Hino J08C-TP, J08C-TR Service Manual

Models	1INDEX		ENGINE 3-1-1
	J08C-TP and J08C-TR
			3-228E-05

3

CHAPTER 3

ENGINE

Models: J08C-TP and J08C-TR

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

3-1-2 ENGINE	Models	1 page 1
		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
Models J08C-TP and J08C-TR	ENGINE 3-1-3

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
							cylinder liner
		●	Worn, sticking or broken piston rings ............				Replace piston rings and
							cylinder liner
		●	Insufficient tension on piston rings ................				Replace piston rings and
							cylinder liner
		●	Unsatisfactory break-in of piston rings ..........				Replace piston rings and
							cylinder liner
		●	Unsuitable oil (viscosity too low) ...................				Change oil as required and
							replace piston rings and
							cylinder liner
		●	Incorrectly fitted piston rings (upside down) ..				Replace piston rings
		●	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
							and shaft
			Excess oil feed
		●	Defective oil level gauge ...............................				Replace oil level gauge
		●	Oil level too high ...........................................				Drain excess oil

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

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
					Other problems
			●		Overcooled engine ........................................			Warm up engine before moving
					(low temperature wear)			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

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

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”

3-1-6 ENGINE	Models	1 page 1
		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

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

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

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

Symptom					Possible cause			Remedy/Prevention
Leakage of exhaust				Other problems
			●		Incorrect injection timing ...............................			Adjust injection timing

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
								connections or replace battery
								cable
		●	Breakdown of starter .....................................					Replace starter
		●	Broken glow plug ..........................................					Replace
			Injection pump			.............................................		Refer to “FUEL INJECTION
								PUMP”
			Air cleaner
		●	Clogged element ...........................................					Clean the element or replace
								the element
			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
								pressure line
		●	Water in fuel ..................................................					Drain and clean fuel system

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

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

3-1-10 ENGINE	Models	1 page 1
		J08C-TP and J08C-TR

Symptom

Possible cause

Remedy/Prevention

Rough idling

Other problems

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

Replace line

● Leakage due to improper tightening .............

Tighten sleeve nut

of high pressure injection line

● Improperly adjusted or broken ......................

Adjust or replace accelerator

accelerator cable

cable

●

Engine seizure ..............................................

Replace pistons, piston rings

and liners

●

Incorrect valve timing ....................................

Replace camshaft

Diesel knock

Refer to “FUEL INJECTION

Injection pump...............................................

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

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

Symptom

Possible cause

Remedy/Prevention

Unusual engine noise

Piston

●

Wear of piston pin boss or piston pin ............

Replace piston and/or piston

pin

●

Seized, damaged, or worn piston pin ...........

Replace piston pin bushing.

bushing

●

Worn pistons or cylinder liners ......................

Replace piston or cylinder liner

●

Damaged or seized piston ............................

Replace piston and cylinder

liner

●

Foreign matter on top surface of the piston ..

Remove foreign matter and

repair or replace piston, cylinder

liner, and/or cylinder head

Valve mechanism

●

Incorrect valve clearance ..............................

Adjust valve clearance

●

Valve cotter out of place ................................

Replace valve cotter

●

Seized valve stem .........................................

Replace valve and valve guide

●

Broken valve .................................................

Replace valve

●

Damaged rocker arm support .......................

Replace rocker arm support

●

Broken valve spring ......................................

Replace valve spring

Bearings seizure

●

Insufficient lubricating oil ...............................

Add oil

●

Excessive or insufficient tightening of ...........

Retighten to specified torque

bearing housings

●

Pits and scratches on bearing surface ..........

Replace bearing and crankshaft

●

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

Replace bearing

●

Improper installation of bearing ....................

Replace bearing

●

Reduction of spread dimension of bearing ...

Replace bearing

●

Distorted bearing housing .............................

Replace or correct bearing

housing

●

Excessive oil clearance.................................

Replace bearing

3-1-12 ENGINE	Models	1 page 1
		J08C-TP and J08C-TR

Symptom				Possible cause				Remedy/Prevention
Unusual engine noise				Various other parts
		● Exhaust gas leakage from exhaust ...............						Retighten joints
				pipe joints
		● Loosen or missing intake manifold ...............						Retighten or replace
				flange gasket
		● Intake valve seating is not concentric ...........						Replace or correct the valve
								and valve seat
		●		Intake gas leakage ........................................				Retighten
				Other problems
		● Loose cooling fan mounting bolts or .............						Tighten the fan and
				fan pulley nut				crankshaft pulley
		● Lack of lubricating oil ....................................						Lubricate
				(coolant pump, valves, etc.)
		●		Worn timing gear ...........................................				Replace the timing gear
		● Breakage of turbine or blower .......................						Refer to TURBOCHARGER in
								CHAPTER 51

