Page 1 FOREWORD This workshop manual has been prepared to provide information covering general service repairs for the W04D J engine equipped on the HINO DUTRO. Applicable models: WU300, 340, 410 series Please note that the publications below have also been prepared as relevant service manuals for the compo- nents and systems in this vehicles.
Page 2 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle.
Page 3 INTRODUCTION PREPARATION SERVICE SPECIFICATIONS FUEL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING & CHARGING ALPHABETICAL INDEX...
Page 4: Table Of Contents
......01 4 TERMS FOR ENGINE REPAIR MANUAL ..01 7 ABBREVIATIONS USED IN THIS MANUAL . . . 01 7 GLOSSARY OF SAE AND HINO TERMS ..01 12...
Page 5: How To Use This Engine Repair Manual
01 1 INTRODUCTION HOW TO USE THIS ENGINE REPAIR MANUAL HOW TO USE THIS ENGINE REPAIR MANUAL 0108J 02 GENERAL INFORMATION GENERAL DESCRIPTION This manual is made in accordance with SAE J2008. Generally repair operations can be separated in the following 3 main processes: 1.
Page 6: Terms Definition
01 2 INTRODUCTION HOW TO USE THIS ENGINE REPAIR MANUAL Tightening torque, oil applying position, and non reusable parts are described as important points in the procedure. NOTICE: There are cases where such information can only be indicated by an illustration. In that case, all the information such as torque, oil, etc.
Page 7 01 3 INTRODUCTION HOW TO USE THIS ENGINE REPAIR MANUAL SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys- tem of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf)
Page 8: Repair Instruction For Engine Repair Manual
01 4 INTRODUCTION REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL 0108K 02 PRECAUTION TO PREVENT FROM ENTERING FOREIGN SUBSTANCES When foreign substances such as dust, grain of sand or metallic dust enter inside of engine, it often causes functional failure of the engine.
Page 9 01 5 INTRODUCTION REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL NOTICE: Do the torque checking with the lower limit value of the torque tolerance. Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens.
Page 10 01 6 INTRODUCTION REPAIR INSTRUCTION FOR ENGINE REPAIR MANUAL Never use any electric equipment like an electric motor or a working light as they may cause spark or high temperature. Never use an iron hammer as it may cause spark. Dispose the shop lag separately from any fuel deposit.
Page 11: Terms For Engine Repair Manual
01 7 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL TERMS FOR ENGINE REPAIR MANUAL 0108H 02 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D.
Page 12 01 8 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL Abbreviations Meaning DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Cam Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code ECAM Engine Control And Measurement System Electronic Controlled Diesel ECDY Eddy Current Dynamometer...
Page 13 01 9 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL Abbreviations Meaning Integrated Circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Idle Speed Control Junction Block Junction Connector Kick Down Local Area Network Liftback Liquid Crystal Display...
Page 14 01 10 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL Abbreviations Meaning Parking Brake Progressive Power Steering Power Steering Power Take Off Power Window R & P Rack And Pinion Relay Block Recirculating Ball Type Steering Reinforcement Rigid Front Suspension Rigid Rear Suspension Right Hand Right Hand Drive Relay...
Page 15 01 11 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL Abbreviations Meaning Variable Power Steering Vehicle Skid Control Vacuum Switching Valve Vacuum Transmitting Valve VVT i Variable Valve Timing intelligent With Wagon Wire Harness Without First Second Two Wheel Drive Vehicle (4 x 2) Third Fourth Four Wheel Drive Vehicle (4 x 4)
Page 16: Glossary Of Sae And Hino Terms
TERMS FOR ENGINE REPAIR MANUAL 0108I 02 GLOSSARY OF SAE AND HINO TERMS This glossary lists all SAE J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their HINO equivalents. HINO TERMS SAE TERMS ABBREVIATIONS...
Page 17 01 13 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel Shutoff Idle Speed Control Knock Sensor...
Page 18 01 14 INTRODUCTION TERMS FOR ENGINE REPAIR MANUAL Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three Way Catalytic (TWC) Three Way Catalytic Converter Manifold Converter TWC+OC Three Way + Oxidation Catalytic Converter...
Page 19 PREPARATION FUEL ........02 1 PREPARATION .
Page 20: Fuel
02 1 PREPARATION FUEL FUEL 02269 01 PREPARATION Equipment Brass brush Injection nozzle tester Torque wrench Retaining nut wrench (Part No. 95092 10500 for DENSO made) Wooden stick...
Page 21: Intake
02 2 PREPARATION INTAKE INTAKE 0226A 01 PREPARATION Recomended Tools 09200 00010 Engine Adjust Kit INTAKE MANIFOLD Equipment Dye penetrant Precision straight edge...
