Hino S5-LJ05E04A, S5-LJ05E05A Workshop Manual

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FOREWORD

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

Applicable for J05E engine

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

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CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

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

CHAPTER

MANUAL NO.

MODEL J05E

GENERAL INTRODUCTION 1-001

STANDARD VALUE 2-001

REQUIRED ITEMS 3-001

MOUNTING AND DISMOUNTING THE ENGINE 5-001

ENGINE CONTROL 6-001

FUEL SYSTEM 7-001

EMISSION CONTROL 8-001

S5-LJ05E04A (U.S.A.), S5-LJ05E05A (CANADA)

INTAKE 9-001

ENGINE MECHANICAL 10-001

EXHAUST 11-001

COOLING 12-001

LUBRICATION 13-001

STARTING/CHARGING 16-001

TURBOCHARGER 17-001

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INDEX: ENGINE GROUP 1/2

GENERAL INTRODUCTION

STANDARD VALUE

REQUIRED ITEMS

WORKSHOP MANUAL

TROUBLESHOOTING

MOUNTING AND DISMOUNTING THE ENGINE

ENGINE CONTROL

FUEL SYSTEM

EMISSION CONTROL

INTAKE

ENGINE MECHANICAL

EXHAUST

COOLING

LUBRICATION

SPEED CONTROL SYSTEM

IGNITION

STARTING/CHARGING

TURBOCHARGER

AIR COMPRESSOR

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INDEX: ENGINE GROUP 2/2

ENGINE PTO (POWER TAKE-OFF)

GENERAL INTRODUCTION 1–1

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GENERAL INTRODUCTION

HOW TO IDENTIFY VEHICLE TYPE...........................1-2

VEHICLE MODEL ...................................................1-2

VEHICLE IDENTIFICATION NUMBER (VIN)

STRUCTURE ..........................................................1-3

APPEARANCE OF VEHICLE ......................................1-4

APPEARANCE OF VEHICLE .................................1-4

SAFETY INSTRUCTIONS AND READINESS

TO WORK.....................................................................1-5

WARNING...............................................................1-5

IDENTIFICATION INFORMATION ..........................1-9

SAFETY INSTRUCTIONS FOR WORK................1-12

INTRODUCTION TO WORKSHOP MANUAL.......1-15

TIGHTENING OF BOLTS AND NUTS ..................1-19

HANDLING OF LIQUID GASKET.........................1-29

GLOSSARY................................................................1-30

DEFINITION OF ABBREVIATION

IN THIS MANUAL..................................................1-30

LUBRICANTS ............................................................1-36

RECOMMENDED LUBRICANTS .........................1-36

1-001

GENERAL INTRODUCTION1–2

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CLASSIFICATION

REPORTED MODEL

Ԙԙ

㧦ENGINE MODEL

㧦VEHICLE MODEL

HEAVY DUTY TRACK

㧦CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE

CAB WIDTH

DRIVE WHEEL BASE

FRAME ASSEMBLY WIDTH

FRAME

FORM

WIDE 2WD MEDIUMOPEN

WIDE 2WD LONGOPEN

WIDE 2WD SUPER LONGOPEN

840 mm {33 in.}

2,900 mm {114 in.}

3,500 mm {138 in.}

3,800 mm {150 in.}

4,400 mm {173 in.}

㧦TYPE OF SUSPENSION

FRONT RIGID, REAR RIGID

CAB FORM BRAKE TYPE

㧦CAB FORM, BRAKE TYPE

㧦STEERING WHEEL POSITION

LEFT HAND DRIVE

SINGLE CAB VACUUM

CREW CAB VACUUM

SINGLE CAB HYDRAULIC

CREW CAB HYDRAULIC

SINGLE CAB VACUUM

SINGLE CAB HYDRAULIC

㧦DECK HEIGHT

HIGH FLOOR

㧦TRANSMISSION

6AT

㧦DECK FORM

CHASSIS WITH CAB

㧦ENGINE HORSEPOWER, FUEL

FUEL

HORSEPOWER EXHAUST

VERY HIGH US10

DIESEL OIL

㧦LOADING CAPACITY, GVW, REAR TIRES

㧦DESTINATION

DESTINATION

U.S., CANADA

6.58 t {14,500 lbs}

8.14 t {17,950 lbs}

8.85 t {19,500 lbs}

REAR DOUBLE

J05E-UG (HV)

