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Engine J08E-TI Service
Engine J08E-TI Service
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1 MENU
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
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 print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
(14'914&HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧤ᣣޓἫᦐᣣޓඦ೨㧝㧜ᤨ㧠㧥ಽ
EN08-001
EN08-002
TURBOCHARGER (VARIABLE NOZZLE TURBINE
(WASTE GATE VALVE TYPE)
TYPE)
EN12-001 EN12-002
STARTER
(24V, 4.5 kW) (24V, 5.0 kW)
EN13-004
EN13-001 EN13-002 EN13-003
AIR COMPRESSOR (271 cm3 x 2
(154 cm3) (227 cm3) (271 cm3)
CYLINDERS)
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE P.T.O.
(POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
OTHERS
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GENERAL INTRODUCTION.....................GN01-2
WARNING .......................................................GN01-2
HOW TO USE THIS MANUAL.........................GN01-3
PRECAUTIONS FOR WORK ..........................GN01-8
TIGHTENING OF BOLTS
AND NUTS FOR ENGINE .............................GN01-13
TIGHTENING OF BOLTS
AND NUTS FOR CHASSIS ...........................GN01-15
TIGHTENING OF FLARE NUTS
AND HOSES..................................................GN01-17
SEALANT ON THE TAPERED SCREW
FOR PIPING ..................................................GN01-18
NYLON TUBE ................................................GN01-19
ASSEMBLY OF JOINT/GASKET
FOR PIPING ..................................................GN01-23
HANDLING OF LIQUID GASKET..................GN01-25
TROUBLESHOOTING
USING THE TROUBLE LIST.........................GN01-26
TROUBLESHOOTING
USING A DIAGNOSIS MONITOR .................GN01-27
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE.........GN01-31
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER
AND ENGINE SERIAL NUMBER ..................GN01-34
RECOMMENDED LUBRICANTS ..................GN01-35
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GENERAL INTRODUCTION
WARNING
EN0010601C100001
In order to ensure safety in work and avoid possible damage to vehicle, strictly observe the following precautions:
Audience of this manual is a qualified service engineer who has acquired expertise. In case an unqualified service engi-
neer or a service engineer without appropriate training has performed maintenance, or in case maintenance is performed
without using appropriate tools and units or in accordance with the method described in this manual, the vehicle under
maintenance could be damaged as well as do harm to the service engineer and the people in the maintenance site.
• Appropriate maintenance and repairs are a must for assurance of safety of the service engineer as well as the safety
and reliability of the vehicle. Replace parts of the vehicle with HINO genuine parts. Avoid using degraded parts.
• This manual contains the procedures to follow in performing maintenance and repairs. When performing mainte-
nance and repairs in accordance with the procedures, use special tools designed to meet specific needs in a proper
way.
• Never use a non-recommended work method or tool; this could impair the safety of the service engineer as well as
the safety and reliability of your vehicle.
• This manual contains various items classified into DANGERS, WARNINGS, CAUTIONS and NOTICES in order to
avoid accidents during maintenance and repairs or damage to the vehicle resulting in impairment of its safety and
reliability.
Note that these instructions described as DANGERS, WARNINGS, CAUTIONS and NOTICES are not the minimum
requirements to observe in order to avoid possible dangers.
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1. REPAIR WORK
(1) The repair work is roughly classified into the three processes: "diagnosis", "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work" and "final inspection".
(2) This manual describes the first process "diagnosis" and the second process "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work". Description on the third process "final inspection" is omitted.
(3) While this manual does not describe the following element work, the work is to be performed in practical cases:
a. Jack work and lift work
b. Cleaning of removed parts as required
c. Visual inspection
Check for the trouble after the trouble is removed. In case the
(6) Checkup test "Step 4" trouble is hardly replicated, conduct a checkup test under the con-
ditions and environment for the trouble.
(2) Pre-inspection
SHTS001060100001
✩: This is the ID number of an item to be prepared for creating electronic data and is not necessary for repair work.
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SHTS001060100002
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4. DEFINITION OF TERMS
This manual defines the terms used herein as follows:
(1) Direction
a. Chassis
• To-and-fro direction
The direction of forward travel of the vehicle while mounted on the vehicle is forward direction; the direction of back-
ward travel of the vehicle while mounted on the vehicle is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the vehicle is clockwise direction; the counterclockwise direction as
seen from the rear of the vehicle is counterclockwise direction. (In case of engine, the clockwise direction as seen
from the flywheel side is clockwise direction; the counterclockwise direction as seen from the flywheel side is coun-
terclockwise direction.)
• Upward/Downward direction
The upward direction while mounted on the vehicle is upward, and downward direction while mounted on the vehicle
is downward.
• Right/Left direction
The right direction as seen from the rear of the vehicle while mounted on the vehicle is right direction; the left direc-
tion as seen from the rear of the vehicle while mounted on the vehicle is left direction. (In case of engine, the right
direction as seen from the flywheel side is right direction; the left direction as seen from the flywheel side is left direc-
tion.)
b. Standalone unit
• To-and-fro direction
The direction of input of power is forward direction; the direction of output of power is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the unit is clockwise direction; the counterclockwise direction as
seen from the rear of the unit is counterclockwise direction.
• Upward/Downward direction
The upward direction while the unit is mounted on the vehicle (chassis) is upward, and downward direction while the
unit is mounted on the vehicle (chassis) is downward.
• Right/Left direction
The right direction as seen from the rear of the unit is right direction; the left direction as seen from the rear of the unit
is left direction.
(2) Standard value (Assembly standard):
Indicates a basic dimension or including the tolerance and the clearance generated by the clearance of a combina-
tion of two parts
(3) Limit (Service limit):
Indicates a numeric value which requires correction or replacement.
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.
6. UNIT
(1) This manual uses the SI unit system. The SI unit is an international unit which is based on one unit per quantity unlike
the conventional unit system which differs from country to country, in order to facilitate technology exchange.
(2) This manual writes the SI unit and a conventional unit side by side, the conventional unit enclosed in parentheses { }.
*1: X is a value obtained by converting 1 [conventional unit] to an SI unit and is used as a conversion factor of the
conventional unit and SI unit.
*2: The torque conversion value may depend on the unit. Follow the specific value described for each unit.
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GENERAL PRECAUTIONS
To assure safety in work and prevent possible danger, observe the following:
2. SAFETY WORK
(1) To prevent burns, never touch a radiator, muffler, exhaust pipe, and tail pipe just after the engine is turned off.
(2) While the engine is rotating, keep your clothes and tools off the rotating sections, in particular the cooling fan and V-
belt.
(3) Remove the starter key except when starting the engine.
(4) Provide good ventilation to avoid excessive CO when starting the engine.
(5) The fuel/battery gas is flammable. Never make a spark or light a cigarette.
(6) Take utmost care when working on the battery. It contains corrosive sulfuric acid.
(7) 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.
(8) Leaving a tool or waste in the engine room causes the tool or waste to touch the rotating section of the engine and
pop out, which could result in an injury.
3. 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 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct con-
tact with the bumper.
(1) Towing procedures
a. 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.
b. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame. The hook should be used only if the towed vehicle is not loaded.
c. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical 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.
d. Keep the gear shift lever in "Neutral".
e. Make sure that the starter switch is kept in the "ON" position.
f. 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 run-
ning.
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.
g. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
h. 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.
a. 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 automatic or manual
transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with
lubricant if necessary.
b. 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.
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PRECAUTIONS ON MAINTENANCE
Observe following before maintenance:
6. ASSEMBLY
(1) Observe the specified values (tightening torque, adjustment value) to assemble conforming parts in a correct proce-
dure.
(2) Use genuine parts for replacement.
(3) Use new packing, gasket, O-ring and cotter pin.
(4) Use a seal gasket depending on the location of gasket. Apply specified oil or grease to a sliding section where indi-
cated. Apply specified grease to the lip of the oil seal.
SHTS001060100008
SHTS001060100009
SHTS001060100010
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4. HANDLING OF CONNECTOR
(1) To remove a connector, hold the connector (indicated by an arrow
in the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the
connector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.
SHTS001060100011
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SHTS001060100012
(2) In order to prevent damage to ancillary equipment components
from sparks during welding, take steps such as putting fire-resis-
tant covers over things like the engine, meters, steering wheel,
hoses, leaf spring and tires.
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NOTICE
8T bolt conforms to the standard of 7T bolt.
(2) With washer
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw 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 the numeral "4"
Bolt with the numeral "7"
on its head
on its head Bolt with the numeral "9"
Remarks Projection bolt
Stud with chamfered free on its head
Stud with rounded free
end face
end face
NOTICE
8T bolt conforms to the standard of 7T bolt.
2. PRE-COATED BOLT
A pre-coated bolt is a bolt having a thread coated with seal-
ant.
(1) Cases where sealant must be applied again
a. Pre-coated bolt is removed
b. Pre-coated bolt has moved during tightening torque inspec-
tion
(Loosened or tightened)
HINT
Torque check is to be made using the lower limit value. In case the
bolt has moved, retighten it in the following procedure:
SHTS001060100014 (2) How to reuse pre-coated bolt
a. Clean the bolt and the tapped hole (clean the tapped hole
also when the bolt is to be replaced).
b. Blow air to dry up the bolt.
c. Apply a specified sealant to the thread of the bolt.
SHTS001060100015
SHTS001060100016
SHTS001060100017
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HEXAGON BOLT
On the hexagon bolt, the strength category is generally indicated on the head of the bolt by way of depression,
embossment, hollow and upset in accordance with the symbol in the table below.
HEXAGON NUT
The following tables shows examples of symbols to identify the strength category of hexagon nut on the nut itself.
(4) Table of tightening torque of general standard bolt and nut (Standard seat face is shown as a typical case)
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Strength category
4T 7T 9T
Bolt diameter
4.5±1.8 {50±20, 3.6±1.4}
(Cab)
M6 9.0±1.8 {90±20, 6.5±1.4} 11.5±2.0 {117±23, 8.5±1.6}
5.5±1.1 {60±10, 4.4±0.7}
(Chassis)
14.0±3.5
{140±40, 10.1±2.8} (Cab)
22.0±4.0 29.0±5.5
M8 17.0±3.0
{220±40, 15.9±2.8}*2 {300±60, 21.7±4.3}*2
{170±30, 12.3±2.1}
(Chassis)
57.0±11.0
43.0±8.5
{580±110, 41.9±7.9}*2
{440±90, 31.8±6.5}*2 (Cab)
27.0±5.0 (Cab)
M10 51.5±10.0
{276±55, 20.0±3.9} 68.5±13.5
{530±100, 38.3±7.2}
{700±140, 51±10}
(Chassis)
(Chassis)
76.0±15.0 100.0±20.0
{776±150, 56±10}*2 (Cab) {1,020±200, 74±14}*2 (Cab)
48.0±9.5
M12 91.0±18.0 120.0±24.0
{490±98, 35.4±7.0}
{930±180, 67±13} {1,220±240, 88±17}
(Chassis) (Chassis)
77.0±15.0 120.0±24.0 160.0±32.0
M14
{786±157, 57±11} {1,220±240, 88±17} {1,630±326, 118±23}
120.0±24.0 190.0±38.0 250.0±50.0
M16
{1,220±244, 88±17} {1,940±390, 140±28} {2,550±510, 184±37}
165.0±33.0 260.0±52.0 345.0±69.0
M18
{1,680±336, 121±24} {2,650±530, 192±38} {3,520±704, 255±50}
235.0±47.0 370.0±74.0 490.0±98.0
M20
{2,400±480, 174±34} {3,770±750, 273±54} {5,000±1,000, 362±72}
320.0±64.0 505.0±100.0 670.0±130.0
M22
{3,270±654, 236±47} {5,150±1,030, 372±74} {6,840±1,370, 495±99}
405.0±81.0 640.0±125.0 845.0±165.0
M24
{4,130±826, 299±59} {6,530±1,310, 472±94} {8,620±1,720, 623±124}
! CAUTION
• In case of tightening the bolt/nut with the flanged seat face A, the tightening torque value except *2 in the
table is to be increased by 10% from the indicated tightening torque value.
• In case of tightening the bolt/nut with the flanged seat face B, the tightening torque value *2 in the table is to
be increased by 20% from the indicated tightening torque value.
Note that for M8 the tightening torque value is constant for the flanged seat face B also.
• The bolt/nut with flanged seat B which is marked *2 in the table is compatible with a standard seat face as a
pair. Its tightening torque is the same as that of the standard seat face.
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To the tapered thread of the air pipe joint is applied the sealant "LOC-
TITE #575". Follow the procedure below to remove/attach the piping.
1. REMOVAL
(1) The sealant (LOCTITE #575) has a high sealing capability. The
return torque of taper joint is about 1.5 times as high as the initial
tightening torque. To remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability, remove
the auxiliaries with the joint attached then remove the joint.
SHTS001060100023
2. ATTACHING
(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe
the dirt off the sealing section, directly apply the sealant by a
quarter turn (three ridges) starting from the second ridge from the
tip, then assemble in accordance with the tightening torque table
below.
Wipe dirt off the mating part (female screw) before tightening it.
! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.
SHTS001060100024
Tightening torque of tapered joint Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw diameter
1/4 3/8 1/2
Material
49±10
Steel {500±100, 64±15 {650±150, 47±10}
36.2±7.2}
25±5 34±5 44±5
Aluminum, brass {250±50, {350±50, {450±50,
18.1±3.6} 25.3±3.6} 32.5±3.6}
(2) To replace vulcanized tape with sealant, remove the tape before-
hand, same as (1).
NOTICE
Take special care not to let dirt and foreign matters enter the pip-
ing.
(3) In the event of air leakage after sealant is applied and piping
attached, retightening cannot check the air leakage. Follow the
steps (1) and (2) to reassemble the piping.
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NYLON TUBE
EN0010601C100008
1. TYPES OF JOINT
(1) Nylon tube joints have two types: one-touch connector joint and
sleeve nut joint.
! CAUTION
Function and quality of a nylon tube and each joint are guaranteed
as a set. Use HINO genuine parts. Otherwise a burst or break may
result.
SHTS001060100027
SHTS001060100028
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d. After connection, pull the tube and check that the distance
from the connector end (retainer) to the taping at the insertion
length position is 5 mm {0.197 in.} or less.
SHTS001060100031
M12 x 1 (φ6) 23±5 {230±50, 16.6±3.6}
M14 x 1.5 (φ8) 37±4 {380±40, 27.5±2.8}
M16 x 1.5 (φ10) 40±5 {410±50, 29.6±3.6}
M18 x 1.5 (φ12) 55±5 {560±50, 40.5±3.6}
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(2) Assembly of sleeve nut (removing the tube from the joint and re-
attaching it in the same position)
MATCH MARK a. Give a match mark between the connector/union and the
sleeve nut before loosening the sleeve nut so as to memorize
the position.
b. For reassembly, tighten the sleeve nut up to the previous
position (match mark position). After that, retighten by 60°.
c. After reassembly, check for air leakage, if any, retighten until
the leakage stops.
d. If the leakage persists, replace the tube, sleeve and insert
with new ones. If this does not stop the leakage, replace the
SHTS001060100032 sleeve nut and connector/union as well.
! CAUTION
• Cut a tube only when there is extra length or when using a
new tube.
• When cutting a nylon tube, set the squareness of the tube
end with respect to the axis core within 90±5°.
SHTS001060100034
5 OR LESS
SHTS001060100035
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! CAUTION
• Never repair a nylon tube under high temperatures exceeding
the operating temperature range, in particular when drying
the coating.
• For punching, welding and sanding, protect a nylon tube
from tools, cutting, heat source or spark or remove the nylon
tube.
• Never attach the clamp of the welder near the tube.
• Never splash acidic liquid such as battery liquid onto the
tube.
• Never exceed the minimum bending radius R of the nylon
tube listed in the table below. Avoid using a tube with trace of
bending line.
! CAUTION
SHTS001060100036
• Set the tool clamping force to "3" on the dial.
• If the nylon tube is fixed with nonconforming clamping force,
the nylon tube may be damaged.
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2. REMOVING PARTS
(1) To remove each part, never twist a single section but twist the part in alternate directions at the collar or clearance on
the flange. When removing gasket, take care not to let the refuse of gasket enter the engine.
3. OTHER
(1) When the liquid gasket comes in a tube, use the supplied winding tool. When the gasket comes in a cartridge, use a
spray gun.
Note that the cutting position of the nozzle of the tube provides necessary width of application.
SHTS001060100050
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1. DIAGNOSIS MONITOR
(1) When connected to the diagnosis connector dedicated to each
system, the diagnosis monitor indicates a faulty section with
sound and light.
SST: Diagnosis Monitor (S0963-01370)
SHTS001060100051
SHTS001060100052
! CAUTION
The central diagnosis connectors are normally connected to the
(RIGHT-HAND DRIVE)
fixing dummy connectors. Remove the central diagnosis connec-
FIXING DUMMY tors from the dummy connectors before using them. When the
CONNECTOR central diagnosis connectors are not used, they should be
engaged into the fixing dummy connectors.
HINT
• Turning "ON" the starter switch with the diagnosis monitor
BLACK CONNECTOR connected causes the diagnosis monitor to keep sounding
without outputting diagnosis monitor codes. First turn "ON"
the starter switch, wait at least ten seconds, and connect the
WHITE CONNECTOR
diagnosis monitor.
SHTS001060100053
• The method for outputting diagnosis monitor codes differs
from system to system. Follow the instruction in the chapter
for each system.
SHTS001060100054
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4 3
10 6 5
8 7
12 11 9
SHTS001060100055
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LIGHT ON
LIGHT OFF
4.3 SECONDS
0.3 SECONDS
LIGHT ON
LIGHT OFF
SHTS001060100056
! CAUTION
• If the starter switch is placed in "LOCK" position, the past
faults are not erased. Keep the starter switch "ON".
• Erase the malfunction code memory using the PC DIAGNO-
SIS TOOL (Hino DX).
(3) Wait at least 5 seconds. Connect the diagnosis monitor to output
SHTS001060100057 the current fault information.
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SHTS001060100058
2A)0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧤ᣣޓἫᦐᣣޓඦ೨㧝㧝ᤨ㧞㧡ಽ
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis tool.
By connection to the diagnosis connector, the trouble location is
indicated.
SST:
Communication interface assembly (09993-E9070)
Cable communication (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
SHTS001060100059 NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
P P
INTERFACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS001060100060
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SHTS001060100061
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SHTS001060100062
.
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(EXAMPLE)
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND ENGINE
SERIAL NUMBER
ENGRAVED EN0010601C100011
POSITION
1. VEHICLE MODEL AND CHASSIS SERIAL NUMBER OR VEHI-
CLE IDENTIFICATION NUMBER
(1) Vehicle model and chassis serial number or vehicle identification
number are engraved near the front wheel of the right or left frame
SHTS001060100063
of the vehicle. When ordering parts, notify us of these numbers for
quick support.
(2) At the step inside the right door of the cab is attached an identifi-
(RIGHT-HAND DRIVE) cation plate stamped the vehicle model and chassis serial number
or vehicle identification number.
IDENTIFICATION
PLATE
SHTS001060100064
(LEFT-HAND DRIVE)
IDENTIFICATION
PLATE
SHTS001060100065
ENGRAVED
POSITION
SHTS001060100066
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RECOMMENDED LUBRICANTS
EN0010601C100012
Gear oil
(API: GL-4)
Engine oil
(API: CD, CE, CF, SF, SG)
(MIL-L-2104C, D, E)
(MIL-L-46152C, D, E)
EN01-001
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
EN0110601I200001
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 150 r/min.
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 150 r/min.
Maximum revolution (at full load) 2,600 r/min. (Ireland, New zealand)
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 150 r/min.
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
TROUBLESHOOTING
EN0110601F300001
Engine overheating
Symptom Possible cause Remedy/Prevention
Engine overheating (Coolant) Insufficient coolant Add coolant.
Defective thermostat Replace 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
Engine overheating (Coolant pump) Bearing seizure Replace.
Damaged (corroded) vane Replace vane.
Engine overheating (Radiator) Clogged with rust or scale Clean radiator.
Clogged with iron oxide due to leakage Clean coolant passage and correct
of exhaust into cooling system 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.
Engine overheating Poor fuel Use good quality fuel.
