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FOREWORD

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

Applicable for J08C-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 Operation 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.
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.

MANUAL NO. S5-YJ08E17A


CHAPTER
MODEL J08C-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

TURBOCHARGER EN08-001

ALTERNATOR EN11-001 EN11-002

STARTER EN12-001

AIR COMPRESSOR EN13-001 EN13-002

ENGINE P.T.O. (POWER TAKE-OFF) EN14-001

FUEL CONTROL DN02-001 DN02-002


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.
INDEX: ENGINE GROUP 2/2

ENGINE CONTROL

FUEL CONTROL

BRAKE CONTROL

SUSPENSION CONTROL

CAB EQUIPMENT CONTROL

OTHERS
GENERAL INTRODUCTION (ENGINE) GN01–1

GN01 GENERAL INTRODUCTION (ENGINE) GN01-001

GENERAL INTRODUCTION (ENGINE) ...GN01-2


GENERAL PRECAUTIONS .............................GN01-2
HOW TO USE THIS WORKSHOP MANUAL...GN01-3
IDENTIFICATION INFORMATION ...................GN01-5
SPECIFIED TORQUE FOR STANDARD BOLTS AND
NUTS ...............................................................GN01-5
DISMOUNTING AND MOUNTING ..................GN01-6
GN01–2 GENERAL INTRODUCTION (ENGINE)

GENERAL INTRODUCTION (ENGINE)


GENERAL PRECAUTIONS
M00010101BEC1001

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

CAUTION
When working on your engine, observe the following general precautions to prevent personal injury and/or prop-
erty damage, in addition to the particular NOTICES or CAUTIONS in each chapter.

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


• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
• Bind long hair securely behind the head.
• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N"
and block the wheels.
• Always stop the engine and turn off the starter switch, unless the operation requires the engine running.
Removing the key from the switch is recommended.
• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radi-
ator, muffler, exhaust pipe and tail pipe.
• Do not smoke while working on the vehicle, since fuel and gas from battery are flammable.
• Take utmost care when working on the battery. It contains corrosive sulfuric acid.
• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short,
which can result in personal injury and/or property damage.
• Read carefully and observe the instructions placed on the jack before using it.
• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under
a vehicle supported only by a jack.
• Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belt
when the engine is running.
• Be careful not to damage lines and hoses by stepping or holding on them.
• Be careful not to leave any tool in the engine compartment. Tools may be hit by moving parts, which can
cause personal injury.

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 crossmem-
ber when attaching the towing chain. Never lift or tow the vehicle if
the chain is in direct contact with the bumper.

1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is
removed. When the differential gear or rear axle shaft is defective,
remove both right and left rear axle shafts, then cover the hub
opening to prevent loss of axle lubricant and entry of dirt or for-
eign matter.
(2) 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.
(3) The angle of pulling direction of the cable fastened to the towing
hook must not exceed 15 in horizontal and vertical directions from
the straight ahead, level direction. Avoid using the hook in a way
that subjects it to jerk, as in towing a vehicle trapped in a gutter.
GENERAL INTRODUCTION (ENGINE) GN01–3

(4) Keep the gear shift lever in "Neutral".


(5) Make sure that the starter switch is kept in the "ON" position.
(6) Make sure that the engine of the towed vehicle is kept running. If
the engine is off, no compressed air/ no vacuum will be available
for the brake. This is dangerous, as the brake system does not
function if the engine is not running.
In addition, the power steering system will not function. The steer-
ing wheel, therefore, will become unusually hard to turn, making it
impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied,
if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be
less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that


the vehicle is towed only by a tow truck designed for that pur-
pose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off
the ground, remove the rear axle shafts to protect the transmis-
sion and differential gears from being damaged. The hub open-
ings 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 vehi-
cles 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.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fas-
ten and secure the steering wheel in a straight ahead position.

HOW TO USE THIS WORKSHOP MAN-


UAL
M000101BEC1002

This workshop manual is designed as a guide for servicing the vehi-


cles.
An INDEX is provided on the first page of each chapter.

TROUBLESHOOTING is dealt with in each chapter.


When beginning operations, refer to the TROUBLESHOOTING section
for a guide to appropriate diagnoses.

SPECIAL TOOL are dealt with in each chapter.


When ordering a special tool, confirm the part number with the applica-
ble parts catalog.
M00010100001

• REPAIR PROCEDURES
Repair procedures when self-explanatory, such as simple installa-
tion and removal of parts, have been omitted. Illustrations, such
as the one below, have been provided to make such simple proce-
dures clear. Only essential procedures requiring specific direc-
tions have been dealt with explicitly.
GN01–4 GENERAL INTRODUCTION (ENGINE)

TIMING GEAR AND CAMSHAFT


EXAMPLE:

OVERHAUL

3 5 A
12
13 5 B
4
12
C
5 13

2 6
1 7 12
5
13
8

11
5
10
9

M00010100002

1 Gasket 8 Main idle gear


2 Rear end plate 9 Crankshaft gear
3 Camshaft gear 10 Injection pump drive gear
4 Camshaft idle gear 11 Power steering pump drive gear
5 Idle gear thrust plate 12 Pin
6 Sub–idle gear 13 Idle gear shaft
7 Oil pump gear

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A* T= 108 {1,100, 79} C* T= 172 {1,750, 125}
B* T= 108 {1,100, 79} D T= 55 {560, 39} Application of lock sealant
*=Apply oil to the threads and seat surface before tightening.
In some cases, illustrations may be of parts which differ in some nones-
sential way from the parts found on your particular vehicle. In such
cases, the principle or procedure being illustrated applies regardless of
such nonessential differences.
• DEFINITION OF TERMS
This engine rotates counterclockwise viewed from the flywheel
side.
GENERAL INTRODUCTION (ENGINE) GN01–5

IDENTIFICATION INFORMATION
M000101BEC1003

• ENGINE SERIAL NUMBERS.


Please quote these numbers when ordering spare parts or report-
ing technical matter to receive prompt service attention.
The engine serial number is engraved on the engine cylinder
block.

M00010100003

SPECIFIED TORQUE FOR STANDARD


BOLTS AND NUTS
M000101BEC1004

1. FLANGE BOLT Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Class 7T 9T

Representation

7 q
Diameter x Pitch

M8 x 1.25 28.5 {290, 21.0} 36 {370, 26.8}

M10 x 1.25 60 {610, 44.1} 74.5 {760, 55.0}

M10 x 1.5 55 {560, 40.5} 68.5 {700, 50.6}

M12 x 1.25 108 {1,100, 79.6} 136 {1,390, 100.5}

M12 x 1.75 97 {990, 71.6} 125 {1,280, 92.6}

M14 x 1.5 171.5 {1,750, 126.6} 216 {2,210, 159.8}

M14 x 2 154 {1,570, 113.6} 199 {2,030, 146.8}


GN01–6 GENERAL INTRODUCTION (ENGINE)

2. BOLT WITH WASHER Unit: N⋅m {kgf⋅cm, lbf⋅ft}

Class 4T 7T 9T

Representation

7 q

Diameter x Pitch No Mark

M6 x 1 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}

M8 x 1.25 14 {140, 10.1} 25 {250, 18.1} 31 {320, 23.1}

M10 x 1.25 29 {300, 21.7} 51 {520, 37.6} 64 {650, 47.0}

M10 x 1.5 26 {270, 19.5} 47 {480, 34.7} 59 {600, 43.4}

M12 x 1.25 54 {550, 39.8} 93 {950, 68.7} 118 {1,200, 86.8}

M12 x 1.75 49 {500, 36.2} 83 {850, 61.5} 108 {1,100, 79.6}

M14 x 1.5 83 {850, 61.5} 147 {1,500, 108.5} 186 {1,900, 137.4}

M14 x 2 74 {750, 54.2} 132 {1,350, 97.6} 172 {1,750, 126.6}

DISMOUNTING AND MOUNTING


M000101BEH1001

PROCEDURE FOR INSTALLING JOINTS AND GAS-


KETS OF ENGINE PIPING
1. Gasket seal type (aluminum + rubber, asbestos or copper).

Location of gasket seal


GENERAL INTRODUCTION (ENGINE) GN01–7

Tightening torque chart

Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

8 {0.315} 13 {130, 9}

10 {0.394} 20 {200, 14}

12 {0.472} 25 {250, 18}

14 {0.551} 25 {250, 18}

16 {0.630} 29 {300, 22}

18 {0.709} 39 {400, 29}

20 {0.787} *39 {400, 29}

24 {0.945} 69 {700, 51}

28 {1.102} 127 {1,300, 94}

2. Metal seal type (Flare connector type).

Location of metal seal

Tightening torque chart

Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

12 {0.472} 20 {200, 14}

14 {0.551} 31 {320, 23}

16 {0.630} 39 {400, 29}

18 {0.709} 59 {600, 43}

20 {0.787} 64 {650, 47}

3. Metal seal type (Nipple connector type).

Location of metal seal

Tightening torque chart

Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}

10 {0.394} 11 {110, 8}

20 {0.787} 20 {200, 14}


GN01–8 GENERAL INTRODUCTION (ENGINE)

NOTICE:
• Before installing the joints, ensure that is no dirt or burrs
adhering to the various seat faces (pipe joints, gasket, etc.)
• Because the pipes can move relatively freely during installa-
tion and the seat faces are liable to tilt, first temporarily
tighten the pipes, then tighten them to the specified torque
and ensure that there is no leakage from them.
• When tightening two pipes together, be very careful that they
do not rotate together.
• After installing the pipes, apply the correct pressure to each
pipe joint and ensure that there is no leakage.
• Ensure that the various tightening torques conform to the
above table.
*If a soft washer #4840 FR–N (aluminum + rubber and carbon
press fit part) is loosened or removed subsequent to being
installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
ENGINE INTRODUCTION (J08C) EN01–1

EN01 ENGINE INTRODUCTION (J08C) EN01-001

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


DATA AND SPECIFICATIONS ......................... EN01-2
TROUBLESHOOTING ..................................... EN01-4
ENGINE TUNEUP ........................................... EN01-7
SPECIAL TOOL ............................................. EN01-12
OVERHAUL CRITERIA.................................. EN01-12
DISMOUNTING AND MOUNTING ................ EN01-14
LIQUID GASKET AND APPLICATION
POINTS ......................................................... EN01-16
EN01–2 ENGINE INTRODUCTION (J08C)

ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
M01010101BEI2001

Model J08C-UJ

Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,


Type
water-cooled, direct injection

Aspiration Turbocharged with intercooler

Bore and stroke 114x130 mm {4.49x5.11 in.}

Piston displacement 7.961 L {485.7 cu.in.}

Compression ratio 18: 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 3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min

Maximum revolution (at full load) 2,900 r/min

Idling revolution 550-570 r/min

Dry weight Approximately 575 kg {1,268 lb}

Intake 30°
Valve seat angle
Exhaust 45°

Intake 30°
Valve face angle
Exhaust 45°

Intake opens 14° before top dead center

Valve timing Intake closes 30° after bottom dead center


(flywheel travel) Exhaust opens 54° 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

Type Multi-hole nozzle type


Injection nozzle Valve opening pres- 1st:17.7 MPa {180 kgf/cm2, 2,560 lbf/in.2}
sure 2nd:21.6 MPa {220 kgf/cm2, 3,128 lbf/in.2}

Type Forced circulation by volute pump


Coolant pump
Drive By V-belt

Thermostat Type Wax.type, bottom bypass system

3° before top dead center for No.1 cylinder of the compres-


Injection timing (flywheel travel)
sion stroke
ENGINE INTRODUCTION (J08C) EN01–3

Model J08C-UK

Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,


Type
water-cooled, direct injection

Aspiration Turbocharged with intercooler

Bore and stroke 114x130 mm {4.49x5.11 in.}

Piston displacement 7.961 L {485.7 cu.in.}

Compression ratio 18: 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 3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min

Maximum revolution (at full load) 2,900 r/min

Idling revolution 550-570 r/min

Approximately 595 kg {1,312 lb} with 1 cylinder air compres-


sor
Dry weight
Approximately 600 kg {1,323 lb} with 2 cylinder air compres-
sor

Intake 30°
Valve seat angle
Exhaust 45°

Intake 30°
Valve face angle
Exhaust 45°

Intake opens 14° before top dead center

Valve timing Intake closes 30° after bottom dead center


(flywheel travel) Exhaust opens 54° 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

Type Multi-hole nozzle type


Injection nozzle Valve opening pres- 1st:17.7 MPa {180 kgf/cm2, 2,560 lbf/in.2}
sure 2nd:21.6 MPa {220 kgf/cm2, 3,128 lbf/in.2}

Type Forced circulation by volute pump


Coolant pump
Drive By V-belt

Thermostat Type Wax.type, bottom bypass system

3° before top dead center for No.1 cylinder of the compres-


Injection timing (flywheel travel)
sion stroke
EN01–4 ENGINE INTRODUCTION (J08C)

TROUBLESHOOTING
M01010101BEF3001

Engine overheating
Symptom Possible cause Remedy/Prevention
Engine overheating (Coolant) Insufficient coolant Add coolant.
Defective thermostat Replace thermostat.
Coolant overflow due to leakage of Repair.
exhaust into cooling system
Coolant leakage from cylinder head Replace gasket.
gasket
Defective coolant pump Repair or replace.
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.
Clogged radiator core due to mud or Clean radiator.
other debris
Defective radiator cap pressure valve Replace radiator cap.
Engine overheating (Abnormal Incorrect injection timing Adjust injection timing.
combustion) Reduced injection pressure Adjust injection pressure.
Poor fuel Use good quality fuel.
Poor nozzle spray Adjust or replace nozzle.
Unsatisfactory automatic timer Repair or replace timer.
advance angle
Engine overheating (Other prob- Defective or deteriorated engine oil Change engine oil.
lems) Unsatisfactory operation of oil pump Replace or repair.
Insufficient oil Add oil.
Brake drag Repair or adjust.

Excessive oil consumption


Symptom Possible cause Remedy/Prevention
Excessive oil consumption (Pis- Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
tons, 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 braking 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 (Valve Worn valve stem Replace valve and valve guide.
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 (Excess Defective oil level gauge Replace oil level gauge.
oil feed) Oil level too high Drain excess oil.
Excessive oil consumption (Other Overcooled engine (low temperature Warm up engine before moving vehi-
problems) wear) cle. Check cooling system.
Oil leakage from miscellaneous parts Repair.
ENGINE INTRODUCTION (J08C) EN01–5

Piston seizure
Symptom Possible cause Remedy/Prevention
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 Abnormal combustion See Symptom: "Engine overheating".
Piston seizure Coolant See Symptom: "Engine overheating".

Lack of power
Symptom Possible cause Remedy/Prevention
Lack of power Injection pump Refer to CHAPTER FUEL CONTROL.
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 nozzle) Poor nozzle spray Adjust or replace injection nozzle.
Clogged nozzle with carbon Clean nozzle.
Wear or seizure of nozzle Replace nozzle.
Air in fuel system Repair and bleed air from fuel system.
Clogged fuel filter Replace element.
Use of poor fuel Use good quality fuel.
Lack of power Abnormal combustion See Symptom: "Engine overheating".
Lack of power Wear of cylinder liners, and piston See Symptom: "Engine overheating".
rings
EN01–6 ENGINE INTRODUCTION (J08C)

Difficult starting engine


Symptom Possible cause Remedy/Prevention
Difficult starting engine (Electrical Discharged battery Charge battery.
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 fitted)
Difficult starting engine Injection pump Refer to CHAPTER FUEL CONTROL.
Difficult starting engine (Air Clogged element Clean the element or replace the ele-
cleaner) ment.
Difficult starting engine (Fuel sys- No fuel in tank Supply fuel and bleed air from fuel sys-
tem) tem.
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.
Broken or fatigued nozzle spring Replace spring.
Difficulty starting engine (Oil sys- Oil viscosity too high Use proper viscosity oil, or install an oil
tem) immersion heater and warm up oil.
Difficulty starting engine (Other Seized piston Replace piston, piston rings, and liner.
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 accel- Adjust or replace the accelerator
erator cable cable.

Rough idling
Symptom Possible cause Remedy/Prevention
Rough idling Injection pump Refer to CHAPTER FUEL CONTROL.
Rough idling (Nozzles) Uneven injection pressure Adjust.
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 Warm up engine.
Compression pressure of cylinders Overhaul engine.
markedly different from one another
ENGINE INTRODUCTION (J08C) EN01–7

Leakage of exhaust
Symptom Possible cause Remedy/Prevention
Leakage of exhaust (Cylinder head Fatigued gasket (aging) Replace gasket.
gasket) Damage Replace gasket.
Improper installation Replace gasket.
Leakage of exhaust (Cylinder head Loose bolts Tighten bolt.
bolts) Elongated bolts Replace bolt.
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 liner or cylinder
tion (insufficient projection of cylinder block.
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 (Other prob- Incorrect injection timing Adjust injection timing.
lems)

ENGINE TUNEUP
M01010101BEH3001

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


(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-
wheel side) to align mark 16 on the outer periphery of the fly-
wheel with the pointer of the flywheel housing.
NOTICE:
• Always turn the crankshaft counterclockwise (viewed from
the flywheel side).
• In this position the No.1 or No.6 piston is at the Top Dead
Center of the compression stroke.
M01010100069

b. Confirm whether No.1 or No.6 piston is at the Top Dead Cen-


ter 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


M01010100002
EN01–8 ENGINE INTRODUCTION (J08C)

• 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

M01010100046

(2) 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
(3) Confirm that there is no foreign particles or dust between the
cross head and the valve stem.

No Good 2. VALVE CLEARANCE CHECKING


M01010100004 NOTICE:
Before beginning the checking, you must perform "PREPARATION
OF CHECKING AND ADJUSTMENT" described on page EN01-7.
(1) You can understand which valve to adjust when No.1 or No.4 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
ENGINE INTRODUCTION (J08C) EN01–9

(2) Before checking the valve clearance, make sure that the roller is
on the base circle of the camshaft.

M01010100005

(3) Insert a feeler gauge of the specified thickness as below between


ROCKER ARM
the rocker arm and the cross head to check the valve clearance.
FEELER GAUGE VALVE CLEARANCE (when cold)
Intake valve 0.30 mm {0.0118 in.}
Exhaust valve 0.45 mm {0.0177 in.}
CROSS HEAD
CAUTION:
Valve clearance adjustment is performed only when the checking
result is outside the specified value.

M01010100006
3. VALVE CLEARANCE ADJUSTMENT
CAUTION:
Valve clearance adjustment is performed only when the checking
result is outside the specified value.
NOTICE:
• Before beginning the adjustment you must perform "PREPA-
RATION OF CHECKING AND ADJUSTMENT" described on
page EN01-7.
• As for the valve which can adjust the valve clearance refer to
the chart on page EN01-8.
• 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.
10mm or more NOTICE:
C Unless the adjusting screw is completely loose to the valve stem
D head, the following adjustments may be adversely affected.

"Zero" Need
clearance clearance
CROSS HEAD
M01010100007

(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.
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:
M01010100008
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
EN01–10 ENGINE INTRODUCTION (J08C)

(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

M01010100009

(6) Tighten the adjusting screw C of the cross head until the feeler
ROCKER ARM gauge does not move.
TIGHTEN
NOTICE:
C In this situation, clearance between adjusting screw C and valve
stem head is zero.

"ZERO"
"ZERO" clearance
clearance

M01010100010

(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
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

M01010100011

NOTICE:
• Do not over loosen the adjusting screw.
Not over loosen
• Over loosening of the adjusting screw C will cause the same
C
condition as in step (3) again. The feeler gauge may feel cor-
rect, but there may be excessive clearance between the
adjusting screw C of the cross head and the valve stem head
E E. This does not allow for correct adjustment.

"ZERO" (8) Positioning each piston at Top Dead Center of compression stroke
clearance by turning the crankshaft counterclockwise view from flywheel
side. Then adjust the valve clearance for each cylinder in the firing
M01010100012
order.

INJECTION TIMING ADJUSTING PROCEDURES

1. INSPECT THE INJECTION TIMING.


(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 SPECIFICA-
TION".
(2) Check that the injection timing mark on the automatic timer is
aligned with the pointer of the pump.
M01010100013
If not, adjust the injection timing as on the following page.
ENGINE INTRODUCTION (J08C) EN01–11

2. ADJUST THE INJECTION TIMING.


(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 (09511-2500)

(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.
M01010100014
SST: Injection pump coupling wrench (09511-2500: BOSCH)

Tightening Torque:
88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}

NOTICE:
• No clearance is allowed between thin plates.
• No deformation of the flange is allowed due to distortion of a
thin plate.

START THE ENGINE


FILLER CAP CAUTION:
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.

M01010100015

(2) Supply cooling water and bleed air from it.

M01010100016

(3) Bleed air from the fuel system.


BLEEDER PLUG
(4) Check connection to the alternator.
NOTICE:
Start the engine without wiring in place may burn out the alterna-
tor.
(5) Check the engine stopping performance.

M01010100017
EN01–12 ENGINE INTRODUCTION (J08C)

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.

M01010100018

SPECIAL TOOL
M01010101BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

COMPRESSION GAUGE
09552-1090 For Overhaul criteria
ADAPTER (A)

09552-1030 COMPRESSION GAUGE


09552-1060 ADAPTER (B)

OVERHAUL CRITERIA
M01010101BEH3002

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 80C {176°F}).
d. Remove the air cleaner.
e. While the starter switch is at the LOCK position, disconnect
the engine stop motor.
f. Remove all nozzle holders.
ENGINE INTRODUCTION (J08C) EN01–13

(2) Measurement
a. Insert the gauge adaptor into the nozzle holder hole.
SST:
Compression gauge adaptor(A) (09552-1090)
Compression gauge adaptor(B) (09552-1030)
Compression gauge adaptor(B) (09552-1060)
b. Run the engine with the starter and measure the compression
pressure.

Difference between
Standard Limit
each cylinder
M01010100021 3.4-3.7 MPa 2.7 MPa 0.3 MPa
{35-38 kgf⋅cm2, {28 kgf⋅cm2, {3 kgf⋅cm2,
497-540 lbf/in2} 398 lbf/in2} 43 lbf/in2} or less
Engine revolution 280r/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.
CAUTION:
When the starter switch is at ON position, do not connect the
engine stop motor connector. Connection operates the engine
stop motor (motor link is at OFF position) and the lever may catch
your finger.

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 is 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.

M01010100060

d. Measure the oil pressure at a coolant temperature of 80°C


{176°F} or more.
Oil pressure
Standard Limit
49-490 kPa Less than 49kPa
{0.5-5.0 kg/cm2, {0.5 kg/cm2,
7.11-71.10 lbf/in.2} 7.11 lbf/in.2}

3. OTHER FACTORS
M01010100023 (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
EN01–14 ENGINE INTRODUCTION (J08C)

DISMOUNTING AND MOUNTING


M01010101BEH1001

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.
CAUTION:
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 pump.
NOTICE:
Refer to CHAPTER POWER STEERING for details.
(5) 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 switch to the OFF position.
(6) Disconnect the electric lines, fuel lines, air lines, speedometer
cable, accelerator control cable and parking brake cable.
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.
M01010100024
(7) Disconnect the hoses (coolant, heater and air intake) and remove
the radiator.
NOTICE:
Do not damage the radiator.
(8) Disconnect the air intake and exhaust lines.
(9) Disconnect the transmission control and transmission with clutch
housing from the flywheel housing.
NOTICE:
Refer to CHAPTER TRANSMISSION/TRANSFER CONTROL and
CHAPTER TRANSMISSION MAIN UNIT for details.
(10) Remove the cab mounting member from the frame.
ENGINE INTRODUCTION (J08C) EN01–15

(11) Connect a cable from an engine hanger to the hanger bracket (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 section DATA AND SPECIFICATIONS.
(12) Remove the engine mounting fitting nuts (front and rear, both
sides).
(13) Lift the engine hanger so that the cables are fully tightened, then,
after checking that the cables are securely, lift gently and remove
the engine from the vehicle.
NOTICE:
When the transmission is attached to the engine, attach the third
cable to the hanger bolt.

IMPORTANT POINTS - MOUNTING

1. MOUNT THE ENGINE ASSEMBLY.


(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,
M01010100025 or air leaks.

2. CONNECT THE ENGINE STOP CABLE.


(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 positions 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.

M01010100026
EN01–16 ENGINE INTRODUCTION (J08C)

LIQUID GASKET AND APPLICATION


POINTS
M01010101BEH2001

• Liquid gasket is used at the following positions for the J08C series
engine.

Liquid gasket specification:


Three Bond TB1207B: Black
Liquid gasket specification:
Three Bond TB1207D: Silver
Liquid gasket specification:
Three Bond 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.

M01010100027

(2) For cartridge-type gasket, use an application gun.

M01010100028

(3) For tube-type liquid gasket, required width of application can be


obtained by cutting the nozzle to suit.

1: Approxi-
2 mm wide when cut at the first step
mately
2: Approxi-
5 mm wide when cut at the second step
mately

M01010100029
ENGINE INTRODUCTION (J08C) EN01–17

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}

Matching flange face with the block

1.5-2.5
2 Coolant pump {0.0591- Black
0.0984}

Matching flange face with the block

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
4 Dust cover FLYWHEEL {0.0591- Silver
HOUSING 0.0984}
OPENING

Matching flange face with the cylinder head

1.5-2.5
5 Thermostat case {0.0591- Silver
0.0984}

Matching face with the rear edge

1.5-2.5
6 Flange {0.0591- Silver
0.0984}
EN01–18 ENGINE INTRODUCTION (J08C)

Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used

Matching face with the intake manifold


LIQUID GASKET
1.5-2.5
7 Intake pipe {0.0591- Black
0.0984}

Matching parts of block upper face rear end,


gasket, rear end plate, flywheel housing, cylin- — White
der head gasket
Front and rear
1.5-2.5
ends of upper/ Matching parts of oil seal retainer and block
8 {0.0591- Black
lower faces of lower face front end
0.0984}
block
1.5-2.5
Matching parts of block lower front end, gasket,
{0.0591- Silver
rear end plate and flywheel housing
0.0984}

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.
ENGINE INTRODUCTION (J08C) EN01–19

Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used

Matching face of rear end plate

1.5-2.5
Flywheel hous-
9 {0.0591- Silver
ing
0.0984}

1.5-2.5 Black 2 locations


.

