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    Diesel Engine Operators Manual Part 3

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    87 views282 pages

    Diesel Engine Operators Manual Part 3

    Uploaded by

    GRUFASA Grupo Fanjul
    Diesel Engine Operators Manual Part 3

    Copyright:

    © All Rights Reserved
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    of 282
    HINO DIESEL ENGINE WORKSHOP MANUAL P11C-UN oe (Crane) CHIN a 2005.10 Cn: | [STANDARD vaLuE SSC PARTS TO BE PREPARED 3 | ENGINE ASSEMBLY/DISASSEMBLY i FUEL SYSTEM 5 | ELECTRICAL INTAKE is | ENGINE MECHANICAL EXHAUST. ji0 | COOLING LUBRICATION STARTING AND CHARGING : 13 | TURBOCHARGER gi FAILURE DIAGNOSIS FOR EACH ENGINE STATUS. 15 | ENGINE DIAGNOSIS CODE wa GENERAL 4 1 GENERAL Waring, 12 How to road this manual 43 Precautions for work 17 Tightaning of engine bots and nuts. 1 Tightening of chassis bots and nuts. 113 Tightening of flare nuts and hoses. 15 Taper thread sealant for ping 116 Assembly of joints and gaskets for ping. 17 Handing offquid gasket. 119 Fallure diagnos's table for each problem 4-20 Failure dlagnos's procedures. 421 Failure diagnosts using Hino-DX. 123 Connection method of Hino-DX. 1-26 Chassis number and engine numbor 1-26 12 GENERAL Warning Observe the following precautions to work safely and to prevent damage to customers! vehicles. This manual is prepared for quaiiied service engineers who are recognized as technical experts, Those who are not ualtied, who are not appropriately trained, who perform service without appropriate tools of equipment, of who perform service with the way not specified in this manual may not only damage the vehicle, but also put service engineers and surrounding people in danger. + Appropriate service and repair are essential to ensure safely of service enginaers and safety and reliability of vvehioles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality. + Items described in this manual are the procedures to be observed in service and repair. For service and repair according to this procedure, be sure to use the special tools designed for each purpose. + fa method or a too! not recommended is used, safety of sorvice engineers, and safety and reliability of vehicles may be impaired, Never use a method or tool not recommended. ‘This manual shows "Warning" and ‘Caution’ for items that need to be observed so that accidents may not occur during service or repair, or that damage to vehicle due to impropet method may not impair safely and reliability of vohicles. These Instructions cannot give warning forall possible hazards, Note that items with "Waming’ or Caution’ are not absolute for safety. GENERAL, 13 How to read this manual 1. Scope of repair work (1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement, assembly: disassembly and inspection. adjustment’ and "Final inspection". (2) Trismanual describes "Diagnosis in the first process and *Mounting/removal, replacement, assembly. disassembly ‘and inspection. adjustment” in the socond process. Explanation of Final inspection in the third process is omited hore. (3) Although the following work is not deseribed in this manual, it should be performed in actual work. a. Jacking and iting b, Cleaning and washing of removed parts as required ©. Visual inspection 2. Standard value (1) Standard value, limit, action and tightening torque described in the text are summarized in tables. ems to be prepared (1) toms to be prepared before work are SST, tools, gauges and lubricant, otc. These are listod in the ist section of items to be prepared. Items such as general tools, jack, rigid rack, ete. thal are usually equipped in general service shop are omitted. 4, How to read sections and titles (1) Sections are classified according to J2008, SAE standard, (2) Forareas that show system names like "Engine control syste “Replacement”, "Overhaul, ete. of components are described. (8) Forareas that show part names Ike “injection pump’, ‘Mounting/removal and disassembly" is described, (4) Illustrations of the parts catalog are shown for part layout, (Part codes in the parts catalog are described in the illustration. Major names and tightening torque are listed in the table.) Inspection’, “Adjustment”, ANCAUTION The part inyouts inthis manuel are Inserted based on Ikustrations and part numbers ofthe parte catalog CD-ROM issued In October, 2005. (Some areas donot show exploded view. They willbe adtonaly issued when the parts catalog CD is revised} Be sure to use the parts catalog for confirmation of ilustations and part numbers and for ordering parts. 5. How to read troubleshooting (1) Failure diagnosis in this manual desoribes Step 2 and Step 3 below: Hear from customers for conditions and environments of | (1) Question failures and check the fact. top 1" Perform diagnosis inspection, status inspection, function (2) Pre-inspection “stop 2° _|inspection and basic Inspection. Check thefalure status, @) Reproduction method Itt is difficult to reproduce the problem with status, Inspection, use the reproduction method. (4) Troubleshooting for each ‘Summarize inspection results obtained from Step 2. diagnosis code “step or | Perform inspection systematically according to (5) Troubleshooting for each troubleshooting procedures for each diagnosis code or failure status failure status. Check if failure occurs again after repair. If itis difficult to (6) Confirmation test "stop 4" | reproduce a fallure, perform the confirmation test under the conditions and environment of the failure, 14 GENERAL (2) Presinspection Pre inspection Prodnspection Is performed in the following step: Diagnosis inspection Diagnosis deletion ~Failure status check (Use the reproduction method if not reproduced.) ~»Diagnosis recontirmation Estimate the failure system before the reproduction test. Attach a tester and evaluate estimated failure together with falluro status. Refer to the troubleshooting chart for estimated cause of a failure ire occurs instantaneously. If any specific failure is not ‘An error code is displayed if fai found, perform troubleshooting using the reproduction method. Failure status check Hf failure is reproduced,perform Step 2 Step 3 Step 4. I failure Is not reproduced,use the reproduction method (simulation of external conditions or check of each wire hamess and connector, etc.) GENERAL, 6 6. How to read explanation details (1) Part tayout Example Part layout ENGINE MECHANICAL [J08E) Timing Gear Cover and Flywheel Housing reeurreones 7 neta, g vse Lon Part name code ‘tis. __ [sce Fywhoat housing a0 ‘End pate Description of 111308 Oi seat retainer Josesa Front o'scal'-—~ part name code, jit357 —Gaskat los288 earl coat" 357A Gasket peor ete be ead Loft: Part name code (nut) Tightening torque Va [soca ta: A7TSNmit, 750 KoFom, 128 FM) ]BATaA WTB. 186 Nena, 000 RGF, 145 10TH looea) M12: 97 Nenf900 kgtem, 7164) fodiaH __ta1B: 96m, OOO kgt-cm, 145 OF.) 4 Itis the ID number for parts to prepare electronic data, itis not required for repair work, 16 GENERAL z jon of terms Terms in this manual are detined as follows (1) Direction a, Individual unit Frontfback direction ‘The power input side is front and the output side is back, Rotating direction When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is. left rotation. Vertical direction With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction Is lower, Letuight direction When viewed from the rear, the left dection is left and the tight direction is right. (2) Standard value Basi dimension excluding tolerance and clearance generated by tolerances hen two parts are joined (3) Ropairlimit:- - itis the value requiting repair. Symbol of + or - with the value means increase or decrease to the standard value (4) Operation limit: - - Itis the value requiring replacement, Symbol of + or - with the value means Increase or decrease to the standard value. (©) Warning: itis an item that may resultin tisk of human life or stious injury by incorrect handling, (6) Gaution Its an item that should not be performed including inhibited work or an item that requite attention in working procedures. (7) Reterence: Itis supplementary explanation in work. 8. Unit (1) Slunit is used inthis manual. S! units the international unt to uniy the conventional different international Lnits into one unit per quantity and to promote smooth technical communications (2) This manual shows both the SI unit and conventional units. The conventional units aro shown in { }. Conventional | Conversi 7 =x] a conversion value"(1[Conventional unit] = X unit [SI unit) Force kat ‘1kgf=9.80665N Torque’? Nem kgf cm ‘kgf. cm=0.0980665N- m kgtfem? ‘Tkgticm?