Hino S5-LJ05E04A Workshop Manual

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FOREWORD

This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.

Applicable for J05E engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.

As for maintenance items, refer to the Owner's Manual.

All information and specifications in this manual are based upon the latest product information available at the time of printing.

Hino Motors Sales U.S.A. , Inc. reserves the right to make changes at any time without prior notice.

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Summary of Contents for Hino S5-LJ05E04A

Page 1 As for maintenance items, refer to the Owner’s Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A. , Inc. reserves the right to make changes at any time without prior notice.
Page 2 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular truck. MANUAL NO. S5-LJ05E04A (U.S.A.), S5-LJ05E05A (CANADA) CHAPTER MODEL J05E GENERAL INTRODUCTION 1-001 STANDARD VALUE 2-001 REQUIRED ITEMS 3-001 MOUNTING AND DISMOUNTING THE ENGINE...
Page 3 EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION SPEED CONTROL SYSTEM IGNITION STARTING/CHARGING TURBOCHARGER All rights reserved. This manual may not be reproduced or copied in whole in part, with- AIR COMPRESSOR out the written consent of Hino Motors, Ltd.
Page 4 INDEX: ENGINE GROUP 2/2 ENGINE PTO (POWER TAKE-OFF)
Page 5: Table Of Contents
GENERAL INTRODUCTION 1–1 GENERAL INTRODUCTION 1-001 HOW TO IDENTIFY VEHICLE TYPE ......1-2 VEHICLE MODEL ...........1-2 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ............1-3 APPEARANCE OF VEHICLE ........1-4 APPEARANCE OF VEHICLE .........1-4 SAFETY INSTRUCTIONS AND READINESS TO WORK..............1-5 WARNING ...............1-5 IDENTIFICATION INFORMATION ......1-9 SAFETY INSTRUCTIONS FOR WORK....1-12 INTRODUCTION TO WORKSHOP MANUAL..1-15 TIGHTENING OF BOLTS AND NUTS ....1-19...
Page 6: How To Identify Vehicle Type
1–2 GENERAL INTRODUCTION GENERAL INFORMATION HOW TO IDENTIFY VEHICLE TYPE VEHICLE MODEL EN01F01ZZZ000102001001 REPORTED MODEL CLASSIFICATION ENGINE MODEL VEHICLE MODEL DECK HEIGHT HEAVY DUTY TRACK J05E-UG (HV) K HIGH FLOOR J05E-TP (Diesel) CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE TRANSMISSION CAB WIDTH DRIVE FRAME WHEEL BASE...
Page 7: Vehicle Identification Number (Vin) Structure
GENERAL INTRODUCTION 1–3 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE EN01F01ZZZ000102001002 SHTS01ZZZ0000002...
Page 8: Appearance Of Vehicle
1–4 GENERAL INTRODUCTION APPEARANCE OF VEHICLE APPEARANCE OF VEHICLE EN01F01ZZZ000102002001 SHTS01ZZZ0000003...
Page 9: Safety Instructions And Readiness To Work
Improper or incomplete work can cause a mal- function of the vehicle which may result in personal injury and/or property damage. If you have any question about per- forming maintenance, please consult your Hino dealer. WARNING...
Page 10 1–6 GENERAL INTRODUCTION PRECAUTIONS IN TILTING AND LOWERING THE CAB ! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage. •...
Page 11 GENERAL INTRODUCTION 1–7 TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No.
Page 12 1–8 GENERAL INTRODUCTION At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service.
Page 13: Identification Information
A: Vehicle Identification Number (VIN) B: Manufacturer's Label See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page. SHTS01ZZZ0000010 PRODUCTION CODE AND VEHICLE COMPONENTS MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5) XJC700 XJC700 XFC710...
Page 14 1–10 GENERAL INTRODUCTION VEHICLE NOISE EMISSION CONTROL INFORMATION • The Vehicle Noise Emission Control Information is affixed to the left pillar of the cab. The name of manufacturer, production year FOR ALL MODELS and month, and noise emission applicable to medium and heavy trucks in conformity with U.S.
Page 15 GENERAL INTRODUCTION 1–11 EXEMPTION LABEL FOR US GHG REGULATION HINT Exemption label fuel economy comes in paste right side of the front passenger seat. However, this label is limited to one year. EXEMPTION LABEL SHTS01ZZZ0000015...
Page 16: Safety Instructions For Work
"LOCK" position. In this case, use HINO-DX to clear the DTC (P204F and P068A), to turn off the MIL and to conduct DPR regeneration manually.
Page 17 GENERAL INTRODUCTION 1–13 Handling of wire harness a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not inter- fere with the end and acute angle section of the body and a bolt. b.
Page 18 1–14 GENERAL INTRODUCTION Installation of battery disconnect switch ! WARNING • Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF- SCR (DCU) may damage or result in the malfunction of DEF-SCR system. •...
Page 19: Introduction To Workshop Manual
GENERAL INTRODUCTION 1–15 INTRODUCTION TO WORKSHOP MANUAL EN01F01ZZZ000102003004 GENERAL SCOPE OF REPAIR DESCRIPTIONS There are three major processes in repair work: i.e. "troubleshooting," "removal/installation, replacement, overhaul, assembly, inspection and adjustment" and "final inspection". This document covers only the first process (troubleshooting) and the second process (removal/installation, replace- ment, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).
Page 20 1–16 GENERAL INTRODUCTION INTRODUCTION TO DESCRIPTIONS COMPONENT LOCATOR Alphabetical mark indicating the tightening torque in the following tightening torque table Numerical order indicating the part name in the following part name table Numerical order Part name table Part name Tightening torque table Tightening torque Alphabetical mark SHTS01ZZZ0000021...
Page 21 GENERAL INTRODUCTION 1–17 WORK STEPS Indicating the work sequence Descriptive text: Indicating the work method which is gone into detail Indicating the part number of SST required for work SHTS01ZZZ0000022...
Page 22 1–18 GENERAL INTRODUCTION DEFINITION OF TERM Terms used in this document are defined as follows. DIRECTION CHASSIS RELATED Longitudinal direction a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the installed position in a vehicle.
Page 23: Tightening Of Bolts And Nuts
GENERAL INTRODUCTION 1–19 TIGHTENING OF BOLTS AND NUTS EN01F01ZZZ000102003005 BOLTS AND NUTS More than hundreds of bolts/nuts are used in a vehicle and improper handling of them will cause damage and looseness. Because tightening torque varies depending on tightening condition, strength class, and surface treatment, etc., make sure to check the types and tightening torques of bolts/nuts and use them properly.
Page 24 1–20 GENERAL INTRODUCTION TYPES AND IDENTIFICATION There are three types of bolts and nuts. Standard (w/o flange) • Bolts/nuts without flange SHTS01ZZZ0000023 With old flange (w/grooves) • Flange is small and has grooves on its back. GROOVES GROOVES FLANGE OUTER DIAMETER SHTS01ZZZ0000024 With new flange (w/o grooves) •...
Page 25 GENERAL INTRODUCTION 1–21 Comparison of flange outer diameters Bolt With old flange With new flange With old flange With new flange Thread (w/grooves) (w/o grooves) (w/grooves) (w/o grooves) diameter Flange Flange Flange Flange Strength Strength Strength Strength outer outer outer outer class class...
Page 26 1–22 GENERAL INTRODUCTION STRENGTH CLASSES AND SYMBOLS With old flange (w/grooves) Bolt Symbols Strength Strength Symbols class class Carbon steel Boron steel — With new flange (w/o grooves) Bolt Symbols Strength Strength Symbols class class Carbon steel Boron steel 10.9...
Page 27 GENERAL INTRODUCTION 1–23 PART NO. Standard (w/o flange) Bolt Thread Strength Surface Strength Surface diameter Part No. Part No. class treatment class treatment SH111-**** Plating SL113-00807 Plating SH112-**** Plating SH111-**** Plating SL113-01008 Plating SH112-**** Plating SH111-**** Plating SL113-01210 Plating SH112-**** Plating SH112-**** Plating...
Page 28 1–24 GENERAL INTRODUCTION With new flange (w/o grooves) Bolt Thread Strength Surface Strength Surface diameter Part No. Part No. class treatment class treatment 91551-808** Plating 94151-80800 Plating 10.9 91551-008** Plating 91552-E10** Neotorquer 94151-81001 Neotorquer 10.9 91552-F10** Neotorquer 91552-E12** Neotorquer 94151-81201 Neotorquer 10.9 91552-F12**...
Page 29 GENERAL INTRODUCTION 1–25 With old flange (w/grooves) Unit: Nm {kgfcm, lbfft} Thread diameter Strength classes Tightening Torque 22.04.0 {22445, 16.22.9} 29.05.5 {29656, 23.14.0} 51.510.0 {525101, 37.97.3} 68.513.5 {698137, 50.59.9} 91.018.0 {927183, 67.013.2} 120.024.0 {1,223224, 88.417.6} With new flange (w/o grooves) Unit: Nm {kgfcm, lbfft} Thread diameter Strength classes...
Page 30 1–26 GENERAL INTRODUCTION TIGHTENING OF ENGINE BOLTS AND NUTS TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS Representative tightening torque for shouldered bolts Unit: Nm {kgfcm, lbfft} Thread diameter X pitch M8 X 1.25 (coarse thread) 28.5 {290, 21} 36 {370, 27} M10 X 1.25 (fine thread) 60 {610, 44} 74.5 {760, 55}...
Page 31 GENERAL INTRODUCTION 1–27 PRECOAT BOLT Reapply locking agent if: a. a precoat bolt has been removed, or b. a precoat bolt has been turned during a tightening check or other activities. (loosened or tightened) HINT • A precoat bolt is a bolt of which threads are applied with seal locking agent. •...
Page 32 1–28 GENERAL INTRODUCTION TIGHTENING OF FLARE NUTS AND HOSES TIGHTENING TORQUE FOR PIPE FLARE NUTS HINT Steel pipes and copper pipes (excluding power steering pipe). Unit: Nm {kgfcm, lbfft} Outer diameter 4.76 6.35 8 10 12 15 of pipe Brake:15 Clutch:24 {153,11} {245,18}...
Page 33: Handling Of Liquid Gasket
GENERAL INTRODUCTION 1–29 HANDLING OF LIQUID GASKET EN01F01ZZZ000102003006 LIQUID GASKET PROCEDURES FOR APPLYING LIQUID GASKET AND ASSEMBLING PARTS Thoroughly remove old liquid gasket remaining on individual parts and mating parts. Use clean cloth to remove oil, moisture, dirt or other contaminants. Make sure to overlap the start and end points of liquid gasket.
Page 34: Glossary
1–30 GENERAL INTRODUCTION GENERAL INFORMATION GLOSSARY DEFINITION OF ABBREVIATION IN THIS MANUAL EN01F01ZZZ000102006001 LIST OF ABBREVIATION Abbreviations Meaning, or Official Name Air Conditioner Anti-lock Brake System Accessory Automated Manual Transmission After Turbo Catalyst Automatic Transmission Fluid Crank Angle Controller Area Network CD-ROM Compact Disc Read Only Memory Central Processing Unit...
Page 35 Meaning, or Official Name Front Fiber Reinforced Plastic Front Underrun Protector Glow Control Unit Ground Gross Vehicle Weight High HINO-DX HINO Diagnostic eXplorer Hybrid Vehicle HVAC Heating, Ventilating and Air-Conditioning unit I.S.C. Idle Speed Control Integrated Circuits Identification Intelligent Power Device...
Page 36 1–32 GENERAL INTRODUCTION Abbreviations Meaning, or Official Name Particulate Matter Glass-fiber-reinforced Polypropylene Parts Per Million PS pump Power Steering Pump Power Take-Off Physical Vapor Deposit Power QR code Quick Response Code Rear Axle Right Hand Selective Catalytic Reduction Special Service Tool Switch Transmission...
Page 37 GENERAL INTRODUCTION 1–33 GLOSSARY OF SAE AND HINO TERMS This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents. SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS AUTOMATIC TRANSMISSION...
Page 38 1–34 GENERAL INTRODUCTION SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS ENGINE COOLANT TEMPERATURE Coolant Temperature ENGINE COOLANT TEMPERATURE Water Temperature ENGINE FUEL TEMPERATURE Fuel temperature EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor EXHAUST GAS RECIRCULATION EGR Valve EXHAUST GAS RECIRCULATION Valve...
Page 39 GENERAL INTRODUCTION 1–35 SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS PARK/NEUTRAL POSITION Neutral position PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch RAIL FUEL PRESSURE Common rail Pressure RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor SPARK PLUG SPARK PLUG...
Page 40: Lubricants
LUBRICANTS Integral power steering gear HINO GENUINE SERIES Power steering fluid or ATF DEXRON Brake HINO GENUINE SERIES Brake and clutch fluid or Brake fluid (DOT-3) Wheel bearing HINO GENUINE SERIES Bearing grease or Bearing Propeller shaft grease (NLGI No.2 LITHIUM-SOAP)
Page 41 STANDARD VALUE (J05E) 2–1 STANDARD VALUE (J05E) 2-001 MOUNTING AND DISMOUNTING THE ENGINE ..2-3 CYLINDER LINER ..........2-21 ENGINE ASSEMBLY ..........2-3 CYLINDER BLOCK..........2-21 ENGINE MOUNTING AND BRACKET ....2-21 ENGINE CONTROL .............2-4 GLOW PLUG............2-21 ENGINE ECU............2-4 ENGINE SPEED MAIN SENSOR ......2-4 EXHAUST ..............2-23 ENGINE SPEED SUB SENSOR......2-4 EXHAUST MANIFOLD..........2-23 IDLE SET VOLUME ..........2-4...
Page 42 2–2 STANDARD VALUE (J05E) STARTING/CHARGING..........2-35 STARTER ..............2-35 V-BELT ..............2-35 ALTERNATOR (130 A) ..........2-36 TURBOCHARGER .............2-37 TURBOCHARGER ASSEMBLY ......2-37...
Page 43: Mounting And Dismounting The Engine
STANDARD VALUE (J05E) 2–3 BASIC VALUE MOUNTING AND DISMOUNTING THE ENGINE ENGINE ASSEMBLY EN01F02127010701001001 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Permissible limit Action 3.0 MPa 2.7 MPa Compression pressure {31 kgf/cm {28 kgf/cm Overhaul (Per cylinder: Engine revolution 190 r/min) 435 lbf/in 392 lbf/in.
Page 44: Engine Control
2–4 STANDARD VALUE (J05E) ENGINE CONTROL ENGINE ECU EN01F02127010701002001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Engine ECU mounting bolt 28.5 {290, 21} ENGINE SPEED MAIN SENSOR EN01F02127010701002002 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Engine speed main sensor mounting bolt...
Page 45: Accelerator Pedal
STANDARD VALUE (J05E) 2–5 ACCELERATOR PEDAL EN01F02127010701002005 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Accelerator fully-closed 0.6-1.0 V Replace Accelerator sensor 1 output volt- Accelerator fully open 2.8-3.6 V Replace Accelerator fully-closed 1.4-1.8 V Replace Accelerator sensor 2 output volt- Accelerator fully open 3.6-4.4 V Replace...
Page 46: Fuel System
2–6 STANDARD VALUE (J05E) FUEL SYSTEM FUEL TANK EN01F02127010701003001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Fuel tank drain plug 24.5-34.3 {250-349, 19-26} Fuel tank bracket mounting bolt 96-144 {979-1,468, 71-106} For 30 gallon Fuel tank band 10.2-15.0 {105-152, 8-11} For 33 gallon FUEL SENDER GAUGE...
Page 47: Engine-Side Fuel Filter & Case
STANDARD VALUE (J05E) 2–7 ENGINE-SIDE FUEL FILTER & CASE EN01F02127010701003003 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Fuel filter drain plug 5-9 {51-91, 3.7-6.6} Fuel filter air bleeding plug 5-9 {51-91, 3.7-6.6} Fuel filter center bolt 23.1-32.9 {236-335, 18-24} Fuel filter mounting bolt 55 {561, 41}...
Page 48: Supply Pump
2–8 STANDARD VALUE (J05E) SUPPLY PUMP EN01F02127010701003005 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Resistance between terminals of 1.6-2.6  20C {68F} Replace suction control valve –20C {–4F} 13.84-16.33 k Replace 20C {68F} 2.32-2.59 k Replace Resistance between terminals of combustion temperature sensor 80C {176F} 0.310-0.326 k...
Page 49: Common Rail
STANDARD VALUE (J05E) 2–9 COMMON RAIL EN01F02127010701003007 STANDARD VALUE, LIMIT AND ACTION Standard value Inspection item Action (At 20 C {68 F}) 12 Replace 1.05-3.55 k 56 Replace Resistance between terminals of common rail pressure sensor 23 Replace 6.7-18.7 k 45 Replace TIGHTENING TORQUE...
Page 50: Emission Control
2–10 STANDARD VALUE (J05E) EMISSION CONTROL EGR VALVE & COOLER EN01F02127010701004001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks EGR cooler mounting bolt 68.5 {699, 51} Bracket mounting bolt 28.5 {291, 21} EGR pipe mounting bolt 55 {561, 41} Bracket mounting bolt and nut 28.5 {291, 21} CLOSED VENTILATOR...
Page 51: Intake
STANDARD VALUE (J05E) 2–11 INTAKE INTAKE MANIFOLD EN01F02127010701005001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Intake manifold mounting bolt and nut 28.5 {291, 21} DIESEL THROTTLE EN01F02127010701005002 TIGHTENING TORQUE Unit: Nm {kgfcm lbfft} Tightening part Tightening torque Remarks Diesel throttle mounting bolt and nut 28.5 {291, 21}...
Page 52: Air Cleaner
2–12 STANDARD VALUE (J05E) AIR CLEANER EN01F02127010701005005 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Air cleaner housing mounting nut 19.5 {199, 14} Intake hose clamp 2.4-5.0 {25-50, 1.8-3.6} INTAKE TEMPERATURE SENSOR EN01F02127010701005006 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks...
Page 53: Engine Mechanical
STANDARD VALUE (J05E) 2–13 ENGINE MECHANICAL HEAD COVER EN01F02127010701006001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Head cover mounting bolt 28.5 {291, 21} ROCKER ARM ASSEMBLY EN01F02127010701006002 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Permissible limit Action...
Page 54: Camshaft Assembly
2–14 STANDARD VALUE (J05E) CAMSHAFT ASSEMBLY EN01F02127010701006003 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Permissible limit Action Intake 50.067 {1.971} 49.987 {1.968} Replace Cam height Exhaust 52.104 {2.051} 52.024 {2.048} Replace Intake 8.067 {0.318} (7.987 {0.3144}) Replace Cam lift Exhaust...
Page 55: Cylinder Head Assembly
STANDARD VALUE (J05E) 2–15 CYLINDER HEAD ASSEMBLY EN01F02127010701006004 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Permissible limit Action 126.0 {4.961} 126.5 {4.980} Replace Head bolt under head length (M12) 156.0 {6.142} 156.5 {6.161} Replace 187.0 {7.362} 187.5 {7.382} Replace Longitudinal...
Page 56: Valve System
2–16 STANDARD VALUE (J05E) VALVE SYSTEM EN01F02127010701006005 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Permissible limit Action 0.55-0.85 Intake 1.1 {0.0433} Replace {0.0217-0.0335} Valve sink 1.15-1.45 Exhaust 1.7 {0.0669} Replace {0.0452-0.0571} Intake 30 30-3035' Correction Valve seat Exhaust 45...
Page 57: Crankshaft Pulley
STANDARD VALUE (J05E) 2–17 CRANKSHAFT PULLEY EN01F02127010701006006 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Crankshaft pulley mounting bolt 118 {1,203, 87} FRONT OIL SEAL RETAINER EN01F02127010701006007 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Front oil seal retainer mounting bolt 30 {306, 22}...
Page 58: Timing Gear & Cam Idle Gear
2–18 STANDARD VALUE (J05E) TIMING GEAR & CAM IDLE GEAR EN01F02127010701006010 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Permissible limit Action Shaft outer – 57 {2.244} diameter Main idle gear Bushing inner – 57 {2.244} diameter –...
Page 59: Piston & Connecting Rod
STANDARD VALUE (J05E) 2–19 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Sub idle gear shaft mounting bolt 108 {1,101, 80} Main idle gear shaft mounting bolt 172 {1,754, 127} Injection pump drive idle gear shaft mounting bolt 108 {1,101, 80} Bearing case assembly mounting bolt 28.5 {291, 21}...
Page 60: Crankshaft
2–20 STANDARD VALUE (J05E) Inspection item Standard value Permissible limit Action Crankshaft crank pin outer diameter 65 {2.560} 64.3 {2.531} Replace (Note) Oil clearance between crankshaft crank pin 0.031-0.082 0.2 {0.0079} Replace and connecting rod bearing {0.0012-0.0032} Under head length of connecting rod bolt 67.0 {2.638} 68.0 {2.677} Replace...
Page 61: Cylinder Liner
STANDARD VALUE (J05E) 2–21 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Refer to this Bearing cap bolt 69 {704, 51} + 90 + 45 document. CYLINDER LINER EN01F02127010701006013 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Standard value Action...
Page 62 2–22 STANDARD VALUE (J05E) TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Glow plug 20-25 {204-254, 15-18} Glow plug wire mounting nut 1.0-1.5 {11-15, 0.8-1.1}...
Page 63: Exhaust
STANDARD VALUE (J05E) 2–23 EXHAUST EXHAUST MANIFOLD EN01F02127010701007001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Stud bolt 30 {305, 22.1} Exhaust manifold mounting nut 29 {600, 43.5} EXHAUST PIPE EN01F02127010701007002 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks...
Page 64: Def-Scr
2–24 STANDARD VALUE (J05E) DEF-SCR EN01F02127010701007004 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Central-pipe-No.2-to-DEF-SCR mounting bolt and 20-30 {204-306, 14.7-22.1} DEF-SCR-to-tail-pipe mounting bolt and nut 20-30 {204-306, 14.7-22.1} DEF-SCR-to-support-bracket mounting bolt and nut 43-59 {438-602, 438-602} Exhaust pipe protector mounting bolt 31 {316, 22.9} DPR CLEANER...
Page 65: Fuel Addition Valve
STANDARD VALUE (J05E) 2–25 FUEL ADDITION VALVE EN01F02127010701007006 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Insulation resistance between the fuel addi- 10 M or more tion valve upper body and connector (part Replace (Using the 500 V megohmmeter) side).
Page 66: Def Injector
2–26 STANDARD VALUE (J05E) DEF INJECTOR EN01F02127010701007009 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Coolant connector 5-6 {51-61, 3.7-4.4} DEF Injector mounting nut 6-10 {61-102, 4.4-7.4} Hose protector mounting nut 31 {316, 22.9} DEF TANK EN01F02127010701007010 STANDARD VALUE, LIMIT AND ACTION Inspection item Concentration...
Page 67: Dpr Differential Pressure Sensor
STANDARD VALUE (J05E) 2–27 DPR DIFFERENTIAL PRESSURE SENSOR EN01F02127010701007013 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action AB 15 k Replace Resistance between termi- nals BC 15 k Replace TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks DPR differential pressure sensor mounting nut 31 {316, 22.9}...
Page 68: Doc Upstream Temperature Sensor
2–28 STANDARD VALUE (J05E) DOC UPSTREAM TEMPERATURE SENSOR EN01F02127010701007017 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Resistance between termi- 50 C {122 F} 8.0-17.2 k Replace nals TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks DOC upstream temperature sensor 25-35 {255-357, 18.4-25.8}...
Page 69: Scr Upstream Temperature Sensor
STANDARD VALUE (J05E) 2–29 SCR UPSTREAM TEMPERATURE SENSOR EN01F02127010701007020 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Resistance between termi- 50 C {122 F} 235-244  Replace nals TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks SCR upstream temperature sensor 32.5 {331, 24.0}...
Page 70: Cooling
2–30 STANDARD VALUE (J05E) COOLING RADIATOR EN01F02127010701008001 STANDARD VALUE, LIMIT AND ACTION Unit: kPa {kgf/cm , lbf/in Inspection item Injection Pressure Injection Distance Action 2,942-4,903 {30-50, 427-711} 300mm {11.811 in.} Replace Check for blockage 4,903-7,845 {50-80, 711-1,138} 500mm {19.685 in.} Replace TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft}...
Page 71: Intercooler
STANDARD VALUE (J05E) 2–31 INTERCOOLER EN01F02127010701008004 STANDARD VALUE, LIMIT AND ACTION Unit: kPa {kgf/cm , lbf/in Inspection item Injection Pressure Injection Distance Action 2,942-4,903 {30-50, 427-711} 300mm {11.811 in.} Replace Check for blockage 4,903-7,845 {50-80, 711-1,138} 500mm {19.685 in.} Replace TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part...
Page 72: Cooling Fan & Fan Clutch
2–32 STANDARD VALUE (J05E) COOLING FAN & FAN CLUTCH EN01F02127010701008007 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Cooling fan chip clearance 4-7 mm {0.157-0.276 in.} Adjustment TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Cooling fan to fan clutch mounting bolt 11 {112, 8} Fan clutch to coolant pump pulley mounting nut...
Page 73: Lubrication
STANDARD VALUE (J05E) 2–33 LUBRICATION OIL COOLER EN01F02127010701009001 TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Oil pressure switch 24.5 {250, 18} Plug (safety valve) 24.5-34.3 {250-349, 19-25} Oil cooler element mounting nut 19.6-29.4 {200-299, 15-21} Oil cooler assembly mounting bolt 28.5 {291, 21} OIL PUMP EN01F02127010701009002...
Page 74: Oil Pan
2–34 STANDARD VALUE (J05E) Inspection item Standard value Permissible limit Action 0.073-0.207 Backlash between drive gear and driven gear 0.30 {0.012} Replace {0.0029-0.0082} Backlash between oil pump drive gear and 0.030-0.131 0.30 {0.012} Adjustment sub idle gear {0.0012-0.0052} TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque...
Page 75: Standard Value (J05E)
STANDARD VALUE (J05E) 2–35 STARTING/CHARGING STARTER EN01F02127010701012001 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Perform no load performance test 220A or less TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Starter mounting bolt and nut 154 {1,570, 113.5} C terminal mounting bolt 4.5 {46, 3.3}...
Page 76: Alternator (130 A)
2–36 STANDARD VALUE (J05E) ALTERNATOR (130 A) EN01F02127010701012003 STANDARD VALUE, LIMIT AND ACTION Inspection item Standard value Action Verifying the regulators regulated voltage 14.0-14.4V TIGHTENING TORQUE Unit: Nm {kgfcm, lbfft} Tightening part Tightening torque Remarks Bearing cover mounting screw 2.9-4.9 {30-50, 2.1-3.6} Pulley mounting nut 117.6-137.2 {1,199-1,399, 87-101} Field mounting screw...
Page 77: Turbocharger
STANDARD VALUE (J05E) 2–37 TURBOCHARGER TURBOCHARGER ASSEMBLY EN01F02127010701013001 STANDARD VALUE, LIMIT AND ACTION Unit: mm {in.} Inspection item Permissible limit Action Play in axle (thrust) 0.040-0.085 Turbocharger assembly Replace direction {0.0016-0.0033} or less 22.1 kPa Inspecting the boost pressure Replace {0.23 kgf/cm , 3.2 lbfft/in.
Page 78 REQUIRED ITEMS (J05E) 3–1 REQUIRED ITEMS (J05E) 3-001 MOUNTING AND DISMOUNTING THE ENGINE ..3-2 DEF INJECTOR ............3-29 ENGINE ASSEMBLY ..........3-2 DEF TANK .............3-30 DPR DIFFERENTIAL PRESSURE SENSOR ..3-30 ENGINE CONTROL .............3-3 SCR UPSTREAM NOx SENSOR ......3-30 ENGINE ECU............3-3 SCR DOWNSTREAM NOx SENSOR ....3-30 ENGINE MAIN REVOLUTION SENSOR ....3-3 ATC DOWNSTREAM TEMPERATURE ENGINE SUB REVOLUTION SENSOR....3-4...
Page 79: Mounting And Dismounting The Engine
3–2 REQUIRED ITEMS (J05E) PREPARATION ITEM MOUNTING AND DISMOUNTING THE ENGINE ENGINE ASSEMBLY EN01F02127020702001001 Shape Part No. Name Remarks S0955-21110 Compression gauge adapter For inserting a nozzle For 3/4-16UNF Select S0955-21030 Compression gauge adapter thread size according to the For W16 thread size S0955-21060 Compression gauge adapter...
Page 80: Engine Control
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 81: Engine Sub Revolution Sensor
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 82: Accelerator Pedal
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 83: Fuel System
3–6 REQUIRED ITEMS (J05E) FUEL SYSTEM FUEL SENDER GAUGE EN01F02127020702003001 INSTRUMENTS Name Remarks Circuit tester For measuring resistance across terminals WATER LEVEL WARNING SWITCH EN01F02127020702003002 INSTRUMENTS Name Remarks Circuit tester For measuring continuity between terminals...
Page 84: Supply Pump
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 85: Injector
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 86: Common Rail
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 87: Fuel Filter And Case (Vehicle Side)
3–10 REQUIRED ITEMS (J05E) FUEL FILTER AND CASE (VEHICLE SIDE) EN01F02127020702003006 COMMON TOOLS Name Remarks Mityvac For inspecting the fuel heater INSTRUMENTS Name Remarks Cylinder gauge For measuring resistance across terminals...
Page 88: Emission Control
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 89: Closed Ventilator
3–12 REQUIRED ITEMS (J05E) GREASE AND OTHERS Name Remarks Glasses For protecting eyes from splashed detergent Rubber gloves For protecting skin from splashed detergent Protective garment For protecting cloth from splashed detergent Detergent (PK-5300YP) For cleaning the EGR cooler Reservoir (metallic) For cleaning the EGR cooler General-purpose heater For cleaning the EGR cooler...
Page 90: Intake
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 91: Boost Pressure Sensor
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 92: Air Flow Sensor
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 93: Engine Mechanical
3–16 REQUIRED ITEMS (J05E) ENGINE MECHANICAL HEAD COVER EN01F02127020702006001 GREASE AND OTHERS Name Remarks Liquid gasket (ThreeBond TB1207B: Black or equivalent or Apply to the mating area of the half-round plug. ThreeBond TB1217G: Gray or equivalent) ROCKER ARM ASSEMBLY EN01F02127020702006002 INSTRUMENTS Name Remarks...
Page 94: Cylinder Head Assembly
REQUIRED ITEMS (J05E) 3–17 CYLINDER HEAD ASSEMBLY EN01F02127020702006004 Shape Part No. Name Remarks For attaching and detaching S0943-31070 Eye bolt the cylinder head S0947-21210 For staking the nozzle seat For staking the nozzle seat SN441-00610 Steel Ball (combined use with S0947- 21210) COMMON TOOLS Name...
Page 95: Valve System
3–18 REQUIRED ITEMS (J05E) VALVE SYSTEM EN01F02127020702006005 Shape Part No. Name Remarks For attaching and detaching S0947-01170 Valve spring press the valve spring retainer S0943-11020 Valve lapping tool For valve finishing For press-fitting the valve S0947-11520 Guide guide For tapping in the valve S0947-22100 stem seal COMMON TOOLS...
Page 96: Crankshaft Front Oil Seal
REQUIRED ITEMS (J05E) 3–19 GREASE AND OTHERS Name Remarks Lapping compound For valve finishing CRANKSHAFT FRONT OIL SEAL EN01F02127020702006006 Shape Part No. Name Remarks For pulling off a crankshaft S0942-01731 Oil seal puller front oil seal For press-fitting the crank- S0940-71030 Oil seal press shaft front oil seal...
Page 97: Crankshaft Rear Oil Seal
3–20 REQUIRED ITEMS (J05E) GREASE AND OTHERS Name Remarks Burner For attaching and detaching the ring gear CRANKSHAFT REAR OIL SEAL EN01F02127020702006009 Shape Part No. Name Remarks For pulling off a crankshaft S0942-01742 Oil seal puller rear oil seal For mounting crankshaft S0940-71040 Oil seal press rear oil seal...
Page 98: Timing Gear And Cam Idle Gear
