Hino J08C-TP, J08C-TR Service Manual

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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

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

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”

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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

1 page 1

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

● 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)

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

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:

At 2,500 (rpm) 5.7 kg/cm

(81.05 lb/sq.in.)

Service Limit:

At idle speed 0.5 kg/cm

(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

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

Fig. 22

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-4-5

22. REMOVE THE EXHAUST PIPE AND MUFFLER.

SM3-J601A

23. REMOVE THE PROPELLER SHAFT.

1. Remove the center bearing support.

NOTE: Attach a hoist to the propeller shaft.

2. Loosen the flange, then remove the propeller shaft.

Fig. 23

Fig. 24

SM3-J602

SM3-J502

24. REMOVE THE TRANSMISSION.

1. Place a jack under the bottom of the flywheel hous-

ing.

2. Place a transmission jack under the transmission.

WARNING

The engine must be suspended with a hoist until completion of disassembly of the transmission assembly.

3. Remove the mounting bolt of the mounting rubber

behind the transmission.

4. Remove the mounting bolt of the transmission at the

clutch housing, then remove the transmission.

NOTE: Jack up and align the transmission with the en-

gine, then pull the transmission straight out.

Fig. 25

1 page 1

Models J08C-TP and J08C-TR3-4-6 ENGINE

25. REMOVE THE ENGINE ASSEMBLY.

1. Attach hoists to the engine hangers at the front and

rear ends of the engine, and lift slightly.

2. Remove the engine mounting at the frame.

3. Remove the engine assembly together with the ra-

diator and inter cooler.

4. Mount the engine assembly on a work stand.

SM3-J503

26. REMOVE THE RADIATOR AND INTER COOLER.

1. Loosen the tightening band of the fan shroud.

2. Disconnect the radiator hoses and inter cooler hoses

at the engine.

3. Remove the radiator and inter cooler.

NOTE: Attach a hoist to the radiator.

Fig. 26

Fig. 27

SM3-J604

27. REMOVE THE CLUTCH COVER AND CLUTCH DISC.

NOTE: Refer to CLUTCH in CHAPTER 5.

SM3-J746

28. REMOVE THE AIR CONDITIONER COMPRESSOR.

1. Loosen the tension pulley, then remove the V-belt.

2. Remove the air conditioner compressor.

Fig. 1

1 page 1

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

REMOVAL OF THE ENGINE COMPONENT PARTS

1. PREPARATION

1. Loosen the coolant drain cock of the oil cooler, then

discharge coolant.

2. Loosen the oil drain plug of the oil filter, then dis-

charge oil.

SM3-J606

3. Clean the engine assembly. a. Cover openings with tape. b. Clean the engine assembly with a steam cleaner.

NOTE: Do not apply steam directly to the electrical com-

ponents. (Alternator, starter, etc.)

4. Mount the engine assembly on a work stand.

Fig. 2

Fig. 3

Fig. 4

SM3-J504

2. REMOVE THE POWER STEERING OIL PUMP.

SM3-J607

3. REMOVE THE STARTER.

1. Put alignment marks on the harness and the starter

terminal, then remove the harness.

2. Remove the starter from the engine.

SM3-J608

4. REMOVE THE FUEL FILTER AND FUEL LINES.

Remove the fuel lines, oil lines and fuel leakage lines.

NOTE:

● Cover openings to prevent foreign matter from enter-

ing.

● Refer to page 3-12-1.

Fig. 5

SM3-J609

1 page 1

3-5-2 ENGINE

Fig. 6

Models J08C-TP and J08C-TR

5. REMOVE THE INTAKE MANIFOLD.

SM3-J613

6. REMOVE THE INJECTION PUMP.

1. Remove the through bolt of the coupling.

Fig. 7

Fig. 8

Fig. 9

Fig. 10

SM3-J610A

SM3-J611C

SM3-J612

SM3-J614

2. Use the following special tool and loosen the adjust-

ing bolt.

Special tool: Injection pump coupling wrench

(09511 - 2500)

3. Remove the mounting bolt of the injection pump, then

remove the pump assembly.

NOTE: Cover openings to prevent foreign matter from

entering.

7. REMOVE THE AIR COMPRESSOR.

1. Remove the oil lines, refrigerant lines and air lines.

2. Remove the air compressor.

3. Remove the mounting bolt of the air compressor, then

remove the air compressor.

NOTE: Do not remove the air compressor forcefully. The

spigot may be damaged, or oil leakage may occur due to removal of liquid gasket between the flywheel housing and the rear end plate.

Fig. 11

1 page 1

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

8. REMOVE THE TURBOCHARGER.

NOTE: Refer to TURBOCHARGER in CHAPTER 51.

SM3-J615

9. REMOVE THE OIL FILTER AND OIL COOLER.

1. Remove the oil lines.

2. Remove the oil filter.

Special tool: Oil filter wrench (09553 - 1021)

3. Remove the oil cooler.

Fig. 12

Fig. 13

Fig. 14

SM3-J616

10. REMOVE THE EXHAUST MANIFOLD.

SM3-J617

11. REMOVE THE V-BELT AND THE ALTERNATOR.

1. Loosen the V-belt adjustment bolt.

2. Loosen the through bolt.

3. Remove the V-belt, then remove the alternator.

SM3-J619A

12. REMOVE THE FAN CLUTCH TOGETHER WITH THE COOLING FAN.

Fig. 15

SM3-J620

1 page 1

3-5-4 ENGINE

Fig. 16

Models J08C-TP and J08C-TR

13. REMOVE THE THERMOSTAT CASE.

SM3-J621

14. REMOVE THE COOLANT PUMP.

Fig. 17

SM3-J622

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-1

CAMSHAFT HOUSING AND CYLINDER HEAD

Fig. 1

21 22

23 24

25 26 27

32 33

SM3-J264A

1 page 1

Models J08C-TP and J08C-TR3-6-2 ENGINE

Fig. 2

1. Oil filler cap

2. Cylinder head cover

3. Silent block

4. Spacer

5. Head cover gasket

6. Valve rocker shaft

7. Lock nut

8. Valve rocker arm

9. Adjusting screw

10. Nozzle clamp

11. Valve rocker support

12. Camshaft bearing

13. Camshaft bearing cap

14. Camshaft

15. Camshaft drive gear

16. Camshaft housing

17. Camshaft housing gasket

18. Idler gear thrust plate

19. Camshaft idler gear

20. Idler gear shaft

21. Cross head

22. Valve spring retainer

23. Valve spring seat upper

24. Valve spring outer

25. Valve spring inner

26. Valve stem seal

27. Valve spring seat lower

28. Cross head adjusting screw

29. Lock nut

30. Cylinder head

31. Cylinder head gasket

32. Valve seat

33. Valve

34. Valve stem guide

35. Nozzle seat

SM3-J265

Fig. 3

NOZZLE CLAMP BOLT

SM3-J623

LEAKAGE PIPE

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-3

DISMOUNTING

1. REMOVE THE CYLINDER HEAD COVER.

NOTE: Clean all dust from around the cylinder head

cover before removing it to prevent foreign particles from getting in.

2. REMOVE THE INJECTION NOZZLE.

1. Remove the leakage pipe.

2. Loosen the injection pipe nut.

3. Remove the injection pipe seal mounting bolts. Re-

move the injection pipe seal together with the injection pipe out of the cam housing.

4. Remove the nozzle clamp bolt.

Fig. 4

Fig. 5

CAM HOUSING

O-RING

NOZZLE HOLDER ASSEMBLY

SM3-J178

5. Pull out the nozzle holder assembly, avoiding any

interference.

NOTE: If difficult, use a special tool, sliding hammer

(09420 - 1442), for easier removal.

6. Remove the O-ring.

NOTE: Replace the O-ring with a new one.

SM3-J624

Fig. 6

LOCK NUT

ADJUSTING SCREW

ROCKER ARM SUPPORT

124 675 3

1 page 1

Models J08C-TP and J08C-TR3-6-4 ENGINE

3. LOOSEN THE VALVE CLEARANCE ADJUSTING SCREW.

1. Loosen the lock nut at the top of the rocker arm, then

wind up the adjusting screw completely.

NOTE: If the adjusting screw is left unwound, the rocker

shaft may bend when the rocker arm support is loosened.

SM3-J056

4. REMOVE THE ROCKER ARM ASSEMBLY.

1. Remove the rocker arm support bolt in the order as

shown in the figure.

NOTE: When the rocker arm assembly is removed, the

rocker arm and rocker arm support tend to come off the rocker shaft. Be careful in handling.

Fig. 7

Fig. 8

Fig. 9

SM3-J266

5. REMOVE THE CAMSHAFT.

1. Remove the cam bearing cap bolt.

2. Remove the camshaft together with the gear.

NOTE: Be extremely careful not to drop any part into the

interior of the engine.

SM3-J625

6. REMOVE THE CAM HOUSING.

1. Remove the cam housing bolts.

2. Tap and remove the cam housing with a plastic ham-

mer.

SM3-J626

7. REMOVE THE CYLINDER HEAD BOLTS.

Remove the cylinder head bolts in the order as shown in the figure.

Fig. 10

SM3-J276B

Fig. 11

SM3-J627

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-5

8. LIFT AND REMOVE THE CYLINDER HEAD FROM THE CYLINDER BLOCK.

Special tool: Eye bolt (09433 - 1070) NOTE:

● Place a piece of wood between the cylinder head and

table.

● When removing the cylinder head together with the

injection nozzle, avoid contact between the injection nozzle and a piece of wood.

● Check that there is no oil, water or gas leakage in the

cylinder head gasket if overheated or not.

Fig. 12

1 page 1

Models J08C-TP and J08C-TR3-6-6 ENGINE

DISASSEMBLING

REMOVE THE CAM IDLER GEAR.

1. Remove the cam idler gear.

SM3-J628

2. Using the special tool, remove the cam idler gear.

Special tool: Sliding hammer (09420 - 1830)

Fig. 13

Fig. 14

Fig. 15

SM3-J629

SM3-J060

SM3-J061A

DISASSEMBLE THE VALVE SYSTEM.

1. Using the special tool, press fit the valve spring seat

upper, then remove the valve spring retainer.

Special tool: Valve spring press (09470 - 1170)

2. Remove the valve spring seat upper, valve spring

outer and inner.

3. Remove the intake and exhaust valves from the cyl-

inder head.

NOTE:

● Do not remove the valve guide and valve spring seat

lower unless they need to be replaced.

● Align the removed parts in the order of the cylinder

No.

Fig. 16

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-7

INSPECTION AND REPAIR

CYLINDER HEAD NOTE:

● Clean the cylinder head thoroughly with a commercial

cleaning agent before inspection.

● Do not damage the lower surface of the cylinder head.

SM3-J062

INSPECT THE CYLINDER HEAD FOR CRACKS.

Check the head surface and intake and exhaust valve seats, for cracks, using a dye penetrant. If cracks are found, replace the cylinder head.

Fig. 17

Fig. 18

B C

Fig. 19

SM3-J103

CHECK THE CYLINDER HEAD FLATNESS.

