Page 1 FOREWORD This workshop manual has been prepared to provide information covering general service repairs for the S05C B, S05C TA and S05C TB engines equipped on the Hino Motors,Ltd. Applicable models: XZU404, 412, 414, 422, 424, 434 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
INTRODUCTION HOW TO USE THIS ENGINE REPAIR MANUAL ......01 1 GENERAL INFORMATION .
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
01 12 INTRODUCTION 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 INTAKE ....... . . 02 1 PREPARATION ......02 1 ENGINE MECHANICAL .
Page 20: Intake
02 1 PREPARATION INTAKE INTAKE 022E2 01 PREPARATION Recomended Tools 09200 00010 Engine Adjust Kit INTAKE MANIFOLD Equipment Precision straight edge...
Page 21: Engine Mechanical
02 2 PREPARATION ENGINE MECHANICAL ENGINE MECHANICAL 022E7 01 PREPARATION 09201 41020 Valve Stem Oil Seal Replacer CAMSHAFT HOUSING AND CYLINDER HEAD Valve Spring Compressor CAMSHAFT HOUSING AND 09202 70020 CYLINDER HEAD 09960 10010 Variable Pin Wrench Set CAMSHAFT HOUSING AND CYLINDER HEAD 09402 1480 Press sub Assy...
Page 22 02 3 PREPARATION ENGINE MECHANICAL 09481 1140 Guide PISTON, CRANKSHAFT AND CYLINDER BLOCK 09481 1340 Guide CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING 9001 24262 Check Bolt PISTON, CRANKSHAFT AND CYLINDER BLOCK 9191 08252 Bolt PISTON, CRANKSHAFT AND CYLINDER BLOCK Steel Ball CAMSHAFT HOUSING AND...
Page 23 02 4 PREPARATION ENGINE MECHANICAL Press Sliding hammer Soft brush Solvent Spring tester Steam cleaner Steel square Straight edge Torch Torque wrench Valve guide bushing brush Valve seat cutter V block Vernier calipers Wire brush...
Page 24: Exhaust
02 5 PREPARATION EXHAUST EXHAUST 022E3 01 PREPARATION Recomended Tools 09200 00010 Engine Adjust Kit EXHAUST MANIFOLD Equipment Precision straight edge...
Page 25: Cooling
02 6 PREPARATION COOLING COOLING 022E4 01 PREPARATION 09236 00101 Water Pump Overhaul Tool Set WATER PUMP ASSY Bearing Stay WATER PUMP ASSY (09236 15010) 09238 47012 Water Pump Bearing Remover & WATER PUMP ASSY Replacer 09950 50013 Puller C Set WATER PUMP ASSY (09951 05010) Hanger 150...
Page 26: Lubrication
02 7 PREPARATION LUBRICATION LUBRICATION 022E5 01 PREPARATION Equipment Dial gauge Micrometer Torque wrench...
Page 27: Starting & Charging
02 8 PREPARATION STARTING & CHARGING STARTING & CHARGING 022E6 01 PREPARATION 09285 76010 Injection Pump Camshaft Bearing GENERATOR ASSY Cone Replacer Injection Pump Spline Shaft GENERATOR ASSY 09286 46011 Puller 09820 00021 Alternator Rear Bearing Puller GENERATOR ASSY 09820 00030 Alternator Rear Bearing Replacer GENERATOR ASSY 09820 63010...
Page 28 02 9 PREPARATION STARTING & CHARGING Equipment Ammeter (A) Battery specific gravity gauge Except maintenance free battery Belt tension gauge Cylinder indicator Commutator Micro meter Starter clutch Plastic hammer Pull scale Brush spring Sandpaper Commutator Torque wrench Vernier calipers Commutator, Brush, Rotor (Slip ring)
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 03096 06 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class 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 03097 07 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 03098 06 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class 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 030OA 02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Nozzle retaining nut x Nozzle holder body 63.7...
Page 34: Intake
03 5 SERVICE SPECIFICATIONS INTAKE INTAKE 030NN 02 SERVICE DATA Intake manifold Warpage Maximum 0.20 mm (0.0079 in.)
Page 35: Engine Mechanical
03 6 SERVICE SPECIFICATIONS ENGINE MECHANICAL ENGINE MECHANICAL 030NP 03 SERVICE DATA Valve clearance at cold Intake 0.30 mm (0.012 in.) Exhaust 0.45 mm (0.018 in.) Timing gear Main idler gear Outside diameter of main idler gear shaft 56.94 56.97 mm (2.2417 2.2429 in.) Inside diameter of main idler gear bushing 57.00...
Page 36 03 7 SERVICE SPECIFICATIONS ENGINE MECHANICAL Valve Valve seat angle Intake 30˚00’ 30˚30’ Exhaust 44˚15’ 45˚45’ Valve face angle Intake 29˚45’ 30˚00’ Exhaust 44˚45’ 45˚00’ Valve sink dimension STD Intake 0.55 0.85 mm (0.0217 0.0335 in.) Exhaust 1.30 1.60 mm (0.0512 0.0630 in.) Maximum Intake 1.20 mm (0.0472 in.)
