 990kgf cm 9419B M16 196N m 2 000kgf cm SAPH041170900182 Example Part name code Part catalog Fig No Description of part n...

Page 10: ...ld not be performed including inhibited work or an item that require attention in working procedures 7 Reference It is supplementary explanation in work 8 Unit 1 SI unit is used in this manual SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications 2 This manual shows both the SI unit and co...

Page 11: ... Precautions for service work Pay attention to the following points before service work 1 Preparation before disassembly a Prepare general tools special tools and gauges before work b To disassemble a complicated area put a stamp or match mark on the location not functionally affected to ease assembly To repair the electric system disconnect the cable from the minus terminal of the battery before ...

Page 12: ...f electronic parts a Do not give impact on electronic parts such as computer and relay b Do not place electronic parts at a high temperature and humidity area c Do not expose electronic parts to water in washing of a vehicle 3 Handling of wire harness a Mark clamps and clips to prevent interference of a wire harness with body edge sharp edge and bolts Be sure to reassemble it to the original posit...

Page 13: ...nal of the battery according to the removal procedure of the battery cable 4 Disconnect connectors of each computer 5 Remove all fuses For locations of fuses refer to Electrical System Chapter 6 Be sure to connect grounding of the electric welding machine near the welding area Connect grounding from a bolt plated bolt or a frame near the welding area Remove paint of the frame for connection of gro...

Page 14: ...1 750 216 2 210 M14 x 2 Coarse thread 154 1 570 199 2 030 Remark Bolt with number 7 on the head Bolt with number 9 on the head Screw diameter x Pitch 4T 7T 9T M6 x 1 Coarse thread 6 60 10 100 13 130 M8 x 1 25 Coarse thread 14 140 25 250 31 320 M10 x 1 25 Fine thread 29 300 51 520 64 650 M10 x 1 5 Coarse thread 26 270 47 480 59 600 M12 x 1 25 Fine thread 54 550 93 950 118 1 200 M12 x 1 75 Coarse th...

Page 15: ...e method 1 Precautions Some engines are tightened with the plastic region tightening method Since it is different from the conventional method tighten it according to the instruction in the text 2 Parts tightened Cylinder head bolt crankshaft main bearing cap bolt connecting rod bearing cap bolt etc CAUTION Measure the overall length of the bolt before assembly and replace the bolt if the length e...

Page 16: ...ification method with product Hexagonal bolt Strength zone of hexagonal bolts is in principle indicated with recession relief surface depression and upset on the head with the symbol in the table 1 9 may be misread with 6 It is expressed in q Hexagonal nut Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below 3 Types of general standard bolts and n...

Page 17: ...alue Strength zone 4T 7T 9T Bolt diameter mm M6 4 5 1 8 50 20 Cab 5 5 1 1 60 10 Chassis 9 0 1 8 90 20 11 5 2 0 117 23 M8 14 0 3 5 140 40 Cab 17 0 3 0 170 30 Chassis 22 0 4 0 220 40 2 29 0 5 5 300 60 2 M10 27 0 5 0 276 55 43 0 8 5 440 90 2 Cab 51 5 10 0 530 100 Chassis 57 0 11 0 580 110 2 Cab 68 5 13 5 700 140 Chassis M12 48 0 9 5 490 98 76 0 15 0 776 150 2 Cab 91 0 18 0 930 180 Chassis 100 0 20 0 ...

Page 18: ...r φ4 76 φ6 35 φ8 φ10 φ12 φ15 Material Steel pipe 15 5 150 50 25 5 250 50 36 5 370 50 52 7 530 70 67 7 680 70 88 8 900 80 Hose outer diameter φ10 5 fitting Hose outer diameter φ13 φ20 φ22 fitting at packing Hose outer diameter PF3 8 fitting Air hose 21 5 1 5 215 15 41 5 2 5 425 25 Only meter gauge 10 100 Brake hose Packing 51 5 7 5 525 75 Screw nominal size M12 M16 M20 M27 Tightening torque 15 2 15...

Page 19: ...htening torque in the table below Remove dirt completely from the mating part female before tightening CAUTION If your eye or skin comes in contact with sealant wash it off immediately with water Tightening torque of taper joint Unit N m kgf cm 2 When a sealing tape is replaced with sealant remove the tape completely first as in 1 CAUTION Be careful to prevent entry of dirt or foreign matter in th...

Page 20: ...3 After tightening apply the specified pressure to each pipe joint to ensure that there is no leak 4 Observe the values above for each tightening torque When assembled soft washer 4840FR N aluminum and rubber carbon pressure bonding is loosened or removed be sure to replace it with a new part This is not necessary for normal retightening Sealing method Gasket sealing method Aluminum Rubber or Copp...

Page 21: ...et Sealing surface 5 places Sealing surface 3 places Nut Connector nipple Flare connector Gasket Sealing surface 5 places Joint bolt Sealing surface 8 places Lock washer Nut Bracket Sealing surface 1 place Nut Connector nipple Sealing surface 1 place Flare connector Box nut Sealing surface 8 places Joint pipe Nut Lock washer 3 way joint Bracket Sealing surface 3 places One piece eye joint without ...

Page 22: ...e the liquid gasket and apply it again 4 Start the engine at least 15 minutes or more after assembly of parts 2 Removal of parts 1 When parts are removed do not pry one place only Remove parts by prying each other using collar or clearance on the flange When gasket is removed be careful to prevent entry of gasket offal into the engine 3 Others 1 When the liquid gasket is contained in a tube use th...

Page 23: ... ring Replace piston ring and cylinder liner Faulty fixing of piston ring Replace piston ring and cylinder liner Faulty assembly of piston ring Replace piston ring and cylinder liner Faulty engine oil Replace engine oil Faulty piston ring joint Reassemble piston ring Large engine oil consumption valve and valve guide Wear of valve stem Replace valve and valve guide Wear of valve guide Replace valv...

Page 24: ... installation method refer to the instruction manual accompanying the CD 2 List of failure diagnosis tools SAPH311990100032 Part name Part No External shape General description and function PC DOS V standard Operating system OS Windows95 Windows98 IE5 0 or later Windows2000 SP3 IE5 0 or later WindowsXP SP1a IE6 0 or later CPU and memory Conditions that assure operation of the above operating syste...

Page 25: ... signal check harness and put a testing rod on the signal check connector of the signal check harness for meaurement a Disconnect the connector from the ECU CAUTION Do not break the locking tab of the connector b Connect the signal check harness to the machine harness and the ECU Signal check harness for common rail fuel injection system Part No 09049 1080 SAPH311990100032 Unit harness Signal chec...

Page 26: ...GENERAL 1 22 2 Terminal No For the signal check harness connector the ECU terminal number in the text is treated as follows ECU unit Signal check harness ECU side Unit side SAPH311990100038 ...

Page 27: ...ey to ON and start HinoDX Setup layout Layout Chassis number and engine number JP31199010401001 1 Engine type and engine number 1 Engine type and engine number are stamped at the left cylinder block when viewed from the cooling fan For order of parts information of this number will facilitate procedures smoothly Ex J05E TA10101 Engine ECU Failure diagnosis connector SAPH311990100039 Failure diagno...

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Page 29: ...ake 2 3 Tightening torque 2 3 Engine Mechanical 2 4 Standard value 2 4 Tightening torque 2 11 Exhaust 2 12 Tightening torque 2 12 Cooling 2 12 Standard value 2 12 Lubrication 2 12 Standard value 2 12 Tightening torque 2 14 Starting and Charging 2 14 Standard value Alternator 50A 2 14 Tightening torque Alternator 50A 2 15 Standard value starter 2 15 Tightening torque starter 2 16 Turbocharger 2 16 ...

Page 30: ...r 150 r min 3 4 3 7 35 38 493 237 2 7 28 392 Tightening area Tightening torque Remark Starter B terminal 7 8 8 8 80 110 5 8 6 5 Alternator B terminal 3 3 4 4 33 45 2 4 3 2 Oil pan drain cock 41 420 30 Radiator hose band 4 5 5 0 45 50 3 3 3 7 Tightening area Tightening torque Remark Injector clamp 25 250 18 Supply pump Bearing holder case 28 5 290 21 Bearing holder case Pump drive 28 5 290 21 Suppl...

Page 31: ...nso part No is used At the time of inspection Deflection 10 12mm 0 394 0 472in Reference push force 98N 10kgf 22lbf Compression gauge 09444 1210 is used Tension 320 400 N 33 41 kgf 72 90 lbf Belt tension gauge 95506 00090 Denso part No is used Tightening area Tightening torque Remark Starter mounting bolt 154 1 570 114 Starter mounting nut 171 5 1 750 126 Battery cable mounting nut 16 22 165 225 1...

Page 32: ...17 008 4 6063 4 6066 B 117 008 117 014 4 6066 4 6068 C 117 014 117 022 4 6068 4 6072 Cylinder liner outer diameter A 116 982 116 99 4 6056 4 6059 B 116 99 116 996 4 6059 4 6061 C 116 996 117 004 4 6061 4 6064 Clearance between cylinder liner and cylinder block 0 01 0 026 0 0003 0 0010 Cylinder liner inner diameter 112 4 4094 112 15 4 4154 Cylinder Replace liner Piston outer diameter Pin hole 23mm ...

Page 33: ...Second 2 0 0787 0 2 0 0079 Oil 4 0 1574 0 1 0 0039 Clearance between piston ring and piston ring groove Top 0 09 0 13 0 0035 0 0051 Replace piston ring or piston Second 0 04 0 08 0 00016 0 0031 Oil 0 02 0 06 0 0008 0 0024 Piston pin outer diameter 37 1 4567 0 04 0 0015 Replace piston pin Piston boss inner diameter 37 1 4567 0 05 0 0020 Replace piston Clearance between piston pin and piston boss 0 ...

Page 34: ...nce 0 051 0 102 0 0020 0 0040 0 2 0 0079 Replace bearing Note 2 Center journal width 36 1 4173 1 00 0 039 Replace crankshaft Thickness of thrust bearing 2 5 0 2342 Crankshaft end play 0 050 0 219 0 0020 0 0086 0 50 0 0020 1 219 0 0480 Replace thrust bearing or crankshaft Crankshaft runout 0 15 0 0059 Ground to under size Crank pin width 34 13 386 0 8 0 0315 Replace crankshaft Note 1 Correction wit...

Page 35: ... 100 0 178 0 0039 0 0070 Replace camshaft Camshaft runout 0 04 0 0016 0 1 0 039 Replace camshaft Rocker shaft outer diameter 22 0 8661 0 08 0 0031 Replace rocker shaft Rocker arm bushing inner diameter 22 0 8661 0 08 0 0031 Replace rocker arm bushing Rocker arm oil clearance 0 030 0 101 0 00012 0 0040 0 15 0 0059 Valve stem outer diameter IN 7 0 2756 Replace valve EX 7 0 2756 Valve guide inner dia...

Page 36: ...gle 44 30 45 Valve spring Inner Set length 44 8 1 764 Set load 129N 13 1kgf 29lbf Free length 64 6 2 5433 3 0 0 3543 Replace spring Squareness 2 0 0 0787 Replace spring Outer Set length 46 8 1 8252 Set load 314N 32 0kgf 70lbf Free length 75 7 2 9803 3 0 0 3543 Replace spring Squareness 2 0 0 0787 Replace spring Inspection item Standard value Repair limit Service limit Action ...

Page 37: ...00 0 30 0 0012 Main idle Shaft outer diameter 57 2 2441 Bushing inner diameter 57 2 2441 Clearance between shaft and bushing 0 030 0 090 0 0012 0 0084 0 20 0 0079 Replace shaft or bushing Gear width 44 1 7322 Shaft length 44 1 7322 End play 0 114 0 160 0 0045 0 0063 0 30 0 0012 Replace shaft or gear Sub idle Shaft outer diameter 50 1 9685 Bushing inner diameter 50 1 9685 Clearance between shaft an...

Page 38: ...place shaft or bushing Gear width 28 5 1 1220 Shaft length 28 5 1 1220 End play 0 016 0 22 0 0006 0 0087 Flatness under cylinder head Flatness above cylinder block Longitudinal direction 0 06 0 0024 Square direction 0 03 0 0012 0 20 0 0079 Grinding is inhibited because backlash between cam idle sub idle gears is changed Surface runout of flywheel 0 15 0 0060 Camshaft gear mounting bolt 31 1 2205 R...

Page 39: ...ker arm and crosshead adjusting screw lock nut 25 250 18 Rocker arm support bolt 59 600 44 Head bolt 59 600 44 90 90 Cam idle gear shaft mounting bolt 108 1 100 80 Main bearing cap mounting bolt 69 700 51 90 45 Refer to the main text Connecting rod cap mounting bolt 69 700 51 90 45 Oil check valve 22 220 16 Sub idle gear shaft mounting bolt 108 1 100 80 Main idle gear shaft mounting bolt 172 1 750...