1. Check the cylinder head surface for flatness with a

straight edge and a thickness gauge. If the measurements exceed service limits, replace the cylinder head.

Standard: 0.06 mm (0.0024 in.) or less for longitudinal di-

rection

0.03 mm (0.0012 in.) or less for lateral direc-

SM3-J630

tion

Service limit: 0.20 mm (0.0079 in.)

E’

F’

G’

SM3-J505

A’

C’

D’

B’

2. Check the flatness of the intake and exhaust mani-

folds mounting surfaces.

Standard: 0.06 mm (0.0024 in.) or less for longitudinal di-

rection

0.03 mm (0.0012 in.) or less for lateral direction

Service limit: 0.20 mm (0.0079 in.)

Fig. 20

SM3-J506

Fig. 21

Fig. 22

1 page 1

Models J08C-TP and J08C-TR3-6-8 ENGINE

INSPECT THE V AL VE CONT ACT SURF ACES FOR PROPER CONTACT.

1. Visually check valves for damage, burn marks, car-

bon accumulation, warpage, or cracks in valve heads, valve stems, and valve stem grooves. Replace valves which are excessively worn, burnt, warped or cracked.

SM3-J631

2. Check the valve seating condition.

Lightly apply red lead marking compound to the valve face. Install the valve with a special tool, tap and rotate the valve against the seat. Check the valve face and valve seat for seating. When the red lead mark is not concentric or even all around the valve face or seat, correct the valve face or the valve seat.

Special tool: Valve lapping tool (09431 - 1020)

SM3-J104

Fig. 23

Fig. 24

SM3-J507A

SM3-J632

SM3-J507

HAND-LAP THE VALVE AND VALVE SEAT.

Lightly apply lapping compound to the valve face. Install the valve with a special tool, tap and rotate the valve against the seat.

NOTE:

● Following completion of hand-lapping, clean off any

lapping compound which has adhered to the valves and valve seats.

● Following hand-lapping, always recheck the seating

condition.

Special tool: Valve lapping tool (09431 - 1020)

GRIND VALVES NOTE:

● Grinding of valves should only be performed when

hand-lapping does not result in proper seating.

● Following hand-lapping, always recheck the seating

condition.

WARNING

When grinding, a metal tip may fly off on impact. Wear safety glasses to protect your eyes.

Fig. 25

30˚

INTAKE

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-9

Assembly standard:

Valve seat (Intake): 30°00' - 30°35' Valve face (Intake): 29°30' - 30°00' Valve seat (Exhaust): 45°00' - 45°30' Valve face (Exhaust): 44°30' - 45°00'

45˚

EXHAUST

SM3-J097

HAMMER

VALVE

Fig. 26

Fig. 27

INTAKE

BLOCK BRASS

VALVE SEAT

ELECTRIC WELDING APPLIED

GRIND THIS POINT WITH A GRINDER

SM3-J064

EXHAUST

SM3-J065

IF NECESSARY, REPLACE THE VALVE SEAT.

1. Cut three places on the circumference of an un-

wanted valve and weld it to the valve seat.

NOTE: To protect the lower surface of the cylinder head

from welding spatter, be sure to apply grease before welding.

2. Place a back plate at the top of the valve stem and

strike it with a hammer to remove the valve seat.

NOTE: When striking, a metal tip may fly off on impact.

Wear safety glasses to protect your eyes.

3. Machine the valve seat according to the specified

valve seat dimensions.

Dimensions of the valve seat machining:

Clynder head side

Valve seat side

Intake

Unit:mm Unit:in. Unit:mm Unit:in. A 41-41.016 1.6142-1.6148 39-39.016 1.5355-1.5360 B 9.4-9.6 0.3701-0.3779 8.6-8.8 0.3386-0.3464 C 41.085-41.1 1.6176-1.6181 39.12-39.135 1.5402-1.5407 D 7-7.2 0.2756-0.2834 6-6.2 0.2363-0.2440

Exhaust

Fig. 28

SM3-J066

4. Heat the cylinder head to approx. 80°C (176°F) 90°C (194°F) with hot water . Cool the valve seat with dry ice for approx. 30 minutes. Hold the seat with pincers and place it into the heated cylinder head. The valve seat can be easily made to fit by lightly hitting it.

WARNING

● Never touch the cooled valve seat with your bear

hands.

● When striking, a metal tip may fly off on impact.

Wear safety glasses to protect your eyes.

● Following valve grinding, always recheck the

seating condition.

Fig. 29

Fig. 30

Fig. 31

VALVE SINK DIMENSION

90°

VALVE SEAT

CYLINDER

HEAD

VALVE

SM3-J508

SM3-J509

SM3-J510

1 page 1

Models J08C-TP and J08C-TR3-6-10 ENGINE

MEASURE THE VALVE SINK. Assembly standard:

Intake: 0.55 - 0.85 mm (0.0217 - 0.0334 in.) Exhaust: 1.05 - 1.35 mm (0.0414 - 0.0531 in.)

Repair limit:

Intake: 1.1 mm (0.0433 in.) Exhaust: 1.6 mm (0.0630 in.)

NOTE:

● If the valve heads are protruding from cylinder head

surface, the valve heads may hit against the pistons while the engine is running.

● Following replacement of valve and valve seat, always

recheck the seating condition.

MEASURE THE CLEARANCE BETWEEN THE V AL VE STEM AND VALVE GUIDE.

1. Measure the outside diameter of the valve stem with a micrometer. If the value exceeds the service limit, replace the valve.

Nominal dimension: 7.0 mm (0.2756 in.) Service limit: Intake 6.92 mm (0.2724 in.)

Exhaust 6.84 mm (0.2693 in.)

2. Calculate the clearance between the valve stem and valve guide. If the clearance exceeds the service limit, replace the valve or valve guide.

Nominal dimension:

Intake: 0.023 - 0.058 mm (0.0010 - 0.0022 in.) Exhaust: 0.037 - 0.067 mm (0.0015 - 0.0026 in.)

Service limit:

Intake: 0.10 mm (0.0039 in.) Exhaust: 0.12 mm (0.0047 in.)

IF NECESSARY, REPLACE THE VALVE GUIDE.

1. Remove the valve stem seal.

2. Strike the valve guide out with a brass bar and a hammer.

Fig. 32

WARNING

When striking, a metal tip may fly off on impact. Wear safety glasses to protect your eyes.

SM3-J51 1

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-11

Fig. 33

VALVE STEM SEAL

VALVE SPRING SEAT LOWER

Fig. 34

INTAKE

EXHAUST

VALVE

COAT OIL

SM3-J065

SPECIAL TOOL

SM3-J068

3. Press fit a new valve guide straight allowing it to protrude as shown in the figure.

NOTE: Apply engine oil lightly to the valve guide outer

circumference before installation.

IF NECESSARY, REPLACE THE VALVE STEM SEAL.

Replace the valve stem seal when the valve guide is replaced or when seal clearance is excessive or the stem seal has been worn or damaged.

First, install the lower spring seat and valve to the cylinder head (for guide of special tool), then apply engine oil to the lip of the stem seal and drive the guide with a special tool.

Special tool: Valve stem seal press (09472 - 2100)

WARNING

When striking, a metal tip may fly off on impact. Wear safety glasses to protect your eyes.

Fig. 35

Fig. 36

NOTE:

● After installing the valve stem seal, make sure there

is a gap (A) and (B) as shown in the figure.

SM3-J068

● Do not use the special tool if its surface contacting

the valve spring lower seat is deformed.

INSPECT THE VALVE SPRINGS.

1. Check the valve springs for squareness using a square and a thickness gauge. If a spring is out of square beyond the service limit, replace it.

Limit: 2.0 mm (0.078 in.) or more

SM3-J098

Fig. 37

1 page 1

Models J08C-TP and J08C-TR3-6-12 ENGINE

2. Measure the valve spring tension at a specified length with the valve spring tester. If the spring force is lower than the service limit, replace it.

SM3-J098

Outer spring

Inner spring

Fig. 38

Intake

Exhaust

Intake

Exhaust

Free length mm (in.)

Nominal dimension

75.7 (2.980) 75.4 (2.968) 46.8 (1.843) 46.4 (102.23) —

75.7 (2.980) 75.4 (2.968) 46.8 (1.843) 44.2 (97.44) —

64.6 (2.543) 64.3 (2.531) 44.8 (1.764) 21.7 (47.85) —

64.6 (2.543) 64.3 (2.531) 44.8 (1.764) 20.4 (44.98) —

Service limit

Setting height

mm (in.)

Nominal dimension

Setting load kg (lb)

3. Visually check the contact surface of the upper and lower valve spring seats. Replacement is necessary if damage such as wear and scratches is excessive.

SM3-J099

INSPECT THE CYLINDER HEAD COOLANT GALLERY FOR LEAKS.

Close all coolant holes and apply air pressure of about

2.5 kg/cm

(36 lb/sq. in.) from one of the coolant holes. Immerse the cylinder head into the water, then check for air leakage. If any leakage is found, replace the cylinder head.

Service limit

Fig. 39

IF NECESSARY, REPLACE THE NOZZLE SLEEVE.

1. Engage a tap to the nozzle sleeve from the bottom

of the cylinder head. Screw in an appropriate bolt, then strike the bolt head with a hammer and drive out the nozzle sleeve.

WARNING

When striking, a metal tip may fly off on impact.

SM3-J070SM3-J069

Wear safety glasses to protect your eyes.

Fig. 40

SPECIAL TOOL

CYLINDER HEAD

O-RING

NOZZLE SLEEVE

SM3-J071

NOZZLE SLEEVE

CYLINDER HEAD

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-13

2. Install an O-ring to the nozzle sleeve insert hole of

the cylinder head. Then apply liquid gasket (Three Bond No. 121 1 or equivalent) to the bottom of a new nozzle sleeve, and insert it to the nozzle sleeve insert hole of the cylinder head.

NOTE: Be sure to install a new O-ring. Reused O-rings

may cause water or gas leakage and lead to overheating or cracked heads.

3. Caulk the nozzle sleeve with the special tool.

Special tool: Sleeve bar (09472 - 1210)

Steel ball (9800 - 06100)

Fig. 41

Fig. 42

Fig. 43

Fig. 44

SM3-J072

CYLINDER HEAD

SM3-J100

SM3-J142

SM3-J634

4. Install the injection nozzle to the cylinder head. Then

measure the protrusion of the injection nozzle from the lower surface of the cylinder head with a vernier caliper. If the value exceeds the service limit, replace the injection nozzle.

NOTE: Refer to page 3-12-5. Assembly standard: 2.25 - 2.75 mm (0.0886 - 0.1082 in.) Service limit: 2.75 mm (0.1082 in.)

MEASURE THE CLEARANCE BETWEEN THE CAM IDLER GEAR SHAFT AND CAM IDLER GEAR BUSHING.

1. Measure the outside diameter of the cam idler gear

shaft with a micrometer. If the value exceeds the service limit, replace the cam idler gear shaft.

Assembly standard: 34.0 mm (1.3386 in.) Service limit: 33.95 mm (1.3366 in.)

2. Measure the inside diameter of the cam idler gear

bushing with a cylinder gauge. If the value exceeds the service limit, replace the cam idler gear.

