Engine J08E TI

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FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for J08E-TI engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
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CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S5-YJ08E29B

CHAPTER
MODEL J08E-TI
GENERAL INTRODUCTION GN01-001
ENGINE INTRODUCTION EN01-001
ENGINE MECHANICAL EN02-001
AIR INTAKE SYSTEM EN03-001
EXHAUST SYSTEM EN04-001
LUBRICATING SYSTEM EN05-001
COOLING SYSTEM EN06-001
FUEL SYSTEM EN07-001
EN08-001
EN08-002
TURBOCHARGER (VARIABLE NOZZLE TURBINE
(WASTE GATE VALVE TYPE)
TYPE)
FUEL INJECTION PUMP EN09-001
EMISSION CONTROL EN10-001
EN11-001 EN11-002 EN11-003

ALTERNATOR
(24V-50A) (24V-60A) (24V-90A)
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)
ENGINE P.T.O. (POWER TAKE-OFF) EN14-001
ENGINE CONTROL EN16-001
FUEL CONTROL DN02-001

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INDEX: ENGINE GROUP 1/2
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
WORKSHOP AIR INTAKE SYSTEM
MANUAL EXHAUST SYSTEM
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
FUEL INJECTION PUMP
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE PTO
(POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL
All rights reserved. This manual may not be

reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
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INDEX: ENGINE GROUP 2/2
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
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GENERAL INTRODUCTION (J08E) GN01–1
GN01 GENERAL INTRODUCTION (J08E) GN01-001
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 ..................................................GN01-22
HANDLING OF LIQUID GASKET..................GN01-24
TROUBLESHOOTING
USING THE TROUBLE LIST.........................GN01-25
TROUBLESHOOTING
USING A DIAGNOSIS MONITOR .................GN01-26
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE .........GN01-30
CHASSIS SERIAL NUMBER,
VEHICLE IDENTIFICATION NUMBER
AND ENGINE SERIAL NUMBER ..................GN01-33
GN01–2 GENERAL INTRODUCTION (J08E)
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.
HOW TO USE THIS MANUAL

EN0010601C100002
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
2. TROUBLESHOOTING IN THIS MANUAL

(1) This manual describes the following steps 2 and 3.
Thoroughly listen to the conditions and environment for the trou-

(1) Interview "Step 1"
ble and confirm the fact.
Perform diagnostic inspection, checkup of the symptom, function

(2) Pre-inspection
"Step 2" inspection and basic inspection to confirm the trouble. If the trou-
(3) Replication method
ble hardly recurs, use the replication method.
Classify the inspection results obtained in step 2 to systematically

(4) Troubleshooting by diagnosis code
"Step 3" perform inspection accordance with the troubleshooting proce-
(5) Troubleshooting by trouble
dure by diagnosis code or trouble.
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
• Execute the following steps to perform pre-inspection.

Diagnostic inspection → diagnosis code erasure → trouble check (If the trouble does not recur,
use the replication method.) → Diagnosis code re-check
• Assume the faulty system before the replication test. Connect a tester and determine a proba-
ble cause of trouble together with checkup of the trouble. For a probable cause of trouble, refer
to the troubleshooting chart.
Pre-inspection
• In case the trouble is momentary or in case an error code is displayed but no special trouble
takes place, execute related troubleshooting procedures while using the replication method.
• Trouble checkup
In case the trouble recurs, follow steps 2, 3 and 4 in this order.
Otherwise, use the replication method, that is, reproduce the external conditions, and inspect
each wire harness and connector parts.
3. DESCRIPTION IN THIS MANUAL

(1) Component Locator
SHTS001060100001
✩: This is the ID number of an item to be prepared for creating electronic data and is not necessary for repair work.
(2) Work item
SHTS001060100002
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 counter-
clockwise 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.
5. DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.

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 { }.
Conven- Conversion value*1 Conven- Conversion value*1

SI unit tional (1[Conventional unit] SI unit tional (1[Conventional unit]
unit = X [SI unit]) unit = X [SI unit])
Spring 1 kgf/mm=
Force N kgf 1 kgf=9.80665 N N/mm kgf/mm
constant 9.80665 N/mm
1 kgf⋅cm=
Torque*2 N⋅m kgf⋅cm Volume L cc 1 cc=1 mL
0.0980665 N⋅m
1kgf/cm2=
2
kgf/cm 98.0665 kPa= Efficiency W PS 1 PS=0.735499 kW
Pressure Pa 0.0980665 Mpa
Quantity
mmHg 1mmHg=0.133322 kPa W⋅H cal 1 kcal=1.13279 W⋅h
of heat
r/min. 1 rpm=1 r/min. Fuel con-
Rotation 1 g/PS⋅h=
rpm sumption g/W⋅h g/PS⋅h
speed min.-1 1 rpm=1 min.-1 ratio
1.3596 g/kW⋅h
*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.
PRECAUTIONS FOR WORK

EN0010601C100003
GENERAL PRECAUTIONS
To assure safety in work and prevent possible danger, observe the following:
1. CLOTHES AND APPEARANCE

(1) Use safety glasses.
(2) To prevent injury, remove a watch, necktie, ring, bracelet and necklace.
(3) Bind long hair behind.
(4) Wear a cap and safety boots.
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.
PRECAUTIONS ON MAINTENANCE
Observe following before maintenance:
1. PREPARATIONS FOR DISASSEMBLY

(1) Prepare general tools, special tools and instruments before work.
(2) Before disassembling complicated sections, make a fitting mark where functions are not affected to facilitate the
assembly work. Before repair of the electrical system, remove the cable from the minus terminal of the battery.
(3) Follow the inspection procedure in this manual before disassembly
2. INSPECTION DURING DISASSEMBLY

(1) Each time you remove a part, inspect the state of the assembly of the part, deformation, damage, wear and flaws.
3. ARRANGEMENT OF DISASSEMBLED PARTS

(1) Arrange the disassembled parts in order. Discriminate parts to be reused from replacement parts.
4. CLEANING OF DISASSEMBLED PARTS

(1) Thoroughly clean the parts to be reused.
5. INSPECTION AND MEASUREMENT

(1) Inspect and measure the parts to be reused as required.
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.
7. ADJUSTMENT WORK CHECK

(1) Use a gauge and a tester to adjust to the specified maintenance value.
PRECAUTIONS FOR ELECTRICAL SYSTEM
1. REMOVING THE BATTERY CABLE

(1) Before electrical system work, remove the cable from the minus
terminal of the battery in order to avoid burning caused by short-
circuiting.
LOOSEN (2) To remove the battery cable, fully release the nut to avoid damage
to the battery terminal. Never twist the terminal.
SHTS001060100008
2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
SHTS001060100009
3. HANDLING OF WIRE HARNESS

(1) Perform marking on a clamp and a clip and secure then in original
position so that the wire harness will not interfere with the end and
acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.
SHTS001060100010
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
PRECAUTIONS FOR ELECTRIC WELDING
1. Improperly performing electric welding on the cab or chassis causes a backflow of the welding electric cur-
rent thus damaging various electrical equipment and electrical components. Observe the following in elec-
tric welding:
(1) Turn off the starter switch.
(2) Check that all switches are off.
(3) Follow the battery cable removal procedure to remove the minus terminal of the battery.
(4) Disconnect the connector of the computers.
(5) Remove all fuses.
(6) Ground the electric welder in the proximity of the welding section.
a. Welding to the frame
Ground the welder at a plated bolt or frame in the proximity of the welding section.
To ground at the frame itself, peel off the coating on the frame.
Grounding at a chassis spring is inhibited because it causes damage to the spring.
b. Welding to cab
Open the front panel and ground at the mounting bolt of the cab hinge or cab itself.
(7) Other precautions
a. To avoid sputter in welding, cover the rubber holes, wire harnesses, pipes, chassis springs and tires before work.
b. Perform welding under appropriate welding conditions in order to reduce influence of heat to the surrounding as
well as to secure the quality of welding.
(8) Once the welding work is complete, attach the removed fuse and the minus terminal of the battery in this order to
reconstruct the original structure.
In case the coating on frame or cab has been removed, apply rustproof coating of the same color.
(9) After reconstruction, perform functional checkup to ensure normal operation.
FLOW OF WELDING CURRENT
1. WITHOUT TREATMENT OF ITEMS (1) THROUGH (5)
EQUIPMENT GROUND
ELECTRONIC
UNIT
WELDER
CHASSIS FRAME
CAB GROUNDING WIRE
BATTERY
THE WELDING CURRENT FLOWS IN TWO DIRECTIONS: (A) FROM CAB

TO ELECTRONIC UNIT TO BATTERY TO WELDER GROUND AND (B)
FROM CAB TO CAB GROUND TO WELDER GROUND. THIS DAMAGES THE
ELECTRIC UNIT.
2. WITH TREATMENT OF ITEMS (1) THROUGH (5)
EQUIPMENT GROUND
ELECTRONIC
UNIT
WELDER
REMOVE THE FUSE. TURN OFF THE
STARTER SWITCH.
CHASSIS FRAME
CAB GROUNDING WIRE
BATTERY REMOVE THE MINUS TERMINAL.
THE WELDING CURRENT FLOWS LOOPS BACK TO THE WELDER WITHOUT

PASSING THROUGH THE ELECTRONIC UNIT.
SHTS001060100012
TIGHTENING OF BOLTS AND NUTS FOR ENGINE

EN0010601C100004
1. TIGHTENING TORQUE OF GENERAL STANDARD

(1) Washer based bolt
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw diameter x pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}
M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}
M10 x 1.5 (Coarse thread) 55 {560, 40} 68.5 {700, 51}
M12 x 1.25 (Fine thread) 108 {1,100, 80} 136 {1,390, 101}
M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1,280, 93}
M14 x 1.5 (Fine thread) 171.5 {1,750, 127} 216 {2,210, 160}
M14 x 2 (Coarse thread) 154 {1,570, 114} 199 {2,030, 147}
Remarks Bolt with the numeral "7" on its head Bolt with the numeral "9" on its head
NOTICE
8T bolt conforms to the standard of 7T bolt.
(2) With washer
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.
R FACE (4T) C FACE (7T)

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.
3. TENSION CONTROL WITH ANGULAR TORQUING METHOD

IN PLASTIC REGION OF MATERIAL
(1) Precautions
Part of an engine uses the Tension control with angular torquing
method in plastic region of material.
This is different from the conventional tightening method. Follow
the instructions in each chapter.
SHTS001060100015
(2) Target region

Cylinder head bolt, crankshaft main bearing cap bolt, connecting
rod bearing, cap bolt and so on.
! CAUTION
Before assembly, measure the entire length of the bolt and if the
use limit is exceeded, replace the bolt with new one.
Apply engine oil to the bolt seat face and bolt thread.
SHTS001060100016
(3) Tightening after tightening at the pre-set seating torque.

Further tighten by 90° or 135° (a turn by 90° and another by 45°)
or 180° (two turns by 90°).
SHTS001060100017
TIGHTENING OF BOLTS AND NUTS FOR CHASSIS

EN0010601C100005
1. TIGHTENING TORQUE OF GENERAL STANDARD BOLT/NUT

(1) Selection of tightening torque
a. To select the tightening torque of a bolt, find the corresponding strength category in the table below. Select the
corresponding value from the tightening torque table given later.
b. To select the tightening torque of a nut, use the above method based on the mating bolt.
(2) Identification of bolt strength
a. Identification on the part itself
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.
Strength category 6T 7T 8T 9T 10T 11T 12T
Symbol on the part 6 7 8 q*1 10 11 12
(*1): 9 is likely to be confused with 6 so that 9 is represented in q.
HEXAGON NUT
The following tables shows examples of symbols to identify the strength category of hexagon nut on the nut itself.
(3) Types of general standard bolt and nut
Standard seat face Flanged seat face A Flanged seat face B

(4) Table of tightening torque of general standard bolt and nut (Standard seat face is shown as a typical case)
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.
TIGHTENING OF FLARE NUTS AND HOSES

EN0010601C100006
1. TIGHTENING TORQUE OF PIPE FLARE NUT

Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
15±5 25±5 36±5 52±7 67±7 88±8
Steel pipe {150±50, {250±50, {370±50, {530±70, {680±70, {900±80,
10.8±3.6} 18.1±3.6} 26.8±3.6} 38.3±5.0} 49.2±5.0} 65.1±5.7}
2. TIGHTENING TORQUE OF HOSE

Hose outer diameter
Hose outer diameter Hose outer diameter
φ13, φ20, φ22 metal fitting for
φ10.5 metal fitting PF3/8 metal fitting
packing
21.5±1.5 {215±15, 15.5±1.0}
Air hose 41.5±2.5 {425±25, 30.7±1.8} —
Meter gauge only 10 {100, 7.2}
Packing
Brake hose — —
51.5±7.5 {525±75, 38.0±5.4}
3. TIGHTENING TORQUE OF FLARE JOINT FOR NYLON TUBE

Nominal diameter of
M12 M16 M20
screw
Tightening torque 14.7±2 {150±20, 10.8±1.4} 29.4±5 {300±50, 21.7±3.6} 51.9±5 {530±50, 38.3±3.6}
4. TIGHTENING TORQUE OF LOCK NUT FOR BRASS JOINT

Nominal diameter of
M12 M16 M20 M27
screw
15±2 66±6 97±9 209±19
Tightening torque
{150±20, 10.8±1.4} {670±60, 48.4±4.3} {990±90, 71.6±6.5} {2,130±190, 154±13}
SEALANT ON THE TAPERED SCREW

FOR PIPING
EN0010601C100007
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⋅ft, 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.
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.
Structure of joint and components
One-touch connector joint Sleeve nut joint
2. ONE-TOUCH CONNECTOR JOINT

(1) Remove the one-touch connector joint.
SHTS001060100027
a. Check that there is no dust or dirt in the proximity of the con-

nector end. If any, use air blow to remove dust or dirt before
removal.
SHTS001060100028
2A)0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧡ಽ
b. To remove the connector, pull out the nylon tube at a stroke in

the axial direction while holding down the retainer of the con-
nector. Use a dedicated special tool to hold down the retainer
of the connector.
Size of special tool
Tube outer diameter Part No. Name
φ6 S0942-11510
φ8 S0942-11520
φ10 S0942-11530 Release tool
φ12 S0942-11540
SHTS001060100029
φ15 S0942-11550
Set in above five
S0942-11560 Release tool set
sizes
c. To connect the connector joint, give a mark such as taping at

the tube insertion length and insert the tube to the position of
the mark.
! CAUTION
Fully insert the nylon tube to the position although shock is felt
two times as the nylon tube passes through the retainer hook and
O-ring.
Tube outer diameter Tube insertion length (mm {in.})

φ6 21.5-22.5 {0.847-0.885}
SHTS001060100030 φ8, φ10 22.0-23.0 {0.867-0.905}
φ12 22.5-23.5 {0.886-0.925}
φ15 24.0-25.0 {0.945-0.984}
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.
3. SLEEVE NUT JOINT

(1) Connection of sleeve nut
a. To cut a nylon tube in a predetermined length, use a dedi-
cated special tool.
SST: Nylon Tube Cutter (S0946-01020)
! 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°.
SHTS001060100031
b. Thread the sleeve nut and sleeve in this order into the tube.
Then push in the insert at the tip.
! CAUTION
Take care of the assembling direction.
5 OR LESS
SHTS001060100032
c. For connection, push the insert until its end strikes the con-
nector/union while taking care not to let the sleeve nut, sleeve
INSERT and insert drop. In this state, fully tighten the sleeve nut with
hand. The position of sleeve nut is referred to as the "hand-
tightening position".
TUBE
CONNECTOR/UNION
d. Hold down the tube so that it will not move (come loose) and
tighten the sleeve nut in accordance with the torque in the
SLEEVE table below.
Tightening torque of sleeve nut Unit: N⋅m {kgf⋅cm, lbf⋅ft}
SLEEVE NUT Nominal diameter of screw x pitch Tightening torque
M12 x 1 (φ6) 23±5 {230±50, 16.6±3.6}
SHTS001060100033
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}
(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 posi-
tion (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
SHTS001060100034 sleeve nut and connector/union as well.
4. HANDLING OF NYLON TUBE

(1) Types of nylon tube
Tube outer Operating tem-

Tube indication
diameter perature range
-40-90°C
DIN tube φ6, φ10, φ12
{-40-194°F}
! 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.
Minimum bending radius in use:

Tube outer diameter
R (mm {in.})
φ6 30 {1.181}
φ8 50 {1.969}
φ10 65 {2.559}
φ12 70 {2.756}
φ15 80 {3.150}
2A)0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧡ಽ
(2) Fixing the nylon tube

a. To fix the nylon tube to a vehicle, use a dedicated clamp and a
dedicated special tool or clamping tool available on the mar-
ket.
SST:
Clamp (S4783-71230)
Nylon Tube Tensioning Tool Assembly (S0962-01010)
Tool available on the market: Clamping tool (Tyton MK6)

Clamping torque (reference): 166.6 N {17 kgf, 37.5 lbf}
! 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.
ASSEMBLY OF JOINT/GASKET FOR PIPING

EN0010601C100009
1. TIGHTENING TORQUE OF JOINT

Metal seal system
Seal system Gasket seal system (Flare pipe system, nipple connector system)
(aluminum+rubber or copper)
Tightening screw size Type A Type B
M8 13 {130, 9.4}
M10 20 {200, 14} 11 {110, 8.0}
M12 25 {250, 18} 20 {200, 14}
M14 25 {250, 18} 31 {320, 23}
M16 29 {300, 22} 39 {400, 29}
M18 39 {400, 29} 59 {600, 43}
M20 *39 {400, 29} 64 {650, 47}
M24 69 {700, 51} 20 {200, 14}
M28 *127 {1,300, 94}
2. JOINT ASSEMBLY PROCEDURE AND POST-INSPECTION

(1) Before starting assembly, check that there is no dust or burr on each seat surface (mating part, pipe joint, gasket).
(2) Pipes are provided with the degree of freedom in assembly. The seat face is likely to be tilted. Temporarily tighten the
pipe then perform final tightening in order to avoid leakage.
(3) When the tightening is complete, apply a regular pressure to each pipe joint and check that there is no leakage.
(4) Observe the above tightening torque values.
NOTICE
When a soft washer of the aluminum plus rubber carbon press-fitting type is once mounted then loosened or
removed, replace it with a new one. This does not apply to normal retightening.
3. EXAMPLES OF JOINT SYSTEM FOR PIPING
Metal seal system

Gasket seal system
Type A (Flare pipe system) Type B (Nipple connector system)
HANDLING OF LIQUID GASKET

EN0010601C100010
1. APPLICATION OF LIQUID GASKET AND ASSEMBLY OF PARTS

(1) Thoroughly remove the old liquid gasket on each part and mating part and clean the parts by using waste to wipe off
oil, water and dust.
Overlap the coating at the beginning and end of coating.
(2) To assemble coated part, beware of any dislocation from the mating part. If any dislocation is found, coat the part
again.
(3) Finish assembly within 20 minutes of completion of liquid gasket application.
If 20 minutes is exceeded, remove the liquid gasket and apply it again.
(4) Wait at least 15 minutes after assembly of parts before starting the engine.
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.
1: Approx. 2 mm {0.079 in.} when cut at the first segment

2: Approx. 5 mm {0.197 in.} when cut at the second segment
TROUBLESHOOTING USING THE TROUBLE LIST

EN0010601F200001
SHTS001060100050
TROUBLESHOOTING USING A DIAGNOSIS MONITOR

EN0010601F200002
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
2. CONNECTION OF DIAGNOSIS MONITOR

(1) Turn "ON" the starter switch.
(2) Connect a dedicated harness to the black (or white) connector out
of the central diagnosis connectors (total 2) at the lower right sec-
tion of the instrumental panel at the driver's seat, and connect the
diagnosis monitor to the connector having the tag of "each system
name".
SST: Dedicated Harness (S0963-02300)
SHTS001060100052
! CAUTION
(RIGHT-HAND DRIVE) The central diagnosis connectors are normally connected to the
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
SHTS001060100053
diagnosis monitor.
• The method for outputting diagnosis monitor codes differs
from system to system. Follow the instruction in the chapter
for each system.
SHTS001060100054
TAG AND SYSTEM NAME OF DEDICATED HARNESS
Tag name Name of system to be diagnosed
1 STD: ENG Common rail
3 STD: AIR BAG Not used
5 STD: ABS/ASR ABS
7 STD: ES START ES START
10 STD: VSC Not used
11 STD: TIRE Not used
2 OPT: RTD/4WD Not used
4 OPT: SHAKAN Not used
6 OPT: AIR SUS Not used
8 OPT: IDL STOP Not used
9 OPT: ATM Not used
12 OPT: PRO SHIFT Not used
DEDICATED HARNESS (S0963-02300) 2 1
4 3
10 6 5
8 7
12 11 9
SHTS001060100055
3. INDICATION OF DIAGNOSIS MONITOR CODE

(1) Diagnosis code can be checked on the diagnosis monitor and
check engine light. For example, diagnosis codes 32 and 21 are
indicated as described below. The indication method uses the
blinking interval of light. For the first code, "3" in the ten place illu-
minates for 0.5 seconds three times and twice after 1.5 seconds.
For the second code, the light illuminates twice and once for the
same period as the first code after an interval of 4.3 seconds; this
operation is repeated. In case there is no fault in the system, light
repeats blinking for 3 seconds.
HINT
Indication of a diagnosis code in the figure below is a typical
example. For details, refer to chapter on each system.
INDICATION OF DIAGNOSIS MONITOR CODE (EXAMPLE)
WHEN CODES 32 AND 21 ARE INDICATED:

0.5 SECONDS 0.5 SECONDS
LIGHT ON
LIGHT OFF
4.3 SECONDS
1.5 SECONDS CODE 21

CODE 32 THE OPERATION IS REPEATED
WHEN THE SYSTEM IS NORMAL
0.3 SECONDS
LIGHT ON
LIGHT OFF
SHTS001060100056
4. ERASURE OF PAST FAULTS

(1) Record the first output diagnosis monitor code.
(2) Remove the diagnosis monitor with the starter key in the "ON"
position.
! CAUTION
• If the starter key is placed in "LOCK" position, the past faults
are not erased. Keep the starter key "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.
5. HOW TO USE TROUBLESHOOTING BY DIAGNOSIS MONI-

TOR CODE
(1) The "diagnosis code table" and "Troubleshooting by code" are
shown for each system which outputs diagnosis codes. In case
the diagnosis code is identified, troubleshooting may be initiated
referring to the code list.
SHTS001060100058
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS

TOOL WITH INTERFACE
EN0010601F200003
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 (S0912-11040)
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.
2. CONNECT THE PC DIAGNOSIS TOOL

(1) Turn the starter switch to the "LOCK" position.
(2) Connect the diagnosis cable between diagnosis connector and
interface.
(3) Connect the interface to the PC.
(4) Turn the starter switch to the "ON" position.
(5) The opening menu will be displayed on the PC screen.
(LEFT-HAND DRIVE) (RIGHT-HAND DRIVE)
P P
INTER FACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS001060100060
3. CONNECTION OF SIGNAL CHECK HARNESS

(1) To prevent damage to ECU connector and improve workability,
connect a signal check harness. Perform measurement while
placing the test lead on the signal check connector of the signal
check harness.
a. Remove the connector from ECU.
! CAUTION
Take care not to snap off the lock lug of the connector.
b. Connect a signal check harness to the vehicle harness and
ECU.
SST: Signal Check Harness (for common rail type fuel injec-
tion system) (S0904-91080)
(2) Terminal number
ECU terminal numbers in the text correspond to connectors of
signal check harness as shown below.
SHTS001060100061
SHTS001060100062
.
(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
2. ENGINE MODEL AND ENGINE SERIAL NUMBER

(1) Engine model and engine serial number are engraved on the right
side of the cylinder block.
When ordering parts, notify us of these numbers for quick sup-
port.
ENGRAVED
POSITION
SHTS001060100066
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧤ᤨ㧠㧥ಽ
ENGINE INTRODUCTION (J08E) EN01–1
ENGINE INTRODUCTION (J08E)

EN01
EN01-001
ENGINE ASSEMBLY ................................ EN01-2

DATA AND SPECIFICATIONS ......................... EN01-2
TROUBLESHOOTING ..................................... EN01-5
TROUBLESHOOTING
(COMMON RAIL SYSTEM) ........................... EN01-13
ENGINE TUNEUP ......................................... EN01-14
SPECIAL TOOL ............................................. EN01-20
OVERHAUL CRITERIA.................................. EN01-21
DISMOUNTING AND MOUNTING ................ EN01-22
LIQUID GASKET AND
APPLICATION POINTS ................................. EN01-24
EN01–2 ENGINE INTRODUCTION (J08E)
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
EN0110601I200001
ENGINE SERIES: J08E-TB/ -TE
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,

Type
water-cooled, direct injection
Aspiration Turbocharged with intercooler
Bore and stroke 112 x 130 mm {4.41 x 5.11 in.}
Piston displacement 7.684 L {468.9 cu.in.}
Compression ratio 18.5: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order from

Firing order
the crankshaft pulley side)
Direction of rotation Counterclockwise viewed from flywheel
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) 2,550 r/min.
Idling revolution 550 r/min.
Dry weight Approximately 600 kg {1,323 lb.}
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Intake opens 13° before top dead center
Valve timing Intake closes 21° after bottom dead center

(flywheel travel) Exhaust opens 59° before bottom dead center
Exhaust closes 13° after top dead center
Valve clearance Intake 0.30 mm {0.0118 in.}

(when cold) Exhaust 0.45 mm {0.0177 in.}
Type Full forced pressure feed by gear pump

Engine oil pump
Drive By gear
Engine oil cooler Multi-plate type, water cooled
Injector Type Multi-hole nozzle type
Type Forced circulation by volute pump

Coolant pump
Drive By V-belt
Thermostat Type Wax.type, bottom bypass system
0° before top dead center for No.1 cylinder of the compres-

Injection timing (flywheel travel)
sion stroke
ENGINE SERIES: J08E-UB/ -UC/ -UD/ -UE
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead cam-

Type
shaft, water-cooled, direct injection
Compression ratio 18: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order

Firing order
from the crankshaft pulley side)
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Intake closes 21° after bottom dead center

J08E-UB/ -UC
Exhaust opens 59° before bottom dead center
Valve timing Exhaust closes 13° after top dead center

(flywheel travel) Intake opens 14° before top dead center
Intake closes 30° after bottom dead center

J08E-UD/ -UE
Exhaust opens 54° before bottom dead center


Engine oil pump
Drive By gear
Injector Type Multi-hole nozzle type

Coolant pump
Drive By V-belt
0° before top dead center for No.1 cylinder of the com-

pression stroke
ENGINE SERIES: J08E-UF/ -UG
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead cam-

Type
shaft, water-cooled, direct injection
Compression ratio 18: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order

Firing order
from the crankshaft pulley side)
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Valve timing Intake closes 30° after bottom dead center

(flywheel travel) Exhaust opens 54° before bottom dead center


Engine oil pump
Drive By gear
Type Multi-hole nozzle type

Injection nozzle 1st: 17.7 MPa {180 kgf/cm2, 2,570 lbf/in.2}
Type
2nd: 24.5 MPa {250kgf/cm2, 3,550 lbf/in.2}

Coolant pump
Drive By V-belt
8° before top dead center for No.1 cylinder of the com-

pression stroke
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧥ಽ
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 water temperature sensor Replace it.
Engine overheating Lugging the engine Operate engine properly.
(Severe operating condition)
Excessive oil consumption

Excessive oil consumption Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
(Pistons, cylinder liners, and piston Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
rings)
Insufficient tension on piston rings Replace piston rings and cylinder liner.
Unsatisfactory breaking in of piston Replace piston rings and cylinder liner.
rings
Unsuitable oil (viscosity too low) Change oil as required and replace
piston rings and cylinder liners.
Incorrectly fitted piston rings (upside Replace piston rings.
down)
Gaps of piston rings in cell with each Reassemble piston rings.
other
Excessive oil consumption Worn valve stem Replace valve and valve guide.
(Valve and valve guides) Worn valve guide Replace valve guide.
Incorrectly fitted valve stem seal Replace the stem seal.
Excessive lubricant on rocker arm Check clearance of rocker arm and
shaft.
Excessive oil consumption Defective oil level gauge Replace oil level gauge.
(Excess oil feed) Oil level too high Drain excess oil.
Excessive oil consumption Oil leakage from oil seal Replace oil seal.
(Oil leakage from miscellaneous Cracks or blowhole in cylinder block Replace cylinder block.
parts)
Oil leakage from connections of oil Tighten connections of oil lines.
lines
Oil leakage from oil cooler Replace oil cooler.
Oil leakage from oil pan gasket Replace oil pan gasket.
Oil leakage from O-ring Replace O-ring.
Excessive oil consumption Overcooled engine (low temperature Warm up engine before moving vehi-
(Other problems) wear) cle. Check cooling system.
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.
Piston seizure
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
Lack of power
Lack of power (Supply pump) Damaged suction control valve Replace the supply pump.
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.
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.
Leakage of exhaust
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.
Difficulty starting engine

Difficulty starting engine Discharged battery Charge battery.
(Electrical system) Defective wiring in starter circuit Repair wiring of starter.
Loose or open-circuit battery cable Tighten battery terminal connections
or replace battery cable.
Broken glow plug or intake air heater Replace.
(If so equipped)
Difficulty starting engine (Supply Defective supply pump Replace the supply pump.
pump) (Except J08E-UF, UG)
Difficult starting engine Injection pump Refer to the chapter "FUEL INJEC-
(Injection pump) (J08E-UF, UG) TION PUMP".
Difficulty starting engine Clogged element Replace the element.
(Air cleaner)
Difficulty starting engine No fuel in tank Supply fuel.
(Fuel system) Clogged fuel line Clean fuel line.
Air sucked into fuel system through Tighten fuel line connections.
fuel line connections
Clogged fuel filter Replace element.
Loose connection in high-pressure line Tighten sleeve nut of high-pressure
line.
Water in fuel Drain and clean fuel system.
Difficulty starting engine (Nozzles) Seized nozzle Replace nozzle.
(J08E-UF, UG) Broken or fatigued nozzle spring Replace spring.
Difficulty starting engine Oil viscosity too high Use proper viscosity oil, or install an oil
(Oil system) immersion heater and warm up oil.
Difficulty starting engine Seized piston Replace piston, piston rings, and liner.
(Other problems) Seized bearing Replace bearing and/or crankshaft.
Reduced compression pressure Overhaul engine.
Ring gear damaged or worn Replace the ring gear and/or starter
pinion.
Improperly adjusted or broken acceler- Adjust or replace the accelerator
ator cable (J08E-UF, UG) cable.
Rough idling
Rough idling (Supply pump) Damaged suction control valve Replace the supply pump.
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.
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
Diesel knock (Supply pump) Damaged suction control valve Replace the supply pump.
Diesel knock (Injector) Breakdown of injector Replace the injector.
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)
Unusual engine noise

Unusual engine noise (Piston) Wear of piston pin boss or piston pin Replace piston and/or piston pin.
Seized, damaged, or worn piston pin Replace piston pin bushing.
bushing
Worn pistons or cylinder liners Replace piston or cylinder liner.
Damaged or seized piston Replace piston and cylinder liner.
Foreign matter on top surface of the Remove foreign matter and repair or
piston replace piston, cylinder liner, and/or
cylinder head.
Unusual engine noise Incorrect valve clearance Adjust valve clearance.
(Valve mechanism) Valve cotter out of place Replace valve cotter.
Seized valve stem Replace valve and valve guide.
Broken valve Replace valve.
Damaged rocker arm support Replace rocker arm support.
Broken valve spring Replace valve spring.
Unusual engine noise Insufficient lubricating oil Add oil.
(Bearings seizure) Excessive or insufficient tightening of Retighten to specified torque.
bearing housings
Pits and scratches on bearing surface Replace bearing and crankshaft.
Oil film formed on back of bearing Replace bearing.
Improper installation of bearing Replace bearing.
Reduction of spread dimension of Replace bearing.
bearing
Distorted bearing housing Replace or correct bearing housing.
Excessive oil clearance Replace bearing.
Unusual engine noise Exhaust gas leakage from exhaust Retighten joints.
(Various other parts) pipe joints
Loosen or missing intake manifold Retighten or replace.
flange gasket
Intake valve seating is not concentric Replace or correct the valve and valve
seat.
Intake gas leakage Retighten.
Unusual engine noise (Other prob- Loose cooling fan mounting bolts or Tighten the fan and crankshaft pulley.
lems) fan pulley nut
Lack of lubricating oil (coolant pump, Lubricate.
valves, etc.)
Worn timing gear Replace the timing gear.
Breakage of turbine or blower Replace turbocharger.
NOTICE
The items on this page concern unusual engine noise which is due to causes other than those given for diesel
knock.
TROUBLESHOOTING (COMMON RAIL SYSTEM)

EN0110601F300002
Engine does not start

Engine does not start Fuel lines clogged or damaged Clean or replace fuel lines.
(Fuel not reaching supply pump) Fuel filter clogged Clean or replace the filter element.
Air in fuel caused by improper connec- Repair connections.
tions of fuel line between fuel tank and
feed pump
Filter incorporated in inlet side of feed Remove foreign material.
pump clogged
Breakdown feed pump Replace the supply pump.
Engine does not start Leakage due to improper tightening of Tighten sleeve nut.
(Fuel reaching supply pump) high pressure fuel line
Breakdown ECU Replace the ECU.
Engine does not start Injector broken Replace the injector.
(Injector faulty)
Engine does not start Defective sensors or circuits Refer to the chapter "FUEL CON-
(Electrical system) TROL".
Engine starts and stops Fuel lines clogged Clean or replace fuel lines.
Air in fuel caused by damaged fuel Repair fuel lines or replace fuel lines
lines or improper connection of fuel and gaskets.
lines
Engine has low power Injector broken Replace the injector.
(Injector faulty)
Engine has low power Defective sensors or circuits Refer to the chapter "FUEL CON-
(Electrical system) TROL".
Excessive smoke (Black smoke)

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.
Low idle speed irregular

Low idle speed irregular Defective sensors or circuits Refer to the chapter "FUEL CON-
TROL".
Defective injector Replace the injector.
ENGINE TUNEUP
EN0110601H300001
VALVE CLEARANCE CHECKING AND ADJUSTING

PROCEDURES
! CAUTION
Valve clearance adjustment is performed only when the checking
result is not within the specified value.
1. PREPARATION OF CHECKING AND ADJUSTMENT

(REPRESENTATIVE TYPE) (1) Positioning the No.1 or No.6 piston at Top Dead Center of the
compression stroke.
a. Turn the crankshaft counterclockwise (viewed from the fly-
FLYWHEEL
wheel side) to align mark "1" or "16" on the outer periphery of
the flywheel with the pointer of the flywheel housing.
1 NOTICE
FLYWHEEL
• Always turn the crankshaft counterclockwise (viewed from
HOUSING
the flywheel side).
• In this position the No.1 or No.6 piston is at the Top Dead
Center of the compression stroke.
SHTS011060100001
b. (J08E-UF, UG) Confirm whether No.1 or No.6 piston is at the

Top Dead Center of the compression stroke by the following
two steps.
• If the timer timing mark is nearly aligned with the pointer, the No.1
piston is at the Top Dead Center of the compression stroke.
NOTICE
When the timing mark of the timer is at the rear (180° opposite),
the No.6 piston is at the Top Dead Center of the compression
stroke.
POINTER TIMING MARK

SHTS011060100002
(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
2. VALVE CLEARANCE CHECKING

NOTICE
Before beginning the checking, you must perform "PREPARATION
OF CHECKING AND ADJUSTMENT" described on page EN01-14.
(1) You can understand which valve to adjust when No.1 or No.6 pis-
ton is at the Top Dead Center of the compression stroke by the fol-
lowing chart.
Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
Two drill holes

With No.1
and camshaft
piston at
housing is hor-
T.D.C. on
izontal.
compres-
The rest of drill
sion Cam- hole is visible.
stroke shaft #1
gear
condi- Two drill holes
With No.6
tion and camshaft
piston at
housing is hor-
T.D.C. on
izontal.
compres-
The rest of drill
sion
hole is invisi-
stroke
ble. #1
• #1= View from rear side of camshaft housing

• Mark: Possible to check valve clearance
• Firing order: 1-4-2-6-3-5
• T.D.C.: Top Dead Center
(2) Before checking the valve clearance, make sure that the roller is
on the base circle of the camshaft.
SHTS011060100007
(3) Insert a feeler gauge of the specified thickness as below between

the rocker arm and the cross head to check the valve clearance.
ROCKER ARM
VALVE CLEARANCE (when cold)
FEELER GAUGE
Intake valve 0.30 mm {0.0118 in.}
Exhaust valve 0.45 mm {0.0177 in.}
CROSS HEAD
! CAUTION
result is outside the specified value.
SHTS011060100008
3. VALVE CLEARANCE ADJUSTMENT

! CAUTION
result is outside the specified value.
NOTICE
• Before beginning the adjustment you must perform "PREPA-
RATION OF CHECKING AND ADJUSTMENT" described on
page EN01-14.
• As for the valve which can adjust the valve clearance refer to
the chart on page EN01-15.
• Make sure that the cylinder head bolt, rocker arm support
bolt, nozzle clamp bolt, cam housing bolt and cam bearing
cap bolt are tightened to the specified torque.
(1) Loosen the adjusting screw lock nut A, D of the rocker arm and
A B cross head fully.
ROCKER ARM (2) The cross head adjusting screw must protrude 10 mm {0.394 in.}
or more from the cross head upper face.
10 mm or more NOTICE
Unless the adjusting screw is completely loose to the valve stem
C
D head, the following adjustments may be adversely affected.
"Zero" Need
clearance clearance
CROSS HEAD
SHTS011060100009
(3) Insert a feeler gauge of the specified thickness shown below

between the rocker arm and the cross head, and adjust the valve
clearance with the adjust screw of the rocker arm.
FEELER GAVGE VALVE CLEARANCE (when cold)
Intake valve 0.30 mm {0.0118 in.}
Exhaust valve 0.45 mm {0.0177 in.}
(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
(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 cross
LOOSEN head securely with the specified tightening torque when the feeler
C 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 by
clearance
turning the crankshaft counterclockwise viewed from flywheel
side. Then adjust the valve clearance for each cylinder in the firing
SHTS011060100014 order.
INJECTION TIMING INSPECTION PROCEDURES

(REPRESENTATIVE TYPE)
1. INSPECT THE INJECTION TIMING. (EXCEPT J08E-UF, UG)
FLYWHEEL (1) Turn the crankshaft counterclockwise (viewed from the flywheel
side) to align mark "1" or "16" on the outer periphery of the fly-
wheel with the pointer of the flywheel housing.
1
FLYWHEEL NOTICE
HOUSING Always turn the crankshaft counterclockwise (viewed from the fly-
wheel side).
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 don't tighten in too much. In this case, the timing is not fit. So, per-
INSPECTION SEATED form again the setting for Top Dead Center of No.1 cylinder com-
HOLE PLUG pression stroke in above (1).
SHTS011060100016
2. INSPECT THE INJECTION TIMING. (J08E-UF, UG)

(1) Turn the crankshaft clockwise (viewed from the timing gear side)
to align the timing mark on the outer periphery of the flywheel at
(A°) before Top Dead Center of the compression stroke with the
pointer of the flywheel housing.
Injection timing (A°): Refer to section "DATA AND SPECIFI-
CATION".
(2) Check that the injection timing mark on the automatic timer is
aligned with the pointer of the pump.
If not, adjust the injection timing as on the following page.
SHTS011060100017
3. ADJUST THE INJECTION TIMING. (J08E-UF, UG)

(1) Make sure that the timing mark on the outer periphery of the fly-
wheel is aligned with the timing pointer.
(2) Loosen two adjusting bolts of the injection pump coupling. Do not
remove the bolts.
SST: Injection pump coupling wrench (S0981-91707)
(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
Tightening Torque:
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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START THE ENGINE

! WARNING
Do not leave tools on or around the engine. Contact of tools with
moving parts may result in personal injury or damage to equip-
ment.
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
(J08E-UF, UG) BLEEDER

PLUG
SHTS011060100020
LUBRICATION
1. CHECK THE ROCKER ARM.

(1) Remove the head cover.
(2) Set the engine revolution to the specified idling revolution.
(3) After the engine starts, check that oil is supplied to the following
locations of all rocker arms within approximately 10 seconds.
a. Roller and cam face A
b. Cross head top C and spring upper seat top face D through
adjusting screw B
NOTICE
If the supply of oil is delayed or not happening, hydraulic pressure
may be low or the oil gallery may be clogged. Insufficient supply
of oil may lead to seizure, abnormal wear or abnormal noise.
Recheck the assembly.
SHTS011060100021
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SPECIAL TOOL
EN0110601K100001
Prior to starting an engine overhaul, it is necessary to have these special tools.
Illustration Part number Tool name Remarks
Except J08E-UF, UG
SZ105-08067 GUIDE BOLT
For "ENGINE TUNEUP"
INJECTION PUMP COUPLING J08E-UF, UG

S0981-91707
WRENCH For "ENGINE TUNEUP"
J08E-UF, UG
S0955-21090
COMPRESSION GAUGE For "OVERHAUL CRITERIA"
ADAPTER (A) Except J08E-UF, UG
S0955-21110
For "OVERHAUL CRITERIA"
S0955-21030 COMPRESSION GAUGE

For "OVERHAUL CRITERIA"
S0955-21060 ADAPTER (B)
OVERHAUL CRITERIA
EN0110601H300002
FACTORS TO DETERMINE THE ENGINE OVERHAUL
1. LOW COMPRESSION PRESSURE

(1) Before measurement
a. Charge the battery completely.
b. Set the valve clearance to the correct value.
c. Idle the engine (Coolant temperature at 80°C {176°F}).
d. Remove the air cleaner.
e. Remove all injectors.
(2) Measurement
a. Insert the gauge adaptor into the nozzles.
SST:
Compression gauge adaptor (J08E-UF, UG) (A)
(S0955-21090)
Compression gauge adaptor (Except J08E-UF, UG) (A)
(S0955-21110)
Compression gauge adaptor (B) (S0955-21030)
Compression gauge adaptor (B) (S0955-21060)
b. Run the engine with the starter and measure the compression
pressure.
SHTS011060100026
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.
2. ENGINE OIL PRESSURE

(1) Check the oil pressure warning lamp when the oil and coolant
temperature is hot [about 80°C {176°F}].
a. If the warning lamp lightens, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure
gauge.
SHTS011060100027
d. Measure the oil pressure at a coolant temperature of 80°C

Viscosity recommendations (SAE) {176°F} or more.
Oil pressure
Standard Limit
49-490 kPa Less than 49 kPa
{0.5-5.0 kgf/cm2, {0.5 kgf/cm2,
7.11-71.10 lbf/in.2} 7.11 lbf/in.2}
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
DISMOUNTING AND MOUNTING

EN0110601H100001
IMPORTANT POINT - DISMOUNTING
1. DISMOUNT THE ENGINE ASSEMBLY.

(1) Park the vehicle on level ground and then block the wheels.
(2) Tilt the cab.
(3) Drain coolant from the radiator and cylinder block, and engine oil
from the oil pan.
! WARNING
To avoid the danger of burns, do not drain the coolant and engine
oil while the engine and radiator are still hot.
(4) Disconnect the power steering piping and hose.
(5) (J08E-UG, UF) Disconnect the engine stop cable.
a. Set the starter switch to the "ON" position.
NOTICE
• Do not start the engine.
• Checking the engine stop inner cable by turning the starter
switch to the ON position facilitates dismounting, mounting
and adjustment of the cable.
b. Make sure that the engine stop lever of the fuel injection
pump is in the engine running position, then disconnect the
connectors of the engine stop motor harness.
c. Set the engine starter swtich to the "LOCK" position.
(6) Disconnect the electric lines, fuel lines and air lines.
NOTICE
• Disconnect the battery cable from the negative terminal (-) of
the battery and disconnect the electric lines.
• Cover open ends of the pipes, hoses and pumps to prevent
entry of dirt.
SHTS011060100029
(7) Disconnect the hoses (coolant, heater and air intake) and remove
the radiator.
NOTICE
Do not damage the radiator.
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧥ಽ
(8) Disconnect the air intake and exhaust lines.

(EXAMPLE) (9) Disconnect the propeller shaft.
(10) Disconnect the transmission control and transmission with clutch
FRONT housing from the flywheel housing.
(11) Remove the cab mounting member from the frame.
(12) Connect a cable from an engine hanger to the generator brace (1
point) on the front of the engine, and to the hanger bracket (1
point) on the flywheel housing at the rear of the engine. Using a
hoist, raise the hanger until there is a bit of slack in the cables.
Engine weight: Refer to the section "DATA AND SPECIFICA-
TIONS".
(13) Remove the engine mounting fitting nuts (front and rear, both
sides).
(14) Lift the engine hanger so that the cables are fully tightened, then,
HANGER BOLT
after checking that the cables are securely, lift gently and remove
REAR the engine from the vehicle.
NOTICE
When the transmission is attached to the engine, attach the third
cable to the hanger bolt.
IMPORTANT POINT - MOUNTING
1. MOUNT THE ENGINE ASSEMBLY.

