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494 views282 pagesDiesel Engine Operators Manual Part 3
Diesel Engine Operators Manual Part 3
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100% found this document useful (1 vote)
494 views282 pagesDiesel Engine Operators Manual Part 3
Diesel Engine Operators Manual Part 3
Uploaded by
GRUFASA Grupo FanjulCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
HINO DIESEL ENGINE
WORKSHOP MANUAL
P11C-UN
oe (Crane)
CHIN a
2005.10 Cn: |
[STANDARD vaLuE SSC
PARTS TO BE PREPARED 3 |
ENGINE ASSEMBLY/DISASSEMBLY i
FUEL SYSTEM 5 |
ELECTRICAL
INTAKE is |
ENGINE MECHANICAL
EXHAUST. ji0 |
COOLING
LUBRICATION
STARTING AND CHARGING : 13 |
TURBOCHARGER gi
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS. 15 |
ENGINE DIAGNOSIS CODE wa GENERAL 4
1 GENERAL
Waring, 12
How to road this manual 43
Precautions for work 17
Tightaning of engine bots and nuts. 1
Tightening of chassis bots and nuts. 113
Tightening of flare nuts and hoses. 15
Taper thread sealant for ping 116
Assembly of joints and gaskets for ping. 17
Handing offquid gasket. 119
Fallure diagnos's table for each problem 4-20
Failure dlagnos's procedures. 421
Failure diagnosts using Hino-DX. 123
Connection method of Hino-DX. 1-26
Chassis number and engine numbor 1-26 12 GENERAL
Warning
Observe the following precautions to work safely and to prevent damage to customers! vehicles.
This manual is prepared for quaiiied service engineers who are recognized as technical experts, Those who are not
ualtied, who are not appropriately trained, who perform service without appropriate tools of equipment, of who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
+ Appropriate service and repair are essential to ensure safely of service enginaers and safety and reliability of
vvehioles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
+ Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
+ fa method or a too! not recommended is used, safety of sorvice engineers, and safety and reliability of vehicles
may be impaired, Never use a method or tool not recommended.
‘This manual shows "Warning" and ‘Caution’ for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to impropet method may not impair safely and reliability of
vohicles. These Instructions cannot give warning forall possible hazards, Note that items with "Waming’ or
Caution’ are not absolute for safety. GENERAL, 13
How to read this manual
1. Scope of repair work
(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly: disassembly and inspection. adjustment’ and "Final inspection".
(2) Trismanual describes "Diagnosis in the first process and *Mounting/removal, replacement, assembly. disassembly
‘and inspection. adjustment” in the socond process. Explanation of Final inspection in the third process is omited hore.
(3) Although the following work is not deseribed in this manual, it should be performed in actual work.
a. Jacking and iting
b, Cleaning and washing of removed parts as required
©. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
ems to be prepared
(1) toms to be prepared before work are SST, tools, gauges and lubricant, otc. These are listod in the ist
section of items to be prepared. Items such as general tools, jack, rigid rack, ete. thal are usually equipped
in general service shop are omitted.
4, How to read sections and titles
(1) Sections are classified according to J2008, SAE standard,
(2) Forareas that show system names like "Engine control syste
“Replacement”, "Overhaul, ete. of components are described.
(8) Forareas that show part names Ike “injection pump’, ‘Mounting/removal and disassembly" is described,
(4) Illustrations of the parts catalog are shown for part layout, (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
Inspection’, “Adjustment”,
ANCAUTION The part inyouts inthis manuel are Inserted based on Ikustrations and part numbers ofthe
parte catalog CD-ROM issued In October, 2005. (Some areas donot show exploded view.
They willbe adtonaly issued when the parts catalog CD is revised} Be sure to use the
parts catalog for confirmation of ilustations and part numbers and for ordering parts.
5. How to read troubleshooting
(1) Failure diagnosis in this manual desoribes Step 2 and Step 3 below:
Hear from customers for conditions and environments of |
(1) Question failures and check the fact.
top 1"
Perform diagnosis inspection, status inspection, function
(2) Pre-inspection “stop 2° _|inspection and basic Inspection. Check thefalure status,
@) Reproduction method Itt is difficult to reproduce the problem with status,
Inspection, use the reproduction method.
(4) Troubleshooting for each ‘Summarize inspection results obtained from Step 2.
diagnosis code “step or | Perform inspection systematically according to
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.
Check if failure occurs again after repair. If itis difficult to
(6) Confirmation test "stop 4" | reproduce a fallure, perform the confirmation test under
the conditions and environment of the failure, 14
GENERAL
(2) Presinspection
Pre
inspection
Prodnspection Is performed in the following step:
Diagnosis inspection Diagnosis deletion ~Failure status check (Use the reproduction
method if not reproduced.) ~»Diagnosis recontirmation
Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with falluro status. Refer to the troubleshooting chart for
estimated cause of a failure
ire occurs instantaneously. If any specific failure is not
‘An error code is displayed if fai
found, perform troubleshooting using the reproduction method.
Failure status check
Hf failure is reproduced,perform Step 2 Step 3 Step 4.
I failure Is not reproduced,use the reproduction method (simulation of external
conditions or check of each wire hamess and connector, etc.) GENERAL,
6
6. How to read explanation details
(1) Part tayout
Example
Part layout
ENGINE MECHANICAL [J08E)
Timing Gear Cover and Flywheel Housing
reeurreones
7
neta, g
vse Lon
Part name code
‘tis. __
[sce Fywhoat housing a0 ‘End pate Description of
111308 Oi seat retainer Josesa Front o'scal'-—~ part name code,
jit357 —Gaskat los288 earl coat"
357A Gasket
peor ete be ead Loft: Part name code (nut)
Tightening torque Va
[soca ta: A7TSNmit, 750 KoFom, 128 FM) ]BATaA WTB. 186 Nena, 000 RGF, 145 10TH
looea) M12: 97 Nenf900 kgtem, 7164) fodiaH __ta1B: 96m, OOO kgt-cm, 145 OF.)
4 Itis the ID number for parts to prepare electronic data, itis not required for repair work, 16 GENERAL
z jon of terms
Terms in this manual are detined as follows
(1) Direction
a, Individual unit
Frontfback direction
‘The power input side is front and the output side is back,
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is.
left rotation.
Vertical direction
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction Is lower,
Letuight direction
When viewed from the rear, the left dection is left and the tight direction is right.
(2) Standard value Basi dimension excluding tolerance and clearance generated by tolerances
hen two parts are joined
(3) Ropairlimit:- - itis the value requiting repair. Symbol of + or - with the value means increase or decrease
to the standard value
(4) Operation limit: - - Itis the value requiring replacement, Symbol of + or - with the value means Increase or
decrease to the standard value.
(©) Warning: itis an item that may resultin tisk of human life or stious injury by incorrect handling,
(6) Gaution Its an item that should not be performed including inhibited work or an item that
requite attention in working procedures.
(7) Reterence: Itis supplementary explanation in work.
8. Unit
(1) Slunit is used inthis manual. S! units the international unt to uniy the conventional different international
Lnits into one unit per quantity and to promote smooth technical communications
(2) This manual shows both the SI unit and conventional units. The conventional units aro shown in { }.
Conventional | Conversi 7 =x]
a conversion value"(1[Conventional unit] = X
unit [SI unit)
Force kat ‘1kgf=9.80665N
Torque’? Nem kgf cm ‘kgf. cm=0.0980665N- m
kgtfem? ‘Tkgticm?=98.0665kPa=0,0980665MPa |
Pressure Pa
mmHg ‘ImmHg=0.133322KPa
min ‘rpm=ti/min
Rotational speed _—— rpm
mint trpm=tmin™
Spring constant Nimm kgtmm ‘Tkgtimm=960665Nimm
Volume L ce 4eo=tmL
Efficiency w Ps - “1PS=0.735499KW
Caloritic value WH cal tkeal=1,13279W. h
Fuel consumption rate| GW. h gPSh 1g/PS. h=1.3596g/KW. h
“2X means the value when 1 [Conventional unit] is converted to the SI unit. Its used as the
conversion factor from the conventional unit to the SI unit.
“2:The conversion value of the torque may vary depending on the unit. Observe the standard
values described for each unit. GENERAL 17
Precautions for work
General precautions
To ensure safety in work and to prevent accidents, observe the following items:
(1) Appearance
a. Wear saloty goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
‘6. Bind long hair at the back.
Be sure to wear a cap and safety shoes,
(2) Satety work
‘2, Donot touch radiator, muffler, exhaust pipe, tall pipe, etc. after stop of the engine to prevent burn,
[Link] put your clothes or tools near the rotating par (in particular, cooling fan or V-belt) during
‘operation of the engine.
Remove the starter key when the engine is not started.
‘Sart the engine at 2 well ventilated place so that carbon monoxide may not be filled,
‘Since gas from the fuel or the battery is flammable, do not spark a fre or smoke a cigarette near the area,
‘Since the battery fluid Is poisonous and corrosive sulurie acid, be careful for handling,
Do not short-ircut the cable ofthe battery or starter. Otherwise, the cable may be butned or burn may
h. Ifa tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
iL To tow a failure vehicle, refer to "Towing or being towed!"
in the ‘Operation manual" of the vehicle
2. Precautions for service work
Pay attention to the following points before service work
(1) Preparation before disassembly
4. Prepare goneral tools, special tools and gauges before work
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally effected
to ease assembly. To repair the electric system, disconnect the cable fom the minus terminal of tho
battery before work
«. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every lime parts are removed, check the area whore the parts are assembled and check for deformation,
damage, wear or scratch.
(@) Arrangement of cisassembied parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused,
(4) Washing of disasserbied parts
Clean and wash parts to be roused well
(8) Inspection and moasurement
Inspect and measure parts to be reused as required
(8) Assombly
a. Keep the specified standard values (lightening torque, adjusting values, etc.) and assomble comect parts
in the correct order.
b, Be sure o use genuine parts for parts tobe replaced.
¢. Use new packings, gaskets, O-rings and cotter pins.
