Hino EC13 Engine Workshop Manual

FOREWORD

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

Applicable for E13C engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print­ing.
Hino Motors reserves the right to make changes at any time without prior notice.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.

MANUAL NO. S5-YE13E01A

CHAPTER

MODEL E13C

GENERAL INTRODUCTION GN01-001

ENGINE INTRODUCTION EN01-001

ENGINE MECHANICAL EN02-001

AIR INTAKE SYSTEM EN03-001

EXHAUST SYSTEM EN04-001

LUBRICATING SYSTEM EN05-001

COOLING SYSTEM EN06-001

FUEL SYSTEM EN07-001

TURBOCHARGER EN08-001

ALTERNATOR EN11-001 EN11-002

STARTER EN12-001

AIR COMPRESSOR EN13-001 EN13-002

ENGINE P.T.O. (POWER TAKE-OFF) EN14-001

ENGINE RETARDER EN15-001

FUEL CONTROL DN02-001

INDEX: ENGINE GROUP 1/2

GENERAL INTRODUCTION

ENGINE INTRODUCTION

ENGINE MECHANICAL

WORKSHOP
MANUAL

AIR INTAKE SYSTEM

EXHAUST SYSTEM

LUBRICATING SYSTEM

COOLING SYSTEM

FUEL SYSTEM

TURBOCHARGER

FUEL INJECTION PUMP

EMISSION CONTROL

All rights reserved. This manual may not be
reproduced or copied in whole in part, with­out the written consent of Hino Motors, Ltd.

ALTERNATOR

STARTER

AIR COMPRESSOR

ENGINE P.T.O.
(POWER TAKE-OFF)

ENGINE RETARDER

ENGINE CONTROL

INDEX: ENGINE GROUP 2/2

ENGINE CONTROL

FUEL CONTROL

BRAKE CONTROL

SUSPENSION CONTROL

CAB EQUIPMENT CONTROL

OTHERS

GN01

GENERAL INTRODUCTION

GENERAL INTRODUCTION.....................GN01-2

WARNING........................................................GN01-2

HOW TO USE THIS MANUAL.........................GN01-3

PRECAUTIONS FOR WORK ..........................GN01-8

TIGHTENING OF BOLTS AND

NUTS FOR ENGINE......................................GN01-13

TIGHTENING OF BOLTS AND

NUTS FOR CHASSIS....................................GN01-15

TIGHTENING OF FLARE NUTS

AND HOSES..................................................GN01-17

SEALANT ON THE TAPERED SCREW

FOR PIPING ..................................................GN01-18

NYLON TUBE................................................GN01-19

ASSEMBLY OF JOINT/GASKET

FOR PIPING ..................................................GN01-22

HANDLING OF LIQUID GASKET..................GN01-24

TROUBLESHOOTING USING

THE TROUBLE LIST .....................................GN01-25

TROUBLESHOOTING USING

A DIAGNOSIS MONITOR..............................GN01-26

DIAGNOSIS USING THE PC (PERSONAL
COMPUTER) DIAGNOSIS TOOL

WITH INTERFACE.........................................GN01-30

CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND ENGINE SERIAL

NUMBER .......................................................GN01-33

GN01-001

GENERAL INTRODUCTION

WARNING

EN0011001C100001

In order to ensure safety in work and avoid possible damage to vehicle, strictly observe the following precautions:
Audience of this manual is a qualified service engineer who has acquired expertise. In case an unqualified service engi­neer or a service engineer without appropriate training has performed maintenance, or in case maintenance is performed
without using appropriate tools and units or in accordance with the method described in this manual, the vehicle under
maintenance could be damaged as well as do harm to the service engineer and the people in the maintenance site.

• Appropriate maintenance and repairs are a must for assurance of safety of the service engineer as well as the safety

and reliability of the vehicle. Replace parts of the vehicle with HINO genuine parts. Avoid using degraded parts.

• This manual contains the procedures to follow in performing maintenance and repairs. When performing mainte-

nance and repairs in accordance with the procedures, use special tools designed to meet specific needs in a proper
way.

• Never use a non-recommended work method or tool; this could impair the safety of the service engineer as well as

the safety and reliability of your vehicle.

• This manual contains various items classified into DANGERS, WARNINGS, CAUTIONS and NOTICES in order to

avoid accidents during maintenance and repairs or damage to the vehicle resulting in impairment of its safety and
reliability.
Note that these instructions described as DANGERS, WARNINGS, CAUTIONS and NOTICES are not the minimum
requirements to observe in order to avoid possible dangers.

HOW TO USE THIS MANUAL

EN0011001C100002

1. REPAIR WORK

(1) The repair work is roughly classified into the three processes: "diagnosis", "mounting/dismounting, replacement,

assembly/disassembly and inspection/adjustment work" and "final inspection".

(2) This manual describes the first process "diagnosis" and the second process "mounting/dismounting, replacement,

assembly/disassembly and inspection/adjustment work". Description on the third process "final inspection" is omitted.

(3) While this manual does not describe the following element work, the work is to be performed in practical cases:

a. Jack work and lift work

b. Cleaning of removed parts as required

c. Visual inspection

2. TROUBLESHOOTING IN THIS MANUAL

(1) This manual describes the following steps 2 and 3.

(1) Interview "Step 1"

(2) Pre-inspection
(3) Replication method

(4) Troubleshooting by diagnosis code
(5) Troubleshooting by trouble

"Step 2"

"Step 3"

(6) Checkup test "Step 4"

(2) Pre-inspection

• Execute the following steps to perform pre-inspection.

Diagnostic inspection → diagnosis code erasure → trouble check (If the trouble does not recur,
use the replication method.) → Diagnosis code re-check

• Assume the faulty system before the replication test. Connect a tester and determine a proba-

ble cause of trouble together with checkup of the trouble. For a probable cause of trouble, refer

Pre-inspection

to the troubleshooting chart.

• In case the trouble is momentary or in case an error code is displayed but no special trouble

takes place, execute related troubleshooting procedures while using the replication method.

• Trouble checkup

In case the trouble recurs, follow steps 2, 3 and 4 in this order.
Otherwise, use the replication method, that is, reproduce the external conditions, and inspect
each wire harness and connector parts.

Thoroughly listen to the conditions and environment for the trou­ble and confirm the fact.

Perform diagnostic inspection, checkup of the symptom, function
inspection and basic inspection to confirm the trouble. If the trou­ble hardly recurs, use the replication method.

Classify the inspection results obtained in step 2 to systematically
perform inspection accordance with the troubleshooting proce­dure by diagnosis code or trouble.

Check for the trouble after the trouble is removed. In case the
trouble is hardly replicated, conduct a checkup test under the con­ditions and environment for the trouble.

3. DESCRIPTION IN THIS MANUAL

(1) Component Locator

SHTS001100100001

✩: This is the ID number of an item to be prepared for creating electronic data and is not necessary for repair work.

(2) Work item

SHTS001100100002

4. DEFINITION OF TERMS
This manual defines the terms used herein as follows:

(1) Direction

a. Chassis

• To-and-fro direction

The direction of forward travel of the vehicle while mounted on the vehicle is forward direction; the direction of back­ward travel of the vehicle while mounted on the vehicle is backward direction.

• Direction of rotation

The clockwise direction as seen from the rear of the vehicle is clockwise direction; the counterclockwise direction as
seen from the rear of the vehicle is counterclockwise direction. (In case of engine, the clockwise direction as seen
from the flywheel side is clockwise direction; the counterclockwise direction as seen from the flywheel side is counter­clockwise direction.)

• Upward/Downward direction

The upward direction while mounted on the vehicle is upward, and downward direction while mounted on the vehicle
is downward.

• Right/Left direction

The right direction as seen from the rear of the vehicle while mounted on the vehicle is right direction; the left direc­tion as seen from the rear of the vehicle while mounted on the vehicle is left direction. (In case of engine, the right
direction as seen from the flywheel side is right direction; the left direction as seen from the flywheel side is left direc­tion.)
b. Standalone unit

• To-and-fro direction

The direction of input of power is forward direction; the direction of output of power is backward direction.

• Direction of rotation

The clockwise direction as seen from the rear of the unit is clockwise direction; the counterclockwise direction as
seen from the rear of the unit is counterclockwise direction.

• Upward/Downward direction

The upward direction while the unit is mounted on the vehicle (chassis) is upward, and downward direction while the
unit is mounted on the vehicle (chassis) is downward.

• Right/Left direction

The right direction as seen from the rear of the unit is right direction; the left direction as seen from the rear of the unit
is left direction.

(2) Standard value (Assembly standard):

Indicates a basic dimension or including the tolerance and the clearance generated by the clearance of a combina­tion of two parts

(3) Limit (Service limit):

Indicates a numeric value which requires correction or replacement.

5. DEFINITION OF SAFETY TERMS

Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.

Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.

Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.

Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

6. UNIT

(1) This manual uses the SI unit system. The SI unit is an international unit which is based on one unit per quantity unlike

the conventional unit system which differs from country to country, in order to facilitate technology exchange.

(2) This manual writes the SI unit and a conventional unit side by side, the conventional unit enclosed in parentheses { }.

1

SI unit

Conven-

tional

unit

Conversion value*

(1[Conventional unit]

= X [SI unit])

Force N kgf 1 kgf=9.80665 N

Torque*

2

N⋅mkgf⋅cm

Pressure Pa

kgf/cm

2

1 kgf⋅cm=

0.0980665 N⋅m

1kgf/cm2=

98.0665kPa=

0.0980665Mpa

mmHg 1mmHg=0.133322 kPa

Rotation

speed

r/min

min

-1

rpm

1 rpm=1 r/min Fuel con-

1 rpm=1 min

SI unit

Spring

constant

N/mm kgf/mm

Volume L cc 1 cc=1 mL

Efficiency W PS 1 PS=0.735499 kW

Quantity

of heat

-1

sumption

ratio

W⋅H cal 1 kcal=1.13279 W⋅h

g/W⋅hg/PS⋅h

Conven-

tional

unit

Conversion value*1

(1[Conventional unit]

= X [SI unit])

1 kgf/mm=

9.80665 N/mm

1 g/PS⋅h=

1.3596 g/kW⋅h

*1: X is a value obtained by converting 1 [conventional unit] to an SI unit and is used as a conversion factor of the
conventional unit and SI unit.
*2: The torque conversion value may depend on the unit. Follow the specific value described for each unit.

PRECAUTIONS FOR WORK

EN0011001C100003

GENERAL PRECAUTIONS

To assure safety in work and prevent possible danger, observe the fol­lowing:

1. CLOTHES AND APPEARANCE

(1) Use safety glasses.
(2) To prevent injury, remove a watch, necktie, ring, bracelet and

necklace.
(3) Bind long hair behind.
(4) Wear a cap and safety boots.

2. SAFETY WORK

(1) To prevent burns, never touch a radiator, muffler, exhaust pipe,

and tail pipe just after the engine is turned off.
(2) While the engine is rotating, keep your clothes and tools off the

rotating sections, in particular the cooling fan and V-belt.
(3) Remove the starter key except when starting the engine.
(4) Provide good ventilation to avoid excessive CO when starting the

engine.
(5) The fuel/battery gas is flammable. Never make a spark or light a

cigarette.
(6) Take utmost care when working on the battery. It contains corro-

sive sulfuric acid.
(7) Large electric current flows through the battery cable and starter

cable. Be careful not to cause a short, which can result in per-

sonal injury and/or property damage.
(8) Leaving a tool or waste in the engine room causes the tool or

waste to touch the rotating section of the engine and pop out,

which could result in an injury.

3. TOWING

• When being towed, always place the gear shift lever in "Neutral"

and release the parking brake completely. In order to protect the

bumper, fit a protection bar against the lower edge of the bumper

and put a wood block under the frame near the No. 1 crossmem-

ber when attaching the towing chain. Never lift or tow the vehicle if

the chain is in direct contact with the bumper.
(1) Towing procedures

a. Make sure that the propeller shaft of the vehicle to be towed is

removed. When the differential gear or rear axle shaft is
defective, remove both right and left rear axle shafts, then
cover the hub opening to prevent loss of axle lubricant and
entry of dirt or foreign matter.

b. Use a heavy duty cable or rope when towing the vehicle. Fas-

ten the cable securely to the towing hook on the frame. The
hook should be used only if the towed vehicle is not loaded.

c. The angle of pulling direction of the cable fastened to the tow-

ing hook must not exceed 15° in horizontal and vertical direc­tions from the straight ahead, level direction. Avoid using the
hook in a way that subjects it to jerk, as in towing a vehicle

trapped in a gutter.
d. Keep the gear shift lever in "Neutral".
e. Make sure that the starter switch is kept in the "ON" position.
f. Make sure that the engine of the towed vehicle is kept run-

ning. If the engine is off, no compressed air/ no vacuum will

be available for the brake. This is dangerous, as the brake

system does not function if the engine is not running.

In addition, the power steering system will not function. The

steering wheel, therefore, will become unusually hard to turn,

making it impossible to control the vehicle.
g. Note that the engine brake and exhaust brake cannot be

applied, if the propeller shaft is removed.

h. Make a slow start to minimize shock. Towing speed should be

less than 30 km/h {18 mile/h}.

(2) If the engine of the towed vehicle is defective, make sure that the

vehicle is towed only by a tow truck designed for that purpose.
a. Front end towing (with front wheels raised off the ground)

When towing from the front end with the front wheels raised
off the ground, remove the rear axle shafts to protect the
transmission and differential gears from being damaged. The
hub openings should be covered to prevent the loss of axle
lubricant or the entry of dirt or foreign matter.
The above-mentioned precautions should be observed for
vehicles equipped with either automatic or manual transmis­sion, and for even short distance towing. After being towed,
check and refill the rear axle housing with lubricant if neces­sary.

b. Rear end towing

When being towed with the rear wheels raised off the ground,
fasten and secure the steering wheel in a straight ahead posi­tion.

PRECAUTIONS ON MAINTENANCE

Observe following before maintenance:

1. PREPARATIONS FOR DISASSEMBLY

(1) Prepare general tools, special tools and instruments before work.
(2) Before disassembling complicated sections, make a fitting mark

where functions are not affected to facilitate the assembly work.
Before repair of the electrical system, remove the cable from the
minus terminal of the battery.

