Hino J08C-TP, J08C-TR Service Manual

1 INDEX

CHAPTER 3

ENGINE

Models: J08C-TP and J08C-TR

TROUBLESHOOTING...............................................................3- 1-3

SPECIAL TOOLS ......................................................................3- 2-1

ENGINE 3-1-1Models J08C-TP and J08C-TR

3-228E-05

3

ENGINE OVERHAUL CRITERIA ..............................................3- 3-1

DISMOUNTING THE ENGINE ASSEMBLY ..............................3- 4-1

REMOVAL OF THE ENGINE COMPONENT PARTS ...............3- 5-1

CAMSHAFT HOUSING AND CYLINDER HEAD......................3- 6-1

CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND

FLYWHEEL HOUSING ..............................................................3- 7-1

TIMING GEAR ...........................................................................3- 8-1

PISTON, CRANKSHAFT AND CYLINDER BLOCK.................3- 9-1

LUBRICATING SYSTEM ...........................................................3-10-1

COOLING SYSTEM...................................................................3-11-1

FUEL SYSTEM ..........................................................................3-12-1

AIR INTAKE AND EXHAUST SYSTEM ....................................3-13-1

ENGINE CONTROL SYSTEM...................................................3-14-1

ELECTRICAL PARTS................................................................3-15-1

AIR COMPRESSOR AND POWER STEERING PUMP............3-16-1

INSTALLATION OF THE ENGINE COMPONENT PARTS .......3-17-1

ENGINE TUNE-UP ....................................................................3-18-1

MOUNTING THE ENGINE ASSEMBLY ....................................3-19-1

LIQUID GASKET AND APPLICATION POINTS.......................3-20-1

POWER TAKE-OFF (IF FITTED) ..............................................3-21-1

1 page 1

3-1-2 ENGINE

Models J08C-TP and J08C-TR

TROUBLESHOOTING
(ENGINE)

Symptom Possible cause Remedy/Prevention

Engine overheating Coolant

● Insufficient coolant ........................................Add coolant

`

● Defective thermostat ..................................... Replace the thermostat

● Overflow of coolant due to leakage of ..........Repair

exhaust into cooling system

● Damaged rubber hose ..................................Replace rubber hose

● Coolant leakage due to deteriorated.............Replace rubber hose

rubber hose

● Coolant leakage from coolant pump .............Replace the coolant pump

● Coolant leakage from rubber hose ...............Retighten or replace clamp

connection

● Coolant leakage from cylinder head ............. Replace gasket

gasket

Coolant pump

● Bearing seizure .............................................Replace

● Damaged (corroded) vane ............................Replace vane

Radiator

● Clogged with rust and scale..........................Clean radiator

● Clogged with iron oxide due to leakage ........ Clean coolant passage and

of exhaust into cooling system correct exhaust leakage

● Coolant leakage ............................................Repair or replace radiator

● Damaged cooling fan .................................... Replace cooling fan

● Clogged radiator core due to mud or ............Clean radiator

other debris

● Defective radiator cap pressure valve ..........Replace radiator cap

Abnormal combustion

● Incorrect injection timing ...............................Adjust injection timing

● Reduced injection pressure .......................... Adjust injection pressure

● Poor fuel........................................................Use good quality fuel

● Poor nozzle spray .........................................Adjust or replace nozzle

● Unsatisfactory automatic timer......................Repair or replace timer

advance angle

1 page 1

ENGINE 3-1-3Models J08C-TP and J08C-TR

Symptom Possible cause Remedy/Prevention

Engine overheating Other problems

● Defective or deteriorated engine oil ..............Change engine oil

● Unsatisfactory operation of oil pump ............Replace or repair

● Insufficient oil ................................................Add oil

● Brake drag .................................................... Adjust

Severe operating conditions

● Lugging the engine ....................................... Operate engine properly

Excessive oil consumption Pistons, cylinder liners and piston rings

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

● Worn, sticking or broken piston rings............Replace piston rings and

● Insufficient tension on piston rings................Replace piston rings and

● Unsatisfactory break-in of piston rings..........Replace piston rings and

● Unsuitable oil (viscosity too low) ................... Change oil as required and

●

Incorrectly fitted piston rings (upside down)..