4. Use seal gaskets for some areas where gaskels are used. Apply specified ol or grease to siding areas
‘were application of oll is required, and apply specifi groase tothe cil seal ip before assembly
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester. 18 GENERAL
8. Precautions for electric system
(1) Removal of battery cable
‘a. Inanlectric systom, remove the cable from the battery
‘minus (-) terminal to prevent burnout due to short-
circuit.
b. When the battery cable is removed, the battery terminal
‘may be damaged. Loosen the nut completely and never
pry itfor removal,
Looeen
(2) Handling of electronic parts
‘a. Donot give impact on electronic parts such as
‘computer and relay.
[Link] place electronic parts at a high temperatura and
humidity area,
‘&.Donot expose electronic parts to water in washing of a
vehicle.
(8) Handling of wire harness
a. Mark clamps and clips to prevent interference of a wire (
hamess with body edge, sharp edge and bolts, Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch 2
wire harness, GENERAL
(4) Handling of connector
‘a. When a connector is removed, hold the connector (as
shown by the arrow in the left figure) and pull it out. Do
rot pull the wire harness.
Unlock the locking connector before pulling,
Insert the locking connector completely until it clicks.
4d, Toinsert a test load into the connector, insert itfrom the
back of the connector.
It tis alficult to insert a test lead from the back of the
connector, prepare a harness for inspection. 1-10 GENERAL
4
Precautions for electric welding
Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and olectronic parts. Observe the following items for electric
welding,
(1) Tum "OFF" the starter switch.
(2) Make sure that switches are "OFF*
(8) Disconnect the minus (-) terminal ofthe battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(6) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter")
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint ofthe frame for connection of grounding from the frame.
(7) Other precautions
‘a. Put a cover on rubber hoses, wire harnesses, pipes, tives, etc, around the welding area so that they may
not bo exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
‘maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color,
(9) After reassembly, check the function if it operates correctly, GENERAL,
Tightening of engine bolts and nuts
1. Tightening torque of general standard bolts,
(1) Forbolts with seatings
Unit: mekgf- emp
Remark
Bolt with number “7"on the hea
(2) For bolts with washers
A\CAUTION * 8Tboltis in accordance with 7T bolt.
Bott with number “
‘Serow diameter x Pitch 7 oT
Mi x 1.25 (Coarse thread) 28.5(290} 36(370}
Mt0 x 1.25 (Fine thread) 60610) 74.5(760)
M0 x 1.5 (Coarse thread) 55(860) 68.5(700}
12 x 1.25 (Fine thread) 108{1,100) 136(1,390}
M12 x 1.75 (Coarse thread) 97(990) 125(1,280)
M14 x 1.5 (Fine thread) 171.5(1,750) 216(2.210)
14 x2 (Coarse thread) 184(1,570) | 199(2,080} |
‘on the hi
Unit:N- m{kgf- em}
|" Serew diameter x Pitch 7 7 oT
M6 x 1 (Coarse thread) (60) 10100) 134130)
mx 1.25 (Coarse aq 2ste50 sits20
peo 140) | (250) 1320)
M10x1.25 (Fine thread) | ___—_-2(300} 51520} 64650)
M10 x 1.5 (Coarse
ea 26(270) 47(480} 59(600)
1412 x 1.25 Fine thread) 54(850) 99,950) 118(7,200)
Chari 49(500} 89(050) 100(1,100)
thread) ded ame
M14 x 1.5 (Fine thread) | '83{850} 147(1,500} 186(1,900}
M14 x2 (Coarse thread) (750) 192(1,950) 172(1,750)
Bolt with number °4° on
Bolt with number *7" on
the head Bolt with numbe
eae Projection bot Stud with | {he Mead Blvd WIR | the head
A surface at free end ne
A\cAUTION + 8T bolts in accordance with 7T bolt
eurce (27) auece 7) este)
(Frat)
Ten as
(Sear a)
GENERAL
Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.
(1) When re-application of lock agent is required!
‘a, When precoated bolts are removed
b. When precoated bolts are moved due to tightening
‘check (for loosening or tightening)
NoTICE + Check torque with the lower limit of the
tightening torque allowable value. If
‘movement is found, tighten the bolt according
to tho procedure below.
(2) Re-use method of precoated bolt lock
‘. Clean bolt and screw holes. (Clean screw holes for
roplacement,)
b._ Dry completely by blowing ar.
Apply the specified seal lock agent to the thread of the
bolt
3. Plastic region tightening method (angle method)
(1) Precautions
‘Some engines are tightened with the plastic region
tightening method.
Since itis different from the conventional method, tighten
it according to the instruction in the text.
(2) Parts tightened
Cylinder head bolt, crankshaft main bearing cap bolt,
Connecting rod beating cap bolt, etc.
AXCAUTION. + Measure the overall length ofthe bolt betore
assembly and replace the bolt if the length
exceeds the oporation limit
Apply engine oll to bolt seating and bolt
thread in assombly.
(8) Tightening method atter tightening to seating torque
Tightening of 90°, 135°(80° once and 45° once) and
180° (90° wice) is available GENERAL 1413
Tightening of chassis bolts and nuts
41. Tightening torque of general standard bolts and nuts
(1) Selection method of tightening torque
Find the applicable strength zone from the table below and select the bolt tightening torque from the
table described later.
', Soloct the nut tightening torque from the mating bolt as described above.
(2) Identification method of bolt strength zone
‘a. Identification method with product
Hexagonal bolt
‘Strength zone of hexagonal bolts s, in principle, indicated with recession, rele, surlace depression and
upset on the head with the symbol in the table.
7
Strength zone er 107 wT 1 |
7 eae
Identification symbol for part| 6
10 1" 12
("1}: 9 may be misread with 6. Itis expressed in q,
Depression Relist
Hexagonal nut
‘Symbol example for identiication of the strength zone of the hexagonal nut is shown in the table below:
(3) Types of general standard bolts and nuts
Standard seating Seating A with flange Seating B with flange
@o|4 GENERAL,
(4) Standard tightening torque table of general standard bolts and nuts
ightoning torq
(Representative standard sealing is described.)
Unit:N- mfkgt cm)
Strength
zone
Bolt aT 7 st
diameter
(mm)
‘4.531.5(60120)
| (cab) ”
Me ee) 9.0:4.8(90:20) 11.5:2.0(117:23}
(Chassis)
14.019,5(140:40}
ms (cab) 22,0:4.0(220:40}? 29,0:5.5(300:60}
17.013.0(170:80) ae Oe
(Chassis)
2 143.0:8.5(440:90) 57.0:47.0(5802110) ®
(Cab) (Cab)
-015.0{276:55)
mo eeemeaeaee 51.5110.0(530:100} 68.5113.5(7001140)
| (Chassis) (Chassis)
7 76.0118.0(776%150) ® "100.0220.0(1,020:200)
(Cab) (Cab)
m2 eeameaael 91.0:18,0(930:180), 120.0:24.0(1,220:240)
| (Chassis) (Chassis)
mia 77.0:5.0(786:157) 120.0124,0(1,220:240) 160.0:52.0(1,630:526)
m6 ¥20.0224.0(1,220:244} 190.0:38.0(1,940:080} 250.0350.0(2,550:510)
me 165.0258.0(7,6802536) 260,0152.0(2,650:590) 345.0369.0(9,520-708)
M20 235,0307.0(2,400:480) | $70.0:74.0(8,70:750), {490.0396.0(6,000,000)
22, '320,0364.0(8,270:654) | 505.0:100.0{6,150:1,090} | _670.0:130.0(6,84011,370)
za 405.0381.0(4,1303626) | _640.0:125.0(6,530:1,310) | 845.0:165.0(6,620:1,720)
AXCAUTION. « Use the tightening torque value fo seating A with flange except for ‘inthe table larger by
10% than the tightening torque value in the tabl
+ Use the tightening torque value for seating B with tlange of *2 in the table larger by 20%
than the tightening torque value in the table.
The tightening torque value of M& for seating B with flange remains unchanged.
+ Seating B with flange of *2 in the table is interchangeable with the standard seating in
pairs. Use the standard seating for the tightening torque value. GENERAL
Tightening of flare nuts and hoses
1
Tightening torque of pipe flare nut
Unit:N- m{kgt- em}
Hose outer diameter
#105 fitting
packing
Hose outer diameter
.13,c20,422, fiting at
Pipe outer
diameter) 94.76 6.35 e wo m2 m5
Material
Stooipipe | ECsos50) | aisasnisn | saBlrO) | S270) | eT(66070) | saw(eoniso)
2, Tightening torque of hoses
Unit:N- {kgf em)
Hose outer diameter
PF9/B fitting
21.514 5(215415)
| Air hose ~ Only meter gauge 41.612.5(425:25}
10100}
Packing
Cot 51.5:7.5(525475) a J
3, Lock nut tightening torque of brass joint
Unit:N- (kgf em}
oJ a aa m6 M20 M27 |
: = |
pat 9 feeaaee 6645(670:60} 19719990:90} 209119(2190:190), 116 GENERAL
Taper thread sealant for piping
‘The taper thread of the air pipe joint has application of sealant
[Loctite #575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes,
————__________ 1. Fordisconnection
Removal saree Lee mate she)
seaase > (1) The sealant (#Lootte 575) has strong sealing feature. The
pp a roturn torque of the taper joint is increased about 1.5
A tea times the intial tightening torque, When the joint is
disconnected, use a long wrench for disconnection
fea (2) When a joint at a poorly accessible area is replaced,
ove Femove accessories first and disconnect the joint.
2. For connection
(1) For application of sealant (#Loctite 675), wipe the sealing
area completely with a rag or thinner. Apply sealant
at directly to about tree ridges for quarer round with offset
“od of one ridge trom the end. Tighten it according to the
tightening torque inthe table below.
Remove dirt completely trom the mating part (femalo)
belore tightening
commer /NCAUTION * If your eye or skin comes in contact with
sealant, wash It off immediately with water.
Tightening torque of taper joint UnitiNe (kal om)
‘Screw
diameter! 4 3B we
Material
Stool eee 164:15(650:150)
100)
‘Aluminum,
ee 2515(250:50) | 34:5;950:50) | 4935(450:50}
(2) When a sealing tape is replaced with sealant, remove the
tape completely frst as in (1).
A\cAUTION. * Be caroful to pravent entry of dirt or foreign
matter in the pipe.