(3) Follow the inspection procedure in this manual before disassem-

bly

2. INSPECTION DURING DISASSEMBLY

(1) Each time you remove a part, inspect the state of the assembly of

the part, deformation, damage, wear and flaws.

3. ARRANGEMENT OF DISASSEMBLED PARTS

(1) Arrange the disassembled parts in order. Discriminate parts to be

reused from replacement parts.

4. CLEANING OF DISASSEMBLED PARTS

(1) Thoroughly clean the parts to be reused.

5. INSPECTION AND MEASUREMENT

(1) Inspect and measure the parts to be reused as required.

6. ASSEMBLY

(1) Observe the specified values (tightening torque, adjustment

value) to assemble conforming parts in a correct procedure.
(2) Use genuine parts for replacement.
(3) Use new packing, gasket, O-ring and cotter pin.
(4) Use a seal gasket depending on the location of gasket. Apply

specified oil or grease to a sliding section where indicated. Apply

specified grease to the lip of the oil seal.

7. ADJUSTMENT WORK CHECK

(1) Use a gauge and a tester to adjust to the specified maintenance

value.

LOOSEN

SHTS001100100008

PRECAUTIONS FOR ELECTRICAL SYSTEM

1. REMOVING THE BATTERY CABLE

(1) Before electrical system work, remove the cable from the minus

terminal of the battery in order to avoid burning caused by short­circuiting.

(2) To remove the battery cable, fully release the nut to avoid damage

to the battery terminal. Never twist the terminal.

2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.

(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.

SHTS001100100009

SHTS001100100010

3. HANDLING OF WIRE HARNESS

(1) Perform marking on a clamp and a clip and secure then in original

position so that the wire harness will not interfere with the end and
acute angle section of the body and a bolt.

(2) To attach a part, take care not to bite the wire harness.

SHTS001100100011

4. HANDLING OF CONNECTOR

(1) To remove a connector, hold the connector (indicated by an arrow

in the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the

connector.
(5) In case it is difficult to insert a test lead from behind the connector,

prepare a harness for inspection and perform inspection.

PRECAUTIONS FOR ELECTRIC WELDING

1. Improperly performing electric welding on the cab or chassis

causes a backflow of the welding electric current thus dam-

aging various electrical equipment and electrical compo-

nents. Observe the following in electric welding:

(1) Turn off the starter switch.
(2) Check that all switches are off.
(3) Follow the battery cable removal procedure to remove the minus

terminal of the battery.
(4) Disconnect the connector of the computers.
(5) Remove all fuses.
(6) Ground the electric welder in the proximity of the welding section.

a. Welding to the frame

Ground the welder at a plated bolt or frame in the proximity of
the welding section.
To ground at the frame itself, peel off the coating on the frame.
Grounding at a chassis spring is inhibited because it causes
damage to the spring.

b. Welding to cab

Open the front panel and ground at the mounting bolt of the
cab hinge or cab itself.

(7) Other precautions

a. To avoid sputter in welding, cover the rubber holes, wire har-

nesses, pipes, chassis springs and tires before work.

b. Perform welding under appropriate welding conditions in

order to reduce influence of heat to the surrounding as well as
to secure the quality of welding.

(8) Once the welding work is complete, attach the removed fuse and

the minus terminal of the battery in this order to reconstruct the

original structure.

In case the coating on frame or cab has been removed, apply

rustproof coating of the same color.
(9) After reconstruction, perform functional checkup to ensure normal

operation.

FLOW OF WELDING CURRENT

1. WITHOUT TREATMENT OF ITEMS (1) THROUGH (5)

EQUIPMENT GROUND

ELECTRONIC
UNIT

CAB GROUNDING WIRE

THE WELDING CURRENT FLOWS IN TWO DIRECTIONS: (A) FROM CAB
TO ELECTRONIC UNIT TO BATTERY TO WELDER GROUND AND (B)
FROM CAB TO CAB GROUND TO WELDER GROUND. THIS DAMAGES THE
ELECTRIC UNIT.

2. WITH TREATMENT OF ITEMS (1) THROUGH (5)

WELDER

CHASSIS FRAME

BATTERY

EQUIPMENT GROUND

ELECTRONIC
UNIT

REMOVE THE FUSE.

TURN OFF THE
STARTER SWITCH.

CHASSIS FRAME

CAB GROUNDING WIRE

BATTERY

THE WELDING CURRENT FLOWS LOOPS BACK TO THE WELDER WITHOUT
PASSING THROUGH THE ELECTRONIC UNIT.

WELDER

REMOVE THE MINUS TERMINAL.

SHTS001100100012

TIGHTENING OF BOLTS AND NUTS FOR

ENGINE

EN0011001C100004

1. TIGHTENING TORQUE OF GENERAL STANDARD

(1) Washer based bolt

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Screw diameter x pitch 7T 9T

M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}

M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}

M10 x 1.5 (Coarse thread) 55 {560, 40} 68.5 {700, 51}

M12 x 1.25 (Fine thread) 108 {1,100, 80} 136 {1,390, 101}

M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1,280, 93}

M14 x 1.5 (Fine thread) 171.5 {1,750, 127} 216 {2,210, 160}

M14 x 2 (Coarse thread) 154 {1,570, 114} 199 {2,030, 147}

Remarks Bolt with the numeral "7" on its head Bolt with the numeral "9" on its head

NOTICE
8T bolt conforms to the standard of 7T bolt.

(2) With washer

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Screw diameter x pitch 4T 7T 9T

M6 x 1 (Coarse thread) 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}

M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}

M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}

M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}

M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1,200, 87}

M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1,100, 80}

M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1,500, 108} 186 {1,900, 137}

M14 x 2 (Coarse thread) 74 {750, 54} 132 {1,350, 98} 172 {1,750, 127}

Remarks

Bolt with the numeral "4"

on its head

Projection bolt

Stud with rounded free

end face

Bolt with the numeral "7"

on its head

Stud with chamfered free

end face

Bolt with the numeral "9"

on its head

NOTICE
8T bolt conforms to the standard of 7T bolt.

R FACE (4T)

C FACE (7T)

2. PRE-COATED BOLT
A pre-coated bolt is a bolt having a thread coated with seal­ant.

(1) Cases where sealant must be applied again

a. Pre-coated bolt is removed
b. Pre-coated bolt has moved during tightening torque inspec-

tion
(Loosened or tightened)

HINT
Torque check is to be made using the lower limit value. In case the
bolt has moved, retighten it in the following procedure:

SHTS001100100014

SHTS001100100015

(2) How to reuse pre-coated bolt

a. Clean the bolt and the tapped hole (clean the tapped hole

also when the bolt is to be replaced).
b. Blow air to dry up the bolt.
c. Apply a specified sealant to the thread of the bolt.

3. TENSION CONTROL WITH ANGULAR TORQUING METHOD
IN PLASTIC REGION OF MATERIAL

(1) Precautions

Part of an engine uses the Tension control with angular torquing
method in plastic region of material.
This is different from the conventional tightening method. Follow
the instructions in each chapter.

(2) Target region

Cylinder head bolt, crankshaft main bearing cap bolt, connecting
rod bearing, cap bolt and so on.

!CAUTION
Before assembly, measure the entire length of the bolt and if the
use limit is exceeded, replace the bolt with new one.
Apply engine oil to the bolt seat face and bolt thread.

SHTS001100100016

SHTS001100100017

(3) Tightening after tightening at the pre-set seating torque.

Further tighten by 90° or 135° (a turn by 90° and another by 45°)
or 180° (two turns by 90°).

TIGHTENING OF BOLTS AND NUTS FOR CHASSIS

EN0011001C100005

1. TIGHTENING TORQUE OF GENERAL STANDARD BOLT/NUT

(1) Selection of tightening torque

a. To select the tightening torque of a bolt, find the corresponding strength category in the table below. Select the

corresponding value from the tightening torque table given later.

b. To select the tightening torque of a nut, use the above method based on the mating bolt.

(2) Identification of bolt strength

a. Identification on the part itself

HEXAGON BOLTOn the hexagon bolt, the strength category is generally indicated on the head of the bolt by way
of depression, embossment, hollow and upset in accordance with the symbol in the table below.

Strength category 6T 7T 8T 9T 10T 11T 12T

Symbol on the part 6 7 8 q*

(*1): 9 is likely to be confused with 6 so that 9 is represented in q.

1

10 11 12

HEXAGON NUTThe following tables shows examples of symbols to identify the strength category of hexagon nut
on the nut itself.

(3) Types of general standard bolt and nut

Standard seat face Flanged seat face A Flanged seat face B

(4) Table of tightening torque of general standard bolt and nut (Standard seat face is shown as a typical case)

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Strength category

Bolt diameter

4T 7T 9T

4.5±1.8 {50±20, 3.6±1.4}

M6

5.5±1.1 {60±10, 4.4±0.7}

(Cab)

9.0±1.8 {90±20, 6.5±1.4} 11.5±2.0 {117±23, 8.5±1.6}

(Chassis)

14.0±3.5

M8

{140±40, 10.1±2.8} (Cab)

17.0±3.0

{170±30, 12.3±2.1}

22.0±4.0

{220±40, 15.9±2.8}*

2

29.0±5.5

{300±60, 21.7±4.3}*

(Chassis)

57.0±11.0

{580±110, 41.9±7.9}*

(Cab)

68.5±13.5

{700±140, 51±10}

(Chassis)

100.0±20.0

120.0±24.0

{1,220±240, 88±17}

(Chassis)

160.0±32.0

{1,630±326, 118±23}

250.0±50.0

{2,550±510, 184±37}

345.0±69.0

{3,520±704, 255±50}

490.0±98.0

{5,000±1,000, 362±72}

670.0±130.0

{6,840±1,370, 495±99}

845.0±165.0

{8,620±1,720, 623±124}

M10

M12

M14

M16

M18

M20

M22

M24

27.0±5.0

{276±55, 20.0±3.9}

48.0±9.5

{490±98, 35.4±7.0}

77.0±15.0

{786±157, 57±11}

120.0±24.0

{1,220±244, 88±17}

165.0±33.0

{1,680±336, 121±24}

235.0±47.0

{2,400±480, 174±34}

320.0±64.0

{3,270±654, 236±47}

405.0±81.0

{4,130±826, 299±59}

43.0±8.5

{440±90, 31.8±6.5}*

51.5±10.0

{530±100, 38.3±7.2}

(Chassis)

76.0±15.0

{776±150, 56±10}*

91.0±18.0

{930±180, 67±13}

(Chassis)

120.0±24.0

{1,220±240, 88±17}

190.0±38.0

{1,940±390, 140±28}

260.0±52.0

{2,650±530, 192±38}

370.0±74.0

{3,770±750, 273±54}

505.0±100.0

{5,150±1,030, 372±74}

640.0±125.0

{6,530±1,310, 472±94}

2

(Cab)

2

(Cab)

{1,020±200, 74±14}*2 (Cab)

2

2

!CAUTION

• In case of tightening the bolt/nut with the flanged seat face A, the tightening torque value except *2 in the

table is to be increased by 10% from the indicated tightening torque value.

• In case of tightening the bolt/nut with the flanged seat face B, the tightening torque value *2 in the table is to

be increased by 20% from the indicated tightening torque value.
Note that for M8 the tightening torque value is constant for the flanged seat face B also.

• The bolt/nut with flanged seat B which is marked *2 in the table is compatible with a standard seat face as a

pair. Its tightening torque is the same as that of the standard seat face.

TIGHTENING OF FLARE NUTS AND HOSES

1. TIGHTENING TORQUE OF PIPE FLARE NUT
Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Pipe outer

diameter

Material

Steel pipe

2. TIGHTENING TORQUE OF HOSE

Air hose

Brake hose

3. TIGHTENING TORQUE OF FLARE JOINT FOR NYLON TUBE

Nominal diameter of

Tightening torque 14.7±2 {150±20, 10.8±1.4} 29.4±5 {300±50, 21.7±3.6} 51.9±5 {530±50, 38.3±3.6}

Meter gauge only 10 {100, 7.2}

screw

φ4.76 φ6.35 φ8 φ10 φ12 φ15

15±5

{150±50,

10.8±3.6}

Hose outer diameter

φ10.5 metal fitting

21.5±1.5 {215±15, 15.5±1.0}

Packing

51.5±7.5 {525±75, 38.0±5.4}

25±5

{250±50,

18.1±3.6}

M12 M16 M20

36±5

{370±50,

26.8±3.6}

Hose outer diameter

φ13, φ20, φ22 metal fitting for

packing

41.5±2.5 {425±25, 30.7±1.8} —

——

52±7

{530±70,

38.3±5.0}

67±7

{680±70,

49.2±5.0}

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Hose outer diameter

PF3/8 metal fitting

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

EN0011001C100006

88±8

{900±80,

65.1±5.7}

4. TIGHTENING TORQUE OF LOCK NUT FOR BRASS JOINT

Nominal diameter of

screw

Tightening torque

{150±20, 10.8±1.4}

M12 M16 M20 M27

15±2

{670±60, 48.4±4.3}

66±6

97±9

{990±90, 71.6±6.5}

Unit: N⋅m {kgf⋅cm, lbf⋅ft}

209±19

{2,130±190, 154±13}

SEALANT ON THE TAPERED SCREW

SHTS001100100023

FOR PIPING

EN0011001C100007

To the tapered thread of the air pipe joint is applied the sealant "LOC­TITE #575". Follow the procedure below to remove/attach the piping.

1. REMOVAL

(1) The sealant (LOCTITE #575) has a high sealing capability. The

return torque of taper joint is about 1.5 times as high as the initial
tightening torque. To remove the joint, use a longer wrench.

(2) For replacement of joint in a place with poor workability, remove

the auxiliaries with the joint attached then remove the joint.

2. ATTACHING

(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe

the dirt off the sealing section, directly apply the sealant by a
quarter turn (three ridges) starting from the second ridge from the
tip, then assemble in accordance with the tightening torque table
below.
Wipe dirt off the mating part (female screw) before tightening it.