Page 22: Engine Mechanical
02 3 PREPARATION ENGINE MECHANICAL ENGINE MECHANICAL 0226B 01 PREPARATION 09201 41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY Valve Spring Compressor CYLINDER HEAD ASSY 09202 70020 (09202 00030) Attachment CYLINDER HEAD ASSY 09215 00013 Crankshaft Bearing Remover & TIMING GEAR AND CAMSHAFT Replacer Set B (09215 00461)
Page 23 02 4 PREPARATION ENGINE MECHANICAL 09420 1460 Cylinder Liner Puller PISTON, CRANKSHAFT CYLINDER BLOCK 09481 1130 Guide PISTON, CRANKSHAFT CYLINDER BLOCK 09481 1140 Guide PISTON, CRANKSHAFT CYLINDER BLOCK 09481 1340 Guide CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING Timing Setting TIMING GEAR AND CAMSHAFT 09512 2100 9191 08252...
Page 24 02 5 PREPARATION ENGINE MECHANICAL Equipment Abrasive compound Connecting rod aligner Cylinder gauge Dial gauge Dye penetrant Heater Micrometer Piston ring compressor Piston ring expander Precision straight edge Press Sliding hammer Soft brush Solvent Spring tester Steam cleaner Steel square Straight edge Torch Torque wrench...
Page 25: Exhaust
02 6 PREPARATION EXHAUST EXHAUST 0226C 01 PREPARATION Recomended Tools 09200 00010 Engine Adjust Kit EXHAUST MANIFOLD Equipment Dye penetrant Precision straight edge...
Page 26: Cooling
02 7 PREPARATION COOLING COOLING 0226D 01 PREPARATION 08826 00100 ”Seal Packing 1282B,” WATER PUMP ASSY THREE BOND 1282B or equivalent (FIPG) Equipment Bolt Thread diameter: 10.0 mm (0.394 in.) Thread pitch: 1.5 mm (0.059 in.) Heater Press Steel pipe Length: More than 57 mm (2.24 in.) Inside diameter: 18 21 mm (0.71...
Page 27: Lubrication
02 8 PREPARATION LUBRICATION LUBRICATION 0226E 01 PREPARATION Equipment Dial gauge Micrometer Torque wrench Vise...
Page 28: Starting & Charging
02 9 PREPARATION STARTING & CHARGING STARTING & CHARGING 0226J 01 PREPARATION 09820 00031 Alternator Rotor Rear Bearing STARTER ASSY Replacer Recommend Tools Electrical Tester STARTER ASSY 09082 00040 GENERATOR ASSY Equipment Dial indicator Micrometer Plastic hammer Press Pull scale Brush spring Sandpaper Commutator...
Page 29: Service Specifications
SERVICE SPECIFICATIONS STANDARD BOLT ......03 1 HOW TO DETERMINE BOLT STRENGTH ..03 1 SPECIFIED TORQUE FOR STANDARD BOLTS .
Page 30: Standard Bolt
03 1 SERVICE SPECIFICATIONS STANDARD BOLT STANDARD BOLT 030Y3 03 HOW TO DETERMINE BOLT STRENGTH Bolt Type Class Hexagon Head Bolt Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/Washer w/Washer B06431...
Page 31: Specified Torque For Standard Bolts
03 2 SERVICE SPECIFICATIONS STANDARD BOLT 030Y4 03 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class Class N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 56 in.·lbf 65 in.·lbf 1.25...
Page 32: How To Determine Nut Strength
03 3 SERVICE SPECIFICATIONS STANDARD BOLT 030Y5 03 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Class Present Standard Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/Washer) No Mark (w/Washer) No Mark 7N (5T) 10N (7T)
Page 33: Fuel
03 4 SERVICE SPECIFICATIONS FUEL FUEL 030YC 06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Nozzle holder body x Nozzle holder retaining nut 68.5...
Page 34: Intake
03 5 SERVICE SPECIFICATIONS INTAKE INTAKE 030Y7 04 SERVICE DATA Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)
Page 35: Engine Mechanical
03 6 SERVICE SPECIFICATIONS ENGINE MECHANICAL ENGINE MECHANICAL 030YD 04 SERVICE DATA Cyliner head Warpage STD Longitudinal direction 0.05 mm (0.0020 in.) or less Lateral direction 0.05 mm (0.0020 in.) or less Maximum 0.10 mm (0.0039 in.) Valve and valve Valve seat angle Intake 29˚...
Page 36 03 7 SERVICE SPECIFICATIONS ENGINE MECHANICAL Timing gear Idle gear and shaft Shaft diameter 49.950 49.975 mm (1.9665 1.9675 in.) Gear bush inside diameter 50.000 50.025 mm (1.9685 1.9695 in.) Oil clearance between bush and shaft 0.025 0.075 mm (0.0010 0.0030 in.) Maximum 0.10 mm (0.0039 in.)
Page 37 03 8 SERVICE SPECIFICATIONS ENGINE MECHANICAL Piston and piston Piston pin diameter 36.989 37.000 mm (1.4563 1.4567 in.) ring Minimum 36.96 mm (1.4551 in.) Piston diameter 103.908 mm (4.0909 in.) Minimum 103.902 mm (4.0906 in.) Piston oil clearance 0.0140 0.0172 mm (0.0056 0.0068 in.) Piston pin boss inside diameter 36.987...