(8) Ifa leak is found after assembly with application of
‘sealant, air leak cannct be stopped with adaitional
tightening. Assemble the part again according to (1) and
@. Assembly of joints and gaskets for piping
1. Tightening torque of joints
Unit: m¢kat em}
Metal sealing method
eee Gasket sealing method (Flare pipe type, nip connector type)
TeaNningseew | (mina Rube or coon =a a
Ma 7 ~_13(130)
m0 20(200) Tiet19)
m2 25 (250) ~ 20(200)
mia 25(250) 310920)
m6 29{300) 39 {400}
wie 39(400) 59(600} :
20 *39(400) 64(650} ~~ 20(200)
‘M24 69{700} 7
M28 a *127{1300} —
2. Joint assembly procedure and subsequent inspection
Bofore assembly, make sure thal there is no dirt or burr on the seating surface (mating part, pipe joint,
a
@
®
“0
gasket, oc.)
Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
Aer tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
Observe the values above for each tightening torque.
“When assembled soft washer #4840FR.N (aluminum and rubber carbon pressure bonding) is loosened or
removed, be sure to replace it with a new part. This is not necessary for normal retightening. GENERAL,
3. Examples of joint methods in various pipes
Metal sealing method
Gasket sealing method Type A Type B
(Far pipe type) (tipple connector type)
sa a nar em
ee
— Se
Joint bolt Lock washer Bracket oa
i
Sealing sutace
Slaces
Seating sutace
Bplaces ‘Connecor nipple
seat surat: pace Sealing sutace: 1 place
Flare connector
Nul Lock washer
Box nat
vay jon
Sealing sutace
B places
ont pine =
(ona poce ey nt whout stove
Jon bot
Seat sure paces
Joint bot
Sealing surtace: 6 paces GENERAL
Handling of liquid gasket
1. Application of liquid gasket and part assembly procedure
(3) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
doposit of oil, moisture, dirt, ote.
Be sure to overlap parts at the beginning and at the end of application.
(2) Be careful or offset with the mating part whon a part applied with liquid gaskets assembled, Apply the
liquid gasket again if ofset occurs.
(2) _Assembfe parts within 20 minutes after application ofthe liquid gasket
1120 minutes has passed, remove the liquid gasket and apply it again,
(4) Start the engine at least 15 minutes or more after assembly of part.
2, Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is romoved, be careful to provent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it Is contained in
a cartridge, use the application gun
Sx S
a EY /
Tube: 1509 Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
{:Approx. 2 mm at the tst section cut
2:Approx. 5 mm at the 2nd section cut
Nozzle of tube 1-20 GENERAL
Failure diagnosis table for each problem
Engine mechanical ‘The cause and action for each item are described.
‘Seatus Cause ation
Engine overheat (coolant) Theaffeentcootont Replonish coolant
Faulty thermostat Replace thermostat
Water leak fom cooing system | Coweton
Faull coolant pump Repair or replace
Faull head gasket Replace heed gasket
Engine overheat Clogging of radiator leaning of aditor
(radiator) Corrosion of cooling system ‘lean and repair cooling system
‘Clogging of aditor core front pert_| Clean radiator
Faulty reditor cap Replace radiator cap
Engine overheat (compression | Non-synchronous injection timing | Adust injection timing
pressure) Faully fuel injection pressure “Adjustinjecton pressure
Fully fuel Replace with corect fuel
Faully njeclor Replace injocior
Engine overheat (lubrication | Deterioration of engine of Replace engine of
unit) Faully ol pump place oll pump
Tnsuficent engine of Replerish engine of
Large engine oll consumption | Wear of piston ring and Gyindor | Replace piston ring and eyindor
(piston, cylinder iner and piston | liner liner
ring) Damage io pison rng "Replace piston ng and eyindar
liner
Fat ng of piston ing Replace piston ring and oylinder
finer
Faulty assembly of piston ring | Replace piston ring and eyindor
liner
Faulty engine of Replace engine
Fauly piston ing ot ‘Resssemble piston fing
‘Large engine oif consumption | Wear of valve stem Replace vale and valve gue
{valve and valve guide) Wear of vave guide Replace vahe guide
Faully assembly of vale som seat | Replace slom seal
‘Excessive ol brication i racker | Inspection of dlaarance belween
am rocker arr and rocker arm shat
Large engine oil consumption | Faulyollevel gauge Replace with correctievel gauge:
(others) Excessive ling of engiie Fil with appropiate amour ofl
Leak of engine ail Repair or replace the part of oF
teak
Piston seizure (in operation) | Sudden slap of engine Perform warnvup before slop of
engine
Piston seizure (lubrication unit) | insufficient engine Replenish engine ol
Delarioraion of engine of Replace engine of
Incorrect engine all Replace with correct engine ol
Tow of pressure Inspection of ubricaion unit
Fully of pump FRoplace all pump
Piston seizure ‘Rbnormal combustion Rolerto overheat selon
Piston seizure Coang unit Roles to overheat section GENERAL
Failure diagnosis procedures
1. Display of failure code
(1) When there is error in the system, the diagnosis monitor code can be viewed with the check engine lamp.
For example, the process display for diagnosis monitor codes 92 and 21 is as follows: The display method
is blinking intorval ofthe lamp, For the first code, the lamp illuminates three times for 0.6 second for "3" at
the place of 10 and illuminates twice 1.5 seconds later. For the seconds code, the lamp illurinates 21
times at intervals of 4.3 seconds similar to the first code. Subsequently, this is repeated. When there Is no
error in the system, the lamp keeps blinking with the illumination time of 0.3 seconds.
NOTICE + The display of the diagnosis monitor code below Is a typical example.
Display of iagrsie monkor cde (exam)
(Check engin lamp
Winon codes 32 and 21 ate spied
In normal operation
03 second
on
OFF
2. Deletion of past failures
(1) Te delete past failures of the engine ECU, use HINO-OX
‘on the PC. (Refer to "Hino field support system operation
manual’) a
“
How to read troubleshooting for each diagnosis monitor code
“Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives
‘output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be
started from the code list.
ENGINE DIAGNOSIS CODE [Engr
Failure of main speed sensor (DTC code P0338/diagnosis monitor code 13)
7__ [Measurement of resistance beiweon tominals
_
Oy» arose
2 Remove the ECU sie connector of be slgal cack hemes
snd moausr the resistance beben erinal 86 and terminal
ee ——~Detalls of work
0 Standard value: Approx. 125.5 17 (20 dC)
1NG_> [fice esoneno eaves beeen oar nba
2 [Sao dara de
7
‘Connect he ECU side connector ofthe signal check harness,
‘Aor deleting te pat fur, cuput he dlagnosis code aga
Standard: Normal
Contact aire of EGU comecior, ECU fal
we
urement of resistance between terminal
1
"Remove the connector ofthe main engine speed sensor and
resstare betwoen No.1 and No.2 terminals a
Standard value: Approx. 126. 17 (20 dC)
t
ao
isis)
NG
Fale of man ongine peed sacar
wo,
Indicates replacement of the main
engine revolution sensor.
‘Check the harness of the relevant circuit and repair the faulty area,
Harness lacoonostion or connector lure Failure diagnosis using Hino-DX
A\CAUTION Hino-DX is used for inspection and adjustment
of the system in addition to fallure diagnosis.
1. Hino-DX
(1) With Hine-DX, failure of the common ral fue injection
system can be diagnosed. The interface box (Hino-
Bowie) and the special cable are required for connection
to the vehicle
Special tool : 09121-1040 Hine-Bowle
(09042-1190 Cable between vehicle and
Hino-Bowie
Field support system (CD-ROM for
software) Hino Diagnostic eXplorer
(Hino DX)
XCAUTION + Install the software of the Hino Diagnostic
Xplorer (Hino DX) in the PC. For the
Installation method, refer to the instruction
‘manual accompanying the CD.
2. List of failure diagnosis tools
Part name Part No. External shape General description and function
PC + Operating system (05): Windows 95,
(DOSW standard) Windows 98 (IES.0 or later), Windows
2000 (SP3, IES.0 or later), Windows XP
(SPta, 1E6.0 or later)
- + CPU and memory: Conditions that
assure operation of the above operating
system
+ Display: 800 x 600, 256 colors or more
Hino-Bowie ‘09121 - 1040 + PC interlace
(Interface box) Gable between |
vohiole and Hino-
Bowie (09042 -
1190)
‘Signal check (08049 - 1080 Interrupting installation between vehicle
harness (for common rail fuel harness and ECU allows inspection with a
injection system) {ester rod while the power is supplied. 1-24
GENERAL,
3. Connection of signal check harness
(1) To provent damage to the ECU connector and to improve
accessibilty, connect the signal check hamess and put a
testing rod on the signal check connector of the signal
check harness for measurement.
4 Disconnect the connector rom the ECU
ANcAUTION + Do not break the locking tab ofthe connector.
fh Connect the signal check harness to the mactine
harness and he ECU,
Signal check harness
(for common rail fu
Part No.
09049-1080
jection systern) GENERAL
(2) Terminal No.
For the signal check hamess connector, the ECU terminal number in the text is treated as follows:
ECU unit
a fee ee
Elie i
‘Signal check
harness
(eg [ye 1-28
Hine Bowie
creo ees
‘Stamp postion
GENERAL
Connection method of Hino-DX
4. Connection of Hino-DX
(1) Flemove the lot side covar at the rear ofthe driver's set
and connect the failure diagnosis connector with a PC
Which installed Hino-DX through the interface box.
‘Special tool : 09121-1040 Hino-Bowle (Interface box)
(09042-1190 Connecting cable
CD-ROM Hino-Dx
(2) Set the starter key to “ON and start Hino-DX.
Chassis number and engine number
1. Engine type and engine number
Engine type and engine number are
stamped on the left side
of the cylinder block.
When ordering parts, report this number for smooth
processing.
Example: P11C TB10001 STANDARD VALUE 2
Engine Body.
‘Standard value,
Fuel System
“Tightening torque.
Intake.
‘Tightening torque,
Engine Mechanical
‘Standard value
Tightening torque
Exhaust.
Tightening torque
Cooling.
Standard value
Tightening torque.
Lubrication...
‘standard valu.