=98.0665kPa=0,0980665MPa | Pressure Pa mmHg ‘ImmHg=0.133322KPa min ‘rpm=ti/min Rotational speed _—— rpm mint trpm=tmin™ Spring constant Nimm kgtmm ‘Tkgtimm=960665Nimm Volume L ce 4eo=tmL Efficiency w Ps - “1PS=0.735499KW Caloritic value WH cal tkeal=1,13279W. h Fuel consumption rate| GW. h gPSh 1g/PS. h=1.3596g/KW. h “2X means the value when 1 [Conventional unit] is converted to the SI unit. Its used as the conversion factor from the conventional unit to the SI unit. “2:The conversion value of the torque may vary depending on the unit. Observe the standard values described for each unit. GENERAL 17 Precautions for work General precautions To ensure safety in work and to prevent accidents, observe the following items: (1) Appearance a. Wear saloty goggles. b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work. ‘6. Bind long hair at the back. Be sure to wear a cap and safety shoes, (2) Satety work ‘2, Donot touch radiator, muffler, exhaust pipe, tall pipe, etc. after stop of the engine to prevent burn, b.Donot put your clothes or tools near the rotating par (in particular, cooling fan or V-belt) during ‘operation of the engine. Remove the starter key when the engine is not started. ‘Sart the engine at 2 well ventilated place so that carbon monoxide may not be filled, ‘Since gas from the fuel or the battery is flammable, do not spark a fre or smoke a cigarette near the area, ‘Since the battery fluid Is poisonous and corrosive sulurie acid, be careful for handling, Do not short-ircut the cable ofthe battery or starter. Otherwise, the cable may be butned or burn may h. Ifa tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine, resulting in injury. iL To tow a failure vehicle, refer to "Towing or being towed!" in the ‘Operation manual" of the vehicle 2. Precautions for service work Pay attention to the following points before service work (1) Preparation before disassembly 4. Prepare goneral tools, special tools and gauges before work b. To disassemble a complicated area, put a stamp or match mark on the location not functionally effected to ease assembly. To repair the electric system, disconnect the cable fom the minus terminal of tho battery before work «. Perform inspection according to the procedure in the text before disassembly. (2) Inspection during disassembly Every lime parts are removed, check the area whore the parts are assembled and check for deformation, damage, wear or scratch. (@) Arrangement of cisassembied parts Place removed parts neatly in order. Separate parts to be replaced from parts to be reused, (4) Washing of disasserbied parts Clean and wash parts to be roused well (8) Inspection and moasurement Inspect and measure parts to be reused as required (8) Assombly a. Keep the specified standard values (lightening torque, adjusting values, etc.) and assomble comect parts in the correct order. b, Be sure o use genuine parts for parts tobe replaced. ¢. Use new packings, gaskets, O-rings and cotter pins. 4. Use seal gaskets for some areas where gaskels are used. Apply specified ol or grease to siding areas ‘were application of oll is required, and apply specifi groase tothe cil seal ip before assembly (7) Check of adjustment Make adjustments to the service standard values using a gauge or tester. 18 GENERAL 8. Precautions for electric system (1) Removal of battery cable ‘a. Inanlectric systom, remove the cable from the battery ‘minus (-) terminal to prevent burnout due to short- circuit. b. When the battery cable is removed, the battery terminal ‘may be damaged. Loosen the nut completely and never pry itfor removal, Looeen (2) Handling of electronic parts ‘a. Donot give impact on electronic parts such as ‘computer and relay. b.Donot place electronic parts at a high temperatura and humidity area, ‘&.Donot expose electronic parts to water in washing of a vehicle. (8) Handling of wire harness a. Mark clamps and clips to prevent interference of a wire ( hamess with body edge, sharp edge and bolts, Be sure to reassemble it to the original position. b. When parts are assembled, be careful not to pinch 2 wire harness, GENERAL (4) Handling of connector ‘a. When a connector is removed, hold the connector (as shown by the arrow in the left figure) and pull it out. Do rot pull the wire harness. Unlock the locking connector before pulling, Insert the locking connector completely until it clicks. 4d, Toinsert a test load into the connector, insert itfrom the back of the connector. It tis alficult to insert a test lead from the back of the connector, prepare a harness for inspection. 1-10 GENERAL 4 Precautions for electric welding Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding circuit, resulting in damage to electric and olectronic parts. Observe the following items for electric welding, (1) Tum "OFF" the starter switch. (2) Make sure that switches are "OFF* (8) Disconnect the minus (-) terminal ofthe battery according to the removal procedure of the battery cable. (4) Disconnect connectors of each computer. (6) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter") (6) Be sure to connect grounding of the electric welding machine near the welding area. Connect grounding from a bolt (plated bolt) or a frame near the welding area. Remove paint ofthe frame for connection of grounding from the frame. (7) Other precautions ‘a. Put a cover on rubber hoses, wire harnesses, pipes, tives, etc, around the welding area so that they may not bo exposed to spatter. b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also ‘maintain welding quality. (8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same color, (9) After reassembly, check the function if it operates correctly, GENERAL, Tightening of engine bolts and nuts 1. Tightening torque of general standard bolts, (1) Forbolts with seatings Unit: mekgf- emp Remark Bolt with number “7"on the hea (2) For bolts with washers A\CAUTION * 8Tboltis in accordance with 7T bolt. Bott with number “ ‘Serow diameter x Pitch 7 oT Mi x 1.25 (Coarse thread) 28.5(290} 36(370} Mt0 x 1.25 (Fine thread) 60610) 74.5(760) M0 x 1.5 (Coarse thread) 55(860) 68.5(700} 12 x 1.25 (Fine thread) 108{1,100) 136(1,390} M12 x 1.75 (Coarse thread) 97(990) 125(1,280) M14 x 1.5 (Fine thread) 171.5(1,750) 216(2.210) 14 x2 (Coarse thread) 184(1,570) | 199(2,080} | ‘on the hi Unit:N- m{kgf- em} |" Serew diameter x Pitch 7 7 oT M6 x 1 (Coarse thread) (60) 10100) 134130) mx 1.25 (Coarse aq 2ste50 sits20 peo 140) | (250) 1320) M10x1.25 (Fine thread) | ___—_-2(300} 51520} 64650) M10 x 1.5 (Coarse ea 26(270) 47(480} 59(600) 1412 x 1.25 Fine thread) 54(850) 99,950) 118(7,200) Chari 49(500} 89(050) 100(1,100) thread) ded ame M14 x 1.5 (Fine thread) | '83{850} 147(1,500} 186(1,900} M14 x2 (Coarse thread) (750) 192(1,950) 172(1,750) Bolt with number °4° on Bolt with number *7" on the head Bolt with numbe eae Projection bot Stud with | {he Mead Blvd WIR | the head A surface at free end ne A\cAUTION + 8T bolts in accordance with 7T bolt eurce (27) auece 7) este) (Frat) Ten as (Sear a) GENERAL Precoated bolt Precoated bolt is the bolt with application of seal lock agent at the thread. (1) When re-application of lock agent is required! ‘a, When precoated bolts are removed b. When precoated bolts are moved due to tightening ‘check (for loosening or tightening) NoTICE + Check torque with the lower limit of the tightening torque allowable value. If ‘movement is found, tighten the bolt according to tho procedure below. (2) Re-use method of precoated bolt lock ‘. Clean bolt and screw holes. (Clean screw holes for roplacement,) b._ Dry completely by blowing ar. Apply the specified seal lock agent to the thread of the bolt 3. Plastic region tightening method (angle method) (1) Precautions ‘Some engines are tightened with the plastic region tightening method. Since itis different from the conventional method, tighten it according to the instruction in the text. (2) Parts tightened Cylinder head bolt, crankshaft main bearing cap bolt, Connecting rod beating cap bolt, etc. AXCAUTION. + Measure the overall length ofthe bolt betore assembly and replace the bolt if the length exceeds the oporation limit Apply engine oll to bolt seating and bolt thread in assombly. (8) Tightening method atter tightening to seating torque Tightening of 90°, 135°(80° once and 45° once) and 180° (90° wice) is available GENERAL 1413 Tightening of chassis bolts and nuts 41. Tightening torque of general standard bolts and nuts (1) Selection method of tightening torque Find the applicable strength zone from the table below and select the bolt tightening torque from the table described later. ', Soloct the nut tightening torque from the mating bolt as described above. (2) Identification method of bolt strength zone ‘a. Identification method with product Hexagonal bolt ‘Strength zone of hexagonal bolts s, in principle, indicated with recession, rele, surlace depression and upset on the head with the symbol in the table. 7 Strength zone er 107 wT 1 | 7 eae Identification symbol for part| 6 10 1" 12 ("1}: 9 may be misread with 6. Itis expressed in q, Depression Relist Hexagonal nut ‘Symbol example for identiication of the strength zone of the hexagonal nut is shown in the table below: (3) Types of general standard bolts and nuts Standard seating Seating A with flange Seating B with flange @o|4 GENERAL, (4) Standard tightening torque table of general standard bolts and nuts ightoning torq (Representative standard sealing is described.) Unit:N- mfkgt cm) Strength zone Bolt aT 7 st diameter (mm) ‘4.531.5(60120) | (cab) ” Me ee) 9.0:4.8(90:20) 11.5:2.0(117:23} (Chassis) 14.019,5(140:40} ms (cab) 22,0:4.0(220:40}? 