● Gaps of piston rings in line with each other ..Reassemble piston rings

Valves and valve guides

● Worn valve stem ...........................................Replace valve and valve guide

● Worn valve guide ..........................................Replace valve guide

● Incorrectly fitted valve stem seal...................Replace the stem seal

● Excessive lubricant on rocker arm ................ Check clearance of rocker arm

cylinder liner

cylinder liner

cylinder liner

cylinder liner

replace piston rings and
cylinder liner
Replace piston rings

and shaft

Excess oil feed

● Defective oil level gauge ............................... Replace oil level gauge

● Oil level too high ........................................... Drain excess oil

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3-1-4 ENGINE

Symptom Possible cause Remedy/Prevention

Excessive oil consumption Oil leakage from miscellaneous parts

● Oil leakage from oil seal................................Replace oil seal

● Cracks or blowhole in cylinder block.............Replace cylinder block

● Oil leakage from connections of oil lines ......Tighten connections of oil lines

● Oil leakage from oil cooler ............................ Replace oil cooler

● Oil leakage from oil pan gasket ....................Replace oil pan gasket

● Oil leakage from O-ring.................................Replace O-ring

●

Models J08C-TP and J08C-TR

Other problems

Overcooled engine ........................................

(low temperature wear)

Warm up engine before moving
vehicle

Check cooling system

NOTE: If oil consumption is excessive, the problems above will occur. Complaints from the

customer are often related to such problems.

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

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

3. The tail pipe is blackened with oil.

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

5. Lack of power.

6. Excessive blow-by gas.

Piston seizure Pistons, cylinder liners and piston rings

● Incorrect clearance between piston ..............Replace piston, piston rings

and cylinder liner and cylinder liner

● Unsatisfactory installation of piston pin.........Replace piston, piston rings,

cylinder liner and piston pin as
required

● Broken piston ring ......................................... Replace piston, piston rings

and cylinder liner

● Difference in expansion due to use of...........Replace piston, piston rings

wrong piston and cylinder liner

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ENGINE 3-1-5Models J08C-TP and J08C-TR

Symptom Possible cause Remedy/Prevention

Piston seizure Coolant

● Reduction in capacity of coolant pump .........Replace the coolant pump

(due to vane corrosion)

● Leakage of coolant........................................Repair

● Insufficient coolant ........................................Add coolant

● Dirty coolant ..................................................Clean and replace coolant

● Defective radiator..........................................Repair or replace the radiator

(coolant leakage, clogging)

● Defective rubber hose (leakage)...................Replace rubber hose

● Defective thermostat ..................................... Replace the thermostat

● Leakage of exhaust into cooling system ....... Repair

Operation

● Abrupt stoppage of engine after running ......Operate engine properly

at high speed

● Hill climbing using unsuitable gear ...............Select suitable gear

Oil

● Insufficient oil ................................................Add oil

● Dirty oil ..........................................................Change oil

● Poor quality oil .............................................. Replace with proper engine oil

● High oil temperature......................................Repair

● Low oil pressure............................................Repair

● Defective oil pump ........................................ Repair oil pump

● Reduced performance due to worn ..............Replace oil pump

oil pump

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

Abnormal combustion

● Use of defective fuel ..................................... Change fuel

● Incorrect injection timing ...............................Adjust injection timing

● Engine overheating .......................................See Symptom: “Engine

overheating”

1 page 1

3-1-6 ENGINE

Models J08C-TP and J08C-TR

NOTE: If piston seizure occurs, the problems above will occur. Complaints from the customer

are often related to these problems.

1. White smoke is emitted.

2. Lack of power

3. Excessive blow-by gas

Symptom Possible cause Remedy/Prevention

Lack of power Injection pump ............................................Refer to “FUEL INJECTION

PUMP”

Intake

● Clogged air cleaner.......................................Clean element or replace

element

Overheating ...............................................See Symptom: “Engine

overheating”

Fuel and nozzle

● Poor nozzle spray .........................................Adjust or replace injection

nozzle

● Nozzle clogged with carbon .......................... Clean nozzle

● Wear or seizure of nozzle .............................Replace nozzle

● Air in fuel system...........................................Repair and bleed air from fuel

system

● Clogged fuel filter .......................................... Replace element

● Use of poor fuel.............................................Use good quality fuel

Pistons, cylinder liners and piston rings

● Seized or wear of piston ............................... Replace the piston, piston rings

and liner

● Worn or broken piston rings,.........................Replace piston rings, piston

piston and cylinder liner and liner

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ENGINE 3-1-7Models J08C-TP and J08C-TR