Page 38: Torque Specification
03 9 SERVICE SPECIFICATIONS ENGINE MECHANICAL 030YE 04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Cylinder head x Cylinder block Cylinder head bolt 1,350 Cylinder head Additional bolt Nozzle holder and nozzle set x Cylinder head Cylinder head cover x Cylinder head Nozzle leakage pipe x Nozzle holder and nozzle set 12.3 Injection pipe x Nozzle holder and nozzle set...
Page 39: Exhaust
03 10 SERVICE SPECIFICATIONS EXHAUST EXHAUST 030Y8 04 SERVICE DATA Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)
Page 40: Cooling
03 11 SERVICE SPECIFICATIONS COOLING COOLING 030Y9 04 SERVICE DATA Thermostat Valve opening temperature 84˚C (176 183˚F) Valve lift at 95˚C (203˚F) 10 mm (0.39 in.) or more...
Page 41: Lubrication
03 12 SERVICE SPECIFICATIONS LUBRICATION LUBRICATION 030YA 04 SERVICE DATA Backlach 0.091 0.217 mm (0.0036 0.0085 in.) Oil pump Maximum 0.30 mm (0.0118 in.) Drive gear shaft diameter 18.088 18.106 mm (0.7121 0.7128 in.) Minimum 18.062 mm (0.7111 in.) Drive gear bush inside diameter 18.146 18.173 mm (0.7144 0.7155 in.)
Page 42: Torque Specification
03 13 SERVICE SPECIFICATIONS LUBRICATION 030YB 03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pump case sub assy x Cylinder block 22.5...
Page 43: Starting & Charging
03 14 SERVICE SPECIFICATIONS STARTING & CHARGING STARTING & CHARGING 030YQ 04 SERVICE DATA Starter assy Starter armature Commutator diameter 32.8 mm (1.291 in.) assy Minimum 30.0 mm (1.181 in.) Commutator undercut depth 0.8 mm (0.020 0.032 in.) Minimum 0.2 mm (0.008 in.) Starter brush Brush length 18.0 mm (0.709 in.)
Page 44: Torque Specification
03 15 SERVICE SPECIFICATIONS STARTING & CHARGING 030YW 03 TORQUE SPECIFICATION Starter assy Part tightened kgf cm ft lbf Starter commutator end frame assy x Starter drive housing 14.7 Motor housing x Starter drive housing Magnet starter switch assy x Starter drive housing 14.7 Starter commutator end frame assy x Starter brush holder assy 38 in.
Page 45 FUEL NOZZLE HOLDER AND NOZZLE SET ..11 1 COMPONENTS ......11 1 OVERHAUL .
Page 46 11 1 FUEL NOZZLE HOLDER AND NOZZLE SET (W04D J) NOZZLE HOLDER AND NOZZLE SET 110NZ 01 COMPONENTS z Gasket Joint Bolt Adjusting Shim Pressure Spring Nozzle Holder Body Pressure Pin Distance Piece Nozzle Assy 68.5 (700, 51) Nozzle Holder Retaining Nut N·m (kgf·cm, ft·lbf) : Specified torque z Non reusable part...
Page 47 11 2 FUEL NOZZLE HOLDER AND NOZZLE SET (W04D J) 110O0 01 OVERHAUL REMOVE NOZZLE ASSY Retaining Nut Wrench Using a retaining nut wrench, unscrew the retaining nut. Part No. 95092 10500 (DENSO made) NOTICE: When disassembling the nozzle, be careful not to drop the inner parts.
Page 48 11 3 FUEL NOZZLE HOLDER AND NOZZLE SET (W04D J) Check that the needle falls into the body vent smoothly by its own weight when released. Repeat this test, rotating the needle slightly every time. If the needle does not fall smoothly, replace the nozzle assy. A71950 A71746 INSTALL NOZZLE ASSY...
Page 49 INTAKE INTAKE MANIFOLD ..... . 13 1 INSPECTION ......13 1...
Page 50: Intake Manifold
13 1 INTAKE INTAKE MANIFOLD (W04D J) INTAKE MANIFOLD 1305E 01 INSPECTION INSPECT INTAKE MANIFOLD HINT: Clean the intake manifold with a commercial cleaning agent be- fore the inspection. Using a dye penetrant, check the intake manifold for cracks. If cracks are found, replace the manifold. A71759 Using a precision straight edge and feeler gauge, mea- sure the surface contacting the cylinder head for war-...
Page 51: Engine Mechanical
ENGINE MECHANICAL CYLINDER HEAD ASSY ....14 1 COMPONENTS ......14 1 OVERHAUL .
Page 52: Cylinder Head Assy
14 1 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) CYLINDER HEAD ASSY 14147 01 COMPONENTS 25 (250, 18) Cylinder Head Bolt 132 (1,350, 97) Cylinder Head Cover Sub assy Cylinder Head Bolt 132 (1,350, 97) x 13 Oil Filler Cap z Gasket Cylinder Head Additional Bolt...