29,0:5.5(300:60} 17.013.0(170:80) ae Oe (Chassis) 2 143.0:8.5(440:90) 57.0:47.0(5802110) ® (Cab) (Cab) -015.0{276:55) mo eeemeaeaee 51.5110.0(530:100} 68.5113.5(7001140) | (Chassis) (Chassis) 7 76.0118.0(776%150) ® "100.0220.0(1,020:200) (Cab) (Cab) m2 eeameaael 91.0:18,0(930:180), 120.0:24.0(1,220:240) | (Chassis) (Chassis) mia 77.0:5.0(786:157) 120.0124,0(1,220:240) 160.0:52.0(1,630:526) m6 ¥20.0224.0(1,220:244} 190.0:38.0(1,940:080} 250.0350.0(2,550:510) me 165.0258.0(7,6802536) 260,0152.0(2,650:590) 345.0369.0(9,520-708) M20 235,0307.0(2,400:480) | $70.0:74.0(8,70:750), {490.0396.0(6,000,000) 22, '320,0364.0(8,270:654) | 505.0:100.0{6,150:1,090} | _670.0:130.0(6,84011,370) za 405.0381.0(4,1303626) | _640.0:125.0(6,530:1,310) | 845.0:165.0(6,620:1,720) AXCAUTION. « Use the tightening torque value fo seating A with flange except for ‘inthe table larger by 10% than the tightening torque value in the tabl + Use the tightening torque value for seating B with tlange of *2 in the table larger by 20% than the tightening torque value in the table. The tightening torque value of M& for seating B with flange remains unchanged. + Seating B with flange of *2 in the table is interchangeable with the standard seating in pairs. Use the standard seating for the tightening torque value. GENERAL Tightening of flare nuts and hoses 1 Tightening torque of pipe flare nut Unit:N- m{kgt- em} Hose outer diameter #105 fitting packing Hose outer diameter .13,c20,422, fiting at Pipe outer diameter) 94.76 6.35 e wo m2 m5 Material Stooipipe | ECsos50) | aisasnisn | saBlrO) | S270) | eT(66070) | saw(eoniso) 2, Tightening torque of hoses Unit:N- {kgf em) Hose outer diameter PF9/B fitting 21.514 5(215415) | Air hose ~ Only meter gauge 41.612.5(425:25} 10100} Packing Cot 51.5:7.5(525475) a J 3, Lock nut tightening torque of brass joint Unit:N- (kgf em} oJ a aa m6 M20 M27 | : = | pat 9 feeaaee 6645(670:60} 19719990:90} 209119(2190:190), 116 GENERAL Taper thread sealant for piping ‘The taper thread of the air pipe joint has application of sealant [Loctite #575 (by Japan Loctite)]. Follow the procedures below for connection or disconnection of pipes, ————__________ 1. Fordisconnection Removal saree Lee mate she) seaase > (1) The sealant (#Lootte 575) has strong sealing feature. The pp a roturn torque of the taper joint is increased about 1.5 A tea times the intial tightening torque, When the joint is disconnected, use a long wrench for disconnection fea (2) When a joint at a poorly accessible area is replaced, ove Femove accessories first and disconnect the joint. 2. For connection (1) For application of sealant (#Loctite 675), wipe the sealing area completely with a rag or thinner. Apply sealant at directly to about tree ridges for quarer round with offset “od of one ridge trom the end. Tighten it according to the tightening torque inthe table below. Remove dirt completely trom the mating part (femalo) belore tightening commer /NCAUTION * If your eye or skin comes in contact with sealant, wash It off immediately with water. Tightening torque of taper joint UnitiNe (kal om) ‘Screw diameter! 4 3B we Material Stool eee 164:15(650:150) 100) ‘Aluminum, ee 2515(250:50) | 34:5;950:50) | 4935(450:50} (2) When a sealing tape is replaced with sealant, remove the tape completely frst as in (1). A\cAUTION. * Be caroful to pravent entry of dirt or foreign matter in the pipe. (8) Ifa leak is found after assembly with application of ‘sealant, air leak cannct be stopped with adaitional tightening. Assemble the part again according to (1) and @. Assembly of joints and gaskets for piping 1. Tightening torque of joints Unit: m¢kat em} Metal sealing method eee Gasket sealing method (Flare pipe type, nip connector type) TeaNningseew | (mina Rube or coon =a a Ma 7 ~_13(130) m0 20(200) Tiet19) m2 25 (250) ~ 20(200) mia 25(250) 310920) m6 29{300) 39 {400} wie 39(400) 59(600} : 20 *39(400) 64(650} ~~ 20(200) ‘M24 69{700} 7 M28 a *127{1300} — 2. Joint assembly procedure and subsequent inspection Bofore assembly, make sure thal there is no dirt or burr on the seating surface (mating part, pipe joint, a @ ® “0 gasket, oc.) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten pipes finally after temporary tightening to prevent leak. Aer tightening, apply the specified pressure to each pipe joint to ensure that there is no leak. Observe the values above for each tightening torque. “When assembled soft washer #4840FR.N (aluminum and rubber carbon pressure bonding) is loosened or removed, be sure to replace it with a new part. This is not necessary for normal retightening. GENERAL, 3. Examples of joint methods in various pipes Metal sealing method Gasket sealing method Type A Type B (Far pipe type) (tipple connector type) sa a nar em ee — Se Joint bolt Lock washer Bracket oa i Sealing sutace Slaces Seating sutace Bplaces ‘Connecor nipple seat surat: pace Sealing sutace: 1 place Flare connector Nul Lock washer Box nat vay jon Sealing sutace B places ont pine = (ona poce ey nt whout stove Jon bot Seat sure paces Joint bot Sealing surtace: 6 paces GENERAL Handling of liquid gasket 1. Application of liquid gasket and part assembly procedure (3) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent doposit of oil, moisture, dirt, ote. Be sure to overlap parts at the beginning and at the end of application. (2) Be careful or offset with the mating part whon a part applied with liquid gaskets assembled, Apply the liquid gasket again if ofset occurs. (2) _Assembfe parts within 20 minutes after application ofthe liquid gasket 1120 minutes has passed, remove the liquid gasket and apply it again, (4) Start the engine at least 15 minutes or more after assembly of part. 2, Removal of parts (1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or clearance on the flange. When gasket is romoved, be careful to provent entry of gasket offal into the engine. 3. Others (1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it Is contained in a cartridge, use the application gun Sx S a EY / Tube: 1509 Cartridge type: 300 g For a tube, desired application width may be obtained from the cut position at the nozzle end. {:Approx. 2 mm at the tst section cut 2:Approx. 5 mm at the 2nd section cut Nozzle of tube 1-20 GENERAL Failure diagnosis table for each problem Engine mechanical ‘The cause and action for each item are described. ‘Seatus Cause ation Engine overheat (coolant) Theaffeentcootont Replonish coolant Faulty thermostat Replace thermostat Water leak fom cooing system | Coweton Faull coolant pump Repair or replace Faull head gasket Replace heed gasket Engine overheat Clogging of radiator leaning of aditor (radiator) Corrosion of cooling system ‘lean and repair cooling system ‘Clogging of aditor core front pert_| Clean radiator Faulty reditor cap Replace radiator cap Engine overheat (compression | Non-synchronous injection timing | Adust injection timing pressure) Faully fuel injection pressure “Adjustinjecton pressure Fully fuel Replace with corect fuel Faully njeclor Replace injocior Engine overheat (lubrication | Deterioration of engine of Replace engine of unit) Faully ol pump place oll pump Tnsuficent engine of Replerish engine of Large engine oll consumption | Wear of piston ring and Gyindor | Replace piston ring and eyindor (piston, cylinder iner and piston | liner liner ring) Damage io pison rng "Replace piston ng and eyindar liner Fat ng of piston ing Replace piston ring and oylinder finer Faulty assembly of piston ring | Replace piston ring and eyindor liner Faulty engine of Replace engine Fauly piston ing ot ‘Resssemble piston fing ‘Large engine oif consumption | Wear of valve stem Replace vale and valve gue {valve and valve guide) Wear of vave guide Replace vahe guide Faully assembly of vale som seat | Replace slom seal ‘Excessive ol brication i racker | Inspection of dlaarance belween am rocker arr and rocker arm shat Large engine oil consumption | Faulyollevel gauge Replace with correctievel gauge: (others) Excessive ling of engiie Fil with appropiate amour ofl Leak of engine ail Repair or replace the part of oF teak Piston seizure (in operation) | Sudden slap of engine Perform warnvup before slop of engine Piston seizure (lubrication unit) | insufficient engine Replenish engine ol Delarioraion of engine of Replace engine of Incorrect engine all Replace with correct engine ol Tow of pressure Inspection of ubricaion unit Fully of pump FRoplace all pump Piston seizure ‘Rbnormal combustion Rolerto overheat selon Piston seizure Coang unit Roles to overheat section GENERAL Failure diagnosis procedures 1. Display of failure code (1) When there is error in the system, the diagnosis monitor code can be viewed with the check engine lamp. For example, the process display for diagnosis monitor codes 92 and 21 is as follows: The display method is blinking intorval ofthe lamp, For the first code, the lamp illuminates three times for 0.6 second for "3" at the place of 10 and illuminates twice 1.5 seconds later. For the seconds code, the lamp illurinates 21 times at intervals of 4.3 seconds similar to the first code. Subsequently, this is repeated. When there Is no error in the system, the lamp keeps blinking with the illumination time of 0.3 seconds. NOTICE + The display of the diagnosis monitor code below Is a typical example. Display of iagrsie monkor cde (exam) (Check engin lamp Winon codes 32 and 21 ate spied In normal operation 03 second on OFF 2. Deletion of past failures (1) Te delete past failures of the engine ECU, use HINO-OX ‘on the PC. (Refer to "Hino field support system operation manual’) a “ How to read troubleshooting for each diagnosis monitor code “Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives ‘output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be started from the code list. ENGINE DIAGNOSIS CODE [Engr Failure of main speed sensor (DTC code P0338/diagnosis monitor code 13) 7__ [Measurement of resistance beiweon tominals _ Oy» arose 2 Remove the ECU sie connector of be slgal cack hemes snd moausr the resistance beben erinal 86 and terminal ee ——~Detalls of work 0 Standard value: Approx. 