Hino J05E-TH Workshop Manual

HINO DIESEL ENGINE

WORKSHOP MANUAL

J05E-TH

(HS ENGINE for 25t)

KSS-SMJ5-E111E

2007.6

GENERAL

1

STANDARD VALUE

PARTS TO BE PREPARED

ENGINE ASSEMBLY/DISASSEMBLY

FUEL SYSTEM

EMISSION CONTROL

ELECTRICAL

INTAKE

ENGINE MECHANICAL

EXHAUST

COOLING

2

3

4

5

6

7

8

9

10

11

LUBRICATION

STARTING AND CHARGING

TURBOCHARGER

AIR COMPRESSOR

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

ENGINE DIAGNOSIS CODE

For your information:

This documentation does not contain any descriptions in
regard to the hatched part

12

13

14

15

16

17

"6. Emission Control".
"15. Air Compressors".

GENERAL 1–1

ENGINE

1 GENERAL

GeneralGeneral information

Warning................................................................... 1-2

How to read this manual ........................................ 1-3

Precautions for work ............................................... 1-7

Tightening of engine bolts and nuts...................... 1-10

Tightening of chassis bolts and nuts..................... 1-12

Tightening of flare nuts and hoses........................ 1-14

Taper thread sealant for piping ............................. 1-15

Assembly of joints and gaskets for piping............. 1-16

Handling of liquid gasket....................................... 1-18

Failure diagnosis table for each problem .............. 1-19

Failure diagnosis using HinoDX............................ 1-20

Connection method of HinoDX ............................. 1-23

Chassis number and engine number ................... 1-23

1

GENERAL1–2

Warning

JP31199010102001

Observe the following precautions to work safely and to prevent damage to customers' vehicles.

This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not

qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who

perform service with the way not specified in this manual may not only damage the vehicle, but also put service

engineers and surrounding people in danger.

• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of

vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.

• Items described in this manual are the procedures to be observed in service and repair. For service and repair

according to this procedure, be sure to use the special tools designed for each purpose.

• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles

may be impaired. Never use a method or tool not recommended.

• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur

during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of

vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or

“Caution” are not absolute for safety.

GENERAL 1–3

How to read this manual

JP31199010102002

1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,

assembly⋅disassembly and inspection⋅adjustment" and "Final inspection".

(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,

assembly⋅disassembly and inspection⋅adjustment" in the second process. Explanation of "Final inspection"

in the third process is omitted here.

(3) Although the following work is not described in this manual, it should be performed in actual work.

a. Jacking and lifting

b. Cleaning and washing of removed parts as required

c. Visual inspection

2. Standard value

(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.

3. Items to be prepared

(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list

section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually

equipped in general service shop are omitted.

4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.

(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",

"Replacement", "Overhaul", etc. of components are described.

(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.

(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in

the illustration. Major names and tightening torque are listed in the table.)

!CAUTION

The part layouts in this manual are inserted based on illustrations and part numbers of the

parts catalog CD-ROM issued in April, 2007. (Some areas do not show exploded view. They

will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts

catalog for confirmation of illustrations and part numbers and for ordering parts.

GENERAL1–4

5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :

(1) Question "Step 1"

(2) Pre-inspection

(3) Reproduction method

(4) Troubleshooting for each

diagnosis code

(5) Troubleshooting for each failure

status

(6) Confirmation test "Step 4"

(2) Pre-inspection

• Pre-inspection is performed in the following steps :

Diagnosis inspection→Diagnosis deletion→Failure status check (Use the reproduction

method if not reproduced.)→Diagnosis reconfirmation

"Step 2"

"Step 3"

Hear from customers for conditions and environments

of failures and check the fact.

Perform diagnosis inspection, status inspection,

function inspection and basic inspection. Check the

failure status. If it is difficult to reproduce the problem

with status inspection, use the reproduction method.

Summarize inspection results obtained from Step 2.

Perform inspection systematically according to

troubleshooting procedures for each diagnosis code or

failure status.

Check if failure occurs again after repair. If it is difficult

to reproduce a failure, perform the confirmation test

under the conditions and environment of the failure.

Pre-

inspection

• Estimate the failure system before the reproduction test. Attach a tester and evaluate

estimated failure together with failure status. Refer to the troubleshooting chart for

estimated cause of a failure.

• An error code is displayed if a failure occurs instantaneously. If any specific failure is not

found, perform troubleshooting using the reproduction method.

• Failure status check

If failure is reproduced, perform Step 2 → Step 3 → Step 4.

If failure is not reproduced, use the reproduction method (simulation of external

conditions or check of each wire harness and connector, etc.)

6. How to read explanation details

(1) Part layout

Example

Timing Gear Cover and Flywheel Housing

GENERAL 1–5

ENGINE MECHANICAL [J08E] 9–17

Part layout

JP04117090402003

Part name code

Part catalog Fig. No.

SAPH041170900182

11308

11309

11357

11357A

*Parts not to be reused.

Tightening torque

9069H

9069J

Flywheel housing

Oil seal retainer

Gasket*

Gasket*

Left: Part name code (nut)

M14 : 171.5N m{1, 750kgf cm}

M12 : 97N m{990kgf cm}

Serviceproce dureOverhaulitem

11390

9828A

9828B

9419A

9419B

End plate

Front oil seal*

Rear oil seal*

M16 : 196N m{2, 000kgf cm}

M16 : 196N m{2, 000kgf cm}

Description of
part name code

✩:It is the ID number for parts to prepare electronic data. It is not required for repair work.

SAPH311990100001

GENERAL1–6

7. Definition of terms

Terms in this manual are defined as follows :

(1) Direction

a. Individual unit

Front/back direction

The power input side is front and the output side is back.

Rotating direction

When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is

left rotation.

Vertical direction

With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is lower.

Left/right direction

When viewed from the rear, the left direction is left and the right direction is right.

(2) Standard value ⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two

parts are joined

(3) Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to

the standard value.

(4) Service limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or

decrease to the standard value.

(5) Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.

(6) Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require

attention in working procedures.

(7) Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.

8. Unit

(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international

units into one unit per quantity and to promote smooth technical communications.

(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.

*1

S I u n i t

Convent

ional

Conversion value

(1[Conventional unit]

unit

Spring

constant

N/mm kgf/mm

1kgf/mm=980665N/

Volume L cc 1cc=1mL

= X [SI unit])

mm

S I u n i t

Convent

ional

unit

Conversion value

(1[Conventional

unit] = X [SI unit])

Force N kgf 1kgf=9.80665N

Torque

*2

N⋅mkgf⋅cm

1kgf⋅cm=0.0980665

N⋅m

1kgf/

Pressure Pa

Rotational

speed

r/min

min

-1

kgf/cm

mmHg

rpm

2

2

cm

=98.0665kPa

Efficiency W PS 1PS=0.735499kW

=0.0980665MPa

1mmHg=0.133322kPaCalorific

value

1rpm=1r/min Fuel

1rpm=1min

-1

consumpt

ion rate

W⋅h cal 1kcal=1.163W⋅h

g/W⋅hg/PS⋅h

1g/PS⋅h=1.3596g/

kW⋅h

*1

*1

: X means the value when 1 [Conventional unit] is converted to the SI unit.

It is used as the conversion factor from the conventional unit to the SI unit.

*2

: The conversion value of the torque may vary depending on the unit.

Observe the standard values described for each unit.

GENERAL 1–7

Safety information

Precautions for work

1. General precautions

To ensure safety in work and to prevent accidents, observe the following items :

(1) Appearance

a. Wear safety goggles.

b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.

c. Bind long hair at the back.

d. Be sure to wear a cap and safety shoes.

(2) Safety work

a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.

b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during

operation of the engine.

c. Remove the starter key when the engine is not started.

d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.

e.

Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.

f. Since the battery fluid is poisonous and corrosive, be careful for handling.

g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may

occur.

h. If a tool or rag is left in the engine compar tment, it may be bounced with a rotating part of the engine,

resulting in injury.

i. To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.

JP31199010101001

2. Precautions for service work

Pay attention to the following points before service work

(1) Preparation before disassembly

a. Prepare general tools, special tools and gauges before work.

b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected

to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the

battery before work.

c. Perform inspection according to the procedure in the text before disassembly.

(2) Inspection during disassembly

Every time parts are removed, check the area where the parts are assembled and check for deformation,

damage, wear or scratch.

(3) Arrangement of disassembled parts

Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.

(4) Washing of disassembled parts

Clean and wash parts to be reused well.

(5) Inspection and measurement

Inspect and measure parts to be reused as required.

(6) Assembly

a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct

parts in the correct order.

b. Be sure to use genuine parts for parts to be replaced.

c. Use new packing, gasket, O–ring and cotter pin.

d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas

where application of oil is required, and apply specified grease to the oil seal lip before assembly.

(7) Check of adjustment

Make adjustments to the service standard values using a gauge or tester.

Loosen

SAPH311990100002

GENERAL1–8

3. Precautions for electric system

(1) Removal of battery cable

a. In an electric system, remove the cable from the

battery minus (-) terminal to prevent burnout due to

short-circuit.

b. When the battery cable is removed, the battery

terminal may be damaged. Loosen the nut completely

and never pry it for removal.

(2) Handling of electronic parts

a. Do not give impact on electronic parts such as

computer and relay.

b. Do not place electronic parts at a high temperature and

humidity area.

c. Do not expose electronic parts to water in washing of a

vehicle.

SAPH311990100003

SAPH311990100004

(3) Handling of wire harness

a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure

to reassemble it to the original position.

b. When parts are assembled, be careful not to pinch a

wire harness.

GENERAL 1–9

(4) Handling of connector

a. When a connector is removed, hold the connector (as

shown by the arrow in the left) and pull it out. Do not pull

the wire harness.

b. Unlock the locking connector before pulling.

c. Insert the locking connector completely until it clicks.

d. To insert a test lead into the connector, insert it from the

back of the connector.

e. If it is difficult to insert a test lead from the back of the

connector, prepare a harness for inspection.

SAPH311990100005

4. Precautions for electric welding

Inadvertent electric welding on a cab or chassis may cause reverse welding current from the grounding

circuit, resulting in damage to electric and electronic parts. Observe the following items for electric

welding.

(1) Turn "OFF" the starter switch.

(2) Make sure that switches are "OFF".

(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.

(4) Disconnect connectors of each computer.

(5) Remove all fuses. (For locations of fuses, refer to "Electrical System Chapter".)

(6) Be sure to connect grounding of the electric welding machine near the welding area.

Connect grounding from a bolt (plated bolt) or a frame near the welding area.

Remove paint of the frame for connection of grounding from the frame.

(7) Other precautions

a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they

may not be exposed to spatter.

b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also

maintain welding quality.

(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery

disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same

color.

(9) After reassembly, check the function if it operates correctly.

General information

GENERAL1–10

Tightening of engine bolts and nuts

1. Tightening torque of general standard bolts

(1) For bolts with seatings

Screw diameter x Pitch 7T 9T

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

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

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

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

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

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

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

Remark Bolt with number “7” on the head Bolt with number “9” on the head

!CAUTION

• 8T bolt is in accordance with 7T bolt.

JP31199010102003

Unit : N⋅m{kgf⋅cm}

(2) For bolts with washers

Unit : N⋅m{kgf⋅cm}

Screw diameter x Pitch 4T 7T 9T

M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}

M8 x 1.25 (Coarse thread) 14{140} 25{250} 31{320}

M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}

M10 x 1.5 (Coarse thread) 26{270} 47{480} 59{600}

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

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

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

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

Bolt with number “4”on

Bolt with number“7”on

the head Stud with C

surface at free end

Bolt with number “9”on

the head

Remark

the head

Projection bolt Stud

with R surface at free

end

!CAUTION

• 8T bolt is in accordance with 7T bolt.

R surface (4T)

C surface (7T)

SAPH311990100006

Seal Lock Agent

SAPH311990100007

GENERAL 1–11

2. Precoated bolt

Precoated bolt is the bolt with an application of a seal lock

agent at the thread.

(1) When re-application of lock agent is required

a. When precoated bolts are removed

b. When precoated bolts are moved due to tightening

check (for loosening or tightening)

OTICE

• Check torque with the lower limit of the

tightening torque allowable value. If

movement is found, tighten the bolt

according to the procedure below.

(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for

replacement.)

b. Dry completely by blowing air.

c. Apply the specified seal lock agent to the thread of the

bolt.