REQUIRED ITEMS (J05E) 3–21 TIMING GEAR AND CAM IDLE GEAR EN01F02127020702006011 Shape Part No. Name Remarks For pulling off the main idle S0942-01100 Sliding hammer gear shaft and sub idle gear shaft For attaching and detaching S0941-11300 Socket wrench the Torx bolt COMMON TOOLS Name Remarks...
Page 99: Piston And Connecting Rod
3–22 REQUIRED ITEMS (J05E) PISTON AND CONNECTING ROD EN01F02127020702006012 Shape Part No. Name Remarks For mounting/dismounting a S0944-21011 Piston ring expander piston ring For attaching and detaching the connecting rod small S0948-11130 Guide end bush (combined use with S0940-21530) For attaching and detaching S0940-21530 Press subassembly the connecting rod small...
Page 100 REQUIRED ITEMS (J05E) 3–23 COMMON TOOLS Name Remarks Scraper Removing carbon INSTRUMENTS Name Remarks For measuring the cylinder liner inner diameter, piston boss Cylinder gauge inner diameter, connecting rod bush inner diameter, and connecting rod big end bearing inner diameter For measuring the piston outer diameter, piston ring thick- Micrometer ness, piston pin outer diameter, and crank pin outer diame-...
Page 101: Crankshaft
3–24 REQUIRED ITEMS (J05E) RECOMMEND SERVICE TOOLS THICKNESS: ABOUT 10mm {0.394 in.} (ARBITRARY) ABOUT 20mm {0.787 in. } M12X1.5 27mm {1.063 in. } CRANKSHAFT EN01F02127020702006013 INSTRUMENTS Name Remarks For measuring the crankshaft end play and crankshaft rota- Dial gauge tion runout For measuring the outer diameters of the crankshaft jour- Micrometer nal and crank pin...
Page 102: Cylinder Liner
REQUIRED ITEMS (J05E) 3–25 CYLINDER LINER EN01F02127020702006014 Shape Part No. Name Remarks For removing the cylinder S0942-02100 Cylinder liner puller liner For inserting the cylinder S0947-11490 Guide liner COMMON TOOLS Name Remarks Bearing scraper Removing rust from the cylinder liner INSTRUMENTS Name Remarks...
Page 103: Cylinder Block
3–26 REQUIRED ITEMS (J05E) CYLINDER BLOCK EN01F02127020702006015 Shape Part No. Name Remarks For inspection and adjust- SZ910-24098 Bolt for checking ment of cooling jet For inspection and adjust- 09219-E4030 Gauge ment of cooling jet Plug A tapping tool 09211-E4020 09211-E4030 Plug B tapping tool COMMON TOOLS Name...
Page 104: Exhaust
REQUIRED ITEMS (J05E) 3–27 EXHAUST EXHAUST MANIFOLD EN01F02127020702007001 COMMON TOOLS Name Remarks Torque socket For attaching and detaching the stud bolt Stud bolt remover (commercially available) For removing the stud bolt...
Page 105: Dpr
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 106: Fuel Addition Valve
REQUIRED ITEMS (J05E) 3–29 FUEL ADDITION VALVE EN01F02127020702007003 Configuration Part Number Name Remarks — 09950-E9010 Nozzle for cleaning Air hose and using together INSTRUMENTS Name Remarks 500 V megohmmeter For measuring parts Circuit tester For measuring resistance across terminals GREASE AND OTHERS Name Remarks Glasses...
Page 107: Def Tank
3–30 REQUIRED ITEMS (J05E) DEF TANK EN01F02127020702007006 INSTRUMENTS Name Remarks DEF analyzer For DEF measurement Refractive index measurement For DEF measurement GREASE AND OTHERS Name Remarks pH test paper For DEF measurement DPR DIFFERENTIAL PRESSURE SENSOR EN01F02127020702007007 INSTRUMENTS Name Remarks Circuit tester For measuring resistance across terminals SCR UPSTREAM NOx SENSOR...
Page 108: Atc Downstream Temperature Sensor
REQUIRED ITEMS (J05E) 3–31 ATC DOWNSTREAM TEMPERATURE SENSOR EN01F02127020702007010 INSTRUMENTS Name Remarks Circuit tester For measuring resistance across terminals GREASE AND OTHERS Name Remarks Anti-seizure lubricant (equivalent to NEVER-SEEZ Heavy Apply to the threaded portion of ATC downstream tempera- Metal Free manufactured by Bostic, Inc.) ture sensor DOC UPSTREAM TEMPERATURE SENSOR EN01F02127020702007011...
Page 109: Dpr Downstream Temperature Sensor
3–32 REQUIRED ITEMS (J05E) DPR DOWNSTREAM TEMPERATURE SENSOR EN01F02127020702007013 INSTRUMENTS Name Remarks Circuit tester For measuring resistance across terminals GREASE AND OTHERS Name Remarks Anti-seizure lubricant (equivalent to NEVER-SEEZ Heavy Apply to the threaded portion of DPR downstream temper- Metal Free manufactured by Bostic, Inc.) ature sensor SCR UPSTREAM TEMPERATURE SENSOR EN01F02127020702007014...
Page 110: Exhaust Brake
REQUIRED ITEMS (J05E) 3–33 EXHAUST BRAKE EN01F02127020702007016 Configuration Part Number Name Remarks For measuring clearance 09240-00020 Wire gauge set between the valve and body Wire gauge (0.2 mm) For measuring clearance 09242-00020 (content) between the valve and body COMMON TOOLS Name Remarks Mityvac...
Page 111: Cooling
3–34 REQUIRED ITEMS (J05E) COOLING RADIATOR CAP EN01F02127020702008001 INSTRUMENTS Name Remarks Radiator cap tester (commercially available) For measuring valve opening pressure THERMOSTAT CASE AND THERMOSTAT EN01F02127020702008002 INSTRUMENTS Name Remarks Vernier calipers For measuring valve lift amount COMMON TOOLS Name Remarks Scraper For removing liquid gasket GREASE AND OTHERS...
Page 112: Coolant Pump
REQUIRED ITEMS (J05E) 3–35 COOLANT PUMP EN01F02127020702008003 COMMON TOOLS Name Remarks Scraper For removing liquid gasket GREASE AND OTHERS Name Remarks Liquid gasket (ThreeBond TB1207B: Black or equivalent) Apply to the coolant pump joint surface. COOLANT TEMPERATURE SENSOR EN01F02127020702008004 INSTRUMENTS Name Remarks Circuit tester...
Page 113: Lubrication
3–36 REQUIRED ITEMS (J05E) LUBRICATION OIL FILTER EN01F02127020702009001 Shape Part No. Name Remarks For attaching and detaching S0950-31090 Oil filer wrench the oil filter OIL COOLER EN01F02127020702009002 COMMON TOOLS Name Remarks Scraper For removing liquid gasket GREASE AND OTHERS Name Remarks For washing the water/oil groove well of the oil cooler ele- Kerosene or detergent...
Page 114: Oil Pump
REQUIRED ITEMS (J05E) 3–37 OIL PUMP EN01F02127020702009003 INSTRUMENTS Name Remarks For measuring width of drive gear and depth of cylinder Depth gauge block side pump housing For measuring the drive gear shaft outer diameter and Micrometer driven gear shaft outer diameter For measuring the cylinder block side bush inner diameter, Cylinder gauge driven gear bush inner diameter, cylinder block side pump...
Page 115: Starting/Charging
3–38 REQUIRED ITEMS (J05E) STARTING/CHARGING STARTER EN01F02127020702012001 INSTRUMENTS Name Remarks Ammeter For measuring parts Circuit tester For measuring parts Dial gauge For measuring parts Thickness gauge For measuring parts V-BELT EN01F02127020702012002 Shape Part No. Name Remarks S0944-41210 Compression gauge ALTERNATOR (130A) EN01F02127020702012003 INSTRUMENTS Name...
Page 116: Turbocharger
(*1):To use Hino-Bowie (the interface box) "09993-E9070", it is necessary to update the hardware. For details, see the Manual in the HINO-DX CD. Also keep the firmware (Hino-Bowie internal software) updated by using the software in the HINO-DX CD. For details, see the Manual in the HINO-DX CD.
Page 117 3–40 REQUIRED ITEMS (J05E) COMMON TOOLS Name Remarks Stud bolt remover For removing the stud bolt INSTRUMENTS Name Remarks For measuring play in the axle (thrust) direction of the tur- Dial gauge bine shaft...
Page 118 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–1 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5-001 ENGINE ASSEMBLY............5-2 PRECAUTIONS IN TILTING AND LOWERING THE CAB ..........5-2 MEASUREMENT OF COMPRESSION PRESSURE ............5-2 ADJUSTING THE VALVE CLEARANCE....5-5 REPLACEMENT .............5-7...
Page 119: Engine Assembly
5–2 MOUNTING AND DISMOUNTING THE ENGINE (J05E) REPLACING POINTS ITEM ENGINE ASSEMBLY PRECAUTIONS IN TILTING AND LOWERING THE CAB EN01F02121040706004001 ! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, seri- ous injury and/or property damage.
Page 120 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–3 PREPARATION BEFORE MEASUREMENT Fully charge the battery. Inspect the valve clearance. When it exceeds the standard value, adjust it. Reference: MOUNTING AND DISMOUNTING THE ENGINE (J05E), ENGINE ASSEMBLY, ADJUSTING THE VALVE CLEARANCE (Page 5-5) Warm up the engine and set the coolant temperature to 80 C {176 F}.
Page 121 2.7 {28, 392} Overhaul the engine if the compression pressure is at or below the permissible limit. Put back the removed parts in place after measurement. Use the HINO-DX to delete the past malfunctions. (Refer to the HINO-DX user's manual.)
Page 122: Adjusting The Valve Clearance
MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–5 ADJUSTING THE VALVE CLEARANCE EN01F02121040706004003 ! CAUTION • Before adjustment, make sure that the tightening bolts of the cylinder head, rocker arm support, nozzle clamp, and cam- shaft bearing cap are tightened with their specified torque. •...
Page 123 5–6 MOUNTING AND DISMOUNTING THE ENGINE (J05E) Insert a thickness gauge in between the rocker arm and the crosshead and turn the rocker arm adjust screw to adjust a clear- LOCK NUT ADJUST SCREW ance before tightening the lock nut. Tightening Torque: THICKNESS ROCKER ARM...
Page 124: Replacement
MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–7 REPLACEMENT EN01F02121040706004004 REMOVING THE ENGINE ASSEMBLY REMOVING THE SERVICE PLUG (HV ONLY) Wear insulated gloves and remove the service plug from the PCU. Reference: CHASSIS (S1-LXJE03A), HYBRID Reference: CHASSIS (S1-LXJE04A), HYBRID DISCONNECTING BATTERY NEGATIVE TERMINAL Disconnect the battery negative terminal.
Page 125 5–8 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 10. REMOVING VACUUM RESERVOIR Reference: CHASSIS (S1-LXJE03A), BRAKE Reference: CHASSIS (S1-LXJE04A), BRAKE 11. REMOVING RELAY BLOCK Remove the relay block from the cab mounting bracket. 12. REMOVING THE AIR CLEANER BODY ASSEMBLY Reference: INTAKE (J05E), AIR CLEANER, REPLACEMENT, REMOVING THE AIR CLEANER ELEMENT AND BODY ASSEMBLY (Page 9-21) 13.
Page 126 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–9 21. DISCONNECTING THE FUEL HOSE Unfasten the 2 clamps from the fuel pipe at the left rear of the fly- wheel housing and disconnect the fuel hose (return side) and fuel POWER STEERING POWER STEERING hose (feed side) from fuel feed pipe No.4 and return pipe No.3.
Page 127 5–10 MOUNTING AND DISMOUNTING THE ENGINE (J05E) Unfasten 2 engine mounting the installation nuts and disconnect the engine mounting and frame. LEFT SIDE RIGHT SIDE SHTS021270400013 Completely tighten the commercially available shackle and SST wire. Ensure that the wire is hooked to the engine hanger securely WIRE ROPE 10°...
Page 128 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–11 MOUNTING THE ENGINE ASSEMBLY MOUNTING THE ENGINE Lift the engine in the similar fashion to removing and set the WIRE ROPE 10° OR ENGINE engine to the frame. LESS RIGHT ! CAUTION SIDE 10°...
Page 129 5–12 MOUNTING AND DISMOUNTING THE ENGINE (J05E) CONNECTING THE POWER STEERING OIL HOSE AND OIL PIPE Replace with a new gasket and tighten the union bolt to connect POWER STEERING POWER STEERING the power steering oil pipe to the power steering pump. OIL HOSE OIL PIPE Tightening Torque:...
Page 130 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–13 CONNECTING THE HARNESS AND CABLE CONNECTING TO THE HV MOTOR (HV ONLY) Reference: CHASSIS (S1-LXJE03A), TRANSMISSION Reference: CHASSIS (S1-LXJE04A), TRANSMISSION CONNECTING THE STARTER HARNESS Reference: STARTING/CHARGING (J05E), STARTER, REPLACEMENT, MOUNTING THE STARTER (Page 16-4) 10.
Page 131 5–14 MOUNTING AND DISMOUNTING THE ENGINE (J05E) NEXT STEPS AFTER INSTALLATION ADDING ENGINE OIL Pour engine oil from filler cap of the engine head cover. FILLER CAP SHTS021270400023 Add the engine oil from the filler cap while checking the oil level with the oil level gauge at the left of the engine.
Page 132 MOUNTING AND DISMOUNTING THE ENGINE (J05E) 5–15 INSPECTION FOR ENGINE OIL LEAKAGE Inspect for engine oil leakage. ADDING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, MOUNTING THE RADIATOR (Page 12-9) INSPECTION FOR COOLANT LEAKAGE Reference: COOLING (J05E), THERMOSTAT CASE AND THERMOSTAT, OVERHAUL, INSPECTING THE COMPO- NENTS (Page 12-26) ADDING POWER STEERING FLUID...
Page 133 ENGINE CONTROL (J05E) 6–1 ENGINE CONTROL (J05E) 6-001 CONTROL PARTS ............6-2 ATC DOWNSTREAM TEMPERATURE SENSOR ..6-25 SYSTEM BLOCK DIAGRAM........6-2 REPLACEMENT ...........6-25 ENGINE ECU ...............6-3 DOC UPSTREAM TEMPERATURE SENSOR ..6-25 COMPONENT LOCATOR ........6-3 REPLACEMENT ...........6-25 REPLACEMENT .............6-4 DPR UPSTREAM TEMPERATURE SENSOR ...6-26 VEHICLE CONTROL ECU .........6-10 REPLACEMENT ...........6-26 REPLACEMENT ...........6-10...
Page 134: Control Parts
6–2 ENGINE CONTROL (J05E) SYSTEM DRAWING CONTROL PARTS SYSTEM BLOCK DIAGRAM EN01F02127050405019001 ACTUATOR RELAY FUSE POWER SOURCE FUSE KEY SWITCH STARTER SWITCH MAIN RELAY ACCELERATOR PEDAL BATTERY POSITION SENSOR 1, 2 CAN COMMUNICATION (VARIABLE NOZZLE TURBO CHARGER, EGR VALVE DEF DOSING SYSTEM) PTO ACCELERATOR SENSOR OTHERS ENGINE SPEED SENSOR...
Page 135: Engine Ecu
ENGINE CONTROL (J05E) 6–3 COMPOSITION DIAGRAM ENGINE ECU COMPONENT LOCATOR EN01F02127050402007001 SHTS021270500002 Engine ECU ECU bracket Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {290, 21}...
Page 136: Replacement
6–4 ENGINE CONTROL (J05E) REPLACEMENT EN01F02127050402007002 DISCONNECTING THE ENGINE ECU CONNECTOR CAUTIONS ! CAUTION Perform replace after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) ENGINE ECU CONNECTOR CONNECTOR SHTS021270500003...
Page 137 ENGINE CONTROL (J05E) 6–5 Using the small brush, carefully remove dirt and foreign matter remaining at the sliding portion. ! CAUTION While working, do not disconnect the connectors. Using the waste cloth, wipe off around the engine ECU connector and engine ECU surface. ! CAUTION •...
Page 138 6–6 ENGINE CONTROL (J05E) If the side of the harness side connector is found dirty, wipe it off with a moistened waste cloth while being careful not allowing dirt PORTIONS TO DO NOT WIPE and foreign matter to drop. BE WIPE CLEAN OFF THE ! CAUTION TERMINAL...
Page 139 ENGINE CONTROL (J05E) 6–7 REMOVING THE ENGINE ECU REMOVING THE ENGINE ECU Unfasten the 4 bolts to remove the engine ECU from the ECU ECU BRACKET bracket. ! CAUTION • Protect with plastic covers to avoid entry of dirt and foreign matter into the connectors of the engine ECU.
Page 140 6–8 ENGINE CONTROL (J05E) ATTACHING THE ENGINE ECU CONNECTOR ATTACHING THE ENGINE ECU CONNECTOR Check that the harness side connector lever is fully open and place it straight on the engine ECU side connector. ! CAUTION At this time, check that the lever is fully open. LEVER SHTS021270500014 NOTICE...
Page 141 ENGINE CONTROL (J05E) 6–9 Move the lever in the direction of the arrow as shown in the figure until a "click" is heard and attach the connector. ! CAUTION If the lever cannot move smoothly, repeat steps (1) and (2). Also drop a few drops of water to the sliding portion to make it smooth.
Page 142: Vehicle Control Ecu
6–10 ENGINE CONTROL (J05E) VEHICLE CONTROL ECU REPLACEMENT EN01F02127050402022001 REMOVING THE VEHICLE CONTROL ECU REMOVING THE INSTRUMENT PANELS Reference: CHASSIS (S1-LXJE03A), BODY INSIDE ACCES- SORY Reference: CHASSIS (S1-LXJE04A), BODY INSIDE ACCES- SORY DISCONNECTING THE HARNESS Reference: CHASSIS (S1-LXJE03A), ELECTRICAL Reference: CHASSIS (S1-LXJE04A), ELECTRICAL REMOVING THE VEHICLE CONTROL ECU Reference: CHASSIS (S1-LXJE03A), ELECTRICAL Reference: CHASSIS (S1-LXJE04A), ELECTRICAL...
Page 143: Engine Speed Main Sensor
ENGINE CONTROL (J05E) 6–11 ENGINE SPEED MAIN SENSOR COMPONENT LOCATOR EN01F02127050402009001 SHTS021270500019 Engine speed main sensor Flywheel housing Tightening torque Unit: Nm {kgfcm, lbfft} 10 {102, 7}...
Page 144: Inspection
6–12 ENGINE CONTROL (J05E) INSPECTION EN01F02127050402009002 INSPECTING THE ENGINE SPEED MAIN SENSOR Use the HINO-DX, inspect the engine speed main sensor. (Refer to the HINO-DX user's manual.) ENGINE SPEED MAIN SENSOR SHTS021270500020 REPLACEMENT EN01F02127050402009003 REMOVING THE ENGINE SPEED MAIN SENSOR...
Page 145: Engine Speed Sub Sensor
ENGINE CONTROL (J05E) 6–13 ENGINE SPEED SUB SENSOR COMPONENT LOCATOR EN01F02127050402010001 SHTS021270500023 Engine speed sub sensor Cylinder head Tightening torque Unit: Nm {kgfcm, lbfft} 4-6 {41-61, 3.0-4.4}...
Page 146: Inspection
6–14 ENGINE CONTROL (J05E) INSPECTION EN01F02127050402010002 INSPECTING THE ENGINE SPEED SUB SENSOR Use the HINO-DX, inspect the engine speed sub sensor. (Refer to the HINO-DX user's manual.) ENGINE SPEED SUB SENSOR SHTS021270500024 REPLACEMENT EN01F02127050402010003 REMOVING THE ENGINE SPEED SUB SENSOR...
Page 147: Idle Set Volume
ENGINE CONTROL (J05E) 6–15 IDLE SET VOLUME COMPONENT LOCATOR EN01F02127050402023001 SHTS021270500027 Idle set volume Idle set button Ring nut...
Page 148: Replacement
6–16 ENGINE CONTROL (J05E) REPLACEMENT EN01F02127050402023002 REMOVING THE IDLE SET VOLUME REMOVING THE IDLE SET VOLUME While pressing the idle set volume claw using a flat-blade screw- driver wrapped with protective tape, pull out the idle set button. Disconnect the connector of the harness and remove the ring nut to detach the idle set volume.
Page 149 ENGINE CONTROL (J05E) 6–17 MOUNTING THE IDLE SET VOLUME MOUNTING THE IDLE SET VOLUME Insert the idle set volume in the same direction as the hole of the instrument panel and fix it with the ring nut. ! CAUTION • Do not break the idle set volume.
Page 150: Accelerator Pedal
6–18 ENGINE CONTROL (J05E) ACCELERATOR PEDAL COMPONENT LOCATOR EN01F02127050402003001 SHTS021270500032 Accelerator pedal assembly Tightening torque Unit: Nm {kgfcm, lbfft} 5.5 {56, 4}...
Page 151: Replacement
Unfasten the 2 nuts and remove the accelerator pedal assembly. SHTS021270500033 SINGLE UNIT INSPECTION INSPECTION OF ACCELERATOR PEDAL ASSEMBLY Use the HINO-DX, inspect the output voltage. (Refer to the HINO-DX user's manual.) If the output voltage does not meet the standard, replace the accelerator pedal assembly.
Page 152: Block Heater
6–20 ENGINE CONTROL (J05E) BLOCK HEATER COMPONENT LOCATOR EN01F02127050402086001 SHTS021270500035 Bracket Socket Tightening torque Unit: Nm {kgfcm, lbfft} 1.4-1.7 {14-17, 1.0-1.3}...
Page 153: Replacement
ENGINE CONTROL (J05E) 6–21 REPLACEMENT EN01F02127050402086002 REMOVING BLOCK HEATER HARNESS REMOVING THE HARNESS Disconnect the block heater harness from the block heater or the SOCKET SIDE SOCKET cylinder block. CONNECTOR Unfasten the clamp and remove the harness. Remove the socket side connector from the socket. Unfasten the bolt to remove the socket from the bracket.
Page 154: Fuel Sender Gauge
Reference: INTAKE (J05E), DIESEL THROTTLE, REPLACE- MENT, REMOVING THE DIESEL THROTTLE (Page 9-9) SINGLE UNIT INSPECTION Use the HINO-DX for inspection. (Refer to the HINO-DX user's manual.) MOUNTING THE DIESEL THROTTLE Reference: INTAKE (J05E), DIESEL THROTTLE, REPLACE- MENT, MOUNTING THE DIESEL THROTTLE (Page 9-10)
Page 155: Boost Pressure Sensor
REPLACEMENT, REMOVING THE BOOST PRESSURE SEN- SOR (Page 9-30) SINGLE UNIT INSPECTION Use the HINO-DX for inspection. (Refer to the HINO-DX user's manual.) MOUNTING THE BOOST PRESSURE SENSOR Reference: INTAKE (J05E), BOOST PRESSURE SENSOR, REPLACEMENT, MOUNTING THE BOOST PRESSURE SEN-...
Page 156: Dpr Differential Pressure Sensor
6–24 ENGINE CONTROL (J05E) DPR DIFFERENTIAL PRESSURE SENSOR REPLACEMENT EN01F02127050402045001 REMOVING THE DPR DIFFERENTIAL PRESSURE SENSOR Reference: EXHAUST (J05E), DPR DIFFERENTIAL PRES- SURE SENSOR, REPLACEMENT, REMOVE THE DPR DIF- FERENTIAL PRESSURE SENSOR (Page 11-96) SINGLE UNIT INSPECTION Reference: EXHAUST (J05E), DPR DIFFERENTIAL PRES- SURE SENSOR, REPLACEMENT, SINGLE UNIT INSPECTION (Page 11-96) MOUNTING THE DPR DIFFERENTIAL PRESSURE SENSOR...
Page 157: Atc Downstream Temperature Sensor
ENGINE CONTROL (J05E) 6–25 ATC DOWNSTREAM TEMPERATURE SENSOR REPLACEMENT EN01F02127050402032001 REMOVING THE ATC DOWNSTREAM TEMPERATURE SEN- Reference: EXHAUST (J05E), ATC UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, REMOVING THE ATC UPSTREAM TEMPERATURE SENSOR (Page 11-105) SINGLE UNIT INSPECTION Reference: EXHAUST (J05E), ATC UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, SINGLE UNIT INSPECTION (Page 11-105) MOUNTING THE ATC DOWNSTREAM TEMPERATURE SEN-...
Page 158: Dpr Upstream Temperature Sensor
6–26 ENGINE CONTROL (J05E) DPR UPSTREAM TEMPERATURE SENSOR REPLACEMENT EN01F02127050402079001 REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR Reference: EXHAUST (J05E), DPR UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR (Page 11-111) SINGLE UNIT INSPECTION Reference: EXHAUST (J05E), DPR UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, SINGLE UNIT INSPECTION (Page 11-111) MOUNTING THE DPR UPSTREAM TEMPERATURE SENSOR...
Page 159: Scr Upstream Temperature Sensor
ENGINE CONTROL (J05E) 6–27 SCR UPSTREAM TEMPERATURE SENSOR REPLACEMENT EN01F02127050402036001 REMOVING THE SCR UPSTREAM TEMPERATURE SENSOR Reference: EXHAUST (J05E), SCR UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, REMOVING THE SCR UPSTREAM TEMPERATURE SENSOR (Page 11-116) SINGLE UNIT INSPECTION Reference: EXHAUST (J05E), SCR UPSTREAM TEMPERA- TURE SENSOR, REPLACEMENT, SINGLE UNIT INSPECTION (Page 11-117) MOUNTING THE SCR UPSTREAM TEMPERATURE SENSOR...
Page 160: Coolant Temperature Sensor
6–28 ENGINE CONTROL (J05E) COOLANT TEMPERATURE SENSOR REPLACEMENT EN01F02127050402043001 REMOVING THE COOLANT TEMPERATURE SENSOR Reference: COOLING (J05E), COOLANT TEMPERATURE SENSOR, REPLACEMENT, REMOVING THE COOLANT TEM- PERATURE SENSOR (Page 12-38) SINGLE UNIT INSPECTION Reference: COOLING (J05E), COOLANT TEMPERATURE SENSOR, REPLACEMENT, SINGLE UNIT INSPECTION (Page 12-38) MOUNTING THE COOLANT TEMPERATURE SENSOR Reference: COOLING (J05E), COOLANT TEMPERATURE...
Page 161 FUEL SYSTEM (J05E) 7–1 FUEL SYSTEM (J05E) 7-001 FUEL SYSTEM.............7-2 FUEL SYSTEM DIAGRAM........7-2 FUEL TANK..............7-3 COMPONENT LOCATOR ........7-3 REPLACEMENT (30 GALLON) ......7-4 REPLACEMENT (33 GALLON) ......7-7 FUEL SENDER GAUGE ..........7-11 COMPONENT LOCATOR ........7-11 REPLACEMENT ...........7-12 FUEL FILTER AND CASE (ENGINE SIDE)....7-14 COMPONENT LOCATOR ........7-14 REPLACEMENT ...........7-15 WATER LEVEL WARNING SWITCH ......7-24...
Page 162: Fuel System
7–2 FUEL SYSTEM (J05E) MECHANICAL SYSTEM DRAWING FUEL SYSTEM FUEL SYSTEM DIAGRAM EN01F02127060407020001 POSITIVE PRESSURE NEGATIVE PRESSURE INJECTOR RETURN COMMON RAIL SUPPLY PUMP SUCTION CONTROL FEED PUMP VALVE FUEL QUANTITY FUEL SHUT VALVE VALVE NEGATIVE POSITIVE ENGINE SIDE FUEL PRESSURE PRESSURE FILTER SIDE...
Page 163: Fuel Tank
FUEL SYSTEM (J05E) 7–3 COMPOSITION DIAGRAM FUEL TANK COMPONENT LOCATOR EN01F02127060402011001 30 GALLON (REPRESENTATIVE EXAMPLE) SHTS021270600002 Fuel sender gauge Clamp Drain plug Fixed bracket Gasket * Fuel tank Fuel hose Fuel tank band Breather hose Fuel tank support *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 24.5-34.3 {250-349, 19-26}...
Page 164: Replacement (30 Gallon)
7–4 FUEL SYSTEM (J05E) REPLACEMENT (30 GALLON) EN01F02127060402011002 REMOVING THE FUEL TANK CAUTIONS ! CAUTION While working, be careful not to make dirt and water enter parts. REMOVING THE FUEL TANK Disconnect the connector connected to the fuel sender gauge. Disconnect the 2 harness clamps.
Page 165 FUEL SYSTEM (J05E) 7–5 MOUNTING THE FUEL TANK CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 166 7–6 FUEL SYSTEM (J05E) Align the alignment marks, connect the feed hose, return hose, fuel hose and breather hose. Fasten each hose with the clamp. FUEL HOSE BREATHER HOSE SHTS021270600008 Connect the connector of the fuel sender gauge, then connect the 2 harness clamps.
Page 167: Replacement (33 Gallon)
FUEL SYSTEM (J05E) 7–7 REPLACEMENT (33 GALLON) EN01F02127060402011003 REMOVING THE FUEL TANK CAUTIONS ! CAUTION While working, be careful not to make dirt and water enter parts. REMOVING THE FUEL TANK Disconnect the connector connected to the fuel sender gauge. Disconnect the harness clamp.
Page 168 7–8 FUEL SYSTEM (J05E) Unfasten the double nut to remove the fuel tank band. Remove the fuel tank from the fuel tank support. FUEL TANK FUEL TANK FUEL TANK BAND SUPPORT DOUBLE NUT SHTS021270600013...
Page 169 FUEL SYSTEM (J05E) 7–9 MOUNTING THE FUEL TANK CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 170 7–10 FUEL SYSTEM (J05E) With the alignment marks aligned with each other, connect the feed hose and the return hose. ! CAUTION If the fuel tank support is removed, make sure of the correct insert direction of bolt. Fasten the feed hose and the return hose with the clamps. SHTS021270600017 Connect the harness clamp.
Page 171: Fuel Sender Gauge
FUEL SYSTEM (J05E) 7–11 FUEL SENDER GAUGE COMPONENT LOCATOR EN01F02127060402010001 SHTS021270600019 Fuel sender gauge Fuel tank Gasket * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 1.5-2.5 {16-25, 1.2-1.8}...
Page 172: Replacement
7–12 FUEL SYSTEM (J05E) REPLACEMENT EN01F02127060402010002 REMOVING THE FUEL SENDER GAUGE CAUTIONS ! CAUTION While working, be careful not to make dirt and water enter parts. DISCONNECTING THE HARNESS Disconnect the connector connected to the fuel sender gauge. REMOVING THE FUEL SENDER GAUGE Unfasten the bolts (5 pcs.) securing the fuel sender gauge, and remove the fuel sender gauge and the gasket from the fuel tank.
Page 173 FUEL SYSTEM (J05E) 7–13 MOUNTING THE FUEL SENDER GAUGE MOUNTING THE FUEL SENDER GAUGE Replace the gasket with a new one, and fasten the fuel sender gauge to the fuel tank with the bolts (5 pcs.). Tightening Torque: 1.5-2.5 N·m {16-25 kgf·cm, 1.2-1.8 lbf·ft} ! CAUTION •...
Page 174: Fuel Filter And Case (Engine Side)
7–14 FUEL SYSTEM (J05E) FUEL FILTER AND CASE (ENGINE SIDE) COMPONENT LOCATOR EN01F02127060402042001 SHTS021270600023 Fuel filter Priming pump Drain plug Air bleeding plug Tightening torque Unit: Nm {kgfcm, lbfft} 5-9 {51-91, 3.7-6.6} 55 {561, 41} 23.1-32.9 {236-335, 18-24}...
Page 175: Replacement
FUEL SYSTEM (J05E) 7–15 REPLACEMENT EN01F02127060402042002 DRAINING WATER FROM FUEL FILTER (ENGINE SIDE) CAUTIONS ! CAUTION • Air enters the fuel pipe in the process of mounting the pre- fuel filter case. After mounting is completed, thoroughly purge air from the fuel pipe. •...
Page 176 7–16 FUEL SYSTEM (J05E) AIR BLEEDING OF FUEL SYSTEM CAUTIONS ! CAUTION While working, be careful not to make dirt and water enter parts. AIR BLEEDING OF FUEL SYSTEM Connect the hose to the air bleeding plug and prepare a container PRIMING AIR BLEEDING under the air bleeding hose to catch the drained fuel.
Page 177 REPLACE THE ELEMENT CAUTIONS ! CAUTION • Use Hino's genuine fuel filter element. • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them.
Page 178 7–18 FUEL SYSTEM (J05E) MOUNTING THE ELEMENT Replace the O-rings of the air bleeding plug and drain plug with CENTER BOLT new ones. Clean the element setting face inside the fuel filter case and inside the cap. ELEMENT Insert a new element into the fuel filter case. O-RINGS ! CAUTION If the element is replaced with the fuel remained in the fuel filter...
Page 179 FUEL SYSTEM (J05E) 7–19 REMOVING THE FUEL FILTER CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Be careful when disconnecting the fuel pipe because the fuel may run out. FUEL DISCHARGE Prepare reservoir under the drain plug to receive the drained fuel.
Page 180 7–20 FUEL SYSTEM (J05E) Remove the nut and then the clip. RETURN PIPE No.2 CLIP SHTS021270600038 Remove the nut and then the clip. Unfasten 2 clamps to remove the hose from the fuel filter. FUEL FEED Unfasten 3 union bolts to disconnect fuel feed pipe No.1 and fuel PIPE No.1 feed pipe No.2 from the fuel filter and supply pump.
Page 181 FUEL SYSTEM (J05E) 7–21 Remove the nut and then the clip. INTERCEPTION VALVE FUEL FEED PIPE No.3 SHTS021270600041 REMOVING THE FUEL FILTER Remove the bolts (2 pcs.) and remove the fuel filter. FUEL FILTER ! CAUTION Be careful not to spill the residual fuel in the fuel filter case. SHTS021270600042...
Page 182 7–22 FUEL SYSTEM (J05E) MOUNTING THE FUEL FILTER (ENGINE SIDE) CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 183 FUEL SYSTEM (J05E) 7–23 Connect fuel feed pipe No.1 and fuel feed pipe No.2 to the fuel fil- ter and supply pump with a new gasket and 3 union bolts. FUEL FEED PIPE No.1 Tightening Torque: 25 N·m {255 kgf·cm, 18 lbf·ft} Supply pump side HOSE 30 N·m {306 kgf·cm, 22 lbf·ft}...
Page 184: Water Level Warning Switch
7–24 FUEL SYSTEM (J05E) WATER LEVEL WARNING SWITCH COMPONENT LOCATOR EN01F02127060402022001 SHTS021270600050 Air bleeding plug Drain plug Water level warning switch O-ring * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 5-9 {51-91, 3.7-6.6} 2-3 {21-30, 1.5-2.2}...
Page 185: Replacement
FUEL SYSTEM (J05E) 7–25 REPLACEMENT EN01F02127060402022002 REMOVING THE WATER LEVEL WARNING SWITCH FUEL DISCHARGE Prepare reservoir under the drain plug to receive the drained fuel. AIR BLEEDING PLUG Loosen the drain plug and then the air bleeding plug of the fuel fil- ter, and drain the fuel from the drain plug.
Page 186 7–26 FUEL SYSTEM (J05E) SINGLE UNIT INSPECTION INSPECTING CONTINUITY Move the float of the water level warning switch up and down by WATER LEVEL hand. Using the circuit tester, measure continuity between termi- WARNING SWITCH nals. If any problem is found, replace the water level warning switch.
Page 187: Supply Pump
FUEL SYSTEM (J05E) 7–27 SUPPLY PUMP COMPONENT LOCATOR EN01F02127060402007001 SHTS021270600057 Pipe A O-ring * Pipe B Cup ring flange Supply pump Bearing holder case Cut ring O-ring * *: Nonreusable part...
Page 188: Replacement