Page 40: ... manifold mounting stud bolt 30 300 22 Exhaust manifold mounting nut 53 540 40 Inspection item Standard value Repair limit Service limit Action Thermostat valve open temperature 74 5 78 5 C 166 1 173 3 F Replacement Thermostat valve lift Set temperature 95 C 10mm 0 3937 in or more Replacement Inspection item Standard value Repair limit Service limit Action Hydraulic alarm switch operation pressure...

Page 41: ...aft outer diameter and bushing inner diameter at cylinder block side 0 040 0 099 0 0016 0 0039 Replace drive gear or bushing Outer diameter of driven gear shaft 18 0 7087 Cylinder block hole diameter 18 0 7087 Clearance between driven gear shaft outer diameter and cylinder block hole diameter 0 030 0 075 0 0012 0 0030 Replace oil pump Outer diameter of driven gear shaft 18 0 7087 Inner diameter of...

Page 42: ...24 5 4 9 250 50 18 4 Inspection item Standard value Repair limit Service limit Action Resistance between stator coil terminals for 2 phases 0 22 0 26Ω Replacement Resistance between stator coil core and coil 1MΩor more Replacement Resistance of feed coil 5 6 6 8Ω Replacement Resistance between feed coil core and coil 1MΩor more Replacement Shaft outer diameter of rotor assembly Front 25mm 0 9843 i...

Page 43: ...eplace yoke assembly Brush length 18 0 7087 13 0 5118 or less Replace brush Armature assembly Resistance between commutator and core 1MΩor more 1kΩor less Replace armature assembly Commutator outer diameter 36 1 4173 34 1 1458 or less Shaft outer diameter A 12 0 4724 11 98 0 4717 or less Shaft outer diameter B 9 0 3643 8 98 0 3535 or less Undercut depth 0 5 0 8 0 0197 0 2 0 0079 or less Correction...

Page 44: ...sembly Between C terminal and body H coil 1 13 1 25Ω Tightening area Tightening torque Remark C lead wire mounting bolt 2 3 19 25 1 2 M lead wire mounting nut 12 3 15 2 126 154 9 11 Commutator end frame mounting through bolt 15 7 17 6 160 179 12 13 Brush holder set bolts of commutator end frame 3 6 4 9 37 49 3 4 Start magnet switch assembly mounting bolt at pinion case 3 6 4 9 37 49 3 4 Pinion cas...

Page 45: ... 2 Electrical 3 2 Special tool 3 2 Engine Mechanical 3 3 Special tool 3 3 Instruments 3 6 Lubricant etc 3 6 Lubrication 3 6 Special tool 3 6 Lubricant etc 3 6 Starting and Charging 3 7 Jig reference dimensional drawing for manufacture 3 7 Instruments 3 8 Lubricant etc 3 8 Turbocharger 3 8 Special tool 3 8 Engine Failure Diagnosis 3 9 Special tool 3 9 ...

Page 46: ...Remark 09491 1010 Wire rope For engine lifting 09552 1030 Compression gauge adapter 09552 1060 Compression gauge adapter 09552 1110 Compression gauge adapter Name Remark Guide pin SZ105 08067 For supply pump positioning Shape Part No Name Remark 09444 1210 Compression gauge For V belt tension adjustment 95506 00090 Denso part No Belt tension gauge For V belt tension adjustment ...

Page 47: ...s For crankshaft front oil seal press fit 09433 1070 Eye bolt For assembly disassembly of cylinder head 09470 1170 Valve spring press For assembly disassembly of valve spring retainer 09471 1520 Guide For valve guide press fit 09472 1210 Bar For nozzle seat clamping 9800 06100 Steel ball For nozzle seat clamping together with 09472 1210 09431 1020 Valve lapping tool For valve adjustment ...

Page 48: ...or 09402 1540 09402 1530 Press sub assembly For assembly disassembly of connecting rod small end bushing 9233 10360 Wing nut For assembly disassembly of connecting rod small end bushing together with 09402 1530 09481 1130 Guide For assembly disassembly of connecting rod small end bushing together with 09402 1530 09402 1540 Spindle For assembly disassembly of connecting rod small end bushing 09481 ...

Page 49: ...1100 Sliding hammer For main sub idle gear assembly and cam idle gear shaft removal 09420 1442 09411 1300 Socket wrench For assembly disassembly of Torx bolt 09407 1040 Oil seal press For crankshaft rear oil seal press fit 09471 1490 Guide For insertion of cylinder liner 09472 1620 Tool For cooling jet repair 9001 24262 Check bolt For cooling jet inspection and adjustment Shape Part No Name Remark...

Page 50: ...h clearance Dial gauge For measurement of parts Name Remark Liquid gasket Threebond TB1207B or equivalent Black For sealing of parts Liquid gasket Threebond TB1207D or equivalent Silver For sealing of parts Liquid gasket Threebond TB1211 or equivalent White For sealing of parts Red lead Valve adjustment Dye penetrant For inspection of crack Shape Part No Name Remark 09503 1110 Oil filter wrench Na...

Page 51: ...are shown in the figures below Jig A Roller bearing insertion jig Jig B Support jig Unit mm in φ23 20 827 φ34 1 339 φ54 2 126 φ60 2 362 φ25 0 984 φ41 1 614 φ64 2 520 φ70 2 756 φ50 1 969 φ30 1 181 φ19 0 748 1C 0 039 1C 0 039 50 1 964 50 1 964 10 20 0 394 0 787 0 5 0 0196 0 35 1 378 70 2 756 Jig C Jig D 20 0 787 40 1 575 20 0 787 40 1 575 10 0 394 10 0 394 SAPH311990300034 ...

Page 52: ...tor checker G M Machinery ICD 101D or equivalent For inspection of regulator Name Remark Circuit tester For measurement of parts Micrometer For measurement of part outer diameter Growler tester For inspection of armature Cylinder gauge For measurement of part inner diameter Name Remark Kyodo Yushi Multemp AC N For lubrication of parts Nisseki Mitsubishi Pyroknock 2 For lubrication of parts Shape P...

Page 53: ...IE6 0 or later CPU and memory Conditions that assure operation of the above operating system Display 800 x 600 256 colors or more HinoDX Failure diagnosis software CD ROM 09121 1040 Hino Bowie Interface box Used together with the cable between the vehicle and Hino Bowie 09042 1220 09049 1080 Signal check harness This is installed as interruption between vehicle harness and the ECU Tester inspectio...

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Page 55: ...EMBLY 4 1 4 ENGINE 4 ENGINE ASSEMBLY DISASSEMBLY Service procedure Overhaul item Inspection Before Service 4 2 Measurement of compression pressure 4 2 Engine Body 4 4 Removal 4 4 Installation 4 6 Work after installation 4 6 ...

Page 56: ... 6 Remove all injectors 7 To prevent spread of engine oil attach a jig which cuts a head cover in half Cut it so that the camshaft may be covered 2 Measurement 1 Attach a special tool to the nozzle sheet of the cylinder where the compression pressure is measured with nozzle clamp and clamp fixing bolts Special tool Compression gauge adapter 2 Turn the starter and measure the compression pressure C...

Page 57: ...compression pressure is the service limit or less or if the difference between cylinders is over the standard value overhaul the engine 5 After measurement reassemble the removed parts Compression pressure Unit MPa kgf cm2 lbf in 2 Standard value 3 4 3 7 35 38 493 537 Service limit 2 7 28 392 Difference between cylinders 0 3 3 44 or less ...

Page 58: ...emperature is sufficiently low To dispose coolant observe the specified method waste disposal or the method with attention to environment 2 Drain engine oil from the oil pan drain plug as required CAUTION To prevent burn drain coolant after the temperature is sufficiently low Dispose coolant according to the specified method waste treatment or with a method considering the environment 3 Removal of...

Page 59: ... water and engine oil with waste 6 Engine lifting Lifting the engine single unit 1 Place a commercially available shackle and a special tool wire rope with the engine hanger Special tool 09491 1010 Wire rope 2 Keep a little slack of the wire rope CAUTION Keep the wire inclination 30 from the vertical line 3 When the wire is completely tense make sure that the wire is firmly engaged with the engine...

Page 60: ...ve fuel at the end of the drain valve 2 Loosen the air bleeding plug of the fuel filter 3 The priming pump is moved front and back 4 Move the pump until fuel without bubble comes out from the drain valve 5 Tighten the air bleeding bolt Tightening torque 1 7 2 6 N m 17 3 23 kgf cm 1 2 1 9 lbf ft 6 Move the priming pump again until it becomes heavy CAUTION After work wipe off spilled fuel After star...

Page 61: ...Part layout 5 3 Fuel filter drain on machine main unit 5 5 Replacement of fuel filter element on machine main unit 5 6 Replacement of supply pump 5 9 Inspection of supply pump 5 11 Replacement of injector 5 12 Inspection of injector 5 13 Replacement of common rail 5 14 Inspection of common rail 5 14 ...

Page 62: ...uel System Fuel system diagram JP31199050402001 Fuel tank Fuel filter Through feed pipe Leakage pipe Injector Injection pipe Overflow pipe Supply pump Pressure limiter Feed pipe Common rail Flow damper SAPH311190500001 ...

Page 63: ...mmon rail assembly 11491A Common rail bracket 9645A O ring 22100 Supply pump 9851A O ring 22825 63 7N m 650 kgf cm 47lbf ft 9068 08320 28 5N m 290kgf cm 21lbf ft 900124 108N m 1 100 kgf cm 80lbf ft 9068 08400 28 5N m 290kgf cm 21lbf ft 900124A 25N m 250 kgf cm 18lbf ft 9068 08850 28 5N m 290kgf cm 21lbf ft 9068 08250 28 5N m 290kgf cm 21lbf ft SAPH311190500002 ...

Page 64: ...cedure item 23081 Leakage pipe 23816A Through feed pipe 23711 Injection pipe 23816B Through feed pipe 23712 Injection pipe 9659B Gasket 23713 Injection pipe 9659C Gasket 23714 Injection pipe 9659D Gasket 23783A Fuel pipe 9659E Gasket 23816 Through feed pipe SAPH311190500003 ...

Page 65: ...s fuel observe the local disposal procedure for disposal 3 Close the drain valve 4 Start the priming pump and bleed air from the system CAUTION Make sure that the fuel filter air bleeding bolt is loose 5 Tighten the fuel filter air bleeding bolt Tightening torque 1 7 2 6 N m 17 3 23 kgf cm 1 2 1 9 lbf ft CAUTION After work wipe off spilled water or fuel After start of the engine make sure that the...

Page 66: ...e fuel filter element and draining of water should be performed before each start of operation Always use an original fuel filter element 1 Removal of water cup 1 Refer to Drain of the fuel filter and discharge water from the fuel filter 2 Remove the water cup of the fuel filter CAUTION Completely remove any dust around the water cup 2 Removal of fuel filter element 1 Remove the fuel filter elemen...

Page 67: ... of the fuel filter element has been changed CAUTION Tighten after confirming whether the O ring is a new or an old one As the O ring is included in the element kit do not use an O ring again after it has been removed once Install the O ring after applying fuel to the surface of the O ring Do not use a tool but tighten by hand New Old Cross section shape Tightening angle Old supply part 3 4 to 1 5...

Page 68: ...element 2 Tighten the fuel filter drain valve 5 Bleeding air from the fuel system 1 Start the priming pump and bleed air from the system CAUTION Make sure that the fuel filter air bleeding bolt is loose 2 Tighten the fuel filter air bleeding bolt Tightening torque 1 7 2 6 N m 17 3 23 kgf cm 1 2 1 9 lbf ft CAUTION After work wipe off spilled fuel After start of the engine make sure that there is no...

Page 69: ... contact other than the stopper key for the coupling flange Do not tighten hard 2 Removal of supply pump 1 Remove the fuel pipe connected to the supply pump CAUTION Do not remove pipes A 2 Remove the supply pump at the bearing holder case 3 Remove the drive gear using the special tool designed for that purpose Special tool 09650 1101 Bearing puller 3 Assembly of supply pump and bearing holder case...

Page 70: ... CAUTION Adjust the gear so that the compression top dead center alignment of the No 1 cylinder may not be changed Be sure to remove the guide bolt in cranking the engine After assembly be sure to remove the guide bolt and install the inspection window plug 5 Update of supply pump learning value 1 When the supply pump is replaced update the learning value memorized in the engine ECU with the failu...

Page 71: ... terminals using a circuit tester If it is beyond the standard remove the supply pump assembly and request for replacement at the Denso service shop Fuel temperature sensor Suction control valve SAPH311190500016 Between suction control valve terminals Standard value 7 65 8 15Ω at 20 C 68 F Terminals between fuel temperature sensors Standard value 13 5 16 5kΩ at 20 C 68 F 2 2 2 7kΩ at 20 C 68 F 0 2...