Assembly standard: 34.0 mm (1.339 in.) Service limit: 34.025 mm (1.340 in.)

3. Calculate the clearance between the idler gear shaft

and idler gear bushing. If the value exceeds the service limit, replace the idler gear shaft and/or idler gear bushing.

Assembly standard: 0.025 - 0.075 mm (0.0010-0.0029 in.) Service limit: 0.20 mm (0.0079 in.)

Fig. 45

Fig. 46

SM3-J635

SM3-J517

1 page 1

Models J08C-TP and J08C-TR3-6-14 ENGINE

INSPECT THE INTAKE AND EXHAUST MANIFOLDS. NOTE: Clean the intake and exhaust manifolds with a

commercial cleaning agent before inspection.

1. Check the intake and exhaust manifolds for cracks,

using a dye penetrant. If cracks are found, replace the manifold.

2. Measure the intake manifold flatness with a straight

edge and a thickness gauge. If the value exceeds the service limit, replace the intake manifold.

Service limit: 0.2 mm (0.0079 in.)

3. Measure the exhaust manifold flatness with a straight

edge and a thickness gauge. If the value exceeds the service limit, correct the exhaust manifold by grinding it to become within 0.14 mm (0.006 in.) per 2 flanges or 0.1 mm (0.004 in.) per flange.

Service limit: 0.2 mm (0.0079 in.)

Fig. 47

Fig. 48

4. Visually check the seal ring of the exhaust manifold

for deformation or wear. Replacement is necessary if damage such as deformation and wear is excessive.

SM3-J570

INSPECT THE CAMSHAFT.

1. Visually check the camshaft surface for wear and

scratches.

SM3-J518

Fig. 49

SM3-J636

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-15

2. Measure the cam height.

Measure the dimensions (A) shown in the figure with a micrometer. If the value exceeds the service limit, replace the camshaft.

Nominal dimension A : Intake = 50.0667 ± 0.15 mm

(1.9711 ± 0.0059 in. ) Exhaust = 52.1038 ± 0.15 mm

(2.0513 ± 0.0059 in.)

Service limit: –0.5 mm (–0.0197 in.)

Fig. 50

Fig. 51

Fig. 52

SM3-J519A

SM3-J637

SM3-J638

3. Measure the clearance of camshaft journal. a. Measure the outside diameter of camshaft journal

with a micrometer. If the value exceeds the service limit, replace the camshaft.

Nominal dimension: 40.0 mm (1.575 in.) Service limit: 39.85 mm (1.569 in.)

b. Measure the inside camshaft bearing with a cylinder

gauge. If the value exceeds the service limit, replace the camshaft bearing.

Nominal dimension: 40.0 mm (1.575 in.) Service limit: 40.15 mm (1.581 in.)

c. Calculate the clearance from the above measure-

ment. If the clearance is greater than the limit, replace the camshaft or camshaft bearing.

Nominal dimension: 0.020 - 0.063 mm (0.0008 - 0.0024 in.) Service limit: 0.1 mm (0.0039 in.)

Fig. 53

1 page 1

Models J08C-TP and J08C-TR3-6-16 ENGINE

4. Measure the camshaft end play.

Support the camshaft with V -blocks and measure the run out at the center journal with a dial gauge. If the value exceeds the service limit, replace it.

Service limit: 0.10 mm (0.0039 in.)

SM3-J639

IF NECESSARY, REPLACE THE CAMSHAFT GEAR.

1. Measure the length of the cam gear bolts, if the length

is A or more, replace with new bolts.

A = 51 mm (2.0078 in.)

2. Make sure there is no dirt or scratch on the cam-

shaft gear or tightening surface of the camshaft.

Fig. 54

Fig. 55

Fig. 56

SM3-J080

90˚

SM3-J081 SM3-J082

SM3-J640

3. Apply clean engine oil to the bolt seating and bolt

thread, then tighten the bolt to the specified torque below.

Tightening torque: 600 kg·cm (43 lb·ft)

4. Retighten them 90° (1/4 turn).

NOTE: When adding torque, never untighten the nuts,

even it they have been overtightened.

INSPECT THE ROCKER ARM ASSEMBLY AND ROCKER ARM SHAFT.

1. Measure the inside diameter of the rocker arm bush-

ing with a cylinder gauge. If wear exceeds the service limit, replace it.

Nominal dimension: 22.0 mm (0.8661 in.) Service limit: 22.08 mm (0.8693 in.) NOTE: When installing a bushing into the rocker arm,

align the bushings with the oil holes of the rocker arm.

Fig. 57

Fig. 58

SM3-J641

SM3-J642

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-17

2. Measure the outside diameter of the rocker arm shaft with a micrometer. If wear exceeds the service limit, replace the rocker arm.

Nominal dimension: 22.0 mm (0.8661 in.) Service limit: 21.92 mm (0.8630 in.)

3. Calculate the clearance between the rocker arm bushing and rocker arm shaft. If the clearance is greater than the specified limit, replace the rocker arm bushing.

Assembly standard: 0.03 - 0.101 mm (0.0012 - 0.0039 in.) Repair limit: 0.15 mm (0.0059 in.)

INSPECT THE ROCKER ARM AND CROSS HEAD.

Visually check the contact between the rocker arm and cross head. Replace the rocker arm and the cross head if damage such as wear and scratches is excessive. If there is only a minimal amount of wear, correct the surface with a resurfacer.

Visually check the adjusting screw thread. Replace the adjusting screw if damage such as wear and scratches is excessive.

Fig. 59

Fig. 60

SM3-J060

SM3-J643

1 page 1

Models J08C-TP and J08C-TR3-6-18 ENGINE

ASSEMBLING

ASSEMBLE THE VALVE SYSTEM. NOTE: If parts are reused, install them to their initial

position.

1. Apply engine oil to the intake and exhaust valve stems. Then insert them to the valve guide installed to the cylinder head.

2. Install the valve inner and outer springs and valve spring seat upper.

3. Press fit the valve spring seat upper with the special tool, then securely fit the valve spring retainer.

Special tool: Valve spring press (09470 - 1022)

ASSEMBLE THE ROCKER ARM ASSEMBLY.

1. Make sure of the correct direction of the rocker arm support and assemble the rocker arm assembly.

NOTE: Wrong mounting of the rocker arm support results

in seizure of the valve mechanism due to incorrect lubrication.

2. Wind up the adjusting screw of the rocker arm completely.

NOTE: If the adjusting screw is left unwound, the rocker

shaft may bend when the rocker arm support is tightened.

Fig. 61

Fig. 62

SM3-J644

SM3-J645

INSTALL THE CAM IDLER GEAR.

1. Install the cam idler gear with the snap ring side facing the cylinder head.

2. Install the cam idler gear shaft through a thrust plate, with the oil filler facing downward.

NOTE: Refer to page 3-6-1.

3. Tighten the idler gear shaft bolt to the specified torque below.

Tightening torque: 1,100 kg·cm (80 lb·ft)

MEASURE THE CAM IDLER GEAR END PLAY.

After installing the cam idler gear, measure the clearance between the cam idler gear and thrust bearing with a dial gauge. If the clearance exceeds the service limit, replace the thrust bearing.

Nominal clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Service limit: 0.30 mm (0.0118 in.)

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-19

MATCHING SURFACE WITH HEAD END

LIQUID GASKET

Fig. 63

HEAD SIDE HOLE

SM3-J037

INSTALL THE IDLER GEAR COVER.

1. Clean the cylinder head mounting surface of the idler gear cover.

2. Apply liquid gasket to the idler gear cover, then install it to the cylinder head within 20 minutes.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.) NOTE:

● If left more than 20 minutes, clean off the liquid gas-

ket completely and reapply the liquid gasket.

● Refer to page 3-20-1.

COOLANT SEAL RING

Fig. 64

LIQUID GASKET APPLICATION POINT

LIQUID GASKET

CYLINDER HEAD

CYLINDER

BLOCK REAR END PLATE

GEAR CASE PRINTED SEAL

SM3-J268

PRINT SEAL

LIQUID GASKET APPLICATION POINT

FLYWHEEL HOUSING

CORRECT

CLEARANCE

TOO POOR

1 page 1

Models J08C-TP and J08C-TR3-6-20 ENGINE

MOUNTING

1. INSTALL THE CYLINDER HEAD GASKET. NOTE:

● Never reuse the cylinder head gasket as it may cause

engine damage.

● Before installing the cylinder head gasket, remove dirt,

moisture and oil on the cylinder head and cylinder block surface.

● The coolant seal rings between the bores are easily

damaged. Do not touch them with your hands or other objects. Make sure that the seal rings are not loose or damaged.

● Since silicon material is used for the gear case print

seal, make sure that there is no peeling before assembly.

1. Install the cylinder head gasket on the cylinder block and flywheel housing.

2. Fill the hole at the back of the cylinder head gasket with liquid gasket.

NOTE: Make sure that the liquid gasket surface is flush

with the cylinder head gasket upper surface.

CLEARANCE

Fig. 65

Fig. 66

A-A SECTION

CLEARANCE

PROTRUDING

SM3-J075

2. INSTALL THE CYLINDER HEAD ON THE CYLINDER BLOCK.

SM3-J627

3. INSTALL THE CYLINDER HEAD BOLT.

1. Preparation a. Measure the length of the M12 head bolts, if the

length is A or more, replace with new bolts.

A = 126 mm (4.9606 in.)

b. Make sure that no dirt or scratch is on the tightening

surface of the cylinder head bolt.

Fig. 67

SM3-J076A

Fig. 68

Fig. 69

PAINT

90˚

SM3-J078

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-21

c. Apply clean engine oil to the bolt surface and bolt

threads.

NOTE: Since the cylinder head bolts are unique to this

engine, do not substitute ordinary bolts.

2. Tighten the cylinder head bolt. a. Tighten No.1 - No.26 (M12)bolts in

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

Tightening torque: 600 kg·cm (43 lb.in.)

SM3-J269B

b. Mark the bolts with paint to indicate the same direc-

tions as shown in the figure. c. Turn No.1 - No.26 bolts 90° (1/4 turn). d. Retighten them 90° (1/4 turn).

NOTE: Total tightening amounts to 180°. It must not be-

come 200° or more.

e. Make sure that all paint marks face the same direc-

tion.

NOTE: When adding torque, never untighten the nuts,

even if they have been overtightened.

Fig. 70

Fig.71

FLYWHEEL HOUSING

FLYWHEEL

f. Tighten No.27 - No.29 (M10) bolts in

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

Tightening torque: 600 kg·cm (43 lb·ft)

SM3-J288A

4. INSTALL THE CAM HOUSING.

1. Using the timing line on the flywheel, align No.1 cyl-

inder with the upper dead point.

NOTE: Refer to page 3-18-1.

SM3-J009

Fig. 72

ARROW OF MARK

1 page 1

Models J08C-TP and J08C-TR3-6-22 ENGINE

2. Install the cam housing on the cylinder head.

NOTE: When installing the cam housing, make sure the

cam housing gasket is correctly fitted and is free of uneven deformation.