One turn by 90°

Tighten it 90°

One turn by 90°
One turn by 45°

Tighten it 90°
(First time)

SAPH311990100008

Tighten it 45°
(Second time)

SAPH311990100009

3. Plastic region tightening method (angle method)

(1) Precautions

Some engines are tightened with the plastic region

tightening method.

Since it is different from the conventional method, tighten

it according to the instruction in the text.

(2) Parts tightened

Cylinder head bolt, crankshaft main bearing cap bolt,

connecting rod bearing cap bolt, etc.

!CAUTION

• Measure the overall length of the bolt before

assembly and replace the bolt if the length

exceeds the service limit.

Apply engine oil to bolt seating and bolt

thread in assembly.

Two turns by 90°

Tighten it 90°
(First time)

Tighten it 90°
(Second time)

SAPH311990100010

(3) Tightening method after tightening to seating torque

Tightening of 90 °, 135 °(90 °once and 45 °once) and

180 °(90 °twice) is available.

GENERAL1–12

Tightening of chassis bolts and nuts

JP31199010102004

1. Tightening torque of general standard bolts and nuts

(1) Selection method of tightening torque

a. Find the applicable strength zone from the table below and select the bolt tightening torque from the

table described later.

b. Select the nut tightening torque from the mating bolt as described above.

(2) Identification method of bolt strength zone

a. Identification method with product

Hexagonal bolt

Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression

and upset on the head with the symbol in the table.

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

Identification symbol for part 6 7 8 q

(*1) : 9 may be misread with 6. It is expressed in q.

Depression Relief Base depression Upset

*1

10 11 12

Hexagonal nut

Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :

Formula

(3) Types of general standard bolts and nuts

Standard seating Seating A with flange Seating B with flange

SAPH311990100011

GENERAL 1–13

(4) Standard tightening torque table of general standard bolts and nuts

(Representative standard seating is described)

Strength

zone

Unit : N⋅m{kgf⋅cm}

Bolt

4T 7T 9T

diameter

(mm)

4.5±1.8{50±20}

M6

(Cab)

5.5±1.1{60±10}

(Chassis)

14.0±3.5{140±40}

M8

(Cab)

17.0±3.0{170±30}

(Chassis)

M10 27.0±5.0{276±55}

M12 48.0±9.5{490±98}

9.0±1.8{90±20} 11.5±2.0{117±23}

22.0±4.0{220±40}

43.0±8.5{440±90}

(Cab)

51.5±10.0{530±100}

(Chassis)

76.0±15.0{776±150}

(Cab)

91.0±18.0{930±180}

(Chassis)

*2

29.0±5.5{300±60}

*2

57.0±11.0{580±110}

(Cab)

68.5±13.5{700±140}

(Chassis)

*2

100.0±20.0{1, 020±200}

(Cab)

120.0±24.0{1, 220±240}

(Chassis)

*2

*2

*2

M14 77.0±15.0{786±157} 120.0±24.0{1, 220±240} 160.0±32.0{1, 630±326}

M16 120.0±24.0{1, 220±244} 190.0±38.0{1, 940±390} 250.0±50.0{2, 550±510}

M18 165.0±33.0{1, 680±336} 260.0±52.0{2, 650±530} 345.0±69.0{3, 520±704}

M20 235.0±47.0{2, 400±480} 370.0±74.0{3, 770±750} 490.0±98.0{5, 000±1, 000}

M22 320.0±64.0{3, 270±654} 505.0±100.0{5, 150±1, 030} 670.0±130.0{6, 840±1, 370}

M24 405.0±81.0{4, 130±826} 640.0±125.0{6, 530±1, 310} 845.0±165.0{8, 620±1, 720}

!CAUTION

• Use the tightening torque value for seating A with flange except for *2 in the table larger by

10% than the tightening torque value in the table.

• Use the tightening torque value for seating B with flange of *2 in the table larger by 20%

than the tightening torque value in the table.

The tightening torque value of M8 for seating B with flange remaines unchanged.

• Seating B with flange of *2 in the table is interchangeable with the standard seating in

pairs. Use the standard seating for the tightening torque value.

GENERAL1–14

Tightening of flare nuts and hoses

JP31199010102005

1. Tightening torque of pipe flare nut

Unit : N⋅m{kgf⋅cm}

Pipe outer

diameter

Material

Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}

2. Tightening torque of hoses

Air hose

φ4.76 φ6.35 φ8 φ10 φ12 φ15

Unit : N⋅m{kgf⋅cm}

Hose outer diameter

φ10.5 fitting

21.5±1.5{215±15}

Only meter gauge

10{100}

Hose outer diameter

φ13, φ20, φ22, fitting at

packing

41.5±2.5{425±25} —

Hose outer diameter

PF3/8 fitting

Brake hose

3. Lock nut tightening torque of brass joint

Screw nominal

size

Tightening

torque

15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}

Packing

51.5±7.5{525±75}

M12 M16 M20 M27

——

Unit : N⋅m{kgf⋅cm}

GENERAL 1–15

Removal of joint (Example: Use of magnetic valve)

Magnetic valve

Frame

1/4 turn

Amount of application: 0.1 g/piece

3 threads

Air pipe (Flare joint)
(No application of sealant)

Since sealant is
applied to this area,
remove accessories
with the joint

Air hose

attached and
remove the joint.

SAPH311990100016

SAPH311990100017

1 thread

Taper thread sealant for piping

JP31199010102006

The taper thread of the air pipe joint has application of sealant

[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for

connection or disconnection of pipes.

1. For disconnection

(1) The sealant ( # Loctite 575) has strong sealing feature.

The return torque of the taper joint is increased about 1.5

times the initial tightening torque. When the joint is

disconnected, use a long wrench for disconnection.

(2) When a joint at a poorly accessible area is replaced,

remove accessories first and disconnect the joint.

2. For connection

(1) For application of sealant ( # Loctite 575), wipe the

sealing area completely with a rag or thinner. Apply

sealant directly to about three ridges for quarter round

with offset of one ridge from the end. Tighten it according

to the tightening torque in the table below.

Remove dirt completely from the mating part (female)

before tightening.

!CAUTION

• If your eye or skin comes in contact with

sealant, wash it off immediately with water.

Tightening torque of taper joint Unit : N⋅m{kgf⋅cm}

Screw

diameter

1/4 3/8 1/2

Material

Steel 49±10{500±100} 64±15{650±150}

Aluminum,

brass

25±5{250±50} 34±5{350±50} 44±5{450±50}

(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).

!CAUTION

• Be careful to prevent entry of dirt or foreign

matter in the pipe.

(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional

tightening. Assemble the part again according to (1) and

(2).

GENERAL1–16

Assembly of joints and gaskets for piping

JP31199010102007

1. Tightening torque of joints

Unit : N⋅m{kgf⋅cm}

Sealing method

Tightening screw

size

M8 13{130}

M10 20{200} 11{110}

M12 25{250} 20{200}

M14 25{250} 31{320}

M16 29{300} 39{400}

M18 39{400} 59{600}

M20 *39{400} 64{650} 20{200}

M24 69{700}

Gasket sealing method

(Aluminum + Rubber or Copper)

(Flare pipe type, nipple connector type)

Metal sealing method

Type A Type B

M 28 * 12 7 {1 30 0}

2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,

gasket, etc.).

(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten

pipes finally after temporary tightening to prevent leak.

(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.

(4) Observe the values above for each tightening torque.

*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened

or removed, be sure to replace it with a new part. This is not necessary for normal retightening.

3. Examples of joint methods in various pipes

Sealing surface: 3 places

Nut

Connector nipple

Flare connector

Gasket

Sealing surface: 5 places

GENERAL 1–17

Metal sealing method

Gasket sealing method

Joint bolt

Gasket

Sealing surface
: 4 places

One piece eye joint
with sleeve

Gasket

Joint bolt

Sealing surface
: 8 places

Type A

(Flare pipe type)

Connector

Joint bolt

Gasket

Gasket

Lock washer

Nut

Sealing surface: 1 place

Type B

(Nipple connector type)

Flare pipe

Flare nut

Sealing surface
: 5 places

Nut

Bracket

Connector nipple

Sealing surface: 1 place

Flare connector

Box nut

Sealing surface
: 8 places

Joint pipe

One piece eye joint without sleeve

Joint bolt

Sealing surface: 4 places

Joint bolt

Nut

Lock washer

3-way joint

Bracket
Sealing surface
: 3 places

Sealing surface: 6 places

Joint pipe

GENERAL1–18

Handling of liquid gasket

JP31199010102008

1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent

deposit of oil, moisture, dirt, etc.

Be sure to overap parts at the beginning and at the end of application.

(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the

liquid gasket again if offset occurs.

(3) Assemble parts within 20 minutes after application of the liquid gasket.

If 20 minutes has passed, remove the liquid gasket and apply it again.

(4) Start the engine at least 15 minutes or more after assembly of parts.

2. Removal of parts

(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or

clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the

engine.

3. Others

(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in

a cartridge, use the application gun.

Tube: 150 g

Winding tool

Cartridge type: 300 g

Application gun

For a tube, desired application width may be obtained from the cut position at the nozzle end.

1 : Approx. 2 mm at the 1st section cut

2 : Approx. 5 mm at the 2nd section cut

Nozzle of tube

General informationDescrip tion of function

GENERAL 1–19

Failure diagnosis table for each problem

Engine mechanical

Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant

Engine overheat

(radiator)

Engine overheat (compression

pressure)

Engine overheat (lubrication

unit)

Large engine oil consumption

(piston, cylinder liner and piston

ring)

Large engine oil consumption

(valve and valve guide)

Large engine oil consumption

(others)

Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of

Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil

Piston seizure Abnormal combustion Refer to overheat section.

Piston seizure Cooling unit Refer to overheat section.

Causes and actions are described for each item.

Faulty thermostat Replace thermostat

Water leak from cooling system Correction

Faulty coolant pump Repair or replace

Faulty head gasket Replace head gasket

Clogging of radiator Cleaning of radiator

Corrosion of cooling system Clean and repair cooling system

Clogging of radiator core front part Clean radiator

Faulty radiator cap Replace radiator cap

Non-synchronous injection timing Adjust injection timing.

Faulty fuel injection pressure Adjust injection pressure

Faulty fuel Replace with correct fuel

Faulty injector Replace injector

Deterioration of engine oil Replace engine oil

Faulty oil pump Replace oil pump

Insufficient engine oil Replenish engine oil

Wear of piston ring and cylinder

liner

Damage to piston ring Replace piston ring and cylinder

Faulty fixing of piston ring Replace piston ring and cylinder

Faulty assembly of piston ring Replace piston ring and cylinder

Faulty engine oil Replace engine oil

Faulty piston ring joint Reassemble piston ring

Wear of valve stem Replace valve and valve guide

Wear of valve guide Replace valve guide

Faulty assembly of valve stem seal Replace stem seal

Excessive oil lubrication to rocker

arm

Faulty oil level gauge Replace with correct level gauge

Excessive filling of engine oil Fill with appropriate amount of oil.

Leak of engine oil Repair or replace the part of oil

Deterioration of engine oil Replace engine oil

Incorrect engine oil Replace with correct engine oil.

Low oil pressure Inspection of lubrication unit

Faulty oil pump Replace oil pump

JP31199010301001

JP03Z01020601001

Replace piston ring and cylinder

liner

liner

liner

liner

Inspection of clearance between

rocker arm and rocker arm shaft

leak.

engine

SAPH311990100031

GENERAL1–20

SAPH311990100032

Failure diagnosis using HinoDX

!CAUTION

1. HinoDX

(1) With HinoDX, failure of the common rail fuel injection

!CAUTION

• HinoDX is used for inspection and adjustment

of the system in addition to failure diagnosis.

system can be diagnosed. The interface box (Hino-Bowie)

and the special cable are required for connection to the

vehicle.

Special tool : 09121-1040 Hino-Bowie

09042-1220 Cable between vehicle and

Hino-Bowie

CD-ROM HinoDX

• Install the software of the Hino Diagnostic

eXplorer (HinoDX) in the PC. For the

installation method, refer to the instruction

manual accompanying the CD.

JP31199010301002

2. List of failure diagnosis tools

Part name Part No. External shape General description and function

PC

(DOS/V standard)

• Operating system (OS) : Windows95,

Windows98(IE5.0 or later),

Windows2000(SP3, IE5.0 or later),

WindowsXP(SP1a, IE6.0 or later)

—

• CPU and memory : Conditions that

assure operation of the above operating

system

• Display : 800 x 600, 256 colors or

more

Hino-Bowie

(Interface box)

09121 - 1040

Cable between

• PC interface

vehicle and Hino-

Bowie (09042 -

1220)

Signal check

harness

09049 - 1080

(for common rail fuel

injection system)

Interrupting installation between vehicle

harness and ECU allows inspection with a

tester rod while the power is supplied.