125.5 17 (20 dC) 1NG_> [fice esoneno eaves beeen oar nba 2 [Sao dara de 7 ‘Connect he ECU side connector ofthe signal check harness, ‘Aor deleting te pat fur, cuput he dlagnosis code aga Standard: Normal Contact aire of EGU comecior, ECU fal we urement of resistance between terminal 1 "Remove the connector ofthe main engine speed sensor and resstare betwoen No.1 and No.2 terminals a Standard value: Approx. 126. 17 (20 dC) t ao isis) NG Fale of man ongine peed sacar wo, Indicates replacement of the main engine revolution sensor. ‘Check the harness of the relevant circuit and repair the faulty area, Harness lacoonostion or connector lure Failure diagnosis using Hino-DX A\CAUTION Hino-DX is used for inspection and adjustment of the system in addition to fallure diagnosis. 1. Hino-DX (1) With Hine-DX, failure of the common ral fue injection system can be diagnosed. The interface box (Hino- Bowie) and the special cable are required for connection to the vehicle Special tool : 09121-1040 Hine-Bowle (09042-1190 Cable between vehicle and Hino-Bowie Field support system (CD-ROM for software) Hino Diagnostic eXplorer (Hino DX) XCAUTION + Install the software of the Hino Diagnostic Xplorer (Hino DX) in the PC. For the Installation method, refer to the instruction ‘manual accompanying the CD. 2. List of failure diagnosis tools Part name Part No. External shape General description and function PC + Operating system (05): Windows 95, (DOSW standard) Windows 98 (IES.0 or later), Windows 2000 (SP3, IES.0 or later), Windows XP (SPta, 1E6.0 or later) - + CPU and memory: Conditions that assure operation of the above operating system + Display: 800 x 600, 256 colors or more Hino-Bowie ‘09121 - 1040 + PC interlace (Interface box) Gable between | vohiole and Hino- Bowie (09042 - 1190) ‘Signal check (08049 - 1080 Interrupting installation between vehicle harness (for common rail fuel harness and ECU allows inspection with a injection system) {ester rod while the power is supplied. 1-24 GENERAL, 3. Connection of signal check harness (1) To provent damage to the ECU connector and to improve accessibilty, connect the signal check hamess and put a testing rod on the signal check connector of the signal check harness for measurement. 4 Disconnect the connector rom the ECU ANcAUTION + Do not break the locking tab ofthe connector. fh Connect the signal check harness to the mactine harness and he ECU, Signal check harness (for common rail fu Part No. 09049-1080 jection systern) GENERAL (2) Terminal No. For the signal check hamess connector, the ECU terminal number in the text is treated as follows: ECU unit a fee ee Elie i ‘Signal check harness (eg [ye 1-28 Hine Bowie creo ees ‘Stamp postion GENERAL Connection method of Hino-DX 4. Connection of Hino-DX (1) Flemove the lot side covar at the rear ofthe driver's set and connect the failure diagnosis connector with a PC Which installed Hino-DX through the interface box. ‘Special tool : 09121-1040 Hino-Bowle (Interface box) (09042-1190 Connecting cable CD-ROM Hino-Dx (2) Set the starter key to “ON and start Hino-DX. Chassis number and engine number 1. Engine type and engine number Engine type and engine number are stamped on the left side of the cylinder block. When ordering parts, report this number for smooth processing. Example: P11C TB10001 STANDARD VALUE 2 Engine Body. ‘Standard value, Fuel System “Tightening torque. Intake. ‘Tightening torque, Engine Mechanical ‘Standard value Tightening torque Exhaust. Tightening torque Cooling. Standard value Tightening torque. Lubrication... ‘standard valu. Tightening torque, Starting and Charging.. ‘Standard value (alternator SOA) snes 213 Tightening torque (alternator 508), 243 ‘Standard value (starter) 24 Tightening torque (starter) 248 ‘Turbocharger : Standard value. peeeeeaie Tightening torque, rs 218; STANDARD VALUE Engine Body Standard value Inspection item Standard value Unit: MPa {kgt/em?, Ibtfin.2} Repair limit Operation limit eae Fuel System Tightening torque Tightening area Ti 7 2.5(26, 362} | Overhaul ightening torque Unit:N- m{kgt- em, Ibt- 1). Remark Injector clamp mounting bolt 26(270, 19} Injector union bolt | 20(200, 15) toate pe cylinder head 20(200, 18) injection pipe (M14) 441450, 22) Injection pipe (M16) 54{550, 40) ‘Supply pump cotter bolt 91{930, 67} ; ‘Supply pump coupling bolt 611620, 45) o ‘Supply pump mounting bolt 726(290, 20) - | Supply pump drive gear mounting nut 245(2,500, 180) a) Fuel filter center bolt - 7 24.5 - 34.3(250-360, 18-25) | Fuel filter air bleeding bolt 4.9- 8.9(60 -90, 3.6 -6.5) ‘STANDARD VALUE Tightening torque Intake Unit:N- m{kegf. em, IDF ft} [ Tightening area Tightening torque Remark Intake manifold mounting bolt '55(560, 40) Int take pi ” intake air heater mounting nut and intake pipe 5620, 40) mou ‘Standard value Engine Mechanical Unitzmm(in.y Inspection item Standard vatue | FePalr) Operation | ction timit | imi Compression pressure | Per cylinder 2.9MPa 25 MPa ‘Overhaul (Engine revolution 20011 {80 katlem?, 4201611] — | (26 kgtlom?, min) in} 363 Ibtin2} ‘cylinder liner protrusion 0.04 -0.10(0.0016- a] 0.0039} — Cylinder liner flange with ~8(0.315) = Cylinder block flange width 80.315) — | 7.97(0.3138) | Replacement | Cylinder block inner diameter «| —*427(6.000) = _| Cylinder liner outer diameter. 127(6.000) = = ~ | Clearance between cylinderliner and | 0.0120- cylinder block o.029(0.0005- | — _ 0.0011) Cylinder liner inner diameter 122t8.803) ___ | 122.15(4.809 | Replacement o Piston outer diameter (Pin hole 25 mm ‘above the lower end of the skirt square | 121.95(4.8012) | — = direction) Piston cle 0.060 -0,080(0.0024 Replace liner or — | 0.15(0.005) =0,0031} ame piston STANDARD VALUE pair | Oporatio Inspection item | Standard value | RePalt Operation Action Hit | iit Piston |Freejoint | Top ‘Approx. 12.7 = fing fotearancs | Second ‘Approx 146 | — = hire ‘Approx. 15 = = oil “Approx. 14 _ a | ying Top 00-0500078-| | sre qago) | RePees Piston cng liner Joint 0.0196) forassembly [Second | 0.50-0.70(0.0107- Clearance ae — | 1.2(0.0472} Third 0:35 -0.50(0.0138- — | 240.0472) | 0.0196) Oil 0.30 - 0.50{0.0118 - Ihe tecy — | 1.0(0.03983 Piston ring |Top asraqo.is0 | — | aper) thickness [Second 2:306(0.0908} = (Taper) 2.0{0.0787} — | 1:80(0.0708} | 4.0(0.1575, | — | 8.90(0.1595) Piston | Piston ring (Taper) = = Replace piston. ring and _| groove re = — ring | moore 2.0{0.0787} = = oir “4.0(0.1875) = Clearance |Top : Replace piston ring between [Secona = = = or piston. piston ring Third 10.065 -0.105(0.0026 and ring = . groove -0.0041) comin 0.025 - 0.065{0.0010 Pama — | 0:1040.0039) | Piston pin | Piston pin outer diameter 471.850) = —_| Replace piston pin Piston boss inner diameter | _47{.050) = = Clearance between piston | 0.041 -0.059(0.0017 Replace piston or pin and piston boss =0,0023} 005(0.018) | piston pin Connecti | Small end bushing inner ~ art - = ng rod moter 741-850) Small end bushing olf 0.685-0989(00988 | | 049 ggaq) | Re@ioe piston pin clearance -0.0015) | or connecting rod, Large end with 42.85(1.6800) | — = End play | 0.15-0320.0059- || cia gage) | Replace connecting 0.0125} rod or erankshatt Connecting rod bolt length 102.5{4.0354} — | 105.0(4.1338} Replacement . Repair] Operation Inspeetio lard value ction Inspection item Standard value | Fyfat| Came At Cranksha | Journal outer diameter 90(3.543} | — _| 88.8(3.4960) | Replace crankshaft 7 Journal bearing thickness. 3(0.118) = = foumatbereg or —_ eranksha Journal erankshatt ofl 0.044 -0.097(0.0018 0300118 clearance = 0.0038) ee Pin outer diameter 79.83. 