(Abnormal combustion) Breakdown of injector Replace the injector.
(Except J08E-UF, UG)
Incorrect injection timing Adjust injection timing.
(J08E-UF, UG)
Poor nozzle spray (J08E-UF, UG) Adjust or replace nozzle.
Unsatisfactory automatic timer Repair or replace timer.
advance angle (J08E-UF, UG)
Reduced injection pressure Adjust injection pressure.
Engine overheating Defective or deteriorated engine oil Change engine oil.
(Other problems) Unsatisfactory operation of oil pump Replace or repair.
Insufficient oil Add oil.
Brake drag Repair or adjust.
Break coolant temperature sensor Replace it.
Engine overheating Lugging the engine Operate engine properly.
(Severe operating condition)
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NOTICE
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.
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Piston seizure
Symptom Possible cause Remedy/Prevention
Piston seizure Incorrect clearance between piston Replace piston, piston rings and cylin-
(Pistons, cylinder liners and piston and cylinder liner der liner.
rings) Unsatisfactory installation of piston pin Replace piston, piston rings, cylinder
liner and piston pin as required.
Broken piston ring Replace piston, piston rings and cylin-
der liner.
Difference in expansion due to use of Replace piston, piston rings and cylin-
wrong piston der liner.
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 (coolant leakage, Repair or replace the radiator.
clogging)
Defective rubber hose (leakage) Replace rubber hose.
Defective thermostat Replace the thermostat.
Leakage of exhaust into cooling sys- Repair.
tem
Piston seizure (Operation) Abrupt stoppage of engine after run- Operate engine properly.
ning at high speed
Hill climbing using unsuitable gear Select suitable gear.
Piston seizure (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 oil Replace oil pump.
pump
Suction strainer sucking air Add oil and/or repair strainer.
Piston seizure Use of defective fuel Change fuel.
(Abnormal combustion) Engine overheating See Symptom: "Engine overheating"
Breakdown of injector Replace the injector.
NOTICE
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
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Lack of power
Symptom Possible cause Remedy/Prevention
Lack of power (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J08E-UF, UG)
Lack of power (Injection pump) Injection pump Refer to the chapter "FUEL INJEC-
(J08E-UF, UG) TION PUMP".
Lack of power (Intake) Clogged air cleaner Clean element or replace element.
Lack of power (Overheating) See Symptom: "Engine overheating".
Lack of power [Fuel and injector Air in fuel system Repair and bleed air from fuel system
(or injection nozzle)] Clogged fuel filter Replace element
Use of poor fuel Use good quality fuel.
Breakdown of injector Replace the injector.
(Except J08E-UF, UG)
Poor nozzle spray (J08E-UF, UG) Adjust or replace injection nozzle.
Clogged nozzle with carbon Clean nozzle.
(J08E-UF, UG)
Wear or seizure of nozzle Replace nozzle.
(J08E-UF, UG)
Lack of power Seized or wear of piston Replace the piston, piston rings and
(Pistons, cylinder liners and piston liner.
rings) Worn or broken piston rings, piston Replace piston rings, piston and liner.
and cylinder liner
Lack of power (Other problems) Exhaust brake butterfly valve stuck in Replace or repair exhaust brake.
half-open position
Connecting rod bent Replace or repair connecting rod.
Exhaust pipe or muffler crushed Replace exhaust pipe or muffler.
(increased back-pressure)
Breakage of turbine or blower Replace turbocharger.
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Leakage of exhaust
Symptom Possible cause Remedy/Prevention
Leakage of exhaust (Head gasket) Fatigued gasket (aging) Replace gasket.
Damage Replace gasket.
Improper installation Replace gasket.
Leakage of exhaust (Head bolts) Loose bolts Tighten bolts.
Elongated bolts Replace bolts.
Improper tightening torque or tighten- Tighten properly.
ing sequence
Leakage of exhaust (Cylinder block) Cracking Replace cylinder block.
Surface distortion Repair or replace.
Fretting of cylinder liner insertion por- Replace cylinder block.
tion (insufficient projection of cylinder
liner)
Leakage of exhaust (Cylinder head) Cracking Replace cylinder head.
Surface distortion Repair or replace.
Leakage of exhaust (Cylinder liners) Cracking Replace cylinder liner.
Corrosion Replace cylinder liner.
Insufficient projection of cylinder liner Replace cylinder liner.
Leakage of exhaust Incorrect injection timing Adjust injection timing.
(Other problems) (J08E-UF, UG)
NOTICE
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.
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Rough idling
Symptom Possible cause Remedy/Prevention
Rough idling (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J08E-UF, UG)
Rough idling Injection pump Refer to the chapter "FUEL INJEC-
(Injection pump) (J08E-UF, UG) TION PUMP".
Rough idling (Injector) Breakdown of injector Replace the injector.
(Except J08E-UF, UG)
Rough idling (Nozzles) Uneven injection pressure Adjust.
(J08E-UF, UG) Poor nozzle spray Adjust or replace nozzle.
Carbon deposit on nozzle tip Remove carbon.
Seized needle valve Replace nozzle.
Rough idling (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
Rough idling (Other problems) Clogged high pressure injection line Replace line.
Leakage due to improper tightening of Tighten sleeve nut.
high pressure fuel line
Engine seizure Replace pistons, piston rings and lin-
ers.
Incorrect valve timing Replace camshaft.
Diesel knock
Symptom Possible cause Remedy/Prevention
Diesel knock (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J08E-UF, UG)
Diesel knock (Injector) Breakdown of injector Replace the injector.
(Except J08E-UF, UG)
Diesel knock (Injection nozzle) Bad fuel nozzle spray pattern after- Check and correct it.
(J08E-UF, UG) dribble
High nozzle opening pressure Adjust the opening pressure.
Diesel knock (Fuel system) Use of poor fuel Use good quality fuel.
Incorrect fuel deliveries to some noz- Readjust the fuel deliveries
zles (J08E-UF, UG)
Diesel knock (Other problems) Excessively cooled or heated engine Warm up or cool engine.
Insufficient air intake Correct.
Insufficient compression pressure Repair.
Compression pressure leaks at cylin- Replace head gasket.
der head gasket
Improper valve clearance or valve Adjust or repair.
sticking
Tappet sticking Replace tappet and camshaft.
Improper injection timing Correct it.
(J08E-UF, UG)
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NOTICE
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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Excessive smoke
Symptom Possible cause Remedy/Prevention
Excessive smoke (Black smoke) Defective sensors or circuits Refer to the chapter "FUEL CON-
TROL".
Defective injector Replace the injector.
Excessive smoke (White smoke) Water in fuel Check and clean fuel lines.
Glow plug not operating Check glow plug circuit.
ENGINE TUNEUP
EN0110601H300001
(2) Among three drill holes on the camshaft gear, when two drill holes
are on horizontal position, and the rest of the drill hole is visible,
the No.1 piston is at the Top Dead Center of the compression
stroke.
NOTICE
If the rest of drill hole is invisible by camshaft housing, the No.6
piston is at the Top Dead Center of the compression stroke.
DRILL HOLE
SHTS011060100003
(3) Make sure that the valve stem is correctly inserted in the cross
head.
NOTICE
Click Move the cross head with fingers right and left to confirm the
valve stem is correctly inserted in the cross head by listening to
the clicking sound.
Good
(4) Confirm that there are no foreign particles or dust between the
cross head and the valve stem.
No Good
SHTS011060100004
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Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
SHTS011060100007
SHTS011060100008
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"Zero" Need
clearance clearance
CROSS HEAD
SHTS011060100009
(4) After completion of the adjustment, tighten the lock nut A securely
with the specified tightening torque.
Tightening Torque:
SHTS011060100010 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
(5) The condition of inserted feeler gauge, loosen the adjusting screw
of the cross head, make sure that the feeler gauge does not feel
LOOSEN
loose.
C
NOTICE
If the feeling of the feeler gauge becomes loose, repeat steps from
(1).
D
Need
clearance
SHTS011060100011
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(6) Tighten the adjusting screw C of the cross head until the feeler
ROCKER ARM gauge does not move.
TIGHTEN
C
NOTICE
In this situation, clearance between adjusting screw C and valve
stem head is zero.
"ZERO"
"ZERO" clearance
clearance
CROSS HEAD
SHTS011060100012
(7) While loosening the adjusting screw C of the cross head gradu-
ally, adjust the valve clearance. Tighten the lock nut D of the
LOOSEN cross head securely with the specified tightening torque when the
C feeler gauge feels correct.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
D
SHTS011060100013
NOTICE
• Do not over loosen the adjusting screw.
Not over loosen
C • Over loosening of the adjusting screw C will cause the same
condition as in step (3) again. The feeler gauge may feel cor-
rect, but there may be excessive clearance between the
E adjusting screw C of the cross head and the valve stem head
E. This does not allow for correct adjustment.
Need (8) Position each piston at Top Dead Center of compression stroke
clearance
by turning the crankshaft counterclockwise viewed from flywheel
side. Then adjust the valve clearance for each cylinder in the fir-
SHTS011060100014 ing order.
SHTS011060100015
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(2) Taking off the inspection hole plug, located at bearing holder case
BEARING HOLDER CASE of supply pump and tightening slightly the special tool therein,
check that the seat face of tool is fitting snugly with the bearing
holder.
FITTING
SNUGLY SST: Guide bolt (SZ105-08067)
NOTICE
When it is not well seated, it means it is contacting with other
parts than the turning stopper hole of coupling flange. Therefore,
NOT WELL do not tighten in too much. In this case, the timing is not fit. So,
INSPECTION SEATED perform again the setting for Top Dead Center of No.1 cylinder
HOLE PLUG compression stroke in above (1).
SHTS011060100016
SHTS011060100017
(3) Turn the automatic timer to the left (counterclockwise viewed from
the drive shaft) to align the automatic timer mark with the pointer
of the pump.
(4) Tighten the adjusting bolt to the specified torque.
SHTS011060100018
SST: Injection pump coupling wrench (S0981-91707)
Tightening Torque:
64 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}
NOTICE
• No clearance is allowed between thin plates.
• No deformation of the flange is allowed due to distortion of a
thin plate.
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1. PREPARATION
(1) Supply engine oil.
(2) Supply cooling water and bleed air from it.
(3) Bleed air from the fuel system.
(EXCEPT J08E-UF, UG)
BLEEDER PLUG
(4) Check connection to the alternator.
NOTICE
Starting the engine without wiring in place may burn out the alter-
nator.
(5) Check the engine stopping performance.
PRIMING PUMP
SHTS011060100019
SHTS011060100020
LUBRICATION
SHTS011060100021
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SPECIAL TOOL
EN0110601K100001
Except J08E-UF, UG
SZ105-08067 GUIDE BOLT
For "ENGINE TUNEUP"
J08E-UF, UG
S0955-21090
COMPRESSION GAUGE For "OVERHAUL CRITERIA"
ADAPTER (A) Except J08E-UF, UG
S0955-21110
For "OVERHAUL CRITERIA"
OVERHAUL CRITERIA
EN0110601H300002
Difference
Standard Limit between each
cylinder
3.4-3.6 MPa 2.3 MPa 0.3 MPa
{35-36 kgf/cm2, {24 kgf/cm2, {3 kgf/cm2,
494-522 lbf/in.2} 334 lbf/in.2} 43 lbf/in.2} or less
Engine revolution 150 r/min.
NOTICE
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.
SHTS011060100027
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3. OTHER FACTORS
SHTS011060100028
(1) Increase of blowby gas
(2) Defective engine start
(3) Decrease of engine output
(4) Increase of fuel consumption
(5) Increase of engine noise
(6) Increase of oil consumption
SHTS011060100030
NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
or air leaks.
SHTS011060100031
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• Liquid gasket is used at the following positions for the J08E series
engine.
2. REMOVE PARTS
(1) When removing parts, do not use a tool for removal at one loca-
tion only. Use the tool at various locations such as a flange step
or gap for removal. When removing the gasket, be careful that
gasket residue does not enter the engine.
3. OTHERS
(1) For tube-type liquid gasket, use the winding tool that comes with
the liquid gasket.
SHTS011060100032
SHTS011060100033
SHTS011060100034
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
1 Oil seal retainer {0.0591- Black
0.0984}
LIQUID GASKET
1.5-2.5
2 Coolant pump {0.0591- Black
0.0984}
1.5-2.5
3 Oil cooler {0.0591- Silver
0.0984}
1.5-2.5
5 Thermostat case {0.0591- Black
0.0984}
1.5-2.5
6 Flange {0.0591- Silver
0.0984}
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
LIQUID GASKET
1.5-2.5
7 Intake pipe {0.0591- Black
EXCEPT J08E-UF, UG 0.0984}
LIQUID GASKET
J08E-UF, UG
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
Matching parts of oil seal retainer and block
{0.0591- Black
lower face front end
0.0984}
1.5-2.5
Matching parts of block lower front end, gasket,
{0.0591- Silver
rear end plate and flywheel housing
0.0984}
LIQUID GASKET
LIQUID GASKET
Front and rear
ends of upper/
8
lower faces of
block
NOTICE
Cut the rear end plate gasket with a craft knife
flush with the block upper face.
LIQUID
GASKET 1.5-2.5
Flywheel hous-
9 {0.0591- Silver
ing
0.0984}
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧝㧤ಽ
Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1. Matching faces with cam housing and plug 1.5-2.5 Black 2 locations
{0.0591- at front and
2. Matching parts of cam housing, plug, cylin-
0.0984} rear ends
der head cover and gasket
NOTICE
• Application area of liquid gasket is half cir-
cle of cam housing. Never apply it to the
10 Cam housing upper half circle of the plug.
• Remove the excessive gasket completely.
NOTICE
Figure on the right shows application "pattern" of the liquid gasket.
Apply the liquid gasket to the center of seal flange inside whenever pos-
sible.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-27
COMPONENT LOCATOR ............................. EN02-27
SPECIAL TOOL ............................................. EN02-28
OVERHAUL ................................................... EN02-29
INSPECTION AND REPAIR .......................... EN02-33
CYLINDER HEAD
COMPONENT LOCATOR
EN0310602D100001
EXCEPT J08E-UF, UG
2
1
A
C
20
21
B
K
19
5
29 6
7 E
8 10
F
11
D
9 11
I
16 12 14
25
J 26
G
18 15
30
13
23 17
22
24
27
28
31
32
SHTS031060200001
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS031060200002
J08E-UF, UG
A 5
2
3
C
20
19
21
29
D
6
9
7 E
F 8 10
11
11
I
25 12 14
G 17
26
15
30 18
23 13
22 16
24
27
28
31
32
SHTS031060200003
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS031060200002
SPECIAL TOOL
EN0310602K100001
S0949-11010 WIRE
S0947-11520 GUIDE
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
OVERHAUL
EN0310602H200001
SHTS031060200013
7 5 3 1 2 4 6
SHTS031060200014
SHTS031060200015
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(7) Lift and remove the cylinder head using the special tool and hoist.
SST:
Eye bolt (S0943-31070)
Wire (S0949-11010)
NOTICE
• Do not damage the cylinder head lower surface or cylinder
block upper surface during removal of the cylinder head.
• If it is difficult to lift off the cylinder head, pry with a chisel
between the cylinder head and cylinder block.
SHTS031060200016
SHTS031060200017
SHTS031060200018
SHTS031060200019
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(3) When installing a new valve guide, do not twist the end. Press fit
the valve guide using the special tool.
SHTS031060200020 SST: Guide (S0947-11520)
NOTICE
• Be careful not to damage the valve stem at the upper or lower
end of the guide during press-fitting.
• Be sure to apply engine oil around the valve guide during
press-fitting.
ELECTRIC
(2) Place a (brass) back plate at the top of the valve system and
VALVE WELDING strike it with a hammer to remove the valve seat.
CUT THREE ! WARNING
PLACES HERE Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
SHTS031060200021
(4) Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water.
After cooling the valve seat, insert it into the cylinder head.
! WARNING
Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
SHTS031060200023
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200024
! WARNING
Punching the valve stem seal during installation may cause metal
chips to fly up. Be sure to wear protective goggles.
NOTICE
After assembly of the stem seal, check for deformation or cracking
of the rubber or incline.
APPLICATION OF OIL
RUBBER
SHTS031060200025
(2) After punching the valve stem seal, measure the height A.
VALVE STEM
SEAL SPRING Height A: 22.5-23.0 mm {0.886-0.906 in.}
VALVE SPRING
LOWER SEAT
SHTS031060200026
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200027
(2) After inserting the O-ring into the nozzle seat insertion hole of the
cylinder head, apply liquid packing (ThreeBond No.1211 or equiv-
alent) to the lower part of the new nozzle seat and assemble it
onto the cylinder head.
NOTICE
Be sure to replace the O-ring with a new one. Reuse of the O-ring
may cause water or gas leakage, resulting in overheating or crack-
ing of the cylinder head.
SHTS031060200028
SHTS031060200029
NOTICE
• Be sure to apply engine oil to the contact surface of each
part before assembly.
• Be sure to place each valve in its original position.
SHTS031060200017
• When the valve spring is compressed, be careful of damage
to the stem seal due to contact of the upper seat.
• Since this valve spring is evenly pitched, it can be installed
either end up.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(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.
NOTICE
Make sure that the liquid gasket surface is flush with the cylinder
head gasket upper surface.
SHTS031060200031
SHTS031060200032
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200016
(2) Apply clean engine oil to the bolt surface and bolt threads of the
M10 and M12 bolts.
(3) Clean the bolt seats completely on the cylinder head upper sur-
face.
(4) Tighten No.1-No.26 (M12 bolts) in the order shown in the figure to
the specified torque.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
SHTS031060200033
(5) Mark the M12 bolts with paint to indicate the same directions as
(EXAMPLE) shown in the figure.
(6) Turn No.1-No.26 (M12 bolts) 90° (1/4 turn) in the same order as in
PAINT MARK (4).
(7) Retighten them 90° (1/4 turn) as step (6).
90 (8) Make sure that all paint marks face the same direction.
90
NOTICE
When adding torque, never untighten the bolts, even if they have
been overtightened.
SHTS031060200034
(9) Tighten No.27-No.29 (M10 bolts) in the order shown in the figure
to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
SHTS031060200035
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
LUBRICATION
CYLINDER HEAD HOLE
SHTS031060200036
SHTS031060200037
(2) Make sure that there is neither damage to the camshaft gear or
camshaft nor dirt on them.
(3) Apply clean engine oil to the bolt surface and bolt threads and
tighten them to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
SHTS031060200038
SHTS031060200039
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧢ᤨ㧡㧤ಽ
SHTS031060200041
(4) (J08E-UF, UG) Tighten the nozzle clamp bolt to the specified
torque.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
SHTS031060200043
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
NOTICE
Make sure the oil hole is placed below.
SHTS031060200044
SHTS031060200045
(4) Install the camshaft housing plug to camshaft housing with torx
bolt.
Tightening Torque:
6 N⋅m {62 kgf⋅cm, 4.4 lbf⋅ft}
NOTICE
• Wipe out excess liquid gasket completely.
• Make sure that the camshaft housing plug installed with no
tilt.
SHTS031060200046
SHTS031060200047
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(5) Install the head cover gasket into the gasket groove at the head
cover lower surface.
NOTICE
Make sure that there are no foreign particles (including liquid gas-
ket), or oil on the gasket grooves of the head cover, gasket or cam
housing upper surface nor damage to them.
CYLINDER PLUG
(6) Apply liquid gasket to plug corner at the front and rear ends of the
cam housing before installing the head cover.
CAM HOUSING
SHTS031060200048
(7) Insert the silent block from the head cover lower surface.
(8) Tighten the bolt through the silent block to the specified torque
below and fix the head cover on the cam housing.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
SHTS031060200049
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Unit: mm {in.}
Replace
40 40.15
Camshaft bearing inside diameter camshaft
{1.5748} {1.5807}
bearing.
Replace
Clearance between
0.020-0.063 camshaft
camshaft journal and —
{0.0008-0.0024} and/or cam
camshaft bearing
bearing.
Measure
0.100-0.178 Replace
Camshaft end play —
{0.0040-0.0070} camshaft.
49.966 Measure
IN 50.046 {1.9703}
{1.9672}
J08E-UB, UC, Replace
UR 52.659 camshaft.