SHTS011060100030 (1) Mount the engine assembly in the reverse order of dismounting.
Tightening Torque:
74 N⋅m {750 kgf⋅cm, 54 lbf⋅ft} (Engine mounting fitting nuts)
NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
or air leaks.
2. CONNECT THE ENGINE STOP CABLE. (J08E-UF, UG)

(1) Set the starter switch to the "ON" position.
NOTICE
Do not start the engine.
(2) Connect the connectors of the engine stop motor harness.
! CAUTION
Do not connect the electric harness to the engine stop motor
while the engine starter switch is at the "LOCK" or "ACC" posi-
tions as this operates the engine stop motor instantaneously and
the link lever of the engine stop motor and the engine stop lever of
the injection pump move, resulting in your fingers being caught
by the lever.
(3) Connect and adjust the engine stop cable with adjusting nut so
that clearance "A" between the clevis and cable stopper is 1-3 mm
{0.04-0.11 in.}.
(4) Set the starter switch to the "LOCK" position.
NOTICE
After adjustment, confirm correct execution of engine start and
stop.
SHTS011060100031
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧤ᤨ㧡㧝ಽ
LIQUID GASKET AND

APPLICATION POINTS
EN0110601H200001
• Liquid gasket is used at the following positions for the J08E series
engine.
Liquid gasket specification:

ThreeBond TB1207B: Black
ThreeBond TB1207D: Silver
ThreeBond TB1211: White
1. LIQUID GASKET APPLICATION AND PART ASSEMBLY PRO-

CEDURE
(1) Remove old liquid gasket from each part and matching parts and
wipe off oil, moisture or dirt with a rag.
(2) Overlap the liquid gasket at the start and end of application.
(3) Be careful of misalignment when assembling parts with liquid gas-
ket. If they are misaligned, reapply the liquid gasket.
(4) Assemble parts within 20 minutes of application.
If more than 20 minutes have passed, remove and reapply the liq-
uid gasket.
(5) Wait for at least 15 minutes or more after assembly of parts before
starting the 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 gas-
ket 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
(2) For cartridge-type gasket, use an application gun.
SHTS011060100033
(3) For tube-type liquid gasket, required width of application can be

obtained by cutting the nozzle to suit.
1: Approximately 2 mm {0.079 in.} wide when cut at the first step

2: Approximately 5 mm {0.197 in.} wide when cut at the second step
SHTS011060100034
4. PARTS AND POSITIONS FOR LIQUID GASKET

(1) Apply liquid gasket to positions and types of gasket according to
the table shown below.
Follow the application pattern at each position shown in the fig-
ures.
Unit: mm {in.}
Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
Matching flange face with the block
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}

LIQUID GASKET
1.5-2.5
3 Oil cooler {0.0591- Silver
0.0984}
Matching flange face with the flywheel housing

LIQUID GASKET
1.5-2.5
Dust cover
4 FLYWHEEL {0.0591- Silver
(J08E-UF, UG)
HOUSING 0.0984}
OPENING
Matching flange face with the cylinder head

LIQUID GASKET
1.5-2.5
5 Thermostat case {0.0591- Black
0.0984}
Matching face with the rear edge
1.5-2.5
6 Flange {0.0591- Silver
0.0984}
Gasket
Application
width
used
Matching face with the intake manifold
LIQUID GASKET
1.5-2.5
7 Intake pipe {0.0591- Black
EXCEPT J08E-UF, UG 0.0984}
LIQUID GASKET
J08E-UF, UG
Gasket
Application
width
used
Matching parts of block upper face rear end,

gasket, rear end plate, flywheel housing, cylin- — White
der head gasket
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.
Matching face of rear end plate

LIQUID GASKET
LIQUID
GASKET 1.5-2.5
Flywheel hous-
9 {0.0591- Silver
ing
0.0984}
Gasket
Application
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.
• When the cylinder head cover is assem-

bled, reapply the liquid gasket. (Assembly
must be done within 20 minutes.)
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'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧞ᤨ㧝㧠ಽ
ENGINE MECHANICAL (J08E) EN02–1
ENGINE MECHANICAL (J08E)

EN02
EN02-001
CYLINDER HEAD ..................................... EN02-2

COMPONENT LOCATOR................................ EN02-2
SPECIAL TOOL ............................................... EN02-8
OVERHAUL ..................................................... EN02-9
INSPECTION AND REPAIR .......................... EN02-20
CRANKSHAFT FRONT END.................. EN02-24

COMPONENT LOCATOR.............................. EN02-24
SPECIAL TOOL ............................................. EN02-25
OVERHAUL ................................................... EN02-25
FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-27
SPECIAL TOOL ............................................. EN02-28
OVERHAUL ................................................... EN02-29
TIMING GEAR......................................... EN02-34

SPECIAL TOOL ............................................. EN02-36
OVERHAUL ................................................... EN02-36
MAIN MOVING PARTS AND

CYLINDER BLOCK................................. EN02-43
SPECIAL TOOL ............................................. EN02-45
OVERHAUL ................................................... EN02-47
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧝㧝ಽ
EN02–2 ENGINE MECHANICAL (J08E)
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
1 Oil filler cap 17 Collar

2 Cylinder head cover 18 Valve rocker shaft
3 Silent block 19 Camshaft bearing cap
4 Head cover gasket 20 Camshaft gear
5 Harness assembly 21 Camshaft
6 Union bolt 22 Nut
7 Gasket 23 Plate
8 Leakage pipe 24 Injection pipe oil seal
9 Injector clamp bolt 25 Injector
10 Rocker arm support bolt 26 O-ring
11 Rocker arm assembly 27 Camshaft housing
12 Lock nut 28 Camshaft housing gasket
13 Adjust screw 29 Camshaft bearing
14 Rocker arm support 30 Plug
15 Rocker arm 31 Cylinder head assembly
16 Injector clamp 32 Cylinder head gasket
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 28.5 {290, 20} G 23 {230, 16}
B 31 {320, 23} H 59 {600, 43}+90°+90°#
C 59 {600, 43}+90°# I 25 {250, 18}
D 25 {250, 18} J 6 {61, 4.4}
E 59 {600, 43} K 28 {286, 21}
F 13.5 {138, 10}
#=Apply oil to the threads and seat surfaces before tightening.
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS031060200002
1 Flange 10 Valve stem seal

2 Idle gear shaft 11 Valve spring seat lower
3 Camshaft idle gear 12 Valve stem guide
4 Idle gear thrust plate 13 Valve seat
5 Cross head 14 Valve
6 Valve spring retainer 15 Nozzle seat
7 Valve spring seat upper 16 O-ring
8 Valve spring outer 17 Cylinder head block
9 Valve spring inner

A 108 {1,100, 79}#
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧤ಽ
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
1 Oil filler cap 17 Bushing

2 Cylinder head cover 18 Valve rocker shaft
3 Silent block 19 Camshaft bearing cap
4 Silent block 20 Camshaft gear
5 Head cover gasket 21 Camshaft
6 Union bolt 22 Nut
7 Gasket 23 Plate
8 Leakage pipe 24 Injection pipe oil seal
9 Nozzle clamp bolt 25 Injection nozzle
10 Rocker arm support bolt 26 O-ring
11 Rocker arm assembly 27 Camshaft housing
12 Lock nut 28 Camshaft housing gasket
13 Adjust screw 29 Camshaft bearing
14 Rocker arm support 30 Plug
15 Rocker arm 31 Cylinder head assembly
16 Nozzle clamp 32 Cylinder head gasket

A 28.5 {290, 20} F 12.25 {125, 9}
B 31 {320, 23} G 23 {230, 16}
C 59 {600, 43}+90°# H 59 {600, 43}+90°+90°#
D 25 {250, 18} I 25 {250, 18}
E 59 {600, 43}
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS031060200002
1 Flange 10 Valve stem seal

2 Idle gear shaft 11 Valve spring seat lower
3 Camshaft idle gear 12 Valve stem guide
4 Idle gear thrust plate 13 Valve seat
5 Cross head 14 Valve
6 Valve spring retainer 15 Nozzle seat
7 Valve spring seat upper 16 O-ring
8 Valve spring outer 17 Cylinder head block
9 Valve spring inner

A 108 {1,100, 79}#
SPECIAL TOOL
EN0310602K100001
S0943-31070 EYE BOLT
S0949-11010 WIRE
S0947-01170 VALVE SPRING PRESS
S0943-11020 VALVE LAPPING TOOL
S0947-22100 VALVE STEM SEAL PRESS
S0947-21210 BAR For Nozzle sleeve
SN441-00610 STEEL BALL Used with S0947-21210
S0947-11520 GUIDE
OVERHAUL
EN0310602H200001
IMPORTANT POINTS - DISASSEMBLY
1. DISASSEMBLE THE CYLINDER HEAD.

(1) Clean parts around the injector and fuel system connections.
NOTICE
Entry of foreign particles into the combustion chamber may result
in engine trouble.
(2) (Except J08E-UF, UG) Remove the injector harness assembly.

a. Disconnect the connector of injector.
b. Remove the 7 nuts, disconnect the injector harness assembly
with plate.
(3) (Except J08E-UF, UG) Remove the injector assembly.
NOTICE
Refer to the section “INJECTOR” in the chapter “FUEL SYSTEM
(J08E)”.
(4) (J08E-UF, UG) Remove the nozzle holder assembly.
NOTICE
Refer to the chapter “FUEL SYSTEM (J08E)”.
SHTS031060200012
(5) Remove the rocker arm assembly.

a. Loosen the lock nut at the end of the rocker arm and turn the
ADJUSTING
SCREW adjusting screw counterclockwise completely.
NOTICE
LOCK NUT
Not untightening the adjusting screw may result in a bent rocker
shaft.
b. Loosen the injector clamp bolt.
SHTS031060200013
c. Loosen the rocker arm support bolt as shown in the figure.

(EXAMPLE) NOTICE
If the cross head is removed from the valve during disassembly of
the rocker arm assembly, reassemble the cross head as it was.
ROCKER ARM SUPPORT
7 5 3 1 2 4 6
SHTS031060200014
(6) Remove the cylinder head bolts.

a. Gradually loosen bolts three times in the order shown in the
figure.
SHTS031060200015
(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
2. DISASSEMBLE THE VALVE SYSTEM.

(1) Remove the valve spring retainer using the special tool.
SST: Valve spring press (S0947-01170)
SHTS031060200017
(2) Remove the intake and exhaust valve.

NOTICE
Attaching tags to the valves (giving corresponding cylinder Nos.)
will eliminate time required for lapping the valve seats on reas-
sembly.
SHTS031060200018
3. CLEAN THE CYLINDER HEAD.

(1) Clean the cylinder head and remove carbon deposits or foreign
particles.
NOTICE
Be careful not to damage the cylinder head lower surface when
removing carbon deposits or foreign particles.
SHTS031060200019
IMPORTANT POINTS - REPLACEMENT
1. REPLACE THE VALVE GUIDE.

(1) Remove the valve stem seal.
(2) For removal, strike the valve guide with a brass bar and hammer.
! WARNING
Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
(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.
2. REPLACE THE VALVE SEAT.

(1) When replacing the valve seat, cut three places on the circumfer-
VALVE SEAT
BACK PLATE ence of an unwanted valve and weld it to the valve seat.
NOTICE
To protect the lower surface of the cylinder head from welding
spatter, be sure to apply grease before welding.
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
SHTS031060200021
(3) Machine the valve according to the valve seat dimensions.

Unit: mm {in.}
Intake Exhaust
41-41.016 39-39.016
A
Cylinder {1.6142-1.6148} {1.5355-1.5360}
head side 9.4-9.6 8.6-8.8
B
{0.3701-0.3779} {0.3386-0.3464}
41.085-41.1 39.12-39.135
C
Valve seat {1.6176-1.6181} {1.5402-1.5407}
side 7-7.2 6-6.2
D
SHTS031060200022 {0.2756-0.2834} {0.2363-0.2440}
(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
SHTS031060200023
(5) Apply a small amount of lapping compound to the contact sur-

faces of the valve and valve seat. Turn the valve using the special
tool and tap it lightly to lap.
SST: Valve lapping tool (S0943-11020)
SHTS031060200024
3. REPLACE THE VALVE STEM SEAL.

(1) After removing the valve stem seal, assemble the spring lower
STEM SEAL seat and apply engine oil to the stem seal lip. Punch it into the
SPECIAL TOOL
SPRING valve guide using the special tool.
LOWER SEAT SST: Valve stem seal press (S0947-22100)
! 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
4. REPLACE THE NOZZLE SEAT.

(1) Tap the nozzle seat from the cylinder head lower surface.
Then, screw in a suitable bolt and strike the bolt head with a ham-
mer to remove the nozzle seat from the cylinder head.
! WARNING
Punching the nozzle seat during removal may cause metal chips
to fly up. Be sure to wear protective goggles.
NOTICE
After removing the nozzle seat, remove the rest of liquid gasket or
the adhesion such as dust completely.
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
(3) Caulk the nozzle seat with the special tools.

SST:
Bar (S0947-21210)
Steel ball (SN441-00610)
SHTS031060200029
IMPORTANT POINTS - ASSEMBLY
1. ASSEMBLE THE VALVE AND VALVE SPRING.

(1) Install the valve spring retainer at the valve spring upper seat
using the special tool.
SST: Valve spring press (S0947-01170)
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.
2. INSTALL THE CYLINDER HEAD GASKET.

NOTICE
• When installing the cylinder head, install the new gasket after
removing dirt, moisture and oil on the cylinder head and cyl-
inder block surface.
• Never reuse the gasket as it may cause engine damage.
• The twelve water hole seal rings between the bores are easily
damaged. Do not touch them with your hands or other
objects. Make sure that the seal rings are not loose or dam-
aged.
• Since silicon material is used for the gear case print seal,
SHTS031060200030
make sure that there is no peeling before assembly.
(1) Install the cylinder head gasket on the cylinder block and flywheel
housing.
(2) Fill the hole at the back of the cylinder head gasket with liquid
gasket.
NOTICE
Make sure that the liquid gasket surface is flush with the cylinder
head gasket upper surface.
SHTS031060200031
3. MEASURE THE CYLINDER HEAD BOLT.

(1) Measure the length of the M12 head bolts, if the length is A or
more, replace with new bolts.
Dimension A 126.5 mm {4.980 in.}
SHTS031060200032
4. INSTALL THE CYLINDER HEAD.

(1) Using the special tool and hoist, put the cylinder head.
SST:
Eye bolt (S0943-31070)
Wire (S0949-11010)
NOTICE
When put the cylinder head, attention to cam idle gear and sub
idle gear engagement.
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:
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
PAINT MARK in (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 fig-
ure to the specified torque below.
Tightening Torque:
SHTS031060200035
5. INSTALL THE CAM IDLE GEAR.

IDLE GEAR
NOTICE
THRUST PLATE • Install the cam idle gear shaft through the thrust plate as
shown in the figure so that the lubrication hole is downward.
• Apply clean engine oil to the bolt seat and bolt threads.
LUBRICATION
CYLINDER HEAD HOLE
SHTS031060200036
6. ASSEMBLE THE CAMSHAFT GEAR.

(1) Measure the length of the camshaft gear bolts, if the length is A or
more, replace with new bolts.
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:
SHTS031060200038
(4) Turn bolts an additional 90° (1/4 turn).

(EXAMPLE)
NOTICE
MARKING When adding torque, never untighten the bolt, even if it has been
overtightened.
90
SHTS031060200039
7. INSTALL THE CAMSHAFT.

(1) Align the mark on the damper or the flywheel with the flywheel
housing pointer to set the No. 1 piston to top dead center of the
compression stroke.
NOTICE
Engine adjustment - Refer to "PREPARATION OF CHECKING AND
ADJUSTMENT" in the section "ENGINE TUNEUP" in the chapter
"ENGINE INTRODUCTION (J08E)".
(2) Install the camshaft into the cam housing.
NOTICE
Two drill holes on the camshaft gear should be located at left side
SHTS031060200040 and lower drill hole should match with the camshaft housing
upper surface.
(3) Install Camshaft bearing caps by fitting the position, in the

FRONT stamped order of 1, 2, 3, 4 and 5, with each engraved mark
headed toward Engine front.
1
SHTS031060200041
8. INSTALL THE ROCKER ARM ASSEMBLY.

(1) Make sure that the cross head is on each valve.
ROCKER ARM SUPPORT NOTICE
If the cross head is assembled whilst off the valve, the upper seat
will be pressed, resulting in a loose valve.
(2) Make sure that the adjusting screw at the end of the rocker arm is
completely screwed in.
7 2 6
(3) Tighten the rocker arm support bolt as shown in the figure to the
5 3 1 4
specified torque.
Tightening Torque:
SHTS031060200042
(4) (J08E-UF, UG) Tighten the nozzle clamp bolt to the specified
torque.
Tightening Torque:
(5) Make sure that the rocker arm moves smoothly.

HINT
(J08E-UF, UG) When assembling the rocker arm assembly, fix the
arm and nozzle clamp with an O-ring as shown in the figure to
facilitate installation.
SHTS031060200043
NOTICE
Make sure the oil hole is placed below.
SHTS031060200044
9. INSTALL THE HEAD COVER.

(1) Remove the camshaft housing plugs at the front and rear ends of
the camshaft housing.
NOTICE
If there is no oil leakage from plug, do not remove the plug.
(2) Remove the liquid gasket from camshaft housing plugs and cam-
shaft housing completely.
(3) Apply liquid gasket to the front and rear half circles of the cam-
shaft housing.
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
(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:
SHTS031060200049
INSPECTION AND REPAIR

EN0310602H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
40 39.85 Replace Measure

Camshaft journal outside diameter
{1.5748} {1.5689} camshaft.
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}
Except Replace
J08E-UF, UG 52.659 camshaft.
EX 52.739 {2.0763}
{2.0732}
Cam height
49.987 Measure
IN 50.067 {1.9711}
{1.9680}
Replace
J08E-UF, UG
52.024 camshaft.
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.
Stem Replace the Measure

7 {0.2756} —
outside diameter valve.
Replace the
Guide inside diame-
7 {0.2756} — valve
ter
Intake valve guide.
Replace the
0.023-0.058 valve and/
Clearance —
{0.0010-0.0022} or valve
guide.
Stem Replace the

7 {0.2756} —
outside diameter valve.
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}
Replace the Measure

0.55-0.85 1.1
IN valve and
{0.0217-0.0334} {0.0433} VALVE SINK
valve seat.
Valve sink Except 1.15-1.45 1.7

J08E-UF, UG {0.0453-0.0570} {0.0669} Replace the
EX valve and
1.05-1.35 1.6 valve seat.
J08E-UF, UG
{0.0414-0.0531} {0.0630}
Measure
IN 30° 30°-30°35'
Valve seat angle
EX 45° 45°-45°30'
Resurface
the valve
and/or
IN 30° 29°30°-30' valve seat.
Valve face angle

44°30°-
EX 45°
45''
314 N Measure
Setting load {32.0 kgf, 70.5 lbf} — Replace.
at 46.8 {1.843}
Outer Free length 72.7

75.7 {2.980} Replace.
valve (reference value) {2.862}
spring Except 2.0
J08E-UF, UG {0.0787}
Squareness — Replace.
2.3
J08E-UF, UG
{0.0905}
129 N
Setting load {13.2 kgf, 29.1 lbf} — Replace.
at 44.8 {1.764}
Free length 61.6

64.6 {2.543} Replace.
(reference value) {2.425}
Inner valve
spring
2.0
Squareness — Replace.
{0.0787}
Visual check
Wear and damage of valve spring seat

— — Replace.
upper and lower
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 or less
{0.0024 or less}
for longitudinal
direction Replace.
NOTICE:
Cylinder head lower 0.20
Do not
surface flatness {0.0078}
grind for
0.03 or less repair.
{0.0012 or less}
for lateral
direction
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
Cam idle gear shaft Measure

34 {1.3386} — —
outside diameter
Cam idle gear shaft

34 {1.3386} — —
bushing inside diameter
Replace
idle gear
Clearance between cam idle gear shaft 0.025-0.075 0.2
shaft bush-
and cam idle gear bushing {0.0010-0.0029} {0.0078}
ing and/or
idle gear.
CRANKSHAFT FRONT END

COMPONENT LOCATOR
EN0310602D100002
A
4
SHTS031060200065
1 Crankshaft pulley 3 Oil seal retainer

2 Torsional damper 4 Crankshaft oil seal

A 118 {1,200, 86}# B 108 {1,100, 80}#
SPECIAL TOOL
EN0310602K100002
S0942-01731 OIL SEAL PULLER
S0940-71030 OIL SEAL PRESS
OVERHAUL
EN0310602H200002
1. REMOVE THE CRANKSHAFT FRONT OIL SEAL.

SST: Oil seal puller (S0942-01731)
(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
2. INSTALL THE CRANKSHAFT FRONT OIL SEAL.

GUIDE SST: Oil seal press (S0940-71030)
(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'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧥ಽ
FLYWHEEL AND FLYWHEEL HOUSING

COMPONENT LOCATOR
EN0310602D100003
B
5
A 6 A 2
C
X A A
W
X
W
4
3
SHTS031060200075
1 Flywheel housing 4 Flywheel

2 Dust cover 5 Ring gear
3 Crankshaft oil seal 6 Hanger bracket

A M8: 28.5 {290, 21} B 186 {1,900, 137}#
M10: 55 {560, 40.5} C 36 {367, 27}
M16: 196 {2,000, 145}
#=Apply oil to the threads and seat surface before tightening.
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
SPECIAL TOOL
EN0310602K100003
S0942-01742 REAR OIL SEAL PULLER
S0948-11340 GUIDE BAR

OVERHAUL
EN0310602H200003

O-RING
1. REMOVE THE FLYWHEEL.

(1) (Except J08E-UF, UG) Remove the main engine speed sensor
from the flywheel housing.
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
(2) Install the special tool, remove the flywheel.

SST: Guide bar (S0948-11340)
! WARNING
SST
The flywheel is heavy when removing, be careful not to drop it on
your feet.
SHTS031060200081

PLATE
1. REMOVE THE CRANKSHAFT REAR OIL SEAL.
SST: Oil seal puller (S0942-01742)
(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE
Match the plate hole to the crankshaft collar knock part.
SHTS031060200082
(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
2. INSTALL THE CRANKSHAFT REAR OIL SEAL.

SST: Oil seal press (S0940-71040)
GUIDE
(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
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
(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
3. REPLACE THE FLYWHEEL RING GEAR.

(1) Heat the ring gear evenly to about 200°C {392°F} with a torch. Tap
the ring gear periphery lightly using a cushion bar to remove the
gear.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
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
IMPORTANT POINT - ASSEMBLY
1. INSTALL THE FLYWHEEL.

(1) Make sure that there are no burns or dirt on the contact surface or
in the threaded holes of the crankshaft or flywheel. Install the spe-
SST cial tool onto the crankshaft.
SST: Guide bar (S0948-11340)
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

EN0310602H300002
Unit: mm {in.}
Measure
Flywheel surface deflection — 0.15 {0.0059} Repair.
Measure
CSP350 43 {1.693} — —
Flywheel
flange depth
(Dimension
A)
CSP380 48 {1.890} — —
CSP350 21 {0.827} 22 {0.866} Replace.

Flywheel
thickness
(Dimension
B)
CSP380 23 {0.906} 22 {0.866} Replace.
Flywheel surface crank on Visual check

— — Repair.
heat spot
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
1 Gasket 8 Main idle gear

2 Rear end plate 9 Crankshaft gear
3 Camshaft gear 10 Power steering pump drive gear
4 Cam idle gear 11 Air compressor drive gear
5 Idle gear thrust plate 12 Air compressor idle gear
6 Sub-idle gear 13 Idle gear bushing
7 Oil pump gear 14 Idle gear shaft

A 108 {1,100, 80}# C 55 {560, 41} Application of lock sealant
B 172 {1,750, 127}#
J08E-UF, UG
SHTS031060200098
1 Gasket 7 Oil pump gear

2 Rear end plate 8 Main idle gear
3 Camshaft gear 9 Crankshaft gear
4 Cam idle gear 10 Air compressor drive gear
5 Idle gear thrust plate 11 Power steering pump drive gear
6 Sub-idle gear 12 Idle gear shaft

A 108 {1,100, 80}# C 172 {1,750, 127}#
B 108 {1,100, 80}# D 55 {560, 41} Application of lock sealant
SPECIAL TOOL
EN0310602K100004
S0942-01100 SLIDING HAMMER For Main idle gear
For Sub and main cam

S0942-01442 SLIDING HAMMER
idle gear
S0941-11300 SOCKET WRENCH For Torx bolt
OVERHAUL
EN0310602H200004
IMPORTANT POINT - DISASSEMBLY
1. REMOVE THE IDLE GEAR SHAFT.

(1) Remove the idle gear shaft using the special tool.
SST:
Sliding hammer (for main idle gear) (S0942-01100)
Sliding hammer (for sub and cam idle gear) (S0942-01442)
SHTS031060200102
SHTS031060200103
1. INSTALL THE REAR END PLATE.

(1) Apply lock sealant (Nut Lock Super 5M or equivalent) to the
threads of the torx bolts in the side of the air compressor fitting (2
places) and tighten to the specified torque using the special tool.
TORX BOLTS
SST: Socket wrench (S0941-11300)
REAR END
PLATE Tightening Torque:
SHTS031060200104
2. INSTALL THE CRANKSHAFT GEAR.

(1) Heat the crankshaft gear in oil heated to 100°C -150°C {212°F-
302°F}.
! WARNING
Never touch the heated gear with your bare hand. This can result
in personal injury.
(2) Align the crankshaft gear groove with crankshaft pin.
(3) Install the crankshaft gear onto the crankshaft as shown in the fig-
ure.
Dimension A: 22 mm {0.866 in.}
SHTS031060200105
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.
• EXCEPT J08E-UF, UG
SHTS031060200106
• 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.
4. MEASUREMENT OF GEAR BACKLASH

(1) Measure the backlash between the gears with a dial gauge.
(Refer to the table of INSPECTION AND REPAIR)
NOTICE
After measurement of the backlash, apply engine oil to each gear
surface.
SHTS031060200108

EN0310602H300003
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
Main idle-Sub 0.030-0.113

0.30 {0.0118}
idle {0.0012-0.0044}
Sub idle-Oil 0.030-0.131

0.30 {0.0118}
pump {0.0012-0.0051}
Sub idle-Cam 0.050-0.218

0.30 {0.0118}
idle {0.0020-0.0085}
Cam idle- 0.030-0.253

0.30 {0.0118}
Camshaft {0.0012-0.0099}
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.
Gear width 44 {1.732} — —
Shaft length 44 {1.732} — —
0.114-0.160 Replace gear and/ Measure

End play 0.30 {0.0118}
{0.0045-0.0062} or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside 50 {1.969} — —
diameter
Sub idle 0.025-0.075 Replace bushing
{0.0010-0.0029} and/or shaft.
Gear width 22 {0.866} — —
0.040-0.120 Replace gear and/

End play 0.30 {0.0118}
{0.0016-0.0047} or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside — —
diameter
Cam idle 0.025-0.075 Replace bushing
{0.0010-0.0029} and/or shaft.
Gear width 22 {0.866} — —

End play 0.30 {0.0118}
{0.0016-0.0047} or thrust plate.
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.
Gear width 28.5 {1.1220} — —
Shaft length 28.5 {1.1220} — —
0.160-0.220
End play — —
{0.0063-0.0086}
J08E-UF, UG
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Main idle-Air 0.030-0.218 Measure

0.30 {0.0118}
compressor {0.0012-0.0085}
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}
Sub idle-Oil 0.030-0.131

0.30 {0.0118}
pump {0.0012-0.0051}
Sub idle-Cam 0.050-0.218

0.30 {0.0118}
idle {0.0020-0.0085}
Cam idle- 0.030-0.253

0.30 {0.0118}
Camshaft {0.0012-0.0099}
Shaft outside
57 {2.244} — —
diameter
Bushing
inside diame- 57 {2.244} — —
ter
Measure
Main idle 0.030-0.090 Replace gear and/
{0.0012-0.0035} or shaft.
Gear width 44 {1.732} — —

End play 0.30 {0.0118}
{0.0045-0.0062} or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside diame- 50 {1.969} — —
ter
Sub idle 0.025-0.075 Replace gear and/
{0.0010-0.0029} or shaft.
Gear width 22 {0.866} — —

End play 0.30 {0.0118}
{0.0016-0.0037} or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside diame- — —
ter
Cam idle 0.025-0.075 Replace gear and/
{0.0010-0.0029} or shaft.
Gear width 22 {0.866} — —

End play 0.30 {0.0118}
{0.0016-0.0037} or shaft.
MAIN MOVING PARTS AND CYLINDER BLOCK

COMPONENT LOCATOR
EN0310602D100005
SHTS031060200111
1 Cylinder liner 7 Retainer ring 13 Crankshaft main bearing

2 Cylinder block 8 Connecting rod 14 Crankshaft gear
3 Piston cooling jet 9 Connecting rod bushing 15 Collar knock
4 Piston ring 10 Connecting rod bearing 16 Main bearing cap
5 Piston 11 Crankshaft
6 Piston pin 12 Crankshaft thrust bearing

A 22 {220, 15.5} C 69 {700, 50}+90°+45°#
B 69 {700, 50}+90°+45°#
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
2 3
A
4
SHTS031060200112
1 Gasket 3 Soft washer

2 Oil pan 4 Drain plug

A 41 {420, 30} B 30 {300, 21}
SHTS031060200113
1 Injection pump bracket (J08E-UF, UG only)

SPECIAL TOOL
EN0310602K100005
S0944-21011 PISTON RING EXPANDER For Piston ring
S0942-02100 PULLER For Cylinder liner
SZ910-24098 CONNECTOR BOLT For Piston cooling jet
S0947-21620 ADJUSTING BAR
S0947-11490 GUIDE
S0940-21540 SPINDLE
S0948-11540 GUIDE
SH691-20825 BOLT
S0948-11130 GUIDE For Connecting rod bushing

S0940-21530 PRESS SUB-ASSEMBLY
SL271-01036 WING NUT
S0944-11370 PISTON RING HOLDER
S0947-01280 TOOL ASSEMBLY

OVERHAUL
EN0310602H200005
1. REMOVE THE PISTONS WITH CONNECTING RODS.

(1) Remove the pistons and connecting rods from the cylinder block
upper side.
NOTICE
• Remove carbon deposits from the end inside the cylinder
liner with a scraper or emery paper (recommended: No. 150)
in a circular direction.
SHTS031060200127
• Arrange the removed pistons and connecting rod caps in the

order of cylinder Numbers. Be careful not to change the com-
bination of the connecting rod and cap.
SHTS031060200128
2. REMOVE THE PISTON RINGS.

(1) Remove the piston ring using the special tool.
SST: Piston ring expander (S0944-21011)
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
3. REMOVE THE CYLINDER LINER.

(1) Before removing the cylinder liner, put alignment marks on the
cylinder block and liner flange.
NOTICE
Do not make alignment marks with a punch.
SHTS031060200130
(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
1. INSPECT AND ADJUST THE PISTON COOLING JET.

(1) Install the piston cooling jet on the cylinder block using the special
tool.
SST: Connector bolt (SZ910-24098)
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 (7mm {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 venti-
lated room and do not use naked lights in the room.
SHTS031060200135
(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
2. INSTALL THE CYLINDER LINER.

NOTICE
• When assembling the cylinder liner with the cylinder block,
clearance can be set to three levels.
• The upper surface and side surface of the cylinder block are
stamped A, B or C depending on the inside diameter. Insert a
matching cylinder liner having the same symbol.
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
3. MEASURE THE PROTRUSION AT THE CYLINDER LINER

FLANGE.
Tightening Torque:
9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
Standard 0.01-0.08 mm {0.0004-0.0031 in.}
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.}
(2) Dimension of fillet "R"
Crank pin 2.5-3.0 mm {0.0985-0.1181 in.}

NOT "R" SMALL "R"
STEPPED STEPPED
Journal 2.5-3.0 mm {0.0985-0.1181 in.}
R
GOOD NOT GOOD
SHTS031060200141
5. INSTALL THE CRANKSHAFT.

(1) Install the main bearing onto the bearing caps and the cylinder
block.
NOTICE
• Install the bearing with the oil hole on the block side and the
bearing without the oil hole on the cap side.
• Apply clean engine oil to inner surfaces of the bearings.
(2) Install the thrust bearing with the groove side (front) toward the
crank arm and with the part No. stamp (back) toward the main
bearing cap or cylinder block.
HINT
Apply engine oil or grease to the back of the bearing to prevent
loosening during installation.
(3) Install the crankshaft onto the cylinder block.
SHTS031060200142
6. INSTALL THE MAIN BEARING CAP.

(1) Install the main bearing cap onto the cylinder block.
NOTICE
Check the number stamped on the cap.
(2) Measure the length below the head of the bearing cap bolt and
APPLICATION replace any bolts not meeting the limit with new ones.
POSITION OF
A
ENGINE OIL
Dimension A 108 mm {4.252 in.}
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:
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
7. REPLACE THE CONNECTING ROD BUSHING.

(1) Prepare the special tools.
a. Assembly the guide and press sub-assembly inserting its pin
into the guide then secure them with the wing nut.
SST:
Guide (S0948-11130)
Press sub-assembly (S0940-21530)
Wing nut (SL271-01036)
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'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝㧞ᤨ㧠㧠ಽ
(2) Using a special tool, remove the connecting rod bushing.

a. Set the connecting rod assembled without connecting rod
bearing on the guide and press sub-assembly.
SHTS031060200147
b. Install the spindle into the bushing.

SST: Spindle (S0940-21540)
NOTICE
Align the groove of the spindle with the groove of the press sub
assembly.
SHTS031060200148
c. Using a hydraulic press, remove the bushing.

NOTICE
Always operate the press slowly and smoothly.
SHTS031060200149
(3) Chamfer one edge of the bushing hole at the small end of the con-
necting 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
(4) Mount the bushing on the spindle.

a. Set the bushing and guide on the spindle as shown in the fig-
ure, then secure them with the bolt.
SST:
Spindle (S0940-21540)
Guide (S0948-11540)
Bolt (SH691-20825)
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.
(6) Using a press, install the bushing in the connecting rod.
SHTS031060200152
(7) Inspect the bushing positioning after installation.

a. Make sure that the oil hole of the bushing and the oil path of
the connecting rod are suitably aligned allowing a 6 mm
{0.2362 in.} diameter rod to penetrate.
NOTICE
Misalignment can lead to insufficient lubrication, which may result
in seizure.
b. Insert a new piston pin. When it is turned gently, make sure

that there is no catch or rough movement.
SHTS031060200153
8. ASSEMBLE THE PISTON AND CONNECTING ROD.

(1) Heat the piston to 50°C {122°F}.
(2) Assemble the piston 0-mark to be opposite to the connecting rod
match mark.
NOTICE
Replace the retainer ring with a new one.
SHTS031060200128
9. ASSEMBLE THE PISTON RING.

(1) Install in the order of oil ring, second ring and top ring using the
special tool.
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
10. INSTALL THE PISTON.

COOLING JET (1) Apply engine oil to the piston, cylinder liner and connecting rod
bearing, then compress the piston ring using the special tool.
SST: Piston ring holder (S0944-11370)
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
(2) Insert the piston into the cylinder liner.
SHTS031060200158
SHTS031060200159
11. TIGHTEN THE CONNECTING ROD BOLT.

(1) Measure the length of the bolts, if the length is A or more, replace
with new bolts.
(2) Apply clean engine oil to the bolt thread and the nut seat surface
of the connecting rod cap.
SHTS031060200160
(3) Tighten the connecting rod nut to the specified torque.

Tightening Torque:
(4) Mark the nut heads in the same direction with paint.
(5) Tighten the connecting rod nut 90° (1/4 turn).
(6) Tighten the connecting rod nut 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 turning
counterclockwise, the axial force of the bolts might fall short and
it is feared that this could reduce the engine reliability. Also there
is a possibility that this could reduce the number of times a bolt
can be reused.
12. INSTALL THE OIL PAN.

(EXAMPLE) BOLT TIGHTENING (1) Make sure that there is no deformation, impact marks or foreign
DIRECTION particles on the cylinder block, oil pan or flange surface. Apply liq-
uid gasket to the front and back ends of the cylinder block lower
surface.
NOTICE
Refer to "PARTS AND POSITIONS FOR LIQUID GASKET" in the
section "LIQUID GASKET AND APPLICATION POINTS" in the
chapter "ENGINE INTRODUCTION (J08E)".
REAR (2) Install the gasket so that the protrusion is at the flywheel housing
side and the intake side. (the print seal surface is at the cylinder
block side)
FRONT (3) Place a guide pin of 70 mm {2.76 in.} or more in the cylinder block
and assemble the oil pan against the guide.
PROTRUSION
(4) Tighten oil pan fitting bolts according to the arrows with an impact
wrench.
OIL STRANER
Tightening Torque:
19.7-24.5 N⋅m {200-250 kgf⋅cm, 15-18 lbf⋅ft}
(5) Finish tightening the bolts with a torque wrench to the specified
torque. Tighten the bolts according to the arrows in the figure.
NOTICE
Make sure that the washer is not on the flange.
LIQUID GASKET
SHTS031060200162

EN0310602H300004
Unit: mm {in.}
Cylinder block flange Measure

8 {0.3150} — —
depth
Cylinder liner thickness 8 {0.3150} — —
0.01-0.08
Cylinder liner protrusion — —
{0.0004-0.0031}
117-117.008 Reference only

A
{4.6063-4.6066}
Block
117.008-117.014
inside B — —
{4.6067-4.6068}
diameter
117.014-117.022
C
{4.6069-4.6071}
116.982-116.990 Reference only

A
{4.6056-4.6058}
Liner
116.990-116.996
outside B — —
{4.6059-4.6061}
diameter
116.996-117.004
C
{4.6062-4.6064}
0.010-0.026 Reference only

A
{0.0004-0.0010}
Clearance
between 0.012-0.024
B — —
block and {0.0005-0.0009}
liner
0.010-0.026
C
{0.0004-0.0010}
Piston outside 111.892-111.908 Measure

—
diameter at A:23 {0.9055} {4.4051-4.4058}
Liner inside diameter

(Apply the value
A
obtained at the most
112 {4.409} 112.15 {4.415}
worn point to the
Replace piston and/
cylinder liner
or liner.
inside diameter.)
Clearance between 0.092-0.108

—
piston and cylinder liner {0.0036-0.0042}
Top 2.5 {0.0984} 2.4 {0.0945} Measure
Second 2.0 {0.0787} 1.9 {0.0748}

Piston ring
Replace ring.
width
Oil 4.0 {0.1575} 3.9 {0.1535}
Top 2.5 {0.0984} 2.7 {0.1062} Measure
Piston ring Second 2.0 {0.0787} 2.2 {0.0866}

groove Replace piston.
width
Oil 4.0 {0.1575} 4.1 {0.1614}
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}
Piston pin outside diam- Measure

37 {1.4567} 36.96 {1.4551} Replace piston pin.
eter
Piston pin bore inside

37 {1.4567} 37.05 {1.4586} Replace piston.
diameter
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
Connecting rod Replace connecting

37 {1.4567} 37.1 {1.4606}
bushing inside diameter rod bushing.
Clearance between Replace piston pin

0.035-0.056
piston pin and 0.08 {0.0031} and/or connecting —
{0.0014-0.0022}
connecting rod bushing rod bushing
Visual check
Wear or damage of
connecting rod
— — Replace.
*Dye penetrant check
(Color check)
Visual check
Clogging of connecting
— — Replace.
rod oil hole
More than Measure

0.2 {0.0079} Regrind under size.
Crank pin outside 65 {2.559} (Repair) 90
diameter measure
64.3 {2.5314} 2 part
Replace crankshaft.
(Service)
Clearance between
0.031-0.082 Replace connecting
connecting rod bearing 0.2 {0.0079}
{0.0013-0.0032} rod bearing.
and crank pin
Connecting rod large end Replace connecting Measure

34 {1.339} 33.2 {1.3071}
width rod.
Crank pin width 34 {1.339} 34.8 {1.371} Replace crankshaft.
Replace connecting
0.20-0.52
Connecting rod end play 1.0 {0.0394} rod and/or
{0.0079-0.0204}
crankshaft.
More than Measure

0.2 {0.0079} Regrind under size.
Crank journal outside (Repair)
80 {3.150}
diameter 90
79.3 {3.1220}
Replace crankshaft.
(Service)
Clearance between crank 0.051-0.102 Replace main

0.2 {0.0079}
journal and main bearing {0.0021-0.0040} bearing.
Measure
Center journal width 36 {1.417} 37 {1.456} Replace crankshaft.
Thrust bearing Measure

2.5 {0.0984} — —
thickness
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)
Measure
Crankshaft deflection — 0.15 {0.0059} Regrind under size.
Visual check
Clogging of crankshaft
— — Clean.
oil hole
Visual check
Crack and wear of crank-

shaft
— — Replace.
*Dye penetrant check
(Color 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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧝㧣ಽ
AIR INTAKE SYSTEM (J08E) EN03–1
AIR INTAKE SYSTEM (J08E)

EN03
EN03-001
AIR INTAKE MANIFOLD AND PIPE ........ EN03-2

DISMOUNTING AND MOUNTING .................. EN03-3
AIR INTAKE .............................................. EN03-4

OVERHAUL ..................................................... EN03-6
AIR CLEANER .......................................... EN03-9

OVERHAUL ..................................................... EN03-9
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧠ಽ
EN03–2 AIR INTAKE SYSTEM (J08E)
AIR INTAKE MANIFOLD AND PIPE

COMPONENT LOCATOR
EN0110603D100001
EXCEPT J08E-UF, UG
6
A
SHTS011060300001
1 Intake manifold 4 Intake pipe gasket

2 Intake manifold gasket 5 Intake pipe
3 Intake pipe sub assembly 6 Intake pipe bracket

A 28.5 {291, 21}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧝㧥ಽ
J08E-UF, UG
SHTS011060300002
1 Intake manifold gasket 3 Intake pipe

2 Intake manifold 4 Intake pipe gasket

EN0110603H100001
1. INSTALL THE INTAKE MANIFOLD GASKET.

(1) Install the intake manifold gasket so that the protrusion is posi-
tioned at the stud bolt side of the cylinder head rear end.
SHTS011060300003
AIR INTAKE
COMPONENT LOCATOR
EN0110603D100002
Z
2 5
1 6
4
7
A
5
5
Z
9 A
8
5
SHTS011060300004
1 Air cleaner 6 Air hose (Inter cooler)

2 Air cleaner pipe 7 Air hose (Air cleaner)
3 Dust indicator 8 Fixing plate
4 Dust hose 9 Air cleaner bracket
5 Clamp

A 5.5-6.5 {56-66, 4.1-7.3} B 4.5-5.5 {46-56, 3.4-4.0}
1
2
X
4
5
1
SHTS011060300005
1 Air intake bracket 5 Air hose

2 Intake pipe 6 Air guide plate
3 Pre-cleaner 7 Spring guide
4 Clamp
OVERHAUL
EN0110603H100002
1. INSTALL THE AIR HOSES.

(1) Install the air hoses as shown in the figure.
(2) Tighten the clamp.
Tightening Torque:
Clamp A: 5.5-6.5 N⋅m {56-66 kgf⋅cm, 4.079-7.231 lbf⋅ft}
Clamp B: 4.5-5.5 N⋅m {46-56 kgf⋅cm, 3.326-4.049 lbf⋅ft}
(REPRESENTATIVE TYPE: MODELS FOR HONG KONG, SINGAPORE AND TAIWAN)
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
ALIGN THE ARROW MARK

AIR HOSE WITH THE STOPPER'S CENTER.
INTAKE PIPE
(INTER COOLER)

A WITH THE STOPPER'S CENTER.
SHTS011060300006
(REPRESENTATIVE TYPE: MODELS FOR THAILAND AND CHILE)
AIR CLEANER

WITH THE STOPPER'S CENTER.
AIR HOSE
VEHICLE (AIR CLEANER)
FRONT
A INTAKE PIPE
B
B
AIR HOSE ALIGN THE ARROW MARK

(INTER COOLER) WITH THE STOPPER'S CENTER.
AIR HOSE
(INTER COOLER) INTAKE PIPE

SHTS011060300007
(MODELS FOR INDONESIA)
AIR CLEANER

WITH THE STOPPER'S CENTER.
AIR HOSE
(AIR CLEANER)
VEHICLE
FRONT B
A
B
AIR HOSE
(INTER COOLER) ALIGN THE
ARROW MARKS.
INTAKE PIPE
AIR HOSE
(INTER COOLER)
INTAKE PIPE

SHTS011060300008
AIR CLEANER
COMPONENT LOCATOR
EN0110603D100003
SHTS011060300009
1 Body 4 Clamp
2 Filter element 5 Dust unloader valve
3 Cover
OVERHAUL
EN0110603H100003
IMPORTANT POINT - INSPECTION
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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧠㧟ಽ
EXHAUST SYSTEM (J08E) EN04–1
EXHAUST SYSTEM (J08E)

EN04
EN04-001
EXHAUST MANIFOLD AND PIPE............ EN04-2

EXHAUST PIPE AND MUFFLER.............. EN04-5

OVERHAUL ..................................................... EN04-7
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧜ಽ
EN04–2 EXHAUST SYSTEM (J08E)
EXHAUST MANIFOLD AND PIPE

COMPONENT LOCATOR
EN0110604D100001
MODELS FOR CHILE, INDONESIA AND THAILAND
SHTS011060400001
1 Heat insulator 8 Hose

2 Exhaust connector 9 Intake pipe
3 Coolant pipe 10 Exhaust manifold
4 Oil pipe 11 Seal ring
5 Turbocharger 12 Exhaust manifold gasket
6 Gasket 13 Spacer
7 Clamp

A 53 {540, 39} B 61 {620, 44}
MODELS FOR HONG KONG, SINGAPORE AND TAIWAN
3
4
1
2
9 5
7 8 4
A 14
11
13
B
1
12
10
SHTS011060400002
1 Heat insulator 8 Hose

2 Exhaust connector 9 Intake pipe
3 Coolant pipe 10 Bracket
4 Oil pipe 11 Exhaust manifold
5 Turbocharger 12 Seal ring
6 Gasket 13 Exhaust manifold gasket
7 Clamp 14 Spacer

A 53 {540, 39} B 56 {570, 41}

EN0110604H100001
IMPORTANT POINTS - MOUNTING
1. INSTALL THE EXHAUST MANIFOLD GASKET.

NOTICE
Since the exhaust manifold gasket must be installed in one way,
install the gasket with the black side facing toward the exhaust
manifold.
SHTS011060400003
2. INSTALL THE EXHAUST MANIFOLD.