Page 72: ...en the injection pipe oil seal and the injection nozzle may cause oil leak or poor assembly of the injection pipe 4 Assemble the injection pipe temporarily and tighten the fixing bolt of the nozzle clamp holder Tightening torque 25 N m 250 kgf cm 1 8 lbf ft 3 Entry of injector correction value to the engine ECU entry using HinoDX and QR code reader CAUTION When the injector is replaced it is neces...

Page 73: ...tween two terminals above 4 If the resistance value in 2 and 3 exceeds the standard value replace the injector assembly 2 Cleaning of injector 1 Remove sludge at or around the terminal if any CAUTION In removing sludge do not use a cleaning agent Wipe it off with a rag Use of a cleaning agent may result in electric failure due to penetration of the agent QR Code reader New injector Engine use code...

Page 74: ...llation of common rail 1 Install the common rail on the intake manifold Inspection of common rail JP31199050704008 1 Inspection of common rail pressure sensor 1 Measure the resistance value between terminals using a circuit tester If it exceeds the standard value replace the common rail assembly Flow damper Pressure sensor Pressure limiter SAPH311190500021 SAPH311190500022 SAPH311190500023 Between...

Page 75: ...GINE 7 ELECTRICAL Setup layout Layout Electrical System 7 2 Part layout 7 2 Layout of components 7 5 Inspection of components 7 8 Installation of component 7 10 Installation of starter 7 10 Installation of alternator 7 11 ...

Page 76: ...1 Tightening torque 82051 Injector harness 89390 Boost pressure sensor 83420 Water temperature sender gauge 89410 Engine sub revolution sensor 83530 Oil pressure warning switch 89411 Engine main revolution sensor 9190 06121 4N m 40kgf cm 3lbf ft SAPH311990700001 ...

Page 77: ...acket 9241 10107 Fixing bolt at brace 27040 Alternator assembly 9189A Adjusting bolt 28100 Starter assembly 9069A 154N m 1 570kgf cm 114lbf ft 9241 10107 51N m 520kgf cm 38lbf ft 9011 64401 83N m 850kgf cm 61lbf ft 9241 14147 154N m 1 570kgf cm 114lbf ft 9189A 5 9N m 60kgf cm 4lbf ft SAPH311990700002 ...

Page 78: ...ELECTRICAL 7 4 19110 Glow plug SAPH311990700003 ...

Page 79: ...ts JP31199070402003 Left side view Common rail pressure sensor Fuel temperature sensor Engine revolution sensor Engine main revolution sensor Engine sub revolution sensor Boost pressure sensor Suction control valve SCV SAPH311990700004 ...

Page 80: ...pper view Fuel temperature sensor Engine main revolution sensor Engine sub revolution sensor Oil pressure warning switch Coolamt temperature sender gauge Boost pressure sensor Suction control valve SCV SAPH311990700005 ...

Page 81: ...ELECTRICAL 7 7 Service procedure Overhaul item Engine revolution sensor Front view Boost pressure sensor Coolamt temperature sender gauge SAPH311990700006 ...

Page 82: ...circuit tester If it is faulty replace the gauge Between A and C Between B and body SAPH311990700007 At no load or less than 39kPa 0 4kgf cm2 5 6565lbf in 2 With continuity At 39kPa 0 4kgf cm2 5 6565lbf in 2 Without continuity Oil pressure warning switch ON OFF 39 2 58 8kPa 0 4 0 6kgf cm 5 7 8 5 lbf in 2 9kPa 0 3kgf cm 4 7lbf in Within Toward pressure increase 2 2 2 2 SAPH311990700008 Connector co...

Page 83: ...el temperature sensor refer to the chapter of J05E FUEL SYSTEM 5 Inspection of common rail pressure sensor 1 For inspection and replacement of the common rail pressure sensor refer to the chapter of J05E FUEL SYSTEM 6 Inspection of injector 1 For inspection and replacement of the injector refer to the chapter of J05E FUEL SYSTEM SAPH311990700010 Standard value Resistance value Ω Normal temperature...

Page 84: ...or on top of the flywheel housing and one on the cam housing NOTICE Since this sensor is a flange type gap does not have to be adjusted Installation of starter JP31199070702003 1 Install the starter with bolts and nuts Tightening torque 154 N m 1 570 kgf cm 114 lbf ft Engine sub revolution sensor Engine main revolution sensor O ring O ring SAPH311990700013 SAPH311990700014 ...

Page 85: ...ew V belt has reached the value after complete initial stretching A new V belt completes initial stretching after running the engine for approximately two hours 1 Tighten the through bolt of the commutator end frame Tightening torque Through bolt 83 N m 850 kgf cm 61 lbf ft 2 Tighten the lock nut on the brace side Tightening torque Adjusting bolt 51 N m 520 kgf cm 38 lbf ft 3 Tighten the adjusting...

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Page 87: ...INTAKE 8 1 8 ENGINE 8 INTAKE Setup layout Layout Intake Manifold 8 2 Part layout 8 2 Replacement 8 4 ...

Page 88: ...2001 Parts not to be reused Tightening torque 17103 Intake pipe 17113 Intake pipe 17111 Intake manifold 17171 Gasket 9068 08320 28 5 N m 290 kgf cm 21lbf ft 9240 08087 28 5 N m 290 kgf cm 21lbf ft 9068 08550 28 5 N m 290 kgf cm 21lbf ft SAPH311990800001 ...

Page 89: ...INTAKE 8 3 Parts not to be reused Service procedure Replacement procedure item 17104A Gasket 17148 Plate SAPH311990800002 ...

Page 90: ...e intake manifold and tighten it with bolts and nuts Tightening torque 28 5 N m 290 kgf cm 21 lbf ft 3 Installation of intake pipe 1 After removing contamination on the contact surface apply liquid gasket Threebond TB1207B black or equivalent to the circumference of the contact surface CAUTION Apply it continuously Apply the liquid gasket at the width of 1 5 to 2 5 mm 0 0591 to 0 09843 in Install ...

Page 91: ...out 9 22 Replacement of piston and connecting rod 9 23 Inspection of piston and connecting rod 9 27 Replacement of connecting rod bushing 9 29 Replacement of crankshaft 9 31 Inspection of crankshaft 9 33 Replacement of crankshaft pulley 9 36 Replacement of flywheel 9 36 Camshaft and Idle Gear 9 39 Part layout 9 39 Removal of camshaft 9 40 Disassembly of camshaft 9 40 Inspection of camshaft and cam...

Page 92: ...AL 9 2 Cylinder Head Part layout JP31199090402001 Parts not to be reused 11101 Cylinder head assembly 11135 Exhaust valve seat 11122 Valve guide 11176 Nozzle seat 11131 Intake valve seat 900115 O ring SAPH311990900001 ...

Page 93: ...ular plug 12505 Silent block 11201 Cylinder head cover 23074 Injection pipe oil seal 11213 Head cover gasket 11185 59N m 600kgf cm 44lbf ft 90 90 9069B 59N m 600kgf cm 44lbf ft 11185A 59N m 600kgf cm 44lbf ft 90 135 9349A 30N m 300kgf cm 22lbf ft 11185B 59N m 600kgf cm 44lbf ft 90 180 SZ105 59N m 600kgf cm 44lbf ft 9068 08400 28 5N m 290kgf cm 21lbf ft SAPH311990900002 ...

Page 94: ...070 Eye bolt NOTICE If it is difficult to remove the cylinder head insert a chisel between the cylinder head and the cylinder block and move the chisel vertically so that the contact surface may not be damaged Then separate the cylinder head 2 Inspection of head bolt length 1 Measure the underhead length of the head bolt M12 only using vernier calipers If it is beyond the service limit replace it ...

Page 95: ...appropriate amount of liquid gasket Threebond TB1211 white or equivalent to the cylinder head gasket hole at the joint surface between the cylinder block and the flywheel housing CAUTION Apply the liquid gasket so that the surface of the liquid gasket may be raised on the cylinder head gasket Install the oil cooler within 20 minutes after application of the liquid gasket 4 Installation of cylinder...

Page 96: ...e outside in the order shown in the figure Tightening torque 59 N m 600 kgf cm 44 lbf ft 5 After tightening tighten head bolts 1 to 18 again from the center to the outside Tightening torque 59 N m 600 kgf cm 44 lbf ft 6 Mark the head parts of head bolts M12 1 to 18 with paint in the same direction 7 Tighten head bolts M12 1 to 18 in tightening order for another 90 First time 8 Tighten head bolts M...

Page 97: ...l the cylinder head cover with the gasket attached and execute a parallel adjustment of the semicircular plugs CAUTION Be sure to wipe protruding liquid gasket Replacement of head cover JP31199090704003 1 Installation of head cover 1 Wipe off the liquid gasket stuck to the sides of the semicircular plugs on the front and rear ends of the cylinder head 2 Wipe dirt including liquid gasket and oil on...

Page 98: ... the cylinder head CAUTION To remove carbon or other deposit do not damage the lower surface of the cylinder head 2 Replacement of valve guide 1 Remove the valve stem seal 2 Remove the valve guide using a brass bar or press 3 When a new valve guide is assembled do not pry the end in assembly and press fit using a special tool Special tool 09471 1520 Guide CAUTION In press fit be careful not to dam...

Page 99: ...der head to approx 80 to 100 C and strike the cooled valve seat into the mounting area of the cylinder head 5 Apply small amount of lapping compound to the contact surface between the valve and the valve seat 6 Strike gently while turning the valve using a special tool for adjustment Special tool 09431 1020 Valve lapping tool 4 Replacement of nozzle seat 1 Tap the nozzle seat from the cylinder hea...

Page 100: ...f cylinder head distortion a Measure distortion of the cylinder head lower surface and the manifold mounting surface using a ruler b If the measurement value is beyond the service limit replace it CAUTION Repair of the lower surface by grinding can change backlash of the timing gear Do not grind it 2 Inspection of cylinder head crack a With dye penetrant test method red check make sure that there ...

Page 101: ...ock Part layout JP31199090402002 Tightening torque Service procedure Overhaul item 11401 Cylinder block assembly 11467 Cylinder liner 11408 Cooling jet 11521 69N m 700kgf cm 51lbf ft 90 45 15605 22N m 220kgf cm 16lbf ft SAPH311990900026 ...

Page 102: ...ward the cylinder block upper part using a special tool Special tool 09420 2100 Cylinder liner puller CAUTION Be careful for handling of the cylinder liner Do not reuse the cylinder liner which has been dropped Do not touch the cooling jet during work 3 Apply engine oil to the inner bore of the cylinder block 4 Align the match mark of the cylinder liner with that of the cylinder block Install the ...

Page 103: ...cial tool 09420 2100 Cylinder liner puller 2 Measure protrusion of the flange using a dial gauge 3 Inspection and adjustment of cooling jet 1 Remove the standard oil check valve and install the cooling jet on the cylinder block using a special tool Special tool 9001 24262 Check bolt Liner identification mark Engine type Block front Front of engine SAPH311990900030 Cylinder liner A B and C marking ...

Page 104: ...tion center hits within the specified line of the gauge it is considered normal CAUTION Oil is susceptible to combustion due to spread Do not use fire near around Work at well ventilated place 6 Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling jet pipe Oil hose Check bolt SAPH311990900034 Special tool Tool assembly Cylinder liner Cooling ...

Page 105: ...ton at the piston bottom dead center 4 Inspection of cylinder block 1 Inspection of cylinder block distortion a Measure distortion on the cylinder block using a ruler b If the measurement value is beyond the service limit replace it CAUTION Repair of the upper surface by grinding can change backlash of the timing gear Do not grind it 2 Inspection of cylinder block crack a With dye penetrant test m...

Page 106: ...0 End plate 11351 Flywheel housing 9828A Front oil seal 11357 Gasket 9828B Rear oil seal 11357A Gasket 9068 08000 36N m 370kgf cm 27lbf ft 90124A 196N m 2 000kgf cm 145lbf ft 9068 10750 55N m 560kgf cm 41lbf ft 9241 10107 55N m 560kgf cm 41lbf ft 9068 60850 55N m 560kgf cm 41lbf ft 9339A 55N m 560kgf cm 41lbf ft 90124 196N m 2 000kgf cm 145lbf ft 9419A 196N m 2 000kgf cm 145lbf ft SAPH311990900040...

Page 107: ...ly the liquid gasket at the width of 1 5 to 2 5 mm 0 0591 to 0 0984 in Install the oil cooler within 20 minutes after application of the liquid gasket 3 Install the flywheel housing on the cylinder block with bolts Tightening torque 196 N m 2 000 kgf cm 145 lbf ft Area A 36 N m 370 kgf cm 27 lbf ft Area B 55 N m 560 kgf cm 41 lbf ft Area C CAUTION Tighten bolts fixing the flywheel housing from the...

