Hino Motors J08E-VC Workshop Manual

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FOREWORD

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

Applicable for J08E-VB, VC engine

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

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

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

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

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Hino Motors J08E-VC

Page 1 As for maintenance items, refer to the Driver’s / Owner’s Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Page 2 CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular truck. MANUAL NO. S5-UJ08E10A (U.S.A.), S5-CJ08E10A (CANADA) CHAPTER MODEL J08E-VB, VC GENERAL INTRODUCTION GN01-001 ENGINE INTRODUCTION EN01-001 ENGINE MECHANICAL EN02-001 AIR INTAKE SYSTEM EN03-001 EXHAUST SYSTEM EN04-001...
Page 3 INDEX: ENGINE GROUP 1/2 GENERAL INTRODUCTION ENGINE INTRODUCTION ENGINE MECHANICAL WORKSHOP AIR INTAKE SYSTEM MANUAL EXHAUST SYSTEM LUBRICATING SYSTEM COOLING SYSTEM FUEL SYSTEM TURBOCHARGER FUEL INJECTION PUMP EMISSION CONTROL ALTERNATOR STARTER AIR COMPRESSOR ENGINE PTO (POWER TAKE-OFF) ENGINE RETARDER ENGINE CONTROL...
Page 4 INDEX: ENGINE GROUP 2/2 VEHICLE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS...
Page 5: Table Of Contents
GENERAL INTRODUCTION (ENGINE) GN01–1 G ENERAL INTRODUCTION (ENGINE) G N 0 1 GN01-001 GENERAL INTRODUCTION (ENGINE) ...GN01-2 GENERAL PRECAUTIONS ......GN01-2 HOW TO USE THIS WORKSHOP MANUAL...GN01-5 IDENTIFICATION INFORMATION ....GN01-7 PRECAUTIONS ..........GN01-8 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS ...GN01-11 DISMOUNTING AND MOUNTING ....GN01-12 SYMPTOM SIMULATION ......GN01-15 GLOSSARY OF SAE AND HINO TERMS ..GN01-17...
Page 6: General Introduction (Engine)
GN01–2 GENERAL INTRODUCTION (ENGINE) GENERAL INTRODUCTION (ENGINE) GENERAL PRECAUTIONS EN00106010100001 Some recommended and standard maintenance services for your engine are included in this section. When performing main- tenance on your engine, be careful not to get injured by using improper work procedures. Improper or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property damage.
Page 7 GENERAL INTRODUCTION (ENGINE) GN01–3 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 8 GN01–4 GENERAL INTRODUCTION (ENGINE) CLEAN AIR ACT Heavy-duty engine rebuilding practices. § 86.004-40 • The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine.
Page 9: How To Use This Workshop Manual
GENERAL INTRODUCTION (ENGINE) GN01–5 HOW TO USE THIS WORKSHOP MANUAL EN00106010200001 This workshop manual is designed as a guide for servicing the vehicles. An INDEX is provided on the first page of each chapter. TROUBLESHOOTING is dealt with in each chapter. When beginning operations, refer to the TROUBLESHOOTING section for a guide to appropriate diagnoses.
Page 10 GN01–6 GENERAL INTRODUCTION (ENGINE) TIMING GEAR AND CAMSHAFT EXAMPLE: SHTS001060100007 Gasket Main idle gear Rear end plate Crankshaft gear Camshaft gear Power steering pump drive gear Cam idle gear Air compressor drive gear Idle gear thrust plate Air compressor idle gear Sub-idle gear Idle drive bushing Oil pump gear...
Page 11: Identification Information
GENERAL INTRODUCTION (ENGINE) GN01–7 IDENTIFICATION INFORMATION EN00106010200002 • ENGINE SERIAL NUMBERS. Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention. The engine serial number is engraved on the engine cylinder block. SHTS001060100008...
Page 12: Precautions
GN01–8 GENERAL INTRODUCTION (ENGINE) PRECAUTIONS EN0010601C100001 PRECAUTIONS FOR ELECTRICAL SYSTEM REMOVING THE BATTERY CABLE ! WARNING • Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you disconnect the battery ter- Loosen minals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after...
Page 13 GENERAL INTRODUCTION (ENGINE) GN01–9 HANDLING OF CONNECTOR To remove a connector, hold the connector (indicated by an arrow in the figure) to pull it out. Never pull the harness. To remove a connector with lock, release the lock then pull it out. To connect a connector with lock, insert it until it clicks.
Page 14 GN01–10 GENERAL INTRODUCTION (ENGINE) PRECAUTIONS FOR ELECTRIC WELDING PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc.
Page 15: Specified Torque
GENERAL INTRODUCTION (ENGINE) GN01–11 SPECIFIED TORQUE STANDARD BOLTS AND NUTS EN00106013200001 1. FLANGE BOLT Unit: Nm {kgfcm, lbfft} Class Representation Diameter x Pitch M8 x 1.25 28.5 {290, 21.0} 36 {370, 26.8} M10 x 1.25 60 {610, 44.1} 74.5 {760, 55.0} M10 x 1.5 55 {560, 40.5} 68.5 {700, 50.6}...
Page 16: Dismounting And Mounting
GN01–12 GENERAL INTRODUCTION (ENGINE) DISMOUNTING AND MOUNTING EN00106013200002 PROCEDURE FOR INSTALLING JOINTS AND GAS- KETS OF ENGINE PIPING 1. Gasket seal type (aluminum + rubber, asbestos or copper). Location of gasket seal Tightening torque chart Clamping screw size (Diameter) mm {in.} Tightening torque Nm {kgfcm, lbfft} 8 {0.315} 13 {130, 9}...
Page 17 GENERAL INTRODUCTION (ENGINE) GN01–13 2. Metal seal type (Flare connector type). Location of metal seal Tightening torque chart Clamping screw size (Diameter) mm {in.} Tightening torque Nm {kgfcm, lbfft} 12 {0.472} 20 {200, 14} 14 {0.551} 31 {320, 23} 16 {0.630} 39 {400, 29} 18 {0.709} 59 {600, 43}...
Page 18 GN01–14 GENERAL INTRODUCTION (ENGINE) 3. Metal seal type (Nipple connector type). Location of metal seal Tightening torque chart Clamping screw size (Diameter) mm {in.} Tightening torque Nm {kgfcm, lbfft} 10 {0.394} 11 {110, 8} 24 {0.945} 20 {200, 14} NOTICE •...
Page 19: Symptom Simulation
GENERAL INTRODUCTION (ENGINE) GN01–15 SYMPTOM SIMULATION EN00106013200003 HINT The most difficult case in troubleshooting is when no problem symp- toms occur. In such a case, a thorough problem analysis must be car- ried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out.
Page 20 GN01–16 GENERAL INTRODUCTION (ENGINE) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE • Never sprinkle water directly into the engine compartment. Indi- rectly change the temperature and humidity by spraying water onto the front of the radiator.
Page 21: Glossary Of Sae And Hino Terms
GENERAL INTRODUCTION (ENGINE) GN01–17 GLOSSARY OF SAE AND HINO TERMS EN00Z00020200005 This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as well as their HINO equivalents. HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS AUTOMATIC TRANSMISSION Automatic transmission AMBIENT AIR TEMPERATURE...
Page 22 GN01–18 GENERAL INTRODUCTION (ENGINE) HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch EXHAUST BACK PRESSURE Backpressure EXHAUST BACK PRESSURE Exhaust backpressure EBP Sensor EXHAUST BACK PRESSURE Sensor Back Pressure Sensor EXHAUST BACK PRESSURE REGULATOR EBPR Valve...
Page 23 GENERAL INTRODUCTION (ENGINE) GN01–19 HINO TERMS SAE TERMS ABBREVIATIONS ( )--ABBREVIATIONS MAF Sensor MASS AIR FLOW Sensor Air flow sensor MALFUNCTION INDICATOR LAMP Check engine OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor PC Solenoid Valve PRESSURE CONTROL Solenoid Valve...
Page 24 ENGINE INTRODUCTION (J08E) EN01–1 E NGINE INTRODUCTION (J08E) E N 0 1 EN01-001 ENGINE ASSEMBLY ........ EN01-2 DATA AND SPECIFICATIONS ......EN01-2 TROUBLESHOOTING ........EN01-4 TROUBLESHOOTING (COMMON RAIL SYSTEM) ......EN01-11 ENGINE TUNEUP ......... EN01-12 SPECIAL TOOL ..........EN01-18 OVERHAUL CRITERIA........EN01-19 DISMOUNTING AND MOUNTING ....
Page 25: Engine Assembly
EN01–2 ENGINE INTRODUCTION (J08E) ENGINE ASSEMBLY DATA AND SPECIFICATIONS EN0110601I200001 Model J08E-VC Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft, Type water-cooled, direct injection Aspiration Turbocharged with intercooler Bore and stroke 112x130 mm {4.41x5.11 in.} Piston displacement 7.684 L {468.9 cu.in.} Compression ratio 17.5: 1...
Page 26 ENGINE INTRODUCTION (J08E) EN01–3 Model J08E-VB Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft, Type water-cooled, direct injection Aspiration Turbocharged with intercooler Bore and stroke 112x130 mm {4.41x5.11 in.} Piston displacement 7.684 L {468.9 cu.in.} Compression ratio 17.5: 1 1-4-2-6-3-5 (The cylinder numbers are counted in order from the Firing order crankshaft pulley side)
Page 27: Troubleshooting
EN01–4 ENGINE INTRODUCTION (J08E) TROUBLESHOOTING EN0110601F300001 Engine overheating Symptom Possible cause Remedy/Prevention Engine overheating (Coolant) Insufficient coolant Add coolant Defective thermostat Replace thermostat Overflow of coolant due to leakage of Repair exhaust into cooling system Damaged rubber hose Replace rubber hose Coolant leakage due to deteriorated Replace rubber hose rubber hose...
Page 28 ENGINE INTRODUCTION (J08E) EN01–5 Excessive oil consumption Symptom Possible cause Remedy/Prevention Excessive oil consumption (Pis- Wear of piston ring and cylinder liner Replace piston rings and cylinder liner tons, cylinder liners, and piston Worn, sticking or broken piston rings Replace piston rings and cylinder liner rings) Insufficient tension on piston rings Replace piston rings and cylinder liner...
Page 29 EN01–6 ENGINE INTRODUCTION (J08E) Piston seizure Symptom Possible cause Remedy/Prevention Piston seizure (Pistons, cylinder lin- Incorrect clearance between piston Replace piston, piston rings and cylin- ers and piston rings) and cylinder liner der liner Unsatisfactory installation of piston pin Replace piston, piston rings, cylinder liner and piston pin as required Broken piston ring Replace piston, piston rings and cylin-...
Page 30 ENGINE INTRODUCTION (J08E) EN01–7 Lack of power Symptom Possible cause Remedy/Prevention Lack of power (Supply pump) Damaged suction control valve (SCV) Replace the suction control valve (SCV) Use of poor fuel Use good quality fuel Lack of power (Intake) Clogged air cleaner Clean element or replace element Lack of power (Overheating) See Symptom: "Engine overheating"...
Page 31 EN01–8 ENGINE INTRODUCTION (J08E) Difficulty starting engine Symptom Possible cause Remedy/Prevention Difficulty starting engine (Electrical Discharged battery Charge battery system) Defective wiring in starter circuit Repair wiring of starter Loose or open-circuit battery cable Tighten battery terminal connections or replace battery cable Broken glow plug Replace Difficulty starting engine (Supply...
Page 32 ENGINE INTRODUCTION (J08E) EN01–9 Diesel knock Symptom Possible cause Remedy/Prevention Diesel knock (Supply pump) Damaged suction control valve (SCV) Replace the suction control valve (SCV) Use of poor fuel Use good quality fuel Diesel knock (Injector) Breakdown of injector Replace the injector Use of poor fuel Use good quality fuel Diesel knock (Fuel system)
Page 33 EN01–10 ENGINE INTRODUCTION (J08E) Symptom Possible cause Remedy/Prevention Unusual engine noise (Various other Exhaust gas leakage from exhaust Retighten joints parts) pipe joints Loosen or missing intake manifold Retighten or replace flange gasket Intake valve seating is not concentric Replace or correct the valve and valve seat Intake gas leakage Retighten...
Page 34: Troubleshooting (Common Rail System)
ENGINE INTRODUCTION (J08E) EN01–11 TROUBLESHOOTING (COMMON RAIL SYSTEM) EN0110601F300002 Engine does not start Symptom Possible cause Remedy/Prevention Engine does not start (Fuel not Fuel lines clogged or damaged Clean or replace fuel lines reaching supply pump) Fuel filter clogged Clean or replace the filter element Air in fuel caused by improper connec- Repair connections tions of fuel line between fuel tank and...
Page 35: Engine Tuneup
EN01–12 ENGINE INTRODUCTION (J08E) ENGINE TUNEUP EN0110601H300001 VALVE CLEARANCE CHECKING AND ADJUSTING PROCEDURES NOTICE Valve clearance adjustment is performed only when the checking result is not within the specified value. PREPARATION OF CHECKING AND ADJUSTMENT Positioning the No.1 or No.6 piston at Top Dead Center of the com- pression stroke.
Page 36 ENGINE INTRODUCTION (J08E) EN01–13 Make sure that the valve stem is correctly inserted in the cross head. NOTICE Move the cross head with fingers right and left to confirm the valve stem is correctly inserted in the cross head by listening to the clicking Click sound.
Page 37 EN01–14 ENGINE INTRODUCTION (J08E) Insert a feeler gauge of the specified thickness as below between the rocker arm and the cross head to check the valve clearance. Rocker arm VALVE CLEARANCE (when cold) Feeler gauge Intake valve 0.30 mm {0.0118 in.} Exhaust valve 0.45 mm {0.0177 in.} Cross head...
Page 38 ENGINE INTRODUCTION (J08E) EN01–15 The condition of inserted feeler gauge, loosen the adjusting screw of the cross head, make sure that the feeler gauge does not feel loose. Loosen NOTICE If the feeling of the feeler gauge becomes loose, repeat steps from (1). Need clearance SHTS011060100012...
Page 39 EN01–16 ENGINE INTRODUCTION (J08E) INJECTION TIMING INSPECTION PROCEDURES INSPECT THE INJECTION TIMING. Turn the crankshaft counterclockwise, as viewed from the flywheel Flywheel side, and then align the timing mark in the check window of the fly- wheel housing with a mark of "1/6". At this time, the No.1 cylinder or the No.6 cylinder is in the top dead center.
Page 40 ENGINE INTRODUCTION (J08E) EN01–17 Supply cooling water and bleed air from it. SHTS011060100019 Bleed air from the fuel system. Refer to the section "AIR BLEEDING" in the chapter "FUEL SYS- TEM (J08E)" on page EN07-30. Check connection to the alternator. NOTICE Starting the engine without wiring in place may burn out the alterna- tor.
Page 41: Special Tool
EN01–18 ENGINE INTRODUCTION (J08E) SPECIAL TOOL EN0110601K100001 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks COMPRESSION GAUGE S0955-21110 For Overhaul criteria ADAPTER (A) COMPRESSION GAUGE For 3/4-16UNF Select S0955-21030 ADAPTER (B) thread size...
Page 42: Overhaul Criteria
ENGINE INTRODUCTION (J08E) EN01–19 OVERHAUL CRITERIA EN0110601H300002 FACTORS TO DETERMINE THE ENGINE OVERHAUL LOW COMPRESSION PRESSURE. Before measurement a. Charge the battery completely. b. Set the valve clearance to the correct value. c. Idle the engine (Coolant temperature at 80C {176F}). d.
Page 43: Dismounting And Mounting
EN01–20 ENGINE INTRODUCTION (J08E) d. Measure the oil pressure at a coolant temperature of 80C {176F} or more. Viscosity recommendations (SAE) Oil pressure Standard Limit SAE 5W-30 SAE 5W-30 49-490 kPa Less than 49kPa {0.5-5.0 kgf/cm {0.5 kgf/cm SAE 10W-30 SAE 10W-30 7.11-71.10 lbf/in.
Page 44 ENGINE INTRODUCTION (J08E) EN01–21 (12) Dismount the engine assembly using the special tool. SST: Front Engine hanger (S1228-11901) Bolt (SH782-41235) Tightening Torque: 100 Nm {1020 kgfcm, 73.8lbfft} (13) Connect a cable from an engine hanger to the hanger bracket (1 point) on the front of the engine, and to the hanger bracket (1 point) on the flywheel housing at the rear of the engine.
Page 45: Liquid Gasket And Application Points
EN01–22 ENGINE INTRODUCTION (J08E) LIQUID GASKET APPLICATION POINTS EN0110601H200001 • Liquid gasket is used at the following positions for the J08E series engine. Liquid gasket specification: S0413-21217: Black Liquid gasket specification: S0413-21207: Silver Liquid gasket specification: S0413-21211: White LIQUID GASKET APPLICATION AND PART ASSEMBLY PROCE- DURE.