EX 52.739 {2.0763}
{2.0732}
Cam height
49.987 Measure
IN 50.067 {1.9711}
{1.9680}
Except
Replace
J08E-UB, UC,
52.024 camshaft.
UR EX 52.104 {2.0513}
{2.0482}
Measure
0.1 Replace
Camshaft deflection 0.04 {0.0016}
{0.0039} camshaft.
Replace Measure
22.08
Rocker arm bushing inside diameter 22 {0.866} rocker arm
{0.8693}
bushing.
Replace
21.92
Rocker shaft outside diameter 22 {0.866} rocker
{0.8630}
shaft.
Replace
rocker arm
Clearance between rocker shaft and 0.030-0.101 0.15 bushing
rocker arm bushing {0.0012-0.0039} {0.0059} and/or
rocker
shaft.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧢ᤨ㧡㧥ಽ
Replace the
Guide inside
7 {0.2756} — valve
diameter
Intake valve guide.
Replace the
0.023-0.058 valve and/
Clearance —
{0.0010-0.0022} or valve
guide.
Replace the
Guide inside diameter 7 {0.2756} — valve
Exhaust guide.
valve
Except 0.050-0.083 Replace the
J08E-UF, UG {0.0020-0.0032} valve and/
Clearance —
0.037-0.067 or valve
J08E-UF, UG guide.
{0.0015-0.0026}
Measure
IN 30° 30°-30°35'
EX 45° 45°-45°30'
Resurface
the valve
and/or
IN 30° 29°30'-30° valve seat.
EX 45° 44°30'-45°
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
314 N Measure
Setting load {32.0 kgf, 70.5 lbf} — Replace.
at 46.8 {1.843}
129 N
Setting load {13.2 kgf, 29.1 lbf} — Replace.
at 44.8 {1.764}
2.0
Squareness — Replace.
{0.0787}
Visual check
Measure
Except 2.45-2.95
J08E-UF, UG {0.0965-0.1161}
Replace
Nozzle protrusion —
nozzle seat.
2.25-2.75
J08E-UF, UG
{0.0886-0.1083}
Measure
0.06 {0.0024}
or less
for longitudinal
direction Replace.
NOTICE:
Cylinder head lower 0.20
Do not
surface flatness {0.0078}
grind for
repair.
0.03 {0.0012}
or less for lateral
direction
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧠㧣ಽ
Visual check
Cracks of damage to
cylinder head — — Replace.
(Dye penetrant check)
Visual check
Entire periphery
Contact of valve Matches
of valve head —
(Use of Red lead marking compound) valve.
evenly in contact
Replace
idle gear
Clearance between cam idle gear 0.025-0.075 0.2
shaft bush-
shaft and cam idle gear bushing {0.0010-0.0029} {0.0078}
ing and/or
idle gear.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
A
4
SHTS031060200065
SPECIAL TOOL
EN0310602K100002
OVERHAUL
EN0310602H200002
(1) Place the plate at the crankshaft end using the crankshaft pulley
bolts.
PLATE
SHTS031060200068
(2) Engage the hook with the oil seal notch and install the hook using
REMOVE THIS AFTER INSTALLING THE HOOK the bolt supplied.
(3) Remove the installed bolt in step (1).
NOTCH
HOOK
SHTS031060200069
(4) Install the center bolt and tighten it to remove the oil seal.
CENTER BOLT
SHTS031060200070
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(1) Clean the edges and surface of the crankshaft and the special
tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal press.
OIL SEAL
SHTS031060200071
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS031060200072
(3) Apply a little engine oil to the seal portion of the crankshaft oil
seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE BOLT
SHTS031060200073
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
PRESS
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
CENTER BOLT
SHTS031060200074
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(REPRESENTATIVE TYPE)
B
5
A 6 A 2
C
X A A
W
X
W
4
3
SHTS031060200075
SPECIAL TOOL
EN0310602K100003
OVERHAUL
EN0310602H200003
MAIN ENGINE
SPEED SENSOR
SHTS031060200079
NOTICE
MAIN ENGINE SPEED SENSOR
(Except J08E-UF, UG) When dismounting and remounting the fly-
wheel. Remove the main engine speed sensor. If not removed, it
will result in damage of the sensor.
FLYWHEEL
1 mm
{0.394 in.}
SHTS031060200080
! WARNING
SST
The flywheel is heavy when removing, be careful not to drop it on
your feet.
SHTS031060200081
(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE
Match the plate hole to the crankshaft collar knock part.
SHTS031060200082
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(2) Engage the hook with the oil seal notch and install the hook using
NOTCH the bolt supplied.
(3) Remove the installed flywheel bolts in step (1).
HOOK
SHTS031060200083
(4) Install the center bolt and tighten it to remove the oil seal.
SHTS031060200084
OIL SEAL
SHTS031060200085
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS031060200086
(3) Apply a little engine oil to the seal portion of the crankshaft oil
OIL SEAL seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE
GUIDE BOLT
SHTS031060200087
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
OIL SEAL
PRESS
SHTS031060200088
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
SHTS031060200089
SHTS031060200090
(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.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
SHTS031060200091
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
NOTICE
Place one guide bar at the collar knock and another at the oppo-
site side of the collar knock.
SHTS031060200092
(2) Insert the flywheel slowly until it contacts the collar knock to pre-
vent impact on the guide bar. Adjust the position, then insert the
flywheel completely.
! WARNING
The flywheel is too heavy. When installing, be careful not to drop it
on your feet.
(3) Apply clean engine oil to the threads of the flywheel bolt and the
flywheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces)
with a low-torque impact wrench.
(4) Pull out the guide bar and tighten the remaining two flywheel bolts
SHTS031060200093 provisionally as in step (3).
(5) Tighten the flywheel in the order shown in the figure to the speci-
fied torque below.
Tightening Torque:
186 N⋅m {1,900 kgf⋅cm, 137 lbf⋅ft}
(6) Loosen all bolts and tighten them again to the specified torque.
SHTS031060200094
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Unit: mm {in.}
Measure
Measure
CSP350 43 {1.693} — —
Flywheel
flange depth
(Dimension
A)
CSP380 48 {1.890} — —
TIMING GEAR
COMPONENT LOCATOR
EN0310602D100004
EXCEPT J08E-UF, UG
14 A
3
13
4
2 14 B
13
1 5
6 14
13
7
5 A
8 12 14
11
10
9
5
C
SHTS031060200097
J08E-UF, UG
SHTS031060200098
SPECIAL TOOL
EN0310602K100004
OVERHAUL
EN0310602H200004
SHTS031060200102
SHTS031060200103
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200104
SHTS031060200105
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.
• EXCEPT J08E-UF, UG
SHTS031060200106
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧜ಽ
• J08E-UF, UG
SHTS031060200107
NOTICE
• Install each idle gear shaft through the thrust plate as shown
in the figure so that the lubrication hole is downward.
• Adjust the timing of the main idle gear to align with the air
compressor gear as shown in the figure.
SHTS031060200108
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
EXCEPT J08E-UF, UG
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Main idle-Air
0.032-0.096
compressor 0.10 {0.0039}
{0.0013-0.0038}
idle
Measure
Air compres-
0.020-0.083
sor idle-Air 0.10 {0.0039}
{0.0008-0.0033}
compressor
Air compres-
Timing gear sor-Power 0.030-0.134
0.30 {0.0118} Replace gear.
backlash steering {0.0012-0.0052}
pump
Shaft outside
57 {2.244} — —
diameter
Bushing
inside 57 {2.244} — —
diameter
Main idle 0.030-0.090 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} and/or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside 50 {1.969} — —
diameter
Sub idle 0.025-0.075 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} and/or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside — —
diameter
Cam idle 0.025-0.075 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} and/or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside — —
diameter
Air
compressor 0.025-0.057 Replace bushing
Clearance 0.10 {0.0039}
idle {0.0010-0.0022} and/or shaft.
0.160-0.220
End play — —
{0.0063-0.0086}
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
J08E-UF, UG
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Air compres-
sor-Power 0.030-0.183
0.30 {0.0118}
steering {0.0012-0.0072}
Timing pump
gear back- Replace gear.
Main idle-Sub 0.030-0.162
lash 0.30 {0.0118}
idle {0.0012-0.0063}
Shaft outside
57 {2.244} — —
diameter
Bushing
inside diame- 57 {2.244} — —
ter
Measure
Main idle 0.030-0.090 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside diame- 50 {1.969} — —
ter
Sub idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside diame- — —
ter
Cam idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.
SHTS031060200111
2 3
A
4
SHTS031060200112
SHTS031060200113
SPECIAL TOOL
EN0310602K100005
S0947-11490 GUIDE
S0940-21540 SPINDLE
S0948-11540 GUIDE
SH691-20825 BOLT
OVERHAUL
EN0310602H200005
SHTS031060200127
SHTS031060200128
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• Keep the piston rings for each cylinder separately.
SHTS031060200129
SHTS031060200130
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧠㧣ಽ
(2) Pull the cylinder liner from the cylinder block using the special
tool.
SST: Puller (S0942-02100)
NOTICE
• Carefully set the special tool to prevent touching to the pis-
ton cooling jet.
• After removing the cylinder liners, arrange them in sequence.
SHTS031060200131
SHTS031060200132
(2) For the jet test, connect the oil hose to the connector bolt from the
cylinder block lower side.
NOTICE
Use clean engine oil for jet flow.
SHTS031060200133
(3) Set the special tool on the cylinder block upper surface against
the dowel pin.
SST: Tool assembly (S0947-01280)
(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic
pressure of 196 kPa {2 kgf/cm2, 28 lbf/in.2}.
SHTS031060200134
(5) If the center of the jet flow is within the target circle (7 mm {0.2756
in} diameter: Red), the test is acceptable.
NOTICE
Fire may occur due to splattered oil during the jet flow test. Do not
use naked lights near the test area.
! WARNING
Engine oil is flammable. Carry out this test in a well ventilated
room and do not use naked lights in the room.
SHTS031060200135
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
(6) If the center of the jet flow is out of the target circle, realign the
nozzle using the special tool.
SST: Adjusting bar (S0947-21620)
SHTS031060200136
SHTS031060200137
SHTS031060200138
(1) Apply engine oil to the inner surface of the block bore and insert
the cylinder liner using the special tool.
SST: Guide (S0947-11490)
NOTICE
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)
SHTS031060200139
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Tightening Torque:
9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
SHTS031060200140
4. MEASURE THE CRANKSHAFT.
(1) If necessary, grind the crankshaft and use an under size bearing.
Outside diameter
Bearing size
Crank pin Journal
64.94-64.96 mm 79.94-79.96 mm
Standard
{2.5567-2.5574 in.} {3.1473-3.1480 in.}
64.69-64.71 mm 79.69-79.71 mm
0.25US
{2.5469-2.5476 in.} {3.1375-3.1381 in.}
64.44-64.46 mm 79.44-79.46 mm
0.50US
{2.5371-2.5377 in.} {3.1276-3.1283 in.}
SHTS031060200141
SHTS031060200142
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200143
(3) Apply clean engine oil to the bolt seat and bolt threads.
(4) Tighten the bolts in the order as shown in the figure to the speci-
FRONT fied torque.
Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
2 4 6 8 10 12 14 (5) Loosen all bolts, tap the front and back ends of the crankshaft
1 2 3 4 5 6 7
using a plastic hammer.
1 3 5 7 9 11 13 (6) Tighten the bolts as in step (4).
(7) Mark the bolt heads with paint.
SHTS031060200144
(8) Tighten the bolts 90° (1/4 turn) in the same order as in step (4).
(9) Retighten the bolts 45° (1/8 turn) as in step (8).
(10) Make sure that all paint marks face the same direction.
NOTICE
When adding torque, never untighten the bolt, even if they have
been overtightened.
(11) After tightening, tap the front and back ends of the crankshaft
using a plastic hammer to allow complete fit.
SHTS031060200145
NOTICE
• Bring lever "H" punched on the guide above the pin.
SHTS031060200146
• Making sure to align both supporting surfaces of the guide
and press sub-assembly flush on a flat plane.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
SHTS031060200147
NOTICE
Align the groove of the spindle with the groove of the press sub
assembly.
SHTS031060200148
SHTS031060200149
(3) Chamfer one edge of the bushing hole at the small end of the
connecting rod uniformly by 0.5-1.0 mm {0.0197-0.0393 in.}.
NOTICE
• Irregular chamfering can cause out-of-roundness of the
pressed bushing, which may result in jamming during inser-
tion.
• Remove dust from the inner surface of the small-end hole.
SHTS031060200150
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Tightening Torque:
5.0-6.8 N⋅m {50-70 kgf⋅cm, 3.62-5.06 lbf⋅ft} (Bolt)
NOTICE
SHTS031060200151
• Align the groove of the spindle with the groove of the press
sub assembly.
• Make sure that the contact surfaces of the bushing seats
firmly against the contact surfaces of the spindle and guide.
b. Apply the fresh engine oil around the bushing and guide.
(5) Align the oil hole of the bushing with the oil hole of the connecting
rod.
NOTICE
• Put the connecting rod to the press sub assembly that cham-
fer side of the small end to the bushing side.
• Apply the fresh engine oil to the bore of the connecting rod.
SHTS031060200152
SHTS031060200153
SHTS031060200128
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
NOTICE
Install the second ring that turn the identification print on the pis-
ton ring to upper surface.
(2) Connect the joint of the coil expander for the oil ring and install it
inside the piston ring. Assemble the ring with the joint 180° oppo-
site to the matching point.
SHTS031060200154
(3) Position the matching points of the piston ring at a even distance
SECOND RING as shown in the figure.
OIL RING
TOP RING
SHTS031060200155
NOTICE
• When installing the piston, be careful that the cooling jet is
not struck by the connecting rod.
• Make sure that the 0-mark on the piston is at the exhaust
side.
SHTS031060200157
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧤ᣣޓἫᦐᣣޓඦ೨㧝㧝ᤨ㧟㧢ಽ
SHTS031060200158
SHTS031060200159
(2) Apply clean engine oil to the bolt thread and the bolt seat surface
of the connecting rod cap.
SHTS031060200160
(4) Mark the bolt heads in the same direction with paint.
(5) Tighten the connecting rod bolt 90° (1/4 turn).
(6) Tighten the connecting rod bolt 45° (1/8 turn).
(7) Make sure that the paint marks face the same direction.
NOTICE
• When adding torque, never untighten the nuts, even if they
have been overtightened.
SHTS031060200161
• If the angle of bolts is adjusted to the specified angle by turn-
ing counterclockwise, the axial force of the bolts might fall
short and it is feared that this could reduce the engine reli-
ability. Also there is a possibility that this could reduce the
number of times a bolt can be reused.
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Unit: mm {in.}
0.01-0.08
Cylinder liner protrusion — —
{0.0004-0.0031}
117.014-117.022
C
{4.6069-4.6071}
0.09-0.13
Clearance Top
{0.0036-0.0051}
between
piston 0.04-0.08 Replace piston ring
Second — —
ring and {0.0016-0.0031} and/or piston.
piston ring
groove 0.02-0.06
Oil
{0.0008-0.0023}
0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
Gap 0.75-0.90
between Second 1.2 {0.0472}
{0.0296-0.0354} Replace piston ring.
ends of pis-
ton ring
0.15-0.30 Piston ring
Oil 1.2 {0.0472}
{0.0059-0.0118}
Clearance between
-0.002-0.025 Replace piston and/
piston pin and piston pin 0.05 {0.0020}
{-0.00008-0.00098} or piston pin.
bore
Measure
Visual check
Wear or damage of
connecting rod
— — Replace.
*Dye penetrant check
(Color check)
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Visual check
Clogging of connecting
— — Replace.
rod oil hole
Clearance between
0.031-0.082 Replace connecting
connecting rod bearing 0.2 {0.0079}
{0.0013-0.0032} rod bearing.
and crank pin
Replace connecting
0.20-0.52
Connecting rod end play 1.0 {0.0394} rod and/or
{0.0079-0.0204}
crankshaft.
Measure
More than
Replace over size
0.5 {0.0197}
0.050-0.270 thrust bearing.
Crankshaft end play (Repair)
{0.0020-0.0106}
1.270 {0.0499}
Replace crankshaft.
(Service)
2A'0AOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧜ಽ
Measure
Visual check
Clogging of crankshaft
— — Clean.
oil hole
Visual check
Measure
Longitudinal direc-
Replace.
tion: 0.06 {0.0024}
Cylinder block upper sur- NOTICE:
Right angle direc- 0.20 {0.0080}
face flatness Do not grind for
tion: 0.03 {0.0012}
repair.
or less
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
EN03-001
EXCEPT J08E-UF, UG
(REPRESENTATIVE TYPE)
6
A
SHTS011060300001
J08E-UF, UG
SHTS011060300002
SHTS011060300003
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
AIR INTAKE
COMPONENT LOCATOR
EN0110603D100002
(REPRESENTATIVE TYPE)
Z
2 5
1 6
4
7
A
5
5
Z
9 A
8
5
SHTS011060300004
1
2
X
4
5
1
SHTS011060300005
OVERHAUL
EN0110603H100002
AIR CLEANER
VEHICLE
FRONT
ALIGN THE ARROW MARK ALIGN THE
WITH THE STOPPER'S CENTER. ARROW MARKS.
A
B
AIR HOSE
(AIR CLEANER)
AIR HOSE
(INTER COOLER)
INTAKE PIPE
SHTS011060300006
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
AIR CLEANER
AIR HOSE
(INTER COOLER) INTAKE PIPE
AIR CLEANER
VEHICLE
FRONT B
A
B
AIR HOSE
(INTER COOLER) ALIGN THE
ARROW MARKS.
INTAKE PIPE
AIR HOSE
(INTER COOLER)
INTAKE PIPE
SHTS011060300008
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
SHTS011060300009
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
(REPRESENTATIVE TYPE: MODELS FOR AUSTRALIA AND NEW ZEALAND (DOUBLE CAB))
INTAKE PIPE
AIR HOSE
AIR HOSE
(INTER COOLER)
B (AIR CLEANER)
SHTS011060300010
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧜ಽ
AIR CLEANER
COMPONENT LOCATOR
EN0110603D100003
SHTS011060300011
1 Body 4 Clamp
2 Filter element 5 Dust unloader valve
3 Cover
OVERHAUL
EN0110603H100003
1. INSPECTING
(1) If on inspection the dust indicator is red, clean or replace the filter
element.
(2) If the cover, body or dust unloader valve are damaged, replace
the parts.
(3) Check the filter element to see if it is flattened or deformed, or
whether the filter paper of the element is torn.
(4) Check to see if the sealing of the packing is complete.
! CAUTION
If an abnormality is found during the above inspection, replace the
element with a new one. If dust is taken into the engine, the engine
will wear and its performance will deteriorate.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧡ಽ
EN04-001
SHTS011060400001
MODELS FOR AUSTRALIA, HONG KONG, IRELAND, NEW ZEALAND, SINGAPORE AND
TAIWAN
(REPRESENTATIVE TYPE)
3
4
1
2
9 5
7 8 4
A 14
11
13
B
1
12
10
SHTS011060400002
SHTS011060400003
14 15 8 9 2 3 5 6 11 12 17 18
13 7 10 16
1 4
SPACER
SHTS011060400004
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧡ಽ
5
10 9
c 6
a
10 7 Y
7 A c
6
8 X 6
A
A 6
10 7
6 6
B 8
10 b
7 6 4
1
A 3 10
3 11 6
13
7
3 D C
D 12 X 6
Z 6
7 7
2
5 6
6 a D
10
C 6
Y
8
Z 8
SHTS011060400005
3 X
11
Y
5
8
4
B
11 9
5
5
4 Z
11
11 B 4
10 W
11 5
Y 4
11
4
11 5 Z
11
9
4 11
B 4
C 4 B 5 D
9 7
6
1 4
1
W 12
X
1
10 5 2
A A
6
SHTS011060400006
1 Gasket 7 Muffler
2 Exhaust pipe 8 Muffler support
3 Noise insulator 9 Tail pipe
4 Clamp 10 Plate
5 Bracket 11 Cushion
6 Heat insulator 12 Exhaust brake
OVERHAUL
EN0110604H200001
! WARNING
If the position on the tail pipe is incorrect, exhaust fumes may
1-3 mm {0.04-0.12 in.} blow onto passers by and burns may also result.