J05E-TP (Diesel)

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GENERAL INFORMATION

HOW TO IDENTIFY VEHICLE TYPE

VEHICLE MODEL

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GENERAL INTRODUCTION 1–3

WMI VDS CD VIS

(1) (2) (3) (4) (5) (6) (7) (8) (9)

(10) (11) (12) (13) (14) (15) (16)

JHH KDM2H 5 E K00100

(17)

MANUFACTURER ,TYPE

MODEL, CAB TYPE,

WHEEL BASE,

BRAKE SYSTEM

MODEL YEAR

ENGINE MODEL

ASSEMBLY PLANTSERIES

MAKE

CHECK DIGIT

SEQUENTIAL NUMBER

CODE

JHN INCOMPLETE VEHICLE

TYPEMANUFACTURER

HINO MOTORS, LTD.

2AY

INCOMPLETE VEHICLE

HINO MOTORS

CANADA, LTD.

CODE CODE YEARYEAR

H 2017

J 2018

K 2019

L 2020

M 2021

C 2012

D 2013

E 2014

F 2015

G 2016

CODE

PM Hybrid

APPLICATIONENGINE MODEL

J05E

DM DieselJ05E

CODE

ASSEMBLY PLANT

HINO MOTORS, LTD.

HINO PLANT IN JAPAN

HINO MOTORS, LTD.

Hamura Plant in Japan

3 Canada Plant

W.V Plant

CODE

MAKE

SERIES GVWR

HINO

6,580 kg

{14,500 lbs.}

8,140 - 8,850 kg

{17,950 - 19,500 lbs.}

CODE CLASS MODEL

PRODUCTION

CODE

CAB TYPE WHEEL BASE

BRAKE

SYSTEM

HINO 195h

HINO 195

HINO 155

HINO 195

HINO 155

XFC710

HINO 155h

XFC720

HINO 155h

XFC740

HINO 195h

XFC720

HINO 195h

XFC740

HINO 155h

XFC710

HINO 195h

XFC720

HINO 195h

XFC740

HINO 155h

XFC740

HINO 155h

XFC720

HINO 195 XJC710

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

SINGLE CAB

COE

CREW CAB

COE

CREW CAB

COE

CREW CAB

COE

CREW CAB

3500mm{138 in.}

2900mm{114 in.}

3800mm{150 in.}

4400mm{173 in.}

XJC700

XJC710

XJC720

XJC740

XJC720

XJC740

XJC720

XJC740

HYDRAULIC

VACUUM

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VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

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GENERAL INTRODUCTION1–4

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APPEARANCE OF VEHICLE

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GENERAL INTRODUCTION 1–5

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SAFETY INSTRUCTIONS AND READINESS TO WORK

WARNING

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GENERAL PRECAUTIONS

Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer.

WARNING

When working on your vehicle, observe the following general precautions to prevent death, personal injury and/ or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.

• Always wear safety glasses or goggles to protect your eyes.

• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.

• Bind long hair securely behind the head.

• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N"

and block the wheels.

• Always turn off the starter switch to stop the engine, unless the operation requires the engine running.

Removing the key from the switch is recommended.

• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold,

radiator, muffler, exhaust pipe and tail pipe.

• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.

• Take utmost care when working on the battery. It contains corrosive sulfuric acid.

• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short

which can result in personal injury and/or property damage.

• Read carefully and observe the instructions specified on the jack before using it.

• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under

a vehicle supported only by a jack.

• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is

firmly applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.

• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.

• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts

when the engine is running.

• Be careful not to damage lines and hoses by stepping or holding your feet on them.

• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can

cause personal injury.

GENERAL INTRODUCTION1–6

! WARNING

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PRECAUTIONS IN TILTING AND LOWERING THE CAB

Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage.

• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.

• Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is

equipped with automatic transmission).

• Stop the engine and block the wheels.

• Remove any articles in or over the cab and close the doors firmly.

• Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the

cab.