Page 46 ENGINE INTRODUCTION (J08E) EN01–23 For tube-type liquid gasket, required width of application can be obtained by cutting the nozzle to suit. 1: Approximately 2 mm wide when cut at the first step 2: Approximately 5 mm wide when cut at the second step SHTS011060100033 PARTS AND POSITIONS FOR LIQUID GASKET.
Page 47 EN01–24 ENGINE INTRODUCTION (J08E) Gasket Application Part name Application position and pattern to be Remarks width used Matching face with the rear edge 1.5-2.5 Flange {0.0591- Silver 0.0984} Matching face with the intake manifold Matching face with the intake manifold Liquid gasket 1.5-2.5 Intake pipe...
Page 48 ENGINE INTRODUCTION (J08E) EN01–25 Gasket Application Part name Application position and pattern to be Remarks width used Front and rear ends of upper/ lower faces of block NOTICE Cut the rear end plate gasket with a craft knife flush with the block upper face. Matching face of rear end plate Matching face of rear end plate Liquid...
Page 49 EN01–26 ENGINE INTRODUCTION (J08E) Gasket Application Part name Application position and pattern to be Remarks width used 1.5-2.5 Black 2 locations Matching faces with cam housing and plug {0.0591- at front and Matching parts of cam housing, plug, cylin- 0.0984} rear ends der head cover and gasket NOTICE...
Page 50 ENGINE MECHANICAL (J08E) EN02–1 E NGINE MECHANICAL (J08E) E N 0 2 EN02-001 CYLINDER HEAD ........EN02-2 COMPONENT LOCATOR........ EN02-2 SPECIAL TOOL ..........EN02-5 OVERHAUL ............. EN02-6 INSPECTION AND REPAIR ......EN02-17 CRANKSHAFT FRONT END....EN02-21 COMPONENT LOCATOR......EN02-21 SPECIAL TOOL ..........EN02-22 OVERHAUL ...........
Page 51: Cylinder Head
EN02–2 ENGINE MECHANICAL (J08E) CYLINDER HEAD COMPONENT LOCATOR EN0110602D100001 SHTS011060200001...
Page 52 ENGINE MECHANICAL (J08E) EN02–3 Oil filler cap Valve rocker shaft Cylinder head cover Camshaft bearing cap Silent block Camshaft gear Heater plug Camshaft Head cover gasket Union bolt Plate Gasket Injection pipe oil seal Leakage pipe Injector Injector clamp bolt O-ring Rocker arm support bolt Camshaft housing...
Page 53 EN02–4 ENGINE MECHANICAL (J08E) SHTS011060200002 Flange Valve stem seal Idle gear shaft Valve spring seat lower Camshaft idle gear Valve stem guide Idle gear thrust plate Valve seat Cross head Valve Valve spring retainer Nozzle seat Valve spring seat upper O-ring Valve spring outer Cylinder head block...
Page 54: Special Tool
ENGINE MECHANICAL (J08E) EN02–5 SPECIAL TOOL EN0110602K100001 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0943-31070 EYE BOLT S0949-11010 WIRE S0947-01170 VALVE SPRING PRESS S0943-11020 VALVE LAPPING TOOL S0947-22100 VALVE STEM SEAL PRESS S0947-21210...
Page 55: Overhaul
EN02–6 ENGINE MECHANICAL (J08E) OVERHAUL EN0110602H200001 IMPORTANT POINTS - DISASSEMBLY DISASSEMBLE THE CYLINDER HEAD. Clean parts around the injector and fuel system connections. NOTICE Entry of foreign particles into the combustion chamber may result in engine trouble. Remove the injector harness assy. a.
Page 56 ENGINE MECHANICAL (J08E) EN02–7 Lift and remove the cylinder head using the special tool and hoist. SST: Eye bolt (S0943-31070) Wire (S0949-11010) NOTICE • Do not damage the cylinder head lower surface or cylinder block upper surface during removal of the cylinder head. •...
Page 57 EN02–8 ENGINE MECHANICAL (J08E) IMPORTANT POINTS - REPLACEMENT REPLACE THE VALVE GUIDE. Remove the valve stem seal. For removal, strike the valve guide with a brass bar and hammer. ! WARNING Be sure to wear protective goggles. Striking the valve guide when removing the valve guide may cause metal chips to fly up.
Page 58 ENGINE MECHANICAL (J08E) EN02–9 Apply a small amount of lapping compound to the contact surfaces of the valve and valve seat. Turn the valve using the special tool and tap it lightly to lap. SST: Valve lapping tool (S0943-11020) SHTS011060200023 REPLACE THE VALVE STEM SEAL.
Page 59 EN02–10 ENGINE MECHANICAL (J08E) REPLACE THE NOZZLE SEAT. Tap the nozzle seat from the cylinder head lower surface. Then, screw in a suitable bolt and strike the bolt head with a hammer to remove the nozzle seat from the cylinder head. ! WARNING Be sure to wear protective goggles.
Page 60 ENGINE MECHANICAL (J08E) EN02–11 INSTALL THE CYLINDER HEAD GASKET. NOTICE • When installing the cylinder head, install the new gasket after removing dirt, moisture and oil on the cylinder head and cylinder block surface. • Never reuse the gasket as it may cause engine damage. •...
Page 61 EN02–12 ENGINE MECHANICAL (J08E) TIGHTEN THE CYLINDER HEAD BOLT. Measure the length of the M12 head bolts, if the length is A or more, replace with new bolts. Dimension A 125.5 mm {4.941 in.} SHTS011060200031 Apply clean engine oil to the bolt surface and bolt threads of the M10 and M12 bolts.
Page 62 ENGINE MECHANICAL (J08E) EN02–13 INSTALL THE CAM IDLE GEAR. NOTICE Idle gear • Install the cam idle gear shaft through the thrust plate as shown thrust plate in the figure so that the lubrication hole is downward. • Apply clean engine oil to the bolt seat and bolt threads. Lubrication hole Cylinder head...
Page 63 EN02–14 ENGINE MECHANICAL (J08E) INSTALL THE CAMSHAFT. Align the mark on the flywheel with the flywheel housing pointer to set the No. 1 piston to top dead center of the compression stroke. NOTICE Engine adjustment - Refer to "PREPARATION OF CHECKING AND ADJUSTMENT".
Page 64 ENGINE MECHANICAL (J08E) EN02–15 10. INSTALL THE HEAD COVER. Remove the camshaft housing plugs at the front and rear ends of the camshaft housing. NOTICE Do not remove the plug except when there is oil leakage from plug. Remove the liquid gasket from camshaft housing plugs and camshaft housing completely.
Page 65 EN02–16 ENGINE MECHANICAL (J08E) Insert the silent block from the head cover upper surface. Tighten the bolt through the silent block to the specified torque below and fix the head cover on the cam housing. Tightening Torque: 28.5 Nm {290 kgfcm, 21 lbfft} SHTS011060200047...
Page 66: Inspection And Repair
ENGINE MECHANICAL (J08E) EN02–17 INSPECTION AND REPAIR EN0110602H300001 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Camshaft journal outside 39.85 Measure Replace camshaft. diameter {1.5748} {1.5689} Camshaft bearing inside 40.15 Replace cam bear- diameter {1.5748} {1.5807} ing. Clearance between cam- 0.020-0.063 Replace camshaft shaft journal and camshaft...
Page 67 EN02–18 ENGINE MECHANICAL (J08E) Inspection item Standard Limit Remedy Inspection procedure Stem outside Measure 7 {0.2756} 6.92 {0.2724} Replace the valve. diameter Guide inside Replace the valve Intake valve 7 {0.2756} 7.04 {0.2772} diameter guide. 0.023-0.058 Replace the valve Clearance 0.12 {0.0047} {0.0010-0.0022} and/or valve guide.
Page 68 ENGINE MECHANICAL (J08E) EN02–19 Inspection item Standard Limit Remedy Inspection procedure 291.8 N Measure 314 N {29.8 kgf, Setting load {32.0 kgf, 70.5 lbf} Replace. 65.6 lbf} at 46.8 {1.843} at 46.8 {1.843} Outer valve spring Free length (reference 75.7 {2.980} 72.7 {2.862} Replace.
Page 69 EN02–20 ENGINE MECHANICAL (J08E) Inspection item Standard Limit Remedy Inspection procedure Visual check Cracks or damage to cylin- der head (Dye penetrant — — Replace. check) Visual check Contact of valve (Use of Entire periphery of Red lead marking com- valve head evenly —...
Page 70: Crankshaft Front End
ENGINE MECHANICAL (J08E) EN02–21 CRANKSHAFT FRONT END COMPONENT LOCATOR EN0110602D100002 SHTS011060200063 Crankshaft pulley Oil seal retainer Torsional damper Crankshaft oil seal Tightening torque Unit: Nm {kgfcm, lbfft} 118 {1,200, 86.8}# 108 {1,100, 79.6}# #=Apply oil to the threads and seat surfaces before tightening.
Page 71: Special Tool
EN02–22 ENGINE MECHANICAL (J08E) SPECIAL TOOL EN0110602K100002 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0942-01731 OIL SEAL PULLER S0940-71030 OIL SEAL PRESS...
Page 72: Overhaul
ENGINE MECHANICAL (J08E) EN02–23 OVERHAUL EN0110602H200002 IMPORTANT POINTS - REPLACEMENT REMOVE THE CRANKSHAFT FRONT OIL SEAL. SST: Oil seal puller (S0942-01731) Place the plate at the crankshaft end using the crankshaft pulley bolts. Plate SHTS011060200066 Engage the hook with the oil seal notch and install the hook using the Remove this after installing the hook bolt supplied.
Page 73 EN02–24 ENGINE MECHANICAL (J08E) INSTALL THE CRANKSHAFT FRONT OIL SEAL. Guide SST: Oil seal press (S0940-71030) Clean the edges and surface of the crankshaft and the special tools. Insert a new crankshaft oil seal into the guide of the oil seal press. Oil seal SHTS011060200069 NOTICE...
Page 74: Component Locator
ENGINE MECHANICAL (J08E) EN02–25 FLYWHEEL AND FLYWHEEL HOUSING COMPONENT LOCATOR EN0110602D100003 Example (torx bolt) SHTS011060200073 Flywheel housing Ring gear Dust cover Flywheel Crankshaft oil seal Pilot bearing Hanger bracket Stay Tightening torque Unit: Nm {kgfcm, lbfft} 186 {1,900, 137.4}# M8: 28.5 {290, 21} 97 {990, 71.6} M8 Torx bolt: 36 {370, 26.8} 171.5 {1,750, 126.6}...
Page 75: Special Tool
EN02–26 ENGINE MECHANICAL (J08E) SPECIAL TOOL EN0110602K100003 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0942-01742 REAR OIL SEAL PULLER S0940-71040 OIL SEAL PRESS S0948-11340 GUIDE BAR OVERHAUL EN0110602H200003 IMPORTANT POINT - DISASSEMBLY REMOVE THE FLYWHEEL ASSY.
Page 76 ENGINE MECHANICAL (J08E) EN02–27 Remove the 8 bolts of the flywheel assy. Example SHTS011060200079 Install the special tool, remove the flywheel assy. SST: Guide bar (S0948-11340) Example ! WARNING Be careful not to drop the flywheel on your foot when removing it, because it is very heavy.
Page 77 EN02–28 ENGINE MECHANICAL (J08E) Install the center bolt and tighten it to remove the oil seal. Example Center bolt SHTS011060200083 INSTALL THE CRANKSHAFT REAR OIL SEAL. SST: Oil seal press (S0940-71040) Clean the edges and surface of the crankshaft and the special tools. Insert a new crankshaft oil seal into the guide of the oil seal press.
Page 78 ENGINE MECHANICAL (J08E) EN02–29 Insert the oil seal press by adjusting the oil seal press hole to the guide bolt. Press the crankshaft oil seal inside by attaching the accompanying center bolt onto the oil seal press and tightening it until it stops. Press Center bolt SHTS011060200087...
Page 79 EN02–30 ENGINE MECHANICAL (J08E) b. Unfasten the bolts to remove the flywheel housing. SHTS011060200091 Mounting the flywheel housing. Liquid gasket a. Using the scraper, remove dirt on the joint surfaces of the axle housing and differential carrier assembly. b. Apply a liquid gasket to the flywheel housing as shown in the fig- ure.
Page 80 ENGINE MECHANICAL (J08E) EN02–31 IMPORTANT POINT - ASSEMBLY INSTALL THE FLYWHEEL. Make sure that there are no burns or dirt on the contact surface or in the threaded holes of the crankshaft or flywheel. Install the special tool onto the crankshaft. SST: Guide bar (S0948-11340) NOTICE Place one guide bar at the collar knock and another at the opposite...
Page 81: Inspection And Repair
EN02–32 ENGINE MECHANICAL (J08E) INSPECTION AND REPAIR EN0110602H300002 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Measure Flywheel surface deflec- — 0.15 {0.0059} Repair. tion Measure EATON SAS1401 Flywheel SAS1402 thickness MD DM 43.5 {1.7126} 42.5 {1.6732} Repair. (Dimen- series sion A)
Page 82: Timing Gear
ENGINE MECHANICAL (J08E) EN02–33 TIMING GEAR COMPONENT LOCATOR EN0110602D100004 SHTS011060200101 Gasket Main idle gear Rear end plate Crankshaft gear Camshaft gear Power steering pump drive gear Cam idle gear Air compressor drive gear Idle gear thrust plate Air compressor idle gear Sub-idle gear Idle gear bushing Oil pump gear...
Page 83: Special Tool
EN02–34 ENGINE MECHANICAL (J08E) SPECIAL TOOL EN0110602K100004 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0942-01100 SLIDING HAMMER For MAIN IDLE GEAR For SUB AND CAM S0942-01442 SLIDING HAMMER IDLE GEAR S0941-11300 SOCKET WRENCH...
Page 84: Overhaul
ENGINE MECHANICAL (J08E) EN02–35 OVERHAUL EN0110602H200004 IMPORTANT POINT - DISASSEMBLY REMOVE THE IDLE GEAR SHAFT. Remove the idle gear shaft using the special tool. SST: Sliding hammer (for main idle gear) (S0942-01100) Sliding hammer (for sub and cam idle gear) (S0942-01442) SHTS011060200105 SHTS011060200106 IMPORTANT POINTS - ASSEMBLY...
Page 85 EN02–36 ENGINE MECHANICAL (J08E) INSTALL THE IDLER GEAR SHAFT AND GEAR. SHTS011060200109 NOTICE • Install each idle gear shaft through the thrust plate as shown in the figure so that the lubrication hole is downward. • Adjust the timing of the main idle gear to align with the air com- pressor gear as shown in the figure.
Page 86: Inspection And Repair
ENGINE MECHANICAL (J08E) EN02–37 INSPECTION AND REPAIR EN0110602H300003 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Crankshaft- 0.030-0.167 0.30 {0.0118} Main idle {0.0012-0.0065} Main idle-Air 0.020-0.096 compressor 0.10 {0.0039} {0.0008-0.0038} idle Measure Air compres- sor idle-Air 0.020-0.083 0.10 {0.0039} compressor {0.0008-0.0033} gear...
Page 87 EN02–38 ENGINE MECHANICAL (J08E) Inspection item Standard Limit Remedy Inspection procedure Shaft outside 57 {2.244} — — diameter Bushing inside diame- 57 {2.244} — — Main idle 0.030-0.090 Replace gear and/ Clearance 0.20 {0.0079} shaft {0.0012-0.0035} or shaft. Gear width 44 {1.732} —...
Page 88: Main Moving Parts And Cylinder Block
ENGINE MECHANICAL (J08E) EN02–39 MAIN MOVING PARTS AND CYLINDER BLOCK COMPONENT LOCATOR EN0110602D100005 SHTS011060200113 Cylinder liner Connecting rod bearing Cylinder block Crankshaft Piston cooling jet Crankshaft thrust bearing Piston ring Crankshaft main bearing Piston Crankshaft gear Piston pin Collar knock Retainer ring Main bearing cap Connecting rod...
Page 89 EN02–40 ENGINE MECHANICAL (J08E) Tightening torque Unit: Nm {kgfcm, lbfft} 22 {220, 15.9} 69 {700, 51}+90+45# 69 {700, 51}+90+45# #=Apply oil to the threads and seat surfaces before tightening. =Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again. SHTS011060200114 Engine mounting bracket, front Engine mounting, front...
Page 90 ENGINE MECHANICAL (J08E) EN02–41 SHTS011060200115 Gasket Soft washer Oil pan Drain plug Tightening torque Unit: Nm {kgfcm, lbfft} 41 {420, 30} 30 {310, 22.4}...
Page 91: Special Tool
EN02–42 ENGINE MECHANICAL (J08E) SPECIAL TOOL EN0110602K100005 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0944-21011 PISTON RING EXPANDER For Piston ring S0942-02100 PULLER For Cylinder liner SZ910-24098 CONNECTOR BOLT For Piston cooling jet S0947-11490...
Page 92 ENGINE MECHANICAL (J08E) EN02–43 Illustration Part number Tool name Remarks S0940-21530 PRESS SUB-ASSEMBLY SL271-01036 WING NUT S0944-11370 PISTON RING HOLDER 09219-E4010 GAGE...
Page 93: Overhaul
EN02–44 ENGINE MECHANICAL (J08E) OVERHAUL EN0110602H200005 IMPORTANT POINTS - DISASSEMBLY REMOVE THE PISTONS WITH CONNECTING RODS. Remove the pistons and connecting rods from the cylinder block upper side. NOTICE • Remove carbon deposits from the end inside the cylinder liner with a scraper or emery paper (recommended: No.
Page 94 ENGINE MECHANICAL (J08E) EN02–45 Pull the cylinder liner from the cylinder block using the special tool. SST: Puller (S0942-02100) NOTICE • Carefully set the special tool to prevent touching the piston cool- ing jet. • After removing the cylinder liners, arrange them in sequence. SHTS011060200132 REMOVE THE BLOCK HEATER.
Page 95 EN02–46 ENGINE MECHANICAL (J08E) For the jet test, connect the oil hose to the connector bolt from the cyl- inder block lower side. NOTICE Use clean engine oil for jet flow. SHTS011060200136 Set the special tool on the cylinder block upper surface against the dowel pin.