(1) Install the exhaust manifold onto the cylinder head and tighten the
TIGHTENING ORDER .... NEW MANIFOLD
mounting nut in the order shown in the figure to the specified
torque.
18 17 16 15 14 13 12 11 10 9 8 7 Tightening Torque:
(2) Retighten the same nuts according to the same procedure again.
1 2 5 6 NOTICE
3 4
Be sure to carry out the procedure.
TIGHTENING ORDER .... REUSED MANIFOLD
14 15 8 9 2 3 5 6 11 12 17 18
13 7 10 16
1 4
SPACER
SHTS011060400004
EXHAUST PIPE AND MUFFLER

COMPONENT LOCATOR
EN0110604D100002
(REPRESENTATIVE TYPE: LONG TAIL) b
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
1 Insulator 8 Exhaust pipe support bracket

2 Exhaust pipe 9 Spacer
3 Gasket 10 Cushion
4 Muffler 11 Heat insulator
5 Tail pipe 12 Exhaust brake
6 Clamp 13 Exhaust pipe U-bolt
7 Exhaust pipe support

A 29.5-37.5 {300-382, 21-27} C 16.5-20.5 {168-209, 12-15}
B 21-27 {214-275, 15-19} D 56-84 {571- 856, 41- 61}
NOTICE
Unspecified tightening torque shall be as follows.
M8: T= 20-24 N⋅m {205-245 kgf⋅cm, 15-17 lbf⋅ft}
M10: T= 46-56 N⋅m {470-571 kgf⋅cm, 34-41 lbf⋅ft}
M12: T= 82-100 N⋅m {840-1,020 kgf⋅cm, 61-73 lbf⋅ft}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧡ᤨ㧡㧟ಽ
(REPRESENTATIVE TYPE: STACK TAIL)
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

A 56-84 {571-856, 41-61} C 16.5-20.5 {168-209, 12-15}
B 29.5-37.5 {300-382, 21-27} D 21-27 {214-275, 15-19}
NOTICE
Unspecified tightening torque shall be as follows.
M8: T= 20-24 N⋅m {205-245 kgf⋅cm, 15-17 lbf⋅ft}
M10: T= 46-55 N⋅m {470-560 kgf⋅cm, 34-40 lbf⋅ft}
M12: T= 82-100 N⋅m {840-1,020 kgf⋅cm, 61-73 lbf⋅ft}
OVERHAUL
EN0110604H200001

! WARNING
Do not touch the exhaust manifold when it could be hot. You can
be severely burned.
IMPORTANT POINT - INSPECTION
1. EXHAUST MUFFLER AND PIPES.

NOTICE
• Be particularly careful of rust holes and dents caused by fly-
ing stones.
• If there are holes or cracks in the exhaust muffler and pipe,
the exhaust noise will increase. In addition, hot gas may blow
out, resulting in the risk of fire.
• If the exhaust muffler and pipe is severely dented by flying
stones, etc., the exhaust resistance will increase, causing
SHTS011060400007
output decrease and resulting in an increase of fuel con-
sumption.
1. INSTALL THE EXHAUST MUFFLER AND PIPES.

NOTICE
• Replace the gasket with a new one.
• The mounting portion of the exhaust manifold is subjected to
heat and is likely to come loose, so special nuts are
employed. Be sure to use the correct nuts.
• When tightening the clamp, first tighten the upper bolt then
the lower bolt.
• Removal and installation should be done completely.
• Fit the clamp to the muffler as shown in the figure.
MUFFLER
SLIT • Caution when handling and assembling the catalytic muffler.
The ceramic part, which is easily broken, is contained inside
TAIL PIPE
the muffler. Be careful not to apply shocks to it. Excessive
loads, hitting of hard things such as tools etc., onto the
VEHICLE
FRONT
edges could cause it to shatter and drop off.
! 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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧝㧤ಽ
LUBRICATING SYSTEM (J08E) EN05–1
LUBRICATING SYSTEM (J08E)

EN05
EN05-001
LUBRICATING SYSTEM .......................... EN05-2

DIAGRAM ........................................................ EN05-2
OIL PUMP AND OIL STRAINER .............. EN05-4

OVERHAUL ..................................................... EN05-5
INSPECTION AND REPAIR ............................ EN05-6
OIL FILTER AND OIL COOLER ............... EN05-7

SPECIAL TOOL ............................................... EN05-9
EN05–2 LUBRICATING SYSTEM (J08E)
LUBRICATING SYSTEM
DIAGRAM
EN0110605J100001
EXCEPT J08E-UF, UG
ROLLER
PIN
CAM ROLLER
CROSS ADJUST ROCKER ROCKER ARM

VALVE
HEAD SCREW ARM SHAFT
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
PISTON COOLING JET SUB

(CHECK VALVE) OIL HOLE
MAIN IDLE
GEAR SHAFT
AIR COMPRESSOR
IDLE GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011060500001
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧞㧢ಽ
J08E-UF, UG
ROLLER
PIN
CAM ROLLER
CROSS ADJUST ROCKER ROCKER ARM

VALVE
HEAD SCREW ARM SHAFT
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
PISTON COOLING JET SUB

(CHECK VALVE) OIL HOLE
MAIN IDLE
GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011060500002
OIL PUMP AND OIL STRAINER

COMPONENT LOCATOR
EN0110605D100001
EXCEPT J08E-UF, UG
1 A
8 9
SHTS011060500003
1 Gasket 6 Safety valve

2 Oil pump 7 Relief spring
3 Driven gear 8 Spring seat
4 Oil strainer 9 Cotter pin
5 O-ring

A 28.5 {290, 21}
J08E-UF, UG
SHTS011060500004
1 Gasket 6 Safety valve

2 Oil pump 7 Relief spring
3 Driven gear 8 Spring seat
4 Oil strainer 9 Cotter pin
5 O-ring

A 28.4 {290, 21} B 31 {320, 23}
OVERHAUL
EN0110605H200001
1. INSTALLING THE OIL PUMP.

(1) Apply oil to the pump case and bearings of the block (hatched
area) before installing the oil pump.
NOTICE
Not applying oil may cause oil suction failure at start-up, resulting
in seizure and abnormality.
(2) To prevent misalignment of the gasket, apply grease to the gasket
matching face of the block. Then, place and fix the gasket.
(3) Tighten the oil pump mounting bolts provisionally in the order as
SHTS011060500005 shown in the figure. Tighten them to the specified torque.

EN0110605H300001
Unit: mm {in.}
Gear outside diameter 54 {2.126} — — Measure
Block side pump body

54 {2.126} — —
inside diameter
0.100-0.202 Replace gear or

Tip clearance 0.30 {0.0118}
{0.004-0.0079} pump.
Gear width 37.5 {1.476} — — Measure
Block side pump body

37.5 {1.476} — —
inside depth

End play 0.15 {0.0059}
{0.0020-0.0044} pump.
Shaft outside Measure

18 {0.709} — —
diameter
Block side
bushing inside 18 {0.709} — —
diameter
Drive gear

Clearance —
{0.0016-0.0038} bushing.
Shaft outside Measure

18 {0.709} — —
diameter
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
0.040-0.083 Replace pump or

Clearance 0.15 {0.0059}
{0.0016-0.0032} bushing.
Measure
0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0081}
OIL FILTER AND OIL COOLER

COMPONENT LOCATOR
EN0110605D100002
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
1 Oil cooler with filter assembly 6 Regulator valve

2 O-ring 7 Oil filter safety valve
3 Oil cooler element 8 Oil cooler safety valve
4 Gasket 9 Insert
5 Oil cooler case 10 Oil filter element

A 29.4-39.2 {300-400, 22-28} D 19.6-29.4 {200-300, 15-21}
B 24.5-34.3 {250-350, 19-25} E 28.4 {290, 21}
C 39.2-49.0 {400-500, 29-36}
J08E-UF, UG
SHTS011060500012
1 Oil cooler with filter assembly 6 Regulator valve

2 O-ring 7 Oil filter safety valve
3 Oil cooler element 8 Check valve
4 Gasket 9 Oil cooler safety valve
5 Oil cooler case 10 Oil filter element

A 29.5-39.2 {300-400, 22-28} F 24.5-34.3 {250-350, 19-25}
B 24.6-34.3 {250-350, 19-25} G 28.4 {290, 21}
C 14.7-24.5 {150-250, 11-18} H 29.4-39.2 {300-400, 22-28}
D 19.7-29.4 {200-300, 15-21} I 19.6-29.4 {200-300, 15-21}
E 14.7-19.5 {150-200, 11-14} J 29.4-39.2 {300-400, 22-28}
SPECIAL TOOL
EN0110605K100001
Prior to starting an engine overhaul, it is necessary to have this special tool.
S0950-31110 OIL FILTER WRENCH

EN0110605H200002
1. REMOVE THE OIL FILTER.

(1) Remove the drain plug from bottom of the oil filter and drain the
engine oil.
SHTS011060500014
(2) Using the special tool, remove the oil filter.

SST: Oil filter wrench (S0950-31110)
NOTICE
Make sure that O-rings are not on the oil cooler case side.
SHTS011060500015
1. INSTALL THE OIL FILTER.

(1) Remove the dust on installation surface of oil cooler case side.
(2) Apply the engine oil to the O-ring on new oil filter.
(3) Install the oil filter by turning it lightly to the right by hand until it
comes in contact with the surface of the oil cooler. Then using the
special tool, tighten the oil filter about 270°-360° (3/4-1 turn).
SST: Oil filter wrench (S0950-31110)
NOTICE
SHTS011060500016 • Do not reuse the O-ring.
• Attention the O-ring to damage.
2. INSTALL THE OIL COOLER AND OIL FILTER ASSEMBLY.

(1) Insert the O-ring into the O-ring groove of the oil cooler.
NOTICE
• Face the flat area of the O-ring toward the oil cooler for instal-
lation.
• Do not reuse the O-ring and gasket.
• Attention the O-ring to damage.
(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

EN0110605H300002
Oil cooler air leakage Air Visual check

Replace
pressure: 588 kPa {6 kgf/ 0 mL —
if necessary.
cm2, 85 lbf/in.2}
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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧠㧡ಽ
COOLING SYSTEM (J08E) EN06–1
EN06 COOLING SYSTEM (J08E) EN06-001
COOLING SYSTEM .................................. EN06-2

DIAGRAM ........................................................ EN06-2
COOLANT PUMP...................................... EN06-4

SPECIAL TOOL ............................................... EN06-5
OVERHAUL ..................................................... EN06-5
THERMOSTAT .......................................... EN06-9

OVERHAUL ................................................... EN06-10
RADIATOR .............................................. EN06-12

SPECIAL TOOL ............................................. EN06-12
OVERHAUL ................................................... EN06-13
COOLING FAN........................................ EN06-17

2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧠ಽ
EN06–2 COOLING SYSTEM (J08E)
COOLING SYSTEM
DIAGRAM
EN0110606J100001
1
4
2
5
11
3 12
10
7 9
8 13
14 14
SHTS011060600001
1 Reservoir tank 8 Coolant pump

2 Radiator cap 9 Air compressor
3 Radiator 10 Turbocharger
4 Coolant temperature gauge 11 Cylinder head
5 Thermostat case 12 Cylinder block
6 Thermostat 13 Oil cooler
7 Car heater (If so equipped) 14 Drain plug
MODELS FOR HONG KONG, SINGAPOLE AND TAIWAN
2 12
5 18
4
3 6
13
8 7
17
14
16
11
15
16
10
9
SHTS011060600002
1 Reservoir tank 10 EGR valve

2 Radiator cap 11 Coolant pump
3 Radiator 12 EGR cooler
4 Coolant temperature gauge 13 Cylinder head
5 Water outlet 14 Cylinder block
6 Thermostat case 15 Oil cooler
7 Thermostat 16 Drain plug
8 Thermostat case cover 17 Turbocharger
9 Air compressor 18 Car heater
COOLANT PUMP
COMPONENT LOCATOR
EN0110606D100001
11
10
7
6
SHTS011060600003
1 Fan pulley spacer 7 Retainer ring

2 Fan pulley 8 Coolant shaft
3 O-ring 9 Pump case
4 Coolant pump assembly 10 Coolant seal
5 Water hose through joint (If so equipped) 11 Vane
6 Pulley center
SPECIAL TOOL
EN0110606K100001
For coolant pump pulley cen-

S0942-01810 PULLER
ter
S0942-01820 PULLER For coolant pump vane
S0948-22060 PRESS For coolant pump seal
OVERHAUL
EN0110606H200001
1. DISASSEMBLE THE COOLANT PUMP.

(1) Remove the vane from the shaft using the special tool.
SHTS011060600007
(2) Remove the pulley center from the shaft using the special tool.
SHTS011060600008
(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
1. ASSEMBLE THE COOLANT PUMP.

(1) Install the coolant shaft onto the pump case using a hydraulic
press.
Assembly standard (A): 4.9-5.1 mm {0.193-0.200 in.}
NOTICE
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.
SHTS011060600012
(2) Install the retainer ring onto the pump case using snap ring pliers.
SHTS011060600013
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧡ᤨ㧡㧣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
(4) Install the new coolant seal.

a. Apply liquid gasket (ThreeBond #1104 or equivalent) to the
seal outer circumference and case bore.
b. Install the slinger and seal to the case using a press.
SST: Press (S0948-22060)
SHTS011060600015
c. Install the seal to the vane.

NOTICE
Replace the coolant seal with new one.
SHTS011060600016
(5) Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.6-1.2 mm {0.0237-0.0472 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

EN0110606H300001
Unit: mm {in.}
Inspection item Standard LImit Remedy Inspection procedure
Visual check
Wear, damage and

— — Replace parts.
corrosion
Measure
Tightness of shaft and 0.017-0.048 Replace shaft and/or

—
vane {0.0007-0.0018} vane.
Measure
Tightness of shaft and 0.017-0.051 Replace shaft and/or

—
pulley center {0.0007-0.0020} pulley center.
NOTICE
• Tightness= Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is
within the standard value.
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧠ಽ
THERMOSTAT
COMPONENT LOCATOR
EN0110606D100002
2
3
4
1
5
6
2
SHTS011060600021
1 Thermostat case assembly 4 Thermostat case

2 Thermostat case cover 5 Thermostat
3 O-ring 6 Gasket
MODELS FOR HONG KONG, SINGAPOLE AND TAIWAN
1
2
4
5
6
SHTS011060600022
1 Water outlet 4 Thermostat

2 O-ring 5 Gasket
3 Thermostat case 6 Thermostat case cover
OVERHAUL
EN0110606H200002
IMPORTANT POINT - INSPECTION AND REPAIR

T1 : Valve opening temperature
T2 : Valve opened temperature 1. INSPECT THE THERMOSTAT FUNCTION.
13 mm (1) Place the thermostat in hot water and check the valve opening
{0.518 in.}
temperature and the valve lift.
Thermostat valve opening temperature:
Thermostat valve opening tem-
Service standard
perature. (T1)
82°C {180°F} 80-84°C {176-183°F}
SHTS011060600023 NOTICE
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
Thermostat valve lift:

Thermostat valve Measuring temp.
Valve lift (L2-L1)
opening temp. (T1) (T2)
13 mm {0.512 in.} or
82°C {180°F} 95°C {203°F}
more
L 1: When cold
L 2: When (T2 ) C
L 2-L1: Valve lift (2) Immerse the opened thermostat in water at normal temperature. If
it completely closes within 5 minutes, it is satisfactory. If it remains
slightly open, it is defective and must be replaced.
SHTS011060600024
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.
1. INSTALL THE THERMOSTAT CASE ASSEMBLY.

(1) Apply liquid gasket to the thermostat case.
LIQUID GASKET (2) Install the o-ring into the groove of the coolant pump.
SHTS011060600026
(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
RADIATOR
COMPONENT LOCATOR
EN0110606D100003
11
7
10
9 3
8
7
6
5
4
SHTS011060600029
1 Radiator cap 7 O-ring

2 Upper tank 8 Distance piece
3 Radiator core 9 Radiator fitting cushion
4 Left support 10 Right support
5 Drain plug 11 Coolant level switch
6 Lower tank

A 6-7 {62-71, 4.5-5.1}
SPECIAL TOOL
EN0110606K100002
Prior to starting a radiator overhaul, it is necessary to have these special tools.
S0976-01030 RADIATOR TOOL For uncaulking
For caulking
S0976-01040 RADIATOR TOOL
(Used with S0976-01030)
OVERHAUL
EN0110606H200003
1. DISMOUNT THE RADIATOR.

! WARNING
To avoid the danger of burns and scalds, do not drain the coolant
while the engine and radiator are still hot.
NOTICE
When dismounting and mounting the radiator, do not damage the
radiator core.

NOTICE
Recaulking should be limited to twice.
1. DISASSEMBLE THE UPPER TANK, LOWER TANK AND RADI-

ATOR CORE.
(1) Remove the left support and right support.
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
(3) Using a special tool, lift the staked part.

NOTICE
Do not lift up tangs more than 90°.
SHTS011060600034
(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
1. ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIA-

TOR CORE.
(1) Exchange the crow of the radiator tool (S0976-01030) for the radi-
ator tool (S0976-01040) as shown in the figure.
SST:
Radiator tool (S0976-01030)
Radiator tool (S0976-01040)
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
(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
(7) Check the dimension C.

Assembly standard: 7.27-7.85 mm {0.2863-0.3090 in.}
If the dimension is out of the standard value, adjust the stopper
bolt of the handle once again and perform the caulking again.
SHTS011060600042

EN0110606H300002
Unit: MPa {kgf/cm2, lbf/in.2}
Air leakage (When the air Visual check

pressure of 100 {1,14} is — — Replace radiator.
applied.)
Clogging of the Fines — — Clean.
Radiator cap Measure

valve open-
ing pressure
40-58
Mark 0.5 — Replace.
{0.4-0.6, 5.7-8.5}
Intercooler
• Air leakage test
(when the air pres- 0 mL —
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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧟㧜ಽ
COOLING FAN
COMPONENT LOCATOR
EN0110606D100004
3
SHTS011060600046
1 Cooling fan 3 Fan pulley spacer

2 Fan clutch
NOTICE
• Shock to the fan clutch and fan.
During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting
damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become
damaged or deformed if force is applied to it.
• Replace the fan.
Do not replace the fan unless it is faulty. When replacing the fan, replace with the same type. If the fan is
replaced with one of a larger capacity because of overheating or, conversely is replaced with one of a smaller
capacity due to overcooling, the performance may in fact be reduced and durability may be jeopardized.
• Other items
Check the bimetal to see if there is any mud or dust on it. If the bimetal is covered with mud or dust, the fan
performance will be erratic, and may result in overheating or overcooling. In such case, carefully remove
mud and dust adhering to the surface of the bimetal, using a wire brush, or the like.
Take particular care not to apply excessive force.
Do not paint the fan or fan clutch. Do not place any paint or other reagents which are likely to dissolve plastic
in contact with the fan.

EN0110606H300003
Visual check
Cooling fan and fan clutch Replace

— —
deformation and damage if necessary.
2A'0AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧠㧟ಽ
FUEL SYSTEM (J08E) EN07–1
FUEL SYSTEM (J08E)

EN07
EN07-001
FUEL SYSTEM
(EXCEPT J08E-UF, UG)............................ EN07-2
DIAGRAM ........................................................ EN07-2
FUEL SYSTEM (J08E-UF, UG)................. EN07-4

DIAGRAM ........................................................ EN07-4
DESCRIPTION ................................................ EN07-5
SPECIAL TOOL ............................................... EN07-6
OVERHAUL ..................................................... EN07-6
SUPPLY PUMP
(EXCEPT J08E-UF, UG)............................ EN07-9
DESCRIPTION ................................................ EN07-9
SPECIAL TOOL ............................................. EN07-10
OVERHAUL ................................................... EN07-11
COMMON RAIL....................................... EN07-15

DESCRIPTION .............................................. EN07-15
OVERHAUL ................................................... EN07-16
INJECTOR (EXCEPT J08E-UF, UG) ...... EN07-21

DESCRIPTION .............................................. EN07-21
OVERHAUL ................................................... EN07-22
INJECTION NOZZLE
(TWO-SPRING TYPE - DENSO MAKE)
(J08E-UF, UG) ......................................... EN07-25
DESCRIPTION .............................................. EN07-25
SPECIAL TOOL ............................................. EN07-27
OVERHAUL ................................................... EN07-28
FUEL FILTER .......................................... EN07-34

DESCRIPTION .............................................. EN07-34
FUEL TANK............................................. EN07-36

2A'0AA/QMKLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧣ಽ
EN07–2 FUEL SYSTEM (J08E)
FUEL SYSTEM (EXCEPT J08E-UF, UG)

DIAGRAM
EN0110607J100001
5 4 3 2
13
6 12
11
7
9
10
8
SHTS011060700001
1 Injector 8 Fuel filter

2 Injection pipe 9 Fuel prefilter
3 Flow damper 10 Fuel tank
4 Common rail 11 Through feed pipe
5 Force feed pipe 12 Overflow pipe
6 Pressure limiter 13 Leakage pipe
7 Supply pump
COMPONENT LOCATOR
EN0110607C100001
SHTS011060700002
1 Injector 3 Common rail

2 Supply pump 4 Fuel filter

A 25 {250, 18} C 44 {450, 32}
B 54 {550, 40} D 55 {560, 41}
FUEL SYSTEM (J08E-UF, UG)

DIAGRAM
EN0110607J100002
SHTS011060700003
1 Return pipe 5 Feed pump

2 Injection nozzle 6 Fuel filter
3 Through feed pipe 7 Injection pipe
4 Fuel tank
DESCRIPTION
EN0110607C100002
SHTS011060700004
1 Injection nozzle 3 Fuel injection pump

2 Fuel filter

A 12.3 {125, 9} C 25 {250, 18}
B 34 {350, 25}
SPECIAL TOOL
EN0110607K100001
S0950-31040 FUEL FILTER WRENCH
INJECTION PUMP COUPLING

S0981-91707
WRENCH
OVERHAUL
EN0110607H200001
1. REMOVE THE FUEL INJECTION PUMP.

(1) Disconnect the fuel lines, oil lines and engine control lines.
(2) Remove the through bolt of the coupling and loosen the adjusting
bolt using the special tool.
(3) Remove the injection pump mounting bolt and dismount the
pump.
SST: Wrench (S0951-52470)
After dismounting the pump, cover the pump and high pressure
pipe to prevent entry of dirt.
1. INSTALL THE FUEL INJECTION PUMP.

(1) To adjust the injection timing, turn the flywheel in the rotation
direction (counterclockwise viewed from the flywheel side). Align
the pointer at the inspection side on the flywheel housing to injec-
tion timing before top dead center for No.1 cylinder compression
stroke.
SHTS011060700008
(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: Wrench (S0951-52470)
Tightening Torque:
SHTS011060700010
(4) Tighten the adjusting bolt using the special tool.

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}
(6) Install pipes and engine control cables.

NOTICE
SHTS011060700011 Cylinder numbers are stamped on the flare nuts at the pump side
of the injection pipe.
1. REMOVE THE FUEL FILTER.

(1) Remove the fuel filter using the special tool.
SST: Fuel filter wrench (S0950-31040)
SHTS011060700012
2. INSTALL THE FUEL FILTER.

(1) Remove the dust on installation surface.
(2) Apply light oil to gasket of new fuel filter.
(3) Install the fuel filter by turning it lightly to the right by hand until it
comes in contact with the surface of the fuel filter cover. Then
using the special tool, tighten the fuel filter about 240° (2/3 turn).
SST: Fuel filter wrench (S0950-31040)
NOTICE
• Do not reuse the element.
• Be careful not to damage the gasket.
SHTS011060700013
AIR BLEEDING FROM FUEL SYSTEM

BLEEDER PLUG
1. BLEED AIR FROM THE FUEL FILTER.
(1) Bleed air from the fuel filter.
(2) Loosen the bleeder plug on the fuel filter.
(3) Operate the priming pump knob until the air will not come out from
the bleeder plug.
(4) Tighten the bleeder plug.
Tightening Torque:
4.9-8.9 N⋅m {50-90 kgf⋅cm, 3.7-6.5 lbf⋅ft}
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.
SUPPLY PUMP (EXCEPT J08E-UF, UG)

DESCRIPTION
EN0110607J100003
SHTS011060700015
1 Supply pump assembly

COMPONENT LOCATOR
EN0110607C100003
5
B
8
7 3
4
A
SHTS011060700016
1 Supply pump assembly 5 Bracket

2 Bearing holder case 6 Coupling assembly
3 O-ring 7 Plug
4 Coupling flange 8 Gasket

A 63.7 {650, 47} B 28.5 {290, 21}
SPECIAL TOOL
EN0110607K100002
SZ105-08067 GUIDE BOLT

OVERHAUL
EN0110607H200002
IMPORTANT POINTS - DISMOUNTING
1. TURN THE STARTER SWITCH TO THE LOCK POSITION.
! 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
2. POSITION THE No.1 CYLINDER TO THE TOP DEAD CENTER.

(REPRESENTATIVE TYPE) (1) Turn the crankshaft counterclockwise (viewed from the flywheel
side) to align mark "1" or "16" on the outer periphery of the fly-
wheel with the pointer of the flywheel housing.
FLYWHEEL
NOTICE
Always turn the crankshaft counterclockwise (viewed from the fly-
1
wheel side).
FLYWHEEL
HOUSING
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 don't tighten in too much. In this case, the timing is not fit. So, per-
INSPECTION SEATED form again the setting for Top Dead Center of No.1 cylinder com-
HOLE PLUG pression stroke in above (1).
SHTS011060700020
3. REMOVE THE FUEL SUPPLY PUMP.

OVERFLOW PIPE HINT
When the flow amount lacking, visit DENSO service center for the
FUEL PIPE
repair.
FORCE FEED (1) Disconnect the fuel lines, oil lines and harness connector.
PIPE
NOTICE
PIPE A Do not disconnect the pipe A and B shown in the figure.
SUPPLY PUMP
PIPE B
SHTS011060700021
(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

SUPPLY PUMP
1. INSTALL THE FUEL SUPPLY PUMP.
O-RING
(1) Install the O-ring to the supply pump.
(2) Replace the O-ring with a new one and install the bearing holder
to the supply pump.
BEARING
HOLDER CASE
SHTS011060700025
(3) Install the coupling flange to the shaft.

BEARING HOLDER CASE (4) Fixing the supply pump and performing the turning stop of Cou-
pling flange with hand-vice or the like, tighten the nut in.
NOTICE
Don't use the special tool to stop the turning of Shaft.
SST
COUPLING
FLANGE
TURNING STOPPER HOLE

SHTS011060700026
(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-
SHTS011060700026 ance of the tip is 2 mm {0.079 in.}).
(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
2. RESETTING FOR THE VALUES OF SUPPLY PUMP.

(1) Reset the values memorized in Engine ECU by re-programing
when replacing Supply pump.
NOTICE
Unless the same values are not reset, correct control of common
rail will not be done, which will cause Engine stall or abnormality
in high common rail pressure. Therefore, make sure to reset the
same values when replacing Supply pump.
IMPORTANT POINT - ONBOARD INSPECTION

FUEL TEMPERATURE SENSOR
1. INSPECT THE SUCTION CONTROL VALVE (SCV) AND FUEL
SUCTION CONTROL VALVE TEMPERATURE SENSOR.
(1) Measure the resistance between terminals.
If not standard value, replace supply pump assembly.
Standard:
SCV 7.65-8.15 Ω at 20°C {68°F}
Fuel temperature sensor 13.5-16.5 kΩ at - 20°C {-4°F}

SHTS011060700029 2.2-2.7 kΩ at 20°C {68°F}
0.29-0.35 kΩ at 80°C {176°F}
NOTICE
If SCV and fuel temperature sensor need replacements, they
should be serviced by Denso service dealer.
COMMON RAIL
DESCRIPTION
EN0110607J100004
2 3
SHTS011060700030
1 Common rail 3 Flow damper

2 Pressure limiter 4 Pressure sensor
OVERHAUL
EN0110607H200003

(EXAMPLE)
1. CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND

THE FUEL LINE CONNECTORS.
NOTICE
If foreign matter is allowed to enter the combustion chamber,
engine trouble may result.
2. REMOVE THE FUEL INJECTION PIPE.

(1) Remove the return pipe.
(2) Loosen the injection pipe nut.
SHTS011060700031 (3) Remove the force feed pipe.
NOTICE
Cover open ends of the pipes and fuel supply pump to prevent
entry of dirt.
SHTS011060700032
3. REMOVE THE COMMON RAIL

(1) Disconnect the connectors.
(2) Remove the 2 bolts and common rail.
SHTS011060700033
1. REMOVE THE FLOW DAMPER

(1) Using a 19 mm {0.749 in.} width across flats deep socket wrench,
STOPPER
loosen the flow damper by turning in counter-clockwise direction.
PISTON SPRING (2) Remove the flow damper assembly (spring, piston and stopper).
NOTICE
Be careful not drop parts into common rail.
SHTS011060700034
2. REMOVE THE PRESSURE LIMITER.

loosen the pressure limiter by turning in counter-clockwise direc-
tion.
(2) Remove the pressure limiter.
(3) Using tweezers, remove the gasket.
NOTICE
Be careful not to damage the seal surface.
SHTS011060700035
3. REMOVE THE COMMON-RAIL PRESSURE SENSOR.

loosen the common-rail sensor by turning in counter-clockwise
direction.
(2) Remove the common-rail sensor.
NOTICE
Never reuse a used common-rail pressure sensor.
Because if it is reused, its thread may break.
SHTS011060700036

NOTICE
• Every part of the common rail should be washed clean care-
fully laying threaded side below.
APPLY
GREASE • Be careful to prevent dust from entering inside.
1. INSTALL THE COMMON-RAIL PRESSURE SENSOR.

(1) Install the new common-rail pressure sensor.
NOTICE
• Apply clean grease to the pressure sensor as shown in the
SHTS011060700037 figure.
• Be careful to prevent dust from entering inside.
(2) Tighten the new pressure sensor.
Tightening Torque:
98 N⋅m {1,000 kgf⋅cm, 72 lbf⋅ft}
2. INSTALL THE PRESSURE LIMITER.

(1) Install the pressure limiter with a new gasket.
Tightening Torque:
172 N⋅m {1,750 kgf⋅cm, 126 lbf⋅ft}
GASKET
SHTS011060700038
3. INSTALL THE FLOW DAMPER.

(1) Install the stopper.
(2) Install the flow damper with the piston and spring.
Tightening Torque:
STOPPER 128 N⋅m {1,305 kgf⋅cm, 94 lbf⋅ft}
PISTON SPRING
SHTS011060700039
1. INSTALL THE COMMON RAIL ASSY.

(1) Install the common rail with 2 bolts.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
(2) Connect the connector.

NOTICE
• Be careful to prevent dust from entering inside the common
rail and parts when the mounting is performed. Dust and for-
SHTS011060700040
eign matter must not adhere to the seats of the parts and
common rail main unit.
• After mounting is completed, check fuel leak using "Activa-
tion Test" menu of HINO DX.
(3) Tighten the injector pipe nuts to the specified torque.
(EXAMPLE)
Tightening Torque:
SHTS011060700041
(4) Tighten the force feed pipe nuts to the specified torque.
(EXAMPLE)
Tightening Torque:
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'0AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧠㧝ಽ
IMPORTANT POINTS - ONBOARD INSPECTION
1. INSPECT THE PRESSURE SENSOR.

(1) If the diagnosis monitor light come on, and the following malfunc-
tion is displayed at the diagnosis system, replace the pressure
sensor.
a. Harness disconnection or short-circuit in the pressure sensor
circuit
b. Common rail pressure does not change at a certain time
while the engine is running.
If not standard value, replace sensor.
Standard: (Engine stop condition)
Terminal 2 and 3 6.5 - 18.5 kΩ
Terminal 1 and 2 0.5 - 3.0 kΩ
1 2 3
SHTS011060700043
2. INSPECT THE PRESSURE LIMITER.

(EXAMPLE)
(1) Remove the follow screw from pressure limiter.
(2) Block pipe ends to prevent fuel leak.
BLOCK PIPE ENDS
REMOVE THE FOLLOW SCREW
SHTS011060700044
(3) Install the union to the pressure limiter.

(EXAMPLE) (4) Set a vinyl hose to the union and set a drain tank.
(5) Start the engine. If the fuel flows continuously, replace the pres-
sure limiter.
! WARNING
UNION When the pressure limiter is working, fuel flows out at a high tem-
perature and pressure. Serious injury like scalding could result
VINYL HOSE
from this hot fuel being blown out under pressure.
DRAIN TANK
SHTS011060700045
3. INSPECT THE FLOW DAMPER.

(1) Check that the piston is not sticking in the body. If the piston
sticks, replace the flow damper.
(2) Inspect the contact surface 1 between piston and fuel supply port.
If there is wear and damage, replace the flow damper assembly.
(3) Inspect clogging on the piston orifice. Clean or replace the flow
damper assembly.
SHTS011060700046
INJECTOR (EXCEPT J08E-UF, UG)

DESCRIPTION
EN0110607C100004
7
1
8
2
3
4
9
5 10
6 11
12
13
14
15
16
17
SHTS011060700047
1 Return joint bolt 10 Lower body

2 Gasket 11 Guide bushing
3 Outlet connector 12 Shim
4 Steel washer 13 Nozzle spring
5 Filter 14 Pressure pin
6 Inlet connector 15 Tip seal
7 O-ring 16 Nozzle
8 Two-way valve (TWV) 17 Retaining nut
9 Piston
OVERHAUL
EN0110607H200004

NOTICE
2. REMOVE THE INJECTOR.

(1) Disconnect of the harness coupler.
(2) Remove the leakage pipe.
SHTS011060700048
(3) Remove the injection pipe.
(4) Remove the bolt of the injection pipe seal and pull it with the injec-
tion pipe from the camshaft housing.
NOTICE
Cover open ends of the pipes and fuel supply pump to prevent
entry of dirt.
3. REMOVE THE INJECTOR ASSEMBLY.

(1) Remove the injector clamp bolt.
(2) Pull out the injector assembly taking care not to contact other
parts.
BOLT (3) Remove the O-ring.
INJECTOR NOTICE
Replace the O-ring with a new one.
INJECTION
PIPE
CLAMP
OIL SEAL
O-RING
SHTS011060700049
2A'0AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧡㧡ಽ
1. INSTALL THE INJECTOR ASSEMBLY.

(1) Install a new O-ring into the groove of the cylinder head, and then
BOLT
INJECTOR insert the injector.
NOTICE
Apply engine oil to the O-ring, so that the O-ring will not be
INJECTION
PIPE caught.
(2) Install the injector clamp, and install the injector temporarily.
NOTICE
CLAMP Do not fix the injector clamp before the injection pipe is tempo-
rarily installed.
(3) Cover the injector with a new injection pipe oil seal, and then
install the plate and nut.
OIL SEAL NOTICE
Be careful not to apply excessive force to the injector when apply-
O-RING ing the injection pipe oil seal to it. If the injection pipe oil seal and
injector are moved even slightly, it may cause oil leakage or faulty
assembling of the injection pipe.
(4) Assemble the injection pipe temporarily, and tighten the installa-
tion bolt of the injector clamp.
Tightening Torque:
SHTS011060700050 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
(5) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
(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}
(7) Connect the harness couplers.
2. ENTER THE ID CODES IN THE ECU.

(1) QR (Quick Response) codes displaying various injector character-
istics and are engraved on the injector head.
NOTICE
• When replacing injectors with QR codes, or the engine ECU,
it is necessary to record the ID codes (QR codes) in the ECU
by using the Diagnostic tool. (If the ID codes of the installed
injector are not registered correctly, engine failure such as
rough idling and noise will result.)
• For registering the ID codes, refer to the instruction manual
supplied with parts box of replacement injectors.
SHTS011060700051
IMPORTANT POINT - ONBOARD INSPECTION
1. INSPECT THE INJECTOR.

UPPER If not standard value, replace injector assembly.
BODY
Standard:
0.35-0.55 Ω at 20°C {68°F}
SHTS011060700052
(2) Measure the resistance of insulation between terminals and

upper body. If not standard value, replace injector assembly.
Standard:
More than 10 MΩ
UPPER NOTICE
BODY Other inspections and nozzle replacements should be done by
Denso service dealer.
(3) Inspect terminals.
Remove any sludge adhering to the terminals or area surrounding
the terminals.
NOTICE
SHTS011060700053 When removing sludge, do not use cleaning fluids.
Use dry cloth. (If cleaning fluids are used, there is a possibility
that an electrical malfunction will occur.)
INJECTION NOZZLE (TWO-SPRING TYPE - DENSO MAKE)

(J08E-UF, UG)
DESCRIPTION
EN0110607C100005
SHTS011060700054
1 Joint bolt 9 Second pressure adjusting shim

2 Gasket 10 Second pressure spring
3 Cap nut 11 Second pressure spring seat
4 Gasket 12 Pre-lift adjusting shim
5 Adjusting screw 13 Distance piece
6 First pressure spring 14 Nozzle assembly
7 Push rod 15 Retaining nut
8 Nozzle holder 16 Pre-lift
2A'0AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧥ᤨ㧠㧞ಽ
COMPONENT LOCATOR
EN0110607D100001
SHTS011060700055
1 Joint bolt 9 Second pressure adjusting shim

2 Gasket 10 Second pressure spring
3 Cap nut 11 Second pressure spring seat
4 Gasket 12 Pre-lift adjusting shim
5 Adjusting screw 13 Distance piece
6 First pressure spring 14 Nozzle assembly
7 Push rod 15 Retaining nut
8 Nozzle holder

A 12.3 {125, 9} C 63.7 {650, 47}
B 53.9 {550, 40}
SPECIAL TOOL
EN0110607K100003
S0942-01442 SLIDING HAMMER
S0946-21130 NOZZLE HOLDER ADAPTER Used with S0942-01442
95991-10150 SOCKET WRENCH
S0946-21420 BASE, TWO-SPRING

OVERHAUL
EN0110607H200005

NOTICE
2. REMOVE THE FUEL INJECTION PIPE.

(1) Remove the return pipe.
(2) Loosen the injection pipe nut.
SHTS011060700060
(3) Remove the bolt of the injection pipe seal and pull it with the injec-
tion pipe from the camshaft housing.
NOTICE
Cover open ends of the pipes and fuel injection pump to prevent
entry of dirt.
3. REMOVE THE NOZZLE HOLDER ASSEMBLY.

(1) Remove the nozzle clamp bolt.
(2) Pull out the nozzle holder assembly taking care not to contact
other parts. If it is difficult to remove the assembly, use of the spe-
cial tool.
SST:
Sliding hammer (S0942-01442)
Nozzle holder adapter (S0946-21130)
(3) Remove the O-ring.

NOTICE
Replace the O-ring with a new one.
SHTS011060700061
IMPORTANT POINTS - INSPECTION
1. CHECK THE INJECTION PRESSURE.

(1) Install the nozzle holder assembly to the nozzle tester.
! CAUTION
• Since diesel oil is flammable, check and adjust the nozzle in
a well ventilated room. Never use naked lights in the room.
• Since injected fuel is highly pressurized, direct contact with
the body may be harmful to health. Provide a screen to pre-
vent scattering of fuel.
SHTS011060700062
(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
2. TEST THE SPRAY PROFILE.

(1) In the case of a new nozzle, operate the lever at the rate of 30 to
60 strokes per minute, and for a used nozzle, operate the lever at
the rate of 15 to 16 strokes per minute. If spray is coarse, replace
or clean the nozzle.
SHTS011060700064
3. TEST THE FUEL LEAKAGE.

(1) When checking for fuel leakage from the nozzle, apply a pressure
about 0.99-1.96 MPa {10-20 kgf/cm2, 142.3-284.4 lbf/in.2} lower
than the correct injection pressure to the nozzle using a nozzle
tester.
If faulty, replace or clean the nozzle.
SHTS011060700065
1. REMOVE THE RETAINING NUT

NOTICE
To prevent dropping parts, face the nozzle holder toward the
retaining nut side.
SST: Socket wrench (95991-10150)
SHTS011060700066
IMPORTANT POINT - INSPECTION AFTER DISAS-

SEMBLY
1. TEST THE NOZZLE SINKING.

(1) Wash the nozzle proper with diesel fuel oil, them immerse it in die-
sel fuel oil.
(2) Next slide the needle inside the nozzle proper and ensure that it
moves smoothly. The needle valve should fall under its own
weight when withdrawn vertically about 1/3 its length and
released. If its motion is sluggish, replace the nozzle with a new
one.
When assembling, you must reinstall the same parts in the same
nozzle holder. Do not mix them up.
IMPORTANT POINTS - ADJUSTMENT

SPRING SEAT
DISTANCE PIECE 1. CHECK AND ADJUST PRE-LIFT.
NOZZLE ASSEMBLY
(1) The nozzle assembly, distance piece, and spring seat are
attached in order to the special tool.
NOTICE
Each part must be washed carefully to eliminate any debris.
SPECIAL TOOL
SST: Base, two-spring (S0946-21420)
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) Install the pre-lift adjusting shim.

PRE-LIFT
(4) Measurement the pre-lift.
PRE-LIFT: 0.077-0.113mm {0.0031-0.0044 in.}
SHIM (5) If the pre-lift out of the assembly standard, suitable shims are then
used to adjust this pre-lift value to a standard value.
NOTICE
PRE-LIFT • Thick shims=increase the pre-lift
• Thin shims=decrease the pre-lift
Pre-lift adjusting shim line-up Unit: mm {in.}
SHTS011060700070 Parts number Shim thickness

22885-6820~ 1.30-1.42 {0.052-0.055}
22885-6880 (jump at 0.02)
22885-6900~ 1.44-1.70 {0.057-0.066}
22885-7030 (jump at 0.02)
2. ADJUSTMENT OF THE FIRST OPENING PRESSURE

SECOND PRESSURE NOZZLE HOLDER (1) Attach the second opening pressure adjusting shim, second pres-
ADJUSTING SHIM SECOND PRESSURE sure spring and adjusted parts to the bottom of the nozzle holder.
SPRING
SPRING SEAT (2) Using a wrench, tighten the retaining nut.
DISTANCE PIECE
Tightening Torque:
PRE-LIFT ADJUSTING
SHIM 63.7N⋅m {650kgf⋅cm,47lbf⋅ft}
NOZZLE ASSEMBLY
NOTICE
RETAINING NUT • Adjust the first opening pressure. Then the second opening
pressure is adjusted at the same time.
• Exchange parts is nozzle assembly and opening pressure
SHTS011060700071
adjusting shim. Do not exchange other parts.
(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.
2,632-2,745 lbf/in.2}
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
3. ADJUSTMENT OF SECOND OPENING PRESSURE

NOTICE
SECOND PRESSURE NOZZLE HOLDER
ADJUSTING SHIM SECOND PRESSURE
• This operation is necessary only when changing the second
SPRING pressure adjusting shim, second pressure spring, spring
SPRING SEAT
DISTANCE PIECE
seat, and distance piece. This procedure is not required in
NOZZLE ASSEMBLY other cases.
(1) Preparation
RETAINING NUT After adjusting the first opening pressure, dismantle the bottom of
the nozzle and remove the pre-lift shim. Then assemble the sec-
ond pressure adjusting shim (generally 1.4 mm {0.055 in.}), sec-
ond pressure spring, spring seat, distance piece, and nozzle
SHTS011060700075 assembly. Then attach and tighten the retaining nut.
NOTICE
• Do not install the pre-lift shim.
Tightening Torque:
63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}

(2) Adjustment
The nozzle holder is mounted on a nozzle hand tester to deter-
mine the pressure at the start of injection. This value is used as
the second valve opening pressure. Suitable shims are used to
keep this value within a standard range.
Second opening pressure
4,537-4,678 lbf/in.2}
4,467-4,608 lbf/in.2}
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
22885-7670~ 1.0-1.375 {0.0394-0.0541} (jump
22885-7820 at 0.025 {0.001}
22885-7040~ 1.4-1.7 {0.0551-0.0669} (jump at
22885-7160 0.025 {0.001}
22885-7180~ 1.725-2.1 {0.0679-0.0827} (jump
22885-7330 at 0.025 {0.001}
(3) Confirm the first opening pressure

a. Preparation
After adjusting the second opening pressure, the bottom of
the nozzle is dismantled. Then, the same pre-lift adjusting
SPRING SEAT shim is installed between the spring seat and distance piece.
DISTANCE PIECE
The unit is then reassembled.
PRE-LIFT ADJUSTING
SHIM Tightening Torque:
63.7 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}
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.
2,632-2,745 lbf/in.2}
2,561-2,673 lbf/in.2}
SHTS011060700076
1. INSTALL THE NOZZLE HOLDER ASSEMBLY.

(1) Install a new O-ring into the groove of the cylinder head.
(2) Make sure that there is no dirt or foreign particles at the sealing
part between the nozzle holder and related parts (O-ring, nozzle
seat and injection pipe seal), and connecting part between the
nozzle holder and nut of the injection pipe.
(3) Insert the nozzle holder taking care not to contact the valve spring
as shown in the figure.
NOTICE
Apply clean engine oil to the O-ring and be careful that the O-ring
is not caught.
(4) Put the end of the injection pipe seal on the nozzle holder as
shown in the figure and tighten the bolts to fasten the injection
pipe seal to the camshaft housing.
(5) Tighten the nut of the injection pipe provisionally.
(6) Tighten the nozzle clamp bolt to the specified torque.
Tightening Torque:
24.5 N⋅m {250 kgf⋅cm, 18.1 lbf⋅ft}
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}
(8) Install the return pipe.