SHTS001100100024

! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.

Tightening torque of tapered joint Unit: N⋅m {kgf⋅ft, lbf⋅ft}

Screw diameter

Material

1/4 3/8 1/2

49±10

Steel

{500±100,

64±15 {650±150, 47±10}

36.2±7.2}

Aluminum, brass

25±5

{250±50,

18.1±3.6}

34±5

{350±50,

25.3±3.6}

44±5

{450±50,

32.5±3.6}

(2) To replace vulcanized tape with sealant, remove the tape before-

hand, same as (1).

NOTICE
Take special care not to let dirt and foreign matters enter the pip­ing.

(3) In the event of air leakage after sealant is applied and piping

attached, retightening cannot check the air leakage. Follow the
steps (1) and (2) to reassemble the piping.

NYLON TUBE

1. TYPES OF JOINT

(1) Nylon tube joints have two types: one-touch connector joint and

sleeve nut joint.

!CAUTION
Function and quality of a nylon tube and each joint are guaranteed
as a set. Use HINO genuine parts. Otherwise a burst or break may
result.

Structure of joint and components

One-touch connector joint Sleeve nut joint

EN0011001C100008

SHTS001100100027

SHTS001100100028

2. ONE-TOUCH CONNECTOR JOINT

(1) Remove the one-touch connector joint.

a. Check that there is no dust or dirt in the proximity of the con-

nector end. If any, use air blow to remove dust or dirt before
removal.

SHTS001100100029

b. To remove the connector, pull out the nylon tube at a stroke in

the axial direction while holding down the retainer of the con­nector. Use a dedicated special tool to hold down the retainer
of the connector.

Size of special tool

Tube outer diameter Part No. Name

φ6 09421-1510

φ8 09421-1520

φ10 09421-1530

Release tool

φ12 09421-1540

φ15 09421-1550

Set in above five
sizes

09421-1560 Release tool set

c. To connect the connector joint, give a mark such as taping at

the tube insertion length and insert the tube to the position of
the mark.

!CAUTION
Fully insert the nylon tube to the position although shock is felt
two times as the nylon tube passes through the retainer hook and
O-ring.

SHTS001100100030

SHTS001100100031

Tube outer diameter Tube insertion length (mm {in.})

φ6 21.5-22.5 {0.847-0.885}

φ8, φ10 22.0-23.0 {0.867-0.905}

φ12 22.5-23.5 {0.886-0.925}

φ15 24.0-25.0 {0.945-0.984}

d. After connection, pull the tube and check that the distance

from the connector end (retainer) to the taping at the insertion
length position is 5 mm {0.197 in.} or less.

3. SLEEVE NUT JOINT

(1) Connection of sleeve nut

a. To cut a nylon tube in a predetermined length, use a dedi-

cated special tool.

SST:

Nylon Tube Cutter (09460-1020)

!CAUTION

• Cut a tube only when there is extra length or when using a

new tube.

• When cutting a nylon tube, set the squareness of the tube

end with respect to the axis core within 90±5°.

5 OR LESS

SHTS001100100032

b. Thread the sleeve nut and sleeve in this order into the tube.

Then push in the insert at the tip.

!CAUTION
Take care of the assembling direction.

TUBE

INSERT

SLEEVE NUT

MATCH MARK

CONNECTOR/UNION

SLEEVE

SHTS001100100033

SHTS001100100034

c. For connection, push the insert until its end strikes the con-

nector/union while taking care not to let the sleeve nut, sleeve
and insert drop. In this state, fully tighten the sleeve nut with
hand. The position of sleeve nut is referred to as the "hand­tightening position".

d. Hold down the tube so that it will not move (come loose) and

tighten the sleeve nut in accordance with the torque in the
table below.

Tightening torque of sleeve nut Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Nominal diameter of screw x pitch Tightening torque

M12 x 1 (φ6) 23±5 {230±50, 16.6±3.6}

M14 x 1.5 (φ8) 37±4 {380±40, 27.5±2.8}

M16 x 1.5 (φ10) 40±5 {410±50, 29.6±3.6}

M18 x 1.5 (φ12) 55±5 {560±50, 40.5±3.6}

(2) Assembly of sleeve nut (removing the tube from the joint and re-

attaching it in the same position)
a. Give a match mark between the connector/union and the

sleeve nut before loosening the sleeve nut so as to memorize
the position.

b. For reassembly, tighten the sleeve nut up to the previous posi-

tion (match mark position). After that, retighten by 60°.

c. After reassembly, check for air leakage, if any, retighten until

the leakage stops.

d. If the leakage persists, replace the tube, sleeve and insert

with new ones. If this does not stop the leakage, replace the
sleeve nut and connector/union as well.

4. HANDLING OF NYLON TUBE

(1) Types of nylon tube

Tube indication

Tube outer

diameter

DIN tube φ6, φ10, φ12

!CAUTION

• Never repair a nylon tube under high temperatures exceeding

the operating temperature range, in particular when drying
the coating.

• For punching, welding and sanding, protect a nylon tube

from tools, cutting, heat source or spark or remove the nylon
tube.

• Never attach the clamp of the welder near the tube.

• Never splash acidic liquid such as battery liquid onto the

tube.

• Never exceed the minimum bending radius R of the nylon

tube listed in the table below. Avoid using a tube with trace of
bending line.

Tube outer diameter

Minimum bending radius in use:

R (mm {in.})

φ6 30 {1.181}

φ8 50 {1.969}

φ10 65 {2.559}

φ12 70 {2.756}

φ15 80 {3.150}

Operating tem­perature range

-40-90°C

{-40-194°F}

SHTS001100100036

(2) Fixing the nylon tube

a. To fix the nylon tube to a vehicle, use a dedicated clamp and a

dedicated special tool or clamping tool available on the mar­ket.

SST:
Clamp (47837-1230)
Nylon Tube Tensioning Tool Assembly (09620-1010)

Tool available on the market: Clamping tool (Tyton MK6)
Clamping torque (reference): 166.6 N {17 kgf, 37.5 lbf}

!CAUTION

• Set the tool clamping force to "3" on the dial.

• If the nylon tube is fixed with nonconforming clamping force,

the nylon tube may be damaged.

ASSEMBLY OF JOINT/GASKET FOR PIPING

EN0011001C100009

1. TIGHTENING TORQUE OF JOINT
Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Seal system

Tightening screw size Type A Type B

Gasket seal system

(aluminum+rubber or copper)

(Flare pipe system, nipple connector system)

M8 13 {130, 9.4}

M10 20 {200, 14} 11 {110, 8.0}

M12 25 {250, 18} 20 {200, 14}

M14 25 {250, 18} 31 {320, 23}

M16 29 {300, 22} 39 {400, 29}

M18 39 {400, 29} 59 {600, 43}

M20 *39 {400, 29} 64 {650, 47}

M24 69 {700, 51} 20 {200, 14}

M28 *127 {1,300, 94}

2. JOINT ASSEMBLY PROCEDURE AND POST-INSPECTION

(1) Before starting assembly, check that there is no dust or burr on each seat surface (mating part, pipe joint, gasket).
(2) Pipes are provided with the degree of freedom in assembly. The seat face is likely to be tilted. Temporarily tighten the

pipe then perform final tightening in order to avoid leakage.
(3) When the tightening is complete, apply a regular pressure to each pipe joint and check that there is no leakage.
(4) Observe the above tightening torque values.

NOTICE
When a soft washer of the aluminum plus rubber carbon press-fitting type is once mounted then loosened or
removed, replace it with a new one. This does not apply to normal retightening.

Metal seal system

3. EXAMPLES OF JOINT SYSTEM FOR PIPING

Gasket seal system

Metal seal system

Type A (Flare pipe system) Type B (Nipple connector system)

HANDLING OF LIQUID GASKET

EN0011001C100010

1. APPLICATION OF LIQUID GASKET AND ASSEMBLY OF PARTS

(1) Thoroughly remove the old liquid gasket on each part and mating part and clean the parts by using waste to wipe off

oil, water and dust.

Overlap the coating at the beginning and end of coating.
(2) To assemble coated part, beware of any dislocation from the mating part. If any dislocation is found, coat the part

again.
(3) Finish assembly within 20 minutes of completion of liquid gasket application.

If 20 minutes is exceeded, remove the liquid gasket and apply it again.
(4) Wait at least 15 minutes after assembly of parts before starting the engine.

2. REMOVING PARTS

(1) To remove each part, never twist a single section but twist the part in alternate directions at the collar or clearance on

the flange. When removing gasket, take care not to let the refuse of gasket enter the engine.

3. OTHER

(1) When the liquid gasket comes in a tube, use the supplied winding tool. When the gasket comes in a cartridge, use a

spray gun.

Note that the cutting position of the nozzle of the tube provides necessary width of application.

1: Approx. 2 mm {0.079 in.} when cut at the first segment
2: Approx. 5 mm {0.197 in.} when cut at the second segment

TROUBLESHOOTING USING THE TROUBLE LIST

EN0011001F200001

SHTS001100100050

TROUBLESHOOTING USING A DIAGNOSIS MONITOR

1. DIAGNOSIS MONITOR

(1) When connected to the diagnosis connector dedicated to each

system, the diagnosis monitor indicates a faulty section with
sound and light.

SST:

Diagnosis Monitor (09630-1370)

SHTS001100100051

2. CONNECTION OF DIAGNOSIS MONITOR

(1) Turn "ON" the starter switch.
(2) Connect a dedicated harness to the black (or white) connector out

of the central diagnosis connectors (total 2) at the lower right sec­tion of the instrumental panel at the driver's seat, and connect the
diagnosis monitor to the connector having the tag of "each system
name".

SST: Dedicated Harness (09630-2300)

EN0011001F200002

FIXING DUMMY CONNECTOR

WHITE CONNECTOR

BLACK CONNECTOR

SHTS001100100052

SHTS001100100053

!CAUTION
The central diagnosis connectors are normally connected to the
fixing dummy connectors. Remove the central diagnosis connec­tors from the dummy connectors before using them. When the
central diagnosis connectors are not used, they should be
engaged into the fixing dummy connectors.

HINT

• Turning "ON" the starter switch with the diagnosis monitor

connected causes the diagnosis monitor to keep sounding
without outputting diagnosis monitor codes. First turn "ON"
the starter switch, wait at least ten seconds, and connect the
diagnosis monitor.

• The method for outputting diagnosis monitor codes differs

from system to system. Follow the instruction in the chapter
for each system.

TAG AND SYSTEM NAME OF DEDICATED HARNESS

Tag name Name of system to be diagnosed

1 STD: ENG Common rail

3 STD: AIR BAG Not used

5 STD: ABS/ASR ABS

7 STD: ES START ES START

10 STD: VSC Not used

11 STD: TIRE Not used

2 OPT: RTD/4WD Not used

4 OPT: SHAKAN Not used

6 OPT: AIR SUS HEIGHT CONTROL

8 OPT: IDL STOP Not used

9 OPT: ATM Not used

12 OPT: PRO SHIFT Not used

12DEDICATED HARNESS (09630-2300)

34

5610

78

91112

SHTS001100100054

3. INDICATION OF DIAGNOSIS MONITOR CODE

(1) Diagnosis code can be checked on the diagnosis monitor and

check engine lamp. For example, diagnosis codes 32 and 21 are
indicated as described below. The indication method uses the
blinking interval of lamp. For the first code, "3" in the ten place illu­minates for 0.5 seconds three times and twice after 1.5 seconds.
For the second code, the lamp illuminates twice and once for the
same period as the first code after an interval of 4.3 seconds; this
operation is repeated. In case there is no fault in the system, lamp
repeats blinking for 3 seconds.

HINT
Indication of a diagnosis code in the figure below is a typical
example. For details, refer to chapter on each system.

INDICATION OF DIAGNOSIS MONITOR CODE (EXAMPLE)

WHEN CODES 32 AND 21 ARE INDICATED:

0.5 SECONDS

0.5 SECONDS

4.3 SECONDS

LAMP ON

LAMP OFF

1.5 SECONDS

CODE 32

WHEN THE SYSTEM IS NORMAL

0.3 SECONDS

4. ERASURE OF PAST FAULTS

(1) Record the first output diagnosis monitor code.
(2) Remove the diagnosis monitor with the starter key in the "ON"

!CAUTION
If the starter key is placed in "LOCK" position, the past faults are
not erased. Keep the starter key "ON".

(3) Wait at least 5 seconds. Connect the diagnosis monitor to output

SHTS001100100056

CODE 21

LAMP ON

LAMP OFF

THE OPERATION IS REPEATED

position.

the current fault information.

SHTS001100100055

5. HOW TO USE TROUBLESHOOTING BY DIAGNOSIS MONI­TOR CODE

(1) The "diagnosis code table" and "Troubleshooting by code" are

shown for each system which outputs diagnosis codes. In case
the diagnosis code is identified, troubleshooting may be initiated
referring to the code list.

SHTS001100100064

.

DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS

TOOL WITH INTERFACE

SHTS001100100057

EN0011001F200003

1. DIAGNOSIS TOOL

• Trouble diagnosis can be performed using the PC diagnosis tool.

By connection to the diagnosis connector, the trouble location is
indicated.

SST:
Interface (09121-1010)
Diagnosis cable (09042-1150)

DIagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager

NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.

2. CONNECT THE PC DIAGNOSIS TOOL

(1) Turn the starter switch to the "LOCK" position.
(2) Connect the diagnosis cable between diagnosis connector and

interface.
(3) Connect the interface to the PC.
(4) Turn the starter switch to the "ON" position.
(5) The opening menu will be displayed on the PC screen.

SHTS001100100058

SHTS001100100059

3. CONNECTION OF SIGNAL CHECK HARNESS

(1) To prevent damage to ECU connector and improve workability,

connect a signal check harness. Perform measurement while
placing the test lead on the signal check connector of the signal
check harness.
a. Remove the connector from ECU.

!CAUTION

Take care not to snap off the lock lug of the connector.

b. Connect a signal check harness to the vehicle harness and

ECU.