80(8.150} “rery | 70801029) ‘Journal bearing thickness 2.5(0.0984) | — — Pin connecting rod oil __ | 0.025-0.084(0.0010 | | clearance = 0.0033) cael eensuuans ‘Thickness of thrust bearing 301 | = ” ‘Crankshaft end play (0.170 -0.240(0.0004 Replace thrust ~0.0094} Gt arcane bearing. (Crankshaft runout 7 = —_ | 0.07(0.0027) | Replace crankshatt. Grankpin width | —=—S(1.693), = = ‘Camshaft [Camshaft | No. 65.0(2.5590} = —__| Replace camshatt. Journal outer [No 64.6(2.5433) = = Nos (64.2(2.5275) = = No 63.8(2.5118) Nos 63.4(2.4960) Nos 168.0(2.4803) = : No.7 62.6(2.4685) = = | Bearing oll clearance | 0.030-0.120(0.0012 Replace camshatt | -0.0047) 0-310.0118) | or boating, Cam height [IN 55.45{2.1830} —_| 55.2(2.1732) | Replace camshatt. ®x sacsittsy | — ae camuit [IN 7.25(0.2830) —_ | 7.10(0.2795) 7 [=x 8.69(0.3421) — | 8.54(0.9362} Thrust plate thickness 80.315) = = End play 010-028 — | estocriey | Replace thrust plate. [Camshaft runout = — | 0.05(0.0019} | Replace camshaft. | 26 STANDARD VALUE Inspection item Standard value | RePair | Operation ‘Action Valve | Roller tappet | Tappet outer 28 (1.102) = = systom | outer diameter ame | diameter [Tappet guide | inner 25 (1.102) diameter Ot clearanee | 0.020-0.062(0.0008 || 9 5.9959) | _ RoPae® tapet ~0.0028) Rocker arm | Shatt outer 27.92{1.0982 | _ Replace shat. Srametor 2(1.102} - i Bushin . ing ae(t.10ss | Replace bushing inner 20(1.102} i | diamotor Oil clearance | 0.044 -0.120(0.0018 Replace shatt or ~ 0.0393} bushing. STANDARD VALUE Repair | Operation Inspection item Standard value | FPA) Pera Action Valve [Valve stem [IN 30.315) — | 7.80(0:3102) | Replace valve. system | outer x anaes 80.315) — | r89(o.s102) Valve guide [IN 80.315) = __| Retertothe | Replace vaive innor diameter | = amas =} main text. a Oilclearance [IN 0.040 -0.077;0.0016 Replace valve or — | 0.1240.0047) between =0.0030} 10.0087) | valve guide valve system [ey ere 0.057-0.09440.0025 |__| sae 0055) aaa -0.0087} Valve sink | IN -0.05-0.35¢0.0020- || a gars) | Replecevave or 0.0137) valve seat, lex 0.58 -0.95(0.0217 - — | 13(0.0511) | 0.0374) cae Valve seat [IN 30° 7 = Correction angle = i = = Valve spring | Set le ere eee 54.72.1535} = _ inner (IN) | Valve spring | Set length 158.0N tnner (EX) ae (s6kgt24.4 60 Valve spring |Set load 1474N | Replacement inner (IN) ee — | {15.0kgf33.01 oo Valve spring | Set load inner (EX) '72.0{2.8346} — | 70.0{2.7559} va sping [Feo lra |S saaemy | — _ | Valve spring | Set length ~ outer (IN) 58.7{2.3110} - - Valve spring | Set length 367.9N oy eee pence | won Valve spring | Set load a51.1N | Replacement oa S82SNG8.0KGI86.0/ | sey 78.9 i tb Valve spring |Setload | banana ss.op.csry | — | 91.02.5825) Valve spring | Free length fae _ - 0.5(0.0197} Push rod bend 54.72.1595) = - 28 ‘STANDARD VALUE : Repair | Operation Inspection ite ti Ps m Standard value | Fynet | OP Action Timing Power steoring pump- | 0.05 -0.21(0.0020- 1.30(0.0118) | Place each gear. | gear —_| supply pump 0.0082} : backlash | Supply pump-main idle | 0.05 -0.19{0.0020- o0(001%8) (No.2) 0.0074) : [cam gear- main idle (No.2) | 0.07 - 0.19{0.0028 - Te. Baar 0.0074) : ‘Rir compressor idle- Air | 0.04 -0.14(0.0016 - compressor drive 0.0055} idan Main idle gear (No.1) -erank | 0.07 -0,19(0.0028 - 300.0118) gear 0.0074} : Oil pump drive- oll pump | 0.06 - 0.90(0.0024- ares | — | 0.30(0.0118 Cam gear alr compressor | 0.06-0.19(0.024- si nore 0.30(0.0118) Main idle | Shaft outer diameter sa2520) | — = Bushing inner diameter 64(2.520) = Oil clearance "| 0.030-0.080(0.0012 Replace shaft or =0,0035) 0.20(0.0028} | "bushing. End play 0.085 -0.149(0.0026 a 0.0088) ae 7 - | Air ‘Shaft outer diameter 52(2.047) =-[ - compress / Bushing inner diameter 52(2.047) = = or idle : Oil clearance 0,030 -0,090(0,0002 zoco.on2e, | FePlace sat or -00035, | ne bushing. End play 0.070 -0.125(0.0028 es =0.0049} oe Head bolt length (long) 250(9.643) =| 2520921) | Replacement Head bolt iength (short) 158(6.220) — | 16176.338) | Replacement injector protrusion 2.9(0.1142} 7 7 7 Flatness under cylinder head 0105(0.0019) ortess |°7500-| | Grind or coreton 0059} Flatnoss above eylindr bloc 0.1500.) K 0105(0.0018) ortess |°"50-| __| Grind or corecton 0059) Flywheel | Yoke assembly runout 0.2(0.0076) ortess | — 7 Correction Valve clearance N 0.45{0.0177} = = ‘Adjustment (Cold engine) EX 0.60(0.0236) = = STANDARD VALUE Inspection item Standard value Valve Exhaust valve open a ~ timing | (before BDC) _ _ Exhaust valve close | a | (atter BDC) | ~ ~ Intake vaive open . | - (before BDC) _ _ Intake valve close . (after B0¢) 2 7 7 Supply pump drive bearing rolling 039-1170 m | ‘Shim adjustment torque {4-12kgt-om,3.5-| — | — to.Albt- in.) Tightening torque Unit:N mikgf- om, tf ft} Tightening area Tightening torque Remark Head cover mounting bolt (upper) 25250, 18) ad cover mounting bolt (lower) '54{550, 40) Head bolt 118(1,200, 67}490°490° | Angle method ‘Additional head bolt 69(700, 51) Rocker support bolt '52(620, 38) 7 Rocker arm adjusting screw lock nut ae 7 ug) 1450, 92} Rocker arm adjusting screw lock nut 7 "| Exhaust si (ami) 69(700, 51} with engine retarder Cross head adjusting screw lock nut ia 28(280, 20) (Cross head adjusting screw lock nut a um) (290, 20) ‘Tappet stopper key set screw 44(450, 32) Idle gear shaft mounting bolt - = 4 = 20 {air compressor idle) Lamune Idle gear shaft mounting bolt ne (main ide) ame Supply pump drive gear mounting nut 24542500, 180) Supply pump drive bearing case retainer mounting - = 25(250, 18) Flywheel mounting bolt (standard) 270{2,750, 200} z 240 STANDARD VALUE "Tightening area ightening torque Remark Flywheel mounting bolt (vehicle with PTO) on Bolt must not be reused. Flywheel housing mounting boit (Ma) 25(250, 18) Flywheel housing mounting bolt (M14) ] 113(7,150, 83) Flywheel housing stay mounting bolt (M14) 113{1,150, 83} Flywheel housing stay mounting bolt (M16) 211 (2,180, 156) ‘Connecting rod mounting nut 69(700, 51}+90"+90" | ‘Angle method Cooling jet mounting bolt 23(230,17) - ‘Main bearing cap mounting bolt 274(2,800, 200) ~ Camshaft gear mounting bolt 187(1,400, 100) Warm fitting Crankshaft damper - crank pulley mounting bolt 108(1,100, 80) Crank pulley - crankshaft _ 7245(2,500, 180) [Timing gear case cover mounting bolt a “44{450, 32) Engine mounting bracket mounting bolt " 76(770, 56) Exhaust Tightening torque Unit:N- rm{kgf- em, tht: ft) Tightening area Tightening torque Remark | Exhaust manifold mounting nut '59{600, 44) | Exhaust manifold mounting stud bolt 80(800, 22} Cooling Standard value Unitzmm{in.y Inspection item Standard Repairtimit | Operation Action ‘V-belt deflection (in assembly of new 60- bolt) pushing force: 96N(10kgf, 22Ibf) | 8.0mmyo.236 | — 7 7 2-0.8149} ‘V-belt deflection (in reinstallation) 75- pushing force: 96N(t0kgf, 22Ibf) 8.5mm(0.295 = = 2-0.3740} ‘Thermostat valve open temperature 20- Replacement 84°C{176- 5 - 183°F} Thermostat valve lift ] 10(0:384} or _ Replacement (Set temperature 95 °C(203 °F}) more ~ STANDARD VALUE at Tightening torque Unit: m{kgt- om, bff) Tightening area Tightening torque Remark Tension pulley bracket - timing gear case cover '55{560, 40} wo | 7211 (2,160, 156) m6 Fan drive ASSY - timing gear case cover ~ 47(480, 35) 2 Tension pulley fixing nut ~108(1,100, 80} [Fan drive pulley-fan spacer | 601610, 44) Cooling fan - fan spacer 47 (480, 35) ‘Thermostat case mounting bolt '55(560, 40) Lubrication Standard value Sane | Repaerin | OPO” Ollpump [End play 0.085 - Replacement drive gear oxosyo.0018| = — —_| 0.1540.0059) =0.0041) Tip clearance 0.038 Replacement os15005| — — | 0.17(0.0086) | = 0.0048) Shaft outer diameter | 20(0.787} = = Case cover inner diameter | 20(0.787} = = Oil elearance 0.040- Replacement 0.074(0.0018 0.17(0.0066) 0028) | Olt pump | Shaft outer diameter 2010-787) = = driven gear Bushing inner diameter | _20{0.787) - = Oil clearance 0.040- Replacement 0.074(0.0016 = 0.170.066) = 0.0029) Drive gear and driven gear backlash 0.072- Replacement 0.208{0.0029 = 0.4{0.0157} 0.0081} 212 STANDARD VALUE Tightening torque Unit:N- m{kgt cm, Ibf- ft} Tightening area Tightening torque Remark il pan mounting bolt (plate) 7 = 25(250, 18) Oil pan mounting bolt alurninum) 25(250, 18) 7 Oil pan stiffener mounting bolt 44(450, 32) | il pan drain cock 83(646, 61) [Oil pump mounting bok (10) 47(480, 35) il pump mounting bott (M14) 113(1,150, 83) Oil pump feod pipe mounting bolt (Ma) L 21(210, 15) (il pump food pipe mounting bolt (M110) - 23(230, 17) [Oil strainer mounting bolt | 23(230, 17) il Oil pump case assembly bolt A 10.7 - 25.5(200 -260, 15-18) _ Oil pump case assembly bolt B 39.1 - 48,9(400 - 500, 29 - 36) ” Oil cooler element mounting nut 14.7 - 24.5(160 - 200, 11 -18) il cooler with oll iter mounting bolt (Ma) 25(250, 18} Oil cooler with ol iter mounting Bott (M10) 47 (480, 35) Oil pressure switch 19(190, 14) _ Oil filter warning switeh ~ 24.5 - 34.3(250 - 300, 18-25) (il filter drain plug 7 14,7 -19.7(150 -200, 11-14) Oil filter mounting sensor bolt 39.2 - 49{400 - 500, 29 - 36), Starting and Charging Standard value (alternator 50A) Unit:N: m{kgf- em, tf: tt} Inspection tom standard value [*°°2"] operation tnt | Action Rnisancebowensaerotomin’ | oo oma | o = Replacement (ior 2 phases) sistance between salorcollco and col| iter more | — | Replacoment Fesltance of feed coll ea-toa_ | — Replacement Resistance betveen feed collcor and call | _iMermore | — = Replacement Shat outer ameter [Front 2imm(0.883in) | —[ea.sbmm(0.9094in} | Replacement of rotor assembly | Rear ‘T7mm(0.669in) | — | 16.98mm(0.6685in,} Resistance between Forward resistance value | Approx. 10 2 — |* - | Replacement «diode and rectifier holder | Reverse resistance value Infinite = - Resistance between Forward resistance value | Approx. 10 — - | Replacement regulator terminals F-E | poverse resistance value Infinite _ _— \V-belt deflection (in assembly of new belt) | 13-15mm{0.512 | _ ‘Adjustment pushing force: 98N(10kgf, 22Ibf) = 0.591in} ~ | Vb detection in relstalation) ~~ 17-mm(0.668 | ~ Tajustment | pushing force: SoN(Okgt 226) “a7asin} Tightening torque (alternator 50A) Tightening area Tightening torque Remark 0,3) Fixing bolt at brace 47480, 35) Alternator mounting through bolt 132{1,350, 97} “| Bearing cover mounting bolt 4.9 - 2.5(20 - 25, 1.4- 1.8} Pulley mounting nut 127 - 157(1,300 - 1,600, 94- 115} Feed coil mounting bolt 2.8-8.9{30- 39, 21-25) Rectifier and regulator mounting bolt 1.9 -2.5(20- 25, 1.4- 1.8) Inside B terminal mounting nut 4.9 -5.9(60 - 60, 3.7 - 4.3} ‘Outside B terminal mounting nut Through bolt 3- 5{83- 45, 22-9.6) 7.8 - 8.8(80- 99, 6-7) Coupler holder mounting bolt 1.9 2.5(20- 25, 1.4- 1.8) [Covermountingbott | 88-4404 44, 26-32) | Adjusting bolt 6(60, 4) Brace fixing bolt 83(846, 61) 244 Standard value (starter) STANDARD VALUE assembly | body (H coil) Unit:mm{in.