FUEL FILTER
DESCRIPTION
EN0110607J100005
SHTS011060700079
1 Hand priming pump 5 Vent plug

2 Element 6 Center bolt
3 Drain plug 7 Body
4 Water level sensor 8 Cap
COMPONENT LOCATOR
EN0110607C100006
SHTS011060700080
1 Center bolt 7 Element

2 O-ring 8 Gasket
3 Vent plug 9 Body
4 Cap 10 Hand priming pump
5 Spring 11 Water level sensor
6 Holder 12 Drain plug
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}1

A 24.5-34.3 {250-350, 18.1-25.3} B 4.9-8.9 {50-91, 3.6-6.5}
FUEL TANK
COMPONENT LOCATOR
EN0110607J100006
(REPRESENTATIVE TYPE: 200L+200L) 3

1
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
1 Fuel tank 8 Fuel plug

2 Fuel tank band 9 Fuel drain plug
3 Fuel tank cap 10 Elbow
4 Fuel tank support 11 Hose
5 Bracket 12 Fuel feed pipe
6 Fuel cock 13 Clip
7 Fuel sender gauge 14 Gasket

A 73-109 {745-1,111, 54-80} C 19.6-39.2 {200-400, 14-28}
B 10-13 {102-132, 7-9}
2A'0A806A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧠㧤ಽ
TURBOCHARGER (J08E: VARIABLE NOZZLE TURBINE TYPE) EN08–1
TURBOCHARGER EN08
EN08 (J08E: VARIABLE NOZZLE TURBINE TYPE)

EN08-001
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
SPECIAL TOOL ............................................. EN08-11
EN08–2 TURBOCHARGER (J08E: VARIABLE NOZZLE TURBINE TYPE)
TURBOCHARGER
DESCRIPTION
EN0110608C100001
7 5-B 4-A
2 3 1
SHTS011060800001
1 Turbine housing 5 Compressor bolt

2 Compressor housing 6 Actuator assembly
3 Center housing and rotating assembly 7 O-ring
4 Turbine bolt

A 20.9-24.3 {213-248, 15.4-17.9} B 10.8-14.2 {110-145, 7.9-10.4}
NOTICE
This turbocharger should not be disassembled unless by turbo-
charger manufacture. The turbocharger parts cannot be replaced.
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
Possible causes and remedies

(See Notes A and H✩) (See Notes G and C✩) (See Notes D,F and G✩)
NO Loose compressor NO NO NO
Dirty air cleaner Leakage at engine Leakage at engine
to intake manifold
element intake manifold exhaust manifold
duct connections
YES YES YES YES
Tighten duct Refer to engine Refer to engine

Replace air cleaner
connections as manufacturer's manufacturer's
element
required service manual service manual
(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
YES YES YES YES
Check condition of Perform

Remove restriction Remove restriction
gasket at troubleshooting
or replace or replace
turbocharger procedures
turbocharger as turbocharger as
mounting flange and outlined in table 1-
necessary necessary
tighten loose bolts 7
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.)
YES YES YES
Remove restriction
Refer to engine Refer to engine
or replace
manufacturer's manufacturer's
turbocharger as
service manual service manual
necessary
SHTS011060800002
✩ Shown on Table 1-9

2. Table 1-2. Troubleshooting Engine Exhaust Emits WHITE or BLUE SMOKE
ENGINE EXHAUST
SYMPTOM O R TROUBL E EMITS WHITE OR
BLUE SMOKE
POSSIBLE CAUSES AND REMEDIES

(See Notes A and H✩) (See Not es H✩)
Restricted duct be-

Seal leakage at
Dirty air cleaner NO Plugged engine oil NO tween air cleaner NO NO
compressor end of
element filter and turbocharger
turbocharger
compressor
YES YES YES YES
Service oil filter in

Remove restriction Perform
Replace air cleaner accordance with
or replace damaged troubleshooting
element engine
parts as necessary procedures outlined
manufacturer's
in Table 1-6
service manual
Engine malfunction NO Seal leakage at

(rings,pistons, turbine end of
valves,etc) turbocharger
YES YES
Perform
Refer to engine
troubleshooting
manufacturer's
procedures outlined
service manual
in Table 1-7
SHTS011060800003
✩ Shown on Table 1
3. Table 1-3. Troubleshooting Engine Oil Consumption Excessive
ENGINE OIL
SYMPTOM OR TROUBLE CONSUMPTION
EXCESSIVE
Seal leakage at Seal leakage at Oil in engine exhaust

Wrong type or vis- compressor end of turbine end of manifold (indicating
cosity of engine NO turbocharger (indicated NO turbocharger NO malfunction of
lubricating oil by oil in housing or on (indicated by oil in rings,pistons,valves,
wheel) housing or on wheel) etc)
YES YES YES YES
Service engine lube

system in Perform
Perform troubleshoot- Refer to engine
accordance with troubleshooting
ing procedures out- manufacturer's
engine procedures outlined
lined in Table 1-6 service manual
manufacturer's in Table 1-9
service manual
SHTS011060800004
4. Table 1-4. Troubleshooting Noisy Turbocharger
NOISY
SYMPTOM OR TROUBLE TURBOCHARGER

(See Notes A and H✩) (See Notes H✩)
Foreign object or
Foreign object or
material in Foreign object in
Dirty air cleaner NO NO material in NO
compressor inlet engine exhaust
element compressor to intake
duct or system
manifold duct
compressor housing
YES YES YES YES
Remove foreign Remove foreign Remove foreign

object. Repair air object. Repair air object. Repair NO
Replace air
intake system and intake system and exhaust system and
cleaner element
replace turbocharger replace turbocharger replace turbocharger
as necessary as necessary as necessary
NO Turbocharger rotating NO Loose intake or

Carbon build-up in
assembly binding or exhaust duct
turbine housing
dragging systems
YES YES YES
Clean housing or
Perform
replace turbocharger
troubleshooting
as required. Eliminate all leaks
procedures outlined
Check engine
in Table1-5
operating procedures
SHTS011060800005

5. Table 1-5. Troubleshooting Turbocharger Rotating Assembly Binding or Dragging
TURBOCHARGER
ROTATING
SYMPTOM OR TROUBLE
ASSEMBLY BINDING
OR DRAGGING

(See Notes J✩)
Damaged
Damaged turbine Compressor wheel or Excessive dirt build-
compressor wheel NO NO NO NO
wheel due to foreign turbine wheel rubbing up in compressor fan
due to foreign object
object impact on housing housing or wheel
impact
YES YES YES YES
Clean and repair air Clean and repair air

Clean and repair Worn bearings,shaft
intake system as intake system as
engine exhaust jourmals,or bearing
necessary. Replace necessary. Clean
system as necessary. bores. Replace
turbocharger compressor or
Replace turbocharger turbocharger
replace turbocharger
Excessive carbon
build-up behind NO Sludged or cocked
turbine wheel center housing
YES YES
Coked oil combustion

Service engine
deposits.
lubrication system.
Replace
Replace
turbocharger
turbocharger
SHTS011060800006

6. Table 1-6. Troubleshooting-Seal Leakage at Compressor End of Turbocharger
OIL SEAL LEAKAGE AT

SYMPTOM OR TROUBLE COMPRESSOR END OF
TURBOCHARGER
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
YES YES YES YES
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
YES YES YES YES
Clean and remove Clean and repair air Perform

Refer to engine
restriction or intake system as troubleshooting
manufacturer's
replace oil drain line necessary. Replace procedures outlined
service manual
as required turbocharger in Table 1-8
Engine malfunction
(excessive piston
blow by or high
internal crankcase
pressure)
YES
Refer to engine
manufacturer's
service manual
SHTS011060800007
7. Table 1-7. Troubleshooting-Seal Leakage at Turbine End of Turbocharger
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
YES YES YES YES
Clean and remove Service engines

Refer to engine
Oil will burn away restriction or lubrication system.
manufacturer's
No action required replace oil drain line Replace
service manual
as required turbocharger
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
8. Table 1-8. Troubleshooting-Turbocharger Bearings, Bores, or Journals are Worn
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
YES YES YES YES
Service engine lube

system in Remove restriction
Follow proper
Follow pre-oiling accordance with or replace
engine operating
instructions engine turbocharger as
procedures
manufacturer's necessary
service manual
Abrasive wear due Insufficient lube oil

to flaking of supplied to
Plugged engine oil
NO particles from NO turbocharger due to
filter
center housing engine oil pump
internal surfaces malfunction
YES YES YES
Service engine lube

system in
Refer to engine Refer to engine
accordance with
manufacturer's manufacturer's
engine
service manual service manual
manufacturer's
service manual
SHTS011060800009
✩ Replace turbocharger, then use this table to determine cause of failure.

9. Table 1-9. Troubleshooting Procedures Notes

a. Refer to engine manufacturer's service manual for inspection requirements and replacement specifications.
b. With engine stopped, check duct clamping devices for tightness.
c. With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indi-
cated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the
engine combustion chambers.
d. With engine running at idle speed, check duct connections for leaks by applying lightweight oil or liquid soap to areas
of possible leakage and checking for bubbles. Exhaust gas leakage between the engine block and the turbocharger
inlet will also create a noise level change.
e. With engine running at idle speed, check for unusual noise and vibration. If either condition is noted, shut down the
engine immediately to protect the turbocharger and engine from further damage. With the engine stopped, check the
turbocharger shaft wheel assembly for damage as outlined Note I, below.
f. With engine running, a change in the noise level to a higher pitch can indicate air leakage between the air cleaner
and the engine or a gas leak between the engine block and the turbocharger inlet.
g. Exhaust gas leakage may be indicated by hat discoloration in the area of the leak.
h. With the engine running, noise level cycling from one level to another can indicate a plugged air cleaner, a restriction
in the air-cleaner to compressor duct, or a heavy build-up of dirt in the compressor housing or on the compressor
wheel.
i. Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the
oil drain opening. When a slugged or cocked condition exists, a heavy sludge build-up will be seen on the shaft
between the bearing journals and in the center housing from the oil drain opening back to the turbine end.
j. Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object
impact. In many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is
not changed, these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same
manner as the original unit.
k. With the air inlet and exhaust gas ducting removed from the turbocharger, examine both the compressor and turbine
wheels for blade damage. Examine the outer blade tip edges for evidence of rubbing on housing surfaces.
• Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly side-ways while
rotating to feel for wheel rub. If there is any indication of rubbing, perform the bearing clearance inspection procedure.
If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that the tur-
bocharger is serviceable.
SPECIAL TOOL
EN0110608K100001
Prior to starting a turbocharger overhaul, it is necessary to have this special tool.
For measuring the turbine

S0944-41800 END PLAY GAUGE shaft end play with a dial
gauge.
2A'0A806A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧠ಽ
OVERHAUL CRITERIA
EN0110608H300001
1. CONDITIONS WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL MAY BE NEEDED ON ENGINE

TROUBLESHOOTING.
The most common symptoms of turbocharger failure are related to engine performance:
• Lack of power
• Excessive exhaust smoke
• Unusual noise
• Excessive oil or fuel consumption.
NOTICE
Any of these symptoms could be the result of an internal engine problem, and might not involve the turbocharger
at all.
2. EXAMINE THE TURBOCHARGER EXTERIOR AND INSTALLATION.

! WARNING
Do not work on the turbocharger while it could be still hot. This can result in personal injury.
Visually check for:
• Missing or loose nuts and bolts.
• Loose or damaged intake and exhaust pipe.
• Damaged oil supply and drain lines.
• Cracked or deteriorating turbocharger housings.
• External oil or coolant leakage.
Correct any installation problems. If turbocharger parts are damaged, the unit should be overhauled after completion of the
remainder of this troubleshooting procedure.
! WARNING
Operation of the turbocharger without the intake pipe and air cleaner connected can result in personal injury and
damage to equipment from foreign objects entering the turbocharger.
3. INSPECTION TURBINE WHEEL AND HOUSING.

Remove the duct from the turbine outlet. Using a flash-light, check the
turbine for wheel to housing rub, evidence of oil leakage or foreign
object damage. Foreign object damage to the turbine is not usu-
ally visible through the turbine outlet unless the damage is severe.
(1) Wheel to housing rub
a. If wheel rub is found, and the housing attaching hardware is
secure, then the turbocharger is probably damaged internally
and must be overhauled.
(2) Oil leakage
a. If oil deposits are found, determine whether the oil has come
SHTS011060800011 from, the engine exhaust or from the turbocharger center
housing.
b. If the oil has come from the engine, consult CHAPTER
ENGINE MECHANICAL and correct the problem. If oil depos-
its on the wheel are heavy, the turbocharger should be disas-
sembled, cleaned, and overhauled if necessary.
(3) Foreign object damage
a. If foreign object damage to the turbine is visible, the turbo-
charger must be overhauled. Such damage destroys the
wheel's balance and causes internal damage to the seal
bores and journal bearings. Be sure to find the source of the
foreign object. In many cases, the object has come out of the
engine, and there may be engine damage as well.
4. EXAMINE COMPRESSOR WHEEL AND HOUSING.

• Remove the duct from the compressor inlet. Using a flashlight,
check the compressor for wheel to housing rub, evidence of oil
leakage, or foreign object damage.
If wheel rub is found, and the housing attaching hardware is
secure, then the turbocharger is probably damaged internally and
must be overhauled.
(2) Oil leakage
Oil leakage into the compressor can be caused by:
a. Long periods of idling on a restricted oil drain line.
SHTS011060800012 b. Oil leakage into the compressor can also be caused by a
restricted air intake system.
c. Oil leakage into the compressor can be caused by frequent
use of the engine as a brake. In this case, nothing is wrong
with either the engine or the turbocharger, but frequent com-
pressor wheel and housing clean-up is recommended.
If the compressor wheel has been damaged by a foreign object,
the turbocharger must be overhauled.
5. CHECK ROTATING ASSEMBLY FOR NOISE OR EXCESSIVE

PLAY.
(1) If no damage is visible in the turbine and compressor areas, spin
the rotating assembly by hand. It should spin freely with no drag
or grinding noises.
SHTS011060800013
6. CHECK AXIAL BEARING CLEARANCES.

(1) Check the turbine rotor (exhaust side) for axial play using the spe-
cial tool and dial gauge.
SST: End play gauge (S0944-41800)
Standard: 0.040-0.085 mm {0.0016-0.0033 in.}
(2) If the measurement is out of service limit, the turbocharger is

worn or damaged internally and must be overhauled.
SHTS011060800014
2A'0A9)A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧠㧥ಽ
TURBOCHARGER (J08E: WASTE GATE VALVE TYPE) EN08–1
TURBOCHARGER EN08
(J08E: WASTE GATE VALVE TYPE)

EN08
EN08-002
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
SPECIAL TOOL ............................................. EN08-12
EN08–2 TURBOCHARGER (J08E: WASTE GATE VALVE TYPE)
TURBOCHARGER
DESCRIPTION
EN0110608C100001
SHTS011060800001
1 Turbine housing 13 Hexagon nut

2 Compressor housing 14 Piston ring
3 Center bearing 15 Journal bearing
4 Clamp 16 Spacer
5 Bolt 17 Thrust bearing
6 Actuator bracket 18 Thrust collar
7 Actuator assembly 19 Seal ring
8 Hexagon nut 20 Back plate
9 Hose 21 Compressor wheel
10 Hose clamp 22 O-ring
11 Rod end 23 Turbine wheel assembly
12 Retaining nut 24 Wheel shroud
TROUBLESHOOTING
EN0110608F300001
1. Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
SHTS011060800002
*Shown on Table 1-9

2. Table 1-2. Troubleshooting - Engine Exhaust Emits Blue Smoke
SHTS011060800003
*Shown on Table 1-9

3. Table 1-3 Troubleshooting - Engine Oil Consumption Excessive
SHTS011060800004
4. Table 1-4. Troubleshooting - Noisy Turbocharger
SHTS011060800005
*Shown on Table 1-9

5. Table 1-5. Troubleshooting - Turbocharger Rotating Assembly Binding or Dragging
SHTS011060800006
*Shown on Table 1-9

6. Table 1-6. Troubleshooting - Seal Leakage at Compressor End of Turbocharger
SHTS011060800007
7. Table 1-7. Troubleshooting - Seal Leakage at Turbine End of Turbocharger
SHTS011060800008
8. Table 1-8. Troubleshooting - Turbocharger Bearings, Bores, or Journals are Worn
SHTS011060800009
*Overhaul turbocharger, then use this table to determine cause of failure.

9. Table 1-9. Troubleshooting Procedures Notes

a. Refer to engine manufacturer's service manual for inspection requirements and replacement specifications.
b. With engine stopped, check duct clamping devices for tightness.
c. With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indi-
cated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the
engine combustion chambers.
d. With engine running at idle speed, check duct connections for leaks by applying lightweight oil or liquid soap to areas
of possible leakage and checking for bubbles. Exhaust gas leakage between the engine block and the turbocharger
inlet will also create a noise level change.
e. With engine running at idle speed, check for unusual noise and vibration. If either condition is noted, shut down the
engine immediately to protect the turbocharger and engine from further damage. With the engine stopped, check the
turbocharger shaft wheel assembly for damage as outlined Note I, below.
f. With engine running, a change in the noise level to a higher pitch can indicate air leakage between the air cleaner
and the engine or a gas leak between the engine block and the turbocharger inlet.
g. Exhaust gas leakage may be indicated by hat discoloration in the area of the leak.
h. With the engine running, noise level cycling from one level to another can indicate a plugged air cleaner, a restriction
in the air-cleaner to compressor duct, or a heavy build-up of dirt in the compressor housing or on the compressor
wheel.
i. Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the
oil drain opening. When a slugged or coked condition exists, a heavy sludge build-up will be seen on the shaft
between the bearing journals and in the center housing from the oil drain opening back to the turbine end.
j. Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object
impact. In many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is
not changed, these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same
manner as the original unit.
k. With the air inlet and exhaust gas ducking removed from the turbocharger, examine both the compressor and turbine
wheels for blade damage. Examine the outer blade tip edges for evidence of rubbing on housing surfaces.
• Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly side-ways while
rotating to feel for wheel rub. If there is any indication of rubbing, perform the bearing clearance inspection procedure.
If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that the tur-
bocharger is serviceable.
COMPONENT LOCATOR
EN0110608D100001
SHTS011060800010
1 Air hose 8 Elbow assembly

2 Clamp 9 Gasket
3 Compressor housing 10 Connector pipe
4 Clamp 11 Rod end
5 O-ring 12 Retaining ring
6 Bearing with turbine and blower case 13 Bracket
7 Turbine housing 14 Actuator assembly

A 20.3-22.5 {207-229, 15-16} D 5.7-7.9 {59-80, 4.3-5.7}
B 44.1-49.0 {450-499, 33-50} E 20.9-24.3 {214-247, 16-17}
C 9.0-13.6 {92-138, 6.7-10.0}
SPECIAL TOOL
EN0110608K100001
Prior to starting a turbocharger overhaul, it is necessary to have this special tool.
For measuring the turbine

S0944-41130 END PLAY GAUGE shaft end play with a dial
gauge.
2A'0A9)A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧡ಽ
OVERHAUL CRITERIA
EN0110608H300001
1. CONDITION WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL MAY BE NEEDED ON ENGINE

TROUBLESHOOTING.
The most common symptoms of turbocharger failure are related to engine performance:
• Lack of power
• Excessive exhaust smoke
• Unusual noise
• Excessive oil or fuel consumption.
NOTICE
Any of these symptoms could be the result of an internal engine problem, and might not involve the turbocharger
at all.
2. EXAMINE THE TURBOCHARGER EXTERIOR AND INSTALLATION.

! WARNING
Do not work on the turbocharger while it is still hot. This can result personal injury.
Visually check for:
• Missing or loose nuts and bolts.
• Loose or damaged intake and exhaust pipe.
• Damaged oil supply and drain lines.
• Cracked or deteriorating turbocharger housings.
• External oil or coolant leakage.
Correct any installation problems. If turbocharger parts are damaged, the unit should be overhauled after completion of the
remainder of this troubleshooting procedure.
! WARNING
Operation of the turbocharger without the intake pipe and air cleaner connected can result in personal injury and
damage to equipment from foreign objects entering the turbocharger.
3. INSPECTION TURBINE WHEEL AND HOUSING.

Remove the duct from the turbine outlet. Using a flash-light, check the
turbine for wheel to housing rub, evidence of oil leakage or foreign
object damage. Foreign object damage to the turbine is not usually vis-
ible through the turbine outlet unless the damage is severe.
a. If wheel rub is found, and the housing attaching hardware is
secure, then the turbocharger is probably damaged internally
and must be overhauled.
(2) Oil leakage
a. If oil deposits are found, determine whether the oil has come
SHTS011060800012 from the engine exhaust or from the turbocharger center
housing.
b. If the oil has come from the engine, consult CHAPTER
ENGINE MECHANICAL and correct the problem. If oil depos-
its on the wheel are heavy the turbocharger should be disas-
sembled, cleaned, and overhauled if necessary.
a. If foreign object damage to the turbine is visible, the turbo-
charger must be overhauled. Such damage destroys the
wheel's balance and causes internal damage to the seal
bores and journal bearings. Be sure to find the source of the
foreign object. In many cases, the object has come out of the
engine, and there may be engine damage as well.
4. EXAMINE COMPRESSOR WHEEL AND HOUSING.

Remove the ducting from the compressor inlet. Using a flashlight,
check the compressor for wheel to housing rub, evidence of oil leakage,
or foreign object damage.
If wheel rub is found, and the housing attaching hardware is
secure, then the turbocharger is probably damaged internally and
must be overhauled.
(2) Oil leakage
Oil leakage into the compressor can be caused by:
a. Long periods of idling on a restricted oil drain line.
SHTS011060800013 b. Oil leakage into the compressor can also be caused by a
restricted air intake system.
c. Oil leakage into the compressor can be caused by frequent
use of the engine as a brake. In this case, nothing is wrong
with either the engine or the turbocharger, but frequent com-
pressor wheel and housing clean-up is recommended.
If the compressor wheel has been damaged by a foreign object,
the turbocharger must be overhauled.
5. CHECK ROTATING ASSEMBLY FOR NOISE OR EXCESSIVE

PLAY.
(1) If no damage is visible in the turbine and compressor areas, spin
the rotating assembly by hand. It should spin freely with no drag
or grinding noises.
SHTS011060800014
6. CHECK AXIAL BEARING CLEARENCES.

(1) Check the turbine rotor (exhaust side) for axial play using the spe-
cial tool and dial gauge.
SST: End play gauge (S0944-41130)
Service limit: 0.045-0.090 mm {0.0018-0.0035 in.}
(2) If the measurement is out of service limit, the turbocharger is

worn or damaged internally and must be overhauled.
SHTS011060800015
7. CHECK WASTEGATE PERFORMANCE.

(1) Remove hose clamps and hose from wastegate sensing port.
(2) Attach a dial gauge, set to the turbocharger so that the dial gauge
rests on the end of the actuator rod in the plane of the rod, as
applicable.
DIAL GAUGE (3) Set the dial indicator to zero.
(4) While gently tapping the turbine housing with a soft mallet, apply
air pressure until the rod movement shows 0.38 mm {0.015 in.} on
the dial gauge. Make sure that this pressure is within the specified
value.
Specified air pressure:
SHTS011060800016 Parts No. Air pressure: kPa {mmHg, inHg}
S2410-03251 130-136 {975-1,025, 39-40}
(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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟㧡ಽ
FUEL INJECTION PUMP (J08E) EN09–1
FUEL INJECTION PUMP (J08E)

EN 09
EN09-001
FUEL INJECTION PUMP.......................... EN09-2

DESCRIPTION (NB-TYPE) ........................... EN09-10
TROUBLESHOOTING ................................... EN09-11
COMPONENT LOCATOR (NB-TYPE)........... EN09-14
SPECIAL TOOL ............................................. EN09-15
OVERHAUL ................................................... EN09-17
ADJUSTMENT (NB-TYPE)............................ EN09-28
TIMER (SA2 TYPE)................................. EN09-32

SPECIAL TOOL ............................................. EN09-33
OVERHAUL ................................................... EN09-34
FEED PUMP (KD-TYPE)......................... EN09-38

OVERHAUL ................................................... EN09-39
GOVERNOR (R901) ................................ EN09-41

DESCRIPTION .............................................. EN09-41
SPECIAL TOOL ............................................. EN09-44
OVERHAUL ................................................... EN09-45
ADJUSTMENT............................................... EN09-49
BOOST COMPENSATOR ....................... EN09-55

ADJUSTMENT............................................... EN09-56
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧞ಽ
EN09–2 FUEL INJECTION PUMP (J08E)
FUEL INJECTION PUMP

EN0110609I200001
ENGINE MODEL: J08E-UF

INJECTION PUMP NUMBER: 22010-E0140
Engine model J08E-UF
Injection pump part number 22010-E0140

INJECTION Injection pump type ND-PE6NB110C721L
PUMP
SPECIFICATION Governor type R901
Timer type ND/SA2/750-1250/3.7L
Feed pump type KD22
Test nozzle type ND-DN12SD12A
17.16-17.65 MPa
Test nozzle opening pressure
{175-180 kgf/cm2, 2,490-2,560 lbf/in.2}
Outer diameter 6.0 mm {0.24 in.}
Injection pipe Inner diameter 2.0 mm {0.08 in.}

TEST
CONDITION Length 600 mm {23.6 in.}
Type of fuel SAE J967C

Calibration
Fuel temperature 40-45°C {104-113°F}
Fuel feed pressure 196 kPa {2.0 kgf/cm2, 28.4 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}
Rotation Counterclockwise viewed from drive side
Injection order 1-4-2-6-3-5

INJECTION
Injection interval 60°±15'
TIMING
Pre-stroke No.1 cylinder 3.07-3.13 mm {0.121-0.123 in.}
No.2-No.6 cylinder 3.05-3.15 mm {0.120-0.124 in.}
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
15.7 {0.618} 1,250 85.25-88.25 {5.203-5.385} 4.0 {0.244} or less
Adjuster lever position Pump speed r/min Advance angle
TIMER 750 0.3° or less

ADVANCE Full load 1,200 3.4°-4.0°
1,250 3.4°-4.0°
Adjusting position
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
100 11.5-11.9 {0.453-0.468}
185 11.5 {0.453} or more
Idling speed Idling 205 0 11.2 {0.441} or less

control 12.5°±5° 275 {0} 8.5-8.7 {0.335-0.342}
400 7.4-7.8 {0.292-0.307}
900 4.7-5.3 {0.185-0.208}
300 12.3-12.7 {0.485-0.499}
500 12.4-12.8 {0.489-0.503}

Full load
Medium speed 93.3
39°±3° 750 13.0-13.4 {0.512-0.527}
control {700, 27.6}
Between idling and full load
1,000 14.1-14.5 {0.556-0.570}
1,250 15.5-15.9 {0.611-0.625}
1,430 14.8-15.2 {0.583-0.598}

Full load
Maximum speed 93.3
39°±3° 1,535 9.3 {0.366}
control {700, 27.6}
1,700 6.5 {0.256} or less
BOOST COMPENSATOR ADJUSTMENT
Pump speed Boost pressure kPa Control rack position

Adjusting lever position
r/min {mmHg, inHg} mm {in.}
100 0 {0, 0} 13.6-14.2 {0.536-0.559}

Full load
39°±3° 300 0 {0, 0} 10.85 {0.427}
Between idling and full 300 22.7 {170, 6.7} 10.95-11.15 {0.432-0.438}
load
500 93.3 {700, 27.6} 12.4-12.8 {0.489-0.503}
MEASURE THE INJECTION VOLUME
Pump speed Boost pressure kPa Measuring Injection volume

r/min {mmHg, inHg} Stroke cm3 {cu.in.}
Full load 750 74.75-76.25 {4.562-4.653}

39°±3° 93.3 {700, 27.6}
Between idling and full load 1,250 87-90 {5.310-5.492}
Full load 100 500 77.5 {4.729}

(Boost compensator control)
0 {0, 0}
39°±3° 300 34.5-36.5 {2.106-2.227}
CONTROL RACK POSITION ADJUSTMENT

Idling
275 0 {0, 0} 8.5-8.7 {0.335-0.342}
12.5°±5°
LEVER ANGLE
Adjusting lever angle Stop lever angle

GOVERNOR CHARACTERISTIC DIAGRAM
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, con-
trol rack should be 5.0mm {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.
BOOST COMPENSATOR CHARACTERISTIC DIAGRAM.
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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧟ಽ
ENGINE MODEL: J08E-UG

INJECTION PUMP NUMBER: 22010-E0130
Engine model J08E-UG
Injection pump part number 22010-E0130

INJECTION Injection pump type ND-PE6NB110C721L
PUMP
SPECIFICATION Governor type R901
Timer type ND/SA2/750-1250/3.7L
Feed pump type KD22
Test nozzle type ND-DN12SD12A
17.16-17.65 MPa
Test nozzle opening pressure
{175-180 kgf/cm2, 2,490-2,560 lbf/in.2}
Outer diameter 6.0 mm {0.24 in.}
Injection pipe Inner diameter 2.0 mm {0.08 in.}

TEST
CONDITION Length 600 mm {23.6 in.}
Type of fuel SAE J967C

Calibration
Fuel temperature 40-45°C {104-113°F}
Fuel feed pressure 196 kPa {2.0 kgf/cm2, 28.4 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}
Rotation Counterclockwise viewed from drive side
Injection order 1-4-2-6-3-5

INJECTION
Injection interval 60°±15'
TIMING
Pre-stroke No.1 cylinder 3.07-3.13 mm {0.121-0.123 in.}
No.2-No.6 cylinder 3.05-3.15 mm {0.120-0.124 in.}
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
14.95 {0.589} 1,250 75.5-78.5 {4.608-4.790} 4.0 {0.244} or less
Adjuster lever position Pump speed r/min Advance angle

TIMER
750 0.3° or less
ADVANCE Full load
1,250 3.4°-4.0°
Adjusting position
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
100 11.9-12.3 {0.469-0.484}
185 11.9 {0.469} or more
Idling speed Idling 205 0 11.6 {0.456} or less

control 13.5°±5° 275 {0} 8.9-9.1 {0.351-0.358}
400 7.7-8.1 {0.304-0.318}
900 4.0-4.6 {0.158-0.181}
400 12.15-12.55 {0.479-0.494}
500 12.2-12.6 {0.481-0.496}

Full load 750 13.0-13.4 {0.512-0.527}
Medium speed 93.3
37°±3°
control 1,000 {700, 27.6} 13.7-14.1 {0.540-0.555}
1,250 14.75-15.15 {0.581-0.596}
1,350 14.45-14.85 {0.569-0.584}
Full load 1,550 10.25-10.65 {0.404-0.419}

Maximum speed 93.3
37°±3°
control 1,800 {700, 27.6} 6.9 {0.272} or less
BOOST COMPENSATOR ADJUSTMENT

100 0 {0, 0} 13.9-14.5 {0.548-0.570}

Full load
37°±3° 300 0 {0, 0} 10.9 {0.429}
Between idling and full 300 17.3 {130, 5.1} 11.0-11.2 {0.433-0.440}
load
500 93.3 {700, 27.6} 12.2-12.6 {0.481-0.496}
MEASURE THE INJECTION VOLUME
Pump speed Boost pressure kPa Measuring Injection volume

r/min {mmHg, inHg} Stroke cm3 {cu.in.}
Full load 750 69.25-70.75 {4.226-4.317}

37°±3° 93.3 {700, 27.6}
Between idling and full load 1,250 75.5-78.5 {4.608-4.790}
Full load 100 500 80 {4.882}

(Boost compensator control)
0 {0, 0}
37°±3° 300 31.5-33.5 {1.923-2.044}
CONTROL RACK POSITION ADJUSTMENT

Idling
275 0 {0, 0} 8.5-8.7 {0.335-0.342}
13.5°±5°
LEVER ANGLE
Adjusting lever angle Stop lever angle

GOVERNOR CHARACTERISTIC DIAGRAM
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 5.0mm {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.
BOOST COMPENSATOR CHARACTERISTIC DIAGRAM.
(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)
DESCRIPTION (NB-TYPE)
EN0110609C100001
SHTS011060900009
1 Delivery valve holder 7 Control sleeve

2 Delivery valve 8 Plunger spring
3 Shim 9 Lower spring seat
4 Injection pump element (Cylinder Plunger) 10 Camshaft
5 Upper spring seat 11 Tappet
6 Control rack 12 Pump housing
TROUBLESHOOTING
EN0110609F300001
Engine dose not start

Engine dose not start Fuel lines clogged or damaged Clean or replace fuel lines.
(Fuel not reaching injection pump) Fuel filter clogged Clean or replace the filter element.
Air in fuel caused by improper connec- Repair connections.
tions of fuel line between fuel tank and
feed pump
Filter incorporated in inlet side of feed Remove foreign particles pump
clogged.
Faulty feed pump check valve Repair or replace it.
Feed pump piston spring broken Replace it.
Feed pump push rod or tapped stick- Repair or replace it.
ing
Engine dose not start Faulty connection of accelerator cable Repair connections.
(Fuel reaching injection pump) to pump adjusting lever
Control rack faulty or sticking Repair it.
Damage camshaft bearing Repair it.
Plunger worn or sticking Correct or replace it.
Faulty connection of engine stop cable Repair it.
to pump stop lever
Engine dose not start Fuel leakage caused by loosened noz- Inspect and tighten it.
(Nozzle faulty) zle holder
Low opening pressure of nozzle Adjust it.
Nozzle pressure spring broken Replace it.
Nozzle needle sticking to nozzle body Correct or replace it.
Engine dose not start Improperly retarded injection timing Correct injection timing.
(Pump out of timing) Incorrect timing caused by improper Check engine timing and correct it.
Woodruff key for pump camshaft cut Replace it.
off
Improper pre-stroke adjustment Correct it to obtain specified injection
timing.
Excessive smoke
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.
Low idle speed irregular

Low idle speed irregular Improper adjustment of idle button Correct it.
Bad fuel spray characteristic of noz- Check and repair them.
zles
Incorrect injection timing Correct it.
Incorrect initial tension setting of idling Adjusting or replace it.
spring or the spring broken
Control rack not smoothly move Disassemble pump and repair it.
Plunger worn Replace it.
Governor linkage not moving smoothly Correct it.
Defective feed pump Disassemble and repair it.
Engine always runs at high speed

Engine always runs at high speed Accelerator cable sticking Check and correct it.
Governor linkage sticking Disassemble and repair the governor.
Check rack sticking Check and correct it.
Engine starts and stops

Engine starts and stops Fuel lines clogged Clean or replace fuel lines.
Air in fuel caused by damaged fuel Repair fuel lines or replace fuel lines
lines or improper connection of fuel and gaskets.
lines
Engine has low power

Engine has low power Excessive advanced timing resulting in Check and correct it.
(Pump out of timing) loud knocking
Excessively retarded timing resulting Check and correct it.
in black smoke
Defective injection pump overflow Repair or replace it.
valve
Feed pressure too low Repair the feed pump.
Improper accelerator cable adjustment Adjust it.
Engine has low power Fuel leakage from nozzle holder Replace nozzle assembly.
(Nozzle faulty) Bad nozzle spray characteristic Replace nozzle assembly.
Loosened adjusting screw in nozzle Adjust it.
holder, resulting in low opening pres-
sure
Nozzle pressure spring broken Replace it.
Engine has low power (Pump faulty) Fuel leakage from delivery valve Retighten the delivery valve holder if it
holder is loosened or replace O-ring if the O-
ring is defective.
Defective seat of delivery valve Repair or replace it.
assembly
Delivery valve spring broken Replace the spring.
Plunger worn Replace it.
Wear of tappet roller Replace the roller.
Camshaft bearing worn or broken Replace it.
Improper adjustment of governor full- Adjust it.
road stopper screw
Loud knocking
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
COMPONENT LOCATOR (NB-TYPE)

EN0110609D100001
SHTS011060900010
1 Delivery valve holder 16 Camshaft adjustment ring

2 O-ring 17 Taper roller bearing
3 Delivery valve stopper 18 Bearing cover
4 Delivery valve spring 19 Oil seal
5 Delivery valve 20 Screw plug
6 Gasket 21 Gasket
7 Shim 22 Joint bolt
8 Injection pump element 23 Over flow valve
9 Control sleeve 24 Adapter
10 Upper spring seat 25 Pointer
11 Plunger spring 26 Control rack
12 Lower spring seat 27 Pump housing
13 Tappet 28 Adapter
14 Camshaft 29 Rack guide bolt
15 Woodruff key 30 Bearing

A 88.3 {900, 65} D 17.2 {175, 13}
B 19.1 {195, 14} E 17.2 {175, 13}
C 7.8 {80, 6}
SPECIAL TOOL
EN0110609K100001
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
S0951-21790 BOX WRENCH
DELIVERY VALVE HOLDER

S0951-22380
REMOVER
S0951-22400 CONTROL SLEEVE REMOVER
SPRING COMPRESSION
S0951-22410
TOOL
S0951-21620 TWEEZERS
S0951-22370 CIRCLIP PLIERS
S0951-22390 SETTING SUPPORT
S0951-22330 OUTER RACE PULLER

S0951-22350 BEARING DRIVING TOOL
CAMSHAFT PROTRUDANCE
S0951-22340
GUIDE RAIL
S0951-01150 CAMSHAFT END PLAY GAUGE
S0951-01130 PUMP STAND
S0951-01160 BEARING REMOVER

OVERHAUL
EN0110609H200001

! CAUTION
• Removing the special bolts or crimp caps by anyone other
than HINO or pump manufacture authorized service stations
to make these adjustment will void the warranty.
• If fuel pump or governor difficulties are suspected, consult
only HINO or pump manufacture authorized service stations,
where the problem can be corrected and the injection pump
special bolts and crimp caps can be reinstalled as required.
• Measure and record the fuel delivery characteristics of the
pump before disassembling it.
• Keep the parts for each cylinder in separate groups and in an
orderly arrangement. Parts to be replaced and parts to be
used again must be kept separately.
1. REMOVE THE TIMER ASSEMBLY.

(1) Refer to the section "TIMER (SA2 TYPE)".
2. REMOVE THE GOVERNOR.

(1) Refer to the section "GOVERNOR (R901)".
3. SET THE INJECTION PUMP ON A PUMP STAND.

SST: Pump stand (S0951-01130)
4. REMOVE THE DELIVERY VALVE GROUP.

(1) Using a special tool, remove the nut that secures the cylinder.
SST: Box wrench (S0951-21790)
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 to 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
(4) Pull the special tool upward to remove the delivery valve group.
SHTS011060900027
5. REMOVE THE RACK GUIDE BOLT.
SHTS011060900028
6. REMOVE THE CONTROL SLEEVE.

(1) Pull the control rack to the left (viewed from the feed pump) as far
as it goes.
(2) Hook the end of the control sleeve remover onto the groove of the
control sleeve and remove it.
SST: Control sleeve remover (S0951-22400)
NOTICE
Set the camshaft at bottom dead center before removing the con-
trol sleeve.
SHTS011060900029
7. REMOVE THE CONTROL RACK.
8. REMOVE THE PLUNGER.

(1) Bring the camshaft of the cylinder to top dead center.
NOTICE
• Do not mix up the plungers since they must be put back into
the same cylinders.
• Handle the plunger very difficulty, in order not to damage it.
• Keep the removed plungers in a pan containing clean diesel
fuel.
SHTS011060900030
9. REMOVE THE UPPER SPRING SEAT.

(1) Pushing the handle down to push in the plunger spring, turn the
guide lever 90° (in either direction) to remove the upper spring
seat from the stopper pin.
SST: Spring compression tool (S0951-22410)
NOTICE
First bring the cam of the cylinder to bottom dead center.
SHTS011060900031
10. REMOVE THE UPPER SEAT AND THE PLUNGER SPRING.
11. REMOVE THE LOWER SPRING SEAT.

(1) Use a special tool to pull out the lower spring seat.
SST: Tweezers (S0951-21620)
SHTS011060900032
12. REMOVE THE TAPPET.

(1) Use a special tool to pull out the tappet.
SST: Circlip pliers (S0951-22370)
NOTICE
The tappet can be removed more easily when the cam of the cylin-
der is at top dead center.
SHTS011060900033
13. REMOVE THE CAMSHAFT FROM THE PUMP HOUSING.

(1) Remove the center bearing set screws.
(2) Loosen the bearing cover set screws.
(3) Lightly tap the camshaft with a plastic hammer from the governor
side, and remove the camshaft and bearing cover together.
NOTICE
Put the round nut of governor to the camshaft at the governor side
to protect the threads.
SHTS011060900034
14. DISASSEMBLE THE DELIVERY VALVE GROUP.

(1) Mount the delivery valve group in the special tool, and remove the
delivery valve holder.
SST: Setting support (S0951-22390)
SHTS011060900035
15. REMOVE THE TAPER ROLLER BEARING FROM THE CAM-

SHAFT.
(1) Remove the taper roller bearing from the drive end of the cam-
shaft using the special tool.
SST: Bearing remover (S0951-01160)
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

! CAUTION
• Wash all parts with clean diesel fuel before installing them,
and any defective or damaged parts must be replaced.
• Do not allow dust or other foreign particles to enter the pump
during assembly.
• Apply grease to O-rings and oil seals before installing them.
• Assemble the parts in correct order and to correct tightening
torques, assembled dimensions etc.
• Assembly takes place in the reverse order of disassembly.
1. INSTALL THE BEARINGS.

(1) Put the special tool on the bearing outer race, and press-fit it into
the bearing cover using a hand press.
SST: Bearing driving tool (S0951-22350)
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
2. INSTALL THE CAMSHAFT.

(1) Place the center bearing on the camshaft and insert the camshaft
into the pump body, then tighten the center bearing set screws.
3. INSTALL THE BEARING COVER AND GOVERNOR HOUSING.

Tightening Torque:
Bearing cover: 7.8 N⋅m {80 kgf⋅cm, 6 lbf⋅ft}
Governor housing: 12.7 N⋅m {130 kgf⋅cm, 9 lbf⋅ft}
SHTS011060900034
4. MEASURE THE PROTRUDING LENGTH OF THE CAMSHAFT.

(1) Measure the distance from the surface of the end of the pump
housing to the surface of the end of the special tool (where the
tapered section of the camshaft starts).
SST: Guide rail (S0951-02340)
Standard length: 16-17 mm {0.63-0.66 in.}
SHTS011060900041
(2) If the specification is not met, use appropriate shim at the gover-
nor end of camshaft until the specification is met.
SHTS011060900042
5. MEASURE THE CAMSHAFT END PLAY.

(1) Attach the special tool onto the camshaft drive end and measure
the thrust clearance of the camshaft with a dial gauge.
SST: Camshaft end play gauge (S0951-01150)
Standard end play: 0.03-0.05 mm {0.0012-0.0020 in.}
SHTS011060900043
(2) If the specification is not met, use, appropriate shim at the drive
end of camshaft until the specification is met.
SHTS011060900044
6. INSTALL THE TAPPETS.

(1) Install the tappet using the special tool.
SST: Circlip pliers (S0951-22370)
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
7. INSTALL THE LOWER SPRING SEATS.

(1) Install the lower spring seat, using the special tool.
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
8. INSTALL THE PLUNGER SPRINGS.
9. INSTALL THE UPPER SPRING SEATS.

(1) Insert the upper spring seat with the projected part of the seat fac-
ing at the drive end of the housing.
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
10. INSTALL THE PLUNGER.

(1) Put the flange of the plunger foot through the hole provided in the
lower spring seat, with the part number marking facing the spill
side (away from the feed pump), then turn it clockwise 90°.
NOTICE
• The plunger can be installed more easily if the cam of the cyl-
inder is at top dead center.
• Grip the plunger at the top, and pull up to check that it does
not come out.
SHTS011060900030
11. INSTALL THE CONTROL RACK AND CONTROL SLEEVE.

(1) Insert the control rack.
(2) Install the control sleeve.
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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧠ಽ
12. ASSEMBLE THE DELIVERY VALVE GROUP.

(1) Install the valve gasket, delivery valve, valve spring, shim, and the
valve holder in that order inside the cylinder.
NOTICE
• Apply grease to each O-ring first to protect it from damage.
Install O-ring (a) and (b) in that order.
• Use new valve gaskets and O-rings. Never reuse them.
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
13. INSTALL THE DELIVERY VALVE GROUP.

(1) Apply a small amount of grease to the O-rings and the outside of
the cylinder, position the cylinder with the marked line on its
flange facing the spill side of the feed pump, slip the cylinder over
the plunger, moving the control rack in and out, and insert the
delivery valve group inside the pump housing.
NOTICE
• Install the cylinder in the correct position. This is very impor-
tant since, otherwise, the relative position of the feed hole
and the spill port will be reversed and the characteristics of
the injection volume will be different.
SHTS011060900055 • Each time a cylinder is inserted, move the control rack to
check that it slides smoothly.
(2) Put a pair of shims under the flange of the cylinder.

NOTICE
• Use a pair of shims of the same thickness at the sides of
each cylinder.
• Install the shims with the thickness marking facing up. (They
cannot be installed upside down since the delivery valve
holder cover will be in the way).
• Push each shim completely in until it touches the cylinder.
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
14. MEASURE THE SLIDING RESISTANCE OF THE CONTROL

RACK.
(1) After the pump housing has been assembled, attach a spring
scale to the control rack and check that the control rack slides
smoothly through its entire stroke.
Assembly standard: Less than 100 gf {3.52 oz}
15. INSTALL THE COUPLING.

Round nut tightening torque:
137 N⋅m {1,400 kgf⋅cm, 101 lbf⋅ft}
SHTS011060900059 16. INSTALL THE GOVERNOR

(1) Refer to the section "GOVERNOR (R901)".

EN0110609H300001
Unit: mm {in.}
Plunger spring square- Measure

— 2 {0.0787} Replace spring.
ness
Delivery valve spring

— 1 {0.0394} Replace spring.
squareness
Measure
Total play of tappet
roller, Replace tappet
— 0.3 {0.0118}
roller bushing and roller assembly.
pin
Measure
Camshaft runout — 0.15 {0.0059} Replace camshaft.
Measure
Tappet surface wear — 0.2 {0.0079} Replace tappet.
Visual check
Camshaft wear — — Replace camshaft.
Visual check
Taper roller bearing Replace if neces-

— —
wear, any other damage sary.
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
(4) Fill the pump camshaft chamber with engine oil.
SHTS011060900068
ADJUSTING THE INJECTION TIMING
1. PREPARATION OF THE PRE-STROKE.

(1) Remove the screw plug from the pre-stroke measuring hole of the
first cylinder.
(2) Remove the overflow valve, attach the inlet adaptor and connect
the fuel hose of the pump tester. Close the fuel port of the injec-
tion pump with a blind plug.
(3) Install a pre-stroke measuring instrument. Bring the tappet of the
first cylinder to its bottom dead center, and set the pointer tip on
the tappet.
SHTS011060900069
2. MEASURE THE PRE-STROKE (No.1 PLUNGER)

(1) Set the control rack at full-load position.
(2) Loosen the overflow screw of each nozzle holder.
(3) Operate the high-pressure pump of the pump tester and let fuel
run out of the overflow line.
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
(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
3. ADJUST THE PRE-STROKE.