Page 96 ENGINE MECHANICAL (J08E) EN02–47 INSTALL THE CYLINDER LINER. NOTICE • When assembling the cylinder liner with the cylinder block, clearance can be set to three levels. • The upper surface and side surface of the cylinder block are stamped A, B or C depending on the inside diameter. Insert a matching cylinder liner having the same symbol.
Page 97 EN02–48 ENGINE MECHANICAL (J08E) MEASURE THE CRANKSHAFT. If necessary, grind the crankshaft and use an undersize bearing. Outside diameter Bearing size Crank pin Journal 64.94-64.96 mm 79.94-79.96 mm Standard {2.5567-2.5574 in.} {3.1473-3.1480 in.} 64.69-64.71 mm 79.69-79.71 mm 0.25US {2.5469-2.5476 in.} {3.1375-3.1381 in.} 64.44-64.46 mm 79.44-79.46 mm...
Page 98 ENGINE MECHANICAL (J08E) EN02–49 INSTALL THE MAIN BEARING CAP. Install the main bearing cap onto the cylinder block. NOTICE Check the number stamped on the cap. Measure the length below the head of the bearing cap bolt and replace any bolts not meeting the limit with new ones. Application position of engine oil...
Page 99 EN02–50 ENGINE MECHANICAL (J08E) Using a special tool, remove the connecting rod bushing. a. Set the connecting rod assembled without connecting rod bearing on the guide and press sub-assembly. SHTS011060200149 b. Install the spindle into the bushing. SST: Spindle (S0940-21540) NOTICE Align the groove of the spindle with the groove of the press sub assembly.
Page 100 ENGINE MECHANICAL (J08E) EN02–51 Mount the bushing on the spindle. a. Set the bushing and guide on the spindle as shown in the figure, then secure them with the bolt. SST: Spindle (S0940-21540) Guide (S0948-11540) Bolt (SH691-20825) Tightening Torque: 5.0-6.8 Nm {50-70 kgfcm, 3.62-5.06 lbfft} (Bolt) NOTICE SHTS011060200153 •...
Page 101 EN02–52 ENGINE MECHANICAL (J08E) ASSEMBLE THE PISTON RING. Install in the order of oil ring, second ring and top ring using the spe- cial tool. SST: Piston ring expander (S0944-21011) NOTICE Install the second ring with the identification print on the piston ring facing towards the upper surface.
Page 102 ENGINE MECHANICAL (J08E) EN02–53 11. INSTALL THE PISTON. Apply engine oil to the piston, cylinder liner and connecting rod bear- ing, then compress the piston ring using the special tool. SST: Piston ring holder (S0944-11370) NOTICE • When installing the piston, be careful that the cooling jet is not struck by the connecting rod.
Page 103 EN02–54 ENGINE MECHANICAL (J08E) 13. INSTALL THE OIL PAN. Make sure that there is no deformation, impact marks or foreign parti- cles on the cylinder block, oil pan or flange surface. Apply liquid gas- ket to the front and back ends of the cylinder block lower surface. NOTICE Refer to "PARTS AND POSITIONS FOR LIQUID GASKET".
Page 104 ENGINE MECHANICAL (J08E) EN02–55 Tighten the socket head capscrew. Tightening Torque: 2.3-3.3 Nm {23-33 kgfcm, 1.7-2.3 lbfft} NOTICE Do not overtighten. If overtightened, the flat bar could come off the socket head capscrew and drop into the water jacket. This could cause the engine to over heat due to cooling system damage.
Page 105 EN02–56 ENGINE MECHANICAL (J08E) 15. REFILL THE HINO LONG LIFE COOLANT. Concentration of Hino long life coolant. • The freezing point of the coolant varies with the concentration of anti- freeze. Select the appropriate concentration to protect against freez- ing according to the following table. NOTICE If water to coolant ratio is not mixed according to the following table the engine will overheat and block heater coil will melt.
Page 106: Inspection And Repair
ENGINE MECHANICAL (J08E) EN02–57 INSPECTION AND REPAIR EN0110602H300004 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Cylinder block flange Measure 3 {0.1181} — — depth Cylinder liner thickness 3 {0.1181} — — 0.01-0.08 Cylinder liner protrusion — — {0.0004-0.0031} 117-117.008 Reference only...
Page 107 EN02–58 ENGINE MECHANICAL (J08E) Inspection item Standard Limit Remedy Inspection procedure — — Measure 1.970-1.990 Second 1.9 {0.0748} {0.0776-0.0783} Piston ring Replace ring. width 3.970-3.990 3.9 {0.1535} {0.1563-0.1570} — — Measure 2.055-2.075 Piston Second 2.2 {0.0866} {0.0809-0.0817} groove Replace piston. width 4.015-4.035 4.1 {0.1614}...
Page 108 ENGINE MECHANICAL (J08E) EN02–59 Inspection item Standard Limit Remedy Inspection procedure Clearance between pis- Replace piston pin 0.035-0.056 ton pin and connecting 0.08 {0.0031} and/or connecting — {0.0014-0.0022} rod bushing rod bushing. Visual check Wear or damage of con- necting rod —...
Page 109 EN02–60 ENGINE MECHANICAL (J08E) Inspection item Standard Limit Remedy Inspection procedure Center journal width 36 {1.417} 37 {1.456} Replace crankshaft. Measure Thrust bearing thick- 2.5 {0.0984} — — ness More than Replace over size 0.5 {0.0197} thrust bearing. 0.050-0.270 {0.0020- (Repair) Crankshaft end play 0.0106}...
Page 110 AIR INTAKE SYSTEM (J08E) EN03–1 A IR INTAKE SYSTEM (J08E) E N 0 3 EN03-001 AIR INTAKE MANIFOLD AND PIPE ..EN03-2 COMPONENT LOCATOR........ EN03-2 DISMOUNTING AND MOUNTING ....EN03-3 AIR INTAKE ..........EN03-4 COMPONENT LOCATOR........ EN03-4 AIR CLEANER .......... EN03-5 DESCRIPTION ..........
Page 111: Air Intake Manifold And Pipe
EN03–2 AIR INTAKE SYSTEM (J08E) AIR INTAKE MANIFOLD AND PIPE COMPONENT LOCATOR EN0110603D100001 SHTS011060300001 Intake manifold gasket Intake throttle valve Intake manifold Bracket Intake pipe Gasket Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {290, 21}...
Page 112: Dismounting And Mounting
AIR INTAKE SYSTEM (J08E) EN03–3 DISMOUNTING AND MOUNTING EN0110603H100001 IMPORTANT POINT - MOUNTING INSTALL THE INTAKE MANIFOLD GASKET. Install the intake manifold gasket so that the protrusion is positioned at the stud bolt side of the cylinder head rear end. SHTS011060300002...
Page 113: Air Intake
EN03–4 AIR INTAKE SYSTEM (J08E) AIR INTAKE COMPONENT LOCATOR EN0110603D100002 Example Vehicle's right side Vehicle's front SHTS011060300003 Hood Air flow sensor Air intake grille Air hose Air cleaner Air cleaner bracket Air hose Intake pipe...
Page 114: Air Cleaner
AIR INTAKE SYSTEM (J08E) EN03–5 AIR CLEANER DESCRIPTION EN0110603D100003 SHTS011060300004 Body assembly Unloader valve Cover Adapter Thumb screw...
Page 115: Overhaul
EN03–6 AIR INTAKE SYSTEM (J08E) OVERHAUL EN0110603H100002 IMPORTANT POINTS - DISMOUNTING REMOVE THE AIR CLEANER ELEMENT. Remove the thumb screw as shown in the figure and remove the cover. Hold the outer projection end of the element and turn slightly, then detach the element.
Page 116: Air Hose
AIR INTAKE SYSTEM (J08E) EN03–7 AIR HOSE COMPONENT LOCATOR EN0110603D100004 SHTS011060300008 Air cleaner bracket Clamp (B) Air cleaner Dust indicator Air hose Intake throttle valve Clamp (A) Separator Intake pipe Air hose Air hose Air hose (Separator) Air hose (Intercooler) Cover (If so equipped) Tightening torque Unit: Nm {kgfcm, lbfft}...
Page 117: Overhaul
EN03–8 AIR INTAKE SYSTEM (J08E) OVERHAUL EN0110603H100003 IMPORTANT POINTS - MOUNTING INSTALL THE AIR HOSE. Location of the rotation direction of the intake pipe and the air hose should match emboss mark as shown in the figure. Tighten the clamp. Tightening Torque: 4.5-5.5 Nm {46-56 kgfcm, 3,326-4,049 lbfft} SHTS011060300009...
Page 118: Air Flow Sensor
AIR INTAKE SYSTEM (J08E) EN03–9 AIR FLOW SENSOR COMPONENT LOCATOR EN0110603D100005 SHTS011060300011 Air flow sensor Clamp Air cleaner Dust indicator Air hose Tightening torque Unit: Nm {kgfcm, lbfft} 1.17-1.77 {12-17, 0.9-1.3}...
Page 119: Replacement
EN03–10 AIR INTAKE SYSTEM (J08E) REPLACEMENT EN0110603H300001 REMOVE THE AIR FLOW SENSOR. Disconnect the connector of the air flow sensor. Air flow sensor Remove a bolt to remove the air flow sensor. SHTS011060300012 ISNTALL THE AIR FLOW SENSOR. Install the air flow sensor, and tighten a bolt. Air flow sensor Tightening Torque: 1.17-1.77 Nm {12-18 kgfcm, 0.9-1.3 lbfft}...
Page 120: Boost Pressure Sensor
AIR INTAKE SYSTEM (J08E) EN03–11 BOOST PRESSURE SENSOR COMPONENT LOCATOR EN0110603D100006 SHTS011060300014 Boost pressure sensor Intake manifold Intake pipe Intake manifold gasket Tightening torque Unit: Nm {kgfcm, lbfft} 10 {102, 7.3}...
Page 121: Replacement
EN03–12 AIR INTAKE SYSTEM (J08E) REPLACEMENT EN0110603H300002 REMOVE THE BOOST PRESSURE SENSOR. Disconnect the connector of the boost pressure sensor. Remove two clamps to remove the hose from the boost pressure sen- sor. Remove two bolts to remove the boost pressure sensor from the intake pipe.
Page 122 EXHAUST SYSTEM (J08E) EN04–1 E XHAUST SYSTEM (J08E) E N 0 4 EN04-001 EXHAUST MANIFOLD AND PIPE.... EN04-2 COMPONENT LOCATOR........ EN04-2 DISMOUNTING AND MOUNTING ....EN04-3 EXHAUST PIPE AND MUFFLER UNIT ..EN04-4 DESCRIPTION ..........EN04-4 COMPONENT LOCATOR........ EN04-5 OVERHAUL ........... EN04-11 DPR (DIESEL PARTICULATE REDUCTION SYSTEM) ......
Page 123: Exhaust Manifold And Pipe
EN04–2 EXHAUST SYSTEM (J08E) EXHAUST MANIFOLD AND PIPE COMPONENT LOCATOR EN0110604D100001 SAPH011060400001 Exhaust manifold sub assembly Heat insulator Gasket Spacer Bracket Tightening torque Unit: Nm {kgfcm, lbfft} 65 {660, 48}...
Page 124: Dismounting And Mounting
EXHAUST SYSTEM (J08E) EN04–3 DISMOUNTING AND MOUNTING EN0110604H100001 IMPORTANT POINT - MOUNTING INSTALL THE EXHAUST MANIFOLD GASKET. NOTICE Since the exhaust manifold gasket must be installed in one way, install the gasket with the black side facing toward the exhaust mani- fold.
Page 125: Exhaust Pipe And Muffler Unit
EN04–4 EXHAUST SYSTEM (J08E) EXHAUST PIPE AND MUFFLER UNIT DESCRIPTION EN0110604H200001 (Example) SAPH011060400004 Exhaust pipe Muffler unit with burner Exhaust control cylinder (Exhaust brake) Tail pipe Bracket Bracket sub assembly...
Page 126: Component Locator
EXHAUST SYSTEM (J08E) EN04–5 COMPONENT LOCATOR EN0110604D100002 EXHAUST PIPE SAPH011060400005 Exhaust pipe No.1 Gasket Exhaust pipe No.2 Exhaust control cylinder (Exhaust brake) Gasket Bracket Tightening torque Unit: Nm {kgfcm, lbfft} 56-84 {571-856, 42-62} 41-61 {418-622, 30-45} 49-61 {500-622, 36-50}...
Page 127 EN04–6 EXHAUST SYSTEM (J08E) MUFFLER UNIT SAPH011060400006 Combustion chamber Outlet chamber sub assembly Gasket Flange Particulate filter assembly Support (Front) Chamber sub assembly (Rear) Support (Rear) Gasket Bracket (Front) Chamber sub assembly (Front) Bracket (Rear) Monolithic converter assembly Pipe sub assembly Tightening torque Unit: Nm {kgfcm, lbfft} 64 {653, 47}...
Page 128 EXHAUST SYSTEM (J08E) EN04–7 MUFFLER SUPPORT SAPH011060400007 Support sub assembly (Front) Insulator Support sub assembly (Rear) Clamp sub assembly Support sub assembly (Front, lower) Lifting clamp Support sub assembly (Rear, lower) Muffler unit Bracket Protector Tightening torque Unit: Nm {kgfcm, lbfft} 80-120 {816-1,223, 59-88} 69-103 {704-1,050, 51-76} 34-44 {347-448, 25-32}...
Page 129 EN04–8 EXHAUST SYSTEM (J08E) TAIL PIPE (SHORT TAIL TYPE) SAPH011060400008 Tail pipe Muffler unit Tightening torque Unit: Nm {kgfcm, lbfft} 108-132 {1,101-1,346, 80-97}...
Page 130 EXHAUST SYSTEM (J08E) EN04–9 TAIL PIPE (STACK TYPE) SAPH011060400009...
Page 131 EN04–10 EXHAUST SYSTEM (J08E) Bracket sub assembly Clamp * Exhaust pipe bracket Exhaust flexible pipe Bracket Muffler unit Tail pipe sub assembly Clamp * Tail pipe sub assembly Clamp Tail pipe U-bolt Insulator *: Nonreusable. Be sure to use new parts. Tightening torque Unit: Nm {kgfcm, lbfft} 104-126 {1,060-1,284, 77-92}...
Page 132: Overhaul
EXHAUST SYSTEM (J08E) EN04–11 OVERHAUL EN0110604H200002 IMPORTANT POINT - DISMOUNTING ! WARNING Do not touch the exhaust manifold when it could be hot. You can be severely burned. DISMOUNTING Disconnect the battery ground terminal. ! CAUTION Be sure to disconnect the battery terminals from the battery in accor- dance with the procedures in this manual and never use the battery disconnect switch when it is necessary to break the supply of electric- ity completely.
Page 133 EN04–12 EXHAUST SYSTEM (J08E) Disconnect the DPR filter front/rear exhaust gas temperature sensor (Example) Connector connector. Exhaust gas temperature sensor SAPH011060400013 Disconnect the combustion chamber exhaust gas temperature sensor connector. Exhaust gas temperature sensor Connector SAPH011060400014 Remove the front ignition cable of the combustion chamber. Ignition cable SAPH011060400015 Remove the front atomized fuel pipe of the combustion chamber.
Page 134 EXHAUST SYSTEM (J08E) EN04–13 Disconnect the burner flame temperature sensor connector. Burner flame Connector temperature sensor SAPH011060400017 (10) Remove the burner burning air hose. NOTICE Swivel • When removing, be sure to remove the swivel on the vehicle upper side. •...
Page 135 EN04–14 EXHAUST SYSTEM (J08E) (13) Remove the DEF hose connecting to the injector. NOTICE After removal, do not allow foreign objects to get into the pipe. Clip HINT Remove it by pushing inward the 2 white knobs of the connector. Connector SAPH011060400021 (14) Remove the clamp of the harness connecting to the injector and the...
Page 136 EXHAUST SYSTEM (J08E) EN04–15 (16) Disconnect the NOx sensor 1 connector and remove the NOx sensor Harness controller. connector NOx sensor controller SAPH011060400024 (17) Disconnect the NOx sensor 2 connector and remove the NOx sensor controller. Connector NOx sensor controller SAPH011060400025 (18) Remove the differential pressure hose.
Page 137 EN04–16 EXHAUST SYSTEM (J08E) (19) Remove the muffler unit mounting bolts or nuts (4 pcs each in the top Bolt and inside the vehicle) and then the muffler unit. NOTICE Do not apply heavy load or impact to the muffler unit when mounting and dismounting.
Page 138 EXHAUST SYSTEM (J08E) EN04–17 IMPORTANT POINT -MOUNTING MOUNTING Mount the muffler unit with bolts or nuts. Bolt NOTICE Do not apply heavy load or impact to the muffler unit when mounting and dismounting. Muffler unit SAPH011060400029 Mount the tail pipe. Tail pipe SAPH011060400030 Connect the combustion chamber and the exhaust pipe.
Page 139 EN04–18 EXHAUST SYSTEM (J08E) Install the differential pressure hose. Difference pressure hose SAPH011060400033 NOTICE Assemble without crossing hoses. Correct Incorrect SAPH011060400034 Install the NOx sensor 2 and connect the harness connector. Harness connector Tightening Torque: 3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft} NOx sensor controller SAPH011060400035...
Page 140 EXHAUST SYSTEM (J08E) EN04–19 Connect the DOC rear exhaust gas temperature sensor connector and install the clip. Connector Clip SAPH011060400037 Install the clamp of the harness connecting to the injector and the injector connector. Clamp Connector SAPH011060400038 Install the DEF hose connecting to the injector. NOTICE Before reassembling, wash away crystallized DEF on the connector Clip...
Page 141 EN04–20 EXHAUST SYSTEM (J08E) (11) Connect the harness connector. Harness connector SAPH011060400041 (12) Install the burner burning air hose. Swivel NOTICE • When tightening, fix the hexagonal part under the swivel with the wrench. • Before reassembling, remove the combustion air valves (✩ 2 places) without bending the hose so that the valves will be free.