} Inspection item Stanerd | Repairiimit | Peravon Action Yoke | Resistance between coil : — | anmortoce | Replace yoke assembly | lead wire and yoke assembly. I 13(0.512) or | Roplace brush. Brush length on _ fos} place brush ‘Armature | Resistance between tuoormoe! | rumorose | Replace armature assembly | commutator and core assombly. et 38(1.339) oF Commutater outer diameter | es a7) _ 1999) Shaft outer diameter A 11.98(0.4717 12{0.472} ~ yor less Shaft outer diameter B a —_ [eamease8 Undercut depth 05. Correction asooisr-) | 2000079) 0.0314) Holder | Resistance between holder Replace holder = — | tknortess assembly | and plate assembly. rush len 310.512} 0 rush. Brush length 140.709) ___ | 180512} or | Replace brush, tess Sha [A — | 2.90¢1.0197 assembly Jorless: Replace shaft outer - ; 1404(0.5525 | assembly. diameter ee — Shorless Clutch assembly inner sleeve outer 27.90{1.0986 291.102 = cement diameter Mt : y Jorless a vet ‘nner dk = 1 ishing inner diameter of pinion 28.2{1.1102} | Rey ion Metal bushing inner diameter of pi aie _ {1.1102} |” Replace pink case or more case, ‘Metal bushing inner diameter of center Replace center | 2561.0 = 21. bracket CA foaarued bracket. Motal bushing inner diameter of shaft Replace shat 9(0:354 ~ : assembly : : Cat assembly. ousing inner diameter of rear 28.1(1.1082} | Replace rear Bearing housing inner diameter of zeca100) _ {1.1062} | Replac bracket or more bracket. Start [Between CterminalandM |) jigo] Replace start magnet _| terminal (P coll) magnet switch switch | Between © terminal a assembly. Between Cterminaland | 43 yoga) _ - 3 PARTS TO BE PREPARED Engine Body ‘Spacial tools Fuel Systom ‘Spocial tools Electrieal.. Special tools Engine Mechanical. Special tools Instruments Lubricant, et, Cooling Special tools Lubrication, Instruments 36 Starting and Charging veveninninnsinnninnine 37 aig (reference dimensional drawing for manutacture) 3- o Common tools, 7 Instruments 37 Lubricant, ote 38 ‘Turbocharger. 8 Special tools 38 Inetrumante 38 PARTS TO BE PREPARED a a PARTS TO BE PREPARED 3 PARTS TO BE PREPARED Engine Body wrnnnn so 2 ‘Special tools 32 Fuel System 22 ‘Special tools 32 Electrical, : eens Special tools 39 Engine Mechanical Special tools Instruments Lubricart, et. Cooling : 36 ‘Special tools : seeete Lubrieation... Intruments| Starting and Charging. sig (reference dimensional crawing for manufacture) - 7 Common took o a7 Inetruments vo vn AT Lubricant, et. 38 Turbocharger. eee 28 Special toole So 8 Instruments 38 32 PARTS TO BE PREPARED Engine Body Shape Part No. Description Remark 09552-1030 | Compression gauge adapter (09552-1060 | Compression gauge adapter 09552-1080 | Compression gauge adapter 00405-1190 | Engine it Fuel System Special tools ‘Shape Part No. ‘Name mark o> prereont lene peepee ceed For assemblyidisassembly (09819-1707 | Supply pump coupling wronch oe Pt ume coupling Won | eo pump coupling cosso.z200 | Prose For supply pump drive oil seal press-fit PARTS TO BE PREPARED 3 Electrical Special tools ‘Shape Part No. Name Romark For V-belt tension x 09444-1210 | Compression gauge fer oa Engine Mechanical Special tools Part No. Name Romark oszo-1900 | puser For crankshaft front ol seal removal . For assembly/disassembly 09470-1120 | Valve spring press Srahe corn eter 09431-1010 | Valve lapping tool For valve adjustment 09472-1870 _| Valve stom seal press Forvaie stem seal mounting For assembly/disassembly 09442-1280 | Piston ring expander Spon eg For cooling jet inspection 9001-24262 | Check bolt aise osarocit¢0 | Testxt For cooling jet inspection and adjustment PARTS TO BE PREPARED =D =r = foe acetate than proe ted KO 09420-1750 | Cylinder liner puller For cylinder liner removal sowrstco loess Seer eae course |pmee oer &> wwocim: [potea ee < osa72-1210 | Bar For nozzle seat press seoo.osio0 |nazdosest press (ttt. | Fornoze sat laneng 2 poten a eae re) PARTS TO BE PREPARED a5 09420-1442 ‘Sliding hammer o nee Xx ee oe = 09420-1111 Timing gear puller ‘supply pump drive gear al ee Instruments i fe oe ee So a — See = ieee me sere aes nee ad 36 PARTS TO BE PREPARED Lubricant, etc. ‘Name Remark Liquid gasket (Threebond 1812076 or equivalant : Red) | Push rod cover and flywheel housing Liquid gasket (Thresbond T8121 1 or equivalent : White) | Lower part of nozzle seat and oll pan Red lead For inspection of valve contact ‘Lapping compound For valve adjustment ‘Dye penetrant For inspection of crack and damage Cooling Special tools Shape Part No. Name Remark 09420-1820 | Puller For vane removal 09420-1810 | Puller For pulley center removal 094822940 | Press For mechanical seal ‘mounting 09482-1700 | Press For vane pross-it Lubrication Instruments Name Remark Micrometer For measurement of part outer dlameter Cylinder gauge For measurement of part inner diameter Thickness gauge For measurement of each clearance PARTS TO BE PREPARED a7 Starting and Charging Jig (reference dimensional drawing for manufacture) Alternator This is used for assembly of bearing. Refetence dimensions are shown in the figures below: sig A (Rater bearing insertion ji) iB (Support) Unit ming ezstznaen 250.864) 040.039) a ssc. 7012758) 640.039) S001 964) “0-20 p54 955) oan “Qt 010017 Nee HOse4- O77 3300.18 sinc Jed y94tt399) pac 014) [ern [eon lors) 0.575) 1040.94) vaso wo) P1._s6s.520 st |_ 70796 “rT Common tools Alternator ‘Name Romark Soldering bit 80-100 Instruments Alternator Name Remark Circuit tester For measurement of parts Megger tester For inspection of insulation Micrometer For measurement of parts Regulator checker (G&M Machinery ICD-101D or are For inspection of regulator 38 PARTS TO BE PREPARED Starter ‘Name Remark iru tester For measurement of paris Micrometer For measurement of par outer darter Growler tester For inepeation of armature Cylinder gauge For measurement of pat inner diameter For measurement of brush length and commutator outer diameter Dial gauge For measurement of shaft runout Magnet stand For measurement of shaft runout Lubricant, etc. Starter Name Remark ‘Kyodo Yushi Multemp AC-N For lubrication of parts Nissekd Mitsubishi Pyroknack #2 For lubrication of parts Grease syringe For pouring grease into the metal (center bearing) grease reservoir Turbocharger Special tools ‘Shape Part No, Name Remark 09407-1280 | Tool assembly Instruments Name ‘Remark Dial gauge For measurement of turbine shaft bend 4 ENGINE ASSEMBLY/DISASSEMBLY Inspection Before Services. Measurement of compression pressure sn A Engine Body. Removal Installation Work ater instalation ENGINE ASSEMBLY/DISASSEMBLY ses 2 42 43 45 45 42 ENGINE ASSEMBLY/DISASSEMBLY Inspection Before Service Measurement of compression pressure NOTICE + Measure the compression pressure botoro disassembly ofthe engine and record the result, Regular measurement of the compression pressure can tell the engine status, 1. Preparation before measurement (1) Charge the battery completly (2) Check the valve clearance and adjust it when exceeding the standard value (8) Warm the engine and set the water temperature to 80 S0(176 °F} (4) Remove the air leaner. (5) Remove the head cover (6) Remove al injectors. (7) To prevent spread of engine cil attach ajig which cuts a head cover in half (Cut itso thatthe camshaft may be covered. Measurement (1) Attach a special too! to the nozzle sheet of the cylinder where the compression pressure is measured. ‘Special tool : 09952-1080, 09552-1060, 09552-1030 Compression gauge adaptor (2) Tur the starter and measure the compression pressure A\CAUTION + Donot operate the starter for 15 seconds or more. rrr + Since the air cleaner is removed, provent entry of dirt. (8) Measure the compression pressure of each cylinder continuously. Engine revolution 200r/min {rpm} ‘Compression pressure: Unit MPa tkgt/em?,tbtfin.2} [ Standard value 2.9 {90, 421} 2.5 (26, 962} ‘Operation (4) Ifthe compression pressure is below the operation limit, overhaul the engine, (5) After measurement, reassemble the removed parts. ENGINE ASSEMBLY/DISASSEMBLY Engine Body Removal 1. Preliminary work before removal of engine (1) Place the vehicle on a level ground. (2) Block tres with scotch. (3) Remove the battery cable from the battery minus terminal, 2. Drain of coolant and engine oil, Fight sie of engine : (1) Drain coolant from the radiator drain cock and the oll cooler drain plug. NOTICE + Removal of the filer cap facilitates quick drain, + Connection of an appropriate hose to the oi cooler drain pipe facilitates drain of coolant without spread, Ol cooler rain plug A\CAUTION + To prevent burn, drain coolant after the temperature is sutficiently low. + To dispose coolant, observe the specified ‘method (waste disposal) or the method with attention to the environment. r ———____()__ Drain engine oil rom the oll pan drain plug as required. A\CAUTION + To prevent bur, drain coolant after the temperature is sutficfently low. *+ Dispose coolant according to the specified method (waste treatment) or with a method considering the environment. 