(1) Use the delivery valve remover to lift the cylinder and install the
proper shim.
SST: Delivery valve holder remover (S0951-22380)
NOTICE
• Insert a pair of shims of same thickness to the cylinder. (If
different thickness shims are used the rack will not move
smoothly and hunting and other trouble will result.)
• Use only one shim on each side.
• Always install the shims with the thickness marking facing
up.
SHTS011060900073
SHTS011060900074
4. ADJUST THE INJECTION INTERVAL.

(1) Using the No.1 cylinder injection starting point as a base, inspect
and adjust the injection interval in the order of injection.
Injection interval: 59°45'-60°15'
Injection order: 1-4-2-6-3-5
SHTS011060900075
(2) If the injection intervals are not within specification, adjust by

using the same procedure as for pre-stroke adjustment.
(3) After adjustment, make sure the injection timing is correct.
SHTS011060900076
5. MEASURING AND ADJUSTING THE INJECTION VOLUME.

(1) Connect the fuel line and the overflow valve in their correct posi-
tions.
(2) Measure the injection volume for each control rack position and
pump revolution.
Injection volume: "DATA AND SPECIFICATIONS".
SHTS011060900077
a. To adjust the injection volume, loosen the delivery valve holder

tightening nut and rotate the delivery valve holder.
b. After adjustment has been completed, tighten the nuts alternately
to the specified torque.
Tightening Torque:
19.1 N⋅m {195 kgf ⋅cm, 14 lbf⋅ft}
SHTS011060900078
TIMER (SA2 TYPE)

COMPONENT LOCATOR
EN0110609D100002
SHTS011060900079
1 Oil seal 9 Timer spring

2 Driving flange 10 Shim
3 Timer cam 11 Spring seat
4 Timer hub 12 Timer roller
5 Timer weight 13 Driving flange
6 Timer weight rod 14 O-ring
7 Spring seat retainer 15 Timer cover
8 Spring seat 16 Screw

A 13.7 {140, 10}
SPECIAL TOOL
EN0110609K100002
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
S0951-22430 TIMER EXTRACTOR
S0951-22200 TIMER HOLDER
S0951-22210 TIMER WRENCH
S0951-22310 WEIGHT SPRING PRESS

OVERHAUL
EN0110609H200002
1. REMOVE THE TIMER FROM THE INJECTION PUMP.

(1) Remove the timer round nut from the timer.
(2) Remove the timer from the injection pump.
SST: Timer extractor (S0951-22430)
SHTS011060900085
1. REMOVE THE TIMER COVER.

(1) Fix the special tool on a vise.
SST: Timer holder (S0951-22200)
(2) Set the timer on the special tool.
NOTICE
Face the cover side upward.
(3) Remove the two screws.
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
2. REMOVE THE TIMER WEIGHT.

(1) Remove the timer weight subassembly (with spring, timer weight
rod etc.)
NOTICE
Leave timer cams on timer hub.
3. REMOVE THE TIMER CAMS AND TIMER HUB.

NOTICE
Remember the position of timer cams.
SHTS011060900089
4. REMOVE THE TIMER SPRING.

(1) Using the special tool, compress the timer spring, then remove
the spring seat retainer.
SST: Weight spring press (S0951-22310)
SHTS011060900090
5. REMOVE THE OIL SEAL.

(1) Using a screwdriver, remove the oil seals from the timer cover and
driving flange.
SHTS011060900091
1. INSTALL THE OIL SEAL.

(1) Using the special tool, push the oil seals into the timer cover and
driving flange.
NOTICE
The oil seals must be replaced with new ones.
SHTS011060900092
2. INSTALL THE TIMER HUB AND TIMER CAMS.

(1) Fix the special tool on a vise.
SST: Timer holder (S0951-22200)
(2) Set the driving flange to the special tool.

(3) Install the timer hub and timer cams to the driving flange as
shown in the figure.
SHTS011060900089
3. INSTALL THE TIMER SPRING TO TIMER WEIGHT.

NOTICE
Take care of the spring seat direction.
SST: Weight spring press (S0951-22310)
SHTS011060900093
4. INSTALL THE TIMER COVER.

NOTICE
O-ring must be replaced with new one.
(1) 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)
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
ADJUSTMENT OF THE TIMER
1. INSPECT THE TIMER ADVANCE.

(1) Set a stroboscope on a pump tester.
(2) Check the timer advance.
Advance angle: Refer to "DATA AND SPECIFICATIONS".
(3) If the angle is not within specification, adjust with an appropriate
shim.
FEED PUMP (KD-TYPE)

COMPONENT LOCATOR
EN0110609D100003
SHTS011060900096
1 Plug 11 Push rod

2 Gasket 12 Feed pump housing
3 Spring 13 Tappet
4 Check valve 14 Sliding block
5 Joint bolt 15 Roller
6 Special washer 16 Pin
7 Screw plug 17 Retainer ring
8 Priming pump 18 Filter
9 Piston spring 19 Oil seal
10 Piston
OVERHAUL
EN0110609H200003
1. REMOVE THE PRIMING PUMP AND CHECK VALVES.

(1) Remove the priming pump.
(2) Remove the outlet check valve and spring.
SHTS011060900097
2. REMOVE THE TAPPET.

(1) Remove the retainer ring and pull out the tappet.
SHTS011060900098
3. REMOVE THE FILTER FROM INLET PIPE JOINT.

(1) Clean the filter with clean diesel fuel.
SHTS011060900099
1. INSTALL THE TAPPET.
2. INSTALL THE RETAINER RING.
3. INSTALL THE PISTON.

(1) Insert the piston and spring in the housing and install the plug with
a new gasket.
SHTS011060900100
4. INSTALL THE PRIMING PUMP AND CHECK VALVES.
SHTS011060900097
GOVERNOR (R901)
DESCRIPTION
EN0110609C100002
SHTS011060900101
1 Diaphragm plate 17 Inner lever

2 Adapter 18 Floating lever
3 Cam plate 19 Control lever
4 Control rack 20 Return spring
5 Stopper 21 Return spring
6 Connecting bolt 22 Cam plate
7 Guide lever 23 Guide shaft
8 Return spring 24 Sliding block
9 Screw plug 25 Guide lever
10 Spring seat 26 Floating lever
11 Flyweight 27 Adjusting lever shaft
12 Bolt 28 Flyweight holder
13 Bell crank shaft 29 Bolt
14 Nut 30 Bush
15 Rack limiter 31 Control lever
16 Stopper screw 32 Straight pin
COMPONENT LOCATOR
EN0110609D100004
SHTS011060900102
1 Bracket 23 Spring seat

2 Return spring 24 Idling inner spring
3 End cover 25 Idling outer spring
4 Gasket 26 Bushing
5 Adapter 27 Flyweight sub-assembly
6 Oil seal 28 Timer weight rod
7 Guide lever 29 Flyweight assembly
8 Key 30 Governor cover
9 Cam plate 31 Governor housing
10 Speed control lever 32 Screw plug
11 Floating lever sub-assembly 33 Shim
12 Floating lever 34 Stopper
13 Control lever 35 Rack limiter cap
14 Tension shaft 36 Rack limiter
15 Sliding lever 37 Boost compensator
16 Straight pin 38 Stopper screw
17 Inner lever 39 Cap nut
18 Guide lever 40 Idling spring
19 Nut 41 Shaft
20 Adapter 42 Collar
21 Plain washer 43 Diaphragm plate
22 Governor spring 44 Connector pin
SPECIAL TOOL
EN0110609K100003
Prior to starting a governor overhaul, it is necessary to have these special tools.
S0951-21320 ROUND NUT WRENCH
S0951-21670 SPRING NUT WRENCH
S0951-21770 WRENCH
CAMSHAFT BUSHING
S0951-22260 EXTRACTOR
(DAMPER WEIGHT MODEL)
S0951-22510 BIT
S0951-22520 DRIVER CHUCK

OVERHAUL
EN0110609H200004

! CAUTION
• Removing the special bolts or crimp caps by anyone other
than HINO or pump manufacture authorized service stations
to make these adjustment will void the warranty.
• If fuel pump or governor difficulties are suspected, consult
only HINO or pump manufacture authorized service stations,
where the problem can be corrected and the injection pump
special bolts and crimp caps can be reinstalled as required.
1. REMOVE THE GOVERNOR COVER.

(1) With the adjusting lever hold in its "idling" position, detach the
governor cover by lifting it up in such as way that the sliding block
can slide out of the slit in the floating lever.
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
2. REMOVE THE FLYWEIGHT ROUND NUT.

NOTICE
Use the holding spanner to keep the camshaft from rotating.
SST: Round nut wrench (S0951-21320)
SHTS011060900111
3. REMOVE THE FLYWEIGHT SUB-ASSEMBLY.

(1) Remove the flywheel sub-assembly using a screwdriver to pull it
out slowly.
SHTS011060900112
(2) Remove the bushing.

SST: Camshaft bushing extractor (S0951-22260)
SHTS011060900113
(3) Remove the adapter from the flyweight sub-assembly.
SHTS011060900114
4. DISASSEMBLE THE FLYWHEEL SUB-ASSEMBLY.

(1) Remove the adjusting nut with special tool, and disassemble the
inner parts of the flyweight sub-assembly.
SST: Spring nut wrench (S0951-21670)
SHTS011060900115

! CAUTION
• Wash all parts with clean diesel fuel before installing them,
and any defective or damaged parts must be replaced.
• Do not allow dust or other foreign particles to enter the pump
during assembly.
• Apply grease to O-rings and oil seals before installing them.
• Assemble the parts in correct order and to correct tightening
torque, assembled dimensions etc.
• Assembly takes place in the reverse order of disassembly.
1. INSTALL THE STOPPER.

(1) Install the stopper as shown.
(2) Measure the thrust clearance of the guide lever.
Thrust clearance: 0.05-0.10 mm {0.002-0.004 in.}
NOTICE
The O-ring should be coated with grease before being fitted.
SHTS011060900116
2. ASSEMBLE THE FLYWEIGHT.

NOTICE
Be sure to install the spring inner seat correctly; its "LAPPED"
surface should face downwards.
(1) Tighten the adjusting nut with the special tools.
SST: Spring nut wrench (S0951-21670)
Protrusion of adjusting nut A: -0.4 to 0.2 mm {-0.015 to 0.007

in.}
SHTS011060900117
3. IF EQUIPPED WITH ADAPTER, ADJUST THE ADAPTER

THRUST CLEARANCE.
This provides a clearance between the flyweight and the bushing.
(1) Temporarily install the bushing on the camshaft.
(2) Install the flyweight without the adapter.
(3) Temporarily fit the governor round nut.
SHTS011060900118
(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
4. INSTALL THE TENSION SHAFT.

(1) Measure the free play of the jointing bolt along its axis.
Standard free play: 1.5-2.0 mm {0.0591-0.0787 in.}
NOTICE
Make sure the bearing bolt can be moved smoothly thought the
bush.
SHTS011060900120
(2) Measure the fitting dimension of the tension shaft.

a. While pulling on the tension shaft, measure the dimension "L" with
calipers.
Fitting dimension: 49.7-50.1 mm {1.957-1.972 in.}
SHTS011060900121
5. ASSEMBLE THE GOVERNOR COVER.

(1) Install the cam plate on the governor cover and shim with E-ring.
NOTICE
Shim A about of 0.5 mm {0.02 in.} in thickness should be installed
with the E-ring.
(2) Measure the cam plate thrust clearance B.
Thrust clearance B: 0.08-0.12 mm {0.0032-0.0047 in.}
SHTS011060900122
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
2. STEP IN GOVERNOR ADJUSTMENT.

(1) Perform governor testing and adjustment in the following
sequence:
a. Preliminary adjustment of the cam plate.

b. Adjustment of idling speed control.
c. Preliminary adjustment of maximum speed control.
d. Adjustment of medium speed control.
e. Adjustment of maximum speed control.
f. Adjustment of fuel injection volume under full-load.
g. Inspection of stopper operation.
SHTS011060900124
(2) Preliminary adjustment of cam plate.

L1= L2= About 25.5 mm {1.004 in.}
SHTS011060900125
(3) Adjustment of idling speed control.

NOTICE
The speed control lever should always be in the "IDLING" position
during adjustment of the idling speed control.
a. At a pump speed of Na r/min, measure the control rack position

Ra mm.
Na and Ra: Refer to "DATA AND SPECIFICATIONS".
If there are not within specifications, adjust with the idle adjusting
screw.
SHTS011060900126
NOTICE
The idle adjusting screw will change the governor characteristics
as show on the left.
SHTS011060900127
b. At a pump speed of Nb r/min, measure the control rack position

Rb mm.
Nb and Rb: Refer to "DATA AND SPECIFICATIONS".
SHTS011060900128
c. At a pump speed of Nc r/min, measure the control rack position

Rc mm.
Nc and Rc: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the idle outer spring.
NOTICE
Protrusion of the adjusting nut (A) should be within -0.4 mm {-
0.0158 in.} - 0.2 mm {0.0078 in.}.
SHTS011060900129
d. At a pump speed of Nd r/min, measure the control rack position

Rd mm.
Nd and Rd: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the washer (A).
SHTS011060900130
e. At a pump speed of Ne r/min, measure the control rack position

Re mm.
Ne and Re: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the washer (B).
SHTS011060900131
(4) Preliminary adjustment of maximum speed control.

a. Apply a P mmHg boost pressure to the boost compensator.
P: Refer to "DATA AND SPECIFICATIONS".
b. The speed control lever should be in the "FULL-LOAD" position.
c. At a pump speed of Nj r/min, measure the control rack position Rj
mm.
Nj and Rj: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the idle adjusting screw.
SHTS011060900132
(5) Adjusting of medium speed control.

NOTICE
• The speed control lever should always be in the "FULL-
LOAD" position during adjustment of the medium speed con-
trol.
• Apply a 13.3 kPa {100 mmHg} boost pressure to the boost
compensator.
SHTS011060900133
a. At a pump speed of Nf r/min, measure the control rack position Rf

mm.
Nf and Rf: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the stopper screw.
SHTS011060900134
b. At a pump speed of Ng r/min, measure the control rack position

Rg mm.
Ng and Rf: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the adapter screw (A).
SHTS011060900135
c. At a pump speed of Nh r/min, measure the control rack position

Rh mm.
Nh and Rh: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the adapter screw (A) and
(B).
SHTS011060900136
d. Confirm the rack position Ri mm with at a pump speed of Ni r/min.

Ni and Ri: Refer to "DATA AND SPECIFICATIONS".
SHTS011060900137
(6) Adjustment of maximum speed control.

NOTICE
• Speed control lever should be in the "FULL-LOAD" position.
• Apply a 13.3 kPa {100 mmHg} boost pressure to the boost
compensator.
a. At the pump speed of Nj r/min, measure the control rack position

Rj mm.
Ni and Rj: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the stroke adjusting screw.
b. Confirm the rack position Rm and Rn mm, with at a pump speed
SHTS011060900138
Nm and Nn r/min.
Each speed and rack position: Refer to "DATA AND SPECIFI-
CATIONS".
(7) Adjustment of the boost compensator.
NOTICE
The speed control lever should be in the "FULL-LOAD" position
during adjustment of the boost compensator.
SHTS011060900139
a. Without boost pressure, N1 r/min measure the injection volume

and read the rack position.
Injection volume: Refer to "DATA AND SPECIFICATIONS".
Rack position: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust the volume with the stop screw.
SHTS011060900140
b. Apply boost pressure of P1kPa to the boost compensator. At a

pump speed of N1 r/min, adjust with the guide bushing to adjust
the rack position.
Boost pressure: Refer to "DATA AND SPECIFICATIONS".
c. Apply boost pressure of P2kPa to the boost compensator. At a
pump speed of N2 r/min, confirm the rack position.
Boost pressure: Refer to "DATA AND SPECIFICATIONS".
SHTS011060900141
(8) Adjusting of fuel injection volume under "FULL-LOAD". Measure

the injection volume in the "FULL-LOAD" position. Apply a p
mmHg boost pressure to the boost compensator.
P: Refer to "DATA AND SPECIFICATIONS".
If the average injection volume is not at standard value, adjust
with the stopper screw.
Injection volume: Refer to "DATA AND SPECIFICATIONS".
SHTS011060900142
(9) Inspection of stopper operation.

Speed control lever at "IDLING" position and pump speed at "0" r/
min, the control rack position should be Rq mm.
Control rack position Rq: Refer to "DATA AND SPECIFICA-
TIONS".
3. INSTALL THE RACK LIMITER AND THE CAP.
4. SECURE THE RACK LIMITER AND RACK LIMITER CAP TO

GOVERNOR HOUSING WITH SPECIAL BOLTS USING THE
SPECIAL TOOL.
SHTS011060900143
SST:
Bit (S0951-22510)
Driver chuck (S0951-22520)
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.
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
ADJUSTMENT
EN0110609H300004
PRE-ADJUSTMENT OF BOOST COMPENSATOR
1. PRE-ADJUSTMENT OF BOOST COMPENSATOR.

(1) Before installing the boost compensator on the full-load stopper
housing, should be done pre-adjustment the boost compensator
as follows.
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
(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'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧡㧢ಽ
EMISSION CONTROL (J08E) EN10–1
EMISSION CONTROL (J08E)

EN 10
EN10-001
EGR VALVE AND EGR PIPE.................... EN10-2

EGR VALVE............................................... EN10-3

DESCRIPTION ................................................ EN10-3
EN10–2 EMISSION CONTROL (J08E)
EGR VALVE AND EGR PIPE

COMPONENT LOCATOR
EN0110610J100001
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
1 Water pipe 7 EGR pipe

2 Clip 8 EGR valve
3 Water hose 9 Coolant pipe
4 Radiator hose 10 O-ring
5 EGR cooler 11 Air escape pipe
6 Gasket

A 55 {560, 40}
EGR VALVE
DESCRIPTION
EN0110610J100002
SHTS011061000002
1 EGR valve assembly 3 EGR lift sensor

2 Actuator

EN0110610H200001
1. REMOVE THE EGR VALVE.

NOTICE
To prevent burns ensure the engine is cold before changing the
valve. (At least 30 minutes after switching off the engine)
(1) Disconnect the harness coupler.
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
(6) Remove the EGR valve from the intake pipe.
SHTS011061000006
1. INSTALL THE EGR VALVE.

(1) Install the EGR valve to the intake pipe.
Tightening Torque:
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
(7) Connect the harness coupler.
SHTS011061000010
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AIR BLEEDING FROM EGR COOLER

B 1. BLEED AIR FROM THE EGR COOLER.
A
(1) The hose connection parts are (A), (B), and (C), and the others
are to be plugged or to be made closed circuits.
(2) Supply water from (B). (C) is closed during cooling by the thermo-
stat.)
(3) Air venting (judgment of water filling) is completed when cooling
water reaches the hose connected to (A), and cooling water
C remains in the hose even when the water supply is stopped.
NOTICE
SHTS011061000011 • This work is the procedure for air venting for the engine by
itself.
• Air remaining in the hose of part (A) after completion of water
supply is eliminated by operating the engine.
• Visual confirmation of the water flow must be possible at the
hose connected to part (A). Also, the hose should not sag
down.
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧤ಽ
ALTERNATOR (J08E: 24V-50A) EN11–1
ALTERNATOR (J08E: 24V-50A)

EN1
EN11-001
ALTERNATOR........................................... EN11-2
DESCRIPTION ................................................ EN11-2
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
EN11–2 ALTERNATOR (J08E: 24V-50A)
ALTERNATOR
EN0110611I200001
Nominal voltage 24V
Nominal output 24V-50A
Max. output 50A at 28V, 5,000 r/min.
Initial output starting speed 950 r/min. at 27V
Max. rotating 8,400 r/min.
Rotating direction Right (seen from pulley side)
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
1 Rectifier holder 8 Fan

2 Lead wire connector 9 Pulley
3 Regulator 10 Ball bearing
4 Condenser 11 Drive end frame
5 Field coil 12 Retainer plate
6 Rotor assembly 13 Rectifier end frame
7 Stator assembly 14 Diode
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002
1 Alternator 7 Charge warning light

2 Condenser 8 Fuse
3 Diode 9 Starter switch
4 Stator coil 10 Load
5 Field coil 11 Battery
6 IC Regulator
TROUBLESHOOTING
EN0110611F300001

Charging current does not flow I.C. regulator faulty Replace I.C. regulator.
(Warning light dose not light) Stator coil faulty (Disconnecting or rare Replace stator coil.
short)
Field coil faulty (Disconnecting or rare Replace field coil.
short)
Diode faulty (Open or short circuit) Replace rectifier holder.
Lead wiring disconnected or loose Repair or replace.
(Plate, support etc.)
Wiring disconnection (Including fuse) Replace.
Voltmeter indicates 29V or more I.C. regulator faulty Replace I.C. regulator.
(Warning light dose not light) I.C. regulator installation faulty (EX: Repair or replace.
Installation support)
Charging current flows normally I.C. regulator faulty Replace I.C. regulator.
(Warning light does not light)
Charging current is always insuffi- Stator coil faulty Replace stator coil.
cient (Battery goes dead) (Warning Diode faulty (open or short circuit) Replace rectifier holder.
light remains dark)
Lead wiring disconnecting or loose Repair or replace.
(Plate or support)
Volume of using load is too high (Vol- Decrease the load.
ume of using load is imbalance)
Charging current is always too I.C. regulator faulty Replace stator coil.
great (Battery does dry in short I.C. regulator installation faulty (EX: Replace rectifier holder.
amount of time) (Warning light Installation of support)
remains dark)
Battery nearly over its life period Repair it.
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside (Bearing inside and Repair or replace.
bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
COMPONENT LOCATOR
EN0110611D100001
SHTS011061100003
1 Brace 4 Bracket
2 Harness 5 V-belt
3 Alternator 6 Strap band

A 5.9 {60, 4.3} C 3.2-4.4 {33-45, 2.4-3.2}
B 51 {520, 38} D 83 {850, 61}
SHTS011061100004
1 Cover 13 Field coil

2 Condenser 14 Stator assembly
3 Regulator 15 Roller bearing
4 Terminal insulator 16 Rotor assembly
5 Terminal insulator 17 Retainer plate
6 Rectifier holder 18 Ball bearing
7 Holder 19 Drive end frame
8 Terminal bolt 20 Space collar
9 Clamp 21 Fan
11 Rectifier end frame 23 Lock nut
12 Through bolt

A 3.2-4.4 {33-45, 2.4-3.2} E 2.9-3.9 {30-40, 2.2-2.8}
B 4.9-5.9 {50-60, 3.7-4.3} F 7.8-9.8 {80-100, 5.8-7.2}
C 127-157 {1,300-1,600, 95-115} G 1.9-2.5 {19-25, 1.4-1.8}
D 1.9-2.5 {19-25, 1.4-1.8}
SPECIAL TOOL
EN0110611K100001
Prior to starting a alternator overhaul, it is necessary to have this special tool.
S0944-41210 COMPRESSION GAUGE
OVERHAUL
EN0110611H200001

FIXING NUT
A COOLANT
PUMP 1. ADJUST THE ALTERNATOR V-BELT DEFLECTION.
PULLEY (1) Loosen the through bolt and the fixing nut.
(2) Apply a load of about 98 N {10 kgf} by pressing the measuring
ADJUSTING point A.
BOLT
CRANK (3) Turn the adjusting bolt, and adjust the deflection of the belt at
SHAFT measuring point A, so that it comes within the standard value.
ALTERNATOR PULLEY SST: Compression gauge (S0944-41210)
PULLE Y
THROUGH BOLT Standard: 8-10 mm {0.314-0.394 in.}
• When installing a new V-belt, be sure to repeat the adjust-
ment two or three times, after running the engine.
• When adjusting the V-belt, do not apply the lever directly
against the alternator.
(4) After adjusting the deflection, tighten the through bolt and then
securely tighten the fixing nut.
(5) Retighten the adjusting bolt.
(6) Connecting the harness.

NOTICE
The work should be done on such thing as rubber mat and the
like.
1. DISASSEMBLE THE RECTIFIER END FRAME AND DRIVE

END FRAME.
(1) Remove the cover.
NOTICE
On removing the cover, push the cover claws part. In this time,
take care not to damage claws part pushing by full force.
SHTS011061100007
(2) Remove the bolt and clamp.
SHTS011061100008
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(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS011061100009
2. REMOVE THE ROTOR.

(1) Remove the pulley lock nut.
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
that pulley is held with V-belt as a cushion.
(2) Remove the pulley, fan and space collar.
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
3. REMOVE THE FRONT BALL BEARING.

(1) Remove the retainer plate.
SHTS011061100012
(2) Using a press, remove the ball bearing.

JIG NOTICE
• Attach the jig to inner race of the ball bearing and remove
bearing, using a press.
• A removed bearing should not be reused. Replace it with a
new one.
SHTS011061100013
4. REMOVE THE STATOR.

(1) Unsolder the lead wire from the stator and remove it by pulling
gently.
NOTICE
• Unsolder the wiring connections at the stator and diode and
take off excess solder spread claws part at the connections
and disconnect stator lead wires.
• In case that diode is distorted, do not reuse the diode.
• Unsoldering work should be done for short moment (Within 5
sec.).
SHTS011061100014
(2) Remove the stator from the rectifier end frame.

NOTICE
Be careful not to damage the stator.
SHTS011061100015
5. REMOVE THE RECTIFIER HOLDER, REGULATOR AND FIELD

COIL.
(1) Unsolder lead wire from field coil.
NOTICE
• Unsolder lead wire after opening the terminal of regulator.
sec.).
SHTS011061100016
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100017
(2) Loosen the "B" terminal nut.

NOTICE
Loosen the nut to some extent and do not take it out of terminal B.
SHTS011061100018
(3) Remove the rectifier holder and regulator.

NOTICE
• Lock agent is used not to be unscrewed easily. So, be careful
not to damage the groove on bolt head.
• Make sure to clean the screw hole when reusing rear bracket.
SHTS011061100019
(4) Remove the condenser.

(5) Remove the field coil.
SHTS011061100020
(6) Attach the jig to inner race of the roller bearing and remove roller
NOTICE
new one.
SHTS011061100021

NOTICE
JIG
like.
1. INSTALL THE ROTOR.

(1) Using a press and a jig, install the new ball bearing into the drive
end frame.
NOTICE
Attach the jig on the outer race of the ball bearing.
SHTS011061100022
(2) Install the retainer plate.

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100023
(3) Using a press, install the rotor.

NOTICE
• When pressing in rotor, it should be supported by the inner
lace of bearing.
• Take care not to damage the rotor shaft.
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
V-BELT that pulley is held with V-belt as a cushion.
SHTS011061100025
2. INSTALL THE ROLLER BEARING.

(1) Using a press, jig A and jig B, install the roller bearing into the rec-
tifier end frame.
JIG A
NOTICE
Press fit until jig A hits to the rectifier end frame.
ROLLER
BEARING
JIG B
SHTS011061100026
3. INSTALL THE FIELD COIL, REGULATOR AND RECTIFIER

HOLDER.
(1) Install the field coil to the rectifier end frame.
Tightening Torque:
2.9-3.9 N⋅m {30-39 kgf⋅cm, 2.2-2.8 lbf⋅ft}
NOTICE
Tighten the bolt evenly.
SHTS011061100027
(2) Install the stator coil to the rectifier end frame.

NOTICE
Do not damage the stator coil.
SHTS011061100028
(3) Refer to the section "COMPONENT LOCATOR", then install the

each parts.
Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS011061100029
(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
(5) Tighten the inner nut of the B terminal.

Tightening Torque:
4.9-5.9 N⋅m {50-60 kgf⋅cm, 3.7-4.3 lbf⋅ft}
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
SHTS011061100032
4. ASSEMBLE THE RECTIFIER END FRAME AND DRIVE END

FRAME.
(1) Assemble the rectifier end frame and drive end frame with the
through bolts.
Tightening Torque:
7.8-9.8 N⋅m {80-99 kgf⋅cm, 5.8-7.2 lbf⋅ft}
NOTICE
Tighten the through bolt evenly.
SHTS011061100033
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧟ಽ
(2) Install the clamp and bolt.

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100034
(3) Install the cover.

NOTICE
Do not hit the cover since its hook is fragile.
SHTS011061100035
CHECK THE ALTERNATOR.
1. CHECK THE ALTERNATOR FOR PROPER ROTATION.

(1) Turn the pulley by hand and make sure that there is no noise,
catching or rough movement in the shaft direction and that it
rotates smoothly.
SHTS011061100036
2. CHECK THE RESISTANCE BETWEEN TERMINALS.

(EXAMPLE) (1) Measure the resistance between terminals. If the resistance is not
specified value, reassemble the alternator.
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
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.
1. ALTERNATOR PERFORMANCE TEST

CHARGING LIGHT (1) Turn switch SW1 on and SW2 off to increase the revolution of the
alternator slowly.
(2) When voltage reaches 28V, turn on switch SW2 to regulate load
resistance. Increase the revolution of the rotor keeping voltage at
28V.
Standard output speed: 4,000 r/min. at 27.5V 50A
2. VOLTAGE REGULATOR TEST

(1) Turn switch SW1 on and SW2 off to increase the revolution of the
rotor to 5,000 r/min.
SHTS011061100039 Standard voltage: 28.0-29.0V

EN0110611H300001
Unit: mm {in.}
Measure
Resistance of field coil

6.4-7.0 Ω — Replace.
[at 20°C (68°F)]
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
W
Resistance of stator
0.31-0.33 Ω — Replace. V U
coil [at 20°C (68°F)]
WIRING
Measure
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Rotor shaft outside

diameter (Front bearing 25 {0.984} 24.98 {0.9835} Replace.
portion)
Measure
Rotor shaft outside

diameter (Rear bearing 17 {0.669} 16.98 {0.6685} Replace.
portion)
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.

EN1
EN11-002
ALTERNATOR........................................... EN11-2
DESCRIPTION ................................................ EN11-2
OVERHAUL ..................................................... EN11-7
ALTERNATOR
EN0110611I200001
Nominal voltage 24V
Initial output starting speed 950 r/min. at 27V
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
1 Rectifier holder 8 Pulley

2 Lead wire connector 9 Ball bearing
3 Regulator 10 Drive end frame
7 Fan
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧥ಽ
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002

2 Condensor 8 Fuse
6 I.C. Regulator
TROUBLESHOOTING
EN0110611F300001

(Warning light does not light) Stator coil faulty (Disconnecting or rare Replace stator coil.
short)
Field coil faulty (Disconnecting or rare Replace field coil.
short)
(Warning light does not light) I.C. regulator installation faulty (EX: Repair or replace.
Installation support)
cient (Battery goes dead) (Warning Diode faulty (open or short circuit) Replace rectifier holder.
light remains dark)
(Plate or support)
Volume of using load is too high (Vol- Decrease the load.
ume of using load is imbalance)
great (Battery does dry in short I.C. regulator installation faulty (EX: Replace rectifier holder.
amount of time) (Warning light Installation of support)
remains dark)
Bumping inside (Bearing inside and Repair or replace.
bracket abrasion)
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧥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

A 51 {520, 38} B 83 {846, 61}
SHTS011061100004
1 Cover 12 Field coil

2 Regulator 13 Stator assembly
3 Terminal insulator 14 Roller bearing
5 Rectifier holder 16 Retainer plate
6 Holder 17 Ball bearing
7 Terminal bolt 18 Drive end frame
8 Clamp 19 Space collar
9 Lead wire connector 20 Fan
10 Rectifier end frame 21 Pulley
11 Through bolt 22 Lock nut

A 1.9-2.5 {20-25, 1.5-1.8} D 7.8-9.8 {80-99, 5.8-7.2}
B 4.9-5.9 {50-60, 3.7-4.3} E 2.9-3.9 {30-39, 2.2-2.8}
C 3.2-4.4 {33-44, 2.4-3.2} F 127-157 {1,300-1,600, 94-115}
OVERHAUL
EN0110611H200001
1. INSTALL THE V-RIBBED BELT.

(1) Install the V-ribbed belt on the pulleys except alternator pulley.
(2) Using a wrench, move the tension pulley slowly to arrow marked
direction, then install the V-ribbed belt on the alternator pulley.
SHTS01106110

NOTICE
like.

END FRAME.
NOTICE
SHTS011061100006
SHTS011061100007
SHTS011061100008
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧢ಽ

NOTICE
(2) Remove the pulley, fan and space collar.
SHTS011061100009
NOTICE
SHTS011061100010

SHTS011061100011

NOTICE
JIG
new one.
SHTS011061100012

gently.
NOTICE
sec.).
SHTS011061100013

NOTICE
SHTS011061100014

COIL.
REGULATOR NOTICE
sec.).
SHTS011061100015
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100016

NOTICE
TERMINAL B
SHTS011061100017
(3) Remove the rectifier holder and regulator.

NOTICE
SHTS011061100018

SHTS011061100019
NOTICE
new one.
SHTS011061100020

JIG
NOTICE
like.
1. INSTALL THE ROTOR.

(1) Using a press and a jig, install the new ball bearing into the drive
end frame.
NOTICE
SHTS011061100021
(2) Install the retainer plate.

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100022

NOTICE
• When pressing in rotor, it should be supported by the inner
lace of bearing.
SHTS011061100023
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
V-BELT
SHTS011061100024

JIG A tifier end frame.
NOTICE
ROLLER
BEARING
JIG B
SHTS011061100025

HOLDER.
Tightening Torque:
2.9-3.9 N⋅m {30-39 kgf⋅cm, 2.2-2.8 lbf⋅ft}
NOTICE
SHTS011061100026

NOTICE
SHTS011061100027

each parts.
Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
NOTICE
SHTS011061100028
REGULATOR lator and field coil as well as the stator coil and diode.
NOTICE
lator.
sec.).
SHTS011061100029
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100030

Tightening Torque:
4.9-5.9 N⋅m {50-60 kgf⋅cm, 3.7-4.3 lbf⋅ft}
HINT
necting its wiring.
TERMINAL B
SHTS011061100031

FRAME.
through bolts.
Tightening Torque:
7.8-9.8 N⋅m {80-99 kgf⋅cm, 5.8-7.2 lbf⋅ft}
NOTICE
SHTS011061100032

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100033

Tightening Torque:
3.3-4.4 N⋅m {34-44 kgf⋅cm, 2.5-3.1 lbf⋅ft}
NOTICE
Do not hit the cover since its hook is fragile.
SHTS011061100034

rotates smoothly.
SHTS011061100035

(1) Measure the resistance between terminals. If the resistance is not
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
PERFORMANCE TEST
NOTICE
connections.
ness.
tester.

alternator slowly.
28V.


EN0110611H300001
Unit: mm {in.}
Measure

[at 20°C (68°F)]
Measure
field coil
Measure
0.31-0.33 Ω — Replace. V U
coil [at 20°C (68°F)]
WIRING
Measure
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Rotor shaft outside

portion)
Measure
Rotor shaft outside

portion)
Measure
Normal direction
APPROX. 10 Ω E
Reverse direction
∞Ω
F
Resistance of con-
tester.
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧡㧥ಽ

EN1
EN11-003
ALTERNATOR........................................... EN11-2
DESCRIPTION ................................................ EN11-2
OVERHAUL ..................................................... EN11-7
ALTERNATOR
EN0110611I200001
Nominal voltage 24V
Initial output starting speed 1,000 r/min. at 27V
Regulator Mount-on
DESCRIPTION
EN0110611C100001
SHTS011061100001
1 Rectifier holder 8 Fan

3 Regulator 10 Ball bearing
4 Condenser 11 Drive end frame
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS011061100002

2 Condenser 8 Fuse
6 I.C. Regulator
TROUBLESHOOTING
EN0110611F300001

(Warning light does not light) Stator coil faulty Replace stator coil.
(Disconnecting or rare short)
Field coil faulty Replace field coil.
(Disconnecting or rare short)
(Warning light does not light) I.C. regulator installation faulty Repair or replace.
(EX: Installation support)
cient (Battery goes dead) Diode faulty (open or short circuit) Replace rectifier holder.
(Warning light remains dark)
(Plate or support)
Volume of using load is too high Decrease the load.
(Volume of using load is imbalance)
great (Battery does dry in short I.C. regulator installation faulty Replace rectifier holder.
amount of time) (EX: Installation of support)
(Warning light remains dark)
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧝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

A 51 {520, 38} B 83 {846, 61}
D
E
SHTS011061100004
1 Cover 12 Through bolt

2 Condenser 13 Field coil
3 Regulator 14 Stator assembly
4 Terminal insulator 15 Roller bearing
6 Rectifier holder 17 Retainer plate
7 Holder 18 Shim
8 Terminal bolt 19 Ball bearing
9 Clamp 20 Drive end frame
10 Lead wire connector 21 Fan and pulley
11 Rectifier end frame 22 Lock nut

A 1.9-2.5 {20-25, 1.5-1.8} D 2.9-3.9 {30-39, 2.2-2.8}
B 4.9-5.9 {50-60, 3.7-4.3} E 5.9-8.8 {60-90, 4.4-6.4}
C 3.2-4.4 {33-44, 2.4-3.2} F 127-157 {1,300-1,600, 94-115}
OVERHAUL
EN0110611H200001
1. INSTALL THE V-RIBBED BELT.

(1) Install the V-ribbed belt on the pulleys except alternator pulley.
(2) Using a wrench, move the tension pulley slowly to arrow marked
direction, then install the V-ribbed belt on the alternator pulley.
SHTS011061100005

NOTICE

END FRAME.
NOTICE
SHTS011061100006
SHTS011061100007
SHTS011061100008
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧞㧤ಽ

NOTICE
V-BELT Wind V-belt around pulley groove and grip it securely in a vise so
(2) Remove the pulley and fan.
SHTS011061100009
NOTICE
SHTS011061100010

SHTS011061100011

NOTICE
JIG
new one.
SHTS011061100012

gently.
NOTICE
sec.).
SHTS011061100013

NOTICE
SHTS011061100014

COIL.
NOTICE
sec.)
SHTS011061100015
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100016

NOTICE
TERMINAL B
SHTS011061100017
(3) Remove the rectifier holder, regulator and condenser.

NOTICE
SHTS011061100018

SHTS011061100019
NOTICE
new one.
SHTS011061100020

JIG 1. INSTALL THE ROTOR.
(1) Using a press and a jig, install the cover and a new ball bearing
into the drive end frame.
NOTICE
SHTS011061100021
(2) Install the shim and retainer plate.

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100022

NOTICE
• Attach the jig on the inner race of the ball bearing.
SHTS011061100023
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
V-BELT
SHTS011061100024

JIG A tifier end frame.
NOTICE
ROLLER
BEARING
JIG B
SHTS011061100025

HOLDER.
Tightening Torque:
2.9-3.9 N⋅m {30-39 kgf⋅cm, 2.2-2.8 lbf⋅ft}
NOTICE
SHTS011061100026

NOTICE
SHTS011061100027

each parts.
Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
NOTICE
SHTS011061100028
2A'0A#HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧞ಽ
REGULATOR lator and field coil as well as the stator coil and diode.
NOTICE
lator.
sec.).
SHTS011061100029
TERMINAL
LEAD WIRE
REGULATOR
SHTS011061100030

Tightening Torque:
4.9-5.9 N⋅m {50-60 kgf⋅cm, 3.7-4.3 lbf⋅ft}
HINT
necting its wiring.
TERMINAL B
SHTS011061100031

FRAME.
through bolts.
Tightening Torque:
5.9-8.8 N⋅m {60-90 kgf⋅cm, 4.4-6.4 lbf⋅ft}
NOTICE
SHTS011061100032

Tightening Torque:
1.9-2.5 N⋅m {20-25 kgf⋅cm, 1.5-1.8 lbf⋅ft}
SHTS011061100033

Tightening Torque:
3.3-4.4 N⋅m {34-44 kgf⋅cm, 2.5-3.1 lbf⋅ft}
NOTICE
Don’t hit the cover since its hook is fragile.
SHTS011061100034

rotates smoothly.
SHTS011061100035

(1) Measure the resistance between terminals. If the resistance is not
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
PERFORMANCE TEST
NOTICE
connections.
ness.
tester.

alternator slowly.
28V.


EN0110611H300001
Unit: mm {in.}
Measure

[at 20°C (68°F)]
Measure
field coil
Measure
W
0.11-0.12 Ω — Replace. U
coil [at 20°C (68°F)] V
WIRING
Measure
stator
Measure
Resistance of diode Normal direction

NOTICE APPROX. 10 Ω
— Replace.
Do not use digital Reverse direction
tester. ∞Ω
Measure
Rotor shaft outside

portion)
Measure
Rotor shaft outside

portion)
Normal direction
APPROX. 10 Ω
Reverse direction
∞Ω
Resistance of con-
tester.
2A'0AM9HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧡㧡ಽ
STARTER (J08E: 24V, 4.5 kW) EN12–1
STARTER (J08E: 24V, 4.5 kW)

EN12
EN12-001
STARTER .................................................. EN12-2

DESCRIPTION ................................................ EN12-2
OVERHAUL ..................................................... EN12-6
EN12–2 STARTER (J08E: 24V, 4.5 kW)
STARTER
EN0110812I200001
Type Reduction gear type
Rated output 24 V, 4.5 kW
Number of teeth of pinion 11
Module 3
Rotating direction Clockwise (Seen from pinion side)
DESCRIPTION
EN0110812C100001
SHTS011081200001
1 Holder assembly 7 Pinion gear

2 Brush 8 Drive housing assembly
3 Yoke assembly 9 Gear housing
4 Magnetic switch assembly 10 Armature assembly
5 Lever 11 Field coil
6 Drive shaft assembly 12 Commutator end frame
TROUBLESHOOTING
EN0110812F300001

Engine does not crank, or cranks Poor contact Clean or replace contacts.
slowly. (Starter switch)
Engine does not crank, or cranks Discharged battery Charge.
slowly. (Battery) Short circuit between electrodes Replace battery.
Poor contact at battery terminal Clean or retighten.
Engine does not crank, or cranks Improper viscosity oil Change oil.
slowly. (Engine oil)
Engine does not crank, or cranks Poor contact caused by burnt contact Clean or replace contact plate.
slowly. (Magnetic switch) plate
Contact plate worn out Repair.
Holding coil disconnected (Overrun- Replace field coil.
ning clutch moves back and forth)
Pull-in coil disconnected or short cir- Replace.
cuit
Engine does not crank, or cranks Defective or poor contact Repair or replace.
slowly. (Starter relay)
Engine does not crank, or cranks Brush worn out Replace.
slowly. (Starter) Commutator burnt out Correct on lathe.
Commutator worn out Correct by undercutting.
Field winding shorted or grounded Rewind or replace.
Armature winding shorted or grounded Replace armature.
Insufficient brush spring tension Replace brush spring.
Poor contact between magnetic switch Repair.
and field windings
Armature contact pole core because of Replace bearing brush or armature.
worn bearing bushing or bent arma-
ture shaft
Overrunning clutch malfunction Replace.
Engine does not crank while starter Overrunning clutch malfunction Replace.
is running in good condition Pinion teeth worn out Replace.
(Overrunning clutch)
Poor sliding of spline teeth Remove foreign particles, dirt or
replace.
Starter does not stop running. Contacts keep closing Replace.
(Starter switch) Key switch sticks Replace.
Overrunning clutch sticks to armature Repair or replace overrunning or
armature.
Starter does not stop running. Contacts keep closing Repair or replace.
(Starter relay)
COMPONENT LOCATOR
EN0110812D100001
SHTS011081200002
1 "C" terminal lead 14 Spring

2 Magnetic switch assembly 15 Holder
3 O-ring 16 Pin
4 Through bolt 17 Lever
5 Commutator end frame 18 Packing
6 Brush holder assembly 19 Plate
7 Brush spring 20 Drive shaft assembly
9 Yoke assembly 22 Bushing
10 Felt 23 Dust cover
11 Armature assembly 24 Pinion gear
12 Needle roller bearing 25 Retainer ring
13 Gear housing 26 Starter

A 14-16 {140-160, 10.2-11.5} E 2-3 {19-25, 1.4-1.8}
B 4-5 {37-50, 2.7-3.6} F 154 {1,570, 114}
C 14-16 {140-160, 10.2-11.5} G 12-15 {125-155, 10-11}
D 154 {1,570, 114}
OVERHAUL
EN0110812H200001

When disassembling the starter, prepare a work stand as shown in the
figure.
D:Diameter = 110 mm {4.331 in.}
T:Thickness = 10 mm {0.394 in.}
H:Height = 120 mm {4.724 in.}
SHTS011081200003
1. REMOVE THE TERMINAL LEAD.

M TERMINAL LEAD CAP (1) Remove the bolt, disconnect the "C" terminal lead.
(2) Remove the nut, disconnect the "M" terminal lead.
CAP
C TERMINAL LEAD
SHTS011081200004
2. REMOVE THE COMMUTATOR END FRAME.

(1) Remove the through bolt.
SHTS011081200005
(2) Remove the bolt and O-ring, remove the commutator end frame.
COMMUTATOR
END FRAME
SHTS011081200006
3. REMOVE THE HOLDER ASSEMBLY.

(1) Using a long nose plier, remove the brush of the yoke from the
holder.
SHTS011081200007
(2) Remove the holder assembly from the armature.

NOTICE
Do not cut the fixed clamp of brush lead.
SHTS011081200008
4. REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEM-

G1 BLY.
(1) Remove the yoke assembly and armature assembly from the gear
housing.
G1
SHTS011081200009
5. REMOVE THE START MAGNET SWITCH ASSEMBLY.

A (1) Remove two bolts.
(2) Remove the start magnet switch assembly.
NOTICE
When removing the start magnet switch assembly, tilt the head of
B
the start magnet switch assembly to the side A, and then remove it
pulling to the side B (upper side).
SHTS011081200010
6. REMOVE THE DRIVE SHAFT ASSEMBLY.

(1) Remove the gear housing from the drive housing
SHTS011081200011
(2) Remove the retainer ring.

(3) Remove the pinion gear.
SHTS011081200012
(4) Remove the lever and drive shaft assembly from the drive hous-
ing.
HOLDER
PIN
LEVER
SHAFT ASSEMBLY
SHTS011081200013

DRIVE HOUSING
1. INSTALL THE DRIVE SHAFT ASSEMBLY.
DUST SEAL BUSHING (1) Fill up the grease (Multemp AC-N) to the reservoir from bushing
hole that until overflow from other hole.
HOLE
RESERVOIR
SHTS011081200014
(2) Assemble the holder, pin and lever.