Tightening torque,
Starting and Charging..
‘Standard value (alternator SOA) snes 213
Tightening torque (alternator 508), 243
‘Standard value (starter) 24
Tightening torque (starter) 248
‘Turbocharger :
Standard value. peeeeeaie
Tightening torque, rs 218; STANDARD VALUE
Engine Body
Standard value
Inspection item Standard value
Unit: MPa {kgt/em?, Ibtfin.2}
Repair limit
Operation
limit eae
Fuel System
Tightening torque
Tightening area Ti
7 2.5(26, 362} | Overhaul
ightening torque
Unit:N- m{kgt- em, Ibt- 1).
Remark
Injector clamp mounting bolt 26(270, 19}
Injector union bolt | 20(200, 15)
toate pe cylinder head 20(200, 18)
injection pipe (M14) 441450, 22)
Injection pipe (M16) 54{550, 40)
‘Supply pump cotter bolt 91{930, 67} ;
‘Supply pump coupling bolt 611620, 45) o
‘Supply pump mounting bolt 726(290, 20) - |
Supply pump drive gear mounting nut 245(2,500, 180) a)
Fuel filter center bolt - 7 24.5 - 34.3(250-360, 18-25) |
Fuel filter air bleeding bolt 4.9- 8.9(60 -90, 3.6 -6.5) ‘STANDARD VALUE
Tightening torque
Intake
Unit:N- m{kegf. em, IDF ft}
[ Tightening area Tightening torque Remark
Intake manifold mounting bolt '55(560, 40)
Int take pi ”
intake air heater mounting nut and intake pipe 5620, 40)
mou
‘Standard value
Engine Mechanical
Unitzmm(in.y
Inspection item Standard vatue | FePalr) Operation | ction
timit | imi
Compression pressure | Per cylinder 2.9MPa 25 MPa ‘Overhaul
(Engine revolution 20011 {80 katlem?, 4201611] — | (26 kgtlom?,
min) in} 363 Ibtin2}
‘cylinder liner protrusion 0.04 -0.10(0.0016- a]
0.0039} —
Cylinder liner flange with ~8(0.315) =
Cylinder block flange width 80.315) — | 7.97(0.3138) | Replacement |
Cylinder block inner diameter «| —*427(6.000) = _|
Cylinder liner outer diameter. 127(6.000) = = ~ |
Clearance between cylinderliner and | 0.0120-
cylinder block o.029(0.0005- | — _
0.0011)
Cylinder liner inner diameter 122t8.803) ___ | 122.15(4.809 | Replacement
o
Piston outer diameter (Pin hole 25 mm
‘above the lower end of the skirt square | 121.95(4.8012) | — =
direction)
Piston cle 0.060 -0,080(0.0024 Replace liner or
— | 0.15(0.005)
=0,0031} ame piston STANDARD VALUE
pair | Oporatio
Inspection item | Standard value | RePalt Operation Action
Hit | iit
Piston |Freejoint | Top ‘Approx. 12.7 =
fing fotearancs | Second ‘Approx 146 | — =
hire ‘Approx. 15 = =
oil “Approx. 14 _ a |
ying Top 00-0500078-| | sre qago) | RePees Piston cng
liner Joint 0.0196)
forassembly [Second | 0.50-0.70(0.0107-
Clearance ae — | 1.2(0.0472}
Third 0:35 -0.50(0.0138-
— | 240.0472)
| 0.0196)
Oil 0.30 - 0.50{0.0118 -
Ihe tecy — | 1.0(0.03983
Piston ring |Top asraqo.is0 | — | aper)
thickness [Second 2:306(0.0908} = (Taper)
2.0{0.0787} — | 1:80(0.0708} |
4.0(0.1575, | — | 8.90(0.1595)
Piston | Piston ring (Taper) = = Replace piston.
ring and _| groove re = —
ring |
moore 2.0{0.0787} = =
oir “4.0(0.1875) =
Clearance |Top : Replace piston ring
between [Secona = = = or piston.
piston ring
Third 10.065 -0.105(0.0026
and ring = .
groove -0.0041) comin
0.025 - 0.065{0.0010
Pama — | 0:1040.0039) |
Piston pin | Piston pin outer diameter 471.850) = —_| Replace piston pin
Piston boss inner diameter | _47{.050) = =
Clearance between piston | 0.041 -0.059(0.0017 Replace piston or
pin and piston boss =0,0023} 005(0.018) | piston pin
Connecti | Small end bushing inner ~
art - =
ng rod moter 741-850)
Small end bushing olf 0.685-0989(00988 | | 049 ggaq) | Re@ioe piston pin
clearance -0.0015) | or connecting rod,
Large end with 42.85(1.6800) | — =
End play | 0.15-0320.0059- || cia gage) | Replace connecting
0.0125} rod or erankshatt
Connecting rod bolt length 102.5{4.0354} — | 105.0(4.1338} Replacement . Repair] Operation
Inspeetio lard value ction
Inspection item Standard value | Fyfat| Came At
Cranksha | Journal outer diameter 90(3.543} | — _| 88.8(3.4960) | Replace crankshaft
7 Journal bearing thickness. 3(0.118) = = foumatbereg or
—_ eranksha
Journal erankshatt ofl 0.044 -0.097(0.0018 0300118
clearance = 0.0038) ee
Pin outer diameter 79.83.
80(8.150} “rery | 70801029)
‘Journal bearing thickness 2.5(0.0984) | — —
Pin connecting rod oil __ | 0.025-0.084(0.0010 | |
clearance = 0.0033) cael eensuuans
‘Thickness of thrust bearing 301 | = ”
‘Crankshaft end play (0.170 -0.240(0.0004 Replace thrust
~0.0094} Gt arcane bearing.
(Crankshaft runout 7 = —_ | 0.07(0.0027) | Replace crankshatt.
Grankpin width | —=—S(1.693), = =
‘Camshaft [Camshaft | No. 65.0(2.5590} = —__| Replace camshatt.
Journal outer [No 64.6(2.5433) = =
Nos (64.2(2.5275) = =
No 63.8(2.5118)
Nos 63.4(2.4960)
Nos 168.0(2.4803) =
: No.7 62.6(2.4685) = = |
Bearing oll clearance | 0.030-0.120(0.0012 Replace camshatt |
-0.0047) 0-310.0118) | or boating,
Cam height [IN 55.45{2.1830} —_| 55.2(2.1732) | Replace camshatt.
®x sacsittsy | — ae
camuit [IN 7.25(0.2830) —_ | 7.10(0.2795) 7
[=x 8.69(0.3421) — | 8.54(0.9362}
Thrust plate thickness 80.315) = =
End play 010-028 — | estocriey | Replace thrust
plate.
[Camshaft runout = — | 0.05(0.0019} | Replace camshaft. | 26 STANDARD VALUE
Inspection item Standard value | RePair | Operation ‘Action
Valve | Roller tappet | Tappet outer
28 (1.102) = =
systom | outer diameter ame
| diameter [Tappet guide |
inner 25 (1.102)
diameter
Ot clearanee | 0.020-0.062(0.0008 || 9 5.9959) | _ RoPae® tapet
~0.0028)
Rocker arm | Shatt outer 27.92{1.0982 | _ Replace shat.
Srametor 2(1.102} - i
Bushin .
ing ae(t.10ss | Replace bushing
inner 20(1.102} i
| diamotor
Oil clearance | 0.044 -0.120(0.0018 Replace shatt or
~ 0.0393} bushing. STANDARD VALUE
Repair | Operation
Inspection item Standard value | FPA) Pera Action
Valve [Valve stem [IN 30.315) — | 7.80(0:3102) | Replace valve.
system | outer x
anaes 80.315) — | r89(o.s102)
Valve guide [IN 80.315) = __| Retertothe | Replace vaive
innor diameter | = amas =} main text. a
Oilclearance [IN 0.040 -0.077;0.0016 Replace valve or
— | 0.1240.0047)
between =0.0030} 10.0087) | valve guide
valve system [ey
ere 0.057-0.09440.0025 |__| sae 0055)
aaa -0.0087}
Valve sink | IN -0.05-0.35¢0.0020- || a gars) | Replecevave or
0.0137) valve seat,
lex 0.58 -0.95(0.0217 -
— | 13(0.0511) |
0.0374) cae
Valve seat [IN 30° 7 = Correction
angle = i = =
Valve spring | Set le
ere eee 54.72.1535} = _
inner (IN) |
Valve spring | Set length 158.0N
tnner (EX) ae (s6kgt24.4
60
Valve spring |Set load 1474N | Replacement
inner (IN) ee — | {15.0kgf33.01
oo
Valve spring | Set load
inner (EX) '72.0{2.8346} — | 70.0{2.7559}
va sping [Feo lra |S saaemy | — _ |
Valve spring | Set length ~
outer (IN) 58.7{2.3110} - -
Valve spring | Set length 367.9N
oy eee pence
| won
Valve spring | Set load a51.1N | Replacement
oa S82SNG8.0KGI86.0/ | sey 78.9
i tb
Valve spring |Setload |
banana [Link] | — | 91.02.5825)
Valve spring | Free length
fae _ - 0.5(0.0197}
Push rod bend 54.72.1595) = - 28 ‘STANDARD VALUE
: Repair | Operation
Inspection ite ti
Ps m Standard value | Fynet | OP Action
Timing Power steoring pump- | 0.05 -0.21(0.0020- 1.30(0.0118) | Place each gear. |
gear —_| supply pump 0.0082} :
backlash | Supply pump-main idle | 0.05 -0.19{0.0020- o0(001%8)
(No.2) 0.0074) :
[cam gear- main idle (No.2) | 0.07 - 0.19{0.0028 - Te. Baar
0.0074) :
‘Rir compressor idle- Air | 0.04 -0.14(0.0016 -
compressor drive 0.0055} idan
Main idle gear (No.1) -erank | 0.07 -0,19(0.0028 - 300.0118)
gear 0.0074} :
Oil pump drive- oll pump | 0.06 - 0.90(0.0024-
ares | — | 0.30(0.0118
Cam gear alr compressor | 0.06-0.19(0.024-
si nore 0.30(0.0118)
Main idle | Shaft outer diameter sa2520) | — =
Bushing inner diameter 64(2.520) =
Oil clearance "| 0.030-0.080(0.0012 Replace shaft or
=0,0035) 0.20(0.0028} | "bushing.