Symptom Possible cause Remedy/Prevention

Lack of power Other problems

● Exhaust brake butterfly valve stuck...............Replace or repair exhaust

in half-open position brake

● Connecting rod bent......................................Replace or repair connecting

rod

● Exhaust pipe or muffler crushed ...................Replace exhaust pipe or

(increased back-pressure) muffler

● Breakage of turbine or blower.......................Refer to TURBOCHARGER in

CHAPTER 51

Leakage of exhaust Head gasket

● Fatigued gasket (aging) ................................Replace gasket

● Damage.........................................................Replace gasket

● Improper installation......................................Replace gasket

Head bolts

● Loose bolts....................................................Tighten bolts

● Elongated bolts .............................................Replace bolts

● Improper tightening torque or........................Tighten properly

tightening sequence

Cylinder block

● Cracking........................................................Replace cylinder block

● Surface distortion .......................................... Repair or replace

● Fretting of cylinder liner insertion portion ...... Replace cylinder block

(insufficient projection of cylinder liner)

Cylinder head

● Cracking........................................................Replace cylinder head

● Surface distortion .......................................... Repair or replace

Cylinder liners

● Cracking........................................................Replace cylinder liner

● Corrosion.......................................................Replace cylinder liner

● Insufficient projection of cylinder liner ........... Replace cylinder liner

1 page 1

3-1-8 ENGINE

Symptom Possible cause Remedy/Prevention

Leakage of exhaust Other problems

● Incorrect injection timing ...............................Adjust injection timing

Models J08C-TP and J08C-TR

NOTE: If leakage of the exhaust occurs, the problems above will occur. Complaints from the

customer are often related to these problems.

1. Lack of power.

2. The engine overheats.

3. The coolant is discolored.

Difficulty starting engine Electrical system

● Discharged battery........................................Charge battery

● Defective wiring in starter-circuit ................... Repair wiring of starter

● Loose or open-circuit battery cable...............Tighten battery terminal

● Breakdown of starter.....................................Replace starter

● Broken glow plug .......................................... Replace

Injection pump .............................................Refer to “FUEL INJECTION

Air cleaner

● Clogged element...........................................Clean the element or replace

Fuel system

● No fuel in tank ...............................................Supply fuel

● Clogged fuel line ...........................................Clean fuel line

● Air sucked into fuel system through .............. Tighten fuel line connections

fuel line connections

● Clogged fuel filter .......................................... Replace element

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

● Water in fuel..................................................Drain and clean fuel system

connections or replace battery
cable

PUMP”

the element

pressure line

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ENGINE 3-1-9Models J08C-TP and J08C-TR

Symptom Possible cause Remedy/Prevention

Difficulty starting engine Nozzles

● Seized nozzle................................................Replace nozzle

● Broken or fatigued nozzle spring .................. Replace spring

Oil system

● Oil viscosity too high .....................................Use proper viscosity oil, or

install an oil immersion heater
and warm up oil

Other problems

● Seized piston ................................................ Replace piston, piston rings,

and liner

● Seized bearing .............................................. Replace bearing and crankshaft

● Reduced compression pressure ...................Overhaul engine

● Ring gear damaged or worn ......................... Replace the ring gear and/or

accelerator cable starter pinion

● Improperly adjusted or broken ......................Adjust or replace the

accelerator cable

Rough idling Injection pump ............................................Refer to “FUEL INJECTION

PUMP”

Nozzles

● Uneven injection pressure ............................ Adjust

● Poor nozzle spray .........................................Adjust or replace nozzle

● Carbon deposit on nozzle tip ........................ Remove carbon

● Seized needle valve......................................Replace nozzle

Engine proper

● Improper valve clearance .............................Adjust valve clearance

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

valve seat

● Idling speed too low ......................................Adjust idling speed

● Coolant temperature too low.........................Warm up engine

● Compression pressure of cylinders...............Overhaul engine

markedly different from one another

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3-1-10 ENGINE

Symptom Possible cause Remedy/Prevention

Rough idling Other problems

● Clogged high pressure injection line ............. Replace line

● Leakage due to improper tightening ............. Tighten sleeve nut

● Improperly adjusted or broken ......................Adjust or replace accelerator

● Engine seizure ..............................................Replace pistons, piston rings