HOLDER (3) Apply the grease (G1: Multemp AC-N, G2: Pyronoc No.2) to the
G1 portion as shown in the figure.
(4) Install the drive shaft assembly and lever into the drive housing
G2 assembly at the same time.
G2
NOTICE
Make sure that the holder is installed securely and it slides
smoothly.
G1
SHTS011081200015
2. INSTALL THE PINION GEAR.

(1) Put the drive shaft assembly on the working bench. Using a brass
bar and a hammer, install the pinion gear in the drive shaft assem-
bly with tapping the pinion gear evenly.
(2) Using a pair of pliers, install a new retainer ring in the drive shaft
assembly to fix the pinion gear.
NOTICE
Install the pinion gear facing its chamfered surface outward.
SHTS011081200016
3. INSTALL THE GEAR HOUSING.

PACKING (1) Apply the grease (G1: Multemp AC-N) to the portion as shown in
PLATE
SPRING the figure.
G1
(2) Install the spring, new packing and plate.
G1 (3) Install the gear housing.
SHTS011081200017
4. INSTALL THE START MAGNET SWITCH ASSEMBLY.

A (1) Install the start magnet switch assembly.
NOTICE
When installing the start magnet switch assembly, tilt the head of
the start magnet switch assembly to the side A, and then insert it
B
into direction B.
SHTS011081200018
5. INSTALL THE ARMATURE ASSEMBLY.

G1 (1) Apply the grease (G1: Multemp AC-N) to the portion as shown in
the figure.
(2) Install the new felt to the armature assembly.
(3) Install the armature assembly to the gear housing.
G1
SHTS011081200009
6. INSTALL THE YOKE ASSEMBLY.

(1) Align the notches, install the yoke assembly.
SHTS011081200019
7. INSTALL THE HOLDER ASSEMBLY AND THE COMMUTATOR

END FRAME.
(1) Install the holder assembly in the commutator of the armature
assembly aligning two location notches (concavity) of the holder
assembly with convexity of the M lead wire and with convexity on
the opposite surface of the M lead wire.
SHTS011081200020
(2) Install the brush to the brush holder.
SHTS011081200021
(3) Apply grease (G1: Multemp AC-N) to the portion as shown in the
LOCATION G1 figure.
GIDE (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
8. AFTER ASSEMBLING THE STARTER, MEASURE THE PINION

GEAR THRUST GAP.
C (1) Arrange the circuit.
S1 (2) Close switches S1 and S2.
(3) Open S2 alone when the pinion pops out.
M
S2
M 24V
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
0.5-3.0 mm
{0.020-0.118 in.}
SHTS011081200024

NOTICE
These tests must be performed within 3 to 5 seconds to avoid
burning out the coil.
1. PERFORM PULL-IN TEST.

(1) Disconnect the field coil lead wire from the terminal M.
(2) Connect battery to the magnetic switch as shown.
(3) Check that the pinion gear moves outward.
SHTS011081200025
2. PERFORMANCE HOLD-IN TEST.

(1) While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal M.
(2) Check that the pinion gear remains out.
SHTS011081200026
3. INSPECTION PLUNGER RETURN. (Solenoid Coil Balance

Check)
(1) Disconnect the positive (+) lead from the terminal C.
(2) Check that the pinion gear returns inward.
SHTS011081200027
4. PERFOM NO-LOAD PERFOMANCE TEST.

(1) The following test should be carried out after reassembling the
starter. If suitable equipment is not available, at least the no-load
test should be carried out.
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.
Revolution 4,000 r/min or more

Current 100 A or less
SHTS011081200028

EN0110812H300001
Unit: mm {in.}
Measure
If the iron rod does

Armature short circuit
not vibrated,
test (Using a growler — Replace.
the armature is
tester)
good.
Measure
Less than
Armature insulation More than 1 MΩ Replace.
0.5 MΩ
Measure
Continuity between the

segments of the com- Continuity — Replace.
mutator
Measure
Outside diameter of the 30.0 {1.181} or

32.0 {1.260} Replace.
commutator less
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

brush and the "M" ter- Continuity — Replace.
minal
Measure
Insulation between the

Less than
brush and the yoke More than 1 MΩ Replace.
0.5 MΩ
body
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
Insulation between the Less than

More than 1 MΩ Replace.
brush and brush holder 0.5 MΩ
Measure
Brush length 18.0 {0.709} 12.0 {0.472} Replace.
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
Inside diameter of the 26.2 {1.031} or

26.0 {1.024} Replace the metal.
drive housing assembly more
Measure

12.1 {0.476} Replace.
gear housing more
Measure
Inside diameter of com- 12.2 {0.480} or

12 {0.472} Replace.
mutator end frame more
Visual check
NEEDLE
ROLLER
Rotating of needle roller
— — Replace. BEARING
bearing
Visual check
Replace, if both side

Rotating of pinion — — turn or does not turn
at all.
Measure
Resistance between the

C terminal and M termi- 0.16-0.19 Ω — Replace.
nal (Pulling Coil)
Measure
Resistance between the

C Terminal and the 0.84-0.94 Ω — Replace.
body (Holding Coil)
2A'0AM9HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧡㧢ಽ
STARTER (J08E: 24V, 5.0 kW)

EN12
EN12-002
STARTER .................................................. EN12-2

DESCRIPTION ................................................ EN12-2
OVERHAUL ..................................................... EN12-5
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧜ಽ
STARTER
EN0110612I200001
Type Reduction gear type
Rated output 24 V, 5.0 kW
Number of teeth of pinion 11
Module 3
Rotating direction Clockwise (Seen from pinion side)
DESCRIPTION
EN0110612C100001
SHTS011061200001
1 Holder assembly 7 Pinion gear

3 Yoke assembly 9 Gear housing
4 Magnetic switch assembly 10 Armature assembly
5 Lever 11 Field coil
6 Drive shaft assembly 12 Commutator end frame
TROUBLESHOOTING
EN0110612F300001

Engine does not crank, or cranks Poor contact Clean or replace contacts.
slowly. (Starter switch)
Engine does not crank, or cranks Discharged battery Charge.
slowly. (Battery) Short circuited between electrodes Replace battery.
Poor contact at battery terminal Clean or retighten.
Engine does not crank, or cranks Improper viscosity oil Change oil.
slowly. (Engine oil)
Engine does not crank, or cranks Poor contact caused by burnt contact Clean or replace contact plate.
slowly. (Magnetic switch) plate
Contact plate worn out Repair.
Holding coil disconnected (Overrun- Replace field coil.
ning clutch moves back and forth)
Pull-in coil disconnected or short cir- Replace.
cuited
Engine does not crank, or cranks Defective or poor contact Repair or replace.
slowly. (Starter relay)
Engine does not crank, or cranks Brush worn out Replace.
slowly. (Starter) Commutator burnt out Correct on lathe.
Commutator worn out Correct by undercutting.
Field winding shorted or grounded Rewind or replace.
Armature winding shorted or grounded Replace armature.
Insufficient brush spring tension Replace brush spring.
Poor contact between magnetic switch Repair.
and field windings
Armature contact pole core because of Replace bearing brush or armature.
worn bearing bushing or bent arma-
ture shaft
Overrunning clutch malfunction Replace.
Engine does not crank while starter Overrunning clutch malfunction Replace.
is running in good condition. Pinion teeth worn out Replace.
(Overrunning clutch)
Poor sliding of spline teeth Remove foreign particles, dirt or
replace.
Starter does not stop running. Contacts keep closing Replace.
(Starter switch) Key switch sticks Replace.
Overrunning clutch sticks to armature Repair or replace overrunning or
armature.
Starter does not stop running. Contacts keep closing Repair or replace.
(Starter relay)
COMPONENT LOCATOR
EN0110612D100001
SHTS011061200002
1 "C" terminal lead 13 Magnetic switch assembly

2 Center bracket assembly 14 Internal gear
3 Clutch sub-assembly 15 Planetary gear
4 Through bolt 16 Cover
5 Commutator end frame 17 Lever
6 Brush holder assembly 18 Packing
7 Brush spring 19 Plate
8 Brush 20 Retainer ring
9 Yoke assembly 21 Drive housing assembly
10 Shaft assembly 22 Bushing
11 Armature assembly 23 Dust cover
12 Bearing 24 Pinion gear

A 3.6-4.9 {37-50, 2.7-3.6} C 15.7-17.6 {160-180, 11.6-13.0}
B 14-16 {140-160, 10.2-11.5}
OVERHAUL
EN0110612H200001

When disassembling the starter, prepare a work stand as shown
in the figure.
D: Diameter = 110 mm {4.331 in.}
T: Thickness = 10 mm {0.394 in.}
H: Height = 120 mm {4.724 in.}
SHTS011061200003
1. REMOVE THE TERMINAL LEAD.

M TERMINAL LEAD (1) Remove the bolt, disconnect the "C" terminal lead.
(2) Remove the nut, disconnect the "M" terminal lead.
M TERMINAL
SHTS011061200004
2. REMOVE THE COMMUTATOR END FRAME.

THROUGH BOLT (1) Remove the through bolt.
REAR BRACKET
SHTS011061200005
(2) Remove the bolt, remove the commutator end frame.
BOLT
SHTS011061200006
3. REMOVE THE HOLDER ASSEMBLY.

(1) Using a long nose plier, remove the brush of the yoke from the
holder.
SHTS011061200007
(2) Remove the holder assembly from the armature.

NOTICE
Do not cut the fixed clamp of brush lead.
SHTS011061200008
4. REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEM-

BLY.
M TERMINAL LEAD (1) Remove the yoke assembly and armature assembly from the cen-
YOKE ASSEMBLY ter bracket assembly.
SHTS011061200009
5. REMOVE THE BEARING.

(1) Using the puller, remove the ball bearing from the armature
assembly.
BALL BEARING
PULLER
SHTS011061200010
6. REMOVE THE GEAR.

(1) Remove the cover and packing.
PACKING COVER
SHTS011061200011
(2) Remove the planetary gear.

(3) Remove the internal gear.
PLANETARY
GEAR
CARRIER PIN
INTERNAL
GEAR
SHTS011061200012
7. REMOVE THE PINION GEAR.

(1) Remove the retainer ring.
PINION GEAR
! CAUTION
RETAINER Wear a pair of safety goggles, because the retainer ring may
RING spring out the groove at the time of removal.
SHTS011061200013
SHTS011061200014
(2) Remove the pinion stopper.

(3) Remove the pinion gear.
RETAINER
RING
SHTS011061200015
8. REMOVE THE DRIVE HOUSING ASSEMBLY.

(1) Remove the bolt, remove the drive housing assembly.
SHTS011061200016
9. REMOVE THE LEVER.

(1) Pushing the lever toward clutch.
SHTS011061200017
(2) Turn the lever and remove the lever.
SHTS011061200018
10. REMOVE THE BRAKE PLATE.

(1) Holding the outer diameter of the clutch case and sliding the
clutch assembly to upper side, remove it, pinching the clip of fixing
the brake plate with a pliers.
SHTS011061200019
(2) Remove the brake plate.
BRAKE PLATE
SHTS011061200020
11. REMOVE THE CLUTCH ASSEMBLY.

(1) Pushing the clutch assembly toward center bracket assembly,
CLUTCH ASSEMBLY shift a bit by a tooth the phase of helical spline.
(2) Pulling out to upper direction from its shifted location, remove the
clutch assembly.
CENTER
BRACKET
ASSEMBLY
SHTS011061200021
12. REMOVE THE SHAFT ASSEMBLY.

(1) Turning the center bracket assembly up side-down, pull out the
WASHER shaft assembly, holding the carrier plate.
NOTICE
Be careful not to lose the washers of upper and lower sides of the
carrier plate.
SHAFT ASSEMBLY
SHTS011061200022
13. REMOVE THE PACKING.

(1) Turning the center bracket assembly upside-down again, remove
the packing reversed.
NOTICE
The packing is not reusable.
PACKING
SHTS011061200023
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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

NOTICE
These tests must be performed within 3 to 5 seconds to avoid
burning out the coil.
1. PERFORM PULL-IN TEST.

(1) Disconnect the field coil lead wire from the terminal M.
(2) Connect battery to the magnetic switch as shown.
(3) Check that the pinion gear moves outward.
SHTS011061200025
2. PERFORM HOLD-IN TEST.

(1) While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal M.
(2) Check that the pinion gear remains out.
SHTS011061200026
3. INSPECTION PLUNGER RETURN (Solenoid Coil Balance

Check)
(1) Disconnect the positive (+) lead from the terminal C.
(2) Check that the pinion gear returns inward.
SHTS011061200027
4. PERFOM NO-LOAD PERFOMANCE TEST.

(1) The following test should be carried out after reassembling the
starter. If suitable equipment is not available, at least the no-load
test should be carried out.
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.
Revolution 4,000 r/min. or more

Current 100 A or less
SHTS011061200028

EN0110612H300001
Unit: mm {in.}
Measure
If the iron rod does

Armature short circuit
not vibrated,
test (Using a growler — Replace.
the armature is
tester)
good.
Measure
Less than
Armature insulation More than 1 MΩ Replace.
1 KΩ
Measure

segments of the com- Continuity — Replace.
mutator
Measure
Outside diameter of the 34.0 {1.339} or

36.0 {1.417} Replace.
commutator less
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

brush and the "M" ter- Continuity — Replace.
minal
Measure
Insulation between the

Less than
brush and the yoke More than 1 MΩ Replace.
1 kΩ
body
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
Insulation between the Less than

More than 1 MΩ Replace.
brush and brush holder 1 kΩ
Measure
Brush length 18.0 {0.709} 13.0 {0.512} Replace.
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
Outside diameter of the A: 24.90

A: 25.0 {0.984} Replace.
clutch sub assembly {0.980}
Measure

25.0 {0.984} Replace the metal.
drive housing assembly more
Measure
Inside diameter of the

center bracket 26.0 {1.024} 26.2 {1.031} Replace.
assembly
Measure
Inside diameter of the

9.0 {0.354} 9.2 {0.362} Replace.
shaft assembly
Measure
Inside diameter of com-

28.0 {1.102} 28.1 {1.106} Replace.
mutator end frame
Visual check
Rotating of ball bearing — — Replace.
Visual check
Replace, if both side

Rotating of pinion — — turn or does not turn
at all.
Measure
C
Resistance between the M

C terminal and M termi- 0.12-0.14 Ω — Replace.
nal (Pulling coil)
Measure
Resistance between the C

C Terminal and the 1.13-1.25 Ω — Replace.
body (Holding coil)
BODY
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'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧝㧝ಽ
AIR COMPRESSOR (J08E: 154 cm3) EN13–1
AIR COMPRESSOR (J08E: 154 cm3)

EN13
EN13-001
AIR COMPRESSOR.................................. EN13-2

DESCRIPTION ................................................ EN13-2
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
EN13–2 AIR COMPRESSOR (J08E: 154 cm3)
AIR COMPRESSOR
EN0110613I200001
Type Reciprocating, single cylinder
Discharge amount 154cm3 {9.4 cu.in.}
Bore x stroke 70 mm x 40 mm {2.76 in. x 1.57 in.}
Lubrication system Forced feed lubrication
Cooling system Forced water-circulated
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
TROUBLESHOOTING
EN0110613F300001

Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace.
tact
Charging efficiency dropped Worn piston and cylinder liner Replace.
(Piston, Cylinder liner and piston Seized piston Replace (piston, piston rings and cylin-
rings) der liner).
Worn or broken piston ring Replace.
Charging efficiency dropped Leakage of high-pressure air Replace or tighten pipe joint.
(Air pipe and joints) Clogged air pipe Replace.
Charging efficiency dropped Clogged element Clean or replace element.
(Air cleaner)
Noisy operation (Piston) Wear of piston pin boss or piston pin Replace.
Seized, damaged or worn connecting Replace.
rod small end
Worn piston or cylinder liner Replace.
Damaged or seized piston Replace.
Foreign particles on the top surface of Clean or replace.
piston
Noisy operation (Bearing) Damaged, or worn ball bearing and/or Replace.
connecting rod bearing
Excessive carbon or oil in the com- Worn, sticking or broken piston rings Replace piston rings and/or cylinder
pressor cylinder head or discharge liner.
line (Piston ring) Insufficient piston ring tension Replace piston rings and/or cylinder
liner.
Malfunction of piston rings Replace piston rings and/or cylinder
liner.
Excessive carbon or oil in the com- Worn cylinder liner and piston rings Replace.
pressor cylinder head or discharge
line (Cylinder liner and piston rings)
COMPONENT LOCATOR
EN0110613D100001
b
a
a
a b
c
a
1 Z
Y
Y
Z
SHTS011061300002
1 Air compressor

A 353 {3,600, 260} #
#= Apply oil to the threads and seat surface before tightening.
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
1 Cylinder head 10 Lock washer

2 Gasket 11 Piston pin
3 Valve seat 12 Retainer ring
4 O-ring 13 Coupling
5 Cylinder liner 14 Ball bearing
6 Piston ring 15 Cylinder block
8 Connecting rod 17 Woodruff key
9 Connecting rod bearing 18 Bearing holder

A 25-30 {255-305, 19-22} D 6-7.5 {61-76, 4.4-5.5}
B 23-26 {235-265, 17-19} E 30-35 {306-356, 23-25}
C 30-36 {305-367, 22-26}
SPECIAL TOOL
EN0110613K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
S0965-01310 PULLER ASSEMBLY
S0944-01060 PISTON RING EXPANDER
S0965-01101 BEARING PULLER

2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧟ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧠ಽ
OVERHAUL
EN0110613H200001
1. REMOVE THE SUPPLY PUMP.

(1) Refer to the chapter "FUEL SYSTEM".
2. REMOVE THE AIR COMPRESSOR.

(1) Remove the six air compressor mounting bolts and remove the air
compressor without applying excessive force.
NOTICE
Excessive force to the air compressor may damage the mounting
spigot or may cause oil leakage due to flaking of liquid gasket
between the flywheel housing and plate.

1. INSTALLATION PROCEDURES
FLYWHEEL (1) Fit the No.1 cylinder to the Top Dead Center.
NOTICE
1 Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
FLYWHEEL INTRODUCTION (J08E)".
HOUSING
SHTS011061300007
(3) Insert the O-ring into the O-ring groove of the air compressor of
"0" MARK bearing holder side.
COUPLING FLANGE PROTRUSION

SHTS011061300008
(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 Ibf⋅ft}
SHTS011061300009
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(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.
2. INSTALL THE SUPPLY PUMP.

SHTS011061300010

DRIVE GEAR
1. REMOVE THE DRIVE GEAR.
(1) Remove the lock nut from the compressor drive gear.
NOTICE
If the spread is insufficient, the drive gear will be damaged when
loosening the nut.
LOCK THE GEAR
BY VISE
SHTS011061300011
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Bearing puller (S0965-01101)
SHTS011061300012
2. REMOVE THE CYLINDER HEAD, GASKET, VALVE SEAT AND

O-RING.
(1) Remove the cylinder head, gasket, valve seat and o-ring.
NOTICE
• Put the marking through the cylinder head to the cylinder
VALVE SEAT
liner.
• Do not disassemble the valve seat.
MARKING
SHTS011061300013
3. REMOVE THE CONNECTING ROD WITH THE PISTON.

(1) Rotate the crankshaft to the top dead center position.
(2) Spread the staking of the nut completely with a chisel, then
loosen the nut.
ALIGNING
MARKS NOTICE
Put the aligning marks to the connecting rod and the cap.
(3) Remove the connecting rod with piston.
SHTS011061300014

(1) Remove the piston rings.
SST SST: Piston ring expander (S0944-01060)
NOTICE
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
SHTS011061300015
5. REMOVE THE PISTON.

RETAINER RING
(1) Remove the retainer rings installed on both ends of the piston,
using retainer ring pliers.
! WARNING
Wear a pair of safety goggles, because the retainer rings may
spring out the groove at the time of removal.
(2) Strike out the piston pin.
NOTICE
Warm up the piston first in hot water, 80-90°C {176-194°F}, for
PISTON PIN
approximately 5 minutes before removing the piston pin.
SHTS011061300016
6. REMOVE THE CRANKSHAFT.

(1) Remove the coupling.
(2) Remove the bearing holder fitting bolts.
(3) Using a press, remove the crankshaft with bearing holder.
SHTS011061300017
7. REMOVE THE BEARING HOLDER.

(1) Strike the circumference of the holder lightly with a plastic ham-
mer or a mallet and remove the holder.
NOTICE
Be careful not to damage the bearing holder.
SHTS011061300018
8. REMOVE THE BALL BEARING.

(1) Using the special tool, remove the ball bearing from the end of the
crankshaft.
SST:
Bearing puller (S0965-01101, for supply pump side)
Puller assembly (S0965-01310, for drive gear side)
SHTS011061300019
1. INSTALL THE BALL BEARING.

(1) Install the ball bearing.
STRIKING
TOOL
SHTS011061300020

(1) Using a copper hammer, install the crankshaft to the bearing
holder.
STRIKING
TOOL
SHTS011061300021
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧠ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧠㧜ಽ
(2) Install the crankshaft and bearing holder in the crankcase.

(3) Tighten the bearing holder fitting bolt.
SHTS011061300022

(1) Install the coupling.
SHTS011061300023
4. INSTALL THE CONNECTING ROD AND MEASURE THE END

PLAY.
NOTICE
ALIGNING • Be sure to align the aligning mark.
MARKS • Apply engine oil to the bearing.
(1) Apply engine oil to the thread before installing the connecting rod
bolt.
SHTS011061300024
(2) Measure the connecting rod end play.

Limit: 0.5 mm {0.02 in.}
SHTS011061300025
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧢ಽ
(3) Lock the nut with a lock washer.

BENT SURFACE FITS
CLOSE TO THE NUT
AND CONNECTING ROD
SHTS011061300026
5. MEASURE THE END PLAY OF THE CRANKSHAFT.

Assembly standard: 0-0.6 mm {0-0.023 in.}
Limit: 1.0 mm {0.039 in.}
SHTS011061300027
END PLAY
SHTS011061300028
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧝㧞ಽ
6. ASSEMBLE THE PISTON.

NOTICE
Assemble the various parts after applying engine oil to the sliding
parts.
(1) When installing the piston rings on the piston, ensure that the pis-
ton skirt is at the bottom, and use the special tool.
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011061300029

NOTICE
Warm up the piston first in hot water, to 80-90°C {176-194°F}, for
approximately 5 minutes.
(1) Install the retainer ring at one end of the piston holes.
(2) Apply engine oil to the piston pin.
(3) Fix the piston and connecting rod by inserting the pin.
(4) Fit the new retainer ring at the other end.
! WARNING
The retainer ring may spring out of the groove during assembly.
SHTS011061300030 Wear a pair of safety goggles during assembly.
8. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.

THIRD TOP
RING (2) Arrange the piston rings so that their gaps are equally spaced.
45 45 RING
OIL
RING
SECOND
RING PIN HOLE
SHTS011061300031
(3) Install the cylinder liner.

O-RING
NOTICE
• Align the aligning marks.
• Do not twist the O-ring when installing.
ALIGNIG MARK
SHTS011061300032
(4) Install the cylinder head.

NOTICE
O-RING
MARKING
SHTS011061300033
9. INSTALL THE DRIVE GEAR.

(1) Install the key to the crankshaft.
DRIVE (2) Insert the drive gear.
GEAR
(3) Insert the collar and lock nut.
Tightening Torque:
353 N⋅m {3,600 kgf⋅cm, 260 lbf⋅ft}
NOTICE
LOCK THE Apply oil to the threads and seat surface before tightening.
GEAR
BY VISE
SHTS011061300034

EN0110613H300001
Unit: mm {in.}
Visual check
Cracks or defects of the

— — Replace.
connecting rod
Visual check
Damage and scratches of the

— — Replace.
cylinder liner
Visual check
Replace valve
Worn or damaged delivery valve — —
seat.
Visual check
Replace valve
Worn or damaged suction valve — —
seat.
Measure
Outside diameter of piston pin 14.0 {0.551} —
Replace pis-
ton pin or con-
necting rod.
Clearance between the piston 0.016-0.044

0.07 {0.0028}
pin and connecting rod {0.0007-0.0017}
Inside diameter of the connect-

ing rod (with bearings): A
34 {1.339} —
#Tighten the bearing cap to the
specified torque
Outside diameter of the crank

34 {1.339} —
pin: B
Replace con-
necting rod
bearing.
Oil clearance between the con-
necting rod and the crank pin: C 0.017-0.083
0.1 {0.0039}
# Oil clearance {0.0007-0.0032}
C= A-B
Measure
Outside diameter of the piston
70 {2.756} —
(Measure at A and B)
Inside diameter of the cylinder

70 {2.756} —
liner (Measure at A and B) Replace pis-
ton or cylinder
A: 0.18-0.245 liner.
0.285 {0.0112}
{0.0071-0.0096}
Clearance between the piston
and the cylinder liner
B: 0.084-0.144
0.184 {0.0072}
{0.0033-0.0056}
Inside diameter of the piston pin Measure

14.0 {0.551} —
hole: A
Outer diameter of the piston pin:

14.0 {0.551} —
B
Replace pis-
ton or piston
Clearance between the piston pin.
pin hole and the piston pin: C 0-0.026
0.08 {0.0031}
# Clearance {0-0.0010}
C= A-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
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}
Outside diameter of the

Replace.
crankshaft journal
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
Worn or damaged bearing — — Replace.
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 crank
Crankshaft end play 0-0.6 {0-0.023} 1.0 {0.039}
shaft bearing.
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧝㧟ಽ
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧝㧡ಽ

EN13
EN13-002

DESCRIPTION ................................................ EN13-2
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
AIR COMPRESSOR
EN0110613I200001
Discharge amount 227cm3 {13.9 cu.in.}
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'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧤ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦᓟ㧞ᤨ㧞㧝ಽ
TROUBLESHOOTING
EN0110613F300001

tact
Charging efficiency dropped Worn piston and cylinder liner Replace.
(Piston, Cylinder liner and piston Seized piston Replace (piston, piston rings and cylin-
rings) der liner).
(Air cleaner)
rod small end
piston
liner.
liner.
COMPONENT LOCATOR
EN0110613D100001
b
a
a
a b
c
a
1 Z
Y
Y
Z
SHTS011061300002
1 Air compressor

A 353 {3,600, 260} #
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧣ಽ
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
1 Cylinder head 10 Lock washer

3 Valve seat 12 Retainer ring
4 O-ring 13 Coupling
5 Cylinder liner 14 Ball bearing
6 Piston ring 15 Cylinder block
8 Connecting rod 17 Woodruff key
9 Connecting rod bearing 18 Bearing holder

A 25-30 {255-305, 19-22} D 6-7.5 {61-76, 4.4-5.5}
B 23-26 {235-265, 17-19} E 30-35 {306-356, 23-25}
C 30-36 {305-367, 22-26}
SPECIAL TOOL
EN0110613K100001

2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧟ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧡㧣ಽ
OVERHAUL
EN0110613H200001
1. REMOVE THE SUPPLY PUMP.

2. REMOVE THE AIR COMPRESSOR.

(1) Remove the six air compressor mounting bolts and remove the air
NOTICE

1. INSTALLATION PROCEDURES
FLYWHEEL (1) Fit the No.1 cylinder to the Top Dead Center.
NOTICE
1 Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
FLYWHEEL INTRODUCTION (J08E)".
HOUSING
SHTS011061300007
(3) Insert the O-ring into the O-ring groove of the air compressor of
"0" MARK bearing holder side.

SHTS011061300008
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 20 Ibf⋅ft}
SHTS011061300009
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧟ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧡㧣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.
2. INSTALL THE SUPPLY PUMP.

SHTS011061300010

DRIVE GEAR
NOTICE
loosening the nut.
LOCK THE GEAR
BY VISE
SHTS011061300011
key.
SHTS011061300012

O-RING.
NOTICE
VALVE SEAT
liner.
MARKING
SHTS011061300013

loosen the nut.
ALIGNING
MARKS NOTICE
Put the aligning marks to the connecting rod and the cap.
SHTS011061300014

SST SST: Piston ring expander (S0944-01060)
NOTICE
SHTS011061300015

RETAINER RING
! WARNING
NOTICE
PISTON PIN
SHTS011061300016

(1) Remove the coupling.
SHTS011061300017

NOTICE
SHTS011061300018

crankshaft.
SST:
Bearing puller (S0965-01101, for supply pump side)
Puller assembly (S0965-01310, for drive gear side)
SHTS011061300019

STRIKING
TOOL
SHTS011061300020

holder.
STRIKING
TOOL
SHTS011061300021
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧠ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧠㧞ಽ

SHTS011061300022

(1) Install the coupling.
SHTS011061300023

PLAY.
NOTICE
ALIGNING • Be sure to align the aligning mark.
MARKS • Apply engine oil to the bearing.
bolt.
SHTS011061300024

Limit: 0.5 mm {0.02 in.}
SHTS011061300025
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧝㧜ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧤ಽ

BENT SURFACE FITS
CLOSE TO THE NUT
AND CONNECTING ROD
SHTS011061300026

Limit: 1.0 mm {0.039 in.}
SHTS011061300027
END PLAY
SHTS011061300028
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧝㧣ಽ

NOTICE
parts.
NOTICE
ring facing up.
SHTS011061300029

NOTICE
! WARNING

THIRD TOP
RING (2) Arrange the piston rings so that their gaps are equally spaced.
45 45 RING
OIL
RING
SECOND
RING PIN HOLE
SHTS011061300031
(3) Install the cylinder liner.

O-RING
NOTICE
ALIGNIG MARK
SHTS011061300032
(4) Install the cylinder head.

NOTICE
O-RING
ALIGNING MARK
SHTS011061300033

DRIVE (2) Insert the drive gear.
GEAR
Tightening Torque:
353 N⋅m {3,600 kgf⋅cm, 260 lbf⋅ft}
NOTICE
LOCK THE Apply oil to the threads and seat surface before tightening.
GEAR
BY VISE
SHTS011061300034

EN0110613H300001
Unit: mm {in.}
Visual check
Cracks or defects of the

— — Replace.
connecting rod
Visual check

— — Replace.
cylinder liner
Visual check
Worn or damaged delivery Replace valve

— —
valve seat.
Visual check
Worn or damaged suction Replace valve

— —
valve seat.
Measure
Outside diameter of piston pin 18.0 {0.709} —
Replace pis-
ton pin or con-
necting rod.
Clearance between the piston 0.016-0.044

0.07 {0.0028}
Inside diameter of the con-

necting rod (with bearings): A
34 {1.339} —
#Tighten the bearing cap to
the specified torque

34 {1.339} —
pin: B
Replace con-
necting rod
bearing.
Oil clearance between the
connecting rod and the crank
0.017-0.083
pin: C 0.1 {0.0039}
{0.0007-0.0032}
# Oil clearance
C= A-B
Measure
Outside diameter of the piston
85 {3.346} —
(Measure at A and B)
Inside diameter of the cylinder

85 {3.346} —
liner (Measure at A and B) Replace pis-
ton or cylinder
A: 0.18-0.245 liner.
0.285 {0.0112}
{0.0071-0.0096}
and the cylinder liner
B: 0.09-0.155
0.195 {0.0076}
{0.0036-0.0061}
Inside diameter of the piston Measure

18.0 {0.709} —
pin hole: A
Outer diameter of the piston

18.0 {0.709} —
pin: B
Replace pis-
ton or piston
Clearance between the piston pin.
pin hole and the piston pin: C 0-0.028
0.08 {0.0031}
# Clearance {0-0.0011}
C= A-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
Second, third 0.005-0.040

0.08 {0.0031}
ring {0.0002-0.0016}
Measure
Piston ring gap: 0.1-0.3

1.0 {0.0394} Replace.
compression ring {0.0040-0.0118}
Measure
A: 40.002-40.013
39.995 {1.575}
{1.5749-1.5753}
Outside diameter of the

Replace.
crankshaft journal
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 crank
shaft bearing.
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧠㧣ಽ

EN13
EN13-003

DESCRIPTION ................................................ EN13-2
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
AIR COMPRESSOR
EN0110813I200001
Discharge amount 271 cm3 {16.5 cu.in.}
DESCRIPTION
EN0110813C100001
SHTS011081300001
1 O-ring 8 Crankshaft
2 Cylinder head assembly 9 Crankcase
4 Valve seat 11 Piston ring
5 Piston A Suction
6 Connecting rod B Delivery
7 Bearing
TROUBLESHOOTING
EN0110813F300001

tact
Charging efficiency dropped (Pis- Worn piston and cylinder liner Replace.
ton, Cylinder liner and piston rings) Seized piston Replace (piston, piston rings and cylin-
der liner).
(Air cleaner)
rod small end
piston
liner.
liner.
COMPONENT LOCATOR
EN0110813D100001
SHTS011081300002
1 Air compressor

A 353 {3,600, 260} #
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟㧠ಽ
SHTS011081300003
1 Cylinder head 12 Retainer ring

2 Gasket 13 Bearing retainer
3 Valve seat 14 Ball bearing
4 O-ring 15 Cylinder block
5 Cylinder liner 16 Crankshaft
6 Piston ring 17 Woodruff key
7 Piston 18 Bearing holder
8 Connecting rod 19 Oil seal
9 Connecting rod bearing 20 Oil seal sleeve
10 Lock washer 21 Drive gear
11 Piston pin 22 Lock nut

A 25-30 {255-305, 19-22} D 14-18 {143-183, 11-13}
B 23-26 {235-265, 17-19} E 25-30 {255-305, 19-22}
C 353 {3,600, 260} #
#= Apply oil to the threads and seat surfaces before tightening.
SPECIAL TOOL
EN0110813K100001
S0942-01830 PULLER
S0948-22220 SLEEVE PRESS

OVERHAUL
EN0110813H200001

Remove the five air compressor mounting bolts and remove the air
NOTICE
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
SHTS011081300012
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
SHTS011081300013
NOTICE
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
SHTS011081300014
2. INSTALL THE FUEL PIPES FOR THE INJECTION PUMP AND

AIR COMPRESSOR.

NOTICE
loosing the nut.
SHTS011081300015
key.
SHTS011081300016

O-RING.
NOTICE
liner.
SHTS011081300017
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟㧠ಽ

loosen the nut.
SHTS011081300018

NOTICE
SHTS011081300019

! WARNING
NOTICE
SHTS011081300020

(3) Using a plastic hammer, strike out the bearing holder from the
crankshaft.
SHTS011081300021

NOTICE
SHTS011081300022
8. REMOVE THE OIL SEAL SLEEVE.

(1) Remove the oil seal sleeve with the special tool.
SST: Puller assembly (S0942-01670)
SHTS011081300023

crankshaft.
SHTS011081300024
1. INSTALL THE BALL BEARING AND OIL SEAL SLEEVE.

(2) Install the oil seal sleeve with the special tool.
SST: Sleeve press (S0948-22220)
SHTS011081300025

(1) Install the oil seal with the special tool.
NOTICE
Coal lithium base grease to the sliding surface between seal lips.
SHTS011081300026

holder.
(4) Install the ball bearing to the crankshaft.
(5) Install the bearing retainer.
SHTS011081300027

PLAY.
NOTICE
• Be sure to align the aligning mark.
• Apply engine oil to the bearing.
bolt.
SHTS011081300028

Limit: 0.5 mm {0.02 in.}
SHTS011081300029
SHTS011081300030

Limit: 0.4 mm {0.016 in.}
SHTS011081300031

NOTICE
parts.
NOTICE
ring facing up.
SHTS011081300032
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧟㧡ಽ

NOTICE
! WARNING

NOTICE
Do not twist the O-ring when installing it on the cylinder liner and
cylinder head.
(2) Arrange the piston rings so that their gaps are equally spaced.
(3) Install the cylinder liner and cylinder head.

(2) Insert the drive gear.
Tightening Torque:
353 N⋅m {3,600 kgf⋅cm, 260 lbf⋅ft}
NOTICE
Apply oil to the threads and seat surface before tightening.
SHTS011081300034
2A'0AA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧝ಽ

EN0110813H300001
Unit: mm {in.}
Visual check
Cracks or defects of the con-

— — Replace.
necting rod
Outside diameter of piston pin 16.0 {0.630} — Measure
Clearance between the piston 0.016-0.044 Replace.

0.07 {0.0028}
Inside diameter of the con-

necting rod (without bear-
37 {1.457} —
ings): A # Tighten the bearing
cap to the specified torque.
Thickness of the connecting

1.5 {0.0591} —
rod bearing: B,C

34 {1.339} —
pin: D
Replace.

0.017-0.083
pin: E 0.1 {0.0039}
{0.0007-0.0032}
# Oil clearance
E= A-(B+C+D)
Replace con-
0.2-0.4
Connecting rod end play 0.5 {0.0197} necting rod or
{0.0079-0.0157}
crankshaft.
Visual check

— — Replace.
cylinder liner
A: 79.79-79.82 Measure
{3.1414-3.1425}
Outside diameter of the piston —
B: 79.90-79.93
{3.1457-3.1468}
Inside diameter of the cylinder 80.00-80.03

—
liner {3.1496-3.1507}
Replace.
A: 0.18-0.24
0.33 {0.0130}
{0.0071-0.0094}
and the cylinder liner B: 0.07-0.13
0.18 {0.0071}
{0.0028-0.0051}
Clearance between the piston 0-0.028 Measure

0.08 {0.0031}
pin hole and the piston pin {0-0.0011}
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.
Clearance between the ring

0.02-0.055
groove and the compression 0.08 {0.0031}
{0.0008-0.0021}
ring
Visual check

Visual check
Worn or damaged delivery Replace valve

— —
valve seat.
Visual check
Worn or damaged suction Replace valve

— —
valve seat.
Top 0.3-0.5 Measure

Second {0.0119-0.0196}
Piston ring
gap: com- 0.1-0.3
Third 1.0 {0.0394} Replace.
pression ring, {0.0040-0.0118}
oil ring
0.2-0.8
Oil ring
{0.0079-0.0314}
Drive side 35 {1.378} 34.985 {1.3774} Measure

Outside
diameter of
Opposite Replace.
the crank- 35 {1.378} 34.985 {1.3774}
shaft journal drive side
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 crank
shaft bearing
2A'0AZA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧡㧞ಽ
AIR COMPRESSOR (J08E: 271 cm3 x 2 CYLINDERS) EN13–1
AIR COMPRESSOR
EN 13
(J08E: 271 cm3 x 2 CYLINDERS)

EN 13
EN13-004

DESCRIPTION ................................................ EN13-2
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
2A'0AZA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧞ಽ
EN13–2 AIR COMPRESSOR (J08E: 271 cm3 x 2 CYLINDERS)
AIR COMPRESSOR
EN0110813I200001
Type Reciprocating, two cylinder
Discharge amount 271 cm3 {16.5 cu.in.} x 2 cylinders
Bore x stroke 80 mm x 54mm {3.15 in. x 2.13 pin.}
DESCRIPTION
EN0110813C100001
SHTS011081300001
1 Unloader valve 8 Cylinder liner

2 Inlet valve 9 Connecting rod
3 Piston ring 10 Bearing
4 Piston pin 11 Crankshaft
5 Delivery valve A From pressure regulator
6 Cylinder head B To tank
7 Piston C Air suction
TROUBLESHOOTING
EN0110813F300001

tact
Charging efficiency dropped (Pis- Worn piston and cylinder liner Replace.
ton, Cylinder liner and piston rings) Seized piston Replace (piston, piston rings and cylin-
der liner).
Charging efficiency dropped (Air Leakage of high-pressure air Replace or tighten pipe joint.
pipe and joints) Clogged air pipe Replace.
Charging efficiency dropped (Air Clogged element Clean or replace element.
cleaner)
rod small end
piston
Noisy operation (Valve) Inlet valve is lowered excessively Repair or replace.
Loosen discharge valve holder Tighten it.
liner.
liner.
Malfunction of unloader valve Sticky Clean or replace.
(Unloader valve) Deflection or wear Repair or replace unloader valve
assembly.
Malfunction of unloader valve (Air Air leakage Replace or tighten pipe joints.
pipe and joints)
Malfunction of unloader valve Function Adjust and/or repair pressure regula-
(Pressure regulator) tor.
COMPONENT LOCATOR
EN0110813D100001
SHTS011081300002
1 Air compressor

A 353 {3,600, 260}#
2A'0AZA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧟ಽ
SHTS011081300003
1 Cylinder block 13 Connecting rod bearing 25 Cylinder head

2 Crank shaft 14 Connecting rod bolt 26 Delivery valve assembly
3 Oil seal sleeve 15 Connecting rod nut 27 Delivery valve holder
4 O-ring 16 Connecting rod washer 28 Through bolt
5 Suction valve assembly 17 Piston 29 Lock washer
6 Bearing holder assembly 18 Piston pin 30 Bearing
7 Bearing holder 19 Retainer ring 31 Piston ring set
8 Oil seal 20 Straight pin 32 Unloader valve assembly
9 Bearing retainer 21 Cylinder liner gasket 33 Unloader valve holder
10 Bolt 22 Cylinder liner 34 Unloader valve spring
11 Woodruff key 23 Cylinder liner gasket 35 Unloader valve
12 Connecting rod assembly 24 Cylinder head assembly 36 Spacer

A 98.1-117.7 {1,000-1,200, 73-86} D 24.5-29.4 {250-300, 19-21}
B 39.2-49.0 {400-500, 29-36} E 13.7-17.6 {140-180, 11-13}
C 22.6-25.5 {230-260, 17-18}
2A'0AZA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧞ಽ
SPECIAL TOOL
EN0110813K100001
S0942-01830 PULLER
S0948-22220 SLEEVE PRESS
INLET VALVE HOLDER

S0948-11090
ADAPTER
OVERHAUL
EN0110813H200001

Remove the five air compressor mounting bolts and remove the air
NOTICE
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
SHTS011081300013
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
SHTS011081300014
NOTICE
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
2. INSTALL THE FUEL PIPES FOR THE INJECTION PUMP AND

AIR COMPRESSOR.
SHTS011081300015

NOTICE
loosing the nut.
SHTS011081300016
key.
SHTS011081300017
2. REMOVE THE CYLINDER HEAD, O-RING AND CYLINDER

LINER.
(1) Remove the cylinder head, O-ring and cylinder liner.
NOTICE
Put the aligning mark through the cylinder head to the cylinder
liner.
SHTS011081300050

! WARNING
(2) Strike out the piston pin, using a tapping rod and a hammer.
NOTICE
SHTS011081300018
4. REMOVE THE CONNECTING ROD.

loosen the nut.
(3) Remove the connecting rod.
SHTS011081300019

NOTICE
SHTS011081300020

(1) Remove the bearing retainer.
SHTS011081300021
(2) Press the crankshaft end face and remove the crankshaft with the
bearing holder.
SHTS011081300022

NOTICE
SHTS011081300023
8. REMOVE THE OIL SEAL SLEEVE.

(1) Using the special tool, remove the oil seal sleeve.
SST: Puller assembly (S0942-01670)
SHTS011081300024

crankshaft.
SHTS011081300025
10. REMOVE THE SUCTION VALVE ASSEMBLY.

(1) Using the special tool, remove the suction valve holder.
SST: Inlet valve holder adapter (S0948-21090)
SHTS011081300026
(2) Disassemble the suction valve.
SHTS011081300027
11. REMOVE THE UNLOADER VALVE ASSEMBLY.

(1) Loosen the unloader valve guide and take it out together with the
unloader valve.
SHTS011081300028
(2) Remove the retainer ring and disassemble the unloader valve.
SHTS011081300029
12. REMOVE THE DELIVERY VALVE ASSEMBLY.

(1) Remove the delivery valve holder.
SHTS011081300030
(2) Disassemble the delivery valve.
SHTS011081300031
1. ASSEMBLE THE SUCTION VALVE ASSEMBLY.

NOTICE
Replace the gasket with new one.
(1) Assemble the gasket, valve seat, suction valve and valve spring in
that order from the lower side of the cylinder head, then install the
suction valve holder and tighten provisionally.
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
2. ASSEMBLE THE DELIVERY VALVE ASSEMBLY.

NOTICE
O-ring should be replaced with new one.
(1) Assemble the valve seat, delivery valve, valve spring and O-ring
from the upper side of cylinder head, then install the delivery vale
holder and tighten provisionally.
(2) Push in the delivery valve with a finger or bar from the lower side
of the cylinder head, and check that the delivery valve and valve
spring move smoothly.
SHTS011081300036
(3) Tighten the delivery valve holder to the specified torque.

(4) Make sure that the delivery valve stroke is approximately 1 mm
{0.0394 in.}.
SHTS011081300037
3. ASSEMBLE THE UNLOADER VALVE

(1) Assemble the valve spring, unloader valve with O-ring and spacer
in the unloader valve holder, and secure them with the retainer
ring.
(2) Push the unloader valve from the upper side with a finger or bar,
and check that the unloader valve and valve spring move
smoothly.
(3) Assemble the unloader valve holder from the upper side of the
cylinder head and tighten the unloader valve holder to the speci-
fied torque.
SHTS011081300038

(1) Install the ball bearing on the both end of the crankshaft.
SHTS011081300039
5. INSTALL THE OIL SEAL SLEEVE.

(1) Using the special tool, install the oil seal sleeve onto the crank-
shaft.
SST: Sleeve press (S0948-22220)
SHTS011081300040

(1) Using the special tool, install the oil seal into the bearing holder.
SHTS011081300041

holder.
SHTS011081300042

SHTS011081300021

PLAY.
NOTICE
• Be sure to align the aligning mark.
• Apply engine oil to the bearing.
bolt.
SHTS011081300043

Limit: 0.5 mm {0.0197 in.}
SHTS011081300044
SHTS011081300045

Limit: 0.4 mm {0.0157 in.}
SHTS011081300046

NOTICE
parts.
NOTICE
ring facing up.
SHTS011081300047
SHTS011081300048

NOTICE
! CAUTION
Wear a pair of safety goggles during assembly.
SHTS011081300018

(1) Arrange the piston rings so that their gaps are equally spaced.
SHTS011081300049
(2) Install the cylinder liner and cylinder head.
SHTS011081300050

(1) Install the woodruff key to the crankshaft.
(2) Install the drive gear.
(3) Install the collar and lock nut.
SHTS011081300051

EN0110813H300001
Unit: mm {in.}
Visual check
Cracks or defects of the con-

— — Replace.
necting rod
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}
Inside diameter of the con- Measure

necting rod (without bear-
37
ings): A #Tighten the bearing —
{1.457}
cap to the specified
torque
Thickness of the connecting 1.5

—
rod bearing: B,C {0.0594}
Outside diameter of the crank 34

—
pin: D {1.339}
Replace.