Page 37 03 8 SERVICE SPECIFICATIONS ENGINE MECHANICAL Connecting rod Length 82.5 mm (3.280 in.) bolt 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 S05C B: 113.920 113.944 mm (4.4850 4.4860 in.) Minimum 113.920 mm (4.4860 in.)
Page 38 03 9 SERVICE SPECIFICATIONS ENGINE MECHANICAL Cylinder block Warpage 0.05 mm (0.0020 in.) or less Maximum 0.20 mm (0.0079 in.) Main bearing bore diameter (w/o bearing) 84.985 85.000 mm (3.3459 3.3465 in.) Maximum 85.20 mm (3.3543 in.) Main bearing bore diameter (w/ bearing) 80.00 mm (3.1496 in.) Maximum 80.30 mm (3.1614 in.)
Page 39: Torque Specification
03 10 SERVICE SPECIFICATIONS ENGINE MECHANICAL 030O8 03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Rear end plate bolt Oil pump x Cylinder block 28.5 Sub idler gear shaft x Cylinder block 1,100 Main idler gear shaft x Cylinder block 1,750 Camshaft gear x Camshaft 59 + 90˚...
Page 40: Exhaust
03 11 SERVICE SPECIFICATIONS EXHAUST EXHAUST 030O3 02 SERVICE DATA Exhaust manifold Warpage Maximum 0.20 mm (0.0079 in.)
Page 41: Cooling
03 12 SERVICE SPECIFICATIONS COOLING COOLING 030O4 04 SERVICE DATA Water Pump Water Pump bearing Refarence value 5 mm (0.020 in.) Water Pump pulley Refarence value 6.3 mm (0.25 in.) Thermostat Valve opening temperature 84˚C (176 183˚F) Valve lift at 95˚C (203˚F) 10 mm (0.39 in.) or more...
Page 42: Lubrication
03 13 SERVICE SPECIFICATIONS LUBRICATION LUBRICATION 030O5 04 SERVICE DATA Oil pump Backlach 0.073 0.203 mm (0.0029 0.0081 in.) Maximum 0.3 mm (0.0118 in.) Shaft diameter Driven gear shaft 18.064 18.082 mm (0.7112 0.7119 in.) Inside diameter Driven gear bush 18.122 18.147 mm (0.7135 0.7144 in.)
Page 43: Starting & Charging
03 14 SERVICE SPECIFICATIONS STARTING & CHARGING STARTING & CHARGING 030O6 02 SERVICE DATA Commutator Starter Diameter 32.0 mm (1.260 in.) Minimum 30.0 mm (1.181 in.) Undercut depth 0.7 mm (0.028 in.) Minimum 0.2 mm (0.008 in.) Brash length 18.0 mm (0.709 in.) Minimum 12.0 mm (0.472 in.) Spring installed load...
Page 44: Torque Specification
03 15 SERVICE SPECIFICATIONS STARTING & CHARGING 030O7 02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Motor housing x Starter drive housing Magnetic switch x Starter drive housing 14.7 Commutator end frame x Starter drive housing 14.7 Commutator end frame x Brush holder 38 in.·lbf Bearing retainer x Drive end frame 26 in.·lbf...
Page 45 FUEL NOZZLE HOLDER AND NOZZLE SET ..11 1 COMPONENTS ......11 1 OVERHAUL .
Page 46 11 1 FUEL NOZZLE HOLDER AND NOZZLE SET NOZZLE HOLDER AND NOZZLE SET 110R0 01 COMPONENTS Nozzle Clamp Nozzle Holder and Nozzle Set 63.7 (650, 47) z O Ring Sleeve z O Ring Nozzle Holder Body Joint Bolt z Gasket Nozzle Holder Cap Nut Nozzle...
Page 47 11 2 FUEL NOZZLE HOLDER AND NOZZLE SET 110R1 01 OVERHAUL REMOVE NOZZLE ASSY Remove the nozzle holder retaining nut. NOTICE: When disassembling the nozzle, be careful not to drop the inner parts. Disassemble the nozzle holder and nozzle set, and re- move the nozzle assy.
Page 48 11 3 FUEL NOZZLE HOLDER AND NOZZLE SET Check the seat of the nozzle body for burns or corrosion. Check the nozzle needle tip for damage or corrosion. If any of these conditions are present, replace the nozzle assy. A71022 INSPECT NOZZLE ASSY Wash the nozzle in clean diesel fuel.
Page 49 11 4 FUEL NOZZLE HOLDER AND NOZZLE SET INSPECT NOZZLE HOLDER AND NOZZLE SET Check for leaks. While maintaining pressure at about 981 1,961 kPa (10 20 kgf/cm 284 psi) below No.1 opening pressure (adjust it by tester handle), check that there is no dripping from the injection hole or around the retaining nut for 10 seconds.
Page 50 INTAKE INTAKE MANIFOLD ..... . 13 1 INSPECTION ......13 1...
Page 51: Intake Manifold
13 1 INTAKE INTAKE MANIFOLD INTAKE MANIFOLD 1305Z 01 INSPECTION INSPECT INTAKE MANIFOLD HINT: Clean the intake manifold with a commercial cleaning agent be- fore the inspection. Using a dye penetrate, check the intake manifold for cracks, using a dye penetrate. If cracks are found, replace the manifold.