● Incorrect valve timing ....................................Replace camshaft

Models J08C-TP and J08C-TR

of high pressure injection line

accelerator cable cable

and liners

Diesel knock Injection pump...............................................Refer to “FUEL INJECTION

PUMP”

Nozzles

● Incorrect injection pressure...........................Adjust

● Poor nozzle spray .........................................Adjust or replace nozzle

● Sticking of nozzle .......................................... Check and/or replace

● Fatigued or broken nozzle spring .................Replace spring

Fuel system

● Use of poor fuel.............................................Use good quality fuel

● Fuel leakage into combustion chamber ........Adjust nozzles

(during engine starting)

Other problems

● Excessively cooled or heated engine ...........Warm up or cool engine

● Insufficient air intake .....................................Correct

● Insufficient compression pressure ................ Repair

● Compression pressure leaks at .................... Replace head gasket

cylinder head gasket

● Improper valve clearance or valve sticking ... Adjust or repair

● Tappet sticking .............................................. Replace tappet and camshaft

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ENGINE 3-1-11Models J08C-TP and J08C-TR

Symptom Possible cause Remedy/Prevention

Unusual engine noise Piston

● Wear of piston pin boss or piston pin............Replace piston and/or piston

pin

● Seized, damaged, or worn piston pin ...........Replace piston pin bushing.

bushing

● Worn pistons or cylinder liners......................Replace piston or cylinder liner

● Damaged or seized piston ............................Replace piston and cylinder

liner

● Foreign matter on top surface of the piston ..

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

Valve mechanism

● Incorrect valve clearance .............................. Adjust valve clearance

● Valve cotter out of place................................Replace valve cotter

● Seized valve stem.........................................Replace valve and valve guide

● Broken valve .................................................Replace valve

● Damaged rocker arm support .......................Replace rocker arm support

● Broken valve spring ...................................... Replace valve spring

Bearings seizure

● Insufficient lubricating oil...............................Add oil

● Excessive or insufficient tightening of ........... Retighten to specified torque

bearing housings

● Pits and scratches on bearing surface..........Replace bearing and crankshaft

● Oil film formed on back of bearing ................Replace bearing

● Improper installation of bearing ....................Replace bearing

● Reduction of spread dimension of bearing ... Replace bearing

● Distorted bearing housing ............................. Replace or correct bearing

housing

● Excessive oil clearance.................................Replace bearing

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3-1-12 ENGINE

Symptom Possible cause Remedy/Prevention

Unusual engine noise Various other parts

● Exhaust gas leakage from exhaust...............Retighten joints

● Loosen or missing intake manifold ...............Retighten or replace

● Intake valve seating is not concentric ...........Replace or correct the valve

● Intake gas leakage........................................Retighten

● Loose cooling fan mounting bolts or .............Tighten the fan and

● Lack of lubricating oil .................................... Lubricate

● Worn timing gear...........................................Replace the timing gear

● Breakage of turbine or blower.......................Refer to TURBOCHARGER in

Models J08C-TP and J08C-TR

pipe joints

flange gasket

and valve seat

Other problems

fan pulley nut crankshaft pulley

(coolant pump, valves, etc.)

CHAPTER 51

NOTE: The items on this page concern unusual engine noise which is due to causes other than

those given for diesel knock.

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(FUEL INJECTION PUMP)

Symptom Possible cause Remedy

Engine does not start Fuel not reaching injection pump

● Fuel lines clogged or damaged.....................Clean or replace fuel lines

● Fuel filter clogged .........................................Clean or replace the filter

element

● Air in fuel caused by improper ...................... Repair connections

connections of fuel line between
fuel tank and feed pump

● Filter incorporated in inlet side ...................... Remove foreign material

of feed pump clogged

● Faulty feed pump check valve ...................... Repair or replace it

● Feed pump piston spring broken .................. Replace it

● Feed pump push rod or tappet sticking ........Repair or replace it

ENGINE 3-1-13Models J08C-TP and J08C-TR

Fuel reaching injection pump

● Faulty connection of accelerator cable ......... Repair connection

to pump adjusting lever

● Control rack faulty or sticking........................Repair it

● Damaged camshaft bearing..........................Repair it

● Plunger worn or sticking................................Correct or replace it

● Faulty connection of engine .......................... Repair it

stop cable to pump stop lever

Nozzle faulty

● Fuel leakage caused by loosened ................ Inspect and tighten it

nozzle holder

● Low opening pressure of nozzle ...................Adjust it

● Nozzle pressure spring broken .....................Replace it

● Nozzle needle sticking to nozzle body .......... Correct or replace it

Pump out of timing

● Improperly retarded injection timing..............Correct injection timing

● Incorrect timing caused by improper.............Check engine timing and

installation of pump correct it

● Woodruff key for pump camshaft cut off. ......Replace it

● Improper pre-stroke adjustment....................Correct it to obtain specified