7–28 FUEL SYSTEM (J05E) REPLACEMENT EN01F02127060402007002 REMOVING THE SUPPLY PUMP ! CAUTION While working, be careful not to make dirt and water enter parts. TURNING THE STARTER SWITCH TO THE LOCK POSITION ! CAUTION Perform the following work after the engine cools off to avoid fire or burning.
Page 189 FUEL SYSTEM (J05E) 7–29 REMOVING THE PRESSURE FEED PIPE Unfasten the nuts (2 pcs.), and remove the clips (2 pcs.). Loosen the nut to remove the pressure feed pipe from the com- mon rail and supply pump. ! CAUTION PRESSURE FEED PIPE •...
Page 190 7–30 FUEL SYSTEM (J05E) Remove the timing check window plug from the bearing holder case of the supply pump. BEARING HOLDER CASE Attach the SST specified below to the timing check window of the CORRECT bearing holder case to see that the bearing surface of the SST is seated on the supply pump.
Page 191 FUEL SYSTEM (J05E) 7–31 Unfasten 4 bolts to remove the supply pump, coupling and O-ring from the engine. BEARING HOLDER CASE ! CAUTION Remove the supply pump and the bearing holder case together. COUPLING FLANGE O-RING SUPPLY PUMP SHTS021270600068 Unfasten the nut with the coupling flange locked with a vise, and remove the coupling flange.
Page 192 INSPECTING THE SUCTION CONTROL VALVE AND THE FUEL TEMPERATURE SENSOR SUCTION CONTROL VALVE Using the HINO-DX, inspect the suction control valve and the fuel temperature sensor. If any abnormality is found in either of the parts, replace the supply pump. (Refer to the HINO-DX user's manual.)
Page 193 FUEL SYSTEM (J05E) 7–33 MOUNTING THE SUPPLY PUMP CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 194 7–34 FUEL SYSTEM (J05E) Insert the SST specified below into the bearing holder case and bring it into close contact with the detent of the coupling flange. BEARING HOLDER CASE SST: SZ105-08067 Guide bolt ! CAUTION • Do not tighten the SST by applying it to a part other than the detent of the coupling, or do not use a tool other than the SST for locking.
Page 195 (ENGINE SIDE), REPLACEMENT, AIR BLEEDING OF FUEL SYSTEM (Page 7-16) UPDATING THE SUPPLY PUMP LEARNED VALUE When replacing the supply pump, update the learned value recorded in the engine ECU by using HINO-DX. (Refer to the HINO-DX user's manual.) ! CAUTION •...
Page 196: Injector
7–36 FUEL SYSTEM (J05E) INJECTOR COMPONENT LOCATOR EN01F02127060402004001 SHTS021270600083 Leakage pipe Injector Gasket * Injector clamp Injection pipe oil seal O-ring * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 25 {255, 18}...
Page 197: Replacement
FUEL SYSTEM (J05E) 7–37 REPLACEMENT EN01F02127060402004002 REMOVING THE INJECTOR ! CAUTION • While working, be careful not to make dirt and water enter parts. • Clean off surrounding area of the injectors and fuel line con- nectors. REMOVING THE HEAD COVER Reference: ENGINE MECHANICAL (J05E), HEAD COVER, REPLACEMENT, REMOVING THE HEAD COVER (Page 10-3) REMOVING THE LEAKAGE PIPE...
Page 198 7–38 FUEL SYSTEM (J05E) REMOVING THE INJECTION PIPE Unfasten 5 nuts to remove 5 clips. SHTS021270600087 Loosen the nuts securing the injection pipes (4 pcs.), and remove them from the injector and the common rail. ! CAUTION • Do not reuse the injection pipes. SHTS021270600088 •...
Page 199 FUEL SYSTEM (J05E) 7–39 Unfasten the injector clamp mounting bolts to remove the injector and injector clamp. INJECTOR BOLT Remove the O-ring. NOTICE Replace the O-ring with a new one. O-RING INJECTOR CLAMP SHTS021270600091 SINGLE UNIT INSPECTION INSPECTING THE RESISTANCE Use the 1,000 V megohmmeter, measure the insulation resis- MEGOHMMETER tance between either of 2 terminals (no polarity) to which the...
Page 200 7–40 FUEL SYSTEM (J05E) CLEANING THE INSIDE OF THE NOZZLE SEAT If sludge sticks to the inside of the nozzle seat, spray a detergent CYLINDER HEAD over it, wipe it off with a waste cloth, and wash it out with the detergent.
Page 201 FUEL SYSTEM (J05E) 7–41 MOUNTING THE INJECTOR CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. • Air enters the fuel pipe in the process of mounting the pre- fuel filter case.
Page 202 7–42 FUEL SYSTEM (J05E) Temporarily mount new injection pipes (4 pcs.) on the injector and the common rail. ! CAUTION • Do not fail to replace the injection pipes with new ones because they are subjected to high pressure and may cause fuel leakage.
Page 203 NOTICE • Injector compensation value can be written by means of a SHTS021270600101 combined use of the PC tool and QR code reader. • The work flow is indicated below. For the detailed procedure, see the HINO-DX instruction manual.
Page 204 Read the QR code of the injector by using the scanner of the QR code reader to create a compensation data file. Write the injector compensation value in the engine ECU from a computer. COMPUTER QR CODE READER HINO-BOWIE ENGINE SPECIFICATION CODE DST-i QR CODE NEW INJECTOR CONNECTOR...
Page 205 FUEL SYSTEM (J05E) 7–45 MOUNTING THE LEAKAGE PIPE Remove dirt or foreign matters from the gasket mounting surface. UNION BOLT UNION BOLT Mount the leakage pipe to the injector and cylinder head with a new gasket and 5 union bolts. Tightening Torque: 9.8-4.7 N·m {100-149 kgf·cm, 7.3-10.8 lbf·ft} ! CAUTION...
Page 206: Common Rail
7–46 FUEL SYSTEM (J05E) COMMON RAIL COMPONENT LOCATOR EN01F02127060402005001 SHTS021270600108 Common rail Injection pipe * Common rail pressure sensor Clip Bracket *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21} 44 {449, 32}...
Page 207: Inspection
INSPECTING THE FLOW DAMPER Start the engine and change the engine revolution from idling to full throttle. Use HINO-DX to check the diagnosis code of the "flow damper operation." If the diagnosis code of the "flow damper operation" is detected, replace the relevant injector and inspect it again.
Page 208: Replacement
7–48 FUEL SYSTEM (J05E) REPLACEMENT EN01F02127060402005003 REMOVING THE COMMON RAIL ! CAUTION • While working, be careful not to make dirt and water enter parts. • Clean off surrounding area of the injectors and fuel line con- nectors. DISCONNECTING THE HARNESS Disconnect the connector connected to the common rail pressure sensor.
Page 209 FUEL SYSTEM (J05E) 7–49 REMOVING THE COMMON RAIL Unfasten the bolts (2 pcs.) securing the common rail, and remove the common rail and the bracket from the intake manifold. ! CAUTION BRACKET • Protect with clean vinyl to avoid entry of dirt into the com- mon rail.
Page 210 7–50 FUEL SYSTEM (J05E) MOUNTING THE COMMON RAIL CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 211 FUEL SYSTEM (J05E) 7–51 MOUNTING THE INJECTION PIPE Mount the new injection pipes (4 pcs.) on the injector and the common rail. Tightening Torque: 44 N·m {449 kgf·cm, 32 lbf·ft} ! CAUTION • Do not fail to replace the injection pipes with new ones because they are subjected to high pressure and may cause fuel leakage.
Page 212 7–52 FUEL SYSTEM (J05E) CONNECTING THE HARNESS Connect the connector to the common rail pressure sensor. COMMON RAIL SHTS021270600121 ! CAUTION • Engage the female connector with the male connector until MALE CONNECTOR the spring lock "clicks" and returns. COMMON RAIL FEMALE •...
Page 213: Fuel Filter And Case (Vehicle Side)
FUEL SYSTEM (J05E) 7–53 FUEL FILTER AND CASE (VEHICLE SIDE) COMPONENT LOCATOR EN01F02127060402041001 SHTS021270600123 Drain plug O-ring Air bleeding plug Clamp Cover Fuel filter Tightening torque Unit: Nm {kgfcm, lbfft} 17.5 {178, 13}...
Page 214: Replacement
After mounting is completed, thoroughly purge air from the fuel pipe. • Use Hino's genuine fuel filter element. FUEL DISCHARGE Prepare reservoir under the drain plug to receive the drained fuel. Loosen the drain plug and then the air bleeding plug of the fuel fil- ter, and drain the fuel from the drain plug.
Page 215 FUEL SYSTEM (J05E) 7–55 REMOVING THE ELEMENT Disengage the claw and loosen the fuel filter cover to remove it. CLAW COVER DIRECTION OF ROTATION SHTS021270600125 Remove the fuel filter element from the fuel filter cover. Remove the O-ring from the fuel filter cover. ! CAUTION Prepare a tray to catch the fuel remaining in the fuel filter cover.
Page 216 7–56 FUEL SYSTEM (J05E) Tighten the fuel filter cover by hand until the claw is engaged as shown in the figure. ! CAUTION • Be careful not to damage the O-ring by twisting it. • Check that the O-ring is in correct contact with the sealing surface.
Page 217 FUEL SYSTEM (J05E) 7–57 REMOVING VEHICLE SIDE FUEL FILTER ASSEMBLY CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 218 7–58 FUEL SYSTEM (J05E) Check that the fuel is no longer drained from the drain plug and then tighten the drain plug and air bleeding plug. ! CAUTION • Do not use a tool to tighten it. • Drain the fuel in accordance with the regulation of disposal specified in each region.
Page 219 FUEL SYSTEM (J05E) 7–59 REMOVING FUEL FILTER ASSEMBLY Unfasten 2 bolts to remove the fuel filter assembly. ! CAUTION • Be careful not to spill the fuel remaining in the fuel filter cover. • Return the fuel remaining in the fuel filter cover into the fuel tank.
Page 220 7–60 FUEL SYSTEM (J05E) MOUNTING VEHICLE SIDE FUEL FILTER ASSEM- CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 221 FUEL SYSTEM (J05E) 7–61 CONNECTING THE HARNESS Connect the connector to the fuel heater. (Vehicle with fuel heater) ! CAUTION Before connecting the connectors, make sure that the terminals are free of a spark mark. AIR BLEEDING OF FUEL SYSTEM Reference: FUEL SYSTEM (J05E), FUEL FILTER AND CASE (ENGINE SIDE), REPLACEMENT, AIR BLEEDING OF FUEL SYSTEM (Page 7-16)
Page 222: Fuel Cooler
7–62 FUEL SYSTEM (J05E) FUEL COOLER COMPONENT LOCATOR EN01F02127060402027001 SHTS021270600138 Clamp Fuel cooler Fuel hose Bracket Tightening torque Unit: Nm {kgfcm, lbfft} 25{255, 18}...
Page 223: Replacement
FUEL SYSTEM (J05E) 7–63 REPLACEMENT EN01F02127060402027002 REMOVING FUEL COOLER CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 224 7–64 FUEL SYSTEM (J05E) MOUNTING FUEL COOLER CAUTIONS ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting parts, make sure that there is no dirt on the connection between them. • Air enters the fuel pipe in the process of mounting the pre- fuel filter case.
Page 225 EMISSION CONTROL (J05E) 8–1 EMISSION CONTROL (J05E) 8-001 EGR VALVE & COOLER..........8-2 COMPONENT LOCATOR ........8-2 INSPECTION ............8-3 REPLACEMENT .............8-3 CLOSED VENTILATOR ..........8-10 COMPONENT LOCATOR ........8-10 REPLACEMENT ...........8-12...
Page 226: Egr Valve & Cooler
8–2 EMISSION CONTROL (J05E) COMPOSITION DIAGRAM EGR VALVE & COOLER COMPONENT LOCATOR EN01F02114070402016001 SHTS021270700001 EGR pipe EGR cooler Gasket * EGR valve Coolant hose Gasket * Clamp *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 68.5 {699, 51} 55 {561, 41}...
Page 227: Inspection
EN01F02114070402016002 INSPECTION BEFORE SERVICING Reference: INTAKE (J05E), AIR FLOW SENSOR, REPLACE- MENT, REMOVING THE AIR FLOW SENSOR (Page 9-35) Using the HINO-DX for operation check of the EGR valve on board. (Refer to the HINO-DX user's manual.) REPLACEMENT EN01F02114070402016003 REMOVING THE EGR VALVE & COOLER...
Page 228 8–4 EMISSION CONTROL (J05E) DISCONNECTING THE COOLANT HOSE Unfasten the 3 clamps to disconnect 2 coolant hoses from the EGR cooler and coolant pipe. Unfasten the 2 clamps to disconnect the coolant hose from the EGR cooler and thermostat case. REMOVING THE EGR COOLER Unfasten the 2 bolts to remove the bracket from the EGR cooler.
Page 229 EMISSION CONTROL (J05E) 8–5 REMOVING THE EGR VALVE Disconnect the connector from the EGR valve. Remove the EGR valve and gasket from the intake manifold. EGR VALVE ! CAUTION INTAKE • Do not step on the EGR valve during engine service work. MANIFOLD •...
Page 230 8–6 EMISSION CONTROL (J05E) INSPECTING THE COMPONENTS INSPECTING THE EGR COOLER Visually inspect the EGR cooler for cracks and clogging. If there is something wrong with the EGR cooler, replace it. CLEANING THE EGR COOLER CAUTIONS ! CAUTION • This agent is alkali. Wear protective equipment (glasses, rub- ber gloves, and protective garment) to prevent it from con- tacting eyes, skin, and cloth.
Page 231 EMISSION CONTROL (J05E) 8–7 RINSING AFTER CLEANING THE EGR COOLER After immersing for about 1 hour, pour new detergent (PK- EGR COOLER 5300YP) into the EGR cooler. Cover both ends with packing tape, shake it about 10 times, and then let the inside detergent out. (Repeat this 2-3 times.) NOTICE Dissolved carbon inside the EGR cooler flows out.
Page 232 8–8 EMISSION CONTROL (J05E) MOUNTING THE EGR VALVE & COOLER MOUNTING THE EGR VALVE Replace with a new gasket and temporarily attach the EGR valve to the intake manifold. EGR VALVE Connect the EGR valve to the connector. INTAKE MANIFOLD LINK GASKET SHTS021270700011...
Page 233 EMISSION CONTROL (J05E) 8–9 MOUNTING THE EGR PIPE Replace with a new gasket and mount the EGR pipe with 4 bolts and 2 nuts. Tightening Torque: 55 N·m {561 kgf·cm, 41 lbf·ft} EGR PIPE SHTS021270700013 Mount the 2 brackets to the EGR pipe with 3 bolts and a nut. Tightening Torque: BRACKET 28.5 N·m {291 kgf·cm, 21 lbf·ft}...
Page 234: Closed Ventilator
8–10 EMISSION CONTROL (J05E) CLOSED VENTILATOR COMPONENT LOCATOR EN01F02114070402011001 SHTS021270700015 Clamp Closed ventilator Oil pipe Ventilator hose A Bracket Ventilator hose B Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 23}...
Page 235 EMISSION CONTROL (J05E) 8–11 SHTS021270700016 Closed ventilator Element Body...
Page 236: Replacement
8–12 EMISSION CONTROL (J05E) REPLACEMENT EN01F02114070402011002 REPLACE THE ELEMENT REMOVING THE ELEMENT Remove the 2 bolts and remove the closed ventilator cover. COVER SHTS021270700017 Remove the cap while pressing and turning it counterclockwise. CLOSED VENTILATOR SHTS021270700018 Remove the element from the body. Remove the O-ring from the cap.
Page 237 EMISSION CONTROL (J05E) 8–13 MOUNTING THE ELEMENT Replace with a new O-ring and apply engine oil. Mount it to the cap. Replace with a new element and mount it by aligning with the body center boss. O-RING ELEMENT BODY CENTER BOSS SHTS021270700020 Mount the cap by turning clockwise until it lifts up.
Page 238 8–14 EMISSION CONTROL (J05E) REMOVING THE CLOSED VENTILATOR REMOVING THE HOSE Unfasten the 2 clamps and bolt to disconnect the ventilator hose VENTILATOR A from the closed ventilator and intake hose. HOSE A Unfasten the 2 clamps and bolt to disconnect the ventilator hose B from the closed ventilator and cylinder head.
Page 239 EMISSION CONTROL (J05E) 8–15 REMOVING THE CLOSED VENTILATOR Remove the 2 bolts and remove the closed ventilator cover. COVER SHTS021270700027 Unfasten the 4 bolts to remove the closed ventilator from the bracket. CLOSED VENTILATOR SHTS021270700028 Using the SST, remove the clamp on the flywheel housing side break.
Page 240 8–16 EMISSION CONTROL (J05E) MOUNTING THE CLOSED VENTILATOR MOUNTING THE CLOSED VENTILATOR Hose attached to the flywheel housing, attach the clamp is CLAMP crimped using a SST. Standard value: (X) 6 mm {0.236 in.} or less SST: S0920-E0010 Vemt pipe tool NOTICE •...
Page 241 EMISSION CONTROL (J05E) 8–17 Connect the oil hose to the closed ventilator and flywheel housing with 2 clamps. CLAMP NOTICE • Install the new clamp. • Do not twist the oil hose. • Connect it in a way that the white mark is positioned on the vehicle rear side.
Page 242 INTAKE (J05E) 9–1 INTAKE (J05E) 9-001 INTAKE MANIFOLD.............9-2 COMPONENT LOCATOR ........9-2 REPLACEMENT .............9-3 DIESEL THROTTLE .............9-8 COMPONENT LOCATOR ........9-8 INSPECTION ............9-9 REPLACEMENT .............9-9 INTAKE PIPE (EXHAUST SIDE)........9-11 COMPONENT LOCATOR ........9-11 REPLACEMENT ...........9-12 INTERCOOLER............9-14 OVERHAUL............9-14 STACK DUCT .............9-15 COMPONENT LOCATOR ........9-15 CLEANING THE PRECLEANER HOUSING ..9-16 REPLACEMENT ...........9-17 AIR CLEANER ............9-19...
Page 243: Intake Manifold
9–2 INTAKE (J05E) COMPOSITION DIAGRAM INTAKE MANIFOLD COMPONENT LOCATOR EN01F02114080402004001 SHTS021270800001 Intake manifold Gasket * *: Nonreusable part...
Page 244: Replacement
INTAKE (J05E) 9–3 REPLACEMENT EN01F02114080402004002 REMOVING THE INTAKE MANIFOLD DISCONNECTING THE HARNESS Remove the connector and clip and disconnect the engine har- ness around the intake manifold. REMOVING THE EGR PIPE Reference: EMISSION CONTROL (J05E), EGR VALVE & COOLER, REPLACEMENT, REMOVING THE EGR VALVE & COOLER (Page 8-3) REMOVING THE CLOSED VENTILATOR Reference: EMISSION CONTROL (J05E), CLOSED VENTILA-...
Page 245 9–4 INTAKE (J05E) REMOVING THE EGR VALVE Remove the EGR valve and gasket from intake manifold. EGR VALVE ! CAUTION • Do not step on the EGR valve during engine service work. INTAKE • Do not remove or loosen the bolts, nuts, and snap rings that MANIFOLD are components of the EGR valve.
Page 246 INTAKE (J05E) 9–5 Unfasten the 8 bolts and 2 nuts to remove the intake manifold and gasket from the cylinder head. GASKET NOTICE Block the openings of the intake manifold with gummed tape to prevent the ingress of dirt into it. INTAKE MANIFOLD SHTS021270800006...
Page 247 9–6 INTAKE (J05E) MOUNTING THE INTAKE MANIFOLD MOUNTING THE INTAKE MANIFOLD Clean the inside of the intake manifold and cylinder head. GASKET PROJECTION Replace the gasket with a new one, and mount the intake mani- fold on the cylinder head with 8 bolts and 2 nuts that secured the intake manifold.
Page 248 INTAKE (J05E) 9–7 CONNECTING THE RETURN PIPE No.3 Replace with a new gasket and connect the return pipe No.3 with bolts. Mount the clip with the nut, and fix the return pipe No.3. RETURN PIPE No.3 SHTS021270800010 MOUNTING THE FUEL FILTER CASE Reference: FUEL SYSTEM (J05E), FUEL FILTER AND CASE (ENGINE SIDE), REPLACEMENT, MOUNTING THE FUEL FIL- TER (ENGINE SIDE) (Page 7-22)
Page 249: Diesel Throttle
9–8 INTAKE (J05E) DIESEL THROTTLE COMPONENT LOCATOR EN01F02114080402017001 SHTS021270800011 Intake manifold Gasket * Diesel throttle *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21}...
Page 250: Inspection
INTAKE (J05E) 9–9 INSPECTION EN01F02114080402017002 INSPECTING THE DIESEL THROTTLE Use the HINO-DX, inspect the diesel throttle. (See the HINO-DX manual.) REPLACEMENT EN01F02114080402017003 REMOVING THE DIESEL THROTTLE REMOVING THE INTERCOOLER HOSE (OUTLET HOSE) Reference: COOLING (J05E), INTERCOOLER, OVERHAUL, REMOVING THE INTERCOOLER (Page 12-21)
Page 251 9–10 INTAKE (J05E) MOUNTING THE DIESEL THROTTLE CONNECTING THE HARNESS Connect the connector to the diesel throttle. CONNECTOR DIESEL THROTTLE SHTS021270800014 MOUNTING THE DIESEL THROTTLE Replace the gasket with a new one, temporarily fasten the diesel INTAKE throttle to intake manifold with 2 bolts and 2 nuts, and tighten MANIFOLD them to the specified torque in a crisscross pattern.
Page 252: Intake Pipe (Exhaust Side)
INTAKE (J05E) 9–11 INTAKE PIPE (EXHAUST SIDE) COMPONENT LOCATOR EN01F02114080402020001 SHTS021270800016 Primary intake hose Clamp Turbocharger...
Page 253: Replacement
9–12 INTAKE (J05E) REPLACEMENT EN01F02114080402020002 REMOVING THE INTAKE PIPE (EXHAUST SIDE) DISCONNECTING THE HARNESS Remove the joint connector and clip, and disconnect the engine harness from the primary intake hose and secondary intake pipe. REMOVING THE INTERCOOLER HOSE (INLET HOSE) Reference: COOLING (J05E), INTERCOOLER, OVERHAUL, REMOVING THE INTERCOOLER (Page 12-21) REMOVING THE INTAKE PIPE (EXHAUST SIDE)
Page 254 INTAKE (J05E) 9–13 MOUNTING THE INTAKE PIPE (EXHAUST SIDE) MOUNTING THE INTAKE PIPE (EXHAUST SIDE) Check the intake system for dirt or foreign matter. Wash off oil on the intake hose insertion part and inner side of the hose inlet. Insert the primary intake hose to the turbocharger assembly.
Page 255: Intercooler
9–14 INTAKE (J05E) INTERCOOLER OVERHAUL EN01F02114080402018001 REMOVING THE INTERCOOLER Reference: COOLING (J05E), INTERCOOLER, REMOVING THE INTERCOOLER (Page 12-21) INSPECTING THE INTERCOOLER Inspect the radiator core for dirt or crushing. If found defective, clean or adjust or replace it. MOUNTING THE INTERCOOLER Reference: COOLING (J05E), INTERCOOLER, MOUNTING THE INTERCOOLER (Page 12-22)
Page 256: Stack Duct
INTAKE (J05E) 9–15 STACK DUCT COMPONENT LOCATOR EN01F02114080402011001 SHTS021270800019 Stack duct Duct mount Intake hose Tightening torque Unit: Nm {kgfcm, lbfft} 19.5 {199, 14} 13 {133, 10}...
Page 257: Cleaning The Precleaner Housing
9–16 INTAKE (J05E) CLEANING THE PRECLEANER HOUSING EN01F02114080402011002 REMOVING THE WING Unfasten the 8 screws, and remove the wing and plate from the STACK DUCT stack duct. PLATE WING SHTS021270800020 CLEANING THE PRECLEANER HOUSING Clean the inside of the precleaner housing with a cloth. ! CAUTION When cleaning the precleaner housing, exercise care not to allow PRECLEANER...
Page 258: Replacement
INTAKE (J05E) 9–17 REPLACEMENT EN01F02114080402011003 REMOVING THE STACK DUCT REMOVING THE STACK DUCT Unfasten the 3 nuts to remove the stack duct from the duct mount. Loosen the clamp, and disconnect the intake hose from the bot- tom of the stack duct. STACK DUCT INTAKE HOSE...
Page 259 9–18 INTAKE (J05E) MOUNTING THE STACK DUCT MOUNTING THE DUCT MOUNT Mount the 2 duct mounts to the bracket with 2 bolts. Tightening Torque: DUCT 19.5 N·m {199 kgf·cm, 14 lbf·ft} MOUNT Mount the duct mount to the cab with the bolt. BRACKET Tightening Torque: 19.5 N·m {199 kgf·cm, 14 lbf·ft}...
Page 260: Air Cleaner
INTAKE (J05E) 9–19 AIR CLEANER COMPONENT LOCATOR EN01F02114080402008001 WIDE CAB (SINGLE CAB) SHTS021270800027 Air cleaner body assembly Air cleaner element Cover Air flow sensor *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 2.4-5.0 {25-50, 1.8-3.6}...
Page 261 9–20 INTAKE (J05E) WIDE CAB (CREW CAB) SHTS021270800028 Air cleaner body assembly Air cleaner element Cover Air flow sensor *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 2.4-5.0 {25-50, 1.8-3.6}...
Page 262: Replacement
INTAKE (J05E) 9–21 REPLACEMENT EN01F02114080402008002 REMOVING THE AIR CLEANER ELEMENT AND BODY ASSEMBLY REMOVING THE AIR CLEANER ELEMENT Remove the clamps (3 pcs.) and remove the cover from the air SINGLE CAB cleaner body assembly. NOTICE When removing the air cleaner of the crew cab model, pull off the cover toward the vehicle rear side and press the cover to the inboard side.
Page 263 9–22 INTAKE (J05E) REMOVING THE AIR CLEANER BODY ASSEMBLY Disconnect the connector from the air flow sensor. AIR FLOW INTAKE HOSE No.1 Loosen the clamp, and disconnect the intake hose No.1 from the SENSOR air cleaner body assembly. CONNECTOR CLAMP SHTS021270800031 Remove the fender side apron (right).
Page 264 INTAKE (J05E) 9–23 MOUNTING THE AIR CLEANER ELEMENT AND BODY ASSEMBLY MOUNTING THE AIR CLEANER BODY ASSEMBLY Clean the inside of the cover of the air cleaner and of the air SINGLE CAB cleaner body assembly with a waste cloth. Mount the air cleaner body assembly to the air cleaner bracket with 4 nuts.
Page 265 9–24 INTAKE (J05E) MOUNTING THE AIR CLEANER ELEMENT Hold the grip at the center of the air cleaner element and insert SINGLE CAB the seal rubber of the air cleaner element to the air cleaner body AIR CLEANER SEAL RUBBER assembly securely.
Page 266: Cleaning The Air Cleaner Element
INTAKE (J05E) 9–25 CLEANING THE AIR CLEANER ELEMENT EN01F02114080402008003 CLEANING THE AIR CLEANER ELEMENT Check the seal rubber for damage. If found defective, replace the air cleaner element. SEAL RUBBER AIR CLEANER ELEMENT SHTS021270800037 If dry dust is adhered, blow compressed air (690 kPa {7.0 kgf/cm 100 lbf/in.
Page 267: Intake Temperature Sensor
9–26 INTAKE (J05E) INTAKE TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02114080402026001 INTAKE MANIFOLD SHTS021270800039 Intake temperature sensor Washer * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 19.6 {200, 14}...
Page 268 INTAKE (J05E) 9–27 INTERCOOLER SHTS021270800040 Intake temperature sensor Washer * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 19.6 {200, 14}...
Page 269: Replacement
9–28 INTAKE (J05E) REPLACEMENT EN01F02114080402026002 REMOVING THE INTAKE TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the intake temperature sensor. Remove the clip from the bracket. REMOVING THE INTAKE TEMPERATURE SENSOR Remove the intake temperature sensor and washer from the intake manifold and intercooler.
Page 270: Boost Pressure Sensor
INTAKE (J05E) 9–29 BOOST PRESSURE SENSOR COMPONENT LOCATOR EN01F02114080402021001 SHTS021270800043 Boost pressure sensor Hose Clamp...
Page 271: Inspection
9–30 INTAKE (J05E) INSPECTION EN01F02114080402021002 INSPECTING THE BOOST PRESSURE SENSOR Using the HINO-DX, inspect the boost pressure sensor. (See the HINO-DX manual.) REPLACEMENT EN01F02114080402021003 REMOVING THE BOOST PRESSURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the boost pressure sen- BOOST PRESSURE sor.
Page 272 INTAKE (J05E) 9–31 MOUNTING THE BOOST PRESSURE SENSOR MOUNTING THE BOOST PRESSURE SENSOR Mount the hose to the boost pressure sensor with the clamps (2 BOOST PRESSURE pcs.) that secured the hose. SENSOR Mount the boost pressure sensor on the intake manifold with 2 bolts.
Page 273: Air Flow Sensor
9–32 INTAKE (J05E) AIR FLOW SENSOR COMPONENT LOCATOR EN01F02114080402009001 SHTS021270800048 Air flow sensor Tightening torque Unit: Nm {kgfcm, lbfft} 0.56-0.82 {5.8-8.3, 0.42-0.60}...
Page 274: Inspection
• Before implementing the "EGR solenoid valve operation check by using the HINO-DX," inspect this air flow sensor. Before inspection, clean the air cleaner element or replace with a new one. Prepare a new air flow sensor aside from the one mounted to the vehicle.
Page 275 9–34 INTAKE (J05E) Judgment of presence or absence of deteriorated characteristics of the air flow sensor a. If the detected air flow rate of the air flow sensor mounted to the vehicle shows a decrease by 10% or more in comparison with that of a new air flow sensor (See the following for the calculating formula), the air flow sensor mounted to the vehi- cle is deteriorated.
Page 276: Replacement
INTAKE (J05E) 9–35 REPLACEMENT EN01F02114080402009003 REMOVING THE AIR FLOW SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the air flow sensor. AIR FLOW SENSOR Removing the air flow sensor Unfasten the screws (2 pcs.) securing the air flow sensor, and remove it.
Page 277 ENGINE MECHANICAL (J05E) 10–1 ENGINE MECHANICAL (J05E) 10-001 HEAD COVER ............10-2 CRANKSHAFT ............10-101 COMPONENT LOCATOR ........10-2 COMPONENT LOCATOR .........10-101 REPLACEMENT ...........10-3 REPLACEMENT ..........10-103 ROCKER ARM ASSEMBLY........10-6 CYLINDER LINER..........10-112 COMPONENT LOCATOR ........10-6 COMPONENT LOCATOR .........10-112 OVERHAUL............10-7 REPLACEMENT ..........10-113 CAMSHAFT ASSEMBLY ......... 10-14 CYLINDER BLOCK..........10-116 COMPONENT LOCATOR ........
Page 278: Head Cover
10–2 ENGINE MECHANICAL (J05E) COMPOSITION DIAGRAM HEAD COVER COMPONENT LOCATOR EN01F02127090402013001 SHTS021270900001 Half-round plugs Head cover Head cover gasket * Silent block *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21}...
Page 279: Replacement
ENGINE MECHANICAL (J05E) 10–3 REPLACEMENT EN01F02127090402013002 REMOVING THE HEAD COVER REMOVING THE CLOSED VENTILATOR HOSE Reference: EMISSION CONTROL (J05E), CLOSED VENTILA- TOR, REPLACEMENT, REMOVING THE CLOSED VENTILA- TOR (Page 8-14) DISCONNECTING THE HARNESS Disconnect the connector, then detach the harness from top of the cylinder head.
Page 280 10–4 ENGINE MECHANICAL (J05E) MOUNTING THE HEAD COVER MOUNTING THE HALF-ROUND PLUG (ONLY IF THE HALF- ROUND PLUG IS REMOVED) Remove the all oil and dirt on the half-round plug and cylinder head. Apply liquid gasket (ThreeBond TB1207B: Black or equivalent or ThreeBond TB1217G: Gray or equivalent) to the half-round areas at the cylinder head front and rear ends as shown in the figure.
Page 281 ENGINE MECHANICAL (J05E) 10–5 MOUNTING THE HEAD COVER Remove the dirt (including the liquid gasket) or oil on the joint sur- BOLT HEAD COVER face of the head cover and cylinder head. SILENT Mount the new head cover gasket to the head cover groove. BLOCK Set the head cover to the cylinder head mounting position and mount it with 13 bolts through the silent block.
Page 282: Rocker Arm Assembly
10–6 ENGINE MECHANICAL (J05E) ROCKER ARM ASSEMBLY COMPONENT LOCATOR EN01F02127090402014001 SHTS021270900009 Crosshead Spacer Rocker arm (intake) Adjust screw Rocker arm shaft Rocker arm (exhaust) Rocker support Tightening torque Unit: Nm {kgfcm, lbfft} 25 {255, 18} 36 {367, 27}...
Page 283: Overhaul
ENGINE MECHANICAL (J05E) 10–7 OVERHAUL EN01F02127090402014002 REMOVING THE ROCKER ARM ASSEMBLY REMOVING THE HEAD COVER Reference: ENGINE MECHANICAL (J05E), HEAD COVER, REPLACEMENT, REMOVING THE HEAD COVER (Page 10-3) REMOVING THE INJECTOR HARNESS Reference: FUEL SYSTEM (J05E), INJECTOR, REPLACE- MENT, REMOVING THE INJECTOR (Page 7-37) REMOVING THE ROCKER ARM ASSEMBLY Loosen the lock nut to wind up the adjust screw completely.
Page 284 10–8 ENGINE MECHANICAL (J05E) DISASSEMBLING THE ROCKER ARM ASSEMBLY REMOVING THE ROCKER ARM Remove the rocker support, rocker arm (exhaust), spacer and ROCKER SUPPORT rocker arm (intake) in the sequential order from the rocker arm ROCKER ARM shaft. (EXHAUST) SPACER ROCKER ARM (INTAKE) ROCKER ARM SHAFT...
Page 285 ENGINE MECHANICAL (J05E) 10–9 ASSEMBLING THE ROCKER ARM ASSEMBLY MOUNTING THE ROCKER ARM Apply engine oil to the rocker arm shaft and the inner surfaces of ROCKER SUPPORT the rocker support, rocker arm (exhaust), spacer and rocker arm ROCKER ARM (intake).
Page 286 10–10 ENGINE MECHANICAL (J05E) Check that the adjust screw of the rocker arm is wound up. ! CAUTION Failure to wind up the adjust screw may cause the shaft to bend ADJUST when tightening the rocker support bolt. SCREW LOCK NUT SHTS021270900018 NOTICE To facilitate this work step, use a piece of flexible wire of approxi-...