Page 108: ... gasket with a scraper to be flush to the upper lower surfaces of the cylinder block Replacement procedure item Replacement of crankshaft front oil seal JP31199090704004 1 Removal of front oil seal 1 Install the plate of the special tool oil seal puller on the crankshaft using two crankshaft damper mounting bolts Special tool 09420 1731 Oil seal puller 2 Hook the special tool oil seal puller with ...

Page 109: ...e front oil seal The felt surface is at the crankshaft damper side 2 Remove contamination from the joint surface of the front oil seal and the cylinder block 3 Apply small amount of engine oil to the seal area of the front oil seal 4 Install the oil seal press guide inserting a new front oil seal with accompanying guide bolts on the crankshaft 5 Align the oil seal press hole to the guide bolt and ...

Page 110: ...nstall the hook on the plate of the oil seal puller with accompanying bolts 3 Remove two bolts which installed the plate of the oil seal puller on the crankshaft 4 Attach the accompanying center bolt to the oil seal puller and tighten it Pull out the rear oil seal 2 Installation of rear oil seal 1 Insert a new rear oil seal into the guide of the oil seal press Special tool 09407 1040 Oil seal pres...

Page 111: ...inserting a new rear oil seal with accompanying guide bolts on the crankshaft CAUTION Align the large hole of the guide with the collar dowel of the crankshaft 5 Align the oil seal press hole to the guide bolt and insert the oil seal press 6 Attach the accompanying center bolt to the oil seal press and tighten it until stop Press fit the rear oil seal Setup layout Layout SAPH311990900056 SAPH31199...

Page 112: ... rod bush 11703 Main bearing US 0 25 13411 Crankshaft 11704 Main bearing US 0 50 13450 Flywheel assembly 13005 Piston Piston ring set 13453 Ring gear 13041 Connecting rod bearing 13470 Crankshaft pulley 13041A Connecting rod bearing 13521 Crankshaft gear 13041B Connecting rod bearing 9819A Retainer ring 13265 69N m 700kgf cm 51lbf ft 90 45 900125 118N m 1 200 kgf cm 87lbf ft 13455 186N m 1 900 kgf...

Page 113: ...er liner inner surface with a scraper or a sand paper No 150 or so in the circumferential direction CAUTION Do not damage parts lower than the carbon deposit area 3 Fix the cylinder liner with bolts and a plate 4 Hit the connecting rod from underneath the engine using a handle of a hammer Remove the piston together with the connecting rod NOTICE In removing the piston rotate the connecting rod as ...

Page 114: ...reful for handling Store piston rings for each cylinder number Store the piston rings so that the upper and lower surfaces may be identified 3 Assembly of piston and connecting rod 1 Install the piston on the connecting rod so that the 0 mark on the piston may be opposite to the match mark stamp on the connecting rod 2 Install a new retainer ring using a snap ring pliers CAUTION Make sure that the...

Page 115: ...tion of piston and connecting rod 1 Allocate the joints of the piston ring with uniform intervals as shown in the figure 2 Install the connecting rod bearing to suit concave shape of the connecting rod CAUTION Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the connecting rod 3 Apply engine oil to the piston cylinder liner and connecting rod bearing and co...

Page 116: ...g rod cap 6 Align the match mark of the connecting rod cap with that of the connecting rod and fix it with a dowel pin CAUTION Do not change the combination between the connecting rod and the connecting rod cap 7 Measure the underhead length of the connecting rod bolt using a vernier calipers If it is out of the service limit replace it with a new one 8 Apply engine oil to the connecting rod bolt ...

Page 117: ...asuring position is 23 mm 0 9055 in above the piston lower end and square to the pin hole 3 Calculate the difference between the inner diameter of the cylinder liner and the outer diameter of the piston If it is beyond the standard value replace the cylinder liner and the piston 2 Inspection of clearance between piston ring and ring groove 1 Measure the piston ring width using a micrometer If it i...

Page 118: ...of the piston pin contact area with the piston boss and the inner diameter of the piston boss If it is out of the service limit replace the piston pin or piston T Tightening allowance L Clearance Replacement procedure item SAPH311990900078 Standardvalue mm in Service limit mm in Top ring groove 2 5 0 0984 2 70 0 1063 Second ring groove 2 0 0787 2 20 0 0866 Oil ring groove 4 0 1575 4 10 0 1614 Pist...

Page 119: ...ure that the lower end of the guide and the press sub assembly is flat 2 With the large end bearing removed assemble the connecting rod and put it on the assembled special tool 3 Install the special tool spindle on the bushing of the connecting rod Special tool 09402 1540 Spindle CAUTION Align the press sub assembly groove with the special tool spindle groove for installation 4 Remove the bushing ...

Page 120: ...the connecting rod oil hole with the bushing oil hole assembled on the special tool Make sure that the groove of the special tool spindle is in alignment with the groove of the special tool press sub assembly CAUTION Place the connecting rod so that the chamfer side of the connecting rod small end inner diameter may be the bushing side Apply engine oil to the inner diameter surface of the connecti...

Page 121: ...y engine oil or grease to the back of the thrust bearing 2 Install the main bearing on the cylinder block and each bearing cap CAUTION Assemble the bearing with oil hole on the cylinder block and assemble the bearing without oil hole on the cap Apply new engine oil to the sliding surfaces of each bearing 3 Align the crankshaft with the cylinder block 4 Align the main bearing cap which has the thru...

Page 122: ...ring cap bolt heads in the same direction with paint 12 Tighten 90 deg 1 4 turn with the same order as in 7 13 Retighten 45 deg 1 8 turn as in 7 14 Make sure that all paint marks are in the same direction CAUTION If it is excessively retightened do not loosen it 15 After tightening hit the front rear ends of the crankshaft gently with a plastic hammer for initial fit CAUTION Make sure that the cra...

Page 123: ...d use the undersize bearing 3 Inspection of journal wear 1 Measure the outer diameter of the crankshaft journal using a micrometer If it is faulty grind or replace the crankshaft When the crankshaft is ground use the undersize bearing SAPH311990900095 Standard value mm in Repair limit mm in Service limit mm in 0 050 0 219 0 020 0 0086 0 50 0 0197 1 219 0 0480 Figure is an example of work SAPH31199...

Page 124: ...l and the inner diameter of the crankshaft bearing If it is beyond the repair limit grind the crankshaft and use the undersize bearing NOTICE Standard bearing thickness 2 5mm Undersize bearing value 0 25 0 50 0 75 1 00 Figure is an example of work SAPH311990900098 Standard value mm in Service limit mm in 36 1 4173 37 0 1 4567 90 SAPH311990900099 Standard value mm in Service limit mm in 80 3 1496 7...

Page 125: ...6 Inspection of pin wear 1 Measure the outer diameter of the crankshaft crank pin using a micrometer If it is faulty grind or replace the crankshaft When the crankshaft is ground use the undersize bearing R Good Poor Step Step Radius is small Radius is incomplete SAPH311990900101 Figure is an example of work SAPH311990900102 Figure is an example of work SAPH311990900103 90 Measurement at 2 places ...

Page 126: ... lbf ft NOTICE Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft Replacement of flywheel JP31199090704009 1 Removal of flywheel 1 Remove the engine revolution sensor 2 Remove bolts fixing the flywheel NOTICE Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to ...

Page 127: ...el CAUTION Do not touch the ring gear and the flywheel with bare hand while they are hot 3 Installation of ring gear 1 Heat the entire ring gear circumference with a burner until it is about 200 C 392 F CAUTION Do not touch the ring gear and the flywheel with bare hand while they are hot 2 Face the chamfered side toward the flywheel and install it on the flywheel quickly CAUTION Do not touch the r...

Page 128: ...e crankshaft 5 Apply engine oil to the bolt seat and the bolt thread of the flywheel mounting bolt 6 Tighten 6 bolts by 2 to 3 threads temporarily with hand in the bolt holes without installation of the special tool 7 Tighten 6 bolts gradually and tighten temporarily 8 Remove the special tool and tighten remaining two bolts temporarily as in 6 and 7 9 Tighten the flywheel according to the order in...

Page 129: ...e 13505 Cam idle gear 13581 Idle gear shaft 13505A Sub idle gear 13581A Idle gear shaft 13505B Main idle gear 13581B Idle gear shaft 13520 Camshaft gear 9867A Idle gear bush 13572 Idle gear thrust plate 9867B Idle gear bush 13572A Idle gear thrust plate 900124 59N m 600kgf cm 44lbf ft 90 900125 172N m 1 750 kgf cm 127lbf ft 900124A 108N m 1 100 kgf cm 80lbf ft SAPH311990900117 ...

Page 130: ...w may bend the rocker shaft 2 Loosen the rocker arm support bolts gradually from the center and remove the rocker arm and the rocker arm shaft Disassembly of camshaft JP31199090702007 1 Disassembly of camshaft 1 Fix the camshaft gear using a vice to disassemble the camshaft CAUTION Prevent faulty conditions on the gear such as deformation impact scratch etc Rock nut SAPH311990900118 SAPH3119909001...

Page 131: ...urnal using a micrometer 2 Measure the camshaft bearing inner diameter using a cylinder gauge 3 Calculate the difference of the camshaft journal bearing inner diameter If it is beyond the standard value replace the camshaft or the camshaft bearing SAPH311990900121 Standard value mm in Service limit mm in Cam height IN 50 067 1 9711 49 987 1 9680 EX 52 104 2 0513 52 024 2 0482 Cam lift IN 8 067 0 3...

Page 132: ...t and the bolt thread of the camshaft gear mounting bolt 3 Set the dowel pin to the camshaft and the camshaft gear and tighten the camshaft gear mounting bolt Tightening torque 59 N m 600 kgf cm 44 lbf ft 4 Retighten 90 deg 1 4 turn CAUTION If it is excessively retightened do not loosen it Prevent faulty conditions on the gear such as deformation impact scratch etc Underhead length SAPH31199090012...

Page 133: ... caps in numerical order 1 2 3 4 5 from the front of the engine making sure the five sided mark on the cap points forward 3 Make sure the crosshead is correctly laid across each valve CAUTION To make sure the crosshead is correctly in place move it to the left and right by hand and make sure it clicks against the valves If the crosshead is not sitting properly on the valves it will push the upper ...

Page 134: ...correctly laid on the crosshead Then tighten the bolts in the sequence shown in the figure making several passes and gradually tightening them each time Tightening torque 28 5 N m 290 kgf cm 21 lbf ft CAUTION After the bolts are tightened make sure the rocker arm moves smoothly Setup layout Layout SAPH311990900129 ...

Page 135: ...02011 1 Removal of main idle gear 1 Remove the idle gear shaft mounting bolt and pull out the main idle gear assembly using a special tool Special tool 09420 1100 Sliding hammer 09420 1442 Sliding hammer 2 Remove the idle gear thrust plate 3 Remove the idle gear shaft from the main idle gear SAPH311990900130 SAPH311990900131 ...

Page 136: ...ear shaft outer diameter using a micrometer and the idle gear bushing inner diameter using a cylinder gauge 2 Calculate the difference between the idle gear bushing inner diameter and the idle gear shaft outer diameter If it is beyond the service limit replace the idle gear shaft and the idle gear bushing SAPH311990900132 SAPH311990900133 Standardvalue mm in Main idle gear shaft Shaft outer diamet...

Page 137: ... on the idle gear shaft 5 Apply engine oil to the bolt seat and the bolt thread of the idle gear shaft mounting bolt 6 Install the idle gear shaft mounting bolt Tightening torque 108 N m 1 100 kgf cm 80 lbf ft 2 Installation of main idle gear 1 Install the idle gear shaft on the main idle gear 2 Install the idle gear thrust plate Cylinder block Lubricating hole Thrust plate Idle gear thrust plate ...

Page 138: ...wing 4 Apply engine oil to the bolt seat and the bolt thread of the idle gear shaft mounting bolt 5 Install the idle gear shaft mounting bolt Tightening torque 172 N m 1 750 kgf cm 127 lbf ft 6 Measure backlash and end play of each idle gear Make sure that it is within the standard value Crankshaft gear A Arrange drilled holes in line Detail Main idle gear Oil pump gear Sub idle gear SAPH311990900...

Page 139: ...ment Supply pump 2 Disconnect the bearing case assembly CAUTION One bolt is tightened from the timing gear case 3 Fix the bearing case with a vice 4 Remove the sub idle gear shaft mounting bolt and pull out the idle gear shaft using a sliding hammer 5 Remove the sub idle gear 6 Remove the idle gear thrust plate SAPH311990900139 SAPH311990900140 SAPH311990900141 ...

Page 140: ... Install the idle gear thrust plate 2 Install the gear shaft on the sub idle gear 3 Face the lubricating hole of the gear shaft downward and install it on the bearing case 4 Install the sub idle gear shaft mounting bolt Tightening torque 108 N m 1 100 kgf cm 80 lbf ft 5 Assemble the supply pump and bearing case Tightening torque 28 5 N m 290 kgf cm 21 lbf ft CAUTION Be careful for fall of the O ri...