1. Matching faces with cam housing and plug


{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.
ENGINE MECHANICAL (J08C) EN02–1

ENGINE MECHANICAL (J08C)


EN 02

EN02-001

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


COMPONENT LOCATOR................................ EN02-2
SPECIAL TOOL ............................................... EN02-5
OVERHAUL ..................................................... EN02-6
INSPECTION AND REPAIR .......................... EN02-15

CRANKSHAFT FRONT END.................. EN02-19


COMPONENT LOCATOR.............................. EN02-19
SPECIAL TOOL ............................................. EN02-20
OVERHAUL ................................................... EN02-20

FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-22
COMPONENT LOCATOR.............................. EN02-22
SPECIAL TOOL ............................................. EN02-23
OVERHAUL ................................................... EN02-23
INSPECTION AND REPAIR .......................... EN02-26

TIMING GEAR......................................... EN02-27


COMPONENT LOCATOR.............................. EN02-27
SPECIAL TOOL ............................................. EN02-28
OVERHAUL ................................................... EN02-28
INSPECTION AND REPAIR .......................... EN02-30

MAIN MOVING PARTS AND


CYLINDER BLOCK................................. EN02-32
COMPONENT LOCATOR.............................. EN02-32
SPECIAL TOOL ............................................. EN02-35
OVERHAUL ................................................... EN02-36
INSPECTION AND REPAIR .......................... EN02-45
EN02–2 ENGINE MECHANICAL (J08C)

CYLINDER HEAD
COMPONENT LOCATOR
M01020101BED1001

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

M01020100089
ENGINE MECHANICAL (J08C) EN02–3

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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 28.5 {290, 20} F 14.5 {148, 10.7}
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}
#=Apply oil to the threads and seat surfaces before tightening.
EN02–4 ENGINE MECHANICAL (J08C)

4
5
1

6 A
2
7
3
8
9
10 16
11
17
12

13

18

14

15

M01020100090

1 Flange 10 Valve spring inner


2 Idle gear thrust plate 11 Valve stem seal
3 Idle gear shaft 12 Valve spring seat lower
4 Camshaft idle gear 13 Valve stem guide
5 Idle gear thrust plate 14 Valve seat
6 Cross head 15 Valve
7 Valve spring retainer 16 Nozzle seat
8 Valve spring seat upper 17 O-ring
9 Valve spring outer 18 Cylinder head block

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 108 {1,100, 79}#
#=Apply oil to the threads and seat surfaces before tightening.
ENGINE MECHANICAL (J08C) EN02–5

SPECIAL TOOL
M01020101BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09433-1070 EYE BOLT

09491-1010 WIRE

09470-1170 VALVE SPRING PRESS

09431-1020 VALVE LAPPING TOOL

09472-2100 VALVE STEM SEAL PRESS

09472-1210 BAR For Nozzle sleeve

9800-06100 STEEL BALL Used with 09472-1210

09471-1520 GUIDE
EN02–6 ENGINE MECHANICAL (J08C)

OVERHAUL
M01020101BEH2001

IMPORTANT POINTS DISASSEMBLY

1. DISASSEMBLE THE CYLINDER HEAD.


(1) Clean parts around the nozzle holder and fuel system connec-
tions.
NOTICE:
Entry of foreign particles into the combustion chamber may result
in engine trouble.
(2) Remove the nozzle holder assembly.
NOTICE:
Refer to FUEL SYSTEM.
(3) Remove the rocker arm assembly.
ADJUSTING a. Loosen the lock nut at the end of the rocker arm and turn the
SCREW adjusting screw counterclockwise completely.
NOTICE:
LOCK NUT Not untightening the adjusting screw may result in a bent rocker
shaft.

b. Loosen the nozzle clamp bolt.

M01020100010

c. Loosen the rocker arm support bolt as shown in the figure.


NOTICE:
If the cross head is removed from the valve during disassembly of
ROCKER ARM SUPPORT the rocker arm assembly, reassemble the cross head as it was.

7 5 3 1 2 4 6

M01020100094

(4) Remove the cylinder head bolts.


a. Gradually loosen bolts three times in the order shown in the
figure.

M01020100091
ENGINE MECHANICAL (J08C) EN02–7

(5) Lift and remove the cylinder head using the special tool and hoist.
SST:
Eye bolt (09433-1070)
Wire (09491-1010)

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.

M01020100013

2. DISASSEMBLE THE VALVE SYSTEM.


(1) Remove the valve spring retainer using the special tool.
SST: Valve spring press (09470-1170)

M01020100014

(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.

M01020100015

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.

M01020100016
EN02–8 ENGINE MECHANICAL (J08C)

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.
CAUTION:
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.
M01020100017 SST: Guide (09471-1520)

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 CAUTION:
PLACES HERE Striking the valve seat for removal may cause metal chips to fly
up. Be sure to wear protective goggles.
M01020100018

(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
M01020100019 D
{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.
CAUTION:
Striking the valve seat during installation may cause metal chips
to fly up. Be sure to wear protective goggles.

M01020100020
ENGINE MECHANICAL (J08C) EN02–9

(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 (09431-1020)

M01020100021

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 (09472-2100)

CAUTION:
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

M01020100022

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.
CAUTION:
Punching the nozzle seat during installation may cause metal
chips to fly up. Be sure to wear protective goggles.
NOTICE:
After removed the nozzle seat, removed the rest of liquid gasket or
the adhesion such as dust completely.

M01020100023
EN02–10 ENGINE MECHANICAL (J08C)

(2) After inserting the O-ring into the nozzle seat insertion hole of the
cylinder head, apply liquid packing (Three Bond No. 1211 or
equivalent) 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.

M01020100024

(3) Caulk the nozzle seat with the special tools.


SST:
Bar (09472-1210)
Steel ball (9800-06100)

M01020100025

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 (09470-1170)

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.
M01020100014 • 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,
M01020100026 make sure that there is no peeling before assembly.
ENGINE MECHANICAL (J08C) EN02–11

(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.

M01020100027

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.}

M01020100028

4. INSTALL THE CYLINDER HEAD.


(1) Using the special tool and hoist, put the cylinder head.
SST:
Eye bolt (09433-1070)
Wire (09491-1010)
NOTICE:
When put the cylinder head, attention to cam idle gear and sub
idle gear engagement.

M01020100013
EN02–12 ENGINE MECHANICAL (J08C)

(2) Apply clean engine oil to the bolt surface and bolt threads of the
M10 and M12 bolts.
(3) Clean the bolt seats completely on the cylinder head upper sur-
face.
(4) Tighten No. 1 - No. 26 (M12 bolts) in the order shown in the figure
to the specified torque.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}

M01020100092

(5) Mark the M12 bolts with paint to indicate the same directions as
shown in the figure.
(6) Turn No. 1 - No. 26 (M12 bolts) 90° (1/4 turn) in the same order as
in (4) .
(7) Retighten them 90° (1/4 turn) as step (6).
(8) Make sure that all paint marks face the same direction.
NOTICE:
When adding torque, never untighten the bolts, even if they have
been overtightened.

M01020100031

(9) Tighten No. 27 - No. 29 (M10 bolts) in the order shown in the fig-
ure to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}

M01020100093

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

M01020100033
ENGINE MECHANICAL (J08C) EN02–13

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.

Dimension A 51 mm {2.008 in.}

M01020100034

(2) Make sure that there is neither damage to the camshaft gear or
camshaft nor dirt on them.
(3) Apply clean engine oil to the bolt surface and bolt threads and
tighten them to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}

M01020100035

(4) Turn bolts an additional 90° (1/4 turn).


NOTICE:
When adding torque, never untighten the bolt, even if it has been
overtightened.

M01020100036

7. INSTALL THE CAMSHAFT.


(1) Align the mark on 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.
(2) Install the camshaft into the cam housing.
NOTICE:
Two drill holes on the camshaft gear should be located at left side
and lower drill hole should match with the camshaft housing
upper surface.
M01020100060

(3) Install the camshaft bearing cap, and tighten the bolts.
EN02–14 ENGINE MECHANICAL (J08C)

8. INSTALL THE ROCKER ARM ASSEMBLY.


(1) Make sure that the cross head is on each valve.
NOTICE:
ROCKER ARM SUPPORT 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 5 3 1 2 4 6 (3) Tighten the rocker arm support bolt as shown in the figure to the
specified torque.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100094

(4) Tighten the nozzle clamp bolt to the specified torque.


Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}

(5) Make sure that the rocker arm moves smoothly.


HINT:
When assembling the rocker arm assembly, fix the arm and nozzle
clamp with an O-ring as shown in the figure to facilitate installa-
tion.

M01020100038

9. INSTALL THE HEAD COVER.


(1) Remove the camshaft housing plugs at the front and rear ends of
the camshaft housing.
NOTICE:
Do not remove the plug except there is no oil leakage from plug.
(2) Remove the liquid gasket from camshaft housing plugs and cam-
shaft housing completely.

M01020100039

(3) Install the camshaft housing plug to camshaft housing with torx
bolt.
NOTICE:
Make sure that the camshaft housing plug installed with no tilt.

M01020100040

(4) Apply liquid gasket to the front and rear half circles of the cam-
shaft housing.
NOTICE:
Wipe out excess liquid gasket completely.

M01020100041
ENGINE MECHANICAL (J08C) EN02–15

(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

M01020100042

(7) Insert the silent block (No.1) from the head cover lower surface.
(8) Tighten the bolt through the silent block (No.2) to the specified
torque below and fix the head cover on the cam housing.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}

M01020100043

INSPECTION AND REPAIR


M01020101BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Camshaft journal outside 40 39.85 Measure


Replace camshaft.
diameter {1.5748} {1.5689}

Camshaft bearing inside 40 40.15 Replace cam bear-


diameter {1.5748} {1.5807} ing.

Clearance between cam- Replace camshaft


0.020-0.063
shaft journal and cam- — and/or cam bear-
(0.0008-0.0024)
shaft bearing ing.

Measure

0.100-0.178
Camshaft end play — Replace camshaft.
(0.0040-0.0070)

49.987 Measure
IN 50.067{1.9711}
{1.9680}

Cam height Replace camshaft.


52.024
EX 52.104{2.0513}
{2.0482}
EN02–16 ENGINE MECHANICAL (J08C)

Inspection item Standard Limit Remedy Inspection procedure

Measure

Camshaft deflection 0.04 {0.0016} 0.1 {0.0039} Replace camshaft.

Rocker arm bushing Replace rocker Measure


22 {0.866} 22.08 {0.8693}
inside diameter arm.

Rocker shaft outside Replace rocker


22 {0.866} 21.92 {0.8630}
diameter shaft.

Clearance between rocker


0.030-0.101 Replace rocker arm
shaft and rocker arm 0.15 {0.0059}
{0.0012-0.0039} and/or rocker shaft.
bushing

Stem out- Measure


side diame- 7 {0.2756} 6.92 {0.2724} Replace the valve.
ter

Intake valve Guide inside Replace the valve


7 {0.2756} 7.04 {0.2772}
diameter guide.

0.023-0.058 Replace the valve


Clearance 0.12 {0.0047}
{0.0010-0.0022} and/or valve guide.

Stem out-
side diame- 7 {0.2756} 6.85 {0.2697} Replace the valve.
ter
Exhaust Guide inside Replace the valve
valve 7 {0.2756} 7.04 {0.2772}
diameter guide.

0.037-0.067 Replace the valve


Clearance 0.15 {0.0059}
{0.0015-0.0026} and/or valve guide.

0.55-0.85 Replace the valve Measure


IN 1.1 {0.0433}
{0.0217-0.0334} and valve seat.
VALVE SINK

Valve sink
1.05-1.35 Replace the valve
EX 1.6 {0.0630}
{0.0414-0.0531} and valve seat.

Valve seat IN 30° 30°-30°35' Measure


angle EX 45° 45°-45°30'

IN 30° 29°30°-30'

Resurface the
valve and/or valve
Valve face seat.
angle EX 45° 44°30°-45''
ENGINE MECHANICAL (J08C) EN02–17

Inspection item Standard Limit Remedy Inspection procedure

314 N 291.8 N Measure


Setting load {32.0 kgf, 70.5 lbf} {29.8 kgf, Replace.
at 46.8 {1.843} 65.6 lbf}

Outer valve Free length


spring (reference 75.7 {2.980} 72.7 {2.862} Replace.
value)

2.6 {0.1023}
Squareness — Replace.
(2.0°)

129 N 119.5 N
Setting load {13.2 kgf, 29.1 lbf} {12.2 kgf, Replace.
at 44.8 {1.764} 26.9 lbf}

Free length
(reference 64.6 {2.543} 61.6 {2.425} Replace.
value)
Inner valve
spring

2.3 {0.0905}
Squareness — Replace.
(2.0°)

Visual check
Wear and damage of valve
spring seat upper and — — Replace.
lower

Measure

2.25-2.75 Replace nozzle


Nozzle protrusion —
{0.0886-0.1083} seat.

0.06 or less Measure


{0.0024 or less}
for longitudinal
direction

Replace.
Cylinder head lower sur-
0.20 {0.0078} NOTICE: Do not
face flatness 0.03 or less grind for repair.
{0.0012 or less}
for lateral
direction
EN02–18 ENGINE MECHANICAL (J08C)

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Cracks of damage to cylin-


der head (Dye penetrant — — Replace.
check)

Visual check

Contact of valve (Use of Entire periphery


Red lead marking com- of valve head — Matches valve.
pound) evenly in contact

Cam idle gear shaft out- Measure


34 {1.3386} — —
side diameter

Cam idle gear shaft bush-


34 {1.3386} — —
ing inside diameter

Clearance between cam Replace idle gear


0.025-0.075
idle gear shaft and cam 0.2 {0.0078} shaft and/or idle
{0.0010-0.0029}
idle gear bushing gear.
ENGINE MECHANICAL (J08C) EN02–19

CRANKSHAFT FRONT END


COMPONENT LOCATOR
M01020201BED1001

M01020200017

1 Crankshaft pulley 4 Crankshaft oil seal


2 Torsional damper 5 Oil seal retainer
3 Seal sub-assembly

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 108 {1,100, 80}#
#=Apply oil to the threads and seat surfaces before tightening.
EN02–20 ENGINE MECHANICAL (J08C)

SPECIAL TOOL
M01020201BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1731 OIL SEAL PULLER

09407-1030 OIL SEAL PRESS

OVERHAUL
M01020201BEH2001

IMPORTANT POINTS - REPLACEMENT

1. REMOVE THE CRANKSHAFT FRONT OIL SEAL.


SST: Oil seal puller (09420-1731)

(1) Place the plate at the crankshaft end using the crankshaft pulley
bolts.

PLATE

M01020200003

(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

M01020200004

(4) Install the center bolt and tighten it to remove the oil seal.

CENTER BOLT

M01020200005
ENGINE MECHANICAL (J08C) EN02–21

2. INSTALL THE CRANKSHAFT FRONT OIL SEAL.


GUIDE SST: Oil seal press (09407-1030)

(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

M01020200006

NOTICE:
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).

M01020200007

(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

M01020200008

(5) Insert the oil seal press by adjusting the oil seal press hole to the
PRESS guide bolt.
(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

M01020200009
EN02–22 ENGINE MECHANICAL (J08C)

FLYWHEEL AND FLYWHEEL HOUSING


COMPONENT LOCATOR
M01020301BED1001

M01020300022

1 Flywheel housing 5 Ring gear


2 Dust cover 6 Flywheel
3 Crankshaft oil seal 7 Pilot bearing
4 Hanger bracket 8 Stay

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 186 {1,900, 137}# D M8: 28.5 {290, 21}
B 97 {990, 72} D M10: 55 {560, 40.5}
C 171.5 {1,750, 127} D M16: 176.5 {1,800, 130}
#=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.
ENGINE MECHANICAL (J08C) EN02–23

SPECIAL TOOL
M01020301BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1742 REAR OIL SEAL PULLER

09407-1040 OIL SEAL PRESS

09481-1340 GUIDE BAR

OVERHAUL
M01020301BEH2001

IMPORTANT POINTS - REPLACEMENT


COLLAR KNOCK
1. REMOVE THE CRANKSHAFT REAR OIL SEAL.
SST: Oil seal puller (09420-1742)

(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE:
Match the plate hole to the crankshaft collar knock part.

M01020300002

(2) Engage the hook with the oil seal notch and install the hook using
HOOK the bolt supplied.
NOTCH (3) Remove the installed flywheel bolts in step (1).

M01020300003
EN02–24 ENGINE MECHANICAL (J08C)

(4) Install the center bolt and tighten it to remove the oil seal.

CENTER
BOLT

M01020300004

2. INSTALL THE CRANKSHAFT REAR OIL SEAL.


SST: Oil seal press (09407-1040)

(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.

M01020300005

NOTICE:
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).

M01020300006

(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

M01020300007

(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
(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.
PRESS

CENTER BOLT

M01020300008
ENGINE MECHANICAL (J08C) EN02–25

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.
CAUTION:
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.

M01020300009

(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.
CAUTION:
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.

M01020300010

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-
cial tool onto the crankshaft.
SST: Guide bar (09481-1340)

NOTICE:
Place one guide bar at the collar knock and another at the oppo-
site side of the collar knock.
M01020300011
(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.
CAUTION:
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
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.

M01020300012
EN02–26 ENGINE MECHANICAL (J08C)

INSPECTION AND REPAIR


M01020301BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure

Flywheel surface
— 0.15 {0.0059} Repair.
deflection

Flywheel Measure
flange
depth CS350 43 {1.693} 43 {1.693} Repair.
(Dimen- series
sion A) (Diameter
Flywheel 350 mm
thickness {14 in.})
21 {0.827} 20 {0.787} Repair.
(Dimen-
sion B)

Flywheel
flange
depth 48 {1.890} 48 {1.890} Repair.
(Dimen- CS380
sion A) series
(Diameter
Flywheel 380 mm
thickness {15 in.})
23 {0.906} 22 {0.866} Repair.
(Dimen-
sion B)

Flywheel surface crank Visual check


— — Repair.
on heat spot
ENGINE MECHANICAL (J08C) EN02–27

TIMING GEAR
COMPONENT LOCATOR
M01020401BED1001

M01020400001

1 Gasket 8 Main idle gear


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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 108 {1,100, 80}# C 172 {1,750, 127}#
B 108 {1,100, 80}# D 55 {560, 41} Application of lock sealant
#=Apply oil to the threads and seat surfaces before tightening.
EN02–28 ENGINE MECHANICAL (J08C)

SPECIAL TOOL
M01020401BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1100 SLIDING HAMMER For MAIN IDLE GEAR

For SUB AND CAM


09420-1442 SLIDING HAMMER
IDLE GEAR

09411-1300 SOCKET WRENCH For TORX BOLT

OVERHAUL
M01020401BEH2001

IMPORTANT POINTS - DISASSEMBLY

1. REMOVE THE IDLE GEAR SHAFT.


(1) Remove the idle gear shaft using the special tool.
SST:
Sliding hammer (for main idle gear) (09420-1100)
Sliding hammer (for sub and cam idle gear) (09420-1442)

M01020400005

M01020400006
ENGINE MECHANICAL (J08C) EN02–29

IMPORTANT POINTS - ASSEMBLY

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.
SST: Socket wrench (09411-1300)

Tightening Torque:
55 N⋅m {560 kgf⋅cm, 41 lbf⋅ft}

M01020400007

2. INSTALL THE CRANKSHAFT GEAR.


(1) Heat the crankshaft gear in oil heated to 100°C -150°C {212°F-
302°F}.
CAUTION:
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.}

M01020300024
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.

M01020400008

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.
EN02–30 ENGINE MECHANICAL (J08C)

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.

M01020400009

INSPECTION AND REPAIR


M01020401BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

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}
ENGINE MECHANICAL (J08C) EN02–31

Inspection item Standard Limit Remedy Inspection procedure

Shaft outside
57 {2.244} — —
diameter

Bushing
inside diame- 57 {2.244} — —
ter
Measure
Main idle 0.030-0.090 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} or shaft.

Gear width 44 {1.732} — —

Shaft length 44 {1.732} — —

0.114-0.160 Replace gear and/


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/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.

Gear width 22 {0.866} — —

Shaft length 22 {0.866} — —

0.040-0.095 Replace gear and/


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/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.

Gear width 22 {0.866} — —

Shaft length 22 {0.866} — —

0.040-0.095 Replace gear and/


End play 0.30 {0.0118}
{0.0016-0.0037} or shaft.
EN02–32 ENGINE MECHANICAL (J08C)

MAIN MOVING PARTS AND CYLINDER BLOCK


COMPONENT LOCATOR
M01020501BED1001

M01020500093
ENGINE MECHANICAL (J08C) EN02–33

1 Cylinder liner 9 Connecting rod bushing


2 Cylinder block 10 Connecting rod bearing
3 Piston cooling jet 11 Crankshaft
4 Piston ring 12 Crankshaft thrust bearing
5 Piston 13 Crankshaft main bearing
6 Piston pin 14 Crankshaft gear
7 Retainer ring 15 Collar knock
8 Connecting rod 16 Main bearing cap

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 22 {220, 15.5} C 69 {700, 50}+90°+45°#
B 69 {700, 50}+90°+45°#
#=Apply oil to the threads and seat surfaces before tightening.
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.

M01020500094

1 Injection pump bracket


EN02–34 ENGINE MECHANICAL (J08C)

M01020500095

1 Gasket 3 Soft washer


2 Oil pan 4 Drain plug

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 41 {420, 30} B 30 {300, 21}
ENGINE MECHANICAL (J08C) EN02–35

SPECIAL TOOL
M01020501BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09442-1011 PISTON RING EXPANDER For Piston ring

09420-1720 PULLER For Cylinder liner

9001-24262 CONNECTOR BOLT For Piston cooling jet

09472-1620 ADJUSTING BAR

09471-1490 GUIDE

09402-1540 SPINDLE

09481-1540 GUIDE

9191-08252 BOLT

09481-1130 GUIDE For Connecting rod bushing


EN02–36 ENGINE MECHANICAL (J08C)

Illustration Part number Tool name Remarks

09402-1530 PRESS SUB-ASSEMBLY

9233-10360 WING NUT

09441-1320 PISTON RING HOLDER

09444-1630 GAUGE

OVERHAUL
M01020501BEH2001

IMPORTANT POINTS - DISASSEMBLY

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.

M01020500017

• 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.

M01020500018
ENGINE MECHANICAL (J08C) EN02–37

2. REMOVE THE PISTON RINGS.


(1) Remove the piston ring using the special tool.
SST: Piston ring expander (09442-1011)

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.

M01020500019

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.

M01020500020

(2) Pull the cylinder liner from the cylinder block using the special
tool.
SST: Puller (09420-1720)

NOTICE:
• Carefully set the special tool to prevent touching to the pis-
ton cooling jet.
• After removing the cylinder liners, arrange them in sequence.

M01020500021

IMPORTANT POINTS - ASSEMBLY

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 (9001-24262)

M01020500022
EN02–38 ENGINE MECHANICAL (J08C)

(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.

M01020500023

(3) Set the special tool on the cylinder block upper surface against
the dowel pin.
SST: Gauge (09444-1630)

(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic
pressure of 196 kPa {2 kgf/cm2, 28 lbf/in2}.

M01020500096

(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.
CAUTION:
• Engine oil is flammable. Carry out this test in a well venti-
lated room and do not use naked lights in the room.

M01020500025

(6) If the center of the jet flow is out of the target circle, realign the
nozzle using the special tool.
SST: Adjusting bar (09472-1620)

M01020500026

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.

M01020500027
ENGINE MECHANICAL (J08C) EN02–39

M01020500028

(1) Apply engine oil to the inner surface of the block bore and insert
the cylinder liner using the special tool.
SST: Guide (09471-1490)

NOTICE:
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)

M01020500029

3. MEASURE THE PROTRUSION AT THE CYLINDER LINER


FLANGE.
SST: Puller (09420-1720)

Tightening Torque:
9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}

Standard 0.01-0.08 mm {0.0004-0.0031 in.}

M01020500030 4. MEASURE THE CRANKSHAFT.


(1) If necessary, grind the crankshaft and use an undersize 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 5.0-5.5 mm {0.1969-0.2165 in.}


NOT "R" SMALL "R" Journal 5.0-5.5 mm {0.1969-0.2165 in.}
STEPPED STEPPED
R

GOOD NOT GOOD

M01020500031
EN02–40 ENGINE MECHANICAL (J08C)

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.

M01020500032

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
replace any bolts not meeting the limit with new ones.

Dimension A 108 mm {4.252 in.}

M01020500033

(3) Apply clean engine oil to the bolt seat and bolt threads.
(4) Tighten the bolts in the order as shown in the figure to the speci-
FRONT fied torque.
Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
2 4 6 8 10 12 14 (5) Loosen all bolts, tap the front and back ends of the crankshaft
1 2 3 4 5 6 7
using a plastic hammer.
1 3 5 7 9 11 13
(6) Tighten the bolts as in step (4).
(7) Mark the bolt heads with paint.

M01020500097

(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.

M01020500035
ENGINE MECHANICAL (J08C) EN02–41

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 (09481-1130)
Press sub-assembly (09402-1530)
Wing nut (9233-10360)

NOTICE:
• Bring lever "H" punched on the guide above the pin.
M01020500036
• Making sure to align both supporting surfaces of the guide
and press sub-assembly flush on a flat plane.

(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.

M01020500037

b. Install the spindle into the bushing.


SST: Spindle (09402-1540)

NOTICE:
Align the groove of the spindle with the groove of the press sub
assembly.

M01020500038

c. Using a hydraulic press, remove the bushing.


NOTICE:
Always operate the press slowly and smoothly.

M01020500039

(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.

M01020500040
EN02–42 ENGINE MECHANICAL (J08C)

(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 (09402-1540)
Guide (09481-1540)
Bolt (9191-08252)

Tightening Torque:
5.0-6.8 N⋅m {50-70 kgf⋅cm, 3.62-5.06 lbf⋅ft} (Bolt)

M01020500041
NOTICE:
• 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.

M01020500042

(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.