End play 0.085 -0.149(0.0026 a
0.0088) ae
7 - |
Air ‘Shaft outer diameter 52(2.047) =-[ -
compress / Bushing inner diameter 52(2.047) = =
or idle :
Oil clearance 0,030 -0,090(0,0002 zoco.on2e, | FePlace sat or
-00035, | ne bushing.
End play 0.070 -0.125(0.0028 es
=0.0049} oe
Head bolt length (long) 250(9.643) =| 2520921) | Replacement
Head bolt iength (short) 158(6.220) — | 16176.338) | Replacement
injector protrusion 2.9(0.1142} 7 7 7
Flatness under cylinder head 0105(0.0019) ortess |°7500-| | Grind or coreton
0059}
Flatnoss above eylindr bloc 0.1500.)
K 0105(0.0018) ortess |°"50-| __| Grind or corecton
0059)
Flywheel | Yoke assembly runout 0.2(0.0076) ortess | — 7 Correction
Valve clearance N 0.45{0.0177} = = ‘Adjustment
(Cold engine) EX 0.60(0.0236) = = STANDARD VALUE
Inspection item Standard value
Valve Exhaust valve open a ~
timing | (before BDC) _ _
Exhaust valve close | a |
(atter BDC) | ~ ~
Intake vaive open . | -
(before BDC) _ _
Intake valve close .
(after B0¢) 2 7 7
Supply pump drive bearing rolling 039-1170 m | ‘Shim adjustment
torque {4-12kgt-om,3.5-| — | —
[Link]- in.)
Tightening torque
Unit:N mikgf- om, tf ft}
Tightening area Tightening torque Remark
Head cover mounting bolt (upper) 25250, 18)
ad cover mounting bolt (lower) '54{550, 40)
Head bolt 118(1,200, 67}490°490° | Angle method
‘Additional head bolt 69(700, 51)
Rocker support bolt '52(620, 38) 7
Rocker arm adjusting screw lock nut ae 7
ug) 1450, 92}
Rocker arm adjusting screw lock nut 7 "| Exhaust si
(ami) 69(700, 51} with engine
retarder
Cross head adjusting screw lock nut
ia 28(280, 20)
(Cross head adjusting screw lock nut a
um) (290, 20)
‘Tappet stopper key set screw 44(450, 32)
Idle gear shaft mounting bolt - = 4 = 20
{air compressor idle) Lamune
Idle gear shaft mounting bolt ne
(main ide) ame
Supply pump drive gear mounting nut 24542500, 180)
Supply pump drive bearing case retainer mounting -
= 25(250, 18)
Flywheel mounting bolt (standard) 270{2,750, 200} z 240 STANDARD VALUE
"Tightening area ightening torque Remark
Flywheel mounting bolt (vehicle with PTO) on Bolt must not
be reused.
Flywheel housing mounting boit (Ma) 25(250, 18)
Flywheel housing mounting bolt (M14) ] 113(7,150, 83)
Flywheel housing stay mounting bolt (M14) 113{1,150, 83}
Flywheel housing stay mounting bolt (M16) 211 (2,180, 156)
‘Connecting rod mounting nut 69(700, 51}+90"+90" | ‘Angle method
Cooling jet mounting bolt 23(230,17) -
‘Main bearing cap mounting bolt 274(2,800, 200) ~
Camshaft gear mounting bolt 187(1,400, 100) Warm fitting
Crankshaft damper - crank pulley mounting bolt 108(1,100, 80)
Crank pulley - crankshaft _ 7245(2,500, 180)
[Timing gear case cover mounting bolt a “44{450, 32)
Engine mounting bracket mounting bolt " 76(770, 56)
Exhaust
Tightening torque
Unit:N- rm{kgf- em, tht: ft)
Tightening area Tightening torque Remark |
Exhaust manifold mounting nut '59{600, 44) |
Exhaust manifold mounting stud bolt 80(800, 22}
Cooling
Standard value
Unitzmm{in.y
Inspection item Standard Repairtimit | Operation Action
‘V-belt deflection (in assembly of new 60-
bolt) pushing force: 96N(10kgf, 22Ibf) | 8.0mmyo.236 | — 7 7
2-0.8149}
‘V-belt deflection (in reinstallation) 75-
pushing force: 96N(t0kgf, 22Ibf) 8.5mm(0.295 = =
2-0.3740}
‘Thermostat valve open temperature 20- Replacement
84°C{176- 5 -
183°F}
Thermostat valve lift ] 10(0:384} or _ Replacement
(Set temperature 95 °C(203 °F}) more ~ STANDARD VALUE at
Tightening torque
Unit: m{kgt- om, bff)
Tightening area Tightening torque Remark
Tension pulley bracket - timing gear case cover '55{560, 40} wo
| 7211 (2,160, 156) m6
Fan drive ASSY - timing gear case cover ~ 47(480, 35) 2
Tension pulley fixing nut ~108(1,100, 80}
[Fan drive pulley-fan spacer | 601610, 44)
Cooling fan - fan spacer 47 (480, 35)
‘Thermostat case mounting bolt '55(560, 40)
Lubrication
Standard value
Sane | Repaerin | OPO”
Ollpump [End play 0.085 - Replacement
drive gear oxosyo.0018| = — —_| 0.1540.0059)
=0.0041)
Tip clearance 0.038 Replacement
os15005| — — | 0.17(0.0086) |
= 0.0048)
Shaft outer diameter | 20(0.787} = =
Case cover inner diameter | 20(0.787} = =
Oil elearance 0.040- Replacement
0.074(0.0018 0.17(0.0066)
0028) |
Olt pump | Shaft outer diameter 2010-787) = =
driven
gear
Bushing inner diameter | _20{0.787) - =
Oil clearance 0.040- Replacement
0.074(0.0016 = 0.170.066)
= 0.0029)
Drive gear and driven gear backlash 0.072- Replacement
0.208{0.0029 = 0.4{0.0157}
0.0081} 212 STANDARD VALUE
Tightening torque
Unit:N- m{kgt cm, Ibf- ft}
Tightening area Tightening torque Remark
il pan mounting bolt (plate) 7 = 25(250, 18)
Oil pan mounting bolt alurninum) 25(250, 18) 7
Oil pan stiffener mounting bolt 44(450, 32) |
il pan drain cock 83(646, 61)
[Oil pump mounting bok (10) 47(480, 35)
il pump mounting bott (M14) 113(1,150, 83)
Oil pump feod pipe mounting bolt (Ma) L 21(210, 15)
(il pump food pipe mounting bolt (M110) - 23(230, 17)
[Oil strainer mounting bolt | 23(230, 17) il
Oil pump case assembly bolt A 10.7 - 25.5(200 -260, 15-18) _
Oil pump case assembly bolt B 39.1 - 48,9(400 - 500, 29 - 36) ”
Oil cooler element mounting nut 14.7 - 24.5(160 - 200, 11 -18)
il cooler with oll iter mounting bolt (Ma) 25(250, 18}
Oil cooler with ol iter mounting Bott (M10) 47 (480, 35)
Oil pressure switch 19(190, 14) _
Oil filter warning switeh ~ 24.5 - 34.3(250 - 300, 18-25)
(il filter drain plug 7 14,7 -19.7(150 -200, 11-14)
Oil filter mounting sensor bolt 39.2 - 49{400 - 500, 29 - 36), Starting and Charging
Standard value (alternator 50A)
Unit:N: m{kgf- em, tf: tt}
Inspection tom standard value [*°°2"] operation tnt | Action
Rnisancebowensaerotomin’ | oo oma | o = Replacement
(ior 2 phases)
sistance between salorcollco and col| iter more | — | Replacoment
Fesltance of feed coll ea-toa_ | — Replacement
Resistance betveen feed collcor and call | _iMermore | — = Replacement
Shat outer ameter [Front 2imm(0.883in) | —[[Link](0.9094in} | Replacement
of rotor assembly | Rear ‘T7mm(0.669in) | — | 16.98mm(0.6685in,}
Resistance between Forward resistance value | Approx. 10 2 — |* - | Replacement
«diode and rectifier holder | Reverse resistance value Infinite = -
Resistance between Forward resistance value | Approx. 10 — - | Replacement
regulator terminals F-E | poverse resistance value Infinite _ _—
\V-belt deflection (in assembly of new belt) | 13-15mm{0.512 | _ ‘Adjustment
pushing force: 98N(10kgf, 22Ibf) = 0.591in} ~ |
Vb detection in relstalation) ~~ 17-mm(0.668 | ~ Tajustment |
pushing force: SoN(Okgt 226) “a7asin}
Tightening torque (alternator 50A)
Tightening area
Tightening torque
Remark
0,3)
Fixing bolt at brace 47480, 35)
Alternator mounting through bolt 132{1,350, 97} “|
Bearing cover mounting bolt
4.9 - 2.5(20 - 25, 1.4- 1.8}
Pulley mounting nut
127 - 157(1,300 - 1,600, 94- 115}
Feed coil mounting bolt
2.8-8.9{30- 39, 21-25)
Rectifier and regulator mounting bolt
1.9 -2.5(20- 25, 1.4- 1.8)
Inside B terminal mounting nut
4.9 -5.9(60 - 60, 3.7 - 4.3}
‘Outside B terminal mounting nut
Through bolt
3- 5{83- 45, 22-9.6)
7.8 - 8.8(80- 99, 6-7)
Coupler holder mounting bolt 1.9 2.5(20- 25, 1.4- 1.8)
[Covermountingbott | 88-4404 44, 26-32)
| Adjusting bolt 6(60, 4)
Brace fixing bolt 83(846, 61) 244
Standard value (starter)
STANDARD VALUE
assembly | body (H coil)
Unit:mm{in.}
Inspection item Stanerd | Repairiimit | Peravon Action
Yoke | Resistance between coil : — | anmortoce | Replace yoke
assembly | lead wire and yoke assembly.
I 13(0.512) or | Roplace brush.