Page 52: Engine Mechanical
ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD ..... . 14 1 COMPONENTS ......14 1 OVERHAUL .
Page 53: Camshaft Housing And Cylinder Head
14 1 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD CAMSHAFT HOUSING AND CYLINDER HEAD 1417J 01 COMPONENTS S05C TB Oil Filler Cap 28.5 (290, 21) Cylinder Head Cover Spacer z Gasket Camshaft Camshaft Bearing 59 (600, 44) + 90˚ Camshaft Timing Gear Valve Rocker Shaft Knock Pin...
Page 54 14 2 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD S05C B, S05C TA Oil Filler Cap S05C TA Model: Oil Filler Cap Cylinder Head Cover 28.5 (290, 21) 28.5 (290, 21) Spacer Spacer z Gasket z Gasket Cylinder Head Cover Camshaft 28.5 (290, 21) Camshaft Bearing...
Page 55: Overhaul
14 3 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD 1417K 01 OVERHAUL REMOVE CYLINDER HEAD COVER SUB ASSY S05C TA NOTICE: S05C TB Clean all dust around the cylinder head cover before re- moving it to prevent foreign particles from getting in. S05C B A64145 A80466...
Page 56 14 4 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD REMOVE NOZZLE HOLDER SEAL REMOVE NOZZLE LEAKAGE PIPE NO.1 S05C TB A64549 REMOVE NOZZLE LEAKAGE PIPE S05C B Remove the 5 joint bolts, fuel return pipe and 5 gaskets. S05C TA A70959 REMOVE INJECTOR HARNESS BRACKET S05C TB...
Page 57 14 5 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD REMOVE INJECTION NOZZLE SUB ASSY S05C B S05C TA Loosen the injection pipe nut. Remove the injection pipe seal mounting bolts. Then, re- move the injection pipe seal together with the injection pipe out of the cam housing.
Page 58: Remove Camshaft
14 6 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD REMOVE VALVE ROCKER ARM ASSY S05C B Remove the rocker arm support bolt in the order as shown S05C TA Rocker Arm Support in the illustration. Remove the valve bridge. NOTICE: When the rocker arm assembly is removed, the rocker arm and support tend to come off the rocker shaft.
Page 59 14 7 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD REMOVE CAMSHAFT TIMING GEAR Using SST, remove the timing gear. 09960 10010 (09962 01000, 09963 01000) A63492 REMOVE VALVE Using SST, press fit the valve spring seat upper, then re- move the valve spring retainer. 09202 70020 A64525 Remove the valve spring seat upper, valve springs outer...
Page 60 14 8 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSPECT CYLINDER HEAD SUB ASSY Inspect for cracks. Using a dye penetrate, check the intake ports, ex- haust ports and the surface contacting the cylinder block. If cracks are found, replace the cylinder head. A63451 Inspect for flatness.
Page 61 14 9 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Tapping and rotating the valve against the seat, check the seating condition. If the red lead mark is not concentric or the compound is scat- tered all around the valve face or seat, correct the valve face or the valve seat.
Page 62 14 10 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL VALVE SEAT Machine the valve seat according to the specified valve seat dimensions. Cylinder head dimension: Intake (A) 41.000 41.016 mm (1.6142 1.6148 in.) Intake (B) 9.400 9.600 mm (0.3701 0.3780 in.) Exhaust (A) 39.000...
Page 63 14 11 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSPECT VALVE STEM AND VALVE GUIDE Using a micrometer, measure the diameter of the stem. Standard valve stem diameter: Intake 6.957 6.977 mm (0.2739 0.2747 in.) Exhaust 6.932 6.950 mm (0.2730 0.2736 in.) Minimum valve stem diameter: Intake...
Page 64 14 12 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL VALVE STEM SEAL Valve Stem Seal Install the lower spring seat and valve to the cylinder head Valve Spring Seat (for guide of SST), then apply engine oil to the lip of the Lower stem seal and drive the guide with SST.
Page 65 14 13 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSPECT VALVE SPRING SEAT Visually check the contact surface of the upper and lower valve spring seats. If damage such, as wear and scratches, is excessive, replace the valve spring seat. A63503 INSPECT CYLINDER HEAD COOLANT GALLERY FOR LEAKS Close all coolant holes and apply air pressure of about 2.5 kgf/cm...
Page 66 14 14 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Install the injector or injection nozzle to the cylinder head. Using vernier calipers, measure the protrusion of the in- jector from the lower surface of the cylinder head. Protrusion: S05C TB Cylinder Head Standard 2.35...
Page 67 14 15 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 50.067 mm (1.9711 in.) Exhaust 52.104 mm (2.0153 in.) Minimum cam lobe height: Intake 49.967 mm (1.9672 in.) Exhaust 52.004 mm (2.0474 in.) If the lobe height is less than the minimum, replace the cam-...
Page 68 14 16 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL CAMSHAFT TIMING GEAR Measure the length of the camshaft gear bolts. Maximum length (A): 30.0 mm (1.181 in.) If the length is greator than A, replace them with new bolts. Make sure that there is no dirt or scratch on the camshaft gear and tightening surface of the camshaft.