Page 141: ...ection of camshaft end play 1 Measure the end play of the camshaft using a thickness gauge If it is beyond the standard value replace the camshaft 3 Inspection of backlash between main idle gear and air compressor idle gear 1 Remove the supply pump drive at the bearing case Reference Replacement Supply pump 2 Insert a large flat tip screwdriver into the main idle gear from the timing gear dust cov...

Page 142: ...d the supply pump drive gear using a dial gauge and a magnet stand If it is beyond the service limit replace each gear 5 Inspection of backlash between main idle gear and sub idle gear 1 Insert a large flat tip screwdriver into the main idle gear from the timing gear dust cover of the flywheel housing to prevent turning of the main idle gear 2 Measure backlash between the main idle gear and the su...

Page 143: ...play of each gear using a thickness gauge If it is beyond the service limit replace each gear or shaft 8 Inspection of backlash between cam idle gear and sub idle gear 1 Insert a large flat tip screwdriver into the sub idle gear from the side of the cam idle gear of the cylinder head to prevent turning of the sub idle gear SAPH311990900154 SAPH311990900155 Standard value mm in Service limit mm in ...

Page 144: ...lash between the cam idle gear and the sub idle gear using a dial gauge If it is beyond the service limit replace each gear Setup layout Layout SAPH311990900158 Standard value mm in Service limit mm in 0 050 0 218 0 0020 0 0086 0 30 0 0118 ...

Page 145: ...justing screw cross head 13711 Intake valve 13830 Rocker arm intake 13715 Exhaust valve 13840 Rocker arm exhaust 13719 Valve stem seal 13901 Rocker shaft 13731 Outer valve spring 13951 Rocker arm support 13732 Inner valve spring 900126 Valve spring retainer 13734 Valve spring lower seat 13788 25N m 250 kgf cm 18lbf ft 9069B 28 5N m 290kgf cm 21lbf ft 9069A 28 5N m 290kgf cm 21lbf ft 9069C 28 5N m ...

Page 146: ... or the rocker arm bushing 2 Removal of valve spring 1 Compress the valve spring using a special tool and remove the valve spring retainer Special tool 09470 1170 Valve spring press 2 Remove the intake and exhaust valves CAUTION Attach a tag with the applicable cylinder number to the valve so that combinations of the valve and the cylinder head may not be mixed SAPH311990900160 Standard value mm i...

Page 147: ...t on the valve spring 2 Compress the valve spring using a special tool and install the valve spring retainer Special tool 09470 1170 Valve spring press CAUTION Apply engine oil to the contact surface of each part before assembly Be sure to assemble each valve at the original cylinder position When the valve spring is compressed avoid contact of the valve spring upper seat with the valve stem seal ...

Page 148: ... gauge 3 Calculate the difference between the valve stem outer diameter and the valve guide inner diameter If it is beyond the standard value replace the valve or the valve guide Clearance A SAPH311990900166 Clearance A mm in 2 0 0 0787 SAPH311990900167 Measuring item Standardvalue mm in Service limit mm in Inner valve spring 64 6 2 5433 61 6 2 4252 Outer valve spring 75 7 2 9803 72 7 2 8622 SAPH3...

Page 149: ...d If the adjusting screw is not completely separated from the valve stem correct adjustment is not allowed 4 Insert a thickness gauge between the rocker arm and the crosshead and adjust the clearance with the adjusting screw of the rocker arm Tighten the lock nut Tightening torque 25 N m 250 kgf cm 18 lbf ft 5 Loosen the adjusting screw of the crosshead with the thickness gauge inserted Make sure ...

Page 150: ...N m 250 kgf cm 18 lbf ft CAUTION Do not over loosen the adjusting screw Over loosening of the adjusting screw reproduces the original status Although feel on the thickness gauge is appropriate there is clearance between the adjusting screw and the valve of the crosshead Correct adjustment is not allowed Close contact Close contact SAPH311990900173 Feel of thickness gauge Start No move Appropriate ...

Page 151: ...EXHAUST 10 1 10 ENGINE 10 EXHAUST Setup layout Layout Exhaust Manifold 10 2 Part layout 10 2 Replacement 10 4 ...

Page 152: ...EXHAUST 10 2 Exhaust Manifold Part layout JP31199100402001 Parts not to be reused Tightening torque 17104 Gasket 17141 Exhaust manifold 9209A 53 N m 540 kgf cm 40lbf ft SAPH311991000001 ...

Page 153: ...EXHAUST 10 3 Parts not to be reused Service procedure Replacement procedure item 17104A Gasket 17148 Plate SAPH311991000002 ...

Page 154: ...has front and back install the black side on the exhaust manifold 2 Tighten the mounting nut of the exhaust manifold according to the order in the figure Tightening torque 53 N m 540 kgf cm 40 lbf ft CAUTION When nuts are tightened prevent each spacer from riding on the counterbore area of the manifold flange The tightening sequence of the exhaust manifold varies between use of a new part and reus...

Page 155: ...11 ENGINE 11 COOLING System drawing System drawing Cooling System 11 2 Cooling system drawing 11 2 Part layout 11 3 Replacement of thermostat case 11 4 Inspection of thermostat 11 5 Replacement of coolant pump 11 6 ...

Page 156: ...ng system drawing JP31199110803001 Setup layout Layout Car heater Reservoir Thermostat Drain cock Drain cock Cylinder block Cylinder head Oil cooler Coolant pump Radiator Thermostat case Water temperature Turbo charger SAPH311991100001 ...

Page 157: ...eused Service procedure Replacement procedure item 16100 Coolant pump assembly 16325 Gasket 16173 Coolant pump pulley 16331 Thermostat case cover 16303 Thermostat case 16377 Fan spacer 16306 Cooling fan 9851A O ring 16323 Thermostat case cover SAPH311991100002 ...

Page 158: ...id gasket at the width of 1 5 to 2 5 mm 0 0591 to 0 0984 in Install the oil cooler within 20 minutes after application of the liquid gasket 3 Install the new O ring on the groove of the coolant pump 4 Put the thermostat case mounting bolt through the thermostat case in advance 5 Align the thermostat case at the mounting position and tighten mounting bolt 1 temporarily to the cylinder head 6 Tighte...

Page 159: ...mostat valve 4 Put the full open thermostat valve in water at normal temperature Make sure that the thermostat valve closes completely within 5 minutes 5 If faulty item is found with the inspection above replace the thermostat Replacement procedure item Thermometer Wire Heat source Valve lift Thermostat SAPH311991100006 13mm 0 5122in T1 Valve opening temperature start of valve opening T2 Full open...

Page 160: ...k or equivalent to the coolant pump as shown in the figure CAUTION Apply it continuously Apply the liquid gasket at the width of 2 to 3mm 0 0787 to 0 1181in Install the oil cooler within 20 minutes after application of the liquid gasket Fill the groove on the water pump flange with the liquid gasket 3 Install the coolant pump to the dowel pin of the cylinder block NOTICE When the coolant pump is i...

Page 161: ...r and Oil Pump 12 2 System drawing 12 2 Part layout 12 3 Replacement of oil cooler 12 5 Overhaul of oil cooler 12 6 Replacement of oil pump 12 9 Overhaul of oil pump 12 10 Replacement of oil strainer 12 13 Oil Pan 12 14 Part layout 12 14 Replacement 12 15 Inspection of lubrication status 12 16 ...

Page 162: ...osshead Adjusting screw Rocker arm Rocker arm shaft Camshaft Cam idle gear shaft Sub idle gear shaft Turbocharger Oil pump Oil cooler Oil filter Main oil hole Piston pin Connecting rod Crankshaft Supply pump drive Sub idle gear shaft supply pump drive Piston cooling jet check valve Sub oil hole Main idle gear shaft Lubrication Return SAPH311991200001 ...

Page 163: ...assembly 9851B D ring 15119 Gasket 15139 Seat2 15132 Relief valve spring 15139A Seat1 15135 Safety valve 9068 08160 28 5N m 290kgf cm 21lbf ft 9068 08750 24 5 4 9N m 250 50kgf cm 18 4llbf ft 9068 08250 31N m 320kgf cm 23lbf ft 9068 08900 24 5 4 9N m 250 50kgf cm 18 4lbf ft 9068 08320 24 5 4 9N m 250 50kgf cm 18 4lbf ft 9068 58100 24 5 4 9N m 250 50kgf cm 18 4llbf ft 9068 08550 28 5N m 290kgf cm 21...

Page 164: ...ring 15675 Safety valve 9739A Elbow 15701 Oil cooler case 9851A O ring 15710 Oil cooler assembly 9851B O ring 15712 Oil cooler element 9851C O ring 15717 Gasket 9851D O ring 15720 Oil cooler case assembly 9851E O ring 15662 44 1 4 9 N m 450 50 kgf cm 33 4llbf ft 9201 10080 24 5 4 9 N m 250 50 kgf cm 18 4llbf ft SAPH311991200003 ...

Page 165: ...cooler CAUTION Face the D ring flat area toward the oil cooler 2 Remove contamination on the joint surface between the oil cooler and the cylinder block using a scraper Apply the liquid gasket Threebond TB1207 silver or equivalent to the oil cooler as shown in the figure CAUTION Apply it continuously Apply the liquid gasket at the width of 1 5 to 2 5 mm 0 0590 to 0 0984 in Install the oil cooler w...

Page 166: ...n it again to the torque above Overhaul item Overhaul of oil cooler JP31199120702001 1 Removal of oil cooler element 1 Remove nuts and remove the oil cooler element 2 Inspection of oil cooler element 1 Wash water and oil channels with kerosene oil or washing fluid 2 Check for crack or deformation on the stud bolt mounting area and element visually 3 Blow air of approx 0 5kgf cm2 into the oil chann...

Page 167: ...ooler case 1 Install a new O ring and install valve spring plugs and safety valves using a hexagonal wrench Tightening torque 24 5 4 9 N m 250 50 kgf cm 18 4 lbf ft M14 M20 29 4 4 9 N m 300 50 kgf cm 22 4 lbf ft M22 34 3 4 9 N m 350 50 kgf cm 25 4 lbf ft M24 2 Apply the liquid gasket Threebond TB1211 white or equivalent to the sealing surface of a new soft washer 3 Install the soft washer in 2 and...

Page 168: ...ssemble new gasket and new O ring and assemble the oil cooler element with nuts Tightening torque 24 5 4 9 N m 250 50 kgf cm 18 4 lbf ft CAUTION In handling the oil cooler element be careful not to give damage to it Replacement procedure item SAPH311991200010 ...

Page 169: ... gasket apply engine oil to the cylinder block in advance and place and fix the gasket CAUTION Assembly with offset gasket may cause faulty sealing Oil in the oil pump may be completely discharged when the engine stops Faulty sealing may cause insufficient suction of oil at initial revolution of engine restart resulting in seizure or abnormal wear 3 Tighten the oil pump according to the order in t...

Page 170: ...ve gear and the inner diameter of the pump chamber at cylinder block 2 Calculate the difference between the outer diameter of the drive gear and the inner diameter of the pump chamber at the cylinder block If it is beyond the service limit replace the oil pump assembly SAPH311991200016 SAPH311991200017 SAPH311991200018 Measuring area Standard value mm in Outer diameter of drive gear 54 2 1260 Inne...

Page 171: ...aft using a micrometer and measure the cylinder block hole diameter using a cylinder gauge 2 Calculate the difference between the outer diameter of the driven gear and the cylinder block hole diameter If it is beyond the service limit replace the oil pump assembly SAPH311991200020 Measuring area Standard value mm in Width of drive gear 28 5 1 1220 Depth of pump chamber at cylinder block 28 5 1 122...

Page 172: ...meter of the driven gear shaft using a micrometer and measure the inner diameter of the driven gear bushing using a cylinder gauge 2 Calculate the difference between the outer diameter of the driven gear shaft and the inner diameter of the driven gear bushing If it is beyond the service limit replace the oil pump assembly or the driven gear bushing SAPH311991200024 Measuring area Standard value mm...

Page 173: ... the oil pump cover assembly with new cotter pins 2 Install the driven gear Replacement procedure item Replacement of oil strainer JP31199120704003 1 Removal of oil strainer 1 Remove bolts and remove the oil strainer 2 Installation of oil strainer 1 Replace the O ring with new ones and install the oil strainer Tightening torque 31 N m 320 kgf cm 23 lbf ft Setup layout Layout SAPH311991200027 Stand...

Page 174: ...2003 Parts not to be reused Tightening torque Service procedure Replacement procedure item 12111 Oil pan assembly 12149 Drain plug 12151 Oil pan gasket 9659A Gasket 12149 30 N m 300 kgf cm 22lbf ft 9068 08800 30 N m 300 kgf cm 22lbf ft SAPH311991200029 ...