Unit harness

Test lead

SAPH311990100032

Signal check harness

GENERAL 1–21

3. Deletion of past failures

(1) To delete past failures of the engine ECU, use HinoDX on

the PC. (Refer to "HinoDX operation manual".)

4. Connection of signal check harness

(1) To prevent damage to the ECU connector and to improve

accessibility, connect the signal check harness and put a

testing rod on the signal check connector of the signal

check harness for meaurement.

a. Disconnect the connector from the ECU.

!CAUTION

• Do not break the locking tab of the connector.

b. Connect the signal check harness to the machine

harness and the ECU.

Signal check harness

(for common rail fuel injection system)

Part No.

09049-1080

Signal check connector

SAPH311990100036

GENERAL1–22

(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows :

ECU unit

Signal check
harness

ECU side Unit side

SAPH311990100038

GENERAL 1–23

Engine ECU

Connection method of HinoDX

JP31199010301003

1. Connection of HinoDX

(1) Remove the left side cover at the rear of the driver's seat

and connect the failure diagnosis connector with a PC

which installed HinoDX through the interface box.

Special tool : 09121-1040 Hino-Bowie (Interface box)

09042-1220 Connecting cable

CD-ROM HinoDX

(2) Set the starter key to "ON" and start HinoDX.

Failure diagnosis
connector

Failure diagnosis connector

Connect to the failure diagnosis
connector at the unit side.

(Example)

SAPH311990100039

Hino-Bowie

Connecting cable

SAPH311990100040

Stamp position

Setup layoutLayout

Chassis number and engine number

JP31199010401001

1. Engine type and engine number

(1) Engine type and engine number are stamped at the left

cylinder block when viewed from the cooling fan. For order

of parts, information of this number will facilitate

procedures smoothly.

SAPH311990100041

Ex. J05E TA10101

STANDARD VALUE 2–1

ENGINE

2 STANDARD VALUE

Specification (performan ce)System drawing

Engine Body................................................................ 2-2

Standard value........................................................ 2-2

Tightening torque....................................................2-2

Fuel System ................................................................ 2-2

Tightening torque....................................................2-2

Electrical...................................................................... 2-3

Standard value........................................................ 2-3

Tightening torque....................................................2-3

Intake ........................................................................... 2-3

Tightening torque....................................................2-3

Engine Mechanical ..................................................... 2-4

Standard value........................................................ 2-4

Tightening torque..................................................2-11

Exhaust...................................................................... 2-12

Tightening torque..................................................2-12

Cooling ...................................................................... 2-12

Standard value...................................................... 2-12

2

Lubrication................................................................ 2-12

Standard value...................................................... 2-12

Tightening torque..................................................2-14

Starting and Charging.............................................. 2-14

Standard value (Alternator 50A) .......................... 2-14

Tightening torque (Alternator 50A) ....................... 2-15

Standard value (starter)........................................ 2-15

Tightening torque (starter) .................................... 2-16

Turbocharger............................................................. 2-16

Standard value...................................................... 2-16

Tightening torque..................................................2-16

STANDARD VALUE2–2

Engine Body

Standard value

MPa {kgf/cm2, lbf/in.2}

Inspection item Standard value

Compression pressure

(Engine revolution per cylinder: 150 r/min)

3.4-3.7

{35-38, 493-237}

Repair

limit

—

Service

limit

2.7

{28, 392}

Tightening torque

Unit:N⋅m{kgf⋅cm, lbf⋅ft}

Tightening area Tightening torque Remark

Starter B terminal

Alternator B terminal

Oil pan drain cock 41 {420, 30}

7.8 - 8.8

{80 - 110, 5.8 - 6.5}

3.3 - 4.4

{33 - 45, 2.4 - 3.2}

JP31199020205001

Action

JP31199020205002

Radiator hose band

4.5 - 5.0

{45 - 50, 3.3 - 3.7}

Fuel System

Tightening torque

Tightening area Tightening torque Remark

Injector clamp 25 {250, 18}

Supply pump - Bearing holder case 28.5 {290, 21}

Bearing holder case - Pump drive 28.5 {290, 21}

Supply pump coupling flange mounting nut 63.7 {650, 47}

Injector harness 2.2 {22, 1.6}

Fuel filter air bleeding bolt 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}

JP31199020205003

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

STANDARD VALUE 2–3

Electrical

Standard value

JP31199020205018

Inspection item item item Standard value Remark

V-belt tension

adjustment

When installing

a new belt

At the time of

inspection

Deflection

Tension

Deflection

Tension

8 - 10mm {0.3152 - 0.394in.}

(Reference push force 98N

{10kgf, 22lbf})

490 - 570 N

{50 - 58 kgf, 110 - 128 lbf}

10 - 12mm {0.394 - 0.472in.}

(Reference push force 98N {10kgf,

22lbf})

320 - 400 N

{33 - 41 kgf, 72 - 90 lbf}

Compression

gauge (09444-

1210) is used.

Belt tension

gauge (95506-

00090 Denso

part No.) is

used.

Compression

gauge (09444-

1210) is used.

Belt tension

gauge (95506-

00090 Denso

part No.) is

used.

Tightening torque

Tightening area Tightening torque Remark

Starter mounting bolt 154 {1,570, 114}

Starter mounting nut 171.5 {1,750, 126}

Battery cable mounting nut 16 - 22 {165 - 225, 11 - 16}

Alternator through bolt 83 {850, 61}

E terminal bolt 3.2 - 4.4{33 - 45, 2 - 3}

Fixing bolt at brace 51{520, 38}

Outside B terminal mounting nut 3.2 - 4.4{33 - 45, 2 - 3}

Through bolt 7.8 - 9.8{80 - 99, 6 - 7}

Intake

Tightening torque

JP31199020205019

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

JP31199020205005

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

Tightening area Tightening torque Remark

Intake manifold mounting bolt 28.5 {290, 21}

STANDARD VALUE2–4

Engine Mechanical

Standard value

Unit : mm {in.}

Inspection item Standard value Repair limit Service limit Action

Valve clearance (cold)

Cylinder liner protrusion

Cylinder liner flange width 8 {0.314} ——

Cylinder block flange width 8 {0.314} ——

Cylinder block inner diameter

IN 0.30 {0.0118} ——

EX 0.45 {0.0177} ——

0.01 - 0.08

{0.003 - 0.003}

A

B

C

A

117 - 117.008

{4.6063 - 4.6066}

117.008 - 117.014

{4.6066 - 4.6068}

117.014 - 117.022

{4.6068 - 4.6072}

116.982 - 116.99

{4.6056 - 4.6059}

——

——

——

——

——

JP31199020205006

Cylinder liner outer diameter

Clearance between cylinder liner and

cylinder block

Cylinder liner inner diameter 112 {4.4094} —

Piston outer diameter

(Pin hole 23mm{0.9 in.} above the lower

end of the skirt Square direction)

Piston clearance

B

C

116.99 - 116.996

{4.6059 - 4.6061}

116.996 - 117.004

{4.6061 - 4.6064}

0.01 - 0.026

{0.0003 - 0.0010}

111.9±0.006

{4.4089±0.0002}

0.088 - 0.112

{0.0034 - 0.0044}

——

——

——

——

——

112.15

{4.4154}

Cylinder

Replace

liner

Cylinder

Liner

Replace

piston

STANDARD VALUE 2–5

Inspection item Standard value Repair limit Service limit Action

Piston

ring

Free joint clearance

Gap between ends

of piston ring

Ring width B

dimension

Top

Second

Top

Second

Oil

Top 2.5 {0.0984} —

Second 2 {0.0787} —

Oil 4 {0.1574} —

Top 2.5 {0.0984} —

Approx. 11.5

{0.4527}

Approx. 14

{0.5512}

0.3 - 0.40

{0.0118 - 0.0157}

0.75 - 0.9

{0.0295 - 0.0354}

0.15 - 0.3

{0.0059 - 0.0118}

——

——

— 1.5 {0.0591}

— 1.2 {0.0472}

— 1.2 {0.0472}

–0.1

{–0.0039}

–0.1

{–0.0039}

–0.1

{–0.0039}

+0.2

{+0.0079}

Replace

piston ring

Replace

piston ring

Piston

Piston ring groove

Clearance between

piston ring and

piston ring groove

Piston pin outer diameter 37 {1.4567} —

Piston boss inner diameter 37 {1.4567} —

Clearance between piston pin

and piston boss

Second 2 {0.0787} —

Oil 4 {0.1574} —

Top

Second

Oil

0.09 - 0.13

{0.0035 - 0.0051}

0.04 - 0.08

{0.00016 - 0.0031}

0.02 - 0.06

{0.0008 - 0.0024}

–0.002T - 0.025L

{0.0000 - 0.0010}

(T : Tightening

allowance,

L : Clearance)

——

——

——

—

+0.2

{+0.0079}

+0.1

{+0.0039}

–0.04

{–0.0015}

+0.05

{+0.0020}

0.05

{0.0020}

Replace

piston

Replace

piston ring

or piston.

Replace

piston pin

Replace

piston

Replace

piston pin

or piston

Connecting rod bushing inner diameter 37 {1.4567} —

+0.1

{0.0039}

Replace

connecting

rod bushing

Inspection item Standard value Repair limit Service limit Action

Connecting rod bushing oil clearance

STANDARD VALUE2–6

0.015 - 0.036

{0.0006 - 0.0014}

—

0.08

{0.0031}

Replace

piston pin

or

connecting

rod bushing

Crank

shaft

Crank pin outer diameter 65 {2.5590} —

Thickness of connecting rod

bearing

Connecting rod oil clearance

Crank journal outer diameter 80{3.1496} —

Thickness of main bearing 2.5 {0.2342} ——

Crankshaft oil clearance

2.0 {0.0787} ——

0.031 - 0.082

{0.0012 - 0.0032}

0.051 - 0.102

{0.0020 - 0.0040}

0.2 {0.0079} —

0.2 {0.0079} —

63.8

{2.5118}

78.8

{3.1024}

Replace the

crankshaft.

(Note 1)

Replace

bearing for

clearance of

0.3 or more

(Note 2)

Crank

Replace

shaft (Note

1)

Replace

bearing

(Note 2)

Center journal width 36 {1.4173} —

Thickness of thrust bearing 2.5 {0.2342} ——

Crankshaft end play

Crankshaft runout —

Crank pin width 34 {13.386} —

Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or

more. Replace crankshaft for wear of 1.20 or more.

Note 2 : Under-size bearing values are 0.25, 0.50, 0.75 and 1.00.

Connecting rod large end width 34 {1.3386} —

0.050 - 0.219

{0.0020 - 0.0086}

0.50

{0.0020}

0.15

{0.0059}

+1.00

{+0.039}

1.219

{0.0480}

—

+0.8

{+0.0315}

–0.8

{–0.0315}

Replace

crankshaft.