SST:

Signal Check Harness (for common rail type fuel injec­tion system) (09049-1080)

(2) Terminal number

ECU terminal numbers in the text correspond to connectors of
signal check harness as shown below.

SHTS001100100060

.

(EXAMPLE)

CHASSIS SERIAL NUMBER, VEHICLE

IDENTIFICATION NUMBER AND ENGINE

IDENTIFICATION
PLATE

ENGRAVED POSITION

ENGRAVED
POSITION

SHTS001100100061

SHTS001100100062

SERIAL NUMBER

EN0011001C100011

1. VEHICLE MODEL AND CHASSIS SERIAL NUMBER OR VEHI­CLE IDENTIFICATION NUMBER

(1) Vehicle model and chassis serial number or vehicle identification

number are engraved near the front wheel of the right or left frame
of the vehicle. When ordering parts, notify us of these numbers
for quick support.

(2) At the step inside the right door of the cab is attached an identifi-

cation plate stamped the vehicle model and chassis serial number
or vehicle identification number.

2. ENGINE MODEL AND ENGINE SERIAL NUMBER

(1) Engine model and engine serial number are engraved on the left

side of the cylinder block.
When ordering parts, notify us of these numbers for quick sup­port.

SHTS001100100063

EN01

ENGINE INTRODUCTION (E13C)

ENGINE ASSEMBLY ................................EN01-2

DATA AND SPECIFICATIONS ......................... EN01-2

TROUBLESHOOTING..................................... EN01-3

TROUBLESHOOTING

(COMMON RAIL SYSTEM)............................. EN01-9

ENGINE TUNEUP ......................................... EN01-10

OVERHAUL CRITERIA...........................EN01-15

SPECIAL TOOL............................................. EN01-15

OVERHAUL CRITERIA.................................. EN01-15

DISMOUNTING AND MOUNTING..........EN01-17

SPECIAL TOOL............................................. EN01-17

DISMOUNTING AND MOUNTING ................ EN01-18

LIQUID GASKET AND

APPLICATION POINTS ................................. EN01-20

EN01-001

ENGINE ASSEMBLY

DATA AND SPECIFICATIONS

Model E13C-TI

Type

Aspiration Turbocharged with intercooler

Bore and stroke 137x146 mm {5.394x5.748 in.}

Piston displacement 12.913 L {788.0 cu.in.}

Compression ratio 17.5: 1

Firing order

Direction of rotation Counterclockwise viewed from flywheel

Compression pressure 3.3 MPa {34 kgf/cm

Maximum revolution (no load) 2,100 or 2,400 r/min

Idling revolution 500 r/min

Dry weight 1,250 kg {2,756 lbf}

Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,
water-cooled, direct injection

1-4-2-6-3-5 (The cylinder numbers are counted in order from
the crankshaft pulley side)

2

, 479 lbf/in.2} at 200 r/min

EN0111001I200001

Valve seat angle

Valve face angle

Valve timing
(flywheel travel)

Valve clearance
(when cold)

Engine oil pump

Engine oil cooler Multi-plate type, water cooled

Injection nozzle

Intake 30°

Exhaust 45°

Intake 30°

Exhaust 45°

Intake opens 12.5° before top dead center

Intake closes 60° after bottom dead center

Exhaust opens 56° before bottom dead center

Exhaust closes 19° after top dead center

Intake 0.28 mm {0.0110 in.}

Exhaust 0.49 mm {0.0193 in.}

Type Full forced pressure feed by gear pump

Drive By gear

Type Multi-hole nozzle type

Valve opening pres­sure

160 MPa {1,630 kgf/cm

2

, 23,200 lbf/in.2}

Coolant pump

Thermostat Type Wax.type, bottom bypass system

Injection timing (flywheel travel)

Type Forced circulation by volute pump

Drive By V-belt

0° at top dead center for No.1 cylinder of the compression
stroke

TROUBLESHOOTING

Engine overheating

Symptom Possible cause Remedy/Prevention

Engine overheating (Coolant) Insufficient coolant Add coolant.

Defective thermostat Replace thermostat.

Overflow of coolant due to leakage of
exhaust into cooling system

Damaged rubber hose Replace rubber hose.

Coolant leakage due to deteriorated
rubber hose

Coolant leakage from coolant pump Replace the coolant pump.

Coolant leakage from rubber hose
connection

Coolant leakage from cylinder head
gasket

Engine overheating (Coolant pump) Bearing seizure Replace.

Damaged (corroded) vane Replace vane.

Engine overheating (Radiator) Clogged with rust or scale Clean radiator.

Clogged with iron oxide due to leakage
of exhaust into cooling system

Coolant leakage Repair or replace radiator.

Damaged cooling fan Replace cooling fan.

Clogged radiator core due to mud or
other debris

Defective radiator cap pressure valve Replace radiator cap.

Engine overheating
(Abnormal combustion)

Engine overheating
(Other problems)

Engine overheating
(Severe operating condition)

Poor fuel Use good quality fuel.

Breakdown of injector Replace the injector.

Defective or deteriorated engine oil Change engine oil.

Unsatisfactory operation of oil pump Replace or repair.

Insufficient oil Add oil.

Brake drag Repair or adjust.

Break water temperature sensor Replace it.

Lugging the engine Operate engine properly.

Repair.

Replace rubber hose.

Retighten or replace clamp.

Replace gasket.

Clean coolant passage and correct
exhaust leakage.

Clean radiator.

EN0111001F300001

Excessive oil consumption

Symptom Possible cause Remedy/Prevention

Excessive oil consumption
(Pistons, cylinder liners, and piston
rings)

Excessive oil consumption
(Valve and valve guides)

Excessive oil consumption
(Excess oil feed)

Excessive oil consumption
(Oil leakage from miscellaneous
parts)

Excessive oil consumption
(Other problems)

Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.

Worn, sticking or broken piston rings Replace piston rings and cylinder liner.

Insufficient tension on piston rings Replace piston rings and cylinder liner.

Unsatisfactory breaking in of piston

Replace piston rings and cylinder liner.

rings

Unsuitable oil (viscosity too low) Change oil as required and replace

piston rings and cylinder liners.

Incorrectly fitted piston rings

Replace piston rings.

(upside down)

Gaps of piston rings in cell with each

Reassemble piston rings.

other

Worn valve stem Replace valve and valve guide.

Worn valve guide Replace valve guide.

Incorrectly fitted valve stem seal Replace the stem seal.

Excessive lubricant on rocker arm Check clearance of rocker arm and

shaft.

Defective oil level gauge Replace oil level gauge.

Oil level too high Drain excess oil.

Oil leakage from oil seal Replace oil seal.

Cracks or blowhole in cylinder block Replace cylinder block.

Oil leakage from connections of oil

Tighten connections of oil lines.

lines

Oil leakage from oil cooler Replace oil cooler.

Oil leakage from oil pan gasket Replace oil pan gasket.

Oil leakage from O-ring Replace O-ring.

Overcooled engine
(low temperature wear)

Warm up engine before moving vehi­cle. Check cooling system.

NOTICE
If oil consumption is excessive, the problems above will occur. Complaints from the customer are often related to
such problems.

1. White smoke is emitted continuously when the engine is run at high speed.

2. White smoke is emitted only immediately after the engine speed is abruptly raised when idling.

3. The tail pipe is blackened with oil.

4. Oil leaks from the flanges of the exhaust manifold.

5. Lack of power.

6. Excessive blow-by gas.

Piston seizure

Symptom Possible cause Remedy/Prevention

Piston seizure
(Pistons, cylinder liners and piston
rings)

Piston seizure (Coolant) Reduction in capacity of coolant pump

Piston seizure (Operation) Abrupt stoppage of engine after run-

Piston seizure (Oil) Insufficient oil Add oil.

Piston seizure
(Abnormal combustion)

Incorrect clearance between piston
and cylinder liner

Replace piston, piston rings and cylin­der liner.

Unsatisfactory installation of piston pin Replace piston, piston rings, cylinder

liner and piston pin as required.

Broken piston ring Replace piston, piston rings and cylin-

der liner.

Difference in expansion due to use of
wrong piston

Replace piston, piston rings and cylin­der liner.

Replace the coolant pump.

(due to vane corrosion)

Leakage of coolant Repair.

Insufficient coolant Add coolant.

Dirty coolant Clean and replace coolant.

Defective radiator

Repair or replace the radiator.

(coolant leakage, clogging)

Defective rubber hose (leakage) Replace rubber hose.

Defective thermostat Replace the thermostat.

Leakage of exhaust into cooling sys-

Repair.

tem

Operate engine properly.

ning at high speed

Hill climbing using unsuitable gear Select suitable gear.

Dirty oil Change oil.

Poor quality oil Replace with proper engine oil.

High oil temperature Repair.

Low oil pressure Repair.

Defective oil pump Repair oil pump.

Reduced performance due to worn oil

Replace oil pump.

pump

Suction strainer sucking air Add oil and/or repair strainer.

Use of defective fuel Change fuel.

Engine overheating See Symptom: "Engine overheating".

Breakdown of injector Replace the injector.

NOTICE
If piston seizure occurs, the problems above will occur. Complaints from the customer are often related to these
problems.

1. White smoke is emitted.

2. Lack of power

3. Excessive blow-by gas

Lack of power

Symptom Possible cause Remedy/Prevention

Lack of power (Supply pump) Damaged suction control valve Replace the supply pump.

Lack of power (Intake) Clogged air cleaner Clean element or replace element.

Lack of power (Overheating) See Symptom: "Engine overheating".

Lack of power (Fuel and injector) Air in fuel system Repair and bleed air from fuel system.

Clogged fuel filter Replace element.

Use of poor fuel Use good quality fuel.

Breakdown of injector Replace the injector.

Lack of power (Pistons, cylinder lin­ers and piston rings)

Lack of power (Other problems) Exhaust brake butterfly valve stuck in

Seized or wear of piston Replace the piston, piston rings and

liner.

Worn or broken piston rings, piston

Replace piston rings, piston and liner.

and cylinder liner

Replace or repair exhaust brake.

half-open position

Connecting rod bent Replace or repair connecting rod.

Exhaust pipe or muffler crushed

Replace exhaust pipe or muffler.

(increased back-pressure)

Breakage of turbine or blower Replace turbocharger.

Leakage of exhaust

Symptom Possible cause Remedy/Prevention

Leakage of exhaust (Head gasket) Fatigued gasket (aging) Replace gasket.

Damage Replace gasket.

Improper installation Replace gasket.

Leakage of exhaust (Head bolts) Loose bolts Tighten bolts.

Elongated bolts Replace bolts.

Improper tightening torque or tighten­ing sequence

Leakage of exhaust (Cylinder block) Cracking Replace cylinder block.

Surface distortion Repair or replace.

Fretting of cylinder liner insertion por­tion (insufficient projection of cylinder
liner)

Leakage of exhaust (Cylinder head) Cracking Replace cylinder head.

Surface distortion Repair or replace.

Leakage of exhaust (Cylinder liners) Cracking Replace cylinder liner.

Corrosion Replace cylinder liner.

Insufficient projection of cylinder liner Replace cylinder liner.

Tighten properly.

Replace cylinder block.

NOTICE
If leakage of the exhaust occurs, the problems above will occur. Complaints from the customer are often related to
these problems.

1. Lack of power.

2. The engine overheats.

3. The coolant is discolored.

Difficulty starting engine

Symptom Possible cause Remedy/Prevention

Difficulty starting engine
(Electrical system)

Difficulty starting engine
(Supply pump)

Difficulty starting engine
(Air cleaner)

Difficulty starting engine
(Fuel system)

Difficulty starting engine
(Oil system)

Difficulty starting engine
(Other problems)

Discharged battery Charge battery.

Defective wiring in starter circuit Repair wiring of starter.

Loose or open-circuit battery cable Tighten battery terminal connections

or replace battery cable

Broken glow plug Replace.

Defective supply pump Replace the supply pump.

Clogged element Replace the element.

No fuel in tank Supply fuel.

Clogged fuel line Clean fuel line.

Air sucked into fuel system through
fuel line connections

Clogged fuel filter Replace element.

Loose connection in high-pressure line Tighten sleeve nut of high-pressure

Water in fuel Drain and clean fuel system.

Oil viscosity too high Use proper viscosity oil, or install an oil

Seized piston Replace piston, piston rings, and liner.

Seized bearing Replace bearing and/or crankshaft.

Reduced compression pressure Overhaul engine.

Ring gear damaged or worn Replace the ring gear and/or starter

Improperly adjusted or broken Adjust.

Tighten fuel line connections.

line.

immersion heater and warm up oil.

pinion.

Rough idling

Symptom Possible cause Remedy/Prevention

Rough idling (Supply pump) Damaged suction control valve Replace the supply pump.

Rough idling (Injector) Breakdown of injector Replace the injector.

Rough idling (Engine proper) Improper valve clearance Adjust valve clearance.

Improper contact of valve seat Replace or repair valve and valve seat.

Idling speed too low Adjust idling speed.

Coolant temperature too low Warm up engine.

Compression pressure of cylinders
markedly different from one another

Rough idling (Other problems) Clogged high pressure injection line Replace line.

Leakage due to improper tightening of
high pressure fuel line

Engine seizure Replace pistons, piston rings and lin-

Incorrect valve timing Replace camshaft.

Overhaul engine.

Tighten sleeve nut.

ers.

Diesel knock

Symptom Possible cause Remedy/Prevention

Diesel knock (Supply pump) Damaged suction control valve Replace the supply pump.

Diesel knock (Injector) Breakdown of injector Replace the injector.

Diesel knock (Fuel system) Use of poor fuel Use good quality fuel.

Diesel knock (Other problems) Excessively cooled or heated engine Warm up or cool engine.

Insufficient air intake Correct.

Insufficient compression pressure Repair.

Compression pressure leaks at cylin­der head gasket

Improper valve clearance or valve
sticking

Tappet sticking Replace tappet and camshaft.

Replace head gasket.

Adjust or repair.

Unusual engine noise

Symptom Possible cause Remedy/Prevention

Unusual engine noise (Piston) Wear of piston pin boss or piston pin Replace piston and/or piston pin.