Page 142 EXHAUST SYSTEM (J08E) EN04–21 (15) Install the front ignition cable of the combustion chamber. Ignition cable SAPH011060400044 (16) Connect the combustion chamber exhaust gas temperature sensor connector. Exhaust gas temperature Connector sensor SAPH011060400045 (17) Connect the DPR filter front/rear exhaust gas temperature sensor (Example) Connector connector.
Page 143: Dpr (Diesel Particulate Reduction System)
EN04–22 EXHAUST SYSTEM (J08E) DPR (DIESEL PARTICULATE REDUCTION SYSTEM) SYSTEM CONFIGURATION EN0110604D100003 SAPH011060400048 Engine Differential pressure sensor Engine ECU DPR-manual regeneration switch Exhaust pipe DPR indicator light Exhaust control valve Check engine light Catalyst coated filter Burner control unit Oxidation catalyst Combustion chamber...
Page 144: Structure Of Dpr-Cleaner
EXHAUST SYSTEM (J08E) EN04–23 STRUCTURE OF DPR-CLEANER EN0110604D100004 SAPH011060400049 Combustion chamber Chamber sub assembly (Front) Gasket Monolithic converter assembly Particulate filter assembly Outlet chamber sub assembly Chamber sub assembly (Rear) Flange Gasket...
Page 145: Dpr Maintenance
EN04–24 EXHAUST SYSTEM (J08E) DPR MAINTENANCE EN0110604H200003 • If "DPR maintenance" is displayed on the information display, DPR maintenance is required. Check the DPR backpressure and determine whether maintenance is required. If the DPR backpressure value is below the specified value, no main- tenance is required.
Page 146: Inspection Procedure Followed When "Dpr Maintenance" Is Displayed On The Information Display
EXHAUST SYSTEM (J08E) EN04–25 INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY EN0110604H300001 NORMAL TRAVELING DPR MAINTENANCE DISPLAY RECEIVING THE VEHICLE FOR SAFETY CHECK CONNECT HINO DX <Checking a fault code against HINO-DX> PAST FAULT CHECK 1.
Page 147: Inspection By Way Of Hino-Dx
EN04–26 EXHAUST SYSTEM (J08E) INSPECTION BY WAY OF HINO-DX EN0110604H200005 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. Then "Manual forced regeneration"...
Page 148 EXHAUST SYSTEM (J08E) EN04–27 Forced regeneration Forced regeneration is done by the "Manual forced regeneration" screen. ! CAUTION • Confirm safety of the surrounding area, then press DPR regener- ation switch inside the cabin to execute the regeneration. • Confirm the PTO switch is OFF. When the "Regeneration switch ON identification"...
Page 149 EN04–28 EXHAUST SYSTEM (J08E) DPR differential pressure check Check the DPR differential pressure through the "DPR Status" dis- play. Confirm the exhaust gas temperature (in and out) is less than 200C {392F}. Engine speed will rise automatically, then record the indicated maxi- mum DPR differential pressure.
Page 150 EXHAUST SYSTEM (J08E) EN04–29 SAPH011060400054...
Page 151: Inspection Procedure Followed When Check Engine Light Illuminates (Abnormal)
EN04–30 EXHAUST SYSTEM (J08E) INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL) EN0110604H300002 NORMAL TRAVELING CHECK ENGINE LIGHTS 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 INSPECTION in exhaust control system)
Page 152 EXHAUST SYSTEM (J08E) EN04–31 *1 Additional information for inspections with HINO-DX Light cases of DPR clogging can be treated without removing the housing. The procedure is shown below. The "DPR STATUS" can be checked with the HINO-DX, and when only the "DPR clogged warning level flag" is "ON", regener- ation processing can be performed with the DPR SW or the tool.
Page 153 Use a washing machine from a manufacturer recommended by Hino Motors. Perform cleaning with correct installation of the attachment for DPR filters made by Hino Motors. In the following instances the filter cannot be cleaned. In these cases, the filter must be replaced.
Page 154: Determination By Way Of Dpr State
EXHAUST SYSTEM (J08E) EN04–33 DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX EN0110604H200006 CHECK THAT THE CHECK ENGINE LIGHT 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.
Page 155: Replacement Of Dpr Filter
EN04–34 EXHAUST SYSTEM (J08E) REPLACEMENT OF DPR FILTER EN0110604H200008 ! WARNING Do not touch the muffler unit when it could be hot. You can be severely burned. REMOVE THE DPR FILTER. Remove the bolts and nuts on the flanges on the exhaust pipe. SAPH011060400056 Remove the front atomized fuel pipe of the combustion chamber.
Page 156 EXHAUST SYSTEM (J08E) EN04–35 Dismount the pipe between the combustion chamber and the differen- tial pressure sensor. Pipe to differential Combustion pressure sensor chamber SAPH011060400060 Remove the lifting clamp. Remove the fastening bolt secured to the DPR filter and then the com- bustion chamber.
Page 157 EN04–36 EXHAUST SYSTEM (J08E) Install the lower side of the lifting clamp. NOTICE When installing the lower side of the lifting clamp, do not forget to place the spacer. Spacer Lifting clamp (Down side) SAPH011060400063 Install the pipe between the combustion chamber and the differential pressure sensor.
Page 158 EXHAUST SYSTEM (J08E) EN04–37 Install the front atomized fuel pipe of the combustion chamber. Fuel pipe SAPH011060400067 Install the exhaust pipe to the flanges on the exhaust brake side and the combustion chamber side. SAPH011060400068...
Page 159: Overall Operation Flow
EN04–38 EXHAUST SYSTEM (J08E) OVERALL OPERATION FLOW EN0110604H100002 VEHICLE RECEIPT FOR INSPECTION Check the malfunction code with the Hino-DX. Standard value: No malfunction code SAPH011060400069 • 4. For P141F, P200C, P244B, P244A, P2459, P2463 • 5. For others than above 2.
Page 160 EXHAUST SYSTEM (J08E) EN04–39 INSPECT THE DPR FILTER. Dismount the DPR filter from the vehicle. Refer to "1. REMOVE THE DPR FILTER" on page EN04-34. Inspect the status of the DPR filter rear surface. Refer to "INSPECT INSIDE THE DPR FILTER" on page EN04-42. Standard value: No soot escape SAPH011060400071 Replace with a new DPR filter and install it on the...
Page 161 EN04–40 EXHAUST SYSTEM (J08E) IN CASE THAT DPR AND BURNER DTC CODE IS DISPLAYED Dismount the DPR filter from the vehicle. Refer to "1. REMOVE THE DPR FILTER" on page EN04-34. Inspect the status of the DPR filter rear surface. Refer to "INSPECT INSIDE THE DPR FILTER"...
Page 162 EXHAUST SYSTEM (J08E) EN04–41 FOR OTHERS THAN DPR AND BURNER DTC CODE IS DIS- PLAYED Check the engine body and repair or replace defective parts if any. Dismount the DPR filter from the vehicle. Refer to "1. REMOVE THE DPR FILTER" on page EN04-34. Inspect the status of the DPR filter rear surface.
Page 163 EN04–42 EXHAUST SYSTEM (J08E) INSPECT INSIDE THE DPR FILTER. HINT This is for detecting abnormalities inside the DPR filter. VISUALLY INSPECT THE FILER REAR SURFACE. Visually inspect the filter rear surface to detect soot escapes (black part). Standard value: No soot escape Oxidation Catalyst coated catalyst...
Page 164 EXHAUST SYSTEM (J08E) EN04–43 VISUALLY INSPECT THE CASE EDGE. Visually inspect the case edge to detect soot escapes (black part). Oxidation Catalyst coated catalyst filter SCR catalyst Combustion chamber Ammonia slip DEF SCR catalyst catalyst SAPH011060400074 Standard value: No soot escape 3.
Page 165 EN04–44 EXHAUST SYSTEM (J08E) INSPECT THE DPR FILTER WITH THE DEDICATED CHECK PROBE. Insert the check probe from the rear surface to inspect the inside. SST: FILTER GAGE ASSEMBLY (09992-E4010) Tighten a screw Align the tip to the Piano wire and am fixed center of the marking.
Page 166 EXHAUST SYSTEM (J08E) EN04–45 AIR CLEANING FLOW (SOOT CLEANING) SOOT SUCTION SOOT AIR BLOW DISPOSE OF THE WASTE AND THE POWDER AS INDUSTRIAL WASTES. SAPH011060400076...
Page 167: Differential Pressure Sensor
EN04–46 EXHAUST SYSTEM (J08E) DIFFERENTIAL PRESSURE SENSOR COMPONENT LOCATOR EN0110604D100005 SAPH011060400077 Differential pressure sensor Muffler unit Hose Tightening torque Unit: Nm {kgfcm, lbfft} 18-26 {183-265, 13-19}...
Page 168: Dismounting And Mounting
EXHAUST SYSTEM (J08E) EN04–47 DISMOUNTING AND MOUNTING EN0110604H100003 REMOVAL OF THE DIFFERENTIAL PRESSURE SEN- REMOVE THE HARNESS. Disconnect the connector attached to the differential pressure sensor. Differential Connector pressure sensor SAPH011060400078 DISCONNECT THE HOSE. Differential Remove the clamps and disconnect the hose from the differential pressure sensor pressure sensor.
Page 169 EN04–48 EXHAUST SYSTEM (J08E) UNIT CHECK RESISTANCE CHECK Measure the resistance of the differential pressure sensor with a cir- cuit tester. If the value exceeds the standard value, replace it. Measurement item Standard value (k) A  B B  C Differential Pressure sensor SAPH011060400081...
Page 170 EXHAUST SYSTEM (J08E) EN04–49 CONNECT THE HOSE. Install the hose to the differential pressure sensor with clamps (4 pcs). Differential pressure sensor NOTICE If the differential pressure sensor hose is inserted incorrectly, the Clamp DPR will not operate properly. Hose Clamp SAPH011060400083 ! CAUTION...
Page 171: Exhaust Control Cylinder
EN04–50 EXHAUST SYSTEM (J08E) EXHAUST CONTROL CYLINDER SYSTEM CONFIGURATION EN0110604D100006 SAPH011060400086 ABS exhaust cut relay Accelerator sensor Exhaust relay Engine ECU Magnetic valve Combination meter ECU Exhaust control cylinder (Exhaust brake) Exhaust brake light Air tank Exhaust brake switch Exhaust pipe To actuator power relay Butterfly valve To ABS ECU...
Page 172: Dpr Inspection Check Sheet
EXHAUST SYSTEM (J08E) EN04–51 DPR INSPECTION CHECK SHEET EN0110604D100007 HINT After the inspection, enter check marks into the empty check boxes. Step Inspection Fuel tank, Filter Air intake system parts Engine ECM VNT turbocharger part  Dirty or clogged fuel fil- ...
Page 173 EN04–52 EXHAUST SYSTEM (J08E) EN0110604D100008 HINT After the inspection, enter check marks into the empty check boxes. EGR valve Supply pump, Injector Fuel injection quantity Manual regeneration  Following characteristic at  Stability of the pump elec-  Injection quantity *To be performed with all the time of inspection (Error trical current value...
Page 174 EXHAUST SYSTEM (J08E) EN04–53 Injection quantity and engine speed standard value table (value with all auxiliary equipment loads off) Speed (rpm) Idling (normal) Injection quantity (q) 7 - 16 At the time of manual regeneration Speed (rpm) (guide value) Speed (rpm) 2,800 Backpressure standard Backpressure (kPa {kgf/cm...
Page 175 LUBRICATING SYSTEM (J08E) EN05–1 L UBRICATING SYSTEM (J08E) E N 0 5 EN05-001 LUBRICATING SYSTEM ......EN05-2 DIAGRAM ............EN05-2 OIL PUMP AND OIL STRAINER ....EN05-4 COMPONENT LOCATOR........ EN05-4 OVERHAUL ............. EN05-5 INSPECTION AND REPAIR ......EN05-6 OIL FILTER AND OIL COOLER ....EN05-8 COMPONENT LOCATOR........
Page 176: Lubricating System
EN05–2 LUBRICATING SYSTEM (J08E) LUBRICATING SYSTEM DIAGRAM EN0110605J100001 SHTS011060500001...
Page 177 LUBRICATING SYSTEM (J08E) EN05–3 Unit: kPa {kgf/cm , lbf/in. Oil pan Piston Oil strainer Valve rocker shaft Oil pump Camshaft Oil pump safety valve Valve 1,648-1,746 {16.8-17.8, 239-253} Rocker arm Oil cooler and oil filter Cross head Oil cooler safety valve Supply pump 352-432 {3.6-4.4, 52-62} Air compressor...
Page 178: Oil Pump And Oil Strainer
EN05–4 LUBRICATING SYSTEM (J08E) OIL PUMP AND OIL STRAINER COMPONENT LOCATOR EN0110605D100001 SHTS011060500002 Gasket Safety valve Oil pump Relief spring Driven gear Spring seat Oil strainer Cotter pin O-ring Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21} 30 {306, 22}...
Page 179: Overhaul
LUBRICATING SYSTEM (J08E) EN05–5 OVERHAUL EN0110605H200001 IMPORTANT POINTS - ASSEMBLY INSTALLING THE OIL PUMP. Apply oil to the pump case and bearings of the block (hatched area) before installing the oil pump. NOTICE Not applying oil may cause oil suction failure at start-up, resulting in seizure and abnormality.
Page 180: Inspection And Repair
EN05–6 LUBRICATING SYSTEM (J08E) INSPECTION AND REPAIR EN0110605H300001 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Gear outside diameter 54 {2.126} — — Measure Block side pump body 54 {2.126} — — inside diameter 0.093-0.252 Tip clearance 0.30 {0.0118} Replace oil pump.
Page 181 LUBRICATING SYSTEM (J08E) EN05–7 Inspection item Standard Limit Remedy Inspection procedure Measure 0.073-0.207 Gear backlash 0.30 {0.0118} Replace pump. {0.0029-0.0082}...
Page 182: Oil Filter And Oil Cooler
EN05–8 LUBRICATING SYSTEM (J08E) OIL FILTER AND OIL COOLER COMPONENT LOCATOR EN0110605D100002 11-M 10-L SHTS011060500009...
Page 183: Special Tool
LUBRICATING SYSTEM (J08E) EN05–9 Oil cooler with filter assembly Oil filter safety valve O-ring Check valve Oil cooler element Oil cooler safety valve Gasket Oil filter element Oil cooler case Insert Regulator valve Tightening torque Unit: Nm {kgfcm, lbfft} 29.4-39.2 {300-400, 22-28} 29.4-39.2 {300-400, 22-28} 24.5-34.3 {250-350, 19-25} 19.6-29.4 {200-300, 15-21}...
Page 184: Dismounting And Mounting
EN05–10 LUBRICATING SYSTEM (J08E) DISMOUNTING AND MOUNTING EN0110605H200002 IMPORTANT POINTS - DISMOUNTING REMOVE THE OIL FILTER. Remove the drain plug from bottom of the oil filter and drain the engine oil. Drain plug SHTS011060500011 Using the special tool, remove the oil filter. SST: Oil filter wrench (S0950-31110) NOTICE Make sure that O-rings are not on the oil cooler case side.
Page 185: Inspection And Repair
LUBRICATING SYSTEM (J08E) EN05–11 INSTALL THE OIL COOLER AND OIL FILTER ASSEMBLY. Insert the O-ring into the O-ring groove of the oil cooler. NOTICE Face the flat area of the O-ring toward the oil cooler for installation. Apply liquid gasket to the oil cooler case and install it onto the cylinder block, then tighten the bolt to the specified torque.
Page 186 COOLING SYSTEM (J08E) EN06–1 C OOLING SYSTEM (J08E) E N 0 6 EN06-001 COOLING SYSTEM ........EN06-2 DIAGRAM ............EN06-2 COOLANT PUMP........EN06-3 COMPONENT LOCATOR........ EN06-3 THERMOSTAT .......... EN06-4 COMPONENT LOCATOR........ EN06-4 OVERHAUL ............. EN06-5 RADIATOR AND INTERCOOLER .... EN06-7 COMPONENT LOCATOR........
Page 187: Cooling System
EN06–2 COOLING SYSTEM (J08E) COOLING SYSTEM DIAGRAM EN0110606J100001 For cooling engine For cooling Auxiliary units Air bleeding SHTS011060600001 Reservoir tank Coolant pump Radiator cap EGR cooler Radiator Cylinder head Coolant temperature gauge Cylinder block Thermostat case cover (Outlet) Oil cooler Thermostat case Drain plug Thermostat...
Page 188: Coolant Pump
COOLING SYSTEM (J08E) EN06–3 COOLANT PUMP COMPONENT LOCATOR EN0110606D100001 SHTS011060600002 Coolant pump assembly O-ring Pulley...
Page 189: Thermostat
EN06–4 COOLING SYSTEM (J08E) THERMOSTAT COMPONENT LOCATOR EN0110606D100002 SHTS011060600003 Thermostat case Water inlet Water outlet O-ring Thermostat...
Page 190: Overhaul
COOLING SYSTEM (J08E) EN06–5 OVERHAUL EN0110606H200001 IMPORTANT POINTS - INSPECTION AND REPAIR INSPECT THE THERMOSTAT FUNCTION. Place the thermostat in hot water and check the valve opening tem- perature and the valve lift. Thermostat valve opening temperature: Thermostat valve opening tem- Service standard perature.
Page 191 EN06–6 COOLING SYSTEM (J08E) IMPORTANT POINTS - MOUNTING INSTALL THE THERMOSTAT CASE ASSEMBLY. Apply liquid gasket to the thermostat case. Liquid gasket Install the o-ring into the groove of the coolant pump. SHTS011060600007 Temporarily tighten the bolts "1" and bolts "2" in that order, and securely contact the fitting surface.
Page 192: Radiator And Intercooler