Replace

thrust

bearing or

crankshaft

Ground to

under-size

Replace

crankshaft

Replace

connecting

rod

Inspection item Standard value Repair limit Service limit Action

Connecting rod end play

STANDARD VALUE 2–7

Replace

0.20 - 0.52

{0.0079 - 0.0205}

— 1.0 {0.0394}

connecting

rod or

crankshaft

Cam

shaft

Camshaft journal outer

diameter

Camshaft bearing inner

diameter

Camshaft bearing oil

Clearance

Cam height

Cam lift

Camshaft journal width

(Rear journal)

Camshaft end play

Camshaft runout

40 {1.5748} —

40 {1.5748} —

0.020 - 0.063

{0.0008 - 0.0025}

IN 50.067 {1.9711} —

EX 52.104 {2.0513} —

IN 8.067 {0.3175} —

EX 10.104 {0.3978} —

33 {1.2992} ——

0.100 - 0.178

{0.0039 - 0.0070}

0.04

{0.0016}

——

——

— 0.1 {0.039}

–0.15

{–0.0059}

+0.15

{+0.059}

–0.08

{–0.0031}

–0.08

{–0.0031}

Replace

camshaft

Bearing

Replacemen

t

Replace

camshaft or

bearing

Replace

camshaft

Replace

camshaft

Replace

camshaft

Replace

camshaft

Rocker shaft outer diameter 22 {0.8661} —

Rocker arm bushing inner diameter 22 {0.8661} —

Rocker arm oil clearance

IN 7 {0.2756} ——

Valve stem outer diameter

EX 7 {0.2756} ——

IN 7 {0.2756} ——

Valve guide inner diameter

EX 7 {0.2756} ——

IN

Oil clearance between valve guide

and valve stem

EX

IN

Valve sink

EX

0.030 - 0.101

{0.00012 - 0.0040}

0.023 - 0.058

{0.0009 - 0.0020}

0.050 - 0.083

{0.0020 - 0.0033}

0.55 - 0.85

{0.0217 - 0.0335}

1.15 - 1.45

{0.0453 - 0.0571}

—

——

——

— 1.1 {0.0433}

— 1.7 {0.0669}

–0.08

{–0.0031}

+0.08

{+0.0031}

0.15

{0.0059}

Replace

rocker shaft

Replace

rocker arm

bushing

Replace

valve

Replace

valve guide

Replace

valve or

valve guide

Replace

valve and

valve seat

STANDARD VALUE2–8

Inspection item Standard value Repair limit Service limit Action

Valve seat angle

Valve face angle

Inner

Valve

spring

IN 30°

EX 45°

IN 30°

EX 45°

Set length

Set load

Free length

Squareness ——

Set length

44.8

{1.764}

129N

{13.1kgf, 29lbf}

64.6

{2.5433}

46.8

{1.8252}

Allowable angle 30° -

30°35'

Allowable angle 45° -

30°30'

Allowable angle 29°30 -

45°

Allowable angle 44°30 -

45°

——

——

—

——

–3.0

{–0.3543}

2.0

{0.0787}

Correction

Replace

spring

Replace

spring

Outer

Set load

Free length

Squareness ——

314N

{32.0kgf, 70lbf}

75.7

{2.9803}

——

—

–3.0

{–0.3543}

2.0

{0.0787}

Replace

spring

Replace

spring

STANDARD VALUE 2–9

Inspection item Standard value Repair limit Service limit Action

Backla

sh

Crank - Main idle

Main idle - Pump

drive idle

Pump drive idle -

Pump drive

Main idle - Sub-idle

Sub-idle - Oil pump

Sub-idle - Cam idle

Cam idle - Cam

Shaft outer diameter 57 {2.2441} ——

Bushing inner

diameter

0.030 - 0.167

{0.0012 - 0.0066}

0.032 - 0.096

{0.0013 - 0.0038}

0.020 - 0.083

{0.0008 - 0.0033}

0.030 - 0.113

{0.0012 - 0.0044}

0.030 - 0.113

{0.0012 - 0.0044}

0.050 - 0.218

{0.0020 - 0.0086}

0.030 - 0.253

{0.0012 - 0.0100}

57 {2.2441} ——

—

—

—

—

—

—

—

0.30

{0.0012}

0.10

{0.00393}

0.10

{0.00393}

0.30

{0.0012}

0.30

{0.0012}

0.30

{0.0012}

0.30

{0.0012}

Gear

replacement

Timing

gear

Main

idle

Sub-

idle

Clearance between

shaft and bushing

Gear width 44 {1.7322} ——

Shaft length 44 {1.7322} ——

End play

Shaft outer diameter 50 {1.9685} ——

Bushing inner

diameter

Clearance between

shaft and bushing

Gear width 22 {0.8661} ——

Shaft length 22 {0.8661} ——

End play

0.030 - 0.090

{0.0012 - 0.0084}

0.114 - 0.160

{0.0045 - 0.0063}

50 {1.9685} ——

0.025 - 0.075

{0.0010 - 0.0030}

0.040 - 0.120

{0.0016 - 0.0047}

—

—

—

—

0.20

{0.0079}

0.30

{0.0012}

0.20

{0.0079}

0.30

{0.0012}

Replace

shaft or

bushing

Replace

shaft or

gear

Replace

shaft or

bushing

Replace

shaft or

gear

STANDARD VALUE2–10

Inspection item Standard value Repair limit Service limit Action

Shaft outer diameter 34 {1.3386} ——

Timing

gear

Cam

idle

Pump

drive

idle

Bushing inner

diameter

Clearance between

shaft and bushing

Gear width 22 {8.6614} ——

Shaft length 22 {8.6614} ——

End play

Shaft outer diameter 34 {1.3386} ——

Bushing inner

diameter

Clearance between

shaft and bushing

Gear width 28.5 {1.1220} ——

34 {1.3386} ——

0.025 - 0.075

{0.0002 - 0.0030}

0.040 - 0.120

{0.0016 - 0.0047}

34 {1.3386} ——

0.025 - 0.075

{0.0002 - 0.0030}

—

—

—

0.20

{0.0079}

0.30

{0.0012}

0.10

{0.0039}

Replace

shaft or

bushing

Replace

thrust plate

or gear

Replace

shaft or

bushing

Shaft length 28.5 {1.1220} ——

End play

Flatness under cylinder head

Flatness above cylinder block

Surface runout of flywheel —

Camshaft gear mounting bolt ——31 {1.2205} Replacement

Bearing cap bolt (Crankshaft mounting) ——108 {4.2520} Replacement

Connecting rod bolt ——68.0 {2.6772} Replacement

long ——

0.016 - 0.22

{0.0006 - 0.0087}

Longitudinal

direction 0.06

{0.0024}

Square direction

0.03 {0.0012}

——

Grinding is

inhibited

because

backlash

between

cam idle –

sub-idle

gears is

changed.

Replacement

—

0.15

{0.0060}

0.20

{0.0079}

—

187.5

{7.3819}

Head bolt

middle ——

short ——

156.5

{6.1614}

126.5

{4.9803}

Replacement

Replacement

STANDARD VALUE 2–11

Valve timing

Exhaust valve open (before BDC) 54°

Exhaust valve close (after TDC) 13°

Intake valve open (before TDC) 14°

Intake valve close (after BDC) 30°

Tightening torque

JP31199020205007

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

Tightening area Tightening torque Remark

Cra nks h af t p ull ey m oun tin g b olt 118 {1 ,20 3, 87}

Head cover mounting bolt 28.5 {290, 21}

Camshaft bearing cap mounting bolt 28.5 {290, 21}

Union bolt of leakage pipe 13.5 {135, 10}

Injector harness mounting nut 28 {290, 21}

Camshaft gear mounting bolt 59 {600, 44}+90°

Rocker arm and crosshead adjusting screw lock

nut

Rocker arm support bolt 59 {600, 44}

Head bolt 59 {600, 44}+90°+90°

Cam idle gear shaft mounting bolt 108 {1,100, 80}

Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.

25 {250, 18}

Connecting rod cap mounting bolt 69 {700, 51}+90°+45°

Oil check valve 22 {220, 16}

Sub-idle gear shaft mounting bolt 108 {1,100, 80}

Main idle gear shaft mounting bolt 172 {1,750, 127}

Flywheel mounting bolt 186 {1,900, 137}

196 {2,000, 145} M16

Flywheel housing mounting bolt

Flywheel housing stay - Flywheel housing 171.5 {1, 750} M14

Rear end plate torx bolt 55 {560, 41}

Supply pump bearing case mounting bolt 28.5 {290, 21}

Air compressor idle gear shaft mounting bolt 108 {1,100, 80}

55 {560, 41} M10

36 {370, 27} M8

STANDARD VALUE2–12

Exhaust

Tightening torque

Tightening area Tightening torque Remark

Exhaust manifold mounting stud bolt 30 {300, 22}

Exhaust manifold mounting nut 53 {540, 40}

Cooling

Standard value

Inspection item

Thermostat valve open temperature

Thermostat valve lift

(Set temperature 95 °C)

Standard

value

74.5 - 78.5°C

{166.1 -

173.3°F}

10mm

{0.3937 in.} or

more

Repair

limit

——Replacement

——Replacement

Service

limit

JP31199020205008

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

JP31199020205009

Action

Standard value

Inspection item Standard value

Hydraulic alarm switch operation pressure

Lubrication

39kPa

{0.4kgf/cm

5.66lbf/in.

JP31199020205010

Unit : mm {in.}

Repair

limit

2

,

2

}

——

Service

limit

Action

STANDARD VALUE 2–13

Oil

pump

Inspection item Standard value

Outer diameter of drive gear 54 {2.1260} ——

Cylinder block side

Oil pump chamber inner diameter

Clearance between drive gear and

cylinder block

Drive gear width 28.5 {1.1220} ——

Cylinder block side

Depth of oil pump chamber

Drive gear end play

Outer diameter of driven gear shaft 18 {0.7087} ——

Cylinder block hole diameter 18 {0.7087} ——

Clearance between drive gear shaft outer

diameter and bushing inner diameter at

cylinder block side

54 {2.1260} ——

0.100 - 0.202

{0.0039 - 0.0080}

28.5 {1.1220} ——

0.049 - 0.113

{0.00193 - 0.0044}

0.040 - 0.099

{0.0016 - 0.0039}

Repair

limit

—

—

——

Service

limit

0.30

{0.0118}

0.15

{0.059}

Action

Replace drive

gear or oil pump

Replace drive

gear or oil pump

Replace drive

gear or bushing

Outer diameter of driven gear shaft 18 {0.7087} ——

Cylinder block hole diameter 18 {0.7087} ——

Clearance between driven gear shaft

outer diameter and cylinder block hole

diameter

Outer diameter of driven gear shaft 18 {0.7087} ——

Inner diameter of driven gear bushing 18 {0.7087} ——

Clearance between driven gear shaft

outer diameter and gear bushing inner

diameter

Backlash between drive gear and driven

gear

0.030 - 0.075

{0.0012 - 0.0030}

0.040 - 0.083

{0.016 - 0.0033}

0.072 - 0.277

{0.0028 - 0.0109}

——

—

—

0.15

{0.059}

0.30

{0.0118}

Replace oil

pump

Replace oil

pump or

bushing

Replace oil

pump

STANDARD VALUE2–14

Tightening torque

JP31199020205011

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

Tightening area Tightening torque Remark

Oil pa n m oun tin g b olt 30 {30 0, 2 2}

Oil st r ai n er 31 {32 0, 2 3}

Oil pa n d rai n c ock 41 {42 0, 3 0}

Oil pump mounting bolt 28.5 {290, 21}

M14 24.5±4.9 {250±50, 18±4 }

M20 24.5±4.9 {250±50, 18±4 }

Oil cooler

Oil circuit spring plug

Coolant drain plug 44.1±4.9 {450±50, 33±4}

Oil cooler case assembly mounting bolt 24.5±4.9 {250±50, 18±4 }

M22 29.4±4.9 {300±50, 22±4 }

M24 34.3±4.9 {350±50, 25±4 }

Starting and Charging

Standard value (Alternator 50A)

JP31199020205012

Inspection item

Resistance between stator coil terminals (for

2 phases)

Resistance between stator coil core and coil

Resistance of feed coil 5.6 - 6.8Ω ——Replacement

Resistance between feed coil core and coil

Shaft outer diameter of

rotor assembly

Resistance between

diode and rectifier holder

Front

Rear

Forward

resistance value

Reverse

resistance value

Standard

value

0.22 - 0.26Ω ——Replacement

1MΩor

more

1MΩor

more

25mm

{0.9843 in.}

17mm

{0.6693 in.}

Approx.

10Ω

Infinite ——

Repair limit

——Replacement

——Replacement

—

—

——

Service

limit

24.98mm

{0.9835 in.}

16.98mm

{0.6685 in.}

Action

Replacement

Replacement

Resistance between

regulator terminals F —

E

Forward

resistance value

Reverse

resistance value

Approx.