injection timing

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3-1-14 ENGINE

Symptom Possible cause Remedy

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

Engine has low power Pump out of timing

● Excessive advanced timing...........................Check and correct it

● Excessively retarded timing ..........................Check and correct it

● Defective injection pump overflow valve ....... Repair or replace it

● Feed pressure too low .................................. Repair the feed pump

● Improper accelerator cable adjustment ........Adjust it

Models J08C-TP and J08C-TR

Air in fuel caused by damaged ..................... Repair fuel lines or replace fuel

fuel lines or improper connection of lines and gaskets
fuel lines

resulting in loud knocking

resulting in black smoke

Nozzle faulty

● Fuel leakage from nozzle holder...................Check and repair nozzle holder

● Bad nozzle spray characteristic ....................Repair or replace it

● Loosened adjusting screw in nozzle .............Adjust it

holder, resulting in low opening pressure

● Nozzle pressure spring broken .....................Replace it

Pump faulty

● Fuel leakage from delivery valve .................. Retighten the delivery valve

holder

holder if it is loosened or replace
O-ring if the O-ring is defective

● Defective seat of delivery valve assembly ....Repair or replace it

● Delivery valve spring broken.........................Replace the spring

● Plunger worn.................................................Replace it

● Large spread in fuel delivery.........................Adjust it

● Wear of tappet roller ..................................... Replace the roller

● Camshaft bearing worn or broken.................Replace it

● Improper adjustment of governor..................Adjust it

full load stopper screw

1 page 1

Symptom Possible cause Remedy

Excessive smoke Black smoke

● Excessive fuel delivery caused by ................

incorrect adjustment of full load
stopper screw

● Excessively advanced injection timing..........Correct it

● Large spread in fuel delivery.........................Adjust it

● Bad nozzle fuel spray characteristics ...........Check and correct them

White smoke

● Unused after glow system.............................Use it

● Improperly retarded injection timing..............Advance injection timing

● Water in fuel..................................................Check and clean fuel lines

● Glow plug not operating ................................ Check glow plug circuit. Refer

Adjust fuel delivery on test stand

to ELECTRICAL EQUIPMENT
in CHAPTER 20

ENGINE 3-1-15Models J08C-TP and J08C-TR

Low idle speed

Improper adjustment of throttle control knob ..

Correct it

irregular Bad fuel spray characteristic of nozzles. ...... Check and repair them

Incorrect injection timing ............................... Correct it

Incorrect initial tension setting of...................Adjust or replace it

idling spring or the spring broken.

Control rack does not move smoothly...........Disassemble pump and repair it

Large spread in fuel delivery.........................Adjust it

Plunger worn.................................................Replace it

Governor linkage does not move smoothly...Correct it

Defective feed pump .....................................Disassemble and repair it

Engine always runs Accelerator cable sticking .............................Check and correct it

at high speed Governor linkage sticking .............................Disassemble and repair the

governor

Control rack sticking......................................Check and correct it

Loud knocking Improper injection timing...............................Correct it

Bad fuel nozzle spray pattern . .....................Check and correct it

after-dribble

High nozzle opening pressure ......................Adjust the opening pressure

Incorrect fuel deliveries to.............................Readjust the fuel deliveries

some nozzles.

1 page 1

Models J08C-TP and J08C-TR

SPECIAL TOOLS

Prior to starting an engine overhaul, it is necessary to have the following.