CLAMP
SHTS011060400008
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧢ಽ
LUBRICATING SYSTEM
DIAGRAM
EN0110605J100001
EXCEPT J08E-UF, UG
ROLLER
PIN
CAM ROLLER
O CAM
I SHAFT
L
P
A CAM
N IDLE SHAFT
SUB
IDLE SHAFT
TURBO
CHARGER
S
T
R
A OIL OIL OIL MAIN
I PUMP COOLER FILTER OIL HOLE
N
E
R PISTON CONNECTING CRANK
PIN ROD SHAFT
AIR
COMPRESSOR
MAIN IDLE
GEAR SHAFT
AIR COMPRESSOR
IDLE GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011060500001
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧢ಽ
J08E-UF, UG
ROLLER
PIN
CAM ROLLER
O CAM
I SHAFT
L
P
A CAM
N IDLE SHAFT
SUB
IDLE SHAFT
TURBO
CHARGER
S
T
R
A OIL OIL OIL MAIN
I PUMP COOLER FILTER OIL HOLE
N
E
R
CONNECTING CRANK
ROD SHAFT
INJECTION
PUMP
AIR
COMPRESSOR
MAIN IDLE
GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011060500002
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧢ಽ
EXCEPT J08E-UF, UG
1 A
8 9
SHTS011060500003
J08E-UF, UG
SHTS011060500004
OVERHAUL
EN0110605H200001
Unit: mm {in.}
Block side
bushing inside 18 {0.709} — —
diameter
Drive gear
Block hole
18 {0.709} — —
diameter
0.030-0.075
Clearance — Replace pump.
{0.0012-0.0029}
Driven
gear Gear bushing
18 {0.709} — —
inside diameter
Measure
0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0081}
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧢ಽ
EXCEPT J08E-UF, UG
3 4 5
2 A
2 6
D
2 B
2
4
2 7 D
C
2
A D
2 2
E D 9 B
A 8
10
2
1
SHTS011060500011
J08E-UF, UG
SHTS011060500012
SPECIAL TOOL
EN0110605K100001
SHTS011060500014
NOTICE
Make sure that O-rings are not on the oil cooler case side.
SHTS011060500015
NOTICE
SHTS011060500016 • Do not reuse the O-ring.
• Attention the O-ring to damage.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧢ಽ
(2) Apply liquid gasket to the oil cooler case and install it onto the cyl-
inder block, then tighten the bolt to the specified torque.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
SHTS011060500017
1. Damage to sliding
Wear or damage to valve
Replace face of valve
spring of oil cooler and — —
if necessary. 2. Valve movement
oil filter
(smoothness)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
EN06-001
COOLING SYSTEM
DIAGRAM
EN0110606J100001
1
4
2
5
11
3 12
10
7 9
8 13
14 14
SHTS011060600001
MODELS FOR AUSTRALIA, HONG KONG, IRELAND, NEW ZEALAND, SINGAPORE AND
TAIWAN
2 12
5 18
4
3 6
13
8 7
17
14
16
11
15
16
10
9
SHTS011060600002
COOLANT PUMP
COMPONENT LOCATOR
EN0110606D100001
11
10
7
6
SHTS011060600003
SPECIAL TOOL
EN0110606K100001
OVERHAUL
EN0110606H200001
SHTS011060600007
(2) Remove the pulley center from the shaft using the special tool.
SST: Puller (S0942-01810)
SHTS011060600008
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
(3) Remove the retainer ring from the pump case using snap ring pli-
ers.
SHTS011060600009
(4) Push the shaft from the vane side using a hydraulic press, and
remove the coolant shaft from the pump case.
NOTICE
Before pressing, recheck that the retainer ring is removed com-
pletely.
SHTS011060600010
(5) Remove the coolant seal from the pump case using a hammer
and brass bar.
! WARNING
Impact due to punching may cause metal chips to fly up. Be sure
to wear protective goggles.
NOTICE
Replace the removed coolant seal with a new one. Never reuse it.
SHTS011060600011
SHTS011060600012
(2) Install the retainer ring onto the pump case using snap ring pliers.
SHTS011060600013
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
(3) Install the pulley center onto the shaft using a hydraulic press.
Standard: 149.7-150.5 mm {5.894-5.925 in.} from the
pulley center mounting surface to the pump
case end surface
SHTS011060600014
SHTS011060600015
SHTS011060600016
(5) Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.7-1.3 mm {0.0275-0.0511 in.}
NOTICE
Press until the vane end face comes into contact with the shaft
end surface.
(6) After assembly, turn the shaft by hand and make sure that there is
no noise, catching or rough movement in the shaft direction and
that it rotates smoothly.
SHTS011060600017
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
Unit: mm {in.}
Visual check
Measure
Measure
NOTICE
• Tightness= Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is
within the standard value.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧡㧞ಽ
THERMOSTAT
COMPONENT LOCATOR
EN0110606D100002
2
3
4
1
5
6
2
SHTS011060600021
MODELS FOR AUSTRALIA, HONG KONG, IRELAND, NEW ZEALAND, SINGAPORE AND
TAIWAN
1
2
4
5
6
SHTS011060600022
OVERHAUL
EN0110606H200002
SHTS011060600023 NOTICE
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
SHTS011060600024
(REPRESENTATIVE TYPE)
IMPORTANT POINT - ASSEMBLY
JIGGLE 1. ASSEMBLE THE THERMOSTAT CASE.
VALVE
NOTICE
• Remove water or dirt adhering to the thermostat case.
• Be sure to replace the gasket if it is corroded, damaged or
flattened.
• Before installing the hose, apply liquid gasket to the hose
installation part of the thermostat case cover.
• To prevent clogging of the radiator, do not use a large
SHTS011060600025 amount of liquid gasket.
• Be sure that the jiggle valve faces upward when installing it.
SHTS011060600026
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
(3) Temporarily tighten the bolts "1" and bolts "2" in that order, and
(TYPE-1)
securely contact the fitting surface.
"2"
(4) Tighten the bolts in numeral order.
"1"
SHTS011060600027
(TYPE-2)
"2"
"1"
SHTS011060600028
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
RADIATOR
COMPONENT LOCATOR
EN0110606D100003
1 A
7 11
10
9 3
8
7
6
5
4
SHTS011060600029
SPECIAL TOOL
EN0110606K100002
For caulking
S0976-01040 RADIATOR TOOL
(Used with S0976-01030)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
OVERHAUL
EN0110606H200003
SHTS011060600032
(2) Grip the handle until it hits to the stopper bolt, then adjust the
dimensions A with stopper bolt.
Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.}
SST: Radiator tool (S0976-01030)
NOTICE
Be sure to adjust the dimension to prevent damage of the crow.
SHTS011060600033
SHTS011060600034
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
(4) Remove the upper tank and lower tank from the radiator core by
tapping lightly with plastic hammer.
NOTICE
Do not remove the tank by forcing or prying.
SHTS011060600035
SHTS011060600036
(2) Grip the handle of the radiator tool until it hits to the stopper bolt,
then adjust the dimensions B with stopper bolt.
Dimension B: 8.4 mm {0.3307 in.}
SHTS011060600037
(3) Install the new O-ring into the groove of the radiator core (upper
and lower) in such away that it will not be twisted.
NOTICE
Be sure to clean the fitting portion before installing. When clean-
ing, lightly rub the inside portion of the groove with the emery
paper.
(4) Install the upper tank and lower tank into the groove of the radia-
tor core.
SHTS011060600038
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
(5) Flap the tangs to obtain a tight contact with the upper tank and
lower tank.
SHTS011060600039
(6) Press the radiator tool (caulking tool) against the side portion.
Temporarily caulk the tangs several times, then proceed to the
final caulking by gripping the handle until it hits the stopper bolt.
NOTICE
For the positions where the radiator tool is not usable, perform the
caulking with pliers.
SHTS011060600040
NOTICE
Perform the caulking according to the sequence as shown in the
figure.
SHTS011060600041
SHTS011060600042
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧡ᣣޓ᳓ᦐᣣޓඦ೨㧝㧝ᤨ㧣ಽ
Measure
Radiator cap
valve 40-58
Mark 0.5 — Replace.
opening {0.4-0.6, 5.7-8.5}
pressure
Intercooler
• Air leakage test 0 mL —
(when the air pres- Replace the inter-
sure of 490 {5.0, 71} is cooler.
applied.)
• Clogging of the fins — —
NOTICE
• The coolant filler cap valve opening pressure is indicated on
the cap and it should be confirmed. If the cap pressure is
incorrect, there is a risk of abnormally high pressure being
generated in the cooling system, which may cause the hose
to drop off or burst and may result in the damage of the
engine.
• When carrying out high pressure washing to remove fin clog-
ging, do not apply excessive pressure to the fins which may
cause deformation and consequent performance deteriora-
tion.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧣ಽ
COOLING FAN
COMPONENT LOCATOR
EN0110606D100004
(REPRESENTATIVE TYPE)
3
SHTS011060600046
Visual check
EN07-001
FUEL SYSTEM
(EXCEPT J08E-UF, UG)............................ EN07-2
DIAGRAM ........................................................ EN07-2
COMPONENT LOCATOR ............................... EN07-3
SUPPLY PUMP
(EXCEPT J08E-UF, UG)............................ EN07-9
DESCRIPTION ................................................ EN07-9
COMPONENT LOCATOR ............................. EN07-10
SPECIAL TOOL ............................................. EN07-10
OVERHAUL ................................................... EN07-11
INJECTION NOZZLE
(TWO-SPRING TYPE - DENSO MAKE)
(J08E-UF, UG) ......................................... EN07-25
DESCRIPTION .............................................. EN07-25
COMPONENT LOCATOR ............................. EN07-26
SPECIAL TOOL ............................................. EN07-27
OVERHAUL ................................................... EN07-28
5 4 3 2
13
6 12
11
7
9
10
8
SHTS011060700001
COMPONENT LOCATOR
EN0110607C100001
SHTS011060700002
SHTS011060700003
COMPONENT LOCATOR
EN0110607C100002
SHTS011060700004
SPECIAL TOOL
EN0110607K100001
OVERHAUL
EN0110607H200001
SHTS011060700007 NOTICE
After dismounting the pump, cover the pump and high pressure
pipe to prevent entry of dirt.
SHTS011060700008
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
(2) Turn the timer counterclockwise slowly viewed from the coupling
(normal direction of engine) and align the mark on the timer with
the mark on the injection pump pointer.
SHTS011060700009
(3) Tighten the injection pump mounting bolt evenly to the torque
below.
SST: Injection pump coupling wrench (S0981-91707)
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
SHTS011060700010
Tightening Torque:
61.3 N⋅m {625 kgf⋅cm, 45 lbf⋅ft}
(5) Tighten the through bolt at the flange.
Tightening Torque:
90.7 N⋅m {925 kgf⋅cm, 67 lbf⋅ft}
SHTS011060700012
NOTICE
• Do not reuse the element.
• Be careful not to damage the gasket.
SHTS011060700013
SHTS011060700014 NOTICE
The bleeder plug should be tightened while the priming pump
knob is operated.
(5) Once again, operate the priming pump knob several times.
(6) Push back the priming pump knob and tighten it.
NOTICE
Wipe up any splashed fuel.
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700015
COMPONENT LOCATOR
EN0110607C100003
5
B
8
7 3
4
A
SHTS011060700016
SPECIAL TOOL
EN0110607K100002
OVERHAUL
EN0110607H200002
! WARNING
Perform the following work after the engine cools off to avoid fire
or burning. The fuel in the common rail could have a high temper-
ature (approx. 100°C {212°F}) immediately after driving.
SHTS011060700018
SHTS011060700019
(2) Taking off the inspection hole plug, located at bearing holder case
BEARING HOLDER CASE of supply pump and tightening slightly the special tool therein,
check that the seat face of tool is fitting snugly with the bearing
holder.
FITTING
SNUGLY SST: Guide bolt (SZ105-08067)
NOTICE
When it is not well seated, it means it is contacting with other
parts than the turning stopper hole of coupling flange. Therefore,
NOT WELL do not tighten in too much. In this case, the timing is not fit. So,
INSPECTION SEATED perform again the setting for Top Dead Center of No.1 cylinder
HOLE PLUG compression stroke in above (1).
SHTS011060700020
PIPE B
SHTS011060700021
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
(2) Remove the six bolts for mounting the air compressor and dis-
AIR COMPRESSOR mounting the supply pump with the air compressor.
SUPPLY O-RING
PUMP
SHTS011060700022
(3) Remove the bolts, and then the supply pump with the bearing
BEARING HOLDER CASE COUPLING holder case from the air compressor.
SUPPLY PUMP
O-RING
AIR COMPRESSOR
SHTS011060700023
(4) Remove the nut, and then the coupling flange from the bearing
BEARING HOLDER CASE holder case.
(5) Remove the bolts, and then the bearing holder from the supply
pump.
SHAFT
NOTICE
After dismounting the pump, cover the pump and high pressure
pipe to prevent entry of dirt.
NUT
COUPLING FLANGE
SHTS011060700024
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
BEARING
HOLDER CASE
SHTS011060700025
SST
COUPLING
FLANGE
(5) Align the aligning mark "0" on the top of coupling flange with pro-
trusion on the compressor housing.
"0" MARK
PROTRUTION
SHTS011060700027
(6) The special tool should be fit snugly with the turning stopper hole
BEARING HOLDER CASE of coupling flange through bearing holder case.
SST: Guide bolt (SZ105-08067)
NOTICE
• Make sure not to tighten the tool, fitting with other parts than
SST the turning stopper hole of the coupling and not to stop its
COUPLING turning with use of other than the special tool.
FLANGE
• The specified tool is designed so that the tip of special tool
TURNING STOPPER HOLE
might not touch deeply with its turning stopper hole (Clear-
ance of the tip is 2 mm {0.079 in.}).
SHTS011060700026
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
(7) Replace the O-ring with a new one and install it to the air com-
BEARING HOLDER CASE COUPLING pressor.
(8) Install the supply pump to the air compressor.
SUPPLY PUMP
O-RING
AIR COMPRESSOR
SHTS011060700023
(9) Replace the O-ring with a new one and install the air compressor
with the supply pump to the flywheel housing.
O-RING
NOTICE
• Without moving the piston position fit to the top dead center
of compression stroke in No.1 cylinder, put the gears (timing
gear side and air compressor one) in engagement.
• When cranking engine, make sure to remove off the special
tool.
• After completing the installation, make sure to remove the
special tool and to install inspection window plug.
SHTS011060700028
Standard:
SCV 7.65-8.15 Ω at 20°C {68°F}
COMMON RAIL
DESCRIPTION
EN0110607J100004
2 3
SHTS011060700030
OVERHAUL
EN0110607H200003
SHTS011060700031
SHTS011060700032
SHTS011060700033
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧣ಽ
SHTS011060700034
SHTS011060700035
SHTS011060700036
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧞㧣ಽ
GASKET
SHTS011060700038
SHTS011060700039
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700041
(4) Tighten the force feed pipe nuts to the specified torque.
(EXAMPLE)
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
NOTICE
• If the tightening torque of the nuts is less than the specified
value, it may cause a fuel leak. If the tightening torque of the
nuts is greater than the specified value it may have a nega-
tive influence on the engine function. As a result, always per-
form torque management.
• After the operation is completed, wipe off the fuel which
SHTS011060700042
leaked and start the engine. Make sure that the fuel does not
leak again.
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700043
SHTS011060700044
SHTS011060700045
SHTS011060700046
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
7
1
8
2
3
4
9
5 10
6 11
12
13
14
15
16
17
SHTS011060700047
OVERHAUL
EN0110607H200004
CLAMP
OIL SEAL
O-RING
SHTS011060700049
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
(5) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
(6) Install the leakage pipe with the 5 new gasket and 5 joint bolts.
Tightening Torque:
12.3 N⋅m {125 kgf⋅cm, 91 lbf⋅ft}
SHTS011060700051
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700052
SHTS011060700054
COMPONENT LOCATOR
EN0110607D100001
SHTS011060700055
SPECIAL TOOL
EN0110607K100003
OVERHAUL
EN0110607H200005
SHTS011060700061
(2) Operate the lever at the rate of 15 to 60 strokes per minute. If the
injection pressure is not within specified value, adjust the injection
pressure with adjusting screw.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
SHTS011060700063
SHTS011060700064
SHTS011060700065
SHTS011060700066
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700068
(2) The hole in the special tool and the pin on the distance piece are
NOZZLE NEEDLE lined up and the dial gauge is pushed down until it contacts the
SPRING SEAT distance piece. Next, set the dial gauge to "0".
SHTS011060700069
(3) Insert the push rod and first pressure spring to the nozzle holder
CAP NUT body. Tighten the adjusting screw.
GASKET (4) Assemble the new gasket, tighten temporarily the cap nut.
ADJUSTING SCREW
FIRST PRESSURE
SPRING
PUSH ROD
NOZZLE HOLDER
SHTS011060700072
(5) Mount the above stated nozzle holder on the nozzle hand tester
to determine the pressure at the start of injection.
This value is used as the first opening pressure. The adjusting
screw is tightened or loosened to keep this value within a set
range.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
NOTICE
SHTS011060700073
• Tightening the adjusting screw → increases pressure
• Loosening the adjusting screw → decreases pressure
(6) After adjustment, a gasket is installed and the cap nut is tightened
down to anchor the adjusting screw.
Tightening Torque:
53.9 N⋅m {550 kgf⋅cm, 40 lbf⋅ft}
NOTICE
Make sure that the adjusting screw does not turn at the same time.
SHTS011060700074
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧡㧡ಽ
NOTICE
SHTS011060700076
• Thick shims → increases pressure
• Thin shims → decreases pressure
• About 88.26 kPa {0.9 kgf/cm2, 12.8 lbf/in.2} of change is
obtained for every 0.01 mm {0.0004 in.} of shim thickness.
Second opening pressure adjusting shim line-up
Parts number Shim thickness
S2288-57670~ 1.0-1.375 {0.0394-0.0541}
S2288-57820 (jump at 0.025 {0.001})
S228-8-7040~ 1.4-1.7 {0.0551-0.0669}
S2288-57160 (jump at 0.025 {0.001})
S2288-57180~ 1.725-2.1 {0.0679-0.0827}
S2288-57330 (jump at 0.025 {0.001})
2A'0AAOQMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧞㧥ಽ
SHTS011060700077
b. Measurement
The nozzle holder is mounted on the nozzle hand tester and a
check is made to determine if the pressure at the start of
injection (first opening pressure) is within the standard range.
If not within the specified pressure, readjust with the adjusting
screw.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
SHTS011060700076
NOTICE
After tightening the bolt, make sure that the rocker arm moves
SHTS011060700078
smoothly.
(7) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
34.3 N⋅m {350 kgf⋅cm, 25.3 lbf⋅ft}
FUEL FILTER
DESCRIPTION
EN0110607J100005
SHTS011060700079
COMPONENT LOCATOR
EN0110607C100006
SHTS011060700080
FUEL TANK
COMPONENT LOCATOR
EN0110607J100006
2 7
14
3
A
4
B
Y 10
C
1 12
13
9 Z
Y
8
6
11
X 10 13 13
12
13 5
X
8 9 11
SHTS011060700081
11
10
Z
c
b Y
12
a
2
A
9
7
5
13 14
C
Z 6
Y
b
a
1
3
SHTS011060700083
TURBOCHARGER EN08
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING..................................... EN08-3
SPECIAL TOOL ............................................. EN08-11
OVERHAUL CRITERIA ................................. EN08-12
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧝ಽ
TURBOCHARGER
DESCRIPTION
EN0110608C100001
7 5-B 4-A
2 3 1
SHTS011060800001
TROUBLESHOOTING
EN0110608F300001
1. Table 1-1. Troubleshooting-Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
OR
ENGINE
ENGINE LACKS
SYMPTOM OR TROUBLE EXHAUST EMITS
POWER
BLACK SMOKE
(See Notes D and F✩) (See Notes K✩) (See Notes H✩) (See Note M✩)
Restricted duct Restricted duct
Leakage at Turbocharger
NO NO between air NO between NO
turbocharger rotating assembly
cleaner and compressor and
mounting flange binding or dragging
turbocharger engine intake
Engine malfunction
Restricted engine NO Restricted engine NO (fuel system
exhaust system intake or exhaust component, valves
(after turbocharger) manifold valve ring, ring
piston, etc.)