Page 53 14 2 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) Valve Rocker Support 15 (150, 11) Valve Rocker Arm Adapter 22.1 (225, 16) Collar 25 (250, 18) Nozzle Holder Keeper Shim Ring Packing Spring Valve Rocker Shaft Retainer Gasket Inner Compression Spring Outer Compression Spring Valve Adjusting Screw...
Page 54: Overhaul
14 3 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) 14148 01 OVERHAUL REMOVE INTAKE AIR CONNECTOR REMOVE INJECTION PIPE SET Loosen the 8 union nuts on the 4 injection pipes. NOTICE: After removing the fuel pipe, put it in a vinyl bag and bind the vinyl bag with a rubber band to prevent foreign objects from getting into the injection nozzle inlet.
Page 55 14 4 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) REMOVE CYLINDER HEAD AND VALVE ROCKER ARM ASSY Loosen the cylinder head additional bolts and rocker arm support bolts in the order as shown in the illustration. A71660 Loosen the cylinder head bolts little in 3 stages, in the or- Exhaust Side der as shown in the illustration.
Page 56 14 5 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) NOTICE: Be careful not to scratch the cylinder block contact sur- face. Using a valve guide bushing brush and solvent, clean all the guide bushes. Using a soft brush and solvent, thoroughly clean the cylin- der head.
Page 57 14 6 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSPECT VALVE Visually check the valves for damage, burns, carbons or warpage, and check the valve heads, valve stems and valve stem grooves for cracks. If wear, burns, warpage or cracks are excessive, replace the valve.
Page 58 14 7 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) REMOVE VALVE SEAT Block Brass Cut the 3 places on the circumference of an unwanted Hammer valve and weld it to the valve seat. Valve Seat NOTICE: To protect the lower surface of the cylinder head from weld- Electric welding ing spatters, be sure to apply grease before welding.
Page 59 14 8 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSPECT VALVE SINK Standard dimension: Intake 0.15 0.45 mm (0.0059 0.0177 in.) Va l v e Exhaust 0.47 0.77 mm (0.0185 0.0303 in.) Seat Maximum dimension: Intake 0.55 mm (0.0217 in.) Valve Sink Exhaust 0.87 mm (0.0342 in.)
Page 60 14 9 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSTALL VALVE GUIDE Press fit a new valve guide straight allowing it to pro- trude, as shown in the illustration. Protrusion height (C): 15 mm (0.59 in.) HINT: Apply engine oil lightly to the valve guide outer circumference before the installation.
Page 61 14 10 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) Using vernier calipers, measure the free length of the spring. Free length: Inner 61.0 mm (2.402 in.) Outer 60.2 mm (2.370 in.) If the free length is not as specified, replace the spring. EM0801 Using a spring tester, measure the tension of the valve spring at the specified installed length.
Page 62 14 11 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSPECT OIL CLEARANCE BETWEEN VALVE ROCKER ARM AND SHAFT Using a cylinder gauge, measure the inside diameter of the rocker arm bush. Standard bush inside diameter: 19.020 19.045 mm (0.7488 0.7498 in.) Maximum bush inside diameter: 19.06 mm (0.7504 in.) If the inside diameter is greater than the maximum, replace the bush.
Page 63 14 12 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSPECT OTHER VALVE SYSTEM PARTS Visually check the contact condition between the rocker arm and valve bridge. Replace the rocker arm and the valve bridge if damage such as wear and scratches is excessive. If there is only a minimal amount of wear, correct the surface with a resurfacer.
Page 64 14 13 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSTALL VALVE ROCKER ARM No. 5 Support Lubricate the rocker arm shaft and bush. NOTICE: Timing Gear Confirm that oil hole of the rocker arm assy No. 5 support Side aligns with the shaft oil hole. Improper installation will re- sult in burning of the entire valve assy.
Page 65 14 14 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSTALL CYLINDER HEAD BOLT Preparation Measure the length of the M12 head bolts. Maximum bolt length (A): Bolt No. Length (A) 118 mm (4.65 in.) 165 mm (6.50 in.) If the length is greater than the maximum, replace them with new bolts.
Page 66: Adjust Valve Clearance
14 15 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSTALL NOZZLE HOLDER AND NOZZLE SET Injection Pipe Install a new gasket, ring packing and shim into the groove of the cylinder head, and then insert the injection Injection Leakage Pipe Assy nozzle assy.
Page 67 14 16 ENGINE MECHANICAL CYLINDER HEAD ASSY (W04D J) INSTALL CYLINDER HEAD COVER SUB ASSY Tighten the 6 bolts. Torque: 25 N m (250 kgf cm, 18 ft lbf) A71658 INSTALL NOZZLE LEAKAGE PIPE ASSY Install 4 new gaskets and the leakage pipe with the 4 joint bolts.
Page 68: Crankshaft Pulley, Oil Pan And Flywheel Housing
14 17 ENGINE MECHANICAL CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING (W04D J) CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING 14149 01 COMPONENTS Crankshaft Pulley Crankshaft Pulley* 18.15 (185, 13) O Ring Spacer 514.8 (5,250, 380) 186 (1,900, 137) Flywheel Housing Dust Cover Flywheel Ring Gear...