• The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very

hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working under the cab.

• Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof

rack.

• Never put your body under the cab while raising or lowering the cab.

• Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch

(E) completely after raising the cab.

• Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the

cab.

• Make sure the handle (B) is caught by the catch after lowering the cab.

Read the Owner’s manual for details.

DEFINITION OF SAFETY TERMS

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

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

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

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

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

GENERAL INTRODUCTION 1–7

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TOWING

• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to

protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with the bumper.

1. Towing procedures

(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft

is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant

and entry of dirt or foreign matter. (2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame. (3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and vertical

directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a

vehicle trapped in a gutter. (4) Keep the gear shift lever in Neutral. (5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running. (6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will

be available for the brake. This is dangerous, as the brake system does not function if the engine is not running.

In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to

turn, making it impossible to control the vehicle. (7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed. (8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck

designed for that purpose.

(1) Front end towing (with front wheels raised off the ground)

When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the

transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of

axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles

equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check

and refill the rear axle housing with lubricant if necessary. (2) Rear end towing

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

ahead position.

CLEAN AIR ACT

1. Heavy-duty engine rebuilding practices.

§ 86.004-40

• The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and

are applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The pro-

cess of engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly,

and also may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine.

Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air

Act (42 U.S.C. 7522(a) (3)). (1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis

for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tol-

erances, calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A

reasonable basis would exist if:

a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and

function of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emissions control as the original parts; and

b. Any parameter adjustment or design element change is made only:

• In accordance with the original engine manufacturer's instructions; or

• Where data or other reasonable technical basis exists that such parameter adjustment or design element change,

when performed on the engine or similar engines, is not expected to adversely affect in-use emissions. (2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a con-

figuration of the same or later model year as the original engine. When an engine is being replaced, the replacement

engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.

GENERAL INTRODUCTION1–8

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(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset

without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during the rebuilding process.

(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt engine,

all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by paragraphs (1) through (3) of this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufacturer recommended practices.

(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The

records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emissions-related control components including a listing of parts and components used, engine parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section. a. Parties may keep records in whatever format or system they choose as long as the records are understandable

to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format when requested.

b. Parties are not required to keep records of information that is not reasonably available through normal business

practices including information on activities not conducted by themselves or information that they cannot reasonably access.

c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine

rebuilt in cases where those rebuild practices are followed routinely.

d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.

§ 86.010-38

(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manufac-

turer shall furnish or cause to be furnished to the ultimate purchaser a statement that

"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway diesel fuel, including a 15 ppm sulfur cap)."

GENERAL INTRODUCTION 1–9

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IDENTIFICATION INFORMATION

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1. VEHICLE IDENTIFICATION NUMBER

(1) The vehicle identification number (VIN) is stamped on the right

frame, as shown in the illustration. This number has also been stamped on the manufacture's label.

A: Vehicle Identification Number (VIN) B: Manufacturer's Label

(2) VIN

See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.

(3) PRODUCTION CODE AND VEHICLE COMPONENTS

MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5)

XJC700 XJC710 XJC720 XJC740

PRODUCTION CODE

XFC710 XFC720 XFC740

TRANSMISSION SERIES A465

1st 3.742

2nd 2.003

3rd 1.343

TRANSMISSION RATIO

4th 1.000

5th 0.773

6th 0.634

REAR AXLE SERIES SH13

REAR AXLE RATIO 4.333 / 4.625 / 4.875 / 5.142 / 5.571 / 5.857

SERVICE BRAKE Vacuum Hydraulic

PARKING BRAKE ACTING ON DIFFERENTIAL OUTPUT SHAFT

SUSPENSION LEAF

XFC710 XFC720 XFC740

XJC700 XJC710 XJC720 XJC740

GENERAL INTRODUCTION1–10

FOR ALL MODELS

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2. VEHICLE NOISE EMISSION CONTROL INFORMATION

• The Vehicle Noise Emission Control Information is affixed to the

left pillar of the cab. The name of manufacturer, production year and month, and noise emission applicable to medium and heavy trucks in conformity with U.S. EPA Regulations are displayed.