Brush length on _ fos} place brush
‘Armature | Resistance between tuoormoe! | rumorose | Replace armature
assembly | commutator and core assombly.
et 38(1.339) oF
Commutater outer diameter | es a7) _ 1999)
Shaft outer diameter A 11.98(0.4717
12{0.472} ~ yor less
Shaft outer diameter B a —_ [eamease8
Undercut depth 05. Correction
asooisr-) | 2000079)
0.0314)
Holder | Resistance between holder Replace holder
= — | tknortess
assembly | and plate assembly.
rush len 310.512} 0 rush.
Brush length 140.709) ___ | 180512} or | Replace brush,
tess
Sha [A — | 2.90¢1.0197
assembly Jorless: Replace shaft
outer -
; 1404(0.5525 | assembly.
diameter ee — Shorless
Clutch assembly inner sleeve outer 27.90{1.0986
291.102 = cement
diameter Mt : y Jorless a
vet ‘nner dk = 1
ishing inner diameter of pinion 28.2{1.1102} | Rey ion
Metal bushing inner diameter of pi aie _ {1.1102} |” Replace pink
case or more case,
‘Metal bushing inner diameter of center Replace center |
2561.0 = 21.
bracket CA foaarued bracket.
Motal bushing inner diameter of shaft Replace shat
9(0:354 ~ :
assembly : : Cat assembly.
ousing inner diameter of rear 28.1(1.1082} | Replace rear
Bearing housing inner diameter of zeca100) _ {1.1062} | Replac
bracket or more bracket.
Start [Between CterminalandM |) jigo] Replace start
magnet _| terminal (P coll) magnet switch
switch | Between © terminal a assembly.
Between Cterminaland | 43 yoga) _ - 3 PARTS TO BE PREPARED
Engine Body
‘Spacial tools
Fuel Systom
‘Spocial tools
Electrieal..
Special tools
Engine Mechanical.
Special tools
Instruments
Lubricant, et,
Cooling
Special tools
Lubrication,
Instruments 36
Starting and Charging veveninninnsinnninnine 37
aig (reference dimensional drawing for manutacture) 3-
o
Common tools, 7
Instruments 37
Lubricant, ote 38
‘Turbocharger. 8
Special tools 38
Inetrumante 38
PARTS TO BE PREPARED
a
a PARTS TO BE PREPARED
3 PARTS TO BE PREPARED
Engine Body wrnnnn so 2
‘Special tools 32
Fuel System 22
‘Special tools 32
Electrical, : eens
Special tools 39
Engine Mechanical
Special tools
Instruments
Lubricart, et.
Cooling : 36
‘Special tools : seeete
Lubrieation...
Intruments|
Starting and Charging.
sig (reference dimensional crawing for manufacture) -
7
Common took o a7
Inetruments vo vn AT
Lubricant, et. 38
Turbocharger. eee 28
Special toole So 8
Instruments 38 32 PARTS TO BE PREPARED
Engine Body
Shape Part No. Description Remark
09552-1030 | Compression gauge adapter
(09552-1060 | Compression gauge adapter
09552-1080 | Compression gauge adapter
00405-1190 | Engine it
Fuel System
Special tools
‘Shape Part No. ‘Name mark
o> prereont lene peepee ceed
For assemblyidisassembly
(09819-1707 | Supply pump coupling wronch
oe Pt ume coupling Won | eo pump coupling
cosso.z200 | Prose For supply pump drive oil
seal press-fit PARTS TO BE PREPARED 3
Electrical
Special tools
‘Shape Part No. Name Romark
For V-belt tension
x 09444-1210 | Compression gauge fer oa
Engine Mechanical
Special tools
Part No. Name Romark
oszo-1900 | puser For crankshaft front ol seal
removal
. For assembly/disassembly
09470-1120 | Valve spring press Srahe corn eter
09431-1010 | Valve lapping tool For valve adjustment
09472-1870 _| Valve stom seal press Forvaie stem seal
mounting
For assembly/disassembly
09442-1280 | Piston ring expander Spon eg
For cooling jet inspection
9001-24262 | Check bolt aise
osarocit¢0 | Testxt For cooling jet inspection
and adjustment PARTS TO BE PREPARED
=D =r = foe
acetate than proe ted
KO 09420-1750 | Cylinder liner puller For cylinder liner removal
sowrstco loess Seer
eae
course |pmee oer
&> wwocim: [potea ee
< osa72-1210 | Bar For nozzle seat press
seoo.osio0 |nazdosest press (ttt. | Fornoze sat laneng
2 poten a eae re) PARTS TO BE PREPARED a5
09420-1442 ‘Sliding hammer o nee
Xx ee oe
=
09420-1111 Timing gear puller ‘supply pump drive gear
al
ee
Instruments
i fe
oe ee
So a
— See
= ieee me sere
aes nee ad 36 PARTS TO BE PREPARED
Lubricant, etc.
‘Name
Remark
Liquid gasket (Threebond 1812076 or equivalant : Red) | Push rod cover and flywheel housing
Liquid gasket (Thresbond T8121 1 or equivalent : White) | Lower part of nozzle seat and oll pan
Red lead For inspection of valve contact
‘Lapping compound For valve adjustment
‘Dye penetrant For inspection of crack and damage
Cooling
Special tools
Shape Part No. Name Remark
09420-1820 | Puller
For vane removal
09420-1810 | Puller
For pulley center removal
094822940 | Press
For mechanical seal
‘mounting
09482-1700 | Press
For vane pross-it
Lubrication
Instruments
Name Remark
Micrometer For measurement of part outer dlameter
Cylinder gauge For measurement of part inner diameter
Thickness gauge For measurement of each clearance PARTS TO BE PREPARED a7
Starting and Charging
Jig (reference dimensional drawing for manufacture)
Alternator
This is used for assembly of bearing. Refetence dimensions are shown in the figures below:
sig A (Rater bearing insertion ji) iB (Support) Unit ming
ezstznaen 250.864)
040.039)
a ssc.
7012758)
640.039) S001 964)
“0-20 p54 955)
oan “Qt 010017 Nee HOse4- O77
3300.18
sinc Jed
y94tt399) pac 014)
[ern [eon
lors) 0.575)
1040.94) vaso
wo) P1._s6s.520
st |_ 70796
“rT
Common tools
Alternator
‘Name Romark
Soldering bit 80-100
Instruments
Alternator
Name Remark
Circuit tester For measurement of parts
Megger tester For inspection of insulation
Micrometer For measurement of parts
Regulator checker (G&M Machinery ICD-101D or
are For inspection of regulator 38 PARTS TO BE PREPARED
Starter
‘Name Remark
iru tester For measurement of paris
Micrometer For measurement of par outer darter
Growler tester For inepeation of armature
Cylinder gauge For measurement of pat inner diameter
For measurement of brush length and commutator
outer diameter
Dial gauge For measurement of shaft runout
Magnet stand For measurement of shaft runout
Lubricant, etc.
Starter
Name Remark
‘Kyodo Yushi Multemp AC-N
For lubrication of parts
Nissekd Mitsubishi Pyroknack #2
For lubrication of parts
Grease syringe
For pouring grease into the metal (center bearing)
grease reservoir
Turbocharger
Special tools
‘Shape Part No, Name Remark
09407-1280 | Tool assembly
Instruments
Name
‘Remark
Dial gauge
For measurement of turbine shaft bend 4 ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Services.
Measurement of compression pressure
sn A
Engine Body.
Removal
Installation
Work ater instalation
ENGINE ASSEMBLY/DISASSEMBLY
ses 2
42
43
45
45 42 ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Service
Measurement of compression pressure
NOTICE + Measure the compression pressure botoro
disassembly ofthe engine and record the
result, Regular measurement of the
compression pressure can tell the engine
status,
1. Preparation before measurement
(1) Charge the battery completly
(2) Check the valve clearance and adjust it when exceeding
the standard value
(8) Warm the engine and set the water temperature to 80
S0(176 °F}
(4) Remove the air leaner.
(5) Remove the head cover
(6) Remove al injectors.
(7) To prevent spread of engine cil attach ajig which cuts a
head cover in half (Cut itso thatthe camshaft may be
covered.
Measurement
(1) Attach a special too! to the nozzle sheet of the cylinder
where the compression pressure is measured.
‘Special tool : 09952-1080, 09552-1060, 09552-1030
Compression gauge adaptor
(2) Tur the starter and measure the compression pressure
A\CAUTION + Donot operate the starter for 15 seconds or
more.
rrr
+ Since the air cleaner is removed, provent
entry of dirt.
(8) Measure the compression pressure of each cylinder
continuously.
Engine revolution 200r/min {rpm}
‘Compression pressure: Unit MPa
tkgt/em?,tbtfin.2}
[ Standard value 2.9 {90, 421}
2.5 (26, 962}
‘Operation
(4) Ifthe compression pressure is below the operation limit,
overhaul the engine,
(5) After measurement, reassemble the removed parts. ENGINE ASSEMBLY/DISASSEMBLY
Engine Body
Removal
1. Preliminary work before removal of engine
(1) Place the vehicle on a level ground.
(2) Block tres with scotch.
(3) Remove the battery cable from the battery minus terminal,
2. Drain of coolant and engine oil,
Fight sie of engine
: (1) Drain coolant from the radiator drain cock and the oll
cooler drain plug.
NOTICE + Removal of the filer cap facilitates quick
drain,
+ Connection of an appropriate hose to the oi
cooler drain pipe facilitates drain of coolant
without spread,
Ol cooler rain plug
A\CAUTION + To prevent burn, drain coolant after the
temperature is sutficiently low.
+ To dispose coolant, observe the specified
‘method (waste disposal) or the method with
attention to the environment.
r ———____()__ Drain engine oil rom the oll pan drain plug as required.
A\CAUTION + To prevent bur, drain coolant after the
temperature is sutficfently low.
*+ Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.
3, Removal of intake hose, intercooler hose and exhaust pipe
(1) Loosen the clamp and remove the intake hose.
(2) Remove nuts and remove the exhaust pipe.
Intake manifoe
AXCAUTION + Close the opening of the intake manifold with
a packing tape to prevent entry of dirt inside
the engine.
Gyindec head
i cet Work image
4, Disconnection of fuel hose
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with iis end facing
upward to prevent spill of fuel.