Unusual engine noise
(Valve mechanism)

Unusual engine noise
(Bearings seizure)

Unusual engine noise
(Various other parts)

Seized, damaged, or worn piston pin
bushing

Worn pistons or cylinder liners Replace piston or cylinder liner.

Damaged or seized piston Replace piston and cylinder liner.

Foreign matter on top surface of the
piston

Incorrect valve clearance Adjust valve clearance.

Valve cotter out of place Replace valve cotter.

Seized valve stem Replace valve and valve guide.

Broken valve Replace valve.

Damaged rocker arm support Replace rocker arm support.

Broken valve spring Replace valve spring.

Insufficient lubricating oil Add oil.

Excessive or insufficient tightening of
bearing housings

Pits and scratches on bearing surface Replace bearing and crankshaft.

Oil film formed on back of bearing Replace bearing.

Improper installation of bearing Replace bearing.

Reduction of spread dimension of
bearing

Distorted bearing housing Replace or correct bearing housing.

Excessive oil clearance Replace bearing.

Exhaust gas leakage from exhaust
pipe joints

Loosen or missing intake manifold
flange gasket

Intake valve seating is not concentric Replace or correct the valve and valve

Intake gas leakage Retighten.

Replace piston pin bushing.

Remove foreign matter and repair or
replace piston, cylinder liner, and/or
cylinder head.

Retighten to specified torque.

Replace bearing.

Retighten joints.

Retighten or replace.

seat.

Symptom Possible cause Remedy/Prevention

Unusual engine noise
(Other problems)

NOTICE
The items on this page concern unusual engine noise which is due to causes other than those given for diesel
knock.

Loose cooling fan mounting bolts or
fan pulley nut

Lack of lubricating oil
(coolant pump, valves, etc.)

Worn timing gear Replace the timing gear.

Breakage of turbine or blower Replace turbocharger.

Tighten the fan and crankshaft pulley.

Lubricate.

TROUBLESHOOTING (COMMON RAIL SYSTEM)

Engine does not start

Symptom Possible cause Remedy/Prevention

Engine does not start
(Fuel not reaching supply pump)

Engine does not start
(Fuel reaching supply pump)

Engine does not start
(Injector faulty)

Engine does not start
(Electrical system)

Engine starts and stops Fuel lines clogged Clean or replace fuel lines.

Engine has low power
(Injector faulty)

Engine has low power
(Electrical system)

Fuel lines clogged or damaged Clean or replace fuel lines.

Fuel filter clogged Clean or replace the filter element.

Air in fuel caused by improper connec­tions of fuel line between fuel tank and
feed pump

Filter incorporated in inlet side of feed
pump clogged

Breakdown feed pump Replace the supply pump.

Leakage due to improper tightening of
high pressure fuel line

Breakdown ECU Replace the ECU.

Injector broken Replace the injector.

Defective sensors or circuits Refer to FUEL CONTROL.

Air in fuel caused by damaged fuel
lines or improper connection of fuel
lines

Injector broken Replace the injector.

Defective sensors or circuits Refer to FUEL CONTROL.

Repair connections.

Remove foreign material.

Tighten sleeve nut.

Repair fuel lines or replace fuel lines
and gaskets.

EN0111001F300002

Excessive smoke (Black smoke)

Symptom Possible cause Remedy/Prevention

Excessive smoke (Black smoke) Defective sensors or circuits Refer to FUEL CONTROL.

Defective injector Replace the injector.

Excessive smoke (White smoke) Water in fuel Check and clean fuel lines.

Glow plug not operating Check glow plug circuit.

Low idle speed irregular

Symptom Possible cause Remedy/Prevention

Low idle speed irregular Defective sensors or circuits Refer to FUEL CONTROL.

Defective injector Replace the injector.

POINTER

SUPPLY
PUMP

FLYWHEEL

ALIGNING
MARK

SHTS011100100001

ENGINE TUNEUP

EN0111001H300001

VALVE CLEARANCE CHECKING AND ADJUSTING
PROCEDURES

NOTICE
Valve clearance adjustment is performed only when the checking
result is not within the specified value.

1. PREPARATION OF CHECKING AND ADJUSTMENT

(1) Positioning the No.1 or No.6 cylinder at Top Dead Center of the

compression stroke.
a. Turn the crankshaft counterclockwise (viewed from the fly-

wheel side) to align mark 1/6 on the outer periphery of the fly­wheel with the pointer of the flywheel housing.

NOTICE

• Always turn the crankshaft counterclockwise (viewed from

the flywheel side).

• In this position, the No.1 or No.6 cylinder is at the Top Dead

Center of the compression stroke.

b. Confirm whether No.1 or No.6 cylinder is at the Top Dead

Center of the compression stroke by the following two steps.

• When the end-face of special tool and the surface of coupling

plate are contacted by inserting special tool into coupling plate,
No. 1 cylinder is set at Top Dead Center of the compression
stroke.

SST:

Supply pump tool (09512-2530)

PLUG

SHTS011100100041

SPECIAL TOOL

COUPLING PLATE

NO.1 CYLINDER IS NOT AT TOP DEAD
CENTER OF COMPRESSION STROKE.

NOTICE
When the end-face of special tool and the surface of coupling
plate are not contacted, No. 6 cylinder is set at Top Dead Center of
the compression stroke. Rotating crankshaft once, reconfirm it
with special tool.

GEAR

NO.1 CYLINDER IS AT TOP DEAD
CENTER OF COMPRESSION STROKE.

SHTS011100100002

CLICK

SHTS011100100003

Good

No Good

SHTS011100100004

•

If the arrows engraved on the both side of the camshaft gear
points up (↑), the No.1 cylinder is at the Top Dead Center of the
compression stroke.

NOTICE
If the arrows are pointing down (↓), the No.6 cylinder is at the Top
Dead Center of the compression stroke.

(2) Make sure that the valve stem is correctly inserted in the cross

head.

NOTICE
Move the cross head with fingers right and left to confirm the
valve stem is correctly inserted in the cross head by listening to
the clicking sound.

(3) Confirm that there is no foreign particles or dust between the

cross head and the valve stem.

With No.1
cylinder
at T.D.C.
on com­pression
stroke

With No.6
cylinder
at T.D.C.
on com­pression
stroke

2. VALVE CLEARANCE CHECKING

NOTICE
Before beginning the checking, you must perform "1. PREPARA­TION OF CHECKING AND ADJUSTMENT".

(1) You can understand which valve to adjust when No.1 or No.6 cyl-

inder is at the Top Dead Center of the compression stroke by the
following chart).

Cylinder 123456

Valve INEXINEXINEXINEXINEXINEX

Arrow points

Cam-

up and under­line is horizon­tal. #1

  

shaft
gear
condi­tion

Arrow points
down and
underline is



horizontal. #1

• #1= View from rear side of cylinder head

• Mark: Possible to check valve clearance

• Firing order: 1-4-2-6-3-5

• T.D.C.: Top Dead Center

CAM

FEELER GAUGE

ROLLER

(2) Before checking the valve clearance, make sure that the roller is

on the base circle of the camshaft.

SHTS011100100007

(3) Insert a feeler gauge of the specified thickness as below between

the roller of the rocker arm and the cam to check the valve clear­ance.

VALVE CLEARANCE (when cold)

Intake valve 0.28 mm {0.0110 in.}

Exhaust valve 0.49 mm {0.0193 in.}

NOTICE
Valve clearance adjustment is performed only when the checking
result is outside the specified value.

SHTS011100100008

3. VALVE CLEARANCE ADJUSTMENT
NOTICE

Valve clearance adjustment is performed only when the checking
result is outside the specified value.

CAM

LOCK NUT

FEELER GAUGE

ROLLER

ADJUST
SCREW

SHTS011100100009

NOTICE

• Before beginning the adjustment you must perform "1.

PREPARATION OF CHECKING AND ADJUSTMENT".

• As for the valve which can adjust the valve clearance refer to

"2. VALVE CLEARANCE CHECKING".

• Make sure that the cylinder head bolt, rocker arm support

bolt, injector clamp bolt and cam bearing cap bolt are tight­ened to the specified torque.

(1) Loosen the adjusting screw lock nut of the rocker arm fully.
(2) Insert a feeler gauge of the specified thickness shown below

between the roller of the rocker arm and the cam, and adjust the
valve clearance with the adjust screw of the rocker arm.

VALVE CLEARANCE (when cold)

Intake valve 0.28 mm {0.0110 in.}

Exhaust valve 0.49 mm {0.0193 in.}

(3) After completion of the adjustment, tighten the lock nut securely

with the specified tightening torque.

Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}

START THE ENGINE

FILLER
CAP

BLEEDER PLUG

SHTS011100100010

SHTS011100100011

!CAUTION
Do not leave tools on or around the engine. Contact of tools with
moving parts may result in personal injury or damage to equip­ment.

1. PREPARATION

(1) Supply engine oil.

(2) Supply cooling water and bleed air from it.

(3) Bleed air from the fuel system.

PRIMING PLUG

SHTS011100100012

(4) Check connection to the alternator.

!CAUTION
Start the engine without wiring in place may burn out the alterna­tor.

(5) Check the engine stopping performance.

SHTS011100100013

LUBRICATION

1. CHECK THE ROCKER ARM.

(1) Remove the head cover.
(2) Set the engine revolution to the specified idling revolution.
(3) After the engine starts, check that oil is supplied to the following

locations of all rocker arms within approximately 10 seconds.
a. Roller and cam face A
b. Cross head top C and spring upper seat top face D through

adjusting screw B

NOTICE
If the supply of oil is delayed or not happening, hydraulic pressure
may be low or the oil gallery may be clogged. Insufficient supply
of oil may lead to seizure, abnormal wear or abnormal noise.
Recheck the assembly.

OVERHAUL CRITERIA

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09508-1060

09552-1030
09552-1060

— 9851-20143 O-RING

COMPRESSION GAUGE
ADAPTER (A)

COMPRESSION GAUGE
ADAPTER (B)

OVERHAUL CRITERIA

FACTORS TO DETERMINE THE ENGINE OVERHAUL

1. LOW COMPRESSION PRESSURE

(1) Before measurement

a. Charge the battery completely.
b. Set the valve clearance to the correct value.
c. Idle the engine (Coolant temperature at 80°C {176°F}).
d. Remove the air cleaner.
e. Remove all injectors.

(2) Measurement

a. Install the O-ring to the groove of the pressure gauge adapter

(A).

SST:
Compression gauge adaptor (A) (09508-1060)
O-ring (9851-20143)

EN0111001K100001

For Overhaul criteria

EN0111001H300002

SHTS011100100016

b. Insert the compression gauge adapter with injector clamp.
c. Tighten the injector clamp installation bolt.

Tightening Torque:
34 N⋅m {350 kgf⋅cm, 25 lbf⋅ft}

d. Connect the pressure gauge using the compression gauge

adapter (B).

SST:
Compression gauge adaptor (B) (09552-1030)
Compression gauge adaptor (B) (09552-1060)

e. Run the engine with the starter and measure the compression

pressure.

Standard Limit

3.3 MPa

{34 kgf⋅cm

2

, 479 lbf/in2}

{31 kgf⋅cm2, 435 lbf/in2}

3.0 MPa

Engine revolution 200r/min

NOTICE
Do not operate the starter for more than 15 seconds.

SHTS011100100017

SHTS011100100018

f. Measure the compression pressure of each cylinder.

NOTICE
Do not allow gas leakage from the seal face.

(3) Reassemble the removed parts.

2. ENGINE OIL PRESSURE

(1) Check the oil pressure warning lamp when the oil and coolant

temperature is hot [about 80°C {176°F}].
a. If the warning lamp is lit, check the oil level.

b. Check oil deterioration.

If oil quality is poor, replace with a suitable grade oil.

c. Remove the oil pressure switch and install the oil pressure

gauge.

d. Measure the oil pressure at a coolant temperature of 80°C

{176°F} or more.

Oil pressure

Standard Limit

49-490 kPa

{0.5-5.0 kg/cm

7.11-71.10 lbf/in.

2

,

2

}

Less than 49kPa

{0.5 kg/cm

7.11 lbf/in.

2

,

2

}

SHTS011100100019

3. OTHER FACTORS

(1) Increase of blowby gas
(2) Defective engine start
(3) Decrease of engine output
(4) Increase of fuel consumption
(5) Increase of engine noise
(6) Increase of oil consumption

DISMOUNTING AND MOUNTING

SPECIAL TOOL

Prior to starting an engine dismounting and mounting, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09405-1190 ENGINE HANGER

12281-2201 ENGINE HANGER

9409-14104 BOLT

EN0111001K100002

12281-2211 ENGINE HANGER

9409-14108 BOLT

DISMOUNTING AND MOUNTING

EN0111001H100001

IMPORTANT POINT - DISMOUNTING

1. DISMOUNT THE ENGINE ASSEMBLY.

(1) Park the vehicle on level ground and then block the wheels.
(2) Tilt the cab.
(3) Disconnect the battery cable from negative (–) pole of the bat-

terry.

(4) Drain coolant from the radiator and cylinder block, and engine oil

from the oil pan.

!CAUTION
To avoid the danger of burns, do not drain the coolant and engine
oil while the engine and radiator are still hot.

(5) Remove the rear cab mounting.

NOTICE
Refer to CHAPTER “CAB” for details.

(6) Remove the radiator.

NOTICE
Refer to CHAPTER “COOLING SYSTEM” for details.

(7) Disconnect the electric lines, fuel lines and air lines.

NOTICE
Cover open ends of pipes and hoses to prevent entry of dirt.

FRONT SIDE REAR SIDE

SHTS011100100025

(8) Remove the mad guard.
(9) Remove the noise insulator cover.
(10) Remove the exhaust pipe, intake hose and intercooler hose.
(11) Remove the cooling fan and fan shroud ring bracket.
(12) Disconnect the propeller shaft.

NOTICE
Refer to CHAPTER “PROPELLER SHAFT” for details.

(13) Dismount the transmission.

NOTICE
Refer to CHAPTER “TRANSMISSION MAIN UNIT” and “TRANS­MISSION/TRANSFER CONTROL” for details.