SM3-J647

5. ASSEMBLE THE CAMSHAFT.

1. Install the camshaft into the cam housing so that the

arrow stamped on the front of the camshaft gear

faces upward and that the lower line is level.

NOTE: Incorrect installation may damage of the engine.

Fig. 73

Fig. 74

SCALE ETC...

SM3-J083

2. Install the camshaft bearing cap to the cam hous-

ing. Make sure there is no dirt or scratch on the tight-

ening surfaces.

3. Apply clean engine oil to the bolt seating and bolt

thread, then tighten the bolt to the specified torque

below.

Tightening torque: 320 kg·cm (23 lb·ft)

SM3-J648

6. MEASURE THE BACKLASH BETWEEN THE CAMSHAFT GEAR AND CAMSHAFT IDLER GEAR.

Measure the backlash between the camshaft gear and camshaft idler gear with a dial gauge. If the value exceeds the service limit, replace the camshaft gear.

Nominal backlash: 0.030 - 0.253 mm (0.0012 - 0.0099 in.) Service limit: 0.30 mm (0.0118 in.)

Fig. 75

Fig. 76

SM3-J649

7. MEASURE THE CAMSHAFT END PLAY.

Measure the thrust clearance between the camshaft and camshaft bearing with a dial gauge. If the clearance exceeds the service limit, replace the camshaft.

Nominal clearance: 0.10 - 0.178 mm (0.0040 - 0.007 in.) Service limit: 0.3 mm (0.0118 in.)

SM3-J650

64 21357

SM3-J270

Fig. 77

VALVE SPRING

ROCKER ARM

LEAKAGE PIPE

NOZZLE CLAMP BOLT

Fig. 78

INJECTION PIPE NUT

INJECTION PIPE SEAL

CAM HOUSING

SM3-J199

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-6-23

8. INSTALL THE ROCKER ARM ASSEMBLY.

1. Install the rocker arm assembly to the cylinder head.

Make sure that the cross head is on each valve.

NOTE: If the cross head is assembled off the valve, the

valve may fall off, resulting in engine damage.

Tightening torque: 480 kg·cm (35 lb·ft)

9. INSTALL THE INJECTION NOZZLE.

1. Install a new O-ring into the groove of the cylinder

head.

2. Make sure that there is no dirt or foreign particles at

the sealing part between the nozzle holder and related parts (O-ring, nozzle sleeve and injection pipe seal), and connecting part between the nozzle holder and nut of the injection pipe.

3. Insert the nozzle holder taking care not to contact

the valve spring as shown in the figure.

NOTE: Apply clean engine oil to the O-ring and be care-

ful that the O-ring is not caught.

4. Cover the end of the injection pipe seal with the noz-

zle holder as shown in the figure and tighten the bolts to fasten the injection pipe seal to the cam housing.

5. Tighten the nut of the injection pipe provisionally.

6. Tighten the nozzle clamp bolt to the specified torque.

Tightening torque: 250 kg·cm (18 lb·ft) NOTE: After tightening the bolt, make sure that the rocker

arm moves smoothly.

7. Tighten the nut of the injection pipe to the specified

torque.

Tightening torque: 400 kg·cm (28 lb·ft)

8. Install the leakage pipe.

10. ADJUST THE VALVE CLEARANCE.

NOTE: Refer to page 3-18-4.

Fig. 79

SM3-J651

1 page 1

Models J08C-TP and J08C-TR3-6-24 ENGINE

CAM HOUSING

Fig. 80

PHASE WHERE NOT APPLIED LIQUID GASKET

COARSE

Fig. 81

HEAD COVER

CYLINDRICAL PLUG

PHASE WHERE

TO APPLY LIQUID GASKET

SM3-J085

GOOD

SM3-J086

11. INSTALL THE CYLINDER HEAD COVER

1. Remove the cylindrical plugs at the front and rear

ends of the cam housing. Clean the cylindrical plugs and the mounting surfaces of the cam housing.

2. Apply liquid gasket to the front and rear half circles

of the cam housing, then install the cylinder plug within 20 minutes.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.) NOTE:

● If left more than 20 minutes, clean off the liquid gas-

ket completely and reapply the liquid gasket.

● Make sure to wipe off excessive liquid gasket.

● Refer to page 3-20-1.

Fig. 82

HEAD COVER

HEAD COVER GASKET

Fig. 83

CAM HOUSING

CLINDRICAL PLUG

BOLT

SILENT BLOCK

SPACER

BOTTOM FACE OF HEAD COVER

SM3-J087

SM3-J088

3. Apply liquid gasket to plug corner A at the front and

rear ends of the cam housing.

4. Install the cylinder head cover gasket into the gas-

ket groove at the head cover lower surface.

5. Insert the spacer from the head cover lower surface.

6. Install the cylinder head cover to the cam housing.

NOTE: If left more than 20 minutes, clean off the liquid

gasket completely and reapply the liquid gasket.

7. Tighten the mounting bolt of the head cover through

the silent block to the specified torque below and fix the head cover on the cam housing.

Tightening torque: 250 kg·cm (18 lb·ft)

1 page 1

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

CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND

FLYWHEEL HOUSING

Fig. 1

1. Fan pulley spacer

2. Crankshaft pulley

3. Pulley center

4. T orsional damper

5. Seal sub assembly

6. Crankshaft oil seal

7. Oil seal retainer

SM3-J274B

Fig. 2

1. Flywheel housing

2. Dust cover

3. Crankshaft oil seal

4. Ring gear

5. Flywheel

SM3-J274A

1 page 1

Models J08C-TP and J08C-TR3-7-2 ENGINE

1 2

1. Oil pan gasket

2. Oil pan

3. Soft washer 3 4

4. Drain plug

Fig. 3

SM3-J273A

Fig. 4

1 page 1

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

DISMOUNTING

1. REMOVE THE CRANKSHAFT PULLEY.

SM3-J652

2. REMOVE THE TORSIONAL DAMPER.

Fig. 5

Fig. 6

Fig. 7

SM3-J653

3. REMOVE THE FLYWHEEL HOUSING STAYS.

SM3-J654

4. REMOVE THE OIL PAN AND OIL STRAINER.

SM3-J655

5. REMOVE THE FLYWHEEL ASSEMBLY.

1. Remove the pilot bearing.

Fig. 8

SM3-J520

Fig. 9

Fig. 10

PLATE

HOOK

SM3-J656

SM3-J119

1 page 1

Models J08C-TP and J08C-TR3-7-4 ENGINE

2. Remove the flywheel mounting bolts.

3. Hold a copper rod through the starter hole against the flywheel and drive the rod lightly with a hammer to remove the flywheel from the crankshaft while rotating the crankshaft.

WARNING

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

6. REMOVE THE CRANKSHAFT OIL FRONT AND REAR SEALS.

1. Remove the crankshaft oil seals with the special tool.

Special tool: Oil seal puller (09420 - 1731) for front

(09420 - 1742) for rear

a. Place the plate at the crankshaft end using the crank

pulley mounting bolts (front) or the flywheel mounting bolts (rear).

b. Install the hook to the crankshaft end using the bolt

supplied.

NOTE: Engage the hook with the oil seal notch.

c. Remove the installed bolt in step a.

Fig. 11

Fig. 12

REMOVE AFTER HOOK INSTALLATION

SM3-J120

CENTER BOLT

SM3-J121

d. Install the center bolt and tighten it to remove the oil

seal.

7. REMOVE THE DUST COVER.

Fig. 13

SM3-J657

Fig. 14

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-7-5

8. REMOVE THE FLYWHEEL HOUSING.

1. Remove the two front mounting bolts of the flywheel

housing.

SM3-J658

2. Remove the rear mounting bolts of the flywheel

housing.

Fig. 15

Fig. 16

3. Remove the flywheel housing by driving it lightly with

a plastic hammer.

SM3-J659

WARNING

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

SM3-J646

9. REMOVE THE OIL SEAL RETAINER.

Fig. 17

SM3-J660

Fig. 18

1 page 1

Models J08C-TP and J08C-TR3-7-6 ENGINE

INSPECTION AND REPAIR

INSPECT THE TORSIONAL DAMPER. NOTE: Clean the torsional damper with a commercial

cleaning agent before inspection.

1. Check if there are any cracks in the damper rubber

section. If the cracks are excessive, replacement is necessary.

SM3-J661

INSPECT THE FLYWHEEL (MODELS: FD, FE, FF)

1. Check the friction surface for scoring or heat crack-

ing. If necessary , grind the friction surface or replace the

flywheel.

Grind limit: 1 mm (0.039 in) Deflection limit: 0.04 mm (0.00157 in.) NOTE: Do not grind the flywheel over than the limit.

Fig. 19

SM5-089

2. Using a straight edge and a feeler gauge, check the

friction surface ware. If the wear is greater than the sevice limit, replace

the flywheel.

Standard: 0.05 mm (0.0020 in.) or less Service limit: 1.0 mm (0.039 in.)

INSPECT THE FLYWHEEL (MODEL: SG)

1. Check the friction surface for scoring or heat crack-

ing. If necessary , grind the friction surface or replace the

flywheel.

Grind limit: 1 mm (0.039 in) Deflection limit: 0.04 mm (0.00157 in.) NOTE: Do not grind the flywheel over than the limit.

2. Using a vernier caliper, check the friction surface

ware. If the wear is greater than the sevice limit, replace

the flywheel.

Standard: 48 mm (1.890 in.) Service limit: 49 mm (1.929 in.)

Fig. 20

SM5-040A

1 page 1

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

Fig. 21

Fig. 22

BOSS

3. After grind the friction surface, adjust the friction sur-

face depth of the flywheel within the service standard by grind the outer bosses of the flywheel.

Fly wheel depth: 48 mm (1.890 in.)

FRICTION SURFACE

SM5-098A

INSPECT THE PILOT BEARING.

Rotate the bearing lightly by hand, and check whether there is any abnormal noise or chatter, and whether the balls run smoothly . If there is any fault, replace the pilot bearing.

SM3-J523

INSPECT THE FLYWHEEL RING GEAR.

Visually check the flywheel ring gear . Replace the parts if damage such as wear and scratches is excessive.

REPLACE THE FLYWHEEL RING GEAR.

1. Heat the ring gear evenly to about 200°C (392°F)

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

Fig. 23

SM3-J125

WARNING

Never touch the ring gear or flywheel when they are hot with your bare hands.

2. Heat the ring gear evenly to about 200°C (392°F)

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

NOTE: Do not overheat the ring gear.

1 page 1

Models J08C-TP and J08C-TR3-7-8 ENGINE

MATCHING FLANGE FACE WITH THE BLOCK

LIQUID GASKET

SM3-J032

Fig. 24

MATCHING FACE WITH THE REAR END PLATE

LIQUID GASKET

MOUNTING

1. INSTALL THE OIL SEAL RETAINER.

1. Clean the cylinder block mounting surface of the oil

seal retainer.

2. Apply liquid gasket to the oil seal retainer, then in-

stall it to the cylinder block within 20 minutes.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.) NOTE:

● Refer to page 3-20-1.

● If left more than 20 minutes, clean off the liquid gasket

completely and reapply the liquid gasket.