3. ENGINE SERIAL NUMBER

(1) The engine serial number is stamped on the cylinder block, as

shown in the illustration.

A: J05E

4. TRANSMISSION SERIAL NUMBER

(1) The transmission serial number is stamped on the transmission,

as shown in the illustration.

A: A465

5. CLEAN IDLE CERTIFIED LABEL FOR U.S.

• Make sure that the following clean engine idling certified label is

affixed to the outside of the left door. By the CARB below, the label must be affixed there to prove that the new vehicle with diesel engine manufactured from Jan., 2008 conforms to this low.

CARB § 1956.8. Exhaust Emission Standard and Test Procedure (a) (b) Heavy-Duty Diesel Engine Idling Requirements

GENERAL INTRODUCTION 1–11

EXEMPTION LABEL

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6. EXEMPTION LABEL FOR US GHG REGULATION

HINT Exemption label fuel economy comes in paste right side of the front passenger seat. However, this label is limited to one year.

GENERAL INTRODUCTION1–12

! WARNING

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LOOSEN

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SAFETY INSTRUCTIONS FOR WORK

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PRECAUTIONS

1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS

(1) Remove the battery cable

• Be sure to wait for at least ten minutes after the starter key is turned to "LOCK" position before you discon-

nect the battery terminals from the battery, as the vehicle data is recorded on ECU and DCU starts working for the exhaust gas after treatment after the starter key is turned to "LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly and DCU will not complete working properly, which may result in the malfunction of DPR system and DEF-SCR system.

• The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again,

even if you wait for at least ten minutes before disconnecting the battery terminals from the battery after the starter key is turned to "LOCK" position. In this case, use HINO-DX to clear the DTC (P204F and P068A), to turn off the MIL and to conduct DPR regeneration manually.

a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burning

caused by short-circuiting.

b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the termi-

nal.

(2) Handling of electronic parts

a. Never give an impact to electronic parts of a computer or relay. b. Keep electronic parts away from high temperatures and humidity. c. Never splash water onto electronic parts in washing the vehicle. d. Do not remove the harness connector, electric component box, and cover except for repair and inspection.

If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector, terminals, electric component box, and cover. In restoration, make sure there is no attachment or entry of water and foreign matters and mount them properly, because it causes degradation of waterproof function.

INCORRECT

GENERAL INTRODUCTION 1–13

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INCORRECT

CORRECT

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(3) Handling of wire harness

a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not inter-

fere with the end and acute angle section of the body and a bolt.

b. To attach a part, take care not to bite the wire harness.

INCORRECT

(4) Handling of connectors

a. When removing a connector, hold a connector (area shown in an arrow in the figure) and then pull it off. Do not

pull wire harnesses. b. Pull off a lockable connector after unlocking. c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound. d. When inserting a test lead, insert it from the back of a connector. e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.

GENERAL INTRODUCTION1–14

! WARNING

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Connect the ground of the ARC welding machine near the place on the frame to be welded but not connect it to plated parts such as fuel pipes, brake pipes and leaf spring.

Disconnect the ground terminal for battery at the connecting point on the frame and disconnect the ground for computer as well.

CHASSIS FRAME

BATTERY

ALTERNATOR ETC.

COMPUTER

ARC WELDING MACHINE

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(5) Installation of battery disconnect switch

• Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-

SCR (DCU) may damage or result in the malfunction of DEF-SCR system.

• Be sure to read and follow the procedures and instructions on the service bulletin before the installation of

the battery disconnect switch.

(6) Handling of battery disconnect switch

• Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to

"LOCK" position. Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR system.

2. PRECAUTION FOR ELECTRIC WELDING Electrical components such as the alternator and tachograph are directly connected to the battery and one end is earthed to the chassis frame. Under these conditions, welding current will flow back along the earth circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, electrical components, etc. Consequently, the following precautions are always to be taken during welding.

(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the

frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and leaf spring, etc.) a. Turn the starter switch off. b. Disconnect the battery’s negative terminal of the battery. c. Earth welding equipment securely, near to the area to be welded. d. Put back battery negative ground as original condition. e. Finally check the functioning of all instruments.

(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as put-

ting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.