Remove restriction
Refer to engine Refer to engine
or replace
manufacturer's manufacturer's
turbocharger as
service manual service manual
necessary
SHTS011060800002
ENGINE EXHAUST
SYMPTOM O R TROUBL E EMITS WHITE OR
BLUE SMOKE
YES YES
Perform
Refer to engine
troubleshooting
manufacturer's
procedures outlined
service manual
in Table 1-7
SHTS011060800003
✩ Shown on Table 1
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧝ಽ
ENGINE OIL
SYMPTOM OR TROUBLE CONSUMPTION
EXCESSIVE
SHTS011060800004
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧝ಽ
NOISY
SYMPTOM OR TROUBLE TURBOCHARGER
Clean housing or
Perform
replace turbocharger
troubleshooting
as required. Eliminate all leaks
procedures outlined
Check engine
in Table1-5
operating procedures
SHTS011060800005
TURBOCHARGER
ROTATING
SYMPTOM OR TROUBLE
ASSEMBLY BINDING
OR DRAGGING
Excessive carbon
build-up behind NO Sludged or cocked
turbine wheel center housing
YES YES
SHTS011060800006
Restricted duct
Loose compressor
Dirty air cleaner between air cleaner Leakage at engine
NO NO to intake manifold NO NO
element and turbocharger intake manifold
duct connection
compressor
Remove restriction
Tighten duct Refer to engine
Replace air cleaner or replace
connections as manufacturer's
element turbocharger as
required service manual
necessary
Turbocharger
Restricted turbo- Plugged engine Worn or damaged bearings, bearing
NO NO NO NO
charger oil drain line crankcase compressor wheel bores or shaft
journals worn
Engine malfunction
(excessive piston
blow by or high
internal crankcase
pressure)
YES
Refer to engine
manufacturer's
service manual
SHTS011060800007
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧝ಽ
SEAL LEAKAGE AT
SYMPTOM OR TROUBLE TURBINE END OF
TURBOCHARGER
Restricted
Plugged engine Sludged or cocked
Excessive pre-oiling NO NO turbocharger oil NO NO
crankcase breather center housing
drain line
Engine malfunction
Turbocharger
excessive piston
bearings, bearing
NO blow by or high
bores or shaft
internal
journals worn
crankcase pressure
YES YES
Perform
Refer to engine
troubleshooting
manufacturer's
procedures out-
service manual
lined in Table 1-8
SHTS011060800008
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧝ಽ
TURBOCHARGER
SYMPTOM OR TROUBLE BEARINGS, BORES,OR
SHAFT JOURNAL WORN ✩
Inadequate pre-
Contaminated or
oiling following Insufficient engine
improper grade or Restricted
turbocharger oil supplied to
NO type of engine NO NO turbocharger oil NO
installation or turbocharger due to
lubricating oil used feed line
engine lube system "oil lag"
in engine
servicing
SHTS011060800009
SPECIAL TOOL
EN0110608K100001
OVERHAUL CRITERIA
EN0110608H300001
SHTS011060800013
SHTS011060800014
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
TURBOCHARGER EN08
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING..................................... EN08-3
COMPONENT LOCATOR ............................. EN08-12
SPECIAL TOOL ............................................. EN08-12
OVERHAUL CRITERIA ................................. EN08-13
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
TURBOCHARGER
DESCRIPTION
EN0110608C100001
SHTS011060800001
TROUBLESHOOTING
EN0110608F300001
1. Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
SHTS011060800002
SHTS011060800003
SHTS011060800004
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
SHTS011060800005
SHTS011060800006
SHTS011060800007
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
SHTS011060800008
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
SHTS011060800009
COMPONENT LOCATOR
EN0110608D100001
SHTS011060800010
SPECIAL TOOL
EN0110608K100001
OVERHAUL CRITERIA
EN0110608H300001
SHTS011060800014
SHTS011060800015
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧞ಽ
(5) Release the air pressure at the sensing port. Note that the dial
gauge pointer returns exactly to zero.
(6) Repeat steps (4) through (5) several times to make sure that
wastegate valve or rod movement has been accurately measured.
(7) If the specified value or rod movement cannot be obtained within
the specified air pressure range.The turbine housing assembly or
actuator assembly must be replaced.
! CAUTION
Operation of the engine with the wastegate calibrated to some
value other than that specified can result in reduced performance
or severe engine damage.
(8) If wastegate performance is within specification, install the hose
onto the wastegate sensing port.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
17.16-17.65 MPa
Test nozzle opening pressure
{175-180 kgf/cm2, 2,490-2,560 lbf/in.2}
Overflow valve opening pressure 240.3-269.7 kPa {2.45-2.75 kgf/cm2, 34.9-39.1 lbf/in.2}
Pump
Rack position Measuring Injection volume Variation limit
revolution
mm {in.} stroke cm3 {cu.in.} cm3 {cu.in.}
r/min
INJECTION
VOLUME 8.6 {0.339} 500 3.75-4.75 {0.229-0.289} 1.5 {0.092} or less
ADJUSTMENT
13.2 {0.520} 750 500 75.0-76.5 {4.577-4.668} 4.0 {0.244} or less
1,250 3.4°-4.0°
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
Adjusting position
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
Idling
275 0 {0, 0} 8.5-8.7 {0.335-0.342}
12.5°±5°
LEVER ANGLE
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, con-
trol rack should be 5.0 mm {0.197 in.} or less.
• Boost compensator inside seal: When pump speed at 1,250 r/min and boost pressure is 93.3 kPa {700
mmHg, 27.6 inHg}, set the boost compensator stopper for control rack position to (A+0.7)±0.3 mm
{(A+0.028)±0.012 in.}. If turn back the full load stopper to end, then turn back to A with bolt.
NOTICE
A = 14.75-15.15 mm {0.581-0.596 in.}
• Set adjusting lever from idle to full load position when boost pressure and pump speed is 0, measure the
starting injection volume at pump speed at 100 r/min.
• Boost compensator air seal: Air pressure drop from 133 kPa {1,000 mmHg, 39.4 inHg} to 131 kPa {980
mmHg, 38.6 inHg} should be taken more than 10 seconds.
Rw (10.85)=Rw2 Rw3
(mm) Q=71 2 (Np=500 r/min)
13 (Np=300 r/min)
12
11 (Rw2+0.2) 0.1
(Np=300 r/min)
22.7
93.3
20 40 60 80 Pb
(kPa)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧡ಽ
17.16-17.65 MPa
Test nozzle opening pressure
{175-180 kgf/cm2, 2,490-2,560 lbf/in.2}
Overflow valve opening pressure 240.3-269.7 kPa {2.45-2.75 kgf/cm2, 34.9-39.1 lbf/in.2}
Pump
Rack position Measuring Injection volume Variation limit
revolution
mm {in.} stroke cm3 {cu.in.} cm3 {cu.in.}
r/min
INJECTION
VOLUME 9.0 {0.354} 500 3.75-4.75 {0.229-0.289} 1.5 {0.092} or less
ADJUSTMENT
13.2 {0.520} 750 500 69.25-70.75 {4.226-4.317} 4.0 {0.244} or less
Adjusting position
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
Idling
275 0 {0, 0} 8.5-8.7 {0.335-0.342}
13.5°±5°
LEVER ANGLE
18
IDLE SPRING INTERSECTION A
16 10 14.95
NP=205 14.65
14.2 13.9
14 13.2
12.1 12.35 12.4
Control rack position (mm)
12
10.45
10 (10.9) IDLE SPRING INTERSECTION
11.9
9.0 NP=300 15
8 IDLE SPRING INTERSECTION 6.9
11.6 7.9
6 NP=(725)
4.3
4
1250
2
1350
1550
1800
1000
500
100
185
205
275
300
400
750
900
0
0 2 4 6 8 10 12 14 16 18 20
(10.8)
Pump revolution (r/min) x10 2
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, con-
trol rack should be 5.0 mm {0.197 in.} or less.
• Boost compensator inside seal: When pump speed at 1,250 r/min and boost pressure is 93.3 kPa {700
mmHg, 27.6 inHg}, set the boost compensator stopper for control rack position to (A+0.7)±0.3 mm
{(A+0.028)±0.012 in.}. If turn back the full load stopper to end, then turn back to A with bolt.
NOTICE
A = 14.75-15.15 mm {0.581-0.596 in.}
• Set adjusting lever from idle to full load position when boost pressure and pump speed is 0, measure the
starting injection volume at pump speed at 100 r/min.
• Boost compensator air seal: Air pressure drop from 133 kPa {1,000 mmHg, 39.4 inHg} to 131 kPa {980
mmHg, 38.6 inHg} should be taken more than 10 seconds.
(10.9)=Rw2 Rw3
Q=65 2 (Np=500 r/min)
Rw (Np=300 r/min)
(mm)
12
11 (Rw2+0.2) 0.1
(Np=300 r/min)
10
17.3
93.3
20 40 60 80 Pb
(kPa)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
DESCRIPTION (NB-TYPE)
EN0110609C100001
SHTS011060900009
TROUBLESHOOTING
EN0110609F300001
Excessive smoke
Symptom Possible cause Remedy/Prevention
Excessive smoke (Black smoke) Excessive fuel delivery caused by Adjust fuel delivery on test stand.
incorrect adjustment of full-load stop-
per screw
Excessively advanced injection timing Correct it.
Large spread in fuel delivery Adjust it.
Bad nozzle fuel spray characteristics Check and correct them.
Excessive smoke (White smoke) Improper retarded injection timing Advance injection timing.
Water in fuel Check and clean fuel lines.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
Loud knocking
Symptom Possible cause Remedy/Prevention
Loud knocking Improper injection timing Correct it.
Bad fuel nozzle spray pattern after- Check and correct it.
dribble
High nozzle opening pressure Adjust the opening pressure.
Incorrect fuel deliveries to some noz- Readjust the fuel deliveries
zles
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900010
SPECIAL TOOL
EN0110609K100001
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
SPRING COMPRESSION
S0951-22410
TOOL
S0951-21620 TWEEZERS
CAMSHAFT PROTRUDANCE
S0951-22340
GUIDE RAIL
OVERHAUL
EN0110609H200001
SHTS011060900024
(2) Fix the special tool on the stud bolts, turn the guide until the clear-
ance between the washer and the handle is approximately 1-2
mm {0.0394-0.0787 in.}, to set the special tool.
NOTICE
The guide of the special tool is left-hand threaded.
SST: Delivery valve holder remover (S0951-22380)
SHTS011060900025
(3) Turn the handle clockwise into the delivery valve holder. Continue
until the O-ring in the cylinder comes off the pump body.
SHTS011060900026
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
(4) Pull the special tool upward to remove the delivery valve group.
SHTS011060900027
SHTS011060900028
NOTICE
Set the camshaft at bottom dead center before removing the con-
trol sleeve.
SHTS011060900029
SHTS011060900030
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
NOTICE
First bring the cam of the cylinder to bottom dead center.
SHTS011060900031
SHTS011060900032
NOTICE
The tappet can be removed more easily when the cam of the cylin-
der is at top dead center.
SHTS011060900033
SHTS011060900034
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900035
SHTS011060900036
(2) Use the special tool to remove the taper roller bearing at the gov-
ernor side.
SST: Bearing remover (S0951-01160)
SHTS011060900037
(3) Use the special tool to tap out the outer race in the bearing cover.
SST: Outer race puller (S0951-22330)
SHTS011060900038
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900039
(2) Install the camshaft adjusting ring, shim and taper roller bearing,
in that order, on the camshaft.
NOTICE
Put a round nut on the other end of the camshaft to protect the
threads.
SHTS011060900040
SHTS011060900034
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900041
(2) If the specification is not met, use appropriate shim at the gover-
nor end of camshaft until the specification is met.
SHTS011060900042
SHTS011060900043
(2) If the specification is not met, use, appropriate shim at the drive
end of camshaft until the specification is met.
SHTS011060900044
NOTICE
Position the groove provided in the tappet in the axial direction of
the camshaft, and position it accurately so that the tappet is
retained in position by the tappet retainer pin which is driven
inside the pump housing.
SHTS011060900033
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
NOTICE
Be sure that the flange of the lower spring seat is accurately
seated in the groove of the tappet.
This is very important since an inaccurately positioned seat may
cause damage to the pump.
SHTS011060900045
SHTS011060900046
(2) Attach the upper spring extractor, and fit the guide groove on the
extractor to the projected part of the upper spring seat.
SST: Spring compression tool (S0951-22410)
SHTS011060900047
(3) Push the handle down to compress the plunger spring, turn the
guide lever 90° toward you, and installing the upper spring seat
underneath the stopper pin which is driven inside the pump hous-
ing.
SHTS011060900048
NOTICE
• First bring the cam of the cylinder to bottom dead center.
• Check that the spring is accurately retained by the stopper
pin.
• Check that the projected part of the upper spring seat faces
away from the rack.
SHTS011060900049
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900030
SHTS011060900050
NOTICE
Position the flanges of the control sleeve and the plunger, and the
projected part of the upper spring seat correctly before inserting
the control sleeve.
SHTS011060900051
(3) Move the control rack until the ball in the control sleeve is accu-
rately inside the groove provided in the control rack.
NOTICE
• The plunger may slip out of its position during installation.
Check the following for a second time.
• The vertical groove of the plunger must face the spill side.
• The plunger must not come out when it is pulled up.
SHTS011060900052
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900053
(2) Put the delivery valve group in the support, and tighten the deliv-
ery valve holder on the delivery valve group.
SST: Setting support (S0951-22390)
Tightening Torque:
88.2 N⋅m {900 kgf⋅cm, 65 lbf⋅ft}
SHTS011060900054
SHTS011060900056
SHTS011060900057
(3) Tighten the nuts finger tight. Then, tighten the nuts alternately to
their specified torque.
SST: Box wrench (S0951-21790)
Tightening Torque:
19.1 N⋅m {195 kgf⋅cm, 14 lbf⋅ft}
SHTS011060900058
Unit: mm {in.}
Measure
Total play of tappet
roller, Replace tappet
— 0.3 {0.0118}
roller bushing and roller assembly.
pin
Measure
Measure
Visual check
Visual check
ADJUSTMENT (NB-TYPE)
EN0110609H300002
PREPARATION
1. PREPARATION
(1) Mount the injection pump correctly on the pump tester.
SHTS011060900066
(2) Attach a rack position measuring device to the control rack and
set to "0".
SST: Rack position measuring assembly (95091-00170)
(3) Install calibration nozzles and lines.
Nozzle and lines: Refer to "DATA AND SPECIFICATIONS".
SHTS011060900067
SHTS011060900068
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧢ಽ
SHTS011060900069
SHTS011060900070
(4) Move the angle dial to set the first cylinder of the pump to bottom
dead center and adjust the pre-stroke gauge to zero.
NOTICE
Bottom dead center is the point at which the pointer of the dial
gauge does not move even when the angle dial is rotated while
fuel is flowing from the overflow line.
SHTS011060900071
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
(5) Turn the camshaft clockwise the angle dial and read the dial
gauge when the fuel stops running out of the overflow line. This
reading is the pre-stroke value of the pump.
Pre-stroke: Refer to "DATA AND SPECIFICATIONS".
(6) If the pre-stroke value is not within specification, change the
shims between the cylinder flange and the pump housing.
SHTS011060900072
SHTS011060900074
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧡㧢ಽ
SHTS011060900075
SHTS011060900076
SHTS011060900077
SHTS011060900078
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900079
SPECIAL TOOL
EN0110609K100002
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
OVERHAUL
EN0110609H200002
SHTS011060900085
SHTS011060900086
(4) Install the special tool on the cover, and fix with the nut.
NOTICE
Do not tighten the nut but leave loosened.
SST: Timer wrench (S0951-22210)
SHTS011060900087
(5) Set the extension bar on the timer wrench, then loosen and
remove the timer cover.
SHTS011060900088
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900089
SHTS011060900090
SHTS011060900091
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900092
SHTS011060900089
SHTS011060900093
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧡㧢ಽ
SHTS011060900094
(2) Hook a spring balancer between the two socket bolts at the end of
the extension bar, then pull the spring balancer until it shows 213
N {22 kgf, 49 lbf} to tighten up the timer cover.
Tightening Torque:
319 N⋅m {3,250 kgf⋅cm, 235 lbf⋅ft}
SHTS011060900095
5. FILL THE PUMP TIMER OIL INTO THE TIMER THEN TIGHTEN-
ING THE SCREWS.
Oil grade: SAE 90
Oil Volume: 140-160 cm3 {8.54-9.76 cu.in.}
Tightening torque for timer hub screw:
13.7 N⋅m {140 kgf⋅cm, 10 lbf⋅ft}
SHTS011060900086
SHTS011060900096
OVERHAUL
EN0110609H200003
SHTS011060900097
SHTS011060900098
SHTS011060900099
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900100
SHTS011060900097
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
GOVERNOR (R901)
DESCRIPTION
EN0110609C100002
SHTS011060900101
COMPONENT LOCATOR
EN0110609D100004
SHTS011060900102
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SPECIAL TOOL
EN0110609K100003
S0951-21770 WRENCH
CAMSHAFT BUSHING
S0951-22260 EXTRACTOR
(DAMPER WEIGHT MODEL)
S0951-22510 BIT
OVERHAUL
EN0110609H200004
SHTS011060900109
NOTICE
Before lifting the governor cover, be sure to pull up the supporting
lever as shown by dotted lines in the figure, so that its lower end
may not obstruct the lifting of the governor cover.
SHTS011060900110
SHTS011060900111
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900112
SHTS011060900113
SHTS011060900114
SHTS011060900115
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900116
SHTS011060900117
SHTS011060900118
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧞ᣣޓἫᦐᣣޓඦ೨㧥ᤨ㧢ಽ
(4) Apply a dial gauge to the end face of the flyweight, and measure
the thrust clearance.
Thrust clearance: 0.02-0.10 mm {0.0008-0.0039 in.}
(5) If not within specification, adjust the clearance by inserting shims
between the bushing and the governor round nut.
SHTS011060900119
SHTS011060900120
SHTS011060900121
SHTS011060900122
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧣ಽ
ADJUSTMENT
EN0110609H300003
PREPARATION
1. PREPARATION
(1) Connect the rack measuring device to the control rack and set to
"0".
(2) Connect the fuel line.
(3) Refill the camshaft chamber with engine oil.
(4) Install the angle gauge on the speed control lever.
(5) Remove the rack limiter cover.
(6) Connect the boost line to the compensator port from the vacuum
pump on a test bench via a "T" connection to a pressure gauge.
SHTS011060900123
SHTS011060900124
SHTS011060900125
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900126
NOTICE
The idle adjusting screw will change the governor characteristics
as show on the left.
SHTS011060900127
SHTS011060900128
SHTS011060900129
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
SHTS011060900130
SHTS011060900131
SHTS011060900132
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧣ಽ
SHTS011060900133
SHTS011060900134
SHTS011060900135
SHTS011060900136
SHTS011060900137
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧣ಽ
SHTS011060900139
SHTS011060900140
SHTS011060900141
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧣ಽ
SHTS011060900142
NOTICE
All adjusting devices on the fuel injection pump governor, except
the low idle adjustment screw, are secured with the special bolts
and crimp caps as a protection for the customer. This is to prevent
unauthorized readjustment which may cause engine malfunction
and/or engine failure. Periodically check to insure that special
bolts and crimp caps are not removed as this will void the war-
ranty.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
BOOST COMPENSATOR
COMPONENT LOCATOR
EN0110609D100005
SHTS011060900144
1 Housing 9 Cover
2 Plate washer 10 Thrust washer
3 Screw plug 11 Diaphragm
4 Push rod 12 Spring upper seat
5 Screw 13 Spring
6 Cap 14 Clamp plate
7 Lock nut 15 Guide bushing
8 Stop screw
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
ADJUSTMENT
EN0110609H300004
SHTS011060900145
(2) Turn the guide bushing with a screw driver inserted through the
screw plug hole and set the "A" clearance to zero.
SHTS011060900146
(3) Tighten the stop screw until it comes in contact with the push rod
end, then further tighten the stop screw by 1/2 turn.
SHTS011060900147
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧣ಽ
(4) Set length "B", by means of the adjust with screw indicated in fig-
ure.