2. INSTALL THE FLYWHEEL HOUSING.

1. Clean the rear end plate mounting surface of the fly-

wheel housing.

2. Apply liquid gasket to the flywheel housing, then in-

stall it to the rear end plate within 20 minutes.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.) NOTE:

● If left more than 20 minutes, clean off the liquid gas-

ket completely and reapply the liquid gasket.

● Refer to page 3-20-1.

Fig. 25

MATCHING FLANGE FACE WITH THE FL YWHEEL HOUSING

FLYWHEEL HOUSING OPENING

Fig. 26

SM3-J041

LIQUID GASKET

SM3-J035

WARNING

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

3. INSTALL THE DUST COVER.

1. Clean the flywheel housing mounting surface of the

dust cover.

2. Apply liquid gasket to the dust cover, then install it

to the flywheel housing within 20 minutes.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.) NOTE:

● Refer to page 3-20-1.

● If left more than 20 minutes, clean off the liquid gas-

ket completely and reapply the liquid gasket.

Fig. 27

NEW OIL SEAL

EDGE OF THE CRANK SHAFT

GUIDE

SM3-J122

FELT SIDE OF THE OIL SEAL

GUIDE BOLT

GUIDE

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-7-9

4. CRANK SHAFT OIL SEALS INSTALLATION (FRONT AND REAR).

Special tools: Oil seal press (09407-1030) Front

(09407-1040) Rear

1. Clean the edges and surface of the crank shaft and

the special tools.

2. Insert a new crank shaft oil seal into the guide of the

oil seal press.

NOTE: Pay attention to the orientation of the crank

shaft oil seal (The felt side should face the outside of the cylinder block).

Fig. 28

Fig. 29

Fig. 30

PRESS CENTER

BOLT

SM3-J806

3. Apply a little engine oil to the seal portion of the crank

shaft oil seal.

4. Attach the oil seal press guide with the new crank

shaft oil seal onto the crank shaft using the attached guide bolt.

GUIDE BOLTS

SM3-J123

5. Insert the oil seal press by adjusting the oil seal press

hole to the guide bolt.

6. Press the crank shaft oil seal inside by attaching the

accompanying center bolt onto the oil seal press and tightening it until it stops.

SM3-J124

Fig. 31

TIGHTENING ORDER

Fig. 32

1 page 1

Models J08C-TP and J08C-TR3-7-10 ENGINE

5. INSTALL THE FLYWHEEL ASSEMBLY.

1. Make sure that there are no burns or dirt on the con-

tact surface or in the threaded holes of the crankshaft or fly-wheel.

2. Insert the special tool onto the crankshaft.

Special tool: Guide bar (09481 - 1340) NOTE: Place one guide bar at the collar knock and an-

other at the opposite side of the collar knock.

3. Insert the flywheel slowly until it contacts the collar

knock to prevent impact on the guide bar. Adjust the position. Then, insert it completely.

WARNING

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

4. Apply clean engine oil to the threads of the flywheel

bolt and the flywheel bolt seat. Be sure to tighten

SM3-J127

two or three threads provisionally by hand. Then, tighten the flywheel bolts (8) with a low-torque impact wrench.

5. Pull out the guide bar and tighten the remaining two

CRANKSHAFT

COLLAR

SM3-J128

Tightening torque: 1,900 kg·cm (137 lb·ft)

fly-wheel bolts provisionally as in step 4.

6. Tighten the flywheel bolts in the order shown in the

figure to the specified torque below.

7. Loosen all bolts and tighten them again to the speci-

fied torque.

8. Measure the sliding surface play of the flywheel.

Measure the sliding surface play of the flywheel with a dial gauge. If the play exceeds the service limit, resurface the sliding surface.

Service limit: 0.2 mm (0.0079 in.)

0.3 mm (0.0118 in.) for model SG only

Fig. 33

Fig. 34

SM3-J129

9. Install the pilot bearing.

SM3-J525

LIQUID GASKET (TWO PARTS EACH)

Fig. 35

REAR

LOBE

BOLT TIGHTENING DIRECTION

OIL STRAINER

SM3-J662

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-7-11

6. INSTALL THE OIL PAN.

1. Make sure that there is no deformation, impact

marks or foreign particles on the mounting surface and stiffener surface of the oil pan.

2. Place a guide pin of 70 mm(2.7559 in.) or longer

in the cylinder block.

3. Apply liquid gasket to the front and back ends of

the cylinder block lower surface.

Liquid gasket: ThreeBond No.1207B Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.)

4. Install the oil pan gasket so that the protrusion is

at the flywheel housing side and the print seal surface is at the cylinder block side.

5. Install the oil pan.

NOTE:

● Install the oil pan along the guide pin.

● If left more than 20 minutes, clean off the liquid

gasket completely and reapply the liquid gasket.

● Refer to page 3-20-1.

6. Tighten the oil pan installation bolts in the order

q-w-e-r as shown in the figure with an impact wrench.

Tightening torque: 250 - 300 kg·cm (18 - 21 lb·ft)

Fig. 36

Fig. 37

INTAKE PORT SIDE

SM3-J112

7. Finish tightening the bolts in the order shown in the

figure with a torque wrench to the specified torque.

Tightening torque: 300 kg·cm (22 lb·ft) NOTE: Make sure that the washer is not on the flange.

7. INSTALL THE FLYWHEEL HOUSING STAYS.

SM3-J663

Fig. 38

1 page 1

Models J08C-TP and J08C-TR3-7-12 ENGINE

8. INSTALL THE TORSIONAL DAMPER.

SM3-J653

9. INSTALL THE CRANKSHAFT PULLEY.

Fig. 39

SM3-J652

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-8-1

TIMING GEAR

Fig. 1

INJECTION PUMP GEAR

CAMSHAFT GEAR

CAM IDLER GEAR

SUB IDLER GEAR

OIL PUMP IDLER GEAR

MAIN IDLER GEAR

CRANK GEAR

SM3-J136

6 7

Fig. 2

1. Gasket

2. Rear end plate

3. Camshaft gear

4. Camshaft idler gear

5. Idler gear thrust plate

6. Sub idler gear

7. Oil pump gear

8. Main idler gear

9. Crankshaft gear

10. Injection pump drive gear

11. Power steering pump drive gear

12. Pin

13. Idler gear shaft

SM3-J130

Fig. 3

1 page 1

Models J08C-TP and J08C-TR3-8-2 ENGINE

DISMOUNTING

1. REMOVE THE MAIN IDLER GEAR.

1. Remove the mounting bolts of the main idler gear

shaft.

2. Remove the main idler gear.

SM3-J666

3. Remove the main idler gear shaft with the special

tool.

Special tool: Sliding hammer (09420 - 1100)

Fig. 4

Fig. 5

Fig. 6

SM3-J667

2. REMOVE THE SUB IDLER GEAR.

1. Remove the mounting bolts of the sub idler gear

shaft.

2. Remove the sub idler gear.

SM3-J668

3. Remove the sub idler gear shaft with the special tool.

Special tool: Sliding hammer (09420 - 1100)

SM3-J669

3. REMOVE THE OIL PUMP ASSEMBLY.

Fig. 7

SM3-J670

Fig. 8

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-8-3

4. REMOVE THE REAR END PLATE.

1. Remove two torx bolts adjacent to the air compres-

sor mounting section using the special tool.

Special tool: Socket wrench (09411 - 1300)

SM3-J135

2. Remove three bolts shown in the figure.

THREE BOLTS

Fig. 9

SM3-J671

Fig. 10

SM3-J526

1 page 1

Models J08C-TP and J08C-TR3-8-4 ENGINE

INSPECTION AND REPAIR

INSPECT THE GEAR TEETH FOR PITTING OR WEAR.

Visually check the gears for pitting or wear. If a gear is damaged, replace the gear.

MEASURE THE CLEARANCE BETWEEN THE IDLER GEAR BUSHING AND SHAFT .

1. Using a micrometer, measure the outside diameter

of the main idler gear shaft. If the diameter exceeds the service limit, replace the main idler gear shaft.

Nominal dimension: 57.0 mm (2.2441 in.) Service limit: 56.94 mm (2.2417 in.)

– 0.03 – 0.06

– 0.0012 – 0.0024

Fig. 11

Fig. 12

Fig. 13

THRUST BEARING

CYLINDER BLOCK

END PLAY

SM3-J672

SM3-J673

SM3-J674

2. Using a cylinder gauge, measure the inside diam-

eter of the main idler gear bushing.

3. Calculate the clearance from the above measure-

ment.

If the clearance exceeds the repair limit, replace the main idler gear shaft and/or main idler gear bushing.

Assembly standard: 0.030 - 0.090 mm (0.0012 - 0.0035 in.) Repair limit: 0.20 mm (0.0079 in.)

MEASURE THE IDLER GEAR END PLAY OF THE MAIN IDLER GEAR.

Using a dial gauge, measure the clearance between the main idler gear and thrust bearing. If the clearance exceeds the repair limit, replace the thrust bearing.

Assembly standard: 0.114 - 0.160 mm (0.0045 - 0.0062 in.) Repair limit: 0.20 mm (0.0079 in.)

MEASURE THE CLEARANCE BETWEEN THE SUB IDLER GEAR SHAFT AND SUB IDLER GEAR BUSHING.

1. Using a micrometer, measure the outside diameter

of the sub idler gear shaft. If the diameter exceeds the service limit, replace the sub idler gear shaft.

Nominal dimension: 50.0 mm (1.969 in.)

– 0.025 – 0.05

– 0.0010 – 0.0020

Service limit: 49.95 mm (1.967 in.)

Fig. 14

SM3-J142

Fig. 15

SM3-J634

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-8-5

2. Using a cylinder gauge, measure the inside diam-

eter of the sub idler gear bushing. If the diameter exceeds the service limit, replace the sub idler gear.

Nominal dimension: 50.0 mm (1.969 in.)

+ 0.03 + 0

+ 0.0012 + 0

Service limit: 50.03 mm (1.970 in.)

3. Calculate the clearance from the above measure-

ment.

If the clearance exceeds the repair limit, replace the sub idler gear shaft and/or sub idler gear bushing.

Assembly standard: 0.025 - 0.075 mm (0.0010 - 0.0029 in.) Repair limit: 0.20 mm (0.0079 in.)

Fig. 16

THRUST BEARING

CYLINDER BLOCK

END PLAY

MEASURE THE IDLER GEAR END PLAY OF THE SUB IDLER GEAR.

Using a dial gauge, measure the clearance between the sub idler gear and thrust bearing. If the clearance exceeds the repair limit, replace the thrust bearing.

Assembly standard: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Repair limit: 0.30 mm (0.0118 in.)

SM3-J676

Fig. 17

1 page 1

Models J08C-TP and J08C-TR3-8-6 ENGINE

MOUNTING

1. INSTALL THE REAR END PLATE.

1. Using the special tool, tighten two torx bolts adja-

cent to the air compressor mounting section to the specified torque below.

Special tool: Socket wrench (09411 - 1300) Tightening torque: 560 kg·cm (41 lb·ft)

SM3-J135

2. Tighten the three bolts shown in the figure to the

specified torque below.