M01020500043

8. ASSEMBLE THE PISTON AND CONNECTING ROD.


(1) Heat the piston to 50°C {122°F}.
(2) Assemble the piston O-mark to be opposite to the connecting rod
match mark.
NOTICE:
Replace the retainer ring with a new one.

M01020500018
ENGINE MECHANICAL (J08C) EN02–43

9. ASSEMBLE THE PISTON RING.


(1) Install in the order of oil ring, second ring and top ring using the
special tool.
SST: Piston ring expander (09442-1011)

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.

M01020500044

(3) Position the matching points of the piston ring at a even distance
as shown in the figure.

M01020500045

10. INSTALL THE PISTON.


(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 (09441-1320)

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.

M01020500046

(2) Insert the piston into the cylinder liner.

M01020500047
EN02–44 ENGINE MECHANICAL (J08C)

11. TIGHTEN THE CONNECTING ROD BOLT.


(1) Measure the length of the bolts, if the length is A or more, replace
with new bolts.

Dimension A 82.5 mm {3.248 in.}

(2) Apply clean engine oil to the bolt thread and the nut seat surface
of the connecting rod cap.

M01020500050

(3) Tighten the connecting rod nut to the specified torque.


Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}

(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.
M01020500048

12. INSTALL THE OIL PAN.


(1) Make sure that there is no deformation, impact marks or foreign
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 ANS POSITIONS FOR LIQUID GASKET.
(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)
(3) Place a guide pin of 70 mm or more in the cylinder block and
assemble the oil pan against the guide.
(4) Tighten oil pan fitting bolts in the order 1 - 2 - 3 - 4 with an impact
wrench.
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 arrow in the figure.
NOTICE:
Make sure that the washer is not on the flange.

M01020500049
ENGINE MECHANICAL (J08C) EN02–45

INSPECTION AND REPAIR


M01020501BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Cylinder block flange Measure


8{0.3150} — —
depth

Cylinder liner thickness 8{0.3150} — —

Cylinder liner protru- 0.01-0.08


— —
sion {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 out-
116.990-116.996
side diam- B — —
{4.6059-4.6061}
eter
116.996-117.004
C
{4.6062-4.6064}

0.010-0.026 Reference only


A
Clear- {0.0004-0.0010}
ance
0.012-0.024
between B — —
{0.0005-0.0009}
block and
liner 0.010-0.026
C
{0.0004-0.0010}

Piston outside diame- 113.877 Measure



ter at A:21{0.8267} {4.4833}

Liner inside diameter


(Apply the value
obtained at the most A
114 {4.488} 114.15 {4.494}
worn point to the cylin-
Replace piston and/
der liner inside diame-
or liner.
ter.)

Clearance between pis- 0.115-0.131 {0.0046-



ton and cylinder liner 0.0051}

2.5 Measure
Top 2.4 {0.0945}
{0.0984}

Piston 2.0
Second 1.9 {0.0748} Replace ring.
ring width {0.0787}

4.0
Oil 3.9 {0.1535}
{0.1575}
EN02–46 ENGINE MECHANICAL (J08C)

Inspection item Standard Limit Remedy Inspection procedure

2.5 Measure
Top 2.7 {0.1062}
{0.0984}
Piston
2.0
groove Second 2.2 {0.0866} Replace piston.
{0.0787}
width
4.0
Oil 4.1 {0.1614}
{0.1575}

Clearance 0.09-0.13
Top
between {0.0036-0.0051}
piston
0.04-0.08
ring and Second — — —
{0.0016-0.0031}
piston
ring 0.02-0.06
groove Oil
{0.0008-0.0023}

0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
Gap
between 0.30-0.45
Second 1.2 {0.0472}
ends of {0.0119-0.0177} Replace piston ring.
piston
ring 0.30-0.45 Piston ring
Oil 1.2 {0.0472}
{0.0119-0.0177}

Piston pin outside 37 Measure


36.96 {1.4551} Replace piston pin.
diameter {1.4567}

Piston pin bore inside 37


37.05 {1.4586} Replace piston.
diameter {1.4567}

Clearance between pis-


-0.013-0.014 Replace piston and/
ton pin and piston pin 0.05 {0.0020}
{-0.0005-0.0006} or piston pin.
bore

Measure

Connecting rod bush- 37 Replace connect-


37.1 {1.4606}
ing inside diameter {1.4567} ing rod bushing.

Clearance between pis- Replace piston pin


0.015-0.036
ton pin and connecting 0.08 {0.0031} and/or connecting —
{0.0006-0.0014}
rod bushing rod bushing

Visual check
Wear or damage of con-
necting rod
— — Replace.
*Dye penetrant check
(Color check)
ENGINE MECHANICAL (J08C) EN02–47

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Clogging of connecting
— — Replace.
rod oil hole

More than Measure


0.2 {0.0079} Regrind under size.
Crank pin outside diam- 65 {2.559} (Repair) 90
eter measure
64.3 {2.5314} Replace crankshaft. 2 part
(Service)

Clearance between con-


0.031-0.082 Replace connecting
necting rod bearing and 0.2 {0.0079}
{0.0013-0.0032} rod bearing.
crankpin

Connecting rod large 34 Replace connecting Measure


33.2 {1.3071}
end width {1.339} rod.

34
Crankpin width 34.8 {1.371} Replace crankshaft.
{1.339}

Replace connecting
Connecting rod end 0.20-0.52
1.0 {0.0394} rod and/or crank-
play {0.0079-0.0204}
shaft.

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
0.051-0.102 Replace main bear-
crank journal and main 0.2 {0.0079}
{0.0021-0.0040} ing.
bearing

Center journal width 36 {1.417} 37 {1.456} Replace crankshaft.


Measure
Thrust bearing thick-
2.5 {0.0984} — —
ness

More than
Replace over size
0.5 {0.0197}
0.050-0.219 thrust bearing.
Crankshaft end play (Repair)
{0.0020-0.0086}
1.0 {0.0393}
Replace crankshaft.
(Service)

Measure

Crankshaft deflection — 0.15 {0.0059} Regrind under size.


EN02–48 ENGINE MECHANICAL (J08C)

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Clogging of crankshaft
— — Clean.
oil hole

Visual check

Crack and wear of


crankshaft
— — Replace.
*Dye penetrant check
(Color check)

Measure

Replace.
Cylinder block upper 0.05 {0.0019}
0.20 {0.0080} NOTICE: Do not
surface flatness or less
grind for repair.
AIR INTAKE SYSTEM (J08C) EN03–1

AIR INTAKE SYSTEM (J08C)


EN03

EN03-001

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


COMPONENT LOCATOR................................ EN03-2
DISMOUNTING AND MOUNTING .................. EN03-2
EN03–2 AIR INTAKE SYSTEM (J08C)

AIR INTAKE MANIFOLD AND PIPE


COMPONENT LOCATOR
M01030101BED1001

M01030100003

1 Intake manifold gasket 4 Intake pipe gasket


2 Intake manifold 5 Boost compensator pipe
3 Intake pipe

DISMOUNTING AND MOUNTING


M01030101BEH1001

IMPORTANT POINT - MOUNTING

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.

M01030100002
EXHAUST SYSTEM (J08C) EN04–1

EXHAUST SYSTEM (J08C)


EN04

EN04-001

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


COMPONENT LOCATOR................................ EN04-2
DISMOUNTING AND MOUNTING .................. EN04-3
EN04–2 EXHAUST SYSTEM (J08C)

EXHAUST MANIFOLD AND PIPE


COMPONENT LOCATOR
M01040101BED1001

M01040100004

1 Heat insulator 8 Hose


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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 53 {540, 39} C 56 {570, 41}
B 61 {620, 44}
EXHAUST SYSTEM (J08C) EN04–3

DISMOUNTING AND MOUNTING


M01040101BEH1001

IMPORTANT POINT - 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.

M01040100002

2. INSTALL THE EXHAUSTMANIFOLD.


(1) Install the exhaust manifold onto the cylinder head and tighten the
inner mounting nut in the order shown in the figure to the specified
torque.
Tightening Torque:
53 N⋅m {540 kgf⋅cm, 39 lbf⋅ft}
(2) Tighten the same nuts according to the same procedure again.
NOTICE:
Be sure to carry out the procedure.
(3) Tighten the outer mounting nut, while in the order shown in the
figure to the specified torque below.
Tightening Torque:
61 N⋅m {620 kgf⋅cm, 45 lbf⋅ft}

NOTICE:
Be sure to hold the inner nut when tightening the outer nut.

M01040100005
LUBRICATING SYSTEM (J08C) EN05–1

LUBRICATING SYSTEM (J08C)


EN05

EN05-001

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


DIAGRAM ........................................................ EN05-2

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


COMPONENT LOCATOR................................ EN05-4
OVERHAUL ..................................................... EN05-4
INSPECTION AND REPAIR ............................ EN05-5

OIL FILTER AND OIL COOLER ............... EN05-6


COMPONENT LOCATOR................................ EN05-6
SPECIAL TOOL ............................................... EN05-7
DISMOUNTING AND MOUNTING .................. EN05-7
INSPECTION AND REPAIR ............................ EN05-8
EN05–2 LUBRICATING SYSTEM (J08C)

LUBRICATING SYSTEM
DIAGRAM
M01050101BEJ1001

M01050100003
LUBRICATING SYSTEM (J08C) EN05–3

1 Oil pan 14 Crankshaft


2 Oil strainer 15 Piston
3 Oil pump 16 Valve rocker shaft
4 Oil pump safety valve 17 Camshaft
1,648-1,746 {16.8-17.8, 239-253} 18 Valve
5 Oil cooler and oil filter 19 Rocker arm
6 Oil cooler safety valve 20 Cross head
352-432 {3.6-4.4, 52-62} 21 Fuel injection pump
7 Oil filter (full flow) 22 Air compressor
8 Oil filter (by-pass) 23 Main idle gear
9 Pressure switch 24 Cam idle gear
10 Oil filter safety valve 25 Sub idle gear
176-216 {1.8-2.2, 26-31} 26 Check valve
11 Regulator valve 245 {2.5, 36}
490-570 {5.0-5.8, 72-82} 27 Check valve for turbocharger
12 Main oil hole 28 Turbocharger
13 Piston cooling jet A To oil pan
2 2
Unit: kPa {kgf/cm , lbf/in. }.
EN05–4 LUBRICATING SYSTEM (J08C)

OIL PUMP AND OIL STRAINER


COMPONENT LOCATOR
M01050201BED1001

M01050200001

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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 28.4 {290, 21} B 31 {320, 23}

OVERHAUL
M01050201BEH2001

IMPORTANT POINTS - ASSEMBLY

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
M01050200002
shown in the figure. Tighten them to the specified torque.
LUBRICATING SYSTEM (J08C) EN05–5

INSPECTION AND REPAIR


M01050201BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

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

0.049-0.113 Replace gear or


End play 0.15 {0.0059}
{0.0020-0.0044} pump.

Shaft out- Measure


side diam- 18 {0.709} — —
eter

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

0.040-0.099
Clearance — —
{0.0016-0.0038}

Shaft out- Measure


side diam- 18 {0.709} — —
eter

Block hole
18 {0.709} — —
diameter

0.030-0.075
Clearance — —
Driven {0.0012-0.0029}
gear
Gear bush-
ing inside 18 {0.709} — —
diameter

0.040-0.083
Clearance 0.15 {0.0059} Replace gear.
{0.0016-0.0032}

Measure

0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0081}
EN05–6 LUBRICATING SYSTEM (J08C)

OIL FILTER AND OIL COOLER


COMPONENT LOCATOR
M01050301BED1001

M01050300001

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
LUBRICATING SYSTEM (J08C) EN05–7

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


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
M01050301BEK1001

Prior to starting an engine overhaul, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

09503-1090 OIL FILTER WRENCH

DISMOUNTING AND MOUNTING


M01050301BEH2001

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE OIL FILTER.


(1) Remove the drain plug from bottom of the oil filter and drain the
engine oil.

M01050300003

(2) Using the special tool, remove the oil filter.


SST: Oil filter wrench (09503-1090)

NOTICE:
Make sure that O-rings are not on the oil cooler case side.

M01050300004
EN05–8 LUBRICATING SYSTEM (J08C)

IMPORTANT POINT - MOUNTING

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 (09503-1090)

NOTICE:
M01050300005 • 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 installa-
tion.

(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:
28.4 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}

M01050300006

INSPECTION AND REPAIR


M01050301BEH3001

Inspection item Standard Limit Remedy Inspection procedure

Oil cooler air leakage Visual check


Replace, if neces-
Air pressure: 588 kPa {6 0 mL —
sary.
kgf/cm2, 85 lbf/in.2}

1. Damage to sliding
Wear or damage to
Replace, if neces- face of valve
valve spring of oil — —
sary. 2. Valve movement
cooler and oil filter
(smoothness)
COOLING SYSTEM (J08C) EN06–1

COOLING SYSTEM (J08C)


EN06

EN06-001

COOLING SYSTEM .................................. EN06-2


DIAGRAM ........................................................ EN06-2

COOLANT PUMP...................................... EN06-3


COMPONENT LOCATOR................................ EN06-3
SPECIAL TOOL ............................................... EN06-4
OVERHAUL ..................................................... EN06-4
INSPECTION AND REPAIR ............................ EN06-7

THERMOSTAT .......................................... EN06-8


COMPONENT LOCATOR................................ EN06-8
OVERHAUL ..................................................... EN06-8

RADIATOR .............................................. EN06-10


COMPONENT LOCATOR.............................. EN06-10
SPECIAL TOOL ............................................. EN06-11
OVERHAUL ................................................... EN06-11
INSPECTION AND REPAIR .......................... EN06-14

COOLING FAN........................................ EN06-15


COMPONENT LOCATOR.............................. EN06-15
INSPECTION AND REPAIR .......................... EN06-16
EN06–2 COOLING SYSTEM (J08C)

COOLING SYSTEM
DIAGRAM
M01060101BEJ1001

1
4

2
5

11

3 12
10
7 9

8 13

14 14

M01060100001

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
COOLING SYSTEM (J08C) EN06–3

COOLANT PUMP
COMPONENT LOCATOR
M01060201BED1001

M01060200028

1 Thermostat case 7 Pulley center


2 Cooling fan 8 Retainer ring
3 Fan clutch 9 Coolant shaft
4 Fan pulley spacer 10 Pump case
5 O-ring 11 Coolant seal
6 Coolant pump assembly 12 Vane
EN06–4 COOLING SYSTEM (J08C)

SPECIAL TOOL
M01060201BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1810 PULLER

09420-1820 PULLER

OVERHAUL
M01060201BEH2001

IMPORTANT POINTS - DISASSEMBLY

1. DISASSEMBLE THE COOLANT PUMP.


(1) Remove the vane from the shaft using the special tool.
SST: Puller (09420 - 1820)

M01060200002

(2) Remove the pulley center from the shaft using the special tool.
SST: Puller (09420 - 1810)

M01060200003

(3) Remove the retainer ring from the pump case using snap ring pli-
ers.

M01060200004
COOLING SYSTEM (J08C) EN06–5

(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.

M01060200005

(5) Remove the coolant seal from the pump case using a hammer
and brass bar.
CAUTION:
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.

M01060200006

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE COOLANT PUMP.


(1) Install the coolant shaft onto the pump case using a hydraulic
press.
Assembly standard (A): 5.9-6.1 mm {0.2323-0.2401 in}
NOTICE:
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.

M01060200007

(2) Install the retainer ring onto the pump case using snap ring pliers.

M01060200004

(3) Install the pulley center onto the shaft using a hydraulic press.
Standard: 129.0 - 129.8 mm {5.079 - 5.110 in.} from the
pulley center mounting surface to the pump
case end surface

M01060200008
EN06–6 COOLING SYSTEM (J08C)

(4) Install the new coolant seal.


a. Apply liquid gasket (Three Bond #1104 or equivalent) to the
seal outer circumference and case bore.
b. Install the slinger and seal to the case using a press.

M01060200009

c. Install the seal to the vane.


NOTICE:
Replace the coolant seal with new one.

M01060200010

(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.

M01060200011
COOLING SYSTEM (J08C) EN06–7

INSPECTION AND REPAIR


M01060201BEH3001

Unit: mm {in.}

Inspection item Standard LImit Remedy Inspection procedure

Visual check

Wear, damage and cor-


— — Replace parts.
rosion

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.
EN06–8 COOLING SYSTEM (J08C)

THERMOSTAT
COMPONENT LOCATOR
M01060301BED1001

M01060300010

1 Thermostat case assembly 4 Thermostat case


2 Thermostat case cover 5 Thermostat
3 O-ring 6 Gasket

OVERHAUL
M01060301BEH2001

IMPORTANT POINTS - INSPECTION AND REPAIR

1. INSPECT THE THERMOSTAT FUNCTION.


(1) Place the thermostat in hot water and check the valve opening
temperature and the valve lift.
Thermostat valve opening temperature:
Thermostat valve opening tem-
Service standard
perture. (T1)
82°C {180°F} 80-84°C {176-183°F}

M01060300002
NOTICE:
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
COOLING SYSTEM (J08C) EN06–9

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

(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.

M01060300003

IMPORTANT POINTS - ASSEMBLY

JIGGLE VALVE
1. ASSEMBLE THE THERMOSTAT CASE.
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
amount of liquid gasket.
M01060300004
• Be sure that the jiggle valve faces upward when installing it.

IMPORTANT POINTS - MOUNTING

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.

M01060300005

(3) Temporarily tighten the bolts "1" and bolts "2" in that order, and
securely contact the fitting surface.
"2"
(4) Tighten the bolts in numeral order.

"1"

M01060300006
EN06–10 COOLING SYSTEM (J08C)

RADIATOR
COMPONENT LOCATOR
M01060401BED1001

M01060400018

1 Radiator cap 7 Drain plug


2 Upper tank 8 Lower tank
3 O-ring 9 O-ring
4 Coolant level switch 10 Distance piece
5 Radiator core 11 Radiator fitting cushion
6 Left support 12 Right support

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 6-7 {62-71, 4.5-5.1}
COOLING SYSTEM (J08C) EN06–11

SPECIAL TOOL
M01060401BEK10001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09760-1030 RADIATOR TOOL TOOL FOR UNCAULKING

TOOL FOR CAULKING


09760-1040 RADIATOR TOOL
(USED WITH 09760-1030)

OVERHAUL
M010604BEH2001

IMPORTANT POINTS - DISMOUNTING

1. DISMOUNT THE RADIATOR.


CAUTION:
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.

IMPORTANT POINTS - DISASSEMBLY


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.

M01060400002

(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 (09760-1030)

NOTICE:
Be sure to adjust the dimension to prevent damage of the crow.

M01060400003
EN06–12 COOLING SYSTEM (J08C)

(3) Using a special tool, lift the staked part.


NOTICE:
Do not lift up tangs more than 90°.

M01060400004

(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.

M01060400005

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIA-


TOR CORE.
(1) Exchange the crow of the radiator tool (09760-1030) for the radia-
tor tool (09760-1040) as shown in the figure.
SST:
Radiator tool (09760-1030)
Radiator tool (09760-1040)

M01060400006

(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.}

M01060400007

(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.

M01060400008
COOLING SYSTEM (J08C) EN06–13

(5) Frap the tangs to obtain a tight contact with the upper tank and
lower tank.

M01060400009

(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.

M01060400010

NOTICE:
Perform the caulking according to the sequence as shown in the
figure.

M01060400011

(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.

M01060400012
EN06–14 COOLING SYSTEM (J08C)

INSPECTION AND REPAIR


M01060401BEH3001

Unit:MPa {kgf/cm2, lbf/in.2}

Inspection item Standard Limit Remedy Inspection procedure

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}

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 clogging, do not apply excessive pressure to the
fins which may cause deformation and consequent performance deterioration.
COOLING SYSTEM (J08C) EN06–15

COOLING FAN
COMPONENT LOCATOR
M01060601BED1001

M01060600006

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 care not to apply excessive force particular.
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.
EN06–16 COOLING SYSTEM (J08C)

INSPECTION AND REPAIR


M01060601BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Cooling fan and fan clutch Replace if neces-


— —
deformation and damage sary.
FUEL SYSTEM (J08C) EN07–1

FUEL SYSTEM (J08C)


EN07

EN07-001

FUEL SYSTEM.......................................... EN07-2


DIAGRAM ........................................................ EN07-2
DESCRIPTION ................................................ EN07-3
SPECIAL TOOL ............................................... EN07-4
OVERHAUL ..................................................... EN07-4

INJECTION NOZZLE
(TWO-SPRING TYPE - BOSCH MAKE)... EN07-7
DESCRIPTION ................................................ EN07-7
COMPONENT LOCATOR................................ EN07-8
SPECIAL TOOL ............................................... EN07-9
OVERHAUL ................................................... EN07-10
EN07–2 FUEL SYSTEM (J08C)

FUEL SYSTEM
DIAGRAM
M01070101BEJ1001

M01070100001

1 Return pipe 5 Feed pump


2 Injection nozzle 6 Fuel filter
3 Through feed pipe 7 Injection pipe
4 Fuel tank
FUEL SYSTEM (J08C) EN07–3

DESCRIPTION
M01070101BEC1001

M01070100019

1 Injection nozzle 3 Fuel injection pump


2 Fuel filter

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 14.5 {148, 11} C 25 {250}
B 34 {350, 25}
EN07–4 FUEL SYSTEM (J08C)

SPECIAL TOOL
M01070101BEK1001

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09503-1040 FUEL FILTER WRENCH

INJECTION PUMP COUPLING


09511-2500
WRENCH

09515-2470 WRENCH

NOTICE:
BOSCH: BOSCH AUTOMOTIVE SYSTEMS CORPORATION

OVERHAUL
M01070101BEH2001

IMPORTANT POINTS - DISMOUNTING

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.
SST: Injection pump coupling wrench (09511-2500)
(3) Remove the injection pump mounting bolt and dismount the
pump.
SST: Wrench (09515-2470)
M01070100006
NOTICE:
After dismounting the pump, cover the pump and high pressure
pipe to prevent entry of dirt.

IMPORTANT POINTS - MOUNTING

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.

M01070100007
FUEL SYSTEM (J08C) EN07–5

(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.

M01070100008

(3) Tighten the injection pump mounting bolt evenly to the torque
below.
SST: Wrench (09515-2470)

Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}

M01070100009

(4) Tighten the adjusting bolt using the special tool.


SST: Injection pump coupling wrench (09511-2500)
Tightening Torque:
88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}

(5) Tighten the through bolt at the flange.


Tightening Torque:
88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}

(6) Install pipes and engine control cables.


NOTICE:
M01010100014
Cylinder numbers are stamped on the flare nuts at the pump side
of the injection pipe.

IMPORTANT POINTS - REPLACEMENT

1. REMOVE THE FUEL FILTER.


(1) Remove the fuel filter using the special tool.
SST: Fuel filter wrench (09503-1040)

M01070100015
EN07–6 FUEL SYSTEM (J08C)

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 (09503-1040)

NOTICE:
• Do not reuse the element.
• Be careful not to damage the gasket.
M01070100016

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}
M01070100017
NOTICE:
The bleeder plug should be tightened while the priming pump
knob is operated.
(5) Once again, operate the priming pump knob several times.
(6) Push back the priming pump knob and tighten it.
NOTICE:
Wipe up any splashed fuel.
FUEL SYSTEM (J08C) EN07–7

INJECTION NOZZLE(TWO-SPRING TYPE - BOSCH MAKE)


DESCRIPTION
M01070201BEC1002

M01070200026

1 Joint bolt 10 Second pressure spring


2 Gasket 11 Second pressure spring seat
3 Cap nut 12 Lift piece
4 Gasket 13 Spacer
5 Adjusting screw 14 Nozzle assembly
6 First pressure spring 15 Retaining nut
7 Push rod 16 Pre lift (L')
8 Nozzle holder 17 Valve lift (L)
9 Second pressure adjusting shim
EN07–8 FUEL SYSTEM (J08C)

COMPONENT LOCATOR
M01070201BED1002

M01070200027

1 Joint bolt 8 Nozzle holder


2 Gasket 9 Second pressure adjusting shim
3 Cap nut 10 Second pressure spring
4 Gasket 11 Second pressure spring seat
5 Adjusting screw 12 Nozzle assembly
6 First pressure spring 13 Retaining nut
7 Push rod

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 14.5 {148, 11} C 68.5 {700, 51}
B 44 {450, 33}
FUEL SYSTEM (J08C) EN07–9

SPECIAL TOOL
M01070201BEK1002

Prior to starting an engine overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

For SUB AND CAM IDLE


09420-1442 IDLE GEAR SLIDING HAMMER
GEAR

09462-1130 NOZZLE HOLDER ADAPTER Used with 09420-1442

Length (L)
157892-4620 157892-4200: 160 mm {6.300
NOTICE: It is BOSCH TOOL SET in}
product number that NOTICE: BOSCH product tool 157892-4300: 110 mm {4.331
mentioned part num- set in}
ber.
EN07–10 FUEL SYSTEM (J08C)

OVERHAUL
M01070201BEH2002

IMPORTANT POINTS - DISMOUNTING

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.
M01070200007 (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 (09420-1442)
Adapter (09462-1130)

(3) Remove the O-ring.


NOTICE:
Replace the O-ring with a new one.

M01070200008

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.

M01070200009
FUEL SYSTEM (J08C) EN07–11

(2) Operate the lever at the rate of 50 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 : 18.1-18.9 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}

M01070200010

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.

M01070200011

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.

M01070200012

IMPORTANT POINTS - DISASSEMBLY

1. REMOVE THE RETAINING NUT.


NOTICE:
To prevent dropping parts, face the nozzle holder toward the
retaining nut side.

M01070200013
EN07–12 FUEL SYSTEM (J08C)

IMPORTANT POINTS - 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.
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.
M01070200014
NOTICE:
When assembling, you must reinstall the same parts in the same
nozzle holder. Do not mix them up.

IMPORTANT POINTS - ASSEMBLY


NOTICE:
• The steps below for adjustment are made during parts
assembly.
• Because the nozzle holder is adjusted 1/100 mm units, it
must be thoroughly washed to remove all dirt and foreign
objects.