(14) Dismount the engine assembly.

a. Install the engine hanger to the front and rear of the engine.

SST:
Engine hanger (12281-2201) (Front side)
Bolt (9401-14101) (2 pieces)
Engine hanger (12281-2211) (Rear side)
Bolt (9401-14108) (2 pieces)

(15) Connect a cable from the engine hanger to the hanger (1 point)

on the front of the engine, and to the hanger (1 point) on the rear
of the engine. Using a hoist, raise the hanger until there is a bit of
slack in the cables.
Engine weight: Refer to section “DATA AND SPECIFICA-

TIONS”.
SST:

Engine hanger (09405-1190)

SHTS011100100026

(16) Remove the engine mounting fitting nuts (front and rear, both

sides).

(17) Lift the engine hanger so that the cables are fully tightened, then,

after checking that the cables are securely, lift gently and remove
the engine from the vehicle.

LESS

THAN 20˚

LESS

THAN 20˚

SHTS011100100027

IMPORTANT POINTS - MOUNTING

1. MOUNT THE ENGINE ASSEMBLY.

(1) Mount the engine assembly in the reverse order of dismounting.

Tightening Torque:
170-230 N⋅m {1,735-2,345kgf⋅cm, 126-169 lbf⋅ft (Front side)}
(Engine mounting fitting bolts)

Tightening Torque:
87-129 N⋅m {885-1,305kgf⋅cm, 64-94 lbf⋅ft (Rear side)} (Engine
mounting fitting bolts)

NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
or air leaks.

LIQUID GASKET AND APPLICATION

POINTS

EN0111001H200001

• Following liquid gaskets are used for the E13C series engine.

Liquid gasket specification:
Three Bond TB1207B: Black
Liquid gasket specification:
Three Bond TB1207C: Red brown
Liquid gasket specification:
Three Bond TB1211: White

1. LIQUID GASKET APPLICATION AND PART ASSEMBLY PRO-

CEDURE.

(1) Remove old liquid gasket from each part and matching parts and

wipe off oil, moisture or dirt with a rag.
(2) Overlap the liquid gasket at the start and end of application.
(3) Be careful of misalignment when assembling parts with liquid gas-

ket. If they are misaligned, reapply the liquid gasket.
(4) Assemble parts within 20 minutes of application.

If more than 20 minutes have passed, remove and reapply the liq-

uid gasket.
(5) Wait for at least 15 minutes or more after assembly of parts before

starting the engine.

2. REMOVE PARTS.

(1) When removing parts, do not use a tool for removal at one loca-

tion only. Use the tool at various locations such as a flange step or

gap for removal. When removing the gasket, be careful that gas-

ket residue does not enter the engine.

SHTS011100100028

SHTS011100100029

3. OTHERS

(1) For tube-type liquid gasket, use the winding tool that comes with

the liquid gasket.

(2) For cartridge-type gasket, use an application gun.

(3) For tube-type liquid gasket, required width of application can be

obtained by cutting the nozzle to suit.

1: Approximately 2 mm {0.079 in.} width when cut at the first step
2: Approximately 5 mm {0.197 in.} width when cut at the second

step

SHTS011100100030

4. PARTS AND POSITIONS FOR LIQUID GASKET

(1) Apply liquid gasket to positions and types of gasket according to

the table shown below.
Follow the application pattern at each position shown in the fig­ures.

Unit: mm {in.}

No. Part name Application position and pattern

Matching flange face with the block

1 Oil seal retainer

Matching flange face with the oil seal retainer

2 Breather pipe

Application

width

3-4

{0.1182-

0.1574}

3-4

{0.1182-

0.1574}

Gasket

to be
used

Red
brown

Red
brown

Remarks

Cylinder head

3

plate

Matching plate face with the cylinder head rear
end

3-4

{0.1182-

0.1574}

Red
brown

No. Part name Application position and pattern

1. Matching faces with cylinder head and side
face, upper face of seal

2. Matching parts of cylinder head, seal, cylin­der head cover and gasket

NOTICE

• Application area of liquid gasket is side

Pressure sensor

4

seal

face of seal. Never apply it to the upper face
of seal.

• Remove the excessive gasket completely.

• When the cylinder head cover is assem-

bled, reapply the liquid gasket. (Assembly
must be done within 20 minutes.)

Application

width

3-4

{0.1182-

0.1574}

Gasket

to be
used

Black

Remarks

No. Part name Application position and pattern

Matching parts of oil seal retainer and block
lower face front end

Matching parts of block lower rear end, gasket,
timing gear case and flywheel housing

Application

width

Gasket

to be
used

Remarks

Front and rear

5

ends of lower
face of block

NOTICE
Cut the rear end plate gasket with a craft knife
flush with the block upper face.

3-4

{0.1182-

0.1574}

Red
brown

No. Part name Application position and pattern

1. Matching faces with cylinder head and plug

2. Matching parts of cylinder head, plug, cyl­inder head cover and gasket

Application

width

Gasket

to be
used

Remarks

6 Cylinder head

NOTICE

• Application area of liquid gasket is half cir-

cle of cylinder head. Never apply it to the
upper cylinder head of the plug.

• Remove the excessive gasket completely.

• When the cylinder head cover is assem-

bled, reapply the liquid gasket. (Assembly
must be done within 20 minutes.)

3-4

{0.1182-

0.1574}

Black

2 locations
at front and
rear ends of
cylinder
head

NOTICE
Figure on the right shows application "pattern" of the liquid gasket.
Apply the liquid gasket to the center of seal flange inside whenever pos­sible.

EN02

ENGINE MECHANICAL (E13C)

CYLINDER HEAD .....................................EN02-2

COMPONENT LOCATOR................................ EN02-2

SPECIAL TOOL ............................................... EN02-5

OVERHAUL ..................................................... EN02-6

INSPECTION AND REPAIR ..........................EN02-17

CRANKSHAFT FRONT END..................EN02-21

COMPONENT LOCATOR.............................. EN02-21

SPECIAL TOOL............................................. EN02-22

OVERHAUL ...................................................EN02-22

FLYWHEEL AND

FLYWHEEL HOUSING............................EN02-25

COMPONENT LOCATOR.............................. EN02-25

SPECIAL TOOL............................................. EN02-26

OVERHAUL ...................................................EN02-26

INSPECTION AND REPAIR ..........................EN02-29

EN02-001

TIMING GEAR......................................... EN02-31

DESCRIPTION .............................................. EN02-31

COMPONENT LOCATOR.............................. EN02-32

SPECIAL TOOL............................................. EN02-33

OVERHAUL ...................................................EN02-33

INSPECTION AND REPAIR ..........................EN02-36

MAIN MOVING PARTS AND

CYLINDER BLOCK.................................EN02-38

COMPONENT LOCATOR.............................. EN02-38

SPECIAL TOOL............................................. EN02-41

OVERHAUL ...................................................EN02-42

INSPECTION AND REPAIR ..........................EN02-49

CYLINDER HEAD

COMPONENT LOCATOR

EN0111002D100001

SHTS011100200001

1 Silent block 8 Cylinder head

2 Oil filler cap 9 Cylinder head gasket

3 Cylinder head cover 10 Injection pipe oil seal

4 Helisert 11 Spacer

5 Cylinder head cover gasket 12 Stud

6 Additional bolt 13 Cylinder head plug

7 Caution plate 14 Head bolt

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 25 {250, 18} C 25 {250, 18}

B 108 {1,100,80} D 118 {1,200, 87}+90°+90°#

#=Apply oil to the threads and seat surfaces before tightening.

SHTS011100200002

1 Engine retarder assembly 11 Adjusting screw

2 Retarder housing support 12 Push rod

3 Rocker support 13 Cross head

4 Rocker shaft 14 Valve spring retainer

5 Rocker arm (Intake) 15 Valve spring seat (Upper)

6 Lock nut 16 Valve spring (Outer)

7 Rocker arm (Retarder) 17 Valve spring (Inner)

8 Rocker arm (exhaust) 18 Valve spring seat (Lower)

9 Torsion spring 19 Exhaust valve

10 Stopper pin 20 Intake valve

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 100 {1,020, 74}# C 59 {600, 44}+120°#

B 69 {700, 51}

#=Apply oil to the threads and seat surfaces before tightening.

SHTS011100200003

1 Camshaft bearing 12 Valve stem oil seal

2 Camshaft 13 Valve guide

3 Pin 14 Nozzle seat

4 Camshaft gear 15 O-ring

5 Idle gear shaft 16 Water pipe

6 Straight pin 17 Cylinder head

7 Bushing 18 Valve seat (Intake)

8 Cam idle gear 19 Valve seat (Exhaust)

9 Thrust plate 20 Expansion plug

10 Cam shaft cap 21 Cylinder head plate

11 Sealing plug

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 422 {4,300, 311}# C 39 {400, 29}#

B 59 {600, 44}# D 28.5 {290, 21}

#=Apply oil to the threads and seats surfaces before tightening.

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09433-1061 EYE BOLT M12 x 1.75

09491-1030 WIRE

09470-1120 VALVE SPRING PRESS

EN0111002K100001

09431-1010 VALVE LAPPING TOOL

09472-2190

09472-1210 BAR For Nozzle sleeve seat

9800-06100 STEEL BALL Used with 09472-1210

VALVE STEM OIL SEAL
PRESS

09420-1442 SLIDING HAMMER For Cam idle gear shaft

LOCK NUT

ADJUSTING
SCREW

OVERHAUL

EN0111002H200001

IMPORTANT POINTS - DISASSEMBLY

1. DISASSEMBLE THE CYLINDER HEAD.

(1) Clean parts around the cylinder head and fuel system connec-

tions.

NOTICE
Entry of foreign particles into the combustion chamber may result
in engine trouble.

(2) Remove the cylinder head cover.
(3) Remove the engine retarder.

Refer to the CHAPTER “ENGINE RETARDER”.

(4) Remove the injector and common rail.

Refer to the CHAPTER “FUEL SYSTEM”.

(5) Remove the rocker arm assembly.

a. Loosen the lock nut at the end of the rocker arm and turn the

adjusting screw counterclockwise completely.

NOTICE
Not untightening the adjusting screw may result in a bent rocker
shaft.

SHTS011100200012

b. Gradually loosen the rocker arm support bolt three times in

the order shown in the figure.

10

13

FRONT SIDE REAR SIDE

9

6

5

2

1

4

3

78

11

(6) Remove the camshaft.

a. Remove the camshaft cap.
b. Remove the camshaft.

12

SHTS011100200013

SHTS011100200014

(7) Remove the cylinder head bolts.

a. Gradually loosen bolts three times in the order shown in the

figure.

2

9

5

6

10

17

13

14

18

25

21

22

26

24

28

27

23

16

20

19

15

8

12

11

4

1

3

7

SHTS011100200015

(8) Lift and remove the cylinder head using the special tool and hoist.

SST:
Eye bolt (09433-1061)
Wire (09491-1030)

NOTICE

• Do not damage the cylinder head lower surface or cylinder

block upper surface during removal of the cylinder head.

• If it is difficult to lift off the cylinder head, pry with a chisel

between the cylinder head and cylinder block.

EXAMPLE

SHTS011100200016

SHTS011100200017

2. DISASSEMBLE THE VALVE SYSTEM.

(1) Remove the valve spring retainer using the special tool.

SST:

Valve spring press (09470-1120)

(2) Remove the valve springs, intake and exhaust valves.

NOTICE
Attaching tags to the valves (giving corresponding cylinder Nos.)
will eliminate time required for lapping the valve seats on reas­sembly.

SHTS011100200018

SHTS011100200019

3. DISASSEMBLE THE ROCKER ARM ASSEMBLY.

(1) Remove the rocker support, rocker arm (intake), rocker arm

(retarder), torsion spring and rocker arm (exhaust).
(2) Drive the stopper pin into the hole of the rocker shaft.
(3) Disassemble the rocker shaft and No. 7 rocker support.

4. CLEAN THE CYLINDER HEAD.

(1) Clean the cylinder head and remove carbon deposits or foreign

particles.

NOTICE
Be careful not to damage the cylinder head lower surface when
removing carbon deposits or foreign particles.

BACK PLATE

SHTS011100200020

SHTS011100200021

VALVE SEAT

IMPORTANT POINTS - REPLACEMENT

1. REPLACE THE VALVE GUIDE.

(1) Remove the valve stem seal.
(2) For removal, strike the valve guide with a brass bar and hammer.

! WARNING
Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.

(3) When installing a new valve guide, do not twist the end. Press fit

the valve guide.

Assembly standard (A): 24-24.3mm {0.945-0.956 in.}

NOTICE

• Be careful not to damage the valve stem at the upper or lower

end of the guide during press-fitting.

• Be sure to apply engine oil around the valve guide during

press-fitting.

2. REPLACE THE VALVE SEAT.

(1) When replacing the valve seat, cut three places on the circumfer-

ence of an unwanted valve and weld it to the valve seat.

NOTICE
To protect the lower surface of the cylinder head from welding
spatter, be sure to apply grease before welding.

VALV E

ELECTRIC
WELDING

CUT THREE
PLACES HERE

SHTS011100200022

(2) Place a (brass) back plate at the top of the valve system and

strike it with a hammer to remove the valve seat.

! WARNING
Striking the valve seat for removal may cause metal chips to fly
up. Be sure to wear protective goggles.

SHTS011100200023

(3) Machine the valve according to the valve seat dimensions.

Unit: mm {in.}

Intake Exhaust

Cylinder
head side

Valve seat
side

A

B

A

C

48-48.016

{1.8898-1.8903}

11.2-11.4

{0.4410-0.4488}

48.085-48.1

{1.8932-1.8937}

8.0-8.2

{0.3150-0.3228}

47.5-47.516

{1.8701-1.8707}

11.1-11.3

{0.4371-0.4448}

47.596-47.606

{1.8740-1.8742}

8.0-8.2

{0.3150-0.3228}

(4) Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water.

After cooling the valve seat, insert it into the cylinder head.

! WARNING
Striking the valve seat during installation may cause metal chips
to fly up. Be sure to wear protective goggles.