GENERAL INTRODUCTION 1–15

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INTRODUCTION TO WORKSHOP MANUAL

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GENERAL

1. SCOPE OF REPAIR DESCRIPTIONS

(1) There are three major processes in repair work: i.e. "troubleshooting," "removal/installation, replacement, overhaul,

assembly, inspection and adjustment" and "final inspection".

(2) This document covers only the first process (troubleshooting) and the second process (removal/installation, replace-

ment, overhaul, assembly, inspection and adjustment) and omits the third process (final inspection).

(3) The element tasks listed below are omitted from this document but must be done in actual repair work.

a. Jacking and lifting b. Cleaning and washing of removed parts as required c. Visual check

2. STANDARD VALUE

(1) Standard values, limits, required actions and tightening torques are tabulated in this document.

3. REQUIRED ITEMS

(1) Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in the

section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items supposedly available at a general service shop are omitted from the list.

4. REPRESENTATION OF SECTION AND TITLE

(1) Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover "INSPEC-

TION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components.

(2) Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover "REPLACE-

MENT" and "OVERHAUL".

GENERAL INTRODUCTION1–16

Alphabetical mark indicating the tightening torque in the following tightening torque table

Numerical order indicating the part name in the following part name table

Numerical order

Part name

Part name table

Tightening torque table

Tightening torque

Alphabetical mark

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INTRODUCTION TO DESCRIPTIONS

1. COMPONENT LOCATOR

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☆ : The ID number is given to required items for the purpose of preparing electronic data and is not needed

in repair work.

2. WORK STEPS

Indicating the work sequence

Descriptive text: Indicating the work method which is gone into detail

Indicating the part number of SST required for work

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GENERAL INTRODUCTION 1–17

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GENERAL INTRODUCTION1–18

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DEFINITION OF TERM

Terms used in this document are defined as follows.

DIRECTION

1. CHASSIS RELATED

(1) Longitudinal direction

a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the

installed position in a vehicle.

(2) Rotational direction

a. The clockwise direction and the counterclockwise direction viewed from the rear side of a vehicle are defined as

right-handed and left-handed respectively.

(3) Vertical direction

a. The upward direction and the downward direction in the installed position in a vehicle are defined as an upper

side and a lower side respectively.

(4) Lateral direction

a. The leftward direction and the rightward direction viewed from the back of a vehicle are respectively defined as a

left side and a right side in the installed position in a vehicle.

2. INDIVIDUAL DEVICES

(1) Longitudinal direction

a. The input side and the output side of motive power are defined as a front side and a rear side respectively.

(2) Rotational direction

a. The clockwise direction and the counterclockwise direction viewed from the back side are defined as right-

handed and left-handed respectively.

(3) Vertical direction

a. The upward direction and the downward direction of a device in its installed position in a vehicle (chassis) are

defined as an upper side and a lower side respectively.

(4) Lateral direction

a. The leftward direction and the rightward direction as viewed from the back side are defined as a left side and a

right side respectively.

STANDARD VALUE

Represents a basic dimension (excluding a tolerance), and a clearance arising from tolerances when two parts are assembled.

REPAIR LIMIT

Represents a numerical value indicating need of correction. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

SERVICE LIMIT

Represents a numerical value indicating need of replacement. A symbol "+" or "-" indicated next to a repair limit represents an increase or a decrease from a standard value.

GENERAL INTRODUCTION 1–19

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TIGHTENING OF BOLTS AND NUTS

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BOLTS AND NUTS

More than hundreds of bolts/nuts are used in a vehicle and improper handling of them will cause damage and looseness. Because tightening torque varies depending on tightening condition, strength class, and surface treatment, etc., make sure to check the types and tightening torques of bolts/nuts and use them properly.

PURPOSES OF TIGHTENING TORQUE

Predefined tightening torque must be applied to ensure sufficient tightening by threads. It also has purposes to prevent the adverse events below due to excessive or insufficient tightening.

Conditions Adverse events

• Stretch or fracture of bolt

• Depression of seat surface and looseness

Excessive tightening

Insufficient tightening

• Gasket damage

• Rounding and damage of hexagon part

• Opening of spring washer

• Looseness

• Gas and liquid Leakages

• Continuity failure

• Damage by fretting wear

NOTICE Unique tightening torque may be specified for some parts. Tighten with the tightening torque specified in the service manual.