Page 287 ENGINE MECHANICAL (J05E) 10–11 Check the crossheads for dislodgement or off-position. CROSSHEADS SHTS021270900021 Adjust the valve clearance. Reference: ENGINE MECHANICAL (J05E), ROCKER ARM ASSEMBLY, OVERHAUL, ADJUSTING THE VALVE CLEAR- ANCE (Page 10-12) MOUNTING THE INJECTOR HARNESS Reference: FUEL SYSTEM (J05E), INJECTOR, REPLACE- MENT, MOUNTING THE INJECTOR (Page 7-41) MOUNTING THE HEAD COVER Reference: ENGINE MECHANICAL (J05E), HEAD COVER,...
Page 288 10–12 ENGINE MECHANICAL (J05E) ADJUSTING THE VALVE CLEARANCE CAUTIONS ! CAUTION • Before adjustment, make sure that the tightening bolts of the rocker arm support, nozzle clamp, cylinder head, and cam- shaft bearing cap are tightened with the specified torque. •...
Page 289 ENGINE MECHANICAL (J05E) 10–13 Insert the thickness gauge in between the rocker arm and the crosshead and turn the rocker arm adjust screw to adjust a clear- ance before tightening the lock nut. Tightening Torque: 25 N·m {255 kgf·cm, 18 lbf·ft} NOTICE It is deemed appropriate if the thickness gauge goes in with some unsmoothness during insertion and then moves smoothly with...
Page 290: Camshaft Assembly
10–14 ENGINE MECHANICAL (J05E) CAMSHAFT ASSEMBLY COMPONENT LOCATOR EN01F02127090402015001 SHTS021270900027 Cylinder head Camshaft bearings...
Page 291 ENGINE MECHANICAL (J05E) 10–15 SHTS021270900028 Camshaft drive gear Camshaft Tightening torque Unit: Nm {kgfcm, lbfft} 59 {602, 44}...
Page 292: Overhaul
10–16 ENGINE MECHANICAL (J05E) OVERHAUL EN01F02127090402015002 REMOVING THE CAMSHAFT ASSEMBLY REMOVING THE HEAD COVER Reference: ENGINE MECHANICAL (J05E), HEAD COVER, REPLACEMENT, REMOVING THE HEAD COVER (Page 10-3) REMOVING THE INJECTOR HARNESS Reference: FUEL SYSTEM (J05E), INJECTOR, REPLACE- MENT, REMOVING THE INJECTOR (Page 7-37) REMOVING THE ROCKER ARM ASSEMBLY Loosen the lock nut and wind up the adjust screw completely to remove the rocker arm assembly.
Page 293 ENGINE MECHANICAL (J05E) 10–17 DISASSEMBLING THE CAMSHAFT ASSEMBLY REMOVING THE CAMSHAFT DRIVE GEAR Use the vise to fix the camshaft drive gear. CAMSHAFT ! CAUTION CAMSHAFT GEAR Be careful that the gear is free from deformation, dent or damage during work. Unbolt and remove the camshaft drive gear from the camshaft.
Page 294 10–18 ENGINE MECHANICAL (J05E) Set the camshaft bearing cap with the camshaft bearing to the cylinder head and tighten them with the specified torque. Use the cylinder gauge to measure the inner diameter of the cam- shaft bearing. Permissible limit Standard value (mm {in.}) (mm {in.}) 40 {1.575}...
Page 295 ENGINE MECHANICAL (J05E) 10–19 ASSEMBLING THE CAMSHAFT ASSEMBLY MOUNTING THE CAMSHAFT DRIVE GEAR Use the vise to fix the camshaft drive gear. Apply engine oil to the CAMSHAFT seat surface and bolt of the camshaft drive gear mounting bolt. ! CAUTION CAMSHAFT GEAR Be careful that the gear is free from deformation, dent or damage during work.
Page 296 10–20 ENGINE MECHANICAL (J05E) Mount the camshaft bearing by aligning with the cylinder head concave and apply engine oil. CAMSHAFT BEARING DENT PART SHTS021270900039 MOUNTING THE CAMSHAFT Place the camshaft assembly in a way that the 2 drill holes posi- TIMING JUDGING tioned at 180...
Page 297: Cylinder Head Assembly
ENGINE MECHANICAL (J05E) 10–21 CYLINDER HEAD ASSEMBLY COMPONENT LOCATOR EN01F02127090402016001 SHTS021270900042 Cylinder head Gasket * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 59 {602, 44}...
Page 298: Replacement
10–22 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402016002 REMOVING PERIPHERAL PARTS AROUND THE CYLINDER HEAD ASSEMBLY REMOVING THE CLOSED VENTILATOR HOSE Reference: EMISSION CONTROL (J05E), CLOSED VENTILA- TOR, REPLACEMENT, REMOVING THE CLOSED VENTILA- TOR (Page 8-14) DISCONNECTING THE HARNESS REMOVING THE INTAKE PIPE (EXHAUST SIDE) Reference: INTAKE (J05E), INTAKE PIPE (EXHAUST SIDE), REPLACEMENT, REMOVING THE INTAKE PIPE (EXHAUST SIDE) (Page 9-12)
Page 299 ENGINE MECHANICAL (J05E) 10–23 11. REMOVING THE COMMON RAIL Reference: FUEL SYSTEM (J05E), COMMON RAIL, REPLACEMENT, REMOVING THE COMMON RAIL (Page 7-48) 12. REMOVING THE GLOW PLUG Reference: ENGINE MECHANICAL (J05E), GLOW PLUG, REPLACEMENT, REMOVING THE GLOW PLUG (Page 10-129) 13.
Page 300 10–24 ENGINE MECHANICAL (J05E) Loosen the head bolts gradually from outside to inside in order as shown in the figure (rotate to a 1/4 turn at a time) to remove them. SHTS021270900044 Mount the SST to the cylinder head. SST: S0943-31070 Eye bolt ! CAUTION...
Page 301 ENGINE MECHANICAL (J05E) 10–25 MOUNTING THE CYLINDER HEAD ASSEMBLY MOUNTING THE HEAD GASKET Use the scraper to cut off an excessive protruding portion of the CUT OFF HERE WITH CYLINDER gasket for the rear end plate so that the gasket will be flush with SCRAPER BLOCK the upper surface of the cylinder block.
Page 302 10–26 ENGINE MECHANICAL (J05E) Set the new head gasket to the dowel pin and place the gasket on the upper surface of cylinder block. GASKET DOWEL PIN SHTS021270900049 ! CAUTION • Never reuse the gasket, or the engine will be broken. •...
Page 303 ENGINE MECHANICAL (J05E) 10–27 MOUNTING THE CYLINDER HEAD ASSEMBLY Clean the head bolt seat surface on the upper surface of the cylin- der head and the bottom surface of cylinder head. After mounting the SST, use the hoist to lift the cylinder head assembly.
Page 304 10–28 ENGINE MECHANICAL (J05E) Tighten the 18 head bolts (M12 only) by 90° (1/4 turns) in the rota- tional direction in the same order as in Step (5), and check that all 180 ° paint marks face to the same direction. FIRST TIME SECOND TIME 135 °...
Page 305 ENGINE MECHANICAL (J05E) 10–29 MOUNTING PERIPHERAL PARTS AROUND THE CYLINDER HEAD ASSEMBLY MOUNTING THE INTAKE MANIFOLD Reference: INTAKE (J05E), INTAKE MANIFOLD, REPLACE- MENT, MOUNTING THE INTAKE MANIFOLD (Page 9-6) MOUNTING THE GLOW PLUG Reference: ENGINE MECHANICAL (J05E), GLOW PLUG, REPLACEMENT, MOUNTING THE GLOW PLUGS (Page 10- 130) MOUNTING THE COMMON RAIL Reference:...
Page 306: Overhaul
10–30 ENGINE MECHANICAL (J05E) OVERHAUL EN01F02127090402016003 DISASSEMBLING CYLINDER HEAD ASSEMBLY AND CAMSHAFT HOUSING REMOVING THE INJECTOR HARNESS CONNECTOR Unfasten the 2 bolts to remove the injector harness connector from the cylinder head. INJECTOR HARNESS CONNECTOR SHTS021270900058 Remove the O-ring from the injector harness connector. O-RING SHTS021270900059 CLEANING THE CYLINDER HEAD...
Page 307 ENGINE MECHANICAL (J05E) 10–31 REMOVING THE CROSSHEAD Remove the crossheads from individual valves. NOTICE CROSSHEADS For storage, sort by cylinder number and by intake and exhaust. SHTS021270900062 REMOVING THE VALVE AND VALVE SPRING Reference: ENGINE MECHANICAL (J05E), VALVE SYSTEM, OVERHAUL, DISASSEMBLING THE VALVE SYSTEM (Page 10-37) REMOVING THE VALVE STEM SEAL Reference: ENGINE MECHANICAL (J05E), VALVE SYSTEM,...
Page 308 10–32 ENGINE MECHANICAL (J05E) INSPECTING THE COMPONENTS INSPECTING THE CYLINDER HEAD Use the straightedge and a thickness gauge to measure strains in the lower surface of the cylinder head and in the manifold mount- STRAIGHTEDGE ing surface. Replace if a measurement reading exceeds the per- missible limit.
Page 309 ENGINE MECHANICAL (J05E) 10–33 ASSEMBLING THE CYLINDER HEAD ASSEMBLY MOUNTING THE NOZZLE SEATS After inserting the new O-ring into a nozzle seat insertion hole in CYLINDER HEAD the cylinder head, apply liquid gasket (ThreeBond TB1211 or equivalent: White) to the bottom of a new nozzle seat before O-RING installing it to the cylinder head.
Page 310 10–34 ENGINE MECHANICAL (J05E) MOUNTING THE CROSSHEAD Apply engine oil to crosshead guide pins and install the cross- heads. CROSSHEAD Check that crossheads are properly seated on (or over) individual valves and apply engine oil to the heads of the crossheads. CROSSHEAD GUIDE PIN SHTS021270900068...
Page 311 ENGINE MECHANICAL (J05E) 10–35 MOUNTING THE INJECTOR HARNESS CONNECTOR Replace with the new O-ring and fit it to the injector harness con- O-RING nector. SHTS021270900071 Mount the injector harness connector to the cylinder head with 2 bolts. INJECTOR HARNESS CONNECTOR SHTS021270900072...
Page 312: Valve System
10–36 ENGINE MECHANICAL (J05E) VALVE SYSTEM COMPONENT LOCATOR EN01F02127090402009001 SHTS021270900073 Crosshead Valve spring retainer Intake valve Exhaust valve Spring Valve stem seal Spring seat (lower) Spring seat (upper)
Page 313: Overhaul
ENGINE MECHANICAL (J05E) 10–37 OVERHAUL EN01F02127090402009002 DISASSEMBLING THE VALVE SYSTEM REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23) PREPARATION Set the wooden board on the workbench and place the cylinder head assembly on it.
Page 314 10–38 ENGINE MECHANICAL (J05E) Face the cylinder head assembly sideways and remove the intake and exhaust valve. NOTICE There is an engraving of I (intake) or E (exhaust) at the center of the valve bottom. VALVE SHTS021270900076 ! CAUTION • The cylinder head assembly can be faced sideways by using manpower.
Page 315 ENGINE MECHANICAL (J05E) 10–39 REMOVING THE VALVE GUIDE Use the dolly block or press to pull off the valve guide. USE A PRESS TO PULL OFF THE VALVE GUIDE. DOLLY BLOCK VALVE GUIDE SHTS021270900080 REMOVING THE VALVE SEAT ! CAUTION DOLLY BLOCK Replace the valve seat in the following procedure may damage the...
Page 316 10–40 ENGINE MECHANICAL (J05E) INSPECTING THE COMPONENTS INSPECTING THE VALVE AND VALVE SEAT Use the straightedge and thickness gauge to measure the valve sink. If a measurement reading exceeds the permissible limit, replace the valve and valve seat. AMOUNT OF VALVE SINKING Standard value Permissible limit...
Page 317 ENGINE MECHANICAL (J05E) 10–41 Use the spring tester to measure the set load of the valve spring. If a measured load exceeds the permissible limit, replace the valve spring. Standard Permissi- Measured item value ble limit Set length – 44.8 {1.764} (mm {in.}) Inner spring Set load...
Page 318 10–42 ENGINE MECHANICAL (J05E) Use the cylinder gauge to measure the inner diameter of the valve guide. Standard value Measured item (mm {in.}) Intake valve guide 7 {0.276} Exhaust valve guide 7 {0.276} Calculate the difference between the outer diameter of the valve stem and the inner diameter of the valve guide.
Page 319 ENGINE MECHANICAL (J05E) 10–43 Apply the small amount of lapping compound on the contact sur- face of the valve and valve seat. Use the SST to tap and lap the valve while rotating it. SST: S0943-11020 Valve lapping tool SHTS021270900092 MOUNTING THE VALVE GUIDE Apply engine oil to the periphery of the valve guide.
Page 320 10–44 ENGINE MECHANICAL (J05E) After tapping in the valve stem seal, check the height from the spring seat (lower) to the spring of the valve stem seal. SPRING PART OF VALVE STEM SEAL Standard value (mm {in.}) 22.5-23.0 {0.886-0.906} SPRING SEAT (LOWER) SHTS021270900095 MOUNTING THE VALVE AND VALVE SPRING...
Page 321 ENGINE MECHANICAL (J05E) 10–45 Use the SST to compress the valve spring to fit in the valve spring retainer. VALVE SPRING SST: S0947-01170 RETAINER Valve spring press ! CAUTION • If eye bolts are used, fasten them via washers and use care not to cause a potential risk of damaging the upper surface of the cylinder head.
Page 322: Crankshaft Pulley
10–46 ENGINE MECHANICAL (J05E) CRANKSHAFT PULLEY COMPONENT LOCATOR EN01F02127090402048001 SHTS021270900102 Crankshaft pulley Tightening torque Unit: Nm {kgfcm, lbfft} 118 {1,203, 87}...
Page 323: Replacement
ENGINE MECHANICAL (J05E) 10–47 REPLACEMENT EN01F02127090402048002 REMOVING THE CRANKSHAFT PULLEY REMOVING THE COOLING FAN ASSEMBLY AND FAN SHROUD RING Reference: COOLING (J05E), COOLING FAN AND FAN CLUTCH, OVERHAUL, REMOVING THE COOLING FAN & FAN CLUTCH (Page 12-34) REMOVING THE V-BELT Reference: STARTING/CHARGING (J05E),...
Page 324 10–48 ENGINE MECHANICAL (J05E) MOUNTING THE CRANKSHAFT PULLEY MOUNTING THE CRANKSHAFT PULLEY Tighten the crankshaft pulley mounting bolts in the order as shown in the figure. Tightening Torque: 118 N·m {1,203 kgf·cm, 87 lbf·ft} NOTICE To prevent the co-rotation of the crankshaft, insert a large flat- blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft.
Page 325: Crankshaft Front Oil Seal
ENGINE MECHANICAL (J05E) 10–49 CRANKSHAFT FRONT OIL SEAL COMPONENT LOCATOR EN01F02127090402018001 SHTS021270900105 Cylinder block Crankshaft front oil seal...
Page 326: Replacement
10–50 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402018002 REMOVING THE CRANKSHAFT FRONT OIL SEAL REMOVING THE CRANKSHAFT PULLEY Reference: ENGINE MECHANICAL (J05E), CRANKSHAFT PULLEY, REPLACEMENT, REMOVING THE CRANKSHAFT PULLEY (Page 10-47) REMOVING THE CRANKSHAFT FRONT OIL SEAL Mount the SST plate to the crankshaft with 2 crankshaft pulley mounting bolts.
Page 327 ENGINE MECHANICAL (J05E) 10–51 Fit and gradually tighten the SST center bolt to pull off the crank- shaft front oil seal. ! CAUTION • Inspect the engagement of the SST and oil seal half way through the work and pull off the seal without removing the SST.
Page 328 10–52 ENGINE MECHANICAL (J05E) Remove the dirt from the joint surfaces of the crankshaft front oil seal and cylinder block. OIL SEAL After inserting the new crankshaft front oil seal into the oil seal guide, fasten SST guide bolts to secure the oil seal guide on the crankshaft.
Page 329: Front Oil Seal Retainer
ENGINE MECHANICAL (J05E) 10–53 FRONT OIL SEAL RETAINER COMPONENT LOCATOR EN01F02127090402025001 SHTS021270900115 Front oil seal retainer Cylinder block Tightening torque Unit: Nm {kgfcm, lbfft} 30 {306, 22}...
Page 330: Replacement
10–54 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402025002 REMOVING THE FRONT OIL SEAL RETAINER REMOVING THE OIL PAN Reference: LUBRICATION (J05E), OIL PAN, REPLACEMENT, REMOVING THE OIL PAN (Page 13-24) REMOVING THE CRANKSHAFT PULLEY Reference: ENGINE MECHANICAL (J05E), CRANKSHAFT PULLEY, REPLACEMENT, REMOVING THE CRANKSHAFT PULLEY (Page 10-47) REMOVING THE CRANKSHAFT FRONT OIL SEAL Reference: ENGINE MECHANICAL (J05E), CRANKSHAFT...
Page 331 ENGINE MECHANICAL (J05E) 10–55 MOUNTING THE FRONT OIL SEAL RETAINER MOUNTING THE FRONT OIL SEAL RETAINER Remove oil and dirt from the joint surface of the front oil seal retainer. APPLY LIQUID GASKET TO Apply liquid gasket (ThreeBond TB1207B: Black or equivalent or THE GROOVE.
Page 332: Flywheel Assembly
10–56 ENGINE MECHANICAL (J05E) FLYWHEEL ASSEMBLY COMPONENT LOCATOR EN01F02127090402020001 SHTS021270900119 Crankshaft Flywheel Ring gear Tightening torque Unit: Nm {kgfcm, lbfft} 186 {1,897, 137}...
Page 333: Overhaul
ENGINE MECHANICAL (J05E) 10–57 OVERHAUL EN01F02127090402020002 REMOVING THE FLYWHEEL ASSEMBLY REMOVING THE ENGINE MAIN REVOLUTION SENSOR Reference: ENGINE CONTROL (J05E), ENGINE SPEED MAIN SENSOR, REPLACEMENT, REMOVING THE ENGINE SPEED MAIN SENSOR (Page 6-12) REMOVING THE FLYWHEEL ASSEMBLY Remove the two horizontal flywheel mounting bolts first and then fasten SST to prevent drop-off.
Page 334 10–58 ENGINE MECHANICAL (J05E) DISASSEMBLING FLYWHEEL ASSEMBLY REMOVING THE RING GEAR Use the burner to heat the periphery of a ring gear to approxi- mately 20C {68F}. ! CAUTION Do not touch with bare hands while the ring gear and flywheel are hot.
Page 335 ENGINE MECHANICAL (J05E) 10–59 MOUNTING THE FLYWHEEL ASSEMBLY MOUNTING THE FLYWHEEL ASSEMBLY Check that there are no burrs or dirt on the joint surface between the crankshaft and flywheel and the screw holes. Mount the 2 SST horizontally to the crankshaft. SST: S0948-11340 Guide...
Page 336 10–60 ENGINE MECHANICAL (J05E) Tighten the flywheel assembly mounting bolts with the specified tightening torque in the sequential order as shown in the figure. Tightening Torque: 186 N·m {1,897 kgf·cm, 137 lbf·ft} NOTICE To prevent the co-rotation of the crankshaft, insert a large flat- blade screwdriver into the flywheel gear from the inspection hole of the flywheel housing and stop the rotation of the crankshaft.
Page 337: Crankshaft Rear Oil Seal
ENGINE MECHANICAL (J05E) 10–61 CRANKSHAFT REAR OIL SEAL COMPONENT LOCATOR EN01F02127090402021001 SHTS021270900130 Crankshaft rear oil seal * *: Nonreusable part...
Page 338: Replacement
10–62 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402021002 REMOVING CRANKSHAFT REAR OIL SEAL REMOVING THE FLYWHEEL ASSEMBLY Reference: ENGINE MECHANICAL (J05E), FLYWHEEL ASSEMBLY, OVERHAUL, REMOVING FLYWHEEL ASSEMBLY (Page 10-57) REMOVING CRANKSHAFT REAR OIL SEAL Fasten the flywheel assembly mounting bolts (2 pcs.) to secure PLATE the SST plate on the crankshaft.
Page 339 ENGINE MECHANICAL (J05E) 10–63 Fit and gradually tighten the SST center bolt to pull off the crank- shaft rear oil seal. ! CAUTION • Inspect the engagement of the SST and oil seal half way through the work and pull off the seal without removing the SST.
Page 340 10–64 ENGINE MECHANICAL (J05E) After inserting the new crankshaft rear oil seal into the oil seal guide, fasten SST guide bolts to secure the oil seal guide on the OIL SEAL crankshaft. ! CAUTION • Align the large hole of the oil seal guide with the collar knock of the crankshaft.
Page 341: Flywheel Housing
ENGINE MECHANICAL (J05E) 10–65 FLYWHEEL HOUSING COMPONENT LOCATOR EN01F02127090402022001 SHTS021270900140 Rear end plate Flywheel housing Housing stay Tightening torque Unit: Nm {kgfcm, lbfft} 55 {561, 41} 196 {1,999, 145} 28 {291, 21} 171.5 {1,749, 126} 97 {989, 72}...
Page 342: Replacement
10–66 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402022002 REMOVING THE FLYWHEEL HOUSING REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23) REMOVING THE STARTER Reference: STARTING/CHARGING (J05E), STARTER, REPLACEMENT, REMOVING THE STARTER (Page 16-3) REMOVING THE POWER STEERING PUMP Reference: CHASSIS (S1-LXJE03A), STEERING Reference: CHASSIS (S1-LXJE04A), STEERING...
Page 343 ENGINE MECHANICAL (J05E) 10–67 Unfasten the bolts and nuts to remove the flywheel housing. NOTICE • If there is no dedicated engine bench, the engine cannot be supported. In this case, turn over the engine and place the cylinder block joint surface on the wooden workbench during work.
Page 344 10–68 ENGINE MECHANICAL (J05E) MOUNTING THE FLYWHEEL HOUSING MOUNTING THE FLYWHEEL HOUSING Fasten the damping stud onto the flywheel housing. Tightening Torque: 55 N·m {561 kgf·cm, 41 lbf·ft} VIBRATION CONTROL STUD SHTS021270900144 Use the scraper to remove dirt and fouling from the joint surfaces of the flywheel housing and rear end plate.
Page 345 ENGINE MECHANICAL (J05E) 10–69 Pre tightening bolts for tight fitting to the flywheel housing and cyl- inder block and tighten them with the specified tightening torques. Tightening Torque: 97 N·m {989 kgf·cm, 72 lbf·ft} 171.5 N·m {1,749 kgf·cm, 126 lbf·ft} HOUSING STAY SHTS021270900147 MOUNTING THE CRANKSHAFT REAR OIL SEAL...
Page 346: Timing Gear & Cam Idle Gear
10–70 ENGINE MECHANICAL (J05E) TIMING GEAR & CAM IDLE GEAR COMPONENT LOCATOR EN01F02127090402024001 SHTS021270900148 Sub idle gear Thrust plate Thrust plate Sub idle gear shaft Main idle gear shaft Injection pump idle gear Main idle gear Injection pump idle gear shaft Tightening torque Unit: Nm {kgfcm, lbfft} 108 {1,101, 80}...
Page 347: Configuration Diagram
ENGINE MECHANICAL (J05E) 10–71 CONFIGURATION DIAGRAM EN01F02127090402024002 INJECTION PUMP DRIVE IDLE GEAR PUMP PUMP SUPPLY PUMP DRIVE GEAR MARK MARK MARK SHTS021270900149 OVERHAUL EN01F02127090402024003 REMOVING THE CAMSHAFT DRIVE GEAR AND CAM IDLE GEAR REMOVING THE CAMSHAFT ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CAMSHAFT ASSEMBLY,...
Page 348 10–72 ENGINE MECHANICAL (J05E) REMOVING THE TIMING GEARS AND THE REAR END PLATE FROM FLYWHEEL HOUSING REMOVING THE FLYWHEEL HOUSING Reference: ENGINE MECHANICAL (J05E), FLYWHEEL HOUSING, REPLACEMENT, REMOVING THE FLYWHEEL HOUSING (Page 10-66) REMOVING THE MAIN IDLE GEAR Unfasten the bolt of the main idle gear shaft. Use the SST to pull off the main idle gear shaft and remove the main idle gear shaft, a main idle gear and a thrust plate.
Page 349 ENGINE MECHANICAL (J05E) 10–73 REMOVING SUB IDLE GEAR Unfasten the bolt of the sub idle gear shaft. SUB IDLE GEAR Use the SST to pull off the sub idle gear shaft and remove the sub SUB IDLE idle gear shaft, sub idle gear, and thrust plate. GEAR SHAFT SST: S0942-01100...
Page 350 10–74 ENGINE MECHANICAL (J05E) Use the cylinder gauge to measure the inner diameter of the idle gear bushing. Standard value Measured item (mm {in.}) Shaft outer 57 {2.244} diameter Main idle gear Bushing inner 57 {2.244} diameter Shaft outer SHTS021270900155 50 {1.969} diameter Sub idle gear...
Page 351 ENGINE MECHANICAL (J05E) 10–75 Use the scraper to cut off excessive upper and lower protruding portions of the gasket so that the gasket will be flush with the GASKET upper and lower surfaces of the cylinder block. CYLINDER REAR END PLATE BLOCK FLY WHEEI HOUSING...
Page 352 10–76 ENGINE MECHANICAL (J05E) MOUNTING THE MAIN IDLE GEAR Mount the main idle gear shaft to the main idle gear. Mount the thrust plate. MAIN IDLE GEAR MAIN IDLE GEAR SHAFT THRUST PLATE BOLT SHTS021270900161 After applying engine oil to the seating surface and threads of the idle gear shaft mounting bolt, orient an oil hole in the idle gear MAIN IDLE GEAR THRUST...
Page 353 ENGINE MECHANICAL (J05E) 10–77 Fasten the main idle gear shaft mounting bolt to secure the main idle gear on the cylinder block. MAIN IDLE GEAR Tightening Torque: SHAFT MOUNTING BOLT 172 N·m {1,754 kgf·cm, 127 lbf·ft} INSPECTING EACH IDLE GEAR Use the thickness gauge to measure the thrust play of each idle gear and use dial gauge to measure the backlash of each idle gear.
Page 354 10–78 ENGINE MECHANICAL (J05E) OVERHAULING INJECTION PUMP DRIVE IDLE GEAR REMOVING BEARING CASE ASSEMBLY Unfasten the 4 bolts to remove the bearing case assembly from the flywheel housing. ! CAUTION Note that one of the bolts is tightened from the flywheel housing side.
Page 355 ENGINE MECHANICAL (J05E) 10–79 Use the cylinder gauge to measure the injection pump drive idle gear shaft inner diameter. Standard value (mm {in.}) 34 {1.339} BUSH Calculate the gap between the outer diameter of the injection pump drive idle gear shaft and the inner diameter of the injection pump drive idle gear bush.
Page 356 10–80 ENGINE MECHANICAL (J05E) Fasten the 4 bolts to secure the bearing case assembly on the fly- wheel housing. Tightening Torque: 28.5 N·m {291 kgf·cm, 21 lbf·ft} ! CAUTION Note that one of the bolts is tightened from the flywheel housing side.
Page 357 ENGINE MECHANICAL (J05E) 10–81 INSPECTING BACKLASH BETWEEN MAIN IDLE GEAR AND INJECTION PUMP DRIVE IDLE GEAR To prevent rotation of the main idle gear, insert a large flat-blade screwdriver into the main idle gear through the dust cover port on the timing gear side in the flywheel housing.
Page 358 10–82 ENGINE MECHANICAL (J05E) INSPECTING BACKLASH BETWEEN SUB IDLE GEAR AND OIL PUMP DRIVE GEAR To prevent rotation of the sub idle gear, insert a large flat-blade screwdriver into the sub idle gear. SHTS021270900182 Use the dial gauge to measure backlash between the sub idle gear and the oil pump drive gear.
Page 359 ENGINE MECHANICAL (J05E) 10–83 INSPECTING BACKLASH BETWEEN CAM IDLE GEAR AND SUB IDLE GEAR To prevent rotation of the sub idle gear, insert a large flat-blade screwdriver into the sub idle gear through a gap around the cylin- der head cam idle gear. SHTS021270900185 Use the dial gauge to measure backlash between the cam idle gear and the sub idle gear.
Page 360: Piston And Connecting Rod
10–84 ENGINE MECHANICAL (J05E) PISTON AND CONNECTING ROD COMPONENT LOCATOR EN01F02127090402027001 SHTS021270900187 Connecting rod bearing Piston ring Piston pin Retainer ring * Piston Connecting rod cap Connecting rod cap *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 69 {704, 51}+90+45...
Page 361: Overhaul
ENGINE MECHANICAL (J05E) 10–85 OVERHAUL EN01F02127090402027002 REMOVING THE PISTON AND CONNECTING ROD REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23) REMOVING THE OIL PAN Reference: LUBRICATION (J05E), OIL PAN, REPLACEMENT, REMOVING THE OIL PAN (Page 13-24) REMOVING THE OIL STRAINER Reference: LUBRICATION (J05E), OIL STRAINER, REPLACE-...
Page 362 10–86 ENGINE MECHANICAL (J05E) Use the plastic hammer to tap the bolt head of the connecting rod cap to separate the connecting rod from the cap. ! CAUTION Use care not to damage bolt heads. NOTICE The connecting rod cap is connected with the dowel pin. However, the rod and the cap can be separated easily by hammering the bolt head.
Page 363 ENGINE MECHANICAL (J05E) 10–87 DISASSEMBLING THE PISTON AND CONNECTING REMOVING THE PISTON AND CONNECTING ROD Use the pliers to remove the retainer ring. ! CAUTION While working, wear safety glasses because the retainer ring may come out. RETAINER RING SHTS021270900195 Put alignment marks on the back and side of the piston before pulling it out and separate the piston from the connecting rod.
Page 364 10–88 ENGINE MECHANICAL (J05E) REMOVING THE CONNECTING ROD BEARING Remove the connecting rod bearing connected to the connecting rod cap. CONNECTING NOTICE ROD CAP Press the one end of the connecting rod bearing at the opposite side of the concave to facilitate removal. CONNECTING ROD BEARING CONCAVE PORTION...
Page 365 ENGINE MECHANICAL (J05E) 10–89 Mount the SST (spindle) to a connecting rod bush. SST: S0940-21540 SPINDLE Spindle GROOVE ! CAUTION Align the groove in the SST press subassembly with a groove in CONNECTING ROD the SST spindle before mounting. PRESS SUB ASSY SHTS021270900203 Use the press to pull off the connecting rod bush.
Page 366 10–90 ENGINE MECHANICAL (J05E) INSPECTING THE COMPONENTS INSPECTING THE PISTON CLEARANCE Use the cylinder gauge to measure the inner diameter of the slid- ing surface of cylinder liner. Permissible limit Standard value (mm {in.}) (mm {in.}) 112 {4.409} 112.15 {4.415} SHTS021270900206 Use the micrometer to measure the outer diameter of the piston.
Page 367 ENGINE MECHANICAL (J05E) 10–91 INSPECTING THE PISTON RING CLOSED GAP CLEARANCE Use the piston to insert the piston ring horizontally to the cylinder liner until it passes through the sliding surface. CYLINDER LINER Use the thickness gauge to measure the closed gap clearance of the piston ring.
Page 368 10–92 ENGINE MECHANICAL (J05E) INSPECTING THE PISTON PIN AND CONNECTING ROD BUSH TAKE MEASUREMENT Use the micrometer to measure the outer diameter of the piston IN THE CENTER pin center. If a measurement reading exceeds the permissible limit, replace the piston pin. Permissible limit Standard value (mm {in.}) (mm {in.})
Page 369 ENGINE MECHANICAL (J05E) 10–93 INSPECTING THE CONNECTING ROD OIL CLEARANCE Use the micrometer to measure an outer diameter of a crank pin on the crankshaft. If a measurement reading exceeds the permis- sible limit, grind or replace the crankshaft. 90 MEASURE IN TWO PLACES Permissible limit Standard value (mm {in.})
Page 370 10–94 ENGINE MECHANICAL (J05E) INSPECTING THE LENGTH OF CONNECTING ROD BOLT Use the vernier calipers to measure the connecting rod bolt under head. If a measurement reading exceeds the permissible limit, replace the head bolt. SHANK LENGTH Permissible limit Standard value (mm {in.}) (mm {in.}) 67.0 {2.638} 68.0 {2.677}...
Page 371 ENGINE MECHANICAL (J05E) 10–95 ASSEMBLING THE PISTON AND CONNECTING ROD MOUNTING THE CONNECTING ROD BUSH Fit the new bush to the SST spindle and mount the SST (guide and bolt). SPINDLE SST: S0940-21540 Spindle GROOVE S0948-11540 BUSH Guide SH691-20825 Bolt GUIDE Tightening Torque: BOLT...
Page 372 10–96 ENGINE MECHANICAL (J05E) Mount the connecting rod bearing by aligning with the connecting rod gap concave and apply engine oil. CONNECTING ROD CONNECTING ROD BEARING CONCAVE PART SHTS021270900225 MOUNTING THE PISTON AND CONNECTING ROD Use the pliers to mount a new retainer ring to only one side of the piston.
Page 373 ENGINE MECHANICAL (J05E) 10–97 Use the pliers to mount a new retainer ring to the other side of the piston. ! CAUTION • While working, wear safety glasses because the retainer ring may come out. • Make sure that the retainer ring is correctly put in the groove. RETAINER RING •...
Page 374 10–98 ENGINE MECHANICAL (J05E) MOUNTING THE PISTON AND CONNECTING ROD MOUNTING THE PISTON AND CONNECTING ROD The crankshaft of the cylinder to which the piston & connecting rod are inserted must be at the top dead center. ! CAUTION If the crankshaft is not at the top dead center, the connecting rod touches the cooling jet.
Page 375 ENGINE MECHANICAL (J05E) 10–99 Apply engine oil to the threaded part and seat surface of the bolts. Align with identification with the connecting rod cap and connect- CONNECTING ROD ing rod removed before tightening the bolts temporarily. ! CAUTION Do not change the combination of the connecting rod and con- necting rod cap.
Page 376 10–100 ENGINE MECHANICAL (J05E) (13) After mounting, use the dial gauge to check that end play meets the standard value. Permissible limit Standard value (mm {in.}) (mm {in.}) 0.20-0.52 {0.0079-0.0205} 1.0 {0.0394} SHTS021270900239 MOUNTING THE OIL STRAINER Reference: LUBRICATION (J05E), OIL STRAINER, REPLACE- MENT, MOUNTING THE OIL STRAINER (Page 13-29) MOUNTING THE OIL PAN Reference: LUBRICATION (J05E), OIL PAN, REPLACEMENT,...
Page 377: Crankshaft
ENGINE MECHANICAL (J05E) 10–101 CRANKSHAFT COMPONENT LOCATOR EN01F02127090402028001 SHTS021270900240 Crankshaft...
Page 378 10–102 ENGINE MECHANICAL (J05E) SHTS021270900241 Thrust bearing Crankshaft bearing...