3, Removal of intake hose, intercooler hose and exhaust pipe (1) Loosen the clamp and remove the intake hose. (2) Remove nuts and remove the exhaust pipe. Intake manifoe AXCAUTION + Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside the engine. Gyindec head i cet Work image 4, Disconnection of fuel hose (1) Remove the fuel hoses (feed side and return side). Wrap the removed hose with a plastic sheet with iis end facing upward to prevent spill of fuel. A\CAUTION * Wipe spilled fuel with a rag 5. Disconnection of water, engine oll pipes, ete. (1) Disconnect the hose between the radiator and the engine, (2) Disconnect the ar heater pipe. (3) Disconnect the ol fiter pipe. AXCAUTION + Wipe off spilled water and engine oil with a rag. Engine lifting (1) Place a hook on the hole in the engine hanger. (2) Keep a litle slack of the wire rope. (8) When the wite is completely tonse, make sure that the Wire Is firmly engaged with the engine hanger. Then, lift the engine slowly. A\CAUTION - Work carefully so that the engine may not come in contact with the frame and others. ENGINE ASSEMBLY/DISASSEMBLY Installation 1. Connection of fuel hose (1) Insert a fuel hose and fix it with a hose band. Work after installation 4. Inspection of engine oil (1) Make sure that the drain cock is closed. @) Pour engine oil Engine oil amount (L{us gal}) pan Oil filter ‘Approx. 23{6.07) ‘Approx. 6.04 Hino genuine Blue Ribbon ePRO-extra PROT SAE#10W-30 Hino genuine Blue Ribbon oPRO-super SAEH 20 ANCAUTION + Check the amount of oll wth an ol level gauge. Air biagcing Priming pump ‘PROTOS 2. Air bleeding of fuel system (1) Propare a rag to receive fuel at the end of the drain valve, (2) Loosen the air bleeding bolt of the fue filter. (3) Tum the priming pump to the left and lit and move it front and back c (4) Move the pump until fuel without bubble comes out from the drain valve, () Tighten the alr bleeding plug. (6) Move the priming pump again § to 6 times, (7) Pross the priming pump and tighten it fully to the right. AXCAUTION + After work, wipe off spilled fuel. After start of the engine, make sure that there Is no fuel leak. FUEL SYSTEM a4 5 FUEL SYSTEM Fu! System cnn Fuel system diagram, Part layout (ypical example) 53 Part layout (ypical example) 54 Par layout ((yplcal example 55 Ful iter drain renee 6 placement of fuel iter element... 58 ‘Assembiyfaisassembly of fel fer case 58 Replacement of supply PUMP ns 58 Feplacement of inj0t0r orn Sat Inspection of njet0r sn 545 Inspection of common rail function parts (evaluation) 516 ‘Overhaul of supply pump drive besring case... 5-17 52 FUEL SYSTEM Fuel System Fuel system diagram eaten pipe Common Food pump | Lsakage poe Tach eed pine “Traugh food pipe Fat tnke FUEL SYSTEM Part layout (typical example) 5 5 Bn, gor gl ae sxman © sence Pe fesoet Leakage pipe [2S766A Fuel pipe l2s900 Fue! fter les7668 Fuel pipe las7ot Injection pipe lea76ec Ful pipe 28702 Injection pipe 2a781 Fuel pipe 22703 Injection pipe laser Feed pump 2704 Injection pipe 1s0596 Gasket lea705 Injection pipe lsosac Gasket” l2a706 Injection pipe 190590 Gasket? “Parts not to be reused. Tightening torque 8081 “44 Nm (450 Kgh om, 82 bt th fearos AN. m (450 kgf cm, 82 BF A 23701 44 Ne m {450 kat: om, 92 IDE ft) l2a706 20 N: m (200 gl: om, 15'bF- ft} ‘2s702 44 Ne m (450 kgf: om, 82 Ibt ft} leaezt Common ral side: 54 N- m {550 kgf: cm, 40 it: #) 23708 44 0+ mm (450 kat: cm, 82 IDF ft} 29871 ‘Supply pump side: 44 N- m (450 kgf cm, 82 It ft) les704 44.N-m (450 kgf cm, 92 bt A 19068-12000 97 N- m {990 kgh cm, 72 lof: ft} Part layout (typical example) FUEL SYSTEM oe meg @ -r9906 T1195 Injector clamp [asai0 Injector 114918 Common rail bracket locas O-tingt 13610 Supply pump drive case assembly 96590, Gasket” 13611 Supply pump drive shaft 96508 Gasket" +3601 Bearing holder case loezen Oil seal" 3693 Bearing retainer loes1A O-ring® 1873 Oil pipe (e51B O-ring sr74 Fuel pipe 1900111 Shim 122730 ‘Supply pump je93-a02060 Bearing \22760 Common rail assembly 1999322070 Bearing “Parts not to be reused. Tightening torque (22780 Caller bolt: 81 N- m (930 kgF Gm, 67 ]aTBT-08400 _25N- m (250 kgh om, 18 [bt A) ttf) 22790 Coupling bolt: 61 N: m {620 kgi- cm, 45 |9191-08901 28 N- m (290 kgf: cm, 20 Ib: ft} Tot) lo00124 26 N: m (270 kgf: om, 19 Ibt ft} lger9A 245 N+ m (2,500 kgf om, 180 Ibt- ft} FUEL SYSTEM 55 Part layout (typical example) 2 Te G * me @ [23500 Fuel iter assembly [8a47 Sedimentor water sensor lzos10 Fuel fiter case 800700 Center bok ass Bot s007s8——O-ting® 23353 Spring e007s8 ‘Fuel iter cap 25885 O-tingt S018 O-ring 2601 Fuel itr element “Parts rot to be roused Tightening torque Basie 4-29 N m(S0-O0kgE om, 36-65 ]B0070 _245-G49N mm[OB0- 360 kal om, 18 tot 25 (bt) int bot Fue! er bedi bal \ \ Drain pipe Fuel ter ran bot Genter bt FUEL SYSTEM Fuel filter dré 1. Propare a water container under the drain pipe. 2. Loosen the fuel filter air bleeding bolt and the fuel filter drain bolt. Discharge water at the bottom of the fuel filter case, + Since discharged water contains fuel, ‘observe the local disposal procedure for disposal. A\caution 3. Tighten the fuel filter drain bolt. 4. Start the priming pump and bleed air from the system, + Make sure that the fuel filter air bleeding bolt Is loose. A\cauTion 8, Tighten the fuel filter air bleeding bolt Tightening torque : 4.9 -8.9N- m (50-90 kgf em, 3.6 -6.5 IbF 1) + After work, wipe off spilled water or fuel. After start of the engine, make sure that there Is no fuel leak. AX caution Replacement of fuel filter element 1. Fuel discharge (1) Prepare a fuel container under the drain pipe. (2) Loosen the fuel fiter air bleeding bolt, fuel fiter drain bolt and joint bolt to discharge fuel in the fue fiter caso. + For disposal of fuel, observe the local disposal procedure, AvcauTion 2. Removal of fuel filter element (1) Loosen the fue! fit center bolt and remove the fuel fier cap. (2) Remove the fuel fer element. + Since the filter contains diesel oll, prepare a tray. Axcaution FUEL SYSTEM oT 3, Installation of fuel flter element (1) Remove contamination or foreign matter from the Installation surface. (2) Store the fuel fiter element in the fuel filler case, (3) Apply diesel ol ightly to the new O-ring. (4) Assemble the O-ring and the fue! fiter cap and tighten the ‘uo! fiter center bolt, Tightening torque : 24.5 - 34.3 N- m (250 - 350 kgf- cm, 18-25 Ibt- tt) A\CAUTION + Element is not reused. + Replace the O-ring with a new one in the ‘element kit. + Be careful for damage to the O-ring due to distortion, ‘+ Make sure that the O-ring is in contact with the sealing surface. + ‘Align the match marks of the fuel filter cap and the fue! filter case. (8) Tighten the fue! fiter drain bott and the joint bot. (8) Start the priming pump and bleed air from the system. AXCAUTION. + Make sure that the fuel iter air bleeding bott Istooee. (7) Tighten the fuel fiter air bleeding bol Tightening torque : 4.9 - 8.9 N: m {60-90 kgf em, 3.6 = 6.5 Ibt- ft} A\CAUTION + After work, wipe off spilled fuol. After start of the engine, make sure that there is no fuel leak. FUEL SYSTEM Assembly/disassembly of fuel filter case 1. Removal of fuel filter case (1) eter to the "Fuel discharge" procedure of ‘Replacement of fuel fiter element" and discharge fuel inthe fuel fiter (2) Disconnect the fuel pipe connected to the fuel filter case, (8) Remove two mounting bolts and remove the fuel fiter A\CAUTION = Since some fuel is not discharged and = remains in the fuel filter caso, be careful not to spill it. 2. Mounting of fuel filter case (1) Assemble the fuel fter case at the specified position and tighten two mounting bots. Tightening torque : 97 N- m (990 kgf- cm, 72 Ibf- ft} (2) Install the fue! pipe to be connected to the fuel fiter case. (3) Loosen the fue! fier air bleeding bolt (4) Start the manual priming pump and bleed air from the system (8) Tighton the fuel filter air blesding bok. Tightening torque : 4.9-8.9N: m (50-90 kgf: cm, 3.6 -6.5 Ibt ft) AXCAUTION + After work, wipe off spilled fuel. After start of - the engine, make sure that there is no fuel teal Fyaneel housing Spector winow ‘Algn FUEL SYSTEM 59 Replacement of supply pump 1. Removal of supply pump NOTICE + The supply pump does not have to be adjusted, + I insufficient discharge rate or a faulty sub- engine speed sensor occurs, contact the Denso service shop. (1) Remove the fuel pipe and ol pipe connected to the supply pump. (2) Align the No. 1 cylinder to the compression top dead center and align the stamp lines of the supply pump. (8) Remove the coupling bolt. Special tool : 09819-1707 Supply pump coupling wrench (4) Remove four bolts and remove the supply pump. (8) Loosen the cotter bolt and ensure shatt play for reinstallation, 2. Installation of supply pump (1) Turn the crankshaft in the engine rotating direction (clockwise as viewed from the cooling fan side), align the "16" stamp line ofthe crankshaft damper with the pointer, and align the No. 1 cylinder to the compression top dead center, A\cAUTION * Ifthe pointer is matched with "16", but the ‘supply pump bearing case shaft key or cotter bolt faces down, No. 6 is at the compression top dead center. Turn the crankshaft one turn and set the No. 1 cylinder at the compression top dead center. 