HINT Check the tightening torque list for general torques.

CAUTIONS TO PREVENT LOOSENESS.

When tightening, pay attention to the followings to prevent looseness after tightening.

• Insufficient tightening torque

• Inclusion of foreign matters (burrs and coatings) in the tightening surface.

• Sagging of coat

• Sinking into the seat surface hole by omitting attaching a plain washer.

• Defective seat surface flatness (wear-out during use)

GENERAL INTRODUCTION1–20

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FLANGE OUTER DIAMETER

GROOVES

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FLANGE OUTER DIAMETER

TYPES AND IDENTIFICATION

There are three types of bolts and nuts.

1. Standard (w/o flange)

• Bolts/nuts without flange

2. With old flange (w/grooves)

• Flange is small and has grooves on its back.

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3. With new flange (w/o grooves)

• Flange is big and does not have grooves on its back.

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SEAT SURFACE WITH OLD FLANGE

SEAT SURFACE WITH NEW FLANGE

NO COMPATIBILITY

BOLTS/NUTS WITH OLD FLANGE (W/GOOVES)

BOLTS/NUTS WITH NEW FLANGE (W/O GOOVES)

SEAT SURFACE WITH OLD FLANGE

SEAT SURFACE WITH NEW FLANGE

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Comparison of flange outer diameters

Bolt Nut

GENERAL INTRODUCTION 1–21

Thread

diameter

With old flange

(w/grooves)

Strength

class

Flange

outer

diameter

With new flange

(w/o grooves)

Strength

class

Flange

outer

diameter

With old flange

(w/grooves)

Strength

class

Flange

outer

diameter

With new flange

(w/o grooves)

Strength

class

M8 7T, 9T 15.5 8.8, 10.9 17 7N 15.5 8 17

8.8 20

M10 7T, 9T 18.5

7N 18.5 8 21.5

10.9 21.5

8.8 24

M12 7T, 9T 21.5

7N 21.5 8 26

10.9 26

M14 ——10.9 30.5 ——12 30

COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)

Flange

outer

diameter

NOTICE [Bolt/nuts with new flange (w/o grooves)] can not be used on the place where [bolts/nuts with old flange (w/ grooves)] were used. In addition, use care to avoid misassembly because even when nominal sizes and pitches are same, there is no compatibility in strength if types are different.

GENERAL INTRODUCTION1–22

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STRENGTH CLASSES AND SYMBOLS

1. With old flange (w/grooves)

Bolt Nut

Strength

class

4T —

2. With new flange (w/o grooves)

Strength

class

Carbon steel Boron steel

Symbols

Bolt Nut

Symbols

Strength

class

7N7T

Strength

class

Symbols

8.8 8

10.9 12

PAR T N O.

1. Standard (w/o flange)

GENERAL INTRODUCTION 1–23

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Thread

diameter

M10

M12

M14 9T SH112-**** Plating 8N SL113-01411 Plating

2. With old flange (w/grooves)

Thread

diameter

Strength

class

7T SH111-**** Plating

9T SH112-**** Plating

7T SH111-**** Plating

9T SH112-**** Plating

7T SH111-**** Plating

9T SH112-**** Plating

Strength

class

7T SH562-**** Plating

9T SH562-**** Plating

Bolt Nut

Par t No.

Bolt Nut

Par t No.

Surface

treatment

Surface

treatment

Strength

class

8N SL113-00807 Plating

8N SL113-01008 Plating

8N SL113-01210 Plating

Strength

class

7N SL151-00809 Plating

Par t No.

Surface

treatment

Surface

treatment

M10

M12

7T SH562-**** Torquer

7N SL151-01011 Plating

9T SH562-**** Torquer

7T SH562-**** Torquer

7N SL151-01213 Plating

9T SH562-**** Torquer

3. With new flange (w/o grooves)

GENERAL INTRODUCTION1–24

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Thread

diameter

M10

M12

M14 10.9 91552-F14** Neotorquer 12 94151-21401 Neotorquer

NOTICE Some bolts/nuts are applied friction stabilizer on thread surface. Note that their tightening torques are different from those of plated-only bolts/nuts even if the strength class is same. (Threads with Neotorquer are colored in light red.)