Work steps

1. Adjustment of first opening pressure Adjust first opening pressure with the adjusting screw.

2. Checking of needle valve full-lifts Check with nozzle cover method.

Check with nozzle cover method.


NOTICE: If pre- lift is not within specified value, replace
3. Checking of pre-lift
pins, lift piece, spacer and nozzle assembly with the
nozzle service kit.

4. Checking of second opening pressure Check with nozzle cover method.

5. Adjusting of second opening pressure Adjust second opening pressure with adjusting shim.

Replace adjustable retaining nut with normal retaining


6. Replacement of the retaining nut
nut.

Check condition of the fuel spray with the nozzle and


7. Final inspection
nozzle holder assembly.

1. ADJUSTMENT OF THE FIRST OPENING PRESSURE


(WORK STEP1.)
(1) Install the adjusting shim, second pressure spring and spring seat
into the nozzle holder.
NOTICE:
The second pressure spring is the same as the first pressure
spring.
(2) Install the pins, lift piece, spacer and nozzle onto the nozzle
holder.

M01070200031
FUEL SYSTEM (J08C) EN07–13

(3) Put the gasket (special tool) onto the nozzle, then use the adjust-
able retaining nut (special tool) to holder the nozzle in place on
the nozzle holder.
SST:
Gasket (157892-1500)
Adjustable retaining nut (157892-4000)

Tightening Torque:
68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
NOTICE:
• Make sure that the pin is all the way in the nozzle and then
M01070200032 tighten adjustable retaining nut.
• Finger-tighten the adjustable retaining nut until it no longer
turns and tighten the nut to specified torque.
(4) Install the push rod, first pressure spring and first pressure adjust-
ing screw into the nozzle holder.
(5) Install the gasket and cap nut onto the first pressure adjusting
screw.

M01070200033

(6) Attach the nozzle holder assembly to the nozzle tester.

M01070200034

(7) Adjusting the first opening pressure to the specified value with the
first pressure adjusting screw.
First opening pressure
With new parts : 18.1-18.9 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}

M01070200035

(8) Holder the nozzle holder body using a adjustable wrench, then
tighten the cap nut to the specified torque.
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 33 lbf⋅ft}

M01070200036
EN07–14 FUEL SYSTEM (J08C)

2. CHECKING OF THE NEEDLE VALVE FULL-LIFTS


(WORK STEP 2.)
(1) Attach the gasket (special tool) and the plug (special tool) onto the
adjustable retaining nut.
SST:
Gasket (026508-1140)
Plug (157892-1600)

M01070200037

(2) Turn the nozzle holder body so that the cap side facing upward.
(3) Attach the holder (special tool) to the cap nut.
SST: Holder (157892-4400)

(4) Temporarily tighten the attachment nut (special tool) onto the
holder.
SST: Nut (157892-1000)

M01070200038

(5) Screw the pin (special tool) into the dial gauge.
SST: Pin (157892-4200 or 157892-4300)

M01070200039
FUEL SYSTEM (J08C) EN07–15

(6) Tighten the nut so that it holds the dial gauge in place in the noz-
zle holder assembly and so that the pin is in contact with the push
rod upper surface.
NOTICE:
• Attach the dial gauge into place so that it can measure a
stroke of approx. 2 mm {0.079 in.}.
• Do not tighten the nut too much, or the dial gauge shaft will
be stuck.

M01070200040

(7) Attach the nozzle holder assembly to the nozzle tester and adjust
the dial gauge to zero.
(8) Operate the nozzle tester to bleed air in the adjustable retaining
nut. Make sure that there are no fuel leaks.

M01070200041

(9) Operate the nozzle tester to raise pressure to 34.3-44.1 MPa


{350-450 kgf/cm2, 4,979-6,400 lbf/in.2} and check the needle
valve lift fully. At this time, record the dimensions of full-lifts as "L".
NOTICE:
This check is made to determine whether the nozzle seat is abnor-
mally worn or not and whether the nozzle is correctly assembled
or not.

M01070200042

3. CHECKING OF THE PRE-LIFT (WORK STEP 3.)


(1) When the needle value is full-lifted, release the nozzle tester han-
dle to lower pressure inside the tube so that decrease the needle
valve lift value (value indicated on dial gauge).

M01070200043
EN07–16 FUEL SYSTEM (J08C)

(2) When the second pressure spring stop to action and the needle
valve drop ends (the needle valve lift dimension "L'" ) read the dial
gauge indication, make sure it is within specified values.

M01070200044

Pre-lift measuring points:


Read the dial gauge at [First opening pressure + approx.1 MPa
{10 kgf/cm2, 142 lbf/in.2}].
NOTICE:
Watch the pressure decrease to find the point.
Pre-lift (L'): 0.055 mm {0.0022 in.}

M01070200045

(3) If pre-lift is not within the specified value, replace the pins, the lift
piece, the spacer and the nozzle assembly with the nozzle service
kit.

M01070200046

4. CHECKING OF THE SECOND OPENING PRESSURE


(WORK STEP 4.)
(1) Check the pre-lift, then operate the nozzle tester to raise pressure
to 34.3-44.1 Mpa {350-450 kgf/cm2, 4,979-6,400 lbf/in.2} and lift
the needle valve fully.
(2) Release the nozzle tester handle to lower pressure inside the
tube, all the while watch the dial gauge indicate.

M01070200047
FUEL SYSTEM (J08C) EN07–17

(3) Read the value indicated on the pressure gauge at the instant the
dial gauge needle indicates the specified needle valve lift value
(pre-lift " L' " + 0.05 mm {0.0020 in.}).
Second opening pressure
With new parts : 22.1-23.1 MPa {225-235 kgf/cm2,
3,200-3,341 lbf/in.2}
With reused parts : 21.6-22.6 MPa {220-230 kgf/cm2,
3,129-3,270 lbf/in.2}

M01070200048

5. ADJUSTING OF THE SECOND OPENING PRESSURE


(WORK STEP 5.)
(1) If the second opening pressure deviates from the specified value,
and the amount of that deviation is small, readjust the first open-
ing pressure within the specified value.
NOTICE:
• If the second opening pressure is lower than the specified
value, readjust the first opening pressure to maximum speci-
fied value, then measure the second opening pressure.
• If the second opening pressure is higher than the specified
value, readjust the first opening pressure to minimum speci-
M01070200049 fied value.

(2) If the first opening pressure has been readjusted and the second
opening pressure still deviates from the specified value, disas-
semble the nozzle side of the nozzle holder and remove the
adjusting shim.
(3) If the second opening pressure is higher than the specified value,
replace the adjusting shim with a thinner one.
(4) After replacing the adjusting shim, remeasure the second opening
pressure, and adjust the pressure until it comes to the specified
value.

Second opening pressure adjusting shim line-up


M01070200050 Unit:mm {in.}
Parts number Shim thickness
22882-2850 0.40 {0.0157}
22882-2860 0.50 {0.0197}
22882-2870 0.52 {0.0205}
22882-2880 0.54 {0.0213}
22882-2890 0.56 {0.0220}
22882-2900 0.58 {0.0228}
22882-2910 0.60 {0.0236}
22882-2920 0.70 {0.0276}
EN07–18 FUEL SYSTEM (J08C)

6. REPLACEMENT OF THE RETAINIG NUT (WORK STEP 6.)


(1) Remove the dial gauge, the nut, the holder and the gasket from
the cap nut.
(2) Remove the adjustable retaining nut and the gasket, and attach a
normal retaining nut.
Tightening Torque:
68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}

M01070200051

7. FAINAL INSPECTION (WORK STEP 7.)


(1) Attach the nozzle holder to the nozzle tester and check the first
opening pressure, the spray condition, the seat's oil seal, and
whether are any oil leaks from any part.

M01070200009

(2) To replace the nozzle, the lift piece, and the spacer, which are all
in one set, with the nozzle service kit.
NOTICE:
Replacing only the nozzle will cause the amount of pre-lift deviate
from the specified value.

M01070200052
FUEL SYSTEM (J08C) EN07–19

IMPORTANT POINT - MOUNTING

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
M01070200025
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.


TURBOCHARGER (J08C) EN08–1

TURBOCHARGER (J08C)
EN08

EN08-001

TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING ..................................... EN08-3
SPECIAL TOOL ............................................. EN08-11
OVERHAUL CRITERIA.................................. EN08-12
COMPONENT LOCATOR.............................. EN08-14
EN08–2 TURBOCHARGER (J08C)

TURBOCHARGER
DESCRIPTION
M01080101BEC1001

M01080100001

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 Backplate
9 Hose 21 Compressor wheel
10 Hose clamp 22 O-ring
11 Rod end 23 Turbine wheel assembly
12 Retaining nut 24 Wheel shroud
TURBOCHARGER (J08C) EN08–3

TROUBLESHOOTING
M01080101BEF3001

1. Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke

M01080100002

*Shown on Table 1-9


EN08–4 TURBOCHARGER (J08C)

2. Table 1-2. Troubleshooting - Engine Exhaust Emits Blue Smoke

M01080100003

*Shown on Table 1-9


TURBOCHARGER (J08C) EN08–5

3. Table 1-3 Troubleshooting - Engine Oil Consumption Excessive

M01080100004
EN08–6 TURBOCHARGER (J08C)

4. Table 1-4. Troubleshooting - Noisy Turbocharger

M01080100005

*Shown on Table 1-9


TURBOCHARGER (J08C) EN08–7

5. Table 1-5. Troubleshooting - Turbocharger Rotating Assembly Binding or Dragging

M01080100006

*Shown on Table 1-9


EN08–8 TURBOCHARGER (J08C)

6. Table 1-6. Troubleshooting - Seal Leakage at Compressor End of Turbocharger

M01080100007
TURBOCHARGER (J08C) EN08–9

7. Table 1-7. Troubleshooting - Seal Leakage at Turbine End of Turbocharger

M01080100008
EN08–10 TURBOCHARGER (J08C)

8. Table 1-8. Troubleshooting - Turbocharger Bearings, Bores, or Journals are Worn

M01080100009

*Overhaul turbocharger, then use this table to determine cause of failure.


TURBOCHARGER (J08C) EN08–11

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 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 proce-
dure. If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that
the turbocharger is serviceable.

SPECIAL TOOL
M01080101BEK1001

Prior to starting a turbocharger overhaul, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

For measuring the turbine


09444-1130 END PLAY GAUGE shaft end play with a dial
gauge.
EN08–12 TURBOCHARGER (J08C)

OVERHAUL CRITERIA
M01080101BEH3001

1. CONDITION WHICH DETERMINE WHEN A TURBOCHARGER


OVERHAUL MAY BE NEEDED ON ENGINE TROUBLESHOOT-
ING.
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 INSTALLA-


TION.
CAUTION:
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.
CAUTION:
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 foreing
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
M01080100011
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
deposits on the wheel are heavy the turbocharger should be
disassembled, 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.
TURBOCHARGER (J08C) EN08–13

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.
(1) Wheel to housing rub
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.
M01080100012
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.
(3) Foreign object damage
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.

M01080100013

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 (09444-1130)

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.

M01080100014

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:
M01080100015
Parts No. Air pressure: kPa {mmHg, inHg}
24100-3251 130-136 {975-1,025, 39-40}
EN08–14 TURBOCHARGER (J08C)

(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.
NOTICE:
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.
ALTERNATOR (J08C: 24V-50A) EN11–1

ALTERNATOR (J08C: 24V-50A)


EN1

EN11-001

ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS ......................... EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING ..................................... EN11-4
COMPONENT LOCATOR................................ EN11-5
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-14
EN11–2 ALTERNATOR (J08C: 24V-50A)

ALTERNATOR
DATA AND SPECIFICATIONS
M01110101BEI2001

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
M01110101BEC1001

M01110100001

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
ALTERNATOR (J08C: 24V-50A) EN11–3

CIRCUIT

3 8
B
10
L
7
R

P
9
5
6 11

M01110100002

1 Alternator 7 Charge warning lamp


2 Condenser 8 Fuse
3 Diode 9 Starter switch
4 Stator coil 10 Load
5 Field coil 11 Battery
6 IC Regulator
EN11–4 ALTERNATOR (J08C: 24V-50A)

TROUBLESHOOTING
M01110101BEF3001

Symptom Possible cause Remedy/Prevention


Charging current does not flow I.C. regulator faulty Replace I.C. regulator.
(Lamp does not light) Stator coil faulty (Disconnecting or Replace stator coil.
rare 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.
(Lamp does 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.
(Lamp does not light)
Charging current is always insuffi- Stator coil faulty Replace stator coil.
cient (Battery goes dead) (Lamp Diode faulty (open or short circuit) Replace rectifier holder.
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) (Lamp remains Installation of support)
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.
ALTERNATOR (J08C: 24V-50A) EN11–5

COMPONENT LOCATOR
M01110101BED1001

M01110100040

1 Brace 4 Bracket
2 Harness 5 V-bolt
3 Alternator 6 Strap band

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 5.9 {60, 4.3} C 3.3-4.4 {33-45, 2.4-3.2}
B 51 {520, 38} D 83 {850, 61}
EN11–6 ALTERNATOR (J08C: 24V-50A)

M01110100003

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
10 Lead wire connector 22 Pulley
11 Rectifier end frame 23 Lock nut
12 Through bolt

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 3.2-4.4 {33-45, 2.4-3.2} E 2.9-3.9 {30-40, 2.2-2.8}
B 3.9-4.9 {40-50, 2.9-3.6} 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}
ALTERNATOR (J08C: 24V-50A) EN11–7

SPECIAL TOOL
M01110101BEK1001

Prior to starting a alternator overhaul, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

09444-1210 COMPRESSION GAUGE

OVERHAUL
M01110101BEH2001

IMPORTANT POINTS - MOUNTING


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 98N {10 kgf} by pressing the measuring
ADJUSTING
BOLT
point A.
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 (09444-1210)
PULLE Y
THROUGH BOLT Standard: 8-10 mm {0.314-0.394 in.}
M01110100046
NOTICE:
• 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.

IMPORTANT POINTS - DISASSEMBLY

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.

M01110100004

(2) Remove the bolt and clamp.

M01110100005
EN11–8 ALTERNATOR (J08C: 24V-50A)

(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.

M01110100006

2. REMOVE THE ROTOR.


(1) Remove the pulley lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.

(2) Remove the pulley and fan.

M01110100007

(3) Remove the rotor from drive end frame, using a press.
NOTICE:
Hold rotor by hand so that it will not fall off.

M01110100008

3. REMOVE THE FRONT BALL BEARING.


(1) Remove the retainer plate.

M01110100009

(2) Using a press, remove the ball bearing.


NOTICE:
Attach the jig to inner race of the ball bearing and remove bearing,
using a press.

M01110100010
ALTERNATOR (J08C: 24V-50A) EN11–9

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 dis-
connect stator lead wires.

M01110100011

(2) Remove the stator from the rectifier end frame.

M01110100012

5. REMOVE THE RECTIFIER HOLDER, REGULATOR AND FIELD


COIL.
(1) Unsolder lead wire from field coil.

M01110100013

(2) Remove the rectifier holder, regulator and condenser.

M01110100015

(3) Loosen the "B" terminal nut.

M01110100014
EN11–10 ALTERNATOR (J08C: 24V-50A)

(4) Remove the field coil.

M01110100016

6. REMOVE THE ROLLER BEARING.


NOTICE:
Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.

M01110100017

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE ROTOR.


(1) Using a press and a jig, install the ball bearing into the drive end
frame.
NOTICE:
Attach the jig on the outer race of the ball bearing.

M01110100018

(2) Install the retainer plate.

M01110100009
ALTERNATOR (J08C: 24V-50A) EN11–11

(3) Using a press, install the rotor.


NOTICE:
Take care not to damage the rotor shaft.

M01110100019

(4) Install the space collar, fan and pulley, tighten the lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.

M01110100020

2. INSTALL THE ROLLER BEARING.


(1) Using a press, jig A and jig B, install the roller bearing into the rec-
tifier end frame.
NOTICE:
Press fit until jig A hits to the rectifier end frame.

M01110100021

3. INSTALL THE FIELD COIL, REGULATOR AND RECTIFIER


HOLDER.
(1) Install the field coil to the rectifier end frame.
NOTICE:
Tighten the bolt evenly.

M01110100022
EN11–12 ALTERNATOR (J08C: 24V-50A)

(2) Refer to " COMPONENT LOCATOR ", then install the each parts.

M01110100023

(3) Install the stator coil to the rectifier end frame.


NOTICE:
Do not damage the stator coil.

M01110100024

(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.
(5) Install the condenser.

M01110100025

(6) Tighten the inner nut of the B terminal.

M01110100026

4. ASSEMBLE THE RECTIFIER END FRAME AND DRIVE END


FRAME.
(1) Assemble the rectifier end frame and drive end frame with the
through bolts.
NOTICE:
Tighten the through bolt evenly.

M01110100027
ALTERNATOR (J08C: 24V-50A) EN11–13

(2) Install the cover.

M01110100028

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


(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.
M01110100029
Standard voltage: 28.0-29.0V
EN11–14 ALTERNATOR (J08C: 24V-50A)

INSPECTION AND REPAIR


M01110101BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure

Resistance of field coil


6.75-7.45Ω — Replace.
[at 20°C (68°F)]

Measure

Insulation resistance of
1MΩ 0.5MΩ or less Replace.
field coil

Measure

Resistance of stator
0.247-0.273Ω — Replace.
coil [at 20°C (68°F)]

Measure

Insulation resistance of
1MΩ or more 0.5MΩ or less Replace.
stator

Measure

Normal direction
7-10Ω
Resistance of diode — Replace.
Reverse direction
∞Ω

Measure

Rotor shaft outside


diameter (front bearing 25 {0.984} 24.98 {0.984} Replace.
portion)

Measure

Rotor shaft outside


diameter (rear bearing 17 {0.669} 16.98 {0.669} Replace.
portion)
ALTERNATOR (J08C: 24V-50A) EN11–15

Inspection item Standard Limit Remedy Inspection procedure

Measure

Drive end frame bearing


62 {2.441} 62.1 {2.445} Replace.
bore inside diameter

Measure

Rectifier end frame


bearing bore inside 23.8 {0.937} 23.81 {0.937} Replace.
diameter

Visual check

Rotates smoothly Replace.


Bearing wear or dam-
with no abnormal — Also, replace every 2
age
noise years.
ALTERNATOR (J08C: 24V-80A) EN11–1

ALTERNATOR (J08C: 24V-80A)


EN1

EN11-002

ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS ......................... EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING ..................................... EN11-4
COMPONENT LOCATOR................................ EN11-5
SPECIAL TOOL ............................................... EN11-6
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-15
EN11–2 ALTERNATOR (J08C: 24V-80A)

ALTERNATOR
DATA AND SPECIFICATIONS
M01110101BEI2001

Nominal voltage 24V

Nominal output 24V-80A

Max. output 80A at 28V, 5,000 r/min

Initial output starting speed 900 r/min at 27V

Max. rotating 8,400 r/min

Rotating direction Right (seen from pulley side)

Regulator Mount-on

DESCRIPTION
M01110101BEC1001

M01110100047

1 Rectifier 7 Fan with pulley


2 Lead wire connector 8 Ball bearing
3 Condenser 9 Retainer plate
4 Regulator 10 Drive end frame
5 Rotor assembly 11 Field coil
6 Stator coil 12 Rectifier end frame
ALTERNATOR (J08C: 24V-80A) EN11–3

CIRCUIT

3 8
B
10
L
7
R

P
9
5
N
6 11

M01110100048

1 Alternator 7 Charge warning lamp


2 Condenser 8 Fuse
3 Diode 9 Starter switch
4 Stator coil 10 Load
5 Field coil 11 Battery
6 IC Regulator
EN11–4 ALTERNATOR (J08C: 24V-80A)

TROUBLESHOOTING
M01110101BEF3001

Symptom Possible cause Remedy/Prevention


Charging current does not flow I.C. regulator faulty Replace I.C. regulator.
(Lamp does not light) Stator coil faulty (Disconnecting or Replace stator coil.
rare 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.
(Lamp does 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.
(Lamp does not light)
Charging current is always insuffi- Stator coil faulty Replace stator coil.
cient (Battery goes dead) (Lamp Diode faulty (open or short circuit) Replace rectifier holder.
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) (Lamp remains Installation of support)
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.
ALTERNATOR (J08C: 24V-80A) EN11–5

COMPONENT LOCATOR
M01110101BED1001

M01110100049

1 Distance piece 4 Bracket


2 Brace 5 V-belt
3 Alternator

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 5.9 {60, 4.3} C 83 {850, 61}
B 51 {520, 38}
EN11–6 ALTERNATOR (J08C: 24V-80A)

M01110100050

1 Cover 12 Regulator
2 Rectifier 13 Field coil
3 Holder 14 Stator coil
4 Rectifier 15 Rotor assembly
5 Terminal insulator 16 Retainer plate
6 Connector 17 Shim
7 Holder insulator 18 Ball bearing
8 Condenser 19 Cover
9 Lead wire connector 20 Drive end frame
10 Rectifier end frame 21 Fan with pulley
11 Roller bearing 22 Lock nut

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 3.2-4.4 {33-45, 2.4-3.2} C 113-147 {1,150-1,500, 84-108}
B 2.9-3.9 {30-40, 2.2-2.8}

SPECIAL TOOL
M01110101BEK1001

Prior to starting an alternator overhaul, it is necessary to have this special tool.

Illustration Part number Tool name Remarks

09444-1210 COMPRESSION GAUGE


ALTERNATOR (J08C: 24V-80A) EN11–7

OVERHAUL
M01110101BEH2001

FIXING BOLT
IMPORTANT POINTS - MOUNTING
A COOLANT
PUMP 1. ADJUST THE ALTERNATOR V-BELT DEFLECTION.
PULLEY (1) Loosen the through bolt and the fixing bolt.
ADJUSTING (2) Apply a load of about 98N {10 kgf} by pressing the measuring
BOLT point A.
CRANK (3) Turn the adjusting bolt, and adjust the deflection of the belt at
SHAFT
ALTERNATOR PULLEY measuring point A, so that it comes within the standard value.
PULLE Y SST: Compression gauge (09444-1210)
THROUGH BOLT
Standard: 8-10 mm {0.314-0.394 in.}
M01110100051
NOTICE:
• 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 bolt.
(5) Retighten the adjusting bolt.
(6) Connecting the harness.

IMPORTANT POINTS - DISASSEMBLY

1. DISASSEMBLE THE RECTIFIER END FRAME AND DRIVE


END FRAME.
(1) Remove the cover.

M01110100052

(2) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.

M01110100053
EN11–8 ALTERNATOR (J08C: 24V-80A)

2. REMOVE THE ROTOR.


(1) Remove the pulley lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.

(2) Remove the fan with pulley.

M01110100054

(3) Remove the rotor from drive end frame, using a press.
NOTICE:
Hold rotor by hand so that it will not fall off.

M01110100008

3. REMOVE THE FRONT BALL BEARING.


(1) Remove the retainer plate and shim.

M01110100055

(2) Using a press, remove the ball bearing.


NOTICE:
Attach the jig to inner race of the ball bearing and remove the ball
bearing, using a press.

M01110100010

4. DISASSEMBLE THE RECTIFIER END FRAME.


(1) Remove the clamp and connector.

M01110100056
ALTERNATOR (J08C: 24V-80A) EN11–9

(2) Unsolder the stator coil lead wires from the diode.
NOTICE:
Raise the positive diode terminal upward, then unsolder the stator
lead wires form the negative diode terminal.

M01110100057

(3) Unsolder the field coil lead wires and condenser lead wire from
the connector.
NOTICE:
After opening the crimped section, remove the soldered portion.

M01110100058

(4) Unsolder the lead wire P and stator coil lead wire from the con-
nector.
NOTICE:
After opening the crimped section, remove the soldered portion.

M01110100059

(5) Unsolder the lead wires from the regulator. (connector lead wire L,
lead wire N, lead wire R, field coil lead wire, stator coil lead wire
N)

M01110100060

(6) Loosen the B terminal nut.


NOTICE:
Loosen the nut part way but make sure that it does not come off of
bolt B.

M01110100061
EN11–10 ALTERNATOR (J08C: 24V-80A)

(7) Remove the regulator fixing bolt, then remove the terminal insula-
tor.

M01110100062

(8) Refer to "COMPONENT LOCATOR", then remove the each parts.

M01110100063

(9) Remove the bolts, then remove the connector with lead wire,
clamp, connector and regulator.

M01110100064

(10) Remove the condenser.

M01110100065

5. REMOVE THE RECTIFIER END FRAME FROM STATOR COIL.

M01110100066
ALTERNATOR (J08C: 24V-80A) EN11–11

6. REMOVE THE FIELD COIL.


(1) Remove the bolt, then remove the field coil from the rectifier end
flame.

M01110100067

7. REMOVE THE ROLLER BEARING.


(1) Using a press, jig A and jig B, remove the roller bearing.

M01110100068

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE ROTOR.


(1) Using a press and a jig, install the ball bearing into the drive end
frame.
NOTICE:
Attach the jig on the outer race of the ball bearing.

M01110100018

(2) Install the retainer plate.


Tightening Torque:
1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}

M01110100069
EN11–12 ALTERNATOR (J08C: 24V-80A)

(3) Using a press, install the rotor.


NOTICE:
Take care not to damage the rotor shaft.

M01110100019

(4) Install the fan with pulley, tighten the lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.

M01110100020

2. INSTALL THE ROLLER BEARING.


(1) Using a press, jig A and jig B, install the roller bearing into the rec-
tifier end frame.
NOTICE:
Press fit until jig A hits the rectifier end frame.

M01110100021

3. INSTALL THE FIELD COIL.


(1) Install the field coil to the rectifier end frame.
Tightening Torque:
2.9-3.9 N⋅m {30-40 kgf⋅cm, 2.2-2.8 lbf⋅ft}

M01110100070
ALTERNATOR (J08C: 24V-80A) EN11–13

4. ASSEMBLE THE RECTIFIER END FRAME.


(1) Install the condenser.

M01110100071

(2) Refer to "COMPONENT LOCATOR", then install the each parts.


Tightening Torque:
Rectifier and regulator
fixing bolt: 1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}

M01110100072

(3) Install the rectifier end frame to the stator coil.