5-10 FUEL SYSTEM (2) Make sure that the cotter bois loose and install the J supply pump on the bracket = Tightening torque : 28 N- m {290 kgf- cm, 20 Ibt- ft} xq en mv alooe ) ‘cotter bolt ve Oe (3) Install two bolts atthe coupling and tighten the coupling bolt by aligning the stamp line of the supply pump. Special tool : 09819-1707 Supply pump coupling wrench Tightening torque : 61 N- m (620 kgf: cm, 45 Ibt ft ANCAUTION. + Make sure that there is no clearance between laminate plates. Make sure that there is no flange deformation due to crashing of laminate plates. (4) Tighten the cotter bot. Tightening torque : 91 N- m {930 kgf- em, 67 Ibf- ft) AXCAUTION * Make sure that laminate plates are not deformed or there is no undue force on them. (6) Replace the gasket with a new one and connect the fuel = Injector pipe and oil pipe to the supply pump. Tightening torque : 44. m (450 kgf. cm, 92 Ibf- ft} (Fuel pipe M14) 54 N. m {550 kgf- cm, 40 Ibt- ft} (Fuel pipe M16) (Common all Special tools Q Replacement of injector 1. Removal of injector harness: (1) Remove each connector and bolt and remove the injector harness A\CAUTION + Since the injector harness bracket is susceptible to distortion, be careful for handling. NoTICE + Refer to the following for installation of the engine retarder. "Reference: Engine ‘mechanical, Engine retarder, Removal’ 2. Removal of leakage pipe (1) Remove the injector and cylinder head union bots (2) Remove bolts and remove the loakage pipe. A\CAUTION. * Since the leakage pipe is susceptible to distortion, be careful for handling. 3. Removal of injector (1) Remove the injection pipe seal. (2) Remove the injector clamp mounting bolt and remove the injector and injector clamp. NoTICE + Ifitis difficutt to pull it out, pull it out with a special tool. Special tool : 09420-2010 Puller (8) Remove the O-ring from the cylinder head. Irecton pipe Sha spring FUEL SYSTEM 4, Installation of injector (1) Install a new O-ring on the eyinder head groove and insert the injector. AXCAUTION + Apply engine oll tothe O-ring and be careful to provent pinching of the O-ring. (2) Puta new injection pipe cil seal on the injector and install itith bolts and nuts AXCAUTION + Do not tixthe injector clamp until the injection pipe is tack welded temporarily. + Install the injection pipe seal to prevent undue {force to the injector. (Offset position between the Injection pipe oll seal and the Injector may cause oll leak or poor assembly of the injoction pipe.) (8) Replace the gasket with a new one and tack weld the leakage pipe tothe injector and cylinder head temporally. AXCAUTION + Install the gasket in a direction in which it does not interfere with the valve spring. + Since the injector top union bolt and the cylinder head joint union bolt are different in screw thread pitch, be careful for handling Injector top union bolt (M10 x 1.0) Cylinder head joint union bott (M10 x 1.5) (4) Tack wold the injection pipe through the injection pipe soat Until it comes in contact with the seat AXCAUTION + Tack weld ity adjusting so that the Injector Is. aligned with the ‘+ Make sure that the seal spring Is installed correctly. jection pipe. Injection olpe FUEL SYSTEM (5) Tighten the injector clamp mounting bolts to fix the injector. Tightening torque : 26 N- m {270 kgf cm, 19 bf. ft} AXCAUTION + After tightening, make sure that the rocker ‘arm moves smoothly. Make sure that there Is no undue force on the injection pipe oil seal. (Otherwise, oil leak or poor assembly of injection pipe may occur) (6) Tighten the injacton pipe. Tightening torque : 44 N- m (450 kgf: cm, 32 Ibf ft) (7) Tighten the leakage pipe. Tightening torque : 20 N- m {200 kot cm, 15 Ib. ft} A\CAUTION + Assemble so that the gasket connection may not come in contact with the rocker arm, Installation of injector harness (1) Connect each connector and install the injector harness. FUEL SYSTEM 6. Entry of injector correction value to the engine ECU (entry using Hino field support system and QR code reader) ASCAUTION + When the injector i replaced, its necessary to enter the Injector correction value (QR code) described on the new injector to the engine ECU, Incorrect entry of the correction ae value may result in faulty engine. NoTIcE * Available entry methods of the injector correction value are the PC tool and the QR code reader. + The work flow is described below. For detailed procedures, refer to the operation manual of the Hino field support system. (1) Read the injector QR code with the scanner of the QR, code reader and prepare the correction data fie (2) Enter the injector correction value directly from the Hino field support system to the engine ECU. => cl ‘Connector ecu FUEL SYSTEM 515 Inspection of injector 1. Inspection of injector insulation (1) Remove the injoctor plastic terminal cap (upper). (2) Measure the insulation resistance between the injector Upper body and one terminal (no polarity) of two terminals for the injactor harness, Cross-section vew of rjctorhed> ‘Terminal (harass Termine esp (upped) Srna) Stan in vurtcap dard value (normal | 09 ac or more nm et temperature) (9) Measure the resistance value between two terminals, SS above. befor hares snd uabar oe ‘Standard value (at 20 | °c(6s °F) 0.45 2:40.1 (4) the resistance value in (2) and (3) exceeds the standard Se value, replace the injactor assembly. UBper body esi) 2. Cleaning of injector (1) Remove sludge at or around the terminal, if any. AXCAUTION + In removing sludge, do not use a cleaning Agent. Wipe it off with a rag, Use of a cleaning agent may result in electric failure due to penetration ofthe agent. 5-46 FUEL SYSTEM Inspection of common rail function parts (evaluation) 1. Inspection of pressure sensor (1) Ifthe check engine lamp illuminates and it applies to “Pressure senor disconnection’, "Pressure sensor short circuit” or "Pressure sensor output does not change" in inspection of failure diagnosis system, replace the pressure sensor. 2. Inspection of pressure limiter (1) Remove the hollow SC of the pressure limiter. (2) _ Install blank plug on the pipe side using a bolt to prevent as Insta lar 149 on the pps, fuol discharge. Remove the hallow SC. 8) _ Install the union on the pressure limiter and connect the plastic hose to the tip ofthe union. (4) Propare a fuel container at the tip of the plastic hose. (5) _ Ifthe engine is started and fuel discharge Is recognized continuously, replace the pressure limiter. Prasichose 8 Comme 3. Inspection of flow damper (1) Start the engine, run it from idling to full throttle and check the diagnosis code of “flow damper operation’. (2) the diagnosis code of “flow damper operation’ Is, dotected, replace the applicable injector and inspect again. (8) Ifthe failure is reproduced after the injector is replaced, replace the flow damper with the common rail assembly. FUEL SYSTEM Overhaul of supply pump drive bearing case 1. Removal of timing gear case cover "Reference: Engine mechanical, timing gear cover and flywheel housing, timing gear case cover replacement" 2. Removal of supply pump drive gear (1) Remove the drive gear mounting nut (2) Remove the oll pipe connected to the supply pump drive bearing case. — ~ (3) Pullout the gear using a special tool or installa box nut on the shaft, hit the shaft with a copper hammer, loosen and cee remove the gear with impact. \ Special tool : 09420-1111 Timing gear puller (4) Remove the supply pump drive bearing case. 3. Disassembly of supply pump drive bearing case (1) Remove the bolt and disassemble the supply pump drive Rg a bearing case 518 estng Shan OT ctu groove SHE speci oo = Oil eoat =} pearing retainer FUEL SYSTEM 4. Assembly and adjustment of supply pump drive bearing case ( (1) Insert the beating and shaft applied with engine oil into the case, replace the O-ring with a new one applied with engine ol and assemble the supply pup boaring case as shown in the figure. Tightening torque : 25 N- m {250 kgf- em, 18 bt. ft} A\CAUTION. + Adjust temporarily with a shim so that the drive shaft Is tuned manually and there is no backlash. + Assemble so that the bearing retainer protrusion (oil return groove) is lower. (2) Measure the rolling torque using a torque wrench and adjust itso that it satisfies the standard value. ‘Standard value (Nm | 0.39 1.17(4 - 12,3.5- {kgf om, Ibf- in) 10.4) (3) Apply engino allo the lip of a new oll seal, : (4) Pross fit the oil seal using a special oo! so that the oll soal is flush with the bearing retainer. ‘Spocial tool : 09482-2330 Press a FUEL SYSTEM 5-19 Installation of supply pump drive bearing case (1) Replace the O-ring with a new one and install the supply pump bearing case with adjusted preload from the back. (2) Fix the drive shaff, align the gear stamp, install the drive gear and tighten the nut Tightening torque : 245 N- m {2,500 kgf: cm, 180 It 1) Installation of timing gear cover “Reference: Engine mechanical, timing gear cover and flywheel housing, timing gear case cover replacement” ELECTRICAL 7 ELECTRICAL Electrical System, : 52 Part layout (typical example). 52 Layout of components. 55 Inspection of components 57 Instalation of components 59 Installation of starter. 59 Installation of altemator. 510 72 ELECTRICAL Electrical System Part layout (typical example) aE @ 2x00 © a eit? an a Btn aE Res “ye a os oe ° sen e208 sy Sd saz08 oO ° BR PE wn ix x

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