Page 379: Replacement
ENGINE MECHANICAL (J05E) 10–103 REPLACEMENT EN01F02127090402028002 REMOVING THE CRANKSHAFT REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23) REMOVING THE PISTON AND CONNECTING ROD Reference: ENGINE MECHANICAL (J05E), PISTON AND CON- NECTING ROD, OVERHAUL, DISASSEMBLING THE PISTON AND CONNECTING ROD (Page 10-87) REMOVING THE FRONT OIL SEAL RETAINER...
Page 380 10–104 ENGINE MECHANICAL (J05E) Remove the main bearing cap and dismount the crankshaft by using the hoist. ! CAUTION • Handle it with care because it is a heavy load. • Note that the crankshaft bearings and thrust bearings mounted to the main bearing caps and cylinder block may fall off due to applied impact.
Page 381 ENGINE MECHANICAL (J05E) 10–105 Remove the crankshaft bearing mounted to the cylinder block. CONCAVE CRANKSHAFT PUSH ! CAUTION PART BEARING The removed crankshaft bearings must be identified and stored in order of cylinder number. NOTICE Press the one end of the crankshaft bearing at the opposite side of the concave with fingers to facilitate removal.
Page 382 10–106 ENGINE MECHANICAL (J05E) INSPECTING WEAR IN JOURNALS Use the micrometer to measure an outer diameter of a crankshaft journal. If a measurement reading exceeds the permissible limit, MEASUREMENT grind or replace the crankshaft. (2 PLACES) Permissible limit Standard value (mm {in.}) (mm {in.}) 80.0 {3.150} 79.3 {3.122}...
Page 383 ENGINE MECHANICAL (J05E) 10–107 INSPECTING THE CRANKSHAFT OIL CLEARANCE Use the micrometer to measure the outer diameter of crankshaft journal. MEASUREMENT (2 PLACES) Standard value (mm {in.}) 80.0 {3.150} SHTS021270900252 Without mounting the crankshaft, mount the crankshaft bearing and main bearing cap to the cylinder block. Use the cylinder gauge to measure the inner diameter of the crankshaft bearing.
Page 384 10–108 ENGINE MECHANICAL (J05E) INSPECTING WEAR IN CRANK PINS Use the micrometer to measure an outer diameter of a crank pin MEASUREMENT on the crankshaft. If a measurement reading exceeds the permis- (2 PLACES) sible limit, grind or replace the crankshaft. Permissible limit Standard value (mm {in.}) (mm {in.})
Page 385 ENGINE MECHANICAL (J05E) 10–109 MOUNTING THE CRANKSHAFT MOUNTING THE CRANKSHAFT BEARING AND THRUST BEARING CONCAVE CRANKSHAFT Mount the crankshaft bearing by aligning with the cylinder block PART BEARING concave and then apply engine oil. OIL HOLE ! CAUTION • Check the oil hole for alignment. •...
Page 386 10–110 ENGINE MECHANICAL (J05E) MOUNTING THE CRANKSHAFT Use the hoist to set the crankshaft to the cylinder block. ! CAUTION Handle it with care because it is a heavy load. SHTS021270900262 Insert the thrust bearing on the cylinder block into the gap between the crankshaft and cylinder block with the groove side (front side) facing to the crank arm side and the part No.
Page 387 ENGINE MECHANICAL (J05E) 10–111 Apply engine oil to bolt seat surfaces and threads of the bearing cap bolts. Tighten the bearing cap bolts in order as shown in the figure. Tightening Torque: 69 N·m {704 kgf·cm, 51 lbf·ft} Loosen the bearing cap mounted with the thrust bearing and use the plastic hammer to tap the crankshaft at its front and back ends.
Page 388: Cylinder Liner
10–112 ENGINE MECHANICAL (J05E) CYLINDER LINER COMPONENT LOCATOR EN01F02127090402029001 SHTS021270900268 Cylinder block assembly Cylinder liner...
Page 389: Replacement
ENGINE MECHANICAL (J05E) 10–113 REPLACEMENT EN01F02127090402029002 REMOVING THE CYLINDER LINER REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23) REMOVING THE PISTON AND CONNECTING ROD Reference: ENGINE MECHANICAL (J05E), PISTON AND CON- NECTING ROD, OVERHAUL, REMOVING THE PISTON AND CONNECTING ROD (Page 10-85) REMOVING THE CYLINDER LINER...
Page 390 10–114 ENGINE MECHANICAL (J05E) INSPECTING THE COMPONENTS INSPECTING THE CYLINDER LINER FOR CRACK AND DAM- Use the dye penetrant testing (red check) to inspect the cylinder liner for crack and damage. If found defective, replace the cylinder liner. ! CAUTION After cleaning the cylinder liners, prevent rusts.
Page 391 ENGINE MECHANICAL (J05E) 10–115 NOTICE • The liner identification mark (A, B or C) is also engraved on EXHAUST SIDE "0" MARK POSITION the upper surface of the cylinder block intake side. "A", "B", "C" MARK POSITION INTAKE SIDE SHTS021270900276 •...
Page 392: Cylinder Block
10–116 ENGINE MECHANICAL (J05E) CYLINDER BLOCK COMPONENT LOCATOR EN01F02127090402030001 SHTS021270900280 Cylinder block assembly Cooling jet Plug A Plug B Dowel pins Tightening torque Unit: Nm {kgfcm, lbfft} 22 {224, 16}...
Page 393: Overhaul
ENGINE MECHANICAL (J05E) 10–117 OVERHAUL EN01F02127090402030002 REMOVING THE CYLINDER BLOCK REMOVING THE COOLING FAN ASSEMBLY AND FAN SHROUD RING Reference: COOLING (J05E), COOLING FAN AND FAN CLUTCH, OVERHAUL, REMOVING THE COOLING FAN & FAN CLUTCH (Page 12-34) REMOVING THE CYLINDER HEAD ASSEMBLY Reference: ENGINE MECHANICAL (J05E), CYLINDER HEAD ASSEMBLY, REPLACEMENT, REMOVING THE CYLINDER HEAD ASSEMBLY (Page 10-23)
Page 394 10–118 ENGINE MECHANICAL (J05E) 13. REMOVING THE POWER STEERING PUMP Reference: CHASSIS (S1-LXJE03A), STEERING Reference: CHASSIS (S1-LXJE04A), STEERING 14. REMOVING THE INJECTION PUMP DRIVE Reference: ENGINE MECHANICAL (J05E), TIMING GEAR & CAM IDLE GEAR, OVERHAUL, REMOVING THE TIMING GEARS AND THE REAR END PLATE FROM FLYWHEEL HOUSING (Page 10-72) 15.
Page 395 ENGINE MECHANICAL (J05E) 10–119 25. REMOVING THE CRANKSHAFT Reference: ENGINE MECHANICAL (J05E), CRANKSHAFT, REPLACEMENT, REMOVING THE CRANKSHAFT (Page 10- 103) 26. REMOVING THE COOLING JET Unfasten the union bolts and remove the cooling jet from the cyl- inder block. COOLING JET SHTS021270900281 INSPECTING THE COMPONENTS INSPECTING THE CYLINDER BLOCK...
Page 396 10–120 ENGINE MECHANICAL (J05E) Use the dye penetrant testing (red check) to inspect the cylinder block for crack and damage. If found defective, replace the cylin- der block. SHTS021270900283 INSPECTING COOLING JET INJECTION POSITION Unfasten the standard union bolt and use the SST to mount the BOLT FOR CHECKING cooling jet to the cylinder block.
Page 397 ENGINE MECHANICAL (J05E) 10–121 Inject oil from the cooling jet nozzle at 196 kPa {2 kgf/cm , 28 lbf/ OIL JET DEVICE (EXAMPLE) PRESSURE NOTICE REGULATOR See the figure for the oil injection device. OIL HOSE AIR TANK (OIL TANK) COMPRESS AIR GAUGE AIR HOSE...
Page 398 10–122 ENGINE MECHANICAL (J05E) MOUNTING THE TIMING GEAR Reference: ENGINE MECHANICAL (J05E), TIMING GEAR & CAM IDLE GEAR, OVERHAUL, MOUNTING THE TIMING GEARS IN THE FLYWHEEL HOUSING AND THE REAR END PLATE (Page 10-74) MOUNTING THE FRONT OIL SEAL RETAINER Reference: ENGINE MECHANICAL (J05E), FRONT OIL SEAL RETAINER, REPLACEMENT, MOUNTING THE FRONT OIL SEAL RETAINER (Page 10-55)
Page 399 ENGINE MECHANICAL (J05E) 10–123 17. MOUNTING THE ENGINE MOUNTING AND BRACKET Reference: ENGINE MECHANICAL (J05E), ENGINE MOUNT- ING AND BRACKET, REPLACEMENT, MOUNTING THE ENGINE MOUNTING AND BRACKET (Page 10-127) 18. MOUNTING THE ENGINE ECU Reference: ENGINE CONTROL (J05E), ENGINE ECU, REPLACEMENT, MOUNTING THE ENGINE ECU (Page 6-7) 19.
Page 400 10–124 ENGINE MECHANICAL (J05E) MOUNTING THE PLUGS TAPPING IN THE DOWEL PIN AND PLUG Tap in 2 dowel pins to the cylinder block upper surface. ! CAUTION Tap in the dowel pin until it hits the bottom. Apply the sealant (Loctite 962T or ThreeBond #1211 or #1215) to the plug As (3 pcs.) and plug Bs (2 pcs.) and tap them into the cyl- inder block with a tapping tool.
Page 401: Engine Mounting And Bracket
ENGINE MECHANICAL (J05E) 10–125 ENGINE MOUNTING AND BRACKET COMPONENT LOCATOR EN01F02127090402031001 SHTS021270900292 Front engine mounting Front engine mounting bracket Rear engine mounting Rear engine mounting bracket Tightening torque Unit: Nm {kgfcm, lbfft} 103 {1,050, 76} 125 {1,275, 92} 64 {653, 47} 98 {999, 72}...
Page 402: Replacement
10–126 ENGINE MECHANICAL (J05E) REPLACEMENT EN01F02127090402031002 INSPECTION BEFORE SERVICING INSPECTING THE ENGINE MOUNTING Check the engine mounting for crack, damage and looseness. If found defective, replace it. REMOVING ENGINE MOUNTING BRACKET LIFTING THE ENGINE ASSEMBLY Before removing the engine mounting, lift up and hold the engine assembly.
Page 403 ENGINE MECHANICAL (J05E) 10–127 MOUNTING ENGINE MOUNTING BRACKET MOUNTING THE ENGINE MOUNTING AND BRACKET Use the bolt and nut, attach the rear engine mounting bracket to REAR ENGINE the flywheel housing. MOUNTING BRACKET Tightening Torque: 103 N·m {1,050 kgf·cm, 76 lbf·ft} REAR ENGINE MOUNTING Mount the rear engine mounting to the rear engine mounting...
Page 404: Glow Plug
10–128 ENGINE MECHANICAL (J05E) GLOW PLUG COMPONENT LOCATOR EN01F02127090402037001 SHTS021270900297 Glow harness Glow plug Connector Tightening torque Unit: Nm {kgfcm, lbfft} 20-25 {204-254, 15-18}...
Page 405: Replacement
ENGINE MECHANICAL (J05E) 10–129 REPLACEMENT EN01F02127090402037002 REMOVING THE GLOW PLUG DISCONNECTING THE HARNESS Disconnect the glow harness connector from a glow plug. GLOW HARNESS SHTS021270900298 REMOVING THE GLOW PLUG Unfasten the nuts (4 pcs.) from glow plugs. GLOW PLUG SHTS021270900299 Unfasten the nuts (4 pcs.) to disconnect the glow plug wire and glow harness from the glow plugs.
Page 406 10–130 ENGINE MECHANICAL (J05E) SINGLE UNIT INSPECTION INSPECTING GLOW PLUGS Use the circuit tester to measure resistance between a body and a terminal. Replace if a failure is found. Standard value 0.55-0.75  (at 20C {68F}) SHTS021270900301 MOUNTING THE GLOW PLUGS MOUNTING THE GLOW PLUGS Mount the glow plugs to the cylinder block.
Page 407 ENGINE MECHANICAL (J05E) 10–131 Mount the caps to the glow plugs. GLOW PLUG SHTS021270900303 CONNECTING THE HARNESS Connect the sub harness connector to the glow plug. GLOW HARNESS SHTS021270900304...
Page 408: Gcu
10–132 ENGINE MECHANICAL (J05E) COMPONENT LOCATOR SHTS021270900305 Bracket Connector *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 8.0 {82, 5.9} REPLACEMENT REMOVING THE GCU Disconnect the connector from the GCU. Unfasten the nut and remove the GCU. MOUNTING THE GCU Mount the nut and remove the GCU.
Page 409 “EXHAUST GAS AFTER TREATMENT SYSTEM REPLACEMENT ..........11-99 MAINTENANCE REQUIREMENT LIGHT” SCR DOWNSTREAM NOx SENSOR ....11-101 LIGHT UP............11-28 COMPONENT LOCATOR .........11-101 INSPECTION BY WAY OF HINO-DX....11-29 REPLACEMENT ..........11-102 INSPECTION PROCEDURE FOLLOWED ATC UPSTREAM TEMPERATURE SENSOR ..11-104 WHEN MALFUNCTION INDICATOR LIGHT COMPONENT LOCATOR .........11-104 ILLUMINATES (ABNORMAL) ......
Page 410 11–2 EXHAUST (J05E) OUTSIDE TEMPERATURE SENSOR....11-119 COMPONENT LOCATOR .........11-119 REPLACEMENT..........11-120 EXHAUST BRAKE ..........11-121 COMPONENT LOCATOR .........11-121 REPLACEMENT..........11-122 EXHAUST BRAKE MAGNETIC VALVE ....11-125 COMPONENT LOCATOR .........11-125 REPLACEMENT..........11-126...
Page 411: Exhaust Manifold
EXHAUST (J05E) 11–3 COMPOSITION DIAGRAM EXHAUST MANIFOLD COMPONENT LOCATOR EN01F02127100402009001 SHTS021271000001 Insulator Stud bolt Exhaust manifold Gasket * Spacer *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 30 {305, 22.1} 59 {600, 43.5}...
Page 412: Replacement
11–4 EXHAUST (J05E) REPLACEMENT EN01F02127100402009002 REMOVING THE EXHAUST MANIFOLD REMOVING THE INTAKE PIPE (EXHAUST SIDE) Reference: INTAKE (J05E), INTAKE PIPE (EXHAUST SIDE), REPLACEMENT, REMOVING THE INTAKE PIPE (EXHAUST SIDE) (Page 9-12) REMOVING THE EGR COOLER Reference: EMISSION CONTROL (J05E), EGR VALVE & COOLER, REPLACEMENT, REMOVING THE EGR VALVE &...
Page 413 EXHAUST (J05E) 11–5 REMOVING STUD BOLTS If corrosion or other failures are found in the stud bolts (12 pcs.), unfasten them with a Torx socket or commercially available stud STUD BOLT bolt remover. Remove dirt on the female threads on the cylinder head side (including sealant) and then clean the threads again with the tap (M10 x 1.5).
Page 414 11–6 EXHAUST (J05E) MOUNTING THE EXHAUST MANIFOLD MOUNTING STUD BOLTS Use the torque socket to tighten with a new stud bolt. Tightening Torque: STUD BOLT 30 N·m {305 kgf·cm, 22.1 lbf·ft} ! CAUTION Note that overtightening with excessive torque may cause cracks in the cylinder head.
Page 415 EXHAUST (J05E) 11–7 Mount the 12 spacers and tighten 12 nuts in the order as shown in the figure. Tightening Torque: WHEN USING A NEW EXHAUST MANIFOLD: 59 N·m {600 kgf·cm, 43.5 lbf·ft} ! CAUTION • When tightening the nuts, use care to avoid interference of individual spacers with the counterbore areas of the exhaust manifold flange.
Page 416: Exhaust Pipe
11–8 EXHAUST (J05E) EXHAUST PIPE COMPONENT LOCATOR EN01F02127100402005001 SHTS021271000010 Exhaust pipe (ATC) Hose protector Gasket * Muffler bracket Front exhaust pipe Plate Muffler Cushion Water pipe Nut* Harness bracket *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 43 {438, 31.7} 31 {316, 22.9} 64 {653, 47.2} 43-59 {438-602, 31.7-43.5}...
Page 417: Replacement
EXHAUST (J05E) 11–9 REPLACEMENT EN01F02127100402005002 REMOVING THE EXHAUST SYSTEM COMPONENT PARTS REMOVING THE HOSE PROTECTOR Remove the hose clip from the hose protector. Unfasten the bolts (2 pcs.) to remove the hose protector from the muffler bracket. HOSE PROTECTOR SHTS021271000011 REMOVING THE DEF INJECTOR Unfasten the 3 nuts to remove the DEF injector from the muffler.
Page 418 11–10 EXHAUST (J05E) DISCONNECTING SENSORS NOTICE Remove the connectors and clips from the vehicle side. Sensors do not need to be removed from the muffler. Remove the DPR differential pressure sensor. Reference: EXHAUST (J05E), DPR DIFFERENTIAL PRES- SURE SENSOR, REPLACEMENT, REMOVE THE DPR DIF- FERENTIAL PRESSURE SENSOR (Page 11-96) Remove the SCR upstream NOx controller.
Page 419 EXHAUST (J05E) 11–11 REMOVING THE FRONT EXHAUST PIPE Unfasten the 7 bolts and 4 nuts to remove the front exhaust pipe and 2 gaskets from the muffler and exhaust pipe (ATC). ! CAUTION FRONT Before disconnecting the front exhaust pipe, put alignment marks. EXHAUST PIPE GASKET GASKET...
Page 420 11–12 EXHAUST (J05E) MOUNTING THE EXHAUST SYSTEM COMPONENT PARTS PRECONNECTING MUFFLER Set the transmission jack under the muffler and use a lashing belt to lash the muffler. ! CAUTION To hold and stabilize the muffler, make sure to use a lashing belt to lash the muffler before installation or removal.
Page 421 EXHAUST (J05E) 11–13 FULLY TIGHTENING EXHAUST SYSTEM COMPONENTS Fully tighten the connecting bolts between the pipes from the engine side in order. EXHAUST PIPE (ATC) FRONT EXHAUST PIPE MUFFLER SHTS021271000019 a. Exhaust pipe (ATC) to front exhaust pipe (part A) Tightening Torque: 43 N·m {438 kgf·cm, 31.7 lbf·ft} b.
Page 422 11–14 EXHAUST (J05E) MOUNTING THE WATER PIPE Mount the water pipe to the muffler bracket with 2 nuts. Tightening Torque: 31 N·m {316 kgf·cm, 22.9 lbf·ft} WATER PIPE SHTS021271000021 MOUNT THE HARNESS Mount the harness to the harness bracket. HARNESS HARNESS BRACKET SHTS021271000022...
Page 423 EXHAUST (J05E) 11–15 MOUNTING THE DEF INJECTOR Replace with a new gasket. MUFFLER Reference: EXHAUST (J05E), DEF INJECTOR, REPLACE- MENT, REMOVING THE DEF INJECTOR (Page 11-67) Mount the DEF injector to the muffler with 3 nuts. Tightening Torque: INJECTOR 6-10 N·m {61-102 kgf·cm, 4.4-7.4 lbf·ft} Mount the DEF injector harness clip.
Page 424: Exhaust Pipe (Atc)
11–16 EXHAUST (J05E) EXHAUST PIPE (ATC) COMPONENT LOCATOR EN01F02127100402041001 SHTS021271000025 Stud bolt Exhaust pipe (ATC) Gasket * Bracket Spacer Clamp *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 70 {714, 51.6} 25.4{259, 18.7} 55 {560, 40.6}...
Page 425: Replacement
EXHAUST (J05E) 11–17 REPLACEMENT EN01F02127100402041002 REMOVING THE EXHAUST PIPE (ATC) REFERENCE NOTICE The ATC will have to be replaced together with the exhaust pipe (ATC). DISCONNECTING THE FRONT EXHAUST PIPE Reference: EXHAUST (J05E), EXHAUST PIPE, REPLACE- MENT, REMOVING THE EXHAUST SYSTEM COMPONENT PARTS (Page 11-9) REMOVING THE FUEL ADDITION VALVE Reference: EXHAUST (J05E), FUEL ADDITION VALVE,...
Page 426 11–18 EXHAUST (J05E) MOUNTING THE EXHAUST PIPE (ATC) REFERENCE NOTICE The ATC will have to be replaced together with the exhaust pipe (ATC). MOUNTING THE EXHAUST PIPE (ATC) Replace with a new gasket and temporarily tighten the exhaust EXHAUST PIPE EXHAUST BRAKE pipe (ATC) to the exhaust brake with 3 nuts.
Page 427: Def-Scr & Dpr
EXHAUST (J05E) 11–19 DEF-SCR & DPR CONFIGURATION DIAGRAM EN01F02127100402052001 DPR SWITCH SENSORS INSTALLED ON MUFFLER TEMPERATURE SENSOR INTER COOLER ENGINE EXHAUST COOLANT PIPING (RETURN) BRAKE TURBOCHARGER DEF PUMP COOLANT CUTOFF VALVE OUTSIDE TEMPERATURE SENSOR DIESEL THROTTLE COOLANT PIPING (AQUEOUS DEF + COOLANT UREA SOLUTION DEFROSTS) FUEL ADDITIVE VALVE PIPING...
Page 428: Cautions On Def/Coolant Piping Attaching And Detaching
11–20 EXHAUST (J05E) CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING EN01F02127100402052002 CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING If the quick joint used in the DEF piping is once removed, DEF powder precipitates on the seal area and leakage may occur after reconnection.
Page 429: Def-Scr
EXHAUST (J05E) 11–21 DEF-SCR COMPONENT LOCATOR EN01F02127100402053001 x 4 x 4 x 4 x 4 SHTS021271000030 Exhaust pipe protector Tail pipe Center pipe No.2 Stay Gasket * Support bracket Exhaust pipe protector stay Washer DEF-SCR *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 22.9} 43-59 {438-602, 31.7-43.5}...
Page 430: Replacement
11–22 EXHAUST (J05E) REPLACEMENT EN01F02127100402053002 REMOVING THE DEF-SCR CAUTIONS ! CAUTION • Perform replacement after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) • Handle the DPR cleaner and DEF-SCR with particular care because they are heavy made of ceramic and can be easily broken.
Page 431 EXHAUST (J05E) 11–23 MOUNTING THE DEF-SCR CAUTIONS ! CAUTION Handle the DPR cleaner and DEF-SCR with particular care because they are heavy made of ceramic and can be easily bro- ken. TEMPORARY MOUNTING OF THE DEF-SCR Set the transmission jack under the DEF-SCR and lash with a CENTER PIPE No.2 TAIL PIPE lashing device.
Page 432 11–24 EXHAUST (J05E) Temporarily tighten 2 support brackets and 8 washers to the DEF- SCR with 8 bolts and 8 nuts. SUPPORT BRACKET DEF-SCR SHTS021271000036 TIGHTENING THE DEF-SCR FULLY Permanently tighten the temporarily tightened bolts and nuts. SUPPORT BRACKET CENTER PIPE No.2 DEF-SCR TAIL PIPE...
Page 433 EXHAUST (J05E) 11–25 INSPECTING THE EXHAUST FLEXIBLE AREA MOUNTING CONDITION 177-191mm {6.97-7.52 in.} Check if the exhaust flexible area is mounted as shown in the fig- ure. BELLOWS BELOW 233mm{9.17 in.} 7mm{0.28 in.} SHTS021271000038 MOUNTING THE EXHAUST PIPE PROTECTOR Mount the exhaust pipe protector to the muffler with the bolts (4 EXHAUST PIPE pcs.).
Page 434: Dpr Cleaner
11–26 EXHAUST (J05E) DPR CLEANER COMPONENT LOCATOR EN01F02127100402002001 x 4 x 4 SHTS021271000040 Support bracket Clip DPR cleaner Center pipe No.1 Gasket * Washer Differential pressure pipe *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 20-30 {204-306, 14.7-22.1} 30-36 {306-367, 22.1-26.5} 43-59 {438-602, 31.7-43.5} 31 {316, 22.9}...
Page 435: Dpr Maintenance
EXHAUST (J05E) 11–27 DPR MAINTENANCE EN01F02127100402002002 • If "Exhaust gas after treatment system maintenance requirement light" is light up on the meter, DPR maintenance is required. If the DPR back pressure value is below the specified value, no maintenance is required. If the DPR back pressure value exceeds the specified value, clean or replace the filter.
Page 436: Inspection Procedure Followed When "Exhaust Gas After Treatment System Maintenance Requirement Light" Light Up
Air intake system inspection: Clogging in the air filter element; air flow meter inspection EGR system inspection: Connect HINO-DX to run the forced driving mode and check opening followability. VNT inspection: Connect HINO-DX to run the forced driving mode and check nozzle opening followability.
Page 437: Inspection By Way Of Hino-Dx
EXHAUST (J05E) 11–29 INSPECTION BY WAY OF HINO-DX EN01F02127100402002005 DPR STATUS CHECK Select the "DPR Reset confirmation" in the "Check function" menu of HINO-DX. Confirm Data View of the "DPR status display"display (monitor), if the value for all the items are "OFF", DPR functions normally.
Page 438 11–30 EXHAUST (J05E) When the "Regeneration switch ON identification" value is ON, wash or replace the filter. When the value is OFF, DPR functions normally. SHTS021271000044 DPR DIFFERENTIAL PRESSURE CHECK Check the DPR differential pressure through the "DPR Status" display. Check and confirm the exhaust gas temperature (in and out) is less than 200C {392F}.
Page 439 EXHAUST (J05E) 11–31 When the differential pressure is unchanged check the following. If the following are normal, the differential pressure sensor should be replaced. a. Check the differential pressure hose for cracks or hole open- ings. b. Check that the hose clamp is neither loose nor disconnected. c.
Page 440 11–32 EXHAUST (J05E) EXHAUST BRAKE OPERATION CHECK Check the difference in injection quantity with ON mode and OFF mode by data monitor. Injection quantity Engine speed Engine coolant temperature SHTS021271000046 Engine coolant temperature More than 82C {180F} Engine speed 980 rpm Exhaust brake valve to OFF (Adjust the engine speed by idle set knob) Injection quantity...
Page 441: Inspection Procedure Followed When Malfunction Indicator Light Illuminates (Abnormal)
LIGHT ILLUMINATES (ABNORMAL) EN01F02127100402002006 NORMAL TRAVELING CHECK MALFUNCTION INDICATOR ILLUMINATES RECIEVING THE VEHICLE FOR SAFETY CHECK CONNECT HINO DX 1. CHECKING THE CURRENTCONDITION PAST FAULT CHECK ENGINE OR BURNER 2. DIAGNOSIS (Inspection of engine system and burner system including trouble...
Page 442 If the operation by means of the DPR SW is not accepted, connect the HINO-DX to the vehicle, record the "HINO-DX Report", erase the trouble code, and then perform manual regeneration according to the following procedure. When manual regeneration has started, wait until regeneration has been completed and confirm that the engine check light has gone out.
Page 443 When the confirmation result in (4) is at or below the standard, DPR manual regeneration and the confirmation work have been completed. Click "Stop" on the DPR Back pressure Check screen to end the work with the HINO-DX. If the exhaust gas back pressure with the inspection in (5) exceeds the standard, repeat the steps (2), (3), (4), and (5).
Page 444: Determination By Way Of Dpr State Determination Monitor Of Hino-Dx
COMES ON. CONNECT HINO-DX. CHECK PAST FAULTS. Check past faults by way of HINO-DX. In case a general engine fault such as a trouble of an exhaust control system is displayed, inspect and repair the pertinent section. Inspect and repair general engine faults and check past faults again.
Page 445: Replacement
EXHAUST (J05E) 11–37 REPLACEMENT EN01F02127100402002009 REMOVING DPR CLEANER CAUTIONS ! CAUTION • Perform replacement after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) • Handle the DPR cleaner and DEF-SCR with particular care because they are heavy made of ceramic and can be easily broken.
Page 446 11–38 EXHAUST (J05E) REMOVING THE DPR Unfasten the 8 bolts and 8 nuts to remove the DPR cleaner and CENTER PIPE No.1 gasket from the center pipe No.1. Set the transmission jack under the DPR cleaner and lash with a lashing device.
Page 447 EXHAUST (J05E) 11–39 TIGHTENING THE DPR CLEANER FULLY Permanently tighten the temporarily tightened bolts and nuts. SUPPORT BRACKET CENTER PIPE No.1 SUPPORT DPR CLEANER BRACKET SHTS021271000053 a. Center pipe No.1 - DPR cleaner (part A) Tightening Torque: 20-30 N·m {204-306 kgf·cm, 14.7-22.1 lbf·ft} b.
Page 448 11–40 EXHAUST (J05E) MOUNTING THE DIFFERENTIAL PRESSURE PIPE Insert the differential pressure pipe into the muffler. After finger- DIFFERENTIAL PRESSURE PIPE tightening the flare nut, tighten it to the muffler with the specified torque. Tightening Torque: 30-36 N·m {306-367 kgf·cm, 22.1-26.5 lbf·ft} ! CAUTION Wipe off old anti-seizure lubricant on the differential pressure pipes and apply new anti-seizure lubricant (equivalent to NEVER-...
Page 449: Overall Operation Flow
EXHAUST (J05E) 11–41 OVERALL OPERATION FLOW EN01F02127100402002010 VEHICLE RECEIPT FOR INSPECTION Check the malfunction code with the HINO-DX. Standard value: No malfunction code 4. For P200C, P244B, P244A, P2459, P2463 5. For others than above SHTS021271000056 2. MANUAL REGENERATION MANUAL REGENERATION After a manual regeneration, check the differential pressure with the HINO-DX.
Page 450 11–42 EXHAUST (J05E) INSPECT THE DPR FILTER Dismount the DPR filter from the vehicle. Reference: EXHAUST (J05E), DPR CLEANER, REPLACE- MENT, REMOVING DPR CLEANER (Page 11-37) Inspect the status of the DPR filter rear surface. Reference: EXHAUST (J05E), DPR CLEANER, OVERALL OPERATION FLOW, INSPECT INSIDE THE DPR FILTER (Page 11-45) Standard value: No soot escape...
Page 451 EXHAUST (J05E) 11–43 IN CASE THAT DPR DTC CODE IS DISPLAYED Dismount the DPR filter from the vehicle. Reference: EXHAUST (J05E), DPR CLEANER, REPLACE- MENT, REMOVING DPR CLEANER (Page 11-37) Inspect the status of the DPR filter rear surface. Reference: EXHAUST (J05E), DPR CLEANER, OVERALL OPERATION FLOW, INSPECT INSIDE THE DPR FILTER (Page 11-45) Standard value: No soot escape...
Page 452 11–44 EXHAUST (J05E) FOR OTHERS THAN DPR DTC CODE IS DISPLAYED Checking the engine and repair or replace defective parts if any. Dismount the DPR filter from the vehicle. Reference: EXHAUST (J05E), DPR CLEANER, REPLACE- MENT, REMOVING DPR CLEANER (Page 11-37) Inspect the status of the DPR filter rear surface.
Page 453 EXHAUST (J05E) 11–45 INSPECT INSIDE THE DPR FILTER NOTICE This is for detecting abnormalities inside the DPR filter. VISUALLY INSPECT THE FILTER REAR SURFACE. Visually inspect the filter rear surface to detect soot escapes (black part). GAS FLOW FILTER FILTER REAR GAS FLOW SURFACE...
Page 454 11–46 EXHAUST (J05E) VISUALLY INSPECT THE CASE EDGE. Visually inspect the case edge to detect soot escapes (black part). GAS FLOW CASE FILTER EDGE GAS FLOW SHTS021271000062 Standard value: No soot escape 3. INSPECT THE DPR FILTER WITH THE DEDI- CATED CHECK PROBE.
Page 455 EXHAUST (J05E) 11–47 INSPECT THE DPR FILTER WITH THE DEDICATED CHECK PROBE. Insert the check probe from the rear surface to inspect the inside. SST: 09992-E4010 FILTER GAUGE ASSEMBLY ALIGN THE TIP TO THE CENTER OF THE TIGHTEN A SCREW PIANO WIRE MARKING.
Page 456: Air Cleaning Flow
11–48 EXHAUST (J05E) AIR CLEANING FLOW EN01F02127100402002011 (SOOT CLEANING) SOOT SUCTION SOOT AIR BLOW DISPOSE OF THE WASTE AND THE POWDER AS INDUSTRIAL WASTES. SHTS021271000064...
Page 457: Fuel Addition Valve
EXHAUST (J05E) 11–49 FUEL ADDITION VALVE COMPONENT LOCATOR EN01F02127100402035001 SHTS021271000065 Coolant pipe D Nozzle clamp Coolant pipe E Fuel addition valve Gasket * O-ring * Fuel feed pipe No.5 Folder Fuel delivery Stud Bolt *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 36 {367, 26.5} 19.6 {200, 14.5} 24.5 {250, 18.1}...
Page 458: Replacement
11–50 EXHAUST (J05E) REPLACEMENT EN01F02127100402035002 REMOVING THE FUEL ADDITION VALVE CAUTIONS ! CAUTION Perform replacement after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for at least 30 min- utes as a guide.) DRAINING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, DRAINING THE COOLANT (Page 12-5)
Page 459 EXHAUST (J05E) 11–51 REMOVING THE FUEL ADDITION VALVE Unfasten the bolts (2 pcs.) to remove the fuel delivery from the folder. FUEL DELIVERY ! CAUTION • Do not allow the O-ring on the fuel addition valve to come off. If it came off, mount the O-ring following "How to mount the fuel addition valve O-ring".
Page 460 11–52 EXHAUST (J05E) HOW TO MOUNT THE FUEL ADDITION VALVE O- RING MOUNTING THE FUEL ADDITION VALVE O-RING Replace with a new O-ring, backup ring, and E-ring and mount E-RING them as shown in the figure. ! CAUTION BACKUP RING No.3 •...
Page 461 EXHAUST (J05E) 11–53 SINGLE UNIT INSPECTION INSULATION RESISTANCE TEST Using the 500 V megohmmeter, measure the insulation resis- tance between the fuel addition valve upper body and connector (part side). Replace if the measurement reading exceeds the standard value. MEGOHMMETER Standard value 10M...
Page 462 11–54 EXHAUST (J05E) CLEANING CARBON CLEANING CARBON ! CAUTION • The carbon cleaner is alkali. Wear protective equipment (glasses, rubber gloves, and protective garment) to prevent it from contacting eyes, skin, and clothes. If it should contact the skin, wash it off with running water immediately.
Page 463 EXHAUST (J05E) 11–55 MOUNTING THE FUEL ADDITION VALVE CAUTIONS ! CAUTION • While working, do not allow dirt and water to enter the parts. • Before mounting parts, make sure that there is no dirt on the connection between them. •...
Page 464 11–56 EXHAUST (J05E) Mount the nozzle clamp to the folder with the bolt. Tightening Torque: 28.5 N·m {290 kgf·cm, 21.0 lbf·ft} NOZZLE CLAMP FOLDER SHTS021271000082 ! CAUTION • When mounting the nozzle clamp to the folder, align the noz- zle clamp with the fuel addition valve groove. •...
Page 465 EXHAUST (J05E) 11–57 Replace with 2 new gaskets and connect the fuel feed pipe No.5 to the fuel delivery with the union bolt. FUEL FEED PIPE No. 5 Tightening Torque: 19.6 N·m {200 kgf·cm, 14.5 lbf·ft} FUEL DELIVERY SHTS021271000086 CONNECTING THE HARNESS Connect the connector to the fuel addition valve.
Page 466: Fuel Cutoff Valve