10Ω

Infinite ——

——

Replacement

STANDARD VALUE 2–15

Tightening torque (Alternator 50A)

Unit : N⋅m{kgf⋅cm, lbf⋅ft}

Tightening area Tightening torque Remark

Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}

Pulley mounting nut 127 - 157 {1, 300 - 1, 600, 94 - 116}

Feed coil - Rear bracket 2.9 - 3.9 {30 - 39, 2 - 3}

Heat sink mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}

Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}

Inside B terminal mounting nut 4.9 - 5.9 {50 - 60, 4 - 4}

Front side - Rear side mounting bolt 7.8 - 9.8 {80 - 99, 6 - 7}

Coupler holder mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}

Cover mounting bolt 3.3 - 4.4 {34 - 44, 2 - 3}

Standard value (starter)

JP31199020205013

Screw lock is

used

JP31199020205014

Unit : mm {in.}

Yoke

assembly

Armature

assembly

Holder

assembly

Shaft

assembly

outer

diameter

Inspection item

Resistance between coil lead

wire and yoke

Brush length 18 {0.7087} 13 {0.5118} or less Replace brush

Resistance between

commutator and core

Commutator outer diameter 36{1.4173} 34 {1.1458} or less

Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less

Shaft outer diameter B 9 {0.3643} 8.98 {0.3535} or less

Undercut depth

Resistance between holder

and plate

Brush length 18 {0.7087} 13 {0.5118} or less Replace brush

A 26 {1.0236} 25.90 {1.0197} or less

B 12.1 {0.4764} 12.04 {4.7401} or less

Standard

value

— 1kΩor less

1MΩor more 1kΩor less

0.5 - 0.8

{0.0197}

— 1kΩor less

Service limit Action

0.2{0.0079} or less Correction

Replace yoke

assembly

Replace armature

assembly

Replace holder

assembly

Replace shaft

assembly

Clutch assembly inner sleeve outer

diameter

Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush

Metal bushing inner diameter of center

bracket

25 {0.9843} 24.90 {0.9803} or more Replacement

26 {1.02362} 26.2 {1.0315}

Replace center

bracket

STANDARD VALUE2–16

Inspection item

Metal bushing inner diameter of shaft

assembly

Bearing housing inner diameter of rear

bracket

Start

magnet

switch

assembly

Between C terminal and M

terminal (P coil)

Between C terminal and body

(H coil)

Standard

value

9 {0.3543} 9.2 {0.3622}

28 {1.1024} 28.1 {1.1063} or more

0.12 - 0.15Ω —

1.13 - 1.25Ω —

Service limit Action

Tightening torque (starter)

Tightening area Tightening torque Remark

C lead wire mounting bolt 2 - 3 {19 - 25, 1 - 2}

M lead wire mounting nut 12.3 - 15.2 {126 - 154, 9 - 11}

Replace shaft

assembly

Replace

commutator end

frame

Replace start

magnet switch

assembly

JP31199020205015

Unit : N⋅m{kgf⋅cm, lbf⋅tt}

Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}

Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}

Start magnet switch assembly mounting bolt at

pinion case

Pinion case switch set bolts 14 - 16 {140 - 160, 10 - 12}

3.6 - 4.9 {37 - 49, 3 - 4}

Turbocharger

Standard value

Inspection item

Axial direction 0.1 {0.0039} ——

Turbine shaft play

Diameter direction 1.0 {0.0397} ——

Tightening torque

Standard

value

Repair limit Service limit Action

JP31199020205016

Unit : mm {in.}

JP31199020205017

Unit : N⋅m{kgf⋅cm, lbf⋅tt}

Tightening area Tightening torque Remark

Turbocharger mounting nut 56 {570, 41}

PARTS TO BE PREPARED 3–1

ENGINE

3 PARTS TO BE PREPARED

Special tool (SST)Special tool

Engine Body................................................................ 3-2

Special tool ............................................................. 3-2

Fuel System ................................................................ 3-2

Lubricant, etc. ........................................................ 3-2

Electrical...................................................................... 3-2

Special tool ............................................................. 3-2

Engine Mechanical ..................................................... 3-3

Special tool ............................................................. 3-3

Instruments ............................................................. 3-6

Lubricant, etc. ........................................................ 3-6

Lubrication.................................................................. 3-6

Special tool ............................................................. 3-6

Lubricant, etc. ........................................................ 3-6

3

Starting and Charging................................................ 3-7

Jig (reference dimensional drawing for manufacture)

................................................................................ 3-7

Instruments ............................................................. 3-8

Lubricant, etc. ........................................................ 3-8

Turbocharger............................................................... 3-8

Special tool ............................................................. 3-8

Engine Failure Diagnosis........................................... 3-9

Special tool ............................................................. 3-9

PARTS TO BE PREPARED3–2

Engine Body

Special tool

Shape Part No. Description Remark

JP31199030901001

09491–1010 Wire rope For engine lifting

09552–1030 Compression gauge adapter

09552–1060 Compression gauge adapter

09552–1110 Compression gauge adapter

Fuel System

Lubricant, etc.

Name Remark

Guide pin (SZ105-08067) For supply pump positioning

Electrical

Special tool

Shape Part No. Name Remark

09444–1210 Compression gauge

95506–00090

(Denso part No.)

Belt tension gauge

JP31199030901002

JP31199030901003

For V–belt tension

adjustment

For V–belt tension

adjustment

PARTS TO BE PREPARED 3–3

Engine Mechanical

Special tool

Shape Part No. Name Remark

09420–1731 Oil seal puller

09407–1030 Oil seal press

09433–1070 Eye bolt

JP31199030901004

For crankshaft front oil seal

removal

For crankshaft front oil seal

press-fit

For assembly/disassembly

of cylinder head

09470–1170 Valve spring press

09471–1520 Guide For valve guide press-fit

09472–1210 Bar For nozzle seat clamping

9800–06100 Steel ball

09431–1020 Valve lapping tool For valve adjustment

For assembly/disassembly

of valve spring retainer

For nozzle seat clamping

(together with 09472–1210)

PARTS TO BE PREPARED3–4

Shape Part No. Name Remark

09472–2100 Bar

09420–2100 Cylinder liner puller

09442–1011 Piston ring expander

9191–08252 Bolt

For valve stem seal

mounting

For removal and inspection

of cylinder liner

For assembly/disassembly

of piston ring

For mounting of connecting

rod small end bushing

(together with 09402–1480

or 09402–1540)

09402–1530 Press sub-assembly

9233–10360 Wing nut

09481–1130 Guide

09402–1540 Spindle

For assembly/disassembly

of connecting rod small end

bushing

For assembly/disassembly

of connecting rod small end

bushing (together with

09402–1530)

For assembly/disassembly

of connecting rod small end

bushing (together with

09402–1530)

For assembly/disassembly

of connecting rod small end

bushing

09481–1540 Guide

For mounting of connecting

rod small end bushing

(together with 09402–1540)

PARTS TO BE PREPARED 3–5

Shape Part No. Name Remark

09441–1370 Piston ring holder For piston mounting

09481–1340 Guide

09420–1742 Oil seal puller

09420–1100

Sliding hammer

09420–1442

09411–1300 Socket wrench

For assembly/disassembly

of flywheel

For crankshaft rear oil seal

removal

For main/sub idle gear

assembly and cam idle gear

shaft removal

For assembly/disassembly

of Torx bolt

09407–1040 Oil seal press

09471–1490 Guide For insertion of cylinder liner

09472–1620 Tool For cooling jet repair

9001–24262 Check bolt

For crankshaft rear oil seal

press-fit

For cooling jet inspection

and adjustment

PARTS TO BE PREPARED3–6

Shape Part No. Name Remark

09470–1280 Tool assembly

For cooling jet inspection

and adjustment

Instruments

Name Remark

Micrometer For measurement of part outer diameter

Cylinder gauge For measurement of part inner diameter

Thickness gauge For measurement of each clearance

Dial gauge For measurement of parts

Lubricant, etc.

Name Remark

Liquid gasket (Threebond TB1207B or equivalent :

Black)

For sealing of parts

JP31199030901005

JP31199030901006

Liquid gasket (Threebond TB1207D or equivalent :

Silver)

Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Red lead Valve adjustment

Dye penetrant For inspection of crack

For sealing of parts

Lubrication

Special tool

Shape Part No. Name Remark

09503–1110 Oil filter wrench

Lubricant, etc.

JP31199030901007

JP31199030901008

Name Remark

Liquid gasket (Threebond TB1207D or equivalent :

Silver)

Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

For sealing of parts

PARTS TO BE PREPARED 3–7

Starting and Charging

Jig (reference dimensional drawing for manufacture)

This is used for assembly of bearing. Reference dimensions are shown in the figures below:

Jig B (Support jig) Unit : mm{in.}

φ25{0.984}

35{1.378}

φ50{1.969}

φ41{1.614}

φ19{0.748}

Jig A (Roller bearing insertion jig)

φ23{20.827}

1C{0.039}

+0.5{0.0196}

0

φ30{1.181}

Jig C Jig D

φ34{1.339}

1C{0.039}

50{1.964}

50{1.964}

10-20
{0.394 - 0.787}

JP31199030901009

70{2.756}

φ54{2.126}

φ60{2.362}

20{0.787}

40{1.575}

10{0.394} 10{0.394}

φ64{2.520}

φ70{2.756}

20{0.787}

40{1.575}

SAPH311990300034

PARTS TO BE PREPARED3–8

Instruments

Alternator

Name Remark

Circuit tester For measurement of parts

Micrometer For measurement of parts

Regulator checker (G&M Machinery ICD-101D or

equivalent)

Starter

Name Remark

Circuit tester For measurement of parts

Micrometer For measurement of part outer diameter

Growler tester For inspection of armature

Cylinder gauge For measurement of part inner diameter

For inspection of regulator

Lubricant, etc.

JP31199030901010

JP31199030901011

Name Remark

Kyodo Yushi Multemp AC-N For lubrication of parts

Nisseki Mitsubishi Pyroknock #2 For lubrication of parts

Turbocharger

Special tool

Shape Part No. Name Remark

09444-1800 Tool assembly

JP31199030901012

PARTS TO BE PREPARED 3–9

Engine Failure Diagnosis

Special tool

Shape Part No. Name Remark

– Personal computer (DOS-V)

Hi no DX

JP31199030901016

• Operating

system(OS):Windows95,

Windows98(IE5.0 or

later),

Windows2000(SP3,

IE5.0 or later),

WindowsXP(SP1a, IE6.0

or later)

• CPU and memory:

Conditions that assure

operation of the above

operating system

• Display: 800 x 600, 256

colors or more

Failure diagnosis software

(CD-ROM)

09121–1040 Hino-Bowie (Interface box)

09049–1080 Signal check harness

Used together with the

cable between the vehicle

and Hino-Bowie (09042-

1220)

This is installed as

interruption between vehicle

harness and the ECU.

Tester inspection is allowed

in energized status.

ENGINE ASSEMBLY/DISASSEMBLY 4–1

ENGINE

4 ENGINE ASSEMBLY/DISASSEMBLY

Service procedureOverhaul item

Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2

Engine Body................................................................ 4-4

Removal.................................................................. 4-4

Installation............................................................... 4-6

Work after installation ............................................. 4-6

4

ENGINE ASSEMBLY/DISASSEMBLY4–2

Inspection Before Service

Measurement of compression pressure

JP31199040702001

OTICE

1. Preparation before measurement

(1) Charge the battery completely.

(2) Check the valve clearance and adjust it when exceeding

(3) Warm the engine and set the water temperature to 80

(4) Remove the air cleaner.

(5) Remove the head cover.

(6) Remove all injectors.

(7)

• Measure the compression pressure before

disassembly of the engine and record the

result. Regular measurement of the

compression pressure can tell the engine

status.

the standard value.

°C{176°F}.

To prevent spread of engine oil, attach a jig which cuts a head

cover in half. (Cut it so that the camshaft may be covered.

Special
tool

Engine

SAPH311990400001

2. Measurement

(1) Attach a special tool to the nozzle sheet of the cylinder

where the compression pressure is measured with nozzle

clamp and clamp fixing bolts.

Special tool : Compression gauge adapter

Part No. Parts tightened

09952-1110

09552-1030

(3/4-16 UNF)

09552-1060

(W16 ridges 18)

Insert in the injector

mounting area

Adjusting to screw size of

air gauge, the adapter

which it selects

(2) Turn the starter and measure the compression pressure.

!CAUTION

• Do not operate the starter for 15 seconds or

more.

• Since the air cleaner is removed, prevent

entry of dirt.

ENGINE ASSEMBLY/DISASSEMBLY 4–3

(3) Measure the compression pressure of each cylinder

continuously.

Engine revolution 150r/min {rpm}

Compression pressure:

Unit MPa {kgf/cm

2

,lbf/in.2}

Standard value 3.4 - 3.7 {35 - 38 ,493 - 537}

Service limit 2.7 {28, 392}

Difference between

cylinders

0.3{3, 44} or less

(4) If the compression pressure is the service limit or less or if

the difference between cylinders is over the standard

value, overhaul the engine.

(5) After measurement, reassemble the removed parts.