SHTS011100200024

SHTS011100200025

(5) Apply a small amount of lapping compound to the contact sur-

faces of the valve and valve seat. Turn the valve using the special
tool and tap it lightly to lap.

SST: Valve lapping tool (09431-1010)

SHTS011100200026

3. REPLACE THE VALVE STEM OIL SEAL.

(1) After removing the valve stem oil seal, install the valve spring

lower seat.
(2) Install the valve.
(3) Apply engine oil to the oil seal lip.
(4) Punch the oil seal into the valve guide using the special tool.

SST:

Valve stem seal press (09472-2190)

Assembly standard (A): 27.3 mm {1.075 in.}

! WARNING
Punching the valve stem seal during installation may cause metal
chips to fly up. Be sure to wear protective goggles.

NOTICE
After assembly of the oil seal, check for deformation or cracking
of the rubber or incline.

O-RING

APPLY LIQUID GASKET.

SHTS011100200027

NOZZLE SEAT

CYLINDER HEAD

SHTS011100200028

4. REPLACE THE NOZZLE SEAT.

(1) Tap the nozzle seat from the cylinder head lower surface.

Then, screw in a suitable bolt and strike the bolt head with a ham­mer to remove the nozzle seat from the cylinder head.

! WARNING
Punching the nozzle seat during installation may cause metal
chips to fly up. Be sure to wear protective goggles.

NOTICE
After removed the nozzle seat, removed the rest of liquid gasket or
the adhesion such as dust completely.

(2) After inserting the O-ring into the nozzle seat insertion hole of the

cylinder head, apply liquid gasket (ThreeBond TB1211 or equiva­lent) to the lower part of the new nozzle seat and assemble it onto
the cylinder head.

NOTICE
Be sure to replace the O-ring with a new one. Reuse of the O-ring
may cause water or gas leakage, resulting in overheating or crack­ing of the cylinder head.

SHTS011100200029

SHTS011100200030

(3) Caulk the nozzle seat with the special tools.

SST:
Bar (09472-1210)
Steel ball (9800-06100)

5. REPLACE THE CAM IDLE GEAR.

(1) Remove the idle gear shaft using the special tool.

SST:

Sliding hammer (09420-1442)

(2) Install the cam idle gear.

Assembly standard (A): 3.5-4.5 mm {0.1378-0.1771 in.}
Assembly standard (B): 9.5-10.5 mm {0.3741-0.4133 in.}

NOTICE

• Install the cam idle gear shaft as shown in the figure so that

the lubrication hole is downward.

• Apply clean engine oil to the bolt seat and bolt threads.

EXAMPLE

SHTS011100200031

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE VALVE AND VALVE SPRING.

(1) Install the valve spring retainer at the valve spring upper seat

using the special tool.

SST:

Valve spring press (09470-1120)

NOTICE

• Be sure to apply engine oil to the contact surface of each

part before assembly.

• Be sure to place each valve in its original position.

• When the valve spring is compressed, be careful of damage

to the valve stem oil seal due to contact of the upper seat.

• Since this valve spring is evenly pitched, it can be installed

either end up.

2. INSTALL THE CYLINDER HEAD GASKET.
NOTICE

• When installing the cylinder head, install the new gasket after

removing dirt, moisture and oil on the cylinder head and cyl­inder block surface.

• Never reuse the gasket as it may cause engine damage.

• Make sure that the seal rings are not loose or damaged.

SHTS011100200032

SHTS011100200033

SHTS011100200034

3. MEASURE THE CYLINDER HEAD BOLT.

(1) Measure the length of the head bolts, if the length is A or more,

replace with new bolts.

Dimension A 160 mm {6.299 in.}

4. INSTALL THE CYLINDER HEAD.

(1) Using the special tool and hoist, put the cylinder head on the cyl-

inder block.

SST:
Eye bolt (09433-1061)
Wire (09491-1030)

NOTICE
When put the cylinder head, attention to cam idle gear (cylinder
head side) and cam idle gear (cylinder block side) engagement.

(2) Apply clean engine oil to the bolt seats surface and bolt threads of

the head bolts.

(3) Clean the bolt seats completely on the cylinder head upper sur-

face.

(4) Tighten No. 1 - No. 26 head bolts in the order shown in the figure

to the specified torque.

Tightening Torque:
118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}

20

24

23

SHTS011100200036

16

15

19

27

12

11

4

8

7

3

5

1

2

6

13

9

10

14

21

17

18

25

28

26

22

SHTS011100200035

(5) Mark the head bolts with paint to indicate the same directions as

shown in the figure.

(6) Turn No. 1 - No. 26 head bolts 90° (1/4 turn) in the same order as

in (4).

(7) Retighten them 90° (1/4 turn) as step (6).

(8) Make sure that all paint marks face the same direction.

NOTICE
When adding torque, never untighten the bolts, even if they have
been overtightened.

(9) Tighten No. 27 - No. 28 additional bolts in the order shown in the

figure to the specified torque below.

27

5

6

13

9

10

14

21

17

18

25

28

26

22

SHTS011100200037

Tightening Torque:
108 N⋅m {1,100 kgf⋅cm, 80 lbf⋅ft}

5. ASSEMBLE THE CAMSHAFT GEAR.

(1) Make sure that there is neither damage to the camshaft gear or

camshaft nor dirt on them.

(2) Apply clean engine oil to the bolt seat surface and bolt threads

and tighten them to the specified torque.

Tightening Torque:
422 N⋅m {4,300 kgf⋅cm, 311 lbf⋅ft}

ARROW

MARK

CYLINDER
HEAD

RULER

BEARING CAP NUMBER

4

3

2

1

SHTS011100200038

6. INSTALL THE CAMSHAFT.

(1) Align the mark 1/6 on the flywheel with the flywheel housing

pointer.

(2) Install the camshaft on the cylinder head.

NOTICE
The arrow engaged on the front of the camshaft gear must face
upward and the line must be level.

SHTS011100200039

7

6

5

(3) Install the camshaft bearing cap, and tighten the bolts.

NOTICE
Check the number engraved on the camshaft bearing cap.

SHTS011100200040

SHTS011100200041

7. ASSEMBLE THE ROCKER ARM.

(1) Assemble the rocker shaft and No. 7 rocker support.

a. Insert the rocker shaft into the No. 7 rocker shaft.
b. Install the stopper pin into the hole.

Assembly standard (B): 4mm {0.1575 in.}

(2) Install the rocker arm (exhaust), torsion spring, rocker arm

(retarder) and rocker arm (intake) to the rocker shaft.

(3) Turn the adjusting screw counterclockwise completely.

NOTICE

• Not untightening the adjusting screw may result in a bent

rocker shaft.

• Make sure the oil hole of the rocker shaft is placed below.

SHTS011100200042

PUSH ROD

CROSS HEAD

SHTS011100200043

8. INSTALL THE ROCKER ARM ASSEMBLY.

(1) Make sure that the cross head and push rod are on each valves.

NOTICE
If the cross head is assembled whilst off the valve, the upper seat
will be pressed, resulting in a loose valve.

SHTS011100200044

(2) Apply clean engine oil to the bolt seat surface and bolt threads of

the rocker support bolts.

(3) Clean the rocker support seats surface and the cylinder head

upper surface.

(4) Set the rocker arm assembly on the cylinder head.

HINT
When assembling the rocker arm assembly, fix the arms with
string as shown in the figure to facilitate installation.

(5) Tighten the rocker support bolts in the order shown in the figure to

the specified torque.

Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}

10

13

FRONT SIDE REAR SIDE

9

6

5

2

1

4

3

78

11

(6) Mark the bolts with paint to indicate the same directions as shown

in the figure.
(7) Turn the bolts 120° (1/3 turn) in the same order as in (6).
(8) Make sure that all paint marks face the same direction.

NOTICE
When adding torque, never untighten the bolts, even if they have
been overtightened.

SHTS011100200046

9. ADJUST THE VALVE CLEARANCE.

(1) Refer to the CHAPTER “ENGINE TUNEUP”.

10. INSTALL THE INJECTOR AND COMMON-RAIL.

(1) Refer to the CHAPTER “FUEL SYSTEM”.

12

SHTS011100200045

11. INSTALL THE ENGINE RETARDER.

(1) Refer to the CHAPTER “ENGINE RETARDER”.

APPLY
LIQUID GASKET

PLUG

SHTS011100200047

12. INSTALL THE HEAD COVER.

(1) Remove the cylinder head plugs at the front and rear ends of the

cylinder head.

NOTICE
Do not remove the plug except there is no oil leakage from plug.

(2) Remove the liquid gasket from cylinder head plugs and cylinder

head completely.

(3) Apply liquid gasket (ThreeBond TB1207B or equivalent) to the

front and rear half circles of the cylinder head.

(4) Install the cylinder head plug to cylinder head.

NOTICE
Make sure that plug installed with no tilt.

NOTICE
Wipe out excess liquid gasket completely.

CYLINDER HEAD PLUG

APPLY LIQUID GASKET

SHTS011100200048

APPLY LIQUID GASKET

(5) Install the cylinder head cover gasket into the gasket groove at

the head cover lower surface.

NOTICE
Make sure that there are no foreign particles (including liquid gas­ket), or oil on the gasket grooves of the head cover, gasket or cyl­inder head upper surface nor damage to them.

(6) Apply liquid gasket (ThreeBond TB1207B or equivalent) to the

plug corner at the front and rear ends of the cylinder head and the
pressure sensor seal before installing the head cover.

PRESSURE SENSOR SEAL

SHTS011100200049

HEAD COVER

HEAD COVER
GASKET

SPACER

RUBBER
(SILENT BLOCK)

SHTS011100200050

(7) Install the cylinder head cover on the cylinder head.
(8) Insert the silent block from the head cover upper surface.
(9) Tighten the bolt through the silent block to the specified torque

below.

Tightening Torque:

25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}

INSPECTION AND REPAIR

Inspection item Standard Limit Remedy Inspection procedure

Camshaft journal outside
diameter

Camshaft bearing inside
diameter

Clearance between cam­shaft journal and cam­shaft bearing

Camshaft end play at No.
7 journal

54.0

{2.1260}

54.0

{2.1260}

0.025-0.072

(0.0010-0.0028)

0.10-0.31

(0.0040-0.0122)

— Replace camshaft.

—

0.3

{0.0118}

0.5

{0.0197}

Replace cam bear­ing.

Replace camshaft
and/or cam bear­ing.

Replace camshaft.

Measure (EXAMPLE)

Measure (EXAMPLE)

EN0111002H300001

Unit: mm {in.}

Cam height

IN

EX

RETARDER

68.418

{2.6936}

71.512

{2.8154}

76.945

{3.0293}

67.618

{2.6621}

70.712

{2.7840}

76.145

{2.9978}

Replace camshaft.

Camshaft deflection 0.05 {0.0020} — Replace camshaft.

Measure (EXAMPLE)

Measure (EXAMPLE)

Inspection item Standard Limit Remedy Inspection procedure

Rocker arm bushing
inside diameter

Rocker shaft outside
diameter

Clearance between rocker
shaft and rocker arm
bushing

Stem out­side diame­ter

Intake valve

Guide inside
diameter

Clearance

Stem out­side diame­ter

Exhaust
valve

Guide inside
diameter

Clearance

31.5

{1.2402}

31.5

{1.2402}

0.044-0.120

{0.0018-0.0047}

31.58

{1.2433}

31.42

{1.2370}

0.15

{0.0059}

Replace rocker
arm.

Replace rocker
shaft.

Replace rocker arm
and/or rocker shaft.

10 {0.3937} 9.85 {0.3878} Replace the valve.

10 {0.3937} — —

0.040-0.077

{0.0016-0.0030}

0.3 {0.0118}

Replace the valve
and/or valve guide.

10 {0.3937} 9.8 {0.3858} Replace the valve.

10 {0.3937} —

0.057-0.094

{0.0023-0.0037}

0.35 {0.0138}

Replace the valve
guide.

Replace the valve
and/or valve guide.

Measure (EXAMPLE)

Measure

Valve sink

Valve seat
angle

Valve face
angle

IN

EX

-0.05-0.35

{-0.0020-0.0137}

-0.05-0.35

{-0.0020-0.0137}

0.7 {0.0276}

0.7 {0.0276}

IN 30° —

EX 45° —

IN 30° —

EX 45° —

Replace the valve
and valve seat.

Replace the valve
and valve seat.

Resurface the
valve and/or valve
seat.

Measure

VALVE SINK

Measure

Inspection item Standard Limit Remedy Inspection procedure

Outer valve
spring

Inner valve
spring

Setting load

Free length
(reference
value)

Squareness

Setting load

Free length
(reference
value)

Squareness

519.8 N

{53.0 kgf,

116.9 lbf}

at 60.0 {2.362}

89.3

{3.516}

less than 3.1

{0.1220}

(2.0°)

123.6 N

{12.6 kgf, 27.8 lbf}

at 57.0 {2.244}

82.9

{3.264}

less than 2.9

{0.1142}

(2.0°)

477.7 N

{48.7 kgf,

107.4 lbf}

——

3.9

{0.1535}

(2.5°)

113.6 N

{11.6 kgf,

25.5 lbf}

——

3.6 {0.1417}
(2.5°)

Replace.

Replace.

Replace.

Replace.

Measure

Wear and damage of valve
spring seat upper and
lower

Nozzle protrusion

Cylinder head lower sur­face flatness

— — Replace.

2.65-3.15

{0.1044-0.1240}

0.075 or less

{0.0030 or less}

—

0.20

{0.0078}

Visual check

Measure

Replace nozzle
seat.

Measure

Regrind.

Inspection item Standard Limit Remedy Inspection procedure

Measure

Cylinder head thickness

Cracks of damage to cylin­der head (Dye penetrant
check)

Contact of valve (Use of
Red lead marking com­pound)

Cam idle gear shaft out­side diameter

167.7-168

{6.6024-6.6141 in.}

— — Replace.

Entire periphery

of valve head

evenly in contact

72 {2.8346} — —

——

— Matches valve.