11–58 EXHAUST (J05E) FUEL CUTOFF VALVE COMPONENT LOCATOR EN01F02127100402037001 SHTS021271000088 Fuel feed pipe No.3 Fuel cutoff valve Gasket * Fuel feed pipe No.5 *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 19.6 {200, 14.5} 28.5{290, 21.0}...
Page 467: Replacement
EXHAUST (J05E) 11–59 REPLACEMENT EN01F02127100402037002 REMOVING THE FUEL CUTOFF VALVE DISCONNECTING THE HARNESS Disconnect the connector from the fuel cutoff valve. CONNECTOR FUEL FEED PIPE No.3 DISCONNECTING PIPES Unfasten the 2 union bolts to disconnect the fuel feed pipe No.3, fuel feed pipe No.5, and 2 gaskets from the fuel cutoff valve.
Page 468: Def Pump
11–60 EXHAUST (J05E) DEF PUMP COMPONENT LOCATOR EN01F02127100402054001 SHTS021271000091 DEF pump assembly DEF pump Outlet connector * Filter Backflow connector * Filter cover Inlet connector * Tank bracket Coolant connector * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 15.2-22.8 {155-232, 11.2-16.8} 5-6 {51-61, 3.7-4.4} 4-5 {41-51, 2.9-3.7}...
Page 469: Replacement
EXHAUST (J05E) 11–61 REPLACEMENT EN01F02127100402054002 REPLACING THE FILTER CAUTIONS ! CAUTION After-run (DEF drawn back to the DEF tank) is performed after the starter key is turned to “LOCK” and the muffler temperature drops. Before starting work, wait for at least 10 minutes after turn- ing the starter key to “LOCK.”...
Page 470 11–62 EXHAUST (J05E) MOUNTING THE FILTER Replace with a new filter and equalizer and mount them to the DEF PUMP DEF pump. FILTER EQUALIZER SHTS021271000094 Turn the filter cover clockwise using a 27 mm {1.06 in.} box (dodecagon) to mount it to the DEF pump. DEF PUMP Tightening Torque: 15-25 N·m {153-255 kgf·cm, 11.1-18.4 lbf·ft}...
Page 471 EXHAUST (J05E) 11–63 DISCONNECTING THE CONNECTOR Disconnect the 2 coolant connectors from the DEF pump using a 15 mm {0.59 in.} spanner. PUMP COOLANT CONNECTOR O-RING 77 mm 18 mm SHTS021271000097 Disconnect the inlet connector from the DEF pump using a 17 mm {0.67 in.} spanner.
Page 472 11–64 EXHAUST (J05E) MOUNTING THE DEF PUMP CONNECTING THE CONNECTOR Apply Mobil Velocite Oil No.6 to the O-ring of the backflow con- nector. PUMP BACKFLOW Connect the backflow connector to the DEF pump using a 17 mm CONNECTOR {0.67 in.} spanner. Tightening Torque: 4-5 N·m {41-51 kgf·cm, 2.9-3.7 lbf·ft} O-RING...
Page 473 EXHAUST (J05E) 11–65 MOUNTING THE DEF PUMP Mount the DEF pump to the tank bracket with the bolts (3 pcs.). Tightening Torque: 15.2-22.8 N·m {155-232 kgf·cm, 11.2-16.8 lbf·ft} DEF PUMP SHTS021271000105 MOUNTING THE DEF TANK ASSEMBLY Reference: EXHAUST (J05E), DEF TANK, REPLACEMENT, MOUNTING THE DEF TANK ASSEMBLY (Page 11-81) ADDING THE COOLANT Inspect the coolant level and if insufficient, pour coolant.
Page 474: Def Injector
11–66 EXHAUST (J05E) DEF INJECTOR COMPONENT LOCATOR EN01F02127100402055001 SHTS021271000106 Gasket * Hose bracket DEF injector Hose protector Coolant connector * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 22.9} 5-6 {51-61, 3.7-4.4} 6-10 {61-102, 4.4-7.4}...
Page 475: Replacement
EXHAUST (J05E) 11–67 REPLACEMENT EN01F02127100402055002 REMOVING THE DEF INJECTOR CAUTIONS ! CAUTION • Perform replacement after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) • After-run (DEF drawn back to the DEF tank) is performed after the starter key is turned to “LOCK”...
Page 476 11–68 EXHAUST (J05E) DISCONNECTING THE HARNESS Disconnect the connector from the DEF injector. MUFFLER DEF INJECTOR CONNECTOR SHTS021271000110 REMOVING THE DEF INJECTOR Unfasten the 3 nuts to remove the DEF injector from the muffler. MUFFLER DEF INJECTOR SHTS021271000111 Lift the tabs (3 places) of the gasket with pliers and remove the gasket from the DEF injector.
Page 477 EXHAUST (J05E) 11–69 DISCONNECTING THE CONNECTOR Disconnect the 2 coolant connectors from the DEF injector using a 15 mm spanner. COOLANT CONNECTOR 20 mm O-RING DEF INJECTOR SHTS021271000114 MOUNTING THE DEF INJECTOR CONNECTING THE CONNECTOR Apply Mobil Velocite Oil No.6 to the O-ring of the coolant connec- tor.
Page 478 11–70 EXHAUST (J05E) CONNECTING THE HARNESS Connect the connector to the DEF injector. MUFFLER DEF INJECTOR CONNECTOR SHTS021271000118 CONNECTING THE HOSE. MUFFLER ! CAUTION DEF INJECTOR Refer to "Cautions on DEF/coolant piping attaching and detach- ing". Reference: EXHAUST (J05E), DEF-SCR & DPR, CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING (Page 11- Connect the DEF inlet hose to the DEF injector.
Page 479 EXHAUST (J05E) 11–71 MOUNTING THE HOSE PROTECTOR Mount the hose protector to the hose bracket with 2 nuts. Tightening Torque: 31 N·m {316 kgf·cm, 22.9 lbf·ft} HOSE PROTECTOR SHTS021271000121 ADDING THE COOLANT Inspect the coolant level and if insufficient, pour coolant. Reference: COOLING (J05E), RADIATOR, REPLACEMENT, ADDING THE COOLANT (Page 12-13)
Page 480: Def Tank
11–72 EXHAUST (J05E) DEF TANK COMPONENT LOCATOR EN01F02127100402056001 CREW CAB SINGLE CAB SHTS021271000122 Tank bracket J-bolt DEF tank Tank band Drain plug Filler cap Water level gauge DEF tank cover Clamp Tightening torque Unit: Nm {kgfcm, lbfft} 38.4-57.6 {392-587, 28.3-42.5} 32 {326, 23.6} 23.5-36.5 {240-372, 17.3-26.9}...
Page 481: Inspection
EXHAUST (J05E) 11–73 INSPECTION EN01F02127100402056002 INSPECTING DEF CONCENTRATION CAUTIONS ! CAUTION There are 3 inspection methods for DEF; DEF analyzer inspection, pH test paper inspection, and refractive index measurement inspection. Use one method from three for inspection. DEF ANALYZER INSPECTION Extract the DEF and put a few drops on the DEF analyzer to mea- sure DEF concentration.
Page 482: Replacement
11–74 EXHAUST (J05E) REPLACEMENT EN01F02127100402056003 REPLACING DEF DRAINING DEF Turn the starter key to “ON”, remove the drain plug, and discharge DEF from the DEF tank. ! CAUTION • If the starter key is turned to “LOCK” with nothing left in the tank, the engine cannot be restarted.
Page 483 EXHAUST (J05E) 11–75 • If diesel fuel has been mistakenly added into the DEF tank. Once the engine is started and the DEF pump is activated, diesel fuel will enter the DEF piping, DEF pump and DEF injector. If diesel fuel has entered the DEF piping, DEF pump and DEF injector, replace them along with the DEF tank and DEF sensor.
Page 484 11–76 EXHAUST (J05E) DISCONNECTING THE HOSE. ! CAUTION Refer to "Cautions on DEF/coolant piping attaching and detach- ing". COOLANT INLET COOLANT OUTLET Reference: EXHAUST (J05E), DEF-SCR & DPR, CAUTIONS ON HOSE HOSE DEF/COOLANT PIPING ATTACHING AND DETACHING (Page 11- Disconnect the DEF backflow hose and DEF outlet hose from the DEF sensor.
Page 485 EXHAUST (J05E) 11–77 MOUNTING THE DEF TANK MOUNTING THE DEF TANK Mount the DEF tank to the tank bracket. TANK BRACKET DEF TANK SHTS021271000133 CONNECTING THE HARNESS Connect the connector to the DEF sensor. CONNECTOR DEF SENSOR DEF TANK SHTS021271000134 CONNECTING THE HOSE ! CAUTION Refer to "Cautions on DEF/coolant piping attaching and detach-...
Page 486 11–78 EXHAUST (J05E) MOUNTING THE DEF TANK COVER Mount the DEF tank cover to the DEF tank with the bolts (3 pcs.). SINGLE CAB Tightening Torque: 32 N·m {326 kgf·cm, 23.6 lbf·ft} DEF TANK COVER DEF TANK CREW CAB DEF TANK COVER DEF TANK SHTS021271000136 MOUNTING THE TANK BAND...
Page 487 EXHAUST (J05E) 11–79 REMOVING THE DEF TANK ASSEMBLY CAUTIONS ! CAUTION After-run (DEF drawn back to the DEF tank) is performed after the starter key is turned to “LOCK” and the muffler temperature drops. Before starting work, wait for at least 10 minutes after turn- ing the starter key to “LOCK.”...
Page 488 11–80 EXHAUST (J05E) DISCONNECT THE HOSE ! CAUTION Refer to "Cautions on DEF/coolant piping attaching and detach- ing". Reference: EXHAUST (J05E), DEF-SCR & DPR, CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING (Page 11- Disconnect the hose from the DEF sensor. Reference: EXHAUST (J05E), DEF TANK, REPLACEMENT, REMOVING THE DEF TANK (Page 11-75) Disconnect the DEF inlet hose, DEF outlet hose, and DEF back-...
Page 489 EXHAUST (J05E) 11–81 MOUNTING THE DEF TANK ASSEMBLY MOUNTING THE DEF TANK ASSEMBLY Lash the transmission jack and DEF tank assembly with a lashing device. DEF TANK ASSEMBLY ! CAUTION Pay attention to weight balance. Set the DEF tank assembly to the DEF tank mounting position while supporting it to prevent falling.
Page 490 11–82 EXHAUST (J05E) CONNECTING THE HARNESS Connect the connector to the DEF pump. DEF PUMP SHTS021271000144 Connect the connector to the outside temperature sensor. Connect the connector to the DEF sensor. DEF SENSOR Connect the connector to the DCU. Reference: EXHAUST (J05E), DCU, REPLACEMENT, MOUNT- ING THE DCU (Page 11-92) OUTSIDE TEMPERATURE...
Page 491: Def Sensor
EXHAUST (J05E) 11–83 DEF SENSOR COMPONENT LOCATOR EN01F02127100402057001 SHTS021271000146 O-ring * DEF sensor *: Nonreusable part...
Page 492: Replacement
11–84 EXHAUST (J05E) REPLACEMENT EN01F02127100402057002 REMOVING THE DEF SENSOR REMOVING THE DEF TANK Reference: EXHAUST (J05E), DEF TANK, REPLACEMENT, REMOVING THE DEF TANK (Page 11-75) REMOVING THE DEF SENSOR Turn the DEF sensor counterclockwise to remove it from the DEF tank.
Page 493 EXHAUST (J05E) 11–85 MOUNTING THE DEF SENSOR MOUNTING THE DEF SENSOR Replace with a new O-ring and mount it to the DEF sensor. Fix the DEF tank and turn the DEF sensor clockwise to mount it to the DEF tank. DEF SENSOR ! CAUTION •...
Page 494: Coolant Cutoff Valve
11–86 EXHAUST (J05E) COOLANT CUTOFF VALVE COMPONENT LOCATOR EN01F02127100402019001 SHTS021271000150 Coolant cutoff valve Clamp Water valve bracket Hose Harness bracket Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 22.9}...
Page 495: Replacement
EXHAUST (J05E) 11–87 REPLACEMENT EN01F02127100402019002 REMOVING THE COOLANT CUTOFF VALVE DISCONNECTING THE HOSE COOLANT CUTOFF ! CAUTION VALVE Refer to "Cautions on DEF/coolant piping attaching and detach- ing". Reference: EXHAUST (J05E), DEF-SCR & DPR, CAUTIONS ON DEF/COOLANT PIPING ATTACHING AND DETACHING (Page 11- Remove the 2 clamps and disconnect 2 hoses from the coolant cutoff valve.
Page 496 11–88 EXHAUST (J05E) MOUNTING THE COOLANT CUTOFF VALVE MOUNTING THE COOLANT CUTOFF VALVE Mount the harness bracket to the coolant cutoff valve with the bolts (2 pcs.). Tightening Torque: COOLANT CUTOFF VALVE 31 N·m {316 kgf·cm, 22.9 lbf·ft} HARNESS BRACKET Mount the water valve bracket to the coolant cutoff valve with the bolts (2 pcs.).
Page 497: Dcu
EXHAUST (J05E) 11–89 COMPONENT LOCATOR EN01F02127100402021001 SHTS021271000157 DCU bracket Tightening torque Unit: Nm {kgfcm, lbfft} 10 {102, 7.4} 22 {224, 16.2}...
Page 498: Replacement
11–90 EXHAUST (J05E) REPLACEMENT EN01F02127100402021002 REMOVING THE DCU REMOVING THE OUTSIDE TEMPERATURE SENSOR Reference: EXHAUST (J05E), OUTSIDE TEMPERATURE SEN- SOR, REPLACEMENT, REMOVING THE OUTSIDE TEMPERA- TURE SENSOR (Page 11-120) DISCONNECTING THE DEF SENSOR CONNECTOR Disconnect the connector from the DEF sensor. DEF SENSOR SHTS021271000158 REMOVING THE DCU BRACKET...
Page 499 EXHAUST (J05E) 11–91 DISCONNECTING THE DCU CONNECTOR Disconnect the connector by moving the slide in the direction of 86 POLE CONNECTOR the arrow as shown in the figure until a "click" is heard. SLIDE 53 POLE CONNECTOR SLIDE SHTS021271000161 Pull out the connector straight. ! CAUTION 86 POLE CONNECTOR SLIDE...
Page 500 11–92 EXHAUST (J05E) REMOVING THE DCU Unfasten the nuts (4 pcs.) and remove the DCU from the DCU bracket. DCU BRACKET SHTS021271000163 MOUNTING THE DCU MOUNTING THE DCU Mount the DCU to the DCU bracket with 4 nuts. Tightening Torque: 10 N·m {102 kgf·cm, 7.4 lbf·ft} DCU BRACKET SHTS021271000164...
Page 501 EXHAUST (J05E) 11–93 Connect the connector by moving the slide in the direction of the arrow as shown in the figure until a "click" is heard. 86 POLE CONNECTOR SLIDE ! CAUTION • If the slide cannot move smoothly, repeat steps (1) and (2). 53 POLE CONNECTOR SLIDE SHTS021271000166...
Page 502 11–94 EXHAUST (J05E) MOUNTING THE DCU BRACKET Mount the harness clamp to the DCU bracket. BRACKET HARNESS SHTS021271000168 Mount the DCU with DCU bracket to the tank bracket with 3 nuts. Tightening Torque: TANK 22 N·m {224 kgf·cm, 16.2 lbf·ft} BRACKET DCU BRACKET SHTS021271000169...
Page 503: Dpr Differential Pressure Sensor
EXHAUST (J05E) 11–95 DPR DIFFERENTIAL PRESSURE SENSOR COMPONENT LOCATOR EN01F02127100402003001 SHTS021271000171 DPR differential pressure sensor Hose Clamp Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 22.9}...
Page 504: Replacement
11–96 EXHAUST (J05E) REPLACEMENT EN01F02127100402003002 REMOVE THE DPR DIFFERENTIAL PRESSURE SENSOR DISCONNECTING THE HARNESS Remove the harness clamp. Disconnect the connector attached to the DPR differential pres- DIFFERENTIAL PRESSURE sure sensor. SENSOR DISCONNECT THE HOSE Indicate alignment marks on the DPR differential pressure sensor and 2 hoses.
Page 505 EXHAUST (J05E) 11–97 MOUNTING THE DPR DIFFERENTIAL PRESSURE SENSOR MOUNTING THE DPR DIFFERENTIAL PRESSURE SENSOR Mount the DPR differential pressure sensor to the bracket with 2 nuts. DIFFERENTIAL PRESSURE Tightening Torque: SENSOR 31 N·m {316 kgf·cm, 22.9 lbf·ft} CONNECTING THE HOSE Align the markings on the hoses, differential pressure sensor, and muffler.
Page 506: Scr Upstream Nox Sensor
11–98 EXHAUST (J05E) SCR UPSTREAM NOx SENSOR COMPONENT LOCATOR EN01F02127100402022001 SHTS021271000175 SCR upstream NOx sensor Clip Tightening torque Unit: Nm {kgfcm, lbfft} 5.5 {56, 4.1} 40-60 {408-612, 29.5-44.2} 31 {316, 22.9}...
Page 507: Replacement
EXHAUST (J05E) 11–99 REPLACEMENT EN01F02127100402022002 REMOVING THE SCR UPSTREAM NOx SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the SCR upstream NOx SCR UPSTREAM controller. NOx SENSOR REMOVING THE SCR UPSTREAM NOx SENSOR Unfasten the 2 nuts and remove SCR upstream NOx controller from the bracket.
Page 508 11–100 EXHAUST (J05E) MOUNTING THE SCR UPSTREAM NOx SENSOR MOUNTING THE SCR UPSTREAM NOx SENSOR Connect the SCR upstream NOx sensor to the muffler and then SCR UPSTREAM the harness clamp. NOx SENSOR Tightening Torque: 40-60 N·m {408-612 kgf·cm, 29.5-44.2 lbf·ft} ! CAUTION •...
Page 509: Scr Downstream Nox Sensor
EXHAUST (J05E) 11–101 SCR DOWNSTREAM NOx SENSOR COMPONENT LOCATOR EN01F02127100402023001 SHTS021271000180 SCR downstream NOx controller Tightening torque Unit: Nm {kgfcm, lbfft} 5.5 {56, 4.1} 40-60 {408-612, 29.5-44.2}...
Page 510: Replacement
11–102 EXHAUST (J05E) REPLACEMENT EN01F02127100402023002 REMOVING THE SCR DOWNSTREAM NOx SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the SCR downstream NOx controller. SCR DOWNSTREAM NOx SENSOR REMOVING THE SCR DOWNSTREAM NOx SENSOR Unfasten the 2 nuts and remove SCR downstream NOx controller from the bracket.
Page 511 EXHAUST (J05E) 11–103 MOUNTING THE SCR DOWNSTREAM NOx SENSOR MOUNTING THE SCR DOWNSTREAM NOx SENSOR Connect the SCR downstream NOx sensor to the muffler and SCR DOWNSTREAM then the harness clamp. NOx SENSOR Tightening Torque: 40-60 N·m {408-612 kgf·cm, 29.5-44.2 lbf·ft} ! CAUTION MUFFLER •...
Page 512: Atc Upstream Temperature Sensor
11–104 EXHAUST (J05E) ATC UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402058001 SHTS021271000185 ATC upstream temperature sensor Tightening torque Unit: Nm {kgfcm, lbfft} 25-35 {255-357, 18.4-25.8}...
Page 513: Replacement
EXHAUST (J05E) 11–105 REPLACEMENT EN01F02127100402058002 REMOVING THE ATC UPSTREAM TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect a connector from the ATC upstream temperature sen- ATC UPSTREAM sor. TEMPERATURE SENSOR REMOVING THE ATC UPSTREAM TEMPERATURE SENSOR Remove the ATC upstream temperature sensor together with a harness clamp from the exhaust pipe (ATC).
Page 514 11–106 EXHAUST (J05E) MOUNTING THE ATC UPSTREAM TEMPERATURE SENSOR MOUNTING THE ATC UPSTREAM TEMPERATURE SENSOR ATC UPSTREAM Connect the ATC upstream temperature sensor to the exhaust TEMPERATURE pipe (ATC) and fasten a harness clamp. SENSOR Tightening Torque: 25-35 N·m {255-357 kgf·cm, 18.4-25.8 lbf·ft} ! CAUTION •...
Page 515: Doc Upstream Temperature Sensor
EXHAUST (J05E) 11–107 DOC UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402025001 SHTS021271000189 DOC upstream temperature sensor Tightening torque Unit: Nm {kgfcm, lbfft} 25-35 {255-357, 18.4-25.8}...
Page 516: Replacement
11–108 EXHAUST (J05E) REPLACEMENT EN01F02127100402025002 REMOVING DOC UPSTREAM TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect a connector from the DOC upstream temperature DOC UPSTREAM sensor. TEMPERATURE SENSOR REMOVING DOC UPSTREAM TEMPERATURE SENSOR Remove the DOC upstream temperature sensor together with a harness clamp from the muffler.
Page 517 EXHAUST (J05E) 11–109 MOUNTING DOC UPSTREAM TEMPERATURE SENSOR MOUNTING DOC UPSTREAM TEMPERATURE SENSOR Connect the DOC upstream temperature sensor to the muffler DOC UPSTREAM and fasten a harness clamp. TEMPERATURE SENSOR Tightening Torque: 25-35 N·m {255-357 kgf·cm, 18.4-25.8 lbf·ft} ! CAUTION •...
Page 518: Dpr Upstream Temperature Sensor
11–110 EXHAUST (J05E) DPR UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402044001 SHTS021271000193 DPR upstream temperature sensor Tightening torque Unit: Nm {kgfcm, lbfft} 25-35 {255-357, 18.4-25.8}...
Page 519: Replacement
EXHAUST (J05E) 11–111 REPLACEMENT EN01F02127100402044002 REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector from the DPR upstream temperature DPR UPSTREAM sensor. TEMPERATURE SENSOR REMOVING THE DPR UPSTREAM TEMPERATURE SENSOR Remove the DPR upstream temperature sensor together with the harness clamp from the muffler.
Page 520: Dpr Downstream Temperature Sensor
11–112 EXHAUST (J05E) DPR DOWNSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402027001 SHTS021271000197 DPR downstream temperature sensor Tightening torque Unit: Nm {kgfcm, lbfft} 25-35 {255-357, 18.4-25.8}...
Page 521: Replacement
EXHAUST (J05E) 11–113 REPLACEMENT EN01F02127100402027002 REMOVING THE DPR DOWNSTREAM TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector from the DPR downstream temperature sensor. REMOVING THE DPR DOWNSTREAM TEMPERATURE SENSOR Remove the DPR downstream temperature sensor together with a harness clamp from the muffler. DPR DOWNSTREAM TEMPERATURE SENSOR MUFFLER...
Page 522 11–114 EXHAUST (J05E) MOUNTING THE DPR DOWNSTREAM TEMPERATURE SENSOR MOUNTING THE DPR DOWNSTREAM TEMPERATURE SENSOR Mount the DPR downstream temperature sensor to the muffler and fasten a harness clamp. Tightening Torque: 25-35 N·m {255-357 kgf·cm, 18.4-25.8 lbf·ft} ! CAUTION • When reusing, clean the old anti-seizure lubricant on the DPR downstream temperature sensor and apply anti-seizure DPR DOWNSTREAM...
Page 523: Scr Upstream Temperature Sensor
EXHAUST (J05E) 11–115 SCR UPSTREAM TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402028001 SHTS021271000201 SCR upstream temperature sensor Christmas tree Tightening torque Unit: Nm {kgfcm, lbfft} 32.5 {331, 24.0}...
Page 524: Replacement
11–116 EXHAUST (J05E) REPLACEMENT EN01F02127100402028002 REMOVING THE SCR UPSTREAM TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the SCR upstream tem- SCR UPSTREAM perature sensor. TEMPERATURE SENSOR REMOVING THE SCR UPSTREAM TEMPERATURE SENSOR Remove the SCR upstream temperature sensor together with the harness clamp from the muffler.
Page 525 EXHAUST (J05E) 11–117 SINGLE UNIT INSPECTION INSPECTING THE RESISTANCE Use the water and a circuit tester to measure resistance between THERMOMETER SCR UPSTREAM terminals. Replace if a measurement reading exceeds the stan- TEMPERATURE SENSOR dard value. Temperature Standard value 50°C {122°F} 235-244...
Page 526 11–118 EXHAUST (J05E) Connect the SCR upstream temperature sensor to the muffler and then the harness clamp. SCR UPSTREAM Tightening Torque: TEMPERATURE 32.5 N·m {331 kgf·cm, 24.0 lbf·ft} SENSOR ! CAUTION • When reusing, clean the old anti-seizure lubricant on the SCR upstream temperature sensor and apply anti-seizure lubricant (equivalent to NEVER-SEEZ Pure Nickel Special Grade manufactured by Bostic, Inc.) to the thread area.
Page 527: Outside Temperature Sensor
EXHAUST (J05E) 11–119 OUTSIDE TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127100402038001 SHTS021271000207 Outside temperature sensor...
Page 528: Replacement
11–120 EXHAUST (J05E) REPLACEMENT EN01F02127100402038002 REMOVING THE OUTSIDE TEMPERATURE SENSOR DISCONNECTING THE HARNESS Disconnect the connector connected to the outside temperature sensor. REMOVING THE OUTSIDE TEMPERATURE SENSOR Unfasten the clamp to remove the outside temperature sensor from the bracket. OUTSIDE TEMPERATURE SENSOR SHTS021271000208...
Page 529: Exhaust Brake
EXHAUST (J05E) 11–121 EXHAUST BRAKE COMPONENT LOCATOR EN01F02127100402008001 SHTS021271000210 Exhaust brake Gasket * *: Nonreusable part...
Page 530: Replacement
11–122 EXHAUST (J05E) REPLACEMENT EN01F02127100402008002 REMOVING THE EXHAUST BRAKE CAUTIONS ! CAUTION Perform replacement after cooling to prevent burns. (Turn the starter key to the "LOCK" position and leave it for more than 30 minutes to cool.) REMOVING THE EXHAUST PIPE (ATC) Reference: EXHAUST (J05E),...
Page 531 EXHAUST (J05E) 11–123 SINGLE UNIT INSPECTION INSPECTING THE EXHAUST BRAKE Check the valve for smooth and complete closing when a load of 80 kPa {600 mmHg, 11.6 inHg} is applied using the exhaust brake valve Mityvac. Check the valve for smooth and complete opening when atmo- spheric pressure is applied to the exhaust brake.
Page 532 11–124 EXHAUST (J05E) MOUNTING THE EXHAUST BRAKE MOUNTING THE EXHAUST BRAKE Replace with a new gasket and mount the exhaust brake to the EXHAUST turbocharger assembly. BRAKE SHTS021271000216 CONNECTING THE VACUUM HOSE Connect the vacuum hose to the exhaust brake. EXHAUST BRAKE VACUUM...
Page 533: Exhaust Brake Magnetic Valve
EXHAUST (J05E) 11–125 EXHAUST BRAKE MAGNETIC VALVE COMPONENT LOCATOR EN01F02127100402045001 SHTS021271000218 Exhaust brake magnetic valve Hose Clamp Tightening torque Unit: Nm {kgfcm, lbfft} 31 {316, 22.9}...
Page 534 11–126 EXHAUST (J05E) REPLACEMENT EN01F02127100402045002 REMOVING THE EXHAUST BRAKE MAGNETIC VALVE DISCONNECTING THE HOSE Unfasten the 2 clamps to disconnect 2 hoses from the exhaust brake magnetic valve. ! CAUTION Before disconnecting the hoses, put alignment marks. DISCONNECTING THE HARNESS Disconnect the connector from the exhaust brake magnetic valve.
Page 535 EXHAUST (J05E) 11–127 MOUNTING THE EXHAUST BRAKE MAGNETIC VALVE MOUNTING THE EXHAUST BRAKE MAGNETIC VALVE Mount the exhaust brake magnetic valve with the bolts (2 pcs.). Tightening Torque: 31 N·m {316 kgf·cm, 22.9 lbf·ft} CONNECTING THE HARNESS Connect the connector to the exhaust brake magnetic valve. CONNECT THE HOSE Align the markings and connect the hoses (2 pcs.) to the exhaust brake magnetic valve.
Page 536 COOLING (J05E) 12–1 COOLING (J05E) 12-001 COOLING SYSTEM ...........12-2 COOLING SYSTEM DIAGRAM ......12-2 RADIATOR ..............12-3 COMPONENT LOCATOR ........12-3 INSPECTION ............12-4 REPLACEMENT ...........12-5 RADIATOR CAP............12-15 COMPONENT LOCATOR ........12-15 REPLACEMENT ..........12-16 RESERVE TANK ............12-18 COMPONENT LOCATOR ........12-18 REPLACEMENT ..........
Page 537: Cooling System
12–2 COOLING (J05E) SYSTEM DRAWING COOLING SYSTEM COOLING SYSTEM DIAGRAM EN01F02127110405009001 COOLANT TEMPERATURE METER RESERVOIR EGR COOLER THERMOSTAT CASE CYLINDER HEAD THERMOSTAT CYLINDER BLOCK TURBO CHARGER HEATER FUEL ADDITION VALVE COOLANT PUMP OIL COOLER DRAIN COCK DRAIN COCK FOR ENGINE COOLING FOR ACCESSORY COOLING AIR PULLING OUT SHTS021271100001...
Page 538: Radiator
COOLING (J05E) 12–3 COMPOSITION DIAGRAM RADIATOR COMPONENT LOCATOR EN01F02127110402019001 SHTS021271100002 Radiator inlet hose Radiator bracket No. 3 Clamp Radiator bracket No. 4 Radiator outlet hose Radiator support seal No. 1 Tightening torque Unit: Nm {kgfcm, lbfft} 19.5 {199, 14}...
Page 539: Inspection
12–4 COOLING (J05E) INSPECTION EN01F02127110402019002 INSPECTION BEFORE SERVICING INSPECTING THE RADIATOR Inspect the radiator visually for coolant leakage, crack and dam- age. If found defective, replace the radiator. If the coolant decreases frequently and requires refilling, inspect the radiator, hose and pipe for coolant leakage. ON-VEHICLE CLEANING CHECK FIN FOR BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner,...
Page 540: Replacement
COOLING (J05E) 12–5 REPLACEMENT EN01F02127110402019003 REMOVING THE RADIATOR DRAINING THE COOLANT Drain coolant from the drain cock of the radiator and the drain RIGHT SIDE OF ENGINE plug of the oil cooler. ! WARNING To avoid burns, do not remove the radiator cap when the engine and the radiator are hot.
Page 541 12–6 COOLING (J05E) DISCONNECTING THE RADIATOR HOSE ! CAUTION • Check for the locating markings at the both ends of the radia- tor hose before removing the hose. If the marking is erased, mark the hose before disconnecting it. • Mark the clamp position on the hose before removing.
Page 542 COOLING (J05E) 12–7 REMOVING THE HEATER PIPE AND RADIATOR BRACKET Unfasten the bolt to remove the heater pipe and reserve pipe. SHTS021271100008 Unfasten the 4 bolts and nuts to remove the radiator bracket No.3 from the radiator. SHTS021271100009 Unfasten the 4 bolts and nuts to remove the radiator bracket No.4 from the radiator.
Page 543 12–8 COOLING (J05E) REMOVING THE RADIATOR Pull out the radiator toward the upper side from the vehicle. ! CAUTION Be careful not to damage the fin of the radiator core during work. REMOVING THE RADIATOR SUPPORT SEAL No.1 Unfasten the 6 bolts to remove the radiator support seal No.1 from the radiator.
Page 544 COOLING (J05E) 12–9 MOUNTING THE RADIATOR MOUNTING THE RADIATOR SUPPORT SEAL No.1 Mount the radiator support seal No.1 to the radiator with 6 bolts. RADIATOR SUPPORT SEAL No.1 SHTS021271100012 MOUNTING THE RADIATOR Insert the radiator from the vehicle upper side and set it to mount- ing position.
Page 545 12–10 COOLING (J05E) Mount the heater pipe with the bolts. Tightening Torque: 21.7-40.3 N·m {222-410 kgf·cm, 17-29 lbf·ft} Mount the reserve pipe with the bolt. Tightening Torque: 19.5 N·m {199 kgf·cm, 14 lbf·ft} SHTS021271100015 MOUNTING THE COOLING FAN AND FAN PULLEY Reference: COOLING (J05E), COOLING FAN AND FAN CLUTCH, OVERHAUL, MOUNTING THE COOLING FAN &...
Page 546 COOLING (J05E) 12–11 CONNECTING THE RADIATOR HOSE Align the markings, and connect the radiator outlet hose to the radiator lower tank with the clamp. ! CAUTION • If crack or peeling is found with the inner surface of the radi- ator outlet hose inserting area, replace it.
Page 547 12–12 COOLING (J05E) Align the markings and connect the radiator inlet hose and radia- tor hose to the radiator with 2 clamps. RADIATOR HOSE RADIATOR Replace with a new tie wrap and then mount it to the radiator inlet INLET HOSE hose.
Page 548 COOLING (J05E) 12–13 ADDING THE COOLANT Tighten the drain cock of the radiator and the drain plug of the oil RIGHT SIDE OF ENGINE cooler. Remove the radiator cap. ! CAUTION Improper or careless removal of the radiator cap may cause burns from spewing hot water or vapor.
Page 549 12–14 COOLING (J05E) INSPECTION FOR COOLANT LEAKAGE ! DANGER To avoid burns, do not remove the radiator cap when the engine and the radiator are hot. Pressure causes the liquid and vapor to burst forth. Remove the radiator cap, and mount the radiator cap tester. Perform pumping up to 137 kPa {1.4 kgf/cm , 20 lbf/in.
Page 550: Radiator Cap
COOLING (J05E) 12–15 RADIATOR CAP COMPONENT LOCATOR EN01F02127110402020001 SHTS021271100023 Radiator cap...
Page 551: Replacement
12–16 COOLING (J05E) REPLACEMENT EN01F02127110402020002 REMOVING THE RADIATOR CAP REMOVING THE RADIATOR CAP Stop the engine and check that the coolant temperature meter RADIATOR CAP reads below the gauge center. Then, rotate the radiator cap to left and remove it. If the coolant is hot, work with a few thick clothes overlapped.
Page 552 COOLING (J05E) 12–17 Pump the tester and measure opening pressure of the relief valve. ! CAUTION This pumping speed applies only to initial pumping. (For the pur- pose of closing the vacuum valve.) Subsequent pumping may be performed at a lower speed. Standard value Limit 93.1-122.9 kPa...
Page 553: Reserve Tank
12–18 COOLING (J05E) RESERVE TANK COMPONENT LOCATOR EN01F02127110402021001 SHTS021271100027 Reserve tank Hose Tightening torque Unit: Nm {kgfcm, lbfft} 3.5-6.5 {36-66, 2.6-4.7}...
Page 554: Replacement
COOLING (J05E) 12–19 REPLACEMENT EN01F02127110402021002 REMOVING THE RESERVE TANK DRAINING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) REMOVING THE RESERVE TANK Disconnect the hose from the reserve tank. NOTICE Prepare a reservoir and clean clothes to collect coolant dripping from the reserve tank when disconnecting the hose.
Page 555: Intercooler
12–20 COOLING (J05E) INTERCOOLER COMPONENT LOCATOR EN01F02127110402039001 SHTS021271100030 Clamp Intercooler Intercooler hose Tightening torque Unit: Nm {kgfcm, lbfft} 14-20 {143-203, 11-14} 6.25 {64, 4.6}...
Page 556: Overhaul
COOLING (J05E) 12–21 OVERHAUL EN01F02127110402039002 REMOVING THE INTERCOOLER DISCONNECTING THE INTERCOOLER HOSE Unfasten the clamp to disconnect the Intercooler hose from the Intercooler. REMOVING THE INTERCOOLER INTERCOOLER Unfasten the 4 bolts to remove the intercooler from the radiator. ! CAUTION Use care not to damage the fins of the radiator core and inter- cooler core.
Page 557 12–22 COOLING (J05E) MOUNTING THE INTERCOOLER MOUNTING THE INTERCOOLER Mount the intercooler to the radiator with bolts (4 pcs.). Tightening Torque: 14-20 N·m {143-203 kgf·cm, 11-14 lbf·ft} INTERCOOLER ! CAUTION Use care not to damage the fins of the radiator core and inter- cooler core.
Page 558: Thermostat Case And Thermostat