Tightening torque: 560 kg·cm (41 lb·ft)

THREE BOLTS

Fig. 18

Fig. 19

SM3-J671

2. INSTALL THE OIL PUMP ASSEMBLY.

1. Apply oil to the pump case and bearings of the block

(hatched area) before installing the oil pump.

NOTE: Not applying oil may cause oil suction failure at

start-up, resulting in seizure and abnormality.

2. To prevent misalignment of the gasket, apply grease

to the gasket matching face of the block. Then, place and fix the gasket.

3. Tighten the oil pump mounting bolts provisionally in

the order as shown in the figure. Then retighten them to the specified torque below.

Tightening torque: 290 kg·cm (21 lb·ft)

APPLY THE OIL

(HATCHED AREA)

SM3-J164

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-8-7

THRUST PLATE

INJECTION PUMP DRIVE GEAR

Fig. 20

MATCH MARKS “2”

CAMSHAFT GEAR

CAM IDLER GEAR

SUB IDLER GEAR

OIL PUMP GEAR

MAIN IDLER GEAR CRANKSHAFT GEAR

MATCH MARKS “1”

3. INSTALL THE SUB IDLER GEAR.

Tightening torque: 1,100 kg·cm (80 lb·ft)

OIL HOLE

SM3-J137

OIL HOLE

SM3-J138

OIL HOLE

SM3-J1369

SM3-J136

CYLINDER BLOCK

THRUST PLATE

CYLINDER BLOCK

THRUST PLATE

CYLINDER BLOCK

C-C SECTION

B-B SECTION

A-A SECTION

1. Install the sub idler gear shaft through the thrust plate

so that the lubrication hole faces downward.

2. Install the sub idler gear.

3. Tighten the mounting bolts of the sub idler gear shaft

to the specified torque below.

Fig. 21

Fig. 22

SM3-J678

SM3-J679

4. INSTALL THE MAIN IDLER GEAR.

1. Install the main idler gear shaft through the thrust

plate so that the lubrication hole faces downward.

2. Install the main idler gear.

NOTE:

● Apply engine oil to the contact surface of the idler

gear and idler gear shaft before installation.

● Adjust the timing of the main idle gear to align with

the injection pump gear (air compressor gear).

INJECTION PUMP GEAR

POWER STEERING GEAR

1 page 1

Models J08C-TP and J08C-TR3-8-8 ENGINE

3. Tighten the mounting bolts of the main idler gear shaft

to the specified torque below.

Tightening torque: 1,750 kg·cm (127 lb·ft)

5. MEASURE THE TIMING GEAR BACKLASH

Using a dial gauge, measure the backlash between the gears. If the backlash exceeds the limit, replace the gear .

CAMSHAFT GEAR

CAM IDLER GEAR

SUB IDLER GEAR

OIL PUMP GEAR

MAIN IDLER GEAR

CRANK SHAFT GEAR

Fig. 23

Unit: mm (in.)

Inspection item Standard Limit Crankshaft - Main idle 0.030 - 0.132 (0.0012 - 0.0051) 0.30 (0.0118) Main idle - Injection pump 0.030 - 0.218 (0.0012 - 0.0085) 0.30 (0.0118) Injection pump - PS pump 0.030 - 0.183 (0.0012 - 0.0072) 0.30 (0.0118) Main idle - Sub idle 0.030 - 0.162 (0.0012 - 0.0063) 0.30 (0.0118) Sub idle - Oil pump 0.030 - 0.131 (0.0012 - 0.0051) 0.30 (0.0118) Sub idle - Cam idle 0.050 - 0.218 (0.0020 - 0.0085) 0.30 (0.0118) Cam idle - Cam 0.030 - 0.253 (0.0012 - 0.0099) 0.30 (0.0118)

SM3-J136A

1 page 1

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

PISTON, CRANKSHAFT AND CYLINDER BLOCK

Fig. 1

1. Cylinder liner

2. Cylinder block

3. Oil jet pipe

4. Piston ring

5. Piston

6. Piston pin

7. Retainer ring

8. Connecting rod

9. Connecting rod bushing

10. Connecting rod bearing

11. Crankshaft

12. Crankshaft thrust bearing

13. Crankshaft main bearing

14. Crankshaft gear

15. Collar

16. Main bearing cap

SM3-J276

1 page 1

Models J08C-TP and J08C-TR 3-9-2 ENGINE

Fig. 2

1. Injection pump bracket

2. Silent block

3. Cover

4. Seal

5. Sound insulator

SM3-J277

Fig. 3

Fig. 4

SM3-J154

SM3-J680

1 page 1

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

DISMOUNTING

1. REMOVE THE PISTONS ALONG WITH THE CONNECT ING RODS.

Remove the connecting rod bearing cap mounting bolts and pull out the pistons along with the connecting rods from the cylinder block upper side.

NOTE:

● Before pulling out the pistons, remove carbon deposits

from the upper end inside the cylinder liner with a scraper or emery paper (recommended: No. 150), working in a circular direction.

● When pulling out the pistons, be careful that the in-

sides of the cylinder liners are not damaged by the connecting rod big ends.

● When pulling out the pistons, be careful that the noz-

zle of the cooling jet is not bent by the connecting rod big ends. If the nozzle is bent, be sure to readjust the cooling jet sight.

● When pulling out the pistons, be careful not to drop

the crankpin bearings from the connecting rod big ends, which may cause deformation or damage.

● Arrange the removed parts in order of the cylinder

numbers. Be careful not to change the combination of the connecting rod and cap.

● Two pistons can be removed at a time. (Nos. 1 and 6,

Nos. 2 and 5, and Nos. 3 and 4).

Fig. 5

Fig. 6

Fig. 7

SM3-J681

SM3-J682

SM3-J157

2. REMOVE THE CRANKSHAFT.

Remove the main bearing cap mounting bolts, then remove the crankshaft.

3. REMOVE THE CYLINDER LINER.

NOTE: Before removing the piston, put alignment marks

on the cylinder liner and cylinder block using a marking pen. The cylinder liner is bent by “runin”. When reusing the cylinder liner, misalignment with the cylinder block may concentrate stress on the thin part of the cylinder liner and it may break.

Fig. 8

1 page 1

Models J08C-TP and J08C-TR 3-9-4 ENGINE

1. The cylinder liner can be pulled out by hand. If this

is difficult, use the special tool.

NOTE: Arrange the removed parts in order of the cylin-

der numbers.

SM3-J683

4. CLEAN THE CYLINDER BLOCK AS FOLLOWS.

1. Rinse the cylinder block in a hot commercial alka-

line solution, and remove oil from the cylinder block.

2. Remove the alkaline solution from the cylinder block

using a steam cleaner.

3. If the water jacket is very dirty, clean it as follows: a. Rinse the cylinder block in a commercial acid solu-

tion.

b. After rinsing it for a while, leave it in the solution for

approximately 30 minutes.

c. Pull out the cylinder block. After the solution has

drained off, re-immerse the cylinder block in the so-

lution and leave it for approximately 10 minutes. d. Repeat step c until deposits are removed. e. Remove the acid solution with hot water. f . Immerse the cylinder block in the alkaline solution

to neutralize the acid. g. Finish by cleaning with the steam cleaner.

4. When the cooling water passage and oil passage are

cleaned completely, dry the cylinder block, press-fit

a new blank cap and apply liquid gasket.

Fig. 9

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-5

DISASSEMBLING

REMOVE THE CONNECTING ROD.

1. Remove the retainer rings from both ends of the pis-

ton pin using snap ring pliers.

WARNING

Removing the retainer rings may cause the retainer rings to fly up. Be sure to wear protective goggles.

SM3-J684

2. Apply the reinforcing plate to the piston pin and punch

out the piston pin using a hammer.

WARNING

Never touch the piston with your bare hands when it is hot.

NOTE: If it is difficult to punch out the piston pin, first

immerse the piston and piston pin in hot water, 80 - 90°C (176 - 194°F), for approximately five minutes to facilitate removal.

Fig. 10

REMOVE THE PISTON RINGS.

1. Remove the piston ring using the special tool.

Special tool: Piston ring expander (09442 - 1011)

NOTE:

● Handle the piston rings carefully because they are

made of a special casting which is easily broken.

● Arrange the piston rings in order of cylinder numbers.

SM3-J685

Fig. 11

1 page 1

Models J08C-TP and J08C-TR 3-9-6 ENGINE

INSPECTION AND REPAIR

INSPECT THE CONNECTING ROD.

1. Check the connecting rod for cracks or damage us-

ing dye penetrant examination or magnetic particle

examination. If there are any cracks or damage, re-

place the connecting rod with a new one.

SM3-J255

2. Check that there is no clogging in the lubrication

passage to the connecting rod small end. If there is

any clogging, blow air through the lubrication pas-

sage using an air gun, or clean by inserting a wire.

Fig. 12

Fig. 13

Fig. 14

Fig. 15

SM3-J527A

SM3-J242

SM3-J527

SM3-J303

SM3-J254

3. Measure bend or distortion of the connecting rod

using a connecting rod aligner. If the value exceeds

the limit, replace the connecting rod with a new one.

Limit:

Bend of connecting rod: 0.05 mm (0.0020 in.)

for each 100 mm (3.94 in.)

Distortion of connecting rod:

0.05 mm (0.0020 in.) for each 100 mm (3.94 in.)

INSPECT THE PISTON PIN AND CONNECTING ROD BUSHING.

1. Measure the piston pin outside diameter using a

micrometer. If the value exceeds the limit, replace

the piston pin with a new one.

NOTE: Never grind the piston pin because the surface

is treated. Standard: 37 mm (1.4567 in.) Limit: 36.96 mm (1.4551 in.)

2. Measure the connecting rod bushing inside diameter using a cylinder gauge. If the value exceeds the limit, replace the connecting rod bushing with a new one.

Standard: 37 mm (1.4567 in.) Limit: 37.1 mm (1.4606 in.)

3. Calculate the clearance between the piston pin and piston pin bushing.

If the value exceeds the limit, replace the piston pin with a new one.

Standard: 0.015 - 0.036 mm (0.0006 - 0.0014 in.) Limit: 0.08 mm (0.0031 in.)

WING NUT

GUIDE

PRESS SUB ASSEMBLY

Fig. 16

CONNECTING ROD

SM3-J466

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-7

REPLACE THE PISTON PIN BUSHING.

1. Prepare the special tools. Assemble the guide and press sub-assembly insert-

ing its pin into the guide then secure them with the wing nut.

Special tool: Guide (09481 - 1130)

Press sub - assembly (09402 - 1530) Wing nut (9233 - 10360)

NOTE:

● Bring lever “H” punched on the guide above the pin.

● Making sure to align both supporting surfaces of the

guide and press sub-assembly flush on a flat plane.

2. Using the special tool, remove the piston pin bushing.

a. Set the connecting rod assembled without crank pin

bore bearing on the guide and press sub-assembly.

GUIDE

Fig. 17

Fig. 18

PRESS SUB ASSEMBLY

GROOVE

OIL HOLE

CONNECTING ROD

SPINDLE

SM3-J467

SPINDLE

BUSHING CONNECTING ROD PRESS SUB ASSEMBLY

SM3-J468

PRESS

b. Install the spindle into the bushing.