ENGINE ASSEMBLY/DISASSEMBLY4–4

Engine Body

Right side of engine

Oil cooler drain plug

SAPH311990400002

Removal

JP31199040702002

1. Preliminary work before removal of engine

(1) Place the vehicle on a level ground.

(2) Block tires with scotch.

(3) Remove the battery cable from the battery minus terminal.

2. Drain of coolant and engine oil

(1) Drain coolant from the radiator drain cock and the oil

cooler drain plug.

OTICE

!CAUTION

• Removal of the filler cap facilitates quick

drain.

• Connection of an appropriate hose to the oil

cooler drain pipe facilitates drain of coolant

without spread.

• To prevent burn, drain coolant after the

temperature is sufficiently low.

• To dispose coolant, observe the specified

method (waste disposal) or the method with

attention to environment.

Intake manifold

Cylinder head
Cover

SAPH311990400003

(2) Drain engine oil from the oil pan drain plug as required.

!CAUTION

• To prevent burn, drain coolant after the

temperature is sufficiently low.

• Dispose coolant according to the specified

method (waste treatment) or with a method

considering the environment.

3. Removal of intake hose, intercooler hose and exhaust

pipe

(1) Loosen the clamp and remove the intake hose.

(2) Remove nuts and remove the exhaust pipe.

!CAUTION

• Close the opening of the intake manifold with

a packing tape to prevent entry of dirt inside

the engine.

ENGINE ASSEMBLY/DISASSEMBLY 4–5

SAPH311990400004

4. Disconnection of fuel hose

(1) Remove the fuel hoses (feed side and return side). Wrap

the removed hose with a plastic sheet with its end facing

upward to prevent spill of fuel.

!CAUTION

• Wipe spilled fuel with a rag.

Fan s hroud

Connector

Clip

Shackle

Cooling

Fan

SAPH311990400005

Within 30

Shackle

5. Disconnection of water, engine oil pipes, etc.

(1) Disconnect the hose between the radiator and the engine.

(2) Disconnect the car heater pipe.

(3) Disconnect the oil filter hose.

(4) Disconnect the fuel filter hose.

!CAUTION

• Wipe off spilled water and engine oil with

waste.

6. Engine lifting (Lifting the engine single unit)

(1) Place a commercially available shackle and a special tool

wire rope with the engine hanger.

Special tool : 09491–1010 Wire rope

(2) Keep a little slack of the wire rope.

!CAUTION

• Keep the wire inclination 30° from the vertical

line.

Image drawing

SAPH311990400006

SAPH311990400007

(3) When the wire is completely tense, make sure that the

wire is firmly engaged with the engine hanger. Then, lift

the engine slowly.

!CAUTION

• Work carefully so that the engine may not

come in contact with the frame and others.

ENGINE ASSEMBLY/DISASSEMBLY4–6

Filler cap

SAPH311990400008

Installation

1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.

Work after installation

1. Inspection of engine oil

(1) Make sure that the drain cock is closed.

(2) Pour engine oil.

(3) Check the amount of oil with an oil level gauge.

Engine oil amount (L{us gal})

Oil pan Oil filter and etc

Approx. 18{4.76} Approx. 2.5{0.66}

!CAUTION

Multi grade SAE #10W-30

• Please use Hino genuine engine oil

JP31199040702003

JP31199040702004

Priming pump

Air bleeding bolt

Drain valve

SAPH311990400009

Single grade SAE #30

2. Air bleeding of fuel system

(1) Prepare a rag to receive fuel at the end of the drain valve.

(2) Loosen the air bleeding plug of the fuel filter.

(3) The priming pump is moved front and back.

(4) Move the pump until fuel without bubble comes out from

the drain valve.

(5) Tighten the air bleeding bolt.

Tightening torque :

1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}

(6) Move the priming pump again until it becomes heavy.

!CAUTION

• After work, wipe off spilled fuel. After start of

the engine, make sure that there is no fuel

leak.

FUEL SYSTEM 5–1

ENGINE

5 FUEL SYSTEM

Setup layoutLayout

Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2

Part layout .............................................................. 5-3

Fuel filter drain (on machine main unit)................... 5-5

Replacement of fuel filter element

(on machine main unit) ........................................... 5-6

Replacement of supply pump ................................ 5-9

Inspection of supply pump .................................... 5-11

Replacement of injector ........................................ 5-12

Inspection of injector............................................. 5-13

Replacement of common rail ................................ 5-14

Inspection of common rail.....................................5-14

5

FUEL SYSTEM5–2

Fuel System

Fuel system diagram

Feed pipe

Pressure limiter

Flow damper

Common rail

Injection pipe

Supply pump

Overflow pipe

JP31199050402001

Injector

Leakage pipe

Through feed pipe

Fuel filter

Fuel tank

SAPH311190500001

FUEL SYSTEM 5–3

Part layout

JP31199050402003

11195

11334

11491A

22100

Nozzle clamp holder

Bearing holder case

Common rail bracket

Supply pump

*Parts not to be reused.

Tightening torque

22825

900124

900124A

9068-08250

63.7N⋅m {650 kgf⋅cm, 47lbf⋅ft}

108N⋅m {1,100 kgf⋅cm, 80lbf⋅ft}

25N⋅m {250 kgf⋅cm, 18lbf⋅ft}

28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}

23670

23810

9645A

9851A

9068-08320

9068-08400

9068-08850

SAPH311190500002

Injector

Common rail assembly

O–ring*

O–ring*

28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}

28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}

28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}

FUEL SYSTEM5–4

23081

23711

23712

23713

23714

23783A

23816

Leakage pipe

Injection pipe

Injection pipe

Injection pipe

Injection pipe

Fuel pipe

Through feed pipe

*Parts not to be reused.

Service procedureReplacement procedure item

23816A

23816B

9659B

9659C

9659D

9659E

SAPH311190500003

Through feed pipe

Through feed pipe

Gasket*

Gasket*

Gasket*

Gasket*

FUEL SYSTEM 5–5

Priming pump

Air bleeding bolt

Drain valve

SAPH311190500004

Fuel filter drain (on machine main unit)

JP31199050704001

1. Prepare a water container under the drain pipe.

2. Loosen the fuel filter air bleeding bolt and the drain valve.

Discharge water at the bottom of the fuel filter case.

!CAUTION

3. Close the drain valve.

4. Start the priming pump and bleed air from the system.

!CAUTION

5. Tighten the fuel filter air bleeding bolt.

!CAUTION

• Since discharged water contains fuel,

observe the local disposal procedure for

disposal.

• Make sure that the fuel filter air bleeding bolt

is loose.

Tightening torque :

1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}

• After work, wipe off spilled water or fuel. After

start of the engine, make sure that there is no

fuel leak.

FUEL SYSTEM5–6

Replacement of fuel filter element (on machine main unit)

!CAUTION

1. Removal of water cup

(1) Refer to "Drain of the fuel filter" and discharge water from the fuel filter.

(2) Remove the water cup of the fuel filter.

!CAUTION

2. Removal of fuel filter element

(1) Remove the fuel filter element.

!CAUTION

• The frequency for water draining and replacement of the fuel filter element differs

according to the fuel situation in the use region.

Replace the fuel filter element every 500 hours or when the engine output decreases,

whichever occurs first.

• Inspection of the fuel filter element and draining of water should be performed before each

start of operation.

• Always use an original fuel filter element.

• Completely remove any dust around the water cup.

• Completely remove any dust around the fuel filter head and especially around the air vent

bolt.

JP31002050704002

• Since the filter contains diesel oil, prepare a tray.

FUEL SYSTEM 5–7

3. Installation of fuel filter element

!CAUTION

• Fuel filter element is not reused.

(1) The soiling and the foreign material of the clamp face are removed.

(2) Install the fuel filter element with according to tightening angle in the table below of a turn after the O-ring

of the fuel filter element comes into contact with the fuel filter head.

OTICE

• The cross-section shape of the O-ring on the side of the fuel filter element has been

changed.

!CAUTION

• Tighten after confirming whether the O-ring is a new or an old one.

• As the O-ring is included in the element kit, do not use an O-ring again after it has been

removed once.

• Install the O-ring after applying fuel to the surface of the O-ring.

• Do not use a tool, but tighten by hand.

Fuel filter head

O-ring

Fuel filter element

عCross section shapeععTightening angleع

(Image with the fuel filter seen from below)

Old New

Old New

3/4

1࡮1/2

New/Old Cross section shape Tightening angle

Old supply part 3/4 to 1.5 turns

New supply part 1/2 turn

1/2

SAPH311190500005

4. Installation of water cup

!CAUTION

• Fuel filter element is not reused.

• Install the O-ring after applying fuel to the surface of the O-ring.

• Do not use a tool, but tighten by hand.

FUEL SYSTEM5–8

Fuel filter element

عTightening angleع

(Image with the fuel filter seen from below)

O-ring

Water cup





SAPH311190500008

(1) Install the fuel filter element with 1/2 to 3/4 of a turn after the O-ring of the water cup comes into contact

with the fuel filter element.

(2) Tighten the fuel filter drain valve.

5. Bleeding air from the fuel system

(1) Start the priming pump and bleed air from the system.

!CAUTION

• Make sure that the fuel filter air bleeding bolt is loose.

(2) Tighten the fuel filter air bleeding bolt.

Tightening torque :

1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}

!CAUTION

• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel

leak.

FUEL SYSTEM 5–9

Flywheel

Flywheel housing

1

SAPH311190500009

Close
contact

Replacement of supply pump

JP31199050704003

1. Compression upper dead center setting of No.1 cylinder

(1) Turn the crankshaft counterclockwise when viewed from

the flywheel. Set the timing mark in the flywheel housing

inspection window to "1".

(2) Remove the inspection window plug in the bearing holder

case of the supply pump. Tighten the guide pin (SZ105-

08067) very gently and make sure that the bolt seating

comes in close contact with the bearing holder.

!CAUTION

• If it is raised, there must be contact other than

the stopper key for the coupling flange. Do

not tighten hard.

Pipe A

Supply pump

Supply pump

O-ring

Raised

SAPH311190500010

SAPH311190500011

2. Removal of supply pump

(1) Remove the fuel pipe connected to the supply pump.

!CAUTION

• Do not remove pipes A.

(2) Remove the supply pump at the bearing holder case.

(3) Remove the drive gear using the special tool designed for

that purpose.

Special tool : 09650-1101 Bearing puller

3. Assembly of supply pump and bearing holder case

(1) Fit a new O-ring to the supply pump and install the

bearing holder case.

Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}

Bearing holder case

Bolt

SAPH311190500012

SAPH311190500013

FUEL SYSTEM5–10

(2) Secure the supply pump, install the injection pump drive

gear on the shaft, and use a vice or similar to prevent

turning while tightening the nut.

Tightening torque : 63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}

!CAUTION

• Do not use the guide bolt for stopper key of

the shaft.

4. Installation of supply pump

(1) Match the match mark of the bearing holder case with the

missing tooth of the injection pump drive gear.

Supply pump

O-ring

SAPH311190500014

SAPH311190500015

(2) Install a new O-ring and mount the air compressor and

supply pump assembly on the flywheel housing.

Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}

!CAUTION

• Adjust the gear so that the compression top

dead center alignment of the No.1 cylinder

may not be changed.

• Be sure to remove the guide bolt in cranking

the engine.

• After assembly, be sure to remove the guide

bolt and install the inspection window plug.

5. Update of supply pump learning value

(1) When the supply pump is replaced, update the learning

value memorized in the engine ECU with the failure

diagnosis tool (HinoDX) using PC. (Refer to "HinoDX

operation manual".)

!CAUTION

• If learning value is not updated, correct

common rail pressure is not controlled,

resulting in engine stall or high common rail

pressure. Therefore, when the supply pump is

replaced, be sure to update the learning

value.

FUEL SYSTEM 5–11

Fuel temperature
sensor

Suction control
valve

SAPH311190500016

Inspection of supply pump

JP31199050704004

1. Inspection of suction control valve and fuel temperature

sensor

(1) Measure the resistance of the suction control valve

terminals and the fuel temperature sensor terminals using

a circuit tester. If it is beyond the standard, remove the

supply pump assembly and request for replacement at the

Denso service shop.