Page 69: Overhaul
14 18 ENGINE MECHANICAL CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING (W04D J) 1414A 01 OVERHAUL REMOVE CRANKSHAFT PULLEY REMOVE OIL PAN SUB ASSY REMOVE PILOT BEARING A71692 REMOVE FLYWHEEL SUB ASSY Remove the flywheel mounting bolts. Hold a copper rod through the starter hole against the fly- wheel, and strike the rod lightly with a hammer to remove the flywheel from the crankshaft while rotating the crank- shaft.
Page 70 14 19 ENGINE MECHANICAL CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING (W04D J) INSPECT FLYWHEEL SUB ASSY Check the friction surface for damage. Check the friction surface for distortion. Grinding and replacement should be performed as necessary. Maximum deflection: 0.04 mm (0.0016 in.) Grind limit: 1.00 mm (0.0394 in.) If the flywheel is ground over the limit, replace it with a new one.
Page 71 14 20 ENGINE MECHANICAL CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING (W04D J) INSTALL ENGINE REAR OIL SEAL Apply a small amount of clean engine oil on the outer pe- riphery of the oil seal. Using SST and a hammer, tap in oil seal to the flywheel housing, checking that it is flush with the end of the fly- wheel housing.
Page 72 14 21 ENGINE MECHANICAL CRANKSHAFT PULLEY, OIL PAN AND FLYWHEEL HOUSING (W04D J) Apply clean engine oil to the threads of the flywheel bolt Crankshaft Collar and the flywheel bolt seat. Be sure to tighten 2 or 3 threads provisionally by hand. Then, tighten the 4 fly- wheel bolts with a low torque impact wrench.
Page 73: Timing Gear And Camshaft
14 22 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) TIMING GEAR AND CAMSHAFT 14143 01 COMPONENTS Camshaft Timing Gear Injection Pump Drive Gear Idle Gear No. 1 z Gasket Oil Pump Drive Gear Rear End Plate Camshaft Crankshaft Timing Gear Thrust Plate 24.5 (250, 18) Camshaft Timing Gear...
Page 74: Overhaul
14 23 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) 14144 01 OVERHAUL REMOVE BEARING HOLDER CASE OR SEAL PLATE A71704 REMOVE INJECTION PUMP ASSY Timer Cover Remove the inspection hole dust cover of the timer. Timing Mark Turn the crankshaft clockwise viewed from the timing gear cover, in order to align the injection timing mark.
Page 75 14 24 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) REMOVE CAMSHAFT AND TIMING GEAR ASSY Remove the thrust plate set bolts, and pull out the cam- shaft together with the gear. NOTICE: Pull out the camshaft by slowly turning it, so as not to dam- age the bearings.
Page 76 14 25 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) INSTALL OIL PUMP ASSY Apply oil to the pump case and bearings of the block be- fore installing the oil pump. HINT: If no oil is applied, oil suction failure may be caused at start up, which results in seizure and abnormality.
Page 77 14 26 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) Minimum journal diameter: No. 1 56.85 mm (2.2382 in.) No. 2 56.65 mm (2.2303 in.) No. 3 56.45 mm (2.2224 in.) If the diameter is less than the minimum, replace the camshaft bearing.
Page 78 14 27 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) REPLACE CAMSHAFT BEARING Seal Plate Remove the 2 bolts, seal plate and O ring. A78201 Using SST, remove the bearings. Front 09215 00013 (09215 00461) No. 3 No. 2 HINT: No.
Page 79 14 28 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) INSTALL CAMSHAFT TIMING GEAR Install the thrust plate and timing gear to the camshaft. HINT: Heat the gear in hot water (approx. 200_C (392_F)), then using a press, install the gear to the camshaft. A74776 INSTALL CAMSHAFT AND TIMING GEAR ASSY Lubricate all the journals of the camshaft.
Page 80 14 29 ENGINE MECHANICAL TIMING GEAR AND CAMSHAFT (W04D J) INSPECT TIMING GEAR BACKLASH Using a dial gauge, measure the backlash between the gears. Standard backlash: Crankshaft timing gear x Idle gear 0.068 0.194 mm (0.0027 0.0076 in.) Idle gear x Injection pump drive gear 0.065 0.232 mm (0.0026 0.0091 in.)
Page 81: Piston, Crankshaft And Cylinder Block
14 30 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) PISTON, CRANKSHAFT AND CYLINDER BLOCK 14145 01 COMPONENTS Tight Plug Tight Plug Cylinder Liner Tight Plug Tight Plug Tight Plug Tight Plug Tight Plug Camshaft Bearing Cylinder Block Bush Tight Plug Crankshaft Main Piston Ring (1st)
Page 82: Overhaul
14 31 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) 14146 01 OVERHAUL REMOVE PISTON AND CONNECTING ROD Remove the connecting rod bearing cap mounting bolts and pull out the pistons along with the connecting rods from the cylinder block upper side. HINT: Before pulling out the pistons, remove carbon deposits from the upper end inside the cylinder liner with a scraper...