COOLING SYSTEM (J08E) EN06–7 RADIATOR AND INTERCOOLER COMPONENT LOCATOR EN0110606D100003 SHTS011060600009 Radiator Inter cooler Inlet hose Radiator stay, RH Reservoir tank Radiator stay, LH Hose Baffle plate Outlet hose OVERHAUL EN0110606H200002 IMPORTANT POINTS - DISMOUNTING DISMOUNT THE RADIATOR. ! WARNING Do not drain the coolant while the engine and radiator are still hot to avoid burns and scalds.
Page 193 EN06–8 COOLING SYSTEM (J08E) IMPORTANT POINTS - MOUNTING INSTALL THE RADIATOR INLET HOSE. NOTICE • Install the radiator hose against the convex portion of the radia- tor. • Match the red mark of the radiator hose and match mark (convex portion) of the radiator.
Page 194: Radiator
COOLING SYSTEM (J08E) EN06–9 RADIATOR COMPONENT LOCATOR EN0110606D100004 SHTS011060600012 Radiator assy Sensor Intercooler assy Packing Fan shroud Drain plug Radiator cap Seal Bracket...
Page 195: Special Tool
EN06–10 COOLING SYSTEM (J08E) SPECIAL TOOL EN0110606K100001 Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration Part number Tool name Remarks S0976-01030 RADIATOR TOOL TOOL FOR UNCAULKING TOOL FOR CAULKING S0976-01040 RADIATOR TOOL (USED WITH S0976-01030) OVERHAUL EN0110606H200003 IMPORTANT POINTS - DISMOUNTING...
Page 196 COOLING SYSTEM (J08E) EN06–11 Grip the handle until it hits to the stopper bolt, then adjust the dimen- sions A with stopper bolt. Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.} SST: Radiator tool (S0976-01030) NOTICE Be sure to adjust the dimension to prevent damage of the claw. SHTS011060600016 Using a special tool, lift the staked part.
Page 197 EN06–12 COOLING SYSTEM (J08E) Grip the handle of the radiator tool until it hits the stopper bolt, then adjust the dimension B with stopper bolt. Dimension B: 9.5mm {0.374 in.} SHTS011060600020 Install the new O-ring into the groove of the radiator core (upper and lower) in such away that it will not be twisted.
Page 198 COOLING SYSTEM (J08E) EN06–13 NOTICE Perform the caulking according to the sequence as shown in the fig- ure. SHTS011060600024 Check the dimension C. Assembly standard: 8.2-8.8 mm {0.323-0.346 in.} If the dimension is out of the standard value, adjust the stopper bolt of the handle once again and perform the caulking again.
Page 199: Inspection And Repair
EN06–14 COOLING SYSTEM (J08E) INSPECTION AND REPAIR EN0110606H300001 Unit: MPa {kgf/cm , lbf/in. Inspection item Standard Limit Remedy Inspection procedure Air leakage (When the air Visual check pressure of 100 {1,14} is — — Replace radiator. applied.) Clogging of the fins —...
Page 200: Cooling Fan
COOLING SYSTEM (J08E) EN06–15 COOLING FAN COMPONENT LOCATOR EN0110606D100005 SHTS011060600029 Cooling fan Seal Fan clutch Bracket Fan shroud NOTICE • Shock to the fan clutch and fan. During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting damage may lower the performance of the fan.
Page 201: Inspection And Repair
EN06–16 COOLING SYSTEM (J08E) INSPECTION AND REPAIR EN0110606H300002 Inspection item Standard Limit Remedy Inspection procedure Visual check Cooling fan and fan clutch Replace if neces- — — deformation and damage sary.
Page 202 FUEL SYSTEM (J08E) EN07–1 F UEL SYSTEM (J08E) E N 0 7 EN07-001 FUEL SYSTEM.......... EN07-2 DIAGRAM ............EN07-2 COMPONENT LOCATOR........ EN07-3 SUPPLY PUMP ......... EN07-4 DESCRIPTION ..........EN07-4 COMPONENT LOCATOR........ EN07-5 SPECIAL TOOL ..........EN07-5 OVERHAUL ............. EN07-6 COMMON RAIL........EN07-15 DESCRIPTION ..........
Page 203: Fuel System
EN07–2 FUEL SYSTEM (J08E) FUEL SYSTEM DIAGRAM EN0110607J100001 SAPH011060700001 Injector Fuel filter Injection pipe Fuel tank Flow damper Through feed pipe Common rail Overflow pipe Pressure feeding pipe Leakage pipe Pressure limiter Bubble separator Supply pump...
Page 204: Component Locator
FUEL SYSTEM (J08E) EN07–3 COMPONENT LOCATOR EN0110607C100001 SAPH011060700002 Injector Common rail Supply pump Bubble separator Tightening torque Unit: Nm {kgfcm, lbfft} 12.3 {126, 9} 25 {250, 18} 44 {450, 32.5}...
Page 205: Supply Pump
EN07–4 FUEL SYSTEM (J08E) SUPPLY PUMP DESCRIPTION EN0110607J100002 SAPH011060700003 Supply pump assembly...
Page 206: Component Locator
FUEL SYSTEM (J08E) EN07–5 COMPONENT LOCATOR EN0110607C100002 SAPH011060700004 Supply pump assembly Bracket Bearing holder case Coupling assembly O-ring Plug Coupling flange Tightening torque Unit: Nm {kgfcm, lbfft} 63.7 {650, 47} 28.5 {290, 21} 28.5 {290, 21} SPECIAL TOOL EN0110607K100001 Prior to starting an engine overhaul, it is necessary to have this special tool. Illustration Part number Tool name...
Page 207: Overhaul
EN07–6 FUEL SYSTEM (J08E) OVERHAUL EN0110607H200001 IMPORTANT POINTS - DISMOUNTING ! CAUTION While working, be careful not to make dirt and water enter parts. TURN THE STARTER SWITCH TO THE LOCK POSITION. ! WARNING Perform the following work after the engine cools off to avoid fire or burning.
Page 208 FUEL SYSTEM (J08E) EN07–7 REMOVING THE FUEL PIPE Unfasten the nuts (2 pcs.) to remove the clips (2 pcs.). Unfasten the union bolts (3 pcs.) securing return pipe No.1 to the pressure limiter, the inlet manifold, and the supply pump, and discon- nect the return pipe No.1.
Page 209 EN07–8 FUEL SYSTEM (J08E) Remove the timing check window plug from the bearing holder case Bearing holder case of the supply pump. Mount the special tool specified below to the timing check window of Seated the bearing holder case to see that the bearing surface of the special tool is seated on the supply pump.
Page 210 FUEL SYSTEM (J08E) EN07–9 Unfasten the bolts (4 pcs.) securing the supply pump, and remove the Coupling Bearing holder case supply pump, the coupling, and the O-ring from the air compressor. Bolt ! CAUTION Remove the supply pump and the bearing holder case together. Supply pump O-ring Air compressor...
Page 211 EN07–10 FUEL SYSTEM (J08E) INSPECTING THE RESISTANCE OF THE SUCTION CONTROL VALVE Using a circuit tester, measure the resistance between the terminals. Suction control valve If the measured value is in excess of the standard value, replace the supply pump. Standard value 1.6-2.6 ...
Page 212 FUEL SYSTEM (J08E) EN07–11 ADJUSTING THE TOP OF THE AIR COMPRESSOR Align the cast mark on the air compressor with the "" mark put on the front face of the coupling. " " mark is put on the front face of the coupling.
Page 213 EN07–12 FUEL SYSTEM (J08E) Replace with a new O-ring, and mount the coupling and the supply Coupling Bearing holder case pump to the air compressor using the bolts (4 pcs.). Bolt Tightening Torque: 28.5 Nm {290 kgfcm, 21 lbfft} ! CAUTION Mount the coupling and the supply pump to the air compressor with the No.1 cylinder set at the compression stroke top dead center and Supply pump...
Page 214 FUEL SYSTEM (J08E) EN07–13 MOUNTING THE FUEL PIPE Replace the gasket with a new one, and mount return pipe No.1 on the supply pump, the inlet manifold, and the pressure limiter with the union bolts (3 pcs.) that secured the return pipe. Tightening torque: (Supply pump side) Return pipe No.1...
Page 215 EN07–14 FUEL SYSTEM (J08E) MOUNTING THE INTAKE PIPE Mount the intake pipe. Refer to the chapter "AIR INTAKE SYSTEM" MOUNTING THE FUEL FILTER CASE Mount the fuel filter case and the fuel pipe. Refer to the chapter "AIR INTAKE SYSTEM" AIR BLEEDING OF FUEL SYSTEM Air bleeding.
Page 216: Common Rail
FUEL SYSTEM (J08E) EN07–15 COMMON RAIL DESCRIPTION EN0110607J100003 SAPH011060700034 Common rail Flow damper Pressure limiter Pressure sensor INSPECTION EN0110607H200002 INSPECTING THE COMMON RAIL 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".
Page 217 EN07–16 FUEL SYSTEM (J08E) INSPECTING THE PRESSURE LIMITER Unfasten the union bolt securing the pressure limiter. Stop the return pipe No.1 side with Stop the return pipe No.1 side with a blank cap to prevent the outflow a blank cap. of fuel.
Page 218: Replacement
FUEL SYSTEM (J08E) EN07–17 REPLACEMENT EN0110607H200003 REMOVING THE COMMON RAIL ! CAUTION • While working, be careful not to make dirt and water enter parts. • Clean off surrounding area of the nozzle and the fuel line con- nectors. DISCONNECTING THE HARNESS Disconnect the connector connected to the common rail pressure sensor.
Page 219 EN07–18 FUEL SYSTEM (J08E) 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. Common rail pressure sensor ! CAUTION • Protect with clean vinyl to avoid entry of dirt into the common rail.
Page 220 FUEL SYSTEM (J08E) EN07–19 Tighten the injection pipe nuts to the specified torque. Tightening Torque: 44 Nm {450 kgfcm, 32.5 lbfft} ! CAUTION • While working, be careful not to make dirt and water enter parts. • Before mounting a part, check that there is no dirt on the con- nection between the parts.
Page 221 EN07–20 FUEL SYSTEM (J08E) NOTICE • If the tightening torque of the nuts is less than the specified value, it may cause a fuel leak. If the tightening torque of the nuts is greater than the specified value it may have a negative influ- ence on the engine function.
Page 222: Injector
FUEL SYSTEM (J08E) EN07–21 INJECTOR DESCRIPTION EN0110607C100003 SAPH011060700047 Return joint bolt Injector assembly Gasket...
Page 223: Replacement
EN07–22 FUEL SYSTEM (J08E) REPLACEMENT EN0110607H200004 REMOVING THE INJECTOR ! CAUTION • While working, be careful not to make dirt and water enter parts. • Clean off surrounding area of the nozzle and the fuel line con- nectors. REMOVING THE HEAD COVER Remove the head cover.
Page 224 FUEL SYSTEM (J08E) EN07–23 REMOVING THE INJECTION PIPE Unfasten the nuts (6 pcs.) securing the clips, and remove the clips. SAPH011060700045 Loosen the nuts securing the injection pipes (6 pcs.) to remove them from the injector and the common rail. ! CAUTION Do not reuse the injection pipes.
Page 225 EN07–24 FUEL SYSTEM (J08E) INSPECTION INSPECTING THE RESISTANCE Megohmmeter Using a 1,000V megohmmeter, measure the insulation resistance between either of the 2 terminals (no polarity) to which the injector harness is connected and the upper body of the injector. Upper body ! CAUTION Never measure between the terminals, or the injector will be dam- aged.
Page 226 FUEL SYSTEM (J08E) EN07–25 MOUNTING THE INJECTOR ! 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 fil- ter case.
Page 227 EN07–26 FUEL SYSTEM (J08E) • Arrange the injector and the injection pipes in a straight line. Injection pipe Injector clamp Injector SAPH011060700057 NOTICE Mount the injection pipes so that the flare tightening nuts of the injec- tion pipes will be arranged in the order of the numbers engraved on the nuts shown in the figure below.
Page 228 FUEL SYSTEM (J08E) EN07–27 Mount the clips with the nuts (6 pcs.), and fix the injection pipes. SAPH011060700045 WRITING A INJECTOR COMPENSATION VALUE TO THE ENGINE ECU (WRITING BY MEANS OF RE-PROGRAMMING) QR code ! CAUTION • If an injector is replaced, write an injector compensation value (QR code) indicated on a new injector in the engine ECU.
Page 229 EN07–28 FUEL SYSTEM (J08E) MOUNTING THE INJECTOR HARNESS Mount the injector harness together with the injector bracket with the Connector bolts (7 pcs.) that secured them. Injector harness Connect each connector of the injector harness. bracket ! CAUTION Before connecting the connectors, make sure that the terminals are Injector free of a spark mark.
Page 230 FUEL SYSTEM (J08E) EN07–29 • An "X" mark is put on the union bolt for the camshaft housing. Camshaft housing side union bolt SAPH011060700066 MOUNTING THE HEAD COVER Mount the head cover. Refer to the chapter "ENGINE MECHANICAL" AIR BLEEDING OF FUEL SYSTEM Perform air bleeding.
Page 231 EN07–30 FUEL SYSTEM (J08E) FUEL FILTER DESCRIPTION EN0110607J100004 SAPH011060700068 Body Stud Cover Drain valve Collar Filter Vent cap Label Spring Heater Fuel pipe (Out) Water level sensor Seal...
Page 232: Fuel Filter
FUEL SYSTEM (J08E) EN07–31 AIR BLEEDING EN0110607H200005 AIR BLEEDING Remove the vent cap from the top of the cover by turning the vent cap counterclockwise. Fill the cover full of clean fuel. Reinstall the cap and tighten. Start the engine. When the lubrication system reaches its normal Vent cap operating pressure, increase engine speed to high for 2 to 3 minutes.
Page 233 EN07–32 FUEL SYSTEM (J08E) DRAIN WATER Connect specific tube to drain outlet. To protect steering joint by draining liquids. Specific tube is available at HINO dealer. (Part No. SZ950-61502) Loose the vent cap and after open drain valve. Vent cap Collect water in to cup.
Page 234: Bubble Separator
FUEL SYSTEM (J08E) EN07–33 BUBBLE SEPARATOR DESCRIPTION EN0110607J100005 SEC A-A (1 : 1) SEC C-C (1 : 1) SAPH011060700072 Body Valve Insert Spring Plug Plug Pipe O-ring Cartridge...
Page 235: Fuel Tank
EN07–34 FUEL SYSTEM (J08E) FUEL TANK COMPONENT LOCATOR EN0110607J100006 50GAL+50GAL 90GAL 50GAL LH.side LH.side SAPH011060700073...
Page 236 FUEL SYSTEM (J08E) EN07–35 Fuel tank Gasket Fuel tank band Plug Joint Fuel tank support Hose Fuel sender Plate, fuel tank set Tightening torque Unit: Nm {kgfcm, lbfft} 91.2-136.8 {930-1,396, 67-100} 0.5-0.7 {5-7, 0.362-0.506} 23-29 {234.5-296, 17-21.4}* *: Nonreusable. Be sure to use new parts.
Page 237 TURBOCHARGER (J08E) EN08–1 T URBOCHARGER (J08E) E N 0 8 EN08-001 TURBOCHARGER........EN08-2 DESCRIPTION ..........EN08-2 TROUBLESHOOTING ........EN08-3 OVERHAUL CRITERIA........EN08-19...
Page 238: Turbocharger
EN08–2 TURBOCHARGER (J08E) TURBOCHARGER DESCRIPTION EN0110608C100001 SHTS011060800001 Turbine housing Center housing and rotating assy Compressor housing Actuator assembly NOTICE This turbocharger should not be disassembled unless by turbocharger manufacture. The turbocharger parts cannot be replaced.
Page 239: Troubleshooting
TURBOCHARGER (J08E) EN08–3 TROUBLESHOOTING EN0110608F300001 Table 1-1 Troubleshooting-Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke ENGINE ENGINE LACKS Symptom or trouble EXHAUST EMITS POWER BLACK SMOKE Possible causes and remedies (See Notes A and H✩) (See Notes B and C✩) (See Notes D,F and G✩) Loose compressor Dirty air cleaner...
Page 240 EN08–4 TURBOCHARGER (J08E) Table 1-2 Troubleshooting Engine Exhaust Emits WHITE or BLUE SMOKE ENGINE EXHAUST EMITS WHITE OR Symptom or trouble BLUE SMOKE Possible causes and remedies (See Notes B and C✩) (See Notes A and H✩) Loose compressor Dirty air cleaner Plugged engine oil Leakage at engine to intake manifold...
Page 241 TURBOCHARGER (J08E) EN08–5 Table 1-3 Troubleshooting Engine Oil Consumption Excessive ENGINE OIL Symptom or trouble CONSUMPTION EXCESSIVE Possible causes and remedies Seal leakage at Seal leakage at Oil in engine exhaust turbine end of Wrong type or vis- compressor end of manifold (indicating turbocharger cosity of engine...
Page 242 EN08–6 TURBOCHARGER (J08E) Table 1-4 Troubleshooting Noisy Turbocharger NOISY TURBOCHARGER Symptom or trouble Possible causes and remedies (See Notes A and H✩) (See Notes H✩) Foreign object or Foreign object or material in Foreign object in Dirty air cleaner material in compressor inlet engine exhaust element...
Page 243 TURBOCHARGER (J08E) EN08–7 Table 1-5 Troubleshooting Turbocharger Rotating Assembly Binding or Dragging TURBOCHARGER ROTATING Symptom or trouble ASSEMBLY BINDING OR DRAGGING Possible causes and remedies (See Notes J✩) Damaged Damaged turbine Compressor wheel or Excessive dirt build- compressor wheel wheel due to foreign turbine wheel rubbing up in compressor fan due to foreign object...