NOTICE:
Do not damage the stator coil.

M01110100073

(4) Using a soldering iron, solder the lead wires to the regulator. (con-
nector lead wire L, lead wire N, lead wire R, field coil lead wire,
stator coil lead wire N)

M01110100074

(5) Using a soldering iron, solder the lead wire P to the connector.

M01110100075
EN11–14 ALTERNATOR (J08C: 24V-80A)

(6) Using s soldering iron, solder the stator coil lead wire, diode lead
wire and connector.

M01110100076

(7) Using a soldering iron, solder the stator coil lead wires to the
diode.

M01110100077

(8) Install the connector and clamp.


Tightening Torque:
1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}

M01110100078

5. ASSEMBLE THE RECTIFIER END FRAME AND THE DRIVE


END FRAME.
(1) Assemble the rectifier end frame and the drive end frame with the
through bolts.
NOTICE:
Tighten the through bolt evenly.

M01110100079

(2) Install the cover.


Tightening Torque:
1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}

M01110100080
ALTERNATOR (J08C: 24V-80A) EN11–15

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


(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 80A

2. VOLTAGE REGULATOR TEST


(1) Turn switch SW1 on and SW2 off to increase the revolution of the
rotor to 5,000 r/min.
M01110100029 Standard voltage: 28.0-29.0V

INSPECTION AND REPAIR


M01110101BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure

Resistance of field coil


5.86-6.51 Ω — Replace.
[at 20°C (68°F)]

Measure

Insulation resistance of
1 MΩ or more 0.5MΩ or less Replace.
field coil

Measure

Resistance of stator
0.152-0.168 Ω — Replace.
coil [at 20°C (68°F)]
EN11–16 ALTERNATOR (J08C: 24V-80A)

Inspection item Standard Limit Remedy Inspection procedure

Measure

Insulation resistance of
1MΩ or more 0.5MΩ or less Replace.
stator

Measure
Normal direction
7-10Ω
Resistance of diode — Replace.
Reverse direction
∞Ω

Measure

Rotor shaft outside


diameter (front bearing 30 {1.181} 29.98 {1.180} Replace.
portion)

Measure

Rotor shaft outside


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

Measure

Drive end frame bearing


72 {2..835} 72.1 {2.839} Replace.
bore inside diameter

Measure

Rectifier end frame


bearing bore inside 23.8 {0.937} 23.81 {0.937} Replace.
diameter

Visual check

Rotates smoothly Replace.


Bearing wear or dam-
with no abnormal — Also, replace every 2
age
noise years.
STARTER (J08C) EN12–1

STARTER (J08C)
EN 12

EN12-001

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


DATA AND SPECIFICATIONS ......................... EN12-2
DESCRIPTION ................................................ EN12-2
TROUBLESHOOTING ..................................... EN12-3
COMPONENT LOCATOR................................ EN12-4
OVERHAUL ..................................................... EN12-5
INSPECTION AND REPAIR .......................... EN12-12
EN12–2 STARTER (J08C)

STARTER
DATA AND SPECIFICATIONS
M01120101BEI2001

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
M01120101BEC1001

M01120100001

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
STARTER (J08C) EN12–3

TROUBLESHOOTING
M01120101BEF3001

Symptom Possible cause Remedy/Prevention


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 (Over- Pinion teeth worn out Replace.
running 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)
EN12–4 STARTER (J08C)

COMPONENT LOCATOR
M01120101BED1001

M01120100002
STARTER (J08C) EN12–5

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
8 Brush 21 Drive housing 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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


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
M01120101BEH2001

IMPORTANT POINTS - DISASSEMBLY


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.}

M01120100003

M TERMINAL LEAD
1. REMOVE THE 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

M01120100004
EN12–6 STARTER (J08C)

2. REMOVE THE COMMUTATOR END FRAME.


(1) Remove the through bolt.

M01120100005

(2) Remove the bolt and O-ring, remove the commutator end frame.

COMMUTATOR
END FRAME

M01120100006

3. REMOVE THE HOLDER ASSEMBLY.


(1) Using a long nose plier, remove the brush of the yoke from the
holder.

M01120100007

(2) Remove the holder assembly from the armature.


NOTICE:
Do not cut the fixed clamp of brush lead.

M01120100008
STARTER (J08C) EN12–7

4. REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEM-


G1
BLY.
(1) Remove the yoke assembly and armature assembly from the gear
housing.
G1

M01120100009

5. REMOVE THE START MAGNET SWITCH ASSEMBLY.


A (1) Remove two bolts.
(2) Remove the start magnet switch assembly.
NOTICE:
B When removing the start magnet switch assembly, tilt the head of
the start magnet switch assembly to the side A, and then remove it
pulling to the side B (upper side).

M01120100010

6. REMOVE THE DRIVE SHAFT ASSEMBLY.


(1) Remove the gear housing from the drive housing

M01120100011

(2) Remove the retainer ring.


(3) Remove the pinion gear.

M01120100012

(4) Remove the lever and drive shaft assembly from the drive hous-
ing.

HOLDER
PIN
LEVER

SHAFT ASSEMBLY
M01120100013
EN12–8 STARTER (J08C)

IMPORTANT POINTS - ASSEMBLY


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

M01120100014

(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
G2 assembly at the same time.
NOTICE:
Make sure that the holder is installed securely and it slides
smoothly.

G1

M01120100015

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.

M01120100016

3. INSTALL THE GEAR HOUSING.


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

M01120100017
STARTER (J08C) EN12–9

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
B the start magnet switch assembly to the side A, and then insert it
into direction B.

M01120100046

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

M01120100009

6. INSTALL THE YOKE ASSEMBLY.


(1) Align the notches, install the yoke assembly.

M01120100018

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.

M01120100019
EN12–10 STARTER (J08C)

(2) Install the brush to the brush holder.

M01120100020

(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
M01120100021

M TERMINAL LEAD
(5) Secure the brush holder with the bolt and a new O-ring.
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

M01120100004

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

M01120100022

(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.}
M01120100023
STARTER (J08C) EN12–11

IMPORTANT POINTS - INSPECTION


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.

M01120100024

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.

M01120100025

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.

M01120100026
EN12–12 STARTER (J08C)

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

M01120100027

INSPECTION AND REPAIR


M01120101BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

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
STARTER (J08C) EN12–13

Inspection item Standard Limit Remedy Inspection procedure

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

Continuity between the


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
EN12–14 STARTER (J08C)

Inspection item Standard Limit Remedy Inspection procedure

Measure

Inside diameter of the 12.3 {0.484} or


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)
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–1

AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)


EN 13

EN13-001

AIR COMPRESSOR.................................. EN13-2


DATA AND SPECIFICATIONS ......................... EN13-2
DESCRIPTION ................................................ EN13-2
TROUBLESHOOTING ..................................... EN13-3
COMPONENT LOCATOR................................ EN13-4
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
INSPECTION AND REPAIR .......................... EN13-14
EN13–2 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

AIR COMPRESSOR
DATA AND SPECIFICATIONS
M01130101BEI2001

Type Reciprocating, single cylinder

Discharge amount 271 cm3 {16.5 cu.in.}

Bore x stroke 80 mm x 54 mm {3.15 in. x 2.13 in.}

Lubrication system Forced feed lubrication

Cooling system Forced water-circulated

DESCRIPTION
M01130101BEC1001

M01130100001

1 O-ring 8 Crankshaft
2 Cylinder head assembly 9 Crankcase
3 Gasket 10 Piston pin
4 Valve seat 11 Piston ring
5 Piston A Suction
6 Connecting rod B Delivery
7 Bearing
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–3

TROUBLESHOOTING
M01130101BEF3001

Symptom Possible cause Remedy/Prevention


Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace.
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).
Worn or broken piston ring Replace.
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)

Symptom Possible cause Remedy/Prevention


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

Symptom Possible cause Remedy/Prevention


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)
EN13–4 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

COMPONENT LOCATOR
M01130101BED1001

M01130100043

1 Air compressor

Tightening torque Unit: N⋅m{ kgf⋅cm, lbf⋅ft}


A 353 {3,600, 260} #
#= Apply oil to the threads and seat surface before tightening.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–5

M01130100002

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

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A T= 25-30 {255-305, 19-22} D T= 14-18 {143-183, 11-13}
B T= 23-26 {235-265, 17-19} E T= 25-30 {255-305, 19-22}
C T= 353 {3,600, 260} #
#= Apply oil to the threads and seat surfaces before tightening.
EN13–6 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

SPECIAL TOOL
M01130101BEK1001

Prior to starting an air compressor overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1830 PULLER

09420-1670 PULLER ASSEMBLY

09482-2220 SLEEVE PRESS

09482-2230 OIL SEAL PRESS

09650-1101 BEARING PULLER

09440-1060 PISTON RING EXPANDER


AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–7

OVERHAUL
M01130101BEH2001

IMPORTANT POINTS - DISMOUNTING


Remove the five 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.

IMPORTANT POINTS - MOUNTING

1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.

M01130100003

(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.

M01130100004

(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.

M01130100005

(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.

M01130100006
EN13–8 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

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.
Refer to CHAPTER FUEL SYSTEM.

M01130100007

IMPORTANT POINTS - DISASSEMBLY

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
loosing the nut.

M01130100008

(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (09420-1830)

M01130100009

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
liner.
• Do not disassemble the valve seat.

M01130100010
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–9

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.
(3) Remove the connecting rod with piston.

M01130100011

4. REMOVE THE PISTON RINGS.


(1) Remove the piston rings.
SST: Piston ring expander (09440-1060)

NOTICE:
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.

M01130100012

5. REMOVE THE PISTON.


(1) Remove the retainer rings installed on both ends of the piston,
using retainer ring pliers.
CAUTION:
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
approximately 5 minutes before removing the piston pin.
M01130100042

6. REMOVE THE CRANKSHAFT.


(1) Remove the bearing holder fitting bolts.
(2) Using a press, remove the crankshaft with bearing holder.
(3) Using a plastic hammer, strike out the bearing holder from the
crankshaft.

M01130100013
EN13–10 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

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.

M01130100014

8. REMOVE THE OIL SEAL SLEEVE.


(1) Remove the oil seal sleeve with the special tool.
SST: Puller assembly (09420-1670)

M01130100015

9. REMOVE THE BALL BEARING.


(1) Using the special tool, remove the ball bearing from the end of the
crankshaft.
SST: Bearing puller (09650-1101)

M01130100016

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE BALL BEARING AND OIL SEAL SLEEVE.


(1) Install the ball bearing.
(2) Install the oil seal sleeve with the special tool.
SST: Sleeve press (09482-2220)

M01130100017
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–11

2. INSTALL THE OIL SEAL.


(1) Install the oil seal with the special tool.
SST: Oil seal press (09482-2230)
NOTICE:
Coal lithium base grease to the sliding surface between seal lips.

M01130100018

3. INSTALL THE CRANKSHAFT.


(1) Using a copper hammer, install the crankshaft to the bearing
holder.
(2) Install the crankshaft and bearing holder in the crankcase.
(3) Tighten the bearing holder fitting bolt.
(4) Install the ball bearing to the crankshaft.
(5) Install the bearing retainer.

M01130100019

4. INSTALL THE CONNECTING ROD AND MEASURE THE END


PLAY.
NOTICE:
• Be sure to align the aligning mark.
• Apply engine oil to the bearing.
(1) Apply engine oil to the thread before installing the connecting rod
bolt.

M01130100020

(2) Measure the connecting rod end play.


Assembly standard: 0.2-0.4 {0.008-0.015 in.}
Limit: 0.5 mm {0.02 in.}

M01130100021

(3) Lock the nut with a lock washer.

M01130100022
EN13–12 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

5. MEASURE THE END PLAY OF THE CRANKSHAFT.


Assembly standard: 0-0.3 mm {0-0.012 in.}
Limit: 0.4 mm {0.016 in.}

M01130100023

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.
SST: Piston ring expander (09440-1060)

NOTICE:
Install the piston rings with the identification mark at the top of the
ring facing up.

M01130100024

7. ASSEMBLE THE PISTON AND CONNECTING ROD.


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.
CAUTION:
The retainer ring may spring out of the groove during assembly.
M01130100025 Wear a pair of safety goggles during assembly.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–13

8. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.


NOTICE:
Do not twist the O-ring when installing it on the cylinder liner and
cylinder head.
(1) Rotate the crankshaft to the top dead center position.
(2) Arrange the piston rings so that their gaps are equally spaced.
(3) Install the cylinder liner and cylinder head.

9. INSTALL THE DRIVE GEAR.


(1) Install the key to the crankshaft.
(2) Insert the drive gear.
(3) Insert the collar and lock nut.
Tightening Torque:
353 N⋅m {3,600 kgf⋅cm, 260 lbf⋅ft}

NOTICE:
Apply oil to the threads and seat surface before tightening.

M01130100026
EN13–14 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

INSPECTION AND REPAIR


M01130101BEH3001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

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}
pin and connecting rod {0.0007-0.0017}

Inside diameter of the con-


necting rod (without bear-
ings): A #Tighten the bearing 37 {1.457} —
cap to the specified
torque

Thickness of the connecting


1.5 {0.0591} —
rod bearing: B,C

Outside diameter of the crank


34 {1.339} —
pin: D
Replace.

Oil clearance between the


connecting rod and the crank
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.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–15

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Damage and scratches of the


— — 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}
Clearance between the piston
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

Worn or damaged bearing — — Replace.


EN13–16 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)

Inspection item Standard Limit Remedy Inspection procedure

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
Crankshaft end play 0-0.3 {0-0.012} 0.4 {0.06}
shaft bearing
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–1

AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)


EN 13

EN13-002

AIR COMPRESSOR.................................. EN13-2


DATA AND SPECIFICATIONS ......................... EN13-2
DESCRIPTION ................................................ EN13-2
TROUBLESHOOTING ..................................... EN13-3
COMPONENT LOCATOR................................ EN13-4
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
INSPECTION AND REPAIR .......................... EN13-17
EN13–2 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

AIR COMPRESSOR
DATA AND SPECIFICATIONS
M01130101BEI2001

Type Reciprocating, V-type 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.}

Lubrication system Forced feed lubrication

Cooling system Forced water-circulated

DESCRIPTION
M01130101BEC1001

M01130100081

1 Unloader valve 8 Cylinder liner


2 Inlet valve 9 Connecting rod
3 Piston ring 10 Crankshaft
4 Piston pin 11 Bearing
5 Delivery valve A From pressure regulator
6 Cylinder head B To tank
7 Piston C Air suction
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–3

TROUBLESHOOTING
M01130101BEF3001

Symptom Possible cause Remedy/Prevention


Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace.
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).
Worn or broken piston ring Replace.
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)

Symptom Possible cause Remedy/Prevention


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
Noisy operation (Valve) Inlet valve is lowered excessively Repair or replace.
Loosen discharge valve holder Tighten it.

Symptom Possible cause Remedy/Prevention


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)

Symptom Possible cause Remedy/Prevention


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.
EN13–4 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

COMPONENT LOCATOR
M01130101BED1001

M01130100123

1 Air compressor

Tightening torque Unit:N⋅m{kgf⋅cm,lbf⋅ft}


A 353 {3,600, 260}#
#=Apply oil to the threads and seat surfaces before tightening.
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–5

M01130100122

1 Cylinder block 23 Cylinder liner gasket


2 Crank shaft 24 Cylinder liner
3 Oil seal sleeve 25 Cylinder liner gasket
4 O-ring 26 Cylinder head assembly
5 Suction valve assembly 27 Cylinder head
6 Bearing holder assembly 28 O-ring
7 Bearing holder 29 Delivery valve assembly
8 Oil seal 30 Delivery valve holder
9 O-ring 31 Bolt
10 Bearing retainer 32 Bolt
11 Bolt 33 Through bolt
12 Woodruff key 34 Lock washer
13 Connecting rod assembly 35 Bearing
14 Connecting rod bearing 36 Bearing
15 Connecting rod bolt 37 Piston ring set
16 Connecting rod nut 38 Unloader valve assembly
17 Connecting rod washer 39 Unloader valve holder
18 Piston 40 Unloader valve spring
19 Piston pin 41 Unloader valve
20 Retainer ring 42 O-ring
21 Bolt 43 Spacer
22 Straight pin 44 Retainer ring
EN13–6 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

Tightening torque Unit:N⋅m{kgf⋅cm,lbf⋅ft}


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}

SPECIAL TOOL
M01130101BEK1001

Prior to starting an air compressor overhaul, it is necessary to have these special tools.

Illustration Part number Tool name Remarks

09420-1830 PULLER

09420-1670 PULLER ASSEMBLY

09482-2220 SLEEVE PRESS

09482-2230 OIL SEAL PRESS

09650-1101 BEARING PULLER

09440-1060 PISTON RING EXPANDER

INLET VALVE HOLDER


09481-1090
ADAPTER
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–7

OVERHAUL
M01130101BEH2001

IMPORTANT POINTS - DISMOUNTING


Remove the five 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.

IMPORTANT POINTS - MOUNTING

1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.

M01130100124

(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.

M01130100004

(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.

M01130100125

(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.

M01130100006
EN13–8 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

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.
Refer to CHAPTER FUEL SYSTEM.

M01130100007

IMPORTANT POINTS - DISASSEMBLY

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
loosing the nut.

M01130100126

(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (09420-1830)

M01130100009

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.

M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–9

3. REMOVE THE PISTON.


(1) Remove the retainer rings installed on both ends of the piston,
using retainer ring pliers.
CAUTION:
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, using a tapping rod and a hammer.
NOTICE:
Warm up the piston first in hot water, 80-90°C {176-194°F}, for
approximately 5 minutes before removing the piston pin.
M01130100086

4. REMOVE THE CONNECTING ROD.


(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.
(3) Remove the connecting rod.

M01130100084

5. REMOVE THE PISTON RINGS.


(1) Remove the piston rings.
SST: Piston ring expander (09440-1060)
NOTICE:
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.

M01130100085

6. REMOVE THE CRANKSHAFT.


(1) Remove the bearing retainer.

M01130100087
EN13–10 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

(2) Press the crankshaft end face and remove the crankshaft with the
bearing holder.

M01130100088

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.

M01130100089

8. REMOVE THE OIL SEAL SLEEVE.


(1) Using the special tool, remove the oil seal sleeve.
SST: Puller assembly (09420-1670)

M01130100090

9. REMOVE THE BALL BEARING.


(1) Using the special tool, remove the ball bearing from the end of the
crankshaft.
SST: Bearing puller (09650-1101)

M01130100016
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–11

10. REMOVE THE SUCTION VALVE ASSEMBLY.


(1) Using the special tool, remove the suction valve holder.
SST: Adapter (09482-1090)

M01130100091

(2) Disassemble the suction valve.

M01130100092

11. REMOVE THE UNLOADER VALVE ASSEMBLY.


(1) Loosen the unloader valve guide and take it out together with the
unloader valve.

M01130100093

(2) Remove the retainer ring and disassemble the unloader valve.

M01130100127

12. REMOVE THE DELIVERY VALVE ASSEMBLY.


(1) Remove the delivery valve holder.

M01130100095
EN13–12 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

(2) Disassemble the delivery valve.

M01130100096

IMPORTANT POINTS - ASSEMBLY

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.

M01130100097

(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.

M01130100059

(3) Tighten the suction valve holder to the specified torque using a
special tool.
SST: Adapter (09481-1090)
(4) Make sure that the suction valve stroke is approximately 2.5 mm
{0.0984 in.}.

M01130100098

(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.)

M01130100099
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–13

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.

M01130100100

(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.}.

M01130100063

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.

M01130100101

4. INSTALL THE BALL BEARING.


(1) Install the ball bearing on the both end of the crankshaft.

M01130100102
EN13–14 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

5. INSTALL THE OIL SEAL SLEEVE.


(1) Using the special tool, install the oil seal sleeve onto the crank-
shaft.
SST: Sleeve press (09482-2220)

M01130100120

6. INSTALL THE OIL SEAL.


(1) Using the special tool, install the oil seal into the bearing holder.
SST: Oil seal press (09482-2230)

M01130100109

7. INSTALL THE CRANKSHAFT.


(1) Using a copper hammer, install the crankshaft to the bearing
holder.

M01130100103

(2) Install the crankshaft and bearing holder in the crankcase.


(3) Tighten the bearing holder fitting bolt.

M01130100087
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–15

8. INSTALL THE CONNECTING ROD AND MEASURE THE END


PLAY.
NOTICE:
• Be sure to align the aligning mark.
• Apply engine oil to the bearing.
(1) Apply engine oil to the thread before installing the connecting rod
bolt.

M01130100105

(2) Measure the connecting rod end play.


Assembly standard: 0.2-0.4 mm {0.0079-0.0157 in.}
Limit: 0.5 mm {0.0197 in.}

M01130100106

(3) Lock the nut with a lock washer.

M01130100107

9. MEASURE THE END PLAY OF THE CRANKSHAFT.


Assembly standard: 0-0.3 mm {0-0.0118 in.}
Limit: 0.4 mm {0.0157 in.}

M01130100110

10. 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.
SST: Piston ring expander (09440-1060)

NOTICE:
Install the piston rings with the identification mark at the top of the
ring facing up.
M01130100069
EN13–16 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

M01130100111

11. ASSEMBLE THE PISTON AND CONNECTING ROD.


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.
CAUTION:
The retainer ring may spring out of the groove during assembly.
Wear a pair of safety goggles during assembly.
M01130100086

12. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.


(1) Arrange the piston rings so that their gaps are equally spaced.

M01130100113

(2) Install the cylinder liner and cylinder head.

M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–17

13. INSTALL THE DRIVE GEAR.


(1) Install the woodruff key to the crankshaft.
(2) Install the drive gear.
(3) Install the collar and lock nut.

M01130100128

INSPECTION AND REPAIR


M01130101BEH3001

Unit:mm{in.}

Inspection item Standard Limit Remedy Inspection procedure

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}
EN13–18 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

Inspection item Standard Limit Remedy Inspection procedure

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.

Oil clearance between the


connecting rod and the crank
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

Damage and scratches of the


— — 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.

Clearance between the piston


and the cylinder liner B: 0.07-0.13 0.18
{0.0028-0.0051} {0.0071}
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–19

Inspection item Standard Limit Remedy Inspection procedure

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

Worn or damaged bearing — — Replace.

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.
EN13–20 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)

Inspection item Standard Limit Remedy Inspection procedure

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
ENGINE P.T.O. (POWER TAKE-OFF) EN14–1

ENGINE P.T.O. (POWER TAKE-OFF) (J08C)


EN14

EN14-001

POWER TAKE-OFF ASSEMBLY .............. EN14-2


DESCRIPTION ................................................ EN14-2
COMPONENT LOCATOR................................ EN14-3
OVERHAUL ..................................................... EN14-4
INSPECTION AND REPAIR ............................ EN14-9
EN14–2 ENGINE P.T.O. (POWER TAKE-OFF)

POWER TAKE-OFF ASSEMBLY


DESCRIPTION
M01140102BEC1001

M01140100028

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
ENGINE P.T.O. (POWER TAKE-OFF) EN14–3

COMPONENT LOCATOR
M01140102BED1001

M01140100029

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

Tightening torque Unit:N⋅m{kgf⋅cm,lbf⋅ft}


A 226 {2,300, 160} B 28.4 {290, 21}
EN14–4 ENGINE P.T.O. (POWER TAKE-OFF)

OVERHAUL
M01040102BEH2001

IMPORTANT POINTS - DISASSEMBLY


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.

M01140100030

(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.

M01140100031

(4) Using a suitable sliding hammer, remove the driven shaft with ball
bearing.
(5) Remove the drive gear.

M01140100032

(6) Using a press, remove the ball bearing from the driven shaft.

M01140100033
ENGINE P.T.O. (POWER TAKE-OFF) EN14–5

(7) Using a press, press the driven shaft into the ball bearing.

M01140100034

(8) Using a suitable sliding hammer, remove the ball bearing with
driven shaft.

M01140100035

(9) Using a press, remove the ball bearing from the driven shaft.

M01140100036

(10) Using a flathead screwdriver, pay off the oil seal evenly until the oil
seal comes off.

M01140100037

IMPORTANT POINTS - ASSEMBLY

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.

M01140100038
EN14–6 ENGINE P.T.O. (POWER TAKE-OFF)

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.

M01140100039

(2) Using a press, press the driven shaft into the ball bearing.

M01140100040

(3) Using the suitable tool and a press, press the ball bearing into the
gear case.

M01140100041

(4) Set the drive gear in position, then press the driven shaft with ball
bearing into the ball bearing.

M01140100042

(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.

M01140100043
ENGINE P.T.O. (POWER TAKE-OFF) EN14–7

(7) Install the output flange, then tighten the lock nut.

M01140100044

IMPORTANT POINTS - MOUNTING

1. INSTALL THE POWER TAKE-OFF.


(1) Insert two knock pins.

M01140100045

(2) Apply liquid gasket to the gear case and the flywheel housing.
(3) Install the power take-off and case cover with 4 bolts.