HINT The * below the hyphen of a part number shows a thread diameter and length under head, so the numbers vary depending on type.

Strength

class

8.8 91551-808** Plating

10.9 91551-008** Plating

8.8 91552-E10** Neotorquer

10.9 91552-F10** Neotorquer

8.8 91552-E12** Neotorquer

10.9 91552-F12** Neotorquer

Bolt Nut

Par t No.

Surface

treatment

Strength

class

8 94151-80800 Plating

8 94151-81001 Neotorquer

8 94151-81201 Neotorquer

Par t No.

Surface

treatment

LIST OF TIGHTENING TORQUE

Apply a tightening torque specified in the strength class of the bolt/nut used.

NOTICE Refer to the service manual because tightening torques of some parts do not conform to it due to their tightening conditions, strength classes, and surface treatments.

1. Standard (w/o flange)

Unit: Nm {kgfcm, lbfft}

Thread diameter Strength classes Tightening Torque

M10

M12

M14 9T 160.032.0 {1,630326, 117.923.5}

7T 22.04.0 {22445, 16.22.9}

9T 29.05.5 {29656, 23.14.0}

7T 43.08.5 {43886, 31.76.2}

9T 57.011.0 {581112, 42.08.1}

7T 76.015.0 {774152, 56.011.0}

9T 100.020.0 {1,019203, 73.714.7}

GENERAL INTRODUCTION 1–25

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2. With old flange (w/grooves)

Thread diameter Strength classes Tightening Torque

Unit: Nm {kgfcm, lbfft}

M10

M12

3. With new flange (w/o grooves)

Thread diameter Strength classes Tightening Torque

M10

M12

7T 22.04.0 {22445, 16.22.9}

9T 29.05.5 {29656, 23.14.0}

7T 51.510.0 {525101, 37.97.3}

9T 68.513.5 {698137, 50.59.9}

7T 91.018.0 {927183, 67.013.2}

9T 120.024.0 {1,223224, 88.417.6}

8.8 31.09.3 {31694, 22.86.8}

10.9 39.011.7 {397119, 28.78.6}

8.8 35.010.5 {356107, 25.87.7}

10.9 46.513.8 {474140, 34.210.1}

8.8 63.018.9 {642

10.9 82.024.6 {836250, 60.418.1}

192, 46.413.9}

Unit: Nm {kgfcm, lbfft}

M14 10.9 130.039.0 {1,325397, 95.828.7} 130.026.0 {1,325265, 95.819.1}*

HINT *: Value is for usage in the fuel tank.

GENERAL INTRODUCTION1–26

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TIGHTENING OF ENGINE BOLTS AND NUTS

1. TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS

(1) Representative tightening torque for shouldered bolts

Unit: Nm {kgfcm, lbfft}

Thread diameter X pitch 7T 9T

M8 X 1.25 (coarse thread) 28.5 {290, 21} 36 {370, 27}

M10 X 1.25 (fine thread) 60 {610, 44} 74.5 {760, 55}

M10 X 1.5 (coarse thread) 55 {560, 40} 68.5 {700, 51}

M12 X 1.25 (fine thread) 108 {1,100, 80} 136 {1,390, 101}

M12 X 1.75 (coarse thread) 97 {990, 72} 125 {1,280, 93}

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

M14 X 2 (coarse thread) 154 {1,570, 114} 199 {2,030, 147}

Remark

(2) Representative torque for washer bolt

Thread diameter X pitch 4T 7T 9T

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

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

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

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

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

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

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

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

Bolt with a numerical character "4" indicated on

Remark

the head Projection bolt. Stud with a rounded free end.

Bolt with a numerical character "7"

indicated on the head

Bolt with a numerical character "7" indicated on the head. Stud with a chamfered free end.

Bolt with a numerical character "9"

indicated on the head

Unit: Nm {kgfcm, lbfft}

Bolt with a numerical character "9" indicated on the head

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