Page 244 EN08–8 TURBOCHARGER (J08E) Table 1-6.Troubleshooting-Seal Leakage at Compressor End of Turbocharger OIL SEAL LEAKAGE AT Symptom or trouble COMPRESSOR END OF TURBOCHARGER Possible causes and remedies Restricted duct Loose compressor Dirty air cleaner between air cleaner Leakage at engine to intake manifold element and turbocharger intake manifold...
Page 245 TURBOCHARGER (J08E) EN08–9 Table 1-7.Troubleshooting-Seal Leakage at Turbine End of Turbocharger SEAL LEAKAGE AT Symptom or trouble TURBINE END OF TURBOCHARGER Possible causes and remedies Restricted Plugged engine Sludged or cocked Excessive pre-oiling turbocharger oil crankcase breather center housing drain line Clean and remove Service engines Refer to engine...
Page 246 EN08–10 TURBOCHARGER (J08E) Table 1-8.Troubleshooting-Turbocharger Bearings, Bores, or Journals are Worn TURBOCHARGER Symptom or trouble BEARINGS, BORES,OR SHAFT JOURNAL WORN ✩ Possible causes and remedies Inadequate pre- Contaminated or oiling following Insufficient engine improper grade or Restricted turbocharger oil supplied to type of engine turbocharger oil installation or...
Page 247 TURBOCHARGER (J08E) EN08–11 Table 1-9. Troubleshooting Procedures Notes Refer to engine manufacturer's service manual for inspection requirements and replacement specifications. With engine stopped, check duct clamping devices for tightness. With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indi- cated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the engine combustion chambers.
Page 248 EN08–12 TURBOCHARGER (J08E) REPLACEMENT REMOVING THE TURBOCHARGER ASSEMBLY NOTICE • Use care not to touch the link rod and adjusting screw. • The link rod the electric actuator has been adjusted. Do not remove it. Removal of the link rod may cause misalignment, resulting in turbocharger functional decline.
Page 249 TURBOCHARGER (J08E) EN08–13 DISCONNECTING THE COOLANT PIPE Turbocharger Coolant Unfasten the union bolts to remove the coolant pipe E and gaskets assembly Pipe E from the folder and oil cooler assembly. NOTICE Use care not to splash the coolant in the pipes and turbocharger assembly.
Page 250 EN08–14 TURBOCHARGER (J08E) Unfasten the bolts to remove the oil pipe B and gaskets from the tur- Oil pipe B Gasket bocharger assembly. NOTICE Use care not to splash the oil in the pipes and turbocharger assembly. HINT Turbocharger When disconnecting the oil pipe, engine oil will spill. Prepare a reser- assembly voir and clean cloths.
Page 251 TURBOCHARGER (J08E) EN08–15 MOUNTING THE TRURBOCHARGER ASSEMBLY ! CAUTION Observe the following instructions when mounting the turbocharger assembly to the engine or handling after installation. Use special care to prevent the entry of foreign matter into the turbocharger assembly. MOUNTING THE TURBOCHARGER ASSEMBLY Before mounting, add engine oil from the oil inlet.
Page 252 EN08–16 TURBOCHARGER (J08E) Replace with new gaskets and connect the oil pipe A to the turbo- Turbocharger charger assembly with a bolt and union bolts . assembly NOTICE • Clean the oil pipe and check the pipe for collapse and dirt and foreign matters inside.
Page 253 TURBOCHARGER (J08E) EN08–17 MOUNTING THE TURBOCHARGER INSULATOR Replace with new bolts and mount the turbocharger insulator (lower) to the turbocharger assembly. Turbocharger insulator(lower) SAPH01Z080800016 Replace with new bolts and install the turbocharger insulator (upper) to the turbocharger assembly. Turbocharger insulator(upper) SAPH01Z080800017 MOUNTING THE INTAKE PIPE (EXHAUST SIDE) Mount the intake pipe (exhaust side).
Page 254 EN08–18 TURBOCHARGER (J08E) INSPECTION AFTER MOUNTING EN01Z08080000001 PROROCEDURES FOR OPERATION After mounting the turbocharger assembly to the engine, start the engine and inspect each part for leakage of oil, coolant and exhaust gas. ! CAUTION • Do not run engine at idle or at a high speed immediately after starting the engine.
Page 255: Overhaul Criteria
TURBOCHARGER (J08E) EN08–19 OVERHAUL CRITERIA EN0110608H300001 CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL MAY BE NEEDED ON ENGINE TROUBLESHOOTING. The most common symptoms of turbocharger failure are related to engine performance: • Lack of power • Excessive exhaust smoke • Unusual noise •...
Page 256 EN08–20 TURBOCHARGER (J08E) Foreign object damage a. If foreign object damage to the turbine is visible, the turbocharger must be overhauled. Such damage destroys the wheel's balance and causes internal damage to the seal bores and journal bear- ings. Be sure to find the source of the foreign object. In many cases, the object has come out of the engine, and there may be engine damage as well.
Page 257 EMISSION CONTROL (J08E) EN10–1 E MISSION CONTROL (J08E) E N 1 0 EN10-001 EGR VALVE AND EGR PIPE....EN10-2 COMPONENT LOCATOR........ EN10-2 EGR VALVE..........EN10-3 DESCRIPTION ..........EN10-3 DISMOUNTING AND MOUNTING ....EN10-4 CLOSED VENTILATOR ......EN10-7 DESCRIPTION ..........EN10-7 REPLACEMENT OF CLOSED VENTILATOR...........
Page 258: Egr Valve And Egr Pipe
EN10–2 EMISSION CONTROL (J08E) EGR VALVE AND EGR PIPE COMPONENT LOCATOR EN0110610J100001 SHTS011061000001 EGR cooler sub assembly Water pipe sub assembly Gasket Water pipe sub assembly EGR pipe assembly Water pipe Gasket Water hose EGR valve Tightening torque Unit: Nm {kgfcm, lbfft} 55 {560, 40}...
Page 259: Egr Valve
EMISSION CONTROL (J08E) EN10–3 EGR VALVE DESCRIPTION EN0110610J100002 SHTS011061000002 EGR valve assembly Butterfly valve DC Motor...
Page 260: Dismounting And Mounting
EN10–4 EMISSION CONTROL (J08E) DISMOUNTING AND MOUNTING EN0110610H200001 IMPORTANT POINTS - DISMOUNTING REMOVE THE EGR VALVE AND EGR COOLER. NOTICE EGR pipe To prevent burns ensure the engine is cold before changing the valve. (At least 30 minutes after switching off the engine) EGR valve Disconnect the harness coupler.
Page 261 EMISSION CONTROL (J08E) EN10–5 NOTICE • If you have to place your feet on the engine while working on it, be careful not to fall off the engine or get your foot caught in the engine parts. • Be careful not to step on the EGR valve when servicing the engine.
Page 262 EN10–6 EMISSION CONTROL (J08E) Close the coolant plug of the oil cooler situated on the right side of the engine. NOTICE Fit the exhaust manifold gasket with the claw of the gasket facing down. SHTS011061000009 Connect the harness coupler. EGR pipe EGR valve Coupler Front of...
Page 263: Closed Ventilator
EMISSION CONTROL (J08E) EN10–7 CLOSED VENTILATOR DESCRIPTION EN0110610C100001 SHTS011061000011 Body Filter Safety valve PCV valve REPLACEMENT OF CLOSED VENTILATOR EN0110610H200002 REMOVE THE CLOSED VENTILATOR. Remove the hoses and then the closed ventilator. INSTALL THE CLOSED VENTILATOR. Connect the hoses and install the closed ventilator. SHTS011061000012...
Page 264: Selective Catalytic Reduction (Scr)
EN10–8 EMISSION CONTROL (J08E) SELECTIVE CATALYTIC REDUCTION (SCR) GENERAL DESCRIPTION EN0110610C100002 • What is SCR? SCR is an abbreviation of "Selective Catalytic Reduction", a general term for aftertreatment equipment which promotes a chemical reac- tion by using a catalyst for eliminating or detoxifying particular chemi- cal ingredients.
Page 265 EMISSION CONTROL (J08E) EN10–9 DEF indicator switch Return Turbocharger Engine Reverting Feed valve DEF pump Motor Filter Coolant cut off valve Feed Engine Feed Intercooler Pressure Dosing sensor control unit (DCU) Ambient air Level and temperature temperature sensor sensor Exhaust gas Air tank Exhaust brake valve drier...
Page 266 EN10–10 EMISSION CONTROL (J08E) COMPONENT LOCATOR EN0110610J100003 SHTS011061000014 DEF tank Exhaust gas temperature sensor DEF level sensor NOx sensor DCU (Dosing control unit) SCR catalyst inlet temperature sensor DEF pump Ambient temperature sensor DEF injector Burner flame temperature sensor...
Page 267: Inspection
EMISSION CONTROL (J08E) EN10–11 INSPECTION EN08Z0904H300001 DEF CONCENTRATION INSPECTION NOTICE There are three inspection methods for DEF; urea analyzer inspec- tion, pH test paper inspection and refractive index measurement inspection. Use one method from three for inspection. UREA ANALYZER INSPECTION Extract DEF, put few drops on the urea analyzer to measure the urea concentration and replace the DEF if the value is outside the standard value.
Page 268: Dismounting And Mounting
EN10–12 EMISSION CONTROL (J08E) DISMOUNTING AND MOUNTING EN0110610H100001 PREPARATION ! WARNING Do not touch the exhaust pipe and muffler unit when it could be hot. You can be severely burned. NOTICE • If the quick joint used in DEF piping is once removed, DEF pow- der will precipitate on the seal surface and leakage may occur after reconnection.
Page 269 EMISSION CONTROL (J08E) EN10–13 Disconnect the battery ground terminal. ! CAUTION • Be sure to disconnect the battery terminals from the battery in accordance with the procedures in this manual and never use the battery disconnect switch when it is necessary to break the supply of electricity completely.
Page 270 EN10–14 EMISSION CONTROL (J08E) DOSING CONTROL UNIT (DCU) IMPORTANT POINT - DISMOUNTING a. Remove the bolt and then the DCU cover. ! CAUTION When dismounting/mounting the DCU, wear the glove to avoid injury. SHTS011061000017 SHTS011061000018 b. Disconnect the harness connectors (53 pin and 86 pin) from the DCU.
Page 271 EMISSION CONTROL (J08E) EN10–15 IMPORTANT POINT - MOUNTING a. Mount the DCU to the DCU bracket and then mount the assembly to the vehicle. Tightening Torque: 8-12 Nm {82-122 kgfcm, 6-8 lbfft} (DCU) Tightening Torque: 18-26 Nm {184-265 kgfcm, 14-19 lbfft} (DCU bracket) b.
Page 272 EN10–16 EMISSION CONTROL (J08E) DEF TANK IMPORTANT POINT - DISMOUNTING a. Dismount the DCU. Refer to "DOSING CONTROL UNIT (DCU)" for details. b. Remove the drain plug from the DEF tank to drain the DEF. SHTS011061000023 c. Remove the nut and then the stay and rod from the bracket. d.
Page 273 EMISSION CONTROL (J08E) EN10–17 IMPORTANT POINT - MOUNTING a. Set the DEF tank on the bracket. b. Mount the coolant and DEF hoses. c. Connect the harness connector. NOTICE Tighten clockwise the connector connecting to the DEF sensor until a "click"...
Page 274 EN10–18 EMISSION CONTROL (J08E) MOUNTING/DISMOUNTING AND INSPECTING DEF SENSOR ! WARNING • If the DEF is frozen, do not mount or dismount the DEF sensor. • Do not allow foreign objects to enter the DEF tank from the open- ing. a.
Page 275 EMISSION CONTROL (J08E) EN10–19 DEF PUMP IMPORTANT POINT - DISMOUNTING a. Dismount the DCU. Refer to "DOSING CONTROL UNIT (DCU)" for details. b. Dismount the DEF tank. Refer to "DEF TANK" for details. c. Remove the ambient air temperature sensor, hose clamp and har- Hose ness clip.
Page 276 EN10–20 EMISSION CONTROL (J08E) IMPORTANT POINT - MOUNTING a. Set the DEF pump at the mounting position. b. Connect the harness wire connector to the DEF pump. Band clamp pump Connector SHTS011061000034 c. Mount the coolant and DEF hoses to the DEF pump. SHTS011061000035 d.
Page 277 EMISSION CONTROL (J08E) EN10–21 REPLACE THE DEF INLET CONNECTOR OF THE DEF PUMP. a. When the connector is exchanged, the O-ring must not be used two times. NOTICE Inlet connector • All sealing surface must be clean. Contamination or particles are not acceptable. •...
Page 278 EN10–22 EMISSION CONTROL (J08E) b. Remove the equalizing element and the filter element. NOTICE Protect filter area in the housing from contamination. Filter element Equalizing element SHTS011061000042 c. Replace the filter element and the equalizing element. NOTICE The sealing surface on the housing must be clean. No contamination or particles acceptable.
Page 279 EMISSION CONTROL (J08E) EN10–23 DEF INJECTOR IMPORTANT POINT - DISMOUNTING DEF hose a. Disconnect the harness wire connector from the DEF injector. Harness wire Connector Coolant Injector SHTS011061000045 b. Disconnect the DEF and coolant hoses connected to the DEF injector. HINT Coolant will spout if the coolant hose is removed.
Page 280 EN10–24 EMISSION CONTROL (J08E) b. Connect the DEF and coolant hoses to the DEF injector. c. Connect the harness wire connector to the DEF injector. DEF hose Harness wire Connector Coolant Injector SHTS011061000049 REPLACE THE DEF INJECTOR GASKET. a. Remove the gasket. NOTICE •...
Page 281 EMISSION CONTROL (J08E) EN10–25 REPLACE THE DEF INJECTOR COOLANT PIPE. a. When the connector is exchanged, The O-ring must not be used Coolant connector two times. 20 mm NOTICE {0.79 in.} • All sealing surface must be clean. • Contamination or particles are not acceptable. •...
Page 282 EN10–26 EMISSION CONTROL (J08E) SCR FRONT TEMPERATURE SENSOR IMPORTANT POINT - DISMOUNTING Coupler a. Remove the clips. b. Disconnect the harness coupler. c. Remove the temperature sensor. NOTICE After removing the sensor, check that there is no entry of foreign mat- Clip ters inside the muffler.
Page 283 EMISSION CONTROL (J08E) EN10–27 NOx SENSOR 2 Harness IMPORTANT POINT - DISMOUNTING coupler a. Remove the clips. b. Disconnect the harness coupler. c. Remove the NOx sensor controller. Clip d. Remove the sensor. NOTICE After removing the sensor, check that there is no entry of foreign mat- ters inside the muffler.
Page 284 EN10–28 EMISSION CONTROL (J08E) BURNER SYSTEM COMPONENT LOCATOR EN0110610J100004 SHTS011061000063 Fuel filter Burner control unit Fuel pump Nozzle Atomizer Flame temperature sensor Combustion air valve Ignition plug Ignition coil Combination chamber...
Page 285: Burner System Warning And Caution
EMISSION CONTROL (J08E) EN10–29 BURNER SYSTEM WARNING AND CAUTION EN0110610A100001 BEFORE YOU BEGIN Read and understand all instructions and procedures before you begin to service components. Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help prevent serious personal injury, damage to components, or both.
Page 286: Dismounting And Mounting
EN10–30 EMISSION CONTROL (J08E) DISMOUNTING AND MOUNTING EN0110610H100002 PREPARATION ! WARNING Do not touch the exhaust pipe and muffler unit when it could be hot. You can be severely burned. Disconnect the battery ground terminal. ! CAUTION • Be sure to disconnect the battery terminals from the battery in accordance with the procedures in this manual and never use the battery disconnect switch when it is necessary to break the supply of electricity completely.
Page 287 EMISSION CONTROL (J08E) EN10–31 BURNER CONTROL UNIT (BCU) IMPORTANT POINT - DISMOUNTING a. Disconnect the harness coupler. b. Remove the BCU. Harness coupler SHTS011061000064 IMPORTANT POINT - MOUNTING a. Mount the BCU. Tightening Torque: 6 Nm {62 kgfcm, 4.4 lbfft} b.
Page 288 EN10–32 EMISSION CONTROL (J08E) IMPORTANT POINT - MOUNTING a. Connect the air hose on the combustion chamber side. Swivel NOTICE • Mount it without bending the hose with the combustion air valve free. • When tightening, fold the hexagonal part under the swivel with the wrench.
Page 289 EMISSION CONTROL (J08E) EN10–33 IMPORTANT POINT - MOUNTING a. Its installation is the reversal of the removal. Tightening Torque: 18-26 Nm {184-265 kgfcm, 14-19 lbfft} (Atomizer) NOTICE When reassembling the ignition cable, apply grease. IGNITION COIL Ignition coil IMPORTANT POINT - DISMOUNTING harness a.
Page 290 EN10–34 EMISSION CONTROL (J08E) ATOMIZED FUEL PIPE IMPORTANT POINT - DISMOUNTING a. Remove the clip. b. Remove the pipe (use the wrench to avoid looseness of the base connector). SHTS011061000073 NOTICE • After removal, be careful to avoid entry of foreign matter into the removed pipe.