M01140100046
EN14–8 ENGINE P.T.O. (POWER TAKE-OFF)

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.}

M01140100047
ENGINE P.T.O. (POWER TAKE-OFF) EN14–9

INSPECTION AND REPAIR


M01040102BEH3001

Unit:mm{in.}

Inspection item Standard Limit Remedy Inspection procedure

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.})
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–1

FUEL CONTROLDN02

(J08C: PRE-STROKE PUMP)


DN02

DN02-001

TE SYSTEM ..............................................DN02-2
OUTLINE OF THE TE SYSTEM...................... DN02-2
OUTLINE OF THE PRE-STROKE
PUMP SYSTEM............................................... DN02-2
COMPONENT LOCATOR................................ DN02-3
DIAGRAM ........................................................ DN02-9
PRECAUTIONS ............................................. DN02-11
INSPECTION ................................................. DN02-12
DIAGNOSIS USING
THE DIAGNOSIS MONITOR ......................... DN02-14
ENGINE SPEED SENSOR NO PULSE
(MALFUNCTION CODE:2-1) ......................... DN02-16
ABNORMALITY OF ENGINE SPEED SENSOR
(MALFUNCTION CODE:3-1) ......................... DN02-17
ABNORMALITY OF COOLANT TEMPERATURE
SENSOR (MALFUNCTION CODE:4-1)......... DN02-18
ABNORMALITY OF STARTER SWITCH
(MALFUNCTION CODE:6-1) ......................... DN02-19
ABNORMALITY OF RACK SENSOR
(MALFUNCTION CODE:14-1) ....................... DN02-20
ABNORMALITY OF PRE-STROKE SENSOR
(MALFUNCTION CODE:16-1) ....................... DN02-21
ABNORMALITY OF PRE-STROKE F/B
(MALFUNCTION CODE:16-2) ....................... DN02-22
ABNORMALITY OF PRE-STROKE LEARNING
(MALFUNCTION CODE:16-3) ....................... DN02-23
ABNORMALITY OF PRE-STROKE POWER SUPPLY
(MALFUNCTION CODE:16-4) ....................... DN02-24
ABNORMALITY OF PRE-STROKE POWER SUPPLY
RELAY (POWER SUPPLY CUT RELAY) CONTROL
CIRCUIT (MALFUNCTION CODE:16-6) ....... DN02-25
ABNORMALITY OF ECU
(MALFUNCTION CODE:22-1) ....................... DN02-27
ENGINE OVERRUN
(MALFUNCTION CODE:23-1) ....................... DN02-27
ENGINE OVERHEAT
(MALFUNCTION CODE:24-1) ....................... DN02-27
ECU CHASSIS SIDE CONNECTOR PIN
ASSIGNMENT ............................................... DN02-28
DISMOUNTING AND MOUTING................... DN02-30
DN02–2 FUEL CONTROL (J08C: PRE-STROKE PUMP)

TE SYSTEM
OUTLINE OF THE TE SYSTEM
M16020101BEF2001

The TE (Total Electronics) system uses electronic control to regulate every aspect of the engine's running condition. It is a
comprehensive electronic control system developed to extract maximum power and low-pollution of the engine.
There are 4 types of the TE system, detail at below, this engine employ the "Pre-stroke" type.

Control of the Intake Air Type

Pre-stroke Pump Type


Hino TE System
Electronic Governer Type

Common Rail Fuel Injection Type

OUTLINE OF THE PRE-STROKE PUMP SYSTEM


M16020101BEF2002

The Pre-stroke Pump 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 Timing

Function of Diagnosis Control of the Injection


Pre-stroke Type Rate
Fuel Injection System

Function of Tachometer
Driver
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–3

COMPONENT LOCATOR
M16020101BEF2003

M16020100060

1 ECU main relay 5 Speed sensor


2 Actuator power supply 6 Pre-stroke actuator and pre-stroke sensor
3 Control unit (ECU) 7 Rack sensor
4 Coolant temperature sensor
DN02–4 FUEL CONTROL (J08C: PRE-STROKE PUMP)

M16020100061

1 Straight pin 17 Tappet roller


2 Control rack 18 Adapter
3 Housing 19 Tappet sub assembly
4 Element sub assembly 20 Plunger spring lower seat
5 Timing rod 21 Plunger spring
6 Bearing 22 Plunger spring upper seat
7 Bushing 23 Plunger control sleeve
8 Connector 24 Camshaft adjust ring
9 Shim 25 Over flow valve
10 Pointer 26 Delivery valve holder
11 Sleeve 27 Delivery valve stopper
12 Oil seal 28 Delivery valve spring
13 Bearing cover 29 Delivery valve
14 O-ring 30 Element holder
15 Camshaft 31 Tappet sub assembly for feed pump
16 Woodruff key

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 108 {1,100, 80}
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–5

M16020100122

1 Boost compensator cover 15 Screw plug 29 Start spring


2 Gasket 16 Joint bolt 30 Spring shaft
3 Stroke adjust screw 17 Pin 31 Adapter
4 Diaphragm 18 Shaft 32 Flyweight sleeve
5 Governor spring 19 Cam plate 33 Round nut
6 Nut 20 Load lever 34 Flyweight
7 Bushing 21 Bracket 35 Governor housing
8 Spring plate 22 Boost compensator shaft 36 Load control lever
9 Return spring 23 Tension lever 37 Stop lever
10 Speed control lever 24 Guide lever 38 Collar
11 Oil seal 25 Floating lever 39 Plain washer
12 Governor cover 26 Link 40 Rack position sensor
13 Shim 27 Load control lever
14 Screw 28 Spring plate
DN02–6 FUEL CONTROL (J08C: PRE-STROKE PUMP)

M16020100040

1 Screw plug 9 Timer spring


2 Gasket 10 Shim
3 Timer hub 11 Retainer ring
4 Timer cam 12 Timer weight
5 Nut 13 Plain washer
6 Timer driving flange 14 O-ring
7 Shaft 15 Timer cover
8 Timer spring seat 16 Oil seal
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–7

M16020100123

1 Joint bolt 7 Plug


2 Gasket 8 Priming pump
3 Feed pump housing 9 Piston spring
4 Check valve 10 Piston
5 Check valve spring 11 Push rod
6 O-ring
DN02–8 FUEL CONTROL (J08C: PRE-STROKE PUMP)

M16020100042

1 Pre-stroke actuator and pre-stroke sensor


FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–9

DIAGRAM
M16020101BEJ1001

FUEL SYSTEM

M16020100035
DN02–10 FUEL CONTROL (J08C: PRE-STROKE PUMP)

ELECTRICAL SYSTEM

+24V
CONTROL UNIT

ACTUATOR POWER
ENGINE SPEED SUPPLY RELAY
SENSOR (N.C)
PRE-STROKE
COOLANT
ACTUATOR
TEMPERATURE
SENSOR

RACK SENSOR

PRE-STROKE
SENSOR
EXHAUST BRAKE
ECU
TACHOMETER SWITCH

CHECK ENGINE
ECU LAMP
MAIN RELAY
(N.O)

STARTER EXHAUST BRAKE


SWITCH INDICATOR LAMP

KEY SWITCH DIAG

N.O: Normal Open N.C: Normal Close


FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–11

PRECAUTIONS
M16020101BEC1011

1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE


ACTUATOR OR MAGNETIC VALVES.

2. PRE-STROKE ACTUATOR.
• Never apply electricity to the pre-stroke actuator except through
the control unit. Never connect the actuator connectors directly to
a power source. Doing so could burn out the actuator coil.
• Also, note that the mounting position of the actuator is carefully
adjusted. Never do anything that could change the actuator's
mounting position.
• To have the actuator or sensor replaced, contact an establishment
specializing in BOSCH (ZEXEL).

3. HARNESS WIRE CONNECTOR.


(1) Multi-contact connectors suitable for the small electrical signals of
electronic circuity 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 twist-
ing 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.

• Do not let water, oil or dust get on the connector when it is discon-
nected, 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 get 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.

4. ERASING THE MALFUNCTION MEMORY STORED IN THE


PAST, CHECK THE CURRENT MALFUNCTION BY PERFORM-
ING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
DN02–12 FUEL CONTROL (J08C: PRE-STROKE PUMP)

5. AFTER COMPLETING THE MALFUNCTION ANALYSIS,


ERASE THE MALFUNCTION MEMORY STORED IN THE PAST.
OTHERWISE, THE MALFUNCTION LAMP IN THE DISPLAY
WILL REMAIN LIT.

6. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE


SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING
LEAD FROM THE BACKSIDE.

7. USING A CIRCUIT TESTER


• Use a circuit tester with an internal resistance of 100kΩ or greater
in the voltage measuring range.

8. 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.

9. USING A QUICK CHARGER


• Disconnect both battery terminal before using a quick charger.

10. AIR CONDITIONER INSTALLATION


• Be careful not to scratch or damage the engine, chassis or the
harness inside the cab when installing an air conditioner. Also,
make sure to reattach afterward any connectors that were discon-
necting during the installation process.

11. ELECTRIC WELDING PERFORMING


• Disconnect connector to the control unit before performing any
electric welding.

12. OTHER
• Make sure to check the fellow of 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
M16020101BEH3001

CHECK ENGINE LAMP STATUS


1. INSPECTION PROCEDURE
(1) Turn the starter switch to the ON position (do not start the engine)
and confirm that the Check Engine Lamp in the indicator area
lights up.
(2) Start the engine.
(3) If the engine is normal, the Check Engine Lamp goes out.
(4) If the Check Engine Lamp does not light up or if it blinks, there is
trouble in the system. Check the system according to the following
chart.
.

M16020100033
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–13

CHECK ENGINE LAMP ILLUMINATION PATTERN

ON Major

BLINKING OFF

0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
Degree
ON of
trouble
ON (1)
OFF

ON

Minor
ON (2) OFF

Light up 30 seconds after engine started

The lamp ON/OFF status and illumination pattern as well as the corre-
sponding conditions they indicate and the measures to be taken-are
shown in the following table.

Lamp ON/OFF
STATUS

This indicates that the engine has stopped or it will not start.
Turn the starter switch to the [LOCK] position and wait few seconds.
Blinking
If the engine does not start and the lamp lights in continuously or blinking after the starter
switch is turned to the [START] position, and move the vehicle to a safe location by traction.

This indicates that the engine has insufficient force and irregular idling occurred due to a sys-
ON (1) tem damage.
This condition must be inspected at a Hino service dealer as soon as possible.

This indicates that a light damage has occurred in the system.


ON (2) Driving is possible, but this condition must be inspected at a HIno service dealer as soon as
possible.
DN02–14 FUEL CONTROL (J08C: PRE-STROKE PUMP)

DIAGNOSIS USING THE DIAGNOSIS MONITOR


M16020101BEF2151

1. CONNECT THE DIAGNOSIS MONITOR.


SST: Diagnosis monitor (09630-1370)

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 the "ON".

M16020100001

(2) Connect the harness to the diagnosis connector.


SST: Harness (09630-2300)

M16020100002

(3) Connect the diagnosis monitor to the connector which tagged a


"STD-ENG" label.

M16020100003

2. READ OUT THE MALFUNCTION CODE.


(1) Turn on the exhaust brake switch.

M16020100004
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–15

(2) Check engine lamp and exhaust brake indicator lamp flashes on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with no distinction between present and past
malfunction codes.

M16020100005

MALFUNCTION CODE DISPLAY PATTERN

Malfunction Code 9 - 2

Code 9 Check Engine Lamp

Turn ON

Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON

Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2

Malfunction Code 3 - 1 and 6 - 1 Check Engine Lamp

Exhaust Brake
2s 2s Indicator Lamp

Code 3 - 1 Code 6 - 1 Code 3 - 1 Code 6 - 1


M16020100006

3. ERASE THE MALFUNCTION CODE MEMORY.


(1) Disconnect the diagnosis monitor with the starter switch set to
"ON".
NOTICE:
In case of disconnecting with the starter switch set to "LOCK", the
malfunction code memory will not be erased. Always disconnect
the diagnosis monitor with the starter switch set to ON.
(2) Wait 5 seconds and connect the diagnosis monitor.
(3) This time, only the present malfunction codes are displayed.
(4) Compare the two sets of codes you get to determine which are
the present codes and which are the past one's.
M16020100007
DN02–16 FUEL CONTROL (J08C: PRE-STROKE PUMP)

MALFUNCTION CODE TABLE

CODE MALFUNCTION CONTENTS PROBABLE CAUSE

1 Normal function of system —

2-1 Engine speed sensor no pulse Excessive air gap or abnormality of sensor

3-1 Abnormality of engine speed sensor Harness disconnection, short circuit or abnormality of sensor

Abnormality of coolant temperature


4-1 Harness disconnection, short circuit or abnormality of sensor
sensor

6-1 Abnormality of starter switch Short circuit or abnormality of starter switch

14-1 Abnormality of rack sensor Harness disconnection, short circuit or abnormality of sensor

16-1 Abnormality of pre-stroke sensor

16-2 Abnormality of pre-stroke F/B Harness disconnection, short circuit or abnormality of sensor

16-3 Abnormality of pre-stroke learning

Abnormality of pre-stroke power sup-


16-4 Harness disconnection, short circuit
ply

Abnormality of pre-stroke power sup-


16-6 Harness disconnection, short circuit or abnormality of relay
ply relay control circuit

22-1 Abnormality of ECU Abnormality of ECU

Engine speed is 3,800 r/min or more or abnormality of engine


23-1 Engine overrun
speed sensor

Engine coolant temperature is 115°C {239°F} or abnormality of


24-1 Engine over heat
coolant temperature sensor

ENGINE SPEED SENSOR NO PULSE (MALFUNCTION CODE:2-1)


M16020101BEF2011

1. Check to see if the sensor is mounted loosely (Turn it by


hand)
NOTICE:
This "Error" is generated (or displayed) when the starter switch is
"ON" position and the Engine is not running, which does not
mean "Abnormal status of the system". However, if this "Error"
persists after the Engine starts, perform an inspection by the fol-
lowing steps:
.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–17

ABNORMALITY OF ENGINE SPEED SENSOR (MALFUNCTION


CODE:3-1)
M16020101BEF2021

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK" and disconnect the 26 pin con-
NE1+ nectors of ECU.
(2) Measure the resistance between NE1+ and NE1- terminals of 26
pin connectors (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11 12 13 Standard: APPROX. 1.8kΩ at 20°C {68°F}
14 15 16 17 18 19 20 21 22 23 24 25 26

NE1-

M16020100008
.

NG
Proceed to 3

OK

2. RECHECK THE MALFUNCTION CODE.


(1) Connect the 26 pin connectors and erase the past malfunction
code.
(2) Check the malfunction code with the diagnosis monitor.
Standard: code 1 (Normal function)
.

NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors

Normal
DN02–18 FUEL CONTROL (J08C: PRE-STROKE PUMP)

3. CHECK THE ENGINE SPEED SENSOR.


(1) Disconnect the connectors of engine speed sensor.
NE- NE+
(2) Measure the resistance between NE+ and NE- terminals of sen-
sor connectors (Sensor harness side).
Standard: APPROX. 1.8 kΩ at 20°C {68°F}

M16020100009
.

NG
Abnormality of sensor

OK

• Harness disconnection or short circuit


• Bad contact of connectors

ABNORMALITY OF COOLANT TEMPERATURE SENSOR


(MALFUNCTION CODE:4-1).
M16020101BEF2031

1. CHECK THE RESISTANCE BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
THW+ (2) Disconnect the 16 pin connectors of ECU.
(3) Measure the resistance between THW+ and THW- terminals of
16 pin connectors (Chassis harness side).
1 2 3 4 5 6 7 8
HINT:
9 10 11 12 13 14 15 16
Measure the resistance under any condition of the following.

Standard:
THW- APPROX. 2.4 kΩ at 20°C {68°F}
APPROX. 1.5 kΩ at 40°C {104°F}
M16020100022 APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–19

2. CHECK THE COOLANT TEMPERATURE SENSOR.


(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals(Sensor side).
HINT:
Measure the resistance under any condition of the following.

Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023

NG
Abnormality of coolant temperature sensor

OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1)


M16020101BEF2041

CAUTION:
Make sure that transmission is in neutral position.

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK" and disconnect the 22 pin con-
ST nectors of ECU.
(2) Measure the voltage between ST and MGD1 terminals of 22 pin
connectors. (Chassis harness side)
1 2 3 4 5 6 7 8 9 10 11
+ - Standard:
12 13 14 15 16 17 18 19 20 21 22
Starter switch "LOCK" : 0V
Starter switch "START" : 24V

MGD1

M16020100036
.

NG
Abnormality of harness

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors

.
DN02–20 FUEL CONTROL (J08C: PRE-STROKE PUMP)

ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1)


M16020101BEF2051

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 26 pin connectors of ECU and 4 pin connectors of
injection pump.
(3) Measure the resistance between terminals of 26 pin connectors
RWML
and 4 pin connectors of injection pump (Chassis harness side).
NOTICE:
1 2 3 4 5 6 7 8 9 10 11 12 13
Combinations of terminals (26 pin connectors-4 pin connectors):
14 15 16 17 18 19 20 21 22 23 24 25 26
RWGD-GND, RWML-MDL, RWOC-OSC.
Standard: 1 Ω or less
RWOC
RWGD

MDL

1 2
3 4

GND
OSC

M16020100011
.

NG
Abnormality of harness and connectors

OK

• Abnormality of injection pump


• Abnormality of ECU connectors
• Bad contact of ECU connectors

.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–21

ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION


CODE:16-1)
M16020101BEF2061

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 26 pin connectors of ECU.
(3) Measure the resistance between PMDL and PGND, PMDL and
POSC terminals of 26 pin connectors (Chassis harness side).
Standard: 4-9 Ω

PMDL

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

PGND
POSC

M16020100012
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
DN02–22 FUEL CONTROL (J08C: PRE-STROKE PUMP)

2. CHECK THE PRE-STROKE SENSOR.


(1) Disconnect the connector of pre-stroke sensor.
PGND (2) Measure the resistance between PMDL and PGND, PMDL and
PMDL POSC terminals of sensor connectors (Sensor harness side)
Standard: 4-9 Ω

POSC

M16020100013
.

NG
Abnormality of pre-stroke sensor
(Injection pump)
OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2)


M16020101BEF2071

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
PS+
(2) Disconnect the 26 pin connectors of ECU.
(3) Measure the resistance between PS+ and PS- terminals of 26 pin
connectors (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11 12 13 Standard: 2-4 Ω
14 15 16 17 18 19 20 21 22 23 24 25 26

PS-

M16020100014
.

NG
Proceed to 2

OK

• Malfunction of pre-stroke actuator


• Malfunction of injection pump link mechanism
• Abnormality of ECU
• Abnormality of ECU connectors
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–23

2. CHECK THE PRE-STROKE ACTUATOR.


(1) Disconnect the connector of pre-stroke actuator.
PS- PS+ (2) Measure the resistance between PS+ and PS- terminals of actua-
tor connectors (Actuator harness side).
Standard: 2-4 Ω

M16020100015
.

NG
Abnormality of pre-stroke actuator
(Injection pump)
OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION


CODE:16-3)
M16020101BEF2081

1. Check that the malfunction code, 16-1, is being displayed,


together with 16-3 in the order at the same time.

M16020100016
.

NG
Abnormal adjustment of pre-stroke sensor
(Injection pump)
OK

Make sure to inspect it in accordance with the contents of Mal-


function Code 16-1.

.
DN02–24 FUEL CONTROL (J08C: PRE-STROKE PUMP)

ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION


CODE:16-4)
M16020101BEF2091

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
PSP+ (2) Disconnect the 26 pin connectors of ECU.
(3) Set the starter switch to "ON" (The engine is stopped).
(4) Measure the voltage between PSP+ and PSGD terminals of 26
1 2 3 4 5 6 7 8 9 10 11 12 13 pin connectors (Chassis harness side).
+ -
14 15 16 17 18 19 20 21 22 23 24 25 26 Standard:
Starter switch "LOCK" : 0V
Starter switch "ON" : 24V
PSGD

M16020100017
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors

2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY).
(1) Set the starter switch to "LOCK".
(2) Disconnect the pre-stroke power supply relay.
S- B (3) Measure the resistance between B and NC terminals.
Standard: 1 Ω or less

NC

S+

M16020100018
.

NG
Abnormality of pre-stroke power supply relay

OK

• Harness disconnection or short circuit


• Abnormality of connectors

.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–25

ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:16-
6)
M16020101BEF2101

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 26 pin connectors of ECU.
PSRY (3) Set the starter switch to "ON" (The engine is stopped).
(4) Measure the voltage between PSRY and PSGD terminals of 26
1 2 3 4 5 6 7 8 9 10 11 12 13
pin connectors (Chassis harness side).
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard:
Starter switch "LOCK" : 0V
Starter switch "ON" : 24V
PSGD

M16020100019
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors

2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY).
(1) Set the starter switch to "LOCK".
(2) Disconnect the pre-stroke power supply relay.
S-
(3) Measure the resistance between S+ and S- terminals.
Standard: 390-490 Ω

S+

M16020100020
.

NG
Abnormality of pre-stroke power relay

OK
DN02–26 FUEL CONTROL (J08C: PRE-STROKE PUMP)

3. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch "LOCK".
(2) Disconnect the pre-stroke power supply relay and 26 pin connec-
tors of ECU.
(3) Measure the resistance between PSRY terminal of 26 pin connec-
tors (Chassis harness side) and S- terminal of relay connectors
(Relay panel side).
Standard: 1 Ω or less

S-

PSRY

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

M16020100021
.

NG
• Harness disconnection
• Abnormality of connectors
OK

Bad contact of connectors

.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–27

ABNORMALITY OF ECU (MALFUNCTION CODE:22-1)


M16020101BEF2111

1. After the starter switch is positioned on the "LOCK" once, it


shall be turned to "ON" position again.

2. After erasing the malfunction memory stored in the past,


check that the same code is displayed again.

M16020100016
.

NG
The same code is being shown up: Malfunction
of ECU.
OK

Normal
(Temporary malfunction because of radio interference noise)

ENGINE OVERRUN (MALFUNCTION CODE:23-1)


M16020101BEF2121

1. The malfunction code will be displayed, once detected over


3,800 r/min. in the Engine revolution. Also, the fuel injection
will be suspended during the malfunction code to be
detected and the fuel injection will be resumed when Engine
revolution goes down less than 3,600 r/min.
NOTICE:
The malfunction code is aimed not for detecting the Engine over-
run 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 "over-run" will be
detected by misunderstanding the Engine revolution, with a noise
to be generated by harness abnormality and its modification.
.

ENGINE OVERHEAT (MALFUNCTION CODE:24-1)


M16020101BEF2131

1. CHECK THE COOLANT TEMPERATURE SENSOR.


(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals.
HINT:
Measure the resistance under any condition of the following.

Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023
DN02–28 FUEL CONTROL (J08C: PRE-STROKE PUMP)

NG
Abnormality of coolant temperature sensor

OK

Abnormality 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 malfunction code is being detected, Max.
volume of fuel injection will be limited and will return back to nor-
mal control volume when it descends less than 105°C {221°F}.
.

ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT


M16020101BEF2141

26 PIN CONNECTORS

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

VIEW CHASSIS HARNESS

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 14 —

2 — 15 —

3 — 16 —

4 MVB Power source VB 17 EBLP Exhaust brake indicator lamp

5 RWML Rack sensor (Signal) 18 —

6 RWOC Rack sensor (Power source) 19 RWGD Rack sensor ground

7 PMDL 20 PSLD Pre-stroke sensor shield

8 PGND Pre-stroke sensor ground 21 POSC Pre-stroke sensor

9 — 22 —

10 NE+ Engine speed sensor + 23 NE- Engine speed sensor -

11 — 24 PSRY Pre-stroke power supply relay control

12 PSP+ Pre-stroke power supply 25 PSGD Pre-stroke actuator ground

13 PS+ Pre-stroke actuator + 26 PS- Pre-stroke actuator-


FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–29

22 PIN CONNECTORS

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22

VIEW CHASSIS HARNESS

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 12 —

2 VB1 Power source (ECU main relay) 13 MGD1 Ground

3 MRL1 ECU main relay control 14 —

4 DGSW Diagnosis monitor 15 IDLE Exhaust brake accelerator switch

5 — 16 —

6 — 17 EBSW Exhaust brake switch

7 ST Power source (Starter switch) 18 —

8 — 19 —

9 CE/G Engine check warning lamp 20 —

10 SSWS Power source (Fuse E/G2) 21 —

11 — 22 —

16 PIN CONNECTORS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

VIEW CHASSIS HARNESS

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 9 —

2 — 10 —

3 — 11 —

4 — 12 —

5 — 13 —

6 THW+ Coolant temperature sensor + 14 THW- Coolant temperature sensor -

7 — 15 —

8 CGD1 Ground 16 —
DN02–30 FUEL CONTROL (J08C: PRE-STROKE PUMP)

12 PIN CONNECTORS

1 2 3 4 5 6

7 8 9 10 11 12

VIEW CHASSIS HARNESS

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 7 —

2 — 8 —

3 — 9 —

4 — 10 —

5 — 11 CASE ECU case ground

6 TACH Tachometer 12 —

DISMOUNTING AND MOUTING


M16020101BEF2150

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE SPEED SENSOR.


(1) Disconnect the connector (Black), loosen the lock nut using two
wrenches.
(2) Remove the speed sensor from the adapter plate.

IMPORTANT POINT - MOUNTING

1. INSTALL THE SPEED SENSOR.


(1) Turn the crankshaft to align the mark 16, 34 or 25 on the outer
periphery of the flywheel with the pointer of the flywheel housing.
NOTICE:
• The pulse protrusion will line up with the center of the hole at
the piston top dead center point.
• The speed sensor damage may occur during engine opera-
tion if these adjustments are neglected.