Special tool: Spindle (09402 - 1540) NOTE: Align the grooving of the spindle with the oil hole

of the bushing.

c. Using a hydraulic press, remove the bushing.

NOTE: Always operate the press slowly and smoothly.

Fig. 19

Fig. 20

SM3-J469

C 0.5 - 1.0 mm

CONNECTING ROD

SM3-J470

3. Assemble the piston pin bushing. Chamfer one edge of the bushing hole at the small end

of the connecting rod uniformly by C 0.5 - 1.0 mm (0.0196

- 0.0393 in.).

NOTE:

● Irregular chamfering can cause out-of-roundness of

the pressed bushing, which may result in jamming during insertion.

● Remove dust from the inner surface of the smaller

hole.

1 page 1

Models J08C-TP and J08C-TR 3-9-8 ENGINE

OIL HOLE (B)

GUIDE

Fig. 21

OIL HOLE (B)

OIL PATH

Fig. 22

Fig. 23

BOLT

SPINDLE

BUSHING

PRESS

GROOVE

GUIDE

SPINDLE BUSHING

GUIDE

CONNECTING ROD

GROOVE

OIL HOLE (A)

SM3-J471

SM3-J472

SM3-J242

4. Mount the bushing on the spindle

a. Set the bushing and guide on the spindle, then se-

cure them with the bolt.

Special tool: Spindle (09402 - 1540)

Guide (09481 - 1540) Bolt (9191 - 08252)

NOTE: Align oil hole (A) in the bushing with both groove

or the spindle and guide, making sure oil hole (B) will meet with oil path in the connecting rod led from crank pin bore in the rod.

Tightening torque: 50 - 70 kg·cm (3.61 - 5.06 lb·ft)

b. Apply fresh engine oil around the bushing and guide.

5. Install the bushing in the connecting rod. Position the bushing tool assembly so that oil hole

(B) align with the oil path through the connecting rod.

Before installing, fully coat the bore in the connecting rod with fresh engine oil.

6. Inspect the bushing positioning after installation.

a. Make sure that the oil hole of the bushing and the oil

path of the connecting rod are suitably aligned allowing a 6 mm (0.23 in.) diameter rod to penetrate.

NOTE: Misalignment can lead to insufficient lubrication,

which may result in seizure.

b. Make sure that with a new piston pin inserted in the

piston pin, the bushing can be rotated by hand without rattling.

Fig. 24

SM3-J527

1 page 1

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

MEASURE THE ROUNDNESS OF THE CONNECTING ROD BIG END.

After tightening the connecting rod cap, measure the inside diameter of the connecting rod big end using a cylinder gauge to calculate the roundness.

Standard: 68.985 - 69 mm (2.7159 - 2.7165 in.) Limit: 0.06 mm (0.0024 in.) NOTE: For tightening of the connecting rod cap, refer to

page 3-9-22.

Fig. 25

Fig. 26

Fig. 27

SM3-J528A

MEASURE THE CLEARANCE BETWEEN THE CRANKPIN AND CONNECTING ROD BEARING.

1. Measure the crankpin outside diameter using a micrometer.

Standard: 65.0 mm (2.559 in.) Limit: 64.30 mm (2.5315 in.)

SM3-J687

X’

Y’

SM3-J529

Fig. 28

SM3-J527

1 page 1

Models J08C-TP and J08C-TR 3-9-10 ENGINE

2. Measure the connecting rod bearing inside diameter using a cylinder gauge.

Standard: 65 mm (2.559 in.)

3. Calculate the clearance between the crankpin and connecting rod bearing. If the value exceeds the limit, grind the crankpin to the specified undersize below to correct. Replace the connecting rod bearing with the correct one.

Standard: 0.031 - 0.082 mm (0.0012 - 0.0032 in.) Limit: 0.2 mm (0.0079 in.) Undersize machining dimension: Two sizes below

0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.)

NOTE: Make sure you replace the top and bottom con-

necting rod bearings as one set. The top and bottom connecting rod bearings must be profiled by roundness.

Fig. 29

Fig. 30

Fig. 31

SM3-J528

MEASURE THE CLEARANCE BETWEEN THE PISTON AND THE CYLINDER LINER.

NOTE: Before measurement, remove carbon deposits

from the upper end inside the cylinder liner with a scraper or emery paper (recommended: No.

150), working in a circular direction. Make sure that there are no scratches inside the cylinder liner.

SM3-J154

1. Measure the piston outside diameter at the following points using a micrometer. If the value exceeds the limit, replace the piston with a new one.

Standard: 114 mm (4.4882 in.) Limit: 113.92 mm (4.4850 in.)

SM3-J530

Fig. 32

OUTSIDE DIAMETER

21 mm

(0.83 in.)

SM3-J540

Fig. 33

Fig. 34

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-11

2. Measure the cylinder liner inside diameter at the four points in the piston boss and thrust direction as shown in the figure using a cylinder gauge. If the value exceeds the limit, replace the cylinder liner with a new one.

Standard: 114 mm (4.4882 in.) Limit: 114.15 mm (4.4941 in.) NOTE:

SM3-J544

● Apply the value obtained at the most worn point to

the cylinder liner inside diameter.

● If the cylinder liner is hardly worn, and when only the

20 (0.79)

40 (1.57)

80 (3.15)

160 (6.30)

piston ring must be replaced, correct the corrugation at the top of cylinder liner.

3. Measure the clearance between the piston and cylinder liner. If the value exceeds the limit, replace the cylinder liner with a new one.

Unit: mm (in.)

NOTE: Apply the value obtained at the most worn point

to the cylinder liner inside diameter.

SM3-J251

Standard: 0.056 - 0.088 mm (0.0022 - 0.0034 in.) Limit: 0.15 mm (0.0059 in.)

Fig. 35

Fig. 36

SM3-J303

90˚

SM3-J541

MEASURE THE CLEARANCE BETWEEN THE PISTON PIN AND THE PISTON PIN BOSS.

1. Measure the piston pin outside diameter using a micrometer. If the value exceeds the limit, replace the piston pin with a new one.

Standard: 37 mm (1.4567 in.) Limit: 36.96 mm (1.4551 in.)

2. Measure the piston pin boss inside diameter using a cylinder gauge. If the value exceeds the limit, replace the piston with a new one.

Standard: 37 mm (1.4567 in.) Limit: 37.05 mm (1.4587 in.)

3. Calculate the clearance between the piston pin and the piston pin boss. If the value exceeds the limit, replace the piston or piston pin.

Standard: -0.013T - 0.014L mm (-0.00051T - 0.00055L in.) Limit: 0.05 mm (0.0019 in.) NOTE: T = tightening allowance, L = clearance

Fig. 37

1 page 1

Models J08C-TP and J08C-TR 3-9-12 ENGINE

MEASURE THE CLEARANCE BETWEEN THE PISTON RING AND THE PISTON RING GROOVE.

Insert the piston ring into the piston ring groove and measure the clearance between the piston ring and piston ring groove using a feeler gauge. If the value exceeds the limit, measure the width of the piston ring and piston ring groove individually and replace any parts not meeting the limit with new ones.

SM3-J545

SM3-J546

Fig. 38

Clearance

Assembly standard Repair limit Top ring 0.06-0.10 (0.0024-0.0039) 0.25 (0.0098) 2.5 (0.0984) 2.4 (0.0945) 2.5 (0.0984) 2.7 (0.1063)

2nd ring 0.04-0.08 (0.0016-0.0031) 0.25 (0.0098) 2.0 (0.0787) 1.9 (0.0748) 2.0 (0.0787) 2.2 (0.0866)

Oil ring 0.02-0.06 (0.0008-0.0023) 0.15 (0.0059) 4.0 (0.1575) 3.9 (0.1535) 4.0 (0.1575) 4.1 (0.1614)

Fig. 39

Ring thickness

Dimension

Service limit Dimension

Unit: mm (in.)

Groove width

Service limit

MEASURE THE MATCHING POINT CLEARANCE OF THE PISTON RING.

Fit the piston ring into the cylinder liner and measure the matching point clearance of the piston ring using a feeler gauge. If the value exceeds the limit, replace the piston ring with a new one.

Fig. 40

SM3-J253

Piston Ring Gap; Unit: mm (in.)

Assembly standard Service limit

Top ring 0.3 - 0.40 (0.0119 - 0.0157) 1.5 (0.0590) 2nd ring 0.3 - 0.45 (0.0119 - 0.0177) 1.2 (0.0472)

Oil ring 0.3 - 0.45 (0.0119 - 0.0177) 1.2 (0.0472)

Fig. 41

SM3-J261

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-13

INSPECT THE CRANKSHAFT. NOTE: Before inspection, clean the crankshaft with a

commercial cleaning agent and clean the lubrication passage using an air gun.

1. Check the crankshaft for cracks using the dye penetrant test. If any are found, replace the crankshaft with a new one.

NOTE: Pay special attention to the finished R section and

oil hole of the crank journal and crankpin.

2. Check the condition of the crank journal and crankpin visually for damage or wear. Grind the crank journal and crankpin to correct as required, or replace the crankshaft with a new one.

Fig. 42

Fig. 43

Fig. 44

45˚ 45˚

SM3-J262

SM3-J688

SM3-J689

3. Support both end journals of the crankshaft with V blocks and measure the deflection of the crankshaft at the center journal using a dial gauge. If the value exceeds the limit, replace the crankshaft with a new one.

Limit: 0.15 mm (0.0059 in.)

MEASURE THE ROUNDNESS OF THE MAIN BEARING CAPS

After tightening the main bearing caps, measure the inside diameter of the main bearing caps using a cylinder gauge to calculate the roundness. If the value exceeds the limit, carry out boring after overlay welding or replace the cylinder block with a new one.

Standard: 85 mm (3.3465 in.) Limit: 0.06 mm (0.0024 in.) NOTE:

● When installing the main bearing caps, make sure to

return them to the original position with reference to the number stamped on the caps. The main bearing caps together with the cylinder block are profiled by roundness.

● For tightening of the main bearing caps, refer to page

3-9-18.

Fig. 45

SM3-J547

Fig. 46

1 page 1

Models J08C-TP and J08C-TR 3-9-14 ENGINE

MEASURE THE CLEARANCE BETWEEN THE CRANK JOURNAL AND THE MAIN BEARING.

1. Measure the crank journal outside diameter using a micrometer. If the value exceeds the limit for repair, grind the crank journal to correct. If the value exceeds the limit for use, replace the crankshaft with a new one.

Standard: 80 mm (3.1496 in.)

SM3-J690

Limit for repair: 79.80 mm (3.1417 in.) Limit for use: 78.80 mm (3.1024 in.)

Fig. 47

Fig. 48

SM3-J529

2. After installing and tightening the main bearing caps, measure the main bearing inside diameter using a cylinder gauge. If the value exceeds the limit, replace the main bearing with a new one.