Page 69 14 17 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSPECT VALVE ROCKER ARM AND VALVE BRIDGE Visually check the contact 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 using a resurfacer.
Page 70 14 18 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL CYLINDER HEAD GASKET HINT: Do not reuse the head gasket for any reason, because it Seal Packing Application Point will cause the engine damage. Before installing the cylinder head gasket, remove dirt, moisture and oil on the cylinder head and cylinder block surface.
Page 71 14 19 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Tighten the cylinder head bolts. Tighten bolts No. 1 No. 18 (M12) in the order shown in the illustration. Torque: 59 N m (600 kgf cm, 44 ft lbf) After tightening bolt No. 18, check the torque again all through the bolts from No.
Page 72 14 20 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL CAMSHAFT BEARING CAP Adjust the orientation and position of the camshaft bear- ing and cam cap, and install them Do not tighten the bolt at this time. HINT: Front Side The stamp marks (triangle) of the camshaft bearing cap are di- rected to the front side of the engine, and they are arranged in order of 1 through 5 from the front side.
Page 73 14 21 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSPECT CAMSHAFT THRUST CLEARANCE HINT: Using a feeler gauge, measure the thrust clearance between the camshaft and camshaft bearing. Thrust clearance: Maximum 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the camshaft.
Page 74 14 22 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD INSTALL INJECTION NOZZLE SUB ASSY S05C B Injection Install a new O ring into the groove of the cylinder head. Valve Spring S05C TA Pipe Unit Make sure that there is no dirt or foreign particles at the sealing part between the nozzle holder and related parts (O ring, nozzle sleeve and injection pipe seal), and con- necting part between the nozzle holder and nut of the in-...
Page 75 14 23 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Check only those valves indicated in the illustration with S05C TB the No.1 piston in the top dead center. Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. Standard clearance: Intake 0.30 mm (0.012 in.)
Page 76: Adjust Valve Clearance
14 24 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD ADJUST VALVE CLEARANCE Loosen the adjusting screw nut of the valve bridge com- pletely. Adhesion 10 mm HINT: or more The adjusting screw must protrude by 10 mm (0.3931 in.) or more from the valve bridge upper surface. Unless the adjusting screw is completely loose to the valve stem, the following adjustments may be adversely affected.
Page 77 14 25 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD The adjustable valve clearance, when either the No. 1 or No. 4 piston is at the TDC of the compression stroke, is shown in the following chart. After completing the valve clearance adjustment when the No.1 piston is at the TDC of the compression stroke, turn the crankshaft one com- plete revolution and make the No.4 piston be at the TDC...
Page 78 14 26 ENGINE MECHANICAL CAMSHAFT HOUSING AND CYLINDER HEAD Apply seal packing to plug corner A at the front and rear ends of the cam housing. Install the cylinder head cover gasket into the gasket groove at the head cover lower surface. Insert the spacer from the head cover to the cam housing.
Page 79: Crankshaft Front End, Oil Pan, Flywheel And Flywheel Housing
14 27 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING 1417L 01 COMPONENTS Oil Seal Retainer Crankshaft Front Oil Seal Flywheel Housing Rear End Plate Dust Cover z Gasket Crankshaft Position Sensor Dust Cover...
Page 80 14 28 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING S05C TA S05C TB See page 14 47 69 (700, 43) + 90˚+ 45˚ Liner Oil Jet Valve 22 (220, 16) S05C TB Only z Gasket Upper Oil Pan Oil Level Gauge 28.5 (290, 21) 171.5 (1,750, 127)
Page 81 14 29 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING S05C B z Gasket Oil Pan Soft Washer Drain Plug 28.5 : Specified torque N m (kgf cm, ft lbf) z Non reusable part A70968...
Page 82: Overhaul
14 30 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING 1417M 01 OVERHAUL REMOVE CRANKSHAFT PULLEY A64128 REMOVE OIL PAN S05C TA Remove the oil pan cover. S05C TB Remove the lower oil pan. Remove the upper oil pan. A64524...
Page 83 14 31 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING REMOVE OIL PAN AND OIL STRAINER S05C B A70969 REMOVE FLYWHEEL SUB ASSY Remove the pilot bearing. S05C TB: Remove the crankshaft position sensor from the flywheel housing.
Page 84 14 32 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING Install SST (center bolt) and tighten it to remove the oil seal. A64520 REMOVE FLYWHEEL HOUSING Remove the 2 front mounting bolts of the flywheel hous- ing. Remove the rear mounting bolts of the flywheel housing.
Page 85 14 33 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING REMOVE OIL SEAL RETAINER A63426 INSPECT CRANKSHAFT PULLEY HINT: Clean the torsional damper with a commercial cleaning agent before the inspection. Use a cleaning agent that does not damage gum. Check if there are any cracks in the damper rubber sec- tion.
Page 86 14 34 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING REMOVE FLYWHEEL RING GEAR Using a torch, heat the ring gear evenly to about 200_C (392_F) with a torch. Insert the ring gear periphery lightly, using a cushion bar to remove the gear. CAUTION: Never touch the ring gear or flywheel with your bare hands when they are hot.