0.02-0.09 0.1
pin: E
{0.0008-0.0035} {0.0039}
# Oil clearance
E= A-(B+C+D)
Measure
Replace con-
0.2-0.4 0.5
Connecting rod end play necting rod or
{0.0079-0.0157} {0.0197}
crankshaft.
Visual check

— — Replace.
cylinder liner
80 Measure
Outside diameter of the piston —
{3.150}
Inside diameter of the cylinder 80

—
liner {3.150}
A: 0.25-0.30 0.33
{0.0099-0.0118} {0.0130] Replace.

and the cylinder liner B: 0.07-0.13 0.18
{0.0028-0.0051} {0.0071}
Clearance between the piston 0-0.026 0.08 Measure

pin hole and the piston pin {0-0.0010} {0.0031}
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}
Compression 3.0 Measure

—
Piston ring ring {0.1181}
thickness 4.0
Oil ring —
{0.1575}
Compression 3.0
—
Piston ring ring {0.1181}
Replace.
groove 4.0
Oil ring —
{0.1575}
Clearance between the ring

0.02-0.055 0.08
groove and the compression
{0.0008-0.0021} {0.0031}
ring
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.
34.99-35.0 34.985 Measure

Drive side (A)
{1.3776-1.3779} {1.3774}
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}
Measure
0-0.3 0.4 Replace crank

Crankshaft end play
{0-0.0118} {0.0157} shaft bearing
4.41 N
{0.45 kgf, 3.63 N Measure
Suction valve spring setting
0.992 lbf} {0.36 kgf, Replace.
load
at 7.0mm 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'0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝㧤ಽ
ENGINE P.T.O. (POWER TAKE-OFF) (J08E) EN14–1
ENGINE P.T.O. (POWER TAKE-OFF) (J08E)

EN14
EN14-001
POWER TAKE-OFF ASSEMBLY .............. EN14-2

DESCRIPTION ................................................ EN14-2
OVERHAUL ..................................................... EN14-4
EN14–2 ENGINE P.T.O. (POWER TAKE-OFF) (J08E)
POWER TAKE-OFF ASSEMBLY

DESCRIPTION
EN0110814C100001
SHTS011081400001
1 Case cover 5 Crankshaft gear

2 Power take off assembly 6 Drive gear
3 Output coupling 7 Ball bearing
4 Main idle gear 8 Oil seal
COMPONENT LOCATOR
EN0110814D100001
SHTS011081400002
1 Case cover 4 Ball bearing 7 Gear cover

2 Gear case 5 Drive gear 8 Oil seal
3 Knock pin 6 Driven shaft 9 Output coupling

A 226 {2,300, 160} B 28.4 {290, 21}
2A'0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧢ಽ
OVERHAUL
EN0110814H200001

! CAUTION
Do not work on the while engine is still hot. This can result in per-
sonal injury.
1. DISASSEMBLE THE POWER TAKE-OFF.

(1) Remove the output coupling.
SHTS011081400003
(2) Remove the bolt.

(3) Using flathead drivers, pry up the flange of the gear cover from
the gear case.
NOTICE
When removing the gear cover, pry up by an even amount at each
gap until the gear cover comes off.
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
(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'0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧣ಽ
1. ASSEMBLE THE POWER TAKE-OFF.

(1) Using the suitable tool, press a new oil seal into the gear cover.
NOTICE
To prevent gouging of the rubber around the outside edge of the
oil seal, apply engine oil to the portion of the gear cover where the
oil seal will be pressed.
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
(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
1. INSTALL THE POWER TAKE-OFF.

(1) Insert two knock pins.
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
2. CHECK THE GEAR BACKLASH.

(1) Using a dial gauge, measure the backlash between gears at the
bolt hole of the output flange.
Standard: 0.035-0.211 mm {0.0014-0.0083 in.}
SHTS011081400020

EN0110814H300001
Unit: mm {in.}
Shaft and gear: — — Replace, Visual check

Wear and damage if necessary.
Oil seal lip: — — Replace, Visual check

Wear and damage if necessary.
Bearing improper — — Replace, Visual check

rotation if necessary.
Drive gear backlash 0.035-0.211 0.3 {0.0118} Replace, Measure

(Measure at bolt of out- {0.0014-0.0083} if necessary.
put coupling P.C.D: 100
mm {3.937 in.})
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧠ಽ
ENGINE CONTROL (J08E) EN16–1
EN16 ENGINE CONTROL (J08E) EN16-001
ACCELERATOR PEDAL........................... EN16-2

DESCRIPTION ................................................ EN16-2
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧥ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧠ᤨ㧠ಽ
EN16–2 ENGINE CONTROL (J08E)
ACCELERATOR PEDAL
DESCRIPTION
EN0110616F200001
SHTS011061600001
1 Accelerator pedal assy
ADJUSTMENT
EN0110616H300001
1. ADJUSTMENT FOR OUTPUT VOLTAGE OF THE ACCELERA-

TOR STROKE SENSOR.
(1) Check the output voltage with use of Hino-DX.
(2) When the output voltage does not match with the standard, adjust
(Sensor long hole) by moving the installation position of accelera-
tor stroke sensor toward its rotation direction or replace accelera-
tor stroke sensor with a new one.
ACCELERATOR Item Standard value (V)

STROKE
SENSOR Pedal idle 0.70-1.00
Pedal full stroke 3.55-4.4
Exhaust brake switch “ON” 0.70-1.00
SHTS011061600002
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧟㧝ಽ
FUEL CONTROL (J08E: COMMON RAIL) DN02–1
FUEL CONTROL
DN02
(J08E: COMMON RAIL)

DN02
DN02-001
COMMON RAIL COMMON RAIL PRESSURE SENSOR

FUEL INJECTION SYSTEM .....................DN02-2 MALFUNCTION ............................................. DN02-47
ACCELERATOR SENSOR 1 (VOLTAGE) ...... DN02-49
OVERVIEW...................................................... DN02-2
ACCELERATOR SENSOR 1 ......................... DN02-51
COMPONENT LOCATOR................................ DN02-3
ACCELERATOR SENSOR 2 (VOLTAGE) ...... DN02-52
DIAGRAM ........................................................ DN02-4
ACCELERATOR SENSOR 2 ......................... DN02-54
ELECTRICAL................................................... DN02-5
ACCELERATOR SENSOR 1 & 2 ................... DN02-54
PRECAUTIONS ............................................... DN02-8
ACCELERATOR SENSOR
INSPECTION ................................................. DN02-17
(FOR OPERATION OF P.T.O.) ....................... DN02-55
DIAGNOSIS USING
VEHICLE SPEED SENSOR .......................... DN02-57
THE DIAGNOSIS MONITOR ......................... DN02-18
ECU ............................................................... DN02-58
DIAGNOSIS USING THE PC
INJECTOR SOLENOID VALVE DRIVING SYSTEM
(PERSONAL COMPUTER)
SHORT-CIRCUIT (GND)................................ DN02-59
DIAGNOSIS TOOL WITH INTERFACE ......... DN02-20
DIAGNOSIS TROUBLE CODE TABLE.......... DN02-21
SHORT-CIRCUIT (24V) ................................. DN02-61
INSPECTION OF AIR FLOW SENSOR
INJECTOR SOLENOID VALVE SYSTEM
(CHECK/ADJUSTMENT OF
DISCONNECTION......................................... DN02-63
AIR INTAKE VOLUME BY HINO-DX) ............ DN02-25
CYLINDER CONTRIBUTION/BALANCE....... DN02-66
CHECK THE ECU
SUPPLY PUMP
POWER SUPPLY VOLTAGE.......................... DN02-26
SUCTION CONTROL VALVE (SCV).............. DN02-68
CHECK THE GROUND ................................. DN02-26
SUPPLY PUMP.............................................. DN02-69
ENGINE SPEED MAIN SENSOR
EGR SOLENOID VALVE 1............................. DN02-70
(CIRCUIT) ...................................................... DN02-27
EGR SOLENOID VALVE 2............................. DN02-71
ENGINE SPEED MAIN SENSOR
EGR ............................................................... DN02-73
(PULSE)......................................................... DN02-28
EGR VALVE 1 ................................................ DN02-74
ENGINE SPEED SUB SENSOR
EGR VALVE 2 ................................................ DN02-74
(CIRCUIT) ...................................................... DN02-30
EGR LIFT SENSOR 1.................................... DN02-75
ENGINE SPEED SUB SENSOR
EGR LIFT SENSOR 2.................................... DN02-77
(PULSE)......................................................... DN02-32
VNT (VARIABLE NOZZLE TURBINE)
ENGINE SPEED MAIN AND
TURBOCHARGER CONTROLLER ............... DN02-79
SUB SENSOR ............................................... DN02-33
VNT (VARIABLE NOZZLE TURBINE) ........... DN02-80
COOLANT TEMPERATURE SENSOR.......... DN02-34
EXHAUST BRAKE MAGNETIC VALVE ......... DN02-81
ENGINE OVERHEAT ..................................... DN02-35
INJECTOR CORRECTION DATA .................. DN02-82
ENGINE OVERRUN ...................................... DN02-35
MAIN RELAY ................................................. DN02-83
FUEL TEMPERATURE SENSOR.................. DN02-36
IDLE VOLUME ............................................... DN02-84
BOOST PRESSURE SENSOR ..................... DN02-37
ACCELERATOR SWITCH ............................. DN02-86
BOOST PRESSURE SENSOR
STARTER SWITCH ....................................... DN02-87
(CHECK BY HINO-DX) .................................. DN02-39
CLUTCH SWITCH ......................................... DN02-88
TURBOCHARGER OVER BOOST................ DN02-40
NEUTRAL SWITCH ....................................... DN02-89
AIR FLOW SENSOR ..................................... DN02-40
AIR FLOW SENSOR
(CHECK BY HINO-DX) .................................. DN02-42
INTAKE AIR TEMPERATURE SENSOR ....... DN02-43
COMMON RAIL EXCESSIVE PRESSURE,
CONTROL SYSTEM...................................... DN02-44
COMMON RAIL PRESSURE
AND SUPPLY PUMP ..................................... DN02-45
COMMON RAIL PRESSURE SENSOR
STICKING ...................................................... DN02-46
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧟ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧥ಽ
DN02–2 FUEL CONTROL (J08E: COMMON RAIL)
COMMON RAIL FUEL INJECTION SYSTEM

OVERVIEW
EN1610602F200001
COMMON RAIL FUEL INJECTION SYSTEM

The Common Rail Fuel Injection System has a lot of control functions than the conventional injection pump system. These
functions are controlled by the ECU (Electronic Control Unit).
Control of the Fuel Control of the Injection

Injection Amount
Control of VNT Control of the Injection

(Variable Nozzle Turbine) Pressure (Common Rail
Turbocharger Pressure Control)
Common Rail Type
Control of the Injection
Electronic Fuel Injection Control of EGR valve
Timing
System
Control of the Injection

Function of Diagnosis
Rate
Function of Tachometer
Driver
SHTS161060200001
NOTICE
The functions with an asterisk ( 㧖 ) are applied to models for Hong kong, Singapore and Taiwan.
COMPONENT LOCATOR
EN1610602F200002
6
a e
d 9
4 7
1
2 8
b c
5 e 10
c
a d
f
b
3
15 11
12
16 g
14
18
13
20 17
21
19
SHTS161060200002
1 Coolant temperature sensor 12 Suction control valve (SCV)

2 Boost pressure sensor 13 Supply pump
3 Injector 14 Engine ECU
4 Common rail pressure sensor 15 Accelerator switch
5 Pressure limiter 16 Accelerator sensor
6 Common rail assembly 17 Idle volume
7 Flow damper 18 ECU main relay (Right-hand drive)
8 Injector harness connector 19 Actuator power relay (Right-hand drive)
9 Engine speed sub sensor 20 ECU main relay (Left-hand drive)
10 Engine speed main sensor 21 Actuator power relay (Left-hand drive)
11 Fuel temperature sensor
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧝㧞ಽ
DIAGRAM
EN1610602F200003
6 7
2 3
8
9
10
13 12 11
SHTS161060200003
1 Fuel tank 8 Pressure limiter

2 Fuel prefilter 9 Flow damper
3 Fuel filter 10 Injector
4 Suction control valve 11 Engine speed sub sensor
5 Supply pump 12 Engine speed main sensor
6 Common rail 13 ECU
7 Common rail pressure sensor A To sensors (Additional information)
ELECTRICAL
EN1610602F200004
MODELS FOR HONG KONG AND SINGAPORE

Fuse
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
Clutch SW Check engine light

Diagnosis SW
Tachometer (Drive signal)
Neutral SW
Exhaust brake
combination SW
PTO switch
PTO Accelerator sensor

(For operation)
EGR valve 1 drive signal
Idle-up signal 1
Idle-up signal 2
CAN communication (VNT)
Vehicle speed sensor
Exhaust brake drive signal
Injector drive signal

Supply pump
Supply pmp SCV drive signal

Supply pump drive signal S/P
CAN communication Meter ECU

Exhaust brake light
EGR lift sensor 2

EGR lift sensor 1
Engine speed main sensor Fuel temperature sensor (On Supply pump)
Engine speed sub sensor
Boost pressure sensor
Intake air temperature sensor (Built into Air flow sensor)
Common rail Air flow sensor
pressure sensor 2
Common rail
pressure sensor 1 ENGINE ECU
Coolant
Common rail T
temperature
P sensor DC/DC
Air flow converter
T sensor
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
SHTS161060200004
MODEL FOR TAIWAN
Actuator relay
Fuse
Fuse
Battery
ECU main relay
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
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

(For operation) EGR valve 1 drive signal
Idle-up signal 1
CAN communication (VNT)
Idle-up signal 2
AT identification signal

Supply pump

CAN communication
Meter ECU
Exhaust brake light
AT
EGR lift sensor 2 ECU
EGR lift sensor 1

Intake air temperature sensor (Built into Air flow sensor)
Common rail Air flow sensor
pressure sensor 2
Common rail
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
SHTS161060200005
MODELS FOR CHILE AND THAILAND
ECU main relay

Fuse
Battery
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Interface PC
diagnosis
Idle volume
Stop light SW
Accelerator SW
Clutch SW Check engine light

Diagnosis SW
Tachometer (Drive signal)
Neutral SW
Exhaust brake
combination SW
PTO switch

(For operation)
Idle-up signal 1
Idle-up signal 2


Supply pump

CAN communication Meter ECU

Exhaust brake light
Common rail
pressure sensor 2
Coolant temperature sensor
Common rail
Common rail
P
T
P
G
ENGINE
N
Exhaust
muffler
Exhaust brake
solenoid
NOTICE:
SW = Switch
SHTS161060200006
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.
2. HARNESS WIRE CONNECTOR.

(1) Multi-contact connectors suitable for the small electrical signals of electronic circuitry are used for wiring connections
to the sensors, actuator and control unit. Be very careful when handling them.
• Before disconnecting any connectors, make sure that the starter switch is in the "LOCK" position.
• When disconnecting connectors, try to pull them out in a straight line, disengaging the lock and holding onto the
housing.
• Do not try to disconnect connectors by gripping the wires or twisting them, as this could bend the contacts.
• Do not disconnect connectors unnecessarily.
• When using a circuit tester, apply the tester probe to the harness wire side only. Never stick the tester probe into the
holes on the connector terminal side, as this could cause poor contacts when the connector is reconnected.
SHTS161060200007
• 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.
6. USING A CIRCUIT TESTER

• Use a circuit tester with an internal resistance of 100 kΩ or greater in the voltage measuring range.
7. USING A SIGNAL CHECK HARNESS

• To prevent breakage of the ECU connector, connect the signal check harness and perform measuring by bringing the
test lead into contact with the signal check harness side (Contact box).
AFT+ IVS CASE
COMPUTER (ECU) VS ACS2 ACS1 ISOK
TERMINAL SIGNAL TACH
VB3 VB2 VB1
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. 0 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
SHTS161060200008
8. CONNECT THE SIGNAL CHECK HARNESS.

(1) Disconnect the connectors from the ECU.
(2) Connect a signal check harness to the vehicle harness and the
ECU.
SST: Signal check harness (S0904-91080)
SHTS161060200009
(3) COMPUTER (ECU) PIN ASSIGNMENT
SIGNAL CHECK HARNESS (CONTACT BOX)
ECU SIDE VEHICLE SIDE

Common Rail
09049-1080
A B C D E
SHTS161060200010
VIEW
COMPUTER (ECU) TERMINAL SIGNAL
THF+ AGD3 AGD2 AGD1 GVCC PCR2 GGND DGSW NUSW AVC5 EGS2 AFT+ IVS
CASE CANL CANH THW+ PIM EGS1 AVC1 AVC2 AVC3 AFSG PCR1 G3+ AGD6 CA2L CA2H BUSW PTO BSW1 IDLE AVC4 SWSS AGD5 AGD4 VS ASCS ACS2 ACS1 ISOK
SCVH SCVH SCVL SCVL EGR2 EGR1 CE/G FIUP 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
COMPUTER (ECU) TERMINAL No.
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)
SIGNAL CHECK HARNESS (CONTACT BOX) TERMINAL No.
(E) (D) (C) (B) (A)

31 pin 35 pin 32 pin 35 pin 34 pin
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30 21 22 23 24 25 26 27 28 29 30
31 31 32 33 34 35 31 32 31 32 33 34 35 31 32 33 34
SHTS161060200011
DN02–11
9. COMPUTER (ECU) PIN CONNECTION

• The terminal number in the table correspond with the contact box of signal check harness.
CONTACT BOX (A)
No. Signal Connection destination No. Signal Connection destination
1 – 21 ACS1 Accelerator sensor (Signal 1)
2 – 22 ACS2 Accelerator sensor (Signal 2)
3 – 23 ACCS P.T.O. accelerator sensor (Signal)
4 – 24 –
5 VB1 ECU main relay 25 –
6 VB2 ECU main relay 26 –
7 VB3 Exhaust clutch switch 27 VS Vehicle speed pulse converter
8 – 28 –
9 TACH Tachometer 29 –
10 – 30 IVS Idle volume (Signal)
11 – 31 –
12 – 32 AFT+ Air flow sensor [Power (Temperature)]
13 – 33 –
14 – 34 –
15 –
16 –
17 BATT Fuse 25 (Room light)
18 –
19 ISOK Diagnosis connector (16P)
20 –
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧝㧟ಽ
CONTACT BOX (B)
1 +BF2 Exhaust clutch switch 21 AGD5 Accelerator sensor (Ground 2)
2 EBMV Exhaust brake magnetic valve 22 SWSS Fuse 39 [Engine (M)]
Accelerator sensor (Power 1)

3 – 23 AVC4 Idle volume (Power)
P.T.O. accelerator sensor (Power)
4 – 24 IDLE Accelerator switch
5 NESD Engine speed main sensor shield ground 25 –
6 NE1+ Engine speed main sensor (+) 26 –
Stop light switch

7 NE1– Engine speed main sensor (–) 27 BSW1
Integrated unit
8 – 28 –
9 – 29 EGS2 EGR lift sensor 1
10 – 30 –
11 – 31 AVC5 Accelerator sensor (Power 2)
12 SSWS Fuse 39 [Engine (M)] 32 NUSW Neutral switch
13 – 33 –
14 ST Starter relay 34 DGSW Diagnosis switch
15 EBSW Wiper and retarder brake switch 35 –
16 –
17 –
18 –
19 BSW2 Brake switch
Accelerator sensor (Ground 1)

20 AGD4 Idle volume (Ground)
P.T.O. accelerator sensor (Ground)
CONTACT BOX (C)
1 – 21 BUSW Air conditioner idling up 2
2 – 22 –
3 CGD1 Sensor ground 23 –
4 CGD2 Sensor ground 24 RES Cruise control set switch (Resume)
5 MRL1 ECU main relay 25 –
6 MRL2 ECU main relay 26 CA2H CAN communication line (H)
7 +BF1 Exhaust clutch switch 27 CA2L CAN communication line (L)
8 CLSW Exhaust clutch switch 28 –
9 – 29 –
10 – 30 –
11 – 31 –
12 FIUP Air conditioner idling up 1 32 –
Check engine light

13 CE/G
Diagnosis switch
14 –
15 –
16 –
17 –
18 –
19 –
20 PTO P.T.O. switch

CONTACT BOX (D)
1 PGD1 Power ground 21 AFSG Air flow sensor [Signal (Flow)]
2 INJ1 No.1 Fuel injector (–) 22 AVC3 EGR lift sensor 2
3 INJ2 No.2 Fuel injector (–) 23 –
4 INJ3 No.3 Fuel injector (–) 24 AVC2 Common-rail pressure sensor
5 IJ1+ No.1 Fuel injector (+) 25 AVC1 Boost pressure sensor (Power)
6 I1+S No.2, 3 Fuel injector (+) 26 EGS1 EGR lift sensor 1
7 EGR1 EGR valve 1 27 PIM Boost pressure sensor (Signal)
8 EGR2 EGR valve 2 28 –
9 – 29 –
10 – 30 GGND Engine speed sub sensor (Ground)
11 – 31 PCR2 Common-rail pressure sensor (Signal)
12 – 32 GVCC Engine speed sub sensor (Power)
Boost pressure sensor (Power)

13 – 33 AGD1
Common-rail pressure sensor (Power)
Coolant temperature sensor (Ground)

14 – 34 AGD2 Fuel temperature sensor (Ground)
Air flow sensor [Ground (Temperature)]
15 – 35 AGD3 EGR lift sensor 1 and 2
16 –
17 ADG6 Air flow sensor [Ground (Flow)]
18 –
19 G3+ Engine speed sub sensor (Signal)
20 PCR1 Common-rail pressure sensor (Signal)

CONTACT BOX (E)
1 INJ4 No.4 Fuel injector (–) 21 CANH VNT controller
2 INJ6 No.6 Fuel injector (–) 22 CANL VNT controller
3 INJ5 No.5 Fuel injector (–) 23 –
4 PGD2 Power ground 24 –
5 PGD3 Power ground 25 CASE Engine ground
6 IJ2+ No.4,5 Fuel injector (+) 26 –
7 I2+S No.6 Fuel injector (+) 27 THF+ Fuel temperature sensor (+)
8 SCVL Suction control valve 28 –
9 SCVL Suction control valve 29 –
10 SCVH Suction control valve 30 –
11 SCVH Suction control valve 31 –
12 –
13 –
14 –
15 –
16 –
17 –
18 –
19 THW+ Coolant temperature sensor (+)
20 –
10. RADIO INSTALLATION

• There is a danger that the control unit might malfunction if a high output radio transmitter (Over 50W) is installed in
the vehicle.
11. USING A QUICK CHARGER

• Disconnect both battery terminals before using a quick charger.
12. AIR CONDITIONER INSTALLATION

• Be careful not to scratch or damage the engine, chassis or the harness inside the cab when installing an air condi-
tioner. Also, make sure to reattach afterward any connectors that were disconnected during the installation process.
13. PERFORMING ELECTRIC WELDING

• Disconnect connector to the control unit before performing any electric welding.
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.
INSPECTION
EN1610602F200006
CHECK ENGINE LIGHT STATUS

1. INSPECTION PROCEDURE
(1) Turn the starter switch to "ON" position (Do not start the engine)
and confirm that the check engine light in the indicator area lights
up.
(2) Start the engine.
(3) If the engine is normal, the check engine light goes out.
(4) If the check engine light does not go out, the system is abnormal.
Check the system according to diagnosis on the following page.
.
SHTS161060200012
CHECK ENGINE LIGHT ILLUMINATION PATTERN
START
STARTER ON
SWITCH
LOCK
RUNNING
ENGINE
STOP
CHECK
ON
ENGINE
LIGHT OFF
SHTS161060200013
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦ೨㧝㧝ᤨ㧝㧟ಽ
DIAGNOSIS USING THE DIAGNOSIS MONITOR

EN1610602F200007
1. CONNECT THE DIAGNOSIS MONITOR.

SST: Diagnosis monitor (S0963-01370)
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".
SHTS161060200014
(2) Connect the dedicated harness to the diagnosis connector.

(RIGHT-HAND DRIVE) SST: Dedicated harness (S0963-02300)
FIXING DUMMY
CONNECTOR
BLACK CONNECTOR
WHITE CONNECTOR
SHTS161060200015
SHTS161060200016
(3) Connect the diagnosis monitor to the connector which tagged a

"STD-ENG" label.
SHTS161060200017
2. READ OUT THE MALFUNCTION CODE.

(1) Read out the malfunction codes and write down the malfunction
codes that are indicated.
NOTICE
Malfunction codes are indicated, starting from the lowest and pro-
gressing upward, with no distinction between present and past
malfunction codes.
MALFUNCTION CODE INDICATION PATTERN
Malfunction Code 32 and 21
0.5S 0.5S
Turn ON
Turn OFF
1.5S 4.3S
Code 32 Code 21
Repeat
Normal
0.3S
Turn ON
Turn OFF S: Seconds

SHTS161060200018
3. ERASE THE MALFUNCTION CODE MEMORY.

(1) Erase the malfunction code memory using the PC DIAGNOSIS
TOOL (Hino DX).
.
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS

TOOL WITH INTERFACE
EN1610602F200008
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 (S0912-11040)
Cable communication (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
NOTICE
SHTS161060200019
Only ECU reprogramming can be performed by authorized HINO
dealer.
2. CONNECT THE PC DIAGNOSIS TOOL.

(1) Turn the starter switch to "LOCK" position.
(2) Connect the diagnosis cable between diagnosis connector and
interface.
(3) Connect the interface to the PC.
(4) Turn the starter switch to "ON" position.
(5) The opening menu will be displayed on the PC screen.
(LEFT-HAND DRIVE) (RIGHT-HAND DRIVE)
P P
INTER FACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS161060200020
.
2A&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧥ᤨ㧟㧠ಽ
DIAGNOSIS TROUBLE CODE TABLE

EN1610602F200009
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 sensor circuit malfunction DN02-27
YES A, B 13 P0335 Engine speed main and sub sensor circuit malfunction DN02-33
YES A, B 13 P0336 Engine speed main sensor pulse abnormal DN02-28
YES A, B 3 P0606 CPU malfunction (Hard detection) DN02-58
YES A, B 74 P0629 Supply pump SCV malfunction (Power source line short) DN02-68
YES C 59 P0200 ECU charge circuit high input DN02-58
YES C 59 P0611 ECU charge circuit low input DN02-58
NO C 22 P2120 Accelerator sensor 1 and 2 malfunction DN02-54
NO C 6 P0217 Engine overheat DN02-35
NO C 39 P0234 Turbocharger over boost DN02-40
YES C 35 P0045 VNT turbocharger controller malfunction DN02-79
YES C 35 P2263 VNT nozzle sticking DN02-80
YES C 36 P0045 VNT turbocharger controller malfunction DN02-79
YES C 68 P0088 Excessive common rail pressure (1st step) DN02-44
YES C 69 P0088 Excessive common rail pressure (2nd step) DN02-44
YES C 76 P0087 Lack of forced feed in supply pump DN02-45
Excessive common rail pressure, supply pump excess forced

YES C 76 P0088 DN02-45
feed
YES C 17 P0101 Abnormality of air flow sensor characteristic DN02-42
YES C 17 P0102 Air flow sensor circuit low input DN02-40
YES C 17 P0103 Air flow sensor circuit high input DN02-40
YES C 17 P0106 Abnormality of boost pressure sensor characteristic DN02-39
YES C 37 P0108 Boost pressure sensor circuit high input DN02-37
YES C 11 P0116 Abnormality of coolant temperature sensor characteristic DN02-34
YES C 11 P0117 Coolant temperature sensor circuit low input DN02-34
YES C 11 P0118 Coolant temperature sensor circuit high input DN02-34
YES C 67 P0191 Common rail pressure sensor sticking DN02-46
YES C 67 P0192 Common rail pressure sensor circuit low input DN02-47
YES C 67 P0193 Common rail pressure sensor circuit high input DN02-47
CHECK
DTC REFER
No. PAGE
LIGHT
YES C 51 P0201 Injector circuit malfunction -cylinder 1 DN02-63
YES C 37 P0237 Boost pressure sensor circuit low input DN02-37
YES C 88 P0400 Abnormal flow amount of EGR DN02-73
YES C 88 P0404 EGR valve 1 sticking DN02-74
YES C 86 P0405 EGR lift sensor 1 circuit low input DN02-75
YES C 86 P0406 EGR lift sensor 1 circuit high input DN02-75
YES C 87 P0407 EGR lift sensor 2 circuit low input DN02-77
YES C 87 P0408 EGR lift sensor 2 circuit high input DN02-77
YES C 81 P0489 EGR solenoid 1 malfunction (Open circuit or ground line short) DN02-70
YES C 81 P0490 EGR solenoid 1 malfunction (Power source line short) DN02-70
YES C 3 P0605 Flash ROM error DN02-58
YES C 3 P0607 Monitoring IC malfunction in CPU DN02-58
YES C 75 P0628 Supply pump SCV malfunction (All discharge mode) DN02-68
YES C 57 P1211 Injector common 1 ground line short DN02-59
YES C 57 P1212 Injector common 1 power source line short DN02-61
YES C 57 P1212 Injector common 1 open circuit DN02-61
YES C 58 P1214 Injector common 2 ground line short DN02-59
YES C 58 P1215 Injector common 2 power source line short DN02-61
YES C 58 P1215 Injector common 2 open circuit DN02-61
YES C 89 P1401 EGR valve 2 sticking DN02-74
YES C 82 P1402 EGR solenoid 2 malfunction (Open circuit or ground short) DN02-71
YES C 82 P1403 EGR solenoid 2 malfunction (Power source line short) DN02-71
NO 43 P1565 Cruise switch malfunction DN02-77
YES C 2 P1601 Injector correction data conformity error DN02-82
YES C 15 P2227 Abnormality of atmospheric pressure sensor characteristic DN02-58
YES C 15 P2228 Atmospheric pressure sensor circuit low input DN02-58
YES C 15 P2229 Atmospheric pressure sensor circuit high input DN02-58
YES C 75 P2635 Supply pump SCV sticking DN02-69
YES C 8 U1123 CAN communication error (VNT) DN02-79
YES C 8 U0073 CAN communication malfunction (Engine) DN02-79
YES 16 P0112 Intake air temperature sensor circuit low input DN02-43
CHECK
DTC REFER
No. PAGE
LIGHT
YES 16 P0113 Intake air temperature sensor circuit high input DN02-43
YES 14 P0182 Fuel temperature sensor circuit low input DN02-36
YES 14 P0183 Fuel temperature sensor circuit high input DN02-36
YES 12 P0340 Engine speed sub sensor circuit malfunction DN02-30
21 P0500 Vehicle speed sensor circuit low input DN02-57
21 P0501 Vehicle speed sensor circuit high input DN02-57
YES 5 P0686 Main relay malfunction DN02-83
YES 22 P2121 Accelerator sensor 1 malfunction (Open sticking) DN02-49
YES 22 P2121 Accelerator sensor 1 malfunction (Close sticking) DN02-49
YES 22 P2122 Accelerator sensor circuit 1 low voltage DN02-51
YES 22 P2123 Accelerator sensor circuit 1 high voltage DN02-51
YES 22 P2126 Accelerator sensor 2 malfunction (Open sticking) DN02-52
YES 22 P2126 Accelerator sensor 2 malfunction (Close sticking) DN02-52
YES 22 P2127 Accelerator sensor 2 circuit 2 low voltage DN02-54
YES 22 P2128 Accelerator sensor 2 circuit 2 high voltage DN02-54
NO 12 P0341 Engine speed sub sensor pulse abnormal DN02-32
NO 7 P0219 Engine overrun DN02-35
NO 61 P0263 Cylinder 1 contribution / balance fault DN02-66
NO 42 P0510 Accelerator switch malfunction DN02-86
NO 45 P0617 Starter switch malfunction DN02-87
NO 41 P0704 Clutch switch malfunction DN02-88
NO 47 P0850 Neutral switch malfunction DN02-89
NO 44 P1142 Idle set controller low voltage DN02-84
NO 44 P1143 Idle set controller high voltage DN02-84
Exhaust brake magnetic valve malfunction (Open circuit, ground

NO 28 P1681 DN02-81
line short)
Exhaust brake magnetic valve malfunction (Power source line

NO 28 P1682 DN02-81
short)
NO 79 P2635 Supply pump abnormal high pressure record DN02-69
NO 9 U0155 CAN communication error (Meter) –
NO 9 U1001 CAN communication error (EDAS, AT) –
NO 23 P1132 P.T.O. accelerator sensor circuit low voltage DN02-55

CHECK
DTC REFER
No. PAGE
LIGHT
NO 23 P1133 P.T.O. accelerator sensor circuit high voltage DN02-55
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&0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧞㧟ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧜ಽ
INSPECTION OF AIR FLOW SENSOR

(CHECK/ADJUSTMENT OF AIR INTAKE VOLUME BY HINO-DX)
EN1610602F200010
1. INSPECTION OF AIR FLOW SENSOR.

(1) Clean or replace it with a new air cleaner before checking under
this method. Or, prepare a new air flow sensor, separate from the
one installed on the vehicle.
(2) Connect the PC DIAGNOSIS TOOL (Hino-DX).
(3) Following the air intake volume measurement by Hino-DX, gauge
air intake volume under NMR (No Load Maximum Revolution)
with "Air flow sensor installed on the vehicle". ⋅⋅⋅(A)
(4) Confirming a safety around the engine, entirely warmed up, stabi-
lize the revolution by depressing the accelerator pedal from its
idling condition (keep depressing the accelerator pedal).
Under the same condition, read out "Engine Revolution per min.
(rpm)" and "Air intake volume (g/sec.)" from the PC screen.
(5) After stopping engine and locking the starer key, remove air flow
sensor unit from air cleaner case by removing off air flow sensor
connector.
(6) Make sure to fit the connector after installing "New air flow sen-
sor" prepared.
(7) Gauge air intake volume as the above (3) with "New air flow sen-
sor". ⋅⋅⋅(B)
(8) Judgement against deterioration of air flow sensor performance.
a. When checked air flow volume with "Air flow sensor installed
on the vehicle", which is 10% lower than the one detected by
a "New air flow sensor" (Refer to the calculation form listed
SHTS161060200021 below), a "New air flow sensor" should remain installed on the
vehicle to complete this check due to the fact that the original
one installed was deteriorated.
Calculation form: {(B)-(A)} / (B) x 100 >10
b. When the both air flow sensors identical flow volume, it
means that "Air flow sensor installed on the vehicle" is func-
tioning correctly. So, you can complete the check by swapping
air flow sensor for its installation on the vehicle.
NOTICE
• Air flow detecting portion (Wire) is accurately machined,
which is very fragile. Therefore, work carefully not to make
direct touch by hand with the same detection portion.
• Don’t put on excessive torque thereon when tightening bolt
(M4) installing air flow sensor.
AIR FLOW Tightening Torque:
DETECTING 1.68 N⋅m {17 kgf⋅cm, 1.24 lbf⋅ft}
PORTION
(WIRE)
• In case that the check result is not within specified area
under this method, replace the air flow sensor with a new
SHTS161060200022
one.
.
CHECK THE ECU POWER SUPPLY VOLTAGE

EN1610602F200011
1. CHECK THE VOLTAGE BETWEEN TERMINALS.

(1) Set the starter switch to "LOCK" and connect the signal check
A5 A A6
A7
D1 D E4 E E5
harness.
(2) Set the starter switch to "ON" (The engine is stopped).
(3) Measure the voltage between VB1 (A5), VB2 (A6), VB3 (A7) and
PGD1 (D1), PGD2 (E4), PGD3 (E5) terminals of ECU connector
(Vehicle harness side).
Standard: More than 20V
SHTS161060200023
NO
• 0V: Fuse blows, harness malfunction,
ground malfunction.
YES • Less than 20V: Battery retrogradation,
ground malfunction.
Normal.
CHECK THE GROUND

EN1610602F200012

D1 D E4 E E5
harness.
(2) Disconnect the signal check harness connector on the ECU side.
(3) Measure the resistance between PGD1 (D1), PGD2 (E4), PGD3
(E5) terminals and battery (–) terminal.
Standard: Less than 1 Ω
SHTS161060200024
NO
• Ground harness disconnection.
• Bad contact of terminal.
YES
Normal.
.
ENGINE SPEED MAIN SENSOR (CIRCUIT)

EN1610602F200013
MC No. 13 DTC No. P0335 Engine speed main sensor circuit malfunction

B (1) Set the starter switch to "LOCK" and connect the signal check
B6 B7 harness.
(3) Measure the resistance between NE1+ (B6) and NE1- (B7) termi-
nals.
Standard: APPROX. 108.5-142.5 Ω at 20°C {68°F}
SHTS161060200025
NO
Proceed to 3.
YES
2. RECHECK THE MC OR DTC.

(1) Connect the signal check harness connector on the ECU side.
(2) Erase the MC or DTC memory.
(3) Check the MC or DTC.
.
NO
• Bad contact of ECU connectors.
• Malfunction of ECU.
YES • Malfunction of harness (Short circuit).
Normal.
3. CHECK THE ENGINE SPEED MAIN SENSOR.

(1) Disconnect the connectors of engine speed main sensor.
(2) Measure the resistance between terminals of engine speed main
sensor.
Standard: APPROX. 108.5-142.5 Ω at 20°C {68°F}
SHTS161060200026
NO
Malfunction of engine speed main sensor.
YES
• Harness disconnection.
• Bad contact of connectors.
ENGINE SPEED MAIN SENSOR (PULSE)

EN1610602F200014
MC No. 13 DTC No. P0336 Engine speed main sensor pulse abnormal
1. CHECK THE INPUT PULSE GENERATION TO ENGINE ECU.

B6 B B7
harness.
(3) Measure the pulse generation between NE1+ (B6) and NE1- (B7)
terminals using an oscilloscope.
Standard: 56 pulse (Between non-signal holes)
(4) After measurement, stop the engine.
SHTS161060200027
NO
Proceed to 2.
YES
• Malfunction of ECU connectors.

(1) Connector of engine main sensor remains connected.
(2) Measure the resistance between NE- main sensor connector
NE+
(Vehicle harness side) and signal check harness NE1- (B7).
In same way, measure the resistance between NE+ main sensor
connector (Vehicle harness side) and signal check harness NE1+
NE- B6 B B7 (B6).
SHTS161060200028
NO
Malfunction of harness.
YES
Proceed to 3.
3. CHECK THE OUTPUT PULSE GENERATION FROM SENSOR.

(1) Connector of engine speed main sensor remains connected.
(3) Measure the pulse generation between terminals using an oscillo-
scope.
Standard: 56 pulse (Between non-signal holes)
SHTS161060200029
NO
• Engine speed main senor malfunction.
• Flywheel signal hole abnormal.
YES
Bad contact of connector.
.
ENGINE SPEED SUB SENSOR (CIRCUIT)

EN1610602F200015
MC No. 12 DTC No. P0340 Engine speed sub sensor circuit malfunction

MREG MREV harness.
(2) Disconnect the connector of the engine speed sub sensor.
(4) Measure the voltage between MREV and MREG terminals of the
engine speed sub sensor connector (Vehicle harness side).
Standard: 4.5-5.5V
SHTS161060200030
NO
Proceed to 2.
YES
Proceed to 3.

(1) Measure the voltage between GVCC (D32) and GGND (D30) ter-
D minals.
D32 D30
Standard: 4.5-5.5V
(After measurement, turn the starter switch to "LOCK" position.)
SHTS161060200031
NO
YES

(1) Set the starter switch to "LOCK" and connect the connector of the
D D19 engine speed sub sensor.
D30 (2) Start the engine.
(3) Measure the voltage between G3+ (D19) and GGND (D30) termi-
nals.
Standard: Pulse wave-shape by 0↔ 5V
SHTS161060200032
NO
Proceed to 4.
YES
• Malfunction of engine ECU.


(1) Connector of engine speed sub sensor remains connected.
(2) Measure the resistance between MRES terminal of the engine
D19 speed sub sensor connector (Vehicle harness side) and G3+
(D19) terminal.
NOTICE
MRES This figure is viewed from the coupling surface side.
SHTS161060200033
NO
YES
Malfunction of engine speed sub sensor.
.
ENGINE SPEED SUB SENSOR (PULSE)

EN1610602F200016
MC No. 12 DTC No. P0341 Engine speed sub sensor pulse abnormal
1. CHECK THE VOLTAGE BETWEEN SENSOR TERMINALS.

harness.
MREG MREV (2) Disconnect the connector of the engine speed sub sensor.
(3) Set the starter switch to "ON" (The engine is stopped)
(4) Measure the voltage generation between MREV and MREG ter-
minals of the engine speed sub sensor connector (Vehicle har-
ness side).
Standard: 4.5-5.5V
SHTS161060200034
NO
Proceed to 2.
YES
Proceed to 3.

(1) Connector of engine sub sensor remains connected.
(2) Measure the resistance between MRES terminal of the engine
D19 speed sub sensor connector (Vehicle harness side) and G3+
(D19) terminal.
MRES NOTICE
This figure is viewed from the coupling surface side.
SHTS161060200035
NO
YES
Proceed to 3.
3. CHECK THE INPUT PULSE GENERATION TO ENGINE ECU.

(1) Connector of engine speed sub sensor remains connected.
D D19 (2) Start the engine.
D30 (3) Measure the pulse generation between terminals G3+ (D19) and
CGND (D30) terminals using an oscilloscope.
Standard: 7 pulse (Including extra signal pin)
SHTS161060200036
NO
Proceed to 3.
YES
4. CHECK THE OUTPUT PULSE GENERATION FROM SENSOR.

MREG MREV (1) Connector of engine speed sub sensor remains connected.
(3) Measure the pulse generation between MREG and MREV termi-
nals using an oscilloscope.
Standard: 7 pulse (Including extra signal pin)
NOTICE
SHTS161060200037
NO
• Engine speed main senor malfunction.
• Camshaft gear signal pin abnormal.
YES
Bad contact of connector.
ENGINE SPEED MAIN AND SUB SENSOR

EN1610602F200017
MC No. 13 DTC No. P0335 Engine speed main and sub sensor circuit malfunction
1. MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE

CONTENTS OF MC No.12, 13 OR DTC No. P0335, P0340.
.
COOLANT TEMPERATURE SENSOR

EN1610602F200018
MC No. 11 DTC No. P0116 Abnormality of coolant temperature sensor characteristic
MC No. 11 DTC No. P0117 Coolant temperature sensor circuit low input
MC No. 11 DTC No. P0118 Coolant temperature sensor circuit high input

harness.
D E (2) Disconnect the signal check harness connector on the ECU side.
E19 (3) Measure the resistance between THW+ (E19) and AGD2 (D34)
D34
terminals of ECU connector (Vehicle harness side).
Standard (Measure at one of the followings.):
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}
SHTS161060200038
NO
Proceed to 2.
YES
• Malfunction of harness (Short circuit).
2. CHECK THE COOLANT TEMPERATURE SENSOR.

(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals (Sensor side).
Standard (Measure at one of the followings.):
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}
SHTS161060200039
NO
Malfunction of coolant temperature sensor.
YES
• Malfunction of connectors.
.
ENGINE OVERHEAT
EN1610602F200019
MC No. 6 DTC No. P0217 Engine overheat
1. CHECK THE COOLANT TEMPERATURE SENSOR.

(1) Set the starter switch to "LOCK".
(2) Disconnect the connector of coolant temperature sensor.
HINT
Measure the resistance under any of the following conditions.
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}
SHTS161060200039
NO
Malfunction of coolant temperature sensor.
YES
Malfunction of engine cooling system.
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
EN1610602F200020
MC No. 7 DTC No. P0219 Engine overrun
1. The MC or DTC will be displayed, once detected over 4,000 r/

min. in the Engine revolution. Also, the fuel injection will be
suspended during the MC or DTC to be detected and the fuel
injection will be resumed when Engine revolution goes down
less than 3,800 r/min.
NOTICE
The MC or DTC aim is not for detecting the Engine overrun under
abnormal operation of the system, but for storing in memory the
high revolution of the Engine. (For detection of wrong shifting,
etc.) Also, there is a case in which "overrun" will be detected by
misunderstanding the Engine revolution, with a noise to be gener-
ated by harness malfunction and its modification.
.
FUEL TEMPERATURE SENSOR

EN1610602F200021
MC No. 14 DTC No. P0182 Fuel temperature sensor circuit low input
MC No. 14 DTC No. P0183 Fuel temperature sensor circuit high input

harness.
D E (2) Disconnect the signal check harness connector on the ECU side.
D34 E27 (3) Measure the resistance between THF+ (E27) and AGD2 (D34)
terminals.
HINT
Standard:
2.45 kΩ at 20°C {68°F}
1.15 kΩ at 40°C {104°F}
584 kΩ at 60°C {140°F}
SHTS161060200040
318 kΩ at 80°C {176°F}
.
NO
Proceed to 2.
YES
2. CHECK THE FUEL TEMPERATURE SENSOR.

(1) Disconnect the connector of fuel temperature sensor.
HINT
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}
SHTS161060200041
NO
Malfunction of fuel temperature sensor.
YES
.
BOOST PRESSURE SENSOR

EN1610602F200022
MC No. 37 DTC No. P0108 Boost pressure sensor circuit high input
MC No. 37 DTC No. P0237 Boost pressure sensor circuit low input

harness.
GND VCC
(2) Tilt the cab and disconnect the connector of boost pressure sen-
sor.
(3) Set the stater switch to "ON" (The engine is stopped).
(4) Measure the voltage between VCC and GND terminals of boost
pressure sensor (Vehicle harness side).
Standard: 4.5-5.5V
SHTS161060200042
NO
Proceed to 2.
YES
Proceed to 3.