Page 175: ...sket protrusion at the intake side and the flywheel housing printed seal surface at cylinder block Align the new oil pan gasket and oil pan to the cylinder block lower surface and tighten bolts in the arrow order of the figure Tightening torque 19 6 24 5 N m 200 250 kgf cm 14 18 lbf ft 5 Remove positioning stud bolts and install the correct bolts 6 Tighten bolts in the arrow order of the figure Ti...

Page 176: ...2 Adjust the engine revolution to the standard idling revolution 1 000 min rpm 3 After start of the engine make sure that oil is supplied to the areas below of all rocker arms within about 10 seconds Roller and cam surface Cross head and spring upper seat surface through adjusting screw CAUTION If time until lubrication is long or if lubrication is not performed the oil pressure may be low or the ...

Page 177: ...ter 13 2 Part layout typical example 13 2 Disassembly 13 3 Inspection of components 13 9 Assembly 13 14 Alternator 50A 13 21 Part layout typical example of 50A 13 21 Circuit drawing 50A 13 22 Disassembly 13 23 Inspection of components 13 26 Assembly 13 29 Inspection after assembly 13 33 ...

Page 178: ...5 Start drive housing 28150 Center bracket 28117 Packing 28160 Armature assembly 28117A Packing 28168 Retainer clip 28118 Plate 28199 Dust protector 28118A Brake plate 28240 Start magnet switch 28118B Plate 28251 Pinion 28118C Sim 28252 Rear side bearing 28118D Cover 28255 Shaft assembly 28120 Yoke assembly 28253 Planetary gear 28133 Commutator end frame 28253A Internal gear 28112 14 16 N m 140 16...

Page 179: ...terminal 2 Remove nuts and remove the M lead wire 2 Removal of commutator end frame 1 Loosen and remove two through bolts 2 Remove two set bolts and remove the commutator end frame CAUTION Hold the M lead wire and remove the commutator end frame by lifting M terminal M lead wire SAPH311991300002 Through bolt Commutator end frame SAPH311991300003 Set bolt SAPH311991300004 ...

Page 180: ...y 1 Remove the yoke assembly from the center bracket assembly CAUTION Do not hold the M lead wire and hold the yoke assembly outer diameter for removal 5 Removal of packing 1 Remove the packing from the centering parts at both ends of the yoke assembly CAUTION Damaged packing must not be resued Replace it with a new part Brush holder Assembly Brush lead Brush Spring Clamp SAPH311991300005 Yoke ass...

Page 181: ...ION Removed bearing must not be reused Replace it with a new one 8 Removal of cover 1 Remove the cover from the center bracket assembly 2 Remove the packing CAUTION Damaged packing must not be resued Replace it with a new part 9 Removal of planetary gear 1 Remove the planetary gear from the carrier pin CAUTION Make sure that the gear is not damaged or chipped Armature assembly Center bracket assem...

Page 182: ... Remove the retainer clip using a tool such as snap ring pliers CAUTION Retainer clip must not be reused Replace it with a new one NOTICE Push upward or pull out the chipped part of the clip mouth 2 Remove the pinion stopper 3 Remove the pinion CAUTION Make sure that the gear is not damaged or chipped Internal gear Center bracket SAPH311991300012 Shim SAPH311991300013 Retainer clip Pinion stopper ...

Page 183: ...and remove the center bracket 14 Removal of lever 1 Hold the lever holder and press the entire lever to the clutch Remove the link with the plunger 2 Turn and pull out the lever assembly using the clutch as the axis Center bracket Clutch assembly SAPH311991300016 Plunger Holder Lever assembly SAPH311991300017 Lever assembly SAPH311991300018 ...

Page 184: ...assembly offset the helical spline by one tooth Pull out the clutch assembly upward from the offset position and remove it 17 Removal of shaft assembly 1 Turn the center bracket assembly upside down Hold the carrier plate and pull out the shaft assembly CAUTION Washers are available at the upper and lower parts of the carrier plate Be careful for loss of the washers SAPH311991300019 Brake plate SA...

Page 185: ...e is no discoloration at the coil 3 Measure the resistance between the coil lead wire and the yoke with a circuit tester and check insulation When the value is below the service limit replace it CAUTION After cleaning and drying take measurements 4 Measure the brush length using vernier calipers When the value is below the service limit replace it Packing SAPH311991300023 SAPH311991300024 Tester r...

Page 186: ...en the commutator and the core using a circuit tester and check insulation When the value is below the service limit replace it CAUTION After cleaning and drying take measurements 5 Measure the commutator outer diameter using vernier calipers When the value is below the service limit replace it CAUTION After removing roughness on the surface after polishing take measurements Commutator outer diame...

Page 187: ...he service limit replace it CAUTION After cleaning and drying take measurements 2 Measure the brush length using vernier calipers When the value is below the service limit replace it 3 Make sure that the spring has pressure Segment Undercut length 0 5 to 0 8 mm 0 0197 0 0315 Insulating material SAPH311991300031 Standard value mm in Service limit mm in 0 5 0 8 0 0197 0 0315 0 2 0 0079 or less A B S...

Page 188: ...cylinder gauge If it is beyond the service limit replace the bushing 2 Measure the bearing metal inner diameter 2 in the figure of the center bracket using a cylinder gauge If it is beyond the service limit replace the center bracket B A SAPH311991300035 Measuring area Standard value mm in Service limit mm in Area 26 1 0236 25 90 1 0197 or less Area 12 1 0 4764 12 04 0 4740 or less SAPH31199130003...

Page 189: ... start magnet switch 8 Inspection of start magnet switch assembly resistance of H coil 1 Measure the H coil resistance between the C terminal and the body using a circuit tester If it is beyond the service limit replace the start magnet switch 9 Inspection of start magnet switch assembly electric continuity inspection 1 Check electric continuity between the B terminal and the M terminal using a ci...

Page 190: ...cket assembly upside down and hold the carrier plate Lubricate parts refer to the lubrication point drawing and the lubrication list and install the shaft assembly CAUTION Washers are available at the upper and lower parts of the carrier plate Be careful for loss of the washers 3 Installation of clutch assembly 1 Lubricate parts refer to the lubrication point drawing and the lubrication list and i...

Page 191: ...assembly using the clutch as the axis 6 Installation of pinion case 1 Install two set bolts at the switch using a box screwdriver or offset wrench Tightening torque 14 16 N m 140 160 kgf cm 10 12 lbf ft 7 Installation of pinion 1 Lubricate parts refer to the lubrication point drawing and the lubrication list and install the pinion and the pinion stopper Brake plate SAPH311991300045 Lever assembly ...

Page 192: ...rnal gear 1 Lubricate parts refer to the lubrication point drawing and the lubrication list and install the internal gear on the center bracket 10 Installation of planetary gear 1 Lubricate parts refer to the lubrication point drawing and the lubrication list and install the planetary gear on the carrier pin Retainer clip Pinion stopper Pinion SAPH311991300014 Shim SAPH311991300013 Internal gear C...

Page 193: ...assembly is installed the washer at the end of the gear may be dropped and lost Be careful for handling 14 Installation of packing 1 Install a new packing on the centering location at both ends of the yoke assembly CAUTION Damaged packing must not be resued Replace it with a new part 15 Installation of yoke assembly 1 Install the yoke assembly on the center bracket assembly Packing Cover SAPH31199...

Page 194: ...end frame 1 Tighten the through bolt of the commutator end frame Tightening torque 15 7 17 6 N m 160 179 kgf cm 12 13 lbf ft 2 Tighten two set bolts Tightening torque 3 6 4 9 N m 37 49 kgf cm 3 4 lbf ft CAUTION Hold the M lead wire and remove the commutator end frame by lifting Brush holder Assembly Brush lead Brush Spring Clamp SAPH311991300005 Through bolt Commutator end frame SAPH311991300003 S...

Page 195: ...d wire 1 Install the M lead wire 19 Lubrication Refer to the following figure and table for lubricant to be applied CAUTION There shall be no lubricant on the commutator surface brush and contact M terminal M lead wire SAPH311991300002 SAPH311991300046 ...

Page 196: ...her Kyodo Yushi 6 Internal gear Multemp AC N 7 11 0 25 0 39 Kyodo Yushi Armature gear Planetary gear 7 Pinion straight Spline Multemp AC N 0 5 1 0 02 0 04 Kyodo Yushi 8 Inner sleeve metal Multemp AC N 0 3 0 6 0 01 0 02 Kyodo Yushi 9 Helical spline Multemp AC N 0 5 1 0 02 0 04 Kyodo Yushi 10 Clutch case lever shifter Pyroknock No 2 1 2 0 04 0 07 Nippon Oil Corporation 11 Bracket rear bearing housin...

Page 197: ...ollar 27330 Rotor assembly 27431 Pulley 27350 End frame assembly 27441 Fan 27353 Rectifier minus 27445A Coupler holder 27356 Rectifier plus 27700 Regulator 27359 End frame 28252 Front bearing 27383 Insulator 28252A Rear bearing 27317 7 8 9 8 N m 80 99 kgf cm 6 7lbf ft 27317C 1 9 2 5 N m 20 25 kgf cm 1 2lbf ft 27317A 1 9 2 5 N m 20 25 kgf cm 1 2lbf ft 27391 127 157 N m 1 300 1 600 kgf cm 94 116lbf ...

Page 198: ...RGING 13 22 Circuit drawing 50A JP31199130803001 Service procedure Overhaul item Alternator Stator coil Feed coil Regulator Diode Capacitor Fuse L Load Starter switch Battery 24V Lamp 1 4 to 3W R P N E SAPH311991300048 ...

Page 199: ... for removal Be careful not to break the tab with excessive force 2 Remove bolts with a screwdriver and remove the coupler holder 3 Remove three through bolts and disconnect the front from the rear 2 Disassembly of front 1 Remove nuts and remove the pulley fan and collar CAUTION Tie around a general V belt in the pulley groove and fix the pulley with a vice SAPH311991300049 SAPH311991300050 SAPH31...

Page 200: ...ON Place jig C at the inner race of the front bearing Removed bearing must not be reused 3 Disassembly of rear 1 Remove solder of the lead wire connecting the stator coil and the diode using a soldering bit and suction line or a solder suction device CAUTION At solder of the stator coil and the diode the end of the diode is clamped Do not damage the diode by prying Deformed diode must not be reuse...

Page 201: ... coil using a soldering bit CAUTION Remove the lead wire of the field coil by raising the terminal of the regulator Perform soldering in a short time within 5 seconds 4 Loosen the nut at the B terminal CAUTION Loosen the nut to some extent and do not remove it from the B terminal SAPH311991300057 SAPH311991300058 Regulator assembly Terminal Lead wire SAPH311991300059 SAPH311991300060 ...

Page 202: ...ve three bolts with a screwdriver and remove the field coil from the rear bracket 8 Remove the roller bearing from the rear bracket using a press jig A and jig B CAUTION Removed bearing must not be reused Inspection procedure item Inspection of components JP31199130703002 CAUTION Place a rubber mat and perform work on the mat 1 Inspection of stator coil and field coil 1 Measure the resistance betw...

Page 203: ...cumference must not be reused 4 Measure the resistance between the core and the coil using a megger tester 2 Inspection of rotor assembly 1 Measure the outer diameter of the shaft at the ball bearing insertion area of the rotor assembly using a micrometer SAPH311991300065 Standard value MΩ 1 or more SAPH311991300066 Standard value Ω 6 4 7 0 SAPH311991300067 Standard value MΩ 1 or more SAPH31199130...

Page 204: ... terminal and the body using a circuit tester Make sure that it indicates 800 kΩ and then immediately indicates infinite value 3 Inspection of regulator Measure the resistance between regulator terminals F and E using a circuit tester Overhaul item SAPH311991300069 Standard value mm in 17 0 6693 Service limit mm in 16 98 0 6685 SAPH311991300070 Standard value Forward resistance value Approx 10 Ω R...

Page 205: ...cover with bolts Tightening torque 1 9 2 5 N m 20 25 kgf cm 1 2 lbf ft 3 Install the rotor assembly using a press CAUTION Be sure to support the inner race of the bearing for press fit of the rotor Do not damage the shaft 4 Install the space collar fan and pulley on the shaft of the rotor assembly Tightening torque 127 157 N m 1 300 1 600 kgf cm 94 116 lbf ft CAUTION Tie around a general V belt in...

Page 206: ...gf cm 2 3 lbf ft CAUTION Tighten bolts finally after temporary tightening Tighten them evenly 3 Assemble the stator coil on the rear bracket temporarily CAUTION Do not damage the stator coil 4 Install parts referring to the part layout Tightening torque 1 9 2 5 N m 20 25 kgf cm 1 2 lbf ft CAUTION Apply screw lock to the ends of the heat sink mounting bolt and the regulator mounting bolt Jig A Roll...