(1) Lifting parts

Shape Parts No. Parts name No./unit Application

09491 - 1010 Wire cable 1 Lifting engine

SM3-J052

ENGINE 3-2-1

09433 - 1070 Eye bolt 2 Lifting cylinder head

SM3-J048

(2) Related parts of cylinder head

Shape Parts No. Parts name No./unit Application

09472 - 1210 Bar 1

SM3-J050

9800-06100 (Steel ball) 1

Caulking nozzle seat
(Use together with 9800 - 06100)

Caulking nozzle seat
(Use together with 09472-1210)

SM3-J054

SM3-J021

09552-1090

Compression gauge
adaptor (for size PF3/8)

1

Measuring compression

3-2-2 ENGINE

Shape Parts No. Parts name No./unit Application

SM3-J022

SM3-J055

1 page 1

Models J08C-TP and J08C-TR

09552 - 1060

Press gauge adaptor 1 Measuring compression

09552 - 1030

09472 - 2100 Bar 1 Strike-fitting valve stem seal

09471 - 1520 Guide 1 Strike-fitting valve guide

SM3-J051

09420 - 1100 Sliding hammer 1 Removing main idle gear shaft

SM3-J131

09420 - 1442

(Same as tool

for pulling out

injection nozzle)

SM3-J132

(3) Related parts of valve

Removing sub- and cam idle

Sliding hammer 1 gear shafts (Remove the

adaptor from the top before use)

Shape Parts No. Parts name No./unit Application

09431 - 1020 Valve wrapping tool 1 Valve wrapping

SM3-J053

1 page 1

Models J08C-TP and J08C-TR

Shape Parts No. Parts name No./unit Application

ENGINE 3-2-3

09470 - 1170 Valve spring press 1

SM3-J049

(4) Related parts of flywheel

Shape Parts No. Parts name No./unit Application

09481 - 1340 Guide 1

SM3-J116

(5) Related parts of cylinder block

Removing and installing valve
spring

Removing and installing
flywheel

Shape Parts No. Parts name No./unit Application

09407 - 1030 Oil seal press 1 Press-fitting front oil seal

09407 - 1040 Oil seal press 1 Press-fitting rear oil seal

SM3-J118

09420 - 1731 Oil seal puller 1 Pulling out front oil seal

SM3-J115

3-2-4 ENGINE

Shape Parts No. Parts name No./unit Application

SM3-J117

SM3-J148

1 page 1

Models J08C-TP and J08C-TR

09420 - 1742 Oil seal puller 1 Pulling out rear oil seal

09420 - 1720 Cylinder liner puller 1 Pulling out cylinder liner

SM3-J149

SM3-J133

SM3-J146

SM3-J151

09471 - 1490 Guide 1 Insert guide for cylinder liner

09411 - 1300 Socket wrench 1 Rear end plate TORX® bolt

09444 - 1630 Gauge 1 Cooling jet check

9001 - 24262 Check bolt 1 Cooling jet check

SM3-J780

09472 - 1620 Tool 1

Cooling jet check (Fixture for
correction)

(6) Related parts of piston

Shape Parts No. Parts name No./unit Application

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-2-5

SM3-J153

SM3-J145

SM3-J781

09441 - 1320 Piston ring holder

09442 - 1011 Piston ring expander 1

09481-1130 Guide 1

09402-1530 Press sub assembly 1

1

Used when inserting piston into
cylinder block

Removing and installing piston
ring

For replacing the piston pin
bushing

SM3-J782

SM3-J783

9233-10360 Wing nut 1

3-2-6 ENGINE

(7) Related parts of connecting rod

Shape Parts No. Parts name No./unit Application

09481 - 1540 Guide 1

SM3-J147

1 page 1

Models J08C-TP and J08C-TR

09402-1540

SM3-J152

9191 - 08252 Bolt 1

SM3-J150

(8) Related parts of filter

Shape Parts No. Parts name No./unit Application

09553 - 1021 Oil filter wrench 1 Removing and installing oil filter

Press sub assembly 1

Replacing connecting rod
bushing

SM3-J784

SM3-J785

09553 - 1010

Fuel filter wrench 1

Removing and installing fuel filter

(9) Related parts of injection pump

Shape Parts No. Parts name No./unit Application

09511 - 2500 Wrench 1 Injection pump coupling

SM3-J200

(10) Related parts for injection nozzle

Shape Parts No. Parts name No./unit Application

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-2-7

09420 - 1442

(Same as the
parts to remove
idler gear shaft)

SM3-J132

09462 - 1 130 Adaptor 1

SM3-J172

(11) Related parts of coolant pump

Shape Parts No. Parts name No./unit Application

09420 - 1820 Puller assembly 1 Coolant pump vane

Sliding hammer 1

Pulling out injection nozzle
(Use together with 09462 - 1 130)

Pulling out injection nozzle
(Use together with 09420 - 1442)