(1) Set the stater switch to "ON" (The engine is stopped).
D D25 (2) Measure the voltage between AVC1 (D25) and AGD1 (D33) ter-
minals.
Standard: 4.5-5.5V
D33 (After measurement, turn the starter switch to "LOCK" position.)
SHTS161060200043
NO
• Malfunction of ECU connector.
YES

(1) Connect the connector of boost pressure sensor.
D D27 (3) Measure the voltage between PIM (D27) and AGD1 (D33) termi-
nals.
Standard: 0.2-4.8V
D33
SHTS161060200044
NO
proceed to 4.
YES
4. CHECK THE BOOST PRESSURE SENSOR.

(1) Connector of boost pressure sensor remains connected.
(2) Measure the voltage between SIG and GND terminals of boost
pressure sensor.
Standard: 0.2-4.8V
A
GND
SIG
VIEW A
SHTS161060200045
NO
Malfunction of boost pressure sensor.
YES
.
BOOST PRESSURE SENSOR (CHECK BY HINO-DX)

EN1610602F200023
MC No. 17 DTC No. P0106 Abnormality of boost pressure sensor characteristic
1. CHECK THE BOOST PRESSURE SENSOR USING THE PC

DIAGNOSIS TOOL (Hino DX).
(1) Connect the PC DIAGNOSIS TOOL (Hino DX).
(2) Set the stater switch to "ON".
(3) Confirm that no other MC or DTC is displayed. If another the MC
No. 37 or DTC No. P0106 is displayed again. Especially in case of
display MC or DTC in regard to engine speed sensor (main and
sub) system, perform repair so that these MC or DTC are not dis-
played.
(4) Measure the boost pressure in accordance with the screen of the
turbocharger inspection.
SHTS161060200046 Standard: More than 110 kpa {1.122 kgf/cm2, 15.95 Ibf/in.2}
.
NO
Malfunction of boost pressure sensor.
YES
Normal.
(5) If the above check shows no abnormalities, erase the MC or DTC

and start the engine. If the same MC or DTC is displayed again,
following malfunctions can be assumed.
a. Clogging or leakage of the hose between boost pressure sen-
sor and intake pipe.
b. Improper connection, loosen or leakage of the boost hose.
.
TURBOCHARGER OVER BOOST

EN1610602F200024
MC No. 39 DTC No. P0234 Turbocharger over boost
1. CHECK THE VNT TURBOCHARGER CONTROLLER.

(1) Set the starter switch to "ON" position.
(2) Confirm the VNT turbocharger controller malfunction (MC No. 35,
8 or DTC No. P0045, U0073, U1123) is not displayed.
(3) Select the "VNT check" in the "Check function" menu.
(4) Check the actual opening value is followed up by input value by
activating the VNT turbocharger controller.
Standard: Difference value is less than 5%
.
NO
Malfunction of VNT turbocharger controller.
YES
Carry out diagnosis of the boost pressure sensor (MC No. 37 or

DTC No. P0108, P0237).
AIR FLOW SENSOR

EN1610602F200025
MC No. 17 DTC No. P0102 Air flow sensor circuit low input
MC No. 17 DTC No. P0103 Air flow sensor circuit high input

AFVB (1) Disconnect the connector of the air flow sensor.
AFGD
(2) Set the starter to "ON" position.
(3) Measure the voltage between AFVB and AFGD terminals of air
flow sensor connector (Vehicle harness side).
SHTS161060200047
NO
YES
Proceed to 2.

D (1) Set the starter switch "LOCK" position.
D21 (2) Connect the connector of air flow sensor.
(3) Set the starter switch to "ON" position and measure the voltage
between AFSG (D21) and AGD6 (D17) terminals of signal check
harness.
D17 Standard: 0.2-4.8V
SHTS161060200048
NO
Proceed to 3.
YES

(1) Air flow sensor connector remains connected.
AFGD AFSG
(2) Measure the voltage between AFGD and AFSG terminals of air
flow sensor connector (vehicle harness side).
Standard: 0.2-4.8V
NOTICE
SHTS161060200049
NO
Malfunction of air flow sensor.
YES
.
AIR FLOW SENSOR (CHECK BY HINO-DX)

EN1610602F200026
MC No. 17 DTC No. P0101 Abnormality of air flow sensor characteristic
1. CHECK THE AIR FLOW SENSOR USING THE PC DIAGNOSIS

TOOL (Hino DX)
(1) Confirm that no other MC or DTC is displayed. If another MC or
DTC is displayed, repair that trouble and confirm that the MC No.
17 or DTC No. P0101 is displayed again. Especially in case of dis-
play MC or DTC in regard to engine speed sensor (main and sub)
system, perform repair so that these MC or DTC are not dis-
played.
(2) Carry out "INSPECTION OF AIR FLOW SENSOR (CHECK/
ADJUSTMENT OF AIR INTAKE VOLUME BY HINO-DX)", refer
to DN02-25.
SHTS161060200050 (3) Carry out diagnosis of the intake air temperature sensor (MC No.
16 or DTC No. P0112, P0113).
(4) Carry out diagnosis of the boost pressure sensor (MC No. 37 or
DTC No. P0106, P0237).
(5) Carry out diagnosis of the EGR (MC No. 81, 82, 86, 87, 88, or
DTC No. P0400, P0404, P0405, P0406, P0407, P0408, P0489,
P0490, P1401, P1402, P1403).
following malfunctions can be assumed.
a. Clogging of air cleaner
b. Improper connection or leakage of the air hose connected to
engine from air cleaner.
.
SHTS161060200051
INTAKE AIR TEMPERATURE SENSOR

EN1610602F200027
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

harness.
A D (2) Disconnect the signal check harness connector on the ECU side.
A32 D34 (3) Measure the resistance between AFT+ (A32) and AGD2 (D34)
terminals of ECU connector (Vehicle harness side).
HINT
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}
SHTS161060200052
NO
Proceed to 2.
YES
2. CHECK THE INTAKE AIR TEMPERATURE SENSOR.

AFT+ (1) Disconnect the connector of intake air temperature (air flow) sen-
AFT- sor.
(2) Measure the resistance between AFT- and AFT+ terminals of the
intake air temperature (air flow) sensor.
HINT
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}
SHTS161060200053
NO
Malfunction of intake air temperature (air flow)
sensor.
YES
.
COMMON RAIL EXCESSIVE PRESSURE, CONTROL SYSTEM

EN1610602F200028
MC No. 68 DTC No. P0088 Excessive common rail pressure (1st step)
MC No. 69 DTC No. P0088 Excessive common rail pressure (2nd step)

harness.
D D20
D31
(3) Measure the voltage between PCR1 (D20), PCR2 (D31) and
AGD1 (D33) terminals.
D33
Standard: 3.6-4.7V
SHTS161060200054
NO
• Bad contact of harness connector.
YES
Malfunction of common rail pressure sensor.
.
COMMON RAIL PRESSURE AND SUPPLY PUMP

EN1610602F200029
MC No. 76 DTC No. P0087 Lack of forced feed in supply pump
MC No. 76 DTC No. P0088 Excessive common rail pressure, supply pump excess forced feed

D D20
harness.
D31
(3) Perform warm-up until the coolant temperature gauge moves.
D33 (4) At engine speed idling. The target pressure (PFIN) = APPROX. 30
MPa {306 kgf/cm2, 4,351 lbf/in.2} (APPROX. 1.5V)
Standard: Less than 1.56V
SHTS161060200054
NO
Malfunction of common rail pressure sensor.
YES
2. CHECK THE MC OR DTC.

DTC is displayed repair that trouble and confirm that the MC No.
76 or DTC No. P0088, P0087 is displayed again. Especially in
case of display MC or DTC in regard to engine speed sensor
(main and sub) system, perform repair so that these MC or DTC
are not displayed.
(2) Confirm the injection timing of the supply pump. If installation has
not been done at top dead center 0°, install correctly.
malfunction of supply pump, malfunction of common rail pressure
SHTS161060200055 sensor system, and malfunction ECU can be assumed.
.
COMMON RAIL PRESSURE SENSOR STICKING

EN1610602F200030
MC No. 67 DTC No. P0191 Common rail pressure sensor sticking

D D20 harness.
D31 (2) Set the starter switch to "ON" (The engine is stopped).
D33
Standard: 0.9-1.1V
SHTS161060200056
NO
YES

(5) While measuring the voltage between PCR1 (D20), PCR2 (D31)
D D20 and AGD1 (D33) terminals of ECU connector, repeat opening and
D31 closing at full throttle.
Standard: 1.0 to 3.2V (The voltage shall vary)
D33
SHTS161060200057
NO
• Malfunction of common rail pressure sen-
sor.
YES • Bad contact of harness connector.
.
COMMON RAIL PRESSURE SENSOR MALFUNCTION

EN1610602F200031
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

D D20
harness.
D31
D33 AGD1 (D33) terminals.
Standard: 0.7-4.7V
SHTS161060200058
NO
Proceed to 2.
YES

(1) Set the starter switch to "LOCK" and disconnect the connector of
PCR- PCR+ common rail pressure sensor.
(3) Measure the voltage between PCR+ and PCR- terminals of com-
mon rail pressure sensor (Vehicle harness side).
Standard: 4.5-5.5V
SHTS161060200059
NO
Proceed to 3-(3).
YES
3. CHECK THE RESISTACE BETWEEN TERMINALS.

D (2) Measure the resistance between PCR1 and PCR2 (D20 and D31)
D20 terminals and PCR terminal of common rail pressure sensor
D31 (Vehicle harness side).
PCR
SHTS161060200060
NO
YES
Bad contact of harness connector.
(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).
SHTS161060200061
D PCR-
D33
SHTS161060200062
.
NO
YES
.
ACCELERATOR SENSOR 1 (VOLTAGE)

EN1610602F200032
MC No. 22 DTC No. P2121 Accelerator sensor 1 malfunction (Open sticking)
MC No. 22 DTC No. P2121 Accelerator sensor 1 malfunction (Close sticking)

GND1 (1) Set the starter switch to "LOCK" and connect the signal check
harness.
(2) Disconnect the connector of the accelerator sensor.
(4) Measure the voltage between VCC1 and GND1 terminals of
accelerator sensor (Vehicle harness side).
VCC1
Standard: 4.5-5.5V
SHTS161060200063
NO
Proceed to 2.
YES
Proceed to 3.

(1) Measure the voltage between AVC4 (B23) and AGD4 (B20) termi-
B23 B B20
nals.
Standard: 4.5-5.5V
SHTS161060200064
NO
YES

A B accelerator sensor.
A21 B20
(3) Measure the voltage between ASC1 (A21) and AGD4 (B20) termi-
nals.
Standard:
0.7-1.0V: Release the accelerator pedal.
3.55-4.4V: Depress the accelerator pedal fully.
NOTICE
SHTS161060200065 The standard value at the full throttle is based on the actual mea-
surement value.
.
NO
Proceed to 4.
YES

GND1 (1) Connector of accelerator sensor remains connected.
(3) Measure the voltage between SIG1 and GND1 terminals of accel-
+ - erator sensor (Vehicle harness side).
Standard:
SIG1 3.7-4.4V: Depress the accelerator pedal fully.
VIEW NOTICE
CHASISS HARNESS SIDE
The standard value at the full throttle is based on the actual mea-
SHTS161060200066 surement value.
.
NO
Malfunction of accelerator sensor.
YES
Harness disconnection or short circuit.
.
ACCELERATOR SENSOR 1
EN1610602F200033
MC No. 22 DTC No. P2122 Accelerator sensor circuit 1 low voltage
MC No. 22 DTC No. P2123 Accelerator sensor circuit 1 high voltage

A B harness.
A21 B20
(3) Measure the voltage between ACS1 (A21) and AGD4 (B20) termi-
nals.
Standard: 0.7-1.0V: Release the accelerator pedal.
SHTS161060200067
NO
YES
nals while depressing the accelerator pedal.
A B
A21 B20 Standard: 1V or more, with the voltage change proportional
to the accelerator pedal depression amount.
SHTS161060200068
NO
YES
.
ACCELERATOR SENSOR 2 (VOLTAGE)

EN1610602F200034

VCC2 harness
(2) Disconnect the connector of the accelerator sensor.
(4) Measure the voltage between VCC2 and GND2 terminals of
GND2 accelerator sensor (Vehicle harness side).
Standard: 4.5-5.5V
SHTS161060200069
NO
Proceed to 2.
YES
Proceed to 3.

nals.
B
Standard: 4.5-5.5V
B21
B31
SHTS161060200070
NO
YES

A B accelerator sensor.
A22
B21 (2) Set the starter switch to "ON" (The engine is stopped).
(3) Measure the voltage between ASC2 (A22) and AGD5 (B21) termi-
nals.
Standard:
NOTICE
SHTS161060200071 The standard value at the full throttle is based on the actual mea-
surement value.
.
NO
Proceed to 4.
YES

GND2 (1) Connector of the accelerator sensor remains connected
(3) Measure the voltage between SIG2 and GND2 terminals of accel-
erator sensor.
+ -
Standard:
SIG2 0.7-1.0V: Release the accelerator pedal.
VIEW NOTICE
CHASISS HARNESS SIDE The standard value at the full throttle is based on the actual mea-
SHTS161060200072 surement value.
.
NO
YES
.
ACCELERATOR SENSOR 2
EN1610602F200035
MC No. 22 DTC No. P2127 Accelerator sensor circuit 2 low voltage
MC No. 22 DTC No. P2128 Accelerator sensor circuit 2 high voltage

A B
A22 harness.
B21 (2) Set the starter switch to "ON" (The engine is stopped).
nals.
Standard: 0.7-1.0V: Release the accelerator pedal.
SHTS161060200073
NO
YES
nals while depressing the accelerator pedal.
A B
A22 Standard: 1V or more, with the voltage change proportional
B21
to the accelerator pedal depression amount.
SHTS161060200074
NO
YES
ACCELERATOR SENSOR 1 & 2

EN1610602F200036
MC No. 22 DTC No. P2120 Accelerator sensor 1 and 2 malfunction
1. MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE

CONTENTS OF MC No.22 or DTC No. P2121, 2126.
.
ACCELERATOR SENSOR (FOR OPERATION OF P.T.O.)

EN1610602F200037
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

VCC (1) Disconnect the connector of the accelerator sensor.
(3) Measure the voltage between VCC and GND terminals of accel-
erator sensor (Vehicle harness side).
Standard: 4.5-5.5V
GND
SHTS161060200075
NO
Proceed to 2.
YES
Proceed to 3.

B27 B B20
harness.
nals of accelerator sensor (Vehicle harness side).
Standard: 4.5-5.5V
SHTS161060200076
NO
YES

A (1) Connect the connector of the accelerator sensor.
B B20
(3) Measure the voltage between ASCS (A23) and AGD4 (B20) ter-
minals.
A23 Standard:
APPROX. 0.6-4.6V (Idle to full throttle)
SHTS161060200077
NO
Proceed to 4.
YES

(1) Connector of accelerator sensor remains connected.
SIG (3) Measure the voltage between SIG and GND terminals of acceler-
GND
ator sensor (Vehicle harness side).
Standard:
APPROX. 0.6-4.6V (Idle to full throttle)
NOTICE
SHTS161060200078
NO
YES
.
VEHICLE SPEED SENSOR

EN1610602F200038
MC No. 21 DTC No. P0500 Vehicle speed sensor circuit low input
MC No. 21 DTC No. P0501 Vehicle speed sensor circuit high input

C3, C4 (1) Set the starter switch to "LOCK" position and connect the signal
A27
A C
check harness.
(2) Prepare the voltage measurement between VS (A27) terminal
and CGD (C3, C4) terminals.
(3) Measure the voltage while the vehicle starts to run at the speed of
10 km/h {6.2 miles/h}.
NOTICE
Start the vehicle with much caution around.
Standard: Pulse wave-shape by more than 4V↔1.0V
SHTS161060200079
NO
Proceed to 2.
YES
2. CHECK THE RESISTANCE BETWEEEN TERMINALS.

(1) Set the starter switch to "LOCK" position and disconnect the sig-
A27 A SPD
nal check harness connector on the ECU side.
(2) Disconnect the connector of pulse adjust computer.
(3) Measure the resistance between VS (A27) terminal of ECU and
SPD terminal of pulse adjust computer (Vehicle harness side).
Standard: 1 Ω or less.
SHTS161060200080
NO
Harness disconnection of vehicle speed sen-
sor circuit.
YES
Proceed to 3.
3. CHECK THE INSULATION RESISTANCE BETWEEN TERMI-

NALS.
A A27 BODY GND (1) Set the starter switch to "LOCK" position and connect the connec-
tor of signal check harness to ECU.
(2) Measure the insulation resistance between VS (A27) terminal of
ECU and body GND.
Standard: ∞ Ω
SHTS161060200081
NO
Short circuit of vehicle speed sensor circuit.
YES
Malfunction of vehicle speed sensor.

(Check only the vehicle speed sensor. Erase the past MC or
DTC and conduct a test run. When the same MC or DTC is still
displayed, replace the ECU with a new one.)
ECU
EN1610602F200039
MC No. 3 DTC No. P0605 Flash ROM error
MC No. 3 DTC No. P0606 CPU malfunction (Hard detection)
MC No. 3 DTC No. P0607 Monitoring IC malfunction in CPU
MC No. 15 DTC No. P2227 Abnormality of atmospheric pressure sensor characteristic
MC No. 15 DTC No. P2228 Atmospheric pressure sensor circuit low input
MC No. 15 DTC No. P2229 Atmospheric pressure sensor circuit high input
MC No. 59 DTC No. P0200 ECU charge circuit high input
MC No. 59 DTC No. P0611 ECU charge circuit low input
1. After the starter switch is positioned on the "LOCK" once, it

should be turned to "ON" position again.
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.)
.

SHORT-CIRCUIT (GND)
EN1610602F200040
MC No. 57 DTC No. P1211 Injector common 1 ground line short
MC No. 58 DTC No. P1214 Injector common 2 ground line short
1. CHECK THE RESISTANCE BETWEEN TERMINAL AND GND.

D5, 6 D E E6, 7 (1) Set the starter switch to "LOCK" and connect the signal check
harness.
(3) Measure the resistance between the terminals and ECU case
GND.
ECU CASE GND
(ECU MOUNTING BOLT)
Resistance measurement
MC No. DTC NO.
+ side – side
57 P1211 IJ1+ (D5), I1+S (D6) ECU case GND

SHTS161060200082
58 P1214 IJ2+ (E6), I2+S (E7) ECU case GND
Standard: ∞ Ω
.
NO
Proceed to 3.
YES

(1) Set the starter switch to "LOCK" position and reconnect the signal
check harness on the ECU side.
(2) Start the engine and erase the MC or DTC.
(3) If the same MC or DTC is displayed, replace ECU. If no MC or
DTC is displayed, a temporary failure would have occurred.
3. CHECK THE RESISTANCE BETWEEN TERMINALS AND GND.

(3) Disconnect the injector harness connector that is located on the
1 2 3 4 front side of the cylinder.
(4) Measure the resistance between the terminals of injector harness
5 6 7 8 connector (Vehicle harness side) and ECU case GND.
9 10 11 12 ! WARNING
Never start the engine during the inspection above because it can
result in electrical shock or vehicle damage.
SHTS161060200083
Failure position Resistance measurement

MC NO. DTC NO.
(Breaking position) + side – side
No.1 injector 11, 12
57 P1211 No.2 injector 3, 4
No.3 injector 5, 6
ECU case GND
No.4 injector 7, 8
58 P1214 No.5 injector 1, 2
No.6 injector 9, 10
Standard: ∞ Ω
.
NO
(The harness is defective if the resistance
value is out of standard.)
YES
Check the harness in the head cover.

(A short-circuit could occur between the harness in the head
cover and the GND line.)
.

SHORT-CIRCUIT (24V)
EN1610602F200041
MC No. 57 DTC No. P1212 Injector common 1 power source line short
MC No. 57 DTC No. P1212 Injector common 1 open circuit
MC No. 58 DTC No. P1215 Injector common 2 power source line short
MC No. 58 DTC No. P1215 Injector common 2 open circuit
1. CHECK THE VOLTAGE BETWEEN TERMINALS AND GND.

D5, 6 D E E6, 7 (1) Set the starter switch to "LOCK" and connect the signal check
harness.
(3) Measure the voltage between the terminals and ECU case GND.
ECU CASE GND

(ECU MOUNTING BOLT) Voltage measurement
MC No. DTC NO.
+ side – side
57 P1212 IJ1+ (D5), I1+S (D6) ECU case GND
SHTS161060200084 58 P1215 IJ2+ (E6), I2+S (E7) ECU case GND
Standard: Less than 14V

.
NO
Proceed to 3.
YES

(1) Set the starter switch to "LOCK" position and reconnect the signal
check harness on the ECU side.
(3) If the same MC or DTC is displayed, replace ECU. If no MC or
DTC is displayed, a temporary failure would have occurred.
3. CHECK THE VOLTAGE BETWEEN TERMINALS AND GND.

(2) Disconnect the injector harness connector that is located on the
front side of the cylinder.
1 2 3 4 (3) Set the starter switch to "ON" (The engine is stopped).
(4) Measure the voltage between the terminals of injector harness
5 6 7 8 connector (Vehicle harness side) and ECU case GND.
9 10 11 12
SHTS161060200085
Failure position Voltage measurement

MC NO. DTC NO.
(Breaking position) + side – side
No.1 injector 11
57 P1212 No.2 injector 3
No.3 injector 6
ECU case GND
No.4 injector 7
58 P1215 No.5 injector 2
No.6 injector 10
Standard: Less than 14V

.
NO
(The harness is defective if the resistance
value is out of standard.)
YES
Check the harness in the head cover.

(Harness disconnection could occur between the harness in the
head cover and the power source line.)
.
INJECTOR SOLENOID VALVE SYSTEM DISCONNECTION

EN1610602F200042
MC No. 51 DTC No. P0201 Injector circuit malfunction -cylinder 1

harness connector.
D3 (2) Disconnect the signal check harness connector on the ECU side.
D2
D D6
D4
Failure position Resistance
D5 MC NO. DTC NO.
(Breaking position) measurement
51 P0201 No.1 Injector INJ1 (D2) ↔ IJ1+ (D5)
52 P0202 No.2 Injector INJ2 (D3) ↔ IJ1+ (D5)
53 P0203 No.3 Injector INJ3 (D4) ↔ I1+S (D6)

E
E2 E6
54 P0204 No.4 Injector INJ4 (E1) ↔ IJ2+ (E6)
E7
E1 55 P0205 No.5 Injector INJ5 (E3) ↔ IJ2+ (E6)
56 P0206 No.6 Injector INJ6 (E2) ↔ I2+S (E7)

E3
SHTS161060200086
NO
Proceed to 3.
YES

(1) Set the starter switch to "LOCK" position and connect the signal
check harness connector on the ECU side.
(3) Check the present failure. If the same MC or DTC is displayed,
replace ECU.
If there is no MC or DTC, then the connector contact would have
been defective. As long as no MC or DTC is displayed, there is no
problem.

(2) Disconnect the injector harness connector that is located at the
front side of the cylinder head.
4 3 2 1 (3) Measure the resistance between the terminals of the injector har-
ness connector (Injector side).
8 7 6 5
12 11 10 9 Failure position Resistance
MC NO. DTC NO.
(Breaking position) measurement
51 P0201 No.1 injector 11 ↔ 12

SHTS161060200087 52 P0202 No.2 injector 3↔4
53 P0203 No.3 injector 6↔5
56 P0206 No.6 injector 10 ↔ 9

.
NO
Proceed to 4.
YES
Harness disconnections (Vehicle harness side).

(Check the harness between ECU and the injector connector.)
4. CHECK THE RESISTANCE BETWEEN TERMINALS OF THE

INJECTOR.
(2) Dismount the head cover.
(3) Disconnect the injector connector (Injector side) of the cylinder
displayed by MC or DTC. Measure the resistance between the ter-
minals of the injector (Injector side).
Standard: 0.35-0.55 Ω at 20°C {68°F}
SHTS161060200088
NO
Proceed to 5.
YES
Bad contact of the connector or the harness in the head cover.

(Check the connector or the harness in the head cover.)
5. CHECK THE INSULATION RESISTANCE BETWEEN TERMI-

NAL AND INJECTOR BODY.
(1) Remove the injector terminal cap of the cylinder displayed by MC
or DTC.
Measure the insulation resistance between terminal and injector
body.
Standard: Less than 10 MΩ
SHTS161060200089
NO
Injector coil disconnection. (Replace the injec-
tor assembly.)
YES
Injector harness disconnections. (Replace the injector harness.)
.
CYLINDER CONTRIBUTION/BALANCE
EN1610602F200043
MC No. 61 DTC No. P0263 Cylinder 1 contribution/balance fault
1. CHECK THE FLOW DAMPER.

(1) Turn the starter switch to "LOCK" and stop the engine.
(2) Wait for about 30 seconds and then start the engine.
(3) Perform warm-up until the coolant temperature becomes 60°C
{140°F} or higher. And erase the MC or DTC.
(4) If the same MC or DTC is displayed again after erasing it, inspect
the flow damper of displayed cylinder.
MC No. DTC NO. Inspection flow damper
61 P0263 No.1 Cylinder
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.
SHTS161060200090

(1) Check that the other MC or DTC is not displayed.
If the other MC or DTC is displayed, repair the trouble.
a If the same MC or DTC is displayed again, it is possibly from the
d following problems.
a. Excessive fuel flow will cause fuel leakage from injection pipe
b (Between flow damper and injector) by bending, cracking and pipe
connection looseness.
c → Check leakage.
b. Excessive or shortage fuel flow will cause an increase in the inter-
nal leakage of injector.
→ Check injector leakage using nozzle tester.
c. Excessive fuel flow will cause injector seat defection.
→ Check injector nozzle seat using nozzle tester.
e d. Excessive or shortage fuel flow will cause injector operation mal-
function.
→ Check by replacing the injector.
e. Shortage fuel flow will cause clogging of the fuel supply system.
→ Check fuel filter.
(2) The above problems can be diagnosed using the "Data Monitor"
e
menu to determine the cylinder contribution quantity and "Activa-
tion Test" menu to stop the injector.
.
SHTS161060200091
SUPPLY PUMP SUCTION CONTROL VALVE (SCV)

EN1610602F200044
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)
1. CHECK THE RESISTANCE OF SCV.

(2) Disconnect the connector of the supply pump SCV.
(3) Measure the resistance between terminals of SCV connector
(SCV side).
Standard: 7.4-8.4 Ω at 20°C (68°F)
SHTS161060200092
NO
Malfunction of SCV. (Replace the supply
pump)
YES

(2) Measure the resistance between SCVH (E10, E11) terminals and
SVCH terminal of SCV connector (Vehicle harness side).
SCVL In the same way, measure the resistance between SCVL (E8, E9)
SCVH terminals and SCVL terminal of SCV connector.
Standard: less than 1 Ω
E E8
E9 E10
E11
SHTS161060200093
NO
YES

E4 E E8, E9
(2) Measure the voltage between PGD2 (E4) terminal and SCVL (E8
E9) terminals.
Standard: Pulse wave-shape by 24↔0V
NOTICE
Measure the voltage within 40 seconds after turning the starter
switch to "ON".
SHTS161060200094
NO
Malfunction of ECU connector.
YES
Malfunction of ECU.
SUPPLY PUMP
EN1610602F200045
MC No. 75 DTC No. P2635 Supply pump SCV sticking
MC No. 79 DTC No. P2635 Supply pump abnormal high pressure record
1. CHECK THE SUPPLY PUMP.

(1) Turn the starter switch to "LOCK" and stop the engine.
(2) Wait for about 30 seconds and then start the engine.
(3) Perform warm-up until the coolant temperature become 60°C
{140°F} of higher. And erase the MC or DTC.
(4) Confirm that the same MC or DTC is displayed again when raising
engine revolution up to "No load max revolution" or racing engine.
.
NO
Replace supply pump.
YES
2. CHECK THE MC OR DTC.

DTC is displayed repair that trouble and confirm that the MC No.
75, 77, 79 or DTC No. P2635 is displayed again. Especially in
case of display MC or DTC in regard to engine speed sensor
(main and sub) system, perform repair so that these MC or DTC
are not displayed.
malfunction of supply pump and malfunction ECU can be
assumed.
SHTS161060200095 .
EGR SOLENOID VALVE 1

EN1610602F200046
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)

D7
harness.
D (2) Set the starter switch to "ON" position.
(3) Measure the voltage between EGR1 (D7) and PGD1 (D1) termi-
nals of ECU connector (vehicle harness side).
D1
SHTS161060200096
NO
Proceed to 2.

EGV1 EGR1 (1) Set the starter switch to "LOCK" position.
(2) Disconnect the connector of EGR valve 1.
(3) Measure the resistance between EGV1 and EGR1 terminals of
EGR valve 1 connector.
Standard: 25.5-29.5 Ω at 20°C {68°F}
SHTS161060200097
NO
Malfunction of EGR Solenoid 1.
YES
Proceed to 3.

EGR1 D7 (1) Set the starter switch to "LOCK" and disconnect the signal check
D harness connectors on ECU side.
(2) Measure the resistance between EGR1 (D7) terminals of ECU
connector (Vehicle harness side) and EGR1 terminal of EGR
valve1 (Vehicle harness side).
SHTS161060200098
NO
YES
EGR SOLENOID VALVE 2

EN1610602F200047
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)

D8
harness.
D (2) Set the starter switch to "ON" position.
(3) Measure the voltage between EGR2 (D8) and PGD1 (D1) termi-
nals of ECU connector (Vehicle harness side).
D1
SHTS161060200099
NO
Proceed to 2.

EGV2 EGR2 (1) Set the starter switch to "LOCK" position.
(2) Disconnect the connector of EGR valve 2.
(3) Measure the resistance between EGV2 and EGR2 terminals of
EGR valve 2 connector.
Standard: 25.5-29.5. Ω at 20°C {68°F}
SHTS161060200100
NO
Malfunction of EGR Solenoid 2.
YES
Proceed to 3.

EGR2 D8 (1) Set the starter switch to "LOCK" and disconnect the signal check
D harness connectors on ECU side.
(2) Measure the resistance between EGR2 (D8) terminals of ECU
connector (Vehicle harness side) and EGR2 terminal of EGR
valve2 (Vehicle harness side).
SHTS161060200101
NO
YES
.
EGR
EN1610602F200048
MC No. 88 DTC No. P0400 Abnormal flow amount of EGR
1. CHECK THE EGR USING THE PC DIAGNOSIS TOOL (Hino

DX).
DTC is displayed, repair that trouble and confirm that the MC No.
17 or DTC No. P0101 is displayed again. Especially in case of dis-
play MC or DTC in regard to engine speed sensor (main and sub)
system, perform repair so that these MC or DTC are not dis-
played.
(2) Carry out "INSPECTION OF AIR FLOW SENSOR (CHECK/
ADJUSTMENT OF AIR INTAKE VOLUME BY HINO-DX)", refer
to DN02-25.
SHTS161060200102
(4) Set the starter switch to "ON".
(5) Confirm the EGR solenoid malfunction (MC No. 81, 83 or DTC
No. P0489, P0490, P1402, P1403) and EGR lift sensor malfunc-
tion (MC No. 86, 87 or DTC No. P0405, P0406, P0407, P0408) is
not displayed.
activating the EGR valve.
.
NO
YES
Normal.

malfunction of air flow sensor can be assumed. Carry out the unit
check of air flow sensor.
.
EGR VALVE 1
EN1610602F200049
MC No. 88 DTC No. P0404 EGR valve 1 sticking
1. CHECK THE EGR VALVE 1 STICK.

(2) Confirm the EGR solenoid 1 malfunction (MC No. 88 or DTC No.
P0489, P0490) and EGR lift sensor 1 malfunction (MC No. 86 or
DTC No. P0405, P0406) is not displayed.
(3) Select the "EGR check" in the "Check function" menu.
.
NO
Malfunction of EGR valve 1.
YES
Normal.
EGR VALVE 2
EN1610602F200050
MC No. 89 DTC No. P1401 EGR valve 2 sticking
1. CHECK THE EGR VALVE 2 STICK.

(2) Confirm the EGR solenoid 2 malfunction (MC No. 82 or DTC No.
P1402, P1403) and EGR lift sensor 2 malfunction (MC No. 87 or
DTC No. P0407, P0408) is not displayed.
(3) Select the "EGR check" in the "Check function" menu.
.
NO
Malfunction of EGR valve 2.
YES
Normal.
.
EGR LIFT SENSOR 1

EN1610602F200051
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

LSG1
LSV1
check harness.
(2) Disconnect the connectors of EGR valve1.
(4) Measure the voltage between LSG1 and LSV1 terminals of con-
nector (Vehicle harness side) of EGR sensor.
Standard: 4.5-5.5V
SHTS161060200103
NO
Proceed to 2.
YES
Proceed to 3.

(1) Measure the voltage between AGD3 (D35) and AVC3 (D22) ter-
D D22 minals of signal check harness.
D35
Standard: 4.5-5.5V
SHTS161060200104
NO
YES
Proceed to 3.

(1) Set the starter switch to "LOCK" position and connect the connec-
D D26 tor of EGR valve1.
(3) Measure the voltage between EGS1 (D26) and AGD3 (D35) ter-
D35 minals of signal check harness.
Standard: 1.3-4.0V
SHTS161060200105
NO
Proceed to 4.
YES
• Malfunction of ECU
• Malfunction of ECU connector
4. CHECK THE VOLTAGE BETWEEN TERMINALS

(1) EGR lift sensor connector remains connected.
LSS1 LSG1 (2) Measure the voltage between LSS1 and LSG1 terminals of EGR
lift sensor connector (Vehicle side).
Standard: 1.3-4.0V
SHTS161060200106
NO
Malfunction of EGR lift sensor1.
(Replace the EGR assembly)
YES
.
EGR LIFT SENSOR 2

EN1610602F200052
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

LSG2
LSV2
check harness.
(2) Disconnect the connectors of EGR valve2.
(4) Measure the voltage between LSG2 and LSV2 terminals of con-
nector (Vehicle harness side) of EGR sensor.
Standard: 4.5-5.5V
SHTS161060200107
NO
Proceed to 2.
YES
Proceed to 3.

(1) Measure the voltage between AGD3 (D35) and AVC3 (D22) ter-
D D22 minals of signal check harness.
D35
Standard: 4.5-5.5V
SHTS161060200108
NO
YES
Proceed to 3.

(1) Set the starter switch to "LOCK" position and connect the connec-
B D D35 tor of EGR valve2.
B29
(3) Measure the voltage between EGS2 (B29) and AGD3 (D35) ter-
minals of signal check harness.
Standard: 1.3-4.0V
SHTS161060200109
NO
Proceed to 4.
YES
4. CHECK THE VOLTAGE BETWEEN TERMINALS

(1) EGR lift sensor connector remains connected.
LSS2 LSG2 (2) Measure the voltage between LSS2 and LSG2 terminals of EGR
lift sensor connector (Vehicle side).
Standard: 1.3-4.0V
NOTICE
SHTS161060200110
NO
Malfunction of EGR lift sensor 2.
(Replace the EGR assembly)
YES
.
VNT (VARIABLE NOZZLE TURBINE) TURBOCHARGER CONTROLLER

EN1610602F200053
MC No. 35 DTC No. P0045 VNT turbocharger controller malfunction
MC No. 36 DTC No. P0045 VNT turbocharger controller malfunction
MC No. 8 DTC No. U1123 CAN communication error (VNT)
MC No. 8 DTC No. U0073 CAN malfunction (Engine)

(1) Set the starter switch to "LOCK" position.
(2) Disconnect the connectors of VNT turbocharger controller.
VNTG (3) Set the starter switch to "ON" position.
VNTV
(4) Measure the voltage between VNTV and VNTG terminals of
VNTG connector (Vehicle harness side).
SHTS161060200111
NO
YES
Proceed to 2.
2. CHECK THE VOLTAGE BETWEEN VNT ACTUATOR TERMI-

NALS.
E (1) Set the starter switch to "LOCK" position.
E21 (2) Connect the signal check harness to the VNT turbocharger con-
troller.
E22 (3) Set the starter switch to "ON" position and measure the voltage
between CANL (E22) and CANH (E21) terminals of signal check
harness.
Standard: Pulse wave-shape by 0-5V
SHTS161060200112
NO
• Harness disconnection, short circuit
(Ground line, power source line).
YES • Bad contact of harness or connector.
Malfunction of VNT turbocharger controller.
.
VNT (VARIABLE NOZZLE TURBINE)

EN1610602F200054
MC No. 35 DTC No. P2263 VNT nozzle sticking
1. CHECK THE VNT USING THE PC DIAGNOSIS TOOL (Hino

DX).
(3) Confirm that VNT turbocharger controller malfunction (MC No. 35,
36, 8 or DTC No. P0045, U1123, U0073) is not displayed.
activating the VNT.
SHTS161060200113
NO
Malfunction of EGR.
YES
Normal.
.
EXHAUST BRAKE MAGNETIC VALVE

EN1610602F200055
Exhaust brake magnetic valve malfunction (Open circuit, ground

MC No. 28 DTC No. P1681
line short)
Exhaust brake magnetic valve malfunction (Power source line

MC No. 28 DTC No. P1682
short)

B2
B D1 D E4 E E5 harness.
(4) Measure the voltage between terminals.
+ side – side
EBMV (B2) PGD1 (D1), PGD2 (E4), PGD3 (E5)
SHTS161060200114 Standard: More than 19V

.
NO
Proceed to 2.
YES
2. CHECK THE EXHAUST BRAKE MAGNETIC VALVE.

(1) Disconnect the connector of exhaust brake magnetic valve.
(2) Measure the resistance between terminals (Exhaust brake mag-
netic valve side).
Standard: 35-45 Ω
SHTS161060200115
NO
Malfunction of exhaust brake magnetic valve.
YES
Malfunction of harness or connector.
.
INJECTOR CORRECTION DATA

EN1610602F200056
MC No. 2 DTC No. P1601 Injector correction data conformity error
1. CHECK THE QR CODE.

(1) Read the QR codes using "Injector Calibration" menu.
Standard: Same as the installed injector or service record.
.
NO
Re-input the QR codes.
YES
Replace the ECU.
.
MAIN RELAY
EN1610602F200057
MC No. 5 DTC No. P0686 Main relay malfunction

A6 (1) Set the starter switch to "LOCK" and connect the signal check
A5 A A7 harness.
(2) Set the starter to "ON" position.
(3) Measure the voltage between VB1 (A5), VB2 (A6), VB3 (A7) ter-
minal and Chassis GND.
Standard: 0V
SHTS161060200116
NO
Proceed 2.
YES

(1) Set the starter switch to "LOCK" and remove the main relay.
Standard:
1. 282-370 Ω
2. ∞ Ω
1 2
SHTS161060200117
NO
Malfunction of main relay.
YES
.
IDLE VOLUME
EN1610602F200058
MC No. 44 DTC No. P1142 Idle set controller low voltage
MC No. 44 DTC No. P1143 Idle set controller high voltage

harness.
GND (2) Disconnect the connector of idle set controller.
(4) Measure the voltage between + and GND terminals of idle set
controller connectors (Vehicle harness side).
Standard: 4.5-5.5V
+ (After measurement, turn the starter switch to "LOCK" position.)
SHTS161060200118
NO
Proceed to (5).
YES
Proceed to (7).

B nals.
B23 B20
Standard: 4.5-5.5V
SHTS161060200119
NO
YES
Harness disconnection.
(7) Connect the connector of idle set controller.

A30 B20
A B (9) Measure the voltage between IVS (A30) and AGD4 (B20) termi-
nals.
Standard:
APPROX. 0V: Turn control knob to left fully.
APPROX. 0.7V: Turn control knob to left.
APPROX. 4.3V: Turn control knob to right fully.
SHTS161060200120
NO
Proceed to (10).
YES

(11) Measure the voltage between SIG and GND terminals of idle set
controller connectors (Chassis harness side).
Standard:
APPROX. 0V: Turn idle control knob to left fully.
APPROX. 0.7V: Turn idle control knob to left.
APPROX. 4.3V: Turn idle control knob to right fully.
SHTS161060200121
NO
Malfunction of idle set controller.
YES
.
ACCELERATOR SWITCH
EN1610602F200059
MC No. 42 DTC No. P0510 Accelerator switch malfunction

B C3 C harness.
B24 C4
(3) Measure the voltage between IDLE (B24) and CGD (C3 and C4)
terminals.
Standard:
More than 19V (Accelerator pedal released)
0V (With full throttle)
SHTS161060200122
NO
Proceed to 2.
YES
Malfunction of ECU.
2. CHECK THE ACCELERATOR SWITCH.

(2) Disconnect connector of the accelerator switch.
(3) Measure the resistance between terminals (Switch side).
Standard:
Less than 2 Ω (Accelerator pedal released)
∞ Ω (With full throttle)
SHTS161060200123
NO
Malfunction of accelerator switch.
YES
.
STARTER SWITCH
EN1610602F200060
MC No. 45 DTC No. P0617 Starter switch malfunction

NOTICE
Make sure that transmission is in neutral position.
harness.
B B14 C C4 (2) Disconnect the signal check harness connector on the ECU side.
(3) Measure the voltage between ST (B14) and CGD (C3 and C4)
C3
terminals.
Standard:
0V (Starter switch "LOCK")
24V (Starter switch "START")
SHTS161060200124
NO
YES
• Bad contact of ECU connectors.
.
CLUTCH SWITCH
EN1610602F200061
MC No. 41 DTC No. P0704 Clutch switch malfunction
1. CHECK THE VOLTAGE BETWEEN TERMINAL AND GND.

harness.
C C8 (2) Disconnect the signal check harness connector on the ECU side.
(4) Measure the voltage between CLSW (C8) terminal and cab GND.
Standard:
More than 19V (Clutch pedal released)
0V (Clutch pedal pressed)
SHTS161060200125
NO
Proceed to 2.
YES
Malfunction of ECU.
2. CHECK THE CLUTCH SWITCH.

(2) Disconnect the clutch switch connector.
(3) Measure the resistance between clutch switch terminals.
Standard:
∞ Ω (Clutch switch not pressed)
Less than 1 Ω (Clutch switch pressed)
SHTS161060200126
NO
Malfunction of clutch switch.
YES
.
NEUTRAL SWITCH
EN1610602F200062
MC No. 47 DTC No. P0850 Neutral switch malfunction
1. CHECK THE VOLTAGE BETWEEN TERMINAL AND GND.

B harness.
B32 (2) Disconnect the signal check harness connector on the ECU side.
(4) Measure the voltage between NUSW terminal and chassis GND.
Standard:
More than 19V (Transmission: Neutral position)
0V (Transmission: Not neutral position)
SHTS161060200127
NO
Proceed to 2.
YES
Malfunction of ECU.
2. CHECK THE NEUTRAL SWITCH.

(2) Disconnect the connector of neutral switch.
(3) Measure the resistance between terminals (Neutral switch side).
Standard:
∞ Ω (Neutral switch not pressed)
Less than 1 Ω (Neutral switch pressed)
SHTS161060200128
NO
Malfunction of neutral switch.
YES
.
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Pub. No. S5-YJ08E29B ’06-11

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Applicable for J08E-TI engine

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL NO. S5-YJ08E29B

GENERAL INTRODUCTION GN01-001

ENGINE INTRODUCTION EN01-001

ENGINE MECHANICAL EN02-001

AIR INTAKE SYSTEM EN03-001

EXHAUST SYSTEM EN04-001

LUBRICATING SYSTEM EN05-001

COOLING SYSTEM EN06-001

FUEL SYSTEM EN07-001

FUEL INJECTION PUMP EN09-001

EMISSION CONTROL EN10-001

EN11-001 EN11-002 EN11-003

ENGINE P.T.O. (POWER TAKE-OFF) EN14-001

ENGINE CONTROL EN16-001

FUEL CONTROL DN02-001

INDEX: ENGINE GROUP 1/2

WORKSHOP AIR INTAKE SYSTEM

MANUAL EXHAUST SYSTEM

FUEL INJECTION PUMP

All rights reserved. This manual may not be

INDEX: ENGINE GROUP 2/2

CAB EQUIPMENT CONTROL

GENERAL INTRODUCTION (J08E) GN01–1

GN01 GENERAL INTRODUCTION (J08E) GN01-001

GN01–2 GENERAL INTRODUCTION (J08E)

GENERAL INTRODUCTION (J08E) GN01–3

HOW TO USE THIS MANUAL

2. TROUBLESHOOTING IN THIS MANUAL

Thoroughly listen to the conditions and environment for the trou-

Perform diagnostic inspection, checkup of the symptom, function

Classify the inspection results obtained in step 2 to systematically

• Execute the following steps to perform pre-inspection.

GN01–4 GENERAL INTRODUCTION (J08E)

3. DESCRIPTION IN THIS MANUAL

GENERAL INTRODUCTION (J08E) GN01–5

(2) Work item

GN01–6 GENERAL INTRODUCTION (J08E)

5. DEFINITION OF SAFETY TERMS

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

GENERAL INTRODUCTION (J08E) GN01–7

Conven- Conversion value*1 Conven- Conversion value*1

GN01–8 GENERAL INTRODUCTION (J08E)

PRECAUTIONS FOR WORK

1. CLOTHES AND APPEARANCE

GENERAL INTRODUCTION (J08E) GN01–9

1. PREPARATIONS FOR DISASSEMBLY

2. INSPECTION DURING DISASSEMBLY

3. ARRANGEMENT OF DISASSEMBLED PARTS

4. CLEANING OF DISASSEMBLED PARTS

5. INSPECTION AND MEASUREMENT

7. ADJUSTMENT WORK CHECK

GN01–10 GENERAL INTRODUCTION (J08E)

PRECAUTIONS FOR ELECTRICAL SYSTEM

1. REMOVING THE BATTERY CABLE

2. HANDLING OF ELECTRONIC PARTS

3. HANDLING OF WIRE HARNESS

GENERAL INTRODUCTION (J08E) GN01–11

PRECAUTIONS FOR ELECTRIC WELDING

GN01–12 GENERAL INTRODUCTION (J08E)

FLOW OF WELDING CURRENT

1. WITHOUT TREATMENT OF ITEMS (1) THROUGH (5)

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧞ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧡㧡ಽ

Conven- Conversion value1 Conven- Conversion value1