Page 83 14 32 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) REMOVE CYLINDER LINER HINT: Before removing the piston, put matchmarks on the cylinder lin- Matchmark er and cylinder is bent by ”run in”. When reusing the cylinder liner, misalignment with the cylinder block may concentrate stress on the thin part of the cylinder liner and it may break.
Page 84 14 33 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) REMOVE PISTON RING SET Using a piston ring expander, remove the piston ring. HINT: Handle the piston rings carefully because they are made of a special casting which is easily broken. Arrange the piston rings in the order of the cylinder num- bers.
Page 85 14 34 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSPECT PISTON PIN Using a micrometer, measure the piston pin diameter. Standard piston pin diameter: 36.989 37.000 mm (1.4563 1.4567 in.) Minimum piston pin diameter: 36.96 mm (1.4551 in.) If the diameter is less than the minimum, replace the piston pin with a new one.
Page 86 14 35 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSPECT CRANKSHAFT PIN AND BEARING Using a micrometer, measure the crankshaft pin diame- ter. Standard pin diameter: 61.940 61.960 mm (2.4386 2.4394 in.) Minimum pin diameter: 60.76 mm (2.3921 in.) A69301 Using a cylinder gauge, measure the connecting rod big end inside diameter.
Page 87 14 36 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSPECT PISTON AND CYLINDER LINER HINT: Before the measurement, remove carbon deposits from the up- per end inside the cylinder liner with a scraper or an emery pa- per (recommended: No. 150), working in a circular direction. Make sure that there is no scratches inside the cylinder liner.
Page 88 14 37 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) HINT: Apply the value measured at the most worn point to the cylinder liner inside diameter. INSPECT PISTON PIN BOSS Using a cylinder gauge, measure the piston pin boss in- side diameter.
Page 89 14 38 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) Standard ring thickness: 2.47 2.49 mm (0.0972 0.0980 in.) 1.97 1.99 mm (0.0776 0.0783 in.) 4.97 4.99 mm (0.1957 0.1965 in.) Maximum groove width: 2.32 mm (0.0913 in.) 1.82 mm (0.0717 in.) 4.95 mm (0.1949 in.) A71726 INSPECT PISTON RING END GAP...
Page 90 14 39 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSPECT CRANKSHAFT BEARING CAP After tightening the main bearing caps without bearing, using a cylinder gauge, measure the bore diameter of the main bearing caps to calculate the roundness. Standard bore diameter (w/o Bearing): 77.985 78.000 mm (3.0703...
Page 91 14 40 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) After installing and tightening the bearing caps, using a cylinder gauge, measure the bearing inside diameter. Standard bearing inside diameter: 73.000 mm (2.8740 in.) Maximum bearing inside diameter: 73.30 mm (2.8858 in.) If the inside diameter is greater than the maximum, replace the bearing with a new one.
Page 92 14 41 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSPECT CYLINDER BLOCK Remove the water gallery plug, and visually check the condition of the worn hole. If the wear is excessive, replace the part with a new one. Also inspect the inside of the cylinder block, and clean the cylinder block main body with a commercial cleaning agent as required.
Page 93 14 42 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) Using a press, remove the bush. Press HINT: Spindle Always operate the press slowly and smoothly. Connecting Rod A72437 Assemble the bush. Uniformly chamfer one edge of the bush hole at the small end of the connecting rod by C (0.5 1.0 mm (0.0196...
Page 94 14 43 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSTALL CYLINDER LINER HINT: When assembling the cylinder liner with the cylinder block, clearance can be set to three levels. When using a new cylinder liner, the upper surface and side surface of the cylinder block are stamped A, B or C.
Page 95: Install Crankshaft
14 44 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSTALL CRANKSHAFT Install the main bearings onto the cylinder block and main bearing caps. HINT: When reusing a bearing, make sure to reassemble the re- moved bearing as it was originally installed. Install the bearing with the oil hole on the block side and install the bearing without the oil hole on the cap side.
Page 96 14 45 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) Measure the length of the bearing cap bolts. Standard length (A): 94.00 mm (3.7008 in.) Maximum length (A): 95.20 mm (3.7480 in.) If the length is greater than the maximum, replace them with new bolts.
Page 97 14 46 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) Insert the piston pin into the piston. HINT: Insert the piston pin from the piston boss attached to the retainer ring so that the ring groove is not damaged. Install a new retainer ring to the other end of the piston boss.
Page 98: Install Piston And Connecting Rod
14 47 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) INSTALL CONNECTING ROD BEARING NOTICE: When reusing the bearing, make sure to reassemble the removed bearing as it was originally installed. Install the bearing with the oil hole on the connecting rod side and install the bearing without the oil hole on the cap side.
Page 99 14 48 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK (W04D J) Measure the length of the bolts. Standard length (A): 59.00 mm (2.3228 in.) Maximum length (A): 60.00 mm (2.3622 in.) If the length is greater than the maximum, replace them with new bolts.