Page 87 14 35 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING INSTALL CRANKSHAFT OIL SEAL Clean the edges and surface of the crankshaft and SST. Guide Insert a new crankshaft oil seal into SST (guide of oil seal press).
Page 88 14 36 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING INSTALL FLYWHEEL SUB ASSY Make sure that there are no burns or dirt on the contact surface or in the threaded hole of the crankshaft or fly- wheel.
Page 89: Install Oil Pan
14 37 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING Install the pilot bearing. S05C TB: Install the crankshaft position sensor. A63436 INSTALL OIL PAN Make sure that there is no deformation, impact marks or Seal Packing (2 Parts Each) foreign particles on the mounting surface and stiffener surface of the upper oil pan.
Page 90 14 38 ENGINE MECHANICAL CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND FLYWHEEL HOUSING Install the upper oil pan gasket so that the protrusion will Bolt Tightening Direction S05C B be on the flywheel housing side and the print seal surface will be on the cylinder block side.
Page 91: Timing Gear
14 39 ENGINE MECHANICAL TIMING GEAR TIMING GEAR 1417N 01 COMPONENTS Camshaft Timing Gear Camshaft Idler Gear Main Idler Gear Sub Idler Gear Vacuum Pump Gear Power Steering Oil Pump Drive Gear Pump Gear Supply Pump Drive Gear Crankshaft Timing Gear Camshaft Rear End Plate Camshaft Idler Gear...
Page 92: Overhaul
14 40 ENGINE MECHANICAL TIMING GEAR 1417O 01 OVERHAUL REMOVE MAIN IDLER GEAR Remove the mounting bolts of the main idler gear shaft. Remove the main idler gear. A60057 Using a sliding hammer, drive out the main idler gear shaft. Check the teeth of each gear for wear and pitching.
Page 93 14 41 ENGINE MECHANICAL TIMING GEAR REMOVE OIL PUMP ASSY A63420 REMOVE REAR END PLATE Using a socket wrench, remove the 2 torx bolts adjacent to the supply pump drive shaft mounting section. Rear End Plate A16232 A16124 A63421 INSPECT OIL CLEARANCE BETWEEN MAIN IDLER GEAR BUSH AND SHAFT Using a micrometer, measure the diameter of the main idler gear shaft.
Page 94 14 42 ENGINE MECHANICAL TIMING GEAR If the oil clearance is greater than the maximum, replace the main idler gear shaft and/or main idler gear bush. INSPECT OIL CLEARANCE BETWEEN SUB IDLER GEAR BUSH AND SHAFT Using a micrometer, measure the outside diameter of the sub idler gear shaft.
Page 95: Cylinder Block
14 43 ENGINE MECHANICAL TIMING GEAR INSTALL OIL PUMP ASSY Apply oil to the pump case and bearings of the block (hatched area) before installing the oil pump. HINT: Not applying oil may cause oil suction failure at start up, result- ing in seizure and abnormality.
Page 96 14 44 ENGINE MECHANICAL TIMING GEAR INSTALL SUB IDLER GEAR Install the sub idler gear shaft through the thrust plate so that the lubrication hole faces downward. Install the sub idler gear. Apply engine oil to the seat and thread of the bolt. Tighten the mounting bolts of the sub idler gear shaft.
Page 97 14 45 ENGINE MECHANICAL TIMING GEAR INSPECT TIMING GEAR BACKLASH Using a dial gauge, measure the backlash between the gears. Backlash: Item Standard backlash Maximum backlash Crankshaft x Main idler 0.030 0.167 mm (0.0012 0.0065 in.) Main idler x Injection pump or Supply 0.030 0.218 mm (0.0012 0.0085 in.)
Page 98: Components
14 46 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK PISTON, CRANKSHAFT AND CYLINDER BLOCK 1417P 01 COMPONENTS Piston Pin Piston Retainer Ring Piston Ring Camshaft z Connecting Rod Bush 1,100 Connecting Rod z Connecting Rod Cap 1,750 Main Idler Gear Cylinder Liner Connecting Rod Bearing Cylinder Block...
Page 99: Overhaul
14 47 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK 1417Q 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. A64171 HINT: Before pulling out the pistons, remove carbon deposits...
Page 100 14 48 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Remove the crankshaft. A64176 REMOVE CYLINDER LINER HINT: Before removing the piston, put alignment marks on the cylin- der liner and cylinder is bent by ”run in”. When reusing the cyl- inder liner, misalignment with the cylinder block may concen- trate stress on the thin part of the cylinder liner and it may be broken.
Page 101 14 49 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK REMOVE CONNECTING ROD SUB ASSY Using snap ring pliers, remove the retainer rings from the both ends of the piston pin. CAUTION: Removing the retainer rings may cause the retainer rings to fly up.
Page 102 14 50 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Using a rod aligner and feeler gauge, check the connect- ing rod alignment. Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the bend is greater than the maximum, replace the connecting rod with a new one.
Page 103 14 51 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSPECT CONNECTING ROD BIG END After tightening the connecting rod cap without bearing, using a cylinder gauge, measure the inside diameter of the connecting rod big end to calculate the roundness. Standard inside diameter: 68.985 69.000 mm (2.7159...