SM3-J786

SM3-J787

09420 - 1810 Puller assembly 1 Coolant pump pulley center

1 page 1

3-2-8 ENGINE

Shape Parts No. Parts name No./unit Application

09444 - 1210 Belt tension gauge 1 Adjusting V-belt tension

SM3-J788

(12) Related parts of air compressor

Shape Parts No. Parts name No./unit Application

Models J08C-TP and J08C-TR

SM3-J002

SM3-J003

SM3-J004

09420 - 1670 Puller assembly 1

09482 - 2220 Press 1

Pulling out air compressor
sleeve

Strike-fitting air compressor

sleeve

09482 - 2230 Press 1

seal

Strike-fitting air compressor oil

09420 - 1680 Puller assembly 1 Pulling out air compressor gear

SM3-J005

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-3-1

GENERAL

WARNING

The following items should be observed to prevent
injury to yourself and others when servicing the
engine or vehicle;

● Stop the engine and keep the engine off during

checks and adjustments.

● Place the starter key in the “LOCK” position.

● Leave the engine stop knob pulled out fully.

(For model equipped with manual engine stop
control)

● Place the transmission shift lever in “NEUTRAL”.

● Apply the parking brake firmly.

● Block the wheels.

Fig. 1

SM3-J580

ENGINE OVERHAUL CRITERIA
FACTORS TO DETERMINE THE ENGINE

OVERHAUL

1. LOW COMPRESSION PRESSURE

(1) Before measurement

1. Charge the battery completely.

2. Set the valve clearance to the correct value.

Intake : 0.30 mm (0.0118 in.)
Exhaust : 0.45 mm (0.0177 in.)
(when engine is cold)

NOTE: Refer to page 3-18-4.

3. Idle the engine (to 80 °C {176°F}).

4. While the starter switch is at the LOCK position, dis­connect the engine stop motor.

5. Remove all nozzle holders.

NOTE: Refer to page 3-6-3.

6. Remove the air cleaner hose.

1 page 1

3-3-2 ENGINE

Models J08C-TP and J08C-TR

(2) Measurement

1. Insert the gauge adaptor into the nozzle holder hole.

Special tool: Compression gauge adaptor

(09552 - 1090)
(09552 - 1060)
(09552 - 1030)

2. Run the engine with the starter and measure the
compression pressure.

SM3-J581

Fig. 2

NOTE: Do not operate the starter for more than 15 sec-

onds.

3. Measure the compression pressure of each cylinder.

NOTE: Do not allow gas leakage from the seal face.

Unit: kg/cm2 (lb/sq.in.)

Assembly standard Assembly limit Difference among Engine speed

individual cylinders (rpm)

35 - 38 (498-540) 28 (398) Less than 3 (43) 180 - 220

Fig. 3

SM3-J580

(3) After measurement

1. Install the removed parts.

WARNING

Do not connect the electric harness with the en­gine stop motor while the engine starter key is at
ON position as this may operate the engine stop
motor instantaneously and the link lever of the
engine stop motor and the engine stop lever of the
fuel injection pump will move, resulting in your
fingers caught by the lever.

Fig. 4

S.A.E.

GRADE

40
30
20W/20
15W/40
10W/30

Fig. 5

OIL

SM3-J024

ATMOSPHERIC TEMPERATURE

-10 0 32 50 70 90 100 ˚F

-23 -18 0 10 21 32 39 ˚C

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-3-3

2. DECREASED OIL PRESSURE

Check the oil pressure warning lap when the oil and cool­ant temperature is hot [about 80°C (176°F)].

a. If the warning lamp is lit, check the oil level.
b. Check oil deterioration.

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

c. Remove the oil pressure switch and install the oil

pressure gauge.

d. Measure the oil pressure at oil temperature 100°C

(212°F).

Standard oil Pressure:

2

At 2,500 (rpm) 5.7 kg/cm

(81.05 lb/sq.in.)

Service Limit:

At idle speed 0.5 kg/cm

2

(7.11 lb/sq.in.)

3. OTHER FACTORS

a. Blow-by gas increases.
b. Engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.

Fig. 1

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-4-1

DISMOUNTING THE ENGINE ASSEMBLY

1. BLOCK THE WHEELS OF THE VEHICLE.

1. Park the vehicle on level ground.

2. Block the wheels.

SM3-J500

2. DISCONNECT THE ENGINE CONTROL AND THE STOP
CABLE.

1. Set the starter switch to the ON position.

2. Disconnect the wires of the engine stop motor at the

connector.