Standard: 80 mm (3.1496 in.) Limit: 0.3 mm (0.0118 in.) NOTE:

● When installing the main bearing caps, make sure to

SM3-J689

return them to the original position with reference to the number stamped on the caps. The main bearing caps together with the cylinder block are profiled by roundness.

45˚ 45˚

● For tightening of the main bearing cap, refer to page

3-9-18.

SM3-J547

Fig. 49

Under

size

STD 64.940 - 64.960 79.940 - 79.960

0.25US 64.690 - 64.710 79.690 - 79.710

0.50US 64.440 - 64.460 79.440 - 79.460

Fig. 50

Outside diameter

Pin Journal

3. Calculate the clearance between the crank journal and the main bearing. If the value exceeds the limit, grind the crank journal to the specified undersize below to correct. Replace the main bearing with a correct one.

Standard: 0.051 - 0.102 mm (0.0020 - 0.0040 in.) Limit: 0.20 mm (0.0079 in.) Undersize machining dimension: Two sizes below.

0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.)

NOTE: Make sure you replace the top and bottom main

bearings as one set. The top and bottom main bearings must be profiled by roundness.

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-15

NOTE: Machined dimension of fillet “R”

Crank pin: 5.0 - 5.5 mm (0.1968 - 0.2165 in.) Crank journal: 5.0 - 5.5 mm (0.1968 - 0.2165 in.)

CORRECT

Fig. 51

Fig. 52

E’

B C

Fig. 53

COOLING JET

SPECIAL TOOL

OIL HOSE

Fig. 54

SPECIAL TOOL

WRONG

F’

SM3-J234

SM3-J548

G’

SM3-J505

SM3-J159

CYLINDER BLOCK MAIN BODY

1. Remove the water gallery plug, and check the condition of the worm hole visually. If the wear is excessive, replace the part with a new one. Also inspect inside the cylinder block, and clean the cylinder block main body with a commercial cleaning agent as required.

NOTE: Refer to page 3-9-4.

2. Check the cylinder block for cracks. Check the cylinder block for cracks using the dye

penetrant test. If any are found, replace the cylinder

A’

C’

block with a new one.

3. Check the flatness of the cylinder block upper surface.

Check the flatness of the cylinder block upper surface in the direction as shown in the figure using a

D’ B’

straight edge and feeler gauge. If the value exceeds the limit, replace the cylinder block with a new one.

Flatness of the cylinder block upper surface:

Standard: 0.05 mm (0.0020 in.) or less Limit: 0.20 mm (0.0079 in.)

INSPECT AND ADJUST THE COOLING JET.

1. After removing the cooling jet checking bolt, reinstall the cooling jet on the cylinder block using the special tool.

Special tool: Checking bolt (9001 - 24262)

2. Connect a commercial oil pump (hydraulic pressure:

2 kg/cm

(28 lb/sq.in.)) to the special tool using a

hose.

3. Set the special tool on the cylinder block upper surface against the dowel pin.

Special tool: Gauge (09444 - 1630)

Fig. 55

CYLINDER BLOCK

SM3-J421

ABNORMAL

Fig. 56

SPRAY

ABNORMAL

SPRAY PATTERN

1234

TARGET

NORMAL

COOLING JET

NORMAL

SM3-J161

SPRAY

1 page 1

Models J08C-TP and J08C-TR 3-9-16 ENGINE

4. Start the oil pump, let the engine oil spray out the cooling jet nozzle to check that the center of the jet flow is within the ∅7 mm (∅0.27 in.) reference line of the gauge as well as to judge whether the jet flow is good based on the figure.

NOTE: Use new engine oil.

WARNING

Engine oil is flammable. This spray test should be done in a well ventilated room and away from any open flames or electric sparks.

Fig. 57

Fig. 58

ABNORMAL

SM3-J549

SM3-J550

7. If the center of the jet flow is out of the ∅7 mm (∅0.27 in.) reference line of the gauge, adjust the nozzle sight using the special tool.

Special tool: Adjusting bar (09672 - 1620)

8. Remove the checking bolt after inspection, install the cooling jet onto the cylinder block using the cooling jet checking bolt.

NOTE:

● Always install the soft washer.

● When installing the piston, make sure that the cool-

ing jet is not struck by the piston when at bottom dead center.

INSPECT THE ENCLOSURE COVER.

Check the sound insulator for damage or wear visually . If there is any damage or wear , replace the parts with new ones.

Fig. 59

SM3-J277B

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-17

ENGINE NUMBER

Fig. 60

Fig. 61

Fig. 62

FRONT

CYLINDER LINER

LINER IDENTIFICATION MARK

MARKS OF LINER

SM3-J231A

SM3-J232

SM3-J692

MATCH MARKS

MOUNTING

1. ASSEMBLE THE CYLINDER LINER. NOTE:

● When assembling the cylinder liner with the cylinder

block, clearance can be set to three levels.

● When using a new cylinder liner, the upper surface

and side surface of the cylinder block are stamped A, B or C. Insert a matching cylinder liner having the same symbol.

1. Insert a cylinder liner into the cylinder block using the special tool.

Special tool: Guide (09471 - 1490) NOTE:

● Handle the cylinder liner carefully because it is thin.

If it falls on the floor, it cannot be used.

● Install the cylinder liner after engine oil has been

applied to the inner surface of the cylinder block bore.

● When reusing a cylinder liner, install it according to

the alignment marks made during removal. The cylinder liner is bent by “run-in”. When reusing the cylinder liner, misalignment with the cylinder block may concentrate stress on the thin part of the cylinder liner and it may break.

Fig. 63

Fig. 64

SM3-J693

SM3-J233

2. MEASURE THE PROTRUSION AT THE CYLINDER LINER.

1. Install the special tool onto the cylinder block.

Special tool: Cylinder liner puller (09420 - 1720)

2. Tighten the center bolt to the specified torque below

to set the cylinder liner in the normal installation condition.

Tightening torque: 100 kg·cm (7.23 lb·ft)

3. Measure the protrusion at the cylinder liner using the

dial gauge. If the value exceeds the limit, replace the cylinder liner.

PRESSURE: 500 kg (1,100 lb)

1 page 1

Models J08C-TP and J08C-TR 3-9-18 ENGINE

Standard: 0.01 - 0.08 mm (0.0004 - 0.0031 in.) Limit: 0.08 mm (0.0031 in.)

Fig. 65

Fig. 66

Fig. 67

PROTRUSION

SM3-J250A

SM3-J551

SM3-J682

3. INSTALL THE CRANKSHAFT.

1. Install the main bearings onto the cylinder block and

main bearing caps.

NOTE:

● When reusing a bearing, make sure you reassemble

the removed bearing as it was originally installed.

● Install the bearing with the oil hole on the block side

and the bearing without the oil hole on the cap side.

● Match the bearing protrusion with the notch of the

block or cap.

● After installation, apply engine oil to the journal sur-

faces of the bearings.

2. Install the crankshaft onto the cylinder block.

3. Install the thrust bearings onto the four points of the

No. 4 journal of the cylinder block and either side of the main bearing caps.

NOTE:

● When reusing a bearing, make sure you reassemble

the removed bearing as it was originally installed.

● Install the thrust bearing with the groove side (front)

toward the crankarm and with the part number stamp (back) toward the main bearing cap or cylinder block.

● Apply engine oil or grease to the back of the bearing

to prevent loosening during installation.

● Fit the bearing to the mounting groove of the block

and cap side.

4. Install the main bearing cap.

NOTE: Facing the arrow stamped on the cap forward,

install in the order of stamped numbers.

Fig. 68

SM3-J235

Fig. 69

w r y i !0 !2 !4

FRONT

1 page 1

Models J08C-TP and J08C-TR ENGINE 3-9-19

a. Measure the length of the bearing cap bolts, if the

length is A or more, replace with new bolts.

A = 108 mm (4.2520 in.)

b. Apply clean engine oil to the bolt seat and bolt

threads.

SM3-J236

c. Tighten the bolts in the order as shown in the figure

to the specified torque below.

Tightening torque for preload: 700 kg·cm (51 lb·ft)

d. Loosen all bolts. e. Tighten the bolts as in step c.

Tightening torque for preload: 700 kg·cm (51 lb·ft)

q e t u o !1 !3

Fig. 70

PAINT MARK

90°

Fig. 71

45°

SM3-J280

SM3-J238

f . Mark the bolts with paint to indicate the same direc-

tion.

g. Tighten the bolts 90° (1/4 turn) in the same order as

in step c. h. Finally, retighten the bolts 45° (1/8 turn) as in step g. i. Make sure that all paint marks face the same direc-

tion.

NOTE: When adding torque, never untighten the nuts,

even it they have been overtightened.

j. After tightening, tap the front and back ends of the

crankshaft using a plastic-faced hammer to allow

complete fit.

5. MEASURE THE CRANKSHAFT END PLAY.

Measure the crankshaft end play using a dial gauge. If the value exceeds the limit, replace the thrust bearing with the oversize one of 0.25 mm (0.0098 in.).

Standard: 0.050 - 0.219 mm (0.0020 - 0.0086 in.) Limit: 0.50 mm (0.0196 in.)

Fig. 72

PISTON IDENTIFICATION SYMBOL

TOP VIEW

Fig. 73

SM3-J695

SM3-J696

6. CHECK THE PISTON.

Before assembling the piston with the connecting rod, check whether the piston is specified for this engine.

NOTE: Check using the engine compatible identification

code on the top of the piston.

Engine compatible identification code: 72

Fig. 74

“O” MARK

EXHAUST PORT SIDE

SM3-J697

PISTON

INTAKE PORT SIDE

1 page 1

Models J08C-TP and J08C-TR 3-9-20 ENGINE

7. ASSEMBLE THE PISTON WITH THE CONNECTING ROD.

1. Install a new retainer ring onto one end of the piston

boss.

NOTE: Installing the retainer ring may cause it to fly up.

Be sure to wear protective goggles.

2. Immerse the piston in hot water, 80 - 90°C (176 -

194°F) for approximately five minutes.

3. Assemble the piston O-mark to be opposite the con-

necting rod alignment mark.

WARNING

Never touch the piston when it is hot with your bare hands.

Fig. 75

OIL HOLE

MATCH MARKS

SM3-J234

4. Insert the piston pin into the piston.

NOTE:

● Never touch the piston when it is hot with your bare

hands.

● Insert the piston pin from the piston boss attached to

the retainer ring so that the ring groove is not damaged.

5. Install a new retainer ring to the other end of the pis-

ton boss.

WARNING

Installing the retainer ring may cause it to fly up. Be sure to wear protective goggles.

NOTE:

● When using an oversize piston, hone so that clear-

ance between the cylinder liner and the piston is the standard value.

● Prevent parts from damage by wrapping them in a

cloth while they are being installed onto the cylinder block.

● Measure the entire length of the connecting rod bolt.

(Refer to page 3-9-22.)

Hino J08C-TP, J08C-TR Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ENGINE

SPECIAL TOOLS

DISMOUNTING THE ENGINE ASSEMBLY

REMOVAL OF THE ENGINE COMPONENT PARTS

CAMSHAFT HOUSING AND CYLINDER HEAD

TIMING GEAR

PISTON, CRANKSHAFT AND CYLINDER BLOCK