M01010100061 (2) Coat a sealing compound (Three-Bond 1215 or equivalent) on the


thread face and lock nut sealing surface of the sensor.
NOTICE:
Sensor adjustment should be carried out within 30 minutes from
application of the sealing compound. After 30 minutes, the sealing
compound will harden and it will become difficult to turn the sen-
sor by hand.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–31

(3) Screw in the sensor by hand until the leading edge of the sensor
lightly contacts to the protrusion.
(4) After contacting the sensor to the protrusion, unscrew the sensor
1.0-1.5 turns (to create a gap of 1.0-1.5 mm {0.0394-0.0590 in.}).
(5) Tighten the lock nut while the hexagonal part on the sensor is
held to prevent the gap from changing.
Tightening Torque:
45-54 N⋅m {450-550 kgf⋅cm, 33-39 lbf⋅ft}

M16020100067
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–1

FUEL CONTROL DN02

(J08C: ELECTRONIC GOVERNOR)


DN 02

DN02-002

TE SYSTEM ..............................................DN02-2 ABNORMALITY OF PRE-STROKE LEARNING


OVERVIEW ...................................................... DN02-2 (MALFUNCTION CODE:16-3) ....................... DN02-43
COMPONENT LOCATOR................................ DN02-3 ABNORMALITY OF PRE-STROKE POWER SUPPLY
DIAGRAM ........................................................ DN02-9 (MALFUNCTION CODE:16-4) ....................... DN02-44
PRECAUTIONS ............................................. DN02-11 ABNORMALITY OF PRE-STROKE POWER SUPPLY
INSPECTION ................................................. DN02-12 RELAY (POWER SUPPLY CUT RELAY) CONTROL
DIAGNOSIS USING THE DIAGNOSIS MONITOR CIRCUIT (MALFUNCTION CODE:16-6) ....... DN02-45
(WITH MECHANICAL TRANSMISSION) ...... DN02-14 ABNORMALITY OF GOVERNOR F/B
DIAGNOSIS USING THE DIAGNOSIS MONITOR (MALFUNCTION CODE: 17-1) ...................... DN02-46
(WITH AUTOMATIC TRANSMISSION). ........ DN02-16 ABNORMALITY OF GOVERNOR
ABNORMALITY OF MAIN ENGINE SPEED SENSOR (MALFUNCTION CODE: 17-2) ...................... DN02-47
(MALFUNCTION CODE:3-1) ......................... DN02-20 ABNORMALITY OF ECU
ABNORMALITY OF SUB ENGINE SPEED SENSOR (MALFUNCTION CODE:22-1) ....................... DN02-49
(MALFUNCTION CODE:3-2) ......................... DN02-21 ENGINE OVERRUN
ABNORMALITY OF MAIN AND SUB ENGINE SPEED (MALFUNCTION CODE:23-1) ....................... DN02-49
SENSOR (MALFUNCTION CODE:3-1 & 2) .. DN02-22 ENGINE OVERHEAT
ABNORMALITY OF COOLANT TEMPERATURE (MALFUNCTION CODE:24-1) ....................... DN02-50
SENSOR (MALFUNCTION CODE:4-1)......... DN02-23 ECU CHASSIS SIDE CONNECTOR PIN
ABNORMALITY OF STARTER SWITCH ASSIGNMENT ............................................... DN02-51
(MALFUNCTION CODE:6-1) ......................... DN02-24 DISMOUNTING AND MOUTING................... DN02-55
ABNORMALITY OF BOOST PRESSURE SENSOR
(MALFUNCTION CODE:7-1) ......................... DN02-24
ABNORMALITY OF VOLTAGE OF ACCELERATOR
SENSOR 1 (MALFUNCTION CODE: 8-1)..... DN02-27
ABNORMALITY OF VOLTAGE OF ACCELERATOR
SENSOR 2 (MALFUNCTION CODE: 8-2)..... DN02-29
ABNORMALITY OF VOLTAGE OF ACCELERATOR
SENSOR 1 &2
(MALFUNCTION CODE 8-1 & 2)................... DN02-30
ABNORMALITY OF OUTPUT VOLTAGE OF
ACCELERATOR SENSOR 1
(MALFUNCTION CODE: 8-3) ........................ DN02-31
ABNORMALITY OF OUTPUT VOLTAGE OF
ACCELERATOR SENSOR 2
(MALFUNCTION CODE: 8-4) ........................ DN02-32
ABNORMALITY OF ACCELERATOR SWITCH
(MALFUNCTION CODE: 8-6) ........................ DN02-33
ABNORMALITY OF Q-ADJUSTMENT RESISTER
(MALFUNCTION CODE: 9-1) ........................ DN02-34
ABNORMALITY OF IDLE SET CONTROLLER
(MALFUNCTION CODE: 9-2) ........................ DN02-35
ABNORMALITY OF VEHICLE SPEED SENSOR
(MALFUNCTION CODE: 11-1) ...................... DN02-38
ABNORMALITY OF RACK SENSOR
(MALFUNCTION CODE:14-1) ....................... DN02-40
ABNORMALITY OF PRE-STROKE SENSOR
(MALFUNCTION CODE:16-1) ....................... DN02-41
ABNORMALITY OF PRE-STROKE F/B
(MALFUNCTION CODE:16-2) ....................... DN02-42
DN02–2 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

TE SYSTEM
OVERVIEW
M16020101BEC1001

TE SYSTEM
The TE (Total Electronics) system uses electronic control to regulate
every aspect of the engine's running condition. It is a comprehensive
electronic control system developed to extract maximum power and
low-pollution of the engine.
There are 4 types of the TE system, detail at below, this engine employ
the "Pre-stroke" and "Electronic Governor" type.

Control of the Intake Air Type

Pre-stroke Pump Type


Hino TE System
Electronic Governor Type

Common Rail Fuel Injection Type


M16020100081

PRE-STROKE PUMP AND ELECTRONIC GOVER-


NOR SYSTEM
The Pre-stroke Pump and Electronic Governor System have 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 Timing

Function of Diagnosis Control of the Injection


Pre-stroke Pump and Rate
Electronic Governor
Fuel Injection System
Function of Tachometer
Driver
M16020100082
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–3

COMPONENT LOCATOR
M16020101BED1001

M16020100107

1 ECU main relay 8 Coolant temperature sensor


2 Actuator power supply relay 9 Booster pressure sensor
3 Pulse adjust computer 10 Electronic governor
4 Electronic governor ECU 11 Rack sensor and sub engine speed sensor
5 Accelerator sensor 12 Pre-stroke actuator and pre-stroke sensor
6 Accelerator switch 13 Main engine speed sensor
7 Q-adjustment resistor
DN02–4 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

M16020100069

1 Straight pin 17 Tappet roller


2 Control rack 18 Adapter
3 Housing 19 Tappet sub assembly
4 Element sub assembly 20 Plunger spring lower seat
5 Timing rod 21 Plunger spring
6 Bearing 22 Plunger spring upper seat
7 Bushing 23 Plunger control sleeve
8 Connector 24 Camshaft adjust ring
9 Shim 25 Over flow valve
10 Pointer 26 Delivery valve holder
11 Sleeve 27 Delivery valve stopper
12 Oil seal 28 Delivery valve spring
13 Bearing cover 29 Delivery valve
14 O-ring 30 Element holder
15 Camshaft 31 Tappet sub assembly for feed pump
16 Woodruff key

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}


A 108 {1,100, 80}
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–5

M16020100125

1 Control unit 4 Governor housing sub assembly


2 Load sensor sub assembly 5 Governor housing
3 Gasket 6 Governor cover sub assembly
DN02–6 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

M16020100070

1 Screw plug 10 Shim


2 Gasket 11 Retainer ring
3 Timer hub 12 Timer weight
4 Timer cam 13 Plain washer
5 Nut 14 O-ring
6 Timer driving flange 15 Timer cover
7 Shaft 16 Oil seal
8 Timer spring seat 17 Speed sensor
9 Timer spring 18 Bracket
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–7

M16020100071

1 Joint bolt 7 Priming pump


2 Gasket 8 Connector
3 Feed pump housing 9 Plug
4 Check valve 10 Piston spring
5 Check valve spring 11 Piston
6 O-ring 12 Push rod
DN02–8 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

M16020100042

1 Pre-stroke actuator and pre-stroke sensor


FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–9

DIAGRAM
M16020101BEJ1001

FUEL SYSTEM

ELECTRICAL WIRING

CHECK ENGINE
LAMP ACCELERATOR SENSOR

CONTROL
UNIT
POWER
SUPPLY

COOLANT TEMPERATURE
SENSOR PRE-STROKE
ACTUATOR

MAIN ENGINE
SUB ENGINE SPEED SENSOR, SPEED SENSOR
RACK SENSOR AND ELECTRONIC
GOVERNOR ACTUATOR
INJECTION PUMP

M16020100072
DN02–10 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ELECTRICAL SYSTEM

+24 V
CONTROL UNIT

ACTUATOR POWER
MAIN ENGINE SUPPLY RELAY
SPEED SENSOR (N.C)

SUB ENGINE PRE-STROKE


SPEED SENSOR ACTUATOR

COOLANT GOVERNOR
TEMPERATURE ACTUATOR
SENSOR

RACK SENSOR

PRE-STROKE EXHAUST BRAKE


SENSOR SWITCH
BOOST
PRESSURE
SENSOR

ACCELERATOR CHECK ENGINE


CPU
SENSOR 1 WARNING LAMP

ACCELERATOR BRAKE SWITCH 2


SENSOR 2 (WITH AUTOMATIC
TRANSMISSION)
IDLE SETTING POWER TAKE-OFF
BUTTON CLUTCH SWITCH
(WITH MECHANICAL
Q-ADJUSMENT TRANSMISSION)
RESISTER

VEHICLE
SPEED SENSOR

TACHOMETER

ECU EXHAUST BRAKE


MAIN RELAY INDICATOR LAMP
(N.O)

STARTER DIAG
SWITCH

N.O: Normal open, N.C: Normal close


M16020100126
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–11

PRECAUTIONS
M16020101BEC1011

1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE


ACTUATOR OR MAGNETIC VALVES.

2. PRE-STROKE ACTUATOR.
• Never apply electricity to the pre-stroke actuator except through
the control unit. Never connect the actuator connectors directly to
a power source. Doing so could burn out the actuator coil.
• Also, note that the mounting position of the actuator is carefully
adjusted. Never do anything that could change the actuator's
mounting position.
• To have the actuator or sensor replaced, contact an establishment
specializing in BOSCH (ZEXEL).

3. HARNESS WIRE CONNECTOR.


(1) Multi-contact connectors suitable for the small electrical signals of
electronic circuity 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 twist-
ing 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.

M16020100032

• Do not let water, oil or dust get on the connector when it is discon-
nected, 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 get 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.

4. ERASING THE MALFUNCTION MEMORY STORED IN THE


PAST, CHECK THE CURRENT MALFUNCTION BY PERFORM-
ING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
DN02–12 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

5. AFTER COMPLETING THE MALFUNCTION ANALYSIS,


ERASE THE MALFUNCTION MEMORY STORED IN THE PAST.
OTHERWISE, THE MALFUNCTION LAMP IN THE DISPLAY
WILL REMAIN LIT.

6. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE


SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING
LEAD FROM THE BACKSIDE.

7. USING A CIRCUIT TESTER


• Use a circuit tester with an internal resistance of 100 kΩ or
greater in the voltage measuring range.

8. 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.

9. USING A QUICK CHARGER


• Disconnect both battery terminal before using a quick charger.

10. AIR CONDITIONER INSTALLATION


• Be careful not to scratch or damage the engine, chassis or the
harness inside the cab when installing an air conditioner. Also,
make sure to reattach afterward any connectors that were discon-
necting during the installation process.

11. ELECTRIC WELDING PERFORMING


• Disconnect connector to the control unit before performing any
electric welding.

12. OTHER
• Make sure to check the fellow of 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
M16020101BEH3001

CHECK ENGINE LAMP STATUS


1. INSPECTION PROCEDURE
(1) Turn the starter switch to the ON position (do not start the engine)
and confirm that the Check Engine Lamp in the indicator area
lights up.
(2) Start the engine.
(3) If the engine is normal, the Check Engine Lamp goes out.
(4) If the Check Engine Lamp does not light up or if it blinks, there is
trouble in the system. Check the system according to the following
chart.
.

M16020100033
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–13

CHECK ENGINE WARNING LAMP ILLUMINATION


PATTERN

ON Major

BLINKING OFF

0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
Degree
ON of
trouble
ON (1)
OFF

ON

Minor
ON (2) OFF

Light up 30 seconds after engine started

M16020100034
The lamp ON/OFF status and illumination pattern as well as the corre-
sponding conditions they indicate and the measures to be taken-are
shown in the following table.

Lamp ON/OFF
STATUS

This indicates that the engine has stopped or it will not start.
Turn the starter switch to the [LOCK] position and wait few seconds.
Blinking
If the engine does not start and the lamp lights in continuously or blinking after the starter
switch is turned to the [START] position, and move the vehicle to a safe location by traction.

This indicates that the engine has insufficient force and irregular idling occurred due to a sys-
ON (1) tem damage.
This condition must be inspected at a Hino service dealer as soon as possible.

This indicates that a light damage has occurred in the system.


ON (2) Driving is possible, but this condition must be inspected at a HIno service dealer as soon as
possible.
DN02–14 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH MECHANICAL


TRANSMISSION)
M16020101BEF2001

1. CONNECT THE DIAGNOSIS MONITOR.


SST: Diagnosis monitor (09630-1370)

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 the "ON" (Do not start the engine).

M16020100001

(2) Connect the harness to the diagnosis connector.


SST: Harness (09630-2300)

M16020100002

(3) Connect the diagnosis monitor to the connector which tagged a


"STD-ENG" label.

M16020100003

2. READ OUT THE MALFUNCTION CODE.


(1) Turn on the exhaust brake switch.

M16020100004
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–15

(2) Check engine lamp and exhaust brake indicator lamp flashes on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with no distinction between present and past
malfunction codes.

M16020100005

MALFUNCTION CODE DISPLAY PATTERN

Malfunction Code 9 - 2

Code 9 Check Engine Lamp

Turn ON

Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON

Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2

Malfunction Code 3 - 1 and 6 - 1 Check Engine Lamp

Exhaust Brake
2s 2s Indicator Lamp

Code 3 - 1 Code 6 - 1 Code 3 - 1 Code 6 - 1


M16020100006

3. ERASE THE MALFUNCTION CODE MEMORY.


(1) Disconnect the diagnosis monitor with the starter switch set to
"ON".
NOTICE:
In case of disconnecting with the starter switch set to "LOCK", the
malfunction code memory will not be erased. Always disconnect
the diagnosis monitor with the starter switch set to ON.
(2) Wait 5 seconds and connect the diagnosis monitor.
(3) This time, only the present malfunction codes are displayed.
(4) Compare the two sets of codes you get to determine which are
the present codes and which are the past one's.
M16020100007
.
DN02–16 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH AUTOMATIC


TRANSMISSION).
M16020101BEF2023

1. REMOVE THE FUSE OF THE AUTOMATIC TRANSMISSION


ECU.
(1) Set the starter switch to the "LOCK".
(2) Remove the fuse (TRANSFER CONTROL AUTO T/M) of the
automatic transmission ECU.

M16020100127

2. CONNECT THE DIAGNOSIS MONITOR.


SST: Diagnosis monitor (09630-1370)

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 the "ON" (Do not start the engine).

M16020100001

(2) Connect the harness to the diagnosis connector.


SST: Harness (09630-2300)

M16020100002
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–17

(3) Connect the diagnosis monitor to the connector which tagged a


"STD-ENG" label.

M16020100003

3. READ OUT THE MALFUNCTION CODE.


(1) Turn on the exhaust brake switch.

M16020100004

(2) Check engine lamp and exhaust brake indicator lamp flashed on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with to distinction between present and past
malfunction codes.

M16020100005
DN02–18 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

MALFUNCTION CODE DISPLAY PATTERN

Malfunction Code 9 - 2

Code 9 Check Engine Lamp

Turn ON

Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON

Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2

Malfunction Code 3 - 1 and 6 - 1 Check Engine Lamp

Exhaust Brake
2s 2s Indicator Lamp

Code 3 - 1 Code 6 - 1 Code 3 - 1 Code 6 - 1


M16020100006

4. ERASE THE MALFUNCTION CODE MEMORY.


(1) Disconnect the diagnosis monitor with the starter switch set to
"ON".
NOTICE:
In case of disconnecting with the starter switch set to "LOCK", the
malfunction code memory will not be erased. Always disconnect
the diagnosis monitor with the stater switch set to "ON".
(2) Wait 5 seconds and connect the diagnosis monitor.
(3) This time, only the present malfunction codes are displayed.
(4) Compare the two sets of codes you get to deter mine which are
the present codes and which are the past one's.
M16020100007
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–19

5. INSTALL THE FUSE OF AUTOMATIC TRANSMISSION ECU.


(1) Set the starter switch to the "LOCK".
(2) Install the fuse (TRANSFER CONTROL AUTO T/M: 10A) of the
automatic transmission ECU.

M16020100128

MALFUNCTION CODE TABLE

CODE MALFUNCTION CONTENTS PROBABLE CAUSE

1 Normal function of system —

3-1 Abnormality of main engine speed sensor


Harness disconnection, short circuit or abnormality of
3-2 Abnormality of sub engine speed sensor
sensor
3-1 & 2 Abnormality of main and sub engine sensor

Harness disconnection, short-circuit or abnormality of


4-1 Abnormality of coolant temperature sensor
sensor

6-1 Abnormality of starter switch Short-circuit or abnormality of starter switch

Harness disconnection, short circuit or abnormality of


7-1 Abnormality of boost pressure sensor
sensor

Abnormality of voltage of accelerator sensor


8-1
1

Abnormality of voltage of accelerator sensor


8-2
2

Abnormality of voltage of accelerator sensor Harness disconnection, short-circuit or abnormality of


8-1 & 2
1&2 sensor

Abnormality of output voltage of accelerator


8-3
sensor 1

Abnormality of output voltage of accelerator


8-4
sensor 2

8-6 Abnormality of accelerator switch Short-circuit of accelerator switch

9-1 Abnormality of Q-adjustment resistor Q-adjustment resistor is not installed. Short-circuit

9-2 Abnormality of idle set controller Short-circuit or abnormality of idle set controller

Harness disconnection, short circuit or abnormality of


11-1 Abnormality of vehicle speed sensor
sensor

Harness disconnection, short circuit or abnormality of


14-1 Abnormality of rack sensor
sensor

16-1 Abnormality of pre-stroke sensor


Harness disconnection, short-circuit or abnormality of
16-2 Abnormality of pre-stroke F/B
sensor
16-3 Abnormality of pre-stroke learning

16-4 Abnormality of pre-stroke power supply Harness disconnection, short-circuit

Abnormality of pre-stroke power supply relay Harness disconnection, short-circuit or abnormality of


16-6
control circuit relay

17-1 Abnormality of governor F/B Abnormality of injection pump


DN02–20 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

MALFUNCTION CODE TABLE

CODE MALFUNCTION CONTENTS PROBABLE CAUSE

17-2 Abnormality of governor F/B Harness disconnection

22-1 Abnormality of ECU Abnormality of ECU

Engine speed is 3,800 r/min or more or abnormality of


23-1 Engine overrun
engine speed sensor

Engine coolant temperature is 115°C {239°F} or above or


24-1 Engine over heat
abnormality of coolant temperature sensor

*Q-adjustment resistor: Resistor for adjusting MAX. injection vol-


ume
.

ABNORMALITY OF MAIN ENGINE SPEED SENSOR (MALFUNCTION


CODE:3-1)
M16020101BEF2021

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK" and disconnect the 32 pin con-
NE1+
nectors of ECU.
(2) Measure the resistance between NE1+ and NE1- terminals of 32
pin connectors (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11
Standard: APPROX. 1.8kΩ at 20°C {68°F}
12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

NE1-

M16020100074
.

NG
Proceed to 3

OK

2. RECHECK THE MALFUNCTION CODE.


(1) Connect the 32 pin connectors and erase the past malfunction
code.
(2) Check the malfunction code with the diagnosis monitor.
Standard: code 1 (Normal function)
.

NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors

Normal
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–21

3. CHECK THE MAIN ENGINE SPEED SENSOR.


NE+ NE- (1) Disconnect the connectors of main engine speed sensor.
(2) Measure the resistance between NE+ and NE- terminals of sen-
sor connectors (Sensor harness side).
Standard: APPROX. 1.8 kΩ at 20°C {68°F}

M16020100075
.

NG
Abnormality of sensor
(Injection pump)
OK

• Harness disconnection or short circuit


• Bad contact of connectors

ABNORMALITY OF SUB ENGINE SPEED SENSOR (MALFUNCTION


CODE:3-2)
M16020101BEF2037

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK" and disconnect the 32 pin con-
NE2+
nectors of ECU.
(2) Measure the resistance between NE2+ and NE2- terminals of 32
pin connectors (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11
Standard: APPROX. 1.8kΩ at 20°C {68°F}
12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

NE2-

M16020100076
.

NG
Proceed to 3

OK
DN02–22 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

2. RECHECK THE MALFUNCTION CODE.


(1) Connect the 32 pin connectors and erase the past malfunction
code.
(2) Check the malfunction code with the diagnosis monitor.
Standard: code 1 (Normal function)
.

NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors

Normal

3. CHECK THE SUB ENGINE SPEED SENSOR.


(1) Disconnect the connectors of sub engine speed sensor.
NE- (2) Measure the resistance between NE+ and NE- terminals of sen-
NE+
sor connectors (Sensor harness side).
Standard: APPROX. 1.8 kΩ at 20°C {68°F}

M16020100129
.

NG
Abnormality of sensor
(Injection pump)
OK

• Harness disconnection or short circuit


• Bad contact of connectors

ABNORMALITY OF MAIN AND SUB ENGINE SPEED SENSOR


(MALFUNCTION CODE:3-1 & 2)
M16020101BEF2024

1. MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE


CONTENTS OF MALFUNCTION CODE 3-1 AND 3-2.
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–23

ABNORMALITY OF COOLANT TEMPERATURE SENSOR


(MALFUNCTION CODE:4-1)
M16020101BEF2031

1. CHECK THE RESISTANCE BETWEEN TERMINALS.


THW+ (1) Set the starter switch to "LOCK".
(2) Disconnect the 32 pin connectors of ECU.
(3) Measure the resistance between THW+ and THW- terminals of
1 2 3 4 5 6 7 8 9 10 11 32 pin connectors (Chassis harness side).
12 13 14 1516 17 18 19 20 21 2223 24 HINT:
25 26 27 2829 30 31 32
Measure the resistance under any condition of the following.

Standard:
APPROX. 2.4 kΩ at 20°C {68°F}
THW-
APPROX. 1.5 kΩ at 40°C {104°F}
M16020100077 APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors

2. CHECK THE COOLANT TEMPERATURE SENSOR.


(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals.
HINT:
Measure the resistance under any condition of the following.

Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023

NG
Abnormality of coolant temperature sensor

OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

.
DN02–24 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1)


M16020101BEF2041

CAUTION:
Make sure that transmission is in neutral position.
1. CHECK THE VOLTAGE BETWEEN TERMINALS.
(1) Set the starter switch to "LOCK" and disconnect the 25 pin con-
ST nectors of ECU.
(2) Measure the voltage between ST and MGD1 terminals of 25 pin
1 2 3 4 5 6 7 8 connectors. (Chassis harness side)
9 10 11 12 13 14 15 16 17 18 + - Standard:
Starter switch "LOCK" : 0V
19 2021 22 23 24 25
Starter switch "START" : 24V

MGD1

M16020100078
.

NG
Abnormality of harness

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors

ABNORMALITY OF BOOST PRESSURE SENSOR (MALFUNCTION


CODE:7-1)
M16020101BEF2043

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


PIM (1) Set the stater switch to "ON" (ECU connectors remain connected
and the engine is stopped).
1 2 3 4 5 6 7 8 9 10 11
(2) Measure the voltage between PIM and PIM- terminals of 32 pin
12 13 14 1516 17 18 19 20 21 2223 24 connectors.
+ -
25 26 27 2829 30 31 32 Standard: 0.2-4.8V

PIM-

ECU VIEW

M16020100145
.

NG
Proceed to (3)

OK

• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–25

(3) Set the starter switch to "LOCK" and disconnect the connector of
GND VCC
boost pressure sensor.
(4) Set the starter switch to"ON" and measure the voltage between
VCC and GND Terminals (Chassis harness side).
Standard: 4.5V or more

M16020100053
.

NG
Proceed to 2 - (4)

OK

2. CHECK THE CONTINUITY BETWEEN TERMINALS.


PIM (1) Set the stater switch to "LOCK".
1 2 3 4 5 6 7 8 9 10 11
(2) Disconnect the 32 pin connectors of ECU and connector of boost
12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32
pressure sensor.
(3) Measure the resistance between PIM terminal of 32 pin connec-
SIG tors and SIG connector of boost pressure sensor (Chassis har-
ness side).
Standard: 2Ω or less

M16020100146
.

NG
Abnormality of harness

OK

• Abnormality of boost pressure sensor


• Bad contact of connectors
DN02–26 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

(4) Set the starter switch to "LOCK".


(5) Disconnect the 32 pin connectors of ECU and connector of boost
PIM+ 1 2 3 4 5 6 7 8 9 10 11
pressure sensor.
12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32
(6) Measure the resistance between PIM+ terminal of 32 pin connec-
tors and VCC terminal of boost pressure sensor (Chassis harness
VCC side), PIM- terminal of 32 pin connectors and GND terminal of
boost pressure sensor (Chassis harness side).
Standard: 2Ω or less

M16020100147

PIM-
1 2 3 4 5 6 7 8 9 10 11

12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

GND

M16020100148
.

NG
Abnormality of harness

OK

• Abnormality of ECU
• Bad contact of connectors

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–27

ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1


(MALFUNCTION CODE: 8-1)
M16020101BEF2025

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


(1) Disconnect the connector of the accelerator sensor (ECU connec-
GND1 tors remain connected).
(2) Set the starter switch to "ON" (The engine is stopped).
(3) Measure the voltage between VCC1 and GND1 terminals of
accelerator sensor (Chassis harness side).
Standard: 4.5-5.5 V

VCC1

M16020100130
.

NG
Proceed to (4)

OK

Proceed to (5)

(4) Measure the voltage between VAC1 and AGD1 terminals of 31


VAC1 pin connectors.
Standard: 4.5-5.5 V
10 9 8 7 6 5 4 3 2 1

222120191817161514131211
+ -
313029 282726 252423

AGD1

ECU VIEW
M16020100079
.

NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK

Abnormality of harness
DN02–28 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

(5) Set the starter switch to "LOCK".


ACS1 (6) Connect the connector of the accelerator sensor.
(7) Set the starter switch to "ON" (The engine is stopped).
10 9 8 7 6 5 4 3 2 1 (8) Measure the voltage between ACS1 and AGD1 terminals of 31
222120191817161514131211
+ - pin connectors.
Standard:
313029 282726 252423 0.7-1.0 V: Release the accelerator pedal.
3.55-4.0 V: Depress the accelerator pedal fully.
AGD1

ECU VIEW
M16020100080
.

NG
Proceed to (9)

OK

• Abnormality of ECU
• Abnormality of ECU connectors

(9) Measure the voltage between SIG1 and GND1 terminals of accel-
GND1 erator sensor. (Chassis harness side).
Standard:
0.7-1.0 V: Release the accelerator pedal.
1 2 3 + - 3.55-4.0 V: Depress the accelerator pedal fully.
4 5 6

SIG1

VIEW
CHASISS HARNESS SIDE
M16020100083
.