Page 100 EXHAUST EXHAUST MANIFOLD ....15 1 INSPECTION ......15 1...
Page 101: Exhaust Manifold
15 1 EXHAUST EXHAUST MANIFOLD (W04D J) EXHAUST MANIFOLD 1507V 01 INSPECTION INSPECT EXHAUST MANIFOLD HINT: Clean the exhaust manifold with a commercial cleaning agent before the inspection. Using a dye penetrate, check the exhaust manifold for cracks. If cracks are found, replace the manifold. A71760 Using a precision straight edge and feeler gauge, mea- sure the surface contacting the cylinder head for war-...
Page 102 COOLING WATER PUMP ASSY ..... 16 1 COMPONENTS ......16 1 OVERHAUL .
Page 103: Water Pump Assy
16 1 COOLING WATER PUMP ASSY (W04D J) WATER PUMP ASSY 160IP 01 COMPONENTS Housing Pulley Seat Rotor Water Pump Seal Bearing & Shaft Sub assy Slinger Rotor Bearing & Shaft Sub assy Housing Pulley Seat Water Pump Seal Slinger z Water Pump Seal Set z Non reusable part A71749...
Page 104: Overhaul
16 2 COOLING WATER PUMP ASSY (W04D J) 160IQ 01 OVERHAUL REMOVE WATER PUMP ROTOR Using a bolt, remove the rotor by screwing in a bolt. Bolt size: Thread diameter 10.0 mm (0.394 in.) Thread pitch 1.5 mm (0.059 in.) A71751 REMOVE WATER PUMP PULLEY SEAT Using a puller, remove the pulley seat.
Page 105 16 3 COOLING WATER PUMP ASSY (W04D J) INSTALL WATER PUMP PULLEY SEAT Using a press, press in the pulley seat into place as shown in the illustration. Dimension (A): 61.5 mm (2.421 in.) A71755 INSTALL WATER PUMP SEAL SET Apply seal packing to a new seal outside circumference and water pump body.
Page 106: Thermostat
16 4 COOLING THERMOSTAT (W04D J) THERMOSTAT 160IR 01 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. 82_C A64555 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 84˚C (176 183˚F)
Page 107 LUBRICATION OIL PUMP ASSY ......17 1 COMPONENTS ......17 1 OVERHAUL .
Page 108: Oil Pump Assy
17 1 LUBRICATION OIL PUMP ASSY (W04D J) OIL PUMP ASSY 170D0 01 COMPONENTS EXAMPLE Oil Pump Assy Driven Gear Driven Gear Oil Pump Case Sub assy z Gasket 22.5 (230, 17) z O Ring Guide Oil Pump Strainer N·m (kgf·cm, ft·lbf) : Specified torque z Non reusable part A71761...
Page 109: Overhaul
17 2 LUBRICATION OIL PUMP ASSY (W04D J) 170D1 01 OVERHAUL REMOVE OIL PUMP ASSY Remove the 7 bolts, the oil pump assy, drive gear and gasket. REMOVE OIL PUMP DRIVEN GEAR Remove the driven gear from the oil pump. NOTICE: Since the drive gear is a press fit type, it can not be disas- sembled.
Page 110 17 3 LUBRICATION OIL PUMP ASSY (W04D J) Inspect the clearance between the driven gear shaft and driven gear bush. Using a micrometer, measure the diameter of the driven gear shaft. Standard shaft diameter: 17.979 17.997 mm (0.7078 0.7085 in.) Minimum shaft diameter: 17.97 mm (0.7075 in.) B58377 Using a dial gauge, measure the inside diameter of...
Page 111: Oil Cooler Assy
17 4 LUBRICATION OIL COOLER ASSY (W04D J) OIL COOLER ASSY 170D2 01 INSPECTION INSPECT OIL COOLER ASSY NOTICE: Before the inspection, please refer to the following items. Be sure to clean the oil cooler element and oil pas- sage, using a commercial cleaning agent. Clean the metal parts, using treated oil.
Page 112: Starting & Charging
STARTING & CHARGING STARTER ASSY ......19 1 COMPONENTS ......19 1 OVERHAUL .
Page 113: Starter Assy
19 1 STARTING & CHARGING STARTER ASSY (W04D J) STARTER ASSY 190KF 01 COMPONENTS Cover Magnet Starter Switch Assy Plate Starter Commutator 14.7 (150, 11) End Frame Assy Brush Starter Yoke Assy 4.3 (44, 38 in. lbf) Starter Armature Assy Starter Brush z O ring Holder Assy...
Page 114: Overhaul
19 2 STARTING & CHARGING STARTER ASSY (W04D J) 190KG 01 OVERHAUL REMOVE STARTER YOKE ASSY Remove the cap, nut and lead wire. A71217 Remove the 2 through bolts, and pull out the starter yoke together with the armature. HINT: Hold the starter by hand so that it will not fall.
Page 115 19 3 STARTING & CHARGING STARTER ASSY (W04D J) REMOVE MAGNET STARTER SWITCH ASSY Loosen the 2 bolts holding the magnet switch to the drive housing. Pull out the magnet switch in direction B by tilting the up- per part of the main switch in direction A, as shown in the illustration.