A\CAUTION * Wipe spilled fuel with a rag
5. Disconnection of water, engine oll pipes, ete.
(1) Disconnect the hose between the radiator and the engine,
(2) Disconnect the ar heater pipe.
(3) Disconnect the ol fiter pipe.
AXCAUTION + Wipe off spilled water and engine oil with a
rag.
Engine lifting
(1) Place a hook on the hole in the engine hanger.
(2) Keep a litle slack of the wire rope.
(8) When the wite is completely tonse, make sure that the
Wire Is firmly engaged with the engine hanger. Then, lift
the engine slowly.
A\CAUTION - Work carefully so that the engine may not
come in contact with the frame and others. ENGINE ASSEMBLY/DISASSEMBLY
Installation
1. Connection of fuel hose
(1) Insert a fuel hose and fix it with a hose band.
Work after installation
4. Inspection of engine oil
(1) Make sure that the drain cock is closed.
@) Pour engine oil
Engine oil amount (L{us gal})
pan Oil filter
‘Approx. 23{6.07) ‘Approx. 6.04
Hino genuine Blue Ribbon ePRO-extra
PROT SAE#10W-30
Hino genuine Blue Ribbon oPRO-super
SAEH 20
ANCAUTION + Check the amount of oll wth an ol level
gauge.
Air biagcing
Priming pump
‘PROTOS
2. Air bleeding of fuel system
(1) Propare a rag to receive fuel at the end of the drain valve,
(2) Loosen the air bleeding bolt of the fue filter.
(3) Tum the priming pump to the left and lit and move it front
and back c
(4) Move the pump until fuel without bubble comes out from
the drain valve,
() Tighten the alr bleeding plug.
(6) Move the priming pump again § to 6 times,
(7) Pross the priming pump and tighten it fully to the right.
AXCAUTION + After work, wipe off spilled fuel. After start of
the engine, make sure that there Is no fuel
leak. FUEL SYSTEM a4
5 FUEL SYSTEM
Fu! System cnn
Fuel system diagram,
Part layout (ypical example) 53
Part layout (ypical example) 54
Par layout ((yplcal example 55
Ful iter drain renee 6
placement of fuel iter element... 58
‘Assembiyfaisassembly of fel fer case 58
Replacement of supply PUMP ns 58
Feplacement of inj0t0r orn Sat
Inspection of njet0r sn 545
Inspection of common rail function parts
(evaluation) 516
‘Overhaul of supply pump drive besring case... 5-17 52 FUEL SYSTEM
Fuel System
Fuel system diagram
eaten pipe
Common
Food pump |
Lsakage poe
Tach eed pine
“Traugh food pipe
Fat tnke FUEL SYSTEM
Part layout (typical example)
5
5 Bn,
gor gl
ae
sxman © sence
Pe
fesoet Leakage pipe [2S766A Fuel pipe
l2s900 Fue! fter les7668 Fuel pipe
las7ot Injection pipe lea76ec Ful pipe
28702 Injection pipe 2a781 Fuel pipe
22703 Injection pipe laser Feed pump
2704 Injection pipe 1s0596 Gasket
lea705 Injection pipe lsosac Gasket”
l2a706 Injection pipe 190590 Gasket?
“Parts not to be reused.
Tightening torque
8081 “44 Nm (450 Kgh om, 82 bt th fearos AN. m (450 kgf cm, 82 BF A
23701 44 Ne m {450 kat: om, 92 IDE ft) l2a706 20 N: m (200 gl: om, 15'bF- ft}
‘2s702 44 Ne m (450 kgf: om, 82 Ibt ft} leaezt Common ral side: 54 N- m {550 kgf: cm,
40 it: #)
23708 44 0+ mm (450 kat: cm, 82 IDF ft} 29871 ‘Supply pump side: 44 N- m (450 kgf cm,
82 It ft)
les704 44.N-m (450 kgf cm, 92 bt A 19068-12000 97 N- m {990 kgh cm, 72 lof: ft} Part layout (typical example)
FUEL SYSTEM
oe
meg @ -r9906
T1195 Injector clamp [asai0 Injector
114918 Common rail bracket locas O-tingt
13610 Supply pump drive case assembly 96590, Gasket”
13611 Supply pump drive shaft 96508 Gasket"
+3601 Bearing holder case loezen Oil seal"
3693 Bearing retainer loes1A O-ring®
1873 Oil pipe (e51B O-ring
sr74 Fuel pipe 1900111 Shim
122730 ‘Supply pump je93-a02060 Bearing
\22760 Common rail assembly 1999322070 Bearing
“Parts not to be reused.
Tightening torque
(22780 Caller bolt: 81 N- m (930 kgF Gm, 67 ]aTBT-08400 _25N- m (250 kgh om, 18 [bt A)
ttf)
22790 Coupling bolt: 61 N: m {620 kgi- cm, 45 |9191-08901 28 N- m (290 kgf: cm, 20 Ib: ft}
Tot)
lo00124 26 N: m (270 kgf: om, 19 Ibt ft} lger9A 245 N+ m (2,500 kgf om, 180 Ibt- ft} FUEL SYSTEM 55
Part layout (typical example)
2 Te
G *
me @
[23500 Fuel iter assembly [8a47 Sedimentor water sensor
lzos10 Fuel fiter case 800700 Center bok
ass Bot s007s8——O-ting®
23353 Spring e007s8 ‘Fuel iter cap
25885 O-tingt S018 O-ring
2601 Fuel itr element
“Parts rot to be roused
Tightening torque
Basie 4-29 N m(S0-O0kgE om, 36-65 ]B0070 _245-G49N mm[OB0- 360 kal om, 18
tot 25 (bt) int bot Fue! er bedi bal
\
\
Drain pipe Fuel ter ran bot
Genter bt
FUEL SYSTEM
Fuel filter dré
1. Propare a water container under the drain pipe.
2. Loosen the fuel filter air bleeding bolt and the fuel filter
drain bolt. Discharge water at the bottom of the fuel filter
case,
+ Since discharged water contains fuel,
‘observe the local disposal procedure for
disposal.
A\caution
3. Tighten the fuel filter drain bolt.
4. Start the priming pump and bleed air from the system,
+ Make sure that the fuel filter air bleeding bolt
Is loose.
A\cauTion
8, Tighten the fuel filter air bleeding bolt
Tightening torque : 4.9 -8.9N- m (50-90 kgf em, 3.6
-6.5 IbF 1)
+ After work, wipe off spilled water or fuel. After
start of the engine, make sure that there Is no
fuel leak.
AX caution
Replacement of fuel filter element
1. Fuel discharge
(1) Prepare a fuel container under the drain pipe.
(2) Loosen the fuel fiter air bleeding bolt, fuel fiter drain bolt
and joint bolt to discharge fuel in the fue fiter caso.
+ For disposal of fuel, observe the local
disposal procedure,
AvcauTion
2. Removal of fuel filter element
(1) Loosen the fue! fit center bolt and remove the fuel fier
cap.
(2) Remove the fuel fer element.
+ Since the filter contains diesel oll, prepare a
tray.
Axcaution FUEL SYSTEM oT
3, Installation of fuel flter element
(1) Remove contamination or foreign matter from the
Installation surface.
(2) Store the fuel fiter element in the fuel filler case,
(3) Apply diesel ol ightly to the new O-ring.
(4) Assemble the O-ring and the fue! fiter cap and tighten the
‘uo! fiter center bolt,
Tightening torque : 24.5 - 34.3 N- m (250 - 350
kgf- cm, 18-25 Ibt- tt)
A\CAUTION + Element is not reused.
+ Replace the O-ring with a new one in the
‘element kit.
+ Be careful for damage to the O-ring due to
distortion,
‘+ Make sure that the O-ring is in contact with
the sealing surface.
+ ‘Align the match marks of the fuel filter cap
and the fue! filter case.
(8) Tighten the fue! fiter drain bott and the joint bot.
(8) Start the priming pump and bleed air from the system.
AXCAUTION. + Make sure that the fuel iter air bleeding bott
Istooee.
(7) Tighten the fuel fiter air bleeding bol
Tightening torque : 4.9 - 8.9 N: m {60-90 kgf em, 3.6
= 6.5 Ibt- ft}
A\CAUTION + After work, wipe off spilled fuol. After start of
the engine, make sure that there is no fuel
leak. FUEL SYSTEM
Assembly/disassembly of fuel filter case
1. Removal of fuel filter case
(1) eter to the "Fuel discharge" procedure of ‘Replacement
of fuel fiter element" and discharge fuel inthe fuel fiter
(2) Disconnect the fuel pipe connected to the fuel filter case,
(8) Remove two mounting bolts and remove the fuel fiter
A\CAUTION = Since some fuel is not discharged and
= remains in the fuel filter caso, be careful not
to spill it.
2. Mounting of fuel filter case
(1) Assemble the fuel fter case at the specified position and
tighten two mounting bots.
Tightening torque : 97 N- m (990 kgf- cm, 72 Ibf- ft}
(2) Install the fue! pipe to be connected to the fuel fiter case.
(3) Loosen the fue! fier air bleeding bolt
(4) Start the manual priming pump and bleed air from the
system
(8) Tighton the fuel filter air blesding bok.
Tightening torque : 4.9-8.9N: m (50-90 kgf: cm, 3.6
-6.5 Ibt ft)
AXCAUTION + After work, wipe off spilled fuel. After start of
- the engine, make sure that there is no fuel
teal Fyaneel housing
Spector winow
‘Algn
FUEL SYSTEM 59
Replacement of supply pump
1. Removal of supply pump
NOTICE + The supply pump does not have to be
adjusted,
+ I insufficient discharge rate or a faulty sub-
engine speed sensor occurs, contact the
Denso service shop.
(1) Remove the fuel pipe and ol pipe connected to the supply
pump.
(2) Align the No. 1 cylinder to the compression top dead
center and align the stamp lines of the supply pump.
(8) Remove the coupling bolt.
Special tool : 09819-1707 Supply pump coupling
wrench
(4) Remove four bolts and remove the supply pump.