COOLING (J05E) 12–23 THERMOSTAT CASE AND THERMOSTAT COMPONENT LOCATOR EN01F02127110402011001 SHTS021271100034 Coolant pipe F Gasket * Gasket * Thermostat Coolant pipe A Water outlet pipe Heater pipe O-ring * Thermostat case *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 285 {291, 21} 24.5 {250, 18}...
Page 559: Overhaul
12–24 COOLING (J05E) OVERHAUL EN01F02127110402011002 REMOVING THERMOSTAT CASE & THERMOSTAT DRAINING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) REMOVING THE COOLING FAN & FAN CLUTCH Reference: COOLING (J05E), COOLING FAN AND FAN CLUTCH, OVERHAUL, REMOVING THE COOLING FAN & FAN CLUTCH (Page 12-34) REMOVING THE EGR COOLER Reference: EMISSION CONTROL (J05E), EGR VALVE &...
Page 560 COOLING (J05E) 12–25 Unfasten the 3 bolts to remove the coolant pipe A, thermostat and gasket from the thermostat case. THERMOSTAT GASKET COOLANT PIPE A THERMOSTAT CASE SHTS021271100037 REMOVING THE THERMOSTAT CASE Unfasten the 2 bolts to remove the water outlet pipe and O-ring from the thermostat case.
Page 561 12–26 COOLING (J05E) INSPECTING THE COMPONENTS INSPECTING THE THERMOSTAT Submerge the thermostat in water for heating as shown in the fig- ure. ! CAUTION • To keep the thermostat away from the heat sources, support it at the center with wire. •...
Page 562 COOLING (J05E) 12–27 MOUNTING THERMOSTAT CASE AND THERMO- STAT MOUNTING THE THERMOSTAT CASE Use the scraper, remove dirt on the joint surface between the THERMOSTAT CASE thermostat case and cylinder head. Apply liquid gasket (ThreeBond TB1207B: Black or equivalent) to the thermostat case as shown in the figure.
Page 563 12–28 COOLING (J05E) MOUNTING THE THERMOSTAT Replace with the new gasket and mount the thermostat and cool- THERMOSTAT ant pipe A to the thermostat case with 3 bolts. Tightening Torque: GASKET 28.5 N·m {291 kgf·cm, 21 lbf·ft} COOLANT PIPE A THERMOSTAT CASE SHTS021271100047...
Page 564 COOLING (J05E) 12–29 Replace with the new 2 gaskets and connect the coolant pipe F to the thermostat case with a union bolt. COOLANT PIPE F Tightening Torque: 24.5 N·m {250 kgf·cm, 18 lbf·ft} THERMOSTAT GASKET CASE SHTS021271100051 MOUNTING THE COOLANT TEMPERATURE SENSOR Reference: COOLING (J05E), COOLANT TEMPERATURE SENSOR, REPLACEMENT, MOUNTING THE COOLANT TEM- PERATURE SENSOR (Page 12-39)
Page 565: Coolant Pump
12–30 COOLING (J05E) COOLANT PUMP COMPONENT LOCATOR EN01F02127110402008001 SHTS021271100052 Coolant pipe B Coolant pump Gasket * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21}...
Page 566: Replacement
COOLING (J05E) 12–31 REPLACEMENT EN01F02127110402008002 REMOVING THE COOLANT PUMP DRAINING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) REMOVING THERMOSTAT CASE & THERMOSTAT Reference: COOLING (J05E), THERMOSTAT CASE AND THERMOSTAT, OVERHAUL, REMOVING THERMOSTAT CASE & THERMOSTAT (Page 12-24) REMOVING THE CRANKSHAFT PULLEY Reference: ENGINE MECHANICAL (J05E), CRANKSHAFT PULLEY, REPLACEMENT, REMOVING THE CRANKSHAFT...
Page 567 12–32 COOLING (J05E) MOUNTING THE COOLANT PUMP MOUNTING THE COOLANT PUMP Use the scraper, remove dirt on the joint surface between the COOLANT PUMP coolant pump and cylinder block. Apply liquid gasket (ThreeBond TB1207B: Black or equivalent) to the coolant pump as shown in the figure. ! CAUTION •...
Page 568: Cooling Fan And Fan Clutch
COOLING (J05E) 12–33 COOLING FAN AND FAN CLUTCH COMPONENT LOCATOR EN01F02127110402031001 SHTS021271100058 Cooling fan Tightening torque Unit: Nm {kgfcm, lbfft} 11 {112, 8}...
Page 569: Overhaul
12–34 COOLING (J05E) OVERHAUL EN01F02127110402031002 REMOVING THE COOLING FAN & FAN CLUTCH DISCONNECTING THE RADIATOR INLET HOSE AND RADIA- TOR HOSE Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) REMOVING THE COOLING FAN ! CAUTION Place a corrugated board on the radiator core not to damage it. Remove the intercooler hose.
Page 570 COOLING (J05E) 12–35 REMOVING THE FAN CLUTCH Unfasten the 4 nuts to remove the fan clutch from the cooling fan. COOLING FAN FAN CLUTCH SHTS021271100061 INSPECTING THE COMPONENTS INSPECTING THE FAN CLUTCH BEARING Inspect the fan clutch for axial backlash. If found defective, replace the fan clutch.
Page 571 12–36 COOLING (J05E) MOUNTING THE COOLING FAN & FAN CLUTCH MOUNTING THE FAN CLUTCH Mount the fan clutch to the cooling fan with 4 nuts. COOLING FAN Tightening Torque: 11 N·m {112 kgf·cm, 8 lbf·ft} FAN CLUTCH SHTS021271100065 MOUNTING THE COOLING FAN Put from the top fan clutch, fan shroud and cooling fan.
Page 572: Coolant Temperature Sensor
COOLING (J05E) 12–37 COOLANT TEMPERATURE SENSOR COMPONENT LOCATOR EN01F02127110402012001 SHTS021271100068 Coolant temperature sensor Gasket * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 27.0-31.9 {276-325, 20-23}...
Page 573: Replacement
12–38 COOLING (J05E) REPLACEMENT EN01F02127110402012002 REMOVING THE COOLANT TEMPERATURE SEN- REMOVING THE COOLANT TEMPERATURE SENSOR Disconnect the connector from the coolant temperature sensor. THERMOSTAT CASE CONNECTOR SHTS021271100069 Remove the coolant temperature sensor and gasket from the thermostat case. THERMOSTAT NOTICE Prepare a reservoir and clean clothes to collect dripping coolant when removing the coolant temperature sensor.
Page 574 COOLING (J05E) 12–39 MOUNTING THE COOLANT TEMPERATURE SEN- MOUNTING THE COOLANT TEMPERATURE SENSOR Replace with the new gasket and mount the coolant temperature THERMOSTAT sensor to the thermostat case. Tightening Torque: 27.0-31.9 N·m {276-325 kgf·cm, 20-23 lbf·ft} COOLANT TEMPERATURE SENSOR GASKET SHTS021271100072 Connect the connector to the coolant temperature sensor.
Page 575 LUBRICATION (J05E) 13–1 LUBRICATION (J05E) 13-001 LUBRICATION SYSTEM..........13-2 LUBRICATION SYSTEM DIAGRAM .....13-2 OIL FILTER..............13-3 COMPONENT LOCATOR ........13-3 REPLACEMENT ...........13-4 OIL COOLER .............13-6 COMPONENT LOCATOR ........13-6 OVERHAUL............13-7 OIL PUMP ..............13-14 COMPONENT LOCATOR ........13-14 OVERHAUL............13-15 OIL PAN..............13-23 COMPONENT LOCATOR ........13-23 REPLACEMENT ..........
Page 576: Lubrication System
13–2 LUBRICATION (J05E) COMPOSITION DIAGRAM LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EN01F02114120402011001 ROLLER ROLLER CROSS ADJUST ROCKER ROCKER VALVE HEAD SCREW ARM SHAFT SHAFT CAM IDLE GEAR SHAFT SUB IDLE GEAR SHAFT TURBO CHARGER MAIN OIL PUMP COOLER FILTER HOLE PISTON CONNECTING CRANK SHAFT...
Page 577: Oil Filter
LUBRICATION (J05E) 13–3 OIL FILTER COMPONENT LOCATOR EN01F02114120402006001 SHTS021271200002 Oil filter * Oil cooler assembly *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 39.2-49.0 {400-499, 29-36}...
Page 578: Replacement
13–4 LUBRICATION (J05E) REPLACEMENT EN01F02114120402006002 REMOVING THE OIL FILTER DISCHARGING ENGINE OIL Remove the drain plug of the oil pan to drain engine oil. Reference: MOUNTING AND DISMOUNTING THE ENGINE (J05E), ENGINE ASSEMBLY, REPLACEMENT, REMOVING THE ENGINE ASSEMBLY (Page 5-7) REMOVING THE OIL FILTER Remove the drain plug at the oil filter lower end to drain engine OIL COOLER...
Page 579 LUBRICATION (J05E) 13–5 MOUNTING THE OIL FILTER MOUNTING THE OIL FILTER Remove dirt on the oil filter cap mounting surface. Apply engine oil lightly to the 2 O-rings of a new oil filter element. Use the SST, mount the oil filter to the oil cooler assembly. OIL COOLER ASSEMBLY Tightening Torque: 39.2-49.0 N·m {400-499 kgf·cm, 29-36 lbf·ft}...
Page 580: Oil Cooler
13–6 LUBRICATION (J05E) OIL COOLER COMPONENT LOCATOR EN01F02114120402002001 SHTS021271200007 Oil cooler Gasket O-ring * Oil cooler element *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 19.6-29.4 {200-299, 15-21}...
Page 581: Overhaul
LUBRICATION (J05E) 13–7 OVERHAUL EN01F02114120402002002 REMOVING THE OIL COOLER ASSEMBLY DRAINING THE COOLANT Drain the coolant. Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) DISCHARGING ENGINE OIL Remove the drain plug of the oil pan to drain engine oil. Reference: MOUNTING AND DISMOUNTING THE ENGINE (J05E), ENGINE ASSEMBLY, REPLACEMENT, REMOVING THE ENGINE ASSEMBLY (Page 5-7)
Page 582 13–8 LUBRICATION (J05E) REMOVING THE OIL COOLER ASSEMBLY Unfasten the 2-4 bolts and mount 2-4 guide bolts to the oil cooler assembly to prevent dropping. GUIDE BOLTS BOLT OIL COOLER SHTS021271200010 Unfasten the remaining 9-11 bolts to remove the oil cooler assem- bly straight from the cylinder block.
Page 583 LUBRICATION (J05E) 13–9 DISASSEMBLING THE OIL COOLER ASSEMBLY REMOVING THE OIL COOLER ELEMENT Unfasten the nuts (4 pcs.) to remove the oil cooler element, gas- OIL COOLER kets (2 pcs.), and O-rings (2 pcs.) from the oil cooler case. ELEMENT O-RING GASKET OIL COOLER...
Page 584 13–10 LUBRICATION (J05E) INSPECTING THE COMPONENTS INSPECTING THE OIL COOLER ELEMENT Visually check the oil cooler element for crack or damage. If any, replace it. OIL COOLER ELEMENT SHTS021271200017 INSPECTING THE SAFETY VALVE Inspect the safety valve sliding surface for wear and damage. If found defective, replace it.
Page 585 LUBRICATION (J05E) 13–11 ASSEMBLING THE OIL COOLER ASSEMBLY MOUNTING THE OIL PRESSURE SWITCH Apply liquid gasket (ThreeBond TB1211: White or equivalent) to the sealing surface of a new gasket. OIL COOLER CASE Mount the gasket and oil pressure switch to the oil cooler case. Tightening Torque: 29 N·m {296 kgf·cm, 21 lbf·ft} OIL PRESSURE...
Page 586 13–12 LUBRICATION (J05E) MOUNTING THE OIL COOLER ASSEMBLY MOUNTING THE OIL COOLER ASSEMBLY Using the scraper, remove dirt (including liquid gasket) and oil on OIL COOLER ASSEMBLY LIQUID GASKET the joint surface between the oil cooler assembly and cylinder block. Apply the liquid gasket (ThreeBond TB1207B: Black or equiva- lent) to the oil cooler assembly.
Page 587 LUBRICATION (J05E) 13–13 Mount the oil cooler assembly to the cylinder block with 13 bolts. Tightening Torque: 28.5 N·m {291 kgf·cm, 21 lbf·ft} ! CAUTION Unfasten the 2 - 4 guide bolts after temporarily tightening 9 - 11 oil cooler assembly mounting bolts. NOTICE Tighten together with the alternator earth cable at one place.
Page 588: Oil Pump
13–14 LUBRICATION (J05E) OIL PUMP COMPONENT LOCATOR EN01F02114120402008001 SHTS021271200029 Oil pump Seat 1 Gasket * Seat 2 Drive gear Valve spring Driven gear Safety valve Cotter pin * *: Nonreusable part...
Page 589: Overhaul
LUBRICATION (J05E) 13–15 OVERHAUL EN01F02114120402008002 REMOVING THE OIL PUMP REMOVING THE FLYWHEEL HOUSING Remove the flywheel housing. Reference: ENGINE MECHANICAL (J05E), FLYWHEEL ASSEMBLY, OVERHAUL, REMOVING FLYWHEEL ASSEMBLY (Page 10-57) REMOVING THE TIMING GEAR Remove the main idle gear and sub idle gear. Reference: ENGINE MECHANICAL (J05E), TIMING GEAR &...
Page 590 13–16 LUBRICATION (J05E) REMOVING THE SAFETY VALVE Remove the cotter pin to remove the seat 1, seat 2, valve spring, and safety valve. SAFETY VALVE ! CAUTION Note that the seat 1, seat 2, and valve spring jump out when the VALVE cotter pin is removed.
Page 591 LUBRICATION (J05E) 13–17 INSPECTING THE CLEARANCE BETWEEN THE DRIVE GEAR SHAFT OUTER DIAMETER AND BUSHING INNER DIAMETER ON THE CYLINDER BLOCK SIDE Using the micrometer, measure the drive gear shaft outer diame- ter. Standard value (mm {in.}) 18.0 {0.709} OIL PUMP DRIVE GEAR SHAFT SHTS021271200035 Using the cylinder gauge, measure the bushing inner diameter on...
Page 592 13–18 LUBRICATION (J05E) INSPECTING THE CLEARANCE BETWEEN THE DRIVEN GEAR SHAFT OUTER DIAMETER AND DRIVEN GEAR BUSH- ING INNER DIAMETER Using the micrometer, measure the driven gear shaft outer diam- eter. Standard value (mm {in.}) 18.0 {0.709} DRIVEN GEAR OIL PUMP SHAFT SHTS021271200039 Using the cylinder gauge, measure the driven gear bushing inner...
Page 593 LUBRICATION (J05E) 13–19 INSPECTING THE BACKLASH OF THE DRIVE GEAR Using the vise, secure the oil pump. DIAL GAUGE DRIVEN GEAR Using the dial gauge, measure the backlash between the drive gear and driven gear. If exceeding the permissible limit, replace the oil pump.
Page 594 13–20 LUBRICATION (J05E) ASSEMBLING THE OIL PUMP MOUNTING THE SAFETY VALVE Insert the safety valve, valve spring, seat 2, and then seat 1 to the oil pump, and fix them with a new cotter pin. SAFETY VALVE VALVE SPRING SEAT 2 SEAT 1 COTTER PIN COTTER PIN...
Page 595 LUBRICATION (J05E) 13–21 Mount the guide bolts (2 pcs.) to the cylinder block. GUIDE BOLTS SHTS021271200047 Replace with the new gasket and align the oil pump with the cylin- der block mounting position. Mount the oil pump to the cylinder block with bolts (9 pcs.) in the GASKET order shown in the figure.
Page 596 13–22 LUBRICATION (J05E) MOUNTING THE TIMING GEAR Mount the main idle gear and sub idle gear. Reference: ENGINE MECHANICAL (J05E), TIMING GEAR & CAM IDLE GEAR, OVERHAUL, MOUNTING THE TIMING GEARS IN THE FLYWHEEL HOUSING AND THE REAR END PLATE (Page 10-74) INSPECTING THE BACKLASH Using the dial gauge, measure the backlash between the oil pump drive gear and sub idle gear.
Page 597: Oil Pan
LUBRICATION (J05E) 13–23 OIL PAN COMPONENT LOCATOR EN01F02114120402005001 SHTS021271200050 Cylinder block Gasket * Oil pan *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 30 {306, 22}...
Page 598: Replacement
13–24 LUBRICATION (J05E) REPLACEMENT EN01F02114120402005002 REMOVING THE OIL PAN DISCHARGING ENGINE OIL Remove the drain plug of the oil pan to drain engine oil. Reference: MOUNTING AND DISMOUNTING THE ENGINE (J05E), ENGINE ASSEMBLY, REPLACEMENT, REMOVING THE ENGINE ASSEMBLY (Page 5-7) REMOVING THE OIL PAN Unfasten the 26 bolts to remove the oil pan and gasket from the CYLINDER...
Page 599 LUBRICATION (J05E) 13–25 MOUNTING THE OIL PAN MOUNTING THE OIL PAN Using the scraper, cut the rear end plate gasket to make it flush CYLINDER GASKET with the cylinder block lower surface. BLOCK REAR END PLATE NOTICE FLYWHEEL Not necessary when attaching and detaching the single oil pan. HOUSING SCRAPER PROCESSING...
Page 600 13–26 LUBRICATION (J05E) Align the new gasket and oil pan with the cylinder block lower sur- face and tighten 26 bolts in the order of the arrows shown in the figure. Tightening Torque: 19.6-24.5 N·m {200-249 kgf·cm, 15-18 lbf·ft} Remove the guide bolt and tighten 26 bolts again. Tightening Torque: 30 N·m {306 kgf·cm, 22 lbf·ft} ! CAUTION...
Page 601 LUBRICATION (J05E) 13–27 INSPECTING THE LUBRICATION AFTER A LUBRI- CATION OVERHAUL INSPECTING THE VALVE SYSTEM ! CAUTION • Make sure to perform an inspection after a lubrication over- haul. • Perform the inspection at the coolant temperature about 60°C {140°F}. Remove the head cover.
Page 602: Oil Strainer
13–28 LUBRICATION (J05E) OIL STRAINER COMPONENT LOCATOR EN01F02114120402003001 SHTS021271200057 Oil strainer O-ring * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 30 {306, 22}...
Page 603: Replacement
LUBRICATION (J05E) 13–29 REPLACEMENT EN01F02114120402003002 REMOVING THE OIL STRAINER REMOVING THE OIL PAN Remove the oil pan from the cylinder block. Reference: LUBRICATION (J05E), OIL PAN, REPLACEMENT, REMOVING THE OIL PAN (Page 13-24) REMOVING THE OIL STRAINER Unfasten the 2 bolts to remove the oil strainer and O-ring from the cylinder block.
Page 604: Oil Pressure Switch
13–30 LUBRICATION (J05E) OIL PRESSURE SWITCH COMPONENT LOCATOR EN01F02114120402016001 SHTS021271200060 Oil pressure switch Gasket * *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 24.5 {250, 18}...
Page 605: Replacement
LUBRICATION (J05E) 13–31 REPLACEMENT EN01F02114120402016002 REMOVING THE OIL PRESSURE SWITCH REMOVING THE OIL PRESSURE SWITCH Disconnect the connector from the oil pressure switch. OIL COOLER CASE OIL PRESSURE HARNESS SWITCH SHTS021271200061 Remove the oil pressure switch and gasket from the oil cooler case.
Page 606 13–32 LUBRICATION (J05E) MOUNTING THE OIL PRESSURE SWITCH MOUNTING THE OIL PRESSURE SWITCH Apply liquid gasket (ThreeBond TB1211: White or equivalent) to the sealing surface of a new gasket. OIL COOLER CASE Mount the gasket and oil pressure switch to the oil cooler case. Tightening Torque: 24.5 N·m {250 kgf·cm, 18 lbf·ft} OIL PRESSURE...
Page 607: Oil Level Gauge And Guide
LUBRICATION (J05E) 13–33 OIL LEVEL GAUGE AND GUIDE COMPONENT LOCATOR EN01F02114120402017001 SHTS021271200066 Oil level gauge and guide O-ring * Oil level gauge Cylinder block *: Nonreusable part...
Page 608: Replacement
13–34 LUBRICATION (J05E) REPLACEMENT EN01F02114120402017002 REMOVING THE OIL LEVEL GAUGE AND GUIDE REMOVING THE OIL LEVEL GAUGE Pull out the oil level gauge from the oil level gauge guide. OIL LEVEL GAUGE NOTICE Prepare the clean clothes to receive dripping engine oil when pull- ing out the oil level gauge.
Page 609 LUBRICATION (J05E) 13–35 MOUNTING THE OIL LEVEL GAUGE AND GUIDE MOUNTING THE OIL LEVEL GAUGE GUIDE Replace with the new O-ring and mount the oil level gauge guide to the cylinder block. Mount the clip with the nut and secure the oil level gauge guide. OIL LEVEL GAUGE GUIDE O-RING...
Page 610 STARTING/CHARGING (J05E) 16–1 STARTING/CHARGING (J05E) 16-001 STARTER ..............16-2 COMPONENT LOCATOR ........16-2 REPLACEMENT ...........16-3 V-BELT ...............16-8 COMPONENT LOCATOR ........16-8 REPLACEMENT ...........16-9 ALTERNATOR (130A) ..........16-12 COMPONENT LOCATOR ........16-12 OVERHAUL............16-13...
Page 611: Starter
16–2 STARTING/CHARGING (J05E) MECHANICAL SYSTEM DRAWING STARTER COMPONENT LOCATOR EN01F02127150407006001 SHTS021271500001 Starter assembly Tightening torque Unit: Nm {kgfcm, lbfft} 21 {214, 15.4} 4.5 {46, 3.3} 154 {1,570, 113.5} 154 {1,570, 113.5}...
Page 612: Replacement
STARTING/CHARGING (J05E) 16–3 REPLACEMENT EN01F02127150407006002 REMOVING THE STARTER REMOVING OF BATTERY CABLE Disconnect the battery earth cable from the negative battery ter- minal. DISCONNECTING THE HARNESS Disconnect the 2 wire harness clamps. Remove the bolt and the wire harness clamp bracket. Pull off the terminal cap and remove the nut, and disconnect the starter wire from terminal B.
Page 613 16–4 STARTING/CHARGING (J05E) MOUNTING THE STARTER MOUNTING THE STARTER Install the starter assembly with the bolt and nut. STARTER Tightening Torque: 154 N·m {1,570 kgf·cm, 113.5 lbf·ft} CONNECTING THE HARNESS Connect the C terminal with the nut. Tightening Torque: 4.5 N·m {46 kgf·cm, 3.3 lbf·ft} Install the starter wire to terminal B with the nut, and install the ter- minal cap.
Page 614 STARTING/CHARGING (J05E) 16–5 STARTER UNIT INSPECTION Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Measure OHMMETER Continuity between CONTINUITY 1  or less 1  the segments of the Replace. commutator Measure OHMMETER No continuity between the connec- 10 k...
Page 615 16–6 STARTING/CHARGING (J05E) Inspection item Standard Limit Remedy Inspection procedure Measure OHMMETER Continuity between CONTINUITY 1  or less 1  the field coil end and Replace. the read wire. Measure OHMMETER No continuity between the field coil CONTINUITY 10 k or more 10 k...
Page 616 STARTING/CHARGING (J05E) 16–7 Inspection item Standard Limit Remedy Inspection procedure Visual check Rotating of needle Sticks or does — Replace. roller front bearing not rotate Visual check Rotating of needle Sticks or does — Replace. roller rear bearing not rotate Measure CONTINUITY OHMMETER...
Page 617: V-Belt
16–8 STARTING/CHARGING (J05E) V-BELT COMPONENT LOCATOR EN01F02127150407001001 SHTS021271500021 Alternator V-belt Tightening torque Unit: Nm {kgfcm, lbfft} 6 {60, 4.4} 55 {560, 40.5}...
Page 618: Replacement
STARTING/CHARGING (J05E) 16–9 REPLACEMENT EN01F02127150407001002 REMOVING THE V-BELT REMOVING THE V-BELT (FRONT SIDE) Loosen the nuts, bolts and through bolt of the alternator. Loosen the adjusting bolt to remove the V-belt (front side). REMOVING THE V-BELT (REAR SIDE) Reference: CHASSIS (S1-LXJE03A), HEATER AND AIR CON- DITIONER Reference: CHASSIS (S1-LXJE04A), HEATER AND AIR CON- DITIONER...
Page 619 16–10 STARTING/CHARGING (J05E) In the case that correct maintenance has been performed In case adjusting tension is high High adjusting tension Tension when mounting Tension when mounting a new part a new part Tension when adjusting Tension when adjusting Damage Stable tension Relationship between driving time and tension...
Page 620 STARTING/CHARGING (J05E) 16–11 Condition of the V-belt Remaining life (for reference) Same distance as the travel distance from the time of a new vehicle or replacement to inspection, or more Half of the travel distance from the time of a new vehicle or replacement to inspection One fourth of the travel distance from the time of a new vehicle or replacement to inspection...
Page 621: Alternator (130A)
16–12 STARTING/CHARGING (J05E) ALTERNATOR (130A) COMPONENT LOCATOR EN01F02127150407028001 SHTS021271500029 Cover Stator Terminal B sub assembly Rotor Insulator (inner) Cover bearing Regulator Bearing Rectifier Drive frame Through bolt Collar Insulator (outer) Rear frame Pulley Field coil Tightening torque Unit: Nm {kgfcm, lbfft} 15.7-20.6 {160-210, 12-15} 6.5-9.3 {66-95, 4.8-6.9} 7.8-10.8 {80-110, 5.8-7.9}...
Page 622: Overhaul
STARTING/CHARGING (J05E) 16–13 OVERHAUL EN01F02127150407028002 IMPORTANT POINTS - MOUNTING MOUNTING THE V-BELT Reference: STARTING/CHARGING (J05E), V-BELT, REPLACEMENT, MOUNTING THE V-BELT (Page 16-9) IMPORTANT POINTS - DISASSEMBLY REMOVING THE REAR COVER Remove the 3 screws to remove the rear cover. SCREW SHTS021271500030 SEPARATE THE FRONT AND REAR PORTIONS Remove the 4 screws and separate the stator outlet terminal and...
Page 623 16–14 STARTING/CHARGING (J05E) While keeping the stator and the rear frame together, lift them away from the drive frame. STATOR REAR FRAME DRIVE FRAME SHTS021271500033 Drive and rear frames separated. REAR FRAME DRIVE FRAME SHTS021271500034 REMOVING THE PULLEY Remove the pulley lock nut using an impact wrench. IMPACT WRENCH PULLEY SHTS021271500035...
Page 624 STARTING/CHARGING (J05E) 16–15 REMOVING THE FAN COLLAR SHTS021271500037 REMOVING THE COLLAR REMOVING THE ROTOR Using the JIG A and press, remove the rotor from the drive frame. PRESS ROTOR SHAFT NOTICE DRIVE FRAME Do not drop the rotor. JIG A SHTS021271500038 REMOVING THE FRONT BEARING Remove the 3 screws to remove the bearing cover.
Page 625 16–16 STARTING/CHARGING (J05E) SEPARATING THE REAR FRAME AND STATOR Pull out the rear frame to separate it from the stator. REAR FRAME STATOR SHTS021271500041 REMOVING THE REGULATOR Remove the 3 screws to separate the rectifier, the exciting coil outlet terminal, and the regulator. SCREW Remove the 2 screws to remove the regulator.
Page 626 STARTING/CHARGING (J05E) 16–17 Remove the screw from the rectifier's (-) terminal. Remove the 4 screws to remove the rectifier. SCREW SHTS021271500045 Rectifier removed. RECTIFIER SHTS021271500046 11. REMOVING THE I TERMINAL Loosen the I terminal nut to remove the I terminal. I TERMINAL REAR FRAME SHTS021271500047...
Page 627 16–18 STARTING/CHARGING (J05E) 12. REMOVING THE FIELD COIL Remove the 3 screws to remove the field coil from the rear frame. REAR FRAME SHTS021271500049 Field coil removed. FIELD COIL SHTS021271500050 13. REMOVING THE REAR BEARING Using the JIG E and press, remove the rear bearing from the rear JIG E (FOR PRESS) PRESS frame.
Page 628 STARTING/CHARGING (J05E) 16–19 IMPORTANT POINTS - ASSEMBLY INSTALL THE FRONT BEARING Using the JIG D and press, press the front bearing into the drive FRONT BEARING frame. JIG D Using the 3 screws, install the bearing cover. DRIVE Tightening Torque: FRAME 2.9-4.9 N·m {30-50 kgf·cm, 2.1-3.6 lbf·ft} SHTS021271500052...
Page 629 16–20 STARTING/CHARGING (J05E) ASSEMBLING THE RECTIFIER Using the 4 screws, install the rectifier. Tightening Torque: 2.9-4.9 N·m {30-50 kgf·cm, 2.1-3.6 lbf·ft} Using the screw, install the rectifier's (-) terminal. Tightening Torque: 2.9-4.9 N·m {30-50 kgf·cm, 2.1-3.6 lbf·ft} Tighten the B terminal nut (inside). Tightening Torque: 7.8-10.8 N·m {80-110 kgf·cm, 5.8-7.9 lbf·ft} ASSEMBLING THE REGULATOR...
Page 630 STARTING/CHARGING (J05E) 16–21 Install the 4 through bolts. Tightening Torque: THROUGH BOLT 6.5-9.3 N·m {66-95 kgf·cm, 4.8-6.9 lbf·ft} SHTS021271500058 Using the 4 screws, install the stator outlet terminal to the rectifier. Tightening Torque: 1.9-2.5 N·m {19-25 kgf·cm, 1.4-1.8 lbf·ft} SCREW Using the 3 screws, install the rear cover.
Page 631 16–22 STARTING/CHARGING (J05E) MAGNETIZING Apply the battery (12V) to the L terminal (positive) and F terminal (negative) of the regulator as shown in the figure. SHTS021271500060 MEASURING THE SELF-EXCITED STARTING RPM Turn Switch 1 ON. Gradually increase the alternator rpm. Measure the rpm (starting rpm) at which the charging current starts to flow.
Page 632 STARTING/CHARGING (J05E) 16–23 PRECAUTIONS PRECAUTIONS DURING OPERATION • Do not disconnect the battery while the alternator is rotating. • Do not operate the alternator with the alternator's B terminal (out- put terminal) disconnected. • Do not expose the alternator to water. OTHER PRECAUTIONS •...
Page 633 16–24 STARTING/CHARGING (J05E) INSPECTION AND REPAIR Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Measure — Resistance of field coil 2-3 Replace. Measure Insulation resistance of — 1M min. Replace. field coil Measure Resistance of stator — 0.01-0.10 Replace.
Page 634 STARTING/CHARGING (J05E) 16–25 Inspection item Standard Limit Remedy Inspection procedure Measure When polarity is changed, there is Resistance of rectifier continuity in one — (between diode termi- Replace. direction but not in nal and heat sink) the opposite direction. Measure Rotor shaft outside 25.00-25.01 diameter (front bearing...
Page 635 TURBOCHARGER (J05E) 17–1 TURBOCHARGER (J05E) 17-001 TURBOCHARGER ASSEMBLY ........17-2 COMPONENT LOCATOR ........17-2 INSPECTION ............17-3 REPLACEMENT ...........17-5...
Page 636: Turbocharger Assembly
17–2 TURBOCHARGER (J05E) MAINTENANCE POINTS ITEM TURBOCHARGER ASSEMBLY COMPONENT LOCATOR EN01F02114160704005001 SHTS021271600001 Turbocharger assembly Gasket * Turbocharger insulator Oil pipe B Oil pipe A *: Nonreusable part Tightening torque Unit: Nm {kgfcm, lbfft} 70 {714, 52}...
Page 637: Inspection
Using the HINO-DX, inspect the operation of the turbocharger assembly. (Refer to the HINO-DX user's manual.) INSPECTING THE ELECTRIC ACTUATOR Using the HINO-DX, operate the electric actuator and check for operation follow-up. (Refer to the HINO-DX user's manual.) ! CAUTION •...
Page 638 17–4 TURBOCHARGER (J05E) INSPECTING THE TURBINE SHAFT SIMPLIFIED INSPECTION Holding the blower impeller tip, inspect for rotating condition by TURN THE TIP OF THE lightly rotating the turbine shaft by hand. BLOWER IMPELLER If the turbine shaft does not rotate or does not rotate smoothly, or the blower impeller contacts with the blower case, replace the tur- bocharger assembly.
Page 639: Replacement
TURBOCHARGER (J05E) 17–5 REPLACEMENT EN01F02114160704005003 REMOVING THE TURBOCHARGER ASSEMBLY CAUTIONS ! CAUTION • Use care not to touch the link plate and adjusting screw dur- ing work. • Do not remove the link plate of the turbocharger assembly. • The adjusting screw for opening/closing operation of the tur- bocharger assembly has been adjusted.
Page 640 17–6 TURBOCHARGER (J05E) DRAINING THE COOLANT Reference: COOLING (J05E), RADIATOR, REPLACEMENT, REMOVING THE RADIATOR (Page 12-5) REMOVING THE INTAKE HOSE Reference: INTAKE (J05E), INTAKE PIPE (EXHAUST SIDE), REPLACEMENT, REMOVING THE INTAKE PIPE (EXHAUST SIDE) (Page 9-12) REMOVING THE INTAKE PIPE Reference: INTAKE (J05E), INTAKE PIPE (EXHAUST SIDE), REPLACEMENT, REMOVING THE INTAKE PIPE (EXHAUST SIDE) (Page 9-12)
Page 641 TURBOCHARGER (J05E) 17–7 DISCONNECTING THE COOLANT PIPE Remove the nut and then the clip. COOLANT Unfasten the 2 union bolts and detach the coolant pipe E and 4 PIPE E gaskets from the folder and turbocharger assembly. ! CAUTION Use care not to splash the coolant in the pipes and turbocharger assembly.
Page 642 17–8 TURBOCHARGER (J05E) REMOVING THE FLEXIBLE Reference: EXHAUST (J05E), EXHAUST PIPE, REPLACE- MENT, REMOVING THE EXHAUST SYSTEM COMPONENT PARTS (Page 11-9) 10. REMOVING THE EXHAUST PIPE (ATC) Reference: EXHAUST (J05E), EXHAUST PIPE (ATC), REPLACEMENT, REMOVING THE EXHAUST PIPE (ATC) (Page 11-17) 11.
Page 643 TURBOCHARGER (J05E) 17–9 MOUNTING THE TURBOCHARGER ASSEMBLY CAUTIONS ! CAUTION Observe the following instructions when mounting the turbo- charger assembly to the engine or handling after installation. Use special care to prevent the entry of foreign matter into the turbo- charger assembly.
Page 644 17–10 TURBOCHARGER (J05E) MOUNTING THE COOLANT PIPE Replace with the new gaskets and mount the coolant pipe F to the turbocharger assembly and thermostat case with 2 union bolts. ! CAUTION • Clean the coolant pipe and check the pipe for collapse and dirt and foreign matters inside.
Page 645 TURBOCHARGER (J05E) 17–11 MOUNTING THE TURBOCHARGER INSULATOR Replace with the 3 new bolts and mount the turbocharger insula- tor to the turbocharger assembly. TURBO- CHARGER ASSEMBLY TURBOCHARGER INSULATOR SHTS021271600021 CONNECTING THE HARNESS Connect the connector to the electric actuator. 10. MOUNTING THE INTAKE PIPE Reference: INTAKE (J05E), INTAKE PIPE (EXHAUST SIDE), REPLACEMENT, MOUNTING THE INTAKE PIPE (EXHAUST SIDE) (Page 9-13)
Page 646 22.1 kPa {0.23 kgf/cm engine speed) 3.2 lbf/in. } or more ! CAUTION When using the HINO-DX, the boost pressure is added to the atmospheric pressure. (Check the pressure when engine is CONNECTOR stopped.) SHTS021271600022 Remove the boost pressure sensor of the intake pipe and connect the SST (boost pressure measuring hose).
Page 647 U.S.A. , Inc. Hino Motors Sales 41180 Bridge Street, Novi, MI 48375 Telephone: (248) 699-9300 PRINTED IN JAPAN Pub.No. S5-LJ05E04A '12. 11...