Page 116 19 4 STARTING & CHARGING STARTER ASSY (W04D J) INSPECT STARTER ARMATURE ASSY Ohmmeter Continuity If the surface of the commutator is dirty or burned, polish the part with sandpaper (#400) or replace the armature assy. Check the commutator open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator.
Page 117 19 5 STARTING & CHARGING STARTER ASSY (W04D J) Inspect for ground. No Continuity Using an ohmmeter, check that there is no continu- ity between the brush and the starter yoke body. If there is continuity, repair or replace the starter yoke assy. Ohmmeter B58394 INSPECT BRUSH...
Page 118 19 6 STARTING & CHARGING STARTER ASSY (W04D J) Using an ohmmeter, check that there is no continuity be- tween terminal C and 30. If there is continuity, replace the magnet switch assy. Push the main switch assembly, when using an ohmme- ter, check that there is continuity between terminal C and If there is no continuity, replace the magnet switch assy.
Page 119 19 7 STARTING & CHARGING STARTER ASSY (W04D J) INSPECT MOTOR HOUSING Using a cylinder gauge, check the inside diameter of the motor housing bush. Standard diameter: 12.1 mm (0.476 in.) Maximum diameter: 12.3 mm (0.484 in.) If the diameter is greater than maximum, replace the motor housing.
Page 120 19 8 STARTING & CHARGING STARTER ASSY (W04D J) Apply much grease to the extent that it would overflow from the reservoir of the start drive housing. : Apply Grease B58432 INSTALL PINION GEAR Install the pinion gear and new snap ring. B58433 INSTALL ARMATURE BEARING Using a press, install the bearing.
Page 121 19 9 STARTING & CHARGING STARTER ASSY (W04D J) INSTALL STARTER ARMATURE ASSY Apply grease to the portions of the armature as shown in illustration. Install the armature to the motor housing. Apply Grease B58436 INSTALL STARTER YOKE ASSY Align the cutout of the starter yoke with the cutout of the motor housing.
Page 122: Generator Assy
19 10 STARTING & CHARGING GENERATOR ASSY (W04D J) GENERATOR ASSY 190KH 01 COMPONENTS Generator Rotor Assy Stator Coil Bearing Retainer Retainer Plate Generator Rotor Bearing Felt Cover Felt Front Bracket Front Bracket Assy 2.2 (22, 19 in. lbf) 7.4 (75, 65 in. lbf) 129 (1320, 95) Collar Pulley...
Page 123: Overhaul
19 11 STARTING & CHARGING GENERATOR ASSY (W04D J) 190KI 01 OVERHAUL HINT: The following procedure is published important points for the generator overhaul. REMOVE GENERATOR BRUSH HOLDER ASSY Unsolder the lead wire from the regulator. Remove the brush holder assembly. A71212 REMOVE GENERATOR ROTOR ASSY Using a press, press out the rotor.
Page 124 19 12 STARTING & CHARGING GENERATOR ASSY (W04D J) REMOVE STATOR COIL Unsolder the each terminal of the stator coil and remove the stator coil. A71539 INSPECT RECTIFIER Continuity No Continuity Check the positive side rectifier. Connect the ohmmeter positive (+) lead to the recti- fier holder and the ( ) lead to the rectifier terminal.
Page 125 19 13 STARTING & CHARGING GENERATOR ASSY (W04D J) Check for open circuit. Ohmmeter Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 12.5 at 20˚C (68˚F) If there is no continuity, replace the rotor assy. Continuity A71544 Check for ground.
Page 126 19 14 STARTING & CHARGING GENERATOR ASSY (W04D J) Check for ground. Ohmmeter Using an ohmmeter, check that there is no continu- ity between the coil lead and stator coil body. If there is continuity, replace the stator coil. No Continuity A71548 INSTALL STATOR COIL Install the stator coil and solder each terminal of the stator...
Page 127 19 15 STARTING & CHARGING GENERATOR ASSY (W04D J) INSTALL GENERATOR BRUSH HOLDER ASSY Install the brush holder assembly. Solder the lead wire to the regulator. A71212...
Page 128: Alphabetical Index
00 1 ALPHABETICAL INDEX...
Page 129 00 2 ALPHABETICAL INDEX (A Page Page ABBREVIATIONS USED IN THIS MANUAL LUBRICATION ........02 8 (TERMS FOR ENGINE REPAIR MANUAL) .
Page 130 00 3 ALPHABETICAL INDEX (T Page TORQUE SPECIFICATION (ENGINE MECHANICAL) ....... 03 9 TORQUE SPECIFICATION (FUEL) .

Hino W04D-J Workshop Manual

Introduction

Preparation

Service Specifications

Engine Mechanical

Cooling

Lubrication

Starting & Charging

Quick Links

Chapters

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hino W04D-J

Summary of Contents for Hino W04D-J

Table of Contents