Visual check

Visual check

Measure

Cam idle gear shaft bush­ing inside diameter

Clearance between cam
idle gear shaft and cam
idle gear bushing

Cam idle gear end play

72 {2.8346} — —

0.030-0.090

{0.0012-0.0035}

0.090-0.145

{0.0036-0.0057}

0.2 {0.0078}

0.3 {0.0118}

Replace idle gear
shaft and/or idle
gear.

Replace thrust
plate idle gear
shaft and/or
idle gear.

Measure

CRANKSHAFT FRONT END

COMPONENT LOCATOR

EN0111002D100002

SHTS011100200067

1 Crankshaft pulley 5 Crankshaft oil seal

2 Straight pin 6 Vent pipe

3 Crankshaft damper 7 Stud

4 Oil seal retainer

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 78 {800, 58}+90°# C 28.5 {290, 21}

B 98-118 {1,000-1,200, 73-86}

#=Apply oil to the threads and seat surfaces before tightening.

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-2060 OIL SEAL PULLER

09407-1200 OIL SEAL PRESS

EN0111002K100002

SLEEVE

HOOK

SHTS011100200070

OVERHAUL

EN0111002H200002

IMPORTANT POINTS - REPLACEMENT

1. REMOVE THE CRANKSHAFT FRONT OIL SEAL.
SST:

Oil seal puller (09420-2060)

(1) Engage the hook with the oil seal notch and install the hook using

the bolt supplied.

(2) Place the sleeve on the hook.

(3) Install the center bolt and tighten it to remove the oil seal.

SHTS011100200072

SHTS011100200073

SHTS011100200074

2. INSTALL THE CRANKSHAFT FRONT OIL SEAL.
SST:

Oil seal press (09407-1200)

(1) Apply a little engine oil to the new oil seal inner and outer ring sur-

faces.

(2) Making sure it is properly oriented, insert the new oil seal by hand

until it stops against the crankshaft.

NOTICE
Install the oil seal so that the felt surface faces outward and the
surface with the slinger (steel plate) faces in forward the engine.

(3) Install the plate on the crankshaft end using the guide bolts.

(4) Fit the press over the guide bolts, fix it in place by tightening the

center bolt, and then press-fit the oil seal.

NOTICE
Make sure the press is set so that pressure will be applied evenly
around the entire circumference of the oil seal

SHTS011100200075

(5) Tighten the press until it contacts the crankshaft end, and then

confirm that the oil seal is uniformly press-fitted.

Assembly standard (A): 25.7-26.3mm {1.0119-1.0354 in.}

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE CRANKSHAFT DAMPER.

1

6

4

3

5

2

SHTS011100200076

SHTS011100200077

(1) Apply clean engine oil to the bolt seat surface and bolt threads.
(2) Install the crankshaft damper to the crankshaft, then tighten the

bolts in the order shown in the figure to the specified torque.

Tightening Torque:
78 N⋅m {800 kgf⋅cm, 58 lbf⋅ft}

(3) Mark the bolts with paint to indicate the same direction as shown

in the figure.
(4) Turn the bolts 90° (1/4 turn) in the same order as in (3).
(5) Make sure that all paint marks face the same direction.

NOTICE
When adding torque, never untighten the bolts, even if they have
been overtightened.

FLYWHEEL AND FLYWHEEL HOUSING

COMPONENT LOCATOR

EN0111002D100003

SHTS011100200078

1 Pin 8 Ball bearing

2 Flywheel housing gasket 9 Bearing stopper

3 Dust cover 10 Rear oil seal

4 Flywheel housing 11 Helisert

5 Stud 12 Engine mounting (Rear)

6 Ring gear 13 Flywheel housing stay

7 Flywheel (Representative)

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A M16: 225 {2,300, 166} D 200 {2,000, 147}

B M12: 125 {1,275, 92} E 225 {2,300, 166}

C 345 {3,500, 254}#

#=Apply oil to the threads and seat surface before tightening.

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1780 REAR OIL SEAL PULLER

09407-1210 OIL SEAL PRESS

EN0111002K100003

ENGINE SPEED
SENSOR

SHTS011100200081

OVERHAUL

EN0111002H200003

IMPORTANT POINT - DISASSEMBLY

1. REMOVE THE FLYWHEEL.

(1) Remove the engine speed sensor.

NOTICE
When removing the flywheel, remove the engine speed sensor.

(2) Remove the flywheel.

! WARNING
The flywheel is too heavy. When removing, be careful not to drop it
on your feet.

IMPORTANT POINTS - REPLACEMENT

1. REPLACE THE CRANKSHAFT REAR OIL SEAL.

(1) Place the plate at the crankshaft end using the flywheel bolts.

NOTICE
Tighten the flywheel bolts only finger-tight.

SHTS011100200082

SST:

Oil seal puller (09420-1742)

SHTS011100200084

SHTS011100200085

(2) Engage the hook with the oil seal notch and install the hook using

the bolt supplied.

(3) Remove the installed flywheel bolts in step (1).

(4) Install the center bolt and tighten it to remove the oil seal.

(5) Clean the edges and surface of the crankshaft and the special

tools.

SST:

Oil seal press (09407-1210)

(6) Apply a little engine oil to the new oil seal inner and outer ring sur-

face.

(7) Making sure it is properly oriented, insert the new oil seal into the

oil seal guide.

NOTICE
Install the oil seal so that the felt surface faces outward and the
surface with the slinger (steel plate) faces in toward the engine.

SHTS011100200086

SHTS011100200087

(8) Install the oil seal guide on the crankshaft end using the guide

bolts.

(9) Fit the press over the guide bolts, fix it in place by tightening the

center bolt, and then press-fit the oil seal.

NOTICE
Make sure the press is set so that pressure will be applied evenly
around the entire circumference of the oil seal.

(10) Tighten the press until it contacts the oil seal guide, and then con-

firm that the oil seal is uniformly press-fitted.

Assembly standard (A): 3.7-4.3mm {0.1457-0.1692 in.}

SHTS011100200088

SHTS011100200089

2. REPLACE THE FLYWHEEL RING GEAR.

(1) Heat the ring gear evenly to about 200°C {392°F} with a torch.

Tap the ring gear periphery lightly using a cushion bar to remove
the gear.

! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.

(2) Heat the ring gear evenly to about 200°C {392°F} with a torch.

Insert the ring gear into the flywheel so that the chamfered side is
upward.

! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.

SHTS011100200090

IMPORTANT POINT - ASSEMBLY

1. INSTALL THE FLYWHEEL.

(1) Make sure that there are no burns or dirt on the contact surface or

in the threaded holes of the crankshaft or flywheel. Install a suit­able guide bar onto the crankshaft.

(2) Insert the flywheel slowly until it contacts the straight pin to pre-

vent impact on the guide bar. Adjust the position, then insert the
flywheel completely.

! WARNING
The flywheel is too heavy. When installing, be careful not to drop it
on your feet.

(3) Apply clean engine oil to the threads of the flywheel bolt and the

flywheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces)
with a low-torque impact wrench.

(4) Pull out the guide bar and tighten the remaining two flywheel bolts

provisionally as in step (3).

(5) Tighten the flywheel in the order shown in the figure to the speci-

fied torque below.

Tightening Torque:
345 N⋅m {3,500 kgf⋅cm, 254 lbf⋅ft}

SHTS011100200091

INSPECTION AND REPAIR

EN0111002H300002

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure

Flywheel surface
deflection

Flywheel
flange
depth
(Dimen­sion A)

Flywheel
thickness
(Dimen­sion B)

Flywheel
flange
depth
(Dimen­sion A)

Flywheel
thickness
(Dimen­sion B)

DSP-430
(Pull)
series
(Diameter
430 mm
{17 in.})

DSP-430
(SACHS)
series
(Diameter
430 mm
{17 in.})

— 0.2 {0.0079}

48 {1.890} 48 {1.890} Repair.

26 {1.024} 25 {0.985} Replace.

10 {0.394} — —

40 {1.575} 39 {1.536} Replace.

Regrind and/or
replace.

Measure

Measure

Inspection item Standard Limit Remedy Inspection procedure

Flywheel
flange
depth
(Dimen­sion A)

Flywheel
thickness
(Dimen­sion B)

Flywheel
flange
depth
(Dimen­sion A)

Flywheel
thickness
(Dimen­sion B)

CLF-3802
(TWIN
PLATE)
series
(Diameter
380 mm
{15 in.})

F & S-380
(TWIN
PLATE)
series
(Diameter
380 mm
{15 in.})

Measure

4.5 {0.177} — —

32.8 {1.291} 31.8 {1.252} Replace.

6 {0.236} — —

31.3 {1.232} 30.3 {1.193} Replace.

Flywheel surface crack
or heat spot

——

Regrind and/or
replace.

Visual check

TIMING GEAR

DESCRIPTION

EN0111002D100004

1 Power steering pump drive gear 7 Air compressor idle gear

2 Idle gear 8 Oil pump driven gear

3 Cam idle gear (cylinder block side) 9 Oil pump drive gear

4 Cam idle gear (cylinder head side) 10 Crankshaft gear

5 Camshaft gear 11 Supply pump drive gear

6 Air compressor drive gear

SHTS011100200096

COMPONENT LOCATOR

EN0111002D100005

SHTS011100200097

1 Timing gear case gasket 8 Cam idle gear (cylinder head side)

2 Timing gear case 9 Straight pin

3 Plug 10 Idle gear shaft

4 Gasket 11 Cam idle gear (cylinder head side)

5 Pin 12 Thrust plate

6 Helisert 13 Main idle gear

7 Camshaft gear 14 Air compressor idle gear

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 125 {1,275, 92} C 108 {1,100, 80}#

B 59 {600, 44}#

#=Apply oil to the threads and seat surfaces before tightening.

SPECIAL TOOL

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1510 SLIDING HAMMER

EN0111002K100004

For Main idle gear, cam idle
gear (cylinder block) and air
compressor idle gear

09420-1442 SLIDING HAMMER

SHTS011100200099

For Cam idle gear
(cylinder head)

OVERHAUL

EN0111002H200004

IMPORTANT POINT - DISASSEMBLY

1. REMOVE THE MAIN IDLE GEAR, AIR COMPRESSOR IDLE
GEAR AND CAM IDLE GEAR (CYLINDER BLOCK).

(1) Remove the idle gear attaching bolts.
(2) Remove the idle gear shaft using the special tool.

SST:
Sliding hammer (09420-1510)
Sliding hammer (for cam idle gear) (09420-1442)

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE REAR END PLATE.

SHTS011100200101

NOTICE
Install each idle gear shaft as shown in the figure so that the lubri­cation hole is downward.

2. CHECK THE BACKLASH AND THE END PLAY.

(1) Measure the backlash between the gears with a dial gauge.

(Refer to the table of INSPECTION AND REPAIR.)

(2) Measure the end play between the gear and thrust plate with a

feeler gauge.
(Refer to the table of INSPECTION AND REPAIR.)

NOTICE
After measurement of the backlash, apply engine oil to each gear
surface.

3. WHEN THE LOWER SURFACE OF CYLINDER HEAD IS
GROUND, ADJUST BACKLASH BETWEEN CAM IDLE GEAR
(CYLINDER HEAD SIDE), CAM IDLE GEAR (CYLINDER
BLOCK SIDE) AND CAM SHAFT GEAR.

NOTICE
Once the lower surface of cylinder head is ground, installing
dimension between cylinder head and straight pin becomes
shorten by ground dimension. As a result, backlash adjustment is
needed since backlash value between the cam idle gears (cylinder
head side and cylinder block one) becomes smaller.

CAM IDLE GEAR

THRUST PLATE

CAMSHAFT GEAR

BACKLASH

IDLE GEAR
SHAFT

BOLT

BEFORE

BACKLASH

REMOVE THE STRAIGHT PIN.

STRAIGHT PIN

A

A= GROUND DIMENSION

CYLINDER HEAD

SHTS011100200102

(1) Remove out straight pin of idle gear shaft.

NOTICE
By removing straight pin, installing position of gear shaft can be
changed by the clearance between the bolt hole and the bolt of the
Idle gear shaft.

(2) Tighten temporally cam idle gear on the ground cylinder head.
(3) Mount cylinder head on cylinder block.

NOTICE
Refer to the CHAPTER “CYLINDER HEAD”.

(4) Install cam shaft on cylinder head.

NOTICE
Refer to the CHAPTER “CYLINDER HEAD”.

IDLE
GEAR
SHAFT

CAM IDLE
GEAR

SHTS011100200103

(5) By moving little by little the installing position of cam idle gear,

adjust backlash between cam idle gears (cylinder head side and
cylinder block one) and between cam idle gear (cylinder head
side) and camshaft gear to the standard value.

(6) Tighten the bolt for installing cam idle gear.

Tightening Torque:
59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}

NOTICE
Apply engine oil to the bolt seat surfaces and bolt threads before
tightening.

INSPECTION AND REPAIR

Inspection item Standard Limit Remedy Inspection procedure

Crankshaft

Timing
gear back­lash

gear­Main idle
gear

Main idle
gear-Air com­pressor idle
gear

Main idle
gear-Power
steering
pump drive
gear

Main idle
gear -Cam
idle gear
(Block)

Main idle
gear-Supply
pump drive
gear

0.039-0.135

{0.0016-0.0053}

0.046-0.142

{0.0019-0.0055}

0.043-0.199

{0.0017-0.0078}

0.040-0.136

{0.0016-0.0053}

0.043-0.177

{0.0017-0.0069}

0.40 {0.0157}

0.40 {0.0157}

0.40 {0.0157}

Measure

0.40 {0.0157}

Replace gear.

0.40 {0.0157}

EN0111002H300003

Unit: mm {in.}

Air compres­sor idle gear
Air compres­sor drive gear

Cam idle gear
(Block)-Cam
idle gear
(Head)

Cam idle gear
(Head)-Cam­shaft gear

Oil pump
drive gear-Oil
pump driven
gear

0.035-0.204

{0.0014-0.0080}

0.038-0.356

{0.0015-0.0140}

0.038-0.139

{0.0015-0.0053}

0.034-0.261

{0.0014-0.0102}

0.40 {0.0157}

0.40 {0.0157}

0.40 {0.0157}

0.40 {0.0157}