This manual is also suitable for:

S5-lj05e05a

Hino S5-LJ05E04A Workshop Manual

General Introduction

How to Identify Vehicle Type

Appearance of Vehicle

Safety Instructions and Readiness to Work

Glossary

Lubricants

Standard Value (J05E)

Mounting and Dismounting the Engine

Engine Control

Fuel System

Emission Control

Intake

Engine Mechanical

Exhaust

Cooling

Lubrication

Starting/Charging

Turbocharger

Required Items (J05E)

Mounting and Dismounting the Engine

Engine Control

Fuel System

Emission Control

Intake

Engine Mechanical

Exhaust

Cooling

Lubrication

Starting/Charging

Turbocharger

Mounting and Dismounting the Engine (J05E)

Engine Control (J05E)

Control Parts

Engine Ecu

Vehicle Control Ecu

Engine Speed Main Sensor

Engine Speed Sub Sensor

Idle Set Volume

Accelerator Pedal

Block Heater

Diesel Throttle

Intake Temperature Sensor

Fuel Sender Gauge

Air Flow Sensor

Boost Pressure Sensor

SCR UPSTREAM Nox SENSOR

Dpr Differential Pressure Sensor

SCR DOWNSTREAM Nox SENSOR

Atc Downstream Temperature Sensor

Doc Upstream Temperature Sensor

Dpr Downstream Temperature Sensor

Dpr Upstream Temperature Sensor

Outside Temperature Sensor

Scr Upstream Temperature Sensor

Oil Pressure Switch

Coolant Temperature Sensor

Fuel System (J05E)

Fuel System

Fuel Tank

Fuel Sender Gauge

Fuel Filter and Case (Engine Side)

Water Level Warning Switch

Supply Pump

Injector

Common Rail

Fuel Filter and Case (Vehicle Side)

Fuel Cooler

Emission Control (J05E)

Egr Valve & Cooler

Closed Ventilator

Intake (J05E)

Intake Manifold

Diesel Throttle

Intake Pipe (Exhaust Side)

Intercooler

Stack Duct

Air Cleaner

Intake Temperature Sensor

Boost Pressure Sensor