Page 104 14 52 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Using a cylinder gauge, measure the connecting rod bearing inside diameter. Standard inside diameter: 64.991 65.022 mm (2.5587 2.5599 in.) Maximum inside diameter: 65.022 mm (2.5599 in.) Calculate the clearance between the crankshaft pin and connecting rod bearing.
Page 105 14 53 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Using a micrometer, measure the piston diameter at the in the illustration points. Standard piston diameter: S05C B: 113.920 113.944 mm (4.4850 4.4859 in.) S05C TA, TB: 113.869 113.885 mm (4.4830 4.4837 in.) Minimum piston diameter: 113.869 mm (4.4850 in.) If the piston diameter is less than the minimum, replace the pis-...
Page 106 14 54 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSPECT PISTON PIN BOSS Using a cylinder gauge, measure the piston pin boss in- side diameter. Standard piston pin boss inside diameter: 36.987 37.003 mm (1.4561 1.4568 in.) Maximum piston pin boss inside diameter: 37.05 mm (1.4587 in.) If the inside diameter is greater than the maximum, replace the piston with a new one.
Page 107 14 55 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Groove width: S05C B Item Standard Maximum 2.55 2.57 mm 1st ring 2.70 mm (0.1062 in.) (0.1003 0.1011 in.) 2.03 2.05 mm 2nd ring 2.20 mm (0.0866 in.) (0.0799 0.0807 in.) 4.01 4.03 mm Oil ring...
Page 108 14 56 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSPECT CRANKSHAFT HINT: Before the inspection, clean the crankshaft with a commercial cleaning agent and clean the lubrication passage using an air gun. A64193 Performing the dye penetrant test, and check the crank- shaft for cracks.
Page 109 14 57 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSPECT CRANKSHAFT JOURNAL AND BEARING Using a micrometer, measure the main journal outside di- ameter. Standard journal diameter: 79.940 79.960 mm (3.1472 3.1480 in.) Minimum journal diameter: Repair 79.80 mm (3.1417 in.) 78.80 mm (3.1024 in.) If the diameter is less than the minimum for use, replace the crankshaft with a new one.
Page 110 14 58 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK HINT: Make sure to replace the top and bottom main bearings as one set. The top and bottom main bearings must be round. HINT: Machined dimension of filet R Main crankshaft journal: CORRECT WRONG 5.5 mm (0.1969...
Page 111 14 59 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSPECT OIL JET Check the oil jet for damage or clogging. If necessary, replace the oil jet. A64515 ADJUST OIL JET Align the pin of the jet with the pin hole of the cylinder Oil Jet block.
Page 112 14 60 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK If the center of the jet flow is out of the ø 7 mm (ø 0.27 in.) refer- ence line of the gauge, adjust the jet sight using the SST. Remove the checking bolt after the inspection. 09472 1620 A64311 INSTALL CHECK VALVE AND OIL JET...
Page 113 14 61 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Using a press, remove the bush. Press HINT: Spindle Always operate the press slowly and smoothly. Connecting Rod A64168 Assemble the bush. C 0.5 1.0 mm Chamfer one edge of the bush hole at the small end of the connecting rod uniformly by C 0.5 1.0 mm (0.0196...
Page 114 14 62 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSTALL CYLINDER LINER HINT: Marks of Liner 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 115 14 63 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK After the installation, apply engine oil to the journal sur- faces of the bearings. Install the thrust washers onto the 4 points of the No. 2 journal of the cylinder block and either side of the bearing caps.
Page 116 14 64 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Tighten the bolts in the order shown in the illustra- tion. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) Loosen all the bolts. Front Tighten the bolts as in step (3). Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) A64314 Mark the bolts with paint to indicate the same direc- tion.
Page 117 14 65 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Immerse the piston in hot water, 80 90˚C (176 194˚F) for approximately 5 minutes. Assemble the piston with the O mark being opposite to Piston O Mark the connecting rod matchmark. CAUTION: Never touch the piston with your bare hands while it is hot.
Page 118 14 66 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK INSTALL PISTON RING Facing the identification marks on the piston ring upper Ring Upper Face surface, install them in the order of oil ring, 2nd ring and 1st ring using a piston ring expander. HINT: Never change the combination of the coil and oil ring.
Page 119 14 67 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK HINT: Before the installation, apply engine oil to the piston pin, piston ring, cylinder liner and connecting rod bearing. Recheck the matching point of each piston ring. Oil Jet A64319 Make sure that the O mark on the piston is at the exhaust Exhaust Port Side O Mark side.
Page 120 14 68 ENGINE MECHANICAL PISTON, CRANKSHAFT AND CYLINDER BLOCK Turn the crank to make the piston in the bottom dead cen- ter, and then check that the piston and oil jet nozzle of the block do not interfere each other. HINT: When adding torque, never untighten the nuts even if they have been overtightened.
Page 121 EXHAUST EXHAUST MANIFOLD ....15 1 INSPECTION ......15 1...