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

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

(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
					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

3-1-14 ENGINE	Models	1 page 1
		J08C-TP and J08C-TR

Symptom						Possible cause					Remedy
Engine starts and stops					Fuel lines clogged .........................................						Clean or replace fuel lines
						Air in fuel caused by damaged					Repair fuel lines or replace fuel
						fuel lines or improper connection of					lines and gaskets
						fuel lines
Engine has low power					Pump out of timing
			●			Excessive advanced timing...........................					Check and correct it
						resulting in loud knocking
			●			Excessively retarded timing ..........................					Check and correct it
						resulting in black smoke
			● Defective injection pump overflow valve .......								Repair or replace it
			● Feed pressure too low ..................................								Repair the feed pump
			● Improper accelerator cable adjustment ........								Adjust it
						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
Models J08C-TP and J08C-TR	ENGINE 3-1-15

Symptom

Possible cause

Remedy

Excessive smoke

Black smoke

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

Adjust fuel delivery on test stand

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

to ELECTRICAL EQUIPMENT

in CHAPTER 20

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

ENGINE 3-2-1

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
	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	Caulking nozzle seat
					(Use together with 9800 - 06100)
SM3-J050
	9800-06100		(Steel ball)	1	Caulking nozzle seat
					(Use together with 09472-1210)
SM3-J054
	09552-1090		Compression gauge	1	Measuring compression
			adaptor		(for size PF3/8)
SM3-J021

			1 page 1
3-2-2 ENGINE		Models J08C-TP and J08C-TR
Shape	Parts No.	Parts name			No./unit	Application
	09552 - 1060
		Press gauge adaptor			1	Measuring compression
	09552 - 1030
SM3-J022
	09472 - 2100	Bar			1	Strike-fitting valve stem seal
SM3-J055
	09471 - 1520	Guide			1	Strike-fitting valve guide
SM3-J051
	09420 - 1100	Sliding hammer			1	Removing main idle gear shaft
SM3-J131
	09420 - 1442					Removing suband cam idle
	(Same as tool
		Sliding hammer			1	gear shafts (Remove the
	for pulling out
						adaptor from the top before use)
	injection nozzle)
SM3-J132
(3) Related parts of valve
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					ENGINE 3-2-3
	Shape		Parts No.		Parts name				No./unit	Application
		09470 - 1170			Valve spring press			1		Removing and installing valve
										spring
	SM3-J049
(4) Related parts of flywheel
	Shape		Parts No.		Parts name				No./unit	Application
		09481 - 1340			Guide			1		Removing and installing
										flywheel
	SM3-J116
	(5) Related parts of cylinder block
	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

				1 page 1
3-2-4 ENGINE			Models J08C-TP and J08C-TR
	Shape	Parts No.	Parts name			No./unit	Application
		09420 - 1742	Oil seal puller			1	Pulling out rear oil seal
	SM3-J117
		09420 - 1720	Cylinder liner puller			1	Pulling out cylinder liner
	SM3-J148
		09471 - 1490	Guide			1	Insert guide for cylinder liner
	SM3-J149
		09411 - 1300	Socket wrench			1	Rear end plate TORX® bolt
	SM3-J133
		09444 - 1630	Gauge			1	Cooling jet check
	SM3-J146
		9001 - 24262	Check bolt			1	Cooling jet check
	SM3-J151
		09472 - 1620	Tool			1	Cooling jet check (Fixture for
							correction)
	SM3-J780

			1 page 1
		Models J08C-TP and J08C-TR				ENGINE 3-2-5
(6) Related parts of piston
Shape	Parts No.	Parts name			No./unit	Application
	09441 - 1320	Piston ring holder			1	Used when inserting piston into
						cylinder block
SM3-J153
	09442 - 1011	Piston ring expander			1	Removing and installing piston
						ring
SM3-J145
	09481-1130	Guide			1
SM3-J781
	09402-1530	Press sub assembly			1	For replacing the piston pin
						bushing
SM3-J782
	9233-10360	Wing nut			1
SM3-J783

			1 page 1
3-2-6 ENGINE		Models J08C-TP and J08C-TR
(7) Related parts of connecting rod
Shape	Parts No.	Parts name			No./unit	Application
	09481 - 1540	Guide			1
SM3-J147
	09402-1540	Press sub assembly			1	Replacing connecting rod
						bushing
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
SM3-J784
	09553 - 1010	Fuel filter wrench			1	Removing and installing fuel filter
SM3-J785