Page 207: ... the stator coil before soldering Perform soldering in a short time within 5 seconds 6 Tighten the nut inside the B terminal Tightening torque 4 9 5 9 N m 50 60 kgf cm 3 6 4 3 lbf ft NOTICE After installation of the alternator connect the wire and tighten the outside nut 3 Joint of front and rear 1 Joint the front with the rear with bolts Tightening torque 7 8 9 8 N m 80 99 kgf cm 6 7 lbf ft CAUTI...

Page 208: ...htening torque 1 9 2 5 N m 20 25 kgf cm 1 2 lbf ft 3 Align the tab and install the cover Fix it with bolts Tightening torque 3 3 4 4 N m 34 44 kgf cm 2 3 lbf ft CAUTION Do not hit the cover because the tab may be broken Inspection procedure item SAPH311991300085 SAPH311991300086 ...

Page 209: ...ith internal parts and if rotation is smooth 2 Measure the resistance between B and E terminals and between P and E terminals using a circuit tester If it is beyond the standard value e g 0 Ω disassemble it again and reassemble the unit correctly SAPH311991300087 SAPH311991300088 Circuit tester lead Standard value B E Approx 20 Ω E B Infinite P E Approx 7 Ω E P Infinite L R N Connector details P B...

Page 210: ......

Page 211: ...TURBOCHARGER 14 1 14 ENGINE 14 TURBOCHARGER Setup layout Layout Turbocharger Assembly 14 2 Part layout 14 2 Inspection 14 3 Replacement 14 6 ...

Page 212: ...ion preventive service List of maintenance inspection 15407 Oil inlet pipe 24109 Gasket 16691 Coolant pipe 24109A Gasket 16691A Coolant pipe 24135 Gasket 17291 Exhaust manifold connector 24135A Gasket 24100 Turbocharger assembly 9654 12100 Gasket 24107 Oil outlet pipe 9659A Gasket 9209A 56 N m 570 kgf cm 41lbf ft SAPH311991400001 ...

Page 213: ...ly and inspection are not allowed 2 Inspection procedure with special tool 1 Remove dial gauge key No 1 loosen the bolt key No 13 of the guide key No 13 and turn the guide key No 2 90 Put the dial gauge into the plate key No 8 which is inspected for axial play and tighten the bolt key No 19 for fixing 2 Insert the guide key No 9 to preventment horizontal movement of the measuring instrument SAPH31...

Page 214: ...ial gauge may come at the center 4 Hold the puller key No 5 and press it toward the turbine in the axial direction Set the dial gauge reading to 0 5 Pull it to the opposite side and measure movement in the axial direction 6 Take three measurements and use the average value as the measurement value SAPH311991400006 0 point adjustment SAPH311991400007 SAPH311991400008 ...

Page 215: ... name Assembly 1 2 3 4 5 6 7 8 9 Tool assembly Gauge dial gauge Guide Stopper Bar Puller Sleeve Plate Plate Guide Key No Part name 10 11 12 13 14 15 16 17 18 19 Stopper Bolt Sleeve Bolt Bolt Bolt Hook Snap ring cotter pin Bar spring Bolt Special Tool Details SAPH311991400009 ...

Page 216: ...turbocharger is installed on the engine or after installation observe the following precautions for work Pay special attention to entry of foreign matter inside the turbocharger Tightening torque 56 N m 570 kgf cm 41 lbf ft Turbocharger to exhaust manifold 2 Lubrication and cooling system a Before installation on the engine pour new engine oil from the oil inlet and turn the turbocharger with hand...

Page 217: ...ilures such as damage due to clogging or loosening of tightened areas c Be sure to install the air feed pipe and the air hose correctly to prevent air leak from connections 4 Exhaust system a Make sure that there is no dirt or foreign matter in the exhaust piping system b Since heat resistant steel is used for bolts and nuts do not mix them with normal bolts for installation ...

Page 218: ......

Page 219: ...ENGINE STATUS 16 1 16 ENGINE 16 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Failure diagnosis Failure diagnosis list FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16 2 Engine mechanical 16 2 Alternator 16 5 Starter 16 6 Turbocharger 16 7 ...

Page 220: ...on ring Wear of piston ring and cylinder liner Replace piston ring and cylinder liner Damage to piston ring Replace piston ring and cylinder liner Faulty fixing of piston ring Replace piston ring and cylinder liner Faulty assembly of piston ring Replace piston ring and cylinder liner Faulty engine oil Replace engine oil Faulty piston ring joint Reassemble piston ring Large engine oil consumption v...

Page 221: ... connection or replace cable Faulty operation of starter Replace starter assembly Faulty start assist unit Replace start assist unit Faulty engine start air cleaner Clogging of air cleaner element Clean or replace air cleaner element Faulty engine start fuel unit Insufficient fuel Replenish fuel and bleed air from fuel system Clogging of fuel system Clean fuel system Air intake from connection of ...

Page 222: ... Replace gasket Damage Replace gasket Replace gasket Replace gasket Gas leak head bolt Loose head bolt Tighten bolt Incorrect tightening sequence or incorrect tightening torque Tighten bolt to correct torque according to the correct tightening sequence Extension of head bolt Replace bolt Gas leak cylinder block Crack Replace cylinder block Distortion of cylinder block upper surface Repair or repla...

Page 223: ...OFF Charge current is always limited Battery goes flat alternator Faulty stator coil disconnection of 1 phase rare shorting Replace stator coil Faulty diode open shorting Replace rectifier Disconnection or poor contact of lead wire plate support etc Repair or replace lead wire Lamp is OFF Charge current is always limited Battery goes flat operation load Operation load is large Load balance is poor...

Page 224: ...ding wire is disconnected Be sure to connect it Use of incorrect engine oil Replace with correct oil Faulty contact of start magnet switch assembly Replace start magnet switch assembly Faulty contact or failure of starter relay Replace starter relay Wear of starter brush Replace brush Seizure of commutator Repair commutator Wear of commutator Undercut Shorting of armature Replace armature assembly...

Page 225: ...l Seizure of bearing Balance of revolving body is poor Replace or clean revolving part Seizure of bearing insufficient warm up or sudden stop from loaded operation Unloaded operation Observe the precautions strictly in the operation manual Contact of or damage to turbine shaft and blower impeller excessive operation Check and repair engine parts Contact of or damage to turbine shaft and blower imp...

Page 226: ...engine output Gas leak from exhaust system parts Check and repair faulty areas Air leak from blower outlet Check and repair faulty areas Clogging of air cleaner element Clean or replace air cleaner element Contamination of or damage to turbocharger Replace turbocharger Acceleration follow up of turbocharger is poor slow Carbon deposit at the turbine disc sealing area makes revolution of the turbin...

Page 227: ...the turbocharger mounting status and repair faulty areas Failure of metal contact between revolving part and peripheral parts or damage to the blower impeller of the turbine rotor due to entry of foreign matter is found Replace turbocharger Remove foreign matter completely if any Balance of revolving body is poor Replace revolving body Status Cause Action ...

Page 228: ......

Page 229: ...n rail pressure sensor malfunction DTC code P0192 P0193 17 24 Accelerator sensor 1 malfunction DTC code P2122 P2123 17 26 Accelerator sensor 2 malfunction DTC code P2127 P2128 17 28 Accelerator sensor 1 and 2 malfunction DTC code P2120 17 30 Emergency accelerator sensor malfunction DTC code P1133 17 31 Atmospheric pressure sensor malfunction DTC code P2228 P2229 17 33 Injector common 1 ground shor...

Page 230: ...minals are damaged or short circuited Delete the past failure memory after recording Perform failure diagnosis again to check current failure After failure analysis delete the past failure memory If the past failure memory is not deleted the failure indicator lamp remains ON All connector drawings are viewed from the connecting surface Place the tester rod from the back System drawing System drawi...

Page 231: ...l temperature sensor Supply pump Injector drive signal Key switch signal Starter signal Fuse Fuse Main relay ACT Relay Each Sensor Power Supply pump drive signal Supply pump control valve drive signal S P INPUT Others Glow relay Supply pump Accelerator signal 1 2 Diagnosis switch Accelerator sensor for operation Engine speed main sensor Engine speed sub sensor Battery I F Diagnosis tool PC Diagnos...

Page 232: ...which installed HinoDX through the interface box Special tool 09121 1040 Hino Bowie Interface box 09042 1220 Connecting cable CD ROM HinoDX 2 Deletion method of past failure 1 To delete past failures of the engine ECU use HinoDX on the PC Refer to HinoDX operation manual Failure diagnosis List of failure diagnosis Engine ECU Failure diagnosis connector SAPH311991700003 Failure diagnosis connector ...

Page 233: ...put LOW idle 800rpm fixing b DTC code indication P2120 Accelerator sensor 1 and 2 malfunction 17 30 a Low output b DTC code indication P0217 Engine overheat 17 17 a Difficult to start engine b DTC code indication P0540 Preheat circuit malfunction 17 46 a Low output b DTC code indication P0234 Turbocharger over boost 17 21 P0088 Excessive common rail pressure 17 21 P0088 Excessive common rail press...

Page 234: ...ector correction data conformity error 17 47 P2228 Atmospheric pressure sensor circuit low input 17 33 P2229 Atmospheric pressure sensor circuit high input 17 33 P2635 Supply pump SCV sticking 17 45 P2635 Supply pump malfunction 17 45 a Other problems b DTC code indication P0182 Fuel temperature sensor circuit low input 17 18 P0183 Fuel temperature sensor circuit high input 17 18 P0340 Engine spee...

Page 235: ...ault 17 41 P0266 Cylinder 2 contribution balance fault 17 41 P0269 Cylinder 3 contribution balance fault 17 41 P0272 Cylinder 4 contribution balance fault 17 41 P0617 Starter signal malfunction 17 49 P2635 Supply pump abnormal pressure record 17 45 U1001 Interruption of CAN communication unit a Failure diagnosis and b Alarm display alarm status DTC code Estimated failure cause Page ...

Page 236: ...heck harness to prevent damage to the connector Place the tester rod on the contact box of the signal check harness for measurement NOTICE Terminal numbers in the text and the illustrations correspond as shown below in the Computer pin arrangement ECU terminal name Example For A8 terminal ECU terminal number Signal check harness contact box SAPH311991700006 ...

Page 237: ... and disconnect the connector from the engine ECU 2 Connect the signal check harness to the engine ECU and the unit harness Special tool Signal check harness 09049 1080 Specification performance Wiring diagram Unit harness Signal check harness Test lead Signal check connector SAPH311991700007 ...

Page 238: ...ENGINE DIAGNOSIS CODE 17 10 Computer pin arrangement JP31199170201001 Failure diagnosis Failure diagnosis list SAPH311991700008 ...

Page 239: ...F and connect the signal check harness 2 Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals D1 E4 E5 and the terminal of the battery Standard value 1 Ω or less NG OK 1 Measurement of voltage between terminals 㧭 㧱 㧰 SAPH311991700009 0 V Blown fuse harness failure ground failure etc 20 V or less Battery deterioration ground failure etc Normal 1...

Page 240: ...l B7 Standard value Approx 125 5 17 Ω 20 C 68 F NG OK 1 Connect the ECU side connector of the signal check harness After deleting the past failure Start the engine and confirm that no diagnostic code is put out Standard No diagnostic code NG OK 1 Measurement of resistance between terminals B B6 B7 SAPH311991700011 3 Go to measurement of resistance between sensor terminals 2 Check of diagnosis code...

Page 241: ...speed sensor and measure the resistance between No 1 and No 2 terminals at the sensor Standard value Approx 125 5 17 Ω 20 C 68 F NG OK 3 Measurement of resistance between terminals SAPH311991700013 Failure of main engine speed sensor Harness disconnection or connector failure ...

Page 242: ...D terminal of the sub speed sensor connector at unit harness side Standard value 5 0 0 5 V NG OK 1 Measure voltage between terminal D32 and terminal D30 of the signal check harness Standard value 5 0 0 5V NG OK 1 Measurement of voltage between sensor terminals 5V GND SAPH311991700014 2 Go to measurement of voltage between terminals 3 Go to measurement of voltage between terminals 2 Measurement of ...

Page 243: ...e sub speed sensor in the figure is viewed from the fitting surface Standard value 2 Ω or less NG OK Engine speed main and sub sensor circuit malfunction DTC code P0335 JP31199170601006 1 Inspection item 1 Take actions of DTC code P0335 and DTC code P0340 Reference Engine speed main sensor circuit malfunction DTC code P0335 Engine ECU Engine diagnosis code Reference Engine speed sub sensor circuit...

Page 244: ...t temperature sensor and measure the resistance between No 1 and No 2 terminals at the sensor Standard value Measure either one point of the following 2 45 kΩ Coolant temperature at 20 C 68 F 1 15 kΩ Coolant temperature at 40 C 104 F 584 Ω Coolant temperature at 60 C 140 F 318 Ω Coolant temperature at 80 C 176 F NG OK DTC P0117 Coolant temperature sensor circuit low input DTC P0118 Coolant tempera...