Length "B": 13.5 mm {0.531 in.}
SHTS011060900148
(5) Check screw traveling length, "E" while apply 133.3 kPa {1,000
mmHg} boost pressure to port "D".
Traveling length "E": 4-5 mm {0.157-0.196 in.}
(6) Check the boost compensator air seal. While applied 133.3 kPa
{1,000 mmHg} boost pressure to port "D", the time required for
pressure to drop to 130.7 kPa {980 mmHg} should be more than
10 seconds.
SHTS011060900149
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧥ಽ
4
9
3 2
A 2
1
2
3
3
2
10 2
6 8
A
X
1
2
3
5
2
Y
11 X 10
7
6
9 a 6
2
a
9
Y
SHTS011061000001
EGR VALVE
DESCRIPTION
EN0110610J100002
SHTS011061000002
SHTS011061000003
(2) Drain the coolant out of the drain plug of oil cooler situated on the
right side of the engine.
SHTS011061000004
(3) Disconnect and remove all pipes connected to the EGR pipe as
well as coolant hose and related parts.
(4) Remove EGR pipe.
(5) Remove the oil level gauge clamp and inter cooler hose from the
intake pipe. Remove the intake pipe (with EGR valve) from the
intake manifold.
SHTS011061000005
SHTS011061000006
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧟㧥ಽ
NOTICE
Use a new gasket.
SHTS011061000007
(2) Install the intake pipe (with EGR valve) to the intake manifold.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
(3) Install the oil level gauge clamp and intercooler hose to the intake
pipe.
(4) Install the EGR pipe.
NOTICE
Fit the exhaust manifold gasket with the claw of the gasket facing
down.
(5) Connect and install all pipes connected to the EGR pipe as well
SHTS011061000008 as coolant hose and related parts.
NOTICE
Install all pipes with new gasket.
(6) Close the coolant plug of the oil cooler situated on the right side of
the engine.
NOTICE
Fit the exhaust manifold gasket with the claw of the gasket facing
down.
SHTS011061000009
SHTS011061000010
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧟㧤ಽ
ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS........................ EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING..................................... EN11-4
COMPONENT LOCATOR ............................... EN11-5
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-17
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
ALTERNATOR
DATA AND SPECIFICATIONS
EN0110611I200001
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002
TROUBLESHOOTING
EN0110611F300001
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
COMPONENT LOCATOR
EN0110611D100001
SHTS011061100003
1 Brace 4 Bracket
2 Harness 5 V-belt
3 Alternator 6 Strap band
SHTS011061100004
SPECIAL TOOL
EN0110611K100001
OVERHAUL
EN0110611H200001
SHTS011061100008
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS011061100009
SHTS011061100010
(3) Remove the rotor from drive end frame, using a press.
NOTICE
• Do not damage to the screw tip.
• Hold rotor by hand so that it will not fall off.
SHTS011061100011
SHTS011061100012
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
SHTS011061100013
SHTS011061100015
SHTS011061100016
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100017
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
SHTS011061100018
SHTS011061100019
SHTS011061100020
(6) Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
NOTICE
A removed bearing should not be reused. Replace it with a new
one.
SHTS011061100021
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧞ᣣޓἫᦐᣣޓඦ೨㧥ᤨ㧣ಽ
SHTS011061100022
SHTS011061100023
SHTS011061100024
(4) Install the space collar, fan and pulley, tighten the lock nut.
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
V-BELT that pulley is held with V-belt as a cushion.
SHTS011061100025
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
ROLLER
BEARING
JIG B
SHTS011061100026
NOTICE
Tighten the bolt evenly.
SHTS011061100027
SHTS011061100028
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS011061100029
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
(4) Using a solder ring iron, solder the lead wire connecting the regu-
lator and field coil as well as the stator coil and diode.
NOTICE
• Soldering work should be done just after tightening the bolt.
• Solder lead wire after bending and fixing the terminal of regu-
lator.
• Solder field coil after caulking the tip of diode.
• Soldering work should be done for short moment (Within 5
sec.).
SHTS011061100030
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100031
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
SHTS011061100032
NOTICE
Tighten the through bolt evenly.
SHTS011061100033
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
SHTS011061100034
SHTS011061100035
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
SHTS011061100036
Test lead
Standard
(+) (–)
B E APPROX. 20 Ω
E B ∞Ω
P E APPROX. 7 Ω
E P ∞Ω
SHTS011061100037
E A B
R L
N P
DETAIL OF A
SHTS011061100038
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧜ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
W
Resistance of stator
0.31-0.33 Ω — Replace. U
coil [at 20°C (68°F)] V
WIRING
Measure
Insulation resistance of
1 MΩ or more — Replace.
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Normal direction
E
APPROX. 10 Ω
Resistance of regulator — Replace.
Reverse direction
∞Ω
F
Resistance of con-
denser Indicate 800 Ω
NOTICE ↓ (Immediately) — Replace.
Do not use digital Indicate ∞ Ω
tester.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
ALTERNATOR
DATA AND SPECIFICATIONS
EN0110611I200001
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002
TROUBLESHOOTING
EN0110611F300001
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
COMPONENT LOCATOR
EN0110611D100001
2 Z
6
Z
B 5
SHTS011061100003
1 Alternator 4 Brace
2 Belt tension pulley 5 Bracket
3 V-ribbed belt 6 Through bolt
SHTS011061100004
OVERHAUL
EN0110611H200001
SHTS01106110
SHTS011061100007
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS011061100008
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
SHTS011061100009
(3) Remove the rotor from drive end frame, using a press.
NOTICE
• Do not damage to the screw tip.
• Hold rotor by hand so that it will not fall off.
SHTS011061100010
SHTS011061100011
SHTS011061100012
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
SHTS011061100014
SHTS011061100015
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100016
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
TERMINAL B
SHTS011061100017
SHTS011061100018
SHTS011061100019
(6) Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
NOTICE
A removed bearing should not be reused. Replace it with a new
one.
SHTS011061100020
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧞ᣣޓἫᦐᣣޓඦ೨㧥ᤨ㧤ಽ
SHTS011061100021
SHTS011061100022
SHTS011061100023
(4) Install the space collar, fan and pulley, tighten the lock nut.
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
V-BELT
that pulley is held with V-belt as a cushion.
SHTS011061100024
JIG B
SHTS011061100025
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
NOTICE
Tighten the bolt evenly.
SHTS011061100026
SHTS011061100027
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS011061100028
(4) Using a solder ring iron, solder the lead wire connecting the regu-
REGULATOR lator and field coil as well as the stator coil and diode.
NOTICE
• Soldering work should be done just after tightening the bolt.
• Solder lead wire after bending and fixing the terminal of regu-
lator.
• Solder field coil after caulking the tip of diode.
• Soldering work should be done for short moment (Within 5
sec.).
SHTS011061100029
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100030
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
TERMINAL B
SHTS011061100031
NOTICE
Tighten the through bolt evenly.
SHTS011061100032
SHTS011061100033
NOTICE
Do not hit the cover since its hook is fragile.
SHTS011061100034
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
SHTS011061100035
Test lead
Standard
(+) (–)
B E APPROX. 20 Ω
E B ∞Ω
P E APPROX. 7 Ω
E P ∞Ω
SHTS011061100036
E
B
R L
N P
DETAIL OF A
SHTS011061100037
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧝ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
Resistance of stator
0.31-0.33 Ω — Replace. V U
coil [at 20°C (68°F)]
WIRING
Measure
Insulation resistance of
1 MΩ or more — Replace.
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Normal direction
APPROX. 10 Ω E
Resistance of regulator — Replace.
Reverse direction
∞Ω
F
Resistance of con-
denser Indicate 800 Ω
NOTICE ↓ (Immediately) — Replace.
Do not use digital Indicate ∞ Ω
tester.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS........................ EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING..................................... EN11-4
COMPONENT LOCATOR ............................... EN11-5
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-17
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
ALTERNATOR
DATA AND SPECIFICATIONS
EN0110611I200001
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002
TROUBLESHOOTING
EN0110611F300001
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
COMPONENT LOCATOR
EN0110611D100001
2 Z
6
Z
B 5
SHTS011061100003
1 Alternator 4 Brace
2 Belt tension pulley 5 Bracket
3 V-ribbed belt 6 Through bolt
D
E
SHTS011061100004
OVERHAUL
EN0110611H200001
SHTS011061100005
SHTS011061100007
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS011061100008
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
SHTS011061100009
(3) Remove the rotor from drive end frame, using a press.
NOTICE
• Do not damage to the screw tip.
• Hold rotor by hand so that it will not fall off.
SHTS011061100010
SHTS011061100011
SHTS011061100012
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
SHTS011061100014
SHTS011061100015
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100016
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
TERMINAL B
SHTS011061100017
SHTS011061100018
SHTS011061100019
(6) Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
NOTICE
A removed bearing should not be reused. Replace it with a new
one.
SHTS011061100020
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
SHTS011061100021
SHTS011061100022
SHTS011061100023
(4) Install the space collar, fan and pulley, tighten the lock nut.
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
V-BELT
that pulley is held with V-belt as a cushion.
SHTS011061100024
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
JIG B
SHTS011061100025
NOTICE
Tighten the bolt evenly.
SHTS011061100026
SHTS011061100027
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS011061100028
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
(4) Using a solder ring iron, solder the lead wire connecting the regu-
REGULATOR lator and field coil as well as the stator coil and diode.
NOTICE
• Soldering work should be done just after tightening the bolt.
• Solder lead wire after bending and fixing the terminal of regu-
lator.
• Solder field coil after caulking the tip of diode.
• Soldering work should be done for short moment (Within 5
sec.).
SHTS011061100029
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100030
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
TERMINAL B
SHTS011061100031
NOTICE
Tighten the through bolt evenly.
SHTS011061100032
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
SHTS011061100033
NOTICE
Do not hit the cover since its hook is fragile.
SHTS011061100034
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
SHTS011061100035
Test lead
Standard
(+) (–)
B E APPROX. 20 Ω
E B ∞Ω
P E APPROX. 7 Ω
E P ∞Ω
SHTS011061100036
E
B
R L
N P
DETAIL OF A
SHTS011061100037
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧞ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
W
Resistance of stator
0.11-0.12 Ω — Replace. U
coil [at 20°C (68°F)] V
WIRING
Measure
Insulation resistance of
1 MΩ or more — Replace.
stator
Measure
Measure
Measure
Normal direction
APPROX. 10 Ω
Resistance of regulator — Replace.
Reverse direction
∞Ω
Resistance of con-
denser Indicate 800 Ω
NOTICE ↓ (Immediately) — Replace.
Do not use digital Indicate ∞ Ω
tester.
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
EN12-001
STARTER
DATA AND SPECIFICATIONS
EN0110812I200001
Module 3
DESCRIPTION
EN0110812C100001
SHTS011081200001
TROUBLESHOOTING
EN0110812F300001
COMPONENT LOCATOR
EN0110812D100001
SHTS011081200002
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
OVERHAUL
EN0110812H200001
SHTS011081200003
C TERMINAL LEAD
SHTS011081200004
SHTS011081200005
(2) Remove the bolt and O-ring, remove the commutator end frame.
COMMUTATOR
END FRAME
SHTS011081200006
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011081200007
SHTS011081200008
G1
SHTS011081200009
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011081200010
SHTS011081200011
SHTS011081200012
(4) Remove the lever and drive shaft assembly from the drive hous-
ing.
HOLDER
PIN
LEVER
SHAFT ASSEMBLY
SHTS011081200013
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
RESERVOIR
SHTS011081200014
G1
SHTS011081200015
SHTS011081200016
SHTS011081200017
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011081200018
SHTS011081200009
SHTS011081200019
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011081200020
SHTS011081200021
(3) Apply grease (G1: Multemp AC-N) to the portion as shown in the
LOCATION G1 figure.
GUIDE (4) Install the commutator end frame aligning the location guide of the
commutator end frame (convexity) with notches of the holder
assembly (concavity).
NOTCH
HOLDER
ASSEMBLY
M LEAD WIRE
SHTS011081200022
(5) Secure the brush holder with the bolt and a new O-ring.
M TERMINAL LEAD CAP (6) Secure the drive housing assembly and commutator end frame
with the through bolt.
CAP (7) Connect the terminal lead, install the cap.
C TERMINAL LEAD
SHTS011081200004
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧠㧡ಽ
SHTS011081200023
(4) If the above condition, push pinion back to measure the gap.
Standard: 0.5-0.3 mm {0.020-0.118 in.}
NOTICE
Perform the inspection work for an instance (within 15 seconds).
PUSH BACK THE
PINION SLIGHTLY.
GAP
0.5-0.3 mm
{0.020-0.118 in.}
SHTS011081200024
SHTS011081200025
SHTS011081200026
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011081200027
No-load test
• With the starter securely clamped in a vise.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
SHTS011081200028
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧞ᣣޓἫᦐᣣޓඦ೨㧥ᤨ㧥ಽ
Unit: mm {in.}
Measure
Measure
Measure
Measure
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure
Measure
A: 11.98 Measure
Outside diameter of the A: 12.0 {0.472} {0.471}
Replace. B
armature assembly B: 15.0 {0.591} B: 14.98 A
{0.589}
Measure
Measure
Measure
A: 25.88 B A
Outside diameter of the A: 26.0 {1.024}
{1.018} Replace.
drive shaft assembly B: 12.1 {0.476}
B: 12.0 {0.472}
Measure
Measure
Measure
Visual check
NEEDLE
ROLLER
Rotating of needle roller
— — Replace. BEARING
bearing
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
Visual check
Measure
Measure
EN12-002
STARTER
DATA AND SPECIFICATIONS
EN0110612I200001
Module 3
DESCRIPTION
EN0110612C100001
SHTS011061200001
TROUBLESHOOTING
EN0110612F300001
COMPONENT LOCATOR
EN0110612D100001
SHTS011061200002
OVERHAUL
EN0110612H200001
SHTS011061200003
SHTS011061200004
REAR BRACKET
SHTS011061200005
BOLT
SHTS011061200006
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011061200007
SHTS011061200008
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011061200009
PULLER
SHTS011061200010
SHTS011061200011
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
PLANETARY
GEAR
CARRIER PIN
INTERNAL
GEAR
SHTS011061200012
SHTS011061200013
SHTS011061200014
RETAINER
RING
SHTS011061200015
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011061200016
SHTS011061200017
SHTS011061200018
SHTS011061200019
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
BRAKE PLATE
SHTS011061200020
SHTS011061200021
SHAFT ASSEMBLY
SHTS011061200022
PACKING
SHTS011061200023
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
1. ASSEMBLING PROCEDURE
(1) Follow the assembling procedure in the reverse order from the
final process.
2. TIGHTENING TORQUE
(1) Refer to the section "COMPONENT LOCATOR".
3. LUBRICATION
(1) Apply the grease to the portion as shown in the figure.
G1: Multemp AC-N
G2: Pyronoc No.2
NOTICE
Grease should be adhered on commutator surface, brash nor
other connecting points.
G1
G1
G1
G1
G1
G2
G1 G1
G1 G1
G2 G2 G1
G1
SHTS011061200024
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
SHTS011061200025
SHTS011061200026
SHTS011061200027
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧠ಽ
No-load test
• With the starter securely clamped in a vise.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
SHTS011061200028
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧞ᣣޓἫᦐᣣޓඦ೨㧥ᤨ㧝㧝ಽ
Unit: mm {in.}
Measure
Measure
Measure
Measure
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure
Measure
A: 11.98 Measure
Outside diameter of the A: 12.0 {0.472} {0.471} A
Replace.
armature assembly B: 9.0 {0.354} B: 8.98
{0.354} B
Measure
Measure
Measure
A: 25.90
Outside diameter of the A: 26.0 {1.024} {1.020}
Replace.
drive shaft assembly B: 12.1 {0.476} B: 12.04 B A
{0.474}
Measure
Measure
Measure
Measure
Measure
Visual check
Visual check
Measure
C
Measure
Measure
M CONNECTOR
Continuity between B
No continuity — Replace.
terminal and M terminal
B CONNECTOR
Measure
Continuity between B
Continuity — Replace.
terminal and M terminal
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
EN13-001
AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN0110613I200001
DESCRIPTION
EN0110613C100001
B
13
2
A
4
3
12 11
1
10 5
SHTS011061300001
1 O-ring 9 Crankcase
2 Cylinder head assembly 10 Piston pin
3 Gasket 11 Piston ring
4 Valve seat 12 Suction valve
5 Piston 13 Delivery valve
6 Connecting rod A Suction
7 Bearing B Delivery
8 Crankshaft
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
TROUBLESHOOTING
EN0110613F300001
COMPONENT LOCATOR
EN0110613D100001
(REPRESENTATIVE TYPE)
b
a
a
a b
c
a
1 Z
Y
Y
Z
SHTS011061300002
1 Air compressor
1
6
12
7
2
11
3 B
8 D
4 10
9
5 17
A
14
18
4
14
16
9
13
8
C
15
SHTS011061300003
SPECIAL TOOL
EN0110613K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
OVERHAUL
EN0110613H200001
SHTS011061300007
(2) Align the aligning mark "0" on the top of coupling flange with pro-
trusion on the compressor housing.
(3) Insert the O-ring into the O-ring groove of the air compressor of
"0" MARK bearing holder side.
(4) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
(EXAMPLE)
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(5) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 20 lbf⋅ft}
SHTS011061300009
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
(6) Make sure that the aligning mark "0" on the top of the coupling
"0" MARK
flange is aligning with protrusion on the compressor housing.
SHTS011061300010
SHTS011061300011
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Bearing puller (S0965-01101)
SHTS011061300012
MARKING
SHTS011061300013
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
SHTS011061300014
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
SHTS011061300015
SHTS011061300017
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
SHTS011061300018
SHTS011061300019
SHTS011061300020
STRIKING
TOOL
SHTS011061300021
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
SHTS011061300022
SHTS011061300023
SHTS011061300024
SHTS011061300025
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
SHTS011061300026
SHTS011061300027
END PLAY
SHTS011061300028
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011061300029
! WARNING
The retainer ring may spring out of the groove during assembly.
SHTS011061300030 Wear a pair of safety goggles during assembly.
OIL
RING
SECOND
RING PIN HOLE
SHTS011061300031
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
ALIGNING MARK
SHTS011061300032
O-RING
MARKING
SHTS011061300033
SHTS011061300034
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧢ಽ
Unit: mm {in.}
Visual check
Visual check
Visual check
Replace valve
Worn or damaged delivery valve — —
seat.
Visual check
Replace valve
Worn or damaged suction valve — —
seat.
Measure
Replace pis-
ton pin or con-
necting rod.
Measure
Outside diameter of the piston
70 {2.756} —
(Measure at A and B)
Measure
Clearance
Replace pis-
between the ring Top, second 0.005-0.040
0.08 {0.0031} ton or piston
groove and the ring {0.0002-0.0016}
ring.
piston ring
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧠㧣ಽ
Measure
0.15-0.35
Top ring 1.0 {0.0394}
{0.0060-0.0137}
Piston ring gap:
Replace.
compression ring
Second, 0.1-0.3
1.0 {0.0394}
third ring {0.0040-0.0118}
Measure
A: 40.002-40.013
39.995 {1.575}
{1.5749-1.5753}
B: 50.002-50.011
49.995 {1.968}
{1.9686-1.9689}
Measure
Cylinder
80 {3.1496} 80.04 {3.151}
block
Inside
diameter of the Replace.
bearing holder
Bearing
90 {3.543} 90.04 {3.545}
holder
Visual check
Measure
Replace
END PLAY
0.2-0.4 connecting
Connecting rod end play 0.5 {0.0197}
{0.0079-0.0157} rod or
crankshaft.
Measure
Replace
Crankshaft end play 0-0.6 {0-0.023} 1.0 {0.039} crankshaft
bearing.
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
EN13-002
AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN0110613I200001
DESCRIPTION
EN0110613C100001
SHTS011061300001
1 O-ring 9 Crankcase
2 Cylinder head assembly 10 Piston pin
3 Gasket 11 Piston ring
4 Valve seat 12 Suction valve
5 Piston 13 Delivery valve
6 Connecting rod A Suction
7 Bearing B Delivery
8 Crankshaft
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
TROUBLESHOOTING
EN0110613F300001
COMPONENT LOCATOR
EN0110613D100001
(REPRESENTATIVE TYPE)
b
a
a
a b
c
a
1 Z
Y
Y
Z
SHTS011061300002
1 Air compressor
1
6
12
2 7
11
3 B
8 D
4 10
9
5 17
A
14
18
4
14
16
9
13
8
C
15
SHTS011061300003
SPECIAL TOOL
EN0110613K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
OVERHAUL
EN0110613H200001
SHTS011061300007
(2) Align the aligning mark "0" on the top of coupling flange with pro-
trusion on the compressor housing.