Page 122: Exhaust Manifold
15 1 EXHAUST EXHAUST MANIFOLD EXHAUST MANIFOLD 1508L 01 INSPECTION INSPECT EXHAUST MANIFOLD S05C TA HINT: S05C TB 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.
Page 123 COOLING WATER PUMP ASSY ..... 16 1 OVERHAUL ....... 16 1 THERMOSTAT .
Page 124: Water Pump Assy
16 1 COOLING WATER PUMP ASSY WATER PUMP ASSY 160KS 01 OVERHAUL REMOVE WATER PUMP ROTOR Using SST, remove the rotor. 09420 1820 B58339 REMOVE WATER PUMP PULLEY SEAT Remove the 4 stud bolts. Using SST, remove the pulley seat. 09950 50013 (09951 05010, 09952 05010, 09953 05010, 09954 05021) B58340...
Page 125 16 2 COOLING WATER PUMP ASSY REMOVE WATER PUMP SEAL SET Using SST and a press, press out the seal. 09236 00101 (09236 15010) B58343 INSTALL WATER PUMP BEARING & SHAFT SUB ASSY Using a press, press in the bearing and shaft into the place, as shown in the illustration.
Page 126: Thermostat
16 3 COOLING THERMOSTAT THERMOSTAT 160KT 01 INSPECTION INSPECT THERMOSTAT CASE ASSY HINT: The thermostat is numbered with the valve opening tempera- ture. 76.5 _C A64555 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 74.5 78.5˚C (166...
Page 127 LUBRICATION OIL PUMP ASSY ......17 1 COMPONENTS ......17 1 OVERHAUL .
Page 128: Oil Pump Assy
17 1 LUBRICATION OIL PUMP ASSY OIL PUMP ASSY 170EI 01 COMPONENTS Oil Cooler with Oil Filter 24.5 (250, 18) O Ring Oil Pump 28 (290, 20.7) Gasket Driven Gear Relief Valve Relief Valve Spring Seat Seat Cotter Pin O Ring 28 (290, 20.7) Oil Strainer N·m (kgf·cm, ft·lbf) : Specified torque...
Page 129: Overhaul
17 2 LUBRICATION OIL PUMP ASSY 170EJ 01 OVERHAUL 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. B58348 REMOVE OIL PUMP RELIEF VALVE Pull out the cotter pin, and remove the 2 seats, relief valve spring and safety valve.
Page 130 17 3 LUBRICATION OIL PUMP ASSY Inspect the clearance between the diameter of the driven gear shaft and the inside diameter of the driven gear bush. Using a micrometer, measure the diameter of the driven gear shaft. Shaft diameter: 18.064 18.082 mm (0.7112 0.7119 in.) B58377...
Page 131 17 4 LUBRICATION OIL PUMP ASSY INSTALL OIL PUMP DRIVEN GEAR Install the driven gear to the oil pump. B58348...
Page 132: Oil Cooler
17 5 LUBRICATION OIL COOLER OIL COOLER 170EK 01 INSPECTION INSPECT OIL COOLER NOTICE: Before the inspection, please refer to the following items. Be sure to clean the oil cooler element and oil passage, using a commercial cleaning agent. Clean the metal parts using treated oil. Carry out a pneumatic test for the oil cooler element.
Page 133: Starting & Charging
STARTING & CHARGING STARTER ASSY ......19 1 COMPONENTS ......19 1 OVERHAUL .
Page 134: Starter Assy
19 1 STARTING & CHARGING STARTER ASSY STARTER ASSY 190LZ 01 COMPONENTS Lead Wire Magnet Starter Switch 4.3 (44, 38 in.·lbf) O Ring 14.7 (150, 11) Brush Holder Starter Yoke Assy 14.7 (150, 11) Commutator End Frame Felt Brush Washer Armature Felt (Commutator)
Page 135: Overhaul
19 2 STARTING & CHARGING STARTER ASSY 190M0 01 OVERHAUL REMOVE STARTER YOKE ASSY Lead Wire M Move the cap of terminal M, then remove the nut and lead Terminal M (Cap) wire M. Terminal C Move the cap of terminal C, then remove the bolt. (Cap) Lead Wire C B58381...
Page 136 19 3 STARTING & CHARGING STARTER ASSY 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 the direction A, as shown in the illustration.
Page 137 19 4 STARTING & CHARGING STARTER ASSY 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. Check the commutator open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator.
Page 138 19 5 STARTING & CHARGING STARTER ASSY Inspect for ground. No Continuity Using an ohmmeter, check that there is no continu- ity between the field coil end and starter yoke. If there is continuity, repair or replace the starter yoke assy. Ohmmeter B58394 INSPECT BRUSH...
Page 139 19 6 STARTING & CHARGING STARTER ASSY Using an ohmmeter, check that there is continuity be- Main Switch Assembly tween terminals B and M. If there is continuity, replace the magnet switch assy. Push the main switch assembly, using an ohmmeter, check that there is continuity between terminals B and M.
Page 140 19 7 STARTING & CHARGING STARTER ASSY INSPECT STARTER COMMUTATOR END FRAME ASSY Using a cylinder gauge, check the inside diameter of the end frame bush. Inside diameter: Standard Minimum 12.0 mm (0.472 in.) 12.2 mm (0.480 in.) If the diameter is greater than the minimum, replace the frame. B58428 INSTALL STARTER DUST PROTECTOR Using SST and a plastic faced hammer, tap in the protec-...