Page 245: ...lume is restricted When the coolant temperature is 80 C 176 F or less normal control is resumed NG OK Engine overrun DTC code P0219 JP31199170601009 1 This failure code is displayed when the engine speed of 2 600 r min or more is detected While this failure code is detected fuel injection is stopped When the engine speed is lower than 2 500 r min fuel injection is resumed NOTICE The objective of t...

Page 246: ...r of the fuel temperature sensor and measure the resistance between No 1 and No 2 terminals at the sensor Standard value Measure either one point of the following 2 45 kΩ Fuel temperature at 20 C 68 F 1 15 kΩ Fuel temperature at 40 C 104 F 584 Ω Fuel temperature at 60 C 140 F 318 Ω Fuel temperature at 80 C 176 F NG OK DTC P0182 Fuel temperature sensor circuit low input DTC P0183 Fuel temperature s...

Page 247: ...it harness side Standard value 5 0 5 V NG OK 1 Measure the voltage between terminal D25 and terminal D33 of the signal check harness Standard value 5 0 5 V NG OK DTC P0108 Boost pressure sensor circuit high input DTC P0237 Boost pressure sensor circuit low input 1 Measurement of voltage between sensor terminals GND 5V SAPH311991700022 2 Go to measurement of voltage between terminals 3 Go to measur...

Page 248: ...or of the boost pressure sensor connected 2 Measure the voltage between the SIG terminal and the GND terminal of the boost pressure sensor connector at unit harness side Standard value 0 2 to 4 8 V NG OK 3 Measurement of voltage between terminals D D27 D33 SAPH311991700024 4 Go to measurement of voltage between terminals Engine ECU failure ECU connector failure 4 Measurement of voltage between sen...

Page 249: ...13 1 Set the starter key to OFF and connect the signal check harness 2 Set the starter key to ON and measure the voltage between terminals D20 D31 and terminal D33 of the signal check harness Standard value 3 6 to 4 7 V NG OK 1 Inspection with failure diagnosis tool SAPH311991700026 Perform diagnosis of the boost pressure sensor DTC code P0108 P0237 1 Measurement of voltage between terminals D D33...

Page 250: ... make sure again that DTC code P0088 is output In particular if a failure code of the main and sub engine speed sensor systems is output make necessary repairs to prevent output of the code 2 Check the fuel injection timing of the supply pump If the timing is not set 0 for the top dead center set it correctly 3 When there is no error after the check above delete the past failure using the PC diagn...

Page 251: ... While measuring the voltage between terminals D20 D31 and terminal D33 of the signal check harness repeat full opening closing of the accelerator Standard Voltage must change 1 0 to 3 2 V NG OK 1 Measurement of voltage between terminals D D33 D31 D20 SAPH311991700029 Engine ECU failure or harness connector contact failure 2 Measurement of voltage between terminals 㧰 D33 D31 D20 SAPH311991700030 C...

Page 252: ... pressure sensor 2 Set the starter key to ON and measure voltage between the 5V terminal and the GND terminal of the common rail pressure sensor connector at unit harness side Standard value 5 0 5 V NG OK DTC P0192 Common rail pressure sensor circuit low input DTC P0193 Common rail pressure sensor circuit high input 1 Measurement of voltage between terminals D D20 D31 D33 SAPH311991700031 2 Go to ...

Page 253: ...tance between terminals D24 of the signal check harness and the 5 V terminal of the common rail pressure sensor connector at unit harness side Standard value 2 Ω or less 3 Measure the resistance between terminal D33 of the signal check harness and the GND terminal of the common rail pressure sensor connector at unit harness side Standard value 2 Ω or less NG OK 3 Measurement of resistance between ...

Page 254: ...sure the voltage between terminal A21 and terminal B20 of the signal check harness Standard value NG OK DTC P2122 Accelerator sensor circuit 1 low voltage DTC P2123 Accelerator sensor circuit 1 high voltage 1 Measurement of voltage between terminals B20 A21 SAPH311991700036 3 Voltage measuring at the output port of the mechatronic controller 2 Measurement of voltage between terminals B20 A21 SAPH3...

Page 255: ...troller and B21 of the signal check harness When an abnormal value is detected the mechatronics controller becomes defective Abnormal value 0 3 V or less 4 85 V or more NG OK 3 Voltage measuring at the output port of the mechatronic controller Engine ECU failure ECU connector failure or disconnection of harness short circuit of harness Defective mechatronic controller ...

Page 256: ... the voltage between terminal A22 and terminal B21 of the signal check harness Standard value NG OK DTC P2127 Accelerator sensor circuit 2 low voltage DTC P2128 Accelerator sensor circuit 2 high voltage 1 Measurement of voltage between terminals 㧭 㧮 A22 B21 SAPH311991700037 3 Voltage measuring at the output port of the mechatronic controller 2 Measurement of voltage between terminals 㧭 㧮 A22 B21 S...

Page 257: ...troller and B21 of the signal check harness When an abnormal value is detected the mechatronics controller becomes defective Abnormal value 0 3 V or less 4 85 V or more NG OK 3 Voltage measuring at the output port of the mechatronic controller Engine ECU failure ECU connector failure or disconnection of harness short circuit of harness Defective mechatronic controller ...

Page 258: ...DTC code P2120 JP31199170601019 1 Take action of DTC code P2120 Reference Accelerator sensor 1 malfunction DTC code P2122 P2123 Engine ECU Engine diagnosis code Reference Accelerator sensor 2 malfunction DTC code P2126 Engine ECU Engine diagnosis code 1 Inspection item ...

Page 259: ...n the figure is seen from the fitting surface Standard value 5 0 0 5 V NG OK 1 Measure the voltage between terminals B20 and B23 of the signal check harness Standard value 5 0 0 5 V NG OK 1 Power supply voltage measuring GND 5V SAPH311991700038 2 Go to measurement of voltage between terminals 3 Go to measurement of voltage between terminals 2 Measurement of voltage between terminals 㧮 B23 B20 SAPH...

Page 260: ...measure the voltage between the terminals SIG and GND of the sensor CAUTION The connector in the figure is seen from the fitting surface Standard value Approx 0 0 to 3 2 V idle to full throttle NG OK 3 Measurement of voltage between terminals B20 A23 SAPH311991700040 4 Go to measurement of voltage between terminals Engine ECU failure engine ECU connector failure 4 Measurement of voltage between se...

Page 261: ...g PC check again if the same code DTC code P2228 P2229 is output Standard Normal NG OK DTC P2228 Atmospheric pressure sensor circuit low input DTC P2229 Atmospheric pressure sensor circuit high input 1 Check of diagnosis code SAPH311991700026 Engine ECU failure Since it may be a temporary malfunction due to radio interference it is acceptable when the system recovers normal operation ...

Page 262: ...and connect the ECU side connector of the signal check harness 2 Start the engine and delete the past failures with the failure diagnosis tool HinoDX using PC 3 If the same failure code is output again replace the engine ECU If the normal code is output it is considered that a temporary error has occurred 1 Measurement of resistance between terminals D E ECU case ground ECU mounting bolt D6 D5 E7 ...

Page 263: ...ard value Ω NG OK 3 Measurement of resistance between injector terminals 9 5 11 3 4 7 8 1 2 10 6 12 SAPH311991700043 DTC code Terminal to measure resistance side side P1211 5 6 10 12 ECU case ground P1214 2 4 7 8 ECU case ground Harness failure failure including pinching of harness which has not satisfied the standard value Inspection of harness inside head cover Short circuit of the harness insid...

Page 264: ...ic shock Standard value 14 V or less NG OK 1 Set the starter key to OFF and connect the ECU side connector of the signal check harness 2 Start the engine and delete the past failures with the failure diagnosis tool HinoDX using PC 3 If the same failure code is output again replace the common rail ECU If the normal code is output it is considered that a temporary error has occurred 1 Measurement of...

Page 265: ...ine because it may cause failure of the unit or electric shock Standard value 14 V or less NG OK 3 Measurement of voltage between injector terminals 9 5 11 3 4 7 8 1 2 10 6 12 SAPH311991700043 DTC code Terminal to measure voltage side side 1212 5 6 ECU case ground 1215 7 8 ECU case ground Harness failure harness failure of terminal that has not satisfied the standard value Inspection of harness in...

Page 266: ...ool HinoDX using PC 3 If the same failure code is output again replace the common rail ECU If the normal code is output it is considered that a temporary error has occurred DTC P0201 Injector circuit malfunction cylinder 1 DTC P0202 Injector circuit malfunction cylinder 2 DTC P0203 Injector circuit malfunction cylinder 3 DTC P0204 Injector circuit malfunction cylinder 4 1 Measurement of resistance...

Page 267: ...the No 1 terminal and the No 2 terminal Standard value 0 45 0 05 Ω NG OK 3 Measurement of resistance between injector terminals 1 2 3 4 5 6 7 8 9 10 11 12 SAPH311991700046 DTC code Terminal to measure resistance P0201 5 10 P0202 7 11 P0203 3 8 P0204 2 6 4 Go to measurement of resistance between injector terminals unit harness disconnection Check the harness between the ECU and the injector cluster...

Page 268: ...ode and measure the insulation resistance between the terminal and the upper body Standard value 1 000 MΩ or more NG OK 5 Measurement of resistance between injector terminals SAPH311991700048 Injector TWV coil disconnection Replace the injector assembly Injector harness disconnection Replace the injector harness ...

Page 269: ... Remove the flow damper from the common rail and run air from one side of the flow damper Check if the damper is not blocked by release of air to the opposite side CAUTION When air is run be careful so that dirt water etc may not enter the flow damper Standard value Air must flow Flow damper is normal NG OK DTC P0263 Cylinder 1 contribution balance fault DTC P0266 Cylinder 2 contribution balance f...

Page 270: ...o increase of leak inside inside the injector Check for leak on the individual injector with a nozzle tester Excessive fuel flow due to failure of injection nozzle and seat Check for seat failure on the individual injector with a nozzle tester Too large or too small fuel flow due to malfunction of the injector Check with replacement of injector Too small fuel flow due to clogging in the fuel suppl...

Page 271: ...11 of the signal check harness and the No 1 terminal of the supply pump solenoid valve at unit harness side In a similar manner measure the resistance of terminals E8 E9 of the signal check harness and the No 2 terminal of the supply pump solenoid valve connector at unit harness side Standard value 1 Ω or less NG OK DTC P0628 Supply pump SCV malfunction Full discharge mode DTC P0629 Supply pump SC...

Page 272: ... E4 and terminals E8 E9 of the signal check harness Standard value Pulse waveform at 24V 0V NG OK CAUTION After turning ON the starter key take measurements within 40 seconds 3 Measurement of voltage between terminals E E9 E4 E8 SAPH311991700053 Failure of ECU connector Engine ECU failure ...

Page 273: ...peat no load operation from LOW idle to HI idle two or three times and confirm that the same fault code is displayed again NG OK 1 Make sure that other failure code is not output If other failure code is output repair the failure code and make sure again that DTC code P2635 is output 2 When there is no error after the check above delete the past failure and operate the engine If the same code is o...

Page 274: ...terminals C1 C2 and terminals D1 E4 E5 Standard value 25 2 5 Ω NG OK 1 Remove the heater relay and measure the resistance between terminals Standard value 24 8 0 5 Ω NG OK 1 Measurement of resistance between terminals C E D C1 C2 E5 E4 D1 SAPH311991700055 2 Go to measurement of resistance between terminals Engine ECU failure ECU connector failure 2 Measurement of relay resistance SAPH311991700056 ...

Page 275: ...arter key to OFF and set it to ON again 2 After deleting the past failure check if the same code DTC code P0605 P0606 P0607 is output again Standard Normal NG OK 1 Inspection of QR code SAPH311991700026 Write the QR code again Replace engine ECU DTC P0605 Flash ROM error DTC P0606 CPU malfunction Hard detection DTC P0607 Monitoring IC malfunction in CPU 1 Check of diagnosis code SAPH311991700026 E...

Page 276: ...eting the past failure check if the same code DTC code P0611 P0200 is output again Standard Normal NG OK DTC P0200 ECU charge circuit high input DTC P0611 ECU charge circuit malfunction 1 Check of ECU SAPH311991700026 Engine ECU failure Since it may be a temporary malfunction due to radio interference it is acceptable when the system recovers normal operation ...

Page 277: ... connect the signal check harness 2 Disconnect the ECU side connector of the signal check harness and set the starter key to ON 3 Measure voltage between terminal B14 and terminals C3 C4 CAUTION Measuring shall be done in an environment where the engine may be started Standard value 0 V when starter key is at OFF 24 V when starter key is at START NG OK 1 Measurement of voltage between terminals A ...

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