3. Set the starter switch to the LOCK position.

Fig. 2

Fig. 3

Fig. 4

SM3-J580

4. Tilt up the cab.

5. Disconnect the engine control and the stop cable at

the injection pump.

SM3-J582A

3. DISCONNECT THE NEGATIVE TERMINAL OF THE
BATTERY.

WARNING

Always disconnect the battery cable when servic­ing the engine.

SM3-J583

4. DISCONNECT THE PARKING BRAKE CABLE (1).

1. Remove the center console.

2. Disconnect the parking brake cable at the lever.

Fig. 5

SM3-J584

1 page 1

Models J08C-TP and J08C-TR3-4-2 ENGINE

OVER-TILTING
POSITION

Fig. 6

OPEN

DRAINING PLUG

Fig. 7

CLOSE

NORMAL POSITION

DRAINING PLUG

SM3-J705B

Fig. 8

5. OVER-TILT THE CAB

NOTE: Refer to CAB in CHAPTER 19.

SM3-J585

6. DRAIN THE COOLANT AND ENGINE OIL.

WARNING

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

1. Drain the coolant from the radiator. (Fig. 7)

NOTE: The coolant can be drained more easily by

removing the filler cap.

Fig. 9

Fig. 10

DRAINING PLUG

SM3-J791

SM3-J587

2. Drain the coolant from the cylinder block. (Fig. 8)

Coolant capacity: 21 L (22.19 US qt)

23 L (24.30 US qt)
(with transmission oil cooler only)

3. Drain the engine oil through the drain plug.

Engine oil capacity: 13.5 L (14.27 US qt)

7. DISCONNECT THE POWER STEERING LINES A T THE
GEAR UNIT.

NOTE: Place a container under the gear unit.

8. DISCONNECT THE PARKING BRAKE CABLE (2).

1. Remove the bracket behind the cab, then pull out

the parking brake cable.

NOTE: Pull out the cable straight and slowly. If pulled out

forcefully, the gasket will crack. Cracked cables
must be replaced with new ones.

Fig. 11

SM3-J589

Fig. 12

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-4-3

9. DISCONNECT THE SPEEDOMETER CABLE AT THE
TRANSMISSION.

SM3-J590

10. REMOVE THE TRANSMISSION CONTROL ROD
TOGETHER WITH THE BRACKET A T THE TRANSMIS­SION.

Fig. 13

Fig. 14

Fig. 15

SM3-J796

11. REMOVE THE CLUTCH SLAVE CYLINDER.

1. Remove the connecting clip of the clutch hose.

2. Remove the return spring and the clevis of the lever.

3. Remove the slave cylinder together with the lines.

SM3-J593

12. DISCONNECT THE POWER STEERING LINES A T THE
PUMP.

NOTE: Be careful of oil leakage from the removed lines

at the gear unit

SM3-J594

13. DISCONNECT THE AIR HOSES WHICH CONNECT THE
AIR CLEANER AND ENGINE.

14. REMOVE THE SPLASH BOARD.

15. REMOVE THE AIR CLEANER TOGETHER WITH THE
BRACKET.

Fig. 16

SM3-J595

Fig. 17

1 page 1

Models J08C-TP and J08C-TR3-4-4 ENGINE

16. DISCONNECT THE ELECTRICAL WIRES (1).

1. Engine speed sensor

2. Glow plug

3. Rack sensor, pre-stroke actuator

4. Starter terminals B and C and grounding (frame end)

SM3-J596A

17. REMOVE THE REAR CAB MOUNTING BRACKET.

Fig. 18

Fig. 19

Fig. 20

SM3-J597

18. DISCONNECT THE ELECTRICAL WIRES (2).

1. Water temperature sensor (2 parts)

2. Alternator

3. Magnetic clutch of the air conditioner

19. DISCONNECT THE HEATER HOSES.

SM3-J598

20. DISCONNECT THE GAS LINES OF THE AIR CONDI­TIONER.

1. Use the refrigerant collector to discharge refriger-

ant.

2. Disconnect the gas lines of the air conditioner at the

compressor.

SM3-J599

21. DISCONNECT THE RADIATOR FROM THE FRAME.

1. Disconnect the reservoir hose.

2. Remove the radiator mounting.

Fig. 21

SM3-J600A