Page 141 19 8 STARTING & CHARGING STARTER ASSY INSTALL PINION GEAR Install the pinion gear to the shaft by tapping it uniformly. Using pliers, pinch a new retainer and the shaft, then press them in. B58433 INSTALL ARMATURE BEARING Using SST and a press, install the bearing. 09820 36010 B58434 INSTALL MOTOR HOUSING...
Page 142 19 9 STARTING & CHARGING STARTER ASSY INSTALL STARTER YOKE ASSY Align the cutout of the starter yoke with the cutout of the motor housing. Install the starter yoke. Cutout B58437 INSTALL STARTER BRUSH HOLDER ASSY Place the brush holder in position on the armature. Using a screwdriver, hold the brush spring back, and con- nect the brush into the brush holder.
Page 143: Generator Assy
19 10 STARTING & CHARGING GENERATOR ASSY GENERATOR ASSY 190M1 01 COMPONENTS Generator Washer Bearing Cover Rotor 2.9 (30, 26 in.·lbf) Generator Drive End Frame Bearing (Front) Generator Rotor Drive End Frame Bearing (Rear) Bearing Cover Generator Pulley Bearing Retainer Rear End Cover No.2 110 (1,125, 81) 4.1 (42, 36 in.·lbf)
Page 144: Overhaul
19 11 STARTING & CHARGING GENERATOR ASSY 190M2 01 OVERHAUL REMOVE REAR END COVER NO. 2 REMOVE REAR END COVER Remove the nut and terminal insulator. B58309 Remove the 3 nuts, bolt, plate terminal and rear end cover and brush holder cover. B58310 REMOVE GENERATOR BRUSH HOLDER ASSY Remove the 2 screws and brush holder.
Page 145 19 12 STARTING & CHARGING GENERATOR ASSY REMOVE GENERATOR HOLDER W/ RECTIFIER Remove the 4 screws and generator holder. B58314 Remove the 4 rubber insulators. B58315 REMOVE GENERATOR PULLEY SST (A) Hold SST (A) with a torque wrench, and tighten SST (B) SST (B) clockwise to the specified torque.
Page 146 19 13 STARTING & CHARGING GENERATOR ASSY Using SST, remove the rectifier end frame. 09286 46011 B58319 Remove the generator washer. B58320 REMOVE GENERATOR ROTOR ASSY B58338 INSPECT VOLTAGE REGULATOR Using an ohmmeter, check the continuity between termi- nals F and B. Ohmmeter Standard: When the positive and negative poles between termi-...
Page 147 19 14 STARTING & CHARGING GENERATOR ASSY INSPECT GENERATOR ROTOR ASSY Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: Ohmmeter 11.6 12.4 at 20˚C (68˚F) If there is no continuity, replace the rotor assy. Continuity B58321 Check the rotor for ground.
Page 148 19 15 STARTING & CHARGING GENERATOR ASSY INSPECT GENERATOR BRUSH HOLDER ASSY Using vernier calipers, measure the exposed brush length. Standard exposed length: 11.5 mm (0.374 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than the minimum, replace the brush holder assy.
Page 149 19 16 STARTING & CHARGING GENERATOR ASSY Using SST and a press, press out the bearing. 09950 60010, 09950 70010 B58330 INSTALL BEARING (FRONT) Using SST and a press, press in a new bearing. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) Install the bearing retainer with the 4 screws.
Page 150 19 17 STARTING & CHARGING GENERATOR ASSY Using SST, push in the bearing cover (outside). 09285 76010 B58335 INSTALL GENERATOR ROTOR ASSY Place drive end frame on pulley. Install the rotor to the drive end frame. Pulley B66458 INSTALL RECTIFIER END FRAME Place the generator washer on the rotor.
Page 151 19 18 STARTING & CHARGING GENERATOR ASSY INSTALL GENERATOR PULLEY SST (A) Install the pulley to the rotor shaft by tightening the pulley SST (B) nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. 09820 63010 Torque 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft.
Page 152 19 19 STARTING & CHARGING GENERATOR ASSY INSTALL REAR END COVER Place the brush holder cover on the brush holder. B58311 Install the rear end cover and plate terminal with the 2 nuts and bolt. Torque: 3.85 N·m (39 kgf·cm, 34 in.·lbf) for bolt 4.4 N·m (45 kgf·cm, 39 in.·lbf) for nut B58310 Install the terminal insulator with the nut.
Page 153: Alphabetical Index
00 1 ALPHABETICAL INDEX...
Page 154 00 2 ALPHABETICAL INDEX (A Page Page ABBREVIATIONS USED IN THIS MANUAL LUBRICATION ........02 7 (TERMS FOR ENGINE REPAIR MANUAL) .
Page 155 00 3 ALPHABETICAL INDEX (T Page TORQUE SPECIFICATION (ENGINE MECHANICAL) ..... . 03 10 TORQUE SPECIFICATION (FUEL) ....03 4 TORQUE SPECIFICATION (STARTING &...

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