Page 291 EMISSION CONTROL (J08E) EN10–35 IGNITION PLUGS IMPORTANT POINT - DISMOUNTING a. Disconnect the ignition cable on the ignition plug side. b. Remove the ignition plug. Ignition plug NOTICE • After removal, be careful to avoid entry of foreign matter into the ignition cable and combustion chamber.
Page 292 EN10–36 EMISSION CONTROL (J08E) NOZZLE IMPORTANT POINT - DISMOUNTING a. Remove the atomized fuel pipe. Nozzle b. Remove the nozzle. NOTICE • After removal, be careful to avoid entry of foreign matter into the removed pipe and combustion chamber. • If rust is gathered around the nut on the front of the combustion chamber, blow air before removal to avoid rust from getting into the combustion chamber.
Page 293 EMISSION CONTROL (J08E) EN10–37 IMPORTANT POINT - MOUNTING a. Mount the temperature sensor. Tightening Torque: 42.3-47.7 Nm {432-486 kgfcm, 32-35 lbfft} b. Mount the clips. c. Connect the harness connector. NOTICE When reassembling, apply anti-seizure lubricant. 12. FLAME TEMPERATURE SENSOR IMPORTANT POINT - DISMOUNTING Harness connector...
Page 294 EN10–38 EMISSION CONTROL (J08E) 14. FUEL PUMP Eye joint Clip IMPORTANT POINT - DISMOUNTING a. Disconnect the harness connector. b. Remove the bracket fixing nut. c. Remove the fuel pipe fixing clip. d. Disconnect the hose on the pump inlet port side. Harness e.
Page 295 EMISSION CONTROL (J08E) EN10–39 INSPECTION AND REPAIR EN0110610H300002 Inspect the BURNER SYSTEM-related components in accordance with the table below and perform a repair or replacement if necessary. Item Content Action Travel distance DPR filter Ash deposition Clean-up 200,000 mile Hose for difference pressure sensor Replacement Replacement 3 years...
Page 296 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) EN11–1 A LTERNATOR E N 1 1 ( J08E: REMY 12V-130A,135A,180A) E N 1 1 EN11-001 ALTERNATOR........... EN11-2 DATA AND SPECIFICATIONS ......EN11-2 TROUBLESHOOTING ........EN11-2 COMPONENT LOCATOR........ EN11-3 OVERHAUL ............. EN11-4 INSPECTION AND REPAIR ......EN11-7...
Page 297 EN11–2 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) ALTERNATOR DATA AND SPECIFICATIONS EN0110611I200001 Nominal voltage Nominal output 12V-130A/135A/180A Max. output 126A/130A/176A at 13.5V, 5,000 r/min Max. rotating 10,000 r/min Rotating direction Right (seen from pulley side) Regulator Mount-on TROUBLESHOOTING EN0110611F300001 Symptom Possible cause Remedy/Prevention Charge warning light does not light Fuse blown...
Page 298 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) EN11–3 COMPONENT LOCATOR EN0110611D100001 (Example) SHTS011061100001 Brace Bracket Tensioner pulley V-belt Alternator Idler pulley Tightening torque Unit: Nm {kgfcm, lbfft} 88 {897, 65} 68.5 {700, 51} 93 {948, 69} 68.5 {700, 51} 80-95 {816-968, 59-70}...
Page 299 EN11–4 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) OVERHAUL EN0110611H200001 IMPORTANT POINTS - DISMOUNTING Idler pulley Fun pulley REMOVE THE ALTERNATOR. Remove the drive belt. Remove the through bolt and the fixing belt. NOTICE Alternator To remove the belt, turn the nut of the tension pulley with a wrench in counterclockwise direction to turn the tension pulley in arrow direc- Auto tensioner tion.
Page 300 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) EN11–5 IMPORTANT POINTS - MOUNTING Idler pulley Fun pulley INSTALL THE ALTERNATOR. Install the alternator with through bolt and fixing bolt. Tightening Torque: Through bolt: 93 Nm {948 kgfcm, 69 lbfft} Alternator Fixing bolt: 88 Nm {897 kgfcm, 65 lbfft} Auto tensioner Crankshaft pulley SHTS011061100005...
Page 301 EN11–6 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) INSTALL OR CONNECT "I" and/or "R" terminal lead(s) (108 or 109), if used, to threaded termi- nal stud(s) (136 and/or 146), washer(s) and hexagon nut(s) (131 and/ or 141). NOTICE Use suitable open end wrench to hold nut portion of terminal stud(s) (125, 136 and/or 146).
Page 302 ALTERNATOR (J08E: REMY 12V-130A,135A,180A) EN11–7 IMPORTANT POINTS - ON - VEHICLE INSPECTION INSPECT THE DRIVE BELT Alternator If the indicator (engraved line) is out of the belt usage limit line, or if the belt is damaged, replace the belt. View A View A Belt usage limit line Belt usable range...
Page 303 STARTER (J08E) EN12–1 S TARTER (J08E) E N 1 2 EN12-001 STARTER ..........EN12-2 DATA AND SPECIFICATIONS ......EN12-2 DESCRIPTION ..........EN12-2 TROUBLESHOOTING ........EN12-3 COMPONENT LOCATOR........ EN12-4 OVERHAUL ............. EN12-5 INSPECTION AND REPAIR ......EN12-9...
Page 304: Starter
EN12–2 STARTER (J08E) STARTER DATA AND SPECIFICATIONS EN0110612I200001 Type Planetary reduction gear type Rated output 12 V, 4.8 kW Number of teeth of pinion Module Rotating direction Clockwise (Seen from pinion side) DESCRIPTION EN0110612C100001 SHTS011061200001 Holder assembly Pinion gear Brush Drive housing assembly Yoke assembly Armature assembly...
Page 305: Troubleshooting
STARTER (J08E) EN12–3 TROUBLESHOOTING EN0110612F300001 Symptom Possible cause Remedy/Prevention Engine does not crank, or cranks Poor contact Replace the starter switch. slowly. (Starter switch) Engine does not crank, or cranks Discharged battery Charge. slowly. (Battery) Short circuited between electrodes Replace battery. Poor contact at battery terminal Clean or retighten.
Page 306 EN12–4 STARTER (J08E) COMPONENT LOCATOR EN0110612D100001 SHTS011061200002 Pinion gear Brush holder Drive housing assembly End frame Main switch assembly Through bolt Clutch assembly Lever assembly Internal gear assembly Terminal O-ring Cover Armature assembly Plate Yoke assembly Tightening torque Unit: Nm {kgfcm, lbfft} 17 {173, 12.5} 139-169 {1,418-1,723, 103-124} 21 {214, 15.5}...
Page 307: Overhaul
STARTER (J08E) EN12–5 OVERHAUL EN0110612H200001 IMPORTANT POINTS - DISASSEMBLY When disassembling the starter, prepare a work stand as shown in the figure. D: Diameter = 110 mm {4.331 in.} T: Thickness = 10 mm {0.394 in.} H: Height = 120 mm {4.724 in.} SHTS011061200003 REMOVE THE PINION GEAR.
Page 308 EN12–6 STARTER (J08E) Remove the through bolt, remove the commutator end frame. SHTS011061200007 REMOVE THE HOLDER ASSEMBLY. Using a long nose plier, remove the brush of the yoke from the holder. SHTS011061200008 Remove the holder assembly from the armature. SHTS011061200009 REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEMBLY.
Page 309 STARTER (J08E) EN12–7 REMOVE THE GEAR. Remove the cover and plate. NOTICE Remember the assembled position and direction of the plate. SHTS011061200011 Remove the planetary gear. Remove the internal gear. SHTS011061200012 REMOVE THE DRIVE HOUSING ASSEMBLY. Remove the bolt, remove the drive housing assembly. SHTS011061200013 REMOVE THE CLUTCH ASSEMBLY.
Page 310 EN12–8 STARTER (J08E) REMOVE THE LEVER. Remove the lever assembly. SHTS011061200015 IMPORTANT POINTS - ASSEMBLY NOTICE Reverse the order of disassembly to reassemble the starter. LUBRICATION Before reassembling, apply the recommended grease to the following: [Apply Nippondenso No. HL50 grease (Shin-nisseki U3311 grease)] or equivalent.
Page 311: Inspection And Repair
STARTER (J08E) EN12–9 INSPECTION AND REPAIR EN0110612H300001 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Measure Ohmmeter Continuity Continuity between the 1  or less 1  segments of the commu- Replace. tator Measure Ohmmeter No continuity between the connector and arma- 10 k...
Page 312 EN12–10 STARTER (J08E) Inspection item Standard Limit Remedy Inspection procedure Measure Ohmmeter Continuity between the Continuity 1  or less 1  field coil end and the Replace. read wire. Measure Ohmmete No continuity between continuity the field coil end and 10 k...
Page 313 STARTER (J08E) EN12–11 Inspection item Standard Limit Remedy Inspection procedure Visual check Rotating of needle roller Sticks or does — Replace. rear bearing not rotate Measure Continuity Ohmme Continuity between ter- 1  or less 1  Replace. minals 50 and C Terminal Terminal 50 Measure...
Page 314 AIR COMPRESSOR (J08E: 340 cm3) EN13–1 A IR COMPRESSOR (J08E: 340 cm3) E N 1 3 EN13-001 AIR COMPRESSOR........EN13-2 DATA AND SPECIFICATIONS ......EN13-2 DESCRIPTION ..........EN13-3 TROUBLESHOOTING ........EN13-4 COMPONENT LOCATOR........ EN13-5 SPECIAL TOOL ..........EN13-6 OVERHAUL ............. EN13-6 INSPECTION AND REPAIR ......
Page 315: Air Compressor
EN13–2 AIR COMPRESSOR (J08E: 340 cm3) AIR COMPRESSOR DATA AND SPECIFICATIONS EN0110613I200001 Type Reciprocating, single cylinder Discharge amount 340 cm {20.7 cu.in.} Bore x stroke 85 mm x 60 mm {3.35 in. x 2.36 in.} Lubrication system Forced feed lubrication Cooling system Forced water-circulated...
Page 316: Description
AIR COMPRESSOR (J08E: 340 cm3) EN13–3 DESCRIPTION EN0110613C100001 SAPH011061300001 O-ring * Bearing holder Cylinder head assembly Crankcase Suction valve * Piston pin Piston Piston ring Connecting rod Suction Bearing Delivery Crankshaft * Nonreusable part...
Page 317: Troubleshooting
EN13–4 AIR COMPRESSOR (J08E: 340 cm3) TROUBLESHOOTING EN0110613F300001 Symptom Possible cause Remedy/Prevention Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace cylinder head assembly. tact Charging efficiency dropped (Pis- Worn piston and cylinder liner Replace. ton, cylinder liner and piston rings) Seized piston Replace (piston, piston rings and cylin- der liner).
Page 318: Component Locator
AIR COMPRESSOR (J08E: 340 cm3) EN13–5 COMPONENT LOCATOR EN0110613D100001 SAPH011061300002...
Page 319: Special Tool
EN13–6 AIR COMPRESSOR (J08E: 340 cm3) Cylinder head assembly ** Crankcase Suction valve Crankshaft O-ring * Woodruff key Cylinder liner Coupling Piston ring Coupling bolt Piston Connecting rod Air compressor assembly Connecting rod bearing Screw Lock washer * Piston pin Retainer ring * Bearing holder Ball bearing...
Page 320 AIR COMPRESSOR (J08E: 340 cm3) EN13–7 IMPORTANT POINTS - MOUNTING Pointer INSTALLATION PROCEDURES Fit the No.1 cylinder to the Top Dead Center. 1/6 Mark NOTICE Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE INTRODUCTION". Damper SAPH011061300005 Align the aligning mark "0" on the top of coupling flange with protru- sion on the compressor housing.
Page 321 EN13–8 AIR COMPRESSOR (J08E: 340 cm3) Make sure that the aligning mark "0" on the top of coupling flange is aligned with protrusion on the compressor housing. INSTALL THE SUPPLY PUMP AND AIR COMPRESSOR. Refer to the chapter "FUEL SYSTEM". Protrusion "0"...
Page 322 AIR COMPRESSOR (J08E: 340 cm3) EN13–9 REMOVE THE CYLINDER HEAD ASSEMBLY, ASSEMBLY AND O- RING. Remove the cylinder head assembly, assembly and O-ring. NOTICE • Put the marking through the head cover to the cylinder liner. • Do not decompose the cylinder head assembly. SAPH011061300011 REMOVE THE CONNECTING ROD WITH THE PISTON.
Page 323 EN13–10 AIR COMPRESSOR (J08E: 340 cm3) REMOVE THE CRANKSHAFT. Remove the bearing holder fitting screw. Use the press to remove the crankshaft together with the bearing holder. Bearing holder NOTICE Be careful not to damage the bearing holder. Crankshaft SAPH011061300015 REMOVE THE BEARING HOLDER.
Page 324 AIR COMPRESSOR (J08E: 340 cm3) EN13–11 IMPORTANT POINTS - ASSEMBLY INSTALL THE BALL BEARING. Install the ball bearing onto the both ends of the crankshaft. SAPH011061300018 INSTALL THE CRANKSHAFT. Using the press, install the crankshaft to the bearing holder. Install the crankshaft and bearing holder into the crankcase. Tighten the bearing holder fitting screw.
Page 325 EN13–12 AIR COMPRESSOR (J08E: 340 cm3) Lock the nut with a lock washer. SAPH011061300022 MEASURE THE END PLAY OF THE CRANKSHAFT. Assembly standard: 0-0.6 mm {0-0.0236 in.} Limit: 1.0 mm {0.0394 in.} SAPH011061300023 ASSEMBLE THE PISTON. NOTICE Assemble the various parts after applying engine oil to the sliding parts.
Page 326 AIR COMPRESSOR (J08E: 340 cm3) EN13–13 ASSEMBLE THE PISTON AND CONNECTING ROD. NOTICE Warm up the piston first in hot water, to 80-90C {176-194F}, for approximately 5 minutes. Install the retainer ring at one end of the piston pin holes. Apply engine oil to the piston pin.
Page 327: Inspection And Repair
EN13–14 AIR COMPRESSOR (J08E: 340 cm3) INSPECTION AND REPAIR EN0110613H300001 Unit: mm {in.} Inspection item Standard Limit Remedy Inspection procedure Visual check Cracks or defects of the con- — — Replace. necting rod Outside diameter of piston pin 18 {0.709} —...
Page 328 AIR COMPRESSOR (J08E: 340 cm3) EN13–15 Inspection item Standard Limit Remedy Inspection procedure Visual check Damage and scratches of the — — Replace. cylinder liner Outside diameter of the piston 85 {3.346} — Measure Inside diameter of the cylinder 85 {3.346} —...
Page 329 EN13–16 AIR COMPRESSOR (J08E: 340 cm3) Inspection item Standard Limit Remedy Inspection procedure 0.1-0.3 Measure 1.0 {0.0394} {0.0040-0.0118} Gap between ends of piston Replace. 0.1-0.3 ring 1.0 {0.0394} {0.0040-0.0118} Visual check Worn or damaged bearing — — Replace. Visual check Worn or damaged cylinder —...
Page 330 ENGINE CONTROL (J08E) EN16–1 E NGINE CONTROL (J08E) E N 1 6 EN16-001 ACCELERATOR PEDAL......EN16-2 DESCRIPTION ..........EN16-2 ENGINE ECU ..........EN16-3 COMPONENT LOCATOR........ EN16-3 REPLACEMENT ..........EN16-4...
Page 331: Accelerator Pedal
EN16–2 ENGINE CONTROL (J08E) ACCELERATOR PEDAL DESCRIPTION EN0110616F200001 Floor board SAPH011061600001 Accelerator pedal assy...
Page 332: Engine Ecu
ENGINE CONTROL (J08E) EN16–3 ENGINE ECU COMPONENT LOCATOR EN0110610J100004 SAPH011061600002 Engine ECU Tightening torque Unit: Nm {kgfcm, lbfft} 28.5 {291, 21}...
Page 333: Replacement
EN16–4 ENGINE CONTROL (J08E) REPLACEMENT EN0110610H100002 DISCONNECTING THE ENGINE ECU CONNECTOR ! WARNING Perform replacement after cooling to prevent burns. (Wait for at least 30 minutes after setting the starter key to the "LOCK" position.) (Example) Engine ECU Connector Connector SAPH011061600003 CLEANING AND DISCONNECTING THE ENGINE ECU CONNEC- Engine...
Page 334 ENGINE CONTROL (J08E) EN16–5 Using a small brush, carefully remove dirt and foreign matter remain- ing at the sliding portion. NOTICE While working, do not disconnect the connectors. Using a waste cloth, wipe off around the engine ECU connector and engine ECU surface.
Page 335 EN16–6 ENGINE CONTROL (J08E) 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 and for- Portions to eign matter to drop. Do not wipe be wiped off the clean...
Page 336 ENGINE CONTROL (J08E) EN16–7 REMOVING THE ENGINE ECU REMOVING THE ENGINE ECU Cylinder Unfasten the bolts (4 pcs.) and remove the engine ECU from the cylin- block der block. NOTICE • Protect with plastic covers to avoid entry of dirt and foreign mat- ter into the connectors of the engine ECU.
Page 337 EN16–8 ENGINE CONTROL (J08E) CONNECTING THE ENGINE ECU CONNECTOR CONNECTING THE ENGINE ECU CONNECTOR Check that the harness side connector lever is fully open and place it straight on the engine ECU side connector. NOTICE Lever At this time, check that the lever is fully open. SAPH011061600014 HINT Check that it is inserted along the wrong fitting prevention keyway.
Page 338 ENGINE CONTROL (J08E) EN16–9 Move the hook in the direction of the arrow as shown in the figure until a "click" is heard in order to lock the connector. Hook SAPH011061600018...
Page 339 Hino Motors Sales U.S.A., Inc. 41180 Bridge Street, Novi, MI 48375 Telephone: (248) 699-9300 PRINTED IN JAPAN Pub.No. S5-UJ08E10A '12.11...