(8) Loosen the cotter bolt and ensure shatt play for
reinstallation,
2. Installation of supply pump
(1) Turn the crankshaft in the engine rotating direction
(clockwise as viewed from the cooling fan side), align the
"16" stamp line ofthe crankshaft damper with the pointer,
and align the No. 1 cylinder to the compression top dead
center,
A\cAUTION * Ifthe pointer is matched with "16", but the
‘supply pump bearing case shaft key or cotter
bolt faces down, No. 6 is at the compression
top dead center. Turn the crankshaft one turn
and set the No. 1 cylinder at the compression
top dead center. 5-10 FUEL SYSTEM
(2) Make sure that the cotter bois loose and install the
J supply pump on the bracket
= Tightening torque : 28 N- m {290 kgf- cm, 20 Ibt- ft}
xq en mv alooe
) ‘cotter bolt
ve
Oe
(3) Install two bolts atthe coupling and tighten the coupling
bolt by aligning the stamp line of the supply pump.
Special tool : 09819-1707 Supply pump coupling
wrench
Tightening torque : 61 N- m (620 kgf: cm, 45 Ibt ft
ANCAUTION. + Make sure that there is no clearance between
laminate plates. Make sure that there is no
flange deformation due to crashing of
laminate plates.
(4) Tighten the cotter bot.
Tightening torque : 91 N- m {930 kgf- em, 67 Ibf- ft)
AXCAUTION * Make sure that laminate plates are not
deformed or there is no undue force on them.
(6) Replace the gasket with a new one and connect the fuel
= Injector pipe and oil pipe to the supply pump.
Tightening torque :
44. m (450 kgf. cm, 92 Ibf- ft} (Fuel pipe M14)
54 N. m {550 kgf- cm, 40 Ibt- ft} (Fuel pipe M16)
(Common all Special tools
Q
Replacement of injector
1. Removal of injector harness:
(1) Remove each connector and bolt and remove the injector
harness
A\CAUTION + Since the injector harness bracket is
susceptible to distortion, be careful for
handling.
NoTICE + Refer to the following for installation of the
engine retarder. "Reference: Engine
‘mechanical, Engine retarder, Removal’
2. Removal of leakage pipe
(1) Remove the injector and cylinder head union bots
(2) Remove bolts and remove the loakage pipe.
A\CAUTION. * Since the leakage pipe is susceptible to
distortion, be careful for handling.
3. Removal of injector
(1) Remove the injection pipe seal.
(2) Remove the injector clamp mounting bolt and remove the
injector and injector clamp.
NoTICE + Ifitis difficutt to pull it out, pull it out with a
special tool.
Special tool : 09420-2010 Puller
(8) Remove the O-ring from the cylinder head. Irecton pipe
Sha spring
FUEL SYSTEM
4, Installation of injector
(1) Install a new O-ring on the eyinder head groove and
insert the injector.
AXCAUTION + Apply engine oll tothe O-ring and be careful
to provent pinching of the O-ring.
(2) Puta new injection pipe cil seal on the injector and install
itith bolts and nuts
AXCAUTION + Do not tixthe injector clamp until the injection
pipe is tack welded temporarily.
+ Install the injection pipe seal to prevent undue
{force to the injector. (Offset position between
the Injection pipe oll seal and the Injector may
cause oll leak or poor assembly of the
injoction pipe.)
(8) Replace the gasket with a new one and tack weld the
leakage pipe tothe injector and cylinder head temporally.
AXCAUTION + Install the gasket in a direction in which it
does not interfere with the valve spring.
+ Since the injector top union bolt and the
cylinder head joint union bolt are different in
screw thread pitch, be careful for handling
Injector top union bolt (M10 x 1.0)
Cylinder head joint union bott (M10 x 1.5)
(4) Tack wold the injection pipe through the injection pipe soat
Until it comes in contact with the seat
AXCAUTION + Tack weld ity adjusting so that the Injector Is.
aligned with the
‘+ Make sure that the seal spring Is installed
correctly.
jection pipe. Injection olpe
FUEL SYSTEM
(5) Tighten the injector clamp mounting bolts to fix the
injector.
Tightening torque : 26 N- m {270 kgf cm, 19 bf. ft}
AXCAUTION + After tightening, make sure that the rocker
‘arm moves smoothly.
Make sure that there Is no undue force on the
injection pipe oil seal. (Otherwise, oil leak or
poor assembly of injection pipe may occur)
(6) Tighten the injacton pipe.
Tightening torque : 44 N- m (450 kgf: cm, 32 Ibf ft)
(7) Tighten the leakage pipe.
Tightening torque : 20 N- m {200 kot cm, 15 Ib. ft}
A\CAUTION + Assemble so that the gasket connection may
not come in contact with the rocker arm,
Installation of injector harness
(1) Connect each connector and install the injector harness. FUEL SYSTEM
6. Entry of injector correction value to the engine ECU (entry
using Hino field support system and QR code reader)
ASCAUTION + When the injector i replaced, its necessary
to enter the Injector correction value (QR
code) described on the new injector to the
engine ECU, Incorrect entry of the correction
ae value may result in faulty engine.
NoTIcE * Available entry methods of the injector
correction value are the PC tool and the QR
code reader.
+ The work flow is described below. For detailed
procedures, refer to the operation manual of
the Hino field support system.
(1) Read the injector QR code with the scanner of the QR,
code reader and prepare the correction data fie
(2) Enter the injector correction value directly from the Hino
field support system to the engine ECU.
=>
cl
‘Connector
ecu FUEL SYSTEM 515
Inspection of injector
1. Inspection of injector insulation
(1) Remove the injoctor plastic terminal cap (upper).
(2) Measure the insulation resistance between the injector
Upper body and one terminal (no polarity) of two terminals
for the injactor harness,
Cross-section vew of rjctorhed>
‘Terminal (harass Termine esp (upped)
Srna) Stan in
vurtcap dard value (normal | 09 ac or more
nm et temperature)
(9) Measure the resistance value between two terminals,
SS above.
befor hares
snd uabar oe ‘Standard value (at 20
| °c(6s °F)
0.45 2:40.1
(4) the resistance value in (2) and (3) exceeds the standard
Se value, replace the injactor assembly.
UBper body
esi)
2. Cleaning of injector
(1) Remove sludge at or around the terminal, if any.
AXCAUTION + In removing sludge, do not use a cleaning
Agent. Wipe it off with a rag, Use of a cleaning
agent may result in electric failure due to
penetration ofthe agent. 5-46 FUEL SYSTEM
Inspection of common rail function parts
(evaluation)
1. Inspection of pressure sensor
(1) Ifthe check engine lamp illuminates and it applies to
“Pressure senor disconnection’, "Pressure sensor short
circuit” or "Pressure sensor output does not change" in
inspection of failure diagnosis system, replace the
pressure sensor.
2. Inspection of pressure limiter
(1) Remove the hollow SC of the pressure limiter.
(2) _ Install blank plug on the pipe side using a bolt to prevent
as Insta lar 149
on the pps, fuol discharge.
Remove the hallow SC.
8) _ Install the union on the pressure limiter and connect the
plastic hose to the tip ofthe union.
(4) Propare a fuel container at the tip of the plastic hose.
(5) _ Ifthe engine is started and fuel discharge Is recognized
continuously, replace the pressure limiter.
Prasichose 8
Comme
3. Inspection of flow damper
(1) Start the engine, run it from idling to full throttle and check
the diagnosis code of “flow damper operation’.
(2) the diagnosis code of “flow damper operation’ Is,
dotected, replace the applicable injector and inspect
again.
(8) Ifthe failure is reproduced after the injector is replaced,
replace the flow damper with the common rail assembly. FUEL SYSTEM
Overhaul of supply pump drive bearing case
1. Removal of timing gear case cover
"Reference: Engine mechanical, timing gear cover and
flywheel housing, timing gear case cover replacement"
2. Removal of supply pump drive gear
(1) Remove the drive gear mounting nut
(2) Remove the oll pipe connected to the supply pump drive
bearing case.
— ~ (3) Pullout the gear using a special tool or installa box nut on
the shaft, hit the shaft with a copper hammer, loosen and
cee remove the gear with impact.
\ Special tool : 09420-1111 Timing gear puller
(4) Remove the supply pump drive bearing case.
3. Disassembly of supply pump drive bearing case
(1) Remove the bolt and disassemble the supply pump drive
Rg a bearing case 518
estng
Shan
OT ctu groove
SHE speci oo
= Oil eoat
=} pearing retainer
FUEL SYSTEM
4. Assembly and adjustment of supply pump drive bearing
case (
(1) Insert the beating and shaft applied with engine oil into
the case, replace the O-ring with a new one applied with
engine ol and assemble the supply pup boaring case as
shown in the figure.
Tightening torque : 25 N- m {250 kgf- em, 18 bt. ft}
A\CAUTION. + Adjust temporarily with a shim so that the
drive shaft Is tuned manually and there is no
backlash.
+ Assemble so that the bearing retainer
protrusion (oil return groove) is lower.
(2) Measure the rolling torque using a torque wrench and
adjust itso that it satisfies the standard value.
‘Standard value (Nm | 0.39 1.17(4 - 12,3.5-
{kgf om, Ibf- in) 10.4)
(3) Apply engino allo the lip of a new oll seal, :
(4) Pross fit the oil seal using a special oo! so that the oll soal
is flush with the bearing retainer.
‘Spocial tool : 09482-2330 Press a
FUEL SYSTEM 5-19
Installation of supply pump drive bearing case
(1) Replace the O-ring with a new one and install the supply
pump bearing case with adjusted preload from the back.
(2) Fix the drive shaff, align the gear stamp, install the drive
gear and tighten the nut
Tightening torque : 245 N- m {2,500 kgf: cm, 180
It 1)
Installation of timing gear cover
“Reference: Engine mechanical, timing gear cover and
flywheel housing, timing gear case cover replacement” ELECTRICAL
7 ELECTRICAL
Electrical System, : 52
Part layout (typical example). 52
Layout of components. 55
Inspection of components 57
Instalation of components 59
Installation of starter. 59
Installation of altemator. 510 72 ELECTRICAL
Electrical System
Part layout (typical example)
aE @ 2x00 ©
a eit? an a Btn aE
Res “ye a os oe
° sen e208
sy Sd saz08
oO
° BR PE wn
ix x 