(3) Insert the O-ring into the O-ring groove of the air compressor of
"0" MARK bearing holder side.
(4) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(5) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 20 lbf⋅ft}
SHTS011061300009
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
(6) Make sure that the aligning mark "0" on the top of the coupling
"0" MARK
flange is aligning with protrusion on the compressor housing.
SHTS011061300010
SHTS011061300011
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Bearing puller (S0965-01101)
SHTS011061300012
MARKING
SHTS011061300013
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
SHTS011061300014
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
SHTS011061300015
SHTS011061300017
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
SHTS011061300018
SHTS011061300019
SHTS011061300020
STRIKING
TOOL
SHTS011061300021
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
SHTS011061300022
SHTS011061300023
SHTS011061300024
SHTS011061300025
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
SHTS011061300026
SHTS011061300027
END PLAY
SHTS011061300028
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011061300029
! WARNING
The retainer ring may spring out of the groove during assembly.
SHTS011061300030 Wear a pair of safety goggles during assembly.
OIL
RING
SECOND
RING PIN HOLE
SHTS011061300031
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
ALIGNING MARK
SHTS011061300032
O-RING
ALIGNING MARK
SHTS011061300033
SHTS011061300034
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧣ಽ
Unit: mm {in.}
Visual check
Visual check
Visual check
Visual check
Measure
Replace pis-
ton pin or con-
necting rod.
Measure
Outside diameter of the piston
85 {3.346} —
(Measure at A and B)
Measure
0.025-0.060
Top ring 0.1 {0.0039}
{0.0010-0.0023}
Clearance
between the Replace pis-
ring groove ton or piston
and the pis- ring.
ton ring
Measure
Measure
A: 40.002-40.013
39.995 {1.575}
{1.5749-1.5753}
B: 50.002-50.011
49.995 {1.968}
{1.9686-1.9689}
Measure
Cylinder block 80 {3.1496} 80.04 {3.151}
Inside
diameter of
Replace.
the bearing
holder Bearing
90 {3.543} 90.04 {3.545}
holder
Visual check
Measure
Replace
END PLAY
0.2-0.4 connecting
Connecting rod end play 0.5 {0.0197}
{0.0079-0.0157} rod or
crankshaft.
Measure
Replace
Crankshaft end play 0-0.6 {0-0.023} 1.0 {0.039} crankshaft
bearing.
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
EN13-003
AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN0110813I200001
DESCRIPTION
EN0110813C100001
SHTS011081300001
1 O-ring 8 Crankshaft
2 Cylinder head assembly 9 Crankcase
3 Gasket 10 Piston pin
4 Valve seat 11 Piston ring
5 Piston A Suction
6 Connecting rod B Delivery
7 Bearing
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
TROUBLESHOOTING
EN0110813F300001
COMPONENT LOCATOR
EN0110813D100001
SHTS011081300002
1 Air compressor
SHTS011081300003
SPECIAL TOOL
EN0110813K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
S0942-01830 PULLER
OVERHAUL
EN0110813H200001
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
SHTS011081300010
(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.
SHTS011081300011
(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
SHTS011081300012
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
SHTS011081300013
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
NOTICE
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
SHTS011081300014
SHTS011081300015
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (S0942-01830)
SHTS011081300016
SHTS011081300017
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
SHTS011081300018
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
SHTS011081300019
SHTS011081300021
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
SHTS011081300022
SHTS011081300023
SHTS011081300024
SHTS011081300025
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
SHTS011081300026
SHTS011081300027
SHTS011081300028
SHTS011081300029
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
SHTS011081300030
SHTS011081300031
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011081300032
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
! WARNING
The retainer ring may spring out of the groove during assembly.
SHTS011081300033 Wear a pair of safety goggles during assembly.
NOTICE
Apply oil to the threads and seat surface before tightening.
SHTS011081300034
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
Unit: mm {in.}
Visual check
Replace.
Replace con-
0.2-0.4
Connecting rod end play 0.5 {0.0197} necting rod or
{0.0079-0.0157}
crankshaft.
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧠㧥ಽ
Visual check
A: 79.79-79.82 Measure
{3.1414-3.1425}
Outside diameter of the piston —
B: 79.90-79.93
{3.1457-3.1468}
Replace.
Outer diameter of the piston
16 {0.630} —
pin
Compression Measure
Piston ring 3.0 {0.1181} —
ring
thickness
Oil ring 4.0 {0.1575} —
Compression
Piston ring 3.0 {0.1181} —
ring
groove
Oil ring 4.0 {0.1575} — Replace.
Visual check
Visual check
Visual check
79.996 Measure
Cylinder block 80 {3.1496}
{3.1494}
Inside diame-
ter of the
Replace.
bearing Bearing 71.996
holder 72.0 {2.8346}
holder {2.8345}
Measure
Replace
Crankshaft end play 0-0.3 {0-0.012} 0.4 {0.06} crankshaft
bearing.
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧠㧥ಽ
AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN0110813I200001
DESCRIPTION
EN0110813C100001
SHTS011081300001
TROUBLESHOOTING
EN0110813F300001
COMPONENT LOCATOR
EN0110813D100001
SHTS011081300002
1 Air compressor
SHTS011081300003
SPECIAL TOOL
EN0110813K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
S0942-01830 PULLER
OVERHAUL
EN0110813H200001
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
SHTS011081300011
(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.
SHTS011081300012
(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
SHTS011081300013
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
SHTS011081300014
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
NOTICE
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
SHTS011081300015
SHTS011081300016
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (S0942-01830)
SHTS011081300017
SHTS011081300050
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300019
SHTS011081300020
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300021
(2) Press the crankshaft end face and remove the crankshaft with the
bearing holder.
SHTS011081300022
SHTS011081300023
SHTS011081300024
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300025
SHTS011081300026
SHTS011081300027
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300028
(2) Remove the retainer ring and disassemble the unloader valve.
SHTS011081300029
SHTS011081300030
SHTS011081300031
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300032
(2) Before completely tightening the suction valve holder, push in the
suction valve with a finger or bar from the upper side of cylinder
head (unloader valve side), and check that the suction valve and
valve spring moves smoothly.
SHTS011081300033
(3) Tighten the suction valve holder to the specified torque using a
special tool.
SST: Inlet valve holder adapter (S0948-11090)
(4) Make sure that the suction valve stroke is approximately 2.5 mm
{0.0984 in.}.
SHTS011081300034
(5) Caulk three places on the outer periphery of the suction valve
holder.
NOTICE
In this case, be sure that the lower face of the valve holder is not
protruding from the head lower face. (The faces should be flush or
the lower face of the valve holder should be recessed from the
head lower face.)
SHTS011081300035
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300036
SHTS011081300037
SHTS011081300038
SHTS011081300039
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300040
SHTS011081300041
SHTS011081300042
SHTS011081300021
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081300043
SHTS011081300044
SHTS011081300045
SHTS011081300046
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011081300047
SHTS011081300048
SHTS011081300049
SHTS011081300050
SHTS011081300051
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
Unit: mm {in.}
Visual check
16 Measure
Outside diameter of piston pin —
{0.630}
Replace.
Clearance between the piston 0.02-0.04 0.07
pin and connecting rod {0.0008-0.0016} {0.0027}
Replace.
Measure
Replace con-
0.2-0.4 0.5
Connecting rod end play necting rod or
{0.0079-0.0157} {0.0197}
crankshaft.
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
Visual check
80 Measure
Outside diameter of the piston —
{3.150}
A: 0.25-0.30 0.33
{0.0099-0.0118} {0.0130] Replace.
Replace.
Outside diameter of the piston 16
—
pin {0.630}
Compression Measure
0.3-0.5
ring
{0.0119-0.0196}
(Top, Second)
Piston Compression 0.1-0.3
ring gap: ring (Third) {0.0040-0.0118} 1.0
Replace.
compression {0.0394}
ring, oil ring
0.2-0.8
Oil ring
{0.0079-0.0314}
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
Compression 3.0
—
Piston ring ring {0.1181}
Replace.
groove 4.0
Oil ring —
{0.1575}
Visual check
Visual check
Replace
Worn or damaged delivery
— — delivery valve
valve and valve seat
assembly.
Visual check
Replace
Worn or damaged suction
— — suction valve
valve and valve seat
assembly.
Outside
diameter of
Replace.
the crank- Opposite 35.002-35.013 34.997
shaft journal drive side (B) {1.3781-1.3784} {1.3778}
80 79.996 Measure
Cylinder block
{3.1496} {3.1494}
Inside
diameter
Replace.
of the bearing Bearing 72 71.996
holder holder {2.8346} {2.8345}
2A'0AZA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧠ᣣޓἫᦐᣣޓඦᓟ㧣ᤨ㧡㧜ಽ
Measure
Replace
0-0.3 0.4
Crankshaft end play crankshaft
{0-0.0118} {0.0157}
bearing.
4.41 N
{0.45 kgf, 3.63 N Measure
Suction valve spring setting
0.992 lbf} {0.36 kgf, Replace.
load
at 7.0 mm 0.794 lbf}
{0.276 in.}
4.5 N
{0.46 kgf, 3.6 N
Delivery valve spring 1.019 lbf} {0.37 kgf, Replace.
at 9.5 mm 0.816 lbf}
{0.374 in.}
Visual check
Wear or damage of the suc-
tion valve spring and delivery — — Replace.
valve spring
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
EN14-001
SHTS011081400001
COMPONENT LOCATOR
EN0110814D100001
SHTS011081400002
OVERHAUL
EN0110814H200001
SHTS011081400003
SHTS011081400004
(4) Using a suitable sliding hammer, remove the driven shaft with ball
bearing.
(5) Remove the drive gear.
SHTS011081400005
(6) Using a press, remove the ball bearing from the driven shaft.
SHTS011081400006
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
(7) Using a press, press the driven shaft into the ball bearing.
SHTS011081400007
(8) Using a suitable sliding hammer, remove the ball bearing with
driven shaft.
SHTS011081400008
(9) Using a press, remove the ball bearing from the driven shaft.
SHTS011081400009
(10) Using a flathead screwdriver, pay off the oil seal evenly until the oil
seal comes off.
SHTS011081400010
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081400011
NOTICE
• Apply lithium based grease between the main lip and sub-lip
of the oil seal and to the back of the main lip.
• Do not use too much grease. Also, apply grease evenly
around entire circumference.
SHTS011081400012
(2) Using a press, press the driven shaft into the ball bearing.
SHTS011081400013
(3) Using the suitable tool and a press, press the ball bearing into the
gear case.
SHTS011081400014
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
(4) Set the drive gear in position, then press the driven shaft with ball
bearing into the ball bearing.
SHTS011081400015
(5) Apply liquid gasket to the gear cover, then install the gear cover.
NOTICE
Align the threaded hole of the gear case and the bolt hole of the
gear cover.
(6) Tighten the bolts evenly.
SHTS011081400016
(7) Install the output flange, then tighten the lock nut.
SHTS011081400017
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧟㧟ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧡㧜ಽ
SHTS011081400018
(2) Apply liquid gasket to the gear case and the flywheel housing.
(3) Install the power take-off and case cover with 4 bolts.
SHTS011081400019
SHTS011081400020
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧡ᣣޓἫᦐᣣޓඦᓟ㧠ᤨ㧡㧤ಽ
Unit: mm {in.}
EN16-001
ACCELERATOR PEDAL
DESCRIPTION
EN0110616F200001
SHTS011061600001
ADJUSTMENT
EN0110616H300001
SHTS011061600002
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧥ಽ
FUEL CONTROL
DN02
Function of Tachometer
Driver
SHTS161060200001
NOTICE
The functions with an asterisk (*) are applied to models for Hong kong, Ireland, Singapore and Taiwan.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧥ಽ
COMPONENT LOCATOR
EN1610602F200002
6
a e
d 9
4 7
1
2 8
b c
c
5 e 10
a d
f
3 b
15
11
12
g
22
16
14
18
13
20 17
21
19
SHTS161060200002
2,3
5
SHTS161060200003
DIAGRAM
EN1610602F200003
6 7
2 3
8
9
10
13 12 11
SHTS161060200004
ELECTRICAL
EN1610602F200004
Actuator relay
Fuse
To Each sensor (power)
Fuse
Battery
ECU main relay
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Accelerator sensor 1,2
Interface PC
diagnosis
Idle volume
Stop light SW
Accelerator SW
Exhaust brake
combination SW
PTO switch
NOTICE:
SW = Switch
SHTS161060200005
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧥ಽ
Actuator relay
Fuse
To Each sensor (power)
Fuse
Battery
ECU main relay
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Accelerator sensor 1,2
Interface PC
diagnosis
Idle volume
Brake SW
Stop light SW
Accelerator SW
Check engine light
Clutch SW Tachometer (Drive signal)
Diagnosis SW
Neutral SW
Exhaust brake
combination SW
PTO switch
CAN communication
Meter ECU
Exhaust brake light
AT
EGR lift sensor 2 ECU
Common rail
pressure sensor 1 ENGINE ECU
Coolant
Common rail T
temperature
P sensor DC/DC
Air flow converter
T meter
P
G
ENGINE
N
Exhaust
EGR valve 1 muffler
(Linear solenoid) Turbo charger
Exhaust brake
EGR valve 2 DC motor solenoid
(Linear solenoid)
VNT actuator
NOTICE:
SW = Switch
SHTS161060200006
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧥ಽ
Battery
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Accelerator sensor 1,2
Interface PC
diagnosis
Idle volume
Stop light SW
Accelerator SW
Exhaust brake
combination SW
PTO switch
Idle-up signal 1
Idle-up signal 2
Engine speed main sensor Fuel temperature sensor (On Supply pump)
Engine speed sub sensor
Boost pressure sensor
Common rail
pressure sensor 2
Coolant temperature sensor
Common rail
pressure sensor 1 ENGINE ECU
Common rail
P
T
P
G
ENGINE
N
Exhaust
muffler
Exhaust brake
solenoid
NOTICE:
SW = Switch
SHTS161060200007
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧥ಽ
PRECAUTIONS
EN1610602F200005
! WARNING
Approximately 110V is generated for the injector drive actuation system. For this reason, electrical shock may
result if the injector drive circuit is touched directly by hand. Turn the starter switch to the LOCK position if it is
necessary to check or repair the computer, harnesses, or connectors.
1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE ACTUATOR OR MAGNETIC VALVES.
SHTS161060200008
• Do not let water, oil or dust get on the connector when it is disconnected, as this could cause poor contacts when the
connector is reconnected.
• Do not open the control unit cover. It could malfunction if dust or water gets inside.
• Take care to ensure that water, oil or dust do not get on or inside parts.
• When connecting in connectors, push them in all the way and make sure that the lock engages.
3. ERASING THE MALFUNCTION MEMORY STORED IN THE PAST, CHECK THE CURRENT MALFUNCTION BY
PERFORMING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
4. AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN
THE PAST. OTHERWISE, THE MALFUNCTION CODES IN THE DISPLAY WILL REMAIN INDICATED.
5. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT
THE TESTING LEAD FROM THE BACKSIDE.
EXAMPLE:
ECU: A5 TERMINAL
SIGNAL CHECK HARNESS
CONTACT BOX:
A5 TERMINAL B29 B28 A34 A33 A32 A31 A30 A29 A28
B21 B20 A27 A26 A25 A24 A23 A22 A21 E20 A19 A18
COMPUTER (ECU)
TERMINAL No. B9 B8 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8
A5 A
B1 A7 A6 A5 A4 A3 A2 A1
A
SIGNAL CHECK
HARNESS
(CONTACT BOX)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
SHTS161060200009
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SHTS161060200010
A B C D E
SHTS161060200011
DN02–12
VIEW
COMPUTER (ECU) TERMINAL SIGNAL
THF+ ATI+ AGD3 AGD2 AGD1 GVCC PCR2 GGND DGSW NUSW AVC5 EGS2 AFT+ IVS CASE
CASE CANL CANH THW+ PIM EGS1 AVC1 AVC2 AVC3 AFSG PCR1 G3+ AGD6 CA2L CA2H RES BUSW PTO BSW1 CRSW IDLE AVC4 SWSS AGD5 AGD4 VS ASCS ACS2 ACS1 ISOK
SCVH SCVH SCVL SCVL EGR2 EGR1 CE/G FIUP SET CLSW BSW2 EBSW ST SSWS BATT TACH
I2+S IJ2+ PGD3 PGD2 INJ5 INJ6 INJ4 I1+S IJ1+ INJ3 INJ2 INJ1 PGD1 +BF1 MRL2 MRL1 CGD2 CGD1 NE1- NE1+ NESD EBMV +BF2 VB3 VB2 VB1
E31 E30 E29 E28 E27 E26 D35 D34 D33 D32 D31 D30 D29 D28 C32 C31 C30 C29 C28 B35 B34 B33 B32 B31 B30 B29 B28 A34 A33 A32 A31 A30 A29 A28
E25 E24 E23 E22 E21 E20 E19 E18 D27 D26 D25 D24 D23 D22 D21 D20 D19 D18 D17 C27 C26 C25 C24 C23 C22 C21 C20 C19 C18 B27 B26 B25 B24 B23 B22 B21 B20 A27 A26 A25 A24 A23 A22 A21 E20 A19 A18
E17 E16 E15 E14 E13 E12 E11 E10 E9 E8 D16 D15 D14 D13 D12 D11 D10 D9 D8 D7 C17 C16 C15 C14 C13 C12 C11 C10 C9 C8 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8
E7 E6 E5 E4 E3 E2 E1 D6 D5 D4 D3 D2 D1 C7 C6 C5 C4 C3 C2 C1 B7 B6 B5 B4 B3 B2 B1 A7 A6 A5 A4 A3 A2 A1
FUEL CONTROL (J08E: COMMON RAIL)
SHTS161060200012
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4 – 24 –
8 – 28 CASE Ground
9 TACH Tachometer 29 –
11 – 31 –
13 – 33 –
14 – 34 –
15 –
16 –
18 –
20 –
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
6 NE1+ Engine speed main sensor (+) 26 CRSW Cruise main switch
8 – 28 –
10 – 30 –
13 – 33 –
16 –
17 –
18 –
2 – 22 –
9 – 29 –
11 – 31 –
14 –
15 –
16 –
17 –
18 –
19 –
4 INJ3 No.3 Fuel injector (–) 24 AVC2 Common rail pressure sensor
5 IJ1+ No.1 Fuel injector (+) 25 AVC1 Boost pressure sensor (Power)
9 – 29 –
16 –
18 –
6 IJ2+ No.4, 5 Fuel injector (+) 26 ATI+ Intake manifold gas temperature sensor
7 I2+S No.6 Fuel injector (+) 27 THF+ Fuel temperature sensor (+)
12 –
13 –
14 –
15 –
16 –
17 –
18 –
20 –
14. OTHER
• Make sure to check the other connectors before connecting them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with dust, water, fuel or oil when performing inspections or
removing and replacing parts.
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INSPECTION
EN1610602F200006
SHTS161060200013
START
STARTER ON
SWITCH
LOCK
RUNNING
ENGINE
STOP
CHECK
ON
ENGINE
LIGHT OFF
TIME
SHTS161060200014
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
NOTICE
Trouble diagnosis also can be performed using the diagnosis
monitor. The malfunction codes are indicated by sound and light.
(1) Turn the starter switch to "ON".
SHTS161060200015
BLACK CONNECTOR
WHITE CONNECTOR
SHTS161060200016
SHTS161060200017
SHTS161060200018
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
0.5S 0.5S
Turn ON
Turn OFF
1.5S 4.3S
Code 32 Code 21
Repeat
Normal
0.3S
Turn ON
SHTS161060200019
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis tool.
By connection to the diagnosis connector, the trouble location is
indicated.
SST:
Communication interface assembly (09993-E9070)
Cable communication (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
NOTICE
SHTS161060200020
Only ECU reprogramming can be performed by authorized HINO
dealer.