Hino Motors J08E-VC Workshop Manual

G Eneral Introduction (Engine)

E Ngine Introduction (J08E)

E Ngine Mechanical (J08E)

Cylinder Head

Crankshaft Front End

Flywheel and Flywheel Housingen02-25

Timing Gear

Main Moving Parts and Cylinder Block

A Ir Intake System (J08E)

Air Intake Manifold and Pipe

Air Intake

Air Cleaner

Air Hose

Air Flow Sensor

Boost Pressure Sensor

E Xhaust System (J08E)

Exhaust Manifold and Pipe

Exhaust Pipe and Muffler Unit

Dpr (Diesel Particulate Reduction System)

Differential Pressure Sensor

Exhaust Control Cylinder

L Ubricating System (J08E)

Lubricating System

Oil Pump and Oil Strainer

Oil Filter and Oil Cooler

C Ooling System (J08E)

Cooling System

Coolant Pump

Thermostat

Radiator and Intercooler

Radiator

Cooling Fan

F Uel System (J08E)

Fuel System

Supply Pump

Common Rail

Injector

Fuel Filter

Bubble Separator

Fuel Tank

T Urbocharger (J08E)

E Mission Control (J08E)

Egr Valve and Egr Pipe

Egr Valve

Closed Ventilator

Selective Catalytic Reduction (Scr)

Burner System

S Tarter (J08E)

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Hino Motors J08E-VC