					1 page 1
				Models J08C-TP and J08C-TR				ENGINE 3-2-7
(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
		09420 - 1442
		(Same as the		Sliding hammer			1	Pulling out injection nozzle
		parts to remove						(Use together with 09462 - 1130)
		idler gear shaft)
SM3-J132
		09462 - 1130		Adaptor			1	Pulling out injection nozzle
								(Use together with 09420 - 1442)
SM3-J172
(11) Related parts of coolant pump
Shape		Parts No.		Parts name			No./unit	Application
		09420 - 1820		Puller assembly			1	Coolant pump vane
SM3-J786
		09420 - 1810		Puller assembly			1	Coolant pump pulley center
SM3-J787

			1page 1
3-2-8 ENGINE		Models J08C-TP and J08C-TR
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
	09420 - 1670	Puller assembly			1	Pulling out air compressor
						sleeve
SM3-J002
	09482 - 2220	Press			1	Strike-fitting air compressor
					sleeve
SM3-J003
	09482 - 2230	Press			1	Strike-fitting air compressor oil
					seal
SM3-J004
	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.

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, dis-
		connect the engine stop motor.
	5.	Remove all nozzle holders.
SM3-J580	NOTE:	Refer to page 3-6-3.
Fig. 1	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.

-J581

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

Fig. 2

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

(3) After measurement

1.Install the removed parts.

			WARNING
			Do not connect the electric harness with the en-
			gine 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
	SM3-J580		engine stop motor and the engine stop lever of the
			fuel injection pump will move, resulting in your
Fig. 3
			fingers caught by the lever.

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-3-3

							OIL
												SM3-J024
Fig. 4
						ATMOSPHERIC TEMPERATURE
	S.A.E.
		-10		0		32			50	70		90		100		˚F
	GRADE
		-23		-18		0			10	21		32		39		˚C
	40
	30
	20W/20
	15W/40
	10W/30

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/cm2 (81.05 lb/sq.in.)

Service Limit:

At idle speed 0.5 kg/cm2 (7.11 lb/sq.in.)

Fig. 5

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.

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-4-1

SM3-J500

Fig. 1

SM3-J580

Fig. 2

SM3-J582A

Fig. 3

SM3-J583

Fig. 4

DISMOUNTING THE ENGINE ASSEMBLY

1.BLOCK THE WHEELS OF THE VEHICLE.

1.Park the vehicle on level ground.

2.Block the wheels.

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.

4.Tilt up the cab.

5.Disconnect the engine control and the stop cable at the injection pump.

3.DISCONNECT THE NEGATIVE TERMINAL OF THE BATTERY.

WARNING

Always disconnect the battery cable when servicing the engine.

4.DISCONNECT THE PARKING BRAKE CABLE (1).

1.Remove the center console.

2.Disconnect the parking brake cable at the lever.

SM3-J584

Fig. 5

		1 page 1
3-4-2 ENGINE	Models J08C-TP and J08C-TR

OVER-TILTING	NORMAL POSITION
POSITION

5.OVER-TILT THE CAB

NOTE: Refer to CAB in CHAPTER 19.

SM3-J585

Fig. 6

OPEN CLOSE

DRAINING PLUG

DRAINING PLUG

SM3-J705B

Fig. 7

Fig. 8

DRAINING PLUG

-J791

Fig. 9

SM3-J587

Fig. 10

SM3-J589

Fig. 11

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.

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 AT 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.

1 page 1

Models J08C-TP and J08C-TR

ENGINE 3-4-3

SM3-J590

Fig. 12

SM3-J796

Fig. 13

SM3-J593

Fig. 14

SM3-J594

Fig. 15

9.DISCONNECT THE SPEEDOMETER CABLE AT THE TRANSMISSION.

10.REMOVE THE TRANSMISSION CONTROL ROD TOGETHER WITH THE BRACKET AT THE TRANSMISSION.

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.

12.DISCONNECT THE POWER STEERING LINES AT THE PUMP.

NOTE: Be careful of oil leakage from the removed lines at the gear unit

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.

SM3-J595

Fig. 16

1 page 1

3-4-4 ENGINE

Models J08C-TP and J08C-TR

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

Fig. 17

SM3-J597

Fig. 18

SM3-J598

Fig. 19

SM3-J599

Fig. 20

17. REMOVE THE REAR CAB MOUNTING BRACKET.

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.

20.DISCONNECT THE GAS LINES OF THE AIR CONDITIONER.

1.Use the refrigerant collector to discharge refrigerant.

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

21.DISCONNECT THE RADIATOR FROM THE FRAME.

1.Disconnect the reservoir hose.

2.Remove the radiator mounting.

SM3-J600A

Fig. 21