B et w ee n s u ct i o n c on t ro l v a lv e t e rm i n al s

Standard

value

Te r m in a ls b et w ee n f u e l t em p er at u re

Standard

value

7.65 - 8.15Ω(at 20°C {68°F})

sensors

13.5 - 16.5kΩ(at -20°C{68°F})

2.2 - 2.7kΩ(at 20°C{68°F})

0.29 - 0.35kΩ(at 80°C{176°F})

FUEL SYSTEM5–12

Fixing bolt

Nozzle clamp
holder

Injector

Injection pipe
oil seal

O-ring

Injection pipe

Replacement of injector

JP31199050704005

1. Removal of injector

(1) Remove the fixing bolt and remove the plate and the

injection pipe oil seal.

(2) Remove the nozzle clamp holder and remove the injector.

2. Installation of injector

(1) Attach a new O-ring to the groove of the cylinder head and

insert the injector.

!CAUTION

(2) Install the nozzle clamp holder and tack weld the injector

!CAUTION

(3) Put a new injection pipe oil seal on the injector and install

!CAUTION

• Apply engine oil to the O-ring and be careful

to prevent pinching of the O-ring.

temporarily.

• Do not fix the nozzle holder until the injection

pipe is tack welded.

the plate.

• Install the injection pipe oil seal to prevent

undue force to the injection nozzle. (Offset

position between the injection pipe oil seal

and the injection nozzle may cause oil leak or

poor assembly of the injection pipe.)

QR code

SAPH311190500017

Injector

SAPH311190500018

(4) Assemble the injection pipe temporarily and tighten the

fixing bolt of the nozzle clamp holder.

Tightening torque : 25 N⋅m {250 kgf⋅cm, 1.8 lbf⋅ft}

3. Entry of injector correction value to the engine ECU (entry

using HinoDX and QR code reader)

!CAUTION

• When the injector is replaced, it is necessary

to enter the injector correction value (QR

code) described on the new injector to the

engine ECU. Incorrect entry of the correction

value may result in faulty engine.

OTICE

• Available entry methods of the injector

correction value are the PC tool and the QR

code reader.

• The flow of work is described in the following.

If you want details regarding any procedure,

however, refer to the PC Tools instruction

manual.

FUEL SYSTEM 5–13

(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.

(2) Enter the injector correction value directly from the PC

tools to the engine ECU.

PC

QR Code reader

Hino-Bowie

Engine-use code

QR code

New injector

<Cross-section view of injector head>

Terminal
(harness tightening area)

Injector harness
and rubber seal

Terminal cap (upper)

Terminal cap
(lower)

Connector

ECU

SAPH311190500019

Inspection of injector

1. Inspection of injector insulation

(1) Remove the injector plastic terminal cap (upper).

(2) Measure the insulation resistance between the injector

upper body and one terminal (no polarity) of two terminals

for the injector harness.

Standard value (normal

temperature)

(3) Measure the resistance value between two terminals

above.

Standard value (at 20°C) 0.45Ω±0.1

1000MΩor more

JP31199050704006

Upper body

SAPH311190500020

(4) If the resistance value in (2) and (3) exceeds the standard

value, replace the injector assembly.

2. Cleaning of injector

(1) Remove sludge at or around the terminal, if any.

!CAUTION

• In removing sludge, do not use a cleaning

agent. Wipe it off with a rag. Use of a cleaning

agent may result in electric failure due to

penetration of the agent.

FUEL SYSTEM5–14

Flow damper

Pressure sensor

Pressure limiter

SAPH311190500021

Replacement of common rail

JP31199050704007

1. Removal of common rail

(1) Remove the common rail together with the flow damper,

pressure sensor and pressure limiter from the intake

manifold.

!CAUTION

2. Installation of common rail

(1) Install the common rail on the intake manifold.

• Remove dirt around parts before removing

the common rail

SAPH311190500022

  

SAPH311190500023

Inspection of common rail

JP31199050704008

1. Inspection of common rail pressure sensor

(1) Measure the resistance value between terminals using a

circuit tester. If it exceeds the standard value, replace the

common rail assembly

Between 1 and 2 Between 2 and 3

Standard value

(kΩ)

At stop of

engine

0.5 - 3.0 6.5 - 18.5

ELECTRICAL 7–1

ENGINE

7 ELECTRICAL

Setup layoutLayout

Electrical System........................................................ 7-2

Part layout............................................................... 7-2

Layout of components.............................................7-5

Inspection of components....................................... 7-8

Installation of component...................................... 7-10

Installation of starter .............................................7-10

Installation of alternator ........................................7-11

7

ELECTRICAL7–2

Electrical System

Part layout

JP31199070402001

82051

83420

83530

Tightening torque

9190-06121

Injector harness

Water temperature sender gauge

Oil pressure warning switch

4N⋅m{40kgf⋅cm, 3lbf⋅ft}

89390

89410

89411

SAPH311990700001

Boost pressure sensor

Engine sub revolution sensor

Engine main revolution sensor

ELECTRICAL 7–3

12509

12511

27040

28100

Alternator brace

Alternator bracket

Alternator assembly

Starter assembly

Tightening torque

9069A

9011-64401

9189A

154N⋅m{1,570kgf⋅cm, 114lbf⋅ft}

83N⋅m{850kgf⋅cm, 61lbf⋅ft}

5.9N⋅m{60kgf⋅cm, 4lbf⋅ft}

9011-64410

9241-10107

9189A

9241-10107

9241-14147

SAPH311990700002

Through bolt

Fixing bolt at brace

Adjusting bolt

51N⋅m{520kgf⋅cm, 38lbf⋅ft}

154N⋅m{1,570kgf⋅cm, 114lbf⋅ft}

ELECTRICAL7–4

19110

SAPH311990700003

Glow plug

ELECTRICAL 7–5

Layout of components

Boost pressure sensor

JP31199070402003

Engine sub revolution sensor

Engine main revolution sensor

Engine revolution sensor

Common rail pressure sensor

Fuel temperature sensor
Suction control valve (SCV)

Left side view

SAPH311990700004

Coolamt temperature sender gauge

ELECTRICAL7–6

Oil pressure warning switch

Engine sub revolution sensor

Engine main
revolution sensor

Boost pressure sensor

Suction control valve (SCV)

Upper view

Fuel temperature sensor

SAPH311990700005

Coolamt temperature sender gauge

ELECTRICAL 7–7

Boost pressure sensor

Engine revolution sensor

Front view

Service procedureOverhaul item

SAPH311990700006

ELECTRICAL7–8

Oil pressure warning switch

39.2 - 58.8kPa
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in }

2.9kPa{0.3kgf/cm ,

4.7lbf/in }

Within

OFF

Toward pressure increase

SAPH311990700007

22

2

2

ON

Inspection of components

1. Inspection of oil pressure warning switch

(Laid out on the oil filter)

(1) Apply pressure with air or oil and check continuity

between terminals using a circuit tester. If it is faulty,

replace it.

At no load or less than 39kPa

{0.4kgf/cm

2

,5.6565lbf/in.2}

At 39kPa

{0.4kgf/cm

2

,5.6565lbf/in.2}

With continuity

Without continuity

JP31199070702001

Coolant temperature sender gauge

Connector color: Dark

A

C

B

SAPH311990700008

SAPH311990700009

2. Inspection of coolant temperature sender gauge

(Installation on thermostat case)

(1) Heat the coolant temperature sender gauge using hot

water.

(2) Measure the resistance between terminals using a circuit

tester. If it is faulty, replace the gauge.

Between A and C

Temperat

ure

(°C{°F})

Resistanc

e value

(Ω)

-20

{-68}

13.84 -

16.33

20

{68}

2.32 -

2.59

80

{176}

0.31 -

0.326

Between B and body

Temperat

ure

(°C,°F)

75

{167}

100

{212}

110

{230}

0.1399 -

0.1435

Resistanc

e value

(Ω)

79 - 92

35.5 -

42.5

Fuel temperature
sensor

SAPH311990700010

ELECTRICAL 7–9

3. Inspection of glow plug

(1) Measure continuity between the body and the terminal

using a circuit tester. If it is faulty, replace the glow plug.

Standard value

Resistance value :

Ω(Normal temperature

2.59 - 3.29

20°C{68°F})

4. Inspection of suction control valve SCV and fuel

temperature sensor

(1) For inspection and replacement of the suction control

valve (SCV) and the fuel temperature sensor, refer to the

chapter of "J05E FUEL SYSTEM ".

Suction control valve
(SCV)

SAPH311990700011

5. Inspection of common rail pressure sensor

(1) For inspection and replacement of the common rail

pressure sensor, refer to the chapter of "J05E FUEL

SYSTEM".

SAPH311990700012

6. Inspection of injector

(1) For inspection and replacement of the injector, refer to

the chapter of "J05E FUEL SYSTEM".

ELECTRICAL7–10

O-ring

Engine sub-revolution sensor

O-ring

Installation of component

JP31199070702002

1. Installation of engine revolution sensor

(1) Confirm that there are O-rings on the sensors and then

mount one sensor on top of the flywheel housing and one

on the cam housing.

OTICE

• Since this sensor is a flange type, gap does

not have to be adjusted.

Engine main revolution sensor

SAPH311990700013

SAPH311990700014

Installation of starter

JP31199070702003

1. Install the starter with bolts and nuts.

Tightening torque : 154 N⋅m {1,570 kgf⋅cm, 114 lbf⋅ft}

ELECTRICAL 7–11

Alternator
Pulley

Coolant Pump Pulley

㧭

Crankshaft
Pulley

SAPH311990700015

Installation of alternator

JP31199070702004

1. Installation of alternator

(1) Tighten the alternator temporarily using through bolts and

nuts.

(2) Tighten the adjusting bolts and fixing bolts temporarily.

2. V–belt tension adjustment

Item

Deflection

Tension

Special tool : 09444-1210 Compression gauge (used at

When installing a

new belt

8 - 10mm

{0.3152 - 0.394in.}

490 - 570 N

{50 - 58 kgf, 110 -

128 lbf}

At the time of inspection

10 - 12mm

{0.394 - 0.472in.}

320 - 400 N

{33 - 41 kgf, 72 - 90 lbf}

the time of measuring the deflection

amount) [Reference push force 98N {10kgf,

22lbf}]

95506-00090 (Denso part No.) Belt tension

gauge (used at the time of measuring the

tension force)

!CAUTION

• If the V-belt is replaced with a new one, it

becomes loose due to initial fitting. Run the

engine for three to five minutes and adjust the

tension of the belt again.

OTICE

• At the time of inspection, the new V-belt has

reached the value after complete initial

stretching. A new V-belt completes initial

stretching after running the engine for

approximately two hours.

(1) Tighten the through bolt of the commutator end frame.

Tightening torque : Through bolt

83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft}

(2) Tighten the lock nut on the brace side.

Tightening torque : Adjusting bolt

51 N⋅m {520 kgf⋅cm, 38 lbf⋅ft}

(3) Tighten the adjusting bolt and make sure the bolt is

locked.

Tightening torque : Adjusting bolt

5.9 N⋅m {60 kgf⋅cm, 4 lbf⋅ft}

(4) Securely connect the ground wire terminal for the

alternator.

Tightening torque : Adjusting bolt

4 N⋅m {40 kgf⋅cm, 3 lbf⋅ft}

ENGINE

8 INTAKE

Setup layoutLayout

Intake Manifold ........................................................... 8-2

Part layout............................................................... 8-2

Replacement........................................................... 8-4

INTAKE 8–1

8

INTAKE8–2

Intake Manifold

Part layout

JP31199080402001

17103

17111

*Parts not to be reused.

Tightening torque

9068-08320

9068-08550

Intake pipe

Intake manifold

28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}

28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}

17113

17171

9240-08087

SAPH311990800001

Intake pipe

Gasket*

28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}

INTAKE 8–3

17104A

Gasket*

*Parts not to be reused.

Service procedureReplacement proced ure item

17148

SAPH311990800002

Plate

INTAKE8–4

Protrusion

SAPH311990800003

Replacement

JP31199080704001

1. Removal of intake manifold

(1) Remove bolts and nuts and remove the intake manifold.

2. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.

(2) Assemble a new gasket.

!CAUTION

(3) Install the intake manifold and tighten it with bolts and

• Install the gasket so that the protrusion may

come at the rear end stud bolt of the cylinder

head.

nuts.

Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}

SAPH311990800004

3. Installation of intake pipe

(1) After removing contamination on the contact surface,

apply liquid gasket [Threebond TB1207B(black) or

equivalent] to the circumference of the contact surface.

!CAUTION

• Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to

2.5 mm {0.0591 to 0.09843 in.}

• Install the oil cooler within 20 minutes after

application of the liquid gasket.

(2) Install the intake pipe with bolts and nuts.