NG
Abnormality of accelerator sensor

OK

Harness disconnection or short circuit

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–29

ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 2


(MALFUNCTION CODE: 8-2)
M16020101BEF2026

1. CHECK THE VOLTAGE BETWEEN TERMINALS


(1) Disconnect the connector of the accelerator sensor (ECU connec-
VCC2 GND2 tors remain connected).
(2) Set the starter switch to "ON" (The engine is stopped).
(3) Measure the voltage between VCC2 and GND2 terminals of
accelerator sensor (Chassis harness side).
Standard: 4.5-5.5 V

M16020100110
.

NG
Proceed to (4)

OK

Proceed to (5)

(4) Measure the voltage between VAC2 and AGD2 terminals of 31


VAC2 pin connectors.
Standard: 4.5-5.5 V
10 9 8 7 6 5 4 3 2 1

222120191817161514131211
+ -
313029 282726 252423

AGD2

ECU VIEW
M16020100085
.

NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK

Abnormality of harness
DN02–30 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

(5) Set the starter switch to "LOCK".


ACS2 (6) Connect the connector of the accelerator sensor.
(7) Set the starter switch to "ON" (The engine is stopped).
10 9 8 7 6 5 4 3 2 1 (8) Measure the voltage between ACS2 and AGD2 terminals of 31
222120191817161514131211
+ - pin connectors.
Standard:
313029 282726 252423 0.7-1.0 V: Release the accelerator pedal.
3.55-4.0 V: Depress the accelerator pedal fully.
AGD2

ECU VIEW
M16020100086
.

NG
Proceed to (9)

OK

• Abnormality of ECU
• Abnormality of ECU connectors

(9) Measure the voltage between SIG2 and GND2 terminals of accel-
GND2 erator sensor. (Chassis harness side).
Standard:
0.7-1.0 V: Release the accelerator pedal.
1 2 3 3.55-4.0 V: Depress the accelerator pedal fully.
4 5 6
+ -

SIG2

VIEW
CHASISS HARNESS SIDE
M16020100087
.

NG
Abnormality of accelerator sensor

OK

Harness disconnection or short circuit

ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1 &2


(MALFUNCTION CODE 8-1 & 2)
M16020101BEF2027

1. MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE


CONTENTS OF MALFUNCTION CODE 8-1 AND 8-2.
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–31

ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 1


(MALFUNCTION CODE: 8-3)
M16020101BEF2028

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


ACS1 (1) Set the starter switch to "ON" (The engine is stopped).
(2) Measure the voltage between ACS1 and AGD1 terminals of 31
10 9 8 7 6 5 4 3 2 1 pin connectors (ECU connectors remain connected).
+ -
222120191817161514131211 Standard:
313029 282726 252423 0.7-1.0 V: Release the accelerator pedal

AGD1

ECU VIEW
M16020100080

NG
Abnormality of accelerator sensor

OK

(3) Measure to voltage between ACS1 and AGD1 by depressing


ACS1 acceleration pedal deeply.
Standard:
10 9 8 7 6 5 4 3 2 1 More than 1.0 V (The voltage should be changed in propor-
222120191817161514131211
+ - tion to depressing amount of the accelerator.)

313029 282726 252423

AGD1

ECU VIEW
M16020100080
.

NG
Abnormality of accelerator sensor

OK

Abnormality of harness

.
DN02–32 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 2


(MALFUNCTION CODE: 8-4)
M16020101BEF2029

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


ACS2 (1) Set the starter switch to "ON" (The engine is stopped).
(2) Measure the voltage between ACS2 and AGD2 of 31 pin connec-
10 9 8 7 6 5 4 3 2 1 tors (ECU connectors remain connected).
+ -
222120191817161514131211 Standard:
313029 282726 252423 0.7-1.0 V: Release the accelerator pedal

AGD2

ECU VIEW
M16020100086

NG
Abnormality of accelerator sensor

OK

(3) Measure to voltage between ACS2 and AGD2 by depressing


ACS2 acceleration pedal deeply.
Standard:
10 9 8 7 6 5 4 3 2 1 More than 1.0 V (The voltage should be changed in propor-
222120191817161514131211
+ - tion to depressing amount of the accelerator.)

313029 282726 252423

AGD2

ECU VIEW
M16020100086
.

NG
Abnormality of accelerator sensor

OK

Abnormality of harness

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–33

ABNORMALITY OF ACCELERATOR SWITCH (MALFUNCTION CODE:


8-6)
M16020101BEF2030

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


IDLE (1) Set the starter switch to "ON" (ECU connector remain connected
and the engine is stopped).
10 9 8 7 6 5 4 3 2 1
(2) Measure the voltage between IDLE and CASE terminals of 31 pin
222120191817161514131211
+ - connectors.
Standard:
313029 282726 252423 19 V or more: Release the accelerator pedal
0 V: Depress the accelerator pedal fully
CASE

ECU VIEW
M16020100090
.

NG
Proceed to 2

OK

Abnormality of ECU

2. CHECK THE CONTINUTY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the connector of accelerator switch.
(3) Measure the resistance between terminals of switch connector
(Switch side).
Standard:
2 Ω or less: Release the accelerator pedal
∞ Ω: Depress the accelerator pedal fully

M16020100111
.

NG
Abnormality of accelerator switch

OK

Abnormality of harness

.
DN02–34 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF Q-ADJUSTMENT RESISTER (MALFUNCTION


CODE: 9-1)
M16020101BEF2100

1. CHECK IF CORRECTLY INSTALLED THE Q-ADJUSTMENT


RESISTOR.
.

NG
No resistance of Q-adjustment resistor:
Install the register No.4 of Q-adjustment resis-
tor as listed below.
OK

2. CHECK THE RESISTENCE BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK" and disconnect the 25 pin con-
QREG nectors of ECU.
(2) Measure the resistance between QREG and QGND terminals of
1 2 3 4 5 6 7 8 25 pin connectors (Chassis harness side).
Standard:
9 10 11 12 13 14 15 16 17 18

192021 22 23 24 25 Resistor Color of identification


Resistor Part
value
NO. number Main body Connector
(Unit: Ω)
QGND
1 21109-1010 270 Ω Black White
M16020100091 2 21109-1020 510 Ω ↑ Green
3 21109-1030 820 Ω ↑ Yellow
4 21109-1040 1,300 Ω ↑ Brown
5 21109-1050 2,000 Ω Blue White
6 21109-1060 3,300 Ω ↑ Green
7 21109-1070 5,600 Ω ↑ Yellow
8 21109-1080 15,000 Ω ↑ Brown

NG
Proceed to (3)

OK

• Abnormality of ECU
• Abnormality of ECU connector
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–35

(3) Remove the Q-adjustment resistor.


(4) Measure the resistance between terminals of resistor (Resistor
side).
Standard:

Resistor Color of identification


Resistor Part
value
NO. number Main body Connector
(Unit: Ω)
1 21109-1010 270 Ω Black White
2 21109-1020 510 Ω ↑ Green
3 21109-1030 820 Ω ↑ Yellow
M16020100112
4 21109-1040 1,300 Ω ↑ Brown
5 21109-1050 2,000 Ω Blue White
6 21109-1060 3,300 Ω ↑ Green
7 21109-1070 5,600 Ω ↑ Yellow
8 21109-1080 15,000 Ω ↑ Brown

NG
Abnormality of Q-adjustment resistor

OK

Harness disconnection or short circuit

ABNORMALITY OF IDLE SET CONTROLLER (MALFUNCTION CODE:


9-2)
M16020101BEF2032

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


(1) Disconnect the connector of idle set controller (ECU connectors
remain connected).
GND (2) Set the starter switch to "ON" (The engine is stopped).
(3) Measure the voltage between + and GND terminals of idle set
controller connectors (Chassis harness side).
Standard: 4.5-5.5 V

M16020100113
.

NG
Proceed to (4)

OK

Proceed to (5)
DN02–36 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

(4) Measure the voltage between IV+ and IVG terminals of 26 pin
IV+ connectors.
Standard: 4.5-5.5 V

13 12 11 10 9 8 7 6 5 4 3 2 1 + -
26 25 24 23 22 21 20 19 18 17 16 15 14

IVG

ECU VIEW

M16020100093
.

NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK

Harness disconnection

(5) Set the starter switch to "LOCK"


IVS
(6) Connect the connector of idle set controller.
(7) Set the starter switch to "ON" (The engine is stopped).
(8) Measure the voltage between IVS and IVG terminals of 26 pin
13 12 11 10 9 8 7 6 5 4 3 2 1 + - connectors.
26 25 24 23 22 21 20 19 18 17 16 15 14 Standard:
APPROX. 0 V: Turn idle control knob to left fully
APPROX. 0.7 V: Turn idle control knob to left.
IVG APPROX. 4.3 V: Turn idle control knob to right fully
ECU VIEW

M16020100094
.

NG
Proceed to (9)

OK

• Abnormality of ECU
• Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–37

(9) Measure the voltage between SIG and GND terminals of Idle set
controller connectors (Chassis harness side).
Standard:
APPROX. 0 V: Turn idle control knob to left fully
APPROX. 0.7 V: Turn idle control knob to left.
APPROX. 4.3 V: Turn idle control knob to right fully

M16020100114
.

NG
Abnormality of idle set controller

OK

Harness disconnection or short circuit

.
DN02–38 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF VEHICLE SPEED SENSOR (MALFUNCTION


CODE: 11-1)
M16020101BEF2033

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


VS (1) Start the engine (ECU connectors remain connected).
(2) Prepare the voltage measurement between VS and CASE termi-
10 9 8 7 6 5 4 3 2 1
nals of 31 pin connectors.
222120191817161514131211
+ - (3) Measure the voltage while the vehicle starts to run at the speed of
10 km/h{6.2 miles/h}
313029 282726 252423 NOTICE:
Start the vehicle with much caution around.
CASE Standard: Pulse wave-shape by 12 V-0 V
ECU
(4) Stop the vehicle.
VIEW
M16020100084
.

NG
Proceed to

OK

• Abnormality of ECU
• Bad contact of harness connector

2. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8
(2) Disconnect the 31 pin connectors of ECU and connectors of pulse
111213141516171819202122
9 10 11 12 13 14 15 16 adjust computer.
232425 262728 293031
(3) Measure the resistance between VS terminal of 31 pin connectors
and PCO4 terminal of pulse adjust computer connectors (Chassis
harness side).
PCO4 Standard: 1 Ω or less
VS

M16020100089

NG
Harness disconnection of vehicle speed sen-
sor circuit
OK
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–39

(4) Connect the 31 pin connectors of ECU.


(5) Measure the resistance between VS terminal of 31 pin connectors
and ground.
Standard: ∞ Ω

10 9 8 7 6 5 4 3 2 1
GROUND
222120191817161514131211

313029 282726 252423

VS

ECU VIEW

M16020100131
.

NG
Short circuit of vehicle speed sensor circuit

OK

Speed Sensor Fault (The speed sensor of vehicle should be


solely checked. Delete the fault records in the past and if dis-
played again the same code on the screen after testing, ECU
should be replaced with a new one.)

.
DN02–40 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1)


M16020101BEF2051

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 25 pin connectors of ECU and 8 pin connectors of
1 2 3 4 5 6 7 8
injection pump.
VIST 9 10 11 12 13 14 15 16 17 18 (3) Measure the resistance between VIST terminal of 25 pin connec-
192021 22 23 24 25
tors and VIST terminal of 8 pin connectors of injection pump
(Chassis harness side).
1 2 3 4 Standard: 1 Ω or less
5 6 7 8
VIST

M16020100098
.

NG
Abnormality of harness and connectors

OK

• Abnormality of injection pump


• Abnormality of ECU connectors
• Bad contact of ECU connectors

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–41

ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION


CODE:16-1)
M16020101BEF2061

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 32 pin connectors of ECU.
(3) Measure the resistance between PMDL and PGND, PMDL and
POSC terminals of 32 pin connectors (Chassis harness side).
Standard: 4-9 Ω

POSC
PMDL

1 2 3 4 5 6 7 8 9 10 11

12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

PGND

M16020100099
.

NG
Proceed to 2

OK

• Abnormality of injection pump


• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
DN02–42 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

2. CHECK THE PRE-STROKE SENSOR.


(1) Disconnect the connector of pre-stroke sensor.
PGND (2) Measure the resistance between PMDL and PGND, PMDL and
PMDL POSC terminals of sensor connectors (Sensor harness side)
Standard: 4-9 Ω

POSC

M16020100013
.

NG
Abnormality of pre-stroke sensor
(Injection pump)
OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2)


M16020101BEF2071

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


PS- (1) Set the starter switch to "LOCK".
(2) Disconnect the 32 pin connectors of ECU.
(3) Measure the resistance between PS+ and PS- terminals of 32 pin
1 2 3 4 5 6 7 8 9 10 11
connectors (Chassis harness side).
Standard: 2-4 Ω
12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

PS+

M16020100100
.

NG
Proceed to 2

OK

• Malfunction of pre-stroke actuator


• Malfunction of injection pump link mechanism
• Abnormality of ECU
• Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–43

2. CHECK THE PRE-STROKE ACTUATOR.


(1) Disconnect the connector of pre-stroke actuator.
PS- PS+ (2) Measure the resistance between PS+ and PS- terminals of actua-
tor connectors (Actuator harness side).
Standard: 2-4 Ω

M16020100015
.

NG
Abnormality of pre-stroke actuator
(Injection pump)
OK

• Harness disconnection or short circuit


• Abnormality of connectors
• Bad contact of connectors

ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION


CODE:16-3)
M16020101BEF2081

1. Check that the malfunction code 16-1 is being displayed


together with 16-3 in the order at the same time.

M16020100016
.

NG
Abnormal adjustment of pre-stroke sensor
(Replace the injection pump)
OK

Make sure to inspect it in accordance with the contents of Mal-


function Code 16-1.

.
DN02–44 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION


CODE:16-4)
M16020101BEF2091

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


PSP+ (1) Set the starter switch to "LOCK".
(2) Disconnect the 32 pin connectors of ECU.
(3) Set the starter switch to "ON" (The engine is stopped).
+ - (4) Measure the voltage between PSP+ and PSGD terminals of 32
1 2 3 4 5 6 7 8 9 10 11
pin connectors (Chassis harness side).
12 13 14 1516 17 18 19 20 21 2223 24 Standard:
25 26 27 2829 30 31 32 Starter switch "LOCK" : 0V
Starter switch "ON" : 24V

PSGD
M16020100088
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors

2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY).
(1) Set the starter switch to "LOCK".
(2) Disconnect the pre-stroke power supply relay.
S- B (3) Measure the resistance between B and NC terminals.
Standard: 1 Ω or less

NC

S+

M16020100018
.

NG
Abnormality of pre-stroke power supply relay

OK

• Harness disconnection or short circuit


• Abnormality of connectors

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–45

ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:16-
6)
M16020101BEF2101

1. CHECK THE VOLTAGE BETWEEN TERMINALS.


PSRY (1) Set the starter switch to "LOCK".
(2) Disconnect the 31 pin connectors of ECU.
(3) Set the starter switch to "ON".
1 2 3 4 5 6 7 8 9 10 (4) Measure the voltage between PSRY and CASE terminals of 31
+ - pin connectors (Chassis harness side).
111213141516171819202122
Standard:
232425 262728 293031 Starter switch "LOCK" : 0V
Starter switch "ON" : 24V

CASE
M16020100092
.

NG
Proceed to 2

OK

• Abnormality of ECU
• Abnormality of ECU connectors

2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER


SUPPLY CUT RELAY).
(1) Set the starter switch to "LOCK".
(2) Disconnect the pre-stroke power supply relay.
S-
(3) Measure the resistance between S+ and S- terminals.
Standard: 390-490 Ω

S+

M16020100020
.

NG
Abnormality of pre-stroke power supply relay

OK
DN02–46 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

3. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch "LOCK".
(2) Disconnect the pre-stroke power supply relay and 31 pin connec-
tors of ECU.
(3) Measure the resistance between PSRY terminal of 31 pin connec-
tors (Chassis harness side) and S- terminal of relay connectors
(Relay panel side).
Standard: 1 Ω or less

S-

1 2 3 4 5 6 7 8 9 10

111213141516171819202122

232425 262728 293031

PSRY

M16020100101
.

NG
• Harness disconnection
• Abnormality of connectors
OK

Bad contact of connectors

ABNORMALITY OF GOVERNOR F/B (MALFUNCTION CODE: 17-1)


M16020101BEF2034

1. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 25 pin connectors of ECU and 8 pin connectors of
1 2 3 4 5 6 7 8
injection pump.
VIST 9 10 11 12 13 14 15 16 17 18 (3) Measure the resistance between VIST terminal of 25 pin connec-
192021 22 23 24 25 tors and VIST terminal of 8 pin connectors of injection pump
(Chassis harness side).
1 2 3 4 Standard: 1 Ω or less
5 6 7 8
VIST

M16020100098
.

NG
Abnormality of harness and connectors

OK

Abnormality of injection pump (Replace the injection pump)


FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–47

ABNORMALITY OF GOVERNOR (MALFUNCTION CODE: 17-2)


M16020101BEF2035

1. CHECK THE POSITION OF THE EMERGENCY ENGINE STOP


KNOB AND STOP LEVER.
(1) Make sure that the emergency engine stop knob and the stop
lever of the injection pump are returned to the engine start (drive)
position.
.

NG
Return the emergency engine stop knob and
stop lever to the engine start (drive) position
OK

2. CHECK THE CONTINUITY BETWEEN TERMINALS.


(1) Set the starter switch to "LOCK".
(2) Disconnect the 25pin connectors of ECU, 7 pin connectors of
injection pump and 8 pin connectors of injection pump.
(3) Measure the resistance between terminals of 25 pin connectors
and 7 pin connectors, 25 pin connectors and 8 pin connectors
(Chassis harness side).

Combination of terminals

7 pin connectors 25 pin connectors

Terminal Terminal
Terminal No. Terminal No.
name name

1 GVB 2 7 GVB 2
1 2 3 4 5 6 7 8
1 2
2 GND 1 17 GND 1
9 10 11 12 13 14 15 16 17 18
3 4 5
6 7 19 2021 22 23 24 25
3 SOL 1 6 SOL 1

4 +5V 1 5 +5V 1

M16020100095
DN02–48 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

8 pin connectors 25 pin connectors

Terminal Terminal
Terminal No. Terminal No.
name name

1 GVB 1 8 GVB 1

2 GND 2 24 GND 2

3 SOL 2 15 SOL 2

4 +5V 2 14 +5V 2
1 2 3 4 5 6 7 8
1 2 3 4 9 10 11 12 13 14 15 16 17 18 Standard: 1 Ω or less
5 6 7 8
19 2021 22 23 24 25

M16020100096
.

NG
Abnormality of harness and connectors

OK

• Abnormality of injection pump


• Bad contact of connectors

.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–49

ABNORMALITY OF ECU (MALFUNCTION CODE:22-1)


M16020101BEF2111

1. After the starter switch is positioned on the "LOCK" once, it


shall be turned to "ON" position again.

2. After erasing the malfunction memory stored in the past,


check that the same code is displayed again.

M16020100016
.

NG
The same code is being shown up: Malfunction
of ECU.
OK

Normal
(Temporary malfunction because of radio interference noise)

ENGINE OVERRUN (MALFUNCTION CODE:23-1)


M16020101BEF2121

1. The malfunction code will be displayed, once detected over


3,800 r/min. in the Engine revolution. Also, the fuel injection
will be suspended during the malfunction code to be
detected and the fuel injection will be resumed when Engine
revolution goes down less than 3,600 r/min.
NOTICE:
The malfunction code is aimed not for detecting the Engine over-
run 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 "over-run" will be
detected by misunderstanding the Engine revolution, with a noise
to be generated by harness abnormality and its modification.
.
DN02–50 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

ENGINE OVERHEAT (MALFUNCTION CODE:24-1)


M16020101BEF2131

1. CHECK THE COOLANT TEMPERATURE SENSOR.


(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals.
HINT:
Measure the resistance under any condition of the following.

Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023

NG
Abnormality of coolant temperature sensor

OK

Abnormality 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 malfunction code is being detected, Max.
volume of fuel injection will be limited and will return back to nor-
mal control volume when it descends less than 105°C {221°F}.
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–51

ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT


M16020101BEF2141

32 PIN CONNECTORS

1 2 3 4 5 6 7 8 9 10 11

12 13 14 1516 17 18 19 20 21 2223 24

25 26 27 2829 30 31 32

VIEW CHASSIS HARNESS


M16020100102

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 MVB Power source 17 —

2 PSP+ Pre-stroke power supply 18 PIM Booster sensor (Signal)

3 PDWN Rack sensor 19 NE2- Sub engine speed sensor -

4 POSC Pre-stroke sensor 20 THW+ Coolant temperature sensor +

5 — 21 NE1- Main engine speed sensor -

6 PIM+ Boos sensor + 22 —

7 NE2+ Sub engine speed sensor - 23 —

8 NE1+ Main engine speed sensor + 24 —

9 — 25 PSGD Pre-stroke actuator ground

10 — 26 PGND Pre-stroke sensor ground

11 PTO Position switch (with P.T.O.) 27 PSLD Pre-stroke sensor shield

12 PS- Pre-stroke actuator - 28 —

13 PS+ Pre-stroke actuator + 29 PIM- Boos sensor -

14 LPHM Rack sensor 30 THW- Coolant temperature sensor +

15 PMDL Pre-stroke sensor 31 —

16 BSW1 Stop lamp switch 32 —

• with P.T.O.: with Power take-off


DN02–52 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

25 PIN CONNECTORS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19 2021 22 23 24 25

VIEW CHASSIS HARNESS


M16020100103

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 14 +SV2 Rack sensor

2 DGSW Diagnosis monitor 15 SOL2 Rack sensor

3 — 16 VIST Rack sensor

4 QREG Q-Adjustment resistor+ 17 GND1 Governor actuator ground

5 +5V1 Rack sensor 18 MGD1 Ground

6 SOL1 Rack sensor 19 —

7 GVB2 Governor actuator power supply 20 BSW2 Brake switch (with ATM)

8 GVB1 Governor actuator power supply 21 —

9 EBSW Exhaust brake switch 22 SLD Rack sensor

10 — 23 SGND Rack sensor

11 ST Power source (starter switch) 24 GND2 Ground

12 SSWS Power source 25 MGD2 Ground

13 QGND Q-Adjustment resistor -

• with ATM: with Automatic transmission


FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–53

31 PIN CONNECTORS

1 2 3 4 5 6 7 8 9 10

111213141516171819202122

232425 262728 2930 31

VIEW CHASSIS HARNESS

M16020100104

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 17 ACS1 Accelerator sensor 1 (signal)

Power take off clutch switch


2 — 18 CLST
(with MTM)

3 — 19 NUSW Neutral switch (with P.T.O.)

4 IDLE Accelerator switch 20 —

5 VAC2 Accelerator sensor 2 21 —

6 VAC1 Accelerator sensor 1 22 —

7 — 23 —

8 — 24 CASE Ground

9 — 25 —

10 — 26 —

11 — 27 AGD2 Accelerator sensor 2

12 — 28 AGD1 Accelerator sensor 1

13 VS Pulse adjust computer 29 —

14 PSRY Actuator power supply relay 30 —

15 PWTM Automatic transmission ECU 31 —

16 ACS2 Accelerator sensor 2 (signal)

• with MTM: with Mechanical transmission


• with P.T.O.: with Power take-off
DN02–54 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

16 PIN CONNECTORS

1 2 3 4 5

6 7 8 9 101112

13 141516

VIEW CHASSIS HARNESS

M16020100105

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 VB2 ECU main relay 9 —

2 VB1 Power source 10 —

3 CE/G Check engine lamp 11 TACH Pulse adjust computer

4 — 12 —

5 — 13 MRL2 ECU main relay

6 CGD1 ECU ground 1 14 —

7 CGD2 ECU ground 2 15 —

8 MRL1 Power source 16 —


FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–55

26 PIN CONNECTORS

1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 1617181920212223 24 25 26

VIEW CHASSIS HARNESS

M16020100106

No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION

1 — 14 —

2 — 15 —

3 IV+ Idle set controller + 16 IVS Idle set controller (signal)

4 EBLP Exhaust brake indicator lamp 17 IVG Idle set controller -

5 AT Ground 18 —

6 — 19 —

7 — 20 —

8 — 21 —

9 — 22 —

10 — 23 —

11 — 24 —

12 SWSS Power source (Fuse E/G2) 25 —

13 — 26 —

DISMOUNTING AND MOUTING


M16020101BEF2036

IMPORTANT POINT - DISMOUNTING

1. REMOVE THE SPEED SENSOR.


(1) Disconnect the connector (Black), loosen the lock nut using two
wrenches.
(2) Remove the speed sensor from the adapter plate.

IMPORTANT POINT - MOUNTING

1. INSTALL THE SPEED SENSOR.


(1) Turn the crankshaft to align the mark 16, 25 or 34 on the outer
periphery of the flywheel with the pointer of the flywheel housing.
NOTICE:
• The pulse protrusion will line up with the center of the hole at
the piston top dead center point.
• The speed sensor damage may occur during engine opera-
tion if these adjustments are neglected.

M16020100068
DN02–56 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)

(2) Coat a sealing compound (Three-Bond 1215 or equivalent) on the


thread face and lock nut sealing surface of the sensor.
NOTICE:
Sensor adjustment should be carried out within 30 minutes from
application of the sealing compound. After 30 minutes, the sealing
compound will harden and it will become difficult to turn the sen-
sor by hand.
(3) Screw in the sensor by hand until the leading edge of the sensor
lightly contacts to the protrusion.
(4) After contacting the sensor to the protrusion, unscrew the sensor
1.0-1.5 turns (to create a gap of 1.0-1.5 mm {0.0394-0.0590 in.}).
(5) Tighten the lock nut while the hexagonal part on the sensor is
held to prevent the gap from changing.
Tightening Torque:
45-54 N⋅m {450-550 kgf⋅cm, 33-39 lbf⋅ft}

M16020100067
1-1, HINODAI 3-CHOME, HINO-SHI, TOKYO 191-8660 JAPAN

PRINTED IN JAPAN

Pub. No. S5-YJ08E17A ’02-11