P P
INTERFACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS161060200021
.
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1. INSPECTION PREPARATIONS
(1) Set the shift position to N-range or P-range.
(2) Switch off the air conditioner.
SHTS161060200022
(3) Read DTC by observing the MIL. If any DTC is not detected, the
MIL blinks as shown in the illustration.
SHTS161060200023
(4) Example: If DTCs 12 and 31 are detected, the MIL flashes once
(for 0.5 seconds) and flashes twice after the 1.5 seconds interval,
then flashes 3 times after a 2.5 seconds interval from the previous
DTC and flashes once. If the interval between the previous DTC
and the next DTC is 4.5 seconds, it means the previous DTC is
the last one of the multiple string DTCs. The MIL repeats the indi-
cation of DTCs from the initial cycle (refer to the illustration on the
left).
(5) Check the details of the malfunction using the DTC table on page
DN02-24, DN02-28.
(6) After completing the check, disconnect terminals 13 (TC) and 4
SHTS161060200024 (CG) and turn off the display.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
NOTICE
MC No.: Diagnosis Monitor Code (Using the diagnosis monitor)
DTC No.: Diagnosis Trouble Code (Using the PC diagnosis tool)
A: Engine does not start
B: Engine stops
C: Engine has low power
D: Difficulty starting engine
YES: Check engine light: Light
NO: Check engine light: Not light
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
YES A, B 13 P0335 Engine speed main and sub sensor circuit malfunction DN02-41
YES A, B 74 P0629 Supply pump SCV malfunction (Power source line short) DN02-78
YES C 67 P0192 Common rail pressure sensor circuit low input DN02-57
YES C 67 P0193 Common rail pressure sensor circuit high input DN02-57
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
YES C 81 P0489 EGR solenoid 1 malfunction (Open circuit or ground line short) DN02-80
YES C 81 P0490 EGR solenoid 1 malfunction (Power source line short) DN02-80
YES C 75 P0628 Supply pump SCV malfunction (All discharge mode) DN02-78
YES C 82 P1402 EGR solenoid 2 malfunction (Open circuit or ground short) DN02-81
YES C 82 P1403 EGR solenoid 2 malfunction (Power source line short) DN02-81
YES 16 P0112 Intake air temperature sensor circuit low input DN02-53
YES 16 P0113 Intake air temperature sensor circuit high input DN02-53
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
DN02-
NO 9 U0155 CAN communication error (Meter)
102
DN02-
NO 9 U1001 CAN communication error (Vehicle)
102
DN02-
NO 9 U0101 CAN communication error (Automatic transmission)
102
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
NOTICE
• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at
the time of ECU service replacement, so ensure sufficient time (Several minutes) is available.
• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using
the diagnosis tool.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
NOTICE
MC No.: Diagnosis Monitor Code (Using the diagnosis monitor)
DTC No.: Diagnosis Trouble Code (Using the PC diagnosis tool)
A: Engine does not start
B: Engine stops
C: Engine has low power
D: Difficulty starting engine
E: Torque limit (EURO 4-STEP2, on -board diagnostic systems)
G: Do not erase the past MC or DTC with the generic scan tool within 9600 Hr after confirming no abnormalities.
YES: Check engine light: Light
F: Check engine light: Flash
NO: Check engine light: Not light
CHECK Regula-
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE tions/
No. PAGE
LIGHT others
CHECK Regula-
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE tions/
No. PAGE
LIGHT others
YES C 67 P0192 Common rail pressure sensor circuit low input DN02-57
YES C 67 P0193 Common rail pressure sensor circuit high input DN02-57
YES C 75 P0628 Supply pump SCV malfunction (All discharge mode) DN02-78
CHECK Regula-
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE tions/
No. PAGE
LIGHT others
YES 16 P0112 Intake air temperature sensor circuit low input DN02-53
YES 16 P0113 Intake air temperature sensor circuit high input DN02-53
CHECK Regula-
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE tions/
No. PAGE
LIGHT others
DN02-
NO 9 U0155 CAN communication error (Meter)
102
DN02-
NO 9 U1001 CAN communication error (Vehicle)
102
DN02-
F E 85 P0401 Abnormal of EGR low flow G
101
NOTICE
• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at
the time of ECU service replacement, so ensure sufficient time (Several minutes) is available.
• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using
the diagnosis tool.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200027
NO
• 0V: Fuse blows, harness malfunction,
ground malfunction.
YES • Less than 20V: Battery retrogradation,
ground malfunction.
Normal.
SHTS161060200028
NO
• Ground harness disconnection.
• Bad contact of terminal.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 13 DTC No. P0335 Engine speed main sensor circuit malfunction
SHTS161060200029
NO
Proceed to 3.
YES
NO
• Bad contact of ECU connectors.
• Malfunction of ECU.
YES • Malfunction of harness (Short circuit).
Normal.
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SHTS161060200030
NO
Malfunction of engine speed main sensor.
YES
• Harness disconnection.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 13 DTC No. P0336 Engine speed main sensor pulse abnormal
SHTS161060200031
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS161060200032
NO
Malfunction of harness.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200033
NO
• Engine speed main senor malfunction.
• Flywheel signal hole abnormal.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 12 DTC No. P0340 Engine speed sub sensor circuit malfunction
SHTS161060200034
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200035
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200036
NO
Proceed to 4.
YES
SHTS161060200037
NO
Malfunction of harness.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 12 DTC No. P0341 Engine speed sub sensor pulse abnormal
SHTS161060200038
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200039
NO
Malfunction of harness.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200040
NO
Proceed to 3.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS161060200041
NO
• Engine speed main senor malfunction.
• Camshaft gear signal pin abnormal.
YES
MC No. 13 DTC No. P0335 Engine speed main and sub sensor circuit malfunction
MC No. 11 DTC No. P0117 Coolant temperature sensor circuit low input
MC No. 11 DTC No. P0118 Coolant temperature sensor circuit high input
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
SHTS161060200043
NO
Malfunction of coolant temperature sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
ENGINE OVERHEAT
EN1610602F200022
Standard:
2.45 kΩ at 20°C {68°F}
1.15 kΩ at 40°C {104°F}
584 Ω at 60°C {140°F}
318 Ω at 80°C {176°F}
SHTS161060200043
NO
Malfunction of coolant temperature sensor.
YES
HINT
This code will be displayed when the coolant temperature sensor
operates normally and coolant temperature ascends over 115°C
{239°F}. Also, while the MC or DTC is being detected, Max. volume
of fuel injection will be limited and will return back to normal con-
trol volume when it descends less than 80°C {176°F}.
.
ENGINE OVERRUN
EN1610602F200023
MC No. 14 DTC No. P0182 Fuel temperature sensor circuit low input
MC No. 14 DTC No. P0183 Fuel temperature sensor circuit high input
Standard:
2.45 kΩ at 20°C {68°F}
1.15 kΩ at 40°C {104°F}
SHTS161060200044
584 kΩ at 60°C {140°F}
318 kΩ at 80°C {176°F}
.
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
Standard:
2.45 kΩ at 20°C {68°F}
1.15 kΩ at 40°C {104°F}
584 kΩ at 60°C {140°F}
318 kΩ at 80°C {176°F}
SHTS161060200045
NO
Malfunction of fuel temperature sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 37 DTC No. P0108 Boost pressure sensor circuit high input
MC No. 37 DTC No. P0237 Boost pressure sensor circuit low input
SHTS161060200046
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200047
NO
• Malfunction of ECU.
• Malfunction of ECU connector.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200048
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
A
GND
SIG
VIEW A
SHTS161060200049
NO
Malfunction of boost pressure sensor.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
SHTS161060200050 Standard: More than 110 kPa {1.122 kgf/cm2, 15.95 lbf/in.2}
.
NO
Malfunction of boost pressure sensor.
YES
Normal.
100
2sec continue
80
60
10sec continue
40
1times
20
0
500 1000 1500 2000 2500 3000 3500
Engine speed (rpm)
SHTS161060200051
(7) One or more cycles of the driving pattern where full acceleration
from 1,800 rpm or lower engine speed is maintained for at least 2
seconds using the highest operable transmission gear after idling
for at least 10 seconds. A 10 kPa or greater change in boost pres-
sure will be judged to be normal, and a change of less than 5 kPa
will be judged to be abnormal.
(8) To delete the malfunction code P0401 (EGR COOLER CHOKE),
a status must be judged to be normal for this diagnosis permis-
sion.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
NO
Malfunction of VNT turbocharger controller.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧜ಽ
MC No. 17 DTC No. P0102 Air flow sensor circuit low input
MC No. 17 DTC No. P0103 Air flow sensor circuit high input
SHTS161060200052
NO
Malfunction of harness.
YES
Proceed to 2.
SHTS161060200053
NO
Proceed to 3.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧟㧜ᣣᦐޓᣣޓඦᓟ㧝ᤨ㧞㧢ಽ
SHTS161060200054
NO
Malfunction of air flow sensor.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200056
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 16 DTC No. P0112 Intake air temperature sensor circuit low input
MC No. 16 DTC No. P0113 Intake air temperature sensor circuit high input
Standard:
13.6-18.4 kΩ at -20°C {-4°F}
2.21-2.69 kΩ at 20°C {68°F}
SHTS161060200057
0.49-0.67 kΩ at 60°C {140°F}
.
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
Standard:
13.6-18.4 kΩ at -20°C {-4°F}
2.21-2.69 kΩ at 20°C {68°F}
0.49-0.67 kΩ at 60°C {140°F}
SHTS161060200058
NO
Malfunction of intake air temperature (air flow)
sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 68 DTC No. P0088 Excessive common rail pressure (1st step)
MC No. 69 DTC No. P0088 Excessive common rail pressure (2nd step)
SHTS161060200059
NO
• Malfunction of ECU.
• Bad contact of harness connector.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200059
NO
Malfunction of common rail pressure sensor.
YES
SHTS161060200061
NO
• Malfunction of ECU.
• Bad contact of harness connector.
YES
SHTS161060200062
NO
• Malfunction of common rail pressure sen-
sor.
YES • Bad contact of harness connector.
• Malfunction of ECU.
• Bad contact of harness connector.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 67 DTC No. P0192 Common rail pressure sensor circuit low input
MC No. 67 DTC No. P0193 Common rail pressure sensor circuit high input
SHTS161060200063
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS161060200064
NO
Proceed to 3-(3).
YES
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200065
NO
Malfunction of harness.
YES
(3) Disconnect the signal check harness connector on the ECU side.
(4) Measure the resistance between AVC2 (D24) terminals and
D PCR+ PCR+ terminal of common rail pressure sensor (Vehicle harness
D24 side), AGD1 (D33) terminal and PCR- terminal of common rail
pressure sensor (Vehicle harness side).
Standard: Less than 2 Ω
SHTS161060200066
D PCR-
D33
SHTS161060200067
.
NO
Malfunction of harness.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200068
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200069
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
ACCELERATOR SENSOR 1
EN1610602F200036
SHTS161060200072
NO
Malfunction of accelerator sensor.
YES
(4) Measure the voltage between ACS1 (A21) and AGD4 (B20) ter-
minals while depressing the accelerator pedal.
A B
A21 B20 Standard: 1V or more, with the voltage change proportional
to the accelerator pedal depression amount.
(After measurement, turn the starter switch to "LOCK" position.)
SHTS161060200073
NO
Malfunction of accelerator sensor.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200074
NO
Proceed to 2.
YES
Proceed to 3.
B31
SHTS161060200075
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
ACCELERATOR SENSOR 2
EN1610602F200038
SHTS161060200078
NO
Malfunction of accelerator sensor.
YES
(4) Measure the voltage between ACS2 (A22) and AGD5 (B21) ter-
minals while depressing the accelerator pedal.
A B
A22 Standard: 1V or more, with the voltage change proportional
B21
to the accelerator pedal depression amount.
(After measurement, turn the starter switch to "LOCK" position.)
SHTS161060200079
NO
Malfunction of accelerator sensor.
YES
Malfunction of harness.
MC No. 23 DTC No. P1132 P.T.O. accelerator sensor circuit low voltage
MC No. 23 DTC No. P1133 P.T.O. accelerator sensor circuit high voltage
SHTS161060200080
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200081
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200082
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS161060200083
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 21 DTC No. P0500 Vehicle speed sensor circuit low input
MC No. 21 DTC No. P0501 Vehicle speed sensor circuit high input
! WARNING
Start the vehicle with much caution around.
SHTS161060200084
Standard: Pulse wave-shape by more than 4V↔1.0V
.
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS161060200085
NO
Harness disconnection of vehicle speed sen-
sor circuit.
YES
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
(4) Set the starter switch to "LOCK" position and connect the connec-
tor of signal check harness to ECU.
A A27 BODY GND (5) Measure the insulation resistance between VS (A27) terminal of
ECU and body GND.
Standard: ∞ Ω
SHTS161060200086
NO
Short circuit of vehicle speed sensor circuit.
YES
ECU
EN1610602F200042
MC No. 15 DTC No. P2228 Atmospheric pressure sensor circuit low input
MC No. 15 DTC No. P2229 Atmospheric pressure sensor circuit high input
2. After erasing the MC or DTC, check that the same code is dis-
played again.
.
NO
Malfunction of ECU.
YES
Normal.
(Temporary malfunction because of radio interference noise.)
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
Standard: ∞ Ω
.
NO
Proceed to 3.
YES
SHTS161060200088
No.3 injector 5, 6
ECU case GND
No.4 injector 7, 8
No.6 injector 9, 10
Standard: ∞ Ω
.
NO
Malfunction of harness.
(The harness is defective if the resistance
value is out of standard.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 57 DTC No. P1212 Injector common 1 power source line short
MC No. 58 DTC No. P1215 Injector common 2 power source line short
NO
Proceed to 3.
YES
SHTS161060200090
No.1 injector 11
No.3 injector 6
ECU case GND
No.4 injector 7
No.6 injector 10
NO
Malfunction of harness.
(The harness is defective if the resistance
value is out of standard.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
D4
Failure position Resistance
D5 MC No. DTC No.
(Breaking position) measurement
SHTS161060200091
NO
Proceed to 3.
YES
NO
Proceed to 4.
YES
SHTS161060200093
NO
Proceed to 5.
YES
SHTS161060200094
NO
Injector coil disconnection. (Replace the injec-
tor assembly.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
CYLINDER CONTRIBUTION/BALANCE
EN1610602F200046
Inspection:
a. When removing the flow damper from the common rail, check that
the piston is not sticking in the body. If the piston sticks, replace
the flow damper.
b. Inspect the contact surface 1 between piston and fuel supply port.
If there is wear and damage, replace the flow damper assembly.
c. Inspect clogging on the piston orifice. Clean or replace the flow
damper assembly.
SHTS161060200095
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 74 DTC No. P0629 Supply pump SCV malfunction (Power source line short)
MC No. 75 DTC No. P0628 Supply pump SCV malfunction (All discharge mode)
SHTS161060200097
NO
Malfunction of SCV. (Replace the supply
pump)
YES
SHTS161060200098
NO
• Harness disconnection.
• Bad contact of harness connector.
YES
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200099
NO
Malfunction of ECU connector.
YES
Malfunction of ECU.
SUPPLY PUMP
EN1610602F200048
MC No. 79 DTC No. P2635 Supply pump abnormal high pressure record
NO
Replace supply pump.
YES
SHTS161060200100 .
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 81 DTC No. P0489 EGR solenoid 1 malfunction (Open circuit or ground line short)
MC No. 81 DTC No. P0490 EGR solenoid 1 malfunction (Power source line short)
SHTS161060200101
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES • Malfunction of harness (Short circuit).
Proceed to 2.
SHTS161060200102
NO
Malfunction of EGR solenoid 1.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200103
NO
• Harness disconnection.
• Malfunction of connectors.
YES
MC No. 82 DTC No. P1402 EGR solenoid 2 malfunction (Open circuit or ground short)
MC No. 82 DTC No. P1403 EGR solenoid 2 malfunction (Power source line short)
SHTS161060200104
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES • Malfunction of harness (Short circuit).
Proceed to 2.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200105
NO
Malfunction of EGR solenoid 2.
YES
Proceed to 3.
SHTS161060200106
NO
• Harness disconnection.
• Malfunction of connectors.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
EGR
EN1610602F200051
NO
Malfunction of ECU.
YES
Normal.
EGR VALVE 1
EN1610602F200052
NO
Malfunction of EGR valve 1.
YES
Normal.
EGR VALVE 2
EN1610602F200053
NO
Malfunction of EGR valve 2.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 86 DTC No. P0405 EGR lift sensor 1 circuit low input
MC No. 86 DTC No. P0406 EGR lift sensor 1 circuit high input
SHTS161060200108
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200109
NO
• Malfunction of ECU.
• Malfunction of ECU connector.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200110
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS161060200111
NO
Malfunction of EGR lift sensor 1.
(Replace the EGR assembly)
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 87 DTC No. P0407 EGR lift sensor 2 circuit low input
MC No. 87 DTC No. P0408 EGR lift sensor 2 circuit high input
SHTS161060200112
NO
Proceed to 2.
YES
Proceed to 3.
SHTS161060200113
NO
• Malfunction of ECU.
• Malfunction of ECU connector.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200114
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS161060200115
NO
Malfunction of EGR lift sensor 2.
(Replace the EGR assembly)
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200116
NO
Malfunction of harness.
YES
Proceed to 2.
SHTS161060200117
NO
• Open circuit or short circuit (VNGT short or
VNTV short).
YES • Bad contact of harness or connector.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200118
NO
Malfunction of EGR.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
+ side – side
NO
• Malfunction of exhaust brake relay.
• Malfunction of exhaust brake magnetic
YES valve.
• Malfunction of harness.
• Malfunction of harness connector.
• Malfunction of ECU.
• Malfunction of ECU connector.
NO
Re-input the QR codes.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MAIN RELAY
EN1610602F200060
SHTS161060200120
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
1 2
SHTS161060200121
NO
Malfunction of main relay.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200122
NO
Proceed to (5).
YES
Proceed to (7).
SHTS161060200123
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Harness disconnection.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
SHTS161060200124
NO
Proceed to (10).
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS161060200125
NO
Malfunction of idle set controller.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
ACCELERATOR SWITCH
EN1610602F200062
MC No. 42 DTC No. P0510 Accelerator switch malfunction (ON side sticking)
MC No. 42 DTC No. P0510 Accelerator switch malfunction (OFF side sticking)
SHTS161060200126
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS161060200127
NO
Malfunction of accelerator switch.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
STARTER SWITCH
EN1610602F200063
NO
Malfunction of harness.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Bad contact of ECU connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
CLUTCH SWITCH
EN1610602F200064
SHTS161060200129
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS161060200130
NO
Malfunction of clutch switch.
YES
• Harness disconnection.
• Malfunction of harness.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
NEUTRAL SWITCH
EN1610602F200065
SHTS161060200131
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS161060200132
NO
Malfunction of neutral switch.
YES
• Harness disconnection.
• Malfunction of harness.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
MC No. 18 DTC No. P0097 Intake manifold gas temperature sensor circuit low input
MC No. 18 DTC No. P0098 Intake manifold gas temperature sensor circuit high input
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
NO
Malfunction of intake manifold gas temperature
sensor. (Proceed to (3))
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧟㧜ᣣᦐޓᣣޓඦᓟ㧞ᤨ㧣ಽ
100
5sec continue
80
60
5 times
40
20
5sec continue
0
500 1000 1500 2000 2500 3000 3500
Engine speed (rpm)
SHTS161060200135
(4) Four or more repeated cycles of the driving pattern where full
acceleration from 1,500 rpm or lower engine speed is maintained
for at least 5 seconds using the highest operable transmission
gear and then the accelerator is released for at least 5 seconds. A
2°C {35.6°F} or greater change in gas temperature in the intake
manifold will be judged to be normal, and a change of less than
2°C {35.6°F} will be judged to be abnormal.
(5) To delete the malfunction code P0401 (EGR COOLER CHOKE),
a status must be judged to be normal for this diagnosis permis-
sion.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧥ᐕ㧝㧝㧞㧜ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧝㧟ಽ
NO
• Malfunction of EGR cooler.
• Clogging of air cleaner.
YES • Improper connection or leakage of the air
hose connected to engine from air cleaner.
Normal.