ENGINE MECHANICAL 9–1

ENGINE

9 ENGINE MECHANICAL

Setup layoutLayout

Cylinder Head ............................................................. 9-2

Part layout............................................................... 9-2

Replacement of cylinder head ................................ 9-4

Liquid gasket application procedure for semicircular

plug (only when semicircular plug is removed) ....... 9-7

Replacement of head cover.................................... 9-7

Overhaul of cylinder head....................................... 9-8

Cylinder Block .......................................................... 9-11

Part layout............................................................. 9-11

Overhaul ............................................................... 9-12

Timing Gear Cover and Flywheel Housing............. 9-16

Part layout............................................................. 9-16

Replacement of flywheel housing ......................... 9-17

Replacement of end plate ..................................... 9-17

Replacement of crankshaft front oil seal............... 9-18

Replacement of crankshaft rear oil seal................ 9-20

Main Moving Parts.................................................... 9-22

Part layout............................................................. 9-22

Replacement of piston and connecting rod .......... 9-23

Inspection of piston and connecting rod ............... 9-27

Replacement of connecting rod bushing...............9-29

Replacement of crankshaft ................................... 9-31

Inspection of crankshaft........................................ 9-33

Replacement of crankshaft pulley......................... 9-36

Replacement of flywheel ...................................... 9-36

9

Camshaft and Idle Gear ........................................... 9-39

Part layout............................................................. 9-39

Removal of camshaft ............................................ 9-40

Disassembly of camshaft...................................... 9-40

Inspection of camshaft and camshaft bearing ...... 9-41

Assembly of camshaft........................................... 9-42

Installation of camshaft......................................... 9-43

Gear train layout ................................................... 9-45

Removal of timing gear ........................................ 9-45

Inspection of timing gear components.................. 9-46

Installation of timing gear...................................... 9-47

Overhaul of sub-idle gear (bearing case side)...... 9-49

Inspection of installation status for each gear ...... 9-51

Valve System............................................................. 9-55

Part layout............................................................. 9-55

Overhaul of valve system...................................... 9-56

Adjustment of valve clearance .............................. 9-59

ENGINE MECHANICAL9–2

Cylinder Head

Part layout

JP31199090402001

11101

11122

11131

*Parts not to be reused.

Cylinder head assembly

Val ve guide

Intake valve seat

11135

11176

900115

SAPH311990900001

Exhaust valve seat

Nozzle seat

O-ring*

ENGINE MECHANICAL 9–3

11115

11188

11201

11213

Cylinder head gasket

Semicircular plug

Cylinder head cover

Head cover gasket

*Parts not to be reused.

Tightening torque

11185

11185A

11185B

9068-08400

59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+90°

59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+135°

59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+180°

28.5N⋅m{290kgf⋅cm, 21lbf⋅ft}

Service procedureReplacement proced ure item

12108

12505

23074

9069B

9349A

SZ105

SAPH311990900002

Oil filler cap

Silent block

Injection pipe oil seal*

59N⋅m{600kgf⋅cm, 44lbf⋅ft}

30N⋅m{300kgf⋅cm, 22lbf⋅ft}

59N⋅m{600kgf⋅cm, 44lbf⋅ft}

ENGINE MECHANICAL9–4













Figure is an
example of work.















 













SAPH311990900003

SAPH311990900004

Replacement of cylinder head

JP31199090704001

1. Removal of cylinder head and head gasket

(1) First remove the head bolts 1 to 3.

(2) Then gradually loosen the head bolts 4 to 21 from the

outside to the inside (approx. 1/4 turn each time) and

remove them.

(3) Remove the cylinder head using a special tool and hoist.

Special tool : 09433–1070 Eye bolt

OTICE

• If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and

the cylinder block, and move the chisel

vertically so that the contact surface may not

be damaged. Then, separate the cylinder

head.

Underhead length

SAPH311990900005

2. Inspection of head bolt length

(1) Measure the underhead length of the head bolt (M12 only)

using vernier calipers. If it is beyond the service limit,

replace it with a new one.

Service limit (mm{in.}) 126.5{4.9803 in.}

Water hole seal ring

SAPH311990900006

ENGINE MECHANICAL 9–5

3. Installation of cylinder head gasket and liquid gasket

application procedure

(1) Cut the rear end plate gasket to be flush with the surface

of the cylinder block upper surface using a scraper.

(2) Install the cylinder head gasket on the cylinder block and

the flywheel housing.

!CAUTION

• Remove dirt, water or oil from the mounting

surfaces of the cylinder head and the cylinder

block before work.

• Never reuse the gasket. Otherwise, it may

damage the engine.

• The water hole seal ring of the cylinder head

gasket is susceptible to damage. Avoid

contact with hand or object.

• Before installation of the cylinder head

gasket, make sure that there is no fall of or

damage to the seal ring.

Application area of liquid gasket

Cylinder head

Cylinder
block

Clearance Clearance

SectionA-A

Liquid gasket

Flywheel
housing

Rear end plate

Clearance

The arrow
shape
area is
different
from the
actual
shape.

Application area of
liquid gasket

Small

Too small

Raised from upper
surface

SAPH311990900007

(3) Apply appropriate amount of liquid gasket [Threebond

TB1211 (white) or equivalent] to the cylinder head gasket

hole at the joint surface between the cylinder block and

the flywheel housing.

!CAUTION

• Apply the liquid gasket so that the surface of

the liquid gasket may be raised on the

cylinder head gasket.

• Install the oil cooler within 20 minutes after

application of the liquid gasket.

4. Installation of cylinder head

(1) Clean the head bolt seat at the cylinder head upper

surface and the cylinder head lower surface.

(2) Apply engine oil to the head bolt seat and the bolt thread.

Figure is an
example of work.

ENGINE MECHANICAL9–6

(3) Align the dowel pins of the cylinder block using a special

tool and hoist and mount the cylinder head.

Special tool : 09433–1070 Eye bolt









!CAUTION

• Before mounting the cylinder head, make

sure that there is no foreign matter in the

cylinder.

• When the cylinder head is mounted, be

SAPH311990900004

careful for engagement between the cam idle

gear and the sub-idle gear. (Contact of gear

teeth with undue force may cause impact

mark or chipping, resulting in abnormal noise

or missing tooth.)

OTICE

• Mounting of the cylinder head with guide bolt

can prevent displacement of the liquid gasket.

(4) Sequentially tighten head bolts (M12) 1 to 18 from the

center to the outside in the order shown in the figure.

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





















 





(5) After tightening, tighten head bolts 1 to 18 again from the

center to the outside.

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

(6) Mark the head parts of head bolts (M12) 1 to 18 with paint

in the same direction.

(7) Tighten head bolts (M12) 1 to 18 in tightening order for

SAPH311990900008

another 90°. (First time)

(8) Tighten head bolts (M12) 1 to 18 according to the same

procedure by the angles shown in the table. (Second time)

Paint mark

SAPH311990900009

SAPH311990900010

Tightening angle Head bolts No.

90° 1,2,7,8,9,10,15,16,17

135° 4,5,12,13

180° 3,6,11,14,18

(9) Make sure the head bolts that have the same tightening

angle markings have the same orientation.

!CAUTION

• If a bolt is turned excessively in retightening,

do not loosen it.

ENGINE MECHANICAL 9–7

(10) Tighten the remaining bolts (M10) 1 to 3 in the order

shown in the figure.

This just 3 tighten

SAPH311990900012

Semicircular plug







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

Liquid gasket application procedure for

semicircular plug (only when semicircular

plug is removed)

JP31199090704002

1. Remove liquid gasket from the cylinder plug and the

camshaft housing.

2. Coat the semicircular plugs at the front and rear of the

cylinder head with liquid gasket (Three Bond TB 1207B-

Black or equivalent), and install the semicircular plugs.

Liquid gasket
application region

bolt

Silent
Block

Cylinder
Head Cover

SAPH311990900013

Cylinder Head
Cover Gasket

3. Temporarily install the cylinder head cover with the gasket

attached, and execute a parallel adjustment of the

semicircular plugs.

!CAUTION

• Be sure to wipe protruding liquid gasket.

Replacement of head cover

JP31199090704003

1. Installation of head cover

(1) Wipe off the liquid gasket stuck to the sides of the

semicircular plugs on the front and rear ends of the

cylinder head.

(2) Wipe dirt (including liquid gasket) and oil on the joint

surfaces of the cylinder head cover and the camshaft

housing. Install a new head cover gasket on the cylinder

head cover.

SAPH311990900014

SAPH311990900015

ENGINE MECHANICAL9–8

(3) Coat the semicircular plugs with liquid gasket (Three Bond

TB 1207B-Black or equivalent) just before you install the

cylinder head cover.

!CAUTION

• Install the oil cooler within 20 minutes after

application of the liquid gasket.

Cylinder
Head cover

Cylinder
Head cover
gasket

Bolt

Silent block

Cylinder Head
cover lower
surface

Cylinder head

SAPH311990900016

(4) Put the cylinder head cover on the cylinder head and

tighten bolts.

Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}

OTICE

• Silent block the rubber is attached to the

spacer

Overhaul item

Overhaul of cylinder head

1. Cleaning of cylinder head

(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.

!CAUTION

• To remove carbon or other deposit, do not

damage the lower surface of the cylinder

head.

JP31199090702001

SAPH311990900017

Intake Exhaust

Lower surface of cylinder head

SAPH311990900018

2. Replacement of valve guide

(1) Remove the valve stem seal.

(2) Remove the valve guide using a brass bar or press.

(3) When a new valve guide is assembled, do not pry the end

in assembly and press fit using a special tool.

Special tool : 09471–1520 Guide

!CAUTION

• In press fit, be careful not to damage the

valve stem at the upper/lower ends of the

guide.

• In press fit, be sure to apply engine oil to the

circumference of the valve guide.

Backing
metal

Valve

Valv e seat

Electric welding

Cut three areas
from here.

SAPH311990900019

ENGINE MECHANICAL 9–9

3. Replacement of valve seat

!CAUTION

• The valve seat replacement procedure below

may damage the cylinder head depending on

the case. It is recommended that a request for

replacement be made to a machining vendor.

(1) If the valve seat is replaced, use an out-of-use valve.

After cutting three pieces from the valve circumference,

weld them to the valve seat.

!CAUTION

• Apply grease to protect the cylinder head

lower surface from welding spatter before

work.

(2) Put a backup metal (e.g. brass bar) at the valve stem

head and pull out the valve seat using a press.

(3) Remove welding spatter or dirt on the valve seat surface.

(4) Heat the cylinder head to approx. 80 to 100 °C and strike

the cooled valve seat into the mounting area of the

cylinder head.

SAPH311990900020

SAPH311990900021

SAPH311990900022

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

surface between the valve and the valve seat.

(6) Strike gently while turning the valve using a special tool

for adjustment.

Special tool : 09431–1020 Valve lapping tool

4. Replacement of nozzle seat

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

Then, put an appropriate bolt inside.

(2) Hit the bolt head using a hammer and pull out the nozzle

seat toward the the cylinder head upper part.

(3) Remove the O-ring from the cylinder head.

!CAUTION

• After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid

gasket or dirt.

Cylinder head

O-ring

Nozzle sheet

SAPH311990900023

ENGINE MECHANICAL9–10

(4) After attaching a new O-ring into the nozzle seat hole of

the cylinder head, apply the liquid gasket [Threebond

TB1211 (white) or equivalent] at the lower part of a new

nozzle seat and assemble it on the cylinder head.

!CAUTION

• Be sure to replace the O-ring with a new part.

Reuse may cause water leak or gas leak,

resulting in overheat or crack of the cylinder

head.

Bar

Steel ball

Stamp out and clamp

Nozzle seat

Cylinder
Head

SAPH311990900024

(5) Clamp the nozzle seat using a special tool.

Special tool : 09472–1210 Bar

9800–06100 Steel ball

5. Inspection of cylinder head

(1) Inspection of cylinder head distortion

a. Measure distortion of the cylinder head lower surface

and the manifold mounting surface using a ruler.

Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction

0.06{0.0024}

Square direction 0.03{0.0012}

0.2{0.0079}

SAPH311990900025

b. If the measurement value is beyond the service limit,

replace it.

!CAUTION

• Repair of the lower surface by grinding can

change backlash of the timing gear. Do not

grind it.

(2) Inspection of cylinder head crack

a. With dye penetrant test method (red check), make sure

that there is no crack or damage in the cylinder head.

Setup layoutLayout